Minolta PP9100 Service Manual

PagePro™9100 Series

.minolta-qms.com

1750053-001A

Service Manual

The essentials of imaging

www.minolta-qms.com

Trademarks

The following are registered trademarks of MINOLTA-QMS, Inc.: QMS and the MINOLTA-QMS logo. Minolta, and PagePro are trademarks of Minolta Co., Ltd. Other product names mentioned in this guide may also be trademarks or registered trademarks of their respective owners.

Proprietary Statement

The digitally encoded software included with your printer is Copyrighted © 2002 by MINOLTA-QMS, Inc. All Rights Reserved. This software may not be reproduced, modified, displayed, transferred, or copied in any form or in any manner or on any media, in whole or in part, without the express written permission of MINOLTA-QMS, Inc.

This manual is Copyrighted © 2002 by MINOLTA-QMS, Inc., One Magnum Pass, Mobile, AL 36618. All Rights Reserved. This document may not be copied, in whole or part, nor transferred to any other media or language, without written permission of MINOLTA-QMS, Inc.

Manual Notice

MINOLTA-QMS, Inc. reserves the right to make changes to this manual and to the equipment described herein without notice. Considerable effort has been made to ensure that this manual is free of inaccuracies and omissions. However, MINOLTA-QMS, Inc. makes no warranty of any kind including, but not limited to, any implied warranties of merchantability and fitness for a particular purpose with regard to this manual. MINOLTA-QMS, Inc. assumes no responsibility for, or liability for, errors contained in this manual or for incidental, special, or consequential damages arising out of the furnishing of this manual, or the use of this manual in operating the equipment, or in connection with the performance of the equipment when so operated.

1. Safety Precautions for Inspection and Service ............................................................. 1

1-1. Outlines of safety precautions ............................................................................. 1

1-2. Warning ............................................................................................................... 1

1-3. Caution ................................................................................................................ 4

1-4. Other precautions ................................................................................................. 6

1-5. Precautions for service ........................................................................................ 8

1-6. Safety information ............................................................................................... 11

(1) Laser Safety ................................................................................................ 11

(2) Internal Laser Radiation ............................................................................. 11

1-7. Laser safety label ................................................................................................. 14

1-8. Laser caution label ............................................................................................... 14

1-9. Precautions for handling the equipment .............................................................. 14

2. INSTALLATION ......................................................................................................... 15

2-1. Installation environment ...................................................................................... 15

2-2. Usage environment .............................................................................................. 16

2-3. Installing the power supply ................................................................................. 16

2-4. Space requirements .............................................................................................. 17

(1) Standard ...................................................................................................... 17

(2) With options installed ................................................................................. 17

3. GENERAL INFORMATION ..................................................................................... 19

3-1. Specifications ...................................................................................................... 19

(1) Printer ....................................................................................................... 19

(2) 500-sheet lower feed unit (optional) ........................................................... 22

(3) Duplex unit (optional) ................................................................................ 23

(4) 4-bin mailbox (optional) ............................................................................. 23

3-2. Parts identification ............................................................................................... 24

3-3. Component diagram ............................................................................................ 26

3-4. Drive system ........................................................................................................ 27

(1) Overview of the drive system for the standard configuration .................... 27

(2) Diagram of the drive system for the standard configuration ...................... 28

(3) Overview of the drive system when options are installed .......................... 29

3-5. Electrical components layout .............................................................................. 30

(1) Printer ....................................................................................................... 30

(2) Lower feed unit (optional) .......................................................................... 32

(3) Duplex unit (optional) ................................................................................ 32

(4) 4-bin mailbox (optional) ............................................................................. 33

3-6. Electrical components functions .......................................................................... 34

(1) Printer ....................................................................................................... 34

(2) Lower feed unit (optional) .......................................................................... 35

(3) Duplex unit (optional) ................................................................................ 36

(4) 4-bin mailbox (optional) ............................................................................. 36

(5) PWB-A (main control board) ..................................................................... 37

(6) PWB-D (new-imaging-cartridge detection board) ..................................... 38

(7) PU1 (power supply board ) ......................................................................... 38

(8) HV1 (high voltage unit ) ............................................................................. 39

(9) PWB-G (toner-empty detection board) ......................................................40

(10) PWB-H (paper full detection board) .......................................................... 40

(11) PWB-O (control panel board) ..................................................................... 40

(12) PWB-A (control board of the lower feed unit) ........................................... 41

(13) PWB-A (DUP) (control board of the duplex unit) ..................................... 41

(14) PWB-A (control board of the 4-bin mailbox) ............................................ 42

3-7. Video interface .................................................................................................... 43

(1) Overview .................................................................................................... 43

(2) Signal descriptions ...................................................................................... 44

3-8. Timing chart ........................................................................................................ 45

(1) Pre-process sequence .................................................................................. 45

(2) Print (print interval) sequence .................................................................... 46

(3) Post-process sequence ................................................................................ 46

4. MECHANICAL/ELECTRICAL ..................................................................................47

4-1. Paper path ............................................................................................................ 47

(1) Standard configuration ............................................................................... 47

(2) With options installed ................................................................................. 49

4-2. Paper take-up section ........................................................................................... 50

(1) Multipurpose paper tray: paper take-up mechanisms & process ................ 50

(2) Multipurpose paper tray: paper feed retry control ...................................... 52

(3) Multipurpose paper tray: paper empty detection mechanism ..................... 53

(4) Multipurpose paper tray: paper near-empty detection mechanism ............ 54

(5) Universal paper cassette (first through fourth paper cassettes):

paper take-up mechanism ........................................................................... 55

(6) Universal paper cassette (first paper cassette): paper feed retry control .... 55

(7) Lower feed unit (second through fourth paper cassettes): paper feed

retry control ................................................................................................ 56

(8) Universal paper cassette (first paper cassette): paper empty

detection mechanism .................................................................................. 57

(9) Universal paper cassette (second through fourth paper cassettes):

paper empty detection mechanism ............................................................. 58

(10) Universal paper cassette (first through fourth paper cassettes): paper

near-empty detection mechanism ............................................................... 59

(11) Universal paper cassette: paper size detection mechanism ........................ 60

4-3. Imaging cartridge ................................................................................................. 61

(1) Overview .................................................................................................... 61

(2) Toner empty detection ................................................................................ 63

4-4. Drum charging ..................................................................................................... 65

4-5. Laser exposure ..................................................................................................... 66

4-6. Development ........................................................................................................ 67

4-7. Image transfer ...................................................................................................... 68

4-8. Fusing section ...................................................................................................... 69

(1) Fusing temperature control circuit .............................................................. 70

(2) Heater lamp control .................................................................................... 70

(3) Overview of temperature control modes during stand-by .......................... 71

(4) Temperature control mode during stand-by: mode 1 ................................. 71

(5) Temperature control mode during stand-by: mode 2 ................................. 71

(6) Temperature control mode during stand-by: mode 3 ................................. 71

(7) Temperature control modes during printing ............................................... 72

(8) Temperature control: software protection .................................................. 73

(9) Temperature control: hardware protection ................................................. 73

(10) Temperature control: overheat protection .................................................. 73

4-9. Paper exit section ................................................................................................. 74

(1) Paper-full detection mechanism ................................................................. 75

(2) Paper output roller drive-switching mechanism ......................................... 76

(3) Paper-output-swiching mechanism ............................................................ 77

4-10. Duplex section (optional duplex unit) ................................................................. 78

(1) Overview .................................................................................................... 78

(2) Single-sided printing mechanism ............................................................... 79

(3) Double-sided printing mechanism .............................................................. 80

4-11. Sorting section (optional 4-bin mailbox) ............................................................. 81

(1) Drive mechanism ........................................................................................ 81

(2) Paper-switching mechanism ....................................................................... 82

(3) Bin-switching mechanism .......................................................................... 83

(4) Fed paper detection mechanism ................................................................. 84

(5) Full mailbin detection mechanism .............................................................. 84

5. MAINTENANCE/DISASSEMBLY ............................................................................ 85

5-1. Precautions for maintenance/disassembly ........................................................... 85

(1) Precautions for disassembly ...................................................................... 85

(2) Parts that must not be touched .................................................................... 85

(3) During transportation/storage the PWBs with MOS ICs: .......................... 85

(4) During replacement the PWBs with MOS ICs: .......................................... 85

(5) During Inspection the PWBs with MOS ICs: ............................................. 86

(6) During transportation/storage the imaging cartridge: ................................. 86

(7) Handling the imaging cartridge: ................................................................. 86

5-2. Cleaning schedule ................................................................................................ 87

5-3. Maintenance schedule ......................................................................................... 87

5-4. Required service tools ......................................................................................... 87

5-5. List of screws used .............................................................................................. 88

5-6. Printer disassembly procedures ........................................................................... 89

(1) Disassembly procedure chart ...................................................................... 89

(2) Pre-disassembly preparation 1 (removing the imaging cartridge) ............. 90

(3) Pre-disassembly preparation 2 (removing the multi-purpose paper tray) .. 91

(4) Pre-disassembly preparation 3 (removing the first paper cassette) ............ 92

(5) Pre-disassembly preparation 4 (removing the paper-full

detection board) ..........................................................................................93

(6) Pre-disassembly preparation 5 (removing the fusing unit) ......................... 94

(7) Replacing the exhaust filter ........................................................................ 96

iii

(8) Replacing the paper take-up roller of the multi-purpose paper tray ........... 97

(9) Replacing the toner empty detection board (PWB-G) ................................ 98

(10) Replacing the paper empty sensor (PC4) and the paper near-empty

sensor (PC5) for the multi-purpose paper tray ........................................... 99

(11) Replacing the paper take-up solenoid (SL1) of the multi-purpose tray ..... 101

(12) Replacing the paper empty sensor (PC6) for the first paper cassette ......... 102

(13) Replacing the paper take-up rollers and the paper-separating roller

for the first paper cassette and the expansion paper cassettes .................... 103

(14) Replacing the heater (H1), thermostat (TS1), thermal fuse (TF1),

thermistor 1 (TH1), and heat roller ............................................................. 107

(15) Replacing the paper output sensor (PC3) of the fusing section .................. 115

(16) Replacing the image transfer roller unit ..................................................... 116

(17) Replacing the new-imaging-cartridge detection board (PWB-D) .............. 117

(18) Removing the outer covers .........................................................................118

(19) Replacing the control panel ........................................................................ 120

(20) Removing the shield ................................................................................... 121

(21) Replacing thermistor 2 (TH2) ..................................................................... 122

(22) Replacing the humidity sensor (HS1) ......................................................... 122

(23) Replacing the power supply unit fan motor ................................................ 123

(24) Replacing interlock switch 1 (S2) .............................................................. 124

(25) Replacing the main control board (PWB-A) .............................................. 125

(26) Replacing the print head unit ...................................................................... 127

(27) Replacing the ozone fan motor (M6) .......................................................... 128

(28) Replacing the power supply board (PU1) ................................................... 129

(29) Replacing the high voltage unit (HV1) ....................................................... 130

(30) Replacing the power switch (S1) ................................................................ 131

(31) Replacing interlock switch 2 (S3) .............................................................. 132

(32) Replacing the main motor (M1) and imaging cartridge drive motor (M2) 133 (33) Replacing the paper size detection switch (S4), the paper empty sensor

(PC6), and the paper take-up clutch (CL2) for the first paper cassette ...... 134

(34) Replacing the fusing fan motor (M3) ......................................................... 136

(35) Replacing the transport roller clutch (CL1) and the paper sensor (PC1)

of the image transfer section ....................................................................... 137

5-7. Duplex unit disassembly procedures ................................................................... 139

(1) Replacing the transport motor (M1), the switchback motor (M2),

the control board (PWB-A), and the duplex cover switch (PC1) ............... 139

5-8. 500-sheet lower feed unit disassembly procedures ............................................. 141

(1) Replacing the control board (PWB-A) ....................................................... 141

(2) Replacing the paper take-up clutch (CL1) and the paper take-up

motor (M1) ................................................................................................. 142

(3) Replacing the paper sensor (PC1) .............................................................. 143

(4) Replacing the paper empty sensor (PC2) ................................................... 144

(5) Replacing the paper size detection switch (S1) and the paper

near-empty sensor (PC3) ............................................................................ 145

5-9. 4-bin mailbox disassembly procedures ................................................................146

(1) Replacing the lower transport sensor (PC9) ............................................... 146

(2) Replacing the sensors of mailbins 1 and 3 ................................................. 147

(3) Replacing the sensors of mailbin 2 ............................................................. 148

(4) Replacing the sensors of mailbin 4 and the cover sensor ........................... 149

(5) Replacing the set sensor (PC12) and the control board (PWB-A) ............. 151

(6) Replacing the transport motor (M1) and the solenoids .............................. 152

6. ADJUSTMENT ............................................................................................................ 155

6-1. Adjustment of image registration ........................................................................ 155

7. TROUBLESHOOTING ............................................................................................... 157

7-1. Paper misfeed detection ...................................................................................... 157

(1) Detecting paper remaining in the machine ................................................ 157

(2) Detecting a paper misfeed while feeding ................................................... 157

(3) Operation when a paper misfeed is detected .............................................. 158

(4) Conditions under which a paper misfeed is detected ................................. 158

(5) Procedure for resetting after a paper misfeed is detected ........................... 160

7-2. Malfunction detection ..........................................................................................161

(1) Laser malfunction - Service Call 10 H-Sync .............................................. 161

(2) Polygon motor malfunction - Service Call 0A Polygon Motor .................. 161

(3) Fusing malfunctions - Service Call 18 Fuser Warmup .............................. 161

(4) Power supply unit fan motor malfunction

- Service Call 0C Power Supply ................................................................. 161

(5) Ozone fan motor malfunction - Service Call 0D Power Supply Fan 2 ..... 161

(6) Fusing fan motor malfunction - Service Call 0B Internal Fan ................... 162

(7) Image transfer voltage error - Service Call 0F High Voltage .................... 162

(8) Main motor malfunction - Service Call 08 Main Motor ............................ 162

(9) Imaging cartridge drive motor malfunction

- Service Call 09 IC Motor ......................................................................... 162

(10) 4-bin mailbox transmission error - Service Call 02 I/F Communication ... 162

7-3. Troubleshooting for paper misfeeds .................................................................... 163

(1) Paper misfeed when the power switch is turned on ................................... 163

(2) Paper misfeed between the paper feed-in section and the

transport section .......................................................................................... 163

(3) Paper misfeed between the transport section and the paper

feed-out section .......................................................................................... 164

(4) Paper jam display messages and associated sections ................................. 165

7-4. Troubleshooting for operation malfunctions ....................................................... 166

(1) Hardware errors .......................................................................................... 166

(2) No power .................................................................................................... 166

7-5. Image quality troubleshooting ............................................................................. 167

8. Parts Listing ............................................................................................................ 173

9. Wiring Diagram.............................................................................................................. 213

1. SAFETY PRECAUTIONS FOR INSPECTION AND

SERVICE

1-1. Outlines of safety precautions

When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure utmost safety.

Depending on the model, some of the precautions given do not apply.

✽

Different markings are used to denote specific meanings as detailed below.

Indicates a potentially hazardous situation which, if not avoided, could

WARNING

CAUTION

The following graphic symbols are used to give instructions that need to be observed.

Used to call the service technician’s attention to what is graphically represented inside the marking (including a warning).

Used to prohibit the service technician from doing what is graphically represented inside the marking.

Used to instruct the service technician to do what is graphically represented inside the marking.

result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

1-2. Warning

WARNING

1. Always observe precautions.

• Parts requiring special attention in this product include a label containing the mark shown on the left plus precautionary notes. Be sure to observe the precautions.

• Be sure to observe the “Safety Information” given in the Operator’s Manual.

2. Before starting any procedures, be sure to unplug the power cord.

• This product contains a high-voltage unit and a circuit with a large current capacity that may cause an electric shock or burn.

• The product also contains parts that can jerk suddenly and cause injury.

• This product uses a laser. Laser beam leakage may cause eye damage or blindness.

SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE

3. Use the specified parts

• For replacement parts, always use the genuine parts specified in the manufacturer’s parts manual. Installing a wrong or unauthorized part could cause dielectric breakdown, overload, or undermine safety devices, resulting in possible electrical shock or fire.

• Replace a blown electrical fuse or thermal fuse with its corresponding genuine part specified in the manufacturer’s parts manual. Installing a fuse of a different make or rating could lead to a possible fire. If a thermal fuse blows frequently, the temperature control system may have a problem and action must be taken to eliminate the cause of the problem.

4. Handle the power cord with care and never use a multiple outlet.

• Do not break, crush or otherwise damage the power cord. Placing a heavy object on the power cord, or pulling or bending it may damage it, resulting in a possible fire or electrical shock.

• Do not use a multiple outlet to which any other appliance or machine is connected.

• Be sure the power outlet meets or exceeds the specified capacity.

5. Be careful with the high-voltage parts.

• A part marked with the symbol shown on the left carries a high voltage. Touching it could result in an electrical shock or burn. Be sure to unplug the power cord before servicing this part or the parts near it.

6. Do not work with wet hands.

• Do not unplug or plug in the power cord, or perform any kind of service or inspection with wet hands. Doing so could result in an electrical shock.

7. Do not touch a high-temperature part.

• A part marked with the symbol shown on the left and other parts such as the exposure lamp and fusing roller can be very hot while the machine is energized. Touching them may result in a burn.

• Wait until these parts have cooled down before replacing them or any surrounding parts.

8. Maintain a grounded connection at all times. (This item may not apply in the USA.)

• Be sure to connect the ground wire to the ground terminal even when performing an inspection or repair. Without proper grounding, electrical leakage could result in an electrical shock or fire.

• Never connect the ground wire to a gas pipe, water pipe, telephone ground wire, or a lightning conductor.

9. Do not modify the product.

• Modifying this product in a manner not authorized by the manufacturer may result in a fire or electrical shock. If this product uses a laser. Laser beam leakage may cause eye damage or blindness.

10. Restore all parts and harnesses to their original positions.

• To promote safety and prevent product damage, make sure the harnesses are returned to their original positions and properly secured in their clamps and saddles in order to avoid hot parts, high-voltage parts, sharp edges, or being crushed.

• To promote safety, make sure that all tubing and other insulating materials are returned to their original positions. Make sure that floating components mounted on the circuit boards are at their correct distance and position off the boards.

SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE

1-3. Caution

CAUTION

1. Precautions for Service Jobs

• A toothed washer and spring washer, if used originally, must be reinstalled. Omitting them may result in contact failure which could cause an electric shock or fire.

• When reassembling parts, make sure that the correct screws (size, type) are used in the correct places. Using the wrong screw could lead to stripped threads, poorly secured parts, poor insulating or grounding, and result in a malfunction, electric shock or injury.

• Take great care to avoid personal injury from possible burrs and sharp edges on the parts, frames and chassis of the product.

• When moving the product or removing an option, use care not to injure your back or allow your hands to be caught in mechanisms.

2. Precautions for Servicing with Covers and Parts Removed

• Wherever feasible, keep all parts and covers mounted when energizing the product.

• If energizing the product with a cover removed is absolutely unavoidable, do not touch any exposed live parts and use care not to allow your clothing to be caught in the moving parts. Never leave a product in this condition unattended.

• Never place disassembled parts or a container of liquid on the product. Parts falling into, or the liquid spilling inside, the mechanism could result in an electric shock or fire.

• Never use a flammable spray near the product. This could result in a fire.

• Make sure the power cord is unplugged before removing or installing circuit boards or plugging in or unplugging connectors.

• Always use the interlock switch actuating jig to actuate an interlock switch when a cover is opened or removed. The use of folded paper or some other object may damage the interlock switch mechanism, possibly resulting in an electric shock, injury or blindness.

3. Precautions for the Working Environment

• The product must be placed on a flat, level surface that is stable and secure.

• Never place this product or its parts on an unsteady or tilting workbench when servicing.

• Provide good ventilation at regular intervals if a service job must be done in a confined space for a long period of time.

• Avoid dusty locations and places exposed to oil or steam.

• Avoid working positions that may block the ventilation ports of the product.

4. Precautions for Handling Batteries (Lithium, Nickel-Cadmium, etc.)

• Replace a rundown battery with the same type as specified in the manufacturer’s parts manual.

• Before installing a new battery, make sure of the correct polarity of the installation or the battery could burst.

• Dispose of used batteries according to the local regulations. Never dispose of them at the user’s premises or attempt to try to discharge one.

5. Precautions for the Laser Beam (Only for Products Employing a Laser)

• Removing the cover marked with the following caution label could lead to possible exposure to the laser beam, resulting in eye damage or blindness. Be sure to unplug the power cord before removing this cover.

• If removing this cover while the power is ON is unavoidable, be sure to wear protective laser goggles that meet specifications.

• Make sure that no one enters the room when the machine is in this condition.

• When handling the laser unit, observe the “Precautions for Handling Laser Equipment.”

SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE

1-4. Other precautions

Other Precautions

• When handling circuit boards, observe the “HANDLING of PWBs.”

• The PC Drum is a very delicate component. Observe the precautions given in “HANDLING OF THE PC DRUM” because mishandling may result in serious image problems.

• Note that replacement of a circuit board may call for readjustments or resetting of particular items, or software installation.

Used Batteries Precautions

ALL Areas

Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions.

Germany

Explosionsgefahr bei unsachgemäßem Austausch der Batterie. Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ. Entsorgung gebrauchter Batterien nach Angaben des Herstellers.

France

Il y a danger d’explosion s’il y a remplacement incorrect de la batterie. Remplacer uniquement avec une batterie du même type ou d’un type équivalent recommandé par le constructeur. Mettre au rebut les batteries usagées conformément aux instructions du fabricant.

Denmark ADVARSEL! Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering. Udskiftning må kun ske med batteri af samme fabrikat og type. Levér det brugte batteri tilbage til leverandøren.

Finland, Sweden

Paristo voi räjähtää, jos se on virheellisesti asennettu. Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hävitä käytetty paristo valmistajan ohjeiden mukaisesti.

CAUTION

VORSICHT!

ATTENTION

VA R O l T U S

Explosionsfara vid felaktigt batteribyte. Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren. Kassera använt batteri enligt fabrikantens instruktion.

VA R N I N G

Norway

ADVARSEL

Eksplosjonsfare ved feilaktig skifte av batteri.

Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.

Brukte batterier kasseres i henhold til fabrikantens instruksjoner.

SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE

1-5. Precautions for service

When performing inspection and service procedures, observe the following precautions to prevent mishandling of the machine and its parts.

Depending on the model, some of the precautions do not apply.

✽

Precautions Before Service

• When the user is using a word processor or personal computer from a wall outlet of the same line, take necessary steps to prevent the circuit breaker from opening due to overloads.

• Never disturb the LAN by breaking or making a network connection, altering termination, installing or removing networking hardware or software, or shutting down networked devices without the knowledge and express permission of the network administrator or the shop supervisor.

How to Use this Book

1. DIS/REASSEMBLY, ADJUSTMENT

• To reassemble the product, reverse the order of disassembly unless otherwise specified.

2. TROUBLESHOOTING

• If a component on a PWB or any other functional unit including a motor is defective, the text only instructs you to replace the whole PWB or functional unit and does not give troubleshooting procedures applicable within the defective unit.

• All troubleshooting procedures contained herein assume that there are no breaks in the harnesses and cords and all connectors are plugged into the right positions.

• The procedures preclude possible malfunctions due to noise and other external causes.

Precautions for Service

• Check the area surrounding the service site for any signs of damage, wear or need of repair.

• Keep all disassembled parts in good order and keep tools under control so that none will be lost or damaged.

• After completing a service job, perform a safety check. Make sure that all parts, wiring and screws are returned to their original positions.

• Do not pull out the toner hopper while the toner bottle is turning. This could result in a damaged motor or locking mechanism.

• If the product is to be run with the front door open, make sure that the toner hopper is in the locked position.

• Do not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other sensors, as they can cause electrostatic destruction. Use a blower brush and cloth. If a unit containing these sensors is to be cleaned, first remove the sensors from the unit.

Precautions for Dis/Reassembly

• Be sure to unplug the printer from the outlet before attempting to service the printer.

• The basic rule is not to operate the printer anytime during disassembly. If it is absolutely necessary to run the printer with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears.

• Before attempting to replace parts and unplug connectors, make sure that the power cord of the printer has been unplugged from the wall outlet.

• While the product is energized, do not unplug or plug connectors into the circuit boards or harnesses.

• Never use flammable sprays near the printer.

• A used battery should be disposed of according to the local regulations and never be discarded casually or left unattended at the user’s premises.

• When reassembling parts, make sure that the correct screws (size, type) and toothed washer are used in the correct places.

• If it becomes necessary to replace the thermal fuse or any other fuse mounted on a board, be sure to use one of the rating marked on the blown fuse. Always note the rating marked on the fuse, as the rating and mounting site or number used are subject to change without notice.

Precautions for Circuit Inspection

• Never create a closed circuit across connector pins except those specified in the text and on the printed circuit.

• When creating a closed circuit and measuring a voltage across connector pins specified in the text, be sure to use the GND wire.

Handling of PWBs

1. During Transportation/Storage:

• During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags.

• Do not store or place P.W. Boards in a location exposed to direct sunlight and high temperature.

• When it becomes absolutely necessary to remove a Board from its conductive bag or case, always place it on its conductive mat in an area as free as possible from static electricity.

• Do not touch the pins of the ICs with your bare hands.

• Protect the PWBs from any external force so that they are not bent or damaged.

SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE

2. During Inspection/Replacement:

• Avoid checking the IC directly with a multimeter; use connectors on the Board.

• Never create a closed circuit across IC pins with a metal tool.

• Before unplugging connectors from the P.W. Boards, make sure that the power cord has been unplugged from the outlet.

• When removing a Board from its conductive bag or conductive case, do not touch the pins of the ICs or the printed pattern. Place it in position by holding only the edges of the Board.

• When touching the PWB, wear a wrist strap and connect its cord to a securely grounded place whenever possible. If you cannot wear a wrist strap, touch a metal part to discharge static electricity before touching the PWB.

• Note that replacement of a PWB may call for readjustments or resetting of particular items.

Handling of Other Parts

• The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy disk, magnetic card, or CRT tube.

Handling of the Imaging Cartridge

Only for Products Employing an Imaging Cartridge.

✽

1. During Transportation/Storage:

• The storage temperature is in the range between –20°C and +40°C.

• In summer, avoid leaving the Imaging Cartridge in a car for a long time.

2. Handling:

• Store the Imaging Cartridge in a place that is not exposed to direct sunlight.

3. Precautionary Information on the PC Drum Inside the Imaging Cartridge:

• Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter.

• Do not scratch the surface of the PC Drum.

• Do not attempt to wipe clean the surface of the PC Drum.

4. Be sure to keep the imaging cartridge out of the reach of children. Ingesting contents of the

imaging cartridge is harmful to your health.

WARNING

Do not throw toner or the toner bottle into a fire. Toner expelled from the fire may cause burns.

1-6. Safety information

(1) Laser Safety

• This is a digital machine certified as a Class 1 laser product. There is no possibility of danger from the laser, provided the machine is serviced according to the instructions in this manual.

(2) Internal Laser Radiation

semiconductor laser specifications

Maximum power of the laser diode 15 mW

Maximum average radiation power

Wavelength 775-795 nm

• This product employs a Class 3b laser diode that emits an invisible laser beam.

• The print head section consists of two units: the print head unit and the mirror unit. The laser diode and a polygon mirror are incorporated into the print head unit. A laser-beam-reflecting mirror is incorporated into the mirror unit.

• The laser beam is emitted from the print head unit, passes through the mirror unit, then is radiated into the interior of the printer through the laser aperture of the mirror unit.

• The print head section (print head unit and mirror unit) is not a field service item. Therefore, it must not be disassembled or adjusted under any circumstance.

(at laser aperture of mirror unit

(at laser Aperture of print head unit)

37 µW

70 µW

Laser Aperture ofthe Print head unit

)

SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE

Print head unit

Mirror unit

This figure shows the view inside the Rear Upper Cover with the Imaging Cartridge removed.

the USA, Canada (CDRH Regulation)

• This machine is certified as a Class I Laser product under Radiation Performance Stan-dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration of the U.S. Department of Health and Human Services (DHHS). This means that the device does not produce hazardous laser radiation.

• The label shown to page 22 indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States.

CAUTION

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

Semiconductor laser

Maximum power of the laser diode 15 mW

Wavelength 775-795 nm

All Areas

CAUTION

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

Semiconductor laser

Maximum power of the laser diode 15 mW

Wavelength 775-795 nm

Denmark

ADVARSEL

Usynlig laserstråling ved åbning, når sikkerhedsafbrydere er ude af funktion. Undgå udsættelse for stråling. Klasse 1 laser produkt der opfylder IEC60825 sikkerheds kravene.

Halvlederlaser

Laserdiodens højeste styrke 15 mW

bølgelængden 775-795 nm

Finland, Sweden

LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT

VAROITUS!

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

Puolijohdelaser

Laserdiodin suurin teho 15 mW

Aallonpituus 775-795 nm

VARNING!

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

halvledarlaser

Den maximala effekten för laserdioden 15 mW

våglängden 775-795 nm

VARO!

Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättomälle lasersäteilylle. Älä katso säteeseen.

VARNING!

Osynlig laserstråining när denna del är öppnad och spärren är urkopplad. Betrakta ej stråien.

SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE

Norway

ADVERSEL

Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisning, kan brukeren utsettes för unsynlig laserstrålning, som overskrider grensen for laser klass 1.

Halvleder laser

Maksimal effekt till laserdiode 15 mW

Bølgelengde 775-795 nm

1-7. Laser safety label

• A laser safety label is attached to the outside of the machine as shown below.

CLASS 1 LASER PRODUCT LASER KLASSE 1 PRODUKT

1-8. Laser caution label

• Three laser caution labels are attached to the inside of the machine as shown below.

1-9. Precautions for handling the equipment

• When laser protective goggles are to be used, select ones with a lens conforming to the above specifications.

• When a disassembly job needs to be performed in the laser beam path, such as when working around the print head unit and PC Drum, be sure first to turn the printer OFF.

• If the job requires that the printer be left ON, take off your watch and ring and wear laser protective goggles.

• A highly reflective tool can be dangerous if it is brought into the laser beam path. Use utmost care when handling tools on the user’s premises.

2. INSTALLATION

2-1. Installation environment

When installing the printer, please avoid the types of locations listed below, both for safety considerations and to avoid breakdowns.

• Areas with high temperatures or humidity, or with low temperatures and humidity.

• Areas where the temperature and/or humidity fluctuate sharply.

• Places where the printer will be in direct sunlight.

• Areas near a cooler, heater, ventilation opening or in the direct path of wind.

• Areas near oil stoves or other heat-generating equipment.

• Locations with poor ventilation.

• Areas where water is likely to fall on the equipment or electrical leakage is likely.

• Areas where corrosive gases (ammonia gases, etc.) are present.

• Areas where there is a high volume of dust, dirt and vibration.

• Areas where the floor is not sufficiently strong or is not level.

• Areas containing volatile and flammable materials and curtains.

War ni ng

Two people are required to lift the printer. Hold it as shown in the illustration. Be careful not to strain your back when lifting the printer.

INSTALLATION

2-2. Usage environment

In order to make sure the printer operates properly, please make sure the ambient environment satisfies the following requirements:

Temperature 10-35°C ;50 °F-95 °F

Temperature fluctuation ±10°C or ±18°F per hour or less

Humidity 15-85%RH

Humidity fluctuation ±20% RH per hour or less

2-3. Installing the power supply

• Do not plug the power cord into a power outlet via an extension cord supplying electricity to more than one unit.

• Do not connect the printer to a power outlet used for other equipment or appliances. More than one appliance connected to a single outlet could cause a drop or surge in the electrical supply, resulting in operational problems for the printer.

Voltage fluctuation Specified voltage: ±10%

Frequency fluctuation Specified frequency: ±3Hz

The following items should be checked periodically:

• Make sure the power supply plugs do not feel warm.

• Power supply cords should be free of cracks and scratches.

• Power supply plugs should be firmly plugged into outlets.

2-4. Space requirements

(1) Standard

423 mm

(16-3/4 in)

539 mm(21-1/4 in)

(2) With options installed

Installed options: Lower feeder unit (3 levels), duplex unit, and 4-bin mailbox.

1,082 mm

(42-1/2 in)

448 mm(17-3/4 in)

566 mm(22-1/4 in)

INSTALLATION

539 mm(21-1/4in)

611 mm(24 in)*1

*1: With the media trays installed

3. GENERAL INFORMATION

3-1. Specifications

(1) Printer

Typ e

Exposure method

Printing method

Print resolution

Media sizes

Media types

Desktop laser beam printer Laser diode + Polygon mirror scanning Electrophotographic 600 dpi (dots/inch) A5 to A3/Half Letter to Ledger A3 (297 mm × 420 mm/11.7” x 16.5”) B4 (257 mm × 364 mm/10.1” x 14.3”)

Folio (210 mm × 330 mm/8.27” x 13”) A4 (210 mm × 297 mm/8.2” x 11.7”) JIS-B5 (182 mm × 257 mm/7.2” x 10.1”)

ISO-B5 (176 mm × 250 mm/6.6” x 9.8”)

A5 (148 mm × 210 mm/5.9” x 8.3”) Ledger (279.4 mm x 432 mm/11” × 17”) Legal (215.9 mm x 355.6 mm/8.5” × 14”)

G-Legal (215.9 mm x 330.2 mm/8.5 × 13) Letter (215.9 mm x 279.4 mm/8.5” × 11”) G-Letter (203.2 mm x 266.7 mm/8” × 10.5”)

Executive (184.15 mm x 266.7 mm/7.25” × 10.5”)

Statement (139.7 mm x 215.9 mm/5.5” × 8.5”)*1,

Japanese Postcard (100 mm x 148 mm/3.9” x 5.8”)

Com 10 (105 mm x 241.3 mm/4.1”x 9.5”)

DL (110 mm x 220 mm/4.3” x 8.7”) Monarch (98 mm x 191 mm/3.9” x 7.5”)

C5 (162 mm x 229 mm/6.4” x 9”)

C6 (114 mm x 162 mm/4.5” x 6.4”)*

8 Kai (260 mm x 370 mm/10.24” x 14.57”)

16 Kai (185 mm x 260 mm/7.3” x 10.24”)

32 Kai (130 mm x 185 mm/5.12” x 7.3”)

Multipurpose paper tray only

Plain paper (60 to 90 g/m Recycled paper (60 to 90 g/m

Transparencies Thick paper

Multipurpose paper tray only

(91 to 163 g/m2; 24 to 43 lbs.), Post cards

; 16 to 24 lbs.)

, Letterheads*, Envelopes*, Label sheets*

; 16 to 24 lbs.)

GENERAL INFORMATION

First-page print time

Multi-page print speed

Warm-up time

System speed

Paper feed-in method

Paper capacity

Paper feed-out

Drum-charging method

Developing method

Development density control

Image transfer method

PC Drum

PC Drum cleaning method

Paper separation

Fusing method

Single-sided prints Multipurpose paper tray: Less than 10 seconds *

Universal paper cassette: Less than 10 seconds * Double-sided prints

Multipurpose paper tray*: Less than 15 seconds * Universal paper cassette*: Less than 14.5 seconds *

With A4 or Letter paper. Single-sided prints Multipurpose paper tray/A4: 35 ppm Multipurpose paper tray/Letter: 34.5 ppm Double-sided prints Multipurpose paper tray/A4: 26 ppm Multipurpose paper tray/Letter: 25.6 ppm

Less than 70 seconds* Recovery time from power save mode: Within 30 seconds*

At a room temperature of 23 °C (73.4 °F) and at the rated voltage

160.0 mm/s

2-way (maximum 5-way)*

Multipurpose paper tray Universal paper cassette

Lower feeder unit (optional)*

Can be expanded to as much as a 5-way system by installing up to three optional Lower feeder units

Multipurpose paper tray

When using paper with a weight of 16 to 90 lbs (60 - 163 g/m

): 200 sheets

Universal paper cassette

When using paper with a weight of 16 to 24 lbs (60 - 90 g/m

): 500 sheets With recommended paper Face-down Output tray capacity

When using paper with a weight of 16 to 24 lbs (60 - 90 g/m

): 500 sheets With recommended paper Needle electrode/scorotron system

Single-element developing system (S MicroToning developing system) Bias adjustment system

Roller transfer system

OPC (Organic Photoconductor) Blade system

Mechanical separation by means of paper separator fingers Heated roller fusing system

Dimensions

Wei ght

Rated input power supply voltage

Frequency

Amperage

Power consumption

Acoustic noise

Operating environment

Imaging cartridge life

Standard configuration Width: 539 mm(21-1/4 in) Depth: 448 mm(17-3/4 in) with out the Universal paper cassette

566 mm(22-1/4 in) with the Universal paper cassette installed Height: 423 mm(16-3/4 in) With options installed

(with three Lower feeder unit and the duplex unit installed) Width: 539 mm(21-1/4 in) Depth: 611 mm(24 in) Height: 762 mm(30 in) With options installed

(with three lower feeder units, the duplex unit and the 4-bin mailbox installed) Width: 539 mm(21-1/4 in) Depth: 611 mm(24 in) Height: 1,082 mm(42-1/2 in)

28.0 kg(61-3/4 lbs.) or less* Imaging cartridge: Approx. 2.5 kg(5-1/2 lbs.)

Weight of the standard configuration does not include the imaging cartridge. AC 120 V (operation guaranteed) AC 230 V (operation guaranteed) 50/60 Hz ±3 Hz AC 120 V :10A or less AC 230 V :5A or less

Maximum power consumption: 1,150 W or less* Average power consumption while printing: 850 W or less

Average power consumption during stand-by: 350 W or less Average power consumption with the heater off: 40 W or less Average power consumption in power save mode: 150 W or less

At a room temperature of 23 °C(73.4 °F); except when the heater is on

During stand-by: 38 dB or less*

While printing: 57 dB or less*

Average sound level in four directions with the standard configuration

* Temperature 10 to 35 °C(50 to 95 °F) Humidity 15-85%RH Start-up imaging cartridge:

Average 6,000 or more printer (multi-page printing; black/white ratio=5%) Replacement imaging cartridge:

Average 15,000 or more prints (multi-page printing; black/white ratio=5%)

GENERAL INFORMATION

Standard accessories (one each )

Options

Power cord Imaging cartridge

Lower feeder unit (Up to 3 can be installed) Duplex unit 4-bin Mailbox

(2) 500-sheet lower feed unit (optional)

Name

Typ e

Installation method

Media types

Media sizes

Paper cassette capacity

Paper separation mechanism in the paper feed-in section

Power source

Drive source

Dimensions

Wei ght

Standard accessories

500-Sheet lower feed unit Expansion paper feed unit (stacking type) Secured at the top/bottom

Plain paper 16 to 24 lbs (60 - 90 g/m Universal A3 (297 mm × 420 mm/11.7” x 16.5”) B4 (257 mm × 364 mm/10.1” x 14.3”) A4 (210 mm × 297 mm/8.2” x 11.7”) JIS-B5 (182 mm × 257 mm/7.2” x 10.1”) Ledger (279.4 mm x 432 mm/11” × 17”) Legal (215.9 mm x 355.6 mm/8.5” × 14”) Letter (215.9 mm x 279.4 mm/8.5” × 11”) G-Letter (203.2 mm x 266.7 mm/8” × 10.5”) G-Legal (215.9 mm x 330.2 mm/8.5 × 13)

When using paper with a weight of 16 to 24 lbs (60 - 90 g/m

Pathway roller paper separation system with torque limiter

Supplied by the printer (DC24 V, DC5 V) Step motor Width: 512 mm(20-1/4 in) Depth: 551 mm(21-3/4 in) Height: 134 mm(5-1/4 in); 110 mm(4-1/4 in) /unit when stacked Approx. 9.2 kg(20-1/4 lbs.) Universal paper cassette

), Recycled paper 16 to 24 lbs (60 - 90 g/m2)

): 500 sheets

+ 190 hidden pages

Minolta PP9100 Service Manual

CONTENTS

SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE

INSTALLATION

GENERAL INFORMATION