Sony C9000 User Manual

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Page 1

C9000 Series Color LED Page Printer

Service Manual

ODA

05-18-200 Based on Rev.2

41388601TH Rev.2A 1 / 157

Page 2

Document Revision History

3 05-18-2001 ODA Revisions ODA Training

Rev.No. Date

No.

Corrected items

Page Description of change

Person in

charge 1 2000-12-05 ISSUE EM3 Murakami 2 2000-12-13 8 Correction of errors in K Yamazaki

the parts list

41388601TH Rev.2A 2 /

Page 3

PREFACE

This maintenance manual provides procedures and techniques for the troubleshooting, maintenance, and repair of C9000.

This manual is written for maintenance personnel, but it should always be accompanied with the C9000 User’s Manual for procedures for handling and operating C9000. For repairing each component of C9000, see the Troubleshooting manual.

[Notices] The contents of this manual are subject to change without prior notice. Although reasonable efforts have been taken in the preparation of this manual to assure its accuracy, this manual may still contain some errors and omissions. OKI will not be liable for any damage caused or alleged to be caused, by the customer or any other person using this maintenance manual to repair, modify, or alter C9000 in any manner.

[Warning] Many parts of C9000 are very sensitive and can be easily damaged by improper servicing. We strongly suggest that C9000 be serviced by OKI’s authorized technical service engineers.

41388601TH Rev.2 3 /

Page 4

1. SPECIFICATIONS ............................................................................................ 7

1.1 Basic System Configuration............................................................................................. 7

1.2 Printer Engine Specifications ........................................................................................... 8

1.3 Option Configuration ........................................................................................................ 9

1.4 Specifications................................................................................................................. 10

2. OPERATION DESCRIPTION ......................................................................... 12

2.1 Main Control Board (CRM-PWB) ................................................................................... 13

2.2 Engine Control Board (K73 PWB).................................................................................. 15

2.3 Power Units.................................................................................................................... 16

2.4 Mechanical Processes ................................................................................................... 17

2.4.1 Electrophotographic process............................................................................ 18

2.4.2 Paper running process ..................................................................................... 22

2.5 Sensor............................................................................................................................ 31

2.5.1 Paper related sensors ...................................................................................... 31

2.5.2 Other sensors................................................................................................... 32

2.6 Color Misalignment Correction....................................................................................... 33

2.7 Transfer Control Responds to Environmental Changes

(Room Temperatures and Relative Humidities)............................................................. 33

2.8 Paper Jam Detection ..................................................................................................... 34

2.9 Cover Opening............................................................................................................... 35

2.10 Toner Low Detection...................................................................................................... 36

2.11 Paper Size Detection ..................................................................................................... 37

2.12 Operation at Power-on................................................................................................... 38

2.12.1 Self-diagnostic test........................................................................................... 38

2.13 Color Misalignment Detection ........................................................................................ 39

2.14 Version Read of Periodically Replaced Units ................................................................ 40

2.15 Life Counter for Replaceable Units ................................................................................ 40

2.16 Toner Consumption Detection ....................................................................................... 40

3. PARTS REPLACEMENT................................................................................41

3.1 Precautions in Replacing Parts...................................................................................... 41

3.2 Parts Layout................................................................................................................... 43

3.3 Replacing Parts..............................................................................................................50

3.3.1 Top cover.......................................................................................................... 51

3.3.2 LED Assy/ LED Assy spring ............................................................................. 52

3.3.3 Top cover unit................................................................................................... 53

3.3.4 Control panel Assy/ Control panel bezel/ LED control PWB/ Toner sensor/

Stack full sensor/ Control panel tape harness/ Eject roller............................... 54

3.3.5 Top cover handle/ Tope cover latch/ Top cover latch spring............................ 55

3.3.6 Eject guide Assy ............................................................................................... 56

3.3.7 Cassette Assy/ Blind cover/ Side cover R Assy ............................................... 57

3.3.8 Feed rollers....................................................................................................... 58

3.3.9 Left side cover .................................................................................................. 59

3.3.10 Face-up tray ..................................................................................................... 60

3.3.11 Front cover ....................................................................................................... 61

3.3.12 Rear cover........................................................................................................ 62

3.3.13 Multipurpose tray Assy/ Multipurpose tray cover Assy/ Links/

Multipurpose tray top cover/ Multipurpose tray drive gear................................ 63

3.3.14 Drum contact Assys.......................................................................................... 64

3.3.15 Registration roller Assy (A)/ Registration drive gear (A)................................... 65

41388601TH Rev.2 4 /

Page 5

3.3.16 Registration roller Assy (B)............................................................................... 66

3.3.17 Registration clutch, Registration motor Assy.................................................... 67

3.3.18 Cooling fan ....................................................................................................... 68

3.3.19 Color registration sensor Assy.......................................................................... 69

3.3.20 Duplex guide Assy............................................................................................ 70

3.3.21 Electrical chassis/ Electrical chassis cooling fan.............................................. 71

3.3.22 Printer engine controller PWB .......................................................................... 72

3.3.23 Printer unit chassis........................................................................................... 73

3.3.24 Entrance cassette sensor actuator................................................................... 74

3.3.25 Entrance sensor PWB ...................................................................................... 75

3.3.26 Entrance MT sensor actuator and Entrance belt sensor actuator.................... 76

3.3.27 Main motor fan/ Fuser eject roller..................................................................... 77

3.3.28 Eject sensor Assy............................................................................................. 78

3.3.29 Fuser latching handle (L).................................................................................. 79

3.3.30 Belt motor Assy ................................................................................................ 80

3.3.31 Fuser latching handle (R)................................................................................. 81

3.3.32 Main motor Assy............................................................................................... 82

3.3.33 Contact Assy/ Side plate Assy.......................................................................... 83

3.3.34 Low voltage power supply ................................................................................ 84

3.3.35 High voltage power supply ............................................................................... 85

3.3.36 Main feed Assy................................................................................................. 86

3.3.37 Fuser unit.......................................................................................................... 87

3.3.38 Belt unit............................................................................................................. 88

3.3.39 Duplex unit........................................................................................................ 89

3.3.40 CU Assy............................................................................................................ 90

4. Adjustment .................................................................................................... 92

4.1 Maintenance Menu and Its Functions ............................................................................ 92

4.2 Short Plug Settings ........................................................................................................ 93

4.3 Printing Singly Using Controller-Equipped Printer ......................................................... 93

4.4 Adjustment after Part Replacement ............................................................................... 94

4.5 Color Balance Adjustment ............................................................................................. 95

4.6 EEPROM Replacement after CRM Board and K73 Board Replacement ...................... 97

5. Regular Maintenance ....................................................................................98

5.1 Parts to be Replaced Regularly ..................................................................................... 98

5.2 Cleaning......................................................................................................................... 98

5.3 Cleaning of LED Lens Array .......................................................................................... 98

5.4 Cleaning of Pick-up Roller ............................................................................................. 98

6. TROUBLESHOOTING PROCEDURES .........................................................99

6.1 Tips for Troubleshooting ................................................................................................ 99

6.2 Check Points before Correcting Image Problems.......................................................... 99

6.3 Tips for Correcting Image Problems .............................................................................. 99

6.4 Preparation for Troubleshooting .................................................................................. 100

6.5 Troubleshooting Flow................................................................................................... 100

6.5.1 LCD Message List .......................................................................................... 101

6.5.2 LCD message troubleshooting ....................................................................... 106

6.5.3 Image troubleshooting.................................................................................... 117

7. WIRING DIAGRAM...................................................................................... 129

7.1 Resistance Check ........................................................................................................ 129

7.2 Parts Layout on Boards ............................................................................................... 134

8. Parts List...................................................................................................... 138

41388601TH Rev.2 5 /

Page 6

Job

offset

LED Head

Junction Board

Pulse Motors

Engine Controller

Low-Voltage

Power Unit

Fuser Unit

High-Voltage

Power Unit

2nd/3rd T r ay/

Large-Capacity

Tray

Duplex Unit

Belt Unit

<Sensors, Switches and Thermistors>

Paper carrier sensors

Paper size detection

Fuser temperature detection

Ambient temperature and humidity detection

Toner remaining detection

Color registration sensor

ID, belt and fuser checks

C-ID

Unit

M-ID

Unit

Y-ID

Unit

K-ID

Unit

C ID

Heater

M ID

Y ID

K ID

Belt

MT/

Registration

Hopping

Geared

motor

DC motor

Operator Panel

Centronics

USB

IDE

HDD

FAN

Ethernet

ROM DIMM × 3

SDRAM DIMM

× 4

Controller

Block

1. SPECIFICATIONS

1.1 Basic System Configuration

The basic system configuration of C9000 is illustrated in Figure 1.1.

Figure 1.1

41388601TH Rev.2 6 /

Page 7

1.2 Printer Engine Specifications

The inside of the printer is composed of the followings:

• Electrophotographic Processor

• Paper Paths

• Controller Block (CU and PU)

• Operator Panel

• Power Units (High-Voltage Unit and Low-Voltage Unit) Figure 1-2 shows the printer configuration.

Figure 1.2

41388601TH Rev.2 7 /

Page 8

1.3 Option Configuration

The followings are available as options on C9000. (1) 2nd Tray/ 3rd Tray

(2) Duplex Unit

(3) Large-Capacity Tray

(4) Expansion Memory 64/128/256MB

(5) Internal Hard Disk

(6) Ethernet Board

41388601TH Rev. 2 8 /

Page 9

1.4 Specifications

(1) Dimensions Height: 18.11 in. Width: 26.22 in. Length: 24.65 in. (2) Weight 158.7 lbs. (3) Paper Type: Ordinary paper and transparencies (Recommended: ML OHP01)

(4) Print Speed Color: 21 pages per minute (Transparency: 5 pages per minute)

(5) Resolution 600 × 600 DPI / 600 x 1200 DPI (C9200 series) & 1200 x 1200 DPI (C9400 series) (6) Power Input 100VAC ±10% (7) Power Consumption Peak: 1400W Normal Operation: 550W (5% duty)

Size: Postal card, Legal 13" or 14", Executive, A4, A5, B5, A6, A3 A3-Nobi, B4

(Only the 1st tray and the front feeder support A6 and postal card sizes.)

Weight: 1st tray 55 kg to 90 kg (64 to 105g/m

)

Front feeder 55 kg to 140 kg (64 to 163g/ m2)

Monochrome: 26 pages per minute (Transparency: 15 pages per minute) Postal Card, Label, Thick Paper: 10 pages per minute

Idle: 150W Power Saving Mode: 50W (8) Frequency 50Hz or 60Hz ± 2% (9) Noise Operating: 54 dB (without Second tray)

Standby: 45 dB Power Saving: 43 dB

(10) Consumable Life Toner Cartridge: 15,000 pages (5% duty)

(in each of Y, M, C and K) Image Drum: 39,000 pages (5% duty, Continuous printing)

(in each of Y, M, C and K)

(11) Parts Replaced Periodically Fuser Unit Assy: Every 80,000 pages

Belt Cassette Assy: Equivalent of 80,000 pages (3P/J) Transfer Belt cartridge: 60,000 prints

41388601TH Rev.2 9 /

Page 10

(12) Temperatures and Relative Humidities Temperature

Temperature (ºF) RemarkTemperature (ºC)

Operating 50 to 89.6 10 to 32

Non-Operating 32 to 109.4 0 to 43 Power-off Storage (Max. One Year) -14 to 109.4 -10 to 43 With drum and toner Transport (Max. One Month) -20 to 122 -29 to 50 With drum and without toner Transport (Max. One Month) -20 to 122 -29 to 50 With drum and toner

17 to 27ºC (Temperatures to assure full color print quality)

Humidity

Relative Humidity (%) Max. Wet-Bulb Temperature (ºC) Remark

Operating 20 to 80 25 50 to 70%

(Humidities to assure full color print quality) Non-Operating 10 to 90 26.8 Power-off Storage 10 to 90 35 Transport 10 to 90 40

(13 Printer Life 1,000,000 pages (on a A4 basis) or five years

41388601TH Rev.2 10 /

Page 11

Stacker Open

Microswitch

SUMI Card

Sensor/Microswitch

New C9000 Connector

Backup Roller

Thermistor

L-Side Color Registration Adjustment

AOUT3

R-Side Color Registration Adjustment

AOUT2

Eject Sensor Heater

Shutter Clutch

SHUTTER

Regist

Clutch

SNS

WER

UIFPSIZE

OLT

DEN

ENS

1OP

BEL

THETDUPLEX

K73 Main Board

UFL

PAR

TTEMP

SHU

TTER

DCLFC

OVER

COV

NDF

HP1

POS

PWID

M7L Board

M7R Board

AN1

AN2

FF/

Registration

Motor

VOPN

Right Side Cover

Open Microswitch

Upper Cover

Open Microswitch

(+38V cut)

Y71 Head

Relay Board

TNRK

TNRY

STUCK POWER

PANEL

MPOW2

CPOW2

YPOW2

KPOW2

TNRM

TNRC

Stacker Full Sensor

Geared

Motor

Loading Clutch

Pickup Clutch

Carrier Sensor

Paper Width Sensor

Offset

Motor

Hopping

Motor

Offset Zero Sensor

C73

I/F Board

Finisher

A73 Retard Sensor Board

Lifter Sensor

Loading Sensor

Belt

Fuse

I DPOSK

I DPOSY

I DPOSM

I DPOSC

N71 Board

(charge elimination relay)

IDC

IDM

IDY

D2 Green

D2 Yellow

NBLT

4 x P73 Boards

Input

Fan 3 (off-the-shelf)

Fan 2 (power eject)

Fan 1 (PU)

works as stepper

PEND

PNEND

Offset PE Sensor

Offset Sensor

STDUCOV

BOFF

OPTN

KPOW

K12 00

Y12 00

M120 0

MPOW

YPOW

PFF

PUCL

C1200 CPOW

ACE

EED

PAPSIZ3-0

aVR

Paper Width

Sensing Board

HOP

LIFT

MAIL

HOP(I

NSNS1)

EMP

R71

Board

PAPIN(

INSNS2)

PSWR(

WRSNS)

RFUL

ARED

K IDU

Motor

JOB

OFFS

JOB

OFFPE

connected to next tray

(no tray in lowest section)

connected to trays of up to 5th,

including 2nd tray

(does not exist in the lowest)

2nd T ray/3rd Tray

Large-Capacity T ray

Geared

Motor

Carrier Clutch

(does not exist

in the lowest)

Loading Clutch

V73 Board

Paper End

Paper Near

End

Cover Opem SW

Carrier Sensor

Paper Width

Sensing Board

T9 Blue

T3 White

T4 Red

T5 Red

T8 Red

T2 Blue

Yellow

Lifter Sensor

Loading Sensor

Retard Sensor

Board A73

T2 White

T1 Blue

T1 White

T7 White

T11

(does not exist

in the lowest)

DUP-In Sensor

DUP Middle Sensor

DUP Front Sensor

DUP

DUP Front Clutch DUP Rear Clutch

D3 Blue

V73 Board

Duplex

D1 Blue

D1 White

Belt

Motor

P1 Yellow

P1 White

P2 Yellow

P3 White

P2 Blue

P2 Red

P4 Red

P4 Yellow

P4 Blue/

White

P6 Brown

P7 Blue

P7 Gray

attached to

sensor

P9 Black

P10P10

P10 Brown

P11

P11 Blue

P11 White

P21P21

P22

P12P12

P12 Yellow

P13

P13 Red

P14

P14 Yellow

P14 Red

P15 Red

P16 Browm

P17 Red

attached to motor

P16

P5 Red

P18 Black

P19

P18

P17

P20

P18 Yellow

P18 Red

P18 Blue

attached to clutch

P19 White

P19 Red

P20 White

P20 Yellow

P24 to P31

P23

Y1 White

Y2 Blue

Y1 White

S1 Gray

Heater Unit

Heat Roller

Thermistor

Sensor

Fuse

ERM1

ERM2

NFULH

RTMP

High-Voltage

Power Supply

CN4-

2,6-2

CN4-

1,6-1

Low-Voltage

Power Supply

attached to fan

Heat

Motor

WPAP

Jam Sensor

P2 White

P4 Green

Fan 0 (power-on)

Face-Down Solenoid

Eject Solenoid

Removed-Edge Side

Removed-

Edge Side

P33 White

P33 Blue

Temperature Sensor

P33 Green

Fan 0 (power eject)

DUP_PAP

Blue

White

connected to next tray

(no tray in lowest section)

Geared

Motor

Carrier Clutch

Loading Clutch

V73 Board

Paper End

Paper Near

End

Cover Opem SW

Carrier Sensor

Paper Width

Sensing Board

T9 Blue

T3 White

T4 Red

T5 Red

T8 Red

T2 Blue

Yellow

Lifter Sensor

Loading Sensor

Retard Sensor

Board A73

T2 White

T10 Red

T1 Blue

T1 White

T7 White

T11

Blue

White

Black

Removed-

Edge Side

White

Black

DUP Rear Sensor

P24 to P31

Y IDU

Motor

M IDU

Motor

C IDU

Motor

P17 Yellow

Black

Y4 Green

Y3 Yellow

Y3 Red

Y5 Blown

X71 Board

P24 P28

P25 P29

P26 P30

P27 P31

Operator Panel

C Charge Elimination Lamp Fuse

M Charge Elimination Lamp Fuse

Y Charge Elimination Lamp Fuse

K Charge Elimination Lamp Fuse

P27

ACSW

Assy

FAN

RAM

CRM Board

ROM

HDD

LAN

USB

CENTRO

2. OPERATION DESCRIPTION

C9000, a tandem color electrophotographic page printer, adopts technologies such as 4992-LED array, OPC, dry single-component non-magnetic developing, roller transfer and heat-compression fusing. The printing method is black writing by shedding light on print areas.

Figure 2-1 provides the block diagram of this device.

Figure 2.1

41388601TH Rev.2 11 /

Page 12

2.1 Main Control Board (CRM-PWB)

PPC

750

Cache

Delay

Buf

16244

Buf

16244

IF Bus

EEPROM

Cont

Y, M, C and K Video Data

PU-CU I/F,

Operator Panel

A/D,Cont

A/D, Cont(SUB Bus)

14.31818MHz Crystal Resonator

CY2292

CY2308

FET SW

162212

FLASH ROM

FLASH DIMM

×3

SDRAM DIMM

·4

IMI1530

Fluctuation Circuit

Internal-CLK-

Setting

Resistance

Reset

DS1834

to C2 and

3.3V ICs

to 5V ICs

PU Board Connector, 200 Pins

Inverter

RESET-P

2.0V Regulator

2.5V Regulator

C1 LSI

MHM

2030-002

C2 LSI

MHM2031-002

CDC516

80MHz

LVC244

LVC161284

Centro USB

L60851

PCI Bus

LAN Board

IDE

HDD

LVC245

80MHz

3.3V5V

40MHz

48MHz

33MHz

·2

SPD

80MHz

×2

80MHz

×16

A,Cont

A,Cont A,Cont A,Cont

DDD

Figure 2-2 provides the block diagram of the main control board (CRM-PWB).

Figure 2.2

41388601TH Rev.2 12 /

Page 13

(1) CPU

The CPU is 64-bit bus RISC processor PowerPC750, which receives an input of 80MHz (=BUS CLK) and operates at 400MHz, four-times the input.

(2) Secondary Cache SRAM

SRAM is included as a secondary cache of the CPU on the board.

(3) ROM

The ROM is inserted into the three 168-pin DIMM slots. The slot A is for a program ROM and the slot B is for the Japanese Kanji font. The slot C is not assigned.

(4) RAM

The RAM is inserted into the four 168-pin DIMM slots. The DIMMs must be fitted in descending order of the type No. labeled on each of them into the slots 1, 3, 2 and 4.

SDRAM DIMM Specifications:

Speed: PC100 or more Capacity: 64/128/256MB Configuration: Without parity and ECC. Requires the SPD information. Number of

chips contained = 8 or 16.

(5) EEPROM

The EEPROM (16Kb), an 8-pin DIP package, is inserted into the IC socket supplying the 3.3V power. Settings for controlling the controller block are stored in the memory.

(6) Flash ROM

A 2-megabyte flash ROM is surface-mounted on the CRM board. The flash ROM, composed of four chips of 256 kilo x 16 bits, can store fonts and macros.

(7) Memory Control LSI (CI)

A 696-pin BGA package ASIC made by NEC, which is equipped with a cooling heat sink and mainly controls the CPU I/F, memory, video data compression and decompression, and PUvideo I/F.

(8) Interface Control LSI (C2)

A BGA package ASIC made by Toshiba, which controls the PU command I/F, operator panel I/F, IDE I/F, Centronics I/F, USB I/F, PCI I/F, EEPROM and SPD (SDRAM DIMM) I/F.

(9) IDE HDD

An IDE connector is surface-mounted on the board to which an IDE HDD, assembled using molds for the purpose, is connected. The IDE HDD is used for storing font data, spooling edited video data temporarily and registering form data.

(10) PCI Bus Option

Two PCI I/F slots are provided for option board use. The bus, which uses an Oki Data original connector, can accept an Ethernet board.

(11) Host Interface

Standard: Centronics two-way parallel I/F (IEEE-1284-compliant)

USB (USB1.1-compliant)

Additional Board: (connected to PCI BUS)

Ethernet Board

41388601TH Rev.2 13 /

Page 14

2.2 Engine Control Board (K73 PWB)

28MHz

Control Panel

Duplex

Cassette 2/3

Analog output

(Color registration sensor adjustment)

Analog input

(Temperature change)

Analog Input

Switch

Analog input (OHP)

Analog input (Various densities)

CPU BUS

32bit Video I/F

Heater control

Fuse Cut Driver

EEPROM

Toner and ID sensors ID check

D/A

48MHz

CU I/F

CPU

MSM66Q577

A/D CON

LSI

(VIDEO MEM

Containing

4Mbit DRAM)

Fan control Cover front/upper open Stacker full Test switch (Power supply cooling)

8Mbit(1MByte)

Motor interruption UART interruption

K Head I/F Y Head I/F M Head I/F C Head I/F

Motor Driver

DC Motor Driver

High-Voltage Power Supply Serial Interface (2 channels)

FLASH

256Kbit(32KByte)

SRAM

9x Pulse Motors

DC Motor

(Geared Motor)

Paper Feed System Sensors

(Paper Feed, Paper Registration and Eject Sensors)

MT Sensor (Stage position and paper empty) Cassette 1 Sensor (Paper empty and near empty) Shutter, clutch, belt and fuser checks Cassette size

Figure 2.3

The engine control block (PU) is controlled by the engine control board (K73 PWB) which consists of a CPU (MSM66Q577), general LSI chip, flash ROM, EEPROM, pulse motor drivers, and video memory (see Figure 2.3).

(1) CPU

This, a 16-bit CPU with an AD converter (OKI MIM66Q577), controls the entire system.

(2) General LSI

This LSI (MG63P011-001LA), which is contained in the printer engine control block, incorporates 4 megabits of video memory and has functions such as engine-controller interfacing, LED interfacing, motor control, sensor input, video memory control, main scan color misalignment correction, skew correction and high-voltage power supply control.

41388601TH Rev.2 14 /

Page 15

(3) Flash ROM

8 megabits of flash ROM (MBM29F800TA-70) which stores PU programs.

(4) EEPROM

4 kilobits of EEPROM (NM93C66N-NW) which is mounted on the board with an IC socket and stores correction values.

(5) Pulse Motor Driver

The pulse motor driver (A2918, A2919, A3955) drives nine pulse motors to revolve the EP and carry media.

(6) SRAM

This SRAM (62256LFP-7LL) is used as working memory of the CPU.

2.3 Power Units

There is a low-voltage power unit, which consists of an AC filter circuit, low-voltage power circuit and heater driver circuit, and a high-voltage power unit which supplies a high-voltage power circuit.

(1) Low-Voltage Power Unit

This circuit generates the following voltages:

Output voltage Use for

+3.3 V Logic circuit power supply +3.8V Logic circuit power supply +5 V Motor and drive voltage for high-voltage power supply +32 V OP Amp, High-voltage power supply +12 V LED head

(2) High-Voltage Power Unit

This circuit generates the following 34V or more voltages, which are required for electrophotographic process, according to control sequences from the control board.

Output Voltage Use for Remarks

CH -900 to -1400±50V Voltage to charging roller DB Y, M, C: -10 to -400V/+300V Voltage to developing roller

K: -10 to -400V/+300V

SB Y, M, C: -100 to -700/0V Voltage to toner supplying roller TR 0 to 7KV Voltage to transfer roller Variable

41388601TH Rev.2 15 /

Page 16

2.4 Mechanical Processes

Paper Eject Roller

Paper Ejection

(Face down)

Power Supply

Charging Roller

Cleaning Blade

Paper Path

Selection

Heat Roller

Ejection

Roller

Fusing

Backup Roller

Control Signals

LED Head

Developing Roller

Power Supply

Toner Cartridge

Transfer Roller

Registration

Roller 1

Paper loading

Hopping Roller

Power

Supply

Registration

Roller 2

Paper Ejection Fusing Cleaning Transfer

Paper carriage Paper advance

Paper traveling

OPC drum revolution

Transfer

Charging

Expose

Development

Cleaning

Paper Eject Sensor

Paper Feed Sensor 1

Paper Ejection

(Face up)

Paper Feed Sensor 2

Multipurpose

Tray

Paper Cassette

Paper

registration

Paper

registration

(MT, 1ST, 2ND)

Write Sensor

x 4

YMC

Figure 2.4 shows the mechanical processes of the printer.

41388601TH Rev.2 16 /

Figure 2.4

Page 17

2.4.1 Electrophotographic process (1) Electrophotographic process

The following is the outline of electrophotographic process: 1 Charging

DC voltage is applied to the charging roller and the surface of the OPC drum is negatively and evenly charged.

2 Exposure

The LED head, under image signals, emits light to the negatively charged surface of the OPC drum. The radiated portions of the drum surface attenuate in negative charge according to the intensity of the light and, based on the surface potentials, a latent electrostatic image is formed on the drum surface.

3 Development

Negatively charged toner contacts the OPC drum and, by electrostatic force, adheres to the latent electrostatic image to form a clear image on the drum surface.

4 Transfer

Paper is placed on the surface of the OPC drum, and positively, or opposite to the polarity of the toner, charged by the transfer roller on its back to transfer the toner image to the paper.

5 Cleaning

The cleaning blade removes residual toner from the OPC drum after the transfer.

6 Fusing

The toner image on the paper is fused into place through the application of heat and pressure to it.

41388601TH Rev.2 17 /

Page 18

(2) Charging

Negative DC voltage is applied to the charging roller contacting the surface of the OPC drum.

Power

Unit

Charging roller

OPC drum

(3) Exposure

The negatively charged surface of the OPC drum is radiated with light from the LED head. The negative charge of the radiated portions of the drum surface attenuates in response to the intensity of the light and a latent electrostatic image responsive to the potentials of the surface is formed on the drum surface.

LED head

Power

Unit

Charging roller

OPC drum

Paper

LED head

OPC drum

41388601TH Rev.2 18 /

Page 19

(4) Developing

By the adhesion of toner to the latent electrostatic image on the drum surface, the image is changed to a toner image. The developing is processed at the contact part between the OPC drum and the developing roller.

1 The sponge roller causes toner to adhere to the developing roller. The toner becomes

negatively charged.

Developing roller

Charging roller

OPC drum

Developing blade

Sponge roller

Developing roller

2 The developing blade removes excess toner from the developing roller and a thin layer

of remaining toner is formed on the developing roller.

3 The toner is drawn by the latent electrostatic image at the contact portion between the

OPC drum and the developing roller. The latent electrostatic image on the drum surface is made visible with the toner.

(5) Transferring

The transfer roller, which is made of conductive sponge, presses paper against the surface of the OPC drum and brings the paper into intimate contact with the drum surface. The paper is placed on the drum surface and positively (opposite to the charge of the toner) charged by the transfer roller on its back. Applying positive high voltage from the power supply to the transfer roller moves the positive charge induced by the transfer roller to the paper surface at the contact portion between the transfer roller and the paper, the paper surface drawing the negatively charged toner from the drum surface.

OPC drum

Paper

Carrier belt

Transfer roller

Power unit

41388601TH Rev.2 19 /

Page 20

(6) Fusing

When passed between the heat roller and the backup roller, the toner image transferred to the paper is fused into place by the application of heat and pressure to it. The Teflon coated heat roller is heated by the built-in heat roller of 800W/backup roller of 500W (halogen lamp). The fusing temperature is controlled by the sum of the temperature detected by the thermistor moving over the surface of the heat roller and the temperature detected by the thermistor moving over the surface of the backup roller. A thermostat, which is provided for safety, becomes open by a heat roller temperature rise of not less than fixed degrees and cuts off voltage supply to the heater. The backup roller is being pressed against the heater by the pressure springs on both sides.

Thermostat

Thermistor

Heat roller

Paper

Thermostat

Backup roller

Thermistor

(7) Cleaning

Non-fused, residual toner on the OPC drum is scraped with the cleaning blade and collected in the waste toner area of the toner cartridge.

Waste toner area

(8) Cleaning

Residual toner on the transfer belt is scraped with the cleaning blade and collected in the waste toner box of the transfer belt unit.

41388601TH Rev.2 20 /

Cleaning blade

Waste toner box

Page 21

2.4.2 Paper running process Figure 2.5 shows how paper moves in the C9000.

Face-down stacker

Heat roller

Fuser

Registration roller Assy (B)

4 x LED heads

4 x LED Units

Eject roller

Backup roller

Low-voltage power supply

Cassette 1

Cassette 2

Cassette 3

Cassette 4

Belt unit

High-voltage power supply

Registration roller Assy (B)

Hopping roller

Multipurpose tray

Registration roller Assy (A)

Cleaning blade

Transfer roller

Feed roller

Cassette 5

Figure 2.5 Paper Route

41388601TH Rev.2 21 /

Page 22

(1) Paper Loading from 1st Tray

1. The paper loading motor runs (CCW), the paper loading clutch is engaged and, until the entrance cassette sensor is turned on, paper is advanced (the on/off operations of the paper loading clutch control the pickup roller).

2. After the paper turns the entrance cassette sensor on, the paper is forwarded a further fixed length and touches the registration roller Assy (A) (this corrects paper skew).

3. The electromagnetic clutch is engaged and the paper is carried onto the carrier belt.

Pickup roller

Registration roller Assy (B)

Entrance belt sensor

Feed roller

Electromagnetic clutch

Registration motor

Entrance sensor

Electromagnetic clutch

Entrance cassette sensor

Registration roller Assy (A)

Loading sensor

Paper

Retard roller

Loading motor

Figure 2.6

41388601TH Rev.2 22 /

Page 23

(2) Paper Loading from Option Tray

1. The paper loading motor runs (CW), the paper loading clutch is engaged and, until the carrier sensor on a tray which sits atop a loading tray is turned on, paper is advanced.

2. After the paper turns the carrier sensor on, the paper is forwarded a further fixed length and touches the carrier roller (this corrects paper skew).

3. The carrier clutch is thrown in and the paper is fed into the main body.

Pinch roller

Carrier roller

Carrier clutch

Carrier sensor

Upper tray Optional paper loading tray

Pickup roller

Feed roller

Planet gear

Paper loading clutch

Paper loading sensor

Retard roller

Paper loading motor

Figure 2.7

41388601TH Rev.2 23 /

Page 24

(3) Paper Loading from Multipurpose Tray (MT)

1. The release lever usually pushes down the hopping plate to a position to turn the micro SW on (Figure 2.8-a).

2. The running of the motor in the (a) direction drives the MT feed roller, causing the cam to turn. The cam pushes the release lever and the hopping plate picks up paper sent out by the MT feed roller (Figure 2.8-b), where the registration roller Assy (B) does not move as its one-way clutch gear (1) idles.

3. After the front edge of the paper turns the entrance sensor on, the paper is forwarded a fixed length. The paper stops when its front edge reaches the registration roller Assy (B).

4. Concurrently, the cam pushes down the hopping plate. The release lever that has been placed in its original position by the spring locks the hopping plate (Figure 2.8-c).

5. After the completion of the paper feed operation, the registration motor runs in the direction of the arrow (b) to drive the registration roller Assy (B), where the one-way clutch gear does not allow the MT feed roller to move.

Oneway clutch gear (2)

MT feed roller

Entrance sensor

Entrance belt sensor

Paper

Registration roller Assy(B)

Oneway clutch gear (1)

Relerse lever

Figure 2.8

Registration motor

Spring

Feed roller

Micro SW

Figure 2.8-a Figure 2.8-b Figure 2.8-c

41388601TH Rev.2 24 /

Hopper plate

Page 25

(4) Carrier Belt

1. The running of the carrier belt motor in the direction of the arrow (a) drives the carrier belt. The belt unit sits with one carrier roller immediately below each color’s drum, and the carrier belt between them. By the application of a fixed voltage, the carrier belt and carrier roller feed paper on the carrier belt into the fuser unit, transferring a toner image from each color’s drum.

Drum

Carrier belt

KYMC

Carrier (transfer) roller

Carrier (transfer) belt motor

Figure 2.9

41388601TH Rev.2 25 /

Page 26

(5) Driving and Up-and-Down Movements of I/D Unit

1. The I/D unit driving and up-and-down movements are effected by a single-pulse motor. The running of the main motor in the direction of the arrow (a) turns the lever 1 to the left. Then, the lever 2 that was lifted by the lever 1 lowers to move down the I/D unit. After the up-and-down sensor is turned on (Figure 2.10-c), the specified downward pulsing places the I/D unit in its lowest position (or equivalently, printing position). The drum gear engages with the driving gear and starts revolving to transfer an image on the drum to running paper, where the one-way gear idles upon placement of the lever in its lowest position.

2. With the running of the main motor in the direction of the arrow (b), the lever 1 pushes up the I/D unit via the lever 2. After the up-and-down sensor is activated (Figure 2.10-d), the lever 1 lifts the I/D unit to a specified level and stops to keep space to an extent between the drum and the carrier belt (Figures 2.10-c and 2.10-e). The drum gear is not engaged with the driving gear and does not revolve.

3. When the two pins of the up-and-down sensor are pushed up by the I/D unit, and touches and electrically connected to the plate above the pins, the sensor recognizes the on state. When the two pins are pushed down by the I/D unit, and separated and insulated from the plate, the sensor recognizes the off state. The installation of the I/D unit can also be verified by recognizing the off state of the upand-down sensor.

Lever 2

I/D unit

Drum

One-way gear

Driving gear

Figure 2.10-a Figure 2.10-b

41388601TH Rev.2 26 /

Lever 1

Page 27

Plate

Pin Spring

Board

Up-and-down Sensor

Figure 2.10-c

Figure 2.10-d

Figure 2.10-e

41388601TH Rev.2 27 /

Page 28

(6) Fuser Unit and Paper Ejection

1. A single-pulse motor drives the fuser unit and the eject rollers. In response to the running of the heat motor in the direction of the arrow (a), the heat roller turns. This roller fuses a toner image to paper by heat and pressure.

2. At the same time, the four eject rollers move to eject the paper.

3. The paper separator solenoid switches the path back and forth between the route to the face-up stacker and the route to face-down stacker.

Eject rollers

Fuser unit

Fuser motor

Heat rollers

Paper separator

Face-up stacker

Figure 2.11

41388601TH Rev.2 28 /

Page 29

(7) Duplex Unit

1. When the duplex unit receives an instruction from the printer to print on both sides of a sheet of paper, the solenoid opens the separator after the completion of one side printing of a sheet of paper sent from the tray. The path is switched to that to the duplex unit. At this time, as the roller (1) turns in the direction of the arrow “a,” the paper is retracted on the rear of the cassette.

2. When fixed time has elapsed after the front edge of the paper passes through the duplexin sensor, the rollers reverse and the roller (1) turns in the direction of the arrow “b” to feed the paper into the duplex unit. After that, the paper passes through the rollers (2), (3) and (4), and ejected with the other side printed, and fed again into the printer.

Separator

Solenoid

Duplex-in sensor

Roller(1)

Motor

Roller(2)

Roller(3)

Roller(4)

Figure 2.12

41388601TH Rev.2 29 /

Page 30

2.5 Sensor

2.5.1 Paper related sensors

Face-down paper eject sensor

Face-down sensor

Paper eject sensor

Backup roller

Duplex roller

Paper eject roller

Heat roller

Driving roller

Duplex-in sensor

Duplex rear sensor

Stacker full sensor

C drum

Carrier belt

Duplex front sensor

Duplex feed roller

Entrance belt sensor

K drumY drumM drum

Driving roller

Belt cleaning blade

Registration roller B

Entrance MT sensor

1st feed roller

2nd feed roller

MT feed roller

Pinch roller 2

Pinch roller 1

Registration roller A

Entrance cassette senso

Auxiliary roller

Carrier sensor

Sensor

Entrance MT Sensor Entrance Cassette sensor

Entrance Belt sensor

Detects the beginning of incoming paper to determine the timing for switching from hopping to carriage.

Detects the beginning of transferred paper and, based on the time taken until the paper front edge reaches the sensor, determines the paper length.

Paper Eject sensor

Detects the beginning and end of paper to determine the paper ejection timing.

Duplex-In sensor

Detects the beginning of paper which enters into the duplex unit to determine the time taken until the reversed rollers turn in forward direction.

Duplex Rear sensor

Detects the beginning of paper after the turns in reverse direction, in the duplex unit.

Duplex Front sensor

Detects the end of paper after the turns in reverse direction to determine the paper ejection timing, in the duplex unit.

Stacker Full sensor

Face-Down Paper Eject sensor

Face-Down Route sensor

Detects the face-down stacker full of paper.

Detects paper carriage to the paper eject roller to determine the timing for job offset operation.

Detects the face-down carrier route jammed with paper when it has a paper jam.

Function

Sensor status

: Paper exists.

OFF

: Paper is empty.

: Paper exists.

OFF

: Paper is empty.

: Paper exists.

OFF

: Paper is empty.

: Paper exists.

OFF

: Paper is empty.

: Paper exists.

OFF

: Paper is empty.

: Paper exists.

OFF

: Paper is empty.

: Stacker is full.

OFF

: Stacker is empty.

: Stacker is full.

OFF

: Stacker is empty.

: Stacker is full.

OFF

: Stacker is empty.

Carrier sensor

41388601TH Rev.2 30 /

Detects paper carriage from the option tray.

: Stacker is full.

OFF

: Stacker is empty.

Page 31

2.5.2 Other sensors 1 Paper Empty sensor

This sensor checks whether the paper cassette is empty.

2 Paper Near sensor

This sensor checks whether the paper cassette is near empty.

3 MPF Paper Empty sensor

This sensor checks whether the front feeder has paper.

4 MPF Hopping switch

This microswitch checks whether the front feeder table is in the up position or in the down position.

5 Stacker Full sensor

This sensor checks whether the stacker is full.

6 Paper Size switch

This sensor detects the size of paper in the paper cassette.

7 EP Up/Down sensor (one for each of colors, Y, M, C and K)

This sensor checks whether the I/D unit is in the up position or in the down position.

8 Toner K, Y, M and C sensors

By measuring the time interval between regular opening movements of each sensor’s lever, the sensor checks whether its toner cartridge is empty.

9 Temperature sensor

See Section 2.6 (Transfer Control Responds to Environmental Changes)

0 Humidity sensor

See Section 2.6 (Transfer Control Responds to Environmental Changes)

A OHP sensor

This sensor detects the presence or the absence of transparencies.

B Alignment sensor

When color misalignment has been corrected, this sensor reads the alignment pattern printed at the right and left ends of the transfer belt (see Section 2.13).

41388601TH Rev.2 31 /

Page 32

2.6 Color Misalignment Correction

C9000 is equipped with multiple LED heads, which can result in color misalignment. The mechanically induced color misalignment is automatically corrected as follows:

(1) Color alignment to be corrected

1 Color misalignment in X-axis direction (Positional error caused by LED head) 2 Color misalignment in slanting direction (Positional error caused by LED head) 3 Color misalignment in Y-axis direction (Positional error caused by I/D unit and LED head)

(2) Correcting

Printing the preset color misalignment detection pattern on the belt and, by a reflection sensor, reading the printed pattern detects each color’s misalignment value to determine its correction value. The correction value is used to change each color’s (Cyan, Magenta and Yellow) writing timing in comparison with that of Black.

2.7 Transfer Control Responds to Environmental Changes (Room Temperatures and Relative Humidities)

C9000 measures room temperature and relative humidity using a room temperature sensor and humidity sensor, and calculates an optimum transfer voltage under its measurement environment to perform real-time control on printing with the optimum voltage.

41388601TH Rev.2 32 /

Page 33

2.8 Paper Jam Detection

C9000 detects paper jams after power-on and during printing. When a paper jam occurs, the printer immediately suspends the printing operation. Opening the cover to remove the jammed paper and closing it resumes the printing.

LCD Error Code

400 372

390 5-395

4-394 3-393 2-392 1-391 370

383 371

382

381 380 490

5-495 4-494 3-493 2-492 1-491

Error

Paper Size Error

The entrance cassette sensor does not turn off within fixed time

after it turns on. Loading of plural sheets of paper is sensed. Misfeed from Duplex Carrier Assembly Misfeed from Multipurpose Tray (MT)

Paper could not be loaded from the duplex carrier assembly.

Paper could not be loaded from the MT (the entrance MT

sensor does not turn on within fixed time after the hopping). Misfeed from Cassette 1, 2, 3, 4 or 5

Paper could not be loaded from the cassette 1, 2, 3, 4 or 5 (the

entrance cassette sensor does not turn on within fixed time after

the hopping).

Duplex Paper Jam in Reversing

The duplex rear sensor does not turn on during the paper

reversing operation of the duplex unit. Duplex Unit Entrance Paper Jam

The duplex-in sensor does not turn on during the paper loading

in the duplex unit. Duplex Unit Input Paper Jam Paper Ejection Jam

The duplex front sensor does not turn on during the operation.

The paper eject sensor does not detect the end of paper within

fixed time after sensing the beginning of it. The paper eject

sensor does not turn off after it turns on. Paper Carriage Jam

The paper eject sensor does not turn on while paper is running

on the belt. Loading Jam

Paper does not reach the entrance belt sensor or the MT sensor

after the completion of the hopping. MT Paper Empty Cassette 1, 2, 3, 4 or 5 Paper Empty

Printing occurs with no paper in the MT.

The cassette 1, 2, 3, 4 or 5 has no paper.

Description

Duplex-in sensor

Duplex Rear Sensor

Paper Ejection

Paper eject sensor

Duplex Entry

Duplex rear sensor

Entrance belt sensor

Paper Carriage

Duplex Input

Duplex front sensor

Entrance MT sensor

Cassette

Cassette Cassette

Paper Ejection

Misfeed from MT

Entrance cassette sensor

Multipurpose T ray

(MT)

Misfeed from Duplex Unit Misfeed from Cassette 1 Misfeed from Cassette 2 Misfeed from Cassette 3 Misfeed from Cassette 4

Misfeed from Cassette 5

41388601TH Rev.2 33 /

Page 34

2.9 Cover Opening

When the top cover of the printer is open, the cover open microswitch turns opens to cut off the highvoltage power supply, and outputs which are not less than 32V. At the same time, the CPU receives CVOPN signals indicating the status of the microswitch and performs cover open operations.

Detection

Circuit

CPU

66577

P10, 5

P7, 6

71K-PCB

Top cover microswitch

+32V

COVOPN (2P)

High-voltage power supply board

HVOLT (16P)

detect circuit

High-voltage power supply unit

detect circuit

+32V

FCOVER(3P)

Duplex (16P)

Front cover microswitch

+32V

Duplex unit

V71-PCB

41388601TH Rev.2 34 /

Page 35

2.10 Toner Low Detection

• Structure This device consists of the stirring gear which revolves at a constant speed, the stirring bar, and

the magnet on the stirring bar. The stirring bar turns in synchronization with the protrusion of the stirring gear.

Stirring gear

Link

Stirring bar

• Detection A toner low condition is detected by measuring the contact time between the sensor lever magnet

and the stirring bar.

Toner low sensor

Sensor lever A

Toner Full Condition

• The stirring bar turns in synchronization with the stirring gear.

Sensor lever B

• Since the opposite side is in toner, the stirring bar turns by the force of the stirring gear even when the stirring magnet is placed in its highest position.

Toner cartridge

Stirring bar

Toner Low Condition

• The stirring bar reaches its highest position, then

Sensor lever A

Toner low sensor

falls to its lowest position under its own weight because of the absence of toner resistance on the opposite side. In this situation, bar-magnet contact time becomes long. By measuring the time, a toner low condition can be detected.

41388601TH Rev.2 35 /

Sensor lever B

Toner cartridge

Stirring bar

Page 36

Toner Full Condition (At warming-up,A4 transverse:16ppm *1)

TNRSNS

T=2.3

Toner Low Condition (At warming-up,A4 transverse:16ppm *1)

1.12

TNRSNS

T=2.3

t1 1.12

• When the toner low condition is detected 20 consecutive times, toner low is detected.

(The toner low message is displayed when about 1000 A4 sheets at 5% density have been printed after toner low had been detected.) The detection is not performed until toner low occurs after the detection of toner low.

• When the toner full condition is detected 10 consecutive times, toner low is removed.

• When the toner sensor remains unchanged for more than 15 cycles of 2.3 seconds, the toner

sensor alarm is activated.

• The toner sensor does not perform the detection while the drum motor is not running.

* 16ppm is the print speed at warm-up. T and t1 change in proportion to the print speed.

41388601TH Rev.2 36 /

Page 37

2.11 Paper Size Detection

Via the cam tied to the paper guide of the paper cassette, the four tab pieces are driven according to the set position of the paper guide.

Upon installation of the paper cassette, the microswitch detects the condition of the tab pieces and the paper size is recognized.

Without Cassette A3-Nobi Tabloid A3 B4 Regal 14" Regal 13" A4 in Portrait Orientation Letter in Portrait Orientation Executive B5 in Portrait Orientation Letter in Landscape Orientation A4 in Landscape Orientation A5 B5 in Landscape Orientation A6

PSZSW1

0 0 1 1 0 0 0 1 1 1 1 1 0 0 1 0

PSZSW2

0 0 0 0 0 1 1 1 1 1 1 0 0 1 0 1

PSZSW3

0 1 1 0 0 0 0 1 1 0 0 1 1 1 0 1

PSZSW4

0 1 1 1 1 1 0 0 1 1 0 0 0 0 0 1

41388601TH Rev.2 37 /

Page 38

2.12 Operation at Power-on

2.12.1 Self-diagnostic test (1) Initial test

The following checks are automatically performed at power-on. (a)ROM check (b)RAM check (c) EEPROM check (d)Flash ROM check

(2) ROM check

The ROM is checked by calculating a HASH value.

(3) RAM check

(a)Checking is conducted by RAM type. Out-of-specification RAM is judged as an error. (b)The order of mounted RAMs is checked. Out-of-standard RAM is judged as an error. (c) The RAM in each slot is checked by read-after-write operation.

(4) EEPROM Check

Specific data stored at the fixed EEPROM address is checked.

(5) Flash ROM Check

The flash ROM format is checked. Unformatted ROM is formatted after the read-after-write checking.

(6) Option Unit Check

Checking whether the option units (including a HDD, NIC, option trays and the duplex unit) are equipped with the printer is performed.

41388601TH Rev.2 38 /

Page 39

2.13 Color Misalignment Detection

Reflection-type optical sensors (Z71-PCB) are mounted at the right and left ends of the belt, respectively, in front of the toner scraping (cleaning) blade which is at the back of the belt unit. The color misalignment detection pattern is printed on the belt at the right and left ends each and, by reading the patterns by the reflection-type optical sensors, the misalignment amounts are measured with respect to Black to determine correction values. Then, the misalignment in mainscanning, sub-scanning and slanting directions is corrected. These operations are performed at power-on, at cover-close and every 400 pages.

CMYK

Transfer belt

LED head

Belt running direction

Color alignment sensors L and R

Transfer Belt

Color alignment sensor R

Belt running direction

Color alignment sensor L

(Bottom View)

Cleaning blade

41388601TH Rev.2 39 /

Page 40

2.14 Version Read of Periodically Replaced Units

The condition (new or used) of the I/D, fuser unit and belt unit are determined by an internal fuse within the units. When the unit is powered on or the upper cover is opened and closed, the printer scans for consumables fuses. If a conducting fuse is found, that unit's counter is reset and the fuse is opened. The life counters of the consumables are checked at each power on and each closing of the upper cover. Once a fuse is opened the consumable is judged used.

2.15 Life Counter for Replaceable Units

Each life of the periodically replaced units - I/D, fuse unit and belt unit is counted as shown in the following table:

Unit Name

I/D

Toner Cartridge

Belt Unit

Fuser Unit

The number of drum revolutions is counted in the unit of letter paper length + paper interval in continuous printing. End of Life: Time when a distance equivalent to pages of 26K is printed (on 3P/J).

The number of dots printed is counted. The used amount is determined based on the counter value (See Section 2.16). End of Life: Time when a toner-low error occurs.

The number of turns revolutions is counted in the unit of letter paper length + paper interval in continuous printing. End of Life: Time when the counter value reaches 80K.

One is counted every time when one page is passed. End of Life: Time when the counter value reaches 80K.

2.16 Toner Consumption Detection

The used toner amount is detected by counting the number of dots printed. The counting starts after toner-low is released. The sum of the counted values is stored in EEPROM. When toner-low is detected, the amount used is forcedly set to 7%. When the equivalent of pages of 1K on A4 and 5% duty is reached after that, toner-empty is detected.

Condition

Action

Warning (the unit can still be used).

Do not use the unit anymore.

Warning (the unit can still be used).

41388601TH Rev.2 40 /

Page 41

3. PARTS REPLACEMENT

This section describes the procedure for replacing the parts, assemblies and units in the field. The replacing procedure is given for detachment. To attach, use the reverse procedure.

3.1 Precautions in Replacing Parts

(1) Before replacing the parts, be sure to remove the AC cable and the interface cable.

(a) To remove the AC cable, always use the following procedure.

1 Flip the power switch of the printer off (to “O”). 2 Pull the AC inlet plug of the AC cable out of the AC receptable. 3 Remove the AC cable and the interface cable from the printer.

(b) To connect the printer again, always use the following procedure.

1 Connect the AC cable and the interface cable to the printer. 2 Insert the AC inlet plug into the AC receptacle. 3 Flip the power switch of the printer on (to “I”).

Disconnect

(2) Do not disassemble the printer so long as it operates properly. (3) Minimize the disassembly. Do not detach parts other than those shown in the replacing

(4) For maintenance applications, use designated tools. (5) Follow the order instructed to disassemble the printer. Incorrect order may damage the

(6) Small parts such as screws and collars tend to get lost, so temporarily replace them in (7) When handling ICs and circuit boards such as microprocessors, ROMs and RAMs, do not (8) Do not place the printed circuit boards directly on the printer or the floor.

Connect

procedure.

parts. their original positions. use gloves that are likely to have static.

41388601TH Rev.2 41 /

Page 42

[Maintenance Tools] Table 3-1 lists tools necessary to replace the units.

Table 3-1 Maintenance Tools

No.

7 1

No. 1-100 Philips screwdriver

No. 2-200 Philips screwdriver, Magnetized

No. 3-100 screwdriver

No. 5-200 screwdriver

Digital multimeter

Pliers

Handy cleaner

LED Head cleaner P/N 4PB4083-2248P001

High voltage probe

Q' ty Place of use RemarksService Tools

2~2.5 mm screws

3~5 mm screws

Cleans LED head

41388601TH Rev.2 42 /

Page 43

3.2 Parts Layout

Figure 3.1

41388601TH Rev.2 43 /

Page 44

[Top Cover Assy]

Figure 3.2

41388601TH Rev.2 44 /

Page 45

[Printer Unit-1/2]

Figure 3.3

41388601TH Rev.2 45 /

Page 46

[Printer Unit-2/2]

Figure 3.4

41388601TH Rev.2 46 /

Page 47

[Cassette Guide Assy (L), (R)]

Figure 3.5

41388601TH Rev.2 47 /

Page 48

41388601TH Rev.2 48 /

Page 49

[Duplex Unit]

Figure 3.6

41388601TH Rev.2 49 /

Page 50

3.3 Replacing Parts

This section describes how to replace the parts and assemblies illustrated below.

41531301 41515110

Print Engine Controller PWB (3.3.22) 41502304 × 4 LED Assy (3.3.2) 40737401 Power-Unit AC-DC Switching (115V) (3.3.34) 40737501 Power-Unit AC-DC Switching (230V) (3.3.34) 40737601 HV Power Supply (3.3.35) 41531402, 41531404 Fuser Unit (3.3.37) 41531502 Belt Unit (3.3.38) 41178202 Duplex Unit (3.3.39)

41480901 Printer NIP

41483001 Printer Unit

41481001 Unit-Lower-Frame (3.3.36)

41500101 Insurator 41483701 Main Cooling Fan Assy (3.3.18) 2381018P0001 HV Tape Harness

41484101 Electrical Chassis (3.3.21)

41483801 Main Motor Assy (3.3.32) 41483902 Belt Motor Assy (3.3.30)

41489001 Plate Assy-Side (3.3.33) 41493002 Multipurpose Tray (3.3.13) 41276502 Rear Cover (3.3.12) 41277402 Left Side Cover (3.3.9) 41481202 Right Side Cover (3.3.7) 41276402 Front Cover (3.3.11) 41277502 Face Up Tray (3.3.10) 41504401 Top Cover 41484402 Top cover (3.3.1) 40866212 Control panel Bezel (3.3.4)

41493002 Multipurpose Tray Assy (3.3.13)

41484902 Cassette Assy (3.3.7) 41277902 Cover-Blind (3.3.7) 41481701 Feed-Roller (3.3.8) 40863801 Plate-Side (3.3.21)

41483102 Printer Chassis (3.3.23) 41483202 Regist Roller Assy (A) (3.3.15) 41483301 Regist Roller Assy (B) (3.3.16) 41483401 Registration Motor Assy (3.3.17) 41187101 Registration Clutch (3.3.17) 41486601 Duplex Guide Assy (3.3.20)

41481301 Main Feed Assy (3.3.36) 41515801 PCE-Size Sence (3.3.36) 22011000P0140 IMSA-9714N-14A (3.3.36)

41490702 Electrical Chassis Cooling Fan

40841402 Fuser Latching Handle (R) (3.3.31) 41628301 Fuser Latching Handle Spring (3.3.31)

40850201 Contact Assy (3.3.33)

41045802 × 2 Link (3.3.13) 41486202 MT Tray Cover Assy (3.3.13) 41278002 MT Top Cover (3.3.13) 40325101 MT Drive Gear (3.3.13)

40841302 Fuser Latching Handle (L) (3.3.29) 41628301 Fuser Latching Handle Spring (3.3.29) 40841601 Entrance Sensor Actuator #1 (3.3.24) 41578501 Entrance Sensor Actuator #2 (3.3.26) 40841801 Entrance Sensor Actuator #3 (3.3.26) 41621801 Registration Shutter Solenoid Assy 41488801 Registration Shutter 41589401 Registration Shutter Spring 41641701 Fuser Driver Gear-A (3.3.27) 41095901 Fuser Exit Roller (3.3.27) 4PP4043-4489P001 Fuser Exit Roller Bushing (L) (3.3.27) 4PP4076-3949P001 Fuser Exit Roller Bushing (R) (3.3.27) 41189701 × 4 Drum Contact Assy (3.3.14) 41258301 Entrance Sensor PWB (3.3.25) 41491001 Color Registration Sensor Assy (3.3.19) 41073601 Exit Sensor Assy (3.3.28) 41483701 Main Motor FAN Assy (3.3.27)

40861001 × 8 LED Assy Spring (3.3.2) 41257902 LED Control PWB (Y71) (3.3.4) 41349801 Stack Full Sensor (3.3.4) 41349301 × 4 Eject Roller (3.3.4) 41484501 Control Panel Assy (3.3.4) 2381005P0015 Control Panel Tape Harness (3.3.4) 41514101 LED Harness K 41514102 LED Harness Y 41514103 LED Harness M 41514104 LED Harness C 41328402 Top Cover Handle (3.3.5) 41277602 Top Cover Latch (3.3.5) 40861401 × 2 Top Cover Latch Spring (3.3.5) 41484701 Eject Guide Assy (3.3.6)

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3.3.1 Top cover (1) Open the top cover Assy.

(2) Remove the nine screws 1 to detach the top cover 2.

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3.3.2 LED Assy/ LED Assy spring (1) Open the top cove 1.

(2) Remove the three cables, and unhook the LED Assy 2 at the two places to demount it (The

two springs 3 become detached together with the LED Assy 2).

(3) Detach the LED connector 4.

When assembling, attach the LED connector 4 to the LED head and insert the flat cable.

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3.3.3 Top cover unit (1) Remove the top cover (see section 3.3.1).

(2) Remove the rear cover (see section 3.3.12). (3) Remove the front cover (see section 3.3.11). (4) Remove the electrical chassis (see section 3.3.21). (5) Unscrew the screws 1 and 2 to remove the limiters (F) 3 and (R) 4. (6) Remove the inner shaft 5, then the top cover unit 8 (The inner springs 6 and 7 become

detached).

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3.3.4 Control panel Assy/ Control panel bezel/ LED control PWB/ Toner sensor/ Stack full sensor/ Control panel tape harness/ Eject roller

(1) Detach the control panel bezel 1. (2) Remove the screws 2 to demount the control panel 3. (3) Detach the control panel tape harness 4. (4) Remove the screws 6, unhook the connector 7 and demount the LED control PWB 8. (5) Unscrew the screws 9 to remove the plate 0. (6) Disengage the claw to demount the toner sensor A. (7) Demount the stacker full sensor B. (8) Unscrew the eject sensor bracket C, D.

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3.3.5 Top cover handle/ Top cover latch/ Top cover latch spring (1) Remove the two screws 1 to detach the top cover handle 2 and disengage the top cover

latch 3 (The two top cover latch springs 4 become detached).

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3.3.6 Eject guide Assy (1) Remove the seven screws 1 to detach the eject guide Assy 2.

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3.3.7 Cassette Assy/ Blind cover/ Side cover R Assy (1) Detach the cassette Assy 1.

(2) Disengage the blind cover 2 at the two places to detach it. (3) Unscrew the two screws to remove the stopper 4. (4) Disengage the claw on the left support of the side cover R to detach the side cover R.

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3.3.8 Feed rollers (1) Remove the cassette.

(2) Unlatch and demount the feed rollers 1.

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3.3.9 Left side cover (1) Remove the four screws 1 to detach the left side cover 2.

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3.3.10 Face-up tray (1) Open the face-up tray in the arrow direction and move the links 2 out of engagement (at two

places each of the links) to detach the face-up tray 1.

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3.3.11 Front cover (1) Open the top cover 1.

(2) Disengage the claws and remove the blind cover 2. (3) Unscrew the six screws 4 to detach the front cover 3.

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3.3.12 Rear cover (1) Open the top cover 1,

(2) Remove the five screws 3 and 4 to detach the rear cover 2.

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3.3.13 Multipurpose tray Assy/ Multipurpose tray cover Assy/ Links/ Multipurpose tray top cover/ Multipurpose tray drive gear

(1) Remove the rear cover (see section 3.3.12). (2) Remove the front cover (see section 3.3.11). (3) Unscrew the three screws 1 to detach the multipurpose tray top cover 2. (4) Unscrew the two screws 3 and remove the connector to detach the multipurpose tray 4. (5) Disengage 4 and 5 to detach the multipurpose tray cover Assy 5 (the links 7 become

detached).

(6) Unhook and detach the multipurpose tray drive gear 8.

Engagement

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3.3.14 Drum contact Assys (1) Insert a flatblade screwdriver between the printer case and the drum contact Assy 1 to

demount the drum contact Assy.

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3.3.15 Registration roller Assy (A)/ Registration drive gear (A) (1) Remove the front cover (see section 3.3.11).

(2) Remove the rear cover (see section 3.3.12). (3) Remove the multipurpose tray (see section 3.3.13). (4) Unscrew the four screws 1 to demount the registration roller Assy (A) 2. (5) Remove the E ring 3 to detach the registration gear (A) 4.

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3.3.16 Registration roller Assy (B) (1) Remove the cassette Assy.

(2) Remove the front cover (see section 3.3.11). (3) Remove the rear cover (see section 3.3.12). (4) Remove the electrical chassis (see section 3.3.21). (5) Remove the registration clutch (see section 3.3.17). (6) Remove the printer chassis (see section 3.3.23). (7) Unscrew the four screws and pull out the registration Assy (B) 2 in the arrow direction.

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3.3.17 Registration clutch, Registration motor Assy (1) Remove the left side cover (see section 3.3.9).

(2) Remove the electrical chassis (see section 3.3.21). (3) Remove the connector and the E ring 1, then screws 3 and 4, and then the earth plate 5. (4) Remove the connector and unscrew the two screws 6 to demount the registration motor Assy

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3.3.18 Cooling fan (1) Unhook the connector 1, and remove the screws 2 and the cooling fan 3.

air direction

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3.3.19 Color registration sensor Assy (1) Remove the two screws 1 and the three connectors to demount the color registration sensor

Assy 2.

(2) Remove the earth plate B 3.

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3.3.20 Duplex guide Assy (1) Unlatch and demount the duplex guide Assy 1.

(2) Remove the springs 2.

Main chassis (L side)

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3.3.21 Electrical chassis/ Electrical chassis cooling fan (1) Unscrew the five screws 1 and two screws 2 to remove the plate A 3.

(2) Unscrew the thirty-one screws 4 to remove the shield plate B 5. (3) Remove the printer engine controller PWB (see section 3.3.22). (4) Unscrew the eleven screws 6 to detach the electrical chassis 7. (5) Unscrew the two screws 8 to demount the electrical chassis cooling fan 9.

air direction

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3.3.22 Printer engine controller PWB (1) Remove the rear cover (see section 3.3.12).

(2) Remove the electrical chassis and the electrical cooling fan (see section 3.3.21). (3) Remove the five screws 1 and all the connectors to demount the printer engine controller

PWB 2.

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3.3.23 Printer unit chassis (1) Unscrew the screw 1 and remove the AC switch Assy 2.

(2) Remove the four black screws 3 and six screws 4 to detach the printer unit chassis 5.

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3.3.24 Entrance cassette sensor actuator (1) Remove the printer unit chassis (see section 3.3.23).

(2) Turn over the main chassis. (3) Remove the two clamps with tweezers to demount the entrance cassette sensor actuator 1.

Main chassis

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3.3.25 Entrance sensor PWB (1) Remove the registration roller Assy (B) (see section 3.3.16).

(2) Remove the two screws 1 to demount the entrance sensor PWB 2.

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3.3.26 Entrance MT sensor actuator and Entrance belt sensor actuator (1) Remove the entrance sensor PWB (R71) (see section 3.3.25).

(2) Unlatch and detach the entrance MT sensor actuator 1. (3) Unlatch and detach the entrance belt actuator 2.

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3.3.27 Main motor fan/ Fuser eject roller (1) Unscrew the two screws 1 to remove the fan Assy 2.

(2) Unscrew the fuser eject roller contact 4. (3) Remove the fuser drive gear 5. (4) Unscrew the fuser drive gear Assy 8. (5) Remove the screws and washers 0 to demount the fan A. (6) Unlatch and detach the fuser eject roller bearing (L) B and fuser eject roller C.

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3.3.28 Eject sensor Assy (1) Remove the fuser eject roller (see section 3.3.27).

(2) Remove the screw 1 and connector 2 to demount the (red/blue) eject sensor Assy 2.

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3.3.29 Fuser latching handle (L) (1) Remove the latching handle spring 1.

(2) Unscrew the fuser latching handle (L) 3.

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3.3.30 Belt motor Assy (1) Remove the fuser latching handle (R) (see section 3.3.32).

(2) Unscrew the two screws 1 to detach the two connector 2. (3) Demount the belt motor Assy 3.

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3.3.31 Fuser latching handle (R) (1) Remove the printer unit chassis (see section 3.3.23).

(2) Remove the E ring 1. (3) Remove the fuser latching handle spring 2 to detach the fuser latching handle (R) 3.

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3.3.32 Main motor Assy (1) Remove the belt motor Assy (see section 3.3.30).

(2) Remove all the connectors. (3) Remove the two screws 1 to demount the main motor Assy 2.

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3.3.33 Contact Assy/ Side plate Assy (1) Remove the printer unit chassis (see section 3.3.23).

(2) Remove the four screws 1 to detach the side plate Assy 2. (3) Remove the three screws 3 to detach the contact Assy 4.

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3.3.34 Low voltage power supply (1) Remove the printer unit chassis (see section 3.3.23).

(2) Unhook the connector 1. (3) Remove the eight screws 2 to demount the low voltage power supply 5.

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3.3.35 High voltage power supply (1) Remove the contact Assy (see section 3.3.33).

(2) Unhook the connector of the high voltage power supply 2. (3) Remove the two screws 1 to detach the high voltage power supply 2 and the tape harness

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3.3.36 Main feed Assy (1) Remove the printer unit chassis (see section 3.3.23).

(2) Remove the low voltage power supply and high voltage power supply (see sections 3.3.34

and 3.3.35). (3) Unscrew the five screws 1 to remove the lower plate 2. (4) Unscrew the six screws 3 to demount the main feed Assy 4. (5) Unscrew the screws 5 to detach the cable and then the PCB size board 6. (6) Unscrew the screw 7 to detach the duplex connector 8. (7) Unscrew the screws 9 to detach the second tray connector 0.

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3.3.37 Fuser unit (1) Open the top cover 1.

(2) Push the right and left fuser levers (blue) 2 in the arrow direction to detach the fuser unit 3.

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3.3.38 Belt unit (1) Open the top cover 1.

(2) Remove the I/D unit. (3) Push the lever (blue) 2 in the arrow direction, raise the handle (blue) and detach the belt unit

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3.3.39 Duplex unit (1) Remove the cassette Assy, the front cover and the front cover inner buffle.

(2) Unlatch the rear at the right and left and pull the duplex unit 1 toward the front.

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3.3.40 CU Assy (1) Pulling out Control Board

1. Loosen the two screws 1.

2. Pull the control board 2 out.

3. Place the control board 2 on a flat table.

(2) Detaching Fan

1. Remove the connector 3.

2. Remove the two screws 4.

3. Detach the fan 5.

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(3) Demounting CRM Board

1. Remove the three screws 6 to detach the fan bracket 7.

2. Remove the four screws 8 to detach the plate support 9 and the guide rail 0.

3. Remove the two screws A to detach the guide rail B.

4. Remove the two screws C and three screws D, then demount the CRM board E.

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4. ADJUSTMENT

Adjustments are carried out by key operations on the operator panel. The maintenance menu is included in the general menu of this printer. Choose the maintenance

menu for adjustment.

4.1 Maintenance Menu and Its Functions

The general menu has the category, MAINTENANCE MENU. The items adjustable in this menu are shown below.

Maintenance Menu

5. REGULAR MAINTENANCE

5.1 Consumables to be Regulary Replaced

It is recommended that a user should replace the consumables below according to the replacement standard. (If not replaced, print quality is not assured or it may result in a failure.)

Part Name

Large-capacity Toner Cartridge

ID Cartridge

Fuser Unit

Belt Unit

The above consumables replacement may be performed by a user.

5.2 Cleaning

The inside and outside of this printer should be cleaned with a hand vacuum cleaner, if necessary.

Note:

Do not touch the Image drum terminal, LED lens array and LED head connectors.

Time for Replacement

When the message “Toner Low” is displayed.

When the message “Drum Life” is displayed.

When the message “Fuser Life” is displayed.

When the message “Belt Life” is displayed.

Replacement Condition

After 15,000 copies have been printed.

After 26,000 copies have been printed. (at 3P/J)

After 80,000 copies have been printed.

After 80,000 copies have been printed. (at 3P/J)

Adjustment after Replacement

Replace the Toner cartridge.

Reset the drum counter after drum replacement.

Reset the fuser counter.

Reset the belt counter.

5.3 Cleaning of LED Lens Array

When a longitudinal white band or stripes (that is, void or light printing) appear on a printed paper surface, the LED lens array should be cleaned.

Note:

The LED head cleaner must be used to clean the LED lens array. (The LED head cleaner is included in the Toner cartridge box.)

White band, white stripes (Void or light printing)

5.4 Cleaning of Pick-up Roller

When papers are not fed normally, the Pick-up roller should be cleaned.

Note:

Clean it with a soft cloth and alcohol. Be cautious not to damage the roller surface.

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6. TROUBLESHOOTING PROCEDURES

6.1 Tips for Troubleshooting

(1) Check the basic check points covered in the user’s manual. (2) Gather as much information on the problem from the customer as possible. (3) Perform inspections in conditions close to those in which the problem had occurred.

6.2 Check Points before Correcting Image Problems

(1) Is the printer being run in proper ambient conditions? (2) Have the consumables toner and image drum cartridges been replaced properly? (3) Is the paper normal? See paper specifications section. (4) Has the image drum cartridge been loaded properly?

6.3 Tips for Correcting Image Problems

(1) Do not touch, or bring foreign matter into contact with the image drum surface. (2) Do not expose the image drum to direct sunlight. (3) Keep hands off the fuser unit as it is heated during operation. (4) Do not expose the image drum to light for longer than 3 minutes at room temperature.

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6.4 Preparation for Troubleshooting

(1) Operator panel display

The failure status of this printer is indicated on the LCD (liquid crystal display) of the Operator panel. Take the proper corrective action according to the message displayed on the LCD.

6.5 Troubleshooting Flow

If a problem should develop in this printer, troubleshoot in the following procedure.

Problem

Problem that results in LCD message indication

Image problem (and a problem that does not result in LCD message indication.)

Troubleshoot based on the LED message list. See 6.5.1.

Perform troubleshooting with the troubleshooting flow chart. See 6.5.2.

Perform troubleshooting with the troubleshooting flow chart. See 6.5.3.

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Sony C9000 User Manual

Document Revision History

PREFACE

CONTENTS

1. SPECIFICATIONS

2. OPERATION DESCRIPTION

3. PARTS REPLACEMENT

4. ADJUSTMENT

5. REGULAR MAINTENANCE

6. TROUBLESHOOTING PROCEDURES