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FACSIMILE EQUIPMENT
SERVICE MANUAL
MODEL: MFC5100C/MFC590
© 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 facsimile equipment. It includes information required for field troubleshooting and repair--disassembly, reassembly, and lubrication--so that service personnel will be able to understand equipment function, to rapidly repair the equipment and order any necessary spare parts. To perform appropriate maintenance so that the facsimile equipment 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.
CHAPTER 1
GENERAL DESCRIPTION
CHAPTER 1 GENERAL DESCRIPTION CONTENTS
1.1
EQUIPMENT 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 EQUIPMENT OUTLINE
1.1.1 External Appearance and Weight
The figure below shows the equipment appearance and approximate dimensions.
(D) 467 mm 18.4"
(H) 370 mm 14.6" (W) 468 mm 18.4" (including handset)
Weight: 1.1.2 Components
Machine proper In package
Approx. 15 kg (33.1 lbs.) Approx. 11 kg (24.2 lbs.)
The equipment consists of the following major components:
Scanner top cover ADF & document tray ASSY
Scanner base Control panel ASSY
Relay PCB Jam clear cover
Main cover
Rear cover
Auto sheet feeder (ASF)
Main chassis Bottom plate Enclosure cover NCU PCB Purge unit
Main PCB Lower cover Ink absorber box Power supply PCB
1 -1
1.2 SPECIFICATIONS
(1/2)
Model Name GENERAL Print Engine Modem Speed (bps) Transmission Speed (sec.) ITU-T Group Coding System Print Paper Size (W x L) Document Size for ADF (W x L) Max. Document Size for Flat-bed Scan (W x L) Print Paper Margin (upper, lower, left, right) ADF (pages) LCD Columns LCD Lines LCD Backlight Backup Clock Memory Backup Memory Capacity (physical) Optional Memory Dimensions w/ Carton (WxDxH) Dimensions w/o Carton (WxDxH) Weight w/ Carton Weight w/o Carton Color Standby Mode PC-Fax Protocol Compliance Simultaneous Operation Energy Star Compliant Operating Environment Temperature Humidity Power Source Power Consumption (Standby/Peak) On/Off Switch TELEPHONE Handset One-Touch Dial Speed Dial Speaker Phone Chain Dialing Caller ID Call Waiting Caller ID Distinctive Ringing Hold/Mute Key Hook Key Power Failure Dialing Speaker Volume Ring Volume Handset Volume FAX Scan Speed (A4:Standard) Memory Transmission (Brother#1 Chart) Memory Transmission (ITU-T Chart) Out-of-Paper Reception (Brother #1 Chart) Out-of-Paper Reception (ITU-T Chart) Color FAX (Document Send/Receive) Color FAX (Memory Send/Receive) Approx. 3 sec./page (A4: standard) Yes (200:MMR) Yes (170:MMR) Yes (200:MMR) Yes (170:MMR) Yes/Yes No/Yes No No Max. 40 No Yes No No Yes No No No No Yes (2 steps + OFF) No Ink Jet (BH 2-head) 14,400 (Fax) 6 (Brother#1, MMR) G3 MH/MR/MMR/JPEG 3.5"-8.5" x 5.0"-14" 5.8"-8.5" x 5.7"-14" 8.5" x 11.7" 0.12, 0.43, 0.12, 0.12 inch (3, 11, 3, 3 mm) Up to 30 16 characters 1 line No Yes (1 hour) N/A 8MB (RAM) No 23.3"x22.3"x18.1" (592x566x460 mm) 18.4"x18.4"x14.5" (468x467x368 mm) 34.1 lbs/15.5 kg 24.2 lbs/ 11 kg Gray 1495 No N/A Yes (Print/Fax, Print/Scan) Yes 10 - 35 degrees Centigrade 20% to 80% 120 VAC, 50/60 Hz Under 13.5W/40W No MFC-5100C
1 -2
(2/2)
Model Name INTERFACE External TAD Interface Host Interface (IEEE1284) Host Interface (USB) LAN Interface PRINTER Color/Mono Engine Type Resolution (dpi) Color/Mono Piezo Ink Jet (2-head BH: 75 nozzles/color) 1200x1200 /2400x1200 (Mono/Color) 10/8 (Mono/Color: 600*150) 4/3.5 (Mono/Color: 600*300) 2/1.5 (Mono/Color: 600*600) 0.2/0.2 (Mono/Color: 1200*1200/2400*1200) 100 50 Windows GDI No Yes Yes LTR, LGL, A4, B5, A5, EXE, Post card, Photo, Index card N/A OHP, Envelopes 64-120 g/m2 (17 - 32 lb) N/A Win95/98/98SE/Me/2000Professinal/NT4.0/ MacOS 8.5-9.1 Yes Yes Yes No MFC-5100C
Speed (ppm)
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 Cassette) (Manual Slot)
Printer Driver COPY Color/Mono Speed (ppm) Multi Copy (Stack) Multi Copy (Sort) Resolution (dpi) SCANNER Color/Mono Resolution (dpi) (Physical) Resolution (dpi) (Logical) Speed (ppm) Gray Scale TWAIN Compliant&Operating System PCI Scanner (Parallel/Serial) Color Depth ACCESSORIES Cartridge Life / Yield (Draft, 5% Coverage)
Color/Mono 7/5 (Mono/Color) Yes (Color) or Via PC Yes (Color) or Via PC Max. 1200x1200 (color) Color/Mono CCD: 600x2400 (Opt.) 9600 (Int.) Max. 3 sec 256 Win95/98/98SE/2000Professinal/NT4.0/Me MacOS 8.6-/9.1 Parallel/ USB 36-bit color processing (24-bit external) 4 colors (each separate tank) BK: 950, CL: 450
1 -3
(1/2)
Model Name GENERAL Print Engine Modem Speed (bps) Transmission Speed (sec.) ITU-T Group Coding System Print Paper Size (W x L) Document Size for ADF (W x L) Max. Document Size for Flat-bed Scan (W x L) Print Paper Margin (upper, lower, left, right) ADF (pages) LCD Columns LCD Lines LCD Backlight Backup Clock Memory Backup Memory Capacity (physical) Optional Memory Dimensions w/o Carton (WxDxH) Dimensions w/ Carton (WxDxH) Weight w/o Carton Weight w/ Carton Color Operating Environment Temperature Humidity Power Source Power Consumption (Standby/Peak) On/Off Switch TELEPHONE Handset One-Touch Dial Speed Dial Speaker Phone Chain Dialing Caller ID Call Waiting Caller ID Distinctive Ringing Hold/Mute Key Hook Key (Tel Key) Power Failure Dialing Speaker Volume Ring Volume Handset Volume FAX Scan Speed (A4:Standard) Memory Transmission (Brother#1 Chart) Memory Transmission (ITU-T Chart) Out-of-Paper Reception (Brother #1 Chart) Out-of-Paper Reception (ITU-T Chart) Color FAX (Document Send/Receive) Color FAX (Memory Send/Receive) INTERFACE External TAD Interface Host Interface (IEEE1284) Host Interface (USB) LAN Interface Yes Yes Yes No Approx. 3 sec./page (A4: standard) Yes (200:MMR) Yes (170:MMR) Yes (200:MMR) Yes (170:MMR) Yes/Yes No/Yes N/A N/A Max. 100 No Yes No No Yes (Only UK, Denmark) No Tel (for F/T switch) No No Yes (2 steps + OFF) No Ink Jet (BH 2-head) 14,400 (Fax) 6 (Brother#1, MMR) G3 MH/MR/MMR/JPEG 90-216 x 127-216 mm 147-216 x 145-356 mm 216 x 297 mm 0.12, 0.43, 0.12, 0.12 inch (3, 11, 3, 3 mm) Up to 30 16 characters 1 line Yes Yes (1 hour) N/A 4 MB (Actually 8 MB) No 23.3"x22.3"x18.1" (592x566x460 mm) 18.4"x18.4"x14.6" (468x467x370 mm) 24.2 lbs/ 11 kg 33.1 lbs/15 kg Gray 1495 10 - 35 degrees Centigrade 20% to 80% 240 VAC, 50/60 Hz Under 13W/50W No MFC-590
1 -4
(2/2)
Model Name PRINTER Color/Mono Engine Type Resolution (dpi) Color/Mono Piezo Ink Jet (2-head BH: 75 nozzles/color) 1200x1200 /2400x1200 (Mono/Color) 10/8 (Mono/Color: 600*150) 4/3.5 (Mono/Color: 600*300) 2/1.5 (Mono/Color: 600*600) 0.2/0.2 (Mono/Color: 1200*1200/2400*1200) 100 50 Windows GDI N/A Yes Yes LTR, LGL, A4, B5, A5, EXE, Post card, Index card N/A OHP, Envelopes 64-120 g/m2 (17 - 32 lb) N/A Win95/98/98SE/Me/2000Professinal/NT4.0/ MacOS 8.5/8.5.1/8.6/9.0/9.04/9.1 Color/Mono 7/4 Yes (Color) or Via PC Yes (Color) or Via PC Max. 1200x1200 Color/Mono CCD 600x2400 (Opt.) 9600 (Int.) Max. 3 sec. 256 Win95/98/98SE/2000Professinal/NT4.0/Me MacOS 8.6/9.0/9.04/9.1 Parallel/ USB 36-bit color processing (24-bit external) 4 colors (each separate tank) BK: 950, CL: 450 MFC-590
Speed (ppm)
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 Cassette) (Manual Slot)
Printer Driver COPY Color/Mono Speed (ppm) Multi Copy (Stack) Multi Copy (Sort) Resolution (dpi) SCANNER Color/Mono Resolution (dpi) (Physical) Resolution (dpi) (Logical) Speed (ppm) Gray Scale TWAIN Compliant&Operating System PCI Scanner (Parallel/Serial) Color Depth ACCESSORIES Cartridge Life / Yield (Draft, 5% Coverage)
1 -5
CHAPTER 2
INSTALLATION
CHAPTER 2 INSTALLATION CONTENTS
2.1 2.2 2.3
INSTALLING THE UPDATE DATA TO THE FACSIMILE MACHINE.............................2-1 SETTING ID CODES TO FACSIMILE MACHINES .........................................................2-3 UPDATING HEAD PROPERTY INFO STORED IN THE FACSIMILE MACHINE ..........2-5
2.1 INSTALLING THE UPDATE DATA TO THE FACSIMILE MACHINE
If you want to update the current program stored in the flash ROM of the main PCB to the newer version or after you replace the main PCB, install the update program onto the flash ROM. The program installation requires a PC/AT-compatible computer (which is capable of running MS-DOS or its compatible OS).
Connecting the facsimile machine to your PC (1) Make sure that your PC is turned off. (2) Make sure that the power cord of the facsimile machine is unplugged from a wall socket or other power source. (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 PC and secure it with two screws. (5) While pressing the 5 key on the machine's control panel, plug the machine's power cord into a wall socket. (6) Check to see that the following pattern displays on the LCD. If it does not display, go back to step (2) above.
(7) Turn on your PC.
Parallel interface cable Lock wires
Host computer
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 PC 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 Where filename is an update data file, e.g., 5100x.upd and 590xxxx.upd. 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
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 the facsimile machine to your PC (See the illustration on page 2-1.) (1) Make sure that your PC is turned off. (2) Make sure that the power cord of the facsimile machine 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) While holding down the Menu key, plug the machine's power cord into a wall socket or other power source. (6) Turn on your PC. Running the setup utility (1) On your PC, run the ID/head property setup utility (BRUSBSN.EXE). The following window will appear.
(2) On the Model menu, click BH. In Port, make sure that the LPT1 is selected. In the Serial No = BRO box, type 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.
2 -3
The setup 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. (3) 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 5.3.6). The facsimile machine will print out a Configuration List. At the right top of the list, "SER.#: BROXXXXXXXXX" is printed. (4) 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 -4
2.3 UPDATING HEAD PROPERTY INFO STORED IN THE FACSIMILE MACHINE
To keep the print quality, the controller optimizes the head drive strength, ink jet-out timing, and other drive conditions according to the electromechanical properties unique to individual print heads and ambient temperature. The head property information is stored in the EEPROM of the main PCB. If you replace the print head unit and/or main PCB of the machine, then you need to update head property information according to the procedure given here. TIP: The updating procedure given here uses a PC. For the updating procedure in the maintenance mode without using a PC, refer to CHAPTER 5, Subsection 5.3.14. Connecting the facsimile machine to your PC (See the illustration on page 2-1.) (1) Make sure that your PC is turned off. (2) Make sure that the power cord of the facsimile machine 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 two screws. (5) While holding down the Menu key, plug the machine's power cord into a wall socket or other power source. (6) Turn on your PC. Running the setup utility (1) On your PC, run the ID/head property setup utility (BRUSBSN.EXE). The following window will appear.
(2) On the Model menu, click BH. In Port, make sure that the LPT1 is selected.
2 -5
In the Head Info. box, type upper 12 digits (e.g., 66667F657031) out of the 13-digit property code (enclosed with asterisks, e.g., *66667F657031H*) which is printed on the bar code label attached to the print head unit. Then press the Enter key. The setup utility will transmit the entered data from your PC to the facsimile machine and then it will terminate. The facsimile machine will automatically return to the standby mode. (3) To check whether the entered head property is correct, make the machine enter the maintenance mode (refer to CHAPTER 5, Section 5.1) and then press the 7 key twice. The facsimile machine will print out the Equipment's Log. On the line about 1/3 of full length of the log sheet below from the top, the 12-digit code will be printed. (4) Check that the character string entered in step (2) is printed in "XXXXXXXXXXXX." If it is OK, press the 9 key twice to exit from the maintenance mode. If something other than that is printed in XXXXXXXXXXXX, check the connection between the PC and facsimile machine and go back to step (1).
2 -6
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 Ink Jet Printing Mechanism ..................................................................................3-6 Paper pulling-in, registration, feeding, and ejecting mechanisms................3-6 Ink jet printing and capping mechanisms.....................................................3-8 Purging mechanism ...................................................................................3-11 Carriage drive mechanism .........................................................................3-14
3.2.2.1 3.2.2.2 3.2.2.3 3.2.2.4 3.2.3 3.3
Sensors and Actuators .......................................................................................3-15
CONTROL ELECTRONICS...........................................................................................3-18 3.3.1 Configuration ......................................................................................................3-18
3.1 OVERVIEW
Host
Control panel
Centronics parallel interface
USB interface
Fax Control Section
Printer Control Section Print data
Line
NCU
ADF unit - ADF motor
Scanner unit - CCD unit - CCD motor
Ink jet printer unit - Ink jet print head unit - Carriage motor - Carriage ASSY - Purge unit
Paper feeding mechanism - Paper feed motor
Power supply
AC
3 -1
3.2 MECHANISMS
The facsimile machine is classified into the following mechanisms: SCANNER MECHANISM - ADF mechanism - Document scanning mechanism INK JET PRINTING MECHANISM - Paper pulling-in, registration, feeding, and ejecting mechanisms - Ink jet printing and head capping mechanisms - Purging mechanism - Carriage drive mechanism SENSORS AND ACTUATORS
3 -2
SCANNER MECHANISM
Ink jet printing and head capping mechanisms Purge mechanism Carriage drive mechanism Paper pulling-in, registration, feeding, and ejecting mechanisms
INK JET PRINTING MECHANISM
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.
Document guide base
Document tray Document ejection roller
ADF & document tray ASSY
ADF motor
Scanner top cover Document feed roller Separation roller ASSY
CCD drive belt CCD motor CCD unit CCD rail
Scanner unit
CCD flat cable CCD HP sensor
Scanner base
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 Ink Jet Printing Mechanism 3.2.2.1 Paper pulling-in, registration, feeding, and ejecting mechanisms
The paper pulling-in, registration, feeding, and ejecting mechanisms are driven by a single paper feed motor located at the left side of the main chassis via the gear train. (See the illustration given on the next page.) First, the paper feed motor rotates clockwise (when viewed from the output gear). The rotation is transmitted to the PF roller gear that rotates paper feed roller. At the right end of the paper feed roller is the PF roller gear R which is always engaged with the ASF/purge idle gear. Engaged with the ASF/purge idle gear, the ASF-purge switching gear 23 transmits the rotation via gear 25 and the ASF gear train to the ASF roller unit. This way, the ASF roller will pull in paper. When the ASF roller is pulling in paper, the paper feed roller rotates in the backward direction to register the leading edge of the pulled-in paper. Next, the paper feed motor rotates counterclockwise to rotate the paper feed roller in the forward direction. The paper will advance through the paper path. During the paper feeding operation, no rotation is transmitted to the ASF roller because of the planetary gear system built in the ASF roller unit. The above paper pulling-in and feeding operations take place when the carriage is in printing operation. If the carriage reaches the purge position, the ASF-purge switching gear 23 will be disengaged from the gear 25 and engaged with purge bevel gear A. For the purging mechanism, refer to Subsection 3.2.2.3.
Recording paper
(Carriage) (Carriage rail) (Ink cartridges)
ASF
Paper pulling-in mechanism
Star wheels Paper ejection roller
Paper ejecting mechanism
ASF roller unit
Paper pressure holders Paper chute
Registration & paper feeding mechanisms
Registration sensor actuator Paper width sensor actuator Paper feed roller
Platen (Print head unit)
3 -6
Gear 31MF Gear shaft 17
ASF roller unit
PF roller gear R Gear 39 Paper feed roller Gear 25 ASF-purge switching gear 23 ASF/purge idle gear
PF roller gear
Paper feed motor
3 -7
3.2.2.2
Ink jet printing and capping mechanisms
Carriage encoder Main chassis
Carriage PCB Ink cartridge sensors Ink cartridges Ink empty sensor Carriage (Star wheels)
Carriage motor
(Paper ejection roller)
Carriage rail
Platen
Print head unit
(1) Print head unit This machine uses drop-on-demand ink jet printing. Each of the right and left print heads has an ink-jet unit that has a pair of nozzle columns for two color inks. A nozzle column consists of 75 nozzles, 75 channels covered with piezoelectric ceramic (PZT), a manifold, and filter. As illustrated below, the pair of nozzle columns is staggered.
Nozzle Layout (viewed from the bottom) 3 -8
If the controller issues a print command, a biased voltage will be applied to all electrodes formed on the surface of the piezoelectric ceramic so that each actuator will be distorted as shown with broken lines. If the electrodes on a target channel are deenergized according to drive signals, then the associated piezoelectric ceramic actuator returns to the previous form so that the ink in the manifold will be vacuumed out to the channel. If the voltage is applied again, the piezoelectric ceramic actuator will be distorted again to apply pressure to the ink in the channel, causing the ink to jet out through the nozzle. The jetted-out ink drop will be splashed and produce a dot on paper held by the platen.
As the carriage holding the print head unit travels at the printing speed, the controller sends print command pulses to the piezoelectric actuator driver circuit embedded in the print head unit.
(2) Ink cartridges The machine uses four ink cartridges (black, cyan, yellow, and magenta) of disposable type to supply ink to the print head unit. As shown below, an ink cartridge contains an ink-impregnated urethane foam. If ink-jet print operation or purging operation takes place, ink comes out of the urethane foam and is supplied to the print head unit through the ink room, filters, and manifold. For the ink cartridge sensors on the carriage PCB, refer to Subsection 3.2.3.
3 -9
(3) Head caps Shown below is a head cap mechanism that prevents the nozzles of the print heads from drying up when they are not in use. Upon completion of printing, the carriage travels to the right and moves the head cap holder provided on the purge unit to the right together. In the head cap holder is a head cap unit which is supported with a lift lever. The rightward movement of the head cap holder turns the lift lever and pushes up the head cap unit to the position where the head caps come into tight contact with the print heads. This way, the nozzles will be capped.
3 -1 0
3.2.2.3
Purging mechanism
The purge mechanism is driven by the paper feed motor located at the left side of the main chassis. As described in Subsection 3.2.2.1, the motor rotation is transmitted to the ASF/purge idle gear at the right side of the main chassis. Engaged with the ASF/purge idle gear, the ASF-purge switching gear 23 works as a clutch gear. When the carriage travels from the left to right to reach the purge position, the tab provided on the back of the carriage pushes the purge lever on the main chassis to the right (see the illustration below). Accordingly, the ASF-purge switching gear 23 (which was shifted to the left by the purge lever) will move to the right by the switching gear spring so as to become disengaged from the gear 25 and engaged with the purge bevel gear A. (See the illustration given on the next page.) This engagement will transmit the motor rotation to the purge bevel gear B on the purge unit. This way, when the carriage is in the purge position, the motor rotation is transmitted to the purge unit. On the contrary, if the carriage travels from the purge position to the left, the tab on the back of the carriage releases the purge lever which will be pulled back to the left. The ASF-purge switching gear 23 will be disengaged from the purge bevel gear A.
3 -1 1
During printing: The ASF-purge switching gear 23 is not engaged with purge bevel gear A (but engaged with gear 25 in the ASF gear train).
During purging: The ASF-purge switching gear 23 is engaged with purge bevel gear A.
When the motor rotation is transmitted to the purge unit, its counterclockwise rotation will drive the purge cam and its clockwise rotation, the pump switching unit (when viewed from the output gear of the motor).
When the paper feed motor rotates counterclockwise
When the paper feed motor rotates clockwise 3 -1 2
The purge cam is so designed that: - the carriage lock pops out to lock the carriage before purging and pops in before cleaning with the head wiper (see the illustration below), - the pump works to draw out ink from each of the four head nozzles and drain it to the ink absorber felts, and - the head wiper comes out to clean the nozzle surface (see the illustration below). The pump switching cam is so designed that: - the pump switching unit switches application of the pump's negative pressure between the four head nozzles in the order of black, cyan, yellow, and magenta nozzles. When the pump switching cam is in the home position, normal atmospheric pressure will be restored. The home position of the purge cam and pump switching cam are detected by their HP switches. For those switches, refer to Subsection 3.2.3. (1) Carriage lock If the purge cam is driven, the carriage lock of the purge unit pops out and locks the carriage to align ink-jet units with the mating head caps during purge operation. After purging but before cleaning with the head wiper, it pops in to release the carriage. When the power is off, the carriage lock keeps the print heads pressed against the head caps. (2) Purging If activated, the pump draws out ink to purge air bubbles or dust from the inside of the head nozzles and channels. As the purge cam rotates by one turn, the piston of the pump reciprocates two strokes. To complete purging of all four nozzles and channels, the purge cam rotates by two turns ad the piston reciprocates four strokes. (3) Draining The pump drains drawn ink into the ink absorber felts. (4) Cleaning with the head wiper After purging operation, the head wiper comes out and the carriage moves from the right to left so as to clean ink remaining on the heads' surface. (5) Restoring the pump's pressure to normal atmospheric pressure When the pump switching cam is in the home position, the controller stops to produce negative pressure and restore the pump's pressure to normal atmospheric pressure.
3 -1 3
3.2.2.4
Carriage drive mechanism
The carriage motor controls horizontal motion. The motor rotation is transmitted via the motor pulley to the timing belt. The carriage, which is supported and guided by the carriage rail, is secured to the timing belt. Clockwise and counterclockwise rotations of the carriage motor move the carriage to the right and left, respectively. On the back of the carriage is the carriage encoder which tells the control circuitry the current carriage position counted based on the carriage motor position by using the encoder strip attached to the main chassis.
3 -1 4
3.2.3 Sensors and Actuators
This machine has the following sensors and thermister. Sensor name Document front sensor Document rear sensor Document tray open sensor Scanner open sensor Registration sensor Paper width sensor CCD HP sensor Ink empty sensor Ink cartridge sensors Carriage encoder Head thermister Purge cam HP switch Pump switching cam HP switch Type Photosensor Photosensor Mechanical switch Photosensor Photosensor Photosensor Photosensor Photosensor Mechanical switches Photosensor Thermister Mechanical switch Mechanical switch Purge unit Carriage PCB Located on Document sensor PCB in the ADF Document tray Control panel PCB ASSY Paper chute Main PCB CCD PCB on the CCD unit Sensor support
· 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 width sensor which detects whether the paper width is "A4-size or wider" or "narrower than A4-size." · CCD HP sensor which detects whether the CCD unit is placed in the home position. · Ink empty sensor which detects at the start of printing whether any of the four ink cartridges is near empty. According to this sensor signal, the controller may display "NEAR EMPTY XXX" message. · Ink cartridge sensors, each of which detects whether an ink cartridge is loaded. · Carriage encoder which detects the current carriage position and carriage travel speed. If the carriage travels speed varies abnormally, the controller regards it as a paper jam. · Head thermister which allows the controller to control the temperature of the print heads. According to the change of the thermister's internal resistance monitored, the control circuitry regulates the drive voltage applied to the piezoelectric ceramic actuators on each print head since the viscosity of the ink varies depending upon the temperature.
3 -1 5
· Purge cam HP switch which detects whether the purge cam is in the home position. · Pump switching cam HP switch which detects whether the pump switching cam is in the home position.
These photosensors (except the ink empty sensor that is a reflection type) 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 6
Registration sensor Registration sensor actuator (Paper chute)
Document front sensor actuator Document front sensor (Document sensor PCB)
Document tray open sensor (Relay PCB) Document rear sensor actuator Document rear sensor CCD HP sensor CCD HP sensor plate Paper width sensor Paper width sensor actuator Ink empty sensor (Main PCB) (Sensor support) Scanner open sensor actuator Scanner open sensor
(Control panel PCB) (Purge unit) Purge cam HP switch Pump switching cam HP switch
Location of Sensors and Actuators
3 -1 7
3.3 CONTROL ELECTRONICS
3.3.1 Configuration
The hardware configuration of the facsimile machine is shown below.
INK JET PRINTER UNIT Paper width sensor Carriage PCB Ink cartridge sensors Carriage encoder Head thermister Sensor support Paper chute
Print head Print head
3-pin 3-pin
Ink empty sensor Registration sensor
DC motor driver Stepping motor driver
2-pin 4-pin
Carriage motor Paper feed motor Purge cam HP switch Purge unit
4-pin
Pump switching cam HP switch
Main PCB
EEPROM
12-pin 2-pin
Document tray open sensor Document sensor PCB (Document front sensor and document rear sensor) ADF motor CCD unit (CCD motor) (CCD HP sensor) ADF UNIT
Engine GA
11-pin 9-pin
4-pin
4-pin
SDRAM (8MB/2MB) Main ASIC
Relay PCB
7-pin
SCANNER UNIT
Control panel PCB ASSY (Scanner open sensor) Piezo ringer
ROM (2MB)
MODEM
7-pin (10-pin)*
NCU PCB
Line External telephone
11-pin
USB Parallel interface (ECP) Power supply PCB PC
AC line
* 7-pin: American models 10-pin: Other models
Configuration of Facsimile Machine 3 -1 8
CHAPTER 4
DISASSEMBLY/REASSEMBLY, LUBRICATION, AND ADJUSTMENT
CHAPTER 4 DISASSEMBLY/REASSEMBLY, LUBRICATION, ADJUSTMENT 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 Print Head Unit .....................................................................................................4-6 ADF Cover and Document Guide Base .............................................................4-10 ADF Components on the Upper ADF Chute ......................................................4-11 Gear cover ...........................................................................................................4-11 Separation roller ASSY and document feed roller ....................................................4-12 Separation rubber unit, ADF thickness adjuster, and pressure rollers .........................4-13 Upper ADF chute..................................................................................................4-15 4.1.4 ADF Components on the Lower ADF Chute ......................................................4-16 Document front and rear sensor actuators................................................................4-16 Document sensor PCB...........................................................................................4-16 Document guide clips............................................................................................4-17 Document ejection roller .......................................................................................4-17 Document pressure bar ..........................................................................................4-18 Lower ADF chute, pinch rollers, and ADF motor.....................................................4-19 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9 Document Tray Open Sensor and Document Stopper ......................................4-21 Jam Clear Cover, Rear Cover, and Inner Cover ................................................4-22 Scanner Unit and Control Panel ASSY (Together with Document Tray) ...........4-23 Disassembly of the Control Panel ASSY............................................................4-28 Disassembly of the Scanner Unit .......................................................................4-29
4.1.10 Auto Sheet Feeder (ASF) and Separation Pad ASSY .......................................4-34
4.1.11 Edge Cover, Scanner Links and Their Guides...................................................4-36 4.1.12 Relay PCB and PCB Plate .................................................................................4-37 4.1.13 Bottom Plate, Ink Absorber Box, Main PCB, NCU PCB, and Power Supply PCB .............................................................................................4-38 4.1.14 Enclosure Cover.................................................................................................4-42 4.1.15 Main Cover .........................................................................................................4-43 4.1.16 Purge Unit ..........................................................................................................4-45 4.1.17 Main Chassis......................................................................................................4-47 4.1.18 ASF Roller Unit and its Related Gears...............................................................4-49 4.1.19 Paper Pressure Holders .....................................................................................4-51 4.1.20 Paper Chute and Registration Sensor................................................................4-52 4.1.21 Paper Ejection Roller Gear, Ink Empty Sensor PCB, Platen, Star Wheel Support, and Paper Ejection Roller .................................................4-54 4.1.22 Paper Feed Motor and Paper Feed Roller .........................................................4-57 4.1.23 Encoder Strip and Carriage Motor......................................................................4-58 4.1.24 Carriage Rail, Carriage ASSY, and Purge-Related Parts ..................................4-60 4.1.25 Flushing Gutter and Paper Width Sensor Actuator ............................................4-65 4.1.26 Harness Routing.................................................................................................4-66 4.2 4.3 LUBRICATION ...............................................................................................................4-68 ADJUSTMENT ...............................................................................................................4-75
4.1 DISASSEMBLY/REASSEMBLY
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) Be careful not to lose screws, washers, or other parts removed for parts replacement. (3) 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. (4) When using soldering irons and other heat-generating tools, take care not to damage the resin parts such as wires, PCBs, and covers. (5) 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. (6) When transporting PCBs, be sure to wrap them in conductive sheets such as aluminum foil. (7) Be sure to reinsert self-tapping screws correctly, if removed. (8) Tighten screws to the torque values listed on the next page. (9) 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. (10) Before reassembly, apply the specified lubricant to the specified points. (Refer to Subsection 4.2 in this chapter.) (11) After repairs, check not only the repaired portion but also that the connectors and other related portions function properly before operation checks. (12) Once the print head unit prints, it will start head locking operation after five seconds from the end of printing. The head locking operation will take 5 to 10 seconds. NEVER unplug the power cord before the machine completes the head locking operation; doing so will make the print head unit unusable and require replacement with a new print head unit. When you receive the machine from the user or when you pack it for sending it back to the user, check the head locking state.
4 -1
Tightening Torque List Location ADF thickness adjuster Upper ADF chute Lower ADF chute Grounding wire ADF drive unit ADF motor Rear cover Screw type Taptite, pan B M3x6 Taptite, cup B M3x10 Taptite, cup B M3x10 Taptite, cup B M3x8 Taptite, cup B M3x8 Screw, pan (s/p washer) M3x6 Taptite, cup B M3x12 Q'ty 1 2 2 1 2 1 2 1* 2 3 3 6 1 3 7 2 4 3 1 2 4 2 2 1 1 2 11 1 1 3 (4)* 1 2 1 1 1 1 1 2 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 0.69 ±0.10 0.98 ±0.20 0.98 ±0.20 0.59 ±0.10 0.59 ±0.10 0.39 ±0.10 0.49 ±0.10 0.49 ±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 0.69 ±0.10 0.69 ±0.10 0.69 ±0.10 0.39 ±0.10 0.39 ±0.10 0.69 ±0.10 0.59 ±0.10 0.59 ±0.10 0.98 ±0.20 0.69 ±0.10 0.59 ±0.10 0.69 ±0.10 0.69 ±0.10 0.69 ±0.10 0.59 ±0.10 0.59 ±0.10 0.78 ±0.10 (4 ±1) (7 ±1) (7 ±1) (7 ±1) (7 ±1) (7 ±1) (7 ±1) (10 ±2) (10 ±2) (6 ±1) (6 ±1) (4 ±1) (5 ±1) (5 ±1) (4 ±1) (4 ±1) (10 ±2) (7 ±1) (7 ±1) (7 ±1) (7 ±1) (7 ±1) (7 ±1) (7 ±1) (4 ±1) (4 ±1) (7 ±1) (6 ±1) (6 ±1) (10 ±2) (7 ±1) (6 ±1) (7 ±1) (7 ±1) (7 ±1) (6 ±1) (6 ±1) ] (8 ±1)
Grounding wires Screw, bind B tite M4x16 (from the ADF drive unit and relay PCB) Document tray Hinge base R Hinge L Control panel ASSY Scanner open sensor PCB Piezo ringer cap Reinforcement plate Control panel PCB Scanner top cover Guide plate CCD HP sensor plate Flat cable clamp ASF Edge cover Scanner link guides Relay PCB USB I/F connector Parallel I/F connector Bottom plate Grounding terminal Ink absorber box Main cover Side frame supporter Purge unit FG plate R (Lower cover) (Main chassis) FG plate L (Main chassis) Shield film (Main chassis) [ (Lower cover) Chassis supporters R and L Taptite, bind B M4x12 Taptite, cup B M3x10 Taptite, cup B M3x10 Taptite, cup B M3x12 Taptite, cup B M3x8 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 M3x12 Taptite, cup B M3x12 Taptite, cup B M3x12 Taptite, cup S M3x6 Screw, pan M3x6 Screw, pan M3x6 Taptite, cup B M3x12 Screw, pan (washer) M4x8 Taptite, cup B M3x12 Screw, bind B tite M4x16 Screw, pan (s/p washer) M3x6 Taptite, cup B M3x8 Taptite, cup B M3x12 Taptite, cup S M3x5 Taptite, cup S M3x5 Taptite, cup S M3x5 Taptite, cup S M3x5 Taptite, cup B M3x12
* The main cover is secured with four screws together with the two grounding wires.
4 -2
Location ASF roller unit ASF gear holders Paper chute Ink empty sensor PCB Platen Platen plate R Platen plate L Paper feed motor Idle pulley holder Carriage motor Eccentric bushings R, L Flushing gutter
Screw type Taptite, cup S M3x6 Taptite, cup B M3x10 Taptite, cup S M3x6 Taptite, cup B M3x8 Shoulder screw Screw, bind B tite, M3x10 Taptite, bind B M2.6x10 Taptite, bind B M2.6x10 Screw, pan (s/p washer) M3x6 Taptite, cup S M3x8 Shoulder screw Screw, cup S tite, M3x6 Screw, pan (s/p washer) M3x6 Screw, pan (s/p washer) M3x6DB Taptite, cup B M3x12
Q'ty 3 1 1 1 1 1 1 1 2 1 1 1 2 2 1
Tightening torque N·m (kgf·cm) 0.98 ±0.10 0.49 ±0.10 0.98 ±0.10 0.59 ±0.10 0.59 ±0.10 0.59 ±0.10 0.39 ±0.10 0.39 ±0.10 0.78 ±0.10 0.98 ±0.10 0.78 ±0.10 0.98 ±0.10 0.78 ±0.10 0.78 ±0.10 0.69 ±0.10 (10 ±1) (5 ±1) (10 ±1) (6 ±1) (6 ±1) (6 ±1) (4 ±1) (4 ±1) (8 ±1) (10 ±1) (8 ±1) (10 ±1) (8 ±1) (8 ±1) (7 ±1)
4 -3
Preparation
Prior to proceeding to the disassembly procedure, (1) Unplug - the modular jack of the telephone line, - the PC interface cable if connected (Not shown below), and - the modular jack of an external telephone set if connected (Not shown below). (2) Remove - the paper wire extension and - the paper tray. NOTE: Do not remove the ink cartridges when disassembling the machine except when removing the print head unit.
Paper wire extension
Telephone line cord
Paper tray
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 purge unit, for example, first find it on the flow and learn its number ( in this case). You need to remove parts numbered , , , , , and so as to access the purge unit. · Unless otherwise specified, the disassembled parts or components should be reassembled in the reverse order of removal.
4 -4
Disassembly Order Flow
4.1.3 4.1.6
Jam clear cover Rear cover
4.1.13
Ink absorber box
4.1.2
ADF cover
4.1.2
ADF components on the upper ADF chute Gear cover
Document guide base Separation roller ASSY
4.1.10
Document feed roller
Auto sheet feeder (ASF) - Separation pad ASSY
4.1.12
Relay PCB cover Relay PCB
4.1.13
Bottom plate Separation rubber unit ADF thickness adjuster
4.1.4
Upper ADF chute
Pressure rollers
4.1.12 4.1.6
Inner cover PCB plate
4.1.13
Power supply PCB Enclosure cover
4.1.13
NCU PCB
ADF components on the lower ADF chute Document sensor actuators Document sensor PCB
(NOTE 5)
4.1.12
4.1.14
Document guide clips Document ejection roller
Document pressure bar
4.1.13
Main PCB
(NOTE 1)
Lower ADF chute
Pinch rollers
4.1.7 4.1.7
ADF motor
Scanner unit with document tray
4.1.8 4.1.7 4.1.5 4.1.5
Control panel ASSY - Control panel PCB with scanner open sensor PCB - Reinforcement plate - FPC key - LCD - Keys (NOTE 4)
Document tray Hinges
4.1.9
Document tray open sensor
Document stopper
(NOTE 2) Scanner unit
Scanner top cover CCD drive belt CCD unit (NOTE 3) CCD flat cable
4.1.7
Scanner open lever Lever spring Scanner open sensor actuator Piezo ringer
4.1.11
4.1.15
Main cover
Edge cover Scanner links Scanner link guides Scanner link springs
4.1.1
Print head unit
4.1.17
4.1.16
FG plates
4.1.17
Purge unit (NOTE 6)
Main chassis
4.1.23 4.1.18 4.1.23
Idle pulley holder ASF roller unit and its gears Paper pressure holders Paper chute - Registration sensor (NOTE 7)
4.1.21 4.1.24 4.1.23
Encoder strip
4.1.19
Carriage motor
4.1.24
Carriage rail
4.1.20
Paper ejection roller gear Sensor support Ink empty sensor PCB (NOTE 8)
4.1.24
Carriage ASSY
4.1.24
4.1.21
Purge-related parts
Carriage PCB (with head flat cables) (NOTE 9)
4.1.21
Platen - Star wheel support - Platen plates - Flushing sponge - Paper ejection roller
4.1.22
4.1.22
4.1.22
(NOTE 1) (NOTE 2) (NOTE 3) (NOTE 4) (NOTE 5) (NOTE 6) (NOTE 7) (NOTE 8) (NOTE 9)
PF roller gear
Paper feed motor
Paper feed roller
On the main PCB is a paper width sensor. On the document tray is a document tray open sensor. On the CCD unit is a CCD HP sensor. On the control panel PCB ASSY is a scanner open sensor. On the document sensor PCB in the ADF are a document front sensor and document rear sensor. On the purge unit are a purge cam HP switch and pump switching cam HP switch. On the paper chute is a registration sensor. On the sensor support is an ink empty sensor. On the carriage PCB are four ink cartridge sensors, a carriage encoder, and head thermister.
4.1.17
Vibration absorbers (Rubber bushings)
4.1.25
4.1.25
Flushing gutter
Paper width sensor actuator
4 -5
4.1.1 Print Head Unit
During disassembly jobs (except when removing the purge unit, carriage rail, or carriage ASSY), the print head unit and all the four ink cartridges should be kept in place. NOTE: To replace the print head unit with a new one, you need to move the carriage to the ink replacement position by placing the machine in the ink replacement mode. Do not move the carriage by hand when the power is off. NOTE: If you replace the print head unit with a new one, replace also the ink absorber box and ink cartridges with new ones. (1) Plug the power cord into a wall socket. (2) Press the Ink key to place the machine in the ink replacement mode. (3) Press the 2 key to choose "2. REPLACE INK." (4) Press the Menu/Set key. The carriage automatically moves left to the ink replacement position. (5) Unplug the power cord from the wall socket. (6) Pull the scanner open lever towards you and open the scanner unit.
Scanner unit
Scanner open lever
(7) Push the colored ink cartridge covers and remove all ink cartridges. (Or, remove the shipping cover.)
PUSH
PUSH
PUSH
PUSH
Ink cartridge covers
4 -6
(8) Pull the head clamp springs in the direction of arrows head unit. (9) Lift the print head unit up and out of the carriage (arrow
Head clamp spring Carriage Head clamp spring
shown below to release the print ).
Setting the head clamp spring
Correct
Carriage Locks provided on the carriage
Boss of the print head unit
Boss of the carriage
Print head unit
Wrong
Scanner unit
Head clamp spring Boss of the print head unit Boss of the carriage Locks provided on the carriage
Wrong
NOTE: Do not touch the printing ends (nozzles) of the print head unit or the ink orifices of the ink cartridges; doing so will not only stain your hands with ink but result in an ink jet-out failure. Once you touch them, clean them with a dedicated cleaning stick and liquid. NOTE: Be sure to put a head nozzle seal and filter seal on the print head unit as shown below. Leaving the print head unit without those seals will dry up its printing ends and filters, resulting in a damaged head. NOTE: Do not touch the dimple contact section of the print head unit.
Head filter seal
Print head unit
Head nozzle seal
4 -7
NOTE: Once the ink cartridges are removed, their colored covers rise upright. If you turn the machine upside down with those covers being upright, then they will break. To prevent it, set and pushing them them to the horizontal position by turning them in the direction of arrow up in the direction of arrow .
(10) Turn the head adjuster lever located on the right side of the carriage to position 1.
(11) To install a new (or removed) print head unit, remove the head nozzle seal. (12) Put the print head unit into the carriage with care for the dimple contact so that the electrical contact on the head PCB comes into uniform contact with that on the carriage PCB as illustrated below.
Remove the head filter seal.
4 -8
(13) Press the front center of the carriage to the rear and move the print head unit to the right and left several times. This is to assure the dimple contact between the head PCB and carriage PCB.
Carriage
Print head unit
(14) While pressing the front center of the print head unit, lock the print head unit with the head clamp springs. (15) Remove the head filter seal. (16) Set new ink cartridges into the carriage. (17) Press the bottom right front corner of the carriage to the rear.
(18) Close the scanner unit. (19) Plug the power cord into a wall socket. The carriage automatically moves to the right-hand home position. (20) Follow the instructions shown on the LCD. NOTE: The machine enters a "head cleaning" cycle that takes approx. 3 minutes for each ink cartridge. (21) Load paper into the ASF. (22) Correct the positioning error of the print head unit, referring to Section 4.3 "ADJUSTMENT." (23) Adjust the alignment of vertical print lines, referring to CHAPTER 5, Subsection 5.3.13.
4 -9
4.1.2 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 ).
ADF cover
Boss
Stopper tab
Inside of the ADF cover
Correct
Wrong
Setting the ADF cover back into place
(2) Remove the document support. (3) 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.
Document support
Document guide base Groove Latches Groove
Guides ADF & document tray ASSY
Reassembling Notes
· When setting the ADF cover back into place, fit its bottom edge under the stopper tabs as illustrated above.
4 -1 0
4.1.3 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 ).
Flat screwdriver Rib
Gear cover
Latch
Latch Ribs Latch
Upper ADF chute
(Front)
(Left)
4 -1 1
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.
Plastic retaining rings
Separation roller ASSY Document feed roller ADF drive unit
(Rear) ADF & document tray ASSY
Bushings S
Ribs of the bushings
Separation roller
ADF drive unit Upper ADF chute Plastic retaining rings
Separation roller shaft Document feed roller shaft Spring plate
When setting the separation roller, take care not to apply force to the spring plate at an angle
Fitting the bushings into the cutouts provided in the ADF drive unit and setting the plastic retaining rings inside the upper ADF chute
4 -1 2
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 with its rib facing up. 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.
4 -1 3
(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.
Taptite, pan B M3x6
Upper ADF chute
ADF thickness adjuster Lubricated with grease
(Rear) Pressure rollers Pressure roller shaft
Pressure roller springs
Latches
Correct position of the boss
ADF thickness adjuster
Guide
Wrong position: Boss placed on the guide
When setting the ADF thickness adjuster, do not put the boss provided on the underside of the adjuster on the guide.
4 -1 4
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 ( ).
Taptite, cup B M3x10
(Rear)
Upper ADF chute
Latches Document tray
"Y" Latches Tabs
Upper ADF chute
(2) (3) (Left) (4)
(1)
Document tray
Latches
Latching the upper ADF chute (Viewed from "Y")
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.
4 -1 5
4.1.4 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 front sensor actuator Document rear sensor actuator Lower ADF chute
(Rear)
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.
Document front sensor Document sensor PCB Document sensor harness Lower ADF chute
(Rear) Document rear sensor Locking pawl
Cable hooks
4 -1 6
Document guide clips
(4) Press the tab of each document guide clip. Each clip will snap out of the document ejection roller shaft.
Document guide clip Lower ADF chute Document ejection roller shaft
(Rear)
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.
Boss Document ejection roller Rear bushing
ADF drive unit
(Rear)
Pawled bushing
Lower ADF chute
4 -1 7
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.
Document pressure bar Spring
Setting the spring (Viewed from "X")
Correct "X" Supports Wrong
ADF & document tray ASSY
Document pressure bar
Spring
Reassembling Note: After setting the document pressure bar, check in the direction of arrow "X" that the spring is into place as illustrated above.
4 -1 8
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 Planet gear Lower ADF chute
Anti-static brush (Do not touch this.) Pinch roller shaft Taptite, cup B M3x10 Pinch rollers
Pinch roller spring ADF motor harness
Grounding wire
Document sensor harness
Latch
4 -1 9
(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 4.1.26, "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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4.1.5 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.
Document tray
Document tray open sensor harness
Document tray open sensor
Latches
(4) Slightly open the document stopper and remove it while warping it.
Document stopper Document tray
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4.1.6 Jam Clear Cover, Rear Cover, and Inner Cover
(1) Open the jam clear cover and remove it while warping it. (2) Remove the two screws from the rear cover and take if off to the rear.
Jam clear cover Taptite, cup B M3x12 Rear cover
(3) Slightly pull up the rear edge of the inner cover and pull it out to the rear.
Inner cover Lower cover
Auto sheet feeder (ASF)
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4.1.7 Scanner Unit and Control Panel ASSY (Together with Document Tray)
(1) Release the grounding wires (coming from the ADF drive unit and relay PCB) by removing the screw. (2) Disconnect the following harnesses and flat cable from the relay PCB: - CCD flat cable - Document tray open sensor harness - Document sensor harness - Panel harness - ADF motor harness NOTE: Handle the CCD flat cable with care.
Screw, bind B tite M4x16 Grounding wire (From the ADF drive unit) Grounding wire
(Rear)
Relay PCB
CCD flat cable
Document tray open sensor harness Document sensor harness Relay PCB Panel harness ADF motor harness
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(3) Pull the scanner open lever towards you and open the scanner unit. (4) At each of the right and left scanner links, fully push up the lock of the scanner link support (in the direction of arrow ) and press the upper end of the scanner link inwards (arrow ) to release its boss from the scanner link support. (5) Open the scanner unit further and lift up its rear edge to disengage it from the main cover in the direction of arrow .
Panel harness CCD flat cable Scanner link Scanner link
Harnesses (Document tray open sensor harness, document sensor harness, ADF motor harness, and grounding wire) covered with the cable sheath Main cover
Be careful with this boss (provided for the scanner open sensor actuator)
Scanner open lever
Scanner unit Scanner link Boss
Releasing the scanner link from the scanner link support secured to the underside of the scanner unit
Scanner link support
Lock
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(6) Remove the two screws from the bottom rear of the hinges. (7) 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. (8) Lift up the document tray.
(9) From the hinge base R, remove the hinge arm as shown below. Remove the three screws and release the hinge base R. (10) From the hinge L that should be kept opened, remove the three screws.
Document tray Hinge base R
Taptite, cup B M3x10
Hinge arm Hinge L Taptite, cup B M3x10
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(11) Remove the six screws from the underside of the scanner base. (12) Slightly lift up the control panel ASSY and disconnect the panel harness and piezo ringer harness from the control panel PCB. (13) Turn the scanner open sensor actuator as shown below and remove it. (14) 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 4.1.8 and 4.1.9, respectively.) (15) Remove the three screw from the piezo ringer cap and take out the piezo ringer and its cap. (16) Remove the lever spring. 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.
Control panel ASSY
"a"
Scanner open sensor PCB Lever spring "c" Scanner open sensor actuator
"s" "b" Piezo ringer cap Piezo ringer harness Piezo ringer Scanner open lever Panel harness "b" Lock
Scanner base
"a" and "c": Taptite, cup B M3x8 "b": Taptite, cup B M3x12
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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 4-25). Move those bound harnesses to the rear section of the opening. Route the bound section thro