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Multi-Function Machine
SERVICE MANUAL
MODEL: MFC6800/DCP1000 MFC9180/MFC9160
© Copyright Brother 2001 All rights reserved. No part of this publication may be reproduced in any form or by any means without permission in writing from the publisher. Specifications are subject to change without notice.
PREFACE
This publication is a Service Manual covering the specifications, construction, theory of operation, and maintenance of the Brother multi-function machine. It includes information required for field troubleshooting and repair--disassembly, reassembly, and lubrication--so that service personnel will be able to understand machine function, to rapidly repair the machine and order any necessary spare parts. To perform appropriate maintenance so that the machine is always in best condition for the customer, the service personnel must adequately understand and apply this manual. This manual is made up of six chapters and appendices.
CHAPTER 1 CHAPTER 2 CHAPTER 3 CHAPTER 4 CHAPTER 5 CHAPTER 6 Appendix 1. Appendix 2. Appendix 3.
GENERAL DESCRIPTION INSTALLATION THEORY OF OPERATION DISASSEMBLY/REASSEMBLY AND LUBRICATION MAINTENANCE MODE ERROR INDICATION AND TROUBLESHOOTING EEPROM Customizing Codes Firmware Switches (WSW) Circuit Diagrams
This manual describes the models and their versions to be destined for major countries. The specifications and functions are subject to change depending upon each destination.
SAFETY INFORMATION
Laser Safety (110-120V Model only)
This printer is certified as a Class 1 laser product under the US Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968. This means that the printer does not produce hazardous laser radiation. Since radiation emitted inside the printer is completely confined within the protective housings and external covers, the laser beam cannot escape from the machine during any phase of user operation.
CDRH Regulations (110-120V Model only)
The Center for Device and Radiological Health (CDRH) of the US Food and Drug Administration implemented regulations for laser products on August 2, 1976. These regulations apply to laser products manufactured from August 1, 1976. Compliance is mandatory for products marketed in the United States. The label shown below indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States.
The label for Chinese products MANUFACTURED: JUNE 2001 BROTHER CORP. (ASIA) LTD. BROTHER BUJI NAN LING FACTORY Gold Garden Industry, Nan Ling Village, Buji, Rong Gang, Shenzhen, China. This product complies with FDA radiation performance standards, 21 CFR Subchapter J. C
CHAPTER 1
GENERAL DESCRIPTION
CHAPTER 1 GENERAL DESCRIPTION CONTENTS
1.1
OUTLINE..........................................................................................................................1-1 1.1.1 1.1.2 External Appearance and Weight ........................................................................1-1 Components .........................................................................................................1-1
1.2
SPECIFICATIONS............................................................................................................1-2
1.1 OUTLINE
1.1.1 External Appearance and Weight
The figure below shows the machine appearance and approximate dimensions.
(H) 354 mm 13.9"
(D) 458 mm 18.0"
(W) 459 mm 18.1"
Weight:
Machine proper Machine (incl. drum unit & toner cartridge) In package
Approx. 11 kg Approx. 12 kg Approx. 16 kg
1.1.2 Components
The machine consists of the following major components:
1 -1
1.2 SPECIFICATIONS
Model Name GENERAL Print Engine Modem Speed (bps) Transmission Speed (sec.) ITU-T Group Coding Method Input/Output Width Input/Output Length ADF (pages) LCD Size LCD Backlight Backup Clock Memory Capacity (physical) Optional Memory Dimensions w/ Carton (WxDxH) Dimensions w/o Carton (WxDxH) Weight w/ Carton Weight w/o Carton Color Operating Environment Temperature Humidity Power Source Power Consumption (Sleep/Standby/Peak) On/Off Switch Warm Up Time TELEPHONE Handset One-Touch Dial Speed Dial Speaker Phone Chain Dialing Caller ID Call Waiting Caller ID Distinctive Ringing Call Manage Hold/Mute Key Power Failure Dialing Speaker (Volume) Ring (Volume) Handset Volume PBX Feature Transfer Method FAX Internet FAX Easy Receive/Fax Detect Fax/Tel Switch Enhanced Remote Activate Scan Speed (sec./page, A4:Standard) Memory Transmission (Brother#1 Chart) Memory Transmission (ITU-T Chart) Broadcasting Manual Broadcasting Out-of-Paper Reception (Brother #1 Chart) Out-of-Paper Reception (ITU-T Chart) Auto Reduction ECM (Error Correction Mode) Group Dial Memory Security Memory Backup Color FAX (Document Send/Receive) Color FAX (Memory Send/Receive) LIST/REPORT Activity Report/Journal Report Transmission Verification Report INTERFACE External TAD Interface Host Interface (Serial) Host Interface (IEEE1284) Host Interface (USB) LAN Interface Acceptable Media Card Slot Analog Video Port YL4-FB(MFC) MFC 6800 Laser (YL4) 14,400 (Fax) 6 (Brother#1,MMR) G3 MH/MR/MMR 5.8"-8.5"/3.5"-8.5" 5"-14"/5"-14" Up to 30 16 characters x 2 lines No Yes (1 hour) 8 Mbytes (RAM) No 596 x 566 x 452 mm 459 x 458 x 354 mm 16 kg 11 kg Gray 1495 10 - 32.5 degrees Centigrade 20 - 80% 120 VAC 50/60Hz 15W/ 75W/ 940W or less Yes Approx. 13 sec. No No 100 No Yes Yes No Yes No No No Yes (3 steps + OFF) Yes (3 steps + OFF) No No N/A Yes Yes Approx. 3 500 pages (MMR/Standard Resolution) 400 pages (MMR/Standard Resolution) Yes (150 locations) Yes 500 pages (MMR/Standard Resolution) 400 pages (MMR/Standard Resolution) Yes Yes Yes (up to 6) No No No No Yes (up to 200) Yes Yes No Yes Yes No N/A N/A YL4-DCP DCP 1000 Laser (YL4) 5.8"-8.5"/3.5"-8.5" 5"-14"/5"-14" Up to 30 16 characters x 2 lines No Yes (1 hour) 8 Mbytes (RAM) No 596 x 566 x 452 mm 459 x 458 x 354 mm 16 kg 11 kg Gray 1495 10 - 32.5 degrees Centigrade 20 - 80% 120 VAC 50/60Hz 15W/ 75W/ 940W or less Yes Approx. 13 sec. No No No Yes Yes No N/A N/A
(1/2)
1 -2
(2/2)
Model Name PRINTER Color/Mono Engine Type Resolution (dpi) Speed (ppm) Paper Capacity (sheets) Additional Paper Capacity (sheets) Output Paper Capacity (sheets) Standard Print Language Emulation Resident Fonts Fonts Disk Based Paper Handling Size Manual Feed Slot Other Paper Type Sheet Weight (Paper Tray) (Manual Slot) Printer Driver YL4-FB(MFC) MFC 6800 Mono Laser (YL4) 600 x 600 up to 10 200 No 50 Windows GDI No No Yes LTR, LGL, A4, B5, A5, EXE N/A OHP, Envelopes, Organizer 2 64-158 g/m (16 - 42 lb) N/A Win95/98/98SE/Me/2000Professional/ NT4.0WS MacOS 8.5.1-9.1 YL4-DCP DCP 1000 Mono Laser (YL4) 600 x 600 up to 10 200 No 50 Windows GDI No No Yes LTR, LGL, A4, B5, A5, EXE N/A OHP, Envelopes, Organizer 2 64-158 g/m (16 - 42 lb) N/A Win95/98/98SE/Me/2000Professional/ NT4.0WS MacOS 8.5.1-9.1
COPY Color/Mono Speed (cpm) Multi Copy (Stack) Multi Copy (Sort) Reduction/Enlargement (%) Resolution (dpi) First Copy Out Time (From Ready Mode/ADF) (From Ready Mode/FB) SCANNER Color/Mono Resolution(Optical : dpi) Resolution(Int. : dpi) Gray Scale Color Depth TWAIN Compliant&Operating System PCI Scanner (Parallel/Serial) BUNDLED SOFTWARE For Windows Support OS version Printer Driver TWAIN Viewer
Mono Up to 10 Yes Yes (ADF only) 25 -- 400 in 1% increments 300 x 300 Approx. 13 sec. Approx. 12 sec.
Mono Up to 10 Yes Yes (ADF only) 25 -- 400 in 1% increments 300 x 300 Approx. 13 sec. Approx. 12 sec.
Color 600x300 (Max. 600x2,400) 9,600x9,600 256 24 bit (8 bits x 3) Win95/98/98SE/Me, WinNT4.0WS/ 2000Professional, MacOS 8.6-9.1 Parallel/USB
Color 600x300 (Max. 600x2,400) 9,600x9,600 256 24 bit (8 bits x 3) Win95/98/98SE/Me, WinNT4.0WS/ 2000Professional, MacOS 8.6-9.1 Parallel/USB
Win95/98/98SE/Me, WinNT4.0WS/2000Professional
Win95/98/98SE/Me, WinNT4.0WS/2000Professional
Pop Up Menu OCR
PC Fax Remote Setup PC Diagnostics Others For iMac/G3/G4 Support OS version Printer Driver TWAIN Viewer
Yes Yes Yes Yes Yes Yes(TX:FAX Share only) Yes Yes Auto E-mail Printing(Win 95/98(SE)/Me only)
Yes Yes Yes Yes Yes N/A No No Auto E-mail Printing(Win 95/98(SE)/Me only)
Printer Driver TWAIN
Pop Up Menu OCR
PC Fax Remote Setup PC Diagnostics Others ACCESSORY Life / Yield Toner : TN-250 Drum : DR-250
MacOS 8.5.1-9.1 MacOS 8.6-9.1 Yes Yes Yes No Yes Yes No No -
MacOS 8.5.1-9.1 MacOS 8.6-9.1 Yes Yes Yes No Yes No No No -
Starter: 2,200 pages @5% coverage Regular:2,200 pages @5% coverage 20,000 pages @5% cvrg: 20 pages/job 8,000 pages @5% cvrg: 1 page/job
Stater: 2,200 pages @5% coverage Regular:2,200 pages @5% coverage 20,000 pages @5% cvrg: 20 pages/job 8,000 pages @5% cvrg: 1 page/job
1 -3
(1/2)
Model Name GENERAL Print Engine Modem Speed(bps) Transmission Speed(sec.) ITU-T Group Coding Method Input/Output Width Input/Output Length ADF(pages) LCD size LCD Backlight Backup Clock Memory Capacity (physical) Optional Memory Dimensions w/ Carton (WxDxH) Dimensions w/o Carton (WxDxH) Weight w/ Carton Weight w/o Carton Color Operating Environment Temperature Humidity Power Source Power Consumption (Sleep/Standby/Peak) On/Off Switch Warm Up Time TELEPHONE Handset One-Touch Dial Speed Dial Speaker Phone Chain Dialing Caller ID Call Waiting Caller ID Distinctive Ringing Call Manage Hold/Mute key Power Failure Dialing Speaker Volume Ring Volume Handset Volume PBX Feature Transfer Method FAX Internet FAX Easy Receive/Fax Detect Fax/Tel Switch Enhanced Remote Activate Quick Scan(Memory transmission) Memory Transmission (ITU-T #1 Chart) Memory Transmission (Brother#1 Chart) Broadcasting Manual Broadcasting Out-of-Paper Reception (ITU-T #1 Chart) Out-of-Paper Reception (Brother#1 Chart) Auto Reduction ECM(Error Correction Mode) Group Dial Memory Security Memory Backup Color FAX (Document Send/Receive) Color FAX (Memory Send/Receive) LIST/REPORT Activity Report/Journal Report Transmission Verification Report INTERFACE External TAD Interface Host Interface (Serial) Host Interface (IEEE1284) Host Interface (USB) LAN Interface Acceptable Media Card Slot Analog Video Port YL4-FB(w/ Modem) MFC-9180 Laser (YL4) 14,400 (Fax) Approx. 6 (brother #1chart,MMR) G3 MH/MR/MMR 5.8"-8.5"/3.5"-8.5" 5"-14"/5"-14" 2 Up to 30 (75 g/m ) 16 characters x 2 lines Yes Yes (9 hours) 8 Mbytes (RAM) N/A 596 x 566 x 452 mm 459 x 458 x 354 mm 16 kg 11 kg Gray 1495 10 - 32.5 degrees Centigrade 20 - 80 % 220-240 VAC 50/60Hz 15W/ 75W/ 940W or less Yes Approx. 12 sec. YL4-FB(w/o Modem) MFC-9160 Laser (YL4) 5.8"-8.5"/3.5"-8.5" 5"-14"/5"-14" 2 Up to 30 (75 g/m ) 16 characters x 2 lines Yes Yes (1 hour) 8 Mbytes (RAM) N/A 596 x 566 x 452 mm 459 x 458 x 354 mm 16 kg 11 kg Gray 1495 10 - 32.5 degrees Centigrade 20 - 80 % 220-240 VAC 50/60Hz 15W/ 75W/ 940W or less Yes Approx. 12 sec. N/A N/A -
No No 100 No Yes N/A N/A Yes (UK.DEN only) No N/A N/A Yes (3 steps + OFF) Yes (3 steps + OFF) N/A Yes Flash
N/A Yes Yes Yes Yes as default. Approx.2.8 sec/page (A4 standard) 400 pages (MMR/Standard Resolution) 500 pages (MMR/Standard Resolution) Yes ( 150 locations) Yes (50 locations ) 400 pages (MMR/Standard Resolution) 500 pages (MMR/Standard Resolution) Yes Yes Yes (up to 6) Yes Yes ( Max. 4 days ) No / No No / No
Yes (up to 200) Yes
-
Yes No Yes Yes No N/A N/A
No No Yes Yes No N/A N/A
1 -4
(2/2)
Model Name PRINTER Color/Mono Engine Type Resolution (dpi) Speed (ppm) Paper Capacity (sheets) Additional Paper Capacity (sheets) Output Paper Capacity (sheets) Standard Print Language Emulation Resident Fonts Fonts Disk Based Paper Handling Size Manual Feed Slot Other Paper Type Sheet Weight (Paper Tray) (Manual Slot) Printer Driver COPY Color/Mono Speed (cpm) Multi Copy (Stack) Multi Copy (Sort) Reduction/Enlargement (%) Resolution (dpi) First Copy Out Time (From Ready Mode/ADF) (From Ready Mode/FB) YL4-FB(w/ Modem) MFC-9180 Mono Laser (YL4) 600 x 600 up to 10 2 200 (75 g/m ) No 50 Windows GDI Yes (PCL5e) Yes ( Bitmap font: LetterGothic16.66, OCR-A, OCR-B, Scalable font: 49 fonts ) Yes LTR, LGL, A4, A5, EXE, A6, ISO B5, ISO B6 N/A OHP, Envelopes, Organizer 2 64-158 g/m (16 - 42 lb) N/A Win95/98(SE)/Me/NT4.0WS/2000 professional YL4-FB(w/o Modem) MFC-9160 Mono Laser (YL4) 600 x 600 up to 10 2 200 (75 g/m ) No 50 Windows GDI Yes (PCL5e) Yes ( Bitmap font: LetterGothic16.66, OCR-A, OCR-B, Scalable font: 49 fonts ) Yes LTR, LGL, A4, A5, EXE, A6, ISO B5, ISO B6 N/A OHP, Envelopes, Organizer 2 64-158 g/m (16 - 42 lb) N/A Win95/98(SE)/Me/NT4.0WS/2000 professional
Mono Up to 10 Yes Yes (on ADF only ) 25 to 400 in 1% increments 300 x 300 (print) Approx. 13 sec. Approx. 12 sec.
Mono Up to 10 Yes Yes (on ADF only ) 25 to 400 in 1% increments 300 x 300 (print) Approx. 13 sec. Approx. 12 sec.
SCANNER Color/Mono Resolution (Optical: dpi) Resolution (Int.: dpi) Gray Scale Color Depth TWAIN Compliant&Operating System PCI Scanner (Parallel/Serial) BUNDLED SOFTWARE(For Windows) For Windows Support OS version Printer Driver TWAIN Viewer Pop Up Menu OCR PC Fax Remote Setup PC Diagnostics Others For iMac/G3/G4 Support OS version Printer Driver TWAIN Viewer Pop Up Menu OCR PC Fax Remote Setup PC Diagnostics Others ACCESSORY Life / Yield Toner:TN-8000 Drum:DR-8000
Color/Mono 600 x 2,400 9,600 x 9,600 256 24 bits (8 bits x 3) Win95/98(SE)/Me/NT4.0WS/2000Professional MacOS 8.6-9.1 Parallel/USB
Color/Mono 600 x 2,400 9,600 x 9,600 256 24 bits (8 bits x 3) Win95/98(SE)/Me/NT4.0WS/2000Professional MacOS 8.6-9.1 Parallel/USB
Win95/98/98SE/Me, WinNT4.0WS/2000Profrssional
Win95/98/98SE/Me, WinNT4.0WS/2000Profrssional
Yes Yes Yes Yes Yes Yes Yes Yes No
Yes Yes Yes Yes Yes No No Yes No
Print Others
MacOS8.5.1-9.1 MacOS8.6-9.1 Yes Yes No No No Yes No No No
MacOS8.5.1-9.1 MacOS8.6-9.1 Yes Yes No No No No No No No
Starter: N/A Regular:2,200 pages @5% coverage 20,000 pages @5% cvrg: Continuous printing 8,000 pages @5% cvrg: 1 page/job
Starter: N/A Regular:2,200 pages @5% coverage 20,000 pages @5% cvrg: Continuous printing 8,000 pages @5% cvrg: 1 page/job
1 -5
CHAPTER 2
INSTALLATION
CHAPTER 2 INSTALLATION CONTENTS
2.1 2.2
INSTALLING THE UPDATE DATA TO THE FACSIMILE MACHINE.............................2-1 SETTING ID CODES TO FACSIMILE MACHINES .........................................................2-3
2.1 INSTALLING THE UPDATE DATA TO THE FACSIMILE MACHINE
If the program version is updated or the main PCB is replaced, then install the update program onto the flash ROM of the main PCB. The program installation requires a PC/AT-compatible computer (which is capable of running MSDOS or its compatible OS).
Connecting the facsimile machine to your computer
(1) Make sure that your computer is turned off. (2) Make sure that the machine's power cord is unplugged from a wall socket. (If the machine has a power ON/OFF switch, make sure that the switch is turned off.) (3) Connect the parallel interface cable to the parallel port on the back of the machine and secure it with the lock wires. (4) Connect the other end of the interface cable to the printer port of your computer and secure it with the two screws. (5) While pressing the 5 key on the machine's control panel, plug the machine's power cord into a wall socket (or turn on the power ON/OFF switch if the machine has the switch). (6) Check to see that the following pattern displays on the LCD. If it does not display, go back to step (2) above.
1st row: Blank-and-black patterns 2nd row: Blank
(7) Turn on your computer.
Parallel interface cable
Host computer
Lock wires
2 -1
Installing the update data onto the flash ROM of the facsimile machine
NOTE: The following is an installation procedure example on a PC that is running Windows 95/98.
(1) Copy the update data and transfer utility onto the desired directory of the hard disk. e.g., C:\UPDATE (2) Click the Start button, point to Programs, and then click MS-DOS Prompt to open an MS-DOS window. (3) Type the drive letter where the update data and transfer utility are located. In the above example, type C:\ from the command line and press the ENTER key. Then type CD UPDATE and press the ENTER key. (4) Check that your computer is connected with the facsimile machine correctly. (5) To start the transfer utility transmitting the update data to the flash ROM of the facsimile machine, type the following: ICEN filename /b Then press the ENTER key. During downloading, the machine beeps intermittently. Upon completion of the downloading, the machine beeps continuously.
NOTE: If the facsimile machine cannot return to the standby state after completion of downloading, turn the power off and on.
2 -2
2.2 SETTING ID CODES TO FACSIMILE MACHINES
Function
Brother facsimile machines are assigned unique ID codes (character strings) at the factory. If you replace the main PCB of the machine, the machine will lose its assigned ID code so that it will not be identified by the connected PC*. You need to assign a unique ID code (character string) to the machine according to the procedure given here. For models covered by this manual, set serial numbers given to individual machines as ID codes.
(*ID codes are essential when more than one machine is connected to a single PC via USB.)
Connecting each of facsimile machines to your PC
(1) Make sure that your PC is turned off. (2) Make sure that the machine's power cord is unplugged from a wall socket or other power source. (3) Connect the interface cable to the parallel interface port on the back of the facsimile machine and secure it with the lock wires. (4) Connect the other end of the interface cable to the printer port of your PC and secure it with the two screws. (5) Plug the machine's power cord into a wall socket or other power source. (6) Turn on your PC.
Operating Procedure
(1) On your PC, run the ID setting utility. Follow the instructions shown on the PC's screen and enter the 9-digit serial number (e.g., G01012345) printed on the nameplate labeled to the back of the facsimile machine as an ID code. Then press the Enter key. The ID setting utility will transmit the ID code data from your PC to the facsimile machine and then it will terminate. The facsimile machine will automatically return to the standby mode. (2) To check whether the entered character string (ID code) is correct, make the machine enter the maintenance mode (refer to CHAPTER 5, Section 5.1) and then press the 1 key twice (Subsection 5.3.5). The facsimile machine will print out a Configuration List. At the right top of the list, "SER.#: BROXXXXXXXXX" is printed. (3) Check that the character string entered in step (2) is printed in "XXXXXXXXX." If it is OK, press the 9 key twice to exit from the maintenance mode. If something other than that is printed in XXXXXXXXX, check the connection between the PC and facsimile machine and go back to step (1).
2 -3
CHAPTER 3
THEORY OF OPERATION
CHAPTER 3 THEORY OF OPERATION CONTENTS
3.1 3.2
OVERVIEW ......................................................................................................................3-1 MECHANISMS .................................................................................................................3-2 3.2.1 3.2.2 Scanner Mechanism ............................................................................................3-4 Laser Printing Mechanism....................................................................................3-6 Paper pulling-in, registration, feeding, and ejecting mechanism..................3-6 Print process mechanism.............................................................................3-8 Heat-fixing mechanism ................................................................................3-9
3.2.2.1 3.2.2.2 3.2.2.3 3.2.3 3.3
Sensors and Actuators .......................................................................................3-10
CONTROL ELECTRONICS...........................................................................................3-12 3.3.1 Configuration ......................................................................................................3-12
3.1 OVERVIEW
* Provided on models supporting facsimile function.
3 -1
3.2 MECHANISMS
The facsimile machine is classified into the following mechanisms: n SCANNER MECHANISM n LASER PRINTING MECHANISM - ADF mechanism - Document scanning mechanism - Paper pulling-in and registration mechanism - Print process mechanism (consisting of charging, exposing, developing, transferring, and erasing processes) with paper feeding mechanism - Heat-fixing mechanism with paper feeding mechanism - Paper ejecting mechanism n SENSORS AND ACTUATORS
3 -2
3 -3
3.2.1 Scanner Mechanism
This mechanism consists of the document guide base, ADF & document tray ASSY and scanner unit. The ADF (automatic document feeder) unit contains a separation roller ASSY, document feed roller ASSY, document ejection roller, ADF motor, and document front and rear sensors. The scanner unit consists of a scanner top cover, CCD unit, CCD drive mechanism, CCD HP sensor, and scanner base. For details about the sensors, refer to Subsection 3.2.3.
3 -4
This scanner mechanism supports a dual scanning system. (1) If you set documents on the document guide base with their faces up and start the scanning operation, then the ADF motor rotates to pull in those documents into the ADF unit, starting from the top sheet to the bottom, page by page. Each document curves downwards and turns to the right with the document feed roller so as to advance above the CCD unit, and then it is fed out to the document tray with the document ejection roller ASSY. This way, documents move above the CCD unit being kept in a stationary position. (2) If you open the ADF & document tray ASSY, put a sheet of document (or put a bound book opened) on the glass of the scanner top cover, close the ADF & document tray ASSY, and start the scanning operation, then the CCD drive mechanism will be driven. The CCD motor built in the CCD unit rotates. As illustrated below, the CCD drive gear and idle pulley carry the CCD drive belt on the underside of the CCD unit, so clockwise and counterclockwise rotations of the CCD motor move the CCD unit to the right and left, respectively. In this scanning system, the CCD unit moves horizontally beneath a document being kept in stationary position.
The CCD unit contains a charge coupled device (CCD) image sensor. The cold-cathode fluorescent lamp illuminates a document and the reflected light of the scanned image data is transmitted via the mirrors into the lens which reduces the scanned data so as to form the image on the CCD.
3 -5
3.2.2 Laser Printing Mechanism 3.2.2.1 Paper pulling-in, registration, feeding, and ejecting mechanism
3 -6
Paper pulling-in and registration mechanism
The paper pulling-in and registration mechanism consists of the pull-in roller gear (incorporated in the auto sheet feeder ASF), planetary gear system, paper feed solenoid, solenoid lever, clutch release lever, and registration sensor. (For the details about the sensor, refer to Subsection 3.2.3.) If the main motor rotates clockwise, the rotation is transmitted to the intermediate gear of the planetary gear system. As the intermediate gear rotates, the pull-in roller drive gear also rotates since the clutch gear is locked by the solenoid lever and the clutch release lever. Accordingly, the pull-in roller in the ASF rotates to pull in paper into the machine, a sheet at a time. If the paper feed solenoid is retracted and the clutch release lever is operated according to the cam profile of the pull-in roller drive gear so as to release the clutch gear, the clutch gear rotates and the pull-in roller drive gear does not rotate. This way, the clutch gear switches the transmission of the motor rotation to the pull-in roller drive gear on and off. The solenoid on/off timing and the clutch release lever timing allow this mechanism to pull in a sheet and register it against the registration roller.
Paper feeding and ejecting mechanism
If the main motor rotates clockwise, the rotation is transmitted via the gear train to the drum drive gear, heater roller drive gear, and paper ejection roller drive gear. After the paper passes through the heat-fixing process, it will be ejected onto the paper tray. If the leading edge of the paper pushes up the actuator of the paper ejection sensor, the photosensor becomes opened, signaling the start of paper ejection. If the trailing edge has passed through the sensor actuator, the sensor becomes closed, signaling the completion of paper ejection. Then, the main motor stops rotation.
3 -7
3.2.2.2
Print process mechanism
The print process unit works with laser beam, electrical charges, and toner. The graph below shows the transition of electrical charge on the surface of the laser-sensitive drum through the five processes: charging, exposing, developing, transferring, and erasing processes.
A single cycle of laser-sensitive drum operation
1 2 3 4
+1000 Electrical +700 charge on the drum surface (V) +400 +300
(a)
1 Charges the drum surface positively. 2 Exposes the drum surface to a laser beam
(b)
to form a latent image and develops the latent image with toner. (a) Unexposed area (Non-image area) (b) Exposed area (Image area)
3 Transfers the toner-formed image from the
drum to paper.
4 Erases the residual potential.
Time
3 -8
3.2.2.3
Heat-fixing mechanism
As the paper passes between the heater roller and the pressure roller in the heat-fixing unit, the heater roller fuses the toner on the paper.
3 -9
3.2.3 Sensors and Actuators
This machine has ten sensors: seven photosensors, two thermistors and a mechanical switch as described below. Sensor name Document front sensor Document rear sensor Document tray open sensor Scanner open sensor Registration sensor Paper ejection sensor CCD HP sensor Toner sensor Toner thermistor Heater thermistor Type Photosensor Photosensor Mechanical switch Photosensor Photosensor Photosensor Photosensor Photosensor Thermistor Thermistor Located on Document sensor PCB in the ADF Document tray Control panel PCB Main-fan PCB High-voltage power supply PCB CCD PCB on the CCD unit Toner sensor PCB Heat-fixing unit
· Document front sensor which detects the presence of documents. · Document rear sensor which detects the leading and trailing edges of pages to tell the control circuitry when the leading edge of a new page has reached the starting position and when the scan for that page is over. · Document tray open sensor which detects whether the document tray is closed. · Scanner open sensor which detects whether the scanner unit is closed. · Registration sensor which detects the leading and trailing edges of paper, which allows the controller to determine the registration timing and check paper jam. · Paper ejection sensor which detects whether the recording paper goes out of the machine. · CCD HP sensor which detects whether the CCD unit is placed in the home position. · Toner sensor which detects whether there is toner or a toner cartridge is loaded. · Toner thermistor which allows the controller to monitor the ambient temperature of the toner cartridge. · Heater thermistor which allows the controller to monitor the temperature of the heater roller of the fixing unit. These photosensors are a photointerrupter consisting of a light-emitting diode and a light-sensitive transistor. Each of them has an actuator separately arranged as shown on the next page.
3 -1 0
Location of Sensors and Actuators
3 -1 1
3.3 CONTROL ELECTRONICS
3.3.1 Configuration
The hardware configuration of the facsimile machine is shown below.
Configuration of Facsimile Machine (NOTE 1) Provided on models equipped with facsimile function. (NOTE 2) Provided on the European, Pacific, and Asian versions. 3 -1 2
CHAPTER 4
DISASSEMBLY/REASSEMBLY AND LUBRICATION
CHAPTER 4 DISASSEMBLY/REASSEMBLY AND LUBRICATION CONTENTS
4.1
DISASSEMBLY/REASSEMBLY......................................................................................4-1 Safety Precautions ........................................................................................................4-1 Tightening Torque List......................................................................................................4-2 Preparation ...................................................................................................................4-4 How to Access the Object Component .........................................................................4-4 Disassembly Order Flow...............................................................................................4-5 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9 ADF Cover and Document Guide Base ...............................................................4-6 ADF Components on the Upper ADF Chute ........................................................4-7 ADF Components on the Lower ADF Chute ......................................................4-12 Document Tray Open Sensor and Document Stopper ......................................4-17 Scanner Unit and Control Panel ASSY (Together with Document Tray) ...........4-18 Disassembly of the Control Panel ASSY............................................................4-25 Disassembly of the Scanner Unit .......................................................................4-26 Front Cover ........................................................................................................4-31 Relay PCB ..........................................................................................................4-32
4.1.10 Scanner Mount ...................................................................................................4-33 4.1.11 Board Access Cover and Auto Sheet Feeder (ASF) ..........................................4-34 4.1.12 Heat-fixing Unit, FU Lamp, and Paper Ejection Sensor Actuator.......................4-40 4.1.13 Laser Unit and Toner Sensor PCB.....................................................................4-42 4.1.14 Main PCB ...........................................................................................................4-43 4.1.15 Bottom Plate.......................................................................................................4-46 4.1.16 Low-voltage Power Supply PCB.........................................................................4-47 4.1.17 High-voltage Power Supply PCB........................................................................4-48 4.1.18 Main-Fan PCB, Duct, and Fan ...........................................................................4-49 4.1.19 Power Supply Shield ..........................................................................................4-50 4.1.20 Speaker ..............................................................................................................4-51 4.1.21 Gear Drive Unit...................................................................................................4-52
4.1.22 PCB Support and NCU PCB ..............................................................................4-54 4.1.23 Scanner Grounding Plate ...................................................................................4-55 4.1.24 EL (Eraser Lamp) Board ....................................................................................4-56 4.1.25 Harness Routing.................................................................................................4-57 4.1.26 Cleaning of High-voltage Contacts and Grounding Contacts.............................4-61 4.2 4.3 4.4 LUBRICATION ...............................................................................................................4-62 PERIODICAL REPLACEMENT PARTS ........................................................................4-64 MTBF/MTTR ..................................................................................................................4-65
4.1 DISASSEMBLY/REASSEMBLY
n Safety Precautions
To prevent the creation of secondary problems by mishandling, observe the following precautions during maintenance work. (1) Unplug the power cord from the power outlet before replacing parts or units. When having access to the power supply, be sure to unplug the power cord from the power outlet. (2) When servicing the optical system of the laser printing unit, be careful not to place screwdrivers or other reflective objects in the path of the laser beam. Be sure to take off any personal accessories such as wrist watches and rings before working on the printer. A reflected beam, though invisible, can permanently damage your eyes. (3) If the machine has been printing, allow the heat-fixing unit sufficient time to cool down before starting maintenance jobs. It is HOT! (4) Be careful not to lose screws, washers, or other parts removed for parts replacement. (5) Do not remove gears from the document feed roller ASSY or ejection roller ASSY if at all possible. Once removed, they will become unusable and new gears will have to be put back in. (6) When using soldering irons and other heat-generating tools, take care not to damage the resin parts such as wires, PCBs, and covers. (7) Before handling the PCBs, touch a metal portion of the machine to discharge static electricity; otherwise, the electronic parts may be damaged due to the electricity charged in your body. (8) When transporting PCBs, be sure to wrap them in conductive sheets such as aluminum foil. (9) Be sure to reinsert self-tapping screws correctly, if removed. (10) Tighten screws to the torque values listed on the next page. (11) When connecting or disconnecting cable connectors, hold the connector bodies not the cables. If the connector has a lock, always slide the connector lock to unlock it. (12) Before reassembly, apply the specified lubricant to the specified points. (Refer to Subsection 4.2 in this chapter.) (13) After repairs, check not only the repaired portion but also that the connectors and other related portions function properly before operation checks.
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Tightening Torque List Location ADF thickness adjuster Upper ADF chute Lower ADF chute Grounding wire ADF drive unit ADF motor Grounding wire on the scanner mount Document tray Hinge base R Hinge L Control panel ASSY Scanner open sensor PCB Reinforcement plate Control panel PCB Scanner top cover Guide plate CCD HP sensor plate Flat cable clamp Front cover guides Relay PCB Scanner mount Board access cover Release lever Grounding leaf spring R Grounding leaf spring L Heat-fixing unit Fixing unit upper cover Lock plate Fuse plate R Laser unit Main shield Parallel interface connector Main PCB Bottom plate Screw type Taptite, pan B M3x6 Taptite, cup B M3x10 Taptite, cup B M3x10 Taptite, cup B M3x10 Taptite, cup B M3x8 Screw, pan (s/p washer) M3x6 Taptite, cup B M3x10 Taptite, bind B M4x12 Taptite, cup B M3x10 Taptite, cup B M3x10 Taptite, cup B M3x12 Taptite, cup B M3x8 Taptite, cup B M3x6 Taptite, cup B M3x6 Taptite, cup B M4x12 Taptite, cup B M3x8 Taptite, cup B M3x8 Taptite, cup B M3x8 Taptite, cup B M3x10 Taptite, cup B M3x10 Taptite, bind B M4x12 Taptite, bind B M4x12 Taptite, bind B M4x10 Taptite, bind B M2.6x8 Taptite, bind B M2.6x8 Taptite, cup B M4x16 Taptite, bind B M3x12 Taptite, pan B M3x10 Screw, pan (washer) M2.6x6DA Taptite, bind B M4x12 Taptite, cup S M3x6 Taptite, pan S M3x12 Taptite, cup S M3x6 Taptite, bind B M4x12 Taptite, cup S M3x6 Q'ty 1 2 2 1 2 1 1 2 3 3 6 1 7 2 4 3 1 2 2 2 2 2 1 1 2 2 2 1 1 3 2 2 2 5 4 Tightening torque N·m (kgf·cm) 0.39 ±0.10 0.69 ±0.10 0.69 ±0.10 0.69 ±0.10 0.69 ±0.10 0.69 ±0.10 0.39 ±0.10 0.98 ±0.20 0.69 ±0.10 0.69 ±0.10 0.39 ±0.10 0.39 ±0.10 0.39 ±0.10 0.39 ±0.10 0.98 ±0.20 0.69 ±0.10 0.69 ±0.10 0.69 ±0.10 0.69 ±0.10 0.39 ±0.10 0.98 ±0.20 0.78 ±0.10 0.98 ±0.20 0.39 ±0.10 0.39 ±0.10 0.98 ±0.20 0.69 ±0.20 0.69 ±0.20 0.39 ±0.10 0.98 ±0.20 0.69 ±0.20 0.69 ±0.20 0. 69 ±0.20 0.98 ±0.20 0. 69 ±0.20 (4 ±1) (7 ±1) (7 ±1) (7 ±1) (7 ±1) (7 ±1) (4 ±1) (10 ±2) (7 ±1) (7 ±1) (4 ±1) (4 ±1) (4 ±1) (4 ±1) (10 ±2) (7 ±1) (7 ±1) (7 ±1) (7 ±1) (4 ±1) (10 ±2) (8 ±1) (10 ±2) (4 ±1) (4 ±1) (10 ±2) (7 ±2) (7 ±2) (4 ±1) (10 ±2) (7 ±2) (7 ±2) (7 ±2) (10 ±2) (7 ±2)
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Low-voltage power supply PCB (Low-voltage insulator sheet) Grounding wire Power inlet support High-voltage power supply PCB Duct Fan support Power supply shield Gear drive unit Main motor Gear support plate PCB support NCU shield NCU PCB Scanner grounding plate
Taptite, cup S M3x6 Screw, pan (washer) M4x8DB Taptite, cup S M3x6 Taptite, bind B M4x12 Taptite, bind B M4x12 Taptite, cup B M3x8 Taptite, cup S M3x6 Taptite, bind B M4x14 Taptite, cup S M3x6 Taptite, cup S M3x16 Taptite, bind B M4x12 Taptite, cup S M3x6 Taptite, cup S M3x6 Taptite, cup B M3x8
2 1 1 1 2 1 2 4 2 2 2 2 1 1
0. 69 ±0.20 0.39 ±0.20 0. 69 ±0.20 0.98 ±0.20 0.98 ±0.20 0. 49 ±0.20 0. 69 ±0.20 0. 98 ±0.20 0. 69 ±0.20 0. 69 ±0.20 0. 98 ±0.20 0. 69 ±0.20 0. 69 ±0.20 0. 49 ±0.20
(7 ±2) (4 ±2) (7 ±2) (10 ±2) (10 ±2) (5 ±2) (7 ±2) (10 ±2) (7 ±2) (7 ±2) (10 ±2) (7 ±2) (7 ±2) (5 ±2)
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n Preparation
Prior to proceeding to the disassembly procedure, (1) Unplug - the modular jack of the telephone line (only for models equipped with the fax function), - the power cord, - the modular jack of the curled cord (and remove the handset), - the PC interface cable (parallel cable or USB cable) if connected (Not shown below), and - the modular jack of an external telephone set if connected (Not shown below). (2) Remove - the paper support, - the paper tray, and - the drum unit (with the toner cartridge loaded)
n How to Access the Object Component
· On the next page is a disassembly order flow which helps you access the object components. To remove the gear drive unit, for example, first find it on the flow and learn its number ( this case). You need to remove parts numbered access the gear drive unit. · Unless otherwise specified, the disassembled parts or components should be reassembled in the reverse order of removal. , , , , , , and in so as to
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n Disassembly Order Flow
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4.1.1 ADF Cover and Document Guide Base
(1) Open the ADF cover, press its front end to release the boss, and take it off (in the direction of arrows , , and ).
(2) Release the two latches of the document guide base and slide it up straight along the guides. NOTE: Do not turn it to the left. Doing so will break the groove sections of the document guide base.
n Reassembling Notes
· When setting the ADF cover back into place, fit its bottom edge under the stopper tabs as illustrated above.
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4.1.2 ADF Components on the Upper ADF Chute
Gear cover
(1) As illustrated below, insert the tip of a flat screwdriver into the slot and lift up the right edge of the gear cover (arrow ) and move the gear cover to the front (arrow ).
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Separation roller ASSY and document feed roller
(2) From the rear end of each of the separation roller ASSY and document feed roller, remove the plastic retaining ring. Lift up the rear ends of them and take them out together with bushings S. NOTE: Take care not to drop bushings S.
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Reassembling Note: If you have disassembled the separation roller ASSY, set the separation roller on its shaft with the boss facing towards the pin and then snap the plastic retaining ring into place, as illustrated below.
Reassembling Note: When setting the separation roller ASSY, take care not to apply force to the spring plate at an angle, as illustrated on the previous page. Reassembling Note: After setting the rear end of the separation roller ASSY or document feed roller to the ADF drive unit, fit its bushing into the cutout provided in the ADF drive unit and then set the plastic retaining ring inside the upper ADF chute, as illustrated on the previous page.
Separation rubber unit, ADF thickness adjuster, and pressure rollers
(3) Turn the separation rubber unit as shown below and lift it up.
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(4) Remove the screw and take the ADF thickness adjuster out of the upper ADF chute. NOTE: The ADF thickness adjuster is lubricated with grease, so take care not to smear surrounding parts with the grease when handing the ADF thickness adjuster. (5) At either end of the pressure roller shaft, press the latch to the right and take out the pressure rollers and their shaft. Then remove their springs.
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Upper ADF chute
(6) Remove the two screws from the upper ADF chute. (7) Open the document tray ( ). (8) From the underside of the document tray, release the two leftmost latches ( ) and then pull up the left end of the upper ADF chute ( ).
Reassembling Note: When latching the upper ADF chute, first fit tabs (1) of the right end into the openings provided in the document tray, then press latches (2), (3), and (4) into place in this order as shown above.
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4.1.3 ADF Components on the Lower ADF Chute
Document front and rear sensor actuators
(1) Lift up the document front sensor actuator. Fully turn the document rear sensor actuator counterclockwise, then lift it up.
Document sensor PCB
(2) Take the document sensor harness out of the cable hooks, then disconnect it from the document sensor PCB. (3) Press the locking pawl to the front and take out the document sensor PCB.
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Document guide clips
(4) Press the tab of each document guide clip. Each clip will snap out of the document ejection roller shaft.
Document ejection roller
(5) Remove the pawled bushing from the front end of the document ejection roller shaft by pulling its pawls outwards. (6) Slide the rear bushing to the rear and then lift up the document ejection roller.
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Reassembling Note: When fitting the rear bushing of the document ejection roller into the cutout of the ADF drive unit, orient the boss as illustrated on the previous page.
Document pressure bar
(7) Open the ADF & document tray ASSY. (8) Pull either of the front and rear supports of the document pressure bar outwards and remove the document pressure bar. The spring also comes off.
Reassembling Note: After setting the document pressure bar, check in the direction of arrow "X" that the spring is into place as illustrated above.
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Lower ADF chute, pinch rollers, and ADF motor
(9) Take the document sensor harness out of cable hooks provided on the lower ADF chute. (10) Disconnect the ADF motor harness from the motor, then take its harness out of the cable guides and hooks. (11) Release the grounding wire from the ADF drive unit by removing the screw. (12) Remove the two screws from the lower ADF chute. (13) Lift up the lower ADF chute in the direction of the arrow shown below, taking care not to touch the anti-static brush. (14) Press the latch to the left and remove the pinch rollers and its shaft.
When reinstalling the lower ADF chute, turn the planet gear counterclockwise (when viewed from the rear)
ADF drive unit
Grounding wire Taptite, cup B M3x10 Planet gear Lower ADF chute
Anti-static brush (Do not touch this.) Pinch roller shaft Pinch rollers
Pinch roller spring ADF motor harness Taptite, cup B M3x10 Grounding wire
Document sensor harness
Latch
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(15) Remove the two screws from the ADF drive unit and release the ADF motor. NOTE: When using a screwdriver, take care not to scratch or damage gears on the ADF drive unit.
Reassembling Note: When setting the ADF motor, hook the non-screw side of the flange on section "x" (shown above) and secure it with the screw. Reassembling Note: Before reinstalling the lower ADF chute to the document tray, be sure to turn the planet gear on the ADF drive unit counterclockwise when viewed from the rear, as illustrated on the previous page. Reassembling Note: For routing the ADF motor harness, document sensor harness, and grounding wire, refer to Subsection 4.1.25, "Harness routing A." Secure the grounding wire at the angle shown on the previous page and let it hold down the ADF motor harness and document sensor harness as shown in "Harness routing A."
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4.1.4 Document Tray Open Sensor and Document Stopper
(1) Disconnect the document tray open sensor harness from the sensor. (2) Open the document tray. (3) Press the right and left latches of the document tray open sensor with the tip of a flat screwdriver as shown below and push it down.
(4) Slightly open the document stopper and remove it while warping it.
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4.1.5 Scanner Unit and Control Panel ASSY (Together with Document Tray)
(1) Pull the scanner open lever and open the scanner unit. (2) Unhook the two scanner springs. (The right-hand scanner spring is shorter than the left-hand one.)
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(3) At each of the right and left rear edges of the front cover, push up the lock of the front cover connector (in the direction of arrow ) and press the rear edge of the front cover inwards (arrow ) to release its boss from the front cover connector.
(4) While keeping the scanner unit open, unlatch the relay PCB cover and take it out.
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(5) While keeping the scanner unit open (in the direction of arrow cable (arrow ) from the relay PCB. NOTE: Handle the CCD flat cable with care.
), disconnect the CCD flat
(6) Open the scanner unit further and lift up its rear edge to disengage it from the scanner mount. Then shift the scanner unit to the front right as shown below (arrow ) so that the relay PCB can be fully seen. CAUTION: When putting the scanner unit on the scanner mount, take special care not to bend, wrinkle, or scratch the CCD flat cable or not to break the boss of the front cover (that is provided for the scanner open sensor actuator) by the bottom of the scanner unit.
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(7) Disconnect the following harnesses from the relay PCB: Document tray open sensor harness Document sensor harness ADF motor harness Panel harness
(8) Release the grounding wire (coming from the ADF drive unit) by removing the screw. (9) Lift up the scanner unit together with the document tray and control panel ASSY.
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(10) Remove the two screws from the bottom rear of the hinges. (11) Be sure to open the document tray, then release the harnesses (bound and covered with the cable sheath) from the latch and move them to the front in the opening. (12) Lift up the document tray.
(13) From the hinge base R, remove the hinge arm as shown below. Remove the three screws and release the hinge base R. (14) From the hinge L that should be kept opened, remove the three screws.
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(15) Remove the six screws from the underside of the scanner base. (16) Release the two latches of the control panel ASSY from the scanner base. (17) Slightly lift up the control panel ASSY and disconnect the panel harness from the control panel PCB. (18) Turn the scanner open sensor actuator as shown below and remove it. (19) Remove the screw from the scanner open sensor PCB. Then the control panel ASSY is separated from the scanner unit. (For the disassembly procedure of the control panel ASSY and scanner unit, refer to Subsections 4.1.6 and 4.1.7, respectively.) (20) Remove the lever spring. (21) Insert the tip of a flat screwdriver into slit "s," push up the lock, and remove the scanner open lever in the direction of the arrow.
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n Reassembling Notes
· When setting the document tray on the scanner unit, pass the bound harnesses (ADF motor harness, document sensor harness, document tray open sensor harness, and grounding wire) through the front section of the opening provided in the left rear corner of the document tray, with its bound section facing up (see the illustration given on page 4-22). Move those bound harnesses to the rear section of the opening. Route the bound section through the cable guide so that the cable binder comes into contact with the cable guide as illustrated on page 4-22. Refer to Subsection 4.1.25 "Harness routing A." · When putting the scanner unit on the scanner mount, take special care not to bend, wrinkle, or scratch the CCD flat cable or not to break the boss of the front cover by the bottom of the scanner unit. (See the illustration given on page 4-20.) · Route the document sensor harness, document tray open sensor harness, ADF motor harness, panel harness, and grounding wire on the scanner mount as shown on page 4-21. Wind the document sensor harness and document tray open sensor harness around the cable clip on the relay PCB, and then bend the cable clip as shown in Subsection 4.1.25, "Harness routing B."
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4.1.6 Disassembly of the Control Panel ASSY
(1) Remove the two screws from the control panel PCB. (2) Slightly lift up the control panel PCB, then unlock the FPC key connector and disconnect the FPC key. Next, unlock the LCD cable connector and disconnect the LCD flat cable. (3) Remove the seven screws and take off the reinforcement plate and FPC key.
(4) As shown below, pull the lock arms outwards to release the LCD and pull the LCD flat cable gently.
n Reassembling Notes
· Before reinstalling the LCD to the control panel, wipe fingerprints or dust off the LCD surface and control panel window with a soft cloth. · A new LCD is covered with a protection sheet. Before installing it, remove the protection sheet.
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4.1.7 Disassembly of the Scanner Unit
The disassembly job of the scanner unit should be done in a clean room to prevent dust or dirt from getting into the scanner unit. (1) Remove the four screws from the scanner top cover. (2) Separate the scanner top cover from the scanner base.
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(3) Release the CCD drive belt from boss "a." (4) At the left front end of the CCD drive belt, unhook the belt spring from boss "b." NOTE: Do not remove the belt spring or belt clip from the CCD drive belt. (5) As illustrated below, move the CCD unit to the right, lift up its front end and turn the CCD unit upright. The CCD drive belt will slip off the CCD idle pulley and gear on the underside of the CCD unit.
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(6) Disconnect the CCD flat cable from the CCD PCB, then release the cable that is attached to the underside of the CCD unit with double-sided adhesive tape. NOTE: Only when the CCD unit or CCD flat cable is defective and requires replacement, release the flat cable. Once released, the flat cable should be attached using new double-sided adhesive tape. (7) Lift up the CCD rail together with the CCD unit from the scanner base, then pull out the CCD rail. NOTE: When handling the CCD unit, do not touch the CCD PCB or glasses but hold the hatched sections as shown on the next page.
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(8) Remove the three screws and lift up the guide plate. (9) Remove the screw from the CCD HP sensor plate.
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(10) Remove the two screws and take off the flat cable clamp. (11) To take out the panel harness, remove sponges F and R that are backed with adhesive tape. NOTE: Once removed, those sponges will become unusable and new parts will have to be put back in. (12) To take out the CCD flat cable, remove sponge R.
n Reassembling Notes
· When replacing the CCD unit with a new one, you need to attach a CCD protector to it as specified on page 4-28. A new CCD protector is covered with a protection sheet, so remove the protection sheet before attaching. · When using a new CCD flat cable, fold it and secure it to the scanner base with double-sided adhesive tape and sponge R (backed with adhesive tape) as illustrated above. Then attach it to the underside of the CCD unit with double-sided adhesive tape. · When reassembling the components inside the scanner unit, use screws (Taptite, cup B M3x8). Never use longer ones (e.g., M3x10). Using longer ones will bore a hole in the scanner base. · When installing the CCD drive belt to the scanner base, set its rear end within the range specified on page 4-27.
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4.1.8 Front Cover
(1) Press the rear ends of the front cover inwards (in the direction of arrow "a" from the front cover guides. (2) Remove the screw from each of the front cover guides.
) to release bosses
(3) While pulling the tab of each front cover guide up and to the front (in the direction of arrow ) to release the guide from boss "b," remove the guide in the direction of arrow .
n Reassembling Notes
· When setting the front cover guides back into place, fit sections "y" and "x" into "Y" and "X" of the scanner mount, respectively, while pushing the guides down and to the front.
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4.1.9 Relay PCB
(1) Disconnect the three relay harnesses from the relay PCB. (2) Remove the two screws. The cable clip will come off and the grounding wire will be released. (3) Lift up the relay PCB.
Taptite, cup B M3x10
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4.1.10 Scanner Mount
(1) Remove the harness cover. NOTE: Once removed, the harness cover will become unusable and a new part will have to be put back in. (2) Remove the relay (ADF) harness from seven latches and then bring it to the right.
(3) Remove the two screws from the scanner mount (4) Remove the scanner mount in the direction of the arrows.
n Reassembling Notes
· Route the relay (ADF) harness through seven latches on the scanner mount. Refer to Subsection 4.1.25, "Harness routing C."
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4.1.11 Board Access Cover and Auto Sheet Feeder (ASF)
(1) Remove the two screws from the board access cover. (Those screws secure also the ASF to the main cover.) (2) Push down the top of the board access cover to release the two latches from the main cover, then pull it to the rear. (3) Pull the ASF to the front and then lift it up.
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[Disassembling the ASF]
1) Unhook the release lever spring. 2) Remove screw "a" and pull out the release lever. 3) Turn the release cam to the front and pull it out to the left.
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4) At the right end of the ASF, remove the screw from the grounding leaf spring R. (It is not necessary to remove the leaf spring.) Next pull out the pawled bushing R. At the left end of the ASF, remove the sector gear and its spring. Unlatch the pawled bushing L to the left and then remove it from the paper pull-in roller shaft. Remove the paper pull-in roller.
5) Push the right and left ends of the separation pad ASSY inwards and take it out. The spring also comes off.
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6) Turn the ASF upside down, then remove the registration sensor actuator.
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7) There are two sets of pinch roller units. At each set, remove the leaf spring (in the order of to shown below), pinch rollers, and pinch roller shaft. 8) At the right end of the paper feed roller, remove the screw and take off the grounding leaf spring R if you have not removed it in step 4) above. Remove the pawled pushing R. 9) At the left end of the paper feed roller, remove two screws and take off the grounding leaf spring L, pawled PF gear, and idle gear. Then remove the paper feed roller.
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10) Press the lock arm provided at the left inside of the ASF to the rear with a screwdriver, slide the ASF chute ASSY to the left, and take it out to the front. NOTE: To replace only the black film attached to the chute, do not remove the chute ASSY from the ASF. NOTE: A new chute and black film will be provided separately. When replacing the ASF chute ASSY, first set the chute into the ASF and then attach the black film to the chute. If you first attach the black film to the chute and then set the ASF chute ASSY, then the black film may be bent or wrinkled.
n Reassembling Notes
· Set the paper feed roller into the ASF with the D-shaped end facing leftwards. · Set the paper pull-in roller into the ASF with the D-shaped end facing leftwards. · When setting the release lever back into place, turn the release cam to the rear and then set the release lever so that the bottom end of the release lever comes in the front of the boss provided on the ASF, as illustrated on page 4-35.
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4.1.12 Heat-fixing Unit, FU Lamp, and Paper Ejection Sensor Actuator
(1) Remove the two screws from the heat-fixing unit. (2) Lift up the heat-fixing unit and disconnect the blue and brown heater wires (of the heater harness) from the heat-fixing unit. Then disconnect the heater thermistor harness from the EL (eraser lamp) board. (3) Remove the paper ejection sensor actuator from the bottom of the heat-fixing unit.
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(4) To take out the FU lamp from the heat-fixing unit, remove two screws "a." (5) Fully open the upper cover and remove it. (6) Unlatch the idle gear 16 and remove it. (7) Loosen screw "b." (8) Remove screw "c" and take out the lock plate. (9) Slightly lift up the left end of the heater roller and hold the left end of the FU lamp. While pinching the fuse plate R with your right hand, pull out the FU lamp from the heater roller. CAUTION: Do not touch the FU lamp. If you have touched it, clean it thoroughly with alcohol.
n Reassembling Notes
· When setting the FU lamp into the heat-fixing unit, be sure to insert the right edge of the wire into the folded fuse plate R. · A new heat-fixing unit will be provided with the heater thermistor harness being taped to the unit. When installing the unit, remove the tape. · Route the blue and brown heater wires on the main cover as illustrated in Subsection 4.1.25, "Harness routing F."
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4.1.13 Laser Unit and Toner Sensor PCB
(1) Disconnect the polygon motor flat cable, toner sensor harness, and laser diode harness from the main PCB. (2) Remove the three screws from the laser unit. (3) Lift up the laser unit. NOTE: When handling the laser unit, take care not to touch the inside of the unit, glass, or mirror. NOTE: On the small PCB at the right side of the laser unit is a 2-pin connector which is for the adjustment in the factory. Do not disturb it.
n Reassembling Notes
· When replacing the laser unit with a new one, be sure to attach a ferrite core to the laser diode harness of the new laser unit. Wind the harness around the ferrite core by two turns as shown above, just like the laser diode harness of the old laser unit. · On the underside of the laser unit, route the laser diode harness, polygon motor flat cable, and toner sensor harness as illustrated in Subsection 4.1.25, "Harness routing G." · Before putting the laser unit back into place, check for any toner particles, paper dust or dirt, and clean them out. · Make sure that the sponge is placed below the laser unit.
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4.1.14 Main PCB
(1) Disconnect the following harnesses and flat cable from the main PCB: · NCU harness · Low-voltage power harness · Main motor harness · Relay (ADF) harness · Relay (CCD/PANEL) harness · High-voltage power flat cable · Main-fan harness · Solenoid harness · Relay (CCD/SEN) harness · Speaker harness (2) Remove two screws "a" from the main shield. (3) Remove two screws "b" from the parallel interface connector. (4) Remove two screws "c" from the main PCB and then take it off from the PCB support. The grounding wire will be released.
"a" and "c": Taptite, cup S M3x6 "b": Taptite, pan S M3x12 4 -4 3
n Reassembling Notes
· Be sure to route the harnesses and flat cable as illustrated in Subsection 4.1.25, "Harness routing D." Make sure that the main motor harness is routed closest to the main PCB and that the relay (CCD/SEN) harness is routed after other harnesses are connected. Make sure that harnesses having ferrite cores are taped. In particular, the main motor harness should be taped above and below the ferrite core. · If you replace the main PCB, be sure to follow the flowchart given on the next page.
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Setting up the main PCB after replacement
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4.1.15 Bottom Plate
(1) Turn the machine upside down. (2) Remove the nine screws (four "x" and five "y") from the bottom plate, then lift it up.
"x": Taptite, cup S M3x6 "y": Taptite, bind B M4x12
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4.1.16 Low-voltage Power Supply PCB
(1) Remove screw "a" and take off the low-voltage insulator sheet. (2) Remove screws "c" and "d" to release the grounding wire and power inlet support, respectively. (3) While pulling the right rear of the main cover (placed upside down) outwards to release the ON/OFF switch, lift up the power inlet support. For the new type of the power inlet support having an opening: You need to cut off the binder that fastens the blue and brown lead wires of the AC power cord to the power inlet support. (4) Remove screw "b." (5) Slightly lift up the low-voltage power supply PCB and disconnect the low-voltage power harness and heater harness (of the blue and brown wires).
Power inlet support "d" (Opening provided in the new type of the power inlet support) "a" Low-voltage insulator sheet "c"
Grounding wire Heater harness
Low-voltage power supply PCB Low-voltage power harness
"b" "e" U-shaped cutout
Main cover (placed upside down)
"g" Opening provided in the power supply shield "f" Openings provided in the power supply shield
"a," "b," and "d": Taptite, cup S M3x6 "c": Screw, pan (washer) M4x8DB
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n Reassembling Notes
· Be sure to route the heater harness through U-shaped cutout "e" provided in the power supply shield. Then, route the AC power cable through the same cutout "e" on the heater harness. (Refer to Subsection 4.1.25, "Harness routing H." · Fit the front tabs of the low-voltage power supply PCB into openings "f." · Fit the front tab of the insulator sheet into opening "g." · To prevent the blue and brown lead wires of the AC power cord from getting damaged by the edge of the power inlet support or the end of screw "c," be sure to observe the following routing instructions: For the power inlet support having no opening 1) Route the grounding wire between the boss and the power supply shield as shown below. 2) Push down the ferrite cores of the AC lead wires and grounding wire. 3) Secure the grounding terminal to the power inlet support with screw "c" at an angle shown below.
Push down these ferrite cores.
(Rear)
Power supply shield Boss
Screw "c"
Secure the grounding terminal at this angle.
Route the grounding wire between the boss and the power supply shield.
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For the new type of the power inlet support having an opening 1) Route the AC lead wires (blue and brown) through the opening provided in the power inlet support and pull them in the direction shown below to bring the ferrite cores closer to the opening. 2) Fasten the AC lead wires to the power inlet support with a binder.
For machines without power switch
Power inlet support Power inlet support B A View B 1 mm min. Power inlet support
max.
3 to 9 mm
Pull the AC lead wires in this direction.
For machines with power switch 1 mm max. View A Fasten the AC lead wires with a binder.
3 to 9 mm
View B 1 mm min.
3) Secure the grounding wire to the power inlet support with screw "c."
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2 mm
4.1.17 High-voltage Power Supply PCB
(1) Remove the screw and take off the high-voltage insulator sheet. (2) Slightly lift up the high-voltage power supply PCB and disconnect the high-voltage power flat cable and EL (eraser lamp) harness.
n Reassembling Notes
· Fold the high-voltage power flat cable and route it as illustrated above. · Before reinstalling the high-voltage power supply PCB, check the high-voltage contacts for any toner particles, paper dust or dirt, and clean them out.
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4.1.18 Main-Fan PCB, Duct, and Fan
(1) Take off the duct by removing the two screws. (2) Unlatch the main-fan PCB and lift it up and out of the main cover. (3) Disconnect the fan harness from the PCB. (4) Take off the fan support by removing the screw. (5) Lift up the fan.
n Reassembling Notes
· Route the fan harness on the fan as illustrated above. · Put the fan back into place with the label side facing outwards and with its harness directed as shown above.
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4.1.19 Power Supply Shield
(1) Remove the two screws and lift up the power supply shield.
n Reassembling Notes
· When reinstalling the power supply shield, route the low-voltage power harness through the opening and route the heater harness through U-shaped cutout "e" as shown above.
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4.1.20 Speaker
(1) Pull the speaker spring inwards and pull up the speaker together with the spring.
n Reassembling Notes
· Put the speaker into place with its harness facing up. · Route the speaker harness through the latch together with the solenoid harness and main motor harness as shown above.
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4.1.21 Gear Drive Unit
(1) Make sure that the heat-fixing unit is removed. (2) Take out the heater harness from the cable guides provided on the top of the gear drive unit. (3) Remove the four screws and lift up the gear drive unit.
(4) Remove the two screws and take off the main motor.
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(5) To take off the paper feed solenoid, solenoid lever, or clutch release lever, remove the two screws.
n Reassembling Notes
· If the friction spring in the gear drive unit slips off, fit the straight end of the spring in the support hole of the gear drive unit as illustrated above. · When putting the gear drive unit back into the main cover, route the solenoid harness and main motor harness along the outside of the gear drive unit. Be sure to sandwich the grounding plate between the contact plate and gear drive unit. See the illustration given on the previous page. · After securing the gear drive unit, route the heater harness through the cable guides provided on the top of the gear drive unit.
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4.1.22 PCB Support and NCU PCB
(1) Remove the two screws and lift up the PCB support.
(2) Remove the two screws and take off the NCU shield. (3) Remove the screw and take off the NCU PCB from the PCB support. (4) Disconnect the NCU h