Brother MFC590, MFC5100 Service Manual

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FACSIMILE EQUIPMENT

SERVICE MANUAL

MODEL: MFC5100C/MFC590

form or by any means without perm ission in writing from the publisher.

Specifications are subject to change without notice.

PREFACE

This publication is a Service Manual covering the specifications, construction, theory of operation, and maintenance of the Brother facsimile equipment. It includes information required for field troubleshooting and repair--disassembly, reassembly, and lubrication--so that service personnel will be able to understand equipment function, to rapidly repair the equipment and order any necessary spare parts.

To perform appropriate maintenance so that the facsimile equipment is always in best condition for the customer, the service personnel must adequately understand and apply this manual.

This manual is made up of six chapters and appendices.

CHAPTER 1 GENERAL DESCRIPTION CHAPTER 2 INSTALLATION CHAPTER 3 THEORY OF OPERATION CHAPTER 4 DISASSEMBLY/REASSEMBLY AND LUBRICATION CHAPTER 5 MAINTENANCE MODE CHAPTER 6 ERROR INDICATION AND TROUBLESHOOTING

Appendix 1. EEPROM Customizing Codes Appendix 2. Firmware Switches (WSW) Appendix 3. Circuit Diagrams

This manual describes the models and their versions to be destined for major countries. The specifications and functions are subject to change depending upon each destination.

CHAPTER

GENERAL DESCRIPTION

CHAPTER 1 GENERAL DESCRIPTION

CONTENTS

1.1 EQUIPMENT OUTLINE ...................................................................................................1-1

1.1.1 External Appearance and Weight ........................................................................1-1

1.1.2 Components.........................................................................................................1-1

1.2 SPECIFICATIONS............................................................................................................1-2

1.1 EQUIPMENT OUTLINE

1.1.1 External Appearance and Weight

The figure below shows the equipment appearance and approximate dimensions.

Weight: Machine proper Approx. 15 kg (33.1 lbs.)

In package Approx. 11 kg (24.2 lbs.)

1.1.2 Components

The equipment consists of the following major components:

1-1

1.2 SPECIFICATIONS

Model Name MFC-5100C

GENERAL

Print Engine Ink Jet (BH 2-head) Modem Speed (bps) 14,400 (Fax) Transmission Speed (sec.) 6 (Brother#1, MMR) ITU-T Group G3 Coding System MH/MR/MMR/JPEG Print Paper Size (W x L) 3.5"-8.5" x 5.0"-14" Document Size for ADF (W x L) 5.8"-8.5" x 5.7"-14" Max. Document Size for Flat-bed Scan (W x L) 8.5" x 11.7" Print Paper Margin (upper, lower, left, right) 0.12, 0.43, 0.12, 0.12 inch (3, 11, 3, 3 mm) ADF (pages) Up to 30 LCD Columns 16 characters LCD Lines 1 line LCD Bac klight No Backup Clock Yes (1 hour) Memory Backup N/A Memory Capacity (physical) 4MB (RAM) Optional Memory No Dimension s w/ Carton (WxDxH) Dimensions w/o Carton (WxDxH) 18.4"x18.4"x14.6" (468x467x370 mm) Weight w/ Carton 33.1 lbs/15 kg Weight w/o Carton 24.2 lbs/ 11 kg Color Gray 1495 Standby Mode No PC-Fax Protocol Compliance N/A Simultaneous Operation Yes (Print/Fax, Print/Scan) Energy Star Compliant Yes

Operating Environment Temperature Humidity

Power Source 120 VAC, 50/60 Hz Power Consumption (Standby/Peak) Under 13.5W/40W On/Off Switch No

TELEPHONE

Handset No One-Touch Dial 0 Speed Dial Max. 40 Speaker Phone No Chain Dialing Yes Caller ID No Call Waiting Caller ID No Distinctive Ringing Yes Hold/Mut e Key No Hook Key No Power Failure Dialing No Speaker Volume No Ring Volume Yes (2 steps + OFF) Handset Volume No

FAX

Scan Speed (A4:Standard) Approx. 3 sec./page (A4: standard) Memory Transmission (Brother#1 Chart) Yes (200:MMR) Memory Transmission (ITU-T Chart) Yes (170:MMR) Out-of-Paper Reception (Brother #1 Chart) Yes (200:MMR) Out-of-Paper Reception (ITU-T Chart) Yes (170:MMR) Color FAX (Document Send/Receive) Yes/Yes Color FAX (Memory Send/Receive) No/Yes

(1/2)

23.3"x22.3"x18.1" (592x566x460 mm)

10 - 35 degrees Centigrade

20% to 80%

1-2

Model Name MFC-5100C

INTERFACE

External TAD Interface Yes Host Interface (IEEE1284) Host Interface (USB) LAN Interface

PRINTER

Color/Mono Color/Mono Engine Type Piezo Ink Jet (2-head BH: 75 nozzles/color) Resolution (dpi) 1200x1200 /2400x1200 (Mono/Color)

10/8 (Mono/Color: 600*150)

Speed (ppm)

Paper Capacity (sheets) 100 Output Paper Capacity (sheets) 50 Standard Print Language Windows GDI Emulation No Resident Fonts Yes Fonts Disk Based Yes

Paper Handling Size

Manual Feed Slot N/A Other Paper Type OHP, Envelopes

Sheet Weight (Paper Cassette) (Manual Slot)

Printer Driver

COPY

Color/Mono Color/Mono Speed (ppm) 7/4 (Mono/Color) Multi Copy (Stack) Yes (Color) or Via PC Multi Copy (Sort) Yes (Color) or Via PC Resolution (dpi) Max. 1200x1200 (color)

SCANNER

Color/Mono Color/Mono Resolution (dpi) (Physical) CCD: 600x2400 (Opt.) Resolution (dpi) (Logical) 9600 (Int.) Speed (ppm) Max. 3 sec Gray Scale 256

TWAIN Compliant&Operati ng System

PCI Scanner (Parallel/Serial) Color Depth 36-bit color processing (24-bit external)

ACCESSORIES

Cartridge 4 colors (each separate tank) Life / Yield (Draft, 5% Coverage) BK: 950, CL: 450

4/3.5 (Mono/Color: 600*300) 2/1.5 (Mono/Color: 600*600)

0.2/0.2 (Mono/Color: 1200*1200/2400*1200)

LTR, LGL, A4, B5, A5, EXE,

Post card, Photo, Index card

64-120 g/m2 (17 - 32 lb)

Win95/98/98SE/Me/2000Professinal/NT4.0/

Win95/98/98SE/2000Professinal/NT4.0/Me

Yes Yes

N/A

MacOS 8.5-9.1

MacOS 8.6-/9.1

Parallel/ USB

(2/2)

1-3

Model Name MFC-590

GENERAL

Print Engine Ink Jet (BH 2-head) Modem Speed (bps) 14,400 (Fax) Transmission Speed (sec.) 6 (Brother#1, MMR ) ITU-T Group G3 Coding System MH/MR/MMR/JPEG Print Paper Size (W x L) 90-216 x 127-216 mm Document Size for ADF (W x L) 147-216 x 145-356 mm Max. Document Size for Flat-bed Scan (W x L) 216 x 297 mm Print Paper Margin (upper, lower, left, right) 0.12, 0.43, 0.12, 0.12 inch (3, 11, 3, 3 mm) ADF (pages) Up to 30 LCD Columns 16 characters LCD Lines 1 line LCD Bac klight Yes Backup Clock Yes (1 hour) Memory Backup N/A Memory Capacity (physical) 4 MB (Actually 8 MB) Optional Memory No Dimensions w/o Carton (WxDxH) Dimensions w/ Carton (WxDxH) 18.4"x18.4"x14.6" (468x467x370 mm) Weight w/o Carton 24.2 lbs/ 11 kg Weight w/ Carton 33.1 lbs/15 kg Color Gray 1495

Operating Environment Temperature Humidity

Power Source 240 VAC, 50/60 Hz Power Consumption (Standby/Peak) Under 13W/50W On/Off Switch No

TELEPHONE

Handset N/A One-Touch Dial N/A Speed Dial Max. 100 Speaker Phone No Chain Dialing Yes Caller ID No Call Waiting Caller ID No Distinctive Ringing Yes (Only UK, Denmark) Hold/Mute Key No Hook Key (Tel Key) Tel (for F/T switch) Power Failure Dialing No Speaker Volume No Ring Volume Yes (2 steps + OFF) Handset Volume No

FAX

INTERFACE

External TAD Interface Yes Host Interface (IEEE1284) Host Interface (USB) LAN Interface

23.3"x22.3"x18.1" (592x566x460 mm)

10 - 35 degrees Centigrade

20% to 80%

Yes Yes

(1/2)

1-4

Model Name MFC-590

PRINTER

Color/Mono Color/Mono Engine Type Piezo Ink Jet (2-head BH: 75 nozzles/color) Resolution (dpi) 1200x1200 /2400x1200 (Mono/Color)

10/8 (Mono/Color: 600*150)

Speed (ppm)

Paper Capacity (sheets) 100 Output Paper Capacity (sheets) 50 Standard Print Language Windows GDI Emulation N/A Resident Fonts Yes Fonts Disk Based Yes

Paper Handling Size

Manual Feed Slot N/A Other Paper Type OHP, Envelopes

Sheet Weight (Paper Cassette) (Manual Slot)

Printer Driver

COPY

Color/Mono Color/Mono Speed (ppm) 7/4 Multi Cop y (Stack) Yes (Color) or Via PC Multi Cop y (Sor t) Yes (Color) or Via PC Resolution (dpi) Max. 1200x1200

SCANNER

Color/Mono Color/Mono Resolution (dpi) (Physical) CCD 600x2400 (Opt.) Resolution (dpi) (Logical) 9600 (Int.) Speed (ppm) Max. 3 sec. Gray Scale 256

TWAIN Compliant&Opera ting System

PCI Scanner (Parallel/Serial) Color Depth 36-bit color processing (24-bit external)

ACCESSORIES

Cartridge 4 colors (each separate tank) Life / Yield (Draft, 5% Coverage) BK: 950, CL: 450

4/3.5 (Mono/Color: 600*300) 2/1.5 (Mono/Color: 600*600)

0.2/0.2 (Mono/Color: 1200*1200/2400*1200)

LTR, LGL, A4, B5, A5, EXE,

Post card, Index card

64-120 g/m2 (17 - 32 lb)

N/A

Win95/98/98SE/Me/2000Professinal/NT4.0/

MacOS 8.5/8.5.1/8.6/9.0/9.04/9.1

Win95/98/98SE/2000Professinal/NT4.0/Me

MacOS 8.6/9.0/9.04/9.1

Parallel/ USB

(2/2)

1-5

CHAPTER

INSTALLATION

CHAPTER 2 INSTALLATION

CONTENTS

2.1 INSTALLING THE UPDATE DATA TO THE FACSIMILE MACHINE.............................2-1

2.2 SETTING ID CODES TO FACSIMILE MACHINES CONNECTED TO A SINGLE

PC VIA THE USB PORT..................................................................................................2-3

2.3 SETTING HEAD PROPERTY TO THE FACSIMILE MACHINE .....................................2-4

2.1 INSTALLING THE UPDATE DATA TO THE FACSIMILE MACHINE

If the program version is updated or the main PCB is replaced, then install the update program onto the flash ROM of the main PCB.

The program installation requires a PC/AT-compatible computer (which is capable of running MSDOS or its compatible OS).

Connecting the facsimile machine to your PC

(1) Make sure that your PC is turned off. (2) Make sure that the machine’s power cord is unplugged from a wall socket or other power

source.

(3) Connect the parallel interface cable to the parallel port on the back of the machine and secure

it with the lock wires.

(4) Connect the other end of the interface cable to the printer port of your PC and secure it with

two screws.

(5) While pressing the 5 key on the machine’s control panel, plug the machine’s power cord into a

wall socket.

(6) Check to see that the following pattern displays on the LCD. If it does not display, go back to

step (2) above.

(7) Turn on your PC.

Parallel interface cable

Lock wires

Host computer

2-1

Installing the update data onto the flash ROM of the facsimile machine

NOTE: The following is an installation procedure example on a PC that is running Windows 95/98.

(1) Copy the update data and transfer utility onto the desired directory of the hard disk.

e.g., C:\UPDATE

(2) Click the Start button, point to Programs, and then click MS-DOS Prompt to open an MS-DOS

window.

(3) Type the drive letter where the update data and transfer utility are located. In the above

example, type C:\ from the command line and press the ENTER key. Then type CD UPDATE and press the ENTER key.

(4) Check that your PC is connected with the facsimile machine correctly. (5) To start the transfer utility transmitting the update data to the flash ROM of the facsimile

machine, type the following:

ICEN filename /b

Then press the ENTER key. During downloading, the machine beeps intermittently. Upon completion of the downloading, the machine beeps continuously.

NOTE: If the facsimile machine cannot return to the standby state af ter completion of downloading, turn the power off and on.

2-2

2.2 SETTING ID CODES TO FACSIMILE MACHINES CONNECTED TO A SINGLE PC VIA THE USB PORT



 Function



Brother facsimile machines are assigned unique ID codes (character strings) at the factory. If you replace the main PCB of the machine, the machine will lose its assigned ID code so that it will not be identified by the connected PC.

To connect those machines to a PC via USB, you need to assign ID codes (character strings) to those individual machines according to the procedure given here. For models covered by this manual, set serial numbers given to individual machines as ID codes.



 Connecting each of facsimile machines to your PC



(1) Make sure that your PC is turned off. (2) Make sure that the machine's power cord is unplugged from a wall socket or other power

source.

(3) Connect the interface cable to the parallel interface port on the back of the facsimile machine

and secure it with the lock wires.

(4) Connect the other end of the interface cable to the printer port of your PC and secure it with

the two screws. (5) Plug the machine's power cord into a wall socket or other power source. (6) Turn on your PC.



 Operating Procedure



(1) On your PC, run the ID setup utility. Follow the instructions shown on the PC's screen and

enter the 9-digit serial number (e.g., G01012345) printed on the nameplate labeled to the back

of the facsimile machine as an ID code. Then press the Enter key.

The ID setting utility will transmit the ID code data from your PC to the facsimile machine

and then it will terminate.

The facsimile machine will automatically return to the standby mode. (2) To check whether the entered character string (ID code) is correct, make the machine enter the

maintenance mode (refer to CHAPTER 5, Section 5.1) and then press the 1 key twice

(Subsection 5.3.5).

The facsimile machine will print out a Configuration List. At the right top of the list, "SER.#:

BROXXXXXXXXX" is printed. (3) Check that the character string entered in step (2) is printed in "XXXXXXXXX."

If it is OK, press the 9 key twice to exit from the maintenance mode.

If something other than that is printed in XXXXXXXXX, check the connection between the

PC and facsimile machine and go back to step (1).

2-3

2.3 SETTING HEAD PROPERTY TO THE FACSIMILE MACHINE



 Function



To keep the print quality, the controller optimizes the head drive strength, ink jet-out timing, and other drive conditions according to the electromechanical properties unique to the individual print head and ambient temperature. The head property information is stored in the EEPROM of the main PCB.

If you replace the print head unit and/or main PCB of the machine, then you need to update the head property according to the procedure given here.



 Connecting the facsimile machine to your PC



(1) Make sure that your PC is turned off. (2) Make sure that the machine's power cord is unplugged from a wall socket or other power

source.

(3) Connect the interface cable to the parallel interface port on the back of the facsimile machine

and secure it with the lock wires.

(4) Connect the other end of the interface cable to the printer port of your PC and secure it with

two screws. (5) Plug the machine's power cord into a wall socket or other power source. (6) Turn on your PC.



 Operating Procedure



(1) On your PC, run the head property setup utility. Follow the instructions shown on the PC's

screen and enter upper 12 digits (e.g., 55557B657031) out of the 13-digit property code

(enclosed with asterisks, e.g., *55557B657031H*) which is printed on the bar code label

attached to the print head unit.

The utility will transmit the head property from your PC to the facsimile machine and then it

will terminate.

The facsimile machine will automatically return to the standby mode. (2) To check whether the entered head property is correct, make the machine enter the

maintenance mode (refer to CHAPTER 5, Section 5.1) and then press the 7 key twice

(Subsection 5.3.15).

The facsimile machine will print out the Equipment's Log. On the line about 1/3 of full length

of the log sheet below from the top, the 12-digit code is printed. (3) Check that the character string entered in step (2) is printed in "XXXXXXXXXXXX."

If it is OK, press the 9 key twice to exit from the maintenance mode.

If something other than that is printed in XXXXXXXXXXXX, check the connection between

the PC and facsimile machine and go back to step (1).

2-4

CHAPTER

THEORY OF OPERATION

CHAPTER 3 THEORY OF OPERATION

CONTENTS

3.1 OVERVIEW ......................................................................................................................3-1

3.2 MECHANISMS.................................................................................................................3-2

3.2.1 Scanner Mechanism ............................................................................................3-4

3.2.2 Ink Jet Printing Mechanism..................................................................................3-6

3.2.2.1 Paper pulling-in, registration, feeding, and ejecting mechanisms................3-6

3.2.2.2 Ink jet printing and capping mechanisms.....................................................3-8

3.2.2.3 Purging mechanism ...................................................................................3-11

3.2.2.4 Carriage drive mechanism .........................................................................3-14

3.2.3 Sensors and Actuators.......................................................................................3-15

3.3 CONTROL ELECTRONICS...........................................................................................3-18

3.3.1 Configuration......................................................................................................3-18

3.1 OVERVIEW

Host

Line

Control panel

NCU

Fax Control Section

ADF unit

- ADF motor

Scanner unit

- CCD unit

- CCD motor

Print data

Ink jet printer unit

- Ink jet print head unit

- Carriage motor

- Carriage ASSY

- Purge unit

Centronics parallel interface

Printer Control Section

Paper feeding mechanism

- Paper feed motor

USB interface

Power supply

3-1

3.2 MECHANISMS

The facsimile machine is classified into the following mechanisms:

 SCANNER MECHANISM - ADF mechanism

 INK JET PRINTING MECHANISM - Paper pulling-in, registration, feeding, and ejecting

 SENSORS AND ACTUATORS

- Document scanning mechanism

mechanisms

- Ink jet printing and head capping mechanisms

- Purging mechanism

- Carriage drive mechanism

3-2

SCANNER MECHANISM

3-3

Ink jet pri nting and head capping mechanisms

Purge mechanism Carriage drive mechanism

Paper pulling-in, registration, feeding, and ejecting mechanisms

INK JET PRINTING MECHANISM

3.2.1 Scanner Mechanism

This mechanism consists of the document guide base, ADF & document tray ASSY and scanner unit.

The ADF (automatic document feeder) unit contains a separation roller ASSY, document feed roller ASSY, document ejection roller, ADF motor, and document front and rear sensors.

The scanner unit consists of a scanner top cover, CCD unit, CCD drive mechanism, CCD HP sensor, and scanner base.

For details about the sensors, refer to Subsection 3.2.3.

3-4

This scanner mechanism supports a dual scanning system. (1) If you set documents on the document guide base with their faces up and start the scanning

operation, then the ADF motor rotates to pull in those documents into the ADF unit, starting

from the top sheet to the bottom, page by page. Each document curves downwards and turns to

the right with the document feed roller so as to advance above the CCD unit, and then it is fed

out to the document tray with the document ejection roller ASSY.

This way, documents move above the CCD unit being kept in a stationary position. (2) If you open the ADF & document tray ASSY, put a sheet of document (or put a bound book

opened) on the glass of the scanner top cover, close the ADF & document tray ASSY, and

start the scanning operation, then the CCD drive mechanism will be driven.

The CCD motor built in the CCD unit rotates. As illustrated below, the CCD drive gear and

idle pulley carry the CCD drive belt on the underside of the CCD unit, so clockwise and

counterclockwise rotations of the CCD motor move the CCD unit to the right and left,

respectively.

In this scanning system, the CCD unit moves horizontally beneath a document being kept in

stationary position.

The CCD unit contains a charge coupled device (CCD) image sensor. The cold-cathode fluorescent lamp illuminates a document and the reflected light of the scanned image data is transmitted via the mirrors into the lens which reduces the scanned data so as to form the image on the CCD.

3-5

3.2.2 Ink Jet Printing Mechanism

3.2.2.1 Paper pulling-in, registration, feeding, and ejecting mechanisms

The paper pulling-in, registration, feeding, and ejecting mechanisms are driven by a single paper feed motor located at the left side of the main chassis via the gear train. (See the illustration given on the next page.)

First, the paper feed motor rotates clockwise (when viewed from the output gear). The rotation is transmitted to the PF roller gear that rotates paper feed roller. At the right end of the paper feed roller is the PF roller gear R which is always engaged with the ASF/purge idle gear. Engaged with the ASF/purge idle gear, the ASF-purge switching gear 23 transmits the rotation via gear 25 and the ASF gear train to the ASF roller unit. This way, the ASF roller will pull in paper.

When the ASF roller is pulling in paper, the paper feed roller rotates in the backward direction to register the leading edge of the pulled-in paper.

Next, the paper feed motor rotates counterclockwise to rotate the paper feed roller in the forward direction. The paper will advance through the paper path. During the paper feeding operation, no rotation is transmitted to the ASF roller because of the planetary gear system built in the ASF roller unit.

The above paper pulling-in and feeding operations take place when the carriage is in printing operation. If the carriage reaches the purge position, the ASF-purge switching gear 23 will be disengaged from the gear 25 and engaged with purge bevel gear A. For the purging mechanism, refer to Subsection 3.2.2.3.

Paper pulling-in mechanism

Registration & paper feeding mechanisms

ASF

ASF roller unit

Paper pressure holders

Paper chute

Registration sensor actuator

Paper width sensor actuator

Paper feed roller

Recording paper

(Carriage)

(Carriage rail)

(Ink cartridges)

Platen

(Print head unit)

Star wheels

Paper ejection roller

Paper ejecting mechanism

3-6

Gear 31MF

ASF roller unit

PF roller gear

Gear shaft 17

PF roller gear R

Gear 39

Paper feed roller

Gear 25

ASF-purge switching gear 23

ASF/purge idle gear

Paper feed motor

3-7

3.2.2.2 Ink jet printing and capping mechanisms

Carriage encoder

Carriage motor

Carriage rail

(1) Print head unit

Main chassis

Platen

Carriage PCB

Ink cartridge sensors

Ink cartridges

Ink empty sensor

Carriage

(Star wheels)

(Paper ejection roller)

Print head unit

This machine uses drop-on-demand ink jet printing. Each of the right and left print heads has an ink-jet unit that has a pair of nozzle columns for two color inks. A nozzle column consists of 75 nozzles, 75 channels covered with piezoelectric ceramic (PZT), a manifold, and filter. As illustrated below, the pair of nozzle columns is staggered.

Nozzle Layout (viewed from the bottom)

3-8

If the controller issues a print command, a biased voltage will be applied to all electrodes formed on the surface of the piezoelectric ceramic so that each actuator will be distorted as shown with broken lines.

If the electrodes on a target channel are deenergized according to drive signals, then the associated piezoelectric ceramic actuator returns to the previous form so that the ink in the manifold will be vacuumed out to the channel.

If the voltage is applied again, the piezoelectric ceramic actuator will be distorted again to apply pressure to the ink in the channel, causing the ink to jet out through the nozzle. The jetted-out ink drop will be splashed and produce a dot on paper held by the platen.

As the carriage holding the print head unit travels at the printing speed, the controller sends print command pulses to the piezoelectric actuator driver circuit embedded in the print head unit.

(2) Ink cartridges

The machine uses four ink cartridges (black, cyan, yellow, and magenta) of disposable type to supply ink to the print head unit. As shown below, an ink cartridge contains an ink-impregnated urethane foam. If ink-jet print operation or purging operation takes place, ink comes out of the urethane foam and is supplied to the print head unit through the ink room, filters, and manifold.

For the ink cartridge sensors on the carriage PCB, refer to Subsection 3.2.3.

3-9

(3) Head cap

Shown below is a head cap mechanism that prevents the nozzles of the print heads from drying up when they are not in use.

Upon completion of printing, the carriage travels to the right and moves the head cap holder provided on the purge unit to the right together. In the head cap holder is a head cap which is supported with a lift lever. The rightward movement of the head cap holder turns the lift lever and pushes up the head cap to the position where the head cap comes into tight contact with the print heads. This way, the nozzles will be capped.

3-10

3.2.2.3 Purging mechanism

The purge mechanism is driven by the paper feed motor located at the left side of the main chassis. As described in Subsection 3.2.2.1, the motor rotation is transmitted to the ASF/purge idle gear at

the right side of the main chassis. Engaged with the ASF/purge idle gear, the ASF-purge switching gear 23 works as a clutch gear.

When the carriage travels from the left to right to reach the purge position, the tab provided on the back of the carriage pushes the purge lever on the main chassis to the right (see the illustration below). Accordingly, the ASF-purge switching gear 23 (which was shifted to the left by the purge lever) will move to the right by the switching gear spring so as to become disengaged from the gear 25 and engaged with the purge bevel gear A. (See the illustration given on the next page.) This engagement will transmit the motor rotation to the purge bevel gear B on the purge unit. This way, when the carriage is in the purge position, the motor rotation is transmitted to the purge unit.

On the contrary, if the carriage travels from the purge position to the left, the tab on the back of the carriage releases the purge lever which will be pulled back to the left. The ASF-purge switching gear 23 will be disengaged from the purge bevel gear A.

3-11

During printing: The ASF-purge switching gear 23 is not engaged with pur ge bevel gear A ( but engaged with gear 25 in the ASF gear train).

During purging: T he ASF-purge switching gear 23 is engaged with purge bevel gear A.

When the motor rotation is transmitted to the purge unit, its counterclockwise rotation will drive the purge cam and its clockwise rotation, the pump switching unit (when viewed from the output gear of the motor).

When the paper feed motor rotates counterclockwise

When the paper feed motor rotates clockwise

3-12

The purge cam is so designed that:

- the carriage lock pops out to lock the carriage before purging and pops in before cleaning with

the head wiper (see the illustration below),

- the pump works to draw out ink from each of the four head nozzles and drain it to the ink

absorber felts, and

- the head wiper comes out to clean the nozzle surface (see the illustration below). The pump switching cam is so designed that:

- the pump switching unit switches application of the pump's negative pressure between the four

head nozzles in the order of black, cyan, yellow, and magenta nozzles. When the pump switching cam is in the home position, normal atmospheric pressure will be restored.

The home position of the purge cam and pump switching cam are detected by their HP switches. For those switches, refer to Subsection 3.2.3.

(1) Carriage lock

If the purge cam is driven, the carriage lock of the purge unit pops out and locks the carriage to align ink-jet unit with the mating purge caps during purge operation. After purging but before cleaning with the head wiper, it pops in to release the carriages. When the power is off, the carriage lock keeps the print heads pressed against the head caps.

(2) Purging

If activated, the pump draws out ink to purge air bubbles or dust from the inside of the head nozzles and channels. As the purge cam rotates by one turn, the piston of the pump reciprocates two strokes. To complete purging of all four nozzles and channels, the purge cam rotates by two turns ad the piston reciprocates four strokes.

(3) Draining

The pump drains drawn ink into the ink absorber felts.

(4) Cleaning with the head wiper

After purging operation, the head wiper comes out and the carriage moves from the right to left so as to clean ink remaining on the heads' surface.

(5) Restoring the pump's pressure to normal atmospheric pressure

When the pump switching cam is in the home position, the controller stops to produce negative pressure and restore the pump's pressure to normal atmospheric pressure.

3-13

3.2.2.4 Carriage drive mechanism

The carriage motor controls horizontal motion. The motor rotation is transmitted via the motor pulley to the timing belt.

The carriage, which is supported and guided by the carriage rail, is secured to the timing belt. Clockwise and counterclockwise rotations of the carriage motor move the carriage to the right and left, respectively.

On the back of the carriage is the carriage encoder which tells the control circuitry the current carriage position counted based on the carriage motor position by using the encoder strip attached to the main chassis.

3-14

3.2.3 Sensors and Actuators

This machine has the following sensors and thermister.

Sensor name Type Located on Document front sensor Photosensor Document rear sensor Photosensor

Document sensor PCB in the ADF

Document tray open sensor Mechanical switch Document tray Scanner open sensor Photosensor Control panel PCB ASSY Registration sensor Photosensor Paper chute Paper width sensor Photosensor Main PCB CCD HP sensor Photosensor CCD PCB on the CCD unit Ink empty sensor Photosensor Sensor support Ink cartridge sensors Mechanical switches Carriage encoder Photosensor

Carriage PCB Head thermister Thermister Purge cam HP switch Mechanical switch

Purge unit Pump switching cam HP switch Mechanical switch

• Document front sensor which detects the presence of documents.

• Document rear sensor which detects the leading and trailing edges of pages to tell the control circuitry when the leading edge of a new page has reached the starting position and when the scan for that page is over.

• Document tray open sensor which detects whether the document tray is closed.

• Scanner open sensor which detects whether the scanner unit is closed.

• Registration sensor which detects the leading and trailing edges of paper, which allows the controller to determine the registration timing and check paper jam.

• Paper width sensor which detects whether the paper width is "A4-size or wider" or "narrower than A4-size."

• CCD HP sensor which detects whether the CCD unit is placed in the home position.

• Ink empty sensor which detects at the start of printing whether any of the four ink cartridges is near empty. According to this sensor signal, the controller may display "NEAR EMPTY XXX" message.

• Ink cartridge sensors, each of which detects whether an ink cartridge is loaded.

• Carriage encoder which detects the current carriage position and carriage travel speed. If the carriage travels speed varies abnormally, the controller regards it as a paper jam.

• Head thermister which allows the controller to control the temperature of the print heads. According to the change of the thermister's internal resistance monitored, the control circuitry regulates the drive voltage applied to the piezoelectric ceramic actuators on each print head since the viscosity of the ink varies depending upon the temperature.

3-15

• Purge cam HP switch which detects whether the purge cam is in the home position.

• Pump switching cam HP switch which detects whether the pump switching cam is in the home position.

These photosensors (except the ink empty sensor that is a reflection type) are a photointerrupter consisting of a light-emitting diode and a light-sensitive transistor. Each of them has an actuator separately arranged as shown on the next page.

3-16

Registration sensor

Registration sensor actuator

(Paper chute)

Document front sensor actuator

Document front sensor

(Document sensor PCB)

Document tray open sensor

(Relay PCB)

Document rear sensor actuator

Document rear sensor

CCD HP sensor

CCD HP sensor plate

Paper width sensor

Paper width sensor actuator

(Main PCB)

Scanner open sensor actuator Scanner open sensor

(Control panel PCB)

(Purge unit)

Purge cam HP switch

Pump switching cam HP switch

Ink empty sensor

(Sensor support)

Location of Sensors and Actuators

3-17

3.3 CONTROL ELECTRONICS

3.3.1 Configuration

The hardware configuration of the facsimile machine is shown below.

Carriage PCB

Paper width sensor

Ink cartridge sensors

Carriage encoder

Head thermister

INK JET PRINTER UNIT

Print head Print head

EEPROM

Engine

Main

ASIC

Main PCB

DC motor driver

Stepping motor driver

SDRAM

(8MB/2MB)

3-pin

2-pin

4-pin

Ink empty sensor

Registration sensor

Carriage motor

Paper feed motor

Purge cam HP switch

Pump switching cam HP switch

2-pin

12-pin

11-pin

9-pin

4-pin

Relay PCB

7-pin

Sensor support

Paper chute

Purge unit

Document tray open sensor

Document sensor PCB (Document front sensor and document rear sensor)

ADF motor

ADF UNIT

CCD unit (CCD motor) (CCD HP sensor)

SCANNER UNIT

ROM

(2MB)

USB

MODEM

Parallel interface

(ECP)

7-pin

(10-pin)*

11-pin

Power supply PCB

NCU PCB

AC line

* 7-pin: American models 10-pin: Other models

Configuration of Facsimile Machine

3-18

Control panel PCB ASSY (Scanner open sensor)

Piezo ringer

Line External telephone

CHAPTER

DISASSEMBLY/REASSEMBLY,

LUBRICATION, AND ADJUSTMENT

CHAPTER 4 DISASSEMBLY/REASSEMBLY, LUBRICATION,

ADJUSTMENT

CONTENTS

4.1 DISASSEMBLY/REASSEMBLY......................................................................................4-1

 Safety Precautions.......................................................................................................4-1

Tightening Torque List......................................................................................................4-2

 Preparation ..................................................................................................................4-4

 How to Access the Object Component........................................................................4-4

 Disassembly Order Flow..............................................................................................4-5

4.1.1 Print Head Unit.....................................................................................................4-6

4.1.2 ADF Cover and Document Guide Base .............................................................4-10

4.1.3 ADF Components on the Upper ADF Chute......................................................4-11

Gear cover ...........................................................................................................4-11

Separation roller ASSY and document feed roller....................................................4-12

Separation rubber unit, ADF thickness adjuster, and pressure rollers.........................4-13

Upper ADF chute..................................................................................................4-15

4.1.4 ADF Components on the Lower ADF Chute......................................................4-16

Document front and rear sensor actuators................................................................4-16

Document sensor PCB...........................................................................................4-16

Document guide clips............................................................................................4-17

Document ejection roller.......................................................................................4-17

Document pressure bar..........................................................................................4-18

Lower ADF chute, pinch r ollers, and ADF moto r.....................................................4-19

4.1.5 Document Tray Open Sensor and Document Stopper ......................................4-21

4.1.6 Jam Clear Cover, Rear Cover, and Inner Cover................................................4-22

4.1.7 Scanner Unit and Control Panel ASSY (Together with Document Tray) ...........4-23

4.1.8 Disassembly of the Control Panel ASSY............................................................4-28

4.1.9 Disassembly of the Scanner Unit.......................................................................4-29

4.1.10 Auto Sheet Feeder (ASF) and Separation Pad ASSY .......................................4-34

4.1.11 Edge Cover, Scanner Links and Their Guides...................................................4-36

4.1.12 Relay PCB and PCB Plate .................................................................................4-37

4.1.13 Bottom Plate, Ink Absorber Box, Main PCB, NCU PCB, and

Power Supply PCB.............................................................................................4-38

4.1.14 Enclosure Cover.................................................................................................4-42

4.1.15 Main Cover.........................................................................................................4-43

4.1.16 Purge Unit ..........................................................................................................4-45

4.1.17 Main Chassis......................................................................................................4-47

4.1.18 ASF Roller Unit and its Related Gears...............................................................4-49

4.1.19 Paper Pressure Holders.....................................................................................4-51

4.1.20 Paper Chute and Registration Sensor................................................................4-52

4.1.21 Paper Ejection Roller Gear, Ink Empty Sensor PCB, Platen,

Star Wheel Support, and Paper Ejection Roller.................................................4-54

4.1.22 Paper Feed Motor and Paper Feed Roller .........................................................4-57

4.1.23 Encoder Strip and Carriage Motor......................................................................4-58

4.1.24 Carriage Rail, Carriage ASSY, and Purge-Related Parts ..................................4-60

4.1.25 Flushing Gutter and Paper Width Sensor Actuator............................................4-65

4.1.26 Harness Routing.................................................................................................4-66

4.2 LUBRICATION...............................................................................................................4-68

4.3 ADJUSTMENT...............................................................................................................4-73

4.1 DISASSEMBLY/REASSEMBLY



 Safety Precautions



To prevent the creation of secondary problems by mishandling, observe the following precautions during maintenance work.

(1) Unplug the power cord from the power outlet before replacing parts or units. When having

access to the power supply, be sure to unplug the power cord from the power outlet. (2) Be careful not to lose screws, washers, or other parts removed for parts replacement. (3) Do not remove gears from the document feed roller ASSY or ejection roller ASSY if at all

possible. Once removed, they will become unusable and new gears will have to be put back in. (4) When using soldering irons and other heat-generating tools, take care not to damage the resin

parts such as wires, PCBs, and covers. (5) Before handling the PCBs, touch a metal portion of the machine to discharge static electricity;

otherwise, the electronic parts may be damaged due to the electricity charged in your body. (6) When transporting PCBs, be sure to wrap them in conductive sheets such as aluminum foil. (7) Be sure to reinsert self-tapping screws correctly, if removed. (8) Tighten screws to the torque values listed on the next page. (9) When connecting or disconnecting cable connectors, hold the connector bodies not the cables.

If the connector has a lock, always slide the connector lock to unlock it.

(10) Before reassembly, apply the specified lubricant to the specified points. (Refer to Subsection

4.2 in this chapter.)

(11) After repairs, check not only the repaired portion but also that the connectors and other related

portions function properly before operation checks.

(12) Once the print head unit prints, it will start head locking operation after five seconds from the

end of printing. The head locking operation will take 5 to 10 seconds. NEVER unplug the

power cord before the machine completes the head locking operation; doing so will make the

print head unit unusable and require replacement with a new print head unit.

When you receive the machine from the user or when you pack it for sending it back to the

user, check the head locking state.

4-1

Tightening Torque List

Location Screw type Q'ty Tightening torque

N•m (kgf•cm)

ADF thickness adjuster Taptite, pan B M3x6 1 0 .39 ±0.10 (4 ±1) Upper ADF chute Taptite, cup B M3x10 2 0.69 ±0.10 (7 ±1)

Lower ADF chute Taptite, cup B M3x10 2 0.69 ±0.10 (7 ±1) Grounding wire Taptite, cup B M3x8 1 0.69 ±0.10 (7 ±1) ADF drive unit Taptite, cup B M3x8 2 0.69 ±0.10 (7 ±1) ADF motor Screw, pan (s/p washer) M3x6 1 0.69 ±0.10 (7 ±1)

Rear cover Taptite, cup B M3x12 2 0.69 ±0.10 (7 ±1) Grounding wires Screw, bind B tite M4x16 1* 0.98 ±0.20 (10 ±2)

(from the ADF drive unit and relay PCB) Document tray Taptite, bind B M4x12 2 0.9 8 ±0.20 (10 ±2)

Hinge base R Taptite, cup B M3x10 3 0.59 ±0.10 (6 ±1) Hinge L Taptite, cup B M3x10 3 0.59 ±0.10 (6 ±1)

Control panel ASSY Taptite, cup B M3x12 6 0.49 ±0.10 (5 ±1) Scanner open sensor PCB Taptite, cup B M3x8 1 0.59 ±0.10 (6 ±1) Piezo ringer cap Taptite, cup B M3x12 3 0.59 ±0.10 (6 ±1) Reinforcement plate Taptite, cup B M3x6 7 0.49 ± 0 .10 (5 ±1) Control panel PCB Taptite, cup B M3x6 2 0.49 ±0.10 (5 ±1)

Scanner top cover Taptite, cup B M4x12 4 0.98 ±0.20 (10 ±2) Guide plate Taptite, cup B M3x8 3 0.69 ±0.10 (7 ±1) CCD HP sensor plate Taptite, cup B M3x8 1 0.69 ±0.10 (7 ±1) Flat cable clamp Taptite, cup B M3x8 2 0.69 ±0.10 (7 ±1)

ASF Taptite, cup B M3x12 4 0.69 ±0.10 (7 ±1) Edge cover Tap tite, cup B M3 x12 2 0.69 ±0.10 (7 ±1)

Scanner link guides Taptite, cup B M3x12 2 0.69 ±0.10 (7 ±1) Relay PCB cover Taptite, cup B M3x6 1 0.69 ±0.10 (7 ±1)

Relay PCB Taptite, cup B M3x6 1 0.69 ±0.10 (7 ±1) USB I/F connector Screw, pan M3x6 1 0.39 ±0.10 (4 ±1) Parallel I/F connector Screw, pan M3x6 2 0.39 ±0.10 (4 ±1)

Bottom plate Taptite, cup B M3x12 11 0.69 ±0.10 (7 ±1) Grounding terminal Screw, pan (washer) M4x8 1 0.59 ±0.20 (6 ±2)

Ink absorber box Taptite, cup B M3x12 1 0.78 ±0.10 (8 ±1) Main cover Screw, bind B tite M4x16 3 (4)* 0.98 ±0.20 (10 ±2) Side frame supporter Screw, pan (s/p washer) M3x6 1 0.69 ±0.10 (7 ±1)

Purge unit Taptite, cup B M3x8 2 0.59 ±0.10 (6 ±1) FG plate R (Lower cover) Taptite, cup B M3x12 1 0.78 ±0.10 (8 ±1)

(Main chassis) Taptite, cup S M3x5 1 0.78 ±0.10 (8 ±1)

FG plate L (Main chassis) Taptite, cup S M3x5 1 0.78 ±0.10 (8 ±1) Shield film (Main chassis) Taptite, cup S M3x5 1 0.59 ±0.10 (6 ±1)

[ (Lower cover) Taptite, cup S M3x5 1 0.59 ± 0.10 (6 ±1) ]

Chassis supporters R and L Taptite, cup B M3x12 2 0.78 ±0.10 (8 ±1)

* The main cover is secured with four screws together with the two grounding wires.

4-2

Location Screw type Q'ty Tightening torque

N•m (kgf•cm)

ASF roller unit Taptite, cup S M3x6 3 0.98 ±0.10 (10 ±1) ASF gear holders Taptite, cup B M3x10 1 0.49 ± 0.10 (5 ± 1 )

Paper chute Taptite, cup S M3x6 1 0.98 ±0.10 (10 ±1) Ink empty sensor PCB Taptite, cup B M3x8 1 0.59 ±0.10 (6 ±1 ) Platen Shoulder screw 1 0.59 ±0.10 (6 ±1)

Screw, bind B tite, M3x10 1 0.5 9 ±0.10 (6 ±1) Platen plate R Taptite, bind B M2.6x10 1 0.3 9 ±0.10 (4 ±1) Platen plate L Taptite, bind B M2.6x10 1 0.39 ±0 .1 0 (4 ±1)

Paper feed motor Screw, pan (s/p washer) M3x6 2 0.78 ±0.10 (8 ±1) Idle pulley holder Taptite, cup S M3x8 1 0.98 ±0.10 (10 ±1)

Shoulder screw 1 0.78 ±0.10 (8 ±1)

Screw, cup S tite, M3x6 1 0.98 ±0.10 (10 ±1) Carriage motor Screw, pan (s/p washer) M3x6 2 0.78 ±0.10 (8 ±1) Eccentric bushings R, L Screw, pan (s/p washer) M3x6DB 2 0.78 ±0.10 (8 ±1)

Flushing gutter Taptite, cup B M3x12 1 0.69 ±0.10 (7 ±1)

4-3



 Preparation



Prior to proceeding to the disassembly procedure, (1) Unplug

- the modular jack of the telephone line,

- the PC interface cable if connected (Not shown below), and

- the modular jack of an external telephone set if connected (Not shown below).

(2) Remove

- the paper wire extension and

- the paper tray.

NOTE: Do not remove the ink cartridges when disassembling the machine except when removing the print head unit.

Telephone line cord

Paper wire extension

Paper tray



 How to Access the Object Component



• On the next page is a disassembly order flow which helps you access the object components. To remove the purge unit, for example, first find it on the flow and learn its number ( case). You need to remove parts numbered purge unit.

• Unless otherwise specified, the disassembled parts or components should be reassembled in the reverse order of removal.

in this

, , , , , and so as to access the

4-4



 Disassembly Order Flow



4.1.6

Jam clear cover Rear cover

4.1.10

Auto sheet feeder (ASF)

- Separation pad ASSY

4.1.6

4.1.12

4.1.13

4.1.7

Scanner unit with document tray

4.1.7

Document tray Hinges

(NOTE 2)

4.1.9

Scanner unit

Inner cover

PCB plate

Main PCB

4.1.5

Document tray open sensor

4.1.12

(NOTE 1)

Scanner top cover

CCD drive belt

CCD unit

(NOTE 3)

4.1.7

CCD flat cable

4.1.13

Relay PCB cover

Relay PCB

4.1.5

Document stopper

Scanner open lever Lever spring Scanner open sensor actuator Piezo ringer

Ink absorber box

4.1.13

Bottom plate

4.1.13

4.1.14

4.1.2

ADF cover

4.1.2

Document guide base

Power supply PCB

Enclosure cover

4.1.7

Control panel ASSY

4.1.8

- Control panel PCB with scanner open sensor PCB

- Reinforcement plate

- FPC key

- LCD

- Keys

4.1.13

NCU PCB

(NOTE 4)

4.1.3

ADF components on the upper ADF chute

Separation roller ASSY

Separation rubber unit ADF thickness adjuster

4.1.4

ADF components on the lower ADF chute

Document sensor actuators Document sensor PCB

Gear cover

Upper ADF chute

(NOTE 5)

Document feed roller

Pressure rollers

Document guide clips Document ejection roller

Lower ADF chute

Pinch rollers

Document pressure bar

ADF motor

4.1.15

Main cover

4.1.17

Main chassis

4.1.18

ASF roller unit and its gears

4.1.19

Paper pressure holders

4.1.20

Paper chute

- Registration sensor

4.1.21

Platen

- Star wheel support

- Platen plates

- Flushing sponge

- Paper ejection roller

4.1.17

Vibration absorbers (Rubber bushings)

4.1.17

FG plates

(NOTE 7)

4.1.11

Edge cover Scanner links Scanner link guides Scanner link springs

4.1.23

4.1.21

4.1.22

Paper feed roller

4.1.25

4.1.1

4.1.16

Purge unit

(NOTE 6)

Idle pulley holder

Carriage motor

Paper ejection roller gear

Sensor support Ink empty sensor PCB

(NOTE 8)

4.1.22

PF roller gear

Flushing gutter

Print head unit

4.1.23

Encoder strip

4.1.24

Carriage rail

4.1.24

Carriage ASSY

4.1.24

Purge-related parts

4.1.22

Paper feed motor

4.1.25

Paper width sensor actuator

4.1.24

Carriage PCB (with head flat cables)

(NOTE 9)

(NOTE 1) On the main PCB is a paper width sensor. (NOTE 2) On the document tray is a document tray open sensor. (NOTE 3) On the CCD unit is a CCD HP sensor. (NOTE 4) On the control panel PCB ASSY is a scanner open sensor. (NOTE 5) On the document sensor PCB in the ADF are a document

front sensor and document rear sensor.

(NOTE 6) On the purge unit are a purge cam HP switch and pump

switching cam HP switch. (NOTE 7) On the paper chute is a registration sensor. (NOTE 8) On the sensor support is an ink empty sensor. (NOTE 9) On the carriage PCB are four ink cartridge sensors,

a carriage encoder, and head thermister.

4-5

4.1.1 Print Head Unit

During disassembly jobs (except when removing the purge unit, carriage rail, or carriage ASSY), the print head unit and all the four ink cartridges should be kept in place.

NOTE: To replace the print head unit with a new one, you need to move the carriage to the ink

replacement position by placing the machine in the ink replacement mode. Do not move the carriage by hand when the power is off.

NOTE: If you replace the print head unit with a new one, replace also the ink absorber box and ink cartridges with new ones.

(1) Plug the power cord into a wall socket. (2) Press the Ink key to place the machine in the ink replacement mode. (3) Press the 2 key to choose "2. REPLACE INK." (4) Press the Menu/Set key.

The carriage automatically moves left to the ink replacement position. (5) Unplug the power cord from the wall socket. (6) Pull the scanner open lever towards you and open the scanner unit.

Scanner unit

Scanner open lever

(7) Push the colored ink cartridge covers and remove all ink cartridges. (Or, remove the shipping

cover.)

PUSH

PUSHPUSH

Ink cartridge covers

4-6

(8) Pull the head clamp springs in the direction of arrows shown below to release the print

head unit. (9) Lift the print head unit up and out of the carriage (arrow

Head clamp spring

Scanner unit

Head clamp spring

Boss of the print head unit

Carriage

Head clamp spring

Print head unit

Locks provided on the carriage

NOTE: Do not touch the printing ends (nozzles) of the print head unit or the ink orifices of

the ink cartridges; doing so will not only stain your hands with ink but result in an ink jet-out

failure. Once you touch them, clean them with a dedicated cleaning stick and liquid.

NOTE: Be sure to put a head nozzle seal and filter seal on the print head unit as shown below.

Leaving the print head unit without those seals will dry up its printing ends and filters,

resulting in a damaged head.

NOTE: Do not touch the dimple contact section of the print head unit.

4-7

NOTE: Once the ink cartridges are removed, their colored covers rise upright. If you turn the

machine upside down with those covers being upright, then they will break. To prevent it, set

them to the horizontal position by turning them in the direction of arrow

up in the direction of arrow

and pushing them

(10) Turn the head adjuster lever located on the right side of the carriage to position 1.

(11) To install a new (or removed) print head unit, remove the head nozzle seal. (12) Put the print head unit into the carriage with care for the dimple contact so that the electrical

contact on the head PCB comes into uniform contact with that on the carriage PCB as

illustrated below.

4-8

(13) Press the front center of the carriage to the rear and move the print head unit to the right and

left several times. This is to assure the dimple contact between the head PCB and carriage

PCB.

(14) While pressing the front center of the print head unit, lock the print head unit with the head

clamp springs.

(15) Remove the head filter seal. (16) Set new ink cartridges into the carriage. (17) Press the bottom right front corner of the carriage to the rear.

(18) Close the scanner unit. (19) Plug the power cord into a wall socket.

The carriage automatically moves to the right-hand home position.

(20) Follow the instructions shown on the LCD.

NOTE: The machine enters a "head cleaning" cycle that takes approx. 3 minutes for each ink

cartridge.

(21) Load paper into the ASF. (22) Correct the positioning error of the print head unit, referring to Section 4.3 "ADJUSTMENT." (23) Adjust the alignment of vertical print lines, referring to CHAPTER 5, Subsection 5.3.12.

4-9

4.1.2 ADF Cover and Document Guide Base

(1) Open the ADF cover, press its front end to release the boss, and take it off (in the direction of

arrows

Inside of the ADF cover

, , and ).

ADF cover

Stopper tab

Setting the ADF cover back into place

Boss

Correct Wrong

(2) Remove the document support. (3) Release the two latches of the document guide base and slide it up straight along the guides.

NOTE: Do not turn it to the left. Doing so will break the groove sections of the document

guide base.

Document support

Document guide base

Groove

Latches

ADF & document tray ASSY

Groove

Guides



 Reassembling Notes



• When setting the ADF cover back into place, fit its bottom edge under the stopper tabs as

illustrated above.

4-10

4.1.3 ADF Components on the Upper ADF Chute

Gear cover

(1) As illustrated below, insert the tip of a flat screwdriver into the slot and lift up the right edge

of the gear cover (arrow

) and move the gear cover to the front (arrow ).

Flat screwdriver

Latch

Ribs

Upper ADF chute

Gear cover

Rib

Latch

(Front)

(Left)

4-11

Separation roller ASSY and document feed roller

(2) From the rear end of each of the separation roller ASSY and document feed roller, remove the

plastic retaining ring. Lift up the rear ends of them and take them out together with bushings

NOTE: Take care not to drop bushings S.

Plastic retaining rings

Separation roller ASSY

Document feed roller

ADF drive unit

(Rear)

ADF & document tray ASSY

Ribs of the bushings

ADF drive unit

Upper ADF chute

Plastic retaining rings

Fitting the bushings into the cutouts provided in the ADF drive unit and setting the plastic retaining rings inside the upper ADF chute

Separation roller shaft

Document feed roller shaft

Spring plate

Bushings S

Separation roller

When setting the separation roller, take care not to apply force to the spring plate at an angle

4-12

Reassembling Note: If you have disassembled the separation roller ASSY, set the separation

roller on its shaft with the boss facing towards the pin and then snap the plastic retaining ring

into place, as illustrated below.

Reassembling Note: When setting the separation roller ASSY, take care not to apply force to

the spring plate at an angle, as illustrated on the previous page.

Reassembling Note: After setting the rear end of the separation roller ASSY or document

feed roller to the ADF drive unit, fit its bushing into the cutout provided in the ADF drive unit

with its rib facing up. Then set the plastic retaining ring inside the upper ADF chute, as

illustrated on the previous page.

Separation rubber unit, ADF thickness adjuster, and pressure rollers

(3) Turn the separation rubber unit as shown below and lift it up.

4-13

(4) Remove the screw and take the ADF thickness adjuster out of the upper ADF chute.

NOTE: The ADF thickness adjuster is lubricated with grease, so take care not to smear

surrounding parts with the grease when handing the ADF thickness adjuster. (5) At either end of the pressure roller shaft, press the latch to the right and take out the pressure

rollers and their shaft. Then remove their springs.

Taptite, pan B M3x6

Pressure roller shaft

Pressure roller springs

Upper ADF chute

Pressure rollers

(Rear)

Latches

ADF thickness adjuster

Lubricated with grease

Correct position of the boss

ADF thickness adjuster

Wrong position: Boss placed on the guide

Guide

When setting the ADF thickness adjuster, do not put the boss provided on the underside of the adjuster on the guide.

4-14

Upper ADF chute

(6) Remove the two screws from the upper ADF chute. (7) Open the document tray (

(8) From the underside of the document tray, release the two leftmost latches (

up the left end of the upper ADF chute (

Taptite, cup B M3x10

(Rear)

Latches

Upper ADF chute

Document tray

) and then pull

"Y"

Upper ADF chute

(3)

(Left)

Latches

(4)

Latching the upper ADF chute (Viewed from "Y")

Latches

(2)

Tabs

(1)

Document tray

Reassembling Note: When latching the upper ADF chute, first fit tabs (1) of the right end

into the openings provided in the document tray, then press latches (2), (3), and (4) into place

in this order as shown above.

4-15

4.1.4 ADF Components on the Lower ADF Chute

Document front and rear sensor actuators

(1) Lift up the document front sensor actuator. Fully turn the document rear sensor actuator

counterclockwise, then lift it up.

Document rear sensor actuator

Lower ADF chute

(Rear)

Document sensor PCB

Document front sensor actuator

(2) Take the document sensor harness out of the cable hooks, then disconnect it from the

document sensor PCB. (3) Press the locking pawl to the front and take out the document sensor PCB.

Document front sensor

Document sensor PCB

Document sensor harness

Lower ADF chute

(Rear)

Document rear sensor

Locking pawl

Cable hooks

4-16

Document guide clips

(4) Press the tab of each document guide clip. Each clip will snap out of the document ejection

roller shaft.

Document guide clip

Lower ADF chute

(Rear)

Document ejection roller shaft

Document ejection roller

(5) Remove the pawled bushing from the front end of the document ejection roller shaft by

pulling its pawls outwards. (6) Slide the rear bushing to the rear and then lift up the document ejection roller.

ADF drive unit

Lower ADF chute

Boss

Document ejection roller

Rear bushing

(Rear)

Pawled bushing

4-17

Reassembling Note: When fitting the rear bushing of the document ejection roller into the

cutout of the ADF drive unit, orient the boss as illustrated on the previous page.

Document pressure bar

(7) Open the ADF & document tray ASSY. (8) Pull either of the front and rear supports of the document pressure bar outwards and remove

the document pressure bar. The spring also comes off.

ADF & document tray ASSY

Supports

Document pressure bar

"X"

Spring

Setting the spring (Viewed from "X")

Correct

Wrong

Document pressure bar

Reassembling Note: After setting the document pressure bar, check in the direction of arrow

"X" that the spring is into place as illustrated above.

Spring

4-18

Lower ADF chute, pinch rollers, and ADF motor

(9) Take the document sensor harness out of cable hooks provided on the lower ADF chute.

(10) Disconnect the ADF motor harness from the motor, then take its harness out of the cable

guides and hooks.

(11) Release the grounding wire from the ADF drive unit by removing the screw. (12) Remove the two screws from the lower ADF chute. (13) Lift up the lower ADF chute in the direction of the arrow shown below, taking care not to

touch the anti-static brush.

(14) Press the latch to the left and remove the pinch rollers and its shaft.

When reinstalling the lower ADF chute, turn the planet gear counterclockwise (when viewed from the rear)

ADF drive unit

Taptite, cup B M3x10

ADF motor harness

Grounding wire

Document sensor harness

Planet gear

Grounding wire

Lower ADF chute

Anti-static brush (Do not touch this.)

Pinch roller shaft

Pinch rollers

Pinch roller spring

Latch

4-19

(15) Remove the two screws from the ADF drive unit and release the ADF motor.

NOTE: When using a screwdriver, take care not to scratch or damage gears on the ADF drive

unit.

Reassembling Note: When setting the ADF motor, hook the non-screw side of the flange on

section "x" (shown above) and secure it with the screw.

Reassembling Note: Before reinstalling the lower ADF chute to the document tray, be sure to

turn the planet gear on the ADF drive unit counterclockwise when viewed from the rear, as

illustrated on the previous page.

Reassembling Note: For routing the ADF motor harness, document sensor harness, and

grounding wire, refer to Subsection 4.1.26, "Harness routing A." Secure the grounding wire at

the angle shown on the previous page and let it hold down the ADF motor harness and

document sensor harness as shown in "Harness routing A."

4-20

4.1.5 Document Tray Open Sensor and Document Stopper

(1) Disconnect the document tray open sensor harness from the sensor. (2) Open the document tray. (3) Press the right and left latches of the document tray open sensor with the tip of a flat

screwdriver as shown below and push it down.

Document tray

Document tray open sensor harness

Document tray open sensor

Latches

(4) Slightly open the document stopper and remove it while warping it.

Document stopper

Document tray

4-21

4.1.6 Jam Clear Cover, Rear Cover, and Inner Cover

(1) Open the jam clear cover and remove it while warping it. (2) Remove the two screws from the rear cover and take if off to the rear.

Jam clear cover

Taptite, cup B M3x12

Rear cover

(3) Slightly pull up the rear edge of the inner cover and pull it out to the rear.

Inner cover

Lower cover

Auto sheet feeder (ASF)

4-22

4.1.7 Scanner Unit and Control Panel ASSY (Together with Document Tray)

(1) Release the grounding wires (coming from the ADF drive unit and relay PCB) by removing

the screw. (2) Disconnect the following harnesses and flat cable from the relay PCB:

- CCD flat cable

- Document tray open sensor harness

- Document sensor harness

- Panel harness

- ADF motor harness

NOTE: Handle the CCD flat cable with care.

Screw, bind B

Grounding wire (From the ADF drive unit)

Grounding wire

tite M4x16

(Rear)

Document tray open sensor harness

Document sensor harness

Panel harness

ADF motor harness

Relay PCB

CCD flat cable

Relay PCB

4-23

(3) Pull the scanner open lever towards you and open the scanner unit. (4) At each of the right and left scanner links, fully push up the lock of the scanner link support

(in the direction of arrow

to release its boss from the scanner link support. (5) Open the scanner unit further and lift up its rear edge to disengage it from the main cover in

the direction of arrow

Panel harness

CCD flat cable

Harnesses (Document tray open sensor harness, document sensor harness, ADF motor harness, and grounding wire) covered with the cable sheath

) and press the upper end of the scanner link inwards (arrow )

Scanner link

Be careful with this boss (provided for the scanner open sensor actuator)

Main cover

Scanner unit

Scanner link support

Releasing the scanner link from the scanner link support secured to the underside of the scanner unit

Scanner open lever

Scanner link

Boss

Lock

4-24

(6) Remove the two screws from the bottom rear of the hinges. (7) Be sure to open the document tray, then release the harnesses (bound and covered with the

cable sheath) from the latch and move them to the front in the opening. (8) Lift up the document tray.

(9) From the hinge base R, remove the hinge arm as shown below. Remove the three screws and

release the hinge base R.

(10) From the hinge L that should be kept opened, remove the three screws.

Document tray

Hinge base R

Taptite, cup B M3x10

Hinge arm

Hinge L

Taptite, cup B M3x10

4-25

(11) Remove the six screws from the underside of the scanner base. (12) Slightly lift up the control panel ASSY and disconnect the panel harness and piezo ringer

harness from the control panel PCB.

(13) Turn the scanner open sensor actuator as shown below and remove it. (14) Remove the screw from the scanner open sensor PCB. Then the control panel ASSY is

separated from the scanner unit.

(For the disassembly procedure of the control panel ASSY and scanner unit, refer to

Subsections 4.1.8 and 4.1.9, respectively.)

(15) Remove the three screw from the piezo ringer cap and take out the piezo ringer and its cap. (16) Remove the lever spring.

Insert the tip of a flat screwdriver into slit "s," push up the lock, and remove the scanner open

lever in the direction of the arrow.

Control panel ASSY

"a"

Piezo ringer cap

Piezo ringer harness

Piezo ringer

Panel harness

"b"

Scanner base

"c"

Lock

"s"

Scanner open sensor PCB

Lever spring

"b"

Scanner open lever

"a" and "c": Taptite, cup B M3 x8 "b": Taptite, cup B M3x12

Scanner open sensor actuator

4-26



 Reassembling Notes



• When setting the document tray on the scanner unit, pass the bound harnesses (ADF motor

harness, document sensor harness, document tray open sensor harness, and grounding wire) through the front section of the opening provided in the left rear corner of the document tray, with its bound section facing up (see the illustration given on page 4-25).

Move those bound harnesses to the rear section of the opening. Route the bound section through the cable guide so that the cable binder comes into contact with the cable guide as illustrated on page 4-25. Refer to Subsection 4.1.26 "Harness routing A."

• When putting the scanner unit on the scanner mount, take special care not to bend, wrinkle, or

scratch the CCD flat cable or not to break the boss of the main cover by the bottom of the scanner unit. (See the illustration given on page 4-24.)

• Connect the document sensor harness, document tray open sensor harness, ADF motor harness,

and panel harness to the relay PCB, and secure the two grounding wires to the main cover as shown in Subsection 4.1.26, "Harness routing B."

4-27

4.1.8 Disassembly of the Control Panel ASSY

(1) Remove the two screws from the control panel PCB. (2) Slightly lift up the control panel PCB, then unlock the FPC key connector and disconnect the

FPC key. Next, unlock the LCD cable connector and disconnect the LCD flat cable. (3) Remove the seven screws and take off the reinforcement plate and FPC key.

Control panel

FPC key

LCD

Scanner open sensor

Control panel PCB

Taptite, cup B M3x6

Reinforcement plate

(4) As shown below, pull the lock arms outwards to release the LCD and pull the LCD flat cable

gently.

Lock arm

(Rear)



 Reassembling Notes



• Before reinstalling the LCD to the control panel, wipe fingerprints or dust off the LCD surface

and control panel window with a soft cloth.

• A new LCD is covered with a protection sheet. Before installing it, remove the protection sheet.

LCD

Lock arm

4-28

4.1.9 Disassembly of the Scanner Unit

The disassembly job of the scanner unit should be done in a clean room to prevent dust or dirt from getting into the scanner unit.

(1) Remove the four screws from the scanner top cover. (2) Separate the scanner top cover from the scanner base.

4-29

(3) Release the CCD drive belt from boss "a." (4) At the left front end of the CCD drive belt, unhook the belt spring from boss "b."

NOTE: Do not remove the belt spring or belt clip from the CCD drive belt. (5) As illustrated below, move the CCD unit to the right, lift up its front end and turn the CCD

unit upright. The CCD drive belt will slip off the CCD idle pulley and gear on the underside of

the CCD unit.

4-30

(6) Disconnect the CCD flat cable from the CCD PCB, then release the cable that is attached to

the underside of the CCD unit with double-sided adhesive tape.

NOTE: Only when the CCD unit or CCD flat cable is defective and requires replacement,

release the flat cable. Once released, the flat cable should be attached using new double-sided

adhesive tape. (7) Lift up the CCD rail together with the CCD unit from the scanner base, then pull out the CCD

rail.

NOTE: When handling the CCD unit, do not touch the CCD PCB or glasses but hold the

hatched sections as shown on the next page.

4-31

(8) Remove the three screws and lift up the guide plate. (9) Remove the screw from the CCD HP sensor plate.

4-32

(10) Remove the two screws and take off the flat cable clamp. (11) To take out the panel harness, remove sponges F and R that are backed with adhesive tape.

NOTE: Once removed, those sponges will become unusable and new parts will have to be put

back in.

(12) To take out the CCD flat cable, remove sponge R.



 Reassembling Notes



• When replacing the CCD unit with a new one, you need to attach a CCD protector to it as

specified on page 4-31. A new CCD protector is covered with a protection sheet, so remove the protection sheet before attaching.

• When using a new CCD flat cable, fold it and secure it to the scanner base with double-sided

adhesive tape and sponge R (backed with adhesive tape) as illustrated above. Then attach it to the underside of the CCD unit with double-sided adhesive tape.

• When reassembling the components inside the scanner unit, use screws (Taptite, cup B M3x8).

Never use longer ones (e.g., M3x10). Using longer ones will bore a hole in the scanner base.

• When installing the CCD drive belt to the scanner base, set its rear end within the range

specified on page 4-30.

4-33

4.1.10 Auto Sheet Feeder (ASF) and Separation Pad ASSY

(1) Remove the four screws from the ASF to release it.

Taptite, cup B M3x12

Main cover

ASF

(2) Pull out the separation pad ASSY. (3) Remove the ASF film.

NOTE: Once removed, the ASF film will become unusable and a new part will have to be put

back in.

ASF

Separation pad ASSY

ASF film

4-34

(4) Disassemble the separation pad ASSY as shown below.

Cap



 Reassembling Notes



• When attaching a new ASF film to the ASF, align its left, right and rear edges with the recessed

section as illustrated below, taking care not to let the film override those edges of the recessed section.

Pad holder

0.15 +0.05 mm

Separation pad

Separation pad ASSY

Take care not to let the film override the edges of the recessed section.

ASF

0.5 mm max.

ASF film

(Top view)

4-35

4.1.11 Edge Cover, Scanner Links and Their Guides

(1) Remove two screws "x" and take out the edge cover. (2) Unhook the rear edges of the scanner link springs from the main cover, then remove the

scanner links. (3) From each of the scanner link guides, remove screw "y." Pull up the rear end of each scanner

link guide (in the direction of arrow

) and slide the guide to the rear (arrow ).

Scanner link

Scanner link spring

"x"

Edge cover

"y"

"x"

Scanner link spring

Scanner link

"y"

Scanner link guides

4-36

Main cover

"x" and "y": Taptite, cup B M3x12

4.1.12 Relay PCB and PCB Plate

(1) Disconnect the three relay harnesses (Main 1 through Main 3) from the relay PCB. (2) Pull out the relay PCB cover. (3) Remove screw "a" and take out the relay PCB. (4) Remove screw "b" if not removed on page 4-23. (5) Remove screw "c" from the USB I/F connector to release the PCB plate and then pull up the

PCB plate. (6) To remove the main PCB in the next subsection, remove two screws "d" from the parallel I/F

connector.

Grounding wire (From the ADF drive unit)

PCB plate

"b"

Main 1 relay harness

Main 2 relay harness

Relay

PCB Main 3 relay harness

"a"

Relay PCB

Relay PCB cover

Lower cover

"d"

4-37

"d"

Main 3 (white leads, 9-pin)

"c"

Main 2 (red leads, 11-pin)

Main 1 (white leads, 12-pin)

"a": Taptite, cup B M3 x6 "b": Screw, bind B tite M4x16 "c" and "d": Screw, pan M3x6

Relay harnesses

4.1.13 Bottom Plate, Ink Absorber Box, Main PCB, NCU PCB, and Power Supply PCB

(1) Disconnect the following harnesses and flat cables from the main PCB:

• Head flat cables

• Ink empty sensor harness

• Paper feed motor harness

• Carriage motor harness

• Purge switch harness

• Registration sensor harness

Main PCB

(Rear)

(Paper width sensor)

Registration sensor harness

Purge switch harness

(Main 1 relay harness)

Head flat cable 1

Head flat cable 2

(Main 3 relay harness)

(Main 2 relay harness)

Ink empty sensor harness

Paper feed motor harness

Carriage motor harness

4-38

(2) Turn the machine upside down. (3) Remove 11 screws from the bottom plate. (4) Remove the screw from the grounding terminal. (5) Lift up the bottom plate. (6) Remove the screw from the ink absorber box. Then push down the latch and remove the ink

absorber box as illustrated below. NOTE: Do not remove the ink absorber box unless it requires replacement. When replacing it,

set a new one soon after the removal to prevent the machine from getting stained with drained ink.

NOTE: If the print head unit is replaced with a new one, replace also the ink absorber box with new one.

NOTE: If the ink absorber box or the surrounding parts are stained with ink, wipe them with a waste cloth.

Bottom plate

Taptite, cup B M3x12

Ink absorber box

Latch

Screw, pan (washer) M4x8

Grounding terminal

Lower cover (placed upside down)

4-39

Relay harnesses

(7) Remove the screw from the FG plate R. (8) Slightly pull up the FG plate R, pull two latches "a" outwards, and then lift up the power

supply PCB. Disconnect the power supply harness from the PCB.

(9) Slightly pull up the FG plate L and release the main PCB from it. Release the NCU PCB from

latch "b" and disconnect it from the main PCB.

(10) Disconnect the power supply harness from the main PCB.

Power supply PCB

NCU PCB

Main PCB

Main 1 (white leads, 12-pin)

Main 3 (white leads, 9-pin)

Main 2 (red leads, 11-pin)

Latches "a"

"x"

Power supply harness

Lower cover (placed upside down)

FG plate L

Main PCB



 Reassembling Notes



Enclosure cover

Latch "b"

FG plate R

Power supply PCB

Grounding terminal

Boss of the lower cover

Rubber bushing of the power cord

• Be sure to route the power supply harness as illustrated above. Route the other harnesses and flat cables as illustrated in Subsection 4.1.26, "Harness Routing B."

• Be sure to route the grounding wire as illustrated above.

• After you replace the main PCB, be sure to follow the flowchart given on the next page.

4-40

Setting up the main PCB after replacement

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Important - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - NOTE: Before starting the following procedure, make sure that the print head unit is installed.

4-41

4.1.14 Enclosure Cover

(1) While pulling up the FG plate R, lift up the enclosure cover.

Lower cover

Enclosure cover

FG plate R

4-42

4.1.15 Main Cover

(1) Turn the machine to the normal position. (2) Remove the three screws from the main cover. Also remove screw "c" if not removed. (3) Press the cover retainers R inwards with the tip of a flat screwdriver to release the rear hooks

provided on the inside of the main cover.

(4) Lift up the main cover.

CAUTION: After removing the main cover, do not turn the machine upside down. The main chassis may be warped or distorted so that the print quality could deteriorate.

Grounding wire (From the ADF drive unit)

Grounding wire (From the relay PCB)

PCB plate

"c"

Main cover

Screw, bind B tite M4x16

Rear hook

Cover retainer R

Lower cover

Media cover

4-43



 Reassembling Notes



• When installing the upper cover, take care not to bring the tab of the ASF roller unit inside the upper cover. The tab should be fitted to the rear edge of the upper cover as illustrated below.

4-44

4.1.16 Purge Unit

(1) Remove the print head unit (refer to Subsection 4.1.1). (2) Disconnect the purge switch harness (blue and white) from the main PCB if you have not

removed the main PCB. Remove the purge switch harness from the cable guides provided on the lower cover. (Refer to

Subsection 4.1.26 "Harness Routing C." (3) Remove screw "a" from the side frame supporter and lift it up. (4) Remove two screws "b", one from the right side and the other from the rear side of the purge

unit. (5) Remove the drain tube from the tube guides and pull it out.

NOTE: Cover the end of the drain tube with a waste cloth to prevent drained ink from leaking

out and making stains on the machine. (6) Pull the purge unit to the front in the direction of arrow

end of the main chassis slightly (arrow

), pull out the purge unit to the front (arrow ).

. Then while pulling the right front

4-45

"a": Screw, pan (s/p washer) M3x6 "b": Taptite, cup B M3x8

Purge bevel gear A

Purge switch

"X"

Routing the purge switch harness (blue and white)

Pump switching cam HP switch

Purge cam HP switch

Hole that leads to the ink absorber box

Tube guides

Drain tube

"Y"

Leads of the purge cam HP switch (white)

Leads of the pump switching cam HP switch (blue)

Cover retainer

(7) Take off the purge cam HP switch and pump switching cam HP switch from the purge unit by

pulling the latches outwards, respectively.

(Viewed from the rear)

Cable guide

Pump switching cam HP switch (Blue lead)

Purge unit

(Rear)

Purge switch harness

Pump switching cam HP switch (Blue lead)

(8) Remove the purge bevel gear A. (See the illustration given on the previous page.)



 Reassembling Notes



• When installing the purge unit, be sure to insert the end of the drain tube into the hole

(provided in the lower cover) that leads to the ink absorber box.

Latches

Drain tube

Purge cam HP switch (White lead)

4-46

(Viewed from the front)

Purge cam HP switch (White lead)

4.1.17 Main Chassis

(1) Disconnect the carriage motor harness, registration sensor harness, ink empty sensor harness,

head flat cables, and paper feed motor harness from the main PCB if you have not removed

the main PCB.

Remove those harnesses from the cable guides provided on the lower cover. (2) Remove screw "x" from the lower end of FG plate R (see the next page) if you have not

removed it on page 4-40. (3) Remove screws "y" and "z" from the upper ends of FG plates R and L, respectively, then

remove those plates. Removing the FG plate L releases the head flat cables. (4) Remove screw "a" from each of the chassis supporters. (5) Unhook the two latches and lift up the main chassis.

NOTE: If vibration absorbers (black rubber bushings) are left in the lower cover, pull them

out.

4-47

Chassis supporter L

Shield film

Lower cover

"a"

"y"

FG plate R

Chassis supporter R

"a"

Carriage motor harness

Carriage motor

Registration sensor harness

Paper feed motor harness

"z"

FG plate L

Head flat cables

Paper feed motor harness

Ink empty sensor harness

Vibration absorbers

"z"

Shield film

Lower cover

Registration

Main chassis

sensor harness

Vibration absorbers

Latches

Ink empty sensor harness



 Reassembling Notes



• When installing the main chassis to the lower cover, make sure that the four vibration absorbers

are fitted on the bottom ends of the main chassis.

• After installing the main chassis, be sure to route the harnesses and flat cables as illustrated

above and in Subsection 4.1.26 "Harness Routing B" and "Harness Routing C."

Latch

FG plate L

4-48

FG plate R

"x"

"x": Taptite, cup B M3x12 "y" and "z": Taptite, cup S M3x5 "a": Taptite, cup B M3x12

4.1.18 ASF Roller Unit and its Related Gears

(1) Remove the three screws from the rear of the ASF. (2) Move the ASF to the left and remove it to the rear. (3) Remove the gear 31MF by pulling its pawls outwards. The gear shaft 17 and bushing also

come off.

NOTE: Take care not to lose the bushing. (4) Remove gear 39 and gear 25 from the main chassis.

4-49

Disassembly of the ASF Roller Unit

1) Pull the pawl of the ASF gear 31 outwards and pull out the gear shaft 15. The ASF roller ASSY and the ASF gear 32 also come off.

2) Remove the screw from the ASF roller ASSY. Then it will be disassembled as shown below.

4-50

4.1.19 Paper Pressure Holders

(1) At each of the paper pressure holders, unhook the top end of the spring from the main chassis. (2) Remove the paper pressure holders.



 Reassembling Notes



• When replacing films on the paper pressure holders with new ones, attach them as illustrated below.

4-51

4.1.20 Paper Chute and Registration Sensor

(1) Remove the screw from the rear of the paper chute and take it off from the main chassis.

4-52

(2) Unhook the registration sensor. (3) Unhook the actuator spring. (4) Push the lock arm and slide the sensor actuator in the direction of arrows

and .

4-53

4.1.21 Paper Ejection Roller Gear, Ink Empty Sensor PCB, P laten, Star Wheel Support, and Paper Ejection Roller

(1) Pull out the paper ejection roller gear from the left end of the paper ejection roller. (2) Remove the screw from the left side of the sensor support and take it off in the direction of the

arrow.

Support spring

Main chassis

Paper ejection joint

Paper ejection roller gear

Left end of the paper ejection roller

(3) Remove the screw from the ink empty sensor PCB.

Taptite, cup S M3x6

Ink empty sensor PCB

Sensor support

4-54

(4) Remove the screws from the platen and pull it out in the direction of the arrow.

NOTE: Take care not to touch the flushing sponge that is impregnated with ink.

Main chassis

Screw, bind B tite M3x10

Flushing sponge

Platen

Shoulder screw

4-55

(5) Unhook the four latches of the star wheel support and separate it from the platen. (6) Remove star wheels A and B from the star wheel support. (7) Remove the pawled bushing from the left end of the paper ejection roller by pulling its pawls

outwards. (8) Remove the paper ejection roller and bushing (white). (9) Remove the screw from each of the right and left platen plates.

Star wheel spring

Star wheel B

Star wheel support

Star wheel A

Latches

Star wheel A

Platen plate L

Flushing sponge

Pawled bushing

Star wheel B

Platen plate R

Star wheel spring

Taptite, bind B M2.6x10

Bushing (white)

Platen

Paper ejection roller

4-56

4.1.22 Paper Feed Motor and Paper Feed Roller

(1) Remove the paper feed motor by removing the two screws. (2) Remove the crescent ring from the PF roller gear and pull out the gear. (3) Unhook the PF spring. (4) Turn the PF bushings as shown below and disengage them from the main chassis. Then

remove the paper feed roller.

NOTE: When disengaging PF bushing R, slide the ASF/purge idle gear outwards.

NOTE: When removing the right end of the paper feed roller from the main chassis, move the

carriage to the left; when removing the left end, move it to the right. (5) Remove the PF idle gear and its spring.



 Reassembling Notes



• When replacing the paper feed roller, check the color marking (shown above) made on the

current roller and use a new roller having the same color marking.

• When setting the PF spring into place, hook the looped end on the main chassis and the open

end on the paper feed roller with its edge facing down.

• When installing the paper feed motor, face the connector towards the rear. When tightening the

two screws, take care not to scratch the paper feed roller with a screwdriver.

• When fitting the PF roller gear over the left end of the paper feed roller, do not set it at an

angle. Take care not to damage the gear teeth.

4-57

4.1.23 Encoder Strip and Carriage Motor

(1) At the left end of the encoder strip, unhook the spring from the main chassis.

NOTE: Take care not to scratch or damage the encoder strip.

"a": Taptite, cup S M3x8 "b": Shoulder screw "c": Screw, cup S tite M3x6

(2) Move the carriage to the center of its travel. (3) Loosen two screws "a" and "c" on the idle pulley holder. (See the above illustration.) (4) While pushing the idle pulley holder to the right, remove the timing belt from the carriage

motor pulley and idle pulley.

4-58

(5) Remove the carriage motor by removing the two screws.



 Reassembling Notes



• Pass the encoder strip through the strip guide provided on the back of the carriage so that the

encoder strip will route as illustrated on the previous page and the left. Then hook the points up.

▲-marked end comes to the

▲-marked end on the spring hooked on the main chassis so that the ▲ mark

4-59

4.1.24 Carriage Rail, Carriage ASSY, and Purge-Related Parts

(1) If the ink cartridges and print head have not been removed, remove them as follows:

Push the colored ink cartridge covers and remove all ink cartridges (arrow

Pull the head clamp springs in the direction of arrow

Lift the print head up and out of the carriage (arrow

to release the print head.

NOTE: Do not touch the printing ends (nozzles) of the print head unit or the ink orifices of

the ink cartridges; doing so will not only stain your hands with ink but result in an ink jet-out

failure. Once you touch them, clean them with a dedicated cleaning stick and liquid.

NOTE: Be sure to put a head nozzle seal and filter seal on the print head unit (shown on page

4-6). Leaving the print head unit without those seals will dry up its printing ends and filters,

resulting in a damaged head.

NOTE: Do not touch the dimple contact section of the print head unit.

(2) Remove the head clamp springs as shown below.

4-60

(3) Remove the screw from the eccentric bushing R, then turn it to align its boss with the cutout

provided in the main chassis and pull it out. The wavy washer also comes off.

NOTE: Take care not to lose the wavy washer. (4) Pull out the carriage rail to the right.

NOTE: The oil-impregnated carriage felt will drop from the carriage. (5) At the left side of the main chassis, remove the screw from the eccentric bushing L, if

necessary.

4-61

Brother MFC590, MFC5100 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CHAPTER 1 GENERAL DESCRIPTION

1.1 EQUIPMENT OUTLINE

1.1.1 External Appearance and Weight

1.1.2 Components

1.2 SPECIFICATIONS

CHAPTER 2 INSTALLATION

2.1 INSTALLING THE UPDATE DATA TO THE FACSIMILE MACHINE

2.2 SETTING ID CODES TO FACSIMILE MACHINES CONNECTED TO A SINGLE PC VIA THE USB PORT

2.3 SETTING HEAD PROPERTY TO THE FACSIMILE MACHINE

CHAPTER 3 THEORY OF OPERATION

3.1 OVERVIEW

3.2 MECHANISMS

3.2.1 Scanner Mechanism

3.2.2 Ink Jet Printing Mechanism

3.2.2.1 Paper pulling-in, registration, feeding, and ejecting mechanisms

3.2.2.2 Ink jet printing and capping mechanisms

3.2.2.3 Purging mechanism

3.2.2.4 Carriage drive mechanism

3.2.3 Sensors and Actuators

3.3 CONTROL ELECTRONICS

3.3.1 Configuration

4.1 DISASSEMBLY/REASSEMBLY

 Safety Precautions

Tightening Torque List

 Preparation

 How to Access the Object Component

 Disassembly Order Flow

4.1.1 Print Head Unit

4.1.2 ADF Cover and Document Guide Base

4.1.3 ADF Components on the Upper ADF Chute

Gear cover

Separation roller ASSY and document feed roller

Separation rubber unit, ADF thickness adjuster, and pressure rollers

Upper ADF chute

4.1.4 ADF Components on the Lower ADF Chute

Document front and rear sensor actuators

Document sensor PCB

Document guide clips

Document ejection roller

Document pressure bar

Lower ADF chute, pinch rollers, and ADF motor

4.1.5 Document Tray Open Sensor and Document Stopper

4.1.6 Jam Clear Cover, Rear Cover, and Inner Cover

4.1.7 Scanner Unit and Control Panel ASSY (Together with Document Tray)

4.1.8 Disassembly of the Control Panel ASSY

4.1.9 Disassembly of the Scanner Unit

4.1.10 Auto Sheet Feeder (ASF) and Separation Pad ASSY

4.1.11 Edge Cover, Scanner Links and Their Guides

4.1.12 Relay PCB and PCB Plate

4.1.13 Bottom Plate, Ink Absorber Box, Main PCB, NCU PCB, and Power Supply PCB

4.1.14 Enclosure Cover

4.1.15 Main Cover

4.1.16 Purge Unit

4.1.17 Main Chassis

4.1.18 ASF Roller Unit and its Related Gears

4.1.19 Paper Pressure Holders

4.1.20 Paper Chute and Registration Sensor

4.1.21 Paper Ejection Roller Gear, Ink Empty Sensor PCB, P laten, Star Wheel Support, and Paper Ejection Roller

4.1.22 Paper Feed Motor and Paper Feed Roller

4.1.23 Encoder Strip and Carriage Motor

4.1.24 Carriage Rail, Carriage ASSY, and Purge-Related Parts