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Table Of Contents - Brother MFC640CW Service Manual

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User manual (235 pages)

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Quick setup manual (45 pages)

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Repair instructions (5 pages)

Table Of Contents

Table of Contents

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Table of Contents

Service Manual1

How This Manual Is Organized3

Safety Precautions6

To Use The Machine Safely6

Choosing A Location8

Parts Names & Functions9

Control Panel13

Message Center Keys15

Telephone Keys15

Fax Resolution16

Navigation Keys16

Copy Keys (Temporary Settings)17

Ink Management18

Liquid Crystal Display18

Specifications20

Table Of Contents21

General Specifications22

Dimensions (W X D X H)23

Paper Specifications24

Recommended Paper24

Brother Paper24

Paper Type And Size For Each Operation24

Paper Weight, Thickness And Capacity25

Paper Capacity Of The Output Paper Support25

Printable Area27

Unprintable Area27

Specifications List28

Theory Of Operation37

Chapter 3 Theory Of Operation38

Mechanical Components40

Scanner Mechanism41

Printing Mechanism41

Adf Scanning: Document Moves Across Stationary Cis Unit44

Flat-Bed Scanning: Cis Unit Moves Under Stationary Document44

Cis Drive Mechanism44

Paper Pulling-In, Registration, Feeding And Ejecting Mechanisms45

Paper Stop Position Control47

Fixed-Speed Paper Feed47

Paper Feeding Amount Control47

Ink Supply And Ink Jet Mechanism48

3 ] Head/Carriage Unit50

Front End Components And Their Main Roles51

Nozzle Array (Head Bottom Plate)51

Ink Spray Function51

Piezoelectric Plate51

Back End Components And Their Main Roles53

Damper Assembly53

Air Vent Unit53

Color Dampers54

Air Buffering54

Air Bubble Growth55

What's So Bad About Air Bubble Growth?56

Ink Cartridge Features57

4 ] Ink Cartridges57

Ink Cartridge Components And Their Main Roles58

5 ] Ink Refill Assembly59

Ink Refill Assembly Components And Their Main Roles60

Ink Refill Base60

Cartridge Clamp Springs60

Ink Cartridge Sensors60

6 ] Ink Supply Tubes61

Head Maintenance Mechanism62

Pump Switching Unit62

1 ] Maintenance Mechanism Components62

2 ] Maintenance Unit Components62

Planetary Arm63

3 ] Head Capping Mechanism64

Gears Between Paper Feed Motor And Maintenance Unit65

4 ] Purge Mechanism65

Switching Arm Assembly Inside Maintenance Unit67

Purge Cam Mechanism67

Carriage Lock68

Switching Pump69

Purge Types, Ink Used, Purge Counts, And Purge Trigger Keys71

Ink Cartridge Capacities72

Ink Cartridge Lifetimes72

Carriage Drive Mechanism73

Adjusting Print Head Angle Relative To Carriage74

Viewed From The Bottom74

Sensors And Actuators75

Control Electronics78

Transfer Of Data Left In The Machine To Be Sent For Repair80

Transferring Received Fax Data82

Cover Page Sample84

End Page Sample84

Disassembly/Reassembly And Lubrication85

Disassembly/Reassembly87

Tightening Torque88

How To Access The Target Component89

Removing The Handset Mount89

Setting The Handset Mount Back Into Place89

Disassembly Flowchart90

Draining The Ink From The Ink Tubes91

Jam Clear Cover93

Scanner Cover (Scanner Unit)94

Release The Grounding Wire By Removing The Screw96

Reassembling Notes99

Adf & Document Cover Assy100

Disassembly Of The Adf & Document Cover Assy101

Adf Cover Assy101

Document Stopper And Document Ejection Films103

Separating The Document Cover And The Adf Unit103

Document Guides (F And R)104

Document Front And Rear Sensor Actuators105

Adf Motor And Document Feed Roller106

Document Front And Rear Sensors107

Document Pull-In Roller107

Document Separation Roller107

Control Panel Assy And Scanner Open Sensor Actuator109

Disassembly Of The Control Panel Assy110

Center Panel Assy And Color Lcd (Mfc820Cw)113

Warp The Cable Protection Plate And Release It From The Color Lcd114

When Mounting The Upper Cover116

Hook Switch Actuator And Hook Switch Pcb (Mfc640Cw)117

Head/Carriage Unit119

Removing The Head Cover120

Removing The Carriage Pcb And Head Flat Cables121

Removing The Head Joint123

Removing The Head/Carriage Unit And Cr Timing Belt124

Backup Battery (Mfc640Cw/820Cw)128

Ink Refill Assy130

Media Module Cover, Main Pcb, And Wlan Pcb131

Mj/Ps Shield Box, Mj Pcb* And Power Supply Pcb136

Ink Absorber Box138

Engine Unit And Maintenance Unit140

Removing The Engine Unit140

Removing The Maintenance Unit And Related Parts141

Components On The Engine Unit142

Removing The Cr Encoder Strip142

Removing The Paper Pull-In Gear Shaft And Roller Holder143

Removing The Paper Ejection Roller144

Removing The Platen145

Removing The Star Wheel Holder Assy146

Removing The Paper Pressure Holder And Registration Sensor Actuator147

Removing The Carriage Motor151

Removing The Pf Sensor Pcb152

Routing Of The Harnesses And Flat Cables155

Routing B: Adf Harness On The Adf Unit155

Routing D: Backup Battery Harness And Ink Supply Tubes157

Routing E: Harnesses, Flat Cables And Ink Tubes On The Lower Cover158

Routing F: Mj-Main Harness And Mj-Line Harness Through Sdaa Enclosure160

Document Pull-In Roller And Document Separation Roller162

Adjustments And Updating Of Settings163

Required After Parts Replacement163

Requirements166

Executables / Files Required For Adjustments And Updating Of Settings166

Spare Parts/Supplies Required For Adjustments/Updating Of Settings166

Loading The Update Programs/Data To The Machine167

If You Replace The Head/Carriage Unit Or Engine Unit171

1 ] Update The Head Property Information Stored In The Eeprom171

On The Main Pcb173

2 ] Clean The New Head/Carriage Unit174

3 ] Correct The Positioning Error Of The Head/Carriage Unit175

4 ] Update The Paper Feeding Correction Value177

5 ] Align Vertical Print Lines180

6 ] Margin Adjustment In Near-Edge Printing182

7 ] Print Out A Test Pattern185

8 ] Switch Back To Standby185

9 ] Replace The Ink Cartridges With Protective Ones185

If You Replace The Main Pcb186

1 ] Load Update Programs/Data186

2 ] Initialize The Eeprom On The Main Pcb (Function Code 01)186

3 ] Customize The Eeprom On The Main Pcb (Function Code 74)187

4 ] Check The Control Panel Pcb For Normal Operation (Function Code 13)187

5 ] Make A Sensor Operational Check (Function Code 32)187

6 ] Acquire White Level Data And Set The Cis Scanner Area (Function Code 55)187

7 ] Set An Id Code And Update The Head Property Information187

8 ] Update The Paper Feeding Correction Value190

9 ] Align Vertical Print Lines190

10 ] Margin Adjustment In Near-Edge Printing190

11 ] Adjust The Light Intensity Of The Lcd Backlight190

12 ] Specify The Cis Type (Function Code 59)190

13 ] Switch Back To Standby190

If You Replace The Ink Absorber Box191

If You Replace The Control Panel Pcb192

If You Replace The Scanner Cover192

Scanner Unit192

Cleaning The Maintenance Unit195

Maintenance Mode196

Entry Into The Maintenance Mode199

List Of Maintenance-Mode Functions200

User-Access To The Maintenance Mode201

Detailed Description Of Maintenance-Mode Functions203

Eeprom Parameter Initialization (Function Code 01, 91)203

Printout Of Scanning Compensation Data (Function Code 05)204

Test Pattern (Function Code 09)206

Print Quality Check207

Firmware Switches (Wsw01 Through Wsw51)208

Firmware Switch Setting And Printout (Function Codes 10 And 11)208

Operating Procedure209

Details Of Firmware Switches210

Printout Of Firmware Switch Data211

Operational Check Of Lcd (Function Code 12)213

Checking The Display State Of The Lcd213

Adjusting The Light Intensity Of The Backlight214

Operational Check Of Control Panel Pcb (Function Code 13)215

Sensor Operational Check (Function Code 32)217

To Check The Number Of Received Files219

To Transfer The Activity Report Only219

To Transfer The Communication List For The Latest Communication219

Transfer Of Received Fax Data And/Or Equipment's Log (Function Code 53)219

Fine Adjustment Of Scanning Start/End Position (Function Code 54)221

Acquisition Of White Level Data And Cis Scanner Area Setting (Function Code 55)222

Updating Of Paper Feeding Correction Value (Function Code 58)223

Specifying Of Cis Type (Function Code 59)227

Specify The Cis Type228

Travel Check Of The Head/Carriage Unit And Initial Setup Mode (Function Code 63)229

Alignment Of Vertical Print Lines In Monochrome (Function Code 65)230

Vertical Alignment Check Patterns232

Margin Adjustment In Near-Edge Printing (Function Code 66)233

Margin Check Pattern235

Updating Of Property Data (Function Code 68)236

Head/Carriage Unit Traveling Speed Check (Function Code 69)238

Eeprom Customizing (Function Code 74)239

Travel Of Head/Carriage Unit (For Recovery From Paper Jam Caused At Maintenance Unit) (Function Code 75)240

Purging Operation (Function Code 76)241

Resetting Purge Or Flushing Counter243

Display Of The Equipment's Log (Function Code 80)244

Equipment Error Code Indication (Function Code 82)247

Output Of Transmission Log To The Telephone Line (Function Code 87) (Not Applicable To Dcp340Cw)247

Cancellation Of The Pin Tx Lock Mode (Not Applicable To U.s.a. Models Or Dcp340Cw)248

Error Indication And Troubleshooting249

Error Indication252

Equipment Errors252

1 ] Error Messages Appearing On The Lcd252

2 ] Error Codes Contained In "Machine Error X X" Messages256

Communications Errors270

Definition Of Error Codes On The Communications List271

Command Reception271

Compatibility [Checking The Nsf And Dis]272

Instructions Received From The Remote Terminal273

Dcn Reception274

Tcf Transmission/Reception274

Signal Isolation275

Video Signal Reception275

General Communications-Related276

Checking Prior To Troubleshooting277

Environmental Conditions277

Introduction277

Recording Paper278

Troubleshooting Based On Problem Type279

1 ] Control Panel Problems279

2 ] Telephone Problems279

3 ] Communications Problems280

4 ] Paper/Document Feeding Problems280

Examples Of Defective Images281

5 ] Print-Image Problems281

Completely Blank282

Random Color282

Straight Or Blurred Vertical Stripes283

Print Edges Not Aligned284

Random Missing Dots284

White Horizontal Streaks285

Stained Leading Edge Of Recording Paper285

Overlapping Or Separated Lines Over The Whole Page285

6 ] Pc-Driven Printing Problems286

7 ] Memory Card Driven Printing (Smartmedia, Compact Flash, Memory Stick, Sd Card, Or Xd)286

8 ] Wireless Lan (Wlan)287

Problems Encountered Frequently In The Past288

Problems Due To The User's Actions288

Problems Due To Machine Malfunction288

1 ] Paper Jams288

2 ] "Machine Error 41" Error Message289

3 ] Ink-Related Problems289

4 ] Auto Document Feeder (Adf) Malfunction290

Possible Component Defects And Resulting Problems292

1 ] Adf Mechanism292

Cis Flat Cable293

Scanner Drive Unit293

2 ] Scanner Mechanism293

3 ] Head/Carriage Unit Drive And Purge Mechanisms294

4 ] Print Head Mechanism295

Pf Encoder Disk296

5 ] Asf Mechanism296

6 ] Paper Feeding Mechanism296

8 ] Control Panel297

10 ] Adjustments/Data In The Memories298

Serial Numbering System300

Head Property Label302

Property Label For The Head/Carriage Unit302

Serial Number Label For Ink Cartridge's303

Firmware Installation304

Loading The Update Programs/Data To The Flash Rom305

Installing The Bhl2-Maintenance Printer Driver305

Loading The Update Programs/Data Onto The Flash Rom Of Machine309

After Replacing The Main Pcb With A New One309

Customizing Codes According To Shipping Destination313

Eeprom Customizing Codes314

Firmware Switches (Wsw)315

Selectors 1 And 2: Dial Pulse Generation Mode317

Selectors 3 And 4: Break Time Length In Pulse Dialing317

Selectors 5 And 6: Inter-Digit Pause317

Switching Between Pulse (Dp) And Tone (Pb) Dialing, By Function Switch318

Default Dialing Mode, Pulse (Dp) Or Tone (Pb) Dialing318

Tone Signal Transmission Time Length And Min. Pause In Tone Dialing318

Attenuator For Pseudo Ring Backtone To The Line318

Cng Detection When Sharing Modular Wall Socket With A Telephone319

Detection Time Length Of Pabx Dial Tone, Required For Starting Dialing319

Dial Tone Detection In Pabx320

Earth Function In Transfer Facility (Not Used.)320

Dual Tone Detection Frequency In Icm Recording320

Dual Tone Detection Sensitivity In Icm Recording321

1St Dial Tone Detection322

Max. Pause Time Allowable For Remote Id Code Detection322

Busy Tone Detection In Automatic Sending Mode322

Busy Tone Detection In Automatic Receiving Mode322

Selectors 4 Through 6: Detection Of International Tone324

No. Of 2Nd Dial Tone Detection Cycles324

Allowable Instantaneous Interrupt During Reception Of 2Nd Dial Tone324

Dial Tone Frequency Band Control325

Line Current Detection (Not Used.)325

Allowable Instantaneous Interrupt During Reception Of 1St Dial Tone325

1St Dial Tone Detection Time Length326

Time-Out Length For 1St And 2Nd Dial Tone Detection326

Frame Length Selection327

Use Of Non-Standard Commands327

Time Length From Transmission Of The Last Dial Digit To Cml On328

Time Length From Cml On To Cng Transmission328

Time Length From Cml On To Ced Transmission328

Selectors 1 And 2: Busy Tone Frequency Band Control329

Selectors 3 Through 8: On/Off Time Length Ranges For Busy Tone329

Line Connection Timing330

Selectors 1 And 2: Cable Equalizer331

Selectors 3 And 4: Reception Level331

Selectors 5 Through 8: Modem Attenuator331

Frequency Band Selection For Incoming Calling Signal (Ci)332

Selectors 5 Through 8: No. Of Rings In Auto Ans Mode332

Selectors 1 Through 6: Redial Interval And No. Of Redialings333

Itu-T (Ccitt) Superfine Recommendation334

Max. Document Length Limitation334

Stop Key Pressed During Reception334

Selectors 1 And 2: Off-Hook Alarm335

Calendar Clock Type335

Non-Ring Reception335

Selectors 2 And 3: Detection Enabled Time For Cng Or No Tone336

Registration Of Station Id336

Selectors 7 And 8: Tone Sound Monitoring336

First And Last Choices Of Transmission Speed For Fallback337

Ep Tone Prefix338

Selectors 2 And 3: Overseas Communications Mode338

Selectors 8: Limitation On Cng Detection339

Selectors 1 Through 5: Max. Waiting Time For Voice Signal339

Selectors 6 And 7: Taping The Call339

Call Waiting Caller Id340

Acceptable Tcf Bit Error Rate340

Starting Point Of Training Check (Tcf)341

Selectors 2 And 3: Allowable Training Error Rate341

Limitation Of Attenuation Level341

Selectors 1 And 2: Maximum Ogm Recording Time342

Attenuator For Playback Of Icm/Ogm To The Line342

Pause Between Paging Number And Pin343

Ringer Off Setting345

Automatic Playback Of Ogm When Switched To The Tad Mode345

Recording Quality345

Transmission Level Of Dtmf High-/Low-Band Frequency Signal346

Prompt Beep For Activity Report347

Dial Tone/Busy Tone Detection Level During Recording Of Icm348

Selectors 5 And 6: Default Resolution350

Selectors 7 And 8: Default Contrast350

Detection Threshold Level Of "No Tone" During Recording Of Icm351

Fax Receiving Speed To Be Kept Within Transmission Speed Limit To Pc351

Comfortable Noise Level351

Max. Detection Period Of Dial Tone/Busy Tone During Recording Of Icm353

Ecp Mode (Not Used.)354

Recovery From Inactive Pc Interface (Not Used.)354

Pc Power-Off Recognition Time (Not Used.)354

Printout Of Stored Image Data Of Unsent Document Onto Error Report355

Selectors 1 And 2: Setting Of The Equalizer356

Sending Level Of Guard Tone At Phase 2356

Stepping Down The Transmission Speed At Fallback Each356

Selectors 3 Through 8: Masking Of Symbol Rate(S)358

Effective Time Length Of The White Level Compensation Data Obtained362

Standby Position Of The Cis Unit (Not Used.)363

Monitoring The Pc On/Off State364

Parallel Port Output Pins Kept At High Level (Not Used.)364

Previous Filtering Parameters For White Level Compensation (Not Used.)364

Handling Paper At The Occurrence Of A Paper Feed Timing Error365

Selectors 6 Through 8: Usb Setup Latency366

Selectors 4 And 5: Command Flag Detection Time366

Current Control To Be Applied Immediately After Connection Of The Line367

Selector 2: Cr Motor Control For Reducing Torque Fluctuation368

Switching From Ink Near-Empty To Ink Empty When Opening Scanner Cover368

Wiring Diagrams370

Mfc640Cw/Dcp340Cw371

Circuit Diagrams373

Power Supply Pcb376

Viewing The Event Log File378

Bh3 Installation Log File379

System Information379

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Troubleshooting

This manual is also suitable for:

Dcp340cw Mfc820cw