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Epson EPL-5500W, Service Manual

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Chapter 3

Disassembly and Assembly

Table of Contents

3.1  GENERAL INFORMATION

3-1

3.1.1 Precautions for Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.3 Small Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.4 Service Checks after Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2  DISASSEMBLY AND ASSEMBLY

3-4

3.2.1 Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2.1.1 Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2.2 Removal of the Controller Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.2.2.1 Main Board (C180 MAIN Board) Removal . . . . . . . . . . . . . . . . . . 3-5

3.2.3 Disassembling the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.2.3.1 Optical Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.2.3.2 Image Transfer Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.3.3 Upper Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.2.3.4 High-Voltage Supply Board (PWB-F) Removal . . . . . . . . . . . . . . 3-10
3.2.3.5 Power Supply Unit (PWB-E) Removal. . . . . . . . . . . . . . . . . . . . . 3-11
3.2.3.6 Fusing Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.2.3.7 Fusing Unit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

List of Figures

Figure 3-1. Removing the Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-2. Removing the Shield Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-3. Removing the C169 MAIN-B Board . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-4. Removing the Optical Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3-5. Removing the Image Transfer Unit -1. . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-6. Removing the Image Transfer Unit -2. . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-7. Moving the Image Transfer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-8. Reinstalling the Electrode Comb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-9. Removing the Harness Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-10. Removing the Upper Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-11. Removing the PWB-F Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Figure 3-12. Removing the PWB-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Figure 3-13. Removing the PWB-E Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Figure 3-14. Removing the PWB-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Figure 3-15. Gear and Spring Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-16. Removing the Fusing Guide Plate . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-17. Removing the Harness Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Figure 3-18. Removing the Fusing Entrance Guide . . . . . . . . . . . . . . . . . . . . . 3-13
Figure 3-19. Removing the Fusing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Figure 3-20. Roller Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Figure 3-21. Removing the Heater Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Figure 3-22. Removing the Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Figure 3-23. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Figure 3-24. Removing the Paper Separator . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Figure 3-25. Paper Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Figure 3-26. Removing the G-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Summary of Contents for EPL-5500W

Page 1: ...EPSON TERMINAL PRINTER EPL 5500W SERVICE MANUAL EPSON 4005668 ...

Page 2: ... ii ...

Page 3: ...of this manual However should any errors be detected SEIKO EPSON would greatly appreciate being informed of them The above notwithstanding SEIKO EPSON can assume no responsibility for any errors in this manual or the consequence thereof Epson is a registered trademark of Seiko Epson Corporation General Notice Other product names used herein are for identication purposes only and may be trademarks ...

Page 4: ... NOT CON NECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS WARNING 1 REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTI FIED REPAIR TECHNICIAN 2 MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED VOLTAGE LISTED ON THE SERIAL NUMBER RATING ...

Page 5: ...ucts marketed in the United States The label shown below indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States WARNING Use of controls adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure Internal Laser Radiation Maximum Radiation Power 5 0 10 4 W Wave Length 790 2...

Page 6: ...ettaessa olet alttiina näkymättömälle laser säteilylle Älä katso säteeseen VARNING Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad Betrakta ej strålen For Norway Users ADVARSEL Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisning kan brukeren utsettes for unsynlig laserstråling som overskrider grensen for laser klasse 1 Dette er en halvleder laser Ma...

Page 7: ... Label inside printer The following laser safety label will be attached inside the printer as shown below For Denmark Finland Sweden and Norway v ...

Page 8: ...ts of the printer CHAPTER 2 OPERATING PRINCIPLES Describes the theory of printer operation CHAPTER 3 DISASSEMBLY AND ASSEMBLY Includes a step by step guide for product disassembly and assembly CHAPTER 4 ADJUSTMENTS Includes a step by step guide for adjustment CHAPTER 5 TROUBLESHOOTING Provides Epson approved techniques for adjustment CHAPTER 6 MAINTENANCE Describes preventive maintenance technique...

Page 9: ...REVISION SHEET Revision Issue Date Revision Page Rev A November 24 1995 1st issue vii ...

Page 10: ...TABLE OF CONTENTS CHAPTER 1 GENERAL DESCRIPTION CHAPTER 2 OPERATING PRINCIPLES CHAPTER 3 DISASSEMBLY AND ASSEMBLY CHAPTER 4 ADJUSTMENTS CHAPTER 5 TROUBLESHOOTING CHAPTER 6 MAINTENANCE APPENDIX viii ...

Page 11: ...S 1 9 1 4 1 Control Panel 1 9 1 4 2 Display of Messages 1 10 1 4 2 1 Status Messages 1 10 1 4 2 2 Error Messages 1 10 1 4 3 Printing Resolution Host PC Capability Dependency 1 11 1 5 MAIN COMPONENTS 1 12 1 5 1 C180 MAIN Board 1 13 1 5 2 PWB E Board 1 14 1 5 3 PWB F Board 1 14 1 5 4 Optical Unit 1 15 1 5 5 FUSING UNIT 1 15 1 5 6 Photoconductor Unit 1 16 1 5 7 Developing Cartridge 1 16 List of Figur...

Page 12: ... 5500W 1 2 Table 1 2 Paper Feed Methods 1 3 Table 1 3 Paper Types 1 3 Table 1 4 Usability of Special Papers 1 4 Table 1 5 Electrical Specifications 1 5 Table 1 6 Status Messages 1 10 Table 1 7 Error Messages 1 10 Table 1 8 Host PC Conditions 1 11 ...

Page 13: ...Rev A 1 iii ...

Page 14: ...he development toner cartridge and photoconductor unit Ease of use with Microsoft Windows Printing System WPS PCL4 software emulation mode High throughput especially with fine pitch halftone image output Freedom from the memory overflow Freedom from document incompatibility True WYSIWYG Bidirectional parallel interface ECP and Microsoft Peppy modes Achieves high throughput with a very high speed p...

Page 15: ...its available for the EPL 5500W Table 1 1 Options for the EPL 5500W Cat No Description Note S050005 Developer cartridge Developer and toner cartridge S051029 Photoconductor unit General Description EPL 5500W Service Manual 1 2 Rev A ...

Page 16: ...XEC LGL 16 to 24 lb 60 to 90 g m2 5 to 10 Monarch DL C5 Env 10 11 12 14 Envelopes made of 20 to 24 lb 75 to 90 g m2 paper Manual feed slot 1 Any size feedable Note 2 16 to 42 lb 60 to 157 g m2 Notes 1 The weight in pounds lb is determined by the weight of 500 sheets cut to 17 22 inches 1 g m2 0 2659763 lb 2 Paper size range width 3 to 8 5 inches 76 to 216 mm length 5 to 14 0 inches 127 to 356 mm P...

Page 17: ...rection Center alignment for all sizes Paper ejection Face down Output tray capacity 100 sheets face down Printable area standard paper See Figure 1 2 Note The actual printable area depends on the printer mode Noise Less than 35 dB A standby Less than 47 dB A operating Ozone density Less than 0 01 ppm Toxicity No toxicity exists in organic photoconductor OPC toner or plastic materials Printable Ar...

Page 18: ...ltiple paper feeds 1 out of 500 sheets or less Paper curl height 30 mm 1 2 inches or less Leading edge bending 1 cm or more 1 out of 1 000 sheets MTTR Mean Time To Repair 30 minutes or less Durability 5 years or 1 800 000 sheets 1 2 4 Environmental Conditions for Operation Including Imaging Cartridge Temperature 10 to 35 C 50 to 95 F Humidity 15 to 85 RH Altitude 2 500 m 8 200 feet or lower Leveln...

Page 19: ...S environmental law must contain no CdS 1 2 7 Specifications for Consumables Life Developer and toner cartridge 3 000 pages Photoconductor unit 20 000 pages Note In continuous printing mode with A4 letter paper at a 5 image ratio black white ratio The life varies depending on the printing mode continuous or intermittent and or the image ratio Environmental Conditions for Storage and Transportation...

Page 20: ...1 2 9 Software Specifications Built in modes Microsoft Windows Printing System PCL4 software emulation EPL 5500W Service Manual General Description Rev A 1 7 ...

Page 21: ...nterface 1 3 1 Parallel Interface The parallel interface has the following two modes ECP mode Microsoft Peppy mode Pin assignments Fully IEEE 1284 compliant Connector type P90 25027 1 Amphenol receptacle Applicable plug 57 30360 Amphenol or equivalent General Description EPL 5500W Service Manual 1 8 Rev A ...

Page 22: ...gives you easy control over most common printer operations The panel consists of the indicator lights described below Indicator Lights GREEN light ON Printer is ready or idle Blinking Printer is currently receiving data RED light ON Printer has detected errors GREEN Light RED Light Figure 1 3 Control Panel EPL 5500W Service Manual General Description Rev A 1 9 ...

Page 23: ...nd what measures to take to eliminate the error Table 1 7 Error Messages Message Status Measures Configuration error The user is unable to redirect a port or system software cannot find a file to complete a request Check the printer connection port and reinstall the driver Low memory Memory in PC has run out Add the memory to the PC No local printer The printer is not connected to the local port w...

Page 24: ... set This printer can print pages at the resolution if the HOST PC fulfill the following conditions Table 1 8 Host PC Conditions CPU Installed DRAM Quantity Windows 3 1 WFW 3 11 Windows 95 8 MB 8 MB 8 MB 12 MB 80386SX 16 20 25 33 MHz or compatibles 300 DPI Note 1 300 DPI Note 1 80386DX 16 20 25 33 MHz or compatibles 300 DPI Note 1 300 DPI Note 1 300 DPI Note 1 300 DPI Note 1 80486SX DX 16 20 MHz o...

Page 25: ...onents are C180 MAIN Board Main board PWB E Board Power supply circuit board PWB F Board High voltage supply circuit board Optical Unit Printhead unit Fusing Unit Photoconductor unit Developer cartridge Housing Optical Unit C180 MAIN Board PWB E Board PWB F Board Fusing Unit Figure 1 4 Main Components General Description EPL 5500W Service Manual 1 12 Rev A ...

Page 26: ...age to the engine controller via the video interface Memory chips 4M bit DRAM U4 Custom ICs ASIC E05B23 U6 The engine controller consists of an M3807 x 8 bit CPU including a MASK ROM It controls laser scanning the polygon mirror drive motor image synchronization laser beam pulse width and power M3807 IC201 E05B23 U6 4M DRAM U4 Figure 1 5 C180 MAIN Board EPL 5500W Service Manual General Description...

Page 27: ...e two circuits is only in the input section CAUTION Do not touch VR1 on PWB E board This volume is for factory setting only 1 5 3 PWB F Board The PWB F is the high voltage supply circuit board It converts the development bias OPC drum charge bias and image transfer bias CAUTION Do not touch VR3 on the PWB F board These volumes are for factory setting only F1 VR1 Figure 1 6 PWB E Board VR3 Figure 1...

Page 28: ...f the polygon mirror as well as several mirrors and lenses to create a latent electro photographic image on the drum 1 5 5 Fusing Unit The fusing unit fixes the toner to the paper using heat and pressure This unit has a heater lamp thermistor and thermal fuse There are two types of fusing units the 120 V type and the 220 240 V type The only difference between them is the heater lamp Figure 1 8 Opt...

Page 29: ...harging and imaging are integrated into this unit 1 5 7 Developing Cartridge The developing mechanism for the printing process is integrated into this cartridge Figure 1 10 Photoconductor Unit Figure 1 11 Developing Unit General Description EPL 5500W Service Manual 1 16 Rev A ...

Page 30: ...gure 2 3 Paper Feeding from the Paper Feed Tray 2 3 Figure 2 4 Drum Charge 2 4 Figure 2 5 Laser Exposure 2 5 Figure 2 6 Development 2 5 Figure 2 7 Image Transfer 2 6 Figure 2 8 Fusing 2 6 Figure 2 9 Engine Controller Connecting Diagram 2 7 Figure 2 10 Gear and Roller Positions 2 8 Figure 2 11 Main Motor Drive Circuit 2 9 Figure 2 12 Paper Take Up Sensor and Paper Exit Sensor On Off Timing 2 9 Figu...

Page 31: ...List of Tables Table 2 1 Functions of C180 MAIN Board Main Elements 2 18 ...

Page 32: ... Paper Lift up Plate 3 Paper Exit Sensor PC3 13 Paper Take up Roller 4 Upper Fusing Roller 14 Paper Transport Roller 5 Heater Lamp H1 15 Paper Take up Sensor PC1 6 Paper Exit Roller 16 Pre image Transfer Roller 7 Print Tray 17 Electrode Comb 8 Optical Unit 18 Drum Cartridge 9 Toner Cartridge 10 Manual Feed Guide 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Figure 2 1 Main Components EPL 5500W Serv...

Page 33: ...ws a diagram of the print process Optical Unit Drum Cartridge Toner Cartridge Paper Feeding Tray Fusing Image Transfer Print Exit Drum Charge Toner Hopper Develop ment Multi Feeding 150 sheets Manual Feed 1 sheet Exposure Figure 2 2 Print Process Diagram Operating Principles EPL 5500W Service Manual 2 2 Rev A ...

Page 34: ...oller via the paper take up clutch a one way clutch to rotate the paper take up roller one revolution At the same time the depression cam rotates and releases the paper lift up plate to feed the top first paper The fixed separating pad is used for the paper separation system It prevents the second or later sheets from being fed together with the top paper Upper Fusing Roller Paper Exit Roller Lowe...

Page 35: ...can be charged with low voltage because the charge is directly applied to the PC drum The charge brush is rotated by the drive of the M1 main motor via its gear Drum Cartridge Rotating Charge Brush PC Drum Protecting Shutter PC Drum Charged Surface approx 800 V PC Drum Protecting Shutter Drum Charging and Pre film Bias PWB F C180 MAIN A B Pre film A Drum Charging Bias B Drum Ground IC201 Figure 2 ...

Page 36: ... hopper and sends the toner to the toner transport roller 3 Toner transport roller Transports the toner to the sleeve roller 4 Doctor blade Spreads a thin even coat of toner over the resin sleeve The toner is negatively charged by passing between this blade and resin sleeve 5 Sleeve roller Rotates the resin sleeve 6 Resin sleeve Carries the toner to the PC drum surface for development 7 Bias seal ...

Page 37: ...lower fusing rollers Thermistor TH1 detects and controls the temperature of the upper fusing roller Thermal fuse TF1 blows when the temperature exceeds 200 C 392 F shutting down power to the heater lamp Image Transfer Unit Housing Pre Image Transfer Roller Housing Electrode Comb Electrode Comb Housing Pre Image Transfer Roller Housing Ground Image Transfer Bias PWB F CN1F PWB S C180 MAIN IC201 CN2...

Page 38: ...ction diagram C180 MAIN Board Main Motor M1 Polygon Motor M2 Fan Motor M2 Exit Sensor PC3 Paper Take up Sensor PC1 Paper Take up Solenoid SL1 Fusing Roller Thermistor TH1 PWB S PWB F High Voltage Unit Image Transfer Housing Image Transfer Charger PWB D Laser Diode Drive PWB E Power Unit Heater Lamp Interlock Switch Figure 2 9 Engine Controller Connection Diagram EPL 5500W Service Manual Operating ...

Page 39: ...cassette via each gear as shown below Toner Cartridge Sleeve Roller A Paper Exit Roller Upper Fusing Roller Lower Fusing Roller PC Drum Pre image Transfer Roller Main Motor M1 Optional Second Paper Feeding Unit Paper Take Up Roller Paper Transport Roller A Figure 2 10 Gear and Roller Positions Operating Principles EPL 5500W Service Manual 2 8 Rev A ...

Page 40: ...paper jams and feed jams If the paper take up sensor does not turn on for paper feeding the printer detects a feed jam or no paper A feed jam is a paper jam that occurs in the feed process If any of the following conditions is detected the printer detects a paper jam A paper jam is a jam that occurs in the printing process area The paper take up sensor PC1 or the paper exit sensor PC3 is on at pow...

Page 41: ...cedure 1 Warm up After printer initialization printer warm up starts and the heater lamp turns on until the upper fusing roller s temperature reaches approximately 172º C 342º F 2 Standby In standby mode the upper fusing roller s temperature is controlled to maintain 156º C 313º F When this condition continues for 3 minutes the printer goes into standby mode at low temperature 3 Print cycle When t...

Page 42: ...o save power in the idle state the heater lamp is turned OFF Thermo fuse TF1 cuts power if the temperature of the fusing section rises to an abnormally high level over 200 C 392 F 2 1 2 4 Scanner Motor Control Figure 2 16 is the scanner motor M2 control circuit The scanner motor is driven while it receives the POLYGON CTL signal Motor rotation speed is 8622 rpm If the any of following conditions a...

Page 43: ...e laser diode is forcibly activated after scanner motor M2 turns on At this time laser emission power is adjusted LDAPC1 and LDAPC2 are the laser emission power adjust signals they are analog signals LDAPC1 is a tuning and LDAPC2 is a fine tuning signal If either of the following conditions is detected the printer indicates a laser error The LDAPC1 signal or LDAPC2 signal has been out of the speci...

Page 44: ... is charged to from 3 to 6K VDC by the high voltage supply circuit HV SEL1 and HV SEL2 are image transfer bias level control signals The HVB signal is the digital signal for developing bias voltage control This signal controls the bias on off The BIAS MON signal controls the bias voltage level 300 V to 375K VDC using pulse data The image density is controlled by the developing bias voltage level 2...

Page 45: ...sec Print Command Polygon Motor M3 Paper Take up Sensor PC1 Paper Take up Solenoid SL1 2 Main Motor M1 Drum Charge Laser Exposure Development Image Transfer 20 200 500 300 2310 150 500 260 1st 770 2nd 2820 1st 790 to 1300 2nd 2670 to 3080 480 1st 1510 2nd 1680 Normal M3 Rotation 4000 Figure 2 21 Print Sequence Start m sec Polygon Motor M3 Main Motor M1 Drum Charge Laser Exposure Development Image ...

Page 46: ... mV or lower for 2 sec 2 1 2 8 Power Supply Circuit Function and Safety Protection The printer s power supply board PWB E supplies the 5 VDC and 24 VDC The 24 VDC is used as the bias voltage supply main motor M1 drive scanner motor M2 drive fan motor M3 drive and solenoid drive For safety protection the 24 VDC line is cut when the interlock switch case open switch is off AC IN Interlock SW 24 VDC ...

Page 47: ... 1 C180 MAIN Board Operation Figure 2 25 shows a block diagram of parallel interface controller section of the C180 MAIN board C180 MAIN Board Parallel Interface Controller Section Engine Controller Section Figure 2 24 Parallel Interface Controller Section E05B23 U8 4M DRAM U4 Bidirectional Parallel I F Engine Controller Section Figure 2 25 C180 MAIN Board Block Diagram Operating Principles EPL 55...

Page 48: ...s of C180 MAIN Board Main Elements Element Location Function E05B23 ASIC U8 This ASIC contains the following functions Changing from parallel I F to video I F DRAM management refresh control RAS CAS control DRAM U4 These DRAMs are used as the working area of the E05B23 EPL 5500W Service Manual Operating Principles Rev A 2 17 ...

Page 49: ...emoving the C169 MAIN B Board 3 5 Figure 3 4 Removing the Optical Unit 3 6 Figure 3 5 Removing the Image Transfer Unit 1 3 7 Figure 3 6 Removing the Image Transfer Unit 2 3 7 Figure 3 7 Moving the Image Transfer Unit 3 8 Figure 3 8 Reinstalling the Electrode Comb 3 8 Figure 3 9 Removing the Harness Cover 3 9 Figure 3 10 Removing the Upper Unit 3 9 Figure 3 11 Removing the PWB F Cover 3 10 Figure 3...

Page 50: ... Figure 3 28 Removing the Lower Fusing Roller 3 19 Figure 3 29 Removing the Thermal Fuse 3 19 List of Tables Table 3 1 Tools 3 1 Table 3 2 Abbreviations Used for Screws 3 2 Table 3 3 Screw Types and Abbreviations 3 2 Table 3 4 Checks after Repair 3 3 ...

Page 51: ... printer do not place it in direct sunlight Do not disassemble the optical unit Never turn power on if the optical unit is not installed To prevent damage to ICs from static electricity do not touch the ICs on the circuit board or the terminals of peripheral electrical components with your hands Use only the recommended tools to ensure safe and efficient maintenance work Inappropriate tools may da...

Page 52: ...d lock washer CP S P1 Cross recessed Pan head with Spring lock washer and 1 Plain washer CCB Cross recessed Cup head Bind SCB Slotted Cross recessed B tight SCB S P1 Slotted Cross recessed Bind with Spring washer and 1 Plain washer Table 3 3 Screw Types and Abbreviations Head Body Washer Assembled Top Side 1 Cross recessed head 2 Slotted Cross recessed head 1 Bind 2 Pan 3 Cup 1 Normal 2 B tight 1 ...

Page 53: ...print Does data print in all modes Adjustments Print position Is the gap between the top edge of the paper and the horizontal line in the adjustment printing sheet print exactly 4 2 mm 0 17 inch Cleaning Is toner and dust removed from the paper path Is the paper take up roller cleaned Is the roller in the fusing unit cleaned Is the outer surface of the printer clean Packing Are the consumables rem...

Page 54: ... 1 Housing Removal This section describes how to remove the cases and the rear frame 3 2 1 1 Case Removal 1 Push the upper unit lock release button and open the upper unit 2 Remove each cover in the following order ASSEMBLY POINT When reinstalling each cover securely insert the protrusions for the cover into the cutouts in the printer frame 2 Front Cover 1 Left cover 3 Operation Cover 4 Rear Cover...

Page 55: ...inter so that its right side faces you 2 Remove the right cover 3 Remove 2 screws and then remove the shield case 4 Disconnect all connectors on the C180 MAIN board 5 Remove the 5 screws for the C180 MAIN board 6 Remove the C180 MAIN board Figure 3 2 Removing the Shield Case Figure 3 3 Removing the C180 MAIN Board EPL 5500W Service Manual Disassembly and Assembly Rev A 3 5 ...

Page 56: ...t under any conditions Do not remove the circuit board from the optical unit under any conditions 1 Open the top cover 2 Remove the right cover left cover and front cover Refer to Section 3 2 1 1 3 Remove the cover shield plate 4 Disconnect connectors CN205 and CN210 from the C180 MAIN board 4 Remove the 6 screws from the optical unit 5 Remove the optical unit Figure 3 4 Removing the Optical Unit ...

Page 57: ... Section 3 2 3 3 3 Remove the 2 screws and holders at both ends of the image transfer unit 4 Disconnect the 2 connectors and remove the unit Figure 3 5 Removing the Image Transfer Unit 1 Figure 3 6 Removing the Image Transfer Unit 2 EPL 5500W Service Manual Disassembly and Assembly Rev A 3 7 ...

Page 58: ...SSEMBLY POINT When reinstalling the electrode comb be careful of the direction of installation Install the electrode comb so that the comb terminal faces the image transfer roller drive gear Figure 3 7 Moving the Image Transfer Unit Figure 3 8 Reinstalling the Electrode Comb Disassembly and Assembly EPL 5500W Service Manual 3 8 Rev A ...

Page 59: ...and CN211 from the C180 MAIN 4 Remove harness covers A and B and pull CN1 out from the PWB E board 5 Remove the image transfer unit Refer to Section 3 2 3 2 6 Slide and remove the unit as shown in the illustration A B Figure 3 9 Removing the Harness Cover Figure 3 10 Removing the Upper Unit EPL 5500W Service Manual Disassembly and Assembly Rev A 3 9 ...

Page 60: ...e 1 screw from the PWB F cover 3 Remove the PWB F cover 4 Remove the 4 screws from the PWB F board 5 Disconnect 2 connectors 6 Remove the PWB F board Figure 3 11 Removing the PWB F Cover Figure 3 12 Removing the PWB F Disassembly and Assembly EPL 5500W Service Manual 3 10 Rev A ...

Page 61: ... 3 2 Remove 6 screws and remove the PWB E cover 3 Disconnect connector CN207 from the C180 MAIN board 4 Remove 4 screws and 2 screws and then remove the PWB E Figure 3 13 Removing the PWB E Cover Figure 3 14 Removing the PWB E EPL 5500W Service Manual Disassembly and Assembly Rev A 3 11 ...

Page 62: ...he spring and remove the drive gear section of the fusing unit ASSEMBLY POINT When rehooking the spring be sure to hook it in the correct position 6 Remove 2 screws and remove the fusing guide plate drive gear section of the Fusing unit drive transport gear hook of the spring drive tension section of the Fusing unit Figure 3 15 Gear and Spring Position Figure 3 16 Removing the Fusing Guide Plate D...

Page 63: ...emove the harness cover 8 Remove the fusing entrance guide Figure 3 17 Removing the Harness Cover Figure 3 18 Removing the Fusing Entrance Guide EPL 5500W Service Manual Disassembly and Assembly Rev A 3 13 ...

Page 64: ...nstalling the fusing unit check the direction of the bushings on the paper exit roller and the connection between the roller and the ground plate Figure 3 19 Removing the Fusing Unit Figure 3 20 Roller Position Disassembly and Assembly EPL 5500W Service Manual 3 14 Rev A ...

Page 65: ...uch the glass surface of the lamp with your bare hands 1 Remove the fusing guide plate Refer to Section 3 2 3 8 2 Pull the heater lamp out of the lamp holder from the front side ASSEMBLY POINT When reinstalling the lamp position its voltage indicator to the left side non gear end Figure 3 21 Removing the Heater Lamp EPL 5500W Service Manual Disassembly and Assembly Rev A 3 15 ...

Page 66: ...n 3 2 3 6 2 Remove the 1 screw and remove the thermistor ASSEMBLY POINT When reinstalling the thermistor wire the harness as shown below Figure 3 22 Removing the Thermistor Figure 3 23 Wiring Disassembly and Assembly EPL 5500W Service Manual 3 16 Rev A ...

Page 67: ... When reinstalling the paper separators be careful of their positions because the middle one differs from the others Paper Exit Sensor 1 Remove the fusing unit Refer to Section 3 2 3 6 2 Remove the paper exit sensor Figure 3 24 Removing the Paper Separators Figure 3 25 Paper Exit Sensor EPL 5500W Service Manual Disassembly and Assembly Rev A 3 17 ...

Page 68: ...nstalling the G rings Be careful of the direction Securely position them into the grooves of the fusing roller 3 Remove the upper fusing roller drive gear 4 Remove the upper fusing roller Figure 3 26 Removing the G Rings Figure 3 27 Removing the Upper Fusing Roller Disassembly and Assembly EPL 5500W Service Manual 3 18 Rev A ...

Page 69: ...Fuse 1 Remove the fusing unit Refer to Section 3 2 3 6 2 Remove 2 screws and remove the thermal fuse Figure 3 28 Removing the Lower Fusing Roller Figure 3 29 Removing the Thermal Fuse EPL 5500W Service Manual Disassembly and Assembly Rev A 3 19 ...

Page 70: ...Chapter 4 Adjustment Table of Contents 4 1 ADJUSTMENT 4 1 4 1 1 Print Position Adjustment 4 1 List of Figures Figure 4 1 Print Position Adjustment 4 1 ...

Page 71: ...4 ii Rev A ...

Page 72: ...the registration gap between the leading edge of the sheet and the horizontal line printed on the page is within the following range 4 2 2 5 mm 0 17 0 1 inches for a adjustment printing sheet on A4 paper If the gap is not correct adjust the print position as described in the next few steps 9 Turn printer power off 10 Open the right cover and shield plate See Chapter 3 11 Adjust the image synchroni...

Page 73: ... Table 5 1 Error Codes 5 1 Table 5 2 Symptoms and Reference Tables 5 3 Table 5 3 The Printer Does Not Operate at All 5 4 Table 5 4 Both LED Lights Do Not Come On 5 4 Table 5 5 Clear Paper Jam 1 5 4 Table 5 6 Clear Paper Jam 2 5 5 Table 5 7 Check Toner Cover 5 6 Table 5 8 Service Error 1 5 6 Table 5 9 Service Error 2 5 7 Table 5 10 Service Error 3 5 7 Table 5 11 Service Error 4 5 7 Table 5 12 Print...

Page 74: ...re not using the EPL 5500W printer driver skip to step 9 CAUTION The tool program cannot run if EPL 5500W printer driver output is directed a printer port in Windows 3 1 because the EPL 5500W printer driver and special tool both use an interface protocol program The interface protocol program for the special tool cannot be active in Windows 3 1 while the interface protocol for the EPL 5500W printe...

Page 75: ...motor error 0x40 Fusing unit error 0x43 Fusing unit and fan motor error 0x51 Fusing unit and scanner mirror motor error 0x52 Fusing unit scanner mirror motor and fan motor error 0x61 Fusing unit and laser light error 0x62 Fusing unit laser light and fan motor error 0x70 Fusing unit laser light and scanner mirror motor error 0x73 Fusing unit laser light scanner mirror motor and fan motor error Trou...

Page 76: ...s on 5 3 Status not available or Check printer cable is displayed Status not available or Check printer cable is displayed by the printer driver interface 5 4 Clear paper jam is displayed Clear paper jam is displayed by the printer driver interface during power on 5 5 Clear paper jam is displayed by the printer driver interface during printing 5 6 Check Toner Cover is displayed Check Toner Cover i...

Page 77: ...d may be dead 1 If you replace the C180 MAIN board do the LEDs come on Yes Replace the C180 MAIN board Table 5 5 Clear Paper Jam 1 Cause Step Checkpoint Finding Solution The paper take up sensor flag position may be incorrect 1 Is the paper take up sensor flag position OK No Reposition the paper take up sensor flag The paper exit sensor flag position may be incorrect 2 Is the paper exit sensor fla...

Page 78: ...ny current Yes Replace the paper take up solenoid and the C180 MAIN board The main motor coils may be open or shorted 2 Disconnect CN206 on the C180 MAIN board and check the coil resistance between pins 1 and 2 and between pins 3 and 4 2 points total on the disconnected cable side of the connector using a multimeter Pin 1 Pin 2 Pin 3 Pin 4 Are the resistances of all four points approximately 10 oh...

Page 79: ...No Replace the interlock switch The PWB E board may be dead 3 With power on is there an output of 24 VDC between pin 1 and pin 2 for CN207 on C180 MAIN board No Replace the PWB E board Table 5 8 Service Error 1 Cause Step Checkpoint Finding Solution The connector for the thermistor may be disconnected 1 Is the thermistor connector disconnected Yes Connect it The C180 MAIN board may be bad 2 Does t...

Page 80: ...e it Table 5 10 Service Error 3 Cause Step Checkpoint Finding Solution The optical unit may be bad 1 Replace the optical unit The C180 MAIN board may be bad 2 Replace the C180 MAIN board Table 5 11 Service Error 4 Cause Step Checkpoint Finding Solution The optical unit may be bad 1 Replace the optical unit The C180 MAIN board may be dead 2 Replace the C180 MAIN board EPL 5500W Service Manual Troub...

Page 81: ...d Replace the image transfer unit PWB F board Replace the PWB F board Defective PC drum Photoconduc tor unit Replace the photoconductor unit Improper print density setting Adjust the print density using the printer settings Foggy background Poor develop ment Toner cartridge Replace the toner cartridge Improper charging Drum charge Replace the PWB F board Check the wiring of the PC drum charging bi...

Page 82: ...nter settings Defective optical unit Optical unit Replace the optical unit Black print Improper charging Photoconduc tor unit Replace the photoconductor unit PWB F board Replace the PWB F board Poor development Toner cartridge Replace the toner cartridge PWB F board Replace the PWB F board Improper print density setting Adjust the print density using the printer settings Defective optical unit Opt...

Page 83: ...PWB F Replace the PWB F board Poor development PWB F Replace the PWB F board Improper fusing Fusing unit Replace the fusing unit Offset print Improper fusing Fusing unit Replace the fusing unit White spots Poor image transfer Image transfer unit Replace the image transfer unit PWB F Replace the PWB F board Troubleshooting EPL 5500W Service Manual 5 10 Rev A ...

Page 84: ...cement of Consumables 6 2 6 1 2 Service Maintenance 6 3 6 1 2 1 Periodic Service Maintenance 6 3 6 1 2 2 Cleaning 6 3 List of Figures Figure 6 1 Position of the Special Tool 6 1 Figure 6 2 Cleaning the Electrode Comb 6 1 List of Tables Table 6 1 Periodic Service Maintenance 6 3 Table 6 2 Cleaning Parts and Procedures 6 3 ...

Page 85: ...6 ii Rev A ...

Page 86: ...ribes the cleaning required for optimal print quality External Cleaning Be sure to disconnect the printer from the power outlet before cleaning it Wipe the cover and external parts of the printer with a damp cloth that has been soaked in a neutral cleaning solution Internal Cleaning Be sure the printer has been disconnected from the power supply and that the fusing unit has cooled down If the elec...

Page 87: ...n A4 or letter size pages with a 5 print ratio If printed images become faint remove the toner cartridge and gently shake it This will distribute the toner and may make the images darker If the image is still too light replace the toner cartridge cartridge If the printed image remains faint after you have replaced the toner cartridge change the photo conductor unit Maintenance EPL 5500W Service Ma...

Page 88: ... above is only a reference value You do not need to perform service maintenance exactly at this time 6 1 2 2 Cleaning Some parts of this printer require regular cleaning Clean each part using the specified method and tools Refer to Chapter 3 for disassembly procedures Table 6 2 Cleaning Parts and Procedures Parts Name Cleaning Procedure Paper take up roller Wipe the surface with a dry soft cloth U...

Page 89: ...Maintenance EPL 5500W Service Manual 6 4 Rev A ...

Page 90: ...PWB E 220 240V Circuit Diagram A 11 Figure A 6 C180 MAIN Component Layout Side A A 12 Figure A 7 C180 MAIN Component Layout Side B A 13 List of Tables Table A 1 Board Connector Summary A 2 Table A 2 CN2 Pin Assignments A 3 Table A 3 CN202 Pin Assignments A 4 Table A 4 CN203 Pin Assignments A 4 Table A 5 CN204 Pin Assignments A 4 Table A 6 CN205 Pin Assignments A 4 Table A 7 CN206 Pin Assignments A...

Page 91: ... 1 2 3 4 5 6 7 8 PWB S 8 7 6 5 4 3 2 1 CN204 PWB F High Voltage Unit 8 7 6 5 4 3 2 1 G N D 24 VDC CN1F Image Transfer Housing Image Transfer Charger 1 2 3 24 VDC FEED2 N C 4 5 6 5 VDC GN D P EMP2 7 8 PSIZE0 2NDBIN 9 10 mm inches UNIVERSAL 11 8 CHECK1 PWB A 8 7 6 5 4 3 2 1 CN1A 1 2 11 10 9 CN209 1 2 SL2 Paper Take up Solenoid 24 VDC FEED2 2nd Paper Feeding Unit Optional CHECK2 7 6 5 4 3 2 1 1 2 3 4...

Page 92: ...e A 6 CN206 Connector for motor 4 pins Table A 7 CN207 Connector for power supply board PWB E board 5 pins Table A 8 CN208 Connector for paper exit sensor 3 pins Table A 9 CN209 Connector for lower paper cassette 12 pins Table A 10 CN210 Connector for optical unit 5 pins Table A 11 CN211 Connector for fan 2 pins Table A 12 Power Supply Board PWB E Board CN1 Connector for AC power inlet 4 pins CN2 ...

Page 93: ...it 8 10 ACKNLG O ACKNLG signal 11 BUSY O BUSY signal 12 PE O PE signal 13 SLCT O SLCT signal 14 AUTO FEED I AUTO FEED signal 15 NC Not connected 16 GND GND 17 CHASSIS GND CHASSIS GND 18 NC Not connected 19 GND GND 20 GND GND 21 GND GND 22 GND GND 23 GND GND 24 GND GND 25 GND GND 26 GND GND 27 GND GND 28 GND GND 29 GND GND 30 GND GND 31 INIT I INIT signal 32 ERROR O ERROR signal 33 GND GND 34 NC No...

Page 94: ...in No Signal Name I O Description 1 HV C 2 HV T I 3 HV S 4 HV S2 5 HV B 6 BIAS M O 7 GND2 Ground 8 24 24 VDC Table A 6 CN205 Pin Assignments Pin No Signal Name I O Description 1 SSCAN I Horizontal synchronous signal 2 LD CTL I Laser power signal 3 LDAPC2 O Laser power adjust 2 4 LDAPC1 O Laser power adjust 1 5 GND1 Ground 6 LDATA O Laser data 7 5V 5 VDC Table A 7 CN206 Pin Assignments Pin No Signa...

Page 95: ...o Signal Name I O Description 1 24 V 24 VDC 2 FEED2 O Lower cassette solenoid on 3 NC Not connected 4 5V 5 VDC 5 GND1 Ground 6 PE2 I Lower cassette paper empty 7 PSIZ0 8 PSIZ1 9 PSIZE2 10 CHECK1 11 CHECK2 12 CHECK3 Table A 11 CN210 Pin Assignments Pin No Signal Name I O Description 1 NC Not connected 2 24V 24 VDC 3 GND2 Ground 4 5V 5 VDC 5 P CTL O Polygon motor control Table A 12 CN211 Pin Assignm...

Page 96: ...Appendix EPL 5500W Service Manual A 6 Rev A ...

Page 97: ...A 2 CIRCUIT DIAGRAMS Figure A 2 C180 MAIN Circuit Diagram 1 2 EPL 5500W Service Manual Appendix Rev A A 7 ...

Page 98: ...Appendix EPL 5500W Service Manual A 8 Rev A ...

Page 99: ...8 1000P C237 1000P C236 1000P C235 1000P C232 1000P C 231 1000P C230 1000P C229 1000P C259 0 1U C243 0 1U PLAC E NE AR C N205 PLACE NEAR CN210 NC 1 24V 2 5V 4 P_CTL 5 GND2 3 CN210 5V 2 TH 1 CN202 TP 202 TP 24V 2 FA N 1 C N211 C206 1000P R227 6 8 1 4W 200m A R203 3 0K 1 0 C214 1000P DT201 FB1L3N R226 47K R295 10K C 216 0 01U 1 2 3 4 8 7 6 5 R M202 4 7K R233 4 7K R234 4 7K R 236 47K 24V 1 5V 4 NC 3 ...

Page 100: ...T1 Z04 96 D 2 Y G 90 1C 2 D 5LC 2 0U D 3 Y G 8 01 C 4 D 5S C 4M F M B 24 M C 1 7 3 30 0u F 1 0V C 15 10 00 uF 35 V C1 6 100 0uF 35V R 2 7 1 2K 0 5W R 19 1 2K 0 5W R 2 0 1 2 K 0 5 W R 2 6 1 2 K 0 5 W L 9 L7 Z0 400 S C R 1 T F 32 15 2 P 4M Z D 4 H Z S 2 7 ZD 3 H ZS6 R 2 9 33 R 30 3 3 C 21 1 uF 50V R 2 2 10 0 0 5W 3 4 2 1 5 S W 2 A M 51 66 2A 53 1 C N 1 24 V 2 4V GN D 5 V G N D 5 1 V H L R 12 1K 0 25...

Page 101: ...pF R 6 2W 10 0 Q 1 80 0V 3A R 1 2 4 7 K 1 4 W R 5 3 W 1 00 K D 1 8 00 1 A C 8 63 0 V 0 0 1uF T 1 T M 19 9 D 2 7 0V 0 1 5A C 1 0 0 03 3 u F Q2 50 V 2A V R 1 2 0 0 C 11 0 0 4 7u F R 7 2W 16 R 8 2 W 1 6 R 9 2W 16 R 10 39 0 D 3 2 0 2 2V R 1 1 1 00 D 4 7 0V 0 15 A C 62 3 5V 2 200 u F R 63 2 W 1 2 K R 6 4 2 W 1 2K S W 6 1 L 62 C L 08 6 C 6 4 1 0V 2 20 0 u F C 65 50 V 10 u F R 7 3 W IR E P E S R 6 6 3W 3...

Page 102: ...A 3 CIRCUIT BOARD COMPONENT LAYOUTS Figure A 6 C180 MAIN Component Layout Side A Appendix EPL 5500W Service Manual A 12 Rev A ...

Page 103: ...Figure A 7 C180 MAIN Component Layout Side B EPL 5500W Service Manual Appendix Rev A A 13 ...

Page 104: ...hi 427 08290 Cerdanyola del Valles 20099 Sesto S Giovanni MI Italy Barcelona Spain Phone 02 262331 Phone 582 15 00 Fax 02 2440750 Fax 582 15 55 EPSON AUSTRALIA PTY LTD EPSON SINGAPORE PTE LTD 1 70 Gibbes Street No 1 Raffles Place 26 00 Chatswood 2067 NSW Australia OUB Centre Singapore 0104 Phone 02 415 9000 Phone 5330477 Fax 02 417 0077 Fax 5338119 EPSON HONG KONG LTD EPSON TAIWAN TECHNOLOGY 20 F ...

Page 105: ...EPSON Printed in Japan 95 11 01 S ...

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