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HP Color 9850mfp Service Manual - Page 522

Printed in USA, Printed on, recycled paper, © 2004 Hewlett-Packard Development Company

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© 2004 Hewlett-Packard Development Company, L.P. The information contained herein is subject to change without notice. The only warranties for HP products and services are set forth in the express warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty. HP shall not be liable for technical or editorial errors or omissions contained herein. Printed on recycled paper Printed in USA www.hp.com Q3225-90935

Section	Page
hp Color 9850mfp Service Manual	1
CONTENTS	3
SAFETY AND IMPORTANT WARNING ITEMS	9
IMPORTANT NOTICE	9
DESCRIPTION ITEMS FOR DANGER	9
SAFETY WARNINGS	10
SAFETY INFORMATION	18
IMPORTANT INFORMATION	18
SAFETY CIRCUITS	19
INDICATION OF WARNING ON THE ENGINE	21
I OUTLINE	27
1. Product information	27
1.1 Product features	27
1.2 Product specifications	28
Identification	28
Specifications	28
Environmental specifications	29
1.3 Product overview	30
External assembly locations	30
Accessories (system outline)	31
Internal engine parts	32
1.4 Space requirements	32
Printer with packaging	32
Printer physical dimensions	33
1.5 Setup	34
1.6 Media specifications	35
Guidelines for selecting media	35
Supported media and capacity for input and output	36
Recommended media	37
Special media specifications	39
Storing print media	40
Testing media specifications	41
1.7 Media assessment tools and suppliers	45
1.8 Functions	46
1.9 Maintenance and life	47
2. CENTER CROSS SECTION	48
3. PAPER PATH	49
4. DRIVE SYSTEM DIAGRAM	51
4.1 Drum drive	51
4.2 Transfer belt conveyance/pressure drive	52
4.3 Developing drive	53
4.4 Toner supply drive	54
4.5 Toner collection drive	55
4.6 Fixing drive	56
4.7 Paper feed drive	57
4.8 ADU drive	60
4.9 Engine paper exit drive	64
4.10 Scanner drive	65
5. IMAGE CREATION PROCESS	66
5.1 Image creation flow and function	66
5.2 Charging process (Step 1)	67
5.3 Laser exposure process (Step 2)	67
5.4 Developing process (Step 3)	68
5.5 1st transfer process (Step 4)	69
5.6 2nd transfer process (Step 5)	70
5.7 Separation process (Step 6)	70
5.8 Drum cleaning (Sub step 1)	71
5.9 Pre-charging exposure (Sub step 2)	71
5.10 Transfer belt cleaning (Sub step 3)	72
5.11 2nd transfer roller L cleaning (Sub step 4)	72
5.12 Toner collection (Sub step 5)	73
5.13 Process speed	73
II UNIT EXPLANATION	75
1. SCANNER	75
1.1 Composition	75
1.2 Operation	76
2. WRITE	86
2.1 Composition	86
2.2 Operation	88
3. DRUM UNIT	95
3.1 Composition	95
3.2 Operation	99
4. DEVELOPING UNIT	100
4.1 Composition	100
4.2 Operation	102
5. TRANSFER BELT UNIT	104
5.1 Composition	104
5.2 Operation	106
6. TONER SUPPLY	109
6.1 Composition	109
6.2 Operation	110
7. TONER COLLECTION	112
7.1 Composition	112
7.2 Operation	113
8. PAPER FEED TRAY 1 TO 3	114
8.1 Composition	114
8.2 Operation	116
9. BY-PASS FEED	120
9.1 Composition	120
9.2 Operation	121
10.VERTICAL CONVEYANCE	122
10.1 Composition	122
10.2 Operation	122
11. REGISTRATION/ADU/REVERSE/PAPER EXIT	123
11.1 Composition	123
11.2 Operation	127
12.FIXING UNIT	138
12.1 Composition	138
12.2 Operation	140
13.INTERFACE	143
13.1 Composition	143
14.IMAGE STABILIZATION CONTROL	144
14.1 Toner density control	144
14.2 Dmax control	144
14.3 Charging potential control	145
14.4 Dot diameter adjustment control	146
14.5 Gamma correction control	147
15.OTHER CONTROLS	148
15.1 Parts to which power is supplied even when the reset switch is turned off	148
15.2 Parts that operate only when the power switch is turned on	149
15.3 Fan control	150
15.4 Operation board control	151
15.5 Counter control	152
15.6 ACS control	154
III DISASSEMBLY/ASSEMBLY	155
1. EXTERIOR	155
1.1 Replacing the dust filter 2	155
1.2 Replacing the dust filter 1 and the ozone filter 1	157
1.3 Replacing the toner collection box	159
1.4 Angle adjustment of the operation board	161
1.5 Removing and reinstalling the main board unit	162
2. SCANNER	166
2.1 Screws that must not be removed	166
2.2 Removing and reinstalling the scanner glass	167
2.3 Removing and reinstalling the CCD unit	168
2.4 Removing and reinstalling the exposure unit	170
2.5 Removing and reinstalling the exposure lamp	173
2.6 Removing the scanner wire	174
2.7 Reinstalling the scanner wire	176
3. WRITING	179
3.1 Screw that must not be removed	179
3.2 Removing and reinstalling the write unit	180
4. PROCESS UNIT	183
4.1 Flow of the disassembly of the process unit section	183
4.2 Cleaning the charging corona unit	184
4.3 Cleaning/replacing, removing and reinstalling the charging wire assy /the charging control plate	186
4.4 Pulling out the process unit	187
4.5 Removing and reinstalling the transfer belt unit	188
4.6 Replacing the belt cleaning brush unit	191
4.7 Replacing the belt cleaning blade	192
4.8 Replacing the toner collection sheet 1	193
4.9 Replacing the belt separation claw	194
4.10 Replacing the transfer belt	195
4.11 Replacing the 1st transfer roller	197
4.12 Replacing the 2nd transfer roller U	198
4.13 Replacing the drum cartridge	199
4.14 Removing and reinstalling the drum	200
4.15 Replacing the developing unit	202
4.16 Replacing the developer	204
4.17 Replacing the belt separation claw solenoid	206
4.18 Removing and reinstalling the process unit	207
4.19 Removing and reinstalling the image correction unit	208
5. TONER SUPPLY	209
5.1 Opening and closing the toner supply section	209
5.2 Replacing the charging dust filter	210
6. PAPER FEED TRAYS 1 to 3	211
6.1 Removing and reinstalling the paper feed unit	211
6.2 Removing and reinstalling the paper feed trays 1 to 3	213
6.3 Replacing the paper feed roller and the feed rubber	214
6.4 Replacing the double feed prevention rubber	216
6.5 Replacing the paper feed clutch and the pre-registration clutch	217
6.6 Removing and reinstalling the tray up/down wire	218
7. BY-PASS TRAY	222
7.1 Replacing the paper feed roller and the feed roller	222
7.2 Replacing the double feed prevention roller	224
7.3 Replacing the paper feed clutch BP	225
8. VERTICAL CONVEYANCE	227
8.1 Removing and reinstalling the vertical conveyance	227
8.2 Replacing the intermediate conveyance clutch 1	230
9. FIXING	231
9.1 Screws that must not be removed	231
9.2 Removing and reinstalling the fixing unit	232
9.3 Replacing the fixing upper heater lamps 1 and 2	233
9.4 Replacing the fixing lower heater lamp	235
9.5 Replacing the fixing roller U, ball bearing U and the heat insulating sleeve U	238
9.6 Replacing the fixing roller L, ball bearing L and the heat insulating sleeve L	240
9.7 Replacing the fixing tempering and reinstalling the fixing temperature sensor 3, and remove temperature sensor 1 and the thermostat 1	242
9.8 Replacing the fixing tempering and reinstalling the fixing ature sensor 4, and removtemperature sensor 2 and the thermostat L	247
9.9 Replacing the fixing drive gear	252
9.10 Replacing the fixing cleaning unit	254
9.11 Replacing the fixing torque limiter	256
10.REGISTRATION/ADU/ REVERSE/PAPER EXIT	258
10.1 Removing and reinstalling the ADU	258
10.2 Replacing the registration cleaning sheet	260
10.3 Replacing the separation corona unit	261
10.4 Replacing the transfer ground plate unit and the 2nd transfer roller L	262
10.5 Replacing the registration roller	263
10.6 Replacing the intermediate conveyance clutches 2 and 3	265
10.7 Replacing the ADU conveyance clutches 1 and 2	266
10.8 Replacing the ADU pre-registration clutch	267
10.9 Replacing the decurler roller	268
Automatic Document Feeder Q3228A	271
CONTENTS	273
I OUTLINE	275
1. PRODUCT SPECIFICATIONS	275
2. CENTER CROSS SECTION	277
3. DRIVE SYSTEM DIAGRAM	278
3.1 Paper feed drive	278
3.2 Conveyance drive	278
3.3 Reverse/paper exit drive	279
II UNIT EXPLANATION	281
1. PAPER FEED	281
1.1 Composition	281
1.2 Operation	284
III DISASSEMBLY/ASSEMBLY	297
1. EXTERIOR	297
1.1 RADF hinge opening/closing angle adjustment	297
1.2 Removing and reinstalling the front cover	299
1.3 Removing and reinstalling the rear cover	300
1.4 Removing and reinstalling the registration roller cover	301
2. PAPER FEED	302
2.1 Cleaning the no paper sensor	302
2.2 Removing and reinstalling the paper feed unit	303
2.3 Replacing the paper feed roller and the feed roller	305
2.4 Replacing the double feed prevention roller	307
3. PAPER FEED	309
3.1 Cleaning the registration roller	309
3.2 Cleaning the registration sensor	310
3.3 Removing and reinstalling the conveyance belt	311
4. REVERSE/PAPER EXIT	313
4.1 Cleaning the paper exit roller/the paper exit sensor	313
4.2 Cleaning the reverse roller	313
5. REMOVING AND REINSTALLING RADF	314
3000-sheet finishers Q5686A / Q5687A	315
CONTENTS	317
I OUTLINE	319
1. PRODUCT SPECIFICATIONS	319
2. CENTER CROSS SECTION	324
3. DRIVE SYSTEM DIAGRAM	325
3.1 Paper conveyance drive	325
3.2 Stacker drive	326
3.3 Staple drive	327
3.4 Tray drive	328
3.5 Folding drive	329
II UNIT EXPLANATION	331
1. CONVEYANCE	331
1.1 Composition	331
1.2 Operation	332
2. MAIN TRAY	341
2.1 Composition	341
2.2 Operation	342
3. STACKER	344
3.1 Composition	344
3.2 Operation	345
4. STAPLER	358
4.1 Composition	358
4.2 Operation	359
5. FOLDING/THREE-FOLDING (Q5687A ONLY)	364
5.1 Composition	364
5.2 Operation	365
III DISASSEMBLY/ASSEMBLY	369
1. EXTERIOR	369
1.1 Removing and reinstalling of the booklet tray (Q5687A only)	369
1.2 Removing and reinstalling of the top cover 1	370
1.3 Removing and reinstalling of the top cover 2	370
1.4 Removing and reinstalling of the side cover	371
1.5 Removing and reinstalling of the finisher door	371
1.6 Removing and reinstalling of the rear cover	372
1.7 Removing and reinstalling of the main tray	373
1.8 Removing and reinstalling of the main paper exit opening cover	374
1.9 Removing and reinstalling of the booklet paper exit opening cover (Q5687A only)	374
2. CONVEYANCE	375
2.1 Replacing the paper exit roller A (sponge roller)	375
2.2 Replacing the intermediate conveyance roller (sponge roller)	377
2.3 Removing and reinstalling of the paper exit opening unit	378
3. MAIN TRAY	380
3.1 Replacing the tray up/down motor	380
3.2 Removing and reinstalling of the up/down wire	381
4. STACKER	385
4.1 Replacing the stacking assist roller	385
4.2 Removing and reinstalling of the stacker unit cover	385
5. STAPLER	389
5.1 Removing and reinstalling of the stapler unit cover	389
5.2 Replacing the clincher	390
5.3 Replacing the stapler	392
2500-sheet High Capacity Input Q5690A	395
CONTENTS	397
I OUTLINE	399
1. Q5690A PRODUCT SPECIFICATIONS	399
2. CENTER CROSS SECTION	400
3. DRIVE SYSTEM DIAGRAM	401
3.1 Paper feed drive	401
3.2 Up/down plate drive	403
II UNIT EXPLANATION	405
1. PAPER FEED	405
1.1 Composition	405
1.2 Operation	407
III DISASSEMBLY/ASSEMBLY	411
1. EXTERIOR	411
1.1 Removing and reinstalling the front cover	411
1.2 Removing and reinstalling the clutch replacement cover and the rear cover	413
1.3 Removing and reinstalling the paper feed pick-up cover	414
2. PAPER FEED	415
2.1 Cleaning the paper dust removing brush	415
2.2 Removing and reinstalling the paper feed unit	416
2.3 Replacing the paper feed roller and the feed roller	417
2.4 Replacing the double feed prevention roller Q5690A	418
2.5 Replacing the paper feed clutch and the pre-registration clutch	420
3. TRAY UP/DOWN	421
3.1 Removing and reinstalling the rear drive	421
3.2 Removing and reinstalling the up/down wire	426
Post insertion kit Q3636A	435
Contents	437
Post insertion overview	439
Post insertion kit (Q3636A) product specifications	440
Type	440
Functions	440
Copy paper	440
Power, weight, dimensions	440
Maintenance	441
Operating environment	441
Center cross section	441
Drive system diagram	442
Feeding process	443
Automatic sheet feeding (online operation)	443
Manual sheet feeding (offline operation)	443
Post insertion unit explanation	445
External section	446
Mechanisms	446
Interlock control	446
Paper feed unit	447
Composition	447
Mechanisms	447
Feed control	448
Post insertion disassembly/assembly	455
External section	456
Removing/reinstalling the external covers	456
Paper feed unit	457
Replacing the paper pick roller and pick roller	457
Replacing the double feed prevent roller and torque limiter	458
Index	459
Hole Punch kit (Q3689A, Q3635A, Q3690A, Q3691A)	461
Contents	463
Punch kit overview	465
Punch Kit product specifications	466
Type	466
Functions	466
Applicable paper	466
Punch kit data	467
Maintenance	467
Operating environment	467
Center cross-sectional view	468
Drive system diagram	469
Punch section	469
Moving section	469
Punching process	470
Movement of the standby position of the punch unit	470
Formation of a registration loop	471
Correction of the punch position	472
Punch	472
Punch kit unit explanation	475
Punch section	476
Composition	476
Mechanisms	477
Punch control	477
Punch waste box section	480
Composition	480
Mechanisms	480
Punch waste conveyance control	481
Punch kit disassembly/assembly	483
Punch section	484
Screws that should not be removed	484
Replacing the punch unit	484
Cleaning the punch edges and punch waste full PS (PS802)	486
Index	487
Trimmer Unit Q3224A	489
CONTENTS	490
OUTLINE	491
PRODUCT SPECIFICATIONS	493
CENTER CROSS-SECTIONAL VIEW	494
DRIVE SYSTEM DIAGRAM	495
[1] Conveyance Drive Section	495
[2] Stopper Drive/Stopper Release Drive Section	495
[3] Press Drive Section	496
[4] Pusher Plate Drive/Holder Plate Drive	496
TRIMMING PROCESS	497
[1] Booklet Conveyance	497
[2] Trimming Position Adjustment	497
[3] Booklet Press	498
[4] Trimming	498
[5] Press Release/Stopper Release	499
[6] Booklet Ejection	499
UNIT EXPLANATION	501
EXTERNAL SECTION	503
[1] Composition	503
[2] Mechanisms	503
CONVEYANCE SECTION	504
[1] Composition	504
[2] Mechanisms	504
[3] Conveyance Control	504
PRESS SECTION	506
[1] Composition	506
[2] Mechanisms	506
[3] Stopper/Press Control	507
TRIMMER SECTION	510
[1] Composition	510
[2] Mechanisms	510
[3] Trimmer Control	511
[4] Scraps Removal Control	512
STACKER SECTION	513
[1] Composition	513
[2] Mechanisms	513
[3] Booklet Ejection/Stack Control	514
DISASSEMBLY/ASSEMBLY	517
TRIMMER SECTION	519
[1] Replacing the Upper and Lower Knives	519