EPSON TERMINAL PRINTER EPL-5500W SERVICE MANUAL EPSON 4005668
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NOTICE All rights reserved. Reproduction of any part of this manual in any form whatsoever without SEIKO EPSON’s express written permission is forbidden. The contents of this manual are subjects to change without notice. All efforts have been made to ensure the accuracy of the contents of this manual. However, should any errors be detected, SEIKO EPSON would greatly appreciate being informed of them.
PRECAUTIONS Precautionary notations throughout the text are categorized relative to 1) personal injury and 2) damage to equipment. DANGER Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in performing procedures preceded by DANGER Headings. WARNING Signals a precaution which, if ignored, could result in damage to equipment.
SAFETY INFORMATION This printer is a page printer which operates by means of a laser. There is no possibility of danger from the laser, provided the printer is operated according to the instructions in this manual provided. Since radiation emitted by the laser is completely confined within protective housings, the laser beam cannot escape from the machine during any phase of user operation. For United States Users; [Laser Safety] This printer is certified as a Class 1 Laser product under the U.S.
VAROITUS Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteiylle. VARNING Om apparaten används på annat sätt än i denna bruksanvisning specificerats, kan användaren utsättas för osynlig laserstrålning, som överskrider gränsen för laser klass 1. For Finland, Sweden Service People VAROITUS Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle laser-säteilylle. Älä katso säteeseen.
[Label inside printer] The following laser safety label will be attached inside the printer as shown below.
PREFACE This manual describes functions, theory of electrical and mechanical operations, maintenance, and repair of EPL-5500W. The instructions and procedures included herein are intended for the experience repair technician, and attention should be given to the precautions on the preceding page. The chapters are organized as follows: CHAPTER 1. GENERAL DESCRIPTION Provides a general product overview, lists specifications, and illustrates the main components of the printer. CHAPTER 2.
REVISION SHEET Revision Issue Date Revision Page Rev.
TABLE OF CONTENTS CHAPTER 1. CHAPTER 2. CHAPTER 3. CHAPTER 4. CHAPTER 5. CHAPTER 6.
Chapter 1 General Description Table of Contents 1.1 FEATURES 1-1 1.2 SPECIFICATIONS 1.2.1 Basic Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.2 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3 Reliability Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.4 Environmental Conditions for Operating (Include Imaging Cartridge) . . . . 1.2.
List of Tables Table 1-1. Options for the EPL-5500W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Table 1-2. Paper Feed Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Table 1-3. Paper Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Table 1-4. Usability of Special Papers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Table 1-5. Electrical Specifications . . . . . . . . . . . . .
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EPL-5500W Service Manual General Description 1.1 FEATURES The EPSON EPL-5500W laser printer has a 300/600 dots per inch (dpi) resolution and 6 pages per minute (ppm) printing speed in a dedicated Microsoft® Windows Printing System. It works under Microsoft Windows 3.1x and Windows 95, achieving very high performance due to the recent advances in PC technology.
General Description EPL-5500W Service Manual Table 1-1 lists the optional units available for the EPL-5500W. Table 1-1. Options for the EPL-5500W Cat. No. S050005 S051029 1-2 Description Developer cartridge Photoconductor unit Note Developer and toner cartridge — Rev.
EPL-5500W Service Manual General Description 1.2 SPECIFICATIONS This section provides statistical data for the EPL-5500W. 1.2.1 Basic Specifications Printing method: Laser beam scanning and dry electrophotography Resolution: 600/300 dpi Printing speed: 6 ppm (letter/A4) First printing time (A4/LT): Less than 20 seconds (face-up output) Warm-up time: Less than 35 seconds (at rated current and 23° C (73° F) temperature) Paper supply: See Table 1-2. Table 1-2.
General Description EPL-5500W Service Manual Usability of special papers: See Table 1-4. Table 1-4. Usability of Special Papers Input OHP Envelopes Labels Card Stock Letterhead P P P P R P P P P R Standard built-in paper tray Manual feed slot R: Reliable feeding and good image quality. P: Possible, but better avoided. N: Not supported.
EPL-5500W Service Manual General Description 1.2.2 Electrical Specifications Table 1-5. Electrical Requirements and Ranges Description 100 V Version 200 V Version Rated voltage Input voltage range Rated frequency range Input frequency range Power consumption Power consumption while in standby mode 100 ∼ 120 VAC 90 ∼ 132 VAC 220 ∼ 240 VAC 198 ∼ 264 VAC 50 ∼ 60 Hz 47 ∼ 63 Hz Less than 500 W Less than 600 W Less than 15 W (without option) 1.2.
General Description EPL-5500W Service Manual 1.2.6 Applicable Standards Safety Standards 120 VAC model: 220/240 VAC model: UL 1950, CSA 22.2 No.
EPL-5500W Service Manual General Description 1.2.9 Software Specifications Built-in modes: Rev.
General Description EPL-5500W Service Manual 1.3 INTERFACE SPECIFICATIONS The EPL-5500W is equipped with the following external interfaces: ❏ Parallel interface 1.3.1 Parallel Interface The parallel interface has the following two modes: ❏ ❏ ECP mode Microsoft Peppy mode Pin assignments: Fully IEEE-1284 compliant Connector type: P90-25027-1 (Amphenol) receptacle Applicable plug: 57-30360 (Amphenol or equivalent) 1-8 Rev.
EPL-5500W Service Manual General Description 1.4 OPERATING INSTRUCTIONS This section describes printer functions, including control panel operation and messages. 1.4.1 Control Panel The printer control panel gives you easy control over most common printer operations. The panel consists of the indicator lights described below. GREEN Light RED Light Figure 1-3. Control Panel Indicator Lights ❏ GREEN light ON: Printer is ready or idle. Blinking: Printer is currently receiving data.
General Description EPL-5500W Service Manual 1.4.2 Display of Messages This printer indicates two types of messages with the status message window for the printer driver on the PC. 1.4.2.1 Status Messages This section describes the status messages. Table 1-6. Status Messages Message Status Printer ready Printer is ready. Printing Printer is printing. Manual feed Printer is loading paper from manual feed slot. Paused Printer is in pause mode.
EPL-5500W Service Manual General Description Table 1-7. Error Messages (Continued) Message Status Measures Check Toner & Cover Printer is cover open or no toner cartridge is installed. Check the cover and toner cartridge. Wrong paper loaded Paper in the tray to be fed into the printer is different from the specified paper size. Check the paper size. Change paper Paper settings are wrong. Check the paper size settings. 1.4.
General Description EPL-5500W Service Manual 1.5 MAIN COMPONENTS To simplify maintenance and repair, the main components of the EPL-5500W have been designed for easy removal and replacement.
EPL-5500W Service Manual General Description 1.5.1 C180 MAIN Board The C180 MAIN board contains a parallel interface controller and engine controller board. The primary functions of this board are receiving print data from the host and sending the print image to the engine controller via the video interface. ❏ Memory chips 4M-bit DRAM (U4) ❏ Custom ICs ASIC E05B23 (U6) The engine controller consists of an M3807 x 8-bit CPU, including a MASK ROM.
General Description EPL-5500W Service Manual 1.5.2 PWB-E Board The PWB-E is the power supply board, which consists of a switching regulator circuit. It converts the AC line voltage into +24 V and +5 VDC voltages. There are two types of power supply board, the 100/120 V type and 220/240 V type. The difference between the two circuits is only in the input section. CAUTION Do not touch VR1 on PWB-E board. This volume is for factory setting only. VR1 F1 Figure 1-6. PWB-E Board 1.5.
EPL-5500W Service Manual General Description 1.5.4 Optical Unit The optical unit consists of the laser diode (semi-conductor laser), the mirror motor (scanner motor) which drives the polygon mirror for laser scanning, and several mirrors and lenses. The laser beam generated by the laser diode is conducted to the OPC drum surface by way of the polygon mirror, as well as several mirrors and lenses, to create a latent electro-photographic image on the drum. Figure 1-8. Optical Unit 1.5.
General Description EPL-5500W Service Manual 1.5.6 Photoconductor Unit Core mechanisms of the printing process, such as charging and imaging, are integrated into this unit. Figure 1-10. Photoconductor Unit 1.5.7 Developing Cartridge The developing mechanism for the printing process is integrated into this cartridge. Figure 1-11. Developing Unit 1-16 Rev.
Chapter 2 Operating Principles Table of Contents 2.1 ENGINE OPERATION 2-1 2.1.1 Print Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.1.1.1 Paper Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.1.1.2 Drum Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.1.1.3 Laser Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Tables Table 2-1. Functions of C180 MAIN Board Main Elements . . . . . . . . . . . . . . .
EPL-5500W Service Manual Operating Principles 2.1 ENGINE OPERATION This section describes the functions and operating principles of the EPL-5500W engine. Figure 2-1 shows the locations and names of the main engine components. 4 7 5 6 3 8 2 1 9 18 10 11 17 16 14 13 12 15 Figure 2-1. Main Components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Operating Principles EPL-5500W Service Manual 2.1.1 Print Process This section describes the print process from paper feeding to paper exit. Figure 2-2 shows a diagram of the print process. Optical Unit Print Exit Fusing Exposure Drum Cartridge Drum Charge Image Transfer Toner Hopper Development Toner Cartridge Paper Feeding Tray Multi Feeding (150 sheets) Manual Feed (1 sheet) Figure 2-2. Print Process Diagram 2-2 Rev.
EPL-5500W Service Manual Operating Principles 2.1.1.1 Paper Feeding Paper can be fed into the printer from the paper feed tray (150 sheets) or from the manual feed slot (1 sheet at a time). Paper fed by the paper take-up roller is transported to the transport roller, pre-image transfer roller, and then exit roller. After this, the paper is fed out onto the print tray. The starting position of an image is decided by the paper take-up sensor (PC1).
Operating Principles EPL-5500W Service Manual 2.1.1.2 Drum Charge The PC drum is charged with static electricity before laser exposure. The rotating charge brush and pre-film are used as the charging method. Less ozone is generated by the corona charge of the rotating charge brush and the pre-film, and the PC drum can be charged with low voltage because the charge is directly applied to the PC drum. The charge brush is rotated by the drive of the M1 main motor via its gear.
EPL-5500W Service Manual Operating Principles 2.1.1.3 Laser Exposure The laser beam, emitted from the optical unit, makes an invisible static image. The SOS (start of scan) sensor, installed on the laser diode control board (PWB-D), unifies the laser emission timing for each scan line. Charged Surface C180 MAIN Reflector Mirror IC201 CN210 1 5 Laser-Exposed Surface: (Approx. -50 V) CN205 PWB-D 1 M2 SOS Sensor Laser Diode 7 Figure 2-5. Laser Exposure 2.1.1.
Operating Principles EPL-5500W Service Manual 2.1.1.5 Image Transfer The electrode comb is an image transfer system that transfers the toner image on the PC drum onto the paper. Image Transfer Unit Housing Housing Electrode Comb Pre-Image Transfer Roller C180 MAIN Electrode Comb IC201 PWB-F PWB-S Housing 1 Pre-Image Transfer Roller 8 CN1F 1 1 8 8 CN204 1 8 Housing Ground Image Transfer Bias Figure 2-7. Image Transfer 2.1.1.
EPL-5500W Service Manual Operating Principles 2.1.2 Engine Control This section describes engine control, the power supply board, and the high-voltage supply board. The engine is controlled by the main board (C180 MAIN board). Figure 2-9 shows the engine controller connection diagram.
Operating Principles EPL-5500W Service Manual 2.1.2.1 Main Motor Functions and Control The M1 main motor transmits the drive to the printer rollers and the optional second paper feed unit (lower cassette) via each gear, as shown below. Toner Cartridge Sleeve Roller A Paper Exit Roller Upper Fusing Roller Lower Fusing Roller PC Drum Pre-image Transfer Roller Main Motor (M1) A Optional Second Paper Feeding Unit Paper Take-Up Roller Paper Transport Roller Figure 2-10.
EPL-5500W Service Manual Operating Principles Figure 2-11 shows the main motor drive circuit. The M1 main motor is a four-phase stepping motor, controlled by the CPU (IC201) on the main board (C180 MAIN). This board has a stepping motor driver IC that drives the M1 main motor with a constant current. C1 80 MAIN Board M1 Main Motor C N 206 A A B B 1 2 3 4 Figure 2-11. Main Motor Drive Circuit 2.1.2.2 Paper Take-Up Sensor and Paper Exit Sensor The paper take-up sensor has three functions: 1.
Operating Principles EPL-5500W Service Manual 2.1.2.3 Fuser Control The heater lamp, powered by AC voltage, heats the fuser. When the power supply board receives a FUSER signal from the main board (C180 MAIN), the power supply board (PWB-E) supplies the AC voltage to the heater lamp. This AC voltage is cut by an interlock switch when the case is open. Thermistor TH1 detects the surface temperature of the upper fusing roller and inputs that analog voltage to the 77-pin chip, IC201.
EPL-5500W Service Manual Operating Principles If any of the following conditions are detected, the printer indicates a fuser error: 1. 2. 3. 4. If the thermistor detects the temperature has not risen by 20º C for 50 msec. within 12 to 30 sec. after warm up. (This error applies only when the thermistor detects a temperature of 90º C (194º F) or less.) If the thermistor detects that the temperature has not reached 172º C (342º F) within 60 sec. after warm up.
Operating Principles EPL-5500W Service Manual 2.1.2.5 Laser Diode Drive Figure 2-16 shows the laser diode drive circuit. Laser diode emission is controlled by three signals (LDATA, LDAPC1, and LDAPC2) from the main board (C180 MAIN). Laser Diode SSCAN LD_CTL LDAPC1 LDAPC2 SOS Mirror LD SOS (PWB-D) L DATA SOS Sensor C180 MAIN B oard Figure 2-16. Laser Diode Drive Circuit The LDATA signal is the laser on/off signal. When it is LOW, the laser emits, and when it is HIGH, the laser stops emitting.
EPL-5500W Service Manual Operating Principles 2.1.2.6 Bias Voltages and Laser Drive Timing Figure 2-19 is a diagram of the drum charge bias voltage, image transfer bias voltage, and the developing bias voltage control circuit. These bias voltages are generated from the +24 VDC from the high-voltage supply board (PWB-F). If the printer detects a case-open condition, the interlock switch is set to off, which cuts the +24 VDC, which, in turn, cuts the bias voltages.
Operating Principles EPL-5500W Service Manual Figure 2-20 shows the print process. Brush Roller Charging Laser Exposure PC Drum Development Image Transfer Figure 2-20. Print Process Figure 2-21 shows the start print sequence. The printer’s engine starts printing when it receives the PRINT signal from the video controller circuit.
EPL-5500W Service Manual Operating Principles 2.1.2.7 Fan Motor Control The fan motor (M3) rotates at engine initialization, and stops after 2 sec. The fan motor also rotates during printing. When printing ends, the fan motor stops after 3 min. If the following condition is detected, the printer indicates a laser error: The voltage equivalent to the motor current of the fan motor remains 160 mV or lower for 2 sec. 2.1.2.
Operating Principles EPL-5500W Service Manual 2.2 PARALLEL INTERFACE CONTROLLER OPERATION The parallel interface controller section converts from a bidirectional parallel interface to a video interface. The parallel interface controller section is in the C180 MAIN board. C180 MAIN Board Parallel Interface Controller Section Engine Controller Section Figure 2-24. Parallel Interface Controller Section 2.2.
EPL-5500W Service Manual Operating Principles Table 2-1 lists the functions of the main elements of the video controller section in the C180 MAIN board. Table 2-1. Functions of C180 MAIN Board Main Elements Element Location E05B23 ASIC U8 DRAM U4 Rev. A Function This ASIC contains the following functions: Changing from parallel I/F to video I/F. DRAM management (refresh control, RAS/CAS control). These DRAMs are used as the working area of the E05B23.
Chapter 3 Disassembly and Assembly Table of Contents 3.1 GENERAL INFORMATION 3.1.1 Precautions for Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.3 Small Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.4 Service Checks after Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-27. Removing the Upper Fusing Roller . . . . . . . . . . . . . . . . . . . . . . . 3-18 Figure 3-28. Removing the Lower Fusing Roller . . . . . . . . . . . . . . . . . . . . . . . 3-19 Figure 3-29. Removing the Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 List of Tables Table 3-1. Table 3-2. Table 3-3. Table 3-4. Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abbreviations Used for Screws. . . . . . . . . . . .
EPL-5500W Service Manual Disassembly and Assembly 3.1 GENERAL INFORMATION This chapter describes disassembly/assembly procedures to use to replace the main assemblies of the EPL-5500W. 3.1.1 Precautions for Disassembly/Assembly Follow the precautions below when disassembling/assembling the printer. WARNING ❒ Disconnect the power cord before disassembling/assembling the printer. ❒ Be sure to handle the fusing unit carefully, because the unit remains hot for a while after the printer stops printing.
Disassembly and Assembly EPL-5500W Service Manual 3.1.3 Small Parts In the following sections, abbreviations are used for small parts, such as screws and washers. Tables 3-2 and 3-3 list these abbreviations. Table 3-2.
EPL-5500W Service Manual Disassembly and Assembly 3.1.4 Service Checks after Repair Check the repaired unit using the following list on completion of servicing. Table 3-4. Checks after Repair Item Location Operation Control panel Heater lamp Test Page Data print Adjustments Print position Cleaning Packing Rev.
Disassembly and Assembly EPL-5500W Service Manual 3.2 DISASSEMBLY AND ASSEMBLY This section describes and illustrates procedures for removing and disassembling components of the EPL-5500W. Cleaning is described in Chapter 6. The assembly procedures are not described, except for special notes where necessary, because assembly can be accomplished by performing disassembly in reverse. 3.2.1 Housing Removal This section describes how to remove the cases and the rear frame. 3.2.1.1 Case Removal 1.
EPL-5500W Service Manual Disassembly and Assembly 3.2.2 Removal of the Controller Section The control section is comprised of the controller board (the C180 MAIN board). 3.2.1.1 Main Board (C180 MAIN Board) Removal 1. Turn the printer so that its right side faces you. 2. Remove the right cover. 3. Remove 2 screws, and then remove the shield case. Figure 3-2. Removing the Shield Case 4. Disconnect all connectors on the C180 MAIN board. 5. Remove the 5 screws for the C180 MAIN board. 6.
Disassembly and Assembly EPL-5500W Service Manual 3.2.3 Disassembling the Engine This section describes disassembling the engine, including the high-voltage unit (PWB-F) and power supply board (PWB-E). 3.2.3.1 Optical Unit Removal CAUTION ❒ Do not touch the optical unit, except during replacement. ❒ Do not open the unit under any conditions. ❒ Do not remove the circuit board from the optical unit under any conditions. 1. Open the top cover. 2. Remove the right cover, left cover, and front cover.
EPL-5500W Service Manual Disassembly and Assembly 3.2.3.2 Image Transfer Unit Removal 1. Open the top cover. 2. Remove harness cover A. (Refer to Section 3.2.3.3.) 3. Remove the 2 screws and holders at both ends of the image transfer unit. Figure 3-5. Removing the Image Transfer Unit - 1 4. Disconnect the 2 connectors and remove the unit. Figure 3-6. Removing the Image Transfer Unit - 2 Rev.
Disassembly and Assembly EPL-5500W Service Manual ASSEMBLY POINT After reinstalling the image transfer unit, check that the unit smoothly moves up and down. Figure 3-7. Moving the Image Transfer Unit 5. Remove the electrode comb. ASSEMBLY POINT When reinstalling the electrode comb, be careful of the direction of installation. Install the electrode comb so that the comb terminal faces the image transfer roller drive gear. Figure 3-8. Reinstalling the Electrode Comb 3-8 Rev.
EPL-5500W Service Manual Disassembly and Assembly 3.2.3.3 Upper Unit Removal 1. Open the upper unit. 2. Remove the right cover and left cover. (Refer to Section 3.2.1.1.) 3. Disconnect connectors CN202, CN208, and CN211 from the C180 MAIN. 4. Remove harness covers A and B, and pull CN1 out from the PWB-E board. 5. Remove the image transfer unit. (Refer to Section 3.2.3.2.) A B Figure 3-9. Removing the Harness Cover 6. Slide and remove the unit as shown in the illustration. Figure 3-10.
Disassembly and Assembly EPL-5500W Service Manual 3.2.3.4 High-Voltage Supply Board (PWB-F) Removal 1. Open the top cover. 2. Remove 1 screw from the PWB-F cover. 3. Remove the PWB-F cover. Figure 3-11. Removing the PWB-F Cover 4. Remove the 4 screws from the PWB-F board. 5. Disconnect 2 connectors. 6. Remove the PWB-F board. Figure 3-12. Removing the PWB-F 3-10 Rev.
EPL-5500W Service Manual Disassembly and Assembly 3.2.3.5 Power Supply Unit (PWB-E) Removal 1. Remove the upper unit. (Refer to Section 3.2.3.3.) 2. Remove 6 screws, and remove the PWB-E cover. Figure 3-13. Removing the PWB-E Cover 3. Disconnect connector CN207 from the C180 MAIN board. 4. Remove 4 screws and 2 screws, and then remove the PWB-E. Figure 3-14. Removing the PWB-E Rev.
Disassembly and Assembly EPL-5500W Service Manual 3.2.3.6 Fusing Unit Removal 1. Open the top cover. (Refer to Section 3.2.3.3.) 2. Remove the image transfer unit. (Refer to Section 3.2.3.2.) 3. Remove 1 screw, and remove the drive tension section of the fusing unit. 4. Remove the transport gear. 5. Release the hook for the spring and remove the drive gear section of the fusing unit. ASSEMBLY POINT When rehooking the spring, be sure to hook it in the correct position.
EPL-5500W Service Manual 7. Disassembly and Assembly Remove the harness cover. Figure 3-17. Removing the Harness Cover 8. Remove the fusing entrance guide. Figure 3-18. Removing the Fusing Entrance Guide Rev.
Disassembly and Assembly EPL-5500W Service Manual 10. Remove 4 screws, and remove the fusing unit. Figure 3-19. Removing the Fusing Unit ASSEMBLY POINT After reinstalling the fusing unit, check the direction of the bushings on the paper exit roller and the connection between the roller and the ground plate. Figure 3-20. Roller Position 3-14 Rev.
EPL-5500W Service Manual Disassembly and Assembly 3.2.3.7 Fusing Unit Disassembly This section describes how to remove the paper exit sensor, heater lamp, lower fusing roller, and upper fusing roller. Heater Lamp CAUTION Do not touch the glass surface of the lamp with your bare hands. 1. Remove the fusing guide plate. (Refer to Section 3.2.3.8.) 2. Pull the heater lamp out of the lamp holder from the front side. Figure 3-21.
Disassembly and Assembly EPL-5500W Service Manual Thermistor 1. Remove the fusing unit. (Refer to Section 3.2.3.6.) 2. Remove the 1 screw, and remove the thermistor. Figure 3-22. Removing the Thermistor ASSEMBLY POINT When reinstalling the thermistor, wire the harness as shown below. Figure 3-23. Wiring 3-16 Rev.
EPL-5500W Service Manual Disassembly and Assembly Paper Separator 1. Remove the fusing unit. (Refer to Section 3.2.3.6.) 2. Release the lock of the holder, and remove the 3 paper separators. Figure 3-24. Removing the Paper Separators ASSEMBLY POINT When reinstalling the paper separators, be careful of their positions, because the middle one differs from the others. Paper Exit Sensor 1. Remove the fusing unit. (Refer to Section 3.2.3.6.) 2. Remove the paper exit sensor. Figure 3-25.
Disassembly and Assembly EPL-5500W Service Manual Fusing Roller 1. Remove the fusing unit. (Refer to Section 3.2.3.6.) 2. Remove the 2 G-rings from the fusing unit. Figure 3-26. Removing the G-Rings CAUTION When reinstalling the G-rings: ❒ Be careful of the direction. ❒ Securely position them into the grooves of the fusing roller. 3. Remove the upper fusing roller drive gear. 4. Remove the upper fusing roller. Figure 3-27. Removing the Upper Fusing Roller 3-18 Rev.
EPL-5500W Service Manual 5. Disassembly and Assembly Take out the lower fusing roller. Figure 3-28. Removing the Lower Fusing Roller Thermal Fuse 1. Remove the fusing unit. (Refer to Section 3.2.3.6.) 2. Remove 2 screws, and remove the thermal fuse. Figure 3-29. Removing the Thermal Fuse Rev.
Chapter 4 Adjustment Table of Contents 4.1 ADJUSTMENT 4-1 4.1.1 Print Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 List of Figures Figure 4-1. Print Position Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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EPL-5500W Service Manual Adjustments 4.1 ADJUSTMENTS This section describes the adjustment procedures for the EPL-5500W. You must perform these adjustments after servicing the printer, especially when any component or part is replaced. 4.1.1 Print Position Adjustment You can adjust the vertical print position on a sheet of paper by turning the image synchronizing volume control on the main board (C180 MAIN). After replacing a main board, be sure to adjust the print position using the procedure below. 1.
Chapter 5 Troubleshooting Table of Contents 5.1 OVERVIEW 5-1 5.2 SELF-DIAGNOSTIC FUNCTION AND TOOL 5-1 5.3 TROUBLESHOOTING 5-3 5.3.1 Troubleshooting of Abnormal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.3.2 Print Quality Anomaly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 List of Tables Table 5-1. Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 5-2.
EPL-5500W Service Manual Troubleshooting 5.1 OVERVIEW The EPL-5500W has a sophisticated, built-in, self-diagnostic function that reduces troubleshooting time by identifying failed parts or components. This self-diagnostic test identifies the troubleshooting problems for page printers, in which even a trivial failure can result in a serious print quality problem. 5.
Troubleshooting EPL-5500W Service Manual Table 5-1.
EPL-5500W Service Manual Troubleshooting 5.3 TROUBLESHOOTING This section describes troubleshooting abnormal operations and print quality problems. 5.3.1 Troubleshooting of Abnormal Operations This section describes how to detect malfunctions, and determine their cause, and it suggests what actions to take for various types of malfunctions. Each paragraph refers you to a detailed troubleshooting table. Table 5-2. Symptoms and Reference Tables Symptom The printer does not operate at all.
Troubleshooting EPL-5500W Service Manual Table 5-3. The Printer Does Not Operate at All Cause Step Connector CN207 on the C180 MAIN board may be disconnected. The fuse on the PWB-E board may be blown. Is connector CN207 on the C180 MAIN board disconnected? Has the fuse blown on the PWB-E board? With power on, is there an output of +5 VDC between pin 4 (+) and pin 3 (–) for CN207 on C180 MAIN board? 1 2 PWB-E board may be dead. 3 C180 MAIN board may be dead.
EPL-5500W Service Manual Troubleshooting Table 5-6. Clear Paper Jam (2) Cause The paper take-up solenoid coils may be open or shorted. Step 1 2 The main motor coils may be open or shorted. 3 Checkpoint Disconnect CN203 on the C180 MAIN board, and check the coil resistance between pins 5 and 6 on the disconnected cable side of the connector using a multimeter. Is the resistance approximately 80 ohms? If the coil is shorted, check the solenoid drive circuit using the procedure below: 1.
Troubleshooting EPL-5500W Service Manual Table 5-6. Clear Paper Jam (2) (Continued) Cause Step Paper take-up sensor flag position may be incorrect. Paper take-up roller may be bad. Checkpoint 4 Is the paper take-up sensor flag position incorrect? 5 — Finding Solution Reseat the paper take-up sensor flag. Replace the paper take-up roller. Yes — Table 5-7. Check Toner & Cover Cause Step The interlock switch lever is bad. The interlock switch may be bad.
EPL-5500W Service Manual Troubleshooting Table 5-9. Service Error (2) Cause Connector CN211 on the C180 MAIN board may be disconnected. The fan motor may be bad. Step Checkpoint Finding Solution 1 Is CN211 on the C180 MAIN board disconnected? Yes Connect it. 2 — — Replace it. Table 5-10. Service Error (3) Cause Step Checkpoint Finding The optical unit may be bad. 1 — — The C180 MAIN board may be bad. 2 — — Solution Replace the optical unit. Replace the C180 MAIN board.
Troubleshooting EPL-5500W Service Manual 5.4.2 Print Quality Anomalies This section describes how to isolate possible causes of a print quality problem. Table 5-12. Print Quality Anomalies Symptom Low image density Possible Cause Poor development Check Item — Replace the PWB-F board. Image transfer unit Check to see if the surface of image transfer unit is damaged. Replace the image transfer unit.
EPL-5500W Service Manual Troubleshooting Table 5-12. Print Quality Anomalies (Continued) Symptom Possible Cause Blank print Part Name Check Item Remedy Imaging cartridge Check whether the toner cartridge is installed properly. PWB-F board — PWB-F board — Image transfer unit Check the surface of the image transfer unit. Replace the image transfer unit. PWB-F board — Replace the PWB-F board.
Troubleshooting EPL-5500W Service Manual Table 5-12. Print Quality Anomalies (Continued) Symptom Toner smudges on the back side of the sheet. Possible Cause Improper charging Poor development Part Name Check Item Remedy Replace the PWB-F board. Replace the PWB-F board. PWB-F — PWB-F — Improper fusing Fusing unit — Replace the fusing unit. Improper fusing Fusing unit — Replace the fusing unit.
Chapter 6 Maintenance Table of Contents 6.1 MAINTENANCE 6.1.1 User Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.1.1 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.1.2 Replacement of Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.2 Service Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.2.1 Periodic Service Maintenance . . .
6-ii Rev.
EPL-5500W Service Manual Maintenance 6.1 MAINTENANCE The EPL-5500W is a page printer that uses an electrophotographic printing method. Unlike most impact or ink-jet printers, the key components in the electrophotographic process are integrated into two expendable units (the photoconductor unit and toner cartridge). Therefore, periodic replacement of them is essential to ensure high-quality output.
Maintenance EPL-5500W Service Manual 6.1.1.2 Replacement of Consumables This printer uses a consumable photoconductor unit and toner cartridge. The life of photoconductor unit is 20,000 pages and the toner cartridge life is 3,000 pages, when printing on A4- or letter-size pages with a 5% print ratio. If printed images become faint, remove the toner cartridge and gently shake it. This will distribute the toner and may make the images darker.
EPL-5500W Service Manual Maintenance 6.1.2 Service Maintenance This section describes the periodic service maintenance and the cleaning required. 6.1.2.1 Periodic Service Maintenance The following units need service maintenance periodically, because they are subject to functional deterioration as the total number of printed pages increases, resulting in bad print quality. Table 6-1. Periodic Service Maintenance Unit Service Interval Image transfer unit Approx. 100,000 pages Fusing unit Approx.
Maintenance 6-4 EPL-5500W Service Manual Rev.
Appendix A Reference Materials Table of Contents A.1 CONNECTOR PIN ASSIGNMENTS A-1 A.1.1 Main Board (C180 MAIN-B Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 A.2 CIRCUIT DIAGRAM A-7 A.3 CIRCUIT BOARD COMPONENT LAYOUT A-12 List of Figures Figure A-1. Connector Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Figure A-2. C180 MAIN Circuit Diagram (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Figure A-3.
EPL-5500W Service Manual Appendix A.1 CONNECTOR PIN ASSIGNMENTS Figure A-1 illustrates the interconnection of the primary components. Table A-1 gives the size and a description of each connector.
Appendix EPL-5500W Service Manual Table A-1.
EPL-5500W Service Manual Appendix A.1.1 Main Board (C180 MAIN Board) Table A-2. CN2 Pin Assignments Pin No. Signal Name I/O 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 STROBE DATA1 DATA 2 DATA 3 DATA 4 DATA 5 DATA 6 DATA 7 DATA 8 ACKNLG BUSY PE SLCT AUTO-FEED NC GND CHASSIS GND NC GND GND GND GND GND GND GND GND GND GND GND GND INIT ERROR GND NC +5 SLCT IN I I I I I I I I I O O O O I — — 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Rev.
Appendix EPL-5500W Service Manual Table A-3. CN202 Pin Assignments Pin No. 1 2 Signal Name I/O +5 TH — I Description +5 VDC Fuser temperature Table A-4. CN203 Pin Assignments Pin No. 1 2 3 4 5 6 Signal Name I/O PS1 GND1 PS1 NC +24V FEED1 I — I — — O Description Paper take-up sensor Ground Paper take-up sensor Not connected +24 VDC Paper take-up solenoid drive Table A-5. CN204 Pin Assignments Pin No.
EPL-5500W Service Manual Appendix Table A-8. CN207 Pin Assignments Pin No. 1 2 3 4 5 Signal Name I/O +24V GND2 GND1 +5V FUSER — — — — O Description +24 VDC Ground Ground +5 VDC Heater lamp on Table A-9. CN208 Pin Assignments Pin No. 1 2 3 Signal Name I/O PS3 PS3 GND I I — Description Paper exit sensor Paper exit sensor Ground Table A-10. CN209 Pin Assignments Pin No.
Appendix A-6 EPL-5500W Service Manual Rev.
EPL-5500W Service Manual Appendix A.2 CIRCUIT DIAGRAMS Figure A-2. C180 MAIN Circuit Diagram (1/2) Rev.
Appendix A-8 EPL-5500W Service Manual Rev.
Rev. A 7 1 6 4 3 2 5 CN206 GN D1 + 5V 1 2 5 1 A 2 A 3 B 4 B 3 4 TP + 24V GND2 FUSER CN207 TP 202 2 1 2 +5V 1 TH +24V FA N C N211 CN202 1 NC 2 + 24V 4 +5V 5 P_CTL 3 GND2 CN210 +5V SSCA N LDATA LDAP C1 LDAP C2 LD_C TL GN D1 CN205 1A R203 TP TP203 C201 220U /16V TP TP201 200m A 3.0K 1.0% 0.1U C243 0.1U C259 0.1U C258 33 680 R206 R253 0.01U C239 R 207 13 820P 56K 820P C211 R 218 C209 2.
L N 3 1 CN3 5 3 25 9 -0 32 0 N L F1 6.3 A , 12 5 V R1 4 70 K C1 0 .22 u F 1 25V NR 1 ENC2 71D -1 0 Z7D2 71 L1 Z 0 408 , Z 04 6 2 C3 C4 C3 , C 4 220 0pF 125 V C2 0.1u F 12 5V C5 2 20 0 pF 1 25 V BD 1 D 2 5 8A 50 D 2 S 86 0 T h1 10 0 -g, M 1 00 1 0C , M 1 00 0 7 C N T H9 D 1 0 0L A C5 3 30u F 2 00V + C8 6 80p 1 kV 5 00V R5 22 2W C19 0.01 u 25 0V L 10 R 24 1 0 0K 0 .5W D4 EU 2A, A GIC ER A22-06 Q1 2S K1 445 2S K1 446 R7 4.7 ZD2 H Z S15 R 11 68 K R4 22 0K -18 0K 0.25 W R5 390 K 0.
Rev. A L. 2 HE A TE R 36 0W 3 1 IN L1 3 N. L. HEA TE R 2 36 0W 1 C N2 SW1 W H2 W H1 C1 2 50 V 0 .3 3 u F F1 2 50V 5A VS1 4 70 V L1 C M 1 02 R2 1 /4W 4 70K R1 1 /4 W 4 70 K C3 2 50 V 2 20 0 p F C2 2 50 V L2 2 20 0p F C M 1 02 C4 250 V 0.1 u F RC1 6 0 0V , 1 .5A C7 4 0 0V 8 2 uF RT1 10 VS2 47 0 V R6 2W 10 0 + C9 1KV 1 00 pF C 21 2 50V 0 .1u F R1 2 4.7 K 1/4 W Q2 50 V 2A Q1 80 0V 3A C 22 0 .0 1u F R22 1/2W 33 C 11 0.
Appendix EPL-5500W Service Manual A.3 CIRCUIT BOARD COMPONENT LAYOUTS Figure A-6. C180 MAIN Component Layout (Side A) A-12 Rev.
EPL-5500W Service Manual Appendix Figure A-7. C180 MAIN Component Layout (Side B) Rev.
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