DEC DEClaser 5100 Service Manual Download Page 6

Page: 6 / 274

9 Removing and Replacing FRUs

9.1

Removing and Replacing FRUs . . . . . . . . . . . . . . . . . . . . . . . . . .

9–1

9.2

Assembly, Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–2

9.3

Assembly, Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–5

9.4

Assembly, High-Voltage Power Supply (HVPSA) . . . . . . . . . . . . .

9–7

9.5

Assembly, Low-Voltage Power Supply (LVPSA) . . . . . . . . . . . . . .

9–8

9.6

Assembly, Optional Hard Disk Drive

. . . . . . . . . . . . . . . . . . . . .

9–11

9.7

Assembly, Paper Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–15

9.8

Assembly, Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–18

9.9

Assembly, Scanner

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–21

9.10

Board, LCIT Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–23

9.11

Board, Feed Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–27

9.12

Board, DC Control

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–29

9.12.1

Page Count Memory (NVRAM) . . . . . . . . . . . . . . . . . . . . . . .

9–32

9.13

Board, Ethernet

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–33

9.14

Board, SIMMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–35

9.15

Board, Video Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–37

9.16

Cage, Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–39

9.17

Cartridge, EP-ED (toner)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–40

9.18

Cover, Left-Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–41

9.19

Cover, Right-Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–43

9.20

Cover, Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–45

9.21

Door, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–47

9.21.1

Rear Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–49

9.22

Door, Front and Guide Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–50

9.22.1

Guide Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–52

9.23

Fan Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–54

9.24

Feeder, Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–57

9.25

Fusing Unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–59

9.26

Guide, HVPSA Contact Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–60

9.27

Interconnect, HVPSA/Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–70

9.28

Motor, Main

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–74

9.29

Motor, LCIT Pickup

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–75

9.30

Pad, Front Tray Separation

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–78

9.31

Roller Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–79

9.32

Roller, Cassette Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–80

9.33

Roller, Front Tray Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–81

9.34

Roller, LCIT Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–83

9.35

Sensor, Fusing Exit/Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–84

Summary of Contents for DEClaser 5100

Page 1: ...DEClaser 5100 Printer Service Guide Order Number EK LNX09 SV A01 Digital Equipment Corporation Maynard Massachusetts ...

Page 2: ...MENT and the DIGITAL logo are trademarks of Digital Equipment Corporation ITC Souvenir is a registered trademark of International Typeface Corporation PCL and LaserJet are registered trademarks of the Hewlett Packard Company Microsoft is a registered trademark of Microsoft Corporation WordPerfect is a registered trademark of WordPerfect Corporation PostScript is a registered trademark of Adobe Sys...

Page 3: ...tion Board 1 21 2 Technical Description 2 1 Print Engine Control 2 2 2 1 1 Video Controller Board and SmartPage 2 4 2 1 2 Print Engine Modes 2 6 2 1 3 Low voltage Power Supply Assembly 2 8 2 1 4 Fusing Heater Control 2 9 2 1 5 Fusing Malfunction 2 10 2 1 6 Interlocks 2 12 2 2 Paper Feeding System 2 12 2 2 1 Size Sensing Cassettes 2 14 2 3 Xerographic Process 2 15 2 3 1 Primary Charging Process 2 1...

Page 4: ...ript Error Report 4 7 4 7 Engine Board Test Pattern 4 8 4 8 Locking and Unlocking the Set Up Menu 4 9 4 9 Adjusting the Leading Edge Registration 4 10 4 10 Reading the Page Count 4 11 4 11 Formatting the Optional Disk 4 12 5 Start FIP and Total Call Concept 5 1 Preliminary Information 5 2 5 2 Start FIP 5 2 5 3 Total Call Concept TCC Procedure 5 5 5 3 1 200K Maintenance Procedure 5 7 6 Power and Co...

Page 5: ... Paper Feed Area Jams 7 4 7 4 Fusing and Delivery Area Jams 7 6 7 5 Phantom Jams 7 6 8 FIPs For Fixing Image Defects 8 1 Image Defects Lookup 8 2 8 2 Light or Faint Images 8 3 8 3 Blank or White Prints 8 4 8 4 Black or Too Dark Prints 8 5 8 5 In line Vertical Dots 8 5 8 6 Dirt on Back of Page 8 6 8 7 Vertical Black Lines 8 7 8 8 Black Smudged Vertical Bands 8 7 8 9 Black Smudged Horizontal Bands 8...

Page 6: ...9 33 9 14 Board SIMMs 9 35 9 15 Board Video Controller 9 37 9 16 Cage Card 9 39 9 17 Cartridge EP ED toner 9 40 9 18 Cover Left Side 9 41 9 19 Cover Right Side 9 43 9 20 Cover Top Cover 9 45 9 21 Door Rear 9 47 9 21 1 Rear Door Latch 9 49 9 22 Door Front and Guide Plate 9 50 9 22 1 Guide Plate 9 52 9 23 Fan Exhaust 9 54 9 24 Feeder Envelope 9 57 9 25 Fusing Unit 9 59 9 26 Guide HVPSA Contact Plate...

Page 7: ...ws NT Drivers B 4 B 3 Connecting the Printer to a Macintosh Computer B 5 B 3 1 Macintosh Printer Driver B 6 B 4 Connecting to OpenVMS VAX or ULTRIX Systems B 7 C DEClaser 5100 Specifications C 1 Operating Requirements C 4 C 1 1 Space Requirements C 4 C 1 2 Environmental Requirements C 6 D Training Documentation and Tools D 1 Training D 1 D 2 Documentation Ordering Information D 2 D 3 Tools D 3 Ind...

Page 8: ...ontrol Circuit 2 23 2 12 EP ED Cartridge 2 25 3 1 Control Panel 3 2 3 2 Overall Key Menu Map 3 7 4 1 Test Power Up Page 4 2 4 2 Menu Guide 4 3 4 3 Demo Page 4 4 4 4 PostScript and PCL Settings Pages 4 5 4 5 Font Lists 4 6 4 6 PostScript Error Report 4 7 4 7 Engine Board Test Pattern 4 8 4 8 VR202 Registration Adjustment 4 11 6 1 LVPSA Diagram 6 4 6 2 Print Engine Wiring Diagram 1 6 21 6 3 Print En...

Page 9: ...assettes 1 13 1 7 LCIT 1 15 1 8 Envelope Feeder 1 17 2 1 Size Sensing Switches 2 14 3 1 Control Panel 3 2 3 2 Indicators and Keys 3 3 3 3 Online and Paused Messages 3 4 5 1 Start FIP 5 3 5 2 200K Maintenance Procedure 5 7 7 1 Types of jams 7 2 7 2 Jam Areas 7 3 7 3 Feed Area Swap Lists 7 5 10 1 FRUs 10 1 B 1 Parallel Port AUTOEXEC BAT Modifications B 3 B 2 Serial Port AUTOEXEC BAT Modifications B ...

Page 10: ......

Page 11: ...ent personal injury On Line All control panel keys are represented by a box with the name of the key inside the box Value When this symbol appears next to a control panel message it shows that a string of numbers normally accompanies the message For example in the Parity Value message the value can be one of five different words PRNT A line over a signal name indicates that when the signal is asse...

Page 12: ...hapter 6 contains FIPs for fixing power control panel and error message malfunctions Chapter 7 contains the paper jam FIPs Chapter 8 contains the image defect FIPs Chapter 9 contains procedures for removing and replacing field replaceable units FRU s Chapter 10 contains the FRU part numbers Appendix A contains a map of the control panel key menus and a glossary style description of each feature an...

Page 13: ...DSG 000172 Notes 1 ...

Page 14: ......

Page 15: ...Claser 5100 printer complies with 21 CFR Chapter 1 Subchapter J as a Class 1 laser product under the U S Department of Health and Human Services DHHS Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968 The DEClaser 5100 printer does not emit hazardous light because the laser beam is totally enclosed during all modes of customer operation and maintena...

Page 16: ...l Description Figure 1 1 presents a view of the front and right side of the printer The names and functions of the items are described in Table 1 1 Figure 1 1 Front View DSG 00 0425 6 1 3 7 8 4 5 2 1 2 Physical and Functional Description ...

Page 17: ...ch Connects to the main LVPSA switch by a mechanical linkage Font cartridge slot Holds up to two optional PCMCIA font cartridges The cartridges can be hot swapped with power applied but the printer must be paused Control panel Consists of seven multipurpose keys an alphanumeric display panel and indicators that light or flash to show status conditions See Chapter 3 for additional information Inter...

Page 18: ...ription Figure 1 2 shows the components that are accessible through the front tray of the printer Table 1 2 describes the components Figure 1 2 Front Tray Open DSG 000863 1 2 3 4 1 4 Physical and Functional Description ...

Page 19: ...ds and prints one copy of the engine board test pattern from the internal cassette only See Section 4 7 for additional information Adjustable paper guides The adjustable guide is moved to hold the media against the fixed guide Image skewing paper jams or bad image positioning can occur if the adjustable guide is too loose or over tightened Front tray and door Shown in the open position The tray ac...

Page 20: ...on Figure 1 3 shows the inside components that are accessible through the top door of the printer Table 1 3 describes each component Figure 1 3 Inside the Top Door DSG 000861 1 3 4 2 5 1 6 Physical and Functional Description ...

Page 21: ...The foam transfer roller is a crucial part of the xerographic process See Section 2 3 3 for additional information When you handle the transfer roller only touch the extreme ends Fingerprints on the roller can cause image defects Cleaning brush The cleaning brush is used to sweep toner and dust out of the static eliminator which is located next to the transfer roller The hooked end of the brush is...

Page 22: ...ption Figure 1 4 shows the components that are accessible through the rear door of the printer Table 1 4 describes each component Figure 1 4 Rear Panel 1 2 3 4 9 5 6 8 7 DSG 000582 1 8 Physical and Functional Description ...

Page 23: ... the DEClaser 5100 or if the fusing unit is replaced Operating the printer with one or both of the levers up causes fusing failure or paper jams to occur Fusing exit rear door sensor This sensor monitors the fusing exit paper path and the rear door Fusing exit The fusing exit opens to allow removal of jammed paper Rear door Press the latch to open the rear door to the position shown The door opens...

Page 24: ...escription Figure 1 5 shows the components that are visible from underneath the printer Table 1 5 describes each component Figure 1 5 LCIT Interconnection DSG 000 583 1 2 3 4 1 10 Physical and Functional Description ...

Page 25: ...al LCIT cassette slot and the other in the internal cassette slot Each set consists of three switches The size sensing switches read the configuration of the keys on the side of the installed cassette This information is compared to the selected size by the firmware A mismatch causes an error to display LCIT interface connector This 4 pin connector connects the LCIT controller board to the feed un...

Page 26: ... 6 describes the cassette components Universal cassettes are available for the LCIT and for the internal cassette The internal cassettes are shallower and have a paper path slot in front Figure 1 6 Universal Cassette 1 2 8 7 6 5 4 3 D S G 0 0 0 5 8 4 1 12 Physical and Functional Description ...

Page 27: ...Actuate the size sensing switches on the side of the cassette slot The size information is compared with the size entered in the menu or received from the host If a mismatch occurs a paper size error appears Table 2 1 gives the key configuration for each paper size Paper size adjuster Sets the size sensing keys An incorrectly set paper size causes false paper jams or paper mismatch errors Cassette...

Page 28: ...rs 1 4 Optional Feeders Figure 1 7 shows the DEClaser 5100 large capacity input tray LCIT and Table 1 7 identifies the components Figure 1 7 LCIT D S G 0 0 0 5 8 6 2 3 4 5 6 7 8 1 1 14 Physical and Functional Description ...

Page 29: ...mation Interface connector A 4 pin connector that connects the LCIT controller board to the feed unit controller Size sensing switches Three size sensing switches read the configuration of the keys on the side of the installed cassette Table 1 6 shows and describes the size sensing keys This information is compared to the selected size by the firmware A mismatch causes an error to appear There are...

Page 30: ...8 shows the DEClaser 5100 optional envelope feeder and Table 1 8 identifies the components The envelope feeder is a field replaceable unit Figure 1 8 Envelope Feeder D S G 0 0 0 4 7 1 1 3 2 4 1 16 Physical and Functional Description ...

Page 31: ...he envelope feed rollers Adjustable guide Adjusts to hold the envelope stack against the left side of the envelope feeder Support tray Provides support for long envelopes Envelope feed rollers Feeds envelopes from the bottom of the stack into the printer Physical and Functional Description 1 17 ...

Page 32: ...fonts remain in the printer through power cycles Storing fonts on the disk leaves the RAM free for other needs The disk is customer installable and the disk formatting procedure is automatic and interactive See the following locations for additional information Section 4 11 contains the formatting procedure Section 6 11 contains the hard disk display messages and FIP Section 9 6 contains the hard ...

Page 33: ... Ethernet Network Board An optional Ethernet network board slides into the rear of the printer and provides a ThinWire or twisted pair connection Figure 1 9 Ethernet Network Board DSG 000592 Physical and Functional Description 1 19 ...

Page 34: ...idge being installed into the font cartridge slot The notch must be facing up for the cartridge to install correctly The PCMCIA compliant font cards can be inserted in while the printer is on Figure 1 10 Font Cartridge Installation DSG 000580 1 1 20 Physical and Functional Description ...

Page 35: ...bit map in the video controller board memory DECimage uses a 600 x 600 dpi bitmap This memory usage might cause memory overflow or print overrun errors described in Section 6 8 when printing complex images or using many downline loaded fonts The RGE enhances the appearance of all PostScript and PCL images Low resolution image enhancement begins as soon as the RGE board is plugged in and power is t...

Page 36: ...1 8 Resolution Graphics Enhancements Option Board DSG 000172 Notes 1 22 Physical and Functional Description ...

Page 37: ...sembly LVPSA and interlock systems and presents board and connector level wiring diagrams Section 2 2 describes the paper feeding system plus paper size sensing and detection Section 2 3 describes the xerographic process Sections 2 4 and 2 5 present a detailed description of the scanner and high voltage power supply assembly HVPSA See the detailed wiring diagrams in Figures 6 2 through 6 5 Technic...

Page 38: ...ll nonshaded components are operated by discrete binary signals The DC control board operates all the print engine devices solenoids sensors motors and so on The DC control board can operate the printer and print the engine test pattern with no video control board installed Section 2 1 1 describes the operation and functioning of the video controller board 2 2 Technical Description ...

Page 39: ...aser Driver BD Scanner Motor Scanner Unit HVPSA Main Motor Exit Sensor Main Fan Feed Unit Control Board LVPSA Fusing Unit Heater LCIT Envelope Feeder Sensors Pickup Motor Solenoids HVPSA Contact Plate Primary Charge Developer Charge Transfer Charge Static Eliminator Toner Sensor DSG 000593 Technical Description 2 3 ...

Page 40: ...ional Ethernet network card The video controller board accepts PostScript level 2 or PCL5E code files from either the host or Ethernet interfaces and creates a bitmap image The bitmap is fed to the DC controller board as the V DO signal that is described in Section 2 4 Traditionally an entire page is bitmapped into RAM before the printer is commanded to feed and print Such a system requires a cons...

Page 41: ...ory overflow or print overrun error message See Section 6 8 Fails to print from the point of error to the end of the sheet Continues to print until the job is finished Figure 2 2 Video Controller Block Diagram Operator Panel Video Controller Board DC Control Board Serial AppleTalk Options Disk Drive RGE Network Card Parallel Font Cartridge 1 Font Cartridge 2 5Vdc DSG 000594 SIMMS Technical Descrip...

Page 42: ...main and scanner motors Turns the high voltage bias supplies on and off Cleans the transfer roller 2 If all the wait checks pass the printer enters standby STBY mode until a print request is received During standby fusing temperature and interlocks are maintained Standby ends when a print command is received from the video controller or from the test print switch 3 After a PRNT signal is received ...

Page 43: ...otation mode immediately begins Figure 2 3 Print Engine Modes Timing Diagram WAIT STBY INTR PRINT LSTR STBY Transfer charges Develop DC charge Develop AC charge Primary DC charge Primary AC charge Scanner motor Main motor VSYNC Vertical SYNC signal PRINT signal Fusing heater READY WAIT indicator Flashing Steady glow 162ºC 172ºC 183ºC 172ºC 0 2 0 3 0 3 0 73 0 51 0 65 Between the pages bias Print bi...

Page 44: ... breaker Note A 6 3 amp fuse is used in place of the circuit breaker of power supplies that carry the Sanken label When the top door is closed the top door switch provides the 24VB to the motors and high voltage supplies Section 2 1 4 describes the operation of the fusing heater control circuit and the THOUT RLD and FSRD signals Figure 2 4 LVPSA Diagram DC Control Board Top Door Switch Exit Sensor...

Page 45: ...stor TH1 and adjusted by the DC control board The fusing temperature sets the resistance of TH1 establishing the voltage level for the analog FSRTH signal The resistance of TH1 decreases as the fusing temperature increases The following TH1 resistance readings are measurable across pins 1 and 2 of the fusing unit connector J743 Room temperature resistance of TH1 is approximately 239K Operating tem...

Page 46: ...emperature rise occurs the thermoswitch TP1 opens to permanently disconnect the fusing current When a fusing error occurs C202 is charged to approximately 5 Vdc which prevents the operation of the fusing circuit C202 discharges only when the power is turned off If power is turned on before the charge is completely drained C202 fully recharges The printer must remain off for approximately 10 minute...

Page 47: ...ng Control Circuits HVPSA fuser interconnect Safety Circuit LVPSA RL101 J212 3 1 2 THOUT FSRD RLD J210 2 1 FSRTH Q207 5V CPU IC201 69 30 29 74 27 DC Control Board 2 3 4 1 2 3 4 Fusing Unit Connector DSG 000599 1 TPI Technical Description 2 11 ...

Page 48: ... Feed unit contoller board PSNS 5V DOPEN 24VA 24VB DC Contoller Board J201 12 13 8 9 10 11 4 Top door switch DSG 000600 2 2 Paper Feeding System Paper can feed from the cassette underneath the printer or from the front tray or envelope feeder at the front of the printer The paper feed unit mechanically and electrically controls all media feeding The front tray can feed paper envelopes labels and s...

Page 49: ...oller and moves a sheet of paper into the nip of the oblique rollers The two oblique rollers drive the sheet forward and sideways into the left side plate and then into the registration sensor This action deskews the sheet squarely aligning it with the axis of the print drum When the paper triggers the registration sensor the paper feed motor pauses to allow the print drum to rotate into alignment...

Page 50: ...are molded into the body of the cassette The keys on the universal cassette are set by the user The size sensing information is compared to the user requested size If a mismatch occurs an operator load tray message appears Table 2 1 Size Sensing Switches Paper Size Sensing Switches Size SW603 SW604 SW605 Legal On On Off Letter On Off On Executive Off On On B5 Off On Off A4 Off Off On No cassette O...

Page 51: ...n the next table each item is listed with a reference for more information Process See Section Primary Charging Process 2 3 1 Exposure Process 2 3 2 Development Process 2 3 3 Paper Feeding System 2 2 Transfer Process 2 3 4 Separation Process 2 3 5 Fusing Process 2 3 7 Print Drum Cleaning Process 2 3 6 Figure 2 9 Xerographic Process DSG 000602 8 7 4 5 6 1 3 2 Technical Description 2 15 ...

Page 52: ...ltage bias and produces less ozone then corona type charging systems used on other printers As the OPC drum turns the primary charge is subjected to the exposure process 2 3 2 Exposure Process Unexposed Area Exposed Area ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ QQQQ Laser Beam Time t Surface Potential V 0 100 500 Exposed Area Primary Charge Scanning Process Transfer Primary Charge The data mod...

Page 53: ...he surface of the OPC drum On the OPC drum the highly charged unexposed areas repel the toner The lesser charged or exposed areas are painted with the toner thus making the image visible to the naked eye The developer dc bias varies from the primary dc bias see Section 2 3 3 2 3 4 Transfer Process ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ ÀÀÀ OPC T...

Page 54: ...ÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ ÀÀÀÀ QQQQ QQQQ QQQQ QQQQ À ÀÀ ÀÀ À ÀÀ ÀÀ À ÀÀ ÀÀ À ÀÀ ÀÀ À ÀÀ ÀÀ À ÀÀ ÀÀ Cleaning Blade OPC After the toner image is transferred and the sheet travels to the fusing unit residual toner is cleaned from the OPC drum surface The sweeper strip and cleaning blade scrape any remaining toner off the OPC drum This toner falls into a...

Page 55: ...roller accumulates the charge from the residual transfer charge that adheres the unfused toner to the sheet This negative charge repels the like charged toner particles from the upper roller thus making it difficult for the toner to stick to the fusing rollers The nonstick coating on the upper roller also helps prevent toner from sticking Technical Description 2 19 ...

Page 56: ... then 2 5 seconds while the scanner motor is running When the scanning beam passes the beam detect BD mirror it reflects the light into the beam detector creating the BDI signal The DC control board receives BDI and sends BD to the video controller board In response to BD the video controller transmits the video data out V DO signal to the DC control board which sends it to the laser driver as the...

Page 57: ...rce Laser Driver Video Controller Board DC Control Board J206 6 2 3 4 5 APCOUT LON ENBL VDATA APCIN BD VDO VSYNC BDI SCNCLK SCNON SCNRDY Scanner Motor and Mirror Focus Lenses BD Mirror Cylindrical Lens Beam Detector Flat Mirror Print Drum Laser Diode Photo Diode Technical Description 2 21 ...

Page 58: ... and development processes The dc component varies according to laser beam intensity and to the setting of the user assessable density adjustment The HVPSA couples this dc component to the development bias The transfer bias switches from negative for cleaning and to positive for printing The static eliminator removes the residual transfer charge from the paper sheet TB402 and the contact plate cap...

Page 59: ...act Plate 24 VB 5 V J401 B3 B4 B5 B1 B2 GND A1 A2 A4 A3 A5 SLO2 SLI2 HVRST TVOUT TVIN 8 3 TB406 TB404 TB405 TB403 TB402 TB401 Primary Charge Toner Sensor Transport Entrance Guide Transfer Charge Static Eliminator Developer Charge DSG 000611 Technical Description 2 23 ...

Page 60: ...he location of the EP ED electrical connectors See Section 2 5 for functional description and schematic diagrams Primary bias Developer roller bias Toner sensor contact Cartridge ground Drum shutter Print drum Alignment guides 2 24 Technical Description ...

Page 61: ...2 5 HVPSA Figure 2 12 EP ED Cartridge DSG 000612 2 1 3 4 5 6 7 Technical Description 2 25 ...

Page 62: ...2 5 HVPSA DSG 000172 Notes 2 26 Technical Description ...

Page 63: ...ol panel indicators and keys Section 3 2 explains the control panel operational modes The print engine operational modes are described Section 2 1 2 Section 3 2 2 maps out the structure of the control panel menus See Appendix A for a definition of each feature and value that appear on the control panel menus Operating the Control Panel 3 1 ...

Page 64: ...Alarm Data Enter DSG 000409 2 1 3 4 Table 3 1 Control Panel Message display The sixteen character alphanumeric vacuum fluorescent display VFD shows error status and operator messages Graphic display The display shows jam locations and active and faulted feeders Green indicates the active feeder and amber indicates a non fatal error Keypad Table 3 2 describes the seven control panel keys Indicators...

Page 65: ...enus see Section 3 2 2 _ Scrolls through the key menu features see Section 3 2 2 This Indicator When On Line On the printer is on line and can receive and print a file from the host system Flashing a job is printing Ready On the printer is powered on and ready to receive and process data Flashing the printer is resetting or initializing Alarm Amber On a fault or error condition exists Flashing a m...

Page 66: ...e scanning all ports for incoming data After the port scan detects data the printer Locks onto the port Analyzes the data to identify the file type Switches to the appropriate interpreter Receives interprets and prints the host data file PS Serial PCL Parallel PS Network The printer is busy interpreting data and identifies the receiving port SER Waiting LOC Waiting Identify the receiving port and ...

Page 67: ...Indicate a fatal error Printing stops for a fatal error until the operator or service engineer clears the error A jam or printer open message clears automatically when the door is opened and then closed The 50 ERROR message requires that you power off the printer for a minimum of 20 minutes Operating the Control Panel 3 5 ...

Page 68: ...s See the detailed map in Figure A 1 for a more in depth view Appendix A explains all the features and values The printer must be paused before you can enter a key menu Using the map and the four arrow keys you can scroll around through the two dimensional matrix of the key menus The Test Fonts Reset and Feeder Select key menus are one level deep The complex Set up key menu extends an additional t...

Page 69: ...Reset Feeder Select Internal LCIT Front Envelope Front Int Int LCIT All Feeders Set Up Show page count Print menu guide Print PS menus Print PCL menus Print PS fonts Print PCL fonts Print demo page PCL PostScript Miscellaneous Communication See Figure A 1 for more information DSG 000714 Operating the Control Panel 3 7 ...

Page 70: ...3 2 Control Panel Operation DSG 000172 Notes 3 8 Operating the Control Panel ...

Page 71: ...ollowing printouts are described The seven printouts available from the Test Fonts key menu see 4 1 through 4 5 Test page prints at power up Menu guide Demo page PostScript and PCL setting pages PostScript and PCL font lists PostScript error report see Section 4 6 Engine board test pattern see Section 4 7 Test Patterns and Miscellaneous Procedures 4 1 ...

Page 72: ...nics PostScript PostScript Office printer 4 Courier The Digital logo is a trademark of Digital Equipment Corporation Page design copyright 1991 1993 Digital Equipment Corporation 199999 DSG 000578 pDYW Tekton Parisian Formata Barmeno Kaufmann Lithos Park Avenue Americana Trajan ITC Souvenir ITC Bookm an A d o b e C a s l o n I T C Z a p f C h a n c e r y I T C L u b a l i n G r a p h A d o b e G a...

Page 73: ...rints when you select the Print menu guide from the Test Fonts key menu Using this map helps to navigate the control panel key menus The menu guide shows only the features See Figure A 1 for a full key menu map Figure 4 2 Menu Guide DSG 000620 Test Patterns and Miscellaneous Procedures 4 3 ...

Page 74: ... 4 3 shows the PostScript demonstration page The demo page is useful for evaluating print quality and for testing all the features of the level 2 PostScript interpreter Figure 4 3 Demo Page DSG 000575 1 5 3 2 4 4 4 Test Patterns and Miscellaneous Procedures ...

Page 75: ...efault RAM size Page count Number of copies Margins Max local VM Max global VM Total available VM Current font cache Max font cache Current font cache Max font cache Current pattern cache Max pattern cache Current screen storage Max screen storage Page count Sheet count Number of copies Margins DEClaser 5100 Steve s HPPS v1 08 2013 109 119 6 0MB 526 1 0 0 726018 744538 1470552 418866 629145 0 1000...

Page 76: ...ts DSG 000706 Font List PERMANENT SOFT FONTS LEFT FONT CARTRIDGE RIGHT FONT CARTRIDGE DISK FONTS INTERNAL FONTS Font Font Symbol Fix Pitch Point Style Stroke Name or Default Print Sample ID Set PS cpi Size Weight Typeface Orient Escape Sequence I000 Font Roman 8 F 18 00 6 0 Upright Medium Courier Port ABCDEfghijÁÁ ÇÑ esc 8U esc s0p10 ooh1 I000 Font Roman 8 F 18 00 6 0 Upright Medium Courier Port A...

Page 77: ...ltype savetype bottom unnamed dict 1220 unnamed dict 23400 statusdict 3720 userdict 2740 lpe lpsdict 3720 userdict 2740 shareddict 2740 systemdict 354300 bottom graphics state execution stack 15 elements VM status save level 3 max VM 1136640 VM used 128484 VM avail 1006156 cvs ok load and exec file disableinterrupt aborted cleaninterrupt disableinterrupt exch 0 exch put clear aborted procedure arr...

Page 78: ...ine board test pattern is resident in the firmware on the DC controller board and can print without a video controller board present in the printer To print the engine board test pattern press the test print switch shown in Table 1 2 with a paper clip or some other suitable tool Figure 4 7 Engine Board Test Pattern DSG 000711 4 8 Test Patterns and Miscellaneous Procedures ...

Page 79: ...e the arrow keys to scroll to a The Miscellaneous submenu b The Set Up menu lock feature c The LOCK enabled value 4 Press Enter to enter the selection 5 Press 3 when the message Press to lock message appears Temporarily bypass the Set Up menu lock as follows 1 Press On Line to pause the printer The Paused message appears 2 Press and hold 3 3 Press and release Set Up 4 Release 3 to display Set Up m...

Page 80: ...ge registration margin 1 Use a small screwdriver to turn VR202 to the zero 0 position in the center of its adjustment range Figure 4 8 shows the location of VR202 2 Before doing the following step be ready to mark the leading edge of the test print DSG 000703 a Leading Edge of Paper 3 Use a suitable tool to press the test print switch and print a copy of the engine board test pattern See Figure 1 ...

Page 81: ...s transferred if the video controller board is replaced Transferring the NVRAM preserves the page count history When you replace the NVRAM record the event and the last known page count number in the site maintenance log Use the following procedure to display the page count information 1 Press On Line to pause the printer The Paused message appears 2 Press Test Fonts to enter the Test Fonts key me...

Page 82: ...rmatting procedure 1 The Disk Added message appears Press 3 to continue 2 The to format disk message appears Press 3 to start formatting or press any other key to not format 3 The Formatting disk message appears while the disk is formatting this takes about 20 seconds 4 The Restart printer message appears Power off the printer then power it on again 4 12 Test Patterns and Miscellaneous Procedures ...

Page 83: ...pter 8 8 1 Image Defects Chapter 5 5 3 TCC Procedures End The FIPs are a collection of yes no flow steps charts and tables that provide a way to fix or ensure the correct operation of the hardware The adjacent flowchart show all the FIP procedures The darkened area is the overall start FIP Use the start FIP to test the printer If a problem exists use the start FIP to isolate the problem and direct...

Page 84: ...ection 5 3 to make sure no other problems exist Keep the following in mind when the FIP tells you to check a signal or power supply voltage Unless otherwise stated all voltage readings should be within 5 of the stated value Voltage level low means 0 to 0 5V Voltage level high means 5V 0 5V The bar over a signal name PRNT shows that that signal when asserted is low 5 2 Start FIP See Table 5 1 to be...

Page 85: ...t sheet for print quality and make sure all installed options are listed If the print quality is good Go to step 4 If the print quality is poor Go to Section 8 1 If one or more installed options is not listed Goto Section 6 2 4 Print several test sheets from each input tray If the printer can print reliably with no errors jams or defects Go to step 5 If you see any Control panel faults Go to Secti...

Page 86: ...ction 5 3 Printer is OK Return to start FIP Key note All the display message FIPs can be found in Sections 6 3 through 6 16 The messages are listed in the table of contents at the front of this book or you can look for a message by flipping through Chapter 6 reading the section information 5 4 Start FIP and Total Call Concept ...

Page 87: ...omponents While cleaning look for broken plastic or metal components or for any signs of damage Replace any damaged components Before ending a service call make sure you have done the following 1 Discuss the operation of the printer with the customer 2 If more then 200 000 sheets have printed perform the 200K maintenance procedure see Section 5 3 1 The page count appears when you select the Show p...

Page 88: ...ean the delivery exit rollers 10 Clean the external covers 11 Repeat the test prints until the printer is performing flawlessly 12 Power on the printer Make sure the printer boots and is on line Ready appears on the display 13 Enter the following information in the maintenance log The nature of the original problem and any other malfunctions All parts replaced Any observation that might be helpful...

Page 89: ... customer s site Make sure to record the event in the maintenance log Table 5 2 200K Maintenance Procedure FRU Name Part Number R R Section Number Fusing unit FD 41594 01 115 Vac FD 41595 01 220 Vac 9 25 Pad front tray separation FD 41622 01 9 30 Roller cassette pickup FD 41629 01 9 32 Roller front tray pickup MP tray pickup roller FD 41630 01 9 33 Roller LCIT pickup FD 41631 01 9 34 Roller transf...

Page 90: ......

Page 91: ...ter See Chapters 7 and 8 for jam and image defect FIPs DSG 000623 Start Chapter 5 5 2 Start FIP Chapter 6 6 1 Power Fault FIP Error Message FIPs Chapter 7 7 1 Jam FIPs Chapter 8 8 1 Image Defects Chapter 5 5 3 TCC Procedures End The adjacent start FIP map shows the position of this chapter in the overall fault isolation procedure If a problem exists use the start FIP to isolate the problem and dir...

Page 92: ...The main motor turns rounding the paper path rollers for approximately six seconds If the covers are removed you can see the fuser heater glowing Review the following two sets of symptoms and choose the one that describes the malfunction Symptom 1 The following symptoms indicate a working print engine with a malfunctioning control panel circuit At power up the rounding cycle completes The fusing u...

Page 93: ...ntioned in the following steps 4 Inspect the 6 wire cable that runs from the DC control board to the J103 connector on the LVPSA Make sure it is properly plugged in and in good condition 5 Remove the video controller board and all optional equipment 6 Press the test print switch to see if the printer can print or use a VOM to measure the power supplies from the LVPSA on J103 7 Skip the following a...

Page 94: ...ontroller Board HVPSA Scanner Motor BD Detector Laser Scanner Assembly Fusing Unit 24VA 5V 5V 24VB 5V 24VB 5V 5V 24VA 5V 5V DC Power Regulator 24VA DC Power Regulator Circuit Breaker Noise Filter Fusing Heater Control J103 1 2 3 4 5 6 J212 1 2 3 1 2 J104F 3 FSRD RLD THOUT DSG 000596 Video Control Board 6 4 Power and Control Panel FIPs ...

Page 95: ...ither socket If two SIMMs are installed they can be of different sizes and installed in any order Memory is available from Digital Equipment Corporation in 4 16 or 32 Mb SIMM boards A customer can purchase and install standard personal computer memory The SIMMs must comply to the following requirements 32 bit wide non parity 72 pin SIMMs that conform to JEDEC Standard 21 36 bit wide parity 72 pin ...

Page 96: ...1 8 for more information about the RGE The Ethernet network board connects to a socket mounted on the video controller board When power is turned on the Ethernet board s self test runs If the self test passes a status sheet not shown in this service guide is printed On the status sheet you can find the following The Ethernet address The setting of the twisted pair ThinWire jumpers Information for ...

Page 97: ...e of a job The dc control board cannot recognize the type of installed font cartridge only the presence or absence of a cartridge Signal diagram reference See the block diagram in Figure 2 2 Action Do the following if the display cannot be cleared or if the message appears intermittently 1 Make sure the video controller board is installed correctly and the cartridge connector is undamaged 2 Swap t...

Page 98: ...gram reference See Figure 6 6 Action Do the following if the message appears intermittently or fails to clear 1 Remove the envelope feeder and inspect the four pin connector the pins that align the envelope feeder and the general area for damage Replace any damaged FRUs 2 Swap the following FRUs The envelope feeder The DC control board The paper feed controller board or the paper feed unit 6 8 Pow...

Page 99: ...panel menus set the paper size and feed device See the menu map in Figure A 1 for more information Set the paper size through the Front Tray Size feature of the Feeders submenu from the Set Up key menu Set the feed device through the Default feeder feature of the Feeders submenu from the Set Up key menu Signal diagram reference See Figure 6 2 for wiring diagrams Action Do the following if the mess...

Page 100: ...e and inspect the 500 sheet LCIT cassette Replace the cassette if you find any damage If the cassette is a universal type cassette make sure the size sensing cams are set to the correct size 3 Manually actuate the size sensing switches Replace the paper feed control board if the switches stick bind or fail to operate 4 Inspect the linkage of the LCIT paper sensor Replace the LCIT if the linkage st...

Page 101: ...ference See Figure 6 2 for wiring diagrams Action Do the following if the message appears intermittently or fails to clear 1 Remove and inspect the cassette If damaged replace the cassette If the cassette is a universal type cassette make sure the size sensing cams are set to the correct size 2 Manually actuate the size sensing switches Replace the paper feed control board if the switches stick bi...

Page 102: ...er board or memory SIMMs SmartPage failures occur when the customer prints pages that are too complex for the SmartPage process To correct SmartPage errors advise the customer to Invoke the page protect mode This forces the printer to build a full page in memory before printing occurs and slows down the completion of the print job Page protect is invoked from the PostScript or PCL Set Up key menu ...

Page 103: ...ocess EP ED cartridge checks are performed during power up after top door closing or control panel keying Signal diagram reference See Figures 6 5 and 2 11 for wiring diagrams Action Do the following 1 The toner might be damp Remove the EP ED cartridge and shake it to loosen up the toner 2 Swap the EP ED cartridge with a known good unit 3 Inspect the toner sensor contacts on the EP ED cartridge an...

Page 104: ...he top door To clear this error close the top cover Signal diagram reference See Figures 2 8 2 4 and 6 2 for wiring diagrams Action Do the following 1 Make sure the top cover is installed correctly as shown in Section 9 20 2 Open and inspect the top cover and tang If you see any broken or damaged plastic replace the top cover 3 Use a small screwdriver to manually depress the spring linkage If the ...

Page 105: ...error The disk cannot read or write to a previously good area of the disk surface Disk error Disk error nnnn An unknown or known disk error has occurred Where 1218 Disk access failure 5033 Master drive format failure 5034 Master drive buffer failure 5035 Master drive ECC failure 5036 Master drive microprocessor failure 5037 Master drive interface failure 5038 Slave drive diagnostics failure 1234 I...

Page 106: ...e following to measure the resistance of thermistor TH1 and the fusing heater element Skip this step if you do not have a volt ohm milliamp VOM meter a Connect the VOM leads across pins 1 and 2 of the fusing unit connector shown in Figure 2 7 If the resistance reading is outside of the following parameters replace the fusing unit Room temperature resistance is approximately 239K Operating temperat...

Page 107: ...nchronous scanner motor To clear either error press 3 Signal diagram reference See Sections 6 3 and 2 10 for wiring diagrams Action Do the following a If the printer has been moved from a cold to a warm room the optical lenses might be misted by condensation Allow about 6 hours for the mist to evaporate b Remove the top cover to inspect the scanner assembly connectors c Make sure the connectors ar...

Page 108: ...or is fully closed and the interlock switch is fully depressed 2 Remove the right side cover and video controller board 3 Inspect the connectors and cabling that runs between J211 on the DC control board and J131 on the main motor driver board Make sure both connectors are correctly plugged in and the cable is in good shape 4 Make sure the printer power is off 5 Do the following to test the main m...

Page 109: ...error The single speed exhaust runs when the DC control board asserts the FAND signal If the exhaust fan stalls the exhaust fan asserts the FLOCK signal that is detected by the DC control board Signal diagram reference See section Figure 6 4 for wiring diagrams Action Do the following 1 Remove the right side cover and video controller board 2 Inspect the exhaust fan blades for foreign objects that...

Page 110: ... the DEClaser 5100 printer The following conventions apply to the wiring diagrams Unless otherwise stated all voltage readings should be within 5 of the stated value Voltage level low means 0 to 0 5V Voltage level high means 5V 0 5V The bar over a signal name for example PRNT shows that the signal when asserted is low Figure 6 6 and Figure 6 7 are the wiring diagrams for the optional envelope feed...

Page 111: ...idden switch Top door open switch SW603 SW604 SW605 SW602 SW601 602 A1 B1 A2 B2 A3 B3 A4 B4 A5 B5 PA PA MP PB 1ST PB MPS MPE GND 24VA J605 4 5 6 RESL GND RESS J605 1 2 3 1 STL GND 1STS 3 2 1 3 2 1 3 1 2 2 6 7 9 10 J210 2 1 J208 1 3 2 Feed Unit Control Board DC Control Board 5V PSNS FSRTH SLO1 SLI1 DOPEN 2 3 4 J201 1 7 8 9 10 11 12 13 2 3 4 J601 1 7 8 9 10 11 12 13 5V 24VB 24VA DSG 000624 HVPSA Fus...

Page 112: ...1 8 7 6 5 4 3 2 1 24VB 5V TVIN HVRST TVOUT SLI2 SLO2 J401 B5 A5 B4 A4 B3 A3 B2 A2 B1 A1 HVPSA J743 3 2 Fusing Unit HVPSA Fusing Interconnect Scanner Motor 24VA J204 1 2 3 3 2 1 Beam Detector BD Signal 5V LON ENBL VDATA APCIN APCOU J206 1 2 3 4 5 6 7 7 6 5 4 3 2 1 Laser Diode and Driver Circuit 5V Scanner Assembly DSG 000625 BDI 6 22 Power and Control Panel FIPs ...

Page 113: ...Sensor Interconnect Board 5V FAND FLOCK J209 1 2 3 Main Fan FM1 DSG 000626 J601 1 2 3 7 8 9 10 11 12 13 24VB 24VA A1 B1 A2 B2 A3 B3 A4 B4 A5 B5 PA PA MP PB 1ST PB MPS MPE GND 24VA J703 1 2 3 4 J704 1 2 J702 1 2 PA PA PB PB 24VA 1STD 24VA MPD M2 SL701 SL702 Paper Feed Motor Cassette Feed Solenoid Tray Feed Solenoid Power and Control Panel FIPs 6 23 ...

Page 114: ...ser Interconnect FSRD RDL THOUT J212 1 2 3 LVPSA DSG 000627 24VB J743 8 1 M1 Toner Sensor HVPSA Contact Plate Main Motor EP E Cartridge J104 3 2 1 SW101 J102 1 2 TP1 Relay Quartz Fusing Heater Element MRDY MON J211 1 2 3 4 J210 8 9 J131 1 2 3 4 SL702 HVPSA TB403 SLO2 6 24 Power and Control Panel FIPs ...

Page 115: ...diagrams for the optional envelope feeder and LCIT Figure 6 6 Optional Envelope Feeder Wiring Diagram DC Control Board Feed Unit Control Board Envelope Board DSG 000628 24VA ENVO ENVI J932 1 2 3 4 A A B B M4 Envelope Motor J604 1 2 3 4 J201 1 2 3 12 13 SLO1 SLI1 24 VA Envelope Paper Sensor Power and Control Panel FIPs 6 25 ...

Page 116: ...l Board DSG 000715 24VA 24VA 2NDO 2NDI GND J932 1 2 3 4 A A B B M4 Envelope Motor J603 1 2 3 4 J201 1 2 3 12 13 SLO1 Serial Line Output 1 SLI1 Serial Line Input 1 nsor Feed Unit and Option Interconnect SW851 SW852 SW853 LCIT Size Sensing Switches J853 1 2 24VA 2STD SL801 Feed Solenoid 6 26 Power and Control Panel FIPs ...

Page 117: ...Chapter 5 5 2 Start FIP Chapter 6 6 1 Power Fault FIP Error Message FIPs Chapter 7 7 1 Jam FIPs Chapter 8 8 1 Image Defects Chapter 5 5 3 TCC Procedures End The adjacent start FIP map shows the position of this chapter in the overall fault isolation procedure To find the correct paper jam FIP see Section 7 1 and Section 7 2 to determine the type and location of your jam FIPs for Fixing Paper Jams ...

Page 118: ... or continuously Phantom jams might occur without any paper feeds These jams are commonly caused by a bad sensor cabling or control board Wrinkled Skewed Notched Dog eared or Shredded Paper damage caused by a serious paper path malfunction A common cause might be obstructions broken paper path guides rollers or roller pressure springs 7 2 Identifying the Location of the Jam This section describes ...

Page 119: ...eed area includes the paper path from the selected input device to the entrance of the fusing unit See Section 2 2 for a description of the feed path 7 3 In the fusing and delivery area includes the paper path from the fusing unit to the exit of the delivery rollers 7 4 and As a phantom jam 7 5 and see Table 7 1 FIPs for Fixing Paper Jams 7 3 ...

Page 120: ...t the following for damage or malfunction If you see any broken or cracked plastic replace the damaged components The LCIT and internal cassettes The envelope feeder The EP ED cartridge The paper path guides registration sensor linkage jam plate 5 Feed paper from all available inputs Note the feeder that causes the jam and the type of jam 6 Table 7 3 lists the originating feeder vertically and the...

Page 121: ...e Paper feed roller Feed assembly Bad paper Incorrect paper loading Internal cassette Feed assembly Paper feed roller Feed assembly LCIT Paper feed roller LCIT controller Feed assembly Bad paper Incorrect paper loading LCIT cassette LCIT Feed assembly Paper feed roller LCIT LCIT controller Feed assembly Feed assembly interconnect Envelope Feeder Envelope feeder Feed assembly Bad paper Envelope fee...

Page 122: ... Fusing exit area Fusing assembly levers in down position Fusing exit sensor linkage moves freely with no binding The cabling and connectors that run between J208 on the DC control board and the fusing exit rear door sensor 3 To fix fusing and delivery area jams swap the following FRUs in the order shown Fusing unit Delivery unit Fusing exit rear door sensor DC control board Main motor Gear assemb...

Page 123: ...r and inspect the registration sensor lever It should move freely with no binding 3 Inspect the following The J208 connector on the DC control board to the fusing exit rear door sensor The 13 pin connector that plugs into J201 on the DC controller board 4 Swap the following to fix a phantom jam Fusing exit rear door sensor DC control board Paper feed assembly FIPs for Fixing Paper Jams 7 7 ...

Page 124: ...7 5 Phantom Jams DSG 000172 Notes 7 8 FIPs for Fixing Paper Jams ...

Page 125: ...SG 000632 Start Chapter 5 5 1 Start FIP Chapter 6 6 1 Power Fault FIP Error Message FIPs Chapter 7 7 1 Jam FIPs Chapter 8 8 1 Image Defects Chapter 5 5 2 TCC Procedures End The adjacent map shows the position of this chapter in the overall fault isolation procedure To find the type of defect and the most appropriate FIP see Section 8 1 FIPs For Fixing Image Defects 8 1 ...

Page 126: ...À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À À Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q LP 8 4 Dark or Black Printing 8 5 Inline Vertical Dots 8 6 Dirt on Back of Page LP 8 7 Vertical Black Lines LP 8 8 Black Smudged Vertical Bands LP 8 9 Black Smudged Horizontal Bands LP 8 10 Blank or White Spots À À À À À À À À À À À À À À À À À À À À À À À...

Page 127: ...he following print drum test a Print a test sheet b Interrupt the test print by opening the top door c Remove the EP ED cartridge d Open the drum shutter 10 seconds maximum and examine the image on the drum If there is a faint image on the drum Swap the EP ED cartridge if you did not do so in step 3 Inspect the connectors and wiring between J210 on the DC controller board and J401 J742 on the HVPS...

Page 128: ...stalled the left side guide pushes the pivot pin that opens the shutter To quickly test the shutter remove the EP ED cartridge and manually press the pivot pin with a suitable tool You should hear the shutter open and close with a definite clanking sound The shutter mechanism is shown in Section 9 26 2 Swap the following a EP ED toner cartridge b HVPSA c DC control board d Scanner assembly e HVPSA...

Page 129: ... connector block See Figure 2 12 Clean any dirt or replace the damaged component 4 Inspect the connectors and wiring between J210 on the DC controller board and J401 J742 on the HVPSA 5 Swap the following a HVPSA b DC control board c Scanner assembly d HVPSA Fuser interconnect 8 5 In line Vertical Dots Do the following when rows of white dots appear on a chaotic muddy and dark background 1 Inspect...

Page 130: ...an the entire paper path 2 Inspect the EP ED cartridge for leaking toner If it leaks replace the cartridge 3 Inspect the fusing unit If the lower roller is dirty replace it Make sure the two installation screws shown in Section 9 25 are tightly secured If the screws are loose the fusing unit grounding diodes shown in Section 9 25 might not work 4 Swap the following Transfer roller Fusing unit 8 6 ...

Page 131: ...10 seconds maximum and examine the image on the drum If the offending band appears on the print drum replace the EP ED cartridge If the pattern on the drum is all right swap the fusing unit 8 8 Black Smudged Vertical Bands Replace the EP ED cartridge when the test print has black smudged and smeared bands running vertically from the leading to trailing edges of the sheet If the lines are clearly d...

Page 132: ...e of the toner detection circuit See Section 6 9 to fix the toner sensor circuit b Transfer roller c HVPSA d DC control board e HVPSA contact plate guide 8 11 Vertical White Lines Do the following if well defined vertical lines of uniform width run through the dark areas of text and graphics of the test print 1 Remove the EP ED cartridge and shake it as shown in the instructions that are embossed ...

Page 133: ...age 2 Make sure a correct type and size paper is being used See Digital Laser Printers Guide to Paper and Other Media for paper specifications 3 Inspect the pickup and oblique rollers for damage wear or surface contamination 4 Make sure the registration sensor lever works without sticking or binding If the sensor lever fails to work replace the paper feed unit 5 Adjusting the REGVR potentiometer t...

Page 134: ...ed See Digital Laser Printers Guide to Paper and Other Media for paper specifications 2 Open the rear door Make sure the two fusing assembly levers are in the down position The levers are shown in Section 9 25 3 Remove the fusing unit and examine the connectors 4 Swap the following a Fusing unit b DC control board c HVPSA Fuser interconnect 8 10 FIPs For Fixing Image Defects ...

Page 135: ...place any FRU that is damaged This connector Should connect to Comment J211 Main motor Plugs into J131 on the motor board J201 Paper feed unit Plugs into feed unit controller J205 Scanner assembly Motor and BD circuit J206 Scanner assembly Laser diode 2 Perform this step only if there is a distorted image Inspect the condition of the oblique feed rollers and pressure springs If you see any surface...

Page 136: ... defined spot or hairline Use Figure 8 2 to measure the distance between the marks and to identify the defective roller Figure 8 2 Roller Defect Ruler First occurrence of Print Defect Primary Charge Roller 1 5 in 38 mm Developer Roller 2 in 51 mm Transfer Roller 2 1 8 in 54 mm Upper or Lower Fusing Roller 2 1 2 in 63 mm EP S Photosensitive Print Drum 3 11 16 in 94 mm DSG 000634 8 12 FIPs For Fixin...

Page 137: ... Removing and Replacing FRUs Unless otherwise noted you must reverse the removal procedure to replace an FRU Caution To protect the FRU and the print engine from static electricity always use antistatic equipment and procedures Caution messages are included in the removal and replacement procedures of the most vulnerable FRUs Removing and Replacing FRUs 9 1 ...

Page 138: ...nd top covers as shown in Section 9 19 and Section 9 20 3 Remove the three screws that hold the metal panel to the printer 4 Remove the metal panel When you replace the metal panel and tighten the three screws make sure the linkage for the power switch is not pinched and that the action of the power switch is smooth and positive 1 DSG 000635 9 2 Removing and Replacing FRUs ...

Page 139: ...9 2 Assembly Control panel 5 Unplug the connector from J131 on the video control board DSG 0006 37 Removing and Replacing FRUs 9 3 ...

Page 140: ...move the top and side screws 7 Release the two clips that hold the control panel to the metal bulkhead 8 Release the one remaining clip and partially withdraw the control panel assembly 3 2 DSG 000860 9 4 Removing and Replacing FRUs ...

Page 141: ... Remove the following parts FRU See section a Right side cover 9 19 b Card cage Section 9 16 c Video controller Board Section 9 15 d Fusing unit Section 9 25 e Main motor Section 9 28 2 Remove the two screws that secure the gear assembly to the printer DSG 000638 Removing and Replacing FRUs 9 5 ...

Page 142: ...9 3 Assembly Gear 3 Remove the gear assembly through the rear of the printer DSG 000639 9 6 Removing and Replacing FRUs ...

Page 143: ...A 1 If installed remove the optional LCIT as shown in Section 9 10 2 Remove the EP ED cartridge as shown in Section 9 17 3 Stand the printer up on the right side cover 4 Remove the two screws 5 Release the two clips while wiggling the HVPSA 6 Carefully withdraw the HVPSA Caution Do not damage the contact springs and connectors DSG 000640 1 Removing and Replacing FRUs 9 7 ...

Page 144: ... Remove the right side cover as shown in Section 9 19 2 Remove the three screws that hold the metal panel to the printer 3 Remove the metal panel When you replace the metal panel and tighten the three screws make sure the linkage for the power switch is not pinched and that the action of the power switch is smooth and positive 1 DSG 000635 9 8 Removing and Replacing FRUs ...

Page 145: ...tage Power Supply LVPSA 4 Use a large needlenose pliers to flex and remove the switch linkage from the LVPSA 5 Flex and remove the switch linkage from the front switch D S G 0 0 0 6 4 2 3 2 Removing and Replacing FRUs 9 9 ...

Page 146: ...d the LVPSA to the printer Caution Do not bend the sheet metal In the next step you might have to flex the bottom of the card cage upward to remove the LVPSA If the LVPSA cannot be removed remove the card cage as shown in Section 9 16 9 Use a suitable tool to gently pry the LVPSA out of the printer DS G 00 06 43 5 4 9 10 Removing and Replacing FRUs ...

Page 147: ...Disk Drive Use the following procedure to remove the optional hard disk drive 1 Remove the right side cover as shown in Section 9 19 2 Remove the screw that latches the card cage cover door 3 Open the card cage cover door DSG 0005 59 Removing and Replacing FRUs 9 11 ...

Page 148: ... three screws that hold the disk drive option to the video controller board Caution Do not use a magnetic screwdriver to install the disk drive option is risky The magnetic tip can destroy the disk formatting DSG 000556 9 12 Removing and Replacing FRUs ...

Page 149: ...9 6 Assembly Optional Hard Disk Drive 5 Wiggle the disk drive option to unplug and remove it DSG 000554 Removing and Replacing FRUs 9 13 ...

Page 150: ...9 6 Assembly Optional Hard Disk Drive 6 Unsnap and remove the guide plate DS G 0 00 55 3 9 14 Removing and Replacing FRUs ...

Page 151: ...the following procedure to remove the output assembly 1 Remove the following parts FRU As shown in section a Left side cover 9 18 b Right side cover 9 19 c Top cover 9 20 2 Remove the EMI ground strap the metal frame DSG 0006 45 Removing and Replacing FRUs 9 15 ...

Page 152: ...9 7 Assembly Paper Delivery 3 Press and release the two clips DS G 0 006 46 1 9 16 Removing and Replacing FRUs ...

Page 153: ...from the chassis When replacing the output assembly make sure the clips are fully engaged and the assembly is squarely seated The assembly s alignment pins must not be damaged and must be centered in the chassis holes 5 Remove the output assembly D S G 0 0 0 6 4 7 Removing and Replacing FRUs 9 17 ...

Page 154: ...feed assembly 1 Remove the following parts Part As shown in section a Paper cassette b Envelope feeder 9 24 If installed c Control panel assembly 9 2 d Left side cover 9 18 e Right side cover 9 19 f Top cover 9 20 g Front door 9 22 h Guide plate 9 22 1 9 18 Removing and Replacing FRUs ...

Page 155: ...9 8 Assembly Feed 2 Remove the three screws that hold the feed assembly to the left side panel DSG 000649 Removing and Replacing FRUs 9 19 ...

Page 156: ... 3 Unplug the two connectors from the paper feed controller board 4 Remove the two screws that hold the feed assembly to the front of the printer 5 Remove the feed assembly DSG 000650 1 9 20 Removing and Replacing FRUs ...

Page 157: ...canner Use the following procedure to remove the scanner assembly 1 Remove the following parts FRU As shown in section a Left side cover 9 18 b Right side cover 9 19 c Top cover 9 20 d Output assembly 9 7 Removing and Replacing FRUs 9 21 ...

Page 158: ...the cables from the restraints 3 pin fusing exit and rear door sensor 6 pin scanner motor connector 7 pin laser diode connector 4 pin beam detection connector 3 Remove the four screws 4 Remove the scanner assembly DS G 00 07 00 4 2 3 1 9 22 Removing and Replacing FRUs ...

Page 159: ... 10 Board LCIT Controller Use the following procedure to remove the LCIT controller board 1 Remove the screw securing the cover 2 Press to release the two latches and open the cover 1 DSG 0 00651 1 Removing and Replacing FRUs 9 23 ...

Page 160: ...9 10 Board LCIT Controller 3 Unplug the three connectors from the controller board 4 Cut and remove the plastic cable tie D S G 0 00 65 2 9 24 Removing and Replacing FRUs ...

Page 161: ...ntroller 5 Grasp the upper edge of the control board as shown 6 Slide a flat blade screwdriver between the plastic tab and the controller board Disengage the tab from the board DSG 000653 Removing and Replacing FRUs 9 25 ...

Page 162: ...9 10 Board LCIT Controller 7 Lift the controller board out of the plastic slides D S G 0 0 0 6 5 4 9 26 Removing and Replacing FRUs ...

Page 163: ...ve the feed controller board 1 Remove the following parts Part As shown in section a Paper cassette b Control panel assembly 9 2 c Left side cover 9 18 d Right side cover 9 19 e Top cover 9 20 f Front door 9 22 g Guide plate 9 22 1 h Paper feed assembly 9 8 Removing and Replacing FRUs 9 27 ...

Page 164: ... 3 Remove the two screws 4 Release the four clips Caution The actuator linkage for the top door open switch might pop out when you remove the board in the next step 5 Remove the feed controller board 2 3 2 2 1 2 DSG 000655 9 28 Removing and Replacing FRUs ...

Page 165: ... Use the following procedure to remove the DC control board 1 Remove the following parts FRU As shown in section a Ethernet option board 9 13 b Right side cover 9 19 c Card cage 9 16 d Video controller board 9 15 Removing and Replacing FRUs 9 29 ...

Page 166: ...09 10 pin J210 4 pin J211 that connects to the main motor 6 pin cable that connects to J103 on the LVPSA 3 pin J212 3 Press and release the left and right side restraint clips 4 Wiggle the DC controller board to extract it from the mounting pin 5 Remove the DC controller board 9 30 Removing and Replacing FRUs ...

Page 167: ...9 12 Board DC Control 1 2 4 5 7 8 9 6 3 10 DSG 000657 Removing and Replacing FRUs 9 31 ...

Page 168: ...rocedures before you handle this sensitive electronic component 1 If installed remove the hard disk option as shown in Section 9 6 2 Remove the video controller board as shown in Section 9 15 3 Use a suitable tool to gently pry up the 8 pin IC 4 Remove the IC When replacing the IC make sure to orientate pin 1 is as shown DSG 000659 9 32 Removing and Replacing FRUs ...

Page 169: ...ve the optional Ethernet board 1 Disconnect the ThinWire or twisted pair connectors from the rear panel 2 Remove the two screws that hold the mounting plate to the rear connector panel If installing a new Ethernet option you must remove the blank plate 3 Pull on the Ethernet board to unplug it from the connector on the video controller board DSG 000486 Removing and Replacing FRUs 9 33 ...

Page 170: ...hernet board is installed and the printer is powered on a network status report prints This report contains all the information to show that the Ethernet board is working properly and is communicating with the host system See for troubleshooting information Twisted Pair ThinWire TP TN J P 1 TP TN J P 1 DSG 000855 9 34 Removing and Replacing FRUs ...

Page 171: ...ing procedure to remove the single inline memory module board 1 Remove the right side cover as shown in Section 9 19 2 Remove the screw that latches the card cage cover door 3 Open the card cage cover door DSG 0005 59 Removing and Replacing FRUs 9 35 ...

Page 172: ... 4 Simultaneously release the two clips The SIMM should move or spring forward in the socket 5 Remove the SIMM When replacing the SIMM the notched end must face left D S G 0 0 0 5 6 4 1 9 36 Removing and Replacing FRUs ...

Page 173: ...video controller board 1 Remove the following FRUs FRU See section a Right side cover 9 19 b Card cage Section 9 16 2 If installed remove the following video board options FRU See section a Font cartridge 1 7 b Ethernet board 9 13 c Optional disk 9 6 d RAM SIMMs 9 14 Removing and Replacing FRUs 9 37 ...

Page 174: ...troller 3 Disconnect the connector from J131 on the video control board 4 Remove the four screws 5 Wiggle the board to disconnect the connector 6 Remove the video control board 1 DSG 000666 9 38 Removing and Replacing FRUs ...

Page 175: ...e following procedure to remove the replace the card cage 1 Remove the right side cover as shown in Section 9 19 2 Remove the four screws 3 Wiggle the metal card cage to release and withdraw it DSG 000660 Removing and Replacing FRUs 9 39 ...

Page 176: ... EP ED cartridge in the light proof wrapping bag or in a dark place Do not touch the surface of the OPC drum 1 Open the top door 2 Grasp the cartridge and pull on it to remove it 3 Before you install a new EP ED cartridge Remove the plastic shipping strip as shown on the top of the EP ED cartridge Shake the EP ED cartridge as shown on the top of the cartridge DSG 000411 9 40 Removing and Replacing...

Page 177: ...wing procedure to remove the left side cover 1 Remove the right side and top covers as shown in Section 9 19 and Section 9 20 2 Press down to release the clip that holds the cover to the left side of the printer DSG 000664 1 Removing and Replacing FRUs 9 41 ...

Page 178: ...4 Swing down the left side cover When you replace the left side cover make sure the three plastic alignment pins fully engage the metal bulkhead holes 5 Lift the left side cover to disengage the hinges and remove the cover D S G 0 00 66 3 3 2 9 42 Removing and Replacing FRUs ...

Page 179: ...ver Right Side 9 19 Cover Right Side Use the following procedure to remove the right side cover 1 Remove the screw that secures the right side cover to the printer DSG 000 557 Removing and Replacing FRUs 9 43 ...

Page 180: ...ge the top clips 3 Swing the cover down When you replace the right side cover pull the cover backwards as in step two otherwise the hinges bind 4 Lift the cover to disengage the hinges and remove the right side cover DSG 000 558 9 44 Removing and Replacing FRUs ...

Page 181: ...er Use the following procedure to remove the top cover 1 Remove the right side cover as shown in Section 9 19 2 Open the rear door and remove the two screws that hold the top cover to the printer DSG 000 665 Removing and Replacing FRUs 9 45 ...

Page 182: ...ve the one screw that holds the top cover to the top of the printer 5 Use a flat blade screwdriver to release the two front clips 6 Slightly pinch and bend the top cover to release the left side clip 7 Lift and remove the top cover 2 DSG 000641 1 9 46 Removing and Replacing FRUs ...

Page 183: ...21 Door Rear Use the following procedure to remove the rear door 1 Remove or partially extend the cassette 2 Use needlenose pliers to lift and disengage the door support strap DSG 000668 Removing and Replacing FRUs 9 47 ...

Page 184: ...9 21 Door Rear 3 Flex the bottom of the door to disengage the hinge pins from the plastic bulkhead DSG 000 669 9 48 Removing and Replacing FRUs ...

Page 185: ...emove and replace the rear door latch as follows To remove the latch use a screwdriver to gently release the hinge clips To replace the latch first seat the spring then snap the hinges together DSG 000670 1 1 Removing and Replacing FRUs 9 49 ...

Page 186: ... Plate 9 22 Door Front and Guide Plate Use the following procedure to remove the front door 1 Remove the cassette 2 Flex the guide plate to disengage the sliding hinges from the door DSG 000709 9 50 Removing and Replacing FRUs ...

Page 187: ...9 22 Door Front and Guide Plate 3 Fully extend the paper support plate 4 Flex the door to disengage the hinge pins 5 Remove the door DSG 000671 1 Removing and Replacing FRUs 9 51 ...

Page 188: ...emove the following FRU As shown in section a Paper cassette b Left side cover 9 18 c Right side cover 9 19 d Top cover 9 20 e Front door 9 22 f Control panel assembly 9 2 2 Remove the two screws that hold the crossmember bracket to the printer 3 Remove the crossmember bracket DSG 00 0672 9 52 Removing and Replacing FRUs ...

Page 189: ...9 22 Door Front and Guide Plate 4 Swing the guide plate down until the hinges can be pulled apart DS G 00 06 73 Removing and Replacing FRUs 9 53 ...

Page 190: ...ing FRU As shown in section a Right side cover 9 19 b Card cage 9 16 c Video controller board Section 9 15 d Video controller board 9 15 2 Unplug the 3 pin J209 connector from the DC controller board 3 Remove the exhaust fan lead in cable from the wire raceway DSG 000674 2 1 9 54 Removing and Replacing FRUs ...

Page 191: ...9 23 Fan Exhaust 4 Use a small screwdriver to pry loose the two clips and separate the fan shroud DSG 000675 Removing and Replacing FRUs 9 55 ...

Page 192: ...9 23 Fan Exhaust 5 Pry up to release the four clips and remove the exhaust fan 3 D S G 0 0 0 6 7 6 9 56 Removing and Replacing FRUs ...

Page 193: ...pe Use the following procedure to remove the envelope feeder 1 Open the front door of the printer 2 Pinch together the two plastic tabs and pull down the blockoff plate 3 Remove the blockoff plate DSG 000710 Removing and Replacing FRUs 9 57 ...

Page 194: ...4 Feeder Envelope 4 Insert the nose of the envelope feeder into the print engine 5 Gently push in the envelope feeder until you feel it securely lock into place DSG 000704 9 58 Removing and Replacing FRUs ...

Page 195: ...t is hot 1 Open the rear door When replacing the fusing unit make sure the two fusing assembly levers are in the down position Fusing failure occurs if the levers are left up 2 Remove the two screws 3 Wiggle the fusing unit to release the connector 4 Remove the fusing unit 1 DS G 0 006 77 Removing and Replacing FRUs 9 59 ...

Page 196: ...emove the left EP ED guide plate 6 Remove the HVPSA contact plate Caution The plastic pieces of the parts that required handling can be easily damaged This might result in deteriorated image quality or intermittent unaccountable faults If you find a damaged clip or any other damage replace the part do not attempt to fix it 1 Remove the following preliminary parts FRU As shown in section a Paper ca...

Page 197: ...9 26 Guide HVPSA Contact Plate 2 The crossmember a Remove the two screws that hold the crossmember b Remove the crossmember DSG 00 0678 Removing and Replacing FRUs 9 61 ...

Page 198: ...rt guide plate b Use a suitable tool to pry up the rear of the transport guide plate to disengage it from the HVPSA contact plate Be careful when you lift the contact guide plate The six paper rollers might fly about and be lost when the front of the plate is removed 1 DSG 000 629 9 62 Removing and Replacing FRUs ...

Page 199: ...9 26 Guide HVPSA Contact Plate c Lift and remove the contact plate d Remove each of the six rollers and store in a safe place 2 DSG 000680 Removing and Replacing FRUs 9 63 ...

Page 200: ...9 26 Guide HVPSA Contact Plate 4 The pivot pin a Disconnect the spring from the pivot pin arm b Flex the arm up and over the shutter linkage DSG 000681 9 64 Removing and Replacing FRUs ...

Page 201: ...9 26 Guide HVPSA Contact Plate c Flex the arm clockwise to enable the arm to pass through the chassis hole d Remove the pivot linkage DSG 000682 Removing and Replacing FRUs 9 65 ...

Page 202: ...A Contact Plate 5 The left EP ED guide plate a Remove the self tapping plastic screw b Note the location of the clip and alignment pins that secure the EP ED guide plate DSG 000 683 3 9 66 Removing and Replacing FRUs ...

Page 203: ...sh the clip and alignment pins to disengage the EP ED guide plate from the left side chassis d Rotate and wiggle the guide plate to remove it Some flexing of the EP ED guide plate is necessary DSG 000684 Removing and Replacing FRUs 9 67 ...

Page 204: ...9 26 Guide HVPSA Contact Plate 6 The HVPSA contact plate a Release the five clips and lift the HVPSA guide plate up DSG 000588 4 9 68 Removing and Replacing FRUs ...

Page 205: ...9 26 Guide HVPSA Contact Plate b Remove the HVPSA contact plate DS G 0 00 68 5 Removing and Replacing FRUs 9 69 ...

Page 206: ...nect that connects the fusing unit and HVPSA to the DC control board 1 Remove the following parts FRU As shown in section a LCIT if installed 9 10 b EP ED cartridge 9 17 c Right side cover 9 19 d Card cage 9 16 e Video controller board Section 9 15 f LVPSA 9 5 g Fusing unit 9 25 9 70 Removing and Replacing FRUs ...

Page 207: ...9 27 Interconnect HVPSA Fuser 2 Unplug the 10 pin J210 connector from the DC control board 3 Unwind the cable from the wire raceway DSG 000691 1 2 Removing and Replacing FRUs 9 71 ...

Page 208: ...ont panel 5 Remove the screw that holds the rear cover to the printer 6 Pull and wiggle to release the clip and pry the rear cover away to disengage the hinges 7 Lift the rear cover off the hinges and remove the rear cover 3 4 DSG 000 692 9 72 Removing and Replacing FRUs ...

Page 209: ...he release clips and push the connector through the chassis hole 9 Press the clip to release it 10 Swing down the HVPSA fuser interconnect 11 Lift the HVPSA fuser interconnect to disengage the hinges DSG 0006 93 5 6 7 Removing and Replacing FRUs 9 73 ...

Page 210: ... following parts FRU See section a Right side cover 9 19 b Card cage 9 16 c Video controller board 9 15 2 Unplug the 4 pin J131 connector from the main motor board 3 Remove the four screws that hold the main motor to the printer 4 Remove the main motor 1 DSG 000644 9 74 Removing and Replacing FRUs ...

Page 211: ...p Use the following procedure to remove the LCIT pickup motor 1 Lift the printer off of the LCIT 2 Remove the screw that secures the cover 3 Press the two latches to release them and open the cover 1 DSG 0 00651 1 Removing and Replacing FRUs 9 75 ...

Page 212: ...otor LCIT Pickup 4 Unplug the 2 pin connector 5 Unplug the 4 pin connector 6 Unsnap the two clips that hold the cover to the raceway 7 Remove the cover 2 D S G 0 0 0 6 9 4 3 4 9 76 Removing and Replacing FRUs ...

Page 213: ...otor LCIT Pickup 8 Remove the motor cable from the wire raceway 9 Remove the two screws that hold the motor to the feed unit assembly 10 Remove the LCIT feed motor DSG 0007 08 Removing and Replacing FRUs 9 77 ...

Page 214: ... pickup roller as shown in Section 9 33 2 Insert a flat bladed screwdriver in the notch underneath the silver strip 3 Gently pry the pad up and out of the socket When replacing the pad avoid touching the surface or installing the pad upside down When the pad is correctly installed the silver strip is down DSG 000697 9 78 Removing and Replacing FRUs ...

Page 215: ...ity When handling the transfer roller touch only the extreme end of the foam roller or the metal shaft 1 Remove the EP ED cartridge as shown in Section 9 17 2 Use the end of the cleaning brush to hook onto the left side of the transfer roller shaft 3 Pull up until the shaft releases from the bearing 4 Move the roller to the left to disengage the right bearing and remove the transfer roller DSG 000...

Page 216: ... Remove the cassette 3 Stand the printer on the left side cover on top of a soft cloth or paper to prevent scratching the cover 4 Pinch the clips and lift the roller off the shaft When replacing the roller make sure the clip firmly holds the roller on the shaft Avoid touching the surface of the pickup roller DSG 000696 9 80 Removing and Replacing FRUs ...

Page 217: ...e to remove the front tray pickup roller 1 Power down the printer 2 If installed remove the envelope feeder as shown in Section 9 24 then go to step 5 3 Open the front door 4 Pinch the clips together pull downwards and remove the envelope panel DSG 000710 Removing and Replacing FRUs 9 81 ...

Page 218: ...9 33 Roller Front Tray Pickup 5 Pinch the clips together and remove the pickup roller DSG 000699 9 82 Removing and Replacing FRUs ...

Page 219: ...LCIT Pickup Use the following procedure to remove the paper pickup roller from the LCIT Lift the printer off of the LCIT Pinch the restraining clips together and pull the roller off the shaft DS G 00 07 13 Removing and Replacing FRUs 9 83 ...

Page 220: ...Remove the following parts FRU See section a Left side cover 9 18 b Right side cover 9 19 c Top cover 9 20 d Output assembly 9 7 2 Unplug the 3 pin connector from the sensor 3 Grasp the plastic stub with needlenose pliers 4 Pull up and backwards to release and disengage the sensor assembly D S G 0 0 0 7 0 1 1 9 84 Removing and Replacing FRUs ...

Page 221: ... replacement procedure is listed next to each FRU Table 10 1 FRUs FRU Name Order Name Part Number Section Number Assembly control panel Same 29 31474 01 9 2 Assembly main drive gear Main drive gear assy FD 42845 01 9 3 Assembly high voltage power supply HVPSA HV power supply FD 41616 01 9 4 Assembly low voltage power supply LVPSA Power supply FD 41614 01 115Vac FD 41616 01 220Vac 9 5 Assembly opti...

Page 222: ... Board Ethernet Multi protocol Ethernet card LN09X NW 9 13 Board Resolution Graphic Enhancement Same LN09X XL None Board SIMMs 32MB 32MB RAM SIMM LN09X MF 9 14 Board SIMMs 16MB 16MB RAM SIMM LN09X ME 9 14 Board SIMMs 4MB 4MB ram SIMM LN09X MA 9 14 Board video controller Same 29 31710 01 9 15 Brush cleaning Same 29 31475 01 None Cartridge EP ED toner Same LNOXX AA 9 17 Cassette internal universal P...

Page 223: ... 41594 01 115Vac FD 41595 01 220Vac 9 25 Motor main DC 5 8W motor FD 41597 01 9 28 Motor LCIT pickup DC 3 3W stepping motor 29 31507 01 9 29 Pad front tray separation Separation pad FD 41622 01 9 30 Page count memory 2048 bit serial EEPROM 21 40579 01 9 12 1 Paper exit sensor Paper out sensor assy FD 42843 01 9 35 Roller cassette pickup Roller pick up FD 41629 01 9 32 Roller front tray pickup MP t...

Page 224: ...10 1 Field Replaceable Units DSG 000172 Notes 10 4 FRU Part Numbers ...

Page 225: ...ight receive plus the features and values of the key menus Control panel operation and modes are described in Chapter 3 A 1 Key Menu Map Figure A 1 shows all the key menu features and values Using the map and the arrow keys you can scroll through the two dimensional matrix of the key menus Key Menu Map Features and Values A 1 ...

Page 226: ...er select Set Up Set Up menus inside please turn page Use this card as a guide to locate the printer features and values you want Note Printer must be Paused in order to display menu choices FEED Set Up menu Press to select feature Enter available when Envelope feeder option is installed available when LCIT option is installed available when LCIT option is installed available when LCIT option is i...

Page 227: ...up menu Q U I C K R E F E R E N C E C A R D DEClaser 5100 to PostScript menu FEED SIZE MANUAL ENV available when LCIT option is installed available when Envelope feeder option is installed available when LCIT option is installed available when LCIT option is installed available when Envelope feeder option is installed 3 875 x 7 5 Manual timeout TIME 60 seconds infinite set by host 20 seconds 40 se...

Page 228: ... Allow reset Wait timeout enabled disabled enabled disabled Enable Adjust off on 300 x 300 600 x 300 600 x 600 1200 x 600 1200 x 1200 Q U I C K R E F E R E N C E C A R D DEClaser 5100 to PCL menu PostScript RES WAIT RESET PRINT PROTECT DECimage ENA ADJ available when High resolution option is installed available when High resolution option is installed PS Press to select value Enter DSG 000822 con...

Page 229: ...hru 99 99 12 4 0 thru 99 75 Q U I C K R E F E R E N C E C A R D DEClaser 5100 to Communications menu please turn page PCL PCL ORIEN PROTECT COPIES FORM LENGTH SOURC RES SIZE PITCH NUMBER Resolution Available Symbol Sets are displayed here Letter A4 Legal Executive SIZE A5 B5 C5 DL 4 125 x 9 5 3 875 x 7 5 Legal Page size available when High resolution option is installed available when High resolut...

Page 230: ...ntrol Robust XON DTR polarity Stop bits LOC Interpreter I O timeout INT PostScript TIME Interpreter I O timeout NET PAR INT TIME 15 minutes 60 seconds 10 seconds PCL Automatic PostScript 10 seconds PCL Automatic PostScript INT PCL Automatic PostScript 10 seconds EIA 232 EIA 422 MODE TIME 300 thru 57600 BAUD PARITY mark FLOW off on DTR high low ROBUST XON STOP BITS available when Network interface ...

Page 231: ...y language 7 1 thru 15 yes no 2 hours 4 hours Off 30 min disabled enabled English Français Deutsch Italiano Espanol Miscellaneous Q U I C K R E F E R E N C E C A R D DEClaser 5100 START PAGE RECOVER JAM DENSITY SAVER LOCK LANG Nederlands Set Up TM Press to select value Enter PostScript P C L Communications DSG 000825 Key Menu Map Features and Values A 7 ...

Page 232: ...ed with this prompt see the Print density entry Default feeder Value This feature which exists under the Set Up key menu menu can be confused with the values found under the Feeder Select key menu Also the FEED Value does the same thing as this feature When the Set Up lock feature is enabled the Default feeder values are unavailable The Feeder Select key menu values are always available to the con...

Page 233: ... no values control the automatic printing of the start up test page Envelope size The following values are available under the Envelope size feature ENV 4 125x9 ENV 3 87x7 5 ENV A5 ENV C5 ENV DL Factory def Ltr or A4 Sets all features in the Set Up and Feeder Select menus to factory default values Two features are available for letter Ltr or A4 size paper The Resetting menus message appears while ...

Page 234: ...ociated with this prompt see the Default feeder entry FLOW XON XOFF Value For the values associated with this prompt see the SER Flow control entry FORM LENGTH Value For the values associated with this prompt see the PCL Form length entry Front tray size This Feeders submenu feature sets the front tray paper size to one of the following values FRONT Letter FRONT A4 FRONT Legal FRONT Executive FRON...

Page 235: ...nual feeding Do not confuse the features of the Feeder submenu and the Feeder Select key menu MODE Value For the values associated with this prompt see the PAR Mode entry NUMBER Value For the values associated with this prompt see the PCL Font number entry ORIEN landscape or portrait For the values associated with this prompt see the PCL Orientation entry PAGES Value For the values associated with...

Page 236: ...atch the description of the host system s parallel port PARITY Value For the values associated with this prompt see the SER Parity entry PCL Copies Value The value of 1 through 999 that you enter determines how many copies of each page are printed Press and hold or to increase or decrease the number PCL Font number This feature issues the NUMBER Value prompt that determines which font is used from...

Page 237: ...f the selected monospaced typeface When selected the PITCH 10 00 prompt appears The character spacing number spans from 00 44 to 99 99 characters per inch CPI The default is 10 00 The value changes by 00 01 when you press or and by 1 00 as you hold down the key PCL Point size The value you select sets the size of the proportional typeface selected by the font source and number values When selected...

Page 238: ...age parameter adjustment Do not confuse this standard DECimage feature with the optional XLI image enhancement feature The following prompts appear when Enable is selected ENA host only ENA always ENA never The Adjust value prompts for the following DECimage parameters ADJ normal ADJ bright ADJ dark ADJ hi contrast ADJ lo contrast ADJ set by host PS Page protect The PROTECT off PROTECT Ltr A4 and ...

Page 239: ...n reduce the likelihood of the complex page errors For additional information about the resolution feature see the DEClaser 5100 Printer User s Guide PS Wait timeout This feature sets the PostScript wait timeout to one of the following values WAIT 20 seconds WAIT 40 seconds WAIT 60 seconds WAIT infinite WAIT set by host Power saver The power saver feature turns off the fuser heater after exceeding...

Page 240: ...ey menu feature prints a PostScript demonstration page Print density When this feature is selected the DENSITY prompt appears This feature produces a slightly darker printing The selected value varies the primary and developer bias see Sections 2 3 1 and 2 3 3 The values vary from 1 to 15 The recommended value is 7 Printer Open This message appears when the top cover of the printer is open See the...

Page 241: ...ffer Resets the interpreters Clears downline loaded information such as soft fonts Clears the active communication buffer Resetting For a description of this message see the Reset printer entry Resetting Menus For a description of this message see the Factory def Ltr or Factory def A4 entry SAVER Value For the values associated with this prompt see the Power saver entry SER Baud rate When selected...

Page 242: ...orts for data This timeout period can compensate for a busy network or host system The following value are available under this selection TIME 10 seconds TIME 30 seconds TIME 60 seconds SER Interpreter When this feature is selected the following values appear The identical values are shown for the parallel PAR and LocalTalk LOC interpreters features The selection sets either the PostScript or PCL ...

Page 243: ...an XON character by the host or by a network device See the SER Flow control entry SER Stop bits The STOP BITS 1 or STOP BITS 2 value must match those of the attached host or modem The default is STOP BITS 1 SET Value For the values associated with this prompt see the PCL Symbols entry SOU Value For the values associated with this prompt see the PCL Font source entry START PAGE Value For the value...

Page 244: ...oximately 2 seconds The page count also prints on the start up page Test Fonts Press Test Fonts to enter the Test fonts key menu The following features are available Show page count Print menu guide Print PS menus Print PCL menus Print PS fonts Print PCL fonts Print demo page For a description of each Test Fonts feature see the feature s entry TIME Value For the values associated with this prompt ...

Page 245: ...see Section B 1 IBM compatible PC see Section B 2 Apple Macintosh see Section B 3 OpenVMS VAX or ULTRIX Systems see Section B 4 B 1 Connecting to an Ethernet Network Instructions for installing the optional interface card are packaged with the option See Section 9 13 for removal and replacement procedures General Information B 1 ...

Page 246: ...tional and Centronics unidirectional communications The DEClaser 5100 printer serial port supports both the EIA 232 and EIA 422 communication protocols EIA 323 is universally accepted while EIA 422 is available on most systems Choose EIA 232 for distances up to 15 meters 50 feet and baud rates up to 19200 Use lower speeds for longer distances Choose EIA 422 for high baud rates and long distances T...

Page 247: ...f the port is busy during a status check Table B 1 Parallel Port AUTOEXEC BAT Modifications If you are using Add the following command MS DOS Version 4 0 or newer MODE LPT1 B MS DOS Version 3 3 or older MODE LPT1 P COM1 Serial Port The following examples show one MODE command setting the COM1 communication characteristics The second MODE commands redirects the data from the default parallel LPT1 p...

Page 248: ... installing and selecting printer drivers Make sure the printer port interpreter is set to PostScript or PCL or to automatic interpreter detection and switching PostScript Driver PostScript printer drivers are supplied with the DEClaser 5100 printer Other PostScript drivers can be used but might not take advantage of the DEClaser 5100 printer features and performance Install the printer driver acc...

Page 249: ...nterminated When using an unterminated connector box you must add a terminating resistor Note Do not leave the AppleTalk network open or unterminated Always notify the network users before disconnecting the Appletalk network Installing the DEClaser 5100 printer between devices interrupts network operation until the new connections are made See the system manager if you are not sure if your printer...

Page 250: ...nter Driver User Guide Macintosh Version instructions that comes with the diskettes labeled Macintosh Refer to your Macintosh User s Guide for additional information about installing and selecting printer drivers Install the Macintosh printer driver as follows 1 Insert the diskettes labeled Macintosh Printer Driver into your diskette drive 2 Click on OK in the title screen 3 Click on Install in th...

Page 251: ... for the serial communication default settings protocol selection All Digital host systems and DECservers with a built in DECconnect interface or built in OpenDECconnect interface are EIA 422 compatible Caution Damage to the DEClaser 5100 printer might occur if the H8571 or H8575 adapters are used with the EIA 232 interface protocol Figure B 2 shows the H8575 x adapter for use in some configuratio...

Page 252: ...ns DSG 000419 H8575 E H8575 E H8575 A BC16E XX BC16E XX H8575 E BC16E XX EIA 232 EIA 422 WORKSTATION WORKSTATION H8585 AD BN24H XX WORKSTATION 6 PIN DECserver BN 26X XX 8 PIN DECserver H8575 E BN24H XX 8 PIN DECserver 6 PIN DECserver BN24H XX H8585 AD H8585 AD continued on next page B 8 General Information ...

Page 253: ...DECstation 3100 DECserver 300 DECserver 90L DECserver 90L LATprint DECserver 200MC DECserver 700 8 DECserver 900 DECserver 700 16 DECserver 90TL DECserver 90M EIA 232 None BC16E xx H8575 E or EIA 422 None BN24H xx H8585 AD EIA 232 H8575 A BC16E xx H8575 E EIA 422 None BN26X xx H8585 AD 1 Host System Server Host Adapter Cable Printer Adapter EIA Interfaces 1 1 1 1 General Information B 9 ...

Page 254: ...B 4 Connecting to OpenVMS VAX or ULTRIX Systems DSG 000172 Notes B 10 General Information ...

Page 255: ...dpi 600 x 600 dpi Optional Resolution Graphics Enhancement Board 1200 x 600 dpi 1200 x 1200 dpi Optional Hard Disk Drive 120 MB disk drive Optional Font Card Slots 2 slots are available to accept optional PCMCIA font cards for PCL and PostScript fonts Printing Speed 8 pages minute maximum using A4 or Letter size paper from the internal tray Warm Up Time 100V 115V 60 seconds or less at 20 C 68 F Wa...

Page 256: ...b to 24 lb Paper Weight Range Manual Feed 64 g m2 to 105 g m2 basis weight 17 lb to 28 lb Resident Fonts The DEClaser 5100 printer has 120 resident fonts 73 PostScript Level 2 fonts 47 HP PCL5E emulation fonts Built in RAM 2 MB Add on RAM Built in RAM expandable to 66 MB with optional SIMMs Communication Interfaces OPENcomm architecture provides simultaneous support for all available interfaces Se...

Page 257: ...F Storage Humidity 10 to 80 relative humidity noncondensing Power Requirements 100 115 Vac 50 60 Hz North America and Japan 220 240 Vac 50 Hz Rest of the world Power Consumption Maximum 100 115 Vac 530W 220 240 Vac 520W Average at 20 pages per hour 100 115 Vac 90W 220 240 Vac 90W Power saving mode 100 115 Vac Less than 30W 220 240 Vac Less than 30W EPA Energy Star Compliant Shipping Weight Approxi...

Page 258: ... The following sections describe Space requirements Environmental requirements C 1 1 Space Requirements Install the DEClaser 5100 printer in an area that meets the following requirements A flat level surface free from vibrations Enough surrounding space to allow ventilation and easy access to the printer to perform daily operations Figure C 1 C 4 DEClaser 5100 Specifications ...

Page 259: ...C 1 Operating Requirements Figure C 1 Operating Space 610 mm 24 in 510 mm 20 in 560 mm 22 in 1270 mm 50 in 100 mm 4 in 100 mm 4 in 305 mm 12 in 100 mm 4 in DSG 000400 DEClaser 5100 Specifications C 5 ...

Page 260: ...s are met Ambient temperature of 10 C to 32 5 C 50 F to 90 5 F Relative humidity of 20 to 80 noncondensing Good ventilation to avoid heat build up Dust free or almost dust free area No sudden changes in temperature or high humidity No hot or cold drafts from a heating system or air conditioner No direct sunlight C 6 DEClaser 5100 Specifications ...

Page 261: ...rder numbers and information about the courses Table D 1 Training Order Number Description EY H990E Printer Maintenance Course United States Training Prerequisite Courses EY 7629E IV Hardcopy and video specialist core course EY 5528E IV Laser safety and printer concepts course Europe and GIA Training Prerequisite Courses EY 2830E IV Data Communication Fundamentals EY 2239E IV Hardcopy Theory EY 24...

Page 262: ...rinter User s Guide EK DL510 AD DEClaser 5100 Printer Documentation Addendum EK D5100 DK DEClaser 5100 Printer Documentation Kit User documentation EK D5100 RC DEClaser 5100 Printer User Feature Card EK DL51M IN DEClaser 5100 Printer Memory Upgrade Option Installation EK DL510 IN DEClaser 5100 Printer Installation and Setup Guide EK D5100 IN DEClaser 5100 Printer Disk Option Installation EK DLPL2 ...

Page 263: ...iption 29 26106 00 50 Hz terminal tool kit 29 26109 00 60 Hz terminal tool kit 29 11762 00 Antistatic kit 29 26259 00 Vacuum1 and attachments 200 volts 29 25526 00 Vacuum1 and attachments 120 volts 29 26017 00 Filter bags and filter shell 29 26234 00 Cleaning kit 29 27340 01 Terminal tool kit 1Special vacuum cleaner for toner powder Training Documentation and Tools D 3 ...

Page 264: ...D 3 Tools DSG 000172 Notes D 4 Training Documentation and Tools ...

Page 265: ...ands 8 7 Blank prints 8 4 spots 8 8 C Card cage remove replace 9 39 Cartridge ground EP ED connections 2 24 Cassette Inspection of 7 4 internal sizes 1 3 Cassette pickup roller FRU part number 10 3 remove replace 9 80 Centronics A 12 connector location 1 9 Circuit breaker 2 8 Cleaning fusing roller 2 18 transfer roller 2 17 Cleaning brush FRU part number 10 3 COM1 B 3 Complex pages about 2 4 Conne...

Page 266: ...plays control panel 3 2 Distorted printing 8 11 Do jam recovery A 9 Document conventions xi Documentation related D 2 Door open switch actuator 9 28 two poles 6 14 Dots black page with row of dots 8 5 separation process 2 18 Driver Macintosh B 6 Drivers Windows and Windows NT B 4 Drum shutter EP ED connections 2 24 E EIA 232 or 422 B 2 Engine board test pattern 4 8 Envelope feeder feed area jams 7...

Page 267: ...3 non error FIP 6 6 Fonts PostScript and PCL 4 6 Front door remove replace 9 50 guide plate remove replace 9 52 pad remove replace 9 78 pickup roller remove replace 9 81 Front door FRU part number 10 3 Front tray FRU part number 10 3 paper size selection A 10 Front tray pickup roller FRU part number 10 3 Front tray separation pad FRU part number 10 3 FRUs 10 1 jam swap list 7 4 Fuse 2 8 Fusing des...

Page 268: ...eter A 11 Interlock Fusing exit rear door sensor about 2 12 fusing jumper 6 22 rear door open A 11 Interlock cont d rear door sensor 9 84 test print switch is wiring diagram 6 20 top door open message A 16 top door switch location 1 3 top door switch wiring diagram 6 20 Intermittent operation 6 3 Internal universal cassette FRU part number 10 3 Interpreter selecting features A 18 INTR mode about 2...

Page 269: ... replace 9 8 wiring diagram 6 24 M Macintosh B 5 Main drive gear assembly FRU part number 10 3 Main motor FRU part number 10 3 remove replace 9 74 wiring diagram 6 24 Main Motor delivery area jams 7 6 Measurements LVPSA 6 3 Memory expansion SIMMs 1 18 overflow FIP 6 12 overflow message explanation 2 5 Menu guide 4 3 printing A 16 Message Display Location of 3 2 Messages Explanation of each A 1 Onl...

Page 270: ...finition 3 4 PCL available fonts 4 6 menu page 4 5 PCL Drivers B 4 PCMCIA font cartridge 1 20 non error FIP 6 6 Phantom jams definition of 7 2 Pickup motor LCIT remove replace 9 75 Pickup motor and solenoids wiring diagram 6 23 Pickup roller LCIT 9 83 Ports scanning 3 4 PostScript available fonts 4 6 demonstration page 4 4 drivers B 4 error report 4 7 limitcheck error 6 12 Menu page 4 5 Power shor...

Page 271: ... FRU part number 10 3 circuit description 2 20 remove replace 9 21 Scanner cont d wiring diagram 6 22 Scanning of ports 3 4 OPC image exposure 2 16 Sensor fusing and rear door 9 84 Sensor interconnect board wiring diagram 6 23 SER Robust XON A 19 SER Interpreter A 18 Serial connector location 1 9 Serial cables and adapters B 7 68 SERVICE 9 32 Service Messages 6 5 to 6 20 Set up menu levels 3 6 loc...

Page 272: ... TH1 fusing thermistor 2 9 Thermistor wiring diagram 6 20 Thermoswitch 2 9 ThinWire jumpers 6 6 9 33 Toner sensor contact EP ED connections 2 24 Top cover remove replace 9 45 Top door interlock circuit 2 12 open message A 16 wiring diagram 6 20 Training tools D 1 Transfer block assembly FRU part number 10 3 Transfer roller cleaning 2 17 FRU part number 10 3 remove replace 9 79 Transport guide plat...

Page 273: ...W Wait mode description 2 6 online mode 3 4 Windows drivers B 4 Wiring diagrams 6 20 Write black 2 16 X Xerographic Processes 2 15 XLI versus DECimage A 14 Index 9 ...

Page 274: ......

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