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Brother DCP-9045CDN Reference Manual

Brother color laser printer reference manual
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Brother Color Laser Printer
REFERENCE MANUAL
DCP-9045CDN/MFC-9840CDW
Read this manual thoroughly before carrying out any maintenance work.
Keep this manual in a convenient place for quick and easy reference at all times.
July 2007
SM-FAX077
MODEL:

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  • Page 1 Brother Color Laser Printer REFERENCE MANUAL MODEL: DCP-9045CDN/MFC-9840CDW Read this manual thoroughly before carrying out any maintenance work. Keep this manual in a convenient place for quick and easy reference at all times. July 2007 SM-FAX077...

  • Page 2: Reference 1 Specifications

    (hereinafter referred to as "the machine"). This information is vital to the service personnel to maintain the high printing quality and performance of the machine. This reference manual covers the DCP-9045CDN/MFC-9840CDW machines. This manual consists of the following chapters: REFERENCE 1: SPECIFICATIONS Provides specifications of each model, which enables you to make a comparison of the different models.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS REFERENCE 1 SPECIFICATIONS............Ref.1-1 1. COMPONENTS ....................Ref.1-1 2. SPECIFICATIONS LIST ..................Ref.1-2 2.1 Printing ..........................Ref.1-2 2.2 Functions........................Ref.1-4 2.3 Electronics and Mechanics ...................Ref.1-7 2.4 Network Connectivity ....................Ref.1-8 2.5 Service Information .....................Ref.1-11 2.6 Paper...........................Ref.1-12 2.6.1 Paper handling ....................Ref.1-12 2.6.2 Media specifications..................Ref.1-12 2.6.3 Type and size of paper ..................Ref.1-13 2.7 Printable Area......................Ref.1-14 2.7.1 PCL5e emulation....................Ref.1-14...
  • Page 4 3.4.2 Toner Life End....................Ref.2-19 3.4.3 New Toner Detection ..................Ref.2-23 3.5 Print ..........................Ref.2-25 3.5.1 Principle of Color Overlapping ................Ref.2-25 3.5.2 Basic Printing Principle ..................Ref.2-26 3.5.3 Print Process.....................Ref.2-27 3.5.4 Switch between Color Print Mode and Monochrome Print Mode.....Ref.2-33 APPENDIX 1: TONER CARTRIDGE WEIGHT INFORMATION ..App.1-1 APPENDIX 2: REFERENCES ............

  • Page 5: Components

    REFERENCE 1 SPECIFICATIONS COMPONENTS The equipment consists of the following major components: ADF unit Document scanner unit NCU unit Paper eject ASSY DX Back cover upper Panel unit Joint cover ASSY Back cover ASSY Laser unit Belt unit drive motor ASSY Speaker ASSY Side cover R ASSY Fuser unit...

  • Page 6: Specifications List

    SPECIFICATIONS LIST Printing Model DCP-9045CDN MFC-9840CDW Print method Electrophotography by semiconductor laser beam scanning Laser Method: 1 polygon motor, 4 laser beams Wavelength: 780nm~800nm Output: 25mW (Max)  Resolution 2400dpi Windows 2000/XP/ XP Professional x64 Edition, Windows   (2400x600)
  • Page 7 Model DCP-9045CDN MFC-9840CDW Consumables Belt unit Life expectancy: 50,000pages/ belt unit * when printing A4/ Letter-size paper at 5% print coverage. Waste toner Life expectancy: 20,000pages/ waste toner box * when printing A4/ Letter-size paper at 5% print coverage. Note: Print speed varies depending on the paper size or media type.

  • Page 8: Functions

    Functions <Controller> Model DCP-9045CDN MFC-9840CDW 300MHz Memory Standard 128MB Option 1 DIMM slot; expandable up to 640MB Interface Hi-Speed USB 2.0, 10BASE- Hi-Speed USB 2.0, 10BASE- T/100BASE-TX Ethernet, T/100BASE-TX Ethernet, USB Host External TAD, USB Host, Wireless LAN IEEE 802.11b/g ...
  • Page 9 For Linux Web Base Management <Direct Print feature> Model DCP-9045CDN MFC-9840CDW Direct Print PDF version1.6 , JPEG, Exif+JPEG, PRN, TIFF (MH/Scannerd by Brother model) The data including JBIG2 image file, JPEG2000 image file and layered files are not supported. Ref.1-5 Confidential...
  • Page 10 <System requirements> Computer Platform & Processor Speed Minimum Recom- Available Operating System Version mended Hard Disk Space    Windows 2000 Intel Pentium 64MB 128MB 50MB Professional equivalent XP Home 128MB 256MB 50MB Edition Professional AMDOpteron™ 256MB 384MB 50MB Professional AMDAthlon™64 ...

  • Page 11: Electronics And Mechanics

    Electronics and Mechanics Model DCP-9045CDN MFC-9840CDW Power Printing Average 510W at 25°C (77°F) consumption Standby Average 85W at 25°C (77°F) Sleep Average 20W at 25°C (77°F) Noise level Sound ADF copy: 56dB(A) Pressure Standby: 30dB(A) Sound power ADF copy: LWAd = 7.0Bell(A) Standby: LWAd = 4.4Bell(A)

  • Page 12: Network Connectivity

    Minimum PowerPC G4/G5, Intel Core™ Solo/Duo, Processor Processor PowerPC G3 350MHz Minimum RAM 128MB Recommended 160MB  Operating Mac OS X 10.2.4 or greater system If you want to use the IPv6 protocol, visit http://solutions.brother.com for more information. Ref.1-8 Confidential...
  • Page 13 Data rates 802.11b 11/5.5/2/1 Mbps 802.11g 54/48/36/24/18/12/11/9/6/5.5/2/1 Mbps A wireless network connection is supported only between the Brother printer and an access   point for PC’s running Windows XP Professional x64 Edition and Windows Server 2003 x64 Edition.
  • Page 14 Web BRAdmin Windows NT 4.0, Windows 2000 Professional /  Server / Advanced Server, Windows Professional/XP Professional x64 Edition, Windows  Vista™, Windows Server 2003/2003 x64 Edition BRAdmin Professional and Web BRAdmin are available as a download from http://solutions.brother.com Ref.1-10 Confidential...

  • Page 15: Service Information

    Service Information These are key service information to maintain the product. Machine life: 200,000pages/ 5years MTBF (Meantime between failure): Up to 4000hours MTTR (Meantime to repair): Average 30minutes Monthly volume: 35,000pages Periodical replacement parts: Parts Approximate Life Fuser unit & Toner filter frame ASSY 80,000pages Laser unit 100,000pages...

  • Page 16: Paper

    Paper 2.6.1 Paper handling DCP-9045CDN MFC-9840CDW Model Paper Input Multi-purpose 50sheets tray Paper tray (T1) 250sheets Lower tray (LT) 500sheets Paper Face-down 150sheets Output Duplex Manual Duplex Automatic Duplex Calculated with 80g/m (20lb) paper 2.6.2 Media specifications DCP-9045CDN MFC-9840CDW Model...

  • Page 17: Type And Size Of Paper

    2.6.3 Type and size of paper The printer loads paper from the installed paper tray or the multi-purpose tray. The name s for the paper trays in the printer driver as follows; Paper tray (T1) Tray 1 Multi-purpose tray (MP) MP Tray Optional lower tray unit (LT) Tray 2...

  • Page 18: Printable Area

    Printable Area 2.7.1 PCL5e emulation When using PCL emulation, the edges of the paper that cannot be printed on are shown below. Portrait Physical page Printable area Logical page Physical page length Maximum logical page length Distance from edge of physical page to edge of logical page   Note: - “Logical page” shows the printable area for a PCL driver. - “Printable area”...
  • Page 19 The table below shows the printable areas when printing on Portrait for each paper size. Size 215.9mm 279.4mm 203.2mm 279.4mm 6.35mm 4.2mm Letter 8.5” 11.0” 8.0” 11.0” 0.25” 0.16” (2,550dots) (3,300dots) (2,400dots) (3,300dots) (75dots) (50dots) 215.9mm 355.6mm 203.2mm 355.6mm 4.2mm Legal 8.5”...
  • Page 20 Landscape       Physical page Printable area Logical page B             Physical page length D             Maximum logical page length F              Distance from edge of physical                 page to edge of logical page Note: - “Logical page” shows the printable area for a PCL driver. - “Printable area” shows mechanical printable area of the machine. - Therefore, the machine can only print within the shaded area when you use a PCL driver. Ref.1-16 Confidential...

  • Page 21: Pcl6 Emulation

    The table below shows the printable areas when printing on Landscape for each paper size. Size 279.4mm 215.9mm 269.3mm 215.9mm 5.0mm 4.2mm Letter 11.0” 8.5” 10.6” 8.5” 0.2” 0.16” (3,300dots) (2,550dots) (3,180dots) (2,550dots) (60dots) (50dots) 355.6mm 215.9mm 345.5mm 215.9mm 4.2mm Legal 14.0”...

  • Page 22: Print Speeds With Various Settings

    Print Speeds with Various Settings Print speed is up to 20ppm for A4 size and 21ppm for Letter size when loading A4 or Letter size paper from the paper tray in the plain paper mode. Actual print speed varies depending on the media type or paper size as shown in the tables below;...

  • Page 23: Telephone

    Telephone Model DCP-9045CDN MFC-9840CDW Handset Chain Dialing Automatic Redial PBX Feature Yes (Europe only) Speaker Phone Hold/Mute Key Music on Hold Handset Volume Speaker Volume Yes (3 steps + OFF) Buzzer Volume Yes (3 steps + OFF) Ring Volume Yes (3 steps + OFF)

  • Page 24: Fax

    2.10 Fax Model DCP-9045CDN MFC-9840CDW Modem Speed 33,600bps (Fax) Transmission Speed Approx. 2sec. (Brother#1 Std resolution, JBIG) ITU-T Group Super G3 Coding Method MH / MR / MMR / JBIG / JPEG Color FAX Send (Document) Receive Color FAX Send...
  • Page 25 MFC-9840CDW Sending Memory up to 400 pages Transmission (ITU-T Test Chart, Standard Resolution, JBIG) up to 500 pages (Brother #1Chart, Standard Resolution, JBIG) ECM (Error Correction Mode) Error Re- Transmission Broadcasting (366 locations = One-Touch Dial + Speed Dial + Manual...

  • Page 26: Copy

    2.11 Copy Model DCP-9045CDN MFC-9840CDW Copy Speed Monochrome Up to 16 cpm / up to 17cpm Simplex Full Color Up to 16 cpm / up to 17cpm (A4 / LTR) Copy Speed Monochrome Up to 7 sides per minute (3.5 sheets per minute)

  • Page 27: Theory Of Operation

    REFERENCE 2 THEORY OF OPERATION GENERAL BLOCK DIAGRAM Video control system Wireless LAN module USB host block CCD unit (MFC-9840CDW) Extended RAM DIMM 144pin Interface USB device ADF sensors (USB host) or Digital camera Internal RAM Speaker Interface (Network) Battery Interface (Centronics) Low-voltage...

  • Page 28: Electronics General Block Diagram

    ELECTRONICS GENERAL BLOCK DIAGRAM Develop drive motor Front cover interlock switch Paper feed/belt cleaner motor Back cover sensor Belt unit drive motor Toner sensor PCB K (TE/NEW) Develop release motor Toner sensor PCB Y (TE/NEW) Drum drive motor 1 Toner sensor PCB M (TE/NEW) Drum drive motor 2 Toner sensor PCB C (TE/NEW) T1 paper feed solenoid...

  • Page 29: Mechanics

    MECHANICS Cross-section Drawing Exposure drum (M) Exposure drum (C) Paper eject roller shaft ASSY Exposure drum (Y) Exposure drum (K) Outer chute Supply roller Develop roller Registration rear actuator Thermistor Registration roller Heat roller MP registration front actuator MP paper feed roller Paper eject actuator MP PE actuator Pressure roller ASSY...

  • Page 30: Scanner Mechanism

    Scanner Mechanism < > Duplex scanning mechanism This mechanism consists of the document cover, document scanner unit (scanner top cover), and the automatic document feeder (ADF). The document scanner unit consists of a scanner top cover, CCD unit and scanner base. Document cover Automatic document feeder (ADF) ADF&...
  • Page 31 The automatic document feeder (ADF) consists of the pick-up roller, separation roller, paper feed rollers 1/2/3/4, eject roller, ADF motor, switch back sensor, document rear sensor and document front sensors 1/2. For further details on the sensors, see Section 1.4.11 in chapter Paper feed roller 1 Flap D Switch back sensor...
  • Page 32 Document glass scanning (The CCD unit moves under the immovable document to scan.) Open the document cover, place a sheet of the document (or opened book) onto the document glass, and close the document cover. Then, the machine starts scanning, and the CCD drive mechanism is started.
  • Page 33 ADF simplex scanning (The document moves over the immovable CCD unit.) (1) Set the document face up into the document chute. When the machine starts simplex scanning, the ADF motor is rotated clockwise, the pick-up roller draws the document, and the separation roller and separation pad send a sheet of the document to the ADF one by one from the top page of the stacked documents.
  • Page 34 ADF duplex scanning (The document moves over the immovable CCD unit.) (1) Set the document face up into the document chute. When the machine starts duplex scanning, the ADF motor is rotated clockwise, the pick-up roller draws the document, and the separation roller and separation pad send a sheet of the document to the ADF one by one from the top page of the stacked documents.
  • Page 35 (4) The switch back roller ASSY is turned counter again, and the document is drawn in again. The document is passed through the paper feed rollers 1, 2 and 3, and ejected to the document cover by the eject roller. This is so that the stacked documents are ejected face down in the correct order.

  • Page 36: Paper Feeding

    Paper Feeding The following figure shows the paper feeding paths. MP path Paper tray path LT path DX path Fig. Ref2-11 Ref. 2-10 Confidential...

  • Page 37: Plate-Up Function Of The Paper Tray

    3.3.1 Plate-up Function of the Paper Tray The plate of the paper tray is pushed up by the force exerted by the motor not by springs so as to keep paper-feeding performance constant irrespective of the quantity of papers remaining in the tray.

  • Page 38: Paper Supply

    3.3.2 Paper Supply The T1 paper feed roller picks up a few sheets or one sheet of paper from the paper tray every time it is rotated and feeds it to the T1 separation roller. Subsequently, stacks of paper are caught between the T1 separation roller and T1 separation pad, they are then separated into single sheets.

  • Page 39: Paper Registration

    3.3.3 Paper Registration The front-edge position of a sheet of paper after separation by the separation roller is detected by the T1 registration front actuator. Then, the paper is fed further for a certain time, and its front edge hits the stopped registration roller so that the paper skew is corrected. After such correction, the registration roller is rotated in the normal direction and the paper is carried to the belt unit.

  • Page 40: Paper Eject

    3.3.4 Paper Eject Toner on paper is fused by the heat roller and pressure roller ASSY of the fuser unit. Paper moves along the outer chute and is ejected into the face-down output tray from the paper eject roller shaft ASSY with its print side down. Paper eject roller shaft ASSY Outer chute Fuser unit...

  • Page 41: Paper Feeding For Duplex Printing (Dx)

    3.3.5 Paper Feeding for Duplex Printing (DX) After the paper eject actuator detects the edge of the paper and a certain volume of paper is sent from the paper eject roller shaft ASSY, it rotates against the normal direction of rotation, thereby enabling the paper to be pulled in and pass between the outer chute and the back cover.

  • Page 42: Paper Feeding From The Mp Tray (Mp)

    3.3.6 Paper Feeding from the MP Tray (MP) When the MP paper feed roller making contact with paper is driven, the paper is drawn out of the MP tray. The drawn paper is separated into individual sheets by the MP separation roller. MP registration front actuator MP tray MP paper feed roller...

  • Page 43: Paper Feeding From The Tray 2 (Lt)

    3.3.7 Paper Feeding from the Tray 2 (LT) The driving force from the paper feed/belt cleaner motor is transmitted to the gear of tray 2 (LT) to rotate the LT paper feed roller so that the paper is fed. The paper is separated into individual sheets by the LT separation roller and fed to the machine.

  • Page 44: Toner Cartridge

    Toner Cartridge 3.4.1 Methods for Detecting and Counting Toner Life “Toner Life End” is displayed through the following two ways. First, such indication is displayed when detection is performed by the toner sensor; second, it is displayed at the time when a rotation rate of the develop roller reaches its upper limit.

  • Page 45: Toner Life End

    3.4.2 Toner Life End A new toner cartridge can print with standard toner approximately 2,500 (black), 1,500 (yellow, magenta, cyan), with high capacity toner, approximately 5,000 (black), 4,000 (yellow, magenta, cyan) in the case of A4 or Letter size single-sided pages at 5% coverage. If printing A4 paper at 5% print coverage or less, the “Toner Life End”...
  • Page 46 Standard toner cartridge (Yellow, Magenta, Cyan) * Approximately 1500 pages Page/job 1,800 2,763 3,364 3,773 4,071 4,297 4,474 4,617 4,735 4,833 4,917 4,989 Cartridge life 1,092 1,845 2,396 2,816 3,147 3,415 3,637 3,822 3,980 4,116 4,235 4,339 Cartridge life+ON/OFF 1,500 1,500 1,500 1,500...
  • Page 47 High-capacity toner cartridge (Black) * Approximately 5000 pages Page/job 6,000 9,212 11,212 12,578 13,570 14,323 14,914 15,390 15,782 16,110 16,389 16,629 Cartridge life 3,639 6,150 7,986 9,387 10,491 11,385 12,122 12,740 13,267 13,721 14,116 14,463 Cartridge life+ON/OFF 5,000 5,000 5,000 5,000 5,000 5,000...
  • Page 48 High-capacity toner cartridge (Yellow, Magenta, Cyan) * Approximately 4000 pages Page/job 5,000 7,676 9,343 10,482 11,308 11,935 12,428 12,825 13,152 13,425 13,658 13,858 Cartridge life 3,033 5,125 6,655 7,822 8,743 9,487 10,101 10,617 11,056 11,434 11,763 12,052 Cartridge life+ON/OFF 4,000 4,000 4,000 4,000...

  • Page 49: New Toner Detection

    3.4.3 New Toner Detection When a toner cartridge is changed, discrimination between new and secondhand toner cartridges is performed by means of the new toner detection mechanism shown below. <New Toner Detection Mechanism> The rotation of the gear (1) of the toner cartridge is transmitted to the reset gear, and the rib of the gear pushes down the reset upper lever attached to the drum unit.
  • Page 50 <Developing Bias Voltage> When the new toner detection mechanism detects the change to a new toner cartridge, the developing bias voltage is reset. Toner in use tends to have a low printing density at the time of first use, but the density gradually becomes higher after a certain period of use. The properties of the toner is controlled by means of the developing bias voltage.

  • Page 51: Print

    Print 3.5.1 Principle of Color Overlapping The human eye distinguishes one color from others by receiving light’s three primary colors (Red, Green, Blue). When monochrome lights are received, each color can be sensed. However, when two-color lights, red (R) and green (G), are received, they are recognized as “yellow”;...

  • Page 52: Basic Printing Principle

    3.5.2 Basic Printing Principle The printing process consists broadly of 6 processes: Charging, Exposure, Development, Transfer, Fusing and Cleaning. 1. Charging: The surface of the drum is electrically charged (Primary Charge). 2. Exposure: A printed image is formed on the surface of the drum by applying laser beam (Electrostatic Latent Image).

  • Page 53: Print Process

    3.5.3 Print Process 1. Charging The flow of the ion charge is controlled by the constant voltage of the grid 870 V to ensure it is distributed evenly on the drum surface. In order to coat toner on the exposure drum, the drum needs to be evenly electrified.
  • Page 54 2. Exposure Four laser beams radiated from a laser diode inside the laser unit are concentrated into a constant width by a slit in the CO lens cell and then reflected by a polygon mirror rotating at high speed. The evenly charged exposure drum is irradiated with reflected light and exposed. Surface potential is lowered by such exposure and an Electrostatic latent image is formed.
  • Page 55 3. Development Toner is attracted to the latent-image area on the exposure drum where surface potential is lowered due to exposure. By controlling the developing bias voltage supplied to the develop roller, the amount of toner taken to the drum is adjusted to keep printing density constant. Charging Laser beam 150 V...
  • Page 56 4. Transfer By applying a minus charge to the belt unit, the toner adhered to the exposure drum is transferred to paper. Exposure drum (K) Exposure drum (Y) Exposure drum (M) Exposure drum (C) EL PCB (K) EL PCB (M) EL PCB (C) EL PCB (Y) Belt unit...
  • Page 57 5. Fusing The toner transferred on to the paper passes between the heat roller and the pressure roller ASSY in the fuser unit and are fused by heat and pressure. The thermistor detects surface temperature of the heat roller and turns ON/OFF the halogen heater lamp to keep the temperature constant.
  • Page 58 6. Toner cleaning (1) Toner remaining on the exposure drum which has not completely been transferred on to the paper is pulled onto the cleaning roller with a lower potential and the drum is cleaned. (2) After the above step, the potential of the roller is raised during printing, and such attracted toner is returned to the drum again.

  • Page 59: Switch Between Color Print Mode And Monochrome Print Mode

    3.5.4 Switch between Color Print Mode and Monochrome Print Mode By switching the mode between color print and monochrome print to avoid unnecessary load on the toner cartridges and keep the specified product life, the rotation and press/release operations of the develop roller are controlled, and the print operation is executed. <Rotation of the develop roller>...

  • Page 60: Appendix 1 Toner Cartridge Weight Information

    APPENDIX 1 TONER CARTRIDGE WEIGHT INFORMATION Note: This information shows approximate weight of the toner cartridge. High-capacity toner cartridge BK (5K) Y (4K) M, C (4K) (TN-115, TN-135, TN-155) Brand New Toner Cartridge Weight 695g (±10g) 675g (±10g) 670g (±10g) Toner Weight at “Brand New Toner Cartridge”...

  • Page 61: Appendix 2 References

    APPENDIX 2 REFERENCES This page provides reference information. It is possible to get the full instructions of the subjects listed by just clicking on the links below. 1. Error codes (Refer to “2.1 Error Indication”, Chapter 1 of the Service Manual.) 2.

  • Page 62: Appendix 3 Glossary

    APPENDIX 3 GLOSSARY ACRONYMS AND TECHNICAL TERMS In this manual and the Service Manual, the manual specific acronyms and technical terms are used in addition to the generally used ones. The table below contains typical acronyms and technical terms that are used throughout these manuals. Automatic Document Feeder Liquid Crystal Display APIPA...

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