Brother HL1060 - B/W Laser Printer, HL-1060 Service Manual

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SERVICE MANUAL

MODEL:HL-1060

LASER PRINTER

Page 2

© Copyright Brother 1997 All rights reserved. No part of this publication may be reproduced in any form or by any means without permission in writing from the publisher. Specifications are subject to change without notice.

Trademarks: The brother logo is a registered trademark of Brother Industries, Ltd.

Apple,the Apple Logo,and Macintosh are trademarks,registered in the United States and other countries,and True Type is a trademark of Apple computer, Inc. Epson is a registerd trademark and FX-80 and FX-850 are trademarks of Seiko Epson Corporation. Hewlett Packard is a registered trademark and HP Laser Jet is a trademark of Hewlett Packard Company. IBM, IBM PC and Proprinter are registered trademarks of International Business Machines Corporation. Microsoft and MS-DOS are registered trademarks of Microsoft Corporation. Windows is a registered trademark of Microsoft Corporation in the U.S. and other countries.

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PREFACE

This service manual contains basic information required for after-sales service of the laser printer (here- in-after referred to as "this machine" or "the printer"). This information is vital to the service technician to maintain the high printing quality and performance of the printer.

This service manual covers the HL-1060 laser printer. This manual consists of the following chapters:

CHAPTER I : FEATURES AND SPECIFICATIONS

Features, specifications, etc.

CHAPTER II : THEORY OF OPERATION

Basic operation of the mechanical system, the electrical system and the electrical circuits, and their timing information.

CHAPTER III : DISASSEMBLY AND REASSEMBLY

Procedures for disassembling and reassembling the mechanical system.

CHAPTER IV : MAINTENANCE AND TROUBLESHOOTING

Reference values and adjustments, troubleshooting image defects, troubleshooting malfunctions, etc.

APPENDICES :SERIAL NO. DESCRIPTIONS, CONNECTION DIAGRAMS, PCB CIRCUIT

DIAGRAMS.

Information in this manual is subject to change due to improvement or re-design of the product. All relevant information in such cases will be supplied in service information bulletins (Technical Information).

A thorough understanding of this printer, based on information in this service manual and service information bulletins, is required for maintaining its print quality performance and for improving the practical ability to find the cause of problems.

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CONTENTS

CHAPTER I FEATURES AND SPECIFICATIONS ..........................................I-1

1. FEATURES.........................................................................................................................I-1

2. SPECIFICATIONS ..............................................................................................................I-3

2.1 Printing.......................................................................................................................................I-3

2.2 Functions...................................................................................................................................I-3

2.3 Electrical and Mechanical..........................................................................................................I-4

2.4 Paper Specification....................................................................................................................I-5

2.5 Print Delivery .............................................................................................................................I-6

2.6 Paper.........................................................................................................................................I-6

2.7 Effective Printing Area...............................................................................................................I-7

3. SAFETY INFORMATION ....................................................................................................I-9

3.1 Laser Safety (110 - 120V Model only).......................................................................................I-9

3.2 FDA Regulations (110 - 120V Model only)................................................................................I-9

3.3 Caution for Laser Product..........................................................................................................I-10

CHAPTER II THEORY OF OPERATION ........................................................ II-1

1. ELECTRONICS..................................................................................................................II-1

1.1 General Block Diagram.............................................................................................................II-1

1.2 Main PCB Block Diagram.........................................................................................................II-2

1.3 Main PCB..................................................................................................................................II-3

1.3.1 CPU Core....................................................................................................................II-3

1.3.2 ASIC............................................................................................................................II-4

1.3.3 ROM............................................................................................................................II-7

1.3.4 Optional ROM..............................................................................................................II-7

1.3.5 DRAM..........................................................................................................................II-8

1.3.6 Optional RAM..............................................................................................................II-9

1.3.7 Optional Serial I/O .....................................................................................................II-10

1.3.8 EEPROM...................................................................................................................II-10

1.3.9 Reset Circuit..............................................................................................................II-11

1.3.10 Parallel I/O.................................................................................................................II-11

1.3.11 Engine I/O..................................................................................................................II-12

1.3.12 Paper Feed Motor Drive Circuit.................................................................................II-13

1.4 Driver PCB..............................................................................................................................II-13

1.5 SW Panel PCB........................................................................................................................II-13

1.6 Power Supply..........................................................................................................................II-14

1.6.1 Low-voltage Power Supply........................................................................................II-14

1.6.2 High-voltage Power Supply, SR PCB........................................................................II-15

2. MECHANICS.................................................................................................................... II-16

2.1 Overview of Printing Mechanism............................................................................................II-16

2.2 Paper Transfer........................................................................................................................II-17

2.2.1 Paper Supply.............................................................................................................II-17

2.2.2 Paper Registration.....................................................................................................II-17

2.2.3 Paper Eject................................................................................................................II-18

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2.3 Sensors...................................................................................................................................II-19

2.3.1 Cover Sensor ............................................................................................................II-19

2.3.2 Toner Empty Sensor .................................................................................................II-19

2.4 Drum Unit................................................................................................................................II-20

2.4.1 Photosensitive Drum.................................................................................................II-20

2.4.2 Primary Charger........................................................................................................II-20

2.4.3 Developer Roller........................................................................................................II-20

2.4.4 Transfer Roller...........................................................................................................II-20

2.4.5 Cleaner Roller............................................................................................................II-20

2.4.6 Erase Lamp ..............................................................................................................II-20

2.5 Print Process ..........................................................................................................................II-20

2.5.1 Charging ...................................................................................................................II-20

2.5.2 Exposure Stage.........................................................................................................II-21

2.5.3 Developing.................................................................................................................II-22

2.5.4 Transfer.....................................................................................................................II-22

2.5.5 Drum Cleaning Stage ................................................................................................II-23

2.5.6 Erasing Stage............................................................................................................II-23

2.5.7 Fixing Stage...............................................................................................................II-23

CHAPTER III DISASSEMBLY AND REASSEMBLY.......................................III-1

1. SAFETY PRECAUTIONS..................................................................................................III-1

2. DISASSEMBLY FLOW......................................................................................................III-2

3. DISASSEMBLY PROCEDURE .........................................................................................III-3

3.1 Drum Unit.................................................................................................................................III-3

3.2 Output Tray ASSY...................................................................................................................III-3

3.3 Top Cover................................................................................................................................III-4

3.4 MP Sheet Feeder 1 ASSY.......................................................................................................III-4

3.5 MP Sheet Feeder 2 ASSY.......................................................................................................III-7

3.6 Under Shoot ASSY..................................................................................................................III-7

3.7 SR PCB / Relay PCB ..............................................................................................................III-9

3.8 Fixing Unit..............................................................................................................................III-10

3.9 Scanner Unit..........................................................................................................................III-14

3.10 Main PCB ASSY ....................................................................................................................III-15

3.11 Base Plate ASSY...................................................................................................................III-15

3.12 Driver PCB ASSY ..................................................................................................................III-17

3.13 Low-voltage Power Supply PCB ASSY .................................................................................III-18

3.14 High-voltage Power Supply PCB ASSY ................................................................................III-19

3.15 Fan Motor ASSY ...................................................................................................................III-19

3.16 Drive Unit...............................................................................................................................III-20

3.17 Main Motor ASSY ..................................................................................................................III-21

3.18 Gears and Solenoid...............................................................................................................III-22

3.19 Paper Support........................................................................................................................III-24

3.20 Extension Support Wire.........................................................................................................III-24

4. PACKING........................................................................................................................III-25

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iii

CHAPTER IV MAINTENANCE AND TROUBLESHOOTING..........................IV-1

1. INTRODUCTION.............................................................................................................. IV-1

1.1 Initial Check.............................................................................................................................IV-1

1.2 Basic Procedure ......................................................................................................................IV-2

2. CONSUMABLE PARTS ...................................................................................................IV-2

2.1 Drum Unit.................................................................................................................................IV-2

2.2 Toner Cartridge........................................................................................................................IV-2

2.3 Periodical Replacement Parts .................................................................................................IV-3

3. IMAGE DEFECTS............................................................................................................ IV-4

3.1 Image Defect Examples...........................................................................................................IV-4

3.2 Troubleshooting Image Defects...............................................................................................IV-5

3.3 Location of High-voltage Contacts and Grounding Contacts.................................................IV-19

3.4 Location of Feed Roller Shaft and Grounding Contacts........................................................IV-20

4. PAPER JAM...................................................................................................................IV-21

5. TROUBLESHOOTING MALFUNCTIONS ...................................................................... IV-22

6. INSPECTION MODE...................................................................................................... IV-27

6.1 Incorporated Inspection Modes .............................................................................................IV-27

6.2 Error Codes ...........................................................................................................................IV-29

APPENDICES

1. Serial No. Descriptions......................................................................................................V-1

2. Connection Diagram..........................................................................................................V-2

3. Main PCB Circuit Diagram, (1/4).......................................................................................V-3

4. Main PCB Circuit Diagram, (2/4).......................................................................................V-4

5. Main PCB Circuit Diagram, (3/4).......................................................................................V-5

6. Main PCB Circuit Diagram, (4/4).......................................................................................V-6

7. Driver PCB Circuit Diagram...............................................................................................V-7

8. Switch Panel/Solenoid, Bin/Relay PCB Circuit Diagram ................................................... V-8

9. Low-voltage Power Supply PCB Circuit Diagram (110 - 240V).......................................... V-9

10.Low-voltage Power Supply PCB Circuit Diagram (220 - 240V)........................................V-10

11.High-voltage Power Supply PCB Circuit Diagram............................................................ V-11

12.SR PCB Circuit Diagram .................................................................................................V-12

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CHAPTER I -1

CHAPTER I FEA TURES AND SPECIFICA TIONS

1. FEATURES

This printer has the following features:

1200dpi Resolution and 10ppm Printing Speed

600 dots per inch (dpi) with microfine toner and ten pages per minute (ppm) printing speed (A4 or Letter size paper). The printer also supports 1200 (H) x 600 (V) dots per inch (dpi) resolution for Windows DIB graphics. ( It is recommended to add memory when printing in 1200 x 600dpi mode.)

User-Friendly Operation for Windows

The dedicated printer driver and TrueType

-compatible fonts for

Microsoft

Windows 3.1 and Windows 95 are available on the floppy disk supplied with your printer. You can easily install them into your Windows system using our installer program. The driver supports our unique compression mode to enhance printing speed in Windows applications and allows you to set various printer settings including toner saving mode, custom paper size, sleep mode, gray scale adjustment, resolution, and so forth. You can easily setup these print options in the graphic dialog boxes through the Printer Setup menu within the Windows Control Panel.

Printer Status Monitor with Bi-directional Parallel Interface

The printer driver can monitor your printer’s status using bi-directional parallel communications. The printer status monitor program can show the current status of your printer. When printing, an animated dialog box appears on your computer screen to show the current printing process. If an error occurs, a dialog box will appear to let you know what to correct. For example: when your printer is out of paper, the dialog box will display “Paper Empty” and instructions for the corrective action to take.

Versatile Paper Handling

The printer has two multi-purpose sheet feeders and a straight paper path mechanism. From the front Feeder 1, you can load A4, letter, legal, B5, A5, A6, and executive sizes of paper, and various types of media including envelopes, postcards, organizer paper, or your custom paper size. From the rear Feeder 2 you can load A4, letter, legal, B5 and executive sizes of paper. The front Feeder 1 also allows manual paper loading, so you can also use labels and transparencies.

Environment-Friendly

Economy Printing Mode: This feature will cut your printing cost by saving toner. It is useful to obtain draft copies for proof-reading. You can select from two economy modes 25% toner saving and 50% toner saving, through the Windows printer driver supplied with your printer.

Sleep Mode (Power Save Mode): Sleep mode automatically reduces power consumption when the printer is not in use. The printer consumes less than 13W when in sleep mode.

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CHAPTER I -2

Low Running Cost: The toner cartridge is separate from the drum unit. You need to replace only the toner cartridge after around 2,200 pages, which is cost effective and ecologically friendly.

Remote Printer Console Program for DOS

The utility program, Remote Printer Console (RPC), is available on the floppy disk supplied with your printer. When you operate your computer in the DOS (Disk Operating System) environment, this program allows you to easily change the default settings of the printer such as fonts, page setup, emulations and so on. This program also provides a status monitor program, which is a Terminate-and-Stay Resident (TSR) program. It can monitor the printer status while running in the background and report the current status or errors on your computer screen.

Popular Printer Emulation Support

This printer supports three printer emulation modes, HP LaserJet 5P, Epson FX-850, and IBM Proprinter XL. The printer also supports Auto-emulation switching between HP and Epson or HP and IBM. If you want to select the printer emulation, you can do it using the Remote Printer Console Program.

Enhanced Memory Management

The printer provides its own data compression technology in its printer hardware and the supplied printer driver software, which can automatically compress graphic data and font data efficiently into the printer's memory. You can avoid memory errors and print most full page 600dpi graphic and text data, including large fonts, with the printer's standard memory.

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CHAPTER I -3

2. SPECIFICATIONS

2.1 Printing

Print method Electrophotography by semiconductor laser beam scanning Resolution 600 x 600dpi (for Windows/DOS)

300 x 300dpi (under Apple Macintosh using optional RS-100M) 1200 x 600dpi (Horizontal x Vertical) (for Windows DIB graphics)

Print speed 10 page/minute (when loading Letter-size paper from the

multipurpose sheet feeder 1) Warm-up Max. 30 seconds at 23°C (73.4°F) First print 15 seconds (when loading Letter-size paper from the multipurpose

sheet feeder 1) Print media Toner cartridge

Life Expectancy: 2,200 pages/cartridge (when printing A4 or letter -

size paper at 5% print coverage) Developer Drum unit, separated from toner cartridge

Life Expectancy: 20,000 pages/drum unit (4% coverage, continuous

printing) at 20 pages per job

8,000 pages at 1 page per job

2.2 Functions

CPU IDT 79R3041-20J 20mhz Emulation Automatic emulation selection among HP LaserJet 5P, EPSON

FX-850, and IBM Proprinter XL

BR-Script (option) Printer driver Windows 95/Windows

3.1 driver, supporting Brother Native Compression mode and bi-directional capability Optional Macintosh

® QuickDraw driver (Standard in some

countries)

Interface Bi-directional parallel interface (IEEE 1284 compatible)

A RS-422A/RS-232C serial interface is optionally available. (The serial interface is a standard in some countries.)

Memory 2.0Mbytes with Data Compression Technology

Expandable up to 34Mbytes with the SIMM

Control panel 1 switch and 5 lamps Diagnostics Self-diagnostic program

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CHAPTER I -4

2.3 Electrical and Mechanical

Power source U.S.A. and Canada: AC 110 to 120V, 60Hz

Europe and Australia: AC 220 to 240V, 50Hz/60Hz

Power consumption Printing: 280W or less

Standing by: 60W or less Sleep: 13W or less

Noise Printing: 49dB A or less

Standing by: 38dB A or less

Temperature Operating: 10 to 32.5°C (59 to 90.5°F)

Storage: 0 to 40°C (38 to 104°F)

Humidity Operating: 20 to 80% (non condensing)

Storage: 10 to 85% (non condensing)

Dimensions (W x D x H) 402 (W) x 439 (D) x 274 (H)

(when the output tray is closed and the Multi-purpose sheet feeder is removed.)

Weight Approx. 9.6kg (21.2lb.) including the drum unit and toner cartridge

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CHAPTER I -5

2.4 Paper Specification

(1) Multi-purpose sheet feeder loading

< Sheet Feeder 1 (Front)> Paper size: A4, Letter, Legal, B5, A5, A6, and Executive, and other sizes of media that can be handled by the feed mechanism, can be loaded.

69.8 to 229 mm

105 to 406mm (face down)

Feeding direction

Feedable paper weight: 60 (16lb.) to 157 (42lb.) g/m

Maximum load height : 22mm (200 sheets of 80g/m2 paper) letter size Envelopes : 10 envelopes Setting method: Pull the MP sheet feeder 1 cover toward you, insert the

stack of paper into the feeder, aligning the top edge of the sheets, then push the cover back to its original position.

<Sheet Feeder 2 (Rear)> Paper size: A4, Letter, Legal, B5, and Executive, and other sizes of media that can be handled by the feed mechanism, can be loaded, except special papers such as envelopes, OHP sheets, labels and organizer sheets.

90 to 229 mm

250 to 406mm (face down)

Feeding direction

Feedable paper weight: 60 (16lb.) to 157 (42lb.) g/m

Maximum load height: 22mm (200 sheets of 80g/m2 paper) letter size. Setting method: Pull the MP sheet feeder 2 cover toward you, insert the

stack of paper into the feeder, aligning the top edge of the sheets, then push the cover back to its original position.

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CHAPTER I -6

2.5 Print Delivery

(1) With the output tray opened Tray capacity : Maximum 100 sheets (80g/m

), face-down only

(2) With the output tray closed Tray capacity : 1 sheet (80g/m

), face-down only

Note: Face down: Deliver the printed face of the paper downward.

Environment : 23°C

2.6 Paper

(1) Types of paper

<Sheet Feeder 1 (Front)> (a) Normal paper (60 to 157g/m

, specified types of high-quality paper)

• A4 size

• Letter size

• Legal size

• B5 size

• A5 size

• A6 size

• Executive size

• 9" envelop size (maximum printable area) * The recommended types of plain paper are as follows:

Letter : Xerox 4200 (75g/m

)

A4 : Xerox 80 Premier Paper (80g/m

)

(b) Special paper (specified types)

• Labels

• Envelopes (DL, C5, COM10)

• Postcards

• Organizers (K, L, and J sizes of DAY-TIMERS) <Sheet Feeder 2 (Rear)> (a) Normal paper (60 to 157g/m

, specified types of high-quality paper)

• A4 size

• Letter size

• Legal size

• B5 size

• Executive size

• The specified types of plain paper are as follows:

Letter : Xerox 4200 (75g/m

)

A4 : Xerox 80 Premier Paper

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CHAPTER I -7

(2) Paper feed conditions

Type Name Feeder Manual feed

Feeder 1 Feeder 2

60 to 80 g/m

{

(200 sheets){(200 sheets)

{

Normal paper (cut sheet) 80 g/m2 paper (Legal)

{

(100 sheets){(100 sheets)

{

157 g/m

{

(30 sheets){(30 sheets)

{

Labels

{

(50 sheets)

{

Special paper (cut sheet) Envelopes

{

(10 sheets)

{

Postcards

{

(30 sheets)

{

Organizers

{

(10 sheets)

{

2.7 Effective Printing Area

Printable area

The effective printing area means the area within which the printing of all the data received without any omissions can be guaranteed.

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CHAPTER I -8

The table below shows the effective printing areas.

Size A B C D E F

A 4

210.0mm

8.27” (2,480 dots)

297.0mm

11.69” (3,507 dots)

203.2mm

8.0” (2,400 dots)

288.5mm

11.36” (3,407 dots)

3.4mm

0.13” (40 dots)

4.23mm

0.17” (50 dots)

Letter

215.9mm

8.5” (2,550 dots)

279.4mm

11.0” (3,300 dots)

203.2mm

8.0” (2,400 dots)

271.0mm

10.67” (3,200 dots)

6.35mm

0.25” (75 dots)

Legal

215.9mm

8.5” (2,550 dots)

355.6mm

14.0” (4,200 dots)

203.2mm

8.0” (2,400 dots)

347.1mm

13.67” (4,100 dots)

ÇÇ

B 5 (JIS)

182.0mm

7.16” (2,149 dots)

257.0mm

10.12” (3,035 dots)

170.0mm

6.69” (2,007 dots)

248.5mm

9.78” (2,935 dots)

6.01mm

0.24” (71 dots)

B 5 (ISO)

176.0mm

6.93” (2,078 dots)

250.0mm

9.84” (2,952 dots)

164.0mm

6.46” (1,936 dots)

241.5mm

9.5” (2,852 dots)

ÇÇ

Executive

184.15mm

7.25” (2,175 dots)

266.7mm

10.5” (3,150 dots)

175.7mm

6.92” (2,075 dots)

258.3mm

10.17” (3,050 dots)

6.35mm

0.25” (75 dots)

A 5

148.5mm

5.85” (1,754 dots)

210.0mm

8.27” (2,480 dots)

135.8mm

5.35” (1,604 dots)

201.5mm

7.93” (2,380 dots)

6.01mm

0.24” (71 dots)

A6 105.0mm

4.13” (1,240 dots)

148.5mm

5.85” (1,754 dots)

93.0mm

3.66” (1,098 dots)

140.0mm

5.51” (1,654 dots)

ÇÇ

Organizer (J size)

69.85mm

2.75” (825 dots)

127.0mm

5.0” (1,500 dots)

57.15mm

2.25” (675 dots)

118.5mm

4.66” (1,400 dots)

6.35mm

0.25” (75 dots)

Organizer (K size)

95.25mm

3.75” (1,125 dots)

171.45mm

6.75” (2,025 dots)

82.55mm

3.25” (975 dots)

162.98mm

6.42” (1,925 dots)

ÇÇ

Organizer (L size)

139.7mm

5.5” (1,650 dots)

215.9mm

8.5” (2,550 dots)

127.0mm

5.0” (1,500 dots)

207.43mm

8.17” (2,450 dots)

ÇÇ

COM-10

104.78mm

4.125” (1,237 dots)

241.3mm

9.5” (2,850 dots)

92.11mm

3.63” (1,087 dots)

232.8mm

9.16” (2,750 dots)

ÇÇ

MONARCH

98.43mm

3.875” (1,162 dots)

190.5mm

7.5” (2,250 dots)

85.7mm

3.37” (1,012 dots)

182.0mm

7.16” (2,150 dots)

ÇÇ

C 5

162mm

6.38” (1,913 dots)

229mm

9.01” (2,704 dots)

150.0mm

5.9” (1,771 dots)

220.5mm

8.68” (2,604 dots)

6.01mm

0.24” (71 dots)

110mm

4.33” (1,299 dots)

220mm

8.66” (2,598 dots)

98.0mm

3.86” (1,157 dots)

211.5mm

8.33” (2,498 dots)

ÇÇ

(Note that the paper sizes indicated here should conform to the nominal dimensions specified by JIS.) A4 paper must accommodate 80 characters printed in pica pitch (203.2 mm). The dot size is based on 300 dpi resolution.

Page 15

CHAPTER I -9

3. SAFETY INFORMATION

3.1 Laser Safety (110 - 120V Model only)

This printer is certified as a Class 1 laser product under the US Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968. This means that the printer does not produce hazardous laser radiation. Since radiation emitted inside the printer is completely confined within the protective housings and external covers, the laser beam cannot escape from the machine during any phase of user operation.

3.2 FDA Regulations (110 - 120V Model only)

The US Food and Drug Administration (FDA) has implemented regulations for laser products manufactured on and after August 2, 1976. Compliance is mandatory for products marketed in the United States. One of the following labels on the back of the printer indicates compliance with the FDA regulations and must be attached to laser products marketed in the United States.

The label for Japanese manufactured products

MANUFACTURED: BROTHER INDUSTRIES, LTD.

15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467, Japan. This product complies with FDA radiation performance standards, 21 CFR Subchapter J.

The label for US manufactured products

MANUFACTURED: BROTHER INDUSTRIES (USA) INC.

2950 Brother Blud., Bartlet, TN 38133, U.S.A. This product complies with FDA radiation performance standards, 21 CFR Subchapter J.

Fig. 1.1

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CHAPTER I -10

3.3 Caution for Laser Product (Warnhinweis für Laserdrucker)

CAUTION: When the machine during servicing is operated with the cover open, the

regulations of VBG 93 and the performance instructions for VBG 93 are

valid.

CAUTION: In case of any trouble with the laser unit, please replace the laser unit itself.

To prevent direct exposure to the laser beam, do not try to open the enclosure of the laser unit.

ACHTUNG: Im Falle von Störungen der Lasereinheit muß diese ersetzt werden. Das

Gehäuse der Lasereinheit darf nicht geöffnet werden, da sonst Laserstrahlen austreten können.

(1) Location of the laser beam window.

Fig. 1.2

(2) Location of Caution Label for Laser Product. (200V only)

CLASS 1LASER PRODUCT APPAREIL Å LASER DE CLASSE 1 LASER KLASSE 1 PRODUKT

Fig. 1.3

Window

Page 17

CHAPTER II -1

CHAPTER II THEORY OF OPERATION

1. ELECTRONICS

1.1 General Block Diagram

Fig. 2.1 shows a general block diagram of the HL-1060 printer.

Optional RAM(SIMM)

(Max. 32Mbytes)

Optional ROM

(Max. 4Mbytes)

Optional I/F Board ( RS-232C)

Expansion Memory I/O Expansion I/O

Expansion ROM I/O

Parallel

Video Control Block

Interface Block

Engine Control Block

Operation Block

(Operation Panel)

Control System

Low-voltage Power

Supply Block

High-voltage Power

Supply Block

Laser Scanner Unit

Drive Block

(Stepping Motor)

Drum Unit

Transfer Block

Developing

Block

Drum

Charging

Block

Cleaner

Block

External Device

Paper Tray Unit

Paper Feeder

Manual Feed

Fixing Unit

Paper Eject Block

Paper Feed System

Image Generation System

Toner Cartridge

Erase Lamp

Fig. 2.1

Page 18

CHAPTER II -2

1.2 Main PCB Block Diagram

Fig. 2.2 shows the block diagram of the main PCB.

Reset Circuit

Program + Font ROM

(4Mbytes)

RAM

(2Mbytes)

Option RAM (SIMM)

(Max. 32Mbytes)

Optional ROM

(Max. 4Mbytes)

Option Serial I/O

(RS232C & RS422A)

EEPROM (512 x 8bits)

CPU Core

R3041

A S I C

Oscillator (40MHz)

Address Decoder

DRAM Control

Timer

FIFO

DATA EXTENSION

Parallel I/O

Software Support

EEPROM I/O

Engine Control I/O

Motor Driver

To Panel Sensor PCB

BUS

INT

To PC

Fig. 2.2

Page 19

CHAPTER II -3

1.3 Main PCB

1.3.1 CPU Core

Fig. 2.3. shows the CPU circuit block on the main PCB. The CPU is an IDT 79R3041-20J which is driven at a clock frequency of 20MHz. This clock frequency is made by dividing the source clock frequency of 40.0MHz by two. The address and data bus are both 32bits consisting of AD0 to AD31. The total addressable memory space is 4Gbytes.

Fig. 2.3

Page 20

CHAPTER II -4

1.3.2 ASIC

The ASIC is composed of a Cell Based IC that contains the following functional blocks. (1) Oscillator circuit

Generates the main clock for the CPU by dividing the source clock frequency by two.

(2) Address Generator

Generates the address bus by latching the AD bus with the ALE signal.

(3) Address decoder

Generates the CS signal for each device.

(4) DRAM control

Generates the RAS, CAS, WE, OE and MA signals for the DRAM and controls the refresh processing (CAS before RAS self-refreshing method).

(5) Interrupt control

Interrupt levels: Priority High 9 TIMER 3 (Watch Dog)

8 MONITOR 7 FIFO 6 EXINT 5 TIMER 1 4BD 3 SPARE 2 CDCC / BOISE / DATA EXTENTION

Low 1 TIMER 2

Note: All the interrupts can be masked.

(6) Timers

The following timers are included:

Timer 1 16-bit timer Timer 2 10-bit timer Timer 3 Watch-dog timer

(7) FIFO

A 10Kbit FIFO is included. Data for one raster is transferred from the RAM to the FIFO by DMA transmission and is output as serial video data. The data cycle is

6.13mhz.

Page 21

CHAPTER II -5

(8) Parallel I/O

<Data receive Mode> There are two modes in this unit. One is the CPU receive mode and the other is the DMA receive mode. In the CPU receive mode the CPU receives the command data from the PC, and after the CPU is switched to the DMA mode, it receives the image data and writes it to the DRAM directly.

90 µsec

STROBE

BUSY ACK

STROBE

BUSY ACK

0.5 µsec

0.5 µsec1.5 µsec

CPU Receive Mode

DMA Receive Mode

BUSY goes HIGH at the falling edge of the STROBE signal. The data (8 bits) from the PC is latched into the data buffer at the rising edge of the STROBE signal. The pulse width of ACK varies according to the speed MODE as shown above. BUSY goes LOW on the rising edge of ACK.

<IEEE1284 support> This supports the IEEE1284 data transfer with the following mode.

Nibble mode Byte mode ECP mode

(9) Data extension

This circuit extents the compressed image data which are received from the PC, and writes the bit map data to the FIFO.

(10) Software support

Supports 16 x 16 rotation, bit expansion, bit search, and decimal point conversion.

(11) EEPROM I/O

One output port and one I/O port are assigned.

Page 22

CHAPTER II -6

(12) Engine control I/O

This I/O is used for the connection to the driver PCB. It controls the main motor, solenoid, sensors, etc.

Fig. 2.4

Page 23

CHAPTER II -7

1.3.3 ROM

The program and the font data are stored in 4Mbytes of ROM. The ROM is composed of two 16Mbit masked ROMs which are mounted in 42-pin IC sockets.

Fig. 2.5

1.3.4 Optional ROM

The program and the font data are stored in 4Mbytes of ROM. The ROM is composed of two 16Mbit masked ROMs which are mounted in 42-pin IC sockets.

Fig. 2.6

Page 24

CHAPTER II -8

1.3.5 DRAM

Four 4Mbit DRAM (x 8bit) are used as the printer memory.

Fig. 2.7

Page 25

CHAPTER II -9

1.3.6 Optional RAM

A 32bit SIMM (72 pin) can be fitted as optional RAM. The main PCB has one slot and its capacity is for SIMM from 1Mbytes to 32Mbytes.

Fig. 2.8

Page 26

CHAPTER II -10

1.3.7 Optional Serial I/O

The interrupt of the serial I/O is input to the EXINT terminal of the ASIC, and recognized by the CPU. A 32-byte space for a register is provided for this I/O, which is read and written to by the CPU.

Fig. 2.9

1.3.8 EEPROM

The EEPROM is an X24C04F two-wire type with a 512 x 8bits configuration.

Fig. 2.10

Page 27

CHAPTER II -11

1.3.9 Reset Circuit

The reset IC is a PST591DMT. The reset voltage is 4.2V (typ.) and the LOW period of the reset signal is 50ms (typ.).

Fig. 2.11

1.3.10 Parallel I/O

Fig. 2.12 shows the parallel interface circuit.

Fig. 2.12

Page 28

CHAPTER II -12

1.3.11 Engine I/O

Fig. 2.13 shows the engine interface circuit.

Fig. 2.13

Page 29

CHAPTER II -13

1.3.12 Paper Feed Motor Drive Circuit

A DC motor is used for paper feeding.

Fig. 2.14

1.4 Driver PCB

The following parts are mounted on the driver PCB.

• Connectors ..................Low-voltage, high-voltage, solenoid, main motor, toner sensor,

laser, polygon motor, connector for main PCB

• Registration sensor

1.5 SW Panel PCB

The following parts are mounted on the SW panel PCB.

• Operation panel ........1 Key, 5 LEDs

Page 30

CHAPTER II -14

1.6 Power Supply

1.6.1 Low-voltage Power Supply

The power supply uses a switching regulation system to generate the regulated DC power (+5V and +24V), which are converted from the AC line.

Heater

Circuit

Thermal

Fuse

Lightning

Surge

Absorber

Feedback

Line

Filter

Fuse

Rectifier Oscillator

24V

Regulation

Circuit

Regulation

Circuit

24V

Lamp

(Heater)

(Driver Circuit)

Fig. 2.15

Page 31

CHAPTER II -15

1.6.2 High-voltage Power Supply, SR PCB

This generates and outputs the voltages and currents for the charging, development and transfer functions.

Transfer Roller

Supply Roller

Photosensitive

Drum

Developing

Roller

Cleaner

Roller

Corona

Unit

Current

Regulator

Current

Regulator

Voltage

Regulator

Voltage

Regulator

Voltage

Regulator

Voltage

Regulator

Voltage

Regulator

T101

Current

Regulator

24VI

T601 Q602

T701 Q702

Z301

PC001

PAPER

SENSOR

VR301

VR401

VR501

VR201 VR202

24VI

GND

IP001

IC PROTECTOR

GND

24VI GND

Fig. 2.16

Page 32

CHAPTER II -16

2. MECHANICS

2.1 Overview of Printing Mechanism

Fig. 2.17

EL PCB

Main Motor

Fan Motor

Toner Empty Sensor PCB

HighVoltage Power Supply

Primary Charger (Corona Wire)

Primary Charger (Grid)

Developer Roller Transfer Roller

Toner Empty Sensor

SW Panel PCB

Scanner Unit

Solenoid Resist

Main Cotrol PCB

Driver PCB

SR PCB Relay PCB

Solenoid Bin

Thermistor (for Heat roller)

Thermistor (for Tonner)

Fig. 2.18

MP Feeder 2 cover

Papers Multi-purpose Sheet Feeder 1

Manual Paper Path

Multi-purpose Sheet Feeder 2

Papers

Hopper Plate

Paper Pick-up Roller

Pinch Roller Paper Feed Roller

MP Feeder 1 Cover

Paper Pick-up Roller Paper Feed

Roller

Pitch Roller

Drum Unit

Blade

Photosensitive Drum

Transfer Roller

Erase Lamp

Fixing Unit

Pressure Roller

Eject Roller

Hopper Plate

Registration Sensor Lever

Toner Cartrid

Polygon Mirror

Laser Scanner

Toner Empty Sensor

Suppl

y Roller

Scanner Unit

Corona Wire

Developm ent Roller

Cleanin

g Roller

Eject Sensor Actuator

Heat Roller

Thermistor

Page 33

CHAPTER II -17

2.2 Paper Transfer

2.2.1 Paper Supply

The pick-up roller picks up one sheet of paper from the paper feeder every time it is rotated and feeds it to the paper feed roller.

Fig. 2.19

The paper is gripped between the pick-up roller and the separation pad and separated into individual sheets. The pick-up roller is directly connected to the sector gear, whose rotation is forcibly stopped by the gear stopper; when the pick-up solenoid is activated, the clutch mechanism is engaged by the solenoid action and the sector gear is driven; when it has completed one full turn its rotation is stopped again by the gear stopper. The paper drawn out by the pick-up roller pushes against the top of form sensor lever and the paper top position/absence of paper is detected by sensing the motion of the lever.

2.2.2 Paper Registration

When paper picked up from the multi-purpose sheet feeder (MPF) pushes against the top of form sensor actuator, the registration sensor lever is caused to turn, and the photo sensor detects this motion. When this signal from the sensor is detected the paper feed roller is stopped temporarily by the clutch. The paper is fed to the nip point between the paper feed roller and the pinch roller in the multi-purpose sheet feeder, and the skew of the paper is corrected by pushing the leading edge of the paper against the nip point. When the paper feed roller starts to be rotated again when it is released by the clutch, paper with the leading edge correctly aligned, is fed by the paper feed roller and is transported to the transfer roller.

Clutch mechanism (engaged/released by the solenoid assembly) Released when the solenoid is ON and engaged when the solenoid is OFF.

Fig. 2.20

Hopper plate

Pick-up roller

Registration sensor lever

Separation pad

Paper

Pinch roller

Transfer roller

Drum

Paper feed roller

Page 34

CHAPTER II -18

2.2.3 Paper Eject

The completion of paper eject is detected in the following manner: (a) When the leading edge of the paper pushes down the eject sensor actuator located in the fixing unit, the photo sensor (photo interrupter) is opened and detects the start of paper eject. (b) When the trailing edge of the paper has passed through the paper eject sensor actuator, the photo sensor is closed and the completion of paper eject is recognized.

Fig. 2.21







Fig. 2.22

Transfer roller

Pressure roller

Drum

Eject sensor actuator

Eject roller

Heat roller

Eject sensor actuator

High-voltage power supply PCB

Sensor

ject sensor actuator

Sensor

Paper

Page 35

CHAPTER II -19

2.3 Sensors

2.3.1 Cover Sensor

Detects opening and closing of the top cover.

Fig. 2.23

2.3.2 Toner Empty Sensor

Detects if there is toner in the toner cartridge. It also detects whether or not the drum unit is installed. (The toner cartridge is installed in the drum unit).

Fig. 2.24

Toner Empty Sensor

Cover Switch

Top Cover

Page 36

CHAPTER II -20

2.4 Drum Unit

2.4.1 Photosensitive Drum

Generates the latent electrostatic image and develops the image on the drum surface.

2.4.2 Primary Charger

Forms a uniform charge on the drum surface. (1) Corona wire

Generates the ion charge on the drum.

(2) Grid

Spreads the ion charge evenly over the drum surface.

2.4.3 Developer Roller

Develops the latent electrostatic image on the drum surface by the addition of the toner.

2.4.4 Transfer Roller

Transfers the toner image to the paper from the drum surface.

2.4.5 Cleaner Roller

Removes and recycles the toner remaining on the drum surface.

2.4.6 Erase Lamp

Discharges the electrostatic latent image on the drum.

2.5 Print Process

2.5.1 Charging

The drum is charged to approx. +1000V by an ion charge which is generated by the primary charger. The charge is generated by ionization of the corona wire, which has a DC bias from high-voltage power supply applied to it. The flow of the ion charge is controlled by the grid to ensure it is distributed evenly on the drum surface. The drum sleeve is regulated to approx. 280V by the voltage regulator.

---

Fig. 2.25

The primary charge uses a corona wire, but since the drum is positively charged, only less than 1/10 of the usual quantity of ozone is generated compared with the negatively charged drum. The level of ozone expelled from the printer is therefore not harmful to the human body. Applicable safety standards have been complied with.

Passive Type Voltage Regulator

Grid

Voltage Regulator

Corona wire

HVPS

1000V

280V

Aluminum drum sleeve

Organic Photoconductor layer

Drum

Page 37

CHAPTER II -21

2.5.2 Exposure Stage

After the drum is positively charged, it is exposed to the light emitted from the laser unit.

Fig. 2.26

The area exposed to the laser beam is the image to be printed. The surface potential of the exposed area is reduced forming the electrostatic image to be printed.

1 Cycle of drum

Surface Potential (V)

+1000

+700

+400 +300

123

(a)

(b)

Time

1 2

Primary charging Laser beam exposure and developing

(a) Unexposed area ( Non image area ) (b) Exposed area ( Image area )

Transfer the image to paper Erase the residual potential

Drum Sleeve

Fig. 2.27

Drum

Paper

Laser beam

f lens

Pol

ygon mirror

Motor

Lens

Laser diode

Laser detector

Laser Beam

Page 38

CHAPTER II -22

2.5.3 Developing

Developing causes the toner to be attracted to the electrostatic image on the drum so as to transform it into a visible image. The developer consists of a non-magnetic toner. The development roller is made of conductive rubber and the supply roller which is also made of conductive sponge rotate against each other. The toner is charged and carried from the supply roller to the development roller. The toner adheres to the development roller and is conveyed to the drum at an even thickness controlled by the blade. The toner is nipped between the development roller and the drum and developed onto the latent image on the drum. The electrostatic field between the drum and the development roller, which is DC-biased from the high-voltage power supply, creates the electrostatic potential to attract toner particles from the development roller to the latent image area on the drum surface.

Fig. 2.28

2.5.4 Transfer

(a) Transfer process

After the drum has been charged and exposed, and has received a developed image, the toner formed is transferred onto the paper by applying a negative charge to the backside of the paper. The negative charge applied to the paper causes the positively charged toner to leave the drum, and adhere to the paper. As a result, the image is visible on the paper.

(b) Cleaning process of transfer roller

If the toner is not transferred onto the paper perfectly, it is possible that there may be residual toner on the drum which will adhere to the transfer roller. The transfer voltage charges to a positive voltage during non-printing rotation of the drum. Therefore the transfer roller is cleaned by returning the positive charged toner adhered on the transfer roller onto the photo-conductive drum.

(

a) Transfer process [ON]

(

b) Cleaning process [ON]

Drum

Erase lamp

(a) Collecting process

(

b) Discharging process

Cleanin

roller

Development roller

DC-bias

SR-bias

Supply roller

Develop housing

Auger

Separator

Blade

Transfer roller

Toner

Page 39

CHAPTER II -23

2.5.5 Drum Cleaning Stage

In the image transfer stage, not all the toner on the photosensitive drum is transferred onto the paper but some remains on the drum. In the drum cleaning stage, the drum surface is cleaned by the cleaning roller, so that residual toner on the drum surface is removed and collected on the cleaning roller itself. The residual toner on the cleaning roller will be discharged to the drum when starting or non-printing time. The toner will be collected by the developing roller and reused (for further developing).

2.5.6 Erasing Stage

Before the cleaning stage, the drum surface is exposed to the light emitted from the erase lamp. (LED lamp) This stage prepares the drum by decreasing its surface voltage uniformly, ready to receive uniform change in the primary charging stage.

2.5.7 Fixing Stage

An image transferred on paper by static electricity is fixed by heat and pressure when passing through the heat roller and the pressure roller in the fixing unit. The thermistor ASSY keeps the surface temperature of the heat roller constant by detecting the surface temperature of the heat roller and turning on or off the halogen heater lamp. The cleaner ASSY HR eliminates toner stains on the surface of the heat roller.

,,,







,,,,

,,,,,

,,,,

























,,,











,,,,



























,













Fig. 2.29

Pressure roller

Cleaner ASSY HR

Thermistor ASSY

Halogen heater lamp

Heat roller

Cleaner ASSY

Page 40

III-1

CHAPTER III DISASSEMBLY AND REASSEMBLY

1. SAFETY PRECAUTIONS

To avoid creating secondary problems by mishandling, be careful to follow the following precautions during maintenance work.

(1) Always turn off the power switch and unplug the power cord from the power outlet

before accessing any parts inside the printer. (2) Be careful not to lose screws, washers, or other parts removed. (3) Be sure to apply grease to the gears and applicable positions specified in this

chapter. (4) When using soldering irons or other heat-generating tools, take care not to

accidentally damage parts such as wires, PCBs, and covers. (5) Before handing any PCBs, touch a metal portion of the equipment to discharge any

static electricity charge on your body, or the electronic parts or components may

be damaged. (6) When transporting PCBs, be sure to wrap them in the correct protective packaging. (7) Be sure to replace self-tapping screws correctly, if removed. Unless otherwise

specified, tighten screws to the following torque values.

TAPTITE, BIND or CUP B

M3 : 7kgf • cm M4 : 10kgf • cm

TAPTITE, CUP S

M3 : 8kgf • cm

SCREW

M3 : 7kgf • cm M4 : 8kgf • cm

(8) When connecting or disconnecting cable connectors, hold the connector bodies,

but not the cables. If the connector has a lock, release the connector lock first to

unlock it. (9) After a repair, check not only the repaired portion but also all connectors, also

check that other related portions are functioning properly before operational

checks.

Page 41

III-2

2. DISASSEMBLY FLOW

DRUM UNIT

MP SHEET FEEDER ASSY

TOP COVER

FIXING UNIT SR PCB / RELAY PCB

SCANNER UNIT

PAPER SUPPORT

EXTENSION SUPPORT WIRE

MAIN PCB ASSY

BASE PLATE ASSY

DRIVER PCB

LOW-VOLTAGE

PS PCB ASSY

UNDER SHOOT ASSY

OUTPUT TRAY ASSY

DRIVE UNIT

MAIN MOTOR ASSY

GEARS and SOLENOID

FAN MOTOR

BOTTOM

HIGH-VOLTAGE

PS PCB ASSY

Page 42

III-3

3. DISASSEMBLY PROCEDURE

3.1 Drum Unit

(1) Open the top cover. (2) Lift out the drum unit.

Fig. 3.1

3.2 Output Tray ASSY

(1) Press the hinges at the left and right ends of the output tray inwards to release the

output tray from the main cover.

Fig. 3.2

Drum unit

Top cover

Main cover

Output tray

Page 43

III-4

3.3 Top Cover

(1) Open the top cover. (2) Press the hinges at the left and right ends of the top cover inwards to release the

top cover from the main cover.

Note: If it is impossible to release the top cover in the above way, press the side of the

top cover (



) while pulling the side of the main cover (  ).

Fig. 3.3

3.4 MP Sheet Feeder 1 ASSY

Note: When disassembling the MP sheet feeder ASSY, the grease which smears your

fingers will stick to the separation pad or the paper pick-up roller, and then spread to the paper and the drum unit. It might cause to appear black spots on the printing page.

(1) Slide the upper portion of MP sheet feeder 1 toward you and remove it.

Fig. 3.4





Main cover

Top cover

Main cover

MP sheet feeder 1

MP sheet feeder 2

Main cover

Page 44

III-5

(2) Raise the pick-up roller cover (

 ) and remove it (  ).

(3) Remove the MP feeder cover (

 ).

Fig. 3.5

(4) Remove the tray side covers R and L by releasing the three hooks inside each of

the covers as the following order.

Fig. 3.6

MP feeder cover







Pick-up roller cover

Top side cover L

Tray side cover R







1. Release the hook



by hands.

2. Release the hook



by using a screwdriver.

3. Release the hook



by using a screwdriver.

4. Pull out the tray side covers straight.









Page 45

III-6

(5) After removing the sector gear, paper feed bearing, and bearing 6, take off the

paper pick-up roller unit.

Fig. 3.7

(6) Raise the pressure plate toward you and press both sides of the pad inward to

release it by pressing the separation pad holder. Then take off the spring.

Note: If it is impossible to release the pressure plate in the above way, press the side of

the pressure plate (



) while pulling the side of the sheet feeder (  ).

Fig. 3.8

Note: Be sure to replace the regist sensor actuator film together whenever replacing

the regist sensor actuator.

Bearing 6

Paper feed bearing

Sector gear

Paper pick-up roller unit





Separation pad

Pressure plate

Spring

Separation pad holder

<HL-1060> PR98062

Page 46

III-7

3.5 MP Sheet Feeder 2 ASSY

(1) Remove the four screws. (2) Disassemble any other parts of MP sheet feeder 2 in the same way as described

for MP sheet feeder 1.

Fig. 3.9

3.6 Under Shoot ASSY

(1) Disconnect the two cable harnesses from the relay PCB.

Fig. 3.10

Screws

MP sheet feeder 2

Screw

Main cover

Cable harness

Rela

y PCB ASSY

Under shoot ASSY

Page 47

III-8

(2) Remove the two screws. (3) Lift the rear portion of the under shoot assy to remove it.

Fig. 3.11

Note: Follow the number above in order when assembling.

Fig. 3.11.1









Main cover





Under shoot ASSY









Plate spring

Feed shaft roller

Page 48

III-9

3.7 SR PCB / Relay PCB

(1) Remove the SR protect sheet. (2) Disconnect the connector of the SR harness ASSY connecting the SR PCB and

the driver PCB and remove the high-voltage cover.

Fig. 3.12

(3) Disconnect the connector of the relay harness ASSY connecting the SR PCB and

the relay PCB and remove the two screws on the SR PCB, and remove the SR

PCB. (4) Remove the relay PCB. (5) Remove the two screws, and remove the electrode SR1, SR2.

Fig. 3.13

SR protect sheet

Taptite, cup B M4x14

High-voltage cover

SR harness ASSY

Relay harness ASSY

Main cover

SR PCB

Ground wire

Relay PCB

Taptite, cup B M4x14

Taptite, cup B

Electrode SR2

Main cover

Electrode SR2

Page 49

III-10

3.8 Fixing Unit

(1) Remove the two screws. (2) Lifting the fixing unit, disconnect the two heater harnesses and the thermistor

connector on the EL PCB.

Fig. 3.14

(3) Unhook the harness of the thermistor ASSY from the hook of the fixing unit. (4) Remove the screw. (5) Remove the thermistor ASSY. (6) Remove the cleaner ASSY.

Fig. 3.15

Fixing unit

Cup B tight M3x14

Hook

Cleaner ASSY

Thermistor ASSY

Fixing unit

Screws

Thermistor connector

Heater harness (White)

Thermistor harness

EL PCB

Page 50

III-11

Note: Follow instructions below when installing the thermistor in the fixing unit.

• Place the cleaner felt of the cleaner ASSY under the heat roller.

• Place the end of the thermistor on the heat roller.

• Insert the boss1 of the thermistor into the hole of the fixing unit frame.

• Do not place the thermistor on the boss2 of the fixing unit frame.

Fig. 3.16

(7) Remove the two screws. (8) Open the fixing unit cover along the open side of the fixing unit cover.

Fig. 3.17

Screws

Fixing unit cover

Shaft

Fixing unit

Pressure roller

Thermistor

Cleaner ASSY HR

Boss2

Fixin

unit frame

Heat roller

Boss1

Cleaner ASSY

Fixing unit frame

Page 51

III-12

(9) Release the cleaner lock from the cleaner ASSY HR. (10) Remove the cleaner ASSY HR from the fixing unit.

Fig. 3.18

(11) Release the right side of the paper eject roller shaft. (12) Remove the four eject pinch rollers and the pinch springs from the fixing unit

frame. Then, remove the pinch spring from each pinch roller.

Fig. 3.18a

Eject Pinch Roller

Paper eject roller shaft

Pinch Spring

Screw

Cleaner ASSY HR

Cleaner lock

Fixing unit

PR98292

Page 52

III-13

Note: Follow instructions below when installing the cleaner ASSY HR.

• Put the cleaner ASSY HR on the heat roller.

• Rotate the hook of the cleaner ASSY HR as shown in the figure to fit it into the fixing unit frame.

• Insert the cleaner lock into the fixing unit frame.

















Fig. 3.19

(13) Remove the bind B tight 3 x 10 screw securing the connector plate. (14) Remove the connector plate from the fixing unit frame and loosen the other bind B

tight 3 x 10 screw securing the fixing unit cover. (15) After removing the idle gear 16 from the fixing unit frame, the heat roller can be

removed. You can then remove the halogen heater lamp from the heat roller.

Note: Never touch the surface of the halogen heater lamp.

Fig. 3.20

Cleaner ASSY HR



Put the cleaner ASSY HR on the heat roller and rotate it in this direction to fit it into the hole.

Heat roller

Fixing unit frame





Cleaner lock

Halogen heater lamp

(Blue 100V, Red 200V)

Heat roller

Bind B tight M3x10

Connector plate

Bind B tight M3x10

Fixing unit frame

Idle gear 16

Page 53

III-14

3.9 Scanner Unit

(1) Remove the three screws. (2) Lift out the scanner unit.

Fig. 3.21

(3) Disconnect the three connectors from the driver PCB. (4) Remove the screw and the tape, and lift the toner sensor PCB from the scanner

unit.

Note: Never touch the inside of the scanner unit or the mirror when disassembling or

reassembling. If there is any dirt or dust on the mirror, blow it off.

Fig. 3.22

Screws

Screw

Scanner unit

Main cover

Driver PCB

Toner sensor PCB

Screw

Tape

Scanner unit

Page 54

III-15

(5) Turn the scanner unit upside down and remove the screw to release the toner

sensor harness.

Fig. 3.22-1

3.10 Main PCB ASSY

(1) Remove the four screws. (2) Hold the hooks at left and right to pull out the main PCB ASSY.

Fig. 3.23

Screw

Scanner unit

Hook

Toner sensor harness

Screws

Hook

Main PCB ASSY

Page 55

III-16

3.11 Base Plate ASSY

Note: Prior to turning the printer upside-down, ensure that the drum unit has been

removed from the printer.

(1) Turn the printer upside down. (2) Remove the five M4 and four M3 self tapping screws and one screw.

Fig. 3.24

(3) Lift the base plate ASSY and remove the grounding screw.

Fig. 3.25

Base plate ASSY

Ground wire

Screw

Low-voltage power supply PCB ASSY

Screw

Taptite, cup M3x2

Taptite

, cup M3x2

Taptite, bind M4x2

Taptite, cup M3x2

Base plate ASSY

Soundproof sponge

Page 56

III-17

Note: See the Fig. 3.26 about the position installing the dumping material and the

soundproof sponge A,B.

Fig. 3.26

3.12 Driver PCB ASSY

(1) Remove the screw securing the driver PCB ASSY. (Slide the PCB A from

underneath the main shield.)

Fig. 3.27

Screw

Driver PCB ASSY

Main shield

Driver PCB ASSY

Insulation tape

Dumping material

Soundproof sponge A

Soundproof sponge B

Soundproof sponge A

Page 57

III-18

97-P-56

(2) Disconnect the eleven connectors from the PCB. (Three connectors have already

been disconnected when removing the scanner unit.)

(Name of the harnesses)

1. SW panel harness

2. Scan motor harness

3. Toner harness

4. Laser harness

5. Fan motor harness

7. Main connector

8. High-voltage flat cable

9. Erase lamp harness

10. SR harness

11. Solenoid harness

12. Main motor harness

13. Low-voltage harness

Fig. 3.28

Note 1: When reassembling, the cable connectors must be inserted securely into the

PCB connectors and the PCB must not be stressed by the harnesses.

Note 2: The connectors should be inserted by matching the housing color and the

number of pins.

3.13 Low-voltage Power Supply PCB ASSY

(1) Remove the screw securing the low-voltage power supply PCB ASSY. (2) Disconnect the two connectors for the heater harness and the LV harness from the

PCB.

Fig. 3.29

Driver PCB

ASSY

Main frame

LV harness

Screw

Low-voltage power supply ASSY

Main cover

<200V only>

Page 58

III-19

3.14 High-voltage Power Supply PCB ASSY

(1) Remove the screw securing the high-voltage power supply PCB ASSY. (2) Disconnect the HV flat cable from the PCB.

Fig. 3.30

Note: When reassembling, the flat side of the density dial shaft must be aligned with the

flat side of the density dial plastic adjustment cover.

3.15 Fan Motor ASSY

(1) Remove the screw securing the fan motor ASSY. (2) Release the two hooks of the fan holder from the main cover.

Fig. 3.31

Screw

Density dial

Main cover

HV flat cable

High-voltage power suppl

PCB ASSY

Screw

Fan motor ASSY

Hook

Page 59

III-20

(3) Remove the two screws securing the fan motor.

Fig. 3.32

3.16 Drive Unit

(1) Unhook the heater harness from the drive unit.

Fig. 3.33

SW panel PCB

Fan motor holder

Fan motor

Screws

Heater harness

Drive unit

Hook

Page 60

III-21

(2) Release the hook to remove the gear cover. (3) Remove the six screws securing the drive unit. Lift the drive unit while pressing

and releasing the static removal plate spring on the drive unit.

Fig. 3.34

3.17 Main Motor ASSY

(1) Remove the four screws securing the main motor ASSY.

Fig. 3.35

Gear cover

Hook

Screws

Drive unit

Gear cover

Static removal

plate sprin

Screws

Drive unit

Screws

Main motor ASSY

Page 61

III-22

3.18 Gears and Solenoid

(1) Apply grease to the points shown below.

M, L

Fig. 3.36

Page 62

III-23

Note: Follow instructions below when applying the grease.

Sign When applying the grease Grease Application amount A Before installing the gear. Dow Corning LTD. EM-30L 1 rice-grain size B After installing the bending

washer, and before installing the gear.

Dow Corning LTD. EM-30L 1 rice-grain size

C Before installing the gear. Dow Corning LTD. EM-30L 1 rice-grain size D Dow Corning LTD. EM-30L 5 rice-grain size E Dow Corning LTD. EM-30L 5 rice-grain size F Dow Corning LTD. EM-D110 Refer to the Fig. 3.36 G Dow Corning LTD. EM-30L 1 rice-grain size H After installing the drive unit on

main body.

Dow Corning LTD. EM-30L 5 rice-grain size

J After installing the drive unit on

main body.

Kanto Kasei LTD. FLOIL GE334C or GE676

1/2 rice-grain size

K Dow Corning LTD. EM-30L 1 rice-grain size L Dow Corning LTD. EM-D110 Refer to the Fig. 3.36 M Dow Corning LTD. EM-D110 Refer to the Fig. 3.36 N Before installing the gear. Dow Corning LTD. EM-D110 5 rice-grain size

Page 63

III-24

3.19 Paper Support

(1) Pull the paper support down toward you and pull both legs outwards to release it.

Fig. 3.37

3.20 Extension Support Wire

(1) Raise the extension support wire toward you, press both legs inward to release it,

and then release the paper stopper from the wire.

Fig. 3.38

Paper support

MP sheet feeder 1,2

Output tray

Paper stopper

Extension support wire

Page 64

III-25

4. PACKING

Fig. 3.39

Documents

Carton, SF assy

Dust cover

Pad

PE sheet

Bag

Pad

Carton

Page 65

CHAPTER IV -1

CHAPTER IV MAINTENANCE AND TROUBLESHOOTING

1. INTRODUCTION

1.1 Initial Check

(1) Operating environment

Check if :

• The source voltage stays within ±10% from the rated voltage shown on the rating plate.

• 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%.

• The printer is not located in a dusty place.

• The printer is not exposed to ammonia fumes or other harmful gases.

• The printer is not located in a hot or humid area (such as near water or a humidifier).

• The printer is not exposed to direct sunlight.

• The room is well-ventilated.

• The printer is not placed where the ventilation hole of the printer is blocked.

(2) Print paper

Check if :

• A recommended type of print paper is being used (if the paper is too thick or too thin, or tends to curl, paper jams or paper feed problems may occur, or printed images may be blurred).

• The print paper is damped. [If so, use fresh paper, and check whether the print quality improves or not.]

(3) Consumables

Check if :

• The Toner lamp is not lit on the control panel when a toner cartridge is installed in the printer. [If the above lamp is lit, replace the cartridge with a new one. If blank spots occur on printouts, take out the drum unit and slowly rock it to redistribute the toner evenly.]

(4) Others

Condensation: When the printer is moved from a cold room into a warm room in cold weather,

condensation may occur inside the printer, causing various problems as listed below:

• Condensation on the optical surfaces such as the scanning mirror, lenses, the reflection mirror and the protection glass may cause the print image to be light.

• If the photosensitive drum is cold, the electrical resistance of the photosensitive layer is increased, making it impossible to obtain the correct contrast when printing.

• Condensation on the corona unit may cause corona charge leakage.

• Condensation on the hopper gate and separation pad may cause paper feed troubles.

Page 66

CHAPTER IV -2

If condensation has occurred, wipe the effected units or parts with a dry cloth. If the drum unit is unpacked soon after it is moved from a cold room to a warm room,

condensation may occur inside the unit, which may cause incorrect images. Instruct the user to allow the unit to come to room temperature before unpacking it. This will take one or two hours.

1.2 Basic Procedure

If a malfunction or incorrect print appears, make an initial check following the basic procedure below:

(1) Check the error lamps following the inspection procedure described later in this

section. If no error lamps are lit, see Section 4 for troubleshooting information.

(2) If any defective image output is found, follow the image defect fault descriptions in

this section.

2. CONSUMABLE PARTS

2.1 Drum Unit

The Drum lamp is on when the drum unit is nearly at the end of its life. Life expectancy: 20,000 pages at 20 pages per job

8,000 pages at 1 page per job

Note: There are many factors that determine the actual drum life, such as temperature,

humidity, type of paper and toner that you use, the number of pages per print job, etc..

2.2 Toner Cartridge

Toner low: The Data and Alarm lamps blink once every five seconds. Toner empty: The Data and Alarm lamps blink once every second. Life expectancy: 2,200 pages/a new toner cartridge

(when printing A4- or letter-size paper at 5% print coverage)

Note: Toner life expectancy will vary depending on the type of average print job printed.

Page 67

CHAPTER IV -3

2.3 Periodical Replacement Parts

No. Description Part No. Qty se r v i ce li f e ( number of print) Remarks 1 Fixing Unit Y

(Cleaner ASSY HR)

UH3308001 (UH3310001)11

(100,000) 120V

Fixing Unit Y (Cleaner ASSY HR)

UH3309001 (UH3310001)11

(100,000) 230V

2 Scanner Unit Y 1 (100,000) 3 MP sheet feeder 1 ASSY Y

(P pick-up roller shaft ASSY Y)

1 1

(100,000)

4 MP sheet feeder 2 ASSY Y

(P pick-up roller shaft ASSY Y)

1 1

(100,000)

Note: The above table shows only estimated value, so these values are subject to

change without prior notice.

Page 68

CHAPTER IV -4

3. IMAGE DEFECTS

3.1 Image Defect Examples

I-2 DarkI-1 Light I-2 Dark I-3 Completely blank I-4 All black

I-5 Dirt on back of paper I-6 Black vertical

streaks

I-6 Black vertical streaks

I-7 Black horizontal stripes

I-9 White vertical streaks

I-8 Black vertical streaks

I-10 Faulty

registration

I-11 Poor fixing

I-12 Image distortion

I-13 Faint print I-14 White spots

I-15 Black spots

I-17 Gray background I-18 I-19 Downward fogging

of solid black

Hollow print

I-21 Light rainI-20 Horizontal lines

Print out test print out test print out test Print out test print o

Print out test print o

Print out test print out test print out test Print out test print o

Print out test print o

Print out test print out test print out test Print out test print o

Print out test print o

Print out test print out test print out test Print out test print o

Print out test print o

Print out test print out test print out test Print out test print o

Print out test print o

Print out test print out test print out test Print out test print o

Print out test print o

Print out test print out test print out test Print out test print o

Print out test print o

Print out test print out test print out test Print out test print o

Print out test print o

Print out test print out test print out test Print out test print o

Print out test print o

Print out test print out test print out test Print out test print o

Print out test print o

Print out test print out test print out test Print out test print o

Print out test print o

Print out test print out test print out test Print out test print o

Print out test print o

Print out test print out test print out test Print out test print o

Print out test print o

Print out test print out test print out test Print out test print oPrint out test print o

I-16 Black band

Fig. 4.1

Page 69

CHAPTER IV -5

3.2 Troubleshooting Image Defects

The following procedures should be followed in the event of specific image defects. See subsection 3.3 for information about the location of the high-voltage contacts and grounding contacts.

I-1 Light

Possible cause Step Check Result Remedy

HV.GND contacts (Fig.4-5)

Density dial 1 Is the density dial in the center

of the click position?

No Set it to the center

detect position. Toner sensing failure (printer side)

2 Can printing be started with the

drum unit removed?

Yes Toner sensor failure.

Check if the toner

sensor needs

cleaning and check

the toner sensor

connection. Toner sensing failure (toner cartridge side)

3 Is the problem solved when 4 or

5 pages are printed after the toner cartridge is replaced with a full one?

Yes The wiper of the toner

cartridge is defective.

Replace the toner

cartridge. Drum connection failure

4 Is all the contacts (HV, GND)

connected with electrode when the drum unit is installed?

No Clean contact

electrodes both in the

printer body and on

the drum unit.

High-voltage power supply PCB failure

5 Check the harness connection

between the high-voltage power supply PCB and the driver PCB.

No If the connection is

normal, replace the

high-voltage power

supply PCB. Driver PCB or main PCB failure

6 Perform the same check as

step 5 above and also between the driver PCB and the main PCB.

No Replace the driver

PCB or the main

PCB.

Scanner unit failure

7 Is the problem solved by

repealing the scanner unit?

Yes Replace the scanner

unit.

Page 70

CHAPTER IV -6

I-2 Dark

Possible cause Step Check Result Remedy

HV.GND contacts (Fig.4-5)

Density dial 1 Is the density dial at the center

click position?

No Set it to the center

click position or

reasonable position. Corona failure (soiled wire)

2 Is the corona wire dirty? Yes Clean the corona wire

by using the wire

cleaner.

Corona failure (contact failure)

3 Are the corona electrodes

between the printer body and drum unit dirty?

No Clean both electrodes.

Drum unit failure 4 Is the problem solved when the

drum unit is replaced?

Yes Replace the drum unit

with a new one. H.V. power supply PCB

5 Are there any disconnected

connectors?

No Replace the H.V.

power supply. Main PCB 6 Are there any disconnected

connectors?

No Replace the main

PCB. Driver PCB 7 Are there any disconnected

connectors?

No Replace the driver

PCB.

Page 71

CHAPTER IV -7

I-3 Completely blank

Possible cause Step Check Result Remedy

HV.GND contacts (Fig.4-5)

Developing bias contact failure

1 Are the developing bias

contacts between the printer body and drum unit dirty?

Yes Clean the electrodes

at both sides.

Drum unit 2 Are the drum shaft and drum

electrode of the printer body

Yes Clean the shaft and

the electrode.

connected correctly? No Che ck t h e c onnection

between the shaft and

the electrode.

Drum unit failure 3 Is the problem solved after the

drum unit is replaced?

Yes Replace the drum

unit. Scanner harness connection failure

4 Is the scanner harness

connected securely? Is there any play in the connection?

Yes Reconnect the

connector properly.

Main/Driver PCB connection failure

5 Are printing signals being input

to the scanner? Is the problem solved after the main PCB or the driver PCB replaced?

Yes Replace the main

PCB or the driver

PCB.

Scanner unit failure

6 Scanner interlock lever

damaged.

Yes Replace the scanner

unit.

Scanner mirror is broken or loose.

No Replace the H.V.

power supply.

Page 72

CHAPTER IV -8

I-4 All black

Possible cause Step Check Result Remedy

HV.GND contacts (Fig.4-5)

Corona failure 1 Is the corona wire of the drum

unit broken?

Yes Replace the drum

unit.

2 Are the electric terminal springs

in the printer body and the electrode on the bottom face of the drum unit dirty?

Yes Clean the terminals in

the printer and on the

drum.

Harness connection

3 Is the scanner unit connected

with the driver PCB correctly?

Yes Check the harness

connection between

the scanner unit and

the driver PCB. H.V. power supply PCB

4 Is the problem solved after H.V.

power supply PCB replaced?

Yes Replace the H.V.

power supply PCB. Ditto 5 Perform the same check as in

step 3.

No Replace the panel

sensor PCB. Main PCB 6 Is the problem solved after

main PCB replaced?

Yes Replace the main

PCB. Driver PCB 7 Is the problem solved after

driver PCB replaced?

Yes Replace the driver

PCB.

Page 73

CHAPTER IV -9

I-5 Dirt on the back of paper

Possible cause Step Check Result Remedy

Fixing unit 1 Is the pressure roller dirty?

Is any other area in the printer dirty?

Yes Clean the pressure roller.

(See the following note.)

Dirt in the drum unit

2 Is the transfer roller dirty?

is the problem solved after the drum unit replaced?

Yes Replace the drum unit

No Replace the H.V. power supply

PCB.

Note: Cleaning of the pressure roller

(1) Set three or more sheets of paper in MP sheet feeder 1 (or 2).

2) Open the top cover. (3) Turn on the power switch while holding down the switch on the control panel. (4) Release the panel switch when the Drum lamp is on. (5) Close the top cover. (6) Hold down the panel switch until the Ready lamp is on, and then release the

switch. (7) Print three patterns; grid, zip and solid black. (8) Turn off the power switch with the top cover closed. (9) Set paper in the manual slot with the solid black side up. (10) Turn on the power switch while holding down the switch on the control panel. (11) Release the panel switch when the Drum lamp is on. (12) Press the panel switch again and release it immediately. (13) Print a page of test pattern while cleaning the pressure roller.

Page 74

CHAPTER IV -10

I-6 Black vertical streaks Black and blurred vertical streaks

Possible cause Step Check Result Remedy

HV.GND contacts (Fig.4-5)

Corona failure 1 Is the corona wire dirty? Yes Clean the corona wire

with the wire cleaner.

Corona failure 2 Is the vertical block streak

about 10mm wide? Is the corona wire cleaner not in its home position?

Yes Return the wire

cleaner to its home position.

Dirt in the paper feed system

3 Is the paper tray or feed system

on the drum unit soiled with toner?

Yes Clean the toner off.

Scratch on the drum

4 Is the drum surface scratched? Yes Replace the drum

unit.

Cleaning failure 5 Is the drum surface dirty with

toner in streaks?

Yes Replace the drum

unit. Scratch on the heat roller

6 Is the surface of the heat roller

scratched?

Yes Replace the fixing

unit.

Note: Is you print the same pattern continuously, the drum will be worn away and black

vertical streaks appear on the paper.

I-7 Black and blurred horizontal stripes

Possible cause Step Check Result Remedy Scratch on the drum

1 Are the horizontal stripes at

94mm (OPC drum) intervals?

Yes Replace the drum unit.

Toner stuck on the developer roller

2 Are the horizontal stripes at

25mm (developer roller) intervals?

Yes Print several sheet and see

what happens. The problem will disappear after a while. If not, replace the

drum unit. Scratch on the fixing roller

3 Are the horizontal streaks at

63mm (heat roller) intervals?

Yes Replace the fixing unit.

SR PCB 4 Is the problem solved after the

SR PCB replaced?

Yes Replace the SR PCB.

Page 75

CHAPTER IV -11

I-8 Black vertical streaks (in the gray background)

Possible cause Step Check Result Remedy Translucent stain on the scanner window

1 Are there any stains? Yes Clean the scanner window.

If it is not effective, replace the scanner unit.

I-9 White vertical streaks

Possible cause Step Check Result Remedy Scanner window dirty

1 Is the scanner window dirty? Yes Clean the scanner window with

a dry tissue.

Transfer failure 2 Is the transfer roller scratched? Yes Replace the drum unit.

I-10 Faulty registration

Possible cause Step Check Result Remedy Excessive paper load

1 Is the paper loaded in the paper

feeder more than 22mm deep?

Yes Instruct the user to keep paper

loads below 22mm in depth.

Print paper 2 Is the specified weight of the

recommended paper being used?

No Instruct the user to use the

recommended types of paper.

Ditto 3 Is the first printing position

within ±1mm of the tolerance specification?

Yes Adjust the Y offset by using the

utility software supplied.

Paper resist sensor position incorrect

4 Is the position of the paper

resist sensor normal?

No Reposition the sensor to the

correct position.

Page 76

CHAPTER IV -12

I-11 Poor fixing

Possible cause Step Check Result Remedy Printing paper 1 Is thick paper more than 36lb

weight in use?

Yes Instruct the user to use paper of

the recommended weight and

thickness. Toner sensing failure

2 Is the problem solved by

replacing the drum unit or the toner cartridge? (When printing is faint.)

Yes Toner is empty.

The toner sensing is defective,

clean the toner sensor.

If the wiper in the toner

cartridge is broken, replace the

toner cartridge with a new one. Thermistor failure

3 Is the thermistor fitted

correctly?

No Fit the thermistor correctly.

Low-voltage power supply PCB failure

4 Is the problem solved by

replacing the low-voltage power supply PCB?

Yes Replace the low-voltage power

supply PCB.

I-12 Image distortion

Possible cause Step Check Result Remedy

Scanner 1 Is the scanner unit secured to

the frame incorrectly? Is there any play?

Yes Secure the unit correctly and

tighten the screws.

Scanner LD emission failure Scanner motor rotation failure

2 Is the laser diode or the laser

scanner motor defective?

Yes Replace the scanner unit.

Scanner connection failure

3 Is the scanner harness

connected properly? Is it coming loose?

Yes Connect the harness correctly.

Page 77

CHAPTER IV -13

I-13 Faint print

Print out test print out test print out test Print out test print oPrint out test print o

Possible cause Step Check Result Remedy

Printer not level 1 Is the printer placed

horizontally?

No Place the printer on a flat

surface. Drum unit 2 Does the problem happened

immediately after replacing the drum unit with a new one?

Yes Remove and shake the drum

unit horizontally with care.

Scanner window dirty

3 Is the window of the laser

scanner dirty?

Yes Clean the scanner window with

a dry tissue. Scanner unit failure

4 Is the problem solved by

replacing the scanner unit?

Yes Replace the scanner unit.

I-14 White spots

Possible cause Step Check Result Remedy

Toner cartridge 1 Is the toner in the toner

cartridge almost empty?

Yes Shake the drum unit

horizontally. Replace the toner

cartridge with a new one.

No Replace the drum unit.

Print paper 2 Is the problem solved after

change to specified of fresh unpacked paper?

Yes Recommend the user to

change the paper.

(Damp (wet) paper might be

used.) Environment 3 Check if the problem still

appears after the printer has warmed up.

Yes Replace the drum unit.

Advise the user of the specified

print environment.

Page 78

CHAPTER IV -14

I-15 Black spots

Possible cause Step Check Result Remedy

Drum unit 1 Are the spots at 94mm

intervals? The problem is not solved after printing a few pages.

Yes If toner remains stuck, wipe it

off gently with a cotton swab.

Replace the drum unit if the

OPC drum is scratched or

deteriorated (exposed).

(Refer to the following note.) Fixing unit 2 Are the spots at 63mm

intervals? And the problem is not solved after printing a few pages.

Yes Check and clean the heat roller

with a cloth dampened with

alcohol.

Replace the fixing unit. SR PCB 3 Is the problem solved after the

SR PCB replaced?

Yes Replace the SR PCB.

Note: Clean the drum unit as follows:

(1) Place the printing samples in front of the process unit, and find the exact

portion of image defect.

Fig. 4.2

(2) Turn the drum gear by finger while looking at the surface of the OPC drum.

Fig. 4.3

Position of smudge on the drum

94mm interval

Page 79

CHAPTER IV -15

(3) Wipe the surface of the photosensitive drum with a cotton swab until the dust

or paper powder on the surface toner lamp comes off.

Fig. 4.4

Caution: Don't wipe the surface of the photosensitive drum with something sharp. (ball-

point pen etc.) Use the cleaning liquid which is mixed ethyl alcohol and pure water at the rate of

each 50%.

Photo sensitive drum

Toner cartrid

Cleaning roller

Paper path

Separator

Page 80

CHAPTER IV -16

I-16 Black bank

Possible cause Step Check Result Remedy

Drum unit 1 Is the wire cleaner positioned at

its home position?

No Return the wire cleaner to its

home position.

Yes Replace the drum unit.

I-17 Gray background

Possible cause Step Check Result Remedy

Density dial 1 Is the problem corrected by

adjusting the density dial?

Yes Adjust the dial to the most

suitable position. Print paper 2 Does the paper being used

meet the paper specification (weight, etc.).

No Recommend to change the

paper to a specified type of the

paper.

Yes Recommend to change the

paper to a fresh pack paper. Drum unit 3 Is the problem solved after

replacing the drum unit?

Yes Replace the H.V. power supply.

Replace the drum unit.

Note: The following cases raise the possibility of this problem.

1. The drum unit is at the end of its life.

2. There is dust or paper powder.

3. A large number of paper whose width is narrower than A4 is printed.

Page 81

CHAPTER IV -17

I-18 Hollow print

Possible cause Step Check Result Remedy

Print paper 1 Is thick paper of more than 42lb

being used or extremely rough surface paper?

Yes Recommend to use the

specified type of paper.

No Refer and compare with I-14.

I-19 Downward fogging of solid black

Possible cause Step Check Result Remedy

Drum unit 1 Is the problem solved after

replacing the drum unit?

Yes Replace the drum unit.

SR PCB 2 Is the problem solved after

replacing the SR PCB?

Yes Replace the SR PCB.

Page 82

CHAPTER IV -18

I-20 Horizontal lines

Possible cause Step Check Result Remedy

HV.GND contacts (Fig.4-5)

SR electrode 1 Are the SR electrodes between

the printer body and the drum unit dirty?

Yes Clean both

electrodes.

SR connection failure

2 Are the SR electrodes between

the printer body and the drum unit connected correctly?

No Check the SR

connection.

Feed roller 3 Are the feed roller shaft and the

ground contact connected correctly?

No Check the

connection between

the shaft and the

ground contact.

I-21 Light rain

Possible cause Step Check Result Remedy

Drum unit failure 1 Is the problem solved after

replacing the drum unit which contains no more starter sheet**?

Yes Replace the drum unit.

SR PCB failure 2 Is the problem solved after

replacing the SR PCB?

Yes Replace the SR PCB.

High-voltage power supply PCB failure

3 Is the problem solved after

replacing the High-voltage power supply PCB?

Yes Replace the High-voltage

power supply PCB.

**Note: Make sure to use the used drum unit which has already ejected the starter sheet.

It is not possible to find the drum unit failure if you use a new drum unit with the starter sheet.

Note: Make the printer in the light rain test mode as follows before

checking;

1. Turn on the power switch and open the top cover.

2. Hold down the panel switch until all the lamps are on, and then release the switch.

Page 83

CHAPTER IV -19

3.3 Location of High-voltage Contacts and Grounding Contacts

Fig. 4.5

Fig. 4.6

Grounding contacts

Grounding wire

Drum shaft

High-voltage contacts

For transfer

roller

Drum unit

For cleaning

roller

For grid

Wire cleaner

For corona wire

For development

roller

For supply roller

To SR PCB

For supply roller

Grounding wire

For drum

For development roller

For corona wire

For cleaning roller

For transfer roller

For corona wire

For transfer roller

For cleaning roller

For grid

For development roller

Page 84

CHAPTER IV -20

3.4 Location of Feed Roller Shaft and Grounding Contacts

Fig. 4.7

Feed shaft roller

For feed roller

Page 85

IV-21

4. PAPER JAM

Problem Type of jam Cause Temp measure Jam at power on Paper stuck The paper feed

sensor of paper eject sensor is turned on.

Remove the paper inside the printer. If there is no paper exist, check suspected sensors referring to note and

clear the problem. Top of paper stopped at 20mm from the fixing unit. The paper feed roller rotated twice.

No paper The paper feed

sensor is not turned on.

Check the paper feed

sensor motion referring

to note and clear the

problem.

Top of paper stopped at 250mm from the fixing unit. Next paper is not fed.

1) Jam caused by paper length considered longer than 400mm (16 inches).

1) The paper feed sensor is not returned properly, and is not turned off.

1) Check the paper feed

sensor motion referring

to note and clear the

problem.

2) Jam caused by malfunction of the regist sensor

2) The regist sensor actuator is not returned to the home position.

2) Attach the film onto

the regist sensor

actuator.

Top paper stopped at the transfer roller.

Jam caused by paper length considered shorter than 80mm.

The paper feed sensor was turned off earlier.

Malfunction of actuator

or hardware noise.

Check sensors referring

to note and clear the

cause of the problem. Paper was fed approx. 20mm transfer roller.

Jam caused by delay of paper feed.

Due to the paper dust or rubber of the paper feed roller war, paper was not fed in proper timing.

Remove the paper dust

attached to the paper

feed roller. If the rubber

is worn out, replace it

with new one. Top of paper stopped at 17mm from the contact point of the heat roller and pressure roller.

Jam caused paper is not ejected from paper eject sensor.

Paper eject sensor does not work properly and is not turned off. (single printing)

Check the sensor motion

referring to note and

clear the problem.

Top of paper stopped at 35mm from the contact point of the heat roller and pressure roller.

Jam caused paper is not ejected from paper eject sensor.

Paper feed sensor is not turned on.

Check the sensor motion

referring to not and clear

the problem.

Jam occurred after ejecting paper.

Same as above. Same as above.

(continuous printing)

Same as above.

Top of paper stopped at 20mm from the

1) Cover open. 1) Cover is not closed properly.

1) Check if the drum unit is installed correctly.

fixing unit. 2) Bug 2) Bug 2) Please inform BIL.

Note: How to make the sensors

(1) Open the cover. (2) Power on the printer while pressing the panel switch. (3) Release the panel switch. (4) Press and release the panel switch.

Results:

*Alarm Lamp is ON = Paper feed sensor is turned ON *Drum Lamp is ON = Paper eject sensor is turned ON

Page 86

CHAPTER IV -22

5. TROUBLESHOOTING MALFUNCTIONS

When carrying out countermeasures for malfunctions as described in this section, check connectors for contact failure before measuring the voltage at the specified connector pins.

M-1 No AC power supplied

Possible cause Step Check Result Remedy

Supply voltage 1 Is the correct voltage present at

the outlet?

No Inform the user that the correct

voltage is not supplied at the outlet.

Power plug 2 Is the power cord securely

plugged into the outlet?

No Plug the power cord securely

into the outlet.

Fuse (F1, F2) 3 is the fuse blown? Yes If the fuse blows again

immediately after replacing the low-voltage power supply PCB, check that there is not a short circuit somewhere in the AC power supply line.

Wiring 4 Unplug the power supply plug.

Is there a broken wire between the AC input connector of the low-voltage power supply and the power plug?

Yes Replace the AC power cord.

M-2 No DC power supplied

Possible cause Step Check Result Remedy

AC power supply 1 Is AC power supplied between

connectors CN1-L and CN1-N when the power plug is plugged into the outlet?

No Follow the same check

procedure of M-1 “No AC power supplied”.

Wiring, DC load 2 Turn the power switch OFF and

disconnect the P13 connector (Driver PCB). Turn the power switch ON again. Measure the voltages between the terminals. Do the measured voltage satisfy the prescribed value in the table below?

Yes Turn the power switch OFF,

reconnect the connector and turn the power switch ON again. If the protector circuit is activated, check the connector, the wiring from the connector, and the DC load.

Low-voltage power supply PCB

PCB + lead pin - lead pin Voltage

Driver P13-4.5 P13-2.3 Approx. 24V

P13-8.9 P13-6.7 Approx. 5V

No Replace the low-voltage power

supply PCB.

Caution: If you analyze malfunctions with the power plug inserted into the power outlet,

special caution should be exercised even if the power switch is OFF because it is a single pole switch.

Page 87

CHAPTER IV -23

M-3 Main motor unrotated

Possible cause Step Check Result Remedy Failure of connector

1 Is the connection of connector

P12 on the driver PCB correct?

No Reconnect the connector.

Main motor (M1) 2 Disconnect connector P12 from

the driver PCB. Measure the resistance between the connector pins of the main motor by using a circuit tester. Do the measured resistances satisfy the prescribed values in the table below?

P12-1 and P12-3 P12-4 and P12-6 Approx. 9

Approx. 9

No Replace the Main motor.

Driver PCB 3 is the problem solved by

replacing the driver PCB?

Yes Replace the driver PCB.

M-4 No paper supplied

Possible cause Step Check Result Remedy Connection failure

1 Is the contact of connector P11

on the driver PCB good?

No Reconnect the connector.

Driver PCB circuit

2 Set paper on the manual paper

slot and make the test print by pressing the switch on the control panel.

No Replace the driver PCB.

Paper pick-up clutch solenoid

Does the voltage between pins 2 (SOLENOID) and 1 (24V) of the P11 connector on the driver PCB change from approx. 24V DC to 0V within the specified time?

Yes Replace the paper pick-up

solenoid.

MP tray unit failure

3 Is the surface of the separation

pad or the pick up roller worn out or stained?

Yes Clean the surface or replace.

Main PCB 4 Is the problem solved by

replacing the main PCB?

Yes Replace the main PCB.

Relay PCB 5 Is the problem solved by

replacing the relay PCB?

Yes Replace the relay PCB.

Page 88

CHAPTER IV -24

M-5 Insufficient output from high-voltage power supply unit

Possible cause Step Check Result Remedy High-voltage contact

1 Do any of the terminals on the

high-voltage contacts have dirt or contact burns?

Yes Clean the high-voltage contact.

2 Check the connection of the

harness between the highvoltage power supply and the driver PCB is OK.

Yes Replace the high-voltage power

supply PCB.

No Reconnect the harness

between the high-voltage power supply and the driver PCB.

M-6 SR PCB failure

Possible cause Step Check Result Remedy SR bias contact 1 Do any of the terminals on the

SR contacts have dirt or contact burns?

Yes Clean the SR bias contact.

Ditto 2 Check the connection of the

harness between the SR PCB and the driver PCB.

Yes Replace the SR PCB.

M-7 Fixing heater temperature failure

Possible cause Step Check Result Remedy Poor thermistor harness contact

1 Are the connectors on the

erase lamp PCB and the highvoltage power supply PCB secured correctly?

No Connect the connectors

securely.

Blown thermal fuse

2 Remove the fixing unit and

measure the resistance between the input connectors. Is it open circuit?

Yes Replace the fixing unit.

Thermistor failure

3 Is the thermistor installed

properly?

Yes Replace the fixing unit.

No Reinstall the thermistor

properly. Halogen heater lamp failure

4 Remove the fixing unit and

measure the resistance of the fixing unit lamp. Is it open circuit?

Yes Replace the halogen heater

lamp.

Page 89

CHAPTER IV -25

M-8 BD failure

Possible cause Step Check Result Remedy Harness connection failure

1 Is connector P4 on the driver

PCB secured correctly?

No Connect it securely.

M-9 Scanner failure

Possible cause Step Check Result Remedy Harness connection failure

1 Is the connection of the

scanner motor connector P2 on the driver PCB secured?

No Reconnect the connectors

securely.

Power supply input

2 Is the voltage between pins 1

(+24VDC) and 2 (GND) of connector P2 on the driver PCB 24 Volts DC?

No Check if +24VDC is supplied

between pins 4.5 (+24VDC) and 2.3 (+24VRET) of connector P13 on the driver PCB. If not, check the power supply output on the lowvoltage power supply PCB.

Yes Replace the scanner unit.

Page 90

CHAPTER IV -26

F-1 Double feeding

Possible cause Step Check Result Remedy Paper 1 Is paper of a recommended

type being used?

No Instruct the user to use

recommended types of paper.

Separation pad 2 Is the surface of the separation

pad worn out?

Yes Replace the MP sheet feeder.

F-2 Wrinkles

Possible cause Step Check Result Remedy Paper 1 Is paper of a recommended

type being used?

No Instruct the user to use the

recommended types of paper.

2 Is the wrinkle problem solved if

new paper is used?

Yes Instruct the user how to store

paper so that it does not absorb

moisture. Fixing unit entrance guide

3 Is the entrance guide dirty? Yes Clean the entrance guide.

Fixing unit 4 Is the pressure roller dirty? Yes Clean the pressure roller

No Replace the fixing unit.

Page 91

CHAPTER IV -27

6. INSPECTION MODE

6.1 Incorporated Inspection Modes

The printer incorporates various inspection modes such as the factory inspection mode and the test print mode. The inspection mode varies depending on the model of the printer.

This printer supports a factory inspection mode, continuous grid pattern print mode, 3 patterns print mode and NV-RAM value dump mode.

The operation of the inspection mode is as follows. (1) Turn off the power switch of the printer.

(2) With the top cover open, turn on the power switch while holding down the

switch on the control panel. When you enter this inspection mode, the Drum lamp is ON. Holding down the panel

switch will cause the lamps turn ON in the order Drum → Alarm → Ready → Data → Drum. When you release the switch, a mode is selected.

The mode selected is indicated by the lamp which is ON when you release the switch.

The inspection modes are assigned to the respective lamps as shown below.

Lamp Type of inspection

Drum Factory inspection mode Alarm Continuous grid pattern print mode Ready 3 patterns print mode (grid Æ zip Æ black) Data NV-RAM value dump mode Drum + Alarm ROM code reprogramming mode (only when

the flash memory is fitted) Alarm + Ready RAM check Ready + Data 4% density pattern print mode

Details of the factory inspection mode are as follows. This mode is used to check if the sensors in the printer are functioning correctly. In the

process of this inspection, the lamps and the switch on the control panel are also checked. On entering this mode, the lamps show the status of the respective sensors as follows.

Page 92

CHAPTER IV -28

Drum

Feeder2

Alarm

Ready

(Paper)

Data

(Toner)

Paper eject sensor

Registration sensor

Cover sensor

Toner sensor

Switch

Fig. 4.8

Paper eject ON (Paper is detected.) Drum lamp ON sensor OFF (No paper is detected.) Drum lamp OFF Registration ON (Paper is detected.) Alarm lamp ON sensor OFF (No paper is detected.) Alarm lamp OFF Cover ON (The top cover is closed.) Ready lamp OFF sensor OFF (The top cover is open.) Ready lamp ON Toner ON (The toner cartridge is installed.) Data lamp OFF

sensor OFF (No toner cartridge is installed.) Data lamp ON The procedure for the factory inspection mode is as follows. (1) Turn the printer power switch OFF, open the top cover, and remove the drum unit.

(2) Turn the printer power switch ON while holding down the control panel switch. The

Drum lamp comes ON. (3) Lightly press the panel switch again. (4) Check that the Drum(paper eject sensor) and Alarm(regis tration sensor)

lamps go OFF after all the lamps have been ON.

If the paper eject sensor is ON at this point, the Drum lamp stays ON (error).

If the registration sensor is ON at this point, the Alarm lamp stays ON (error). (5) Install the drum unit.

Check that the Data lamp goes OFF. (6) Lightly touch the registration sensor actuator.

Check that the Alarm lamp comes ON. (7) Close the top cover.

Check that the Ready lamp goes OFF. (8) Press the control panel switch. (9) If all the sensors are correct, the printer goes back to the Ready status. If any

error is detected, the corresponding lamp stays ON.

Page 93

CHAPTER IV -29

6.2 Error Codes

In the event of a printer failure, error codes will be indicated as shown below. All the lamps and the specific lamps are turned ON alternately. The specific combination of lamps that are ON indicates the type of the error.

Type of error Data Ready Alarm Drum Feeder

Fuser Malfunction

{

Laser BD Malfunction

{

Scanner Malfunction

{{

ROM Error

{

D-RAM Error

{{

Service A *

{{

Service B *

{{{

NV-RAM Error

{{ {

CPU Runtime Error *

{{{{

Main Motor Error

{

* Refer to the further description of those errors as follows;

• Service A:

Address Error

• Service B:

Buse Error

• CPU Runtime Error:

The error which CPU other than the above two detects, such as Illegal Instruction or Operation Overflow

HOW THE LED INDICATE AN ERROR

Drum

Feeder2

Alarm

Ready

(Paper)

Data

(Toner)

Time delay

: OFF : ON

Fig. 4.9

FUSER MALFUNCTION

Page 94

V-1

APPENDIX 1. SERIAL NO. DESCRIPTIONS

The descriptions as below shows how to read labels on each place. < ID for production month >

A: January E: May J: September B: February F: June K: October C: March G: July L: November D: April H: August M: December

(1) Printer .........................on the main body

D 6 9 5 0 5 4 8 8

(2) Process unit ...............on the package of the process unit

(Drum unit with toner cartridge)

6 D 3 0 0 0 0 A N B

(3) Drum unit ....................on the drum unit

6 E B 0 0 0 0 0 1

(4) Toner cartridge ............on the toner cartridge

6 3 3 1. 0 2 8 E 0 5. N B. 0

(5) Scanner unit ................on the scanner unit

1 9 0 0 1

MONTH

YEAR

FACTORY ID NO.

SERIAL NO.

YEAR

MONTH

DATE

SERIAL NO.

LINE NO.

TONER TYPE

YEAR

MONTH

ASSEMBLY

SERIAL NO.

DATE

MONTH

(X: OCT., Y: NOV., Z: DEC.)

YEAR

FILLING AMOUNT : 0=100g : 1=110g

TONER TYPE: NB

FILLING DATE FILLING MONTH

SERIAL NO. ID NO. 1:HL-700 SERIES 9:HL-1060 FACTORY ID NO.

PR99019

Page 95

Appendix 2. Connection Diagram

V - 2

AC INPUT

LVPS

CN2

CN1 1

HEATER

THERMISTOR

SIMM

OPROM

P1 CENTRO

SERIAL I/F

PARALLEL I/F

OPIO

P2 ENGINE

MAIN PCB

BR-3000

SIMM

P2P1

RS-100M

P7 MAIN

SW2

I/L

PC1

RESIST

SENSOR

LED5

LED4

LED3

LED2

LED1

SW1

SW PANEL

PCB

FAN

LASER

SCAN

MOTOR

SCANNER

MOTOR

TONER

ERASE LAMP

T/R

TRANSFER

PCB

CHG

DRB

HVPS

RELAY PCB

RESIST SOLENOID

2BIN SOLENOID

1BIN SOLENOID

DC MOTOR

P13

LOW

VOLTAGE

P11

SOL

RESI

P12 DCMOTOR

DRIVER PCB

CN1

SR PCB

P10

DEVGRICLN

SW PANEL

SW1

TRAY

TONER

SENSOR

PC001

EJECT

SENSOR

HIGH

VOLTAGE

Page 96

Appendix 3. Main PCB Circuit Diagram, (1/4)

CODE UK3400000

B48K246CIR

NAME

V - 3

Page 97

Appendix 4. Main PCB Circuit Diagram, (2/4)

CODE UK3400000

B48K246CIR

NAME

V - 4

Page 98

Appendix 5. Main PCB Circuit Diagram, (3/4)

CODE UK3400000

B48K246CIR

NAME

V - 5

Page 99

Appendix 6. Main PCB Circuit Diagram, (4/4)

CODE UK3400000

B48K246CIR

NAME

V - 6

Page 100

Appendix 7. Driver PCB Circuit Diagram

CODE UK3634000

B48K280CIR

NAME

V - 7

Brother HL1060 - B/W Laser Printer, HL-1060 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual