Brother MFC-5100C User manual

FACSIMILE EQUIPMENT
SERVICE MANUAL
MODEL: MFC5100C/MFC590

© Copyright Brother 2001
All rights reserved.
No part of this publication may be reproduced in any
form or by any means without permission in writing
from the publisher.
Specifications are subject to change without notice.

PREFACE
This publication is a Service Manual covering the specifications, construction, theory of operation,
and maintenance of the Brother facsimile equipment. It includes information required for field
troubleshooting and repair--disassembly, reassembly, and lubrication--so that service personnel
will be able to understand equipment function, to rapidly repair the equipment and order any
necessary spare parts.
To perform appropriate maintenance so that the facsimile equipment is always in best condition
for the customer, the service personnel must adequately understand and apply this manual.
This manual is made up of six chapters and appendices.
CHAPTER 1 GENERAL DESCRIPTION
CHAPTER 2 INSTALLATION
CHAPTER 3 THEORY OF OPERATION
CHAPTER 4 DISASSEMBLY/REASSEMBLY AND LUBRICATION
CHAPTER 5 MAINTENANCE MODE
CHAPTER 6 ERROR INDICATION AND TROUBLESHOOTING
Appendix 1. EEPROM Customizing Codes
Appendix 2. Firmware Switches (WSW)
Appendix 3. Circuit Diagrams
This manual describes the models and their versions to be destined for major countries. The specifications
and functions are subject to change depending upon each destination.

CHAPTER 1
GENERAL DESCRIPTION

CHAPTER 1 GENERAL DESCRIPTION
CONTENTS
1.1 EQUIPMENT OUTLINE ...................................................................................................1-1
1.1.1 External Appearance and Weight ........................................................................1-1
1.1.2 Components .........................................................................................................1-1
1.2 SPECIFICATIONS............................................................................................................ 1-2

1-1
1.1 EQUIPMENT OUTLINE
1.1.1 External Appearance and Weight
The figure below shows the equipment appearance and approximate dimensions.
Weight: Machine proper Approx. 15 kg (33.1 lbs.)
In package Approx. 11 kg (24.2 lbs.)
1.1.2 Components
The equipment consists of the following major components:
ADF & document tray ASSY
Scanner top cover
Scanner base
Relay PCB
Jam clear cover
Rear cover
Bottom plate
Enclosure cover
NCU PCB
ain PCB
Ink absorber box Power supply PCB
Lower cover
Purge unit
ain chassis
Auto sheet feeder (ASF)
ain cover
Control panel ASSY
(W)
468 mm
18.4"
(including handset)
(H)
370 mm
14.6"
(D)
467 mm
18.4"

1-2
1.2 SPECIFICATIONS
(1/2)
Model Name MFC-5100C
GENERAL
Print Engine Ink Jet (BH 2-head)
Modem Speed (bps) 14,400 (Fax)
Transmission Speed (sec.) 6 (Brother#1, MMR)
ITU-T Group G3
Coding System MH/MR/MMR/JPEG
Print Paper Size (W x L) 3.5"-8.5" x 5.0"-14"
Document Size for ADF (W x L) 5.8"-8.5" x 5.7"-14"
Max. Document Size for Flat-bed Scan (W x L) 8.5" x 11.7"
Print Paper Margin (upper, lower, left, right) 0.12, 0.43, 0.12, 0.12 inch (3, 11, 3, 3 mm)
ADF (pages) Up to 30
LCD Columns 16 characters
LCD Lines 1 line
LCD Backlight No
Backup Clock Yes (1 hour)
Memory Backup N/A
Memory Capacity (physical) 8MB (RAM)
Optional Memory No
Dimensions w/ Carton (WxDxH) 23.3"x22.3"x18.1" (592x566x460 mm)
Dimensions w/o Carton (WxDxH) 18.4"x18.4"x14.5" (468x467x368 mm)
Weight w/ Carton 34.1 lbs/15.5 kg
Weight w/o Carton 24.2 lbs/ 11 kg
Color Gray 1495
Standby Mode No
PC-Fax Protocol Compliance N/A
Simultaneous Operation Yes (Print/Fax, Print/Scan)
Energy Star Compliant Yes
Operating Environment Temperature
Humidity
10 - 35 degrees Centigrade
20% to 80%
Power Source 120 VAC, 50/60 Hz
Power Consumption (Standby/Peak) Under 13.5W/40W
On/Off Switch No
TELEPHONE
Handset No
One-Touch Dial No
Speed Dial Max. 40
Speaker Phone No
Chain Dialing Yes
Caller ID No
Call Waiting Caller ID No
Distinctive Ringing Yes
Hold/Mute Key No
Hook Key No
Power Failure Dialing No
Speaker Volume No
Ring Volume Yes (2 steps + OFF)
Handset Volume No
FAX
Scan Speed (A4:Standard) Approx. 3 sec./page (A4: standard)
Memory Transmission (Brother#1 Chart) Yes (200:MMR)
Memory Transmission (ITU-T Chart) Yes (170:MMR)
Out-of-Paper Reception (Brother #1 Chart) Yes (200:MMR)
Out-of-Paper Reception (ITU-T Chart) Yes (170:MMR)
Color FAX (Document Send/Receive) Yes/Yes
Color FAX (Memory Send/Receive) No/Yes

1-3
(2/2)
Model Name MFC-5100C
INTERFACE
External TAD Interface Yes
Host Interface (IEEE1284) Yes
Host Interface (USB) Yes
LAN Interface No
PRINTER
Color/Mono Color/Mono
Engine Type Piezo Ink Jet (2-head BH: 75 nozzles/color)
Resolution (dpi) 1200x1200 /2400x1200 (Mono/Color)
Speed (ppm)
10/8 (Mono/Color: 600*150)
4/3.5 (Mono/Color: 600*300)
2/1.5 (Mono/Color: 600*600)
0.2/0.2 (Mono/Color: 1200*1200/2400*1200)
Paper Capacity (sheets) 100
Output Paper Capacity (sheets) 50
Standard Print Language Windows GDI
Emulation No
Resident Fonts Yes
Fonts Disk Based Yes
Paper Handling Size LTR, LGL, A4, B5, A5, EXE,
Post card, Photo, Index card
Manual Feed Slot N/A
Other Paper Type OHP, Envelopes
Sheet Weight (Paper Cassette)
(Manual Slot)
64-120 g/m2 (17 - 32 lb)
N/A
Printer Driver Win95/98/98SE/Me/2000Professinal/NT4.0/
MacOS 8.5-9.1
COPY
Color/Mono Color/Mono
Speed (ppm) 7/5 (Mono/Color)
Multi Copy (Stack) Yes (Color) or Via PC
Multi Copy (Sort) Yes (Color) or Via PC
Resolution (dpi) Max. 1200x1200 (color)
SCANNER
Color/Mono Color/Mono
Resolution (dpi) (Physical) CCD: 600x2400 (Opt.)
Resolution (dpi) (Logical) 9600 (Int.)
Speed (ppm) Max. 3 sec
Gray Scale 256
TWAIN Compliant&Operating System Win95/98/98SE/2000Professinal/NT4.0/Me
MacOS 8.6-/9.1
PCI Scanner (Parallel/Serial) Parallel/ USB
Color Depth 36-bit color processing (24-bit external)
ACCESSORIES
Cartridge 4 colors (each separate tank)
Life / Yield (Draft, 5% Coverage) BK: 950, CL: 450

1-4
(1/2)
Model Name MFC-590
GENERAL
Print Engine Ink Jet (BH 2-head)
Modem Speed (bps) 14,400 (Fax)
Transmission Speed (sec.) 6 (Brother#1, MMR)
ITU-T Group G3
Coding System MH/MR/MMR/JPEG
Print Paper Size (W x L) 90-216 x 127-216 mm
Document Size for ADF (W x L) 147-216 x 145-356 mm
Max. Document Size for Flat-bed Scan (W x L) 216 x 297 mm
Print Paper Margin (upper, lower, left, right) 0.12, 0.43, 0.12, 0.12 inch (3, 11, 3, 3 mm)
ADF (pages) Up to 30
LCD Columns 16 characters
LCD Lines 1 line
LCD Backlight Yes
Backup Clock Yes (1 hour)
Memory Backup N/A
Memory Capacity (physical) 4 MB
Optional Memory No
Dimensions w/o Carton (WxDxH) 23.3"x22.3"x18.1" (592x566x460 mm)
Dimensions w/ Carton (WxDxH) 18.4"x18.4"x14.6" (468x467x370 mm)
Weight w/o Carton 24.2 lbs/ 11 kg
Weight w/ Carton 33.1 lbs/15 kg
Color Gray 1495
Operating Environment Temperature
Humidity
10 - 35 degrees Centigrade
20% to 80%
Power Source 240 VAC, 50/60 Hz
Power Consumption (Standby/Peak) Under 13W/50W
On/Off Switch No
TELEPHONE
Handset N/A
One-Touch Dial N/A
Speed Dial Max. 100
Speaker Phone No
Chain Dialing Yes
Caller ID No
Call Waiting Caller ID No
Distinctive Ringing Yes (Only UK, Denmark)
Hold/Mute Key No
Hook Key (Tel Key) Tel (for F/T switch)
Power Failure Dialing No
Speaker Volume No
Ring Volume Yes (2 steps + OFF)
Handset Volume No
FAX
Scan Speed (A4:Standard) Approx. 3 sec./page (A4: standard)
Memory Transmission (Brother#1 Chart) Yes (200:MMR)
Memory Transmission (ITU-T Chart) Yes (170:MMR)
Out-of-Paper Reception (Brother #1 Chart) Yes (200:MMR)
Out-of-Paper Reception (ITU-T Chart) Yes (170:MMR)
Color FAX (Document Send/Receive) Yes/Yes
Color FAX (Memory Send/Receive) No/Yes
INTERFACE
External TAD Interface Yes
Host Interface (IEEE1284) Yes
Host Interface (USB) Yes
LAN Interface No

1-5
(2/2)
Model Name MFC-590
PRINTER
Color/Mono Color/Mono
Engine Type Piezo Ink Jet (2-head BH: 75 nozzles/color)
Resolution (dpi) 1200x1200 /2400x1200 (Mono/Color)
Speed (ppm)
10/8 (Mono/Color: 600*150)
4/3.5 (Mono/Color: 600*300)
2/1.5 (Mono/Color: 600*600)
0.2/0.2 (Mono/Color: 1200*1200/2400*1200)
Paper Capacity (sheets) 100
Output Paper Capacity (sheets) 50
Standard Print Language Windows GDI
Emulation N/A
Resident Fonts Yes
Fonts Disk Based Yes
Paper Handling Size LTR, LGL, A4, B5, A5, EXE,
Post card, Index card
Manual Feed Slot N/A
Other Paper Type OHP, Envelopes
Sheet Weight (Paper Cassette)
(Manual Slot)
64-120 g/m2 (17 - 32 lb)
N/A
Printer Driver Win95/98/98SE/Me/2000Professinal/NT4.0/
MacOS 8.5/8.5.1/8.6/9.0/9.04/9.1
COPY
Color/Mono Color/Mono
Speed (ppm) 7/4
Multi Copy (Stack) Yes (Color) or Via PC
Multi Copy (Sort) Yes (Color) or Via PC
Resolution (dpi) Max. 1200x1200
SCANNER
Color/Mono Color/Mono
Resolution (dpi) (Physical) CCD 600x2400 (Opt.)
Resolution (dpi) (Logical) 9600 (Int.)
Speed (ppm) Max. 3 sec.
Gray Scale 256
TWAIN Compliant&Operating System Win95/98/98SE/2000Professinal/NT4.0/Me
MacOS 8.6/9.0/9.04/9.1
PCI Scanner (Parallel/Serial) Parallel/ USB
Color Depth 36-bit color processing (24-bit external)
ACCESSORIES
Cartridge 4 colors (each separate tank)
Life / Yield (Draft, 5% Coverage) BK: 950, CL: 450

CHAPTER 2
INSTALLATION

CHAPTER 2 INSTALLATION
CONTENTS
2.1 INSTALLING THE UPDATE DATA TO THE FACSIMILE MACHINE.............................2-1
2.2 SETTING ID CODES TO FACSIMILE MACHINES.........................................................2-3
2.3 UPDATING HEAD PROPERTY INFO STORED IN THE FACSIMILE MACHINE..........2-5

2-1
2.1 INSTALLING THE UPDATE DATA TO THE
FACSIMILE MACHINE
If you want to update the current program stored in the flash ROM of the main PCB to the newer
version or after you replace the main PCB, install the update program onto the flash ROM.
The program installation requires a PC/AT-compatible computer (which is capable of
running MS-DOS or its compatible OS).
Connecting the facsimile machine to your PC
(1) Make sure that your PC is turned off.
(2) Make sure that the power cord of the facsimile machine is unplugged from a wall socket or
other power source.
(3) Connect the parallel interface cable to the parallel port on the back of the machine and secure
it with the lock wires.
(4) Connect the other end of the interface cable to the printer port of your PC and secure it with
two screws.
(5) While pressing the 5key on the machine's control panel, plug the machine's power cord into a
wall socket.
(6) Check to see that the following pattern displays on the LCD. If it does not display, go back to
step (2) above.
(7) Turn on your PC.
Host compute
r
Parallel interface
cable Lock wires

2-2
Installing the update data onto the flash ROM of the facsimile machine
NOTE: The following is an installation procedure example on a PC that is running Windows 95/98.
(1) Copy the update data and transfer utility onto the desired directory of the hard disk.
e.g., C:\UPDATE
(2) Click the Start button, point to Programs, and then click MS-DOS Prompt to open an MS-DOS
window.
(3) Type the drive letter where the update data and transfer utility are located. In the above
example, type C:\ from the command line and press the ENTER key.
Then type CD UPDATE and press the ENTER key.
(4) Check that your PC is connected with the facsimile machine correctly.
(5) To start the transfer utility transmitting the update data to the flash ROM of the facsimile
machine, type the following:
ICEN filename /b
Where filename is an update data file, e.g., 5100x.upd and 590xxxx.upd.
Then press the ENTER key.
During downloading, the machine beeps intermittently.
Upon completion of the downloading, the machine beeps continuously.
NOTE: If the facsimile machine cannot return to the standby state after completion of downloading,
turn the power off and on.

2-3
2.2 SETTING ID CODES TO FACSIMILE
MACHINES
Brother facsimile machines are assigned unique ID codes (character strings) at the factory. If you
replace the main PCB of the machine, the machine will lose its assigned ID code so that it will not
be identified by the connected PC*.
You need to assign a unique ID code (character string) to the machine according to the procedure
given here. For models covered by this manual, set serial numbers given to individual machines as
ID codes.
(*ID codes are essential when more than one machine is connected to a single PC via USB.)
Connecting the facsimile machine to your PC (See the illustration on page 2-1.)
(1) Make sure that your PC is turned off.
(2) Make sure that the power cord of the facsimile machine is unplugged from a wall socket or
other power source.
(3) Connect the interface cable to the parallel interface port on the back of the facsimile machine
and secure it with the lock wires.
(4) Connect the other end of the interface cable to the printer port of your PC and secure it with
the two screws.
(5) While holding down the Menu key, plug the machine's power cord into a wall socket or other
power source.
(6) Turn on your PC.
Running the setup utility
(1) On your PC, run the ID/head property setup utility (BRUSBSN.EXE). The following window
will appear.
(2) On the Model menu, click BH.
In Port, make sure that the LPT1 is selected.
In the Serial No = BRO box, type the 9-digit serial number (e.g., G01012345) printed on the
nameplate labeled to the back of the facsimile machine as an ID code. Then press the Enter
key.

2-4
The setup utility will transmit the ID code data from your PC to the facsimile machine and
then it will terminate.
The facsimile machine will automatically return to the standby mode.
(3) To check whether the entered character string (ID code) is correct, make the machine enter the
maintenance mode (refer to CHAPTER 5, Section 5.1) and then press the 1key twice
(Subsection 5.3.6).
The facsimile machine will print out a Configuration List. At the right top of the list, "SER.#:
BROXXXXXXXXX" is printed.
(4) Check that the character string entered in step (2) is printed in "XXXXXXXXX."
If it is OK, press the 9key twice to exit from the maintenance mode.
If something other than that is printed in XXXXXXXXX, check the connection between the
PC and facsimile machine and go back to step (1).

2-5
2.3 UPDATING HEAD PROPERTY INFO STORED
IN THE FACSIMILE MACHINE
To keep the print quality, the controller optimizes the head drive strength, ink jet-out timing, and
other drive conditions according to the electromechanical properties unique to individual print
heads and ambient temperature. The head property information is stored in the EEPROM of the
main PCB.
If you replace the print head unit and/or main PCB of the machine, then you need to update head
property information according to the procedure given here.
TIP: The updating procedure given here uses a PC. For the updating procedure in the maintenance
mode without using a PC, refer to CHAPTER 5, Subsection 5.3.14.
Connecting the facsimile machine to your PC (See the illustration on page 2-1.)
(1) Make sure that your PC is turned off.
(2) Make sure that the power cord of the facsimile machine is unplugged from a wall socket or
other power source.
(3) Connect the interface cable to the parallel interface port on the back of the facsimile machine
and secure it with the lock wires.
(4) Connect the other end of the interface cable to the printer port of your PC and secure it with
two screws.
(5) While holding down the Menu key, plug the machine's power cord into a wall socket or other
power source.
(6) Turn on your PC.
Running the setup utility
(1) On your PC, run the ID/head property setup utility (BRUSBSN.EXE). The following window
will appear.
(2) On the Model menu, click BH.
In Port, make sure that the LPT1 is selected.

2-6
In the Head Info. box, type upper 12 digits (e.g., 66667F657031) out of the 13-digit property
code (enclosed with asterisks, e.g., *66667F657031H*) which is printed on the bar code label
attached to the print head unit. Then press the Enter key.
The setup utility will transmit the entered data from your PC to the facsimile machine and
then it will terminate.
The facsimile machine will automatically return to the standby mode.
(3) To check whether the entered head property is correct, make the machine enter the
maintenance mode (refer to CHAPTER 5, Section 5.1) and then press the 7key twice.
The facsimile machine will print out the Equipment's Log. On the line about 1/3 of full length
of the log sheet below from the top, the 12-digit code will be printed.
(4) Check that the character string entered in step (2) is printed in "XXXXXXXXXXXX."
If it is OK, press the 9key twice to exit from the maintenance mode.
If something other than that is printed in XXXXXXXXXXXX, check the connection between
the PC and facsimile machine and go back to step (1).

CHAPTER 3
THEORY OF OPERATION

CHAPTER 3 THEORY OF OPERATION
CONTENTS
3.1 OVERVIEW ......................................................................................................................3-1
3.2 MECHANISMS .................................................................................................................3-2
3.2.1 Scanner Mechanism ............................................................................................ 3-4
3.2.2 Ink Jet Printing Mechanism ..................................................................................3-6
3.2.2.1 Paper pulling-in, registration, feeding, and ejecting mechanisms................3-6
3.2.2.2 Ink jet printing and capping mechanisms..................................................... 3-8
3.2.2.3 Purging mechanism ................................................................................... 3-11
3.2.2.4 Carriage drive mechanism .........................................................................3-14
3.2.3 Sensors and Actuators.......................................................................................3-15
3.3 CONTROL ELECTRONICS...........................................................................................3-18
3.3.1 Configuration ...................................................................................................... 3-18