Page 1 Maintenance Manual Volume I of II L5535 Multifunction Printer...
Page 3 L5535 Multifunction Printer Maintenance Manual Volume I of II...
Page 4: Trademark Acknowledgements
Epson is a registered trademark of Seiko Epson Corporation. DuraFusion, IGP, LaserLine, LinePrinter Plus, PGL, PrintNet, PSA, and Printronix are registered trademarks, and Ribbon Minder is a trademark of Printronix, Inc. Magnum and QMS are registered trademarks, and Code V is a trademark of Quality Micro Systems, Inc.
Page 5 Hiroshige and Marigold are trademarks of AlphaOmega Typography, Inc. Printronix, Inc. makes no representations or warranties of any kind regarding this material, including, but not limited to, implied warranties of merchantability and fitness for a particular purpose. Printronix, Inc. shall not...
Page 7: Table Of Contents
Volume I Table of Contents 1 Introduction ............I–19 About This Manual................I–19 How To Locate Information ............I–19 Safety Notices And Special Information ........I–19 Switches And Display Messages ..........I–20 Related Documents..............I–20 General Safety Precautions.............. I–20 Setup Safety Precautions ..............I–22 Printer..................
Page 8 Table of Contents Maintenance Schedules ..............I–69 User’s Cleaning Schedule............I–69 User’s Replacement Schedule........... I–70 Tech Service Replacement Schedule ........I–71 Maintenance Kits ................I–72 General Cleaning................I–76 Cleaning The Chargers..............I–82 Cleaning The Fuser Unit Cover Glass And Lamp Filter....I–86 Cleaning The Cut Sheet Option Rollers..........
Page 9 Table of Contents Error Code 0B — Cutter Fail (rear) .......... I–136 Error Code 0C — Transfer Platform Fail (upper) ..... I–138 Error Code 0D — Transfer Platform Fail (lower) ...... I–138 Error Code 11 — Paper Jam at Drum (B) ........ I–140 Error Code 12 —...
Page 10 Table of Contents Error Code 63 — Cut-sheet Feeder Fail ........I–162 Error Code 64 — Cut-sheet Paper Skew ......... I–163 Error Code 65 — Cut-sheet Pick Miss ........I–163 Error Code 66 — No Paper Cassette........I–164 Error Codes 67, 69, and 6B — Paper Jam at Entrance (A) ..I–164 Error Codes 68 and 6A —...
Page 11 Table of Contents Confirming The Main Charger Current Control Circuit ..... I–211 Confirming The Sleeve Motor Operation........I–212 Confirming The Magroll Motor Operation ......... I–212 Confirming The Toner Supply Clutch Operation ...... I–212 Confirming The Head Cooling Fan Operation ......I–212 Confirming The Head Blower Fan Operation ......
Page 12 Table of Contents Motors ..................I–284 Fans ..................I–297 Solenoids ................. I–301 Miscellaneous ................I–303 Under The Top Cover ..............I–314 LED Print Head ................ I–315 High-Voltage (Corona) Power Supply ........I–319 Cutter Unit ................I–320 Sensors And Switches ............. I–323 Gates..................
Page 13 Volume II Table of Contents 7 Illustrated Parts Breakdown ......II–19 Overview..................II–19 Illustrated Parts Breakdown............. II–20 8 Principles of Operation........II–111 Printing System Descriptions............II–111 General ................... II–111 The Printing Process ............... II–111 How Images Are Processed ............II–112 Bit Mapping ................
Page 14 Table of Contents Drive System Descriptions............. II–132 Drum Drive ................II–133 Developing Roller Drive ............II–134 Main Unit Feed Roller Drive ............ II–135 Gate Drive ................II–136 Transfer Unit Drive ..............II–137 Tractor Drive ................II–137 Perforation Cutter Drive ............II–138 Separator Claw Drive ..............
Page 15 Table of Contents Input / Output Signals ..............II–194 LVX040 Controller Board Input/Output Signals....... II–194 MC Board (MC-PCBA) Input/Output Signals......II–203 DC Power Supply Board (PS-PCBA) Input/Output Signals..II–216 Unit Interface ................. II–221 LED Array................II–221 Flash Power Supply ..............II–225 Developing Unit ...............
Page 16 Table of Contents Status Confirmation Processing ..........II–255 Confirmation Processing Of Unit Of Error Occurrence ... II–255 Communication Processing ............ II–255 Driving Actuators ..............II–255 Cut Sheet Output Unit..............II–256 Physical Description ..............II–256 Setup and Connections ............II–258 Basic Principles ............... II–261 C Optional Power Paper Stacker......
Page 17 Table of Contents Basic Operation ................II–289 Status Confirmation Processing ..........II–290 Communication Processing............. II–290 Driving The Stacker..............II–290 Driving The Elevator Motor............II–290 Driving The Swinger Motor............II–290 Driving The Assisting Arm Drive Motor ........II–290 Switch Monitoring ..............II–290 Belt Removal Procedures ..............
Page 18 Table of Contents...
Page 19: Introduction
Introduction About This Manual This manual explains how to maintain and repair the L5535 printer at the field service level of maintenance. It covers alignments and adjustments, preventive and corrective maintenance, basic troubleshooting, and principles of operation. This manual does not explain how to configure or operate the printer. That information is in the User’s Manual, which supplements this manual.
Page 20: Switches And Display Messages
Printers Programmer’s Reference Manual (P/N 148802-001) General Safety Precautions This section provides safety information for technicians who are installing and maintaining L5535 printers. Installation, initial setup, testing and maintenance should be performed only by a factory-trained service representative. WARNING The printer relies on protective devices in the building installation for protection.
Page 21 Related Documents VORSICHT Denken Sie daran, daß sich im Drucker Komponenten befinden, die unter Umständen gefährlich sein können oder leicht zu beschädigen sind. So wird beispielsweise die Fixiereinheit im Normalbetrieb sehr heiß, und mehrere Komponenten arbeiten mit Hochspannung. WARNING When performing operational checkout with the printer turned ON, use extreme caution not to let your clothing or hair get caught in the rotary mechanisms.
Page 22: Setup Safety Precautions
Chapter Setup Safety Precautions • Do not spill any kind of liquid on the printer. If the printer surface is soiled, use only manufacturer-approved cleaning agents and methods. • Do not lean on or place heavy objects on top of the printer. •...
Page 23: Safety Label Locations And Printer Views
Printer Safety Label Locations And Printer Views Face Down Paper Output Tray Top Cover Rear Cover Front Cover Face Up Paper Output Tray WARNING Keep your hands away from stacker while printing. VORSICHT Power Paper Stacker Berühren Sie während des (Optional) Druckvorgangs nicht den Papierstapler.
Page 24 Chapter Safety Label Locations And Printer Views Rear Cover Top Cover Cut Sheet Paper Input Cassette (Optional) Power Switch WARNING Keep your hands away from tractors while printing. Printer emits bright light while Front Cover printing. Do not stare into tractor area while printing.
Page 25 Printer Open/Close Button Front Cover WARNING High voltage on chargers while printing. VORSICHT Ladeeinheiten stehen während des Druckvorgangs unter Hochspannung. WARNING HOT Do not touch fuser unit under glass. VORSICHT HEISS Glasabdeckung der Fixiereinheit nicht behrühren. WARNING Hot surface. Do not touch. VORSICHT Oberfläche heiß...
Page 26 Chapter Safety Label Locations And Printer Views Discharge LED (not visible) Main Charger Cleaning Unit Toner Cartridge Fuser Unit Optional Cut Sheet Output Unit (not visible) Optional Cut Sheet Feeder Unit (not visible) Control Panel Developing Unit Waste Toner Recovery Unit Transport Unit Smoke Filter Box Flash Power Supply...
Page 27 Printer WARNING HIGH VOLTAGE Do not touch charger power supply below this plate. VORSICHT HOCHSPANNUNG Netzteil nicht unterhalb dieser Platte berühren. WARNING HIGH VOLTAGE Do not touch the Power varistor on left. Switch VORSICHT HOCHSPANNUNG Varistor (links) berühren. WARNING Hot surface and hot air. Serial Port Avoid contact.
Page 28: Printer Features
Chapter Printer Features Printer Features The L5535 printer provides the following standard features: • Non-impact/electrophotographic page printer The printer is a non-impact page printer which employs the same electrophotographic system as regular copiers. It meets the needs of users who wish to produce high-quality prints rapidly and quietly.
Page 29: Tools, Test Equipment, And Supplies
Printer Tools, Test Equipment, And Supplies For field maintenance of the printer, you will need these tools: Figure I–6. Installation and Maintenance Tools I–29...
Page 30 Chapter Tools, Test Equipment, And Supplies Item Description: Figure I–6. Installation and Maintenance Tools Part 9-Inch Phillips Screwdriver, No. 2 tip (not shown in figure) 703531-169 Brush Cleaner 703531-186 Developing Unit Scraper 703531-170 Drum Auxiliary Rod (Drum Setting Rod) 703531-171 Drum Freshener Pad (not shown in figure) 703531-173 Dummy Drum...
Page 31: Setup
Setup To prepare the printer for initial operation, do all of the procedures in this chapter. IMPORTANT Only do the procedures in this chapter if you have received the appropriate training. Power Requirements WARNING Do not connect the printer to the power source until instructed to do so and until all shipping restraints have been removed.
Page 32: Site Selection
Chapter Site Selection Site Selection Select a location for the printer that conforms to the following requirements: • The location has a power source that conforms to the requirements specified on page I–31. • The location is within the maximum cable length specifications for the host computer interface.
Page 33 43.50 in. 56.50 in. (110.5 cm) (143.5 cm) 57.25 in. (145.4 cm) Figure I–7. Printer Dimensions (In Crate) I–33...
Page 34 Chapter Site Selection 36.5 in. (92.7 cm) 50.6 in. (128.5 cm) 47.5 in. (120.7 cm) 36.0 in. (91.4 cm.)* *Leave at least 36 in. (91.4 cm.) around the entire printer. Figure I–8. Printer Dimensions (Unpacked) I–34...
Page 35: Unpacking And Leveling
Unpacking And Leveling After a site has been selected for the printer, set up the printer according to the following procedures: 1. Open the packaging and refer to the Unpacking Instructions for a list of parts supplied in the package. Unpack the printer and consumables as described in these instructions.
Page 36 Chapter Unpacking And Leveling 4. Put a level on the top cover and make fine adjustments, using the height- adjusting legs, to level the printer in both directions (shown below). Level in the two orthogonal directions. Height Adjusting Legs (4 Places) I–36...
Page 37: Cable Connections
Power Cord Cable Connections Power Cord The procedure to install the power cord is the same for both domestic and international power cords, using the following power cord part numbers: • P/N 703904-001: for installation in the United States and Canada. The mating connector for the printer power cord should be a NEMA L6-30P female connector, rated at 250 VAC and 30 Amps.
Page 38 Chapter Cable Connections 2. Remove the screw securing the power supply terminal box cover, then remove the cover, as shown below. 3. Remove the screws (2) on the terminal cover inside the terminal box, then remove the cover, as shown below. Terminal Cover Screws (2) Box Cover...
Page 39 Power Cord 4. Refer to the figure below. Connect the power cord to the terminal block as follows: Connect the power and ground wires to each terminal, in the following order: line 1 power wire, line 2 power wire, and ground wire. Line 1 Power Wire Line 2 Power Wire Ground Wire...
Page 40: Interface Cable
Chapter Cable Connections Interface Cable Now connect the printer to the computer. To connect the cables, refer to the following illustration and perform the steps listed below. NOTE: To avoid possible electrical interference, separate the AC power cord and the interface cable. 1.
Page 41: Installing The First Photoreceptor Drum
IMPORTANT The instructions that follow for the initial installation of consumables are written as a continuous procedure, where each task builds upon the previous task. For individual replacement procedures, see the User’s Manual . Installing The First Photoreceptor Drum To install the drum, you will need a drum auxiliary rod. Please read all steps before beginning the installation process.
Page 42 Chapter Installing The First Photoreceptor Drum 3. Open the waste toner recovery unit by pushing the opening lever down. Pull the green handle and swing the unit outward. Waste Toner Recovery Unit Green Handle Opening Lever 4. Loosen the three thumbscrews and remove the upper inner cover. Thumbscrews (3) Upper Inner Cover I–42...
Page 43 CAUTION The transfer charger must be in the down position to avoid scratching the drum. 5. Check that the transfer charger is in the down position, and if not, move it to the down position by rotating the transfer elevator drive shaft counterclockwise.
Page 44 Chapter Installing The First Photoreceptor Drum 7. Loosen the three thumbscrews securing the drum plate and remove the drum plate. Drum Plate Thumbscrews (3) Screws (2) Lower Inner Cover 8. Remove the two screws on the lower inner cover. Remove the cover. 9.
Page 45 10. Screw the drum auxiliary rod onto the drum shaft. Drum Auxiliary Rod P/N 703531-170 11. Wipe the drum shaft clean with a cloth. 12. Remove the new photoreceptor drum from its package. Save the packaging material for future drum disposal. The ends of the drum are identical;...
Page 46 Chapter Installing The First Photoreceptor Drum rotate the drum by hand while applying inward pressure, until the drum moves slightly farther into the printer and locks in place. CAUTION In order to position the drum slot and the drum shaft pin, push the drum in all the way to the back and rotate it until you feel it drop in place.
Page 47: Adding The Developer
Adding The Developer Nozzle Developer Bottle Roller Knob Cover Screws (3) Cover To add developer to the developing unit for the first time, perform the following steps. (To replace developer in an existing developing unit, see the User’s Manual .) CAUTION The toner sensor is sensitive to both electrostatic discharge (ESD) and positional adjustment.
Page 48 Chapter Adding The Developer 5. Pour all the developer powder into the developing unit evenly, while rotating the roller knob counterclockwise. Developer Powder Roller Knob IMPORTANT If toner or developer spills on skin or clothing, use cold water to remove 6.
Page 49: Installing The Developing Unit
Installing The Developing Unit This procedure is for installing the developing unit for the first time. To replace the developing unit, see the User’s Manual . Before you do this procedure, make sure the following conditions are met: • The power switch is OFF. •...
Page 50 Chapter Installing The Developing Unit 3. Rotate the hanger to the right so that it rests against the developing unit, and push the developing unit in. 4. Rotate the developing roller knob counterclockwise until the unit drops into its final resting position. The positioning pin should protrude through the main body of the developing unit.
Page 51 6. Raise the transport unit: after pressing the transport unit in, turn the green lever to the right to lock the transport unit in place. Green Lever 7. Reinstall the lower inner cover, and secure it with the two screws you removed from it earlier.
Page 52: Installing The Toner Cartridge And Waste Toner Bottle
Chapter Installing The Toner Cartridge And Waste Toner Bottle 8. Reinstall the upper inner cover, and secure it with the three thumbscrews. Thumbscrews (3) Upper Inner Cover 9. Install the toner cartridge and waste toner bottle (page I–52). Installing The Toner Cartridge And Waste Toner Bottle This procedure is for installing the toner cartridge and waste toner bottle for the first time.
Page 53 Toner Cartridge 2. Remove the toner cartridge from its package. 3. With the cover tape facing up, insert the cartridge into the toner hopper, and slowly pull off the cover tape as you push the cartridge in. Remove the last of the tape just as the cartridge is completely inside the hopper. Toner Hopper Cover Tape Notch...
Page 54 Chapter Installing The Toner Cartridge And Waste Toner Bottle Toner Cartridge 6. Install a new waste toner bottle in the waste toner recovery unit. (See below.) 7. Remove the cap from the waste toner bottle, and store it in the cap storage location.
Page 55: Loading Fanfold Paper
Loading Fanfold Paper Do this procedure whenever top-of-form must be reset (e.g., after clearing a paper jam, loading new paper, etc.). For details on clearing paper jams, see Chapter 4, “Troubleshooting.” The procedure for loading fanfold paper assumes the following: •...
Page 56 Chapter Loading Fanfold Paper 4. Unlock only the right tractor by pushing forward on the tractor lock. 5. Open the left and right tractor gates and place the paper about halfway onto the tractor pins. IMPORTANT Do not push the paper past the tractors into the area of the paper jam sensor.
Page 57: Loading Cut Sheet Paper
Loading Cut Sheet Paper If the printer is equipped with the cut sheet paper feed option, upper and lower paper input cassettes are provided. When printing on cut sheet paper, the operator can select the face down tray (default) or the face up tray from the control panel.
Page 58 Chapter Loading Cut Sheet Paper 3. Load the new paper uniformly in the cassette. Ensure that the leading edge of the paper is at the front of the cassette. Do not load more paper than specified below, otherwise a paper jam may occur. 17-20 lb.
Page 59: Setting Cassette Paper Size (Optional Procedure
Setting Cassette Paper Size (Optional Procedure) There are three holes in the forward end of the cut-sheet paper feed cassettes. Plastic inserts are set in these holes according to the size of the cut-sheet paper loaded in the cassette (as shown in the table below). When the plastic inserts in the cassette contact the paper size sensors on the printer, the printer determines that the paper cassette is in position and identifies the paper size.
Page 60: Setting The Power Supply Voltage
Chapter Setting The Power Supply Voltage Setting The Power Supply Voltage This procedure assumes the following: • The ON/OFF switch on the printer is set to the 0 (OFF) position. • The power cord is unplugged. • The printer front cover is closed. •...
Page 61 To determine the voltage setting, perform the following steps: 1. Measure and note the RMS AC line voltage that will supply power to the printer. 2. Remove the screw securing the power supply access panel on the right rear cover, then remove the access panel, as shown below. Rear Cover (Right) Screw Power Supply...
Page 62 Chapter Setting The Power Supply Voltage 3. Refer to detail drawing “A” in the following figure and move the circuit breaker lever to the OFF position. (The circuit breaker lever is accessible through the opening behind the terminal box access panel.) 4.
Page 63 5. Using the following figure and chart, slide the power supply voltage switch (SW1) on the DC power supply board to the correct voltage position which you measured in step 1. Power Supply Voltage Switch SW1 DC Power Supply Board (behind Power Supply Cover) Connector CN8...
Page 64 It is very important that the voltage measured across CN8 pins 1 and 2 (the main blower fan) falls within the range of 190V to 220V. If you cannot achieve this, call Printronix Technical Support for assistance. 11. Stop the test print, then turn the ON/OFF switch on the printer to the 0 (OFF) position.
Page 65 17. Move the circuit breaker lever to the ON position, then reinstall the terminal box access panel (shown on page I–37) on the printer rear cover. 18. Turn the ON/OFF switch on the printer to the 1 (ON) position and observe the printer LCD.
Page 66 Chapter Setting The Power Supply Voltage Table I–2. Maximum Paper Stack Height Page Length (inches) Max. Stack Height (inches) 8.66 8.66 8.50 8.07 7.64 7.20 10.0 6.77 10.5 6.34 11.0 5.91 11.5 5.47 12.0 5.12 This completes the initial printer setup. For printer configuration menus and procedures, see the User’s Manual .
Page 67: Scheduled Maintenance
Scheduled Maintenance Maintaining Print Quality To maintain good print quality, perform cleaning procedures according to the schedules and information listed in this chapter. If print quality problems occur, clean the following areas (see page I–29 for tool illustrations and part numbers): 1.
Page 68: Service Level Page Counts
Chapter Service Level Page Counts Service Level Page Counts IMPORTANT Maintain a record of all maintenance performed on the printer. Maintenance log sheets are provided in Appendix A, Maintenance Log Sheets, in the User’s Manual . Photocopy these and keep them in a binder near the printer.
Page 69: Clearing Service Level Messages
Clearing Service Level Messages Clearing Service Level Messages Once you have performed a level of service, you must clear the page count for that service level. When you clear a service level, the levels above it are also cleared. For example, clearing level C also clears levels A and B. To clear a service level (level D, for example), select the Maintenance menu from the control panel, select the Tech Service option, then select “Clear Level D”...
Page 70: User's Replacement Schedule
Chapter Maintenance Schedules Table I–3. User Responsibility — Cleaning Frequency Service Action (Pages) Level Note 1: Every 15,000 pages or 6 paper jams, whichever occurs first. Note 2: Only applies to printers with the cut sheet option installed. User’s Replacement Schedule The following items should be replaced by the user after the specified number of letter size pages (4% coverage) have been printed.
Page 71 Tech Service Replacement Schedule Tech Service Replacement Schedule Each time a service technician completes a level of preventive maintenance, he or she must reset the service level page count by selecting the Technician Service option on the Maintenance menu (refer to the User’s Manual) . This removes the maintenance error message.
Page 72 Chapter Maintenance Kits Table I–5. Service Provider Responsibility — Replacement (continued) Frequency Service Item Part Number Action (Pages) Level LED for discharge lamp 703531-118 2,400,000 Replace EPS1 Sensor Lever 703531-585 2,400,000 Replace EPS3 Sensor Lever 703531-588 2,400,000 Replace EPS4 Sensor Lever 703531-067 2,400,000 Replace...
Page 73: Tech Service Replacement Schedule
Tech Service Replacement Schedule Table I–7. Level E Maintenance Kit Item Part Number Maintenance Kit, Level E, 706803-001 L5031/5035 This kit includes the following items: • Main charger • Precharger • Transfer charger • Smoke filter • Cleaning unit • Halogen lamp •...
Page 74 Chapter Maintenance Kits Table I–9. Level G Maintenance Kit Item Part Number Maintenance Kit, Level G, 706815-001 L5031/5035 This kit includes the following items: • Main charger • Precharger • Transfer charger • Smoke filter • Cleaning unit • Halogen lamp •...
Page 75 Tech Service Replacement Schedule Table I–10. Level H Maintenance Kit Item Part Number Maintenance Kit, Level H, 706827-001 L5035 • EPS1 • EPS3 • L5035 brush kit (1 time only) • LED air filter • Jam sensor lever I–75...
Page 76: General Cleaning
Chapter General Cleaning General Cleaning For best print quality, clean the printer regularly. CAUTION Due to the high intensity of the flash fusing unit, keep the area under the fuser free of paper debris. 1. Turn the power switch OFF. 2.
Page 77 4. On the waste toner recovery unit, press the Open lever down. Pull the handle toward you and open the unit. 5. Vacuum the developing unit and toner hopper. I–77...
Page 78 Chapter General Cleaning 6. Vacuum the cleaning unit. Cleaning Unit 7. Vacuum the fuser unit. I–78...
Page 79 8. Vacuum the lamp housing filter on the underside of the fuser unit. CAUTION The transfer charger must be in the down position to avoid scratching the drum. 9. Check that the transfer charger is in the down position, and if not, move it to the down position by rotating the transfer elevator drive shaft counterclockwise.
Page 80 Chapter General Cleaning CAUTION To avoid damaging the printer or causing false paper jams, the transport lever must be in the fully down position before opening or closing the transport unit. 10. Lower the transport unit by turning the green lever on the transport unit to the left.
Page 81 14. Using an ammonia-based wax-free cleaner or rubbing alcohol, clean the belts to remove residue buildup and restore their tacky surface. 15. After cleaning, return the transport unit to its original position (push it into the printer while holding down the green lever). When the transport unit is in position, raise the green lever to the right to raise the transport surface.
Page 82: Cleaning The Chargers
Chapter Cleaning The Chargers 19. Open the lid on the top cover. 20. Open the paper guide by pressing the guide lever down. 21. Vacuum the paper dust, etc. inside the paper guide. Paper Guide Cleaning The Chargers 1. Turn the power switch OFF. 2.
Page 83 4. Place the main charger on a flat, clean work surface. 5. Using the brush cleaner (listed on page I–29), clean the exposed side of the charger grid and the body of the main charger, as shown below. Brush Cleaner Charger Grid Main Charger 6.
Page 84 Chapter Cleaning The Chargers 7. Using the brush cleaner (listed on page I–29), clean both sides of the charger grid, as shown below. Brush Cleaner Charger Grid 8. Using the wire cleaner (listed on page I–29), clean the two wires in the main charger, as shown below.
Page 85 12. Loosen the precharger thumbscrew and the transfer/separator charger thumbscrew, then remove both chargers by pulling them toward you. Thumbscrews Precharger Transfer/Separator Charger 13. Place the chargers on a flat, clean work surface. 14. Using the brush cleaner and the wire cleaner (listed on page I–29), clean the chargers by removing the dust and dirt on the wires (the precharger contains one wire, while the transfer/separator charger contains two wires).
Page 86: Cleaning The Fuser Unit Cover Glass And Lamp Filter
Chapter Cleaning The Fuser Unit Cover Glass And Lamp Filter Cleaning The Fuser Unit Cover Glass And Lamp Filter WARNING The fuser unit remains hot after operation. Wait until it has completely cooled down before handling it. Never scratch or touch the cover glass or lamps with your hands. Fingerprints on the cover glass or lamps will cause them to break.
Page 87 CAUTION To avoid damaging the printer or causing false paper jams, the transport lever must be in the fully down position before opening or closing the transport unit. 4. Lower the transport unit by turning the green lever on the transport unit to the left.
Page 88 Chapter Cleaning The Fuser Unit Cover Glass And Lamp Filter 10. Wipe away any remaining toner or dirt with a Toraysee cloth (listed on page I–29). 11. Remove the two screws that secure the lamp duct filter unit to the fuser, then remove the lamp duct filter unit and the foam gasket.
Page 89: Cleaning The Cut Sheet Option Rollers
Cleaning The Cut Sheet Option Rollers NOTE: This procedure only applies to printers with the cut sheet option installed. 1. Turn the power switch OFF. 2. Remove the upper and lower paper cassettes from the printer. Upper Pickup Roller Unit Lower Pickup Roller Unit 3.
Page 90 Chapter Cleaning The Cut Sheet Option Rollers 5. Wipe off the dirt on the pickup rollers with a Toraysee cloth (listed on page I–29). Remove any label adhesive or forms residue with rubbing alcohol. Roller 6. Install the upper and lower pickup roller units: a.
Page 91 Upper Reverse Roller Unit Lower Reverse Roller Unit 7. Two reverse roller units (upper and lower) are located at the back of the cassette opening (underneath the upper and lower pickup roller units). On the upper reverse roller unit, loosen the green thumbscrew. Remove the roller unit by moving it downward while sliding it to the left.
Page 92 Chapter Cleaning The Cut Sheet Option Rollers 9. Wipe off the dirt on the reverse rollers with a Toraysee cloth (listed on page I–29). Remove any label adhesive or forms residue with rubbing alcohol. Roller 10. Install the upper and lower reverse roller units: a.
Page 93: Major Cleaning
Major Cleaning 1. Turn the power switch OFF. 2. Open the printer front cover. (See page I–76.) Cleaning Unit 3. Open the waste toner recovery unit by pushing downward on the lever. Pull the green handle and swing the unit outward away from the printer. Waste Toner Recovery Unit Green Handle...
Page 94 Chapter Major Cleaning 5. Loosen the three thumbscrews securing the drum plate and remove the drum plate. Thumbscrews (3) Cleaning Unit Handle Drum Plate 6. Remove the cleaning unit by grasping its handle and pulling it toward you. CAUTION Do not turn the cleaning unit upside down, or toner might spill. 7.
Page 95 Discharge LED CAUTION Do not flex the discharge LED as it will break. 8. Remove the discharge LED screw. Screw Discharge LED 9. Remove the discharge LED by pulling it toward you. 10. Using a Toraysee cloth (listed on page I–29), wipe off the dirt on the discharge LED.
Page 96: Photoreceptor Drum
Chapter Major Cleaning Photoreceptor Drum 12. Remove the developing unit from the printer. (See the User’s Manual .) CAUTION When cleaning the photoreceptor drum, note the following: • Do not touch the drum surface with your hands. • To prevent the drum surface from being scratched, clean it in a location free of dust.
Page 97 overlap each other, and polish the entire drum surface two or three times repeatedly. CAUTION Press lightly when polishing the drum surface, as too much pressure can damage the drum. 17. Using the special dry tissue paper (listed on page I–29), thoroughly wipe the drum freshener off the drum surface.
Page 98 Chapter Major Cleaning Drum Surface Potential Sensor SELFOC Lens 22. Reinstall the main charger. 23. Reinstall the photoreceptor drum. (See “Photoreceptor Drum” on page I– 253.) 24. Reinstall the developing unit. (See the User’s Manual .) 25. Reinstall the cleaning unit. (See the User’s Manual .) I–98...
Page 99: Cleaning The Flash Power Supply Filter
Cleaning The Flash Power Supply Filter 1. Turn the power switch OFF. 2. Remove the two screws securing the right side of the stand cover. Screw Screw Flash Power Supply Stand Cover 3. Pull the right side of the stand cover slightly forward, unhook the two pins in the left side of the cover from the printer, and remove the cover.
Page 100 Chapter Cleaning The Flash Power Supply Filter 4. Remove the screw securing the filter access handle, then remove the handle. Flash Power Supply Filter Screw Filter Access Handle 5. Pull the filter out from the flash power supply. 6. Clean the filter using a vacuum cleaner. 7.
Page 101: Troubleshooting
Troubleshooting Overview This chapter contains the printer main component locations, a system block diagram, the hidden control menus, and procedures for dealing with paper jams, numerical errors, and other printer symptoms. The numerical errors are discussed in numerical sequence by error code, as listed in the chapter contents.
Page 102: System Block Diagram
Chapter System Block Diagram System Block Diagram Host Computer Controller Control Panel Cut Sheet Feeder and Print Engine Output Units (optional) Power Paper Stacker (optional) I–102...
Page 103: Hidden Control Menus
Jam Detection Sensors Hidden Control Menus Figure I–9 shows the hidden control menus. Values that are set or adjusted on these menus are set at the factory and are saved in the printer. These menus are to be used by service personnel only. For details on the items on the hidden control menus, see the sections that follow Figure I–9.
Page 104: Global Memory Adjust Menu
Chapter Hidden Control Menus Global Memory Adjust Menu Global Press UP, DOWN, NEXT, and Memory PREV to view options. Adjust Press ENTER to select an option. Press ONLINE at any time to exit configuration and save changes. * = Factory Default Default is n K Bytes, where n varies, depending on the...
Page 105: Printer Control Menu
Default values will vary depending on the factory settings on the inspection sheet inside the printer. If there is no inspection Printer Control sheet, locate the serial number of the printer and contact Printronix for the factory-set value. Cut-Sheet Surface Volts Bias Volts LED Time LED Factory X Adj.
Page 106 Chapter Hidden Control Menus Surface Volts This option adjusts the drum surface voltage sensor. The default setting is 580. The allowable range is 500 through 700, in increments of 4 volts. The normal setting for toner cartridge 703532-001 is 580. The normal setting for toner cartridges 703532-002 and 174697-001 is 552.
Page 107: Fanfold Paper Jams
Paper Jam Near The Tractor Normal adjustment is as needed. The allowable range is –1 inch through +1 inch, in increments of 1/100 inch. Reset Stacker Selecting this option restores the stacker swinger to its initial (powerup) position. Normally, this option should not be needed because the software automatically restores the position of the stacker swinger at the appropriate time.
Page 108: Paper Jam Near The Paper Output Section
Chapter Fanfold Paper Jams Paper Jam Near The Paper Output Section 1. When paper motion stops, wait 15 seconds, then open the front cover. (See page I–76.) 2. Push down on the opening lever of the waste toner recovery unit, and pull the green handle to swing the unit outward away from the printer.
Page 109 Paper Jam Near The Paper Output Section CAUTION The transfer charger must be in the down position to avoid scratching the drum. Failure to perform steps 4 and 5 will damage the drum. 4. Check that the transfer charger is in the down position, and if not, move it to the down position by rotating the transfer elevator drive shaft counterclockwise.
Page 110 Chapter Fanfold Paper Jams 6. Check to see if any paper is jammed. 7. Raise the scuff roller holding the paper by turning knob “C” clockwise 90° as shown below. Knob C 8. Separate the fanfold paper at the perforations on both the paper input and the output sections.
Page 111: Cut Sheet Paper Jams
Paper Jam At The Back Of The Paper Cassette CAUTION To avoid damaging the printer or causing false paper jams, the transport lever must be in the fully down position before opening or closing the transport unit. 9. After removing the pieces of jammed paper, restore the transport unit, waste toner recovery unit, and knob “C”...
Page 112: Paper Jam In The Transport Input Section
Chapter Cut Sheet Paper Jams 3. Open the lid on the top cover, and pull the green lever up. Remove any jammed paper, and return the green lever to its original position. Green Lever Top Cover Paper Jam In The Transport Input Section 1.
Page 113 Paper Jam In The Transport Input Section CAUTION The transfer charger must be in the down position to avoid scratching the drum. Failure to perform steps 4 and 5 will damage the drum. 3. Check that the transfer charger is in the down position, and if not, move it to the down position by rotating the transfer elevator drive shaft counterclockwise.
Page 114: Paper Jam In The Transport Output Section
Chapter Cut Sheet Paper Jams 5. Remove knob “A” from its storage location, as shown below. Attach knob “A” to the paper feed shaft as shown, then turn knob “A” counterclockwise. This causes the jammed paper to be moved to the eject side.
Page 115: Paper Jam In The Face Up Or Face Down Paper Path
Paper Jam In The Face Up Or Face Down Paper 3. Lower the paper guide by restoring the bottom lever to its original position. Close the front cover. Paper Jam In The Face Up Or Face Down Paper Path 1. When paper motion stops, wait 15 seconds, then open the front cover. (See page I–76.) 2.
Page 116: Status Messages And Error Messages
Chapter Status Messages And Error Messages Status Messages And Error Messages Error Message Table Table I–11 on page I–117 lists each error and status message by its error code. This table shows which errors are operator-correctable, which require field service, and which require reprinting. Some error codes have a detailed troubleshooting procedure associated with them.
Page 117 Error Message Table Table I–11. Status and Error Messages Error LCD Message Remarks Required Action Code (none) TRAY MISMATCH Tray Linking is enabled, the Add paper to the active cut sheet trays are of tray or insert a matching different sizes, and the tray in the alternate tray active tray has run out of position.
Page 118 Chapter Status Messages And Error Messages Table I–11. Status and Error Messages (continued) Error LCD Message Remarks Required Action Code (none) ERROR: FLASH TYPE This type of flash memory Power off the printer and IS NOT SUPPORTED SIMM is unsupported, or the download the program file system in the DC flash again.
Page 119 Error Message Table Table I–11. Status and Error Messages (continued) Error LCD Message Remarks Required Action Code (none) ERROR: PROGRAM The printer requires more Add DC DRAM to the NEEDS MORE DRAM DC DRAM memory in order controller board, or use a to run the downloaded smaller emulation program, or in order to use...
Page 120 Chapter Status Messages And Error Messages Table I–11. Status and Error Messages (continued) Error LCD Message Remarks Required Action Code (none) ERROR: WRONG The printer received the Power off the printer and CHECKSUM complete program or data download the program file, but the checksum did again.
Page 121 Error Message Table Table I–11. Status and Error Messages (continued) Error LCD Message Remarks Required Action Code (none) FILE SYS WRITE One or more errors Optimize the flash file CHECK FLASH occurred while the printer system to delete any was writing a file into the marked files (see the User’s Manual) , then flash file system.
Page 122 Chapter Status Messages And Error Messages Table I–11. Status and Error Messages (continued) Error LCD Message Remarks Required Action Code (none) OPTIMIZING The printer is reclaiming None (wait for the printer FLASH FILES unused space from deleted to reboot). files in the flash file system. (none) RESETTING...
Page 123 Error Message Table Table I–11. Status and Error Messages (continued) Error LCD Message Remarks Required Action Code Cutter Fail See page I–136. (rear) Transfer Platform Fail See Note 1 and page I– (upper) 138. Transfer Platform Fail See Note 1 and page I– (lower) 138.
Page 124 Chapter Status Messages And Error Messages Table I–11. Status and Error Messages (continued) Error LCD Message Remarks Required Action Code Reserved Reserved Reserved Reserved No Cleaning Unit See page I–153. Reserved Waste Toner Full See page I–153. No Waste Toner Box See page I–154.
Page 125 Error Message Table Table I–11. Status and Error Messages (continued) Error LCD Message Remarks Required Action Code Engine CPU Fail See page I–156. Engine CPU Fail See page I–156. Engine CPU Fail See page I–156. Engine CPU Fail See page I–156. Engine CPU Fail See page I–156.
Page 126 Chapter Status Messages And Error Messages Table I–11. Status and Error Messages (continued) Error LCD Message Remarks Required Action Code Stacker Fail Elevator maximum limit See page I–160. switch 1 or 2 (LIMT1 or LIMT2) tripped. Stacker Fail Stacker motor, elevator See page I–161.
Page 127 Error Message Table Table I–11. Status and Error Messages (continued) Error LCD Message Remarks Required Action Code Paper Jam at Entrance (A) PRS (upper) or PFS (lower) See page I–165. went on, but did not go off soon enough. Paper Jam at Entrance (A) PTS went on, but did not go See page I–164.
Page 128: Error Message Troubleshooting Procedures
Chapter Status Messages And Error Messages Table I–11. Status and Error Messages (continued) Error LCD Message Remarks Required Action Code Separator Charger Error See page I–170. Reserved through 1. For error numbers 0C and 0D, verify that the transfer platform is completely seated. 2.
Page 129 Error Code 01 — Front Cover Open e. Measure the resistance between pin 2 and pin 4 of PB-CN6 with the digital multimeter. Reconnect harness connector PB-CN6 to CN6 on the DC Power Supply board. Ω If the resistance reading was 0 (normal), go to Step 4.
Page 130: Error Code 02 - Fan-Fold Paper Empty: Upon Power-On
Chapter Status Messages And Error Messages a. Power off the printer at the breaker, and unplug the power cord from the wall outlet. b. Disconnect the harness connectors from the following connectors on the MC board: CN6, CN13, CN15, CN17, CN18, CN19, CN20, CN24, CN25, and CN26.
Page 131: Error Code 02 - Fan-Fold Paper Empty: When Loading/Beginning Print
Error Code 02 — Fan-fold Paper Empty: When Error Code 02 — Fan-fold Paper Empty: When Loading/Beginning Print CHECKLIST: TRACTOR PAPER BACK FEED SENSOR (PBFS) MC BOARD TRACTOR MOTOR 1. Ensure that the fanfold paper is loaded properly on the tractors. 2.
Page 132: Error Code 04 - Paper Jam At Exit (D) (Transport Section
Chapter Status Messages And Error Messages a. Put the positive lead of the digital multimeter on pin 5 of CN26 on the MC board, and the negative lead on pin 6. b. Push the EPS4 lever down and measure the voltage; 5V is normal. c.
Page 133: Error Code 05 - Paper Jam At Exit (D) (Paper Output Section
Error Code 05 — Paper Jam at Exit (D) (paper out- c. Check the voltage while turning the jam removal knob right and left. The needle on the multimeter should fluctuate between 0V and 5V. d. Feed paper, using the paper feed mode with the engine checker, and monitor the status of EPS0.
Page 134: Error Code 07 - Scuff Lever Open (Knob "C
Chapter Status Messages And Error Messages c. Raise the EPS2 lever up and measure the voltage, which should be about 0V. If voltage is not normal, replace the EPS2 after checking the harness. NOTE: Possible causes for an EPS1 (straight) paper jam: •...
Page 135: Error Code 09 - Transport Motor Fail (Complete Stop
Error Code 09 — Transport Motor Fail (complete 1. Ensure that the paper output transport path guide is closed. 2. Check the MC board. a. Put the positive lead of the digital multimeter on pin 15 of CN3, and the negative lead on the SG. b.
Page 136: Error Code 0A - Cutter Fail (Front
Chapter Status Messages And Error Messages b. If LD23 blinks or does not light, adjust VR29 on the MC board until LD23 emits a continuous light. 2. Check the main unit feed motor encoder. Encoder 20: a. Put the positive lead of the digital multimeter on TP3 on the MC board, and the negative lead on the SG.
Page 137 Error Code 0B — Cutter Fail (rear) d. With the cutter in the rear position, measure the voltage, which should be 0V. If voltage is not normal, replace the CPS0. 4. Check the cutter position sensor 1 (CPS1), with paper loaded. a.
Page 138: Error Code 0C - Transfer Platform Fail (Upper
Chapter Status Messages And Error Messages If the cutter does not move the entire distance across the cutting area, replace the cutter motor. If the cutter does not stop, replace the MC board. Error Code 0C — Transfer Platform Fail (upper) Error Code 0D —...
Page 139 Error Code 0D — Transfer Platform Fail (lower) a. Remove the transfer elevator motor. b. Remove the transfer unit upper limit / lower limit sensors, without disassembling them from the bracket. c. Put the positive lead of the digital multimeter on pin 8 of CN24 on the MC board, and the negative lead on the SG.
Page 140: Error Code 11 - Paper Jam At Drum (B
Chapter Status Messages And Error Messages Error Code 11 — Paper Jam at Drum (B) CHECKLIST: SEPARATOR SECTION (EPS3) EPS3 (PAPER OUTPUT SENSOR 3) LEVER TRANSFER UNIT 1. If there is paper remaining in the separator section (near sensor EPS3), remove it.
Page 141: Error Code 13 - Paper Jam At Exit (D): Straight Output (Faceup
Error Code 13 — Paper Jam at Exit (D): Straight NOTE: You can lower the transport unit and move the sensor lever back and forth, while pressing the transport unit in to maintain contact with the connector in back of the transport unit. Error Code 13 —...
Page 142: Error Code 14 - Tractor Speed Too High
Chapter Status Messages And Error Messages 1. If there is paper remaining in the paper output section (near sensor EPS2), remove it. 2. Ensure that the EPS2 lever is in the up position. 3. Check the EPS1 sensor. a. Place the rotary switch in the “0” position on the MC board. b.
Page 143 Error Code 15 — Tractor Speed Too Low d. After the paper moves forward and back, remove the tractor motor terminal connector from the motor terminal. e. Measure the voltage, which should be about –10V. If the tractor motor is not normal, replace it. 5.
Page 144: Error Code 16 - Paper Jam At Entrance (A
Chapter Status Messages And Error Messages c. Stop the tractor motor. Tractor motor adjustment (reverse): a. Drive the tractor motor in reverse. b. Adjust VR20 so that LEDs LD21 and LD22 on the MC board have the same brightness. c. Stop the tractor motor. 7.
Page 145 Error Code 17 — High Voltage Fail 1. Check the seating of all chargers. Check the installation and seating of all chargers (main charger, transfer/ separator charger, and precharger). If all chargers are seated properly, go to step 2. 2. Check all of the chargers. a.
Page 146: Error Code 18 - Drum Motor Fail (Complete Stop
Chapter Status Messages And Error Messages c. Put the positive lead of a digital multimeter on the conveyor of the transfer unit, connect the negative lead to the printer frame, and measure the voltage. d. If the voltage at the conveyor is about –200V, go to step 8. Otherwise, some portion of the cleaning unit must be shorting to other parts.
Page 147: Error Code 19 - Surface Voltage Too High
Error Code 19 — Surface Voltage Too High a. Place the rotary switch in the “E” position on the MC board. b. Remove the 2-pin connector of the drum motor. c. Hold the connector with the flat part of the connector facing up and the notched part facing down.
Page 148 Chapter Status Messages And Error Messages b. Reinstall the fuser unit. With the printer powered down, measure the resistance from the fuser to the transport unit. Resistance should be Ω about 1 M 2. Verify the surface voltage setting in the configuration menu. Through the printer control panel, select the Printer Control menu, Surface Volts option.
Page 149: Error Code 1A - Surface Voltage Too Low
Error Code 1A — Surface Voltage Too Low Error Code 1A — Surface Voltage Too Low CHECKLIST: FUSER UNIT CONFIGURATION MENU MAIN CHARGER HIGH-VOLTAGE POWER SUPPLY DRUM SURFACE POTENTIAL SENSOR (DSPS) DRUM MC BOARD 1. Check the fuser unit. a. Remove the fuser unit. Determine if the flash guard on the fuser is bent and touching the transport unit.
Page 150: Error Code 1B - Tractor Detent Fail
Chapter Status Messages And Error Messages 7. Check the drum. Determine if the drum is worn or dirty. Also, run a print job and check the print quality. If the drum is not normal, replace it. If the error persists after replacing the drum, replace the MC board.
Page 151: Error Code 1E - Fuser Supply Fail
Error Code 1E — Fuser Supply Fail Error Code 1E — Fuser Supply Fail CHECKLIST: FUSER UNIT FLASH LAMP OR HARNESS TRIGGER COIL OR HARNESS FLASH POWER SUPPLY OR HARNESS MC BOARD 1. Check that the fuser unit is installed properly, and that there are no abnormalities in the high voltage connection terminals.
Page 152: Error Code 20 - Fuser Lamp Overheat
Chapter Status Messages And Error Messages b. Turn off power to the printer and check the continuity of the harness from connector CN6 of the MC board to FP-J11 of the flash power supply. If the continuity is OK, replace the MC board. 4.
Page 153: Error Code 26 - No Cleaning Unit
Error Code 26 — No Cleaning Unit Error Code 26 — No Cleaning Unit CHECKLIST: CLEANING UNIT DRUM CLEANER SET SENSOR (DCS SW) MC BOARD 1. Ensure that the cleaning unit is properly installed. 2. Check the drum cleaner set sensor (DCS SW). a.
Page 154: Error Code 29 - No Waste Toner Box
Chapter Status Messages And Error Messages a. Press CLEAR. b. Unlock the configuration menu. c. Enter the configuration menu and select the Paper Control menu. d. Select the “Reset Toner Full” option and press ENTER. e. Exit the configuration menu. Press ONLINE.
Page 155: Error Code 2B - Toner Density Too High
Error Code 2B — Toner Density Too High When toner level drops below what is sufficient in the developing unit, an oscillation sound is emitted from the toner empty sensor. If necessary, replace the toner cartridge. 2. Check the toner empty sensor circuit. Adjust the toner density sensor (page I–208).
Page 156: Error Codes 38 Through 47 - Mc Board Cpu Internal Error
Chapter Status Messages And Error Messages b. Measure the voltage with the printer powered up, which should be about 24V. c. If the voltage is 24V and the fan does not turn, turn off power to the printer and check the continuity of the harness between connector CN15 on the MC board and JM15102.
Page 157: Error Codes 50 Through 53 And 5B - Stacker Fail
Error Codes 50 through 53 and 5B — Stacker Fail Verify that the controller interface cable is connected properly to MC board connector CN7 at one end, and to controller module backplane connector P8A at the other end. 2. If the connectors are OK, turn off power to the printer and check the continuity of the controller interface cable.
Page 158: Error Code 54 - Stacker Interlock Fail
Chapter Status Messages And Error Messages Error Code 54 — Stacker Interlock Fail CHECKLIST: STACKER SAFETY SENSORS (SS1 AND SS2) SS1 AND SS2 HARNESS STACKER CONTROLLER BOARD STACKER 1. Check the stacker safety sensors, SS1 and SS2. a. Press upward lightly on SS1 and SS1, and verify that they are released.
Page 159: Error Code 56 - Stacker Full
Error Code 56 — Stacker Full Error Code 56 — Stacker Full CHECKLIST: STACKER FULL SENSOR (SFS) SFS HARNESS STACKER CONTROLLER BOARD STACKER 1. Remove the stacked paper from the stacker. Press the AUTO key on the stacker. If the problem persists, go to step 2. 2.
Page 160: Error Code 59 - Stacker Fail
Chapter Status Messages And Error Messages a. Check the continuity of the harness between connector CN4 on the MC board and connector J1 on the stacker controller board. b. Check the continuity of the harness between connector CN13 on the printer DC power supply board and connector J2 on the stacker controller board.
Page 161: Error Code 5A - Stacker Fail
Error Code 5A — Stacker Fail Error Code 5A — Stacker Fail CHECKLIST: STACKER INTERFACE HARNESS STACKER CONTROLLER BOARD STACKER MOTOR ELEVATOR MOTOR SWINGER MOTOR ASSISTING ARM MOTOR MC BOARD STACKER 1. Check the stacker interface harness connectors. a. Verify that the harness connector is connected properly to MC board connector CN4, the stacker connector on the MC board.
Page 162: Error Code 5C - Stacker Fail
Chapter Status Messages And Error Messages Error Code 5C — Stacker Fail CHECKLIST: ELEVATOR DOWN SENSOR (EDS) EDS HARNESS STACKER CONTROLLER BOARD STACKER 1. Press the AUTO key on the stacker. If the problem persists, go to step 2. 2. Check the elevator down sensor, EDS. Turn off power to the printer. Check the continuity of the harness wiring between the stacker controller board and the EDS.
Page 163: Error Code 64 - Cut-Sheet Paper Skew
Error Code 64 — Cut-sheet Paper Skew b. Check the continuity of the harness between connector CN10 on the printer DC power supply board and connector J60101 on the feeder board. If the harness continuity is OK, go to step 3. 3.
Page 164: Error Code 66 - No Paper Cassette
Chapter Status Messages And Error Messages Error Code 66 — No Paper Cassette CHECKLIST: PAPER SIZE SENSORS (IPS10 THROUGH IPS12 AND IPS20 THROUGH IPS22) SENSOR HARNESS FEEDER BOARD CUT SHEET FEEDER 1. Verify that the paper cassettes are installed. If the problem persists, go to step 2. 2.
Page 165: Error Codes 68 And 6A - Paper Jam At Entrance (A
Error Codes 68 and 6A — Paper Jam at Entrance Error Codes 68 and 6A — Paper Jam at Entrance (A) CHECKLIST: PAPER REGISTER SENSOR (PRS) CUT SHEET FEEDER SENSOR (PFS) STACKER CONTROLLER BOARD STACKER 1. Remove any residual paper from the cut sheet feeder. If the problem persists, go to step 2.
Page 166: Error Code 6D - Cut-Sheet Motor Fail
Chapter Status Messages And Error Messages Error Code 6D — Cut-sheet Motor Fail CHECKLIST: CUT SHEET FEEDER INTERFACE HARNESS CUT SHEET PICKUP MOTOR (PPM) CUT SHEET FEEDER MOTOR (PFM) FEEDER BOARD CUT SHEET FEEDER 1. Check the cut sheet feeder interface harness connectors. a.
Page 167: Error Code 6F - Cut-Sheet Paper Empty
Error Code 6F — Cut-sheet Paper Empty Error Code 6F — Cut-sheet Paper Empty CHECKLIST: UPPER LEVEL PAPER EMPTY SENSOR (PES1) LOWER LEVEL PAPER EMPTY SENSOR (PES2) SENSOR HARNESS FEEDER BOARD CUT SHEET FEEDER 1. Verify that there is paper in the paper cassettes. If the problem persists, go to step 2.
Page 168: Error Code 79 - Transfer Charger High Voltage Error
Chapter Status Messages And Error Messages Error Code 79 — Transfer Charger High Voltage Error TRANSFER CHARGER CHECKLIST: TRANSFER CHARGER HARNESS MC BOARD 1. Check the seating of the transfer charger. If the transfer charger is seated properly, go to step 2. 2.
Page 169: Error Code 7B - Cleaning Bias High Voltage Error
Error Code 7B — Cleaning Bias High Voltage Error Error Code 7B — Cleaning Bias High Voltage Error CHECKLIST: CLEANING UNIT CLEANING UNIT HARNESS TRANSFER UNIT TRANSFER UNIT HARNESS MC BOARD 1. Check the cleaning unit. a. Open the front cover. b.
Page 170: Error Code 7C - Developing Bias High Voltage Error
Chapter Status Messages And Error Messages Error Code 7C — Developing Bias High Voltage Error CHECKLIST: DEVELOPING UNIT DEVELOPING UNIT HARNESS MC BOARD 1. Replace the developing unit. If the error persists, go to step 2. 2. Check the high voltage harness of the developing unit. Confirm that high voltage harness connector DRL is connected properly.
Page 171: Troubleshooting Other Symptoms
Error Code 7D — Separator Charger High Voltage Troubleshooting Other Symptoms Symptom Page Smell Of Toner I–172 Broken Fuser Unit Cover Glass I–173 Incomplete Fusing I–174 Paper Jam I–177 Print Quality I–179 Transfer (Elevator) Motor Abnormal Error I–184 Abnormal Noises I–184 Developer Overflows I–184...
Page 172: Smell Of Toner
Chapter Troubleshooting Other Symptoms Smell Of Toner Symptom Cause Action Remarks You can smell toner (1) The smoke filter Install the smoke at the exhaust outlet has not been filter. of the smoke filter installed. blower fan (VEF0). (2) The wooden Replace the smoke frame of the smoke filter.
Page 173: Broken Fuser Unit Cover Glass
Broken Fuser Unit Cover Glass Broken Fuser Unit Cover Glass Symptom Cause Action Remarks The fuser unit cover (1) The lamp cooling (a) Replace the fuse The printer cover is glass (lamp housing blower fan (VEF1) is inside the power hot.
Page 174: Incomplete Fusing
Chapter Troubleshooting Other Symptoms Incomplete Fusing Incomplete Fusing Symptom Cause Action Remarks The flash lamp does Bad xenon flash Replace the xenon not illuminate, and no lamp. flash lamp fusing occurs. A clicking sound is The trigger wire to Rotate the flash lamp heard from the flash the xenon flash lamp to keep the trigger...
Page 175 Increase the paper. developing unit. LED strobe duty cycle or the flash (b) Check for the charge voltage. proper electrophotographic process conditions. (3) The Use paper that is recommended paper recommended by is not being used. Printronix. I–175...
Page 176 Chapter Troubleshooting Other Symptoms Incomplete Fusing (continued) Symptom Cause Action Remarks No fusing occurs. The xenon flash lamp If no xenon flash When installing the is not installed, or it is lamp is installed, xenon lamp, be sure installed incorrectly. install one.
Page 177: Paper Jam
Paper Jam Paper Jam Paper Jam Symptom Cause Action Remarks Paper Jam at the The EPS0 roller is (a) Check if there are scuff roller. not rotating smoothly. any high points on the roller. Ensure that the roller rolls smoothly, with no tendency to “stick”...
Page 178 Chapter Troubleshooting Other Symptoms Paper Jam (continued) Symptom Cause Action Remarks The printer stops with (1) Excessive (a) Remove the the error message mechanical load on cause of the “03 Paper Jam at scuff roller drive excessive load. Fuser (C)” or the system or defective (b) If the motor is not error message “04...
Page 179: Print Quality
Print Quality Print Quality Print Quality Symptom Cause Action Remarks Scratches on the The drum surface Replace the drum. drum appear in the was scratched during image. installation or removal of the drum. Misaligned print. (1) Loose drum nut, Tighten the drum nut causing irregular firmly.
Page 180 Chapter Troubleshooting Other Symptoms Print Quality (continued) Symptom Cause Action Remarks The print pattern (1) The printing Adjust the setting of position is misaligned position is the Horizontal Image (in the direction misadjusted. Shift option on the across the paper Paper Control menu.
Page 181 Print Quality Print Quality (continued) Symptom Cause Action Remarks Printout is not clear The LED bracket is Replace the bracket. because the image is not installed or out of focus. positioned properly. Partial uneven print (1) Defective LED Replace the LED (low print density) print head.
Page 182 Chapter Troubleshooting Other Symptoms Print Quality (continued) Symptom Cause Action Remarks Streaked gray (1) Toner or dust is Clean the wire using background appears caked on the main the wire cleaner. on part of the printout charger corona wire. Clean after every in the paper-feed 15,000 sheets.
Page 183 Print Quality Print Quality (continued) Symptom Cause Action Remarks The top edge of the Toner or dust is Clean the wire using paper tends to roll caked on the the wire cleaner. around the drum separation charger Clean after every during separation, corona wire.
Page 184: Transfer (Elevator) Motor Abnormal Error
Chapter Troubleshooting Other Symptoms Transfer (Elevator) Motor Abnormal Error Symptom Cause Action Remarks The transfer elevator The transfer elevator (a) Cycle the power does not start, and is in some to the printer. the error message intermediate position (b) Manually set the “0C Transfer Platform other than the Up or transfer elevator to...
Page 185: Toner Is Discharged
Toner Is Discharged Toner Is Discharged Symptom Cause Action Remarks A small amount of The urethane rubber Replace the urethane toner is sometimes seal on the front side rubber seal, or discharged from the of the developing replace the area below the roller is defective or developing unit.
Page 186 Use only paper that is paper stops half way paper that is thinner recommended by on the stacker table, than the minimum Printronix (normally, and the paper folds at specified (55 kg/ream 55 kg/ream or places other than the or less).
Page 187 Power Stacker Power Stacker (continued) Symptom Cause Action Remarks The power stacker (1) The DOWN or Reposition the paper stops. STOP switch was and restart. (Return pressed during the power stacker to normal operation. AUTO). (2) The safety switch Remove the paper was pressed during from the safety stop normal operation.
Page 188 Chapter Troubleshooting Other Symptoms I–188...
Page 189: Adjustment Procedures
Adjustment Procedures MC Board Adjustments Use the following checklist when replacing the MC board on the printer. MC board adjustment procedures require the use of an engine checker. (See Appendix D.) IMPORTANT The engine checker does not work when the EPS4 sensor is on (that is, when paper is loaded in the printer) or when the transport unit is not installed.
Page 190 Chapter MC Board Adjustments Table I–12. MC Board Adjustment Checklist (continued) Adjustment Check Drum motor Tractor motor Detent Forward Reverse Surface potential measurement circuit Eraser lamp input voltage Large quantity of light Normal quantity of light Toner density sensor Confirm developing bias voltage control circuit Confirm main charger current control circuit Confirm sleeve motor operation Confirm magroll motor operation...
Page 191: Mc Board Switches
MC Board Switches MC Board Switches The MC board has several types of switches; they are summarized in Table I–13. Details of the switch settings follow the table. Table I–13. MC Board Switches Designation Type Function Rotary Switch Sets the operating mode of the print engine DSW1 DIP Switch...
Page 192 Chapter MC Board Adjustments The locations and settings of the switches on the MC board are shown below and on the pages that follow: Reserved Engine Self-Test Position (“Test Print” Position) Reserved Normal Operating Position Engine Checker Mode (Japanese) Engine Checker Mode (English) NOTE: To perform an engine self-test, both the MC board and the Controller board must be connected to the printer.
Page 193 MC Board Switches Engine Reset Switch S1 DSW1 Print Density L55bkbrd March 15, 2000 Print Density Print Density 400 dpi Reserved 300 dpi 240 dpi Self-Test Paper Select Paper Normal Operation and Fanfold Self-Test Cut Sheet Self-Test Only I–193...
Page 194 Chapter MC Board Adjustments DSW2 Flash Power Supply Type Type F3 (Used in L5035/L5535 printers) Type F4 (Not used in L5035/L5535 printers) I–194...
Page 195: Mc Board Test Points
MC Board Test Points MC Board Test Points Table I–14 below lists each test point on the MC board, the corresponding signal name at that test point (where applicable), and the function of the test point. The illustration following the table shows the locations of the test points on the MC board.
Page 196 Chapter MC Board Adjustments Table I–14. MC Board Test Points (continued) Designation Signal Name Function TP14 PDAI3 Input to Bit 3 of the DAC in the tractor motor drive circuit. TP15 P+24V Power supply (+24 V). TP16 PDAI2 Input to Bit 2 of the DAC in the tractor motor drive circuit.
Page 197 MC Board Test Points Table I–14. MC Board Test Points (continued) Designation Signal Name Function TP25 Feed motor speed control working point voltage. Range: 0 V to 5 V. This voltage will be about 2.5 V when the feed motor is being driven. TP26 Feed motor drive transistor control voltage.
Page 198 Chapter MC Board Adjustments Table I–14. MC Board Test Points (continued) Designation Signal Name Function TP36 Drum motor drive transistor control voltage. 0 V: Transistor is on. 24 V: Transistor is off. TP37 GNDPWR Power supply ground. TP38 Discharge LED drive voltage. Range: 16.6 V to 24 V (19 V at low illumination, 23.3 V at high illumination).
Page 199 MC Board Test Points TP30 TP31 TP37 TP33 TP43 TP38 TP20 TP35 TP50 TP51 TP40 TP13 TP44 TP16 TP41 TP14 TP17 TP21 TP29 TP22 TP23 TP24 TP26 TP34 TP36 TP11 TP18 TP27 TP25 TP12 TP15 TP10 TP19 I–199...
Page 200: Mc Board Variable Resistors
Chapter MC Board Adjustments MC Board Variable Resistors Table I–15 below lists each variable resistor on the MC board, along with its function. The illustration following the table shows the locations of the variable resistors on the MC board. Table I–15. MC Board Variable Resistors Designation Function Sets the magroll motor current limit.
Page 201 MC Board Variable Resistors VR26 VR27 VR28 VR20 VR21 VR22 VR23 VR29 VR30 I–201...
Page 202: Mc Board Leds
Chapter MC Board Adjustments MC Board LEDs Table I–16 below lists each LED on the MC board, its color, and its function. The illustration following the table shows the locations of the LEDs on the MC board. Table I–16. MC Board LEDs Designation Color Function...
Page 203 MC Board LEDs LD25 LD26 LD22 LD21 LD20 LD23 LD24 I–203...
Page 204: Mc Board Fuses
Chapter MC Board Adjustments MC Board Fuses Table I–17 below lists each fuse on the MC board, its current rating, and the circuit that it protects. The illustration following the table shows the locations of the fuses on the MC board. Table I–17.
Page 205 MC Board Fuses F4 (behind heat sink) F6 (behind heat sink) I–205...
Page 206: Setting Nvram Values
If there is no inspection sheet, locate the serial number of the printer and contact Printronix Technical Support for the factory-set value. Table I–18. MC Board NVRAM Settings...
Page 207: Adjusting Feed Motor Speed
Adjusting Feed Motor Speed Adjusting Feed Motor Speed 1. Unload paper. 2. Use the engine checker to operate the feed motor drive at high speed. The menu path is BASIC MENU, VOLUME ADJUSTMENT, FEED MOTOR, HIGH, START. 3. Put the positive lead of the multimeter on TP25 and the negative lead on ±...
Page 208: Adjusting Eraser Lamp Voltage
Chapter MC Board Adjustments 4. Put the positive lead of the multimeter on TP34 and the negative lead on TP37 (power supply ground). ± 5. Adjust VR22 on the MC board to 200 mV (positive applied pressure clockwise, negative applied pressure counterclockwise). 6.
Page 209 Adjusting Toner Density Sensor Table I–19. MC Board Adjustment Chart Process Parameter TP / VR Value Surface Potential 576 V (ROM data) Toner Density Sensor (TDSC) TP44 / VR28 5.5V Bias Voltage of Cleaning Brush -150V Developing Bias Voltage 340V Flash Charge Voltage 1700V Luminance of Discharge Lamp:...
Page 210: Confirming Mc Board Operation
Chapter Confirming MC Board Operation Confirming MC Board Operation Confirming the Developing Bias Voltage Control Circuit 1. Using the engine checker, drive the developing bias. The menu path is BASIC MENU, DEVICE CHECK, OUTPUT SIGNAL, H.V.P.S., DEV. BIAS, START. 2. Put the positive lead of the digital multimeter on TP31 on the MC board, and the negative lead on TP30 (power supply ground) on the MC board.
Page 211: Confirming The Main Charger Current Control Circuit
Confirming The Main Charger Current Control Cir- Confirming The Main Charger Current Control Circuit 1. Using the engine checker, drive the main charger. The menu path is BASIC MENU, DEVICE CHECK, OUTPUT SIGNAL, H.V.P.S., MAIN CHGR, START. 2. Put the positive lead of the digital multimeter on TP35 on the MC board, and the negative lead on TP30 (power supply ground) on the MC board.
Page 212: Confirming The Sleeve Motor Operation
Chapter Confirming MC Board Operation Confirming The Sleeve Motor Operation CAUTION Remove the developing unit when you operate the sleeve motor (otherwise, toner will fall from the developing unit). 1. Use the engine checker to drive the sleeve motor. The menu path is BASIC MENU, DEVICE CHECK, OUTPUT SIGNAL, MOTOR COUNTER, SLEEVE, START.
Page 213: Confirming The Preheat Lamp Operation
Confirming The Preheat Lamp Operation Confirming The Preheat Lamp Operation CAUTION The Fuser R. Cooling Fan should be turned on while performing this test. 1. Use the engine checker to turn on the cooling fan and check the preheating lamp. The menu path is BASIC MENU, DEVICE CHECK, OUTPUT SIGNAL, FAN BLOWER, FUSER R.
Page 214 Chapter Confirming MC Board Operation 7. Connect the white wire of the high voltage power supply to the dummy drum. 8. Remove the access panel on the left rear printer cover (located over the MC board). 9. Set MC board rotary switch SW1 either to position 1 (for messages in Japanese) or to position 2 (for messages in English).
Page 215: Other Print Engine Adjustments
Adjusting The Drum Surface Potential Sensor Other Print Engine Adjustments Adjusting The Drum Surface Potential Sensor Equipment needed: • 9-Inch Phillips screwdriver (small tip) • Drum auxiliary rod (P/N 703531-170) • Dummy drum (P/N 703531-173) 1. Turn off the printer power. 2.
Page 216: Tractor Drive
Chapter Other Print Engine Adjustments IMPORTANT If the tractor shaft is not aligned properly, the tractor holes in the fanfold paper may be damaged when the paper “back-feeds.” NOTE: To make the adjustment, you will need two tractor alignment tools (see page I–29 for part number).
Page 217 Adjusting The Tractors 6. Unlock both tractors, then slide them to the center of the shaft. Left Tractor Spacer 7. Slide the left tractor spacer to the center of the shaft. 8. Place the tractor alignment tools between the tractor splined shaft and the tractor support shaft, one at each end, over the bearings on the splined shaft.
Page 218 Chapter Other Print Engine Adjustments 9. Left side adjustment: Lift up the tractor support shaft and apply a small amount of force toward the tractor splined shaft. Once the tractor support shaft is against the tractor alignment tool, hold them together and tighten the screw holding the tractor support shaft on the left side frame.
Page 219: Adjusting The Top Of Form
Adjusting The Top of Form WARNING Never touch the tractor area while the printer is printing. Never stare at the tractor area while the printer is printing, because the tractor area reflects leakage light from the fuser unit. VORSICHT Kommen Sie während des Druckvorgangs nicht mit den Händen in den Traktorbereich.
Page 220 Chapter Other Print Engine Adjustments MC Board Screws (3) Hinged MC Board Support Assembly 4. Load fanfold paper. 5. Power on the printer. 6. Using the printer control panel, set the Paper Length to match the paper you loaded and ensure that the Burst on Eject option is enabled (see the User’s Manual) .
Page 221 Adjusting The Top of Form If the perforation cutter mark stopped short of the perforation or fell beyond the perforation, continue with step 10. 10. Measure the distance from the perforation cutter mark to the perforation. 11. Power off the printer. 12.
Page 222 Chapter Other Print Engine Adjustments Belt A Pulley C Pulley S I–222...
Page 223: Dc Power Supply Board Adjustments
DC Power Supply Board Switches DC Power Supply Board Adjustments Following are the locations of the switches, variable resistors, and fuses on the PS-PCBA (the main board in the DC power supply). DC Power Supply Board Switches DC Power Supply Board Variable Resistors Table I–20 below lists each variable resistor on the DC power supply board, along with its function.
Page 224 Chapter DC Power Supply Board Adjustments Table I–20. DC Power Supply Board Variable Resistors (continued) Sets the voltage of the +24 V CN11 pins 1, 3, or 4 (Main) supply. Rotate clockwise to raise the voltage. Sets the voltage of the +5 V CN12 pins 1, 2, 3, 4, 5, or LED Head supply.
Page 225: Dc Power Supply Board Fuses
DC Power Supply Board Fuses DC Power Supply Board Fuses Table I–21 below lists each fuse on the DC power supply board, its current rating, and the circuit that it protects. The illustration following the table shows the locations of the fuses on the DC power supply board. Table I–21.
Page 226 Chapter DC Power Supply Board Adjustments F7 F6 F4 (under power resistors) I–226...
Page 227: Flash Power Supply Adjustments
DC Power Supply Board Fuses Flash Power Supply Adjustments To adjust the flash power supply charge voltage, rotate variable resistor V. ADJ on the flash power supply until its arrow points toward the desired voltage (usually 1700 V). Variable resistor V. ADJ is accessible from the rear of the printer, through a hole in the flash power supply enclosure.
Page 228: Loading Flash Memory
Chapter Loading Flash Memory Loading Flash Memory This printer is equipped with flash memory. The flash memory is contained on a flash memory card located on the controller PCBA. Printer emulation and operating system software are loaded into flash memory at the factory, but you will install software or files in the following situations: •...
Page 229 The lasr2fls Utility Program 4. To display a brief help message, at the DOS prompt, enter the command name lasr2fls with no parameters: lasr2fls <Enter> You will then see a help message similar to the following: L50XX Laser Printer Flash File Conversion Utility, Vx.xx, mm/dd/yy USAGE: lasr2fls file_name1 file_name2 file_name3 A <Enter>...
Page 230 Chapter Loading Flash Memory used only to determine the file name to display on the printer front panel menus. IMPORTANT Some earlier printers in this series had floppy disk drives for storing their emulation software. Newer printers use flash memory for emulation storage.
Page 231: Downloading Into Flash Memory
Downloading Into Flash Memory Downloading Into Flash Memory CAUTION When downloading an emulation to the printer, all other optional font files, customer-supplied logos, and setup files will be erased. You will then need to reload these files. Before starting a download procedure, be sure that you have all of the necessary installation files on hand.
Page 232 Chapter Loading Flash Memory 17. Create a directory on your computer hard drive where you will store the recombined files from the emulation diskettes by typing the following at the DOS prompt: MD DOWNLOAD <Enter> 18. Make the newly-created directory the “active” directory by typing the following at the DOS prompt: CD DOWNLOAD <Enter>...
Page 233 Downloading Into Flash Memory 27. Type the following at the DOS prompt: DIR <Enter> You will see a directory listing containing the file part_num.exe, where the filename is the six digit number (e.g., 123456.zip) you noted above. Write down the complete name of the file with the .exe extension. This is the file you will download into the printer.
Page 234 Chapter Loading Flash Memory 37. If you have any additional software to install (logo, form, TIFF, setup, or font files), continue with step 38. If you have no additional software to install, skip to step 49. 38. Set the printer power switch to O (off). 39.
Page 235 Downloading Into Flash Memory 50. Remove the diskette(s) from the computer and store them with the printer. 51. If you had to install a parallel data cable to the computer and printer in step 9, continue with step 52. If not, skip to step 57. 52.
Page 236 Chapter Loading Flash Memory I–236...
Page 237: Replacement Procedures
Replacement Procedures Overview This chapter describes how to remove and install printer components. Installation is usually in the reverse order of the removal procedures. Always return screws to their original positions, because the type of screw can vary with position. Designations such as “Screw (3)” show the number of a particular type of screw.
Page 238: Front Cover
Chapter Overview Front Cover 1. To open the front cover, press the buttons on either side and pull the cover toward you. Open/Close Button Front Cover 2. Remove the screw securing the chains on each side. Support the cover from below, as removing the screws securing the chains will put extra weight on the hinges.
Page 239: Left Rear Cover
Left Rear Cover Left Rear Cover 1. Remove the screws (4) from the controller front panel. 2. Remove the screws (5) from the printer rear side. (The rear of the printer is shown in the figure below.) 3. Raise the left rear cover about 1/2 inch (1 cm) and remove it from the printer.
Page 240: Right Rear Cover
Chapter Overview Right Rear Cover 1. Remove the screws (2) on the paper exit side, then remove the plate. Screws (2) Right Rear Cover Plate 2. Loosen the screws (2) that secure the bottom of the connector cover. Remove the screws (2) that secure the top of the connector cover and remove the cover.
Page 241 Right Rear Cover 3. Remove the screws (2) located behind the connector cover, as shown in the figure below: Screws (2) 4. If your printer has the optional power stacker installed, do the following: a. Remove the screw (with lockwasher) securing the stacker ground wire (FG wire).
Page 242 Chapter Overview 5. Remove the rear side screws (8). 6. Raise the right rear cover about 1/2 inch (1 cm) and remove it from the printer. NOTE: There are two alignment tabs located on the inside of the right rear cover.
Page 243: Top Cover
Top Cover Top Cover 1. Remove the left rear cover (page I–239). 2. Remove the right rear cover (page I–240). 3. Remove the screws (2) fastening the face up paper output tray to the printer, then pull out the tray and remove it from the printer. 4.
Page 244 Chapter Overview 6. Open the front cover. Remove the screws (4) and detach the control panel. 7. Disconnect the front cover interlock (CIL) switch connector. Front Cover Interlock Switch Connector Screws (4) Control Panel I–244...
Page 245 Top Cover 8. Lift and remove the top cover from the printer. Top Cover Screw I–245...
Page 246: Stand Cover
Chapter Overview Stand Cover 1. Remove the screws (2) securing the right side of the stand cover. 2. Pull the right side of the stand cover slightly forward, unhook the two pins in the left side of the cover from the printer, and remove the cover. Screw Screw Stand Cover...
Page 247: Inside The Front Cover
Stand Cover Inside The Front Cover The items shown below are behind the front cover. The green levers and handles are used by the operator on a regular basis. Discharge LED (not Main Charger visible) Toner Cartridge Cleaning Unit Optional Cut Sheet Paper Fuser Unit Output Unit...
Page 248: Waste Toner Recovery Unit
Chapter Inside The Front Cover Waste Toner Recovery Unit The waste toner recovery unit contains a bottle that collects waste toner carried from the drum cleaner via screw conveyer belt. Attached to the right and left sides of the bottle’s neck are the light emitters and receptors of the waste toner bottle full sensor (WTBF), which detects the full condition.
Page 249 Waste Toner Recovery Unit Waste Toner Bottle When the waste toner bottle becomes full, replace it with a new one by doing the steps below, then discard the full bottle. Do not reuse the bottle. 1. Lower the lever, pull the green handle toward you, and open the waste toner recovery unit.
Page 250 Chapter Inside The Front Cover 3. Remove the waste toner bottle from the waste toner recovery unit. 4. Discard the old waste toner bottle. 5. Install a new waste toner bottle. Waste Toner Bottle Full Sensor 1. Remove the waste toner bottle (page I–249). 2.
Page 251 Waste Toner Recovery Unit Waste Toner Bottle Set Sensor The waste toner bottle set sensor (WTBS) is a limit switch that detects whether the waste toner bottle is “set”—that is, whether it is in position. 1. Remove the waste toner bottle (page I–249). 2.
Page 252: Developing Unit
Chapter Inside The Front Cover Waste Toner Bottle Unit 1. Remove the waste toner bottle (page I–249). 2. Disconnect the three connectors, as shown below. 3. Detach one end of the spring. 4. Remove the waste toner bottle unit by lifting it. Connectors (3) Spring Developing Unit...
Page 253: Photoreceptor Drum
Photoreceptor Drum Photoreceptor Drum Drum life depends upon media used and proper maintenance and operation of the printer. Print media other than bond paper (e.g., labels, card stock, plastic, or vinyl) may reduce drum life as much as 50%. To replace the drum, you will need a drum auxiliary rod. Please read all steps before beginning the replacement procedure.
Page 254 Chapter Inside The Front Cover 5. Rotate the developing unit lever fully clockwise so that it points straight up (to separate the developing unit from the photoreceptor drum). Lever 6. Remove the developing unit by holding the lever in one hand and pulling the developing unit partially out of the printer.
Page 255 Photoreceptor Drum 7. With your other hand, grasp the hanger and remove the developing unit from the printer. Hanger 8. Vacuum any spilled toner. CAUTION The transfer charger must be in the down position to avoid scratching the drum. 9. Check that the transfer charger is in the down position, and if not, move it to the down position by rotating the transfer elevator drive shaft counterclockwise.
Page 256 Chapter Inside The Front Cover CAUTION To avoid damaging the printer or causing false paper jams, the transport lever must be in the fully down position before opening or closing the transport unit. 10. Lower the transport unit by turning the green lever on the transport unit to the left.
Page 257 Photoreceptor Drum 13. Remove the nut from the end of the drum shaft. Drum Shaft 14. Screw the drum auxiliary rod onto the drum shaft. Drum Auxiliary Rod P/N 703531-170 I–257...
Page 258 Chapter Inside The Front Cover 15. Carefully pull the old drum along the drum auxiliary rod. Hold the front and back sides when the drum is nearly out of the printer, and remove it with both hands. Drum 16. Pack the old drum for shipment using its original packaging material, and close the cover of the box.
Page 259: Proper Disposal Of A Drum Unit
Proper Disposal Of A Drum Unit Never force the drum onto the shaft. If it feels as though the drum is not seating properly, remove the drum and inspect the shaft for foreign material or burrs. 21. Remove the drum auxiliary rod from the drum shaft. 22.
Page 260: Drum Peripheral Equipment
Chapter Inside The Front Cover Drum Peripheral Equipment The equipment listed below is located around the photoreceptor drum. Note that the main charger, precharger, transfer charger, and the discharge lamp can be removed without removing the drum plate. • Main charger (MCH) •...
Page 261 Drum Peripheral Equipment Discharge Lamp (PEL) 1. Loosen the three thumbscrews on the upper inner cover and remove the cover. 2. Remove the discharge lamp screw and pull the lamp toward you along the guide rail. Discharge Lamp Screw Thumbscrews (3) Inner Cover (Upper) I–261...
Page 262 Chapter Inside The Front Cover Drum Cleaning Unit 1. Loosen the three thumbscrews on the drum plate, then remove the drum plate. 2. Grasp the handle of the drum cleaning unit. Pull the drum cleaning unit toward you and remove it. CAUTION Do not turn the drum cleaning unit upside down, or toner might spill.
Page 263 Drum Peripheral Equipment 3. At the rear side of the printer, disconnect the connector, as shown below. 4. Remove the screws (2), as shown below. Connector Screws 5. At the front side of the printer, remove the screws (2) securing the separator claw assembly, then remove the assembly from the front.
Page 264 Chapter Inside The Front Cover 6. Remove the solenoid E-ring from the tip of the solenoid arm. Separator Claw Solenoid Screws (2) Solenoid Spring Separator Claw Springs (2) Solenoid Solenoid Wires Solenoid E-Ring Solenoid Bushing Connector Collar Separator Claw Shaft Shaft E-Ring Separator Claw...
Page 265 Drum Peripheral Equipment Drum Support Roller There are three small rollers located in the opening where the drum passes when it is removed or installed. These rollers prevent the drum surface from contacting nearby metal parts. To remove either the lower left roller or the lower right roller, remove the screw securing the bracket, then remove the roller.
Page 266: Fuser Unit
Chapter Inside The Front Cover Fuser Unit WARNING The fuser unit remains hot after operation. Wait until it has completely cooled down before handling it. Never scratch or touch the cover glass or lamps with your hands. Fingerprints on the cover glass or lamps will cause them to break. VORSICHT Die Fixiereinheit bleibt nach dem Betrieb heiss.
Page 267 Fuser Unit The fuser unit contains the following replaceable parts: • Preheat lamp (Halogen lamp/HAL) • Flash lamp (Xenon lamp/XEL) • Temperature fuse • Lamp duct filter Preheat Lamp / Flash Lamp 1. With the fuser cover glass facing up, remove the screws (2) securing the paper guide on the feed side of the unit.
Page 268 Chapter Inside The Front Cover 4. Remove the screws (2 for the preheat lamp, 3 for the flash lamp) securing the lamp terminals. NOTE: The preheat (halogen) lamp is the thinner of the two lamps and has only two wire leads. The flash (xenon) lamp is the thicker of the two lamps and has three wire leads.
Page 269 Fuser Unit 6. Refer to the previous figure and loosen, but do not remove, the other bracket screw (near the end of the flash lamp). 7. Shift the bracket outward slightly, then remove the preheat lamp. CAUTION The lamps are fragile. Take care when handling. Never touch lamps with your hands.
Page 270 Chapter Inside The Front Cover Lamp Duct Filter 1. Remove the screws (2) that secure the lamp duct filter unit to the fuser unit, then remove the lamp duct filter unit and the foam gasket. Foam Gasket Screw (2) Filter Holding Plate Lamp Filter (Air Filter) Lamp Duct...
Page 271: Transfer Assembly
Transfer Assembly Transfer Assembly 1. Check that the transfer charger is in the down position, then lower the transport unit by turning the green lever on the transport unit to the left (see steps 9 and 10 on page I–255). 2.
Page 272: Transport Belt
Chapter Inside The Front Cover • TC connector block of the transfer/separator charger • Varistor Transport Belt When replacing the transport belt, the transfer assembly must be turned upside-down. When turning the unit upside-down, be sure to put a rest underneath it to protect the protruding tips of the sensor levers.
Page 273 Transfer Assembly 5. Referring to the figure below, remove the screw (1) and nut (1) securing the stainless plate, then remove the stainless plate. Outer Bearing Outer E-Ring Stainless Conveyer Base Plate Outer E-Ring Drive Shaft Outer Bearing High-Voltage Wire Unit Frame 6.
Page 274 Chapter Inside The Front Cover 10. Referring to the figure below, remove the inner E-rings (2) securing the drive shaft to the conveyer base. Inner Bearing Inner E-Ring Inner Bearing Inner E-Ring Drive Shaft Conveyer Base 11. Referring to the figure above, slip the inner drive shaft bearings (2) out of their holes in the conveyer base, then slide them toward the outer ends of the drive shaft.
Page 275 Transfer Assembly NOTE: When replacing a transport belt, be careful to distinguish the outer surface of the new belt from its inner surface, as shown below. The outer surface looks like graph paper, while the inner surface has an irregular pattern. Adjust the distance between the drive shafts according to the length of the belt.
Page 276 Chapter Inside The Front Cover 14. Referring to the figure below, adjust the distance between the belt and the conveyer base to approximately 1 cm when the belt center is pulled up with a force of 200 grams. Firmly tighten the screws (2 right, 2 left) to secure the belt shaft to the conveyer base.
Page 277 Transfer Assembly 3. Working from the underneath side of the transport assembly, remove the EPS3 mounting screws (2), as shown below. EPS4 Sensor Assembly EPS3 Sensor Assembly EPS4 Mounting Screws (2) EPS3 Mounting Screws (2) Fan Plenum Screws (2) (remove) Vacuum Fan Fan Connector Screws (2) (loosen)
Page 278 Chapter Inside The Front Cover 5. Working from the underneath side of the transport assembly, loosen the 2 fan plenum screws marked “loosen” in the previous figure. Remove the other 2 fan plenum screws (marked “remove” in the figure). 6. Disconnect the fan cable connector, then remove the fan and plenum together from the transport assembly.
Page 279 Transfer Assembly Varistor 1. Remove the screws (front side and rear side, 1 each) securing the transport paper guide. Transport Paper Guide Screws Screws (2) Varistor Spacer 2. Remove the transport paper guide. 3. Remove the screws (2) securing the varistor terminal, and remove the varistor.
Page 280: Inside The Rear Cover
Chapter Inside The Rear Cover Inside The Rear Cover The illustration below shows the area inside the rear cover: Head Blower Fan Head Cooling Fan Sleeve Motor Fuser Reflector Plate Cooling Fan Magroll Motor MC Board Main Unit Feed Motor Power Supply Lamp Cooling Blower...
Page 281: Mc Board
MC Board MC Board IMPORTANT Whenever you replace the MC board, you must perform the necessary adjustments. See the section titled “MC Board Adjustments” on page I– 189 in Chapter 5, “Adjustment Procedures.” 1. Turn OFF the power switch on the printer. 2.
Page 282: Dc Power Supply Board
Chapter Inside The Rear Cover DC Power Supply Board 1. Turn OFF the power switch on the printer. 2. Unplug the printer power cord from the power mains. 3. Remove the right rear cover, as described on page I–240. 4. Refer to detail drawing “A” in the figure on the next page and move the circuit breaker lever to the OFF position.
Page 283 DC Power Supply Board DC Power Supply Board Power Supply Cover ° This view is rotated 90 Screws (4) Circuit Breaker Lever I–283...
Page 284: Motors
Chapter Inside The Rear Cover Motors Cutter Motor 1. Remove the cutter unit, as described on page I–320. 2. Disconnect the cutter motor connector, and remove the connector through the hole in the frame, as shown in the figure below. Screw Pulley Set Screw...
Page 285: Drum Motor
Motors Drum Motor 1. Remove belts A, B, and C, as described on page I–305. 2. Remove the screws (3) securing the motor cover and remove the motor cover by moving it downward, as shown in the figure below. Motor Cover Screws (3) I–285...
Page 286 Chapter Inside The Rear Cover 3. Remove the E-ring and the tab washer from the motor shaft, as shown in the figure below. Connectors (2) Set Screw Screws (4) E-Ring Flywheel Tab Washer 4. Loosen the setscrew using the hex wrench, then remove the flywheel. 5.
Page 287 Motors Sleeve Motor (SLM) / Magroll Motor (MRM) 1. Referring to the figure below, disconnect the connectors (2): one for the sleeve motor, the other for the magroll motor. Bracket Sleeve Motor Magroll Motor Connectors Bracket Screws (8) 2. Remove the screws (8) that secure the assembly bracket (with motors) to the printer, then remove the bracket with the motors attached.
Page 288 Chapter Inside The Rear Cover 3. Loosen the setscrews (4), then remove the gears (2) from the motor shafts. Setscrews Gear Motor Screws (8) E-Ring Bracket Gear 3 Gear 4. If you are replacing gear 3, refer to the figure above and remove the E- ring that secures the gear to the shaft.
Page 289 Motors Feed Motor (FMT) / Encoders (FME19/20) In the feed motor block, encoders 19 and 20, along with the motor itself (with bracket), are replacement parts, and are removed as follows: 1. Referring to the figure below, mark the sensor connectors (2) for identification so that you can connect them properly when you reinstall the motors.
Page 290 Chapter Inside The Rear Cover 8. Referring to the figure below, remove the belt. Belt (703531-031) Feed Motor Setscrew Encoder 19 Disc Motor Bracket Screw Screws (3) Encoder 20 Disc Sensor Bracket Screws (2) 9. Remove the screws (3) that secure the motor bracket to the printer base, then pull out the bracket with the feed motor attached.
Page 291 Motors 13. If you are replacing the sensors, remove the screws (1 each) that secure the sensors to the sensor bracket. Sensors Sensor Bracket Screw Screw I–291...
Page 292 Chapter Inside The Rear Cover Tractor Motor / Tractor Drive Belts Belt A is removed first, belt B second. Belt A (703531-031) Belt B (703531-031) I–292...
Page 293 Motors 1. Remove the MC board retaining screws (3) shown in the figure below, then swing open the MC board support assembly on its hinges. MC Board Screws (3) Hinged MC Board Support Assembly I–293...
Page 294 Chapter Inside The Rear Cover 2. To maintain the correct alignment of the fanfold paper, inscribe alignment marks on pulleys C and S as shown in the figure below. Then, remove belt A by rotating pulley C, and remove belt B by rotating pulley S. Rotate Pulley C until Cutter cuts the perforation Remove Belt A...
Page 295 Motors 3. If you are replacing the tractor motor, do steps step a through step d below. Otherwise, skip to step step 4. a. Remove the motor cover, then disconnect the tractor motor connectors (2). Screws (4) Connectors (2) b. Remove the screws (4) fastening the tractor motor to the printer base. c.
Page 296 Chapter Inside The Rear Cover 5. After replacing the tractor motor or tractor drive belts, adjust the top of form (page I–219). Transfer Elevator Motor 1. Remove the transport unit (page I–271). 2. Detach the cable clamp, and disconnect the motor connector. Screws (4) Connector 3.
Page 297: Fans
Fans Fans Head Cooling Fan (HCF) 1. Disconnect the head cooling fan connector. Connector Bracket Screws (2) 2. Remove the screws (2) securing the bracket to the main unit, then remove the fan with the bracket attached. I–297...
Page 298 Chapter Inside The Rear Cover 3. Remove the screws (2) securing the head cooling fan to the bracket. Bracket Screw Head Cooling Fan I–298...
Page 299 Fans Head Blower Fan (HBF) And LED Air Filter The head blower fan has the role of sending air through the duct inserted between the main charger and LED head, to prevent particles such as toner from adhering to the head. A filter is attached to the intake, to prevent dust from clogging the duct’s draft hole.
Page 300 Chapter Inside The Rear Cover Fuser Reflector Cooling Fan (FCF) To remove the fuser reflector cooling fan, disconnect the connector, and remove the screws (4) securing the fan and fan plate to the duct. Duct Fuser Reflector Cooling Fan Fan Plate Connector Screw I–300...
Page 301: Solenoids
Solenoids Solenoids Paper Exit Gate Solenoid (EGSL) / Face Gate Solenoid (FGSL) To remove either solenoid: 1. Disconnect the connector for the solenoid you want to remove. S3M396 Face Gate Solenoid S3M210 Connectors S3M174 Screws S3M264 S3M264 Paper Exit Gate Solenoid 2.
Page 302 Chapter Inside The Rear Cover Cutter Solenoid (CSL) 1. Disconnect the connector. Bracket Screw Cutter Solenoid Connector 2. Remove the screws (2) securing the solenoid mounting bracket to the printer. I–302...
Page 303: Miscellaneous
Miscellaneous Miscellaneous Tension Arm To remove the tension arm above the eject gate solenoid, remove the E-ring on the rotation axis. Tension Arm E-Ring I–303...
Page 304 Chapter Inside The Rear Cover Main Charger (MCH) Varistor 1. One terminal of the main charger varistor is connected to the main charger connector via high voltage cable. Remove the screw securing this varistor terminal to the high voltage connector. 2.
Page 305 Miscellaneous Drum Motor Drive Belt Three (3) belts are installed with the drum motor drive unit. These belts must be removed in the following order: Belt A, Belt B, then Belt C. Belt A (703531-032) Belt B (703531-031) Belt C (703531-031) I–305...
Page 306 Chapter Inside The Rear Cover 1. Pull downward on the tension roller and remove Belt A from Pulley E. Belt A Pulley E Pulley F Tension Roller Pulley G Belt B Belt C 2. Remove Belt B by turning Pulley F. 3.
Page 307 Miscellaneous Output Roller Drive Belts Five (5) belts, A through E, are incorporated into the roller drive mechanism. These belts must be removed in the following order: A, B, D, E, and C. Belt E (703531-030) Belt D (703531-029) Belt A (703531-028) Belt B (703531-031) Belt C (703531-031) 1.
Page 308 Chapter Inside The Rear Cover 4. Remove the screw (1) fastened to the scuff roller shaft, then remove the flange. Belt E Flange Screw Belt D 5. Remove belts D and E. 6. Remove belt C from around pulley H by turning pulley H. Pulley H Belt C Feed Motor Bracket...
Page 309 Miscellaneous 8. Remove belt C from the printer. 9. Install new belts and the associated parts removed. Facedown Paper Out Drive Belt To remove this belt, slacken the belt by pulling the tension roller toward the right. Tension Roller Belt (703531-034) I–309...
Page 310 Chapter Inside The Rear Cover Pickup Roller Units Two pickup roller units (upper and lower) are located at the back of the cassette opening. Upper Pickup Roller Unit Lower Pickup Roller Unit 1. Remove the upper and lower paper cassettes from the printer. 2.
Page 311 Miscellaneous 4. When installing either pickup roller unit, refer to the figure below and proceed as follows: a. Align the shaft pin with the slot in the coupling, and align the alignment pin on the unit with the hole in the frame. b.
Page 312 Chapter Inside The Rear Cover 1. On the upper reverse roller unit, loosen the green thumbscrew. Remove the unit by moving it downward while sliding it to the left. Thumbscrews 2. On the lower reverse roller unit, loosen the green thumbscrew. Remove the unit by moving it downward while sliding it to the left.
Page 313 Miscellaneous 3. When installing either reverse roller unit, refer to the figure below and proceed as follows: a. Align the shaft pin with the slot in the coupling, and align the alignment pin on the unit with the hole in the frame. b.
Page 314: Under The Top Cover
Chapter Under The Top Cover Under The Top Cover The following items are arranged under the top cover (top view shown): Drum Surface Potential Sensor Drum Cleaner Nip switch Set Sensor LED Print Head Rear Side of Printer Front Side of Printer High-Voltage (Corona) Paper Exit Paper Exit...
Page 315: Led Print Head
LED Print Head LED Print Head NOTE: To install the LED print head, you will need two LED positioning pins and some thermal compound (see page I–29 for part numbers). The LED positioning pins are used to align the print head when installing 1.
Page 316 Chapter Under The Top Cover 3. Remove the screws (3) on the metal fittings which hold the heat pipe, then remove the heat pipe by moving it toward the rear. Screws (3) Heat Pipe I–316...
Page 317 LED Print Head 4. Remove the screws (4) securing the LED print head, then lift the print head to remove it. CAUTION Do not touch the surface of the print head, as you will leave fingerprints. LED Positioning Pin LED Print Head LED Positioning Pin Screws (4) 5.
Page 318 Chapter Under The Top Cover DSW1 Print Density Print Density Print Density 400 dpi Reserved 300 dpi 240 dpi Self-Test Paper Select Paper Normal Operation and Fanfold Self-Test Cut Sheet Self-Test Only I–318...
Page 319: High-Voltage (Corona) Power Supply
High-Voltage (Corona) Power Supply High-Voltage (Corona) Power Supply 1. Ensure that the ON/OFF switch on the printer is in the 0 (OFF) position. 2. Remove the screw securing the frame ground wire to the frame. 3. Disconnect the two multiwire connectors. 4.
Page 320: Cutter Unit
Chapter Under The Top Cover Cutter Unit CAUTION Bearings can fall out of the pulley when you remove it. Also, the pulley must be put on the same way it was removed. This pulley is actually made up of three separate pulleys that are molded into one piece. The middle pulley is much larger than the two outside ones.
Page 321 Cutter Unit 3. Remove the screws (2 each, front and rear) that secure the cutter unit to the printer. Screws Connectors 4. Disconnect the connectors to the cutter motor and cutter sensor in the rear. I–321...
Page 322 Chapter Under The Top Cover 5. Remove the cutter unit by pulling it downward from the rear side. (The front is obstructed by the front panel.) Cutter Unit Screws I–322...
Page 323: Sensors And Switches
Sensors And Switches Sensors And Switches Drum Surface Potential Sensor (DSPS) 1. Remove the MC board retaining screws (3) shown in the figure below, then swing open the MC board support assembly on its hinges. Screws (3) MC Board Hinged MC Board Support Assembly I–323...
Page 324 Chapter Under The Top Cover 2. Remove the screws (4) securing the DSPS-PCBA, as shown below. DSPS-PCBA Screw Screws (4) 3. Remove the screw (1) securing the sensor bracket, as shown above. I–324...
Page 325 Sensors And Switches 4. Remove the screws (2) on the front side. Screws 5. Remove the sensor bracket (with the sensor attached) together with the connected DSPS-PCBA. IMPORTANT When installing the drum surface potential sensor, you must perform the adjustment procedure given on page I–215 in Chapter 5, “Adjustment Procedures.”...
Page 326 Chapter Under The Top Cover Drum Cleaner Set Sensor The drum cleaner set sensor is a limit switch that detects whether the drum cleaner is set (that is, in its correct operating position). The sensor is a microswitch; it is mounted on the inside of the rear panel such that its switch contacts close when the drum cleaner is set.
Page 327 Sensors And Switches 1. On the rear side of the printer, disconnect the harness connector from the microswitch contacts. Bracket Screws (2) Connector Microswitch Screws (2) 2. Remove the screws (2) securing the bracket to the printer. 3. Insert your hand from the top of the rear panel, then remove the sensor with the bracket attached.
Page 328 Chapter Under The Top Cover Paper Exit Sensor 0 (EPS0) 1. Disconnect the connector from paper exit sensor 0. Sensor Bracket E-Ring Sensor Scuff Guide Screw Connector 2. Remove the E-ring that secures the sensor bracket to the scuff guide on the paper output side.
Page 329 Sensors And Switches Nip Switch (NPSW) The nip switch is located closer to the rear panel than is paper exit sensor 0. 1. Remove the screws securing the switch bracket to the scuff guide from the paper output side. Scuff Guide Screws Switch Bracket Nip Switch...
Page 330 Chapter Under The Top Cover Paper Exit Sensor 1 (EPS1) Paper exit sensor 1 is located on the paper guide under the paper output roller at the output to the faceup paper output tray. 1. Disconnect the connector from the sensor. Sensor Connector Screw...
Page 331: Gates
Gates Gates The paper output section has two stages of gates: the paper exit gate and the face gate. Each of these gates is mechanically linked to a controlling solenoid. The two solenoids are the paper exit gate solenoid (EGSL) and the face gate solenoid (FGSL).
Page 332: Behind The Stand Cover
Chapter Behind The Stand Cover Behind The Stand Cover Smoke Filter 1. Remove the stand cover (see page I–246). 2. Loosen the thumbscrew on the filter box cover, then open the cover. Filter Box Thumbscrew 3. Pull the lever out about 3/4 inch (20 mm) to release the filter. Lever I–332...
Page 333: Flash Power Supply
Flash Power Supply 4. Pull out the old smoke filter and remove it. Smoke Filter 5. Rub silicone grease on the rubber seal on the bottom of the new smoke filter to prevent air leaks, then install the filter. 6. Push the lever back in, then close the filter box cover and secure the thumbscrew.
Page 334 Chapter Behind The Stand Cover (Gleichstrom) einiger Komponenten vollständig entladen kann. Erst dann dürfen Sie mit dem nächsten Arbeitsschritt beginnen. Beschriften oder etikettieren Sie beim Entfernen alle Hochspannungskabel und Anschlüsse so, daß Sie diese Kabel später wieder ordnungsgemäß anschließen können. 1.
Page 335 Flash Power Supply 6. At the rear side of the printer, disconnect connectors J11 and TRG from the flash power supply. Rear side of printer Connector J11 (to MC Board) AC Line Terminal Strip Connector TRG (trigger, to lamp trigger coil) Ground Wire (FG Wire) Screw...
Page 336 Chapter Behind The Stand Cover 9. Remove the high-voltage terminal covers from the high-voltage terminals on the rear of the fuser unit. Fuser Unit Screws (2) L55bcksd May 23, 2000 High-Voltage Terminal Covers High-Voltage Cables (from Flash Power Supply) 10. Mark or tag the high-voltage cables and their corresponding high-voltage terminals on the fuser unit, so that you can reconnect them properly later.
Page 337 Flash Power Supply 12. At the front side of the printer, remove the screws (2) securing the flash power supply to the printer frame, as shown in the figure below. Front side of printer Screws (2) I–337...
Page 338 Chapter Behind The Stand Cover 13. At the front side of the printer, grasp the flash power supply and pull it out. If you cannot pull it out, refer to the figure that follows and loosen the screws (4) securing the metal fittings (2) on the rear of the flash power supply.
Page 339 Flash Power Supply 14. With the old flash power supply out of the printer, refer to the figure below and remove the high-voltage terminal cover from the flash power supply. High-Voltage Cables (to Fuser Unit) Hexagonal Nuts High-Voltage Terminal Cover Screws 15.
Page 340: Capacitor
Chapter Behind The Stand Cover 24. Replace the high-voltage terminal covers on the fuser high-voltage terminals. 25. Using the screw you removed earlier, reconnect the ground wire (FG wire) to the printer frame. 26. Reconnect the AC lines “L” (black) and “N” (white) to their proper terminals on the AC line terminal strip on the new flash power supply.
Page 341 Capacitor 1. Remove the flash power supply as described earlier (page I–333). 2. Remove the screws (8) fastening the front cover of the flash power supply, then remove the cover. Flash Power Supply Front Cover Screws (8) I–341...
Page 342 Chapter Behind The Stand Cover 3. Remove the screws (8) fastening the left cover of the flash power supply, then remove the cover. Left Cover Screws (8) 4. Refer to the figure that follows, and mark or tag the wires connected to the capacitor, so that you can reconnect them properly later.
Page 343 Capacitor Screws (4) Ground Wire (FG Wire) Screw Nuts (2) Lockwashers (2) I–343...
Page 344: Other
Chapter Other Other Tractor Removal The tractors are secured by the tractor splined shaft and tractor support shaft, as shown below, and are removed as described in the steps that follow. Tractor Tractor Support Shaft Tractor Splined Shaft 1. Remove the tractor drive belt, belt A (see page I–292). 2.
Page 345 Tractor Removal Tractor Support Shaft Screw E-Ring Tractor Splined Shaft 4. Remove the E-ring securing the left tractor on the tractor support shaft. 5. Slide the tractor splined shaft toward the rear side of the printer and remove it. 6. On the rear side of the printer, remove the screw securing the tractor support shaft, then remove the tractors and the tractor support shaft from the paper feed side.
Page 346: Paper Back-Feed Sensor (Pbfs) (Top Of Form Sensor
Chapter Other Paper Back-Feed Sensor (PBFS) (Top Of Form Sensor) 1. Remove the screws (2) securing the sensor bracket to the printer. 2. Remove the sensor bracket with the sensor attached. 3. Disconnect the connector from the sensor. 4. Remove the screws (2) securing the sensor to the sensor bracket, then remove the sensor.
Page 347: Paper Near-End Sensor (Pnes
Paper Near-End Sensor (PNES) Paper Near-End Sensor (PNES) Photoemitting Board 1. Remove the screws (4) securing the photoemitting board cover, then remove the cover. 2. Remove the screw (1) securing the photoemitting board bracket to the paper near-end sensor assembly. 3.
Page 348 Chapter Other Photoreceptor Board 1. Remove the screws (4) securing the photoreceptor board cover, then remove the cover. 2. Remove the screw (1) securing the photoreceptor board bracket to the paper near-end sensor assembly. 3. Remove the screw (1) securing the photoreceptor board to the photoreceptor board bracket.
Page 349: Control Panel
Control Panel Control Panel 1. Remove the screws (4) securing the control panel to the printer. 2. Disconnect the cable connector from the connector on the rear of the control panel, then remove the panel. Screws (4) Cable Connector I–349...
Page 350: Controller Module
Chapter Controller Module Controller Module The controller module consists of the following subassemblies: • Controller board • Power supply • Cooling fan In addition, the controller board contains socketed terminating resistors for the parallel interface. The values of these resistors might need to be changed for some parallel interface applications.
Page 351 Controller Board Controller Module Controller Board Connector Ribbon Cable I/O Panel Parallel I/O Connector Screws (6) Figure I–12. Controller Board Removal/Installation 9. Carefully remove the following six parts from their sockets on the old controller board and place them on a properly grounded anti-static surface.
Page 352 Chapter Controller Module IMPORTANT When you replace the controller board, always move the existing NVRAM from the old controller board to the new board. (The NVRAM IC stores data that are unique to a particular print engine.) Controller Board DC DRAM SIMM (socket J10) VX DRAM SIMM (Base DRAM)
Page 353 Controller Board 2. Carefully install the following six parts that you removed from the old controller board into their proper sockets on the new controller board. Be sure to observe the correct IC pin orientation. (See Figure I–13.) • NVRAM IC (board location U35) •...
Page 354: Terminating Resistors
Chapter Controller Module Terminating Resistors For parallel interface configurations, the printer is equipped with 470 ohm pullup terminating resistors and 1K ohm pulldown terminating resistors on the controller board. These are suitable for most applications. (See the figure on the following page.) If the standard terminating resistor packs are not compatible with the particular interface driver requirements of the host computer, other values of pullup and pulldown resistors might be required.
Page 355 Terminating Resistors Controller Board Connector NOTE: Shown with I/O panel removed for clarity Terminating Resistors, Removal and Installation I–355...
Page 356: Power Supply (In Controller Module
Chapter Controller Module Power Supply (In Controller Module) 1. Turn off the printer. 2. Disconnect the printer AC power cable from the power source. 3. Remove the printer left rear cover (page I–239). 4. Remove the controller module housing cover (not shown). 5.
Page 357 Power Supply (In Controller Module) Controller Module Power Supply Harness Connectors (2) L55cage March 21, 2000 Power Supply Power Supply PCBA Screws (4) Power Supply I–357...
Page 358: Cooling Fan
Chapter Controller Module Cooling Fan 1. Turn off the printer. 2. Disconnect the printer AC power cable from the power source. 3. Remove the printer left rear cover (page I–239). 4. Remove the controller module housing cover. (See the illustration on the following page.) 5.
Page 359 Cooling Fan Controller Module Controller Module Housing Cover Fan Power Cable Connector Controller Module Screws (4) I–359...
Page 360 Chapter Controller Module I–360...
Page 361 Index Cassette paper jams at back of, I–111 Abbreviations, interconnection diagram, II–176 paper size, I–59, II–125, II–245 About this manual, I–19 Cautions and dangers, I–19 Acronyms, interconnection diagram, II–176 Cleaning Adjustments charges, I–82 loading flash memory, I–231 cleaning unit, I–93 software upgrades, I–228, I–231 cut sheet option rollers, I–89 Auto-load fanfold paper command, theory, II–167...
Page 362 cover, I–239 Cut-sheet Paper Empty (Error 6F), I–167 power supply, I–356 Cut-sheet Paper Skew (Error 64), I–163 Cooling fan, controller, I–358 Cut-Sheet Path Open (Error 08), I–134 Corona power supply, I–319 Cut-sheet Pick Miss (Error 65), I–163 interface, II–231 Cutter Cover motor, I–284 behind stand, I–332...
Page 363 engine checker, II–338 Toner Density, II–339 MC board, I–207 Tractor Motor, II–339 peripheral equipment, I–260 Engine CPU Fail (Errors 38 through 47), I–156 cleaning unit, I–262 Engine, interconnection diagram, II–173 discharge lamp (PEL), I–261 Eraser lamp main charger (MCH), I–260 engine checker, II–338 precharger (PCH), I–260 MC board, I–208...
Page 364 18 - Drum Motor Fail (complete stop), I–146 Errors 19 - Surface Voltage Too High, I–147 cut sheet feeder unit, II–251 1A - Surface Voltage Too Low, I–149 power paper stacker, II–288 1B - Tractor Detent Fail, I–150 1E - Fuser Supply Fail, I–151 Face down paper out drive belt, I–309 1F - Fuser Failure, I–151 Face gate solenoid (FGSL), I–301...
Page 365: Illustrated Parts Breakdown
DC PROGRAM / NOT VALID, I–117 Fuser temperature, monitoring, theory, II–157 DRAM AT / ADDRESS xxxxxxxx, I–117 Fuser unit, I–266 FLASH / DID NOT PROGRAM, I–118 lamp duct filter, I–270 FLASH / NOT DETECTED, I–118 preheat lamp/flash lamp, I–267 FLASH TYPE / IS NOT SUPPORTED, temperature fuse, I–269 I–118 theory, II–122...
Page 366 Intervals, replacement current control circuit, MC board, I–211 consumables, I–70 varistor, I–304 service provider responsibility, I–71 Main Charger High Voltage Error (Error 78), I–167 user responsibility, I–70 Main unit, feed roller drive, theory, II–135 Maintaining print quality, I–67 Maintenance Jam detection sensors, I–101 log sheets, I–68 Jams, paper schedules, I–67...
Page 367 global memory adjust, I–104 Motor printer control, I–105 cutter, I–284 Message table, error messages, I–116 drum, I–285 Messages feed (FMT), I–289 CLEARING PROGRAM / FROM FLASH, I–117 feed encoders (FME 19/20), I–289 DIAGNOSTICS / PASSED, I–117 magroll (MRM), I–287 ERROR magroll, MC board, I–212 DC PROGRAM / NOT VALID, I–117 sleeve (SLM), I–287...
Page 368 output section, theory, II–124 photoemitting board, I–347 output, theory, II–129 photoreceptor board, I–348 parking, theory, II–130 Paper output section, paper jams near, I–108 sensors Paper path, face up or face down, paper empty, II–246 paper jams in, I–115 paper near-end, II–143 Paper size, cassette, I–59, II–125, II–245 paper output (EPS0), II–144 Paper stacker, II–263...
Page 369: Principles Of Operation
stacker full sensor (SFS), II–283 Printer options stacker motor, II–315 cut sheet feeder unit, II–235 stacker motor encoder (SME), II–284 power paper stacker, II–263 swinger, II–277 Printing mechanisms, II–113 swinger belts, II–303 Printing operations, theory, II–162 swinger position sensor (SPS), II–285 Printing system descriptions, II–111 transfer unit paper sensor (PMS), II–280 Processing, images, II–112...
Page 370 Schedule stacker swinger position sensor (SPS), II–285 consumables replacement, user responsibility, stacker transfer unit paper sensor (PMS), I–70 II–280 replacement, service provider responsibility, theory, II–141 I–71 upper/lower paper empty sensor (PES1/PES2), Schedules, maintenance, I–69 II–246 Scuff Lever Open (Error 07), knob "C", I–134 upper/lower paper size sensor, II–244 SECURITY CODE / VIOLATION, I–122 Separator Charger High Voltage Error...
Page 371: Separation
power paper, I–55, II–263 Toner Density Too High (Error 2B), I–155 safety sensors, II–287 Toner Density Too Low (Error 2C), I–155 swinger position sensor, II–285 Toner Empty (Error 2D), I–154 transfer unit paper sensor, II–280 Toner Low (Error 2A), I–154 Stacker Comm.
Page 372: Unit Interface
Unit interface, II–221 Unpacking the printer, I–35 Upgrading software, I–228, I–231 User Maint option, service levels, I–68 Utility program, lasr2fls, I–228 Vacuum cleaners, recommended models, I–30 Vacuum fan (VAF) transfer assembly, I–276 Vacuum fan, MC board, I–212 Varistor main charger, I–304 transfer/transport unit, I–279 Voltage setting, power supply, I–60 WAITING FOR / PROGRAM DOWNLOAD, I–122...
Page 374 Nederland BV P.O. Box 163, Nieuweweg 283 NL-6600 Ad Wijchen The Netherlands Phone: (31) 24 6489489 Fax: (31) 24 6489499 Printronix Schweiz GmbH 42 Changi South Street 1 Changi South Industrial Estate Singapore 486763 Phone: (65) 6542-0110 Fax: (65) 6543-0220...

Printronix L5535 Maintenance Manual

Introduction

Setup

Scheduled Maintenance

Troubleshooting

Adjustment Procedures

Replacement Procedures

Quick Links

Troubleshooting

Related Manuals for Printronix L5535

Summary of Contents for Printronix L5535