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Brother 1660E Service Manual

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  • Page 1: Laser Printer

  • Page 2 No part this publication may be reproduced in any form or by any means without permission in writing from the publisher. Trademarks: • BR-Script, and DX-1600 are registered trademarks of Brother Industries, Ltd. • Centronics is a registered trademark of Genicom Corporation. • PostScrip is a registered trademark of Adobe Systems Incorporated.
  • Page 3 PREFACE This service manual contains basic information required for after-sales service of the laser printer (hereinafter referred to as ”this machine” or ” the printer”). This information is vital to the service technician in maintaining the high printing quality and performance of the printer. This manual consists of the following chapters: Chapter I General...
  • Page 4: Table Of Contents

    CONTENTS CHAPTER I GENERAL FEATURES .......................... I-1 SPECIFICATIONS ....................... I-1 SAFETY INFORMATION ..................... I-6 Laser Safety (110 - 120V Model only) ................ I-6 CDRH Regulations (110 - 120V Model only) ............... I-7 Additional Information ....................I-7 PARTS OF THE PRINTER ....................I-8 External Views ......................
  • Page 5 CHAPTER III ELECTRICAL SYSTEM MAIN PCB ........................III-1 Outline ........................III-1 Video Controller Circuit ................... III-2 Engine Controller Circuit ..................III-7 PAPER FEED DRIVE CIRCUIT ..................III-9 DISPLAY CIRCUIT ......................III-11 Outline ........................III-11 Operation .......................III-11 LOW-VOLTAGE POWER SUPPLY ASSY ................. III-12 Outline ........................
  • Page 6 1.31 DC Gear Holder Assy ....................IV-23 1.32 PS Switch Wire, Remote Switch ................IV-23 1.33 High-Voltage Power Supply PCB Assy ..............IV-24 1.34 Low-Voltage Power Supply PCB Assy ..............IV-24 1.35 Toner Cartridge (EP-ED Cartridge) ................. IV-25 1.36 Paper Tray ......................IV-25 CHAPTER V MAINTENANCE AND SERVICING PERIODICAL REPLACEMENT PARTS ................
  • Page 7: Chapter Igeneral

    CHAPTER I GENERAL 1. FEATURES This high-speed, non-impact (low-noise) printer is based on electrophotography, electronics and laser technology. The printer is compact and easy to carry. The internally-storable, front-loading paper cassette enables you to save an occupation space for the machine; the printer can now be installed in a smaller place.
  • Page 8 Printing system Photosensitive drum Charging Charging Roller Exposure Laser scanning system Development Toner projection development system Paper feed Cassette or manual feed Image transfer Roller method Separation Natural(utilizing a small drum radius), Static charge eliminator Fixing Heated fixing roller Toner supply Included in the replaceable EP-ED cartridge Life expectancy 6000 pages/cartridge...
  • Page 9 (13) Effective printing area Printable area Figure 1.1 Printable Area Effective printable area is referred to as a area within which is guaranteed the printing of all interface signal data on a hard copy without any omission. The tables below shows the effective printable area for each paper size. Table 1.1 Plain Paper SIZE A (mm)
  • Page 10 • Oklahoma, Oblique, Bold, • Portugal Roman, Italic, Bold, Bold Italic Bold Oblique • Calgary Medium Italic • PC Brussels Light, Light Italic, Demi, Brother Original Fonts: Demi Italic • Bermuda Script • PC Tennessee Roman, Italic, Bold, • Germany Bold Italic •...
  • Page 11 BR-Script Level 2 Mode Scalable Fonts: • Atlanta Book, Book Oblique, Demi, • Albertville, Extrabold Demi Oblique • Antique Oakland, Oblique, Bold • Brussels Light, Light Italic, Demi, • Cleveland Condensed Demi Italic • Conecticut • Brougham, Oblique, Bold, Bold Oblique •...
  • Page 12: Safety Information

    Relative humidity Normal (total storage time x 9/10) 35 ~ 85%RH Severe (total storage time x 1/10) High 85 ~ 95%RH 10 ~ 35%RH Air pressure 613 ~ 1013 hPa Total storage time 0.5 years • EP-ED cartridge Temperature Normal (2.45 years max.) 0 ~ 35°C Severe (0.05 years max.) High...
  • Page 13: Cdrh Regulations (110 - 120V Model Only

    CDRH regulations and must be attached to laser products marketed in the United States. MANUFACTURED : BROTHER INDUSTRIES, LTD. 15-1, Naeshiro-cho, Mizuho-ku Nagoya 467, Japan. This product complies with FDA radiation performance standards , 21 CFR chapter 1 subchapter J.
  • Page 14: Parts Of The Printer

    4. PARTS OF THE PRINTER 4.1 External Views Upper cover AC inlet Control panel Face-up print delivery port MP tray Fan outlet port Tray 1 Rating label Tray 2 (Option) Optional I/O slot Font card slot RS-232C interface connector Font cartridge slot Centronics interface connector Power switch Optional interface connector...
  • Page 15: Cross Sectional View

    4.2 Cross Sectional View Registration rollers Low-voltage power supply assy EP-ED cartridge High-voltage power supply assy Photosensitive drum Paper cassette (Tray 1) Laser scanner unit Pick-up rollers Transfer unit MP tray Face-down tray Control panel Print-delivery path Fixing unit Figure 1.5 I - 9...
  • Page 16: Storage And Handling Of Ep-Ed Cartridges

    5. STORAGE AND HANDLING OF EP-ED CARTRIDGES An EP-ED cartridge is influenced by the storage conditions even if it is sealed in its package, so its life depends on the way in which it is used or stored. EP-ED cartridges should be handled carefully.
  • Page 17: Theory Of Operation

    CHAPTER II THEORY OF OPERATION This chapter describes the printer functions, the relationship between the electrical systems and mechanical systems, and the timing of operations. Striped conduits ( ) indicate mechanical linkages; solid thin arrows ( ) appearing with a signal name indicate the transmission of single control signals and outlined thick arrows ( ) indicate the transmission of groups of signals.
  • Page 18: Main Drive

    1.2 Main Drive The power necessary for driving the printer is supplied by the main motor, the paper feed motor and the scanner motor. The main motor is controlled by the main motor drive signal (MDRIVE) output from the main PCB, and the paper feed motor is controlled by the paper feed motor drive signal output from the main PCB, and the scanner motor is controlled by the scanner motor drive signal (SDRIVE) output from the main PCB.
  • Page 19: Basic Sequence Of Operations

    1.3 Basic Sequence of Operations Timing for two consecutive prints on A4 paper. Power on Print WAIT STBY PRINT STBY Ready lamp 170 C 170 C control 190 C control control Fixing heater Main motor Scanner motor Paper feed motor 0.15 sec 0.15 sec 1.88 sec 1.73 sec...
  • Page 20: Laser/Scanner System

    2. LASER/SCANNER SYSTEM To external device Main PCB DATA VOFF Scanner driver Collimator lens Scanning mirror Cylindrical lens Scanner motor Optical sensor Focusing lenses Beam detect mirror Figure 2.4 In response to the print signal transmitted from the external device, the main PCB generates the drive signals (DATA,VOFF) for the laser diode and sends the signals to the scanner unit.
  • Page 21: Image Formation System

    3. IMAGE FORMATION SYSTEM 3.1 Outline The image formation system is the main part of the printer. The print information, after input from the video controller circuit into the engine controller circuit as a TVDO signal, forms a toner image on the photosensitive drum.
  • Page 22: Electrostatic Latent Image Formation Stage

    3. Transfer stage Step 4 Transfer (+) Step 5 Separation 4. Fixing stage Step 6 Fixing 5. Drum cleaning stage Step 7 Drum cleaning Electrostatic latent image formation stage 2. Scanning exposure Paper path Direction of drum rotation 1. Primary charge 3.
  • Page 23 Step 1 Primary charge Primary charging roller AC bias Photosensitive drum DC bias Figure 2.9 As preparation for latent image formation, a uniform negative potential is applied to the photosensitive drum surface. The printer uses the charging method that directly charges the drum for the primary charge.
  • Page 24 3.2.2 Developing stage Development places particles of toner onto the areas of the drum that have been cleared of charge by the laser beam. This makes a visible image. This printer uses the toner projection development method with a single-component toner. Step 3 Development Blade...
  • Page 25 3.2.3 Transfer stage In the transfer stage, the toner image is transferred from the drum surface to the paper. Step 4 Transfer Photo- sensitive Paper drum Transfer charging roller Figure 2.13 A positive charge applied to the back of the paper attracts the negatively charged toner particles to the paper.
  • Page 26 3.2.4 Fixing stage The toner image transferred to the paper in the transfer stage is held only by electrostatic attraction and 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 to the paper to make a permanent image.
  • Page 27: Operation

    3.3 Operation When the engine controller circuit receives a print signal (PRINT) or a pre-feed signal (PRFD) from the video controller circuit, the engine controller circuit drives the main motor to rotate the photosensitive drum. After the drum surface is charged negatively by the primary charge roller, the laser beam modulated by a DATA signal scans the drum surface to from a latent image on the drum.
  • Page 28: Paper Pick-Up/Feed System

    4. PAPER PICK-UP/FEED SYSTEM 4.1 Outline If a tray1 paper pick-up roller solenoid drive signal (PUCL1) is input to the circuit while the paper feed motor is rotating, the paper pick-up solenoid comes on and the paper pick-up roller solenoid is engaged.
  • Page 29: Cassette Feed

    4.2 Cassette Feed When the fixing rollers reach the specified temperature while a cassette with paper is in the printer, the READY lamp changes from flashing to lighting. When the engine controller circuit receives PRNT or PRFD signal from the video controller circuit, the paper feed motor starts rotation.
  • Page 30: Mp Tray Feed

    4.3 MP Tray Feed The timing of the MP tray feed is identical to the timing of the cassette paper feed except for the following points: The paper empty sensors are different. Cassette feed : Tray1 paper empty sensor MP tray feed : MP tray paper empty sensor (2) The pick-up roller solenoids are different.
  • Page 31: Paper Jam Detection

    4.4 Paper Jam Detection The printer has a registration sensor and a paper eject sensor at the paper outlet to detect whether the printed paper has been fed correctly. A paper jam is detected by whether the paper is present at the sensor at the check periods programmed in the engine CPU memory. If the engine CPU detects a paper jam, the main motor, paper feed motor and scanner motor is turned off immediately and the jam status is transmitted to the video controller circuit.
  • Page 32 Jam inside (2) STBY PRINT Main motor Paper feed motor Paper ejection sensor 1.88 sec 1.88 sec Normal Jam check Figure 2.23 Jam rear STBY PRINT Main motor Paper feed motor Paper ejection 7.17 sec sensor 7.17 sec Normal Jam check Figure 2.24 II - 16...
  • Page 33: Chapter Iii Electrical System

    CHAPTER III ELECTRICAL SYSTEM Electric signal levels are expressed by ”High” (approximate the supply voltage) or ”Low” (approximate 0V). Signals with hyphen or slash, such as -FSRD or FSRD/, are low-active and signals without hyphen or slash, such as FSRD, are high-active signals. 1.
  • Page 34: Video Controller Circuit

    1.2 Video Controller Circuit (1) CPU block CPU(#33) MB86832-100 manufactured by Fujitsu RISC chip Clock speed: 19.6608 MHz Appearance: 178-pin QFP Voltage: 3V (2) ASIC/Gate Array Block • #19 MB87F1610(Fujitsu) - 240-pin QFP Controls the address decoder, timers and interfaces (Centronics and RS-232C). •...
  • Page 35 The attached Printer SIMM map shows the memory map for 4 SIMMs combined. (6) ROM block ROMs store the CPU control program and font data. ROMs are two 32Mbit masked ROMs. Optional sockets are available for two 8Mbit EPROM (µPD27C8000DZ-120 - NEC or equivalent) for expansion.
  • Page 36 0000_0000 There are 4 CS terminals for CSROM#0 - CSROM#3. 2MB or 4MB is selectable from CSROM#0 - CSROM#2. 0040_0000 If the both are selected, it will become one memory space 0080_0000 (4 bunk) and ROM#0 supports upto 16MB. CSROM#3 is a rest of the memory space with 256MB Font card 0100_0000...
  • Page 37 ADDRESS 0820 0000 NONE 0830 0000 2MB 2MB 2MB 0840 0000 4MB 4MB 4MB 4MB 4MB 4MB 0850 0000 2MB 2MB 0860 0000 8MB 8MB 8MB 8MB 8MB 8MB 8MB 8MB 8MB 0870 0000 2MB 2MB 0880 0000 4MB 4MB 4MB 0890 0000 08A0 0000 08B0 0000...
  • Page 38 ROM block DRAM block Centronics parallel I/F connector ASIC M65243FP RS-232C serial I/F connector SIMM block CPU(VIDEO) Option I/F connector CPU(ENGINE) Font cartridge connector Control panel connector Font card connector ASIC µPD65626 ASIC M65340 FP Figure 3.4 Main PCB III - 6...
  • Page 39: Engine Controller Circuit

    1.3 Engine Controller Circuit Scanner Unit Primary charging roller Transfer roller High-Voltage Power Supply Assy Developing cylinder Toner sensor Engine Controller Pick-up Solenoid Circuit MP Tray Pick-up Solenoid Paper Feeder Pick-up Motor Detectors Main Motor Fixing Unit Low-Voltage Power Supply Assy Figure 3.5 Engine Controller Block Diagram Components in the Circuit (refer to the next page)
  • Page 40: Paper Feed Drive Circuit

    2. PAPER FEED DRIVE CIRCUIT A. Connector to Main PCB B. Pick-up Motor Drive Circuit and Connector C. Pick-up Solenoid Drive Circuit and Connector D. Multi Purpose Tray Pick-up Solenoid Drive Circuit and Connector E. Sensors E-1. Tray1 Paper Empty Sensor E-2.
  • Page 41 Figure 3.7 Paper Feed/Size-SW PCB Circuit III - 9...
  • Page 42: Display Circuit

    3. DISPLAY CIRCUIT 3.1 Outline The control panel of this printer has four LED lamps, one LCD display, and eight switches. The control panel is connected to the Main PCB and its functions are as follows: (1) The LCD shows the printer status and error message in alpha-numeric characters. (2) The LED lamps indicate the operating conditions of the printer.
  • Page 43: Low-Voltage Power Supply Assy

    4. LOW-VOLTAGE POWER SUPPLY ASSY 4.1 Outline The low-voltage power supply assy consists of the low-voltage generating block (hereinafter the DC block) and the heater drive circuit block to turn the heater on (hereinafter the AC block). When the power switch (SW1) is turned on, AC power is supplied to the low-voltage power supply assy.
  • Page 44 AC IN Lamp Thermal Fuse To Heater Circuit F101 Heater HEAT/ Control F102 Noise Power +24V Rectfier Rectfier Filter Switch (SW1) Chopper +24VRET ±0V ±0V Over Feedback Control Voltage Detector FANLOCK/...
  • Page 45: High-Voltage Power Supply Assy

    5. HIGH-VOLTAGE POWER SUPPLY ASSY 5.1 Outline The High-Voltage Power Supply Assy supplies the high-voltage for the charging roller, the developer cylinder and the transfer roller according to the engine CPU’s control signals. The block diagrams are shown Fig 3.10 and 3.11. 5.2 Operation of the Components of the High-Voltage Power Supply Assy (1) Primary charging When input signal/HV1AC gets the Low level, the primary high-voltage AC is applied to the...
  • Page 46 High-Voltage PRIMARY HIGH-VOLTAGE AC Electrode Current Sin Wave Buffer Generator DBOUT Control Unit (Feedback Circuit) (ON / OFF Circuit) PRIMARY HIGH-VOLTAGE DC Pulse Current Generator Buffer Current Buffer PULSE Control Unit /HV1AC (Feedback Circuit) DNSTY (DNSTY Control Circuit) /HV1DC (ON / OFF Circuit) /DBAC /DBDC High-Voltage...
  • Page 47 High-Voltage TRANSFER HIGH-VOLTAGE Electrode Pulse Current Generator Buffer Current Attenuator Buffer Constant Current Control Unit (Feedback Circuit) (ON / OFF Circuit) /HVT3 Constant Voltage /HVT2 Control Unit HVTFB (HVT4 Control Circuit) HVT4 /HVT1 TONER1 TONER2 Pulse Current Generator Buffer 24VRET +24V TONER SENSE Toner Sense...
  • Page 48: Chapter Iv Mechanical System

    CHAPTER IV MECHANICAL SYSTEM Safety Precautions To prevent the creation of secondary problems by mishandling, observe the following precau- tions during maintenance work. Always turn off the power before replacing parts or units. When having access to the power supply, be sure to unplug the power cord form the power outlet. Be careful not to lose screws, washers, or other parts removed for parts replacement.
  • Page 50: Printer Body

    PRINTER BODY Configuration Upper cover assy Toner cartridge lid Control panel unit Paper tray Rear cover assy Side cover L Side cover R Font cover assy Figure 4.1 Toner Cartridge Lid (1) Remove the supporter from the toner cartridge lid. (2) Remove the toner cartridge lid from the upper cover.
  • Page 51: Font Cover Assy

    1.4 Font Cover Assy (1) Remove the font cover assy by loosening the screw on the top and releasing the hooks on the bottom and the side. Screw Hook Font cover assy Hook Figure 4.4 1.5 Upper Cover Assy, Rear Cover Assy 1.5.1 Upper cover assy, rear cover assy (1) Loosen the 4 screws on the rear (the upper 2 screws secure also the upper cover ).
  • Page 52: Changeover Guide, Jam Remove Cover

    1.5.2 Changeover guide, jam remove cover (1) Open the jam remove cover by hooking your finger on 2 dents ( A ). (2) Remove the jam remove cover with its center part opened by bending the arm of the boss both on sides ( B ) toward the front ( C ). (3) Remove the changeover guide from the boss by bending the right hook (viewed from the rear) of the rear cover ( D ), then remove the changeover guide ( E ).
  • Page 53: Dc Fan Motor

    1.7 DC Fan Motor 97-P031 (1) Remove the DC fan motor from the DC fan motor holder by loosening the two screws. (2) Loosen the screws securing the PCB holder and remove the entire DC fan motor holder. (3) Remove the fan harness connector from the main PCB assy. Screw Fan connector Figure 4.9...
  • Page 54 (3) Remove the PCB holder by loosening PCB holder fixing screws, 2 centronics connector screws and 2 RS-232C connector screws. PCB holder Screws Figure 4.12 (4) Remove the switch flat cable 21P and the feed flat cable 20P. (5) Remove the fan harness 3P, the fuser harness 4P, the SCN harness 4P, the SCN flat cable 6P, the DC motor harness 4P, the HV harness 16P and the LV harness 8P.
  • Page 55: Control Panel Unit

    1.9 Control Panel Unit Screws Switch flat cable 21P Control panel unit Panel arm L Main PCB Figure 4.15 (1) Remove the left side the control panel from the arm L by loosening the screws of the panel arm L. (2) Remove the switch flat cable 21P from the main PCB.
  • Page 56: Scanner Unit

    1.10 Scanner Unit (1) Unplug the LD PCB harness (scanner flat cable) connector (6P), and SCN harness connector (4P). (2) Remove the beam from the body by loosening the screws. (3) Remove the scanner unit from the body by loosening the screws. Caution: Do not disassemble the scanner unit, it can be only adjusted at the factory.
  • Page 57: Paper Feed Chassis Unit

    1.12 Paper Feed Chassis Unit (1) Pull out the unit by loosening the 8 screws (4 screws for front and 4 screws for bottom). Paper feed chassis unit Screws Screws Note: When installing the paper feed chassis unit, screw the left chassis of this paper feed chassis unit, set the paper tray, displace the right chassis of this unit up to the paper tray and screw them.
  • Page 58: Separation Pad Assy

    (4) Remove the paper feed chassis unit. Paper feed chassis unit Figure 4.23 1.13 Separation Pad Assy (1) Remove the paper pick-up roller assy and roller collar. (Refer to subsection 1.22) (2) Remove the separation pad assy by pulling it out from the paper feed guide upper. Paper feed guide upper Paper pick-up roller assy Separation pad assy...
  • Page 59: Mp Pe Sub Actuator

    1.14 MP PE Sub Actuator (1) Pull out the actuator upward from the MP tray assy (pay attention to the hook because it is fragile). MP PE sub actuator Figure 4.26 1.15 P Feed /Size-SW PCB Assy (1) Put the 3 chassis L tabs to their original position. Tabs 2 solenoid harness connector...
  • Page 60: Regist Sensor Actuator

    1.17 Regist sensor actuator (1) Remove the actuator by shifting it to the left from the chassis hole. Regist sensor actuator Regist sensor actuator Figure 4.29 1.18 MP Paper Detection Actuator (1) Remove the actuator by removing the 2 bearings from the roller holder. This operation should be carried out with the PCB removed.
  • Page 61: Tray Sensor Holder

    1.20 Tray Sensor Holder (1) Disengage the DU (Duplex) detection actuator from the hook and slide it to the outside. (2) Loosen the screw and remove the holder by lifting it from the chassis. PE sensor actuator tray, PE actuator link, DU detection actuator Remove the PE actuator link from the PE sensor actuator tray.
  • Page 62: Paper Pick-Up Roller Assy, Bearing

    1.22 Paper Pick-up Roller Assy, Bearing (1) Pull out the MP paper pick-up gear 35 and the tray paper pick-up gear 35, from the paper pick- up roller shafts. MP paper pick-up gear 35 Bearings Paper pick-up roller shafts Tray paper pick-up gear 35 Figure 4.34 (2) Loosen the bearing screws and pull out the paper pick-up rollers.
  • Page 63: Paper Pick-Up Solenoid

    1.23 Paper Pick-up Solenoid (1) Remove each solenoid by loosening their screw. Paper pick-up solenoid Screw Paper pick-up solenoid Screw Figure 4.37 1.24 Paper Feed Motor Assy (1) Pull out the paper feed motor assy by loosening its 2 screws. Screw Paper feed motor assy Screw...
  • Page 64: Mp Tray Cover

    1.25 MP Tray Cover (1) Remove the MP tray cover from the paper feed chassis unit by bending its hook on both sides. Paper feed chassis unit Hook MP tray cover Hook MP extension tray Figure 4.40 (2) Remove the MP extension tray from the MP tray cover by bending the former. MP extension tray MP tray cover Figure 4.41...
  • Page 65: Paper Path Separation Plate, Paper Path Separation Film

    (2) Remove the 2 fixing bushes. (3) Remove the MP tray assy. MP tray assy Fixing bushes Figure 4.43 (4) Remove the MP tray assy from the MP release plate bending its bosses. The MP tray can be easily removed if it is slanted. Boss MP release plate MP tray assy...
  • Page 66: Latch

    1.28 Latch (1) Remove the latch from the paper feed guide upper by releasing the 2 hooks. Paper feed guide upper Latch Hook Hook Figure 4.46 1.29 Fixing unit (for both 120V and 230V, the only difference is the halogen heater) (The fixing unit can be disassembled even after removing the rear cover in section 1.6).
  • Page 67 (4) Take off the halogen heater from the heater support spring, remove the halogen heater by pushing it and pulling the heater support spring at the same time ( A ). Fixing unit Heater support spring Support spring Pull Heater Push Halogen heater Halogen heater Figure 4.49...
  • Page 68 (7) Release the left hook and take off the paper delivery actuator. Paper delivery actuator Fixing unit cover Figure 4.52 Remove the fixing heat insulation cover ( by loosening the 2 screws), the pressure roller spring and pressure roller bearing on both sides, and the pressure roller. Screws Pressure roller bearing Heat insulation cover...
  • Page 69: Transfer Unit

    1.30 Transfer Unit (1) Loosen a screw. (2) Release the 3 right hooks, (see Figure 4.57) lift the right part of the unit ( A ) and slide it to the right ( B ) to take off the left part from the main chassis L. Remove the transfer unit from the body by lifting the former.
  • Page 70: Dc Gear Holder Assy

    1.31 DC Gear Holder Assy (1) Remove the DC motor connector, then remove the paper delivery holder spring. (2) Loosen the 4 screws and remove the DC gear unit from the body. (3) Remove the paper delivery gear assy, the gears, the gear 48 spring, and the washer. (4) Loosen the 3 screws and remove the DC motor assy from the gear holder.
  • Page 71: High-Voltage Power Supply Pcb Assy

    1.33 High-Voltage Power Supply PCB (1) Loosen the 2 screws. (2) Hold the head of 4 resin spacers and lift this side of PCB ( A ). (3) Slide the PCB to the opposite side ( B ). Resin spacers Screws High-voltage power supply PCB assy Resin spacers...
  • Page 72: Toner Cartridge (Ep-Ed Cartridge

    1.35 Toner Cartridge (EP-ED Cartridge) (1) Remove the toner cartridge from the body. Toner cartridge lid EP-ED Cartridge Figure 4.65 1.36 Paper Tray (1) Release the roller holder fixing pawl and remove the roller holder by pulling it out upward. (2) Remove the roller.
  • Page 73 (4) Remove the tray gear holder from the other side by loosening the 3 screws and remove the gear 56T link. Screws Tray gear holder Gear 56T link Figure 4.67 IV - 26...
  • Page 74: Chapter Vmaintenance And Servicing

    CHAPTER V MAINTENANCE AND SERVICING 1. PERIODICAL REPLACEMENT PARTS Periodical replacement parts are the parts to be replaced periodically to maintain product quality at same level (in other words the parts which would affect the product greatly if they lost their function even if they are not damaged or there is no change in their appearance.) It is recommended to replace such parts on the occasion of a periodical service which is carried out before or after the specified number of sheets are used, whichever more...
  • Page 75: List Of Standard Tools

    3. LIST OF STANDARD TOOLS The standard tool set required for servicing the printer is as listed below. These tools are commercially available on the market. Table 5.2 Description Remarks Tool box Lead cable Feeler gauge Compression spring scale (0 1kg) For checking cassette spring strength Phillips screwdriver M4, M5...
  • Page 76: List Of Lubricants And Cleaners

    4. LIST OF LUBRICANTS AND CLEANERS Table 5.3 Material name Components Remarks Alcohol ethyl (pure OH, (CH Cleaning of plastic, Purchase locally • or denatured) or CHOH rubber, and external isopropyl (pure or parts denatured) MEK (methyl ethyl CO-C Cleaning for oil and Purchase locally •...
  • Page 77: Chapter Vi Troubleshooting

    CHAPTER VI TROUBLESHOOTING 1. INTRODUCTION 1.1 Initial Check (1) Operating environment Check if: The source voltage stays within ±10% from the rating voltage shown on the rating label. The printer is installed on a solid, level surface. The room temperature is maintained between 10°C and 32.5°C. The relative humidity is maintained between 20% and 80%.
  • Page 78: Basic Procedure

    1.2 Basic Procedure If a malfunction or incorrect print is appeared, make an initial check, then follow the basic procedure below: Check the status display. If any message is shown, see Section 4 for troubleshooting. If an incorrect image is found, see Section 3.1 to determine the defect type and Section 3.2 for image troubleshooting.
  • Page 79: Image Defects

    3. IMAGE DEFECTS 3.1 Image Defect Examples I-1 Light I-2 Dark I-3 Completely blank I-4 All black I-5 Polka dots I-6 Dirt on back of paper I-7 Black vertical streaks I-8 Black and blurred vertical stripes I-9 Black and thin I-11 Dropout I-12 White vertical I-10 Black and blurred...
  • Page 80: Troubleshooting Image Defects

    3.2 Troubleshooting Image Defects Light Possible cause Step Check Result Remedy Toner shortage Does printed image improve when the EP-ED Replace EP-ED cartridge. cartridge is replaced? Cancel the ECONOMY ECONOMY Is the ECONOMY mode active? mode. mode Adjust the proper setting Printing Does printed image improve when printed on the control panel.
  • Page 81 Possible cause Step Check Result Remedy Development Do the pins 3, 4 and 5 of the connector Replace the scanner unit or input signal error P6 on the main PCB have the following value the harness. respectively when a sheet of paper is fed from the MP tray? P6-3 pin (DBAC) --- Change in voltage from 6V approx.
  • Page 82 Completely blank Possible cause Step Check Result Remedy EP-ED cartridge Does printed image improve when the EP-ED Replace the EP-ED cartridge. cartridge is replaced? Do the pins 3, 4 and 5 of the connector? Replace the main PCB assy Development P6 on the main PCB have the following value or the harness.
  • Page 83 Polka dots Possible cause Step Check Result Remedy Failure in static- Is there any dirt on the static-charge eliminator? Clean the static-charge charge eliminator eliminator. Static-charge Is there continuity between the static-charge Ensure the grounding of the eliminator eliminator and the chassis? static-charge eliminator.
  • Page 84 Black vertical streaks or Blurred vertical line Possible cause Step Check Result Remedy During a printing, open the toner cartridge lid EP-ED cartridge Replace the EP-ED cartridge. in the printer and pull out the EP-ED cartridge. Open the drum shutter of the EP-ED cartridge Fixing unit and check the toner image on the drum.
  • Page 85 I-11 Dropout Possible cause Step Check Result Remedy Paper failure Is recommended paper used? Use recommended paper. Paper soaked Is paper soaked? Store the paper in packing paper to keep it from soaking. EP-ED cartridge Does printed image improve when the EP-ED Replace the EP-ED cartridge.
  • Page 86 I-13 Faulty registration Possible cause Step Check Result Remedy Check again the top margin Top margin Does self test printing have no problem? setting in the printing data. setting error Paper load in Is over-amount of paper than specified load Reduce the paper load below the cassette on the cassette?
  • Page 87: Troubleshooting Of Malfunctions

    4. TROUBLESHOOTING OF MALFUNCTIONS No DC power supplied Possible cause Step Check Result Remedy PCBs Does any PCB have the short circuit between Replace the PCB having the +24V and 0V,+5V and 0V or +24V and +5V? short circuit. Low-voltage Is the voltage of P4-8 in the low-voltage power Replace the low-voltage power power supply...
  • Page 88 Malfunction of control panel switches. Possible cause Step Check Result Remedy Mis-operation Are the switchs operated according to the Operate the switches operation manual? correctly following the operation manual. When a switch is pressed,does the voltage of Replace the Main PCB assy. Switch the following signals change from 5V to 0V? Control panel...
  • Page 89 " CHECK XX TRAY " is displayed even if a paper-loaded cassette is mounted (or even if a paper is set on MP tray) XX is MP/T1/T2 Possible cause Step Check Result Remedy Mis-operation Is the paper feed mode set correctly? Set paper feed mode correctly.
  • Page 90 "16 TONER EMPTY " is displayed Possible cause Step Check Result Remedy EP-ED cartridge Take the EP-ED cartridge out of the printer The problem was caused by and rock it to distribute the toner evenly. toner onesided due to too little toner remaining.
  • Page 91 M-11 "54 MOTOR MALF" is displayed (The main motor rotation disabled) Possible cause Step Check Result Remedy Low-voltage power Is the voltage of P7-1 in the main PCB Replace the main PCB assy supply PCB connector +24V? low-voltage power supply PCB assy, or the LV harness.
  • Page 92 M-13 "55 HIGH VOL MALF" is displayed (Faulty output from the H.V.P.S. ASSY) Possible cause Step Check Result Remedy Main PCB When a test print is carried out, is the voltage Replace the main PCB assy. of the each pin in the main PCB connector P6 turned on and off as the below list? Pin No.
  • Page 93 M-14 "50 FUSER MALF" is displayed Possible cause Step Check Result Remedy Thermal fuse Is the thermal fuse located in the fixing unit Replace the fixing unit. conductive? Thermistor Remove the fixing unit from the printer and Replace the fixing unit. measure the resistance between two pins of the 2 pin connector on the fixing PCB.
  • Page 94 M-17 "41 PRINT CHECK" is displayed Possible cause Step Check Result Remedy Main PCB Does this problem frequently occur? Since this is a temporary problem, remove the paper used when the error occurred and continue to print. Replace the main PCB assy. VI - 18...
  • Page 95: Troubleshooting Paper Transport Problems

    5. TROUBLESHOOTING PAPER TRANSPORT PROBLEMS 5.1 Paper Jams The paper path is divided into following three blocks: The paper pick-up block, (The LCD display "JAM TRAYS") The separation and feed block, (The LCD display "JAM INSIDE") The fixing and paper delivery block, (The LCD display "JAM REAR") Therefore, remedies for paper jam problems are described.
  • Page 96 J-1a Paper pick-up block (Pick miss) Possible cause Step Check Result Remedy Instruct the user to follow the Adjustment Is the position of the adjustment lever of the correct method. lever cassette corresponding to the paper sheet size? (spring pressure switching lever) Is a recommended type of paper being used ? Print paper...
  • Page 97 Separation and feed block (Paper jam) Possible cause Step Check Result Remedy Print Paper Is a recommended type of paper being used? Instruct the user to use recommended type of paper. Static-charge Clean the static-charge Is the static-charge eliminator dirty? eliminator eliminator.
  • Page 98: Incomplete Paper Feed

    5.2 Incomplete Paper Feed F -1 Double feeding Possible cause Step Check Result Remedy Print paper Instruct the user to use Is a recommended type of paper being used? recommended type of paper. Instruct the user to switch Adjustment lever Is the position of the adjustment lever of the adjustment lever position.
  • Page 99: Operation

    6. OPERATION 6.1 Line Inspection Mode Procedure Mount the font cartridge, the flush memory card and the optional MIO board. Note: Use a Hewlett Packard Company C2053A#C01 Word Perfect as font cartridge. While pressing the switch, turn the power on. The LCD will display: LINE TEST Press the...
  • Page 100 (10) Press the CONTINUE switch to check the font cartridge. CART CHECK START FONTCART OK!! The font cartridge is normal. (11) Flash memory check CARD CHECK START FLASH OK!! The flash memory is normal. (12) MIO check MIO CHECK START RAM SIZE = Now initializing LJ WAIT 001P T1...
  • Page 101: Dram Test

    6.2 DRAM Test (1) To start up the test program: While pressing the Switch (RESET switch), turn the power on. ”DRAM CHECK” will be displayed. Then press CONTINUE switch to start DRAM checking. (2) The LCD will display "START DRAM TEST" and the DATA lamp or ALARM lamp will be flashing.
  • Page 102: Status Message List

    7. STATUS MESSAGE LIST Table 6.2 Operator Call Messages Operator Call Message Meaning Action Load a stack of paper The paper cassette (XX CHECK XX TRAY into the cassette. See is MP/T1/T2) is out of M-7. paper. Close the cover. See The upper cover of the 12 COVER OPEN M-6.
  • Page 103 Table 6.3 Error Messages Error Message Meaning Action Press the CONTINUE Print overrun 31 PRINT OVERRUN switch to start printing the next page. Data which overran the print area on the page cannot be printed. Check your page protection setting with the MODE switch.
  • Page 104 Error Message Action Meaning Card overflow 42 CARD FULL Delete unnecessary macros or fonts, or use a new card. Card write error 43 CARD W ERR Set the write protect switch of the card to OFF if it has been set to ON. Use a new card.
  • Page 105 Table 6.4 Service Call Messages Service Call Message Meaning Action Malfunction of fuser Turn off the printer. Wait 9950 FUSER MALF 15 minutes, then turn it on again. See M-14. Malfunction of laser beam Turn off the printer. Wait 51 LASER BD MALF detector a few seconds, then turn it on again.
  • Page 106 Meaning Action Service Call Message Instruction bus error remains, replace the main 99 SERVICE 4 PCB. Turn off the printer. Wait a few seconds, then turn it 99 SERVICE 5 on again. If still remains, Data bus error replace the main PCB. Turn off the printer.
  • Page 107: Engine Block Diagram

  • Page 108: Paper Feed/Size-Sw Pcb Circuitry Diagram (1/1

    95-P053 Appendix 2. Paper Feed/Size-SW PCB Circuitry Diagram (1/1) (JW 27) CODE UK2516000 NAME B48K139/140CIR...
  • Page 109: Main Pcb Circuitry Diagram (1/7

    Appendix 3. Main PCB Circuitry Diagram (1/7) CODE UK3787000 B48K294/295CIR (1/7) NAME...
  • Page 110: Main Pcb Circuitry Diagram (2/7

    Appendix 4. Main PCB Circuitry Diagram (2/7) CODE UK3787000 B48K294/295CIR (2/7) NAME...
  • Page 111: Main Pcb Circuitry Diagram (3/7

    Appendix 5. Main PCB Circuitry Diagram (3/7) CODE UK3787000 NAME B48K294/295CIR (3/7)
  • Page 112: Main Pcb Circuitry Diagram (4/7

    Appendix 6. Main PCB Circuitry Diagram (4/7) CODE UK3787000 NAME B48K294/295CIR (4/7)
  • Page 113: Main Pcb Circuitry Diagram (5/7

    Appendix 7. Main PCB Circuitry Diagram (5/7) CODE UK3787000 B48K294/295CIR (5/7) NAME...
  • Page 114: Main Pcb Circuitry Diagram (6/7

    Appendix 8. Main PCB Circuitry Diagram (6/7) CODE UK3787000 B48K294/295/CIR (6/7) NAME...
  • Page 115: Main Pcb Circuitry Diagram (7/7

    Appendix 9. Main PCB Circuitry Diagram (7/7) CODE UK3787000 B48K294/295CIR (7/7) NAME...
  • Page 116: Control Panel Pcb Circuitry Diagram (1/1

    Appendix 10. Control Panel PCB Circuitry Diagram (1/1) CODE UK2527000 NAME B48K143CIR A-10...
  • Page 117: Scanner Ld Pcb Circuitry Diagram (1/1

    Appendix 11. Scanner LD PCB Circuitry Diagram (1/1) CODE UK2674000 NAME B48K165CIR A-11...