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LASER PRINTER
SERVICE MANUAL
MECHANICS & ELECTRONICS
PREFACE
This service manual contains basic information required for after-sales service of the laser printer (herein-after referred to as "this machine" or "the printer"). This information is vital to the service technical in maintaining the high printing quality and performance of the printer. This service manual covers both HL-630 / HL-631/ HL-641,645 / 650 / 655M. This manual consists of the following chapters:
CHAPTER I
:
FEATURES AND SPECIFICATIONS
Features, specifications, and operation. CHAPTER II : THEORY OF OPERATION
Basic operation of the mechanical system, the electrical system and the electrical circuit, and their timing. CHAPTER III : DISASSEMBLY AND REASSEMBLY
Procedures of disassembling and reassembling the mechanical system. CHAPTER IV : TROUBLESHOOTING
Reference values and adjustment, troubleshooting for image defects, troubleshooting for malfunctions, etc.
Information in this manual is subject to change due to improvement or re-design of the product. All relevant information in such cases will be supplied in service information bulletins (Technical Information). A through understanding of this printer, based on information on this service manual and service information bulletins, is required for maintaining its quality performance and fostering the practical ability to find the cause of troubles.
CONTENTS
CHAPTER I
1 2 FEATURES
FEATURES AND SPECIFICATIONS
..................................................................................................................... I-1
3
SPECIFICATIONS ............................................................................................................... I-2 2.1 Printing ..................................................................................................................... I-2 2.2 Functions ................................................................................................................... I-2 2.3 Electrical and Mechanical .......................................................................................... I-2 2.4 Paper Specification .................................................................................................... I-4 2.5 Print Delivery .............................................................................................................. I-4 2.6 Paper ..................................................................................................................... I-4 2.7 Effective Printing Area ................................................................................................ I-5 SAFETY INFORMATION ..................................................................................................... I-7 3.1 Laser Safty (110 - 120V Model only) ......................................................................... I-7 3.2 CDRH Regulations (110 - 120V Model only) ............................................................. I-7 3.3 Caution for Laser Product .......................................................................................... I-8
CHAPTER II
1
THEORY OF OPERATION
2
ELECTRONICS .................................................................................................................. II-1 1.1 General Block Diagram ............................................................................................. II-1 1.2 Main PCB Block Diagram .......................................................................................... II-2 1.3 Main PCB .................................................................................................................. II-3 1.3.1 CPU ............................................................................................................ II-3 1.3.2 ASIC ........................................................................................................... II-4 1.3.3 ROM ........................................................................................................... II-7 1.3.4 RAM ............................................................................................................ II-7 1.3.5 Optional RAMs ............................................................................................ II-8 1.3.6 Optional Serial I/O ....................................................................................... II-8 1.3.7 EFPROM .................................................................................................... II-9 1.3.8 Reset Circuit ............................................................................................... II-9 1.3.9 CDCC I/O .................................................................................................... II-9 1.3.10 Engine I/O ................................................................................................. II-10 1.4 Driver PCB .............................................................................................................. II-11 1.4.1 Paper Feed Motor Drive Circuit ................................................................ II-11 1.4.2 Solenoid (Pick-up,Clutch), Erase Lamp, Fan Motor Drive Circuit ............ II-11 1.4.3 Operation Panel ........................................................................................ II-12 1.4.4 Scanner Motor, Laser Sensors(Registration, Paper Eject, Toner), Thermistor, High-voltage Power Supply ................................................... II-12 1.5 Power Supply .......................................................................................................... II-13 MECHANICS .................................................................................................................. II-14 2.1 Overview of printing mechanism .............................................................................II-14 2.2 Paper Transfer ........................................................................................................ II-15 2.2.1 Paper Supply ............................................................................................ II-15 2.2.2 Paper Registration .................................................................................... II-15 2.2.3 Paper Eject ............................................................................................... II-16 2.3 Sensors .................................................................................................................. II-17 2.3.1 Multi Purpose Tray (MPT) Sensor ............................................................ II-17 2.3.2 Cover Sensor ............................................................................................ II-17 2.3.3 Toner Empty Sensor ................................................................................. II-17 2.4 Process Unit ............................................................................................................ II-18 2.4.1 Photosensitive Drum ................................................................................. II-18 2.4.2 Primary Charger ........................................................................................ II-18 2.4.3 Developer Roller ....................................................................................... II-18 2.4.4 Transfer Roller .......................................................................................... II-18 2.4.5 Cleaner Blade ........................................................................................... II-18
i
2.5
2.4.6 Toner Auger .............................................................................................. II-18 2.4.7 Erase Lamp .............................................................................................. II-18 Print Process ........................................................................................................... II-18 2.5.1 Charging ................................................................................................... II-18 2.5.2 Exposure Stage ........................................................................................II-19 2.5.3 Developing ................................................................................................ II-20 2.5.4 Transfer .................................................................................................... II-20 2.5.5 Drum Cleaning Stage ................................................................................II-21 2.5.6 Erasing Stage ........................................................................................... II-21
CHAPTER III
1 2 3
DISASSEMBLY AND REASSEMBLY
SAFETY PRECAUTIONS ................................................................................................. III-1 DISASSEMBLING FLOW .................................................................................................. III-2 DISASSEMBLING PROCEDURE .....................................................................................III-3 3.1 Multi-purpose Paper Tray .........................................................................................III-3 3.2 Process Unit ............................................................................................................. III-3 3.3 Top Cover ................................................................................................................ III-4 3.4 Main Cover ............................................................................................................... III-5 3.5 Upper Shoot Cover .................................................................................................. III-6 3.6 Fixing Unit ................................................................................................................ III-6 3.7 Scanner Unit ............................................................................................................ III-7 3.8 Fan Guard ................................................................................................................ III-7 3.9 Interlock Levers ........................................................................................................ III-8 3.10 Fan Motor ................................................................................................................. III-8 3.11 Registration Sensor PCB .........................................................................................III-8 3.12 Solenoid P ................................................................................................................ III-9 3.13 Gear Shaft Plate ...................................................................................................... III-9 3.14 Gears ................................................................................................................. III-10 3.15 Main Motor Unit ...................................................................................................... III-11 3.16 Solenoid C ............................................................................................................. III-11 3.17 Main PCB ............................................................................................................... III-12 3.18 Base Plate .............................................................................................................. III-12 3.19 Driver PCB ............................................................................................................. III-14 3.20 Power Supply PCB ................................................................................................. III-14 3.21 High-voltage Power Supply ....................................................................................III-15 3.22 Tray Extention ........................................................................................................ III-15 3.23 Paper Eject Tray .................................................................................................... III-16 3.24 Filter Cover ............................................................................................................ III-16 PACKING ................................................................................................................. III-17
4
CHAPTER IV
1
TROUBLE SHOOTING
2
3 4
INTRODUCTION ............................................................................................................... IV-1 1.1 Initial check ............................................................................................................. IV-1 1.2 Basic Procedure ...................................................................................................... IV-2 IMAGE DEFECTS ............................................................................................................. IV-3 2.1 Image Defect Example ............................................................................................ IV-3 2.2 Troubleshooting Image Defect ................................................................................ IV-4 TROUBLESHOOTING OF MALFUNCTIONS ................................................................ IV-12 INSPECTION MODE ...................................................................................................... IV-17 4.1 Inspection mode 1 ................................................................................................. IV-17 4.2 Inspection Pattern 1 .............................................................................................. IV-17 4.3 Inspection mode 2 ................................................................................................. IV-19 4.4 Initialization of NV-RAM ........................................................................................ IV-19 4.5 Error codes ........................................................................................................... IV-20
ii
CHAPTER I
1 FEATURES
FEATURES AND SPECIFICATIONS
This printer has the following features: 300dpi Resolution and 6ppm Printing Speed 300 dots per inch (dpi) with microfine toner and six pages per minute (ppm) printing speed (Letter paper). Versatile Paper Handing The printer has a multi-purpose sheet feeder and straight paper path mechanism. Using this mechanism, you can load A4, letter, legal, B5, A5 and executive size of paper, and various types of paper including envelopes, postcard, organizer paper, and your custom paper size. The multi-purpose sheet feeder also allows manual paper loading, so you can also use labels. Remote Printer Console Program for DOS The utility program, Remote Printer Console, is available on the floppy disk supplied with your printer. When you operate your computer in the DOS (Disk Operating System) environment, this allows you to easily change the default setting of the printer such as fonts, page setup, emulations and so on. This program also provides a status monitor program, which is a Terminate-and-Stay Resident (TSR) program. It can monitor the printer status while running in the background and report the current status or errors on your computer screen. Popular Printer Emulation Support This printer supports three printer emulation modes, HP LaserJet IIP, Epson FX-850, and IBM Proprinter XL. When you use DOS application software or WindowsTM version 3.0 or earlier, you can use any of these emulations to operate the printer. The printer also supports Auto-emulation switching between HP and Epson or HP and IBM. If you want to fix the printer emulation, you can do it using the Remote Printer Console Program. Bi-Directional Parallel Interface The parallel interface of this printer allows bi-directional communication with a computer. This interface allows the printer to communicate back to the computer useful information such as the amount of memory installed, and other printer setup conditions. As the supplied Remote Printer Console program or WindowsTM 3.1 driver supports the bi-directional mode, they can both report the printer status. Optional Macintosh Interface (Standard in some countries) The optional Macintosh serial interface kit is available with a driver, which allows your printer to be connected to Macintosh computers. With this option, you can use your printer with both an IBM PC, or its clone, and a Macintosh at the same time. This optional interface board can be used as a RS-422A interface for Macintosh or a RS-232C serial interface for IBM PC or compatible. Enhanced Memory Management The printer has it's own data Compression Technology, which can automatically compress graphic data and downloaded font data efficiently into the printer memory . You can avoid memory errors and print most fullpage 300 dpi graphic and text data, including large fonts, with printer's standard memory.
I-1
2
2.1
SPECIFICATIONS
Printing Print Method Resolution Print Speed Warm-Up First Print Print Media Electrophotography by semiconductor laser beam scanning 300 dots/inch 6 page/minute (when loading Letter-size paper from the multipurpose sheet feeder) Max. 1 minute at 23°C (73.4°F) 20 seconds (when loading Letter-size paper from the multipurposesheet feeder) Toner in a cartridge Life Expectancy: 3,000 pages/cartridge (when printing A4 or letter -size paper at 4% print coverage) Drum unit, separated from toner cartridge (when printing A4 or letter -size paper at 4% print coverage in continuous printing.) Acceptable True TypeTM-compatible soft-fonts for WindowsTM on supplied disk
Developer Download Fonts True Type Fonts on disks
2.2
Functions CPU Emulation Printer Driver
MC68EC000 16 MHz Automatic emulation selection among HP LaserJet IIP, EPSON FX-850, and IBM Proprinter XL WindowsTM 3.1 driver, supporting Brother Native Compression mode and bi-directional capability. Optional Macintosh® QuickDraw driver (Standard in some countries.) Bi-directional Centronics parallel. RS-422A/RS-232C serial interface is optionally available. (The serial interface is a standard in some countries.) 1.0 or 2.0 MB (subject to the printer model) with Data Compression Technology. Expandable up to 2.0 MB with the optional memory board. 2 switches and 4 lamps Self-diagnostic program
Interface
Memory
Control Panel Diagnostics
2.3
Electrical and Mechanical Power Source Power Consumption
U.S.A. and Canada : Europe and Australia: Printing: Standing by: Sleep: Printing: Standing by:
AC 110 to 120 V, 60Hz AC 220 to 240 V, 50Hz
Noise
480 W or less 60 W or less 10 W or less 50 dB A or less 38 dB A or less
I-2
Temperature Humidity Dimensions (W x H x D)
Operating: Storage: Operating: Storage:
10 to 32.5°C (59 to 90.5°F) 0 to 40° C (38 to 104°F) 20 to 80% (without condensation) 20 to 80% (without condensation)
357(W) 351(D) 192(H) mm (when the output tray is closed and the Multi-purpose sheet
I-3
2.4
Paper Specification (1) Multi-purpose tray loading Paper size: A4, Letter, Legal, B5, A5, and Executive, and other sizes of paper that can be handled by the feed mechanism, can be loaded.
90 to 216 mm
148 to 356 mm (face down)
Feeding direction
Feedable paper type Maximum load height Envelopes Setting method
: : : :
60 (16 lb.) to 135 (36 lb.)g/m2 22 mm (200 sheets of 75 g/m2 paper) letter size 10 envelopes Pull the manual paper tray toward you, insert the sheaf of paper into the tray, alining the top edge of the sheets, then push the tray back to its original position.
(2) Manual paper loading The manual paper loading takes priority of feeding and a single sheet of paper can be fed into the printer. The applicable sizes and types of paper are the same as the multi-purpose tray loading above in specification. 2.5 Print delivery (1) At the print delivery tray opened Tray capacity : Maximum 100 sheets (75g/m2), face-down only (2) At the print delivery tray closed Tray capacity : 1 sheet (75 g/m2), face-down only
Note)
Face down : Environment :
Deliver the printed face of the paper downward. 23°C
2.6
Paper (1) Types of paper (a) Normal paper (60 to 135 g/m2, specified types of high-quality paper) · · · · · · * A4 size Letter size Legal size B5 size A5 size Executive size
The specified types of plain paper are as follows: Letter : Xerox 4024 (75 g/m2) A4 : Mitsubishi PPC paper (64 g/m2), Multi Copy (80 g/m2)
I-4
(b) Special paper (specified types) · · · · Labels Envelopes (DL, C5, COM10) Postcards Organizers (K, L, and M sizes of DAY-TIMERS)
(2) Paper feed conditions
Type Normal paper (cut sheet)
Name 60 to 135 g/m2 paper Labels
Tray feed
Manual feed
Special paper (cut sheet)
Envelopes Postcards Organizers
2.7
Effective printing area Printable area E A C F E
B
D
F The effective printing area means the area within which the printing of all the data received without any omissions can be guaranteed.
I-5
The table below shows the effective printing areas.
SIZE A4 A
210.0mm (2,480 dots) 215.9mm 8.5" (2,550 dots) 215.9mm 8.5" (2,550 dots) 182.0 mm 184.15mm 7.25" (2,175 dots) 148.5mm (1,754 dots) 95.25mm 3.75" (1,125 dots) 139.7mm 5.5" (1,650 dots) 104.78mm 4.125" (1,237 dots) 98.43mm 3.875" (1,162 dots) 162mm (1,913 dots) 110mm (1,299 dots)
B
297.0mm (3,507 dots) 279.4mm 11.0" (3,300 dots) 355.6mm 14.0" (4,200 dots) 257.0 mm 266.7mm 10.5" (3,150 dots) 105.0mm (1,240 dots) 171.45mm 6.75" (2,025 dots) 215.9mm 8.5" (2,550 dots) 241.3mm 9.5" (2,850 dots) 190.5mm 7.5" (2,250 dots) 229mm (2,704 dots) 220mm (2,598 dots)
C
203.2.0mm (2,400 dots) 207.5mm 8.0" (2,400 dots) 207.5mm 8.0" (2,400 dots) 173.5 mm 175.7mm 6.92" (2,400 dots)
D
288.5mm 11.36" (3,408 dots) 288.5mm 10.67" (3,200 dots) 288.5mm 10.67" (3,200 dots) 248.5 mm 258.2mm 10.17" (3,200 dots)
E
3.4mm (40 dots) 6.35mm (75 dots)
F
4.23mm (50 dots)
Letter Legal
B5
6.01mm (71 dots) 6.35mm (75 dots)
Executive
A5
Organizer (K size) Organizer (L size) COM-10
(1,654 dots) 86.78mm 3.42" (1,025 dots) 131.23mm 5.17" (1,550 dots)
(1,140 dots) 162.98mm 6.42" (1,925 dots) 207.43mm 8.17" (2,450 dots)
MONARCH
C5 DL
6.01mm (71 dots)
(Note that the paper sizes indicated here should conform to the nominal dimensions specified by JIS.) A4 paper must accommodate 80 characters printed in pica pitch (203.2 mm).
I-6
feeder is removed.) Weight Approx. 7kg (15.4 lb.)
3
3.1
SAFETY INFORMATION
Laser Safety (110 - 120V Model only) This printer is certified as a Class 1 laser product under the US Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968. This means that the printer dose not produce hazardous laser radiation. Since radiation emitted inside the printer is completely confined within the protective housings and external covers, the laser beam cannot escape from the machine during any phase of user operation.
3.2
CDRH Regulations (110 -120 V Model only) The Center for Device and Radiological Health (CDRH) of the US Food and Drug Administration implemented regulations for laser products on August 2, 1976. These regulations apply to laser products manufactured from August 1, 1976. Compliance is mandatory for products marketed in the United States. The label shown below indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States.
MANUFACTURED : BROTHER INDUSTRIES, LTD. 15-1, Naeshiro-cho, Mizuho-ku Nagoya 467, Japan. This product conforms with CDRH radiation performance standard 21 CFR chapter 1 subchapter J. Fig. 1.1
K
I-7
3.3
Caution for Laser Product (1) CAUTION: When the machine during serving is operated with open cover, the regulations of VBG 93 and the performance instructions for VBG 93 are valid. (2) CAUTION: In case of any trouble with the laser unit, please replace the laser unit itself. To prevent direct exposure to the laser beam, do not try to open the enclosure of laser unit.
(3) Location of the Exit Opening of Laser Beam.
Scanner unit
Fig. 1.2 (4) Location of Caution Label for Laser Product.
Y-BSMXL0.33
CLASS 1 LASER PRODUCT APPAREIL A LASER DE CLASSE 1 LASER KLASSE 1 NACH IEC825
UH0741
`
Fig. 1.3
I-8
Y-BSMXL0.34
CHAPTER II
1.
1.1
THEORY OF OPERATION
ELECTRONICS
General Block Diagram Fig. 2.1 shows a general block diagram of this printer.
Optional RAM board (1.0, 1.5 MB)
Optional I/F board (Mac. RS-232C)
Control system Expansion memory I/O Expansion I/O
Low-voltage power supply block
Interface block Video control block
Engine control block Operation block
High-voltage power supply block
(Operation panel)
Drive block Laser scanner unit (Stepping motor)
Paper tray unit Paper tray
Drum unit Transfer block
Manual feed
Fixing unit Developing block Drum Cleaner block
Charging block
Eraser lamp
Paper eject block
Paper feed system Toner cartridge
Image generation system
Fig. 2.1 General Block Diagram II - 1
External device
External device
1.2
Main PCB Block Diagram Fig. 2.2 shows a block diagram of the main PCB.
A S I C CPU RESET CIRCUIT (MC68EC000) BUS INT OSCILLATOR (15.3MHz)
ADDRESS DECODER PROGRAM + FONT ROM 512 KByte DRAM CONTROL
TIMER RAM (0.5M or 1M Byte) FIFO
OPTION RAM (0.5M or 1M Byte) CDCC PARALLEL I/O
OPTION SERIAL I/O (RS232C & RS422A)
SOFT SUPPORT
EEPROM (128
8 bit)
EEPROM I/O
ENGINE CONTROL I/O
TO DRIVER PCB
Fig. 2.2 Main PCB Block Diagram
II - 2
1.3
Main PCB 1.3.1 CPU The CPU is a Motorola MC68EC000FN16 which is driven with a clock frequency of 15.3 MHz. This clock frequency is made by dividing the source clock of 30.67 MHz into two. The address bus is 23 bits of A1 to A23, and the data bus is 16 bits. The total memory space is 16 MBytes.
NC 22 ( ( ( 05) RESET -05F) SCLK -05E) DTACK ( -05F) BR
(
+5V -05F) AVEC
#2 MC68EC000FN16 14 VCC NC 15 VCC 21 53 RESET VCC 20 HALT 1 16 CLK CND 11 17 DTACK CND 18 CND 13 35 BR CND 57 CND 24 BERR 23 12 AVEC BC 27 26 25 30 29 28 19 7 10 8 9
+5V
14 14
0V BC ( -04C)
( ( (
-05F) IPL0 -05F) IPL1 -05F) IPL2 NC A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23
IPL0 IPL1 IPL2
FC0 FC1 FC2
FC0 ( FC1 ( FC2 (
-05F) -05F) -05F)
31 32 33 34 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 54 55 56
A0 MODE A1 AS A2 R/W A3 UDS A4 A5 LDS A6 A7 D0 A8 A9 D1 D2 A10 D3 A11 D4 A12 D5 A13 A14 D6 D7 A15 D8 A16 A17 D9 A18 D10 A19 D11 A20 D12 D13 A21 D14 A22 A23 D15
+5V AS R/W UDS LDS D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 ( ( ( ( -04C) -04C) -04C) -04C)
6 5 4 3 2 68 67 66 65 64 63 62 61 60 59 58
<01> ( <07> (
-04C) ( -11B) (
-08B) -11D) (02-09B)
<02> ( <08> (
-11D) (02-08B) -11B) ( -11D)
Fig. 2.3
II - 3
1.3.2
ASIC (1) Oscillator circuit Generates the main clock for the CPU by deviding the source clock frequency into two. (2) Address decoder Generates the CS for each device. (3) DRAM control Generates the RAS, CAS, WR, OE and MA signals for the DRAM and controls refresh processing (CAS before RAS self-refreshing method). (4) Interrupt control Interrupt levels: Priority High 7 NMI 6 FIFO 5 Timer1 4 BD 3 EXINT (Option Serial I/O) 2 CDCC Low 1 Timer2 (5) Timers The following timers are incorporated: Timer 1 16-bit timer Timer 2 10-bit timer Timer 3 Watch-dog timer 1 Timer 4 Watch-dog timer 2 (6) FIFO A 2,560-bit FIFO is incorporated. Data for one raster is transfered from the RAM to the FIFO by DMA transmission and is out put as serial video data. The data cycle is 1.53 MHz. (7) CDCC parallel I/O CDCC data is received in 4-byte units by DMA transmission. If data of less than 4 bytes remains, a time-out occurs and it is forcibly transferred by DMS transfer. Low Speed Mode
t > 33 µ sec
STROBE
BUSY ACK
3 µ sec
High Speed Mode
t < 33 µ sec
STROBE
BUSY ACK
0.6 µ sec
Fig. 2.4 II - 4
The default setting is "AUTO MODE", which means that the time between the falling edge of the BUSY signal and the rising edge of the STROBE signal is measured, and if it is longer than about 33 µ sec, the mode is automatically switched to the LOW SPEED MODE; if it is shorter, the mode is automatically switched to the HIGH SPEED MODE. It is also possible to fix the mode to the LOW SPEED MODE by sending a command from the PC to rewrite the contents of the NV-RAM. BUSY goes HIGH at the falling edge of STROBE. The data (8-bit) from the PC is latched in the ASIC at the rising edge of STROBE. The pulse width of ACK differs according to the MODE, as shown above. (8) Software support Supports 16 x 16 rotation, bit expansion, and floating decimal point calculations. (9) EEPROM I/O One output port and one I/O port are assigned.
II - 5
(10) Engine control I/O This I/O is for connection to the driver PCB. solenoids, sensors, etc.
#5 UPD93094GM-3ED (02-07C) SELIN (02-07C) HBUSY (02-07C) PRMINT (02-07C) STB (02-04F) EXINT C40 101 0V R29 10K +5V TEST R21 5.1K <01> +5VI R23 0V R27 1K +5V R26 1K 0V R24 100K ( -05D) HEATON 0V ( ( ( ( ( -02F) AS -02F) UDS -02F) LDS -02F) RW -02E) BC (02-04C) RESIST ( -03B) +5VI 69 70 77 78 118 119 123 124 126 130 DCI1 DCI2 DCI3 DCI4 DCI5 DCI6 DCI7 DCI8 C35 309 XL1 C32 309 CSA30.67MXZ D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 17 16 15 14 13 12 11 10 158 1K ( ( ( -08F) MCMP1N -08F) MCMP2N -07A) HCMP1 ( ( ( ( ( -08B) SW1 -08B) SW2 -08B) HAISI -08C) LOCK -08B) TONER 2 4 5 18 19 24 25 31 34 36 38 39 44 20 58 59 60 61 62 63 SELIN HBUSY PRMINT STB EXINT SW1 SW2 HAISI BD LOCK COVER TONER MP XVDO VDO VON CND CND CND CND CND CND CND CND CND CND VCC VCC VCC VCC VCC 1 40 57 81 120 41 42 64 79 80 121 122 156 159 160 32 33 3 7 9 6 8 22 23 26 27 28 29 30 46 43 45 68 47 48 49 50 35 37 51 53 52 54 55 66 67 71 72 73 ROM0 ( ( SCL HEATON ( -02C) SDA ( -02B) FLT (02-07C) (02-07B) PE ACK (02-07B) SLCT (02-07B) BUSY (02-07B) WR (02-04E) OPTION (02-04E) C33 104 +5V
It controls the motors,
0V
(02-04C) SENSE (02-04C) XVDO
(02-07D) DCI(8..1)
MCMP1I FLT MCMP1N PE MCMP2I ACK MCMP2N SLCT HCMP1 BUSY HCMPN WR OPTION TESASI SENTAN LED0 LED1 TEST1 LED2 LED3 TEST2 LED4 AS PCKUP UDS LDS ERS RW BC CRCH RES RIO SD1 SD2 SD3 SD4 SD5 SD6 SD7 SD8 XOUT PMA PMAB PMB PMBB SCANCLK DRIVE HEATON HVT D0DC HVA HVB THM0 THM1 RESERVE ROM0 ROM1 RD DTACK BGACK BR SCLK AVEC IPL0 IPL1 IPL2 FC0 FC1 FC2 XCAS0 XCAS1 ICAS0 ICAS1 RAS MA0 MA1 MA2 MA3 MA4 MA5 MA6 MA7 MA8 MA9 RWU RWL ROE
0V
(R25) (1M) 157 XIN 117 D00 116 D01 115 D02 114 D03 113 D04 112 D05 111 D06 110 D07 109 D08 108 D09 107 D10 106 D11 105 D12 104 D13 103 D14 102 D15 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 76 75 74 NC 56 NC 55 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 NC NC
-11F) -01B)
21 ( -11F) RD 125 DTACK ( -01E) 127 128 ( BR 100 129 R19 SCLK ( 131 AVEC ( -01E) 134 133 132 137 136 135 139 138 153 140 152 148 146 144 142 141 143 145 147 149 150 154 155 151 IPL0 IPL1 IPL2 FC0 FC1 FC2 ( ( ( ( ( ( -01F) -01F) -01F) -02F) -02F) -02F)
-01E) -01E)
XCAS0 (02-09B) XCAS1 (02-09B) ICAS0 ( -11B) ICAS1 <02> RAS <03>
MA0 MA1 MA2 MA3 MA4 MA5 MA6 MA7 MA8 MA9
RWU <08> RWL <07> ROE <06>
<02> ( <08> (
-11D) (02-08B) -11B) ( -11D) (02-09B)
<03> (
-11B) (
-11D) (02-09B)
<04> (
-05E) (02-04E)
Fig. 2.5 II - 6
1.3.3
ROM A program of 512 Kbytes and the font data are stored in the ROM. A 42-pin IC socket is provided: an 8 Mbit ROM (42-pin) can be mounted to this socket normally, but a 4 Mbit ROM (40-pin) must be mounted to leave the 1st and 42nd pins of the socket opened.
#1 UPD27C8000CZ ( -05E) ROM0 <04> RD +5V A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 11 13 32 10 9 8 7 6 5 4 3 41 40 39 38 37 36 35 34 33 2 1 VCC CE CND OE BYTE CND A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 /A-1 NC 22 31 12 14 16 18 20 23 25 27 29 15 17 19 21 24 26 28 30 +5V C26 104 D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 0V
42 NC
Fig. 2.6 1.3.4 RAM A 4-Mbit DRAM (x 16 bits) is used as the RAM. Depending on the specification,There are two models: the 0.5 M model (one mounted), or the 1 M model (two mounted).
+5V #3 M5M44170AJ-8 1 6 20 ( ( ( -05H) ROE 27 13 12 28 14 VCC VCC VCC OE UW LW CAS RAS NC NC NC A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 VSS VSS VSS 21 35 40
C29 104 0V
-05H) RHU -05H) RHL ( -05C) ICAS1 ( -05C) RAS
NC 11 NC 29 NC 30 MA0 MA1 MA2 MA3 MA4 MA5 MA6 MA7 MA8 MA9 16 17 18 19 22 23 24 25 26 15
DQ1 DQ2 DQ3 DQ4 DQ5 DQ6 DQ7 DQ8 DQ9 DQ10 DQ11 DQ12 DQ13 DQ14 DQ15 DQ16
2 3 4 5 7 8 9 10 31 32 33 34 36 37 38 39
D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15
C
+5V
#4 M5M44170AJ-8 1 6 28 ( ( ( ( ( -05H) ROE -05H) RWU -05H) RWL -05C) ICAS1 -05C) RAS 27 13 12 28 14 VCC VCC VCC OE UW LW CAS RAS NC NC NC A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 VSS VSS VSS 21 35 40
C29 104 0V
NC 11 NC 29 NC 30 MA0 MA1 MA2 MA3 MA4 MA5 MA6 MA7 MA8 MA9 16 17 18 19 22 23 24 25 26 15
DQ1 DQ2 DQ3 DQ4 DQ5 DQ6 DQ7 DQ8 DQ9 DQ10 DQ11 DQ12 DQ13 DQ14 DQ15 DQ16
2 3 4 5 7 8 9 10 31 32 33 34 36 37 38 39
D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15
Fig. 2.7 II - 7
1.3.5
Optional RAMs There are two types of optional RAM: the 1 Mbyte model and the 1.5 Mbyte model, but even if the 1.5 Mbyte model is mounted in addition to a 1 M mode, only 2 Mbytes in total will be recognized. 0.5 M model + 1 M optional RAM = 1.5 Mbytes 0.5 M model + 1.5 M optional RAM = 2 Mbytes 1 M model + 1 M optional RAM = 2 Mbytes 1 M model + 1.5 M optional RAM = 2 Mbytes
P2 OPTION RAM (01-05H) ROE (01-05H) RWU (01-05H) RWL (01-05F) XCAS0 (01-05F) XCAS1 (01-05C) RAS MA0 MA1 MA2 MA3 MA4 MA5 MA6 MA7 MA8 MA9 D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 +5V C25 104 (01-07H) D(15..0) 0V 30 28 27 29 7 6 5 40 39 38 37 36 35 34 33 32 31 8 9 10 11 12 13 14 15 26 25 24 20 19 18 17 16 23 4 3 21 22 2 1 OE UW LW ICAS1 XCAS0 XCAS1 RAS A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 DQ1 DQ2 DQ3 DQ4 DQ5 DQ6 DQ7 DQ8 DQ9 DQ10 DQ11 DQ12 DQ13 DQ14 DQ15 DQ16 VCC VCC VCC VSS VSS VSS VSS
R18 (01-05C) ICAS1
0
(01-09C) MA(9..0)
Fig. 2.8 1.3.6 Optional Serial I/O The interrupt of serial I/O are input to the EXINT terminal of the ASIC, and are recognized by the CPU. A 32-byte space for register is provided for this I/O, which are read and written to by the CPU.
P3 OPTION I/F RESET OPCS RD WR A5 A4 A3 A2 A1 D7 D6 D5 D4 D3 D2 D1 D0 OPIRQ SENTAN BD EXVDO LEDR SENSE +5V +5V +5V 0V 0V 0V 0V 17 2 13 1 30 29 15 14 28 24 9 8 23 7 21 6 5 16 27 22 12 20 10 11 25 26 18 4 19 3 RESET (01-01E) OPTION (01-05C) RD (01-11F) WR (01-05B)
E
A(5..1) (01-08C)
EXINT (01-03A) RESIST (01) RBD (01-02A) EXVDO (01-04B) LEDR (01-06C) SENSE (01-04B) +5V C34 104 0V
D(7..0) (01-07C)
Fig. 2.9 II - 8
1.3.7
EEPROM The EEPROM is X24CO1A type of a two-wire method with a 128 x 8 bit configuration.
+5V
#6 XL24C01AF ( -05E) SCL 6 1 2 3 SDA SDA A0 VCC A1 VSS A2 TEST 5 8 4 7
R20 4.7K SDA ( -05D) +5V 0V
C31 104
Fig. 2.10 1.3.8 Reset circuit The reset IC is PST593DMT. The reset voltage is 4.2 V (typ.) and the LOW period of reset is 200 ms (typ.).
+5V
#7 PST593DMT 3 4 VCC OUT CND MR 1 2 NC
R22 1K
RESET (
-01E)
C30 102
G
0V
Fig. 2.11 1.3.9 CDCC I/O Fig. 2.12 shows the CDCC interface circuit.
+5V
RA2 1K
RA4 1K
RA6 1K
5 7 3 8
7 8 6 5
7 8 6 5
101 X5 C52 C51 C37 C48 C53
0V
P4 CDCC 10 ACK 11 BUSY 12 PE 13 SELECT 32 FLT 31 INPRIM 36 SELIN 14 ATFEED 1 STB DI8 DI7 DI6 DI5 DI4 DI3 DI2 DI1 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V +5V 9 8 7 6 5 4 3 2 16 17 19 20 21 22 23 24 25 26 27 28 29 30 18
4 2 6 1
2 1 3 4
2 1 3 4 ACK (01-05B) BUSY (01-05B) PE (01-05B) SLCT (01-05B) FLT (01-05B) PRMINT (01-04A) SELIN (01-04A) HBUSY (01-04A) STB (01-04A) DC18 DC17 DC16 DC15 DC14 DC13 DC12 DC11
RA1 100 5 2 6 1 RA3 8 7 3 4 8 2 3 4 RAS 100 4 7 3 8 1 2 6 5 1 7 6 5
100 0V C45 C36 C38 C41 C43 C44 C49 C50 C54 C39 C47 C42 101 X12
DCI(8..1) (01-03C)
0V +5V
Fig. 2.12 II - 9
1.3.10
Engine I/O
HCMPI ( R10 18K
-04B)
C17 104 +5V 0V
R9 100K
R5 5.1K
R2 6.2K 0V
+5V R15 R6 10K 10K R11 10K
R13 10K
182 X4 0V R28 1K R31 R32 R30 R33 C16 C3 330 330 220 220 C23 C8 ( ( C9 102 -04A) SW1 -04A) SW2 C12 102 R12 R7
R17 470K 100 100
P1
DRIVE I/F SW1 SW2 LED0 LED1 LED2 LED3 N.C. RESIST TONER +5VI HAISI TONERTH HEATTH THERMIN TAIDEN GENZOU TENSHAH TENSHAL HEATON ERASE PICKUP CLUTCH FAN SCANCLK LOCK DRIVE VDO LDON BD PMA PMAB PMB PMBB VINA VINB +5V +5V +5V +5V 0V 0V 0V 0V 0V
(02-04C) RESIST ( -04B) TONER ( -03B) +5VI ( -04A) HAISI
R4 R16 R14
100 100 100 ( ( -10C) TONERTH -10C) HEATTH
C4 C24 C18 0V LEDR (02-04C) 102 X3
(
-04B) LOCK
(
-02A) 8D
(101) 0V Q7 DTC114YK 3 2 C6 C20 C14 C19 (C2) C21 C15 C7 C22 C10 C11
+5V
102 X4
102 X6
C1 6.3V 100UF
Q4 DTC114YK 3
1 2
0V
B16 A16 B18 A18 B17 A17 A3 A14 B21 94 A19 B20 B19 A20 B12 A11 B11 A10 83 A12 B13 A13 B14 89 A9 B10 A7 B8 A8 A6 B6 A5 B7 B5 A4 A2 B2 A15 B15 A1 B1 A21 A22 B22
Q6 DTC114YK 3
1 2
Q9 DTC114YK 3
1 2
+5V Q5 DTC114YK 3 MCMP1N ( 1 Q8 DTC114YK 2 3 MCMP2N ( R8 1K +5V (Q1) (DTA114EK) 1 2 6 5 4 NC 0V 3 0V (Q2) (Q10) (DTC114YK) 3 2 2 0V 1 A[5.1] (02-05F) D[15..0] (02-08E) MA[9.0] (02-08C) 3 (DTA114EK) 1 HEATTH ( -09B) R3 0 TONERTH ( -09B) -04B) -04B) R36 470K R37 470K 1 2
Q3 DTC114YK 3
1 2 DA1 RB731U
C5 102 1 2 3 NC
C13 102
R1
1K
1
0V D[7..0] (02-05C)
<05> (
-02C) (02-04E)
<86> (
-11B) (
-11D) (02-09B)
Fig. 2.13
II - 10
1.4
Driver PCB 1.4.1 Paper Feed Motor Drive Circuit The motor driver is a four-device FET array, which manage the constant current control by feeding back the voltage of the current detection resistor. The comparator for the constant current control is incorporated in the AS IC on the main PCB, which controls the excited output to go OFF by the specified period (12.5µs) when the motor drive current exceeds the specified current level. The excitation method is 2-2 phase excitation with an unipolar drive. The four diodes D1NL2OU and Zener diode are the circuit that protects against overvoltage due to counter-electromotive force.
#1 UPA1572H 3 2
R8
47
+24VI
5 ZD1 RD30FB3 D1NL20U 7 D1 D1NL20U D2 D1NL20U D3 D1NL20U D4 +24V RET
C1 50V 100U
R7
47
4 1
P3 FEED MOTER 1 2 3 4 5 6 PMA COMA PMAB PMB COMB PMBB
R6
47
6
9
R9
47
9 10
R12 100K
R11 100K
R10 100K
R13 100K
0V
R4 1.2 1W +24VRET
R2 1.2 1W
Fig. 2.14 1.4.2 Solenoid (Pick-up, Clutch), Erase Lamp, Fan Motor Drive Circuit A darlington transistor (2SC5060) is used for these circuit. A flywheel diode D1NL20U is provided for the fan motor drive circuit to prevent counter-electromotive force.
+24VI P9 PICKUP CLUTCH RESIST 6 +24V 5 CLUTCH 4 3 PICKUP +5V 2 RESIST 1 GND
A
R14 3.3K
P10 ERASE 1 +24V 2 ERASE 2SC5060 Q4
R15 3.3K
2SC5060 Q43
R16 3.3K
2SC5060 Q2 +24V
P4 FAN 1 2 +24V FAN
R17 3.3K
2SC5060 Q1 D1NL20U DS +24VRET
Fig. 2.15 II - 11
1.4.3
Operation Panel Four LEDS and two switches are mounted on the PCB.
SW1 SW2
0V
LED1 LED2 LED3 LED4
+5V
Fig. 2.16
1.4.4
Scanner Motor, Laser, Sensors (Registration, Paper Eject, Toner), Thermistor, High-voltage Power Supply. Since these are controlled directly from the main PCB, the driver PCB has only relays the above signals of each connectors.
1 2 1 2 3 5 4 3 2 1
TONERTH THERMIN ANODE TONER GND
P13 TONER THERMISTOR
P12 TONER P8 HIGH VOLTAGE 6 5 4 3 2 1 TAIDEN GENZOU TENSHAH TENSHAL GND +24V
THERMISTOR HEATTH THERMIN P11 ANODE THERMISTOR HAISI HAISI GND +24VRET +24VI
C
+24VRET +24VI
1 2 3 4 5
SCANCLK LOCK DRIVE P7 SCANNER MOTER GND +24V
0V +5VI
P6 LASER 1 VDO 2 GND 3 +5V 4 LDON 5 BD
Fig. 2.17
II - 12
1.5
Power Supply The power supply uses the switching regulation system to generate the regulated DC power (+5V and +24V), which are converted from the AC line.
(Heater)
Thermal Fuse Heater Circuit Lamp
Fuse
Lightning Surge Absorber
Feedback
Line Filter
Rectifier
Oscillator
SW
(Driver Circuit)
24VI
24V Regulation Circuit
24V
SW 5VI 5V Regulation Circuit 5V
Fig. 2.18
II - 13
2
2.1
MECHANICS
Overview of printing mechanism
Multi-Purpose Tray Manual Paper Pass
Papers
Paper Supply Unit
Paper Pick Up Roller Process Unit Paper Regist Roller Transfer Roller Hopper Plate Fuser Unit Pressure Roller Registration Sensor Lever Eject Sensor Actuator Exit Roller Photosensitive Drum
Heat Roller Toner Cartridge Toner Developer Empty Roller Sensor Scanner Unit
Primary Changer
Toner Auger
Cleaner Blade
Polygon Mirror
Erase Lamp
Fig. 2.19
Scanner Unit Main Motor Fan Motor Registration Sensor PCB Registration Sensor Solenoid P Solenoid C Primary Changer (Corona Wire) High Voltage Power Supply Primary Changer (Grid)
Main Control PCB
Driver PCB
Developer Roller Transfer Roller
Paper Eject Sensor PCB Toner Empty Sensor PCB
Paper Eject Sensor Thermistor
Toner Empty Sensor
II - 14
2.2
Paper Transfer 2.2.1 Paper Supply The pickup roller picks up one sheet of paper from the paper tray at every one rotation and feeds it to the registration roller one by one.
Papers Pickup roller
Registration sensor lever
Hopper plate
Print pad
Fig. 2.20 The paper is gripped between the pickup roller and the separation pad and separated into individual sheets. The pickup roller is directly connected to the sector gear, whose rotation is forcibly stopped by the gear stopper; when the pickup solenoid (solenoid C assembly) is activated, the gear stopper is released and the sector gear is driven; when it has completed one full turn its rotation is stopped again by the gear stopper. The paper drawn out by the pickup roller presses against the top of form sensor lever and the paper top position/absence of paper is detected by sensing the motion of the lever. 2.2.2 Paper Registration When paper picked up from the multi-paper tray (MPT) presses against the top of form sensor actuator, the registration sensor lever is caused to turn, and the photo sensor detects this motion. With this signal from the sensor the registration roller is stopped of its rotation temporarily by the clutch. Then paper is fed to the nip point between the registration roller and the pinch roller in the process unit, and the skew of the paper is corrected by the bump of the leading edge of paper against the nip point. When the registration roller starts to rotated again by the motion of clutch, paper, leading edge of which has been aligned, is fed by the registration roller and is transported to the transfer roller.
Registration roller Registration roller Paper Transfer roller Paper feed gear
Pinch roller Drum
Clutch mechanism (engaged/released by the solenoid assembly) Released when the solenoid is ON and engaged when the solenoid is OFF.
Fig. 2.21 II - 15
2.2.3
Paper Eject
The completion of paper eject is detected in the following manner: (a) when the leading edge of the paper push up the eject sensor actuator located in the fixing unit, the photo sensor (photo interrupter) is opened and detects the start of paper eject motion. (b) After that, when the bottom of the edge of paper has passed through the paper eject sensor actuator, the photo sensor is closed and the completion of paper eject motion is recognized.
Transfer roller
Fixing unit
Presure roller Eject sensor actuator Eject roller
Heat roller
Eject sensor actuator
Paper Sensor
Fig. 2.22
Y-BSMXL0.35
II - 16
2.3
Sensors 2.3.1 Multi-Paper Tray (MPT) Sensor Detects whether or not the multi-paper tray is installed. 2.3.2 Cover Sensor Detects open or close of the top cover. Toner Empty Sensor Detects if there is toner in the toner cartridge. It also detects whether or not the process unit is installed. (The toner cartridge is installed in the process unit).
2.3.3
Multi-paper tray Top cover
MPT switch lever Cover switch lever
Y-BSMXL0.36
Fig. 2.23
II - 17
2.4
Process Unit 2.4.1 Photosensitive Drum Generates the latent electrostatic image and develops the image on the drum surface. 2.4.2 Primary Charger Forms a uniform charge on the drum surface. (1) Corona wire Generates ion on the drum. (2) Grid Spreads the ion evenly over the drum. 2.4.3 Developer Roller Develops the latent electrostatic image on the drum surface by the toner. 2.4.4 Transfer Roller Transfers the toner image to the paper from the drum surface. 2.4.5 Cleaner Blade Remove the toner remaining on the drum surface. 2.4.6 Toner Auger Transport the waste toner from the cleaner to the developer unit. 2.4.7 Erase lamp Discharges the electrostatic latent image on the drum.
2.5
Print Process 2.5.1 Charging The drum is charged to appox +700V by ion which is generated by the primary charger. Ion is generated by an ionization of the corona wire, which applied DC bias from High Voltage Power Supply. The flow of ion is controlled by the grid to be distributed evenly on the drum surface. The other end of the grid is grounded to the frame through the varistor.
+ + + -- + ++ - - - ++ + + + + + + + + + + + ++ Varistor
-
Aluminum pipe Organic Photoconductor layer Grid
Drum
HVPS
Corona wire
Fig. 2.24 The primary charge uses a corona wire, but since the charging terminal of the drum is a positive terminal , only less than 1/10 of the usual quantity of ozone is generated. The level of ozone expelled from the printer is therefore not harmful to the human body. Applicable safety standards have been complied with.
II - 18
2.5.2
Exposure stage After the drum is positively charged, it is exposed to the light emitted from the laser unit.
Drum Laser Beam Paper Laser beam f Laser detector Laser diode Motor Lens lens Polygon mirror
+ + +
-
-
-
+ + + - - -
Fig. 2.25 The exposed area is the part to be printed. The surface potential of the exposed area is decreated forming an electrostatic image toY-BSMXL0.01 be printed.
1 Cycle of drum
1 4 2
Primary charging Laserbeam exposure and developing (a) Unexposed area ( Non image area ) (b) Exposed area ( Image area ) Transfer the image to paper Erase the residual potential
Surface Potential (V)
1 +700 +500
2 (a)
3
3 (b) +100 Time 4
Fig. 2.26
II - 19
2.5.3
Developing Developing causes the toner to be attracted to the electrostatic image on the drum so as to transform it into a visible image. The Developer Consists of the magnetic carrier and the magnetic toner. The developer makes the magnetic brush on the developer roller which includes the rotatable magnet roller. The magnetic brush softly rubs the drum, and then only the toner developed on the latent electrostatic image. The carrier particles are attracted to the developer roller. The toner receives a positive static charge as the toner particles rub against the carrier particle, rotating developer roller, and trimmer blade. Electrostatic field between the drum and the developer roller, which is DC-biased from the High voltage power supply, makes electrostatic potential to attract toner particles the developer roller to the drum.
Transfer Roller
Carrier " "
from
(a) Transfer process [ON]
Toner " "
(b) Cleaning process [ON]
N S N S N S N S
DC-bias Cleaning blade Erase lamp
Fig. 2.27 2.5.4 Transfer
(a) Transfer process After the drum has been charged and exposed, and has received a developed image, the toner formed image is transferred onto the paper , applying the negative charge from the backside of the paper. The negative charge to the paper causes the positive charged toner to leave the drum, and adhere to the paper. As a result, the image is visible on the paper. (b) Cleaning process of transfer roller If the toner is not transferred onto the paper perfectly due to jamming etc., it is possible that the toner adheres to the charge transfer roller. The transfer voltage charges to positive voltage during non transferring process. Therefore the transfer roller is cleaned by returning the positive charged toner adhered on the transfer roller onto the photo-conductive drum.
II - 20
2.5.5
Drum Cleaning Stage In the image transfer stage, not all the toner on the photosensitive drum is transferred onto the paper but some of them remain on the drum. In the drum cleaning stage, the drum surface is cleaned by the cleaning blade, so that residual toner on the drum surface is removed away and collected in the cleaning housing. In the cleaning housing, collected toner is transported to the developer unit by the toner auger. This toner is mixed with new toner and is used again at the developing stage.
2.5.6
Erasing Stage After the cleaning stage, the drum surface is exposed by the light emitted from the erase lamp. (LED lamp) This stage prepares the drum to decrease its surface voltage uniformly, and to receive an uniform change in the primary charging stage.
II - 21
CHAPTER III
1
DISASSEMBLY AND REASSEMBLY
SAFETY PRECAUTIONS
To prevent the creation of secondary problems by mishandling, be careful about the following precautions during maintenance work. (1) Always turn off the power before replacing parts or units. When accessing the power supply PCB or components, be sure to unplug the power cord from the power outlet. (2) Be careful not to lose screws, washers, or other parts removed. (3) Be sure to apply grease to the gears and applicable popsitions specified in this chapter. (4) When using soldering irons or other heat-generating tools, take care not to damage the resin parts such as wires, PCBs, and covers. (5) Before handing the PCBs, touch a metal portion of the equipment to discharge the static electricity charged in your body, or the electronic parts or components may be damaged. (6) When transporting PCBs, be sure to wrap them in conductive sheet such as aluminum foil. (7) Be sure to replace self-tapping screws correctly, if removed. Unless otherwise specified, tighten screws to the following torque values. TAPTITE, BIND or CUP B M3 : 6kgf · cm M4 : 9kgf · cm TAPTITE, BIND S M3 : 9kgf · cm SCREW M3 : 7kgf · cm M4 : 10kgf · cm (8) When connecting or disconnecting cable connectors, hold the connector bodies, but not the cables. If the connector has a lock, release the connector lock first to unlock it. (9) After a repair, check not only the repaired poprtion but also the connectors, or check if other related portions are functioning properly before doing operation checks.
III - 1
2
BOTTOM
DISASSEMBLING FLOW
1
MP TRAY ASSY
17
MAIN PCB ASSY
B
18 2 PROCESS UNIT 19 3 TOP COVER DRIVER PCB ASSY 20 21 HIGH-VOLTAGE PS ASSY BASE PLATE ASSY
B A
PS PCB ASSY
4
MAIN COVER
III - 2
5
UPPER SHOOT COVER ASSY
8
FAN GUARD
11
13 REGIST SENSOR PCB ASSY
GEAR SHAFT PLATE
A
6 FIXING UNIT 9 INTERLOCK LEVERS 10 12
A
7
FAN MOTOR
SOLENOID P ASSY
14
GEARS
SCANNING UNIT
RIGHT SIDE
A
15 16
MAIN MONITOR UNIT
SOLENOID C ASSY
22 23 24
TRAY EXTENSION PAPER EJECT TRAY ASSY FILTER COVER ASSY
LEFT SIDE
3
3.1
DISASSEMBLING PROCEDURE
Multi-purpose Paper Tray (1) Lift the multi-purpose paper tray upward to remove it.
Multi-purpose paper tray
Fig. 3.1 3.2 Process unit (1) Open the top cover.
Y-BSMXL0.03
(2) Release the locks of the upper shoot cover and open it out toward the front of the printer. (3) Lift out the process unit.
Top cover
3
Process unit
1
Upper shoot cover
2
Y-BSMXL0.04
Fig. 3.2 III - 3
3.3
Top Cover (1) Open the top cover to the first lock position. (2) Prize up the top cover link and free it from the dowel on the top cover to release it inward. (3) Press the link downward.
Top cover Dowel on top cover
Top cover link
(4) Open the top cover further, release the catch of the right side by lifting the top cover upward and then slide the top cover leftward.
Y-BSMXL0.06
Top cover
Hole in top cover Slot in top cover
1
Dowel on main cover
2
Dowel on main cover
Fig. 3.3
Y-BSMXL0.07
III - 4
3.4
Main Cover (1) Remove the four screws securing the main cover. (2) Release the catch on the bottom of the front face of the main cover and lift the main cover upward.
Main cover
Y-BSMXL0.08-2
Switch key holes
Panel light guide Switch keys
Fig. 3.4
Y-BSMXL0.8-1
NOTE: When fitting the main cover, the switch key and panel light guide (on this left side) must be carefully inserted into the corresponding holes in the main cover.
Panel light guide Switch key hole Switch key
Fig. 3.5
Y-BSMXL0.09
III - 5
3.5
Upper Shoot Cover (1) Open the upper shoot cover (2) Push down the release link and release it from the dowel on the fixing unit. (3) Release the locks on the upper shoot cover, then remove the upper shoot cover from the frame by sliding it to the left.
Upper shoot cover Lock lever
Lock lever
Release link
Fixing unit
Fig. 3.6 3.6 Fixing Unit (1) Disconnect the fixing unit connector on the left side. (2) Remove the three screws securing the fixing unit. (3) Lifting up the fixing unit, disconnect the two heater harnesses on the right side.
Paper eject sensor actuator
Y-BSMXL0.10
Fixing unit
Light guide
Heater harness(Blue)
Heater harness(Brown)
Paper eject sensor actuator
Fig. 3.7
Y-BSMXL0.11-1
NOTE: When attaching the fixing unit, be sure to connect the fixing unit connector and the two heater harnesses. Be careful not to damage the paper eject sensor actuator.
Fig. 3.8 III - 6
3.7
Scanner Unit (1) Disconnect the two connectors of the scanner unit from the driver PCB (Refer to 3.19). (2) Remove the four screws. (3) Lift out the scanner unit.
Mirror Scanner unit
Sponge
Connectors
Fig. 3.9
Y-BSMXL0.12
NOTE: Never touch the inside of the scanner unit or the mirror when disassembling or reassembling. If there is any garbage or dust on the mirror, blow it off.
3.8
Fan Guard (1) Remove the two screws securing the fan guard, and take it off.
Frame
Fan guard
Fig. 3.10
Y-BSMXL0.13
III - 7
3.9
Interlock Levers (1) Grease the contacting portions of the interlock levers on assembly.
Grease
Grease: MolyKote EM30L
Grease
Fig. 3.11
3.10
Fan Motor (1) Disconnect the connector from the driver PCB (Refer to 3.19). (2) Take off the fan motor.
Y-BSMXL0.14
Fan motor
Fig. 3.12 3.11 Registration Sensor PCB (1) Remove the screw of the registration sensor PCB. (2) Disconnect three connectors from the Registration sensor PCB.
Y-BSMXL0.15
Registration sensor harness
Registration sensor PCB
Solenoid P Solenoid C
Fig. 3.13
III - 8
Y-BSMXL0.03
3.12
Solenoid P (1) Pull out the solenoid P from the frame by releasing the hook of the solenoid lever.
Solenoid lever
Solenoid P
Fig. 3.14 3.13 Gear Shaft Plate (1) Remove the seven screws securing the gear shaft plate.
Y-BSMXL0.17
Gear shaft plate M4 screw
NOTE: On re-assembly, run the registration sensor harness along the route shown in the figure Y-BSMXL0.18 below.
Paper eject sensor harness
Registration sensor harness Main motor harness
Fig. 3.15
III - 9
Y-BSMXL0.37
3.14
Gears (1) Grease the metal gear shafts and gear surfaces on the specified portion illustrated below when reassembling.
4 7 3 6 Grease
Grease
Grease 1
5
2
Grease
Grease
Grease
Grease
Grease
Grease Grease Grease Grease
Grease
Grease: MolyKote EM30L Fig. 3.16
III - 10
3.15
Main Motor Unit (1) Disconnect three connectors from the driver PCB (Refer to 3.19). (2) Remove two screws securing the main motor unit.
Main motor unit
Fig. 3.17
Y-BSMXL0.20
3.16
Solenoid C (1) Remove the spring of the solenoid C. (2) Remove the solenoid C.
Grease Solenoid C assy Grease Grease
Grease
Grease
Grease: MolyKote EM30L Fig. 3.18
NOTE: When re-assembling, grease up to the specified portions of each gear shown in the above figure.
Y-BSMXL0.21
III - 11
3.17
Main PCB (1) Remove three screws securing the main PCB holder on the back side of the printer. (2) Grasp the hooks at left and right and draw out the main PCB assembly.
Rail
Main PCB assy
Screws
Fig. 3.19 3.18 Base Plate
NOTE: Prior to turning the printer upside-down, the multi-purpose tray assembly and process unit should be removed from the printer.
(1) Turn the printer upside down. (2) Remove the eight self-tapping screw, one M3 screws and two M4 screws. (3) Lift out the base plate and remove the grounding screw.
M4 screws M3 screw Base plate Self-tapping screw
Y-BSMXL0.22
Grounding screw
Grounding wire
Fig. 3.20
Y-BSMXL0.23
III - 12
NOTE: Install the grounding wire after fitting the base plate so that it does not contact the soldered side of the base plate.
Grounding wire
Y-BS
Grounding wire
Power supply PCB
Fig. 3.21
Y-BSMXL0.
III - 13
3.19
Driver PCB (1) Remove the two screws securing the driver PCB. (2) Disconnect the ten connectors from the PCB.
Eject sensor (P11,White) Driver PCB
Toner sensor (P12,White) Laser (P6,Black) Scanner motor (P7) HV harness (P8,White)
Erase lamp (P10,Red)
Registration sensor (P9,White)
LV harness (P2,White)
Fan motor (P4,White) Main motor (P3,Red)
Fig. 3.22
NOTE1: When reassembling, the connectors must be inserted to the PCB without floating and Y-BSMXL0.24 the PCB must not be floated by the harnesses. NOTE2: The connector should be inserted by fitting the housing color and the pin number.
3.20 Power Supply PCB (1) Disconnect the three connectors from the component side of the PCB.
120%
Power supply PCB AC cord
Heater harness Low voltage harness P
Fig. 3.23
Y-BSMXL0.25
III - 14
3.21
High-voltage Power Supply (1) Remove the screw securing the high voltage power supply PCB. (2) Disconnect the two connectors from the PCB.
High-voltage power supply High-voltage harness P
CHG harness
Fig. 3.24
3.22
Tray Extension (1) Pull the manual paper tray down toward the front of the printer.
Y-BSMXL0.26
(2) Put the tray extension down toward the front of the printer, and press the bottom of its both side legs inward to release it.
Tray extention
120%
Manual paper tray
Multi-purpose paper tray
Fig. 3.25
Y-BSMXL0.29
III - 15
3.23
Paper Eject Tray (1) Open the paper eject tray. (2) Press the both sides of hinges of the paper eject tray inward to release it from the dowels on the main cover.
Main cover
Paper eject tray
Fig. 3.26
Y-BSMXL0.30
3.24
Filter Cover (1) Press down on the central part of the top of the filter cover and pull it out toward you to release the catch.
Filter cover
Fig. 3.27
Y-BSMXL0.31
III - 16
4.
PACKING
Box, Manual
Box, Drum
Pad
Carton
Fig. 3.28 III - 17
CHAPTER IV
1
1.1
TROUBLE SHOOTING
INTRODUCTION
Initial check (1) Operating environment Check if : 1) The souce voltage stays within ±10% from the rating voltage shown on the rating plate. 2) 3) 4) 5) 6) 7) The printer is installed on a solid, level surface. The room temperature is maintained between 10°C and 32.5°C. The relative humidity is maintained between 20% and 80%. The printer is not exposed to ammonia fumes or other harmful gases. The printer is not located in a hot or humid area (such as near water or a humidifier) The printer is not exposed to direct sunlight. The room is well-ventilated
(2) Printer paper Check if : 1) A recommended type of print paper is being used (if the paper is too thick or too thin, or tends to curl, paper jams or paper feed problems may occur, or prints may be blurred). 2) the print paper is damped. [If so, use fresh paper, and check whether the print quality improves or not.]
(3) Consumables Check if : 1) The toner LED is not lit on the display when a toner cartridge is installed in the printer. [If the above LED is lit, replace the cartridge with a new one. If blank spots occur on prints, take out the process cartridge and slowly rock it to distribute the toner evenly.] (4) Others Check if : 1) The transfer guide and feed guide are clean. [ If not, clean them with a damp cloth.]
Condensation: When the printer is moved from a cold room into a warm room in cold weather, condensation may occur inside the printer, causing various problems as below: 1) 2) 3) 4) Condensation on the optical surface such as the scanning mirror, lenses, the reflection mirror and the protection glass may raise the print image to be light. If the pfotosensitive drum is cold, the electrical resistance of the photosensitive layer getshigh, making it impossible to obtain a correct contrast in printing. Condensation on the corona unit may cause corona leakage. Condensation on the pick-up guide and feed guide plates may cause paper feed troubles .
IV - 1
If condensation has occured, wipe the effected units or parts with a dry cloth. If the process cartridge is unsealed soon after moved from a cold room to a warm room, condensation may occur inside the cartridge, which may cause incorrect image. Instruct the user to allow the cartridge to come to to room temperature before unsealoing it. This will take one to two hours. 1.2 Basic Procedure If a manufunction or incorrect print is appeared, make an initial check, then follow the basic procedure below: (1) Check the error lamps according to the procedure of inspection mode described on the later pages of this section. If no error lamp is lit, see Section 4 for troubleshooting. (2) If any incorrect image is found, follow the imafe defect description in this section.
IV - 2
2.
2.1
IMAGE DEFECTS
Image Defect Example
1-1 Light
1-2 Dark
1-3 Completely blank
1-4 All black
1-5 Dirt back of paper
1-6 Black vertical streaks
1-6 Black and blurred vertical stripes
1-7 Black and blurred horizontal stripes
1-8 Dropout
1-9 White vertical streaks
1-10 Faulty registration
1-11 Poor fixing
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1-12Å@ Image distortion
1-13 Blurred at either side
Fig. 4.1
IV - 3
2.2
Troubleshooting Image Defect Procedures to follow in response to specific image defects.
I-1
Light
Possible cause Poor contrast
Step 1
Check Is the contrast adjustment dial in the center of click position?
Result No
Remedy Set it to the center click position or reasonable position. The wiper of the toner cartridge is defective. Replace the toner cartridge. Toner sensor failure. Check if the toner sensor needs cleaning and check the toner sensor connection. Clean contact electrodes between the printer body and the drum shaft of drum unit . Replace the drum unit.
Toner sensing failure (toner cartridge side) Toner sensing failure (printer side)
2
Is the problem solved when 4 or 5 pages are printed after the cartridge is replaced with a full one? Can printing be started with the drum unit removed?
Yes
3
Yes
Drum GND connection failure Transfer electrode contact failure
4
Is the drum shaft grounded when the drum unit is installed? Is there continuity between the transfer roller shaft and the transfer electrode on the external drum unit? Is the problem solved when the transfer roller is replaced?
No
5
Yes
Transfer failure
6
Yes
Replace the drum unit.
Developing bias contact failure
7
Are the developing bias contacts between the printer body and the drum unit soiled?
Yes
Clean the terminals of both sides.
High-voltage power supply failure
8
Remove the main cover and measure the voltage at the electrode plate at the right side face while printing with the interlocks defeated. Is the voltage correct?
No
Check the harness connection between the high-voltage power supply and the driver PCB. If the connection is normal, replace the high-voltage power supply PCB. Replace the driver PCB.
Driver PCB failure
9
Perform the same check as step 8 above.
No
IV - 4
I-2
Dark
Possible cause Contrast failure
Step 1
Check Is the contrast adjustment dial at the center click position?
Result No
Remedy Set it to the center click position or reasonable position. Clean the corona