Page 2 COPYRIGHT © 1997 CANON INC. Printed in Japan Imprimé au Japon Use of this manual should be strictly supervised to avoid disclosure of confidential information. Prepared by PERIPHERAL PRODUCTS QUALITY ADVANCEMENT DIV. PERIPHERAL PRODUCTS TECHNICAL DOCUMENTATION DEPT. CANON INC. 5-1, Hakusan 7-chome, Toride-City, Ibaraki-Pref. 302, Japan...
Page 3: Service Information
DEC. 12,1997 LOCATION SUBJECT Revision of Service Manual Canon has published a revised version of LBP-2460 Service Manual (RY8-1383-000). Revision 1 (RY8-1383-010) includes supplementary materials as well as corrections, so please use it in place of the original. RY8-1383-01Y Printed in Japan...
Page 5: Chapter 1 Product Information
PREFACE This Service Manual contains basic information required for after-sales service of the LBP-2460 laser beam printer (hereinafter referred to as the "printer"). This information is vital to the service technician in maintaining the high print quality and performance of the printer. The 2,000-sheet paper deck, option controller, envelope feeder, and duplexing unit, which are prepared for the printer as options, are also described in this manual.
Page 6 All graphics were produced with Aldus FreeHand (J), and all documents and page layouts were created with QuarkXPress (J). The video images were captured with Canon Hi-8 8mm video camcorder and MASS microsystems Quickimage 24 video capture board, and modified with Adobe Photoshop (J).
Page 7: Table Of Contents
CONTENTS CHAPTER 1 PRODUCT INFORMATION FEATURES ........1-1 VI. MAINTENANCE AND SPECIFICATIONS......1-3 SERVICING BY THE III. SAFETY INFORMATION ..1-7 CUSTOMER ........1-23 IV. PARTS OF THE PRINTER ....1-8 VII. OPERATION ........1-25 INSTALLATION ....... 1-14 CHAPTER 2 OPERATION AND TIMING BASIC OPERATION ......
Page 8 CHAPTER 3 THE MECHANICAL SYSTEM EXTERNALS ........3-1 SYSTEM ..........3-22 A. External Covers ......3-1 A. EP-W Cartridge ......3-22 B. Fans ..........3-6 B. Transfer Charging Roller ... 3-23 C. Operation Panel Unit ....3-9 VI. FIXING SYSTEM ......3-24 DRIVE SYSTEM .......
Page 9 TROUBLESHOOTING ....4-47 C. Cassette Paper-size Sensing A. Paper Jams ........4-47 Switch PCB ........4-70 B. Incomplete Paper Feed ....4-51 D. High-voltage Power VIII. LOCATION OF ELECTRICAL Supply PCB ........4-71 PARTS/FUNCTION ......4-54 E. Video Controller PCB ....4-72 A.
Page 11 CHAPTER 1 PRODUCT INFORMATION FEATURES ........1-1 VI. MAINTENANCE AND SPECIFICATIONS ......1-3 SERVICING BY THE III. SAFETY INFORMATION ..1-7 CUSTOMER ........1-23 IV. PARTS OF THE PRINTER ....1-8 VII. OPERATION ........1-25 INSTALLATION ....... 1-14...
Page 13: Features
This printer supports Hewlett-Packard's enhanced PCL5 printer language. When the optional Canon Translator module A4(an add-in ROM) is installed, the printer also supports Adobe PostScript Level 2. The printer can sample the print data as it is received and then automatically switch between the PCL and PostScript personalities.
Page 14 CHAPTER 1 This page intentionally left blank 1 - 2...
Page 15: Specifications
CHAPTER 1 II. SPECIFICATIONS A. Printer 1. Printer engine Type Desktop page printer (console type when paper deck is installed) Printing method Electrophotography Printing speed (Note 1) About 24 pages/min. (A4) About 13 pages/min. (A3) First print time (Note 2) 18.9 sec. or less (A4) Wait time (Note 3) 80 sec.
Page 16 CHAPTER 1 Manual duplexing Plain paper (64g/m ~ 128g/m recommended paper) on multi-purpose (Note 4) tray Environment Temperature 10 - 32.5 Humidity 20 - 80% RH Air pressure 746 - 1013hPa (560 - 760mmHg) Power consumption Max. about 1.3kW or less (20 C room temperature, rated voltage) Noise level (Officially announced level based Sound power level (1B=10dB) 6.5B or less (printing)
Page 17 CHAPTER 1 2. Video Controller RISC processor (Intel A80960HD-66 66MHz) Memory (RAM) 4 MB (Expandable to 96 megabytes in total with optional RAM SIMM) ROM DIMM Slots RAM SIMM Slots Host interface Standard: IEEE1284 compliant parallel Option: Expansion interface (LocalTalk, Ethernet, Token Ring) Translators Standard: Enhanced PCL5 Option: Adobe PostScript Level 2...
Page 18 CHAPTER 1 B. Options 1. Envelope feeder (Envelope Feeder EF-9) Feeding speed About 16 envelopes/min. Envelope types COM-10, DL, Monarch, C5, B5 ISO-typed envelope (90g/m recommended paper) Capacity 73mm stack or 100 envelopes Dimensions 368 (W) x 320 (D) x 140 (H) mm Weight About 3kg Power supply...
Page 19: Safety Information
CHAPTER 1 III. SAFETY INFORMATION B. Toner Safety Composed of minute, plastic, colored A. Laser Safety components, toner is a non-poisonous An invisible laser beam is irradiated within substance. the laser/scanner unit. If toner adheres to your skin or clothes, Since the laser beam can injure the eye if remove as much of it as possible with a dry it strikes it, be sure not to disassemble the...
Page 20: Parts Of The Printer
CHAPTER 1 IV. PARTS OF THE PRINTER A. External Views 1. Printer 1: Operation panel unit 2: Face-down tray 3: Upper cover 4: Delivery stopper 5: Test print switch 6: Multi-purpose tray 7: Duplex unit door 8: Upper cassette 9: Lower cassette 10: Power switch 11: Delivery cover 12: Face-up tray...
Page 21 CHAPTER 1 2. Duplex unit 1: Duplexing feed roller 2: Duplex unit removal lever Figure 1-4-4 3. Envelope feeder 1: Envelope guide 2: Extension tray 3: Weight Figure 1-4-5 1 - 9...
Page 22 CHAPTER 1 4. Paper deck 1: Feed cover 2: Tray 3: Interface connectors 4: Power receptacle Figure 1-4-6 Figure 1-4-7 1 - 10...
Page 23 CHAPTER 1 B. Cross Sectional Views 1. Printer, Duplex unit 25 24 23 22 21 20 17 16 15 14 13 12 Figure 1-4-8 1: Delivery roller 14: Photosensitive drum 2: Laser/scanner unit 15: Primary charging roller 3: Developing cylinder 16: Lower cassette 4: EP-W cartridge 17: Upper cassette...
Page 24 CHAPTER 1 2. Envelope feeder Figure 1-4-9 1: Feed rollers 2: Separation guide 3: Separation rollers 4: Pick-up rollers 1 - 12...
Page 25 CHAPTER 1 3. Paper deck Figure 1-4-10 1: Deck 2: Paper guides 3: Pick-up roller 4: Feed roller 1 5: Feed roller 2 6: Registration rollers 7: Separation roller 1 - 13...
Page 26: Installation
CHAPTER 1 V. INSTALLATION A. Notes This printer is packaged and shipped from the factory after careful adjustments and rigorous inspections. When installing the printer, it is important to demonstrate its performance in the same way as when it passes the factory inspection. The service engineer must sufficiently understand the performance of the printer, install it correctly in a location with an appropriate environment, and conduct sufficient checks of the unit.
Page 27 CHAPTER 1 (Unit: mm) 2300 *When paper deck is installed to printer. Required space surrounding the printer with the paper deck installed (option) Figure 1-5-1 C. Unpacking and Installation Condensation will form on metal surfaces when brought into a warm room from the cold. Therefore, when moving the printer to a warm environment, leave it packed in its box for at least an hour to acclimatize to room temperature.
Page 28 CHAPTER 1 4. Duplex unit 1) Open the duplex unit packaging. 2) Take off the plastic bag and peel the tape off. 3) Remove the packing from the duplex unit. 4) Open the delivery cover on the printer. 5) Holding the duplex unit in both hands, install it into the printer. 5.
Page 29 CHAPTER 1 5) Insert the option controller as shown below. 6) Set the option controller with the 3 supplied screws. Screws Option controller Figure 1-5-3 7) Insert a connector. Connector Option controller Figure 1-5-4 8) Insert the PCB to the printer and tighten the 2 screws. 1 - 17...
Page 30 CHAPTER 1 6. Paper deck a. Opening the packaging 1) Open the paper deck packaging and remove the box. 2) Take out the accessories. Confirm that the power cord, manuals and interface cable are included. 3) Remove the top pads (left/right) and remove the paper deck from the box. 4) Take off the plastic bag surrounding the paper deck and peel off the tape holding the various parts.
Page 31 CHAPTER 1 Note: Be aware that connectors on the both ends of the interface connector differ in shape, 15-pin and 14-pin, as shown below. Figure 1-5-6 7) Plug the power cord into the paper deck and the outlet. 7. Operation confirmation 1) Load paper in the lower cassette.
Page 32 CHAPTER 1 D. Storing, Handling the EP-W Cartridge Whether the cartridge is still sealed in its box or installed in the printer, the effect of the natural environment will change it over time regardless of the number of prints. As the progression of this natural change depends on the storage or installation environment, take sufficient care in storing and handling the cartridges.
Page 33 CHAPTER 1 6) Do not leave cartridges near CRT displays, disk drives or floppy disks. 7) Store the cartridges out of reach of children. b. Effective life Cartridges are valid for 2.5 years following the date of manufacture, which is displayed in an abbreviated form on the cartridge.
Page 34 CHAPTER 1 Figure 1-5-8 Note: If light (1500 lux) is exposed to the drum for 5 minutes, and it is left in a dark area for 5 minutes, it will recover to a normal state and will be no effect on prints. However be sure to not expose it to direct sunlight.
Page 35: Maintenance And Servicing By The Customer
CHAPTER 1 VI. MAINTENANCE AND SERVICING BY THE CUSTOMER The customer should do the following maintenance to maximize printer performance. Table 1-6-1 Item Customer maintenance Cartridge Rock the cartridge to redistribute toner. If necessary relace it. Transfer guide When replacing the cartridge, clean the transfer guide area with the area soft dry cloth.
Page 36 CHAPTER 1 Table 1-6-2 Item Customer maintenance Registration roller When replacing the cartridge, clean the registration roller area with area the soft dry cloth. 1 - 24...
Page 37: Operation
CHAPTER 1 VII. OPERATION A. The Operation Panel The operation panel is used to perform basic printer operations, make printer configuration changes that software applications cannot control, identify available typefaces, and check the status of the printer. The operation panel consists of the status indication display, eight indicator lights, and seven menu and operation keys.
Page 38 CHAPTER 1 · ERROR indicator: 1 An error has occurred and printing has stopped. Check the display for a message describing the problem. Off: Operation is normal and there is no error. · POWER indicator: 2 The printer is ready to print. Flashing: The printer is warming up.
Page 39 CHAPTER 1 · ENTER key: 9 Saves a value you selected for an item in the menu. An asterisk (*) marks the value designated as the current default. · SHIFT key: 10 Press SHIFT and another key to access the alternate function of dual-function keys. The two functions on dual function keys are separated by a slash in the key name on the printer control panel.
Page 40 CHAPTER 1 Flashing: The printer is processig a print job. Do not turn the power off, otherwize you may lose print data. Off: The printer is off-line. You can now use the printer control panel keys to view and change settings.
Page 41 CHAPTER 1 B. Operation Panel Menus You can access the following menus though the operation panel: · PCL MENU · PS MENU (Note 1) · FEEDER MENU · CONFIG MENU · MEMCONFIG MENU (Note 1) · PARALLEL MENU · LOCALTALK MENU (Note 2) ·...
Page 42 CHAPTER 1 The reset menu function performs a printer reset to clear all fonts, macros, and page information but returns some of the menu settings to their original factory defaults. A cold reset clears the memory and restores all menu settings to their factory settings with the exception of the page count value, multi-purpose tray page size, envelope feeder size, and display language.
Page 43 CHAPTER 1 Menus Operation Flow At : Press : To move : MENU Forward Menu level SHIFT and MENU Back READY Press ON LINE key to take the printer off-line. ITEM Forward Item level SHIFT and ITEM Back Press ITEM key to select the item. +PLUS/-MENUs Forward Press ENTER key to select the value.
Page 44 CHAPTER 1 1 - 32...
Page 45: Operation And Timing
CHAPTER 2 OPERATION AND TIMING 1. This chapter describes the printer functions, the relationships between mechanisms and circuits, and the timing of operations. Mechanical linkages are indicated by black and white lines ( ), the flow of control signals by solid arrows ( ), and the flow of groups of signals by outline arrows ( 2.
Page 47: Basic Operation
CHAPTER 2 I. BASIC OPERATION A. Functions Printer functions can be divided into six groups: the engine control system, the laser/scanner unit, the image formation system, the paper pick-up/feed system, the overall control system, and the option control system. To external device (host computer, etc.) OPTION CONTROL SYSTEM Option controller PCB OVERALL CONTROL SYSTEM...
Page 48: Basic Operation Sequences
CHAPTER 2 B. Basic operation sequences Operation sequences of the printer are controlled by the microcomputer on the DC controller PCB. Descriptions of each period from ON until the main motor stops are as shown below. See the appendix for timing chart. Table 2-1-1 Period Purpose...
Page 49: Power On Sequences
CHAPTER 2 C. Power on sequences Sequences of the printer from power ON until it enters the standby mode are as shown below. Power ON CPU initialization /PPRDY signal output Duplexing unit connection Duplexing unit initialization Fixing heater ON Main motor, scanner motor, pick-up roller, registration roller, primary AC, transfer negative bias ON Development AC bias ON (Checks if the cartridge is installed and if there is...
Page 50: Engine Control System
CHAPTER 2 II. ENGINE CONTROL SYSTEM A. DC Controller circuit 1. Outline Operation sequences of the printer are controlled by the CPU of this circuit. When DC power is supplied from the power supply by turning ON the power switch of the printer and the printer enters the standby mode, the CPU outputs the signals that drive the loads such as laser diode, motors, and solenoids, based on the print start command and image data.
Page 51 CHAPTER 2 IC 201 IC 205 Gate array IC 203 Expansion I/O Figure 2-2-1 DC controller Serial line Envelope feeder IC 205 Gate array Video controller Serial line Serial line Serial line Duplex unit IC 201 Option controller IC 203 Expansion I/O Figure 2-2-2 2 - 5...
Page 52 CHAPTER 2 3. DC Controller Input/Output Signals DC controller PCB J11-3 J209-5 Registration P5VB3 paper /REGS "L" when the sensor detects pape sensor Pick-up PCB J1201-4 J219-18 J13-3 J1205-1 P5VBDOR P5VBDOR Pick-up unit paper sensor /FEEDS "L" when the sensor detects pape /FEEDS J14-3 J1206-1...
Page 53 CHAPTER 2 DC controller PCB Switch/sensor PCB PS1401 Face-down J1401-10 J205-7 tray paper full FDFULS "H" when the face-down tray is sensor fully loaded with paper. PS1402 Face-down tray delivery FDOUTS "H" when the sensor detects pape sensor PS1403 Fixing unit /FPOUTS "L"...
Page 54 CHAPTER 2 DC controller PCB Laser/scanner unit J1001-9 J202-1 The analog signal is output to adjust the LLCONT intensity of the laser beam. The voltage in proportion to intensity of Laser diode laser beam is input. /LENBL "L" to switch the laser on according to the /LON VDO signal.
Page 55 CHAPTER 2 DC controller PCB J12-1 J218-1 /MMRDY "L" when the main motor runs normally. /MMOTD "L" to run the main motor. -3/-4 -3/-4 Main motor +24VB -5/-6 -5/-6 "H" to rotate at high speed, "L" to J208-1 FAN1D rotate at low speed. Fixing unit/ /FAN1S "L"...
Page 56 CHAPTER 2 DC controller PCB Multi-purpose tray PCB +24VA J1302-2 J1301-2 J214-2 Lifting plate /MPTSLD "L" to drive the lifting plate. If the solenoid plate is up it will drop, if down it wi rise. J1303-2 Manual feed clutch /MTPCLD "L"...
Page 57: Fixing Control
CHAPTER 2 B. Fixing control 1. Fixing temperature control The upper fixing roller contains two heaters: fixing main heater (H1: 500W) and fixing sub heater (H2: 500W). The fixing main heater heats the center of the upper roller, and the fixing sub heater heats both ends of the upper roller.
Page 58 CHAPTER 2 Table 2-2-1 Target temperature (˚C) Normal temper- Initial warm-up temper- ature control ature control WAIT STBY 169 - 177 169 - 177 A3/A4/B4 size Cassette feed Legal size PRINT Other size Manual feed b. 220V model The fixing temperature is detected by the thermistor (TH1) on the surface of the upper fixing roller.
Page 59 CHAPTER 2 3. Fixing unit failure detection The CPU assumes a fixing unit failure in the following cases and reports it to the video controller. a. The rated voltage of the power supply is different to the rated voltage of the fixing roller heater.
Page 60 CHAPTER 2 DC controller PCB GATE ARRAY IC203 Fixing roller heater FSRTH Thermistor GNDT Thermoswitch Fixing J222-1 FSRTYP1 roller FSRTYP2 FSRTP1R FSRTP2R IC201 Low-voltage RL101 Safety circuit power supply circuit Current Current transformer transformer Power supply unit : 220-240V ONLY Figure 2-2-9 2 - 14...
Page 61 CHAPTER 2 3) Reports the fixing unit failure to the video controller. 4. Fixing roller heater start sequence The sequence of operations from the power ON to the standby is as follows: 1) The CPU outputs the fixing sub heater drive signal and then the fixing main heater drive signal to prevent the surge current from increasing after the power is turned ON.
Page 62 CHAPTER 2 5. Envelope position lever function This printer can adjust the nip width in two steps by changing the spring pressure of the lower fixing roller. If an envelope wrinkles after it is printed, set the envelope position lever to the envelope position.
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Page 64: High-Voltage Power Supply
CHAPTER 2 C. High-Voltage Power Supply [T702] J701-B5 /HV1FRQ AC Transformer Primary AC TB701 Drive Circuit Transformer To primary charging roller AC Current detection Circuit Primary DC J701-B7 /HVT1DCD Generation Circuit [T701] DC Transformer DC Transformer Drive Circuit Image Density J701-A6 DENADJ Adjustment...
Page 65 CHAPTER 2 1. Outline In response to the instruction from the microprocessor (CPU) on the DC controller PCB, the high-voltage power supply applies a voltage to the primary charging roller, developing cylinder, transfer charging roller, static charge eliminator, and upper fixing roller. It applies a voltage of DC voltage and AC voltage to the primary charging roller and developing cylinder, applies a positive or negative DC voltage to the transfer charging roller, and a negative DC voltage to the static charge eliminator and the upper fixing roller.
Page 66 CHAPTER 2 the circuit applies a high voltage output bias. The high voltage output bias is applied only at the trailing edge of a single side print and during the second side of a duplex print. e. Toner sensing/cartridge sensing The EP-W cartridge has a toner sensor.
Page 67: Power Supply
CHAPTER 2 D. Power Supply 1. Outline AC power is supplied to the low-voltage power supply when the main switch (SW101) is turned ON. The low-voltage power supply generates the required +24VDC and +5VD for the printer. +24VDC is supplied to the high-voltage power supply PCB to drive the main motor, scanner motor, and fans.
Page 68 CHAPTER 2 If the excess-current protection system is active and the power supply circuit does not output DC voltage, it is necessary to turn the power switch to OFF, correct the problem in the faulty load, then power the printer ON again. If excess-current flows through the AC line, the circuit breaker in the power supply turns OFF to cut off the output voltage.
Page 69: Video Interface Control
CHAPTER 2 E. Video Interface Control 1. Outline To connect the printer to an external device, such as a host computer, a video controller PCB (interface PCB) is needed. This section explains the kinds of interface signals exchanged between the printer and the video controller PCB, and gives information concerning the sequence of printer operation making use of interface signals.
Page 70 CHAPTER 2 b. Video interface signals Video controller DC controller /PPRDY /RDY /VSREQ /SBSY /STTS /PCLK /PDLV /PFED /SPCHG /CBSY /PRNT /VSYNC /CPRDY /CMND /CCLK /FPCS /FPO /FPI FPCK Figure 2-2-15 2 - 24...
Page 71 CHAPTER 2 2. Operation When the power is switched ON, the printer enters WAIT mode. At the end of the WAIT mode, the DC controller sends the READY signal (/RDY) to the video controller to inform it that printer is ready to print. When the /RDY signal is “L”...
Page 72: Laser/Scanner System
CHAPTER 2 III. LASER/SCANNER SYSTEM A. Outline External device Video controller PCB /VSYNC DC controller LLCONT /LON /LENBL PD /SCND /SCNRDY /BDI Cylindrical lens Laser driver Scanner motor BD mirror Mirror Scanning mirror Focusing lens BD PCB Photosensitive drum Figure 2-3-1 When the DC controller receives a print signal (/PRNT) from the video controller, the DC controller automatically stabilizes the intensity of the laser beam (automatic laser power control: See page 2-27).
Page 73: Laser Control Circuit
CHAPTER 2 B. Laser Control Circuit 1. Outline DC controller PCB Laser driver PCB IC201 LLCONT APC1 Analog J202-2 J1001-8 adder APC2 circuit Laser current IC205 setting circuit /LON J202-5 J1001-5 J201-C6 /PRNT /LENBL Gate J202-4 J1001-6 ADBUS array Switching DATA circuit J202-7 J1001-3...
Page 74 CHAPTER 2 a. Initial APC Initial APC is performed to increase the intensity of the laser beam from zero to near the target value during initial rotation, and to obtain the increase rate and between-page APC initial value. After the CPU sets the FORCED LASER ON signal (/LON) to “L”, the CPU changes the APC1 signal (rough adjustment) and lets the LLCONT signal gradually rise.
Page 75 CHAPTER 2 3 mm 3 mm Figure 2-3-3 Notes: 1. Indicates the area where the laser beam writes on the drum. 2. If no paper size is specified by the paper size specification command from the video controller during manual feed, the printer does not recognize the paper width. So the T1 and T2 values are assumed to be UNIVERSAL size (297.0mm 635.0mm), the maximum paper width for this printer.
Page 76: Scanning System
CHAPTER 2 C. Scanning System Figure 2-3-4 shows the scanner motor control circuit. DC controller PCB CPU (IC201) Gate array (IC205) +24VA J207-5 X202 J207-4 Gate array interface bus SCNCLK J207-3 SCNCK J201-C6 /PRNT P10/A0 /SCNRDY J207-1 Scanner NSRDY motor/ driver Extended I/O interface bus...
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Page 78: Image Formation System
CHAPTER 2 IV. IMAGE FORMATION SYSTEM A. Outline The image formation system is the central hub of the printer, and consists of the photosensitive drum, developing unit and charging roller etc. When the PRINT signal (/PRNT) is sent from the video controller to the DC controller, the DC controller drives the main motor to rotate the photosensitive drum with the laser diode, developing cylinder, primary charging roller, and transfer charging roller.
Page 79 CHAPTER 2 Laser beam Cartridge Primary charging roller Blade Developing cylinder Cleaning blade Manual feeding pick-up roller Upper fixing roller Photo- sensitive drum Transfer charging roller Static charge eliminator Lower fixing roller Upper cassette pick-up roller Lower cassette pick-up roller Transfer bias monitor signal (HVTS) Transfer negative bias drive signal (/HVTRVSD) Toner level signal (TONRS)
Page 80: Printing Process
CHAPTER 2 B. Printing Process A major portion of the image formation system is contained with a cartridge as shown in Figure 2-4-2. Laser beam Cartridge Primary charging roller Blade Cleaning blade Developing cylinder Photosensitive drum Transfer charging roller Static charge eliminator Figure 2-4-2 This printer's cartridge has a seamless photosensitive drum with a two-layer surface shown in Figure 2-4-3.
Page 81: Drum Cleaning Stage
CHAPTER 2 5. Drum cleaning stage Step 7 Drum cleaning Electrostatic latent image formation stage Paper path 2. Scanning exposure Direction of drum rotation 1. Primary charge 3. Develop- Developing stage ment Drum cleaning stage 7. Drum cleaning Fixing stage 5.
Page 82 CHAPTER 2 1. Electrostatic latent image formation stage This stage follows two steps to produce an electrostatic latent image on the photosensitive drum. At the end of the stage, negative charges remain on the unexposed “dark” areas, where the laser beam struck (exposed) the drum surface. This image of negative charges on the drum is invisible to the eye, so it is referred to as an called an “electrostatic latent image.”...
Page 83 CHAPTER 2 Step 2 Scanning exposure Laser beam Unexposed area Exposed area Figure 2-4-7 When the laser beam scans the drum surface, it causes the charge to be neutralized in the areas struck by the laser beam. These areas on the drum surface form the electrostatic latent image. 2.
Page 84 CHAPTER 2 As shown in Figure 2-4-8, the developing unit consists of a developing cylinder and a rubber blade. The developing cylinder rotates around a fixed internal magnet. The single-component toner consists of magnetite and a resin binder, and is held to the cylinder by magnetic attraction.
Page 85 CHAPTER 2 Reference: If the image on the photosensitive drum is not completely transferred onto the paper due to jamming, etc., the toner may adhere to the transfer charging roller. The printer removes the toner from the transfer charging roller by switching the transfer voltage between positive and negative in the specified sequence.
Page 86 CHAPTER 2 4. Fixing stage The toner image transferred onto the paper in the transfer stage is held only by electrostatic attraction and a slight physical adhesion, so even a light touch will smear the image. In the fixing stage, the toner image is fixed by heating the paper and applying pressure. This fuses the toner particles onto the paper to create a permanent image.
Page 87 CHAPTER 2 5. Drum cleaning stage In the transfer stage, not all the toner is transferred to the paper. Some remains on the photosensitive drum. This residual toner is cleaned off in the drum cleaning stage so that the next print image will be clear and distinct.
Page 88: Pick-Up/Feed System
CHAPTER 2 V. PICK-UP/FEED SYSTEM A. Outline Presence of paper on the multi-purpose tray is detected by the multi-purpose tray paper sensor (PS1301), and presence of paper in the upper and lower cassettes is detected by the cassette paper-out sensor (PS1207 or PS1208). If the cassette pick-up motor (SMT1) in the paper pick-up unit rotates for cassette feeding, pick-up roller, feed roller 1, and separation roller turn to feed a sheet of paper into the printer.
Page 89 CHAPTER 2 DC controller PCB 9 1 0 1 1 1 2 1 3 Pick-up PCB Multi-purpose tray PCB Switch/sensor PCB PS1401 PS1402 PS1403 PS1301 PS1302 PS1208 SW1601 PS1202 SW1602 SW1603 PS1205 SW1604 PS1206 PS1207 SW1601 SW1602 PS1201 SW1603 PS1203 SW1604 PS1204 : FACE-DOWN TRAY DELIVERY SENSE signal (FDOUTS)
Page 90 CHAPTER 2 DC controller PCB Multi-purpose tray PCB Switch/sensor PCB Pick-up PCB Face-down delivery roller Flapper Upper fixing Manual feeding Photosensitive roller Registration pick-up roller drum roller Face-up Fixing unit Lifting plate Feed delivery delivery roller Transfer Lower roller 2 roller charging fixing...
Page 91: Paper Pick-Up Unit
CHAPTER 2 B. Paper Pick-up Unit 1. Cassette feed Presence of the upper and lower cassettes is detected by the upper cassette sensor (PS1202) and lower cassette sensor (PS1201). The presence of paper is detected by the upper cassette paper- out sensor (PS1207) and lower cassette paper-out sensor (PS1208).
Page 92 CHAPTER 2 Pick-up unit Pick-up PCB Remaining Remaining number paper level of sheets (note) Almost full 430 sheetes or more High 200 - 490 sheetes 50 - 260 sheetes Almost empty 110 sheetes or less Note : Plain paper (75g/m recommended paper) PS1204 or PS1206 PS1203 or PS1205...
Page 93 CHAPTER 2 • Pick-up timing from the upper cassette (A4 : tow pages continuously print) Power switch ON (Unit: Seconds) STBY INTR PRINT LSTR STBY PRINT signal (/PRNT) VERTICAL SYNC signal (/VSYNC) Main motor (MT1) 0.06 Pick-up motor (SMT1) 1.97 Cassette pick-up solenoid (SL1) About 1.5 0.06...
Page 94 CHAPTER 2 a. Pick-up mechanism The printer raises the lifter and lowers the cassette pick-up roller to the paper surface enabling it to pick up paper. When either the upper or lower cassette is installed in the printer, the upper or lower lifter gear is engaged into drive gear, so that the lifter can be raised.
Page 95 CHAPTER 2 Cassette pick-up cam Cassette feed solenoid Cassette pick-up roller shaft Lower lifter Figure 2-5-7 2 - 49...
Page 96 CHAPTER 2 b. Multi-feed prevention mechanism When feeding from the cassette, the printer uses the separation roller to prevent multi-feeding. Normally, the separation roller is imparted with a rotational force opposite to that of the feed roller. However, since the separation roller is equipped with a torque limiter, it rotates with feed roller 1 by transmission of its rotational force via the transported paper.
Page 97 CHAPTER 2 2. Manual feed (multi-purpose tray) The presence of paper on the multi-purpose tray is detected by the multi-purpose tray paper sensor (PS1301). When the DC controller receives the /PRNT signal from the video controller, the lifting plate solenoid (SL2) turns on, the lifting plate is unlocked (the lifting plate rises), and the paper touches the pick-up roller.
Page 98 CHAPTER 2 • Pick-up timing from the munual feed (A4 : tow pages continuously print) Power switch ON (Unit: Seconds) STBY INTR PRINT LSTR STBY PRINT signal (/PRNT) VERTICAL SYNC signal (/VSYNC) Main motor (MT1) About1.1 Lifting plate solenoid (SL2) 0.55 0.27 0.03...
Page 99: Fixing And Delivery Unit
CHAPTER 2 C. Fixing and Delivery Unit The upper and lower rollers of the fixing unit, and the face-up and face-down delivery rollers are driven by the main motor (MT1). The paper separated from the photosensitive drum is fed into the fixing unit, and sent from the fixing unit by the fixing roller and fixing unit delivery roller.
Page 100 CHAPTER 2 The printer switches between face-up and face-down tray delivery with the face-up deflector. When the FACE-UP SOLENOID DRIVE signal (/FUSLD) becomes “L”, the face-up solenoid (SL3) moves the face-up deflector to the face-up tray and the paper is delivered through the face- up tray.
Page 101: Paper Jam Detection
CHAPTER 2 D. Paper Jam Detection The following paper sensors are provided to detect whether paper is present and whether the paper is fed normally. • Registration paper sensor (PS1) • Pick-up unit paper sensor (PS2) • Fixing unit delivery sensor (PS1403) •...
Page 102 CHAPTER 2 2. Pick-up unit delay jam The CPU detects a pick-up unit delay jam has occurred if the paper has not reached the registration paper sensor (PS1) within the prescribed time after the paper has been picked up. (Unit: Seconds) (Unit: Seconds) PRINT PRINT...
Page 103 CHAPTER 2 4. Fixing unit delivery stationary jam The CPU detects a pick-up unit stationary jam has occurred if the paper has not passed through the fixing unit delivery sensor (PS1403) within the prescribed time after the VERTICAL SYNC signal (/VSYNC) has been received. (Unit: Seconds) (Unit: Seconds) PRINT...
Page 104 CHAPTER 2 6. Face-down delivery stationary jam The CPU detects a face-down delivery stationary jam has occurred if the paper has not passed through the face-down tray delivery sensor (PS1402) within the prescribed time after the VERTICAL SYNC signal (/VSYNC) has been received. (Unit: Seconds) (Unit: Seconds) PRINT...
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Page 106: Overall Control System
CHAPTER 2 VI. OVERALL CONTROL SYSTEM A. Video Controller PCB 1. Outline The video controller PCB receives print data consisting of codes or image data from an external device (host computer, etc.) via the interface cable. The video controller PCB analyzes and processes the print data, including the items specified from the control panel, and converts it to dot data.
Page 107 CHAPTER 2 EEPROM ASIC Figure 2-6-1 2 - 61...
Page 108 CHAPTER 2 <J1/J2> <J9/J10> <J11> ROM DIMM Extension Hard disk 80960HD (4MB) CIOA Buffer Buffer Buffer Buffer EEPROM Option <J7> Controler Prarell I/F <J8> Buffer IEEE1284 <J9> Buffer Engine Buffer RAM SIMM <J3/J4/J5> (4MB) 3.3V DC/DC CONVERTER Figure 2-6-2 2 - 62...
Page 109: B. Control Panel
CHAPTER 2 B. Control Panel 1. Outline The control panel contains 7 LEDs, one LCD (liquid-crystal display), 9 switches, and one buzzer on the control panel. The control panel is connected to the video controller PCB, and has the following functions. a.
Page 110: Option Controller
CHAPTER 2 VII. OPTION CONTROL SYSTEM A. Option Controller 1. Outline To use the paper deck installed to the printer, the option controller needs to be attached to the printer. The option controller is a 16-bit microcomputer (CPU: IC101) that controls serial communication with the video controller and serial communication with the paper deck.
Page 111 CHAPTER 2 2. Explanation of main ICs a. CPU (IC101) An NEC 1-chip microcomputer (UPD784020GC-3B9) is used. The CPU communicates with the video controller and controls the optional paper deck. b. EP-ROM (IC109) The EP-ROM has a memory capacity of 64K bytes, and contains the control program for the paper deck's operation.
Page 112: Operation Outline
CHAPTER 2 B. Operation Outline DC Controller Video Controller Option Controller Paper deck driver Serial line Serial line (IC101) /VSYNC PWRON S-RAM /PDLV (IC110) /PFED RETURNBACK (GND) Figure 2-7-3 The video controller supplies a +5V power supply to the option controller when the printer power is turned ON, and communication between them commences after a specified period of time.
Page 113: Envelope Feeder
CHAPTER 2 VIII. ENVELOPE FEEDER A. Outline of the Electrical System The envelope feeder operation sequence is controlled by the DC controller in the printer. The DC controller outputs paper pick-up commands (1st start, 2nd start) to the envelope feeder driver at the appropriate timing via serial lines.
Page 114: Paper Pick-Up/Feed System
CHAPTER 2 B. Paper Pick-up/Feed System The envelope feeder motor is a stepping motor (SMT11) that rotates clockwise and counter-clock wise according to commands received from the envelope feeder driver. When the motor rotates clockwise, all rollers in the envelope feeder are rotated, however when rotated counter clock wise only the upper separation and feed rollers are rotated.
Page 115 CHAPTER 2 Power- ON (Unit: Seconds) STBY INTR PRINT LSTR STBY PRINT signal (/PRNT) VERTICAL SYNC signal (/VSYNC) Main motor (MT1) Forward Backward About 1.0 Envelope feeder pick-up motor (SMT11) About 1 About 0.1 About 1 About 2.7 Pick-up command 1st Start 2nd Start 1st Start...
Page 116: Paper Jam Detection
CHAPTER 2 As the friction between envelopes is weak when ened two or more envelopes are fed simultaneously (multi-feed), the rotating force of the lower roller is not strong enough to keep the upper roller rotating in its original direction. The upper roller therefore rotates in the opposite direction to the pick-up direction (shown by white arrows in figure 2-8-4 below) Any extra envelopes are returned to the feeder while only one is sent through into the printer.
Page 117: Duplexing Unit
CHAPTER 2 IX. DUPLEXING UNIT A. Outline of the Electrical System The operation sequences of the duplexing unit are controlled by the duplexing driver PCB. This PCB utilizes a 4 bit microcomputer (CPU, IC2002) to control the serial communication between the duplexing unit and the DC controller PCB in the printer.
Page 118: Duplexing Driver Input Signals
CHAPTER 2 B. Duplexing Driver Input Signals Duplexing driver PCB PS21 J20-3 J2008-1 +5VB Duplexing /DUPPS "L" when the sensor detects pape unit paper sensor PS23 J21-3 J2006-1 +5VB Side regist- HRHGS "H" when the sensor detects home ration guide position of the side registration home position guide.
Page 119: Duplexing Driver Output Signals
CHAPTER 2 C. Duplexing Driver Output Signals Duplexing driver PCB +24VA J2009-2 Switchback SL21 roller release /PRRESLD When "L", pressure is relased from solenoid the switchback roller. J2002-2 Duplex deflector SL22 solenoid /DUPSLD When "L", paper enters the duplexing unit. +24VA +24VA J2003-2...
Page 120: Paper Pick-Up/Feed System
CHAPTER 2 D. Paper Pick-up/Feed System 1. Outline Paper is guided through the duplexing unit by the duplex deflector to the switchback unit. The paper sent to the switchback unit is then fed back into the duplexing unit by reversing the direction of the paper feed of the switchback roller.
Page 121 CHAPTER 2 DC controller PCB Serial line Duplexing driver Fixing SL22 delivery Duplex Second-pass pick-up wait position roller deflector Fixing rollers SL21 Duplex feed Switchback Feed roller 2 roller 1 roller release PS23 PS22 PS24 plate PS21 Duplex Switchback lower roller guide Side registration...
Page 122 CHAPTER 2 2. Switchback System When the CPU receives commands sent from the printer to the duplexing unit, it turns the duplex deflector drive solenoid (SL22) ON, and the paper is sent into the duplexing unit. When the leading edge of the paper is detected by the switchback paper sensor (PS22) , the CPU rotates the switchback motor (SMT21) backwards (CCW) (*note) to feed the paper into the switchback unit.
Page 123 CHAPTER 2 3. Side Registration Adjustment System When duplex printing, the center of the horizontal scanning direction for the second time print is aligned with the center of the printable area on the drum with side registration adjustment. This adjustment is conducted directly after duplex feed roller 1 starts to rotate, to make sure that the edges of the page are aligned to the side registration guides.
Page 124 CHAPTER 2 4. Second Feed Pick-up System On completion of the side registration adjustment, the CPU turns ON the duplex feed clutch (CL21). The CPU turns OFF CL21 approx. 1.0 second (1.9 seconds for wide and narrow paper types) after detecting the leading edge of the paper at the duplexing unit paper sensor (PS21). The CPU then stops the paper at the second-pass pick-up wait position and waits for second-pass pick-up command to be input from the printer.
Page 125: Paper Jam Detection
CHAPTER 2 E. Paper Jam Detection The following paper sensors are installed to detect the presence of paper and that paper is being fed correctly. • duplexing unit paper sensor (PS21) • switchback paper sensor (PS22) Jams are detected by the CPU on the duplexing driver PCB by determining whether or not paper is at the appropriate sensor at the correct pre-set timing.
Page 126 CHAPTER 2 2. Switchback stationary jam When the paper has not passed through the switchback paper sensor (PS22) in the specified time after the duplexing pick-up process has begun, the CPU assesses that a switchback unit stationary jam has occurred. (Unit: Seconds) (Unit: Seconds) PRINT...
Page 127: Paper Deck
CHAPTER 2 X. PAPER DECK A. Outline The paper deck sends the paper to the printer, which subsequently prints and delivers the paper. The printer is controlled by various commands sent from the video controller, whereas the paper deck is controlled by commands sent from the option controller. The option controller also controls the other options (stapler stacker, etc.) via the paper deck.
Page 128: Outline Of The Electrical System
CHAPTER 2 B. Outline of the Electrical System The paper deck operation sequence is controlled by the paper deck driver PCB. The 8 bit CPU (IC201) in the paper deck driver PCB controls the operation sequence and serial communication with the option controller PCB. The paper deck driver drives the solenoid and motors etc.
Page 129: Paper Deck Driver Inputs
CHAPTER 2 C. Paper Deck Driver Inputs Paper deck driver PCB PS31 J107-3 J102-1 J101-10 J207-1 Registration REGI "L" when the sensor detects paper. paper sensor PS32 J108-3 J102-4 J101-7 J207-4 Paper jam "L" when the sensor detects paper. sensor PS33 J111-3 J110-1...
Page 130: Paper Deck Driver Outputs
CHAPTER 2 D. Paper Deck Driver Outputs Paper deck driver PCB J118-4 J204-3 DCMOT-RDY "L" when deck motor rotates normally. DCMOT-ON Deck motor is driven when "L". -5/-6 -1/-2 Deck motor MT31 +24V -1/-2 -5/-6 J117-1 J116-4 J205-1 FEDBND FEDBD Pick-up motor rotation control signal.
Page 131: Pick-Up/Feed System
CHAPTER 2 E. Pick-up/Feed System 1. Outline Presence of paper in the paper deck is detected by the tray paper-out sensor (PS33), and the remaining amount of paper is detected by outputs from the paper-level sensing switch 1 (SW601) and paper-level sensing switch 2 (SW602). The combination of the two paper-level sensing switches is shown in table 2-10-1.
Page 132 CHAPTER 2 Option controller PCB Serial line Paper deck driver PCB MT31 CL33 Feed roller 2 SMT31 CL31 SL31 CL32 Registration roller Pick-up roller MT31: Deck motor SMT31: Pick-up motor Feed SL31: Pick-up solenoid roller 1 CL31: Lifter clutch CL32: Registration clutch CL33: Feed clutch Lifter Separation...
Page 133 CHAPTER 2 Option controller PCB Serial line Paper deck driver PCB Feed roller 2 PS32 Registration roller Feed roller 1 PS34 PS33 SW31 PS31 SW701 Pick-up roller SW702 Separation SW703 roller SW704 SW601 SW602 PS31: Registration paper sensor Lifter PS32: Paper jam sensor PS33: Tray paper-out sensor PS34: Paper surface sensor SW31...
Page 134 CHAPTER 2 2. Pick-up/Feeding The paper deck driver drives the pick-up motor (SMT31) after receiving a pick-up command from the option controller. SMT31 rotates the pick-up, feed, and separation rollers. The paper deck driver simultaneously turns the feed clutch (CL33) and pick-up solenoid (SL31) ON, and rotates the pick-up cam.
Page 135 CHAPTER 2 (Unit: Seconds) PRINT Pick-up command About 0.51 Deck motor (MT31) Pick-up motor (SMT31) Pick-up solenoid (SL31) About 0.15 Registration clutch (CL32) Feed clutch (CL33) About 0.61 Registration paper sensor (PS31) About 1.18 Paper jam sensor (PS32) Figure 2-10-8 2 - 89...
Page 136 CHAPTER 2 3. Lifter Operation The lifter in the tray is strung by 4 wires. The wires are wound around the 4 pulleys when the deck motor is driven, to raise the lifter. When the tray is pulled out, the gear on the pulley and the motor gear are disengaged, and the lifter drops under its own weight.
Page 137 CHAPTER 2 SW31 PS34 PS34: Paper surface sensor SW31: Lifter abnormal position sensing switch Figure 2-10-10 2 - 91...
Page 138: Paper Jam Detection
CHAPTER 2 F. Paper Jam Detection The following paper sensors are installed to detect the presence of paper and ensure that the paper is fed correctly. • Registration paper sensor (PS31) • Paper jam sensor (PS32) The CPU determines whether or not a paper jam has occurred by monitoring the paper at each of the sensors according to the pre-set 'check timing' in the memory.
Page 139 CHAPTER 2 2. Feed unit delay jam If the paper has not reached the paper jam sensor (PS32) in the designated time after the registration clutch (CL32) is driven, the CPU assesses a feed unit delay jam. (Unit: Seconds) (Unit: Seconds) PRINT PRINT Registration clutch (CL32)
Page 140: Power Supply
CHAPTER 2 G. Power Supply 1. Outline This machine's power supply utilizes the remote switch method. When the printer is turned ON, the printer outputs commands to the option controller through the video controller. The option controller outputs a POWER ON signal (PWRON-IN) to the power supply through the paper deck driver to turn the power ON.
Page 141 CHAPTER 3 THE MECHANICAL SYSTEM This chapter describes mechanical operation as well as disassembly and reassembly procedures of the printer. Note the following precautions during disassembly or reassembly. 1. When you remove the EP cartridge, cover the cartridge with a cloth or put it in a dark place to prevent light from affecting the drum inside the cartridge.
Page 143: Externals
CHAPTER 3 I. EXTERNALS 1. Face-down tray 1) Open the upper cover. 2) Move the lock lever in the direction of A. External Covers the arrow. Upper cover Lock lever Delivery cover unit Upper cover unit Figure 3-1-2 Operation panel unit Face-down tray Upper cover 3) Close the upper cover and remove the...
Page 144 CHAPTER 3 2. Front cover 5) Open the pick-up unit door, and 1) Open the upper cover. disconnect the claw and remove the 2) Open the duplexing unit door. front cover. 3) Remove the 3 screws. Pick-up unit door Duplexing unit door Claw Screws Front cover...
Page 145 CHAPTER 3 3. Upper cover unit 6) Remove the screw, and then the upper 1) Remove the face-down tray. cover unit. 2) Remove the front cover. 3) Remove the 2 claws, and then the operation panel unit. 4) Disconnect the connector from the operation panel unit.
Page 146 CHAPTER 3 4. Rear cover 5. Delivery cover unit 1) Open the upper cover. 1) Open the delivery cover unit. 2) Open the pick-up unit door. 2) Remove the 2 rods holding the delivery 3) Remove the 2 screws, the claw, and the cover unit to the printer.
Page 147 CHAPTER 3 6. Multi-purpose tray 7. Right cover unit 1) Open the multi-purpose tray. 1) Remove the front cover. 2) Remove the 2 stoppers. 2) Remove the right rear cover. 3) Undo the 2 claws holding the multi- 3) Remove the hinge from the right cover purpose tray unit, and pull the tray out unit, and then the 4 screws.
Page 148: Fans
CHAPTER 3 8. Left rear cover B. Fans 1) Open the delivery cover. 1. Summary 2) Remove the video controller PCB unit There are 4 fan motors installed to circulate following the procedure on page 3-32. air within the printer and prevent the 3) Remove the 3 screws and the left rear internal temperature from rising.
Page 149 CHAPTER 3 2. Removal from the printer 6) Remove the cable from the guide. a. Fixing unit/scanner unit fan (FM1) 7) Unhook the claw, then remove the fan 1) Remove the right rear and rear covers. duct. 2) Remove the upper cover unit. 3) Disconnect the connector.
Page 150 CHAPTER 3 b. Power supply fan (FM2) c. Electrical unit fan (FM3) 1) Remove the right rear and rear covers. 1) Remove the right rear and rear covers. 2) Disconnect the connector. 2) Remove the left rear cover. 3) Undo the connector. 4) Pinch the 2 claws holding the electrical unit fan and pull out the fan.
Page 151: Operation Panel Unit
CHAPTER 3 d. Fixing unit fan (FM4) C. Operation Panel Unit 1) Remove the upper cover unit. 1. Removal from the printer 2) Undo the connector. 1) Open the upper cover unit. 3) Remove the screw, and then the fan 2) Remove the front cover.
Page 152: Drive System
CHAPTER 3 II. DRIVE SYSTEM 6) Remove the 2 screws and the drive unit. A. Drive Unit 1. Removal from the printer 1) Remove the pick-up unit following steps 1-7 on Page 3-12. 2) Remove the screw, and then the cassette stay.
Page 153: Main Motor
CHAPTER 3 B. Main Motor 1. Removal from the printer 1) Remove the high-voltage power supply unit following steps 1-2 on Page 3-36. 2) Undo the connector, remove the 4 screws and then the main motor. Connector Screws Main motor Figure 3-2-4 3 - 11...
Page 154: Paper Transport System
CHAPTER 3 III. PAPER TRANSPORT 7) Remove the 4 screws, and take out the SYSTEM pick-up unit. A. Pick-up Unit 1. Removal from the printer 1) Pull out the upper and lower cassettes. 2) Perform steps 1-6 on Page 3-17 to remove the manual feed pick-up unit.
Page 155 CHAPTER 3 Figure 3-3-3 57T gear Upper lift-up cam Pick-up cam 100T gear Lower lift-up cam 31T/47T gear 20T/41T gear 3 - 13...
Page 156 CHAPTER 3 2. Disassembly/reassembly b. Feed clutch a. Pick-up motor 1) Disconnect the connector. 1) Undo the connector. 2) Remove the screw, and disconnect the 2 2) Remove the 2 screws, and slide the claws to remove the pick-up PCB. pick-up motor out in the direction of the arrow.
Page 157: Delivery Unit
CHAPTER 3 c. Cassette pick-up solenoid B. Delivery Unit 1) Disconnect the connector. 1. Removal from the printer 2) Remove the screw and take out the 1) Remove the upper cover unit. cassette pick-up solenoid. 2) Remove the front cover. 3) Remove the right rear and rear covers.
Page 158: Registration Roller Unit
CHAPTER 3 C. Registration Roller Unit 2. Disassembly/reassembly 1. Removal from the printer a. Registration clutch 1) Open the upper cover. 1) Remove the E-ring and the registration 2) Remove the clutch cover. clutch. 3) Open the transfer charging roller guide. E-ring Registration clutch Transfer charging roller guide...
Page 159: Manual Feed Pick-Up Unit
CHAPTER 3 3) Remove the gear, the spring, the E-ring, D. Manual Feed Pick-up Unit the bushing, and then the registration 1. Removal from the printer lower roller. 1) Remove the front cover. 2) Remove the rear cover. 3) Remove the multi-purpose tray. 4) Open the pick-up unit door.
Page 160 CHAPTER 3 2. Disassembly/reassembly b. Lifting plate solenoid a. Manual feed pick-up clutch 1) Perform steps 1-3 on Page 3-19 to 1) Disconnect the connector. remove the manual feeding pick-up 2) Remove the E-ring and the bushing. roller. 3) Remove the 2 screws, then take out the 2) Remove the E-ring and the bushing.
Page 161: Manual Feeding Pick-Up Roller
CHAPTER 3 5) Remove the 2 screws, and then the E. Manual Feeding Pick-up Roller lifting plate solenoid. 1. Removal from the printer 1) Open the multi-purpose tray. 2) Remove the cover. Screws Lifting plate solenoid Cover Figure 3-3-20 Figure 3-3-21 3) While pressing the lifting plate, grasp the manual feeding pick-up roller knob, and pull out the roller.
Page 162: Separation Pad
CHAPTER 3 F. Separation Pad G. Pick-up/Feed/Separation Rollers 1. Removal from the printer 1. Removal from the printer 1) Open the multi-purpose tray. 1) Pull out the upper and lower cassettes. 2) Remove the cover. 2) Grasp the knobs of each roller and pull 3) Remove the manual feeding pick-up the rollers out of the printer.
Page 163: Exposure System
CHAPTER 3 IV. EXPOSURE SYSTEM 2. Removal from the printer 1) Remove the upper cover unit. 2) Disconnect the 3 connectors and the A. Laser/Scanner Unit cable from the laser/scanner unit. 1. Configuration The laser/scanner unit scans the laser beam across the photo-sensitive drum.
Page 164: Electrostatic Imaging/Developing/Cleaning System
CHAPTER 3 V. ELECTROSTATIC IMAGING/DEVELOPING/CLEANING SYSTEM A. EP-W Cartridge 1. Configuration The EP-W cartridge is comprised of the photosensitive drum, primary charging roller, developing unit, cleaning unit, etc. While the photosensitive drum rotates within the cartridge, a visible image is formed on its surface based on print data according to the print process.
Page 165: B. Transfer Charging Roller
CHAPTER 3 2. Photosensitive drum B. Transfer Charging Roller As a general rule, do not touch the photo- 1. Removal from the printer sensitive drum with your hand nor clean it. 1) Open the upper cover. However, if it becomes necessary to clean 2) Open the transfer charging roller guide.
Page 166: Fixing System
CHAPTER 3 VI. FIXING SYSTEM 2. Removal from the printer 1) Open the delivery cover unit. 2) Move the 2 fastening levers of the fixing A. Fixing Unit unit in the direction of the arrow, 1. Configuration slightly lift the fixing unit, and pull it A cross-section of the fixing unit, the out toward you.
Page 167 CHAPTER 3 3. Disassembly/reassembly 3) Take out the 2 connectors. a. Fixing roller heater 4) Disconnect the heater claw of the holder 1) Disconnect the 2 claws that hold the and remove the holder. Then, gently pull wire cover to the fixing unit, and then out the fixing heater from the fixing remove the wire cover.
Page 168 CHAPTER 3 b. Thermoswitch c. Thermistor 1) Remove the wire cover. 1) Remove the wire cover. 2) Remove the 4 screws and then the lead 2) Disconnect the connector and remove wire and the thermoswitch. the cable from the fixing left cover. Screws Connector Thermoswitch...
Page 169 CHAPTER 3 d. Fixing upper roller 4) Remove the E-ring and the spring, then 1) Hold up the left and right levers in the pull out the separation lower guide direction of the arrow. toward you and slide it off in the 2) Holdup the left and right envelope direction of the arrow.
Page 170 CHAPTER 3 9) Remove the screws and the right fixing 10) Remove the 3 screws and the left fixing cover. cover. 11) Remove the 4 gears. Screw Diode holder Screws Left fixing cover Screw Right fixing cover Figure 3-6-13 Figure 3-6-12 12) Remove the 2 screws, the grounding plate, and the thermoswitch stay.
Page 171 CHAPTER 3 13) Remove the screw, undo the 2 claws, 15) Remove the C-ring from the gear. and take off the fixing roller cover. C-ring Screw gear Claw Fixing roller cover Figure 3-6-17 Figure 3-6-15 16) Removing the bushing. 14) Remove the grounding ring. Bushing Grounding ring Figure 3-6-18...
Page 172 CHAPTER 3 17) Remove the C-ring from the bushing. e. Fixing lower roller 18) Remove the bearing from the fixing 1) Remove the fixing upper roller upper roller. following steps 1-18 from Page 3-27. 2) Disconnect the claw and remove the fixing entrance guide.
Page 173 CHAPTER 3 4) Remove the fixing lower roller with its holder. 5) Remove the 2 holders and 2 bushings from the fixing lower roller. Holders Bushings Fixing lower roller Figure 3-6-22 3 - 31...
Page 174: Electronic Components
CHAPTER 3 VII. ELECTRONIC COMPO- 3) Remove the 2 screws (M3), and then NENTS guide. 4) Remove the 2 screws (M4) and the 4 screws (M3), then take out the video A. Video Controller PCB controller PCB. 1) Remove the 2 screws , then pull out the video controller PCB unit.
Page 175: B. Hard Disk
CHAPTER 3 B. Hard disk (optional) C. DC Controller PCB 1. Removal from the video controller 1) Remove the high-voltage power supply PCB unit unit following steps 1-2 on Page 3-36. 1) Remove the video controller PCB unit. 2) Disconnect the 18 connectors from the 2) Remove the connector.
Page 176: D. Pick-Up Pcb
CHAPTER 3 D. Pick-up PCB E. Multi-purpose Tray PCB 1) Remove the pick-up unit following steps 1) Remove the manual feed pick-up unit 1-7 on Page 3-12. following steps 1-6 on Page 3-17. 2) Disconnect the 6 connectors. 2) Remove the manual feed drive unit 3) Remove the screw, disconnect the 2 following steps 1-4 on Page 3-18.
Page 177: F. Switch/Sensor Pcb
CHAPTER 3 F. Switch/Sensor PCB 7) Remove the 5 screws and the shield 1) Remove the upper cover unit. plate. 2) Remove the right rear and rear covers. 3) Remove the left rear cover. 4) Remove the connector, the 2 screws, and then the fan duct.
Page 178 CHAPTER 3 10) Disconnect the connector, remove the 2 G. High-voltage Power Supply PCB screws, and pull out the board. 1) Remove the right rear and rear covers. Disconnect the other connector and 2) Disconnect the 2 connectors, remove the remove the switch/sensor PCB.
Page 179: I. Power Supply
CHAPTER 3 H. Cassette-size Sensing PCB I. Power Supply 1) Remove the cassettes. 1) Remove the left rear and rear covers. 2) Remove the power supply following 2) Disconnect the connector, remove the 2 steps 1-6 on Page 3-37. screws, then take out the fan duct. 3) Disconnect the connector, remove the screw, then take out the cassette-size sensing cover.
Page 180 CHAPTER 3 5) Remove the 4 connectors. Connectors Figure 3-7-18 6) Remove the 2 screws and the power supply unit fan. 7) Remove the 2 screws and take off the power supply unit. Screws Power supply fan Screws Power supply Figure 3-7-19 3 - 38...
Page 181: Envelope Feeder
CHAPTER 3 VIII. ENVELOPE FEEDER b. Front Cover 1) Remove the screw and take off the front cover. 1. Removal of the External Covers a. Rear Cover 1) Remove the screw and take off the rear cover. Screw Front cover Figure 3-8-2 Screw Rear cover...
Page 182 CHAPTER 3 d. Upper Cover 1) Remove the rear and front covers. Notes: 1. Ensure that the separation guide 2) Remove the screw. and upper cover are removed as one unit. However, in the event that the separation guide has already been removed, be sure to follow position adjustment...
Page 183 CHAPTER 3 2. Removal of the Envelope Side Guides 3. Removal of the Envelope Feeder Pick- up Motor 1) Remove the rear, front, lower and upper covers. 2) Remove the envelope side guides as shown in steps 1 and 2 of this page. 3) Remove the C-ring, the gear and the rack.
Page 184 CHAPTER 3 5) Remove the screw and take out the pick- 4. Removal of the Envelope Feeder up motor. Driver PCB 1) Remove the rear, front, lower and upper covers. 2) Remove the envelope guides. 3) Remove the 2 connectors and the screw. Screw Pick-up motor Figure 3-8-11...
Page 185 CHAPTER 3 5. Removal of the Drive Unit 6. Removal of the Envelope Feeder Pick- 1) Remove the pick-up motor following up Roller steps 1 to 5 on page 3-40. 1) Follow steps 1 to 5 on page 3-40 and 2) Remove the screw.
Page 186 CHAPTER 3 7. Removal of the Separation Lower 4) Remove the separation lower shaft from Roller, Separation Upper Roller and the guide. Then take the separation Torque Limiter upper roller and torque limiter off the 1) Follow steps 1 to 5 on page 3-40 to shaft.
Page 187: Duplexing Unit
CHAPTER 3 IX. DUPLEXING UNIT 2. Removal of the Lower Guide 1) Remove the upper cover. 2) Remove the connector. 1. Removal of the Upper Guide 3) Take out the 2 screws, then the guide. 1) Remove the 4 screws, then the upper guide.
Page 188 CHAPTER 3 5) Remove the screw. 3. Removal of the Switchback Roller Release Solenoid 1) Remove the lower guide. 2) Take out the 2 screws, then the PCB cover. Screw Figure 3-9-5 Screws PCB cover 6) Remove the 2 screws, then the lower guide.
Page 189 CHAPTER 3 4) Remove the cable from it’s holders. 4. Removal of the Duplex Deflector 5) Remove the 2 screws that hold the Drive Solenoid switchback roller release solenoid from 1) Remove the upper guide. underneath and take off the solenoid. 2) Remove the PCB cover, and the 4 connectors.
Page 190 CHAPTER 3 5) Remove the 2 screws, and take off the 7) Remove the 2 screws and take off the motor base plate. duplex deflector drive solenoid. Screws Motor base plate Screws Duplex deflector drive solenoid Figure 3-9-12 Figure 3-9-14 6) Remove the screw and take off the solenoid cover.
Page 191 CHAPTER 3 5. Removal of the Switch-back Motor 4) Take out the 2 screws, then slide the 1) Remove the upper guide. switch-back motor in the direction of 2) Take off the PCB cover and remove the the arrow to remove. connector.
Page 192 CHAPTER 3 6. Removal of the Side Registration 7. Removal of the Duplex Feed Clutch Motor 1) Remove the upper guide. 1) Remove the lower guide. 2) Take off the PCB cover and undo the 2) Take off the PCB cover, then remove the connector.
Page 193 CHAPTER 3 8. Removal of the Duplexing Driver PCB 1) Take off the PCB cover, and remove the 9 connectors. Connectors Figure 3-9-22 2) Undo the 2 claws holding the PCB and remove the duplexing driver PCB. Claws Duplexing driver PCB Figure 3-9-23 3 - 51...
Page 194: Option Controller
CHAPTER 3 X. OPTION CONTROLLER 1. Removal from the printer 1) Turn OFF the printer. 2) Remove all the interface cables. 3) Loosen the 2 screws and pull out the video controller PCB unit. Screws Video controller PCB unit Figure 3-10-1 4) Remove the connector.
Page 195: Paper Deck
CHAPTER 3 XI. PAPER DECK 3. Right cover 1) Remove the 2 screws. 2) Undo the claws, and remove the right A. External Covers cover. 1. Front cover 1) Pull out the tray. 2) Remove the paper guide. 3) Remove the 4 screws, undo the left and right claws, and take off the front cover.
Page 196 CHAPTER 3 5. Rear cover B. Drive Unit 1) Remove the 4 screws, and take off the 1. Removal from the main unit. rear cover. 1) Remove the right and rear covers. 2) Pull out the tray. 3) Remove the 2 connectors and 4 screws then take out the drive unit.
Page 197 CHAPTER 3 2. Disassembly/ assembly C. Limit Switch a. Lifter clutch 1. Removal from the main unit. 1) Remove the screw. 1) Remove the 2 screws, then take off the 2) Remove the clutch cover and bushing, upper cover. then take out the lifter clutch. Screws Upper cover Screw...
Page 198 CHAPTER 3 6) Remove the connector from the stay, D. Pick-up Unit then take the cable out of the band. 1. Removal from the main unit. 7) Remove the screw, then take out the 1) Remove the feed unit by following steps limit switch.
Page 199 CHAPTER 3 5) Remove the 4 screws, then take out the 2. Disassembly/ reassembly pick-up unit. a. Pick-up solenoid 1) Undo the 2 claws and remove the gear cover. 2) Remove the connector. Screws Pick-up unit Figure 3-11-13 Claws Gear cover Connector Note: When replacing the various parts of the pick-up unit, remove the pick-...
Page 200 CHAPTER 3 5) Remove the screw, then take out the 4) Remove the 2 screws and then the pick- pick-up solenoid. up motor. Screw Pick-up solenoid Screws Pick-up motor Figure 3-11-16 Figure 3-11-18 b. Pick-up motor 1) Remove the gear side plate by following steps 1 to 4 on this page.
Page 201 CHAPTER 3 E. Feed Unit 2. Disassembly/ reassembly 1. Removal from the main unit. a. Feed clutch 1) Drop the feed unit forward. 1) Remove the feed cover. 2) Remove the connector. 2) Remove the cable from the band. 3) Rotate the feed spacer. 4) Remove the 2 screws then the feed unit.
Page 202 CHAPTER 3 5) Remove the connector, 2 bushings, b. Registration clutch shaft, pin, and gear from the feed clutch. 1) Remove the gear side plate by following steps 1 to 4 on page 3-56. 2) Remove the connector. 3) Remove the E-ring and then the registration clutch.
Page 203 CHAPTER 3 c. Feed roller d. Registration roller 1) Remove the feed cluch by following 1) Remove the registration clutch by steps 1 to 4 on page 3-58. following steps 1 to 3 on page 3-59. 2) Remove the E-ring, gear, pin and 2) Remove the 2 E-rings and the bushing.
Page 204 CHAPTER 3 F. Tray 2. Disassembly 1. Removal from the main unit a. Lifter 1) Remove the front cover. 1) Remove the 2 screws, the damper, then 2) Remove the right and left covers. the gear. 3) Remove the screw and the stopper. Screws Damper Screw...
Page 205 CHAPTER 3 4) Remove the 2 screws then the reference 6) Remove the screw then the wire cover. plate. Screw Wire cover Screws Reference plate. Figure 3-11-34 Figure 3-11-32 7) Remove the E-ring, the rubber ring then 5) Remove the screw then the wire cover. the gear.
Page 206 CHAPTER 3 9) Remove the E-ring and the 2 pulleys. 12) Remove the 2 screws and the wire 10) Remove the wire from the pulleys. cover. E-ring Pulleys Screws Wire cover Wire Figure 3-11-38 Figure 3-11-36 13) Remove the screw and the wire cover, 11) Remove the 3 screws then the reference then take out the tray.
Page 207 CHAPTER 3 14) Remove the 2 screws from the tray, then remove either the front or rear wire units. Screws Front wire unit Figure 3-11-40 Screws Rear wire unit Figure 3-11-41 3 - 65...
Page 208 CHAPTER 3 3. Assembly a. Front wire 1) Insert the pulley alignment pin in the right side(looking from the front) of the shaft. 2) Wind the wire one and a half times starting from the second groove from the front of pulley 1 and insert it on to the shaft.
Page 209 CHAPTER 3 b. Rear wire 1) Insert the pulley alignment pin in the left side(looking from the front) of the shaft. 2) Wind the wire one and a half times starting from the second groove from the front of pulley 2 and insert it on to the shaft.
Page 210 CHAPTER 3 G. Paper Deck Driver PCB H. Power Supply 1. Removal from the main unit. 1. Removal from the main unit. 1) Remove the left cover. 1) Take off the rear cover. 2) Remove the rear cover. 2) Remove the connector and 2 screws, 3) Take out the 8 connectors.
Page 211 CHAPTER 3 I. Paper-size Sensing Switch PCB J. Paper-level Sensing Switch PCB 1. Removal from the main unit. 1. Removal from the main unit. 1) Remove the rear cover. 1) Remove the rear cover. 2) Pull out the tray. 2) Pull out the tray. 3) Remove the screw and the PCB base 3) Remove the screw and then the PCB plate.
Page 212 CHAPTER 3 3 - 70...
Page 213 CHAPTER 4 TROUBLESHOOTING MAINTENANCE AND VII. PAPER FEEDING SERVICING ........4-1 TROUBLESHOOTING ..... 4-47 TOOLS ..........4-5 VIII. LOCATION OF ELECTRICAL III. MEASUREMENT AND PARTS/FUNCTION ......4-54 ADJUSTMENT ........4-14 IX. VARIABLE RESISTORS, LEDS, ..IV. INITIAL CHECK ....... 4-18 TEST PINS, JUMPERS, AND IMAGE DEFECTS ......
Page 215: Maintenance And Servicing
CHAPTER 4 I. MAINTENANCE AND SERVICING A. Periodic Replacement Parts None Note: Periodic replacement parts are parts that must be replaced at regular intervals, even if they are functioning properly and show no signs of wear. (Failure of these parts can seriously affect system performance.) These parts should be replaced during a regular service visit closest to the end of the parts expected life.
Page 216: Service Checkpoints
CHAPTER 4 D. Service Checkpoints Clean lightly with lint-free paper moistened 1. Printer with MEK, only to remove the toner a. Cartridge deposit. • Photosensitive drum As a rule, do not touch or clean the drum. When cleaning is unavoidable, never use solvents.
Page 217 CHAPTER 4 Figure 4-1-1 1: Fixing separation claw 8: Separation roller 2: Photosensitive drum 9: Pick-up roller 3: Transfer guide 10: Transfer charging roller 4: Registration roller unit 11: Static charge eliminator 5: Separation pad 12: Feed guide 6: Manual feeding pick-up roller 13: Fixing entry guide 7: Feed roller 14: Fixing separation guide...
Page 218 CHAPTER 4 2. Paper deck (Option) a. Pick-up roller, separation roller, and feed roller Clean with lint-free paper, either dry or moistened with ethyl/isopropyl alcohol. Replace if badly worn. Figure 4-1-2 1: Pick-up roller 2: Feed roller 3: Separation roller 4 - 4...
Page 219: Tools
CHAPTER 4 II. TOOLS A. Standard Tools The standard tools required for servicing the printer are listed below. Table 4-2-1 Tool name Tool No. Remarks Tool case TKN-0001 Jumper wire TKN-0069 With clips Thickness gauge CK-0057 0.02 mm to 0.3 mm Compression spring scale CK-0058 For checking cassette spring...
Page 220: Special Tools Explanation
CHAPTER 4 B. Special Tools In addition to the standard tools, the following special tools are required when servicing the printer. Table 4-2-2 Tool name Tool No. Shape RANK Application/remarks Printer driver Used for checking printer RY9-0104 tester operations. Thickness gauge RY9-0088 Used for installing the sepa- ration guide of the optional...
Page 221: C. Special Tools Explanation
CHAPTER 4 C. Special Tools Explanation Printer Driver Tester Figure 4-2-1 1. Outline The tester runs the printer independently to test printer operations. It has three uses which are outlined below; a. Commands the printer to print out solid black, horizontal lines, vertical lines and solid blank images.
Page 222 4 bit 3 bit 2 bit 1 DISPLAY SET UP CANON INC. RY9-0104 MADE IN JAPAN Figure 4-2-2 DATA LED Monitors the status of the various loads and sensors sent from the printer with the 16 LEDs. +24VA LED Lights up when +24VA is being supplied to the tester.
Page 223 CHAPTER 4 Table 4-2-3 3. Connector Signal Chart Table 4-2-4 Connector 1 Connector 2 4 - 9...
Page 224 CHAPTER 4 4. Operation Method a. Preparation Figure 4-2-3 Note: < Follow the procedure below when checking envelope feeder operations > J208 J203 J225 J205 J202 J204 J212 J211 J207 J206 J226 J217 Figure 4-2-4 4 - 10...
Page 225: Printer Driver
1 TEST DATA SET ENTER PRINT MODE SELECT bit 8 bit 7 bit 6 bit 5 bit 4 bit 3 bit 2 bit 1 DISPLAY SET UP CANON INC. RY9-0104 MADE IN JAPAN Figure 4-2-5 Table 4-2-5 4 - 11...
Page 226 1 TEST DATA SET ENTER PRINT MODE SELECT bit 8 bit 7 bit 6 bit 5 bit 4 bit 3 bit 2 bit 1 DISPLAY SET UP CANON INC. RY9-0104 MADE IN JAPAN Figure 4-2-6 Notes: 1. 4 - 12...
Page 227 CHAPTER 4 Table 4-2-6 (Note 1) (Note 2) (Note 3) Table 4-2-7 Notes: 1. 4 - 13...
Page 228: Measurement And Adjustment
CHAPTER 4 III. MEASUREMENT AND ADJUSTMENT A. Mechanical Adjustment 1. Checking the nip width of the fixing lower roller Feed-out direction Center of A3 all-black print Figure 4-3-1 2. Installing the separation guide of the envelope feeder (Adjusting the gap between the separation guide and the lower separation roller) 4 - 14...
Page 229 CHAPTER 4 <Cross sectional view of the envelope feeder> Separation gauge Thickness gauge Separation gauge Thickness gauge (1mm, RY9-0088) 1.5mm Thickness gauge Lower separation roller (0.5mm, QY9-0001) Figure 4-3-2 3. Side Registration Adjustment of the Cassette 4 - 15...
Page 230 CHAPTER 4 The value of "a" drops by 0.5mm for each notch moved. Leading edge of paper The value of "a" rises by 0.5mm for each notch moved. Figure 4-3-3 4 - 16...
Page 231 CHAPTER 4 B. Electrical Adjustment The printer does not require electrical adjustment in the field. 4 - 17...
Page 232: Initial Check
CHAPTER 4 IV. INITIAL CHECK 1. Installation environment Make sure that the printer conforms to the following environment standards: a. The power supply voltage is ±10% of the rated voltage. b. The printer is securely installed on a level surface. c.
Page 233: Image Defects
CHAPTER 4 V. IMAGE DEFECTS A. Test Print This printer is capable of executing test prints of two types: engine test print and controller test prints. When an image defect appears, a test print can be made to identify the problem. 1.
Page 234 2) Press the MENU key so that "TEST" appears on the display. 3) Press the ITEM key so that "TEST PRINT" appears on the display. Then press the ENTER key to print a sheet of the pattern shown below. Canon Inc., LBP-2460 Printer Configuration Page MEMCONFIG MENU...
Page 235 CHAPTER 4 B. Examples of Image Defects (The paper is fed vertically.) I-1 Light I-2 Dark I-3 Completely blank I-4 All black I-5 Dots vertically in a line I-6 Dirt on back of I-7 Vertical streaks/lines paper I-8 Smudged horizontal bands I-9 Dirty I-10 Blank spots I-11 White vertical lines...
Page 236: Image Defect
CHAPTER 4 C. Image Defect Troubleshooting I-1 Light <Possible causes> 1. The image density is not adjusted correctly. Action: Adjust the image density by operating the external device. 2. Lack of toner Action: Replace the cartridge. 3. Open the upper cover and remove the EP-W cartridge while a print is being made. Open the drum protective shield of the EP-W cartridge and check the toner image on the photosensitive drum.
Page 237 CHAPTER 4 Action: Replace the high-voltage power supply PCB. 5. The DC controller PCB is defective. Action: Replace the DC controller PCB. I-3 Completely blank <Possible causes> 1. The projection for opening and closing the laser shutter of the EP-W cartridge is damaged. Action: Replace the cartridge.
Page 238 CHAPTER 4 2. The static charge eliminator contact of the high-voltage power supply is not making a good connection with the static charge eliminator contact. Action: If the contacts are dirty, clean them. If the problem continues after cleaning, or parts are deformed or damaged, replace them.
Page 239 CHAPTER 4 2. Periodical stain (separation roller, transfer charging roller, fixing upper roller, EP-W cartridge) Action: Clean dirty rollers as shown in Table 4-5-1 on page 4-27. If they cannot be cleaned, replace them. I-10 Blank spots <Possible causes> 1. The recommended paper is not being used. Action: Replace the paper with the recommended paper.
Page 240 CHAPTER 4 I-13 Poor fixing <Possible causes> 1. The envelope position lever of the fixing unit is raised. Action: Push down the lever. 2. The fixing roller surface is damaged or dented. Action: Replace the roller. 3. The fixing lower roller is dirty. Action: Clean the roller.
Page 241 CHAPTER 4 Table 4-5-1 Periods of appearance of dirt, blank spots on images Phenomenon Diameter (mm) Period on Problem location Dirt on back of image (mm) Dirt Blank spot Poor fixing paper Transfer charging roller 17.9 About 56 Fixing upper roller About 126 Fixing lower roller About 94...
Page 242: Malfunction Troubleshooting
CHAPTER 4 VI. MALFUNCTION TROUBLESHOOTING The printer driver tester is necessary for executing the malfunction troubleshooting outlined in this section. It is used to monitor failures of the printer, sensor and actuator operations. When performing the corrective actions described below, the following precautions should be taken; •...
Page 243 CHAPTER 4 A. Messages Table Message Meaning Action + FORMAT DISK/ Either a request has been made to format the Press + to format the disk or - IGNORE DISK disk or the printer has determined that the press - to ignore the disk. disk needs formatting(Engin a new For new/unformatted disk: If unformatted disk is installed when power...
Page 244 CHAPTER 4 Message Meaning Action Mopier is only available when the hard disk displayed for the duration of the printer’s processing time. @PJL is installed RDYMSG DISPLAY will have higher priority than “# OF ###” message. TONER LOW Toner is low. Replace the toner cartridge as soon as possible.
Page 245 CHAPTER 4 Message Meaning Action IN MOTION after new paper was loaded. Remove the paper from the tray. OUTPUT FULL The specified output bin is full. CHECK BIN 1 OUTPUT FULL The specified output bin is full. Remove the paper from the tray. CHECK BIN 2 OUTPUT FULL The specified output bin is full.
Page 246 CHAPTER 4 Message Meaning Action area. the paper path. The upper cover must be opened and closed to resume. printing. 6 PAPER JAM Paper jam has occurred near the face-down Remove the jammed paper from tray. the paper path. The upper cover must be opened and closed to resume.
Page 247 CHAPTER 4 Message Meaning Action must be opened and closed to resume. printing. 14.2 PAPER JAM Paper jam has occured in the feed cover. Check the Paper Deck. Remove OPEN RIGHT the jammed paper from the COVER paper path. The upper cover must be opened and closed to resume.
Page 248 CHAPTER 4 Message Meaning Action 03 Not at end of frame error Replace the LocalTalk card. 04 LocalTalk network siways busy 05 LocalTalk excess collision error 06 LocalTalk excess defers error 07 LocalTalk unidentified cntl LLAP type 08 Receive Msg length error 10 8751 Internal RAM error 11 Cannot acquire a node ID 12 Aborted during a receive...
Page 249 CHAPTER 4 Message Meaning Action SERVICE See M-10 of page 4-43 13.4 ERROR FAN Fan motor 4 failure. 4 CALL FOR SERVICE 14.1 ERROR AUX Lifter mechanism for the Aux Tray has See M-11 of page 4-43 TRAY CALL FOR failed.
Page 250 CHAPTER 4 Message Meaning Action TEST must be executed every time the staples cartridge is removed reinstalled (regardless if the staple cartridge is full or not). The printer will not staple jobs correctly if STAPLE TEST is not executed. 15.1 ERROR Malfunction of paper delivery motor See service manual of stapler STACKER CALL...
Page 251 CHAPTER 4 Message Meaning Action 63 ERROR CALL NVRAM (EEPROM) error. Turn the power OFF, then turn it FOR SERVICE ON again. If it does not remedy the problem, replace the resident NVRAM. 64 ERROR CALL SRAM in AIR chip error. Replace the video controller PCB.
Page 252 CHAPTER 4 Message Meaning Action enabled at this time. complete the current function. LOCALTALK LocalTalk is initializing. No action required. INITIALIZING MPT TRAY JAM A paper jam has occurred in the MP tray. Clear the paper path. CLEAR PAPER PATH Printer has invoked MRT Compression No action required.
Page 253 CHAPTER 4 Message Meaning Action PRINTCART CLEAR near the unit specified.. PAPERPA TH RESETTING Displays when TEST/RESET PRINTER No action required. PRINTER item is selected. RESTORING Displays when TEST/FACTORY DEFALTS No action required. DEFAULTS item is selected. SRAM ERROR The AIR Chip has failed. Replace the video controller CALL SERVICE PCB.
Page 254: Malfunction Troubleshooting
CHAPTER 4 B. Malfunction Troubleshooting M-1 Fixing Unit Failure (Abnormal Temperature) <Possible causes> 1. The thermistor has shorted. Action: Turn the power OFF and remove the fixing unit. Measure the resistance between the fixing unit connector J50B-2 (FSRTH) and J50B-3 (GNDTH). The connector J50B is the lower terminal of the left connector.
Page 255 CHAPTER 4 Action: Replace the DC controller PCB. M-3 Fixing unit failure (wrong type) <Possible causes> 1. The rated voltage of the fixing unit does not match the power supply voltage. Action: Replace the fixing unit. 2. The type detection circuit in the power supply is defective. Action: Replace the power supply.
Page 256 CHAPTER 4 M-6 Faulty Main Motor <Possible causes> 1. The main motor drive line connectors are loose. Action: Reconnect connector J12 of the main motor and connector J218 on the DC controller PCB. 2. The door switch in the switch/sensor PCB is defective. Action: Remove connectors J205 and J221 on the DC controller PCB.
Page 257 CHAPTER 4 M-9 Electrical Unit Fan (FM3) Failure <Possible causes> 1. The FM3 drive signal line connector is loose. Action: Reconnect connector J210 on the DC controller PCB and connectors J12 and J13. 2. The electrical unit fan is defective. Action: Disconnect connector J210 on the DC controller PCB.
Page 258 CHAPTER 4 M-12 Horizontal Registration Guide Failure (When the Duplexing Unit is Installed) <Possible causes> 1. The horizontal registration guide home position sensor signal line and horizontal registration motor drive signal line connectors are loose. Action: Reconnect connectors J2005 and J2006 on the duplexing driver PCB. 2.
Page 259 CHAPTER 4 Action: Inform the customer that the correct line voltage is not available at the outlet. 2. The power plug is not firmly plugged into the printer, the paper deck or the outlet. Action: Push the power plugs in firmly. 3.
Page 260 CHAPTER 4 supply output of the connector J204. Do not short the connector. If the correct value is not output, replace the power supply. 5. Wiring, DC load, DC controller PCB Action: Turn the power switch OFF. Check the wiring from the DC controller PCB and the DC load.
Page 261 CHAPTER 4 M-17 No Paper Pick-Up from Multi-purpose Tray <Possible causes> 1. Video controller PCB is defective. Action: Make a test print from the multi-purpose tray using the printer driver tester. If the paper is picked up correctly, replace the video controller PCB. 2.
Page 262 CHAPTER 4 M-19 No Paper Pick-Up from Envelope feeder <Possible causes> 1. Video controller PCB is defective. Action: Use the printer driver tester to make a test print from the envelope feeder. If the envelope is picked up correctly from the envelope feeder, replace the video controller PCB.
Page 263 CHAPTER 4 1. Gears are damaged. Action: Replace any damaged gears. 2. The registration clutch is defective. Action: Disconnect registration clutch connector J17. Measure the resistance between connectors J17-1 and J17-2 on the cable side. If it is not about 210 , replace the registration clutch.
Page 264 CHAPTER 4 M-25 Faulty Deck Motor (paper deck) <Possible causes> 1. Poor contact in the deck motor drive signal line connector Action: Reconnect deck motor connector J118 and connector J204 on the paper deck driver PCB. 2. Faulty deck motor Action: Measure the voltage between connectors J204-4 (DCMOT-ON) and J204-2 (GND) on the paper deck driver PCB.
Page 265: Paper Jams
CHAPTER 4 VII. PAPER FEEDING TROUBLESHOOTING A. Paper Jams Paper in the printer passes through five major units: (1) duplexing unit, (2) fixing and delivery unit, (3) envelope feeder unit, (4) pick-up unit, and (5) paper deck unit. The following explains troubleshooting for jams in each of these units.
Page 266 CHAPTER 4 J-1 Pick-up unit <Possible causes> 1. The recommended paper is not being used or the paper is curled or wrinkled. Action: Replace the paper. Advise the customer to use recommended paper and on how to store paper. 2. If jams occur in the manual feed pick-up unit, perform step 6 and subsequent steps. 3.
Page 267 CHAPTER 4 Action: Check whether any gears are worn or missing. 3. The fixing entrance guide is dirty, damaged, or clogged with toner. Action: Clean the guide. 4. The fixing separation guide is dirty, damaged, or clogged with toner. Action: Clean the guide. 5.
Page 268 CHAPTER 4 J-4 Envelope Feeder <Possible causes> 1. The recommended envelopes are not being used. Action: Advise the customer to use the recommended envelopes. 2. Too many envelopes in the envelope feeder Action: Tell the customer not to over load the envelope feeder with envelopes. 3.
Page 269: Incomplete Paper Feed
CHAPTER 4 B. Incomplete Paper Feed T-1 Multiple Paper Feed <Possible causes> 1. The recommended paper is not being used. Action: Replace the paper. Advise the customer to use the recommended paper. 2. If this problem occurs with the multi-purpose tray, perform step 5 and subsequent steps. 3.
Page 270 CHAPTER 4 2. Too much paper loaded in the paper feed slot Action: Advise the customer not to over load the paper feed slot with paper. 3. The paper guide is worn or deformed. Action: Check the paper feed path, and replace the guide if it is damaged or deformed. T-4 Skewing <Possible causes>...
Page 271 CHAPTER 4 This page intentionally left blank 4 - 57...
Page 272: Location Of Electrical Parts/Function
CHAPTER 4 VIII. LOCATION OF ELECTRICAL PARTS/FUNCTION A. Switches SW1401 SW1601 SW1602 SW1603 SW1604 SW101 SW1601 SW1602 SW1603 SW1604 SW601 SW31 SW602 SW701 SW702 SW703 SW704 Figure 4-8-1 4 - 58...
Page 273 CHAPTER 4 Table 4-8-1 Symbol Name Code Role SW101 Switch Power switch SW1401 Door switch SW1601 Lower cassette-size sensing switch SW1602 Lower cassette-size sensing switch SW1603 Lower cassette-size sensing switch SW1604 Lower cassette-size sensing switch SW1601 Upper cassette-size sensing switch SW1602 Upper cassette-size sensing switch SW1603...
Page 274: Sensors
CHAPTER 4 B. Sensors PS1402 PS1401 PS1403 PS1302 TH TP PS1301 PS1206 PS1208 PS1205 PS1202 PS1207 PS1201 PS1204 PS1203 PS24 PS22 PS23 PS21 PS931 Figure 4-8-2 4 - 60...
Page 275 CHAPTER 4 Table 4-8-2 Symbol Name Code Role Registration paper sensor Photointerrupter Pick-up unit paper sensor Right door sensor PS1201 Lower cassette sensor PS1202 Upper cassette sensor PS1203 Lower cassette paper-level sensor 1 PS1204 Lower cassette paper-level sensor 2 PS1205 Upper cassette paper-level sensor 1 PS1206 Upper cassette paper-level sensor 2...
Page 276 CHAPTER 4 PS33 PS34 PS32 PS35 PS31 Figure 4-8-3 4 - 62...
Page 277 CHAPTER 4 Table 4-8-3 Symbol Name Code Role PS31 Photointerrrupter Registration paper sensor (paper deck) PS32 Paper jam sensor (paper deck) PS33 Tray paper-out sensor (paper deck) PS34 Paper surface sensor (paper deck) PS35 Door sensor (paper deck) 4 - 63...
Page 278: Clutches And Solenoids
CHAPTER 4 C. Clutches and Solenoids SL22 SL21 CL21 Figure 4-8-4 4 - 64...
Page 279 CHAPTER 4 SL31 CL33 CL31 CL32 Figure 4-8-5 Table 4-8-4 CL21 CL31 CL32 CL33 SL21 SL22 SL31 4 - 65...
Page 280: Motor And Others
CHAPTER 4 D. Motor and Others FAM4 FAM1 FAM3 FAM2 SMT1 SMT21 SMT22 SMT11 Figure 4-8-6 4 - 66...
Page 281 CHAPTER 4 SMT31 MT31 Figure 4-8-7 Table 4-8-5 4 - 67...
Page 282: Pc Boards
CHAPTER 4 E. PC Boards Figure 4-8-8 4 - 68...
Page 283 CHAPTER 4 Figure 4-8-9 Table 4-8-6 4 - 69...
Page 284: Connectors
CHAPTER 4 F. Connectors J202 J205 J1401 J203 J208 J215 J206 J210 J207 J218 J216 J1001 J221 J1601A J1601B J1402 J225 J219 J209 J1206 J1201 J1204 J1205 J1203 J1202 Figure 4-8-10 4 - 70...
Page 285 CHAPTER 4 J222 J204 J213 J217 J1302 J214 J1304 J1303 J1301 J102 J2009 J2005 J2008 J2007 J2001 J2004 J2002 J2006 J931 J2003 J932 Figure 4-8-11 4 - 71...
Page 286 CHAPTER 4 J207 J208 J210 J120 J206 J601 J205 J204 J114 J203 J101 J116 J209 J701 J119 J118 J901 J115 J117 J110 J113 J111 J205 J108 J203 J102 J107 Figure 4-8-12 4 - 72...
Page 287: Variable Resistors, Leds, Test Pins, Jumpers, And Switches On Pc Boards
CHAPTER 4 IX. VARIABLE RESISTORS, LEDS, TEST PINS, JUMPERS, AND SWITCHES ON PC BOARDS Notes: 1. A. DC Controller PCB J208 J203 J225 J205 J202 J204 J212 J211 J207 J206 J226 J217 Figure 4-9-1 Table 4-9-1 4 - 73...
Page 288: Switch/Sensor Pcb
CHAPTER 4 B. Switch/Sensor PCB J1402 SW1401 J1401 Figure 4-9-2 Table 4-9-2 C. Cassette Paper-size Sensing Switch PCB J1601 SW1604 SW1603 SW1602 SW1601 Figure 4-9-3 Table 4-9-3 4 - 74...
Page 289: High-Voltage Power
CHAPTER 4 D. High-voltage Power Supply PCB VR702 VR701 TB706 J701 TB705 TB703 TB702 TB704 TB701 T704 Figure 4-9-4 Table 4-9-4 4 - 75...
Page 290: Video Controller Pcb
CHAPTER 4 E. Video Controller PCB Figure 4-9-5 Table 4-9-5 4 - 76...
Page 291: Envelope Feeder
CHAPTER 4 F. Envelope Feeder Driver PCB J931 J932 Figure 4-9-6 Table 4-9-6 4 - 77...
Page 292: Option Controller Pcb
CHAPTER 4 G. Option Controller PCB SW101 J101 J102 JP101 Figure 4-9-7 Table 4-9-7 Table 4-9-8 4 - 78...
Page 293: H. Paper Deck Driver Pcb
CHAPTER 4 H. Paper Deck Driver PCB J208 J207 J211 J203 Figure 4-9-8 Table 4-9-9 Notes: 1. 4 - 79...
Page 294 CHAPTER 4 itself, a jam will occur. For this reason it is important that care is taken while operating the test mode to only load one sheet of paper at a time in the tray. If multiple sheets are loaded in the tray, the paper deck will continuously feed paper into the printer until running out causing a paper jam.
Page 295: Paper-Level Sensing
CHAPTER 4 I. Paper-level Sensing Switch PCB J701 SW601 SW602 Figure 4-9-9 Table 4-9-10 Function SW No. SW601 Paper level sensing switch (See table 2-10-1 of page 2-87.) SW602 J. Paper-size Sensing Switch PCB J701 SW704 SW703 SW702 SW701 Figure 4-9-10 Table 4-9-11 Function SW No.
Page 296: List Of Lubricants, Cleaners
CHAPTER 4 X. LIST OF LUBRICANTS, CLEANERS Table 4-10-1 Material name Components Remarks Alcohol: ethyl Cleaning: plastic, rubber, • Purchase locally (pure or CHOH external parts • Flammable: keep away from denatured) or flame isopropyl (pure or denatured) MEK (methyl CO-C Cleaning: oil and toner •...
Page 297: I. General Timing Chart
APPENDIX GENERAL TIMING CHART ... A-1 III. LIST OF SIGNALS ......A-7 GENERAL CIRCUIT DIAGRAM..A-3...
Page 299 GENERAL TIMING CHART-1/2 • Timing chart for two consecutive prints on A4 paper (Lower cassette feed - face-down tray delivery) Power switch ON (Unit: Seconds) Operation WAIT STBY INTR PRINT LSTR STBY 169 C 150 C 180 C 169 C control control 180 C control...
Page 300 GENERAL TIMING CHART-2/2 • Timing chart for two consecutive prints on A4 paper (Duplexing feed) Power switch ON (Unit: Seconds) Operation WAIT STBY INTR PRINT LSTR STBY 155 C 180 C 169 C Fixing roller heater (H1, H2) control 180 C control 169 C control PRINT signal (/PRNT) VERTICAL SYNC signal (/VSYNC)
Page 301 GENERAL CIRCUIT DIAGRAM-1/3 from Fixing unit Registration Registration Scanner FAN3 clutch paper sensor BD PCB Operation Laser driver Electrical J56M motor Fixing unit/ unit fan Video controller panel Scanner unit FAN1 DC controller PCB J221 +24VB J1401 +24VB PS1401 SW1401 +24VB Face-down tray paper full sensor...
Page 302 GENERAL CIRCUIT DIAGRAM-2/3 Pick-up motor Paper-size sensing Paper-level SMT31 switch PCB sensing switch PCB SW701 Lifter clutch Deck motor CL31 MT31 SW702 SW601 SW703 SW602 SW704 (to option controller) (to other option) Paper deck driver PCB Power supply SL31 SW31 Pick-up Lifter abnormal solenoid...
Page 303 GENERAL CIRCUIT DIAGRAM-3/3 J1/2 nRESET MD16 MD16 MD16 nBCAS0 nBCAS0 /CLK nBCAS0 MD17 nBCAS2 MD17 nBCAS2 MD17 nBCAS2 N.C. /CLKN nBCAS3 nBCAS3 nBCAS3 N.C. LD11 LD10 MD18 nBCAS1 MD18 nBCAS1 N.C. N.C. MD18 nBCAS1 LD13 LD12 nRAS0 nRAS2 nRAS4 /STROBE LD15 LD14 MD19...
Page 304 APPENDIX...
Page 305: List Of Signals
APPENDIX III. LIST OF SIGNALS A. Input/output signals to DC controller PCB Connector Abbreviation I/O Logic Signal name J201 /FPCS FRONT PANEL CONTROLLER CHIP SELECT signal Reservrd /VSREQ VSYNC REQUEST signal /VSYNC VERTICAL SYNC signal /STS STATUS signal /CMD COMMAND signal Reserved /SPCHG SPEED CHANGE signal...
Page 306 APPENDIX Connector Abbreviation I/O Logic Signal name J201 BEAM DETECTION signal J202 LLCONT LASER OUTPUT signal PHOTO DETECTION signal /LENBL VIDEO DATA ENABLE signal /LON FORCED LASER ON signal VIDEO signal N.C. J203 /FPO FRONT PANEL SERIAL OUTPUT signal /FPI FRONT PANEL SERIAL INPUT signal /FPCS FRONT PANEL CONTROLLER CHIP SELECT signal...
Page 307 APPENDIX Connector Abbreviation I/O Logic Signal name J209 /REGS REGISTRATION PAPER SENSE signal P5VB3 J210 FAN3D FAN MOTOR 3 DRIVE signal /FAN3S FAN MOTOR 3 ROTATING DETECTION signal J212 FSRTH FIXING ROLLER TEMPERATURE SENSE signal SVIN SERVICE STATUS signal SVOUT SERVICE COMMAND signal +24VA J213...
Page 308 APPENDIX Connector Abbreviation I/O Logic Signal name J217 FSRD2E FIXING SUB HEATER DRIVE signal /FSRCT2 FIXING SUB HEATER TYPE SENSE signal /FSRD2 FIXING SUB HEATER DRIVE ENABLE signal /FSRD2R FIXING SUB HEATER DRIVE ENABLE signal (200V model only) /RLDSNS RELAY DETECTION SENSE signal PSTYP POWER SUPPLY TYPE SENSE signal /REMT24...
Page 309 APPENDIX Connector Abbreviation I/O Logic Signal name J220 /HV1DCD PRIMARY DC BIAS DRIVE signal /DBDCD DEVELOPING DC BIAS DRIVE signal +24VB J221 +24VB +24VB +24VB J222 FSRTYP1 FIXING MAIN HEATER TYPE SENSE signal FSRTP1R FSRTP2R FSRTYP2 FIXING SUB HEATER TYPE SENSE signal FSRTH FIXING ROLLER TEMPERATURE SENSE signal J223...
Page 310 APPENDIX B. Input/output signals to option controller PCB Connector Abbreviation I/O Logic Signal name J101 RESET RESET signal (unused) /PRINT PRINT signal (unused) /SPCHG SPEED CHANGE signal (unused) /PDLV PAPER DELIVERY signal For expansion /undetermined 1 N.C. /CKEN COMMUNICATION READY signal SERIAL IN signal N.C.
Page 311 APPENDIX C. Input/output signals to paper deck driver PCB Connector Abbreviation I/O Logic Signal name J201 SERIAL IN signal SERIAL OUT signal CONTO Communication ready signal +24V SYNCHRONOUS CLOCK signal +24V STRBI STROBE signal PWRON-IN POWER ON signal +24V J202 SERIAL OUT signal SERIAL IN signal CONTI...
Page 312 APPENDIX Connector Abbreviation I/O Logic Signal name LIFTCL LIFTER CLUTCH DRIVE signal J207 REGI REGISTRATION PAPER SENSE signal PAPER JAM SENSE signal REGICL REGISTRATION CLUTCH DRIVE signal +24V FEEDCL FEED CLUTCH DRIVE signal +24V J208 +24V PICKUPSL PICK-UP SOLENOID DRIVE signal PAP-EXIST TRAY PAPER-OUT SENSE signal LIFT...
Page 313 Prepared by PERIPHERAL PRODUCTS QUALITY ADVANCEMENT DIV. PERIPHERAL PRODUCTS TECHNICAL DOCUMENTATION DEPT. CANON INC. Printed in Japan REVISION 0 ( APRIL 1997 ) REVISION 1 ( DEC. 1997 ) 5-1, Hakusan 7–chome, Toride-City, Ibaraki-Pref. 302, Japan...
Page 314 The printing paper contains 70% waste paper. PRINTED IN JAPAN (IMPRIME AU JAPON) 1297AT1.40 CANON INC.

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Canon LBP 2460 - B/W Laser Printer Service Manual

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Chapter 2 Operation and Timing

Chapter 3 The Mechanical System

Chapter 4 Troubleshooting

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Troubleshooting

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