Xerox DCP-7030, DCP-7040, DCP-7045N, MFC-7320, MFC-7340 Service Manual
...
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
Confidential
© Copyright Brother Industries, Ltd. 2008
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.
Confidential
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.
i
Confidential
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”.
ii
Confidential
TABLE OF CONTENTS
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
iii
Confidential
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
iv
Confidential
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
v
Confidential
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
vi
Confidential
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
vii
Confidential
REGULATION
<For Europe and Other countries>
■ 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.
viii
Confidential
■ 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)
ix
Confidential
<For USA and Canada>
■ 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.
x
Confidential
■ 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
xi
Confidential
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.
<Location of the laser beam window>
■ 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.
xii
Confidential
■ 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.
xiii
Confidential
■ 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.
xiv
Confidential
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.
xv
Confidential
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
xvi
Confidential
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.
1-1
Confidential
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
1-2
Confidential
■ 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
1-3
Confidential
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.
1-4
Confidential
(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.
1-5
Confidential
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
50
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
58
(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
5B
malfunction
63
Toner cartridge is at the end of life.
Toner of the toner cartridge is
67
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
72
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
79
temperature thermistor
No detection of main motor lock
7A
signal
1-13 F8 Battery connection failure 1-21
1-13 F9
Maintenance mode 74 Non-
decision
1-22
to:
1-6
Confidential
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.
1-7
Confidential
■ 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
1
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
1
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.
1-8
Confidential
■ 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
1
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
1
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.
1-9
Confidential
■ 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.
1
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.
2
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.
3
4
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.
1-10
Confidential
■ 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
1
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.
Confidential
■ 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
1
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
1
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.
1-12
Confidential
Loading...