Page 1 ® Maintenance Manual Volume 2 L5035 Multifunction Printer...
Page 3: Printer
L5035 Multifunction Printer Maintenance Manual Volume 2 ® 705648-001C...
Page 4: Trademark Acknowledgements
Epson is a registered trademark of Seiko Epson Corporation. DuraFusion, IGP, LaserLine, LinePrinter Plus, PGL, PSA, and Printronix are registered trademarks, and Ribbon Minder is a trademark of Printronix, Inc. Magnum and QMS are registered trademarks, and Code V is a trademark of Quality Micro Systems, Inc.
Page 7: Table Of Contents
Volume 1 Table of Contents 1 Introduction............21 About This Manual................21 How to Locate Information ............21 Safety Notices and Special Information ........21 Switches and Display Messages..........22 Related Documents..............22 General Safety Precautions.............. 23 Setup Safety Precautions ..............25 Printer..................
Page 8: Table Of Contents
Table of Contents Installing the Diskettes (If Applicable)..........74 Setting the Power Supply Voltage ............ 75 4 Scheduled Maintenance ........81 Maintaining Print Quality..............81 Maintenance Tools ................82 Service Level Page Counts .............. 82 Clearing Service Level Messages ..........83 About Page Counter Software ...........
Page 9: Table Of Contents
Table of Contents Fixing Section (Fuser Unit) ............... 130 Preheating .................. 130 Flash Fusing................130 Cleaning Section................131 Precharging (Precleaning Charging) .......... 131 Drum Cleaning ................131 Paper Feed, Transport, and Output Sections ........132 Paper Detection ................. 133 Paper Loading ................134 Paper Transport .................
Page 10: Table Of Contents
Table of Contents Acronyms for Print Engine Interconnection Diagram......185 Explanation of Circuits According to Function ........188 Drum Surface Potential Control Circuit ........188 Developing Bias Control Circuit ..........190 Toner Density and Toner Empty Circuits ........192 Drum Motor Control Circuit ............194 Drum Counter Circuit ..............
Page 11: Table Of Contents
Table of Contents Error Code 02 — Fan-fold Paper Empty: When Loading/Beginning Print Error Code 03 — Paper Jam at Fuser (C)........273 Error Code 04 — Paper Jam at Exit (D) (transport section)..274 Error Code 05 — Paper Jam at Exit (D) (paper output section). 275 Error Code 07 —...
Page 12: Table Of Contents
Table of Contents Error Code 7C — Developing Bias High Voltage Error ....303 Error Code 7D — Separator Charger High Voltage Error ..303 Troubleshooting Other Symptoms ............ 304 Smell of Toner ................304 Broken Fuser Unit Cover Glass ..........305 Incomplete Fusing ..............
Page 13: Table Of Contents
Table of Contents MC Board LEDs ................. 355 MC Board Fuses ................ 357 Setting NVRAM Values .............. 359 Adjusting Feed Motor Speed............360 Checking the Vacuum Fan ............360 Checking the Preheat Lamp............360 Adjusting Drum Motor Speed ............. 360 Adjusting Tractor Motor Gain .............
Page 14: Table Of Contents
Table of Contents...
Page 15: Table Of Contents
Volume 2 Table of Contents 10 Replacement Procedures ........ 399 Overview................... 399 Front Cover ................400 Left rear cover ................401 Right rear cover................402 Top Cover .................. 405 Stand Cover ................408 Inside the Front Cover ..............409 Waste Toner Recovery Unit ............410 Developing Unit ................
Page 16: Table Of Contents
Table of Contents Tractor Adjustment Procedure ........... 508 Paper Back-Feed Sensor (PBFS) (Top of Form Sensor)... 511 Paper Near-End Sensor (PNES)..........512 Control Panel ................514 Controller Module ................515 Controller Board ................. 516 Terminating Resistors ..............519 Power Supply (in Controller Module) ......... 521 Cooling Fan................
Page 17: Setup
Table of Contents Front Side................... 629 Back Side ................... 630 Rear Side (Board Side) .............. 631 Paper Feed Cassette................ 632 Setup and Connections ..............633 Setup ..................633 Connections ................635 Basic Principles ................636 Drive Principles ................637 Cassette Principles ..............637 Control Principles................
Page 18: Table Of Contents
Table of Contents Setup and Connections ..............660 Setup..................660 Connections ................663 Removal.................... 664 Operation ..................665 Sensors and Actuators ..............668 Drive Principles................. 669 Feed Roller and Transfer Belt ............ 669 Swinger ..................671 Assisting Arms ................672 Elevator Table ................
Page 19: Table Of Contents
Table of Contents Stacker Motor ................709...
Page 20: Table Of Contents
Table of Contents...
Page 21: Replacement Procedures
Replacement Procedures Overview This chapter describes the mechanical structure of the printer and how to detach the various parts. The printer should be reassembled in the reverse order of the procedures specified in this chapter. Return the screws to their original positions, as they may vary in type with the position.
Page 22: Front Cover
Chapter Replacement Procedures Front Cover 1. Open the front cover by pressing the open/close buttons on either side and pulling the cover toward you. Open/close button Front cover 2. Remove the screw securing the chains on either side. Support the cover from below, as removing the screws securing the chains will put extra weight on the hinges.
Page 23: Left Rear Cover
Overview Left rear cover 1. Remove the screws (5) from the rear side. (The rear of the printer is shown in the figure below.) 2. Raise the left rear cover about 1/2 inch (1 cm) and remove it from the printer.
Page 24: Right Rear Cover
Chapter Replacement Procedures Right rear cover 1. Remove the screws (2) on the paper exit side, then remove the plate. Screws (2) Right rear cover Plate 2. Loosen the screws (2) that secure the bottom of the connector cover. Remove the screws (2) that secure the top of the connector cover and remove the cover.
Page 25 Overview 3. Remove the screws (2) located behind the connector cover, as shown in the figure below: Screws (2) 4. If your printer has the optional power stacker installed, do the following: a. Remove the screw (with lockwasher) securing the stacker ground wire (FG wire).
Page 26 Chapter Replacement Procedures 5. Remove the rear side screws (8). 6. Raise the right rear cover about 1/2 inch (1 cm) and remove it from the printer. NOTE: There are two alignment tabs located on the inside of the right rear cover.
Page 27: Top Cover
Overview Top Cover 1. Remove the left rear cover (page 401). 2. Remove the right rear cover (page 402). 3. Remove the screws (2) fastening the face up paper output tray to the printer, then pull out the tray and remove it from the printer. 4.
Page 28 Chapter Replacement Procedures 6. Open the front cover. Remove the screws (4) and detach the control panel. 7. Disconnect the front cover interlock (CIL) switch connector. Front cover interlock switch connector Screws (4) Control panel...
Page 29 Overview 8. Lift and remove the top cover from the printer. This may require two people (one for the paper feed side, the other for the paper output side). Top cover Screw...
Page 30: Stand Cover
Chapter Replacement Procedures Stand Cover 1. Remove the screws (2) securing the right side of the stand cover. 2. Pull the right side of the stand cover slightly forward, unhook the two pins in the left side of the cover from the printer, and remove the cover. Screw Screw Stand cover...
Page 31: Inside The Front Cover
Inside the Front Cover Inside the Front Cover The items shown below are behind the front cover. The green levers and handles are used by the operator on a regular basis. Discharge LED (not Main charger visible) Toner cartridge Cleaning unit Optional cut sheet paper Fuser unit...
Page 32: Waste Toner Recovery Unit
Chapter Replacement Procedures Waste Toner Recovery Unit The waste toner recovery unit contains a bottle that collects waste toner carried from the drum cleaner via screw conveyer belt. Attached to the right and left sides of the bottle’s neck are the light emitters and receptors of the waste toner bottle full sensor (WTBF), which detects the full condition.
Page 33: Waste Toner Bottle
Inside the Front Cover Waste toner bottle When the waste toner bottle becomes full, replace it with a new one by doing the steps below, then discard the full bottle. Do not reuse the bottle. 1. Lower the lever, pull the green handle toward you, and open the waste toner recovery unit.
Page 34: Waste Toner Bottle Full Sensor
Chapter Replacement Procedures 3. Remove the waste toner bottle from the waste toner recovery unit. 4. Discard the old waste toner bottle. 5. Install a new waste toner bottle. Waste toner bottle full sensor 1. Remove the waste toner bottle (page 411). 2.
Page 35: Waste Toner Bottle Set Sensor
Inside the Front Cover Waste toner bottle set sensor The waste toner bottle set sensor (WTBS) is a limit switch that detects whether the waste toner bottle is set. 1. Remove the waste toner bottle (page 411). 2. Disconnect the three connectors, as shown below. 3.
Page 36 Chapter Replacement Procedures Waste toner bottle unit 1. Remove the waste toner bottle (page 411). 2. Disconnect the three connectors, as shown below. 3. Detach one end of the spring. 4. Remove the waste toner bottle unit by lifting it. Connectors (3) Spring...
Page 37: Developing Unit
Inside the Front Cover Developing Unit See the User’s Manual for installation and replacement procedures. Toner Cartridge See the User’s Manual for installation and replacement procedures. Photoreceptor Drum Drum life depends upon media used and proper maintenance and operation of the printer. Print media other than bond paper (e.g., labels, card stock, plastic, or vinyl) may reduce drum life as much as 50%.
Page 38 Chapter Replacement Procedures 4. Loosen the three thumbscrews on the upper inner cover, then remove the cover. Upper inner cover Thumbscrews (3) 5. Rotate the developing unit lever fully clockwise so that it is pointing straight up (to separate the developing unit from the photoreceptor drum). Lever...
Page 39 Inside the Front Cover 6. Remove the developing unit by holding the lever in one hand and pulling the developing unit partially out of the printer. Developing unit Lever 7. With your other hand, grasp the hanger and remove the developing unit from the printer.
Page 40 Chapter Replacement Procedures CAUTION The transfer charger must be in the down position to avoid scratching the drum. 9. Check that the transfer charger is in the down position, and if not, move it to the down position by rotating the transfer elevator drive shaft counterclockwise.
Page 41 Inside the Front Cover 11. Loosen the three thumbscrews securing the drum plate and remove the drum plate. Drum plate Thumbscrews (3) Screws (2) Lower inner cover 12. Remove the two screws securing the lower inner cover, then remove the cover.
Page 42 Chapter Replacement Procedures 14. Screw the drum auxiliary rod onto the drum shaft. Drum auxiliary rod P/N 703531-170 15. Carefully pull the old drum along the drum auxiliary rod. Hold the front and back sides when the drum is nearly out of the printer, and remove it with both hands.
Page 43 Inside the Front Cover 18. 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 ends of the drum are identical; there is no front or back end. Wipe inside the endcaps of the drum with a cloth to ensure that they are clean.
Page 44: Proper Disposal Of A Drum Unit
Chapter Replacement Procedures 27. Raise the transport unit by reversing Step 10. 28. Reinstall the upper inner cover and tighten the thumbscrews. 29. Close the waste toner recovery unit and ensure that it latches. 30. Close the printer front cover. Proper Disposal of a Drum Unit Due to the nature of the material used in drum manufacturing, federal regulations prohibit inappropriate disposal of laser print drums.
Page 45 Inside the Front Cover Main charger (MCH), Precharger (PCH), Transfer / separator charger (TCH / SCH) Any of these chargers can be removed by loosening its thumbscrew and pulling it toward you along the guide rail. Main charger thumbscrew Precharger Transfer/separator thumbscrew charger thumbscrew...
Page 46 Chapter Replacement Procedures Discharge lamp (PEL) 1. Loosen the three thumbscrews on the upper inner cover and remove the cover. 2. Remove the discharge lamp screw and pull the lamp toward you along the guide rail. Discharge lamp screw Thumbscrews (3) Inner cover (upper)
Page 47 Inside the Front Cover Drum cleaning unit 1. Loosen the three thumbscrews on the drum plate, then remove the drum plate. 2. Grasp the handle of the drum cleaning unit. Pull the drum cleaning unit toward you and remove it. CAUTION Do not turn the drum cleaning unit upside down, or toner might spill.
Page 48 Chapter Replacement Procedures Separator claw assembly 1. Remove the rear cover and the top cover. 2. Check that the transfer charger is in the down position, then lower the transport unit by turning the green lever on the transport unit to the left (see steps 9 and 10 on page 418).
Page 49 Inside the Front Cover 6. Remove the solenoid E-ring from the tip of the solenoid arm. Separator claw solenoid Screws (2) Solenoid spring Separator claw springs (2) Solenoid Solenoid wires Solenoid E-ring Solenoid Bushing connector Collar Separator claw shaft Shaft E-ring Separator claw Separator claw...
Page 50 Chapter Replacement Procedures Drum support roller There are three small rollers located in the opening where the drum passes when it is removed or installed. These rollers prevent the drum surface from contacting nearby metal parts. To remove either the lower left roller or the lower right roller, remove the screw securing the bracket, then remove the roller.
Page 51: Fuser Unit
Inside the Front Cover Fuser Unit WARNING Take care in handling the fuser unit, as the unit reaches high temperatures immediately after operation. Be sure to wait to handle it until it is completely cooled down. Also, never scratch or touch the cover glass with your hands. Fingerprints on lamps will cause them to break.
Page 52 Chapter Replacement Procedures 4. With your other hand, grasp the second fuser handle and remove the fuser from the printer. 5. Place the fuser on a clean, flat surface with the cover glass facing up. The fuser unit contains the following replaceable parts: •...
Page 53 Inside the Front Cover 4. Remove the screws (2 for the preheat lamp, 3 for the flash lamp) securing the lamp terminals. NOTE: The preheat (halogen) lamp is the thinner of the two lamps and has only two wire leads. The flash (xenon) lamp is the thicker of the two lamps and has three wire leads.
Page 54 Chapter Replacement Procedures 6. Refer to the previous figure and loosen, but do not remove, the other bracket screw (near the end of the flash lamp). 7. Shift the bracket outward slightly, then remove the preheat lamp. CAUTION The lamps are fragile. Take care when handling. Never touch lamps with your hands.
Page 55 Inside the Front Cover Lamp duct filter 1. Remove the screws (2) that secure the lamp duct filter unit to the fuser unit, then remove the lamp duct filter unit and the foam gasket. Foam gasket Screw (2) Filter holding plate Lamp filter (air filter) Lamp duct...
Page 56: Transfer Assembly
Chapter Replacement Procedures Transfer Assembly 1. Check that the transfer charger is in the down position, then lower the transport unit by turning the green lever on the transport unit to the left (see steps 9 and 10 on page 418). 2.
Page 57: Transport Belt
Inside the Front Cover 3. Remove the screws (6) that secure the right and left slide rails to the assembly. Screws Slide rail 4. Lift the assembly from the rails and remove it. The following replaceable parts are on the transfer assembly: •...
Page 58 Chapter Replacement Procedures underneath it to protect the protruding tips of the sensor levers. Also, be careful when handling the green lever. 1. Referring to the figure below, remove the vacuum fan and disconnect its connector. Connector Screw Vacuum fan Transfer assembly Green lever 2.
Page 59 Inside the Front Cover 5. Referring to the figure below, remove the screw (1) and nut (1) securing the stainless plate, then remove the stainless plate. Outer bearing Outer e-ring Stainless Conveyer base plate Outer e-ring Drive shaft Outer bearing high-voltage wire Unit frame...
Page 60 Chapter Replacement Procedures 10. Referring to the figure below, remove the inner E-rings (2) securing the drive shaft to the conveyer base. Inner bearing Inner e-ring Inner e-ring Inner bearing Drive shaft Conveyer base 11. Referring to the figure above, slip the inner drive shaft bearings (2) out of their holes in the conveyer base, then slide them toward the outer ends of the drive shaft.
Page 61 Inside the Front Cover NOTE: When replacing a transport belt, be careful to distinguish the outer surface of the new belt from its inner surface, as shown below. The outer surface looks like graph paper, while the inner surface has an irregular pattern.
Page 62 Chapter Replacement Procedures 14. Referring to the figure below, adjust the distance between the belt and the conveyer base to approximately 1 cm when the belt center is pulled up with a force of 200 grams. Firmly tighten the screws (2 right, 2 left) to secure the belt shaft to the conveyer base.
Page 63 Inside the Front Cover Vacuum fan (VAF) / Paper exit sensor 3 (EPS3) / Paper exit sensor 4 (EPS4) It is not necessary to remove the transfer assembly from the printer to remove these parts. However, the vacuum fan must be removed in order to remove the EPS4 sensor.
Page 64 Chapter Replacement Procedures 3. Working from the underneath side of the transport assembly, remove the EPS3 mounting screws (2), as shown below. EPS4 Sensor Assembly EPS3 Sensor Assembly EPS4 mounting screws (2) EPS3 mounting screws (2) Fan plenum Screws (2) (remove) Vacuum fan Fan connector Screws (2) (loosen)
Page 65 Inside the Front Cover 5. Working from the underneath side of the transport assembly, loosen the 2 fan plenum screws marked "loosen" in the previous figure. Remove the other 2 fan plenum screws (marked "remove" in the figure). 6. Disconnect the fan cable connector, then remove the fan and plenum together from the transport assembly.
Page 66 Chapter Replacement Procedures Varistor 1. Remove the screws (front side and rear side, 1 each) securing the transport paper guide. Transport paper guide Screws Screws (2) Varistor Spacer 2. Remove the transport paper guide. 3. Remove the screws (2) securing the varistor terminal, and remove the varistor.
Page 67: Inside The Rear Cover
Lamp cooling blower Smoke filter blower (not visible in figure; attached to duct) Transfer elevator motor NOTE: Some versions of the L5035 printer have flash memory (located on the controller PCBA). These printers have no diskette drives.
Page 68: Mc Board
Chapter Replacement Procedures MC Board IMPORTANT Whenever you replace the MC board, you must perform the necessary adjustments. See the section titled “MC Board Adjustments” on page 343 in Chapter 9, "Adjustment Procedures." 1. Turn OFF the power switch on the printer. 2.
Page 69 Inside the Rear Cover Screws Screws Screws...
Page 70: Dc Power Supply Board
Chapter Replacement Procedures DC Power Supply Board 1. Turn OFF the power switch on the printer. 2. Unplug the printer power cord from the power mains. 3. Remove the right rear cover, as described on page 402. 4. Refer to detail drawing "A" in the figure on the next page and move the circuit breaker lever to the OFF position.
Page 71 Inside the Rear Cover DC power supply board Power supply cover Screws (4) Circuit breaker lever...
Page 72: Motors
Chapter Replacement Procedures Motors Cutter motor 1. Remove the cutter unit, as described on page 484. 2. Disconnect the cutter motor connector, and remove the connector through the hole in the frame, as shown in the figure below. Screw Pulley Set screw Pulley drive belt Connector...
Page 73: Drum Motor
Inside the Rear Cover Drum motor 1. Remove belts A, B, and C, as described on page 469. 2. Remove the screws (3) securing the motor cover and remove the motor cover by moving it downward, as shown in the figure below. Motor cover Screws (3)
Page 74 Chapter Replacement Procedures 3. Remove the E-ring and the tab washer from the motor shaft, as shown in the figure below. Connectors (2) Set screw Screws (4) E-ring Flywheel Tab washer 4. Loosen the setscrew using the hex wrench, then remove the flywheel. 5.
Page 75 Inside the Rear Cover Sleeve motor (SLM) / Magroll motor (MRM) 1. Referring to the figure below, disconnect the connectors (2): one for the sleeve motor, the other for the magroll motor. Bracket Sleeve motor Magroll motor Connectors Bracket screws (8) 2.
Page 76 Chapter Replacement Procedures 3. From the rear of the bracket, remove the screws (8) that secure the motors to the assembly bracket. Setscrews Gear Motor screws (8) E-ring Bracket Gear 3 Gear 4. Loosen the setscrews (4), then remove the gears (2) from the motor shafts.
Page 77 Inside the Rear Cover Feed motor (FMT) / Encoders (FME19/20) In the feed motor block, encoders 19 and 20, along with the motor itself (with bracket), are replacement parts, and are removed as follows: 1. Referring to the figure below, mark the sensor connectors (2) for identification so that you can connect them properly when you reinstall the motors.
Page 78 Chapter Replacement Procedures 8. Referring to the figure below, remove the belt. Belt (703531-031) Feed motor Setscrew Encoder 19 disc Motor bracket Screw Screws (3) Encoder 20 disc Sensor bracket Screws 9. Remove the screws (3) that secure the motor bracket to the printer base, then pull out the bracket with the feed motor attached.
Page 79 Inside the Rear Cover 13. If you are replacing the sensors, remove the screws (1 each) that secure the sensors to the sensor bracket. Sensors Sensor bracket Screw Screw...
Page 80 Chapter Replacement Procedures Tractor motor/tractor drive belts Belt A is removed first, belt B second. Belt A (703531-031) Belt B (703531-031)
Page 81 Inside the Rear Cover 1. Remove the MC board retaining screws (3) shown in the figure below, then swing open the MC board support assembly on its hinges. MC board Screws (3) Hinged MC board support assembly...
Page 82 Chapter Replacement Procedures 2. To maintain the correct alignment of the fan-fold paper, inscribe alignment marks on pulleys C and S as shown in the figure below. Then, remove belt A by rotating pulley C, and remove belt B by rotating pulley S. Pulley C Belt A Alignment...
Page 83 Inside the Rear Cover 3. If you are replacing the tractor motor, do steps a through d below. Otherwise, skip to step 4. a. Remove the motor cover, then disconnect the tractor motor connectors (2). Screws Connectors b. Remove the screws (4) fastening the tractor motor to the printer base. c.
Page 84 Chapter Replacement Procedures Transfer elevator motor 1. Remove the transport unit, as described on page 434. 2. Detach the cable clamp, and disconnect the motor connector. SCREW CONNECTOR 3. Remove the screws (4) that secure the transfer elevator motor to the bracket, then remove the transfer elevator motor from the bracket.
Page 85: Fans
Inside the Rear Cover Fans Head cooling fan (HCF) 1. Disconnect the head cooling fan connector. CONNECTOR BRACKET SCREWS 2. Remove the screws (2) securing the bracket to the main unit, then remove the fan with the bracket attached.
Page 86 Chapter Replacement Procedures 3. Remove the screws (2) securing the head cooling fan to the bracket. BRACKET SCREW HEAD COOLING FAN...
Page 87 Inside the Rear Cover Head blower fan (HBF) and LED air filter The head blower fan has the role of sending air through the duct inserted between the main charger and LED head, to prevent particles such as toner from adhering to the head. A filter is attached to the intake, to prevent dust from clogging the duct’s draft hole.
Page 88 Chapter Replacement Procedures Fuser reflector cooling fan (FCF) To remove the fuser reflector cooling fan, disconnect the connector, and remove the screws (4) securing the fan and fan plate to the duct. Duct Fuser reflector cooling fan Fan plate Connector Screw...
Page 89: Solenoids
Inside the Rear Cover Solenoids Paper exit gate solenoid (EGSL) / Face gate solenoid (FGSL) To remove either solenoid: 1. Disconnect the connector for the solenoid you want to remove. Face gate solenoid Connectors Screws Paper exit gate solenoid 2. Remove the screw securing the solenoid to the printer. Cutter solenoid (CSL) 1.
Page 90: Miscellaneous
Chapter Replacement Procedures Miscellaneous Tension arm To remove the tension arm above the eject gate solenoid, remove the E-ring on the rotation axis. Tension arm E-ring Main charger (MCH) Varistor 1. One terminal of the main charger varistor is connected to the main charger connector via high voltage cable.
Page 91 Inside the Rear Cover Drum motor drive belt Three (3) belts are installed with the drum motor drive unit. These belts must be removed in the following order: Belt A, Belt B, then Belt C. Belt A (703531-032) Belt B (703531-031) Belt C (703531-031)
Page 92 Chapter Replacement Procedures 1. Pull downward on the tension roller and remove Belt A from Pulley E. Belt A Pulley E Pulley F Tension roller Pulley G Belt B Belt C 2. Remove Belt B by turning Pulley F. 3. Remove Belt C by turning Pulley G. NOTE: New belts are installed in the reverse order.
Page 93 Inside the Rear Cover Output roller drive belts Five (5) belts, A through E, are incorporated into the roller drive mechanism. These belts must be removed in the following order: A, B, D, E, and C. Belt E (703531-030) Belt D (703531-029) Belt A (703531-028) Belt B (703531-031) Belt C (703531-031)
Page 94 Chapter Replacement Procedures 4. Remove the screw (1) fastened to the scuff roller shaft, then remove the flange. Belt E Flange Screw Belt D 5. Remove belts D and E. 6. Remove belt C from around pulley H by turning pulley H. Pulley H Belt C Feed motor bracket...
Page 95 Inside the Rear Cover 8. Remove belt C from the printer. 9. Install new belts and the associated parts removed. Face-down paper out drive belt To remove this belt, slacken the belt by pulling the tension roller toward the right. Tension roller Belt (703531-034) Pickup roller units...
Page 96 Chapter Replacement Procedures 1. Remove the upper and lower paper cassettes from the printer. 2. On the upper pickup roller unit, loosen the green thumbscrew. Slide the unit to the left, and pull the unit toward you and out of the printer. Thumbscrew 3.
Page 97 Inside the Rear Cover Reverse roller units There are two reverse roller units (upper and lower) located at the back of the cassette opening (underneath the upper and lower pickup roller units). Upper reverse roller unit Lower reverse roller unit 1.
Page 98 Chapter Replacement Procedures 3. When installing either reverse roller unit, refer to the figure below and proceed as follows: a. Align the shaft pin with the slot in the coupling, and align the alignment pin on the unit with the hole in the frame. b.
Page 99: Under The Top Cover
Under The Top Cover Under The Top Cover The following items are arranged under the top cover (top view shown): Drum surface potential sensor Drum cleaner set sensor NIP switch LED print head Rear Side of Printer Front Side of Printer High-voltage (corona) Paper exit power supply...
Page 100: Led Print Head
Chapter Replacement Procedures LED Print Head NOTE: To install the LED print head, you will need two LED positioning pins and some thermal compound (see page 38 for part numbers). The LED positioning pins are used to align the print head when installing 1.
Page 101 Under The Top Cover 3. Remove the screws (3) on the metal fittings which hold the heat pipe, then remove the heat pipe by moving it toward the rear. Screws (3) Heat pipe...
Page 102 Chapter Replacement Procedures 4. Remove the screws (4) securing the LED print head, then lift the print head to remove it. CAUTION Do not touch the surface of the print head, as you will leave fingerprints. LED positioning pin LED positioning pin Screws (4) LED print head 5.
Page 103 Under The Top Cover 7. Rub thermal compound over the heat pipe and print head. Install the heat pipe. 8. Attach the metal fittings which hold the heat pipe, and fasten the thermistor terminal to the metal fittings. 9. Connect the print head connectors to their original positions. 10.
Page 104 Chapter Replacement Procedures DSW1 Fanfold paper (This switch is active for 3 and 4 are for print density Reserved fanfold setting (see chart below) paper only.) Cut sheet paper Paper Print density Fanfold 400 dpi Cut Sheet 300 dpi 240 dpi...
Page 105: High-Voltage (Corona) Power Supply
Under The Top Cover High-voltage (Corona) Power Supply 1. Ensure that the ON/OFF switch on the printer is in the 0 (OFF) position. 2. Remove the screw securing the frame ground wire to the frame. 3. Disconnect the two multiwire connectors. 4.
Page 106: Cutter Unit
Chapter Replacement Procedures Cutter Unit CAUTION Bearings can fall out of the pulley when removing it. Also, the pulley must be put on the same way it was removed. This pulley is actually made up of three separate pulleys that are molded into one piece. The middle pulley is much larger than the two outside ones.
Page 107 Under The Top Cover 2. Remove the screws (2 each, front and rear) that secure the cutter unit to the printer. Screws Connectors 3. Disconnect the connectors to the cutter motor and cutter sensor in the rear.
Page 108 Chapter Replacement Procedures 4. Remove the cutter unit by pulling it downward from the rear side. (The front is obstructed by the front panel.) Cutter unit Screws...
Page 109: Sensors And Switches
Under The Top Cover Sensors and Switches Drum surface potential sensor (DSPS) 1. Remove the MC board retaining screws (3) shown in the figure below, then swing open the MC board support assembly on its hinges. Screws (3) MC board Hinged MC board support assembly...
Page 110 Chapter Replacement Procedures 2. Remove the screws (4) securing the DSPS-PCBA, as shown below. DSPS-PCBA Screw Screws (4) 3. Remove the screw (1) securing the sensor bracket, as shown above. 4. Remove the screws (2) on the front side. Screws...
Page 111 Under The Top Cover 5. Remove the sensor bracket (with the sensor attached) together with the connected DSPS-PCBA. IMPORTANT When installing the drum surface potential sensor, you must perform the adjustment procedure given on page 362 in Chapter 9, "Adjustment Procedures."...
Page 112 Chapter Replacement Procedures 2. Remove the screws (2) securing the bracket to the printer. 3. Insert your hand from the top of the rear panel, then remove the sensor with the bracket attached. 4. Remove the screws (2) securing the sensor to the bracket. Paper exit sensor 0 (EPS0) / Nip switch (NPSW) Paper exit sensor 0 and the nip switch are attached to the scuff guide, at the exit of the paper output section.
Page 113 Under The Top Cover 4. Remove the screw securing the sensor to the bracket. Nip switch (NPSW) The nip switch is located closer to the rear panel than is paper exit sensor 0. 1. Remove the screws (not visible in the illustration below) securing the switch bracket to the scuff guide from the paper output side.
Page 114: Gates
Chapter Replacement Procedures 2. Remove the screw securing the sensor to the paper guide. Gates The paper output section has two stages of gates: the paper exit gate and the face gate. Each of these gates is mechanically linked to a controlling solenoid. The two solenoids are the paper exit gate solenoid (EGSL) and the face gate solenoid (FGSL).
Page 115: Behind The Stand Cover
Behind the Stand Cover Behind the Stand Cover Smoke Filter 1. Loosen the thumbscrew on the front and open the cover of the filter box. Smoke filter Thumbscrew 2. Pull the metal fitting out about 3/4 inch (20 mm) and unlock. Lever...
Page 116: Flash Power Supply
Chapter Replacement Procedures 3. Rub petroleum jelly on the rubber seal on the bottom of the smoke filter. Then replace the smoke filter. Smoke filter Flash Power Supply The following steps describe replacement of the flash power supply. (For additional information, see “Flash Power Supply” on page 230 in Chapter 6, "Electrical and Wire Data.") WARNING When replacing the flash power supply, take care of the following:...
Page 117 Behind the Stand Cover 1. Set the ON/OFF switch on the printer to the 0 (OFF) position. 2. Unplug the printer power plug from its electrical outlet. 3. Wait at least 5 minutes for the high-voltage DC charge in some components to be completely discharged before proceeding to the next step.
Page 118 Chapter Replacement Procedures 6. At the rear side of the printer, disconnect connectors J11 and TRG from the flash power supply. Rear side of printer Connector J11 (to MC board) AC line terminal strip Connector TRG (trigger, to lamp trigger coil) Ground wire (FG wire) Screw...
Page 119 Behind the Stand Cover 9. Remove the high-voltage terminal covers from the high-voltage terminals on the rear of the fuser unit. Fuser unit Screws (2) High-voltage terminal covers High-voltage cables (from flash power supply) 10. Mark or tag the high-voltage cables and their corresponding high-voltage terminals on the fuser unit, so that you can reconnect them properly later.
Page 120 Chapter Replacement Procedures 12. At the front side of the printer, remove the screws (2) securing the flash power supply to the printer frame, as shown in the figure below. Front side of printer Screws (2)
Page 121 Behind the Stand Cover 13. At the front side of the printer, grasp the flash power supply and pull it out. If you cannot pull it out, refer to the figure that follows and loosen the screws (4) securing the metal fittings (2) on the rear of the flash power supply.
Page 122 Chapter Replacement Procedures 14. With the old flash power supply out of the printer, refer to the figure below and remove the high-voltage terminal cover from the flash power supply. High-voltage cables (to fuser unit) Hexagonal nuts High-voltage terminal cover Screws 15.
Page 123: Capacitor
Behind the Stand Cover 27. Replace the cover on the AC line terminal strip. 28. Reconnect connectors J11 and TRG to the flash power supply. 29. Reinstall the stand cover (see page 408). 30. Reinstall the right rear cover (see page 402). 31.
Page 124 Chapter Replacement Procedures 1. Remove the flash power supply as described earlier (page 494). 2. Remove the screws (8) fastening the front cover of the flash power supply, then remove the cover. Flash power supply Front cover Screws (8)
Page 125 Behind the Stand Cover 3. Remove the screws (8) fastening the left cover of the flash power supply, then remove the cover. Left cover Screws (8) 4. Refer to the figure that follows, and mark or tag the wires connected to the capacitor, so that you can reconnect them properly later.
Page 126 Chapter Replacement Procedures Screws (4) Ground wire Screw (FG wire) Nuts (2) Lockwashers (2)
Page 127: Other
Other 5. Remove the nuts (2) and lockwashers (2) securing the wires to the capacitor terminals. 6. Remove the screw (1) securing the ground wire (FG wire) to the ground terminal on the capacitor. 7. Remove the screws (4) securing the capacitor to the base of the flash power supply.
Page 128 Chapter Replacement Procedures 1. Remove the tractor drive belt, belt A (see page 458). 2. On the front side of the printer, remove the E-ring securing the tractor splined shaft. Remove the bearing (not shown). Screw E-ring 3. Remove the screw (1) securing the tractor support shaft.
Page 129 Other 4. Remove the E-ring securing the left tractor on the tractor support shaft. Tractor support shaft Screw E-ring Tractor splined shaft 5. Slide the tractor splined shaft toward the rear side of the printer and remove it. 6. On the rear side of the printer, remove the screw securing the tractor support shaft, then remove the tractors and the tractor support shaft from the paper feed side.
Page 130: Tractor Adjustment Procedure
Chapter Replacement Procedures Tractor Adjustment Procedure After removing and replacing tractors, perform the following procedure to align the tractor shaft, in order to alleviate the problem of paper pulling away from the tractor guides. This adjustment spaces the tractor splined shaft and the tractor support shaft evenly apart, and places the tractor support shaft perpendicular to the frame.
Page 131 Other 6. Unlock both tractors, then slide them to the center of the shaft. Left tractor spacer 7. Slide the left tractor spacer to the center of the shaft. 8. Place the tractor alignment tools between the tractor splined shaft and the tractor support shaft, one at each end, over the bearings on the splined shaft.
Page 132 Chapter Replacement Procedures 9. Left side adjustment: Lift up the tractor support shaft and apply a small amount of force toward the tractor splined shaft. Once the tractor support shaft is against the tractor alignment tool, hold them together and tighten the screw holding the tractor support shaft on the left side frame.
Page 133: Paper Back-Feed Sensor (Pbfs) (Top Of Form Sensor)
Other 15. Print a configuration report (see the User’s Manual for instructions, if necessary). After the print job is complete, press page eject. Verify that the tractor holes in the paper are still on the tractor pins. WARNING Never touch the tractor area while the printer is printing. Never stare at the tractor area while the printer is printing, because the tractor area reflects leakage light from the fuser unit.
Page 134: Paper Near-End Sensor (Pnes)
Chapter Replacement Procedures Sensor Connector Screws (2) Sensor bracket Screws (2) Paper Near-End Sensor (PNES) Photoemitting board 1. Remove the screws (4) securing the photoemitting board cover, then remove the cover. 2. Remove the screw (1) securing the photoemitting board bracket to the paper near-end sensor assembly.
Page 135 Other Connector Photoemitting Photoemitting board bracket board Screw Screw Paper near-end sensor assembly Photoemitting board cover Screws (4) Photoreceptor board 1. Remove the screws (4) securing the photoreceptor board cover, then remove the cover. 2. Remove the screw (1) securing the photoreceptor board bracket to the paper near-end sensor assembly.
Page 136: Control Panel
Chapter Replacement Procedures Connector Photoreceptor board Photoreceptor board bracket Screw Paper near-end sensor assembly Screw Photoreceptor board cover Screws (4) Control Panel 1. Remove the screws (4) securing the control panel to the printer. 2. Disconnect the cable connector from the connector on the rear of the control panel, then remove the panel.
Page 137: Controller Module
Controller Module Screws (4) Cable connector Controller Module The controller module consists of the following subassemblies: • Controller board • Power supply • Cooling fan • Floppy disk drives (not used on printers with flash memory) In addition, the controller board contains socketed terminating resistors for the parallel interface.
Page 138: Controller Board
Chapter Replacement Procedures Controller Board Removal CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards and integrated circuits (ICs). 1. Make a configuration printout of all saved configurations. (Refer to the User’s Manual .) 2.
Page 139 Controller Module Controller module Floppy disk drives (Ref.) (Not used on flash memory equipped printers) Controller board (Flash memory equipped printers) Flash memory (Ref.) Host interface panel Screws (4) Washers (4) Controller board (Floppy drive equipped printers) Figure 1. Controller Board Removal/Installation...
Page 140 Chapter Replacement Procedures 10. Find the NVRAM IC on the controller board (board location U6) and determine if the IC is socketed or soldered. (Some controller boards have the NVRAM IC socketed as shown in the figure; other controller boards have this IC soldered to the board.) (See Figure 2.) 11.
Page 141: Terminating Resistors
Controller Module CAUTION When installing the controller board, be sure that you connect the ribbon cables to their proper connectors on the controller board. Also, be sure that you orient each ribbon cable connector properly when you connect it to its mating connector on the controller board. 2.
Page 142 Chapter Replacement Procedures Installation 1. Carefully install the resistor packs in their correct sockets on the controller board. Be sure to orient each resistor pack correctly. (See the figure on the following page.) 2. Install the controller board (page 516). Controller Board RP28 RP29...
Page 143: Power Supply (In Controller Module)
Controller Module Power Supply (in Controller Module) 1. Turn off the printer. 2. Disconnect the printer AC power cable from the power source. 3. Remove the printer left rear cover (page 401). 4. Remove the controller module side cover. (See the illustration on the following page.) 5.
Page 144 Chapter Replacement Procedures Controller module AC connector Power supply Side cover Rotated for clarity...
Page 145: Cooling Fan
Controller Module Cooling Fan 1. Turn off the printer. 2. Disconnect the printer AC power cable from the power source. 3. Remove the printer left rear cover (page 401). 4. Remove the controller module side cover. (See the illustration on the following page.) 5.
Page 146 Chapter Replacement Procedures Floppy Disk Drives (Not Used on Printers with Flash Memory) 1. Turn off the printer. 2. Disconnect the printer AC power cable from the power source. 3. Remove the printer left rear cover (page 401). 4. Remove the controller module side cover. (See the illustration on the following page.) 5.
Page 147 Controller Module Controller module Floppy disk drives (2) Bracket Side cover...
Page 148 Chapter Replacement Procedures...
Page 149: Paper Specifications
Paper Specifications Paper types Fanfold (standard) Cut sheet (optional) Paper sizes Cut sheet paper Letter (landscape), legal (portrait), ledger (portrait), A3 (portrait), B4 (portrait), A4 (landscape) Fanfold paper Width 7 to 16 inches Length* 1 to 24 inches, in multiples of 1/6 inch.
Page 150 Appendix A Paper Specifications Center line “B” Main folding/cutting perforation Fanfold paper “A” “E” Tractor pin hole “C” “D” Center line deviation Paper thickness .010 inch maximum Paper weights Fanfold paper 17 to 44 lb. bond, 44-125 lb. tag/label Cut sheet paper 17 to 44 lb.
Page 151: Maintenance Schedules
Illustrated Parts List Overview This appendix contains the following items: • A parts list sorted alphabetically by description • The illustrated parts for the printer The illustrations begin on page 538. An illustrated list of installation and maintenance tools, with part numbers, begins on page 38.
Page 152: Parts List By Description
Appendix B Illustrated Parts List Parts List by Description Item Part Number Page Bearing, Conveyer 703531-554 Belt, 106MXL 703531-057 Belt, 158MXL 703531-058 Belt, 265MXL4.8 703531-034 Belt, 3M-132-6 703531-028 Belt, 60S3M174 (6 ea./set) 703531-029 Belt, 60S3M177 703531-033 Belt, 60S3M210 703531-030 Belt, 60S3M501 703531-032 Belt, 67MXL6.4 703531-026...
Page 153: Cleaning Unit
Item Part Number Page Cable Assembly, Parallel 703680-001 Cable Assembly, Serial 232/422 703678-001 Cable, Varistor/High Voltage 703531-163 Capacitor (1 per set) 703531-561 Cassette (L250-A3) 703531-008 Cassette (L250-B4) 703531-007 Cassette (L250-Ledger) 703531-010 Cassette (L250-Legal) 703531-009 Cassette (S250-A4) 703531-005 Cassette (S250-Letter) 703531-006 Cassette (S500-A4) 703531-003 Cassette (S500-Letter)
Page 154: Photoreceptor Drum
EPS0 Assembly (Paper Motion Sensor) 703531-131 EPS3 Assembly 703531-125 EPS4 Assembly 703531-126 Fan Assembly, Vacuum 703531-109 Fan, DC Power Supply, L5035 202836-001 Fan, Fuser Cooling 703531-105 Fan, Head Blower (2ea./set) 703531-104 Fan, Lamp Cooling Blower (VEF1) 703531-117 Fan, Smoke Filter Blower (VEF0)
Page 155 703531-142 Fuser Line 703531-101 Fuser Unit 203283-001 Gate Front Block 703531-121 Gate Rear Block 703531-122 Gear Assembly for Developing Unit, L5035 202834-001 Gear Head, Magroller Unit 703531-200 Glass Frame Assembly 703531-138 Glass, Fuser Cover 703531-066 Ground Clip, Developing Unit 703531-199...
Page 156: Discharge
Lever, Jam Sensor (EPS4) 703531-067 Memory, ROM-OP2, Stacker 703531-081 Microswitch 703531-074 Microswitch V-014-1C23 703531-106 Motor Assembly (2 ea./set) 703531-053 Motor Assembly, Drum, L5035 705733-009 Motor Assembly, Elevator 703531-079 Motor Assembly, Elevator 703531-141 Motor Assembly, Feed 703531-040 Motor Assembly, Magroll 705733-011...
Page 157 Part Number Page Paper Press 2, Rubber (2 ea./set) 703531-119 PCBA-1, Cassette Sensor (2ea./set) 703531-071 PCBA-2, Stacker, L5035 705733-015 PCBA A, Sensor, L5035 (2ea./set) 705733-016 PCBA B, Sensor, L5035 (2ea./set) 705733-017 PCBA, EDO-040 Controller, L5035 705668-001 PCBA, MC, L5035 705733-012...
Page 158 Appendix B Illustrated Parts List Item Part Number Page Roller Assembly, Pickup and Reverse 703531-213 Roller Assembly, Reverse (2 ea./set) 703531-051 ROM-01X, Stacker IC-1 703531-514 Screw Kit, L5000 703531-210 Sensor Assembly, Drum Surface Potential 705733-008 Sensor Assembly, PNE (Paper Near-End) 703531-167 Sensor Assembly, Resist (2ea./set) 703531-072...
Page 159 Item Part Number Page Switch Panel, Stacker (OP2) 703531-085 Thumbscrew, In/Out 703531-577 Toner Bottle, Waste 703539-001 Toner Cartridge 703532-001 Tractor Assembly 703531-114 Transfer Assembly 703531-137 Transport Unit Shaft "A" Assembly 703531-212 Transport Unit Shaft "B" Assembly 703531-224 Tray Assembly, Face Up 703531-166 Trigger Coil 703531-165...
Page 160 Appendix B Illustrated Parts List Figure 3. Front View of Printer...
Page 161 Quantity Item Description: Figure 3. Front View of Printer Part Assembly 703531-003 Cassette (S500-A4) 703531-004 Cassette (S500-Letter) 703531-005 Cassette (S250-A4) 703531-006 Cassette (S250-Letter) 703531-007 Cassette (S250-B4) 703531-008 Cassette (S250-A3) 703531-009 Cassette (S250-Legal) 703531-010 Cassette (S250-Ledger) 703531-011 Swing Plate 703531-166 Face Up Tray Assembly 703531-524 Cover, Front Stand, Painted 703531-204...
Page 162 Appendix B Illustrated Parts List Figure 4. Printer Front Cover Assembly Open...
Page 163: Developing Unit
Quantity Item Description: Part Figure 4. Printer Front Cover Assembly Open Assembly 705739-001 Developing Unit (Rebuildable) (See Figure 5, Item 5, For Details) 705741-001 Main Charger (See Figure 6, Item 5, For Details) 703531-118 Discharge LED Assembly (Erase LEDs) (See Figure 6, Item 10, For Details) 705740-001 Cleaning Unit (Rebuildable) (See Figure 7, Item 5, For Details)
Page 164 Appendix B Illustrated Parts List 15 Ref. Figure 5. Developing Unit...
Page 165 Quantity Item Description: Figure 5. Developing Unit Part Assembly 705739-001 Developing Unit (Rebuildable) 703532-001 Toner Cartridge 703548-001 Developer Powder, Bottle (includes Nozzle)
Page 166 Appendix B Illustrated Parts List Figure 6. Miscellaneous Details...
Page 167 Quantity Item Description: Figure 6. Miscellaneous Details Part Assembly 705741-001 Main Charger 703531-118 Discharge LED Assembly (Erase LEDs) 705742-001 Precharger...
Page 168 Appendix B Illustrated Parts List Figure 7. Cleaning Unit and Photoreceptor Drum...
Page 169 Quantity Item Description: Figure 7. Cleaning Unit and Photoreceptor Drum Part Assembly 705740-001 Cleaning Unit (Rebuildable) 703535-001 Photoreceptor Drum...
Page 170: Transfer
Appendix B Illustrated Parts List * Item 16 is not part of this assembly Figure 8. Transfer Assembly (Sheet 1 of 3)
Page 171 Figure 8. Transfer Assembly (Sheet 2 of 3)
Page 172 Appendix B Illustrated Parts List Figure 8. Transfer Assembly (Sheet 3 of 3)
Page 173 Quantity Item Description: Figure 8. Transfer Assembly Part Assembly 703531-208 Guide, Paper, Transport (upper) 703531-103 Varistor Assembly/Transfer Charger 703531-127 High-Voltage Connector Assembly 705743-001 Transfer Charger 703531-139 Conveyor Assembly 703531-212 Transport Unit Shaft "A" Assembly 703531-554 Bearing, Conveyer 703531-553 Holder, Bearing 703531-224 Transport Unit Shaft "B"...
Page 174 Appendix B Illustrated Parts List Figure 9. Fuser Unit (Sheet 1 of 4)
Page 175 Figure 9. Fuser Unit (Sheet 2 of 4)
Page 176 Appendix B Illustrated Parts List Figure 9. Fuser Unit (Sheet 3 of 4)
Page 177 ° This view is rotated 180 Figure 9. Fuser Unit (Sheet 4 of 4)
Page 178 Appendix B Illustrated Parts List (Parts lists continue on next page.)
Page 179 Quantity Item Description: Figure 9. Fuser Unit Part Assembly 202838-001 Lamp Housing Filter, L5035 703531-138 Glass Frame Assembly (This Assembly Includes Six Items) 1 703531-066 Fuser Cover Glass 703531-113 Connector/Fuser FU-Male (2 ea./set) 703531-102 Fuser Fuse Assembly 703541-001 Xenon Lamp Assembly...
Page 180 Appendix B Illustrated Parts List * Item 20 is not part of this assembly. Figure 10. Base, WT (Waste Toner) Assembly...
Page 181 Quantity Item Description: Figure 10. Base, WT (Waste Toner) Assembly Part Assembly Base, WT (Waste Toner) Assembly Sensor A PCBA 703531-153 Microswitch V-014-1C23 703531-106 Sensor B PCBA 703531-154 Waste Toner Bottle 703539-001...
Page 182 Appendix B Illustrated Parts List Figure 11. Back View of Printer...
Page 183 Rear Cover Assembly, Right 703531-201 Rear Cover Assembly, Left 703531-206 Top Cover Holder, C CK --------- See Figure 12 For Close-up Of Printer 705733-005 High Voltage (Corona) Power Supply, L5035 703531-063 Connectors for High Voltage (Corona) Power Supply (set of 5) 1...
Page 184 Appendix B Illustrated Parts List Figure 12. Back View of Printer, Close-up (Sheet 1 of 2)
Page 185 Figure 12. Back View of Printer, Close-up (Sheet 2 of 2)
Page 186 703531-189 Cut Sheet Feeder Assembly (See Figure 15 For Details) --------- See Figure 16 For Details Of This Area 705733-012 MC PCBA, L5035 (See Figure 17 For Details) 703531-167 PNE (Paper Near–End) Sensor Assembly (See Figure 18 For Details) 704056-001...
Page 187 Figure 12. Back View of Printer, Close-up (continued) Assembly 703531-117 Lamp Cooling Blower Fan (VEF1) (AC Blower Assembly) (See Figure 24 For Details) 705733-006 Flash Power Supply, L5035 (behind blower) (See Figure 25 For Details) --------- DC (Main) Power Supply Assembly (See Figure 27 For Details) 703531-147...
Page 188 Appendix B Illustrated Parts List Figure 13. Cut Sheet Output Assembly...
Page 189 Quantity Item Description: Figure 13. Cut Sheet Output Assembly Part Assembly 703531-221 Output Assembly Roller-8 703531-222 Output Assembly Roller-9 703531-226 Output Assembly Roller-12 703531-075 PHINT ON1517LA-(A) (Optical Sensor) 703531-034 Belt, 265MXL4.8...
Page 190 Appendix B Illustrated Parts List Figure 14. LED Print Head (LED Array)
Page 191 Quantity Item Description: Figure 14. LED Print Head (LED Array) Part Assembly 703551-001 LED Print Head, 240 DPI (LED Array) 703551-002 LED Print Head, 300 DPI (LED Array) 703551-003 LED Print Head, 400 DPI (LED Array) 703531-068 Heat Pipe Assembly...
Page 192 Appendix B Illustrated Parts List Figure 15. Cut Sheet Feeder Assembly (Sheet 1 of 4)
Page 193 Figure 15. Cut Sheet Feeder Assembly (Sheet 2 of 4)
Page 194 Appendix B Illustrated Parts List Figure 15. Cut Sheet Feeder Assembly (Sheet 3 of 4)
Page 195 Figure 15. Cut Sheet Feeder Assembly (Sheet 4 of 4)
Page 196 Appendix B Illustrated Parts List (Parts lists continue on next page.)
Page 197 Quantity Item Description: Figure 15. Cut Sheet Feeder Assembly Part Assembly 703531-189 Cut Sheet Feeder Assembly 703531-072 Resist Sensor Assembly 703531-050 Pickup Roller Assembly 703531-577 Thumbscrew, In/Out 703531-051 Reverse Roller Assembly 703531-071 Cassette Sensor PCBA-1 703531-070 Feeder PCBA with ROM-Option 1 703531-069 Feeder ROM-Option 1 703531-077...
Page 198 Appendix B Illustrated Parts List Figure 16. Front View, Left Side (Sheet 1 of 3)
Page 199 Figure 16. Front View, Left Side (Sheet 2 of 3)
Page 200 Appendix B Illustrated Parts List Figure 16. Front View, Left Side (Sheet 3 of 3)
Page 201 Assembly 703531-130 Drum Support Assembly 703531-111 O-Ring CO-0013-A 703531-128 Drum Guide Assembly, Front 703531-114 Tractor Assembly 705733-009 Motor Assembly, Drum, L5035 703531-075 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 703531-041 Motor Assembly, Tractor 706291-001 Pulley, Drum, 3M-51-28 706292-001 Pulley, Tractor, 3M-63 706293-001...
Page 202 Appendix B Illustrated Parts List Figure 17. MC PCBA...
Page 203 Quantity Item Description: Figure 17. MC PCBA Part Assembly 705733-012 MC PCBA, L5035...
Page 204 Appendix B Illustrated Parts List Figure 18. PNE (Paper Near–End) Sensor Assembly...
Page 205 Quantity Item Description: Part Figure 18. PNE (Paper Near–End) Sensor Assembly Assembly 703531-167 PNE (Paper Near-End) Sensor Assembly 703531-154 Sensor B PCBA 703531-153 Sensor A PCBA...
Page 206 Appendix B Illustrated Parts List Figure 19. Controller Module (Sheet 1 of 4)
Page 207 Figure 19. Controller Module (Sheet 2 of 4)
Page 208 Appendix B Illustrated Parts List Figure 19. Controller Module (Sheet 3 of 4)
Page 209 Figure 19. Controller Module (Sheet 4 of 4)
Page 210 Appendix B Illustrated Parts List (Parts lists continue on next page.)
Page 211 Quantity Item Description: Figure 19. Controller Module Part Assembly 704056-001 Controller Module 706441-901 PCBA, EDO-040 Controller (with flash memory) 705668-001 PCBA, EDO-040 Controller (for printers with floppy drives) 1 202904-001 SIMM, EDO DRAM, 4 MB 202903-001 SIMM, EDO DRAM, 8 MB 202902-001 SIMM, EDO DRAM, 16 MB 703678-001...
Page 212 Appendix B Illustrated Parts List Figure 20. Head Blower Fan Assembly...
Page 213 Quantity Item Description: Figure 20. Head Blower Fan Assembly Part Assembly 703531-104 Head Blower Fan 703531-001 LED Air Filter...
Page 214 Appendix B Illustrated Parts List Figure 21. Developing Unit Drive Assembly...
Page 215 Description: Figure 21. Developing Unit Drive Assembly Part Assembly 703531-143 Developing Unit Drive Assembly 703531-219 Plate, Developing Unit Gear #9 202834-001 Gear Assembly For Developing Unit, L5035 703531-215 Plate, Developing Unit Gear #10 705733-011 Magroll Motor Assembly 705733-010 Sleeve Motor Assembly 703531-216...
Page 216 Appendix B Illustrated Parts List Figure 22. General Details (Sheet 1 of 2)
Page 217 Figure 22. General Details (Sheet 2 of 2)
Page 218 Appendix B Illustrated Parts List (Parts lists continue on next page.)
Page 219 Quantity Item Description: Figure 22. General Details Part Assembly 703531-107 I/O 26 Harness Assembly 703531-108 Drawer Harness Assembly 703531-075 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 703531-159 Transfer Elevator Motor...
Page 220 Appendix B Illustrated Parts List Figure 23. Smoke Filter Box...
Page 221 Quantity Item Description: Figure 23. Smoke Filter Box Part Assembly 703540-001 Smoke Filter Box (VEFE Assembly) 703531-116 Smoke Filter Blower Fan (VEF0) (Main Blower Fan)
Page 222 Appendix B Illustrated Parts List Figure 24. Lamp Cooling Blower Fan (AC Blower Assembly)
Page 223 Description: Quantity Item Figure 24. Lamp Cooling Blower Fan (AC Blower Part Assembly) Assembly 703531-117 Lamp Cooling Blower Fan (VEF1) (AC Blower Assembly)
Page 224 Appendix B Illustrated Parts List Figure 25. Flash Power Supply...
Page 225 Quantity Item Description: Figure 25. Flash Power Supply Part Assembly 705733-006 Flash Power Supply, L5035 703531-561 Capacitor...
Page 226 Appendix B Illustrated Parts List Figure 26. Miscellaneous Details...
Page 227 Quantity Item Description: Figure 26. Miscellaneous Details Part Assembly 703531-147 Connector Assembly For Transfer Ozone 703531-163 Varistor/High-Voltage Cable...
Page 228 Appendix B Illustrated Parts List Figure 27. DC (Main) Power Supply...
Page 229 Quantity Item Figure 27. DC (Main) Power Supply Part Description: Assembly 705733-007 DC Power Supply PCBA, L5035 202836-001 Fan, DC Power Supply, L5035 202837-001 Relay, DC Power Supply, L5035...
Page 230 Appendix B Illustrated Parts List Figure 28. Back View, Left Side (Sheet 1 of 5)
Page 231 Figure 28. Back View, Left Side (Sheet 2 of 5)
Page 232 Appendix B Illustrated Parts List Figure 28. Back View, Left Side (Sheet 3 of 5)
Page 233 Figure 28. Back View, Left Side (Sheet 4 of 5)
Page 234 Appendix B Illustrated Parts List Figure 28. Back View, Left Side (Sheet 5 of 5)
Page 235 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 703531-086 Gate Front Block 703531-121 Rubber Paper Press 1 703531-115 Rubber Paper Press 2 703531-119 Cutter Motor Assembly, L5035 705733-013 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 703531-075 Belt MXL-535-6.4 703531-027 Cutter Motor, L5035 705733-013 Belt 67MXL6.4...
Page 236 Appendix B Illustrated Parts List Figure 29. Drum Shaft Assembly and Belts...
Page 237 Quantity Item Description: Figure 29. Drum Shaft Assembly and Belts Part Assembly 705579-001 Cleaner Driver Coupler (metal) 703531-032 Belt 60S3M501 703531-532 Gear, Cleaner Drive 703531-031 Belt 60S3M264 703531-075 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 703531-133 Tension Pulley, Drum Assembly 703531-144 Shaft Assembly, Drum 703531-234 Holder Blk., Gear Assembly 703531-590...
Page 238 Appendix B Illustrated Parts List Figure 30. Flash Duct Assembly...
Page 239 Quantity Item Description: Figure 30. Flash Duct Assembly Part Assembly 703531-105 Fuser Cooling Fan...
Page 240 Appendix B Illustrated Parts List Figure 31. Bracket Assembly, FU (Fuser Unit) Connector...
Page 241 Quantity Item Description: Part Figure 31. Bracket Assembly, FU (Fuser Unit) Connector Assembly 703531-142 Fuser Connector (2 ea./set) 703531-112 Harness Assembly, Halogen...
Page 242 Appendix B Illustrated Parts List Figure 32. Back of Printer, Left Side (Sheet 1 of 6)
Page 243 Figure 32. Back of Printer, Left Side (Sheet 2 of 6)
Page 244 Appendix B Illustrated Parts List Figure 32. Back of Printer, Left Side (Sheet 3 of 6)
Page 245 Figure 32. Back of Printer, Left Side (Sheet 4 of 6)
Page 246 Appendix B Illustrated Parts List Figure 32. Back of Printer, Left Side (Sheet 5 of 6)
Page 247 This view is rotated 180° Figure 32. Back of Printer, Left Side (Sheet 6 of 6)
Page 248 Appendix B Illustrated Parts List (Parts lists continue on next page.)
Page 249 Quantity Item Description: Figure 32. Back of Printer, Left Side Part Assembly 703531-570 Bearing, Shaft Roller 703531-131 EPS0 Assembly (Paper Motion Sensor) 703531-075 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 703531-106 Microswitch SW V-014-1C23 703531-129 Solenoid DS Assembly 703531-052 Separating Finger Assembly (Separator Claw Shaft Assembly) 705733-008 Sensor Assembly, Drum Surface Potential...
Page 250 Appendix B Illustrated Parts List...
Page 251: C Optional Cut Sheet Feeder
Optional Cut Sheet Feeder Physical Description The front, back, and rear views of the cut sheet feeder unit are shown in the following illustrations. Front Side Lower level paper empty sensor (PES2) Carry-out rollers Upper level paper empty sensor (PES1) Cassette support Cassette setter Paper guide...
Page 252: Back Side
Appendix C Optional Cut Sheet Feeder Back Side Cut sheet feeder roller Paper register sensor (PRS) Register roller Paper register clutch (PRC) Paper timing sensor (PTS)
Page 253: Rear Side (Board Side)
Physical Description Rear Side (Board Side) Cut sheet pick up motor (PPM) Upper level cut sheet pick up clutch (PPC1) Cut sheet feeder motor (PFM) Paper register clutch (PRC) Lower level cut sheet pick up clutch (PPC2) Paper guide interlock switch (ICIL) Cut sheet pick up motor encoder (PME) Cut sheet feed motor encoder (FME)
Page 254: Paper Feed Cassette
Appendix C Optional Cut Sheet Feeder Paper Feed Cassette Lower level paper feed cassette (large) Upper level paper feed cassette (small) Hopper stopper Top cover Paper size cap Hopper Hopper pin...
Page 255: Setup And Connections
Setup and Connections Setup and Connections Setup 1. Install the cut sheet feeder unit by hooking the hooks on its front and rear frames onto the printer frame. 2. Secure the burrs of the front and rear feeder frames to the printer frame with 2 bolts each.
Page 256 Appendix C Optional Cut Sheet Feeder 3. Remove the wire cover. Pass the lines going to the front cover interlock switch and the operation panel underneath this cover. Wire cover Connecting line going to the operation panel, Connecting line going to the front cover interlocking switch...
Page 257 Setup and Connections Connections Connect the cut sheet feeder unit to the MC board and DC power supply board, as shown below. Cut sheet feeder unit Control board PBA-Option 1 J60101 J03102 Print Engine Part of CN3 CN10 MC-PCBA PS-PCBA...
Page 258: Basic Principles
Appendix C Optional Cut Sheet Feeder Basic Principles Upon command from the printer, the cut sheet feeder picks up paper from the selected paper cassette and supplies the paper to the transfer point. The cut sheet feeder is equipped with the following sensors and actuators: ICIL2 ICIL1 IPS10-12 /IPS 20-22:...
Page 259: Drive Principles
Basic Principles Drive Principles There are four types of rollers in the transport path of the cut sheet feeder unit: • Carry-out roller — driven by the cut sheet pickup motor, via the cut sheet pickup clutch. • Input feed roller — driven by the cut sheet pickup motor, via the cut sheet pickup clutch.
Page 260: Control Principles
Appendix C Optional Cut Sheet Feeder Control Principles The following controlling detector terminals (sensors, switches) are assembled into the cut sheet feeder unit. Upper Level / Lower Level Paper Size Detector Sensor These sensors are each comprised of 3 switches set on the board. There are 7 paper sizes (including no cassette).
Page 261: Paper Feed Cassettes
Control Principles Paper Feed Cassettes 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 262: Cut Sheet Feed Sensor (Pfs), Paper Register Sensor
Appendix C Optional Cut Sheet Feeder Upper Level / Lower Level Paper Empty Sensor (PES1 / PES2) These sensors are photointerrupters. When the paper in the paper supply cassette runs out, the lever lowers and blocks the light between the light emitters and receptors, causing detection of no paper.
Page 263: Paper Timing Sensor (Pts)
Control Principles Paper Timing Sensor (PTS) This sensor is also a photo-interrupter. However, because the output signal is used as the cut sheet leading-edge detection signal and affects printing quality, the mechanical aspects (lever) have been eliminated. The paper timing sensor consists of an LED light emitter and receptor on either side of the transport path.
Page 264: Cut Sheet Pickup Motor Encoder (Pme)
Appendix C Optional Cut Sheet Feeder Cut Sheet Pickup Motor Encoder (PME) The cut sheet pickup motor encoder is a rotary encoder that consists of a slotted plate attached to the cut sheet pickup motor rotating axis, with a light emitter and receptor on either side of the plate.
Page 265: Cut Sheet Feed Motor Encoder (Fme)
Control Principles Cut Sheet Feed Motor Encoder (FME) The cut sheet feed motor encoder is also a rotary encoder that consists of a slotted plate attached to the cut sheet pickup motor rotating axis, with a light emitter and receptor on either side of the plate. The motor rotation is detected by the pulse string that is created by light passing through the rotating slotted plate.
Page 266: Paper Guide Interlock Switch (Icil)
Appendix C Optional Cut Sheet Feeder Paper Guide Interlock Switch (ICIL) This is a microswitch that detects whether the paper guide is open or not. This switch is also interlocked with the cut sheet feeder 24 V system (actuator drive system), so that when this switch is off, the actuator power is also off. Paper guide interlock switch...
Page 267: Detection Errors
Detection Errors Detection Errors The errors detected by the previously discussed sensors and switches are as follows: Upper Level Cassette Section Error Error Code Contents Pickup miss Paper did not move to the paper register sensor within a certain time after the carry- out roller operated (upper level pickup misjudgment, timer started with PPC1 coming on, and timed out before PRS on).
Page 268: Transfer Unit Error
Appendix C Optional Cut Sheet Feeder Transfer Unit Error Error Code Contents Delayed jam Too much time passed for the paper to move from the paper register clutch to the paper timing sensor (delayed jam, judgment timer started with PRC coming on, and timed out before PTS on).
Page 269: Unit Sequencer Section Errors
Detection Errors Unit Sequencer Section Errors Error Code Contents Motor revolution abnormality 1 Revolution abnormality occurred in the cut sheet pickup motor (PPM revolution abnormality, monitor timer counted up during paper supply preparation operations). Monitor timer setting = 200msec. Motor revolution abnormality 2 Revolution abnormality occurred in the cut sheet feed motor (PFM revolution abnormality, monitor timer counted up...
Page 270: Basic Operation
Appendix C Optional Cut Sheet Feeder Basic Operation The cut sheet feeder unit executes reset start processing (initializing of CPU, etc.) when power is turned on. It then executes the following main routine while waiting for the cassette specification command and the paper supply preparation start command to be transmitted from the printer.
Page 271: Mechanism Initialization
Basic Operation Mechanism Initialization This processing is executed only once, to confirm that there are no errors when stopped or when the motor is on. However, when an initializing request is received from the printer, this process is executed again. The ready condition is deactivated and the bit waiting for basic status (bit 4) is cleared to "0", the same as when initializing after reset starting.
Page 272: Cut Sheet Output Unit
Appendix C Optional Cut Sheet Feeder Cut Sheet Output Unit Physical Description The front and rear views of the cut sheet output unit are shown in the following illustrations. Front Side...
Page 273 Cut Sheet Output Unit Rear Side...
Page 274 Appendix C Optional Cut Sheet Feeder Setup and Connections Setup 1. Install the cut sheet output unit by securing the burrs of the front and rear output unit frames to the printer frame with 2 bolts each.
Page 275 Cut Sheet Output Unit 2. Attach the entrance roller joint shaft, then secure it with the E-ring. E-ring...
Page 276 Appendix C Optional Cut Sheet Feeder Connections Connect the cut sheet output unit connector to the printer frame connector that connects to connector CN3 on the MC board. Printer frame connector Cut sheet output unit connector...
Page 277: Main Unit Feed Roller Drive
Cut Sheet Output Unit Basic Principles The cut sheet output unit guides cut sheet paper ejected from the main unit to the face down paper output tray on the top cover. This unit has three sets of transporting rollers: the entrance rollers, the intermediate paper rollers, and the output paper rollers.
Page 278 Appendix C Optional Cut Sheet Feeder...
Page 279: Paper Stacker
Optional Power Paper Stacker Physical Description The front, rear, and internal views of the power paper stacker are shown in the following figures. Front (Output side) DOWN key HEAVY key STOP key AUTO key Hook Head/tail length measuring gauge (in inches) Safety stop bar Safety stop bar (not visible in figure)
Page 280: Rear (Input Side)
Appendix D Optional Power Paper Stacker Rear (Input side) Assisting arm motor Paper surface sensor 2 (PSS2) Swinger Assisting arms Swinger Elevator motor (SM) Hooks Paper surface sensor 1 (PSS1) Elevator motor drive gear Controller board...
Page 281: Front (Interior)
Physical Description Front (Interior) Safety sensor (SS1) —behind panel Transfer belt Paper surface sensor 2 (PSS2) Paper surface sensor 1 (PSS1)
Page 282 Appendix D Optional Power Paper Stacker Setup and Connections Setup CAUTION Before installing or removing the power paper stacker, the printer must be adjusted to the proper height and be leveled. Failure to do this will damage both the printer and the stacker, and will prevent installation or removal of the stacker.
Page 283 Setup and Connections Power stacker Hook Stud Printer Printer Stud...
Page 284 Appendix D Optional Power Paper Stacker 2. Connect the stacker connector to the printer connector located above the noise filter box on the printer main power supply. Printer connector Noise filter box 3. Attach the stacker ground wire to the correct printer ground terminal with a screw, as shown.
Page 285 Setup and Connections Connections The paper stacker is connected to the printer as follows: Print engine MC-PCBA Power paper stacker Controller board PS-PCBA CN13...
Page 286 Appendix D Optional Power Paper Stacker Removal To release the stacker from the printer, press the release lever (located on the front side) to remove the hooks from the studs. Release lever...
Page 287 Operation Operation The power paper stacker contains the following keys for operating the elevator: • AUTO: Sets the elevator in automatic mode. Pressing this key causes the elevator table to rise until it reaches its maximum upper position and enables the stacker. •...
Page 288 Appendix D Optional Power Paper Stacker The power stacker folds output paper at the perforation and accumulates it on the elevator table. Feed rollers transfer fan fold paper that is output from the printer. After the paper moves between the feed rollers, it is stacked on the elevator table by the action of the swinger swinging back and forth.
Page 289 Operation As fanfold paper is output from the swinger, the assisting arms respond to the actions of the swinger, and fold the paper at the perforations. The transfer belts press the paper, stacking it on the elevator table. As paper accumulates on the elevator table, the table lowers to keep the height of the paper uniform.
Page 290: Sensors And Actuators
Appendix D Optional Power Paper Stacker Sensors and Actuators The power paper stacker has the following sensors and actuators: APS1 ESWA ESWS ESWD ESWH LIMT1 PSS1 PSS2 PSS3 LIMT2 SMT: Stacker motor SS2: Safety sensor 2 SME: Stacker motor encoder SFS: Stacker full sensor Assisting arm drive motor EDS: Elevator down sensor...
Page 291: Feed Roller And Transfer Belt
Drive Principles Drive Principles Feed Roller and Transfer Belt Both feed roller and transfer belt are driven by the stacker motor. Feed roller Stacker motor Transfer belt...
Page 292 Appendix D Optional Power Paper Stacker Also, the space between the transfer belts can be adjusted by the top and bottom adjusting knob. Transfer belt Top and bottom adjusting knob...
Page 293 Drive Principles Swinger The swinger is driven by the swinger motor. Swinger Swinger motor...
Page 294: Assisting Arms
Appendix D Optional Power Paper Stacker Assisting Arms The assisting arms are driven by the assisting arm drive motor. NOTE: The assisting arms are not activated when the head-to-tail length of the sheet is 7 to 8.5 inches. Assisting arm motor Assisting arms Assisting arms...
Page 295: Elevator Table
Drive Principles Elevator Table The elevator table is driven by the elevator motor. Elevator table Elevator motor...
Page 296 Appendix D Optional Power Paper Stacker Control Principles The power paper stacker contains the control detectors (sensors and switches) described in the following sections. Transfer Unit Paper Sensor (Paper Moving Sensor) (PMS) The transfer unit paper sensor is a photointerrupter that is composed of a light emitter and receptor and a lever.
Page 297: Jam Sensor (Pps)
Control Principles Jam Sensor (PPS) The jam sensor is a photointerrupter that is composed of a light emitter and receptor and a lever. This sensor is located partway on the toothed belt. When the paper fold falls on this belt and kicks the lever, the light passing between the light emitter and receptor is blocked, and the sensor turns on.
Page 298 Appendix D Optional Power Paper Stacker Paper Surface Sensor 1 (PSS1), Paper Surface Sensor 2 (PSS2) The paper surface sensor 1 and paper surface sensor 2 are each composed of light emitters and receptors located on the front side and rear side. When paper stacking on the elevator table reaches the height of the sensors, the light is blocked, turning on the sensors.
Page 299: Stacker Full Sensor (Sfs), Elevator Down Sensor (Eds)
Control Principles Stacker Full Sensor (SFS), Elevator Down Sensor (EDS) The stacker full sensor and the elevator down sensor are photointerrupter sensors, each of which detects the position of the elevator table. The stacker full sensor indicates that the amount of folded paper has reached the limit. The elevator down sensor indicates that the elevator table has reached the down position (the position where the operator removes the paper).
Page 300 Appendix D Optional Power Paper Stacker Stacker Motor Encoder (SME), Elevator Motor Encoder (EME) These sensors detect abnormal DC motor revolution. Each sensor consists of a timing disk attached to the motor axis, a light emitter, and a light receptor. The motor revolution is monitored by the length of time that blockages of light occur between the light emitter and receptor.
Page 301 Control Principles Swinger Position Sensor (SPS), Assisting Arm Position Sensor (APS1) Each of these sensors detects the home position of its associated stepping motor. Each sensor consists of a slotted plate, a light emitter, and a light receptor. The location of the slot, as detected by the light emitter and receptor, is set as the home position for that motor.
Page 302 Appendix D Optional Power Paper Stacker Elevator Upper Limit Switch (LIMT1), Elevator Lower Limit Switch (LIMT2) These are limit switches that prevent the elevator table from rising too high or dropping too low. If for some reason the elevator table rises abnormally high or drops abnormally low, one of these switches comes on, and the elevator table stops.
Page 303: Safety Sensor 1 (Ss1), Safety Sensor 2 (Ss)
Control Principles Safety Sensor 1 (SS1), Safety Sensor 2 (SS2) These are safety switches in case the operator accidentally gets his hand caught between the frame and elevator table of the power stacker. When this happens, the bar inside the cover tilts, and the switch contacts open. This switch is interlocked with the power paper stacker 24 V system (actuator drive system).
Page 304: Operator Call Status Errors
Appendix D Optional Power Paper Stacker Detection Errors The errors detected by these sensors and switches are as follows: Operator Call Status Errors Error Code Meaning Interlock action Safety sensor 1 or 2 turned off, and interlock operated. Folding defective Defective folding of paper occurred (PPS on or off time counted up).
Page 305 Basic Operation Basic Operation After initializing (due to turning on the power or receiving an initialization request from the printer), the power stacker enters into the following main loop and repeatedly executes the various subroutines. However, the actuator driving subroutines are selectively executed only upon the power stacker receiving execution commands from the printer.
Page 306: Driving The Stacker
Appendix D Optional Power Paper Stacker Status Confirmation Processing Checks the detection data of the sensors and switches within the paper feeding unit. If there is any abnormality, executes abnormality processing. Communication Processing Loads data transmitted from the printer, executes command analyzing processing, and returns status.
Page 307: Belt Removal Procedures
Belt Removal Procedures Belt Removal Procedures This section describes the mechanical structure of the power paper stacker and how to remove the various belts. The power stacker should be reassembled in the reverse order of the procedures described in this section. Return the screws to their original positions, as they may vary in type.
Page 308: Power Stacker Cover
Appendix D Optional Power Paper Stacker Power Stacker Cover To remove the power stacker cover: 1. Disconnect the connector that is connected to the stacker cover, and remove knob D. 2. Remove the screws (5) securing the stacker cover, then pull the cover outward to remove it.
Page 309: Inside The Left Frame
Belt Removal Procedures Inside the Left Frame Belt S (S3M741) Belt A Tension pulley Belt C (S3M825) Belt D NOTE: Some stacker (S3M900) units might appear slightly different in these areas.
Page 310 Appendix D Optional Power Paper Stacker 1. Remove Belt S: slacken the belt by pushing the tension pulley to the right, then remove the belt. Belt S Tension pulley...
Page 311 Belt Removal Procedures 2. Remove Belt A, the belt that connects the stacker motor assembly output pulley to the large pulley: turn the pulleys by hand and remove the belt. Large pulley Stacker motor assembly output pulley Belt A...
Page 312 Appendix D Optional Power Paper Stacker 3. Remove Belt C: first remove the E-clip. Then, remove the pulley by pulling it toward you. Finally, remove Belt C. Pulley E-clip Belt C NOTE: Some stacker units might appear slightly different in these areas.
Page 313 Belt Removal Procedures 4. Remove Belt D: rotate the pulley by hand and remove it along with the belt. Pulley Belt D NOTE: Some stacker units might appear slightly different in these areas.
Page 314 Appendix D Optional Power Paper Stacker 5. When replacing the belts discussed in steps 1 through 4, reinstall them in reverse order. After replacing Belt D, adjust its belt tension: a. Loosen screws A and B. Screw A Screw B b.
Page 315: Inside The Right Frame
Belt Removal Procedures Inside the Right Frame Belt E (S3M825)
Page 316 Appendix D Optional Power Paper Stacker 1. Remove the E-clip from the pin. Detach the arm from the pin, and tilt the arm in the direction of the arrow, as shown. E-clip 2. Remove the screw securing the plate, then remove the plate. Plate Screw...
Page 317 Belt Removal Procedures 3. Remove the pointer from Belt E. 4. Remove Belt E: first remove the E-clip from the pulley. Then, remove the belt and the pulley together. 5. Install a new Belt E. Belt E Pointer Pulley NOTE: Some stacker units might appear slightly different in E-clip...
Page 318 Appendix D Optional Power Paper Stacker 6. Place the knob on the shaft and rotate the knob fully clockwise. Then place the pointer back on Belt E at the location where it points to the “12" on the scale. Belt E Pointer Scale...
Page 319: Swinger Belts
Belt Removal Procedures Swinger Belts The swinger belts are located on the swinger and assist arm drive units (two belts on each drive unit). Assist arm drive unit Swinger drive unit...
Page 320 Appendix D Optional Power Paper Stacker 1. On the swinger drive unit, disconnect the connectors (2), then detach the cables from the cable clamps. Connector Connector Cable clamps Swinger drive unit...
Page 321 Belt Removal Procedures 2. Remove the E-clip, then remove the link arm from the slotted disc. E-clip Link arm Slotted disc...
Page 322 Appendix D Optional Power Paper Stacker 3. Remove the screws (3) securing the swinger drive unit, then remove the unit. Screws (3) Swinger drive unit...
Page 323 Belt Removal Procedures 4. On the assist arm drive unit, disconnect the connectors (2), then detach the cables from the cable clamps. Connector Connector Cable clamps Assist arm drive unit 5. Remove the E-clip on the arm, then remove the arm. E-clip...
Page 324 Appendix D Optional Power Paper Stacker 6. Remove the screws (3) securing the assist arm drive unit, then remove the drive unit. Assist arm drive unit Screws (3)
Page 325 Belt Removal Procedures 7. On both the swinger and the assist arm drive units: remove the screws (3), E-clip, and bush from the motor side of the plate. Then remove the plate. 8. Replace the two belts on each drive unit. E-clip Screws (3) Bush...
Page 326: Elevator Belt
Appendix D Optional Power Paper Stacker Elevator Belt 1. Remove the screws (4) securing the stacker table assembly to the table support arms (2), then remove the stacker table assembly. Screws (4 places), in step 3 Stacker elevator cover Screws (4), in step 1 Knob Table support arms (2)
Page 327 Belt Removal Procedures 4. Remove the screws (4) securing the table support arms (2) to the stacker arm brackets (2), then remove the two table support arms, as shown below. Screws (4), in step 4 Table support arms (2) Screws (2), in step 5 Stacker arm brackets (2)
Page 328 Appendix D Optional Power Paper Stacker 6. Remove the screws (4) securing the belt clamp plates (2 sets), then remove the two sets of belt clamp plates from around the belts, as shown below. Tension adjustment nuts (4) Screws (4), Elevator upper in step 8 pulley...
Page 329 Belt Removal Procedures 10. Remove the stacker elevator belt from one of the elevator upper pulley assemblies as follows: a. Remove either of the E-clips, then pull the stacker elevator pulley pin out of the stacker elevator pulley bracket. Stacker elevator pulley pin Stacker elevator pulley bracket E-clip E-clip...
Page 330 Appendix D Optional Power Paper Stacker d. Reassemble the elevator upper pulley assembly in reverse order. See the warning note that follows. WARNING When installing the elevator upper pulley assembly, adjust the tension nut such that it takes 14 oz. to deflect the belt 10 mm. Use caution, as the springs are very strong.
Page 331: Stacker Motor
Belt Removal Procedures Stacker Motor 1. Disconnect the sensor connector (not shown) and the stacker motor connector from their mating harness connectors, then detach the cables from the cable clamp. Stacker motor assembly Stacker motor assembly output pulley ° This view is rotated 180 Stacker motor connector...
Page 332 Appendix D Optional Power Paper Stacker 2. Remove Belt S: slacken the belt by pushing the tension pulley to the right, then remove the belt. Belt S Tension pulley...
Page 333 Belt Removal Procedures 3. Remove Belt A, the belt that connects the stacker motor assembly output pulley to the large pulley: turn the pulleys by hand and remove the belt. 4. Remove the E-clip securing the stacker motor assembly output pulley, then remove the output pulley.
Page 334 Appendix D Optional Power Paper Stacker 6. Remove the screws (3) securing the stacker motor assembly to the stacker frame, then remove the stacker motor assembly, as shown below. Stacker frame Stacker motor Sensor Screws (3) Stacker motor assembly Sensor mounting screw (on bottom of sensor) 7.
Page 335 Index Boards DC power supply, II-509 Abbreviations adjustments, I-403 interconnection diagram, I-191 MC, II-507 About this manual, I-21 Acronyms interconnection diagram, I-191 Cable connections, I-47 Adjustments data cables, I-50 loading flash memory, I-413 interface cables, I-50 software upgrades, I-409, I-413 signal cables, I-50 Auto-load fanfold paper command Capacitor...
Page 336 CLEAR FLASH? PRESS ENTER (Error H9), I-280 Cut sheet feeder unit, II-705 CLEAR xxxx? PRESS ENTER (Error H8), I-280 basic operation, II-724 Clearing service level messages, I-85 basic principles, II-712 Command operations cut sheet feed sensor (PFS), II-716 theory, I-182 detection errors, II-721 Connector block feed motor encoder (FME), II-719...
Page 337 DC power supply Drum voltage setting, I-77 cleaner set sensor, II-555 DC power supply board, II-509 cleaning unit, II-485 adjustments, I-403 counter fuses, I-406 MC board, I-401 input/output signals, I-226 counter circuit, I-202 variable resistors, I-404 drive DC PROGRAM NOT VALID (Error K3), I-280 theory, I-147 DELETE FILE: filename.ext (Error H7), I-280 motor, II-512...
Page 338 Electrical 05 - Paper Jam at Exit circuits, I-194 in paper output section, I-289 system, I-185 07 - Scuff Lever Open adjustments, I-408 knob "C", I-291 configuration, I-186 08 - Cut-Sheet Path Open, I-292 Electronics initialization 09 - Transport Motor Fail (complete stop), I-293 theory, I-175 0A - Cutter Fail (front), I-295 Elevator...
Page 339 H0 TEST HARDWARE PLEASE WAIT .., I- vacuum (VAF) transfer assembly, II-502 H1 DIAGNOSTIC PASSED, I-279 Fanfold Paper H2 WAITING FOR FILE DOWNLOAD, I-279 engine checker, I-372 H3 LOADING FILE FROM PORT xxx%, I-279 Fan-fold paper H4 CLEAR FLASH PLEASE WAIT .., I-279 loading, I-69 H5 WRITE FILE: filename.ext, I-279 Fan-fold Paper Empty (Error 02)
Page 340 H5 WRITE FILE: filename.ext, I-279 H6 OPTIMIZING FILE SYSTEM xx%, I-279 Gate drive H7 DELETE FILE: filename.ext, I-280 theory, I-150 H8 CLEAR xxxx? PRESS ENTER, I-280 Gates H9 CLEAR FLASH? PRESS ENTER, I-280 paper output section, II-560 K0 DC NOT 1ST FILE, I-280 Glass K1 FILE NOT COMPATIBLE, I-280 cover...
Page 341: Head Temperature Monitoring
MC board, I-214 K2 WRONG FILE CHECKSUM, I-280 PS-PCBA, I-226 K3 DC PROGRAM NOT VALID, I-280 Insert page break on fanfold paper command K4 NO FLASH FILE SYSTEM, I-280 theory, I-184 K5 DRAM FAIL AT ADDRESS xxxxxxxx, I-280 Installation K6 FLASH MEMORY FAIL, I-280 diskettes, I-76 K7 PROGRAM FLASH FAIL AT xxxxxxxx, I-280 waste toner bottle, I-65...
Page 342 magroll motor, I-400 main charger current control circuit, I-399 Magroll motor, II-514 NVRAM settings, I-392 MC board, I-400 setting NVRAM values, I-392 Main body setting rotary and dip switches, I-377 feed motor sleeve motor, I-400 control circuit, I-205 switches, I-377 Main charger, II-483 test points, I-381 current control circuit...
Page 343: Operational Sequences
K4 NO FLASH FILE SYSTEM, I-280 K5 DRAM FAIL AT ADDRESS xxxxxxxx, I-280 Nip switch (NPSW) K6 FLASH MEMORY FAIL, I-280 sensors/switches, II-557, II-558 K7 PROGRAM FLASH FAIL AT xxxxxxxx, I- No Cleaning Unit (Error 26), I-317 NO FLASH FILE SYSTEM (Error K4), I-280 K8 FLASH MEMORY FULL, I-281 No Waste Toner Box (Error 29), I-319 K9 PROGRAM NEEDS MORE DRAM, I-281...
Page 344 sensors near paper output section, I-259 paper empty, II-716 near tractor, I-258 paper near-end, I-158 Paper near-end sensor (PNES), II-585 paper output (EPS0), I-159 photoemitting board, II-585 paper register, II-716 photoreceptor board, II-586 paper size, II-714 Paper output section paper timing, II-717 paper jams near, I-259 transport Paper path...
Page 345: Printing Operations
belt removal procedures, II-761 Power supply filter cover, II-762 flash detection errors, II-758 cleaning, I-123 drive principles, II-745 Precautions elevator belt, II-780 safety elevator down sensor (EDS), II-753 English, I-23 elevator motor encoder (EME), II-754 German See Safety, I-30 elevator switches (ESWA/ESWS/ESWD/ setup safety ESWH), II-757 English, I-25...
Page 346 Printing system descriptions, I-125 Processing Safety images, I-126 label locations PROGRAM FLASH FAIL AT xxxxxxxx (Error K7), I- English, I-26 German, I-33 PROGRAM NEEDS MORE DRAM (Error K9), I-281 notices, I-21 PS-PCBA precautions fuses, I-406 English, I-23 input/output signals, I-226 German, I-30 variable resistors, I-404 sensors, power paper stacker, II-757...
Page 347 paper registration sensor Separator claw theory, I-159 assembly, II-486 paper timing sensor drive theory, I-159 theory, I-154 Sensors and switches, II-552 Sequence of operation, I-174 Sensors/switches Service levels cut sheet feed motor encoder (FME), II-719 messages cut sheet feed sensor (PFS), II-716 clearing, I-85 cut sheet pickup motor encoder (PME), II-718 page counts, I-84...
Page 348: Block Diagram
elevator motor encoder, II-754 Toner elevator switches, II-757 cartridge full sensor, II-753 installation, I-65 jam sensor, II-751 density motor encoder, II-754 control (theory), I-167 paper moving sensor, II-750 control circuit, I-198 paper surface sensor, II-752 empty power paper, I-69, II-733 detection circuit, I-198 safety sensors, II-757 Toner bottle...
Page 349: Unit Interface
Transfer assembly, II-494 User Maint option paper exit sensor 3 (EPS3), II-502 service levels, I-84 paper exit sensor 4 (EPS4), II-502 Utility program vacuum fan (VAF), II-502 lasr2fls, I-411 Transfer Charger High Voltage Error (Error 79), I- Vacuum cleaners Transfer elevator recommended models, I-39 motor, II-523 Vacuum fan...
Page 352 Nederland BV P.O. Box 163, Nieuweweg 283 NL-6600 Ad Wijchen The Netherlands Phone: (31) 24 6489489 Fax: (31) 24 6489499 Printronix Schweiz GmbH 42 Changi South Street 1 Changi South Industrial Estate Singapore 486763 Phone: (65) 542-0110 Fax: (65) 543-0220...

Printronix L5035 Maintenance Manual

Volume 1

Table of Contents

Volume 2

Stacker Motor

Replacement Procedures

A Paper Specifications

B Illustrated Parts List

C Optional Cut Sheet Feeder

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Summary of Contents for Printronix L5035

Table of Contents