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Printronix L1024 Maintenance Manual

Continuous form laser printer

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Maintenance Manual

L1024 Continuous Form Laser Printer

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Summary of Contents for Printronix L1024

Page 1: Maintenance Manual
Maintenance Manual L1024 Continuous Form Laser Printer...
Page 3 L1024 Continuous Form Laser Printer Maintenance Manual P/N 704792–001, Rev C...
Page 4 Printronix, Inc. shall not be held responsible for errors contained herein or any omissions from this material or for any damages, whether direct, indirect, incidental or consequential, in connection with the furnishing, distribution, performance or use of this material.
Page 5: Table Of Contents
Table of Contents Chapter 1 – Introduction Scope ............. . 1–1 Conventions .
Page 6 Chapter 3 – OPC Drum Unit Subsystem Overview ............3–1 Removal and Disassembly .
Page 7 Adjustment ........... 6–29 Troubleshooting .
Page 8 Troubleshooting ..........9–11 Engine Controller Board .
Page 9 Removal and Disassembly ........12–13 Reassembly and Replacement .
Page 10 32 MISPRINT ERROR—Call Service ......13–41 33 REPLACE EEPRM—Call Service ......13–41 34 REPLACE OPC DRUM—Call Service .
Page 11: Chapter 1 - Introduction
Operator’s Guide and Setup Guide that accompany the printer. Unit Overview The L1024 is a 24-ppm continuous-form laser printer. It contains an internal engine controller and an internal data controller plus a floppy disk drive. The printer includes the major subassemblies shown in Figure 1–1.
Page 12 CLAMSHELL LSU (LASER SCANNING UNIT) HIGH VOLTAGE LED ARRAY SUPPLY LEFT FRAME FUSER ROLLER ASSEMBLY TRACTOR FUSER BASE TRANSFER MOTOR STEPPER MOTOR & CONTROL BOARD DEVELOPER HOUSING BASE VOLTAGE SUPPLY TENSION ROLLER MAIN DRIVE CONTROL PANEL BOTTOM FRAME ENGINE CONTROLLER BOARD BACKPLANE BOARD RIGHT FRAME...
Page 13: Maintenance
aintenance Users The printer is designed so that the user can perform the following maintenance tasks without calling a service technician: Removing and replacing the Toner Cartridge Removing and replacing the Waste Toner Container Replacing the Fuser Felt Wiper Cleaning the Fuser Heat Roller Cleaning the Transfer Corona Wire Cleaning the Charge Corona Wire Removing and replacing the OPC Drum Unit...
Page 14: Cleaning Methods
Cleaning Methods Cleaning kits are provided in the Developer Kits, as well as being sold separately. These kits include cotton swabs, several “wet wipe” tissues in foil pouches, a corona wire cleaning brush, and instructions. Users and service personnel are encouraged to use them on the schedule shown below. Users Users should perform the following actions at the frequencies listed below: When Refilling the Toner (approximately every 8,000 pages)
Page 15: Service Technicians
Service Technicians Service personnel should perform the following actions at or before every 300,000 pages: Clean the LSU Cover Glass. Clean other parts as needed inside the printer, including vacuuming the interior of the printer. WARNING: Turn off power to the printer before cleaning it. NOTE: The inside of the printer should be cleaned and vacuumed including special attention to paper dust on the fuser fan motor.
Page 16 The following table lists the items needing periodic cleaning and the recommended cleaning procedures: Cleaning Cleaning Frequency Tool Method Area Tension Roller 4,000 pages Wet Wipe Turn off the printer. Open the top and front (especially if using Tissue covers of the printer. Remove the OPC regular paper after Drum Unit and the Developer Unit (refer to using labels)
Page 17 Cleaning Cleaning Frequency Tool Method Area Refer to the Setup Guide. Fuser When replacing Felt Refer to the Heat Roller; Wipers and when Setup Guide. Transfer replacing Developer Corona Wire; Unit Charge Corona Wire Inside 30,000 pages Wet Wipe Remove paper powder and toner from the Cleaning Tissue areas listed below:...
Page 18 1–8 Chapter 1 – Introduction...
Page 19: Chapter 2 - Clamshell
Chapter 2 Clamshell Clamshell and Subassemblies Chapter 2 – Clamshell 2–1...
Page 20: Clamshell Parts List
2.1 Clamshell Parts List 2.1.1 Top Cover, Latch, and LED Assemblies Callout Name Vendor Part No. Printronix Part No. Top Cover and Latch Assembly 202104–501 Top Cover Assembly 200864–001 702817–001 Cover, Top 200495–001 703108–001 Seal, Short 200533–001 702820–001 Seal, Medium 200532–001...
Page 21: Led Assembly
Top Cover Latch Assembly Detail LED Assembly LED Array Assembly Detail Top Cover, Latch, and LED Assemblies Chapter 2 – Clamshell 2–3...
Page 22: Catch Release Assembly
2.1.2 Catch Release Assembly Callout Name Vendor Part No. Printronix Part No. Catch Release Assembly 200870–501 702825–001 Frame, Catch Release Lever, Release, Right Lever, Release, Left Shaft, Clamshell Locking 200980–001 Pin, Spring, 2x10mm, SS (2) 080199–110 2.1.3 Left and Right Catch Assemblies...
Page 23 Catch Release Assembly Right Catch Assembly Left Catch Assembly Right Left Hinge Hinge Assembly Assembly Catch Assemblies Chapter 2 – Clamshell 2–5...
Page 24: Left And Right Hinge Assemblies
2.1.5 Left and Right Hinge Assemblies Callout Name Vendor Part No. Printronix Part No. Frame, Clamshell, Left 202163–001 Frame, Clamshell, Right 202164–001 Hinge Assembly, Left 200967–002 704539–114 Hinge Assembly, Right 201231–001 704539–115 Hinge Assembly, Shaft/Bracket 200605–001 Bracket, Hinge Shaft, Hinge Spring, Compression, Hinge 200607–001...
Page 25 NOTE: This is the left side hinge. The right side hinge is a mirror image of the left side hinge. Hinge Assemblies Chapter 2 – Clamshell 2–7...
Page 26: Clamshell Overview
2.2 Clamshell Overview 2.2.1 Mechanical The Clamshell consists of the following basic subassemblies: A. Top Cover Assembly. This includes: The Top Cover. The Toner Dust Baffle. The Baffle is attached to the Top Cover Assembly. With the Clamshell closed, the Baffle is positioned over the waste toner outlet from the OPC Drum Unit.
Page 27: Electrical
2.2.2 Electrical All electrical connections to the Clamshell are via a cable from the Backplane Board to the LSU that passes through the Right Hinge Assembly. The cabling block diagram for the Clamshell is shown below. See Appendix B for a complete electrical block diagram. Backplane Board Block Diagram 2–1.
Page 28: Top Cover Assembly
2.3 Top Cover Assembly 2.3.1 Removal and Disassembly 1. Open the Clamshell and remove 3 Screws from the Clamshell Frame (see Figure 2–1 ), then lift the front of the Top Cover first to help disengage the LSU Locking Tabs from the rear of the Cover.
Page 29 Latch Removal Detail Top Cover Step 4 Step 3 Step 5 Clamshell Frame Step 1 Figure 2–1. Top Cover Disassembly Chapter 2 – Clamshell 2–11...
Page 30 1. Lift Front Cover, then disengage rear Locking Tabs. 2. Depress tab to remove Hinge Cover. Detail 2–1. Removing Top Cover and Hinge Covers 2–12 Chapter 2 – Clamshell...
Page 31: Reassembly And Replacement
2. Remove either Hinge Cover by pressing the lower Locking Tab with a small screwdriver and removing the Hinge Cover by lifting it upward. See Detail 2–2 . NOTE: The Clamshell Frame may need to be closed for removal of the Hinge Covers.
Page 32: Latch Assembly
2.4 Latch Assembly 2.4.1 Removal and Disassembly 1. Open the Clamshell and remove 2 screws, then remove the Latch Assembly. See Figure 2–1 . 2. Remove 1 E-ring, then slide the Latch Shaft free of the Release Lever. This frees the Release Lever and Lower Latch Spring from the Release Button.
Page 33: Reassembly And Replacement
2.4.2 Reassembly and Replacement Reverse Steps 1 through 4 listed above, and also refer to Detail 2–2 below. NOTE: When reinstalling the Latch Assembly onto the Top Cover, make sure the Latch Assembly is properly oriented with the Release Lever. See Detail 2–2.
Page 34: Catch Release Assembly
2.5 Catch Release Assembly 2.5.1 Removal and Disassembly 1. Open the Clamshell, remove 3 Screws from the Clamshell Frame, then lift the front of the Cover. This helps disengage the Locking Tabs of the LSU from the rear of the Cover. See Figure 2–1 and Detail 2–1 .
Page 35 Step 2, page 2–19 Catch Step 2 Release Assembly Step 3 Step 3, Step 4, page 2–19 page 2–19 Step 5, page 2–19 Left Catch Right Catch Step 2, page 2–19 Step 2, page 2–19 Figure 2–3. Catch Release Assembly Removal Chapter 2 –...
Page 36: Reassembly And Replacement
3. Remove the Spring Pin from the desired Release Lever, then slide it off of the Shaft. The Shaft can now be slid free of the Frame. 2.5.2 Reassembly and Replacement Reverse Steps 1 through 3 listed above. NOTE: When reinstalling the Top Cover onto the Clamshell, make sure the Latch Assembly is properly oriented with the Release Lever.
Page 37: Left And Right Catch Assemblies
2.6 Left and Right Catch Assemblies 2.6.1 Removal and Disassembly 1. Open the Clamshell, remove 3 Screws from the Clamshell Frame, then lift the front of the Cover. This helps disengage the Locking Tabs of the LSU from the rear of the Cover. See Figure 2–1 and Detail 2–1 .
Page 38: Clamshell Hinges
2.7 Clamshell Hinges 2.7.1 Removal and Disassembly 1. Place the printer on a phone book or other similar item so that the Bottom Cover edges are not resting on the item. Press gently to release the 2 Locking Tabs on the right side of the Bottom Cover, then gently lower this side.
Page 39 Base Plate for each Hinge. See Figure 2–4. Remove 1 Screw from the top of each Hinge, then remove the entire Clamshell Assembly from the printer. CAUTION: Since the LSU Cable is still connected to the printer, the Clamshell will have limited movement. Be careful not to damage the LSU, the LSU Cable, or the Clamshell Frame.
Page 40: Reassembly And Replacement
6. Remove 1 Screw and the Tension Spring, then remove the Pivot Shaft from the Assembly to free the Hinge Frame from the Clamshell Frame. NOTE: The steps above can be performed for either Hinge Assembly. 2.7.2 Reassembly and Replacement Reverse Steps 1 through 6 above.
Page 41: Chapter 3 - Opc Drum Unit Subsystem
Chapter 3 OPC Drum Unit Subsystem 3.1 Overview The OPC Drum Unit is a user-replaceable consumable. It has a life of around 30,000 pages. It receives the laser light image of the page from the LSU, transfers toner from the developer to the OPC drum to form this image, and allows the toner image to be transferred to the page prior to fusing.
Page 42: Reassembly And Replacement
No disassembly is required. OPC Drum Unit Figure 3–2. Removing the OPC Drum Unit 3.3 Reassembly and Replacement No reassembly is required. To install an OPC Drum Unit, first place the unit in the printer. Then, ensure that the unit is fully seated so that its contacts on the right side are properly set, and so that the Waste Toner Auger Seal opens and fits properly over the Waste Toner Container.
Page 43: Overview
Chapter 4 Developer Subsystem 4.1 Overview The Developer Unit consists of a hopper containing toner and carrier, plus a magnet roller. The magnet roller provides measured amounts of toner to the OPC Drum Unit, for developing the page image. See Figure 4–1.
Page 44 No disassembly is required. Figure 4–2. Removing the Developer Unit 4–2 Chapter 4 – Developer Subsystem...
Page 45: Adjustment
4.3 Reassembly and Replacement No reassembly is required. To install a Developer Unit, first open the top and front covers of the printer. Then, slide the Developer Unit into the printer along the plastic rails on each side, until the unit is fully seated in the printer. Lock both of the locking tabs.
Page 46 4–4 Chapter 4 – Developer Subsystem...
Page 47: Chapter 5 - Transfer Subsystem
Chapter 5 Transfer Subsystem Transfer Charger Chapter 5 – Transfer Subsystem 5–1...
Page 48: Transfer Charger Parts List
5.1 Transfer Charger Parts List Callout Name Vendor Part No. Printronix Part No. Transfer Charger Assembly 202140–501 704539–063 Base, Transfer Charger 201235–001 Transfer Charger Assembly 202142–501 Frame Assembly, Transfer Charger 200554–552 Frame, Transfer Charger Swing Shaft Damper, PVC (2) Transfer Corona Assembly 202143–501...
Page 49 Transfer Charger Assembly Chapter 5 – Transfer Subsystem 5–3...
Page 50: Transfer Corona Parts List
5.2 Transfer Corona Parts List Callout Name Vendor Part No. Printronix Part No. Transfer Corona Assembly 202143–501 704539–064 Wire, Transfer Corona 202144–001 Cover, Transfer Corona (2) 202145–001 Spring, Extension, Transfer Corona 200617–001 Housing, Transfer Corona 200618–001 Mylar Strip, Transfer Corona 202146–001...
Page 51: Engagement Lever Parts List
5.3 Engagement Lever Parts List Callout Name Vendor Part No. Printronix Part No. Engagement Lever Assembly 200502–501 702701–001 Guide, Engagement Lever (2) 200500–001 Engagement Lever Unit 200499–551 Pulley, Cam Lever Shaft, Pulley, Cam Lever Lever, Engagement Spring, Extension, Engagement Lever 200501–001...
Page 52: Transfer Charger Subsystem Overview
5.4 Transfer Charger Subsystem Overview 5.4.1 Mechanical The following is a description of the major mechanical parts of the Transfer Subsystem and their functions. Engagement Lever. This is attached to a cam of the Fuser Cam Shaft. The cam pulls the Transfer Charger carriage away from the paper when the printing process is finished and the Fuser opens.
Page 53: Electrical
5.4.2 Electrical The transfer system has a very limited electrical function. It includes only the transfer corona. See Block Diagram 5–1. Backplane Board +24VB /CHARGE /DEVELOPER HIGH VOLTAGE TRANSFER /TRANSFER POWER SUPPLY CORONA BGND DEVELOPER BIAS /WASTE TONER TONER TNRLOW SENSOR SENSOR BOARD...
Page 54: Transfer Charger
5.5 Transfer Charger 5.5.1 Removal and Disassembly 1. Open the Clamshell and remove the OPC and Developer Units, and any paper that may be present in the Printer. 2. Remove the Front Plastic Paper Guide from the Transfer Charger by pressing down on the center and ends, then sliding it to the left.
Page 55 Step 6 Step 3 Step 5 Step 7 Step 8 Step 2 Step 4 Step 4 Figure 5–3. Transfer Charger Chapter 5 – Transfer Subsystem 5–9...
Page 56 3. Remove the Transfer Charger Paper Guide by gently pressing the Release Tabs at the rear of the Guide toward the front of the Printer. Lift the rear of the Guide to clear the Tabs of the Slots, and release the Front Tabs by rotating the Guide toward the front of the Printer. 4.
Page 57 Detail 5–3 Corona Neck Is Placed Under Retaining Tab DETAIL 5–2 Static Brush Is Placed In Front Of Retaining Detail 5–2 and 5–3. Removing the Static Brush and Rear Paper Guide; Corona Contact and Locking Tab 6. Transfer Corona Assembly: a.
Page 58 Step 6B Step 6C Step 6A Step 6B Step 6D Step 6A Figure 5–4. Transfer Corona Assembly NOTE: When installing the corona assembly, make sure the neck of the corona contact is under its locking tab. See Detail 5–3 . b.
Page 59: Reassembly And Replacement
5.5.2 Reassembly and Replacement Reverse Steps 1 through 8 above. 5.5.3 Adjustment No adjustment of the Transfer Charger Assembly is necessary. 5.5.4 Troubleshooting See Chapter 13 for troubleshooting information. Chapter 5 – Transfer Subsystem 5–13...
Page 60: Engagement Lever
5.6 Engagement Lever 5.6.1 Removal and Disassembly 1. Open the Clamshell, remove the OPC, Developer Unit and any paper present in the Printer. See Figure 5–5 . 5–14 Chapter 5 – Transfer Subsystem...
Page 61 Step 5 Detail 5–5 Detail 5–6 Step 9 Cover overlaps Cover overlaps tractor assembly tractor assembly side frame side frame Step 11 Step 6 Step 8 Step 10 Step 7 Figure 5–5. Engagement Lever Removal Chapter 5 – Transfer Subsystem 5–15...
Page 62 (For Steps 2 through 4 following, refer to Figure 5–3 on page 5–9.) 2. Remove the Front Plastic Paper Guide from the Transfer Charger by pressing down on the ends of the Paper Guide and sliding it to the left. This disengages the Locking Tabs and the Paper Guide can then be easily removed.
Page 63 Detail 5–4. Removing the Lamp Connector Chapter 5 – Transfer Subsystem 5–17...
Page 64: Reassembly And Replacement
(For Steps 7 through 11 following, refer to Figure 5–5 on page 5–15.) 7. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. See Detail 5–5 in Figure 5–5 .
Page 65: Chapter 6 - Paper Feed Subsystem
Chapter 6 Paper Feed Subsystem Paper Feed Subsystem Chapter 6 – Paper Feed Subsystem 6–1...
Page 66: Paper Feed Parts List
6.1 Paper Feed Parts List 6.1.1 Paper Guides Callout Name Vendor Part No. Printronix Part No. Paper Guide, Lower 202149–001 704539–068 Sensor, Paper Empty 202278–551 704539–053 Wire Clamp, Paper Empty Sensor 202288–001 Screw, PPH, CLFW, 3x6mm (3) 030130–306 Guide, Paper Entry 202516–551...
Page 67: Tension Roller Assembly
6.1.2 Tension Roller Assembly Callout Name Vendor Part No. Printronix Part No. Tension Roller Assembly 202100–501 Frame Assembly, Tension Roller 202101–551 Frame, Tension Roller Shaft, Transfer Gear, Tension Roller Shaft, Drive Gear, Tension Roller Gear, Tension Roller (2) 200567–001 Gear, Transfer, Tension Roller 202103–001...
Page 68 Tension Roller Assembly 6–4 Chapter 6 – Paper Feed Subsystem...
Page 69: Drive Gear Assembly
6.1.3 Drive Gear Assembly Callout Name Vendor Part No. Printronix Part No. Drive Gear Assembly 202128–501 Frame Assembly, Drive Gear 202129–551 Frame, Drive Gear Shaft, Gear, Center Shaft, Gear, Lower Stepper Motor Assembly, Drive Gear 202139–501 Cable, Stepper Motor, Drive Gear 202390–551...
Page 70 6.1.3 Drive Gear Assembly (continued) Callout Name Vendor Part No. Printronix Part No. Screw, TPH, MT, 3x6mm, Zinc 035128–306 Screw, PPH, CLFW, 4x16mm, Zinc (4) 030130–416 Screw, PPH, CLFW, 3x6mm, Zinc (3) 030130–306 Screw, PPH, CLFW, 3x10mm, Zinc 030130–310 6–6...
Page 71 Drive Gear Assembly Chapter 6 – Paper Feed Subsystem 6–7...
Page 72: Tractor Assembly And Tractor Base
6.1.4 Tractor Assembly and Tractor Base Callout Name Vendor Part No. Printronix Part No. Tractor Assembly 202150–501 704539–054 Frame Assembly, Tractor 202151–551 Frame, Tractor Shaft, Centering Gear Gear, Centering 200450–001 Sensor, TOF 202153–551 Shaft, Guide, Tractor 200566–002 Tractor Assembly w/Arm, Left 202380–501...
Page 73 Front of Printer Right Side of Printer Left Side of Printer Rear of Printer Tractor Assembly and Tractor Base Chapter 6 – Paper Feed Subsystem 6–9...
Page 74: Overview
6.2 Overview 6.2.1 Mechanical The four units primarily responsible for positioning and moving media (paper or labels) are: The Tension Roller Assembly The Drive Gear Assembly The Tractor Assembly The Lower Paper Guide 6.2.2 Electrical The electrical portion of the paper feed system consists of the following: Drive Gear Assembly.
Page 75 MAIN OZONE STEPPER MOTOR (M1) STEPPER MOTORS CONTROLLER BOARD BACKPLANE PRFAN1 BOARD PRFAN2 FUSER STEPPER /PRPOS CLUTCH MOTOR /PRINIT (M3) /SCPUP /SCPDN PJAM SENSOR EJAM /PRFAN DGND FUSER BASE UNIT EXIT SENSOR COPEN /OPC /NEWOPC TMRSG TMRPWR /OZNFAN /PRCL PHA1 PHB1 /PHA1 /PHB1...
Page 76: Tension Roller Assembly
6.3 Tension Roller Assembly 6.3.1 Removal and Disassembly 1. Open the Clamshell, remove the OPC and Developer Units, and any paper present in the Printer. 2. Remove the Front Plastic Paper Guide from the Transfer Charger Assembly by pressing down on its ends and sliding it to the left. This disengages the Locking Tabs and the Paper Guide can then be easily removed.
Page 77 Detail 6–2 Cover overlaps tractor assembly side frame Step 3 Step 4 Step 4 6.4.1, Step 6 6.4.1, Step 5 6.4.1, Step 4 Figure 6–1 Removing the Lower Paper Guide Chapter 6 – Paper Feed Subsystem 6–13...
Page 78 4. Remove 2 Screws at the rear of the Tension Roller Assembly, and remove it from the Printer. See Figure 6–1 . 5. Remove 1 E-ring from the Drive Gear Shaft and remove the Tension Roller Gear. See Figure 6–2. Step 11 Step 10 Step 10...
Page 79 NOTE: Upon installation, check the dimension between the Shaft and the Tension Roller Frame (without the Tension Roller in place) with a caliper, as shown in Detail 6–3 below. If the dimensions are out of range, gently bend the spring to correct the dimensions. Shaft A, B = 0.492 0.01 inch (12.5 0.3 mm) Detail 6–3.
Page 80: Reassembly And Replacement
6.3.2 Reassembly and Replacement Reverse Steps 1 through 11 above. NOTE: When the Tension Roller Assembly is reinstalled in the printer, it must be positioned correctly using the locating pins. Install the left end of the Paper Guide first, then lock the tabs at the front into the slots on the Roller Frame.
Page 81: Drive Gear Assembly
6.4 Drive Gear Assembly 6.4.1 Removal and Disassembly 1. Open the Clamshell, remove the OPC and Developer Units, and any paper present in the Printer. 2. Remove the Lamp Connector Cover by removing 1 Screw and sliding the cover toward the fuser.
Page 82 Step 2 Step 3 Detail 6–5. Removing Connectors 6–18 Chapter 6 – Paper Feed Subsystem...
Page 83 3. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. See Detail 6–5 . NOTE: Upon installation, the groove on the bottom of the Right Side Cover must straddle the top edge of the right side of the Tractor Frame.
Page 84 Step 9 Step 8 Step 10 Step 10 Step 7 Figure 6–3. Removing the Display Mounting Bracket 6–20 Chapter 6 – Paper Feed Subsystem...
Page 85 DISASSEMBLY NOTE: The Stepper Motor can be removed from the Gear Assembly without removing the Gear Assembly from the Printer. 1. Remove 4 Screws, then remove the Stepper Motor from the Gear Assembly. See Figure 6–4. NOTE: When installing the Stepper Motor onto the Frame, the Cable Connector must face toward the rear of the printer.
Page 86: Reassembly And Replacement
4. Remove 1 E-ring and remove the Inner Transfer Gear. Then, remove 1 E-ring from each end of the Inner Transfer Gear Shaft. The Ball Bearing on each end of the Shaft can now be removed, and the Shaft can be slid clear of the Frame. Do not remove the Spring Pin from the Inner Transfer Gear Shaft unless NOTE: the Shaft is damaged and needs to be replaced.
Page 87: Removal And Disassembly
a. The Inner Transfer Gear is broken. Replace the Inner Transfer Gear. 4. The Stepper Motor loses coordination with the OPC Drum Unit and the Developer Unit, even though the OPC Drum Unit and Developer Unit are new. a. Check the Stepper Motor wire harness. b.
Page 88 Step 1 Detail 6–6 Detail 6–7 Step 5 Cover overlaps Cover overlaps tractor assembly tractor assembly side frame side frame Step 7 Step 2 Step 4 Step 6 Step 3 Figure 6–5. Tractor Removal 6–24 Chapter 6 – Paper Feed Subsystem...
Page 89 2. Remove the Lamp Connector Cover by removing 1 Screw and sliding the cover toward the fuser. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor Board Frame. See Figure 6–5 . 3. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover.
Page 90 Front of Printer Step 5 Left Side of Printer Step 1 Step 7 Step 6 Step 8 Right Side of Printer Step 11 Step 2 Step 8 Step 9 Step 4 Step 3A Step 3B Step 9 Step 3C Rear of Printer Figure 6–6.
Page 91: Front Of Printer
3. Encoder Board Removal: a. Remove the TOF Sensor from the Tractor Frame by gently pressing its retaining tabs. b. Remove 1 Screw from the Encoder Board and carefully slide it free of the Encoder Wheel so that neither the Wheel nor the Optical Sensors are damaged. The Tractor Cable is attached to the Encoder Board and must be removed with it.
Page 92: Rear Of Printer
Right Side of Printer Note: The tractors are marked on the inside of each tractor, DL for left and DR for right. Rear of Printer Note: Align timing marks on both tractors to the timing dot on encoder wheel. Timing dot on encoder wheel Flat face of drive shaft faces the rear...
Page 93: Tractor Assembly
TRACTOR ASSEMBLY REMOVAL 6. Loosen the Tractor Drive Shaft by removing 1 E-ring from the left end of the Shaft and sliding the Bushing off of the Shaft. Do not remove the Spring Pin from the right end of the Shaft. NOTE: 7.
Page 94: Troubleshooting
Front of Printer Note: Loosen this screw, but do not remove it. Left Side of Printer Rear of Printer Detail 6–10. Adjusting the Tractor Encoder Board 3. Refer to Detail 6–10 and perform one of the following Steps: a. If the print is to be moved closer to the page break, slide the Tractor Encoder Board toward the front of the printer.
Page 95: Lower Paper Guide And Paper Empty Sensor
6.6 Lower Paper Guide and Paper Empty Sensor 6.6.1 Removal and Disassembly 1. Open the Clamshell. Remove any paper present in the printer. Remove the OPC Drum Unit, the Developer Unit, and the Waste Toner Container. 2. Remove the Front Plastic Paper Guide of the Transfer Charger Assembly by pressing down on the ends of the Guide and sliding it to the left.
Page 96: Reassembly And Replacement
Bottom Cover Locking Tabs Detail 6–11. Bottom Cover Removal 6. Disconnect the Paper Empty Sensor Cable from Connector S11 on the Backplane Board. The Cable can now be routed through the Left Side Frame. 6.6.2 Reassembly and Replacement Reverse the 6 Steps above. 6.6.3 Adjustment No adjustment is required.
Page 97: Chapter 7 - Fuser Subsystem
Chapter 7 Fuser Subsystem Fuser Subsystem Chapter 7 – Fuser Subsystem 7–1...
Page 98: Fuser Parts List
7.1 Fuser Parts List 7.1.1 Fuser Assembly Callout Name Vendor Part No. Printronix Part No. Fuser Assembly, 115V 202176–501 704539–012 Fuser Assembly, 230V 202213–501 704539–013 Cover Assembly, Fuser Wiper 202177–551 Cover, Fuser Wiper Spring, Retaining, Fuser Wiper (2) Lower Fuser Assembly 202180–501...
Page 99 7.1.1 Fuser Assembly (continued) Callout Name Vendor Part No. Printronix Part No. Caution Label, 115V 202384–001 Caution Label, 230V 202385–001 Fuser Wiper (Not part of this assembly) 202323–501 Chapter 7 – Fuser Subsystem 7–3...
Page 100 (220 to 240V) (100 to 120V) (100 to 120V and 220 to 240V in common) Fuser Assembly 7–4 Chapter 7 – Fuser Subsystem...
Page 101: Fuser Heat Shield Assembly
7.1.2 Fuser Heat Shield Assembly Callout Name Vendor Part No. Printronix Part No. Heat Shield Assembly, Fuser Heat Shield, Fuser 202211–001 Caution Label, High Temp. 202386–001 Caution Label, Fuser Felt 202387–002 Seal, Dust 202388–001 Fuser Heat Shield Assembly Chapter 7 – Fuser Subsystem...
Page 102: Fuser Base Assembly
7.1.3 Fuser Base Assembly Callout Name Vendor Part No. Printronix Part No. Fuser Base Assembly 202216–501 704539–082 Frame Assembly, Fuser Base 202217–551 Frame, Fuser Base Pin, Fuser Clamp (2) Shaft, Exit Cover (2) Shaft, Tension Lever (2) Shaft, Exit Roller Lever (2)
Page 103 Fuser Base Assembly Chapter 7 – Fuser Subsystem 7–7...
Page 104 7.1.3 Fuser Base Assembly (continued) Callout Name Vendor Part No. Printronix Part No. Clamp, Fuser, Left 202232–001 Clamp, Fuser, Right 202233–001 Lever, Exit Roller, Left 202246–001 Spring, Torsion, Left Roller Lever 202247–001 Lever, Exit Roller, Right 202248–001 Spring, Torsion, Right Roller Lever 202249–001...
Page 105 Paper Exit Cover Assembly (Part of Fuser Base Assembly) Chapter 7 – Fuser Subsystem 7–9...
Page 106: Overview
7.2 Overview 7.2.1 Mechanical Cleaner Felt. This cleans the fuser roller of toner that gets deposited on the roller instead of the paper. It is impregnated with silicone which forms a film on the fuser roller that helps prevent toner from sticking. Fuser Sensor Wheel.
Page 107: Electrical
7.2.2 Electrical The electrical portion of the fuser has four main sections: A halogen lamp for heating the Fuser. In series with the lamp is a Thermal Breaker to switch off power to the lamp if there is a problem with the heater control circuit. A sensor board mounted to the Fuser Base Assembly.
Page 108 FUSER UNIT Thermal Breaker Halogen Lamp CNS1 LVPS STEPPER MOTORS CONTROLLER BOARD TMRPW TMRSG 202200 202576 S802 202292 S801 120V to Pin 2 S211 240V to Pin 3 202298 S208 PRFAN1 202238 202241 D112 S212 PRFAN2 FUSER STEPPER 202234 CLUTCH MOTOR /PRPOS D162...
Page 109 7.2.3 Fuser Control Modes Fusing Mode. In Fusing Mode, the Engine Controller keeps the Fuser at the fusing temperature. Fusing temperature is set in 5 C increments from 165 C to 185 C. Proper fusing temperature depends on the media in use. When the Data Controller sends a print command to the Engine Controller, the Engine Controller activates Fusing Mode.
Page 110: Fuser Assembly
7.3 Fuser Assembly 7.3.1 Removal and Disassembly 1. Open the Clamshell and remove the OPC and Developer Units, as well as any paper present in the Printer. 2. Remove the Fuser Heat Shield, then remove the Lamp Connector Cover by removing 1 Screw.
Page 111 7.3.1, Step 5 7.4.1, Step 7 7.3.1, Step 4 7.4.1, Step 6 Depress white retaining 7.3.1, 7.4.1, levers to release fuser Step 2 roller assembly from fuser base 7.4.1, Step 8 Detail 7–3 7.4.1, Step 12 J–1 Connector 7.4.1, Step 4 Cover overlaps tractor assembly side...
Page 112 3. Open the Paper Exit Cover on the back side of the Fuser Base so that it is not in contact with the Fuser Assembly. 4. Depress the Fuser Retaining Lever on each side of the Fuser Base so that the Fuser Assembly is free to move.
Page 113 Step 6 Step 7 Fuser Roller Cover locking tab locations Step 7 Step 8 Pivot is on inside of Frame Step 8 Detail 7–1. Removing the Upper Heat Shield Chapter 7 – Fuser Subsystem 7–17...
Page 114 9. Remove 1 Spring from the right rear side of the Fuser Pressure Roller Frame. See Figure 7–2. Step 15 Step 10 Step 13 Step 18 Step 16 Step 10 Step 12 Step 9 Step 18 Step 19 Step 14 (220 to 240V only) Step 12...
Page 115 10. Remove 1 Screw from each side of the Roller Frame, then remove the Fuser Pressure Roller and its Frame by disengaging the Pivot on each side of the Heat Roller Frame. See Figure 7–2 . 11. Lift the Fuser Pressure Roller out of its Frame. NOTE: Do the next Step (removal of the Fuser Pressure Roller Shaft from the Roller) only if absolutely necessary.
Page 116: Reassembly And Replacement
15. Remove 1 Screw from the Left Lamp Retaining Bracket and remove the Bracket from the Heat Roller Frame. See Figure 7–2 . 16. Remove 1 Screw from the Right Lamp Retaining Bracket and remove the Bracket from the Heat Roller Frame. See Figure 7–2 . 17.
Page 117: Adjustment
7.3.3 Adjustment Thermal Breaker NOTE: The height of the Thermal Breaker from the Fuser Roller must be adjusted every time the Thermal Breaker is removed from the Fuser. If the Thermal Breaker is too close to the Fuser Roller, the Breaker will trip at too low a temperature.
Page 118: Fuser Base
7.4 Fuser Base 7.4.1 Removal and Disassembly 1. Open the Clamshell and remove the OPC and Developer Units, as well as any paper present in the Printer. See Figure 7–1 . 2. Remove the Fuser Heat Shield, then remove the Lamp Connector Cover by removing 1 Screw.
Page 119 Step 13 Step 13A Step 13B Step 13C Step 14 Step 13E Step 13 Step 35 Step 13B Step 13D Step 33 Step 36 Step 31 Step 33 Step 32 Step 16 Step 34 Figure 7–3. Paper Exit Cover Disassembly Chapter 7 –...
Page 120 Step 26 Step 26 Step 22 Step 28 Step 24 Step 25 Step 25A Step 31 Step 22 Step 18 Step 19 Step 17 Step 25B Step 30 Step 25C Step 23 Step 25D Step 25A Step 30 Step 29 Step 20 Step 21 Step 28...
Page 121 a. Remove the Upper Exit Guide Shaft by removing 1 E-ring from the left end of the Shaft and sliding the Shaft to the right. The Shaft must be slid free of the 2 Teflon Rollers and the Frame. b. Disengage the Locking Tab of both Lower Exit Guide Shaft Bushings from the Exit Guide Frame.
Page 122 Clutch cable positioned toward front of printer Front of printer Detail 7–4. Fuser Stepper Motor Clutch Positioning 16. Only if necessary, remove the right side Fuser Roller Locking Lever from the Fuser Base Frame. If the Locking Lever must be removed, do not reuse it. Replace it with a new Locking Lever.
Page 123 24. Remove 1 E-ring from the left end of the Fuser Cam Shaft, then remove the left side Ball Bearing. 25. Lift the left end of the Fuser Cam Shaft free of the Fuser Base Frame, then slide the Shaft to the left to free the right end from the Base Frame.
Page 124 Detail 7–5. Cam Positioning 26. Remove the Rear Paper Lift Spring from both ends of the Lift, then remove 1 Screw from each end of the Lift. Remove the Rear Paper Lift from the Fuser Base Frame. 27. Disconnect the Cable from the Fuser Jam Sensor, then remove the Sensor by carefully releasing the retaining tabs from the Fuser Base Frame.
Page 125 29. Disconnect the Cables for the Fuser Cooling Fans from the Fuser Sensor Board, then remove 1 Screw to remove the Sensor Board. CAUTION: Use care when removing the Exit Guide Jam Sensor Cable from the Fuser Base Frame. The Cable can be damaged easily by the edges of the Frame.
Page 126: Reassembly And Replacement
7.4.2 Reassembly and Replacement Reverse Steps 1 through 36 above. 7.4.3 Adjustment Fuser Thermistor There are no adjustments to the Fuser Thermistor. You can, however, check the voltage across it. Use a digital voltmeter for this measurement. Under normal conditions, the following voltages will be present across the Fuser Thermistor: Approx.
Page 127: Troubleshooting
7.4.4 Troubleshooting To properly troubleshoot the fuser section, mentally separate the assembly into four functional sections: Heater and heat safety section (thermal breaker) Temperature control section (thermistor) Paper positioning section Fuser section Troubleshooting procedures for each of these four functional sections follow. Fuser Heater and Thermal Breaker The fuser heater is a quartz halogen lamp that has a rating of 1000 watts.
Page 128 Thermal Breaker Lamp Thermistor (100 to 120V) (220 to 240V) (100 to 120V and 220 to 240V in common) S211 (CNS1) Figure 7–5. Fuser Lamp, Thermal Breaker, and Thermistor Detail 7–32 Chapter 7 – Fuser Subsystem...
Page 129 3. Measure the resistance across the terminals on the lamp side of the cable (C and D). It should measure less than 2 Ω (less than 6 Ω for 220 VAC units). If not, remove the heat shield cover and measure across the thermal breaker (A and B). It should measure near 0 Ω. If the thermal breaker measures near 0 Ω, then check the lamp.
Page 130 However, if CN2–16 does not change from high to low, then suspect either the wiring harness or the engine controller. To check the harness, remove the power cable and all consumable items from the printer. Then remove the bottom cover from the printer per the cover removal section. Check continuity between the Low Voltage Power Supply CN2–16 and the engine controller.
Page 131 Temperature Control Section (Thermistor Troubleshooting) To detect the temperature of the fuser roller, the engine controller sends an analog signal, TMRPWR, to the Stepper Motors Controller Board. This signal exits the board at connector CN8–1 and is passed through cabling to the thermistor. This, in turn, is fed through the thermistor and back to the Stepper Motors Controller Board at CN8–2 as TMRSG.
Page 132 Then, to measure the fuser temperature, use a temperature probe. Let the printer cool to ambient temperature, then open the printer cover and defeat the cover interlock switch. WARNING: When you defeat the cover interlock switch, there is 115 VAC at various parts of the power supply and high voltage at other contacts—so BE VERY CAREFUL.
Page 133: Chapter 8 - Power Supplies
Chapter 8 Power Supplies High Voltage Power Supply Low Voltage Power Supply Power Supplies Chapter 8 – Power Supplies 8–1...
Page 134: Power Supplies Parts Lists
8.1 Power Supplies Parts Lists 8.1.1 Low Voltage Power Supply Callout Name Vendor Part No. Printronix Part No. Low Voltage Power Supply (LVPS) 202127–552 704539–029 Tie Wrap, Wire Harness, Lamp Power 202175–001 Bracket, Lamp Cable 202215–001 Wire Harness, Lamp Power 202292–503...
Page 135 To Fuser Low Voltage Power Supply Chapter 8 – Power Supplies 8–3...
Page 136: High Voltage Power Supply
8.1.2 High Voltage Power Supply Callout Name Vendor Part No. Printronix Part No. High Voltage Power Supply 202126–551–001 704539–033 Screw, PPH, CLFW, M3x10, Zinc (2) 030130–310 8–4 Chapter 8 – Power Supplies...
Page 137 High Voltage Power Supply Chapter 8 – Power Supplies 8–5...
Page 138: Overview
8.2 Overview 8.2.1 Mechanical There are two power supplies in the printer: The Low Voltage Power Supply (LVPS) and the High Voltage Power Supply (HVPS). 8.2.2 Electrical The LVPS provides +5 VDC, +12 VDC, +24 VDC, and –12 VDC for operation of motors, logic boards, floppy disk drives, and the control panel.
Page 139: Low Voltage Power Supply
FUSER UNIT Thermal Breaker Halogen Lamp AC POWER INLET CNS1 COOLING – TMRPW LOW VOLTAGE POWER SUPPLY TMRSG 202576 202292 S801 S211 120V to Pin 2 202298 240V to Pin 3 S208 202375 S207 (TO ENGINE (TO DATA CONTROLLER CONTROLLER BOARD) BOARD) /PRPOS...
Page 140: Removal And Disassembly
8.3 Low Voltage Power Supply 8.3.1 Removal and Disassembly NOTE: If you are replacing a Fuse or converting the LVPS input voltage, skip to the next section, “Input Voltage Conversion and Fuse Replacement”. 1. Open the Clamshell, remove the OPC Drum Unit, Developer Unit, Waste Toner Container, and any paper present in the printer.
Page 141 Step 2 Step 4 Figure 8–1. Disconnecting the Connectors 3. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. See Figure 8–2 .
Page 142 Cover overlaps tractor assembly side frame Step 3 Figure 8–2. Removing the Right Inside Cover 4. Separate the Fuser Lamp Connector and the Thermistor Connector of the LVPS from the Stepper Motor Board Frame by releasing the Locking Tabs and pushing the Connectors through the hole in the Printer Base Plate.
Page 143: Bottom Cover
Bottom Cover Locking Tabs Figure 8–3. Bottom Cover Removal 6. Remove the printer from the phone book and disconnect 2 Cables from the front of the LVPS. See Figure 8–4 . Chapter 8 – Power Supplies 8–11...
Page 144 Figure 8–4. Removing the LVPS Cables 8–12 Chapter 8 – Power Supplies...
Page 145 7. Remove 2 Screws from the rear of the Base Frame, then lift the LVPS to clear the Base Frame. Push the Power Switch to the OFF position, then slide the LVPS toward the rear of the printer. Use care to avoid damaging the Power Switch. Once the Power Switch is partially past the Frame, switch it to the ON position and slide the LVPS free of the Base Frame.
Page 146 Figure 8–5. Removing the LVPS 8–14 Chapter 8 – Power Supplies...
Page 147 Cable Routing Figure 8–6. LVPS Cable Routing Chapter 8 – Power Supplies 8–15...
Page 148 Figure 8–7. LVPS Locking Tabs 8. To remove the LVPS Cooling Fan, disconnect the Cable from Connector CN3, remove 2 Screws, then remove the Cooling Fan. 8–16 Chapter 8 – Power Supplies...
Page 149: Input Voltage Conversion And Fuse Replacement
8.3.2 Input Voltage Conversion and Fuse Replacement Use this procedure to replace a fuse in the LVPS, or to convert the LVPS input voltage from 115 VAC to 230 VAC or from 230 VAC to 115 VAC. 1. Place the printer on a phone book or other similar item so that the Bottom Cover edges are not resting on the item.
Page 150 Figure 8–9. Removing the LVPS Cables 8–18 Chapter 8 – Power Supplies...
Page 151 3. Remove 2 Screws from the rear of the Base Frame, then lift the LVPS to clear the Base Frame. Push the Power Switch to the OFF position, then slide the LVPS toward the rear of the printer. Use care to avoid damaging the Power Switch. Once the Power Switch is partially past the Frame, switch it to the ON position and slide the LVPS free of the Base Frame.
Page 152 Figure 8–10. Removing the LVPS 8–20 Chapter 8 – Power Supplies...
Page 153 Cable Routing Figure 8–11. LVPS Cable Routing Chapter 8 – Power Supplies 8–21...
Page 154 Figure 8–12. LVPS Locking Tabs 4. Remove 1 Screw from the tie wrap that secures the Lamp Power Wire Harness. 5. To change the input voltage of the LVPS, remove 1 Screw and remove the Connector Bracket. Disconnect the Cable from Connector CN5 or CN6 and connect it to the free one. CN5 is for 115 VAC and CN6 is for 230 VAC.
Page 155 115V Position 230V Position Figure 8–13. Changing LVPS Input Voltage Chapter 8 – Power Supplies 8–23...
Page 156: Reassembly And Replacement
6. Replace Fuse F1, F2, or F3 as needed. 8.3.3 Reassembly and Replacement Reverse all of the Steps listed above. The following table lists the Cable Connectors and Fuses for the LVPS, together with their respective functions and their destinations: Table 8–1.
Page 157: High Voltage Power Supply
8.4 High Voltage Power Supply 8.4.1 Removal and Disassembly 1. Open the Clamshell, remove the OPC Drum Unit, the Developer Unit, and any paper present in the printer. 2. Remove the Left Side Cover of the printer. See Figure 8–14. a.
Page 158 Step 4 Step 6 Step 5 Step 3 Step 7 Figure 8–15. Removing the Transfer Charger Paper Guides 8–26 Chapter 8 – Power Supplies...
Page 159 4. Remove the Transfer Charger Paper Guide by gently pressing the Release Tabs at the rear of the Guide toward the front of the printer. Lift the rear of the Guide to clear the Tabs of the Slots, and release the Front Tabs by rotating the Guide toward the front of the printer. See Figure 8–15 .
Page 160 Step 8 Step 12 Cover overlaps Cover overlaps tractor assembly tractor assembly side frame side frame Step 14 Step 9 Step 11 Step 13 Step 10 Figure 8–17. Removing the Fuser 8–28 Chapter 8 – Power Supplies...
Page 161 9. Remove the Lamp Connector Cover by removing 1 Screw and disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor Board Frame. See Figure 8–17 . 10. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover.
Page 162 Step 17 Step 16 Figure 8–18. Removing the HVPS 17. Disconnect the Cable from the rear of the HVPS and remove 1 Screw from the rear of the HVPS. Slide the HVPS toward the rear of the printer to release the Front Locking Tab from the Base Plate.
Page 163: Reassembly And Replacement
8.4.2 Reassembly and Replacement Reverse Steps 1 through 17 listed above. 8.4.3 Adjustment With rare exceptions, the high voltage power supply should not require adjustment. However, in the event that adjustment is required in order to return the printer to specification, use the HVPS adjustment procedure that follows.
Page 164 Ì Ì Ì Ì User–Adjustable Developer Bias Adjustment Adjustments: Ì Ì Contactor Assembly Lock–down tabs Figure 8–19. High Voltage Test and Adjustment Points 8–32 Chapter 8 – Power Supplies...
Page 165 HVPS ADJUSTMENT PROCEDURE 1. Turn off the printer. 2. Open the printer and remove the OPC Drum Unit and the Developer Unit. 3. Set the user-adjustable developer bias knob to “3”. NOTE: The user-adjustable developer bias knob is the green knob located on the top of the HVPS.
Page 166: Troubleshooting
15. Stop the test by pressing Enter. 16. Turn off the printer. 17. Restore the following to their normal (non-disabled) states: Paper empty switch Cover interlock switch Top-of-form switch OPC drum switch 18. Install the OPC Drum Unit and the Developer Unit, then close the printer top. 8.4.4 Troubleshooting See Chapter 13 for troubleshooting information.
Page 167: Chapter 9 - Controllers And Floppy Disk Drives
Chapter 9 Controllers and Floppy Disk Drives CLAMSHELL HIGH VOLTAGE SUPPLY LEFT FRAME STEPPER MOTOR & CONTROL BOARD BASE HOUSING ENGINE CONTROLLER BOARD BOTTOM FRAME DATA BACKPLANE CONTROLLER BOARD BOARD BOTTOM COVER Controller Boards Chapter 9 – Controllers and Floppy Disk Drives 9–1...
Page 168: Data Controller Board Parts List
9.1 Data Controller Board Parts List Callout Name Vendor Part No. Printronix Part No. Controller Assembly, Data, L1024 704598–001 Data Controller Board 9–2 Chapter 9 – Controllers and Floppy Disk Drives...
Page 169: Engine Controller Board Parts List
9.2 Engine Controller Board Parts List Callout Name Vendor Part No. Printronix Part No. Engine Controller Board, L1024 202505–551 704539–108 Backplane Board, L1024 202289–552 704539–107 Bottom Frame Engine Controller Board Backplane Board Engine Controller and Backplane Boards Chapter 9 – Controllers and Floppy Disk Drives...
Page 170: Stepper Motors Controller Board Parts List
9.3 Stepper Motors Controller Board Parts List Callout Name Vendor Part No. Printronix Part No. Stepper Motor Board Frame Assembly 202168–502 Cover, Side, LVPS 200673–001 Frame, Stepper Motor Board 202169–552 Board, Stepper Motor 202170–551 704539–110 Fan, Ozone 202171–551 704539–111 Actuator, Cover Open 202172–001...
Page 171: Left Side View
Left side view Right side view Stepper Motors Controller Board Chapter 9 – Controllers and Floppy Disk Drives 9–5...
Page 172: Floppy Disk Drives Parts List
9.4 Floppy Disk Drives Parts List Callout Name Vendor Part No. Printronix Part No. Disk Drive Assembly, 3.5 Inch, L1024 704627–001 Cable Kit, L1024 704612–001 Disk Drive, Floppy, 3.5 Inch 2 MB 202377–001 Screw, FL 90D, M3x5, Phil., STL/ZN Clamp, Flat, Cable, 2 Hole Mount 202404–002...
Page 173 Drive A (Standard) Drive B (Optional) Floppy Disk Drives Chapter 9 – Controllers and Floppy Disk Drives 9–7...
Page 174: Overview
9.5 Overview 9.5.1 Mechanical The printer has three Controller Boards: Data Controller Board Engine Controller Board Stepper Motors Controller Board The Data Controller Board oversees and coordinates all printer functions. It communicates with the following: Control Panel Floppy Disk Drives Engine Controller Board Host Computer The Engine Controller Board acts as interface between the Data Controller Board and the...
Page 175: Data Controller Board
9.6 Data Controller Board 9.6.1 Removal and Disassembly WARNING: To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards and components. Do not remove or replace the NVRAM on the Data Controller Board.
Page 176: Reassembly And Replacement
Screw (4) Figure 9–1. Removing Data Controller Board 9.6.2 Reassembly and Replacement Reverse Steps 1 through 5 above. 9.6.3 Adjustment No adjustment of the Data Controller Board is necessary. 9–10 Chapter 9 – Controllers and Floppy Disk Drives...
Page 177: Troubleshooting
9.6.4 Troubleshooting If you have not already done so, run the engine self-test. (Refer to the engine self-test information in Chapter 13.) If errors or other problems occur when running the engine self-test, then the problem is most likely not in the Data Controller Board or the host computer.
Page 178 PARALLEL RS232/RS422 TEST Figure 9–2. Data Controller Board Diagnostic LED Locations As the Data Controller Board starts and initializes, LEDs L1 and L2 will indicate the various portions of the boot sequence, as shown in Table 9–1. Table 9–1. Data Controller Board Boot Sequence Meaning Initial State Running DRAM Diagnostics...
Page 179 If an error occurs during the Data Controller Board power-up self-test, the initialization sequence will stop, and the board will report an error. The board reports the error by beeping the speaker, flashing L1, and flashing L2, all in unison, to signal the error code. The error code will be signalled repeatedly, as long as power to the Data Controller Board remains on.
Page 180 The third LED, LED L3, indicates the relative amount of CPU activity. Referring to Figure 9–3, when the CPU is 100% utilized, L3 will be off. L3 will be on at full intensity when the CPU is idle, such as when the CPU tasks are running faster than the printer engine speed.
Page 181: Engine Controller Board
9.7 Engine Controller Board 9.7.1 Removal and Disassembly 1. Open the Clamshell, remove the OPC Drum Unit, Developer Unit, Waste Toner Container, and any paper present in the printer. 2. Remove the 4 Screws from the printer Back Panel that secure the Data Controller Board. 3.
Page 182: Reassembly And Replacement
Bottom Cover Locking Tabs Figure 9–4. Removing Bottom Cover 7. Remove the printer from the phone book. Remove the Screw from the left side of the Base Frame that secures the Engine Controller Board. 8. Unplug the Engine Controller Board from the Backplane Board and remove the Engine Controller Board from the printer through the opening in the rear of the printer.
Page 183: Removal And Disassembly
9.8 Stepper Motors Controller Board 9.8.1 Removal and Disassembly 1. Open the Clamshell, remove the OPC Drum Unit, Developer Unit, and any paper present in the printer. 2. Remove the Lamp Connector Cover by removing 1 Screw and disconnect the Fuser Lamp and Thermistor Connectors from the Right Side Frame.
Page 184 3. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. NOTE: Upon installation, the groove on the bottom of the Right Inside Cover should straddle the top edge of the right side of the Tractor Frame.
Page 185 Detail 9–2 Step 2 Step 7 Figure 9–6. Releasing Heater Lamp and Thermistor Connectors Chapter 9 – Controllers and Floppy Disk Drives 9–19...
Page 186 8. Loosen, but do not remove, 2 Screws on the top of the Stepper Motor Board Frame. Remove the Frame Cover, and disconnect 7 Cables from the Board. These Cables are at connectors CN1, CN2, CN3, CN4, CN5, CN6 and CN8. See Figure 9–7 and Detail 9–3 in Figure 9–7 . NOTE: The 3 Stepper Motor Cables connect to Connectors CN3, CN4, and CN5 in the order the Motors appear in the printer: the Gear Motor connects to...
Page 187: Stepper Motors Controller Board
Detail 9–3 CN8 CN6 Stepper Motors Controller Board Left side view Connectors Detail Step 12 Step 8 Step 11 Right side view Figure 9–7. Stepper Motors Controller Board Removal and Connectors Detail Chapter 9 – Controllers and Floppy Disk Drives 9–21...
Page 188 9. Remove the Fuser Heat Shield. See Figure 9–8 . 10. Remove the Tractor Paper Guide by removing 1 Screw, then disconnect the Cable from the Fuser. Remove 1 Screw from the Cable Tie to release the Cable from the Base Plate of the printer.
Page 189 Step c Step b Depress white retaining levers to release fuser Step 9 roller assembly from fuser base Step d Step e J–1 Connector Step 10 Figure 9–8. Preparation for Removing the Stepper Motor Board Frame Chapter 9 – Controllers and Floppy Disk Drives 9–23...
Page 190: Reassembly And Replacement
NOTE: The Stepper Motor Board Frame cannot be removed unless the Fuser Base has been removed from the printer. Therefore, remove the Stepper Motor Board Frame only if absolutely necessary. Follow the steps below (see Figure 9–8 ) before removing the Stepper Motor Board Frame (Step 12).
Page 191: Adjustment
Table 9–3. Stepper Motors Controller Board Connectors CONNECTOR FUNCTION DESTINATION Stepper Motors Controller Board CN2 on LVPS Power Stepper Motors Controller Board J6 on Backplane Board Control Main Stepper Motor Main Stepper Motor Tractor Stepper Motor Tractor Stepper Motor Fuser Stepper Motor Fuser Stepper Motor Fuser Cam Motor and Clutch Fuser Cam Motor and Clutch...
Page 192: Floppy Disk Drives
9.9 Floppy Disk Drives 9.9.1 Removal and Disassembly NOTE: Some printers will have only one Floppy Disk Drive installed. The second, or Drive B, Floppy Disk Drive is an option. This procedure is written assuming that the printer being serviced has both Floppy Disk Drives installed.
Page 193 Step 12 Floppy Disk Drive Frame Floppy Disk Drive Frame Floppy Disk (Ref.) Drive Guide (Bezel) Step 5 Figure 9–10. Removing Drive Frame from Printer Chapter 9 – Controllers and Floppy Disk Drives 9–27...
Page 194 DISASSEMBLY 1. Observe the orientation of the Data Cable on the rear of each Floppy Disk Drive, and make a note of it for reference later when you reinstall the Drives. See Figure 9–11 . 2. Disconnect the Data and Power Cable Connectors from the rear of each Floppy Disk Drive. NOTE: When you install a Floppy Disk Drive, be sure to orient the Data Cable correctly when you connect it to the rear of the Drive.
Page 195 Step 2 Drive A (Standard) Drive B (Optional) Step 3 Figure 9–11. Removing Drives from Drive Frame Chapter 9 – Controllers and Floppy Disk Drives 9–29...
Page 196: Reassembly And Replacement
9.9.2 Reassembly and Replacement Reverse all of the Steps listed above. NOTE: When you install a Floppy Disk Drive, be sure to orient the Data Cable correctly when you connect it to the rear of the Drive. NOTE: When you replace a Floppy Disk Drive, be sure to correctly set the Drive Addressing Jumpers and/or Switches on the new Drive before you install it.
Page 197 9.10.2 Installation (see Figure 9–12) 1. Remove the data controller board from the printer, as described in section 9.6.1. 2. Remove the screw holding the I/O cover plate to the L1024 data controller pan (1). Save the screw. 3. Screw the standoff (5) onto the pan, through the hole next to C54.
Page 198 Figure 9–12. Expansion–C/T Board 9–32 Chapter 9 – Controllers and Floppy Disk Drives...
Page 199: Chapter 10 - Control Panel
Chapter 10 Control Panel Keypad Control Panel Chapter 10 – Control Panel 10–1...
Page 200: Control Panel Parts List
10.1 Control Panel Parts List Callout Name Vendor Part No. Printronix Part No. Control Panel Assembly, L1024 202117–552 704539–048 Screw, PPH, W/CLFW, M3x8, Zinc (2) 030130–308 Overlay Sheet 202316–001 Connector CN Control Panel 10–2 Chapter 10 – Control Panel...
Page 201: Overview
10.2 Overview 10.2.1 Mechanical The control panel has a 16-character by 2-line Liquid Crystal Display (LCD). In addition, there are three status lights and seven keys. The keys are membrane-type switches with the function printed on each one. The status lights are used to monitor the printer state, data in the buffer, and the online status. The LCD allows the user to display the programmable functions that control the printer.
Page 202 Pin Number Function (SW FF) Page Eject (Form Feed) Key (SW Menu) Menu Key (SW Store) Store Key (SW Up) Up-Arrow Key (SW Down) Down-Arrow Key (LED Ready) Ready LED (LED Online) On Line LED (LED Data) Data LED (LEDRSV1) Reserved LED output, not currently used (LEDRSV2) Reserved LED output, not currently used 10–4 Chapter 10 –...
Page 203 Following is a block diagram. See Appendix B for a complete electrical block diagram. 202375 202298 S207 S208 (TO ENGINE (TO DATA CONTROLLER CONTROLLER BOARD) BOARD) /PRPOS /PRINIT BACKPLANE BOARD /SCPUP /SCPDN PJAM J3 (TO LCD CONTROL PANEL) EJAM RSVD /SWFF DGND /SWMENU...
Page 204: Control Panel
10.3 Control Panel 10.3.1 Removal and Disassembly 1. Open the printer clamshell. 2. Open the front cover. See Figure 10–1. Step 2 Step 3 Step 4 Figure 10–1. LCD Control Panel Removal 3. Remove the screw on left front of the control panel. 4.
Page 205: Reassembly And Replacement
10.3.2 Reassembly and Replacement Reverse Steps 1 through 6 above. 10.3.3 Adjustment No adjustment of the Control Panel Assembly is necessary. 10.3.4 Troubleshooting Overview The printer LCD panel displays the status of the printer and user-changeable programming information. Printer status information is transmitted by the data controller to the LCD control panel via the 26-pin cable See Figure 10–2.
Page 206 If you observe any of these symptoms, replace the entire display panel, since there are no replaceable parts in it. 1. Missing row of pixels. The quickest way to check whether the panel is good or not is by substitution. If the problem disappears when you replace the panel, the old panel was bad and no further work is required.
Page 207: Lsu Assembly
Chapter 11 Laser Scanning Unit (LSU) Subsystem Top Cover LSU Assembly Clamshell Frame LSU Subsystem Chapter 11 – Laser Scanning Unit (LSU) Subsystem 11–1...
Page 208 11.1 LSU Parts List 11.1.1 LSU Assembly Callout Name Vendor Part No. Printronix Part No. LSU Assembly, L1024 202118–551 Housing, LSU 202395–551 Top Cover, LSU 202396–001 Label, S/N, LSU 202397–001 Label, Warning, Laser 200892–001 Label, Warning, LSU Seal 200893–002 Seal, Drum, LSU 202575–002...
Page 209: Top View
Top View LSU Assembly Chapter 11 – Laser Scanning Unit (LSU) Subsystem 11–3...
Page 210: Erase Led Assembly
11.1.2 Erase LED Assembly Callout Name Vendor Part No. Printronix Part No. Erase LED Assembly 200542–551 702724–001 Cover, LED Assembly 200541–001 Mount, LED, Plastic 200866–001 Board Assembly, LED 200921–551 Screw, PPH, PTC, 3x8mm, Zinc (4) 030129–308 Screw, PPH, W/CLFW, 3x8mm (2) 030130–308...
Page 211: Overview
11.2 Overview 11.2.1 Mechanical The Laser Scanning Unit (LSU) is attached to the printer clamshell and includes the following basic subunits: LSU Assembly. Generates the laser beam for page definition. LED Array (Erase LEDs). Generates light to remove the residual charge from the OPC drum.
Page 212 BACKPLANE BOARD J3 (TO LCD CONTROL PANEL) RSVD /SWFF /SWMENU /SWSTOR /SWUP /SWDWN /LRDY /SWRST /LONLN /SWONL /LDATA 201153 S203 202294 S204 CONTROL PANEL OPC DRUM +24VB UNIT /CHARGE /DEVELOPER HIGH VOLTAGE TRANSFER /TRANSFER POWER SUPPLY CHARGER BGND 202291 DEVELOPER S202 BIAS TONER...
Page 213: Lsu Assembly
11.3 LSU Assembly 11.3.1 Removal and Disassembly 1. Open the Clamshell, remove 3 Screws from the Clamshell Frame, then lift the front of the Cover. This helps disengage the Locking Tabs of the LSU from the rear of the Cover. See Figure 11–1 and Detail 11–1 .
Page 214 Top Cover Clamshell Frame Step 1 Figure 11–1. Top Cover Disassembly 11–8 Chapter 11 – Laser Scanning Unit (LSU) Subsystem...
Page 215 Detail 11–1. Removing the Top Cover Chapter 11 – Laser Scanning Unit (LSU) Subsystem 11–9...
Page 216: Reassembly And Replacement
2. Remove 4 Connectors of the LSU Cable from various points on the LSU. The Connectors are for the Erase LED Assembly, the Laser Driver, the Polygon Motor, and the Beam Detector. See Detail 11–2. Top View Detail 11–2. LSU Cables 3.
Page 217: Adjustment
Correct Latch Release Position Detail 11–3. Clamshell Latch Reassembly 11.3.3 Adjustment When reassembling the unit, ensure that the Clamshell and its Latch are oriented properly. 11.3.4 Troubleshooting See Chapter 13 for troubleshooting information. Chapter 11 – Laser Scanning Unit (LSU) Subsystem 11–11...
Page 218: Erase Led Assembly
11.4 Erase LED Assembly 11.4.1 Removal and Disassembly 1. Open the Clamshell, remove the Top Cover, disconnect the connector on the Erase LED Wire Harness, and remove the Erase LED Harness Bushing. Remove 2 Screws from the ends of the Erase LED Assembly Frame. See Figure 11–2 . CAUTION: The Erase LED Wire Harness is hard-wired to the Erase LED Assembly.
Page 219 Top Cover LED Connector Bushing Figure 11–2. Erase LED Removal Chapter 11 – Laser Scanning Unit (LSU) Subsystem 11–13...
Page 220: Reassembly And Replacement
2. Remove the 2 Inner Screws and remove the Cover from the Erase LED Assembly. 3. Remove the 2 Outer Screws, then remove the entire LED Board and Mount together. NOTE: The Erase LEDs are soldered directly to the LED Board. Thus, if any LEDs are defective, replace the entire LED Board.
Page 221: Chapter 12 - Covers, Frame, And Backplane Board
Chapter 12 Covers, Frame, and Backplane Board Covers and Frame Components Chapter 12 – Covers, Frame, and Backplane Board 12–1...
Page 222: Covers Parts List
12.1 Covers Parts List Callout Name Vendor Part No. Printronix Part No. Cover, Front 202121–001 704539–119 LCD Control Panel 202117–551 704539–048 Cover, Bottom 202122–001 704539–120 Cover, Right Side 200753–001 Cover Assembly, Left Cover, Left 200754–001 Bracket, Mounting, Left Cover 200755–001 Screw, PPH, CLFW, 3x6mm, Zinc (3) 030130–306...
Page 223 Covers Chapter 12 – Covers, Frame, and Backplane Board 12–3...
Page 224 12.1 Covers Parts List (continued) Callout Name Vendor Part No. Printronix Part No. Cover, Hinge, Left 202119–001 704539–116 Cover, Hinge, Right 202120–001 704539–117 Label, Class 1 201394–001 12–4 Chapter 12 – Covers, Frame, and Backplane Board...
Page 225 Hinge Covers Chapter 12 – Covers, Frame, and Backplane Board 12–5...
Page 226: Left Side Frame Parts List
12.2 Left Side Frame Parts List Callout Name Vendor Part No. Printronix Part No. Frame, Left Side Frame Assembly, Left 200468–552 703113–001 Shaft, Waste Toner Container Lever Shaft, Paper Brush Lever, Left Shaft, Developer Clamp Shaft, Safety Lever Side Frame, Left Clamp, Developer 200512–001...
Page 227 High Voltage Warning Label Left Side Frame Chapter 12 – Covers, Frame, and Backplane Board 12–7...
Page 228: Right Side Frame Parts List
12.3 Right Side Frame Parts List Callout Name Vendor Part No. Printronix Part No. Frame, Right Side Frame Assembly, Right 200469–551 703112–001 Shaft, Safety Lever Shaft, Paper Brush Lever Shaft, Developer Clamp Shaft, Clamshell Latch, Right Side Frame, Right Clamshell Latch, Right 200623–001...
Page 229 Right Side Frame Chapter 12 – Covers, Frame, and Backplane Board 12–9...
Page 230 12.4 Base Frame Parts List Callout Name Vendor Part No. Printronix Part No. Base Frame Assembly Frame, Main Base 202279–001 Rubber Foot (4) 200492–001 702698–001 Bracket, Board Support 202280–001 Bracket, Base Frame, Inner 202281–001 Bracket, Backplane Support 202282–001 704539–104 Bracket, Rear EMI 202283–001...
Page 231 NOTE: Arrows show attachment screw positions Base Frame Chapter 12 – Covers, Frame, and Backplane Board 12–11...
Page 232: Overview
12.5 Overview This section deals with parts not included in any other sections and includes: Covers, Ozone Filter Case, and Rating Labels Left Side Frame Right Side Frame Base Frame Backplane Board 12–12 Chapter 12 – Covers, Frame, and Backplane Board...
Page 233: Left Side Frame
12.6 Left Side Frame 12.6.1 Removal and Disassembly 1. Open the Clamshell and the Front Cover, remove the OPC Drum Unit, the Developer Unit the Waste Toner Container, and any paper present in the printer. 2. Remove the Left Side Cover of the printer. See Figure 12–1. a.
Page 234 3. Remove the Front Plastic Paper Guide of the Transfer Charger Assembly by pressing down on its ends and sliding it to the left. This disengages the Locking Tabs and the Guide can be easily removed. See Figure 12–2. Figure 12–2. Removing the Front Plastic Paper Guide 4.
Page 235 Step 4 Detail 12–1 Cover overlaps tractor assembly side frame Step 5 Step 6 Figure 12–3. Removing the Lower Paper Guide and Encoder Cover 5. Remove 1 Screw, then remove the Encoder Cover. See Figure 12–3. 6. Release the left side of the Printer Front Cover from the Tab on the Left Side Frame. See Figure 12–3.
Page 236 Disassembly Step 2 High Voltage Disassembly Warning Step 5 Disassembly Label Step 1 Step 7 Step 8 Disassembly Step 3 Disassembly Step 4 Figure 12–4. Removing the Left Side Frame 8. Remove 3 Screws from the Left Side Frame and carefully remove it from the printer. See Figure 12–4.
Page 237: Reassembly And Replacement
1. Remove the Safety Lever Spring, being careful not to damage it, then remove 1 E-ring and remove the Safety Lever. See Figure 12–4 . NOTE: The curved end of the Safety Spring goes toward the Frame; the straight end goes toward the Lever. 2.
Page 238: Right Side Frame
12.7 Right Side Frame 12.7.1 Removal and Disassembly 1. Open the Clamshell, remove the OPC Drum Unit, the Developer Unit, and any paper present in the printer. 2. Open the Printer Front Cover, then remove the LCD Control Panel by removing 2 Screws. Remove the Front Cover by releasing the left side first, then sliding it to the right.
Page 239: Right Inside Cover
4. Remove the Lamp Connector cover by removing 1 Screw. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor Board Frame. See Figure 12–6. Step 4 Lamp Connector Cover Step 5 Right Inside Cover Figure 12–6. Disconnecting the Lamp and Thermistor Connectors Chapter 12 –...
Page 240 5. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the Warning Label at the front of the Cover. This releases the Locking Tab from the Right Side Cover. See Figure 12–6 . NOTE: Upon installation, the groove on the bottom of the Right Inside Cover should straddle the top edge of the right side of the Tractor Frame.
Page 241 12.7.1, 12.71.1, Step 8 Step 9 12.7.1, Step 10 12.7.1, Step 10 12.7.1, Step 7 Figure 12–7. Removing the Display Mounting Bracket Chapter 12 – Covers, Frame, and Backplane Board 12–21...
Page 242 9. Loosen, but do not remove, 2 Screws on the top of the Stepper Motor Board Frame. Remove the Frame Cover, and disconnect the Gear Assembly Stepper Motor Cable from the Motor. See Figure 12–7 . 10. Remove 4 Screws from the Gear Assembly Frame then remove it from the printer. The Stepper Motor Board Frame will need to be moved in order to free the Gear Assembly from behind it.
Page 243 12.7.1, Step 13 12.7.1, Step 12 12.7.1, Step 11 12.7.1, Step 12 Figure 12–8. Removing the Transfer Charger Assembly Chapter 12 – Covers, Frame, and Backplane Board 12–23...
Page 244 12. Remove 2 Screws at the rear of the Lower Paper Guide, then remove it from the printer by lifting the rear out first. This helps it clear the Contacts for the HVPS and the Transfer Charger Frame. Disengage the Locking Tabs at the front of the Guide from the Tension Roller Frame. See Figure 12–8 .
Page 245 Disassembly Step 3 Disassembly Step 5 Step 15 Disassembly Step 4 Step 14 Step 15 Disassembly Step 2 Figure 12–9. Removing the Right Side Frame Chapter 12 – Covers, Frame, and Backplane Board 12–25...
Page 246: Reassembly And Replacement
DISASSEMBLY NOTE: The following components can be removed from the Right Side Frame without it being removed from the printer, therefore the following directions assume you have not removed the Right Side Frame from the printer. The Display Mounting Bracket must be removed in order for the components in Steps 1 through 3 below to be removed.
Page 247: Removal And Disassembly
12.8 Base Frame 12.8.1 Removal and Disassembly 1. Open the Clamshell, remove the OPC Drum Unit, the Developer Unit, the Waste Toner Container, and any paper present in the printer. 2. Remove the Lamp Connector cover by removing 1 Screw. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor Board Frame.
Page 248 Step 2 Lamp Connector Cover Step 4 Step 3 Right Inside Cover Figure 12–10. Disconnecting the Lamp and Thermistor Connectors 12–28 Chapter 12 – Covers, Frame, and Backplane Board...
Page 249 6. Place the printer on a phone book or other similar item so that the Bottom Cover edges are not resting on the item. Press gently to release the 2 Locking Tabs on the right side of the Bottom Cover, then gently lower this side. Slide the Bottom Cover slightly to the right to release the locking tabs on the left side, then lower the Bottom Cover away from the printer and over the phone book.
Page 250 Figure 12–12. Removing Cables 12–30 Chapter 12 – Covers, Frame, and Backplane Board...
Page 251: Base Frame
10. Remove 2 Screws from the rear of the Base Frame, then lift the LVPS slightly to clear the Base Frame (1). Push the Power Switch to the OFF position (2), then slide the LVPS toward the rear of the printer (3). Use care to avoid damaging the Power Switch. Once the Power Switch is partially past the Frame, switch it to the ON position (4), then slide the LVPS free of the Base Frame (5).
Page 252 Figure 12–13. Removing the LVPS 12–32 Chapter 12 – Covers, Frame, and Backplane Board...
Page 253 Cable Routing Figure 12–14. LVPS Cable Routing Chapter 12 – Covers, Frame, and Backplane Board 12–33...
Page 254 Figure 12–15. LVPS Locking Tabs 11. Remove the Floppy Disk Drive (FDD) Guide (Bezel) by pressing on the Locking Tabs, then rotating it to free the bottom tabs. 12. Remove 3 Screws from the front of the Backplane Board. See Figure 12–16 . 13.
Page 255 Backplane Board is positioned in front of cross brace and behind locating tabs Figure 12–16. Backplane Board Removal and Installation 14. Remove 2 Screws from the front and 1 Screw from the left side of the FDD Frame, then remove the FDD Frame from the Base Frame. See Figure 12–17 . 15.
Page 256 Step 14 Frame Step 16 Rear EMI Bracket Step 15 Backplane Support Bracket Figure 12–17. Removing the Base Frame Hardware NOTE: The components listed below must be removed, in addition to those listed above, before the Base Frame can be removed. In order to remove the Base Frame, most of the components on the top of the Base Plate must be removed.
Page 257 Step 21 Step 17 W ARNING – HIGH TEM- PERA T PLEASE RE- T A T CE CLEAN- Step 20 Depress white retaining levers to release fuser roller assembly from fuser base Step 22 J–1 Connector Step 25 Step 18 Step 24 Step 23 Figure 12–18.
Page 258 18. Remove the Tractor Paper Guide by removing 1 Screw from the center rear of the Tractor Frame. See Figure 12–18 . 19. Open the Paper Exit Guide of the Fuser Base so that it is not in contact with the Fuser Roller Assembly.
Page 259 Step 26 Step 27 Figure 12–19. Removing the Ozone Filter Case and Stepper Motor Board Frame 27. Loosen, but do not remove, 2 Screws on the top of the Stepper Motor Board Frame. Remove the Frame Cover and disconnect 7 Cables from the board (CN1, CN2, CN3, CN4, CN5, CN6, and CN8).
Page 260 Figure 12–20. Stepper Motors Controller Board Connector Identification 28. Remove the Tractor Paper Guide by removing 1 Screw. Disconnect the Cable from the Fuser. Remove 1 Screw from the Cable Tie to release the Cable from the Base Plate of the printer. See Figure 12–21 .
Page 261 Step 28 Step 30 Step Step 30 Step 29 Step 40 Step 39 Step 31 Step Note: arrows show attachment screw positions Step 44 Step 43 Figure 12–21. Removing Various Components Chapter 12 – Covers, Frame, and Backplane Board 12–41...
Page 262 32. Remove the Left Side Cover of the printer. See Figure 12–22. a. Remove 2 Screws from the Left Side Cover. b. Loosen, but do not remove, 1 Screw on the Base Plate. This loosens the Mounting Bracket so it can be slid free of the Base Plate. c.
Page 263 Figure 12–23. Removing the Front Plastic Paper Guide 34. Remove 2 Screws at the rear of the Lower Paper Guide, then remove it from the printer by lifting the rear out first. This helps it clear the Contacts for the HVPS and the Transfer Charger Frame.
Page 264 Step 34 Step 35 W ARNING – HIGH TEM- PERA TU PLEASE RE- T A T SAME TI CE CLEAN- AS T Step 36 Figure 12–24. Removing Paper Guide, Encoder Cover, and Front Cover 37. Disconnect the Cable from Connector J1 of the Toner Sensor Board. See Figure 12–25 . 38.
Page 265 Step 37 J–1 Connector Step 38 Figure 12–25. Removing Left Side Frame 39. Remove 1 Screw from the left front corner of the Base Plate. See Figure 12–21 . 40. Remove the Tractor by removing 3 Screws, then lifting the left end of the Tractor out first. This clears the Encoder of the HVPS, and allows the Tractor room to move to the left so that the Tractor Stepper Motor can clear the Upper Board Frame.
Page 266: Reassembly And Replacement
45. Remove the PCB Guide Rails or Cable Tie from the Base Frame, as needed. 12.8.2 Reassembly and Replacement Reverse the steps listed above, as needed. Table 12–1 on page 12–51 lists the connectors on the Backplane Board, together with their respective functions and destinations.
Page 267: Removal And Disassembly
12.9 Backplane Board 12.9.1 Removal and Disassembly 1. Open the Clamshell, remove the OPC Drum Unit, the Developer Unit, the Waste Toner Container, and any paper present in the printer. 2. Remove the 4 Screws from the printer Back Panel that secure the Data Controller Board. Slide the Board out part way, then disconnect the Floppy Disk Drive data and power connectors from the board.
Page 268 Bottom Cover Locking Tabs Figure 12–26. Bottom Cover Removal 7. Disconnect 10 cables from the front of the Backplane Board. See Figure 12–27 . NOTE: When reinstalling the Backplane Board, refer to Table 12–1 on page 12–51 and Figure 12–29 on page 12–52 for the proper cable connections to the board.
Page 269 Figure 12–27. Removing Cables Chapter 12 – Covers, Frame, and Backplane Board 12–49...
Page 270 8. Remove 3 screws from the front of the Backplane Board. See Figure 12–28. 9. Lift the Backplane Board slightly to free it from the Locating Tabs, then tilt it forward so that the top clears the FDD Frame. Now lift the Backplane Board up to free the bottom edge of the Board from the Base Frame.
Page 271: Reassembly And Replacement
12.9.2 Reassembly and Replacement Reverse the steps listed above, as needed. Table 12–1 below lists the connectors on the Backplane Board, together with their respective functions and destinations. Figure 12–29 , following, shows the locations of the connectors on the Backplane Board. Table 12–1.
Page 272: Adjustment
Figure 12–29. Backplane Board Connectors 12.9.3 Adjustment No adjustment of the Backplane Board is necessary. 12.9.4 Troubleshooting See Chapter 13 for troubleshooting information. 12–52 Chapter 12 – Covers, Frame, and Backplane Board...
Page 273: Chapter 13 - Troubleshooting Guide
Chapter 13 Troubleshooting Guide Operation Sequence Knowing the sequence of operation of the printer is useful as a guide in determining what component is at fault for a given failure. Follow the sequence below to the point where the printer fails. This will be a good starting point for further troubleshooting of the printer.
Page 274: Checking The Power-Up Sequence
to the Engine Controller low, which asserts “Vertical Synchronization” to the Engine Controller. When the Engine Controller detects the asserted “Vertical Synchronization” signal, it starts the print process. The Engine Controller activates the electric clutch and transfer charger solenoid, and prints the data on the page.
Page 275: Guide To Imaging Errors
Guide to Imaging Errors Index to Imaging Errors The following section is an index of common imaging errors. It guides you to the isolation and correction of the errors listed. To use the index, find the error in the index list that appears on the printer’s LCD, then find that index number in the next section, “Detailed Troubleshooting Steps.”...
Page 276 Title Page 260. Distorted image running the length of the page 13–12 270. The output page is creased 13–13 300. Cyclic Image Errors 13–13 310. Black area at a 1 inch interval 13–13 320. White area at a 2.5 inch interval 13–13 330.
Page 277 Title Page 560. The print has many unexplained seemingly random errors 13–21 570. Dirty background accompanied by a ghost image 13–21 580. Print is intermittently dark, then goes to light 13–22 600. Other Image Errors 13–22 610. Vertically blurred image 13–22 620.
Page 278: Detailed Troubleshooting Guide
Detailed Troubleshooting Guide The following section guides you to the cause and repair of the errors found in a printed image. NOTE: Errors that occur on a regularly repeating basis usually are caused by one of the rollers or gears in the printer. The interval of the error is equal to the circumference of the roller or the circumference of the base of the teeth on the gear.
Page 279: Preliminary Steps
Preliminary Steps By following these two steps, you will pinpoint the source of the problem more quickly and make troubleshooting much easier and faster. 1. Engine Self-Test Running the printer engine self-test can help isolate a problem to the printer engine, the Engine Controller Board, the Data Controller Board, or the host computer.
Page 280: Horizontal Image Errors
Detailed Troubleshooting Steps By following these steps, you will be able to pinpoint the source of the problem and make any necessary corrections needed to fix the problem. 100. Horizontal Image Errors 110. Uniform 1 inch interval line (indistinct width and fuzzy edges). This is best exhibited by printing a black page.
Page 281: White Horizontal Line With A 5 Inch Interval
a. Loosen the transfer corona assembly and reseat it to make sure it contacts the H.V.P.S. spring. The assembly should lock under the tab on the left side of the transfer charger frame. Slide the assembly to the right as far as possible. b.
Page 282: Faint Black Horizontal Lines That Occur At Random
The defect could be a broken or damaged tooth, or it could be toner buildup in the base of the teeth on a gear. The pitch or interval of the error is equal to the circumference of the gear, or the circumference of the base of the teeth.
Page 283: Wide White Line (Fuzzy Edges)
211. The laser beam is being blocked and is not reaching the OPC drum. a. Check the LSU cover glass and clean if necessary. b. Replace the cover glass if it is cracked or cannot be cleaned. c. The LSU has something blocking the beam inside it and must be replaced. The LSU cannot be opened and cleaned, it must be replaced.
Page 284: Black Or White Line (Sharp Well Defined Edges)
a. Check and clean the charge corona wire and grid. b. Make sure the contact between the OPC drum unit and the contact spring for the charge corona is good. 1. Clean any corrosion from the contact and the spring. 2.
Page 285 a. Replace the LSU. 270. The output page is creased. 271. There is a crease running down the center of the output page. a. Adjust the fuser rear cover position. The cover is too close to the pressure roller. b. Replace the fuser if the rear cover is damaged or cannot be properly adjusted. 272.
Page 286 331. This is caused by a defect or toner buildup on the fuser roller. a. Clean or replace the fuser roller/fuser assembly. 340. Black or white spot at a 5 inch interval. 341. The OPC drum has a scratch or nick on it. a.
Page 287 This is caused by the paper touching the OPC drum. 421. The paper pressure plate is not functioning properly. a. Make sure the paper pressure plate is properly installed. b. Make sure the mylar sheet is not damaged and is making good physical contact with the paper.
Page 288 a. The developer unit is not locked down. Verify that the developer lock down hooks are properly engaged. There is usually excessive gear noise or grinding noise when the developer is not locked down. b. There is toner buildup on the developer guide roller or on the OPC drum where the guide roller meets the OPC drum.
Page 289 2. If there is no signal, replace the L.V.P.S. A. If the solenoid still does not function after replacing the L.V.P.S., replace the Engine Controller Board. d. The transfer charger is not moving freely and must be replaced. 512. There is no charge on the transfer corona. a.
Page 290 d. If there is no charge after step c, check all wire harnesses. 516. The developer contact spring has the proper charge on it. a. Make sure there is good contact between the spring and the developer unit. Clean off all corrosion on the spring and on the contact.
Page 291 d. Replace the paper brush if the above steps do not remedy the problem. e. The Engine Controller Board has been damaged by static and must be replaced. f. The laser has been damaged and the LSU must be replaced. 522.
Page 292 a. Check the contact between the H.V.P.S. and the OPC drum. Make sure there is no corrosion and that the H.V.P.S. contact spring is not compressed. Pull the spring to lengthen it if necessary. Make sure to pull the spring upward, not at an angle. b.
Page 293: The Print Has Many Unexplained Seemingly Random Errors
A. If the solenoid still does not function after replacing the L.V.P.S., replace the Engine Controller Board. d. The transfer charger is not moving freely and must be replaced. 554. The charge on the transfer corona is not at the proper voltage. a.
Page 294: Other Image Errors
c. Check the developer bias and replace the H.V.P.S. if needed. 580. The print is intermittently dark, then goes light over a period of 1 to three pages. This may be accompanied by 1.5 inch repeating errors. 581. The inner transfer gear is spinning on the main shaft, resulting in the developer sleeve not turning and not being replenished with toner.
Page 295: Ghost Or Mirror Image
a. The paper is not feeding freely into the printer. Make sure there is nothing binding the paper as it enter or exits the printer. b. The electric clutch is slipping and must be replaced. 622. As well as a compressed image, the printer exhibits more noise than during normal operation.
Page 296: Intermittent Black Patches
a. There is a visible toner buildup on the OPC drum. Because the drum surface is coated with photosensitive material, it is impractical to clean it. Replace the OPC drum unit. b. The drum no longer holds a charge and is therefore not being cleaned correctly. Replace the OPC drum unit.
Page 297: Unfused Toner
c. The paper is defective and must be replaced. This is also very rare. 660. Unfused toner. 661. The temperature of the fuser roller is too low. a. The temperature circuitry is not functioning correctly. Replace the fuser. b. The Engine Controller Board is not turning on the lamp; thus, the temperature is too low.
Page 298: Guide To Error Mesages
Guide to Error Mesages Error messages indicate errors that the printer has detected during the power-on self-test or during normal operation. This section provides common printer status and error messages, along with the corrective actions required to return the printer to normal operation. The messages are generated by the Data Controller Board (and its software), then displayed on the printer’s Control Panel LCD.
Page 299: Service Call Error Messages
Service Call Error Messages A fatal error is any error that cannot be corrected by operator actions alone. The errors listed in the table that follows are all potentially fatal errors. However, except for one error, you might be able to clear them by resetting the printer engine.
Page 300 Message Explanation Corrective Action 26 HEATER FAIL The fuser did not warm up See page 13–38. Call Service within its specified time. 27 HEATER FAIL During printing, the fuser is See page 13–38. Call Service not properly maintaining its temperature. 28 BEAM DET FAIL A beam detect failure has See page 13–39.
Page 301: Detailed Troubleshooting Guide
Detailed Troubleshooting Guide 01 CLOSE THE COVER 1. The printer top cover is open. a. Make sure the top cover is closed, especially the right side. b. The right clamshell latch is broken and is not tripping the interlock switch on the L.V.P.S.
Page 302: Add Toner And Chk Waste Bottle
03 ADD TONER AND CHK WASTE BOTTLE CAUTION: Whenever adding toner, always check the level in the waste toner container, and replace the waste toner container if necessary. (The printer has no sensor for “waste toner container full”.) 1. Check the level in the waste toner container. If the container is full, replace it. 2.
Page 303: Install Opc Drum
05 INSTALL OPC DRUM 1. The OPC drum unit is missing. a. Install an OPC drum unit in the printer. 2. The OPC drum unit is not seated correctly, and thus is not activating the “Drum-In” Sensor. a. Remove and reseat the OPC drum unit. 3.
Page 304: Encoder Fail-Call Service
c. Check the Speed Control Paper Guide Sensor. d. See the “General Paper Jam Troubleshooting” section that follows. 25 ENCODER FAIL—Call Service 1. The tractor encoder signal is faulty. a. Clean any toner or paper dust out of the encoder sensor. b.
Page 305 paper guide. If it is not binding on the hole, replace the lever and its stand. b) If the lever is still binding or striking the edges of the hole in the fuser paper guide, replace the guide. 2) Reset the paper into the tractor assembly. Make sure the leading edge of the paper is not torn or wrinkled, since this will cause jams as the paper enters the fuser.
Page 306 b] The fuser drive gear in the pulley assembly is turning, but the fuser drive gear on the fuser is not turning. The fuser drive gear must be replaced. c] The gear on the fuser roller is turning, but the roller is not turning.
Page 307 The paper jam error occurs because the paper is not being fed at the proper speed. When the paper is moving at the correct speed, the tractor encoder generates pulses at a fixed rate. As the paper feed rate slows, the time interval between pulses increases.
Page 308: Fuser Fail-Call Service
2] The L.V.P.S. is not supplying the 24 V to the clutch, and the L.V.P.S. must be replaced. This is unlikely, as several other components use 24 V, and other errors would be occurring during the power-on self-test. d. The paper jam error occurs after the paper moves about 1/2 inch during TOF registration.
Page 309: Thrmistr Fail—Call Service
c. Replace the Fuser Sensor Board. d. Replace the Stepper Motors Controller Board. e. Replace the Engine Controller Board. f. See the “General Fuser Cam Troubleshooting” section that follows. General Fuser Cam Troubleshooting With the top cover open, defeat the cover open switch and turn on the printer. Watch the fuser to see if it closes, then opens, during the power-on sequence.
Page 310: Heater Fail—Call Service
b. Check the thermistor. Replace it if necessary. c. See the “General Fuser Heater Troubleshooting” section that follows. 24 THRMISTR FAIL—Call Service 1. The thermistor in the fuser is shorted, or its leads or associated wires are shorted together, or the printer temperature is extraordinarily high.
Page 311: Beam Det Fail—Call Service
Follow the procedures for fuser testing in Chapter 7, Fuser Subsystem . These procedures are very helpful in learning how the fuser works and in determining what component is at fault. Look through the cooling holes in the rear of the top cover of the printer to see if the lamp is lit during the warmup cycle.
Page 312: Lsu Fail—Call Service
d. Replace the Engine Controller Board. e. See the “General LSU Troubleshooting” section that follows. 29 LSU FAIL—Call Service 1. The LSU phase lock circuit is not sending its “Ready” signal to the Engine Controller Board. a. Check the wiring to the LSU. Repair any wiring problems found. b.
Page 313: Misprint Error-Call Service
32 MISPRINT ERROR—Call Service 1. This usually indicates a handshaking or communication error between the Engine Controller Board and the Data Controller Board during normal operation. One board is not responding to the other’s command or request for status. a. Cycle power to the printer. If the error returns, continue with the following steps. b.
Page 314: Tof Registration Errors
TOF REGISTRATION ERRORS 1. The positioning of the tractor encoder is incorrect. a. Check the mounting bracket for the encoder board on the tractor frame. Make sure the bracket is not loose and that the encoder board is also securely fastened to the bracket.
Page 315: Appendix A Printer Specifications
Appendix A Printer Specifications Mechanical Printing Method: Electrophotographic, using diode laser (black writing) Photosensitive Material: Organic Photoconductor (OPC) drum Imaging Device: Laser diode Toner: 1-1/2 component toner / developer system Fuser: Heat and pressure roller, with electronic temperature selection and control Dimensions: H = 9.8 inch (25 cm) W = 18.2 inch (46 cm)
Page 316 Environmental Operation: Tilt: 5 maximum Temperature: 10 to 32.5 C (50 to 90.5 F) Relative Humidity: 20 to 85% RH, noncondensing Altitude: 7500 feet (2286 m) maximum Shipping / Storage: Shipping Temperature: –30 to +60 C (–22 to +140 F) for 200 hours Storage Temperature: Same as Shipping Relative Humidity:...
Page 317 Optional: Coax / Twinax interface, Ethernet LAN interface, Dataproducts parallel interface Emulations: Standard: Printronix LP+ impact printer emulation Optional: HP PCL5 emulation, IGP / VGL emulation, IGP / PGL emulation Storage Media 1 floppy disk drive; 3.5 inch, double-sided high density (DSHD), 1.44 MB, DOS format (second floppy disk drive...
Page 318 OPC drum unit: 30,000 pages Developer unit: 100,000 pages Ozone filter: 100,000 pages Fuser unit: 300,000 pages A–4 Appendix A – Printer Specifications...
Page 319: Appendix B Wire Data
Appendix B Wire Data Appendix B – Wire Data B–1...
Page 320 MAIN STEPPER OZONE MOTOR (M1) 202390 202171 – – E504 TMRPWR STEPPER MOTORS CONTROLLER BOARD TMRSG 202200 S802 202298 S208 202241 202238 S212 D112 PRFAN1 PRFAN2 FUSER STEPPER 202234 CLUTCH MOTOR D162 (M3) 202296 S210 202392 – – SENSOR FUSER BASE UNIT EXIT SENSOR 202234...
Page 321 FUSER UNIT Thermal Breaker Halogen Lamp AC POWER INLET CNS1 COOLING – TMRPWR LOW VOLTAGE POWER SUPPLY TMRSG 202576 202292 S801 120V to Pin 2 S211 240V to Pin 3 202375 202298 S207 S208 (TO ENGINE (TO DATA CONTROLLER CONTROLLER BOARD) BOARD) /PRPOS...
Page 322 B–4 Appendix B – Wire Data...
Page 323: Appendix C Continuous Form Stacker
Confirm that the unit is unplugged before service. If the fuse blows, be sure to replace it with an exact duplicate (Printronix part #704968–018). Do not operate the stacker in a wet environment.
Page 324: Parts Identification
Parts Identification This section identifies the major subassemblies and components which are available for replacement from Printronix. C–2 Appendix C – Continuous Form Stacker...
Page 325 (See page C–5) (See page C–7) (See page C–15) (See page C–11) (See page C–13) Figure C–1. Continuous Form Stacker Appendix C – Continuous Form Stacker C–3...
Page 326 Callout Name Printronix Part No. Quantity Guide Assembly, Upper 704968–008 Idler Weight, Stacker 704968–025 Cotter Key, Hairpin 704968–022 C–4 Appendix C – Continuous Form Stacker...
Page 327 Figure C–2. Appendix C – Continuous Form Stacker C–5...
Page 328 Callout Name Printronix Part No. Quantity Spring, Coupler, Stacker 202894–001 Cover, Motor, Stacker 704968–024 Motor Assy, 115V, Upper Roller 704968–010 Motor Assy, 230V, Upper Roller 704968–027 C–6 Appendix C – Continuous Form Stacker...
Page 329 (See page C–9 ) (See page C–9) Figure C–3. Appendix C – Continuous Form Stacker C–7...
Page 330 Callout Name Printronix Part No. Quantity Drive, Roll 704968–023 Shaft, Drive 704968–020 Fuse Drawer, 115V 704968–019 Fuse, ABC, 15.0A 704968–018 Power Entry Module 704968–004 C–8 Appendix C – Continuous Form Stacker...
Page 331 Figure C–4. Appendix C – Continuous Form Stacker C–9...
Page 332 Callout Name Printronix Part No. Quantity Wing, Side Guide 704968–017 C–10 Appendix C – Continuous Form Stacker...
Page 333 Figure C–5. Appendix C – Continuous Form Stacker C–11...
Page 334 Callout Name Printronix Part No. Quantity Motor Assy, 115V, Belt 704968–028 Motor Assy, 230V, Belt 704968–029 Idler, Pulley Assy 704968–009 Belt, Paddle Stacker 704968–016 Paddle Drive Pivot 704968–012 Bracket, Paddle Drive 704968–011 Clamp, Paddle Drive 704968–015 Bracket, L, Stacker 704968–014 C–12...
Page 335 Figure C–6. Appendix C – Continuous Form Stacker C–13...
Page 336 Callout Name Printronix Part No. Quantity Power Switch, Rocker 704968–005 Caster, Locking 704968–002 Caster (2–1/16”) 704968–003 Cable, Paper Tray 704968–007 Spring Assy, Stacker 704968–006 C–14 Appendix C – Continuous Form Stacker...
Page 337 ROTATED 180 Figure C–7. Appendix C – Continuous Form Stacker C–15...
Page 338: Disassembly/Reassembly
Disassembly/Reassembly This section provides instruction on the disassembly and reassembly of various stacker assemblies. Required Tools S Small Phillips Screwdriver S Medium Phillips Screwdriver S Needlenose Pliers S 1.5mm Allen Wrench S 2.5mm or 5/32” Hex-head Allen Wrench S 5mm Allen Wrench S 9/16”...
Page 339: The Tabletop
The Tabletop Removal 1. Remove the four screws securing the tabletop to the stacker body. There are two on either side of the tabletop. (See Figure C–9) WARNING: This assembly is heavy and may cause injury should it fall while being removed from the stacker body.
Page 340 Replacement 1. Reverse the above steps, being sure to provide adequate support for the tabletop while removing or replacing screws. CAUTION: The wood screws attaching the tabletop to the brackets should not be removed. In removing or reinstalling them, the holes may be stripped and the tabletop will no longer be securely held.
Page 341: The Paddle Drive Motor Assembly
The Paddle Drive Motor Assembly Removal 1. The paddle drive motor assembly is shielded by a cover which must first be removed to gain access to the motor. To do this, simply remove the two screws which secure the cover to the paddle drive frame.
Page 342 Figure C–11. Paddle Drive Motor Removal Replacement 1. To replace the paddle drive motor assembly, reverse steps 1 through 4, being sure the keyed side of the motor shaft faces the paddle drive pulley’s set screw. NOTE: The gap distance between the pulley and the paddle drive frame should be set to approximately 5/32”...
Page 343: The Upper Drive Motor Assembly
The Upper Drive Motor Assembly Removal 1. Remove the two screws which secure the motor cover to the upper left frame. (See Figure C–12) 2. Disconnect the motor assembly’s two-pin electrical connector. 3. Remove the two screws which secure the motor assembly to the upper left frame. 4.
Page 344: The Paddle Drive Belts
The Paddle Drive Belts Removal 1. Work the belt off the paddle drive pulley as you rotate the belt in a clockwise direction. (See Figure C–13) Figure C–13. Paddle Drive Belt Removal Replacement 1. Place the belt onto the lower paddle drive pulley. 2.
Page 345: The Paper Shelf
The Paper Shelf Removal 1. Remove the four screws which secure the paper shelf to the base assembly. 2. Lift and remove the paper shelf. (See Figure C–14) Figure C–14. Removing the Paper Shelf Replacement 1. Reverse the steps above. Appendix C –...
Page 346: The Front And Rear Paper Guides
The Front and Rear Paper Guides Removal 1. Rear Paper Guide (See Figure C–15) a. Remove 2 screws holding the rear paddle drive to the rear paper guide. b. Lift the rear paper guide until the bottom clears the base frame tie. c.
Page 347 2. Front Paper Guide a. Remove 2 screws holding the front paddle drive to the front paper guide. b. Remove the tray support cable from the paper tray (see Figure C–23 for replacement). c. Remove 6 screws securing the paper tray and remove. d.
Page 348: The Left And Right Vertical Frame Braces
The Left and Right Vertical Frame Braces Removal (see Figure C–16) 1. Remove the 2 Phillips screws securing the left or right frame base to the frame. NOTE: If it becomes necessary to replace both frame braces, do them one at a time to keep the frame assembly square.
Page 349 Figure C–16. Removing the Vertical Frame Braces Appendix C – Continuous Form Stacker C–27...
Page 350: The Left And Right Upper Frames
The Left and Right Upper Frames Removal 1. Remove the tabletop by removing the 4 socket-head cap screws and washers securing the tabletop brackets to the frame. DO NOT remove the 4 Phillips screws holding the tabletop to the brackets. (See Figure C–17) 2.
Page 351 POWER ENTRY SHIELD ON/OFF SWITCH MODE SWITCH Figure C–18. Removing Electrical Components Appendix C – Continuous Form Stacker C–29...
Page 352 4. Using pliers or a flat-head screwdriver, compress the plastic retaining clips holding both switches in the frame and carefully remove the switches. 5. Using needle-nose pliers, gently compress the plastic retaining clips holding the low-voltage cable in the frame and remove the connector plug from the frame. 6.
Page 353 Figure C–19. Final Removal Steps 12. Remove the upper rear frame tie by removing the two Phillips screws holding it in place. (See Figure C–19) 13. Removing the right upper frame requires the removal of the screw-mounted cable clamp which also releases the rear paddle drive cord. 14.
Page 354 Replacement 1. Reverse steps 6 through 15, then: a. Install the OFF/ON and Mode switches in the right frame. (See Figure C–18) b. Re-attach 6 wires to the switches. c. Re-attach the low-voltage cable in the right frame. d. Secure the electrical cover and table top. NOTE: Replacement of the right upper frame will require new paper length and mode labels (attached by factory) plus re-attachment of the serial number...
Page 355: The Upper Drive Bearing
The Upper Drive Bearing Removal 1. Remove the upper drive roll motor cover and motor. (See Figure C–20) 2. Disengage the upper drive roll shaft per Figure C–12. 3. Use a small-tip Phillips screwdriver to remove 2 self-tapping screws securing the upper drive bearing to the right upper frame.
Page 356: The Cable Clamp Screw Mount
The Cable Clamp Screw Mount Removal 1. Use a pair of pliers or similar tool to hold the 4mm nut while removing the Phillips screw (see Figure C–21). 2. Remove the Phillips screw and lift the cable clamp over the rear paddle drive cord. Figure C–21.
Page 357: The Paper Shelf (With Cable Installation
The Paper Shelf (with cable installation) Removal 1. Remove the table top and the electrical cover (see Figure C–17). 2. Remove the tray support cable from the front of the paper tray. Allow the cable to slowly reel into the electrical housing (see Figure C–22). 3.
Page 358 Replacement 1. Reverse steps 2 and 3 in Figure C–22. 2. With the table top and electrical cover off, detach the inside clip of the torsion spring from the support shaft disc (see Figure C–23). 3. Pull the paper tray support cable until it completely unwinds from the tray support shaft. (Note) Figure C–23.
Page 359 5. Feed the cable through the opening formed by the front paper guide and the front paddle drive pivot bracket and re-attach it to the center post of the paper tray. 6. Rewind the cable onto the support shaft, allowing for clearance of the screw holding the support disc to the moveable core.
Page 360 9. Move the paper tray up and down to make sure the paper tray clears the paddle drive idler pulley. If there is contact, adjust the paddle drive left or right by loosening the two screws securing it to the front paper guide. After adjustments have been made, tighten the two screws.
Page 361: Stacker Specifications
Stacker Specifications Functional Characteristics Speed: Up to 24 ppm Media Type: 18–42 lb. continuous fanfold paper and many label stocks Media Size: Width: up to 10” Lengths: 9” to 12” in half-inch increments Warm-up: Immediately ready on power-up Electrical 115VAC @ 60Hz Requirements: (optional 220V @ 50Hz available) 10 Watts + printer consumption...
Page 362 Test Data Media tested: medium weight bond (18–24 lb.) and heavy weight bond (>24 lb. and <40 lb.) Under nominal temperature and humidity 1 mis-stack in 6000 pages 1 mis-fold in 3000 pages Under conditions of extreme temperature and humidity 1 mis-stack in 4000 pages 1 mis-fold in 2000 pages NOTE:...
Page 363: Appendix D Principles Of Operation
Appendix D Principles of Operation Printing This appendix outlines the principles of laser printing technology and gives a step-by-step explanation of the process. The printer performs printing operations in seven steps. The following steps are described in the subsequent paragraphs: Charging the OPC drum Exposing the OPC drum with the LSU to form a latent image Developing the print image by attracting toner onto the OPC drum...
Page 364 Charging the OPC Drum The main component of the printing system is the OPC (organic photoconductor) drum. It is a cylinder with special properties. The material of the OPC is an insulator when in the dark and is conductive when exposed to light. Before beginning the process, the OPC drum must be electrically charged.
Page 365 Exposing the OPC Drum (Forming the Latent Image) Inside the lid of the printer is a modulated semiconductor laser. The beam of the laser shines on a rotating polygonal mirror which causes the beam to scan across the OPC drum. The beam discharges the negative potential of the drum in the pattern of the desire image.
Page 366 Developing the Print Image The OPC drum, with its latent image, rolls past the sleeve and magnet roller, which is part of the developer unit. The powdered toner is magnetized, which keeps it lightly attracted to the sleeve over the magnet roller. The sleeve is charged to approximately –500 volts. As the image on the OPC drum passes the developer unit, the negatively charge toner is attracted to the exposed areas of the drum because of the voltage difference (–500 to –100 volts) as shown in Figure D–3.
Page 367 Transferring the Toner to the Print Media The print medium, normally paper or label stock, passes between the OPC Drum and a second metal channel containing a tungsten wire charged to approximately +4200 volts. This charge is transferred to the media, as shown in Figure D–4. As the media passes the rotating OPC drum, the negatively charged toner is transferred to the positively charged paper in the pattern of the developed image.
Page 368 Cleaning the OPC Drum Any toner remaining on the OPC drum is wiped from the drum with a doctor blade. The toner removed from the OPC drum is dropped into the screw assembly, which moves the used toner laterally to the waste toner container, as shown in Figure D–5. Doctor Blade Drum Rotation...
Page 369 Erasing the Static Charge An array of LEDs shines on the OPC drum before it moves again past the charger assembly, as shown in Figure D–6. The light causes the drum to conduct, allowing the charge to drain to ground before the next cycle begins.
Page 370 Fusing the Toner Image to the Media The media now has the toner image. The media moves between two rollers, a heat roller and a pressure roller, as shown in Figure D–7. Together, the heat roller melts the toner, while the pressure roller presses the image into the media.
Page 372 EDERLAND OX 163, IEUWEWEG 283 NL-6600 A IJCHEN ETHERLANDS (31) 24 6489489 HONE: (31) 24 6489499 RINTRONIX HANGI OUTH TREET 1 HANGI OUTH NDUSTRIAL STATE 486763 INGAPORE (65) 542-0110 HONE: (65) 543-0220 ISIT OUR WEBSITE AT: http://www printronix com 704792–001C...