Acfb_ccd_e_cov MFC9840service
User Manual: MFC9840service
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Brother Color Laser Printer SERVICE MANUAL MODEL: DCP-9045CDN/MFC-9840CDW 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. July 2007 SM-FAX076 (6) Confidential © Copyright Brother Industries, Ltd. 2007 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 color 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-9045CDN/MFC-9840CDW machines. This manual consists of the following chapters: CHAPTER 1: TROUBLESHOOTING Details of error messages and codes that the incorporated self-diagnostic functions 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 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 of the machine. CHAPTER 4: ADJUSTMENTS AND UPDATING OF SETTINGS, REQUIRED AFTER PARTS REPLACEMENT Details of adjustments and updates of settings, which are required if the main PCB and some other parts of the machine 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 making any adjustments using the control 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 Circuit Diagrams and Wiring Diagrams for the connections of the PCBs. i Confidential APPENDIX 1: WORKER SWITCH SETTINGS (WSW) Describes the functions of the worker switches, which can be divided into two groups: one is for customizing preferences designed for the destination and the other is for modifying preferences that match the machine to the environmental conditions. Use the latter group if the machine malfunctions due to mismatching. APPENDIX 2: DELETION OF PERSONAL INFORMATION Provides instructions on how to delete personal information recorded in the machine. APPENDIX 3: SERIAL NUMBERING SYSTEM APPENDIX 4: SCREW CATALOGUE APPENDIX 5: HOW TO MAKE THE DRUM UNIT REMOVE SHEET 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 REGULATION............................................................................................ VIII SAFETY INFORMATION............................................................................ XII CHAPTER 1 TROUBLESHOOTING ........................................................ 1-1 1. INTRODUCTION .........................................................................................................1-1 1.1 Precautions ........................................................................................................................ 1-1 1.2 Initial Check........................................................................................................................ 1-1 2. ERROR CODES ..........................................................................................................1-3 2.1 Error Indication ................................................................................................................... 1-3 2.2 Error Cause and Remedy .................................................................................................. 1-5 2.2.1 Recoverable Error by User Check ........................................................................... 1-5 2.2.2 Service Call Error ..................................................................................................... 1-8 3. PAPER FEEDING PROBLEMS.................................................................................1-40 3.1 No Feeding....................................................................................................................... 1-40 3.2 Double Feeding ................................................................................................................ 1-40 3.3 Paper Jam ........................................................................................................................ 1-41 3.4 Dirt on Paper .................................................................................................................... 1-42 3.5 Wrinkles............................................................................................................................ 1-42 4. IMAGE DEFECT TROUBLESHOOTING...................................................................1-43 4.1 Image Defect Examples ................................................................................................... 1-43 4.2 Diameter of Rollers .......................................................................................................... 1-44 4.3 Troubleshooting Image Defect ......................................................................................... 1-44 5. SOFTWARE SETTING PROBLEMS.........................................................................1-60 6. NETWORK PROBLEMS ...........................................................................................1-61 7. TROUBLESHOOTING OF THE COMMUNICATIONS ERRORS..............................1-62 8. TROUBLESHOOTING OF THE CONTROL PANEL .................................................1-66 9. TROUBLESHOOTING OF FAX FUNCTIONS...........................................................1-68 10. OTHERS PROBLEMS.............................................................................................1-72 CHAPTER 2 PERIODICAL MAINTENANCE........................................... 2-1 1. CONSUMABLE PARTS...............................................................................................2-1 2. PERIODICAL REPLACEMENT PARTS ......................................................................2-4 2.1 Periodical Replacement Parts............................................................................................ 2-4 2.2 Procedures to Replace Periodical Replacement Parts...................................................... 2-5 2.2.1 Fuser Unit & Fuser Filter Frame ASSY.................................................................... 2-5 2.2.2 Laser Unit................................................................................................................. 2-9 2.2.3 Paper Feeding Kit (PF Kit1, PF Kit2) ..................................................................... 2-29 2.2.4 MP Paper Feeding Kit (PF Kit MP) ........................................................................ 2-34 2.3 Parts Life Reset Function................................................................................................. 2-39 iii Confidential CHAPTER 3 DISASSEMBLY AND ASSEMBLY ..................................... 3-1 1. SAFETY PRECAUTIONS ........................................................................................... 3-1 2. PACKING .................................................................................................................... 3-2 3. SCREW TORQUE LIST.............................................................................................. 3-3 4. LUBRICATION ............................................................................................................ 3-7 5. OVERVIEW OF GEARS ........................................................................................... 3-15 6. HARNESS ROUTING ............................................................................................... 3-17 7. DISASSEMBLY FLOW ............................................................................................. 3-31 8. DISASSEMBLY PROCEDURE................................................................................. 3-32 8.1 Paper Tray ........................................................................................................................3-32 8.2 DX Feed ASSY .................................................................................................................3-34 8.3 MP Cover ASSY/ MP Paper Guide ASSY........................................................................3-34 8.4 MP Lift Arm 2/ MP Roller Holder ASSY............................................................................3-37 8.5 Fuser Unit/ Toner Filter Frame ASSY...............................................................................3-40 8.6 Back Cover Upper ............................................................................................................3-42 8.7 Paper Eject ASSY DX.......................................................................................................3-43 8.8 Back Cover ASSY.............................................................................................................3-45 8.9 Paper Guide/ HV TR Top Cover.......................................................................................3-46 8.10 Transfer HVPS PCB Unit................................................................................................3-47 8.11 Registration-mark Sensor PCB ASSY 1, 2/ Density Sensor/ Registration Relay PCB ASSY/ Transfer HVPS PCB ASSY.................................................................................3-48 8.12 Side Cover L ASSY ........................................................................................................3-54 8.13 Side Plate LB ..................................................................................................................3-55 8.14 Drum Unit Fan (OPC) .....................................................................................................3-56 8.15 Side Cover R ASSY........................................................................................................3-57 8.16 Paper Stopper.................................................................................................................3-58 8.17 Driver PCB ASSY ...........................................................................................................3-59 8.18 Pull arm L, R/ Hinge Protection Cover ASSY .................................................................3-61 8.19 ADF Unit .........................................................................................................................3-65 8.20 Panel Unit .......................................................................................................................3-99 8.21 Document Scanner Unit ...............................................................................................3-104 8.22 NCU PCB ASSY (MFC-9840CDW only) ......................................................................3-114 8.23 Battery ASSY ................................................................................................................3-117 8.24 Joint Cover ASSY .........................................................................................................3-118 8.25 Speaker ASSY..............................................................................................................3-124 8.26 Roller Holder ASSY ......................................................................................................3-126 8.27 Paper Feed Frame Unit/ T1 PE/Edge Sensor PCB ASSY ...........................................3-127 8.28 Belt Cleaner Release Sensor PCB ASSY ....................................................................3-135 8.29 THM/HUM Sensor Holder ASSY ..................................................................................3-136 8.30 Release Rack ...............................................................................................................3-138 iv Confidential 8.31 Front Door Unit ASSY .................................................................................................. 3-139 8.32 Harness Cover MP....................................................................................................... 3-142 8.33 Front Door Sub............................................................................................................. 3-143 8.34 EL Electrode Spring L/R............................................................................................... 3-144 8.35 Hook Cover/ Front Cover Release Button/ Button Spring/ Front Door Main ............... 3-145 8.36 Hook Shaft/ Hook/ Hook Spring ................................................................................... 3-147 8.37 Engine PCB ASSY ....................................................................................................... 3-148 8.38 Main PCB ASSY/ Ground Plate/ Ground Spring Plate ................................................ 3-149 8.39 Waste Toner Near/Full Sensor ASSY.......................................................................... 3-151 8.40 Laser Unit/ Hook Slope ................................................................................................ 3-153 8.41 Develop Drive Motor ASSY.......................................................................................... 3-155 8.42 Drum Drive ASSY/ Drum Phase Sensor PCB ASSY 1, 2............................................ 3-160 8.43 Drive Frame Unit ASSY ............................................................................................... 3-164 8.44 Paper Feed/Belt Cleaner Motor ASSY......................................................................... 3-165 8.45 Develop Release Sensor PCB ASSY .......................................................................... 3-166 8.46 Develop Press Drive L ASSY....................................................................................... 3-166 8.47 Front Cover Interlock Switch ASSY ............................................................................. 3-169 8.48 Toner Sensor PCB ASSY K, Y, M, C (TE/NEW) ......................................................... 3-170 8.49 New Toner Actuator/ New Toner Actuator Spring ....................................................... 3-174 8.50 Side Plate R ASSY....................................................................................................... 3-175 8.51 Drum Lock Lever L....................................................................................................... 3-176 8.52 Drum Lock Lever R ...................................................................................................... 3-177 8.53 Charge HVPS PCB ASSY............................................................................................ 3-178 8.54 Toner LED PCB ASSY................................................................................................. 3-180 8.55 Fuser Unit Fan (FU) ..................................................................................................... 3-181 8.56 LVPS Fan (PS)............................................................................................................. 3-181 8.57 Air Intake Fan (AIR) ..................................................................................................... 3-182 8.58 PS PCB Unit................................................................................................................. 3-183 8.59 Belt Unit Drive Motor ASSY ......................................................................................... 3-187 9. DISASSEMBLY PROCEDURE (LT-100CL) ............................................................3-190 9.1 LT Paper Tray ................................................................................................................ 3-190 9.2 LT Cover Rear................................................................................................................ 3-194 9.3 LT Cover Left.................................................................................................................. 3-195 9.4 LT Cover Right ............................................................................................................... 3-196 9.5 LT Relay PCB ASSY ...................................................................................................... 3-197 9.6 LT Solenoid ASSY.......................................................................................................... 3-198 9.7 Collar 6 ........................................................................................................................... 3-199 9.8 Cassette Switch ASSY................................................................................................... 3-199 9.9 LT Paper Feed Frame Unit ............................................................................................ 3-201 v Confidential CHAPTER 4 ADJUSTMENTS AND UPDATING OF SETTING, REQUIRED AFTER PARTS REPLACEMENT.................... 4-1 1. IF YOU REPLACE THE MAIN PCB............................................................................ 4-1 2. IF YOU REPLACE THE ENGINE PCB ..................................................................... 4-11 3. IF YOU REPLACE THE FB UNIT ............................................................................. 4-14 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 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 Scanner Unit 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 Switch (WSW) Setting and Printout.............................................................5-8 1.4.7 Operational Check of LCD (Function code 12) ......................................................5-11 1.4.8 Operational Check of Control Panel Button (Function code 13) ............................5-12 1.4.9 ROM Version Check (Function code 25) ...............................................................5-13 1.4.10 Drum Unit Cleaning (Function code 31)...............................................................5-14 1.4.11 Operational Check of Sensors (Function code 32) ..............................................5-15 1.4.12 Switching of the USB Transfer Speed in the PictBridge Mode/ (Function code 45) ...............................................................................................5-19 1.4.13 EEPROM Customizing (User-accessible) (Function code 52) ............................5-20 1.4.14 Received Data Transfer Function (Function code 53) (MFC-9840CDW only) ....5-21 1.4.15 Fine Adjustment of Scan Start/End Positions (Function code 54) .......................5-23 1.4.16 Acquisition of White Level Data and CCD Scanner Area Setting (Function code 55) ...............................................................................................5-25 1.4.17 Adjustment of Color Registration (Maintenance Mode 66) ..................................5-26 1.4.18 Paper Feeding and Ejecting Test (Function code 67)..........................................5-28 1.4.19 Sensitivity Adjustment of Density Sensor (Function code 72) (Don’t use)...........5-28 1.4.20 EEPROM Customizing (Function code 74)..........................................................5-29 1.4.21 Sensitivity Adjustment of Registration-mark Sensor (Function code 75).............5-30 1.4.22 Operational Check of Fans (Function code 78) ...................................................5-32 1.4.23 Display of the Machine’s Log Information (Function code 80) .............................5-34 1.4.24 Error Code Indication (Function code 82) ............................................................5-36 1.4.25 Developing Bias Voltage Correction (Function code 83) .....................................5-36 1.4.26 Output of Transmission Log to the Telephone Line (Function code 87)..............5-37 1.4.27 Exit from the Maintenance Mode (Function code 99) ..........................................5-37 vi Confidential 2. OTHER SERVICE FUNCTIONS ...............................................................................5-38 2.1 Resetting the Periodical Replacement Parts Life ............................................................ 5-38 2.1.1 Resetting the Life Counter of the Belt Unit ............................................................ 5-38 2.1.2 Resetting the Life Counter of the Fuser Unit ......................................................... 5-38 2.1.3 Resetting the Life Counter of the Drum Unit.......................................................... 5-39 2.1.4 Resetting the Life counter of the Paper Feeding Kit.............................................. 5-39 2.1.5 Resetting the Life Counter of the MP Paper Feeding Kit....................................... 5-40 2.1.6 Resetting the Life Counter of the Laser Unit.......................................................... 5-40 2.2 Develop Roller/ Developing Bias Voltage Counter Reset Function................................. 5-41 2.3 Drum Unit Cleaning Mode................................................................................................ 5-42 2.4 Fuser Motor Speed Adjustment Mode ............................................................................. 5-42 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 HOW TO MAKE THE DRUM UNIT REMOVE SHEET . App.5-1 APPENDIX 6 REFERENCES ........................................................... App.6-1 vii Confidential REGULATIONRadio interference (220 to 240 volt model only) This machine follows EN55022 (CISPR Publication 22)/Class B. Before you use this product, make sure that you use one of the following interface cables. (1) A USB cable. The cable must not be more than 2 meters long. 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. 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 User’s Guide 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: 30 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: DCP-9045CDN and MFC-9840CDW Product option: Lower Tray Unit LT-100CL 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 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 July 26, 2001. Internal laser radiation Maximum radiation power: 30 mW Wave length: 780 - 800 nm Laser class: Class 3B xi Confidential SAFETY INFORMATION Caution for Laser Product (WARNHINWEIS fur Laser drucker) CAUTION: When the machine during servicing is operated with the cover open, the regulations of VBG 93 and the performance instructions for VBG 93 are valid. CAUTION: In case of any trouble with the laser unit, replace the laser unit itself. To prevent direct exposure to the laser beam, do not try to open the enclosure of the laser unit. ACHTUNG: Im Falle von Störungen der Lasereinheit muß diese ersetzt werden. Das Gehäuse der Lasereinheit darf nicht geöffnet werden, da sonst Laserstrahlen austreten können. Additional Information When servicing the optical system of the machine, be careful not to place a screwdriver or other reflective object in the path of the laser beam. Be sure to take off any personal accessories such as watches and rings before working on the machine. A reflected beam, though invisible, can permanently damage the eyes. Since the beam is invisible, the following caution label is attached on the laser unit. 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 Memo Notes tell you useful tips when servicing the machine. Memo tells you bits of knowledge to help understand the machine. xiii Confidential Safety Precautions Listed below are the various kinds of “WARNING” messages included in this manual. WARNING There are high voltage electrodes inside the machine. Before you clean the inside of the machine or replace parts, make sure that you have turned off the power switch and unplugged the machine from the AC power outlet. DO NOT handle the plug with wet hands. Doing this might cause an electrical shock. 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. xiv Confidential WARNING 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. Carefully clean the toner dust with a dry, lint-free cloth and dispose of it according to local regulations. DO NOT use any type of spray to clean inside or outside of the machine. Doing this may cause a fire or electrical shock. If the machine becomes hot, blows smoke, or generates obscure odor, immediately turn off the power switch and unplug the machine from the AC power outlet. If metal objects, water or other liquids get inside the machine, immediately turn off the power switch and unplug the machine from the AC power outlet. To prevent injuries, be careful not to put your hands on the edge of the machine under the document cover. To prevent injuries, be careful not to put your fingers in the area shown in the illustrations. xv Confidential WARNING When you move the machine, grasp the side hand holds that are located at the bottom of the machine. DO NOT carry the machine by holding scanner unit. To prevent injuries when moving or lifting this machine, make sure to use at least two people. 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. 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 Caution Lightning and power surges can damage this product! We recommend that you use a quality surge protection device on the AC power line, or unplug the machine during a lightning storm. xvi Confidential About Copying CAUTION LEGAL LIMITATIONS Color reproductions of certain documents are illegal and may result in either criminal or civil liability. This memorandum is intended to be a guide rather than a complete listing of every possible prohibition. In case of doubt, we suggest that you check with counsel as to any particular questionable documents. The following documents issued by the United States/Canadian Government or any of its Agencies may not be copied: - Money - Bonds or other certificates of indebtedness - Certificates of Deposit - Internal Revenue Stamps (canceled or uncanceled) - Selective Service or draft papers - Passports - United States/Canadian Postage Stamps (canceled or uncanceled) - Food Stamps - Immigration Papers - Checks or drafts drawn by Governmental agencies - Identifying badges or insignias Copyrighted works cannot be copied. Sections of a copyrighted work can be copied for ‘fair use.’ Multiple copies would indicate improper use. Works of art should be considered the equivalent of copyrighted works. Licenses and Certificates of Title to motor vehicles may not be copied under certain state/provincial laws. xvii Confidential CHAPTER 1 TROUBLESHOOTING 1. INTRODUCTION Troubleshooting is the counter measure 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 troubles which may occur in future and determine the troubleshooting procedures, so this chapter covers some sample troubles. However, those 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. Verify again that the repaired portion works properly. 1.2 Initial Check Check the following items before attempting to repair the machine. (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) Ensure the machine is not exposed to direct sunlight, excessive heat, moisture, or dust. (4) Keep the machine horizontal when you carry it. To prevent injuries when moving or lifting this machine, make sure to use at least two people. (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. 1-1 Confidential (1) A recommended type of paper is being used. (Refer to “2.6 Paper” in Reference 1.) (2) The paper is not damp. (3) The paper is not short-grained paper or acid paper. (1) The drum unit (including the toner cartridge) is installed correctly. (2) The belt unit and waste toner box are installed correctly. (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 problems. 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 user to allow the unit to come to room temperature before unpacking it. This will take one or two hours. (2) Low temperature If the room temperature is low the motor may not drive normally, this is due to there being too much load to drive the drum unit. In this case, the “Low Temperature/ Increase room temperature to allow the machine to operate” message will appear on the LCD. Increase the room temperature when the above message is indicated. (3) Cleaning Use a soft dry cloth. CAUTION: DO NOT use any type of spray to clean inside or outside of the machine. Doing this may cause a fire or electrical shock. 1-2 Confidential 2. ERROR CODES This machine includes a self-diagnosis function. If the machine does not work normally it judges that an error has occurred, and indicates the corresponding error message on the LCD, which in turn helps the end user to quickly find out the problem. 2.1 Error Indication The error codes shaded in the table below are recoverable errors if following the User Check items. Error codes Problem Refer to: Error codes 57 Paper jam while turning it over in duplex printing or DX solenoid failure 1-16 58 59 5A 5E Fuser unit failure Fuser unit failure Charge HVPS PCB ASSY failure Replace the belt unit 1-16 1-16 1-17 1-6 5F 60 61 62 63 64 65 66 67 68 69 6A 6B 6C 6D 6E 6F 71 72 73 Replace the waste toner box Toner cartridge (C) is at the end of life. Toner cartridge (M) is at the end of life. Toner cartridge (Y) is at the end of life. Toner cartridge (K) is at the end of life. Replace the toner cartridge (C) Replace the toner cartridge (M) Replace the toner cartridge (Y) Replace the toner cartridge (K) Fuser unit failure Fuser unit failure Fuser unit failure Fuser unit failure Fuser unit failure Fuser unit failure Fuser unit failure Fuser unit failure Polygon motor failure Beam detecting sensor (K) failure Beam detecting sensor (C) failure 1-17 1-18 1-18 1-18 1-18 1-18 1-18 1-18 1-18 1-19 1-19 1-19 1-19 1-19 1-19 1-19 1-19 1-20 1-20 1-20 74 Toner cartridge whose color is used reaches the end of life during printing. 1-21 75 76 78 7C 7D Machine cooling down inside Fuser unit failure Fuser unit failure Engine communication error Dirt on drum unit 82 Density patch measurement is not completed normally when implementing calibration from the control panel. 1-6 1-21 1-21 1-14 1-22 1-22 84 Paper jam rear side of the machine 20 21 22 23 24 25 Laser diode failure (K) Laser diode failure (Y) Laser diode failure (M) Laser diode failure (C) Internal temperature sensor failure Develop drive motor failure 1-8 1-8 1-8 1-8 1-8 1-9 26 27 28 29 2A 2B 2C 2D 2E 2F 30 31 32 Belt drive motor failure Paper feed/belt cleaner motor failure Drum drive motor 1 (K, Y) failure Drum drive motor 2 (M, C) failure Belt cleaner release sensor failure Air intake fan (AIR) failure Toner sensor PCB failure (K) Toner sensor PCB failure (Y) Toner sensor PCB failure (M) Toner sensor PCB failure (C) Incorrect EL lamp current value Density sensor failure Density sensor shutter performance malfunction 1-9 1-9 1-9 1-9 1-10 1-10 1-11 1-11 1-11 1-11 1-11 1-12 1-12 33 34 35 36 37 38 39 3A 3B 3D 3F 50 51 52 53 54 55 56 Color registration sensor failure Color adjustment shutter failure NVRAM failure on Engine PCB Transfer HVPS PCB failure Belt unit temperature sensor failure THM sensor failure HUM sensor failure Engine communication error Main PCB RAM failure Main PCB failure Writing error into engine firmware Replace the drum unit Replace the MP paper feeding kit Replace the T1 paper feeding kit Replace the LT paper feeding kit Replace the fuser unit Replace the laser unit Back cover opened 1-12 1-13 1-13 1-13 1-13 1-14 1-14 1-14 1-15 1-15 1-15 1-5 1-5 1-5 1-5 1-6 1-6 1-15 1-3 Refer to: Problem 1-23 Confidential Refer to: Error codes Tray 1 (T1) is not installed into the machine. Tray 2 (T2) is not installed into the machine. Toner cartridge whose color is used reaches the end of life when implementing calibration from the control panel. 1-24 B2 1-24 B3 1-21 B4 Paper jam inside the machine Incorrect paper size in duplex printing 1-23 Paper jam in Tray 1 (T1) Paper jam in Tray 2 (LT) Paper jam in MP tray (MP) Auto color registration failure when implementing it from the control panel 1-25 1-25 1-25 Sensor sensitivity adjustment failure when implementing auto color registration from the control panel 1-26 Specified paper size is not supported for duplex printing (DX). Request on developing bias voltage adjustment Request on auto color registration 1-7 C0 1-7 C1 1-7 C2 Incorrect sensor measurement value when implementing auto color registration from the control panel 1-26 Toner cartridge whose color is used reaches the end of life when implementing auto color registration from the control panel. A1 A2 A3 A5 Error codes 85 86 87 Problem Refer to: Problem Gain control data level error for CCD unit scanning. Detection error of the scanning area on the left end Detection error of the scanning area on the right end 1-30 1-30 1-30 B5 Detection error of horizontal scanning edge reduction in scanning area setting 1-31 B6 Detection error of horizontal scanning edge magnification in scanning area setting 1-31 B9 Scanning light adjustment error is detected. 1-31 BB BD BE White level data error Black level data error Detection error of scanning starting edge 1-31 1-32 1-32 BF Duplex scanning cannot be implemented due to too long document. Identification failure for a new toner cartridge (K) Identification failure for a new toner cartridge (Y) Identification failure for a new toner cartridge (M) 1-32 C3 Identification failure for a new toner cartridge (C) 1-33 1-21 C4 1-34 Front cover opened Document is too long. Document rear sensor is not turned on when feeding the document. 1-27 1-27 1-27 C5 C6 C7 C8 C9 Tray 2 (LT) plate-up function malfunction EL lamp electrifying failure Toner cartridge mis-dividing Insufficient DIMM memory RAM area for secure data full Defective DIMM is installed. 1-28 CA CB A6 Fax scanning error (The first warning only) Fax scanning error (The second warning that the same error with A5 occurs again) 1-28 CC A7 AD Color parameter failure DMA transfer error 1-28 1-28 AE FB unit home position sensor is not turned on. 1-29 AF FB unit home position sensor is not turned off. 1-29 D0 –DF B0 Harness for CCD unit is not connected correctly. 1-29 E6 EF F8 88 89 8A 8B 8C 8E 8F 99 9B 9C 9D 9E 1-24 1-26 CD 1-4 Excess current to USB device Belt unit is not installed into the machine. Fuser unit is not installed into the machine. Drum unit is not installed into the machine 1-33 1-33 1-33 1-34 1-34 1-7 1-35 1-7 1-35 1-35 1-36 1-36 CE Waste toner box is not installed into the machine. 1-38 CF Waste toner box full Modem error NVRAM error on main PCB Incorrect print coverage value Battery connection failure 1-38 1-39 1-39 1-39 1-39 Confidential 2.2 Error Cause and Remedy 2.2.1 Recoverable Error by User Check These errors are recoverable by following the message indicated on the LCD or following the items indicated in User Check. Error code 50 Drum End Soon Replace the drum unit User Check - Replace the drum unit with a new one. - After replacing the drum unit, reset the counter using the control panel on the machine. (Refer to “2.3 Parts Life Reset Function” in Chapter 2.) Error code 51 Change Parts PF Kit MP Replace the MP paper feeding kit User Check - Replace the MP paper feeding kit with a new one. - After replacing the MP paper feeding kit, reset the counter using the control panel on the machine. (Refer to “2.3 Parts Life Reset Function” in Chapter 2.) Error code 52 Change Parts PF Kit 1 Replace the T1 paper feeding kit User Check - Replace the T1 paper feeding kit with a new one. - After replacing the T1 paper feeding kit, reset the counter using the control panel on the machine. (Refer to “2.3 Parts Life Reset Function” in Chapter 2.) Error code 53 Change Parts PF Kit 2 Replace the LT paper feeding kit User Check - Replace the LT paper feeding kit with a new one. - After replacing the LT paper feeding kit, reset the counter using the control panel on the machine. (Refer to “2.3 Parts Life Reset Function” in Chapter 2.) 1-5 Confidential Error code 54 Change Parts Fuser Unit Replace the fuser unit User Check - Replace the fuser unit with a new one. - After replacing the fuser unit, reset the counter using the control panel on the machine. (Refer to “2.3 Parts Life Reset Function” in Chapter 2.) Error code 55 Change Parts Laser Unit Replace the laser unit User Check - Replace the laser unit with a new one. - After replacing the laser unit, reset the counter using the control panel on the machine. (Refer to “2.3 Parts Life Reset Function” in Chapter 2.) Error code 5E Change Parts Belt Unit Replace the belt unit User Check - Replace the belt unit with a new one. - After replacing the belt unit, reset the counter using the control panel on the machine. (Refer to “2.3 Parts Life Reset Function” in Chapter 2.) Error code 75 Cooling Down 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. 1-6 Confidential Error code 99 Size Error DX Press Cancel. Specify the correct paper and load the same size paper as the Printer driver setting. Specified paper size is not supported for duplex printing (DX). User Check - Check if the selected paper is supported for duplex printing. - Check the size setting of the tray to feed paper. Error code 9B (* This error can be found out only in “Maintenance mode 82”.) Print Unable 9B Request on developing bias voltage adjustment User Check - The machine starts implementing the developing bias voltage adjustment automatically when it enters the standby status. Error code 9C (* This error can be found out only in “Maintenance mode 82”.) Print Unable 9C Request on auto color registration User Check - The machine starts implementing color registration automatically when it enters the standby status. Error code C7 Out of Memory Add more Memory. Insufficient DIMM memory User Check - Install additional DIMM memory. Error code C9 DIMM Error Make sure that the DIMM is inserted correctly. Defective DIMM is installed. User Check - Check if the DIMM is installed correctly. - Replace the DIMM with a new one. 1-7 Confidential 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 20(K) Print Unable 20 Turn the power off and then back on again. Laser diode failure (K) Error code 21(Y) Print Unable 21 Turn the power off and then back on again. Laser diode failure (Y) Error code 22(M) Print Unable 22 Turn the power off and then back on again. Laser diode failure (M) Error code 23(C) Print Unable 23 Turn the power off and then back on again. Laser diode failure (C) Step Cause 1 Laser unit harness connection failure Check the two harness connections of the laser unit and reconnect them. 2 Laser unit failure Replace the laser unit. 3 Engine PCB failure Replace the engine PCB ASSY. Remedy Error code 24 Print Unable 24 Turn the power off and then back on again. Internal temperature sensor failure Step Cause 1 Harness connection failure of internal temperature sensor Check the harness connection of the internal temperature sensor and reconnect it. 2 Engine PCB failure Replace the engine PCB ASSY. Remedy 1-8 Confidential Error code 25 Print Unable 25 Turn the power off and then back on again. Develop drive motor failure Error code 26 Print Unable 26 Turn the power off and then back on again. Belt drive motor failure Error code 27 Print Unable 27 Turn the power off and then back on again. Paper feed/belt cleaner motor failure Step Cause Remedy 1 Motor harness connection failure Check the harness connection of the appropriate motor and reconnect it. 2 Motor failure Replace the appropriate motor. 3 Engine PCB failure Replace the engine PCB ASSY. 4 Low-voltage power supply PCB failure Replace the PS PCB unit. Error code 28 Print Unable 28 Turn the power off and then back on again. Drum drive motor 1 (K, Y) failure Error code 29 Print Unable 29 Turn the power off and then back on again. Drum drive motor 2 (M, C) failure Step Cause Remedy 1 Drum drive motor harness connection failure Check the harness connection of the drum drive motor and reconnect it. 2 Drum phase sensor PCB failure Replace the drum phase sensor PCB ASSY. 3 Drum drive motor failure Replace the drum drive motor. 4 Engine PCB failure Replace the engine PCB ASSY. 1-9 Confidential Error code 2A Print Unable 2A Turn the power off and then back on again. Belt cleaner release sensor failure Step Cause Remedy 1 Rotation defective of release shaft A of waste toner box. Replace the waste toner box. 2 Harness connection failure between belt cleaner release sensor PCB and belt cleaner release solenoid. Check the harness connection between the belt cleaner release sensor PCB and belt cleaner release solenoid and reconnect them. 3 Belt cleaner release sensor actuator performance defective Replace the belt cleaner release ASSY. 4 Belt cleaner release sensor PCB failure Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the belt cleaner release sensor PCB ASSY. 5 Belt cleaner release solenoid failure Replace the belt cleaner release ASSY. 6 Engine PCB failure Replace the engine PCB ASSY. Error code 2B Print Unable 2B Turn the power off and then back on again. Air intake fan (AIR) failure Step Cause Remedy 1 Air intake fan (AIR) harness connection failure Check the harness connection of the air intake fan (AIR) and reconnect it. 2 Air intake fan (AIR) failure Check the fan performance following the procedure described in “Maintenance mode 78”. If any problem occurs, replace the air intake fan (AIR). 3 Engine PCB failure Replace the engine PCB ASSY. 1-10 Confidential Error code 2C(K) Print Unable 2C Turn the power off and then back on again. Error code 2D(Y) Print Unable 2D Turn the power off and then back on again. Error code 2E(M) Print Unable 2E Turn the power off and then back on again. Error code 2F(C) Print Unable 2F Turn the power off and then back on again. Toner sensor PCB failure for the appropriate color Step Cause Remedy 1 Toner sensor PCB (TE/NEW) failure Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the toner sensor PCB ASSY (TE/NEW) for the appropriate color. 2 Engine PCB failure Replace the engine PCB ASSY. Error code 30 Print Unable 30 Turn the power off and then back on again. Incorrect EL lamp current value User Check - Replace the drum unit with a new one. Step 1 Cause Drum unit electrode dirty Remedy Clean the electrodes of the main body and the drum unit. (Refer to Fig.1-1 (P1-37).) 1-11 Confidential Error code 31 Print Unable 31 Turn the power off and then back on again. Density sensor failure Error code 32 Print Unable 32 Turn the power off and then back on again. Density sensor shutter performance malfunction User Check - Check if there is a scratch, dirt or the like on the belt unit. If there is, replace the belt unit with a new one. Step Cause Remedy 1 Harness connection failure of density sensor holder ASSY Check the harness connection between the density sensor holder ASSY and registration relay PCB, and the one between the registration relay PCB and engine PCB. Then, reconnect them. 2 Harness connection failure of density sensor solenoid ASSY Check the harness connection between the engine PCB and registration relay PCB and reconnect them. 3 Density sensor holder ASSY failure Replace the density sensor holder ASSY. 4 Transfer HVPS PCB unit failure Replace the transfer HVPS PCB unit. 5 Engine PCB failure Replace the engine PCB ASSY. Error code 33 Print Unable 33 Turn the power off and then back on again. Color registration sensor failure User Check - Check if there is a scratch, dirt or the like on the belt unit. If there is, replace the belt unit with a new one. Step Cause 1 Harness connection failure of registration-mark sensor PCB ASSY Check the harness connection of the registrationmark sensor PCB ASSY and reconnect it. 2 Registration-mark sensor PCB failure Check the performance of the registration-mark sensor following the procedure described in “Maintenance mode 75”. If any problem occurs, replace the registration-mark sensor PCB ASSY. 3 Transfer HVPS PCB unit failure Replace the transfer HVPS PCB unit. 4 Engine PCB failure Replace the engine PCB ASSY. Remedy 1-12 Confidential Error code 34 Print Unable 34 Color adjustment shutter failure Step Cause Remedy 1 Density sensor shutter catching on some position Correct catching of the density sensor shutter. 2 Density sensor holder ASSY assembling failure Reassemble the density sensor holder ASSY correctly. Error code 35 Print Unable 35 Turn the power off and then back on again. NVRAM failure on Engine PCB Step 1 Cause Engine PCB failure Remedy Replace the engine PCB ASSY. Error code 36 Print Unable 36 Turn the power off and then back on again. Transfer HVPS PCB failure Step Cause 1 Harness connection failure of transfer HVPS PCB ASSY Check the two harness connections between the transfer HVPS PCB and registration relay PCB, and the two ones between the registration relay PCB and engine PCB. Then reconnect them. 2 Transfer HVPS PCB ASSY failure Replace the transfer HVPS PCB ASSY. 3 Engine PCB failure Replace the engine PCB ASSY. Remedy Error code 37 Print Unable 37 Turn the power off and then back on again. Belt unit temperature sensor failure Step 1 Cause Remedy Belt unit temperature sensor harness connection failure Check the harness connection between the belt unit temperature sensor and registration relay PCB, and the one between the registration relay PCB and engine PCB. Then reconnect them. 2 Transfer HVPS PCB unit failure Replace the transfer HVPS PCB unit. 3 Engine PCB failure Replace the engine PCB ASSY. 1-13 Confidential Error code 38 Print Unable 38 Turn the power off and then back on again. THM (Thermistor) sensor failure Error code 39 Print Unable 39 Turn the power off and then back on again. HUM (Humidity) sensor failure Step Cause 1 Harness connection failure of THM/HUM sensor Check the harness connection of the THM/HUM sensor and reconnect it. 2 THM/HUM sensor failure Replace the THM/HUM sensor holder ASSY. 3 Engine PCB failure Replace the engine PCB ASSY. Remedy Error code 3A Print Unable 3A Turn the power off and then back on again. Error code 7C Print Unable 7C Turn the power off and then back on again. Engine communication error Step Cause Remedy 1 Harness connection failure between engine PCB and main PCB Check the harness connection between the engine PCB and main PCB, and reconnect it. 2 Engine PCB failure Replace the engine PCB ASSY. 3 Main PCB failure Replace the main PCB ASSY. 1-14 Confidential Error code 3B Print Unable 3B Turn the power off and then back on again. Main PCB RAM failure Step 1 Cause Remedy Main PCB failure Replace the main PCB ASSY. Error code 3D Print Unable 3D Turn the power off and then back on again. Main PCB failure (Any of the PCBs is judged to be failure by the PCB checker, or it is not tested with the checker.) Step Cause Remedy 1 Main PCB failure Replace the main PCB ASSY. 2 Engine PCB failure Replace the engine PCB ASSY. Error code 3F Print Unable 3F Turn the power off and then back on again. Writing error into engine firmware Step 1 Cause Remedy The machine is turned off while rewriting the data into the engine firmware. Turn the power on. Resend the engine firmware (DJF format) with the USB memory while the error code is being indicated. Error code 56 Cover is Open Close the Back Cover. Back cover opened User Check - Check if the back cover is closed correcty. Step Cause Remedy 1 Back cover switch failure Check the sensor performance following the procedure described in “Maintenance mode 32”. 2 Harness connection failure of back cover switch ASSY Check the harness connection of the back cover switch ASSY and reconnect it. 3 The boss pressing back cover switch is broken. Replace the back cover ASSY. 4 Engine PCB failure Replace the engine PCB ASSY. 1-15 Confidential Error code 57 Jam Duplex Pull out Tray 1 completely. Check inside the machine or open the Back Cover to remove the jammed paper. Paper jam while turning it over in duplex printing, or DX (Duplex) solenoid failure User Check - Check if the paper is jammed or not. If jammed, remove it. Step Cause 1 DX feed ASSY not assembled correctly Reassemble the DX feed ASSY. 2 Paper eject ASSY harness connection failure Check the harness connection of the paper eject ASSY and reconnect it. 3 DX solenoid failure Replace the paper eject ASSY. 4 Engine PCB failure Replace the engine PCB ASSY. Remedy 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 Turn the power off and then back on again. Fuser unit failure * The code included in the message above is one of 68, 69, 6A, 6B, 6C, 6D, 6E, 6F, 76 and 78. Step Cause 1 Harness connection failure between fuser unit connector and engine PCB Check the harness connection between the fuser unit connector and engine PCB, and reconnect it. 2 Fuser unit failure Replace the fuser unit. 3 Low-voltage power supply PCB failure Replace the PS PCB unit. 4 Engine PCB failure Replace the engine PCB ASSY. Remedy 1-16 Confidential Error code 5A Print Unable 5A Turn the power off and then back on again. Charge HVPS PCB failure Step Cause Remedy 1 Charge HVPS PCB ASSY harness connection failure Check the harness connection between the charge HVPS PCB and engine PCB, and the one between the charge HVPS PCB and low-voltage power supply PCB. Then, reconnect them. 2 Charge HVPS PCB failure Replace the charge HVPS PCB ASSY. 3 Engine PCB failure Replace the engine PCB ASSY. Error code 5F Waste Toner Soon Replace the waste toner box User Check - Replace the waste toner box with a new one. Step Cause Remedy 1 Waste toner sensor failure Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the waste toner near/full sensor ASSY. 2 Harness connection failure of waste toner near/full sensor ASSY Check the harness connection of the waste toner near/full sensor ASSY and reconnect it. 3 Engine PCB failure Replace the engine PCB ASSY. 1-17 Confidential Error code 60(C), 61(M), 62(Y), 63(K) Toner Life End Replace ***(*) Toner Cartridge. : The appropriate color is shown in “ ***(*) ”. Toner cartridge is at the end of life. User Check - Gently shake the toner cartridge of the appropriate color from side to side and install it again. - Replace the toner cartridge of the appropriate color. Step Cause Remedy 1 Harness connection failure of toner sensor PCB ASSY (TE/NEW) 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 ASSY (TE/NEW) of the appropriate color, then reconnect it. 2 Toner sensor PCB (TE/NEW) failure (Toner empty) Replace the toner sensor PCB ASSY (TE/NEW) of the appropriate color. 3 Engine PCB failure Replace the engine PCB ASSY. Error code 64(C), 65(M), 66(Y), 67(K) Toner Low Prepare New ***(*) Toner Cartridge. : The appropriate color is shown in “ ***(*) ”. The toner cartridge of the appropriate color shown on the LCD should be replaced. User Check - Gently shake the toner cartridge of the appropriate color from side to side and install it again. - Replace the toner cartridge of the appropriate color. Step Cause Remedy 1 Harness connection failure of toner sensor PCB ASSY (TE/NEW) Check the harness connection of the toner sensor PCB ASSY (TE/NEW) of the appropriate color and reconnect it. 2 Toner sensor (TE/NEW) failure Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the toner sensor PCB ASSY (TE/NEW) of the appropriate color. 3 Engine PCB failure Replace the engine PCB ASSY. 1-18 Confidential Error code 68 Print Unable 68 Turn the power off and then back on again. Fuser unit failure (The side thermistor detects higher temperature than the specified value.) Error code 69 Print Unable 69 Turn the power off and then back on again. Fuser unit failure (The side thermistor detects lower temperature than the specified value.) Error code 6A Print Unable 6A Turn the power off and then back on again. Fuser unit failure (The side thermistor does not detect 60°C within the specified time.) Error code 6B Print Unable 6B Turn the power off and then back on again. Fuser unit failure (The center thermistor does not detect 100°C within the specified time.) Error code 6C Print Unable 6C Turn the power off and then back on again. Fuser unit failure (The center thermistor detects higher temperature than the specified value.) Error code 6D Print Unable 6D Turn the power off and then back on again. Fuser unit failure (The center thermistor detects lower temperature than the specified value.) Error code 6E Print Unable 6E Turn the power off and then back on again. Fuser unit failure (The center thermistor does not detect temperature rising within the specified time.) Error code 6F Print Unable 6F Turn the power off and then back on again. Fuser unit failure (The center and side thermistors detect extremely high temperature.) Step Cause Remedy 1 Fuser unit failure Replace the fuser unit. 2 Low-voltage power supply PCB failure Replace the PS PCB unit. 3 Engine PCB failure Replace the engine PCB ASSY. 1-19 Confidential Error code 71 Print Unable 71 Turn the power off and then back on again. Polygon motor failure Error code 72 Print Unable 72 Turn the power off and then back on again. Beam detecting sensor (K) failure Error code 73 Print Unable 73 Turn the power off and then back on again. Beam detecting sensor (C) failure Step Cause Remedy 1 Condensation on laser unit Turn the power off and leave the machine in an airy place at normal room temperature. 2 Laser unit harness connection failure Check the two harness connections of the laser unit and reconnect them. 3 Laser unit failure Replace the laser unit. 4 Engine PCB failure Replace the engine PCB ASSY. 1-20 Confidential Error code 74 (* This error can be found out only in “Maintenance mode 82”.) Print Unable 74 Toner cartridge whose color is used reaches the end of life during printing. Error code 87 Calibrate Calibration failed. Insufficient Toner for Calibration. Toner cartridge whose color is used reaches the end of life when implementing calibration from the control panel. Error code 9E Registration Registration failed. Insufficient Toner for Registration. Toner cartridge whose color is used reaches the end of life when implementing auto color registration from the control panel. User Check - If any of the toner cartridges reaches the end of life, replace it with a new one. Step Cause Remedy 1 Toner sensor PCB (TE/NEW) failure (Toner empty) Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the toner sensor PCB (TE/NEW) of the appropriate color. 2 Engine PCB failure Replace the engine PCB ASSY. Error code 76 Print Unable 76 Turn the power off and then back on again. Fuser unit failure (The center thermistor detects rapid temperature rising.) Step 1 Cause Fuser unit failure Remedy Replace the fuser unit. Error code 78 Print Unable 78 Turn the power off and then back on again. Fuser unit failure (The center thermistor detects rapid temperature falling.) Step Cause 1 Harness connection failure between fuser unit connector and engine PCB Check the harness connection between the fuser unit connector and engine PCB, and reconnect it. 2 Fuser unit failure Replace the fuser unit. Remedy 1-21 Confidential Error code 7D Drum Error Slide the Green tab on Drum Unit in each color. Refer to the User’s Guide for the procedures. Dirt on drum unit User Check - Clean the corona wire in the drum unit. - Replace the drum unit with a new one. Step Cause Remedy 1 Dirt or dust on drum unit electrodes Clean the electrodes of the main body and the drum unit. (Refer to Fig. 1-1 (P1-37).) 2 Charge HVPS PCB failure Replace the charge HVPS PCB ASSY. 3 Engine PCB failure Replace the engine PCB ASSY. Error code 82 Calibrate Calibration failed. Press start, and try again. Density patch measurement is not completed normally when implementing calibration from the control panel. User Check - Check if there is a scratch, dirt or the like on the belt unit. If there is, replace the belt unit with a new one. - Check if the genuine toner cartridges are installed in the correct order of colors. Step Cause Remedy 1 Density sensor shutter not operating smoothly or catching in some position Correct smooth operation of the density sensor shutter. 2 Harness connection failure of density sensor holder ASSY Check the harness connection of the density sensor holder ASSY and reconnect it. 3 Density sensor failure Replace the density sensor holder ASSY. 4 Transfer HVPS PCB failure Replace the transfer HVPS PCB ASSY. 5 Engine PCB failure Replace the engine PCB ASSY. 1-22 Confidential Error code 84 (Jam Rear) Jam Rear Open the Back Cover and remove the jammed paper. Paper jam rear side of the machine Error code 88 (Jam Inside) Jam Inside Open the Front Cover, pull out the Drum Unit completely and remove the jammed paper. Paper jam inside the machine User Check - Check if the paper is jammed. If jammed, remove it. Step Cause Remedy 1 Harness connection failure of registration front sensor PCB ASSY, registration rear sensor PCB ASSY or paper eject sensor PCB ASSY Check the harness connections of the registration front sensor PCB ASSY, registration rear sensor PCB ASSY and paper eject sensor PCB ASSY, and reconnect them. 2 Registration front actuator, registration rear actuator or paper eject actuator not operating smoothly or catching in some position. Correct smooth operation of the registration front actuator, registration rear actuator or paper eject actuator and ensure they are not catching in any positions. 3a Paper eject sensor PCB failure Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the fuser unit. 3b Registration front sensor PCB failure (MP/ T1/ LT) (MP/ T1) Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the front door unit ASSY. (LT) Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the LT paper feed frame unit. 3c Registration rear sensor PCB failure Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the front door unit ASSY. 4 Engine PCB failure Replace the engine PCB ASSY. 1-23 Confidential Error code 85 No Tray A Tray is not detected, install Tray 1. Tray 1 (T1) is not installed into the machine. User Check - Check if tray 1 (T1) is installed into the machine. - Check if the paper is jammed in tray 1 (T1). Step Cause Remedy 1 T1 PE/edge sensor PCB failure Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the T1 PE/edge sensor PCB ASSY. 2 Harness connection failure of T1 PE/edge sensor PCB ASSY Check the harness connection of the T1 PE/edge sensor PCB ASSY and reconnect it. 3 Engine PCB failure Replace the engine PCB ASSY. Error code 86 No Tray Tray 2 (LT) is not installed into the machine. User Check - Install Tray 2 (LT) into the machine. - Select other tray than Tray 2. Step 1 Cause Cassette sensor failure Remedy Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the LT paper feed frame unit. Error code 89 Size Error DX Specify the correct paper and press start. Incorrect paper size in duplex printing User Check - Use the letter size or longer paper. - Do not use too thin paper. Step Cause Remedy 1 Registration rear sensor PCB failure Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the registration rear sensor PCB ASSY. 1-24 Confidential Error code 8A (T1) Jam Tray 1 Remove the jammed paper from Tray 1. Error code 8B (LT) Jam Tray 2 Remove the jammed paper from Tray 2. Error code 8C (MP) Jam MP Tray Remove the jammed paper from Multi Purpose Tray and press start. Paper jam in the appropriate tray User Check - Check if the paper is jammed in the appropriate tray. If jammed, remove it. - Adjust the paper guide corresponding to the paper size. - Check if too much paper is loaded in the tray. Step Cause 1 Harness connection failure of registration front sensor PCB ASSY Check the harness connection of the registration front sensor PCB ASSY in the appropriate tray, and reconnect it. 2 Paper feeding kit worn out Replace the paper feeding kit of the appropriate tray. (MP/ T1/ LT) 3 Registration front sensor PCB failure (MP/ T1/ LT) Remedy (MP/ T1) Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the front door unit ASSY. (LT) Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the LT paper feed frame unit. 4 Engine PCB failure Replace the engine PCB ASSY. 1-25 Confidential Error code 8E Registration Registration failed. Press start and try again. Auto color registration failure when implementing it from the control panel Error code 8F Registration Registration failed. See Troubleshooting chapter in User’s Guide. Sensor sensitivity adjustment failure when implementing auto color registration from the control panel Error code 9D Registration Registration failed. See Troubleshooting chapter in User’s Guide. Incorrect sensor measurement value when implementing auto color registration from the control panel User Check - Check if there is a scratch, dirt or the like on the belt unit. If there is, replace the belt unit with a new one. Step Cause Remedy 1 Invisible damage on belt unit Check the registration mark sensor performance following the procedure described in “Maintenance mode 75”. If any problem occurs, replace the belt unit. 2 Harness connection failure of registration-mark sensor PCB ASSY Check the harness connection of the registrationmark sensor PCB ASSY and reconnect it. 3 Registration-mark sensor PCB failure Replace the registration-mark sensor PCB ASSY. 4 Transfer HVPS PCB unit failure Replace the transfer HVPS PCB unit. 5 Engine PCB failure Replace the engine PCB ASSY. 1-26 Confidential Error code A1 Cover is Open Close the Front Cover. Front cover opened Step Cause Remedy 1 Front cover interlock switch failure Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the front cover interlock switch ASSY. 2 Harness connection failure of front cover interlock switch ASSY Check the harness connection of the front cover interlock switch ASSY and reconnect it. 3 Part pressing the front cover interlock switch is broken, which is provided at the left side of the front cover inside. Replace the front door main or front door unit ASSY. 4 Engine PCB failure Replace the engine PCB ASSY. Error code A2 Document Jam. Clear the scanner jam, then press the Stop Key. The document is too long. (During scanning, 90 cm or longer of a document is detected.) User Check - Check if the document is jammed in the ADF. If jammed, remove it. Step 1 Cause Document rear actuator not operating smoothly or catching in some position. Remedy Correct smooth operation and that there is no catching of document rear actuator. Error code A3 Document Jam. Clear the scanner jam, then press the Stop Key. Document rear sensor is not turned on when feeding the document. User Check - Check if the document is jammed in the ADF. If jammed, remove it. Step Cause Remedy 1 Document rear actuator not operating smoothly or catching in some position. Correct smooth operation and that there is no catching of document rear actuator. 2 Document rear sensor failure. Replace the document rear sensor. 1-27 Confidential Error code A5 Unable to Scan Remove the original document. Turn the power off, then on again. Fax scanning error (The first warning only) Step 1 Cause Scanning failure Remedy Turn the power switch off and on. Then, try scanning again. Error code A6 Unable to Scan See Troubleshooting and routine maintenance chapter in User's Guide. Fax scanning error (After the A5 error occurs, the same problem occurs again even though turning the power off and on.) Step Cause Remedy 1 Scanner unit failure Replace the FB unit. 2 Main PCB failure Replace the main PCB ASSY. Error code A7 Machine Error Unplug machine, then call Brother. There is no registration in scanning color parameter data. Step Cause Remedy 1 Main PCB failure Replace the main PCB ASSY. 2 CCD unit failure Replace the CCD unit. Error code AD Unable to Scan Remove the original document. Turn the power off, then on again. DMA transfer error Step Remedy Cause 1 Main PCB failure Replace the main PCB ASSY. 2 CCD unit failure Replace the CCD unit. 1-28 Confidential Error code AE Unable to Scan See Troubleshooting and routine maintenance chapter in User's Guide. FB unit home position sensor is not turned on. Step Remedy Cause 1 Drive PCB failure Replace the drive PCB. 2 Belt broken Replace the belt. 3 Home position sensor failure Replace the home position sensor. 4 Scanner motor failure Replace the scanner motor. 5 Main PCB failure Replace the main PCB ASSY. Error code AF Unable to Scan See Troubleshooting and routine maintenance chapter in User's Guide. FB unit home position sensor is not turned off. Step Remedy Cause 1 Drive PCB failure Replace the drive PCB. 2 Belt broken Replace the belt. 3 Home position sensor failure Replace the home position sensor. 4 Hook of the CCD unit broken Replace the CCD unit. 5 Scanner motor failure Replace the scanner motor. 6 Main PCB failure Replace the main PCB ASSY. Error code B0 SCANNER ERROR Harness for CCD unit is not connected correctly. * This error is indicated on the LCD in the maintenance mode. Step Remedy Cause 1 Harness for CCD unit not connected correctly. Reconnect the harness for the CCD unit correctly. 2 Scanner harness broken Replace the FFC cable ASSY. 3 Main PCB failure Replace the main PCB ASSY. 1-29 Confidential Error code B2 SCANNER ERROR Gain control data level error for CCD unit scanning. * This error is indicated on the LCD in the maintenance mode. Step Cause Remedy 1 CCD unit failure Replace the CCD unit. 2 Main PCB failure Replace the main PCB ASSY. Error code B3 SCANNER ERROR Detection error of the scanning area on the left end * This error is indicated on the LCD in the maintenance mode. Step Cause Remedy 1 CCD unit failure Replace the CCD unit. 2 Main PCB failure Replace the main PCB ASSY. Error code B4 SCANNER ERROR Detection error of the scanning area on the right end * This error is indicated on the LCD in the maintenance mode. Step Cause Remedy 1 CCD unit failure Replace the CCD unit. 2 Main PCB failure Replace the main PCB ASSY. 1-30 Confidential Error code B5 SCANNER ERROR Detection error of horizontal scanning edge reduction in scanning area setting * This error is indicated on the LCD in the maintenance mode. Error code B6 SCANNER ERROR Detection error of horizontal scanning edge magnification in scanning area setting * This error is indicated on the LCD in the maintenance mode. Step Cause Remedy 1 White tape dirty of FB unit Clean the white tape. 2 CCD unit failure Replace the CCD unit. 3 Main PCB failure Replace the main PCB ASSY. Error code B9 SCANNER ERROR Scanning light adjustment error is detected. * This error is indicated on the LCD in the maintenance mode. Step Cause Remedy 1 CCD unit failure Replace the CCD unit. 2 Main PCB failure Replace the main PCB ASSY. Error code BB SCANNER ERROR White level data error * This error is indicated on the LCD in the maintenance mode. Step Cause Remedy 1 CCD unit failure Replace the CCD unit. 2 Main PCB failure Replace the main PCB ASSY. 1-31 Confidential Error code BD SCANNER ERROR Black level data error * This error is indicated on the LCD in the maintenance mode. Step Cause Remedy 1 Scanner unit failure Replace the FB unit. 2 Main PCB failure Replace the main PCB ASSY. Error code BE SCANNER ERROR Detection error of scanning starting edge * This error is indicated on the LCD in the maintenance mode. Step Cause Remedy 1 CCD unit failure Replace the CCD unit. 2 Main PCB failure Replace the main PCB ASSY. Error code BF Unable to Scan. Document is too long for duplex scanning. Press Stop key. Longer document than the specified size is detected in duplex scanning. Step Cause 1 Document front actuator 2 not operating smoothly or catching in some position. Correct smooth operation and that there is no catching of the document front actuator 2. 2 Document front sensor 2 failure Replace the document front sensor 2. Remedy 1-32 Confidential Error code C0(K) Cartridge Error Put the Black (K) Toner Cartridge back in. Identification failure for a new toner cartridge (K) Error code C1(Y) Cartridge Error Put the Yellow (Y) Toner Cartridge back in. Identification failure for a new toner cartridge (Y) Error code C2(M) Cartridge Error Put the Magenta (M) Toner Cartridge back in. Identification failure for a new toner cartridge (M) Error code C3(C) Cartridge Error Put the Cyan (C) Toner Cartridge back in. Identification failure for a new toner cartridge (C) User Check - Install the toner cartridges into the machine properly. Step Cause 1 Power off or front cover opened while detecting a new toner cartridge Remedy Reset the developing bias voltage and develop roller counter. (Refer to “2.2 Develop Roller/ Developing Bias Voltage Counter Reset Function” in Chapter 5.) 1-33 Confidential Error code C4 Tray 2 Error Take out Tray 2 and push it back in firmly. Tray 2 (LT) plate-up function malfunction User Check - Check if Tray 2 (LT) is installed into the machine. Step Remedy Cause 1 Connection failure between the machine and LT connector Replace the connector. 2 Harness connection failure of plate motor ASSY LT Check the harness connection of the plate motor ASSY LT and reconnect it. 3 Harness connection failure of LT paper feed frame unit Check the harness connection of the LT paper feed frame unit and reconnect it. 4 LT paper feed frame unit failure Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the LT paper feed frame unit. 5 Engine PCB failure Replace the engine PCB ASSY. Error code C5 EL Error Open the Front Cover and close it again. EL lamp electrifying failure User Check - Open and close the front cover. Step Remedy Cause 1 Dirt on electrodes on drum unit and front cover Clean both electrodes. 2 EL lamp PCB failure Replace the drum unit. 3 EL lamp PCB harness broken Replace the front door unit ASSY. 4 Engine PCB failure Replace the engine PCB ASSY. Error code C6 Toner Error A Toner is not detected. Put all the Toner Cartridges back in correctly. Toner cartridge mis-dividing Remedy Step Cause 1 Harness connection failure of develop release motor Check the harness connection of the develop release motor and reconnect it. 2 Develop release sensor PCB failure Replace the develop release sensor PCB ASSY. 3 Engine PCB failure Replace the engine PCB ASSY. 1-34 Confidential Error code C8 Out of Memory Secure Print Data is full. Press Cancel and delete the previously stored data. RAM area for secure data full User Check - Delete the stored data. Step 1 Cause Main PCB failure Remedy Replace the main PCB ASSY. Error code CA Unusable Device Remove the Device. Turn the power off and back on again. Excess current to USB device User Check - Remove the USB device from the USB direct interface and turn the power off. Turn it on again after a while. - Replace the USB device with another one. Step Cause 1 Harness connection failure of USB host relay PCB ASSY Check the harness connection of the USB host relay PCB ASSY and reconnect it. 2 USB host relay PCB failure Replace the USB host relay PCB ASSY. 3 Main PCB failure Replace the main PCB ASSY. 4 A device whose power consumption is out of the specification is inserted in the USB direct interface Remove the device. Remedy Error code CB No Belt Unit Open the Front Cover, pull out the Drum Unit completely and install the Belt Unit. Belt unit is not installed into the machine. User Check - Check if the belt unit is installed into the machine. Step Cause 1 Harness connection failure of density sensor holder ASSY Check the harness connection of the density sensor holder ASSY and reconnect it. 2 Density sensor failure Replace the density sensor holder ASSY. 3 Transfer HVPS PCB unit failure Replace the transfer HVPS PCB unit. 4 Engine PCB failure Replace the engine PCB ASSY. Remedy 1-35 Confidential Error code CC No Fuser Unit Install the Fuser Unit. Fuser unit is not installed into the machine. User Check - Check if the fuser unit is installed into the machine. Step Cause 1 Harness connection failure between fuser unit connector and engine PCB Check the harness connection between the fuser unit connector and engine PCB, and reconnect it. 2 Engine PCB failure Replace the engine PCB ASSY. 3 Main PCB failure Replace the main PCB ASSY. Remedy Error code CD No Drum Unit Install the Drum Unit. Drum unit is not installed into the machine. User Check - Check if the drum unit is installed into the machine. Step Cause 1 Dirt on electrodes on drum unit and front door unit ASSY Clean both electrodes. (Refer to Fig. 1-1 and Fig 1-2 (P1-37).) 2 Bending of front door unit ASSY electrode contact Correct the electrode bending of the front door unit ASSY. 3 Harness connection failure between front door unit ASSY electrode and engine PCB ASSY Check the harness connection between the front door unit ASSY electrode and engine PCB ASSY. 4 Engine PCB failure Replace the engine PCB ASSY. Remedy 1-36 Confidential Electrodes location of the drum unit Fig. 1-1 Electrodes location of the front door unit ASSY Fig. 1-2 Turn off the power switch. Unplug the machine from the AC power outlet, and leave the machine for a few minutes. Then, wipe the electrodes above carefully with a dry lint-free cloth. Be careful not to change the shapes of the electrodes. 1-37 Confidential Error code CE No Waste Toner Install the Waste Toner Box. Refer to the User’s Guide for how to install. Waste toner box is not installed into the machine. User Check - Check if the waste toner box is installed into the machine correctly. Step Cause Remedy 1 Rotation defective of release shaft A of waste toner box. Replace the waste toner box. 2 Harness connection failure between belt cleaner release sensor PCB and belt cleaner release solenoid. Check the harness connection between the belt cleaner release sensor PCB and belt cleaner release solenoid and reconnect them. 3 Belt cleaner release sensor actuator performance defective Replace the belt cleaner release ASSY. 4 Belt cleaner release sensor PCB failure Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the belt cleaner release sensor PCB ASSY. 5 Belt cleaner release solenoid failure Replace the belt cleaner release ASSY. 6 Engine PCB failure Replace the engine PCB ASSY. Error code CF Waste Toner Full Replace the Waste Toner Box. Refer to the User’s Guide for how to do it. Waste toner box full User Check - Replace the waste toner box with a new one. Step Cause Remedy 1 Waste toner sensor failure Check the sensor performance following the procedure described in “Maintenance mode 32”. If any problem occurs, replace the waste toner near/full sensor ASSY. 2 Harness connection failure of waste toner near/full sensor ASSY Check the harness connection of the waste toner near/full sensor ASSY and reconnect it. 3 Engine PCB failure Replace the engine PCB ASSY. 1-38 Confidential Error code D0-DF Press Stop Key Modem error User Check - Turn the power switch off and on and check if the machine is recovered from the error. Step 1 Cause Main PCB failure Remedy Replace the main PCB ASSY. Error code E6 Print Unable E6 Turn the power off and then back on again. NVRAM error on main PCB Step 1 Cause Main PCB failure Remedy Replace the main PCB ASSY. Error code EF Print Unable EF Turn the power off and then back on again. Incorrect print coverage value User Check - Turn the power off. Turn it on again after a while. Step 1 Cause Main PCB failure Remedy Replace the main PCB ASSY. Error code F8 Machine Error F8 Battery connection failure Step Cause Remedy 1 Battery harness connection failure Reconnect the battery harness. 2 Main PCB failure Replace the main PCB ASSY. 1-39 Confidential 3. PAPER FEEDING PROBLEMS Problems related to paper feeding are end user recoverable if following the User Check items. If the same problem occurs again, follow each procedure in the order of the number described in the Step column in the tables below. 3.1 No Feeding Step 3.2 Cause Check Result Remedy 1 Plate gear damaged Is the plate gear damaged? Yes Replace the paper tray. 2 T1 edge actuator malfunction Does T1 edge actuator move smoothly? No Re-assemble T1 edge actuator. 3 Disconnection of the paper feed solenoid harness Is the harness of the paper feed solenoid disconnected? Yes Reconnect the harness. 4 Paper feed/belt cleaner motor failure Is the problem solved by replacing the paper feed/ belt cleaner motor? Yes Replace the paper feed/ belt cleaner motor. Double Feeding Step 1 Cause Paper feeding kit Check Is the surface of the separation pad worn out? 1-40 Result Yes Remedy Replace the paper feeding kit. Confidential 3.3 Paper Jam Paper jam in the paper tray and front cover Step Cause Check Result Remedy 1 Belt unit malfunction Does the belt unit move correctly? No Replace the belt unit. 2 Registration front actuator move smoothly or catching in some position Does the registration front actuator move smoothly? No Re-assemble the registration front actuator. 3 T1 registration front sensor failure Does T1 registration front sensor move smoothly? (Check it following the procedure described in “Maintenance mode 32”.) No Replace the front door unit ASSY. Paper jam in the back cover and paper eject section Step Cause Check Result Remedy 1 Foreign object around fuser unit Is there a foreign object around the fuser unit? Yes Remove the foreign object. 2 Paper eject ASSY malfunction Is each pinch roller of the paper eject ASSY attached to each paper eject roller properly? No Replace the paper eject ASSY. 3 Paper eject actuator failure Does the paper eject actuator move smoothly? Is it damaged? No Replace the fuser unit. Paper jam in the DX paper feeding section User Check - Use the A4 size paper. - Use paper which has not curled. - Do not use too thin paper. - Check that the DX paper size (A4/Letter) switch lever of the DX feed ASSY is placed in the correct position. Step Cause Check Result Remedy 1 Deformation of paper guide DX on the bottom of the paper tray Is the paper guide DX deformed? No Replace the paper tray. 2 DX feed ASSY failure Is the DX feed ASSY deformed? Do the rollers of the DX feed ASSY move correctly? No Replace the DX feed ASSY. 1-41 Confidential 3.4 Dirt on Paper User Check - Check if the paper is loaded into the paper tray correctly. - Turn over the stack of paper in the paper tray, or try rotating the paper 180° in the paper tray. Step 1 3.5 Cause Fuser unit dirty Check Result Remedy Is there dirt around the entrance of the fuser unit? Yes Clean the entrance of the fuser unit. Is the pressure roller ASSY dirty? Yes Clean the pressure roller ASSY. 2 Dirt on belt unit electrode Is the electrode of the belt unit dirty? Yes Clean the electrode of the main body and the belt unit. 3 Dirt on waste toner box electrode Is the electrode of the waste toner box dirty? Yes Clean the electrode of the main body and the waste toner box. 4 Belt unit dirty Does dirt on the paper disappear after replacing the belt unit with a new one? Yes Replace the belt unit. 5 Toner leak from the waste toner box Is the waste toner box full of toner? Yes Replace the waste toner box. Check the near/full sensor ASSY. Or, replace the main PCB ASSY. Wrinkles User Check - Check if the paper is loaded into the paper tray correctly. - Turn over the stack of paper in the paper tray, or try rotating the paper 180° in the paper tray. Step 1 Cause Fuser unit failure Check Do wrinkles on the paper disappear after replacing the fuser unit with a new one? 1-42 Result Yes Remedy Replace the fuser unit. Confidential 4. IMAGE DEFECT TROUBLESHOOTING 4.1 Image Defect Examples Light on the whole page One color is light Poor fixing Completely blank Dirt on the back of paper Faulty registration Image distortion Dark All one color Vertical streaks Vertical streaks in a light background Horizontal stripes White vertical streaks on one color image White horizontal stripes on one color image Faint print White spots on one color image One color spots or dirt One color band Downward fogging of solid color Unstable color density Horizontal lines Ghost Hollow print Color misregistration Fogging Dirt on the bottom end of paper Fig. 1-3 1-43 Confidential 4.2 Diameter of Rollers Image defects which appear periodically may be caused by failure of a roller. Specify the cause referring to the diameters of the rollers or pitch which appears in the image as shown in the table below. No. 4.3 Parts name Diameter The pitch which appears in the image 1 Develop roller Ø 20.0 mm 37.4 mm 2 Exposure drum Ø 24.0 mm 75.0 mm 3 Heat roller in the fuser unit Ø 25.0 mm 78.5 mm 4 Pressure roller ASSY in the fuser unit Ø 25.0 mm 78.5 mm Troubleshooting Image Defect Image defect related problems are end user recoverable if following the User Check items. If the same problem occurs, follow each procedure in the order of the number described in the Step column in the tables below. Light on the whole page User Check - Check the machine’s environment. High temperature and high humidity conditions can cause this problem. - If the whole page is light, toner save mode may be on. - Replace the toner cartridge or drum unit with a new one. - Implement calibration from the control panel. Step Cause Check Result Remedy 1 Transfer HVPS PCB failure Is the transfer HVPS PCB ASSY connected correctly? Yes Replace the transfer HVPS PCB ASSY. 2 Engine PCB failure Is the harness between the HVPS PCB and engine PCB connected correctly? Yes Replace the engine PCB ASSY. 3 Charge HVPS PCB failure Is the harness of the HVPS PCB connected correctly? Yes Replace the charge HVPS PCB ASSY. 4 Laser unit failure Is the problem solved after replacing the laser unit? Yes Replace the laser unit. 1-44 Confidential One color is light User Check - Check the machine’s environment. High temperature and high humidity conditions can cause this problem. - Replace the toner cartridge or drum unit with a new one. - Implement calibration from the control panel. Step Cause 1 Dirt on exposure drum electrode 2 Dirt on belt unit electrode 3 Dirt on scanner windows 4 Toner sensor failure 5 Check Result Remedy Are the electrodes of the drum unit and the appropriate color and machine body dirty? Are the electrodes of the belt unit and the appropriate color and machine body dirty? Is the scanner windows of the appropriate color dirty? After replacing the toner cartridge of the appropriate color with a new one, does the same problem occur even after printing several pages? Does the machine start printing even after removing the toner cartridge of the appropriate color from the drum unit? Yes Clean both electrodes. Yes Clean both electrodes. Yes Wipe the dirt off with a soft, clean, lint free cloth. No Replace the toner cartridge of the appropriate color. Yes - Clean the toner sensor of the appropriate color. - Check the harness connection of the toner sensor PCB ASSY (TE/NEW) of the appropriate color. - Replace the toner sensor PCB ASSY (TE/NEW) of the appropriate color. Faulty registration Step Cause Check Result Remedy 1 Registration rear actuator operating smoothly or is it catching. Engine PCB failure Does the registration rear actuator move smoothly? No Re-assemble the registration rear actuator. Is the problem solved after replacing the engine PCB ASSY? Yes Replace the engine PCB ASSY. 2 1-45 Confidential Dark User Check - Check the machine’s environment. High temperature and high humidity conditions can cause this problem. - Replace the toner cartridge or drum unit with a new one. - Implement calibration from the control panel. Step Cause Check 1 Corona wire conduction failure Are the electrodes on the drum unit and machine body dirty? Yes Clean both electrodes. 2 Dirt on belt unit electrode Are the electrodes on the belt unit and machine body dirty? Yes Clean both electrodes. 3 Transfer HVPS PCB failure Is the problem solved after replacing the transfer HVPS PCB ASSY? Yes Replace the transfer HVPS PCB ASSY. 4 Charge HVPS PCB failure Is the problem solved after replacing the charge HVPS PCB ASSY? Yes Replace the charge HVPS PCB ASSY. 5 Engine PCB failure Is the harness connected between the HVPS PCB and engine PCB correctly? Yes Replace the engine PCB ASSY. Result Remedy Poor fixing User Check - Replace the drum unit with a new one. - Replace the toner cartridge with a new one. - Implement calibration from the control panel. Step Cause Check Result Remedy 1 Fuser unit failure Is the problem solved after replacing the fuser unit? Yes Replace the fuser unit. 2 Low-voltage power supply PCB failure Is the problem solved after replacing the PS PCB unit? Yes Replace the PS PCB unit. 3 Transfer HVPS PCB failure Is the problem solved after replacing the transfer HVPS PCB ASSY? Yes Replace the transfer HVPS PCB ASSY. 4 Charge HVPS PCB failure Is the problem solved after replacing the charge HVPS PCB ASSY? Yes Replace the charge HVPS PCB ASSY. 5 Engine PCB failure Is the problem solved after replacing the engine PCB ASSY? Yes Replace the engine PCB ASSY. 1-46 Confidential Completely blank User Check - Replace the toner cartridge or drum unit with a new one. Step Cause 1 Developing bias voltage conduction failure Are the electrodes on the drum unit and machine body dirty? Yes Clean both electrodes. 2 Scanner harness connection failure Is the scanner harness connected securely? No Reconnect the scanner harness. 3 Engine PCB failure Is the problem solved after replacing the engine PCB ASSY? Yes Replace the engine PCB ASSY. 4 Laser unit failure Is the problem solved after replacing the Laser unit? Yes Replace the laser unit. 5 Transfer HVPS PCB failure Is the problem solved after replacing the transfer HVPS PCB ASSY? Yes Replace the transfer HVPS PCB ASSY. 6 Charge HVPS PCB failure Is the problem solved after replacing the charge HVPS PCB ASSY? Yes Replace the charge HVPS PCB ASSY. Check Result Check Result Remedy Image distortion Step Cause Remedy 1 Laser unit not assembled correctly Is the laser unit assembled into the machine securely? (Check if there is no gap.) No Assemble the laser unit correctly and secure the screw. 2 Incorrect radiation angle of scanner diode Scanner motor rotation failure Is the problem solved after replacing the laser unit? Yes Replace the laser unit. 1-47 Confidential All one color Step 1 Cause Corona wire failure 2 Check Result Remedy Are the electrodes on the drum unit of the appropriate color and machine body dirty? Yes Clean both electrodes. Is the corona wire damaged? Yes Replace the drum unit. 3 Charge HVPS PCB failure Is the problem solved after replacing the charge HVPS PCB ASSY? Yes Replace the charge HVPS PCB ASSY. 4 Main PCB failure Is the problem solved after replacing the main PCB ASSY? Yes Replace the main PCB ASSY. 5 Engine PCB failure Is the problem solved after replacing the engine PCB ASSY? Yes Replace the engine PCB ASSY. 6 Laser unit failure Is the problem solved after replacing the laser unit? Yes Replace the laser unit. Dirt on the back of paper User Check - If there is dirt on the back of the paper in duplex printing, the back of the paper tray may be dirty. Clean the back of the paper tray. Step 1 Cause Fuser unit dirty Check Result Remedy Is the pressure roller ASSY dirty? Is any other area in the machine dirty? Yes Print approximate 10 pages. No Replace the fuser unit. 2 Dirt in the paper feed system Is the paper tray or feed system on the drum unit dirty with toner? Yes Wipe dirt off. 3 Belt unit dirty Is the problem solved by replacing the belt unit? Yes Replace the belt unit. 4 Waste toner box dirty Is the problem solved by replacing the waste toner box? Yes Replace the waste toner box. 1-48 Confidential Vertical streaks User Check - This problem may occur with noise which is caused by dirt on the corona wire in the drum unit. In this case, clean the corona wire with the wire cleaner. - Replace the drum unit with a new one. - Replace the toner cartridge with a new one. Step Cause Check Result Remedy 1 Dirt in the paper feed system Is the paper tray or feed system on the drum unit dirty with toner? Yes Wipe dirt off. 2 Scratch on the exposure drum Is there a scratch on the surface of the exposure drum? Yes Replace the drum unit. 3 Exposure drum dirty Is there vertical dirt with toner on the surface of the exposure drum? Yes Replace the drum unit. 4 Scratch on the heat roller Is there a scratch on the surface of the heat roller? Yes Replace the fuser unit Note: If the machine prints the same pattern, especially including vertical streaks, continuously, black vertical streaks may appear on the paper since the electrostatic performance of the exposure drum is decreased temporally. Vertical streaks in a light background User Check - Clean the inside of the machine and the corona wire in the drum unit. - Replace the toner cartridge with a new one. Step 1 Cause Drum unit failure Check Result Is the problem solved after replacing the drum unit? Yes 1-49 Remedy Replace the drum unit. Confidential Horizontal stripes User Check - Clean the inside of the machine and the corona wire in the drum unit. - Replace the drum unit with a new one. Step Cause 1 Dirt on the charged electrode Are the electrodes on the drum unit and machine body dirty? Yes Clean both electrodes 2 Paper tray ground terminal provided in the machine body Is the paper tray ground terminal bent, which is provided in the machine body? (Refer to Fig. 1-4.) Yes Correct bending of paper tray ground terminal. 3 Toner attached on the develop roller Are the horizontal stripes at 37.4 mm (develop roller circumference) intervals? Yes This problem will disappear by printing approximate 10 pages. If the same problem occurs, replace the toner cartridge. 4 Scratch on the exposure drum Are the horizontal stripes at 75.0 mm (exposure drum circumference) intervals? Yes Replace the drum unit. 5 Scratch on the heat roller Are the horizontal stripes at 78.5mm (heat roller circumference) intervals? Yes Replace the fuser unit. 6 Transfer HVPS PCB failure Is the problem solved after replacing the transfer HVPS PCB ASSY? Yes Replace the transfer HVPS PCB ASSY. 7 Charge HVPS PCB failure Is the problem solved after replacing the charge HVPS PCB ASSY? Yes Replace the charge HVPS PCB ASSY. Check Result Remedy Paper tray ground terminal Fig. 1-4 1-50 Confidential White vertical streaks on one color image User Check - Clean the scanner windows of the appropriate color with a soft lint-free cloth. - Check if there is no dust in the gap between the toner cartridge and drum frame. - Replace the toner cartridge with a new one. - Check the machine’s environment. High temperature and high humidity conditions can cause this problem. - Damp (wet) paper might be used. Try changeing to fresh unopened paper. Step Cause Check Result Remedy 1 Condensation Has condensation occurred inside the machine? Yes Try to print several pages or leave the machine 2 hours to allow it to reach room temperature. 2 Transfer failure Is the transfer roller of the appropriate color scratched? Yes Replace the drum unit. 3 Scanner windows failure Is the problem solved after replacing the laser unit? Yes Replace the laser unit. White horizontal stripes on one color image User Check - Check that the appropriate media type is selected in the printer driver. - The problem may disappear by itself. Try printing multiple pages to clear this problem especially if the machine has not been used for a long time. - The drum unit may be damaged. Replace the drum unit with a new one. Step Cause Check Result 1 Toner cartridge electrode connection failure Are the electrodes on the toner cartridge and machine body dirty? Yes 1-51 Remedy Clean both electrodes Confidential Faint print User Check - Check that the machine is installed on a level surface. - Replace the toner cartridge with a new one. - Clean the scanner windows with a soft cloth. Step Cause Check Result Remedy 1 Laser unit failure Is the problem solved after replacing the laser unit? Yes Replace the laser unit. 2 Toner empty sensor failure Is the “Toner Life End” message indicated on the LCD after replacing the current toner cartridge with an empty one? No Replace the toner sensor PCB ASSY (TE/NEW) of the appropriate color. White spots on one color image User Check - Toner may be empty. Replace the toner cartridge with a new one. - If the same problem occurs after printing a few pages, the adhesive of a label or the like, paper powder or dirt may be attached on the surface of the exposure drum. When the size of the white spots is less than 0.35mm, feed the drum cleaning sheet from the MP tray one to three times to clean the drum. (For the procedure, refer to “Drum Unit Cleaning Mode” in Chapter 5.) When the size of the spots is 0.35mm or more, or when the same problem occurs after feeding the drum cleaning sheet, wipe off the dirt on the exposure drum with a cotton swab. (For the procedure, refer to Note in the next pages.) - The drum unit may be damaged. Replace the drum unit with a new one. Step Cause Check Result Remedy 1 Drum unit failure Are the white spots at 75.0 mm (exposure drum circumference) intervals? Yes If the exposure drum surface is scratched, replace the drum unit. 2 Drum unit connection failure Are the electrodes on the drum unit and machine body dirty? Yes Clean both electrodes. 3 Transfer HVPS PCB failure Is the problem solved after replacing the transfer HVPS PCB ASSY? Yes Replace the transfer HVPS PCB ASSY. 4 Charge HVPS PCB failure Is the problem solved after replacing the charge HVPS PCB ASSY? Yes Replace the charge HVPS PCB ASSY. 1-52 Confidential Note: If you have print quality problems, clean the drum unit as follows: (1) Pull the drum unit out of the machine and take all the toner cartridges out of the drum unit. (2) Turn the drum unit over by holding the handle. Make sure that the drum unit gears “1” are on the left hand. “1” Fig. 1-5 Caution We recommend that you place the drum unit on a clean, flat surface with a piece of disposable paper underneath it in case you accidentally spill or scatter toner. (3) See the print sample to identify the color causing the problem. The color of the spots is the color of the drum you should clean. For example, if the spots are cyan, you should clean the drum for cyan. Put the print sample in front of the drum, and find the exact position of the poor print. Fig. 1-6 1-53 Confidential (4) Turn the drum unit gear to the direction of the arrow as shown in the figure below by hand while looking at the surface of the drum “1”. “1” Fig. 1-7 (5) When you have found the mark on the drum that matches the print sample, wipe the surface of the drum gently with a cotton swab until the dust or paper powder on the surface comes off. Fig. 1-8 Caution DO NOT clean the surface of the photosensitive drum with a sharp object. (6) Turn the drum unit gear to the direction of the arrow as shown in the figure below by hand to return it to the home position. The home position of each drum can be identified by matching the number on the drum unit gear to the same number on the side of the drum unit as shown in the illustration. Make sure that the number on each of the four drum unit gears matches the corresponding number on the side of the drum unit. Fig. 1-9 1-54 Confidential One color spots or dirt User Check - Damp (wet) paper might be used. Try changeing to freshly unopened paper. - Toner may be empty. Replace the toner cartridge with a new one. - If the same problem occurs after printing a few pages, the adhesive of a label or the like, paper powder or dirt may be attached on the surface of the exposure drum. Feed the drum cleaning sheet from the MP tray one to three times to clean the drum. (For the procedure, refer to “Drum Unit Cleaning Mode” in Chapter 5.) When the same problem occurs after feeding the drum cleaning sheet, wipe off the dirt on the exposure drum with a cotton swab. (For the procedure, refer to Note in the previous pages.) - The drum unit may be damaged. Replace the drum unit with a new one. Step Cause Check Result Remedy 1 Drum unit failure Are the spots at 75.0 mm (exposure drum circumference) intervals? Yes If the surface of the exposure drum is scratched, replace the drum unit. 2 Drum unit connection failure Are the electrodes on the drum unit and machine body dirty? Yes Clean both electrodes 3 Fuser unit failure Are the spots at 78.5mm (heat roller circumference) intervals? Yes Replace the fuser unit. 4 Transfer HVPS PCB failure Is the problem solved after replacing the transfer HVPS PCB ASSY? Yes Replace the Transfer HVPS PCB ASSY. 5 Charge HVPS PCB failure Is the problem solved after replacing the charge HVPS PCB ASSY? Yes Replace the charge HVPS PCB ASSY. One color band User Check - Clean the inside of the machine and the corona wire in the drum unit. If the same problem occurs after cleaning, replace the drum unit with a new one. - The paper tray ground terminal provided in the machine body may be dirty. Clean the contact with a dry cloth. 1-55 Confidential Downward fogging of solid color User Check - Toner may be empty. Replace the toner cartridge with a new one. Step Cause Check Result Remedy 1 Transfer HVPS PCB failure Is the problem solved after replacing the transfer HVPS PCB ASSY? Yes Replace the transfer HVPS PCB ASSY. 2 Charge HVPS PCB failure Is the problem solved after replacing the charge HVPS PCB ASSY? Yes Replace the charge HVPS PCB ASSY. 3 Engine PCB failure Is the problem solved after replacing the engine PCB ASSY? Yes Replace the engine PCB ASSY. Horizontal lines User Check - The paper tray ground terminal provided in the machine body may be dirty. Clean the contact with a dry cloth. Step Cause Check Result Remedy 1 Dirt on charged electrode Are the electrodes on the drum unit and machine body dirty? Yes Clean both electrodes 2 Paper tray ground terminal provided in machine body Is the paper tray ground terminal bent, which is provided in the machine body? Yes Correct bending of paper tray ground terminal. Ghost User Check - Check the machine’s environment, conditions such as high humidity may cause this situation to occur. - Check that the appropriate media type is selected in the printer driver. - Replace the drum unit with a new one. Step Cause Check Result Remedy 1 Transfer HVPS PCB failure Is the problem solved after replacing the transfer HVPS PCB ASSY? Yes Replace the transfer HVPS PCB ASSY. 2 Charge HVPS PCB failure Is the problem solved after replacing the charge HVPS PCB ASSY? Yes Replace the charge HVPS PCB ASSY. 3 Engine PCB failure Is the problem solved after replacing the engine PCB ASSY? Yes Replace the engine PCB ASSY. 1-56 Confidential Color misregistration User Check - Implement the auto color registration by the panel operation. - Replace the belt unit with a new one. - Replace the drum unit with a new one. - Replace the waste toner box with a new one. Step Cause Check Result Remedy 1 Phase shift of gear 39/121 Check if gear 39/121 phase is shifted? Yes Phase the Gear 39/121. For the method how to phase the gear 39/121, refer to “Chapter 3 DISASSEMBLY AND ASSEMBLY”. 2 Engine PCB failure Is the problem solved after replacing the engine PCB ASSY? Yes Replace the engine PCB ASSY. Fogging User Check - Replace the toner cartridge with a new one. - Replace the drum unit with a new one. - Do not use acid paper. - Check if there is dust or paper powder in the machine. Step Cause Check Result Remedy 1 Toner sensor failure (Machine body) Is the toner sensor performed normally by following the procedure described in “Maintenance mode 32” to check. No Replace the toner sensor PCB (TE/NEW) of the appropriate color. 2 Transfer HVPS PCB failure Is the problem solved after replacing the transfer HVPS PCB ASSY? Yes Replace the Transfer HVPS PCB ASSY. 3 Charge HVPS PCB failure Is the problem solved after replacing the charge HVPS PCB ASSY? Yes Replace the charge HVPS PCB ASSY. 4 Engine PCB failure Is the problem solved after replacing the engine PCB ASSY? Yes Replace the engine PCB ASSY. Note: This problem often occurs when the drum unit or toner cartridge is nearly at the end of life. 1-57 Confidential Unstable color density User Check - Replace the belt unit with a new one. - Replace the drum unit with a new one. - Replace the waste toner box with a new one. - Replace the toner cartridge with a new one. Step Cause Check Result Remedy 1 Drum unit conduction failure Are the electrodes on the drum unit and machine body dirty? Yes Clean both electrodes. 2 Toner cartridge electrode connection failure Are the electrodes on the toner cartridge and machine body dirty? Yes Clean both electrodes. 3 Dirt on belt unit electrode Are the electrodes on the belt unit and machine body dirty? Yes Clean both electrodes. 4 Main PCB failure Is the problem solved after replacing the main PCB ASSY? Yes Replace the main PCB ASSY. 5 Engine PCB failure Is the problem solved after replacing the engine PCB ASSY? Yes Replace the engine PCB ASSY. 6 Transfer HVPS PCB failure Is the problem solved after replacing the transfer HVPS PCB ASSY? Yes Replace the transfer HVPS PCB ASSY. 7 Charge HVPS PCB failure Is the problem solved after replacing the charge HVPS PCB ASSY? Yes Replace the charge HVPS PCB ASSY. 8 Laser unit failure Is the problem solved after replacing the laser unit? Yes Replace the laser unit. Hollow print User Check - Select the ‘Thick paper mode’ in the printer driver, or use thinner paper than you are currently using. - Check the machine’s environment, conditions such as high humidity may cause this situation to occur. Step 1 Cause Fuser unit failure Check Is the problem solved after replacing the fuser unit? 1-58 Result Yes Remedy Replace the fuser unit. Confidential Dirt on the bottom end of paper Step Cause Check Result Remedy 1 Dirt on the bottom of drum unit Is the bottom of drum unit dirty? Yes Wipe the dirt with a dry cloth as shown in Fig. 1-10. 2 Dirt on base shaft Is the base shaft dirty? Yes Wipe the dirt with a dry cloth as shown in Fig. 1-11. Fig. 1-10 Base shaft * Figure of the front view Fig. 1-11 1-59 Confidential 5. SOFTWARE SETTING PROBLEMS The machine may not print the data correctly if there are incorrect software settings. User Check - Check that the USB cable is not damaged. - Check that the correct machine is selected if you have an interface switching device. - Check the descriptions on the software setting in the user’s guide. - Try resetting the factory settings. Step Cause Check Result Remedy 1 Failure inside the machine Does the machine print test pattern? (Check it following the procedure described in “Maintenance mode 09”.) No Identify the error type, and then refer to the specified section of this chapter. 2 Machine connection For Macintosh, has the product ID been verified? No Verify the product ID. Product ID: DCP-9045CDN: 01CB* MFC-9840CDW: 01CC* * Hexadecimal 3 USB host relay PCB failure Is the problem solved after replacing the USB host relay PCB ASSY? Yes Replace the USB host relay PCB ASSY. 4 Main PCB failure Is the problem solved after replacing the main PCB ASSY? Yes Replace the main PCB ASSY. 1-60 Confidential 6. NETWORK PROBLEMS User Check - Check the descriptions in the network user’s guide. - Try resetting the factory settings. Step Cause Check Result Remedy 1 Wireless LAN PCB failure Is the problem solved after replacing the wireless LAN PCB ASSY? Yes Replace the wireless LAN PCB ASSY. 2 Main PCB failure Is the problem solved after replacing the main PCB ASSY? Yes Replace the main PCB ASSY. 1-61 Confidential 7. TROUBLESHOOTING OF THE COMMUNICATIONS ERRORS If a communications error occurs, the facsimile equipment (1) Gives the alarm (intermittent bleep) for approximately four seconds. (2) Indicates the appropriate error message on the LCD. (3) Prints the transmission report during fax transmission. Definition of error codes on the communications list (1) Calling Code 1 Code 2 Causes 10 08 Wrong number called. 11 01 No dial tone detected before start of dialing. 11 02 Busy tone detected before dialing. 11 03 2nd dial tone not detected. 11 05 No loop current detected. * 11 06 Busy tone detected after dialing or called. 11 07 No response from the remote station in sending. 11 10 Unobtainable tone detected after dialing. 17 07 No response from the calling station in receiving. * Available in German models only. (2) Command reception Code 1 Code 2 Causes 20 01 Unable to detect a flag field. 20 02 Carrier was OFF for 200 ms or longer. 20 03 Abort detected (“1” in succession for 7 bits or more). 20 04 Overrun detected. 20 05 A frame for 3 seconds or more received. 20 06 CRC error in answerback. 20 07 Error command received. 20 08 Invalid command received. 20 09 Command ignored once for document setting or for dumpingout at turn-around transmission. 20 0A T5 time-out error 20 0B CRP received. 20 0C EOR and NULL received. 20 0C EOR received. 1-62 Confidential (3) Communication code compatibility [checking the NSF and DIS] 1 Code 2 Causes 32 01 Remote terminal only with V.29 capability in 2400 or 4800 bps transmission. 32 02 Remote terminal not ready for polling. 32 10 Remote terminal not equipped with password function or its password switch OFF. 32 11 Remote terminal not equipped with or not ready for confidential mailbox function. 32 12 Remote terminal not equipped with or not ready for relay broadcasting function. 32 13 No confidential mail in the remote terminal. 32 14 The available memory space of the remote terminal is less than that required for reception of the confidential or relay broad-casting instruction. 32 18 Remote terminal not equipped with color function. (4) Instructions received from the remote terminal [checking the NSC, DTC, NSS, and DCS] Code 1 Code 2 Causes 40 02 Illegal coding system requested. 40 03 Illegal recording width requested. 40 05 ECM requested although not allowed. 40 06 Polled while not ready. 40 07 No document to send when polled. 40 10 Nation code or manufacturer code not correct. 40 13 Polled by any other manufacturers' terminal while waiting for secure polling. 40 17 Invalid resolution selected. 40 20 Invalid full color mode selected. (5) Command reception [checking the NSF and DIS after transmission of NSS and DCS] Code 1 Code 2 50 01 Causes Vertical resolution capability changed after compensation of background color. 1-63 Confidential (6) ID checking Code 1 Code 2 Causes 63 01 Password plus “lower 4 digits of telephone number” not coincident. 63 02 Password not correct. 63 03 Polling ID not correct. (7) DCN reception Code 1 Code 2 74 Causes DCN received. (8) TCF transmission/reception Code 1 Code 2 80 01 Causes Fallback impossible. (9) Signal isolation Code 1 Code 2 Causes 90 01 Unable to detect video signals and commands within 6 seconds after CFR is transmitted. 90 02 Received PPS containing invalid page count or block count. 1-64 Confidential (10) Video signal reception Code 1 Code 2 Causes A0 03 Error correction sequence not terminated even at the final transmission speed for fallback. A0 11 Receive buffer empty. (5-second time-out) A0 12 Receive buffer full during operation except receiving into memory. A0 13 Decoding error continued on 500 lines or more. A0 14 Decoding error continued for 10 seconds or more. A0 15 Time-out: 13 seconds or more for one-line transmission. A0 16 RTC not found or carrier OFF detected for 6 seconds. A0 17 RTC found but no command detected for 60 seconds or more. A0 19 No video data to be sent A8 01 RTN, PIN, or ERR received at the calling terminal. * A9 01 RTN, PIN, or ERR received at the called terminal. * AA 18 Receive buffer full during receiving into memory. * Available in German models only (11) General communications-related Code 1 Code 2 Causes B0 02 Unable to receive the next-page data. B0 03 Unable to receive polling even during turn-around transmission due to call reservation. B0 04 PC interface error. BF 01 Communication canceled by pressing the Stop/Exit button before establishment of FAX communication*. BF 02 Communication canceled by pressing the Stop/Exit button after establishment of FAX communication*. BF 03 Transmission canceled due to a scanning error caused by no document or document feed problem in ADF scanning in real time transmission. * Establishment of FAX communication: FAX communication is established when the calling station receives a DIS (reception capability) signal from the called station and the called station receives a NSS or DCS (communications test) signal from the calling station. (12) Maintenance mode Code 1 Code 2 Causes E0 01 Failed to detect 1300 Hz signal in burn-in operation. E0 02 Failed to detect PB signals in burn-in operation. (13) Equipment error Code 1 FF Code 2 XX Causes Equipment error (For X X, refer to “2.1 Error Indication”) 1-65 Confidential 8. TROUBLESHOOTING OF THE CONTROL PANEL Nothing is displayed on the LCD. User Check - Verify if the power switch is turned off. Step Possible cause Check Result Remedy 1 Connection between main PCB and control panel PCB Are the main PCB and control panel PCB connected properly? No Reconnect the connector properly. 2 Harness between main PCB and control panel PCB Is the harness damaged? Yes Replace the harness with a normal one. 3 Connection between main PCB and PS PCB unit Are the main PCB and PS PCB unit connected properly? No Reconnect the connector properly. 4 Harness between main PCB and PS PCB unit Is the harness damaged? Yes Replace the harness with a normal one. 5 LCD Is the problem solved after replacing the LCD? Yes Replace the LCD. 6 Control panel PCB Is the problem solved after replacing the control panel PCB? Yes Replace the control panel PCB. 7 PS PCB unit Is the problem solved after replacing the PS PCB unit? Yes Replace the PS PCB unit. 8 Main PCB Is the problem solved after replacing the main PCB ASSY? Yes Replace the main PCB ASSY. 1-66 Confidential The control panel does not work. Step Possible cause Check Result Remedy 1 Key sticking Is there a key on the control panel stuck? Yes Clean up the panel cover, or remove the burrs from panel cover and panel keys. 2 Connection between main PCB and control panel PCB Are the main PCB and control panel PCB connected properly? No Reconnect the connector properly. 3 Harness between main PCB and control panel PCB Is the harness damaged? Yes Replace the harness with a normal one. 4 Rubber Key Is the problem solved after replacing the rubber key? Yes Replace the rubber Key. 5 Control panel PCB Is the problem solved after replacing the control panel PCB? Yes Replace the control panel PCB. 6 Main PCB Is the problem solved after replacing the main PCB ASSY? Yes Replace the main PCB ASSY. Printing from Macintosh applications fails. User Check - Check that the printer driver which, is supplied with the product, is installed in Library/ Printers, and that the print queue is created. - Check the connecting end on the printer browser. It must be matched with the connecting end which is actually connected. Step Possible cause Check Result Remedy 1 Failure inside the machine Does the machine print test pattern? (Check it following the procedure described in “Maintenance mode 09”.) No Identify the error type, and then refer to the specified section of this chapter. 2 Breakage of main PCB Does the machine make a print using a correct PC and a USB cable? No Replace the main PCB ASSY. 1-67 Confidential 9. TROUBLESHOOTING OF FAX FUNCTIONS FAX can't send it. User Check - Verify that the telephone cord is securely inserted. Step Possible cause Check Result Remedy 1 Dialing mode Setting Does a dialing signal (PB or DP) come out normally in each mode? (Use telephone line emulator.) Yes Check the dialing mode setting at customer's again. Check the telephone line cord between machine and socket. 2 Connection between main PCB and NCU PCB Are the main PCB and NCU PCB connected properly? No Reconnect the connector properly. 3 Harness between main PCB and NCU PCB Is the harness damaged? Yes Replace the harness with a normal one. 4 Connection between main PCB and control panel PCB Are the main PCB and control panel PCB connected properly? No Reconnect the connector properly. 5 Harness between main PCB and control panel PCB Is the harness damaged? Yes Replace the harness with a normal one. 6 Contact of rubber key Does the rubber key work correctly? No Replace the rubber Key. 7 NCU PCB Is the problem solved after replacing the NCU PCB ASSY? Yes Replace the NCU PCB ASSY. 8 Control panel PCB Is the problem solved after replacing the control panel PCB? Yes Replace the control panel PCB. 9 Main PCB Is the problem solved after replacing the main PCB ASSY? Yes Replace the main PCB ASSY. 1-68 Confidential Speed dialing and One-touch dialing can't be used. Step Possible cause Check 1 Speed dialing keys or one-touch dialing keys Can a fax transmission be made using the numeric keys? Yes Replace the main PCB ASSY. 2 Dialing mode Setting Does a dialing signal (PB or DP) come out normally in each mode? (Use telephone line emulator.) Yes Check the dialing mode setting at customer's again. Check the telephone line cord between machine and socket. 3 Connection between main PCB and NCU PCB Are the main PCB and NCU PCB connected properly? No Reconnect the connector properly. 4 Harness between main PCB and NCU PCB Is the harness damaged? Yes Replace the harness with a normal one. 5 Connection between main PCB and control panel PCB Are the main PCB and control panel PCB connected properly? No Reconnect the connector properly. 6 Harness between main PCB and control panel PCB Is the harness damaged? Yes Replace the harness with a normal one. 7 Contact of rubber key Is the problem solved after replacing the rubber key? No Replace the rubber Key. 8 NCU PCB Is the problem solved after replacing the NCU PCB ASSY? Yes Replace the NCU PCB ASSY. 9 Control panel PCB Is the problem solved after replacing the control panel PCB? Yes Replace the control panel PCB. Result Remedy FAX can't be received. User Check - Verify that the telephone cord is securely inserted. Step Possible cause Check Result Remedy 1 Receive mode setting Is the receive mode set to automatic receive mode? No Set the receive mode to automatic receive mode. 2 NCU PCB Is the problem solved after replacing the NCU PCB ASSY? Yes Replace the NCU PCB ASSY. 3 Main PCB Is the problem solved after replacing the main PCB ASSY? Yes Replace the main PCB ASSY. 1-69 Confidential No bell ring. Step Possible cause Check Result Remedy 1 Ring delay Ring delay is set to “0”. Yes Change the ring delay settings to another value. 2 Ring volume Ring volume is set to “OFF”. Yes Change the ring volume setting to another value. 3 Connection between main PCB and NCU PCB Are the main PCB and NCU PCB connected properly? No Reconnect the connector properly. 4 Harness between main PCB and NCU PCB Is the harness damaged? Yes Replace the harness with a normal one. 5 Speaker Is the problem solved after replacing the speaker? Yes Replace the Speaker. 6 NCU PCB Is the problem solved after replacing the NCU PCB ASSY? Yes Replace the NCU PCB ASSY. 7 Main PCB Is the problem solved after replacing the main PCB ASSY? Yes Replace the main PCB ASSY. 1-70 Confidential Speaker is silent during on-hook dialing. Step Possible cause Check 1 Connection between main PCB and speaker Are the main PCB and speaker connected properly? No Reconnect the connector properly. 2 Speaker Is the problem solved after replacing the speaker? Yes Replace the Speaker. 3 Connection between main PCB and NCU PCB Are the main PCB and NCU PCB connected properly? No Reconnect the connector properly. 4 Harness between main PCB and NCU PCB Is the harness damaged? Yes Replace the harness with a normal one. 5 Connection between main PCB and control panel PCB Are the main PCB and control panel PCB connected properly? No Reconnect the connector properly. 6 Harness between main PCB and control panel PCB Is the harness damaged? Yes Replace the harness with a normal one. 7 NCU PCB Is the problem solved after replacing the NCU PCB ASSY? Yes Replace the NCU PCB ASSY. 8 Main PCB Is the problem solved after replacing the main PCB ASSY? Yes Replace the main PCB ASSY. Result Remedy Dialing function does not switch between "tone" and "pulse". Step Possible cause Check Result Remedy 1 Connection between main PCB and NCU PCB Are the main PCB and NCU PCB connected properly? No Reconnect the connector properly. 2 Harness between main PCB and NCU PCB Is the harness damaged? Yes Replace the harness with a normal one. 3 NCU PCB Is the problem solved after replacing the NCU PCB ASSY? Yes Replace the NCU PCB ASSY. 4 Main PCB Is the problem solved after replacing the main PCB ASSY? Yes Replace the main PCB ASSY. 1-71 Confidential 10. OTHERS PROBLEMS The machine is not turned on, or the LCD indication does not appear. Step Cause Check Result Remedy 1 Harness connection failure of LCD panel PCB Is the harness of the LCD panel PCB ASSY connected correctly? No Reconnect the LCD panel PCB ASSY harness. 2 LCD panel PCB failure Is the problem solved after replacing the LCD panel PCB ASSY? Yes Replace the LCD panel PCB ASSY. 3 LCD panel failure Is the problem solved after replacing the LCD panel ASSY? Yes Replace the LCD panel ASSY. 4 Low-voltage power supply failure Is the problem solved after replacing the PS PCB unit? Yes Replace the PS PCB unit. 5 Main PCB Is the problem solved after replacing the main PCB ASSY? Yes Replace the main PCB ASSY. The fan does not work. (Verify the position of each fan referring to “1.4.22 Operational Check of Fans (Function code 78)” in Chapter 5.) Step Cause Check Result 1 Harness connection failure of the appropriate fan Is the harness of the appropriate fan connected correctly? No Reconnect the harness of the appropriate fan correctly. 2 Charge HVPS PCB failure Is the problem solved after replacing the charge HVPS PCB ASSY? Yes Replace the charge HVPS PCB ASSY. Replace the fuser unit fan (FU) and air intake fan (AIR). 3 Low-voltage power supply failure Is the problem solved after replacing the PS PCB unit? Yes Replace the PS PCB unit. Replace the LVPS fan (PS). 4 Engine PCB failure Is the problem solved after replacing the engine PCB ASSY? Yes Replace the engine PCB ASSY. Replace the drum unit fan (OPC). 5 Main PCB Is the problem solved after replacing the main PCB ASSY? Yes Replace the main PCB ASSY. 1-72 Remedy Confidential Pickup function of paper tray does not work. Step Cause Remedy 1 Link lever not operating smoothly or catching. Make sure correct movemet of the link lever. 2 Pickup roller holder ASSY not operating smoothly or catching. Make sure correct movement of the pickup roller holder ASSY. 3 Link lever damaged Replace the link lever. 4 Roller holder ASSY failure Replace the roller holder ASSY. 5 Paper feed/belt cleaner motor failure Replace the paper feed/belt cleaner motor. The new toner is not detected. Step Cause Remedy 1 New toner actuator not operating smoothly or catching. Make sure correct movement of the new toner actuator of the appropriate color. 2 New toner actuator damaged Replace the drum unit. 3 Main PCB failure Replace the main PCB ASSY. 4 Toner sensor PCB (TE/NEW) failure Replace the toner sensor PCB ASSY (TE/NEW) of the appropriate color. 1-73 Confidential CHAPTER 2 PERIODICAL MAINTENANCE To avoid creating secondary problems by mishandling, follow the warnings below during maintenance work. WARNING - Always turn off the power switch and unplug the power cord from the power outlet before accessing any parts inside the machine. - When opening the front cover or back cover to access any parts inside the machine, never touch the shaded parts shown in the following figures. 1. CONSUMABLE PARTS The consumable parts described in this section are parts which are subject to deterioration or damage and should be replaced at least once during the period of warranty of the product if any printing quality problem appears. Parts Toner Cartridge Black Cyan, Magenta, Yellow Approximate Life Standard cartridge Approx. 2,500 pages A4/Letter pages @ 5% coverage High-capacity cartridge Approx. 5,000 pages A4/Letter pages @ 5% coverage Standard cartridge Approx. 1,500 pages A4/Letter pages @ 5% coverage High-capacity cartridge Approx. 4,000 pages A4/Letter pages @ 5% coverage Drum Unit Approx. 17,000 pages A4/Letter pages Life expectancy will vary depending on number of continuous printing pages. (Refer to “Life of Drum Unit”.) Belt Unit Approx. 50,000 pages A4/Letter pages Life expectancy will vary depending on number of continuous printing pages. (Refer to “Life of Belt Unit”.) Waste Toner Box Approx. 20,000 pages A4/Letter pages @ 5% coverage for CMYK each 2-1 Confidential Life of Drum Unit - It initially indicates 100% and gradually decreases. - It indicates 0% when the “Drum End Soon” appears on the LCD. - It stays at 0% even if further printing is done. The drum unit life is based on the “drum counter” or the “number of drum rotations”. The drum counter is based on the total printed pages on each drum unit. This total printed pages should be reset every time you replace the drum unit with a new one. (Refer to “2.3 Parts Life Reset Function” in this chapter.) Basically this amount is equal to the assured printable pages of the drum unit. If the developing bias voltage correction or color registration adjustment is performed frequently, however, only the number of drum rotations increases, and the “page counter based on the number of drum rotation” exceeds the “drum counter” based on the total printed page. Refer to the calculation of the drum unit life based on the number of drum rotation below; The number of drum rotations for the first page printed is about 27. The number of drum rotations per one page for the second or later page printed (continuous printing) is 4.6. Using these figures, the page counter is calculated as follows: Page counter based on the number of drum rotations = (Number of drum rotations for the first page printed + (Number of drum rotations per one page for the second or later page printed x (Number of pages in continuous printing - 1))) / 27 (* The number of drum rotations per one page continuous printing.) Example: Starts to print when the machine is in the Ready state. Continuous printing 1 page/job 2 pages/job 18 pages/job Page counter based on the number of drum rotations (Pages) (27 + (4.6 x (1 - 1))) / 27 = 1 (27 + (4.6 x (2 - 1))) / 27 = 1.17 (27 + (4.6 x (18 - 1))) / 27 = 3.89 If you leave the machine without printing for a long time, the number of drum rotations is increasing because the developing bias voltage correction and the color registration are performed. If you print one page per one job every time after leaving the machine without printing for a long time, the drum unit life is shorter than usual. The number of drum rotations required for the developing bias voltage correction = 40 rotations. Example: Performs the developing bias voltage correction and starts to print after leaving the machine without printing for a long time. Continuous printing 1 page/job 2 pages/job 18 pages/job Page counter based on the number of drum rotations (Pages) (40 + 27 + (4.6 x (1 - 1))) / 27 = 2.48 (40 + 27 + (4.6 x (2 - 1))) / 27 = 2.65 (40 + 27 + (4.6 x (18 - 1))) / 27 = 5.37 The number of drum rotations required for the color registration = 104 rotations Example: Performs the color registration adjustment and starts to print after leaving the machine without printing for a long time. Continuous printing 1 page/job 2 pages/job 18 pages/job Page counter based on the number of drum rotations (Pages) (104 + 27 + (4.6 x (1 - 1))) / 27 = 4.85 (104 + 27 + (4.6 x (2 - 1))) / 27 = 5.02 (104 + 27 + (4.6 x (18 - 1))) / 27 = 7.75 If the developing bias voltage correction and the color registration are performed continuously, the drum unit life is shorter. 2-2 Confidential Life of Belt Unit The belt unit life is decided according to the page counter based on the actual “number of belt rotations”. The page counter based on the number of belt rotations is calculated as follows: Page counter based on the number of belt rotations = (Number of belt rotations for the first page printed + (Number of belt rotations per one page for the second or later page printed x (Number of pages in continuous printing –1))) / 1.25 The number of belt rotations for the first page printed is 3.6. The number of belt rotations per one page for the second or later page printed is 0.63. The number of belt rotations per one page in printing five pages continuously is 1.25. Example: Starts to print when the machine is in the ready state. Continuous printing 1 page/job 2 pages/job 18 pages/job Page counter based on the number of belt rotations (Pages) (3.6 + (0.63 x (1 - 1))) / 1.25 = 2.88 (3.6 + (0.63 x (2 - 1))) / 1.25 = 3.38 (3.6 + (0.63 x (18 - 1))) / 1.25 = 11.45 If you leave the machine without printing for a long time, the number of belt rotations is increasing because the developing bias voltage correction and the color registration are performed. If you print one page per one job every time after leaving the machine without printing for a long time, the belt unit life is shorter than usual. The number of belt rotations required for the developing bias voltage correction = 5.3 rotations. Example: Performs the developing bias voltage correction and starts to print after leaving the machine without printing for a long time. Continuous printing 1 page/job 2 pages/job 18 pages/job Page counter based on the number of belt rotations (Pages) (5.3 + 3.6 + (0.63 x (1 - 1))) / 1.25 = 7.12 (5.3 + 3.6 + (0.63 x (2 - 1))) / 1.25 = 7.62 (5.3 + 3.6 + (0.63 x (18 - 1))) / 1.25 = 15.69 The number of belt rotations required for the color registration = 14 rotations Example: Performs the color registration adjustment and starts to print after leaving the machine without printing for a long time. Continuous printing 1 page/job 2 pages/job 18 pages/job Page counter based on the number of belt rotations (Pages) (14 + 3.6 + (0.63 x (1 - 1))) / 1.25 = 14.08 (14 + 3.6 + (0.63 x (2 - 1))) / 1.25 = 14.58 (14 + 3.6 + (0.63 x (18 - 1))) / 1.25 = 22.65 If the developing bias voltage correction and the color registration are performed continuously, the drum unit life is shorter. 2-3 Confidential 2. PERIODICAL REPLACEMENT PARTS 2.1 Periodical Replacement Parts Periodical replacement parts are the parts to be replaced periodically to maintain product quality. These parts would affect the product quality if they loose their functionality even if they do not appear to be damaged or there is no change in their appearance. The periodical replacement parts listed in the table below should be replaced according to the service life. LCD Q’ty Approximate Life Replacement Procedure Fuser unit & Toner filter frame ASSY Fuser Unit 1 80,000 pages Refer to 2.2.1. Laser unit Laser Unit 1 100,000 pages Refer to 2.2.2. PF Kit 1, PF Kit 2 1 100,000 pages Refer to 2.2.3. PF Kit MP 1 50,000 pages Refer to 2.2.4. Parts Name Paper feeding kit *1 MP paper feeding kit *2 *1 : The paper feeding kit includes the separation pad ASSY, separation pad spring and roller holder ASSY. *2 : MP Paper feeding kit includes the separation pad ASSY MP, separation pad spring MP, and MP roller holder ASSY. When replacing the periodical replacement parts, each of the counters need to be reset in order to count the number of replacement times. Refer to “2.3 Parts Life Reset Function” in this chapter. Also make sure to wipe the dirt on the drum unit as shown in the figure below when replacing each of the periodical replacement parts. The number of printed pages of the machine can be checked by accessing the machine’s log information on the LCD. (Refer to “1.4.23 Display of the Machine’s Log Information” (Function code 80) in Chapter 5.) The actual number of printed page will vary depending on the type of print job or the paper to being used. The figures indicated as the approximate life in the table above are worked out when printing a general business document (with 5% print coverage) on one side of A4-size paper. Note: - Always turn off the power switch of the machine and unplug the power cord from the power outlet before replacing the periodical replacement parts. - If the fuser unit is replaced after errors related to the fuser unit occur, it is necessary to leave the machine power ON for ten minutes after part replacement. This will make the machine to be released from errors. - After disconnecting flat cables, check that each cable is not damaged at its end or shortcircuited. - When connecting flat cables, do not insert them at an angle. After insertion, check that the cables are not at an angle. 2-4 Confidential 2.2 Procedures to Replace Periodical Replacement Parts 2.2.1 Fuser Unit & Toner Filter Frame ASSY (1) Open the Back cover. Back cover Fig. 2-1 (2) Remove the two pan B M4x14 Taptite screws, and then pull out the Fuser unit to the back of the machine. Taptite, pan B M4x14 Fuser unit Taptite, pan B M4x14 Fig. 2-2 2-5 Confidential (3) Remove the Toner filter frame ASSY from the Paper eject ASSY DX. Paper eject ASSY DX 3a 3b Toner filter frame ASSY Fig. 2-3 (1) Assemble the Toner filter frame ASSY onto the Paper eject ASSY DX. Paper eject ASSY DX 1b 1a Toner filter frame ASSY Fig. 2-4 2-6 Confidential (2) Put the Fuser unit into the machine and fix it with the two pan B M4x14 Taptite screws. *1 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. Taptite, pan B M4x14 (Tightening torque: 1.20 ±0.1 N m) *1 Fuser unit Taptite, pan B M4x14 (Tightening torque: 1.20 ±0.1 N m) *1 Fig. 2-5 Note: When assembling the fuser unit, make sure that the two Harnesses are placed in the groove and under the rib of the Plastic frame. If they are not, then correct them as shown in the figure below. Harness Harness Plastic frame Fig. 2-6 2-7 Confidential (3) Close the Back cover. Back cover Fig. 2-7 (4) After replacing the Fuser unit, reset the counter. (Refer to “2.3 Parts Life Reset Function” in this chapter.) 2-8 Confidential 2.2.2 Laser Unit (1) Press the Front cover release button, and open the Front door unit ASSY. Front cover release button 1a 1b Front door unit ASSY Fig. 2-8 (2) Open the Back cover. Back cover Fig. 2-9 2-9 Confidential (3) Remove the two cup S M3x8 Taptite screws, and then remove the Back cover upper. Note: Be careful not to break the plastic. As this can be difficult to remove. Back cover upper Taptite, cup S M3x8 Fig. 2-10 (4) Remove the two cup S M3x8 Taptite screws, and then remove the Back cover ASSY. Hook Taptite, cup S M3x8 Back cover ASSY Hook Taptite, cup S M3x8 Fig. 2-11 2-10 Confidential (5) Remove the one cup S M3x8 Taptite screw and three cup B M4x12 Taptite screws. (6) Release the three Hooks on the bottom and the two Hooks on the back side, and then remove the Side cover L ASSY. Note: When removing the Side cover L ASSY, pay attention to the Wire support rope. Hook Taptite, cup B M4x12 Wire support rope Hooks Side cover L ASSY Taptite, cup S M3x8 Hooks Taptite, cup B M4x12 Fig. 2-12 (7) Remove the three cup S M3x6 Taptite screws, one cup B M4x12 Taptite screw and one cup S M4x8 Taptite screw, and then remove the Side plate LB. Taptite, cup S M4x8 Side plate LB Taptite, cup B M4x12 Taptite, cup S M3x6 Fig. 2-13 2-11 Confidential (8) Remove the two cup B M4x12 Taptite screws and two cup S M4x8 Taptite screws. (9) Release the one Hook on the front side, two Hooks on the bottom and the two Hooks on the back side, and then remove the Side cover R ASSY. Note: When removing the Side cover R ASSY, be careful not to damage section “A”. Taptite, cup S M4x8 Hooks 9a Side cover R ASSY 9b “A” Hook Hooks Taptite, cup S M4x8 Taptite, cup B M4x12 Fig. 2-14 (10) Disconnect the three Connectors (CN1, CN2, CN4) from the Driver PCB ASSY. Driver PCB ASSY CN4 Document scanner unit ASSY Main PCB ASSY CN2 CN1 Fig. 2-15 2-12 Confidential (11) Remove the cup S M3x6 Taptite screw, and then remove the FG harness ADF from the Driver PCB shield. (12) Remove the cup S M3x6 Taptite screw, and then remove the FG harness FB from the Driver PCB shield. Document scanner unit ASSY Driver PCB shield FG harness ADF Taptite, cup S M3x6 Taptite, cup S M3x6 FG harness FB Fig. 2-16 (13) Disconnect the three Connectors (CN14, CN16, CN21) and Flat cable (CN17) from the Main PCB ASSY, and then pull out the Flat cable from the Core. Note: After disconnecting the Flat cable(s), check that each cable is not damaged at its end or short-circuited. Document scanner unit ASSY Core Main PCB ASSY Flat cable (CN17) CN16 CN14 CN21 Fig. 2-17 2-13 Confidential (14) Open the Document scanner unit ASSY, and then release the Hooks of the Pull arms L and R from the joint of the Document scanner unit ASSY. Document scanner unit ASSY Hook Pull arm R Pull arm L Hook Joint cover ASSY Fig. 2-18 (15) Remove the two bind B M4x12 Taptite screws, and then remove the Document scanner unit ASSY from the Joint cover ASSY. Document scanner unit ASSY Hinge Taptite, bind B M4x12 Taptite, bind B M4x12 Joint cover ASSY Hinge Fig. 2-19 2-14 Confidential (16) Disconnect the four Connectors (CN2, CN3, CN7, CN10) from the Main PCB ASSY. (CN2, CN7: MFC-9840CDW only) (17) Remove the Screw pan (S/P washer) M3.5x6, and then remove the FG harness NCU. (MFC-9840CDW only) Screw pan (S/P washer) M3.5x6 FG harness NCU Develop gear plate ASSY CN10 CN7 CN2 Main PCB ASSY CN3 Fig. 2-20 (18) Remove the two cup S M3x8 Taptite screws from the front side of the Joint cover ASSY, and remove two cup S M3x8 Taptite screws from the left side of the Joint cover ASSY. Joint cover ASSY Taptite, cup S M3x8 Taptite, cup S M3x8 Taptite, cup S M3x8 Fig. 2-21 2-15 Confidential (19) Remove the one cup S M3x8 Taptite screw and two bind B M4x12 Taptite screws from the back side of the Joint cover ASSY. Joint cover ASSY Taptite, bind B M4X12 Taptite, cup S M3x8 Taptite, bind B M4X12 Fig. 2-22 (20) Remove the six cup S M4x8 Taptite screws from the top side of the Joint cover ASSY. (21) Release the four Hooks and one Pin to remove the Joint cover ASSY from the Frame unit. Hook Taptite, cup S M4x8 Taptite, cup S M4x8 Joint cover ASSY Hook Frame unit Pin Hooks Fig. 2-23 2-16 Confidential (22) Remove the four cup S M3x8 Taptite screws, and then remove the two Hook slopes. Hook slope Taptite, cup S M3x8 Hook slope Taptite, cup S M3x8 Frame unit Fig. 2-24 (23) Remove the nine cup S M3x6 Taptite screws (8 pieces from the top and 1 piece from the front), and then remove the Scanner cover. Scanner cover Taptite, cup S M3x6 Taptite, cup S M3x6 Taptite, cup S M3x6 Taptite, cup S M3x6 Frame unit Fig. 2-25 2-17 Confidential (24) Disconnect the two flat cables (CN1, CN4) and connector (CN8) from the Laser unit. Note: After disconnecting the Flat cable(s), check that each cable is not damaged at its end or short-circuited. Laser unit Fig. 2-26 (25) Remove the seven cup S M3x6 SR Taptite screws, and then remove the four Scanner holders and Laser unit. Scanner holder Taptite, cup S M3x6 SR Taptite, cup S M3x6 SR Laser unit Taptite, cup S M3x6 SR Taptite, cup S M3x6 SR Scanner holder Scanner holder Frame unit Scanner holder Fig. 2-27 2-18 Confidential (1) Assemble the Laser unit with the four Scanner holders and seven cup S M3x6 SR Taptite screws. Note: When assembling the Laser unit with the Scanner holders, ensure to put the positioning boss of the Laser unit into the positioning hole referring to the figure below. Taptite, cup S M3x6 SR Taptite, cup S M3x6 SR Scanner holder Laser unit Positioning boss Taptite, cup S M3x6 SR Taptite, cup S M3x6 SR Scanner holder Scanner holder Positioning boss Frame unit Scanner holder Positioning hole Positioning hole Fig. 2-28 (2) Connect the two flat cables (CN1, CN4) and one connector (CN8) into the Laser unit. Note: When connecting the flat cable(s), do not insert it at an angle. After insertion, check that the cable is not at an angle. Laser unit Fig. 2-29 2-19 Confidential (3) Assemble the Scanner cover with the nine cup S M3x6 Taptite screws (8 pieces on the top and 1 piece on the front side). Note: When assembling the Scanner cover, secure the Screws in the order of the numbers which are indicated on the Scanner cover. Scanner cover Taptite, cup S M3x6 Taptite, cup S M3x6 Taptite, cup S M3x6 Taptite, cup S M3x6 Frame unit Fig. 2-30 (4) Assemble the two Hook slopes with the four cup S M3x8 Taptite screws. Hook slope Taptite, cup S M3x8 Hook slope Taptite, cup S M3x8 Frame unit Fig. 2-31 2-20 Confidential (5) Catch the four Hooks and one Pin. Then, put the Joint cover ASSY onto the Frame unit and secure the six cup S M4x8 Taptite screws onto the top of the cover. Hook Taptite, cup S M4x8 Taptite, cup S M4x8 Joint cover ASSY Hook Frame unit Hooks Pin Fig. 2-32 (6) Secure the one cup S M3x8 Taptite screw and two bind B M4x12 Taptite screws onto the back side of the Joint cover ASSY. Joint cover ASSY Taptite, bind B M4x12 Taptite, cup S M3x8 Taptite, bind B M4x12 Fig. 2-33 2-21 Confidential (7) Secure the two cup S M3x8 Taptite screws onto the front side of the Joint cover ASSY. (8) Secure the two cup S M3x8 Taptite screws onto the left side of the Joint cover ASSY. Joint cover ASSY Taptite, cup S M3x8 Taptite, cup S M3x8 Taptite, cup S M3x8 Fig. 2-34 (9) Connect the four Connectors (CN2, CN3, CN7, CN10) into the Main PCB ASSY. (CN2, CN7: MFC-9840CDW only) (10) Assemble the FG harness NCU with the Screw pan (S/P washer) M3.5x6. (MFC9840CDW only) Screw pan (S/P washer) M3.5x6 FG harness NCU Develop gear plate ASSY CN10 CN7 CN2 Main PCB ASSY CN3 Fig. 2-35 2-22 Confidential (11) Catch the Hinges on the Document scanner unit ASSY onto the Joint cover ASSY putting the Flat cable of the Document scanner unit ASSY into the hole on the Joint cover ASSY. (12) Secure the Hinges with the two bind B M4x12 Taptite screws. Document scanner unit ASSY Hinge Taptite, bind B M4x12 Flat cable Joint cover ASSY Hinge Taptite, bind B M4x12 Hole Joint cover ASSY Fig. 2-36 (13) Catch the Hooks of the Document scanner unit ASSY with Joint of the Pull arm L, R. Document scanner unit ASSY Hook Pull arm R Pull arm L Hook Joint cover ASSY Fig. 2-37 2-23 Confidential (14) Assemble the FG harness FB with the one cup S M3x6 Taptite screw. (15) Assemble the FG harness ADF with the one cup S M3x6 Taptite screw. Document scanner unit ASSY Driver PCB shield FG harness ADF Taptite, cup S M3x6 Taptite, cup S M3x6 FG harness FB Fig. 2-38 (16) Connect the three Connectors (CN1, CN2, CN4) into the Driver PCB ASSY. Driver PCB ASSY CN4 Document scanner unit ASSY Main PCB ASSY CN2 CN1 Fig. 2-39 2-24 Confidential (17) Put the Flat cable through the Core, and then connect the three Connectors (CN14, CN16, CN21) and one Flat cable (CN17) into the Main PCB ASSY. Note: When connecting the Flat cable(s), do not insert it at an angle. After insertion, check that the cable is not at an angle. Document scanner unit ASSY Core Main PCB ASSY Flat cable (CN17) CN16 CN14 CN21 Fig. 2-40 (18) Catch the Hooks of the Side cover R ASSY with the main body in the order of 18a to 18e and fix the Side cover R ASSY with the two cup B M4x12 Taptite screws and two cup S M4x8 Taptite screws. *1 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. Taptite, cup S M4x8 Hooks 18a 18b Side cover R ASSY Hook 18e 18d 18c Hooks Taptite, cup B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Taptite, cup S M4x8 Fig. 2-41 2-25 Confidential (19) Assemble the Side plate LB with the three cup S M3x6 Taptite screws, one cup B M4x12 Taptite screw and one cup S M4x8 Taptite screw. Taptite, cup S M4x8 Side plate LB Taptite, cup B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Taptite, cup S M3x6 Fig. 2-42 (20) Catch the Hooks of the Side cover L ASSY with the main body and fix the Side cover L ASSY with the one cup S M3x8 Taptite screw and three cup B M4x12 Taptite screws. Note: When assembling the Side cover L ASSY, pay attention to the Wire support rope. Hook Taptite, cup B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Wire support rope Hooks Side cover L ASSY Taptite, cup S M3x8 Taptite, cup B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Hooks *1 Fig. 2-43 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. 2-26 Confidential (21) Catch the Hooks of the Back cover ASSY and assemble it with the two cup S M3x8 Taptite screws. Hook Taptite, cup S M3x8 Back cover ASSY Hook Taptite, cup S M3x8 Fig. 2-44 (22) Assemble the Back cover upper with the two cup S M3x8 Taptite screws. Note: Be careful not to break the plastic. As this can be difficult to reassemble. Back cover upper Taptite, cup S M3x8 Fig. 2-45 2-27 Confidential (23) Close the Back cover. < Back side> Back cover Fig. 2-46 (24) Close the Front door unit ASSY. Front door unit ASSY Fig. 2-47 (25) After replacing the Laser unit, reset the counter. (Refer to “2.3 Parts Life Reset Function” in this chapter.) 2-28 Confidential 2.2.3 Paper Feeding Kit (PF Kit 1, PF Kit 2) (1) Pull out the Paper tray, and remove the paper from the Paper tray. Paper tray Fig. 2-48 (2) Release the two Hooks of the Separation pad ASSY, and then lift up the Separation pad ASSY. Note: Be careful not to loose the Separation pad spring. Hook Separation pad ASSY Hook Paper tray Separation pad spring Fig. 2-49 2-29 Confidential (3) Push both sides of the Separation pad ASSY inwards to release the Pins and remove the Separation pad ASSY from the Paper tray. (4) Remove the Separation pad spring from the Paper tray. Separation pad ASSY 3b 3a Pin 3a Paper tray Separation pad spring Pin Fig. 2-50 (5) Press the Front cover release button, and open the Front door unit ASSY. (6) Push the Lift arm to the direction of the arrow 6a and release the boss of the Roller holder ASSY. Then, turn the Roller holder ASSY to the direction of the arrow 6b. Paper feed frame unit Lift arm Roller holder ASSY Boss Paper feed frame unit 6a 6b Fig. 2-51 2-30 Confidential (7) Slide the Roller holder ASSY to the direction of the arrows 7a, 7b and 7c in this order and remove it. Paper feed frame unit 7b 7a Roller holder ASSY 7c Fig. 2-52 (1) Assemble the Roller holder ASSY onto the Paper feed frame unit in the order of the arrow 1a, 1b and 1c. Paper feed frame unit Paper feed frame unit 1b 1c Holder shaft 1a Roller holder ASSY * Align the holder shaft of the Roller holder ASSY with the shape of the hole on the Paper feed frame unit and put the shaft into the hole. Fig. 2-53 2-31 Confidential (2) Turn the Roller holder ASSY to the direction of the arrow 2a, push the Lift arm to the direction of the arrow 2b and fix the Boss of the Roller holder ASSY into the hole of the Lift arm. Note: Check whether the Lift arm moves by pushing the Roller holder ASSY upwards. If the Lift arm does not move, it is not assembled correctly. Paper feed frame unit Lift arm Roller holder ASSY Boss Paper feed frame unit 2b 2a Fig. 2-54 (3) Close the Front door unit ASSY. (4) Assemble the Separation pad spring. Put the positioning section of the Separation pad ASSY into the spring and catch the two Hooks. Positioning section Separation pad ASSY Hook Hook Paper tray Separation pad spring Fig. 2-55 2-32 Confidential (5) Push both sides of the Separation pad ASSY inwards and put its Pins into the Paper tray. Note: Check that the Separation pad ASSY pivots up and down smoothly by pushing it gently. Pin Pin 5a 5b Separation pad ASSY 5a Paper tray Fig. 2-56 (6) Install the Paper tray into the machine. Paper tray Fig. 2-57 (7) After replacing the Paper feeding kit, reset the counter. (Refer to “2.3 Parts Life Reset Function” in this chapter.) 2-33 Confidential 2.2.4 MP Paper Feeding Kit (PF Kit MP) (1) Press the Front cover release button, and open the Front door unit ASSY. (2) Release the two Hooks to remove the MP feed frame cover from the Front door unit ASSY. Hooks MP feed frame cover Front door unit ASSY Fig. 2-58 (3) Remove the MP lift arm 2. MP lift arm 2 Front door unit ASSY Fig. 2-59 2-34 Confidential (4) Lift up the Hook and release it in the direction of arrow 4a. Slide the Holder bush MP in the direction of arrow 4b, and then remove the Holder bush MP from the shaft of the MP roller holder ASSY. MP roller holder ASSY 4b Holder bush MP 4a Front door unit ASSY Hook Fig. 2-60 (5) Slide the MP roller holder ASSY in the direction of arrow 5a and slightly pull it down in the direction of arrow 5b. Then, remove it. MP roller holder ASSY 5a 5b Front door unit ASSY Fig. 2-61 2-35 Confidential (6) Remove the Separation pad ASSY MP from the Front door unit ASSY. (7) Remove the Separation pad spring MP. Note: Be careful not to loose the Separation pad spring MP. Separation pad spring MP 6a 6b Front door unit ASSY Separation pad ASSY MP Fig. 2-62 (1) Assemble the Separation pad Spring MP. (2) Put the positioning section of the Separation pad ASSY MP into the Separation pad spring MP and catch the two Hooks to fix the Separation pad ASSY MP. Note: Check that the Separation pad ASSY MP moves smoothly by pushing it up and down. Separation pad spring MP Front door unit ASSY 2b Hook 2a Positioning section Hook Separation pad ASSY MP Fig. 2-63 2-36 Confidential (3) Put the Holder shaft into the hole while holding the Separation pad ASSY MP. Slide the MP roller holder ASSY to the direction of the arrow 3b to re-assemble it. MP roller holder ASSY Separation pad ASSY MP Hole 3b Holder shaft 3a Front door unit ASSY Fig. 2-64 (4) Put into the Holder bush MP to the direction of the arrow 4a and turn it to the direction of the arrow 4b so that the Hook catches. MP roller holder ASSY 4a 4b Holder bush MP Front door unit ASSY Hook Fig. 2-65 2-37 Confidential (5) Assemble the MP lift arm 2 with aligning it with the three Bosses provided on the Front door unit ASSY. Note: When assembling the MP lift arm 2, make sure that the shaft of the MP roller holder ASSY is put into the hole on the MP lift arm 2. Hole Shaft (MP roller holder ASSY) MP lift arm 2 Bosses Front door unit ASSY Fig. 2-66 (6) Assemble the MP feed frame cover onto the Front door unit ASSY. (7) Close the Front door unit ASSY. Hooks MP feed frame cover MP feed frame cover Hook Hook Front door unit ASSY Fig. 2-67 (8) After replacing the MP paper feeding kit, reset the counter. (Refer to “2.3 Parts Life Reset Function” in this chapter.) 2-38 Confidential 2.3 Parts Life Reset Function This function is provided for service personnel in order to reset the counter of each periodical replacement part and count the number of replacement times when replacing the periodical replacement parts. (1) Press the 3 and 9 buttons at the same time in the ready status. (2) The “Reset Menu” will appear on the LCD. Select the applicable periodical replacement part by pressing the button and press the OK button. or < Periodical replacement parts are indicated on the LCD > - Drum - Belt Unit - PF Kit MP - PF Kit 2 - Fuser - Laser - PF Kit 1 (3) When the OK button is pressed the “1. Reset 2. Exit” appears on the LCD. Press the 1 button if resetting the counter. If not, press the 2 button. (4) Pressing the 1 button accepts that the machine implements the counter reset. (5) The machine returns to the ready status. Note: - All periodical replacement parts are always indicated on the LCD even though their lives do not reach 0 %. - The PF kit 2 is always indicated even though Tray 2 is not installed, or it is not supported for the model to be used. - The machine returns to the ready state automatically if no panel operation is implemented for 60 seconds. 2-39 Confidential CHAPTER 3 DISASSEMBLY AND ASSEMBLY 1. SAFETY PRECAUTIONS To avoid creating secondary problems by mishandling, follow the warnings and precautions below during maintenance work. HOT SURFACE Some parts inside the machine are extremely hot immediately after the machine is used. When opening the front cover or back cover to access any parts inside the machine, never touch the shaded parts shown in the following figures. Caution: - Be careful not to lose screws, washers, or other parts removed. - Be sure to apply grease to the gears and applicable positions specified in this chapter. - When using soldering irons or other heat-generating tools, take care not to accidentally damage parts such as wires, PCBs and covers. - Static electricity charged in your body may damage electronic parts. When transporting PCBs, be sure to wrap them in conductive sheets. - When replacing the PCB and all the other related parts, put on a grounding wrist band and perform the job on a static mat. Also take care not to touch the conductor sections on the flat cables or on the wire harness. - After disconnecting flat cables, check that each cable is not damaged at its end or shortcircuited. - When connecting flat cables, do not insert them at an angle. After insertion, check that the cables are not at an angle. - When connecting or disconnecting cable connectors, hold the connector body, not the cables. If the connector has a lock, release the connector lock first to release it. - After a repair, check not only the repaired portion but also all connectors. Also check that other related portions are functioning properly before operational checks. 3-1 Confidential 2. PACKING Accessory bag Quick setup guide Panel Option carton Carton cord box Option pad R Option pad L Toner cartridge C, M, Y, K Panel Pad R Middle pad Middle pad Pad L Machine Carton pad Middle pad Carton spacer (US only) Carton pad Pad base Carton pad Carton bottom Carton joint Carton Carton outer (US only) Carton joint 3-2 Confidential 3. SCREW TORQUE LIST Tightening Note: When tightening any of the screws shaded in the table below, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. Note: For verifying the shape of each screw, refer to “APPENDIX 4 SCREW CATALOGUE”. Location of screw Screw type Q'ty Tightening torque N m (kgf • cm) Tray cover ASSY Taptite, bind B M4x12 2 0.80 ±0.1 (8 ±1) Fuser unit Taptite, pan B M4x14 2 1.20 ±0.1 (12 ±1) Back cover upper Taptite, cup S M3x8 2 0.80 ±0.1 (8 ±1) Drive shaft holder Taptite, bind B M3x10 1 0.60 ±0.1 (6 ±1) Paper eject ASSY DX Taptite, cup B M4x12 2 1.20 ±0.1 (12 ±1) Taptite, cup S M3x6 1 0.80 ±0.1 (8 ±1) Taptite, cup S M3x8 2 0.80 ±0.1 (8 ±1) Transfer HVPS PCB unit Taptite, cup S M3x6 2 0.80 ±0.1 (8 ±1) Earth plate 3 Taptite, bind B M3x8 1 0.60 ±0.1 (6 ±1) Density shield plate 1 Taptite, bind B M3x8 2 0.60 ±0.1 (6 ±1) Earth plate 2 Taptite, cup S M3x6 1 0.80 ±0.1 (8 ±1) Registration-mark sensor PCB ASSY 1 Taptite, bind B M3x8 1 0.60 ±0.1 (6 ±1) Registration-mark sensor PCB ASSY 2 Taptite, bind B M3x8 1 0.60 ±0.1 (6 ±1) Back cover ASSY Density sensor Taptite, bind B M3x8 2 0.60 ±0.1 (6 ±1) Registration relay PCB ASSY Taptite, bind B M3x8 1 0.60 ±0.1 (6 ±1) Transfer HVPS PCB ASSY Taptite, cup B M3x10 3 0.50 ±0.1 (5 ±1) Taptite, cup S M3x6 1 0.80 ±0.1 (8 ±1) Taptite, cup B M4x12 3 1.20 ±0.1 (12 ±1) Taptite, cup S M3x8 1 0.80 ±0.1 (8 ±1) Taptite, cup B M4x12 1 1.20 ±0.1 (12 ±1) Taptite, cup S M4x8 1 1.20 ±0.1 (12 ±1) Taptite, cup S M3x6 3 0.80 ±0.1 (8 ±1) Taptite, cup B M4x12 2 1.20 ±0.1 (12 ±1) Taptite, cup S M4x8 2 1.20 ±0.1 (12 ±1) Taptite, cup S M3x6 1 0.80 ±0.1 (8 ±1) Side cover L ASSY Side plate LB Side cover R ASSY FG harness ADF FG harness FB Taptite, cup S M3x6 1 0.80 ±0.1 (8 ±1) Driver PCB ASSY Taptite, cup S M3x6 2 0.80 ±0.1 (8 ±1) Hinge protection cover ASSY Taptite, cup B M4x12 3 0.80 ±0.1 (8 ±1) Hinge Taptite, bind B M4x12 2 0.80 ±0.1 (8 ±1) Hinge base R Taptite, bind B M4x12 1 0.80 ±0.1 (8 ±1) Taptite, cup B M3x10 3 0.50 ±0.1 (5 ±1) Hinge ASSY L Taptite, bind B M4x12 1 0.80 ±0.1 (8 ±1) Taptite, cup B M3x10 3 0.50 ±0.1 (5 ±1) 3-3 Confidential Screw type Q'ty Tightening torque N m (kgf • cm) Taptite, cup S M3x8 SR 1 0.70 ±0.1 (7 ±1) Taptite, cup B M3x10 1 0.50 ±0.1 (5 ±1) ADF back cover Taptite, cup B M3x10 1 0.50 ±0.1 (5 ±1) FG harness ADF Taptite, cup S M3x8 SR 1 0.70 ±0.1 (7 ±1) ADF chute ASSY Taptite, cup B M3x10 4 0.70 ±0.1 (7 ±1) SB chute ASSY Taptite, cup S M3x8 SR 2 0.70 ±0.1 (7 ±1) Exit chute cover ASSY 4 0.50 ±0.1 (5 ±1) ADF motor Taptite, cup B M3x10 Screw pan (S/P washer) M3x6 2 0.70 ±0.1 (7 ±1) Motor frame ASSY DX Taptite, cup S M3x8 SR 3 0.70 ±0.1 (7 ±1) S/B solenoid ASSY PF solenoid ASSY ADF relay PCB ASSY Paper feed plate Paper feed chute ASSY Spring plate ADF front ASSY Drive frame sub ASSY Front frame Upper main chute ASSY Dressing cover ADF 2 ADF front cover 2 Handle cover Panel unit Dressing cover FB FL Dressing cover FB FR Dressing cover FB top Scanner top cover ASSY Lock lever ASSY FFC plate FG harness FB Drive plate ASSY Scanner motor Taptite, cup S M3x8 SR Taptite, cup S M3x8 SR Taptite, cup S M3x8 SR Taptite, cup S M3x8 SR Taptite, cup S M3x8 SR Taptite screw B M3x6 Taptite, cup B M3x10 Taptite, cup B M3x10 Taptite, cup B M3x10 Taptite, cup B M3x10 Taptite, cup B M3x10 Taptite, cup B M3x10 Taptite, cup B M3x10 Taptite, cup B M4x12 Taptite, cup B M4x12 Taptite, cup B M4x12 Taptite, cup B M4x12 Taptite screw B M3x6 Taptite, cup B M3x8 Taptite, cup S M3x6 Taptite, pan B M3x8 Screw pan (S/P washer) M3x6 1 1 1 2 2 1 3 3 4 1 1 2 4 3 3 2 6 2 1 1 4 2 0.70 ±0.1 (7 ±1) 0.70 ±0.1 (7 ±1) 0.70 ±0.1 (7 ±1) 0.70 ±0.1 (7 ±1) 0.70 ±0.1 (7 ±1) 0.40 ±0.05 (4 ±0.5) 0.50 ±0.1 (5 ±1) 0.50 ±0.1 (5 ±1) 0.50 ±0.1 (5 ±1) 0.50 ±0.1 (5 ±1) 0.50 ±0.1 (5 ±1) 0.50 ±0.1 (5 ±1) 0.50 ±0.1 (5 ±1) 0.80 ±0.1 (8 ±1) 0.80 ±0.1 (8 ±1) 0.80 ±0.1 (8 ±1) 0.80 ±0.1 (8 ±1) 0.40 ±0.05 (4 ±0.5) 0.50 ±0.1 (5 ±1) 0.80 ±0.1 (8 ±1) 0.50 ±0.1 (5 ±1) 0.70 ±0.1 (7 ±1) Pulley ASSY Dressing cover FB base L Taptite, pan B M3x6 Taptite, cup B M3x8 Taptite, cup B M4x12 Taptite, cup B M4x12 Screw pan (S/P washer) M3.5x6 Taptite, bind B M4x12 Screw pan (S/P washer) M3.5x6 Taptite, bind B M4x12 Screw pan (S/P washer) M3.5x6 2 1 2 3 1 0.40 ±0.05 (4 ±0.5) 0.50 ±0.1 (5 ±1) 0.80 ±0.1 (8 ±1) 0.80 ±0.1 (8 ±1) 0.40 ±0.05 (4 ±0.5) 4 1 0.80 ±0.1 (8 ±1) 0.40 ±0.05 (4 ±0.5) 2 1 0.80 ±0.1 (8 ±1) 0.40 ±0.05 (4 ±0.5) Taptite, cup S M3x6 Taptite, bind B M4x12 Taptite, cup S M3x8 Taptite, bind B M4x12 Taptite, cup S M4x8 2 2 5 2 6 0.60 ±0.1 (6 ±1) 0.80 ±0.1 (8 ±1) 0.80 ±0.1 (8 ±1) 0.80 ±0.1 (8 ±1) 1.20 ±0.1 (12 ±1) Location of screw ADF front cover 1 Dressing cover FB base R FG harness NCU NCU cover FG harness NCU NCU unit NCU shield plate NCU PCB ASSY Pull arm guide L/ R Joint cover ASSY 3-4 Confidential Location of screw Screw type Q'ty Tightening torque N m (kgf • cm) Joint cover FR Joint cover FL Top cover USB front ASSY USB holder Wireless LAN PCB ASSY Speaker holder Speaker hold spring Taptite, bind B M4x12 Taptite, bind B M4x12 Taptite, bind B M3x8 Taptite, bind B M3x8 Taptite, bind B M4x12 Taptite, cup S M3x6 Taptite, cup S M3x6 2 2 3 3 2 1 1 0.80 ±0.1 (8 ±1) 0.80 ±0.1 (8 ±1) 0.50 ±0.1 (5 ±1) 0.50 ±0.1 (5 ±1) 0.80 ±0.1 (8 ±1) 0.80 ±0.1 (8 ±1) 0.80 ±0.1 (8 ±1) Paper feed frame unit PF plate Taptite, bind B M3x10 Taptite, cup S M3x6 Taptite, bind B M3x8 2 1 5 0.70 ±0.1 (7 ±1) 0.70 ±0.1 (7 ±1) 0.40 ±0.1 (4 ±1) Belt cleaner release sensor PCB ASSY Taptite, bind B M3x8 1 0.50 ±0.1 (5 ±1) THM/HUM sensor holder ASSY Taptite, cup S M3x6 4 0.69 ±0.1 (6.9 ±1) THM/HUM ground plate Taptite, cup S M3x6 1 0.69 ±0.1 (6.9 ±1) Release rack plate Taptite, cup B M3x8 1 0.49 ±0.1 (4.9 ±1) Front door unit earth Taptite, cup S M3x6 1 0.80 ±0.1 (8 ±1) Wire support rope Shoulder screw 1 0.80 ±0.1 (8 ±1) Harness cover MP Taptite, cup S M3x6 1 0.78 ±0.1 (7.8 ±1) Front door sub Taptite, cup B M4x10 5 0.59 ±0.1 (5.9 ±1) Taptite, cup B M3x8 1 0.39 ±0.1 (3.9 ±1) EL electrode spring cover ASSY Taptite, bind B M3x8 2 0.392 ±0.098 (3.92 ±0.98) EL spring harness ASSY Taptite, bind B M3x8 2 0.392 ±0.098 (3.92 ±0.98) Front door main Taptite, bind B M4x10 2 0.59 ±0.1 (5.9 ±1) Hook cover Taptite, cup B M4x10 2 0.59 ±0.1 (5.9 ±1) Engine PCB ASSY Taptite, cup S M3x6 5 0.80 ±0.1 (8 ±1) Ground plate Taptite, cup S M3x6 Taptite, bind B M4x12 1 0.80 ±0.1 (8 ±1) 1 Taptite, cup S M3x6 1 1.20 ±0.1 (12 ±1) 0.80 ±0.1 (8 ±1) (Frame unit side) 0.50 ±0.1 (5 ±1) (Main PCB ASSY side) Ground spring plate 1 Main PCB ASSY Taptite, cup S M3x6 1 0.80 ±0.1 (8 ±1) 0.70 ±0.1 (7 ±1) 0.90 ±0.1 (9 ±1) (Top side) 0.80 ±0.1 (8 ±1) (Front side) Hook slope Taptite, cup S M3x8 4 Scanner cover Taptite, cup S M3x6 8 1 Laser unit Taptite, cup S M3x6 SR 7 0.80 ±0.1 (8 ±1) Develop gear plate ASSY Taptite, cup S M3x6 7 0.80 ±0.1 (8 ±1) Develop drive motor ASSY Taptite, cup S M3x6 3 0.70 ±0.1 (7 ±1) Gear guide holder Taptite, cup B M3x10 5 Harness shield plate Taptite, cup S M3x6 2 0.70 ±0.1 (7 ±1) 0.80 ±0.1 (8 ±1) (Frame unit side) 0.50 ±0.1 (5±1) (Main shield side) 1 Engine PCB plate Taptite, cup S M3x6 4 0.80 ±0.1 (8 ±1) Drum drive motor 1, 2 Taptite, cup S M3x6 4 0.70 ±0.1 (7 ±1) Drum drive ASSY Taptite, bind B M4x12 6 1.20 ±0.1 (12 ±1) Drum phase sensor PCB ASSY 1, 2 Taptite, bind S M3x6 2 0.70 ±0.1 (7 ±1) 3-5 Confidential Location of screw Screw type Q'ty Tightening torque N m (kgf • cm) Drive frame unit ASSY Taptite, bind B M4x12 3 1.20 ±0.1 (12 ±1) Paper feed/belt cleaner motor ASSY Taptite, cup S M3x6 4 0.60 ±0.1 (6 ±1) Develop release sensor PCB ASSY Taptite, cup B M3x8 1 0.60 ±0.1 (6 ±1) Develop press drive L ASSY Taptite, bind B M3x12 3 0.8 ±0.1 (8 ±1) Taptite, cup B M3x12 1 0.8 ±0.1 (8 ±1) Develop release motor ASSY Taptite, bind S M3x6 1 0.70 ±0.1 (7 ±1) Release drive holder Taptite, cup B M3x10 3 0.70 ±0.1 (7 ±1) Toner sensor PCB ASSY (TE/NEW) Taptite, bind B M3x8 3 0.55 ±0.05 (5.5 ±0.5) Taptite, cup B M3x8 1 Taptite, cup S M3x6 2 Taptite, cup S M3x6 2 0.55 ±0.05 (5.5 ±0.5) 0.75 ±0.05 (7.5 ±0.5) (Back side) 0.90 ±0.1 (9 ±1) (Front side) Taptite, cup B M4x12 4 0.90 ±0.1 (9 ±1) Taptite, cup S M4x8 Screw pan (S/P washer) M4x8 DB 1 1.20 ±0.1 (12 ±1) 2 0.80 ±0.1 (8 ±1) Drum lock lever R Screw, bind M3x8 1 0.69 ±0.1 (6.9 ±1) Drum lock lever L Screw, bind M3x8 1 0.69 ±0.1 (6.9 ±1) Charge HVPS PCB ASSY Taptite, cup S M3x6 1 0.80 ±0.1 (8 ±1) 2 1.20 ±0.1 (12 ±1) Toner LED PCB Taptite, bind B M4x12 Screw pan (S/P washer) M3x16 4 0.50 ±0.1 (5 ±1) 2 0.60 ±0.1 (6 ±1) Ground terminal Taptite, flat B M3x10 Screw pan (S/P washer) M4x8 1 0.80 ±0.1 (8 ±1) PS PCB unit Taptite, bind B M4x12 3 0.90 ±0.1 (9 ±1) Belt gear plate ASSY Taptite, cup B M4x12 3 1.20 ±0.1 (12 ±1) Screw, cup M3x6 1 0.70 ±0.1 (7 ±1) Taptite, bind B M3x10 1 0.80 ±0.1 (8 ±1) Belt unit drive motor ASSY Taptite, cup B M4x12 3 1.20 ±0.1 (12 ±1) Belt unit drive motor Screw, bind M3x5 2 0.70 ±0.1 (7 ±1) Q'ty Tightening torque N m (kgf • cm) Side plate R ASSY Power inlet socket LV fan duct LT paper tray Location of screw Screw type Pinch roller holder cover LT Taptite, bind B M4x10 2 0.70 ±0.1 (7 ±1) LT cover rear Shoulder screw 4 0.80 ±0.1 (8 ±1) LT cover left Shoulder screw 3 0.80 ±0.1 (8 ±1) LT cover right Shoulder screw 3 0.80 ±0.1 (8 ±1) LT relay PCB ASSY Taptite, cup S M3x6 1 0.80 ±0.1 (8 ±1) Solenoid holder ASSY Taptite, cup S M3x6 1 0.80 ±0.1 (8 ±1) LT Solenoid ASSY Screw flanged M3x3.5 1 0.50 ±0.1 (5 ±1) LT tray guide left rear ASSY Taptite, cup S M3x8 3 0.80 ±0.1 (8 ±1) LT front cover, LT beam F Taptite, cup S M3x6 4 0.80 ±0.1 (8 ±1) LT frame unit Taptite, cup S M3x6 7 0.80 ±0.1 (8 ±1) Taptite, bind B M4x10 1 0.80 ±0.1 (8 ±1) Taptite, cup S M3x6 2 0.80 ±0.1 (8 ±1) LT beam R 3-6 Confidential 4. LUBRICATION 4 places PG2 GE2 Separation roller shaft ASSY BDX1 PG2: PG-661(W) (2mm dia. ball) GE2: GE-676 (2mm dia. ball) BDX1: BDX-313 (1mm dia. ball) Develop drive motor ASSY Motor shaft BG2 Develop gear plate ASSY 3 places BG2: BG-MU (2mm dia. ball) 3-7 Confidential 4 places Gear 85 PG2 PG2 PG2 Gear 54 4 places (2 places x2) 4 places Motor frame ASSY DX Arm SB Arm 2 places PG2 Arm SB PG2 2 places Motor frame ASSY DX PG2 PG2 Arm PF 2 places 2 places PG2: PG-661(W) (2mm dia. ball) 3-8 Confidential Pinch roller shaft 2 places PG2 2 places PG2 Pinch roller shaft 2 places PG2 SB chute ASSY PG2 2 places Pinch roller shaft PG2: PG-661(W) (2mm dia. ball) Paper feed/belt cleaner motor Gear 90R/24 Gear 80R/30 BG2 3 places BG2 Gear 80R/30 Gear 90R/24 3 places BG2: BG-MU (2mm dia. ball) 3-9 Confidential Gear stopper Gear 39/121 Gear 39/121 BG2 4 places (1 place x4) Gear 39/121 BG2 28 places (7 places x4) Gear 39/121 Drum drive ASSY BG2: BG-MU (2mm dia. ball) MP paper guide ASSY * Cross section of the MP paper guide ASSY PG2 6 places (3 place x2) PG2: PG-661(W) (2mm dia. ball) 3-10 Confidential 60 places (4 place x15) Gear 24 LT PG2 Gear 46/55 A spring is hung, installation part 2 places PG2 Clutch gear 45 Gear 45/40 Gear 32 LT In case of 2mm dia. ball x4 Gear 37/22 Gear 46/55 Gear 46 LT Gear 20A Gear 33 PG2: PG-661(W) (2mm dia. ball) 28 places (4 place x7) PG2 In case of 2mm dia. ball x4 LT frame L PG2: PG-661(W) (2mm dia. ball) 3-11 Confidential F roller shaft LT F roller shaft LT 2 places BG2 LT frame R BG2: BG-MS (2mm dia. ball) F roller shaft LT F roller shaft LT 2 places GE2 LT frame L GE2: GE-676 (2mm dia. ball) 3-12 Confidential Paper feed drive shaft LT ASSY 4 places GE2 4 places PG2 Bush AC LT LT frame L GE2: GE-676 (2mm dia. ball) PG2: PG-661(W) (2mm dia. ball) In case of 2mm dia. ball x2 Clutch gear 45 Clutch gear 45 2 places PG2 Clutch arm Fittings shaft PG2: PG-661(W) (2mm dia. ball) 3-13 Confidential Extension guide R In case of 2mm dia. ball x4 EM2 Extension guide L LT paper tray EM2 EM2: MOLYKOTE EM-D110 (2mm dia. ball) Side guide R 1.4mm Side guide R LT paper tray PG2 PG2: PG-661(W) (2mm dia. ball) 3-14 Confidential 5. OVERVIEW OF GEARS DEVELOPER DRIVE 1 LR0194001 Gear 98 10 LR0199001 Gear 35 2 LR0202001 Gear 100 11 LR0203001 Coupling gear 50 3 LR0201001 Gear 50/100 12 LR0203001 Coupling gear 50 4 LR0197001 Pendulum gear 50 13 LR0200001 Gear 45 5 LR0198001 Gear 38 14 LR0198001 Gear 38 6 LR0199001 Gear 35 15 LR0203001 Coupling gear 50 7 LR0198001 Gear 38 16 LR0200001 Gear 45 8 LR0199001 Gear 35 17 LR0203001 Coupling gear 50 9 LR0199001 Gear 35 18 LR0482001 Eject roller gear 19 LJ7365001 Idle gear 16B 20 LJ7365001 Idle gear 16B 21 LJ7365001 Idle gear 16B 22 LJ7365001 Idle gear 16B 23 LM5016001 Ejector gear 16 24 LM5018001 Ejector gear 16 planetary 25 LM5019001 Ejector gear 22 26 LR0480001 Ejector gear 16/20 27 LR0482001 Eject roller gear 28 LJ7365001 Idle gear 16B 29 LR0979001 Ejector gear 28 sector 30 LM5019001 Ejector gear 22 31 LR1181001 Ejector gear 36 SX 32 LR0478001 Ejector gear 14/24 33 LR0476001 Ejector gear 22B 34 LR0477001 Ejector gear 12/24 PAPER EJECT 18 19 20 21 22 24 23 26 27 28 25 30 29 31 32 33 34 3-15 Confidential PF DRIVE Location of PF drive gears 35 LR0316001 Gear Z35M75 36 LR0311001 PF drive gear Z23M75 37 LR0315001 Gear Z3218M0875 38 LR0326001 PU drive gear Z20M08 39 LR0314001 Gear Z3717M08 40 LR0320001 PU sector gear Z4648M08 41 LR0324001 Torque spring for PU sector Location of parts after removing the parts shown as 35 to 41 in the figure above 43 42 LR0309001 PP gear clutch cam 43 LR0310001 PP gear clutch cam spring 42 Location of parts after removing the parts shown as 42 and 43 in the figure above 44 45 46 3-16 44 LR0308001 Hook C 45 LR0307001 Hook B 46 LR0910001 Hook spring BC Confidential 6. HARNESS ROUTING 1 Transfer HVPS PCB unit (Registration-mark sensor PCB ASSY 1, 2, Density sensor) Registration-mark sensor PCB ASSY 2 Density sensor Registration-mark sensor PCB ASSY 1 Ground plate 2 2 Transfer HVPS PCB unit Registration relay PCB ASSY USB host relay PCB ASSY Joint cover ASSY Fan motor holder 40 Clamps USB host relay PCB ASSY Hooks Front Side frame L Main PCB ASSY 3-17 Confidential 3 T1 PE/edge sensor PCB ASSY, Belt cleaner release sensor PCB ASSY Engine PCB ASSY Side frame L Belt cleaner release solenoid ASSY Belt cleaner release sensor PCB ASSY Front Clamp Hook Hole Belt cleaner release ASSY Clamp SOL PCB sheet Belt cleaner release solenoid ASSY Belt cleaner release sensor PCB ASSY Belt cleaner release ASSY Hook Hook Paper feed frame unit Front Hole Side frame L PF CR harness holder Hole Hook Hook Hook T1 PE/edge sensor PCB ASSY Paper feed frame unit T1 PE/edge sensor PCB ASSY 3-18 Confidential 4 Develop release sensor PCB ASSY Hook Hook Side frame L Develop release sensor PCB ASSY Develop gear plate ASSY Clamp Clamps Engine PCB ASSY Front 5 Toner sensor PCB ASSY K, Y, M, C (TE/NEW) Toner sensor PCB ASSY M (TE/NEW) Toner sensor PCB ASSY C (TE/NEW) Hook Toner sensor PCB ASSY Y (TE/NEW) Hook Hooks Hook Hooks Release drive holder Toner sensor PCB ASSY K (TE/NEW) Front Develop gear plate ASSY Clamp Release drive holder Side frame L Engine PCB ASSY 3-19 Confidential 6 Laser unit Laser unit Front Hole Hole Develop gear plate ASSY Develop gear plate ASSY Side frame L Main PCB ASSY Hole Laser unit Hole Clamp Clamp Develop press drive L ASSY Clamp Hooks Release drive holder Front Engine PCB ASSY Side frame L 3-20 Confidential 7 Develop press drive L ASSY (Develop release motor ASSY, Front cover interlock switch ASSY) Develop release motor ASSY Front cover interlock switch ASSY Side frame L Holes Interlock harness guide Clamps Develop press drive L ASSY Release drive holder Front cover interlock switch ASSY Interlock harness guide Front Hooks Clamp Engine PCB ASSY 8 LVPS fan (PS) Front Charge HVPS PCB ASSY Frame R Harness holder 16AWG Hooks LVPS fan (PS) 3-21 Hook Confidential 9 PS PCB unit Back Front Power Inlet socket Harness holder 16AWG Ground terminal Screw pan (S/P washer) M4x8 Hooks Frame R Power supply switch Power Inlet socket PS PCB unit 10 NCU unit (MFC-9840CDW only) NCU unit FG harness NCU Joint cover ASSY Hook Hook Hole Hole Develop gear plate ASSY Front NCU harness ASSY Main PCB ASSY 3-22 Confidential 11 Paper feed/belt cleaner motor ASSY Rib Front Hook Side frame L Hook Drive frame unit ASSY Paper feed/ belt cleaner motor ASSY Engine PCB plate Drum drive ASSY Hook Hook Hook 3-23 Engine PCB ASSY Hook Confidential 12 ADF unit ADF motor harness ADF relay harness FG harness ADF ADF relay PCB ASSY ADF motor Document cover sensor harness Hook Hook Document cover sensor Hole ADF unit Hole ADF harness Hole Document scanner unit Hook Rib Hook ADF motor harness Front FG harness ADF ADF relay harness Document cover sensor harness Driver PCB ASSY Main PCB ASSY 3-24 Confidential 13 ADF unit (Document front sensor 1, Document front sensor 2) Motor frame ASSY DX Hook Hole Hooks Document front sensor 2 Document front sensor 1 ADF relay PCB ASSY Hole Hole Document front sensor 1 Motor frame ASSY DX ADF relay PCB ASSY Drive frame sub ASSY Document front sensor 2 Document front sensor 1 Actuator front 2 Hook Hook Actuator front 1 Hook Hook Hooks Hook Document front sensor 2 3-25 Paper feed chute ASSY Confidential 14 ADF unit (Document rear sensor, Switch back sensor) Switch back sensor Document rear sensor Switch back sensor Switch back sensor harness ADF relay PCB ASSY Actuator SB Hooks Hook Switch back sensor harness ADF relay PCB ASSY 15 Actuator R Hooks Document rear sensor Lower main chute ASSY Document rear sensor harness Document rear sensor harness ADF unit (S/B solenoid ASSY, PF solenoid ASSY) Hook PF solenoid ASSY Hook ADF chute ASSY S/B solenoid ASSY Hook ADF relay PCB ASSY Motor frame ASSY DX 3-26 Confidential 16 Document scanner unit (CCD unit, HP sensor) Drive plate ASSY Document scanner unit CCD unit Hook Hole Hooks HP sensor HP sensor HP sensor harness Rib Hooks Driver PCB ASSY HP sensor harness Rib Main PCB ASSY Front FFC cable Harness holder 17 Document scanner unit (Scanner motor, FG harness FB) Front Scanner motor Hole Driver PCB ASSY Document scanner unit Drive plate ASSY Rib Hooks FG harness FB 3-27 Confidential 18 Panel unit Panel unit Document scanner unit Hole Panel PCB ASSY Front Panel harness Hook Harness holder Hook Hook Main PCB ASSY 19 Speaker ASSY Hook Clamp Speaker ASSY Clamp Hooks Front Main PCB ASSY 3-28 Confidential 20 Wireless LAN PCB ASSY (MFC-9840CDW only) Hook Wireless LAN PCB ASSY Front Hole Hook Hook Hook Joint cover ASSY Hook Hole Hole Front Joint cover ASSY Wireless LAN PCB harness Main PCB ASSY 3-29 Confidential Preparation Prior to proceeding with the disassembly procedure, (1) Unplug - the AC cord, - the modular jack of the telephone line, - the USB cable, if connected, - the LAN cable, if connected, - the USB cable for PictBridge, if connected, and - the modular jack of the external telephone set if connected. (2) Remove - the Paper tray, - the Toner cartridge x 4, - the Drum unit, - the Belt unit, and - the Waste toner box. Toner cartridge Drum unit Belt unit Waste toner box Paper tray 3-30 Confidential 7. DISASSEMBLY FLOW Disassembly / Re-Assembly (sec.) Basic Operation 5s / 5s 20s / 20s 8.2 20s / 20s DX Feed ASSY 8.3 8.1 10s / 10s Toner cartridge AC cord Drum unit 15s / 15s 8.4 MP cover ASSY/ MP paper guide ASSY 25s / 25s 5s / 5s Paper tray 20s / 20s MP lift arm 2/ MP roller holder ASSY 8.5 5s / 5s Waste toner box Belt unit 8.16 20s / 25s Fuser unit/ Toner filter frame ASSY 8.26 25s / 25s Paper stopper 10s / 10s Roller holder ASSY 8.20 30s / 45s Panel unit 8.9 - Earth plate (15s/15s) - Registration-mark sensor PCB ASSY 1 (10s/10s) - Registration-mark sensor PCB ASSY 2 (10s/10s) - Density sensor (10s/10s) - Registration relay PCB ASSY (10s/10s) - Transfer HVPS PCB ASSY (20s/20s) 10s / 10s 8.6 Paper guide/ HV TR top cover 8.10 45s / 60s 8.7 Transfer HVPS PCB unit 8.11 30s / 50s Paper eject ASSY DX 75s / 75s - ADF cover (20s/25s) - ADF front cover (20s/20s) - ADF back cover (20s/20s) - ADF chute ASSY (50s/80s) - Main chute (35s/45s) - Sub chute ASSY(10s/10s) - Each LF Roller (60s/80s) - Hinge arm (5s/5s) - Hinge base (15s/15s) - Hinge L ASSY (10s/15s) - PF roller holder ASSY (15s/20s) - Exit roller ASSY (15s/20s) - ADF relay PCB ASSY (10s/10s) etc. 8.13 20s / 20s Side plate LB 8.15 8.17 15s / 30s Driver PCB ASSY 8.18 30s / 45s 95s / 120s Paper feed frame unit (35s/50s)/ T1 PE/edge sensor PCB ASSY (60s/70s) 8.28 20s / 50s Belt cleaner release sensor PCB ASSY 8.29 40s / 50s THM/HUM sensor holder ASSY 8.53 8.21 660s / 800s 220s / 280s 8.37 70s / 70s Toner sensor PCB ASSY K, Y, M, C (TE/NEW) - Release drive holder (10s/10s) - Eeach sensor (15s/15s) 8.49 Each 10s / 20s New toner actuator/ New toner actuator spring 8.30 45s / 60s 8.42 60s / 60s 80s / 80s 10s / 10s Paper feed/belt cleaner motor ASSY 8.51 60s / 70s Front door unit ASSY 8.46 35s / 35s Develop press drive L ASSY 8.32 8.56 5s / 5s 8.57 5s / 5s Air intake fan (AIR) 40s / 40s 8.58 40s / 60s PS PCB unit 20s / 20s Speaker ASSY 8.40 5s / 5s Fuser unit fan (FU) 8.59 60s / 70s Belt unit drive motor ASSY 80s / 80s Laser unit (60s/ 60s) Hook slope (20s/ 20s) 10s / 10s Harness cover MP 8.33 8.47 20s / 20s 20s / 20s Front cover interlock switch ASSY 8.34 20s / 40s EL electrode spring L/R 8.35 15s / 20s Drive frame unit ASSY 8.44 8.31 8.55 LVPS fan (PS) 30s / 45s 8.25 Each 10s / 20s Front door sub Drum drive ASSY/ Drum phase sensor PCB ASSY 1, 2 8.43 10s / 15s Release rack 40s/ 40s Develop drive motor ASSY 8.48 8.24 15s / 15s Drum lock lever R 15s / 15s Toner LED PCB ASSY Battery ASSY Drum unit fan (OPC) Engine PCB ASSY 8.41 10s / 10s 8.54 NCU PCB ASSY 10s / 10s 110s / 120s Main PCB ASSY/ Ground plate/ Ground spring plate Develop release sensor PCB ASSY 8.14 8.52 Charge HVPS PCB ASSY Document scanner unit 8.22 35s / 35s Side plate R ASSY Joint cover ASSY 8.38 8.45 8.50 Pull arm L, R/ Hinge protection cover ASSY ADF unit - Scanner top cover ASSY (25s/35s) - Lock lever ASSY (15s/15s) - CCD module (20s/35s) - FFC cable ASSY (10s/20s) - Scanner motor (30s/40s) - Pulley ASSY (10s/20s) - Photo interrupter (10s/15s) - Dressing cover FB FL/FR (30s/30s) - Dressing cover FB base L/R (30s/30s) - Dressing cover FB top (15s/15s) 30s / 30s Side cover R ASSY 8.23 8.27 30s / 30s Side cover L ASSY 8.19 40s / 40s Waste toner near/full sensor ASSY 8.12 10s / 10s Back cover ASSY Registration-mark sensor PCB ASSY 1, 2/ Density sensor/ Registration relay PCB ASSY/ Transfer HVPS PCB ASSY 8.39 8.8 10s / 10s Back cover upper - Drum drive motor (10s/10s) - Drum drive ASSY (50s/50s) - Drum phase sensor PCB ASSY 1 (10s/10s) - Drum phase sensor PCB ASSY 2 (10s/10s) 50s / 60s Hook cover/ Front cover release button/ Button spring (30s/30s)/ Front door main (20s/30s) 8.36 20s / 20s Hook shaft/ Hook/ Hook spring 15s / 15s Drum lock lever L 3-31 Confidential 8. DISASSEMBLY PROCEDURE 8.1 Paper Tray (1) Release the two Hooks of the Separation pad ASSY, and then lift up the Separation pad ASSY. Note: Be careful not to loose the Separation pad spring. Hook Separation pad ASSY Hook Paper tray Separation pad spring Fig. 3-1 (2) Push both sides of the Separation pad ASSY inwards to release the Pins and remove the Separation pad ASSY from the Paper tray. (3) Remove the Separation pad spring from the Paper tray. Separation pad ASSY 2b 2a Pin 2a Separation pad spring Paper tray Pin Fig. 3-2 3-32 Confidential (4) Remove the two bind B M4x12 Taptite screws, and then remove the Tray cover ASSY. Taptite, bind B M4x12 Tray cover ASSY Fig. 3-3 (5) Turn the paper tray upside down. (6) Release the two Hooks to remove the Paper guide DX ASSY. Hook Hook Paper guide DX ASSY Fig. 3-4 3-33 Confidential 8.2 DX Feed ASSY (1) Release the three Hooks to remove the DX hook ASSY. (2) Release the two Bosses to remove the DX feed ASSY. * Release the boss on the right hand side first. DX feed ASSY Boss Boss Hooks DX feed ASSY Top view DX hook ASSY Hook Side view DX feed ASSY Fig. 3-5 8.3 MP Cover ASSY/ MP Paper Guide ASSY (1) Open the MP cover ASSY. MP paper guide ASSY MP cover ASSY Fig. 3-6 3-34 Confidential (2) Release the two Bosses of the MP paper guide ASSY. Boss MP paper guide ASSY MP cover ASSY Boss Fig. 3-7 (3) Lift up the MP paper guide ASSY align the MP paper guide ASSY with section “A” of the MP lower chute. Bend section “A” then, remove the MP paper guide ASSY. MP paper guide ASSY 3b MP paper guide ASSY 3a “A” MP lower chute MP cover ASSY Fig. 3-8 3-35 Confidential (4) Release the Bosses while bending the MP cover ASSY and remove the MP cover ASSY from the Front door main. Front door main Front door main MP cover ASSY Boss Boss Boss MP cover ASSY Boss Fig. 3-9 Assembling Note: When assembling the MP paper guide ASSY, note the assembling method referring to the figure below. Boss A MP paper guide ASSY Boss A MP paper guide ASSY Boss B Boss B Fig. 3-10 3-36 Confidential 8.4 MP Lift Arm 2/ MP Roller Holder ASSY (1) Press the Front cover release button, and open the Front door unit ASSY. (2) Release the two Hooks to remove the MP feed frame cover from the Front door unit ASSY. Hooks MP feed frame cover Front door unit ASSY Fig. 3-11 (3) Remove the MP lift arm 2. MP lift arm 2 Front door unit ASSY Fig. 3-12 3-37 Confidential (4) Release the Hook to slide the Holder bush MP in the direction of arrow 4a, and then remove the Holder bush MP from the shaft of the MP roller holder ASSY. MP roller holder ASSY 4a Holder bush MP Front door unit ASSY Hook Fig. 3-13 (5) Slide the MP roller holder ASSY in the direction of arrow 5a and slightly pull it down in the direction of arrow 5b. Then, remove it. MP roller holder ASSY 5a 5b Front door unit ASSY Fig. 3-14 3-38 Confidential (6) Remove the Separation pad ASSY MP from the Front door unit ASSY. (7) Remove the Separation pad spring MP. Note: Be careful not to loose the Separation pad spring MP. Separation pad spring MP 6a Front door unit ASSY 6b Separation pad ASSY MP Fig. 3-15 3-39 Confidential 8.5 Fuser Unit/ Toner Filter Frame ASSY (1) Turn each of the two Cord holders at the angle of 90 degrees and remove them from the Back cover upper and Side cover R ASSY. Back cover upper Cord holder 1a 1b Side cover R ASSY Cord holder Fig. 3-16 (2) Open the Back cover. Back cover Fig. 3-17 3-40 Confidential (3) Remove the two pan B M4x14 Taptite screws, and then pull out the Fuser unit to the back of the machine. Taptite, pan B M4x14 (Tightening torque: 1.20 ±0.1 N m) *1 Fuser unit Taptite, pan B M4x14 (Tightening torque: 1.20 ±0.1 N m) *1 Fig. 3-18 *1 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. Assembling Note: When assembling the fuser unit, make sure that the two Harnesses are placed in the groove and under the rib of the Plastic frame. If they are not, then correct them as shown in the figure below. Harness Harness Plastic frame Fig. 3-19 3-41 Confidential (4) Remove the Toner filter frame ASSY from the Paper eject ASSY DX. Paper eject ASSY DX 4a 4b Toner filter frame ASSY Fig. 3-20 8.6 Back Cover Upper (1) Remove the two cup S M3x8 Taptite screws, and then remove the Back cover upper. Note: Be careful not to break the plastic. As this can be difficult to remove and reassemble. Back cover upper Taptite, cup S M3x8 Fig. 3-21 3-42 Confidential 8.7 Paper Eject ASSY DX (1) Remove the bind B M3x10 Taptite screw, and then remove the Drive shaft holder. Drive shaft holder Paper eject ASSY DX Taptite, bind B M3x10 1b 1a Fig. 3-22 (2) Release the Hook to remove the Fuser drive gear 18 from the shaft. Paper eject ASSY DX Fuser drive gear 18 Hook Fig. 3-23 3-43 Confidential (3) Remove the two cup B M4x12 Taptite screws and cup S M3x6 Taptite screw. (4) Disconnect the Connector. (5) Remove the Paper eject ASSY DX. Taptite, cup S M3x6 Connector Taptite, cup B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Paper eject ASSY DX Taptite, cup B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Fig. 3-24 *1 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. Parts Replacement Note: The Paper eject ASSY DX is supplied with the Drive shaft holder already fitted. When replacing the Paper eject ASSY DX, remove the Drive shaft holder from the supplied Paper eject ASSY DX first, then assemble the Paper eject ASSY DX. Paper eject ASSY DX Drive shaft holder Taptite, bind B M3x10 Fig. 3-25 3-44 Confidential Assembling Note: (1) Put the Drive shaft holder into the Shaft of the Frame unit. (2) Align the Hook and Pin of the Drive shaft holder with the hole on the Paper eject ASSY DX while inclining the Drive shaft holder 10 degrees downwards. (3) Move the Drive shaft holder to the direction of the arrow 3 to align it with the screw hole of the Paper eject ASSY DX, and secure the Drive shaft holder with the bind B M3x10 Taptite screw. Hole Pin Hook 1 Paper eject ASSY DX 2 Drive shaft holder Paper eject ASSY DX Hole of screw 3 Taptite, bind B M3x10 Drive shaft holder Shaft of the Frame unit Fig. 3-26 8.8 Back Cover ASSY (1) Remove the two cup S M3x8 Taptite screws, and then remove the Back cover ASSY. Hook Taptite, cup S M3x8 Back cover ASSY Hook Taptite, cup S M3x8 Fig. 3-27 3-45 Confidential 8.9 Paper Guide/ HV TR Top Cover (1) Release the two Bosses, and then remove the Paper guide from the Transfer HVPS PCB unit while lifting it up slightly. Note: When removing the Paper guide, be careful not to damage the two Ribs. Transfer HVPS PCB unit Boss Hook Ribs Paper guide Hook Boss Fig. 3-28 (2) Slide the HV TR top cover to the left hand side and release the four Hooks. Then, remove the HV TR top cover. Hooks HV TR top cover Hooks Transfer HVPS PCB unit Fig. 3-29 3-46 Confidential 8.10 Transfer HVPS PCB Unit (1) Disconnect the four Connectors from the Electrode head. Transfer HVPS PCB unit Electrode head Connector Fig. 3-30 (2) Disconnect the flat cable (CN1) and two connectors (CN5, CN8) from the Registration relay PCB unit. Note: - After disconnecting the flat cable(s), check that each cable is not damaged at its end or short-circuited. - When connecting the flat cable(s), do not insert it at an angle. After insertion, check that the cable is not at an angle. CN8 CN5 CN1 Registration relay PCB ASSY Transfer HVPS PCB unit Fig. 3-31 3-47 Confidential (3) Remove the two cup S M3x6 Taptite screws, and then remove the Transfer HVPS PCB unit. Transfer HVPS PCB unit Taptite, cup S M3x6 Taptite, cup S M3x6 Fig. 3-32 8.11 Registration-mark Sensor PCB ASSY 1, 2/ Density Sensor/ Registration Relay PCB ASSY/ Transfer HVPS PCB ASSY (1) Remove the bind B M3x8 Taptite screw, and then remove the Earth plate 3. Taptite, bind B M3x8 Earth plate 3 Transfer HVPS PCB unit Fig. 3-33 3-48 Confidential (2) Remove the two bind B M3x8 Taptite screws, and then remove the Density shield plate 1. Taptite, bind B M3x8 Density shield plate 1 Transfer HVPS PCB unit Fig. 3-34 (3) Remove the cup S M3x6 Taptite screw, and then remove the Earth plate 2. Taptite, cup S M3x6 Earth plate 2 Transfer HVPS PCB unit Fig. 3-35 3-49 Confidential (4) Disconnect the Connector (CN3) of the Registration-mark sensor PCB ASSY 1. (5) Remove the bind B M3x8 Taptite screw, and then remove the Registration-mark sensor PCB ASSY 1 from the Density sensor holder. Taptite, bind B M3x8 Registration-mark sensor PCB ASSY 1 Connector Density sensor holder CN3 (Blue) Registration relay PCB ASSY Transfer HVPS PCB unit Fig. 3-36 (6) Disconnect the Connector (CN4) of the Registration-mark sensor PCB ASSY 2. (7) Remove the bind B M3x8 Taptite screw, and then remove the Registration-mark sensor PCB ASSY 2. Taptite, bind B M3x8 Registration-mark sensor PCB ASSY 2 Connector CN4 (White) Registration relay PCB ASSY Transfer HVPS PCB unit Fig. 3-37 3-50 Confidential (8) Disconnect the Connector (CN7), and remove the two bind B M3x8 Taptite screws, and then remove the Density sensor. Note: Do not touch the Variable resistor on the back of the Density sensor. Variable resistor Density sensor Taptite, bind B M3x8 Connector CN7 Registration relay PCB ASSY Transfer HVPS PCB unit Fig. 3-38 (9) Disconnect the Flat cable (CN2) and three Connectors (CN6, CN9, CN13) from the Registration relay PCB ASSY. Note: - After disconnecting the flat cable(s), check that each cable is not damaged at its end or short-circuited. - When connecting the flat cable(s), do not insert it at an angle. After insertion, check that the cable is not at an angle. CN9 CN13 CN6 Transfer HVPS PCB unit CN2 Registration relay PCB ASSY Fig. 3-39 3-51 Confidential (10) Turn the Transfer HVPS PCB ASSY upside down. Remove the bind B M3x8 Taptite screw from the Registration relay PCB ASSY. (11) Remove the Registration relay PCB ASSY from the Transfer HVPS PCB unit. Taptite, bind B M3x8 Pin 11b 11a Transfer HVPS PCB unit Registration relay PCB ASSY Fig. 3-40 (12) Remove the three cup B 3x10 Taptite screws and one cup S M3x6 Taptite screw, and then remove the HV TR ground plate and Transfer HVPS PCB ASSY. Taptite, cup S M3x6 HV TR ground plate Taptite, cup B M3x10 Transfer HVPS PCB ASSY Hook Transfer HVPS PCB unit Fig. 3-41 3-52 Confidential Assembling Note: When assembling the Registration relay PCB ASSY, put the section “A” of the Registration relay PCB ASSY into the section “B” of the Transfer HVPS PCB unit. “B” “A” Transfer HVPS PCB unit Registration relay PCB ASSY Fig. 3-42 3-53 Confidential 8.12 Side Cover L ASSY (1) Remove the cup S M3x8 Taptite screw and three cup B M4x12 Taptite screws. (2) Release the three Hooks on the bottom and the two hooks on the back side, and then remove the Side cover L ASSY. Note: When removing the Side cover L ASSY, pay attention to the Wire support rope. Hook Taptite, cup B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Wire support rope Hooks Side cover L ASSY Taptite, cup S M3x8 Hooks *1 Taptite, cup B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Fig. 3-43 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. (3) Remove the Access cover from the Side cover L ASSY. Side cover L ASSY 3a 3b Access cover Fig. 3-44 3-54 Confidential 8.13 Side Plate LB (1) Remove the three cup S M3x6 Taptite screws, cup B M4x12 Taptite screw and cup S M4x8 Taptite screw, and then remove the Side plate LB. Taptite, cup S M4x8 Side plate LB Taptite, cup B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Taptite, cup S M3x6 Fig. 3-45 *1 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. 3-55 Confidential 8.14 Drum Unit Fan (OPC) (1) Disconnect the Connector from the Engine PCB ASSY, and then remove the Drum unit fan (OPC). Drum unit fan (OPC) Label Connector Engine PCB ASSY Fig. 3-46 Assembling Note: When assembling the Drum unit fan (OPC), place it so that the attached Label faces outwards. 3-56 Confidential 8.15 Side Cover R ASSY (1) Remove the two cup B M4x12 Taptite screws and two cup S M4x8 Taptite screws. (2) Release the one Hook on the front side, two Hooks on the bottom and the two Hooks on the back side, and then remove the Side cover R ASSY. Note: When removing the Side cover R ASSY, be careful not to damage section “A”. Taptite, cup S M4x8 Hooks 2a Side cover R ASSY 2b “A” Hook Hooks Taptite, cup S M4x8 Taptite, cup B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Fig. 3-47 *1 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. 3-57 Confidential 8.16 Paper stopper (1) Open the Document scanner unit ASSY. (2) Open the Paper stopper and release the Pins on both sides. Document scanner unit ASSY Paper stopper Pin Pin Joint cover ASSY Paper stopper Fig. 3-48 (3) Turn the Paper stopper in the direction of arrow 3a and remove it from the Joint cover ASSY. Paper stopper 3b 3a 3a Joint cover ASSY Fig. 3-49 3-58 Confidential 8.17 Driver PCB ASSY (1) Disconnect the three Connectors (CN1, CN2, CN4) from the Driver PCB ASSY. (2) Release the Lock and disconnect the Connector (CN3) from the Driver PCB ASSY. Driver PCB ASSY CN4 Document scanner unit ASSY Lock CN3 Main PCB ASSY CN1 CN2 Fig. 3-50 (3) Remove the cup S M3x6 Taptite screw, and then remove the FG harness ADF. (4) Remove the cup S M3x6 Taptite screw, and then remove the FG harness FB. (5) Remove the Driver PCB ASSY and Driver PCB shield. Document scanner unit ASSY Driver PCB shield Driver PCB ASSY FG harness ADF Taptite, cup S M3x6 FG harness FB Taptite, cup S M3x6 Fig. 3-51 3-59 Confidential (6) Remove the two cup S M3x6 Taptite screws, and then remove the Driver PCB ASSY from the Driver PCB shield. Driver PCB shield Groove Groove Driver PCB ASSY Taptite, cup S M3x6 Driver PCB ASSY Fig. 3-52 3-60 Confidential 8.18 Pull arm L, R/ Hinge Protection Cover ASSY (1) Disconnect the three Connectors (CN14, CN16, CN21) from the Main PCB ASSY. (2) Disconnect the Flat cable (CN17) from the Main PCB ASSY, and then pull out the Flat cable from the Core. Note: - After disconnecting the flat cable(s), check that each cable is not damaged at its end or short-circuited. - When connecting the flat cable(s), do not insert it at an angle. After insertion, check that the cable is not at an angle. Document scanner unit ASSY Core Main PCB ASSY Flat cable (CN17) CN16 CN14 CN21 Fig. 3-53 (3) Remove the three cup B M4x12 Taptite screws, and then remove the Hinge protection cover ASSY. Document scanner unit ASSY Hinge protection cover ASSY Taptite, cup B M4x12 Fig. 3-54 3-61 Confidential (4) Open the Document scanner unit ASSY, and then release the Hooks of the Pull arms L and R from the joint of the Document scanner unit ASSY. Document scanner unit ASSY Hook Pull arm R Hook Pull arm L Joint cover ASSY Fig. 3-55 (5) Remove the Left and Right Pull arms and Pull arm springs from the Pull arm guide. Document scanner unit ASSY Pull arm L Pull arm spring R Pull arm spring L Pull arm R Pull arm guide Hook Pull arm guide Hook Fig. 3-56 3-62 Confidential (6) Remove the two bind B M4x12 Taptite screws, and then remove the Document scanner unit ASSY from the Joint cover ASSY by lifting upwards. Document scanner unit ASSY Hinge Taptite, bind B M4X12 Taptite, bind B M4X12 Joint cover ASSY Hinge Fig. 3-57 (7) Remove the two Hinges from the Document scanner unit ASSY. Document scanner unit ASSY Hinge Hinge Fig. 3-58 3-63 Confidential (8) Remove the two bind B M4x12 Taptite screws, and then remove the ADF unit from the Document scanner unit. 8a 8b Document scanner unit ADF unit Taptite, bind B M4x12 Taptite, bind B M4x12 Fig. 3-59 3-64 Confidential 8.19 ADF Unit (1) Turn the ADF unit upside down. (2) Remove the Hinge arm R from the Hinge base R. Hinge arm R 2b 2a ADF unit Hinge base R Fig. 3-60 (3) Remove the three cup B M3x10 Taptite screws, and then remove Hinge base R. Taptite, cup B M3x10 Hinge base R ADF unit Fig. 3-61 3-65 Confidential (4) Remove the three cup B M3x10 Taptite screws, and then remove the Hinge ASSY L. Taptite, cup B M3x10 Hinge ASSY L ADF unit Fig. 3-62 (5) Place the ADF unit the correct way up, and then remove the ADF cover ASSY from the ADF unit. ADF cover ASSY ADF unit Fig. 3-63 3-66 Confidential (6) Remove the cup S M3x8 SR Taptite screw and cup B M3x10 Taptite screw from the ADF front cover 1. (7) Release the Hook from the bottom of the ADF unit and remove the ADF front cover 1 from the ADF unit. Taptite, cup S M3x8 SR ADF front cover 1 Latch Taptite, cup B M3x10 Latch ADF unit Hook Hook Fig. 3-64 (8) Lift up the top end of the Document tray ASSY and release the two Hooks. Then, pull it out of the ADF unit. Document tray ASSY Hook 8b Hook 8a ADF unit Fig. 3-65 3-67 Confidential (9) Remove the cup B M3x10 Taptite screw from the ADF back cover. (10) Release the Hook A and Hook B from the bottom of the ADF unit and remove the ADF back cover. ADF back cover Latch 10b 10a Taptite, cup B M3x10 ADF unit Hook Hook B Latch Hook A Hook A Fig. 3-66 3-68 Confidential (11) Disconnect the seven Connectors (CN1~CN7) from the ADF relay PCB ASSY. (12) Disconnect the Connector of the ADF motor harness from the ADF motor. (13) Remove the cup S M3x8 SR Taptite screw, and then remove the FG harness ADF. Connector ADF motor Taptite, cup S M3x8 SR FG harness ADF ADF relay PCB ASSY * ADF relay PCB ASSY CN4 CN7 CN3 CN6 ADF relay PCB ASSY CN2 CN1 CN5 Fig. 3-67 3-69 Confidential (14) Remove the four cup B M3x10 Taptite screws, and then remove the ADF chute ASSY from the Document cover sub ASSY. Taptite, cup B M3x10 Taptite, cup B M3x10 ADF chute ASSY Taptite, cup B M3x10 Taptite, cup B M3x10 Document cover sub ASSY Fig. 3-68 (15) Remove the two cup S M3x8 SR Taptite screws, and then remove the SB chute ASSY from the ADF chute ASSY. Taptite, cup S M3x8 SR SB chute ASSY Taptite, cup S M3x8 SR ADF chute ASSY Fig. 3-69 3-70 Confidential (16) Turn the ADF chute ASSY upside down. (17) Remove the four cup B M3x10 Taptite screws, and then remove the Exit chute cover ASSY from the ADF chute ASSY. Taptite, cup B M3x10 Taptite, cup B M3x10 Exit chute cover ASSY ADF chute ASSY Fig. 3-70 3-71 Confidential (18) Turn the Exit chute cover ASSY upside down. (19) Remove the Earth spring from the Exit chute cover ASSY. Earth spring Exit chute cover ASSY Antistatic brush Fig. 3-71 Assembling Note: When assembling the Earth spring, ensure that the end of the Earth spring is attached onto the Antistatic brush as shown in the figure below. Antistatic brush Earth spring Hooks Exit chute cover ASSY Earth spring Antistatic brush Rib Hook Fig. 3-72 3-72 Confidential (20) Place the ADF chute ASSY the correct way up. (21) Release the Hooks of the Conductive bush A to remove the Conductive bush A. (22) Remove the Bush from the ADF chute ASSY, and remove the PF roller holder ASSY from the ADF chute ASSY. Bush PF roller holder ASSY 22b 22a Conductive bush A Hooks ADF chute ASSY 21 Fig. 3-73 3-73 Confidential (23) Release the Hooks of the Conductive bush A to remove the Conductive bush A. (24) Remove the Bush from the ADF chute ASSY, and remove the LF roller 1 ASSY from the ADF chute ASSY. Bush LF roller 1 ASSY 24b 24a Conductive bush A ADF chute ASSY Hooks 23 Fig. 3-74 Assembling Note: When assembling the LF roller 1 ASSY, assemble the Bush with aligning the Boss of the Bush with the notch on the ADF chute ASSY. Boss ADF chute ASSY Bush Fig. 3-75 3-74 Confidential (25) Release the Hooks of the Conductive bush A to remove the Conductive bush A. (26) Remove the Bush from the ADF chute ASSY, and remove the SB roller ASSY from the ADF chute ASSY. Bush SB roller ASSY 26b 26a Conductive bush A ADF chute ASSY Hooks 25 Fig. 3-76 Assembling Note: - When assembling the SB roller ASSY, assemble the Bush with aligning the Boss of the Bush with the notch on the ADF chute ASSY. Boss ADF chute ASSY Bush Fig. 3-77 3-75 Confidential Assembling Note: - When assembling each of the SB roller ASSY, LF roller 2/3/4 ASSYs and Exit roller ASSY, make sure to assemble it onto the correct position. Identify each roller by the color or three shades of the rollers. * Gray (Identify the rollers by the shades.) LF roller 3 ASSY LF roller 2 ASSY * The shades of the LF roller 2 ASSY and Exit roller ASSY are the same. Exit roller ASSY LF roller 4 ASSY * Light purple SB roller ASSY Fig. 3-78 * It is recommended to mark each of the roller ASSYs when disassembling them. Failure to assemble each roller ASSY onto the correct position may cause paper jam or stretching image. (27) Remove the two screw pan (S/P washer) M3x6, and then remove the ADF motor. ADF motor Screw pan (S/P washer) M3x6 Motor frame ASSY DX Fig. 3-79 3-76 Confidential (28) Remove the three cup S M3x8 SR Taptite screws, and then remove the Motor frame ASSY DX. Motor frame ASSY DX Taptite, cup S M3x8 SR A view < A view > Screws Screw Fig. 3-80 Assembling Note: When assembling the Motor frame ASSY DX, ensure that the gears (indicated with gray) are placed in the positions as shown in the figure below. Motor frame ASSY DX Fig. 3-81 3-77 Confidential (29) Remove the cup S M3x8 SR Taptite screw, and then remove the S/B solenoid ASSY. 29a Motor frame ASSY DX 29b S/B solenoid ASSY Taptite, cup S M3x8 SR Fig. 3-82 (30) Remove the cup S M3x8 SR Taptite screw, and then Remove the PF solenoid ASSY. Motor frame ASSY DX PF solenoid ASSY Taptite, cup S M3x8 SR Fig. 3-83 3-78 Confidential (31) Remove the cup S M3x8 SR Taptite screw, and then remove the ADF relay PCB ASSY. Taptite, cup S M3x8 SR ADF relay PCB ASSY Motor frame ASSY DX Fig. 3-84 (32) Remove the two cup S M3x8 SR Taptite screws, and then remove the Paper feed plate. Taptite, cup S M3x8 SR Paper feed plate Taptite, cup S M3x8 SR ADF chute ASSY Fig. 3-85 3-79 Confidential (33) Remove the two cup S M3x8 SR Taptite screws, and then remove the Paper feed chute ASSY. Taptite, cup S M3x8 SR Paper feed chute ASSY Taptite, cup S M3x8 SR ADF chute ASSY Fig. 3-86 (34) Turn the Paper feed chute ASSY upside down. (35) Release the Hooks of the Photo interrupter to remove the Photo interrupter from the Paper feed chute ASSY. (36) Disconnect the Connector from the Photo interrupter. Connector Hook Photo interrupter Hook Hook Paper feed chute ASSY Fig. 3-87 3-80 Confidential (37) Push down the Stopper, slide the Actuator front 1 to the stopper side and pull up the Actuator front 1 to remove. Actuator front 1 Paper feed chute ASSY Stopper Fig. 3-88 (38) Release the Hooks of the Photo interrupter to remove the Photo interrupter from the Paper feed chute ASSY. (39) Disconnect the Connector from the Photo interrupter. Connector Hook Hook Paper feed chute ASSY Photo interrupter Fig. 3-89 3-81 Confidential (40) Push down the Stopper, slide the Actuator front 2 to the stopper side and pull up the Actuator front 2 to remove. Paper feed chute ASSY Actuator front 2 Stopper Fig. 3-90 3-82 Confidential (41) Remove the ADF film. (42) Remove the B M3x6 Taptite screw, and then remove the Spring plate ADF front ASSY. (43) Remove the back sheet ADF. (44) Remove the Separation rubber. (45) Release the two Hooks and then remove the Rubber holder. (46) Remove the Separation spring. ADF film Taptite screw B M3x6 Spring plate ADF front ASSY Rubber holder Back sheet ADF Separation rubber Separation spring Paper feed chute ASSY Hooks Rubber holder Spring plate ADF front ASSY Fig. 3-91 3-83 Confidential (47) Push the Hook to the direction of the arrow 47a as shown in the figure below while holding the Presser roller, and remove the Presser roller shaft from the Hook. (48) Pull the Presser roller shaft out of the Presser roller. (49) Remove the two LF springs. Presser roller shaft Presser roller 48 LF spring LF spring Paper feed chute ASSY 47a 47b Hook Fig. 3-92 3-84 Confidential (50) Release the Hooks of the Conductive bush A to remove the Conductive bush A. (51) Remove the Bush from the ADF chute ASSY, and remove the LF roller 2 ASSY from the ADF chute ASSY. Bush LF roller 2 ASSY 51b 51a Hooks 50 ADF chute ASSY Conductive bush A Fig. 3-93 Assembling Note: When assembling the LF roller 2 ASSY, assemble the Bush with aligning the Boss of the Bush with the notch on the ADF chute ASSY. Boss ADF chute ASSY Bush Fig. 3-94 3-85 Confidential (52) Release the Hooks of the Conductive bush A to remove the Conductive bush A. (53) Remove the Bush from the ADF chute ASSY, and remove the Exit roller ASSY from the ADF chute ASSY. Bush Exit roller ASSY 53c 53b 53a Conductive bush A ADF chute ASSY Hooks 52 Fig. 3-95 Assembling Note: When assembling the Exit roller ASSY, assemble the Bush with aligning the Boss of the Bush with the notch on the ADF chute ASSY. Boss ADF chute ASSY Bush Fig. 3-96 3-86 Confidential (54) Turn the ADF chute ASSY upside down. (55) Release the Hooks of the Conductive bush A to remove the Conductive bush A. (56) Remove the Bush from the ADF chute ASSY, and remove the LF roller 3 ASSY from the ADF chute ASSY. Bush LF roller 3 ASSY 56c 56b 56a Conductive bush A ADF chute ASSY Hooks 55 Fig. 3-97 Assembling Note: When assembling the LF roller 3 ASSY, assemble the Bush with aligning the Boss of the Bush with the notch on the ADF chute ASSY. Boss ADF chute ASSY Bush Fig. 3-98 3-87 Confidential (57) Remove the four LF4 films from the ADF chute ASSY. LF4 films LF4 films LF4 films LF4 films ADF chute ASSY Fig. 3-99 Assembling Note: When attaching the LF4 films, make sure the positions referring to the figure below. ADF chute ASSY LF4 films LF4 films * Top view of the bottom of the ADF chute ASSY Fig. 3-100 3-88 Confidential (58) Release the Hooks of the Conductive bush A to remove the Conductive bush A. (59) Remove the Bush from the ADF chute ASSY, and remove the LF roller 4 ASSY from the ADF chute ASSY. Bush LF roller 4 ASSY 59b 59a Conductive bush A ADF chute ASSY Hooks 58 Fig. 3-101 Assembling Note: When assembling the LF roller 4 ASSY, assemble the Bush with aligning the Boss of the Bush with the notch on the ADF chute ASSY. Boss ADF chute ASSY Bush Fig. 3-102 3-89 Confidential (60) Release the Hooks of the Conductive bush A to remove the Conductive bush A. (61) Release the Hooks of the Gear ASSY to remove the Gear ASSY. (62) Remove the Flap A ASSY from the ADF chute ASSY. Flap A ASSY 61 Hook Gear ASSY 62 Hooks 60 ADF chute ASSY Conductive bush A Fig. 3-103 (63) Push the Hooks to the direction of the arrows 63a as shown in the figure below to remove the Document hold. Hook Document hold Hook Hook 63a 63b Hook 63a ADF chute ASSY Hook Fig. 3-104 3-90 Confidential (64) Remove the Document hold spring gently to prevent it from jumping. Document hold spring Hook ADF chute ASSY Hooks Fig. 3-105 Assembling Note: When assembling the Document hold spring, make sure the assembled position referring to the figure below. ADF chute ASSY Document hold spring * Top view of the bottom of the ADF chute ASSY Hooks Fig. 3-106 3-91 Confidential (65) Place the ADF chute ASSY the correct way up. (66) Remove the three cup B M3x10 Taptite screws, and then remove the Drive frame sub ASSY. Drive frame sub ASSY Taptite, cup B M3x10 ADF chute ASSY Fig. 3-107 (67) Remove the three cup B M3x10 Taptite screws, and then remove the Front frame. ADF chute ASSY Front frame Taptite, cup B M3x10 Fig. 3-108 3-92 Confidential (68) Remove the four cup B M3x10 Taptite screws, and then remove the Upper main chute ASSY from the Lower main chute ASSY. Taptite, cup B M3x10 Taptite, cup B M3x10 Upper main chute ASSY Lower main chute ASSY Fig. 3-109 (69) Turn the Actuator R to the direction of the arrow 69a and pull it out to the direction of the arrow 69b. Actuator R Lower main chute ASSY 69a 69b Fig. 3-110 3-93 Confidential (70) Release the Hooks of the Photo interrupter to remove the Photo interrupter from the Lower main chute ASSY. (71) Disconnect the Connector from the Photo interrupter. Connector Hook Hook Photo interrupter Lower main chute ASSY Fig. 3-111 (72) Remove the Flap B from the Lower main chute ASSY. Flap B Lower main chute ASSY Fig. 3-112 3-94 Confidential (73) Push down the Stopper, slide the Actuator SB to the stopper side and pull up the Actuator SB to remove. Actuator SB Lower main chute ASSY Stopper Fig. 3-113 (74) Release the Hooks of the Photo interrupter to remove the Photo interrupter from the Lower main chute ASSY. (75) Disconnect the Connector from the Photo interrupter. Connector Hook Stopper Hook Photo interrupter Lower main chute ASSY Fig. 3-114 3-95 Confidential (76) Remove the ADF document output support flap from the Document cover sub ASSY. ADF document output support flap Document cover sub ASSY Fig. 3-115 (77) Release the four Hooks and two bosses to remove the Dressing cover ADF 1. Hooks Hooks Dressing cover ADF 1 Document cover sub ASSY Boss Boss Fig. 3-116 3-96 Confidential (78) Turn the Document cover sub ASSY upside down. (79) Remove the cup B M3x10 Taptite screw from the Dressing cover ADF 2. (80) Release the three Hooks to remove the Dressing cover ADF 2. Taptite, cup B M3x10 Hooks Hook Dressing cover ADF 2 Document cover sub ASSY Fig. 3-117 (81) Place the Document cover sub ASSY the correct way up. (82) Remove the cup B M3x10 Taptite screw from the ADF front cover 2. (83) Release the Hook to remove the ADF front cover 2. Taptite, cup B M3x10 Hook ADF front cover 2 83b 83a Document cover sub ASSY Fig. 3-118 3-97 Confidential (84) Disconnect the Connector from the Document cover sensor. (85) Pull the Document cover sensor downwards to remove it from the Document cover sub ASSY while pressing the Hooks of the Document cover sensor. Hook Document cover sensor Connector Hook Document cover sub ASSY Boss Document cover sub ASSY Document cover sensor Document cover sensor Fig. 3-119 (86) Turn the Document cover sub ASSY upside down. (87) Remove the two cup B M3x10 Taptite screws, and then remove the Handle cover. Taptite, cup B M3x10 Handle cover Document cover sub ASSY Fig. 3-120 3-98 Confidential 8.20 Panel Unit (1) Release the eight Hooks to remove the Printed panel cover from the Document scanner unit. Hooks Document scanner unit Hooks Printed panel cover Hooks Hooks Fig. 3-121 (2) Remove the Address label from the Printed panel cover. Address label Printed panel cover Fig. 3-122 3-99 Confidential (3) Remove the four cup B M3x10 Taptite screws, and then lift up the Panel unit slightly from the Document scanner unit. Taptite, cup B M3x10 Panel unit Taptite, cup B M3x10 Document scanner unit Fig. 3-123 (4) Gently lift up the Panel unit slightly and disconnect the Connector (CN1) from the Panel unit. Panel unit CN1 Document scanner unit Fig. 3-124 3-100 Confidential (5) Turn the Panel unit upside down, and then disconnect the Connector (CN4) from the Panel PCB ASSY. (6) Release the Lock and disconnect the Flat cable (CN3) from the Panel PCB ASSY. Note: - After disconnecting the flat cable(s), check that each cable is not damaged at its end or short-circuited. - When connecting the flat cable(s), do not insert it at an angle. After insertion, check that the cable is not at an angle. CN4 CN3 (Flat cable) CN3 (Flat cable) Panel PCB ASSY Lock Fig. 3-125 (7) Release the eight Hooks to remove the Panel PCB ASSY from the Panel unit. Panel PCB ASSY Hooks Hooks Hooks Panel unit Hooks Fig. 3-126 3-101 Confidential (8) Remove the Rubber key (R, C, L) from the Panel unit. Rubber key L Rubber key C Hooks Rubber key R Panel unit Hooks Hook Hooks Hooks Hooks Fig. 3-127 (9) Remove the Panel insulation sheets. (10) Release the two Hook A to remove the LCD cover and LCD ASSY from the Panel cover. Note: Be careful not to loose the LED guide. Panel insulation sheets Hook LCD cover Hook LCD ASSY LED guide Panel cover Hook A Fig. 3-128 3-102 Confidential (11) Remove the LCD from the Backlight module. LCD Backlight module Fig. 3-129 3-103 Confidential 8.21 Document Scanner Unit (1) Remove the three cup B M4x12 Taptite screws. (2) Release the three Bosses in the order of 2a to 2b to remove the Dressing cover FB FL from the Document scanner unit. Taptite, cup B M4x12 Document scanner unit Dressing cover FB FL 2a 2b Boss Taptite, cup B M4x12 2b Bosses Fig. 3-130 (3) Remove the three cup B M4x12 Taptite screws. (4) Release the three Bosses in the order of 4a to 4b to remove the Dressing cover FB FR from the Document scanner unit. Document scanner unit Taptite, cup B M4x12 Boss 4a Bosses Dressing cover FB FR 4b 4b Taptite, cup B M4x12 Fig. 3-131 3-104 Confidential (5) Remove the two cup B M4x12 Taptite screws. Taptite, cup B M4x12 Document scanner unit Dressing cover FB top Fig. 3-132 (6) Lift up the sections “A” and “B” of the Dressing cover FB top. (7) Slide the Dressing cover FB top in the direction of the arrow to release the Hook and remove it. “B” Dressing cover FB top Hook “A” 7b 7a Document scanner unit Fig. 3-133 3-105 Confidential Note: Be sure not to open the Scanner top cover ASSY in a dusty place. (8) Remove the six cup B M4x12 Taptite screws, and then remove the Scanner top cover ASSY from the Scanner base ASSY. Taptite, cup B M4x12 Taptite, cup B M4x12 Scanner top cover ASSY Taptite, cup B M4x12 Scanner base ASSY Fig. 3-134 (9) Turn the Scanner top cover ASSY upside down. Remove the two cup B M3x6 Taptite screws, and then remove the Lock lever ASSY. Taptite, B M3x6 Lock lever ASSY Scanner top cover ASSY Fig. 3-135 3-106 Confidential (10) Slightly lift up the CCD unit and Guide shaft and pull the Guide shaft out of the CCD unit. 10b CCD unit Guide shaft 10a Scanner base ASSY Fig. 3-136 Assembling Note: When assembling the CCD unit, ensure to put the front side of the CCD drive belt into the slit “A” of the CCD unit. CCD unit CCD drive belt CCD drive belt “A” Fig. 3-137 3-107 Confidential (11) Remove the double-faced adhesive tape which is attached between the FFC cable ASSY and CCD unit, and disconnect the FFC cable ASSY from the CCD unit. Note: - After disconnecting the flat cable(s), check that each cable is not damaged at its end or short-circuited. - When connecting the flat cable(s), do not insert it at an angle. After insertion, check that the cable is not at an angle. CCD unit Connector FFC cable ASSY Double-faced adhesive tape Fig. 3-138 (12) Push the Pulley ASSY to the direction of the arrow 12a and remove the CCD drive belt. CCD drive belt 12b 12a Pulley ASSY Fig. 3-139 3-108 Confidential (13) Remove the cup B M3x8 Taptite screw. (14) Release the two Hooks from the bottom of the Scanner base ASSY and remove the FFC plate. Taptite, cup B M3x8 FFC plate * Top view of the bottom of the Scanner base ASSY Hooks Hook Scanner base ASSY Hook Scanner base ASSY FFC plate Fig. 3-140 (15) Remove the double-faced adhesive tape and remove the Shield sponge from the Scanner base ASSY. (16) Remove the FFC cable ASSY from the Scanner base ASSY, and then remove the Flat core from the FFC cable ASSY. Shield sponge FFC cable ASSY Flat core Scanner base ASSY Fig. 3-141 3-109 Confidential (17) Remove the cup S M3x6 Taptite screw, and then remove the FG harness FB. (18) Remove the four pan B M3x8 Taptite screws, and then remove the Drive plate ASSY. Taptite, cup S M3x6 Taptite, pan B M3x8 FG harness FB Taptite, pan B M3x8 Drive plate ASSY Scanner base ASSY Fig. 3-142 (19) Remove the two Screws pan (S/P washer) M3x6, and then remove the Scanner motor. Drive plate ASSY Screw pan (S/P washer) M3x6 Scanner motor Fig. 3-143 3-110 Confidential (20) Remove the two B M3x6 Taptite screws, and then remove the Pulley ASSY. (21) Remove the Pulley spring. Taptite, pan B M3x6 Pulley spring Pulley ASSY Fig. 3-144 (22) Release the Hooks to remove the Photo interrupter. (23) Disconnect the Connector from the Photo interrupter. Photo interrupter Hooks Hook Connector Scanner base ASSY Fig. 3-145 3-111 Confidential (24) Remove the cup B M3x8 Taptite screw from the Scanner base ASSY. Scanner base ASSY Taptite, cup B M3x8 Dressing cover FB base L Fig. 3-146 (25) Turn the Scanner base ASSY upside down. (26) Remove the two cup B M4x12 Taptite screws, and then remove the Dressing cover FB base L from the Scanner base ASSY. Taptite, cup B M4x12 Dressing cover FB base L Scanner base ASSY Fig. 3-147 3-112 Confidential (27) Remove the three cup B M4x12 Taptite screws from the Dressing cover FB base R. (28) Remove the Dressing cover FB base R from the Scanner base ASSY. Taptite, cup B M4x12 Dressing cover FB base R Scanner base ASSY Fig. 3-148 3-113 Confidential 8.22 NCU PCB ASSY (MFC-9840CDW only) (1) Disconnect the connector (CN7) from the Main PCB ASSY. (2) Remove the Screw pan (S/P washer) M3.5x6 and then remove the FG harness NCU. Joint cover ASSY Screw pan (S/P washer) M3.5x6 FG harness NCU CN7 Main PCB ASSY Fig. 3-149 (3) Remove the four bind B M4x12 Taptite screws, and then remove the NCU cover from the Joint cover ASSY. Taptite, bind B M4x12 Taptite, bind B M4x12 NCU cover Joint cover ASSY Fig. 3-150 3-114 Confidential (4) Remove the Screw pan (S/P washer) M3.5x6, and then remove the FG harness NCU. (5) Remove the two bind B M4x12 Taptite screws, and then remove the NCU unit from the Joint covers ASSY. Taptite, bind B M4x12 Taptite, bind B M4x12 NCU unit Screw pan (S/P washer) M3.5x6 Joint covers ASSY FG harness NCU Fig. 3-151 (6) Remove the Screw pan (S/P washer) M3.5x6, and then remove the NCU shield plate from the NCU shield cover. Screw pan (S/P washer) M3.5x6 NCU shield plate NCU shield cover Fig. 3-152 3-115 Confidential (7) Remove the two cup S M3x6 Taptite screws, and then remove the NCU PCB ASSY. (8) Disconnect the connector of the NCU harness ASSY. Taptite, cup S M3x6 NCU PCB ASSY NCU harness ASSY NCU shield cover Fig. 3-153 3-116 Confidential 8.23 Battery ASSY (1) Release the Hook to remove the Battery ASSY from the Joint cover ASSY. (2) Disconnect the connector from the Battery ASSY. Caution: - There is danger of explosion if the battery is incorrectly replaced. - Do not disassemble or recharge the battery. - Do not dispose of the battery in fire. - Used batteries should be disposed according to the local regulations. Joint cover ASSY Hook Connector Battery ASSY Fig. 3-154 3-117 Confidential 8.24 Joint Cover ASSY (1) Remove the bind B M4x12 Taptite screw, and then remove the Pull arm guide L from the Joint cover ASSY. (2) Remove the bind B M4x12 Taptite screw, and then remove the Pull arm guide R from the Joint cover ASSY. Taptite, bind B M4X12 Pull arm guide L Joint cover ASSY Fig. 3-155 (3) Disconnect the two Connectors (CN2, CN3) from the Main PCB ASSY. (CN2: MFC9840CDW only) Side frame L CN2 Main PCB ASSY CN3 Fig. 3-156 3-118 Confidential (4) Remove the two cup S M3x8 Taptite screws from the front side of the Joint cover ASSY, and remove two cup S M3x8 Taptite screws from the left side. Joint cover ASSY Taptite, cup S M3x8 Taptite, cup S M3x8 Taptite, cup S M3x8 Fig. 3-157 (5) Remove the one cup S M3x8 Taptite screw and two bind B M4x12 Taptite screws from the back side of the Joint cover ASSY. Joint cover ASSY Taptite, bind B M4x12 Taptite, cup S M3x8 Taptite, bind B M4x12 Fig. 3-158 3-119 Confidential (6) Remove the six cup S M4x8 Taptite screws from the top of the Joint cover ASSY, and then release the four Hooks and one Pin to remove the Joint cover ASSY from the Frame unit. Hook Taptite, cup S M4x8 Taptite, cup S M4x8 Hook Joint cover ASSY Frame unit Pin Hooks Fig. 3-159 (7) Turn the Joint cover ASSY up side down. (8) Remove the two bind B M4x12 Taptite screws, and then remove the Joint cover FR from the Joint cover ASSY. Taptite, bind B M4x12 Joint cover ASSY Hook Joint cover FR Fig. 3-160 3-120 Confidential (9) Remove the two bind B M4x12 Taptite screws. (10) Release the two Hooks and one boss to remove the Joint cover FL from the Joint cover ASSY. Taptite, bind B M4x12 Joint cover ASSY Hook Hook Hook Joint cover FL Boss Fig. 3-161 (11) Remove the three bind B M3x8 Taptite screws, and then remove the Top cover USB front ASSY. Taptite, bind B M3x8 Taptite, bind B M3x8 Joint cover FL Top cover USB front ASSY Fig. 3-162 3-121 Confidential (12) Remove the three bind B M3x8 Taptite screws, and then remove the USB holder and USB host relay PCB ASSY. Taptite, bind B M3x8 Taptite, bind B M3x8 USB holder USB host relay PCB ASSY Joint cover FL Fig. 3-163 (13) Disconnect the Main USB host harness ASSY from the USB host relay PCB ASSY. Main USB host harness ASSY USB host relay PCB ASSY Fig. 3-164 3-122 Confidential (14) Remove the two bind B M4x12 Taptite screws, and then remove the Wireless LAN PCB ASSY from the Joint cover ASSY. (MFC-9840CDW only) (15) Disconnect the connector from the Wireless LAN PCB ASSY. (MFC-9840CDW only) Connector Taptite, bind B M4x12 Wireless LAN PCB ASSY Joint cover ASSY Fig. 3-165 (16) Release the Hook to remove the Wireless LAN PCB ASSY from the Wireless LAN PCB holder. (MFC-9840CDW only) Wireless LAN PCB ASSY Hook Wireless LAN PCB holder Fig. 3-166 3-123 Confidential (17) Release the Hooks to remove the Paper stopper guide from the Paper chute. Hook Paper stopper guide Hook 17a 17b Paper chute Hook Fig. 3-167 8.25 Speaker ASSY (1) Disconnect the connector (CN10) from the Main PCB ASSY. Speaker ASSY CN10 Main PCB ASSY Fig. 3-168 3-124 Confidential (2) Remove the cup S M3x6 Taptite screw, and then remove the Speaker holder. Taptite, cup S M3x6 Speaker holder Bosses Scanner cover Fig. 3-169 (3) Remove the cup S M3x6 Taptite screw, and then remove the Speaker hold spring. (4) Remove the Speaker ASSY from the Speaker holder. Taptite, cup S M3x6 Speaker hold spring Speaker ASSY Speaker holder Fig. 3-170 3-125 Confidential 8.26 Roller Holder ASSY (1) Push the Lift arm to the direction of the arrow 1a and release the boss of the Roller holder ASSY. Then, turn the Roller holder ASSY to the direction of the arrow 1b. Paper feed frame unit Lift arm Roller holder ASSY Boss Paper feed frame unit 1a 1b Fig. 3-171 (2) Slide the Roller holder ASSY to the direction of the arrows 2a, 2b and 2c in this order and remove it. Paper feed frame unit 2b 2a Roller holder ASSY 2c Fig. 3-172 3-126 Confidential 8.27 Paper Feed Frame Unit/ T1 PE/Edge Sensor PCB ASSY (1) Disconnect the three connectors (CN1, CN10, CN11) from Engine PCB ASSY. Engine PCB ASSY CN1 CN10 CN11 Fig. 3-173 (2) Close the Front door unit ASSY. Remove the cup S M3x6 Taptite screw and two bind B M3x10 Taptite screws. (3) Open the Front door unit ASSY. Slide the Paper feed frame unit in the direction of arrows 3a and 3b in this order and remove it. Paper feed frame unit 3b 3a Taptite, cup S M3x6 Taptite, bind B M3X10 Taptite, bind B M3X10 Fig. 3-174 3-127 Confidential (4) Release the two Hooks to remove the PF CR harness holder. Hook Hook PF CR harness holder Fig. 3-175 (5) Remove the Harness from the PF CR harness holder. Harness PF CR harness holder Fig. 3-176 3-128 Confidential (6) Remove the five bind B M3x8 Taptite screws, and then remove the PF plate from the Paper feed frame. Taptite, bind B M3X8 Taptite, bind B M3X8 Taptite, bind B M3X8 PF plate Paper feed frame Fig. 3-177 (7) Release the Hook of the Separation roller bush to remove it. Then, remove the Separation roller drive shaft. Separation roller drive shaft Separation roller bush Hook Paper feed frame Fig. 3-178 3-129 Confidential (8) Remove the Edge actuator and PE actuator, and remove the Edge actuator spring. Edge actuator Edge actuator spring PE actuator Paper feed frame Fig. 3-179 (9) Release the three Hooks to remove the T1 PE/edge sensor PCB ASSY. T1 PE/edge sensor PCB ASSY Hook Hook Hook Fig. 3-180 3-130 Confidential Assembling Note: When assembling the Paper feed frame unit, make sure to follow the procedure described below. (1) Put the belt cleaner release sensor harness and belt cleaner release solenoid harness through the hole on the paper feed frame. (2) Put the two harnesses above and T1 PE/edge sensor harness through the PF CR harness holder and put them out of the hole on the Side frame L. (3) Hold the PU lift up cam with a Screwdriver or similar and push to the back of the machine . The section “B” shown in Fig. 3-183 in the next page can be moved up and down by this operation, which makes it easy to assemble the lift arm. PU lift up cam Side frame L Screwdriver Fig. 3-181 3-131 Confidential (4) Assemble the Lift arm, Feed roller shaft TR and Separation roller drive shaft of the Paper feed frame unit following the procedure described below. Implement the operations below while holding the status described in Step (3). 1) When pushing up the Roller holder ASSY with your hand, the end (section “A”) of the Lift arm goes down. That makes easy to push the end of the Lift arm under the section “B” shown in Fig. 3-182. Lift arm Paper feed frame unit “A” Roller holder ASSY Fig. 3-182 2) Push up the section “B” of the Side frame L with the end (section “A”) of the Lift arm and place the section “A” under the section “B”. Then, make sure to put the section “A” into the space between the Hooks B and C inside the machine, and assemble the Paper feed frame unit into the machine. Paper feed frame unit “B” “A” “B” “A” Hook B Hook C Side frame L Fig. 3-183 3-132 Confidential While moving the Paper feed frame unit to the left hand side, turn the Gear to align the section “C” with the Feed roller shaft TR and put the shaft into the section “C”. Gear Paper feed frame unit Feed roller shaft TR Feed roller shaft TR “C” Fig. 3-184 While moving the Paper feed frame unit to the left hand side, turn the Separation roller of the Roller holder ASSY to align the section “D” of the Separation roller drive shaft with the section “E” of the Side frame L and put the section “E” into the section “D”. Separation roller drive shaft Paper feed frame unit Separation roller Side frame L Roller holder ASSY “E” “D” Fig. 3-185 3-133 Confidential (5) Check the engagement of each roller and move the Paper feed frame unit to the left hand side of the main body until it stops to assemble it. Side frame L Paper feed frame unit Fig. 3-186 (6) Make sure that there is no looseness of the harness. If there is, pull the harness from the outside of the side frame L. (7) Check that the Feed roller TR and Roller holder ASSY are moved smoothly. - Check that the Feed roller TR is turns smoothly. - Check that the Separation roller is turns smoothly. - Check that the Roller holder ASSY can push up smoothly. Note: If they are not moved smoothly, they may not be assembled correctly. Reassemble them from the beginning of the procedure. (8) Secure the screws in the order as shown in the figure below with the front door unit ASSY closed. *1 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. Taptite, bind B M3X10 (Tightening torque: 0.70 ±0.1 N m) *1 Taptite, bind B M3X10 (Tightening torque: 0.70 ±0.1 N m) *1 2 1 3 Taptite, cup S M3x6 Fig. 3-187 3-134 Confidential 8.28 Belt Cleaner Release Sensor PCB ASSY (1) Release the two Hooks to remove the Belt cleaner release ASSY from the Middle plate. Middle plate Hook Hook Belt cleaner release ASSY Fig. 3-188 (2) Turn the Belt cleaner release ASSY upside down. Remove the bind B M3x8 Taptite screw, and then remove the SOL PCB sheet and Belt cleaner release sensor PCB ASSY. Taptite, bind B M3X8 SOL PCB sheet Belt cleaner release sensor PCB ASSY Belt cleaner release case Fig. 3-189 3-135 Confidential (3) Disconnect the Connector from the Belt cleaner release sensor PCB ASSY. Connector Belt cleaner release sensor PCB ASSY Fig. 3-190 8.29 THM/HUM Sensor Holder ASSY (1) Disconnect the Connector (CN35) from the Engine PCB ASSY. Engine PCB ASSY CN35 Fig. 3-191 3-136 Confidential (2) Remove the one cup S M3x6 Taptite screw, and then remove the THM/HUM ground plate. (3) Remove the four cup S M3x6 Taptite screws. (4) Release the two Hooks to remove the THM/HUM sensor holder ASSY. Frame unit Hook THM/HUM sensor holder ASSY Taptite, cup S M3x6 THM/HUM ground plate Taptite, cup S M3x6 Hook Fig. 3-192 3-137 Confidential 8.30 Release Rack (1) Remove the Release rack spring from the Hook. Frame unit Hook Release rack spring Fig. 3-193 (2) Remove the cup B M3x8 Taptite screw, and then remove the Release rack plate from the Release rack. (3) Remove the Release rack spring from the Release rack plate. Release rack spring Taptite, cup B M3x8 Release rack plate Release rack Fig. 3-194 3-138 Confidential 8.31 Front Door Unit ASSY (1) Remove the cup S M3x6 Taptite screw, and then remove the Front door unit earth. Frame unit Taptite, cup S M3x6 Front door unit earth Front door unit ASSY Fig. 3-195 (2) Disconnect the six connectors (CN2, CN3, CN4, CN7, CN8, CN9) from the Engine PCB ASSY. Engine PCB ASSY CN7 CN2 CN3 CN4 CN8 CN9 Fig. 3-196 3-139 Confidential (3) Remove the Shoulder screw fixing the Wire support rope, and then release the Wire support rope from the Shaft. Shaft Wire support rope Shoulder screw Frame unit Front door unit ASSY Fig. 3-197 (4) Remove the Collar 3 from the Hinge shaft L, and then remove the Hinge shaft L from the Hinge plate L. Hinge shaft L Hinge plate L Frame unit Collar 3 Front door unit ASSY Fig. 3-198 3-140 Confidential (5) Remove the Collar 3 from the Hinge shaft R, and then remove the Hinge shaft R from the Hinge plate R. (6) Remove the Front door unit ASSY from Frame unit. Frame unit Front door unit ASSY Collar 3 Hinge plate R Hinge shaft R Fig. 3-199 Assembling Note: - When assembling the Wire rope onto the Shaft on the main body, be careful of the direction of Wire rope referring to the figure below. Wire rope Wire rope Shaft Shaft Shoulder screw Shoulder screw Fig. 3-200 3-141 Confidential Assembling Note: - When assembling the Front door unit ASSY onto the Hinge on the main body, make sure to align the Front door unit ASSY with the Hinge as shown in the figure below. Frame unit Hinge Front door unit ASSY Fig. 3-201 8.32 Harness Cover MP (1) Remove the cup S M3x6 Taptite screw, and then remove the Harness cover MP from the Front door unit ASSY. Taptite, cup S M3x6 Hook Harness cover MP Front door unit ASSY Fig. 3-202 3-142 Confidential 8.33 Front Door Sub (1) Remove the five cup B M4x10 Taptite screws and one cup B M3x8 Taptite screw, and then remove the Front door sub. Taptite, cup B M4x10 Taptite, cup B M4x10 Front door unit ASSY Taptite, cup B M4x10 Taptite, cup B M3x8 Front door sub Fig. 3-203 3-143 Confidential 8.34 EL Electrode Spring L/R (1) Remove the two bind B M3x8 Taptite screws, and then remove the EL electrode spring cover ASSY. EL electrode spring cover ASSY Taptite, bind B M3X8 Front door unit ASSY Fig. 3-204 (2) Remove the two bind B M3x8 Taptite screws, and then remove the EL spring harness ASSY (white, red) and EL electrode spring L/R. EL spring harness ASSY (white) Taptite, bind B M3X8 EL electrode spring R EL spring harness ASSY (red) EL electrode spring L Front door unit ASSY Fig. 3-205 3-144 Confidential 8.35 Hook Cover/ Front Cover Release Button/ Button Spring/ Front Door Main (1) Remove the two cup B M4x10 Taptite screws. Taptite, cup B M4x10 Taptite, cup B M4x10 Front door unit ASSY Front door main Fig. 3-206 (2) Remove the two cup B M4x10 Taptite screws. (3) Release the three Hooks to remove the Hook cover from the Front door unit ASSY. Hooks Taptite, cup B M4x10 Taptite, cup B M4x10 Hook Hook cover Front door unit ASSY Fig. 3-207 3-145 Confidential (4) Remove the Front cover release button and Button spring from the Hook cover. Front cover release button Front cover release button Button spring Button spring Hooked Hooked Hook cover Fig. 3-208 (5) Release the two Hooks to remove the Front door Main from the Front door unit ASSY. Front door unit ASSY Front door main Hooks Fig. 3-209 3-146 Confidential 8.36 Hook Shaft/ Hook/ Hook Spring (1) Remove the Hook shaft. Hook shaft MP unit ASSY Fig. 3-210 (2) Remove the Hook and Hook spring L from the MP unit ASSY. (3) Remove the Hook and Hook spring R from the MP unit ASSY in the same way. Hook Hook spring L MP unit ASSY Fig. 3-211 Assembling Note: When assembling the Hook spring, be sure to assemble each of the Hook springs Left and Right onto the correct sides (Left is longer silver one and Right is shorter black one). 3-147 Confidential 8.37 Engine PCB ASSY (1) Disconnect all the connectors from the Engine PCB ASSY. Note: - After disconnecting the flat cable(s), check that each cable is not damaged at its end or short-circuited. - When connecting the flat cable(s), do not insert it at an angle. After insertion, check that the cable is not at an angle. Engine PCB ASSY CN29 CN30 CN31 CN32 CN34 CN42 CN43 CN40 CN38 CN36 CN7 CN1 CN2 CN3 CN8 CN4 CN27 CN9 CN5 CN26 CN10 CN33 CN37 CN35 CN39 CN41 CN28 CN25 CN21 CN24 CN23 CN22 CN20 CN14 CN18 CN19 CN17 CN16 CN15 CN11 CN13 CN6 CN12 Fig. 3-212 (2) Remove the five cup S M3x6 Taptite screws, and then remove the Engine PCB ASSY from the Frame unit. Frame unit Taptite, cup S M3x6 Engine PCB ASSY Fig. 3-213 3-148 Confidential 8.38 Main PCB ASSY/ Ground Plate/ Ground Spring Plate (1) Remove the cup S M3x6 Taptite screw and bind B M4x12 Taptite screw, and then remove the Ground plate. (2) Remove the two cup S M3x6 Taptite screws, and then remove the Ground spring plate. Ground spring plate Taptite, cup S M3x6 Frame unit Taptite, cup S M3x6 Taptite, bind B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Ground plate Main PCB ASSY *1 Fig. 3-214 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. (3) Disconnect all the connectors from the Main PCB ASSY. Note: - After disconnecting the flat cable(s), check that each cable is not damaged at its end or short-circuited. - When connecting the flat cable(s), do not insert it at an angle. After insertion, check that the cable is not at an angle. CN16 CN14 CN10 CN7 Main PCB ASSY CN17 CN8 CN1 CN19 CN2 CN3 CN4 CN21 CN5 CN15 CN13 CN12 Fig. 3-215 3-149 Confidential (4) Remove the cup S M3x6 Taptite screw, and then remove the Main PCB ASSY as shown by arrows 4a and 4b. Main PCB ASSY Frame unit 4a 4b Taptite, cup S M3x6 Fig. 3-216 3-150 Confidential 8.39 Waste Toner Near/Full Sensor ASSY (1) Move the Positioning pin 1a as shown, and slide the Hooks to the direction of the arrow 1b, and then remove the Waste toner sensor holder from the Middle plate. Waste toner sensor holder Middle plate 1b Positioning pin Hook 1b 1a Hook Hook * Figure of the front view Middle plate Fig. 3-217 (2) Release the Hook to remove the Waste toner sensor cover from the Waste toner sensor holder. Waste toner sensor holder Hook Waste toner sensor cover Fig. 3-218 3-151 Confidential (3) Release the three Hooks of each Waste toner sensor to remove the two Waste toner sensors from the Waste toner sensor holder. Waste toner sensor Hook Waste toner sensor holder Hook “A” Hooks Hook Waste toner sensor Hooks Waste toner sensor Fig. 3-219 (4) Disconnect the Connectors (yellow and blue) from each of the Waste toner sensors. Waste toner sensor Connector (yellow) Waste toner sensor Connector (blue) Fig. 3-220 3-152 Confidential 8.40 Laser Unit/ Hook Slope (1) Remove the four cup S M3x8 Taptite screws, and then remove the two Hook slopes. Hook slope Taptite, cup S M3x8 Hook slope Taptite, cup S M3x8 Frame unit Fig. 3-221 (2) Remove the nine cup S M3x6 Taptite screws (8 pieces from the top and 1 piece from the Front), and then remove the Scanner cover. Scanner cover Taptite, cup S M3x6 Taptite, cup S M3x6 Taptite, cup S M3x6 Taptite, cup S M3x6 Frame unit Fig. 3-222 Assembling Note: When assembling the Scanner cover, secure the screws in the order of the numbers which are indicated on the Scanner cover. 3-153 Confidential (3) Disconnect the two flat cables (CN1, CN4) and connector (CN8) from the Laser unit. Note: - After disconnecting the flat cable(s), check that each cable is not damaged at its end or short-circuited. - When connecting the flat cable(s), do not insert it at an angle. After insertion, check that the cable is not at an angle. Laser unit Fig. 3-223 (4) Remove the seven cup S M3x6 SR Taptite screws, and then remove the four Scanner holders and Laser unit. Taptite, cup S M3x6 SR Taptite, cup S M3x6 SR Taptite, cup S M3x6 SR Scanner holder Laser unit Positioning boss Taptite, cup S M3x6 SR Scanner holder Scanner holder Positioning boss Frame unit Scanner holder Positioning hole Positioning hole Fig. 3-224 Assembling Note: When assembling the Laser unit with the Scanner holders, ensure to put the positioning boss of the Laser unit into the positioning hole referring to the figure above. 3-154 Confidential 8.41 Develop Drive Motor ASSY (1) Remove the Rack gear 27 from the Frame unit. Frame unit Rack gear 27 Fig. 3-225 (2) Remove the Alum sheet frame from the Develop gear plate ASSY. (3) Remove the seven cup S M3x6 Taptite screws, and then remove the Develop gear plate ASSY from the Frame unit. Disconnect the Connector from the Develop drive motor ASSY. Develop drive motor ASSY Connector Alum sheet frame 2 Taptite, cup S M3x6 Frame unit Hook 3 Taptite, cup S M3x6 Develop drive motor ASSY Taptite, cup S M3x6 Develop gear plate ASSY Taptite, cup S M3x6 Hook Fig. 3-226 3-155 Confidential (4) Remove the three cup S M3x6 Taptite screws, and then remove the Develop drive motor ASSY from the Develop gear plate ASSY. Taptite, cup S M3x6 Taptite, cup S M3x6 Develop drive motor ASSY Taptite, cup S M3x6 Develop gear plate ASSY Fig. 3-227 (5) Remove the five cup B M3x10 Taptite screws, and then remove the Gear guide holder from the Develop gear plate ASSY. Note: Since the gears on the Gear guide holder and the Coupling gears 50 on the Develop gear plate ASSY come off easily, be careful not to lose them. Taptite, cup B M3x10 Develop gear plate ASSY Coupling gear 50 Gear guide holder Fig. 3-228 3-156 Confidential (6) Remove the Friction cap from the Develop gear plate ASSY. Friction cap Develop gear plate ASSY Fig. 3-229 Assembling Note: - When assembling the Develop gear plate ASSY onto the Frame unit, secure the screws in the order of the numbers which are indicated on the plate. Develop gear plate ASSY 5 1 2 6 7 3 4 Fig. 3-230 3-157 Confidential Assembling Note: - When assembling the Develop gear plate ASSY, make sure to keep the Harness and Flat cable out of the Frame unit to prevent them from going into the Develop gear plate ASSY. Frame unit Flat cable Harness Develop gear plate ASSY Fig. 3-231 - If the Joint release lever is protruding from the Develop gear plate ASSY, push the Joint release lever back into the inside of the Develop gear plate ASSY. Develop gear plate ASSY Joint release lever Fig. 3-232 3-158 Confidential Assembling Note: - Always make sure to attach the Alum sheet frame after assembling the Develop gear plate ASSY and Flat cable. Attach the Alum sheet frame so that it is aligned with the corner of the square hole as shown in the figure below. Alum sheet frame Alum sheet frame Flat cable Corner of the square hole Develop gear plate ASSY Fig. 3-233 3-159 Confidential 8.42 Drum Drive ASSY/ Drum Phase Sensor PCB ASSY 1, 2 (1) Remove the Engine insulation sheet from the Harness shield plate, which is fixed with a two-sided adhesive tape. Harness shield plate Engine insulation sheet Fig. 3-234 (2) Remove the three cup S M3x6 Taptite screws, and then remove the Harness shield plate from the Frame unit. Frame unit Taptite, cup S M3x6 Harness shield plate Taptite, cup S M3x6 Taptite, cup S M3x6 Fig. 3-235 3-160 Confidential (3) Remove the four cup S M3x6 Taptite screws, and then remove the Engine PCB plate. Frame unit Engine PCB plate Taptite, cup S M3x6 Taptite, cup S M3x6 Fig. 3-236 Assembling Note: When assembling the Engine PCB plate, make sure that the section “A” is caught on the Hook of the Drive frame unit ASSY. Engine PCB plate Hook Drive frame unit ASSY “A” Fig. 3-237 3-161 Confidential (4) Remove the two cup S M3x6 Taptite screws, and then remove the Drum drive motor 1. (5) Remove the two cup S M3x6 Taptite screws, and then remove the Drum drive motor 2. Frame unit Drum drive motor 2 Taptite, cup S M3x6 Drum drive motor 1 Taptite, cup S M3x6 Fig. 3-238 Assembling Note: The two Gears 39/121 which are engaged with the same motor are phased with each other when assembling the Drum drive ASSY. If removing the motor to replace it, the gears may be out of phase. When replacing the motor, therefore, be sure to phase the Gears 39/121, and then assemble the motor. For the method how to phase the gears, refer to the figure below (Fig. 3-239). Gears 39/121 Align the mark on the Gear with the line on the Drum drive plate. Drum drive ASSY Gears 39/121 Align the mark on the Gear with the space between the two lines on the Drum drive plate. Fig. 3-239 3-162 Confidential (6) Remove the six bind B M4x12 Taptite screws, and then remove the Drum drive ASSY from the Frame unit. Note: Since the four Gears 39/121 of the Drum drive ASSY are assembled together, which makes one set, DO NOT replace only one gear. If their replacement is required, replace the complete Drum drive ASSY. Frame unit Gears 39/121 Taptite, bind B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Drum drive ASSY Taptite, bind B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Gears 39/121 *1 Fig. 3-240 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. (7) Remove the bind S M3x6 Taptite screw, and then remove the Drum phase sensor PCB ASSY 2 (whose harness is longer) from the Drum drive ASSY. (8) Remove the Drum phase sensor PCB 1 (whose harness is shorter) in the same way. Taptite, bind S M3x6 Taptite, bind S M3x6 Drum phase sensor PCB ASSY 2 (whose harness is longer) Drum phase sensor PCB ASSY 1 (whose harness is shorter) Positioning pin Drum drive ASSY Fig. 3-241 3-163 Confidential 8.43 Drive Frame Unit ASSY (1) Remove the three bind B M4x12 Taptite screws, and then remove the Drive frame unit ASSY from the Frame unit. (2) Disconnect the Connector from the Drive frame unit ASSY. Frame unit Drive frame unit ASSY Connector Taptite, bind B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Drive frame unit ASSY Taptite, bind B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Fig. 3-242 *1 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. 3-164 Confidential 8.44 Paper Feed/Belt Cleaner Motor ASSY (1) Remove the four cup S M3x6 Taptite screws (2 pieces provided on each of the front and back), and then remove the Paper feed/belt cleaner motor ASSY from the Drive frame unit ASSY. Taptite, cup S M3x6 Paper feed/belt cleaner motor ASSY Drive frame unit ASSY Taptite, cup S M3x6 Fig. 3-243 Assembling Note: Be sure to hook the harness of the Paper feed/belt cleaner motor ASSY onto the Rib of the Side frame L as shown in the figure below. Side frame L Rib Drive frame unit ASSY Paper feed/belt cleaner motor ASSY Fig. 3-244 3-165 Confidential 8.45 Develop Release Sensor PCB ASSY (1) Remove the cup B M3x8 Taptite screw. (2) Remove the Develop release sensor PCB ASSY from the Frame unit. Disconnect the Connector from the Develop release sensor PCB ASSY. Frame unit Hook Connector Taptite, cup B M3x8 (Tightening torque: 0.60 ±0.1 N m) *1 Develop release sensor PCB ASSY *1 8.46 Fig. 3-245 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. Develop Press Drive L ASSY (1) Remove the Pull up lever spring (for L) from the Hook of Develop press drive L ASSY. Frame unit Develop press drive L ASSY Hook Pull up lever spring (for L) Pull up lever L Fig. 3-246 3-166 Confidential (2) Remove the three bind B M3x12 Taptite screws and cup B M3x12 Taptite screw, and then remove the Develop press drive L ASSY. Frame unit Taptite, bind B M3X12 (Tightening torque: 0.80 ±0.1 N m) *1 Develop press drive L ASSY Taptite, bind B M3X12 (Tightening torque: 0.80 ±0.1 N m) *1 Taptite, bind B M3X12 (Tightening torque: 0.80 ±0.1 N m) *1 Taptite, cup B M3x12 (Tightening torque: 0.80 ±0.1 N m) *1 Fig. 3-247 *1 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. (3) Remove the bind S M3x6 Taptite screw, and then remove the Develop release motor ASSY from the Develop press drive L ASSY. Develop press drive L ASSY Develop release motor ASSY Taptite, bind S M3x6 Fig. 3-248 3-167 Confidential Assembling Note: - Assemble the Develop press drive L ASSY so that the section of the Pull up lever L, where the spring is hooked is placed as shown in the figure below. Develop press drive L ASSY Pull up lever spring (for L) Pull up lever L Section where the spring is hooked Fig. 3-249 - Catch the harness from the Laser unit onto the Hook as shown in the figure below, and then assemble the Develop press drive L ASSY. Hook Harness from Laser unit Fig. 3-250 3-168 Confidential 8.47 Front Cover Interlock Switch ASSY (1) Remove the Interlock switch holder spring and Interlock harness guide from the Develop press drive L ASSY. Interlock switch holder spring Hook B Hook D Hook B Interlock harness guide Hook C Develop press drive L ASSY Hook A Hook A Hook D Hook C Interlock switch holder spring Interlock harness guide Fig. 3-251 (2) Remove the Front cover interlock switch ASSY from the Develop press drive L ASSY. Develop press drive L ASSY Front cover interlock switch ASSY Fig. 3-252 3-169 Confidential 8.48 Toner Sensor PCB ASSY K, Y, M, C (TE/NEW) (1) Remove the three cup B M3x10 Taptite screws, and then remove the Release drive holder from the Frame unit. Release drive holder Frame unit Taptite, cup B M3x10 (Tightening torque: 0.70 ±0.1 N m) *1 Taptite, cup B M3x10 (Tightening torque: 0.70 ±0.1 N m) *1 Fig. 3-253 *1 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. 3-170 Confidential (2) Remove the bind B M3x8 Taptite screw, and then remove the Toner sensor PCB ASSY K (TE/NEW) from the Frame unit. (3) Remove the cup B M3x8 Taptite screw, and then remove the TE protect film 2 and Toner sensor PCB ASSY Y (TE/NEW) from the Frame unit. (4) Remove the bind B M3x8 Taptite screw, and then remove the Toner sensor PCB ASSY M (TE/NEW) from the Frame unit. (5) Remove the bind B M3x8 Taptite screw, and then remove the Toner sensor PCB ASSY C (TE/NEW) from the Frame unit. Frame unit Toner sensor PCB ASSY C (TE/NEW) Taptite, bind B M3X8 (Tightening torque: 0.55 ±0.05 N m) *1 Taptite, bind B M3X8 (Tightening torque: 0.55 ±0.05 N m) *1 Toner sensor PCB ASSY M (TE/NEW) Taptite, cup B M3X8 (Tightening torque: 0.55 ±0.05 N m) *1 TE protect film 2 Toner sensor PCB ASSY K (TE/NEW) Toner sensor PCB ASSY Y (TE/NEW) *1 Taptite, bind B M3X8 (Tightening torque: 0.55 ±0.05 N m) *1 Fig. 3-254 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. 3-171 Confidential Assembling Note: Assemble the Toner sensor PCB ASSY K, Y, M, C (TE/NEW) as shown in the figure below. For the method to arrange the harnesses, refer to “5. Toner sensor PCB ASSY K, Y, M, C (TE/NEW)”. Toner sensor PCB ASSY Y (TE/NEW) Toner sensor PCB ASSY M (TE/NEW) Toner sensor PCB ASSY C (TE/NEW) Mark Toner sensor PCB ASSY K (TE/NEW) Mark Mark Mark C M Y K CN41 (black) CN38 (cyan) Engine PCB ASSY CN39 (magenta) CN40 (yellow) Fig. 3-255 3-172 Confidential (6) Release the two Hooks of the LED holder to remove it from each of the four Toner sensor PCB ASSYs (TE/NEW). Hook Toner sensor PCB ASSY (TE/NEW) Hook LED holder Fig. 3-256 Assembling Note: Assemble the Toner sensor PCB ASSY (TE/NEW) so that the Shutter of the New toner actuator is put into the sensor section of the Toner sensor PCB ASSY (TE/NEW). Shutter New toner actuator Toner sensor PCB ASSY (TE/ NEW) Sensor section Fig. 3-257 3-173 Confidential 8.49 New Toner Actuator/ New Toner Actuator Spring (1) Release the section “A” of the New toner actuator spring from the Hook of the Frame unit, and then remove the New toner actuator from the Fame unit. “A” Frame unit 1a New toner actuator spring Hook 1b New toner actuator Fig. 3-258 (2) Remove the New toner actuator spring from the New toner actuator. New toner actuator spring Hooked Hooked Hook Hook New toner actuator New toner actuator spring Hook Hooked Fig. 3-259 3-174 Confidential 8.50 Side Plate R ASSY (1) Remove the four cup S M3x6 Taptite screws, four cup B M4x12 Taptite screws and screw pan (S/P washer) M4x8. (2) Remove the cup S M4x8 Taptite screw and screw pan (S/P washer) M4x8, and then remove the Side plate R ASSY from the Frame unit. Frame unit Screw pan (S/P washer) M4x8 DB Taptite, cup S M3x6 “A” Taptite, cup S M4x8 Taptite, cup S M3x6 Screw pan (S/P washer) M4x8 DB Taptite, cup B M4x12 (Tightening torque: 0.90 ±0.1 N m) *1 Taptite, cup S M3x6 Taptite, cup B M4x12 (Tightening torque: 0.90 ±0.1 N m) *1 Side plate R ASSY Taptite, cup S M3x6 Taptite, cup B M4x12 (Tightening torque: 0.90 ±0.1 N m) *1 Fig. 3-260 *1 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. 3-175 Confidential 8.51 Drum Lock Lever L (1) Remove the Screw, bind M3x8, and remove the Drum lock lever plate L ASSY and then remove the Drum lock spring and Drum lock lever L from the Frame unit. Drum lock lever plate L ASSY Frame unit Drum lock spring Drum lock lever L Screw, bind M3x8 Fig. 3-261 Assembling Note: Assemble the Drum lock lever so that both Drum lock lever R and L are in the same direction. Drum lock lever R Assemble so that they are in the same direction. Drum lock lever L Fig. 3-262 3-176 Confidential 8.52 Drum Lock Lever R (1) Remove the Screw, bind M3x8, and remove the Drum lock lever plate R ASSY and then remove the Drum lock lever R from the Frame unit. Frame unit Screw, bind M3x8 Drum lock lever R Drum lock lever plate R ASSY Fig. 3-263 Assembling Note: Assemble the Drum lock lever so that both Drum lock lever R and L are in the same direction. Drum lock lever R Assemble so that they are in the same direction. Drum lock lever L Fig. 3-264 3-177 Confidential 8.53 Charge HVPS PCB ASSY (1) Remove the cup S M3x6 Taptite screw and two bind B M4x12 Taptite screws, and then release the four Hooks to remove the Charge HVPS PCB ASSY from the Frame unit. Hooks Frame unit Hook Taptite, bind B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Positioning pin Taptite, cup S M3x6 Charge HVPS PCB ASSY Taptite, bind B M4x12 (Tightening torque: 1.20 ±0.1 N m) *1 Fig. 3-265 *1 Tightening Note: When tightening the screw, slowly turn it counterclockwise (in the direction to loosen the screw) with your hand until you feel that the screw is a little dropped in the hole. Then, slightly turn it clockwise (in the direction to tighten the screw) with your hand and tighten it according to the specified torque with a screwdriver. (2) Disconnect the eight connectors and flat cable from the Charge HVPS PCB ASSY. Note: - When disconnecting the connectors, they may be damaged if pulling the Charge HVPS PCB ASSY by force. - After disconnecting the flat cable(s), check that each cable is not damaged at its end or short-circuited. - When connecting the flat cable(s), do not insert it at an angle. After insertion, check that the cable is not at an angle. Charge HVPS PCB ASSY CN5 CN6 CN7 CN8 CN4 CN9 CN3 CN1 CN2 Fig. 3-266 3-178 Confidential Assembling Note: - Be careful not to loose the HVPS charge head, HVPS charge head spring, HVPS DEV head and HVPS DEV head spring. Before assembling the Charge HVPS PCB ASSY, check that these four parts are complete, and that they move smoothly. HVPS DEV head HVPS charge head HVPS DEV head spring HVPS charge head spring Frame R Fig. 3-267 - When assembling the Charge HVPS PCB ASSY, be careful not to catch the harness of the Air intake fan (AIR) in the Charge HVPS PCB ASSY. Air intake fan (AIR) Charge HVPS PCB ASSY Caution Fig. 3-268 3-179 Confidential 8.54 Toner LED PCB ASSY (1) Remove the Screw pan (S/P washer) M3x16, and then remove the Toner LED PCB from the Frame unit. Toner LED PCB Frame unit Screw pan (S/P washer) M3x16 Fig. 3-269 (2) Release the two Hooks to remove the LED holder from the Toner LED PCB. (3) Remove the other three Toner LED PCBs in the same way. Hook LED holder Toner LED PCB Hook Fig. 3-270 3-180 Confidential 8.55 Fuser Unit Fan (FU) (1) Remove the Fuser unit fan (FU) from the Frame unit. Frame unit Fuser unit fan (FU) Label Fig. 3-271 Assembling Note: When assembling the Fuser unit fan (FU), place it so that the attached Label faces outwards. 8.56 LVPS Fan (PS) (1) Remove the LVPS fan (PS) from the Frame unit. Frame unit LVPS fan (PS) Label Fig. 3-272 Assembling Note: When assembling the LVPS fan (PS), place it so that the attached Label faces outwards. 3-181 Confidential 8.57 Air Intake Fan (AIR) (1) Remove the Air intake fan (AIR) from the Frame unit. Frame unit Air intake fan (AIR) Label Fig. 3-273 Assembling Note: When assembling the Air intake fan (AIR), place it so that the attached Label faces outwards. 3-182 Confidential 8.58 PS PCB Unit (1) Remove the LVPS insulation sheet and LVPS V0 insulation sheet from the PS PCB unit. LVPS insulation sheet PS PCB unit LVPS V0 insulation sheet Fig. 3-274 (2) Remove the Power supply switch from the Belt gear plate ASSY by pushing the Hooks inwards. Belt gear plate ASSY Hook Power supply switch Hook Fig. 3-275 3-183 Confidential (3) Remove the Screw pan (S/P washer) M4x8, and then remove the Ground terminal. (4) Remove the two Taptite, flat B M3x10, and then remove the Power inlet socket from the Frame unit. Frame unit Taptite, flat B M3x10 (Tightening torque: 0.60 ±0.1 N m) *1 Power inlet socket Screw pan Ground terminal (S/P washer) M4x8 Fig. 3-276 (5) Remove the three bind B M4x12 Taptite screws, and then release the Hook to remove the PS PCB unit from the Frame unit. Frame unit Hook PS PCB unit