Printronix L5035 Maintenance Manual Download Page 10

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Table of Contents

Acronyms for Print Engine Interconnection Diagram........................ 185

Explanation of Circuits According to Function .................................. 188

Drum Surface Potential Control Circuit ...................................... 188

Developing Bias Control Circuit ................................................. 190

Toner Density and Toner Empty Circuits ................................... 192

Drum Motor Control Circuit ........................................................ 194

Drum Counter Circuit ................................................................. 196

Tractor Motor Control Circuit ...................................................... 197

Main Body Feed Motor Control Circuit ....................................... 199

Transfer Elevator Motor Control Circuit...................................... 201

Cutter Motor Control Circuit ....................................................... 204

Input / Output Signals ....................................................................... 206

EDO-040 Controller Board Input/Output Signals ....................... 206

MC Board (MC-PCBA) Input/Output Signals ............................. 208

DC Power Supply Board (PS-PCBA) Input/Output Signals ....... 220

Unit Interface .................................................................................... 225

LED Array................................................................................... 225

Flash Power Supply ................................................................... 230

Developing Unit .......................................................................... 234

High-voltage (Corona) Power Supply......................................... 237

7 Troubleshooting ................................................. 243

Overview........................................................................................... 243

Jam Detection Sensors .............................................................. 243

System Block Diagram ..................................................................... 244

Hidden Control Menus ...................................................................... 245

Global Memory Adjust Menu ...................................................... 246

Printer Control Menu .................................................................. 248

Service Setup—Print All Cfg. Menu ........................................... 250

Fanfold Paper Jams.......................................................................... 251

Paper Jam near the Tractor ....................................................... 251

Paper Jam near the Paper Output Section ................................ 252

Cut Sheet Paper Jams...................................................................... 256

Paper Jam at the Back of the Paper Cassette ........................... 256

Paper Jam in the Transport Input Section.................................. 258

Paper Jam in the Transport Output Section ............................... 260

Paper Jam in the Face Up or Face Down Paper Path ............... 261

Status Messages and Error Messages............................................. 262

Error Message Table.................................................................. 262

Error Message Troubleshooting Procedures ............................. 270

Error Code 01 — Front Cover Open .......................................... 270

Error Code 02 — Fan-fold Paper Empty: Upon Power-on ......... 272

Summary of Contents for L5035

Page 1: ...Maintenance Manual Volume 2 L5035 Multifunction Printer ...

Page 2: ......

Page 3: ...705648 001C Maintenance Manual L5035 Multifunction Printer Volume 2 ...

Page 4: ...n Times New Roman under license from The Monotype Corporation Plc is a product of Agfa Univers is a registered trademark of Linotype AG and or its subsidiaries Letraset is a registered trademark and Aachen Revue and University Roman are trademarks of Esselte Pendaflex Corporation Futura is a registered trademark of Fundición Tipográfica Neufville S A ITC Avant Garde Gothic ITC Benguiat ITC Bookman...

Page 5: ... this document may be reproduced copied translated or incorporated in any other material in any form or by any means whether manual graphic electronic mechanical or otherwise without the prior written consent of Printronix Inc Copyright 1998 2001 Printronix Inc All rights reserved ...

Page 6: ......

Page 7: ...hme 32 Drucker 32 Verbrauchsmaterial 32 Befestigungsorte der Sicherheitsetiketten und Druckeransichten 33 Printer Features 37 Tools Test Equipment and Supplies 38 2 Setup 41 Power Requirements 41 Site Selection 42 Unpacking and Leveling 45 Cable Connections 47 Power Cord 47 Interface Cable 50 Consumables Installation 52 3 Installing Consumables 53 Installing the First Photoreceptor Drum 53 Adding ...

Page 8: ... Cleaning the Fuser Unit Cover Glass and Lamp Filter 103 Cleaning the Cut Sheet Option Rollers 106 Major Cleaning 110 Cleaning Unit 110 Discharge LED 112 Photoreceptor Drum 113 SELFOC Lens LED Print Head 114 Cleaning the Flash Power Supply Filter 116 5 Principles of Operation 119 Printing System Descriptions 119 General 119 The Printing Process 119 How Images are Processed 120 Bit Mapping 120 Job ...

Page 9: ...ation Cutter Drive 147 Separator Claw Drive 148 Cut Sheet Paper Feed Section Drive 149 Control System Descriptions 150 Paper Transport System Monitoring 151 Motor Rotation Control 154 Drum Surface Potential Control 160 Toner Density Control 161 Remaining Toner Level Monitoring 163 Waste Toner Monitoring 163 Head Temperature Monitoring 164 Fuser Temperature Monitoring 166 Developing Bias Adjustment...

Page 10: ...Unit Interface 225 LED Array 225 Flash Power Supply 230 Developing Unit 234 High voltage Corona Power Supply 237 7 Troubleshooting 243 Overview 243 Jam Detection Sensors 243 System Block Diagram 244 Hidden Control Menus 245 Global Memory Adjust Menu 246 Printer Control Menu 248 Service Setup Print All Cfg Menu 250 Fanfold Paper Jams 251 Paper Jam near the Tractor 251 Paper Jam near the Paper Outpu...

Page 11: ...ctor Speed Too High 285 Error Code 15 Tractor Speed Too Low 285 Error Code 16 Paper Jam at Entrance A 287 Error Code 17 High Voltage Fail 287 Error Code 18 Drum Motor Fail complete stop 289 Error Code 19 Surface Voltage Too High 290 Error Code 1A Surface Voltage Too Low 291 Error Code 1B Tractor Detent Fail 292 Error Code 1E Fuser Supply Fail 293 Error Code 1F Fuser Failure 294 Error Code 20 Fuser...

Page 12: ...e Engine Checker 318 Disconnecting the Engine Checker 321 Using the Control Panel 321 Operation 322 Basic Menu 323 Device Check Menu 324 Selecting a Mode Item Device 332 Reading Device Status input device check 333 Driving Stopping a Device output device check 333 Volume Adjustment Menu 335 Surface Potential 336 Eraser Lamp 336 Drum Motor 336 Feed Motor 337 Tractor Motor 337 Toner Density 337 Basi...

Page 13: ...e Main Charger Current Control Circuit 365 Confirming the Sleeve Motor Operation 366 Confirming the Magroll Motor Operation 366 Confirming the Toner Supply Clutch Operation 366 Confirming the Head Cooling Fan Operation 366 Confirming the Head Blower Fan Operation 366 Confirming the Drum Counter Operation 367 Confirming the Drum Surface Potential Sensor Operation 367 DC Power Supply Board Adjustmen...

Page 14: ...Table of Contents ...

Page 15: ...Drum 415 Proper Disposal of a Drum Unit 422 Drum Peripheral Equipment 422 Fuser Unit 429 Transfer Assembly 434 Inside the Rear Cover 445 MC Board 446 DC Power Supply Board 448 Motors 450 Fans 463 Solenoids 467 Miscellaneous 468 Under The Top Cover 477 LED Print Head 478 High voltage Corona Power Supply 483 Cutter Unit 484 Sensors and Switches 487 Gates 492 Behind the Stand Cover 493 Smoke Filter 4...

Page 16: ...ceptor Drum 546 Transfer Assembly 548 Fuser Unit 552 Base WT Waste Toner Assembly 558 Back View of Printer 560 Back View of Printer Close up 562 Cut Sheet Output Assembly 566 LED Print Head LED Array 568 Cut Sheet Feeder Assembly 570 Front View Left Side 576 MC PCBA 580 PNE Paper Near End Sensor Assembly 582 Controller Module 584 Head Blower Fan Assembly 590 Developing Unit Drive Assembly 592 Gene...

Page 17: ...eet Feed Motor Encoder FME 643 Paper Guide Interlock Switch ICIL 644 Detection Errors 645 Upper Level Cassette Section Error 645 Lower Level Cassette Section Error 645 Transfer Unit Error 646 Unit Sequencer Section Errors 647 Basic Operation 648 Mechanism Initialization 649 Analog Input Processing 649 Chattering Absorption Processing 649 Status Confirmation Processing 649 Confirmation Processing O...

Page 18: ... EME 678 Swinger Position Sensor SPS Assisting Arm Position Sensor APS1 679 Elevator Upper Limit Switch LIMT1 Elevator Lower Limit Switch LIMT2 680 Safety Sensor 1 SS1 Safety Sensor 2 SS2 681 Elevator Keys ESWA ESWS ESWD ESWH 681 Detection Errors 682 Operator Call Status Errors 682 Service Call Status Errors 682 Basic Operation 683 Status Confirmation Processing 684 Communication Processing 684 Dr...

Page 19: ...Table of Contents Stacker Motor 709 ...

Page 20: ...Table of Contents ...

Page 21: ...ition Designations such as screws 3 represent the number of screws WARNING For safety always disconnect the power supply plug before removing parts Also never operate the printer with parts removed except when performing inspections and adjustments specified in this manual VORSICHT Aus Sicherheitsgründen müssen immer den Netzstecker herausziehen ehe Sie Teile entfernen Niemals den Lader in Betrieb...

Page 22: ...either side and pulling the cover toward you 2 Remove the screw securing the chains on either side Support the cover from below as removing the screws securing the chains will put extra weight on the hinges 3 Remove the screws 2 on each side securing the hinges Front cover Open close button A A Screw Chain Hinge ...

Page 23: ... Left rear cover 1 Remove the screws 5 from the rear side The rear of the printer is shown in the figure below 2 Raise the left rear cover about 1 2 inch 1 cm and remove it from the printer Left rear cover Screws 5 ...

Page 24: ...e paper exit side then remove the plate 2 Loosen the screws 2 that secure the bottom of the connector cover Remove the screws 2 that secure the top of the connector cover and remove the cover Right rear Plate Screws 2 cover Connector cover Screws 4 This view is rotated 90 for clarity ...

Page 25: ...our printer has the optional power stacker installed do the following a Remove the screw with lockwasher securing the stacker ground wire FG wire b Disconnect the stacker connector Screws 2 Screw with lockwasher for stacker ground wire Stacker ground wire FG wire Stacker connector Power stacker models only ...

Page 26: ...ews 8 6 Raise the right rear cover about 1 2 inch 1 cm and remove it from the printer NOTE There are two alignment tabs located on the inside of the right rear cover When installing the cover insert these tabs into their matching slots on the printer Screws 8 Tabs 2 ...

Page 27: ...ove the screws 2 fastening the face up paper output tray to the printer then pull out the tray and remove it from the printer 4 Remove the screws 4 on the paper exit side 5 Loosen the screw that secures the top cover to the rear frame See illustration on page 407 Screws 4 Screws 2 Face up paper output tray ...

Page 28: ...Replacement Procedures 6 Open the front cover Remove the screws 4 and detach the control panel 7 Disconnect the front cover interlock CIL switch connector Front cover interlock switch connector Screws 4 Control panel ...

Page 29: ...Overview 407 8 Lift and remove the top cover from the printer This may require two people one for the paper feed side the other for the paper output side Top cover Screw ...

Page 30: ...over 1 Remove the screws 2 securing the right side of the stand cover 2 Pull the right side of the stand cover slightly forward unhook the two pins in the left side of the cover from the printer and remove the cover Screw Stand cover Pin Screw Pin ...

Page 31: ... are used by the operator on a regular basis Optional cut sheet paper output unit not visible Fuser unit Cleaning unit Discharge LED not visible Main charger Toner cartridge Optional cut sheet paper feeder unit not visible Control panel Developing unit Waste toner recovery unit Transport unit Smoke filter box Flash power supply ...

Page 32: ...ht and left sides of the bottle s neck are the light emitters and receptors of the waste toner bottle full sensor WTBF which detects the full condition To the left lower side of the bottle is the waste toner bottle set sensor WTBS which detects if the bottle is missing or installed incorrectly not properly seated Opening lever Waste toner bottle full sensor Waste toner bottle Cap Waste toner bottl...

Page 33: ...oing the steps below then discard the full bottle Do not reuse the bottle 1 Lower the lever pull the green handle toward you and open the waste toner recovery unit 2 Remove the cap from the outside of the waste toner bottle and cap the bottle Waste toner recovery unit Green handle Opening lever Cap Waste toner bottle ...

Page 34: ...le Waste toner bottle full sensor 1 Remove the waste toner bottle page 411 2 Disconnect the three connectors as shown below 3 Remove the screws 1 each securing the two brackets protecting the light emitters and receptors 4 Remove the screws 1 each securing the Sensor A and Sensor B PC boards and remove the receptors Sensor B PC Board Sensor A PC Board Screws 4 Connectors 3 ...

Page 35: ... sensor WTBS is a limit switch that detects whether the waste toner bottle is set 1 Remove the waste toner bottle page 411 2 Disconnect the three connectors as shown below 3 Remove the screws 2 securing the sensor bracket 4 Remove the sensor Nut Screw Bracket Sensor Screw Connectors 3 ...

Page 36: ... Procedures Waste toner bottle unit 1 Remove the waste toner bottle page 411 2 Disconnect the three connectors as shown below 3 Detach one end of the spring 4 Remove the waste toner bottle unit by lifting it Spring Connectors 3 ...

Page 37: ...ay reduce drum life as much as 50 To replace the drum you will need a drum auxiliary rod Please read all steps before beginning the replacement procedure CAUTION Do note replace the photoreceptor drum unless you have had the appropriate training Do not attempt this procedure without the drum auxiliary rod P N 703531 170 as you may damage the drum 1 Turn the power switch OFF 2 Open the printer fron...

Page 38: ...e three thumbscrews on the upper inner cover then remove the cover 5 Rotate the developing unit lever fully clockwise so that it is pointing straight up to separate the developing unit from the photoreceptor drum Upper inner cover Thumbscrews 3 Lever ...

Page 39: ...ping unit by holding the lever in one hand and pulling the developing unit partially out of the printer 7 With your other hand grasp the hanger and remove the developing unit from the printer 8 Vacuum any spilled toner Developing unit Lever Hanger ...

Page 40: ...osition by rotating the transfer elevator drive shaft counterclockwise Watch the charger movement a If the charger starts to move up it is in the down position b If the charger starts to move down continue to rotate the drive shaft until the charger is all the way down 10 Lower the transport unit by turning the green lever on the transport unit to the left Transfer charger Transfer elevator drive ...

Page 41: ...mbscrews securing the drum plate and remove the drum plate 12 Remove the two screws securing the lower inner cover then remove the cover 13 Remove the nut from the end of the drum shaft Drum plate Thumbscrews 3 Screws 2 Lower inner cover Nut Drum shaft ...

Page 42: ...rum along the drum auxiliary rod Hold the front and back sides when the drum is nearly out of the printer and remove it with both hands 16 Pack the old drum for shipment using its original packaging material and close the cover of the box 17 Wipe the drum shaft clean with a cloth Drum auxiliary rod P N 703531 170 Drum ...

Page 43: ...um up off of the rubber rollers and rotate the drum by hand while applying inward pressure until the drum moves slightly farther into the printer and locks in place CAUTION In order to position the drum slot and the drum shaft pin push the drum in all the way to the back and rotate it until you feel it drop in place Failure to lock the drum in place properly can cause severe damage to the printer ...

Page 44: ...scataway NJ 08854 Attn Rod Storm Phone 908 560 9410 Outside U S A Fuji Electric GmbH Mr Takeshi Kusaba President Mr Kazumasa Ozawa Manager Lyoner Str 26 D 60528 Frankfurt am Main Germany TEL 069 669 0290 FAX 069 666 1020 Drum Peripheral Equipment The equipment listed below is located around the photoreceptor drum Note that the main charger precharger transfer charger and the discharge lamp can be ...

Page 45: ...Precharger PCH Transfer separator charger TCH SCH Any of these chargers can be removed by loosening its thumbscrew and pulling it toward you along the guide rail Main charger thumbscrew Precharger thumbscrew Transfer separator charger thumbscrew ...

Page 46: ...res Discharge lamp PEL 1 Loosen the three thumbscrews on the upper inner cover and remove the cover 2 Remove the discharge lamp screw and pull the lamp toward you along the guide rail Discharge lamp screw Thumbscrews 3 Inner cover upper ...

Page 47: ...thumbscrews on the drum plate then remove the drum plate 2 Grasp the handle of the drum cleaning unit Pull the drum cleaning unit toward you and remove it CAUTION Do not turn the drum cleaning unit upside down or toner might spill Drum cleaning unit handle Drum plate ...

Page 48: ...e transport unit by turning the green lever on the transport unit to the left see steps 9 and 10 on page 418 3 At the rear side of the printer disconnect the connector as shown below 4 Remove the screws 2 as shown below 5 At the front side of the printer remove the screws 2 securing the separator claw assembly then remove the assembly from the front Connector Screws Screws 2 ...

Page 49: ...llar e Remove the separator claw shaft assembly NOTE When installing the separator claw shaft adjust the position of the collar so that there is no wobble 8 If you are replacing the separator claw solenoid do the following a Remove the solenoid connector and solenoid wires from the separator claw assembly b Remove the screws 2 then remove the solenoid Screws 2 Separator claw Shaft E ring Bushing S...

Page 50: ...en remove the roller The upper right roller is attached to the bracket of the drum surface potential sensor To remove this roller first remove the sensor bracket described in the procedure that begins on page 487 then remove the roller from the bracket Each of the three roller assemblies has a replaceable rubber O ring To remove the O ring from the upper right roller you must first remove the drum...

Page 51: ...ch Inbetriebnahme hohe Temperaturen erreicht Vor dem Berühren erst vollständig abkühlen lassen Verkratzen oder berühren Sie niemals die Glasabdeckung mit der Hand Fingerabdrücke auf Lampen führen zu Glasbruch 1 Check that the transfer charger is in the down position then lower the transport unit by turning the green lever on the transport unit to the left see steps 9 and 10 on page 418 2 Loosen th...

Page 52: ...g up The fuser unit contains the following replaceable parts Preheat lamp Halogen lamp HAL Flash lamp Xenon lamp XEL Temperature fuse Lamp duct filter Preheat lamp Flash lamp 1 With the fuser cover glass facing up remove the screws 2 securing the paper guide on the feed side of the unit 2 Remove the screws 6 that secure the glass frame to the fuser box 3 Remove the glass frame Screws Paper guide ...

Page 53: ... to the figure below Working at the rear end of the fuser unit observe the lamp bracket at that end of the fuser unit This bracket is secured with two screws one near the end of the preheat lamp and the other near the end of the flash lamp Remove only the screw closest to the preheat lamp end of the bracket Flash xenon lamp Preheat halogen lamp Rear End of Fuser Unit Front End of Fuser Unit Screw ...

Page 54: ...of the lamp glass will cause a hot spot and the lamp may fail prematurely due to the glass melting or breaking This is also true for the cover glass 8 Carefully flex the bracket slightly and remove the flash lamp There is a bushing on each end of the flash lamp When you remove the lamp be careful not to lose the bushings Temperature fuse 1 Remove the screw securing the fuse holder to the fuser box...

Page 55: ...he fuser unit then remove the lamp duct filter unit and the foam gasket 2 Remove the screws 2 that secure the filter holding plate to the lamp duct filter unit then remove the filter holding plate and the lamp filter Foam gasket Screw 2 Filter holding plate Lamp filter air filter Lamp duct filter unit Screw 2 ...

Page 56: ...s Transfer Assembly 1 Check that the transfer charger is in the down position then lower the transport unit by turning the green lever on the transport unit to the left see steps 9 and 10 on page 418 2 Pull the assembly out until it stops ...

Page 57: ... replaceable parts are on the transfer assembly Transport belt Vacuum fan VAF Elevator paper start sensor Elevator paper intermediate sensor Connector block for the transfer separator charger Varistor Transport belt When replacing the transport belt the transfer assembly must be turned upside down When turning the unit upside down be sure to put a rest Screws Slide rail ...

Page 58: ... vacuum fan and disconnect its connector 2 Disconnect the cables from the three 3 cable clamps 3 Restore the transfer assembly to its original right side up position 4 Referring to the figure below remove the screws 2 on the front 2 on the rear securing the output guide then remove the output guide Connector Screw Transfer assembly Vacuum fan Green lever Screw Output guide Transfer assembly ...

Page 59: ...to the figure above slip the outer drive shaft bearings 2 out of their holes in the unit frame then slide them toward the outer ends of the drive shaft 8 Referring to the figure above remove the screw 1 fastening the red high voltage wire to the conveyer base 9 Referring to the figure above remove the conveyer base from the unit frame Outer bearing Outer e ring Stainless plate Outer e ring Conveye...

Page 60: ...g to the figure above slip the inner drive shaft bearings 2 out of their holes in the conveyer base then slide them toward the outer ends of the drive shaft 12 Remove the drive shaft from the conveyer base then remove the three 3 transport belts as shown below Inner bearing Inner e ring Inner e ring Conveyer base Drive shaft Inner bearing Transport belt 3 ...

Page 61: ...ner surface has an irregular pattern Adjust the distance between the drive shafts according to the length of the belt 13 To adjust the belt tension refer to the figure below and loosen the screws 2 right 2 left securing the belt shaft to the conveyer base then adjust the tension of the belts by turning the set screws with a hex wrench Outer surface of belt Inner surface of belt Conveyer base Screw...

Page 62: ...figure below adjust the distance between the belt and the conveyer base to approximately 1 cm when the belt center is pulled up with a force of 200 grams Firmly tighten the screws 2 right 2 left to secure the belt shaft to the conveyer base Belt Conveyer base ...

Page 63: ...sembly from the printer to remove these parts However the vacuum fan must be removed in order to remove the EPS4 sensor 1 Check that the transfer charger is in the down position then lower the transport unit by turning the green lever on the transport unit to the left see steps 9 and 10 on page 418 2 Pull the assembly out until it stops ...

Page 64: ...3 mounting screws 2 as shown below 4 Disconnect the EPS3 sensor assembly cable connector not shown then remove the sensor assembly from the transport assembly EPS4 Sensor Assembly EPS3 Sensor Assembly EPS4 mounting screws 2 Fan plenum Fan connector EPS3 mounting screws 2 Screws 2 remove Vacuum fan Screws 2 loosen ...

Page 65: ...PS4 sensor assembly cable connector not shown then remove the sensor assembly from the transport assembly TC Connector block of the transfer separator charger The TC connector block of the transfer separator charger is attached to the unit frame on the rear side of the transport unit When replacing this connector block replace the terminal block that is connected by cable at the same time 1 Remove...

Page 66: ...Remove the screws front side and rear side 1 each securing the transport paper guide 2 Remove the transport paper guide 3 Remove the screws 2 securing the varistor terminal and remove the varistor Transport paper guide Varistor Screws Spacer Screws 2 ...

Page 67: ...ll motor Sleeve motor Head cooling fan Fuser reflector plate cooling fan Main unit feed motor DC power supply Lamp cooling blower NOTE Some versions of the L5035 printer have flash memory located on the controller PCBA These printers have no diskette drives Transfer elevator motor Smoke filter blower not visible in figure attached to duct ...

Page 68: ... adjustments See the section titled MC Board Adjustments on page 343 in Chapter 9 Adjustment Procedures 1 Turn OFF the power switch on the printer 2 Remove the left rear cover as described on page 401 3 Disconnect the connectors 22 from the MC board 4 Remove the screws 6 securing the MC board Refer to the following figure ...

Page 69: ...Inside the Rear Cover 447 Screws Screws Screws ...

Page 70: ...igure on the next page and remove the two lower screws holding the power supply cover 6 Loosen but do not remove the two upper screws holding the power supply cover then remove the cover The DC power supply board will be visible inside the power supply 7 Disconnect all of the connectors that are connected to the DC power supply board 8 Remove the screws 2 securing the two terminals of the noise EM...

Page 71: ...Inside the Rear Cover 449 DC power supply board Power supply cover Screws 4 Circuit breaker lever A A ...

Page 72: ...ctor through the hole in the frame as shown in the figure below 3 Remove the pulley drive belt 4 Remove the set screw 1 which attaches the motor pulley to the rotating shaft using the hex wrench 5 Remove the screws 3 fastening the cutter motor to the frame then remove the motor A new cutter motor may now be installed Screw Pulley Set screw Pulley drive belt Connector ...

Page 73: ... Cover 451 Drum motor 1 Remove belts A B and C as described on page 469 2 Remove the screws 3 securing the motor cover and remove the motor cover by moving it downward as shown in the figure below Motor cover Screws 3 ...

Page 74: ... figure below 4 Loosen the setscrew using the hex wrench then remove the flywheel 5 Remove the screws 4 that hold the drum motor to the printer base then remove the drum motor from the paper feed area 6 Disconnect the connectors 2 and remove the drum motor Connectors 2 Screws 4 Flywheel Tab washer Set screw E ring ...

Page 75: ...e below disconnect the connectors 2 one for the sleeve motor the other for the magroll motor 2 Remove the screws 8 that secure the assembly bracket with motors to the printer then remove the bracket with the motors attached Bracket Sleeve motor Magroll motor Connectors Bracket screws 8 ...

Page 76: ...otors to the assembly bracket 4 Loosen the setscrews 4 then remove the gears 2 from the motor shafts 5 Remove the motors from the bracket 6 If you are replacing gear 3 refer to the figure above and remove the E ring that secures the gear to the shaft E ring Gear 3 Gear Gear Setscrews Motor screws 8 Bracket ...

Page 77: ...an connect them properly when you reinstall the motors 2 Disconnect the sensor connectors 2 3 Remove the sensor wires from the cable clamps 2 4 Mark the motor power connectors 2 for identification 5 Disconnect the motor power connectors 2 6 Remove the motor power wires from the harness clamps 2 located under the motor bracket 7 Remove the harness clamps 2 from the motor bracket Motor bracket Power...

Page 78: ...s 2 from the motor then remove the sensor bracket with the sensors attached 11 Remove the screw 1 fastening the encoder 19 disk to the end of the motor shaft then remove the encoder 19 disk 12 Using a hex wrench loosen the setscrew 1 fastening the encoder 20 disk to the motor shaft then remove the encoder 20 disk Belt 703531 031 Feed motor Motor bracket Screws 3 Setscrew Encoder 19 disc Screw Enco...

Page 79: ...Inside the Rear Cover 457 13 If you are replacing the sensors remove the screws 1 each that secure the sensors to the sensor bracket Sensors Screw Sensor bracket Screw ...

Page 80: ...458 Chapter 10 Replacement Procedures Tractor motor tractor drive belts Belt A is removed first belt B second Belt A 703531 031 Belt B 703531 031 ...

Page 81: ...nside the Rear Cover 459 1 Remove the MC board retaining screws 3 shown in the figure below then swing open the MC board support assembly on its hinges Screws 3 MC board Hinged MC board support assembly ...

Page 82: ...ect alignment of the fan fold paper inscribe alignment marks on pulleys C and S as shown in the figure below Then remove belt A by rotating pulley C and remove belt B by rotating pulley S Pulley C Belt A Pulley S Motor pulley Belt B Alignment marks Belt A Belt B ...

Page 83: ...onnectors 2 b Remove the screws 4 fastening the tractor motor to the printer base c Remove the tractor motor by pulling it through an opening in the paper feed guide d Install the new tractor motor by reversing steps a through c above 4 Reinstall belts A and B making sure that the motor pulley and pulleys C and S are in alignment as shown below Screws Connectors Alignment marks ...

Page 84: ... the cable clamp and disconnect the motor connector 3 Remove the screws 4 that secure the transfer elevator motor to the bracket then remove the transfer elevator motor from the bracket 4 Using a hex wrench loosen the setscrew 1 on the coupling then remove the coupling from the motor shaft SCREW CONNECTOR COUPLING SETSCREW ...

Page 85: ...ear Cover 463 Fans Head cooling fan HCF 1 Disconnect the head cooling fan connector 2 Remove the screws 2 securing the bracket to the main unit then remove the fan with the bracket attached CONNECTOR BRACKET SCREWS ...

Page 86: ...464 Chapter 10 Replacement Procedures 3 Remove the screws 2 securing the head cooling fan to the bracket BRACKET HEAD COOLING FAN SCREW ...

Page 87: ... adhering to the head A filter is attached to the intake to prevent dust from clogging the duct s draft hole 1 Disconnect the fan connector from the main unit 2 Remove the screws 3 fastening the head blower fan and air filter to the bracket 3 The duct is secured to the front side by one screw and can be extracted from the back side by removing the screw Head blower fan Screws 3 Connector LED air f...

Page 88: ...cedures Fuser reflector cooling fan FCF To remove the fuser reflector cooling fan disconnect the connector and remove the screws 4 securing the fan and fan plate to the duct Duct Connector Fuser reflector cooling fan Fan plate Screw ...

Page 89: ...the connector for the solenoid you want to remove 2 Remove the screw securing the solenoid to the printer Cutter solenoid CSL 1 Disconnect the connector 2 Remove the screws 2 securing the solenoid mounting bracket to the printer Face gate solenoid Connectors Screws Paper exit gate solenoid Bracket Screw Cutter solenoid Connector ...

Page 90: ...he rotation axis Main charger MCH Varistor 1 One terminal of the main charger varistor is connected to the main charger connector via high voltage cable Remove the screw securing this varistor terminal to the high voltage connector 2 Remove the screws securing the other varistor terminal to the rear panel Tension arm E ring Varistor Screws 3 ...

Page 91: ...ver 469 Drum motor drive belt Three 3 belts are installed with the drum motor drive unit These belts must be removed in the following order Belt A Belt B then Belt C Belt A 703531 032 Belt B 703531 031 Belt C 703531 031 ...

Page 92: ...downward on the tension roller and remove Belt A from Pulley E 2 Remove Belt B by turning Pulley F 3 Remove Belt C by turning Pulley G NOTE New belts are installed in the reverse order Belt A Pulley E Pulley F Pulley G Tension roller Belt B Belt C ...

Page 93: ...r A B D E and C 1 Remove belt A by removing the tension roller spring and pulling the tension roller upward 2 Remove the E ring from the shaft on which pulley G is mounted 3 Remove belt B and pulley G by turning pulley G Belt E 703531 030 Belt D 703531 029 Belt A 703531 028 Belt B 703531 031 Belt C 703531 031 Tension roller Tension roller spring Pulley G Belt A E ring Belt B ...

Page 94: ...lange 5 Remove belts D and E 6 Remove belt C from around pulley H by turning pulley H 7 Remove the screws 3 that secure the feed motor bracket to the printer frame then remove the feed motor with its bracket attached Belt E Flange Screw Belt D Pulley H Belt C Printer frame Feed motor bracket Feed motor Screws 3 ...

Page 95: ...oved Face down paper out drive belt To remove this belt slacken the belt by pulling the tension roller toward the right Pickup roller units Two pickup roller units upper and lower are located at the back of the cassette opening Belt 703531 034 Tension roller Upper pickup roller unit Lower pickup roller unit ...

Page 96: ... On the lower pickup roller unit loosen the green thumbscrew Slide the unit to the left and pull the unit toward you and out of the printer 4 When installing either pickup roller unit refer to the figure below and proceed as follows a Align the shaft pin with the slot in the coupling and align the alignment pin on the unit with the hole in the frame b Tighten the green thumbscrew Thumbscrew Alignm...

Page 97: ...upper and lower pickup roller units 1 On the upper reverse roller unit loosen the green thumbscrew Remove the unit by moving it downward while sliding it to the left 2 On the lower reverse roller unit loosen the green thumbscrew Remove the unit by moving it downward while sliding it to the left Upper reverse roller unit Lower reverse roller unit Thumbscrews ...

Page 98: ...igure below and proceed as follows a Align the shaft pin with the slot in the coupling and align the alignment pin on the unit with the hole in the frame b Tighten the green thumbscrew 4 Install the upper and lower paper cassettes into the printer Hole in the frame Coupling Alignment pin Shaft pin ...

Page 99: ...ed under the top cover top view shown Drum surface potential sensor NIP switch LED print head Drum cleaner set sensor Paper exit sensor 1 Paper exit sensor 0 High voltage corona power supply Rear Side of Printer Front Side of Printer Top View of Printer with Top Cover Removed ...

Page 100: ...ermal compound see page 38 for part numbers The LED positioning pins are used to align the print head when installing it 1 Remove the developing unit as described in the User s Manual 2 Disconnect the connectors from the LED print head and remove the screw on the head thermistor terminal Connectors Screw Head thermistor terminal Connector ...

Page 101: ...Under The Top Cover 479 3 Remove the screws 3 on the metal fittings which hold the heat pipe then remove the heat pipe by moving it toward the rear Screws 3 Heat pipe ...

Page 102: ...nt head insert the LED positioning pins 2 pins 1 right 1 left into the center holes as shown above Place the LED print head in its original position Make sure the positioning pins align with the holes on the print head 6 After positioning the print head insert the screws 4 into the proper screw holes as shown above tighten them firmly then remove the LED positioning pins 2 LED positioning pin LED ...

Page 103: ...d the heat pipe and fasten the thermistor terminal to the metal fittings 9 Connect the print head connectors to their original positions 10 If the new print head that you installed has a print density dpi value that is different from the old print head then set the print density DIP switches on the MC board as shown in the following figure ...

Page 104: ... OFF Fanfold paper This switch is active for fanfold paper only Cut sheet paper Reserved 1 2 3 4 Paper 1 Print density 3 4 Fanfold Cut Sheet ON OFF 400 dpi 300 dpi 240 dpi OFF OFF ON OFF ON ON 3 and 4 are for print density setting see chart below ...

Page 105: ...he signal name is not visible mark or tag the wire so that later you can connect it to the proper terminal on the new high voltage power supply See the Caution notice below 5 Remove the screws 4 securing the power supply to the printer frame then remove the power supply from the printer CAUTION When installing the high voltage power supply be sure to connect the connectors properly The signal name...

Page 106: ...at are molded into one piece The middle pulley is much larger than the two outside ones Although the two outside pulleys appear to be the same size they are not If the outside pulleys are reversed a jam results IMPORTANT In order to avoid putting pulleys on backwards mark their outside edges with white 1 If necessary remove the rear belts by lifting the tension roller it may not be necessary to re...

Page 107: ...nder The Top Cover 485 2 Remove the screws 2 each front and rear that secure the cutter unit to the printer 3 Disconnect the connectors to the cutter motor and cutter sensor in the rear Screws Connectors ...

Page 108: ...486 Chapter 10 Replacement Procedures 4 Remove the cutter unit by pulling it downward from the rear side The front is obstructed by the front panel Cutter unit Screws ...

Page 109: ...ors and Switches Drum surface potential sensor DSPS 1 Remove the MC board retaining screws 3 shown in the figure below then swing open the MC board support assembly on its hinges Screws 3 MC board Hinged MC board support assembly ...

Page 110: ...eplacement Procedures 2 Remove the screws 4 securing the DSPS PCBA as shown below 3 Remove the screw 1 securing the sensor bracket as shown above 4 Remove the screws 2 on the front side DSPS PCBA Screws 4 Screw Screws ...

Page 111: ...res Drum cleaner set sensor The drum cleaner set sensor is a limit switch that detects whether the drum cleaner is set that is in its correct operating position The sensor is a microswitch it is mounted on the inside of the rear panel such that its switch contacts close when the drum cleaner is set 1 On the rear side of the printer disconnect the harness connector from the microswitch contacts Dru...

Page 112: ...and transport speed of the paper The nip switch detects whether the scuff roller that sends paper from the fuser to the paper output section is nipping In order to remove this sensor and switch you must first remove the paper output section paper retainer the face down paper output tray paper guide and the output paper guide See Cutter Unit on page 484 Paper exit sensor 0 EPS0 1 Disconnect the con...

Page 113: ...e paper output side 2 Insert your hand from the top of the rear panel and remove the switch bracket with the switch attached 3 Disconnect the connector from the switch 4 Remove the screws 2 securing the switch to the bracket Paper exit sensor 1 EPS1 Paper exit sensor 1 is located on the paper guide under the paper output roller at the output to the face up paper output tray 1 Disconnect the connec...

Page 114: ... controlling solenoid The two solenoids are the paper exit gate solenoid EGSL and the face gate solenoid FGSL Both solenoids are located on the rear side of the printer To remove either of the gates 1 Remove the screw securing the solenoid for the gate you want to remove 2 Remove the E rings 2 attached to each end of the gate shaft one at the front panel and one at the rear panel Screw Face gate s...

Page 115: ...and Cover 493 Behind the Stand Cover Smoke Filter 1 Loosen the thumbscrew on the front and open the cover of the filter box 2 Pull the metal fitting out about 3 4 inch 20 mm and unlock Smoke filter Thumbscrew Lever ...

Page 116: ...ts to be completely discharged before proceeding to the next step When removing the high voltage cables mark or tag the cables and their terminals with identifying marks so that later you can properly reconnect the cables VORSICHT Beim Auswechseln des Blitzlampen Netzteils ist folgendes zu beachten Nachdem Sie die Stromzufuhr unterbrochen haben müssen Sie mindestens 5 Minuten lang warten damit sic...

Page 117: ...ectrical outlet 3 Wait at least 5 minutes for the high voltage DC charge in some components to be completely discharged before proceeding to the next step See the WARNING notice above 4 Remove the right rear cover see page 402 5 Remove the stand cover see page 408 and the figure below Pin Stand cover Screws 2 Flash power supply Pin ...

Page 118: ... Open the cover of the AC line terminal strip on the flash power supply and disconnect AC lines L black and N white 8 Remove the screw securing the ground wire FG wire to the printer frame Connector J11 to MC board AC line terminal strip Screw AC lines Connector TRG trigger to lamp trigger coil Rear side of printer Ground wire FG wire ...

Page 119: ...or tag the high voltage cables and their corresponding high voltage terminals on the fuser unit so that you can reconnect them properly later 11 Remove the screws 2 securing the high voltage cables 2 to the high voltage terminals on the fuser unit Fuser unit Screws 2 High voltage cables from flash power supply High voltage terminal covers ...

Page 120: ...8 Chapter 10 Replacement Procedures 12 At the front side of the printer remove the screws 2 securing the flash power supply to the printer frame as shown in the figure below Front side of printer Screws 2 ...

Page 121: ...h power supply and pull it out If you cannot pull it out refer to the figure that follows and loosen the screws 4 securing the metal fittings 2 on the rear of the flash power supply Then try pulling out the flash power supply again Rear side of printer Metal fittings 2 Screws 4 ...

Page 122: ...e ends of the high voltage cables from the new flash power supply to the approximate area of the fuser high voltage terminals 21 At the front of the printer align the screw holes 2 on the flash power supply with their corresponding holes on the base of the printer frame Insert the screws 2 and tighten them firmly 22 At the rear of the printer firmly tighten the screws 4 on the metal fittings loose...

Page 123: ... components to be completely discharged before proceeding to the next step When removing the wires connected to the capacitor terminals mark or tag the wires and their terminals with identifying marks so that later you can properly reconnect the wires VORSICHT Beim Auswechseln des Kondensators des Blitzlampen Netzteils ist folgendes zu beachten Nachdem Sie die Stromzufuhr unterbrochen haben müssen...

Page 124: ...placement Procedures 1 Remove the flash power supply as described earlier page 494 2 Remove the screws 8 fastening the front cover of the flash power supply then remove the cover Flash power supply Front cover Screws 8 ...

Page 125: ...he screws 8 fastening the left cover of the flash power supply then remove the cover 4 Refer to the figure that follows and mark or tag the wires connected to the capacitor so that you can reconnect them properly later Left cover Screws 8 ...

Page 126: ...504 Chapter 10 Replacement Procedures Screws 4 Screw Nuts 2 Lockwashers 2 Ground wire FG wire ...

Page 127: ...capacitor to the base of the flash power supply 8 Remove the capacitor from the flash power supply 9 Replace the capacitor with a new one by reversing the above steps 10 Reinstall the flash power supply Other Tractor Removal The tractors are secured by the tractor splined shaft and tractor support shaft as shown below and are removed as described in the steps that follow Tractor support shaft Trac...

Page 128: ... 1 Remove the tractor drive belt belt A see page 458 2 On the front side of the printer remove the E ring securing the tractor splined shaft Remove the bearing not shown 3 Remove the screw 1 securing the tractor support shaft Screw E ring ...

Page 129: ...t 6 On the rear side of the printer remove the screw securing the tractor support shaft then remove the tractors and the tractor support shaft from the paper feed side NOTE After removing and replacing tractors adjust the tractors by performing the tractor adjustment procedure that begins on the following page Tractor support shaft E ring Screw Tractor splined shaft ...

Page 130: ...ss the shaft without binding and helps the paper to stay on the tractor pins after page ejects IMPORTANT If the tractor shaft is not aligned properly the tractor holes in the fanfold paper may be damaged when the paper back feeds NOTE To make the adjustment you will need two tractor alignment tools see page 38 for part number 1 Power off the printer 2 Remove the left rear cover see page 401 3 Unlo...

Page 131: ...he tractor alignment tools between the tractor splined shaft and the tractor support shaft one at each end over the bearings on the splined shaft Press the alignment tools flush toward the outside against the frame of the printer Left tractor spacer Tractor alignment tool Frame Tractor support shaft Tractor splined shaft Tractor alignment tool ...

Page 132: ...ractor support shaft on the left side frame 10 Right side adjustment Repeat the procedure in step 9 above on the right side frame 11 Ensure that the tractor alignment tools can be easily removed If they are too tight or too loose make the adjustments in steps 9 and 10 again 12 Remove the tractor alignment tools 13 Return the left tractor spacer left and right tractors and E ring to their original ...

Page 133: ...s nicht mit den Händen in den Traktorbereich Sehen Sie während des Druckvorgangs nicht in den Traktorbereich da im Traktorbereich Streulicht von der Fixiereinheit reflektiert wird 16 Repeat step 15 above at least ten times including pressing the page eject key This verifies that the paper feeds properly during paper parking as well as during forward paper motion Paper Back Feed Sensor PBFS Top of ...

Page 134: ...ing board cover then remove the cover 2 Remove the screw 1 securing the photoemitting board bracket to the paper near end sensor assembly 3 Remove the screw 1 securing the photoemitting board to the photoemitting board bracket 4 Disconnect the connector from the photoemitting board Connector Sensor Screws 2 Screws 2 Sensor bracket ...

Page 135: ... photoreceptor board bracket to the paper near end sensor assembly 3 Remove the screw 1 securing the photoreceptor board to the photoreceptor board bracket 4 Disconnect the connector from the photoreceptor board Photoemitting board bracket Connector Photoemitting board Screw Screw Paper near end sensor assembly Photoemitting board cover Screws 4 ...

Page 136: ...ring the control panel to the printer 2 Disconnect the cable connector from the connector on the rear of the control panel then remove the panel Connector Photoreceptor board Photoreceptor board bracket Paper near end sensor assembly Screw Screws 4 Photoreceptor board cover Screw ...

Page 137: ...drives not used on printers with flash memory In addition the controller board contains socketed terminating resistors for the parallel interface The values of these resistors might need to be changed for some parallel interface applications Removal and replacement procedures for each of these items are given in the following pages Screws 4 Cable connector ...

Page 138: ...4 each from the host interface panel and remove the panel See Figure 1 6 Loosen the screws 2 securing the controller board retaining brackets 2 then remove the screws and brackets not shown in Figure 1 7 Grasp the edge of the controller board and pull it slightly out of the card cage to gain access to the ribbon cables connected to the edge mounted connectors on the controller board See Figure 1 8...

Page 139: ...val Installation Floppy disk drives Ref Not used on flash memory equipped printers Host interface panel Washers 4 Controller board Flash memory equipped printers Flash memory Ref Controller board Floppy drive equipped printers Screws 4 Controller module ...

Page 140: ...ing NVRAM IC is socketed always move the existing NVRAM from the old controller board to the new board The NVRAM IC stores the page count data as well as other data that are unique to a particular print engine Figure 2 NVRAM Removal Installation Installation CAUTION To prevent electrostatic damage to electronic components always wear a properly grounded static wrist strap when you handle circuit b...

Page 141: ...rinter 9 Download the emulation s page 374 10 Using the configuration printout s you made in step 1 of the removal procedure restore the printer configuration s Refer to the User s Manual Terminating Resistors For parallel interface configurations the printer is equipped with 470 ohm pullup terminating resistors and 1K ohm pulldown terminating resistors on the controller board These are suitable f...

Page 142: ...all the resistor packs in their correct sockets on the controller board Be sure to orient each resistor pack correctly See the figure on the following page 2 Install the controller board page 516 Controller Board RP28 RP29 Terminating Resistors Removal and Installation ...

Page 143: ...unting hole See the illustration on the following page 7 Remove one nut and disconnect the green yellow power supply ground lug from the standoff screw on the module 8 Remove the screws 4 securing the power supply to the side panel of the module 9 Lift the power supply partially out of the module to access the lugs connected to the terminal strip Remove each terminal strip screw and remove all lug...

Page 144: ...522 Chapter 10 Replacement Procedures Controller module Power supply Side cover A A Rotated for clarity AC connector ...

Page 145: ...dule side cover See the illustration on the following page 5 Disconnect the fan power cable connector and remove the cable tie wrap not shown 6 Remove the screws and washers 2 each securing the fan 7 Lift the cooling fan out of the controller module 8 To install the fan reverse the above steps Controller module Side cover Floppy disk drives Ref Not used on flash memory equipped printers Fan ...

Page 146: ...d power cables from the floppy disk drives If necessary tag the interface cables for identification to ensure that each cable is reconnected to its proper drive later 6 Remove the screws 4 which hold the two disk drive brackets to the controller module Remove the bracket and floppy disk drives from the printer 7 Remove the screws 2 which secure each drive to the bracket 8 To install the disk drive...

Page 147: ...Controller Module 525 Controller module Floppy disk drives 2 Bracket Side cover ...

Page 148: ...526 Chapter 10 Replacement Procedures ...

Page 149: ...ng cutting perforation to main folding cutting perforation Tractor pin holes See the table below and the follow ing figure Specification Inch Millimeter Dimension in Figure Pin hole center to folding perforation 1 6 1 4 1 3 or 1 2 N A A Hole center line to edge of form 0 236 0 028 6 0 0 1 B Hole diameter 0 156 0 004 4 0 0 1 N A Distance between centers of two consecutive holes 0 500 0 002 12 7 0 0...

Page 150: ...atic paper parking mechanism incorporated Fanfold paper 3000 sheets 17 lb Cut sheet paper 250 and 500 sheets 17 lb Paper output Fanfold paper 2000 sheets into power stacker 17 lb Maximum stack is 9 3 inches high Cut sheet paper 250 sheets each into face up and face down trays B Center line Main folding cutting perforation Fanfold paper A Tractor pin hole E C D Center line deviation ...

Page 151: ...art numbers are not listed for common fasteners Parts marked Ref reference are not spared or are part of another assembly In illustrations magnified details are shown with locator arrows and letters Assemblies you can order as kits are shown in the following notation NOTE For replacement procedures for consumables see the User s Manual For replacement procedures for nonconsumable items see Chapter...

Page 152: ...MXL 4 ea set 703531 055 575 Belt 91MXL 703531 056 575 Belt DS3M 300 6 703531 048 Belt Elevator 703531 043 Belt MXL 535 6 4 703531 027 613 Belt S3M 247 6 703531 046 Belt S3M 275 6 2 ea set 703531 047 Belt S3M 84 6 4 ea set 703531 045 Belt Stacker 8 ea set 703531 042 Belt Swinger 703531 044 Belt Tractor Drum 60S3M264 703531 031 579 Belt Transporting 3 ea set 703531 035 551 Cable Assembly Diagnostic ...

Page 153: ...y 703531 135 627 Charger Main 705741 001 541 Charger Transfer 705743 001 551 Cleaning Unit Rebuildable 705740 001 541 Connector Assembly for Transfer Ozone 703531 147 565 605 Connector Assembly High Voltage 703531 127 551 Connectors for High Voltage Corona Power Supply set of 5 703531 063 561 Connector Fuser FU Male 2 ea set 703531 113 557 Control Panel Assembly 704912 901 541 Control Panel Overla...

Page 154: ...xit Gate Solenoid 1 703531 123 613 EGS2 Assembly Exit Gate Solenoid 2 703531 124 613 EPS0 Assembly Paper Motion Sensor 703531 131 627 EPS3 Assembly 703531 125 551 EPS4 Assembly 703531 126 551 Fan Assembly Vacuum 703531 109 551 Fan DC Power Supply L5035 202836 001 607 Fan Fuser Cooling 703531 105 617 Fan Head Blower 2ea set 703531 104 591 Fan Lamp Cooling Blower VEF1 703531 117 565 601 Fan Smoke Fi...

Page 155: ...4 Harness Assembly Power Supply 703531 164 564 Harness Feed P003 Cable Harness 703531 076 575 Harness Feed P004 Wire Harness 703531 077 575 Harness Feed P031 Cable Harness 703531 078 575 Harness for Stacker J011 703531 094 Harness for Stacker J012 703531 095 Harness for Stacker J013 703531 096 Harness for Stacker J018 703531 098 Harness for Stacker J033 703531 097 Harness for Stacker P001 703531 0...

Page 156: ...1 081 Microswitch 703531 074 Microswitch V 014 1C23 703531 106 559 Motor Assembly 2 ea set 703531 053 575 Motor Assembly Drum L5035 705733 009 579 Motor Assembly Elevator 703531 079 Motor Assembly Elevator 703531 141 564 Motor Assembly Feed 703531 040 613 Motor Assembly Magroll 705733 011 593 Motor Assembly Sleeve 705733 010 593 Motor Assembly Stacker 703531 049 Motor Assembly Tractor 703531 041 5...

Page 157: ... ROM Option 1 Feeder 703531 070 575 Pipe Cleaning Assembly 703531 146 Plate Cutter Assembly 703531 136 Plate Drum 703531 140 541 Plate Swing 703531 011 539 Power Supply Assembly in Controller Module 141235 002 589 Power Supply Flash L5035 705733 006 565 603 Power Supply High Voltage Corona L5035 705733 005 561 Precharger 705742 001 541 Pulley Drum 3M 51 28 706291 001 579 Pulley Tension Drum Assemb...

Page 158: ...r Photo Interrupter PHINT ON1517LA A 13ea set 703531 100 Sensor Photo Interrupter PHINT ON1517LA A 2ea set 703531 075 551 575 579 597 613 615 627 Sensor Photo Interrupter PHINT ON1517LA A 8ea set 703531 086 613 Sensor Thermal 703531 161 Sensor Top of Form 703531 232 579 Separating Finger Assembly 703531 052 627 Shaft Assembly Drum 703531 144 564 Shaft Cut Sheet Feeder Gear 703531 525 575 Solenoid ...

Page 159: ...artridge 703532 001 543 Tractor Assembly 703531 114 579 Transfer Assembly 703531 137 541 Transport Unit Shaft A Assembly 703531 212 551 Transport Unit Shaft B Assembly 703531 224 551 Tray Assembly Face Up 703531 166 539 Trigger Coil 703531 165 Varistor Assembly Transfer Charger 703531 103 551 Item Part Number Page ...

Page 160: ...538 Appendix B Illustrated Parts List Figure 3 Front View of Printer 5 10 15 20 25 30 35 40 45 50 55 60 65 ...

Page 161: ...ssette S250 A4 1 20 703531 006 Cassette S250 Letter 1 25 703531 007 Cassette S250 B4 1 30 703531 008 Cassette S250 A3 1 35 703531 009 Cassette S250 Legal 1 40 703531 010 Cassette S250 Ledger 1 45 703531 011 Swing Plate 1 50 703531 166 Face Up Tray Assembly 1 55 703531 524 Cover Front Stand Painted 1 60 703531 204 Front Cover Assembly 1 65 See Figure 4 For Close up View ...

Page 162: ...540 Appendix B Illustrated Parts List Figure 4 Printer Front Cover Assembly Open 22 20 15 10 5 22 55 25 30 40 45 50 35 65 60 ...

Page 163: ...ing Unit Rebuildable See Figure 7 Item 5 For Details 1 22 703531 595 Latch Front Cover 2 25 703531 137 Transfer Assembly See Figure 8 For Details 1 30 203283 001 Fuser Unit See Figure 9 For Details 1 35 703531 140 Plate Drum 1 40 705742 001 Precharger See Figure 6 Item 15 For Details 1 45 703535 001 Photoreceptor Drum See Figure 7 Item 10 For Details 1 50 Base WT Assembly See Figure 10 For Details...

Page 164: ...542 Appendix B Illustrated Parts List Figure 5 Developing Unit 5 10 15 15 Ref A A ...

Page 165: ...Item No Part No Description Figure 5 Developing Unit Quantity per Assembly 5 705739 001 Developing Unit Rebuildable 1 10 703532 001 Toner Cartridge 1 15 703548 001 Developer Powder Bottle includes Nozzle 1 ...

Page 166: ...544 Appendix B Illustrated Parts List Figure 6 Miscellaneous Details 5 10 15 ...

Page 167: ...545 Item No Part No Description Figure 6 Miscellaneous Details Quantity per Assembly 5 705741 001 Main Charger 1 10 703531 118 Discharge LED Assembly Erase LEDs 1 15 705742 001 Precharger 1 ...

Page 168: ...546 Appendix B Illustrated Parts List Figure 7 Cleaning Unit and Photoreceptor Drum 5 10 ...

Page 169: ...547 Item No Part No Description Figure 7 Cleaning Unit and Photoreceptor Drum Quantity per Assembly 5 705740 001 Cleaning Unit Rebuildable 1 10 703535 001 Photoreceptor Drum 1 ...

Page 170: ...548 Appendix B Illustrated Parts List Figure 8 Transfer Assembly Sheet 1 of 3 A 20 5 10 15 16 Item 16 is not part of this assembly ...

Page 171: ...549 Figure 8 Transfer Assembly Sheet 2 of 3 A B 28 29 26 27 26 27 25 26 27 30 30 30 ...

Page 172: ...550 Appendix B Illustrated Parts List Figure 8 Transfer Assembly Sheet 3 of 3 B 55 65 60 45 40 45 35 50 ...

Page 173: ... 212 Transport Unit Shaft A Assembly 1 26 703531 554 Bearing Conveyer 2 27 703531 553 Holder Bearing 2 28 703531 224 Transport Unit Shaft B Assembly 1 29 703531 589 Stop Bracket 3 30 703531 035 Transporting Belt 3 35 703531 126 EPS4 Assembly 1 40 703531 067 Jam Sensor Lever EPS4 1 45 703531 075 Sensor Photo Interrupter PHINT ON1517LA A 1 50 703531 109 Vacuum Fan Assembly 1 55 703531 125 EPS3 Assem...

Page 174: ...552 Appendix B Illustrated Parts List Figure 9 Fuser Unit Sheet 1 of 4 A 5 ...

Page 175: ...553 Figure 9 Fuser Unit Sheet 2 of 4 A B C D 10 15 ...

Page 176: ...554 Appendix B Illustrated Parts List Figure 9 Fuser Unit Sheet 3 of 4 B C 20 25 ...

Page 177: ...555 Figure 9 Fuser Unit Sheet 4 of 4 D 30 35 This view is rotated 180 ...

Page 178: ...556 Appendix B Illustrated Parts List Parts lists continue on next page ...

Page 179: ...001 Lamp Housing Filter L5035 1 10 703531 138 Glass Frame Assembly This Assembly Includes Six Items 1 15 703531 066 Fuser Cover Glass 1 20 703531 113 Connector Fuser FU Male 2 ea set 1 25 703531 102 Fuser Fuse Assembly 1 30 703541 001 Xenon Lamp Assembly 1 35 703531 065 Halogen Lamp 1 ...

Page 180: ...558 Appendix B Illustrated Parts List Figure 10 Base WT Waste Toner Assembly 10 5 15 20 Item 20 is not part of this assembly ...

Page 181: ...ption Figure 10 Base WT Waste Toner Assembly Quantity per Assembly Base WT Waste Toner Assembly 5 703531 153 Sensor A PCBA 1 10 703531 106 Microswitch V 014 1C23 1 15 703531 154 Sensor B PCBA 1 20 703539 001 Waste Toner Bottle 1 ...

Page 182: ...560 Appendix B Illustrated Parts List Figure 11 Back View of Printer 5 35 40 30 20 10 15 ...

Page 183: ...over Assembly 1 10 703531 202 Rear Cover Assembly Right 1 15 703531 201 Rear Cover Assembly Left 1 20 703531 206 Top Cover Holder C CK 1 30 See Figure 12 For Close up Of Printer 35 705733 005 High Voltage Corona Power Supply L5035 1 40 703531 063 Connectors for High Voltage Corona Power Supply set of 5 1 ...

Page 184: ...562 Appendix B Illustrated Parts List Figure 12 Back View of Printer Close up Sheet 1 of 2 10 15 5 20 25 30 35 36 ...

Page 185: ...563 Figure 12 Back View of Printer Close up Sheet 2 of 2 75 70 65 60 55 50 45 40 120 115 110 95 80 85 90 100 ...

Page 186: ...e Figure 19 For Details 1 36 703531 164 Power Supply Harness Assembly 1 40 Bracket Assembly FU Fuser Unit Connector See Figure 31 For Details 1 45 703531 163 Varistor High Voltage Cable not visible in figure See Figure 26 Item 10 For Details 1 50 703531 108 Drawer Harness Assembly See Figure 22 Item 10 For Details 1 55 703531 144 Drum Shaft Assembly See Figure 29 For Details 1 60 Head Blower Fan A...

Page 187: ...06 Flash Power Supply L5035 behind blower See Figure 25 For Details 1 95 DC Main Power Supply Assembly See Figure 27 For Details 1 100 703531 147 Connector Assembly For Transfer Ozone not visible in figure See Figure 26 Item 5 For Details 1 110 See Figure 28 For Details Of This Side Of Printer 115 Flash Duct Assembly See Figure 30 For Details 1 120 Back View Of Printer Left Side See Figure 28 For ...

Page 188: ...566 Appendix B Illustrated Parts List Figure 13 Cut Sheet Output Assembly 5 25 10 20 15 10 15 10 REF ...

Page 189: ... Sheet Output Assembly Quantity per Assembly 5 703531 221 Output Assembly Roller 8 1 10 703531 222 Output Assembly Roller 9 2 15 703531 226 Output Assembly Roller 12 7 20 703531 075 PHINT ON1517LA A Optical Sensor 1 25 703531 034 Belt 265MXL4 8 1 ...

Page 190: ...568 Appendix B Illustrated Parts List Figure 14 LED Print Head LED Array 5 10 15 20 ...

Page 191: ...gure 14 LED Print Head LED Array Quantity per Assembly 5 703551 001 LED Print Head 240 DPI LED Array 1 10 703551 002 LED Print Head 300 DPI LED Array 1 15 703551 003 LED Print Head 400 DPI LED Array 1 20 703531 068 Heat Pipe Assembly 1 ...

Page 192: ...570 Appendix B Illustrated Parts List Figure 15 Cut Sheet Feeder Assembly Sheet 1 of 4 E E D A D C B A 55 50 40 50 41 40 45 40 25 30 35 10 15 10 15 20 ...

Page 193: ...571 Figure 15 Cut Sheet Feeder Assembly Sheet 2 of 4 B 64 62 62 61 5 65 60 ...

Page 194: ...572 Appendix B Illustrated Parts List Figure 15 Cut Sheet Feeder Assembly Sheet 3 of 4 C Ref 75 70 85 Ref 41 41 70 80 ...

Page 195: ...573 Figure 15 Cut Sheet Feeder Assembly Sheet 4 of 4 D E Ref 10 11 Ref 15 ...

Page 196: ...574 Appendix B Illustrated Parts List Parts lists continue on next page ...

Page 197: ...OM Option 1 1 35 703531 077 Harness Feed P004 Wire Harness 1 40 703531 054 Clutch Feeder 3 41 703531 525 Shaft Cut Sheet Feeder Gear 2 45 703531 075 Sensor Photo Interrupter PHINT ON1517LA A 1 50 703531 053 Motor Assembly 2 55 703531 076 Harness Feed P003 Cable Harness 1 60 703531 078 Harness Feed P031 Cable Harness 1 61 703531 565 Registration Roller Cut Shaft 1 62 703531 563 Shaft Feed Roller 2 ...

Page 198: ...576 Appendix B Illustrated Parts List Figure 16 Front View Left Side Sheet 1 of 3 B A 5 20 10 15 D B C A ...

Page 199: ...577 Figure 16 Front View Left Side Sheet 2 of 3 C 30 25 35 42 42 40 40 37 38 39 ...

Page 200: ...578 Appendix B Illustrated Parts List Figure 16 Front View Left Side Sheet 3 of 3 D 45 ...

Page 201: ...ly Front 1 20 703531 114 Tractor Assembly 2 25 705733 009 Motor Assembly Drum L5035 1 30 703531 075 Sensor Photo Interrupter PHINT ON1517LA A 1 35 703531 041 Motor Assembly Tractor 1 37 706291 001 Pulley Drum 3M 51 28 1 38 706292 001 Pulley Tractor 3M 63 1 39 706293 001 Pulley Two gang 3M 64 1 40 703531 031 Belt 60S3M264 3 42 703531 583 Bearing 8 mm 2 45 703531 232 Sensor Top of Form 1 ...

Page 202: ...580 Appendix B Illustrated Parts List Figure 17 MC PCBA 5 ...

Page 203: ...581 Item No Part No Description Figure 17 MC PCBA Quantity per Assembly 5 705733 012 MC PCBA L5035 1 ...

Page 204: ...582 Appendix B Illustrated Parts List Figure 18 PNE Paper Near End Sensor Assembly 10 5 ...

Page 205: ...83 Item No Part No Description Figure 18 PNE Paper Near End Sensor Assembly Quantity per Assembly 703531 167 PNE Paper Near End Sensor Assembly 5 703531 154 Sensor B PCBA 1 10 703531 153 Sensor A PCBA 1 ...

Page 206: ...584 Appendix B Illustrated Parts List Figure 19 Controller Module Sheet 1 of 4 10 15 20 A 7 5 7 6 ...

Page 207: ...585 Figure 19 Controller Module Sheet 2 of 4 B A 35 30 25 ...

Page 208: ...586 Appendix B Illustrated Parts List Figure 19 Controller Module Sheet 3 of 4 C B 40 ...

Page 209: ...587 Figure 19 Controller Module Sheet 4 of 4 C 45 ...

Page 210: ...588 Appendix B Illustrated Parts List Parts lists continue on next page ...

Page 211: ...02904 001 SIMM EDO DRAM 4 MB 7 202903 001 SIMM EDO DRAM 8 MB 7 202902 001 SIMM EDO DRAM 16 MB 10 703678 001 Serial 232 422 Cable 1 15 703679 001 Diagnostic Cable Assembly 1 20 703680 001 Parallel Cable Assembly 1 25 703595 001 Print Engine Cable 1 30 703682 001 Front Panel Cable 1 35 202377 001 Disk Drive Assembly Floppy 3 5 Inch 2 MB 2 40 141235 002 Power Supply 120W 230V 5 12 in Controller Modul...

Page 212: ...590 Appendix B Illustrated Parts List Figure 20 Head Blower Fan Assembly 5 10 ...

Page 213: ...591 Item No Part No Description Figure 20 Head Blower Fan Assembly Quantity per Assembly 5 703531 104 Head Blower Fan 1 10 703531 001 LED Air Filter 1 ...

Page 214: ...592 Appendix B Illustrated Parts List Figure 21 Developing Unit Drive Assembly 5 40 35 30 25 10 15 20 ...

Page 215: ... 703531 219 Plate Developing Unit Gear 9 1 10 202834 001 Gear Assembly For Developing Unit L5035 1 15 703531 215 Plate Developing Unit Gear 10 1 20 705733 011 Magroll Motor Assembly 1 25 705733 010 Sleeve Motor Assembly 1 30 703531 216 Plate Developing Unit Gear 6 1 35 703531 217 Plate Developing Unit Gear 5 1 40 703531 033 Belt 60S3M177 1 ...

Page 216: ...594 Appendix B Illustrated Parts List Figure 22 General Details Sheet 1 of 2 5 10 ...

Page 217: ...595 Figure 22 General Details Sheet 2 of 2 15 15 20 ...

Page 218: ...596 Appendix B Illustrated Parts List Parts lists continue on next page ...

Page 219: ...tion Figure 22 General Details Quantity per Assembly 5 703531 107 I O 26 Harness Assembly 1 10 703531 108 Drawer Harness Assembly 1 15 703531 075 Sensor Photo Interrupter PHINT ON1517LA A 2 20 703531 159 Transfer Elevator Motor 1 ...

Page 220: ...598 Appendix B Illustrated Parts List Figure 23 Smoke Filter Box 5 10 ...

Page 221: ...599 Item No Part No Description Figure 23 Smoke Filter Box Quantity per Assembly 5 703540 001 Smoke Filter Box VEFE Assembly 1 10 703531 116 Smoke Filter Blower Fan VEF0 Main Blower Fan 1 ...

Page 222: ...600 Appendix B Illustrated Parts List Figure 24 Lamp Cooling Blower Fan AC Blower Assembly 5 ...

Page 223: ...601 Item No Part No Description Figure 24 Lamp Cooling Blower Fan AC Blower Assembly Quantity per Assembly 5 703531 117 Lamp Cooling Blower Fan VEF1 AC Blower Assembly 1 ...

Page 224: ...602 Appendix B Illustrated Parts List Figure 25 Flash Power Supply A A 10 ...

Page 225: ...603 Item No Part No Description Figure 25 Flash Power Supply Quantity per Assembly 705733 006 Flash Power Supply L5035 1 10 703531 561 Capacitor 1 ...

Page 226: ...604 Appendix B Illustrated Parts List Figure 26 Miscellaneous Details 5 10 ...

Page 227: ...605 Item No Part No Description Figure 26 Miscellaneous Details Quantity per Assembly 5 703531 147 Connector Assembly For Transfer Ozone 1 10 703531 163 Varistor High Voltage Cable 1 ...

Page 228: ...606 Appendix B Illustrated Parts List Figure 27 DC Main Power Supply 10 15 20 ...

Page 229: ...Item No Part No Description Figure 27 DC Main Power Supply Quantity per Assembly 10 705733 007 DC Power Supply PCBA L5035 1 15 202836 001 Fan DC Power Supply L5035 20 202837 001 Relay DC Power Supply L5035 ...

Page 230: ...608 Appendix B Illustrated Parts List Figure 28 Back View Left Side Sheet 1 of 5 C A 5 10 15 ...

Page 231: ...609 Figure 28 Back View Left Side Sheet 2 of 5 A B 45 40 20 25 30 30 35 ...

Page 232: ...610 Appendix B Illustrated Parts List Figure 28 Back View Left Side Sheet 3 of 5 B 50 55 ...

Page 233: ...611 Figure 28 Back View Left Side Sheet 4 of 5 D C 60 65 70 80 75 85 90 95 90 95 100 ...

Page 234: ...612 Appendix B Illustrated Parts List Figure 28 Back View Left Side Sheet 5 of 5 D 105 105 115 120 110 ...

Page 235: ...EGS1 Assembly Exit Gate Solenoid 1 1 55 703531 124 EGS2 Assembly Exit Gate Solenoid 2 1 60 703531 219 Exit Assembly Roller 14 1 65 703531 122 Gate Rear Block 1 70 703531 225 Exit Assembly Roller 11 1 75 703531 120 Exit Sensor EPS1 1 80 703531 086 Sensor Photo Interrupter PHINT ON1517LA A 1 85 703531 121 Gate Front Block 1 90 703531 115 Rubber Paper Press 1 4 95 703531 119 Rubber Paper Press 2 2 10...

Page 236: ...614 Appendix B Illustrated Parts List Figure 29 Drum Shaft Assembly and Belts 5 40 10 15 45 20 35 25 30 ...

Page 237: ... Coupler metal 1 10 703531 032 Belt 60S3M501 1 15 703531 532 Gear Cleaner Drive 1 20 703531 031 Belt 60S3M264 1 25 703531 075 Sensor Photo Interrupter PHINT ON1517LA A 1 30 703531 133 Tension Pulley Drum Assembly 1 35 703531 144 Shaft Assembly Drum 1 40 703531 234 Holder Blk Gear Assembly 1 45 703531 590 Shaft Pre Drum 1 ...

Page 238: ...616 Appendix B Illustrated Parts List Figure 30 Flash Duct Assembly 5 ...

Page 239: ...617 Item No Part No Description Figure 30 Flash Duct Assembly Quantity per Assembly 5 703531 105 Fuser Cooling Fan 1 ...

Page 240: ...618 Appendix B Illustrated Parts List Figure 31 Bracket Assembly FU Fuser Unit Connector 10 5 5 ...

Page 241: ...619 Item No Part No Description Figure 31 Bracket Assembly FU Fuser Unit Connector Quantity per Assembly 5 703531 142 Fuser Connector 2 ea set 2 10 703531 112 Harness Assembly Halogen 2 ...

Page 242: ...620 Appendix B Illustrated Parts List Figure 32 Back of Printer Left Side Sheet 1 of 6 1 1 A B E H F G ...

Page 243: ...621 Figure 32 Back of Printer Left Side Sheet 2 of 6 A 5 10 15 15 ...

Page 244: ...622 Appendix B Illustrated Parts List Figure 32 Back of Printer Left Side Sheet 3 of 6 25 B D C C D 20 25 ...

Page 245: ...623 Figure 32 Back of Printer Left Side Sheet 4 of 6 F E 31 35 ...

Page 246: ...624 Appendix B Illustrated Parts List Figure 32 Back of Printer Left Side Sheet 5 of 6 G 40 ...

Page 247: ...625 Figure 32 Back of Printer Left Side Sheet 6 of 6 H 50 55 45 55 50 Ref 45 This view is rotated 180 ...

Page 248: ...626 Appendix B Illustrated Parts List Parts lists continue on next page ...

Page 249: ...rupter PHINT ON1517LA A 1 15 703531 106 Microswitch SW V 014 1C23 2 20 703531 129 Solenoid DS Assembly 1 25 703531 052 Separating Finger Assembly Separator Claw Shaft Assembly 1 31 705733 008 Sensor Assembly Drum Surface Potential 1 35 703531 135 Charger Connector Assembly 1 40 703531 106 Microswitch V 014 1C23 1 45 703531 220 NIP SCUFF Assembly 1 50 703531 560 E Ring E 6 2 55 703531 559 Shaft Ful...

Page 250: ...628 Appendix B Illustrated Parts List ...

Page 251: ...ations Front Side Lower level paper empty sensor PES2 Upper level paper empty sensor PES1 Carry out rollers Cassette setter Cassette support Paper guide Upper level paper size detector sensor In the order of IPS10 IPS11 IPS12 as viewed from this side Lower level paper size detector sensor In the order of IPS20 IPS21 IPS22 as viewed from this side ...

Page 252: ...630 Appendix C Optional Cut Sheet Feeder Back Side Cut sheet feeder roller Paper register sensor PRS Register roller Paper register clutch PRC Paper timing sensor PTS ...

Page 253: ...pick up motor PPM Upper level cut sheet pick up clutch PPC1 Cut sheet feeder motor PFM Lower level cut sheet pick up clutch PPC2 Paper register clutch PRC Paper guide interlock switch ICIL Cut sheet pick up motor encoder PME Cut sheet feed motor encoder FME ...

Page 254: ...632 Appendix C Optional Cut Sheet Feeder Paper Feed Cassette Lower level paper feed cassette large Upper level paper feed cassette small Hopper stopper Top cover Paper size cap Hopper Hopper pin ...

Page 255: ...etup 1 Install the cut sheet feeder unit by hooking the hooks on its front and rear frames onto the printer frame 2 Secure the burrs of the front and rear feeder frames to the printer frame with 2 bolts each Rear frame Hooks Front frame Printer frame ...

Page 256: ...3 Remove the wire cover Pass the lines going to the front cover interlock switch and the operation panel underneath this cover Wire cover Connecting line going to the operation panel Connecting line going to the front cover interlocking switch ...

Page 257: ...ons 635 Connections Connect the cut sheet feeder unit to the MC board and DC power supply board as shown below Cut sheet feeder unit Control board PBA Option 1 J60101 J03102 Part of CN3 MC PCBA Print Engine CN10 PS PCBA ...

Page 258: ...0 12 IPS 20 22 Upper Lower level paper size detector sensors PES1 PES2 Upper level Lower level paper empty sensor PPM Cut sheet pickup motor PME Cut sheet pickup motor encoder PPC1 PPC2 Upper level Lower level cut sheet pickup clutch PFM Cut sheet feeder motor FME Cut sheet feeder motor encoder PFS Cut sheet feeder sensor PRS Paper register sensor PRC Paper register clutch PTS Paper timing sensor ...

Page 259: ...or via the paper register clutch Cassette Principles Inside the paper supply cassette there is a metal plate hopper which presses the paper against the carry out roller When no cassette is set this hopper is hooked on the hopper stopper When a cassette is set in place the hopper stopper and the cassette setter make contact the lock is disengaged and springs up When removing the cassette the hopper...

Page 260: ...Level Lower Level Paper Size Detector Sensor These sensors are each comprised of 3 switches set on the board There are 7 paper sizes including no cassette Paper size is detected by the switches turned on by the paper size caps set on the cassette end that is inserted into the receptacle Set the paper size caps according to the paper size Paper size detection sensor boards ...

Page 261: ... in the cassette contact the paper size sensors on the printer the printer determines that the paper cassette is in position and identifies the paper size The available settings for the paper feed cassette are provided in the following table O plastic insert IPS 12 22 IPS 11 21 IPS 10 20 IPS 10 11 and 12 Upper level paper size detector sensors IPS 20 21 and 22 Lower level paper size detector senso...

Page 262: ...s causing detection of no paper Cut Sheet Feed Sensor PFS Paper Register Sensor These sensors are photointerrupters located partway in the paper transport path When paper passes through this location the levers are pushed over blocking light between the light emitters and receptors causing detection of paper in that location paper exists no paper exists Light Lever Light emitter and receptor Light...

Page 263: ...ity the mechanical aspects lever have been eliminated The paper timing sensor consists of an LED light emitter and receptor on either side of the transport path When paper passes through this location light between the light emitter and receptor is blocked causing detection of the leading edge of the paper Light receptor Paper paper exists no paper exists Light Light receptor Light emitter LED Pap...

Page 264: ... detected by the pulse string that is created by light passing through the rotating slotted plate The rotational speed of the cut sheet pickup motor need not be extremely precise Therefore a PWM Pulse Width Modulation circuit is used to control the average voltage to the motor This circuit adjusts the duty cycle of the motor percentage of the time that the motor is turned on via a chopper circuit ...

Page 265: ...er side of the plate The motor rotation is detected by the pulse string that is created by light passing through the rotating slotted plate The rotational speed of the cut sheet feed motor need not be extremely precise Therefore the basic pulse string fed back to the PLL Phase Locked Loop circuit is compared to the basic pulse string created via dividing the circuit of the crystal oscillator in bo...

Page 266: ...itch ICIL This is a microswitch that detects whether the paper guide is open or not This switch is also interlocked with the cut sheet feeder 24 V system actuator drive system so that when this switch is off the actuator power is also off Paper guide interlock switch ...

Page 267: ...nd timed out before PRS on Judgement timer setting 4000msec No cassette 66 There is no upper level paper feed cassette set IPS10 12 all off No paper 6F No paper in upper level cassette PES1 is on Error Code Contents Pickup miss 65 Paper did not move to the cut sheet feeder sensor within a certain time after the carry out roller operated lower level pickup misjudgment timer started with PPC2 coming...

Page 268: ... timer settings A4 2260 msec Letter 2313 msec Legal 3550 msec B4 3624 msec A3 4120 msec Ledger 4225 msec Lodged jam 2 69 Too much time passed for the paper to move by the paper timing sensor PTS lodged jam judgment timer started with PTS coming on and timed out before PTS turned off Judgement timer settings same as Lodged jam 1 Paper remaining 1 6A There is paper at the paper register sensor or th...

Page 269: ...pickup motor PPM revolution abnormality monitor timer counted up during paper supply preparation operations Monitor timer setting 200msec Motor revolution abnormality 2 6D Revolution abnormality occurred in the cut sheet feed motor PFM revolution abnormality monitor timer counted up during paper supply preparation operations Monitor timer setting 200msec ...

Page 270: ...cutes the following main routine while waiting for the cassette specification command and the paper supply preparation start command to be transmitted from the printer Mechanism initialization Analog input processing Chattering absorption processing Status confirmation processing Confirmation processing of unit of error occurrence Communication processing Driving actuators ...

Page 271: ...r the two motor encoders is determined by filter processing of the input port Status Confirmation Processing Data is detected from the sensors including motor encoders and if an error occurs abnormality processing is executed Confirmation Processing Of Unit Of Error Occurrence Checks for errors in the order of the unit sequencer section transport section lower level cassette section and upper leve...

Page 272: ...650 Appendix C Optional Cut Sheet Feeder Cut Sheet Output Unit Physical Description The front and rear views of the cut sheet output unit are shown in the following illustrations Front Side ...

Page 273: ...Cut Sheet Output Unit 651 Rear Side ...

Page 274: ...2 Appendix C Optional Cut Sheet Feeder Setup and Connections Setup 1 Install the cut sheet output unit by securing the burrs of the front and rear output unit frames to the printer frame with 2 bolts each ...

Page 275: ...Cut Sheet Output Unit 653 2 Attach the entrance roller joint shaft then secure it with the E ring E ring ...

Page 276: ... Optional Cut Sheet Feeder Connections Connect the cut sheet output unit connector to the printer frame connector that connects to connector CN3 on the MC board Printer frame connector Cut sheet output unit connector ...

Page 277: ...he output paper exit guide This unit also has two sensors the output paper sensor 2 EPS2 and the cut sheet transport path open sensor CWO The EPS2 sensor is a photointerrupter type which detects the presence or absence of paper This sensor allows the printer to detect paper jams in the cut sheet output unit The CWO sensor is a microswitch that senses whether the output paper intermediate guide is ...

Page 278: ...656 Appendix C Optional Cut Sheet Feeder ...

Page 279: ... views of the power paper stacker are shown in the following figures Front Output side AUTO key DOWN key STOP key HEAVY key Hook Top bottom adjust knob Head tail length measuring gauge in inches Elevator table Safety stop bar not visible in figure Safety stop bar not visible in figure ...

Page 280: ...ptional Power Paper Stacker Rear Input side Hooks Assisting arm motor Assisting arms Paper surface sensor 1 PSS1 Swinger motor SM Elevator motor drive gear Controller board Paper surface sensor 2 PSS2 Swinger Elevator ...

Page 281: ...Physical Description 659 Front Interior Paper surface sensor 1 PSS1 Paper surface sensor 2 PSS2 Safety sensor SS1 behind panel Transfer belt ...

Page 282: ... printer must be adjusted to the proper height and be leveled Failure to do this will damage both the printer and the stacker and will prevent installation or removal of the stacker 1 Install the power paper stacker by pushing it into the lower part of the printer and attaching the front and rear hooks onto the studs of the printer side ...

Page 283: ...Setup and Connections 661 Power stacker Hook Printer Stud Printer Stud ...

Page 284: ...ated above the noise filter box on the printer main power supply 3 Attach the stacker ground wire to the correct printer ground terminal with a screw as shown 4 Install the remaining screws 2 and the cover plate as shown Printer connector Noise filter box Stacker ground wire Stacker connector Cover plate ...

Page 285: ...Setup and Connections 663 Connections The paper stacker is connected to the printer as follows Print engine MC PCBA CN4 PS PCBA CN13 Power paper stacker Controller board J1 J2 ...

Page 286: ...664 Appendix D Optional Power Paper Stacker Removal To release the stacker from the printer press the release lever located on the front side to remove the hooks from the studs Release lever ...

Page 287: ...g after pressing the DOWN key DOWN Lowers the elevator until it reaches its maximum lower position or until the STOP key is pressed HEAVY ON equals Heavy Mode for thicker paper LED is lit OFF equals Normal Mode for thinner paper LED is not lit This key is only active in STOP mode and when there is no paper in the stacker When operating the power stacker in Heavy Mode the maximum stack height follo...

Page 288: ...ion and accumulates it on the elevator table Feed rollers transfer fan fold paper that is output from the printer After the paper moves between the feed rollers it is stacked on the elevator table by the action of the swinger swinging back and forth Stacked paper Elevator table Swinger Feed roller ...

Page 289: ...forations The transfer belts press the paper stacking it on the elevator table As paper accumulates on the elevator table the table lowers to keep the height of the paper uniform NOTE The assisting arms are not activated when the head to tail length of the sheet is 7 to 8 5 inches Elevator table Swinger Assisting arm Transfer belt Stacked paper ...

Page 290: ...t switch PMS Transfer unit paper sensor LIMT2 Elevator minimum limit switch Paper moving sensor SEM Elevator motor SM Swinger motor EME Elevator motor encoder SPS Swinger position sensor ESWA Elevator AUTO key PPS Paper jam sensor ESWS Elevator STOP key PSS1 Paper surface sensor 1 ESWD Elevator DOWN key PSS2 Paper surface sensor 2 ESWH Elevator HEAVY key PSS3 Paper surface sensor 3 PES Paper eject...

Page 291: ...Drive Principles 669 Drive Principles Feed Roller and Transfer Belt Both feed roller and transfer belt are driven by the stacker motor Feed roller Stacker motor Transfer belt ...

Page 292: ...670 Appendix D Optional Power Paper Stacker Also the space between the transfer belts can be adjusted by the top and bottom adjusting knob Transfer belt Top and bottom adjusting knob ...

Page 293: ...Drive Principles 671 Swinger The swinger is driven by the swinger motor Swinger motor Swinger ...

Page 294: ...Stacker Assisting Arms The assisting arms are driven by the assisting arm drive motor NOTE The assisting arms are not activated when the head to tail length of the sheet is 7 to 8 5 inches Assisting arm motor Assisting arms Assisting arms ...

Page 295: ...Drive Principles 673 Elevator Table The elevator table is driven by the elevator motor Elevator motor Elevator table ...

Page 296: ...MS The transfer unit paper sensor is a photointerrupter that is composed of a light emitter and receptor and a lever This sensor is located partway in the paper guide at the entrance of the power stacker When paper output from the printer passes through the guide and kicks the lever the light passing between the light emitter and receptor is blocked causing paper to be detected Light emitter and r...

Page 297: ...per fold falls on this belt and kicks the lever the light passing between the light emitter and receptor is blocked and the sensor turns on This sensor detects improper paper folding If either the on time or off time of this sensor becomes longer than its corresponding preset reference value then an improper folding error is declared Light emitter and receptor Light beam Transfer belt Paper Lever ...

Page 298: ...ght emitters and receptors located on the front side and rear side When paper stacking on the elevator table reaches the height of the sensors the light is blocked turning on the sensors These sensors control the height of the elevator table When both sensors come on for 1 5 seconds the paper surface is judged to have reached this height and the elevator table drops 5 to 7 mm ...

Page 299: ...rrupter sensors each of which detects the position of the elevator table The stacker full sensor indicates that the amount of folded paper has reached the limit The elevator down sensor indicates that the elevator table has reached the down position the position where the operator removes the paper Stacker full sensor Elevator down sensor ...

Page 300: ...rs detect abnormal DC motor revolution Each sensor consists of a timing disk attached to the motor axis a light emitter and a light receptor The motor revolution is monitored by the length of time that blockages of light occur between the light emitter and receptor Light emitter and receptor Motor Timing disk ...

Page 301: ...ach sensor consists of a slotted plate a light emitter and a light receptor The location of the slot as detected by the light emitter and receptor is set as the home position for that motor Also motor revolution abnormality is monitored by determining whether the home position is detected within its preset reference time Light emitter and receptor Motor Slotted plate ...

Page 302: ...h LIMT2 These are limit switches that prevent the elevator table from rising too high or dropping too low If for some reason the elevator table rises abnormally high or drops abnormally low one of these switches comes on and the elevator table stops Elevator upper limit switch Elevator lower limit switch ...

Page 303: ... turned off all motors are turned off except the elevator motor Elevator Keys ESWA ESWS ESWD ESWH These keys are used for operating the elevator Elevator AUTO Key ESWA This sets the elevator in automatic mode When this switch is pressed the elevator first rises until the paper surface sensor comes on then lowers slightly and waits for paper to be transported Elevator STOP Key ESWS This stops the e...

Page 304: ...not ready 57 Power stacker not ready Not auto mode 58 Power stacker not in auto mode Stacker lowest position 5C Elevator table in down position EDS detected elevator table Error Code Meaning Stacker capacity over 59 Elevator table is at highest or lowest position LIMT1 or LIMT2 detected elevator table Motor abnormality detection 1 5A Action abnormality of stacker motor has been detected Motor abno...

Page 305: ...driving subroutines are selectively executed only upon the power stacker receiving execution commands from the printer The timing for driving the various actuators is determined by the page last raster signal LSCA from the printer based on the paper head and tail status setting Status confirmation processing Communication processing Driving the stacker Driving the elevator motor Driving the swinge...

Page 306: ...modes between stop auto and down Also initializes the elevator motor during printer initialization Driving the Swinger Motor Initializes and terminates the swinger Executes normal action 1 2 inch feed action line feed 1 page feed action page feed start position changing action overrun action and paper output action Driving the Assisting Arm Drive Motor Initializes and terminates the assisting arm ...

Page 307: ...verse order of the procedures described in this section Return the screws to their original positions as they may vary in type WARNING For safety always disconnect the power supply plug before removing parts Never operate the power stacker with parts removed VORSICHT Aus Sicherheitsgründen müssen Sie immer den Netzstecker herausziehen ehe Sie Teile entfernen Niemals den Lader in Betrieb nehmen wen...

Page 308: ...er Cover To remove the power stacker cover 1 Disconnect the connector that is connected to the stacker cover and remove knob D 2 Remove the screws 5 securing the stacker cover then pull the cover outward to remove it Connector Stacker cover Knob D Screws 5 ...

Page 309: ...Belt Removal Procedures 687 Inside the Left Frame Tension pulley Belt A Belt S S3M741 Belt C S3M825 Belt D S3M900 NOTE Some stacker units might appear slightly different in these areas ...

Page 310: ...688 Appendix D Optional Power Paper Stacker 1 Remove Belt S slacken the belt by pushing the tension pulley to the right then remove the belt Belt S Tension pulley ...

Page 311: ...rocedures 689 2 Remove Belt A the belt that connects the stacker motor assembly output pulley to the large pulley turn the pulleys by hand and remove the belt Large pulley Belt A Stacker motor assembly output pulley ...

Page 312: ...l Power Paper Stacker 3 Remove Belt C first remove the E clip Then remove the pulley by pulling it toward you Finally remove Belt C Pulley Belt C NOTE Some stacker units might appear slightly different in these areas E clip ...

Page 313: ...Belt Removal Procedures 691 4 Remove Belt D rotate the pulley by hand and remove it along with the belt Belt D NOTE Some stacker units might appear slightly different in these areas Pulley ...

Page 314: ...teps 1 through 4 reinstall them in reverse order After replacing Belt D adjust its belt tension a Loosen screws A and B b Using a spring scale adjust screw A such that a tension of 6 oz deflects the belt by approximately 10 mm c Secure screw B Screw A Screw B Screw A Approximately 10 mm ...

Page 315: ...Belt Removal Procedures 693 Inside the Right Frame Belt E S3M825 ...

Page 316: ... Power Paper Stacker 1 Remove the E clip from the pin Detach the arm from the pin and tilt the arm in the direction of the arrow as shown 2 Remove the screw securing the plate then remove the plate Arm Pin E clip Screw Plate ...

Page 317: ... pointer from Belt E 4 Remove Belt E first remove the E clip from the pulley Then remove the belt and the pulley together 5 Install a new Belt E E clip Belt E Pulley NOTE Some stacker units might appear slightly different in this area Pointer ...

Page 318: ...x D Optional Power Paper Stacker 6 Place the knob on the shaft and rotate the knob fully clockwise Then place the pointer back on Belt E at the location where it points to the 12 on the scale Belt E Scale Pointer ...

Page 319: ...Belt Removal Procedures 697 Swinger Belts The swinger belts are located on the swinger and assist arm drive units two belts on each drive unit Assist arm drive unit Swinger drive unit ...

Page 320: ...698 Appendix D Optional Power Paper Stacker 1 On the swinger drive unit disconnect the connectors 2 then detach the cables from the cable clamps Connector Connector Swinger drive unit Cable clamps ...

Page 321: ...Belt Removal Procedures 699 2 Remove the E clip then remove the link arm from the slotted disc E clip Link arm Slotted disc ...

Page 322: ...700 Appendix D Optional Power Paper Stacker 3 Remove the screws 3 securing the swinger drive unit then remove the unit Screws 3 Swinger drive unit ...

Page 323: ... 701 4 On the assist arm drive unit disconnect the connectors 2 then detach the cables from the cable clamps 5 Remove the E clip on the arm then remove the arm Connector Connector Cable clamps Assist arm drive unit E clip Arm ...

Page 324: ...702 Appendix D Optional Power Paper Stacker 6 Remove the screws 3 securing the assist arm drive unit then remove the drive unit Screws 3 Assist arm drive unit ...

Page 325: ...th the swinger and the assist arm drive units remove the screws 3 E clip and bush from the motor side of the plate Then remove the plate 8 Replace the two belts on each drive unit Screws 3 E clip Bush Plate Belt S2M160 Belt S2M118 Motor ...

Page 326: ...e assembly to the table support arms 2 then remove the stacker table assembly 2 Remove the knob 3 Remove the screws 4 securing the stacker elevator cover then remove the cover as shown above Stacker elevator cover Knob Stacker table assembly Table support arms 2 Screws 4 in step 1 Screws 4 places in step 3 ...

Page 327: ...move the two table support arms as shown below 5 Remove the screws 6 securing the stacker arm brackets 2 to the elevator carriage assembly then remove the two stacker arm brackets as shown above Screws 4 in step 4 Elevator carriage assembly Table support arms 2 Stacker arm brackets 2 Screws 2 in step 5 Screws 4 in step 5 ...

Page 328: ...ecuring the elevator top channel to the stacker base assembly then remove the elevator top channel as shown above CAUTION Be careful not to damage the wiring during removal or replacement 9 Remove the elevator carriage assembly and the two elevator upper pulley assemblies with attached belts by pulling them upward from the stacker base assembly as shown above Screws 4 in step 8 Screws 4 in step 6 ...

Page 329: ... then pull the stacker elevator pulley pin out of the stacker elevator pulley bracket b Remove the stacker elevator pulley with attached stacker elevator belt from the stacker elevator pulley bracket c Replace the stacker elevator belt Stacker elevator belt Stacker elevator pulley Stacker elevator pulley bracket Stacker elevator pulley pin E clip E clip ...

Page 330: ...s the springs are very strong After making the adjustment lock the second nut to secure the adjustment VORSICHT Stellen Sie beim Installieren des oberen Liftantriebs die Zugmutter so ein daß eine Kraft von 4 N erforderlich ist um den Riemen 10 mm einzudrücken Gehen Sie hierbei vorsichtig vor da die Federspannung sehr hoch ist Ziehen Sie nach dem Einstellen die Kontermutter fest um die Einstellung ...

Page 331: ...d the stacker motor connector from their mating harness connectors then detach the cables from the cable clamp Stacker motor assembly output pulley Stacker motor assembly Stacker motor assembly Sensor connector not shown Stacker motor connector Sensor Stacker motor This view is rotated 180 ...

Page 332: ...710 Appendix D Optional Power Paper Stacker 2 Remove Belt S slacken the belt by pushing the tension pulley to the right then remove the belt Belt S Tension pulley ...

Page 333: ... large pulley turn the pulleys by hand and remove the belt 4 Remove the E clip securing the stacker motor assembly output pulley then remove the output pulley 5 Remove the pin from the output pulley shaft then remove the O ring and bush from the shaft Large pulley Belt A Stacker motor assembly output pulley E clip ...

Page 334: ...w securing the sensor to the stacker motor assembly 8 With a hex wrench loosen the set screws 2 securing the stacker motor gear then remove the gear 9 Remove the screws securing the stacker motor to the stacker motor assembly 10 Replace the motor 11 Reassemble the parts in reverse order Stacker motor assembly Sensor mounting screw on bottom of sensor Sensor Screws 3 Stacker frame Stacker motor ...

Page 335: ...er paper stacker II 773 tractor motor tractor drive II 519 transport II 495 Bias volts I 256 Block diagram I 186 Boards DC power supply II 509 adjustments I 403 MC II 507 C Cable connections I 47 data cables I 50 interface cables I 50 signal cables I 50 Capacitor flash power supply II 571 Cassette paper paper jams at back of I 264 paper size I 75 I 139 II 715 Cautions and dangers I 21 Cleaning cle...

Page 336: ...cleaning I 108 Cut sheet feed sensor II 716 Cut sheet feeder unit II 705 basic operation II 724 basic principles II 712 cut sheet feed sensor PFS II 716 detection errors II 721 feed motor encoder FME II 719 paper feed cassette II 708 paper guide interlock switch ICIL II 720 paper register sensor II 716 paper timing sensor PTS II 717 physical description II 705 pickup motor encoder PME II 718 setup...

Page 337: ...hes I 22 Disposal photoreceptor drum II 482 Documents related I 22 DRAM FAIL AT ADDRESS xxxxxxxx Error K5 I 280 Drive system descriptions I 146 Drum cleaner set sensor II 555 cleaning unit II 485 counter MC board I 401 counter circuit I 202 drive theory I 147 motor II 512 control circuit I 200 drive belt II 532 engine checker I 369 MC board I 394 peripheral equipment II 482 cleaning unit II 485 di...

Page 338: ...ver Open knob C I 291 08 Cut Sheet Path Open I 292 09 Transport Motor Fail complete stop I 293 0A Cutter Fail front I 295 0B Cutter Fail rear I 295 0C Transfer Platform Fail upper I 297 0D Transfer Platform Fail lower I 297 11 Paper Jam at Drum I 299 12 Paper Jam at Fuser I 300 13 Paper Jam at Exit face down I 302 13 Paper Jam at Exit face up I 301 14 Tractor Speed Too High I 303 15 Tractor Speed ...

Page 339: ...ath paper jams in I 272 Fan controller cooling II 596 fuser reflector cooling FCF II 527 head blower MC board I 400 head blower HBF and LED air filter II 526 head cooling MC board I 400 head cooling HCF II 524 vacuum VAF transfer assembly II 502 Fanfold Paper engine checker I 372 Fan fold paper loading I 69 Fan fold Paper Empty Error 02 upon power on I 285 when loading beginning print I 286 Fanfol...

Page 340: ...temperature monitoring theory I 172 Fuser unit II 489 lamp duct filter II 493 preheat lamp flash lamp II 490 temperature fuse II 492 theory I 136 Fuser unit cover glass cleaning I 108 G Gate drive theory I 150 Gates paper output section II 560 Glass cover fuser unit cleaning I 108 Global Memory Adjust menu I 253 H H0 TEST HARDWARE PLEASE WAIT I 279 H1 DIAGNOSTIC PASSED I 279 H2 WAITING FOR FILE DO...

Page 341: ... section I 270 near paper output section I 259 near tractor I 258 K K0 DC NOT 1ST FILE I 280 K1 FILE NOT COMPATIBLE I 280 K2 WRONG FILE CHECKSUM I 280 K3 DC PROGRAM NOT VALID I 280 K4 NO FLASH FILE SYSTEM I 280 K5 DRAM FAIL AT ADDRESS xxxxxxxx I 280 K6 FLASH MEMORY FAIL I 280 K7 PROGRAM FLASH FAIL AT xxxxxxxx I 280 K8 FLASH MEMORY FULL I 281 K9 PROGRAM NEEDS MORE DRAM I 281 Kits maintenance I 91 L...

Page 342: ... LEDs I 388 magroll motor I 400 main charger current control circuit I 399 NVRAM settings I 392 setting NVRAM values I 392 setting rotary and dip switches I 377 sleeve motor I 400 switches I 377 test points I 381 toner supply clutch I 400 variable resistors I 386 MC Board CPU Internal Error Errors 38 through 47 I 324 Mechanical initialization theory I 176 Mechanisms printing I 127 Memory loading s...

Page 343: ... theory I 161 main unit feed motor theory I 161 perforation cutter motor theory I 166 power paper stacker II 785 tractor motor theory I 162 transfer elevator motor theory I 164 N Nip switch NPSW sensors switches II 557 II 558 No Cleaning Unit Error 26 I 317 NO FLASH FILE SYSTEM Error K4 I 280 No Waste Toner Box Error 29 I 319 NVRAM values MC board I 392 O Operational sequences I 174 OPTIMIZING FIL...

Page 344: ...03 I 287 Paper Jam at Fuser Error 12 I 300 Paper jams at back of paper cassette I 264 cut sheet I 264 fanfold I 258 in face up or face down paper path I 272 in transport input section I 266 in transport output section I 270 near paper output section I 259 near tractor I 258 Paper near end sensor PNES II 585 photoemitting board II 585 photoreceptor board II 586 Paper output section paper jams near ...

Page 345: ...r module II 594 corona II 548 DC board II 509 flash II 563 adjustments I 408 capacitor II 571 unit interface I 236 high voltage II 548 voltage setting I 77 Power supply board adjustments I 403 Power supply filter flash cleaning I 123 Precautions safety English I 23 German See Safety I 30 setup safety English I 25 German I 32 Precharger II 483 Precharger High Voltage Error Error 7A I 327 Preheat la...

Page 346: ...g controller board controller module II 592 Reverse roller unit II 540 Roller unit pickup II 538 reverse II 540 Rotary and dip switch setting MC board I 377 S Safety label locations English I 26 German I 33 notices I 21 precautions English I 23 German I 30 sensors power paper stacker II 757 setup precautions English I 25 German I 32 Schedule consumables replacement user responsibility I 88 replace...

Page 347: ...2 II 752 stacker safety sensors 1 and 2 SS1 SS2 II 757 stacker swinger position sensor SPS II 755 stacker transfer unit paper sensor PMS II 750 theory I 156 upper lower paper empty sensor PES1 PES2 II 716 upper lower paper size sensor II 714 Separator Charger High Voltage Error Error 7D I 330 Separator claw assembly II 486 drive theory I 154 Sequence of operation I 174 Service levels messages clea...

Page 348: ...ontroller module II 592 Test equipment tools and supplies I 38 TEST HARDWARE PLEASE WAIT Error H0 I 279 Theory of operation I 125 Toner cartridge installation I 65 density control theory I 167 control circuit I 198 empty detection circuit I 198 Toner bottle waste installation I 65 Toner density engine checker I 370 sensor MC board I 397 Toner Density Too High Error 2B I 321 Toner Density Too Low E...

Page 349: ...complete stop Error 09 I 293 Transport output section paper jams in I 270 Troubleshooting I 249 symptoms I 331 U Unit interface I 231 Unpacking the printer I 45 Upgrading software I 409 I 413 User Maint option service levels I 84 Utility program lasr2fls I 411 V Vacuum cleaners recommended models I 39 Vacuum fan MC board I 393 Vacuum fan VAF transfer assembly II 502 Varistor main charger II 531 tr...

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