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R
LASER PRINTER
SERVICE MANUAL
MODEL:HL-820/1020/1040/1050
© Copyright Brother 1998 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. Trademarks: The brother logo is a registered trademark of Brother Industries, Ltd. Apple, the Apple Logo, and Macintosh are trademarks, registered in the United States and other countries, and True Type is a trademark of Apple computer, Inc. Epson is a registered trademark and FX-80 and FX-850 are trademarks of Seiko Epson Corporation. Hewlett Packard is a registered trademark and HP Laser Jet is a trademark of Hewlett Packard Company. IBM, IBM PC and Proprinter are registered trademarks of International Business Machines Corporation. Microsoft and MS-DOS are registered trademarks of Microsoft Corporation. Windows is a registered trademark of Microsoft Corporation in the U.S. and other countries.
PREFACE
This service manual contains basic information required for after-sales service of the laser printer (here- in-after referred to as "this machine" or "the printer"). This information is vital to the service technician to maintain the high printing quality and performance of the printers. This service manual covers the HL-820, 1040, 1050 and 1070 laser printers. (Note that any figures for the printer body are based on the HL-1040 printer.) This manual consists of the following chapters:
CHAPTER I :
FEATURES AND SPECIFICATIONS Features, specifications, etc.
CHAPTER II : THEORY OF OPERATION Basic operation of the mechanical system, the electrical system and the electrical circuits, and their timing information. CHAPTER III : DISASSEMBLY AND REASSEMBLY Procedures for disassembling and reassembling the mechanical system. CHAPTER IV : MAINTENANCE AND TROUBLESHOOTING Reference values and adjustments, troubleshooting image defects, troubleshooting malfunctions, etc. APPENDICES :SERIAL NO. DESCRIPTIONS, CONNECTION DIAGRAMS, PCB CIRCUIT DIAGRAMS.
Information in this manual is subject to change due to improvement or re-design of the product. All relevant information in such cases will be supplied in service information bulletins (Technical Information). A thorough understanding of this printer, based on information in this service manual and service information bulletins, is required for maintaining its print quality performance and for improving the practical ability to find the cause of problems.
CONTENTS
CHAPTER I FEATURES AND SPECIFICATIONS ..........................................I-1
1. FEATURES .........................................................................................................................I-1 2. SPECIFICATIONS ..............................................................................................................I-3
2.1 2.2 2.3 2.4 2.5 2.6 2.7 Printing.......................................................................................................................................I-3 Functions ...................................................................................................................................I-3 Electrical and Mechanical ..........................................................................................................I-4 Paper Specification ....................................................................................................................I-5 Print Delivery..............................................................................................................................I-5 Paper .........................................................................................................................................I-6 Effective Printing Area ...............................................................................................................I-7
3. SAFETY INFORMATION ....................................................................................................I-9
3.1 3.2 3.3 Laser Safety (110 - 120V Model only) .......................................................................................I-9 FDA Regulations (110 - 120V Model only) ................................................................................I-9 Caution for Laser Product........................................................................................................I-10
CHAPTER II THEORY OF OPERATION ........................................................ II-1
1. ELECTRONICS..................................................................................................................II-1
1.1 1.2 1.3 General Block Diagram.............................................................................................................II-1 Main PCB Block Diagram .........................................................................................................II-4 Main PCB..................................................................................................................................II-7 1.3.1 CPU Core ....................................................................................................................II-7 1.3.2 ASIC ............................................................................................................................II-9 1.3.3 ROM ..........................................................................................................................II-15 1.3.4 DRAM ........................................................................................................................II-16 1.3.5 Optional RAM ............................................................................................................II-17 1.3.6 Optional Serial I/O .....................................................................................................II-18 1.3.7 EEPROM ...................................................................................................................II-18 1.3.8 Reset Circuit ..............................................................................................................II-19 1.3.9 CDCC I/O .................................................................................................................. II-19 1.3.10 Engine I/O..................................................................................................................II-21 1.3.11 Paper Feed Motor Drive Circuit .................................................................................II-23 Panel Sensor PCB ..................................................................................................................II-24 Power Supply..........................................................................................................................II-24 1.5.1 Low-voltage Power Supply ........................................................................................II-24 1.5.2 High-voltage Power Supply, SR PCB........................................................................II-25
1.4 1.5
2. MECHANICS....................................................................................................................II-26
2.1 2.2 Overview of Printing Mechanism ............................................................................................II-26 Paper Transfer........................................................................................................................II-27 2.2.1 Paper Supply .............................................................................................................II-27 2.2.2 Paper Registration.....................................................................................................II-27 2.2.3 Paper Eject ................................................................................................................II-28
i
2.3
2.4
2.5
Sensors...................................................................................................................................II-29 2.3.1 Cover Sensor.............................................................................................................II-29 2.3.2 Toner Empty Sensor..................................................................................................II-29 Drum Unit................................................................................................................................II-30 2.4.1 Photosensitive Drum .................................................................................................II-30 2.4.2 Primary Charger ........................................................................................................II-30 2.4.3 Developer Roller........................................................................................................II-30 2.4.4 Transfer Roller........................................................................................................... II-30 2.4.5 Cleaner Roller............................................................................................................ II-30 2.4.6 Erase Lamp ..............................................................................................................II-30 Print Process ..........................................................................................................................II-30 2.5.1 Charging ...................................................................................................................II-30 2.5.2 Exposure Stage .........................................................................................................II-31 2.5.3 Developing.................................................................................................................II-32 2.5.4 Transfer .....................................................................................................................II-32 2.5.5 Drum Cleaning Stage ................................................................................................II-33 2.5.6 Erasing Stage ............................................................................................................II-33 2.5.7 Fixing Stage...............................................................................................................II-33
CHAPTER III DISASSEMBLY AND REASSEMBLY.......................................III-1
1. SAFETY PRECAUTIONS..................................................................................................III-1 2. DISASSEMBLY FLOW......................................................................................................III-2 3. DISASSEMBLY PROCEDURE .........................................................................................III-3
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 Output Tray ASSY ...................................................................................................................III-3 Drum Unit.................................................................................................................................III-3 Top Cover ................................................................................................................................III-4 Rear Cover ..............................................................................................................................III-4 MP Sheet Feeder ASSY ..........................................................................................................III-5 Fixing Unit ................................................................................................................................III-6 Scanner Unit ............................................................................................................................III-8 Main PCB ASSY ....................................................................................................................III-10 Base Plate ASSY ...................................................................................................................III-10 Panel Sensor PCB ASSY ......................................................................................................III-11 Low-voltage Power Supply PCB ASSY .................................................................................III-12 High-voltage Power Supply PCB ASSY.................................................................................III-13 Sub Fan Motor ASSY ............................................................................................................III-14 Fan Motor ASSY ...................................................................................................................III-14 Drive Unit ...............................................................................................................................III-15 Main Motor ASSY ..................................................................................................................III-16 Sub Motor ASSY....................................................................................................................III-16 Paper Support........................................................................................................................III-17 Extension Support Wire .........................................................................................................III-17
4. PACKING........................................................................................................................III-18
ii
CHAPTER IV MAINTENANCE AND TROUBLESHOOTING.......................... IV-1
1. INTRODUCTION ..............................................................................................................IV-1
1.1 1.2 Initial Check........................................................................................................................ IV-1 Basic Procedure ................................................................................................................. IV-2
2. CONSUMABLE PARTS....................................................................................................IV-3
2.1 2.2 2.3 Drum Unit........................................................................................................................... IV-3 Toner Cartridge .................................................................................................................. IV-3 Periodical Replacement Parts............................................................................................. IV-3
3. IMAGE DEFECTS ............................................................................................................IV-4
3.1 3.2 3.3 3.4 Image Defect Examples ..................................................................................................... IV-4 Troubleshooting Image Defects .......................................................................................... IV-5 Location of High-voltage Contacts and Grounding Contacts.............................................. IV-19 Location of Feed Roller Shaft and Grounding Contacts..................................................... IV-20
4. PAPER JAM ...................................................................................................................IV-21 5. TROUBLESHOOTING MALFUNCTIONS.......................................................................IV-22 6. INSPECTION MODE ......................................................................................................IV-27
6.1 6.2 Incorporated Inspection Modes......................................................................................... IV-27 Error Codes...................................................................................................................... IV-29
APPENDICES
1. Serial No. Descriptions ......................................................................................................A-1 2. Connection Diagram, HL-820/1020 ...................................................................................A-2 3. Connection Diagram, HL-1040 ..........................................................................................A-3 4. Connection Diagram, HL-1050 ..........................................................................................A-4 5. Main PCB Circuit Diagram, (HL-820/1020/1040), (1/2)......................................................A-5 6. Main PCB Circuit Diagram, (HL-820/1020/1040), (2/2)......................................................A-6 7. Main PCB Circuit Diagram, (HL-1050), (1/5)......................................................................A-7 8. Main PCB Circuit Diagram, (HL-1050), (2/5)......................................................................A-8 9. Main PCB Circuit Diagram, (HL-1050), (3/5)......................................................................A-9 10. Main PCB Circuit Diagram, (HL-1050), (4/5)....................................................................A-10 11. Main PCB Circuit Diagram, (HL-1050), (5/5)....................................................................A-11 12. Panel Sensor PCB Circuit Diagram .................................................................................A-12 13. Low-voltage Power Supply PCB Circuit Diagram, HL-820/1020/1040 (110 - 120V) ........A-13 14. Low-voltage Power Supply PCB Circuit Diagram, HL-820/1020/1040 (220 - 240V) ........A-14 15. Low-voltage Power Supply PCB Circuit Diagram, HL-1050 (110 - 120V) ........................A-15 16. Low-voltage Power Supply PCB Circuit Diagram, HL-1050 (220 - 240V) ........................A-16 17. High-voltage Power Supply PCB Circuit Diagram............................................................A-17 18. How to Know Drum Unit Life & Page Counter .................................................................A-18 19. Diameter / Circumference of Rollers ................................................................................A-20
iii
CHAPTER I FEATURES AND SPECIFICATIONS
1. FEATURES
This printer has the following features: High Resolution and Fast Printing Speed True 600 dots per inch (dpi) with microfine toner and 8 pages per minute (ppm) printing speed (A4 or Letter paper). True 600 dots per inch (dpi) with microfine toner and 10 pages per minute (ppm) printing speed (A4 or Letter paper). True 600 dots per inch (dpi) and 1200 x 600 dpi for graphics with microfine toner and 10 pages per minute (ppm) printing speed (A4 or Letter paper). Enhanced Printing Performance and User-Friendly Operation for Windows The dedicated printer driver and TrueTypeTM-compatible fonts for Microsoft® Windows 3.1 and Windows 95 are available on the floppy disk and CD-ROM supplied with your printer. You can easily install them into your Windows system using our installer program. The driver supports our unique compression mode to enhance printing speed in Windows applications and allows you to set various printer settings including toner saving mode, custom paper size, sleep mode, gray scale adjustment, resolution, and so forth. You can easily setup these print options in the graphic dialog boxes through the Printer Setup menu within the Windows Control Panel. Printer Status Monitor with Bi-directional Parallel Interface The printer driver can monitor your printer's status using bi-directional parallel communications. The printer status monitor program can show the current status of your printer. When printing, an animated dialog box appears on your computer screen to show the current printing process. If an error occurs, a dialog box will appear to let you know what to correct. For example: when your printer is out of paper, the dialog box will display "No Paper" and instructions for the corrective action to take. Versatile Paper Handling The printer has a multi-purpose sheet feeder and a straight paper path mechanism. Using this mechanism, you can load A4, letter, legal, B5, A5, A6, and executive sizes of paper, and various types of media including envelopes, organizer paper, or your custom paper size. The multi-purpose sheet feeder also allows manual paper loading, so you can also use labels and transparencies.
Economy Printing Mode
This feature will cut your printing cost by saving toner. It is useful to obtain draft copies for proof-reading. You can select from two economy modes, 25% toner saving and 50% toner saving, through the Windows printer driver supplied with your printer.
Environment-Friendly
Sleep Mode (Power Save Mode)
Sleep mode automatically reduces power consumption when the printer is not in use. The printer consumes less than 13W when in sleep mode.
I-1
Low Running Cost
The toner cartridge is separate from the drum unit. You need to replace only the toner cartridge after around 2,400 pages, which is cost effective and ecologically friendly. The actual number of pages printed with each toner cartridge may vary depending on your average type of print job. Enhanced Memory Management The printer provides its own data compression technology in its printer hardware and the supplied printer driver software, which can automatically compress graphic data and font data efficiently into the printer's memory. You can avoid memory errors and print most full page 600dpi graphic and text data, including large fonts, with the standard printer memory. Remote Printer Console Program for DOS (for HL-1040/1050 only) The utility program, Remote Printer Console (RPC), is available on the floppy disk and CD-ROM supplied with your printer. When you operate your computer in the DOS (Disk Operating System) environment, this program allows you to easily change the default settings of the printer such as fonts, page setup, emulations and so on. This program also provides a status monitor program, which is a Terminate-and-Stay Resident (TSR) program. It can monitor the printer status while running in the background and report the current status or errors on your computer screen. Popular Printer Emulation Support (for HL-1040/1050 only) These printers support the following printer emulation modes; The HL-1040 supports HP LaserJet IIP, Epson FX-850, and IBM Proprinter XL The HL-1050 supports HP LaserJet 6P/6L, Epson FX-850 and IBM Proprinter XL. When you use DOS application software or WindowsTM version 3.0 or earlier, you can use any of these emulations to operate the printer in the 300 dpi resolution mode. The printers also support Auto-emulation switching between HP and Epson or HP and IBM. If you want to set the printer emulation, you can do it using the Remote Printer Console Program. USB Interface (for HL-1050 only) The Universal Serial Bus Interface is an interface which allows the printer to connect to multiple peripheral devices. High Resolution Control & Advanced Photoscale Technology (for HL-1050 only) High resolution control (HRC) technology provides clear and crisp printouts. Use this function to get smooth text print quality. Advanced Photoscale Technology enables the printer to print graphics in 256 grayscales, producing nearly photographic quality. Use this function when you want to print photographic images. Optional Apple Macintosh Interface (for HL-1040/1050 only) An optional Apple Macintosh serial interface is available which allows your printer to be connected to Apple Macintosh computers. With this option, you can use your printer with both an IBM PC (or compatible) and an Apple Macintosh at the same time. This optional interface board can be used as an RS-422A interface for Macintosh or an RS-232C serial interface for an IBM PC or compatible.
®
I-2
2.
2.1
SPECIFICATIONS
Printing Print method Laser: Electrophotography by semiconductor laser beam scanning Wave length: Output: HL-820/1020: HL-1040: 780nm 5mW max 600 x 600dots/inch (for Windows) 600 x 600dots/inch (for Windows or DOS) 300 x 300dots/inch (under Apple Macintosh, DOS, or other operating system) 1200(H) x 600(V)dots/inch (for Windows DIB graphics) 600 x 600dots/inch (for Windows or DOS) 300 x 300dpi (under Apple Macintosh using optional RS-100M)
Resolution
HL-1050:
Print speed
HL-820: Up to 8 pages/minute HL-1020/1040/1050: Up to 10 pages/minute (when loading Letter-size paper from the multipurpose sheet feeder) Max. 30 seconds at 23°C (73.4°F) 15 seconds (when loading Letter-size paper from the multipurpose sheet feeder) Toner cartridge Life Expectancy: 2,400 pages/cartridge (when printing A4 or letter-size paper at 5% print coverage) Drum unit, separated from toner cartridge Life Expectancy: 20,000 pages/drum unit at 20 pages per job 8,000 pages at 1 page per job
Warm-up First print
Print media
Developer
2.2
Functions CPU Emulation HL-820/1020/1040: MC68EC000 16Mhz HL-1050: MB86831 66Mhz HL-820/1020: HL-1040: Brother Printing Solution for Windows Brother Printing Solution for Windows Automatic emulation selection among HP LaserJet IIP (PCL level 4), EPSON FX-850, and IBM Proprinter XL Brother Printing Solution for Windows Automatic emulation selection among HP LaserJet 6P (PCL level 6), EPSON FX-850, and IBM Proprinter XL
HL-1050:
Printer driver
WindowsTM 3.1/3.11, Windows 95 and Windows NT 4.0 driver, supporting Brother Native Compression mode and bi-directional capability. Optional Macintosh driver available for System 6.0.7 or higher (for HL1040/1050 only)
I-3
Interface
Bi-directional parallel Universal Serial Bus (USB) (HL-1050 only) RS-422A/RS-232C serial (RS-100M) is optionally available. (HL1040/1050 only) HL-820/1020/1040: 2.0 Mbytes HL-1050: 4.0 Mbytes Expandable up to 36 Mbytes by installing an industry standard SIMM 1 switch and 4 lamps Self-diagnostic program
Memory
Control panel Diagnostics 2.3
Electrical and Mechanical Power source U.S.A. and Canada: Europe and Australia: AC 110 to 120V, 50Hz/60Hz AC 220 to 240V, 50Hz/60Hz
Power consumption Printing: Standing by: Sleep: Noise Printing: Standing by: Operating: Storage: Operating: Storage:
280W or less 60W or less 13W or less 49dB A or less 33dB A or less 10 to 32.5°C (50 to 90.5°F) 0 to 40°C (38 to 104°F) 20 to 80% (non condensing) 10 to 85% (non condensing)
Temperature
Humidity
Dimensions (W x D x H) Weight
390 x 365 x 245 mm (15.4 x 14.4 x 9.7 inches) (when the output tray is closed.) Approx. 7.2kg (15.7lb.) including the drum unit and toner cartridge
I-4
2.4
Paper Loading (1) Multi-purpose sheet feeder loading Paper size: A4, Letter, Legal, B5, A5, A6, and Executive. Other sizes of media that can be handled by the feed mechanism can be loaded.
69.8 to 229 mm
105 to 356mm (face down)
Feeding direction
Feedable paper weight: 60 (16lb.) to 158 (42lb.) g/m2 Maximum load height : Setting method: 22mm (200 sheets of 80g/m2 paper) letter or A4 size Pull the MP sheet feeder cover toward you, insert the stack of paper into the feeder, aligning the top edge of the sheets, then push the cover back to its original position.
(2)
Manual slot loading Paper size: Setting methods: Same as in (1) for the multi-purpose sheet feeder. Place the side of the paper to be printed on face down into the manual feed slot after selecting orientation. Align the paper at the center of the manual feed slot, and be sure to insert it fully into the feed slot. Move the paper guide of the manual feed slot to the paper width. Feedable paper weight: Same as in (1) for the multi-purpose sheet feeder.
Cautions: Before loading paper with holes such as organizer sheets, be sure to fan the stack well. When printing on the back of pre-printed paper, be sure to straighten the paper as much as possible.
2.5 Print Delivery (1) (2) With the output tray opened Tray capacity: Maximum 100 sheets (80g/m2), face-down only With the output tray closed Tray capacity: 1 sheet (80g/m2), face-down only
Note: Face down: Environment :
Deliver the printed face of the paper downward. 23°C
I-5
2.6
Paper (1) Paper type (a) Normal paper (60 to 157g/m2, specified types of high-quality paper) · · · · · · · A4 size Letter size Legal size B5 (JIS ISO) size A5 size A6 size Executive size
* The recommended types of plain paper are as follows: Letter : Xerox 4200 (75g/m2) A4 : Xerox 80 Premier Paper (80g/m2) (b) Special paper (specified types) · Labels · Envelopes (DL, C5, COM10, Monarch) · Organizers (K, L, and J sizes of DAY-TIMERS) (C) Other detailed specifications Cut Sheet Basis Weight Caliper Moisture Content Smoothness 60 to 158 g/m (16 to 42 lb.)
2
0.03 to 0.08 in.
(0.08 to 0.2 mm) 4% to 6% by weight 100 to 250 (Sheffield)
Envelope 2 75 to 90 g/m (20 to 24 lb.) single thickness 0.0033 to 0.0058 in. (0.084 to 0.14 mm) single thickness 4% to 6% by weight 100 to 250 (Sheffield)
Caution: It is recommended to use long-grained paper for the best print quality. If short-grained paper is being used, it might be the cause of paper jams. Use neutral paper. Do not use acid paper to avoid any damage to the printer drum unit.
(2) Paper feed conditions Type Name 60 to 80 g/m Normal paper (cut sheet)
2 2
Feeder
Manual feed
(200 sheets)
80 g/m paper (Legal) 157 g/m Labels
2
(100 sheets) (30 sheets) (50 sheets)
Special paper (cut sheet)
Envelopes Organizers
(10 sheets) (10 sheets)
I-6
2.7
Effective Printing Area Printable area
A C E
F E
B
D
F
The effective printing area means the area within which the printing of all the data received without any omissions can be guaranteed.
I-7
The table below shows the effective printing areas. Size A4 A 210.0mm 8.27" (2,480 dots) 215.9mm 8.5" (2,550 dots) 215.9mm 8.5" (2,550 dots) 182.0mm 7.16" (2,149 dots) 176.0mm 6.93" (2,078 dots) 184.15mm 7.25" (2,175 dots) 148.5mm 5.85" (1,754 dots) 105.0mm 4.13" (1,240 dots) 69.85mm 2.75" (825 dots) 95.25mm 3.75" (1,125 dots) 139.7mm 5.5" (1,650 dots) 104.78mm 4.125" (1,237 dots) 98.43mm 3.875" (1,162 dots) 162mm 6.38" (1,913 dots) 110mm 4.33" (1,299 dots) B 297.0mm 11.69" (3,507 dots) 279.4mm 11.0" (3,300 dots) 355.6mm 14.0" (4,200 dots) 257.0mm 10.12" (3,035 dots) 250.0mm 9.84" (2,952 dots) 266.7mm 10.5" (3,150 dots) 210.0mm 8.27" (2,480 dots) 148.5mm 5.85" (1,754 dots) 127.0mm 5.0" (1,500 dots) 171.45mm 6.75" (2,025 dots) 215.9mm 8.5" (2,550 dots) 241.3mm 9.5" (2,850 dots) 190.5mm 7.5" (2,250 dots) 229mm 9.01" (2,704 dots) 220mm 8.66" (2,598 dots) C 203.2mm 8.0" (2,400 dots) 203.2mm 8.0" (2,400 dots) 203.2mm 8.0" (2,400 dots) 173.5mm 6.83" (2,007 dots) 164.0mm 6.46" (1,936 dots) 175.7mm 6.92" (2,025 dots) 136.5mm 5.37" (1,612 dots) 93.0mm 3.66" (1,098 dots) 56.2mm 2.21" (675 dots) 86.78mm 3.42" (975 dots) 131.23mm 5.17" (1,500 dots) 92.11mm 3.63" (1,087 dots) 85.7mm 3.37" (1,012 dots) 150.0mm 5.9" (1,771 dots) 98.0mm 3.86" (1,157 dots) D 288.5mm 11.36" (3,407 dots) 270.9mm 10.67" (3,200 dots) 347.1mm 13.67" (4,100 dots) 248.5mm 9.78" (2,935 dots) 241.5mm 9.5" (2,852 dots) 258.2mm 10.17" (3,050 dots) 201.5mm 7.93" (2,380 dots) 140.0mm 5.51" (1,654 dots) 118.5mm 4.66" (1,400 dots) 162.98mm 6.42" (1,925 dots) 207.43mm 8.17" (2,450 dots) 232.8mm 9.16" (2,750 dots) 182.0mm 7.16" (2,150 dots) 220.5mm 8.68" (2,604 dots) 211.5mm 8.33" (2,498 dots) E 3.4mm 0.13" (40 dots) 6.35mm 0.25" (75 dots) F 4.23mm 0.17" (50 dots)
Letter
Legal
6.01mm 0.24" (71 dots)
B 5 (JIS)
B 5 (ISO)
6.35mm 0.25" (75 dots) 6.01mm 0.24" (71 dots)
Executive
A5
A6 Organizer (J size) Organizer (K size) Organizer (L size) COM-10
6.35mm 0.25" (75 dots)
6.01mm 0.24" (71 dots)
MONARCH
C5
DL
(Note that the paper sizes indicated here should conform to the nominal dimensions specified by JIS.)
A4 paper must accommodate 80 characters printed in pica pitch (203.2 mm). The dot size is based on 300 dpi resolution. Organizer is not supported by any printer emulations (commands).
I-8
3.
3.1
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.
3.2
FDA Regulations (110 - 120V Model only) The US Food and Drug Administration (FDA) has implemented regulations for laser products manufactured on and after August 2, 1976. Compliance is mandatory for products marketed in the United States. One of the following labels on the back of the printer indicates compliance with the FDA regulations and must be attached to laser products marketed in the United States. The label for Japanese manufactured products MANUFACTURED: BROTHER INDUSTRIES, LTD. K
15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561, Japan. This product complies with FDA radiation performance standards, 21 CFR Subchapter J. The label for Chinese manufactured products MANUFACTURED : BROTHER Corporation (Asia) Ltd. Shenzen Buji Nan Ling Factory Gold Garden Ind., Nan Ling Village, Buji, Rong Gang, Shenzhen, CHINA This product complies with FDA radiation performance standards, 21 CFR Subchapter J. C
I-9
3.3
Caution for Laser Product (Warnhinweis für Laserdrucker) CAUTION: When the machine during servicing is operated with the cover open, the regulations of VBG 93 and the performance instructions for VBG 93 are valid. In case of any trouble with the laser unit, replace the laser unit itself. To prevent direct exposure to the laser beam, do not try to open the enclosure of the laser unit. Im Falle von Störungen der Lasereinheit muß diese ersetzt werden. Das Gehäuse der Lasereinheit darf nicht geöffnet werden, da sonst Laserstrahlen austreten können.
CAUTION:
ACHTUNG:
(1)
Location of the laser beam window.
Window
Fig. 1-1
(2)
Location of Caution Label for Laser Product. (200V only)
CLASS 1LASER PRODUCT APPAREIL Å LASER DE CLASSE 1 LASER KLASSE 1 PRODUKT
Fig. 1-2
I-10
CHAPTER II THEORY OF OPERATION
1.
1.1
ELECTRONICS
General Block Diagram HL-820/1020 Fig. 2-1 shows a general block diagram of the HL-820/1020 printer.
Control system
Low-voltage power supply block
Interface block Video control block
Engine control block
Operation block (Operation panel) Erase lamp
High-voltage power supply block
Laser scanner unit
Drive block (Stepping motor)
Paper tray unit Paper tray
Drum unit Transfer block
Manual feed
Fixing unit Developing block Charging block Drum Cleaner block
Paper eject block
Paper feed system Toner cartridge
Image generation system
Fig. 2-1
II-1
External device
HL-1040 Fig. 2-2 shows a general block diagram of the HL-1040 printer.
Optional I/F board (Mac. RS-232C)
Control system Expansion I/O
Low-voltage power supply block
Interface block Video control block
Engine control block
Operation block (Operation panel) Erase lamp
High-voltage power supply block
Laser scanner unit
Drive block (Stepping motor)
Paper tray unit Paper tray
Drum unit Transfer block
Manual feed
Fixing unit Developing block Charging block Drum Cleaner block
Paper eject block
Paper feed system Toner cartridge
Image generation system
Fig. 2-2
II-2
External device
External device
HL-1050 Fig. 2-3 shows a general block diagram of the HL-1050 printer.
Optional RAM (SIMM) (max. 32Mbytes)
Optional I/F board (Mac. RS-232C)
Control system Expansion memory I/O Expansion I/O
Low-voltage power supply block
Interface block Video control block
Engine control block
Operation block (Operation panel) Erase lamp
High-voltage power supply block
Laser scanner unit
Drive block (Stepping motor)
Paper tray unit Paper tray
Drum unit Transfer block
Manual feed
Fixing unit Developing block Charging block Drum Cleaner block
Paper eject block
Paper feed system Toner cartridge
Image generation system
Fig. 2-3
II-3
External device
External device
1.2
Main PCB Block Diagram HL-820/1020 Fig. 2-4 shows the block diagram of the main PCB.
A S I C CPU Core Reset Circuit (MC68EC000) BUS INT Oscillator (15.3MHz)
Address Decoder Program + Font ROM 512 Kbytes DRAM Control
Timer RAM (2.0 Mbytes) FIFO
DATA EXTENSION
CDCC Parallel I/O
To PC
Soft Support
EEPROM (128
8 bits)
EEPROM I/O
Motor Driver
Engine Control I/O
To Panel Sensor PCB
Fig. 2-4
II-4
HL-1040 Fig. 2-5 shows the block diagram of the main PCB.
A S I C CPU Core Reset Circuit (MC68EC000) BUS INT Oscillator (15.3MHz)
Address Decoder Program + Font ROM 512 Kbytes DRAM Control
Timer RAM (2.0 Mbytes) FIFO
Option Serial I/O (RS232C & RS422A)
DATA EXTENSION
CDCC Parallel I/O
To PC
Soft Support
EEPROM (128
8 bits)
EEPROM I/O
Motor Driver
Engine Control I/O
To Panel Sensor PCB
Fig. 2-5
II-5
HL-1050 Fig. 2-6 shows the block diagram of the main PCB.
A S I C CPU Core Reset Circuit (MB86831) BUS INT Oscillator (33.3MHz)
Address Decoder Program + Font ROM 4.0 Mbytes DRAM Control
Timer RAM (4.0 Mbytes) FIFO
Option RAM (SIMM) (max. 32Mbytes) CDCC Parallel I/O To PC
USB I/O Option Serial I/O (RS232C & RS422A) Soft Support
To PC
EEPROM (512 x 8 bits)
EEPROM I/O
Motor Driver
Engine Control I/O
To Panel Sensor PCB
Fig. 2-6
II-6
1.3
Main PCB 1.3.1 CPU Core HL-820/1020/1040 Fig. 2-7 shows the CPU circuit block on the main PCB. The CPU is a Motorola MC68EC000FN16 which is driven with a clock frequency of 15.3MHz. This clock frequency is made by dividing the source clock of 30.67 MHz into two.
Fig. 2-7
II-7
HL-1050 Fig. 2-8 shows the CPU circuit block on the main PCB. The CPU is a Motorola MB86831 which is driven with a clock frequency of 33MHz. The CPU itself runs at 66MHz.
Fig. 2-8
II-8
1.3.2
ASIC
HL-820/1020/1040 The ASIC is composed of a Cell Based IC that contains the following functional blocks. (1) Oscillator circuit Generates the main clock for the CPU by dividing the source clock frequency into two. (2) Address decoder Generates the CS for each device. (3) DRAM control Generates the RAS, CAS, WE, OE and MA signals for the DRAM and controls refresh processing (CAS before RAS self-refreshing method). (4) Interrupt control Interrupt levels: Priority High 7 6 5 4 3 2 Low (5) Timers The following timers are incorporated: Timer 1 Timer 2 Timer 3 (6) FIFO A 5,120-bit FIFO is incorporated. Data for one raster scan is transferred from the RAM to the FIFO by DMA transmission and is output as serial video data. The data cycle is 10.22 MHz. (7) CDCC parallel I/O There are two modes in this unit. One is the CPU receiving mode and the other is the DMA receiving mode. In the CPU receiving mode the CPU receives the command data from the PC, and after the CPU is switched to the DMA mode, it receives the image data and writes to the DRAM directly. 16-bit timer 10-bit timer Watch-dog timer 1 NMI FIFO EXINT(Option Serial I/O) BD / Timer 1 SCANINT CDCC / BOISE / DATA EXTENSION Timer 2
II-9
CPU Receive Mode
STROBE
BUSY ACK 90 µsec 0.5 µsec
DMA Receive Mode
STROBE
BUSY ACK 1.5 µsec 0.5 µsec
BUSY goes HIGH at the falling edge of STROBE. The data (8 bits) from the PC is latched in the data buffer at the rising edge of STROBE. The pulse width of ACK differs according to the speed MODE as shown above. BUSY goes LOW at the rising edge of ACK. This supports the IEEE1284 data transfer with the following modes. Nibble mode Byte mode (8) Data expansion This circuit expands the compressed image data received from the PC, and writes the bit map data to the FIFO. (9) Software support Supports 16 x 16 rotation, bit expansion, and bit search. (10) EEPROM I/O One output port and one I/O port are assigned.
II-10
(11)
Engine control I/O This I/O is used for the connection to the panel sensor PCB. It controls the main motor, solenoid, sensors, etc.
Fig. 2-9
II-11
HL-1050 The ASIC is composed of a Cell Based IC that contains the following functional blocks. (1) Oscillator circuit Generates the main clock for the CPU. (2) Address decoder Generates the CS for each device. (3) DRAM control Generates the RAS, CAS, WE, OE and MA signals for the DRAM and controls refresh processing (CAS before RAS self-refreshing method). (4) Interrupt control Interrupt levels: Priority High 10 9 8 7 6 5 4 3 2 1 Reserve interrupt 1 (for debug) Watch Dog Timer LSB EMPTY (for VDO FIFO) Timer 1 USB XIO interrupt (RS-100M) or MIO interrupt BD (for engine check) Reserve interrupt 2 CDCC Timer 2
Low
Note: All the interrupts can be masked. The priority of levels 7, 6, and 5 are changeable from the program.
(5) Timers The following timers are incorporated: Timer 1 Timer 2 Timer 3 (6) FIFO A 10Kbit FIFO is included. Data for one raster scan is transferred from the RAM to the FIFO by DMA transmission and is output as serial video data. The data cycle is 10.43MHz. (7) Parallel I/O There are two modes in this unit. One is the CPU receive mode and the other is the DMA receive mode. In the CPU receive mode the CPU receives the command data from the PC, and after the CPU is switched to the DMA mode, it receives the image data and writes it to the DRAM directly. 32-bit timer 32-bit timer Watch-dog timer
II-12
CPU Receive Mode
STROBE
BUSY ACK 90 µsec 0.5 µsec
DMA Receive Mode
STROBE
BUSY ACK 1.5 µsec 0.5 µsec
BUSY goes HIGH at the falling edge of the STROBE signal. The data (8 bits) from the PC is latched into the data buffer at the rising edge of the STROBE signal. The pulse width of ACK varies according to the speed MODE as shown above. BUSY goes LOW on the rising edge of ACK. This supports the IEEE1284 data transfer with the following mode. Nibble Byte ECP (8) Data expansion This circuit expands the compressed image data received from the PC, and writes the bit map data to the FIFO. (9) Software support Supports 16 x 16 rotation, bit expansion, bit search, and decimal point conversion. (10) EEPROM I/O One output port and one I/O port are assigned. mode mode mode
II-13
(11)
Engine control I/O This I/O is used for the connection to the panel sensor PCB. It controls the main motor, solenoid, sensors, etc.
Fig. 2-10
II-14
1.3.3
ROM
HL-820/1020/1040 A program file of 512 Kbytes and the font data are stored in the ROM. A 42-pin IC socket is provided: a 16 Mbits ROM (42-pin) is mounted into this socket normally, but a 4 Mbits ROM (40-pin) can be mounted by leaving the 1st and 42nd pins of the socket open circuit.
Fig. 2-11
HL-1050 A program file of 4.0 Mbytes and the font data are stored in the ROM. Two 42-pin IC sockets are provided: two 16 Mbits ROMs (42-pin) can be mounted into these sockets.
Fig. 2-12
II-15
1.3.4
DRAM
HL-820/1020/1040 A 16M-bit DRAM (x 16bits) is used as the RAM.
Fig. 2-13
HL-1050 Two 16M-bit DRAMs (x 16bits) are used as the RAM.
Fig. 2-14
II-16
1.3.5
Optional RAM
HL-1050 A 32bit (72 pin) SIMM can be fitted as optional RAM. The main PCB has one slot and the capacity of SIMM can be from 1 Mbyte to 32 Mbytes.
Fig. 2-15
II-17
1.3.6
Optional Serial I/O
HL-1040/1050 The interrupt of the serial I/O is input to the EXINT terminal of the ASIC, and is recognized by the CPU. A 32-byte register is provided for this I/O, which is read and written to by the CPU.
Fig. 2-16
1.3.7
EEPROM
HL-820/1020/1040 The EEPROM is an XL24C01AF type of two-wire method with a 128 x 8 bits configuration. M62320FP is an IC which transfers the data received from the serial I/O to the parallel I/O.
Fig. 2-17
HL-1050 The EEPROM is XL24C04AF type of two-wire method with a 512 x 8 bits configuration.
Fig. 2-18
II-18
1.3.8
Reset Circuit
HL-820/1020/1040 The reset IC is a PST598DNR. The reset voltage is 4.2V (typ.) and the LOW period of reset is 200ms (typ).
Fig. 2-19
HL-1050 The reset IC is a PST596DNR. The reset voltage is 4.2V (typ.) and the LOW period of reset is 50ms (typ).
Fig. 2-20
1.3.9
CDCC I/O
HL-820/1020/1040 Fig. 2-21 shows the CDCC interface circuit.
Fig. 2-21
II-19
HL-1050 Fig. 2-22 shows the CDCC interface circuit.
Fig. 2-22
II-20
1.3.10 Engine I/O HL-820/1020/1040 Fig. 2-23 shows the engine interface circuit.
Fig. 2-23
II-21
HL-1050 Fig. 2-24 shows the engine interface circuit.
Fig. 2-24
II-22
1.3.11 Paper Feed Motor Drive Circuit HL-820/1020/1040 The motor driver is a TR array. The excitation method is 2-2 phase excitation with a bipolar drive.
Fig. 2-25
HL-1050 The motor driver is a TR array. The excitation method is 2-2 phase excitation with a bipolar drive.
Fig. 2-26
II-23
1.4
Panel Sensor PCB The following parts are on the panel sensor. · Control Panel ........... 1 Switch, 4 lamps · Connector ................ Low-voltage, high-voltage, solenoid, main motor, toner sensor, laser, polygon motor, connector for main PCB · Registration sensor
1.5
Power Supply 1.5.1 Low-voltage Power Supply The power supply uses a switching regulation system to generate the regulated DC power (+5V and +24V), which are converted from the AC line. The regulated output and the production code of each power supply vary depending on the printer model as listed below; Model HL-820/1020/1040 HL-1050 Regulated Output +5V / 0.6 A +24V / 2.0 A +5V / 1.2A +24V / 2.0A Production Code 100V: MPW1547 200V: MPW1447 100V: MPW1550 200V: MPW1450
(Heater)
Thermal Fuse Heater Circuit Lamp
Fuse
Lightning Surge Absorber
Feedback
Line Filter
Rectifier
Oscillator
(Panel Sensor Circuit)
24V Regulation Circuit
24V
5V Regulation Circuit
5V
Fig. 2-27
II-24
1.5.2
High-voltage Power Supply
This generates and outputs the voltages and currents for the charging, development and transfer functions.
R1 24VI
Current Regulator
B1
Voltage Regulator
Transfer Roller Supply Roller Photosensitive Drum Developing Roller Cleaner Roller
VR22
Current Regulator Corona Unit B81 Q81
Voltage Regulator
B101 Q101 GND Current Regulator
B121 Q121
PAPER SENSOR Voltage Regulator
PC141
Z51
VR51
Voltage Regulator
VR71 Voltage Regulator
VR61
Fig. 2-28
II-25
2.
2.1
MECHANICS
Overview of Printing Mechanism
Papers Multi-purpose Sheet Feeder Manual Paper Path MP Feeder Cover Paper Pick-up Roller Paper Feed Roller Drum Unit Photosensitive Drum Transfer Roller Erase Lamp Fixing Unit Pressure Roller Eject Roller
Pinch Roller Blade Hopper Plate Registration Sensor Lever
Toner Cartridge Polygon Mirror
Eject Sensor Actuator Heat Roller Development Roller Cleaning Roller Thermistor
Toner Empty Laser Scanner Sensor Supply Roller
Corona Wire Scanner Unit
Fig. 2-29
EL PCB Scanner Unit Main Motor Sub Motor Main Fan Motor Sub Fan Motor
Thermistor (for Heat roller)
Main Cotrol PCB
Panel Sensor PCB
HighVoltage Power Supply
Solenoid Primary Charger (Corona Wire) Primary Charger (Grid) Developer Roller Transfer Roller Cleaner Roller Supply Roller Eject Sensor Registration Sensor Toner Empty Sensor Thermistor (for Toner)
Toner Empty Sensor PCB
Fig. 2-30
II-26
2.2
Paper Transfer 2.2.1 Paper Supply The pick-up roller picks up one sheet of paper from the paper feeder every time it is rotated and feeds it to the paper feed roller.
Papers Pick-up roller
Registration sensor lever
Hopper plate
Separation pad Fig. 2-31
The paper is gripped between the pick-up roller and the separation pad and separated into individual sheets. The pick-up roller is directly connected to the sector gear, whose rotation is forcibly stopped by the gear stopper. When the pick-up solenoid is activated, the clutch mechanism is engaged by the solenoid action and the sector gear is driven; when it has completed one full turn its rotation is stopped again by the gear stopper. The paper drawn out by the pick-up roller pushes against the top of form sensor lever and the paper top position/absence of paper is detected by sensing the motion of the lever. 2.2.2 Paper Registration
When paper picked up from the multi-purpose sheet feeder (MPF) pushes against the top of form sensor actuator, the registration sensor lever is caused to turn, and the photo sensor detects this motion. When this signal from the sensor is detected the paper feed roller is stopped temporarily by the clutch. The paper is fed to the nip point between the paper feed roller and the pinch roller in the multi-purpose sheet feeder, and the skew of the paper is corrected by pushing the leading edge of the paper against the nip point. When the paper feed roller starts to be rotated again when it is released by the clutch, paper with the leading edge correctly aligned, is fed by the paper feed roller and is transported to the transfer roller.
Paper Pinch roller Transfer roller
Paper feed roller Drum Clutch mechanism (engaged/released by the solenoid assembly) Released when the solenoid is ON and engaged when the solenoid is OFF. Fig. 2-32
II-27
2.2.3 (a)
Paper Eject When the leading edge of the paper pushes down the eject sensor actuator located in the fixing unit, the photo sensor (photo interrupter) is opened and detects the start of paper eject. When the trailing edge of the paper has passed through the paper eject sensor actuator, the photo sensor is closed and the completion of paper eject is recognized.
Transfer roller
The completion of paper eject is detected in the following manner:
(b)
Pressure roller
Eject sensor actuator Eject roller
Drum Heat roller Fig. 2-33
Eject sensor actuator
High-voltage power Eject sensor actuator supply PCB
, ,
Paper Sensor Sensor Fig. 2-34
II-28
2.3
Sensors 2.3.1 Cover Sensor Detects opening and closing of the top cover.
Top Cover
Cover Switch Fig. 2-35
2.3.2
Toner Empty Sensor
Detects if there is toner in the toner cartridge. It also detects whether or not the drum unit is installed. (The toner cartridge is installed in the drum unit).
Toner Empty Sensor
Fig. 2-36
II-29
2.4
Drum Unit 2.4.1 Photosensitive Drum Generates the latent electrostatic image and develops the image on the drum surface. 2.4.2 (1) (2) Primary Charger Corona wire Generates the ion charge on the drum. Grid Spreads the ion charge evenly over the drum surface. 2.4.3 Development Roller
Forms a uniform charge on the drum surface.
Develops the latent electrostatic image on the drum surface by the addition of the toner. 2.4.4 Transfer Roller
Transfers the toner image to the paper from the drum surface. 2.4.5 Cleaner Roller
Removes and recycles the toner remaining on the drum surface. 2.4.6 Erase Lamp
Discharges the electrostatic latent image on the drum. 2.5 Print Process 2.5.1 Charging The drum is charged to approx. +1150V by an ion charge which is generated by the primary charger. The charge is generated by ionization of the corona wire, which has a DC bias from the high-voltage power supply applied to it. The flow of the ion charge is controlled by the grid to ensure it is distributed evenly on the drum surface. The drum sleeve is regulated to approx. 280V by the voltage regulator.
280V Passive Type Voltage Regulator
Voltage Regulator
+ + + -- + ++ - - - ++ + + 1150V + + + + + + + + + ++
Corona wire Fig. 2-37
-
Aluminum drum sleeve Drum Organic Photoconductor layer Grid
HVPS
The primary charge uses a corona wire, but since the drum is positively charged, only less than 1/10 of the usual quantity of ozone is generated compared with the negatively charged drum. The level of ozone expelled from the printer is therefore not harmful to the human body. Applicable safety standards have been complied with.
II-30
2.5.2
Exposure Stage
After the drum is positively charged, it is exposed to the light emitted from the laser unit.
Drum Laser Beam
Paper Laser beam f lens Laser detector Laser diode Motor Lens Fig. 2-38 Polygon mirror
The area exposed to the laser beam is the image to be printed. The surface potential of the exposed area is reduced, forming the electrostatic image to be printed.
1 Cycle of drum
1 4 2
Primary charging Laser beam exposure and developing (a) Unexposed area ( Non image area ) (b) Exposed area ( Image area ) Transfer the image to paper Erase the residual potential
Surface Potential (V)
1 +1150
2 (a)
3
+700 (b)
3 4
+400 Drum +300 Sleeve Time
Fig. 2-39
II-31
2.5.3
Developing
Developing causes the toner to be attracted to the electrostatic image on the drum so as to transform it into a visible image. The developer consists of a non-magnetic toner. The development roller is made of conductive rubber and the supply roller (which is also made of conductive sponge) rotate against each other. The toner is charged and carried from the supply roller to the development roller. The toner adheres to the development roller and is conveyed to the drum at an even thickness controlled by the blade. The toner is nipped between the development roller and the drum and developed onto the latent image on the drum. The electrostatic field between the drum and the development roller, which is DC-biased from the high-voltage power supply, creates the electrostatic potential to attract toner particles from the development roller to the latent image area on the drum surface.
(a) Transfer process [ON] Transfer roller Blade Toner Separator (b) Cleaning process [ON]
Auger
Drum Erase lamp
Develop housing
(a) Collecting process
Supply roller (b) Discharging process DC-bias SR-bias Development roller Fig. 2-40 Cleaning roller Charger
2.5.4 Transfer (a) Transfer process After the drum has been charged and exposed, and has received a developed image, the toner formed is transferred onto the paper by applying a negative charge to the back of the paper. The negative charge applied to the paper causes the positively charged toner to leave the drum, and adhere to the paper. As a result, the image is visible on the paper. (b) Cleaning process of transfer roller If the toner is not transferred onto the paper perfectly, it is possible that there may be residual toner on the drum which will adhere to the transfer roller. The transfer voltage changes to a positive voltage during non-printing rotation of the drum. Therefore the transfer roller is cleaned by returning the positively charged toner adhering to the transfer roller onto the photo-conductive drum.
II-32
2.5.5 Drum Cleaning Stage In the image transfer stage, not all the toner on the photosensitive drum is transferred onto the paper but some remains on the drum. In the drum cleaning stage, the drum surface is cleaned by the cleaning roller, so that residual toner on the drum surface is removed and collected on the cleaning roller itself. The residual toner on the cleaning roller will be discharged to the drum during starting or non-printing time. The toner will be collected by the developing roller and reused (for further developing). 2.5.6 Erasing Stage
Before the cleaning stage, the drum surface is exposed to the light emitted from the erase lamp (LED lamp). This stage prepares the drum by decreasing its surface voltage uniformly, ready to receive a uniform charge in the primary charging stage. 2.5.7 Fixing Stage
The image transferred to the paper by static electricity is fixed by heat and pressure when passing through the heat roller and the pressure roller in the fixing unit. The thermistor ASSY keeps the surface temperature of the heat roller constant by detecting the surface temperature of the heat roller and turning on or off the halogen heater lamp.
Thermistor ASSY
Halogen heater lamp
, , , ,, , , , ,, , , ,, , , , , , , , , ,, , ,, ,,, , , ,,, ,,
Pressure roller
,,, , , ,, , ,
Heat roller Cleaner ASSY Fig. 2-41
II-33
CHAPTER III DISASSEMBLY AND REASSEMBLY
1. SAFETY PRECAUTIONS
To avoid creating secondary problems by mishandling, be careful to follow the following precautions during maintenance work. (1) (2) (3) (4) (5) Always turn off the power switch and unplug the power cord from the power outlet before accessing any parts inside the printer. Be careful not to lose screws, washers, or other parts removed. Be sure to apply grease to the gears and applicable positions specified in this chapter. When using soldering irons or other heat-generating tools, take care not to accidentally damage parts such as wires, PCBs, and covers. Before handling any PCBs, touch a metal portion of the equipment to discharge any static electricity charge on your body, or the electronic parts or components may be damaged. When transporting PCBs, be sure to wrap them in the correct protective packaging. Be sure to replace self-tapping screws correctly, if removed. Unless otherwise specified, tighten screws to the following torque values. TAPTITE, BIND or CUP B M3 : 7kgf · cm M4 : 10kgf · cm TAPTITE, CUP S M3 : 8kgf · cm SCREW M3 : 7kgf · cm M4 : 8kgf · cm (8) When connecting or disconnecting cable connectors, hold the connector body, not the cables. If the connector has a lock, release the connector lock first to release it. After a repair, check not only the repaired portion but also all connectors. Also check that other related portions are functioning properly before operational checks.
(6) (7)
(9)
III-1
BOTTOM A
8 MAIN PCB ASSY
2.
1
OUTPUT TRAY ASSY
B
2 9 BASE PLATE ASSY
DRUM UNIT
B
10 PANEL SENSOR PCB ASSY 11 LOW-VOLTAGE PS PCB ASSY 12 HIGH-VOLTAGE PS PCB ASSY
DISASSEMBLY FLOW
3
TOP COVER
4 13 SUB FAN MOTOR ASSY 15 DRIVE UNIT
REAR COVER
5
MP SHEET FEEDER ASSY
14
MAIN FAN MOTOR
III-2
16 MAIN MOTOR ASSY 17 SUB MOTOR ASSY
6
FIXING UNIT
7
SCANNER UNIT
A
18
PAPER SUPPORT
19
EXTENSION SUPPORT WIRE
3.
3.1
DISASSEMBLY PROCEDURE
Output Tray ASSY (1) (2) Open the output tray toward you. Press the hinges at the left and right sides of the output tray inwards to release the output tray from the main cover.
Output Tray
Output Tray
Main Cover
Fig. 3.1
3.2
Drum Unit (1) (2) Open the top cover. Lift out the drum unit.
Drum Unit
Top Cover
Main Cover Fig. 3.2
III-3
3.3
Top Cover (1) (2) Open the top cover. Press the hinges at the left and right sides of the top cover inwards to release the top cover from the main cover.
Note: It is recommended for easy removal to press the side of the top cover ( ) while pulling the side of the main cover ( ).
Top Cover
2
Main Cover
1
Main Cover
Top Cover
Fig. 3-3
3.4
Rear Cover (1) (2) Remove the two M4x12 tapping screws. Remove the rear cover.
Multi-purpose Sheet Feeder Taptite, bind M4x12 Taptite, bind M4x12 Rear Cover
Main Cover
Fig. 3-4
Note: When re-assembling the rear cover, hook the two hooks at the right and left hand side (rear), then secure the two screws.
III-4
3.5
MP Sheet Feeder ASSY
Caution: When disassembling the MP sheet feeder ASSY, if you get the grease on your fingers, take care not to touch the separation pad or the paper pick-up roller, the grease spreaded to the paper and the drum unit. It might cause black spots to appear on the printed page.
(1) Push the left rib outwards and pull out the MP sheet feeder. It is not necessary to release the right rib.
Multi-purpose Sheet Feeder
Rib
Fig. 3-5
Note: When re-assembling, apply a suitable amount of grease (2 rice-grain size) between the heat sink of the motor and the ground leaf spring in case of grease shortage. (Refer to the figure below.)
Ground leaf spring
Grease: FLOIL GE-676 (or FLOIL GE-334C) Motor heat sink 6.2MM Fig. 3-6
III-5
3.6
Fixing Unit (1) (2) Remove the two M4x16 tapping screws. Lifting the fixing unit, disconnect the thermistor connector on the EL PCB first, then the two heater harnesses.
Taptite, cup M4x16 Fixing Unit
Taptite, cup M4x16
EL PCB Thermistor harness
Heater harness (Brown) Thermistor connector Heater harness (Blue) Fig. 3-7
Note: The eject sensor actuator may also be removed when removing the fixing unit. In this case be sure to re-assemble the eject sensor actuator when re-assembling the fixing unit.
(3) (4) Remove the two M3x12 tapping screws. Open the fixing unit cover along the open side of the fixing unit cover.
Fixing unit cover
Taptite, bind M3x12 Shaft
Fixing unit cover Pressure roller
Fixing unit frame
Fig. 3-8
III-6
(9) (10) (11)
Remove the M3x10 self tapping screw securing the connector plate. Remove the connector plate from the fixing unit frame and loosen the other M3x10 tapping screw securing the fixing unit cover. Remove the idle gear 16 from the fixing unit frame to remove the heat roller. Then, remove the halogen heater lamp from the heat roller.
Caution : Never touch the surface of the halogen heater lamp and the heat roller.
Halogen heater lamp (Blue 100V, Red 200V) Groove Heat Roller Bearing Heat Roller Washer Retaining ring Heat roller gear Idle gear 16 Heat roller Taptite, pan M3x10 Heat Roller Bearing
Taptite, pan M3x10 Fixing unit frame Connector plate
Fig. 3-9
Note: When re-assembling the bearing at the both ends of the heat roller, ensure that the direction of the bearing is correct referring to the above figure. The heat roller itself is very similar to the one for HL-1060/1070 printers. The heat roller for the HL-820/1020/1040/1050 printers can be distinguished by the groove on the edge of the roller. (Refer to the above figure.) When replacing the heat roller cleaner with a new one, attach the cleaner referring to the figure below;
-1mm ~ +1mm 4mm ~ 5mm
Fig. 3-10
III-7
Follow the instructions below when installing the thermistor in the fixing unit. i) Place the cleaner felt of the cleaner ASSY for the thermistor under the heat roller. ii) Place the end of the thermistor on the heat roller. iii) Insert boss1 of the thermistor into the hole of the fixing unit frame. iv) Do no place the thermistor on boss2 of the fixing unit frame.
3.7
Scanner Unit (1) (2) Remove the three M4x12 tapping screws. Lift out the scanner unit.
Taptite, bind M4x12
Taptite, bind M4x12 Scanner Unit
Main cover
,, ,, ,,,, , ,, , , , ,, , , , , ,, , , ,, , ,
Thermistor Boss2 Boss1 Cleaner ASSY for thermistor
Heat Roller
, ,,
Fig. 3-11 Fig. 3-12
Fixing unit frame
Panel Sensor PCB
III-8
Note: When replacing the scanner unit, ensure to assemble the ferrite core using the cable binder as follows;
Ferrite Core
Cable binder
Flat cable
LD harness Fig. 3-13
(3) (4)
Disconnect the three connectors from the panel sensor PCB. Remove the M3x8 tapping screw, and lift the toner sensor PCB from the scanner unit.
Caution: Never touch the inside of the scanner unit or the mirror when disassembling or reassembling. If there is any dirt or dust on the mirror, blow it off.
Taptite, cup M3x8
Toner Sensor PCB
Scanner Unit
Fig. 3-14
III-9
3.8
Main PCB ASSY (1) (2) Remove the three M4x6 screws. Hold the hooks at the left and right of the mounting frame to pull out the main PCB ASSY.
Screw, pan M4x6
Hook Main PCB ASSY Screw, pan M4x6 Hook Fig. 3-15
3.9
Base Plate ASSY
Caution: Prior to turning the printer upside-down, ensure that the drum unit has been removed from the printer.
(1) (2) Turn the printer upside down. Remove the eight M4 and five M3 self tapping screws.
Taptite, bind M4x12 Taptite, cup M3x6 Taptite, bind M4x12 Taptite, cup M3x6 Taptite, bind M4x12
Base plate ASSY
Taptite, bind M4x12
Fig. 3-16
III-10
(3)
Lift the base plate ASSY and remove the grounding screw.
Base Plate ASSY
Ground wire Screw pan(washer), M3.5x6
Low-voltage Power Supply PCB ASSY
Fig. 3-17
3.10
Panel Sensor PCB ASSY (1) (2) Remove the main shield. Remove the M4x12 screw securing the panel sensor PCB ASSY.
Main shield
Taptite, bind M4x12
A
Main shield
C
Panel Sensor PCB ASSY Panel Sensor PCB ASSY
B
Fig. 3-18
Note: When re-assembling the main shield, ensure that you fit PCB A to underneath the main shield. When re-assembling the panel sensor PCB, ensure that you fit the PCB into hook B and hook C first. Then, fit the two bosses to the PCB and secure the screw.
III-11
(3)
Disconnect the eight connectors from the PCB. (Three connectors have already been disconnected when removing the scanner unit.)
Panel Sensor PCB ASSY
1 2 3 4 5
10 9 8 7
6
Main frame Fig. 3-19
(Name of the Harnesses) 1. Low-voltage harness 2. Erase lamp harness 3. Toner harness 4. Scan motor flat cable 5. Laser harness 6. Solenoid harness 7. Main / sub motor connector 8. Fan motor 1 harness 9. Fan motor 2 harness 10. High-voltage flat cable
Note: When re-assembling, the cable connectors must be inserted securely into the PCB connectors and the PCB must not be stressed by the harnesses. The connectors should be inserted by matching the housing colour and the number of pins.
3.11 Low-voltage Power Supply PCB ASSY (1) (2) Remove the one M4x12 tapping screw securing the low-voltage power supply PCB ASSY. Disconnect the two connectors for the heater harness and the LV harness from the PCB.
Low-voltage Power Supply ASSY
Heater harness
LV harness Fig. 3-20
III-12
(3)
Remove the one M4x12 screw to remove the inlet holder. Then, remove the inlet and the PCB.
Note: When re-assembling the inlet holder and AC inlet, be sure to insert the part A of the holder into the hole of the ferrite core.
Inlet Holder
A
AC Inlet Main Cover
Ferrite Core
Fig. 3-21
3.12
High-voltage Power Supply PCB ASSY (1) (2) (2) Remove the one M4x12 screw securing the high-voltage power supply PCB ASSY. Remove the film covering the PCB. Disconnect the HV flat cable from the PCB.
Taptite, bind M4x12
High-voltage Power Supply PCB ASSY
HV flat cable Insulation Sheet
Main Cover
Fig. 3-22
III-13
3.13
Sub Fan Motor ASSY (1) Sl