Brother mfc-5890cn, mfc-5895cw Service Manual

Inkjet MFC

SERVICE MANUAL

MODEL: MFC5890CN

MFC5895CW

August 2010 SM-FAX097 8CAH17(4)

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

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No part of this publication may be reproduced in any form or by any means without permission in writing from the publisher.

Specifications are subject to change without notice.

Trademarks The Brother logo is a registered trademark of Brother Industries, Ltd.

Brother is a registered trademark of Brother Industries, Ltd. Multi-Function Link is a registered trademark of Brother International Corporation. Windows Vista is ei ther a re gistered trademark or a trade mar k of M ic ros oft Co rp orati on i n t he Un ite d

States and other countries. Microso ft, Windows and Windows Server are reg istered trademarks of Microsoft Corporation in the United States and/or other countries.

Macintosh and TrueType are registered trademarks of Apple Inc. Nuance, the Nuance logo, PaperPort and ScanSoft are trademarks or registered trademarks of

Nuance Communications, Inc. or its affiliates in the United States and/or other countries. Presto! PageManager is a registered trademark of NewSoft Technology Corporation. Microdrive is a trademark of International Business Machines Corporation. CompactFlash is a registered trademark of SanDisk Corporation. Memory Stick is a registered trademark of Sony Corporation. SanDisk is a licensee of the SD and miniSD trademarks. xD-Picture Card is a trademark of Fujifilm Co. Ltd., Toshiba Corporation and Olympus Optical Co. Ltd. PictBridge is a trademark. Memory Stick Pro, Memory Stick Pro Duo, Memory Stick Duo and MagicGate are trademarks of Sony

Corporation. BROADCOM, SecureEasySetup and the SecureEasySetup logo are trademarks or registered

trademarks of Broadcom Corporation in the United States and/or other countries. AOSS is a trademark of Buffalo Inc. Wi-Fi, WPA and WP A 2 are r e gis ter ed trade mar k s and Wi -Fi P ro tec ted Se tup i s a tr ad ema rk of Wi-Fi

Alliance. FaceFilter Studio is a trademark of Reallusion, Inc. Each company who se softw are title is mentione d in thi s manual has a S oftware Lic ense Agreeme nt

specific to its proprietary programs.

All other brand and product names mentioned in this manual are trademarks or registered trademarks of their respective companies.

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Preface

This Service Manual is intended for use by service personnel and details the specifications, construction, theory of operation, and maintenance for the Brother machines noted on the front cover. It includes information required for troubleshooting and service--disassembly, reassembly, and lubrication--so that service personnel will be able to understand equipment function, repair the equipment in a timely manner and order spare parts as necessary.

To perform appropriate maintenance so that the machine is always in the best possible condition for the customer, service personnel must adequately understand and apply this manual.

The table below shows the functional comparison between the models covered by this manual.

Model MFC5890CN MFC5895CW RAM 64 MB 64 MB LCD (with backlight) 3.3-inch wide color 3.3-inch wide c olor T o uc h pa nel --- --Wired LAN √√ Wireless LAN (WLAN PCB) --- √ PhotoCapture Center √√ PictBridge/USB flash memory drive √√ Movable platen --- --Slide tray --- --ADF √√ High-yield ink car tr i dg e sensor --- --Ink cartridge detection sensors √√ Ink empty sensors √√ Handset (Hook switch PCB) --- --Duplex printing --- --Backup battery √√

This manual describes the models and their versions destined for major countries. The specifications and functions are subject to change depending upon each dest ination.

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How this manual is organized

This manual is made up of nine chapters and appendices.

CHAPTER 1 PARTS NAMES AND FUNCTIONS

Contains external views and names of components and describes their functions. Information about the keys on the control panel is included to help you check operation or make adjustments.

CHAPTER 2 SPECIFICATIONS

Lists the specifications of each model, which enables you to make a comparison of different models.

CHAPTER 3 THEORY OF OPERATION

Gives an overview of the scanning and printing mechanisms as well as the sensors, actuators, and control electronics. It aids in understanding the basic principles of operation as well as locating defects for troubleshooting.

CHAPTER 4 ERROR INDICATION AND TROUBLESHOOTING

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

The latter half of this chapter provides sample prob lems that could occ ur in the main sections of the machine and related troubleshooting procedures. This will help service personnel pinpoint and repair defective components.

CHAPTER 5 HANDLING DATA HELD IN THE MACHINE PRIOR TO

REPAIR

Describes how to handle data held in the machine to be repaired. At the user s ite, if the m achine ca nnot print FAX data receiv ed and left in the mach ine due to

the printing mechanism defective, the service personnel should instruct the end user to follow the transfer procedure given in this chapter to transfer the FAX data to another machine before sending the machine for repair.

At the service site, the service personnel should back up the machine information and user setting infor mation held in the machin e into an external memor y for restoration after r epair, using the backup procedure given in this chapter.

CHAPTER 6 DISASSEMBLY/REASSEMBLY AND LUBRICATION

Details procedures for disassembling and rea sse mbli ng t he mac h ine tog et her with related notes. The disassembly order flow provided enables you to see at a glance the quickest way to get to component(s) involved.

At the start of a disassembly job, you check th e dis assembly order flow that guides you throu gh a shortcut to the target components.

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

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CHAPTER 7 ADJUSTMENTS AND UPDATING OF SETTINGS,

REQUIRED AFTER PARTS REPLACEMENT

Details adjustments and updating of settings, which are required if the head/carriage unit, main PCB and some other parts have been replaced.

CHAPTER 8 CLEANING

Provides cleaning procedures not covered by the User's Guide. Before starting any repair work, clean the machine as it may solve the problem concerned.

CHAPTER 9 MAINTENANCE MODE

Describes the maintenance mode which is exclusively designed for the purpose of checks, settings and adjustments of the machine using the keys on the control panel.

In the maintenance mode, you can update memory (EEPROM: electrically erasable programmable read-only memory) contents for optimizing the drive conditions of the head/ carriage unit or the paper feed roller and paper ejection roller in the engine unit, if those units have been replaced, or for setting the CIS scanner area, for example. You can also customize the EEPROM according to the shipment destination of the machine concerned. In addition, you can perform operational checks of the LCD, control panel PCB or sensors, perform a print test, display the log information or error codes, and modify firmware switches (WSW).

Appendix 1 Reading Labels

Shows the location of labels put on some parts and describes the coding information for serial number and head property data.

Appendix 2 Firmware Installation

Provides instructions on how to change firmware stored in the flash ROM on the main PCB or load firmware to a new main PCB from the host PC.

Appendix 3 EEPROM Customizing Codes

Provides instructions on how to set up the EEPROM customizing codes for the various preferences exclusively designed for each destination. The specified customizing code is stored in the EEPROM mounted on the main PCB. If the main PCB is replaced, t her efore, you need to set up the proper customizing code with the machine in the maintenance mode.

Customizing codes customize firmware for individual models, enabling the common firmware to be used for various models. A list of EEPROM customizing codes comes with the firmware data provided by Brother Industries.

Appendix 4 Firmware Switches (WSW)

Describes the functions of the firmware switches, which can be divided into two groups: one is for customizing preferences designed for the shipping destination (as described in Appendix 3) 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 5 Wiring Diagrams

Provides the wiring diagrams that help you understand the connections between PCBs.

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Appendix 6 Circuit Diagrams

Provides the circuit diagrams of the MJ PCB and power supply PCB.

Appendix 7 Deletion of User Setting Information

Provides instructions on how to delete user setting information recorded in the machine.

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SAFETY INFORMATION

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injuries.

CAUTION

CAUTION or moderate injuries.

indicates a potentially hazardous situation which, if not avoided, may result in minor

IMPORTANT

IMPORTANT damage to property or loss of product functionality.

Follow all warnings and instructions marked on the machine.

indicate a potentially hazardous situation which, if not avoided, may result in

Notes tell you how you should respond to a situation that may arise or give tips about how the operation works with other features.

Electrical Hazard icons alert you to possible electrical shock.

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CHAPTER 1

PARTS NAMES AND FUNCTIONS

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CHAPTER 1 PARTS NAMES AND FUNCTIONS

This chapter contains external views and names of components and describes their functions. Information about the keys on the control panel is included to help you check operation or make adjustments.

CONTENTS

1.1 OUTLINE................................................................................................................1-1

1.2 CONTROL PANEL ....... ...... ....... ...... ....... ...... ....... ...... ...... ....... ...... ....... ...................1-3

1.3 COMPONENTS......................................................................................................1-6

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1.1 OUTLINE

Front view

(1) ADF & document cover ASSY

(9) Scanner cover

(Scanner unit)

(8) External telephone

line jack

(2) Control panel

(3) Ink cartridge cover

(4) Media slots for

PhotoCapture Center

(5) Paper tray

(6) Port for PictBridge /

USB flash memory drive

1-1

(7) Telephone line jack

(frontview)

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Back view

(12) LAN cable connector

LAN USB

(11) USB interface connector

(10) Jam clear cover

(backview)

No. Name Description

ADF: Load documents (originals) here. Documents

(1) ADF & document cover ASSY

will be fed into the machine, page by page. Document cover: Open to place the document (original) on the scanner glass.

(2) Control panel

Use the keys to operate the machine. The liquid crystal

display (LCD) shows the machine operation status. (3) Ink cartridge cover Open to replace ink cartridges. (4) Media slots for PhotoCapture Center Insert a memory card here.

(5) Paper tray

Port for PictBridge / USB flash

(6)

memory drive

Telephone line jack

(7)

External telephone line jack

(8)

Load paper here. Paper will be fed into the machine,

sheet by sheet.

Connect a digital camera (with PictBridge) to this

connector using the USB cable.

Insert a USB flash memory drive her e.

Plug in the modular plug on the telephone line here.

Plug in the modular plug o n the external tel ephone line

here. (9) Scanner cover (Scanner unit) Open to remove jammed paper.

(10) Jam clear cover Open to remove paper jammed inside the machine. (11) USB interface connector Connect the USB cable here. (12) LAN cable connector Connect the LAN cable here.

1-2

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1.2 CONTROL PANEL

786

1-3

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1-4

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1-5

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1.3 COMPONENTS

The machine consists of the following major components:

ADF & document cover ASSY

Scanner cover (Scanner unit)

Control panel ASSY

Wire spring

Speaker

Scanner cover damper Scanner cover

support

MJ side cover

Registration sensor PCB

PF encoder PCB Flushing box

MJ PCB

MJ/PS shield unit

Upper cover

Side cover R

Head/carriage unit

Maintenance unit

Ink refill ASSY

Side cover L

Engine unit

Main PCB ASSY

Ink absorber box

Lower cover

Ink cartridge cover

Power supply PCB

Jam clear cover

Inner back cover

WLAN PCB*

1-6

Media module cover

Front cover

Paper tray ASSY

(COMPONENTS_BHL9_MFC5890CN)

* For wireless LAN-enabled model.

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CHAPTER 2

SPECIFICATIONS

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CHAPTER 2 SPECIFICATIONS

This chapter lists the specifications of each model, which enables you to make a comparison of different models.

CONTENTS

2.1 GENERAL ..............................................................................................................2-1

2.1.1 Media Specifications..................................................................................2-2

2.1.2 Paper Handling...... ....... ...... ....... ...... ....... ...... ...... ....... ...... ....... ...................2-2

2.1.3 LCD/LED/Panel.........................................................................................2-3

2.1.4 Memory .....................................................................................................2-3

2.1.5 Security .....................................................................................................2-3

2.1.6 Interface ....................................................................................................2-4

2.1.7 Others........................................................................................................2-4

2.2 TELEPHONE..........................................................................................................2-5

2.2.1 Volume ......................................................................................................2-5

2.2.2 Quick/Auto Dials........................................................................................2-5

2.2.3 Tel Service.................................................................................................2-6

2.2.4 Message Center........................................................................................2-6

2.2.5 List/Report.................................................................................................2-6

2.3 FAX.........................................................................................................................2-7

2.3.1 Sending .....................................................................................................2-8

2.3.2 Receiving...................................................................................................2-8

2.3.3 PC FAX......................................................................................................2-9

2.4 PRINTER................................................................................................................2-9

2.5 COPY .....................................................................................................................2-10

2.6 SCANNER..............................................................................................................2-11

2.7 PHOTO CAPTURE.................................................................................................2-12

2.7.1 PictBridge..................................................................................................2-13

2.8 SOFTWARE ...........................................................................................................2-13

2.9 NETWORK .............................................................................................................2-14

2.9.1 Wired.........................................................................................................2-14

2.9.2 Wireless.....................................................................................................2-15

2.10 SUPPLIES/OPTIONS.............................................................................................2-16

2.11 SERVICE INFORMATION......................................................................................2-16

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2.12 PAPER....................................................................................................................2-17

2.12.1 Paper Specifications ..... ...... ....... ...... ....... ...... ...... ....... ...... ....... ...... ....... ......2-17

2.12.2 Printable Area............................................................................................2-20

Language List ..................................................................................................................2-21

ITU-T Test Chart #1.........................................................................................................2-22

Brother Chart ...................................................................................................................2-23

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2.1 GENERAL

Model MFC5890CN MFC5895CW Technology Inkjet Print Head 94 nozzles/line, 5 lines Variable Dot Print Yes (3 sizes)

Minimum Droplet Size

Scanning Method CIS CPU Speed RISC 192 MHz Backup Clock Yes Simultaneous Operation Yes

U.S.A. Yes (Letter size)

Demo Sheet

Panel Key

Demo

for Demo

LCD Demo

Tes t Print Print Quality & Alignment Check Sheet (by pressing the Ink key . )

Europe Asia/

Oceania U.S.A. Europe Asia/

Oceania U.S.A. Yes Europe Asia/

Oceania

FAX + COPY (Print + LCD demo)

BK: 4 pl

CMY: 1.5 pl

N/A

2-1

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2.1.1 Media Specifications

Model MFC5890CN MFC5895CW

A3, A4, LGR, LTR, LGL, EXE, B4 (JIS), B5 (JIS), A5, A6, Photo (102 x 152 mm/4 x 6 inches),

Indexcard (127 x 203 mm/5 x 8 inches), Photo-L (89 x 127 mm/3.5 x 5 inches),

Photo-2L (127 x 178 mm/5 x 7 inches), Post Card 1 (100 x 148 mm/3.9 x 5.8 inches),

Media Sizes

Media Weights

Media Types

Standard Tray

Photo Tray Lower Tray Duplex Print ADF

(width/length) Scanner Glass

(width/length) Standard Tray 64-220 g/m Photo Tray Lower Tray Duplex Print ADF 64-90 g/m Standard Tray Plain, Inkjet, Glossy (cast/resin coated), Transparency Photo Tray Lower Tray Duplex Print ADF Plain

Post Card 2 (Double) (148 x 200 mm/5.8 x 7.9 inches), C5 Envelope, Com-10,

DL Envelope, Monarch, JE4 Envelope

N/A N/A N/A

148/148 mm to 215.9/355.6 mm (5.8/5.8 inches to 8.5/14.0 inches)

Up to 215.9/297 mm (up to 8.5/11.7 inches)

(17-58 lb.) N/A N/A N/A

(17-24 lb.)

N/A N/A N/A

2.1.2 Paper Handling

Model MFC5890CN MFC5895CW

Standard Tray 150 (80 g/m

Paper Input (sheets)

Output Paper Capacity (sheets)

Photo Tray Lower Tray ADF 50 (90 g/m

N/A N/A

50 (80 g/m

)

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2.1.3 LCD/LED/Panel

Model MFC5890CN MFC5895CW Type & Size 3.3-inch Wide Color LCD Touch Panel Backlight & Color Yes

LCD

Language

Selectable Wallpaper Yes (4 patterns)

Illuminated Key/LED Fax/Scan/Copy/Photo Capture Illuminated Key Color Blue Status LED Color

U.S.A.

Europe See "Language List (page 2-21)." Asia/

Oceania

U.S.A.: English/Spanish, Canada: English/Canada-French

N/A

English/Spanish

N/A

2.1.4 Memory

Model MFC5890CN MFC5895CW

Memory Capacity (physical: megabytes)

Memory Backup (with battery, 24 hours)

Backup Print: ON/OFF (in function menu)

64 MB

Yes

2.1.5 Security

Model MFC5890CN MFC5895CW

Memory Security Transmission Lock Secure Function Lock Yes

2-3

N/A N/A

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2.1.6 Interface

Model MFC5890CN MFC5895CW

Host Interface USB 2.0 Hi-Speed LAN Yes Wireless LAN Bluetooth IrSimple PictBridge Yes USB Flash Memory Yes

Acceptable Media Cards

N/A Yes

N/A N/A

"Compact Flash" "Memory Stick" "Memory Stick Pro" "Secure Digital" "Secure Digital High Capacity" "xD Picture Card" "xD Picture Card TypeM/TypeM+/TypeH"

2.1.7 Others

Model MFC5890CN MFC5895CW

On/Off Switch Yes

U.S.A. 100-120 VAC, 50/60 Hz

Power Source

Operating Environment Tem perature (Best Print Quality)

Humidity 20 - 80% (w/o condensation) Power

Consumption Average (Operating/ Standby/Sleep/ OFF mode)

Machine Noise (Operating) 50 dBA (Maximum) (Belgium only) Machine Dimensions 485 x 408 x 242 mm

Machine Weight

Energy Star Compliant Yes

Blue Angel

TCO99 Speaker Yes

Europe/ Asia/ Oceania

U.S.A. 28 / 6.5 / 4 / 0.9 W

Europe/ Asia/ Oceania

U.S.A.

Europe/ Asia/ Oceania

U.S.A. Europe Yes Asia/

Oceania

220-240 VAC, 50/60 Hz

5-40 (18-33) degrees centigrade

28 / 6.5 / 4 / 0.9 W

10.7 kg

(23.6 lb.)

10.9 kg

(24.0 lb.)

N/A

2-4

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2.2 TELEPHONE

Model MFC5890CN MFC5895CW

Handset Digital Cordless Phone

(Cordless Handset) SKYPE API support

Hook/ Tel R/ Recall/On Hook Key

Duplex Speaker Phone Key PBX Feature (Europe Only) Yes Hold/Mute Music on Hold Monitoring the Line on Hold

with Music

U.S.A. H ook Europe Tel R Asia/

Oceania

N/A

Hook

N/A

N/A N/A

N/A

2.2.1 Volume

Model MFC5890CN MFC5895CW

Handset Volume Speaker V olume Yes (3 steps + OFF) Ring Volume Yes (3 steps + OFF)

N/A

2.2.2 Quick/Auto Dials

Model MFC5890CN MFC5895CW

One Touch Dial Speed Dial 80 x 2 numbers

Figures of One T ouch & S peed Dial

Registerable Number Of Characters

Group Dial (Up to X groups) Yes (6) Telephone Index

(Search/Speed dial key)

Yes - 6 locations

(3 keys + Shift key)

20 digits

16 characters

Yes

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2.2.3 Tel Service

Model MFC5890CN MFC5895CW

Caller ID Yes Call Waiting Caller ID Call from Caller ID List Yes Call from Call List Yes Call waiting Ready Backup Caller ID list Yes Call List Indication Yes External TAD Interface Yes Distinctive Ringing Yes

N/A

2.2.4 Message Center

Model MFC5890CN MFC5895CW

TAD ICM Recording Time Toll Saver Recording Conversation OGM/User Recording Time

(MC/TAD, F/T)

N/A N/A N/A N/A

N/A

2.2.5 List/Report

Model MFC5890CN MFC5895CW

Activity Report/Journal Report Yes (up to 200) Transmission Verification

Report Help List Yes Caller ID List Yes Quick Dial List Yes (Print/Display) Tel Index List ABC User Setting List Yes Order Form Network Configuration Yes

Yes

N/A

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2.3 FAX

Model MFC5890CN MFC5895CW

Modem Speed 33,600 bps Transmission Speed Approx. 3 seconds (Brother #1, MMR) ITU-T Group Super G3

Coding Method

Paper Handling Size LTR, A4, LGL (with ADF)

Document Scanning Width

Document

Color FAX

Display FAX

Super Fine Yes (TX & RX : B&W only)

Gray Scale

Contrast (Auto/S.Light/S.Dark)

Dual Access Yes (B&W only) Enhanced Remote Activate Yes

Station ID

Remote Maintenance Yes Remote Access Ye s Fax Retrieval Yes (B&W only) Paging Yes (U.S.A. only)

(Send/Receive) Memory (Send/

Receive) Send Yes Receive Yes

Mono: MH/MR/MMR

Color: JPEG

LTR (FB): 208 mm

A4 (FB): 204 mm

LTR/LGL (ADF): 208 mm

A4 (ADF): 208 mm

Yes/Yes (ITU-T color FAX)

No/Yes (ITU-T color FAX)

Mono: 64, Color: 256

Yes

20 digits/20 characters

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2.3.1 Sending

Model MFC5890CN MFC5895CW

Delayed Timer Up to 50 / B&W only Polled

Sending (type) *B&W only

Batch Transmission Yes (B&W only/not color) Quick-Scan

(Memory transmission) (ITU-T Test Chart #1 on page

2-22)

Memory Transmission

Broadcasting (Speed/ One Touch + Manual)

Manual Broadcasting Yes (50 locations) Fax Forwarding Yes (B&W only)

U.S.A. Yes (Standard) Europe/Asia/

Oceania

ITU-T Test Chart #1 (see page 2-

22) / MMR

Brother Chart (see page 2-

23) / MMR

Yes (Standard/Secure)

Approx. 3.30 seconds/page @LTR Approx. 3.50 seconds/page @A4

Up to 400 pages

Up to 480 pages

Yes (216 locations)

2.3.2 Receiving

Model MFC5890CN MFC5895CW

Easy Receive/Fax Detect Yes (Fax detect only) Polling

Receiving (type) * B&W only

Auto Reduction Yes

Out-of-Paper Reception

U.S.A. Yes (Standard/Sequential) Europe/Asia/

Oceania

ITU-T Test Chart #1 (see page 2-

22) / MMR

Brother Chart (see page 2-

23) / MMR

(Standard/Sequential/Secure/Timer)

Yes

Up to 400 pages

Up to 480 pages

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2.3.3 PC FA X

Model MFC5890CN MFC5895CW

Color/Mono Mono (A4 only) Sending Yes (Network/USB)

Receiving

PC-Fax Protocol

Broadcasting Up to 50

Yes (Network/USB),

N/A for MAC

RX: Class 2

TX: PC-FAX Driver

2.4 PRINTER

Model MFC5890CN MFC5895CW

Mono/Color Print Speed (A4/LTR)

*Including paper feeding Resolution

(horizontal x vertical) Fonts (CD Based) Auto Duplex Print Manual Duplex Print Yes

(Mono: 450 x 300 dpi/Color: 600 x 15 0 dpi):

<Borderless printing> On: 0, 0, 0, 0 mm/0, 0, 0, 0 inch (*) Off: 3, 3, 3, 3 mm/0.12, 0.12, 0.12, 0.12 inches (**)

Color

Up to 35/28 ppm

Up to 1200 x 6000 dpi

N/A N/A

Print Paper Margin (upper, lower, left, right)

Easy Print Setting for Printer Driver (Japan only)

Color Enhancement (Color Printer)

(*) Borderless for A3, A4, B4, LGR, LTR, A6, Photo (102 x 152 mm/4 x 6 inches), Index card (127 x 203 mm/5 x 8 inches), Photo-L (89 x 127 mm/3.5 x 5 inches), Photo-2L (127 x 178 mm/5 x 7 inches), Post Card 1 (100 x 148 mm/3.9 x 5.8 inches) only (**) 12, 24, 3, 3 mm/0.47, 0.95, 0.12, 0.12 inches for Envelops

N/A

Yes

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2.5 COPY

Model MFC5890CN MFC5895CW

Mono/Color (Color Copy) Color Copy Speed (A4/LTR)

*Including paper feeding **Europe's default is calculated by "normal mode" speed

Resolution (horizontal x vertical)

Multi Copy

Reduction/Enlargement (%) 25 - 400 in 1% increments

N in 1

Poster Yes (3 x 3, 2 x 2) Auto Skew Adjustment Fit to Page Yes

Copy Enhancement

Duplex Copy Print Paper Margin

(upper, lower, left, right)

Paper Sizes (Color Copy)

Mono

Color

Stack Yes (99) Sort Yes

Book Copy (Shadow Correction & Skew Adjustment for book)

Watermark Copy

Standard T ray LGR, LTR, LGL, A3, A4, A5, 10 x 15 cm (4 x 6 inches) Photo Tray Lower Tray

Print: Maximum 1200 x 1200 dpi Scan: Maximum 1200 x 1200 dpi

LGR/LTR/A3/A4 only (*Mono & Color)

3, 3, 3, 3 mm/0.12, 0.12, 0.12, 0.12 inches

23/20 cpm

8/8 cpm (Belgium only)

2 in 1 / 4 in 1

N/A

Yes

Yes N/A

N/A N/A

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2.6 SCANNER

Model MFC5890CN MFC5895CW

Mono/Color (Color Scanner) Color Scan Speed (Mono/Color)

*@100 dpi Resolution

(horizontal x vertical)

Gray Scale 256

Scan to

Document Scanning Width 210 mm Color Depth Input: 48 bits, Output: 24 bits

Optical 1200 x 2400 dpi

Interpolated

Image Yes (Scan Key) OCR Yes (Scan Key) E-mail Yes (Scan Key) File Yes (Scan Key) Media

(Media Card or USB Flash Memory)

FTP Yes (Scan Key) E-mail Server Yes (Download/Scan Key)

(For Windows XP/Vista, up to 19200 x 19200 dpi with Scanner Utility)

Maximum 3.24/4.55 seconds (LTR) Maximum 3.44/4.83 seconds (A4)

1200 x 1200 dpi

Yes (Scan Key)

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2.7 PHOTO CAPTURE

Model MFC5890CN MFC5895CW

Memory Stick: 16-128 MB (Duo with Adapter) Memory Stick Pro: 256 MB - 8 GB (MagicGate: YES if not use MG function)

Secure Digital: 16 MB - 2 GB (MiniSD with

Acceptable Media (Type & Size)

Paper Sizes

Paper Types

Print Paper Margin (upper, lower, left, right) (PCC)

Available Paper Size for Full (Maximum) Size Printing

Direct Print Size for A4/LTR (N/A for A3, LGR, B4)

Borderless/Cropping (Full Auto)

Media Format

Image Format Print by Media Card/USB Flash Memory

Color Enhancement (PCC)

Removable Disk (Media Card/ USB Flash Memory)

Scan to Media (Media = Media Card or USB Flash Memory)

Network Media Card/USB Flash Memory Access

Monochrome/Sepia Yes Trimming Yes Search from D a te Yes Slide-show Yes

Photo Enhance

Media Cards

USB Flash Memory

Standard T ray LGR, LTR, A3, A4, 10 x 15 cm (4 x 6 inches), 13 x 18 cm (5 x 7 inches) Photo Tray Lower Tray Standard T ray Plain, Inkjet, Glossy Photo Tray Lower Tray

Adapter) Secure Digital High Capacity (SDHC): 4-8 GB

xD Picture Card: 16-512 MB xD Picture Card TypeM/Ty peM+/ TypeH: 256 MB - 2 GB

Compact Flash: 4 MB - 8 GB (Type1 only, Type2 & Microdrive are not compatible)

Up to 8 GB Up to 32 GB

N/A N/A

<Borderless printing> On: 0, 0, 0, 0 mm/0, 0, 0, 0 inch Off: 3, 3, 3, 3 mm/0.12, 0.12, 0.12, 0.12 inches

All sizes

8 x 10 cm (3 x 4 inches), 9 x 13 cm (3.5 x 5 inches), 10 x 15 cm (4 x 6 inches), 13 x 18 cm (5 x 7 inches), 15 x 20 cm (6 x 8 inches), Maximum Size

Yes/Yes

DPOF (Ver. 1.0, Ver. 1.1) Exif DCF (Up to Ver. 2.1)

Photo Print: JPEG/JPEG

Yes

Yes (read & write)

(both Card & USB flash memory)

Color: JPEG/PDF

B&W: TIFF/PDF

Yes (read & write)

(both Card & USB flash memory)

Yes

(Remove red-eye/Skin-Tone/Scenery/Auto correct)

Memory Stick: 16-128 MB (Duo, micro with Adapter) Memory Stick Pro: 256 MB - 32 GB (MagicGate: YES if not use MG function) (Duo, micro with Adapter)

Secure Digital: 16 MB - 2 GB (MiniSD, microSD with Adapter) Secure Digital High Capacity (SDHC): 4-32 GB

xD Picture Card: 16-512 MB xD Picture Card TypeM/TypeM+/TypeH: 256 MB - 2 GB

Compact Flash: 4 MB - 32 GB (Type1 only, Tpye2 & Microdrive are not compatible)

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2.7.1 PictBridge

Model MFC5890CN MFC5895CW Paper Size A3, A4, LGR, LTR, 4 x 6 inches, Printer Setting Paper Type Plain Paper, Inkjet Paper, Glossy, Printer Setting Direct Print Size for A4/LTR Maximum size only Borderless / Cropping

(Full Auto) Index Print DPOF Yes Color Enhancement Yes Print Quality Normal, Fine, Printer Setting

Yes/No

N/A

2.8 SOFTWARE

Model MFC5890CN MFC5895CW

Support OS Version

PC Application

Windows Windows 2K/XP/XP Professional x64/Vista

Mac Mac OS X 10.2.4 (greater) Mac OS X 10.4.11, 5.x, 6.x

Win 2K Professional

Win XP Home/XP Professional

Win XP Professional x64

Win Vista

Win Server 2003 (print only via network)

Win Server 2003 x64 (print only via network)

Win Server 2008 (print only via network)

Mac OS X 10.3.9 - 10.4.3

Mac OS X 10.4.4 or greater

Windows 2K/XP/XP Professional X64/

Vista/Win7

Windows® 2000 Professional

Windows® XP Home

Windows® XP Professional

Windows® XP Professional x64 Edition

Windows Vista®

Windows7

Windows Server® 2003 (print only via network)

Windows Server® 2003 x64 Edition

(print only via network)

Windows Server® 2003 R2

(print only via network)

Windows Server® 2003 R2 x64 Edition

(print only via network)

Windows Server® 2008 (print only via network)

Windows Server® 2008 R2

(print only via network)

Mac OS® X 10.4.11, 5.x

Mac OS® X 10.6.x

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2.9 NETWORK

Model MFC5890CN MFC5895CW ITU SUB Addressing Printer Yes Scanner Yes PC FAX Yes Internet FAX (Firmware) Yes (Download)

Format (Scan to E-mail server)

ARP, RARP, BOOTP, DHCP, APIPA (Auto IP), NetBIOS/WINS, LPR/LPD,

Protocols (IPv4)

Protocols (IPv6)

LDAP FAX to E-mail Y e s Network Management

(BRAdmin Light) Network Management (MIB-II

as well as Brother private MIB) Network Reset Yes (for WLAN & WIRED LAN at once) (in LAN Menu)

Custom Raw Port/Port9100, DNS Resolver, mDNS, FTP Server, TELNET,

SNMPv1, TFTP, Scanner Port, LLTD Responder, Web Services, SMTP Client,

POP before SMTP, SMTP- AUTH, POP3, APOP, FTP Client

(Turned off by default) NDP, RA, LPR/LPD, Custom Raw Port/Port9100, mDNS,

FTP Server, TELNET, SNMPv1, TFTP, Scanner Port, LLTD Responder, Web Services,

SMTP Client, POP before SMTP, SMTP-AUTH, POP3, APOP, FTP Client

N/A

Color: PDF/JPEG

B/W: TIFF/PD F

N/A

Yes

2.9.1 Wired

Model MFC5890CN MFC5895CW Model Name (Ethernet) Embedded (NC-170h) Network Connection (Ethernet) Ethernet 10/100 BASE-TX Auto Negotiation

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2.9.2 Wireless

Model MFC5890CN MFC5895CW Model Name (Wireless) Network Connection

(Wireless)

Wireless Security

WiFi Certification WCN

(Windows Connect Now)

Secure EZ Setup

Setup Support Utility

Auto Switch WLAN/WIRED LAN

AOSS (WLAN model only)

WPS (WiFi Protected Setup)

N/A Embedded (NC-180w)

N/A IEEE 802.11b/g

N/A

N/A Wifi B and G

N/A

N/A Yes

N/A

SSID (32 chr), WEP 64/128 bit,

WPA-PSK (TKIP/AES), WPA2-PSK (AES)

**NO LEAP**

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2.10 SUPPLIES/OPTIONS

Model MFC5890CN MFC5895CW

LC61BK/ LC65HY-BK

U.S.A.

Ink Cartridge Model Name

Bundled Ink Cartridge Type High yield

Bundled Cartridges Approx. 770/540 pages

Ink Cartridge Yield (@ISO pattern/ normal)

Brother Paper (for Plain, Glossy and Inkjet)

2.11 SERVICE INFORMATION

Model MFC5890CN MFC5895CW Monthly Volume 4000 pages Machine Life (year) 50000 pages or 5 years MTBF (Mean Time Between

Failures) MTTR (Mean Time To Be

Repaired)

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4000 hours

30 minutes

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2.12 PAPER

2.12.1 Paper Specifications

Paper type and size for each operation

Paper Type Paper Size Usage

Fax Copy Photo

Capture

Cut Sheet Ledger 11 x 17 inches (279.4 x 431.8 mm) Yes Yes Yes Yes

A3 11.7 x 16.5 inches (297 x 420 mm) Yes Yes Yes Yes Letter 8 1/2 x 11 inches (215.9 x 279.4 mm) Yes Yes Yes Yes A4 8.3 x 1 1.7 inc he s (210 x 297 mm ) Yes Yes Yes Yes Legal 8 1/2 x 14 inches (215.9 x 355.6 mm) Yes Yes -- Yes Executive 7 1/4 x 10 1/2 inches (184 x 267 mm) -- -- -- Yes B4 (JIS) 10.1 x 14.3 inches (257 x 364 mm) -- -- -- Yes B5 (JIS) 7.2 x 10.1 inches (182 x 257 mm) -- -- -- Yes A5 5.8 x 8.3 inches (148 x 210 mm) -- Yes -- Yes A6 4.1 x 5.8 inches (105 x 148 mm) -- -- -- Yes

Cards Photo 4 x 6 inches (10 x 15 cm) -- Yes Yes Yes

Photo L 3 1/2 x 5 inches (89 x 127 mm) -- -- -- Yes Photo 2L 5 x 7 inches (13 x 18 cm) -- -- Yes Yes Index Card 5 x 8 inches (127 x 203 mm) -- -- -- Yes Post Card 1 3.9 x 5.8 inches (100 x 148 mm) -- -- -- Yes Post Card 2

(Double)

Envelopes C5 Envelope 6.4 x 9 inches (162 x 229 mm) -- -- -- Yes

DL Envelope 4.3 x 8. 7 inches (110 x 220 mm) -- -- -- Yes COM-10 4 1/8 x 9 1/2 inches (105 x 241 mm) -- -- -- Yes Monarch 3 7/8 x 7 1/2 inches (98 x 191 mm) -- -- -- Yes JE4 Envelope 4.1 x 9.3 inches (105 x 235 mm) -- -- -- Yes

Transparencies Letter 8 1/2 x 11 inches (215.9 x 279.4 mm) -- Yes -- Yes

A4 8.3 x 1 1.7 inc he s (210 x 297 mm ) -- Yes -- Yes

5.8 x 7.9 inches (148 x 20 0 mm) -- -- -- Yes

Printer

Paper weight, thickness and capacity

Paper Type Weight Thickness No. of

Cut Sheet Plain Paper 17 to 32 lb. (64 to 120 g/m

) 3 to 6 mil (0.08 to 0.15 mm) 150

Inkjet Paper 17 to 53 lb. (64 to 200 g/m2) 3 to 10 mil (0.08 to 0.25 mm) 20

Glossy Paper Up to 58 lb. (Up to 220 g/m

Cards Photo 4 x 6 inches Up to 58 lb. (Up to 220 g/m

Index Card Up to 32 lb. (Up to 120 g/m Post Card Up to 53 lb. (Up to 200 g/m

Envelopes 20 to 25 lb. (75 to 95 g/m

) Up to 10 mil (Up to 0.25 mm) 20

) Up to 6 mil (Up to 0.15 mm) 30

) Up to 10 mil (Up to 0.25 mm) 30

) Up to 20 mil (Up to 0.52 mm) 10

Transparencies -- -- 10

Up to 150 sheets of plain paper 20 lb. (80 g/m2).

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Recommended print media

Brother paper

Paper Type Item Ledger Plain BP60PLGR (USA only) Ledger Glossy Photo BP71GLGR Letter Plain BP60PL (USA only) Letter Glossy Photo BP71GP Letter Inkjet (Matte) BP60ML (USA only) 4 x 6 in. Glossy Photo BP71GP A3 Plain BP60PA3 A3 Glossy Photo BP71GA3 A3 Inkjet (Matte) BP60MA3 A4 Plain BP60PA A4 Glossy Photo BP71GA4 A4 Inkjet (Matte) BP60MA 10 x 15 cm Glossy Photo BP71GP

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Handling and using print media

 Store paper in its origin al pac kagi ng, an d keep i t sea led. K eep th e pape r flat a nd away fro m

moisture, direct sunlight and heat.

 Avoid touching the shiny (coa ted) side o f ph oto pap er. Load p hoto pa per wi th the shiny s ide

facing down.

 Avoid touching either side of transparencies because they absorb water and perspiration

easily, and this may cause decreased output quality. Transparencies designed for laser

printers/copiers ma y stain your next doc ument. Use only transpar encies recommended for

inkjet printing.

 You can only print on both sides of the paper with PC printing using Windows.

1 0.08 inches (2 mm) or greater curve

may cause jams to occur

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2.12.2 Printable Area

Top (1) Bottom (2) Left (3) Right (4) Cut Sheet 0.12 inches (3 mm) 0.12 inches (3 mm) 0.12 inches (3 mm) 0.12 inches (3 mm) Envelopes 0.47 inches (12 mm) 0.95 inches (24 mm) 0.12 inches (3 mm) 0.12 inches (3 mm)

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Language List

Product Category

MFC U.S.A. English English

Country Languages Default

Canada English/French English Belgium Dutch/French/English Dutch Switzerland German/French/English Germ an Pan Nordic/Denmark English/Norwegian/Swedish/Finnish/

Danish

General English/Czech/Hungarian/Polish/

Bulgarian/Romanian/Slovak Russia Russian/English Russian Asia English English Oceania English English Hong Kong Traditional Chinese/English Traditional Chinese

Depends on first country setting

English

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ITU-T Test Chart #1

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Brother Chart

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CHAPTER 3

THEORY OF OPERATION

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CHAPTER 3 THEORY OF OPERATION

This chapter gives an overview of the scanning and printing mechanisms as well as the sensors, actuators, and control electronics. It aids in understanding the basic principles of operation as well as locating defects for troubleshooting.

CONTENTS

3.1 OVERVIEW ............................................................................................................3-1

3.2 MECHANICAL COMPONENTS.............................................................................3-2

3.2.1 Scanner Mechanism..................................... ...... ....... ...... ....... ...................3-5

3.2.2 Printing Mechanism...................................................................................3-8

3.2.2.1 Ink supply and ink jet mechanism .........................................................3-10

[ 1 ] Overview ...........................................................................................3-10

[ 2 ] Features............................................................................................3-11

[ 3 ] Head/carriage unit.............................................................................3-12

[ 4 ] Ink cartridges........ ...... ....... ...... ....... ...... ...... ....... ...... ....... ...... ....... ......3-17

[ 5 ] Ink refill assembly. ...... ....... ...... ....... ...... .............................................3-19

[ 6 ] Ink supply tubes ................ ...... ....... ...... .............................................3-20

3.2.2.2 Head maintenance mechanism.............................................................3-21

[ 1 ] Overview ...........................................................................................3-21

[ 2 ] Maintenance unit components ..........................................................3-22

[ 3 ] Mechanisms constituting the head maintenance mechanism...........3-24

[ 4 ] Power transmission route to the head maintenance mechanism

and motor rotational direction............................................................3-29

[ 5 ] Purge types, ink usage, purge counts, and purge codes ..................3-32

[ 6 ] Ink cartridge capacities ........................................... ....... ...... ....... ......3-32

3.2.2.3 Carriage drive mechanism ....................................................................3-33

3.2.2.4 Paper pulling-in, registration, feeding and ejecting mechanisms..........3-37

3.2.3 Sensors and Actuators..............................................................................3-41

3.3 CONTROL ELECTRONICS ......................... ....... ...... ...... .......................................3-44

3.3.1 Components..............................................................................................3-44

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3.1 OVERVIEW

Line

Color LCD

Fax Control Section

SDAA

MJ PCB

Control panel

Speaker

ADF unit

- ADF motor

Backup battery

Scanner unit

- CIS unit

- CIS motor

Host

USB interface

WLAN*

WLAN PCB

Ink jet printer unit

- Head/carriage unit

- Carriage PCB with head flat cables

- Carriage motor

- Ink refill ASSY

- Maintenance unit

LAN

LAN interface

Printer Control Section

Print data

- Compact Flash

- Memory Stick

- SD Memory Card

- xD-Picture Card

PhotoCapture Center

Paper feeding mechanism

- Paper feed motor

- ASF motor

- Digital camera (with PictBridge)

- USB flash memory drive

USB interface

Power supply

(Overview_BHL9_A3)

* For wireless LAN-enabled model.

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3.2 MECHANICAL COMPONENTS

This machine consists of the scanner mechanism and printing mechanism. It uses five motors (CIS motor, ADF motor, paper feed motor, ASF motor, and carriage motor), three encoders (PF encoder, ASF encoder, and CR encoder), various sensors, and two thermistors.

 Scanner Mechanism

Document path for ADF scanning

(Left)

Document for flat-bed scanning

 Printing Mechanism

Ink supply and ink jet mechanism, head maintenance mechanism, and carriage drive mechanism.

(Right)

(BHL9A3_ADF_1)

(Front)

- Carriage drive mechanism

3-2

(Rear)

- Ink supply and ink jet mechanism

- Head maintenance mechanism

(3_01_BHL9_A3)

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Paper pulling-in, registration, feeding and ejecting mechanisms

Recording paper path

(Front)

(Rear)

(3_02_BHL9_A3)

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Scanner Mechanism



(See Section 3.2.1.)

- Document scanning mechanism CIS motor (stepping motor)

 Printing Mechanism

(See Section 3.2.2.)

 Encoders

(See Section 3.2.3.)

- Automatic document feeder (ADF)

mechanism

- Ink supply and ink jet mechanism

(See Section 3.2.2.1.)

- Head maintenance mechanism

(See Section 3.2.2.2.) (Head capping and carriage lock)

+ (Purge, air removing, and head wiper)

-Carriage drive mechanism (See Section 3.2.2.3.)

- Paper pulling-in, registration, feeding and ejecting mechanisms (See Section 3.2.2.4.)

- Paper feed motor encoder (PF encoder)

- ASF motor encoder (ASF e ncoder)

- Carriage motor encoder (CR encoder)

ADF motor (stepping motor)

ASF motor*

(DC motor) + Paper feed motor (DC motor)

Carriage motor (DC motor)

ASF motor*

(DC motor) + Paper feed motor (DC motor)

 Sensors

(See Section 3.2.3.)

 Thermistors

(See Section 3.2.3.)

- Document front sensor

- Document rear sensor

- Scanner cover sensor

- Ink cartridge cover sensor

- Registration sensor

- Paper width (media) sensor

- Purge cam switch

- Cap lift cam switch

- Ink empty sensors (black, yellow, cyan and magenta)

- Ink cartridge detection sensors (black, yellow, cyan and magenta)

- Head thermistor

- Casing internal temperature thermistor

* ASF motor: Auto Sheet Feeder motor

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3.2.1 Scanner Mechanism

This mechanism consists of the automatic document feeder (ADF), document cover, and scanner unit (scanner cover).

The scanner unit consists of a scanner top cover, CIS unit, CIS drive assembly, and scanner base.

The detailed illustration on the nex t page s hows the components making up the ADF: document pull-in roller, document separation roller, document feed rollers, document ejection rollers, ADF motor, and document front and rear sensors.

For further details on the sensors, see Section 3.2.3.

ADF unit

ADF & document cover ASSY

Document cover

White reference film

CIS drive assembly (CIS motor)

CIS unit

Scanner top cover

CIS drive belt

CIS flat cable

Scanner unit (Scanner cover)

Scanner base

CIS idle pulley

CIS rail

(3_03_BHL9)

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Document feed rollers

Document pressure rollers 1

Document separation roller

Document pull-in roller

Document support

Document ejection rollers

Document path for ADF scanning

(Left)

CIS unit

Document rear sensor actuator

Document pressure rollers 2

Pinch rollers

ADF motor

Document front sensor actuator

ADF parts

Document pressure bar

Document for flat-bed scanning

(BHL9A3_ADF_2)

(Right)

The scanner mechanism offers two types of scanning: ADF scanning and flat-bed scanning. It automatically swi tches to the for mer a t t he start of a scan operation if the document front sensor inside the ADF detects a document.

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(1) ADF scanning: Document moves acros s stationary CIS unit

Placing a doc um ent face up in the ADF activates the document front sensor, switching to ADF scanning.

The CIS drive mechanism (details below) operates for each scanning command executed. First, the CIS mot or moves the CIS unit to the white reference film for white level compensation. Secondly, the ADF motor rotates the docu me nt pul l-in roller to pul l the document int o t he ADF. Thirdly, the CIS motor again moves the CIS unit to the ADF scanning position.

The document separation roller feeds the pages one at a time, starting from the top, to the document feed roller, which rotates to move the page in a curve left, down, and right. The page is scanned as it passes over the CIS unit. It then leaves the machine face down onto the document cover. The machine ejects subsequent pages above this one to preserve the document page order.

(2) Flat-bed scanning: CIS unit moves under stationary document

The user lifts the document cover, places a page (or open book) face down with the left and top edges fitting on the left and top guidelines on the glass plate, and closes the document cover.

The CIS drive mechanism (details below) operates for each scanning command executed. The CIS unit first moves to the white reference film for white level compensation. It then moves right, scanning as it goes. It returns to its home position after the scan.

CIS drive mechanism The contact image sensor (CIS) unit rides along the CIS rail, driven by the CIS drive belt.

Clockwise motion of the CIS motor moves the unit to the left; counterclockwise motion, to the right.

This unit consists of the document illumination LED array, the lens array gathering the light reflected from the scanned image, the CIS PCB converting the light input to pixel data output, and the CIS glass.

The CIS unit used in the machine supports color scanning. In scanning color documents, the CIS unit illuminates them by turning on the red (R), green (G), and blue (B) LEDs alternately. In scanning monochrome documents, it turns on the green LEDs only.

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3.2.2 Printing Mechanism

The printing mechanism co nsists of the following.

 Ink supply and ink jet mechanism (Section 3.2.2.1)  Head maintenance mechanism (Section 3.2.2.2)  Carriage drive mechanism (Section 3.2.2.3)  Paper pulling-in, registration, feeding and ejecting mechanisms (Section 3.2.2.4)

The ink supply mechanism

supplies ink to the head/carriage unit, in which the ink jet

mechanism sprays ink droplets from the head nozzles onto paper. The major components of the ink supply mechanism (shown on page 3-10) are:

- Ink refill assembly: This secures the ink cartridges and connects them to the corresponding ink supply tubes.

- Ink supply tubes: These supply the head/carriage unit with ink fed from the ink cartridges via the ink refill assembly.

The major components of the ink jet mechanism (head/carriage unit shown on page 3-12) are:

- Front end: This is an ink-jet head consisting of piezoelectric plate (PZT), metal plates, nozzle plate, and head driver.It jets out ink to produce images on paper.

- Back end: This consists of damper assemblies and air vent unit. Each damper assembly dampens the ink pressure fluctuations in the corresponding ink supply tube and collects air bubbles that result from pressure changes on the ink.

To keep the optimum head performance, the head maintena nce mechanism

(shown on page 3-

31) uses the rotational torque of the ASF motor* to cap the head nozzles in order to prevent

them from drying up. It also uses the rotational torque of the paper feed motor to purge for removing air bubbles from the head/carriage unit and wipe off any ink remaining on the head nozzle surface.

The carriage drive mechanism

(shown on page 3-33) moves the head/carriage unit with a carriage motor (DC motor) along the recording paper. The CR encoder sensor mounted on the head/carriage unit scans the CR encoder strip and monitors the current head position relative to the home position and the current travel speed.

The paper pulling-in, registration, feeding and ejecting mechanisms motor* and paper feed motor (both are DC motors).

The major components are:

- Paper tray: Recording paper is stored in this tray.

- Paper pull-in rollers (shown on page 3-38):

These rollers pull in paper into the machine.

- Bank ASSY (shown on page 6-73):

This separates paper, sheet by sheet to feed it into the printing section.

- Jam clear cover (shown on page 3-37):

Opening this cover allows the user to access paper jammed. It also guides paper pulled in from the paper tray into the printing section.

*ASF motor: Auto Sheet Feeder motor

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are driven by th e ASF

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- Paper feed roller (shown on page 3-38):

This roller performs paper registration and feeds paper to the printing section precisely.

- Paper ejection roller (shown on page 3-37):

This roller ejects paper and keeps paper tension tight.

- ASF motor* (shown on page 3-38):

This motor pulls in paper, switches the paper feed operation modes, and drives the head capping mechanism and carriage lock mechanism of the maintenance unit.

- Paper feed motor (shown on page 3-38):

This motor feeds recording paper and drives the purge mechanism, air removing mechanism and head wiper mechanism of the maintenance unit.

- Clutch gears L and R (shown on page 3-38):

Clutch ge ar L switches the transm ission route of the AS F motor rotation between the paper pulling-in mechanism and the head capping & carriage lock mechanisms.

Clutch gear R transmits the rotational torque of the paper feed motor to the purge gear (for purge, air removing and head wiper mechanisms).

- ASF rotary encoder: This generates a signal indicating the rotation speed of the

ASF motor shaft. The signal is sent to the controller and used for controlling the paper pull-in position and speed.

- PF rotary encoder: This generates a signal indicating the rotation speed of the

PF roller gear. The signal is sent to the controller and used for controlling the paper feed position and speed.

*ASF motor: Auto Sheet Feeder motor

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3.2.2.1 Ink supply and ink jet mec hanism [ 1 ] Overview

The ink supply and ink-jet mec hanism con sist s of the he ad/car riag e unit, four ink cart ridge s, ink refill assembly, and four ink supply tubes.

The head/carriage unit scans the surface of the recording paper, jetting out ink supplied through the ink supply tubes onto the paper to produce images. For further details, see "[ 3 ] Head/

carriage unit" below.

The four ink cartridges (black, yellow, cyan, and magenta) are mounted on the ink refill assembly. For further details, see "[ 4 ] Ink cartridges" below.

The ink refill assembly secures the ink cartridges and connects them to the corresponding ink supply tubes. For further details, see "[ 5 ] Ink refill assembly" below.

The ink supply tubes supply the head/carriage unit with ink fed from the ink cartridges via the ink refill assembly. For further details, see "[ 6 ] Ink supply tubes" below.

(Maintenance unit)

Head/carriage unit

(Flushing box)

Engine unit

(Ink absorber box)

Ink refill assembly

Ink supply tubes

(3_04_BHL9)

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[ 2 ] Features

A distinct feature of this machine is the use of ink supply tubes between the ink cartridges and the head/carriage unit. Relieving the head/carriage unit of the task of carrying heavy ink cartridges back and forth across the page, the approach generally adopted by other ink-jet printers, offers the following advantages.

- Lower po wer consumption

- Lower noise levels

- Lower vibration During print operation, the ink-jet mechanism inside the head/carriage unit sprays ink droplets

from the head nozzles. The loss of this ink from the head produces a negative pressure that replenishes the head with ink from the ink tank through the supply tubes.

Note, however, that the above ink flow is only possible when the ink supply tubes are full of ink. The factory therefore primes the ink supply path by applying strong suction to the head nozzles with the maintenance unit to suck both air and ink through the ink supply tubes.

Leaving too long interval between this priming and actual use, however, risks air bubbles, increased viscosity, and other quality issues with the ink in the supply tubes. Before using this machine for the first time, therefore, this machine automatically replaces the ink supply path contents with fresh ink using an initial purge, a repeat of this priming operation.

When the machine is on standby, a constant negative pressure (which is produced according to the difference in height between the head/carriage unit and ink cartridges) is applied to the rear of the print head, thus preventing ink from leading out of those nozzles.

Note: The above applies only as long as this machine rests on a horizontal surface. Standing this machine on end or even just tilting it backwards with the print head uncapped risks overcoming this slight negative pressure preventing ink leakage from the head nozzles.

Piezoelectric ceramic actuators inside the print head convert this ink to droplets sprayed onto the paper. For further details, see "[ 3 ] Head/carriage unit" below.

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[ 3 ] Head/carriage unit

)

(

)

The head/carriage unit con sist s of a fr ont end ( ink-j et hea d) a nd a back e nd (damper and air vent unit) as shown below.

The front end consists of metal plates laminated together and etched to form ink flow channels. Piezoelectric ceramic actuators generate the spray pressure. The response of individual front

ends to applied voltages and waveforms varies, however, because of the nature of piezoelectric materials, fluctuation in manufacturing accuracy, and other factors. The front end therefore leaves the production line with head property labels giving property data. The manufacturer writes this prope rty data to the EEPROM on the main PCB incorporating this unit. Based on the property data of the front end, the processor drives piezoelectric ceramic actuators to insure consistent performance without fluctuations.

Back end (Buffer and air vent unit

(Front)

Head driver

Filter

Piezo plate

Metal plates

Front end (Ink-jet head)

Nozzle plate

3-12

Head

Confidential

 Front end

Front end components and their main roles

- Piezoelectric pla te Applying a voltage stretches the plate, serving as the actuator for spraying ink. Consisting of

thin piezoelectric plates laminated together, this plate can be driven even by a low voltage.

- Filter This removes foreign materials from the ink.

- Metal plates These form the head nozzle pressure chambers, ink flow paths, and manifolds.

- Nozzle plate This plate has a total of 470 nozzles--47 nozzles x 2 lines staggered x 5 rows (black x 2,

yellow, cyan, and magenta).

- Head driver This flexible circuit board holds the piezoelectric driver chip.

Nozzle array (head bottom plate viewed from the bottom)

Yellow Black

Black

Paper feed direction

Print head travel direction

Cyan

Magenta

Black

Nozzles

Yellow

Channels

Cyan

Magenta

3-13

(Nozzle)

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Ink spray function The head employs drop-on-demand ink-jet printing. Print commands to the drive circuit apply a bias voltage to the layer electrodes on the

piezoelectric ceramic surface stretching the elements perpendicular to that surface. Drive signals removing t hi s voltage for specif ic channel electrode s allow the piezoelect ri c elements to return to their or iginal shape , suc king i nk into the co rresp ondi ng chann els*. Re applyi ng the b ias voltage stretches the elements once again, applying pressure to the ink, spraying it from the head nozzle. The ink drop hits the paper on the platen, forming a dot.

* Pressure chambers for individual nozzles

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 Back end

Damper ASSY (Magenta)

Air bubbles

Left chamber

Damper ASSY (Cyan)

Air bubbles

Right chamber

Left chamber

Damper ASSY (Y ellow)

Air bubbles

Left chamber

Damper ASSY (Black)

Air bubbles

Left chamber

Back end components and their main roles

Right chamber

Shut-off valves

Air vent unit

(Air vent rods)

(A part of maintenance unit)

(Air vent cap)

(BackEnd_E)

- Damper assemblies Each assembly has two roles: dampening the ink pressure fluctuations* in the ink supply tube

as the carriage moves and collecting air bubbles that grow in the ink flow path.

* Ink pressure fluctuations: As the head/carriage unit travels, inertia means that the ink remains in the

same place, temporarily raising or lowering the pressure in the right chamber.

- Air vent unit At regular scheduled in terva ls, thi s vents any air bubbl es that have accumul ate d in the damper

assemblies. The air ven t ro ds in the mai nt enance unit push up the shut-off valves, opening th e air vent flow paths.

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Damping Without damping, ink pressure fluctuations directly affect the size of ink-jet head droplets,

risking lower print quality. Each damper assembly has two chambers. The one on the right in the illustration below has a

loose film across its top and serves as a damper. The film immediately flexes in and out in response to falls and rises in pressure, adjusting the chamber volume to counteract pressure fluctuations in the ink supply tubes.

Film

Left chamber

This loose film flexes in and out in response to changes in ink pressure.

(DamperFunc)

Air buffering Liquid ink contains trace amounts of air. These molecules coalesce into air bubbles as the

piezoelectric ceramic actuators vary t he pressure on the ink in the ink-jet head channel. (See the illustration on page 3-13.) Removing as many of these bubbles as possible before the ink reaches the in k-jet head is ess ential to main taining prop er print qualit y. The above ill ustration shows how the damper assemblies provide air buffers, the chambers on the left, for consolidating th ese ai r bu bbles a way fro m the ink-j et head and vent fl ow path s for pu r gi ng them at regular scheduled intervals.

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[ 4 ] Ink cartridges

Filled with ink

Disc valve S

Sensor actuator

Air

Ink empty sensor

Ink

Disc valve D

Ink near-empty/Ink empty

Ink cartridge features This machine uses four ink cartridges: a black one and three color ones with a slightly lower

capacity. It features horizontal insertion in the ink refill base over plastic needles. Each cartridge has two ports: one supplying the ink for printing and another intaking air to

replace that ink. Both ports have a disc valve preventing ink leakage. When a cartridge is mounted over the plastic needles in the ink refill base, these valves are opened to secure flow paths for both the ink and the air.

(3_06)

These ink cartridges are single-use affairs. There is no provision for refilling them. The design reduces environment load by using only burnable materials yielding no toxic substances.

Inks This machine uses dye-based inks for colors and pigment-based ink for black. Using the

pigment-based black ink reduces fuzziness from print character outlines, boosts resolution for black dots, and produces clearer images on plain paper.

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Ink near-empty/ink empty detection The ink refill assembly has four ink empty sensors (photosensors of transparent type) that

monitor the ink levels with sensor actuators inside the ink cartridges.

Disc valve S

Air intake port

Air

Ink empty sensor

Ink

Ink supply port

Ink empty sensor

Sensor actuator

Disc valve D

Sensor actuator

Float

(InkBackflowPrevention)

(InkEmptySensor_2)

Attached to one end of the sensor actuator is a float. When there is ink in the cartridge, buoyancy lifts the float, rotating the sensor actuator about a pivot near the center of the actuator to block the light beam to the ink empty sensor, indicating that there is ink.

As the ink level in t he ink cart ridge drops, howev er, th e fl oat f alls, event ually moving t he se nsor actuator out of the beam.

Light hitting the s ensor outputs the "i nk ne ar -empt y" si gnal to the controll er t h at sho w s t he " I nk low" message and activates a firmware counter tracking ink usage during ink-jet printing, purges, and other operations. When this counter reaches a predetermined limit, the firmware regards it as "ink empty" and shows the "Cannot Print" message to prompts the user to replace it.

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[ 5 ] Ink refill assembly

Ink empty sensor PCB

Ink empty sensors

Cartridge release levers

Ink refill case

(3_07)

Ink cartridge detection sensors

Ink cartridge detection sensor PCB

Ink foam case

Ink refill base

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Ink foam

Ink refill base foam

(3_08)

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Ink refill as sembly components and thei r main roles

- Ink refill case

- Cartridge release levers

- Ink refill base and its foam

- Ink cartridge detection sensors (on the ink cartridge detection sensor PCB)

- Ink empty sensors (on the ink empty sensor PCB)

- Ink foam and its case

Pushing each ink cartridge into the ink refill case

until it clicks secures it and forces the cartridges' ink supply port into close contact with the ink refill base to prevent ink leakage. Pressing down the cartridge release lever

pops the ink cartridge out of the ink refill case.

The ink from the ink cartridges flows through the ink flow channels provided in the ink refill base into the ink supply tubes. As the ink level in an ink cartridge drops, the pressure inside falls, drawing air in the ink cartridge.

The ink cartridge detection sensors

detect ink car tridges inserted wh en the machine powe r is

ON. The ink empty sensors

detect ink remaining in the ink cartridges loaded. An ink empty sensor actuator blocking the light beam to an ink empty sensor indicates that there is ink in the ink cartridge. When ink runs low, the actuator moves out of the beam, activating the sensor ("Ink near-empty") and showing the "Ink low" message.

If any of the ink cartridges is replaced with the one having different ink volume when the machine power is OFF, the corresponding ink cartridge detection sensor and ink empty sensor issue different sig nal s when the power is turned ON next time so that the control ler prompt s th e user to reload the ink cartridge.

At the back of the ink refill case is an ink foam

that absorbs any ink that leaks from the air intake ports of the ink cartridges loaded when the machine is tilted during transportation or in storage, preventing ink spread in the machine.

[ 6 ] Ink supply tubes

These are made of low-density polyethylene (LDPE) providing a highly impermeable barrier against air ingress and drying out of the ink during extended periods of nonuse. This material is also soft and highly flexible to better withstand the sharp and frequent bending associated with high-speed head operation repeatedly over extended periods.

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3.2.2.2 Head maintenance mechanism [ 1 ] Overview

The head maintenance mechanism, which keeps the optimum head performance, consists of the maintenance unit and the ink absorber box. (See the illustration below.)

The maintenance unit has the following mechanisms.

- Head capping mechanism (See page 3-24.)

- Carriage lock mechanism (See page 3-24.)

- Purge mechanism (See p age 3-2 5.)

- Air removing mechanism (See page 3-27.)

- Head wiper mechanism (See page 3-28.)

The ink absorber box absorbs the ink sucked out by purge operations.

(ASF motor)

Maintenance unit

(Head/carriage unit)

(Paper feed motor)

(Flushing box)

(Engine unit)

Ink absorber box

(Ink refill assembly)

(Ink supply tubes)

(3_09_BHL9)

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[ 2 ] Maintenance unit components

(3_10)

Pump switching unit

Purge gear

Cap lift cam

Cap lift cam gear

(ASF changeover gear)

Head wiper

Maintenance unit

- Cap lift cam and its gear These parts transmit the rotational torque of the ASF motor transmitted via the clutch gear L

to the head cap holder. (See [ 4 ] "Power transmission route to the head maintenance

mechanism and motor rota tional direction.")

- Head cap unit When the power is off or the machine is not printing, the head cap unit fits tightly over the

print head to prevent the head nozzles from drying up and to seal the head nozzles for purge operations to suck up old ink.

Air vent cap

Air vent rods

Carriage loc (Part of head cap holder)

Head cap holder

Head cap unit

Viewed from the top Viewed from the b ot t om

Purge cam

Purge bevel gear

(ASF changeover gear)

Cap lift cam gear

Purge gear

Planetary arm

Tube pump

(3_11)

- Head cap holder This lifts up the head cap unit to fit it tightly over the print head to seal the head nozzles. (The

had cap holder is driven by the ASF motor.)

- Carriage lock This is a part of the head cap hol der. It locks the head/carriage uni t in it s home posit ion so that

the head cap unit protects the head nozzles.

- Purge gear and purge bevel gear These gears transmit the rotational torque of the paper feed motor via the clutch gear R to the

planetary arm. (See [ 4 ] "Power transmission route to the head maintenance mechanism and

motor rotational direction.")

-Planetary arm This switches the rotational t orque of the paper feed motor ( t ran smitted via the purge gear a nd

purge bevel gear) to the pump switching unit or tube pump depending on the direction of paper feed motor rotation .

-Purge cam This rotating cam drives the pump switching unit, the air vent rods, and the head wiper. Each

drive position of the purge cam is detected by the purge cam switch. (See Section 3.2.3.)

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- Pump switching unit This switches the application target of the negative pressure generated by the tube pump

between the head cap for black ink, the one for color ink, and the air vent cap. Usually the pump switching un it is switc hed to the openin g tube to the at mospheri c air so that the pr es sure in the head caps and air vent cap is equal to the normal atmospheric pressure.

- Air vent cap and rods The air vent cap and rods remove air bubbles trapped in the damper assemblies in the back

end of the head/carriage unit. During air venting with the tube pump, the air vent cap fits tightly over the ai r vent uni t in the

head/carriage unit so that the negative pressure applies to the air vent unit. Pushing up the air vent rods opens the shut-off valves inside the air vent unit, removing air bubbles trapped in the damper assemblies. (For the air vent unit, see Section 3.2.2.1, [ 3 ].)

- Head wiper As the head/carriage unit moves, this wipes off any ink remaining on the head nozzle surface.

- Tube pump A roller squeezes the main drain tube looped inside, forcing their contents toward the ink

absorber box and creating negative pressure.

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[ 3 ] Mechanisms constituting the head maintenance mechanism

(1) Head capping mechanism

The ASF motor drives the head capping mechanism. When the power is off or the machine is not printing, this mechanism fits the head cap unit (which contains two head caps) tightly over the print head to prevent the head nozzles from drying up and to keep dust off the head nozzle surface.

The head cap unit is mounted on the head cap holder and supported by the spring. When the head/carriage unit returns to its home position, it presses the mode switching lever

(shown on pages 3-30 and 3-31) to the ri ght s o that the cl utch gear L enga ges wi th the cap l ift cam gear (p urge mod e). D rivi ng the A SF m oto r ro tates the cap lift cam so th at the c ap l ift ar m raises the head cap holder, fitting it tightly over the head nozzle surface.

Purge gear

Cap lift cam

Cap lift cam gear

ASF changeover gear

Cap lift arm

Head cap unit

Head ca

Carriage lock (Part of head cap holder)

holder

(3_12)

(2) Carriage lock mechanism

This mechanism locks the head/carriage unit to prevent the head nozzles fro m gett ing out of the head cap unit accidentally due to external vibration or impact when the machine is not printing, when the power is off, or during transport.

A part of the head cap holder acts as a carriage lock. When the head cap holder rises in head capping operation, the carriage lock also comes up to lock the head/carriage unit.

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(3) Purge mechanism

The paper feed motor drives the purge mechanism. The counterclockwise rotation of the paper feed motor drives the purge cam that aligns the

pump switching unit with either the black or color ink drain position. Next, the paper feed motor reverses to activate the tube pump, producing negative pressure to

drain the air and old ink from the head nozzles and channels into the ink absorber box.

Purge cam

Pump switching unit

Main drain tube

Purge bevel gear

ASF changeover gear

Cap lift cam gear

Main drain tube

Planetary arm

Tube pump

Color drain tube

Black drain tube

Main drain tube

Air vent tube

(3_14)

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(3.1) Switching pump

)

The pump switching unit switches the application target of the negative pressure generated by the pump between the head cap for black ink, the one for color ink, and the air vent cap.

When the purge cam is in a head capping position and the head cap unit fits tightly over the print head, the pump switching unit is switched to the opening tube to the atmospheric air so that the pressure in the head caps and air vent cap returns to the normal atmospheric pressure.

Print head

Head cap for black ink

Head cap for color ink

Black drain tube

To air vent cap

Main drain tube

Color drain tube

Pump switching unit

(Purge_3_2_E)

To opening to atmospheric air

(3.2) Drainin g ink

The tube pump consist s of a pump gear and tube roll er. As the pump gear rotates, the tube roller on its circumference squeezes the main drain tube looped around the pump gear, forcing its content toward the ink absorber box and creating negative pressure.

Main drain tube

Pump gear

Tube pump

Tube roller

(TubePump

For details about the power transmission route to the head maintenance mechanism, see [ 4 ] below.

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(4) Air removing mechanism

Other two positions of th e pur ge cam shift two slide cams--one for bl ack i nk, t he o the r f or color inks, producing vertical motion of a single air vent rod for black ink and three air vent rods for color ink, respectively.

Pushing up the air vent rods opens the shut-off valves inside the air vent unit of the head/ carriage unit. Simu lt ane ousl y adding negative pressu re fr om the tube pump removes air trapped in the damper assemblies.

Maintenance unit

Purge gear

Air vent rod for black ink

(Cap lift cam gear)

(ASF changeover gear)

Air vent rods for color in

Air vent cap

Slide cam for black ink

Slide cam for color ink

Damper ASSY (Magenta)

Air bubbles

Left chamber

Damper ASSY (Cyan)

Air bubbles

Left chamber

Damper ASSY (Y ellow)

Air bubbles

Left chamber

Pur

e cam

(3_16)

Right chamber

Shut-off valves

Air vent unit

Damper ASSY (Black)

Air bubbles

Left chamber

Right chamber

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(Air vent rods)

(A part of maintenance unit)

(Air vent cap)

(BackEnd_E)

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(5) Head wiper mechanism

(3_15)

After the purge operation, the purge cam pushes up the head wiper, wiping off any ink remaining on the head nozzle surface as the head/carriage unit moves from right to left.

Purge gear

(Cap lift cam gear)

(ASF changeover gear)

Head wiper

Purge cam

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[ 4 ] Power transmission route to the head maintenance mechanism and motor rotational

direction

This mecha nism draws it s power from two motors-- the ASF motor (DC motor) in the right rear corner of the engine chassis and the paper feed motor (DC motor) on the left side. The ASF motor is mounted in the ASF motor holder combined with the maintenance unit.

ASF motor

→ Maintenance unit (head capping and carriage lock mechanisms)

As shown on the next page, th e ro tational torque of the ASF motor is a lwa ys t ran smitted via the ASF/maintenance drive gear and idle gear 16 to the clutch gear L.

When the mode switching lever is in the left position (ASF mode), the clutch gear L also meshes with the ASF changeover gear.

When the head/carriage unit moves to the right end of its travel, a tab on the carriage rear panel pushes the mode switching lever to the right (purge mode). The clutch gear spring pushes the clutch gear L to the right, away from the ASF changeover gear, to mesh with the cap lift cam gear. This way, the ASF motor drives the head capping and carriage lock mechanisms. (See

page 3-31 for the related components.)

Paper feed motor

→ Maintenance unit (purge, air removing and head wiper mechani sms)

As shown on the next page, the paper feed motor drives the PF roller gear L that rotates the paper feed ro ller. At the right end o f the roller is the PF ro ller gear R that alwa ys meshes w ith the clutch gear R.

When the mode switching lever is in the left position (ASF mode), the clutch gear R does not mesh with the purge gear but it is just idling.

As the paper feed motor ro tates coun tercl ockwis e, the pl anetar y arm meshes wit h the pur ge cam (as shown below), driving the purge mechanism (pump switching unit), air removing mechanism and head wiper mechanism. On the contrary, the clockwise motor rotation causes the planetary arm to mesh with the tube pump gear, driving the purge mechanism (tube pump). (See page 3-31 for the related components.)

Cap lift cam switch

Tube pump

ASF changeover gear

Cap lift cam gear

Planetary arm

3-29

Purge cam

Black drain tube

Main drain tube

Air vent tube

Pump switching unit

Color drain tube

Purge cam switch

(3_20)

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Clutch gear R (Always engaged with PF roller gear R)

Clutch gear L

ASF/maintenance drive gear

Idle gear 16

ASF motor

Mode switching lever

PF roller gear R

(ASF changeover gear)

Paper feed roller

Purge gear

Purge bevel gear

Planet gear

ASF motor holder ASSY

PF roller gear

Cap lift cam gear

Paper feed roller

Maintenance unit

(Front)

PF roller gear L

Paper feed motor

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(3_17_BHL9)

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ASF motor holder ASSY

Clutch gear spring

Clutch gear L

Clutch gear R

ASF changeover gear

Cap lift cam gear

Cap lift cam

Purge gear

Head wiper

Mode switching lever

Purge cam

Head cap holder

Switching lever spring

Air vent cap

Air vent rods

Maintenance unit

Carriage lock (part of head cap holder)

Head cap unit

(3_19)

ASF/maintenance drive gear

ASF motor holder ASSY

Cap lift cam

Purge gear

Purge bevel gear

Tube pump

Planet gear

ASF motor gear

Planetary arm

Idle gear 16

Clutch gears (L & R)

ASF changeover gear

Pump switching unit

Cap lift cam gear

Maintenance unit

Purge cam

(3_18)

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[ 5 ] Purge types, ink usage, purge counts, and purge codes

Refer to the table given on page 9-48.

[ 6 ] Ink cartridge capacities

Ink Cartridge Type Contents Usable Portion*

Starter and bund led cartridges

Black ink cartridge

High-yield type

Color ink cartridges 10.1 0 ml Approx. 8.59 ml

23.05 ml Approx. 21.11 ml

High-yield type 23.05 ml Approx. 21.11 ml

Black ink cartridge

Standard type 12.40 ml Approx. 10.59 ml

Spare ink cartridges

High-yield type 10.10 ml Approx. 8.59 ml

Color ink cartridges

Standard type 8.25 ml Approx. 6.55 ml

These are the values measured with an actual machine, not the guaranteed ones.

Note: The contents and usable portion of ink cartridges are subject to change without notice. Note: Values given in the above tables are as of August 2008.

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3.2.2.3 Carriage drive mechanism

The head/carriage unit, which integrates the print head unit and carriage, is supported and guided by the CR guide rail and CR support chassis. The CR timing belt transmits the carriage motor rotation to the head/carriage unit. Clockwise motor rotations move the head/carriage unit to the right; counterclockwise ones to the left.

The CR encoder sensor on the top of the head/carriage unit scans the CR encoder strip above the CR support chassis to monitor the current head position relative to the home position. The controller uses this signal for robust control ensuring uniform speed.

The CR encoder strip is a clear film striped in a 1/150 inch cycle. It offers a choice of three travel speeds of the head/carriage unit, 57.7, 43.3 and 21.7 ips, to match the print resolution.

(Paper feed roller)

CR encoder strip

Head/carriage unit

CR guide rail

CR encoder sensor

Idle pulley

Carriage moto pulley

Carriage motor

CR timing belt

CR support chassis

(3_21_BHL9)

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Adjusting the print head angle relative to carriage

For optimal image printing, the print head nozzle array must be perpendicular to the head/ carriage unit's line of travel. Manufacturing limitations, however, make perfect alignment impossible during mas s pr oduc ti on. The angle must be adjus te d at the ind ivi dual machine level.

The following describes this adjustment mechanism's components and their roles. Slider L, the slider, and the rib attach the head/carriage unit to the CR support chassis. The rib

acts as a pivot for the slider's damping springs pressing the head/carriage unit to the rear. Slider L has a head skew adjuster knob that shifts the slider back and forth, adjusting the angle of this backward pressure . Rot at ing th e head skew adjuster kn ob t ilts the entire head/carriage unit, thu s adjusting the head nozzle vertical angle relative to the carriage unit's line of travel.

This knob offers 11 settings, from -5 to +5. For the adjustment procedure, refer to Chapter 7, Section 7.2, [ 4 ].

Viewed from the bottom

Damping springs

CR encoder strip

CR timing belt

Rib

(Front)

Head skew adjuster knob

Slider L

Slider

(3_22)

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Height adjustment of the head/carriage unit

For optimal image pri nt ing, a pa ir of s lider ca ms mount ed on the head/c arri age unit s witches the height of the head/carriage unit against the CR guide rail and support chassis between two levels--2.3 mm (for thick paper and envelops) and 1.6 mm (for other types of paper) in order to bring the optimum distance between the head nozzle surface and paper.

The slider cams can be switched by hitting against the stoppers at the right and left ends of the CR guide rail and CR support chassis.

Head/carriage unit

Slider cam

CR guide rail

Slider ca

CR support chassis

(3_23_BHL9)

For "thick paper and envelopes" and "other types of paper":

The machine adjusts the distance from the platen to the head/carriage unit to 2.3 mm for "thick paper and envelopes" and 1.6 mm for "other types of paper" in order to keep the distance ("a") constant.

For "thick paper and envelopes"

Head nozzle surface

"a"

Paper

Platen

(3_23_1b)

(Paper other than thick paper and envelopes)

For "other types of paper"

Head nozzle surface

"a"

Paper

Platen

(3_23_1a)

(3_24_2)

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(3_24_1)

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As listed below, the printer driver on the connected PC or the paper type setting on the machine controls the slider cams to determine the height of the head/carriage unit.

Controlled by:

Adjustment for:

Thick paper and envelopes Other types of paper Printer driver (in printing from the PC) Yes Yes Paper type setting (in copying and

printing via PhotoCapture Center)

No Yes

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3.2.2.4 Paper pull ing-in, registration, feeding and ejecting mechanisms

These mechanisms are driven via a gear train by two motors--paper feed motor located on the left side of the engine chass is and AS F motor in the r ight rea r corne r. (See the illust rati on on the next page.)

The following illustration is a cross-sectional view of the machine viewed from the right. Place the recording paper face down in the paper tray. This paper first proceeds to the rear, bends upward, heads back toward the front, passes under the head/carriage unit for printing, and finally comes out onto the top of the paper tray cover.

The machine supports two paper feed modes--"normal SF mode" and "high-speed feed mode." Depending upon the selected print quality, either of these two modes applies as listed below.

Print Quality Fast, Normal Other quality Paper Feed Mode High-speed feed mode Normal SF mode

Recording paper path

Paper ejection roller

(Front) (Rear)

Paper tray

Recording paper path

Paper pull-in gear shaft

Platen

Head/carriage unit

ASF idle gears 17

PF roller gear R

Clutch gears (R and L)

ASF/maintenance drive gear

ASF changeove gear

Jam clear cover

Paper pull-in rollers

Paper pull-in roller holder

(3_02_1_BHL9_A3)

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Power transmission routes of the ASF motor and paper feed motor

The rotational torque of the ASF mo tor is transmitted to the ASF/maintenance drive gear which always meshes with the clutch gear L, as described in Section 3.2.2.2, [ 4 ].

When the mode switching lever is in the left position (normal SF or high-speed feed mode), the clutch gear L also meshes with the ASF changeover gear which transmits the ASF motor rotation via a gear train to the paper pull-in rollers.

The rotational torqu e of th e paper feed motor

is transmitted via the PF roller gear L to the paper

feed roller that advances paper to the printing start position.

Mode switching lever

Left position (ASF mode)

ASF motor

Clutch gear R

ASF/maintenance drive gear

Idle gear 16

Clutch gear L

ASF changeover gear

ASF idle gears 17

Right position (Purge mode)

Purge gear

Mode switching lever

Head/carriage uni

Paper pull-in gear shaft

Paper feed motor

PF roller gear L

PF motor gear

Ejection idle gear

PF timing belt

Paper feed roller

Paper pull-in rollers

Paper ejection roller

Paper pull-in gear shaft

ASF idle gears 17

(Front)

(3_25_BHL9_A3)

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Normal SF and high-speed feed mode Normal SF mode

1st stage

2nd stage

3rd stage

The ASF moto r rotates clockwise (when viewed from the output gear side) and its rotational torque is transmitted to the ASF/maintenance drive gear that is always connected v ia th e idle gea r 16 to the clut ch ge ar L . When the mode swit chi ng lev er is placed in the left po sition, t he clut ch gear L also meshe s with t he ASF change over gear.

The rotational torque is further transmitted from the ASF changeover gear via the two ASF idle gears 17, p aper pul l-in gear sha ft and the gear tr ain in the pape r pull -in roller holder. Consequently, the paper pull-in rollers turn in the forward direction to pull in a sheet of paper loaded in the paper tray.

After the pulled-in paper pushes the registration sensor actuator to turn the sensor on, the ASF moto r further rotates clockwise for the predetermined period to align (register) the leading edge of the paper with the paper feed roller. (Registration)

The ASF motor stops and the paper feed motor s ta rt s r ot at ing clockwise to r otate the PF roller gear L that ro ta tes the paper feed roller in the forward direction to advance the paper to the printing start position.

The rotational torque of the PF roller gear L is also transmitted via the ejection idle gear and PF timing belt to the paper ejection roller that rotates in the forward direction to eject the paper printed.

High-speed feed mode

1st stage

Just as in the normal SF mode, the clockwise rotation of the ASF m otor pulls i n a sheet of paper loaded in the paper tray.

The difference from the normal SF mode is that the paper feed motor also rotates

clockwise at the same time as th e ASF motor. The paper feed roller rotates in t he forward direction.

2nd stage

When the paper fed by the paper pull-in rollers reaches the paper feed roller, the roller is already rotating in the forward direction; therefore, the paper continues to advance to the printing start position.

Registration sensor activation has no effect on the paper feeding operation in the high-speed feed mode.

Even during printing of the first sheet of paper, the ASF motor keeps rotating clockwise to rotate the paper pull-in rollers in the forward direction. Immediately after the first sheet leaves the paper tray, the paper pull-in rollers continuously pull in paper sheet by sheet. After the last sheet of paper advances to the printing start position, the ASF motor stops.

The paper feed roller always rotates faster than the paper pull-in rollers; therefore, the trailing edge of the preceding sheet will not overlap with the leading edge of the subsequent one

Just as in the normal SF mode, the ro tational to rque of the P F roller ge ar L is also transmitted via the ejection idle gear and PF timing belt to the paper ejection roller that rotates in the forward direction to eject the paper printed.

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Other controls

Paper feed position and speed control

A PF encoder disk with the resolution of 300 dpi (0.084 mm pitch) is mounted on the PF roller gear L. The PF encoder sensor uses it to generate a signal indicating the gear rotation speed--in other words, the paper feed roller speed--to the controller for use in controlling paper feed position and speed.

Paper stop position control

The controller uses the PF encoder signal for proportional, integration, differential (PID) control of the paper feed motor to produce high-resolution precision paper positioning during printing. This signal also determines the motor parameters for rapidly and precisely positioning the paper.

Fixed-speed paper feed

This operation rotates the paper feed roller to feed the paper at a constant speed regardless of load fluctuations. The primary application is ejecting paper when printing is complete--in other words, in situations where precision stop position control is not needed.

Paper feeding amount control

There is variation in the head nozzle pitch of individual head/carriage units, as well as in the shape of the paper feed and ejection rollers. To make those parts match each other, therefore, updating the paper feeding correction value (Function code 58) is necessary (see Chapter 9,

Section 9.4.16).

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3.2.3 Sensors and Actuators

This machine uses the following sensors and thermistors.

Sensor Name Document front sensor Photosensor Document rear sensor Photosensor Scanner cover sensor Carbon switch Ink cartridge cover sensor Carbon switch Registration sensor Photosensor On th e registration sensor PCB Paper width sensor (media sensor) Photosensor

CR encoder sensor Photosensor PF encoder sensor Photosensor On the PF encoder PCB ASF encoder sensor Photosensor In the ASF motor unit Purge cam switch Mechanical switch Cap lift cam switch Mechanical switch Casing internal temperature thermistor Thermistor Ink empty sensors (four) Photosensor

Ink cartridge detection sensors (four) Photosensor

Sensor Type

On the document sensor PCB in the ADF unit

On the control panel PCB

On the carriage PCBHead thermistor Thermistor

On the maintenance unit

On the ink emp ty sensor PCB inside the ink refill assembly

On the ink cartridge detection sensor PCB on the ink refill assembly

Location

• The document front sensor detects whether there is a document in the ADF.

• The document r ear sens or detect s the leadi ng and trai ling e dges of documen t pages , i ndicati ng to the control circuitry the point at which to start reading and when page scanning is complete.

• The scanner cover sensor detects whether the scanner cover (scanner unit) is properly closed.

• The ink cartridge cover sensor detects whether the ink cartridge cover is properly closed.

• The registration sensor detects the leading and trailing edges of paper for use in determining print start and end timings and detecting paper jams.

• The paper width (media) sensor checks whether recording paper is A4 or greater in width at the start of recording of FAX data received. With this sensor signal, the controller prevents the print head from printing on the outside of paper in borderless printing. It also protects the platen from no-paper printing when a paper jam occurs, preventing stains on the platen and the back side of paper.

• The head thermistor detects the temperature inside the head/carriage unit. According to the sensor information, the controller adjusts the head driver to compensate for changes in ink viscosity.

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• The carriage motor (CR) encoder sensor monitors the current position and speed of the head/

carriage un it. If the co ntroller det ects a head' s travel spee d error, it interprets the error state as a paper jam or any foreign material getting into the carriage travel path and stops the operation.

• The paper feed motor (PF) encoder sensor monitors the PF roller rotation angle and speed for use in optimizing paper feed amount and speed.

• The Auto Sheet Feeder motor (ASF) encoder sensor monitors the rotation angle and speed of the ASF motor shaft for use in optimizing paper pull-in amount and speed.

• The purge cam switch detects the drive positions of the purge cam.

• The cap lift cam switch detects the drive positions of the cap lift cam.

• The casing internal temperature thermistor monitors the temperature inside the machine. With this thermist or signa l, the contro ller dete rmines the periodic al autom atic purge inte rval since the casing internal temperature is almost equal to the ambient temperature of ink inside the ink cartridges.

• There are four ink empty sensors, one for each color. The sensor actuator inside the ink cartridge usually blocks the light path to indicate the presence of ink. When ink runs low (near-empty state), the arm moves out of the beam, activating the sensor. The "Ink low" message appears.

• There are four ink cartridge detection sensors, one for each color. The sensor detects whether an ink cartridge is loaded.

The ON timing of the ink cartridge detection sensor and ink empty sensor enables the controller to discriminate between a standard and high-yield ink cartridges.

Most sensors are photointerrupters consisting of a light-emitting diode and a light-sensitive transistor as shown below. The only exception is the paper width sensor, which uses reflective type. The illustration on the next page gives the sensor and actuator locations.

Actuator's en

Light-emitting diode

Light-sensitive transistor

The scanner cover sensor and the ink cartridge cover sensor use a carbon switch that consists of a carbon on the rubber keypad and a carbon contact printed on the control panel PCB. Opening the scanner cover or the ink cartridge cover releases the corresponding sensor actuator so that the actuator is pressed against the rubber keypad by the spring force. Accordingly, the carbon on the rubber keypad comes into contac t with the carbon contact on the control pan el PCB. The conduction results in a voltage level change of the IC port, signaling the cover open.

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Document front sensor actuator

Document front sensor Document rear sensor

Document rear sensor actuator

ADF & document cover ASSY

(3_26_BHL9)

Document sensor PCB

(Carriage PCB on which the head thermistor is also mounted)

Registration sensor

(Registration sensor PCB)

PF encoder sensor

(PF encoder PCB)

PF encoder disk

Registration sensor actuator

CR encoder sensor

Paper width sensor

CR encoder strip

Cap lift cam switch

(ASF encoder sensor PCB)

(Ink empty sensor PCB on which the casing internal temperature thermistor is also mounted)

(Head/carriage unit)

ASF encoder sensor

ASF encoder disk

(Maintenance unit)

Purge cam switch

Scanner cover sensor actuator

(Control Panel PCB)

Ink cartridge cover sensor actuator

(Ink cartridge detection sensor PCB)

Ink cartridge detection sensors

Ink empty sensors

(3_27_BHL9_A3)

Sensors and Actuators Locations

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3.3 CONTROL ELECTRONICS

3.3.1 Components

The following illustra tion sh ows the har dware compon ents. The c orresp onding wiri ng diagra ms appear in Appendix 5.

WLAN*

WLAN PCB

5 wires used in 6-wire connector housing

Main ASIC

12MB

EEPROM

MODEMROM

LAN

LAN I/F

SDRAM

64MB

USB

Backup battery

5-wire

SDAA

DC motor driver

Speaker

2-wire

5-wire

2-wire

5-wire

28-wire

11-wire (Head 3)

13-wire (Head 1)

12-wire (Head 2)

2-wire

7-wire

9-wire

Power supply PCB

MJ PCB

Control panel PCB

Color LCD

INK JET PRINTING & PAPER FEEDING

Carriage PCB

CR encoder sensor Paper width sensor Head thermistor

Ink refill ASSY

Ink cartridge detection sensor PCB

Ink cartridge detection sensors

Ink empty sensor PCB

Ink empty sensors

Casing internal temperature thermistor

Line External telephone

Carriage motor

Scanner cover sensor

Ink cartridge cover sensor

AC line

Head/ carriage unit

PictBridge

Media 1 (xD/SD/MS card)

USB

- Digital camera

- USB flash memory drive

Main PCB

Stepping motor driver

Media 2 (CF card)

DC motor driver

2-wire 2-wire

4-wire 2-wire

7-wire

2-wire

12-wire

4-wire

5-wire

4-wire

Maintenance unit

Purge cam switch

ASF motor unit

ASF encoder sensor

PF encoder PCB

4-wire

PF encoder sensor

Registration sensor PCB

Registration sensor

3-wire

Paper feed motor

SCANNING

CIS unit

CIS motor

ADF unit

Document sensor PCB

Document front sensor Document rear sensor

ADF motor

Cap lift cam switch

ASF motor

(BlockDiagram_BHL9_A3)

* For wireless LAN-enabled model.

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CHAPTER 4

ERROR INDICATION AND

TROUBLESHOOTING

Confidential

CHAPTER 4 ERROR INDICATION AND TROUBLESHOOTING

This chapter details error messages and codes that the incorporated self-diagnostic functions display if any error or malfunction occurs. If any error message appears, refer to this chapter to find which components 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. This will help service personnel pinpoint and repair defective components.

CONTENTS

4.1 ERROR INDICATION.............................................................................................4-1

4.1.1 Equipment Errors ............................................... ....... ...... ....... ...... ....... ......4-1

[ 1 ] Error messages appearing on the LCD.............................................4-2

[ 2 ] Error codes contained in "MACHINE ERROR X X" messages.........4-7

4.1.2 Communications Errors............. ...... ....... ...... ...... ....... ...... ....... ...... ....... ......4-24

4.2 TROUBLESHOOTING ...........................................................................................4-31

4.2.1 Introduction................................................................................................4-31

4.2.2 Precautions ...............................................................................................4-31

4.2.3 Checking Prior to Troubleshooting............................................................4-31

4.2.4 Troubleshooting Based on Problem Type....................... ....... ...... ....... ......4-33

[ 1 ] Control panel and LCD problems......... ...... ....... ...... ....... ...... .............4-33

[ 2 ] FAX problems....................................................................................4-33

[ 3 ] Communications problems................................ ...... ....... ...... ....... ......4-33

[ 4 ] Paper/document feeding problem s ...... ...... ....... ...... ....... ...... ....... ......4-34

[ 5 ] Print-image problems........................................................................4-35

[ 6 ] PC-driven printing problems..............................................................4-40

[ 7 ] Printing from memory cards--Compact Flash, Memory Stick,

SD Memory Card, xD-Picture Card and USB flash memory drive ....4-41

[ 8 ] Wireless LAN (WLAN)* ........... ....... ...... ...... ....... ...... ....... ...... ....... ......4-41

[ 9 ] Others ...............................................................................................4-41

4.2.5 Problems Encountered Frequently in the Past..........................................4-42

[ 1 ] Paper jams........................................................................................4-42

[ 2 ] Ink-related problems .........................................................................4-43

[ 3 ] Auto document feeder (ADF) malfunction.........................................4-44

4.2.6 Possible Component Defects and Resulting Problems.............................4-45

[ 1 ] ADF mechanism................................................................................4-45

[ 2 ] Scanner mechanism .................................. ....... ...... ....... ...... ....... ......4-46

[ 3 ] Head/carriage unit drive and purge mechanisms..............................4-47

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[ 4 ] Print head mechanism ...................................... ...... ....... ...... ....... ......4-48

[ 5 ] Sheet feeder (SF) mechanism ..........................................................4-49

[ 6 ] Paper feeding mechanism ...................................... ....... ...... ....... ......4-49

[ 7 ] Speaker.............................................................................................4-49

[ 8 ] Control panel.....................................................................................4-50

[ 9 ] PCBs.................................................................................................4-50

[ 10 ] Adjustments/data in the memories....................................................4-51

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4.1 ERROR INDICATION

To help the user or the service personnel promptly locate the cause of a problem (if any), the machine incorporates the self-diagnostic functions which display error messages for equipment errors.

4.1.1 Equipment Errors

If an equipment error occurs, the machine emits an audible alarm (five short beeps twice) and shows the error message on the LCD. For the error messages, see [ 1 ] below.

To display detailed error information, use Function code 82 described in Chapter 9, Section

9.4.28 (that is, make the machine enter the maintenance mode and then press the 8 and 2 keys).

Following the MACHINE ERROR, one of the error codes lis ted in [ 2 ] will appear on the LCD.

4-1

Confidential

[ 1 ] Error messages appearing on the LCD

4-2

Confidential

Brother mfc-5890cn, mfc-5895cw Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

How this manual is organized

SAFETY INFORMATION

CHAPTER 1 PARTS NAMES AND FUNCTIONS

1.1 OUTLINE

1.2 CONTROL PANEL

1.3 COMPONENTS

CHAPTER 2 SPECIFICATIONS

2.1 GENERAL

2.1.1 Media Specifications

2.1.2 Paper Handling

2.1.3 LCD/LED/Panel

2.1.4 Memory

2.1.5 Security

2.1.6 Interface

2.1.7 Others

2.2 TELEPHONE

2.2.1 Volume

2.2.2 Quick/Auto Dials

2.2.3 Tel Service

2.2.4 Message Center

2.2.5 List/Report

2.3 FAX

2.3.1 Sending

2.3.2 Receiving

2.3.3 PC FA X

2.4 PRINTER

2.5 COPY

2.6 SCANNER

2.7 PHOTO CAPTURE

2.7.1 PictBridge

2.8 SOFTWARE

2.9 NETWORK

2.9.1 Wired

2.9.2 Wireless

2.10 SUPPLIES/OPTIONS

2.11 SERVICE INFORMATION

2.12 PAPER

2.12.1 Paper Specifications

2.12.2 Printable Area

Language List

ITU-T Test Chart #1

Brother Chart

CHAPTER 3 THEORY OF OPERATION

3.1 OVERVIEW

3.2 MECHANICAL COMPONENTS

3.2.1 Scanner Mechanism

3.2.2 Printing Mechanism

3.2.2.1 Ink supply and ink jet mec hanism [ 1 ] Overview

[ 2 ] Features

[ 3 ] Head/carriage unit

[ 4 ] Ink cartridges

[ 5 ] Ink refill assembly

[ 6 ] Ink supply tubes

3.2.2.2 Head maintenance mechanism [ 1 ] Overview

[ 2 ] Maintenance unit components

[ 3 ] Mechanisms constituting the head maintenance mechanism

[ 5 ] Purge types, ink usage, purge counts, and purge codes

3.2.2.3 Carriage drive mechanism

3.2.2.4 Paper pull ing-in, registration, feeding and ejecting mechanisms

3.2.3 Sensors and Actuators

3.3 CONTROL ELECTRONICS

3.3.1 Components

CHAPTER 4 ERROR INDICATION AND TROUBLESHOOTING

4.1 ERROR INDICATION

4.1.1 Equipment Errors

[ 1 ] Error messages appearing on the LCD