Page 1 Maintenance Manual Volume 1 L5000 Series Multifunction Printer...
Page 3 L5000 Series Multifunction Printer Maintenance Manual Volume 1 P/N 704766–001, Rev C...
Page 4 Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits. Printronix is not responsible for any radio or television interference caused by using other than recommended cables and connectors or by unauthorized changes or modifications to this equipment.
Page 5 Hinweis: Dieses Genehmigungsverfahren ist von der Deutschen Bundespost noch nicht veröffentlict worden. 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 6: Trademark Acknowledgements
Centronics is a registered trademark of Genicom Corporation. Dataproducts is a registered trademark of Hitachi. Epson is a registered trademark of Epson Seiko Corporation. IGP, LinePrinter Plus, and Printronix are registered trademarks, and DuraFusion, LaserLine, PGL, PSA, and Ribbon Minder are trademarks of Printronix, Inc.
Page 7 Albertus, Gill Sans, and Times New Roman are registered trademarks, and Monotype Baskerville is a trademark of The Monotype Corporation Plc, registered in the U.S. Pat. and TM office and elsewhere. Hiroshige and Marigold are trademarks of AlphaOmega Typography, Inc. COPYRIGHT 1996, 2000, PRINTRONIX, INC.
Page 9: Table Of Contents
Volume 1 Table of Contents Introduction English: General Safety Precautions ..........1–2 Setup Safety Precautions .
Page 10 Consumables Install Consumables (Initial Printer Setup) ........3–2 Install the Photoreceptor Drum .
Page 11 Cleaning the Selfoc Lens (LED Print Head) ....... . 4–27 Cleaning the Discharge LED .
Page 12 Paper Feed, Transport, and Output Sections ....... . . 5–19 Paper Detection .
Page 13 Electrical and Wire Data System Configuration ..........6–2 Interconnect diagram .
Page 14 Troubleshooting Overview ............7–3 Jam Detection Sensors .
Page 15 05 – Paper Jam at Fuser (D): Paper Output Section ......7–37 07 – Scuff Lever Open .
Page 16 Engine Checker Overview ............8–2 Connecting the Engine Checker .
Page 17 Adjusting the Drum Surface Potential Sensor – Procedure 1 ....9–11 Adjusting the Drum Surface Potential Sensor – Procedure 2 ....9–15 Adjusting the Eraser Lamp Input Voltage .
Page 18 Volume 2 Table of Contents Replacement Procedures Overview ............10–3 Covers .
Page 19 Flash Power Supply Unit ..........10–85 Capacitors .
Page 20 Illustrated Parts List Overview ............C–3 Maintenance Tools .
Page 21 Bracket FU Connect Assembly (Fuser Unit Assembly) ......C–98 Back of Printer, Left Side ..........C–101 Installation/Maintenance Tools .
Page 22 Optional Power Paper Stacker Physical Description ........... E–2 Setup and Connection .
Page 23 Host I/O Interfaces Overview ............F–2 Performance Considerations .
Page 24 Table of Contents...
Page 25: Introduction
Introduction Chapter Contents English: General Safety Precautions ..........1–2 Setup Safety Precautions .
Page 26: General Safety Precautions
General Safety Precautions This chapter provides safety information for technicians who are installing and maintaining L5000 Series printers. Installation, initial setup, testing and maintenance should be performed only by a factory-trained service representative. CAUTION The printer relies on protective devices in the building installation for protection.
Page 27 Before servicing the printer, disconnect its power plug from the power outlet. When performing operational checkout with the printer turned ON, use extreme caution not to let your clothing or hair get caught in the rotating mechanisms. Do not block or obstruct any cabinet ventilation slots. Make sure that no foreign matter enters the printer, as injury to personnel, equipment malfunction, or fire may result.
Page 28: Setup Safety Precautions
Setup Safety Precautions When installing the printer, observe the following setup precautions: Printer Do not operate the printer in a room that is not properly ventilated. The room should be at least 1,000 cubic feet with complete air exchange every two hours. Make sure nothing rests on the power cord.
Page 29: Safety Label Locations
Safety Label Locations Rear cover Front upper cover Rear cover Front upper cover Figure 1–1. Safety Labels Introduction 1–5...
Page 30 DANGER Keep your hands away from tractors while printing. Printer emits bright light while printing. Do not stare into tractor area while printing. Figure 1–2. Safety Label – Paper Input Side 1–6 Introduction...
Page 31 DANGER High voltage on chargers while printing. DANGER Hot surface. Do not touch. DANGER HOT Do not touch fuser unit cover glass. Figure 1–3. Safety Labels – Front View with Cover Removed Introduction 1–7...
Page 32 DANGER Hot surface and hot air. Avoid contact. Figure 1–4. Safety Label – Rear Cover 1–8 Introduction...
Page 33 DANGER Keep your hands away from stacker while printing. Figure 1–5. Safety Label – Power Paper Stacker (output side) Introduction 1–9...
Page 34 DANGER HIGH VOLTAGE Do not touch charger power supply below this plate. DANGER HIGH VOLTAGE Do not touch the varistor on left. Figure 1–6. Safety Labels – Rear View 1–10 Introduction...
Page 35: Allgemeine Sicherheitsvorkehrungen
Allgemeine Sicherheitsvorkehrungen Dieses Kapitel enthält Sicherheitsinformation für die richtige Installation und Wartung der L5000 Drucker-Serie. Installation, anfängliches Aufstellen und Wartung sollten nur von einem durch den Hersteller ausgebildeten Servicefachmann vorgenommen werden. VORSICHT Der Schutz des Druckers beruht auf integrierten Schutzeinrichtungen. Der Drucker muß...
Page 36 Die Entwicklerwalzeinheit nicht berühren. Die Xenon- und Halogenlampen sowie die Glasabdeckung des Fixierers nicht berühren, da Fingerabdrücke Hitze anziehen und die Lampen dadurch platzen. Halten Sie magnetisch empfindliche Gegenstände von der Entwicklerwalzeinheit fern, da sie magnetisiert ist. Den Toner nicht in der Nähe von Vinylmaterialien abstellen, da der Toner Vinylchlorid schmilzt.
Page 37: Sicherheitsvorkehrungen Beim Installieren
Sicherheitsvorkehrungen beim Installieren Beachten Sie bitte beim Installieren des Druckers die folgenden Vorsichtsmaßnahmen: Drucker Der Drucker darf nur in einem Raum mit ausreichender Ventialtion eingesetzt werden. Dieser Raum sollte mindestens 28 Kubikmeter groß sein und Frischluftzufuhr sollte alle zwei Stunden erfolgen. Sorgen Sie dafür, daß...
Page 38: Anbringungsorte Der Sicherheitsetiketten
Anbringungsorte der Sicherheitsetiketten Rückseite Vorderseite Rückseite Vorderseite Abbildung 1–1. Sicherheitsetiketten 1–14 Introduction...
Page 39 GEFAHR Während des Druckvorgangs Traktoren nicht anfassen. Drucker emittiert während des Druckvorgangs helles Licht. Nicht in den Traktorbereich schauen. Abbildung 1–2. Sicherheitsetikette - Seite der Papiereingabe Introduction 1–15...
Page 40 GEFAHR Lader stehen während des Druckvorgangs unter hoher Spannung. GEFAHR Heiße Oberfläche. Nicht berühren. GEFAHR - HEISS Abdeckglas der Fixiereinheit nicht anfassen. Abbildung 1–3. Sicherheitsetiketten - Vorderansicht bei entfernter Abdeckung 1–16 Introduction...
Page 41 GEFAHR Heiße Oberfläche und heiße Luft. Kontakt vermeiden. Abbildung 1–4. Sicherheitsetikette - Hintere Abdeckung Introduction 1–17...
Page 42 VORSICHT Während des Druckvorgangs Hände von der automatischen Papierausgabe fernhalten. Abbildung 1–5. Sicherheitsetikette - Seite der automatischen Papierausgabe 1–18 Introduction...
Page 43 GEFAHR HOCHSPANNUNG Netzteil des Laders unterhalb dieser Platte nicht berühren. GEFAHR HOCHSPANNUNG Varistor links nicht berühren. Abbildung 1–6. Sicherheitsetiketten – Rückansicht Introduction 1–19...
Page 44: About This Manual
About This Manual This manual explains how to and repair the L5000 Series printers 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 45: Switches And Display Messages
IMPORTANT An important notice provides information that is vital to proper operation of the printer. NOTE: A note provides information considered important enough to emphasize. Switches and Display Messages In this manual, switches and indicators that are labeled on the printer appear in uppercase letters.
Page 46: Printer Features
Printer Features The L5000 Series printer provides the following standard features: Non-impact/electrophotographic page printer The printer is a non-impact page printer that 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 47 Further, the printer size is minimized to permit effective office space utilization. Printronix System Architecture (PSAt) The controller is compatible with all requirements of the PSA system. This means that all PSA compatible emulations (IGP/PGL, IGP/VGL, Lineprinter Plus, HP PCL5, etc.) can be accommodated, and are configured by exchanging...
Page 48 1–24 Introduction...
Page 49: Setup
Setup Chapter Contents Power Requirements ........... 2–2 Select a Site .
Page 50: Power Requirements
Power Requirements DANGER Do not connect the printer to the power source until instructed to do so and until all shipping restraints have been removed. The operator-accessible power switch does not shut off all power to the printer. Unplug the power cord to shut off all power to the printer. GEFAHR Drucker nicht an das Netz anschließen, ehe Sie dazu angewiesen werden und erst nachdem alle Verpackungsmaterialien entfernt worden sind.
Page 51: Select A Site
Select a Site 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 2–2. The location is within the maximum cable length specifications for the host computer interface.
Page 52 43.50 in. 56.50 in. (110.5 cm.) (143.5 cm.) 57.25 in. (145.4 cm.) Printer Dimensions (In Crate) 2–4 Setup...
Page 53 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. Printer Dimensions (Unpacked) Setup 2–5...
Page 54: Unpack And Level The Printer
Unpack and Level the Printer After a site has been selected for the printer, set up the printer according to the following procedures. 1. Open the packaging, and unpack the printer and consumables, as described in the Unpacking Instructions. 2. Using the casters, transport the printer to the location where it is to be installed. Leave space around the printer when setting up, as shown on the previous page.
Page 55 4. Put a level on the front cover and the tractor splined shaft, and make fine adjustments, using the height-adjusting legs, to level the printer in both directions, as shown below. Level in the two directions Height Adjusting Legs (4 places) Setup 2–7...
Page 56: Connect The Cables
Connect the Cables Power Cord The procedure to install the power cord is identical for both domestic and international power cords, using the following 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 57 2. Loosen the screw on the connector cover in the lower part of the rear cover, and slide the connector cover to the left, as shown. Then remove the screw (1) inside the connector cover. Connector Cover Screw (loosen) Screw (remove) 3.
Page 58 5. Remove the four screws on the power supply terminal box cover. Then remove the cover. 6. Remove the two screws on the transparent terminal cover inside the box. Then remove the cover. Transparent Terminal Cover Screws (2) Screws (4) Terminal Box Cover 2–10...
Page 59 7. Connect the power cord to the terminal block. Connect the power cord and ground wire to each terminal, in the following order: line 1, line 2, and ground wire. Tighten the nut to lock the power cord in position. The breaker should be set to “ON,”...
Page 60: Install Signal Cables
Install Signal Cables Now the printer can be connected to power and to the computer. To connect the cables, refer to the illustration on the following page and perform the steps listed below. 1. Verify that the site line voltage is the same as the voltage specified on the rear side panel label.
Page 61 Power Switch Diskette Drives 232/422 Switch Parallel Diagnostic Port Serial The RS-232/422 select switch located on the cover plate must be set properly for your application. The factory default setting is RS-232. Setup 2–13...
Page 62: Install The Consumables
Install the Consumables After the cables are connected, install the photoreceptor drum, developing unit, and toner cartridge according to the instructions in Chapter 3, “Consumables.” Perform all procedures listed under the topic, “Installing Consumables.” 2–14 Setup...
Page 63: Consumables
Consumables Chapter Contents Install Consumables (Initial Printer Setup) ........3–2 Install the Photoreceptor Drum .
Page 64 Installing Consumables IMPORTANT The following procedures should be performed only by an individual who has received the appropriate training. To prepare the printer for initial operation, perform the following procedures: Install the photoreceptor drum Add the developer to the developing unit Install the developing unit Install the toner cartridge Load fan-fold paper...
Page 65: Install The Photoreceptor Drum
Install the Photoreceptor Drum These instructions describe the initial installation of the photoreceptor drum (P/N 703535-001). (When the drum life of 300,000 pages has been exceeded, the drum must be replaced. To replace the drum, refer to page 3–31.) To install the drum, you will need the auxiliary rod (P/N 703531-170). Please read all steps before beginning the installation process.
Page 66 1. As this is the initial printer installation, the power cord should not yet be plugged in, and the power switch should be OFF. The right rear cover is not attached. 2. Open the printer front upper cover. Open/Close Button Front Cover 3.
Page 67 4. Remove three screws on the upper inner cover. Then remove the cover. Upper Inner Cover Screws (3) CAUTION The transfer charger must be in the down position to avoid scratching the drum. Failure to perform steps 5 and 6 will damage the drum. 5.
Page 68 6. Lower the transport unit by turning the green lever on the transport unit to the left. Green Lever 7. Loosen the three thumb screws securing the drum plate and remove the drum plate. 8. Remove the two screws on the lower inner cover. Then remove the cover. Drum Plate Thumb Screws (3) Screws (2)
Page 69 9. Remove the nut from the end of the drum shaft. Drum Shaft 10. Screw the auxiliary rod onto the drum shaft. 11. Wipe the drum shaft clean with a cloth. Drum Shaft Auxiliary rod for changing the drum, P/N 703531-170 Consumables 3–7...
Page 70 12. Remove the new photoreceptor drum from its package. Do not discard the packaging material, as it will be needed for future drum disposal. Note that the sides of the drum are identical; there are no front or back sides. Wipe inside the end-caps of the drum with a cloth to ensure that they are clean.
Page 71 15. Remove the auxiliary rod from the drum shaft. 16. Install the nut on the drum shaft, and tighten it securely by hand. 17. Install the drum plate and tighten the thumb screws. While installing the drum plate, place your thumb over the copper grounding clip and hold it in place. Otherwise the grounding clip can be bent, making no contact with the drum shaft.
Page 72: Add The Developer
Add the Developer Nozzle Developing Unit Screw Developer Bottle Knob 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 page 3–40.) 1. Remove the developing unit from its package. 2.
Page 73 Developer Powder Roller Knob IMPORTANT If toner or developer spills on skin or clothing, use cold water to remove it. 5. Pour the entire bottle of developer powder into the developing unit evenly, while rotating the roller knob counterclockwise. 6. Replace the cover and tighten the screws. Next, install the developing unit as described in the following procedure.
Page 74: Install The Developing Unit
Install the Developing Unit To install the developing unit for the first time, perform the following steps. (To replace the developing unit, refer to page 3–43.) This procedure assumes the following: The power switch is OFF. The power cord is unplugged. The right rear cover is not attached.
Page 75 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 76 6. Raise the transport unit: while pressing the transport unit in, turn the green lever to the right to lock the transport unit in place. Green Lever 7. Install the lower inner cover, and secure it with the two screws. Screws (2) Lower Inner Cover...
Page 77 8. Install the upper inner cover, and secure it with the three screws. Upper Inner Cover Screws (3) 9. Close the waste toner recovery unit and ensure that it latches. 10. Next, install the toner cartridge as discussed in the following procedure. Consumables 3–15...
Page 78: Install The Toner Cartridge
Install the Toner Cartridge To install the toner cartridge for the first time, perform the following steps. (To replace the toner cartridge when the message “Toner Empty” is displayed on the control panel, refer to page 3–50.) This procedure assumes the following: The power switch is OFF.
Page 79 3. With the cover tape facing up, begin inserting the cartridge into the toner hopper, and slowly pull off the cover tape in the direction of the arrow. Remove the last of the tape just as the cartridge is completely inside the hopper. 4.
Page 80: Loading Fanfold Paper
Loading Fan-fold Paper To load paper, perform the following steps. Repeat 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, refer to Chapter 7, “Troubleshooting.” This procedure assumes the following: The power switch is OFF.
Page 81 3. Move the tractor to the left side of the tractor guide, and place the fan-fold paper box under the tractor unit. 4. Pass the leading edge of the paper between the paper near-end sensor and the guide. The first fold of the paper should be facing towards the printer, otherwise, a paper jam could occur during printing (see illustration).
Page 82 5. Unlock the right tractor only by pushing forward on the tractor lock. Open the tractor gates and place the paper about half way onto the tractor pins. Do not push the paper past the tractors into the area of the paper jam sensor. Tractor Gate 6.
Page 83: Loading Cut-Sheet Paper
Loading Cut-Sheet Paper If the printer is equipped with the cut sheet paper feed option, upper and lower cassettes are provided. Selection of either face up or face down paper output trays is made from the operator control panel. Occasionally, paper may become moist and wavy, resulting in poor print quality. If this occurs, remove the wavy sheets of paper from the cassette and replace them with those from a new package.
Page 84 1. Pull out the desired paper cassette and remove its cover. 2. If you need to change the cassette paper size, see the information on the following page for the available settings. 3. Load the new paper uniformly in the cassette, making sure the leading edge of the paper is at the front of the cassette.
Page 85: Setting Cassette Paper Size
Setting Cassette Paper Size IPS 12 / 22 IPS 12 / 22 IPS 11 / 21 IPS 11 / 21 IPS 10 / 20 IPS 10 / 20 IPS 10, 11, and 12 = Upper-level Paper Size Detector Sensors IPS 10, 11, and 12 = Upper level paper size detector sensors IPS 20, 21, and 22 = Lower-level Paper Size Detector Sensors IPS 20, 21, and 22 = Lower level paper size detector sensors There are three holes in the forward end of the cut-sheet paper feed cassettes.
Page 86: Installing Diskettes
Installing Diskettes The printer contains two diskette drives, as shown below. Certain printer emulations require the use of the second disk drive. When two drives are required, drive A holds the operating system diskettes and drive B holds the font diskettes. To install the operating system diskette, follow these steps: 1.
Page 87: Setting Power Supply Voltage
Setting Power Supply Voltage This procedure assumes the following: The power switch is OFF. The power cord is unplugged. The printer front upper cover is open. The right rear cover is not attached. You have installed the drum, developing unit, and toner cartridge. You have loaded paper (fan-fold and/or cut-sheet).
Page 88 3. Remove the eight screws holding the power supply unit cover; then remove the cover. The DC power supply board is visible inside the power supply unit. Power Supply Unit Cover DC Power Supply Board Screws (8) No-Fuse Breaker Lever 3–26 Consumables...
Page 89 4. Using the following chart, slide the power supply voltage switch (SW1) to the correct voltage position which you measured in step 1. (For the board layout, refer to Chapter 9, “Board Adjustments.”) DC Power Supply Board NOMINAL AC LINE AC LINE VOLTAGE VOLTAGE RANGE...
Page 90 5. Plug the power cord into the wall outlet. 6. Power on the printer. 7. Locate the black-sheathed, white/black wire pair that supplies AC power from the AC power supply to the AC blower assembly (fan). Now locate the red connector, near the AC blower assembly, that connects the pair to the fan.
Page 91 It is very important that the voltage is between the range listed in the chart. If you cannot achieve this, call Printronix Technical Support for assistance. 9. Install the power supply unit cover. 10. Attach the right rear cover to the printer and tighten the screws. Insert the claws into the centering slot so that the rear cover is set in place.
Page 92: Replacing Consumables
Print media other than bond paper (e.g., labels, card stock, plastic, or vinyl) can reduce drum life as much as 50%. NOTE: To ensure optimum print quality, use only genuine Printronix supplies. Part numbers are provided below. To order supplies, call 1-800-733-1900 or 714-863-1900.
Page 93: Replacing The Photoreceptor Drum
Replacing the Photoreceptor Drum When the drum life (300,000 pages maximum for bond paper) has been exceeded or print quality is no longer acceptable, the photoreceptor drum must be replaced. Drum life is dependent 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%.
Page 94 4. 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 Opening Lever 5. Remove three screws and the upper inner cover. Upper Inner Cover Screws (3) 3–32...
Page 95 CAUTION Failure to perform Step 6 will damage the photoreceptor drum. 6. Rotate the developing unit lever fully clockwise so that it is pointing straight up (to separate the developing unit from the photoreceptor drum). Lever 7. Remove the developing unit by holding the lever in one hand and pulling the developing unit partially out of the printer.
Page 96 8. With the other hand, grasp the hanger and remove the developing unit from the printer. 9. Vacuum any spilled toner. Hanger CAUTION The transfer charger must be in the down position to avoid scratching the drum. Failure to perform steps 10 and 11 will damage the drum. 10.
Page 97 Transfer charger Transfer elevator drive shaft 11. Lower the transport unit by turning the green lever on the transport unit to the left. Green lever Consumables 3–35...
Page 98 12. Loosen the three thumb screws securing the drum plate and remove the drum plate. Drum plate Thumb Screws (3) Screws (2) Lower Inner Cover 13. Remove the two screws and the lower inner cover. 14. Remove the nut from the end of the drum shaft. Drum Shaft 3–36 Consumables...
Page 99 15. Screw the auxiliary rod onto the drum shaft. Drum Shaft Auxiliary rod for changing the drum, P/N 703531-170 16. Carefully pull the old drum outward along the auxiliary rod. Hold the front and back sides when the drum is nearly out of the printer, and remove it with both hands.
Page 100 17. Pack the old drum for shipment using the original packaging material, and close the cover of the box. 18. Wipe the drum shaft clean with a cloth. CAUTION Exposing the drum to light shortens its life span. Do not expose the drum to direct sunlight, and install it within five minutes under typical room lighting conditions.
Page 101 22. Remove the auxiliary rod from the drum shaft. 23. Reinstall the nut and tighten it securely by hand on the drum shaft. 24. Reinstall the drum plate and tighten the thumb screws. While installing the drum plate, place your thumb over the copper grounding clip and hold it in place. Otherwise the grounding clip can be bent, making no contact with the drum shaft.
Page 102: Replacing The Developer
Replacing the Developer The following procedure should be used when replacing the developer in the developing unit. The procedure should be performed every 150,000 pages (based on letter size paper at 4% coverage) until the developing unit life (450,000 pages) has been exceeded.
Page 103 Nozzle Developing Unit Developer Bottle Knob Screw Cover 6. Locate a new developer bottle. 7. On the developing unit, remove the three cover screws and the cover. CAUTION The toner sensor is sensitive to both electrostatic discharge (ESD) and positional adjustment.
Page 104 10. Replace the cover and tighten the screws. Developer Powder Roller Knob IMPORTANT If toner or developer spills on skin or clothing, use cold water to remove it. 3–42 Consumables...
Page 105: Replacing The Developing Unit
Replacing the Developing Unit When the developing unit has printed 450,000 pages, replace it. The following steps describe removal of the old developing unit and installation of a new developing unit. Please read all steps before beginning the replacement process. 1.
Page 106 4. 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 Opening Lever 5. Remove the three screws on the upper inner cover. Then remove the cover. Upper Inner Cover Screws (3) 3–44...
Page 107 6. Rotate the developing unit lever fully clockwise so that it is pointing straight up. This separates the developing unit from the photoreceptor drum. CAUTION Failure to perform step 6 will damage the photoreceptor drum. Lever 7. Remove the developing unit by holding the lever in one hand and pulling the developing unit partially out of the printer.
Page 108 8. With the other hand, grasp the hanger and remove the developing unit from the printer. Hanger Lever DANGER The developing unit and toner cartridge are flammable. Dispose of them properly (never into a fire). GEFAHR Die Entwicklereinheit und die Tonerkassette sind feuergefährlich. Vorschriftsgemäß...
Page 109 CAUTION Failure to perform step 12 will damage the photoreceptor drum. 12. On the developing unit, rotate the lever fully clockwise so that it is pointing straight up. 13. Holding the lever in one hand and the hanger in the other hand, insert the developing unit on the guide rail.
Page 110 15. Rotate the developing roller knob counterclockwise until the developing unit drops into its final resting position. The positioning pin should protrude through the main body of the developing unit. 16. Rotate the developing unit lever fully counterclockwise to lock the developing unit in place.
Page 111 18. Close the waste toner recovery unit and ensure that it latches. 19. Close the printer front cover. NOTE: Do step 20. only if the I/O board has been replaced. 20. After a new developing unit is installed, the toner/developer density needs to be adjusted only if the I/O board has been replaced.
Page 112: Replacing The Toner Cartridge
Replacing the Toner Cartridge When the toner empty sensor detects no toner (“TONER EMPTY” message appears on the control panel), replace the toner cartridge using the following procedure, leaving the developing unit in the printer. NOTE: At 4% coverage on letter-size paper (8.5 in x 11 in), the toner yield is approximately 21,000 pages.
Page 113 2. Rotate the old toner cartridge counterclockwise until the notch is aligned with the positioning pin in the toner hopper, and remove the cartridge. Toner cartridge Notch Positioning Pin DANGER The toner cartridge is flammable. Dispose of it properly (never into a fire). GEFAHR Die Tonerkassette ist feuergefährlich.
Page 114 5. Remove the new toner cartridge from its package. 6. With the cover tape facing up, begin inserting the cartridge into the toner hopper, and slowly pull off the cover tape in the direction of the arrow. Remove the last of the tape just as the cartridge is completely inside the hopper.
Page 115: Replacing The Waste Toner Bottle
Replacing the Waste Toner Bottle The waste toner recovery unit (containing the waste toner bottle) is located behind the front cover, as shown below. When the “WASTE TONER FULL” message appears on the control panel, replace the waste toner bottle by performing the following steps, and discard the full bottle.
Page 116 2. Lower the lever, pull the green handle toward you, and open the waste toner recovery unit. Waste Toner Recovery Unit Green handle Lever 3. Remove the cap from the outside of the waste toner bottle, and cap the toner bottle.
Page 117 DANGER The waste toner bottle is flammable. Dispose of it properly (never into a fire). GEFAHR Die verbrauchte Tonerflasche ist feuergefährlich. Vorschriftsgemäß entsorgen (niemals verbrennen). 4. Remove the waste toner bottle from the unit and discard it. 5. Install a new waste toner bottle. 6.
Page 118 3–56 Consumables...
Page 119: Scheduled Maintenance
Scheduled Maintenance Chapter Contents General Cleaning ........... . . 4–2 Print Quality Problems .
Page 120: General Cleaning
General Cleaning To maintain optimum print quality, clean the printer on a regular basis. Depending upon the density of the print jobs, clean the printer after it prints 10,000-20,000 sheets. Clean the following areas with a vacuum cleaner: Area around the developing unit (including the toner cartridge and spray-guard brush).
Page 121: Replacement Intervals
2. Open the front cover. Use a toner vacuum to remove loose toner particles, paper dust, and other debris from the paper input and exit areas, front cover, waste toner area, paper transport area, and paper stacker input area. Then use a damp tissue to further clean the waste toner area and the paper transport area.
Page 122: Maintenance Tools
Maintenance Tools In order to perform maintenance on the printer, the following tools are required. Table 4–1. Required Maintenance Tools Item Part # Brush cleaner 703531-169 Dummy drum 703531-173 Drum auxiliary rod 703531-170 Drum freshener 703531-171 Engine checker 703531-197 Engine height adjuster 703531-174 High voltage power supply 703531-184...
Page 123: Service Level Page Counts
Service Level Page Counts IMPORTANT The user should maintain a record of all maintenance performed on the printer. Maintenance log sheets are provided in Appendix C, Maintenance Logs of the User’s Manual. The user should photocopy these and keep them in a binder near the printer.
Page 124 Note that this condition will not cause the printer to stop printing. When one of the above messages appears, perform the appropriate scheduled maintenance or call the factory-trained service representative to perform the maintenance. When you have performed a level of service, it is necessary to clear the page count for that service level.
Page 125: About The Page Counter Software
About the Page Counter Software The Page Counter preserves an accurate page count continuously. A page is defined as either 11.7 inches of linear paper fed from continuous forms, or a single A4/Letter-size cut-sheet page for cut-sheet printing. Maintaining the page count does not require user interaction unless one of the following occurs: You are using a new printer diskette for the first time.
Page 126 Table 4–1. Page Counter Messages MESSAGE / PROMPT EXPLANATION ID MISMATCH The boot diskette used is either a new one or not the one intended for this printer. STAND-BY Wait for the system to complete disk writing. No action WRITING TO DISK is required.
Page 127: Cleaning Schedule
Cleaning Schedule Each time you perform maintenance, you must reset the maintenance cycle in the Diagnostics menu (refer to the User’s Manual). This removes the error message that maintenance is required. The maintenance cycle tracks the page count since the last maintenance was performed, while the Printer Life option tracks the page count for the life of the printer.
Page 128: Replacement Schedule
Replacement Schedule Replace the following items after the specified number of letter size pages (4% coverage) have been printed. Refer to Appendix C for a parts list, including spares. Table 4–3. User Responsibility – Replacement Item Part # Frequency Service Level Toner Cartridge 703532-001 (Pages) 21 K...
Page 129 Table 4–4. Service Provider Responsibility – Replacement Item Part # Frequency Service Level Lamp housing filter 703544-001 300 K Main charger 703536-001 300 K Transfer charger 703537-001 300 K Cleaning unit 703534-001 300 K Drum belt, 3M264 703531-031 300 K Pre-charger 703538-001 300 K...
Page 130: Cleaning Inside The Front Cover
Cleaning inside the Front Cover 1. Turn the power switch OFF. 2. Unplug the power cord. 3. Open the printer front upper cover. Open/Close Button Front Cover 4. Using a vacuum, clean the toner, paper dust, etc. inside the front cover. 4–12 Scheduled Maintenance...
Page 131 5. On the waste toner recovery unit, press the Open lever down. Pull the handle toward you and open the unit. Lever Handle 6. Vacuum the developing unit and toner hopper. Scheduled Maintenance 4–13...
Page 132 7. Vacuum the drum cleaner. Drum Cleaner 8. Vacuum the fuser unit. 4–14 Scheduled Maintenance...
Page 133 9. Vacuum the lamp housing filter on the underside of the fuser unit. Scheduled Maintenance 4–15...
Page 134: Cleaning The Transport Unit
Cleaning the Transport Unit 1. Turn the power switch OFF. 2. Unplug the power cord. 3. Open the printer front upper cover. Open/close button Front cover 4. On the waste toner recovery unit, press the Open lever down. Pull the handle toward you and open the unit.
Page 135 5. Lower the transport surface by pressing down on the green lever on the transport unit. 6. Pull the transport unit toward you until it stops. 7. Using a vacuum, clean the toner, paper dust, etc. Be sure to clean under the transport unit as well.
Page 136 8. Wipe off the dirt on the transport surface with wet paper towels. Transport surface 9. 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 137: Cleaning The Paper Feed Section
Cleaning the Paper Feed Section 1. Turn the power switch OFF. 2. Unplug the power cord. 3. Using a vacuum, clean the toner, paper dust, etc. in the tractor area. Tractor 4. Open the paper guide by pressi ng the green lever down. 5.
Page 138 6. Open the lid on the top cover. 7. Open the paper guide by pressing the guide lever down. 8. Using a vacuum, clean the paper dust, etc. inside the paper guide. Paper Guide 4–20 Scheduled Maintenance...
Page 139: Cleaning The Photoreceptor Drum
Cleaning the Photoreceptor Drum After 150,000 pages, remove the drum and inspect it for toner and label adhesive build-up. If necessary, clean the drum as explained in the following procedure. If the majority of your printing applications are less than the full width of the drum, rotate the drum on the shaft.
Page 140 4. Remove the photoreceptor drum. (Refer to page 3–31.) 5. Place the drum on a covered work surface. 6. If the drum is only slightly dirty, clean it with ethanol or iso-propyl alcohol. Do not use acetone. 7. If the drum contains toner build-up, clean it with the drum refresher pad. Turn the drum little by little while polishing the drum surface with the refresher pad.
Page 141: Cleaning The Main Charger
Cleaning the Main Charger CAUTION Use caution to avoid damaging or cutting the charger wires. 1. Turn the power switch OFF. 2. Unplug the power cord. 3. Open the printer front upper cover. Open/Close Button Front Cover 4. Loosen the thumb screw and remove the main charger by pulling it toward you. Thumb Screw Main Charger Scheduled Maintenance...
Page 142 5. Place the main charger on a flat, clean work surface. 6. Using the brush cleaner, clean the charger by removing the paper dust, etc. 7. Clean the two wires using the wire cleaner. Be sure that both wires are cleaned thoroughly.
Page 143: Cleaning The Pre-Charger And Transfer/Separator Charger
Cleaning the Pre-charger and Transfer/Separator Charger CAUTION Use caution in handling to avoid damaging or cutting the charger wires. 1. Turn the power switch OFF. 2. Unplug the power cord. 3. Open the printer front upper cover. Open/close button Front cover 4.
Page 144 5. Loosen the two thumb screws, and remove the chargers by pulling them toward you. Pre-charger Thumb Screws Transfer/Separator Charger 6. Place the chargers on a flat, clean work surface. 7. Using the brush cleaner and the wire cleaner, clean the chargers by removing the dust and dirt on the wires (in the same manner as cleaning the main charger, on page 4–24).
Page 145: Cleaning The Selfoc Lens (Led Print Head)
Cleaning the Selfoc Lens (LED Print Head) 1. Turn the power switch OFF. 2. Unplug the power cord. 3. Open the printer front upper cover. 4. Remove the developing unit from the printer. (Refer to page 3–43.) 5. Remove the photoreceptor drum from the printer. (Refer to page 3–31.) 6.
Page 146 Thumb Screw Main Charger 7. Clean the developing unit area with a vacuum cleaner and a soft cloth. CAUTION When wiping the Selfoc lens, be certain not to apply excessive force to the drum surface potential sensor located near the Selfoc lens, as this may cause the sensor to be dislocated.
Page 147: Cleaning The Discharge Led
Cleaning the Discharge LED 1. Turn the power switch OFF. 2. Unplug the power cord. 3. Open the printer front upper cover. Open/close button Front cover 4. Remove the discharge LED screw. 5. Remove the discharge LED by pulling it toward you. Discharge LED Screw Scheduled Maintenance...
Page 148 CAUTION Do not flex the discharge LED, as it will break. 6. Using a Toraysee cloth, wipe off the dirt on the discharge LED. 7. Return the discharge LED to its original position. Discharge LED 4–30 Scheduled Maintenance...
Page 149: Cleaning The Fuser Unit Cover Glass And Lamp Filter
Cleaning the Fuser Unit Cover Glass and Lamp Filter DANGER Since the fuser unit remains hot after operation, do not handle it until it is completely cooled down. GEFAHR Da der Bereich der Fixiereinheit nach dem Betrieb immer heiß bleibt, berühren Sie ihn erst, erst dann, wenn er sich vollkommen abgekühlt hat.
Page 150 4. Lower the transport surface by pressing down on the green lever on the transport unit. 5. Loosen the two thumb screws on the right and left fuser unit holding plates. Holding Plate Green Lever Thumb Screw 6. Grasp the handle and pull out the fuser unit until the second handle is visible. 7.
Page 151 11. With the fuser out of the printer , you can remove the lamp filter for cleaning (vacuuming). Remove the two screws that secure the filter plate to the fuser unit. Screw (4) Filter Plate Lamp Duct Air Filter Filter Unit 12.
Page 152: Cleaning The Developing Unit / Replacing Developer
Cleaning the Developing Unit / Replacing Developer CAUTION Removing the developer should be performed only by an individual who has received the appropriate training. Be careful not to damage sensors (K) while cleaning the developing unit. (If damage occurs, contact your service representative.) IMPORTANT Every 150,000 pages, the developing unit must be cleaned and the developer...
Page 153 1. Turn the power switch OFF. 2. Unplug the power cord. 3. Open the printer front upper cover. Open/Close Button Front Cover 4. Obtain a plastic bag in which the developing unit can be placed. 5. Remove the developing unit from the printer. (Refer to page 3–43.) 6.
Page 154 7. Remove the three screws on the developing unit cover and detach the cover. Developing Unit Toner Cartridge Screw (3) Cover 8. Place the developing unit in the plastic bag and do the following: a. Remove the developer and toner in the toner hopper by shaking the developing unit up and down with the opening of the toner cartridge facing downwards.
Page 155 Toner Spray-guard Brush 11. Vacuum the toner from the spray-guard brush on the developing unit. 12. Replace the developer. (Refer to page 3–40.) Scheduled Maintenance 4–37...
Page 156: Cleaning The Pickup Rollers
Cleaning the Pickup Rollers 1. Turn the power switch OFF. 2. Unplug the power cord. 3. Remove the upper and lower paper cassettes from the printer. There are two pickup roller units at the back (upper and lower). Upper Pickup Roller Unit Lower Pickup Roller Unit 4.
Page 157 6. Clean the pickup rollers with a Toraysee cloth. Roller 7. Install the upper and lower pickup roller units: 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 158: Cleaning The Reverse Rollers
Cleaning the Reverse Rollers 1. Turn the power switch OFF. 2. Unplug the power cord. 3. Remove the upper and lower paper cassettes from the printer. There are two reverse roller units (underneath the upper and lower pickup roller units). Upper Reverse Roller Unit Lower Reverse Roller Unit 4.
Page 159 5. On the lower reverse roller unit, loosen the green thumb screw. Remove the roller unit by moving it downward while sliding it to the left. 6. Clean the reverse rollers with a cloth. Roller 7. Install the upper and lower reverse roller units, aligning the shaft pin with the slot in the coupling and the alignment pin with the hole in the frame.
Page 160: Cleaning The Flash Power Supply Filter
Cleaning the Flash Power Supply Filter Flash Power Supply Circle Plate Filter 1. Locate the circle plate at the bottom of the flash power supply. Loosen the circle plate screw and rotate the plate upward (leaving it attached to the flash power supply unit).
Page 161: Principles Of Operation
Principles of Operation Chapter Contents Printing System Descriptions ..........5–3 General .
Page 162 Paper Transport ........... 5–24 Paper Output .
Page 163: Printing System Descriptions
Printing System Descriptions General The operation of an LED printer is similar to that of a laser printer, but different from that of an impact printer. Quiet and fast, with excellent resolution output, LED printers are “page printers.” They produce an entire page at once, compared to line printers, which produce only successive character lines.
Page 164: How Images Are Processed
How Images are Processed Bit Mapping The L5000 Series are page printers—they receive data from the host and store a “page” of data in memory before printing. The printers do not print character- by-character or line-by-line. Every print job is stored as a full-page bit-map in random access memory.
Page 165 3. Image Transfer/Separation Section 4. Fixing Section 5. Cleaning Section The following page shows the corresponding waveform. Principles of Operation 5–5...
Page 166 5–6 Principles of Operation...
Page 167: Photoconduction Section
Photoconduction Section The photoreceptor drum surface is exposed to light, and toner adheres to the portions of the drum where the charge is neutralized (latent image formation), so that visible images are formed (developed). This section describes the three phases of photoconduction: discharge, main charging, and exposure.
Page 168 This voltage differential controls the ions flying from the drum and past the grid. The ion flow sets up a potential of approximately +580 volts on the surface of the drum as it rotates under the metal channel. The drum surface potential is then monitored after the ensuing exposure step, and the main charger current is controlled according to the results of that monitoring.
Page 169: Exposure
Exposure When the photoreceptor drum (which has been positively and uniformly charged in the main charging step) is exposed to light, the exposed areas of the photosensitive drum surface film go into conduction. Thus the charge in the exposed area is neutralized while the unexposed portions of the drum maintain approximately +580 volts.
Page 170: Developing Section
In the photoconduction section, the drum potential changes as indicated below. Max. 580 V 50 V The dark area potential indicated above is monitored by the drum surface electrometer. The current flowing to the main charger is adjusted in accordance with the difference between the detected and target potentials.
Page 171: Developing Unit
The developer compound coats the developer roller, which has a positive charge. As the photoconductive drum rotates past the developer roller, the positivly charged toner sticks to the negatively charged carrier beads. Remember, all areas that were exposed to LEDs hold low positive charges and thus contain latent images. The positively charged toner leaves the developer roller and adheres to the areas of the drum that were exposed by the LEDs.
Page 172: Principles Of Developing
To accomplish ultra-fine developing, the printer employs a two-component fine-grain developer which consists of a magnetic toner having a particle diameter of about 8 microns and a carrier having a particle diameter of about 40 microns. Note that the carrier is resin-coated to appropriately weaken its magnetism. The developing unit is constructed so that a predetermined amount of toner is always kept in the agitation chamber and that toner is replenished as needed from the toner cartridge.
Page 173 Therefore, when the AC bias renders the developing roller surface potential positive, the strength of an electric field resulting from the difference between that potential and the drum surface potential is greater than the magnetic force exerted between the toner and inner-pole magnet. As a result, the positively charged toner is attracted to the neutralized area of the drum surface (electrostatic latent image).
Page 174: Transfer/Separation Section
Transfer/Separation Section In this section, the toner image, which has been formed on the drum surface in the developing section, is transferred onto the paper supplied from the paper feed section, and then the paper is separated from the drum. Transfer The toner attracted to the photoreceptor drum surface is positively charged due to the charge placed on it by the developing unit.
Page 175 (keeps paper from following drum) (keeps paper from being attracted to drum) If paper separation is not accomplished by an electrical means, the printer uses the separation claws shown above to mechanically separate the paper from the drum. As shown below, the transfer and separation chargers are integrated into a single unit together with the paper supply guide and paper transport section.
Page 176: Fixing Section
Fixing Section In this section, the toner, which has been transferred onto the paper from the drum in the transfer section, is heated to a high temperature so that it is fixed on the paper. The printer employs a non-contact, flash fixing system. This fixing system eliminates the need for fixing section warm-up and covers a wide range of paper thicknesses and paper qualities.
Page 177: Cleaning Section
Cleaning Section In this section, the photoreceptor drum surface, which still contains excess toner from the previous printing operation, is cleaned for the next printing cycle. Pre-cleaning Charging After the paper is separated from the photoreceptor drum, part of the toner, carrier and paper dust remain on the drum surface without being transferred onto the paper.
Page 178: Drum Cleaning
Drum Cleaning The remaining toner particles, which have been positively charged in the pre-cleaning charging step, are scraped away with a semi-conductive brush to which a minus DC bias is applied. The toner attracted to the semi-conductive brush then adheres to a recovery roller to which a greater minus DC bias is applied. The built-in blade then scrapes the toner away from the recovery roller.
Page 179: Paper Feed, Transport, And Output Sections
Paper Feed, Transport, and Output Sections The print paper is fed, transported, and output through the following mechanisms. (The cut-sheet paper feed and paper output sections are optional.) Cut-sheet transfer sensor Entry roller assembly Paper output sensor, EPS0 Scuff roller assembly Main unit Elevator sensor, EPS3 feed motor...
Page 180: Paper Detection
Paper Detection Fan-fold paper detection The paper near-end sensor is used to determine whether the fan-fold paper is loaded. Sensor guide Cut-sheet paper size detection Paper feed cassette IPS 12/22 IPS 11/21 IPS 10/20 IPS 10, 11, and 12 = Upper level paper size detector sensors IPS 20, 21, and 22 = Lower level paper size detector sensors There are three holes in the forward end of the cut-sheet paper feed cassettes.
Page 181 The available settings for the paper feed cassette are provided in the following table (X = plastic insert): Paper size IPS 12/22 IPS 11/21 IPS 10/20 Legal Ledger Letter 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 182: Paper Loading
Paper Loading Fan-fold paper loading When the printing instruction (PRNT signal) is issued from the controller, the fan-fold paper set on the tractor is automatically advanced upon completion of drum cleaning and the image on the photoreceptor drum is transferred onto the paper while advancing.
Page 183 The transfer of the next page of print data is initiated by the MPU asserting the VSYNC signal. The 030 (or 040) controller responds to the VSYNC signal by asserting the PRNT signal, indicating that the data for the next page is ready for transfer.
Page 184: Paper Transport
Paper Transport Fan-fold paper transport When the MPU receives the print instruction (PRNT signal) from the 030 (or 040) controller and completes paper loading, it sends the image data request signal (VSYNC signal) to the controller and, at the same time, begins to expose the drum to the LED array light.
Page 185: Paper Output
Elevator sensor, EPS4 Elevator sensor, EPS3 Cutter Paper Output The paper output direction is controlled by the paper output gate and face gate. Fan-fold paper output In the fan-fold paper mode, the output paper can be oriented downward (toward the stacker) or in the horizontal direction.
Page 186 Cut-sheet paper output In the cut-sheet paper mode, the output paper can be oriented in the horizontal direction (toward the face-up tray) or upward (toward the face-down tray). When the MPU receives the print instruction (PRNT signal) from the 030 (or 040) controller and completes drum cleaning, the transfer unit goes up to its upper limit, and then the paper output gate moves down to open the cut-sheet paper output path.
Page 187: Paper Parking
Paper Parking The paper parking operation depends on whether cut-sheet or fan-fold paper is being printed. For cut-sheet paper, paper parking occurs when the last-printed sheet is output in the cut-sheet mode and no more paper remains in the transport path. In the fan-fold paper mode, however, the paper is transported with printed and unprinted pages joined together.
Page 188: Drive System Descriptions
Drive System Descriptions The printer drive system is shown in the following illustration. Cut sheet paper Cut sheet paper feeder unit (optional) Developing output unit (optional) Unit Fuser unit Main body Transfer conveyer unit (l) Drum motor (DRM) (9) Tractor motor (TRM) (2) Magroll motor (MRM) (10) Cutter motor (CMT) (3) Sleeve motor (SLM)
Page 189: Drum Drive
Drum Drive The photoreceptor drum is driven by the drum motor, which also drives the drum cleaner conductive brush and recovery roller assembly. Drum Cleaning unit Pre-drum roller Drum motor Principles of Operation 5–29...
Page 190: Developing Roller Drive
Developing Roller Drive The developing roller consists of the inner-pole magnet and sleeve. The inner-pole magnet is driven by the magroll motor, whereas the sleeve is driven by the sleeve motor. The magroll motor also drives the agitation roller via the inner-pole magnet. The toner supply clutch is activated to drive the toner supply roller as well as the inner-pole magnet and agitation roller when the toner density sensor detects a low toner density, or when the controller asserts an engine operation request command for...
Page 191: Main Unit Feed Roller Drive
Main Unit Feed Roller Drive The main unit feed roller is driven by the main unit feed motor, which also drives the scuff and paper output rollers. Paper Output Roller Scuff Roller Assembly Intermediate Roller Main Body Feed Roller Entry Roller Paper Output Roller Main Body Feed Motor...
Page 192: Gate Drive
Gate Drive The two paper output path gates are driven by their respective solenoid coils. Face Gate Paper Output Roller Paper Output Gate Face Gate Solenoid Paper Output Gate Solenoid 5–32 Principles of Operation...
Page 193: Transfer Unit Drive
Transfer Unit Drive The transfer unit moves up and down when the cam installed over the transfer elevator motor shaft rotates. Transfer Elevator Motor Transfer Unit Principles of Operation 5–33...
Page 194: Tractor Drive
Tractor Drive The tractor is driven by the tractor motor. The belts are critical, for timing. Be sure to mark the pulleys for future realignment. Tractor You may need to rotate this pulley 1 to 4 full turns. Tractor Motor Ratio = 4:1 Pulley C Belt A...
Page 195: Perforation Cutter Drive
Perforation Cutter Drive The perforation cutter is driven by the cutter motor. When the cutter operates, the cutter solenoid drives the paper retainer so that the paper retainer and scuff roller assembly press the paper at locations just before and after the cutting position. This paper pressure operation is performed to assure that the paper is cut when the cutter (disc) is pressed against the paper perforation section from below.
Page 196: Separation Claw Drive
Separation Claw Drive The separation claws are employed to mechanically remove the cut-sheet paper leading from the drum, because the cut-sheet paper may not separate from the drum when it comes out of the transfer/separation section. These claws are driven by the separation claw solenoid.
Page 197: Cut-Sheet Paper Feed Section Drive
Cut-sheet Paper Feed Section Drive The cut-sheet paper supply and feed rollers in the cut-sheet feed section are driven by the cut-sheet paper pickup motor and feed motor, respectively. Supply Roller Cut-Sheet Paper Pickup Motor Cut-Sheet Feed Roller Cut-Sheet Paper Feed Motor Principles of Operation 5–37...
Page 198: Control System Descriptions
Control System Descriptions The printer sensors are shown in the following illustration. Fuser unit (l) Paper near-end sensor (PNES) (15) Pickup motor encoder (PME) (2) Paper backward-feed sensor (PBFS) (16) Cut-sheet paper feed motor encoder (FME) (3) Paper output sensor 3 (EPS3) (17) Drum surface potential sensor (DSPS) (4) Elevator internal paper intermediate sensor (EPS4) (18) Toner density sensor (TDS)
Page 199: Paper Transport System Monitoring
Paper Transport System Monitoring The paper transport system is monitored by the following sensors. (For the paper size sensors and cassette paper sensor, refer to “Paper Detection” on page 5–20.) Cut-sheet transfer sensor (CWD) Cutter All the above sensors consist of a light emitter and receptor. The state of the sensor is determined by whether the receptor detects the light from the emitter.
Page 200 Paper near-end sensor This is a simple sensor consisting of a light emitter and receptor. It determines paper presence depending on whether the light path between the light emitter and receptor is blocked. Light Paper Misc. sensors The following sensors determine paper presence depending on whether the claws in the transport path are depressed: Paper output sensors 1 and 2 (EPS1, EPS2) Paper output sensor 3 (EPS3)
Page 201 Paper output sensor 0 This sensor consists of a slotted disc which is positioned between a light emitter and a light receptor. When the paper leading edge arrives at the sensor section, causing the disc to rotate, the light passing through the regularly spaced slots generates pulses at fixed intervals.
Page 202: Motor Rotation Control
Motor Rotation Control The following motors are employed. Optional motors are marked with an asterisk (*). Name Type Items Driven Drum motor DC motor Photoreceptor drum and drum cleaner Main unit feed motor output rollers DC motor Main unit feed, scuff, and paper output rollers Tractor motor DC motor...
Page 203 Misc. motors Each of the following motors is provided with a rotating speed sensing encoder (which generates a pulse train in accordance with the speed of a slotted disc rotating between a light emitter and a light receptor): Drum motor Main unit feed motor Cut-sheet paper pickup motor Cut-sheet paper feed motor...
Page 204 Tractor motor Since this motor moves the fan-fold paper forward and backward to determine the print position, it is necessary to control not only its rotating speed but also its rotation direction and amount. Therefore, the encoder for this motor has three sensing elements (consisting of a light emitter and receptor) as shown below.
Page 205 Four hundred pulses are generated during one encoder revolution for phases A and B (the interval between two neighboring broken lines shown above corresponds to one pulse) or 1 for phase Z. One encoder revolution is equivalent to 1/2-inch paper transport.
Page 206 Transfer elevator motor This is a 2-phase 4-pole stepper motor. Its permanent magnet rotor rotates when pulse signals, which are 90 out of phase, are applied to four electromagnets as shown below. (One pulse provides a step angle of 1.8 .) The transfer unit moves up or down when the shaft (cam shaft) of this motor rotates 180 (equivalent to 100 pulses) in the normal or reverse direction.
Page 207 When the transfer elevator motor forward rotation instruction pulse is fed while the transfer unit is in the lower position, the motor rotates so that the transfer unit is lifted by cam action. When the transparent vinyl chloride cylinder installed over the cam shaft rotates, and the tape on the cylinder surface blocks the light path between the light emitter and receptor of the transfer unit upper-limit sensor (TUUL), the motor stops.
Page 208 Perforation cutter motor As shown below, the perforation cutter is secured to the belt which runs between the front and rear sides of the printer. When the cutter motor rotates this belt, the cutter reciprocates. Perforation Cutter Belt Cutter Sensor 1 (CPS1) Cutter Sensor 0 (CPS0) Perforation Cutter Motor When the High level cutter motor signal (start instruction) and High level cutter...
Page 209: Drum Surface Potential Control
Drum Surface Potential Control To assure that the main charger produces a constant potential on the drum surface, the printer measures the drum surface potential between the photoconduction and developing sections. The printer controls the current flow to the main charger in accordance with the difference between the measured drum surface potential and the target potential value stored in the EEPROM of the CPU.
Page 210: Toner Density Control
Toner Density Control When the density of the toner in the developing unit agitation chamber is lowered, the proportion of the carrier in the developer relatively increases, varying the overall magnetic permeability of the developer. The printer checks for magnetic permeability changes to detect a toner density decrease.
Page 211 The toner density monitoring interval is determined by the developer toner density monitoring interval setup command from the controller. The interval setting is expressed by the full dot count (the number of LED dots illuminated between successive density detection operations) and in the range from 0 through 250. Further, while the printer is in the off-line idling state, a one-second toner supply operation can be manually executed using the controller’s engine operation request command for toner supply.
Page 212: Remaining Toner Level Monitoring
Remaining Toner Level Monitoring The toner empty sensors piezoelectric oscillator is embedded in the side of the developing unit toner hopper. While toner particles are in contact with the detection surface, this oscillator does not vibrate. However, if nothing is in contact with the detection surface due to toner level decrease in the hopper, the oscillator begins to vibrate, causing the printer to sense that the remaining toner level is too low.
Page 213: Waste Toner Monitoring
Waste Toner Monitoring The waste toner bottle full sensor, which consists of a light emitter and receptor, is attached to the waste toner recovery unit. When waste toner within the waste toner bottle blocks off the sensor light path, the waste toner bottle full signal (WTBF1) is asserted.
Page 214: Head Temperature Monitoring
Head Temperature Monitoring The printer uses a thermistor (HTS) to monitor the LED head temperature to avoid excessive printhead temperature during printing, When the LED head temperature rises to 45 C, the printer considers it an error, stops printing operations, cools the LED head with a heat pipe and a head cooling fan, waits until the LED temperature falls below 45 C, and goes into the on-line idling state to become ready to resume printing.
Page 215: Fuser Temperature Monitoring
Fuser Temperature Monitoring The fuser temperature also rises considerably when the xenon flash lamp is activated. Therefore, the lamp thermistor (LTS) is employed for fuser temperature monitoring purposes. When a temperature of 80 C or higher is detected by the thermistor, the printer stops printing operations and cools the fuser with the lamp cooling blower and fuser reflector plate cooling fan (FCF).
Page 216: Developing Bias Adjustment
Developing Bias Adjustment The developing bias to be applied to the developing roller can be adjusted by varying the DC component with the developing bias potential setup command from the controller. Controller Control panel 5–56 Principles of Operation...
Page 217: Operational Sequences
Operational Sequences Upon power ON, the printer performs the following operations. Power ON MPU Initialization Controller Initialization Reset Command Sent Mechanical Initialization Error Found Fault State (Off Line) Self-diagnostic Check No Error Found Idling State (On Line) Engine Operation Request Page Received Command Operation Printing State...
Page 218: Electronics Initialization
Electronics Initialization EPRDY signal This signal is asserted by the print engine to inform the controller that the engine is ready for communication. When this signal goes true, the controller may poll the engine status by sending the “Basic Read Status” command. SYNC signal When power is turned on, the engine asserts the SYNC signal (raster sync) at fixed intervals (937.5 µsec for 240 dpi, 750 µsec for 300 dpi, or 562.5 µsec for 400 dpi) in...
Page 219 Software/controller initialization While the engine is performing mechanical initialization, the software will read in the fonts, configuration, etc. In addition, it will periodically (once per second) send the “Read Status” command to the engine to read back any errors within the engine. Switch to online If no errors are reported while reading the fonts, the printer will go online.
Page 220: Mechanical Initialization
Mechanical Initialization Start conditions Mechanical initialization starts when either of the following situations occurs: The mechanical initialization routine is called by the MPU initialization routine. The controller asserts the engine operation request command for a reset (mechanical initialization). Note that the engine operation request command for a reset is asserted when the printer switches from the off-line idling state to the on-line idling state.
Page 221 e. When the drum has made 10 revolutions, the discharge lamp light intensity lowers and the main charger and developing bias turn OFF to stop the magroll and sleeve motors. The pre-charger and cleaning bias simultaneously turn OFF when the drum makes another two revolutions.
Page 222 When fan-fold paper remains: The time is 18.980 msec if mechanical initialization is executed when a reset is requested by an engine operation request command from the controller. 5–62 Principles of Operation...
Page 223 Drum cleaning timing diagram: When no fan-fold paper remains: 1, 2 The drum cleaning timing diagram is the same as for cases where the fan-fold paper remains. The time is 18.980 msec if mechanical initialization is executed when a reset is requested by an engine operation request command from the controller.
Page 224: Printing Operations
Printing Operations Start conditions Printing starts when the controller asserts the PRNT (print) signal while the printer is in the on-line idling state. Description of operations The printing operations for the fan-fold paper are different from those for the cut-sheet paper. The following pages describe the printing operations for two such different types of paper along with their timing diagrams.
Page 225 e. When the drum has made two revolutions, the discharge lamp light intensity drops. Cleaning terminates when the drum makes another revolution. 2. Paper loading. The tractor starts running to load the paper in such a manner that the paper leading end is positioned 1/2 inch before the transfer point.
Page 226 8. LSCA (page last raster) signal assertion. When the last raster of each page begins to be scanned in the fan-fold paper mode, the LSCA signal is asserted to inform the controller of the scanning of the last raster. At this time, checkout is performed to see whether the PRNT signal is asserted by the controller.
Page 227 15. Tractor reversal. When the paper is cut, the tractor reverses to return the leading edge of unprinted pages to the parking position which is immediately in front of the paper backward-feed sensor. 16. Drum cleaning (post-printing). In this step, the following routine is executed. a.
Page 228 5–68 Principles of Operation...
Page 229 Pre-printing drum cleaning: Post-printing drum cleaning: Principles of Operation 5–69...
Page 230 Cut-sheet paper printing (optional) 1. Drum cleaning (pre-printing). The same operations are performed as stated under fan-fold paper printing. 2. Transfer unit ascent. When pre-printing drum cleaning is completed in the cut-sheet paper mode, the transfer unit ascends. 3. Cut-sheet paper output path opening. The paper output gate solenoid moves downward to open the cut-sheet paper output path.
Page 231 6. LED exposure. When the controller receives the VSYNC signal, it waits until the printer asserts the page leading-edge margin SYNC (raster sync) signal, and then asserts the video signal acquisition VGATE (video gate) signal and VDO (video) signal. The VGATE signal is successively asserted for individual horizontal scan periods.
Page 232 12. LED exposure stopped. When VSYNC signal assertion is terminated, the VDO and VGATE signals are no longer fed. Therefore, LED exposure also terminates. 13. Transfer/separation charger OFF; separation claw drive deactivation. The separation claw drive system stops when the leading edge of the last page passes through.
Page 233 Principles of Operation 5–73...
Page 234: Command Operations
Command Operations The engine performs the indicated operations upon receiving the following engine operation request commands from the controller. Auto-load fan-fold paper 1. Opens the paper output path. Opens the face gate (opens the transport path to the face-up paper output tray), and controls the paper output gate to the condition memorized in the fixed memory.
Page 235 3. Activates the jam detecting task. 4. Ejects the unfixed portion of the remaining paper. Activates the tractor motor, and transports the perforation that was at the transfer point to the cutter position. At this time, the flash lamp is turned on and off with the tractor motor activation and deactivation, to fix the unfixed portion.
Page 236 Park fan-fold paper 1. Checks whether or not there is remaining paper. Activates the tractor motor, monitors the sensor output, and checks whether or not there is any paper remaining in the transport pathway. If there is paper remaining, executes steps 2 through 9 of the preceding topic, “Eject fan-fold paper.”...
Page 237 4. Turns off the transport unit. Stops the main unit motor and vacuum fan. 5. Transfers to online idling state. NOTE: Commands to request this operation cannot be received unless the paper back feed sensor has detected paper. Insert page break on fan-fold paper 1.
Page 238 5–78 Principles of Operation...
Page 239 Electrical and Wire Data Chapter Contents System Configuration ..........6–2 Interconnect diagram .
Page 240: Host Interface
System Configuration The printer system electronics are configured as shown below. The interconnection diagram on page 6–3 shows the printer’s electrical interconnections in block diagram form. Use this diagram as a troubleshooting aid. Cut Sheet Paper Stacker Paper stacker Feeder Unit (Optional) (Optional) (optional)
Page 241: Interconnect Diagram
Interconnect Diagram Electrical and Wire Data 6–3...
Page 242 Electrical and Wire Data 6–4...
Page 243: Sensors/Actuators Connected To Mpu Board
Sensors / Actuators connected to MPU board Flash (Xenon) lamp (TRG) Limit switch to check that the path to the face–down tray is open. Limit switch to check that the scuff roller is holding paper. Electrical and Wire Data 6–5...
Page 244: Sensors/Actuators Connected To I/O Board
Sensors / Actuators connected to I/O board Pre–heat (halogen) lamp (PHL) 6–6 Electrical and Wire Data...
Page 245 Lead switch to check that the front cover is closed. Limit switch to check that the drum cleaner unit and waste toner bottle are well set. Electrical and Wire Data 6–7...
Page 246: Input/Output Signals
Input / Output Signals The following pages illustrate the signals connected to the MPU board, I/O board, and Controller board. 6–8 Electrical and Wire Data...
Page 247 MPU Board Signals Electrical and Wire Data 6–9...
Page 248 I/O Board Signals 6–10 Electrical and Wire Data...
Page 249 Controller Board Signals Electrical and Wire Data 6–11...
Page 250: Unit Interface
Unit Interface The interface between the I/O board and the MPU board is described below. I/O board Interface circuit Data is sent and received between this board and the MPU board by a synchronous serial transmission method, through the differential input / output RS–422 interface circuit, based on the 12.288MHz clock signal created by the system clock on the MPU board.
Page 251 Interface signals These are the interface signals that are transmitted (viewed from the MPU board side): Signal MPU board I/O board Clock (CLK) Received Data (RXD) Transmitted Data (TXD) Interrupt (INT) Reset (RES) Signal pin assignments The signals above are assigned to the MPU board connecter (CN3) and I/O board connecter (CN32) pins, as follows: Pin No.
Page 252: Led Array Unit
LED Array Unit Connection This unit is connected to the MPU board head driver and the DC Power Supply board, as shown in following diagram. DC Power Supply Interface signals The following signals are sent and received between the head driver and LED array unit.
Page 253 Clock This signal clocks in data. Data 1–4 This signal transmits data to control illumination of the various LED chips. The signal is asserted for illumination, and negated for no illumination. The print head of this machine is composed of 4 LED arrays. Data 1–4 are serial signals to transmit data concerning illumination of the LED chips comprising these LED arrays.
Page 254 For 240DPI (total number of emitters 3520): Signal Number of dots Data 1 896 dots Data 2 896 dots Data 3 896 dots Data 4 832 dots Load The load signal stores shift register data that is inside LED array unit in a latch register.
Page 255 Interface circuit The interface circuit is for transmission and reception of signals CLOCK, DATA 1–4, LOAD, and *STB1–2. An RS–422 interface circuit is used, the same as the interface between the MPU board and I/O board. Signal pin assignments Interface signals are assigned in the following manner to MPU board connecter (CN4) and I/O board connecter (CN1) pins.
Page 256 The following signals are assigned to the connecters (CN2, CN3) of the LED array unit (DC Power Supply). CN2 pin assignment Pin No. Signal +5V Head +5V Head +5V Head CN3 pin assignment Pin No. Signal +5V Head +5V Head +5V Head 6–18 Electrical and Wire Data...
Page 257: Flash Power Supply
Flash Power Supply Connection This unit is connected with the MPU board and DC Power Supply as shown in the following diagram. DC Power Supply Interface signals The following signals are sent and received between the MPU board and the flash power supply.
Page 258 Charge This signal charges the power unit for the flash. Charging begins when this signal is asserted, and ends when negated. Flash This signal lights the flash lamp. The flash lamp lights when this signal is asserted. The relationship between the charge signal, flash signal, and charge voltage is as follows: Flash duration (f=5.4Hz) Charge duration(175ms min.)
Page 259 Alarm This signal indicates that an abnormality has occurred. When an abnormality occurs, the voltage between the collector and emitter of the interface circuit transistor becomes “H.” Abnormalities that cause the alarm signal: Abnormality in charge voltage Abnormality in temperature/temperature of resistor for discharge Flash error Charge time late Charge status...
Page 260 Interface circuits The following circuits are used for transmitting and receiving control signals (*CHON, TRG, *RESET) and alarm signals (ALARM, *CHOK). Control signal Alarm signal 6–22 Electrical and Wire Data...
Page 261 Signal pin assignments Interface signals are assigned to the MPU board connecter (CN10) and flash power supply interface connector pins. Pin No. Signal *CHON *RESET ALARM *CHOK +24V NC = no connection The following signals from the DC Power Supply are used to drive the flash power supply (see the illustration on page 10–87 in Chapter 10, “Replacement Procedures”).
Page 262: Developing Unit
Developing Unit Connection This unit is connected with the I/O board and high–voltage power supply unit as shown in the following diagram. Interface signals The following 9 types of signals are sent and received between the I/O board or high–voltage power supply unit and developing unit. Signal I/O board Developing unit...
Page 263 Toner supply roller drive (TSMO) This signal controls the engagement/release of the clutch which drives the toner supply roller. Toner density insufficient (TDSD) This is a density digital output signal from the toner density signal, indicating that the toner density has dropped below the level set. Density analog output (TDSI) This is a density analog output signal from the toner density sensor.
Page 264 Interface circuits The developing unit has 2 sensors (toner density sensor and toner empty sensor), and the toner supply clutch. AC and DC bias voltages are applied to the developing roller. Toner density sensor circuit 5.1K The detection concentration of this sensor is set at 11% in the following circuit: R217 1/4W VR11...
Page 265 Toner empty sensor circuit This sensor directly outputs the oscillation output of the piezoelectric vibrator element, and determines whether or not toner exists by its P–P output voltage. However, as this output voltage cannot be directly put into the logic circuit, it is converted into a signal level with the following rectification circuit and comparator.
Page 266 Toner supply clutch circuit The toner supply clutch is driven by the following circuit, based on the output signal of the toner density sensor (TDSD), whose input is the TSM signal created by the gate array. Signal pin assignments Interface signals are assigned to the developing unit and I/O board connectors (CN26) pins.
Page 267: High-Voltage Power Supply Unit
High–voltage Power Supply Unit Connection This unit is connected with the I/O board, the main power supply, and the various units which require high voltage, as shown in the following diagram. Electrical and Wire Data 6–29...
Page 268 Interface signals The following types of signals are sent and received between the I/O board and the High–voltage power supply unit. Signal High–voltage power supply Main charger remote ON/OFF (+HV1 REM) Main charger current control (+HV1 CONT) Pre–charger remote ON/OFF (+HV2 REM) Transfer charger remote ON/OFF (–HV REM) Separator charger remote ON/OFF (HV3 REM) Cleaning bias remote ON/OFF (–V REM)
Page 269 Separator charger remote ON/OFF This is the signal to turn the voltage (constant voltage /DC, AC constituent superimposed folding) sent to the separator charger on or off. The output value of this is variable between +200–500V (DC constituent), 10–12KVPP 500Hz (AC constituent) by variable resistor (B type).
Page 270 Interface circuit The remote ON/OFF signals, control signals, and alarm above are sent and received through the following circuit. Remote ON/OFF circuit The IC7541P output transistor turns on when the input to the NAND circuit goes low, outputing an on–signal to the high–voltage power supply unit. 6–32 Electrical and Wire Data...
Page 271 Control circuit 8–bit control data is converted to analog, amplified to 0–+12V by the operational amplifier, and output. Then the DC constituent of the main charger current and developing bias voltage are within the range of output value, and are controlled according to this voltage.
Page 272 Alarm circuit Because the alarm signal from the high–voltage power supply unit is open collector output, it is pulled up to +5V by 4.7 KΩ resistor. Signal pin assignments The interface signals are assigned to the I/O board connecter (CN23) and interface connecter pins.
Page 273: Explanation Of Circuits According To Function
Explanation of Circuits According to Function The following pages provide an introduction to the structure of the main electrical circuits of this printer. Drum Surface Potential Control Circuit The drum surface potential is picked up as an alternating current approximating 640Hz, by interrupting lines of electrical force flowing into a receiving terminal within the shielded case of the drum surface potential sensor, with a metal tuning fork.
Page 274 6–36 Electrical and Wire Data...
Page 275: Developing Bias Control Circuit
Developing Bias Control Circuit Bias voltage that is printed onto the developing roll is controlled by the target data (8–bit data) set by the developing bias potential setting command from the controller. When drum cleaning begins when initializing the machine or beginning printing, 8–bit data indicating target potential is read in from MPU board data memory to the CPU, and is sent to the I/O board developing bias control circuit.
Page 276 6–38 Electrical and Wire Data...
Page 277: Toner Density Control Circuit
Toner Density Control Circuit Toner density is controlled by the output voltage from the toner density sensor. When toner density in the vicinity of the toner density sensor drops below 11%, the output signal (TDSO) from the toner density sensor becomes “L”, the toner supply roller drive signal (TSMO) is output from the I/O board gate array, and the toner supply clutch is engaged for 1 second.
Page 278 6–40 Electrical and Wire Data...
Page 279: Drum Motor Control Circuit
Drum Motor Control Circuit The drum motor drives the photographic drum that is central in the printing cycle and the pre–drum roller that controls the transfer speed of cut–sheet. Therefore, stable rotation is required of the motor. A rotary encoder is set on the rotating axis. The output pulses and standard pulses (equivalent to 878.90625 rpm motor rotation) created by a crystal oscillator via a frequency divider circuit are compared in a PLL (phase locked loop) circuit, and the input voltage to the motor is controlled to where...
Page 280 DRMP: Positive side of drum motor drive power supply DRMN: Negative side of drum motor drive power supply DME: Drum motor encoder output signal DMON1: Drum motor drive signal DMARM0: Alarm signal to indicate rotation abnormality of drum motor. 6–42 Electrical and Wire Data...
Page 281: Tractor Motor Control Circuit
Tractor Motor Control Circuit The tractor motor controls the transfer of fan–fold paper and has the role of determining print accuracy in fan–fold mode. Therefore, the action of this motor is constantly controlled by the CPU along with the printing process, and is controlled by 4–bit data created in the following digital control unit.
Page 282 1/800 inch transfer distance of paper, the paper transfer speed for constant speed is as follows: (1 inch = to be 25.4mm) Further, since this timer interruption cycle is equivalent to 1/2 of the raster cycle for 400DPI (562.5µsec), in the case of 400DPI, the paper will advance 1/400 inch per 1 raster cycle.
Page 283 Data output from the digital control unit is equivalent to 1V per 1 bit, and at the D/A converter, –8–+8V are output according to inputs of 0000–1111. (Note that 0000 is 0V). This is the voltage calculated from pulse string comparison, but different outputs are required for positive rotation, negative rotation, and detent (keeping position).
Page 284: Main Unit Feed Motor Control Circuit
Main Unit Feed Motor Control Circuit The main unit feed motor is the motor that drives the transmission shaft that rotates the transfer belt. It has the role of pulling the paper that is sent at the speed controlled by the tractor motor or drum motor. Therefore, in cut–sheet mode, the rotation is 878.90625 rpm, the same as the drum motor driving the pre–drum roller.
Page 285 FEEDM: Drive signal of the main unit feed motor. FEEDMA: Alarm to indicate abnormality in motor revolution. FMEOUT: Output signal of the selected encoder. Electrical and Wire Data 6–47...
Page 286: Transfer Elevator Motor Control Circuit
Transfer Elevator Motor Control Circuit This motor is controlled by the following circuit: 6–48 Electrical and Wire Data...
Page 287 The TPOS signal validates drive pulses of both the current switch–over signal (PMDRV) and the various motor phases, along with turning the power supply relay The current switch–over unit switches over the comparator voltage of the current detection voltage V8 by this PMDRV signal, between motor drive and detent conditions, as follows: when in motor drive: 0.99v...
Page 288 TPFA10 TPFB10 TPFA11 TPFB11 Further, the transfer elevator motor is controlled with the transfer unit always in the highest position as standard. When initializing the machine, rotate this motor until the upper limit sensor is off (highest position is detected), confirm the standard position, output 100 pulses again, and control the transfer unit to the lowest limit.
Page 289: Cutter Motor Control Circuit
Cutter Motor Control Circuit The cutter motor is controlled by an H bridge structure circuit using 2 elements each of NPN and PNP transistors. ON/OFF=1, F/R (forward / reverse) =1, and if CPSO=1 at this time, Q1 and Q4 turn on, and the motor rotates forward.
Page 290: Adjustments
Adjustments Adjusting Power Supply Unit For Flash The flash power supply unit is adjusted as follows (refer to pages 10–85 through 10–91 in Chapter 10, “Replacement Procedures,” for additional information). CAUTION If you use the engine checker when adjusting the flash power supply unit, the blower must be on.
Page 291 Troubleshooting Chapter Contents Overview ............7–3 Jam Detection Sensors .
Page 292: Covers
01 – Front Cover Open ..........7–31 02 –...
Page 293: Chapter Contents
Overview This chapter contains the printer main component locations, a system block diagram, the Printer Control menu, and procedures for dealing with paper jams and printer errors. The errors are discussed in numerical sequence by error code, as listed in the chapter contents.
Page 294: Emulations
Printer Components The main components of the printer are listed below, and are illustrated on the following pages. Photoreceptor drum Exposure section LED for discharge Main charger LED array Developing section Developing unit Transfer/separation section Transfer charger Separation charger Fuser section Preheater lamp (halogen lamp) Fixing flash lamp (xenon lamp) Cleaning section...
Page 295: External Views
External Views Top cover Facedown tray Rear cover Faceup tray Front upper cover Power stacker (optional) Rear cover Top cover Upper & Lower Cassettes (optional) Floppy Disk Drives Control panel Host I/O connections Fan–fold paper Troubleshooting 7–5...
Page 296: Front View With Cover Removed
Front View with Cover Removed Main charger Lamp for discharger Fuser unit Toner cartridge Cleaning unit Transport unit Developing unit Cut sheet paper output unit (option- Cut sheet pa- per feeder unit (optional) Operation panel (optional) Waste toner recovery unit Smoke filter box Power supply for flash lamp 7–6...
Page 297: Front View With Cover Removed
Front View with Cover Removed (Detail) Fuser Unit Waste Toner Box Transfer/Separation Charger Transfer Unit Troubleshooting 7–7...
Page 298: I/O Board
Rear View with Cover Removed Head blower fan Head cooling fan Sleeve motor Magroll motor Fuser reflector plate cooling fan Main unit feed motor board MPU board Tractor motor DC Power Supply Lamp cooling blower Drum motor Smoke filter blower Transfer elevator motor 7–8...
Page 299: Component Unit Locations
Component Unit Locations Top Cover LED Array Cut–Sheet Transfer Unit Paper Feeder Unit Cut Sheet Developer Unit Output Unit (optional) Main Charger LED for Discharge Photo Receptor Drum Cleaning Unit Transfer Charger Pre–Charger Fuser Unit Troubleshooting 7–9...
Page 300: System Block Diagram
System Block Diagram Host Computer Controller Control Panel Print Engine Cut Sheet Unit (Optional) Power Stacker Unit (Optional) 7–10 Troubleshooting...
Page 301: Printer Control Menu
Printer Control Menu Figure 7–1 is an overview of the printer configuration menu, showing the Printer Control options. Printer Control values are set at the factory and are saved in the printer engine. With the exception of Reset Toner Full, these options are to be used by service personnel only.
Page 302: Menu Diagram
Press ONLINE at any time to exit locate the serial number of the printer and configuration (will save changes until printer is turned off). contact Printronix for the factory–set value. * = Factory Default Figure 7–2. Printer Control Menu 7–12...
Page 303: Surface Volts
Surface Volts This option adjusts the drum surface voltage sensor. The normal setting is approximately 580 (the default). The allowable range is 500 through 700, in increments of 4 volts. Bias Volts This option adjusts the developer bias. Normal adjustment is as needed. The default is 300 volts (or 340 for the new style of corona power supply).
Page 304: Fan-Fold Paper Jams
Fan–fold Paper Jams Paper jam near the tractor 1. Raise the tractor gates. 2. Pull out the jammed fan–fold paper. If the end of the paper is crumpled, tear it away from the perforation. 3. Reload the paper. The first fold of the paper should be facing towards the printer, otherwise, a paper jam could occur during printing (see the following illustration).
Page 305: Front Cover
Paper jam near the paper output section 1. When paper motion stops, wait 15 seconds and open the front cover. Open/Close Button Front Cover 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 306 3. Remove three screws on the upper inner cover. Then remove the cover. Inner cover (upper) Screws (3) 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.
Page 307 CAUTION To avoid damaging the printer or causing false paper jams, the transport lever must be in the complete down position before opening the transport unit. 5. Lower the transport unit by turning the green lever on the transport unit to the left.
Page 308 8. Separate the fan–fold paper at the perforations on both the paper input and the output sections. Then remove the jammed paper by pulling it out. When removing the paper from the paper input section, raise the tractor gates first, then pull out the jammed paper. Input Section Tractor Gate Output Section...
Page 309: Cut-Sheet Paper Jams
Cut–sheet Paper Jams Paper jam at the back of the paper cassette 1. Pull out the paper cassette. 2. Remove any jammed paper from the back of the cassette tray. 3. Pull the green lever up to lower the paper guide. Remove any jammed paper, and return the green lever to its original position.
Page 310: Top Cover
4. 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 7–20 Troubleshooting...
Page 311: Waste Toner Recovery Unit
Paper jam in the transport input section 1. When paper motion stops, wait 15 seconds and open the front cover. Open/Close Button Front cover 2. Open the waste toner recovery unit cover, and pull the unit toward you. Opening Lever Waste Toner Recovery Unit Troubleshooting...
Page 312 3. To lower the transport route surface, turn the green transport unit lever to the left. CAUTION To avoid damaging the printer or causing false paper jams, the transport lever must be in the complete down position before opening or closing the transport unit.
Page 313: Paper Jam In The Transport Output Section
Paper jam in the transport output section 1. When paper motion stops, wait 15 seconds and open the front cover. Open/close button Front cover 2. Pull the bottom lever up to raise the paper guide, and turn the green knob “B” counterclockwise.
Page 314: Paper Jam In The Face-Up Or Face-Down Paper Path
Paper jam in the face–up or face–down paper path 1. When paper motion stops, wait 15 seconds and open the front cover. Open/close button Front cover 2. Push the top and middle levers down. Pull the bottom lever up to raise the paper guide.
Page 315: Error Message Table
Error Message Table Table 7–1 lists errors by error code and shows which are operator–correctable, which require field service, and which require reprinting. Operator–correctable errors include paper jams, missing consumables, and power paper stacker problems. Errors requiring field service are printer failures that require the attention of service personnel.
Page 316 TABLE NOTES: For any error with Reprint on Fault enabled: If the printer stops while in the middle of printing a page, reloading the paper and reprinting are required. There may be other cases requiring reloading and reprinting; if so, a message will appear. It may be necessary to clear the paper path before reloading. For any error with Reprint on Fault disabled: If the printer stops while in the middle of printing a page, reloading the paper is required and pages are lost.
Page 317 Error Operator Field Service Reprint Code Error Message Correctable Required Required Paper Jam at Fuser (C) Paper Jam at Exit (D) Tractor Speed too High See Note 3 Tractor Speed too Low See Note 3 Paper Jam at Entrance (A) High Voltage Fail Drum Motor Fail Surface Voltage too High...
Page 318 Error Operator Field Service Reprint Code Error Message Correctable Required Required LED Fail Engine CPU Fail Engine CPU Fail Engine CPU Fail Engine CPU Fail Engine CPU Fail Engine CPU Fail Engine CPU Fail Engine CPU Fail Engine CPU Fail Engine CPU Fail Engine CPU Fail Engine CPU Fail...
Page 319 Error Operator Field Service Reprint Code Error Message Correctable Required Required Stacker Fail Stacker Interlock Fail Stacker Fail Stacker Full Stacker Not Ready Stacker Not Ready Stacker Fail Stacker Fail Stacker Fail Stacker Fail Cut–sheet Comm. Fail Cut–sheet Comm. Fail Cut–sheet Comm.
Page 320 Error Operator Field Service Reprint Code Error Message Correctable Required Required Engine CPU Fail Paper Jam at Entrance (A) Paper Jam at Entrance (A) 7–30 Troubleshooting...
Page 321: Front Cover Open
01 – Front Cover Open CHECKLIST: FRONT COVER FRONT COVER INTERLOCK SWITCH DC POWER SUPPLY BOARD 1. Ensure that the front cover is properly closed. If necessary, close the cover and press the CLEAR key to clear the fault. If the fault still exists, go to Step 2. 2.
Page 322: Paper Empty (Fan–Fold Paper): Upon Power–On
02 – Paper Empty (fan–fold paper): Upon Power–on CHECKLIST: PAPER NEAR–END SENSOR (PNES) GUIDE PNES SENSOR I/O BOARD NOTE: If the printer fails to report a paper–empty state, ensure that the PNES sensor is not bent and that the optical transmitter and receiver are in alignment.
Page 323: Paper Empty (Fan–Fold Paper): When Loading/Beginning Print
02–Paper Empty (fan–fold paper): When Loading/Beginning Print CHECKLIST: TRACTOR PAPER BACK FEED SENSOR (PBFS) I/O BOARD TRACTOR MOTOR 1. Ensure that the fan–fold paper is loaded properly on the tractors. 2. Check the PBFS (paper back feed sensor). a. Put the positive lead of the digital multimeter on pin 8 of CN34 on the I/O board, and the negative lead on the SG.
Page 324: Paper Jam At Drum (B)
03 – Paper Jam at Drum (B) CHECKLIST: TRANSPORT BELT EPS4 SENSOR (PAPER OUTPUT SENSOR 4) VACUUM FAN LAMP COOLING BLOWER (VEF1) DRUM MOTOR 1. Ensure that the transport belt activates during power–on. If it does not activate, see “09– Transport Motor Fail” on page 7–41. 2.
Page 325 4. Check the lamp cooling blower (VEF1). a. Check the ozone filter. If it is clogged, remove any blockage. b. Check the voltage: Put the positive lead of the digital multimeter on pin 3 of CN33 on the I/O board, and the negative lead on the SG. Normal voltage is about 5V after powering ON.
Page 326 04 – Paper Jam at Exit (D): Transport Section CHECKLIST: TRANSPORT BELT TRANSPORT PATH EPS0 SENSOR (OUTPUT PAPER SENSOR 0) 1. Remove the fuser. 2. Place the rotary switch on the MPU board in position “E”. 3. Ensure that the transport belt activates during power–on. If it does not, see “Transport Motor Fail”...
Page 327 05 – Paper Jam at Exit (D): Paper Output Section CHECKLIST: TRANSPORT PATH FACE GATE SOLENOID (FGSL) OUTPUT PAPER GATE SOLENOID (EGSL) OUTPUT PAPER SENSOR 1 (EPS1) OUTPUT PAPER SENSOR 2 (EPS2) 1. Ensure that the paper output transport path guide is closed. 2.
Page 328 5. Check the output paper sensor 2 (EPS2). a. Connect the positive lead of the digital multimeter on pin 2 of CN7 on the MPU board, and the negative lead on the SG. b. Push the EPS2 lever down and measure the voltage, which should be about c.
Page 329: Scuff Lever Open
07 – Scuff Lever Open (knob “C”) CHECKLIST: SCUFF ROLLER LEVER NIP SWITCH (NPSW) MPU BOARD 1. Ensure that the scuff roller lever is in the closed position, and that the paper is engaged between the rollers. 2. Check the nip switch (NPSW). a.
Page 330: Cut–Sheet Path Open
08 – Cut–sheet Path Open CHECKLIST: TRANSPORT PATH GUIDE TRANSPORT PATH GUIDE SWITCH (CW0) MPU BOARD 1. Ensure that the paper output transport path guide is closed. 2. Check the transport path guide switch (CW0). a. Disconnect CN7 on the MPU board. b.
Page 331: Transport Motor Fail (Complete Stop)
09 – Transport Motor Fail (complete stop) CHECKLIST: MAIN UNIT FEED MOTOR FUSE (F1) MPU BOARD CONTROL CIRCUIT 1. Ensure that the main unit feed motor operates during power–on. If the motor is operating properly, go to Step 2. Otherwise, go to “Speed Precision Abnormality”...
Page 332 Speed Precision Abnormality NOTE: Refer also to Chapter 9, “Board Adjustments.” 1. Check the main unit feed motor control circuit. a. With paper loaded, use the control panel to run printer test patterns (allowing the feed motor to operate in the low speed mode). The LED (LD1) on the MPU board should emit a steady light.
Page 333 4. If the main unit feed motor is overloaded, determine what is causing the overload. Otherwise, go to Step 5. NOTE: This procedure will cause paper jam errors, but it should not cause Error 09 –– Transport Motor Fail. a. Remove all three belts from the motor, and ensure that gears are moving freely.
Page 334: A – Cutter Fail (Front)
0A – Cutter Fail (front) / 0B – Cutter Fail (rear) CHECKLIST: FUSE (F2) CUTTER POSITION SENSOR 0 (CPS0) CUTTER POSITION SENSOR 1 (CPS1) MOTOR DRIVER MPU BOARD CUTTER MOTOR 1. Place the rotary switch in the “E” position on the MPU board. 2.
Page 335 5. Check the motor driver power. a. Remove CN1 on the MPU board. b. Put the positive lead of the digital multimeter on pin 5 of CN1, and the negative lead on the PG. c. Power ON the printer. d. Measure the voltage, which should be about 0V. e.
Page 336: C – Transfer Platform Fail (Upper)
0C – Transfer Platform Fail (upper) / 0D – (lower) CHECKLIST: TRANSFER ELEVATOR MOTOR FUSE (FU4) I/O BOARD TRANSFER UNIT TRANSFER ELEVATOR TRANSFER UNIT UPPER LEVEL SENSOR (TUUL) TRANSFER UNIT LOWER LEVEL SENSOR (TULL) 1. Place the rotary switch in the “E” position on the MPU board. 2.
Page 337 7. Check the transfer unit upper level sensor (TUUL). 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 CN28 on the I/O board, and the negative lead on the SG.
Page 338 c. With the transfer position lowered to the lower limit, measure the voltage; 0V is normal. d. Put the positive lead of the digital multimeter on pin 11 of CN28 on the I/O board, and the negative lead on the SG. e.
Page 339: Paper Jam At Drum (B)
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. 2. Ensure that the EPS3 lever is in the up position. 3.
Page 340: Paper Jam At Fuser (C)
12 – Paper Jam at Fuser (C) CHECKLIST: FUSER SECTION (EPS4) EPS4 (PAPER OUTPUT SENSOR 4) LEVER TRANSFER UNIT 1. If there is paper remaining in the fuser section (near sensor EPS4), remove it. 2. Ensure that the EPS4 lever is in the up position. 3.
Page 341: Paper Jam At Exit (D): Straight Output (Face–Up)
13 – Paper Jam at Exit (D) – Straight Output (face–up) CHECKLIST: PAPER OUTPUT SECTION (EPS1) EPS1 LEVER 1. If there is paper remaining in the paper output section (near sensor EPS1), remove it. 2. Ensure that the EPS1 lever is in the up position. 3.
Page 342: Paper Jam At Exit (D): Cut–Sheet Face–Down Output
13 – Paper Jam at Exit (D) – Cut–sheet Face–down Output CHECKLIST: PAPER OUTPUT SECTION (EPS2) EPS2 (PAPER OUTPUT SENSOR 2) LEVER 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.
Page 343: Tractor Speed Too High
14 – Tractor Speed Too High / 15 – Tractor Speed Too Low CHECKLIST: TRACTOR MOTOR FUSE (F2) I/O BOARD TRACTOR MOTOR ENCODER (TME) CONTROL CIRCUIT 1. Ensure that the tractor motor operates during power–on. If the motor is operating properly, go to Step 6.
Page 344 5. Check the tractor motor encoder (TME). Place the rotary switch in the “0” position on the MPU board, and perform the following steps. A Phase: a. Put the positive lead of the digital multimeter on TP4 on the I/O board, and the negative lead on the SG.
Page 345 e. Manually turn the tractor motor shaft in a reverse direction to apply the load. Adjust VR1 so the digital multimeter reads 200mV 20mV. g. Stop the tractor motor. Tractor motor adjustment (forward): a. Drive the tractor motor forward. b. Adjust VR2 so that LED3 and LED4 on the I/O board have the same brightness.
Page 346: Paper Jam At Entrance (A)
16 – Paper Jam at Entrance (A) CHECKLIST: PAPER BACK FEED SENSOR (PBFS) 1. Ensure that the paper back feed sensor (PBFS) is not blocked by paper, paper dust, etc. 2. Ensure that the paper is loaded correctly (not too far forward). 3.
Page 347: High Voltage Fail
17 – High Voltage Fail CHECKLIST: BACK BRACKET ON FUSER UNIT MECHANISM SETTINGS HIGH–VOLTAGE POWER SUPPLY DEVELOPING UNIT CHARGERS DRUM 1. Ensure that the back bracket on the fuser unit is not bent. Measure the resistance between the fuser unit and the transport unit near the belt; it should measure open.
Page 348 7. Determine if the transfer/separator charger is normal. The transfer/separator charger causes an Error 17 if the error does not occur during power–on, but does occur when printing starts and the transfer elevator motor operates. If the charger is not normal, check the transfer unit high–tension cable. 8.
Page 349: Drum Motor Fail (Complete Stop)
18 – Drum Motor Fail (complete stop) CHECKLIST: DRUM MOTOR FUSE (F3) I/O BOARD CONTROL CIRCUIT DRUM MOTOR ENCODER (DME) 1. Ensure that the drum motor operates during power–on. If the motor is operating properly, go to Step 2. Otherwise, go to “Speed Precision Abnormality”...
Page 350 Speed Precision Abnormality NOTE: Refer also to Chapter 9, “Board Adjustments.” 1. Check the main unit feed motor control circuit. a. During power–on, the LED (D2) on the I/O board should emit a steady light. b. If LD2 blinks or does not light at all, turn VR5 on the I/O board counterclockwise until LD2 emits a steady light.
Page 351 5. Check the I/O board. a. Remove the drive belt between the drum and the drum cleaner. b. Put the positive lead of the digital multimeter on TP9 (IC16/TC9142P–8) on the I/O board, and the negative lead on the SG. c.
Page 352: Surface Voltage Too High
19 – Surface Voltage Too High CHECKLIST: FUSER UNIT CONFIGURATION MENU I/O BOARD HIGH–VOLTAGE POWER SUPPLY DRUM SURFACE POTENTIAL SENSOR (DSPS) 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 353: A – Surface Voltage Too Low
1A – Surface Voltage Too Low CHECKLIST: FUSER UNIT CONFIGURATION MENU I/O BOARD HIGH–VOLTAGE POWER SUPPLY DRUM SURFACE POTENTIAL SENSOR (DSPS) DRUM 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 354 5. Check the drum surface potential sensor (DSPS) adjustment. Refer to Chapter 9, “Board Adjustments,” for the adjustment procedure. 6. Check the drum. Determine if it is worn or dirty. Also, run a print job and check the print quality. If the drum is not normal, replace the drum.
Page 355: B – Paper Jam At Entrance (A)
1B – Paper Jam at Entrance (A) CHECKLIST: TRACTOR MOTOR ENCODER (TME) I/O BOARD 1. Check the tractor motor encoder (TME). a. Put the positive lead of the digital multimeter on TP5 (Z phase) on the I/O board, and the negative lead on the SG. b.
Page 356: E – Fuser Supply Fail
1E – Fuser Supply Fail CHECKLIST: ALARM LED FUSER UNIT FLASH POWER SUPPLY FLASH VOLTAGE MPU BOARD 1. Ensure that the alarm display LED (“FLS”) for the flash power unit is illuminated. If it is not, go to Step 3. (See illustration on page 6–52.) 2.
Page 357 d. Turn the power ON in this condition. e. Measure the voltage, which should be about 0V. If voltage is normal and the flash power error still occurs, or if voltage is not normal, replace the MPU board after checking the harness. 7.
Page 358: F – Fuser Failure
1F – Fuser Failure CHECKLIST: FLASH POWER FLASH VOLTAGE MPU BOARD 1. Check the flash power connection. a. Put the positive lead of the digital multimeter on the AC IN L terminal of the flash power unit, and the negative lead on the AC IN N terminal. b.
Page 359 4. Check the flash power unit. a. Connect the jack to CN11 of the flash power unit. b. Put the positive lead of the digital multimeter on pin 3 of IC23 on the MPU board, and the negative lead on the SG. c.
Page 360: Fuser Lamp Overheat
20 – Fuser Lamp Overheat CHECKLIST: FUSER UNIT TEMPERATURE FUSE (LTF) I/O BOARD FUSER REFLECTOR COOLING FAN (FCF) LAMP THERMISTOR (LTS) 1. Check the I/O board. a. Put the positive lead of the digital multimeter on pin 2 of IC33 on the I/O board, and the negative lead on the SG.
Page 361 7. Check the I/O board. a. Remove J24 from CN24 on the I/O board. b. Put the positive lead of the digital multimeter on pin 11 of CN24, and the negative lead on the PG. c. Measure the voltage, which should be about 24V when the power is turned ON.
Page 362 9. Check the I/O board. a. Put the positive lead of the digital multimeter on pin 1 of IC33, and the negative lead on the SG. b. Measure the voltage when pins 1 and 2 of CN22 on the I/O board are open.
Page 363: No Cleaning Unit
26 – No Cleaning Unit CHECKLIST: CLEANING UNIT DRUM CLEANER SET SENSOR (DCS) I/O BOARD 1. Ensure that the cleaning unit is properly installed. 2. Check the drum cleaner set sensor. a. Remove connecting jack J21 from the I/O board CN21. b.
Page 364: Waste Toner Full
28 – Waste Toner Full CHECKLIST: WASTE TONER BOTTLE WASTE TONER BOTTLE FULL SENSOR (WTBF) 1. Determine if waste toner in the waste toner bottle is up to the full level. If full, replace the waste toner bottle. 2. Check the waste toner bottle full sensor (WTBF). a.
Page 365: No Waste Toner Box
29 – No Waste Toner Box CHECKLIST: WASTE TONER BOTTLE WASTE TONER BOTTLE SENSOR (WTBS) I/O BOARD 1. Ensure that the waste toner bottle is properly installed. 2. Check the waste toner bottle sensor (WTBS). a. Remove connecting jack J30 from I/O board CN30. b.
Page 366: Toner Cartridge
2A – Toner Empty CHECKLIST: DEVELOPING UNIT I/O BOARD TONER EMPTY SENSOR CIRCUIT The toner empty sensor signal indicates the empty condition. Specifically, the collector output of Q22 on the I/O board becomes 0V. NOTE: On Q22 of the I/O board, the collector is the center pin of the transistor. 1.
Page 367 4. Check the developing unit. a. Connect CN26 on the I/O board. b. Put the positive lead of the digital multimeter on collector Q22 on the I/O board, and the negative lead on the SG. c. Measure the voltage, which should be about 5V. If voltage is not normal, replace the developing unit (the toner empty sensor is defective).
Page 368: B – Toner Density Too High
2B – Toner Density Too High / 2C – Toner Density Too Low CHECKLIST: CONFIGURATION MENU I/O BOARD DEVELOPING UNIT TONER SUPPLY CLUTCH TONER DENSITY SENSOR 1. Verify the toner density setting in the configuration menu. Through the printer control panel, select the Printer Control menu, Toner option. Ensure that the toner density setting is “2”.
Page 369 3. Check the developing unit. a. Connect J26 to CN26 on the I/O board. b. Rotate VR11 completely clockwise, and verify that LED2 (green) is illuminated and LED1 (red) is not illuminated (off). c. Rotate VR11 until the voltage on test point TDSC becomes 5.50V. Verify that LED2 (green) is not illuminated (off) and LED1 (red) is illuminated.
Page 370: Led Head Overheat
32 – LED Head Overheat CHECKLIST: HEAD THERMAL SENSOR (HTS) I/O BOARD HEAD COOLING FAN (HCF) 1. Check the output of the HTS (head thermal sensor). a. Put the positive lead of the digital multimeter on pin 13 of IC33 on the I/O board, and the negative lead on the SG.
Page 371 5. Check the HTS (head thermal sensor). a. Allow the temperature of the LED to cool well (about 30 C). b. Put the positive lead of the digital multimeter on pin 10 of IC33 on the I/O board, and the negative lead on the SG. c.
Page 372 7–82 Troubleshooting...
Page 373 Engine Checker Chapter Contents Overview ............8–2 Connecting the Engine Checker .
Page 374: Overview
Overview The engine checker is a tool created to help troubleshoot the printer engine. It is used to test NVRAM, switches, sensors, and motors, and can run a set of basic functions. It should be used when making potentiometer adjustments (also referred to as “volume”...
Page 375: Connecting The Engine Checker
Connecting the Engine Checker The print engine is connected with the engine checker as shown below. Set the MPU board rotary switch at 1 (Japanese) or 2 (English) when using the engine checker. Be sure to power off the printer, connect the engine checker, and then power on the printer.
Page 376: Using The Control Panel
Using the Control Panel The engine checker control panel is equipped with a message display, indicators and keys, as shown in Figure 8–2. BASIC MENU DEVICE CHECK, VOLUME START STOP ENTER Figure 8–2. Engine Checker Control Panel Indicators Ready lamp – Indicates the engine checker is ready to operate. High-level lamp (green) –...
Page 377: Operation
Operation Power the printer on. The engine checker ready lamp lights and the following message appears on the control panel: BASIC MENU DEVICE CHECK, VOLUME The engine checker contains a two–line message display. The selected menu appears on line 1, and the sub–menu or device appears on line 2. When reading or driving a device, the device appears on line 1 and the status on line 2.
Page 378: Basic Menu
Basic Menu DEVICE CHECK VOLUME ADJUSTMENT Page 8–7 Page 8–17 OUTPUT INPUT SURFACE POTENTIAL SIGNAL SIGNAL ERASER LAMP DRUM MOTOR FEED MOTOR TRACTOR MOTOR TONER DENSITY MOTOR COUNTER TRANSPORT UNIT SOLENOID CLUTCH DRUM TRANS. CUTTER FAN BLOWER DEV. WASTE T. CLR. LAMP ALARM H.V.P.S.
Page 379: Device Check Menu
Device Check Menu The device check menu allows for the operation of motors, solenoids, fans, lamps, and the high voltage power supply. It reads sensors, encoders and input signals for the transport unit, drum transfer cutter, developer waste toner clear, alarm circuits, and switches.
Page 380 DEVICE CHECK OUTPUT INPUT SIGNAL SIGNAL MOTOR SOLENOID LAMP H.V.P.S. BLOWER COUNTER CLUTCH FEED MAGROLL DRUM SLEEVE CUTTER DRUM COUNTER MAGROLL MOTOR CUTTER MOTOR DRUM COUNTER DRUM MOTOR FEED MOTOR SLEEVE MOTOR Press START Press START Press START Press START Press START Press START MAGROLL MOTOR...
Page 381 DEVICE CHECK OUTPUT INPUT SIGNAL SIGNAL MOTOR SOLENOID LAMP H.V.P.S. BLOWER COUNTER CLUTCH CUTTER PAPER OUT GATE SEPARATION CLAW FACE GATE TONER SUPPLY PAPER OUPUT GATE TONER SUPPLY CLUTCH SEPARATION CLAW CUTTER SOLENOID FACE GATE SOLENOID SOLENOID Press START Press START Press START Press START Press START...
Page 382 DEVICE CHECK OUTPUT INPUT SIGNAL SIGNAL MOTOR SOLENOID LAMP H.V.P.S. BLOWER COUNTER CLUTCH HEAD BLOWER VACUUM FAN HEAD COOLING FUSER R. COOLING VACUUM FAN HEAD COOLING FAN HEAD BLOWER FAN FUSER COOLING FAN Press START Press START Press START Press START HEAD COOLING FAN HEAD BLOWER FAN VACUUM FAN...
Page 383 DEVICE CHECK OUTPUT INPUT SIGNAL SIGNAL MOTOR SOLENOID LAMP H.V.P.S. BLOWER COUNTER CLUTCH ERASER HIGH PRE–HEAT ERASER LIGHT FLASH PRE–HEAT LAMP ERASER LAMP LIGHT ERASER LAMP HIGH FLASH LAMP START S/W–7 FLASH Press START Press START Press START Press START ERASER LAMP LIGHT ERASER LAMP HIGH PRE–HEAT LAMP...
Page 384 DEVICE CHECK OUTPUT INPUT SIGNAL SIGNAL MOTOR SOLENOID LAMP H.V.P.S. BLOWER COUNTER CLUTCH TRNS CHGR SEP CHGR DEV BIAS CLNNG BIAS MAIN CHGR PRE CHGR SEPARATION MAIN CHARGER PRE CLEANING DEVELOPING TRANSFER CLEANING BIAS CHARGER CHARGER BIAS CHARGER Press START Press START Press START Press START...
Page 385: Selecting A Mode/Item/Device
Selecting a Mode/Item/Device 1. To select a mode, scroll through the menus using the key. When the target mode appears at the extreme left of the message display, press the key. Example: DEVICE CHECK OUTPUT SIGNAL INPUT 2. To select an item menu, scroll through menus until the target mode appears at the extreme left of the message display, and press the key.
Page 386: Reading Device Status (Input Device Check)
Reading Device Status (input device check) Use the engine checker to read the device status. For example, to read the status of the PBFS (Paper Back Feed Sensor), the menu path is BASIC MENU, DEVICE CHECK, INPUT SIGNAL, TRANSPORT UNIT, BACK FEED, BACK FEED SENSOR.
Page 387 The following is an example of driving a device (the drum motor) and looking at the motor sensor while the motor is driving. BASIC MENU DEVICE CHECK Press ± DEVICE CHECK OUTPUT SIGNAL Press ± OUTPUT SIGNAL MOTOR COUNTER Press ± MOTOR COUNTER DRUM Press ±...
Page 388 Press ³ DEVICE CHECK INPUT SIGNAL Press INPUT SIGNAL TRANSPORT UNIT Press ³ INPUT SIGNAL DRUM TRANS. CUTTER Press DRUM ELV. CUTTER DRUM ENCODER Press DRUM ENCODER LIGHT (OFF, ON) As timing marks pass through the sensor, the ON/OFF state changes on the engine checker message display.
Page 389: Volume Adjustment Menu
Volume Adjustment Menu The volume adjustment menu allows you to adjust voltages and read output for the items shown in Figure 8–10. To select an adjustment item, scroll through the menus until the target item appears at the extreme left of the message display, and press the key.
Page 390: Surface Potential
Surface Potential Turn the high–voltage power supply on, measure the voltage and adjust the volume. The engine checker menu path is BASIC MENU, VOLUME ADJUSTMENT, SURFACE POTENTIAL. Sample message: SURF. POTENTIAL POTENTIAL = 000 Eraser Lamp Use the engine checker to drive the eraser lamp for high and normal light quantities, measure the voltage, and adjust the volume.
Page 391: Tractor Motor
Tractor Motor With paper removed, use the engine checker to drive the tractor forward, reverse and detent, check how LEDs are lighting, measure the voltage and adjust the volume. The menu path is BASIC MENU, VOLUME ADJUSTMENT, TRACTOR MOTOR, FWD., TRACTOR MOTOR (FWD.), START/STOP. Sample message: TRACTOR MOTOR (FWD) DRIVING Toner Density...
Page 392: Basic Operation Menu
Basic Operation Menu The basic operation menu, shown in Figure 8–11, allows you to move fan–fold and cut–sheet paper through the printer. To select a paper type, scroll through the menus until the target item appears at the extreme left of the message display, and press the key.
Page 393: Fan-Fold Paper
Fan–fold Paper Fan–fold paper is discharged straight or toward the stacker. When discharged toward the stacker, the stacker must be removed from the print engine. (The engine checker cannot drive the stacker.) Use the engine checker to select and move fan–fold paper. The menu path is BASIC MENU, BASIC OPERATION, FANFOLD PAPER, STACKER, STACKER (FANFOLD OUT), START/STOP.
Page 394: Memory Operation Menu
Memory Operation Menu The memory operation menu, shown in Figure 8–12, allows you to display and change printer NVRAM values on the MPU board. To select a memory operation item, scroll through the menus until the target item appears at the extreme left of the message display, and press the key.
Page 395: Reading And Changing Data
Reading and changing data Use the engine checker to read and change memory operation data. When displaying a NVRAM value, the item name appears at the top of the message display, and the setting value at the bottom. A sample menu path is BASIC MENU, MEMORY OPERATION, FANFOLD PAPER XO.
Page 396 8–24 Engine Checker...
Page 397 Board Adjustments Chapter Contents MPU Board Adjustment ..........9–2 Adjusting the Feed Motor .
Page 398: Mpu Board Adjustment
MPU Board Adjustment Use the following checklist when replacing the MPU board on the printer. MPU board adjustment procedures require the use of an engine checker. (Refer to Chapter 8, “Engine Checker,” for information on using the engine checker.) NOTE: The engine checker does not work when the EPS4 sensor is on (i.e., when paper is loaded in the printer), or when the transport unit is not installed.
Page 399: Adjusting The Feed Motor
Reserved Rotary Test Print Reserved Factory Setup Engine Checker Mode (Japanese) Engine Checker Mode (English) Adjusting the Feed Motor To adjust the feed motor, perform the following steps: 1. (The printer should not yet be loaded with paper.) Turn the MPU board potentiometer VR1 completely clockwise.
Page 400: Setting Nvram Values
First, use the engine checker to read the value and make a note of it. If this does not work, set the value according to the inspection sheet located inside the printer. If there is no inspection sheet, locate the serial number of the printer and contact Printronix Technical Support for the factory–set value. 9–4 Board Adjustments...
Page 401 Table 9–2. MPU Board NVRAM Settings Item Description Standard Value Fan–fold paper picture position XO See important notice on prior page. Fan–fold paper picture position YO See important notice on prior page. Cut–sheet picture position XO See important notice on prior page. Cut–sheet picture position YO See important notice on prior page.
Page 402: Checking The Vacuum Fan
Checking the Vacuum Fan Use the engine checker to check the vacuum fan. The menu path is BASIC MENU, DEVICE CHECK, OUTPUT SIGNAL, FAN BLOWER, VACUUM. Confirm that the fan rotates and stops correctly. Checking the Pre–heating Lamp CAUTION The Fuser R. Cooling Fan should be turned on while performing this test. Use the engine checker to turn on the cooling fan and check the pre–heating lamp.
Page 403: I/O Board Adjustment
I/O Board Adjustment Use the following checklist when replacing the I/O board on the printer. I/O board adjustment procedures require the use of an engine checker. (Refer to Chapter 8, “Engine Checker,” for information on using the engine checker, including the engine checker menus.) NOTE: The engine checker does not work when the EPS4 sensor is on (i.e., when paper is loaded in the printer), or when the transport unit is not installed.
Page 404 TP26 TP24 TP21 TP25 TP20 TP22 TP23 VR10 TDSC TP13 TP12 DSPOFF TP29 VR11 TP15 TP14 LED2 GREEN TP16 LED1 LED5 TP17 TP19 LED4 LED3 TP27 TP18 DRM1 PRM2 TP10 FDFB TP28 VR12 TP11 DAOT 9–8 Board Adjustments...
Page 405: Adjusting The Drum Motor
Adjusting the Drum Motor To adjust the drum motor, perform the following steps: 1. Turn the I/O board potentiometer VR5 completely counterclockwise. 2. Use the engine checker to drive the drum motor. The menu path is BASIC MENU, VOLUME ADJUSTMENT, DRUM MOTOR. Verify that the drum and cleaner unit are installed properly.
Page 406: Adjusting The Tractor Motor
Adjusting the Tractor Motor To adjust the tractor motor, perform the following steps. There are three adjustments (detent, forward, and reverse). NOTE: If step 1 does not work, perform steps 2 and 3, then repeat step 1. 1. Tractor motor adjustment (detent): a.
Page 407 Adjusting the Drum Surface Potential Sensor Use the following procedures when replacing the I/O board or the drum surface potential sensor (high voltage sensor). Procedure #1 requires certain equipment and results in a more accurate adjustment. Only use Procedure #2 as a temporary measure if you do not have the necessary tools yet or if the printer is down.
Page 408 d. While holding the sensor in place, tighten the two screws securing the sensor. CAUTION Do not rotate the dummy drum before removing the drum plate, as this may damage the sensor. e. Remove the drum plate. Rotate the dummy drum so that the small bar on the drum is not under the sensor.
Page 409 12. On the engine checker, press the key, displaying the following: BASIC MENU VOLUME ADJUSTMENT 13. On the engine checker, press the key, displaying the following: VOLUME ADJUSTMENT SURFACE POTENTIAL 14. On the engine checker, press the key, displaying the following: SURFACE POTENTIAL POTENTIAL = 000 V If the potential is not 000V, adjust VR4 until it is 000V.
Page 410 24. Remove the staple, and attach the cable to the interlock switch. 25. Remove the engine checker, and re–install CN2 and CN4 on the MPU board. Turn the rotary switch to position 0 on the MPU board. 26. Replace both rear covers on the printer. 27.
Page 411: Adjusting The Drum Surface Potential Sensor - Procedure 1
Adjusting the Drum Surface Potential Sensor – Procedure 2 IMPORTANT Only use this procedure if you have not yet obtained a high–voltage power supply, engine checker, and dummy drum. When you obtain these tools, you must then perform Procedure #1. Equipment needed: Volt meter 9”...
Page 412: Adjusting The Eraser Lamp Input Voltage
Adjusting the Eraser Lamp Input Voltage For a high intensity of light (“HIGH” appears on the engine checker): 1. Put the positive lead of the digital multi–meter on TP7 on the I/O board, and the negative lead on the DG. 2.
Page 413: Setting Rotary And Dip Switches
Setting Rotary and Dip Switches The rotary switch settings on the MPU board are shown below. Reserved Test Print Reserved Factory setup Engine checker mode (Japanese) Engine checker mode (English) NOTE: To perform an engine self–test, the I/O board, MPU board, and Controller Unit must be connected.
Page 414 The DIP switch settings on the MPU board are shown below. (This switch Reserved 3 and 4 are for print density is active for setting (see chart below) fan–fold paper only.) 9–18 Board Adjustments...
Page 415: Confirming I/O Board Operation
Confirming I/O 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 multi–meter on TP25 on the I/O board, and the negative lead on the DG.
Page 416: Confirming The Main Charger Current Control Circuit
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 multi–meter on TP26 on the I/O board, and the negative lead on the DG.
Page 417: Confirming The Sleeve Motor 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 418: Confirming The Head Cooling Fan Operation
Confirming the Head Cooling Fan Operation 1. Use the engine checker to drive the head cooling fan. The menu path is BASIC MENU, DEVICE CHECK, OUTPUT SIGNAL, FAN BLOWER, HEAD COOLING, START. 2. Ensure that the fan rotates and stops properly. Confirming the Head Blower Fan Operation 1.
Page 419: Dc Power Supply Board
DC Power Supply Board Board Adjustments 9–23...
Page 420 9–24 Board Adjustments...
Page 421: Fuser Unit
Index Cable connections: Vol. 1 2–8 About this manual: Vol. 1 1–20 power cord: Vol. 1 2–8 Auto–load fanfold paper command, theory: signal cables: Vol. 1 2–12 Vol. 1 5–74 Cassette, paper size: Vol. 1 3–23, 5–20; Vol. 2 D–12 Auxiliary rod: Vol.
Page 422: Physical Description
Connector block, transfer/separator charger: Cut sheet feeder unit Vol. 2 10–39 basic operation: Vol. 2 D–21 basic principles: Vol. 2 D–9 Consumables cut sheet feed sensor (PFS): Vol. 2 D–13 See also Installing consumables; Replacing detection errors: Vol. 2 D–18 consumables feed motor encoder (FME): Vol.
Page 423: Dataproducts Parallel Interface
Documents, related: Vol. 1 1–21 Drive system descriptions: Vol. 1 5–28 Dangers and cautions: Vol. 1 1–20 Drum Dataproducts Parallel Interface: Vol. 2 F–9 cleaner set sensor: Vol. 2 10–79 DC power supply, voltage setting: Vol. 1 cleaning unit: Vol. 2 10–24 3–25 counter, I/O board: Vol.
Page 424 system: Vol. 1 6–1 05 – Paper Jam at Fuser: Vol. 1 7–37 adjustments: Vol. 1 6–52 07 – Scuff Lever Open: Vol. 1 7–39 08 – Cut–Sheet Path Open: Vol. 1 7–40 configuration: Vol. 1 6–2 09 – Transport Motor Fail: Vol. 1 7–41 Electromagnetic interference: Vol.
Page 425: Transfer/Transport Unit
power paper stacker: Vol. 2 E–27 Flash power supply: Vol. 1 6–19 condensers: Vol. 2 10–89 filter: Vol. 1 4–42 unit: Vol. 2 10–85 Floppy disk drives: Vol. 2 10–109 Face down paper out drive belt: Vol. 2 10–65 Front cover: Vol. 2 10–5 inside: Vol.
Page 426: Motors
unit: Vol. 2 10–73 Interfaces Centronics: Vol. 2 F–2, F–6 connector locations: Vol. 2 F–2 Dataproducts: Vol. 2 F–2, F–9 performance considerations: Vol. 2 F–4 I/O board: Vol. 2 10–42 RS–232 serial: Vol. 2 F–13 adjusting drum motor: Vol. 1 9–9 RS–422 serial: Vol.
Page 427: Memory Requirements
varistor: Vol. 2 10–61 cut–sheet paper pickup motor, theory: Vol. 1 5–43 Main unit drum motor, theory: Vol. 1 5–43 feed motor, control circuit: Vol. 1 6–46 main unit feed motor, theory: Vol. 1 5–43 feed roller drive, theory: Vol. 1 5–31 perforation cutter motor, theory: Vol.
Page 428: Solenoids
Page counts, service levels: Vol. 1 4–5 Paper guide interlock switch: Vol. 2 D–17 Paper Jam at Drum (Error 03): Vol. 1 7–34 Paper backward–feed sensor: Vol. 2 10–98 Paper Jam at Drum (Error 11): Vol. 1 7–49 detection, theory: Vol. 1 5–20 Paper Jam at Entrance (Error 16): Vol.
Page 429: Setup And Connection
Power, requirements: Vol. 1 2–2 transfer unit paper sensor (PMS): Vol. 2 E–18 Power cord, connecting: Vol. 1 2–8 Power supply Power paper stacker: Vol. 1 3–18; Vol. 2 controller: Vol. 2 10–105 E–1 DC board: Vol. 2 10–43 assisting arm: Vol. 2 E–16 flash assisting arm position sensor (APS1): Vol.
Page 430: Safety Regulations
Printing operations, theory: Vol. 1 5–64 German: Vol. 1 1–14 notices: Vol. 1 1–20 Printing system descriptions: Vol. 1 5–3 precautions Printronix Standard Architecture (PSA): English: Vol. 1 1–2 Vol. 1 1–23 German: Vol. 1 1–11 regulations: Vol. 2 A–7 sensors, power paper stacker: Vol.
Page 431: Sensors/Switches
elevator internal start sensor, theory: Vol. 1 stacker elevator down sensor (EDS): Vol. 2 5–40 E–21 stacker elevator motor encoder (EME): paper backward–feed sensor, theory: Vol. 1 Vol. 2 E–23 5–40 stacker elevator switches Paper near–end, theory: Vol. 1 5–40 (ESWA/ESWS/ESWD): Vol.
Page 432: Gates
Vol. 2 E–18 Toner density Stand cover: Vol. 2 10–13 engine checker: Vol. 1 8–19 Supplies, genuine Printronix: Vol. 2 A–2 sensor, I/O board: Vol. 1 9–16 Supply toner command, theory: Vol. 1 5–77 Toner Density Too High (Error 2B): Vol. 1 Support roller, drum: Vol.
Page 433: Tractor Adjustment Procedure
Toner Empty (Error 2A): Vol. 1 7–76 Transport Motor Fail (Error 09): Vol. 1 7–41 Toner level, monitoring, (theory): Vol. 1 Transport unit, cleaning: Vol. 1 4–16 5–52 Troubleshooting: Vol. 1 7–1 Toner supply clutch, I/O board: Vol. 1 9–21 Toner/developer, density: Vol.
Page 434 Index–14...
Page 436 NL-6600 A IJCHEN ETHERLANDS (31) 24 6489489 HONE: (31) 24 6489499 RINTRONIX CHWEIZ HANGI OUTH TREET 1 HANGI OUTH NDUSTRIAL STATE 486763 INGAPORE (65) 542-0110 HONE: (65) 543-0220 ISIT OUR WEBSITE AT: 704766–001C http://www printronix com VOLUME 1 OF 2...

Printronix L5000 Series Maintenance Manual

Volume 1

Table of Contents

Introduction

Setup

Consumables

Scheduled Maintenance

Principles of Operation

Electrical and Wire Data

Troubleshooting

Engine Checker

Board Adjustments

Quick Links

Chapters

Related Manuals for Printronix L5000 Series

Summary of Contents for Printronix L5000 Series