Xerox DCP-7030, DCP-7040, DCP-7045N, MFC-7320, MFC-7340 Service Manual

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Laser Multi-Function Center

SERVICE MANUAL

MODEL:

DCP-7030/7040/7045N MFC-7320/7340/7440N/7450/

7840N/7840W

Read this manual thoroughly before carrying out any maintenance work. Keep this manual in a convenient place for quick and easy reference at all times.

Jan 2008 SM-FAX088 8C5C

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Compilation and Publication:

This manual has been complied and published, under the supervision of Brother Industries Ltd., covering the latest product descriptions and specifications. The contents of this manual and the specifications of this product are subject to change without notice. Brother reserves the right to make changes without notice in the specifications and materials contained herein and shall not be responsible for any damages (including consequential) caused by reliance on the materials presented, including but not limited to typographical and other errors relating to the publication. This product is designed for use in a professional environment.

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PREFACE

This service manual contains basic information required for after-sales service of the Laser Multi-Function Center (hereinafter referred to as "the machine"). This information is vital to the service personnel to maintain the high printing quality and performance of the machine.

This service manual covers the DCP-7030/7040/7045N, MFC-7320/7340/7440N/7450/ 7840N/7840W machines.

This manual consists of the following chapters:

CHAPTER 1: TROUBLESHOOTING

Details of error messages and codes that the incorporated self-diagnostic function of the machine will display if any error or malfunction occurs. If any error message appears, refer to this chapter to find which parts should be checked or replaced.

The latter half of this chapter provides sample problems that could occur in the main sections of the machine and related troubleshooting procedures.

CHAPTER 2: PERIODICAL MAINTENANCE

Details of consumable parts and periodical maintenance parts. This chapter also covers procedures for disassembling and assembling periodical maintenance parts.

CHAPTER 3: DISASSEMBLY AND ASSEMBLY

Details of procedures for disassembling and assembling of the machine together with related notes. The disassembly order flow provided enables you to see at a glance the quickest way to get to parts involved.

At the start of a disassembly job, you can check the disassembly order flow that guides you through a shortcut to get to the object parts.

This chapter also covers screw tightening torques and lubrication points to which the specified lubrications should be applied during assembly jobs.

CHAPTER 4: ADJUSTMENTS AND UPDATING OF SETTINGS, REQUIRED

AFTER PARTS REPLACEMENT

Details of adjustments and updating of settings, which are required if the main PCB and some other parts have been replaced. This chapter also covers how to update the firmware.

CHAPTER 5: SERVICE FUNCTIONS

Describes the maintenance mode which is exclusively designed for the purpose of checking the settings and adjustments using the keys on the panel.

This chapter also covers hidden function menus, which activate settings and functions or reset the parts life.

CHAPTER 6: CIRCUIT DIAGRAMS, WIRING DIAGRAM

Provides the Circuit Diagrams and Wiring Diagram for the connections of the PCBs.

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APPENDIX 1: WORKER SWITCH Settings (WSW)

APPENDIX 2: DELETION OF PERSONAL INFORMATION

APPENDIX 3: SERIAL NUMBERING SYSTEM

APPENDIX 4: SCREW CATALOGUE

APPENDIX 5: GLOSSARY

APPENDIX 6: REFERENCES

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

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

There is the service reference manual as well. This service reference manual contains “SPECIFICATIONS”, “THEORY OF OPERATION”, “TONER CARTRIDGE WEIGHT INFORMATION”, “REFERENCES”, and “GLOSSARY”.

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PREFACE ....................................................................................................................i

REGULATION .........................................................................................................viii

SAFETY INFORMATION ..........................................................................................xii

CHAPTER 1 TROUBLESHOOTING ................................................................... 1-1

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

1.1 Precautions ......................................................................................................................... 1-1

1.2 Part names ......................................................................................................................... 1-2

1.3 Initial Check ........................................................................................................................ 1-4

2. ERROR CAUSE .......................................................................................................................... 1-6

2.1 Error indication .................................................................................................................... 1-6

2.2 Error Code Cause and Remedy ......................................................................................... 1-7

2.2.1 Recoverable User Check Errors ............................................................................ 1-7

2.2.2 Service Call Error ................................................................................................... 1-7

3. PAPER FEEDING PROBLEMS ................................................................................................. 1-23

3.1 No Feeding ....................................................................................................................... 1-23

3.2 Double Feeding ................................................................................................................ 1-23

3.3 Paper Jam ........................................................................................................................ 1-24

3.4 Dirt on Paper ..................................................................................................................... 1-25

3.5 Wrinkles or creases .......................................................................................................... 1-25

3.6 Waves in the paper / folds in the paper at the eject roller 2 .............................................. 1-25

3.7 Curl in the paper ............................................................................................................... 1-26

4. TROUBLESHOOTING OF DOCUMENT FEEDING .................................................................. 1-27

4.1 No Feeding ....................................................................................................................... 1-27

4.2 Double feeding ................................................................................................................. 1-27

4.3 Paper Jam ........................................................................................................................ 1-28

5. IMAGE DEFECT TROUBLESHOOTING (Defect Of the Print) .................................................. 1-29

5.1 Image Defect Examples .................................................................................................... 1-29

5.2 Diameter of Rollers ........................................................................................................... 1-29

5.3 Troubleshooting Image Defect .......................................................................................... 1-30

6. TROUBLESHOOTING OF SCANNIG ....................................................................................... 1-43

6.1 Cannot scan the document in the FB unit.

(If scan the document, it is completely white or black.) .................................................... 1-43

6.2 Cannot scan the document in the ADF unit.

(If scan the document, it is completely white or black.) .................................................... 1-43

6.3 Print of the scanning document is light or dark ................................................................. 1-44

6.4 Vertical streaks (White or Black vertical streaks) .............................................................. 1-44

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6.5 Poor fixing ......................................................................................................................... 1-44

6.6 Image distortion ................................................................................................................ 1-44

7. SOFTWARE SETTING PROBLEMS ......................................................................................... 1-45

8. NETWORK PROBLEMS ........................................................................................................... 1-46

9. TROUBLESHOOTING OF THE COMMUNICATIONS ERROR ................................................ 1-47

10. Troubleshooting of the control panel ......................................................................................... 1-51

11. Troubleshooting of fax functions ................................................................................................ 1-53

12. OTHERS PROBLEMS ............................................................................................................... 1-57

CHAPTER 2 PERIODICAL MAINTENANCE ...................................................... 2-1

1. CONSUMABLE PARTS ............................................................................................................... 2-1

2. PERIODICAL PEPLACEMENT PARTS ...................................................................................... 2-2

CHAPTER 3 DISASSEMBLY AND ASSEMBLY ................................................ 3-1

1. SAFETY PRECAUTIONS ............................................................................................................ 3-1

2. PACKING ..................................................................................................................................... 3-2

3. SCREW TORQUE LIST .............................................................................................................. 3-3

4. LUBRICATION ............................................................................................................................. 3-5

5. OVERVIEW OF GEARS .............................................................................................................. 3-8

6. HARNESS ROUTING .................................................................................................................. 3-9

7. DISASSEMBLY FLOW .............................................................................................................. 3-15

8. DISASSEMBLY PROCEDURE .................................................................................................. 3-16

8.1 SEPARATION PAD ASSY ................................................................................................ 3-17

8.2 FRONT COVER ASSY ..................................................................................................... 3-18

8.2.1 FRONT COVER ASSY ......................................................................................... 3-18

8.2.2 PAPER STOPPER L / PAPER STOPPER S ....................................................... 3-20

8.3 BACK COVER / OUTER CHUTE ASSY ........................................................................... 3-21

8.3.1 BACK COVER ...................................................................................................... 3-21

8.3.2 OUTER CHUTE ASSY ......................................................................................... 3-22

8.4 FUSER COVER ASSY ..................................................................................................... 3-23

8.4.1 FUSER COVER ASSY ......................................................................................... 3-23

8.4.2 EJECT ACTUATOR / EJECT ACTUATOR SPRING ........................................... 3-24

8.4.3 EJECT ROLLER ASSY 1 / BUSH C / BUSH R / BUSH L ................................... 3-25

8.5 JOINT COVER SUB CHUTE ASSY ................................................................................. 3-26

8.6 INNER CHUTE ASSY ....................................................................................................... 3-27

8.7 FUSER UNIT .................................................................................................................... 3-28

8.8 CORNER COVER ............................................................................................................ 3-30

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8.9 SIDE COVER L ASSY / SIDE COVER SUB L ................................................................. 3-31

8.9.1 SIDE COVER L ASSY .......................................................................................... 3-31

8.9.2 SIDE COVER SUB L ............................................................................................ 3-32

8.10 MAIN SHIELD COVER PLATE ......................................................................................... 3-32

8.11 ADF UNIT ......................................................................................................................... 3-33

8.11.1 ADF UNIT ............................................................................................................. 3-33

8.11.2 HINGE R / HINGE ARM / HINGE ASSY L ........................................................... 3-35

8.11.3 ADF COVER ASSY .............................................................................................. 3-36

8.11.4 GEAR COVER ..................................................................................................... 3-36

8.11.5 DOCUMENT SEPARATOR ROLLER SHAFT ASSY ........................................... 3-37

8.11.6 UPPER DOCUMENT CHUTE ASSY ................................................................... 3-38

8.11.7 LOWER DOCUMENT CHUTE ASSY .................................................................. 3-40

8.11.8 ADF SENSOR PCB ASSY ................................................................................... 3-41

8.11.9 LF ROLLER ASSY ............................................................................................... 3-43

8.11.10EJECTION ROLLER ASSY .................................................................................. 3-44

8.11.11DRIVE FRAME ASSY .......................................................................................... 3-45

8.11.12ADF MOTOR ........................................................................................................ 3-46

8.11.13PRESSURE ROLLER ASSY ................................................................................ 3-47

8.11.14DOCUMENT STOPPER ...................................................................................... 3-48

8.11.15DOCUMENT DRESS COVER ............................................................................. 3-49

8.12 DOCUMENT SCANNER UNIT ......................................................................................... 3-50

8.12.1 DOCUMENT SCANNER UNIT ............................................................................. 3-50

8.12.2 CORD HOOK ....................................................................................................... 3-52

8.12.3 PANEL UNIT ........................................................................................................ 3-52

8.12.4 PANEL PCB ASSY ............................................................................................... 3-53

8.12.5 RUBBER KEYS L/R ............................................................................................. 3-53

8.12.6 LCD ...................................................................................................................... 3-54

8.12.7 PRINTED PANEL COVER ................................................................................... 3-54

8.12.8 ADDRESS LABEL ................................................................................................ 3-55

8.13 PULL ARM L/R ................................................................................................................. 3-56

8.14 PULL ARM GUIDE ........................................................................................................... 3-57

8.15 NCU PCB .......................................................................................................................... 3-58

8.16 SPEAKER UNIT ............................................................................................................... 3-59

8.17 BATTERY ASSY ............................................................................................................... 3-61

8.18 SIDE COVER R ASSY ..................................................................................................... 3-62

8.19 REGISTRATION GROUNDING SPRING ......................................................................... 3-63

8.20 ROLLER HOLDER ASSY ................................................................................................. 3-64

8.21 WIRELESS LAN PCB ASSY (only MFC7840W) .............................................................. 3-66

8.22 MAIN PCB ASSY .............................................................................................................. 3-67

8.23 JOINT COVER ASSY / PAPER SUPPORTER ................................................................ 3-68

8.24 HIGH-VOLTAGE PS PCB ASSY ...................................................................................... 3-70

8.25 NEW TONER SENSOR HARNESS ASSY ....................................................................... 3-71

8.26 FILTER ASSY ................................................................................................................... 3-72

8.27 LASER UNIT ..................................................................................................................... 3-73

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8.28

FAN MOTOR 60 UNIT / COVER SENSOR HARNESS ASSY / TONER LED PCB ASSY

8.28.1 FAN MOTOR 60 UNIT ......................................................................................... 3-75

8.28.2 COVER SENSOR HARNESS ASSY ................................................................... 3-76

8.28.3 TONER LED PCB ASSY ...................................................................................... 3-77

8.29 LVPS ................................................................................................................................ 3-78

8.29.1 LVPS PCB UNIT .................................................................................................. 3-78

8.29.2 LV SHIELD PLATE 2 ............................................................................................ 3-80

8.30 REGISTRATION FRONT SENSOR PCB ASSY .............................................................. 3-81

8.31 REGISTRATION REAR SENSOR PCB ASSY ................................................................. 3-85

8.32 DRIVE SUB ASSY ............................................................................................................ 3-88

8.33

DEV JOINT / DEV GEAR JOINT/53R / REGISTRATION PENDULUM GEAR SPRING

8.34 THERMISTOR HARNESS UNIT ...................................................................................... 3-91

8.35 TONER SENSOR PCB UNIT ASSY ................................................................................. 3-92

8.36 REGISTRATION SOLENOID / T1 SOLENOID ................................................................ 3-93

8.36.1 REGISTRATION SOLENOID ............................................................................... 3-93

8.36.2 T1 SOLENOID ...................................................................................................... 3-95

8.37 MAIN SHIELD PLATE / EJECT SENSOR PCB ASSY ..................................................... 3-96

8.38 RUBBER FOOT .............................................................................................................. 3-100

........ 3-75

........ 3-90

8.39 MAIN FRAME L ASSY .................................................................................................... 3-101

CHAPTER 4 ADJUSTMENTS AND UPDATING OF SETTINGS,

REQUIRED AFTER PARTS REPLACEMENT .............................. 4-1

1. IF YOU REPLACE THE MAIN PCB ............................................................................................. 4-1

2. IF YOU REPLACE THE WIRELESS LAN PCB ......................................................................... 4-10

3. IF YOU REPLACE THE LASER UNIT ....................................................................................... 4-11

4. IF YOU REPLACE THE FB UNIT .............................................................................................. 4-12

CHAPTER 5 SERVICE FUNCTIONS .................................................................. 5-1

1. MAINTENANCE MODE ............................................................................................................... 5-1

1.1 How to Enter the Maintenance Mode ................................................................................. 5-1

1.2 How to Enter the End User-accessible Maintenance Mode ............................................... 5-1

1.3 List of Maintenance-mode Functions .................................................................................. 5-2

1.4 Detailed Description of Maintenance-mode Functions ....................................................... 5-3

1.4.1 EEPROM Parameter Initialization (Function code 01, 91) ..................................... 5-3

1.4.2 Printout of Scanning Compensation Data (Function code 05) ............................... 5-4

1.4.3 Placement of CIS Unit in Position for Transportation (Function code 06) .............. 5-6

1.4.4 ADF Performance Test (Function code 08) ............................................................ 5-6

1.4.5 Test Pattern (Function code 09) ............................................................................. 5-7

1.4.6 Worker Sw WSW) Setting and Printout ................................................................. 5-8

1.4.7 Operational Check of LCD (Function code 12) .................................................... 5-13

1.4.8 Operational Check of Control Panel Button (Function code 13) .......................... 5-14

1.4.9 ROM Version Check (Function code 25) .............................................................. 5-15

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1.4.10 Operational Check of Sensors (Function code 32) .............................................. 5-16

1.4.11 PC Print Function setting (Function code 32) ....................................................... 5-18

1.4.12 Received Data Transfer Function (Function code 53)

(MFC-7840W/7840N/7450/7440N/7340/7320 only) ............................................. 5-22

1.4.13 Fine Adjustment of Scan Start/End Positions (Function code 54) ........................ 5-24

1.4.14 Acquisition of White Level Data (Function code 55) ............................................. 5-26

1.4.15 Paper Feeding and Ejecting Test (Function code 67) .......................................... 5-26

1.4.16 EEPROM Customizing (Function code 74) .......................................................... 5-27

1.4.17 Operational Check of Fans (Function code 78) .................................................... 5-29

1.4.18 Display of the Machine's Log Information (Function code 80) .............................. 5-31

1.4.19 Error Code Indication (Function code 82) ............................................................ 5-33

1.4.20 Output of Transmission Log to the Telephone Line (Function code 87)

(only MFC7840W/7840N/7450/7440N/7340/7320) .............................................. 5-33

1.4.21 Exit from the Maintenance Mode (Function code 99) ........................................... 5-34

2. OTHER SERVICE FUNCTIONS ................................................................................................ 5-35

2.1 User Maintenance Mode ................................................................................................... 5-35

2.2 Resetting the developing bias voltage counter ................................................................. 5-36

CHAPTER 6 CIRCUIT DIAGRAMS, WIRING DIAGRAM ................................... 6-1

APPENDIX 1 WORKER SWITCH Settings (WSW) ................................... App. 1-1

APPENDIX 2 DELETION OF PERSONAL INFORMATION ....................... App. 2-1

APPENDIX 3 SERIAL NUMBERING SYSTEM .......................................... App. 3-1

APPENDIX 4 SCREW CATALOGUE ......................................................... App. 4-1

APPENDIX 5 GLOSSARY .......................................................................... App. 5-1

APPENDIX 6 REFERENCES ...................................................................... App. 6-1

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REGULATION

■ Radio interference (220 to 240 volt model only)

This machine follows EN55022 (CISPR Publication 22)/Class B.

■ IEC 60825-1 specification (220 to 240 volt model only)

This machine is a Class 1 laser product as defined in IEC 60825-1 specifications. The label shown below is attached in countries where it is needed.

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

This machine has a Class 3B laser diode which produces invisible laser radiation in the laser unit. You should not open the laser unit under any circumstances.

Caution

Use of controls or adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.

For Finland and Sweden

LUOKAN 1 LASERLAITE

KLASS 1 LASER APPARAT

Varoitus!

Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle.

Varning

Om apparaten används på annat sätt än i denna Bruksanvisning specificerats, kan användaren utsättas för osynlig laserstrålning, som överskrider gränsen för laserklass 1.

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■ Internal laser radiation

Maximum radiation power: 10 mW

Wave length: 780 - 800 nm

Laser class: Class 3B

■ EU Directive 2002/96/EC and EN50419

(European Union only)

This equipment is marked with the recycling symbol below. It means that at the end of the life of the equipment you must dispose of it separately at an appropriate collection point and not place it in the normal domestic unsorted waste stream. This will benefit the environment for all. (European Union only)

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■ Federal Communications Commission (FCC) Declaration of Conformity (For USA)

Responsible Party: Brother International Corporation

100 Somerset Corporate Boulevard P.O. Box 6911 Bridgewater, NJ 08807-0911 USA Telephone: (908) 704-1700

declares, that the products

Product name: Laser Multi Function Center DCP-7030/7040/7045N,

MFC-7320/7340/7440N/7450/7840N/7840W

complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the end user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

Important

A shielded interface cable should be used to ensure compliance with the limits for a Class B digital device. Changes or modifications not expressly approved by Brother Industries, Ltd. could void the user’s authority to operate the equipment.

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■ Industry Canada Compliance Statement (For Canada)

This Class B digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.

■ Laser Safety (110 to 120 volt model only)

This machine is certified as a Class 1 laser product under the U.S. Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968. This means that the machine does not produce hazardous laser radiation.

Since radiation emitted inside the machine is completely confined within protective housings and external covers, the laser beam cannot escape from the machine during any phase of user operation.

■ FDA Regulations (110 to 120 volt model only)

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

MANUFACTURED:

Brother Technology (Shenzhen) Ltd. NO6 Gold Garden Ind., Nanling Buji, Longgang, Shenzhen, China This product complies with FDA performance standards for laser products except for deviations pursuant to Laser Notice No.50, dated Jun 24, 2007.

■ Internal laser radiation

Maximum radiation power: 10 mW

Wave length: 780 - 800 nm

Laser class: Class 3B

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SAFETY INFORMATION

■ Caution for Laser Product (WARNHINWEIS fur Laser drucker)

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

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

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

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

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

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

■ Additional Information

When servicing the optical system of the machine, be careful not to place a screwdriver or other reflective object in the path of the laser beam. Be sure to take off any personal accessories such as watches and rings before working on the machine. A reflected beam, though invisible, can permanently damage the eyes.

Since the beam is invisible, the following caution label is attached on the laser unit.

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■ Definitions of Warnings, Cautions, Notes and Memos

The following conventions are used in this manual:

Mark Contents

Warnings tell you what to do to prevent possible personal injury.

Electrical Hazard icons alert you to a possible electrical shock.

Hot Surface icons warn you not to touch machine parts that are hot.

Cautions specify procedures you must follow or avoid to prevent possible damage to the machine or other objects.

Note Notes tell you useful tips when servicing the machine.

Memo Memo tells you bits of knowledge to help understand the machine.

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■ Safety Precautions

Please keep these instructions for later reference and read them before attempting any maintenance.

WARNING

There are high voltage electrodes inside the machine. Before you clean the inside of the machine, make sure you have unplugged the telephone line cord first and then the power cord from the AC power outlet (See Routine

maintenance on page 115.)

DO NOT use flammable substances or any type of spray to clean the inside or outside of the machine. Doing this may cause a fire or electrical shock. Refer to Routine maintenance

on page 115 for how to clean the machine.

DO NOT handle the plug with wet hands. Doing this might cause an electrical shock.

Always make sure the plug is fully inserted.

After you have just used the machine, some internal parts of the machine will be extremely hot. When you open the front or back cover of the machine, DO NOT touch the shaded parts shown in the illustration.

The fuser unit is marked with a caution label. Please DO NOT remove or damage the label.

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WARNING

To prevent injuries, be careful not to put your hands on the edge of the machine under the document cover or scanner cover.

To prevent injuries, be careful not to put your fingers in the area shown in the illustration.

DO NOT use a vacuum cleaner to clean up scattered toner. Doing this might cause the toner dust to ignite inside the vacuum cleaner, potentially starting a fire. Please carefully clean the toner dust with a dry, lint-free cloth and dispose of it according to local regulations.

When you move the machine, grasp the side hand holds that are under the scanner.

Use caution when installing or modifying telephone lines. Never touch telephone wires or terminals that are not insulated unless the telephone line has been unplugged at the wall jack. Never install telephone wiring during a lightning storm. Never install a telephone wall jack in a wet location.

This product must be installed near an AC power outlet that is easily accessible. In case of an emergency, you must disconnect the power cord from the AC power outlet to shut off the power completely.

To reduce the risk of shock or fire, use only a No. 26 AWG or larger telecommunication line cord.

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CAUTION

Lightning and power surges can damage this product! We recommend that you use a quality surge protection device on the AC power line and on the telephone line, or unplug the cords during a lightning storm.

WARNING

IMPORTANT SAFETY INSTRUCTIONS

When using your telephone equipment, basic safety precautions should always be followed to reduce the risk of fire, electric shock and injury to people, including the following:

1 DO NOT use this product near water, for example, near a bath tub, wash bowl,

kitchen sink, washing machine, or in a wet basement or near a swimming pool.

2 Avoid using this product during an electrical storm. There may be a remote risk of

electric shock from lightning. 3 DO NOT use this product to report a gas leak in the vicinity of the leak. 4 Use only the power cord provided with the machine. 5 DO NOT dispose of batteries in a fire. They may explode. Check with local codes

for possible special disposal instructions. SAVE THESE INSTRUCTIONS

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CHAPTER 1 TROUBLESHOOTING

1. INTRODUCTION

Troubleshooting is the countermeasure procedures that the service personnel should follow if an error or malfunction occurs with the machine. It is impossible to anticipate all of the possible problems which may occur in future and determine the troubleshooting procedures, so this chapter covers some sample problems. However, these samples will help the service personnel pinpoint and repair other defective elements.

1.1 Precautions

Be sure to observe and follow all the precautions to prevent any secondary problems from happening during troubleshooting.

(1) Always turn off the power and unplug the power cable before removing any covers or

PCBs, adjusting the machine and so on. If you need to take voltage measurements with

the power switched on, take the greatest of care not to receive an electric shock.

(2) When connecting or disconnecting cable connectors, make sure that you hold the

connector body and not the cables.

(3) Electronic devices are sensitive to static build up; make sure that you touch a metal

portion of the machine to discharge yourself before accessing the PCBs.

Handle PCBs with care when repairing them.

(4) Ensure all Warnings are followed.

The fuser unit becomes extremely hot during operation. Wait until it has cooled down sufficiently before replacing consumable items. DO NOT remove or damage the caution label located on or around the fuser.

(5) Verify again that the repaired portion works properly.

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1.2 Part names

■ Printer part

Back cover

Main PCB ASSY

Pull arm spring ADF R

Fuser cover

Fuser unit

High-voltage

PS PCB ASSY

Pull arm R

Lock claw

Pull arm guide

Outer chute ASSY

Filter ASSY

Pull arm L

Pull arm spring ADF

Joint cover sub chute ASSY

Laser unit

NCU PCB

Joint cover ASSY

Registration rear sensor PCB ASSY

NCU shield

PS PCB unit ASSY

Registration front sensor PCB ASSY

Fan motor 60 unit

Speaker cover

Battery ASSY

Speaker hold spring

Speaker unit

Eject roller ASSY 2

Paper stack lever

Inner chute ASSY

Eject sensor PCB ASSY

Drive sub ASSY

Side cover L ASSY

New toner sensor

harness ASSY

PT sensor holder

DEV joint

DEV gear joint/53R

Registration solenoid lever

Registration

Side cover sub L

T1 solenoid

lever

solenoid

Toner sensor PCB unit ASSY

T1 solenoid

Paper

stopper L

Front cover ASSY

Fig. Ref. 1-1

Corner cover

Roller holder

ASSY

Rubber foot

Paper stopper S

Toner LED PCB ASSY

LED holder

Cover sensor harness ASSY

Side cover

R ASSY

Wireless LAN PCB ASSY

Paper tray ASSY

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■ ADF / FB part

Gear cover

Separate roller shaft ASSY

Separate roller bushing

Upper document chute ASSY

Pressure roller ASSY

Pressure roller spring

Hinge ASSY L

Ejection roller ASSY

LF roller ASSY

LF roller bushing

Drive frame ASSY

ADF cover

Actuator L

Separation rubber

ADF plate spring

Actuator R

Address label

Back light guide

Rubber key L

Hinge R

Hinge arm

Document cover sub ASSY

Cord hook

Panel dress cover

Panel unit

LCD

Diffusion film

Rubber key R

Panel PCB ASSY

Document stopper

Document dress cover

ADF harness unit

harness holder

ADF motor

Lower document chute ASSY

ADF sensor PCB ASSY

Fig. Ref. 1-2

Document scanner unit

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1.3 Initial Check

Check the following items before attempting to repair the machine.

■ Operating Environment

(1) Put your machine on a flat, stable surface such as a desk that is free of vibration and

shocks.

(2) Use the machine in a well-ventilated room; use the machine within the following ranges

of temperature and humidity: temperature between 10°C and 32.5°C (50°F to 90.5°F),

and the relative humidity is maintained between 20% and 80%.

(3) The machine is not exposed to direct sunlight, excessive heat, moisture, or dust.

■ Power Supply

(1) The AC input power supply described on the rating plate of the machine should be within

±10% of the rated voltage.

(2) The AC input power supply is within the regulated value.

(3) The cables and harnesses are connected correctly.

(4) The fuses are not blown.

■ Paper

(1) A recommended type of paper is being used.

(Refer to “2.6 Paper”, Reference 1 of the Service Reference Manual.)

(2) The paper is not damp.

(3) The paper is not short-grained paper or acid paper.

■ Consumable Parts

(1) The drum unit (including the toner cartridge) is installed correctly.

■ Others

(1) Condensation

When the machine is moved from a cold place into a warm room, condensation may

occur inside the machine, causing various problems as listed below.

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

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

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

• Condensation on the plate and separation pad may cause paper feed failures.

If condensation has occurred, leave the machine for at least 2 hours to allow it to reach room temperature.

If the drum unit is unpacked soon after it is moved from a cold place to a warm room, condensation may occur inside the unit which may cause incorrect images. Instruct the end user to allow the unit to come to room temperature before unpacking it. This will take one or two hours.

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(2) Cleaning

Use a soft dry cloth.

CAUTION:

DO NOT use flammable substances or any type of spray to clean the inside or outside of the machine. Doing this may cause a fire or electrical shock.

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2. ERROR CAUSE

This machine includes a self-diagnosis function. If the machine does not work normally it judges that an error has occurred (For example: Print Unable 6A), and indicates the corresponding error message on the LCD, which in turn helps the end user to quickly identify the problem.

The error code is possible to display by the Maintenance mode 82 (Refer to "1.4.19 Error

Code Indication (Function code 82)" in Chapter 5).

2.1 Error indication

The error codes

shaded

in the table below are recoverable errors if you follow the User Check items.

Error

codes

Replacement time of the drum

unit

Problem

Refer

to:

Error

codes

Problem

1-7 7B Main PCB failure 1-13

Refer

56 Fuser cover opened 1-8 7D Dirt on drum unit 1-14

Fuser unit failure

(Stand ready in the given time)

1-8 7F Fax paper setting mismatch 1-14

59 Fuser unit failure 1-8 80 Fax paper size is small 1-14 5A

HVPS PCB ASSY failure New toner detecting lever

malfunction

Toner cartridge is at the end of life. Toner of the toner cartridge is

low

1-9 84

Paper jam in rear of the machine

1-16

1-9 88 Paper jam inside the machine 1-16

1-10 8A Paper jam in Tray 1 (T1) 1-17

1-7 8D Paper jam near paper eject tray 1-17

68 Fuser unit failure 1-11 9F Paper empty 1-18 69 Fuser unit failure 1-11 A1 Front cover open 1-18 6A Fuser unit failure 1-11 A2 Document is too long. 1-18

Document rear sensor is not

6B Fuser unit failure 1-11 A3

turned on when feeding the

1-19

document.

6C Fuser unit failure 1-11 A5

Fax scanning error (First warning only)

1-19

Fax scanning error (The second

6D Fuser unit failure 1-11 A6

warning that the same error with

1-19

A5 occurs again) 6E Fuser unit failure 1-11 AD DMA transfer error 1-19 6F Fuser unit failure 1-11 AF FB unit home position failure 1-20

71 Polygon motor failure 1-12 B0

BD beam detecting sensor

malfunction

1-12 B7 Detection error of scanner 1-20

Harness for scanning is not

connected correctly.

1-20

75 Machine cooling down inside 1-7 B9 Scanning light adjustment error. 1-20 76 Fuser unit failure 1-12 BB White level data error 1-21 77 Fuser unit failure 1-12 E6 NVRAM error on main PCB 1-21 78 Fuser unit failure 1-13 EC Fan performance malfunction 1-21

No detection of the internal

temperature thermistor No detection of main motor lock

signal

1-13 F8 Battery connection failure 1-21

1-13 F9

Maintenance mode 74 Non-

decision

1-22

to:

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2.2 Error Code Cause and Remedy

2.2.1 Recoverable User Check Errors

These errors are recoverable by following the message indicated on the LCD or following the items indicated in User Check

■ Error code 67

Toner Low

Prepare New Toner Cartridge

The toner of the toner cartridge is low. (The toner sensor delects the nearly empty.)

User Check

• Prepare a new toner cartridge. If the toner is empty, Replace it.

■ Error code 75

Cooling Down

Wait for a while

The machine is cooling down inside for protection. The machine indicates "Cooling Down" in one of the conditions below.

(1) The temperature inside the machine is too high.

(2) Both ends of the heat roller are at different temperatures.

(3) The paper media is replaced with different Paper size media.

User Check

• After having passed for a while with having turned the power supply on.

2.2.2 Service Call Error

Check the User Check items first. If the same problem occurs follow each procedure in the order of the number described in the Step column in the table below.

■ Error code 50

Drum End Soon

Replacement time of the drum unit. (The drum counter reached the upper limit.)

User Check

• Replace the drum unit with a new one.

Step Cause Remedy

1 Main PCB failure Replace the main PCB ASSY.

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■ Error code 56

Cover is Open

Close the Fuser Cover.

Fuser cover opened

User Check

• Check if the Fuser cover is closed correctly.

Step Cause Remedy

2 Eject actuator failure Re-assemble the eject actuator

3 Eject sensor PCB ASSY failure Replace the eject sensor PCB ASSY.

4 Main PCB failure Replace the main PCB ASSY.

Harness connection failure of back cover switch ASSY

Check the harness connection of the back cover switch ASSY and reconnect it.

■ Error code 58

Fuser Error

Turn the power off, then on again. Leave the machine for 15 min.

Error code 59

Self-Diagnostic

Will Automatically Restart within 15 minutes.

If the same error is detected again 15 minutes later, the message below is indicated.

Print Unable 6A

See Troubleshooting and routine maintenance chapter in User’s Guide.

Fuser unit failure *It occurs with either of 68, 69, 6A, 6B, 6C, 6D, 6E, 6F, 76 and 78.

Step Cause Remedy

Harness connection failure

2 Fuser unit failure Replace the fuser unit.

3 LVPS PCB failure Replace the LVPS PCB unit.

4 Eject sensor PCB ASSY failure Replace the eject sensor PCB ASSY.

5 Main PCB failure Replace the main PCB ASSY.

between fuser unit and eject sensor PCB

Check the harness connection between the fuser unit and eject sensor PCB, and reconnect it.

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■ Error code 5A

Print Unable 5A

See Troubleshooting and routine maintenance chapter in User’s Guide.

HVPS PCB failure (Developing bias voltage failure)

Step Cause Remedy

HVPS PCB ASSY harness

2 HVPS PCB failure Replace the HVPS PCB ASSY.

3 Main PCB failure Replace the main PCB ASSY.

connection failure

■ Error code 5B

Cartridge Error

Put the Black Toner Cartridge back in.

New toner detection lever malfunction

User Check

• Check if the toner cartridge is attached.

Step Cause Remedy

2 New toner detection switch failure Replace the new toner harness ASSY.

3 Main PCB failure Replace the main PCB ASSY.

New toner detection switch harness connection failure

Check the harness connection between the HVPS PCB and main PCB. Then, reconnect them.

Check the harness connection of the new toner detection switch. Then, reconnect it.

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■ Error code 63

Toner Life End

Replace Toner Cartridge.

Toner cartridge is at the end of its life. (The toner sensor detects the nearly empty, or the drum counter reached the upper limit.)

User Check

• Gently shake the toner cartridge from side to side and install it again.

• Replace the toner cartridge.

Step Cause Remedy

Harness connection failure of new toner sensor harness ASSY.

Check the sensor performance following the procedure described in "Maintenance

mode 32". If any problem occurs, check the

harness connection of the new toner sensor harness ASSY, then reconnect it.

Harness connection failure of toner sensor PCB unit ASSY.

Check the sensor performance following the procedure described in "Maintenance

mode 32". If any problem occurs, check the

harness connection of the toner sensor PCB unit ASSY, then reconnect it.

New toner sensor harness ASSY failure (Toner empty)

Toner sensor PCB unit ASSY failure.

Replace the new toner sensor harness ASSY.

Replace the toner sensor PCB unit ASSY.

5 Main PCB failure Replace the main PCB ASSY.

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■ Error code 68

Print Unable 68

See Troubleshooting and routine maintenance chapter in User’s Guide.

Fuser unit failure (The side thermistor detects higher temperature than the specified value.)

Error code 69

Print Unable 69

See Troubleshooting and routine maintenance chapter in User’s Guide.

Fuser unit failure (The side thermistor detects lower temperature than the specified value.)

Error code 6A

Print Unable 6A

See Troubleshooting and routine maintenance chapter in User’s Guide.

Fuser unit failure (The side thermistor does not detect 60°C within the specified time.)

Error code 6B

Print Unable 6B

See Troubleshooting and routine maintenance chapter in User’s Guide.

Fuser unit failure (The center thermistor does not detect 100°C within the specified time.)

Error code 6C

Print Unable 6C

See Troubleshooting and routine maintenance chapter in User’s Guide.

Fuser unit failure (The center thermistor detects higher temperature than the specified value.)

Error code 6D

Print Unable 6D

See Troubleshooting and routine maintenance chapter in User’s Guide.

Fuser unit failure (The center thermistor detects lower temperature than the specified value.)

Error code 6E

Print Unable 6E

See Troubleshooting and routine maintenance chapter in User’s Guide.

Fuser unit failure (The center thermistor does not detect temperature rising within the specified time.)

Error code 6F

Print Unable 6F

See Troubleshooting and routine maintenance chapter in User’s Guide.

Fuser unit failure (The center and side thermistors detect extremely high temperature.)

Step Cause Remedy

2 Fuser unit failure Replace the fuser unit.

3 LVPS PCB unit failure Replace the LVPS PCB unit.

4 Main PCB failure Replace the main PCB ASSY.

Fuser unit harness connection failure

1-11

Check the harness connection of the fuser unit and reconnect it.

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■ Error code 71

Print Unable 71

See Troubleshooting and routine maintenance chapter in User’s Guide.

Laser unit Polygon mirror motor failure (Cannot detect the period signal of the polygon mirror motor.)

Error code 72

Print Unable 72

See Troubleshooting and routine maintenance chapter in User’s Guide.

BD beam detect sensor malfunction

Step Cause Remedy

2 Laser unit failure Replace the laser unit.

3 Main PCB failure Replace the main PCB ASSY.

Laser unit harness connection failure

Check the two harness connections of the laser unit and reconnect them.

■ Error code 76

Print Unable 76

See Troubleshooting and routine maintenance chapter in User’s Guide.

Fuser unit failure (The center thermistor detects rapidly rising temperature.)

Step Cause Remedy

2 Fuser unit failure Replace the fuser unit.

Fuser unit harness connection failure

Check the harness connection of the fuser unit and reconnect it.

■ Error code 77

Print Unable 77

See Troubleshooting and routine maintenance chapter in User’s Guide.

Fuser error code failure (The error history of the fuser unit is deleted.)

Step Cause Remedy

1 Fuser unit failure Replace the fuser unit.

2 Main PCB failure Replace the main PCB ASSY.

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■ Error code 78

Print Unable 78

See Troubleshooting and routine maintenance chapter in User’s Guide.

Fuser unit failure (The temperature sensor of the fuser unit is broken.)

Step Cause Remedy

1 Fuser unit failure Replace the fuser unit.

2 Main PCB failure Replace the main PCB ASSY.

■ Error code 79

Print Unable 79

See Troubleshooting and routine maintenance chapter in User’s Guide.

No detection of the internal temperature thermistor.

Step Cause Remedy

3 Main PCB failure Replace the main PCB ASSY.

Harness connection failure of internal temperature thermistor

Internal temperature thermistor failure

Check the harness connection of the internal temperature thermistor, and reconnect it.

Replace the internal temperature thermistor.

■ Error code 7A

Print Unable 7A

See Troubleshooting and routine maintenance chapter in User’s Guide.

No detection of the main motor lock signal.

Step Cause Remedy

1 Main motor failure Replace the main motor ASSY.

2 Main PCB failure Replace the main PCB ASSY.

■ Error code 7B

Print Unable 7B

See Troubleshooting and routine maintenance chapter in User’s Guide.

Main PCB failure

Step Cause Remedy

1 Main PCB failure Replace the main PCB ASSY.

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■ Error code 7D

Drum Error

Open the front cover, then clean the corona wire of drum unit according to the label.

Dirt on drum unit

User Check

• Clean the corona wire of the drum unit.

• Replace the drum unit with a new one.

Step Cause Remedy

2 HVPS PCB failure Replace the HVPS PCB ASSY.

3 Main PCB failure Replace the main PCB ASSY.

Dirt or dust on drum unit electrodes

Clean the electrodes on the drum unit. (Refer to Fig. 1-1.)

■ Error code 7F

Size mismatch

Fax received. Set correct paper size in menu.

Fax paper setting mismatch (The setting paper becomes besides the A4/Letter/Legal/Folio.)

User Check

• Set the A4/Letter/Legal/Folio using the paper size setting in menu.

Step Cause Remedy

1 Main PCB failure Replace the main PCB ASSY.

■ Error code 80

Size mismatch

Reload correct paper, then press Start.

Fax paper size is incorrect (The registration rear sensor detected the paper that is smaller than the letter size.)

User Check

• Set the paper of A4 or LETTER-size on the paper tray.

Step Cause Remedy

Registration front actuator catching in some position

1-14

Re-assemble the registration front actuator.

Confidential

■ Electrodes location on the drum unit

Side surface of

Drum unit

Fig. 1-1

■ Electrodes location on the machine

Side surface of

Frame L ASSY inside

Fig. 1-2

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■ Error code 84 (Jam Rear)

Jam Rear

Open the Back Cover and remove the jammed paper.

Paper jam in the rear of the machine (It is detects by the eject sensor)

Error code 88 (Jam Inside)

Jam Inside

Open the Front Cover, pull out the Drum Unit completely and remove the jammed paper.

Paper jam inside the machine (It is detects by the registration rear sensor)

User Check

• Check if the paper is jammed. If there is any jammed paper, remove it.

Step Cause Remedy

Harness connection failure of

registration front sensor PCB ASSY, registration rear sensor PCB ASSY or paper eject sensor PCB ASSY

Registration front actuator,

registration rear actuator or paper eject actuator not operating smoothly or catching in some position.

Check the harness connections of the registration front sensor PCB ASSY, registration rear sensor PCB ASSY and paper eject sensor PCB ASSY, and reconnect them.

Ensure smooth operation of the registration front actuator, registration rear actuator or paper eject actuator and ensure they are not catching in any positions.

Paper eject sensor PCB failure Check the sensor performance following

the procedure described in "Maintenance

mode 32". If any problem occurs, replace

the eject sensor PCB ASSY.

Registration front sensor PCB

failure

Check the sensor performance following the procedure described in "Maintenance

mode 32". If any problem occurs, replace

the registration front sensor PCB ASSY.

Registration rear sensor PCB

failure

Check the sensor performance following the procedure described in "Maintenance

mode 32". If any problem occurs, replace

the registration rear sensor PCB ASSY.

Registration ground spring failure Re-assemble the registration ground

spring. (Refer to Fig. 1-3.)

7 Main PCB failure Replace the main PCB ASSY.

Registration ground spring

Fig. 1-3

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■ Error code 8A

Jam Tray

Remove the jammed paper from Tray.

Paper jam in Tray 1 (T1) (It is detects by the registration front sensor)

User Check

• Check if the paper is jammed in the tray. If jammed, remove it.

• Adjust the paper guide corresponding to the paper size.

• Check if too much paper is loaded in the tray.

Step Cause Remedy

Harness connection failure of

2 Paper feed roller worn out Replace the paper feed roller.

4 Main PCB failure Replace the main PCB ASSY.

registration front sensor PCB ASSY

Registration front sensor PCB failure

Check the harness connection of the registration front sensor PCB ASSY in the appropriate tray, and reconnect it.

Check the sensor performance following the procedure described in "Maintenance

mode 32". If any problem occurs, replace

the registration front sensor PCB ASSY.

■ Error code 8D

Cover is open

Open the Back cover and remove the jammed paper, or close the Fuser Cover.

Paper jam near paper eject tray (When power on, it is detects by the eject sensor.)

User Check

• Remove the jammed paper near the paper eject tray or the back cover.

• Close the fuser cover.

Step Cause Remedy

Paper eject actuator not operating

2 Eject sensor PCB ASSY failure Replace the eject sensor PCB ASSY.

3 Main PCB failure Replace the main PCB ASSY.

smoothly catching in some position.

1-17

Re-assemble the paper eject actuator. Ensure the paper eject sensor operates smoothly.

Confidential

■ Error code 9F

No paper

Reload paper, then press start.

Paper empty (It is detects by the registration front sensor)

User Check

• Replenish the paper in the paper tray.

Step Cause Remedy

4 Main PCB failure Replace the main PCB ASSY.

Registration front actuator catching in some position

Registration front sensor PCB harness connection failure

Registration front sensor PCB failure

■ Error code A1

Cover is open

Close the Front Cover.

Front cover open

User Check

• Close the front cover.

Step Cause Remedy

Harness connection failure of cover sensor harness ASSY.

Re-assemble the registration front actuator.

Check the harness connection of the registration front sensor PCB and reconnect it.

Replace the registration front sensor PCB.

Check the harness connection of the cover sensor harness ASSY, and reconnect it.

3 Main PCB failure Replace the main PCB ASSY.

Cover sensor harness ASSY failure

Replace the cover sensor harness ASSY.

■ Error code A2

Document Jam.

Clear the scanner jam, then press the Stop Key.

The document is too long. (During scanning, 90 cm or longer of a document is detected.)

User Check

• Check if the document is jammed in the ADF. If it is jammed, remove it.

Step Cause Remedy

Document rear actuator not

operating smoothly or catching in some position.

Ensure smooth operation and that there is no catching of document rear actuator.

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■ Error code A3

Document Jam.

Clear the scanner jam, then press the Stop Key.

Document rear sensor is not turned on when feeding the document.

User Check

• Check if the document is jammed in the ADF. If it is jammed, remove it.

Step Cause Remedy

Document rear actuator not

2 Document rear sensor failure. Replace the document rear sensor.

3 ADF motor failure Replace the ADF motor.

operating smoothly or catching in some position.

Ensure smooth operation and that there is no catching of document rear actuator.

■ Error code A5

Scan Unable A5

Remove the original document. Turn the power off, then on again.

Fax scanning error (First warning only)

Step Cause Remedy

Scanning failure Turn the power switch off and on. Then, try

scanning again.

■ Error code A6

Scan Unable A6

Remove the original document. Turn the power off, then on again.

Fax scanning error (After the A5 error occurs, the same problem occurs again even after turning the power off and on.)

Step Cause Remedy

1 FB unit failure Replace the FB unit.

2 Main PCB failure Replace the main PCB ASSY.

■ Error code AD

Scan Unable AD

Remove the original document, Turn the power off, then on again.

DMA transfer error

Step Cause Remedy

1 FB unit failure Replace the FB unit.

2 Main PCB failure Replace the main PCB ASSY

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■ Error code AF

Scan Unable AF

Remove the original document. Turn the power off, then on again.

FB unit home position failure

Step Cause Remedy

1 FB unit failure Replace the FB unit.

2 Main PCB failure Replace the main PCB ASSY.

■ Error code B0

Scanner Error

Harness for scanning is not connected correctly. * This error is indicated on the LCD in the maintenance mode.

Step Cause Remedy

2 Scanner harness broken Replace the FB unit.

3 Main PCB failure Replace the main PCB ASSY.

Scanner harness not connected correctly.

Reconnect the scanner harness correctly.

■ Error code B7

Scanner Error

Detection error of scanner (Scanning reference voltage adjustment malfunction.) * This error is indicated on the LCD in the maintenance mode.

Step Cause Remedy

1 FB unit failure Replace the FB unit.

2 Main PCB failure Replace the main PCB ASSY.

■ Error code B9

Scanner Error

Scanning light adjustment error is detected. * This error is indicated on the LCD in the maintenance mode.

Step Cause Remedy

1 FB unit failure Replace the FB unit.

2 Main PCB failure Replace the main PCB ASSY.

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■ Error code BB

Scanner Error

White level data error * This error is indicated on the LCD in the maintenance mode.

Step Cause Remedy

1 FB unit failure Replace the FB unit.

2 Main PCB failure Replace the main PCB ASSY.

■ Error code E6

Init Unable E6

See Troubleshooting and routine maintenance chapter in User’s Guide.

NVRAM error on main PCB

Step Cause Remedy

1 Main PCB failure Replace the main PCB ASSY.

■ Error code EC

Print Unable EC

See Troubleshooting and routine maintenance chapter in User’s Guide.

Fan performance malfunction

Step Cause Remedy

2 Fan motor failure Replace the fan motor.

3 Main PCB failure Replace the main PCB ASSY.

Harness connection failure of fan motor

Check the harness connection of the fan motor, and reconnect it.

■ Error code F8

Machine Error F8

Battery connection failure

Step Cause Remedy

1 Battery harness connection failure Reconnect the battery harness.

2 Battery exhausted Replace the battery.

3 Main PCB failure Replace the main PCB ASSY.

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■ Error code F9

Machine Error F9

Maintenance mode 74 Non-decision (Inputting omission of the customizing code.)

Step Cause Remedy

Turn the power off, when the

Maintenance mode 74 is in

Implement the Maintenance mode 74 again.

progress.

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3. PAPER FEEDING PROBLEMS

Problems related to paper feeding are end user recoverable if following the User Check items. If the same problem occurs again, follow each procedure in the order of the number described in the Step column in the tables below.

3.1 No Feeding

Step Cause Check

Edge actuator

catching in some position

Roller holder

ASSY catching in some position

Registration front sensor failure

Paper feeding kit failure

Pressure plate

gear damage

T1 solenoid failure Does the T1 solenoid

T1 solenoid Circuit of the high-voltage

power supply PCB broken

Does the edge actuator move smoothly? No

Does the roller holder ASSY move smoothly? Yes

Is the problem solved after replacing the registration front sensor PCB ASSY?

Is the surface of the separation pad or the pickup roller dirty or worn out?

Is the pressure plate gear damaged?

work correctly?

Is the problem solved after replacing the highvoltage power supply PCB ASSY?

Result

Ye s

Remedy

Re-assemble the edge actuator and ensure smooth operation.

Re-assemble the roller holder ASSY and ensure smooth operation.

Replace the registration front sensor PCB ASSY.

1) Clean the surface of the separation pad or pickup roller.

2) Replace the separation pad or pickup roller.

Replace the paper tray.

Replace the T1 solenoid

Replace the high-voltage power supply PCB ASSY.

Main PCB failure Is the problem solved

Main motor failure Is the problem solved

3.2 Double Feeding

Step Cause Check

Paper feeding kit

is abrasion

after replacing the main PCB ASSY?

after replacing the drive sub ASSY?

Is the surface of the separation pad worn out?

Ye s

Result

Ye s

Replace the main PCB ASSY.

Replace the drive sub ASSY.

Remedy

Replace the paper feeding kit.

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3.3 Paper Jam

■ Paper jam in the paper tray and front cover

Step Cause Check

Registration front actuator/edge

actuator catching in some position

Registration front sensor PCB (registration front actuator/edge

actuator failure)

Registration

solenoid failure

Toner sensor PCB

failure

High-voltage power supply PCB

failure

Registration

ground spring loose

Does the registration front actuator/edge actuator move smoothly?

Does the registration front sensor move smoothly? (Check it following the procedure described in

"Operational Check of Sensors (Function code

32)" in Chapter 5)

Is the problem solved after replacing the registration solenoid?

Is the problem solved after replacing the toner sensor PCB?

Is the problem solved after replacing the Highvoltage power supply PCB ASSY?

Is the registration ground spring fitted correctly? No

Result

Ye s

Remedy

Re-assemble the registration front actuator/ edge actuator and ensure smooth operation.

Replace the registration front sensor PCB ASSY.

Replace the registration solenoid.

Replace the toner LED PCB.

Replace the High-voltage power supply PCB ASSY.

Fit the registration ground spring correctly. (Refer to Fig. 1-3.)

Main PCB failure Is the problem solved

after replacing the Main PCB ASSY?

■ Paper jam in the back cover and paper eject section

Step Cause Check

Foreign object

around fuser unit

Paper eject

actuator failure

Fuser cover ASSY

loose

Outer chute ASSY

loose

Eject roller 2 malfunction

Paper eject sensor

PCB failure

Is there a foreign object around the fuser unit?

Does the paper eject actuator move smoothly? Is it damaged?

Is the fuser cover ASSY fitted correctly?

Is the outer chute ASSY fitted correctly?

Is each pinch roller of the inner chute ASSY attached to each eject roller 2 of top cover ASSY properly?

Is the problem solved after replacing the paper eject sensor PCB?

Result

Replace the Main PCB

Ye s

ASSY.

Remedy

Remove the foreign

Ye s

object.

Replace the paper eject

actuator.

Fit the fuser cover ASSY

correctly.

Fit the outer chute ASSY

fitted correctly.

Replace the inner chute ASSY.

Replace the paper eject

Ye s

sensor PCB.

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3.4 Dirt on Paper

User Check

• Check if the paper is loaded into the paper tray correctly.

• Turn over the stack of paper in the paper tray, or try rotating the paper 180° in the paper tray.

Step Cause Check

Fuser unit dirty Is there dirt around the

3.5 Wrinkles or creases

User Check

• Check if the paper is loaded into the paper tray correctly.

• Turn over the stack of paper in the paper tray, or try rotating the paper 180° in the paper tray.

Step Cause Check

Fuser unit dirty Is there dirt around the

Fuser unit failure Is the problem solved if

entrance of the fuser unit?

Is the pressure roller ASSY dirty?

entrance of the fuser unit?

new fuser unit is replaced?

Result

Ye s

Result

Ye s

Remedy

Clean the entrance of the fuser unit.

Clean the pressure roller ASSY.

Remedy

Clean the entrance of the fuser unit.

Replace the fuser unit.

3.6 Waves in the paper / folds in the paper at the eject roller 2

User Check

• Check that the problem is solved if new paper is used.

Step Cause Check

Foreign object

around eject roller 2

Eject roller 2

failure

Is there a foreign object around the eject roller 2?

Is the problem solved after replacing the new eject roller 2?

Result

Ye s

Remove the foreign object.

Replace the top cover ASSY.

Remedy

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3.7 Curl in the paper

Step Cause Check

Fuser unit pressure is high

Is the problem solved after replacing the position of the pressure

Result

Ye s

Remedy

Replace the position of the pressure roller.

roller?

(1) Turn the Nip release lever of right and left to the direction of the arrow.

(2) Hold and turn the PR stopper plate of right and left.

(3) Print it again, and check that the curl in the paper occurs.

(4) When there seems to be still the curl, replace the position of the pressure roller again.

NIP RELEASE LEVER

PRESSURE ROLLER

PR STOPPER PLATE

Fig. 1-4

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4. TROUBLESHOOTING OF DOCUMENT FEEDING

Problems related to document feeding are end user recoverable if following the User Check items. If the same problem occurs again, follow each procedure in the order of the number described in the step column in the tables below.

4.1 No Feeding

User Check

• Check if the document is inserted correctly to the depths of the ADF unit. (If the document is inserted, the LCD indication is changed.)

Step Cause Check

Document front actuator not

operating smoothly or catching

Foreign object

around paper feed roller

Paper feed roller

failure

ADF sensor PCB Is the problem solved by

ADF motor

failure

Drive frame

ASSY failure

Main PCB failure Is the problem solved

Does document front actuator move smoothly? No

Is there a foreign object around the paper feed roller?

Is the surface of the paper feed roller worn out?

replacing the ADF sensor PCB?

Is the problem solved by replacing the ADF motor?

Is the problem solved by replacing the drive frame ASSY?

after replacing the main PCB ASSY?

Result

Ye s

Remedy

Re-assemble document front actuator.

Remove the foreign object.

Replace the separate roller shaft ASSY.

Replace the ADF sensor PCB.

Replace the ADF motor.

Replace the drive frame ASSY.

Replace the main PCB ASSY.

4.2 Double feeding

Step Cause Check

Separation

rubber failure

Is the surface of the separation rubber worn out?

1-27

Result

Ye s

Remedy

Replace the separation rubber.

Confidential

4.3 Paper Jam

User Check

• Check if the paper is loaded into the ADF tray correctly.

• Check if do not use the crimpy or torn paper.

Step Cause Check

Document rear actuator not

operating smoothly or catching

Foreign object around feed

roller / paper eject roller actuator

Pinch roller of

feed roller failure

Pinch roller of

paper eject roller failure

Pressure roller

film unstick

ADF sensor PCB Is the problem solved by

ADF motor

failure

Does document rear actuator move smoothly? No

Is there a foreign object around the feed roller / paper eject roller actuator?

Is pinch roller of feed roller remove?

Is pinch roller of paper eject roller remove? Yes

Does pressure roller film unstick?

replacing the ADF sensor PCB?

Is the problem solved by replacing the ADF motor?

Result

Ye s

Remedy

Re-assemble the document rear actuator.

Remove the foreign object.

Re-assemble the pinch roller of the feed roller.

Re-assemble the pinch roller of the paper eject roller.

Replace the pressure roller film.

Replace the ADF sensor PCB.

Replace the ADF motor.

Drive frame

ASSY failure

Main PCB failure Is the problem solved

Is the problem solved by replacing the drive frame ASSY?

after replacing the main PCB ASSY?

Replace the drive frame

Ye s

ASSY.

Replace the main PCB

Ye s

ASSY.

1-28

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5. IMAGE DEFECT TROUBLESHOOTING (Defect Of the Print)

5.1 Image Defect Examples

Light

Image distortion

Black vertical streaks in a light background

White spots

Faulty registration

All black

Black horizontal stripes

Black spots

Dark

Dirt on the back of paper

White vertical streaks

Black band

White horizontal streaks

Downward fogging of solid color

Poor fixing

Vertical streaks

Completely blank

Faint print

Horizontal lines

Ghost

Fogging

CAUTION:

The image defect at the copy might have the cause in the scanning. When the failure does not reproduce by print the test pattern “MAINTENANCE 09” or PC print, refer to "6. TROUBLESHOOTING OF SCANNIG".

5.2 Diameter of Rollers

Image defects which appear periodically may be caused by failure of a roller. Specify the cause referring to the diameter of the rollers or pitch which appears in the image as shown in the table below.

No. Parts name

1 Develop roller

2 Exposure drum

3 Heat roller in the fuser unit

4 Pressure roller ASSY in the fuser unit

Fig. 1-5

1-29

Diameter

The pitch which

appears in the image

Ø20.0 mm 41.0 mm

Ø24.0 mm 75.0 mm

Ø25.0 mm 78.5 mm

Confidential

5.3 Troubleshooting Image Defect

Image defect related problems are end user recoverable if following the User Check items. If the same problem occurs, follow each procedure in the order of the number described in the Step column in the tables below.

■ Light

User Check

• Check the machine's environment. High temperature and high humidity conditions can cause this problem.

• If the whole page is light, toner save mode may be on.

• Replace the toner cartridge or drum unit with a new one.

Step Cause Check

Dirt on exposure

drum electrode

Dirt on scanner

windows of the laser unit

Toner sensor failure

Between the HVPS PCB/Main

PCB connection failure

Are the electrodes of the drum unit and machine body dirty?

Is the scanner windows of the laser unit dirty? Yes

After replacing the toner cartridge with a new one, does the same problem occur even after printing several pages?

Does the machine start printing even after removing the toner cartridge from the drum unit? Yes

Is the harness of the HVPS PCB ASSY and main PCB ASSY connected correctly?

Result

Ye s

Remedy

Clean both electrodes. (Refer to Fig. 1-1, Fig. 1-2.)

Wipe the dirt off with a soft, clean, lint free cloth.

Replace the toner cartridge.

Clean the toner sensor. (receiving light side) Check the harness connection of the toner LED PCB ASSY. (luminescence side) Replace the toner sensor PCB ASSY or toner LED PCB ASSY.

Reconnect the harness of the HVPS PCB ASSY and main PCB ASSY.

HVPS PCB

failure

Main PCB failure Is the problem solved

Laser unit failure Is the problem solved

Is the problem solved after replacing the HVPS PCB ASSY?

after replacing the main PCB ASSY?

after replacing the laser unit?

1-30

Replace the HVPS PCB

Ye s

ASSY.

Replace the main PCB

Ye s

ASSY.

Replace the laser unit.

Ye s

Confidential

■ Faulty registration

User Check

• Check that the appropriate media type is selected in the printer driver.

Step Cause Check

Registration rear actuator catching

in some position

Does the registration rear actuator move smoothly?

■ Dark

User Check

• Check the machine's environment. High temperature and high humidity conditions can cause this problem.

• Replace the drum unit with a new one.

• Replace the toner cartridge with a new one.

Step Cause Check

The developing bias voltage

failure

HVPS PCB

failure

Is the problem solved after resetting the developing bias counter?

Is the problem solved after replacing the HVPS PCB ASSY?

Result

Ye s

Remedy

Re-assemble the registration rear actuator and ensure smooth operation.

Remedy

Reset the developing bias counter. (Refer to "2.2

Resetting the developing bias voltage counter" in

Chapter 5)

Replace the HVPS PCB ASSY.

Main PCB failure Is the problem solved

after replacing the main PCB ASSY?

Replace the main PCB

Ye s

ASSY.

1-31

Confidential

■ Poor fixing

User Check

• Replace the drum unit with a new one.

• Replace the toner cartridge with a new one.

Step Cause Check

Fuser unit pressure is high

Fuser unit failure Is the problem solved

LVPS PCB failure Is the problem solved

HVPS PCB

failure

Main PCB failure Is the problem solved

Is the problem solved after replacing the position of the pressure roller?

after replacing the fuser unit?

after replacing the LVPS PCB unit?

Is the problem solved after replacing the HVPS PCB ASSY?

after replacing the main PCB ASSY?

■ Completely blank

User Check

• Replace the drum unit with a new one.

• Replace the toner cartridge with a new one.

Result

Ye s

Remedy

Replace the position of the pressure roller. (Refer to Fig. 1-4.)

Replace the fuser unit.

Replace the LVPS PCB unit.

Replace the HVPS PCB ASSY.

Replace the main PCB ASSY.

Step Cause Check

Developing bias voltage

conduction failure

Scanner harness of the laser unit

connection failure

Laser unit failure Is the problem solved

HVPS PCB

failure

Main PCB failure Is the problem solved

Are the electrodes on the drum unit and machine body dirty?

Is the scanner harness of the laser unit connected securely?

after replacing the laser unit?

Is the problem solved after replacing the HVPS PCB ASSY?

after replacing the main PCB ASSY?

1-32

Result

Ye s

Remedy

Clean both electrodes. (Refer to Fig. 1-1, Fig. 1-2.)

Reconnect the scanner harness of the laser unit.

Replace the laser unit.

Replace the HVPS PCB ASSY.

Replace the main PCB ASSY.

Confidential

■ Image distortion

Step Cause Check

Laser unit not assembled correctly

Is the laser unit assembled into the machine securely? (Check if there is no gap.)

Incorrect radiation angle of scanner diode of

laser unit.

Is the problem solved after replacing the laser unit?

Scanner motor rotation failure

Main PCB failure Is the problem solved

after replacing the main PCB ASSY?

Result

Ye s

Remedy

Assemble the laser unit correctly and secure the screw.

Replace the laser unit.

Replace the main PCB ASSY.

1-33

Confidential

■ All black

Step Cause Check

Corona wire failure

Are the electrodes on the drum unit and machine body dirty?

Under FG wire

not assembled

Is the corona wire damaged?

Is the under FG wire connected securely? No

correctly

Scanner harness of the laser unit

connection

Is the scanner harness of the laser unit connected securely?

failure

FG harness ASSY connection

failure

Is the FG harness ASSY between the laser unit and main PCB ASSY connected securely?

HVPS PCB failure

Is the problem solved after replacing the HVPS PCB ASSY?

Main PCB failure Is the problem solved

after replacing the main PCB ASSY?

Result

Ye s

Remedy

Clean both electrodes.

Replace the drum unit.

Re-assemble the under FG wire.

Reconnect the scanner harness of the laser unit.

Reconnect the FG harness ASSY between the laser unit and main PCB ASSY securely.

Replace the HVPS PCB ASSY.

Replace the main PCB ASSY.

Laser unit failure Is the problem solved

after replacing the laser unit?

Replace the laser unit.

Ye s

1-34

Confidential

■ Dirt on the back of paper

Step Cause Check

Scratch or Dirt on the fuser unit

Scratch or Dirt in

the paper feed system

Is the pressure roller ASSY dirty?

Is any other area in the machine dirty?

Is the paper feed system dirty? Yes

■ Vertical streaks

User Check

• This problem may occur with noise which is caused by dirt

• Replace the drum unit with a new one.

• Replace the toner cartridge with a new one.

Step Cause Check

Scratch or Dirt in

the paper feed system

Is the paper feed system dirty? Yes

Result

Print approximate 10

Ye s

pages.

Replace the fuser unit.

Wipe dirt off.

on the corona wire in the drum unit. In this case, clean the corona wire with the wire cleaner.

Result

Wipe dirt off.

Remedy

Scratch or Dirt

on the exposure drum

Scratch or Dirt

on the heat roller

CAUTION:

If the machine prints the same pattern, especially vertical streaks, continuous, black vertical streaks may appear on the paper as the electrostatic performance of the drum is decreased.

Are there scratch and dirt on the surface of the exposure drum?

Are there scratch and dirt on the surface of the heat roller?

Replace the drum unit.

Ye s

Replace the fuser unit.

Ye s

■ Black vertical streaks in a light background

User Check

• Clean the inside of the machine and the corona wire in the drum unit.

• Replace the toner cartridge with a new one.

Step Cause Check

Drum unit failure

Is the problem solved after replacing the drum unit?

Result

Ye s

Remedy

Replace the drum unit.

1-35

Confidential

■ Black horizontal stripes

User Check

• Clean the inside of the machine and the corona wire in the drum unit.

• Replace the drum unit with a new one.

Step Cause Check

Dirt on the

charge electrode

Are the electrodes on the drum unit and machine body dirty?

Paper tray ground terminal

located in the machine body

Toner attached on the develop

roller

Is the paper tray ground terminal bent, which is located in the machine body? (Refer to

Fig. 1-6

Are the horizontal stripes at 41.0 mm (develop roller circumference) intervals?

Scratch and Dirt on the exposure

drum

Are the horizontal stripes at 75.0 mm (exposure drum circumference) intervals?

Scratch and Dirt

on the heat roller

Are the horizontal stripes at 78.5 mm (heat roller circumference) intervals?

HVPS PCB failure

Is the problem solved after replacing the HVPS PCB ASSY?

Result

Remedy

Clean both electrodes

Ye s

(Refer to Fig. 1-1, Fig. 1-2.)

Correct the bending of paper tray ground terminal.

Ye s

This problem will disappear by printing approximate 10 pages.

Ye s

If the same problem occurs, replace the toner cartridge.

Replace the drum unit.

Ye s

Replace the fuser unit.

Ye s

Replace the HVPS PCB

Ye s

ASSY.

Main PCB failure Is the problem solved

Paper tray ground terminal.

after replacing the main PCB ASSY?

Bottom surface of Paper tray

Fig. 1-6

Replace the main PCB

Ye s

ASSY.

1-36

Confidential

■ White vertical streaks

User Check

• Clean the scanner windows of the laser unit with a soft lint-free cloth.

• Replace the toner cartridge with a new one.

• Check the machine’s environment. High temperature and high humidity conditions can cause this problem.

• Damp (wet) paper might be used. Try to change to freshly unpacked paper.

• Check there is no dust in the gap between the toner cartridge and drum frame.

Step Cause Check

Condensation Has condensation

Dirt on scanner

windows

Transfer failure Is the transfer roller

Scanner window

of laser unit failure

occurred inside the machine?

Is the scanner windows dirty?

scratched?

Is the problem solved after replacing the laser unit?

■ White horizontal streaks

User Check

• Check that the appropriate media type is selected in the printer driver.

• The problem may disappear by itself. Try printing multiple pages to clear this problem especially if the machine has not been used for a long time.

• The drum unit may be damaged. Replace the drum unit with a new one.

Result

Ye s

Remedy

Try to print several pages or leave the machine 2 hours to allow it to reach room temperature.

Clean the scanner windows.

Replace the drum unit.

Replace the laser unit.

Step Cause Check

Toner cartridge electrode

connection failure

Are the electrodes on the toner cartridge and machine body dirty?

1-37

Result

Ye s

Remedy

Clean both electrodes (Refer to Fig. 1-1, Fig. 1-2.).

Confidential

■ Faint print

User Check

• Check that the machine is installed on a level surface.

• Replace the toner cartridge with a new one.

• Clean the scanner windows of the laser unit with a soft cloth.

Step Cause Check

Main PCB failure Is the problem solved

Laser unit failure Is the problem solved

Toner empty sensor failure

after replacing the main PCB ASSY?

after replacing the laser unit?

Is the "Toner Life End" message indicated on the LCD after replacing the current toner cartridge with the empty toner cartridge?

■ White spots

User Check

• Toner may be empty. Replace the toner cartridge with a new one.

• If the problem is not solved after printing a few pages, the drum unit may have glue from label stuck on the exposure drum surface. Refer to the next page, and wipe it off gently with a cotton swab.

• The drum unit may be damaged. Replace the drum unit with a new one.

Result

Ye s

Remedy

Replace the main PCB ASSY.

Replace the laser unit.

Replace the toner sensor PCB ASSY.

Step Cause Check

Toner attached on the develop

roller

Scratch and Dirt on the exposure

drum

Drum unit

connection failure

HVPS PCB

failure

Main PCB failure Is the problem solved

Are the white spots at

41.0 mm (develop roller circumference) intervals?

Are the white spots at

75.0 mm (exposure drum circumference) intervals?

Are the electrodes on the drum unit and machine body dirty?

Is the problem solved after replacing the HVPS PCB ASSY?

after replacing the main PCB ASSY?

Result

Ye s

Remedy

This problem will disappear by printing approximate 10 pages. If the same problem occurs, replace the toner cartridge.

Replace the drum unit.

Clean both electrodes (Refer to Fig. 1-1, Fig. 1-2.).

Replace the HVPS PCB ASSY.

Replace the main PCB ASSY.

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Confidential

If you have print quality problems, clean the drum unit as follows:

(1) Put the print sample in front of the drum unit, and find the exact position of the poor print.

Fig. 1-7

(2) Turn the drum unit gear to the direction of the arrow of the figure by hand while looking at

the surface of the exposure drum.

Fig. 1-8

(3) When you have found the mark on the drum that matches the print sample, wipe the

surface of the exposure drum with a dry cotton swab until the dust or glue on the surface comes off.

Fig. 1-9

CAUTION:

DO NOT clean the surface of the exposure drum with a sharp object.

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Confidential

■ Black spots

User Check

• Damp (wet) paper might be used. Try to change to freshly unpacked paper.

• Toner may be empty. Replace the toner cartridge with a new one.

• If the problem is not solved after printing a few pages, the drum unit may have glue from label stuck on the exposure drum surface. Refer to the previous page, and wipe it off gently with a cotton swab.

• The drum unit may be damaged. Replace the drum unit with a new one.

Step Cause Check

Toner attached on the develop

roller

Scratch and Dirt on the exposure

drum

Drum unit

connection failure

Scratch and Dirt on the heat roller

HVPS PCB

failure

Main PCB failure Is the problem solved

Are the black spots at

41.0 mm (develop roller circumference) intervals?

Are the

75.0 mm (exposure drum circumference) intervals?

Are the electrodes on the drum unit and machine body dirty?

Are the black spots at

78.5 mm (heat roller circumference) intervals?

Is the problem solved after replacing the HVPS PCB ASSY?

after replacing the main PCB ASSY?

black spots

Result

Ye s

Remedy

This problem will disappear by printing approximate 10 pages. If the same problem occurs, replace the toner cartridge.

Replace the drum unit.

Clean both electrodes (Refer to Fig. 1-1, Fig. 1-2.).

Replace the fuser unit.

Replace the HVPS PCB ASSY.

Replace the main PCB ASSY.

■ Black band

User Check

• Clean the inside of the machine and the corona wire in the drum unit. If the same problem occurs after cleaning, replace the drum unit with a new one.

• The paper tray ground terminal located in the machine body may be dirty. Clean the contact with a dry cloth.

1-40

Confidential

■ Downward fogging of solid color

User Check

• Toner may be empty. Replace the toner cartridge with a new one.

Step Cause Check

HVPS PCB

failure

Main PCB failure Is the problem solved

Is the problem solved after replacing the HVPS PCB ASSY?

after replacing the main PCB ASSY?

■ Horizontal lines

User Check

• The paper tray ground terminal located in the machine

Step Cause Check

Dirt on charge

electrode

Paper tray ground terminal

located in machine body

Are the electrodes on the drum unit and machine body dirty?

Is the paper tray ground terminal bent, which is located in the machine body?

Result

Replace the HVPS PCB

Ye s

ASSY.

Replace the main PCB

Ye s

ASSY.

body may be dirty. Clean the contact with a dry cloth.

Result

Clean both electrodes

Ye s

(Refer to Fig. 1-1, Fig. 1-2.)

Correct the bending of paper tray ground terminal.

Ye s

Remedy

Laser unit failure Is the problem solved

after replacing the laser unit?

Replace the laser unit.

Ye s

1-41

Confidential

■ Ghost

User Check

• Check the machine's environment, conditions such as high or low humidity may cause this situation to occur.

• Check that the appropriate media type or size is selected in the printer driver.

• Replace the drum unit with a new one.

Step Cause Check

Dirt on cleaner

electrode

HVPS PCB

failure

Are the electrodes of the drum unit and machine body dirty?

Is the problem solved after replacing the HVPS PCB ASSY?

■ Fogging

User Check

• Replace the toner cartridge with a new one.

• Replace the drum unit with a new one.

• Do not use acid paper.

• Check if there is dust or paper powder in the machine.

Step Cause Check

Toner sensor failure (Machine

body)

Is the toner sensor performed normally by following the procedure in "Maintenance mode

32" (Chapter 5).

Result

Ye s

Result

Remedy

Clean both electrodes. (Refer to Fig. 1-1, Fig. 1-2.)

Replace the HVPS PCB ASSY.

Remedy

Replace the toner sensor PCB ASSY.

HVPS PCB

failure

Main PCB failure Is the problem solved

CAUTION:

This problem often occurs when the drum unit or toner cartridge is nearly at the end of life.

Is the problem solved after replacing the HVPS PCB ASSY?

after replacing the main PCB ASSY?

Replace the HVPS PCB

Ye s

ASSY.

Replace the main PCB

Ye s

ASSY.

1-42

Confidential

6. TROUBLESHOOTING OF SCANNIG

6.1 Cannot scan the document in the FB unit. (If scan the document, it is completely white or black.)

User Check

• Check if there is the scanning surface of the FB unit scanning document in the lower side.

Step Cause Check

Document front actuator not

operating smoothly or catching

Each harnesses of FB unit

connection failure

FB unit failure Is the problem solved by

Main PCB failure Is the problem solved

Does document front actuator move smoothly? No

Is the each harnesses of FB unit connected securely?

replacing the FB unit?

after replacing the main PCB ASSY?

6.2 Cannot scan the document in the ADF unit. (If scan the document, it is completely white or black.)

User Check

• Check if there is the scanning surface of the ADF unit document in the upper side.

Result

Ye s

Remedy

Re-assemble the document front actuator.

Reconnect the each harnesses of FB unit.

Replace the FB unit.

Replace the main PCB ASSY.

Step Cause Check

Each harnesses of FB unit

connection failure

FB unit failure Is the problem solved by

Main PCB failure Is the problem solved

Is the each harnesses of FB unit connected securely?

replacing the FB unit?

after replacing the main PCB ASSY?

Result

Ye s

Remedy

Reconnect the each harnesses of FB unit.

Replace the FB unit.

Replace the main PCB ASSY.

1-43

Confidential

6.3 Print of the scanning document is light or dark

User Check

• Check if the ADF or FB glass is not stained.

Step Cause Check

Setting of white

level scanning area malfunction

FB unit failure Is the problem solved by

Main PCB failure Is the problem solved

Is the problem solved after setting the white level of scanning?

replacing the FB unit?

after replacing the main PCB ASSY?

Result

Ye s

6.4 Vertical streaks (White or Black vertical streaks)

User Check

• Check if the ADF or FB glass is not stained.

Step Cause Check

Setting of white

level scanning area malfunction

FB unit failure Is the problem solved by

Is the problem solved after setting the white level of scanning?

replacing the FB unit?

Result

Ye s

Remedy

Set the white level scanning area. (Function code 55)

Replace the FB unit.

Replace the main PCB ASSY.

Remedy

Set the white level scanning area. (Function code 55)

Replace the FB unit.

6.5 Poor fixing

User Check

• Check if the ADF or FB glass is not stained.

Step Cause Check

FB unit failure Is the problem solved by

6.6 Image distortion

Step Cause Check

FB unit failure Is the problem solved by

replacing the FB unit?

Result

Ye s

Result

Ye s

Remedy

Replace the FB unit.

Remedy

Replace the FB unit.

1-44

Confidential

7. SOFTWARE SETTING PROBLEMS

The machine may not print the data correctly if there are incorrect software settings.

User Check

• Check that the USB cable and the network cable is not damaged or broken.

• Check that the correct machine is selected if you have an interface switching device.

• Check the descriptions on the software setting in the user’s guide.

• Try resetting the factory settings.

Step Cause Check

Failure inside the

machine

Machine connection

Main PCB failure Is the problem solved

Does the machine print

"Test Pattern (Function code 09)" ?

For Macintosh, has the product ID been verified?

after replacing the main PCB ASSY?

Result

Ye s

Remedy

Identify the error type, and then refer to the specified section of this chapter.

Verify the product ID. Product ID: DCP7030 : 01EA DCP7040 : 01E9 DCP7045N : 01E8 MFC7320 : 01EB MFC7340 : 01E7 MFC7440N : 01E6 MFC7450 : 01EE MFC7840N : 01ED MFC7840W : 01E5

Replace the main PCB ASSY.

1-45

Confidential

8. NETWORK PROBLEMS

User Check

• Check the descriptions in the network user’s guide.

• Try resetting the factory settings.

Step Cause Check

Wireless LAN PCB failure

(MFC7840W)

Main PCB failure Is the problem solved

Is the problem solved after replacing the wireless LAN PCB ASSY?

after replacing the main PCB ASSY?

Result

Ye s

Remedy

Replace the wireless LAN PCB ASSY.

Replace the main PCB ASSY.

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9. TROUBLESHOOTING OF THE COMMUNICATIONS ERROR

If a communications error occurs, the machine

(1) Gives an alarm (intermittent bleep) for approximately four seconds.

(2) Indicates the appropriate error message on the LCD.

(3) Prints the transmission report during fax transmission.

■ Definition of error codes on the communications list

(1) Calling

Code 1 Code 2 Causes

10 08 Wrong number called.

11 01 No dial tone detected before start of dialing.

11 02 Busy tone detected before dialing.

11 03 2nd dial tone not detected.

11 05 No loop current detected. *

11 06 Busy tone detected after dialing or called.

11 07 No response from the remote station in sending.

11 10 Unobtainable tone detected after dialing.

17 07 No response from the calling station in receiving.

(2) Command reception

Code 1 Code 2 Causes

20 01 Unable to detect a flag field.

20 02 Carrier was OFF for 200 ms or longer.

20 03 Abort detected ("1" in succession for 7 bits or more).

20 04 Overrun detected.

20 05 A frame for 3 seconds or more received.

20 06 CRC error in answerback.

20 07 Error command received.

20 08 Invalid command received.

20 09

Command ignored once for document setting or for dumping-out at turn-around transmission.

* Available in German models only.

20 0A T5 time-out error

20 0B CRP received.

20 0C EOR and NULL received.

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Confidential

(3) Communication code compatibility [checking the NSF and DIS]

Code 1 Code 2 Causes

32 01

Remote terminal only with V.29 capability in 2400 or 4800 bps transmission.

32 02 Remote terminal not ready for polling.

32 10

32 11

32 12

Remote terminal not equipped with password function or its password switch OFF.

Remote terminal not equipped with or not ready for confidential mailbox function.

Remote terminal not equipped with or not ready for relay broadcasting function.

32 13 No confidential mail in the remote terminal.

The available memory space of the remote terminal is less than

32 14

that required for reception of the confidential or relay broadcasting instruction.

32 18 Remote terminal not equipped with color function.

(4) Instructions received from the remote terminal [checking the NSC, DTC, NSS, and DCS]

Code 1 Code 2 Causes

40 02 Invalid coding system requested.

40 03 Invalid recording width requested.

40 05 ECM requested although not allowed.

40 06 Polled while not ready.

40 07 No document to send when polled.

40 10 Nation code or manufacturer code not correct.

40 13

Polled by any other manufacturers' terminal while waiting for secure polling.

40 17 Invalid resolution selected.

40 20 Invalid full color mode selected.

(5) Command reception [checking the NSF and DIS after transmission of NSS and DCS]

Code 1 Code 2 Causes

50 01

Vertical resolution capability changed after compensation of background color.

1-48

Confidential

(6) ID checking

Code 1 Code 2 Causes

63 01

Password plus "lower 4 digits of telephone number" not compatible.

63 02 Password not correct.

63 03 Polling ID not correct.

(7) DCN reception

Code 1 Code 2 Causes

74 DCN received.

(8) TCF transmission/reception

Code 1 Code 2 Causes

80 01 Fallback impossible.

(9) Signal isolation

Code 1 Code 2 Causes

90 01

Unable to detect video signals and commands within 6 seconds after CFR is transmitted.

90 02 Received PPS containing invalid page count or block count.

(10) Image signal reception

Code 1 Code 2 Causes

A0 03

Error correction sequence not terminated even at the final transmission speed for fallback.

A0 11 Receive buffer empty. (5-second time-out)

A0 12 Receive buffer full during operation except receiving into memory.

A0 13 Decoding error continued on 500 lines or more.

A0 14 Decoding error continued for 10 seconds or more.

A0 15 Time-out: 13 seconds or more for one-line transmission.

A0 16 RTC not found or carrier OFF detected for 6 seconds.

A0 17 RTC found but no command detected for 60 seconds or more.

A0 19 No video data to be sent

A8 01 RTN, PIN, or ERR received at the calling terminal. *

A9 01 RTN, PIN, or ERR received at the called terminal. *

AA 18 Receive buffer full during receiving into memory.

* Available in German models only

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Confidential

(11) General communications-related

Code 1 Code 2 Causes

B0 02 Unable to receive the next-page data.

B0 03

Unable to receive polling even during turn-around transmission due to call reservation.

B0 04 PC interface error.

BF 01

BF 02

Communication canceled by pressing the Stop/Exit button before establishment of FAX communication*.

Communication canceled by pressing the Stop/Exit button after establishment of FAX communication*.

Transmission canceled due to a scanning error caused by no

BF 03

document or document feed problem in ADF scanning in real time transmission.

* Establishment of FAX communication:

FAX communication is established when the calling station receives a DIS (reception capability) signal from the called station and the called station receives a NSS or DCS (communications test) signal from the calling station.

(12) Maintenance mode

Code 1 Code 2 Causes

E0 01 Failed to detect 1300 Hz signal in burn-in operation.

E0 02 Failed to detect PB signals in burn-in operation.

(13) Equipment error

Code 1 Code 2 Causes

FF X

Equipment error

(For X X, refer to "2.1 Error indication")

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10. Troubleshooting of the control panel

■ Nothing is displayed on the LCD.

User Check

• Verify if the power switch is turned off.

Step Cause Check

Connection between main

PCB and control panel PCB

Connection between main

PCB and LVPS PCB unit

LCD Is the problem solved

Control panel

PCB

LVPS PCB unit Is the problem solved

Main PCB Is the problem solved

Are the main PCB and control panel PCB connected properly?

Are the main PCB and LVPS PCB unit connected properly?

after replacing the LCD?

Is the problem solved after replacing the control panel PCB?

after replacing the LVPS PCB unit?

after replacing the main PCB ASSY?

Result

Ye s

Remedy

Reconnect the connector properly.

Replace the LCD.

Replace the control panel PCB.

Replace the LVPS PCB unit.

Replace the main PCB ASSY.

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■ The control panel does not work.

Step Cause Check

Key sticking Is a key on the control

Connection between main

PCB and control

panel stuck?

Are the main PCB and control panel PCB connected properly?

panel PCB

Harness between main

PCB and control

Is the harness damaged?

panel PCB

Rubber Key Is the problem solved

after replacing the rubber key?

Control panel PCB

Is the problem solved after replacing the control panel PCB?

Main PCB Is the problem solved

after replacing the main PCB ASSY?

Result

Ye s

Remedy

Clean the panel cover, or remove the any burrs from the panel cover and panel keys.

Reconnect the connector correctly.

Replace the harness with a normal one.

Replace the rubber Key.

Replace the control panel PCB.

Replace the main PCB ASSY.

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11. Troubleshooting of fax functions

■ FAX can't be sent.

User Check

• Verify that the telephone cord is securely connected.

Step Cause Check

Dial mode Setting

Connection between main

PCB and NCU PCB

Connection between main

PCB and control panel PCB

Contact of rubber

keys

NCU PCB Is the problem solved

Control panel

PCB

Can a dialing signal (PB or DP) be heard normally in each mode? (Use telephone line emulator if required.)

Are the main PCB and NCU PCB connected correctly?

Are the main PCB and control panel PCB connected correctly?

Does the rubber keys work correctly?

after replacing the NCU PCB ASSY?

Is the problem solved after replacing the control panel PCB?

Result

Ye s

Remedy

Check the dialing mode setting at customer's again. Check the telephone line cord between machine and socket.

Reconnect the connector.

Replace the rubber Keys.

Replace the NCU PCB ASSY.

Replace the control panel PCB.

Main PCB Is the problem solved

after replacing the main PCB ASSY?

Replace the main PCB

Ye s

ASSY.

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■ Speed dialing and One-touch dialing can't be used.

Step Cause Check

Speed dialing keys or one-

touch dialing keys

Dial mode Setting

Connection between main

PCB and NCU PCB

Connection between main

PCB and control panel PCB

Contact of rubber

keys

NCU PCB Is the problem solved

Can a fax transmission be made using the numeric keys?

Can a dialing signal (PB or DP) be heard normally in each mode? (Use telephone line emulator if required.)

Are the main PCB and NCU PCB connected correctly?

Are the main PCB and control panel PCB connected correctly?

Is the problem solved after replacing the rubber keys?

after replacing the NCU PCB ASSY?

Result

Ye s

Remedy

Replace the main PCB ASSY.

Check the dialing mode setting at customer's again. Check the telephone line cord between machine and socket.

Reconnect the connector.

Replace the rubber Keys.

Replace the NCU PCB ASSY.

Control panel PCB

Is the problem solved after replacing the control panel PCB?

■ FAX can not be received.

User Check

• Verify that the telephone cord is securely inserted.

Step Cause Check

Receive mode

setting

NCU PCB Is the problem solved

Main PCB Is the problem solved

Is the receive mode set to automatic receive mode?

after replacing the NCU PCB ASSY?

after replacing the main PCB ASSY?

Ye s

Result

Ye s

Replace the control panel PCB.

Remedy

Set the receive mode to automatic receive mode.

Replace the NCU PCB ASSY.

Replace the main PCB ASSY.

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■ No ringing sound.

Step Cause Check

Ring delay Ring delay is set to "0".

Ring volume Ring volume is set to

Connection between main

PCB and NCU

"OFF".

Are the main PCB and NCU PCB connected correctly?

PCB

Speaker Is the problem solved

after replacing the speaker?

NCU PCB Is the problem solved

after replacing the NCU PCB ASSY?

Main PCB Is the problem solved

after replacing the main PCB ASSY?

Result

Ye s

Remedy

Change the ring delay settings to another value.

Change the ring volume setting to another value.

Reconnect the connector.

Replace the Speaker.

Replace the NCU PCB ASSY.

Replace the main PCB ASSY.

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■ Speaker is silent during on-hook dialing.

Step Cause Check

Connection between main

PCB and speaker

Speaker Is the problem solved

Connection between main

PCB and NCU PCB

Connection between main

PCB and control panel PCB

NCU PCB Is the problem solved

Main PCB Is the problem solved

Are the main PCB and speaker connected correctly?

after replacing the speaker?

Are the main PCB and NCU PCB connected correctly?

Are the main PCB and control panel PCB connected correctly?

after replacing the NCU PCB ASSY?

after replacing the main PCB ASSY?

Result

Ye s

Remedy

Reconnect the connector.

Replace the Speaker.

Reconnect the connector.

Replace the NCU PCB ASSY.

Replace the main PCB ASSY.

■ Dialing function does not switch between "tone" and "pulse".

Step Cause Check

Connection between main

PCB and NCU PCB

NCU PCB Is the problem solved

Main PCB Is the problem solved

Are the main PCB and NCU PCB connected correctly?

after replacing the NCU PCB ASSY?

after replacing the main PCB ASSY?

Result

Ye s

Reconnect the connector.

Replace the NCU PCB ASSY.

Replace the main PCB ASSY.

Remedy

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12. OTHERS PROBLEMS

■ The machine is not turned on, or the LCD indication does not appear.

Step Cause Check

Harness connection

failure of panel PCB

Panel PCB

failure

LCD failure Is the problem solved

LVPS PCB failure Is the problem solved

Main PCB failure Is the problem solved

Is the harness of the panel PCB ASSY connected correctly?

Is the problem solved after replacing the panel PCB ASSY?

after replacing the LCD?

after replacing the LVPS PCB unit?

after replacing the main PCB ASSY?

■ The fan does not work.

Step Cause Check

Harness connection

failure of the fan motor 60 ASSY.

Is the harness of the fan motor 60 ASSY connected correctly?

Result

Ye s

Result

Remedy

Reconnect the panel PCB ASSY harness.

Replace the panel PCB ASSY.

Replace the LCD.

Replace the LVPS PCB unit.

Replace the main PCB ASSY.

Remedy

Reconnect the harness of the fan motor 60 ASSY correctly.

Toner sensor

PCB failure

Main PCB failure Is the problem solved

Is the problem solved after replacing the toner sensor PCB ASSY?

after replacing the main PCB ASSY?

Replace the toner sensor

Ye s

PCB ASSY.

Replace the main PCB

Ye s

ASSY.

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■ Pickup function of paper tray does not work.

Step Cause Remedy

3 Roller holder ASSY failure Replace the roller holder ASSY.

4 Main motor failure Replace the main motor.

5 Main PCB failure Replace the main PCB ASSY.

Link arm not operating smoothly or catching.

Pickup roller holder ASSY not operating smoothly or catching.

■ The new toner is not detected.

Step Cause Remedy

2 New toner actuator damaged Replace the new toner actuator.

3 Main PCB failure Replace the main PCB ASSY.

New toner actuator does not operate smoothly or is catching.

New toner sensor harness ASSY failure

Make sure correct movemet of the link arm.

Make sure correct movement of the pickup roller holder ASSY.

Make sure correct movement of the new toner actuator.

Replace the new toner sensor harness ASSY.

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CHAPTER 2 PERIODICAL MAINTENANCE

To avoid creating secondary problems by mishandling, follow the warnings below during maintenance work.

WARNING

• Always turn off the power switch and unplug the power cord from the power outlet before accessing any parts inside the machine.

• When opening the front cover or back cover to access any parts inside the machine, never touch the shaded parts shown in the following figures.

1. CONSUMABLE PARTS

The consumable parts described in this section are parts which are subject to deterioration or damage and should be replaced at least once during the period of warranty of the product if any printing quality problem appears.

Parts Name Approximate Life

Toner Cartridge

Drum Unit Approx. 12,000 pages A4/Letter pages (1 page/job)

Approx. cartridge yield is declared in accordance with ISO/IEC 19752. (Letter/A4)

Starter cartridge

Standard cartridge

High yield cartridge

Approx. 1,000 pages A4/Letter pages *

Approx. 1,500 pages A4/Letter pages *

Approx. 2,600 pages A4/Letter pages *

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2. PERIODICAL PEPLACEMENT PARTS

There are no parts to be replaced periodically.

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CHAPTER 3 DISASSEMBLY AND ASSEMBLY

1. SAFETY PRECAUTIONS

To avoid creating secondary problems by mishandling, follow the warnings and precautions below during maintenance work.

WARNING

• Always turn off the power switch and unplug the power cord from the power outlet before accessing any parts inside the machine.

• When opening the front cover or back cover to access any parts inside the machine, never touch the shaded parts shown in the following figures.

• Be careful not to lose screws, washers, or other parts removed.

• Be sure to apply grease to the gears and applicable positions specified in this chapter.

• When using soldering irons or other heat-generating tools, take care not to accidentally damage parts such as wires, PCBs and covers.

• Before handling any PCBs, touch a metal portion of the equipment to discharge any static electricity charge on your body, or the electronic parts or components may be damaged.

• When transporting PCBs, be sure to wrap them in the correct protective packaging.

• When connecting or disconnecting cable connectors, hold the connector body, not the cables. If the connector has a lock, release the connector lock first to release it.

• After a repair, check not only the repaired portion but also all connectors. Also check that other related portions are functioning properly before operational checks.

• After disconnecting flat cables, check that each cable is not damaged at its end or shortcircuited.

• When connecting flat cables, do not insert them at an angle. After insertion, check that the cables are not at an angle.

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2. PACKING

AC cord

Line cord

Printed panel

cover

Printed panel cover

Accessory bag

Set guide DEMO Insertion

Option carton

Printed panel cover

Drum / Toner assy

Pad

Fig. 3-1

Machine

Pad

Carton

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3. SCREW TORQUE LIST

Location of screw Screw type Q’ty

JOINT COVER SUB CHUTE ASSY Taptite bind B M4x12 2 0.8±0.1 (8±1)

INNER CHUTE ASSY Taptite bind B M4x12 2 0.6±0.1 (6±1)

FUSER UNIT Taptite pan (washer) B

M4x14

CONER COVER / SIDE COVER L ASSY

SIDE COVER SUB L Taptite bind B M4x12 1 0.8±0.1 (8±1)

MAIN SHIELD COVER PLATE Taptite cup S M3x6 SR 1 0.9±0.05 (9±0.5)

FG are tightened together Taptite cup S M3x6 SR 2

ADF UNIT Taptite bind B M4x12 1 0.8±0.1 (8±1)

HINGE ARM Taptite bind B M4x12 1 0.8±0.1 (8±1)

HINGE ASSY L Taptite cup S M3x12 1 0.8±0.1 (8±1)

UPPER DOCUMENT CHUTE ASSY Taptite cup B M3x10 4 0.5±0.1 (5±1)

LOWER DOCUMENT CHUTE ASSY

DRIVE FRAME ASSY Taptite cup B M3x10 2 0.5±0.1 (5±1)

ADF harness unit (FG) Taptite cup S M3x6 SR 1 0.8±0.1 (8±1)

ADF MOTOR Taptite bind B M3x6 1 0.8±0.1 (8±1)

DOCUMENT DRESS COVER Taptite cup B M3x8 1 0.5±0.1 (5±1)

CORD HOOK Taptite cup B M3x8 2 0.5±0.1 (5±1)

PANEL UNIT Taptite cup B M3x10 4 0.5±0.1 (5±1)

PRINTED PANEL COVER Taptite cup B M3x8 4 0.4±0.1 (4±1)

NCU SHIELD Taptite bind B M4x12 2 0.8±0.1 (8±1)

NCU PCB Taptite cup S M3x6 SR 2 0.5±0.1 (5±1)

SPEARKER COVER Taptite bind B M4x12 1 0.8±0.1 (8±1)

SIDE COVER R ASSY Taptite bind B M4x12 2 0.8±0.1 (8±1)

MAIN PCB ASSY Taptite cup S M3x6 SR 4 0.6±0.1 (6±1)

JOINT COVER ASSY Taptite bind B M4x12 5 0.8±0.1 (8±1)

HIGH-VOLTAGE PS PCB ASSY Taptite cup S M3x6 SR 2 0.8±0.05 (8±0.5)

LASER UNIT

AIR DUCT Taptite cup S M3x6 SR 2 0.8±0.05 (8±0.5)

LV SHIELD PLATE COVER Screw pan (S/P washer)

Left side of Main frame and back of the reight side.

Front of the right side of Main frame

Taptite bind B M4x12

Taptite cup B M3x10 2 0.5±0.1 (5±1)

Screw pan (S/P washer) M3.5x6

Taptite bind B M4x12 2 0.8±0.05 (8±0.5)

Taptite cup S M3x6 SR

Taptite pan (S/P washer) S M3x8

M3.5x6

Taptite cup S M3x6 SR 2 0.5±0.05 (5±0.5)

Tightening torque

N m (kgf · cm)

20.8±0.1 (8±1)

30.8±0.1 (8±1)

0.55±0.05 (5.5±0.5)

10.5±0.05 (5±0.5)

30.8±0.05 (8±0.5)

10.8±0.05 (8±0.5)

10.5±0.05 (5±0.5)

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Location of screw Screw type Q’ty

Tightening torque

N m (kgf · cm)

SW HOLDER Taptite bind B M4x12 1 0.8±0.1 (8±1)

INLET HARNESS ASSY Screw pan (S/P washer)

M3.5x6

Taptite flat B M3x10 2

10.5±0.05 (5±0.5)

0.45±0.05 (4.5±0.5)

LVPS PCB UNIT Taptite cup S M3x6 SR 2 0.5±0.05 (5±0.5)

LV SHIELD PLATE 2 Taptite bind B M4x12 2 0.8±0.1 (8±1)

Back Side Taptite cup S M3x6 SR 1 0.6±0.1 (6±1)

Front chute ground plate side

Taptite cup S M3x6 SR

10.5±0.05 (5±0.5)

ACTUATOR HOLDER ASSY Taptite bind B M3x10 2 0.5±0.1 (5±1)

REGISTRATION FRONT SENSOR PCB ASSY

Taptite bind B M3x10

10.5±0.1 (5±1)

REAR ACTUATOR HOLDER ASSY Taptite bind B M3x10 2 0.5±0.1 (5±1)

REGISTRATION REAR SENSOR PCB ASSY

Taptite bind B M3x10

10.5±0.1 (5±1)

UNDER FG WIRE Taptite bind B M4x12 1 0.8±0.1 (8±1)

Taptite cup S M3x6 SR 1 0.8±0.05 (8±0.5)

DRIVE SUB ASSY Taptite cup S M3x6 SR 1 0.6±0.1 (6±1)

Taptite bind B M4x12 9 0.8±0.1 (8±1)

TONER SENSOR HARNESS ASSY Taptite bind B M3x10 1 0.5±0.1 (5±1)

REGISTRATION SOLENOID Taptite bind B M3x10 1 0.5±0.1 (5±1)

T1 SOLENOID Taptite bind B M3x10 1 0.5±0.1 (5±1)

FU FRONT PAPER GUIDE Taptite bind B M3x10 3 0.5±0.1 (5±1)

CHUTE GROUND PLATE Taptite cup S M3x6 SR 2 0.6±0.1 (6±1)

MAIN SHIELD PLATE Taptite bind B M4x12 3 0.8±0.1 (8±1)

MAIN FRAME L ASSY Taptite bind B M4x12 4 0.8±0.1 (8±1)

Taptite cup S M3x6 SR 2 0.7±0.1 (7±1)

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4. LUBRICATION

The kind of the lubricating oil

(Maker name)

FLOIL BG-MU (Kanto Kasei)

MOLYKOTE EM-D110 (Dow Corning Toray)

FLOIL GE-676 (Kanto Kasei)

BG2

2 places

Lubrication point Quantity of lubrication

Dev gear joint/53R Drive sub ASSY

2mm dia. ball

BG2

Drum gear 25L/139L

Separation pad ASSY 2mm dia. ball

EM2

LF roller ASSY Ejection roller ASSY

2mm dia. ball

GE2

Drive frame ASSY

BG2

4 places

DEV gear joint / 53R

BG2

2 places

Drum gear 25L/139L

BG2

4 places

BG2

24 places

Drive sub ASSY

BG2: KLOIL BG-MU (2mm dia. ball)

Fig. 3-2

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Paper tray unit

EM2

2 places

Separation pad ASSY

EM2

4 places

EM2: MOLYKOTE EM-D110 (2mm dia. ball)

Paper tray unit

EM2: MOLYKOTE EM-D110 (2mm dia. ball)

CAUTION:

Be careful not to let lubricants touch the opposite side of the Separation pad ASSY.

Fig. 3-3

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GE2

1 places

Conductive bushing

GE2

1 places

Conductive bushing

LF roller ASSY

Ejection roller ASSY

2 places

GE2

2 places

GE2: FLOIL GE-676 (2mm dia. ball)

GE2

2 places

Drive frame ASSY

Fig. 3-4

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5. OVERVIEW OF GEARS

EJECTOR GEAR 15/25

(LU2018001)

EJECTOR GEAR 17

(LU2016001)

FUSER GEAR 22/37

EJECTOR GEAR 26

(LU2017001)

DEV GEAR 17/18R/47R

(LU2053001)

(LU2015001)

REGISTRATION GEAR

27 PENDULUM

(LU2048001)

DEV GEAR 17/33L

(LU2054001)

REGISTRATION GEAR 19

(LU2047001)

REGISTRATION DIFFERENTIAL

GEAR ASSY (LU2049001)

FEEDER GEAR 17/22

(LU2043001)

FEEDER GEAR 26/20

P/P GEAR 29 SECTOR

(LU2045001)

T1 GEAR 38/31 SECTOR

(LU2042001)

(LU2044001)

Fig. 3-5

CAUTION:

The part codes of gears are subject to change without notice.

( ) is part code.

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6. HARNESS ROUTING

1 ADF motor, ADF sensor PCB ASSY to Main PCB ASSY

ADF motor

ADF sensor PCB ASSY

Main PCB ASSY

Main PCB Shield plate

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2 NCU PCB, Battery ASSY, Speaker unit ASSY to MAIN PCB ASSY

NCU PCB

Main PCB ASSY

3 Document scanner unit, Panel PCB ASSY

Battery ASSY

Speaker unit ASSY

Main PCB ASSY

Main shield cover plate

Document scanner unit

3-10

Panel PCB ASSY

Confidential

4 FUSER UNIT

Eject sensor PCB ASSY

PS PCB unit

5 FG HARNESS

Fuser unit

Laser unit

Main PCB ASSY

3-11

FG harness

Confidential

6 MAIN FRAME R ASSY

Cover sensor harness ASSY

Wireless LAN PCB ASSY (only MFC7840W) / Toner LED PCB ASSY / LVPS PCB unit / Main PCB ASSY

Toner LED PCB ASSY Fan motor 60 unit

PS PCB unit SW holder Inlet harness ASSY

Wireless LAN PCB ASSY

(only MFC7840W)

Main PCB ASSY (Main Frame L ASSY)

Toner LED PCB ASSY

3-12

PS PCB unit

Confidential

TONER LED PCB ASSY / REGISTRATION FRONT SENSOR PCB ASSY / REGISTRATION REAR SENSOR PCB ASSY

Toner LED PCB ASSY

Registration rear sensor PCB ASSY

Registration front sensor PCB ASSY

9 TONER SENSOR PCB UNIT ASSY / NEW TONER SENSOR HARNESS ASSY

New toner sensor

harness ASSY

Main PCB ASSY

Toner sensor PCB unit ASSY

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10 HIGH-VOLTAGE PS PCB / REGISTRATION SOLENOID / T1 SOLENOID

Drive sub ASSY

Registration solenoid

High-voltage PS PCB ASSY

T1 solenoid

T1 solenoidRegistration solenoid

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7. DISASSEMBLY FLOW

FRONT COVER

ASSY

00s/00s

ROLLER HOLDER

ASSY

00s/00s

FAN MOTOR 60

UNIT

00s/00s

COVER SENSOR

HARNESS ASSY

00s/00s

CORNER

COVER

00s/00s

SIDE CO VER R

ASSY

00s/00s

SIDE CO VER L

ASSY

00s/00s

JOINT COVER

ASSY

00s/00s

FILTER ASSY

00s/00s

MAIN SHIELD

COVER PLATE

00s/00s

INNER CHUTE

ASSY

00s/00s

FUSER UNIT

00s/00s

ADF UNIT

00s/00s

BACK COVER

00s/00s

FUSER COVER

ASSY

00s/00s

OUTER

CHUTE ASSY

00s/00s

EJECT ACTUATOR SPRING / EJECT

ACTUATOR

00s/00s

DOCUMENT

SCANNER UNIT

00s/00s

SPEAKER /

BATTERY

00s/00s

RUBBER FOOT

00s/00s

SEPARATION PAD

ASSY / SEPARATION

PAD SPRING

00s/00s

EJECT ROLLER

ASSY 1 / BUSH

00s/00s

NCU PCB

00s/00s

TONER LED

PCB ASSY/

LED HOLDER

00s/00s

WIRELESS LAN

PCB

ASSY

00s/00s

LVPS PCB

UNIT

00s/00s

LV SHIELD

PLATE 2

00s/00s

REGISTRATION FRONT

SENSOR PCB ASSY

00s/00s

LASER UNIT

00s/00s

MAIN FRAME

L ASSY

00s/00s

REGISTRATION REAR

SENSOR PCB ASSY

00s/00s

TONER SENSOR

PCB UNIT ASSY

HIGH-VOLTAGE

PS PCB ASSY

00s/00s 00s/00s

DRIVE SUB

DEV JOINT

DEV GEAR

00s/00s

JOINT / 53R

MAIN PCB A SSY

ASSY

00s/00s

REGISTRATION

00s/00s 00s/00s

SOLENOID

T1 SOLENOID

00s/00s00s/00s

MAIN SHIELD

PLATE

00s/00s

EJECT

SENSOR PCB

00s/00s

Fig. 3-6

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8. DISASSEMBLY PROCEDURE

■ Preparation

Prior to proceeding with the disassembly procedure,

(1) Unplug

• the AC cord,

• the modular jack of the telephone line,

• the USB cable, if connected,

• the LAN cable, if connected,

• the modular jack of the external telephone set if connected.

(2) Remove

•the Paper tray,

• the Toner cartridge and Drum unit

USB I/F cable

LAN cable

Telephone line cord

AC cord

Drum/Toner unit

Paper tray unit

Fig. 3-7

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8.1 SEPARATION PAD ASSY

(1) Lift up the Separation pad ASSY.

(2) Release the Boss to remove the Separation pad ASSY from the Paper tray unit.

(3) Remove the Separation pad spring from the Paper tray unit.

Separation pad ASSY

2a 2a

Paper tray ASSY

Separation pad spring

Boss

Paper tray ASSY

Fig. 3-8

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8.2 FRONT COVER ASSY

8.2.1

FRONT COVER ASSY

(1) Open the Front cover ASSY.

(2) Release the Hook to remove the DEV joint link from the Front cover ASSY.

DEV joint link

Hook

Fig. 3-9

3-18

Front cover ASSY

Confidential

(3) Release the Hook of the Front cover ASSY from the Front cover top.

(4) Remove the Boss of the Front chute ASSY, and then remove the Front cover ASSY from

the Main body.

Front chute ASSY

Boss

(Front chute ASSY)

Front cover top

Hook

Boss

(Front chute ASSY)

Front cover ASSY

Front cover top

Front cover ASSY

Front chute ASSY

Boss

Fig. 3-10

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8.2.2

PAPER STOPPER L / PAPER STOPPER S

(1) Release the Boss to remove the Paper stopper L from the Front cover ASSY.

(2) Release the Boss to remove the Paper stopper S from the Paper stopper L.

Paper stopper L

Paper stopper S

2a 2a

Paper stopper S

Boss

Paper stopper L

Boss

1b 1b

Front cover ASSY

Paper stopper L

Fig. 3-11

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8.3 BACK COVER / OUTER CHUTE ASSY

8.3.1

BACK COVER

(1) Open the Back cover.

(2) Release the Boss of the Outer chute ASSY from the Back cover.

(3) Release the Hook from the Side cover R ASSY.

(4) Slide the Back cover from the Main body, and remove it.

Boss

Outer chute ASSY

Boss

Side cover R ASSY

Boss

Hook

Boss

Back cover

Outer chute ASSY

Back cover

Fig. 3-12

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8.3.2

OUTER CHUTE ASSY

(1) Release the Boss to remove the Outer chute ASSY from the Main body.

Boss (Fuser cover ASSY)

Outer chute ASSY

1a1a

Fig. 3-13

Outer chute ASSY

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Xerox DCP-7030, DCP-7040, DCP-7045N, MFC-7320, MFC-7340 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

PREFACE

TABLE OF CONTENTS

REGULATION

SAFETY INFORMATION

CHAPTER 1 TROUBLESHOOTING

1. INTRODUCTION

1.1 Precautions

1.2 Part names

1.3 Initial Check

2. ERROR CAUSE

2.1 Error indication

2.2 Error Code Cause and Remedy

2.2.1 Recoverable User Check Errors

2.2.2 Service Call Error

3. PAPER FEEDING PROBLEMS

3.1 No Feeding

3.2 Double Feeding

3.3 Paper Jam

3.4 Dirt on Paper

3.5 Wrinkles or creases

3.6 Waves in the paper / folds in the paper at the eject roller 2

3.7 Curl in the paper

4. TROUBLESHOOTING OF DOCUMENT FEEDING

4.1 No Feeding

4.2 Double feeding

4.3 Paper Jam

5. IMAGE DEFECT TROUBLESHOOTING (Defect Of the Print)

5.1 Image Defect Examples

5.2 Diameter of Rollers

5.3 Troubleshooting Image Defect

6. TROUBLESHOOTING OF SCANNIG

6.3 Print of the scanning document is light or dark

6.4 Vertical streaks (White or Black vertical streaks)

6.5 Poor fixing

6.6 Image distortion

7. SOFTWARE SETTING PROBLEMS

8. NETWORK PROBLEMS

9. TROUBLESHOOTING OF THE COMMUNICATIONS ERROR

10. Troubleshooting of the control panel

11. Troubleshooting of fax functions

12. OTHERS PROBLEMS

CHAPTER 2 PERIODICAL MAINTENANCE

1. CONSUMABLE PARTS

2. PERIODICAL PEPLACEMENT PARTS

CHAPTER 3 DISASSEMBLY AND ASSEMBLY

1. SAFETY PRECAUTIONS

2. PACKING

3. SCREW TORQUE LIST

4. LUBRICATION

5. OVERVIEW OF GEARS

6. HARNESS ROUTING

7. DISASSEMBLY FLOW

8. DISASSEMBLY PROCEDURE

8.1 SEPARATION PAD ASSY

8.2 FRONT COVER ASSY

FRONT COVER ASSY

PAPER STOPPER L / PAPER STOPPER S

8.3 BACK COVER / OUTER CHUTE ASSY

BACK COVER

OUTER CHUTE ASSY