Canon LBP-2460 Service Manual

RY8-1383-010

DEC. 1997

REVISION 1

SERVICE MANUAL

Prepared by

PERIPHERAL PRODUCTS QUALITY ADVANCEMENT DIV.

PERIPHERAL PRODUCTS TECHNICAL DOCUMENTATION DEPT.

CANON INC.

5-1, Hakusan 7-chome, Toride-City, Ibaraki-Pref. 302, Japan

Printed in Japan

Imprimé au Japon

Use of this manual should be strictly supervised to avoid disclosure of confidential information.

RY8-1383-01Y

RAD-12E-0001 DEC. 12,1997

Issued by Peripheral Products Quality Assurance Center, Canon Inc.

SE RVICE INFORMATION

NO. DATE

MODEL

LOCATION SUBJECT

Printed in Japan

Imprime au Japan

Canon has published a revised version of LBP-2460 Service Manual (RY8-1383-000). Revision 1 (RY8-1383-010) includes supplementary materials as well as corrections, so please use it in place of the original.

Revision of Service Manual

PREFACE

This Service Manual contains basic information required for after-sales service of the LBP-2460 laser beam printer (hereinafter referred to as the "printer"). This information is vital to the service technician in maintaining the high print quality and performance of the printer.

The 2,000-sheet paper deck, option controller, envelope feeder, and duplexing unit, which are

prepared for the printer as options, are also described in this manual.

In this manual, the optional 2,000-sheet paper deck is simply called the paper deck. This manual consists of the following chapters:

Chapter 1: Product information

Features, specifications, operation, and installation

Chapter 2: Operation and Timing

A description of the operating principles and timing sequences of the electrical and mechanical systems.

Chapter 3: The Mechanical System

Explanation of mechanical operation, disassembly, reassembly, and adjustment procedures

Chapter 4: Troubleshooting

Maintenance and servicing, reference values and adjustments, troubleshooting

procedures, lubricants, and solvents Appendix: General timing chart, general circuit diagram, etc. Information in this manual is subject to change as the product is improved or redesigned.

All relevant information in such cases will be supplied in Service Information Bulletins. A thorough understanding of this printer, based on information in this Manual and Service Information Bulletins, is required for maintaining its performance and for locating and repairing the causes of malfunctions.

DTP system

This manual was produced on an Apple PowerMacintosh 9500/132 personal computer and output by an Apple LaserWriter 16/600 PS laser beam printer.

All graphics were produced with Aldus FreeHand (J), and all documents and page layouts were created

with QuarkXPress (J).

The video images were captured with Canon Hi-8 8mm video camcorder and MASS microsystems

Quickimage 24 video capture board, and modified with Adobe Photoshop (J).

CHAPTER 1 PRODUCT INFORMATION

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

II. SPECIFICATIONS............................. 1-3

III. SAFETY INFORMATION ........ 1-7

IV. PARTS OF THE PRINTER .............. 1-8

V. INSTALLATION ............................... 1-14

CHAPTER 2 OPERATION AND TIMING

I. BASIC OPERATION ........................ 2-1

A. Functions ...................................... 2-1

B. Basic Operation

Sequences ...................................... 2-2

C. Power on Sequences ..................... 2-3

II. ENGINE CONTROL SYSTEM ....... 2-4

A. DC Controller Circuit ................. 2-4

B. Fixing Control .............................. 2-11

C. High-Voltage Power

Supply ........................................... 2-18

D. Power Supply ............................... 2-21

E. Video Interface Control .............. 2-23

III. LASER/SCANNER SYSTEM .......... 2-26

A. Outline .......................................... 2-26

B. Laser Control Circuit .................. 2-27

C. Scanning System .......................... 2-30

IV. IMAGE FORMATION SYSTEM..... 2-32

A. Outline .......................................... 2-32

B. Printing Process ........................... 2-34

V. PICK-UP/FEED SYSTEM ................ 2-42

A. Outline .......................................... 2-42

B. Paper Pick-up Unit ...................... 2-45

C. Fixing and Delivery Unit ............. 2-53

D. Paper Jam Detection .................... 2-55

VI. OVERALL CONTROL SYSTEM .... 2-60

A. Video Controller PCB ................. 2-60

B. Control Panel ............................... 2-63

VII. OPTION CONTROL SYSTEM ....... 2-64

VI. MAINTENANCE AND

SERVICING BY THE

CUSTOMER ....................................... 1-23

VII. OPERATION ...................................... 1-25

A. Option Controller ........................ 2-64

B. Operation Outline ........................ 2-66

VIII. ENVELOPE FEEDER ...................... 2-67

A. Outline of the Electrical

System ........................................... 2-67

B. Paper Pick-up/Feed

System ........................................... 2-68

C. Paper Jam Detection .................... 2-70

IX. DUPLEXING UNIT............................ 2-71

A. Outline of the Electrical

System ........................................... 2-71

B. Duplexing Driver Input

Signals ........................................... 2-72

C. Duplexing Driver Output

Signals ........................................... 2-73

D. Paper Pick-up/Feed

System ........................................... 2-74

E. Paper Jam Detection .................... 2-79

X. PAPER DECK .................................... 2-81

A. Outline .......................................... 2-81

B. Outline of the Electrical

System ........................................... 2-82

C. Paper Deck Driver Inputs ........... 2-83

D. Paper Deck Driver

Outputs ......................................... 2-84

E. Pick-up/Feed System ................... 2-85

F. Paper Jam Detection .................... 2-92

G. Power Supply ............................... 2-94

CHAPTER 3 THE MECHANICAL SYSTEM

I. EXTERNALS ..................................... 3-1

A. External Covers ........................... 3-1

B. Fans ............................................... 3-6

C. Operation Panel Unit ................... 3-9

II. DRIVE SYSTEM ............................... 3-10

A. Drive Unit ..................................... 3-10

B. Main Motor .................................. 3-11

III. PAPER TRANSPORT SYSTEM ...... 3-12

A. Pick-up Unit ................................. 3-12

B. Delivery Unit ................................ 3-15

C. Registration Roller Unit .............. 3-16

D. Manual Feed Pick-up Unit........... 3-17

E. Manual Feeding Pick-up

Roller ............................................. 3-19

F. Separation Pad ............................. 3-20

G. Pick-up/Feed/Separation

Rollers ........................................... 3-20

IV. EXPOSURE SYSTEM ...................... 3-21

A. Laser/Scanner Unit ...................... 3-21

V. ELECTROSTATIC IMAGING/

DEVELOPING/CLEANING

SYSTEM ............................................. 3-22

A. EP-W Cartridge ........................... 3-22

B. Transfer Charging Roller ........... 3-23

VI. FIXING SYSTEM .............................. 3-24

A. Fixing Unit .................................... 3-24

VII. ELECTRONIC COMPONENTS...... 3-32

A. Video Controller PCB ................. 3-32

B. Hard Disk ..................................... 3-33

C. DC Controller PCB ...................... 3-33

D. Pick-up PCB ................................. 3-34

E. Multi-purpose Tray PCB ............ 3-34

F. Switch/Sensor PCB ...................... 3-35

G. High-voltage Power Supply

PCB ............................................... 3-36

H. Cassette-size Sensing

PCB ............................................... 3-37

I. Power Supply ............................... 3-37

VIII. ENVELOPE FEEDER ...................... 3-39

IX. DUPLEXING UNIT ........................... 3-45

X. OPTION CONTROLLER ................ 3-52

XI. PAPER DECK .................................... 3-53

CHAPTER 4 TROUBLESHOOTING

I. MAINTENANCE AND

SERVICING ....................................... 4-1

A. Periodic Replacement

Parts .............................................. 4-1

B. Expected Lives of

Consumable Parts ........................ 4-1

C. Periodic Servicing

Schedule ........................................ 4-1

D. Service Checkpoints ..................... 4-2

II. TOOLS ................................................ 4-5

A. Standard Tools ............................. 4-5

B. Special Tools ................................. 4-6

C. Special Tools Explanation............ 4-7

III. MEASUREMENT AND

ADJUSTMENT .................................. 4-14

A. Mechanical Adjustment .............. 4-14

B. Electrical Adjustment .................. 4-17

IV INITIAL CHECK .............................. 4-18

V. IMAGE DEFECTS ............................ 4-19

A. Test Print ...................................... 4-19

B. Examples of Image

Defects ........................................... 4-21

C. Image Defect

Troubleshooting ........................... 4-22

VI. MALFUNCTION

TROUBLESHOOTING .................... 4-28

A. Massage Table .............................. 4-29

B. Malfunction

Troubleshooting ........................... 4-36

VII. PAPER FEEDING

TROUBLESHOOTING .................... 4-47

A. Paper Jams ................................... 4-47

B. Incomplete Paper Feed ................ 4-51

VIII. LOCATION OF ELECTRICAL

PARTS/FUNCTION .......................... 4-54

A. Switches ........................................ 4-54

B. Sensors .......................................... 4-56

C. Clutches and Solenoids ................ 4-60

D. Motor and Others ........................ 4-62

E. PC Boards ..................................... 4-64

F. Connectors .................................... 4-66

IX. VARIABLE RESISTORS, LEDS,

TEST PINS, JUMPERS, AND

SWITCHES ON PC BOARDS ......... 4-69

A. DC Controller PCB ...................... 4-69

B. Switch/Sensor PCB ...................... 4-70

C. Cassette Paper-size Sensing

Switch PCB ................................... 4-70

D. High-voltage Power

Supply PCB .................................. 4-71

E. Video Controller PCB ................. 4-72

F. Envelope Feeder

Driver PCB ................................... 4-73

G. Option Controller PCB ............... 4-74

H. Paper Deck Driver PCB .............. 4-75

I. Paper-level Sensing

Switch PCB ................................... 4-77

J. Paper-size Sensing

Switch PCB ................................... 4-77

X. LIST OF LUBRICANTS,

CLEANERS ........................................ 4-78

APPENDIX

I. GENERAL TIMING CHART .......... A-1

II. GENERAL CIRCUIT DIAGRAM.... A-3

III. LIST OF SIGNALS ........................... A-7

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

II. SPECIFICATIONS ............................ 1-3

III. SAFETY INFORMATION ........ 1-7

IV. PARTS OF THE PRINTER .............. 1-8

V. INSTALLATION ............................... 1-14

VI. MAINTENANCE AND

SERVICING BY THE

CUSTOMER ....................................... 1-23

VII. OPERATION ..................................... 1-25

CHAPTER 1

PRODUCT INFORMATION

CHAPTER 1

1 - 1

I. FEATURES

1. High-speed printing

The controller of this printer has equipped Intel i960HD processor that enables a print speed of up to 24 pages per minute. (A4-size paper, or letter size paper).

2. Superior image quality

High resolution printing at 600 x 600 dpi (dots per inch) is further enhanced with AIR(Automatic Imaging Refinement) technology to smooth jagged edges, and the use of super fine toner.

3. Auto-duplexing

The optional duplex unit enables the printer to conduct automatic duplexing.

4. Large-volume continuous printing

By mounting the optional paper deck, the paper handling capacity is raised by 2,000 sheets (75g/m

). As a result, the upper/lower cassettes, multi-purpose tray, and paper deck together can

accommodate a total of 3,100 sheets (75g/m

) for large-volume continuous printing.

5. 5-way paper feeding (including options)

The addition of the optional paper deck and optional envelope feeder to the standard-equipped multi-purpose tray and upper/lower cassettes results in 5-way paper feeding capability.

6. Memory saving technology

Memory reduction technology accomplishes 600 x 600 dpi printing with only 4 MB of memory. Complex data is compressed.

7. Energy saving and ecology

The printer conserves electricity by automatically reducing power consumption when it remains idle for a specified length of time. The printer then returns to full power after a button of control pane is pressed or print job is started. To save toner the economy mode can be selected to print rough drafts with less toner.

8. Automatic interface switching

In addition to the standard-equipped bi-directional parallel interface (Centronics specifications), the printer has been equipped with expansion port which enables network board to be installed. And, data sent from the host computer is automatically switched among both interfaces no matter which interface port it enters.

9. Automatic emulation switching

This printer supports Hewlett-Packard's enhanced PCL5 printer language. When the optional Canon Translator module A4(an add-in ROM) is installed, the printer also supports Adobe PostScript Level 2. The printer can sample the print data as it is received and then automatically switch between the PCL and PostScript personalities.

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CHAPTER 1

1 - 2

CHAPTER 1

II. SPECIFICATIONS

A. Printer

1. Printer engine

Type Desktop page printer (console type when paper deck is installed) Printing method Electrophotography Printing speed (Note 1) About 24 pages/min. (A4)

About 13 pages/min. (A3)

First print time (Note 2) 18.9 sec. or less (A4) Wait time (Note 3) 80 sec. or less (100V, 220V)

60 sec. or less (120V, 240V)

Scanning pitch

Horizontal 600 DPI Vertical 600 DPI

Image formation system

Laser Semiconductor laser Scanning system Six-faced prism mirror scanning Photosensitive Drum OPC Charging Roller charging Exposure Laser scanning system Toner Magnetic single-component dry toner Development Toner projection development system Toner supply By EP-W cartridge replacement (about 15,000 A4-sized prints; with

image density set in the middle and 4% dot density) Transfer Roller transfer Separation Curvature/discharge bias Cleaning Blade Fixing Heated rollers (500W x 2)

Paper pick-up Multi-purpose tray, upper cassette, lower cassette, envelope feeder

(option), paper deck (option) Print paper Plain paper, coloured paper, labels, OHT, envelopes Paper sizes

Multi-purpose tray 98.4mm (W) x 190.5mm (L) ~ 297mm (W) x 432mm (L) plain paper

(64g/m

Upper cassette B4, A4, Legal, Letter-sized plain paper (64g/m

III. SAFETY INFORMATION

A. Laser Safety

An invisible laser beam is irradiated within the laser/scanner unit.

Since the laser beam can injure the eye if it strikes it, be sure not to disassemble the laser/scanner unit. It cannot be adjusted in the field, anyway.

The label shown below is attached to the laser/scanner unit cover.

Figure 1-3-1

B. Toner Safety

Composed of minute, plastic, colored components, toner is a non-poisonous substance.

If toner adheres to your skin or clothes, remove as much of it as possible with a dry tissue, then wash with cold water. If you use hot water, the toner will gel and become difficult to remove.

As toner easily breaks down vinyl materials, avoid letting toner come into contact with vinyl.

C. Ozone Safety

An infinitesimal amount of ozone gas (O

) is generated during corona discharge from the charging roller used in this printer. The ozone gas is emitted only when the printer is operating.

This printer meets the ozone emission reference value set by Underwriters Laboratory (UL) at the time it is shipped from the factory.

D. Power Supply Unit Safety

Care is needed as even though the printer switch may be OFF, there is a possibility that a current may still flow on the primary side. Be sure to remove the power plug before disassembly and assembly of this printer.

CHAPTER 1

1 - 7

DANGERCAUTION

ATTENTION VORSICHT ATTENZIONE PRECAUCION VARO!

VARNING! ADVARSEL! ADVARSEL

RAYONNEMENT LASER INVISIBLE EN CAS D'O UVERTURE.

EXPOSITION DANGEREUSE AU FAISCEAU. UNSICHTBARE LASERSTRAHLUNG.WENN ABDECKUNG GEÖFFNET.

NICHT DEM STRAHL AUSSETZEN. RADIAZIONE LASER INVISIBILE IN CASO DI APERTURA.

EVITARE L'ESPOSIZIONE AL FASCIO. RADIACION LASER INVISIBLE CUANDO SE ABRE.

EVITAR EXPONERSE AL RAYO. AVATT AESSA OLET ALTTIINA NÄKYMÄTTÖMÄLLE

LASERSÄTEILYLLE. ÄLÄ KATSO SÄTEESEEN. OSYNLIG LASERSTRÅLNING NAR DENNA DEL ÄR ÖPPNAD.

BETRAKTA EJ STRÅLEN. USYNLIG LASER STRÅLING,NÅR DENNE ER ÅBEN.

UNDGÅ BESTRÅLING. USYNLIG LASERSTRÅLING NÅR DEKSEL ÅPNES.

UNNGÅ EKSPONERING FOR STRÅLEN.

Invisible laser radiation when open.

AVOID DIRECT EXPOSURE TO BEAM. INVISIBLE LASER RADIATION WHEN OPEN.

AVOID EXPOSURE TO BEAM.

CHAPTER 1

IV. PARTS OF THE PRINTER

A. External Views

1. Printer

123456

Figure 1-4-1

1: Operation panel unit 2: Face-down tray 3: Upper cover 4: Delivery stopper 5: Test print switch 6: Multi-purpose tray 7: Duplex unit door 8: Upper cassette

9: Lower cassette 10: Power switch 11: Delivery cover 12: Face-up tray 13: Parallel interface connector 14: Power receptacle 15: Connector for option interface (option) 16: Expansion board slots 17: Cleaning brush 18: EP-W cartridge 19: Pick-up unit door

Figure 1-4-2

Figure 1-4-3

1 - 8

2. Duplex unit

Figure 1-4-4

3. Envelope feeder

CHAPTER 1

1: Duplexing feed roller 2: Duplex unit removal lever

1: Envelope guide 2: Extension tray 3: Weight

Figure 1-4-5

1 - 9

CHAPTER 1

4. Paper deck

1: Feed cover

2: Tray

3: Interface connectors

4: Power receptacle

Figure 1-4-6

Figure 1-4-7

1 - 10

B. Cross Sectional Views

1. Printer, Duplex unit

CHAPTER 1

6745231

26 25 24 23 22 21 20 19 18 17 16 15 14 13

Figure 1-4-8

1: Delivery roller 2: Laser/scanner unit 3: Developing cylinder 4: EP-W cartridge 5: Manual feeding pick-up roller 6: Separation pad 7: Multi-purpose tray 8: Feed roller 1

9: Feed roller 2 10: Separation roller 11: Pick-up roller 12: Registration roller 13: Transfer charging roller

11 10 9 8

14: Photosensitive drum 15: Primary charging roller 16: Lower cassette 17: Upper cassette 18: Duplexing unit (option) 19: Fixing upper roller 20: Duplex feed roller (Duplexing unit) 21: Fixing lower roller 22: Duplex deflector 23: Face-up deflector 24: Switchback roller (Duplexing unit) 25: Face-up delivery roller 26: Face-up tray

1 - 11

CHAPTER 1

2. Envelope feeder

321 4

1: Feed rollers 2: Separation guide 3: Separation rollers 4: Pick-up rollers

Figure 1-4-9

1 - 12

3. Paper deck

CHAPTER 1

3261 4 5 7

1: Deck

2: Paper guides

3: Pick-up roller

4: Feed roller 1

5: Feed roller 2

6: Registration rollers

7: Separation roller

Figure 1-4-10

1 - 13

CHAPTER 1

V. INSTALLATION

A. Notes

This printer is packaged and shipped from the factory after careful adjustments and rigorous inspections. When installing the printer, it is important to demonstrate its performance in the same way as when it passes the factory inspection. The service engineer must sufficiently understand the performance of the printer, install it correctly in a location with an appropriate environment, and conduct sufficient checks of the unit.

B. Location Selection

Before taking the printer to the customer's premises, you should confirm the following conditions at the installation location.

1. Power supply

Use the following power supplies:

• Line voltage (AC): 100 - 120V ±10% 220 - 240V -10% +6%

• Power frequency: ±2Hz rated frequency

2. Operating environment

Install in a location that meets the following conditions:

• Level, flat surface

• Temperature, humidity within the following ranges:

Surrounding temperature: 10 to 32.5°C Surrounding humidity: 20 to 80%RH (relative humidity), without condensation

• Cool, well-ventilated space

Do not install in the following locations:

• Exposed to direct sunlight

• If you cannot avoid such a location, hang heavy curtains, etc., to shut out the direct sunlight.

• Near magnets and devices that emit a magnetic field

• Areas with vibration

• Dusty places

• Near fire or water

3. Installation space

Install the printer a suitable distance from the wall, leaving enough room to operate it (see Figure 1-5-1).

When installing the printer on a desk, etc., be sure that it is large enough to accommodate the

printer's feet (rubber pads) and sturdy enough to hold its weight.

1 - 14

900

*When paper deck is installed to printer. Required space surrounding the printer with the

paper deck installed (option)

1086 (1150*)

(Unit: mm)

CHAPTER 1

2300

100

834

857

1337

100

Figure 1-5-1

C. Unpacking and Installation

Condensation will form on metal surfaces when brought into a warm room from the cold. Therefore, when moving the printer to a warm environment, leave it packed in its box for at least an hour to acclimatize to room temperature.

1. Printer

1) Open the printer packaging.

2) Take out the accessories. Confirm that the power cord, cartridge, and face-up tray are included.

3) The printer weighs approx. 48kg, therefore 4 people may be needed to lift the printer and to move to the installation area.

4) Take the plastic bag off the printer and peel the tape off each part. Check that none of the covers were scratched or deformed during shipment.

5) Open the delivery cover, and remove the pressure release spacer from the fixing unit.

6) Open the upper cover, and remove the tape and the packing materials from inside the printer.

7) Pull the two cassettes out of the printer and remove the packaging from the cassette.

2. Cartridge

1) Open the bag holding the cartridge and take out the cartridge.

2) Remove the tape and the black sheet from the printer.

3) Hold the cartridge on each side as shown in figure 1-5-7 and slowly rock it 5 to 6 times to evenly distribute the toner.

4) Place the cartridge on a flat surface. While holding down on the top of the cartridge with one hand, grasp the tab with the other and gently pull out the cylinder tape.

5) Open the upper cover of the printer, and load the cartridge with both hands. Slowly insert it until it firmly contacts with the back of the slot.

3. Envelope feeder

1) Open the envelope feeder packaging.

2) Take off the plastic bag and peel the tape off. Check that none of the covers have been scratched or deformed during shipment.

3) Remove the packing from the envelope feeder.

4) Open the multi-purpose tray and remove the envelope feeder slot cover.

5) Holding the envelope feeder in both hands, install it into the printer.

1 - 15

CHAPTER 1

Option interface cover

4. Duplex unit

1) Open the duplex unit packaging.

2) Take off the plastic bag and peel the tape off.

3) Remove the packing from the duplex unit.

4) Open the delivery cover on the printer.

5) Holding the duplex unit in both hands, install it into the printer.

5. Option controller Note: Discharge electrical static from your body by touching the metal frame of the printer

prior to installing the PCB in order to avoid causing damage by the difference in static charge at that time.

1) Open the option controller packaging.

2) Remove the plastic bag from the optional controller.

3) Loosen the 2 screws on the back of the printer and pull out the PCB.

4) Remove the screw holding the option interface cover of the PCB.

Screw

Video controller PCB ass'y

Figure 1-5-2

1 - 16

5) Insert the option controller as shown below.

6) Set the option controller with the 3 supplied screws.

Screws

Option controller

Figure 1-5-3

CHAPTER 1

7) Insert a connector.

Connector

Option controller

Figure 1-5-4

8) Insert the PCB to the printer and tighten the 2 screws.

1 - 17

CHAPTER 1

6. Paper deck a. Opening the packaging

1) Open the paper deck packaging and remove the box.

2) Take out the accessories. Confirm that the power cord, manuals and interface cable are included.

3) Remove the top pads (left/right) and remove the paper deck from the box.

4) Take off the plastic bag surrounding the paper deck and peel off the tape holding the various parts. Confirm that none of the covers were scratched or deformed during shipment.

5) Open the feed cover and remove the 2 spacers.

6) Open the deck and peel the tape off.

7) Peel off the tape holding the latch of the paper guide.

b. Installation

1) Carry the paper deck to the installation location and lock the casters.

2) Rotate the 4 adjusters to install it on the floor.

3) Open the feed cover.

4) Align the paper deck and the printer in the same direction, and have 4 people lift the printer. Lower the printer onto the paper deck while aligning the 3 locating pins on the paper deck.

5) Close the feed cover.

6) Connect the paper deck and the printer with an interface cable.

1 - 18

14pin

15pin 14pin

Figure 1-5-5

+ 284 hidden pages

Canon LBP-2460 Service Manual

PREFACE

CONTENTS

CHAPTER 1

I. FEATURES

II. SPECIFICATIONS

III. SAFETY INFORMATION

IV. PARTS OF THE PRINTER

V. INSTALLATION