Page 1: Service Manual
Inkjet DCP/MFC SERVICE MANUAL DCPJ525W/J725DW/J925DW MFCJ280W/J425W/J430W/J435W MFCJ625DW/J825DW/J835DW Read this manual thoroughly before maintenance work. Keep this manual in a convenient place for quick and easy reference at all times. April 2011 SM-FAX124 8CAM05 Confidential...
Page 2 Each company whose software title is mentioned in this manual has a Software License Agreement specific to its proprietary programs. Any trade names and product names of companies appearing on Brother products, related documents and any other materials are all trademarks or registered trademarks of those respective companies.
Page 3 The table below shows the functional comparison between the models covered by this manual. Model DCPJ525W DCPJ725DW DCPJ925DW MFCJ280W MFCJ425W MFCJ430W MFCJ435W 1.9-inch color 3.3-inch color 1.9-inch color √ √ √ √ Touch panel √ Wired LAN √ √ √...
Page 4: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS......................i REGULATION........................viii SAFETY INFORMATION...................... xiii CHAPTER 1 SPECIFICATIONS ..................1-1 GENERAL ........................1-1 General........................1-1 Media Specifications....................1-2 Paper Handling...................... 1-5 LCD/Panel ......................1-6 Memory........................1-6 Interface......................... 1-7 Others........................1-9 TELEPHONE ........................ 1-11 FAX..........................
Page 5 Initial Check ......................2-2 OVERVIEW ........................2-3 Cross-section Drawings and Components ............2-3 Paper Path for Documents and Recording Paper ..........2-4 Parts Names and Functions .................. 2-5 Block Diagram ....................... 2-6 Components ......................2-7 ERROR INDICATION ..................... 2-8 Error Codes ......................2-8 Error Messages ....................
Page 6 4.7.2 Troubleshooting from image defect............. 2-81 4.7.3 Other scanning problems ................2-85 Control Panel Problems..................2-86 4.8.1 LCD shows nothing ..................2-86 4.8.2 Control panel inoperative ................2-86 4.8.3 Lamps on the control panel do not light ............2-87 4.8.4 Touch panel inoperative (For models with touch panel) ......
Page 7 DISASSEMBLY PROCEDURE ..................3-30 Preparation ......................3-30 Jam Clear Cover....................3-35 Head/Carriage Unit....................3-36 Document Scanner Unit and Scanner Cover Support......... 3-49 ADF & Document Cover ASSY (For models with ADF), Document Cover ASSY (For models without ADF) ..........3-54 Disassembly of ADF &...
Page 8 1.12 Replace the ink cartridges with the protective part..........4-15 1.13 Obtain machine information at the user site (Instruction to the end user) ... 4-15 IF YOU REPLACE THE MAIN PCB................4-16 Load update programs/data ................4-17 2.1.1 If the main PCB is replaced with a new one..........4-17 2.1.2 If the main PCB loaded with programs is used (Updating existing programs) ..............
Page 9 CHAPTER 5 SERVICE FUNCTIONS ................. 5-1 MAINTENANCE MODE ....................5-1 Entry to the Maintenance Mode................5-1 1.1.1 How to Enter the End User-accessible Maintenance Mode......5-1 1.1.2 How to Enter the Maintenance Mode Exclusive to Service Personnel ..5-2 Key Operation in Maintenance Mode ..............5-2 1.2.1 Entering a Desired Function Code at the Initial Stage of the Maintenance Mode ......................
Page 10 1.4.22 Margin Adjustment in Borderless Printing (Function code 66) (User-accessible) ..................5-44 1.4.23 Updating of Head Property Data and Backup/Restoration of Head Calibration Data (Function code 68) ............5-48 1.4.24 Traveling Speed Check of Head/Carriage Unit (Function code 69) .... 5-50 1.4.25 Cleaning of Leveler Roller (LR) ASSY (Function code 70) ......
Page 11: Regulation
REGULATION Standard telephone and FCC notices (MFC models only) These notices are in effect on models sold and used in the United States only. When programming emergency numbers or making test calls to emergency numbers: • Remain on the line and briefly explain to the dispatcher the reason for the call before hanging •...
Page 12 Federal Communications Commission (FCC) Declaration of Conformity (USA only) Product Name: MFC-J280W/J425W/J430W/J625DW/J825DW/J835DW Confidential...
Page 13 Industry Canada Compliance Statement (Canada only) This Class B digital apparatus complies with Canadian ICES–003. Cet appareil numérique de la classe B est conforme à la norme NMB–003 du Canada. Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of this device.
Page 14 Declaration of Conformity (Europe only) We, Brother Industries, Ltd. 15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561 Japan declare that this product is in compliance with the essential requirements of Directives 1999/5/ EC and 2009/125/EC. The Declaration of Conformity (DoC) is on our Website.
Page 15 The purpose of the International ENERGY STAR Program is to promote the development and popularization of energy-efficient equipment. ® As an ENERGY STAR Partner, Brother Industries, Ltd. has determined that this product ® meets the ENERGY STAR specifications for energy efficiency. Confidential...
Page 16: Safety Information
SAFETY INFORMATION WARNING WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injuries. CAUTION CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injuries. IMPORTANT IMPORTANT indicate a potentially hazardous situation which, if not avoided, may result in damage to property or loss of product functionality.
Page 17 Confidential...
Page 18 Confidential...
Page 19 Confidential...
Page 20 Confidential xvii...
Page 21 Confidential xviii...
Page 22: Chapter 1 Specifications
CHAPTER 1 SPECIFICATIONS This chapter lists the specifications of each model, which enables you to make a comparison of different models. GENERAL General DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Print Head BH11 BK: 3 pl Minimum Droplet Size CMY: 1.5 pl...
Page 23: Media Specifications
Media Specifications DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW A4, LTR, LGL, EXE, JIS B5 , A5, A6, Photo (102x152 mm/4x6"), Indexcard (127x203 mm/5x8"), A4, LTR, EXE, JIS B5* , A5, A6, Photo (102x152 mm/4x6"), Photo-2L (127x178 mm/5x7"), Indexcard (127x203 mm/5x8"), Photo-2L (127x178 mm/5x7"),...
Page 24 MFCJ280W/J425W/J430W/J435W/J625DW/J825DW/J835DW Model MFCJ280W MFCJ425W MFCJ430W MFCJ435W A4, LTR, LGL, EXE, JIS B5 , A5, A6, Photo (102x152 mm/4x6"), Indexcard (127x203 mm/5x8"), Photo-2L Standard Tray (127x178 mm/5x7"), Post Card 1 (100x148 mm/3.9x5.8"), Post Card 2* (Double) (148x200 mm 5.8x7.9"), C5 Envelope, Com-10, DL Envelope, Monarch Photo Tray Media Sizes...
Page 25 Model MFCJ625DW MFCJ825DW MFCJ835DW A4, LTR, LGL, EXE, JIS B5 , A5, A6, Photo (102x152 mm/4x6"), Indexcard (127x203 mm/5x8"), Photo-2L (127x178 mm/5x7"), Standard Tray Post Card 1* (100x148 mm/3.9x5.8"), Post Card 2 (Double) (148x200 mm 5.8x7.9"), C5 Envelope, Com-10, DL Envelope, Monarch Photo (102 x 152 mm / 4 x 6"), Photo Tray Photo-L (89 x 127 mm / 3.5 x 5")
Page 26: Paper Handling
Paper Handling DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Standard Tray 100 sheets (80 g/m 20 sheets Photo Tray (thickness: 0.25 mm) Paper Input (sheets) Lower Tray Base : 15 pages Conditional : 20 pages* Output Paper Capacity 50 (80 g/m (sheets)
Page 27: Lcd/Panel
LCD/Panel DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Size & Type 1.9" STN 3.3" TFT Touch-Panel 3.3" TP MFCJ280W/J425W/J430W/J435W/J625DW/J825DW/J835DW Model MFCJ280W MFCJ425W MFCJ430W MFCJ435W Size & Type 1.9" STN Touch-Panel 3.3" TP Model MFCJ625DW MFCJ825DW MFCJ835DW Size & Type 1.9" STN 3.3" TFT Touch-Panel 3.3"...
Page 28: Interface
Interface DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Host Interface USB 2.0 Hi-Speed Wireless LAN Bluetooth IrSimple PictBridge USB Flash Memory Memory Stick/ Memory Stick Duo: 16-128 MB Memory Stick Pro: 256 MB - 16 GB (MagicGate: YES if not use MG...
Page 29 MFCJ280W/J425W/J430W/J435W/J625DW/J825DW/J835DW Model MFCJ280W MFCJ425W MFCJ430W MFCJ435W Host Interface USB 2.0 Hi-Speed Wireless LAN Bluetooth IrSimple PictBridge USB Flash Memory Acceptable Media (Type & Size) / Media Card Model MFCJ625DW MFCJ825DW MFCJ835DW Host Interface USB 2.0 Hi-Speed Wireless LAN Bluetooth IrSimple PictBridge USB Flash Memory Memory Stick/...
Page 30: Others
Others DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Operating Environment Temperature (Best Print 10-35 (20-33) degrees centigrade Quality) Operating Environment 20-80% (20-80%) Humidity (Best Print Quality) Power U.S.A. 19/5/1.5/0.2 W Consumption Approx. Europe/ (Copy Mode Asia/ 18/5/1.5/0.15 W 18/5.5/1.5/0.15 W 24/6.5/2.5/0.15 W...
Page 31 MFCJ280W/J425W/J430W/J435W/J625DW/J825DW/J835DW Model MFCJ280W MFCJ425W MFCJ430W MFCJ435W Operating Environment Temperature (Best Print 10-35 (20-33) degrees centigrade Quality) Operating Environment 20-80% (20-80%) Humidity (Best Print Quality) U.S.A. 19/5.5/2/0.2 W Power Consumption Europe/ Approx. Asia/ 19/5.5/2/0.15 W (Copy Mode Oceania Ready Mode/ Sleep Mode/OFF) Taiwan 19/5.5/2/0.2 W Sound Pressure Level...
Page 32: Telephone
TELEPHONE DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Handset Digital Cordless Phone MFCJ280W/J425W/J430W/J435W/J625DW/J825DW/J835DW Model MFCJ280W MFCJ425W MFCJ430W MFCJ435W Handset Digital Cordless Phone Model MFCJ625DW MFCJ825DW MFCJ835DW Handset Digital Cordless Phone Confidential 1-11...
Page 33: Fax
DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Modem Speed Transmission Speed ITU-T Group Document (Send/Receive) Color FAX Memory (Send/Receive) MFCJ280W/J425W/J430W/J435W/J625DW/J825DW/J835DW Model MFCJ280W MFCJ425W MFCJ430W MFCJ435W Modem Speed 14,400 bps (FAX) Transmission Speed Approx. 7 seconds (ITU-T Test Chart #1, MMR) ITU-T Group...
Page 34: Printer
PRINTER DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Print Speed ESAT 10 / 8.0 ipm 12 / 10 ipm (based on ISO/IEC 24734) Draft Print Speed (mono/color) *time calculated including 33 / 26 ppm 35 / 27 ppm paper feeding Resolution Up to 1200 x 6000 dpi...
Page 35: Copy
COPY DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Copy Speed ESAT (based on ISO/IEC 24735) 6.0 / 6.0 ipm (600 x 600 dpi) *This spec is for ADF model only Draft Copy Speed (A4/LTR) *time calculated including paper feeding 23 / 20 cpm...
Page 36: Scanner
SCANNER DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Scan Speed A4: 3.37 seconds / 4.83 seconds 3.37 seconds / 3.37 seconds (Mono/Color) *@100 dpi LTR: 3.17 seconds / 4.54 seconds LTR: 3.17 seconds / 3.17 seconds FB: 1200 x 2400 dpi FB: 2400 x 2400 dpi...
Page 37: Software
SOFTWARE DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW 2000/XP/XP Professional x64/Vista/7 Windows Support OS Server 2003/2003 x64/2003 R2/2003 R2 x64/2008/2008 R2 Version Macintosh Mac OS X 10.4.11, 10.5.x, 10.6.x MFCJ280W/J425W/J430W/J435W/J625DW/J825DW/J835DW Model MFCJ280W MFCJ425W MFCJ430W MFCJ435W 2000/XP/XP Professional x64/Vista/7 Windows Support OS Server 2003/2003 x64/2003 R2/2003 R2 x64/2008/2008 R2...
Page 38: Network
NETWORK Network DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Internet FAX (Firmware) MFCJ280W/J425W/J430W/J435W/J625DW/J825DW/J835DW Model MFCJ280W MFCJ425W MFCJ430W MFCJ435W Internet FAX (Firmware) Model MFCJ625DW MFCJ825DW MFCJ835DW Internet FAX (Firmware) Wired DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Model Name (Ethernet) Embedded (NC-250h) Ethernet 10/100BASE-TX Network Connection (Ethernet)
Page 39: Wireless
Wireless DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Model Name (Wireless) Embedded (NC-260w) Network Connection IEEE 802.11 b/g/n (Wireless) SSID (32 chr), WEP 64/128 bit, WPA-PSK (TKIP: AES), WPA2-PSK (AES) Wireless Security **NO LEAP** WiFi Certification WiFi b, g and n (Windows Connect Now)
Page 40: Supplies/Options
SUPPLIES/OPTIONS DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Bundled Cartridges Approx. 80% of supply standard cartridges Cartridge Supply Standard BK: 300 pages Yield Cartridges CL: 300 pages (@ISO pattern/ Supply High Yield BK: 600 pages normal) Cartridges CL: 600 pages MFCJ280W/J425W/J430W/J435W/J625DW/J825DW/J835DW Model...
Page 41: Service Information
SERVICE INFORMATION DCPJ525W/J725DW/J925DW Model DCPJ525W DCPJ725DW DCPJ925DW Monthly Volume 2500 pages Machine Life 30000 pages or 5 years Parts Life 30000 pages (Total in flat-bed and ADF scanning) (Document scanner unit) MTBF (Mean Time Between 4000 hours Failures) MTTR (Mean Time To Be...
Page 42: Paper
20 to 25 lb. (75 to 95 g/m Up to 20 mil (Up to 0.52 mm) Transparencies Up to 100 sheets of plain paper 20 lb. (80 g/m BP71 69 lb. (260 g/m ) paper is especially designed for Brother inkjet machines. Confidential 1-21...
Page 43 Recommended print media To get the best print quality, we suggest using Brother paper. (See the table below.) We recommend using "3M Transparency Film" when you print on transparencies. Paper Type Item Premium Plus Glossy Photo - Letter BP71GLTR - 4 x 6 inches...
Page 44 1 0.08 inches (2 mm) or greater curve may cause jams to occur Confidential 1-23...
Page 45: Printable Area
11.2 Printable Area The printable area depends on the settings in the application you are using. The figures below show the unprintable areas on cut sheet paper and envelopes. The machine can print in the shaded areas of cut sheet paper only when the Borderless print feature is available and turned Top (1) Bottom (2) Left (3)
Page 46: Chapter 2 Error Indication And Troubleshooting
CHAPTER 2 ERROR INDICATION AND TROUBLESHOOTING INTRODUCTION This section gives the service personnel some of the troubleshooting procedures to be followed if an error or malfunction occurs with the machine. It is impossible to anticipate all of the possible problems which may occur in future and determine the troubleshooting procedures, so this section covers some sample problems.
Page 47: Initial Check
Initial Check Prior to proceeding to the troubleshooting procedures, make the following initial checks: Environmental conditions Check that: (1) The machine is placed on a flat, firm surface. (2) The machine is used in a clean environment at or near normal room temperature (10°C to 35°C) with normal relative humidity (20 to 80%).
Page 48: Overview
OVERVIEW Cross-section Drawings and Components Document scanning and feeding mechanisms Document scanning Document feed roller 1 position actuator ADF separation pad Document feed Document pick-up roller roller 2 (Left) (Right) Document detection actuator Document separation roller CIS unit Document pressure bar Printing and paper feeding mechanisms Paper ejection roller Switchback roller...
Page 49: Paper Path For Documents And Recording Paper
Paper Path for Documents and Recording Paper Document path in ADF scanning Document path in ADF scanning Place a document face down. (Right) (Left) Recording paper path Paper path in disc printing (Front) (Rear) Paper path in duplex printing Paper path from paper tray Confidential...
Page 50: Parts Names And Functions
Parts Names and Functions Document scanning and feeding Names Functions Document detection actuator This detects whether documents are set on the document tray. Document pick-up roller This pulls documents loaded in the document tray into the ADF. Document separation roller and These feed document pages (drawn in by the document pick-up separation rubber roller) one at a time to the document feed roller 1.
Page 51: Block Diagram
Block Diagram Control panel ASSY Document scanner unit ADF unit Touch panel * Panel PCB Document detection sensor PCB Carriage motor CIS unit Key matrix Touch panel PCB * Document scanning position sensor PCB Document scanner Document scanner Head/carriage unit motor open sensor ADF motor *...
Page 52: Components
Components *1 For models with ADF *2 For models without ADF *3 For models with speaker *4 For disc printing models ADF & document cover ASSY * Document cover ASSY * Control panel ASSY with touch panel Document scanner unit Speaker spring * Control panel ASSY without touch panel...
Page 53: Error Indication
ERROR INDICATION To help the user or the service personnel promptly locate the cause of a problem (if any), the machine incorporates the self-diagnostic functions which display error messages for equipment errors. Error Codes Error Refer to Contents Code page: In duplex printing, a sensor error has occurred during printing on the second side.
Page 54 Error Refer to Contents Code page: Carriage does not move. (Detected by the CR encoder sensor) 2-28 Cannot detect the origin of the carriage. (Detected by the CR encoder sensor) 2-29 Capping load large. 2-29 Abnormal stop of head/carriage unit. (Error caused by any problem except a 2-30 paper jam when the print head is not jetting out ink) Abnormal stop of head/carriage unit during printing.
Page 55 Error Refer to Contents Code page: Abnormal stop of purge cam during head capping. (When being driven in the 2-41 capping direction) Abnormal stop of purge cam during head uncapping. (When being driven in the 2-41 uncapping direction) Motor driver IC overcurrent protection activated when the purge cam was being 2-42 driven.
Page 56 Error Refer to Contents Code page: Black level data error in scanning. 2-53 SDAA failure. 2-54 Cannot start up the modem normally even after resetting it. 2-54 Wired LAN MAC address not registered. 2-54 Failed to get a wireless LAN MAC address. 2-54 EEPROM write error.
Page 57: Error Messages
Error Messages Error Code Refer to: Error Message Contents B&W Print Only One or more of the color ink cartridges have Chapter 2, Replace Ink reached the end of their life. Section 4.10.8 Replace the color ink cartridge(s). BT Call Sign On BT Call Sign is set to ON, so the Receive Chapter 2, (U.K.
Page 58 Error Code Refer to: Error Message Contents Image Too Long. Image too long to correct or trim. Chapter 2, Section 4.10.4 Image Too Small. Image too small to correct or trim. Chapter 2, Section 4.10.4 Ink Absorber Full Purge counter or flushing counter overflown. p.
Page 59 Error Code Refer to: Error Message Contents Touchscreen The touch screen was pressed before p. 2-56 initialization failed completion of power-on initialization. Unusable Device The connected USB device could be broken. Chapter 2, Disconnect device Section from front connect or 4.10.3 &...
Page 60: Communications Error Codes
Communications Error Codes Code 1 Code 2 Cause Refer to: Wrong number called. Chapter 2, Section 4.9.4 No dial tone detected before start of dialing. Busy tone detected before dialing. 2nd dial tone not detected. No loop current detected. Busy tone detected after dialing or called. No response from the remote station in sending.
Page 61 Code 1 Code 2 Cause Refer to: Remote terminal only with V.29 capability in 2400 or Chapter 2, Section 4800 bps transmission. 4.9.4 Remote terminal not ready for polling. Remote terminal not equipped with password function or its password switch OFF. Remote terminal not equipped with or not ready for confidential mailbox function.
Page 62 Code 1 Code 2 Cause Refer to: Error correction sequence not terminated even at the Chapter 2, Section final transmission speed for fallback. 4.9.4 Receive buffer empty. (5-second timeout) Receive buffer full during operation except receiving into memory. Decoding error continued on 500 lines or more. Decoding error continued for 15 seconds or more.
Page 63 Code 1 Code 2 Cause Refer to: Chapter 2, Section No common modulation mode or polling failed. 4.9.4 Unable to detect JM. Unable to detect CM. Unable to detect CJ. V. 34 negotiation or training not finished. Modem error detected during V. 34 negotiation or training.
Page 64: Status Monitor Errors
Status Monitor Errors Error Message Contents Error Code Refer to: Cover is Open Any cover opened. p. 2-27 p. 2-50 Disc Guide is Open Disc guide opened. Chapter 2, Section 4.10.9 Document Jam Document jam detected in the ADF. p. 2-50 p.
Page 65 Error Message Contents Error Code Refer to: Unable to Print XX Errors other than 3X, 5X, 7X, and AX. Codes other pp. 2-33 to 2-56 than 3X, 5X, 7X and p. 2-22 Wrong Paper Size Recording paper that differs from the setting in size is loaded in the paper tray.
Page 66: Troubleshooting
TROUBLESHOOTING Error Cause and Solutions First see the user check items. If it cannot recover the machine, proceed to the troubleshooting table exclusive to service personnel. Error Code 0E Paper Jam In duplex printing, a sensor error has occurred during printing on the second side. (During switchbacking, the registration sensor outputs an unexpected signal.) User Check - Remove the jammed paper.
Page 67 Error Code 17 Wrong Paper Size Recording paper size error. (Duplex PC print/Duplex copy) (Detected by the paper width sensor or registration sensor) User Check - Check whether the recording paper being used is within the specification. - Check that dark recording paper is not used. Step Cause Solution...
Page 68 Error Code 20 Cannot Detect Cannot identify a black ink cartridge. Error Code 21 Cannot Detect Cannot identify a yellow ink cartridge. Error Code 22 Cannot Detect Cannot identify a cyan ink cartridge. Error Code 23 Cannot Detect Cannot identify a magenta ink cartridge. User Check - Reload the ink cartridge.
Page 69: An Ink Cartridge Of Wrong Color Is Loaded. (A Color Ink Cartridge Is Loaded In The Black Ink Cartridge Slot.)
Error Code 24 Wrong Color INK An ink cartridge of wrong color is loaded. (A color ink cartridge is loaded in the black ink cartridge slot.) User Check - Load the ink cartridge into the correct slot. - Replace the ink cartridge. Step Cause Solution...
Page 70: The Service Life Of The Black Ink Cartridge Will Be Expired Soon. (Detected By The Black Ink Remaining Sensor)
Error Code 26 Ink Low Black The service life of the black ink cartridge will be expired soon. (Detected by the black ink remaining sensor) Error Code 27 Ink Low Yellow The service life of the yellow ink cartridge will be expired soon. (Detected by the yellow ink remaining sensor) Error Code 28 Ink Low Cyan...
Page 71: No Black Ink Cartridge Loaded. (Detected By The Ink Cartridge Detection Sensor)
Error Code 2A No Ink Cartridge Black No black ink cartridge loaded. (Detected by the ink cartridge detection sensor) Error Code 2B No Ink Cartridge Yellow No yellow ink cartridge loaded. (Detected by the ink cartridge detection sensor) Error Code 2C No Ink Cartridge Cyan No cyan ink cartridge loaded.
Page 72: Ink Cartridge Cover Opened
Error Code 2F Cover is Open / Close Ink Cover Ink cartridge cover opened. User Check - Close the ink cartridge cover. Step Cause Solution Broken boss on the ink cartridge Replace the ink cartridge cover. cover, working as an actuator for the ink cartridge cover sensor Connection failure of the ink Check the connection and reconnect the harness.
Page 73: Carriage Does Not Move. (Detected By The Cr Encoder Sensor)
Error Code 30 Unable to Print 30 Carriage does not move. (Detected by the CR encoder sensor) User Check - Remove the jammed paper. Step Cause Solution CR timing belt or pulley out of Set the CR timing belt or the pulley into place. place Foreign materials on the CR Remove foreign materials.
Page 74: Cannot Detect The Origin Of The Carriage. (Detected By The Cr Encoder Sensor)
Error Code 31 Paper Jam / Disc Jam Cannot detect the origin of the carriage. (Detected by the CR encoder sensor) User Check - Remove foreign materials. Step Cause Solution Foreign materials on the CR Remove foreign materials. timing belt or around the head/ carriage unit Switching lever guide out of place Reposition the switching lever guide.
Page 75: Abnormal Stop Of Head/Carriage Unit. (Error Caused By Any Problem Except A Paper Jam When The Print Head Is Not Jetting Out Ink)
Error Code 35 Unable to Print 35 Abnormal stop of head/carriage unit. (Error caused by any problem except a paper jam when the print head is not jetting out ink) Step Cause Solution Foreign materials on the CR Remove foreign materials. timing belt or around the head/ carriage unit Switching lever guide out of place Reposition the switching lever guide.
Page 76: Abnormal Stop Of Head/Carriage Unit During Printing. (Error Caused By Any Problem Except A Paper Jam When The Print Head Is Jetting Out Ink)
Error Code 3B Unable to Print 3B Abnormal stop of head/carriage unit during printing. (Error caused by any problem except a paper jam when the print head is jetting out ink). Step Cause Solution Foreign materials on the CR Remove foreign materials. timing belt or around the head/ carriage unit Switching lever guide out of place Reposition the switching lever guide.
Page 77: Any Abnormality In The Carriage Motor, Asf Motor, Or Paper Feed Motor
Error Code 3E Unable to Print 3E Any abnormality in the carriage motor, ASF motor, or paper feed motor. Step Cause Solution Foreign materials in the recording Remove foreign materials. paper path Foreign materials in the Remove foreign materials. maintenance unit Foreign materials on the CR guide Remove foreign materials.
Page 78: Casing Internal Thermistor Defective. (Detects -20ºc Or Below Or 80ºc Or Higher)
Error Code 40 Unable to Init. 40 Casing internal thermistor defective. (Detects -20ºC or below or 80ºC or higher) Step Cause Solution Casing internal temperature Replace the ink refill ASSY. thermistor defective Main PCB defective Replace the main PCB ASSY. Error Code 42 Unable to Print 42 Head drive voltage dropped below the lower limit.
Page 79: Abnormal Temperature Of The Print Head Driver
Error Code 44 Unable to Print 44 Abnormal temperature of the print head driver. Step Cause Solution Ink sufficient in the print head Turn the power off and on, then perform an initial purge. Print head defective Replace the head/carriage unit. Main PCB defective Replace the main PCB ASSY.
Page 80: Abnormal Head Drive Voltage. (Does Not Rise To The Specified Level)
Error Code 49 Unable to Print 49 Abnormal head drive voltage. (Does not rise to the specified level) Error Code 4F Unable to Print 4F The head drive voltage has dropped from the high to low level in an abnormally short period. Step Cause Solution...
Page 81: Failed To Detect The Origin Of The Purge Cam. (Failed To Detect The Longest Off Domain Of The Purge Cam)
Error Code 52 Unable to Clean 52 Failed to detect the origin of the purge cam. (Failed to detect the longest OFF domain of the purge cam) Step Cause Solution Foreign materials in the Remove foreign materials. maintenance unit ASF drive ASSY defective Replace the ASF drive ASSY.
Page 82: Abnormal Stop Of Purge Cam Being Driven
Error Code 5A Unable to Clean 5A Abnormal stop of purge cam being driven. Error Code 5B Unable to Clean 5B Abnormal stop of pump in the maintenance unit. Step Cause Solution Foreign materials in the Remove foreign materials. maintenance unit or around the paper feed roller PF encoder disc stained Replace the PF encoder disc and clean the flushing...
Page 83: Driver Ic Overcurrent Protection Activated When The Purge Cam Was Being Driven
Error Code 5D Unable to Clean 5D Driver IC overcurrent protection activated when the purge cam was being driven. Error Code 5E Unable to Clean 5E Driver IC overcurrent protection activated when the pump was in operation. Step Cause Solution Main drain tube bent Replace the main drain tube.
Page 84: Driver Ic Overcurrent Protection Activated During Running Of The Asf Motor
Error Code 6C Unable to Print 6C Driver IC overcurrent protection activated during running of the ASF motor. Step Cause Solution Main drain tube bent Replace the main drain tube. Foreign materials in the Remove foreign materials. maintenance unit or engine unit PF encoder sensor PCB defective Replace the PF encoder sensor PCB ASSY.
Page 85: Asf Motor Does Not Stop. (Keeps Rotating For 15 Seconds Or More)
Error Code 6F Unable to Print 6F ASF motor does not stop. (Keeps rotating for 15 seconds or more) Step Cause Solution Paper feed motor harness Check the connection and reconnect the harness. connection failure Carriage motor harness Check the connection and reconnect the harness. connection failure ASF motor harness connection Check the connection and reconnect the harness.
Page 86: Abnormal Stop Of Purge Cam During Head Capping
Error Code 76 Unable to clean 76 Head uncapping failed. Step Cause Solution Foreign materials in the Remove foreign materials. maintenance unit ASF motor defective Replace the ASF drive ASSY. Maintenance unit defective Replace the maintenance unit. Main PCB defective Replace the main PCB ASSY.
Page 87: Motor Driver Ic Overcurrent Protection Activated When The Purge Cam Was Being Driven
Error Code 7D Unable to clean 7D Motor driver IC overcurrent protection activated when the purge cam was being driven. Step Cause Solution Foreign materials in the Remove foreign materials. maintenance unit ASF motor defective Replace the ASF drive ASSY. Paper feed motor defective Replace the paper feed motor.
Page 88: Recording Paper Size Error. (During Fax/List Printing) (The Paper Size Not Suitable For Recording
Error Code 80 Wrong Paper Size Recording paper size error. (During fax/list printing) (The paper size not suitable for recording fax was detected by the paper width sensor or registration sensor.) User Check - Check whether the recording paper being used is within the specification. - Check that the dark recording paper is not used.
Page 89: Recording Paper Size Error. (Except During Fax/List Printing) (The Paper Width Sensor Has Detected That The Paper Width Is Less Than The Specified One.)
Error Code 81 Wrong Paper Size Recording paper size error. (Except during fax/list printing) (The paper width sensor has detected that the paper width is less than the specified one.) User Check - Check whether the recording paper being used is within the specification. - Check that dark recording paper is not used.
Page 90: Recording Paper Jam In Paper Ejecting. (The Registration Sensor Sticks To On Even After Completion Of Paper Ejection.)
Error Code 84 Paper Jam / Disc Jam Recording paper jam in paper ejecting. (The registration sensor sticks to ON even after completion of paper ejection.) User Check - Remove the jammed paper. Step Cause Solution Registration actuator caught on Check and reposition the registration actuator.
Page 91: Pf Encoder Sensor Cannot Detect The Rotation Of The Paper Feed Roller
Error Code 8A PRINTER JAM PF encoder sensor cannot detect the rotation of the paper feed roller. Error Code 8B PRINTER JAM PF encoder sensor detects an abnormal stop of the paper feed roller. User Check - Check whether recording paper is jammed. Step Cause Solution...
Page 92: Driver Ic Overcurrent Protection Activated During Running Of The Paper Feed Motor
Error Code 8C PRINTER JAM Driver IC overcurrent protection activated during running of the paper feed motor. User Check - Check whether recording paper is jammed. Step Cause Solution Foreign materials inside the Remove foreign materials. engine unit PF encoder disc defective Replace the PF encoder disc and clean the flushing guide.
Page 93: Disc Tray Collided Against An Obstacle In The Rear Of The Machine
Error Code 90 Disc Tray hits at the back Disc tray collided against an obstacle in the rear of the machine. User Check - Leave at least 10 cm (4 inches) of free space behind the machine. - Clear any obstacles from the rear of the machine. - Clear any obstacles from the surroundings of the jam clear cover.
Page 94: Pressure Roller Has Failed To Be Depressed
Error Code 92 Unable to Init. 92 Pressure roller has failed to be depressed. Step Cause Solution Switching lever guide defective Replace the switching lever guide. ASF drive ASSY defective Replace the ASF drive ASSY. Engine unit defective Replace the engine unit. Main PCB defective Replace the main PCB ASSY.
Page 95: Document Scanner Unit Opened
Error Code A1 Cover is Open Document scanner unit opened. User Check - Close the document scanner unit. Step Cause Solution Document scanner open actuator Set the document scanner open actuator into place. out of place Document scanner open sensor Replace the control panel ASSY.
Page 96: During Adf Scanning, The Document Scanning Position Sensor Does Not Come On
Error Code A3 DOCUMENT JAM During ADF scanning, the document scanning position sensor does not come ON. User Check - Remove the jammed document. Step Cause Solution Foreign materials in the ADF Remove foreign materials. document path Document scanning position Set the document scanning position actuator into actuator out of place place.
Page 97: Mismatch Between Actual Cis Type And Eeprom Data
Error Code A7 Unable to Scan A7 Mismatch between actual CIS type and EEPROM data. Step Cause Solution CIS type data mismatch Specify the CIS type with Function code 59. Refer to Chapter 5, Section 1.4.18. Main PCB defective Replace the main PCB ASSY. Error Code A8 Unable to Init.
Page 98: Cis Positioning Error. (Home Positioning Failed)
Error Code AF Unable to Scan AF CIS positioning error. (Home positioning failed) Step Cause Solution Document scanner motor harness Check the connection and reconnect the harness. connection failure Document scanner unit defective Replace the document scanner unit. Main PCB defective Replace the main PCB ASSY.
Page 99: Sdaa Failure
Error Code DF Lightning damage often causes this error. Check whether the power supply PCB or MJ PCB has burn marks. Unable to Init. DF SDAA failure. Error Code E0 Unable to Init. E0 Cannot start up the modem normally even after resetting it. Step Cause Solution...
Page 100: Eeprom Write Error
Error Code E6 Unable to Init. E6 EEPROM write error. Step Cause Solution Main PCB defective Replace the main PCB ASSY. Error Code EA DOCUMENT JAM Document removed at phase B. (Detected by the document detection sensor) User Check - Send a fax again. Step Cause Solution...
Page 101: Touch Panel Initialization Failed
Error Code ED Unable to Init. ED Touch panel initialization failed User Check - Check that nothing is placed on the touch panel. Step Cause Solution Touch panel harness connection Check the connection and reconnect the harness. failure Touch panel defective Replace the LCD unit.
Page 102: Recording Paper Or Disc Tray Feeding Problems
Recording Paper or Disc Tray Feeding Problems Problems related to recording paper or disc tray feeding are end user recoverable by following the User Check items. If the problem persists, follow each procedure in the order of the number described in the Step column in the tables below. 4.2.1 Recording paper not fed from paper tray (Error code 18, 82, etc.) User Check - Check that recording paper is loaded correctly in the paper tray.
Page 103: Disc Tray Not Fed In (Error Code 91)
4.2.2 Disc tray not fed in (Error code 91) User Check - Insert the disc tray fully. Step Cause Solution Disc tray worn out, deformed, or Replace the disc tray. broken Foreign materials inside the Remove foreign materials. engine unit Paper feed motor harness Check the connection and reconnect the harness.
Page 104: Recording Paper Jam
4.2.4 Recording paper jam Paper jam in paper tray (Error code 82, 84, 8A, 8B, 8C) User Check - Check that recording paper is loaded correctly in the paper tray. - Adjust the paper guide to match the recording paper size. - Check if too much paper is loaded in the paper tray.
Page 105 Paper jam around paper ejection parts (Error code 84, 8A, 8B, 8C) Step Cause Solution Foreign materials in the recording Remove foreign materials. paper path Registration actuator caught on Check and reposition the registration actuator. the surrounding parts Paper ejection roller worn out Replace the engine unit.
Page 106: Disc Tray Jam (Error Code 31, 38, 3C, 84, 8A, 8B, 8C, 90)
4.2.5 Disc tray jam (Error code 31, 38, 3C, 84, 8A, 8B, 8C, 90) User Check - Remove foreign materials from the surroundings of the jam clear cover. - Check that the jam clear cover is properly closed. Step Cause Solution Disc tray worn out, deformed, or Replace the disc tray.
Page 107: Recording Paper Stained
4.2.6 Recording paper stained User Check - Check that recording paper is loaded correctly in the paper tray. - Print on blank paper several times to clean the rollers. - Clean the paper feed roller. - Clean the platen. - Perform head cleaning. Step Cause Solution...
Page 108: Disc Tray Stained
4.2.7 Disc tray stained User Check - Check whether a stained disc tray is used. - Make sure that the disc is placed with print side face up. - Check that the disc is placed correctly on the disc tray. - Print on several sheets of blank paper to clean the rollers.
Page 109: Print-Image Problems
Print-image Problems 4.3.1 Defective images Examples of defective images Completely All black Random color Light Dark blank Straight Blurred White vertical Ink splash Ink splash vertical stripes vertical stripes streaks Stained White Overlapping Print edges not Random leading edge horizontal lines over the aligned missing dots...
Page 110: Troubleshooting From Image Defect
4.3.2 Troubleshooting from image defect Completely blank User Check - Check that ink remaining is sufficient. - Perform head cleaning. Step Cause Solution Maintenance unit contaminated Clean the maintenance unit. Refer to Chapter 2, Section 4.2.6. Head property data incorrect Enter correct head property data.
Page 111 Random color User Check - Check that ink cartridges are loaded in the correct color slots. - Perform head cleaning. Step Cause Solution Maintenance unit contaminated Clean the maintenance unit. Refer to Chapter 2, Section 4.2.6. Head property data incorrect Enter the correct head property data.
Page 112 Dark User Check - Check whether the paper type setting is correct. - Perform head cleaning. Step Cause Solution Maintenance unit contaminated Clean the maintenance unit. Refer to Chapter 2, Section 4.2.6. Head property data incorrect Enter the correct head property data. Refer to Chapter 5, Section 1.4.23.
Page 113 Blurred vertical stripes User Check - Check whether the recording paper being used is thicker than the specified limit. - Perform head cleaning. - Print on several sheets of blank paper to clean the related rollers. - Clean the platen. Step Cause Solution...
Page 114 Ink splash User Check - Perform head cleaning. - If ink is old, replace the ink cartridge(s). Step Cause Solution Maintenance unit contaminated Clean the maintenance unit. Refer to Chapter 2, Section 4.2.6. Head property data incorrect Enter the correct head property data. Refer to Chapter 5, Section 1.4.23.
Page 115 Random missing dots User Check - Check that ink remaining is sufficient. - Perform head cleaning. Step Cause Solution Maintenance unit contaminated Clean the maintenance unit. Refer to Chapter 2, Section 4.2.6. Carriage PCB defective Replace the carriage PCB ASSY. Maintenance unit defective Replace the maintenance unit.
Page 116 Stained leading edge of recording paper User Check - Check whether the recording paper being used is within the specification. - Perform head cleaning. Step Cause Solution Maintenance unit contaminated Clean the maintenance unit. Refer to Chapter 2, Section 4.2.6. Paper feeding correction value not Update the paper feeding correction value with updated...
Page 117 Separated lines over the whole page User Check - Perform head cleaning. Step Cause Solution Inclination of head not adjusted Adjust inclination of the head. Refer to Chapter 4, Section 1.4. Head calibration data not written Perform head calibration with Function code 02. Refer to Chapter 5, Section 1.4.2.
Page 118 Separated lines at the trailing edge of the recording paper User Check - Perform head cleaning. Step Cause Solution Paper feeding correction value not Update the paper feeding correction value with updated Function code 58. Refer to Chapter 5, Section 1.4.17.
Page 119 Traces of paper pull-in rollers User Check - Check whether the recording paper being used is within the specification. - Clean the paper pull-in rollers. Step Cause Solution Paper pull-in rollers defective Replace the paper pull-in roller holder ASSY. Dirt on the paper User Check - Check whether the recording paper being used is not folded.
Page 120 Random horizontal stains User Check - Check whether the recording paper being used is within the specification. - Check that recording paper is loaded correctly in the paper tray. - Print on several sheets of blank paper to clean the related rollers. - Clean the platen.
Page 121: Software-Related Problems
Software-related Problems The end user can solve problems pertaining to software, for instance, print cannot be made from a computer although test print and printer setting print can be made from the machine by following the User Check items. If the same problem occurs, follow each procedure in the order of the number described in the Step column in the tables below.
Page 122: Network Problems
Network Problems 4.5.1 Cannot make a print through network connection User Check - Check the descriptions in the network user’s guide. - Reset the network settings. (Refer to the user’s guide.) Step Cause Solution Wireless LAN PCB defective Replace the wireless LAN PCB ASSY. Main PCB defective Replace the main PCB ASSY.
Page 123: Document Feeding Problems
Document Feeding Problems 4.6.1 Cannot feed documents User Check - Set documents fully into the document tray. - Limit the number of documents to be set in the ADF to a maximum of 15 sheets. Step Cause Solution Document pull-in rollers stained Clean the document pull-in rollers.
Page 124: Document Jam
4.6.3 Document jam Document jam in the ADF cover (Error code A2, A3, EA) User Check - Check if paper particles such as broken document are jammed around the document slot. Step Cause Solution Foreign materials around and Remove foreign materials. inside the ADF cover Document scanning position Check the connection and reconnect the harness.
Page 125: Wrinkles On Documents
4.6.4 Wrinkles on documents User Check - Check that documents are loaded correctly in the ADF unit. - Check that the document guides match the document size. - Check that documents are not curled. Step Cause Solution Document separation roller worn Replace the document separation roller ASSY.
Page 126: Scanned-Image Problems
Scanned-image Problems 4.7.1 Defective images Light Scanning position failure Dark White vertical Completely blank Vertical streaks streaks Tinged over the whole page 4.7.2 Troubleshooting from image defect Light User Check - Check if the contrast is set to "Light." - Clean the scanner glass or ADF glass. Step Cause Solution...
Page 127 Scanning position failure User Check - Check that the document is placed correctly on the document cover. (1) ADF Step Cause Solution Scanning start position out of Adjust the scanning start position with Function alignment code 54. Refer to Chapter 5, Section 1.4.15.
Page 128 Completely blank User Check - Check whether documents are loaded upside down. - Check that documents are loaded correctly in the ADF. Step Cause Solution White level data defective Obtain the white level data with Function code 55. Refer to Chapter 5, Section 1.4.16.
Page 129 Tinged over the whole page User Check - Check whether the ADF glass or scanner glass is stained. Step Cause Solution White level data defective Obtain the white level data with Function code 55. Refer to Chapter 5, Section 1.4.16. CIS unit defective Replace the document scanner unit.
Page 130: Other Scanning Problems
4.7.3 Other scanning problems CIS unit in the document scanner unit does not move Step Cause Solution Document scanner motor harness Check the connection and reconnect the harness. connection failure Document scanner motor Replace the document scanner unit. defective Main PCB defective Replace the main PCB ASSY.
Page 131: Control Panel Problems
Control Panel Problems 4.8.1 LCD shows nothing User Check - Check if the power switch is OFF. - Load the latest firmware. Step Cause Solution AC cord defective Replace the AC cord. (Europe/Asia/Oceania only) LCD flat cable connection failure Check the connection and reconnect the flat cable. Power supply harness connection Check the connection and reconnect the harness.
Page 132: Lamps On The Control Panel Do Not Light
4.8.3 Lamps on the control panel do not light Step Cause Solution Rubber key(s) not set in place Reposition the control panel ASSY. Panel harness connection failure Check the connection and reconnect the harness. Rubber key(s) defective Replace the rubber key(s). Panel PCB defective Replace the panel PCB ASSY.
Page 133: Fax Problems
Fax Problems 4.9.1 No faxes can be sent User Check - Check if the appropriate telephone cord is used or it is plugged in the socket. - Check the dial mode settings again. Step Cause Solution Connection failure of the MJ Check the connection and reconnect the harness.
Page 134: No Faxes Can Be Received
4.9.3 No faxes can be received User Check - Check the receive mode setting again. - Check that recording paper is loaded correctly in the paper tray. - Check if the appropriate telephone cord is used or it is plugged in the socket. - Check the machine is off-hook.
Page 135: Other Problems
4.10 Other Problems 4.10.1 The machine cannot be powered on or nothing appears on the LCD Step Cause Solution AC cord defective Replace the AC cord. (Europe/Asia/Oceania only) Panel harness connection failure Check the connection and reconnect the harness. LCD flat cable connection failure Check the connection and reconnect the flat cable.
Page 136: Cannot Read Data From Memory Card Loaded In The Media Slot
4.10.4 Cannot read data from memory card loaded in the media slot User Check - Check whether the file data is supported. - Check whether the size of data in the memory card is out of specification. - Turn the power off and on. - Format the memory card.
Page 137: Secure Function Lock Related Problems
4.10.7 Secure Function Lock related problems User Check - Ask the administrator of the machine to unlock the secure function. Step Cause Solution Reset the password with Function code 01. Refer to Cannot unlock the secure function since the user forgot his/her Chapter 5, Section 1.4.1.
Page 138: Chapter 3 Disassembly And Assembly
CHAPTER 3 DISASSEMBLY AND ASSEMBLY This chapter details procedures for disassembling and reassembling the machine together with related notes. The disassembly order flow provided enables you to see at a glance the quickest way to get to component(s) involved. At the start of a disassembly job, you check the disassembly order flow that guides you through a shortcut to the target components.
Page 139 (10) After disconnecting flat cables, check that each cable is not damaged at its end or short- circuited. When connecting flat cables, do not insert them at an angle. After insertion, check again that the cables are not at an angle. (11) If ink gets on your skin or gets into your eyes or mouth, you need the following treatment.
Page 140: Packing
PACKING Confidential...
Page 141: Screw Catalogue
SCREW CATALOGUE Taptite, bind B Taptite, cup S Taptite, bind B Taptite, cup S M4x12 M3x6 Taptite, cup S M3x10 Taptite, cup B Taptite, cup B M3x8 Screw pan (S/P washer) Taptite, cup B Screw pan (S/P washer) M3x10 M3x6 Screw, bind Screw pan (washer) Screw, bind...
Page 142: Screw Torque List
SCREW TORQUE LIST Note: For the shape of screws, refer to Section 3 in this chapter. Tightening torque Location of screw Screw type Q’ty Page • • m (kgf 3-49 Grounding wire (for ADF drive unit) Taptite, cup S M3x6 0.35±0.05 (3.5±0.5) 3-52 Scanner hinge (onto the upper cover)
Page 143: Lubrication
LUBRICATION Apply the specified lubricants to the lubrication points as shown below. Lubricant type Lubricant amount Lubrication points (Manufacturer) per point Permalub BAN-5 Head/carriage unit 1.5 mm diameter ball (Nippon Koyu) Switching lever guide 3 mm diameter ball FLOIL BG1319 Leveller roller (LR) ASSY 1 mm diameter ball (Kanto Kasei)
Page 144 Switching lever guide Apply a 3 mm diameter ball of grease (Permalub BAN-5) to the lubrication point below. Switching lever guide (3_117) Apply grease here. Leveller roller (LR) ASSY Apply a 1 mm diameter ball of grease (FLOIL BG1319) to each of the lubrication points below. Leveler roller (LR) ASSY Apply grease to these 2 points.
Page 145 CR guide rail and CR frame (top face) Apply a 2 mm diameter ball of grease (FLOIL BG1319) to each of the 72 lubrication points below. Lubrication procedure (1) Move the head/carriage unit to the left end of its travel. (2) Before applying grease, wipe dust or dirt off the lubrication area with an alcohol soaked cloth.
Page 146 CR frame (inner sides of the front and rear upright edges) Apply a 2 mm diameter ball of grease (FLOIL BG1319) to each of the 92 lubrication points below. Lubrication procedure (1) Move the head/carriage unit to the left end of its travel. (2) Before applying grease, wipe dust or dirt off the lubrication area with an alcohol soaked cloth.
Page 147 CR guide rail (bottom face) Apply a 1 mm diameter ball of grease (FLOIL BG1319) to each of the lubrication points below. Viewed from the bottom CR frame 50 1 40 1 (Right) 30 1 35 1 20 1 22 1 0.5 -1.0 3.5 0.5 3.5-4.0...
Page 148 Paper pull-in roller L Apply a 1 mm diameter ball of grease (Molykote EM-30LP) to each of the lubrication points below. Paper pull-in roller L Apply grease here. Paper pull-in gear Paper pull-in roller R Engine unit (Bottom side) (3_006) Disc guide cover Apply a 1 mm diameter ball of grease (Molykote EM-30LP) to each of the grooves through which the bosses of the disc guide slide.
Page 149 Outer paper guide Apply a 1 mm diameter ball of grease (Molykote EM-30LP) to each of the joints between the outer paper guide and the switchback roller shaft. Hook Apply grease here. Apply grease here. Hook Outer paper guide (Front) (3_101a) Confidential 3-12...
Page 150: Overview Of Gears
OVERVIEW OF GEARS Maintenance unit <Name of gears> ASF SWITCHING GEAR A LX6797 ASF SWITCHING GEAR B LX3420 GEAR RETAINING RING LX3421 ADF drive unit (Rear) (Left) (3_060a) Confidential 3-13...
Page 151: Routing Of Harnesses, Flat Cables And Ink Suppy Tubes
ROUTING OF HARNESSES, FLAT CABLES and INK SUPPY TUBES Upper cover: Document scanner motor harness, ADF motor harness and grounding wire Document detection sensor harness , and Document scanning position sensor harness *1 For models with ADF Boss Top of the harness spacer Document detection sensor harness * and document scanning position sensor harness *...
Page 152 CIS flat cable Cable guides CIS flat cable Flat core Cable guide Lock arm Upper cover (3_009) Confidential 3-15...
Page 153 Underside of the ADF unit: Document detection sensor harness and ADF motor harness *1 For models with ADF Document detection sensor harness (white) Cable guide "a" ADF unit (Bottom side) Document detection sensor PCB ASSY ADF motor harness Cable guide "b" ADF harness ASSY (3_010) Document detection actuator...
Page 154 Top side of the ADF unit: ADF harness ASSY (consisting of ADF motor harness and grounding wire, document detection sensor harness and document scanning position sensor harness) *1 For models with ADF Document scanning position actuator Cable guide "d" Cable guide "c" ADF unit Document scanning position sensor PCB ASSY...
Page 155 Upper cover: Speaker harness Cable guide Main PCB Speaker (3_012) Cable guide Speaker harness Upper cover (Front) Confidential 3-18...
Page 156 Top left side of the lower cover: ASF motor harness, Carriage motor harness, Paper feed motor harness, Power supply harness, MJ (LINE) harness* and MJ (EXT) harness* * For MFC only MJ (LINE) harness * ASF motor harness (yellow) Section "X"...
Page 157 Front left corner of the lower cover: Wireless LAN PCB harness, PF/registration sensor harness ASSY, Power supply harness, Carriage motor harness, ASF motor harness, Paper feed motor harness, MJ (LINE) harness* and MJ (EXT) harness* * For MFC only ASF motor harness SDAA cover * Carriage motor harness...
Page 158 PS/MJ shield unit: MJ (LINE) harness , MJ (EXT) harness and Power supply harness *1 For MFC only *2 For models with main PCB B57U082 Lower PS/MJ frame Fit left end "g" over here. Power supply PCB MJ shield PS PCB insulator (Right) Power cord Fit right end "f"...
Page 159 *1 For MFC only *2 For models with main PCB B57U082 100 V series Power cord bush Ferrite core Power cord MJ PCB * Cable guides MJ (EXT) harness * (black) Ferrite core * MJ (LINE) harness * (yellow) Power supply PCB Power supply shield Power supply harness (3_017)
Page 160 On the tube support plate: Carriage flat cables Folded section Ferrite core Carriage flat cables Pocket Lower cover Boss Cable guides (3_019) Tube support wire Tube/cable guide Tube support plate Confidential 3-23...
Page 161 On the tube support plate and head/carriage unit: Ink supply tubes Lower cover Sponge Tube clamp (1) Tube clamp (2) Black Yellow Cyan Magenta Tube guides Black (Rear) (3_020) Tube support plate Cyan Bent section of tube support wire Yellow Magenta Note: Bind ink supply tubes with two tube clamps.
Page 162 Around the right side of the lower cover Carriage motor ASF motor Carriage motor harness ASF motor/encoder ASF encoder disc Pressure roller release sensor ASF motor harness harness Pressure roller ASF encoder release sensor sensor harness harness Purge cam ASF encoder switch sensor harness harness...
Page 163 Rear left corner of the lower cover: PF/registration sensor harness ASSY (consisting of PF encoder sensor harness and registration sensor harness) and Paper feed motor harness CR guide rail Registration sensor holder PF encoder sensor PCB ASSY PF encoder disc PF/registration sensor harness ASSY Paper feed motor harness...
Page 164 Whole of the lower cover Lower cover Ink supply tubes Carriage flat cables 1-4 Carriage flat Carriage flat cable 3 cable 1 Pressure roller ASF motor release sensor harness harness MJ (EXT) harness ASF encoder harness (3_024) Purge cam switch harness Carriage Carriage Paper feed...
Page 165: Disassembly Flow
DISASSEMBLY FLOW Confidential 3-28...
Page 166 Confidential 3-29...
Page 167: Disassembly Procedure
DISASSEMBLY PROCEDURE Preparation [ 1 ] Transferring Received FAX Data When the machine at the user site requires to be repaired, unplugging the power cord from the electrical outlet for sending the machine for repair will lose received FAX data if left in the machine.
Page 168 (11) If the "Run PC-Fax on your computer." appears on the LCD, press the OK key. (12) Click Start | All Programs | Brother | MFC-XXXX | PC-FAX Receiving | Receive. Wait for the PC-Fax Receiving dialog box to appear. Confirm the message and click OK.
Page 169 [ 2 ] Backing up Machine Information Before starting repair, the service personnel should back up the following machine information and user setting information into an external memory (memory card or USB flash memory). - Machine information (Preset values, counter values, error information, machine specifications data, etc.) - User setting information (telephone directory, password, station ID, transfer information, telephone area code, user settings, etc.)
Page 170 [ 3 ] Disconnecting Cables and Removing Accessories (1) Disconnect the following: - Power cord from the electrical outlet (or from the machine in the case of 200 V models) - Modular jack of the telephone line - USB cable, if connected - LAN cable , if connected (if not connected, remove the LAN cap - USB digital camera cable or USB flash memory drive...
Page 171 (4) Open the ink cartridge cover, remove all four ink cartridges, and set the protective part instead. Check that the right-hand latch fits in the hole provided in the ink refill ASSY. (3_026) Protective part Confidential 3-34...
Page 172: Jam Clear Cover
Jam Clear Cover (1) Open the jam clear cover. (2) Lightly press the right-hand end (viewed from the rear) of the jam clear cover inwards to release the boss, then remove the jam clear cover. Upper cover (Rear) Boss Jam clear cover (3_027) Confidential 3-35...
Page 173: Head/Carriage Unit
Head/Carriage Unit During disassembly jobs, except when removing the ink refill ASSY or engine unit (including the maintenance unit), leave the head/carriage unit in the machine. Before removing the head/carriage unit, ink refill ASSY or engine unit, you need to remove all four ink cartridges and set the protective part instead (see page 3-34).
Page 174 (4) Unplug the power cord from the electrical outlet. (5) Slightly close the document scanner unit so that the scanner cover support comes to be almost upright. As shown below, press the rib of the section outwards in which the top of the scanner cover support is fitted in order to widen the section, and pull out the boss provided on the top left of the support to the right and towards you.
Page 175 (6) Remove the CIS flat cable cover and the harness cover by inserting the tip of a flat screwdriver into the slots (indicated by arrows in the figure below) and lifting up those covers. For easier removal, start from the rear and finally pull out the tabs. Note: When removing the harness cover, turn the scanner cover support upright for easier removal.
Page 176 (7) Move the head/carriage unit to the left end of its travel (to the place where the whole of the head/carriage unit can be seen) by hand. Head/carriage unit PF encoder disc (3_031) Upper cover (8) Insert the tip of a flat screwdriver into the square hole provided in the head cover to release the latch in the direction of the arrow, then release other three latches and lift up the head cover.
Page 177 (9) Unlock the connector on the carriage PCB and disconnect the head flexible cable. Note: After disconnecting the flexible cable, check that it is not damaged at its end or short-circuited. When connecting the flexible cable, do not insert it at an angle. After insertion, check again that it is not at an angle and then lock the connector.
Page 178 (12) Pull out the head joint spring to the right. (13) Pull the head joint up and off the head/carriage unit. Immediately, wrap the head joint in a clean, lint-free cloth and keep it higher than the ink supply tubes to prevent ink remaining in the ink supply tubes from leaking and the machine from getting stained with leaked ink.
Page 179 (15) Move the head/carriage unit slightly to the right as shown below, then set the LR (Leveler Roller) positioning jig so that its bottom boss fits in the hole provided in the engine chassis. (16) While pressing the idle pulley holder to the right, remove the CR timing belt from the carriage motor pulley and the idle pulley.
Page 180 (17) Loosely tie the CR timing belt in a bundle on the head/carriage unit as shown below. (18) Move the head/carriage unit to the left end of its travel by hand. (19) Press the right and left tabs of the leveler roller (LR) ASSY inwards and pull the ASSY towards you to release it downwards from the head/carriage unit.
Page 181 (21) Remove the CR timing belt from the head/carriage unit. (22) Press the rear ends of the leveller roller (LR) ASSY inwards and take them out through the two cutouts provided in the CR guide rail. Leveler roller (LR) ASSY LR positioning jig Cutouts CR guide rail...
Page 182 (23) A head/carriage unit is assigned a property code that represents the properties unique to that head/carriage unit. The property code is printed on head property labels--bar code label and QR code label, each of which is attached to the lower cover and head/carriage unit, respectively.
Page 183 Note: When storing the removed head/carriage unit for a long period, be sure to put an air buffer cap on the head/carriage unit and store the unit in the head casing. (To secure the head/carriage unit, set it in the lower head casing and slide it to the right as shown below.) Leaving the head/carriage unit out of the casing will cause the head nozzles and ink supply ports to dry up, resulting in a damaged head.
Page 184 4) First fit the front end of the head/carriage unit over the CR frame and then set the rear end onto the CR guide rail. Make sure that the hook (see below) provided on the bottom of the head/carriage unit catches the front edge of the CR frame and the two rear bosses are fitted in the two cutouts (shown on page...
Page 185 7) Remove the LR fitting jig and LR positioning jig. 8) Untie the CR timing belt loosely tied. First, at the left end, set the belt on the idle pulley. Next, press the idle pulley holder to the right and at the right end, set the belt on the carriage motor pulley.
Page 186: Document Scanner Unit And Scanner Cover Support
Document Scanner Unit and Scanner Cover Support The document scanner unit should be removed together with the ADF & document cover ASSY (for models with ADF) or the document cover ASSY (for models without ADF). The removal procedure of the ASSY from the document scanner unit is given in Section 9.5.
Page 187 (5) Slightly tilt the scanner cover support towards you, press the upper cover outwards and pull out the scanner cover support. *1 For models with ADF *2 For models without ADF ADF & document cover ASSY * Document cover ASSY * Scanner cover support CIS flat cable Document...
Page 188 Assembling Notes: • Models with ADF As shown below, route the document scanner motor harness, ADF motor harness*1 and its grounding wire , then set the harness spacer. Next, route the document detection sensor harness and document scanning position sensor harness (which are taped together).
Page 189 (8) At the rear of the machine, remove the screw (black) that secures the scanner hinge. (9) Open the document scanner unit fully, turn up the front end of the scanner hinge bushing, and pull the document scanner unit up and out of the machine. Note: Pulling up the document scanner unit without fully opening it opens the scanner hinges suddenly and unexpectedly with great force.
Page 190 (10) Remove the five screws from the scanner hinge and take it off the document scanner unit. Taptite, bind B M4x12 Scanner hinge Document scanner unit (3_045) Confidential 3-53...
Page 191: Adf & Document Cover Assy (For Models With Adf), Document Cover Assy (For Models Without Adf)
ADF & Document Cover ASSY (For models with ADF), Document Cover ASSY (For models without ADF) *1 For models with ADF *2 For models without ADF (1) Turn the ADF & document cover ASSY or document cover ASSY upright and slightly lift it up.
Page 192 Models with ADF Remove the document sponge ASSY using the steps below. (4) Turn the ADF and document cover ASSY upside down. (5) Using the tip of a flat screwdriver, lightly press the three latches on the document sponge ASSY inwards in the order of to release them.
Page 193: Disassembly Of Adf & Document Cover Assy (For Models With Adf)
Disassembly of ADF & Document Cover ASSY (For models with ADF) Document pressure bar (1) At the front and rear ends of the document pressure bar, pull the lock arms outwards to release the document pressure bar. The spring also comes off. Lock arm Document pressure bar Spring...
Page 194 ADF top covers and decoration sheets (2) Turn the ADF & document cover ASSY right side up. (3) Slide the ADF top cover R outwards to release the hooks from the ADF & document cover ASSY. The decoration sheet R also comes off. (4) Slide the ADF top cover L outwards to release the hooks from the ADF &...
Page 195 ADF front cover and ADF document support (5) Turn the ADF & document cover ASSY upside down. (6) Remove the ADF front cover while releasing the four retainers in the direction of the arrows shown below using a flat screwdriver. ADF &...
Page 196 ADF back cover and ADF cover ASSY (10) Turn the ADF & document cover ASSY upside down. (11) At the rear end of the ADF & document cover ASSY, release the latches provided on the ADF back cover, starting from the right end, with a flat screwdriver and then remove the ADF back cover.
Page 197 ADF unit (15) Remove screw "a." (16) Turn the ADF & document cover ASSY upside down. (17) Remove two screws "b" (that secure the document reinforcement plate and ADF unit together to the document cover ASSY) and the document reinforcement plate. (18) Remove two screws "c."...
Page 198 ADF separation holder (20) Remove the ADF separation holder and its spring. Note: When removing the ADF separation holder, take care not to let the spring bounce off. ADF separation holder ADF separation spring Document cover ASSY (3_055) Scanner hinge support (21) Remove the three screws and take the scanner hinge support off the document cover ASSY.
Page 199 Document detection sensor PCB ASSY (22) Press the lock arm to the rear to release the rear end of the document detection sensor PCB and remove the PCB ASSY. Then disconnect the document detection sensor harness from the PCB and release the harness from the cable guide provided on the ADF unit. Document detection sensor PCB ASSY Cable guide...
Page 200 Document scanning position sensor PCB ASSY (23) Turn the ADF unit right side up. (24) Press the lock arm to the front to release the front end of the document scanning position sensor PCB and remove the PCB ASSY. Then disconnect the document scanning position sensor harness from the PCB and release the harness from the cable guide provided on the ADF unit Document scanning...
Page 201 ADF motor (25) Remove the screw (that secures the ADF motor together with the grounding wire), slightly rotate the ADF motor counterclockwise to release it from the boss on the ADF drive unit, and remove the ADF motor. (26) Disconnect the ADF motor harness from the motor. ADF motor harness Grounding wire Screw, pan...
Page 202 ADF drive unit (27) Remove gear 36/54 by releasing its latch, then remove the separation roller gear (outer) and idle gear 56. (28) Remove gear 31 by releasing its latch. (29) Remove the bushing from each of the document feed roller shafts 1 and 2. ADF unit Document feed roller 1 (Left)
Page 203 (30) Remove the three screws from the ADF drive unit. (31) On the underside of the ADF drive unit, press the lock arm to release the separation roller gear (inner), and pull the ADF drive unit off the ADF unit. (32) Remove the ADF motor harness from the ADF unit.
Page 204 Document pick-up roller and document separation roller (33) Turn the ADF unit upside down. (34) Remove the screw from the document roller holder. (35) Release the two tabs on the document roller holder from the ADF unit and take up the holder.
Page 205: Control Panel Assy
Control Panel ASSY *1 For models with touch panel (1) Remove three screws "a" from the control panel ASSY. (2) Slightly pull up the rear end of the control panel ASSY and press the front end to the rear to separate the ASSY from the upper cover.
Page 206 MFC without touch panel "a" Control panel ASSY "a" "a" LCD flat cable "a": Taptite, cup B M3x10 Upper cover Panel harness (3_064_MFCJ430W) *1 For models with touch panel "a" Control panel ASSY "a" "a" "b" Grounding wire * LCD flat cable Panel harness "a": Taptite, cup B M3x10 "b": Taptite, cup S M3x6*...
Page 207: Disassembly Of Control Panel Assy
Disassembly of Control Panel ASSY (The control panel ASSY contains the document scanner open actuator.) (1) Turn the control panel ASSY upside down. (2) Models with touch panel & 1.9-inch LCD Disconnect the LED harness from the panel PCB. (3) MFC Release the five latches (three "x" and two "y" latches). DCP Release three latches "x."...
Page 208 MFC without touch panel Panel harness Panel PCB ASSY Actuator spring Rubber key L Rubber key R LCD unit Tabs Latches Latch "z" Tabs Document scanner open actuator Latches "y" Latch "z" (3_065_MFCJ430W) Latches "x" *1 For models with touch panel *2 For models with touch panel &...
Page 209 Assembling Notes: • After mounting the document scanner open actuator, check that the actuator springs back if pressed with a finger. • When mounting the control panel PCB ASSY, first fit it below the four tabs on the control panel base and then secure it with the four latches (see the previous page). Make sure that the cable linking the two PCBs is threaded through the cable guide as shown below.
Page 210 *1 For models with touch panel *2 For models with touch panel & 1.9-inch LCD Viewed from the bottom Panel PCB ASSY Panel harness Cable guides Control panel base LED harness * LCD flat cable Touch panel harness * Grounding wire * (3_066_DCPJ525W) (8) Models with touch panel Remove the two screws and take the LCD unit out of the control panel base.
Page 211: Speaker*, Front Cover And Wireless Lan Pcb
Speaker*, Front Cover and Wireless LAN PCB (1) Disconnect the speaker harness* from the main PCB and release it from the cable guides provided on the upper cover. (2) Pull out the speaker spring (wire spring)* and take the speaker* out of the pocket provided on the upper cover.
Page 212 (3) Remove the screw (that secures the front cover and upper cover together to the lower cover). (4) On the inside of the front cover, lightly pull up the retainer to release it from the boss on the upper cover, slightly pull the front cover up and towards you to remove the front cover together with the wireless LAN PCB.
Page 213: Upper Cover, Ink Cartridge Cover And Media Module Cover
9.10 Upper Cover, Ink Cartridge Cover and Media Module Cover (1) Open the ink cartridge cover. (2) Remove the five screws (four screws if the front cover has been removed in the previous section) from the upper cover. (3) Hold the right and left sides of the upper cover and lift it up and off the lower cover. Note: Do not put your hands into the opening above the platen (shown below).
Page 214 (4) Slightly lift up the front end of the lower cover, open the ink cartridge cover fully, warp the cover arm downwards to release it from the slit in the lower cover, and then remove the right and left bosses on the ink cartridge cover downwards from the lower cover. (5) For disc printing models Push down the disc guide and pull it towards you.
Page 215: Main Pcb
9.11 Main PCB Caution: Before replacement of the main PCB, back up the machine information and user setting information (refer to Chapter 5, Section 1.4.12 "Backup of Machine Information (Function code 46) (User-accessible)" and the head calibration data (refer to Chapter 5, Section 1.4.23 "Updating of Head Property Data and Backup/Restoration of Head Calibration Data (Function code 68)."...
Page 216 Main PCB B57U081 * For MFC only (Document detection sensor harness (white)) ASF motor harness (2-wire) Carriage flat cable 3 (10-wire) (3-wire) Carriage motor harness (2-wire) Carriage flat cable 1 (8-wire) (Document MJ (LINE) harness * (CIS flat cable) (16-wire) scanning position (2-wire, yellow) sensor harness (red))
Page 217 (2) Remove the four screws (main PCB B57U081) or three screws (main PCB B57U082) and take the main PCB shield up and off the main PCB. (3) Unlatch the SDAA enclosure by pinching its right and left sides and remove it from the main PCB.
Page 218 Assembling Note: Before securing the main PCB shield, route the harnesses on the top of the lower cover as shown below. Make sure that the MJ (LINE) harness* is routed through the SDAA cover*. Gather the slack of the MJ (LINE) harness* around section "X" shown below. (See the illustration given on page 3-84 for the routing of those harnesses on the left side of the...
Page 219 (5) Remove one screw "a" (main PCB B57U081) or three screws "a" (main PCB B57U082) from the main PCB, then lift up the PCB and its insulation sheet. (6) Remove two screws "b" (that secure the PS/MJ shield unit together) from the main PCB frame, then lift it up.
Page 220: Ps/Mj Shield Unit (Mj Pcb*1 And Power Supply Pcb)
9.12 PS/MJ Shield Unit (MJ PCB and Power Supply PCB) *1 For MFC only *2 For models with main PCB B57U082 (1) If the main PCB frame has not been removed, disconnect the power supply harness, MJ (LINE) harness and MJ (EXT) harness from the main PCB, then remove two screws "b"...
Page 221 Assembling Notes: • Before mounting the PS/MJ shield unit on the lower cover, pass the power supply harness through the U-shaped cutout (shown on the previous page) provided in the lower PS/MJ frame. • After mounting the PS/MJ shield unit on the lower cover, check that lock "x" is caught on pawl "y"...
Page 222 (6) For 100 V series As shown below, unlatch the power cord bush and pull it up from the AC cord holder. Then release the power cord from the cable guides provided on the AC cord holder (shown on page 3-87).
Page 223 Assembling Notes: • Before mounting the MJ shield, route the MJ (LINE) harness and MJ (EXT) harness through the cable guides on the MJ PCB insulator as shown on the next page. • When setting the PS PCB insulator back into place, first pass the power cord through the insulator, fit the right end "f"...
Page 224 *1 For MFC only *2 For models with main PCB B57U082 100 V series Ferrite core Power cord bush Power cord MJ PCB * Cable guides MJ (EXT) harness * (black) Ferrite core * MJ (LINE) harness * (yellow) Power supply PCB Power supply shield Power supply harness (3_017)
Page 225: Cr Encoder Strip And Its Guard Film
9.13 CR Encoder Strip and its Guard Film CR encoder strip (1) At the left end of the CR frame, push the rear end of the encoder strip spring inwards, unhook the left end of the CR encoder strip from the spring, and then unhook the right end from the CR frame.
Page 226 Encoder strip guard film (3) At the right end of the CR frame, push the rear end of the guard film spring inwards, unhook the right end of the encoder strip guard film from the spring, and then unhook the left end from the CR frame.
Page 227: Carriage Pcb Assy, Ink Refill Assy And Ink Cartridge Detection Sensor
9.14 Carriage PCB ASSY, Ink Refill ASSY and Ink Cartridge Detection Sensor Carriage PCB ASSY (Carriage PCB with carriage flat cables) (1) Remove the carriage PCB ASSY from the head/carriage unit, by performing steps (7) through (11) in Section 9.3 "Head/Carriage Unit." (2) Release the carriage flat cables from the cable guides on the tube support plate and take them out together with the flat core.
Page 228 Assembling Note: When mounting the carriage PCB ASSY, route the carriage flat cables as shown below. Pull here to unlock. Head flexible cable Head/carriage unit Connector Carriage PCB ASSY Film Carriage PCB ASSY Lock spring Hole Carriage flat Head/carriage unit cables (3_081) Upper cover...
Page 229 Ink refill ASSY and ink cartridge detection sensor PCB (3) Remove the ink supply tubes from the head/carriage unit, by performing steps (12) through (14) in Section 9.3 "Head/Carriage Unit." (4) Release the four ink supply tubes from the tube guides on the tube support plate, remove the sponge, and then release them from the tube support wire.
Page 230 Assembling Notes: • When binding ink supply tubes with two tube clamps, align four ink supply tubes in the order of Magenta, Cyan, Yellow, and Black from bottom to up, as shown on the previous page. Bind magenta, cyan, and yellow ink tubes from the bottom with tube clamp (1) at the right side (viewed from the front), and then bind black, yellow, and cyan ink tubes from the top with tube clamp (2) at the left side.
Page 231 (7) Release the three ink-related sensor flat cables from the cable guide (shown on page 3-92) on the lower cover. (8) Lift the ink refill ASSY up and out of the lower cover. Note: Do not remove the protective part under the current state. Doing so causes ink in the ink supply tubes to flow out.
Page 232 Tube support plate and tube support wire (10) Release the five harnesses (carriage motor harness, ASF motor harness, pressure roller release sensor harness, ASF encoder sensor harness and purge cam switch harness) routed on the tube support plate from the cable guides on the plate. Engine unit Tube support plate Purge cam switch harness...
Page 233 (11) Pull up the tab on the tube support plate to release the boss on the underside from the lower cover, slide the plate to the right, and take it up and off the lower cover together with the tube support wire. (12) Remove the tube support wire from the tube support plate.
Page 234: Ink Absorber Box And Ink Absorber Felt (For Ink Refill Assy)
9.15 Ink Absorber Box and Ink Absorber Felt (for Ink Refill ASSY) Note: Do not remove the ink absorber box unless it needs to be replaced. Note: If the main drain tube and air vent tube are disconnected from the ink absorber box for replacement of the ink absorber box, they are reusable only one time by trimming their ends vertically 10 mm with scissors clear and free of oil.
Page 235 Assembling Notes: • When connecting the main drain tube and air vent tube to the ink absorber box, take care not to connect them at an angle. Tubes connected at an angle come off easily, resulting in ink leakage. After connection, check that there is no ink leakage. •...
Page 236: Engine Unit And Flushing Box
9.16 Engine Unit and Flushing Box During disassembly jobs, except when removing the ink refill ASSY or engine unit (including the maintenance unit), leave the head/carriage unit in the machine. When removing the head/carriage unit, ink refill ASSY or engine unit, you need beforehand to remove all four ink cartridges and set the protective part instead (see page 3-34).
Page 237 (3) On the left end of the lower cover, release the two harnesses (paper feed motor harness and PF/registration sensor harness ASSY) from the cable guides. (4) Remove the four screws from the engine unit. (5) Hold the inner chute located beneath the CR guide rail, lift up the rear end of the engine unit slightly, and then take it up and out of the lower cover.
Page 238 Assembling Notes: • When mounting the engine unit on the lower cover, first make sure that the disc guide is closed, then slightly tilt the engine unit to the front, fit the grooves provided in the inside of the link rods R and L (white parts) over the bosses on the disc guide (see the previous page), slide the engine unit down, press the front end against the lower cover and lower the rear end.
Page 239 PF encoder disc PF/registration sensor harness ASSY Lower cover Lower cover Paper feed motor harness Registration PF encoder sensor harness sensor harness ASF motor harness Carriage motor harness Purge cam switch harness PF/registration sensor ASF encoder harness harness ASSY (3_096) Pressure roller release sensor harness Confidential 3-102...
Page 240: Components On The Engine Unit
9.17 Components on the Engine Unit (Earth spring, Maintenance unit, Carriage motor, Outer paper guide, Chute cover, Registration sensor PCB ASSY, Inner chute ASSY, Pressure roller release sensor PCB ASSY, PF encoder disc, PF encoder sensor PCB ASSY and PF/registration sensor harness ASSY) Earth spring (1) Release the upper and lower ends of the earth spring from the CR guide rail and the ASF motor, respectively.
Page 241 Maintenance unit (2) Release the left end of the switching lever guide from the maintenance unit (viewed from the rear) and remove the guide. (3) If the ink absorber box has not been removed, pull out the main drain tube and air vent tube from the ink absorber box.
Page 242 (5) Remove the screw from the maintenance unit, slightly slide the ASF drive ASSY to the left and lift it up to detach it from the maintenance unit. (6) Remove the ASF switching gears A and B. ASF drive ASSY ASF switching gear A ASF switching gear B Taptite, cup B...
Page 243 Carriage motor (7) Remove the two screws from the CR frame and detach the carriage motor and its bracket. Screw, bind M3x6 CR guide rail (Rear) CR frame Motor bracket Carriage motor (3_100) Confidential 3-106...
Page 244 Outer paper guide (8) Remove the outer paper guide from the switchback roller shaft, starting from either one of the right and left ends. CR guide rail Switchback roller shaft Hook Center hook CR frame Hook Outer paper guide (Front) (3_101) Part code imprinted Assembling Note: Fit the outer paper guide over the switchback roller shaft, starting from...
Page 245 Chute cover, registration sensor PCB ASSY, inner chute ASSY and pressure roller release sensor PCB ASSY (9) Push down the boss on the lock arm of the chute cover to release it from the hole provided in the CR guide rail, slide the chute cover to the right (to the left viewed from the rear) to release the four locks, and then remove the chute cover.
Page 246 (10) Push down the boss on the lock arm of the registration sensor holder (on which the registration sensor PCB ASSY is mounted) to release it from the hole provided in the CR guide rail, then remove the holder outwards. As shown on the next page, pull the support arms on the registration sensor holder outwards, remove the registration sensor PCB ASSY, and disconnect the registration sensor harness from the PCB.
Page 247 Registration sensor holder Registration sensor PCB ASSY Support arms Registration sensor holder Registration sensor harness (Part of PF/registration sensor harness ASSY) Cable guide (3_104) Registration sensor harness (12) Remove the screw and take the pressure roller release sensor PCB ASSY out of the inner chute ASSY.
Page 248 PF encoder disc, PF encoder sensor PCB ASSY and PF/registration sensor harness ASSY* * The PF/registration sensor harness ASSY consists of a PF encoder sensor harness and registration sensor harness. (13) If the PF encoder disc needs to be replaced, peel it off from the PF roller gear L. Note: Once removed, the PF encoder disc will become unusable and a new disc will have to be put back in.
Page 249 Paper pull-in roller holder ASSY (15) Pull the pawl on the paper pull-in roller R outwards and remove the roller R, then pull out the paper pull-in roller L while rotating it. (16) Remove the paper pull-in gear. Paper pull-in roller holder ASSY Paper pull-in roller L Paper pull-in gear Paper pull-in roller R...
Page 250: Ink Cartridge Cover Sensor Assy, Disc Guide Cover*, Disc Guide* And Disc Guide Sensor Assy
9.18 Ink Cartridge Cover Sensor ASSY, Disc Guide Cover*, Disc Guide* and Disc Guide Sensor ASSY* * For disc printing models (1) Remove the ink cartridge cover sensor ASSY from the front right side of the lower cover as shown below. (Front) Ink cartridge cover sensor ASSY (3_092)
Page 251 (3) Remove the disc guide springs (R and L)* and separate the disc guide* from the disc guide cover*. Disc guide spring R * Disc guide cover * Small loop Large loop Boss Disc guide spring L * Disc guide * Small loop Large loop (Front)
Page 252: Bank Assy And Base Pads On The Paper Tray Assy
9.19 Bank ASSY and Base Pads on the Paper Tray ASSY (1) Pull the four lock arms on the rear of the paper tray ASSY outwards to release the four latches of the bank ASSY, and separate the bank ASSY from the paper tray. (2) If the base pad needs to be replaced, peel it off the bottom of the paper tray.
Page 253 (3) If the photo tray base pads need to be replaced, squeeze the photo bypass tray release button, push the photo bypass tray forward until it clicks into the photo printing position shown below, and peel the base pads off the bottom of the photo bypass tray. Note: Once removed, the photo tray base pads will become unusable and new pads will have to be put back in.
Page 254: Chapter 4 Adjustments And Updating Of Settings, Required After Parts Replacement
CHAPTER 4 ADJUSTMENTS AND UPDATING OF SETTINGS, REQUIRED AFTER PARTS REPLACEMENT This chapter details adjustments and updating of settings, which are required if the head/carriage unit, main PCB and some other parts have been replaced. IF YOU REPLACE THE HEAD/CARRIAGE UNIT OR ENGINE UNIT <Operations>...
Page 255: Update The Head Property Data Stored In The Eeprom On The Main Pcb
Update the head property data stored in the EEPROM on the main PCB* * Updating not required when the engine unit only is replaced Tip: Updating can also be done with Function code 68. (Refer to Chapter 5, Section 1.4.23.) (1) Make sure that the machine's power cord is unplugged from an electrical outlet.
Page 256 (8) In Port on the BrUsbSn screen, select the port number assigned to the Brother Maintenance USB Printer. If the port number is unknown, follow steps 1) through 4) below. 1) Click Start | Settings | Printers. The Printers window appears as shown below.
Page 257 The Brother Maintenance USB Printer Properties window appears as shown below. 4) Click the Ports tab. In this example, the port number assigned to the Brother Maintenance USB Printer is USB001. (9) In the Head Info. box on the BrUsbSn screen...
Page 258: Clean The New Head/Carriage Unit (Function Code 76)
Clean the new head/carriage unit (Function code 76) (1) Open the ink cartridge cover, set comparatively-new ink cartridges (having sufficient ink) into the ink refill ASSY, and close the ink cartridge cover. (2) Carry out a purge operation (with function code 76) using the steps below. (See Chapter 5, Section 1.4.28.)
Page 259: Print Out A Nozzle Test Pattern (Function Code 09)
Print out a nozzle test pattern (Function code 09) To check that the head/carriage unit normally sprays ink droplets from all head nozzles, print out a test pattern with Function code 09 (see Chapter 5, Section 1.4.5) with the following steps. Before starting the operation below, be sure to set letter- or A4-size paper in the paper tray for printing test patterns.
Page 260: Adjust The Inclination Of The Head/Carriage Unit
(head_position_2) (4) Close the document scanner unit. (5) Drag and drop the "incline_mini11.prn" onto the Brother Maintenance USB Printer driver icon in the Filedrgs window. The machine displays the "Receiving Data" on the LCD and prints out the head inclination test pattern "CR-INCLINE EXIT adjust check"...
Page 261 (7) Adjust the inclination of the head/carriage unit using the procedure below. If the least uneven block number in the upper single row is "0": 1) Check the center two rows of blocks and select the block that is the least uneven print. Turn the external knob of the inclination adjuster with a spanner by the selected block number of the scale marks.
Page 262 Upper single row of blocks Center two rows of blocks Head Inclination Test Pattern Confidential...
Page 263: Update The Paper Feeding Correction Value (Function Code 58)
Update the paper feeding correction value (Function code 58) Refer to Chapter 5, Section 1.4.17. Align vertical print lines in monochrome (Function code 65) Refer to Chapter 5, Section 1.4.21. Adjust margins in borderless printing (Function code 66) Refer to Chapter 5, Section 1.4.22.
Page 264: Print Out A Total Quality Check Pattern
In addition to printing the "Total Quality Check Pattern," the disc printing models need to print a disc printing check pattern. Drag and drop the "disc.prn" onto the Brother Maintenance USB Printer driver icon in the Filedrgs window. The machine displays the "Receiving Data" on the LCD and prints out a disc printing check...
Page 265 H: Top margin adjustment Check that the top margin is correct. (Disc printing models only) On the disc printing check pattern, if the top margin is not within the range from 2.0 to 3.0 mm, adjust the top margin in the maintenance mode (Function code 66), referring to Chapter 5, Section 1.4.22.
Page 266 Total Quality Check Pattern : Platen height adjustment : Adjustment of vertical print lines : Inclination adjustment of the head/carriage unit : Paper feed roller adjustment : Margin adjustment for borderless printing (600 dpi) : Margin adjustment for borderless printing (1200 dpi) : Paper ejection roller adjustment Confidential 4-13...
Page 267 Disc Printing Check Pattern :Top margin adjustment (Disc printing models only) :Right and left margins adjustment (Disc printing models only) Confidential 4-14...
Page 268: Switch Back To Standby
(1) On the user computer, click Start | Settings | Printers to display the Printers window. (2) Right-click the Brother Printer driver icon to display the pull-down menu. (3) Click Properties | Print Settings | Advanced | Other print options | Retrieve Printer’s Color Data.
Page 269: If You Replace The Main Pcb
IF YOU REPLACE THE MAIN PCB Note: If you replace the main PCB, it is necessary to make a backup of the machine information, user setting information, and head calibration data into an external memory before starting disassembly of the machine. After the completion of reassembling jobs, restore the backup data to the new main PCB.
Page 270: Load Update Programs/Data
LCD. With the version being displayed, connect the machine to your PC using a USB cable. The PC shows "Brother Maintenance USB Printer (Copy 1)" newly copied. (This does not occur if it was copied.) (2) On the PC, run "filedg32.exe."...
Page 271 Note: If loading operation ends abnormally, turn the machine off and on. Wait for the machine to emit a long beep and automatically enter the firmware loading mode, and then perform the loading procedure above again. [ B ] .pmu firmware file Unplug the power cord of the machine from the electrical outlet and disconnect the USB cable that connects the machine with your PC.
Page 272 (3) On the PC, run "filedg32.exe." The Filedrgs window appears. (4) Drag and drop the firmware (e.g., lz0023_a.pmu) onto the Brother Maintenance USB Printer driver icon in the Filedrgs window. Note: To use a firmware file, extract it beforehand by double-clicking. It is a self-extracting file having the extension .exe.
Page 273: If The Main Pcb Loaded With Programs Is Used (Updating Existing Programs)
(2) On the PC, run "filedg32.exe." The Filedrgs window appears. (3) Drag and drop the target firmware (e.g., lz00001_a.pjl) onto the Brother Maintenance USB Printer driver icon in the Filedrgs window. Note: To use a firmware file, extract it beforehand by double-clicking. It is a self-extracting file having the extension .exe.
Page 274 (2) On the PC, run "filedg32.exe." The Filedrgs window appears. (3) Drag and drop the target firmware (e.g., lz0023_a.pmu) onto the Brother Maintenance USB Printer driver icon in the Filedrgs window. Note: To use a firmware file, extract it beforehand by double-clicking. It is a self- extracting file having the extension .exe.
Page 275: Customize The Eeprom On The Main Pcb (Function Code 74)
Customize the EEPROM on the main PCB (Function code 74) Refer to Chapter 5, Section 1.4.26. Note: Once this procedure is carried out, it is necessary to write the corresponding language data, so be sure to write local programs, referring to Section 2.4 below.
Page 276: Acquire White Level Data And Set Cis Scanner Area (Function Code 55)
2.10 Set an ID code (change the serial number) and update the head property data Note: Make sure that the Brother Maintenance USB Printer driver has been installed to your PC. To do it, click Start | Settings | Printers to call up the Printers window and confirm that the...
Page 277 (6) In the Serial No box on the BrUsbSn screen, type the 15-digit serial number (e.g., U62663C0F000136) printed on the nameplate labeled to the machine as an ID code. (serial_number_label_mini11) Serial number label Tip: The serial number can also be changed with Function code 80. (Refer to Chapter 5, Section 1.4.31.)
Page 278: Update The Paper Feeding Correction Value (Function Code 58)
2.11 Update the paper feeding correction value (Function code 58) Refer to Chapter 5, Section 1.4.17. 2.12 Align vertical print lines (Function code 65) Refer to Chapter 5, Section 1.4.21. 2.13 Adjust margins in borderless printing (Function code 66) Refer to Chapter 5, Section 1.4.22.
Page 279: If You Replace The Adf Or Adf-Related Parts
(3) On the PC, run "filedg32.exe" in the folder created. The Filedrgs window appears as shown below. (4) Drag and drop the "chart.prn" onto the Brother Maintenance USB Printer driver icon in the Filedrgs window shown above. The machine displays the "Receiving Data" on the LCD and prints out the "ADF COPY CHART"...
Page 280 (7) Check the copied chart, referring to the "Check Items on the ADF COPY CHART" given below. If any problem is found, remove the newly mounted ADF unit or ADF-related parts once and set it (them) into place, or check and correct the connection of ADF-related harnesses. Check Items on the ADF COPY CHART Check that the copied chart has none of the following defects.
Page 281 ADF Copy Chart Confidential 4-28...
Page 282: If You Replace The Ink Absorber Box Or Flushing Box
IF YOU REPLACE THE INK ABSORBER BOX OR FLUSHING BOX Reset each of the purge and flushing counts (1) Switch the machine to the maintenance mode. (Refer to Chapter (2) Press the 8 and 0 keys in this order. (3) Press the Black Start (Mono Start) key several times until the purge (or flushing) count appears on the LCD.
Page 283: If You Replace The Control Panel Assy, Panel Pcb Or Lcd Unit
IF YOU REPLACE THE CONTROL PANEL ASSY, PANEL PCB OR LCD UNIT Adjust the touch panel (Function code 78) (For models with touch panel) Refer to Chapter 5, Section 1.4.30. Note: This operation is not required when only the panel PCB is replaced. Check LCD operation (Function code 12) Refer to Chapter 5, Section...
Page 284: If You Replace The Fb Unit* Or Document Scanner Unit
IF YOU REPLACE THE FB UNIT* OR DOCUMENT SCANNER UNIT * FB unit: ADF & document cover ASSY and document scanner unit Acquire white level data and set CIS scanner area (Function code 55) Refer to Chapter 5, Section 1.4.16. Print out an ADF copy chart and make a copy of that chart in ADF scanning Refer to...
Page 285: Chapter 5 Service Functions
CHAPTER 5 SERVICE FUNCTIONS This chapter describes the maintenance mode and other service functions, which are exclusively designed for the purpose of checks, settings and adjustments of the machine and can be triggered by the keys on the control panel*. * For key operations, refer to Section 1.2 in this chapter.
Page 286: How To Enter The Maintenance Mode Exclusive To Service Personnel
1.1.2 How to Enter the Maintenance Mode Exclusive to Service Personnel (1) Models with Press the and Black Start (Mono Start) keys simultaneously. Press the Black Start (Mono Start) key, then press the Color Start key four times. Models without Press the Menu and Black Start (Mono Start) keys in this order, then press the four times.
Page 287: Keys To Be Used In The Maintenance Mode
1.2.2 Keys to be Used in the Maintenance Mode This chapter provides the operating procedure for base models, that is, models with numerical keypad and without touch panel. For other models, see the table below. Base models Models with numerical keypad/ Models with both numerical Models without numerical keypad and touch panel...
Page 288: List Of Maintenance-Mode Functions
List of Maintenance-mode Functions Maintenance-mode Functions Function Reference Function Code Section (Page) EEPROM Parameter Initialization 1.4.1 (5-5) Creating of Head Calibration Data and Writing it into Flash ROM 1.4.2 (5-6) Printout of Scanning Compensation Data 1.4.3 (5-9) ADF Performance Test 1.4.4 (5-11) Printout of Nozzle Test Pattern 1.4.5 (5-12)
Page 289: Detailed Description Of Maintenance-Mode Functions
Detailed Description of Maintenance-mode Functions 1.4.1 EEPROM Parameter Initialization (Function code 01, 91) Function The machine initializes the parameters, user switches, firmware switches and assurance mode switch settings registered in the EEPROM, to the initial values. Entering function code 01 initializes almost all of the EEPROM areas, but entering 91 does not initialize some areas, as listed below.
Page 290: Creating Of Head Calibration Data And Writing It Into Flash Rom (Function Code 02)
EU, AP and others: Xerox Business 80 g/m , Brother BP60PA (1) Drag and drop the "head_calib.prn" onto the Brother Maintenance USB Printer driver icon in the Filedrgs window. The machine displays the "Receiving Data" on the LCD and prints out "Print pattern for creating head calibration data"...
Page 291 Error code The following error has occurred. Do the following: Failed to detect the external • Clean the scanner glass. frame. • Reposition a document along the document guides on the document Internal image inclined. cover. Failed to detect position. •...
Page 292 Print Pattern for Creating Head Calibration Data Confidential...
Page 293: Printout Of Scanning Compensation Data (Function Code 05)
1.4.3 Printout of Scanning Compensation Data (Function code 05) Function The machine prints out the white and black level data for scanning compensation. Operating Procedure Do not start this function merely after powering on the machine but start it after carrying out a sequence of scanning operation.
Page 294 Scanning Compensation Data List Confidential 5-10...
Page 295: Adf Performance Test (Function Code 08)
1.4.4 ADF Performance Test (Function code 08) Function The machine counts the documents fed by the automatic document feeder (ADF) and displays the count on the LCD for checking the ADF performance. Operating Procedure (1) Set documents. (Allowable up to the ADF capacity.) The "DOC.
Page 296: Printout Of Nozzle Test Pattern (Function Code 09)
1.4.5 Printout of Nozzle Test Pattern (Function code 09) Function This function prints out a nozzle test pattern (Print Quality Check sheet) to allow the service personnel to check the print quality. If any print quality problem is found, perform an appropriate purge operation, referring to Section 1.4.28 "Purge Operation (Function code 76) (User-accessible)"...
Page 297 Nozzle Test Pattern Confidential 5-13...
Page 298: Firmware Switch Setting And Printout (Function Codes 10 And 11) (User-Accessible)
1.4.6 Firmware Switch Setting and Printout (Function codes 10 and 11) (User-accessible) [ A ] Firmware switch setting Function The machine incorporates the firmware switch functions which can be activated with the procedures using the control panel keys. For details about the firmware switches, refer to the "Firmware Switches (WSW)" document separately issued.
Page 299 [ B ] Printout of firmware switch data Function The machine prints out the setting items of the firmware switches and their contents specified. Operating Procedure (1) Press the 1 key twice in the initial stage of the maintenance mode. The machine shows "PRINTING"...
Page 300 Configuration List Confidential 5-16...
Page 301: Operational Check Of Lcd (Function Code 12) (User-Accessible)
1.4.7 Operational Check of LCD (Function code 12) (User-accessible) Function This function allows you to check whether the LCD works normally. Operating Procedure Checking the display state of the LCD (1) Press the 1 and 2 keys in this order in the initial stage of the maintenance mode. (2) Press the key.
Page 302: Operational Check Of Panel Pcb (Function Code 13)
(3) After the last number key is pressed, the machine beeps and returns to the initial stage of the maintenance mode. To terminate this operation, press the Stop/Exit key. The machine returns to the initial stage of the maintenance mode. DCPJ525W/J725DW/J925DW MFCJ280W Confidential 5-18...
Page 303 MFCJ430W/J432W MFCJ625DW/J825DW Key Entry Order Confidential 5-19...
Page 304: Eeprom Dump And Log Information Transfer (Function Code 17) (User-Accessible)
1.4.9 EEPROM Dump and Log Information Transfer (Function code 17) (User-accessible) Function The EEPROM dump function transfers the EEPROM settings made in the machine to another fax machine as fax data. The log information transfer function outputs user’s log information (e.g., panel operation) and machine’s operation log information to a USB flash memory or a PC to save it as a CSV file.
Page 305: Updating Of Firmware Using An External Memory (Function Code 28)
Operating Procedure (1) Switch your PC ON and insert an external memory. (2) Create a folder named "BROTHER" in the top layer of the external memory's directory and copy the firmware file having the extension .pjl into that folder. Note: Before copying, check that the file name of the firmware matches with your machine.
Page 306: Sensor Operational Check (Function Code 32)
1.4.11 Sensor Operational Check (Function code 32) Function This function allows you to check the following: • Document detection sensor (For models with ADF) • Document scanning position sensor (For models with ADF) • Document scanner open sensor • Registration sensor •...
Page 307 Given below is the relationship between the LCD indication, sensor name and sensor status. Sensors Sensing status for display on the LCD Document detection sensor No document detected. Document scanning position sensor No document detected. Document scanner open sensor Document scanner unit closed. Registration sensor No recording paper detected.
Page 308: Backup Of Machine Information (Function Code 46) (User-Accessible)
Note: Do not use a Memory Stick; using it may fail to transfer data correctly. Backup Procedure (1) On the PC, create a "Brother" folder in an external memory to be used for saving backup data. (2) Insert the external memory into the slot of the machine in the initial stage of the maintenance mode.
Page 309 (7) Wait for the machine to automatically return to the initial stage of the maintenance mode and show "**** Active" on the LCD. Remove the external memory from the machine and keep it in a safe place. Note: If any of the error messages listed below appears, press the Stop/Exit key, and the machine returns to the initial stage of the maintenance mode.
Page 310: Setting Of Country/Language (Function Code 52) (User-Accessible)
1.4.13 Setting of Country/Language (Function code 52) (User-accessible) Function Machines have been customized for their destination countries with the corresponding EEPROM customizing codes (see Section 1.4.26, Function code 74). However, some customizing codes are shared by two or more destination countries as listed below, so the machines customized by these codes require further specifying individual destination countries or languages.
Page 311: Transfer Of Received Fax Data And/Or Equipment's Log (Function Code 53) (User-Accessible)
1.4.14 Transfer of Received FAX Data and/or Equipment's Log (Function code 53) (User-accessible) Function This function transfers received FAX data to another machine. It is useful when the machine cannot print received data due to the printing mechanism defective. This function also transfers the activity report, the communications list, and the equipment’ log of the machine as fax data.
Page 312 (5) Enter the telephone number of the receiver machine and press the OK key again. Note: Be sure to type the telephone number with the numerical keys. No auto-dial numbers stored in memory can be used in this procedure. The machine displays the "ACCEPTED" for approx. two seconds and starts dialing to transfer data.
Page 313 Cover page sample Title Job number Total number of pages to be transferred Station ID registered in the sender equipment FAX number of the sender equipment Telephone number of the sender equipment Transfer start date Model code Boot ROM info Program manager ROM info Main ROM info Serial number...
Page 314: Fine Adjustment Of Scanning Position (Function Code 54)
1.4.15 Fine Adjustment of Scanning Position (Function code 54) Function This function allows you to adjust the scanning position. Operating Procedure (1) Press the 5 and 4 keys in this order in the initial stage of the maintenance mode. The "SCAN ADJ SELECT" appears on the LCD. (2) To adjust horizontal scanning (right and left edges), press the 0 key.
Page 315: Acquisition Of White Level Data And Cis Scanner Area Setting (Function Code 55)
1.4.16 Acquisition of White Level Data and CIS Scanner Area Setting (Function code 55) Function This procedure allows the machine to obtain white level data for the CIS scanner and save it together with the CIS scanner area into the EEPROM on the main PCB. Operating Procedure (1) Press the 5 key twice in the initial stage of the maintenance mode.
Page 316: Updating Of Paper Feeding Correction Value (Function Code 58)
For the paper feed roller adjustment (1) On your PC, drag and drop the "pfadj.prn" onto the Brother Maintenance USB Printer driver icon in the Filedrgs window. The machine displays the "RECEIVING DATA" on the LCD and prints out "PF-EXIT adjust check"...
Page 317 EXIT2 through EXIT6. For adjustment of horizontal streaks (1) On your PC, drag and drop the "LF300adj.prn" onto the Brother Maintenance USB Printer driver icon in the Filedrgs window. The machine displays the "Receiving Data" on the LCD and prints out "KEISEN2 &...
Page 318 Paper feed roller PF-EXIT Adjust Check Pattern Confidential 5-34...
Page 319 EXIT Adjust Check Pattern 1 Confidential 5-35...
Page 320 EXIT Adjust Check Pattern 2 Confidential 5-36...
Page 321 EXIT Adjust Check Pattern 3 Confidential 5-37...
Page 322 KEISEN2 & LF300 & EXIT ADJUST PATTERN Confidential 5-38...
Page 323: Checking Of Cis Travel And Specifying Of Cis Type (Function Code 59)
1.4.18 Checking of CIS Travel and Specifying of CIS Type (Function code 59) Function This procedure allows you to check the movement of the CIS unit integrated in the document scanner unit. The CIS unit travels to the three positions--the white reference film position, scanning start and end positions.
Page 324: Printout Of Prn/Jpeg Files In Memory Card (Function Code 61)
1.4.19 Printout of PRN/JPEG Files in Memory Card (Function code 61) Function This procedure prints PRN files and JPEG files stored in a memory card supported by PhotoCapture Center. The following four print modes are available. - Printing the specified file once - Printing the specified file repeatedly - Printing all PRN/JPEG files once - Printing all PRN/JPEG files repeatedly...
Page 325: Travel Check Of The Head/Carriage Unit And Operational Check Of The Pressure Roller (Function Code 63)
1.4.20 Travel Check of the Head/Carriage Unit and Operational Check of the Pressure Roller (Function code 63) Function This procedure moves the head/carriage unit to the adjustment position (Function code 63 + *). It also checks releasing and depressing of the pressure roller provided on disc printing models (Function code 63 + #).
Page 326: Alignment Of Vertical Print Lines In Monochrome (Function Code 65)
1.4.21 Alignment of Vertical Print Lines in Monochrome (Function code 65) Function This procedure aligns vertical lines printed in the forward and backward directions of the head/ carriage unit. If the head/carriage unit, main PCB, engine unit, or carriage motor is replaced, you need to make the adjustment given in this section.
Page 327 Vertical Alignment Check Pattern Confidential 5-43...
Page 328: Margin Adjustment In Borderless Printing (Function Code 66) (User-Accessible)
Top/left/right margin adjustment (1) On your PC, drag and drop the "mediaadj_disc_mini11.prn" onto the Brother Maintenance USB Printer driver icon in the Filedrgs window. The machine displays the "Receiving Data" on the LCD and prints out the "MEDIA CHECK"...
Page 329 (7) To adjust the left margin in 600 dpi, enter the measured left margin value (in units of 0.1 mm) multiplied by 10. In this example, the left margin measured in step (2) is 2.8 mm, so press the 2, 8, and OK keys in this order.
Page 330 (2) If the bottom margin is out of the specified range, press the 6 key twice. The "Select 66?" appears on the LCD. (3) Press the Black Start (Mono Start) key. The "MEDIA SENSOR ADJ" appears on the LCD. (4) Press the # key to display "BOTTOM :30." (5) To adjust the bottom margin, enter the measured bottom value (in units of 0.1 mm) multiplied by 10.
Page 331 Left, Right, Top and Bottom Margin Check Pattern Confidential 5-47...
Page 332: Updating Of Head Property Data And Backup/Restoration Of Head Calibration Data (Function Code 68)
1.4.23 Updating of Head Property Data and Backup/Restoration of Head Calibration Data (Function code 68) Function Function code 68 provides two types of procedures--one for updating the head property data and the other for backing up the head calibration data and restoring it. Updating the head property data To keep the print quality, the machine optimizes the drive conditions of individual head/ carriage units according to the head property data.
Page 333 Head Calibration Data Backup/Restoration Procedures Backup procedure (1) Press the 6 and 8 keys in this order in the initial stage of the maintenance mode. (2) Press the 0, 6, 2, and 6 keys in this order. The "Write Head Calib" appears on the LCD. (3) Insert an external memory into the memory slot.
Page 334: Traveling Speed Check Of Head/Carriage Unit (Function Code 69)
1.4.24 Traveling Speed Check of Head/Carriage Unit (Function code 69) Function This procedure checks whether the traveling speed of the head/carriage unit is within the specified range. Be sure to perform this procedure if you replace the head/carriage unit, carriage motor or CR encoder strip, loosen the CR timing belt, or apply lubricant.
Page 335: Cleaning Of Leveler Roller (Lr) Assy (Function Code 70)
1.4.25 Cleaning of Leveler Roller (LR) ASSY (Function code 70) Function This procedure clears ink sticking to the leveler roller (LR) ASSY. Operating Procedure (1) Fold a sheet of A4- or letter-size recording paper in half in a longitudinal direction, unfold it, and set it in the empty paper tray with the valley fold facing up as shown below.
Page 336: Eeprom Customizing (Function Code 74)
(6) On the PC, run "filedg32.exe" to display the Filedrgs window. Drag and drop the target firmware onto the Brother Maintenance USB Printer driver icon in that window. If you press the Stop/Exit key or no keys are pressed for one minute in the above procedure, the machine stops the procedure and returns to the initial stage of the maintenance mode.
Page 337 EEPROM Customizing Codes List France, French Polynesia, Ivory Destination Coast, Morocco, Algeria, Canada Germany Mexico Monaco, New Caledonia, Reunion, Senegal, Tunisia Country code 0053 0055 DCPJ525W 0004 (0003/0014) (0005/0008/0009/0004) 0053 0055 DCPJ725W 0004 (0003/0014) (0005/0008/0009/0004) 0053 0055 DCPJ925W 0004 (0003/0014)
Page 338 Belgium, Norway, Sweden, Finland, Austria Romania, Macedonia, Israel Luxemburg Denmark, Iceland Albania, Bosnia and Herzegovina, Moldova, Greece, Malta, Cyprus, Estonia, Latvia, Lithuania Country code 0057 DCPJ525W 0014 0054 (0007) 0057 DCPJ725W 0014 0054 (0007) 0057 DCPJ925W 0014 0054 (0007) MFCJ280...
Page 339 0054 0004 DCPJ725W 0054 DCPJ925W 0054 MFCJ280 MFCJ430W 0042 0040 0040 0039 MFCJ625DW 0039 0040 MFCJ825DW 0040 0040 0039 The above information is as of April 2011. The up-to-date information is available from your local Brother Customer Service. Confidential 5-55...
Page 340: Travel Of Head/Carriage Unit (For Removing Paper Particles And Dust Accumulated On The Maintenance Unit) (Function Code 75) (User-Accessible)
1.4.27 Travel of Head/Carriage Unit (for removing paper particles and dust accumulated on the maintenance unit) (Function code 75) (User-accessible) Function This function is used to remove paper particles and dust accumulated between the maintenance unit and head/carriage unit. Using this function moves the head/carriage unit to the center of its travel, allowing you to easily remove the paper particles and dust accumulated.
Page 341: Purge Operation (Function Code 76) (User-Accessible)
1.4.28 Purge Operation (Function code 76) (User-accessible) Function The machine can carry out several types of purge operations--normal purge, periodical reset purge, power purge, initial purge, user reset purge, and engine setup purge. This function allows you to select the desired purge type and carry it out. TIP: The purge types and their details are described on the next page.
Page 342 Purge types, ink usage, purge counts, and purge codes Purge Codes (In the Purge Types Description Ink Usage Purge Counts maintenance mode, Function code 76) Normal purge This purge operation Black: 0.240 ml All: removes dried ink sticking Black: Per color: 0.217 ml to the head nozzles.
Page 343 Resetting purge or flushing count 1) Switch the machine to the maintenance mode. 2) Press the 8 and 0 keys in this order in the initial stage of the maintenance mode to call up the machine's log information. (Function code 80. Refer to Section 1.4.31 in this chapter.)
Page 344: Print Of The Equipment's Log (Function Code 77)
1.4.29 Print of the Equipment’s Log (Function code 77) Function The machine prints out its log information or saves it into an external memory. Operating Procedure Printing (1) Press the 7 key twice in the initial stage of the maintenance mode. The machine displays "MAINTENANCE 77"...
Page 345 Real-time clock (RTC) check result RTC backup check result (not required for servicing) Model code Country code (See Section 1.4.26 in this chapter.) Checksum of WSW, PSW, USW, and FSW (not required for servicing) Version and production date of main firmware Version and production date of sub firmware Version and production date of boot firmware Serial number of the machine...
Page 346 ADF scanning page count/Flat-bed scanning page count/ADF paper jam count/FAX scanning count/Scanner count Home positioning error code of the CIS unit/Home positioning detection log data (See Function code 80. Refer to Section 1.4.31 in this chapter.) Purge count/Wiper count/Flushing count Purge count by purge type (automatic/manual) eIP: Engine setup purge count uIP: Initial purge count...
Page 347: Adjustment Of Touch Panel (Function Code 78)
NOTE: The adjustment procedure requires a stylus with a thin tip. A commercially available stylus designed for electronic dictionaries or personal digital assistance (PDA) can be used. If you do not have it on hand, order the "TOUCH PEN" from the Brother’s parts list. Operating Procedure (1) Press the 7 and 8 keys in this order in the initial stage of the maintenance mode.
Page 348 After the fifth symbol (center) is pressed, the "OK" appears if the adjustment is normally completed. After approx. three seconds, the machine returns to the initial stage of the maintenance mode. NOTE: If the touch panel is improperly pressed or a wrong point is pressed, the "NG" appears on the LCD.
Page 349: Display Of The Equipment's Log (Function Code 80) (User-Accessible)
1.4.31 Display of the Equipment's Log (Function code 80) (User-accessible) Function The machine can display its log information on the LCD. Operating Procedure (1) Press the 8 and 0 keys in this order in the initial stage of the maintenance mode. The calendar clock appears on the LCD.
Page 350 Ink cartridge change count (High-yield, black ink cartridge) INK CH4 BK: (The BK/YL/CY/MZ on the LCD indicate the slot positions in the ink refill ASSY.) Ink cartridge detection failure count, indicating how many times an CHGMISS_BK: undetectable cartridge has been inserted Total printed page count, indicating how many pages have been printed PAGE: since the machine was produced...
Page 351 Exit key. The machine returns to the initial stage of the maintenance mode. With the PictBridge information being displayed, pressing the OK key cycles through the following items. PictBridge information PICTBRIDGE: Vendor name BROTHER Model name ***-***** Profile version/DPS version (not required for servicing) **/** PictBridge serial number (not required for servicing)
Page 352 With the page information being displayed, pressing the OK key cycles through the following items. Total printed page count, indicating how many pages have been printed PAGE: since the machine was produced Total number of printed pages (in monochrome) TOTAL_BK Total number of printed pages (in color) TOTAL_CL Number of printed A3-/Ledger pages (in monochrome)
Page 353 Normal purge count (automatic/manual) User reset purge count (automatic/manual) RP3_ Power reset purge count (automatic/manual) Power purge count (automatic/manual) QPP_ Periodical flushing count (only after printing in color) t_FLS With a machine error code being displayed, pressing the OK key cycles through recent nine errors that have occurred.
Page 354: Equipment Error Code Indication (Function Code 82) (User-Accessible)
1.4.32 Equipment Error Code Indication (Function code 82) (User-accessible) Function This function displays an error code of the last error on the LCD. Operating Procedure (1) Press the 8 and 2 keys in this order in the initial stage of the maintenance mode. The LCD shows the "MACHINE ERROR X X."...
Page 355 (7) Press the Stop/Exit key to return the machine to the initial stage of the maintenance mode. Notes: • To cancel this operation and return the machine to the initial stage of the maintenance mode during the above procedure, press the Stop/Exit key. •...
Page 356 • Selectors 3 and 4: Protection of platen from no-paper printing to prevent stains (Functional restriction on the paper width sensor) The setting made by these selectors applies to such printing that is assumed to be at a high resolution, that is, printing from a PC or memory card, copying, and printing via PictBridge.
Page 357 • Selectors 3 to 5: Paper feed amount compensation (for preventing banding at the leading edge of recording paper fed from the photo tray) This compensation function is usually enabled for preventing banding (horizontal streaks) from occurring at the leading edge of recording paper fed from the photo tray. When postcards or small size paper are fed from the standard paper tray, however, this compensation function can be counterproductive.
Page 358 AMS03 (Maintenance assurance 1) Selector Function Setting and Specifications 0: Disable (default) 1: Enable Protection of head caps from drying No. 2 3 0 0 : 30 seconds (default) 0 1 : 5 seconds Auto capping start time 1 0 : 15 seconds 1 1 : 300 seconds Purge more powerful than normal 0: Disable (default)
Page 359 AMS04 (Maintenance assurance 2) Selector Function Setting and Specifications Line monitor volume 0: Normal (default) 1: Extra-high Not used. 0: Printable with black ink only for a certain amount after detection of "Replace Ink" Black ink print mode 1: Printable with black ink only regardless of color ink remaining Automatic purging for color ink 0: Enable (default)
Page 360 • Selectors 6 and 7: Periodical purging intervals These selectors allow you to select the periodical purge interval to reduce ink consumption. Setting these selectors "0, 0" (Prescribed purge intervals) performs purging at the intervals prescribed below. Within 180 days from replacement of ink cartridges Periodical reset purge (black and color) at 60-day intervals Periodical suction purge (black) at 30-day intervals After 180 days from replacement of ink cartridges...
Page 361 • Selector 5: Jam reduction paper feed mode Setting this selector to "1" lowers the paper feeding speed when the recording paper passes along the star wheels for reduction of jams. • Selectors 6 through 8: Adjustment of print head drive voltage rank This selector regulates the print head drive voltage rank for adjusting the ink drop amount.
Page 362: Other Service Functions
OTHER SERVICE FUNCTIONS Cancellation of the Pin TX Lock Mode (Not applicable to Japanese and U.S.A. models) Function This procedure cancels the Pin TX lock mode. Use this procedure if the user forgets his/her password entered when setting the Pin TX lock mode so as not to exit from the mode. Note: Carrying out this procedure loses passwords previously entered but retains FAX messages received in the Pin TX lock mode.
Page 363: Retrieving The Equipment Log Information
Retrieving the Equipment Log Information Function This procedure retrieves the log information from the machine to the connected PC as electronic data. Operating Procedure (1) Make sure that the power cord of the machine is unplugged from an electrical outlet. If the machine is connected to a PC, disconnect the USB cable.
Page 364: Chapter 6 Circuit Diagrams And Wiring Diagrams
CHAPTER 6 CIRCUIT DIAGRAMS AND WIRING DIAGRAMS MJ PCB U.S.A., Canadian, Asian, and Oceanian models @JW2 Line MAIN RCH-855 332K SDAA RCH-855 332K MJ-64J-RD315K(LF) DL-6503C 1 La TRF250-183 2 Lb C682 50VDC C153 (1608) 50VDC (1608) TRF250-183 DL-6503C C153 C473 @CN3 50VDC 50VDC...
Page 365 MJ PCB European models @JW2 Line MAIN RCH-855 332K SDAA RCH-855 332K MJ-64J-RD315K(LF) DL-6503C 1 La TRF250-183 2 Lb C682 50VDC C153 (1608) 50VDC (1608) TRF250-183 DL-6503C C153 C473 @CN3 50VDC 50VDC (1608) (1608) RA-242M-C6 RA-242M-C6 0 (1608) FG1 FG2 DL-6503C 52830-6245(LF) RELAY...
Page 366 MJ PCB S. African models @JW2 Line MAIN RCH-855 332K SDAA MJ-64J-RD315K(LF) DL-6503C 1 La TRF250-183 2 Lb C682 50VDC C153 (1608) 50VDC (1608) TRF250-183 DL-6503C C473 C153 @CN3 50VDC 50VDC (1608) (1608) RA-242M-C6 RA-242M-C6 0 (1608) FG1 FG2 DL-6503C 52830-6245(LF) RELAY @CN2a...
Page 367 Power supply PCB, 100 V series Confidential...
Page 368 Power supply PCB, 200 V series Confidential...
Page 369 Wiring diagrams Confidential...
Page 370: Appendix 1 Serial Numbering System
APPENDIX 1. SERIAL NUMBERING SYSTEM This appendix shows the location of labels put on some parts and describes the coding information for serial number and head property data. Reading Labels An individual machine has a "serial number label" for the machine itself and "property labels" for the head/carriage unit.
Page 371 (2) Head property labels The property code of the head/carriage unit is printed on head property labels--bar code label and QR code label, each of which is attached to the lower cover and the head/carriage unit, respectively. On the lower cover Head property code ALR7795500000 Production lot number...
Page 372: Appendix 2 Deletion Of User Setting Information
APPENDIX 2. DELETION OF USER SETTING INFORMATION This appendix provides instructions on how to delete user setting information recorded in the machine. A2.1 Deleting User Setting Info from the Machine The following user setting information in the machine is recorded in the EEPROM on the main PCB.
Page 373: Appendix 3 Installing The Maintenance Printer Driver
NOTE: Once this installation procedure is carried out for a PC, no more driver/software installation will be required for that PC to identify machines. If the Brother Maintenance USB Printer driver has been already installed to your PC according to this procedure, skip this section.
Page 374 (7) Select "Install the software automatically (Recommended)" and click Next. (8) Alert warning message of WHQL appears. Click Continue Anyway to proceed. Confidential App. 3-2...
Page 375 (9) Repeat steps (6) to (8) three times to complete installation. (10) If the Brother Maintenance USB Printer driver is successfully installed, the following message screen appears. Click Finish to return. Confidential App. 3-3...
Page 376 NOTE: In order to check whether the printer driver is successfully installed, click Start | Settings | Printers to select the Printers window. Then, check that the Brother Maintenance USB Printer icon is shown. Confidential App. 3-4...
Page 377 Disconnect the USB cable that connects the machine with your PC. (2) Turn on your PC. (3) Click the Setup.exe in the Brother Maintenance USB Printer held in an arbitrary folder. (4) Wait for the following screen to appear and click Next.
Page 378 (5) Wait for the following screen to appear and click Finish. (6) Plug the power cord of the machine into an electrical outlet. (7) Switch the machine to the maintenance mode. (Refer to Chapter (8) Connect the machine to your PC using a USB cable. The following window is displayed during installation.

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Brother DCPJ525W Service Manual

Table of Contents

Chapter 1 Specifications

Chapter 2 Error Indication and Troubleshooting

3 Error Indication

Chapter 3 Disassembly and Assembly

Chapter 4 Adjustments and Updating of Settings, Required after Parts Replacement

Chapter 5 Service Functions

CHAPTER 6 Circuit Diagrams and Wiring Diagrams

Appendix 1 Serial Numbering System

Appendix 2 Deletion of User Setting Information

Appendix 3 Installing the Maintenance Printer Driver

Quick Links

SERVICE MANUAL

Chapters

Troubleshooting

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Summary of Contents for Brother DCPJ525W