l1024 24-ppm continuous-form laser printer

P/N 704792–001, Rev C

WARNING

This equipment has been tested and found to comply with the limits for a Class A digital device,pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protectionagainst harmful interference when the equipment is operated in a commercial environment. Thisequipment generates, uses, and can radiate radio frequency energy and, if not installed and usedin accordance with the instruction manual, may cause harmful interference to radiocommunications. Operation of this equipment in a residential area is likely to cause harmfulinterference, in which case the user will be required to correct the interference at his ownexpense.

Properly shielded and grounded cables and connectors must be used in order to meet FCCemission limits. The manufacturer is not responsible for any radio or television interferencecaused by using other than recommended cables and connectors or by unauthorized changes ormodifications to this equipment. Unauthorized changes or modifications could void the user’sauthority to operate the equipment.

This device complies with Part 15 of the FCC Rules. Operation is subject to the following twoconditions: (1) this device may not cause harmful interference, and (2) this device must acceptany interference received, including interference that may cause undesired operation.

The input/output (I/O) cable must be shielded for the printer to comply with FCC rules andregulations Part 15 governing the radiation limits for Class “A” equipment.

This digital apparatus does not exceed the Class A limits for radio noise emissions from digitalapparatus set out in the radio interference regulations of the Canadian Department ofCommunications.

Ce matériel numérique n’émet pas de bruits radio–électriques supérieurs aux limites fixées pourles appareils numériques de la Classe A dans le règlement sur le brouillage radio–électriquepublié par le Ministère des Communications du Canada.

Printronix, Inc. makes no representations or warranties of any kind regarding this material,including, but not limited to, implied warranties of merchantability and fitness for a particularpurpose. Printronix, Inc. shall not be held responsible for errors contained herein or anyomissions from this material or for any damages, whether direct, indirect, incidental orconsequential, in connection with the furnishing, distribution, performance or use of this material.The information in this manual is subject to change without notice.

This document contains proprietary information protected by copyright. No part of this documentmay be reproduced, copied, translated or incorporated in any other material in any form or by anymeans, whether manual, graphic, electronic, mechanical or otherwise, without the prior writtenconsent of Printronix, Inc.

All rights reserved. Revision C. September, 1997.

Trademark Acknowledgements

Printronix is a registered trademark of Printronix, Inc.

COPYRIGHT 1996, 1997 PRINTRONIX, INC.

iiiTable of Contents

Table of Contents

Chapter 1 – IntroductionScope 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventions 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related Documents 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Overview 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Users 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Technicians 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Methods 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Users 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Technicians 1–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 2 – ClamshellClamshell Parts List 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Top Cover, Latch, and LED Assemblies 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . Catch Release Assembly 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left and Right Catch Assemblies 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miscellaneous Components 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left and Right Hinge Assemblies 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clamshell Overview 2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical 2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical 2–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Top Cover Assembly 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 2–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 2–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 2–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Latch Assembly 2–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 2–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 2–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 2–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 2–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Catch Release Assembly 2–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 2–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 2–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 2–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 2–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Left and Right Catch Assemblies 2–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 2–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 2–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 2–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 2–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clamshell Hinges 2–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 2–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 2–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 2–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 2–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Chapter 3 – OPC Drum Unit SubsystemOverview 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4 – Developer SubsystemOverview 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 5 – Transfer SubsystemTransfer Charger Parts List 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Corona Parts List 5–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engagement Lever Parts List 5–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Charger Subsystem Overview 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical 5–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Charger 5–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 5–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 5–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 5–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 5–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engagement Lever 5–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 5–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 5–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 5–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 5–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 6 – Paper Feed SubsystemPaper Feed Parts List 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Guides 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tension Roller Assembly 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Gear Assembly 6–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tractor Assembly and Tractor Base 6–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 6–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical 6–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical 6–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tension Roller Assembly 6–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 6–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 6–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 6–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 6–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Gear Assembly 6–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 6–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 6–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 6–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 6–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tractor Assembly 6–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 6–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 6–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Adjustment 6–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 6–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lower Paper Guide and Paper Empty Sensor 6–31. . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 6–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 6–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 6–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 6–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7 – Fuser SubsystemFuser Parts List 7–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuser Assembly 7–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuser Heat Shield Assembly 7–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuser Base Assembly 7–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Fuser Assembly 7–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 7–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 7–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 7–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 7–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuser Base 7–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 7–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 7–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 7–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 7–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 8 – Power SuppliesPower Supplies Parts Lists 8–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Voltage Power Supply 8–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Voltage Power Supply 8–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 8–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Voltage Power Supply 8–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal and Disassembly 8–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Voltage Conversion and Fuse Replacement 8–17. . . . . . . . . . . . . . . . . Reassembly and Replacement 8–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 8–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 8–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Voltage Power Supply 8–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 8–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 8–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 8–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 8–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 9 – Controllers and Floppy Disk DrivesData Controller Board Parts List 9–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Controller Board Parts List 9–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stepper Motors Controller Board Parts List 9–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floppy Disk Drives Parts List 9–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview 9–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data Controller Board 9–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal and Disassembly 9–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 9–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 9–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Troubleshooting 9–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Controller Board 9–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal and Disassembly 9–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 9–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 9–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 9–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stepper Motors Controller Board 9–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 9–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 9–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 9–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 9–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Floppy Disk Drives 9–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 9–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 9–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 9–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 9–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Expansion C/T Removal and Installation 9–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 10 – Control PanelControl Panel Parts List 10–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview 10–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical 10–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical 10–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel 10–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 10–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 10–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 10–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 10–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 11 – Laser Scanning Unit (LSU) SubystemLSU Parts List 11–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LSU Assembly 11–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Erase LED Assembly 11–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


LSU Assembly 11–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 11–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 11–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 11–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 11–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Erase LED Assembly 11–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 11–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 11–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 11–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 11–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 12 – Covers, Frame, and Backplane BoardCovers Parts List 12–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Side Frame Parts List 12–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Side Frame Parts List 12–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom Frame Parts List 12–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview 12–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Side Frame 12–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

viiTable of Contents

Removal and Disassembly 12–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 12–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 12–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 12–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Right Side Frame 12–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 12–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 12–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 12–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 12–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base Frame 12–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 12–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 12–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 12–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 12–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Backplane Board 12–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly 12–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Replacement 12–51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment 12–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 12–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 13 – Troubleshooting GuideOperation Sequence 13–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power-Up Self-Test 13–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Command 13–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Power-up Sequence 13–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guide to Imaging Errors 13–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index to Imaging Errors 13–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detailed Troubleshooting Guide 13–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guide to Error Mesages 13–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator-correctable Error Messages 13–26. . . . . . . . . . . . . . . . . . . . . . . . . . Service Call Error Messages 13–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Detailed Troubleshooting Guide 13–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 CLOSE THE COVER 13–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 LOAD PAPER 13–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03 ADD TONER AND CHK WASTE BOTTLE 13–30. . . . . . . . . . . . . . . . . . . 04 INSTALL TONER CUP 13–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 INSTALL OPC DRUM 13–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06 CLEAR JAM AT FUSER INPUT 13–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 CLEAR JAM AT FUSER EXIT 13–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08 CLEAR JAM NEAR TOF LEVER 13–31. . . . . . . . . . . . . . . . . . . . . . . . . . . 09 CHECK TOF LEVER 13–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SPEED CTL ERR—Check Paper Path 13–31. . . . . . . . . . . . . . . . . . . . . . 25 ENCODER FAIL—Call Service 13–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 FUSER FAIL—Call Service 13–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 FUSER FAIL—Call Service 13–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 FUSER FAIL—Call Service 13–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 FUSER FAIL—Call Service 13–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 THRMISTR FAIL—Call Service 13–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 THRMISTR FAIL—Call Service 13–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 HEATER FAIL—Call Service 13–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 HEATER FAIL—Call Service 13–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 BEAM DET FAIL—Call Service 13–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 LSU FAIL—Call Service 13–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 LSU FAIL—Call Service 13–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 LSU FAIL—Call Service 13–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

viii Table of Contents

32 MISPRINT ERROR—Call Service 13–41. . . . . . . . . . . . . . . . . . . . . . . . . . 33 REPLACE EEPRM—Call Service 13–41. . . . . . . . . . . . . . . . . . . . . . . . . . 34 REPLACE OPC DRUM—Call Service 13–41. . . . . . . . . . . . . . . . . . . . . . . 35 EC CKSUM FAIL—Call Service 13–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . TOF REGISTRATION ERRORS 13–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A – Printer Specifications

Appendix B – Wire Data

Appendix C – Continuous Form StackerParts Identification C–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly/Reassembly C–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Basic Frame C–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Tabletop C–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Paddle Drive Motor Assembly C–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Upper Drive Motor Assembly C–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Paddle Drive Belts C–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Paper Shelf C–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Front and Rear Paper Guides C–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Left and Right Vertical Frame Braces C–26. . . . . . . . . . . . . . . . . . . . . . . The Left and Right Upper Frames C–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Upper Drive Bearing C–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Cable Clamp Screw Mount C–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Paper Shelf (with cable installation) C–35. . . . . . . . . . . . . . . . . . . . . . . . .

Stacker Specifications C–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix D – Principles of Operation

1–1Chapter 1 – Introduction

Chapter 1Introduction

This manual covers service and parts for the L1024 24-ppm continuous-form laser printer. Each sectioncovers one major subassembly of the printer, in the following order:

Overview

Mechanical Explanation

Electronics Explanation (if appropriate)

Subassembly Removal from the Printer and Disassembly

Subassembly Reassembly and Replacement in the Printer

Adjustment (if needed)

Limited Troubleshooting (See also Chapter 13 for more troubleshooting)

The use of LEFT and RIGHT always assumes you are viewing the front of the printer. For instance, thecontrol panel is on the RIGHT side of the front of the printer.

Notes and Notices that you need to pay special attention to are presented in the following way:

WARNING: Possible danger to you or the user.

CAUTION: Possible equipment or data damage may occur.

NOTE: Extra information for you to consider.

This manual does not explain how to operate or configure the printer. For that information, refer to theOperator’s Guide and Setup Guide that accompany the printer.

The L1024 is a 24-ppm continuous-form laser printer. It contains an internal engine controller and aninternal data controller plus a floppy disk drive.

The printer includes the major subassemblies shown in Figure 1–1.

1–2 Chapter 1 – Introduction

BASEPAN

FUSERBASE

FUSER ROLLERASSEMBLY

CONTROLPANEL

TRANSFER

BOTTOMFRAME

HIGHVOLTAGESUPPLY

TRACTOR

LOWVOLTAGESUPPLY

MAINDRIVE

RIGHTFRAME

LEFTFRAME

DEVELOPER

TENSIONROLLER

LSU (LASER SCANNING UNIT)

BOTTOMCOVER

LED ARRAY

STEPPER MOTOR &CONTROL BOARDHOUSING

MOTOROPC

ENGINE CONTROLLER BOARD

CLAMSHELL

BACKPLANE BOARD

DATA CONTROLLER BOARD

Figure 1–1. Major Subassemblies.


Users

The printer is designed so that the user can perform the following maintenance tasks without calling aservice technician:

Removing and replacing the Toner Cartridge

Removing and replacing the Waste Toner Container

Replacing the Fuser Felt Wiper

Cleaning the Fuser Heat Roller

Cleaning the Transfer Corona Wire

Cleaning the Charge Corona Wire

Removing and replacing the OPC Drum Unit

Removing and replacing the Developer Unit

Removing and replacing the Ozone Filter

Removing and replacing the Fuser Unit

When you are called to service the printer, check these items to be sure that the owner is replacing themaccording to the schedule below. This user maintenance schedule provides the owner with the bestquality printing.

Service Technicians

Service personnel will provide all other maintenance on these printers according to warranty and serviceagreements.

WARNING: Since this unit uses laser light, even though the power is less than 1milliwatt at 780 nm, it is wise to protect your eyes whenever the top ofthe printer (clamshell) is open and the Laser Scanning Unit (LSU) isexposed and functioning. We recommend that you wear protectiveeyewear capable of attenuating laser light at 780 nm to safe levels orcover the LSU cover glass to prevent the laser light from escapingduring servicing.


Cleaning kits are provided in the Developer Kits, as well as being sold separately. These kits includecotton swabs, several “wet wipe” tissues in foil pouches, a corona wire cleaning brush, and instructions.Users and service personnel are encouraged to use them on the schedule shown below.

Users

Users should perform the following actions at the frequencies listed below:

When Refilling the Toner (approximately every 8,000 pages)

Replace the Waste Toner Container.

Replace the Fuser Felt Wiper.

Clean the Fuser Heat Roller.

Clean the Transfer Corona Wire.

Clean the Charge Corona Wire.

When Replacing the OPC Drum Unit (approximately every 30,000 pages)

Clean inside the printer as needed.

When Replacing the Developer Unit (approximately every 100,000 pages)

Replace the Ozone Filter.

Clean the Fuser Heat Roller.

Clean the Transfer Corona Wire.

Clean the Charge Corona Wire.

When Using Label Paper and Regular Paper alternately

Clean the Tension Roller (after each 4,000 pages of labels printed—see the information onthe next page).

WARNING: Turn off power to the printer before cleaning it.


Service Technicians

Service personnel should perform the following actions at or before every 300,000 pages:

Clean the LSU Cover Glass.

Clean other parts as needed inside the printer, including vacuuming the interior of theprinter.

WARNING: Turn off power to the printer before cleaning it.

NOTE: The inside of the printer should be cleaned and vacuumed includingspecial attention to paper dust on the fuser fan motor. This should be donewhenever the printer is serviced, or at 300,000 pages, whichever comesfirst.


The following table lists the items needing periodic cleaning and the recommended cleaning procedures:

CleaningArea

FrequencyCleaning Tool Method

Tension Roller 4,000 pages(especially if usingregular paper afterusing labels)

Wet WipeTissue

Turn off the printer. Open the top and frontcovers of the printer. Remove the OPCDrum Unit and the Developer Unit (refer tothe Setup Guide). Wipe the tension rollerwith a wet wipe tissue while rotating theblack gear on the right side as shown in theillustration below.

Figure 1–2. Cleaning the Tension Roller

(Continued on next page)


CleaningArea

MethodCleaning ToolFrequency

Fuser Heat Roller; Transfer Corona Wire;Charge Corona Wire

When replacing FeltWipers and whenreplacing DeveloperUnit

Refer to theSetup Guide.

Refer to the Setup Guide.

Inside Cleaning

30,000 pages Wet WipeTissue

Remove paper powder and toner from theareas listed below:

Transfer Charger around the mylar sheet(wipe the mylar first, then use the brushfor the wire)

Around the Tractor

Inside the right cover

High Voltage Power Supply cover

Fuser paper guide

Transfer paper guide

Paper guide inlet

Front paper guide (if installed)

LSU Cover Glass

300,000 pages Cotton Swaband RubbingAlcohol

Wipe the LSU Cover Glass with a cottonswab containing anhydrous rubbing alcohol.Rub the glass in one direction only (eitherfrom right-to-left or from left-to-right).Repeat this process, using a new cottonswab each time, until the glass iscompletely clean.

2–1Chapter 2 – Clamshell

Chapter 2Clamshell

Clamshell and Subassemblies

2–2 Chapter 2 – Clamshell

2.1.1 Top Cover, Latch, and LED AssembliesCallout Name Vendor Part No. Printronix Part No.1 Top Cover and Latch Assembly 202104–5012 Top Cover Assembly 200864–001 702817–0013 Cover, Top 200495–001 703108–0014 Seal, Short 200533–001 702820–0015 Seal, Medium 200532–001 702819–0016 Seal, Long 200531–001 702818–0017 Toner Dust Baffle 200563–001 702730–0018 Screw, PPH, CLFW, M3x8, Zinc (2) 030129–3089 Latch Assembly 200489–554 702690–00110 Spring, Torsion, Lower Latch11 Lever, Release12 Button, Release13 Shaft, Latch (2)14 Button, Locking15 Shaft, Locking16 Frame, Latch17 E-Ring, 3mm I.D., Zinc (2) 071151–00418 E-Ring, 4mm I.D., Zinc (2) 071051–00619 Spring, Torsion, Upper Latch20 Screw, PPH, CLFW, M3x6, Zinc (2) 030130–30620 Screw, PPH, CLFW, 3x6mm, Zinc (11) 030130–30621 LSU Base Plate Assembly22 LSU Base Plate 202165–00123 Cover Felt, Clamshell Fuser 202166–00131 Bushing, LED Wire Harness 202167–001

(not shown)26 Erase LED Assembly 200542–501 702724–00127 Cover, LED Assembly 200541–00128 Mount, LED, Plastic29 Board Assembly, LED30 Screw, PPH, PTC, 3x8mm, Zinc (4) 030129–30832 Cable, LSU 202294–55133 LSU 202118–55134 Seal, LSU Drum 202575–001


Top Cover

LED Assembly

203

261 25

1

231

221

316

1

51

41

82

71

2Ref

9120

2

1Ref

208 32

1

202

21Ref

341

33117

2161 18

2

121

101

11113

2141

191

151

281

291

304

26Ref

271

Latch Assembly Detail

LED Array Assembly Detail

Top Cover, Latch, and LED Assemblies


2.1.2 Catch Release AssemblyCallout Name Vendor Part No. Printronix Part No.1 Catch Release Assembly 200870–501 702825–0012 Frame, Catch Release3 Lever, Release, Right4 Lever, Release, Left5 Shaft, Clamshell Locking 200980–0016 Pin, Spring, 2x10mm, SS (2) 080199–110

2.1.3 Left and Right Catch AssembliesCallout Name Vendor Part No. Printronix Part No.7 Catch Assembly, Left 200872–501 702831–0018 Clamshell Catch, Left9 Shaft, Clamshell Catch 200523–00110 E-Ring, 5mm I.D., Zinc 071151–00811 Screw, PPH, CLFW, 3x8mm, Zinc (2) 030130–308

12 Catch Assembly, Right 200871–001 702829–00113 Clamshell Catch, Right9 Shaft, Clamshell Catch 200523–00110 E-Ring, 5mm I.D., Zinc 071151–00811 Screw, PPH, CLFW, 3x8mm, Zinc (2) 030130–308

2.1.4 Miscellaneous ComponentsCallout Name Vendor Part No. Printronix Part No.14 OPC Retaining Spring (2)15 Clamshell Frame, Right 202164–00116 Clamshell Frame, Left 202163–00117 Hinge Assembly, Left 200967–002 704539–11418 Hinge Assembly, Right 201231–001 704539–11519 Screw, PPH, CLFW, 3x6mm, Zinc (6) 030130–306


RightHingeAssembly

LeftHingeAssembly

Left CatchAssembly

CatchReleaseAssembly

2Ref

171

181

151

192

142

161

81

112

7Ref

91

101

1Ref

41

21

51

31

12Ref9

1101 Right

CatchAssembly

62

112

194

131

Catch Assemblies


2.1.5 Left and Right Hinge AssembliesCallout Name Vendor Part No. Printronix Part No.1 Frame, Clamshell, Left 202163–001

Frame, Clamshell, Right 202164–0012 Hinge Assembly, Left 200967–002 704539–114

Hinge Assembly, Right 201231–001 704539–1153 Hinge Assembly, Shaft/Bracket 200605–0014 Bracket, Hinge5 Shaft, Hinge6 Spring, Compression, Hinge 200607–0017 Hinge, Slide 200609–0018 Retention Plate 200610–0019 Frame, Clamshell Hinge 200611–00110 CE-Ring, 7mm I.D., Zinc 072151–01211 Screw, PPH, CLFW, 3x6mm, Zinc (1) 030130–30611 Screw, PPH, CLFW, 3x6mm, Zinc (2) 030130–30612 Shaft, Pivot 200608–00113 Collar, Pivot Shaft 200612–00114 Spring, Compression, Hinge Tension 200613–00115 Shaft, Locking 200614–00116 Screw, PPH, IW, 4x6mm, Zinc 030131–40617 E-Ring, 3mm I.D., Zinc 071151–004


NOTE: This is the left side hinge. Theright side hinge is a mirrorimage of the left side hinge.

111

2Ref

3Ref

41

51

61

71

101

91

81

141

161

171

11

151

121

131

112

Hinge Assemblies


2.2.1 Mechanical

The Clamshell consists of the following basic subassemblies:

A. Top Cover Assembly. This includes:

The Top Cover.

The Toner Dust Baffle. The Baffle is attached to the Top Cover Assembly. With theClamshell closed, the Baffle is positioned over the waste toner outlet from the OPC DrumUnit. The Baffle traps any waste toner dust and prevents contamination of the engine.

Latch Assembly. The Latch Assembly is attached to the Top Cover and is used to open theprinter Clamshell.

Catch Release Assembly. The Catch Release Assembly releases the Clamshell Latcheson each Side Frame from the shafts on the Clamshell Catches.

Left and Right Catch Assemblies. The Catch Assemblies hold the Clamshell closed usingthe Clamshell Latch. The Right Catch Assembly also acts as the Cover Open Interlock.

Clamshell Hinges. The two Hinges allow the Clamshell to rotate upward for insertion ofpaper, replacement of consumables, and service.

B. LSU Base Plate (discussed in more detail in Chapter 11, Laser Scanning Unit Subsystem).This includes:

The LSU. The Laser Scanning Unit generates the laser light, which “writes” a picture of thepage to be printed onto the OPC drum. It is discussed in detail in Appendix C.

The LED Erase Assembly. The Erase Assembly “erases” the charge on the OPC drum byexposing it to light. The drum is erased prior to being charged by the LSU. The LED EraseAssembly is discussed in detail in Appendix C.


2.2.2 Electrical

All electrical connections to the Clamshell are via a cable from the Backplane Board to the LSU thatpasses through the Right Hinge Assembly. The cabling block diagram for the Clamshell is shown below.See Appendix B for a complete electrical block diagram.

J4

TOLSU

1 5 11

Backplane Board

3 7 9 13

+12

V

/QLE

D+

24B

GN

D/P

MO

N

/PM

RD

Y+

5D

GN

D/B

D+

5

DG

ND

/LD

ON

/LV

IDE

OLV

R

Block Diagram 2–1. Top Cover Electrical


2.3.1 Removal and Disassembly

1. Open the Clamshell and remove 3 Screws from the Clamshell Frame (see Figure 2–1), thenlift the front of the Top Cover first to help disengage the LSU Locking Tabs from the rear of theCover. See Detail 2–1.


LatchRemovalDetail

Top Cover

Clamshell Frame

Step 1

Step 3

Step 4

Step 5

Figure 2–1. Top Cover Disassembly


1. Lift Front Cover,then disengagerear Locking Tabs.

2. Depress tab toremove HingeCover.

Detail 2–1. Removing Top Cover and Hinge Covers


2. Remove either Hinge Cover by pressing the lower Locking Tab with a small screwdriver andremoving the Hinge Cover by lifting it upward. See Detail 2–2.

NOTE: The Clamshell Frame may need to be closed for removal of the HingeCovers.

Repeat Step 2 for the other hinge cover.

3. Remove 2 screws, then remove the Toner Dust Baffle. See Figure 2–1.

4. Remove 2 screws, then remove the Latch Assembly from the Top Cover. See Figure 2–1.

5. Remove the Toner Seals from the Top Cover only if absolutely necessary. See Figure 2–1.

2.3.2 Reassembly and Replacement

Reverse Steps 1 through 5 listed above.

NOTE: When reinstalling the Top Cover onto the Clamshell, make sure the LatchAssembly is properly oriented with the Release Lever. See Detail 2–2 onpage 2–15.

2.3.3 Adjustment

No adjustment of the Top Cover Assembly is necessary.

2.3.4 Troubleshooting

See Chapter 13 for troubleshooting information.



1. Open the Clamshell and remove 2 screws, then remove the Latch Assembly. See Figure 2–1.

2. Remove 1 E-ring, then slide the Latch Shaft free of the Release Lever. This frees the ReleaseLever and Lower Latch Spring from the Release Button. See Figure 2–2.

Step 2

Step 3

Step 4

Figure 2–2. Latch Assembly Disassembly

3. Remove the other E-ring, then slide the Latch Shaft free of the Latch Frame. This frees theLatch Frame, Locking Button, Release Button, and Upper Latch Spring from one another.See Figure 2–2.

4. The Locking Shaft can be removed from the Latch Frame by removing the E-ring from eitherend of the Shaft and sliding it off of the Frame. See Figure 2–2



Reverse Steps 1 through 4 listed above, and also refer to Detail 2–2 below.

NOTE: When reinstalling the Latch Assembly onto the Top Cover, make sure theLatch Assembly is properly oriented with the Release Lever. SeeDetail 2–2.

CORRECT LATCH RELEASEPOSITION

Detail 2–2. Correct Latch Release Position

2.4.3 Adjustment

No adjustment of the Latch Assembly is necessary.





1. Open the Clamshell, remove 3 Screws from the Clamshell Frame, then lift the front of theCover. This helps disengage the Locking Tabs of the LSU from the rear of the Cover. SeeFigure 2–1 and Detail 2–1.

2. Remove 4 attachment screws, then remove the Catch Release Assembly from the ClamshellFrame. See Figure 2–3.


Left Catch

Right Catch

CatchReleaseAssembly

Step 2,page 2–19

Step 4,page 2–19

Step 2,page 2–19

Step 3,page 2–19

Step 5,page 2–19

Step 2

Step 3

Step 2,page 2–19

Figure 2–3. Catch Release Assembly Removal


3. Remove the Spring Pin from the desired Release Lever, then slide it off of the Shaft. TheShaft can now be slid free of the Frame.



NOTE: When reinstalling the Top Cover onto the Clamshell, make sure the LatchAssembly is properly oriented with the Release Lever. See Detail 2–2.

2.5.3 Adjustment







2. Remove 4 Screws from the corners of the LSU Base Plate, then remove 1 Screw from theoutside of each Clamshell Frame. This loosens the LSU Base Plate so that the Catches canbe removed from the Clamshell Frames. See Figure 2–3.

3. Remove 2 screws, then remove the Right Clamshell Catch.

4. Remove 2 crews, then remove the Left Clamshell Catch.

5. Remove 1 E-ring, then remove the Shaft from either Catch Assembly.




2.6.3 Adjustment






1. Place the printer on a phone book or other similar item so that the Bottom Cover edges arenot resting on the item. Press gently to release the 2 Locking Tabs on the right side of theBottom Cover, then gently lower this side. See Detail 2–3. Slide the Bottom Cover slightly tothe right to release the locking tabs on the left side, then lower the Bottom Cover away fromthe printer and over the phone book.

BottomCoverLockingTabs

Detail 2–3. Bottom Cover Removal

2. Remove the printer from the phone book and position the printer so that the rear of the BasePlate extends over the edge of the work surface. Remove 1 Screw from the bottom of the


Base Plate for each Hinge. See Figure 2–4. Remove 1 Screw from the top of each Hinge,then remove the entire Clamshell Assembly from the printer.

CAUTION: Since the LSU Cable is still connected to the printer, the Clamshellwill have limited movement. Be careful not to damage the LSU, theLSU Cable, or the Clamshell Frame.

NOTE: This is the left side hinge. Theright side hinge is a mirrorimage of the left side hinge.

Step 2

Step 2

Step 3

Step 4

Step 5

Step 6

Figure 2–4. Clamshell Hinge Removal

DISASSEMBLY (See Figure 2–4)

3. Remove 1 Screw from the Hinge Frame, then remove the Retention Plate. The Hinge Slidecan now be slid free from the Hinge Frame.

4. Remove 1 CE-ring from the Slide, then remove the Slide and Hinge Spring from the HingeShaft.

5. Remove 1 E-ring from the Clamshell Frame, then remove the Locking Shaft, Shaft Collar, andBracket Assembly from the Hinge Assembly.


6. Remove 1 Screw and the Tension Spring, then remove the Pivot Shaft from the Assembly tofree the Hinge Frame from the Clamshell Frame.

NOTE: The steps above can be performed for either Hinge Assembly.


Reverse Steps 1 through 6 above.

2.7.3 Adjustment

Adjust the spring tension (on the side of the hinge) so that when the Clamshell is opened fully andreleased, the Clamshell falls to a 30° angle and then stops. This adjustment prevents the Clamshell frominjuring the fingers of operators or service personnel.

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÏÏÏÏ

ÌÌÌÌÌÌÌÌÌ

ÎÎÎÎ

SpringRetentionPlate

Spring TensionAdjustment Screw

Figure 2–5. Clamshell Hinge Adjustment



3–1Chapter 3 – OPC Drum Unit Subsystem

Chapter 3OPC Drum Unit Subsystem

The OPC Drum Unit is a user-replaceable consumable. It has a life of around 30,000 pages. It receivesthe laser light image of the page from the LSU, transfers toner from the developer to the OPC drum toform this image, and allows the toner image to be transferred to the page prior to fusing. See Figure 3–1.

This unit is factory assembled and factory adjusted. No field adjustments are required.

Figure 3–1. OPC Drum Unit

To remove the OPC Drum Unit from the printer, first open the printer top cover. Then, simply lift the unitout of the printer. See Figure 3–2.

CAUTION: When removing the OPC Drum Unit from the printer, be careful not tospill toner from the waste toner screw (located on the left side of theunit).

3–2 Chapter 3 – OPC Drum Unit Subsystem

No disassembly is required.

OPC Drum Unit

Figure 3–2. Removing the OPC Drum Unit

No reassembly is required.

To install an OPC Drum Unit, first place the unit in the printer. Then, ensure that the unit is fully seated sothat its contacts on the right side are properly set, and so that the Waste Toner Auger Seal opens and fitsproperly over the Waste Toner Container. See Figure 3–2.

The OPC Drum Unit is adjusted at the factory; no field adjustments are required.


4–1Chapter 4 – Developer Subsystem

Chapter 4Developer Subsystem

The Developer Unit consists of a hopper containing toner and carrier, plus a magnet roller. The magnetroller provides measured amounts of toner to the OPC Drum Unit, for developing the page image. SeeFigure 4–1.

This unit is factory assembled and factory adjusted. No field adjustments are required.

Figure 4–1. Developer Unit

To remove the Developer Unit from the printer, first open the top and front covers of the printer. Then,unlock the green locking levers on each side of the Developer Unit, and lift the unit out of the printer alongthe plastic rails on each side. See Figure 4–2.

CAUTION: When removing the Developer Unit from the printer, be careful not toturn the unit over, because toner may spill out of the unit.

4–2 Chapter 4 – Developer Subsystem

No disassembly is required.

1

2

3

3

4

Figure 4–2. Removing the Developer Unit

4–3Chapter 4 – Developer Subsystem

No reassembly is required.

To install a Developer Unit, first open the top and front covers of the printer. Then, slide the DeveloperUnit into the printer along the plastic rails on each side, until the unit is fully seated in the printer. Lockboth of the locking tabs.

If the Developer Unit that you are installing is a new one, follow the instructions in the Operator’s Guidefor replacing carrier and toner. See Figure 4–2.

The Developer Unit is adjusted at the factory; no field adjustments are required.


4–4 Chapter 4 – Developer Subsystem

5–1Chapter 5 – Transfer Subsystem

Chapter 5Transfer Subsystem

Transfer Charger

5–2 Chapter 5 – Transfer Subsystem

Callout Name Vendor Part No. Printronix Part No.1 Transfer Charger Assembly 202140–501 704539–0632 Base, Transfer Charger 201235–0013 Transfer Charger Assembly 202142–5014 Frame Assembly, Transfer Charger 200554–5525 Frame, Transfer Charger6 Swing Shaft7 Damper, PVC (2)8 Transfer Corona Assembly 202143–5019 Screw, PPH, CLFW, Zinc, 3x8mm (2) 030130–30810 Paper Guide, Plastic, Rear 202148–00111 Brush, Static Discharge 202147–55112 Screw, PPH, IW, Chrome, 3x6mm (2) 030231–30613 Shaft, Transfer Charger 200553–00114 E-Ring, 3.0mm I.D., Chrome 071251–00415 Spring , Compression,Transfer Charger (2) 200555–00116 Paper Guide, Plastic, Front 202141–00117 Paper Guide, Transfer Charger 200551–00118 Screw, PPH, CLFW, M3x6, Zinc (6) 030130–30619 Paper Guide, Lower 202149–001 704539–068

(Shown in this view, not part of this assembly)


4Ref

92

1Ref

171

81

142

122

51

72

111

161

61

131

3Ref

101

152

21

184

182

191

Transfer Charger Assembly


Callout Name Vendor Part No. Printronix Part No.1 Transfer Corona Assembly 202143–501 704539–0642 Wire, Transfer Corona 202144–0013 Cover, Transfer Corona (2) 202145–0014 Spring, Extension, Transfer Corona 200617–0015 Housing, Transfer Corona 200618–0016 Mylar Strip, Transfer Corona 202146–001

51

61

21

32 1

Ref

41

Transfer Corona Assembly


Callout Name Vendor Part No. Printronix Part No.1 Engagement Lever Assembly 200502–501 702701–0012 Guide, Engagement Lever (2) 200500–0013 Engagement Lever Unit 200499–5514 Pulley, Cam Lever5 Shaft, Pulley, Cam Lever6 Lever, Engagement7 Spring, Extension, Engagement Lever 200501–0018 Screw, PPH, CLFW, 3x6mm, Zinc (2) 030130–306

3Ref

82

22

51

41

71

61

1Ref

Engagement Lever Assembly


5.4.1 Mechanical

The following is a description of the major mechanical parts of the Transfer Subsystem and theirfunctions.

Engagement Lever. This is attached to a cam of the Fuser Cam Shaft. The cam pulls the TransferCharger carriage away from the paper when the printing process is finished and the Fuser opens.

Transfer Charger Carriage. This carriage raises the Transfer Corona up and down during the printingprocess. It contains the Transfer Corona, Static Brush, and Paper Guide, and is driven by theEngagement Lever.

Static Brush. This brush removes the static charge that is built up during the transfer process.

Transfer Corona. This is a 60 µm gold-plated tungsten wire that, with an electric charge, pulls toner, in theform of a developed image, from the OPC drum to the paper.

Plastic Paper Guide. This guide sets the paper to the correct height from the transfer corona.

Low VoltagePower Supply

High VoltagePower Supply

CN3

Cover Switch

Drum SwitchesTransfer Corona

60 µm wire

Figure 5–1. Physical Arrangement of the Transfer Subsystem


5.4.2 Electrical

The transfer system has a very limited electrical function. It includes only the transfer corona. See BlockDiagram 5–1.

HIGH VOLTAGEPOWER SUPPLYJ10

J9/WASTETNRLOW

+5

DGND

1

6

1

4

CN1CN2

OPC

TRANSFERCORONA

DEVELOPER

DEVELOPERBIAS

TONERSENSOR

+24VB

BGND

/CHARGE

/DEVELOPER/TRANSFER

1

6

J1

1

4

Backplane Board

TONERSENSORBOARD

Block Diagram 5–1. Transfer Subsystem Electrical Components,Transfer Corona

The transfer corona is a small (60 µm) wire that is charged to +4,600 volts (±100 volts) DC. The input forthe Transfer Corona (Block Diagram 5–1) is connector pin CN–3 from the High Voltage Power Supply(HVPS). This connector pin is on a spring-loaded connector that is located under the left side of theTransfer Charger, near the Waste Toner Cup.

NOTE: The Corona Baseplate is grounded to the Charger Baseplate.

When the /TRANSFER signal goes low (zero volts), the HVPS turns on the voltage to the TransferCorona Wire. This voltage then causes the developed image to transfer from the OPC Drum to the paper.



1. Open the Clamshell and remove the OPC and Developer Units, and any paper that may bepresent in the Printer.

2. Remove the Front Plastic Paper Guide from the Transfer Charger by pressing down on thecenter and ends, then sliding it to the left. This disengages the Locking Tabs, allowing thePaper Guide to be easily removed. See Figure 5–3.


Step 5

Step 6

Step 7

Step 8

Step 4

Step 2

Step 3

Step 4

Figure 5–3. Transfer Charger


3. Remove the Transfer Charger Paper Guide by gently pressing the Release Tabs at the rear ofthe Guide toward the front of the Printer. Lift the rear of the Guide to clear the Tabs of theSlots, and release the Front Tabs by rotating the Guide toward the front of the Printer.

4. Remove 4 Screws from the bottom of the Transfer Charger. Remove the Charger from thePrinter by lifting the front of the unit and rotating it toward the rear of the Printer. This makes iteasier to disengage the Swing Shaft from the Engagement Lever. See Detail 5–1.

NOTE: The Transfer Corona Assembly can be removed from the Transfer Chargerwithout removing the Transfer Charger from the Printer. To do this, firstremove the Front Plastic Paper Guide per the instructions in Step 2 above.Then, proceed to Step 5 below.

Swing Shaft

Detail 5–1. Loosening the Transfer Charger

5. Remove the Static Brush and Rear Plastic Paper Guide by removing 2 Screws.

NOTE: When reinstalling the Static Brush, make sure the Brush Frame is in frontof the Locking Tab for the Corona Assembly. See Detail 5–2.


Static BrushIs Placed InFront OfRetainingTab

DETAIL 5–2

Detail 5–3

Corona Neck Is PlacedUnder Retaining Tab

Detail 5–2 and 5–3. Removing the Static Brush and Rear Paper Guide;Corona Contact and Locking Tab

6. Transfer Corona Assembly:

a. Remove 2 Screws and lift the Corona Assembly up slightly while sliding it to the left todisengage the Locking Tabs. See Figure 5–4.


Step 6A

Step 6A

Step 6B

Step 6C

Step 6D

Step 6B

Figure 5–4. Transfer Corona Assembly

NOTE: When installing the corona assembly, make sure the neck of the coronacontact is under its locking tab. See Detail 5–3.

b. Remove the 2 Covers by gently releasing the Locking Tabs with a screwdriver.

CAUTION: The Tabs are extremely fragile and can be easily broken.

c. To remove the Corona Wire, gently pull on the small Eyelet at the opposite end of theWire from the Spring, and remove the small Eyelet from its Post.

CAUTION: The Wire is only 60 µm thick and can be easily broken. Also, do nottouch the wire, as fingerprints may cause it to fail.

d. Remove the large Eyelet from the Spring.

NOTE: The Spring should be removed only if absolutely necessary.

7. Remove the E-ring on the left end of the Main Shaft and remove the Shaft.

8. Remove the Transfer Charger Frame from the Charger Base Plate.




5.5.3 Adjustment

No adjustment of the Transfer Charger Assembly is necessary.





1. Open the Clamshell, remove the OPC, Developer Unit and any paper present in the Printer.See Figure 5–5.


Step 5

Step 6

Step 7

Step 8

Step 9

Step 10

Step 11

Cover overlapstractor assemblyside frame


Detail 5–6 Detail 5–5

Figure 5–5. Engagement Lever Removal


(For Steps 2 through 4 following, refer to Figure 5–3 on page 5–9.)

2. Remove the Front Plastic Paper Guide from the Transfer Charger by pressing down on theends of the Paper Guide and sliding it to the left. This disengages the Locking Tabs and thePaper Guide can then be easily removed.

3. Remove the Transfer Charger Paper Guide by gently pressing the Release Tabs at the rear ofthe Guide toward the front of the Printer. Lift the rear of the Paper Guide to clear the Tabs ofthe Slots, and release the Front Tabs by rotating the Paper Guide toward the front of thePrinter.

4. Remove 4 Screws from the bottom of the Transfer Charger. Remove the Charger from thePrinter by lifting the front of the unit and rotating it toward the rear of the Printer. This makes iteasier to disengage the Swing Shaft from the Engagement Lever. See Detail 5–1 on page5–10.

5. Remove the plastic Fuser Heat Shield. See Figure 5–5.

6. Remove the Lamp Connector Cover by removing 1 Screw and sliding the cover toward thefuser. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor BoardFrame. See Figure 5–5 and Detail 5–4.


Detail 5–4. Removing the Lamp Connector


(For Steps 7 through 11 following, refer to Figure 5–5 on page 5–15.)

7. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the WarningLabel at the front of the Cover. This releases the Locking Tab from the Right Side Cover. SeeDetail 5–5 in Figure 5–5.

NOTE: Upon installation, the groove on the bottom of the Right Inside Covershould straddle the top edge of the right side of the Tractor Frame.

8. Remove the Tractor Encoder Cover by removing 1 Screw.

NOTE: Upon installation, the groove on the bottom of the Encoder Cover shouldstraddle the top of the left end of the Tractor Frame. See Detail 5–6 inFigure 5–5.

9. Remove the Tractor Paper Guide by removing 1 Screw from the center rear of the TractorFrame.

10. Disconnect the Tractor Encoder Cable from the Connector on the Base Plate behind theTractor.

11. Remove the Tractor by removing 3 Screws, then lifting the left end of the Tractor out first.This allows the the Encoder to clear the High Voltage Power Supply, and allows the Tractorroom to move to the left so that the Tractor Stepper Motor can clear the Stepper Motor BoardFrame.

12. Disconnect the Cable from the Tractor Stepper Motor and remove the Tractor from thePrinter.

13. Remove 2 Screws, then remove the Engagement Lever from the Printer.

14. Remove the Engagement Lever Spring from the Rear Guide, then slide the Guide to thecenter of the Lever to remove it. The Front Guide can also be removed by sliding it to thecenter of the Lever.



5.6.3 Adjustment

No adjustment of the Engagement Lever Assembly is necessary.


Ensure that the Engagement Lever moves freely and is engaged with the Fuser Cam and Pivot Shaft ofthe Transfer Charger.

6–1Chapter 6 – Paper Feed Subsystem

Chapter 6Paper Feed Subsystem

Paper Feed Subsystem

6–2 Chapter 6 – Paper Feed Subsystem

6.1.1 Paper GuidesCallout Name Vendor Part No. Printronix Part No.1 Paper Guide, Lower 202149–001 704539–0682 Sensor, Paper Empty 202278–551 704539–0533 Wire Clamp, Paper Empty Sensor 202288–0014 Screw, PPH, CLFW, 3x6mm (3) 030130–3065 Guide, Paper Entry 202516–5516 Guide, Paper Exit 202379–001

21

11

31

43

51

61

Paper Guides


6.1.2 Tension Roller AssemblyCallout Name Vendor Part No. Printronix Part No.19 Tension Roller Assembly 202100–5011 Frame Assembly, Tension Roller 202101–5512 Frame, Tension Roller3 Shaft, Transfer Gear, Tension Roller4 Shaft, Drive Gear, Tension Roller5 Gear, Tension Roller (2) 200567–0016 Gear, Transfer, Tension Roller 202103–0017 Bushing, Tension Roller, Long 201289–0028 Bushing, Tension Roller, Short 201290–0019 Shaft Assembly, Tension Roller 202106–55110 Shaft, Tension Roller11 Roller, Tension (2)12 Shaft, Plastic Pressure Roller 202107–00213 Roller, Pressure, Plastic (4) 202108–00114 Spring, Retaining, Plastic Pressure Roller 202109–00115 E-ring, 2mm I.D., Zinc (2) 071151–00216 E-ring, 4mm I.D., Zinc (3) 071151–00617 Pin, Spring, 1.6x10mm, Steel 080661–00318 Screw, PPH, CLFW, 3x6mm, Zinc (2) 030130–306


21

31 4

151

61

71

81

101

112

121

132 14

1

151

161

171

181

51

181

151

132

162

9Ref

1Ref

19Ref

Tension Roller Assembly


6.1.3 Drive Gear AssemblyCallout Name Vendor Part No. Printronix Part No.1 Drive Gear Assembly 202128–5012 Frame Assembly, Drive Gear 202129–5513 Frame, Drive Gear4 Shaft, Gear, Center5 Shaft, Gear, Lower6 Stepper Motor Assembly, Drive Gear 202139–50137 Cable, Stepper Motor, Drive Gear 202390–55140 Stepper Motor, Main 202709–5517 Gear, Transfer, Inner 200682–0028 Shaft Assembly, Main Gear9 Shaft, Gear, Main 200684–00110 Ball Bearing, Gear Shaft 200683–55111 Pin, Spring, 2x12mm, SS 080651–11212 E-ring, 4mm I.D., Chrome 071251–00610 Ball Bearing, Gear Shaft 200683–55112 E-ring, 4mm I.D., Chrome (5) 071251–00613 Gear, Transfer, Lower 200685–00114 Seal, Ball Bearing 200686–00115 Gear Assembly, Developer Drive16 Ball Bearing, Gear Shaft (2) 200683–55117 Gear, Drive, Developer 200688–00118 Gear, Drive, Tension Roller 200691–00119 Shaft, Assembly, Front Main Drive12 E-ring, 4mm I.D., Chrome 071251–00620 Gear, Drive, Front Main 200689–00221 Spacer, Metal 200690–00122 Shaft, Gear, Front Main 202135–00123 Bushing, Gear Shaft, Upper 200632–00124 Gear, Transfer, Upper 200633–00125 Shaft Assembly, Upper Gear11 Pin, Spring, 2x12mm, SS 080651–11212 E-ring, 4mm I.D., Chrome 071251–00623 Bushing, Gear Shaft, Upper 200632–00126 Gear, Drive, Cleaner Roller 200631–00127 Shaft, Gear, Upper 200635–00128 Pin, Spring, 2x10mm, SS 080651–11029 Shaft Assembly, Lower Gear11 Pin, Spring, 2x12mm, SS 080651–11212 E-ring, 4mm I.D., Chrome 071251–00630 Gear, Drive, OPC 200643–00131 Shaft, Gear, Lower 200644–00132 Bearing, Dry 202133–00132 Bearing, Dry 202133–00133 Gear, Main Drive, Rear 200645–00134 E-Ring, 3mm I.D., Chrome (2) 071251–004


6.1.3 Drive Gear Assembly (continued)Callout Name Vendor Part No. Printronix Part No.35 Screw, TPH, MT, 3x6mm, Zinc 035128–30636 Screw, PPH, CLFW, 4x16mm, Zinc (4) 030130–41638 Screw, PPH, CLFW, 3x6mm, Zinc (3) 030130–30639 Screw, PPH, CLFW, 3x10mm, Zinc 030130–310


1Ref

29Ref

25Ref

15Ref

19Ref

2Ref

8Ref

112

321

261

281

111 23

1241

271

231

123

121

30131

1

201

211

221

351

391

121

41

71

341

321

331

121

401

371

111

364

341

91

101

383

31

51

131

181

101

123

171

102

141

6Ref

Drive Gear Assembly


6.1.4 Tractor Assembly and Tractor BaseCallout Name Vendor Part No. Printronix Part No.1 Tractor Assembly 202150–501 704539–0542 Frame Assembly, Tractor 202151–5513 Frame, Tractor4 Shaft, Centering Gear5 Gear, Centering 200450–0016 Sensor, TOF 202153–5517 Shaft, Guide, Tractor 200566–0028 Tractor Assembly w/Arm, Left 202380–5019 Tractor Assembly, Left 202381–55110 Centering Arm, Left 200452–00111 Screw, PPH, TF, 3x16mm (2) 030129–31612 Tractor Assembly w/Arm, Right 202382–50134 Screw, PPH, TF, 3x12mm (2) 030129–31213 Tractor Assembly, Right 202383–55114 Centering Arm, Right 200451–00115 Stepper Motor Assembly, Tractor 202742–50116 Stepper Motor, Tractor 202155–55117 Bracket, Mounting, Tractor Motor 202156–00118 Screw, PPH, CLFW, 3x6mm, Zinc (2) 030130–30633 Cable, Stepper Motor, Tractor 202392–55119 Shaft, Tractor Drive 202157–00220 Bushing, Tension Roller, Long (4) 201289–00221 Board, Tractor Encoder 202158–55122 Wheel, Tractor Encoder 202159–00223 Gear, Tractor Drive 202160–00124 Shaft, Idler, Tractor 202161–00125 Paper Support (2) 200456–00226 Paper Guide, Tractor 202125–00127 Screw, PPH, W/IW, 4x6mm, Zinc (2) 030131–40628 Screw, PPH, W/IW, 3x6mm, Zinc (4) 030131–30629 E-Ring, 4mm I.D., Chrome (5) 071251–00630 E-Ring, 5mm I.D., Chrome 071251–00831 Pin, Spring, 2x10mm, SS 080660–21032 Screw, PPH, CLFW, 3x6mm, Zinc (3) 030130–306


1Ref

131 12

Ref

342

252

91

8Ref

141

101

291

311

112

301 19

1

202

272

231

331

15Ref

292

211

221

2Ref

161

171 18

2

282

323

51

71

281

316

1

261

241 28

1

202

292

41

Front of Printer

Right Sideof Printer

Rear of PrinterLeft Sideof Printer

Tractor Assembly and Tractor Base


6.2.1 Mechanical

The four units primarily responsible for positioning and moving media (paper or labels) are:

The Tension Roller Assembly

The Drive Gear Assembly

The Tractor Assembly

The Lower Paper Guide

6.2.2 Electrical

The electrical portion of the paper feed system consists of the following:

Drive Gear Assembly. The Stepper Motor of the Drive Gear Assembly is driven by theStepper Motors Controller Board.

Tractor Assembly. The Tractor Stepper Motor is driven by the Stepper Motors ControllerBoard.

Tractor Encoder. The Tractor Encoder Board has two optical sensors that sense the1/8 inch and 1/16 inch slots in the Encoder Wheels. These pulses are sent to the EngineController Board and are used to monitor and control print location and paper movement.

Paper Top Sensor (PTOP). This sensor is located at the center rear of the tractor. It isused to tell the printer when paper is present in the fuser. It is also used to indicate paperlocation when paper is being backfed into the printer.

Paper Empty Sensor. This sensor is located near the entry of the printer and tells theprinter when there is no paper available to be fed in.

Following is a block diagram of the paper motion elements. See Appendix B for a complete electricalblock diagram.


BG

ND

BG

ND

BG

ND

+24

+24

+24

GN

D +5

CO

PE

N

/OP

C/N

EW

OP

CT

MR

SG

TM

RP

WR

/OZ

NFA

N/P

RC

LP

HA

1P

HB

1/P

HA

1/P

HB

1

PH

A2

PH

B2

/PH

A2

/PH

B2

PD

WN

2P

HA

3P

HB

3/P

HA

3/P

HB

3

+5V

L+

24V

B

PD

WN

3

PD

WN

1

18

CN1

CN8

FUSER BASE UNIT

J6

24

1COPEN/OPC

/NEWOPCTMRSG

TMRPWR/OZNFAN

/PRCLPHA1PHB1

PHA2PHB2/PHA2/PHB2

/PHA1/PHB1

PDWN2PHA3PHB3/PHA3/PHB3

+5VL+24VB

PDWN3

PDWN1

1 2410 15 205

CN2 CN61 2

CN51 6

J2

J3

J4

J5

J1

PRFAN1

PRFAN2

JAMSENSOR

EXITJAMSENSOR

FUSERSTEPPERMOTOR(M3)

PRCLUTCH

1

J5

CN3 CN7

CN41 6

J13

J2

J1

TRACTORSTEPPERMOTOR(M2)

PTOPSENSOR

+5PFS8PFS6/PTOPDGND

MAINSTEPPERMOTOR(M1)

OZONEFAN

1 6

ENCODER BOARD

3

BACKPLANEBOARD

STEPPER MOTORS CONTROLLER BOARD

J11

+5/PRPOS/PRINIT/SCPUP/SCPDNPJAMEJAM

/PRFANDGND

+24

1

10

PAPEREMPTYSENSOR

PEPWR

PEMPTY

DGND

1

TRACTOR UNIT

+24

VB

+24

VB A B /A /B

1

10

3

1

3

5

+24

VB

+24

VB A B /A /B

Block Diagram 6–1. Paper Feed Electrical



1. Open the Clamshell, remove the OPC and Developer Units, and any paper present in thePrinter.

2. Remove the Front Plastic Paper Guide from the Transfer Charger Assembly by pressingdown on its ends and sliding it to the left. This disengages the Locking Tabs and the PaperGuide can then be easily removed. See Detail 6–1.

Detail 6–1. Removing the Front Plastic Paper Guide

3. Remove 2 Screws at the rear of the Lower Paper Guide, then remove it from the Printer bylifting the rear out first. See Figure 6–1. This helps it clear the Contacts for the High VoltagePower Supply and the Transfer Charger Frame. Disengage the Locking Tabs at the front ofthe Paper Guide from the Tension Roller Frame.



Detail 6–2

Step 4Step 4Step 3

6.4.1,Step 6

6.4.1,Step 5

6.4.1,Step 4

Figure 6–1 Removing the Lower Paper Guide


4. Remove 2 Screws at the rear of the Tension Roller Assembly, and remove it from the Printer.See Figure 6–1.

5. Remove 1 E-ring from the Drive Gear Shaft and remove the Tension Roller Gear. SeeFigure 6–2.

Step 7

Step 10

Step 5

Step 6

Step 8

Step 9

Step 11

Step 10

Step 10

Step 11

Step 10

Figure 6–2. Removing the Tension Roller Gear

6. Remove 1 E-ring from the Transfer Gear Shaft and remove the Tension Roller Transfer Gear.

7. Remove 1 E-ring from the left end of the Tension Roller Shaft, then remove the Short ShaftBushing.

8. Slide the Shaft to the right, remove the Spring Pin from the right end of the shaft, then removethe Tension Roller Gear from the Shaft.

9. Remove the Long Shaft Bushing, then slide the Shaft to either side so that the opposite endof the Shaft clears the Tension Roller Frame.

10. Remove the Teflon Pressure Roller Shaft by depressing the Retaining Spring and slidingeither end of the Shaft off of the Spring.

11. Remove the 4 Teflon Pressure Rollers from the Shaft by removing 1 of 2 E-rings.

NOTE: Upon installation, the Teflon Pressure Rollers must fit in the slots of theTension Roller Frame.


NOTE: Upon installation, check the dimension between the Shaft and the TensionRoller Frame (without the Tension Roller in place) with a caliper, as shownin Detail 6–3 below. If the dimensions are out of range, gently bend thespring to correct the dimensions.

B

Shaft

A, B = 0.492 ±0.01 inch (12.5 ±0.3 mm)

A

Detail 6–3. Checking Tension Roller Shaft Positioning

12. The Teflon Pressure Roller Retaining Spring can be removed from the Roller Frame, but theSpring should be removed only if the it is damaged and needs to be replaced.

13. Remove the Retaining Spring from the Tension Roller Frame by sliding a flat-bladescrewdriver between the Spring and the Frame.




NOTE: When the Tension Roller Assembly is reinstalled in the printer, it must bepositioned correctly using the locating pins. Install the left end of the PaperGuide first, then lock the tabs at the front into the slots on the RollerFrame. Ensure that the Tabs do not ride too low, under the Tension RollerFrame. See Detail 6–4.

Viewed from the Rear of the Printer

Detail 6–4. Reinstalling the Paper Guide

6.3.3 Adjustment

See Detail 6–3.





1. Open the Clamshell, remove the OPC and Developer Units, and any paper present in thePrinter.

2. Remove the Lamp Connector Cover by removing 1 Screw and sliding the cover toward thefuser. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor BoardFrame. See Detail 6–5.


Step 3

Step 2

Detail 6–5. Removing Connectors


3. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the WarningLabel at the front of the Cover. This releases the Locking Tab from the Right Side Cover. SeeDetail 6–5.

NOTE: Upon installation, the groove on the bottom of the Right Side Cover muststraddle the top edge of the right side of the Tractor Frame. See Detail 6–2in Figure 6–1 on page 6–13.

4. Open the Printer Front Cover, then remove the LCD Control Panel by removing 2 Screws.See Figure 6–1.

5. Remove the Right Side Cover by removing 3 Screws. See Figure 6–1 on page 6–13.

6. Remove 2 Screws from the Ozone Filter Case and remove it from the Printer. See Figure 6–1on page 6–13.

7. Remove the Display Mounting Bracket by removing 2 Screws. See Figure 6–3.

NOTE: The Cable Grounding Screw does not need to be removed.

8. Loosen, but do not remove, 2 Screws on the top of the Stepper Motor Board Frame. Removethe Frame Cover, and disconnect the Gear Assembly Stepper Motor Cable from the Motor.See Figure 6–3.

NOTE: The Frame cannot be removed from the printer until the Fuser Base hasbeen removed.

9. Remove 3 Screws from the Stepper Motor Board Frame (an 8 mm Screw holds the BoardFrame to the Right Side Frame), but do not remove any additional cables from the Frame.This will allow the Frame to be moved in order to remove the Gear Assembly from the printer.See Figure 6–3.

10. Remove 4 Screws from the Gear Assembly Frame (a 10 mm Screw holds the Gear AssemblyFrame to the Right Side Frame), then remove the Gear Assembly Frame from the printer. TheStepper Motor Board Frame must be moved in order to free the Gear Assembly from behindit. See Figure 6–3.


Step 7

Step 8 Step 9

Step 10

Step 10

Figure 6–3. Removing the Display Mounting Bracket


DISASSEMBLY

NOTE: The Stepper Motor can be removed from the Gear Assembly withoutremoving the Gear Assembly from the Printer.

1. Remove 4 Screws, then remove the Stepper Motor from the Gear Assembly. See Figure 6–4.

NOTE: When installing the Stepper Motor onto the Frame, the Cable Connectormust face toward the rear of the printer.

Step 2

Step 4

Step 3

Step 5

Step 10

Step 1

Step 6

Step 7

Step 8

Step 9

Step 4

Figure 6–4. Stepper Motor Disassembly

2. Remove 1 E-ring, then remove the Tension Roller Drive Gear.

3. Remove 1 E-ring, then remove the Developer Drive Gear Assembly. This includes bothbearings.

NOTE: The Bearing Seal and both Ball Bearings can now be removed from theinside of the Gear.


4. Remove 1 E-ring and remove the Inner Transfer Gear. Then, remove 1 E-ring from each endof the Inner Transfer Gear Shaft. The Ball Bearing on each end of the Shaft can now beremoved, and the Shaft can be slid clear of the Frame.

NOTE: Do not remove the Spring Pin from the Inner Transfer Gear Shaft unlessthe Shaft is damaged and needs to be replaced.

5. Remove 1 Screw, then slide the Front Drive Gear and Shaft out of the Gear Assembly Frame.Remove 1 E-ring, then remove the Spacer and Gear from the shaft.

NOTE: When reinstalling the Shaft, ensure that the Slot on the Shaft is alignedwith the Slot in the Frame.

6. Remove 1 E-ring from the center of the Upper Gear Shaft to release the Upper Transfer Gear.

7. Remove 1 E-ring from the right end of the Upper Gear Shaft, then remove the right Bushing.

8. Align the Spring Pin of the Upper Gear Shaft with the Slot in the Frame and slide the Shaft tothe left out of the Frame.

NOTE: Remove the Spring Pin from the Shaft only if the Spring Pin or the leftBushing need to be replaced.

9. Remove the E-ring from the right end of the Lower Gear Shaft and remove the right Bushing.

10. Slide the Shaft to the left while aligning the Spring Pin with the Slot in the Frame. This willallow the Shaft to be slid free of the Frame.

NOTE: Do not remove the Spring Pin from the Shaft unless it is absolutelynecessary.


Reverse all of the Steps listed above.

6.4.3 Adjustment

No adjustment of the Drive Gear Assembly is necessary.


1. A fluttering noise is heard from the Upper Gear Shaft.

a. Add grease (Molykote EM03L or similar) to the area between the Bushing and the UpperGear Shaft.

2. A fluttering noise is heard from the OPC Drum Unit.

a. Add grease (Molykote EM03L or similar) to the area between the Bushing and the UpperGear Shaft.

3. The Developer Sleeve does not rotate.


a. The Inner Transfer Gear is broken. Replace the Inner Transfer Gear.

4. The Stepper Motor loses coordination with the OPC Drum Unit and the Developer Unit, eventhough the OPC Drum Unit and Developer Unit are new.

a. Check the Stepper Motor wire harness.

b. If the total page count is around 1,000 pages, check the Front Drive Gear.


1. Remove the Fuser Heat Shield. See Figure 6–5.


Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7



Detail 6–7 Detail 6–6

Figure 6–5. Tractor Removal


2. Remove the Lamp Connector Cover by removing 1 Screw and sliding the cover toward thefuser. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor BoardFrame. See Figure 6–5.

3. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the WarningLabel at the front of the Cover. This releases the Locking Tab from the Right Side Cover. SeeFigure 6–5.

NOTE: Upon installation, the groove on the bottom of the Right Side Cover muststraddle the top edge of the right side of the Tractor Frame. See Detail 6–6in Figure 6–5.

4. Remove the Tractor Encoder Cover by removing 1 Screw.

NOTE: Upon installation, the groove on the bottom of the Encoder Cover muststraddle the top edge of the left end of the Tractor Frame. See Detail 6–7 inFigure 6–5.


6. Disconnect the Tractor Encoder Cable from the Connector on the Base Plate behind theTractor by pressing on the release tab of the Connector.

7. Remove the Tractor by removing 3 Screws, then lifting the left end of the Tractor out first.This allows the the Encoder to clear the High Voltage Power Supply, and allows the Tractorroom to move to the left so that the Tractor Stepper Motor can clear the Stepper Motor BoardFrame.

8. Disconnect the Cable from the Tractor Stepper Motor and remove the Tractor from thePrinter.

DISASSEMBLY

1. Remove 2 Screws from the Tractor Motor Frame and remove the Stepper Motor Assemblyfrom the Tractor. See Figure 6–6.

2. Remove 2 Screws from the Stepper Motor Frame and remove the Stepper Motor from theFrame.


Rear of Printer

Step 5

Step 1

Step 3A Step 4

Step 6Step 7

Step 9

Step 11

Step 3B

Step 3C

Step 9

Step 8

Right Sideof Printer

Front of Printer

Left Sideof Printer

Step 8

Step 2

Figure 6–6. Tractor Disassembly


3. Encoder Board Removal:

a. Remove the TOF Sensor from the Tractor Frame by gently pressing its retaining tabs.

b. Remove 1 Screw from the Encoder Board and carefully slide it free of the Encoder Wheelso that neither the Wheel nor the Optical Sensors are damaged. The Tractor Cable isattached to the Encoder Board and must be removed with it. Carefully slide the CableConnector free of the Tractor Frame. See Detail 6–8.

NOTE: Be sure to note the Encoder Board position on the Tractor Frame beforeremoving it. The Board can be slid back and forth to change its relation tothe Encoder Wheel. This adjustment affects the position of the first line ofprint in relation to the page perforation. See Detail 6–8.

Front of Printer

Rear of PrinterLeft Sideof Printer

Detail 6–8. Tractor Encoder Board

c. The TOF Sensor cannot be removed through the cutout in the Tractor Frame as theEncoder Cable can. Therefore, the TOF Cable must be disconnected from the EncoderBoard before either can be removed from the Tractor.

4. Remove the Encoder Wheel by removing 1 E-ring from the Tractor Drive Shaft and sliding theWheel off of the Shaft.

NOTE: Upon installation, the Timing Mark of each Tractor must face up. TheTiming Dot on the Encoder Wheel must also face up and away from theTractor Unit. The Flat Face of the Drive Shaft must face toward the rear ofthe printer. See Detail 6–9.


Note: The tractors are marked onthe inside of each tractor,DL for left and DR for right.

Timing dot onencoder wheel

Note: Align timing marks on bothtractors to the timing doton encoder wheel.

Flat face of driveshaft faces the rearof the printer

Rear of Printer

Right Side of Printer

Left Side of Printer

Detail 6–9. Tractor Encoder Board Positioning

5. Remove the Tractor Drive Gear from the Drive Shaft by removing 1 E-ring from the right endof the shaft, then sliding the Gear off of the Shaft.


TRACTOR ASSEMBLY REMOVAL

6. Loosen the Tractor Drive Shaft by removing 1 E-ring from the left end of the Shaft and slidingthe Bushing off of the Shaft.

NOTE: Do not remove the Spring Pin from the right end of the Shaft.

7. Slide the Shaft to the right so that the Bushing is clear of the Frame.

8. Loosen the Guide Shaft by removing 1 Screw from each end of the Shaft.

9. Loosen the Rear Guide Shaft by removing 1 E-ring and Bushing from each end of the Shaft.

10. The Tractor Assemblies and Shafts can now be removed from the Frame by lifting them out.It may be necessary to release the ends of the Guide Shaft from the Tractor Frame by gentlypulling the ends of the Frame.

NOTE: Upon assembly, the ends of the Guide Shaft must be aligned with the holesin the ends of the Tractor Frame.

11. The Centering Gear can be removed from the Tractor Frame by removing 1 E-ring.

12. Remove the Shafts from the Tractor Assemblies.

NOTE: Upon assembly, the Drive Shaft must be installed so that the Timing Markof each Tractor is facing up. This aligns both Tractors so that the PaperPins are in the center of the Drive Shaft. The Drive Shaft must be installedso that the Flat Face for the Encoder Wheel is facing toward the rear of theprinter. See Detail 6–9.

13. Remove the Centering Arm off of each Tractor by removing 2 Screws.


Reverse all of the Steps above as needed.

6.5.3 Adjustment

Adjusting the Tractor Encoder Board moves the first line of print on a page closer to or farther from thepage break perforations. Perform this adjustment only if the original position of the Encoder Board wasnot noted during disassembly, or if the registration of the first line is unsatisfactory.

NOTE: This adjustment will correct a misregistration of print when a customer isusing preprinted forms. However, this adjustment will also affect all stockprinted subsequently.

1. Remove 1 Screw, then remove the Tractor Encoder Cover.

2. Losen, but do not remove, 1 Screw on the Tractor Encoder Board. See Detail 6–10.


Note: Loosen thisscrew, but donot remove it.

Front of Printer

Rear of Printer

Left Sideof Printer

Detail 6–10. Adjusting the Tractor Encoder Board

3. Refer to Detail 6–10 and perform one of the following Steps:

a. If the print is to be moved closer to the page break, slide the Tractor Encoder Boardtoward the front of the printer.

b. If the print is to be moved farther from the page break, slide the Board toward the rear ofthe printer.

4. Tighten the Encoder Board Screw.

5. Run a print job and check the registration of the first print line. Repeat Steps 2, 3, and 4 ifnecessary.

6. Replace the Tractor Encoder Cover.





1. Open the Clamshell. Remove any paper present in the printer. Remove the OPC Drum Unit,the Developer Unit, and the Waste Toner Container.

2. Remove the Front Plastic Paper Guide of the Transfer Charger Assembly by pressing downon the ends of the Guide and sliding it to the left. This disengages the Locking Tabs and theGuide can be removed easily.

3. Remove 2 Screws at the rear of the Lower Paper Guide, then remove it from the printer bylifting the rear out first. See Figure 6–1. This helps the Guide clear the Transfer ChargerFrame and the Contacts for the HVPS. Disengage the Locking Tabs at the front of the Guidefrom the Tension Roller Frame.

4. The Paper Empty Sensor can be removed from the Base Plate by releasing its retaining clipsand removing 1 Screw from the Cable Clamp.

NOTE: The Bottom Cover of the printer must be removed in order to disconnectthe Paper Empty Sensor Cable from the Backplane Board.

5. Place the printer on a phone book or other similar item so that the Bottom Cover edges arenot resting on the item. Press gently to release the 2 Locking Tabs on the right side of theBottom Cover, then gently lower this side. See Detail 6–11. Slide the Bottom Cover slightly tothe right to release the locking tabs on the left side, then lower the Bottom Cover away fromthe printer and over the phone book.



Detail 6–11. Bottom Cover Removal

6. Disconnect the Paper Empty Sensor Cable from Connector S11 on the Backplane Board. TheCable can now be routed through the Left Side Frame.


Reverse the 6 Steps above.

6.6.3 Adjustment

No adjustment is required.



7–1Chapter 7 – Fuser Subsystem

Chapter 7Fuser Subsystem

Fuser Subsystem

7–2 Chapter 7 – Fuser Subsystem

7.1.1 Fuser AssemblyCallout Name Vendor Part No. Printronix Part No.1 Fuser Assembly, 115V 202176–501 704539–012

Fuser Assembly, 230V 202213–501 704539–0132 Cover Assembly, Fuser Wiper 202177–5513 Cover, Fuser Wiper4 Spring, Retaining, Fuser Wiper (2)5 Lower Fuser Assembly 202180–5016 Frame, Fuser Pressure Roller 202181–0017 Roller Assembly, Pressure 202182–5018 Shaft, Pressure Roller 202183–0019 Roller, Fuser Pressure 202184–00110 Paper Peeler Assembly 202185–50111 Paper Peeler 202186–00112 Mylar Strip, Paper Peeler 202187–00113 Spring, Extension, Paper Peeler 202188–00114 E-Ring, 6mm I.D., Zinc (2) 071151–01015 Upper Fuser Assembly, 115V 202189–501

Upper Fuser Assembly, 230V 202210–50116 Frame Assembly, Heat Roller 202190–55117 Frame, Heat Roller18 Shaft, Fuser Locating (4)19 Shaft, Pivot, Lower Assembly (2)20 Roller Assembly, Heat 202194–50121 Roller, Fuser Heat 202195–00122 Collar, Heat Roller (2) 202196–00123 Gear, Drive, Heat Roller 202197–00124 Thermistor 202198–55125 Halogen Lamp, 115V 202199–551

Halogen Lamp, 230V 202212–55126 Wire Harness, Halogen Lamp 202701–55127 Bracket, Lamp Retaining, Right 202201–00128 Bracket, Lamp Retaining, Left 202202–00129 Thermal Breaker Assembly 202203–50130 Thermal Breaker 202204–00131 Bracket, Thermal Breaker 202205–00132 Screw, PPH, MT, 3x4mm (2) 030128–30433 Screw, PPH, CLFW, Zinc, 3x6mm (4) 030130–30634 Snap Ring, External, 25mm I.D., Black 073051–04833 Screw, PPH, CLFW, Zinc, 3x6mm (5) 030130–30635 Cover, Heat Roller 202206–00136 Brush Assembly, Fuser Discharge 202207–50137 Guide, Paper Exit 202208–00138 Brush, Fuser Discharge 202209–55139 Cable Tie, Lamp Harness 201321–001


7.1.1 Fuser Assembly (continued)Callout Name Vendor Part No. Printronix Part No.40 Caution Label, 115V 202384–001

Caution Label, 230V 202385–00141 Fuser Wiper (Not part of this assembly) 202323–501


1

81

91

401 6

1391

42

339

184

222

322

192

142

131

(100 to 120Vand 220 to 240Vin common)

(220 to 240V)or(100 to 120V)

29Ref

20Ref

36Ref

16Ref

5Ref

7Ref

10Ref

171

351

2Ref

15Ref

1Ref

31

281

411

38137

1

211

241

311

301

271

231

341

251

261

111

12

Fuser Assembly


7.1.2 Fuser Heat Shield AssemblyCallout Name Vendor Part No. Printronix Part No.42 Heat Shield Assembly, Fuser43 Heat Shield, Fuser 202211–00144 Caution Label, High Temp. 202386–00145 Caution Label, Fuser Felt 202387–00246 Seal, Dust 202388–001

42Ref

451

441

431

461

Fuser Heat Shield Assembly


7.1.3 Fuser Base AssemblyCallout Name Vendor Part No. Printronix Part No.1 Fuser Base Assembly 202216–501 704539–0822 Frame Assembly, Fuser Base 202217–5513 Frame, Fuser Base4 Pin, Fuser Clamp (2)5 Shaft, Exit Cover (2)6 Shaft, Tension Lever (2)7 Shaft, Exit Roller Lever (2)8 Shaft, Fuser Idler (2)9 Shaft, Input Drive10 Shaft, Idler, Exit Roller11 Paper Guide, Fuser Input 202226–00112 Spring, Extension, Paper Guide (2) 202227–00113 Paper Guide Assembly, Speed Control 202228–55114 Paper Guide, Speed Control15 Shaft, Cam Follower, SCPG16 Spring, Extension, Speed Control 202230–00119 Sensor, Paper Jam, Fuser (2) 202234–55120 Fuser Sensor Board 202235–55121 Fan, Fuser Cooling (2) 202236–55122 Spring, Retaining, Fuser Fan (2) 202237–00123 Stepper Motor, Fuser 202238–55124 Frame, Fuser Stepper Motor 202239–00125 Fuser Clutch 202240–55126 Wire Harness, Fuser Clutch 202241–55127 Gear, Transfer, Stepper Motor 202242–00128 Gear, Drive, Heat Roller 202243–00129 Gear, Drive, Exit Guide 202244–00130 Gear, Drive, Cam 202245–00144 E-Ring, 4mm I.D., Zinc (2) 071151–00646 Ball Bearing, Cam Shaft (2) 202260–55147 Shaft Assembly, Fuser Cam 202261–50148 Shaft, Fuser Cam 202262–00149 Cam, Paper Handling 202263–00150 Cam, Speed Control 202264–00151 Wheel, Fuser Position 202265–00152 E-Ring, 6mm I.D., Zinc (5) 071151–01053 Pin, Dowel, 2.5x12mm, SS (5) 081660–21269 Cam, Pressure Roller (2) 202376–00152 E-Ring, 6mm I.D., Zinc (2) 071151–01071 Screw, PPH, MTF, IFM, 3x6mm, Zinc (7) 030136–30672 Screw, PPH, CLFW, 4x10mm, Zinc (2) 030130–41077 Clamp, Fuser, Mounted 202377–00178 Tie Wrap, Fuser Fan 202378–00180 Spring, Extension, PR Cam (2) 202102–00174 Screw, PPH, CLFW, 3x6mm, Zinc (3) 030130–30675 Wire Harness, Fuser Signal 202296–55176 Clamp, Fuser Wire Harness, Nylon 202297–001


1

101

918

1281 29

1

271

301

251

201

191

261

241

231

122

741

714

72

52

741

62

462

521

535

481

802

42

442

501

511

491

691

691

521

521

521

523

222

212

771

781

711

751

761

712

722

741

47Ref

2Ref

13Ref

1Ref

A

A

111

141

151

191

31

161

8

Fuser Base Assembly


7.1.3 Fuser Base Assembly (continued)Callout Name Vendor Part No. Printronix Part No.17 Clamp, Fuser, Left 202232–00118 Clamp, Fuser, Right 202233–00131 Lever, Exit Roller, Left 202246–00132 Spring, Torsion, Left Roller Lever 202247–00133 Lever, Exit Roller, Right 202248–00134 Spring, Torsion, Right Roller Lever 202249–00135 Cover Assembly, Paper Exit 202250–50136 Cover, Paper Exit 202251–00137 Lever, Jam, Exit Cover 202252–00138 Shaft, Exit Pressure Roller 202253–00139 Roller, Exit Pressure (2) 202254–00140 Shaft Assembly, Exit Roller 202255–501 704539–10241 Shaft, Exit Roller 202256–55242 Bushing, Exit Roller (2) 202257–00143 Gear, Drive, Exit Roller 202258–00144 E-Ring, 4mm I.D., Zinc 071151–00644 E-Ring, 4mm I.D., Zinc (4) 071151–00645 Spring, Extension, Exit Cover (2) 202259–00154 Lever Assembly, Pressure Cam, Left 202266–50144 E-Ring, 4mm I.D., Zinc 071151–00655 Lever Assembly, Pressure, Left 202267–55156 Lever, Pressure, Left57 Bushing, Pressure Lever58 Lever, Cam Pressure, Left 202270–00159 Cam Follower 202271–00160 Shaft, Cam Follower 202272–00161 Spacer, Cam Follower 202273–00162 Spring, Compression, Pressure 202389–00163 Screw, HC, 4x35mm, Zinc 031128–43564 Nut, Hex, 4mm, Zinc 061151–00473 Washer, Flat, 4mm I.D., Zinc 050151–00665 Lever Assembly, Pressure Cam, Right 202274–50144 E-Ring, 4mm I.D., Zinc 071151–00659 Cam Follower 202271–00160 Shaft, Cam Follower 202272–00161 Spacer, Cam Follower 202273–00162 Spring, Compression, Pressure 202389–00163 Screw, HC, 4x35mm, Zinc 031128–33564 Nut, Hex, 4mm, Zinc 061151–00473 Washer, Flat, 4mm I.D., Zinc (2) 050151–00666 Lever Assembly, Pressure, Right 202275–55157 Bushing, Pressure Lever67 Lever, Pressure, Right68 Lever, Cam Pressure, Right 202277–00170 E-Ring, 5mm I.D., Zinc (2) 071151–008


35Ref

361

452

392

442

311

32117

1 371

381

44141

1

40Ref 42

2 431

441

331

341

44163

1

561

731 58

1

54Ref

55Ref

732 63

1

681

571

70170

1

571

181

65Ref

66Ref

671

601

601

621

621

641

641

441

441

591

591

611

611

Paper Exit Cover Assembly (Part of Fuser Base Assembly)


7.2.1 Mechanical

Cleaner Felt. This cleans the fuser roller of toner that gets deposited on the roller instead of the paper. Itis impregnated with silicone which forms a film on the fuser roller that helps prevent toner from sticking.

Fuser Sensor Wheel. This sensor wheel has blades that break the light beam in the optical sensors onthe fuser sensor board. This helps set the fuser cam position.

Fuser Exit Guide. This protects users from touching heated parts and keeps the paper from wrinkling. Italso serves as a paper guide for paper that is exiting the printer. This guide is part of the Fuser BaseAssembly.

Fuser Roller. This Teflon-coated aluminum roller is heated and, in conjunction with the pressure roller,comes in contact with the paper. The heat causes the toner to be fused onto the paper.

Fuser Roller Cam Shaft. This shaft has a cam on it that causes the Pressure Roller to move and press thepaper between the Fuser Roller and the Pressure Roller.

Fuser Frame Assembly. This assembly holds the Fuser Rollers and Thermistor. It is removable for easyreplacement.

Paper Peeler. This prevents paper from curling around the Fuser Roller by peeling the paper off of theFuser Roller.

Pressure Roller. This is a rubber roller that comes in contact with the Fuser Roller during fusing.

Static Brush. This brush removes the static charge from the paper as it exits the printer.

Engagement Lever Cam. This cam is located in the left center of the Fuser Roller Cam Shaft. It movesthe Engagement Lever, thus causing the Transfer Charger to move away from the paper when printingstops.


7.2.2 Electrical

The electrical portion of the fuser has four main sections:

A halogen lamp for heating the Fuser. In series with the lamp is a Thermal Breaker toswitch off power to the lamp if there is a problem with the heater control circuit.

A sensor board mounted to the Fuser Base Assembly. This sensor board has six opticalsensors associated with it that monitor the Fuser when up, the Fuser when down, thePaper Handling Lever position, the Speed Control Lever position, and entry and exit paperjam sensors.

A thermistor sensor mounted to the frame of the Fuser Assembly that monitors the heatof the Fuser Roller.

Two fans mounted in the Fuser Frame that cool the ends of the Pressure Roller.

Details about specific Units:

Fuser Fans. These fans cool the outer edges of the Pressure Roller, which is especially useful duringnarrow-forms printing.

Fuser Cam Clutch. This is a clutch that causes the Fuser Roller Cam Shaft to rotate in order to open orclose the Fuser and move the Paper Handling Lever and the Speed Control Lever.

Fuser Sensor Board. This board has 4 optical sensors: 2 for positioning the Speed Control Paper Guide,and 2 for positioning the Fuser Roller Cam. The Fuser Sensor Board is the interface between the EngineController and the Fuser.

Fuser Stepper Motor. This motor drives the Fuser forward. Additionally, if the Fuser Cam Clutch is on, thismotor drives the Fuser Roller Cam Shaft.

Heater Lamp. The Heater Lamp is located in the center of the Fuser Roller and heats the Fuser Roller.

Thermistor. This is a temperature sensor that is in contact with the Fuser Roller. It is used in conjunctionwith the heater circuitry to keep the Fuser Roller at the correct temperature.

Thermal breaker. This is a heat-activated switch in series with the lamp heater circuitry. It functions as apower shutoff when it reaches 155 °C.


CN1

STEPPER MOTORS CONTROLLER BOARD

CN8

FUSER BASE UNIT

CN6 CN5

J2

J3

J4

J5

J1

PRFAN1

PRFAN2

JAMSENSOR

EXITJAMSENSOR


PRCLUTCH

1

3

1 2 1 6 18B

GN

D

BG

ND

BG

ND

+24

+24

+24

GN

D +5

2

202234D162

202234D162

202241S212

202238D112

202298S208

202200S802

202296S210

1

10

202292S211

*LVPS

TMRPW

TMRSG CN4

J5

+5/PRPOS

/PRINIT/SCPUP

/SCPDNPJAM

EJAM/PRFAN

DGND+24

FUSER UNIT

*120V to Pin 2240V to Pin 3

BACKPLANEBOARD

110

220

Thermal Breaker

Halogen Lamp

16

1

10

1

3

2

TH

ER

MIS

TO

R

CNS1

202576S801

+24

VB

+24

VB A B /A /B

Block Diagram 7–1. Fuser Electrical


7.2.3 Fuser Control Modes

Fusing Mode. In Fusing Mode, the Engine Controller keeps the Fuser at the fusing temperature. Fusingtemperature is set in 5 °C increments from 165 °C to 185 °C. Proper fusing temperature depends on themedia in use.

When the Data Controller sends a print command to the Engine Controller, the Engine Controlleractivates Fusing Mode. This mode is also used during engine self-test.

Standby Mode. In Standby Mode, the Engine Controller keeps the Fuser at standby temperature,approximately 165 °C. Standby Mode keeps the inside of the engine from getting too hot; it also reducespower consumption.

When the Data Controller sends a print command to the Engine Controller, the Engine Controller switchesthe Fuser from Standby Mode to Fusing Mode. If the engine is idle for approximately 180 seconds in theFusing Mode, the Engine Controller automatically switches the Fuser to Standby Mode. The DataController can switch the mode from Idle to Standby by using the Standby Mode Request Command.

Idle Mode. In Idle Mode, the Engine Controller lets the Fuser cool to near ambient temperature by turningoff the power to the Fuser.

When the Fuser receives a print command, the Engine Controller switches the Fuser from Idle Mode toFusing Mode. The Data Controller can request Idle Mode by issuing an Idle Mode Request Command.Note that the Engine Controller does not automatically change the Fuser to this mode.



1. Open the Clamshell and remove the OPC and Developer Units, as well as any paper presentin the Printer.

2. Remove the Fuser Heat Shield, then remove the Lamp Connector Cover by removing 1Screw. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor BoardFrame. See Figure 7–1.


J–1 Connector

Depress white retaininglevers to release fuserroller assembly fromfuser base

Cover overlapstractorassembly sideframe

Detail 7–37.4.1, Step 8

7.3.1, Step 47.4.1, Step 6

7.4.1, Step 9

7.4.1, Step 4

7.4.1, Step 10

7.4.1, Step 11

7.4.1, Step 12

7.3.1, Step 57.4.1, Step 7

7.4.1,Step 3

7.3.1, 7.4.1,Step 2

Figure 7–1. Fuser Assembly Removal


3. Open the Paper Exit Cover on the back side of the Fuser Base so that it is not in contact withthe Fuser Assembly.

4. Depress the Fuser Retaining Lever on each side of the Fuser Base so that the FuserAssembly is free to move.

5. Lift the Fuser Assembly free of the Fuser Base, then remove it from the Printer.

DISASSEMBLY

6. Open, then remove, the Fuser Wiper Cover by gently pressing in on its retaining tabs.Remove the Fuser Wiper. See Detail 7–1.

7. Remove the Upper Heat Shield by removing 1 Screw, then releasing the tabs in the cornersof the Shield using a small flat-blade screwdriver. See Detail 7–1. Do this by gently pulling thesides of the Shield outward, releasing the Front Tabs, then sliding the Shield backwards torelease the Rear Tabs.

8. Remove 2 Screws from the bottom of the Heat Roller Frame and remove the Jam Protector.See Detail 7–1.


Fuser Roller Coverlocking tab locations

Step 8

Step 6

Step 7

Step 8

Pivot is oninside of Frame

Step 7

Detail 7–1. Removing the Upper Heat Shield


9. Remove 1 Spring from the right rear side of the Fuser Pressure Roller Frame. SeeFigure 7–2.

(220 to 240Vonly)OR


(100 to 120Vonly)

Step 10

Step 10

Step 9

Step 11

Step 12

Step 12

Step 13

Step 15

Step 16

Step 18

Step 18

Step 19

Step 14

Figure 7–2. Fuser Assembly Disassembly


10. Remove 1 Screw from each side of the Roller Frame, then remove the Fuser Pressure Rollerand its Frame by disengaging the Pivot on each side of the Heat Roller Frame. See Figure7–2.

11. Lift the Fuser Pressure Roller out of its Frame.

NOTE: Do the next Step (removal of the Fuser Pressure Roller Shaft from theRoller) only if absolutely necessary.

12. Remove 1 E-ring from the each end of the Pressure Roller Shaft, then slide the Shaft fromthe Roller. This will allow you to remove the Paper Peeler from the Roller, and Ball Bearingfrom each end of the Roller. See Figure 7–2.

NOTE: The Shaft has a very tight fit in the Ball Bearings and should be removedonly if the Bearings are seized.

13. Remove the Thermistor by removing 1 Screw. See Figure 7–2.

14. Disconnect both Lamp Leads from the Thermal Breaker, then the Thermal Breaker andBracket can be removed from the Fuser Roller Frame by removing 1 Screw. The ThermalBreaker can be removed from its Mounting Bracket by removing 2 Screws. See Figure 7–2and Detail 7–2.

NOTE: If the Thermal Breaker Mounting Bracket is removed from the Heat RollerFrame, then the height of the Thermal Breaker surface from the HeatRoller must be set properly, as described in the “Adjustment” section thatbegins on page 7–21.

If the Thermal Breaker Mounting Bracket is not removed from the HeatRoller frame, but the leads from the lamp to the Thermal Breaker aredisconnected and reconnected, then the height of the Thermal Breakersurface over the roller must be measured and adjusted if needed.

Detail 7–2. Thermal Breaker and Mounting Bracket


15. Remove 1 Screw from the Left Lamp Retaining Bracket and remove the Bracket from theHeat Roller Frame. See Figure 7–2.

16. Remove 1 Screw from the Right Lamp Retaining Bracket and remove the Bracket from theHeat Roller Frame. See Figure 7–2.

17. Remove the Lamp Assembly from the center of the Heat Roller by sliding it to the right.

NOTE: Ensure that you do not touch the lamp as fingerprints will cause it to fail.Clean it with a cloth and isopropyl alcohol before reinstalling it.

18. Remove the Heat Roller from the Heat Roller Frame by lifting the Retaining Collars free of theFrame. Slide the Retaining Collar on the left end of the Roller off of the Roller. See Figure7–2.

19. Remove the External Snap Ring from the right end of the Heat Roller, then slide the DriveGear and Retaining Collar off of the right side of the Heat Roller. See Figure 7–2.




7.3.3 Adjustment

Thermal Breaker

NOTE: The height of the Thermal Breaker from the Fuser Roller must be adjustedevery time the Thermal Breaker is removed from the Fuser. If the ThermalBreaker is too close to the Fuser Roller, the Breaker will trip at too low atemperature. If the Breaker is too far from the Roller, the Breaker will trip attoo high a temperature. See Detail 7–2.

1. Place the Thermal Breaker Bracket into place so that the left side is flush against the locatingnotches. Put the Bracket Screw in place so that it holds the Bracket loosely in place.

2. Hold the Fuser Roller up into the top of the Frame to simulate a closed Fuser. Using a FeelerGauge, adjust the gap between the Thermal Breaker and the Fuser Roller by sliding theBracket so that the Thermal Breaker just touches the Gauge. This gap must be between0.62 mm and 0.88 mm, with a nominal setting of 0.75 ± 0.13 mm.

3. With the Bracket set so that the Feeler Gauge is not bound by the Thermal Breaker, tightenthe Bracket Retaining Screw to 6.9 inch-pounds (8 1 kg-cm) of torque.





1. Open the Clamshell and remove the OPC and Developer Units, as well as any paper presentin the Printer. See Figure 7–1.

2. Remove the Fuser Heat Shield, then remove the Lamp Connector Cover by removing 1Screw. Disconnect the Fuser Lamp and Thermistor Connectors from the Stepper Motor BoardFrame. See Figure 7–1.


NOTE: Upon installation, the groove on the bottom of the Right Inside Covershould straddle the top edge of the right side of the Tractor Frame. SeeDetail 7–3 in Figure 7–1.


5. Open the Paper Exit Guide of the Fuser Base so that it is not in contact with the Fuser RollerAssembly.

6. Depress the Fuser Assembly Retaining Lever on each side of the Printer so that the FuserAssembly is free to move.

7. Lift the Fuser Assembly free of the Fuser Base, then remove it from the Printer.

8. Disconnect the Fuser Sensor Board by removing the Cable at Connector J1.

9. Open the Printer Front Cover, then remove the LCD Control Panel by removing 2 Screws.

10. Remove the Right Side Cover by removing 3 Screws.

11. Loosen, but do not remove, 2 Screws on the top of the Stepper Motor Board Frame. Removethe Frame Cover, and disconnect 2 Cables from Connectors CN5 and CN6 on the StepperMotor Board.

12. Remove 2 Screws from the rear of the Fuser Base and remove it from the printer.

DISASSEMBLY

13. Remove the Paper Exit Guide by removing 2 Springs, then lifting the Guide off of the Shaft onthe Fuser Base Frame. See Figures 7–3 and 7–4.


Step 13

Step 13

Step 13A

Step 13B

Step 13B

Step 13C

Step 13D

Step 13EStep 14

Step 16

Step 35

Step 32

Step 33

Step 31

Step 33

Step 34

Step 36

Figure 7–3. Paper Exit Cover Disassembly


A

A

Step 15

Step 17

Step 19

Step 18

Step 20

Step 21

Step 22

Step 23

Step 24Step 25

Step 25B

Step 25C

Step 25D

Step 26

Step 22

Step 28Step 27

Step 28

Step 29

Step 30

Step 31

Step 30

Step 26

Step 25A

Step 25A

Figure 7–4. Fuser Base Disassembly


a. Remove the Upper Exit Guide Shaft by removing 1 E-ring from the left end of the Shaftand sliding the Shaft to the right. The Shaft must be slid free of the 2 Teflon Rollers andthe Frame.

b. Disengage the Locking Tab of both Lower Exit Guide Shaft Bushings from the Exit GuideFrame. Rotate both Bushings so that the flat portion of each Bushing is aligned with theflat portion of the Frame. Lift the Shaft free from the Frame.

c. Remove the E-ring from the left end of the Shaft and remove the Bushing.

d. Gently release the tabs of the Lower Shaft Drive Gear and remove it from the Shaft. Slidethe right Bushing off of the Shaft.

CAUTION: The Locking Tabs of the Gear can be easily broken and must begently pried free of the Shaft.

e. Remove the Exit Guide Jam Lever from the Frame by gently spreading the Arms of theFrame to release the Tabs on the Jam Lever.

14. Only if necessary, remove the left side Fuser Roller Locking Lever from the Fuser BaseFrame. If the Locking Lever must be removed, do not reuse it. Replace it with a new LockingLever.

15. Remove 2 Screws, then remove the Stepper Motor and Frame from the Fuser Base Frame.The Stepper Motor can be removed from its Frame by removing 2 Screws. See Figure 7–4.

NOTE: When installing the Stepper Motor and Frame ensure that the alignmentprongs of the Fuser Clutch are engaged around the tab of the StepperMotor Frame. The Cable Connector for the Stepper Motor must face thefront of the Printer. See Detail 7–4.


Clutch cable positionedtoward front of printer

Front of printer

Detail 7–4. Fuser Stepper Motor Clutch Positioning

16. Only if necessary, remove the right side Fuser Roller Locking Lever from the Fuser BaseFrame. If the Locking Lever must be removed, do not reuse it. Replace it with a new LockingLever.

17. Remove the Fuser Transfer Gear from the Fuser Base Frame.

18. Remove 1 E-ring, then remove the Rear Inner Transfer Gear.

19. Remove 1 E-ring, then remove the Exit Guide Drive Gear.

20. Remove 1 E-ring from the Shaft for the Fuser Clutch, then remove the Fuser Clutch from theShaft.

NOTE: Do not disassemble the Fuser Clutch. Keep all Fuser Clutch parts togetheras one Assembly. Do not remove the cable from the Clutch Assemblyunless absolutely necessary.

21. The Front Inner Transfer Gear can be removed after the Clutch Assembly has been removed.

22. Remove the Spring from the center of the Speed Control Paper Guide, then remove 1 Screwfrom each end of the Guide and remove it from the Fuser Base.

23. With the Fuser Clutch removed, slide the right Fuser Cam Ball Bearing off of the Shaft.


24. Remove 1 E-ring from the left end of the Fuser Cam Shaft, then remove the left side BallBearing.

25. Lift the left end of the Fuser Cam Shaft free of the Fuser Base Frame, then slide the Shaft tothe left to free the right end from the Base Frame. This will free the Shaft from the rightPressure Roller Cam.

a. Slide the Pressure Roller Cam from each end of the Cam Shaft and remove the DowelPin. Then remove the E-ring for the Fuser Cam from each end of the Cam Shaft.

b. Remove the E-ring for the left Pressure Roller Cam, then the E-ring for the PaperHandling Cam, and slide the Paper Handling Cam off of the Cam Shaft. Remove thePaper Handling Cam Dowel Pin from the Shaft.

c. Remove the E-ring for the Speed Control Cam, and slide the Cam to the left and off of theShaft. Remove the Speed Control Cam Dowel Pin from the Cam Shaft.

d. Remove the E-ring for the Fuser Position Wheel and slide the Wheel to the left and off ofthe Shaft. Remove the Position Wheel Dowel Pin from the Cam Shaft.

NOTE: When assembling the Fuser Cam Shaft, all of the alignment holes in theCams must be aligned to the bottom of the Shaft. The curved surface ofthe Fuser Cams must face toward the front of the printer (except for thePaper Handling Cam). The slot in the right side of the Position Wheel mustbe facing up, away from the alignment holes. See Detail 7–5.

NOTE: Upon Installation, the right Pressure Roller Cam must be positioned in theFuser Base Frame, then the right end of the Cam Shaft must be slidthrough the Cam and the Base Frame.


Detail 7–5. Cam Positioning

26. Remove the Rear Paper Lift Spring from both ends of the Lift, then remove 1 Screw fromeach end of the Lift. Remove the Rear Paper Lift from the Fuser Base Frame.

27. Disconnect the Cable from the Fuser Jam Sensor, then remove the Sensor by carefullyreleasing the retaining tabs from the Fuser Base Frame.

28. Disconnect the Cable from the Exit Guide Jam Sensor, then remove the Sensor by gentlyreleasing the Retaining Tabs from the Fuser Base Frame.


29. Disconnect the Cables for the Fuser Cooling Fans from the Fuser Sensor Board, then remove1 Screw to remove the Sensor Board.

CAUTION: Use care when removing the Exit Guide Jam Sensor Cable from theFuser Base Frame. The Cable can be damaged easily by the edges ofthe Frame.

30. Remove the Retaining Spring from each Fuser Cooling Fan, then remove the Fans.

31. Remove the Return Spring on the Left Pressure Cam Lever Assembly, then remove 1 E-ringand remove the Assembly from the Fuser Base Frame.

NOTE: Make sure to note the direction of the Return Spring.

32. Remove 1 E-ring and remove the Cam Follower and Shaft from the Left Cam Pressure Lever.

NOTE: Make sure to note the position of the Spacer on the Shaft.

33. Remove 1 Screw, 1 Spacer, and 1 Nut from the Left Pressure Spring, then separate the CamPressure and Pressure Levers from one another. Do not remove the Bushing from the LiftArm.

34. Repeat Steps 31 through 33 for the Right Pressure Cam Lever Assembly.

NOTE: The right Tension Arm Assembly uses 2 Spacers.

35. Remove 1 E-ring, then remove the Left Exit Roller Lever and Spring.

36. Remove 1 E-ring, then remove the Right Exit Roller Lever and Spring.




7.4.3 Adjustment

Fuser Thermistor

There are no adjustments to the Fuser Thermistor. You can, however, check the voltage across it. Use adigital voltmeter for this measurement.

Under normal conditions, the following voltages will be present across the Fuser Thermistor:

Fuser Temperature

Approx. VoltageAcross Thermistor

Approx. 20 °C (ambient temperature) 4.7 VDC

160 °C (standby mode) 0.8 VDC

185 °C (running temperature) 0.5 VDC

If your measurement shows an open condition (∞ Ω, 5.0 volts DC across the Thermistor), refer to thetroubleshooting section on page 7–31 for assistance.



To properly troubleshoot the fuser section, mentally separate the assembly into four functional sections:

Heater and heat safety section (thermal breaker)

Temperature control section (thermistor)

Paper positioning section

Fuser section

Troubleshooting procedures for each of these four functional sections follow.

Fuser Heater and Thermal Breaker

The fuser heater is a quartz halogen lamp that has a rating of 1000 watts. The heater safety device is aone-shot normally-closed thermal breaker that has a trip point of 155 °C. This thermal breaker ensuresthat the printer (not necessarily the fuser) is not damaged if the temperature control does not functioncorrectly. If the thermal breaker senses an over-temperature condition, it will open and remove powerfrom the heater lamp.

During initial power up and during any warmup period, there is a signal generated in the engine controllercalled HEAT. This signal is generated by monitoring the TMRSG line returning from the thermistor.

When the controller decides that it is time to heat the fuser, it generates a low on the HEAT line. Thissignal leaves the controller via J8–8 on the Backplane Board. This TTL signal controls a solid-state relay(TRIAC) in the Low Voltage Power Supply which gates 115 volts out of the supply on pins CN4–1 andCN4–2. (If the Low Voltage Power Supply is set for 230 volts, it gates 230 volts out CN4–1 and CN4–3.)This voltage, in turn, goes to the lamp and thermal breaker, which are wired in series.

If the Fuser Lamp Does Not Heat:

1. Allow the printer cool down to ambient temperature and unplug the printer from the poweroutlet.

2. Open the printer and remove the cover that fits around the drive gear assembly. Locate S211(CNS1), the output from the Low Voltage Power Supply to the fuser lamp, and unplug thefuser lamp connector from it. See Figure 7–5.


ThermalBreaker

C

D

A

AB

BLamp

Thermistor


(100 to 120V)or(220 to 240V)

S211(CNS1)

Figure 7–5. Fuser Lamp, Thermal Breaker, and Thermistor Detail


3. Measure the resistance across the terminals on the lamp side of the cable (C and D). Itshould measure less than 2 Ω (less than 6 Ω for 220 VAC units). If not, remove the heatshield cover and measure across the thermal breaker (A and B). It should measure near 0 Ω.

If the thermal breaker measures near 0 Ω, then check the lamp. Measuring across B and D shouldresult in less than 2 Ω (less than 6 Ω for 220 VAC units). If not, then replace the lamp.

CAUTION: Use extreme care in handling both the old and new lamps, as thelamps are extremely fragile. Also, avoid getting fingerprints on thenew lamp as this will shorten its life. If you get fingerprints on thelamp, wipe the lamp with a soft cloth soaked with alcohol. Allow thelamp to dry completely before powering on the printer.

If the thermal breaker is open (∞ Ω), replace it.

CAUTION: If you replace the thermal breaker, you must check the operation ofthe heat sensing circuit (thermistor and Low Voltage Power Supply).Otherwise, you might be merely correcting symptoms caused by amore serious problem, rather than correcting the more seriousproblem.

4. If both the lamp and thermal breaker check OK, reinstall the heat shield cover. Then defeatthe cover interlock switch, the paper empty switch, and the top-of-form switch. Connect theprinter power cord to the power outlet, turn on the printer, and check the voltage at S211(CNS1).

WARNING: When you defeat the cover interlock switch, there is 115 VAC atvarious parts of the power supply and high voltage at othercontacts—so BE VERY CAREFUL.

Be sure that all cables and test leads are out of the way of any moving parts (gear train, tractor, etc.).At this point, 115 VAC should not be present at the output of S211 (CNS1). If 115 VAC is present, youshould suspect a faulty thermal breaker, one that is intermittent. It is unlikely that the lamp is faulty,since lamp faults usually are visible (broken tungsten wire or cracked glass envelope).

5. If 115 VAC is not present at S211 (CNS1), then turn off the printer and disconnect its powercord. Remove the bottom cover from the printer. Disconnect the 2 connectors CN1 and CN2on the Low Voltage Power Supply. See Figure 7–7 on page 7–34.

Check the main power fuse F1 (6.3 amp, 250 VAC), then check fuse F3 (15 amp, 125 VAC). This isthe fuse that protects the output. If this fuse is good, check the input of the power supply at CN2–16(the HEAT signal). To check this, you will have to very carefully replace the power cord to the printer.You will also need to defeat the cover interlock switches as per Step 4 above.

WARNING: When you replace the power cord, there is 115 VAC at various parts ofthe power supply so BE VERY CAREFUL.

Using either a voltmeter or a logic probe, monitor pin 16 of CN2. When you turn the power back on,the printer should pause for a few seconds and then try to heat the fuser. At this point, the HEATsignal should go from ≈+5.0 VDC to ≈+0.7 VDC. If the voltage changes from high to low and you stilldo not have 115 VAC at CN4, then replace the Low Voltage Power Supply.


However, if CN2–16 does not change from high to low, then suspect either the wiring harness or theengine controller. To check the harness, remove the power cable and all consumable items from theprinter. Then remove the bottom cover from the printer per the cover removal section. Checkcontinuity between the Low Voltage Power Supply CN2–16 and the engine controller. If the harnesschecks good, then replace the engine controller.

Figure 7–6. Fuser Heat Shield

CN5 CN6 CN4F3 F2

F1

CN3RV1

CN2

CN1

RV4

RV2

Figure 7–7. Inside View of Low Voltage Power Supply


Temperature Control Section (Thermistor Troubleshooting)

To detect the temperature of the fuser roller, the engine controller sends an analog signal, TMRPWR, tothe Stepper Motors Controller Board. This signal exits the board at connector CN8–1 and is passedthrough cabling to the thermistor. This, in turn, is fed through the thermistor and back to the StepperMotors Controller Board at CN8–2 as TMRSG.

The heat control thermistor is mounted so that it makes contact with the fuser heat roller at about thecenter of the fuser roller.

The thermistor has a negative thermal coefficient; when the fuser temperature rises, the resistance of thethermistor goes down, and vice-versa. Normal operating boundaries of the fuser are in the range of182 °C to 188 °C. During normal operation, when the temperature reaches the lower trip point of about185 °C, the engine controller turns on the HEAT signal. Then the lamp heats the fuser roller until thetemperature reaches about 186 °C—however, this temperature might be different, depending on thesetting of the temperature on the Control Panel. At this point, the engine controller shuts off the HEATsignal. There will be some thermal lag, so the temperature might exceed this set point by 5 °C or more. Tomeasure the temperature, use a temperature probe. Access to the fuser is limited, so obtain the smallestpossible diameter surface-reading probe.

Thermistor Malfunction Symptoms

There are several conditions where you might suspect that the heat sensing control circuit ismalfunctioning:

If a “THRMISTR FAIL” or “HEATER FAIL” error message is displayed on the front panel.

If the thermal breaker needs replacement (see previous section).

If the printed characters are not fusing to the paper correctly.

1. A “THRMISTR FAIL” or “HEATER FAIL” error message signifies one of the followingconditions:

a. The thermistor circuit has opened up or shorted, or the fuser never reaches the correcttemperature.

b. Units other than the thermistor circuit could be at fault.

The thermistor condition can be checked by removing the fuser heat shield cover. Unplug thethermistor lead. Measure the resistance of the thermistor. At normal ambient temperature(≈20 °C), the reading should be from 150 kΩ to 200 kΩ. If you find an open circuit, replace thethermistor (see fuser removal and replacement).

CAUTION: Be sure to check the heater lamp and thermal breaker according tothe first portion of this section before you continue. An opencondition of either the lamp or the thermal breaker will cause thethermistor to appear defective (by not heating up the fuser roll).

2. If you found the thermal breaker to be open during testing, thoroughly check the thermistorsection using Step 1 above and Step 3 below.

3. If the print on the fused paper feels excessively raised, then there might be anundertemperature condition at the fuser. First, confirm that the fuser temperature set via thecontrol panel matches the type of paper being used.


Then, to measure the fuser temperature, use a temperature probe. Let the printer cool to ambienttemperature, then open the printer cover and defeat the cover interlock switch.

WARNING: When you defeat the cover interlock switch, there is 115 VAC atvarious parts of the power supply and high voltage at othercontacts—so BE VERY CAREFUL.

Defeat the following sensors:

OPC drum switch (if the OPC drum is not installed)

Paper empty at the front of the printer

Top of form sensor at the fuser assembly

Flip the exit paper guide out and away from the printer. Turn on the printer. Be extremely careful ofmoving parts. In about 120 seconds, the fuser roller should come up to proper temperature. Thetemperature of the fuser roller should be about 185 °C (change it, if necessary, using the control panel)and the temperature range about 5 °C. If not, check the position of the thermistor. It should be mounted incontact with, and parallel to, the fuser roller. If the position of the thermistor is correct, you should replaceeither the thermistor or the engine controller, or clean excess toner off of the thermistor.

Paper Positioning Section

The paper positioning section consists of a clutch and a stepping motor that has reduction gears attachedto the driving end to increase the torque of the motor. Without the gears, a much larger motor would berequired.

Troubleshooting the fuser drive motor is fairly straightforward. The motor rotates and the clutch is on untilthe pressure roller is in its initial position during initialization of the printer (if the pressure roller is not in itsinitial position) and after it acts according to print requests. If there is data to be printed, the motor and theclutch are activated and the fuser is cantilevered against the pressure roller. During printing, only themotor is activated. After the data stream stops and the print cycle is finished, the motor and clutch areactivated, which releases the fuser from the pressure roller. When the FORM FEED button is pressed,only the motor cycles. When the motor is in position, it is locked with a detent torque.

Fuser Fan Troubleshooting

The fuser fans cool the ends of the pressure roller. During narrow forms printing, the paper (or label) stockdissipates heat in the center of the pressure roller. The areas of the roller without paper expand andcause the stock to move slower through the fuser.

The fuser fans also cool the end of the heat roller during narrow forms printing. If the heat roller stops, thethermal breaker (thermostat) senses an overtemperature condition. The breaker will then open, whichremoves power to the heater lamp.

The fans are powered by the switched 24 volts supplied from the engine controller board connector J5, tothe fuser sensor board connector J1. Connector J1 sends the 24 volts directly to the fans throughconnectors J2 and J3.

The fuser fans activate only when the heat roller temperature is at fusing temperature, as set from thecontrol panel. Check that the fans are activating when the heat roller is at fusing temperature.

Remove the fuser heat shield and fuser front paper guide. Watch the fans during the printer power upsequence to verify that they are working. If they are not working, check for 24 volts on the fuser sensorboard, connectors J2 and J3. If 24 volts is not present at these connectors, check for a loose connector atJ1.

8–1Chapter 8 – Power Supplies

Chapter 8Power Supplies

High VoltagePower Supply

Low VoltagePower Supply

Power Supplies

8–2 Chapter 8 – Power Supplies

8.1.1 Low Voltage Power SupplyCallout Name Vendor Part No. Printronix Part No.1 Low Voltage Power Supply (LVPS) 202127–552 704539–0292 Tie Wrap, Wire Harness, Lamp Power 202175–0013 Bracket, Lamp Cable 202215–0014 Wire Harness, Lamp Power 202292–5035 Wire Harness, Thermistor 202200–5516 Wire Harness, Lamp 202576–5517 Fuse, 250V, T6.3AH (2: F1 and F2) 200465–0198 Fuse, 125V, 15A (F3) 201938–0149 Screw, PPH, CLFW, 3x10mm, Zinc 030130–30610 Cover, Top, LVPS 202577–00111 Switch, Power, LVPS 202578–55112 Screw, PPH, CSW, 3x6mm, Chrome (2) 030235–30613 Power Cord (see note below)14 Wire Harness, Controller Power, 5V 202375–551

NOTE: Use a power cord that is appropriate for the voltage of the printer and thecountry in use. Cords include the following plugs for the indicated areas:

ContinentalEurope

NOTE: For Switzerland, use an SEV-approved plug.

UnitedKingdom

Australia andNew Zealand

U.S.A. andCanada

Power Plugs


1Ref

122

4Ref

CN5CN6

CN4F3 F2

F1

CN3RV1 RV4

RV2

CN2

CN1

A

To Fuser

A

CN2

CN1

51

61

91

21

101

31

111

91

81

72

Low Voltage Power Supply


8.1.2 High Voltage Power SupplyCallout Name Vendor Part No. Printronix Part No.1 High Voltage Power Supply 202126–551–001 704539–0332 Screw, PPH, CLFW, M3x10, Zinc (2) 030130–310


11

2

2

High Voltage Power Supply


8.2.1 Mechanical

There are two power supplies in the printer: The Low Voltage Power Supply (LVPS) and the High VoltagePower Supply (HVPS).

8.2.2 Electrical

The LVPS provides +5 VDC, +12 VDC, +24 VDC, and –12 VDC for operation of motors, logic boards,floppy disk drives, and the control panel.

The HVPS provides –400 mA for the charge corona, –720 VDC for the charge grid, +4,600 VDC for thetransfer corona, and –550 VDC for the developer.

Note that the fuser lamp is powered directly from the AC supply (115 VAC or 230 VAC) and not fromeither of the internal power supplies. However, on/off control of the fuser lamp is performed at the LVPS.


201153S203

202292S211

*

J7

CN2 CN1

LOW VOLTAGE POWER SUPPLY

CN3

J15

J14

J8

J6

COPEN/OPC

/NEWOPCTMRSG

TMRPWR

/OZNFAN/PRCL

PHA1

PHB1

PHA2

PHB2/PHA2

/PHB2

/PHA1

/PHB1

PDWN2

PHA3PHB3/PHA3

/PHB3

+5VL+24VB

PDWN3

PDWN1

TMRPW

TMRSG CN4

J5

+5/PRPOS

/PRINIT/SCPUP

/SCPDNPJAM

EJAM

/PRFAN

DGND+24

J13

+5PFS8

PFS6/PTOP

DGND

FUSER UNIT


COOLINGFAN

AC POWERINLET

BACKPLANE BOARD

J4

TO LSU

HIGH VOLTAGEPOWER SUPPLY

J10

TONERSENSORBOARD

J9/WASTE

TNRLOW

+5

DGND

CN1

CN2

OPC DRUMUNIT

TRANSFERCHARGER

DEVELOPER

+24VB

BGND

/CHARGE/DEVELOPER

/TRANSFER

110

220

J1

1

2

3

4

5

RSVD

RS

R/W

E

DB0

DB1

DB2

DB3

DB4

DB5

DB6

DB76

7

8

9

10

11

12

13

14

15

16

18

19

20

21

22

23

24

17

/SWRST

/SWONL

/SWFF

/LDATA

/SWMENU

/LONLN

/SWSTOR

/LRDY

/SWDWN

Vss

Vdd

J3 (TO LCD CONTROL PANEL)

/SWUP

(NOTUSED)

Thermal Breaker

Halogen Lamp

(NOTUSED)

J2

(TO DATACONTROLLERBOARD)

J1

(TO ENGINECONTROLLERBOARD)

16

1

10

1

24

1

32

1 5 10 16 1 8

1 81 5 10

1

4

1

4

1

4

1

6

1

6

1

4

1 5 10

TH

ER

MIS

TO

R

+5

DG

ND

+24

+24

+24

BG

ND

BG

ND

BG

ND

+24

BG

ND

+12 –1

2

AG

ND

AG

ND

PW

RO

FF

/HE

AT

+24

BG

ND

+12

–12

AG

ND

AG

ND

PW

RO

FF

/HE

AT

+5

+5

+5

+5

DG

ND

DG

ND

DG

ND

DG

ND

+12

/QLE

D+

24B

GN

D

/PM

ON

/PM

RD

Y +5

DG

ND

/BD +5

DG

ND

/LD

ON

/LV

IDE

OLV

R

DEVELOPERBIAS

TONERSENSOR

J111

PAPEREMPTYSENSOR

PEPWR

PEMPTY

DGND

CNS1

3

LCDCONTROLPANEL

1

2

+–

202576S801

202298S208

202375S207

202278E112

202291S202

202393S201

202294S204

1 24

J3

1

5

+5

+5

+5

+5

DG

ND

DG

ND

DG

ND

DG

ND

14

Block Diagram 8–1. Power Supplies Electrical



NOTE: If you are replacing a Fuse or converting the LVPS input voltage, skip tothe next section, “Input Voltage Conversion and Fuse Replacement”.

1. Open the Clamshell, remove the OPC Drum Unit, Developer Unit, Waste Toner Container,and any paper present in the printer.

2. Remove the Lamp Connector cover by removing 1 Screw, then disconnect the Fuser LampConnector and the Thermistor Connector from their mating Connectors on the Stepper MotorBoard Frame. See Figure 8–1.


Step 2

Step 4

Figure 8–1. Disconnecting the Connectors


NOTE: Upon installation, the groove on the bottom of the Right Inside Covershould straddle the top edge of the right side of the Tractor Frame. (Seedetail in Figure 8–2.)



Step 3

Figure 8–2. Removing the Right Inside Cover

4. Separate the Fuser Lamp Connector and the Thermistor Connector of the LVPS from theStepper Motor Board Frame by releasing the Locking Tabs and pushing the Connectorsthrough the hole in the Printer Base Plate. See Figure 8–1.

5. Place the printer on a phone book or other similar item so that the Bottom Cover edges arenot resting on the item. Press gently to release the 2 Locking Tabs on the right side of theBottom Cover, then gently lower this side. Slide the Bottom Cover slightly to the right torelease the locking tabs on the left side, then lower the Bottom Cover away from the printerand over the phone book. See Figure 8–3.



Figure 8–3. Bottom Cover Removal

6. Remove the printer from the phone book and disconnect 2 Cables from the front of the LVPS.See Figure 8–4.


Figure 8–4. Removing the LVPS Cables


7. Remove 2 Screws from the rear of the Base Frame, then lift the LVPS to clear the BaseFrame. Push the Power Switch to the OFF position, then slide the LVPS toward the rear ofthe printer. Use care to avoid damaging the Power Switch. Once the Power Switch is partiallypast the Frame, switch it to the ON position and slide the LVPS free of the Base Frame. Feedthe Lamp Power Wire Harness through the Printer Base Plate. See Figure 8–5.

CAUTION: Use care to avoid damaging the Fuser Lamp Connector. Ensure that itdoes not catch on the Base Plate. When reinstalling the Lamp, besure that you route the Fuser Lamp Connector through the Base Platebefore you install the LVPS into the Base Frame. See Figure 8–6.

NOTE: When installing the LVPS, ensure that the bottom front of the supply islocked under the locking tabs on the base frame. See Figure 8–7.


5

4

2

3

1

Figure 8–5. Removing the LVPS


Cable Routing

Figure 8–6. LVPS Cable Routing


Figure 8–7. LVPS Locking Tabs

8. To remove the LVPS Cooling Fan, disconnect the Cable from Connector CN3, remove 2Screws, then remove the Cooling Fan.


8.3.2 Input Voltage Conversion and Fuse Replacement

Use this procedure to replace a fuse in the LVPS, or to convert the LVPS input voltage from 115 VAC to230 VAC or from 230 VAC to 115 VAC.


2. Remove the printer from the phone book and disconnect 2 Cables from the front of the LVPS.See Figure 8–9.




Figure 8–9. Removing the LVPS Cables


3. Remove 2 Screws from the rear of the Base Frame, then lift the LVPS to clear the BaseFrame. Push the Power Switch to the OFF position, then slide the LVPS toward the rear ofthe printer. Use care to avoid damaging the Power Switch. Once the Power Switch is partiallypast the Frame, switch it to the ON position and slide the LVPS free of the Base Frame. SeeFigure 8–10.


NOTE: When installing the LVPS, ensure that the bottom front of the supply islocked under the locking tabs on the base frame. See Figure 8–12.


5

4

2

3

1



Cable Routing




4. Remove 1 Screw from the tie wrap that secures the Lamp Power Wire Harness.

5. To change the input voltage of the LVPS, remove 1 Screw and remove the ConnectorBracket. Disconnect the Cable from Connector CN5 or CN6 and connect it to the free one.CN5 is for 115 VAC and CN6 is for 230 VAC. Place the Connector Bracket over the freeConnector and reinstall 1 Screw. See Figure 8–13.


115V Position

230V Position

1

2

3

1

2

3

Figure 8–13. Changing LVPS Input Voltage


6. Replace Fuse F1, F2, or F3 as needed.



The following table lists the Cable Connectors and Fuses for the LVPS, together with their respectivefunctions and their destinations:

Table 8–1. Low Voltage Power Supply Connectors and Fuses

Connector or Fuse Function Destination

CN1 Engine Controller Board Power (+5V) J7 on Backplane Board

CN2

Stepper Motors Controller Board Power CN1 on Stepper Motors ControllerBoard

CN2Engine Controller Board Power (+24V, 12V)and Signals

J8 on Backplane Board

CN3 LVPS Cooling Fan LVPS

CN4 Fuser Lamp Lamp Connector

CN5 115 VAC Input Power LVPS

CN6 230 VAC Input Power LVPS

F1 Lamp Fuse

F2 115 VAC

F3 230 VAC

8.3.4 Adjustment

No adjustment of the LVPS is required.





1. Open the Clamshell, remove the OPC Drum Unit, the Developer Unit, and any paper presentin the printer.

2. Remove the Left Side Cover of the printer. See Figure 8–14.

a. Remove 2 Screws from the Left Side Cover.

b. Loosen, but do not remove, 1 Screw on the Base Plate. This loosens the MountingBracket so it can be slid free of the Base Plate.

c. Lift the front edge of the Cover to disengage the Locking Tabs, then slide the Covertoward the rear of the printer to disengage the Bracket from the Screw in the Base Plate.

ÎÎÏÏ

ÎÎÎÎ

Locking Tabs

ÎÎÎÎ

Step 2a

Step 2b

Figure 8–14. Removing the Left Side Cover

3. Remove the Front Plastic Paper Guide of the Transfer Charger by pressing down on the endsand sliding it to the left. This disengages the Locking Tabs and the Guide can be easilyremoved. See Figure 8–15.


Step 3

Step 4

Step 6

Step 5

Step 7

Figure 8–15. Removing the Transfer Charger Paper Guides


4. Remove the Transfer Charger Paper Guide by gently pressing the Release Tabs at the rear ofthe Guide toward the front of the printer. Lift the rear of the Guide to clear the Tabs of theSlots, and release the Front Tabs by rotating the Guide toward the front of the printer. SeeFigure 8–15.

5. Remove the Static Brush and Rear Plastic Paper Guide from the Corona Assembly byremoving 2 Screws. See Figure 8–15.

NOTE: When reinstalling the Static Brush, ensure that the Brush Frame is in frontof the Locking Tab for the Corona Assembly. See Figure 8–16.

Static BrushIs Placed InFront OfRetainingTab

Figure 8–16. Reinstalling the Static Brush

6. Remove 2 Screws and lift the Corona Assembly up slightly while sliding it to the left todisengage the Locking Tabs. See Figure 8–15.

7. Remove 2 Screws at the rear of the Lower Paper Guide, then remove it from the printer bylifting the rear portion of the Guide out first. This helps the Guide clear the Contacts for theHVPS and the Transfer Charger Frame. Disengage the Locking Tabs at the front of the Guidefrom the Tension Roller Frame. See Figure 8–15.



Step 8

Step 9

Step 10

Step 11

Step 12

Step 13

Step 14



Figure 8–17. Removing the Fuser


9. Remove the Lamp Connector Cover by removing 1 Screw and disconnect the Fuser Lampand Thermistor Connectors from the Stepper Motor Board Frame. See Figure 8–17.


NOTE: Upon installation, the groove on the bottom of the Right Inide Cover shouldstraddle the top edge of the right side of the Tractor Frame. See detail inFigure 8–17.

11. Remove the Tractor Encoder Cover by removing 1 Screw. See Figure 8–17.

NOTE: Upon installation, the groove on the bottom of the Encoder Cover shouldstraddle the top of the left end of the Tractor Frame. See detail in Figure8–17.

12. Remove the Tractor Paper Guide by removing 1 Screw from the center rear of the TractorFrame. See Figure 8–17.

13. Disconnect the Encoder Cable from the Connector on the Base Plate. See Figure 8–17.

14. Remove the Tractor by removing 3 Screws, then lifting the left end of the Tractor out first.This clears the Encoder of the HVPS, and allows the Tractor room to move to the left so thatthe Tractor Stepper Motor can clear the Stepper Motor Board Frame. See Figure 8–17.

15. Disconnect the Cable from the Tractor Stepper Motor and remove the Tractor from the printer.

16. Remove 1 Screw from the rear of the HVPS Contact and slide it toward the rear of the printerto release the Front Locking Tab from the Printer Base Plate. See Figure 8–18.


Step 16

Step 17

Figure 8–18. Removing the HVPS

17. Disconnect the Cable from the rear of the HVPS and remove 1 Screw from the rear of theHVPS. Slide the HVPS toward the rear of the printer to release the Front Locking Tab fromthe Base Plate. See Figure 8–18.

NOTE: Upon installation, ensure that the HVPS Cable is properly routed throughthe grooves in the HVPS Cover.




8.4.3 Adjustment

With rare exceptions, the high voltage power supply should not require adjustment. However, in the eventthat adjustment is required in order to return the printer to specification, use the HVPS adjustmentprocedure that follows.

WARNING: HIGH VOLTAGES are present in numerous places throughout theHigh Voltage, OPC, and Developer assemblies when the printer isturned on.

The table that follows lists specifications, connections, and control interface for the HVPS. Use these as aguide to adjusting the small controls on the side of the HVPS itself. See Figure 8–19.

NOTE: The user-adjustable developer bias knob on the top of the HVPS must beset to “3” when making the following adjustments.

Table 8–2. High Voltage Power Supply Adjustments

Signal

EngineControllerConnector

HV SupplyConnector

Channel

HV OutputConnector

Adjust Output Value Definition

+24V J10–1 6 – – – – +24 VDCsupply

Charge J10–2 5 CH1 CN1 VR1 400±25mA Chargecorona

Develop J10–3 4 CH4 CN2 VR22* –550±50 VDC Developerbias

Transfer J10–4 3 CH3 CN3 VR31 4.6±0.1 kVDC Transfercorona

– – – CH6 CN6 VR61 –720 VDC(parasiticfrom charge)

Charge grid

BGND J10–6 1 – – – – Analogground

*With VR21 set to “3”.


Adjustments:CH2

CH3

CH1

CH6

ÌÌ

ÌÌÌÌ

CN2CN6

CN1

CN3

User–AdjustableDeveloper BiasAdjustment

Contactor AssemblyLock–down tabs

Figure 8–19. High Voltage Test and Adjustment Points


HVPS ADJUSTMENT PROCEDURE

1. Turn off the printer.

2. Open the printer and remove the OPC Drum Unit and the Developer Unit.

3. Set the user-adjustable developer bias knob to “3”.

NOTE: The user-adjustable developer bias knob is the green knob located on thetop of the HVPS. This knob is also called VR21. Turning the knob variesthe high voltage to the developer unit. See Figure 8–19.

4. Disable the following:

Paper empty switch

Cover interlock switch

Top-of-form switch

OPC drum switch

5. Turn on the printer and wait for the printer to display the error message, “03 ADD TONERAND CHK WASTE BOTTLE” on the LCD.

6. Take the printer offline by pressing the On Line key. The top line of the LCD should show“OFFLINE”.

7. Press the Next key until “DIAGNOSTICS” appears on the bottom line of the LCD.

8. Press the Down key. Press Next until “TEST PRINT” appears on the bottom line of the LCD.

9. Press Down . Press Next until “NO. OF PAGES” appears on the bottom line of the LCD.

10. Press Down . Press Next until “CONTINUOUS” appears on the bottom line of the LCD.

11. Press Enter . (If you receive the message “ENTER SWITCH LOCKED”, then unlock it bypressing Up and Down simultaneously. Then press Enter again.)

The number of pages to print has now been set to “Continuous”. This is indicated by anasterisk (*) character on the LCD.

12. Press Up. Press Next until “START TEST PRESS ENTER” appears on the LCD.

13. Press Enter . The message “TEST PRINTING” appears on the LCD. At this point, the printershould be attempting to print.

14. Using a high voltage probe and a DVM, check the voltages at the points listed in the table onpage 8–31.

NOTE: A high voltage probe must be used when measuring each of thesevoltages. Even a good DVM used without a high voltage probe will load thecircuit enough to produce erroneous readings.


15. Stop the test by pressing Enter .

16. Turn off the printer.

17. Restore the following to their normal (non-disabled) states:

Paper empty switch

Cover interlock switch

Top-of-form switch

OPC drum switch

18. Install the OPC Drum Unit and the Developer Unit, then close the printer top.



9–1Chapter 9 – Controllers and Floppy Disk Drives

Chapter 9Controllers and Floppy Disk Drives

BASEPAN

HIGHVOLTAGESUPPLY

LEFTFRAME

BOTTOMCOVER

STEPPER MOTOR &CONTROL BOARDHOUSING

ENGINECONTROLLERBOARD

CLAMSHELL

BACKPLANEBOARD

DATACONTROLLERBOARD

BOTTOMFRAME

Controller Boards

9–2 Chapter 9 – Controllers and Floppy Disk Drives

Callout Name Vendor Part No. Printronix Part No.1 Controller Assembly, Data, L1024 704598–001

Data Controller Board


Callout Name Vendor Part No. Printronix Part No.1 Engine Controller Board, L1024 202505–551 704539–1082 Backplane Board, L1024 202289–552 704539–107

1

BottomFrame

BackplaneBoard

2

EngineControllerBoard

Engine Controller and Backplane Boards


Callout Name Vendor Part No. Printronix Part No.1 Stepper Motor Board Frame Assembly 202168–5022 Cover, Side, LVPS 200673–0013 Frame, Stepper Motor Board 202169–5524 Board, Stepper Motor 202170–551 704539–1105 Fan, Ozone 202171–551 704539–1116 Actuator, Cover Open 202172–001 704539–1127 Actuator, Drum Sensor 202173–002 704539–1138 Label, Inlet Hole Cover 202174–0019 Screw, PPH, CLFW, 3x6mm, Zinc (8) 030030–30610 Screw, PPH, CLFW, 3x10mm, Zinc 030030–31011 Screw, PPH, CLFW, 3x30mm, Zinc (4) 030030–33012 Wire Harness, Thermistor 202200–55113 Wire Harness, Lamp 202576–55114 Cable, Stepper Motor Control 202299–55115 Wire Harness, Power, Controller Board 202298–55116 Tie Wrap, Beaded, Motor Board Harness 202391–001


Right side view

Left side view

131

1Ref

81

91

101

91

61

71

31

51 4

1

151

141

161

21

114

92

92

92

121

Stepper Motors Controller Board


Callout Name Vendor Part No. Printronix Part No.1 Disk Drive Assembly, 3.5 Inch, L1024 704627–0012 Cable Kit, L1024 704612–0013 Disk Drive, Floppy, 3.5 Inch 2 MB 202377–0014 Screw, FL 90D, M3x5, Phil., STL/ZN5 Clamp, Flat, Cable, 2 Hole Mount 202404–0026 Pad, Cushion, Flat Cable Clamp 202403–001


Drive A (Standard)

Drive B (Optional)

Floppy Disk Drives


9.5.1 Mechanical

The printer has three Controller Boards:

Data Controller Board

Engine Controller Board

Stepper Motors Controller Board

The Data Controller Board oversees and coordinates all printer functions. It communicates with thefollowing:

Control Panel

Floppy Disk Drives

Engine Controller Board

Host Computer

The Engine Controller Board acts as interface between the Data Controller Board and theelectromechanical portions of the printer.

The Stepper Motors Controller Board controls the various stepper motors in the printer. The main functionof the stepper motors is moving the paper.

9.5.2 Electrical

See the block diagram in Appendix B for an overview of the connections between the controller boardsand the other areas of the printer.



WARNING: To prevent electrostatic damage to electronic components, alwayswear a properly grounded static wrist strap when you handle circuitboards and components. Do not remove or replace the NVRAM on theData Controller Board. The NVRAM contains a lithium battery that canexplode if the NVRAM is replaced incorrectly. NVRAM is replaced onlyat the factory.

1. Remove the 4 Screws from the printer Back Panel that secure the Data Controller Board. SeeFigure 9–1.

CAUTION: The Floppy Disk Drive Data and Power Cables must be disconnectedfrom the Data Controller Board before the board can be removed fromthe printer.

2. Slide the Data Controller Board out of the printer part of the way, until you can gain access tothe Floppy Disk Drive Power Cable Connector (J5) and Data Cable Connector (J10) on theboard. See Figure 9–1.

3. Disconnect the Floppy Disk Drive Power Cable from Connector J5 on the Data ControllerBoard.

4. Disconnect the Floppy Disk Drive Data Cable from Connector J10 on the Data ControllerBoard.

5. Slide the Data Controller Board out the rest of the way, and remove it from the printer.


J10 J5Screw (4)

Figure 9–1. Removing Data Controller Board



9.6.3 Adjustment

No adjustment of the Data Controller Board is necessary.



If you have not already done so, run the engine self-test. (Refer to the engine self-test information inChapter 13.)

If errors or other problems occur when running the engine self-test, then the problem is most likely not inthe Data Controller Board or the host computer. The problem, in this case, is more likely to be in theEngine Controller Board, or in other areas of the printer engine. Refer to the troubleshooting informationin Chapter 13.

If the engine self-test runs with no errors, however, then the Data Controller Board or host computer isprobably at fault. Run one of the Data Controller Board printing self-tests. These tests are accessible fromthe Diagnostics menu, using the Control Panel keys. (Refer to the Setup Guide for instructions onaccessing and running these tests.) Running a printing self-test will isolate the error to either the DataController Board or the host computer.

If the printing diagnostic tests run correctly, the problem is most likely in the host computer. However, itcould also be in one of the following areas:

The Data Controller Board interface to the host computer (located on the Data ControllerBoard).

The interface cables between the Data Controller Board and the host conputer.

A configuration mismatch between the printer and the host computer.

NOTE: If you suspect a configuration problem, refer to the Setup Guide forinstructions on properly configuring the printer. Refer to the documentationfor your host computer for information on configuring your host computer towork with the printer.

If the printing diagnostic tests do not run correctly, or do not run at all, and the engine self-test rancorrectly, then the problem is most likely to be in the Data Controller Board, not the host computer. Runthe Data Controller Board power-up self-test, as described below.

Data Controller Board Power-Up Self-Test

Turn off power to the printer. When you turn the printer power back on, look through the three small roundholes located on the vertical rear panel of the Data Controller Board, and observe the three tiny greenLEDs mounted flat on the board. These LEDs serve as diagnostic indicators for the board’s power-upself-test. The LEDs are identified as L1, L2, and L3, as shown in Figure 9–2. LEDs L1 and L2 displayinformation about the boot sequence. LED L3, described later, indicates CPU activity (or the lack of it) forthe microprocessor on the Data Controller Board.


RS232/RS422 TEST 5V

L1 L2 L3PARALLEL

Figure 9–2. Data Controller Board Diagnostic LED Locations

As the Data Controller Board starts and initializes, LEDs L1 and L2 will indicate the various portions of theboot sequence, as shown in Table 9–1.

Table 9–1. Data Controller Board Boot Sequence

L1 L2 Meaning

Off Off Initial State

On On Running DRAM Diagnostics

Off Off Running I/O Diagnostics

On On Reading Sector 0 from Disk

On Off Searching for Boot File

Off On Loading Boot File

On On Preparing for Execution

Off Off Normal Execution State


If an error occurs during the Data Controller Board power-up self-test, the initialization sequence will stop,and the board will report an error. The board reports the error by beeping the speaker, flashing L1, andflashing L2, all in unison, to signal the error code. The error code will be signalled repeatedly, as long aspower to the Data Controller Board remains on. Table 9–2 lists the beep and LED error codes.

Table 9–2. Data Controller Board Beep and Diagnostic LED Error Codes

Diagnostic Status LED Flash/Beep Pattern LCD Message Displayed

ROM Checksum Test—Fail ◊ ◊ ◊ ⇒ ◊ ◊ ◊ ⇒ ◊ ◊ ◊ None

DRAM—Bank 1 Failure ◊ ⇒ ◊ ⇒ ◊ None

DRAM—Bank 2 Failure ◊ ⇒ ◊ ⇒ ◊ ◊ None

DRAM—Bank 3 Failure ◊ ⇒ ◊ ⇒ ◊ ◊ ◊ None

DRAM—Bank 4 Failure ◊ ⇒ ◊ ⇒ ◊ ◊ ◊ ◊ None

Vector Interrupt Test—Fail ◊ ⇒ ◊ ◊ ⇒ ◊ None

Autovector Interrupt—Fail ◊ ⇒ ◊ ◊ ⇒ ◊ ◊ None

Front Panel Presence—Fail ◊ ⇒ ◊ ◊ ⇒ ◊ ◊ ◊ Not Applicable

Front Panel LCD Pattern Test Visual Detection RUNNING SELF TEST ....

Key:◊ = L1, L2, and the Beep are all on together for 500 msec.⇒ = Pause for 2 sec.


The third LED, LED L3, indicates the relative amount of CPU activity. Referring to Figure 9–3, when theCPU is 100% utilized, L3 will be off. L3 will be on at full intensity when the CPU is idle, such as when theCPU tasks are running faster than the printer engine speed. During normal operating conditions, LED L3will be somewhere between the two extremes of continuously on and continuously off, and will appeardimmed. This condition is indicated by the gray area labelled “Normal CPU Usage Range” in Figure 9–3.Increasing CPU utilization causes L3 to decrease in intensity, and vice-versa.

CPU 100% Utilized

CPU Idle

Normal CPUUsage Range

ON

OFF

Figure 9–3. Data Controller Board LED L3 Interpretation



1. Open the Clamshell, remove the OPC Drum Unit, Developer Unit, Waste Toner Container,and any paper present in the printer.

2. Remove the 4 Screws from the printer Back Panel that secure the Data Controller Board.

3. Slide the Data Controller Board out of the printer part of the way, until you can gain access tothe Floppy Disk Drive data and power connectors on the board. See Figure 9–1 on page9–10.

4. Disconnect the Floppy Disk Drive data and power connectors from the Data Controller Board.





Figure 9–4. Removing Bottom Cover

7. Remove the printer from the phone book. Remove the Screw from the left side of the BaseFrame that secures the Engine Controller Board.

8. Unplug the Engine Controller Board from the Backplane Board and remove the EngineController Board from the printer through the opening in the rear of the printer.



9.7.3 Adjustment

No adjustment of the Engine Controller Board is necessary.





1. Open the Clamshell, remove the OPC Drum Unit, Developer Unit, and any paper present inthe printer.

2. Remove the Lamp Connector Cover by removing 1 Screw and disconnect the Fuser Lampand Thermistor Connectors from the Right Side Frame. See Figure 9–5 and Figure 9–6.


Detail 9–1Step 2

Step 3

Step 10

Step 6

Step 3

Step 5

Figure 9–5. Removing Various Parts


3. Remove the Right Inside Cover by removing 1 Screw, then pressing down on the WarningLabel at the front of the Cover. This releases the Locking Tab from the Right Side Cover.

NOTE: Upon installation, the groove on the bottom of the Right Inside Covershould straddle the top edge of the right side of the Tractor Frame. SeeDetail 9–1 in Figure 9–5.

4. Open the Printer Front Cover and remove the LCD Control Panel by removing 2 Screws.

5. Remove the Right Side Cover by removing 3 Screws.

6. Remove 2 Screws from the Ozone Filter Case and remove it from the printer.

7. Release the Fuser Lamp Connector and the Thermistor Connector from the Stepper MotorBoard Frame by pressing in on the Locking Tabs. See Detail 9–2 in Figure 9–6.


Detail 9–2

Step 7

Step 2

Figure 9–6. Releasing Heater Lamp and Thermistor Connectors


8. Loosen, but do not remove, 2 Screws on the top of the Stepper Motor Board Frame. Removethe Frame Cover, and disconnect 7 Cables from the Board. These Cables are at connectorsCN1, CN2, CN3, CN4, CN5, CN6 and CN8. See Figure 9–7 and Detail 9–3 in Figure 9–7.

NOTE: The 3 Stepper Motor Cables connect to Connectors CN3, CN4, and CN5 inthe order the Motors appear in the printer: the Gear Motor connects toCN3, the Tractor Motor connects to CN4, and the Fuser Motor connects toCN5.


Right side view

Left side view

Detail 9–3

Stepper Motors Controller BoardConnectors Detail

CN5CN4CN3

CN1CN7

CN2 CN8 CN6

Step 8

Step 12

Step 11

Figure 9–7. Stepper Motors Controller Board Removal and Connectors Detail



10. Remove the Tractor Paper Guide by removing 1 Screw, then disconnect the Cable from theFuser. Remove 1 Screw from the Cable Tie to release the Cable from the Base Plate of theprinter. See Figure 9–8.

11. Remove 2 Screws from the Stepper Motors Controller Board and remove it from the printer.See Figure 9–7.


Depress white retaininglevers to release fuserroller assembly fromfuser base

J–1 ConnectorStep e

Step 9

Step 10

Step d

Step b

Step c

Figure 9–8. Preparation for Removing the Stepper Motor Board Frame


NOTE: The Stepper Motor Board Frame cannot be removed unless the FuserBase has been removed from the printer. Therefore, remove the StepperMotor Board Frame only if absolutely necessary. Follow the steps below(see Figure 9–8) before removing the Stepper Motor Board Frame(Step 12).

a. Open the Paper Exit Guide at the rear of the Fuser Base so that it is not in contact withthe Fuser Roller Assembly.

b. Depress the Fuser Assembly Retaining Lever on each side of the printer so that theFuser Assembly is free to move.

c. Lift the Fuser Assembly free of the Fuser Base, then remove it from the printer.

d. Disconnect the Fuser Sensor Board by removing the Cable at Connector J1.

e. Remove 2 Screws from the rear of the Fuser Base and remove it from the printer.

12. Remove 2 Screws from the Stepper Motor Board Frame and remove the Frame. SeeFigure 9–7 on page 9–21.

DISASSEMBLY

NOTE: Except for the Ozone Fan, all of the components listed below can beremoved from the printer without first removing the Stepper Motor BoardFrame. The Ozone Fan can be removed from the Frame if the LCD ControlPanel and Bracket are first removed from the printer.

1. Disconnect the Cable from Connector CN7, remove 4 Screws from the Ozone Fan, andremove the Fan from the Frame.

2. Remove 2 Screws, then remove the Stepper Motors Controller Board from the Frame.

3. Remove 1 Screw, then remove the OPC Drum Spring.

4. Remove 1 Screw, then remove the Cover Open Spring.



Table 9–3 lists the connectors on the Stepper Motors Controller Board, together with their respectivefunctions and destinations. Figure 9–9 shows the locations of the connectors on the board.


Table 9–3. Stepper Motors Controller Board Connectors

CONNECTOR FUNCTION DESTINATION

CN1 Stepper Motors Controller BoardPower

CN2 on LVPS

CN2 Stepper Motors Controller BoardControl

J6 on Backplane Board

CN3 Main Stepper Motor Main Stepper Motor

CN4 Tractor Stepper Motor Tractor Stepper Motor

CN5 Fuser Stepper Motor Fuser Stepper Motor

CN6 Fuser Cam Motor and Clutch Fuser Cam Motor and Clutch

CN7 Ozone Fan Upper Board Housing Fan

CN8 Thermistor Power Fuser Lamp Connector

CN7

CN1

CN2CN8

CN6

CN5CN4CN3

Figure 9–9. Stepper Motors Controller Board Connectors

9.8.3 Adjustment

No adjustment of the Stepper Motors Controller Board is necessary.





NOTE: Some printers will have only one Floppy Disk Drive installed. The second,or Drive B, Floppy Disk Drive is an option. This procedure is writtenassuming that the printer being serviced has both Floppy Disk Drivesinstalled.

1. Open the Clamshell. Remove any paper present in the printer. Remove the OPC Drum Unit,the Developer Unit, and the Waste Toner Container.

2. Remove the Front and Rear Paper Guides from the printer.

3. Remove the Floppy Disks from the Floppy Disk Drives.

4. Disconnect the Power Cord and Data Cable from the rear of the printer.

5. Remove the plastic Floppy Disk Drive Guide (Bezel) from the front of the printer by pressingin on the Locking Tabs. See Figure 9–10.

6. Remove the 4 Screws from the printer Back Panel that secure the Data Controller Board. SeeFigure 9–1 on page 9–10.

CAUTION: The Floppy Disk Drive Data and Power Cables must be disconnectedfrom the Data Controller Board before the board can be removed fromthe printer.

7. Slide the Data Controller Board out of the printer part of the way, until you can gain access tothe Floppy Disk Drive Power Cable Connector (J5) and Data Cable Connector (J10) on theboard. See Figure 9–1 on page 9–10.

8. Disconnect the Floppy Disk Drive Power Cable from Connector J5 on the Data ControllerBoard.

9. Disconnect the Floppy Disk Drive Data Cable from Connector J10 on the Data ControllerBoard.


11. With paper and all Consumables removed, especially the Waste Toner Container, turn theprinter upside down. Carefully press on the 4 corners of the Bottom Cover to release theLocking Tabs from the Base Plate and remove the Bottom Cover. Turn the printer rightsideup. See Figure 9–4 on page 9–16.

12. Remove 2 Screws from the front and 1 Screw from the left side of the Floppy Disk DriveFrame. See Figure 9–10.

13. Remove the Floppy Disk Drive Frame (with Drives and Drive Cables attached) from theprinter Base Frame, through the front opening of the printer.


Floppy DiskDrive Frame

Floppy DiskDrive Frame(Ref.)Floppy Disk

Drive Guide(Bezel)

Step 12

Step 5

Figure 9–10. Removing Drive Frame from Printer


DISASSEMBLY

1. Observe the orientation of the Data Cable on the rear of each Floppy Disk Drive, and make anote of it for reference later when you reinstall the Drives. See Figure 9–11.

2. Disconnect the Data and Power Cable Connectors from the rear of each Floppy Disk Drive.

NOTE: When you install a Floppy Disk Drive, be sure to orient the Data Cablecorrectly when you connect it to the rear of the Drive.

3. Remove 4 Screws from the bottom of each Floppy Disk Drive and remove the Drives from theFloppy Disk Drive Frame.

NOTE: When you replace a Floppy Disk Drive, be sure to correctly set the DriveAddressing Jumpers and/or Switches on the new Drive before you install it.The first (or only) Drive in the printer must be addressed as Drive A. If theoptional second Drive is present, it must be addressed as Drive B.


Drive A (Standard)

Drive B (Optional)

Step 2

Step 3

Figure 9–11. Removing Drives from Drive Frame




NOTE: When you install a Floppy Disk Drive, be sure to orient the Data Cablecorrectly when you connect it to the rear of the Drive.

NOTE: When you replace a Floppy Disk Drive, be sure to correctly set the DriveAddressing Jumpers and/or Switches on the new Drive before you install it.The first (or only) Drive in the printer must be addressed as Drive A. If theoptional second Drive is present, it must be addressed as Drive B.

9.9.3 Adjustment

No adjustment of the Floppy Disk Drives is necessary.




9.10.1 Removal (see Figure 9–12)

1. Remove the data controller board from the printer, as described in section 9.6.1.

2. Loosen the thumbscrew (4) on the C/T board (3) until the screw is released from the standoff(5).

3. Remove the screw securing the I/O plate to the rear of the card cage (1).

4. Carefully lift the C/T board out of the data controller cutout (6) and off the expansionconnector (7).

9.10.2 Installation (see Figure 9–12)

1. Remove the data controller board from the printer, as described in section 9.6.1.

2. Remove the screw holding the I/O cover plate to the L1024 data controller pan (1). Save thescrew.

3. Screw the standoff (5) onto the pan, through the hole next to C54.

4. Carefully install the C/T card (3) with the expansion connector (7) onto the board.

5. Using the screw which held the I/O cover plate (1), screw the I/O plate (2) to the pan. Tightenthe thumbscrew (4) to the standoff (5).

6. Re-install the data controller as described in section 9.6.2.

9.10.3 Expansion C/T Parts ListCallout Name Printronix Part No.1 Screw Ref2 Card Cage Ref3 Expansion–CT PCBA 152319–0014 Screw, Captive Ref5 Standoff, Hex, 3/16 inch, M/F, .813 Lg. Ref6 L1024 Data Controller Board Ref7 Expansion Connector Ref


1

2

3

4

5

6

7

Figure 9–12. Expansion–C/T Board

10–1Chapter 10 – Control Panel

Chapter 10Control Panel

Keypad

LCD

Control Panel

10–2 Chapter 10 – Control Panel

Callout Name Vendor Part No. Printronix Part No.1 Control Panel Assembly, L1024 202117–552 704539–0482 Screw, PPH, W/CLFW, M3x8, Zinc (2) 030130–3083 Overlay Sheet 202316–001

31

11

21

21

Connector CN

Control Panel


10.2.1 Mechanical

The control panel has a 16-character by 2-line Liquid Crystal Display (LCD). In addition, there are threestatus lights and seven keys. The keys are membrane-type switches with the function printed on eachone. The status lights are used to monitor the printer state, data in the buffer, and the online status. TheLCD allows the user to display the programmable functions that control the printer. It also shows theprinter status and other control information.

10.2.2 Electrical

The control panel is connected to the engine controller via connector CN on the back of the display panel.This is connected to a straight-through 26-pin connector and via a 26-wire cable to the engine controllerat J3. This connector is keyed to make sure it can be plugged in only one way.

The following table lists the interface cable pin connections and their functions:

Table 10–1. Control Panel Interface Signals

Pin Number Function

1 No connection

2 Ground

3 +5 volts

4 (RS) register select; 0 for instruction register, 1 for data regis-ter

5 (R/W) read/write select; 0 for write, 1 for read

6 (E) strobe to signal start of data read or write

7 (DB0) Data bit 0

8 (DB1) Data bit 1

9 (DB2) Data bit 2

10 (DB3) Data bit 3

11 (DB4) Data bit 4

12 (DB5) Data bit 5

13 (DB6) Data bit 6

14 (DB7) Data bit 7

15 (SW Reset) Reset Key

16 (SW Online) Online Key



Pin Number Function

17 (SW FF) Page Eject (Form Feed) Key

18 (SW Menu) Menu Key

19 (SW Store) Store Key

20 (SW Up) Up-Arrow Key

21 (SW Down) Down-Arrow Key

22 (LED Ready) Ready LED

23 (LED Online) On Line LED

24 (LED Data) Data LED

25 (LEDRSV1) Reserved LED output, not currently used

26 (LEDRSV2) Reserved LED output, not currently used


Following is a block diagram. See Appendix B for a complete electrical block diagram.

201153S203

J7J8

J6

COPEN/OPC

/NEWOPCTMRSG

TMRPWR

/OZNFAN/PRCL

PHA1

PHB1

PHA2

PHB2/PHA2

/PHB2

/PHA1

/PHB1

PDWN2

PHA3PHB3

/PHA3

/PHB3

+5VL+24VB

PDWN3

PDWN1

J5

+5/PRPOS

/PRINIT/SCPUP

/SCPDNPJAM

EJAM

/PRFAN

DGND+24

J13

+5PFS8

PFS6/PTOP

DGND

BACKPLANE BOARD

J4

TO LSU


J10

TONERSENSORBOARD

J9/WASTE

TNRLOW

+5

DGND

CN1

CN2

OPC DRUMUNIT

TRANSFERCHARGER

DEVELOPER

+24VB

BGND

/CHARGE/DEVELOPER

/TRANSFER

J1

1

2

3

4

5

RSVD

RS

R/W

E

DB0

DB1

DB2

DB3

DB4

DB5

DB6

DB76

7

8

9

10

11

12

13

14

15

16

18

19

20

21

22

23

24

17

/SWRST

/SWONL

/SWFF

/LDATA

/SWMENU

/LONLN

/SWSTOR

/LRDY

/SWDWN

Vss

Vdd


/SWUP

J2


J1


1

10

1

24

1 81 5 10

1

4

1

6

1

6

1

4

1 5 10

+24

BG

ND

+12

–12

AG

ND

AG

ND

PW

RO

FF

/HE

AT

+5

+5

+5

+5

DG

ND

DG

ND

DG

ND

DG

ND

+12

/QLE

D+

24B

GN

D

/PM

ON

/PM

RD

Y +5

DG

ND

/BD +5

DG

ND

/LD

ON

/LV

IDE

OLV

RDEVELOPERBIAS

TONERSENSOR

J111

PAPEREMPTYSENSOR

PEPWR

PEMPTY

DGND 3

LCDCONTROLPANEL

202298S208

202375S207

202278E112

202291S202

202393S201

202294S204

1 24

J3

1

5

14

Block Diagram 10–1. LCD and Keypad



1. Open the printer clamshell.

2. Open the front cover. See Figure 10–1.

Step 4

Step 3

Step 2

Figure 10–1. LCD Control Panel Removal

3. Remove the screw on left front of the control panel.

4. Remove the screw on the bottom right side of the control panel.

5. Lift the control panel upward and to the right to disengage the tab and shaft.

CAUTION: Be careful not to damage the cable.

6. Disconnect the cable and remove the LCD panel.

NOTE: Do not remove the board from the control panel as the LCD is aligned topanel mask and buttons. The entire assembly should be replaced if anyproblems occur with any of the components.




10.3.3 Adjustment

No adjustment of the Control Panel Assembly is necessary.


Overview

The printer LCD panel displays the status of the printer and user-changeable programming information.Printer status information is transmitted by the data controller to the LCD control panel via the 26-pincable See Figure 10–2. This cable plugs into the Backplane Board at J3 and connects to the displaypanel at connector CN. There are seven keys (membrane-type switches) on the panel that allow the userto program various printer configurations. There are three LEDs that display READY status, ON LINEstatus, and data in the printer buffer.

CN

IC1IC2

Figure 10–2. LCD Control Panel Board, Rear View

Symptoms

There are several symptoms that may lead you to suspect a bad display panel:

The LCD display may be missing a row of pixels, or

The control panel keys may not be operating properly, or

A status LED may be defective.


If you observe any of these symptoms, replace the entire display panel, since there are no replaceableparts in it.

1. Missing row of pixels. The quickest way to check whether the panel is good or not is bysubstitution. If the problem disappears when you replace the panel, the old panel was badand no further work is required. If, however, the panel is still missing pixels, perform acontinuity check of the 26-pin cable that goes to the data controller. Begin by removing thebottom cover of the printer. The panel cable is a one-to-one type that plugs into theBackplane Board at J3. The pinout of the cable is shown in Table 10–1 on page 10–3. If boththe panel and the cable check out OK, replace the data controller.

2. Keys not operating properly. The seven keys on the panel have a decal attached to theplastic housing that makes up the bulk of the display panel. The key coverings, in turn, pressagainst seven small switches that are on the LCD printed circuit board. Two of the probablefailure modes for the keys are:

The key covering is not making contact with the switch underneath it, or

The switch itself is bad.

Check these possibilities as follows:

a. Turn the printer off and remove the display panel.

b. Locate the pin on connector CN for the suspected bad key. See Figure 10–2.

c. Place one lead of an ohmmeter on pin 2 (ground) of CN and the other lead on the pin ofthe suspected bad key. Try pressing the key and see if the reading goes from open toclosed. If not, then replace the display panel.

d. If the ohmmeter reading does cycle from open to closed, then check the wiring harness,the backplane board, and the data controller board.

11–1Chapter 11 – Laser Scanning Unit (LSU) Subsystem

Chapter 11Laser Scanning Unit (LSU) Subsystem

Clamshell Frame

LSU Assembly

Top Cover

LSU Subsystem

11–2 Chapter 11 – Laser Scanning Unit (LSU) Subsystem

11.1.1 LSU AssemblyCallout Name Vendor Part No. Printronix Part No.1 LSU Assembly, L1024 202118–5512 Housing, LSU 202395–5513 Top Cover, LSU 202396–0014 Label, S/N, LSU 202397–0015 Label, Warning, Laser 200892–0016 Label, Warning, LSU Seal 200893–0027 Seal, Drum, LSU 202575–0028 Screw, PPH, CLFW, M3x8, Zinc (3) 030130–308


Top View

21

11

31

41

51

61

71

83

LSU Assembly


11.1.2 Erase LED AssemblyCallout Name Vendor Part No. Printronix Part No.10 Erase LED Assembly 200542–551 702724–00111 Cover, LED Assembly 200541–00112 Mount, LED, Plastic 200866–00113 Board Assembly, LED 200921–55114 Screw, PPH, PTC, 3x8mm, Zinc (4) 030129–30815 Screw, PPH, W/CLFW, 3x8mm (2) 030130–30816 Bushing, LED Harness 202167–001

111

121

131

144

161

10Ref

152

Erase LED Assembly


11.2.1 Mechanical

The Laser Scanning Unit (LSU) is attached to the printer clamshell and includes the following basicsubunits:

LSU Assembly. Generates the laser beam for page definition.

LED Array (Erase LEDs). Generates light to remove the residual charge from the OPCdrum.

LSU Base Plate. Supports and positions the LSU; helps protect the LSU from the wasteheat coming from the fuser.

11.2.2 Electrical

The LSU and LED units are connected via a single 14-wire cable to connector J4 on the Backplane Boardas shown in the following block diagram. See Appendix B for a complete electrical block diagram.


201153S203

J7J8

J6

J5

J13

BACKPLANE BOARD

J4

TOLSU


J10

TONERSENSORBOARD

J9/WASTE

TNRLOW

+5

DGND

CN1

CN2

OPC DRUMUNIT

TRANSFERCHARGER

DEVELOPER

+24VB

BGND

/CHARGE/DEVELOPER

/TRANSFER

J1

1

2

3

4

5

RSVD

RS

R/W

E

DB0

DB1

DB2

DB3

DB4

DB5

DB6

DB76

7

8

9

10

11

12

13

14

15

16

18

19

20

21

22

23

24

17

/SWRST

/SWONL

/SWFF

/LDATA

/SWMENU

/LONLN

/SWSTOR

/LRDY

/SWDWN

Vss

Vdd


/SWUP

J2J11

10

1

24

1 81 5 10

1

4

1

6

1

6

1

4

1 5 10

+12

/QLE

D+

24B

GN

D

/PM

ON

/PM

RD

Y +5

DG

ND

/BD +5

DG

ND

/LD

ON

/LV

IDE

OLV

R

DEVELOPERBIAS

TONERSENSOR

J111

3

LCDCONTROLPANEL

202291S202

202393S201

202294S204

1 24

J3

1

5

14

Block Diagram 11–1. LSU and LED Electrical




NOTE: When reinstalling the unit, the LSU must be properly located and seated inposition by the locking pins in the LSU Housing and the holes in the LSUBase Plate.

NOTE: When reinstalling the Top Cover onto the Clamshell, make sure the LatchAssembly is properly oriented with the Release Lever. See Detail 11–3 onpage 11–11.


Clamshell Frame

Top Cover

Step 1

Figure 11–1. Top Cover Disassembly


Detail 11–1. Removing the Top Cover


2. Remove 4 Connectors of the LSU Cable from various points on the LSU. The Connectors arefor the Erase LED Assembly, the Laser Driver, the Polygon Motor, and the Beam Detector.See Detail 11–2.

Top View

Detail 11–2. LSU Cables

3. Remove 3 Screws from the LSU Housing, then lift the LSU free of the LSU Base Plate. SeeDetail 11–2.

CAUTION: The LSU is a sealed assembly. Do not attempt to open the LSU orrepair it. Opening the LSU will cause it to become contaminated. Ifthere is a problem with the LSU, replace it.



NOTE: When reinstalling the unit, the LSU must be properly located and seated inposition by the locking pins in the LSU Housing and the holes in the LSUBase Plate.



Correct LatchRelease Position

Detail 11–3. Clamshell Latch Reassembly

11.3.3 Adjustment

When reassembling the unit, ensure that the Clamshell and its Latch are oriented properly.





1. Open the Clamshell, remove the Top Cover, disconnect the connector on the Erase LED WireHarness, and remove the Erase LED Harness Bushing. Remove 2 Screws from the ends ofthe Erase LED Assembly Frame. See Figure 11–2.

CAUTION: The Erase LED Wire Harness is hard-wired to the Erase LEDAssembly. When working on the Erase LED Assembly, be careful notto damage any wiring.


LED Connector

Top Cover

Bushing

Figure 11–2. Erase LED Removal


2. Remove the 2 Inner Screws and remove the Cover from the Erase LED Assembly.

3. Remove the 2 Outer Screws, then remove the entire LED Board and Mount together.

NOTE: The Erase LEDs are soldered directly to the LED Board. Thus, if any LEDsare defective, replace the entire LED Board.



11.4.3 Adjustment

No adjustment of the Erase LED Assembly is necessary.



12–1Chapter 12 – Covers, Frame, and Backplane Board

Chapter 12Covers, Frame, and Backplane Board

Covers and Frame Components

12–2 Chapter 12 – Covers, Frame, and Backplane Board

Callout Name Vendor Part No. Printronix Part No.2 Cover, Front 202121–001 704539–1193 LCD Control Panel 202117–551 704539–0484 Cover, Bottom 202122–001 704539–1205 Cover, Right Side 200753–0016 Cover Assembly, Left7 Cover, Left 200754–0018 Bracket, Mounting, Left Cover 200755–0019 Screw, PPH, CLFW, 3x6mm, Zinc (3) 030130–30610 Cover, Right Inside 202123–001 704539–12111 Cover, Lamp Connector 202124–001 704539–12212 Cover, Tractor Encoder 200471–00113 Ozone Filter Case 200470–00117 Screw, PPH, CLFW, 3x8mm, Zinc 030130–30818 Screw, PPH, CLFW, 3x10mm, Zinc (2) 030130–31019 Screw, W/IW, 3x8mm, Chrome (7) 030231–30820 Label, Warning, Ozone 200758–001 703068–00122 Label, Laser Registration 202502–00123 Label, Rating, 115V 202503–001 704831–001

Label, Rating, 235V 202504–001 704833–00125 Screw, TPH, 3x6mm, Chrome 030130–306


6Ref

121

171

182

192

71

131

91

111

101

81

92

201

211

21

191

31

41

191

221

231

51

193

251

Covers


Callout Name Vendor Part No. Printronix Part No.14 Cover, Hinge, Left 202119–001 704539–11615 Cover, Hinge, Right 202120–001 704539–11721 Label, Class 1 201394–001


141

151

211

Hinge Covers


Callout Name Vendor Part No. Printronix Part No.1 Frame, Left2 Side Frame Assembly, Left 200468–552 703113–0013 Shaft, Waste Toner Container Lever4 Shaft, Paper Brush Lever, Left5 Shaft, Developer Clamp6 Shaft, Safety Lever7 Side Frame, Left8 Clamp, Developer 200512–001 702714–0019 Clamshell Latch, Left 200513–001 702715–00110 Spring, Extension, Clamshell Latch 200514–001 702716–00111 Lever, Safety, Left 200516–001 702718–00112 Spring, Torsion, Safety Lever 200515–001 702717–00113 Board Assembly, Sensor, Toner 202115–551 702711–00114 Contact, Toner Sensor (2)15 Lever, Sensor, Waste Toner Container 200517–001 702719–00116 Screw, PPH, CLFW, 3x6mm, Zinc 030130–30617 E-Ring, 5mm I.D., Zinc (2) 071151–00818 Cable, Toner Sensor 202393–551 704539–04519 E-Ring, 4mm I.D., Zinc 071151–00620 CE Ring, 5mm I.D., Zinc 072151–00821 Label, Warning, High Voltage 200815–001 702798–00122 Screw, PPH, CLFW, 3x10mm, Zinc (3) 030130–31023 Label, Hi-Pot Test 202398–001


2Ref

1Ref21

1

201

41

81

91

221

61

101

111

171

171

121

221

31

51

71

14

2181

221

231

131

151 16

1191

HighVoltageWarningLabel

Left Side Frame


Callout Name Vendor Part No. Printronix Part No.1 Frame, Right2 Side Frame Assembly, Right 200469–551 703112–0013 Shaft, Safety Lever4 Shaft, Paper Brush Lever5 Shaft, Developer Clamp6 Shaft, Clamshell Latch, Right7 Side Frame, Right8 Clamshell Latch, Right 200623–001 702763–0019 Spring, Extension, Clamshell Latch 200514–001 702716–00110 Clamp, Developer 200512–001 702714–00111 Lever, Safety, Right 200621–001 702761–00112 Spring, Torsion, Safety Lever 200515–001 702717–00113 Spring, Grounding, OPC Drum 200622–001 702762–00114 Screw, PPH, CLFW, 3x6, Zinc 030130–306

(Screw used to mount OPC Grounding Spring to Frame)15 E-Ring, 5mm I.D., Zinc (2) 071151–00816 CE-Ring, 5mm I.D., Zinc 072151–00814 Screw, PPH, CLFW, 3x6mm, Zinc 030130–306

(Screw used to mount OPC Grounding Spring to Base Plate)17 Screw, PPH, CLFW, 3x10mm, Zinc (5) 030130–310

(Screw used to mount Frame to Base Plate)


142

121

151

111

171

71

161

101

31

41

61

172

131

51

171 17

1

151

81

91

2Ref

1Ref

Right Side Frame


Callout Name Vendor Part No. Printronix Part No.1 Base Frame Assembly2 Frame, Main Base 202279–0013 Rubber Foot (4) 200492–001 702698–0014 Bracket, Board Support 202280–0015 Bracket, Base Frame, Inner 202281–0016 Bracket, Backplane Support 202282–001 704539–1047 Bracket, Rear EMI 202283–0018 Guide Rail, PCB (2) 202284–001 704539–1069 Frame (Bracket), Floppy Disk Drive 202286–001 704539–10310 Guide (Bezel), Floppy Disk Drive 202287–002 704539–11811 Backplane Board 202289–551 704539–10712 Clamp, Mounted, Wire Harness 202290–00113 Screw, PPH, 3x6mm, Zinc (14) 030130–30619 Label, CSA 202214–00120 Engine Controller Board 202505–551 704539–10821 Grounding Contact (EMI Tab),

Backplane Board (3) 202506–001 704539–10513 Screw, PPH, 3x6mm, Zinc (12) 030130–30614 Wire Harness, HVPS and Tractor 202291–55115 Base Plate 202285–00116 Bracket, Display Mounting 200603–00117 Wire Harness, Fuser Signal 202296–551 704539–03818 Clamp, Wire Harness, Fuser Signal 202297–00119 Cable, LCD Control Panel 201153–001


NOTE: Arrows showattachmentscrew positions

191

1Ref

141 17

1 131

181

151

161

121 4

1

71

61

21

91

101

111

82

51

34

213

Base Frame


This section deals with parts not included in any other sections and includes:

Covers, Ozone Filter Case, and Rating Labels

Left Side Frame

Right Side Frame

Base Frame

Backplane Board



1. Open the Clamshell and the Front Cover, remove the OPC Drum Unit, the Developer Unit theWaste Toner Container, and any paper present in the printer.




c. Lift the front edge of the Left Side Cover to disengage the Locking Tabs, then slide theCover toward the rear of the printer to disengage the Bracket from the Screw in the BasePlate.

ÎÎÎÎ

ÏÏ

ÎÎ

Locking Tabs

ÎÎ

Step 2a

Step 2b



3. Remove the Front Plastic Paper Guide of the Transfer Charger Assembly by pressing downon its ends and sliding it to the left. This disengages the Locking Tabs and the Guide can beeasily removed. See Figure 12–2.

Figure 12–2. Removing the Front Plastic Paper Guide

4. Remove 2 Screws at the rear of the Lower Paper Guide, then remove it from the printer bylifting the rear out first. This helps it clear the Contacts for the HVPS and the Transfer ChargerFrame. Disengage the Locking Tabs at the front of the Guide from the Tension Roller Frame.See Figure 12–3.



Detail 12–1Step 4

Step 5

Step 6

Figure 12–3. Removing the Lower Paper Guide and Encoder Cover

5. Remove 1 Screw, then remove the Encoder Cover. See Figure 12–3.

6. Release the left side of the Printer Front Cover from the Tab on the Left Side Frame. SeeFigure 12–3.

CAUTION: Be careful not to break the right side of the Cover where it isconnected to the LCD Panel.

7. Disconnect the Cable from Connector J1 of the Toner Sensor Board. See Figure 12–4.


DisassemblyStep 5

Step 8

Step 7

DisassemblyStep 2

DisassemblyStep 1

DisassemblyStep 4

DisassemblyStep 3

HighVoltageWarningLabel

Figure 12–4. Removing the Left Side Frame

8. Remove 3 Screws from the Left Side Frame and carefully remove it from the printer. SeeFigure 12–4.

CAUTION: The Cable must be removed carefully from behind the Board as theFrame is being removed from the printer.

DISASSEMBLY

NOTE: The following components can be removed from the Left Side Framewithout it being removed from the printer, therefore the following directionsassume you have not removed the Left Side Frame from the printer.


1. Remove the Safety Lever Spring, being careful not to damage it, then remove 1 E-ring andremove the Safety Lever. See Figure 12–4.

NOTE: The curved end of the Safety Spring goes toward the Frame; the straightend goes toward the Lever.

2. Remove the Clamshell Latch Spring, then remove 1 E-ring and remove the Clamshell Latch.See Figure 12–4.

3. Remove 1 E-ring, then remove the Waste Toner Container Lever.

4. Remove 1 Screw, then remove the Toner Sensor Board.

5. Remove 1 CE-ring, then remove the Developer Clamp.



12.6.3 Adjustment

No adjustment of the Left Side Frame is necessary.





1. Open the Clamshell, remove the OPC Drum Unit, the Developer Unit, and any paper presentin the printer.

2. Open the Printer Front Cover, then remove the LCD Control Panel by removing 2 Screws.Remove the Front Cover by releasing the left side first, then sliding it to the right. SeeFigure 12–5.


Detail 12–2

Step 4

Step 5

Step 6

Step 3

Step 2

Figure 12–5. Removing the LCD Control Panel

3. Remove the Right Side Cover by removing 3 Screws. See Figure 12–5.


4. Remove the Lamp Connector cover by removing 1 Screw. Disconnect the Fuser Lamp andThermistor Connectors from the Stepper Motor Board Frame. See Figure 12–6.

Lamp Connector Cover

Right Inside Cover

Step 4

Step 5

Figure 12–6. Disconnecting the Lamp and Thermistor Connectors



NOTE: Upon installation, the groove on the bottom of the Right Inside Covershould straddle the top edge of the right side of the Tractor Frame. SeeDetail 12–2 in Figure 12–5 on page 12–18.

6. Remove 2 Screws from the Ozone Filter Case and remove it from the printer. SeeFigure 12–5 on page 12–18.

7. Remove the Display Mounting Bracket by removing 2 Screws. The Cable Grounding Screwdoes not need to be removed. See Figure 12–7.

8. Remove 3 Screws from the Stepper Motor Board Frame, but do not remove any Cables fromthe Frame. This will allow the Frame to be moved in order to remove the Gear Assembly fromthe printer See Figure 12–7.


12.71.1,Step 9

12.7.1,Step 8

12.7.1,Step 7

12.7.1,Step 10

12.7.1,Step 10

Figure 12–7. Removing the Display Mounting Bracket


9. Loosen, but do not remove, 2 Screws on the top of the Stepper Motor Board Frame. Removethe Frame Cover, and disconnect the Gear Assembly Stepper Motor Cable from the Motor.See Figure 12–7.

10. Remove 4 Screws from the Gear Assembly Frame then remove it from the printer. TheStepper Motor Board Frame will need to be moved in order to free the Gear Assembly frombehind it. See Figure 12–7.



12.7.1,Step 11

12.7.1,Step 12

12.7.1,Step 12

12.7.1,Step 13

Figure 12–8. Removing the Transfer Charger Assembly



13. Remove the Transfer Charger Paper Guide by gently pressing the Release Tabs at the rear ofthe Guide toward the front of the printer. Lift the rear of the Guide to clear the Tabs of theslots, and release the Front Tabs by rotating the Guide toward the front of the printer. SeeFigure 12–8.

14. Remove the Screw for the OPC Grounding Spring from the Base of the printer, but leave theScrew that connects it to the Right Side Frame attached. See Figure 12–9.

15. Remove 3 Screws from the Right Side Frame and carefully remove it from the printer. SeeFigure 12–9.


DisassemblyStep 5

DisassemblyStep 2

DisassemblyStep 4

DisassemblyStep 3

Step 14

Step 15

Step 15

Figure 12–9. Removing the Right Side Frame


DISASSEMBLY

NOTE: The following components can be removed from the Right Side Framewithout it being removed from the printer, therefore the following directionsassume you have not removed the Right Side Frame from the printer. TheDisplay Mounting Bracket must be removed in order for the components inSteps 1 through 3 below to be removed.

1. Remove the Display Mounting Bracket by performing Steps 1 through 7 listed above.

2. Remove the Safety Lever Spring, being careful not to damage it, then remove 1 E-ring andremove the Safety Lever. See Figure 12–9.

NOTE: The curved end of the Safety Spring goes toward the Frame; the straightend goes toward the Lever.

3. Remove the Clamshell Latch Spring, then remove 1 E-ring and remove the Clamshell Latch.See Figure 12–9.

4. Remove 1 CE-ring, then remove the Developer Clamp from the inside of the Frame. SeeFigure 12–9.

5. Remove 1 Screw from the Side Frame, then remove the OPC Grounding Spring. See Figure12–9.



12.7.3 Adjustment

No adjustment of the Right Side Frame is necessary.





1. Open the Clamshell, remove the OPC Drum Unit, the Developer Unit, the Waste TonerContainer, and any paper present in the printer.

2. Remove the Lamp Connector cover by removing 1 Screw. Disconnect the Fuser Lamp andThermistor Connectors from the Stepper Motor Board Frame. See Figure 12–10.


NOTE: Upon installation, the groove on the bottom of the Right Inside Covershould straddle the top edge of the right side of the Tractor Frame.

4. Separate the Fuser Lamp Connector and the Thermistor Connector of the LVPS from theStepper Motor Board Frame by releasing the Connector Locking Tabs and pushing theConnectors through the hole in the Printer Base Plate. See Figure 12–10.

5. Remove the 4 Screws from the printer Back Panel that secure the Data Controller Board.Slide the Board out part way, then disconnect the Floppy Disk Drive data and powerconnectors from the board. Slide the Data Controller Board out the rest of the way andremove it from the printer.


Lamp Connector Cover

Right Inside Cover

Step 2

Step 3

Step 4

Figure 12–10. Disconnecting the Lamp and Thermistor Connectors







9. Disconnect 10 Cables from the front of the Backplane Board and 2 Cables from the front ofthe LVPS. See Figure 12–12.

NOTE: When reinstalling the Base Frame, refer to Table 12–1 on page 12–51 andFigure 12–29 on page 12–52 for the proper cable connections to theBackplane Board.


Figure 12–12. Removing Cables


10. Remove 2 Screws from the rear of the Base Frame, then lift the LVPS slightly to clear theBase Frame (1). Push the Power Switch to the OFF position (2), then slide the LVPS towardthe rear of the printer (3). Use care to avoid damaging the Power Switch. Once the PowerSwitch is partially past the Frame, switch it to the ON position (4), then slide the LVPS free ofthe Base Frame (5). See Figure 12–13.


NOTE: When installing the LVPS, ensure that the bottom front of the Supply islocked under the Locking Tabs on the Base Frame. See Figure 12–15.


5

4

2

3

1



Cable Routing




11. Remove the Floppy Disk Drive (FDD) Guide (Bezel) by pressing on the Locking Tabs, thenrotating it to free the bottom tabs.

12. Remove 3 Screws from the front of the Backplane Board. See Figure 12–16.

13. Lift the Backplane Board slightly to free it from the Locating Tabs, then tilt it forward so thatthe top clears the FDD Frame. Now lift the Backplane Board up to free the bottom edge of theBoard from the Base Frame. See Figure 12–16.

NOTE: When installing the Backplane Board, ensure that the rear is inserted intothe Board Mounting Bracket. The bottom edge of the Backplane Boardmust be inserted between the Locating Tabs. See Figure 12–16.


Backplane Board ispositioned in frontof cross brace andbehind locating tabs

Figure 12–16. Backplane Board Removal and Installation

14. Remove 2 Screws from the front and 1 Screw from the left side of the FDD Frame, thenremove the FDD Frame from the Base Frame. See Figure 12–17.

15. Remove 2 Screws, then remove the Backplane Support Bracket. See Figure 12–17.

16. Remove 2 Screws, then remove the Rear EMI Bracket. See Figure 12–17.


Step 16 ,Rear EMIBracket

Step 15 ,BackplaneSupportBracket

Step 14 ,FDDFrame

Figure 12–17. Removing the Base Frame Hardware

NOTE: The components listed below must be removed, in addition to those listedabove, before the Base Frame can be removed. In order to remove theBase Frame, most of the components on the top of the Base Plate must beremoved. Therefore, it is advisable that the Base Frame be removed onlyin cases where it has been severely damaged and no other options areavailable.



PLEASE RE-PLA

CE CLEAN-ER

FEL TAT

SAME

TIME

AS TO

NER.

WARNING – HIGH

TEM-PERAT

URE

J–1 Connector

Step 22

Step 17

Step 23

Step 18

Step 20

Step 21

Step 24

Step 25

Depress white retaininglevers to release fuser

roller assembly fromfuser base

Figure 12–18. Removing Various Parts


18. Remove the Tractor Paper Guide by removing 1 Screw from the center rear of the TractorFrame. See Figure 12–18.

19. Open the Paper Exit Guide of the Fuser Base so that it is not in contact with the Fuser RollerAssembly.

20. Depress the Fuser Roller Retaining Lever on each side of the printer so that the Fuser RollerAssembly is free to move. See Figure 12–18.

21. Lift the Fuser Roller Assembly free of the Fuser Base, then remove it from the printer. SeeFigure 12–18.

22. Disconnect the Fuser Sensor Board by removing the Cable at Connector J1. See Figure12–18.

23. Open the Printer Front Cover, then remove the LCD Control Panel by removing 2 Screws.See Figure 12–18.

24. Remove the Right Side Cover by removing 3 Screws. See Figure 12–18.

25. Remove 2 Screws from the rear of the Fuser Base and remove it from the printer. See Figure12–18.

26. Remove 2 Screws from the Ozone Filter Case and remove it from the printer. See Figure12–19.


Step 26

Step 27

Figure 12–19. Removing the Ozone Filter Case and Stepper Motor Board Frame

27. Loosen, but do not remove, 2 Screws on the top of the Stepper Motor Board Frame. Removethe Frame Cover and disconnect 7 Cables from the board (CN1, CN2, CN3, CN4, CN5, CN6,and CN8). See Figure 12–19 and Figure 12–20.


CN7

CN2

CN6

CN1 CN8

CN3 CN4 CN5

Figure 12–20. Stepper Motors Controller Board Connector Identification

28. Remove the Tractor Paper Guide by removing 1 Screw. Disconnect the Cable from the Fuser.Remove 1 Screw from the Cable Tie to release the Cable from the Base Plate of the printer.See Figure 12–21.

29. Remove 2 Screws from the Stepper Motor Board Frame and remove it from the printer. SeeFigure 12–21.

30. Remove 2 Screws from the rear corners of the Base Plate. See Figure 12–21.

31. Remove 3 Screws from the right side of the Base Plate. See Figure 12–21.


Note: arrows showattachment screw

positions

Step42

Step42

Step 28

Step 30

Step 30

Step 39

Step 31

Step 40Step 29

Step 43

Step 44

Figure 12–21. Removing Various Components





c. Lift the front edge of the Cover to disengage the Locking Tabs, then slide the Covertoward the rear of the printer to disengage the Bracket from the Screw in the Base Plate.

ÎÎÎÎ

ÏÏ

ÎÎ

Locking Tabs

ÎÎ

Step 32a

Step 32b




Figure 12–23. Removing the Front Plastic Paper Guide


35. Remove 1 Screw, then remove the Encoder Cover. See Figure 12–24.

36. Release the left side of the Printer Front Cover from the Tab on the Left Frame and removethe Cover. See Figure 12–24.


PLEASE RE-PLA

CE CLEAN-ER

FEL TAT

SAMETIME

ASTONER.

WARNING – HIGH

TEM-PERA TU

RE

Step 34

Step 35

Step 36

Figure 12–24. Removing Paper Guide, Encoder Cover, and Front Cover

37. Disconnect the Cable from Connector J1 of the Toner Sensor Board. See Figure 12–25.

38. Remove 3 Screws from the Left Side Frame and carefully remove it from the printer. SeeFigure 12–25.

CAUTION: The Cable must be removed carefully from behind the Board as theFrame is being removed from the printer.


J–1 Connector

Step 37

Step 38

Figure 12–25. Removing Left Side Frame

39. Remove 1 Screw from the left front corner of the Base Plate. See Figure 12–21.

40. Remove the Tractor by removing 3 Screws, then lifting the left end of the Tractor out first.This clears the Encoder of the HVPS, and allows the Tractor room to move to the left so thatthe Tractor Stepper Motor can clear the Upper Board Frame. See Figure 12–21.

41. Disconnect the Cable from the Tractor Stepper Motor and remove the Tractor from the printer.

42. Remove 2 Screws, then remove the Inner Frame Brace. See Figure 12–21.

43. Remove 2 Screws from the bottom of the Base Frame. The Inner Frame can now beremoved from the Base Frame of the printer. See Figure 12–21.

44. Remove 1 Screw from the bottom of the Base Frame, then remove the Board SupportBracket. See Figure 12–21.


45. Remove the PCB Guide Rails or Cable Tie from the Base Frame, as needed.


Reverse the steps listed above, as needed.

Table 12–1 on page 12–51 lists the connectors on the Backplane Board, together with their respectivefunctions and destinations. Figure 12–29 on page 12–52 shows the locations of the connectors on theBackplane Board.

12.8.3 Adjustment

No adjustment of the Base Frame is necessary.





1. Open the Clamshell, remove the OPC Drum Unit, the Developer Unit, the Waste TonerContainer, and any paper present in the printer.

2. Remove the 4 Screws from the printer Back Panel that secure the Data Controller Board.Slide the Board out part way, then disconnect the Floppy Disk Drive data and powerconnectors from the board. Slide the Data Controller Board out the rest of the way andremove it from the printer.




6. Remove the Floppy Disk Drive (FDD) Guide (Bezel) by pressing on the Locking Tabs, thenrotating it to free the bottom tabs.




7. Disconnect 10 cables from the front of the Backplane Board. See Figure 12–27.

NOTE: When reinstalling the Backplane Board, refer to Table 12–1 on page 12–51and Figure 12–29 on page 12–52 for the proper cable connections to theboard.


Figure 12–27. Removing Cables


8. Remove 3 screws from the front of the Backplane Board. See Figure 12–28.

9. Lift the Backplane Board slightly to free it from the Locating Tabs, then tilt it forward so thatthe top clears the FDD Frame. Now lift the Backplane Board up to free the bottom edge of theBoard from the Base Frame. See Figure 12–28.

NOTE: When installing the Backplane Board, ensure that the rear is inserted intothe Board Mounting Bracket. The bottom edge of the Backplane Boardmust be inserted between the Locating Tabs. See Figure 12–28.

Backplane Board ispositioned in frontof cross brace andbehind locating tabs

Figure 12–28. Backplane Board Removal and Installation



Reverse the steps listed above, as needed.

Table 12–1 below lists the connectors on the Backplane Board, together with their respective functionsand destinations. Figure 12–29, following, shows the locations of the connectors on the Backplane Board.

Table 12–1. Backplane Board Connectors

Connector Function Destination

J1 Engine Controller Board Interface Engine Controller Board

J2 Data Controller Board Interface Data Controller Board

J3 LCD Control Panel LCD Control Panel

J4 LSU Cable LSU

J5 Fuser Sensor Board J1 on Fuser Sensor Board

J6 Stepper Motor Control CN2 on Stepper Motors ControllerBoard

J7 Power Input CN1 on LVPS

J8 Stepper Motor Board Power CN2 on LVPS

J9 Toner Sensor Board J1 on Toner Sensor Board

J10 HVPS Rear of HVPS

J11 Paper Empty Sensor Base Plate

J12 Not Used Not Used

J13 Tractor Encoder Board Connector In Base Plate BehindTractor




J10J13

J5J6J1J9

J11J4J2J3

J15J14J8J7

Figure 12–29. Backplane Board Connectors

12.9.3 Adjustment

No adjustment of the Backplane Board is necessary.



13–1Chapter 13 – Troubleshooting Guide

Chapter 13Troubleshooting Guide

Knowing the sequence of operation of the printer is useful as a guide in determining what component is atfault for a given failure. Follow the sequence below to the point where the printer fails. This will be a goodstarting point for further troubleshooting of the printer.

Power-Up Self-Test

When the printer’s AC power is turned on, the first things that occur are the Engine Controller Board andData Controller Board self-tests. Each controller board runs its own self-test independently from the other.At the completion of a successful self-test, the Engine Controller sends a PPRDY command to the DataController, and the Data Controller returns a CPRDY command to the Engine Controller. These signals telleach board that the other board has passed its self-test and is prepared to communicate. The EngineController Board then initiates the engine self-test sequence, as follows:

The Engine Controller first verifies that the top cover is closed, then checks the paper jam sensor in thefuser. Next, the Engine Controller checks the paper empty sensor to see if there is paper present in theprinter. The erase LEDs and the stepper motor are then turned on, followed by the fuser heater. Thedeveloper, OPC drum, and fuser cam motors are all cycled to check for proper operation. While thedeveloper is being cycled, the toner sensor is checked to verify that it is functioning. Once all of thesehave been verified, the Engine Controller tests the LSU to ensure that it is functioning correctly. Thepolygon motor, the beam detector, the laser, and the laser power circuitry are all tested in this step.

The fuser must reach operating temperature within 2 minutes after it is turned on. After the fuser hasreached fusing temperature, the Engine Controller checks for top of form (TOF) registration. If the TOFsensor is tripped by the plastic TOF lever (flag assembly), the Engine Controller will not try to seek TOF. Ifthe sensor is not tripped, the Engine Controller will set TOF by moving paper into the proper position.

To set TOF, the stepper motor, electric clutch, and fuser cam motor are all activated. The fuser closes,then the tractor feeds paper into the printer until the paper depresses the TOF lever. The fuser thenbegins to pull the paper through the printer slightly faster than does the tractor. The Engine Controllermonitors the pulses from the tractor encoder wheel to ensure that the paper is moving at the properspeed. If the encoder malfunctions during TOF registration, the paper will move about 1/2 inch before a“Paper Jam” error occurs.

The Engine Controller feeds two sheets of paper into the printer so that the perforation for the next sheetto be printed is aligned with the OPC drum.

Print Command

Once the Data Controller Board has sent a print command to the Engine Controller Board, the printerperforms the following steps. If the fuser is below the fusing temperature, the Engine Controller turns onthe fuser lamp to heat the fuser. Once the fuser is at the fusing temperature, the Engine Controller turnson the erase LEDs and the stepper motor. Next, the Engine Controller activates the LSU and checks it forproper functioning. This completes the initialization process for the printer.

After initialization has been completed, the Engine Controller Board activates the High Voltage PowerSupply (HVPS), supplying high voltages where needed throughout the printer. The Engine Controller thencloses the fuser and pulls the VSREQ signal to the Data Controller Board low, which asserts “VerticalSynchronization Request” to the Data Controller. In response, the Data Controller pulls the VSYNC signal

13–2 Chapter 13 – Troubleshooting Guide

to the Engine Controller low, which asserts “Vertical Synchronization” to the Engine Controller. When theEngine Controller detects the asserted “Vertical Synchronization” signal, it starts the print process.

The Engine Controller activates the electric clutch and transfer charger solenoid, and prints the data onthe page. The printer will continuously print all of the pages in the print job as long as it continues toreceive print commands from the Data Controller. Note that the print command for the next page must bereceived before the N minus 4th encoder pulse (VLC) of the current page, or the paper will stop betweenpages.

Checking the Power-up Sequence

To observe the power-up sequence, perform the following steps:

1. Turn off the printer power.

2. Open the top cover and defeat the cover open switch.

3. Turn on the printer power and watch for the following actions:

The erase LEDs will light

The fuser will cycle closed then open

The developer and OPC drum units will cycle

The fuser lamp will begin to heat


Index to Imaging Errors

The following section is an index of common imaging errors. It guides you to the isolation and correctionof the errors listed.

To use the index, find the error in the index list that appears on the printer’s LCD, then find that indexnumber in the next section, “Detailed Troubleshooting Steps.” Using that number, you will be guided introubleshooting and correction of that particular error.

Title Page

100. Horizontal Image Errors 13–8

110. Uniform 1-inch-interval line (indistinct width and fuzzy edges) 13–8

120. Black horizontal line (thin with sharp edges) 13–8

130. White horizontal line with a 5 inch interval (indistinct 13–9

width with a tapered shape and fuzzy edges)

140. White horizontal line with a 2.5 inch interval (indistinct 13–9

width with a tapered shape and fuzzy edges)

150. White horizontal lines with intervals other than 13–9

that mentioned above

160. Faint black horizontal lines that occur at random 13–10

170. No print at the top of the page accompanied by a 1 inch 13–10

black streak 1.5 inches down the page.

200. Vertical Image Errors 13–10

210. Narrow white line (sharp edges) 13–10

220. Wide white line (fuzzy edges) 13–11

230. Black line (indistinct width with fuzzy edges) 13–11

240. Black or white line (sharp, well-defined edges) 13–12

250. Wide black line (indistinct edges) 13–12


Title Page

260. Distorted image running the length of the page 13–12

270. The output page is creased 13–13

300. Cyclic Image Errors 13–13

310. Black area at a 1 inch interval 13–13

320. White area at a 2.5 inch interval 13–13

330. White or black area at a 3 inch interval 13–13

340. Black or white spot at a 5 inch interval 13–14

350. Wavy image at far right side of printed page 13–14

360. Black or white horizontal streak at a 1.5 inch interval 13–14

400. Image Errors at the Same Point on Each Page 13–14

410. Fine vertical lines at 1.5 inches from the top perforation 13–14

420. Gray or black horizontal line at the perforation of 13–14

the first page

430. Blurred image on the first line of the first page of 13–15

a print job

440. Blurred image on the first to third line of the last page of 13–15

a print job

450. Uneven or light print density across the page 13–15

500. Image Errors Over a Large Area 13–16

510. No print (blank page) 13–16

520. Full or partial black page 13–18

530. Dirty background in unprinted areas of the page 13–19

540. White or black concentric rings 13–20

550. The print area is weak, barely visible 13–20


Title Page

560. The print has many unexplained seemingly random errors 13–21

570. Dirty background accompanied by a ghost image 13–21

580. Print is intermittently dark, then goes to light 13–22

600. Other Image Errors 13–22

610. Vertically blurred image 13–22

620. Vertically compressed image 13–22

630. Ghost or mirror image 13–23

640. Intermittent black patches 13–24

650. Black spots on white print or white spots on 13–24

black print

660. Unfused toner 13–25

670. The top half of the first line of a print job is missing 13–25

680. Patchy light or dark regions on the page. 13–25


Detailed Troubleshooting Guide

The following section guides you to the cause and repair of the errors found in a printed image.

NOTE: Errors that occur on a regularly repeating basis usually are caused by oneof the rollers or gears in the printer. The interval of the error is equal to thecircumference of the roller or the circumference of the base of the teeth onthe gear. The following table lists examples of the most common sources ofthese errors. These are approximate distances.

Table 13–1. Sources of Repeating Errors

DistanceBetweenRepeatingErrors Typical Source of the Error

1 inch The magnetic sleeve inside the developer roller of the Developer Unit

1.5 inch The inner transfer gear in the developer gear assembly

2.5 inch The guide rollers on the Developer Unit

3 inch The fuser roller

5 inch The OPC drum


Preliminary Steps

By following these two steps, you will pinpoint the source of the problem more quickly and maketroubleshooting much easier and faster.

1. Engine Self-Test

Running the printer engine self-test can help isolate a problem to the printer engine, theEngine Controller Board, the Data Controller Board, or the host computer. The self-test printoutconsists of solid vertical lines (feedlines) every 1/16 inch running the entire length of the pageand over the full width of the page.

a. Press the small button on the Engine Controller Board, accessible through the small round holein the left side of the plastic Bottom Cover. This prints one test page. If you hold the button in,the printer prints continuously until the button is released. Remember that after you push thebutton, if the fuser is not up to its normal operating temperature, there might be a delay whilethe fuser heats, before the printer starts printing.

b. If the engine self-test runs with no errors, the Data Controller Board or host computer isprobably at fault. Run one of the Data Controller Board printing self-tests. These tests areaccessible from the Diagnostics menu, using the Control Panel keys. (Refer to the SetupGuide for instructions on accessing and running these tests.) Running a printing self-test willisolate the error to either the Data Controller Board or the host computer. For further help introubleshooting Data Controller Board and host computer problems, refer to the DataController Board troubleshooting section in Chapter 9, Controllers and Floppy Disk Drives.

c. If errors or other problems occur when running the engine self-test, continue with the followingsteps.

2. Isolation Procedure Using the Engine Self-Test

a. Stop a test print in the middle of a page by turning off the printer or opening the top cover.Remove the OPC drum and check to see if the error is showing on the developed image onthe OPC drum.

Turning off the printer during operation leaves the developed image on the OPC drum. If theprinter is allowed to operate until the print cycle is complete, the OPC drum is cleaned andthere is no developed image.

b. If the error is not apparent in the developed image on the OPC drum, check the unfused pagebetween the OPC drum and the Fuser.

If the error is present on the unfused page, the Transfer Charger is the source of the error. Ifthe error is not present on the unfused page, the Fuser is the source of the error.

c. If the error appears on the OPC drum, block the laser beam at the LSU cover glass and repeatstep 2a above.

If the error is still apparent on the OPC drum, the LSU is not the source of the error and theDeveloper Unit and OPC Drum Unit must be checked.

If the error is not on the OPC drum, the LSU is probably the source of the problem.

d. If the error is well defined on the OPC drum with the laser beam blocked, the source of theerror is most likely the OPC Drum Unit or its power source .

e. If the error occurs on a large portion of the page, the OPC Drum Unit , the Developer Unit , orthe High Voltage Power Supply (H.V.P.S.) may be the source of the error.


Detailed Troubleshooting Steps

By following these steps, you will be able to pinpoint the source of the problem and make any necessarycorrections needed to fix the problem.

100. Horizontal Image Errors

110. Uniform 1 inch interval line (indistinct width and fuzzy edges).

This is best exhibited by printing a black page.

111. The contact between the developer sleeve and the electrode is defective.

a. Apply conductive grease to the developer sleeve contact.

b. Replace the developer unit.

112. The contact between the developer unit and the H.V.P.S. electrode or spring is defective.

a. Make sure there is no corrosion on the spring of the H.V.P.S. contact or on thedeveloper unit contact.

b. Make sure the spring is making good physical contact with the contact. The spring canbe lengthened by pulling it in order to make better contact. Make sure to pull the springupward, not at an angle.

113. The bias voltage from the H.V.P.S. is incorrect.

a. Check the developer roller bias via the procedure in Chapter 8, Power Supplies, andadjust if needed.

b. Replace the H.V.P.S. if the bias cannot be correctly adjusted.

120. Black horizontal line (thin with sharp edges).

This is usually caused by a static discharge to the laser. This may be present on a blank page.

121. The ground connection between the paper brush and the printer is faulty. The paper brush builds a static charge that discharges into the laser drive circuitry through the printer base pan.

a. Remove the paper brush and check to see if the line is still present when printing.

b. Make sure the paper brush is properly seated.

c. Make sure the grounding spring on the paper brush is not damaged or corroded.

d. Make sure the grounding spring is making good physical contact with the shafts of thepaper brushes.

e. Replace the paper brush if the above steps do not fix the problem, or if the line is notpresent in step a.

122. The contact between the transfer charger electrode and the H.V.P.S. contact spring is faulty. This causes discharges (sparks) which cause the laser drive circuitry to turn on thelaser when it should not be on.


a. Loosen the transfer corona assembly and reseat it to make sure it contacts theH.V.P.S. spring. The assembly should lock under the tab on the left side of the transfercharger frame. Slide the assembly to the right as far as possible.

b. Make sure the transfer corona electrode and the H.V.P.S. spring are not corroded.

c. Make sure the H.V.P.S. contact spring is making good physical contact with theelectrode. The spring can be lengthened by pulling (stretching) it. Make sure to pull thespring upward, not at an angle.

d. Make sure that there is no toner or paper dust on the corona wire or in the corona wirechannel.

130. White horizontal line with a 5 inch interval (indistinct width with a tapered shape and fuzzyedges).

The line is narrower in the center of the page. This is best exhibited by printing a black page.

131. There is toner buildup on the OPC drum where the guide roller of the developer contacts the OPC drum.

a. Check for toner buildup on the side of the OPC drum where the stripe is occurring.Clean the toner from the drum. Avoid scratching the drum.

b. Replace the OPC drum unit.

132. The OPC drum has an area on it that has poor electrical characteristics.

a. Replace the OPC drum unit.

140. White horizontal line with a 2.5 inch interval (indistinct width with a tapered shape and fuzzy edges).

The line is narrower in the center of the page. This is best exhibited by printing a black page.

141. There is toner buildup on the guide roller of the developer unit. This will be on the same side of the developer where the line is occurring on the page.

a. Clean the toner from the guide roller.

142. The guide roller has been worn and is no longer round.

a. Replace the developer unit.

150. White or black horizontal lines with intervals other than those mentioned above.

These lines have an indistinct width and fuzzy edges. These are best exhibited by printing a black page.

These errors usually will be caused by a defect in one of the gears in the developer gearassembly. A problem with a gear in the main gear assembly can cause an image error, but itshould be accompanied by “Paper Jam” errors.


The defect could be a broken or damaged tooth, or it could be toner buildup in the base of theteeth on a gear. The pitch or interval of the error is equal to the circumference of the gear, orthe circumference of the base of the teeth.

The approximate diameter of the gear can be found by using the equation

d c

where d is the diameter of the gear, c is the interval of the error, which is equal to thecircumference of the gear, and = 3.14. This will give you a general idea of the size of thegear at fault.

151. White or black horizontal line with an interval of 1.5 inches.

a. This is usually caused by the inner transfer gear in the developer gear assembly. Thegear breaks at its shaft and tends to slip. Remove the developer gear assembly andreplace the inner transfer gear.

152. White or black horizontal lines with a repeating interval.

a. Find the approximate diameter of the defective gear as shown above and replace thegear or its associated assembly.

153. Occasional white streak at an inconsistent interval.

a. The drive gear for the developer gear assembly is broken at the point where itconnects to the shaft. Replace the gear with one that has reinforcing ribs.

160. Faint black horizontal lines occur at random.

161. The plastic paper guide on the transfer charger is not installed correctly. Make sure it is locked down by sliding it to the right.

170. There is no print at the top of the page accompanied by a 1 inch black streak 1.5 inches down the page. The streak may repeat 5 inches down from the original streak.

171. The OPC drum ground connection is faulty, and the OPC drum cleaning system cannot remove the residual toner from the drum. The erase LEDs cannot reduce the drum potential to 0 volts.

a. Check the OPC drum ground spring and replace it if needed.


172. The cleaning brush/tension roller does not have the correct voltage.

a. Check and lengthen the spring contact if needed.

b. Replace the OPC drum as its contact for the cleaning station is defective.

c. Check and replace the H.V.P.S. if needed.

200. Vertical Image Errors.

210. Narrow white line (sharp edges).

This line is not present when the laser beam is blocked at the LSU cover glass.


211. The laser beam is being blocked and is not reaching the OPC drum.

a. Check the LSU cover glass and clean if necessary.

b. Replace the cover glass if it is cracked or cannot be cleaned.

c. The LSU has something blocking the beam inside it and must be replaced. The LSUcannot be opened and cleaned, it must be replaced.

212. There is a foreign object behind the doctor blade in the developer unit that is preventing the toner from reaching the developer sleeve. To verify this, examine the developer sleeve. Look for a line of missing toner.


213. The OPC drum has a defect in it that extends completely around its circumference.

a. The OPC drum has a scratch and must be replaced.

b. The OPC drum has an area of poor electrical characteristics and it must be replaced.

214. If the streak does not appear on the OPC drum, there is a foreign object that is rubbing on the unfused page.

a. Locate and remove the obstruction in the paper path that is somewhere between thetransfer charger and the fuser. This is usually a piece of paper that is touching thepaper and smearing the unfused toner. This is usually at the entrance to the fuser.

215. There is something on the transfer corona wire or in the corona wire channel.

a. Clean any toner from the corona wire with the corona cleaning felt.

b. Remove any paper in the transfer charger channel.

220. Wide white line (fuzzy edges).

221. The printer has been operated with a low toner condition, resulting in an area of light print. This can be seen by looking at the developer sleeve in the developer unit. If it appears gray instead of black, the toner is low.

a. Replace the toner cartridge on the developer unit.

b. The carrier has been depleted from the developer by printing with a low tonercondition. Replace the developer unit with a new one that has been charged recentlywith new carrier.

c. The OPC drum has been damaged by carrier on its surface and must be replaced.

222. There is something on the transfer corona wire or in the corona wire channel.

a. Clean any toner from the corona wire with the corona cleaning felt.

b. Remove any paper in the corona wire channel.

230. Black line (indistinct width with fuzzy edges).

This line will still be present when the printer is operated with the laser beam blocked at the LSU cover glass.

231. The OPC drum is not being charged correctly.


a. Check and clean the charge corona wire and grid.

b. Make sure the contact between the OPC drum unit and the contact spring for thecharge corona is good.

1. Clean any corrosion from the contact and the spring.

2. Stretch the spring by pulling the end of it if the spring is compressed and the contact is still poor. Make sure to pull the spring upward, not at an angle.

c. Check the charge current from the H.V.P.S. according to the procedure in Chapter 8,Power Supplies, and adjust the H.V.P.S. if necessary.

1. Replace H.V.P.S. if the charge current cannot be adjusted correctly.

240. Black or white line (sharp well defined edges).

241. The OPC drum has been scratched. This scratch will extend around the circumference ofthe drum.


242. The OPC drum has an area of poor electrical characteristics and it must be replaced.


243. There is a scratch or toner buildup around the circumference of the fuser roller.

a. Replace the fuser roller.

250. Wide black line (indistinct edges).

This line is not present when the laser beam is blocked at the cover glass.

251. Verify that the Engine Controller Board is set to the correct resolution.

a. Check jumper J1 on the Engine Controller Board to verify correct resolution. It shouldbe present for 240 dpi operation and should be removed for 300 dpi operation.

252. The LSU is out of alignment and the laser beam is reflecting from a surface it should not be striking. This is occurring inside the LSU.

a. Replace the LSU.

53. The laser is being turned on too soon or turned off too late. This causes reflections inside the LSU that strike the OPC drum.

a. Replace the Engine Controller Board.

b. Replace the LSU.

260. Distorted or blurred image running the length of the page.

261. There is something on the LSU cover glass that is causing the laser beam to be distorted.

a. Clean the cover glass and replace it if necessary.

262. There is something on the optics inside the LSU.


a. Replace the LSU.

270. The output page is creased.

271. There is a crease running down the center of the output page.

a. Adjust the fuser rear cover position. The cover is too close to the pressure roller.

b. Replace the fuser if the rear cover is damaged or cannot be properly adjusted.

272. There are creases throughout the output page.

a. Adjust the fuser rear cover position. The cover is too close to the pressure roller.

b. Replace the fuser if the rear cover is damaged or cannot be properly adjusted.

300. Cyclic Image Errors.

310. Black area at a 1 inch interval.

311. The doctor blade gap is too large, causing excess toner to build up, which causes “blocking”. This will be evident by a severe grinding noise in the printer.


312. The contact between the developer sleeve and the electrode is faulty.

a. Apply conductive grease to the developer sleeve contact.


313. The contact between the developer unit and the H.V.P.S. is faulty.

a. Make sure there is no corrosion on the spring of the H.V.P.S. contact or on thedeveloper unit contact.

b. Make sure the spring is making good physical contact with the contact. The spring canbe lengthened by pulling it in order to make better contact.

314. The bias voltage from the H.V.P.S. is incorrect.

a. Check the developer roller bias according to the procedure in Chapter 8, PowerSupplies, and adjust if needed.

b. Replace the H.V.P.S. if the bias cannot be adjusted correctly.

320. White area at a 2.5 inch interval.

321. There is toner buildup on the guide roller of the developer unit.

a. Clean the toner from the guide roller.


322. The guide roller has been worn and is no longer round.


330. Black or white area at a 3 inch interval.


331. This is caused by a defect or toner buildup on the fuser roller.

a. Clean or replace the fuser roller/fuser assembly.

340. Black or white spot at a 5 inch interval.

341. The OPC drum has a scratch or nick on it.


342. There is toner buildup on the OPC drum where the guide roller of the developer contacts the OPC drum.

a. Check for toner buildup on the OPC drum. Clean the toner from the drum. This will belocated on the outside ends of the drum where there is no green coating.


343. The OPC drum has an area on it that has poor electrical characteristics.


350. Wavy image at the far right side of the printed page.

351. The phase-locked loop (PLL) of the LSU polygon motor is not staying locked.

This results in the speed of the polygon motor changing, which causes the length of a printedline to change. If this becomes severe, an “LSU FAIL” error will occur.

a. Replace the LSU.

352. The polygon is not attached securely to the polygon motor spindle.

a. The LSU must be replaced. The adhesive that holds the polygon mirror to the spindleis defective.

360. Black or white horizontal streaks at 1.5 inch intervals.

361. The inner transfer gear has broken where it attaches to the main drive gear. This is in the developer gear assembly.

a. Replace the inner transfer gear.

400. Image Errors Occurring At The Same Place On Each Page.

410. Fine vertical lines at 1.5 inches from the perforation at the top of the page.

This occurs when the printer has been inactive for some period of time.

411. The silicon/toner on the fuser wiper migrates from the wiper onto the fuser roller and paper. This occurs when the fuser wiper is saturated with toner.

a. Replace the fuser wiper.

b. Replace the fuser roller if it is damaged.

420. Gray or black horizontal line at the perforation on the first page of a print job.


This is caused by the paper touching the OPC drum.

421. The paper pressure plate is not functioning properly.

a. Make sure the paper pressure plate is properly installed.

b. Make sure the mylar sheet is not damaged and is making good physical contact withthe paper.

c. Make sure the paper pressure plate spring is functioning correctly. The plate should bespring loaded so that it pushes the paper down away from the OPC drum.

422. The transfer charger is rising too high when it engages.

a. Make sure the dampers on the transfer charger are not missing or excessively worn.

b. Make sure the transfer charger is not engaging or rising before the paper starts tomove.

1) The engagement lever might be bent and not pulling the charger down enough when the fuser closes. Replace the lever.

423. The paper stock being printed is too heavy and is touching the OPC drum when the transfer charger is engaged during printing.

a. Use a lighter stock paper during printing.

424. The paper stock is folding as it enters the printer.

a. The paper brush is not installed in the printer. Replace the paper brush.

430. Blurred image on the first line of the first page of a print job.

431. The transfer charger bounces when it reaches its uppermost position. It strikes the paper causing the toner to scatter.

a. The dampers on the transfer charger are missing. This condition produces a loud noisewhen the charger engages. Replace the transfer charger.

b. The transfer charger is worn and needs to be replaced.

440. Blurred image on the first to third line of the last page of a print job.

Under normal printing conditions, the last page of a print job is not fed through the fuser.

441. The last page of the print job has not been fused, and is still in the printer. The fuser meltsthe toner of the first few lines on the page.

a. As soon as the print job finishes, perform a form feed to fuse the last page.

b. At the end of each print job, print a blank page or include a form feed in the commandsfrom the host to the printer.

450. Uneven or light print density across the page.

451. The gap between the developer sleeve and the OPC drum is too big. This results in uneven toner transfer from the sleeve to the drum.


a. The developer unit is not locked down. Verify that the developer lock down hooks areproperly engaged. There is usually excessive gear noise or grinding noise when thedeveloper is not locked down.

b. There is toner buildup on the developer guide roller or on the OPC drum where theguide roller meets the OPC drum. Clean the toner buildup from the appropriate area.

452. The printer is being operated with low toner.

a. Install a new toner cartridge on the developer unit.

b. If the toner no longer adheres to the developer sleeve or the print is still light, replacethe developer.

Prolonged operation of the developer with low toner depletes the carrier at a faster rate thannormal. The developer will no longer be able to print 100,000 pages.

453. The paper is skewing as it enters the printer.

a. Make sure the paper source is properly aligned with the printer so that the paper is notskewing as it enters the printer.

454. The main drive gear for the developer gear assembly is broken.

This causes the developer sleeve to slip and not rotate properly. This can be checked bymanually removing an area of toner from the developer sleeve. Operate the printer for acouple of pages, then check the sleeve. The sleeve should no longer have the area of no toneron it. If the area of no toner is still present, the developer main drive gear is broken and thedeveloper sleeve is not turning.

a. Verify that the gear is broken and replace it with a gear that has been reinforced withribs. If the gear is not broken, but does not have reinforcing ribs, it should be replacedwith a gear that has been reinforced with ribs.

500. Image errors over a large area of the page.

Note that it is very important to follow the isolation procedure described at the start of thisguide. There are a number of different causes for these failures, and troubleshooting is mucheasier if the isolation procedure is followed.

510. No print (blank page).

Follow the steps below if there is a developed image on the OPC drum:

511. The transfer charger is not rising into position.

a. Make sure the engagement lever is not binding on the transfer charger. Make sure thelever moves freely.

b. Make sure the engagement lever roller is properly seated on the engagement camlever of the fuser.

c. The transfer solenoid is not engaging correctly. Check to make sure the signal torelease the solenoid is being sent from the L.V.P.S.

1. If the signal is present, replace the transfer solenoid.


2. If there is no signal, replace the L.V.P.S.

A. If the solenoid still does not function after replacing the L.V.P.S., replace the Engine Controller Board.

d. The transfer charger is not moving freely and must be replaced.

512. There is no charge on the transfer corona.

a. Make sure the transfer corona wire is not broken.

b. Make sure the contact between the H.V.P.S. and the transfer corona is good.

1. Clean toner or paper dust from the transfer corona contact and the H.V.P.S. spring.

2. Clean off any corrosion on the transfer corona contact.

3. If the spring for the H.V.P.S. contact is compressed, lengthen it by pulling the top of it. This helps ensure gooid electrical contact. Make sure to pull the spring upward, not at an angle.

c. Check the charge from the H.V.P.S. according to the procedure in Chapter 8, PowerSupplies, and replace the power supply if the charge is not present.

d. If the charge is not present after step c, replace the L.V.P.S.

e. If the charge is not present after step d, replace the Engine Controller Board.

f. If there is still no charge present, check all wire harnesses.

Follow the steps below if there is no developed image on the OPC drum:

513. The OPC drum has the proper charge, but is not discharging properly.

a. The OPC drum is no longer sensitive to light and is not discharging when the laserbeam strikes it. Replace the OPC drum.

This usually occurs after the OPC drum unit has been in the printer for quite some time. Thiscan also be caused by the OPC drum being exposed to light for a prolonged period of time.Check the drum count to see how many pages have been printed with the OPC drum. Replacethe drum if the count exceeds 30,000 pages.

b. The OPC drum unit is not properly grounded. Make sure the OPC drum groundingspring is not damaged. It must also make good physical contact with the printer basepan.

514. The main drive gear for the developer gear assembly is broken.

a. The drive gear is broken and is not turning the developer sleeve. Replace the gear withone that has reinforcing ribs.

515. The H.V.P.S. contact spring for the developer unit has no charge.

a. Check the contact spring from the H.V.P.S. according to the procedure in Chapter 8,Power Supplies. If there is no charge, replace the power supply.

b. If there is no charge present with the new H.V.P.S., replace the L.V.P.S.

c. If both power supplies have been replaced, replace the Engine Controller Board.


d. If there is no charge after step c, check all wire harnesses.

516. The developer contact spring has the proper charge on it.

a. Make sure there is good contact between the spring and the developer unit. Clean offall corrosion on the spring and on the contact. Lengthen the spring, if compressed, bypulling it. Make sure to pull the spring upward, not at an angle.

b. Make sure the developer unit has toner in it.

c. The developer unit is defective and must be replaced.

517. The LSU is not aligned properly and the laser beam is not exiting from the LSU cover glass. (If the laser itself were not working, a “BEAM DET FAIL” error or an “LSU FAIL” error would occur.) The LSU could become misaligned if the printer were dropped or severely jarred. This would be a very rare instance.

a. Replace the LSU.

Follow the next step if there is print on the page with the engine self-test, but not when printingfrom the host computer:

518. The host computer is not properly connected to the printer, or is not properly configured for the printer.

a. Verify the cabling from the printer to the computer.

b. Verify the software configuration for the printer.

Follow the next step if there is no print when running a self-test from the Control Panel or if aprint job does not print from the computer. The engine self-test works properly, and step 518has been completed.

519. The Data Controller Board is not functioning properly.

a. Replace the Data Controller Board.

520. Full or partial black page.

Partial areas of black on a page usually indicate static discharges. Check any source of static along the paper path, as this is the most common source of static in the printer. Fullpages of black print usually indicate a missing charge voltage or a damaged laser.

Follow these steps when the page is partially covered with black print:

521. The paper brush is not properly grounded, causing a static discharge to turn on the laser continuously. This may result in black print on any portion of the page.

a. Make sure the paper brush is properly seated into position. The grounding spring mustmake good physical contact with the printer base pan. Remove the paper brush andsee if the error still occurs. Replace the brush if the lines are not present with thebrush removed.

b. Make sure the grounding spring on the paper brush is not corroded or bent. Replace itif necessary.

c. Make sure the grounding spring is making good contact with the roller shafts of thepaper brush. Use conductive grease if necessary to insure good contact.


d. Replace the paper brush if the above steps do not remedy the problem.

e. The Engine Controller Board has been damaged by static and must be replaced.

f. The laser has been damaged and the LSU must be replaced.

522. The static brush on the transfer charger has been damaged and is causing static discharges to the laser.

a. Check to make sure the brush is not damaged and is in good physical contact with thetransfer charger frame.

Follow these steps if the entire page has black print or the above steps did not fix the problemon pages with intermittent black areas:

523. The OPC drum charge is intermittent on pages of partial black print, or is not present on pages with all black print.

a. Check the contact between the H.V.P.S. and the OPC drum. Make sure there is nocorrosion and that the H.V.P.S. contact spring is not compressed. Pull the spring tolengthen it if necessary. Make sure to pull the spring upward, not at an angle.

b. The OPC drum is not holding a charge, and the OPC drum unit must be replaced.

c. The H.V.P.S. is not supplying the proper OPC drum charge. Adjust the H.V.P.S. drumcharge according to the procedure in Chapter 8, Power Supplies. If there is no chargeor the proper charge cannot be obtained, replace the H.V.P.S.

d. The L.V.P.S. is not supplying the correct voltage to the H.V.P.S. and must be replaced.

e. The Engine Controller Board is not turning on the power supplies at the proper timeand must be replaced.

f. The laser in the LSU is defective and the LSU must be replaced.

524. The H.V.P.S. is supplying intermittent voltages to the OPC drum. This usually results in pages with intermittent black areas on them.

a. The H.V.P.S. is beginning to fail and must be replaced.

530. Dirty background in unprinted areas.

531. The developer sleeve is not receiving the correct voltage.

a. The contact between the developer sleeve and the contact spring from the H.V.P.S. isfaulty. Check for corrosion and a compressed spring. The contact may also be faultyinside the developer unit itself. Replace the developer unit if the problem cannot becorrected.

b. The H.V.P.S. is not supplying the correct voltage. Adjust it according to the procedurein Chapter 8, Power Supplies.

c. Replace the power supply if the correct voltage cannot be obtained.

532. The OPC drum is not holding a charge.

a. The drum has been worn out and the OPC drum unit must be replaced.

533. The H.V.P.S. voltage for the OPC drum is incorrect.


a. Check the contact between the H.V.P.S. and the OPC drum. Make sure there is nocorrosion and that the H.V.P.S. contact spring is not compressed. Pull the spring tolengthen it if necessary. Make sure to pull the spring upward, not at an angle.

b. Adjust the drum voltage via the procedure in Chapter 8, Power Supplies.

c. Replace the H.V.P.S. if the correct voltage cannot be obtained.

534. The print density is set too high on the H.V.P.S.

a. Turn the green density knob on the H.V.P.S. down to a level where the background isno longer dirty.

b. If the problem persist after adjusting the green knob, the power supply must bereadjusted according to the procedure in Chapter 8, Power Supplies.

c. The H.V.P.S. must be replaced if the proper voltage cannot be obtained.

535. The doctor blade gap of the developer unit is too large. If this is the cause, the dirty background will disappear as soon as a new developer unit is installed.


540. Black or white concentric rings.

These look like ripples caused in a pond by a stone being thrown into it.

541. The transfer charger static brush is damaged. It is not removing the residual charge from the paper after the toner transfer process. This causes static discharges to occur on the paper before the toner is fused. The static discharges scatter the toner.

a. Replace the transfer charger static brush.

550. The printed image is weak, barely visible.

551. The developer unit is low on toner.

a. Install a new toner cartridge onto the developer unit.

552. The green density knob on the H.V.P.S. is set too low.

a. The power supply is not supplying enough voltage to the developer sleeve. Turn theknob to a higher setting.

553. The transfer charger is not rising into position.

a. Make sure the engagement lever is not binding on the transfer charger. Make sure thelever moves freely.

b. Make sure the engagement lever roller is properly seated on the engagement camlever of the fuser.

c. The transfer solenoid is not engaging correctly. Check to make sure the signal torelease the solenoid is being sent from the L.V.P.S.

1. If the signal is present, replace the transfer solenoid.

2. If there is no signal, replace the L.V.P.S.


A. If the solenoid still does not function after replacing the L.V.P.S., replace the Engine Controller Board.

d. The transfer charger is not moving freely and must be replaced.

554. The charge on the transfer corona is not at the proper voltage.

a. Make sure the contact between the H.V.P.S. and the transfer corona is good.

1. Clean toner or paper dust from the transfer corona contact and the H.V.P.S. spring.

2. Clean off any corrosion on the transfer corona contact.

3. If the spring for the H.V.P.S. contact is compressed, lengthen it by pulling the top of it. This helps ensure the electrical contact. Make sure to pull the spring upward, not at an angle.

b. Check the charge from the H.V.P.S., and adjust the power supply if the charge is notcorrect. Follow the adjustment procedure in Chapter 8, Power Supplies.

c. If the charge is still not correct after step b, replace the H.V.P.S.

555. The developer sleeve is not receiving the correct voltage.

a. The contact between the developer sleeve and the contact spring from the H.V.P.S. isfaulty. Check for corrosion and a compressed spring. The contact may also be faultyinside the developer unit itself. Replace developer unit if the problem cannot becorrected.

b. The H.V.P.S. is not supplying the correct voltage. Adjust according to the procedure inChapter 8, Power Supplies.


556. The OPC drum is not properly grounded and the charge is not being dissipated by the laser.

a. Check the OPC drum grounding spring for proper contact with the OPC drum shaft.Replace the spring if it is severely bent.

b. The OPC drum is defective and should be replaced.

560. The print has many unexplained, seemingly random errors.

561. The contact to the charge grid is poor, resulting in an uneven charge on the OPC drum.


b. Clean and/or lengthen the spring on the H.V.P.S. contact.

c. Check and replace the H.V.P.S. if needed.

570. The print has a dirty background accompanied by a ghost image.

571. The contact to the developer sleeve is poor, resulting in an incorrect developer bias.

a. Check the contact spring. Lengthen it if needed by pulling upward.



c. Check the developer bias and replace the H.V.P.S. if needed.

580. The print is intermittently dark, then goes light over a period of 1 to three pages. This may be accompanied by 1.5 inch repeating errors.

581. The inner transfer gear is spinning on the main shaft, resulting in the developer sleeve not turning and not being replenished with toner. The developer sleeve will be grayish in color instead of being black.

a. Replace the inner transfer gear.

590. The print appears to be smudged as if something has rubbed the toner before it was fused.

591. The inner transfer gear is slipping, causing the developer gear to turn slower. This causesthe OPC drum and developer sleeve to no longer be synchronized. The toner thus drags across the surface of the OPC drum.

a. Replace the inner transfer gear in the developer gear assembly.

600. Other Image Errors

610. Vertically blurred image.

The image appears to be smudged in an area of the page and the smudge runs the entire length of the page.

611. The unfused toner on the paper is being blurred.

a. The toner is being smeared by something in the paper path between the transfercharger and the fuser. The obstruction is usually a piece of paper in the entrance tothe fuser.

b. The paper is skewing as it enters the printer. This causes the paper to buckle. Makesure the paper is being fed correctly into the printer.

612. The transfer charger static brush is damaged and is not touching the paper at some point.

a. Replace the static brush.

613. There is a foreign object that is distorting the laser beam.

a. Inspect the LSU cover glass for any obstructions or defects. Clean or replace the coverglass as needed.

b. There is a foreign object distorting the beam inside the LSU. Replace the LSU.

620. Vertically compressed image.

The image is compressed or smaller than it should be. It runs the entire width of the page. Thisis most noticeable in lines of text where one or more lines are compressed.

621. The paper is not feeding at the proper speed through the printer. It is occasionally movingtoo slowly. (If it were always moving too slowly, a paper jam error would occur.)


a. The paper is not feeding freely into the printer. Make sure there is nothing binding thepaper as it enter or exits the printer.

b. The electric clutch is slipping and must be replaced.

622. As well as a compressed image, the printer exhibits more noise than during normal operation.

a. The drive belt is damaged or missing a tooth. Replace the belt.

b. The spring on the belt tensioner is weak or stretched and must be replaced. Thisresults in the drive belt slipping on the fuser pulley.

c. The drive belt pulley on the fuser is damaged and must be replaced.

d. The stepper motor is not functioning properly. Replace the stepper motor.

e. The stepper motor drive circuitry in the L.V.P.S. is faulty. Replace the L.V.P.S.

630. Ghost or mirror image.

631. The density setting on the H.V.P.S. is too high.

a. The green density knob on the H.V.P.S. is set too high, resulting in too much tonerbeing deposited on the OPC drum.

There is more toner on the drum than can be transferred to the paper, which results in excesstoner being left on the drum. The OPC drum cleaning system cannot handle the excess toner,and some of it is left on the drum after the cleaning process. This residual toner is thendeposited on the paper during the transfer process, during the next rotation of the drum.

632. The erase LEDs are not discharging the OPC drum sufficiently.

a. Inspect the LED assembly, looking for broken or blocked LEDs.

Toner is deposited occasionally on one of the LEDs. The LEDs can be checked by opening theprinter cover, defeating the cover open switch, and turning on the printer. The LEDs willilluminate during the power-on sequence.

b. The LEDs are not being turned on by the Engine Controller Board. Replace the EngineController Board.

c. The LED wires are damaged in the LSU cable. Replace the cable.

d. The connections for LEDs inside the LSU are faulty. Replace the LSU.

633. The OPC drum cleaning voltage from the H.V.P.S. is not correct. It is either too low or not present.

a. Make sure the H.V.P.S. contact springs and the OPC drum unit contacts are clean oftoner and are corrosion free. If compressed, the springs can be lengthened by pulling.Make sure to pull the spring upward, not at an angle.

b. Check the cleaning voltages according to the procedure in Chapter 8, Power Supplies.


634. The OPC drum is worn out or has excessive toner buildup. This usually occurs after the drum count has exceeded 30,000 pages. If the count is this high, the drum should be replaced as its life has been exceeded.


a. There is a visible toner buildup on the OPC drum. Because the drum surface is coatedwith photosensitive material, it is impractical to clean it. Replace the OPC drum unit.

b. The drum no longer holds a charge and is therefore not being cleaned correctly.Replace the OPC drum unit.

635. The fuser roller has excessive toner buildup or is worn out.

a. Occasionally, the fuser wiper becomes saturated with toner and does not clean thefuser roller correctly. Toner builds up on the roller and then becomes burned onto it.Replace the roller or fuser.

636. The developer sleeve is not receiving the correct voltage. The ghosting is accompanied by a dirty background in areas that should be white.

a. The contact between the developer sleeve and the contact spring from the H.V.P.S. isfaulty. Check for corrosion and a compressed spring. The contact may also be faultyinside the developer unit itself. Replace the developer unit if the problem cannot becorrected.

b. The H.V.P.S. is not supplying the correct voltage. Adjust it according to the procedurein Chapter 8, Power Supplies.


640. Intermittent black patches.

641. The H.V.P.S. is supplying intermittent voltages to the OPC drum. This usually results in pages with intermittent black areas on them during the first 3 pages of a print job.

a. The H.V.P.S. is beginning to fail and must be replaced.

642. The paper is dry and has static buildup.

a. In areas of very low humidity, the paper dries out and picks up excessive static chargefrom the voltages in the printer. The paper must be stored at over 30% humidity inorder to avoid problems with excessive static buildup.

b. The plastic paper guide on the transfer charger can be replaced by one that isconductive. These are available on an as-needed basis only. This is a very rareoccurrence.

c. The paper is defective and must be replaced. This is also very rare.

650. Black spots on white print or white spots on black print.

These spots occur at random, and cover the entire page. It looks as if the page has a case ofthe measles.

651. The paper is dry and has static buildup.

a. In areas of very low humidity, the paper dries out and picks up excessive static chargefrom the voltages in the printer. The paper must be stored at over 30% humidity inorder to avoid problems with static buildup.

b. The plastic paper guide on the transfer charger can be replaced by one that isconductive. These are available on an as-needed basis only. This is a very rareoccurrence.


c. The paper is defective and must be replaced. This is also very rare.

660. Unfused toner.

661. The temperature of the fuser roller is too low.

a. The temperature circuitry is not functioning correctly. Replace the fuser.

b. The Engine Controller Board is not turning on the lamp; thus, the temperature is toolow. Replace the Engine Controller Board.

670. The top half of the first line of a print job is missing.

671. Check the mylar strip above the transfer corona on the transfer corona assembly channel. Make sure it is not extending over the corona wire.

a. Trim the strip back so that it is not covering the wire.

b. Replace the transfer corona assembly.

672. This can occur if the user is trying to print on the first line. Printing on the first line is not possible.

a. Do not print on the first line of a page.

680. There are patchy light or dark regions on the page.

681. The paper is skewing as it enters the printer. This causes the paper to buckle.

a. Position the box of paper in front of the printer so paper feeds straight, not at an angle,into the printer.


Error messages indicate errors that the printer has detected during the power-on self-test or duringnormal operation. This section provides common printer status and error messages, along with thecorrective actions required to return the printer to normal operation.

The messages are generated by the Data Controller Board (and its software), then displayed on theprinter’s Control Panel LCD.

NOTE: Some printer emulations may include additional error and status messagesthat are not listed in this manual; see your emulation manual for details onthose messages.

Operator-correctable Error Messages

A nonfatal error is any error that requires only operator attention to correct. The errors listed in the tablethat follows are all nonfatal errors. After you clear an error, the printer will perform its engine self-test.

NOTE: You do not have to turn off the printer to clear operator-correctable errors.

Table 13–2. Operator-correctable Error Messages

Message ExplanationCorrective Action

(See Also Operator’s Guide)

01 CLOSE THE COVER The printer top cover is open. See page 13–29.

02 LOAD PAPER The printer is out of paper. See page 13–29.

03 ADD TONER ANDCHK WASTE BOTTLE

The printer is out of toner orthe developer unit is missing.

See page 13–30.

04 INSTALLTONER CUP

The waste toner container ismissing.

See page 13–30.

05 INSTALLOPC DRUM

The OPC Drum Unit ismissing.

See page 13–31.

06 CLEAR JAMAT FUSER INPUT

The fuser entry jam sensorhas been activated.

See page 13–31.

07 CLEAR JAMAT FUSER EXIT

The fuser exit jam sensor hasbeen activated.

See page 13–31.

08 CLEAR JAMNEAR TOF LEVER

A paper jam has occured inthe paper path.

See page 13–31.

09 CHECK TOF LEVER Top of form sensormalfunction.

See page 13–31.

19 PAPER CTL ERRReload Paper

A paper jam has occured inthe paper path.

See page 13–31.


Service Call Error Messages

A fatal error is any error that cannot be corrected by operator actions alone. The errors listed in the tablethat follows are all potentially fatal errors. However, except for one error, you might be able to clear themby resetting the printer engine. That one exception is the error “33 REPLACE EEPRM,” which is fatal andcannot be cleared by resetting the printer engine.

NOTE: Before performing any corrective actions, reset the printer engine, asdescribed below. If a given error continues to appear on the LCD after youreset the printer engine, then cycle the power to the printer. If the errorpersists, it means that the printer requires further service.

Resetting the Printer Engine

To reset the printer engine, press the Up and Next keys on the control panel simultaneously.

Table 13–3. Service Call Error Messages

Message Explanation Corrective Action

15 FUSER FAILCall Service

A rotation error of thepressure roller cam hasoccurred. There is an unfusedimage at the fuser.

See page 13–36.


The pressure roller cam didnot stop, or is out of positionafter a stop attempt, or thesensor is defective.

See page 13–36.


The pressure roller cam didnot start, or the sensor isdefective.

See page 13–36.


The sensor that detects theposition of the Speed ControlPaper Guide is defective.

See page 13–37.

23 THRMISTR FAILCall Service

One of the thermistor leads orassociated wires is broken, orthe thermistor is open.

See page 13–37.

24 THRMISTR FAILCall Service

The thermistor leads orassociated wires are shortedtogether, or the thermistor isshorted, or the printertemperature is extraordinarilyhigh.

See page 13–38.

25 ENCODER FAILCall Service

The tractor encoder signal isfaulty.

See page 13–32.



Message Corrective ActionExplanation

26 HEATER FAILCall Service

The fuser did not warm upwithin its specified time.

See page 13–38.

27 HEATER FAILCall Service

During printing, the fuser isnot properly maintaining itstemperature.

See page 13–38.

28 BEAM DET FAILCall Service

A beam detect failure hasoccurred. This means that theLSU motor is spinning, but itis not generating interrupts.

See page 13–39.

29 LSU FAILCall Service

The LSU phase lock circuit isnot sending its “Ready” signalto the Engine ControllerBoard.

See page 13–40.


LSU phase lock has beenlost. The LSU either hasfailed to acquire phase lock,or has dropped out of phaselock.

See page 13–40.


The LSU phase lock circuit issending its “Ready” signal tothe Engine Controller Board,but should not be sending it,since the Engine ControllerBoard has not enabled theLSU motor.

See page 13–40.

32 MISPRINT ERRORCall Service

The handshaking has failedbetween the EngineController Board and the DataController Board.

See page 13–41.

33 REPLACE EEPRMCall Service

The EEPROM on the EngineController Board hasexceeded its life of 100,000writes.

See page 13–41.

34 REPLACE OPC DRUMCall Service

The OPC Drum Unit hasexceeded its life of 30,000eleven-inch-long pages (orequivalent).

See page 13–41.

35 EC CKSUM FAILCall Service

A checksum error occurredwhile reading the EEPROMon the Engine ControllerBoard.

See page 13–41.


01 CLOSE THE COVER

1. The printer top cover is open.

a. Make sure the top cover is closed, especially the right side.

b. The right clamshell latch is broken and is not tripping the interlock switch on theL.V.P.S. If the latch is broken, make sure the drive belt cover is installed properly.When the drive belt cover is not seated correctly, the clamshell latch will catch andbreak as it goes through the hole in the cover.

2. The top cover interlock switch is defective.

a. The interlock switch on the L.V.P.S. is not functioning correctly. The switch must bereplaced on the L.V.P.S.

b. The L.V.P.S. is not supplying the 12 V to the switch and must be replaced.

c. The Engine Controller Board is not interpreting the cover open signal correctly andmust be replaced.

d. Check the wire harness from the power supply to the Engine Controller Board andreplace the harness if necessary.

e. The Data Controller Board is defective and must be replaced.

02 LOAD PAPER

1. There is no paper on the input side of the printer.

a. Make sure that there is paper in the printer.

b. Make sure that the paper has been fed between the upper and lower paper rollers. Thepaper must depress the Paper Empty sensor lever.

2. The paper empty sensor is defective.

a. Make sure that the sensor lever is not broken or bent; replace it if needed.

b. Check the paper empty sensor board for toner or paper dust buildup and clean it ifneeded.

c. The paper empty optical sensor is defective. Replace the paper empty sensor board.

d. The Engine Controller Board is faulty and must be replaced.

e. The cable for the paper sensor board is faulty and must be replaced.

f. The L.V.P.S. is faulty and must be replaced.

NOTE: A faulty L.V.P.S. would be unlikely, as there would be numerous otherproblems with the printer. The paper sensor board uses 5 V, as well as theEngine Controller Board. If the 5 V were not present, the Engine ControllerBoard and the printer could not function.


03 ADD TONER AND CHK WASTE BOTTLE

CAUTION: Whenever adding toner, always check the level in the waste tonercontainer, and replace the waste toner container if necessary. (Theprinter has no sensor for “waste toner container full”.)

1. Check the level in the waste toner container. If the container is full, replace it.

2. Verify that the developer unit is installed. If it is, reseat it. If the developer unit is missing, installit.

3. The developer unit is low on toner.

a. Make sure the toner is evenly dispensed in the developer. If the toner is not coveringthe toner sensor, the developer will send a toner low error signal to the EngineController Board.

b. Add toner to the developer unit.

4. The toner sensor in the developer unit is not functioning properly.

a. The toner sensor is faulty and the developer unit will need to be replaced. The tonersensor may be replaced on the developer unit.

b. The toner sensor is not receiving 5 V. Check the paper-empty sensor board to makesure the voltage is passing through it. Replace the board if necessary.

c. The L.V.P.S. is faulty and not supplying 5 V. This is very unlikely as there would benumerous other problems with the printer. The 5 V is used throughout the printer.

5. The Engine Controller Board is not interpreting the toner low signal correctly.

a. The Engine Controller Board is faulty and must be replaced.

b. The paper empty sensor board is not transmitting the toner low signal and must bereplaced.

c. The paper empty wire harness is faulty and must be replaced.

d. The Data Controller Board is malfunctioning and must be replaced.

04 INSTALL TONER CUP

1. The waste toner container is missing.

a. Install a waste toner container.

2. The waste toner sensor is faulty.

a. Clean the sensor of any toner, paper dust, paper fragments, or other foreign material.

b. Make sure the sensor lever is not damaged or broken and replace it if needed.

c. The toner sensor is faulty and the entire sensor board must be replaced.

d. The cable for the paper empty sensor board is faulty and must be replaced.


05 INSTALL OPC DRUM

1. The OPC drum unit is missing.

a. Install an OPC drum unit in the printer.

2. The OPC drum unit is not seated correctly, and thus is not activating the “Drum-In” Sensor.

a. Remove and reseat the OPC drum unit.

3. The “Drum-In” Sensor is faulty.

a. Replace the sensor.

06 CLEAR JAM AT FUSER INPUT

1. The fuser entry jam sensor has been activated.

a. Clear the paper jam in the paper entry area of the fuser.

b. See the “General Paper Jam Troubleshooting” section that follows.

07 CLEAR JAM AT FUSER EXIT

1. The fuser exit jam sensor has been activated.

a. Clear the paper jam in the paper exit area of the fuser.


08 CLEAR JAM NEAR TOF LEVER

1. A paper jam has occured in the paper path.

a. Clear the paper jam along the paper path of the printer, probably in the area of the TOFlever (between the tractors and the fuser).


09 CHECK TOF LEVER

1. The TOF sensor is off when the paper set is ok.

a. Check the plastic TOF lever (flag assembly).

b. Check the microswitch controlled by the TOF lever.

c. See the “General Paper Jam Troubleshooting” section that follows.

19 PAPER CTL ERR—Reload Paper

1. A paper jam has occured in the paper path, or the Speed Control Paper Guide is not movingproperly between its upper and lower limits, or the Speed Control Paper Guide Sensor isdefective.

a. Clear the paper jam along the paper path of the printer, probably in the area of theSpeed Control Paper Guide (between the tractors and the fuser).

b. Check the Speed Control Paper Guide.


c. Check the Speed Control Paper Guide Sensor.

d. See the “General Paper Jam Troubleshooting” section that follows.

25 ENCODER FAIL—Call Service

1. The tractor encoder signal is faulty.

a. Clean any toner or paper dust out of the encoder sensor.

b. Inspect the tractor encoder wheel for damage. Replace it if necessary.

c. The encoder sensor is faulty. Replace the tractor encoder board or the entire tractorunit.

d. The fuser drive clutch is slipping; replace it.

e. Replace the Engine Controller Board.

f. Replace the encoder cable.

g. See the “General Paper Jam Troubleshooting” section that follows.

General Paper Jam Troubleshooting

Paper jam errors can come from a number of different sources. The way in which the paper jam erroroccurs is a very useful tool in determining what component is causing the error. For instance, how theprinter reacts during the top-of-form (TOF) reset will help indicate what component is at fault. If a paperjam error occurs immediately, before the paper moves, the paper jam sensor in the fuser heat shield ismost likely at fault. If the jam occurs after the paper moves about 1/2 inch, the tractor encoder may be atfault.

1. Visible paper jam.

This section deals with errors where there is a real paper jam—that is, where error messagesare being displayed and a paper jam is visible. If error messages are being displayed but thereis no visible paper jam, see the section on page 13–34.

When a jam occurs, the paper will start buckling or bunching until it strikes the paper jamsensor in the fuser heat shield. The paper usually becomes compressed like an accordion.

a. The paper jams as it exits the fuser and printer.

1) Carefully clear the jam so that none of the fuser components becomedamaged. The separator springs in the fuser rear cover can be bent ordamaged easily if the jammed paper is not carefully removed.

2) If the jam reoccurs, check the separator springs for damage and replace partsas needed.

3) Check the other components of the fuser rear cover for damage and replaceparts as needed.

4) The paper is adhering to one of the rollers, causing the jam. Replace the entirefuser unit.

5) Make sure the exiting paper has room to stack as it exits the printer.

b. The paper jams as it enters the fuser.

1) Carefully clear the jam, making sure that the plastic top-of-form (TOF) lever(flag assembly) does not become damaged.

a) Check the TOF lever to make sure it moves freely. If it is not movingfreely, check to see if it is binding on the edge of the hole in the fuser


paper guide. If it is not binding on the hole, replace the lever and itsstand.

b) If the lever is still binding or striking the edges of the hole in the fuserpaper guide, replace the guide.

2) Reset the paper into the tractor assembly. Make sure the leading edge of thepaper is not torn or wrinkled, since this will cause jams as the paper enters thefuser.

3) Make sure the paper is stretched tightly between the tractors so that it is notbowed. Bowed paper will tend to catch as it enters the fuser.

4) Check the fuser paper guide to make sure it is not bent or damaged andreplace it if needed.

c. The paper is jammed, bowed, or buckled between the OPC drum unit and the fuser.This causes the paper to lift off of the TOF lever, which causes a paper jam error.

NOTE: During the registering (setting) of top of form, the tractor pulls the paperthrough the printer until it reaches the fuser. Once the paper has enteredthe fuser, the fuser is the drive mechanism for the paper. It pulls the paperthrough the printer at a slightly faster rate than the tractor does, thuskeeping the paper tight between the tractor and the fuser.

If the rollers in the fuser do not turn, or the rollers are worn so that their diameter issmaller, the tractor will pull the paper through the printer faster than does the fuser.This causes the paper to bow upward and lift off of the TOF lever, or strike the paperjam sensor. When the printer is open, this might not be visible, because when an erroroccurs, the fuser opens and the paper tends to lay flat again.

To check for this bowing phenomenon, turn off the printer while it is still printing and anumber of pages have been printed. Do this while the printer is actually printing. Thefuser will stay closed and any bow of the paper will be visible when you open theprinter.

Verify that the rollers are turning by opening the top cover of the printer, defeating thecover open switch, resetting the paper in the tractor, and resetting TOF. Turn on theprinter and watch the fuser as the top of form is being set. The fuser should be closedand the rollers turning as the paper enters the fuser. If the rollers are not turning,repeat this step and see if the drive belt, fuser drive clutch and gear, and electric clutchare turning.

1) The fuser is not closing.a) Replace the Engine Controller Board.

Step 1) is very unlikely. In order for step 1) to occur at this point, the printerwould have to fail its power-on self-test. The fuser cam motor is cycled duringthe power-on self-test. If the fuser does not close and then open, a “FUSERFAIL” error will occur. If this error does not occur, the Engine Controller Boardis faulty.

2) The fuser roller is not turning.a) The drive belt is turning.

1] The drive belt is turning the drive pulley assembly but thefuser roller is not turning.

a] The fuser drive gear in the pulley assembly is notturning, but the belt pulley is turning. This indicatesthat the drive pulley clutch inside the assembly isdefective, and the pulley assembly must be replaced.


b] The fuser drive gear in the pulley assembly is turning,but the fuser drive gear on the fuser is not turning.The fuser drive gear must be replaced.

c] The gear on the fuser roller is turning, but the roller isnot turning. This indicates that the engagement teethon the gear are broken, and the fuser roller gear mustbe replaced.

2] The drive belt is not turning the drive pulley.a] The drive belt is slipping on the fuser pulley. If this is

happening, there should be excessive noise comingfrom the pulley and belt as the slipping occurs.

1 The belt tensioner spring is weak and must be replaced.

2 The pulley teeth are worn and the pulley assembly must be replaced.

3 The drive belt teeth are worn and the belt must be replaced.b) The drive belt is not turning, but the main gear assembly is turning.

1] The electric clutch assembly is turning, but the drive belt isnot.

a] The belt tensioner spring is loose and the belt is notbeing driven. Replace the belt tensioner spring.

b] The teeth on the electric clutch pulley are worn andthe electric clutch must be replaced.

c] The drive belt is worn and must be replaced.3) The pressure roller is not turning.

a) A foreign object is rubbing on the pressure roller or touching it. Theforeign object must be removed and the roller inspected for damage.If the foreign object cannot be removed or the roller is damaged, thefuser unit must be replaced.

b) The bearings on the pressure roller are worn. The entire fuser unitmust be replaced.

4) The rollers in the fuser are turning. The paper jam error occurs after the printerhas been operating for a prolonged period of time. There is an upward bowpresent in the paper when the printer is stopped during the print process.

a) The drive belt is slipping.1] The belt tensioner spring is loose and the belt is slipping.

Replace the belt tensioner spring.2] The teeth on the clutch pulley are worn and the electric clutch

must be replaced.3] The drive belt is worn and must be replaced.

b) The fuser rollers are worn to a much smaller diameter than when theywere new. The fuser can no longer pull the paper through the printerat a rate that is faster than the tractor. The entire fuser must bereplaced.

2. Paper jam errors, but no jam visible.

This section deals with paper jam errors where error messages are being displayed but thereis no visible paper jam. If a paper jam is visible, see the section on page 13–32.

a. The following paper jam errors occur after the printer has passed its power-on self-testand is ready for a print job. This will be evident by the READY light on the LCD ControlPanel being illuminated.


The paper jam error occurs because the paper is not being fed at the proper speed.When the paper is moving at the correct speed, the tractor encoder generates pulsesat a fixed rate. As the paper feed rate slows, the time interval between pulsesincreases. When the Engine Controller Board detects that the time interval betweenpulses is too long, it signals a paper jam error.

1) The paper jam error occurs after the printer has been operating for aprolonged period of time and the printed image seems to be compressed.

a) The paper is binding or is skewing as it enters the printer. Make surethat the paper source is aligned with the printer, and that the paper isnot dragging over any foreign objects before it enters the printer.

b) The stepper motor is not driving the gear train at the correct speed.1] A drive gear from the stepper motor to the rest of the gear

train is slipping, and the main gear assembly must bereplaced.

2] The stepper motor is faulty and must be replaced.3] The drive circuitry for the motor is faulty. The L.V.P.S. must be

replaced because it contains this circuitry.2) The paper jam error occurs after the printer has been operating for a

prolonged period of time. The bowing problem described in step 1., c., 4) isnot evident.

a) The electric clutch is slipping and must be replaced.b) The drive belt is slipping.

1] The belt tensioner spring is loose and the belt is slipping.Replace the belt tensioner spring.

2] The teeth on the clutch pulley are worn and the electric clutchmust be replaced.

3] The drive belt is worn and must be replaced.c) The stepper motor is not driving the gear train at the correct speed.

1] A drive gear from the stepper motor to the rest of the geartrain is slipping, and the main gear assembly must bereplaced.

2] The stepper motor is faulty and must be replaced.3] The drive circuitry for the motor is faulty. The L.V.P.S. must be

replaced because it contains this circuitry.d) The Engine Controller Board is faulty and must be replaced.

b. A paper jam error occurs immediately after the printer is powered on.

1) The paper jam sensor is giving an error condition.a) Make sure the jam sensor lever is not stuck.b) The jam sensor cable is not connected to the LSU.c) The jam sensor switch is faulty and must be replaced.d) The jam sensor wires inside the LSU cable are damaged. The LSU

cable must be replaced.e) The Engine Controller Board is faulty and must be replaced.f) The connector in the LSU for the jam sensor switch is faulty. The LSU

must be replaced.

c. The paper jam error occurs after the printer completes the warmup cycle during thepower-on self-test. The printer tries to register TOF, but the paper never moves.

1) The electric clutch assembly is not engaging.a) The electric clutch is faulty and must be replaced.b) The electric clutch is not being activated.

1] The Engine Controller Board is faulty and must be replaced.


2] The L.V.P.S. is not supplying the 24 V to the clutch, and theL.V.P.S. must be replaced. This is unlikely, as several othercomponents use 24 V, and other errors would be occurringduring the power-on self-test.

d. The paper jam error occurs after the paper moves about 1/2 inch during TOFregistration.

1) The tractor encoder signal is faulty.a) Clean any toner or paper dust out of the encoder sensor.b) Inspect the tractor encoder wheel for damage. Replace it if necessary.c) The encoder sensor is faulty. Replace the tractor encoder board or the

entire tractor unit.d) The fuser drive clutch is slipping; replace it.e) The Engine Controller Board is faulty; replace it.f) The encoder cable is faulty; replace it.

15 FUSER FAIL—Call Service

1. A rotation error of the pressure roller cam has occurred. There is an unfused image at thefuser.

a. Check the operation of the pressure roller cam. Replace it if necessary.

b. Inspect the pressure roller clutch and associated wiring. Repair any wiring problemsfound.

c. Replace the Fuser Sensor Board.

d. Replace the Stepper Motors Controller Board.


f. See the “General Fuser Cam Troubleshooting” section that follows.


1. The pressure roller cam did not stop, or is out of position after a stop attempt, or the sensor isdefective.








1. The pressure roller cam did not start, or the sensor is defective.








General Fuser Cam Troubleshooting

With the top cover open, defeat the cover open switch and turn on the printer. Watch the fuser to see if itcloses, then opens, during the power-on sequence. If the fuser does not cycle, check the resistance of thefuser cam motor. Disconnect the motor cable and measure the motor resistance. If the motor is open, it isdefective and must be replaced. Also, check the 24 V from the L.V.P.S.

1.The fuser cycles during power-up, but a “FUSER CAM” error still occurs.

a. The fuser cam motor signal is faulty.

1) Check the fuser cam sensor wheel for damage and replace it if necessary.2) The fuser sensor board is faulty and must be replaced.3) The cable from the fuser sensor board is faulty and must be replaced.4) The Engine Controller Board is faulty and must be replaced.

2. The fuser does not cycle during power-up.

a. There is 24 V being supplied from the L.V.P.S. to the fuser cam motor.

1) The fuser cam motor is faulty and must be replaced.2) The cable for the motor is faulty and must be replaced.3) The fuser is binding and the motor cannot close the fuser. The fuser must be

replaced.

CAUTION: If the fuser is binding and, after installing a new motor, you hearsome severe gear grinding or motor binding noise while the motortries to close the fuser, the binding fuser will cause the motor to burnout.

b. The L.V.P.S. is not supplying 24 V to the fuser cam motor. Check the OPC drum duringthe power-up sequence to see if it turns. The 24 V is also supplied to the steppermotor, causing the OPC drum to do a cleaning cycle during the power-up sequence. Ifthe OPC drum and stepper motor are turning, the power supply is probably good.

1) If the OPC drum is turning, replace the Engine Controller Board.2) If the OPC drum does not turn, replace the L.V.P.S.3) Replace the cabling between the L.V.P.S. and the fuser.


1. The sensor that detects the position of the Speed Control Paper Guide is defective.

a. Replace the sensor for the Speed Control Paper Guide.

b. Replace the Speed Control Paper Guide.

23 THRMISTR FAIL—Call Service

1. The thermistor in the fuser is open, or one of its leads or associated wires is broken.

a. Inspect the thermistor leads and associated wiring. Repair any wiring problems found.


b. Check the thermistor. Replace it if necessary.

c. See the “General Fuser Heater Troubleshooting” section that follows.

24 THRMISTR FAIL—Call Service

1. The thermistor in the fuser is shorted, or its leads or associated wires are shorted together, orthe printer temperature is extraordinarily high.

a. Inspect the thermistor leads and associated wiring. Repair any wiring problems found.

b. Inspect the heater lamp leads and associated wiring. Repair any wiring problemsfound.

c. Check the thermistor. Replace it if necessary.

d. Check the heater lamp in the fuser. Replace it if necessary.

e. See the “General Fuser Heater Troubleshooting” section that follows.

26 HEATER FAIL—Call Service

1. The fuser did not warm up within its specified time.

a. Check for a tripped or defective circuit breaker. Replace the breaker if necessary.

b. Inspect the thermistor leads and associated wiring. Repair any wiring problems found.

c. Inspect the heater lamp leads and associated wiring. Repair any wiring problemsfound.

d. Check the thermistor. Replace it if necessary.

e. Check the heater lamp in the fuser. Replace it if necessary.

f. See the “General Fuser Heater Troubleshooting” section that follows.

27 HEATER FAIL—Call Service

1. During printing, the fuser is not properly maintaining its temperature.

a. Inspect the heater lamp leads and associated wiring. Look for a faulty or looseconnection that could cause an intermittent open circuit in the heater circuit. Repairany wiring problems found.

b. Inspect the thermistor leads and associated wiring. Look for a faulty or looseconnection that could cause an intermittent short circuit in the thermistor circuit. Repairany wiring problems found.

c. Check the thermistor. Replace it if necessary.

d. Check the heater lamp in the fuser. Replace it if necessary.

e. See the “General Fuser Heater Troubleshooting” section that follows.

General Fuser Heater Troubleshooting

1. The fuser is not reaching the correct temperature. This can indicate either overheating orunderheating.


Follow the procedures for fuser testing in Chapter 7, Fuser Subsystem. These procedures arevery helpful in learning how the fuser works and in determining what component is at fault.Look through the cooling holes in the rear of the top cover of the printer to see if the lamp is litduring the warmup cycle. This will help to isolate the problem.

If the fuser is underheating and does not reach the correct temperature in a fixed amount oftime, an error will occur. If the fuser overheats, it will cause the thermal breaker to trip, and thelamp will not light at all.

a. Follow these steps if the lamp is lit during the warmup cycle:

1) Make sure the thermistor does not have excessive toner buildup on it, whichwill cause overheating. Clean or replace the thermistor.

NOTE: In a normal overheating condition, the thermal breaker will trip when thefuser temperature reaches the tripping point of the breaker. When there istoner buildup on the thermistor, the temperature will exceed the breaker’strip point, and the breaker will trip. This stops the flow of current to thelamp, and the fuser will no longer heat.

2) The thermistor itself is not functioning correctly, and must be replaced. It maybe intermittent, or it may be sending erroneous information.

3) The Digital-to-Analog converter for the thermistor is faulty. The EngineController Board must be replaced.

4) The reference resistor on the fuser sensor board is faulty. This resistor sets thereference voltage for the desired fusing temperature. The fuser sensor boardmust be replaced.

5) The Data Controller Board is requesting status from the Engine ControllerBoard too often. The Data Controller Board is requesting status informationfrom the Engine Controller Board at a rate faster than once every 10 ms (mayvary depending on the controller). The Engine Controller Board does not havetime to perform the Digital-to-Analog and Analog-to-Digital conversions for thefuser temperature circuitry. The Data Controller Board must be replaced.

b. Follow these steps if the lamp is not lighting:

1) The thermal breaker has tripped due to an overheat condition. Remove thebreaker, measure its resistance, and replace it if it is open (infinite resistance).

2) The lamp is open or broken. Check its resistance to see if it is open, andreplace the lamp if its resistance is more than 2 ohms.

3) Fuse F2 is blown in the L.V.P.S. This prevents 110 V (or 220 V) from beingsupplied to the lamp.

4) The thermistor is faulty and must be replaced. Disconnect its cable from thefuser sensor board and measure its resistance. Make sure the thermistor isnot open.

5) The Fuser Sensor Board is faulty and must be replaced.6) The Digital-to-Analog converter is faulty and the Engine Controller Board must

be replaced.

28 BEAM DET FAIL—Call Service

1. A beam detect failure has occurred. This means that the LSU motor is spinning, but it is notgenerating interrupts.

a. Check the wiring to the LSU. Repair any wiring problems found.

b. Replace the L.V.P.S.

c. Replace the LSU.


d. Replace the Engine Controller Board.

e. See the “General LSU Troubleshooting” section that follows.

29 LSU FAIL—Call Service

1. The LSU phase lock circuit is not sending its “Ready” signal to the Engine Controller Board.



c. Replace the LSU.




1. LSU phase lock has been lost. The LSU either has failed to acquire phase lock, or has droppedout of phase lock.



c. Replace the LSU.




1. The LSU phase lock circuit is sending its “Ready” signal to the Engine Controller Board, butshould not be sending it, since the Engine Controller Board has not enabled the LSU motor.



c. Replace the LSU.



General LSU Troubleshooting

1. This is an error that has been detected in the LSU. Many things can cause this error. Abeam detect problem, a polygon motor problem, or abnormal power to the laser can allcause this error.

a. The LSU cable is faulty and must be replaced.

b. The L.V.P.S. is not supplying the correct voltages to the LSU. The L.V.P.S. must bereplaced.

c. One of the above errors has occurred in the LSU and the entire LSU must be replaced.



32 MISPRINT ERROR—Call Service

1. This usually indicates a handshaking or communication error between the Engine ControllerBoard and the Data Controller Board during normal operation. One board is not responding tothe other’s command or request for status.

a. Cycle power to the printer. If the error returns, continue with the following steps.

b. Verify that the Engine Controller Board and the Data Controller Board are properlyseated on the Backplane Board.

c. The Engine Controller Board is not responding to the Data Controller Board. Replacethe Engine Controller Board.

d. The Data Controller Board is not responding to VSREQ soon enough. Replace theData Controller Board.

33 REPLACE EEPRM—Call Service

1. The life count of the EEPROM on the Engine Controller Board has exceeded 100,000writes. The EEPROM stores all of the page counts for the components of the printer. Datais written to the EEPROM every time the printer is powered down.

a. Record all page counts, then replace the NVRAM chip on the Engine Controller Board.

b. The Engine Controller Board is faulty and must be replaced.

c. The Data Controller Board is faulty and must be replaced.

34 REPLACE OPC DRUM—Call Service

1. The page count of the OPC Drum Unit has exceeded 30,000 pages (normalized to an 11 inchpage length).

CAUTION: If you ignore this error message, the printer will continue to print, butthe print quality will become unacceptable.

a. Replace the OPC Drum Unit.

b. The NVRAM chip on the Engine Controller Board is not recording page countscorrectly. Replace the NVRAM chip on the Engine Controller Board.

c. The Engine Controller Board is faulty and must be replaced.

35 EC CKSUM FAIL—Call Service

1. A checksum error occurred while reading the EEPROM on the Engine Controller Board.

a. Replace the NVRAM chip on the Engine Controller Board.

b. The Engine Controller Board is faulty and must be replaced.


TOF REGISTRATION ERRORS

1. The positioning of the tractor encoder is incorrect.

a. Check the mounting bracket for the encoder board on the tractor frame. Make sure thebracket is not loose and that the encoder board is also securely fastened to thebracket.

b. The position of the first line of print can be adjusted by raising or lowering the encodermounting bracket on the tractor frame.

2. The printer “thinks” that TOF is set, but it is not. This will be evident by the ready light beingilluminated and the paper not being in the fuser. The printer starts a print job and feeds paperinto the fuser. The first line of print will be about midway down the page.

a. The plastic TOF lever (flag assembly) is stuck in the depressed position. Clear thelever and make sure there are no damaged parts.

b. The TOF optical sensor is faulty and the entire fuser sensor board must be replaced.

c. The cable for the TOF sensor board is faulty and must be replaced.


A–1Appendix A – Printer Specifications

Appendix APrinter Specifications

Mechanical

Printing Method: Electrophotographic, using diode laser(black writing)

Photosensitive Material: Organic Photoconductor (OPC) drum

Imaging Device: Laser diode

Toner: 1-1/2 component toner / developer system

Fuser: Heat and pressure roller, with electronic temperature selection and control

Dimensions: H = 9.8 inch (25 cm)

W = 18.2 inch (46 cm)

D = 19.3 inch (49 cm) (with Entry Paper Guide and Exit Paper Guide removed)

Weight (Printer Only): 58 lbs. (26.3 kg), including printer; excluding packaging and consumables

Case: Impact-resistant plastic

Electrical

Operation: 90 to 132 VAC @ 47 to 63 Hz (single phase)

198 to 264 VAC @ 47 to 63 Hz (single phase)

< 1500 Watts (Peak while fusing)

< 1000 Watts (Average while fusing)

Standby Mode: < 300 Watts (average for 80 °F ambient)

Energy Saving Mode: < 45 Watts

Recommended Cooling: 4000 BTU/hr @ 100% printing

A–2 Appendix A – Printer Specifications

Environmental

Operation:

Tilt: 5 ° maximum

Temperature: 10 to 32.5 °C (50 to 90.5 °F)

Relative Humidity: 20 to 85% RH, noncondensing

Altitude: 7500 feet (2286 m) maximum

Shipping / Storage:

Shipping Temperature: –30 to +60 °C (–22 to +140 °F) for 200 hours

Storage Temperature: Same as Shipping

Relative Humidity: 10 to 95% RH, noncondensing

Noise:

Standby: < 47 dBA

Operating: < 53 dBA

Regulatory Approvals

Electrical: UL–1950

CSA C22.2 No. 220–ml986:DIN

IEC 950 / EN60950

Electromagnetic: FCC Class A, Part 15, Subpart J

TUV (VDE) 0871, Class B

Laser: FDA / CDRH 21CFRTUV EN60825SP (Sweden)

Document Handling

Method: Straight-through tractor feed

System: 6-pin pull tractors, auto-centering

Paper:

Type: 0.5 inch pitch tractor feed pin holes

Width: Min. 4.0 inches, edge-to-edge; 3.5 inches, pin-to-pinMax. 10 inches, edge-to-edge; 9.5 inches, pin-to-pin

Length: 3.0 to 33 inches in 1/8 or 1/6 inch increments

Weight: 18 to 42 lb. Bond60 lb. Tag Stock / 99 lb. Card Stock50 lb. Book Carrier / 40 to 60 lb. Label StockAcrylic Adhesive Label Stock

Printable Area: Max. width 8.25 inchMin. length 3.0 inchMax. length 33 inch

Image Orientation: Portrait or landscape

A–3Appendix A – Printer Specifications

Performance

Resolution: 300 x 300 dots per inch

Line Width: 6.8898 ± 0.98 mils (175 ± 25 m)

Print Density: 1.3 optical density nominal ± 0.3

Speed: Up to 24 pages per minute (11 inch length)

Reliability:

MTBF: 300,000 pages

MTTR: 30 minutes maximum

Duty Cycle: 50,000 pages per month

Time to First Print: < 18 seconds (from operating temperature)< 30 seconds (from standby temperature)< 3 minutes (from ambient temperature)

Controller

Data Controller Board, includes:

– Motorola 68EC030–40 32-bit, 40 MHz microprocessor

– 8 MB DRAM, expandable to 40 MB, in increments of 4 MB or 16 MB

– 64 KB EPROM (boot ROM)

– 32 KB NVRAM

– Interface to Engine Controller Board

– Interface to Control Panel

– RS–232, RS–422, and Centronics interfaces

– Floppy disk controller

Interfaces:

Standard: Centronics parallel interface, RS–232 / RS–422 serial interface

Optional: Coax / Twinax interface, Ethernet LAN interface, Dataproducts parallel interface

Emulations:

Standard: Printronix LP+ impact printer emulation

Optional: HP PCL5 emulation, IGP / VGL emulation, IGP / PGL emulation

Storage Media 1 floppy disk drive; 3.5 inch, double-sided high density (DSHD), 1.44 MB, DOS format (second floppy disk drive optional)

Main Parts Lifetime

Machine: 3,000,000 pages or 5 years

Toner: 8,000 pages

Felt wiper: 8,000 pages

Waste toner container: 8,000 pages

A–4 Appendix A – Printer Specifications

OPC drum unit: 30,000 pages

Developer unit: 100,000 pages

Ozone filter: 100,000 pages

Fuser unit: 300,000 pages

Appendix B – Wire Data B–1

Appendix BWire Data

Appendix B – Wire DataB–2

CN1

STEPPER MOTORS CONTROLLER BOARDCN8

FUSER BASE UNIT

CN2 CN6 CN5

J2

J3

J4

J5

J1

PRFAN1

PRFAN2

JAMSENSOR

EXITJAMSENSOR


PRCLUTCH

1TMRPWR

TMRSG

CN3 CN7

CN4

J2

J1

TRACTORSTEPPERMOTOR(M2)

PTOPSENSOR

OZONEFAN

ENCODERBOARD

3

MAINSTEPPERMOTOR(M1)

1 6

1 5 10 15 20 24 1 21 6 1 6 18

CO

PE

N

/OP

C

/NE

WO

PC

TM

RS

G

TM

RP

WR

/OZ

NFA

N

/PR

CL

PH

A1

PH

B1

/PH

A1

/PH

B1

PH

A2

PH

B2

/PH

A2

/PH

B2

PD

WN

2

PH

A3

PH

B3

/PH

A3

/PH

B3

+5V

L

+24

VB

PD

WN

3

PD

WN

1

BG

ND

BG

ND

BG

ND

+24

+24

+24

GN

D +5

TRACTOR UNIT

2

+24

VB

+24

VB A B /A /B

202390– –

202171E504

202392– –

202153G112

202158S102

202291S202

202299S206

202234D162

202234D162

202241S212

202238D112

202298S208

202200S802

202296S210

1

10

+24

VB

+24

VB A B /A /B

+24

VB

+24

VB

A B /A /B

Appendix B – Wire Data B–3

201153S203

202292S211

*

J7

CN2 CN1

LOW VOLTAGE POWER SUPPLY

CN3

J15

J14

J8

J6

COPEN/OPC

/NEWOPCTMRSG

TMRPWR

/OZNFAN/PRCL

PHA1

PHB1

PHA2

PHB2/PHA2

/PHB2

/PHA1

/PHB1

PDWN2

PHA3PHB3/PHA3

/PHB3

+5VL+24VB

PDWN3

PDWN1

TMRPWR

TMRSG CN4

J5

+5/PRPOS

/PRINIT/SCPUP

/SCPDNPJAM

EJAM

/PRFAN

DGND+24

J13

+5PFS8

PFS6/PTOP

DGND

FUSER UNIT


COOLINGFAN

AC POWERINLET

BACKPLANE BOARD

J4

TO LSU


J10

TONERSENSORBOARD

J9/WASTE

TNRLOW

+5

DGND

CN1

CN2

OPC DRUMUNIT

TRANSFERCHARGER

DEVELOPER

+24VB

BGND

/CHARGE/DEVELOPER

/TRANSFER

110

220

J1

1

2

3

4

5

RSVD

RS

R/W

E

DB0

DB1

DB2

DB3

DB4

DB5

DB6

DB76

7

8

9

10

11

12

13

14

15

16

18

19

20

21

22

23

24

17

/SWRST

/SWONL

/SWFF

/LDATA

/SWMENU

/LONLN

/SWSTOR

/LRDY

/SWDWN

Vss

Vdd


/SWUP

(NOTUSED)

Thermal Breaker

Halogen Lamp

(NOTUSED)

J2


J1


16

1

10

1

24

3

12

1 5 10 16 1 8

1 81 5 10

1

4

1

4

1

4

1

6

1

6

1

4

1 5 10

TH

ER

MIS

TO

R

+5

DG

ND

+24

+24

+24

BG

ND

BG

ND

BG

ND

+24

BG

ND

+12 –1

2

AG

ND

AG

ND

PW

RO

FF

/HE

AT

+24

BG

ND

+12

–12

AG

ND

AG

ND

PW

RO

FF

/HE

AT

+5

+5

+5

+5

DG

ND

DG

ND

DG

ND

DG

ND

+12

/QLE

D+

24B

GN

D

/PM

ON

/PM

RD

Y +5

DG

ND

/BD +5

DG

ND

/LD

ON

/LV

IDE

OLV

R

DEVELOPERBIAS

TONERSENSOR

J111

PAPEREMPTYSENSOR

PEPWR

PEMPTY

DGND

CNS1

3

LCDCONTROLPANEL

1

2

+–

202576S801

202298S208

202375S207

202278E112

202291S202

202393S201

202294S204

1 24

J3

8

+5

+5

+5

+5

DG

ND

DG

ND

DG

ND

DG

ND

1

5

14

Appendix B – Wire DataB–4

C–1Appendix C – Continuous Form Stacker

Appendix CContinuous Form Stacker

Introduction

The continuous-form active stacker provides reliable stacking of continuous-form media, whetherpaper or label stock, at speeds of up to 24 forms (11 inch) per minute. Both models feature a built-inprinter support table and an integrated power cable which connects directly to your printer. Thestacker is available in a continuous model — that is, it runs continuously whether the printer iscurrently printing or not — and an automatic control model (a model that can be turned ON and OFFby a printer equipped with a control port and cable).

Safety Precautions

The continuous-form stacker requires caution in the following areas:

Since the unit is powered by 115 or 230 volts, standard precautions should be utilized: Usethe proper cord for the voltage available, and do not use any cord that is frayed ordamaged.

Confirm that the unit is unplugged before service.

If the fuse blows, be sure to replace it with an exact duplicate (Printronix part#704968–018).

Do not operate the stacker in a wet environment.

Operate the stacker on a flat surface (5 degrees).

Be careful not to pinch your fingers in the front or back pulleys.

Be sure the locking casters are locked when operating the stacker, and that they areunlocked when moving the unit.

C–2 Appendix C – Continuous Form Stacker

Parts Identification

This section identifies the major subassemblies and components which are available for replacementfrom Printronix.


(See page C–5)

(See pageC–7)

(See page C–11)

(See pageC–13)

(See pageC–15)

Figure C–1. Continuous Form Stacker


Callout Name Printronix Part No. QuantityA Guide Assembly, Upper 704968–008 110 Idler Weight, Stacker 704968–025 115 Cotter Key, Hairpin 704968–022 2


15

2

101

Figure C–2.


Callout Name Printronix Part No. Quantity20 Spring, Coupler, Stacker 202894–001 125 Cover, Motor, Stacker 704968–024 130 Motor Assy, 115V, Upper Roller 704968–010 1

Motor Assy, 230V, Upper Roller 704968–027 1


20

1

25

1

30Ref

30Ref

301

(See page C–9 )

(See page C–9)

Figure C–3.


Callout Name Printronix Part No. Quantity35 Drive, Roll 704968–023 240 Shaft, Drive 704968–020 145 Fuse Drawer, 115V 704968–019 150 Fuse, ABC, 15.0A 704968–018 155 Power Entry Module 704968–004 1


352

401

551

501

451

Figure C–4.


Callout Name Printronix Part No. Quantity60 Wing, Side Guide 704968–017 2


60

2

Figure C–5.


Callout Name Printronix Part No. Quantity65 Motor Assy, 115V, Belt 704968–028 1

Motor Assy, 230V, Belt 704968–029 170 Idler, Pulley Assy 704968–009 175 Belt, Paddle Stacker 704968–016 180 Paddle Drive Pivot 704968–012 185 Bracket, Paddle Drive 704968–011 190 Clamp, Paddle Drive 704968–015 195 Bracket, L, Stacker 704968–014 1


65Ref

651

65Ref

701

751

801

851

901

951

Figure C–6.


Callout Name Printronix Part No. Quantity100 Power Switch, Rocker 704968–005 1105 Caster, Locking 704968–002 2

Caster (2–1/16”) 704968–003 2110 Cable, Paper Tray 704968–007 1115 Spring Assy, Stacker 704968–006 1


1001

1052

1151

1101

ROTATED 180

Figure C–7.


Disassembly/Reassembly

This section provides instruction on the disassembly and reassembly of various stacker assemblies.

Required Tools

Small Phillips Screwdriver Medium Phillips Screwdriver Needlenose Pliers 1.5mm Allen Wrench 2.5mm or 5/32” Hex-head Allen Wrench 5mm Allen Wrench 9/16” Open-end Wrench 1/8” Small Flathead Screwdriver 1/4” to 1/2” Flathead Screwdriver Large Blade Flathead Screwdriver Strain-Relief Pliers Lightweight Machine Oil (Like 3-IN-ONE) Soft-face Hammer

The Basic Frame

Note that the basic frame (vertical frame assembly) of the stacker is factory aligned and is notfield-adjustable or field-replaceable. The basic frame includes the two vertical columns, the upperframe tie and the lower frame tie as shown below.

Figure C–8. Basic Frame


The Tabletop

Removal

1. Remove the four screws securing the tabletop to the stacker body. There are two on eitherside of the tabletop. (See Figure C–9)

WARNING: This assembly is heavy and may cause injury should it fall whilebeing removed from the stacker body. Be sure to provide somemeans of support for the tabletop when removing the screws.

Figure C–9. Tabletop Removal

2. Remove the tabletop from the stacker body.


Replacement

1. Reverse the above steps, being sure to provide adequate support for the tabletop whileremoving or replacing screws.

CAUTION: The wood screws attaching the tabletop to the brackets should not beremoved. In removing or reinstalling them, the holes may be strippedand the tabletop will no longer be securely held. Replace the wholetable top assembly if the screws become loose or are removed.


The Paddle Drive Motor Assembly

Removal

1. The paddle drive motor assembly is shielded by a cover which must first be removed to gainaccess to the motor. To do this, simply remove the two screws which secure the cover to thepaddle drive frame. (See Figure C–10)

Figure C–10. Paddle Drive Motor Cover Removal

2. Using a 1.5mm Allen wrench, loosen the set screw which secures the paddle drive pulley tothe motor shaft and remove the pulley.

CAUTION: Do not turn motor shaft in counter-clockwise direction or you maydamage the motor.

3. Disconnect the motor assembly’s two-pin connector.

4. Remove the two screws which secure the motor assembly to the paddle drive frame andremove the motor. (See Figure C–11)


Figure C–11. Paddle Drive Motor Removal

Replacement

1. To replace the paddle drive motor assembly, reverse steps 1 through 4, being sure the keyedside of the motor shaft faces the paddle drive pulley’s set screw.

NOTE: The gap distance between the pulley and the paddle drive frame should beset to approximately 5/32” (4mm).

2. Be sure to tighten the pulley set screw against the flat side of the motor shaft.


The Upper Drive Motor Assembly

Removal

1. Remove the two screws which secure the motor cover to the upper left frame. (SeeFigure C–12)

2. Disconnect the motor assembly’s two-pin electrical connector.

3. Remove the two screws which secure the motor assembly to the upper left frame.

4. Remove the motor assembly by holding the motor and gently rotating the idler roller assemblyand coupling spring off as shown.

Figure C–12. Upper Drive Motor Removal

Replacement

1. Reverse the above steps. Note that the idler roller assembly and spring will go onto the motorshaft by gently rotating the idler roller in the same direction as it was rotated to remove.


The Paddle Drive Belts

Removal

1. Work the belt off the paddle drive pulley as you rotate the belt in a clockwise direction. (SeeFigure C–13)

Figure C–13. Paddle Drive Belt Removal

Replacement

1. Place the belt onto the lower paddle drive pulley.

2. Work the belt over the upper paddle drive pulley flange as you rotate the belt in a clockwisedirection.


The Paper Shelf

Removal

1. Remove the four screws which secure the paper shelf to the base assembly.

2. Lift and remove the paper shelf. (See Figure C–14)

Figure C–14. Removing the Paper Shelf

Replacement

1. Reverse the steps above.


The Front and Rear Paper Guides

Removal

1. Rear Paper Guide (See Figure C–15)

a. Remove 2 screws holding the rear paddle drive to the rear paper guide.

b. Lift the rear paper guide until the bottom clears the base frame tie.

c. Rotate the top of the rear paper guide in the slots in the upper frame and remove.

1a

1b

2a

2c

2e

2d

2b

Figure C–15. Removing the Paper Guides


2. Front Paper Guide

a. Remove 2 screws holding the front paddle drive to the front paper guide.

b. Remove the tray support cable from the paper tray (see Figure C–23 for replacement).

c. Remove 6 screws securing the paper tray and remove.

d. Remove the 2 screws holding the side guide and top of the front paper guide to the frame.

e. Remove the 2 screws holding the paper guide to the frame and lift the guide out.

Replacement

1. Reverse the steps above.


The Left and Right Vertical Frame Braces

Removal (see Figure C–16)

1. Remove the 2 Phillips screws securing the left or right frame base to the frame.

NOTE: If it becomes necessary to replace both frame braces, do them one at atime to keep the frame assembly square.

2. Remove 2 socket-head cap screws and washers attaching the frame braces to the baseframe tie.

Replacement

1. Reverse steps 1 and 2 above.


1

2

Figure C–16. Removing the Vertical Frame Braces


The Left and Right Upper Frames

Removal

1. Remove the tabletop by removing the 4 socket-head cap screws and washers securing thetabletop brackets to the frame. DO NOT remove the 4 Phillips screws holding the tabletop tothe brackets. (See Figure C–17)

2. Remove the electrical cover by removing 4 Phillips screws. (See Figure C–17)

Figure C–17. Removing Table Top & Electrical Cover

3. Using needle-nose pliers, remove the 4 wires attached to the ON/OFF switch and the 2 wiresattached to the Mode switch. Remove the wires by gently gripping the plastic connectors withthe pliers and gently pulling the connectors from the switches. (See Figure C–18)


MODE SWITCH

ON/OFF SWITCH

3

34

4

5

POWER ENTRY SHIELD

6

78

910

11b

Figure C–18. Removing Electrical Components


4. Using pliers or a flat-head screwdriver, compress the plastic retaining clips holding bothswitches in the frame and carefully remove the switches.

5. Using needle-nose pliers, gently compress the plastic retaining clips holding the low-voltagecable in the frame and remove the connector plug from the frame.

6. Using a Phillips screw driver, remove the screw holding the plastic cover entry shield in place.Remove the power entry shield.

7. Using needle-nose pliers, remove the two wires at the top of the power entry module —gently! Grip the plastic connectors and pull away from the power entry module. Be aware thatthe green (or green/yellow) ground wire is still attached at the bottom of the module.

8. Compress the top and bottom plastic retaining clips holding the power entry module in placeand remove the module.

NOTE: Use extreme caution, as the clips are breakable. Use a machinists scribeto compress the retaining clip on the bottom of the module.

9. Using a Phillips screwdriver, remove the screw securing the green and yellow ground wirerunning from the power entry module to the electrical housing. Note that there is a starwasher under the screw clip on the wire. This must be in the same position when the groundwire is reattached.

10. Remove the two screws which attach the electrical housing to the right upper frame.

11. To remove the left upper frame, first remove the upper drive roll motor (see page C–21 forremoval of the upper drive motor and cover and release of the upper drive shaft), then theelectrical cord, and then the spring assembly.

a. To remove the connector from the electrical cord, use an AMP Pin Pusher 458994.2 orequivalent. Push the two pins through and remove the connector plug. Using a strainrelief plier, release the strain relief securing the upper drive roll electrical cord to the leftupper frame and pull the cord through. Be sure to disconnect the ground wire and retainthe star washer for reassembly. (See Figure C–20)

b. Remove the two screws which hold the spring assembly in place. Complete the removalof the spring assembly by releasing the tray support cable from the front of the paper tray.

WARNING: The cable is spring loaded and may cause injury.


12

12

12

13

15

Figure C–19. Final Removal Steps

12. Remove the upper rear frame tie by removing the two Phillips screws holding it in place. (SeeFigure C–19)

13. Removing the right upper frame requires the removal of the screw-mounted cable clampwhich also releases the rear paddle drive cord.

14. The electrical housing is now loose and can be moved towards the back (rear) of the stacker.Note that the front paddle drive is still attached.

15. The two screws holding the left and right upper frames are now accessible. Remove thescrews from the side or sides to be replaced and lift the side out. This will cause the electricalhousing to hang by the front paddle drive cord.


Replacement

1. Reverse steps 6 through 15, then:

a. Install the OFF/ON and Mode switches in the right frame. (See Figure C–18)

b. Re-attach 6 wires to the switches.

c. Re-attach the low-voltage cable in the right frame.

d. Secure the electrical cover and table top.

NOTE: Replacement of the right upper frame will require new paper length andmode labels (attached by factory) plus re-attachment of the serial numberlabel from the old frame (attached by field service personnel).Replacement of the left upper frame will require a new voltage label (115Vor 230V).


The Upper Drive Bearing

Removal

1. Remove the upper drive roll motor cover and motor. (See Figure C–20)

2. Disengage the upper drive roll shaft per Figure C–12.

3. Use a small-tip Phillips screwdriver to remove 2 self-tapping screws securing the upper drivebearing to the right upper frame. The bearing should drop off.

1

2

3

Figure C–20. Removing the Upper Drive Bearing

Replacement

1. Use a small-tip Phillips screwdriver to guide a self-tapping screw through the screw holes inthe right upper frame. Applying pressure, turn the screw into the holes in the drive bearing.

NOTE: Be sure the flat edge of the bearing is against the frame. Continue until thescrew is 1/2 to 3/4 of the way in. Install the second screw in the samemanner until it is tight. Now tighten the first screw.

2. Before installing the upper drive shaft, apply a single drop of “3-IN-ONE” oil to the inside ofthe shaft bearing.

3. Reverse the steps in Figure C–12 to install the shaft, motor and motor cover.


The Cable Clamp Screw Mount

Removal

1. Use a pair of pliers or similar tool to hold the 4mm nut while removing the Phillips screw (seeFigure C–21).

2. Remove the Phillips screw and lift the cable clamp over the rear paddle drive cord.

Figure C–21. Removing the Cable Clamp Screw Mount

Replacement

1. Reverse steps 1 and 2 above.


The Paper Shelf (with cable installation)

Removal

1. Remove the table top and the electrical cover (see Figure C–17).

2. Remove the tray support cable from the front of the paper tray. Allow the cable to slowly reelinto the electrical housing (see Figure C–22).

3. Remove the 4 screws securing the paper tray to the left and right paper tray supports.

4. Lift the paper tray out and up to remove.

2

3

3

Figure C–22. Removing the Paper Shelf


Replacement

1. Reverse steps 2 and 3 in Figure C–22.

2. With the table top and electrical cover off, detach the inside clip of the torsion spring from thesupport shaft disc (see Figure C–23).

3. Pull the paper tray support cable until it completely unwinds from the tray support shaft.

2

6

3

4

5

6(Note)

Figure C–23. Reinstallation of Paper Tray Support Cable

4. Loop the tray support cable over the support shaft and feed it through the opening in theelectrical housing.


5. Feed the cable through the opening formed by the front paper guide and the front paddledrive pivot bracket and re-attach it to the center post of the paper tray.

6. Rewind the cable onto the support shaft, allowing for clearance of the screw holding thesupport disc to the moveable core. Continue rewinding until the ball slides reach the top ofthe electrical housing.

NOTE: Make sure the side guide wings are raised to the horizontal position.

7. Adjust the height of the paper tray so there is approximately two inches between the top ofthe front paddle drive idler pulley assembly and the center post of the paper tray (seeFigure C–24).

2”

Figure C–24. Adjustment of Paper Table Height

8. Re-attach the spring assembly clip to one of the upper holes on the support disc. Adjust asnecessary to maintain the proper spacing between the paper tray and the paddle drive idlerassembly (see Figure C–23 and Figure C–24).

NOTE: Center the tray support cable between the front paper guide and thepaddle drive mounting bracket.


9. Move the paper tray up and down to make sure the paper tray clears the paddle drive idlerpulley. If there is contact, adjust the paddle drive left or right by loosening the two screwssecuring it to the front paper guide. After adjustments have been made, tighten the twoscrews.

10. Replace the electrical cover and the tabletop.


Stacker Specifications

Functional Characteristics

Speed: Up to 24 ppm

Media Type: 18–42 lb. continuous fanfoldpaper and many label stocks

Media Size: Width: up to 10”Lengths: 9” to 12” in half-inch increments

Warm-up: Immediately ready on power-up

Electrical Requirements:

115VAC @ 60Hz(optional 220V @ 50Hz available)10 Watts + printer consumption

Operating Environment:

Temperature: 50–90.5F (10–32.5C)Humidity: 20–80% RH

Noise Level: <53 dBA

Dimensions:Tabletop: W: 20.19” (513mm)

H: 36.00” (915mm)D: 31.68” (805mm)

Stand-alone: W: 20.19” (513mm)H: 36.00” (915mm)D: 18.50” (470mm)

Weight: 55 lbs. (24.97 kg)

Certifications: CSA, NRTL/C, TUV

Warranty: Warranty period of one year


Test Data

Media tested: medium weight bond (18–24 lb.) and heavyweight bond (>24 lb. and <40 lb.)

Under nominal temperature and humidity

1 mis-stack in 6000 pages

1 mis-fold in 3000 pages

Under conditions of extreme temperature and humidity

1 mis-stack in 4000 pages

1 mis-fold in 2000 pages

NOTE: A mis-stack is defined as any media movement in the stacker which resultsin a fatal printer fault (printer halts), causes the media to overflow thestacker, or requires operator intervention. A mis-fold is defined asabnormal media handling in the stacker which allows printing and stackingto continue and does not result in paper jams, fatal printer faults, or stackeroverflow.

Extensive testing has proven that the stacker performs reliably when stacking20 lb. paper with a 1/32” tie, eight cuts per inch and 20 lb. microperf paper.Products which may result in stacker mis-stacks or mis-folds are:

16 lb. (or lighter) paper

Microperf paper of less than 20 lb. weight

Light paper at high humidity

Paper with perforations having more than 8 cuts per inch

Label stock with a weak backing and several labels per sheet.

Auto Stacker Interface Specifications

3–24VDC is required to operate the solid-state relay.

At 5VDC, the relay draws <4mA

The potential across these wires should exist when paper begins to move (as evidencedby the PMOVE signal on the engine/controller interface) and continues for about 0.5seconds after the PMOVE signal is absent.

The connector on the Stacker is a Molex Mini-Fit Jr. Receptacle, (Molex P/N 39–01–2020).

The matching plug on the OEM’s connecting wire is the Molex Mini Fit Jr. Plug (Molex P/N39–01–2021).

Maximum cable length from the printer to the stacker is undefined at this time.

No shield ground is provided at the stacker end. This prevents undesirable ground loops.

D–1Appendix D – Principles of Operation

Appendix DPrinciples of Operation

Printing

This appendix outlines the principles of laser printing technology and gives a step-by-step explanationof the process.

The printer performs printing operations in seven steps. The following steps are described in thesubsequent paragraphs:

Charging the OPC drum

Exposing the OPC drum with the LSU to form a latent image

Developing the print image by attracting toner onto the OPC drum

Transferring the toner image from the OPC drum onto the media

Cleaning the OPC drum of the unused toner

Erasing the static charge from the OPC drum

Fusing the toner image to the media

D–2 Appendix D – Principles of Operation

Charging the OPC Drum

The main component of the printing system is the OPC (organic photoconductor) drum. It is a cylinderwith special properties. The material of the OPC is an insulator when in the dark and is conductivewhen exposed to light.

Before beginning the process, the OPC drum must be electrically charged. Figure D–1 shows theorganization of the OPC drum charger. A single tungsten wire is centered in a metal channel over theOPC drum. This channel has a wire grid between the lower open end of the channel and the materialof the drum. The air around the wire is ionized by the high negative potential, approximately –5000volts, of the wire. The grid of the channel is maintained at a voltage “less negative” than the tungstenwire, approximately –680 volts. This voltage differential controls the ions flying toward and past thegrid and onto the OPC drum. These ions set up a negative potential of approximately –700 volts onthe surface of the OPC drum as it rotates under the metal channel.

––

–

––

–– – – –

––

Grid

OPC Drum Rotation

High Negative Potential

Less Negative Potential

Metal Channel

Tungsten Wire (Charge Corona)

OPC Drum Rotation

Figure D–1. Charging the OPC Drum


Exposing the OPC Drum (Forming the Latent Image)

Inside the lid of the printer is a modulated semiconductor laser. The beam of the laser shines on arotating polygonal mirror which causes the beam to scan across the OPC drum. The beamdischarges the negative potential of the drum in the pattern of the desire image. This gives the imageportion of the OPC a less negative potential than the rest of the OPC, approximately –100 volts, whilethe unexposed portion of the OPC maintains approximately –700 volts. The electrical pattern formedby this process is called the “latent image.”

This process is illustrated in Figure D–2.

– – –– – – ––

––

– – – – ––

Light Dark

OPC Material

High Negative VoltageLow Negative Voltage

Conductive Base Material

OPC Drum Surface

Exposed Portion(Low Negative Voltage)

Non–exposed Portion(High Negative Voltage)

Figure D–2. Exposing the OPC Drum


Developing the Print Image

The OPC drum, with its latent image, rolls past the sleeve and magnet roller, which is part of thedeveloper unit. The powdered toner is magnetized, which keeps it lightly attracted to the sleeve overthe magnet roller. The sleeve is charged to approximately –500 volts. As the image on the OPC drumpasses the developer unit, the negatively charge toner is attracted to the exposed areas of the drumbecause of the voltage difference (–500 to –100 volts) as shown in Figure D–3. On non–exposedareas of the drum, the reverse is true. The negatively charged toner is forced away by the highernegative charge on the drum (–500 to –700 volts). The toner image on the drum is called the“developed image.”

OPC Drum

Doctor BladeToner and Carrier

Sleeve

Magnetic Roller

N

N

NN

S S

SS

Figure D–3. Developing the Print Image


Transferring the Toner to the Print Media

The print medium, normally paper or label stock, passes between the OPC Drum and a second metalchannel containing a tungsten wire charged to approximately +4200 volts. This charge is transferredto the media, as shown in Figure D–4. As the media passes the rotating OPC drum, the negativelycharged toner is transferred to the positively charged paper in the pattern of the developed image.

OPC Drum Rotation

––

––––––

++++++++++

–––––––

+

Tungsten Wire(Transfer Corona)

at +4200 Volts

Print Medium

Toner

Metal Channel

Figure D–4. Transferring the Toner to the Media


Cleaning the OPC Drum

Any toner remaining on the OPC drum is wiped from the drum with a doctor blade. The tonerremoved from the OPC drum is dropped into the screw assembly, which moves the used tonerlaterally to the waste toner container, as shown in Figure D–5.

OPCDrumRotation

Toner Removal Screw

Doctor Blade

Toner

Figure D–5. Cleaning the OPC Drum


Erasing the Static Charge

An array of LEDs shines on the OPC drum before it moves again past the charger assembly, asshown in Figure D–6. The light causes the drum to conduct, allowing the charge to drain to groundbefore the next cycle begins.

Charger Unit

OPC Drum Rotation

LED Assembly

Media

Transfer Unit

Light

Tungsten Wire (Charge Corona)

Metal Channel

Figure D–6. Erasing the Static Charge


Fusing the Toner Image to the Media

The media now has the toner image. The media moves between two rollers, a heat roller and apressure roller, as shown in Figure D–7. Together, the heat roller melts the toner, while the pressureroller presses the image into the media. The printing cycle is now complete, and the media exits therear of the printer.

Media – Toner Side

Fuser(Heat)Roller

PressureRoller

Figure D–7. Fusing the Toner Image to the Media

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