Operator’s Guide The Printronix L5535 Multifunction Printer
Consumables Information Printronix® has years of experience designing printer imaging systems. For the best possible performance of your Printronix printer, use Genuine Printronix parts and supplies.
L5535 Multifunction Printer Operator’s Guide 171638-001B
Software License Agreement CAREFULLY READ THE FOLLOWING TERMS AND CONDITIONS BEFORE USING THIS PRINTER. USING THIS PRINTER INDICATES YOUR ACCEPTANCE OF THESE TERMS AND CONDITIONS. IF YOU DO NOT AGREE TO THESE TERMS AND CONDITIONS, PROMPTLY RETURN THE PRINTER AND ALL ACCOMPANYING HARDWARE AND WRITTEN MATERIALS TO THE PLACE YOU OBTAINED THEM, AND YOUR MONEY WILL BE REFUNDED. Definitions. “Software” shall mean the digitally encoded, machine-readable data and program.
e. You may not transmit the Software Product over a network, by telephone, or electronically using any means; or reverse engineer, decompile or disassemble the Software. f. You agree to keep confidential and use your best efforts to prevent and protect the contents of the Software Product from unauthorized disclosure or use. 3. Transfer. You may transfer the Software Product with the printer, but only if the recipient agrees to accept the terms and conditions of this Agreement.
POSSIBILITY OF SUCH DAMAGES, OR ANY DAMAGES CAUSED BY THE ABUSE OR MANIPULATION OF THE SOFTWARE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. 3. Printronix, Inc. will not be liable for any loss or damage caused by delay in furnishing a Software Product or any other performance under this Agreement. 4.
BY ITS TERMS AND CONDITIONS. NEITHER PARTY SHALL BE BOUND BY ANY STATEMENT OR REPRESENTATION NOT CONTAINED IN THIS AGREEMENT. NO CHANGE IN THIS AGREEMENT IS EFFECTIVE UNLESS WRITTEN AND SIGNED BY PROPERLY AUTHORIZED REPRESENTATIVES OF EACH PARTY. BY USING THIS PRINTER, YOU AGREE TO ACCEPT THE TERMS AND CONDITIONS OF THIS AGREEMENT.
Avis de conformite aux normes du ministere des Communcations du Canada: Cet appareil numerique de la classe A est conform á norme NMB-003 du Canada. European Community (EC) Conformity Statement: This product is in conformity with the protection requirements of EC Council Directive 89/336/EEC on the approximation of the laws of the Member States relating to electromagnetic compatibility.
Anmerkung: Um die Einhaltung des EMVG sicherzustellen sind die Geräte, wie in den Handbüchern angegeben, zu installieren und zu betreiben. This product has been tested and found to comply with the limits for Class A Information Technology Equipment according to European Standard EN 55022. The limits for Class A equipment were derived for commercial and industrial environments to provide reasonable protection against interference with licensed communication equipment. Warning This is a Class A product.
Trademark Acknowledgements Centronics is a registered trademark of Genicom Corporation. CSA is a registered certification mark of The Canadian Standards Association. Dataproducts is a registered trademark of Dataproducts Corporation. DuraFusion, IGP, LinePrinter Plus, LaserLine, PSA, PGL, and Printronix are registered trademarks of Printronix, Inc. EIA is a registered service mark of the Electronic Industries Association. Epson is a registered trademark of Seiko Epson Corporation.
This product uses Intellifont Scalable typefaces and Intellifont technology. Intellifont is a registered trademark of Agfa Division, Miles Incorporated (Agfa). CG, Garth Graphic, Intellifont, and Type Director are registered trademarks, and Shannon and CG Triumvirate are trademarks of Agfa Division, Miles Incorporated (Agfa). CG Bodoni, CG Century Schoolbook, CG Goudy Old Style, CG Melliza, Microstyle, CG Omega, and CG Palacio are products of Agfa Corporation.
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 particular purpose. Printronix, Inc. shall not be held responsible for errors contained herein or any omissions from this material or for any damages, whether direct, indirect, incidental or consequential, in connection with the furnishing, distribution, performance or use of this material.
Table of Contents 1 Introduction ............................................. 17 About This Manual...............................................................17 General Safety Precautions.................................................18 Safety Label And Component Locations .............................20 About The Printer ................................................................25 Features ........................................................................25 Emulations ....................
Table of Contents 3 Consumables Replacement .................... 51 Consumables Replacement ................................................51 Replacement Intervals ..................................................51 Replacing The Toner Cartridge.....................................52 Replacing The Waste Toner Bottle ...............................57 Replacing The Photoreceptor Drum..............................60 Proper Disposal Of A Drum Unit ...................................
Table of Contents Discharge LED ............................................................123 Photoreceptor Drum....................................................124 Cleaning The Developing Area ...................................126 5 Troubleshooting .................................... 129 Troubleshooting .................................................................129 Diagnostics ........................................................................129 Offline Diagnostics .....................
Table of Contents 16
1 Introduction About This Manual This manual explains how to use your printer. Safety Notices And Special Information For your safety and to protect valuable equipment, it is very important that you read and comply with all information highlighted under the following special headings: WARNING A warning notice calls attention to a condition that could harm you. WARNUNG Ein Warhinweis dieser Art weist auf Verletzungsgefahr hin.
Chapter 1 IMPORTANT General Safety Precautions An important notice provides information that is vital to proper operation of the printer. NOTE: A note provides information and helpful tips about printer operation. Keys And Display Messages Keys and indicators that are labeled on the printer are printed in uppercase letters. For example: Press ENTER to select the value shown on the LCD.
Keep combustible materials away from the printer. Dispose of used toner properly, as it is flammable. Keep away from components in the printer that are potentially hazardous or easily damaged. For example, the fuser unit becomes very hot under normal operating conditions, and several components use high voltage. Do not block or obstruct any cabinet ventilation slots. Never spill liquid on the printer. Use only approved cleaning agents and methods. Put nothing on the power cord.
Chapter 1 Safety Label And Component Locations Safety Label And Component Locations 4 3 2 5 1 6 7 8 9 10 11 16 12 13 15 14 20
Legend: 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) Face Up Paper Output Tray Rear Cover Face Down Paper Output Tray Top Cover Front Upper Cover Power Paper Stacker (Optional) CAUTION Rear Cover Top Cover Cut Sheet Paper Input Cassette (Optional) Power Switch CAUTION Host I/O Connections Fanfold Paper Control Panel Front Upper Cover Figure 1: Safety Labels and Components 21
Chapter 1 Safety Label And Component Locations % $ 1 $ 2 3 % 5 3 5 4 4 Legend: 1) 2) 3) 4) 5) Open/Close Button Front Upper Cover CAUTION CAUTION WARNING Figure 2: Front View with Front Upper Cover Open 22
2 3 4 5 1 6 7 8 9 10 11 12 Legend: 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) Fuser Unit Cleaning Unit Discharge LED (not visible) Main Charger Toner Cartridge Optional Cut Sheet Paper Input Cassette Control Panel Developing Unit Waste Toner Recovery Unit Transport Unit Smoke Filter Box Power Supply for Flash Lamp Figure 3.
Chapter 1 Safety Label And Component Locations 1 $ 2 $ 5 3 6 4 Legend: 1) 2) 3) 4) 5) 6) Power Switch Serial Port Diagnostic Port General Purpose I/O Port Optional Coax/Twinax Port Parallel Port/Optional Ethernet Port Figure 4: Rear Cover 24
Features About The Printer Features Printing speed is 35 pages per minute on continuous letter size and A4 size fanfold forms (long edge fed). In the optional cut sheet mode, printing speed is 27 pages per minute on letter size and A4 size cut sheet forms (long edge fed). The printer produces printed output with a 300 x 300, (or optionally) 240 x 240 or 400 x 400 dotsper-inch (dpi) resolution in either the continuous form or cut sheet printing mode. See Appendix B for printer specifications.
Chapter 1 About The Printer • • Proprinter® III XL Epson® FX-1050 Printronix LinePrinter Plus provides portrait and landscape image orientation. Automatic 1-up, 2-up, 4-up, and gray bar overprinting are also provided. The emulation also offers optional proportional (scalable) fonts. The following optional emulations are also available: • • • • IGP®/PGL® IGP/VGL PCL5® IPDS™ For specific information on each emulation, see the appropriate emulation manual.
2 Operation Installation Overview The installation and setup of your printer is intended to be done by a service provider who has been trained and authorized by Printronix. Your service provider is also responsible for doing a preinstallation site survey, unpacking the printer, connecting the power and host data cables, and installing the first set of consumable items in the printer. Depending on the terms of your service contract, your service provider might also power on your printer and configure it.
Chapter 2 Loading Paper Loading Paper The following section explains how to load fanfold paper. To load cut sheet paper, go to page 31. Loading Fanfold Paper IMPORTANT When loading fanfold paper, be sure the leading edge of the paper has a clean, separated perforation (without ragged edges or paper chaff). NOTE: If you leave the printer on and replace paper, it will resume printing where it left off when you put it online. To load fanfold paper, perform the following steps.
Loading Fanfold Paper 3. Pass the leading edge of the paper between the lower paper guides, as shown in the illustration below. 1 2 3 Legend: 1) 2) 3) IMPORTANT Tractor Unit Lower Paper Guides First paper fold is toward printer. To prevent jams, place the first fold of the paper facing toward the printer as shown. 4. Unlock only the right tractor by pushing forward on the tractor lock. 5. Open the left and right tractor gates and place the paper about half-way onto the tractor pins.
Chapter 2 Loading Paper 7. Move the right tractor to the left or right until its pins line up with the holes in the right edge of the paper, then close the right tractor gate. NOTE: When you place the paper on the tractors, you should introduce a slight amount of side-to-side tension into the paper. The right tractor must be set far enough to the right so that there are no wrinkles, looseness, etc. in the paper.
Loading Cut Sheet Paper (Option) Loading Cut Sheet Paper (Option) If your printer is equipped with the cut sheet paper feed option, then upper and lower paper input cassettes are provided. When printing on cut sheet paper, you can select either of two paper output trays: the face down tray (default) or the face up tray. To change the paper output tray selection, see the Cut Sheet Output option on the Paper Control menu. Refer to the User’s Manual for details.
Chapter 2 Loading Paper 2. Load the new paper uniformly in the cassette, making sure the leading edge of the paper is at the front of the cassette. Do not load more paper than specified below, otherwise a paper jam may occur. 17-20 lb. bond 21-44 lb. bond Upper cassette Lower cassette 250 sheets or less Upper cassette Lower cassette 1 inch or less in thickness 2 inches or less in thickness 500 sheets or less 1 2 Legend: 1) 2) Cassette Cover Cassette 3.
Loading Cut Sheet Paper (Option) 4. If you are reloading paper following a “CUT-SHEET PAPER EMPTY“ message with the printer power on, press ONLINE to place the printer online. The printer resumes printing. NOTE: Occasionally, paper may become moist and wavy, resulting in poor print quality. If this occurs, remove the wavy sheets of paper from the cassette and replace them with those from a new package. In order to minimize the possibility of a paper jam: • Only use xerographic quality paper.
Chapter 2 Loading Paper Changing Cassette Paper Size (Optional Procedure) The cut sheet option comes with four cassettes (paper trays) preconfigured for either U.S. or Metric paper sizes. Should the configurations of these cassettes not meet your needs, you can reconfigure the cassettes as described below, or you can purchase additional cassettes.
Cut Sheet Tray Linking (Optional Procedure) When the plastic inserts in the cassette contact the paper size sensors on the printer, the printer determines that the paper cassette is in position and identifies the paper size.
Chapter 2 Loading Paper If the cut sheet trays are of different sizes, and Tray Linking is enabled, the printer will not switch to the alternate tray when the first tray runs out of paper, nor will it display the usual “CUT-SHEET PAPER EMPTY” message on the LCD. Instead, the printer stops printing and displays the message “TRAY MISMATCH.” To clear this message, either add paper to the active tray, or insert a matching tray in the alternate tray position. Then, press CLEAR on the control panel.
Custom Tray Length (Optional Procedure) Custom Tray Length (Optional Procedure) If your printer is equipped with the cut sheet paper feed option, it is possible to override the standard cut sheet paper tray lengths. This feature is called Custom Tray Length. The standard cut sheet paper tray sizes are listed in the table on page 35. Using Custom Tray Length and specially modified paper trays, it is possible to use nonstandard paper stock that is longer or shorter than the standard paper length.
Chapter 2 Powering On The Printer Powering On The Printer Printer Functions 1 Legend: 1) CAUTION Power Switch The printer must be connected to the proper power source: 200, 220, or 240 VAC and 50-60 Hz, as shown on the rear panel label. The DC power supply must be set for the proper line voltage. Using an incorrect power source or improperly setting the DC power supply will damage the printer. 1.
Printer Functions 3. Note that when you power on the printer, the following occur: a. The printer reads the emulation and displays the message: “TESTING HARDWARE PLEASE WAIT...” b. If there are no bootup errors, the LCD displays “DIAGNOSTICS PASSED” c. The STAND BY Light flashes. Power Paper Stacker (Option) Safety Feature To prevent injuries, the optional power stacker is equipped with two safety stop bars located under the edge of the stacker (see following illustration).
Chapter 2 Physical Description Physical Description The front (output side) of the power stacker is shown in the following illustration.
Printer Functions Stacker Operation Keys The power paper stacker contains the following keys for operating the elevator: • AUTO: Sets the elevator in automatic mode. Pressing this key causes the elevator table to rise until it reaches its maximum upper position and enables the stacker. • STOP: Stops the elevator, and displays the message “STACKER NOT READY” on the printer control panel. The STOP key may be used to stop the elevator from lowering after pressing the DOWN key.
Chapter 2 Setting The Stacker Page Length 11.0 5.3 11.5 5.0 12.0 4.8 NOTE: Normal Mode supports up to 28 lb. bond (105 g/m2). Heavy Mode must be used for media weights greater than 34 lb. bond (128 g/m2). Some media that are 28 lb. bond (105 g/ m2) and higher require Heavy Mode for reliable stacking. Setting The Stacker Page Length Set the stacker page length to match the actual page length.
Printer Functions Removing Paper 1. Upon completion of a print job, press the PAGE EJECT key on the printer control panel, and separate the paper at the perforation. 2. Press the DOWN key on the stacker to lower the elevator (stacking table). 3. Press the STOP key on the stacker when the elevator is about half-way down. NOTE: The elevator stops automatically when it is fully loaded, without the STOP key being pressed. 4.
Chapter 2 Stacker Full Stacker Full 1. When the stacker becomes full, the printer automatically separates the paper at the perforation, returning the edge of the paper to home position on the tractors. 2. Press the DOWN key on the stacker. 3. Remove all paper from the stacker elevator. 4. Press the AUTO key on the stacker to resume operation. 5. Press the CLEAR key on the printer control panel, to clear the fault message and place the printer online. 6.
Liquid Crystal Display (LCD) Using The Control Panel 1 3 2 FUSER LINE SYNC SYS AVAIL JOB IN PROCESS DRUM STAND BY PAPER PATH UP CANCEL ONLINE FAULT ONLINE CLEAR PREV TEST SHIFT PAGE EJECT NEXT ENTER DOWN 4 1) 2) 3) 4) Status Indicators Liquid Crystal Display (LCD) Paper Path Diagram Function Keys Figure 5. Control Panel The control panel is located on the top right side of the front cover.
Chapter 2 Using The Control Pane l SYS AVAIL Twinax interface only. Indicates there is activity to the current address on the line. JOB IN PROCESS When the printer is receiving data or processing data, JOB IN PROCESS flashes. If data has been processed and is waiting to be printed, or has been printed but not yet fused and ejected by the printer, JOB IN PROCESS lights continuously.
Function Keys Function Keys The pressure-sensitive function keys are located directly below the status indicators. When pressing the keys, a “beep” verifies contact. The function keys permit you to configure the options of the printer. You can access these options via a structured menu which is displayed on the LCD. To navigate through the options, use the UP, DOWN, NEXT, and PREV keys. Press ENTER to select an option that appears on the LCD.
Chapter 2 Using The Control Pane l NOTE: When the printer is not in an error state, pressing ONLINE in any level of the configuration menu causes the printer to accept any configuration changes you have entered and return to online status. When the printer is in an error state, pressing ONLINE in any level of the configuration menu causes the printer to re-display the fault message.
Function Keys Once the paper motion has occurred, the data that was not yet in the buffer should print. The page is then cut at the perforation (unless the Burst On Eject option is disabled). To start downloading files to the printer, power off, then press the PAGE EJECT + ONLINE key and hold them down while powering on the printer. (See “Downloading Files Into Flash Memory” section in Chapter 3.
Chapter 2 Using The Control Pane l UP And DOWN Keys The UP and DOWN keys are used for the configuration menu: • To unlock or lock the ENTER key, press UP + DOWN at the same time when the printer is offline • The ENTER key lock can be configured to be a key combination other than UP + DOWN.
3 Consumables Replacement Consumables Replacement For the best print quality, the printer consumables should be replaced at the intervals specified in the following table. The yield of the supplies is based on a 4% coverage of letter size (8.5 inch x 11 inch) paper.
Chapter 3 Consumables Replacement Replacing The Toner Cartridge NOTE: When replacing the toner cartridge, put the old cartridge on a disposable wrapper (e.g., paper towels, newspaper) to minimize toner spillage. Vinyl gloves may be worn to prevent toner from contacting the skin. If necessary, use only cold water to remove toner from skin or clothing. To replace the toner cartridge, perform the following steps: 1.
Replacing The Toner Cartridge 2. Rotate the old toner cartridge counterclockwise until the notch is aligned with the pin in the toner hopper, and remove the cartridge. 2 1 3 Legend: 1) 2) 3) Notch Toner Cartridge Positioning Pin 3. Put the old cartridge into a plastic bag and discard it.
Chapter 3 Consumables Replacement 4. Keep the new toner cartridge in its package. Hold it level and shake it back and forth three or four times as shown. 1 Legend: 1) Toner Cartridge 5. Remove the new toner cartridge from its package.
Replacing The Toner Cartridge 6. With the cover tape facing up, begin inserting the cartridge into the toner hopper, and slowly pull off the cover tape in the direction of the arrow. Remove the last of the tape just as the cartridge is completely inside the hopper. 2 1 3 4 Legend: 1) 2) 3) 4) Pin Toner Hopper Cover Tape Notch 7. Fit the notch to the pin on the developing unit. Push the new toner cartridge as far as possible into the toner hopper.
Chapter 3 Consumables Replacement 8. Rotate the cartridge clockwise as far as it will turn. 1 Legend: 1) Toner Cartridge 9. If any toner has spilled, remove it with wet tissue paper or a toner vacuum. 10. Close the front upper cover.
Replacing The Waste Toner Bottle Replacing The Waste Toner Bottle The waste toner recovery unit contains the waste toner bottle and is located behind the front cover, as shown below. When the “WASTE TONER FULL” message appears on the control panel, replace the waste toner bottle by performing the following steps, and discard the full bottle. Do not reuse the bottle. 1 Legend: 1) Waste Toner Recovery Unit To replace the waste toner bottle, perform the following steps: 1.
Chapter 3 Consumables Replacement 2. Lower the lever, pull the green handle toward you, and open the waste toner recovery unit.
Replacing The Waste Toner Bottle 3. Remove the cap from the outside of the waste toner bottle, and cap the toner bottle. 1 2 Legend: 1) 2) Cap Waste Toner Bottle 4. Remove the waste toner bottle from the unit and discard it. 5. Install a new waste toner bottle. 6. Close the printer front cover. 7. Clear Error 28, “WASTE TONER FULL,” as follows: a. Press CLEAR. b. Press UP and DOWN to unlock the configuration menu. c. Enter the configuration menu and select the Paper Control menu. d.
Chapter 3 Consumables Replacement Replacing The Photoreceptor Drum Drum life is dependent upon media used and proper maintenance and operation of the printer. Print media other than bond paper (e.g., labels, card stock, plastic, or vinyl) may reduce drum life as much as 50%. To replace the drum, you will need a drum auxiliary rod. Please read all steps before beginning the replacement procedure.
Replacing The Photoreceptor Drum CAUTION Failure to perform Step 5 will damage the photoreceptor drum. 5. Rotate the developing unit lever fully clockwise so that it is pointing straight up (to separate the developing unit from the photoreceptor drum). 1 Legend: 1) Lever 6. Remove the developing unit by holding the lever in one hand and pulling the developing unit partially out of the printer.
Chapter 3 Consumables Replacement 7. With your other hand, grasp the hanger and remove the developing unit from the printer. 8. Vacuum any spilled toner. CAUTION The transfer charger must be in the down position to avoid scratching the drum. 9. Check that the transfer charger is in the down position. Move it to the down position by rotating the transfer elevator drive shaft counterclockwise. Watch the charger movement: a. If the charger starts to move up, it is already in the down position. b.
Replacing The Photoreceptor Drum 10. Lower the transport unit by turning the green lever on the transport unit to the left. 1 Legend: 1) Green Lever 11. Loosen the three thumbscrews securing the drum plate and remove the drum plate.
Chapter 3 Consumables Replacement 12. Remove the two screws on the lower inner cover. Then remove the cover.
Replacing The Photoreceptor Drum 13. Remove the nut from the end of the drum shaft. 1 Legend: 1) Nut 14. Screw the drum auxiliary rod onto the drum shaft.
Chapter 3 Consumables Replacement 15. Carefully pull the old drum out along the drum auxiliary rod. Hold the ends when the drum is nearly out of the printer, and remove it with both hands. 1 Legend: 1) Drum 16. Pack the old drum for shipment using the original packaging material, and close the cover of the box. 17. Wipe the drum shaft clean with a cloth. CAUTION Avoid touching the surface of the drum with your hands; it reduces the life of the drum. 18.
Replacing The Photoreceptor Drum CAUTION Exposing the drum to light shortens its life. Do not expose the drum to direct sunlight, and install it within five minutes under typical room lighting conditions. When removing the drum from its packaging, do not touch the surface of the drum, because fingerprints and scratches can damage the surface and cause poor print quality. 19. Using both hands, carefully slide the drum onto the drum auxiliary rod.
Chapter 3 Consumables Replacement 23. Install the lower inner cover and secure with the two screws removed earlier. 24. Install the drum plate and tighten the thumbscrews. While installing the drum plate, place your thumb over the copper grounding clip and hold it in place. Otherwise the grounding clip can be bent, making no contact with the drum shaft. 25. After installing the drum plate, visually verify good electrical contact between the copper grounding clip and the end of the drum shaft.
Replacing The Developer Replacing The Developer 11 1 10 Cross Section of Developing Unit 2 9 8 3 4 5 7 4 6 Legend: 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) Toner Cartridge Toner Hopper Auger Toner Sensor Agitation Roller Developing Tank Developing Roller Toner Supply Roller Screws (3) Cover Developing Unit 69
Chapter 3 Consumables Replacement Developing Unit Removal 1. Turn the power switch OFF. 2. Open the printer front upper cover. (See page 52) 3. Prepare a plastic bag over which the developing unit can be placed. 4. Remove the developing unit from the printer (See page 73.) and place it on the plastic bag. IMPORTANT When replacing developer in an existing developing unit, you must empty and clean the unit before adding new developer (every 150,000 pages). Removing Old Developer 5.
Removing Old Developer 6. Remove the three screws on the developing unit cover and detach the cover. CAUTION The toner sensor is sensitive to both electrostatic discharge (ESD) and positional adjustment. Do not touch the sensor with your hand or jar it from its factory-set position. 7. Put the developing unit in the plastic bag and do the following: a.
Chapter 3 Consumables Replacement Adding New Developer 11. Shake the new developer bottle several times, remove the bottle cap, and screw the nozzle tightly onto the bottle. 12. While rotating the developing roller knob counterclockwise, evenly pour the entire bottle of developer powder into the developing unit. 1 2 Legend: 1) 2) Bottle of new Developer Developing Roller Knob 13. Replace the cover and tighten the screws.
Replacing The Developing Unit Replacing The Developing Unit CAUTION The developing unit should be removed only by an individual who has received the appropriate training. Be careful not to damage the sensors while cleaning the developing unit. (If damage occurs, contact your service representative.) Developing Unit Removal 1. Turn the power switch OFF. 2. Open the printer front upper cover. (See page 52.) 3. Open the waste toner recovery unit by pushing downward on the lever.
Chapter 3 Consumables Replacement 6. Remove the developing unit by holding the lever in one hand and pulling the developing unit partially out of the printer. 7. With your other hand, grasp the hanger and remove the developing unit from the printer.
Developing Unit Installation 8. Place the old developing unit in a plastic bag and dispose of it properly. 9. Vacuum any spilled toner. 10. Remove a new developing unit from its package, and add developer to the unit. Developing Unit Installation CAUTION Failure to perform step 11 will damage the photoreceptor drum. 11. On the developing unit, rotate the lever fully clockwise so that it is pointing straight up. (See page 75.) 12.
Chapter 3 Consumables Replacement 14. Rotate the developing roller knob counterclockwise until the unit drops into its final resting position. The positioning pin should protrude through the main body of the developing unit. 1 2 3 Legend: 1) 2) 3) Positioning Pin Lever Developer Roller Knob 15. Rotate the developing unit lever fully counterclockwise to lock the developing unit in place. 16. Install the upper inner cover, and secure it with the three thumbscrews. (See page 60.) 17.
4 Scheduled Maintenance Maintaining Print Quality To maintain good print quality, clean the printer according to the schedules and procedures listed in this chapter. If print quality problems occur, clean the following areas (see Maintenance Tools on page 78 for tool part numbers): 1. Do a General Cleaning. (See page 95.) NOTE: Recommended toner vacuum cleaner models are listed on page 78. 2. Clean the main charger, precharger, and transfer charger.
Chapter 4 Maintenance Tools If the print quality is still poor after cleaning the printer, the chargers may need to be replaced. Contact your authorized service representative for further assistance. NOTE: For replacement intervals, see the maintenance schedules that begin on page 81. For replacement procedures, see Chapter 3, “Consumables Replacement.
Service Level Page Counts Service Level Page Counts IMPORTANT You should maintain a record of all maintenance performed on your printer. Maintenance log sheets are provided starting on page 81. These may be photocopied and kept in a binder near the printer. Be sure to use them each time either you or your service provider perform printer maintenance.
Chapter 4 Maintenance Tools A service level includes the levels that precede it. For example, at 150,000 pages, you should perform Level B and Level A service. At 900,000 pages, your service provider should perform Level F, Level E, and Level D service. Note that this condition will not cause the printer to stop printing. When one of the above messages appears, you should perform the appropriate scheduled maintenance or call your factory-trained service representative to perform the maintenance.
User Cleaning Schedule Maintenance Schedules User Cleaning Schedule Each time you perform maintenance, you must reset the service level page count by selecting the User Maintenance option on the Maintenance menu. This removes the maintenance error message. The Maintenance menu is detailed in the User’s Manual. The following actions should be performed after the specified number of letter size pages (4% coverage) have been printed.
Chapter 4 Maintenance Schedules Level A Maintenance - 15,000 Pages (User) Action Item Part # Clean General cleaning n/a Clean Main charger 705741-001 Clean Precharger 705742-001 Clean Transfer charger 705743-001 Clean Cover glass n/a Clean See Note 1 Cut sheet cassette pickup rollers 703531-050 Clean See Note 2 Cut sheet cassette reverse rollers 703531-051 Replace See Note 3 Toner Cartridge 703532-001 Performed By Date Note 1: Every 15,000 pages or 6 page jams, whichever occur
User Cleaning Schedule Level B Maintenance - 150,000 Pages(User) Action Item Part # Clean General cleaning n/a Clean Main charger 705741-001 Clean Precharger 705742-001 Clean Transfer charger 705743-001 Clean See Note1 Cover glass n/a Clean SELFOC lens n/a Vacuum Lamp housing filter 202838-001 Vacuum Cleaning unit 705740-001 See Note 2 Photoreceptor drum 703535-001 Replace See Note 3 Toner cartridge 703532-001 Replace Developer 703548-001 Replace Waste toner bottle 703
Chapter 4 Maintenance Schedules Level C Maintenance - 600,000 Pages (User) Action Item Part # Clean General cleaning n/a Clean See Note 1 Cover glass n/a Clean SELFOC lens n/a See Note 2 Photoreceptor drum 703535-001 Replace Developing unit 703533-001 Replace See Note 3 Toner cartridge 705739-001 Replace Waste toner bottle 703539-001 Replace See Note 4 Cut sheet cassette pickup rollers 703531-050 Replace See Note 4 Cut sheet cassette reverse rollers 703531-051 Performed By D
User Cleaning Schedule Level D Maintenance - 300,000 Pages (Service) Action Item Part # Clean Flash power supply filter n/a Replace Main charger 705741-001 Replace Precharger 705742-001 Replace Transfer charger 705743-001 Replace Smoke filter 703540-001 Performed By Date 85
Chapter 4 Maintenance Schedules Level E Maintenance - 600,000 Pages (Service) Action Item Part # Clean Lamp housing filter 202838-001 Clean LED air filter 703543-001 Clean Flash power supply filter n/a Replace Main charger 705741-001 Replace Precharger 705742-001 Replace Transfer charger 705743-001 Replace See Note 1 Cleaning unit 705740-001 Replace Smoke filter 703540-001 Replace Transporting belt-3 703531-035 Performed By Date Note 1: When the cleaning unit has been vacuu
User Cleaning Schedule Level F Maintenance - 900,000 Pages (Service) Action Item Part # Clean Flash power supply filter n/a Replace Main charger 705741-001 Replace Precharger 705742-001 Replace Transfer charger 705743-001 Replace Smoke filter 703540-001 Replace Xenon lamp 703541-001 Performed By Date 87
Chapter 4 Maintenance Schedules Level G Maintenance - 1,200,000 Pages (Service) Action Item Part # Clean Lamp housing filter 202838-001 Clean LED air filter 703543-001 Clean Flash power supply filter n/a Replace Main charger 705741-001 Replace Precharger 705742-001 Replace Transfer charger 705743-001 Replace See Note 1 Cleaning unit 705740-001 Replace Smoke filter 703540-001 Replace Transporting belt-3 703531-035 Performed By Date Note 1: When the cleaning unit has been vac
User Cleaning Schedule Level H Maintenance - 2,400,000 Pages (Service) Action Item Part # Clean Flash power supply filter n/a Replace Main Charger 705741-001 Replace Precharger 705742-001 Replace Transfer charger 705743-001 Replace See Note 1 Cleaning unit 705740-001 Replace Smoke filter 703540-001 Replace Transporting belt-3 703531-035 Replace Lamp housing filter 202838-001 Replace LED air filter 703543-001 Replace Tractor belt 3M264 703531-031 Replace Drum belt 3M264 70
Chapter 4 WARNING Maintenance Schedules The flash fuser capacitor (P/N 703531-561) must be replaced at least every 2,400,000 letter size pages. Failure to do so may endanger equipment and personnel. WARNUNG Der kondensator der Flash-Einbrennvorrichtung muß nach mindestens 2.400.000 Seiten im Format “Letter” ausgetauscht werden. Geschieht dies nicht, ist mit Personen- und Sachschäden zu rechnen. AVISO El condensador flash del fusor se debe sustituir como mínimo cada 2.400.000 páginas de tamaño carta.
User Cleaning Schedule User Replacement Schedule The following items should be replaced after the specified number of letter size pages (4% coverage) have been printed.
Chapter 4 Maintenance Schedules Tech Service Replacement Schedule Each time a service technician completes a level of preventive maintenance, he or she must reset the service level page count by selecting the Technician Service option on the Maintenance menu. This removes the maintenance error message. The following actions should be performed by a service technician after the specified number of letter size pages (4% coverage) have been printed.
User Cleaning Schedule LED air filter 703543-001 2,400,000 Replace H Tractor belt, 3M264 793531-031 2,400,000 Replace H Drum belt, 3M264 703531-031 2,400,000 Replace H Capacitor (see WARNING on next page) 703542-001 2,400,000 Replace H LED for discharge lamp 703531-118 2,400,000 Replace H Feed Roller 703531-563 2,400,000 See Note 2 Clean and inspect: replace if worn, H Resist Roller 703531-565 2,400,000 See Note 2 Clean and inspect; replace if worn.
Chapter 4 WARNING Maintenance Schedules The flash fuser capacitor (P/N 703531-561) must be replaced at least every 2,400,000 letter size pages. Failure to do so may endanger equipment and personnel. WARNUNG Der kondensator der Flash-Einbrennvorrichtung muß nach mindestens 2.400.000 Seiten im Format “Letter” ausgetauscht werden. Geschieht dies nicht, ist mit Personen- und Sachschäden zu rechnen. AVISO El condensador flash del fusor se debe sustituir como mínimo cada 2.400.000 páginas de tamaño carta.
Vacuuming The Printer General Cleaning To maintain optimum print quality, the printer should be cleaned on a regular basis. Depending upon the density of your print jobs, the printer may require cleaning every 10,000-20,000 sheets.
Chapter 4 General Cleaning Following is the general cleaning procedure: 1. Turn the power switch OFF. 2. Open the printer front upper cover. 3. Using a vacuum, clean the toner, paper dust, etc. inside the front cover.
Vacuuming The Printer 4. On the waste toner recovery unit, press the Open lever down. Pull the handle toward you and open the unit. 5. Vacuum the developing unit and toner hopper.
Chapter 4 General Cleaning 6. Vacuum the cleaning unit. 7. Vacuum the fuser unit.
Vacuuming The Printer 8. Vacuum the lamp housing filter on the underside of the fuser unit.
Chapter 4 CAUTION General Cleaning The transfer charger must be in the down position to avoid scratching the drum. Failure to perform steps 9 and 10 will damage the drum. 9. Check that the transfer charger is in the down position, and if not, move it to the down position by rotating the transfer elevator drive shaft counterclockwise. Watch the charger movement: a. If the charger starts to move up, it is already in the down position. b.
Vacuuming The Printer 10. Lower the transport surface by turning on the green lever on the transport unit to the left. 1 2 Legend: 1) 2) Transport Unit Green Lever 11. Pull the transport unit toward you until it stops. 12. Using a vacuum, clean the toner, paper dust, etc. Be sure to clean under the transport unit as well. 13. Wipe off the dirt on the transport surface with wet tissue paper. 14.
Chapter 4 General Cleaning 16. Using a vacuum, clean the toner, paper dust, etc. in the tractor area. 17. Open the paper guide by pressing the green lever down.
Vacuuming The Printer 18. Using a vacuum, clean the paper dust, etc. inside the paper guide. 19. Open the lid on the top cover. 20. Open the paper guide by pressing the guide lever down. 21. Using a vacuum, clean the paper dust, etc. inside the paper guide.
Chapter 4 General Cleaning Cleaning The Chargers 1. Turn the power switch OFF. 2. Open the printer front upper cover. Main Charger CAUTION Use caution in handling to avoid damaging or breaking the charger wires. 3. Loosen the thumbscrew and remove the main charger by pulling it toward you. 2 1 Legend: 1) 2) Main Charger Thumbscrew 4. Place the main charger on a flat, clean work surface.
Main Charger 5. Using the brush cleaner (listed on page 78), clean the exposed side of the charger grid and the body of the main charger.
Chapter 4 General Cleaning 6. Position the main charger with the charger grid up and the front of the charger toward you, as shown in the figure below. Refer to the inset drawing in the figure and remove the charger grid from the main charger as follows: a. While pressing the front retaining tab toward the rear of the charger, unhook the rear end of the charger grid from the rear retaining tab. b. Release the front retaining tab, then remove the charger grid from it.
Main Charger 7. Using the brush cleaner (listed on page 78), clean both sides of the charger grid, as shown below. 1 2 Legend: 1) 2) Brush Cleaner Charger Grid 8. Using the wire cleaner (listed on page 78), clean the two wires in the main charger, as shown below. Be sure that both wires are cleaned thoroughly. When dirt is caked on, the wires feel gritty. When clean, the wires feel smooth.
Chapter 4 General Cleaning 9. Install the charger grid. 10. Return the main charger to its original position. Fasten the main charger screw to secure it. Precharger and Transfer/Separator Charger CAUTION Use caution in handling to avoid damaging or breaking the charger wires. 11. Open the waste toner recovery unit.
Precharger and Transfer/Separator Charger 12. Loosen the precharger thumbscrew, and transfer/separator charger thumbscrew, and pull the chargers out of the printer. 3 2 2 1 Legend: 1) 2) 3) Transfer/Separator Charger Thumbscrews Precharger 13. Place the chargers on a flat, clean work surface. 14. Using the brush cleaner and the wire cleaner (listed on page 78), remove the dust and dirt on the wires. When dirt is caked on, the wires feel gritty. When clean, the wires feel smooth. 15.
Chapter 4 General Cleaning Cleaning The Fuser Unit Cover Glass WARNING The fuser unit remains hot after operation. Wait until it has completely cooled down before handling it. WARNUNG Die Einbrennvorrichtung behält auch nach dem Betrieb ihre Temperatur bei. Fassen Sie sie erst an, wenn sie vollständig abgekuhlt ist. AVISO La unidad de fusor estará a alta temperatura después de funcionar. Espere a que se haya en friado por completo antes de manipularia.
Cleaning The Fuser Unit Cover Glass CAUTION The transfer charger must be in the down position to avoid scratching the drum. Failure to perform steps 3 and 4 will damage the drum. 3. Check that the transfer charger is in the down position, and if not, move it to the down position by rotating the transfer elevator drive shaft counterclockwise. Watch the charger movement: a. If the charger starts to move up, it is already in the down position. b.
Chapter 4 General Cleaning 4. Lower the transport surface by turning on the green lever on the transport unit to the left. 3 4 5 2 1 Legend: 1) 2) 3) 4) 5) Green Lever Fuser Unit Thumbscrew (not visible in figure) Holding Plate Thumbscrew 5. Loosen the thumbscrews on the right and left fuser unit holding plates. 6. Grasp the handle and pull out the fuser unit until the second handle is visible. 7. With the other hand, grasp the second handle and remove the fuser from the printer. 8.
Cleaning The Fuser Unit Cover Glass 9. Using the fuser cover glass scraper (listed on page 78) remove the dirt and toner buildup from the cover glass surface. 1 Legend: 1) Scraper 10. Wipe away any remaining toner or dirt with a Toraysee cloth (listed on page 78).
Chapter 4 General Cleaning 11. Remove the two screws that secure the lamp duct filter unit to the fuser, then remove the lamp duct filter unit and the foam gasket. 1 2 3 4 5 Legend: 1) 2) 3) 4) 5) Foam Gasket Screw (4) Filter Holding Plate Lamp Filter (Air Filter) Lamp Duct 12. Remove the two screws that secure the filter holding plate to the lamp duct filter unit, then remove the lamp filter. 13. Vacuum the lamp filter, then install it. 14. Vacuum any paper dust from the printer frame. 15.
Cleaning The Cut Sheet Option Rollers Cleaning The Cut Sheet Option Rollers NOTE: This procedure only applies to printers with the cut sheet option installed. 1. Turn the power switch OFF. 2. Remove the upper and lower paper cassettes from the printer.
Chapter 4 General Cleaning 3. There are two pickup roller units (upper and lower) located at the back of the cassette opening. On the upper roller unit, loosen the green thumbscrew. Slide the unit to the left, and pull the unit toward you and out of the printer. 1 Legend: 1) Thumbscrew 4. On the lower roller unit, loosen the green thumb screw. Slide the unit to the left, and pull the unit toward you and out of the printer. 5.
Pickup Rollers 6. Install the upper and lower pickup roller units: a. Align the shaft pin with the slot in the coupling, and align the alignment pin on the unit with the hole in the frame. b. Tighten the green thumbscrew.
Chapter 4 General Cleaning Reverse Rollers 1 2 Legend: 1) 2) Upper Reverse Roller Unit Lower Reverse Roller Unit 7. There are two reverse roller units (upper and lower) located at the back of the cassette opening (underneath the upper and lower pickup roller units). On the upper reverse roller unit, loosen the green thumbscrew. Remove the roller unit by moving it downward while sliding it to the left.
Reverse Rollers 8. On the lower reverse roller unit, loosen the green thumbscrew. Remove the roller unit by moving it downward while sliding it to the left. 9. Wipe off the dirt on the reverse rollers with a Toraysee cloth (listed on page 78). Remove any label adhesive or forms residue with rubbing alcohol.
Chapter 4 General Cleaning 10. Install the upper and lower reverse roller units: a. Align the shaft pin with the slot in the coupling, and align the alignment pin on the unit with the hole in the frame. b. Tighten the green thumbscrew. 2 1 4 3 Legend: 1) 2) 3) 4) Coupling Hole In The Frame Shaft Pin Alignment Pin 11. Install the upper and lower paper cassettes into the printer.
Cleaning Unit Major Cleaning 1. Turn the power switch OFF. 2. Open the printer front upper cover. (See page 52.) Cleaning Unit 3. Open the waste toner recovery unit by pushing downward on the lever. Pull the green handle and swing the unit outward away from the printer. (See page 60.) 4. Loosen the three thumbscrews on the upper inner cover. Then remove the cover. (See page 60.) 5. Loosen the three thumbscrews securing the drum plate and remove the drum plate. 6.
Chapter 4 IMPORTANT Major Cleaning Do not turn the cleaning unit upside down, or toner might spill. 7. Vacuum the brush on the cleaning unit. Turn the end of the shaft to rotate the brush. Continue to rotate and vacuum the brush until the entire brush surface has been cleaned. IMPORTANT Do not touch the brush surface with your hand.
Discharge LED Discharge LED CAUTION Do not flex the discharge LED as it will break. 8. Remove the discharge LED screw. 9. Remove the discharge LED by pulling it toward you. 1 2 Legend: 1) 2) Discharge LED Screw 10. Using a Toraysee cloth (listed on page 78), wipe off the dirt on the discharge LED. 1 Legend: 1) Discharge LED 11. Return the discharge LED to its original position.
Chapter 4 Major Cleaning Photoreceptor Drum CAUTION When cleaning the photoreceptor drum, observe the following precautions: • • Do not touch the drum surface with your hands. • Cleaning the drum may result in stains. A drum left unused in the printer for a long time after cleaning may especially be affected. Therefore, after cleaning and installing the drum in the printer, use maximum size paper to print an image repeatedly until no stains remain.
Photoreceptor Drum 15. If the drum has toner build-up, clean it with the drum freshener pad (listed on page 78). Turn the drum little by little while polishing the drum surface with the freshener pad. Polish with a slight force in the direction of the drum axis, using a circular motion. Let the polished areas slightly overlap each other, and polish the entire drum surface two or three times. CAUTION Press lightly when polishing the drum surface, as too much pressure can damage the drum. 16.
Chapter 4 Major Cleaning Cleaning The Developing Area 21. Loosen the thumbscrew and remove the main charger by pulling it toward you. 2 1 Legend: 1) 2) Thumbscrew Main Charger 22. Clean the developing unit area with a vacuum cleaner and a soft cloth.
Cleaning The Developing Area 23. Wipe the SELFOC® lens by moving a Toraysee cloth (listed on page 78) from the inner part of the printer toward you. Wipe the lens several times until there is no more dirt on the cloth. CAUTION When wiping the SELFOC lens, be certain not to apply excessive force to the drum surface potential sensor near the SELFOC lens, as this may dislocate the sensor. (If this happens, contact your service representative.
Chapter 4 128 Major Cleaning
5 Troubleshooting Troubleshooting This chapter discusses diagnostic tests, paper jams, and status and error messages. For cleaning procedures and schedules, refer to Chapter 4, “Scheduled Maintenance." Diagnostics The printer includes self-diagnostic circuits and software to aid in the discovery, prevention, and correction of system problems and failures.
Chapter 5 Fanfold Paper Jams • Test Print: Prints various predefined graphics pages to verify that the printer can print properly on the entire page (Test Print menu). • Print Statistics: Displays all accumulated print engine statistics, such as number of pages printed and power-on time. This is a display-only feature; there is no printout (Print Statistics menu). • Print Configuration: Prints all current configuration parameters in the printer, including print statistics (Config. Control menu).
Paper Jam Near The Tractor 3. Reload the paper. The first fold of the paper should face the printer; otherwise, a paper jam could occur during printing (see illustration). Do not push the paper past the tractors into the area of the paper jam sensor. 1 2 3 Legend: 1) 2) 3) Left Tractor Right Tractor First paper fold is toward printer.
Chapter 5 Fanfold Paper Jams Paper Jam Near The Paper Output Section 1. When paper motion stops, wait 15 seconds, then open the front cover. 2. Push down on the opening lever of the waste toner recovery unit, and pull the green handle to swing the unit outward away.
Paper Jam Near The Paper Output Section 3. Loosen three thumbscrews on the upper inner cover.
Chapter 5 CAUTION Fanfold Paper Jams The transfer charger must be in the down position to avoid scratching the drum. Failure to perform steps 4 and 5 will damage the drum. 4. Check that the transfer charger is in the down position, and if not, move it to the down position by rotating the transfer elevator drive shaft counterclockwise. Watch the charger movement: a. If the charger starts to move up, it is already in the down position. b.
Paper Jam Near The Paper Output Section CAUTION To avoid damaging the printer or causing false paper jams, the transport lever must be in the fully down position before opening the transport unit. 5. Lower the transport unit by turning the green lever on the transport unit to the left. 1 Legend: 1) Green Lever 6. Check to see if any paper is jammed.
Chapter 5 Fanfold Paper Jams 7. To raise the scuff roller holding the paper, turn knob C clockwise 90° as shown below. 1 Legend: 1) Knob C 8. Separate the fanfold paper at the perforations on both the paper input and the output sections. Then remove the jammed paper by pulling it out. When removing the paper from the paper input section, raise the tractor gates first, then pull out the jammed paper.
Paper Jam Near The Paper Output Section Input Section 1 Output Section Legend: 1) CAUTION Tractor Gate To avoid damaging the printer or causing false paper jams, the transport lever must be in the fully down position before closing the transport unit. 9. After removing the pieces of jammed paper, restore the transport unit, waste toner recovery unit, and knob C to their original positions, and close the upper doors. 10. Reload the paper.
Chapter 5 Cut Sheet Paper Jams Cut Sheet Paper Jams CAUTION Due to the high intensity of the flash fusing unit, the area under the fuser must be kept free of paper debris. Paper Jam At The Back Of The Paper Cassette 1. Pull out the paper cassette, then remove any jammed paper from the back of the cassette tray. 2. To lower the paper guide, pull the green lever up. Remove any jammed paper, and return the green lever to its original position.
Paper Jam At The Back Of The Paper Cassette 3. Open the lid on the top cover, and pull the green lever up. Remove any jammed paper, and return the green lever to its original position.
Chapter 5 Cut Sheet Paper Jams Paper Jam In The Transport Input Section 1. When paper motion stops, wait 15 seconds, then open the front cover. 2. Open the waste toner recovery unit cover, and pull the unit toward you.
Paper Jam In The Transport Input Section CAUTION The transfer charger must be in the down position to avoid scratching the drum. Failure to perform steps 3 and 4 will damage the drum. 3. Check that the transfer charger is in the down position, and if not, move it to the down position by rotating the transfer elevator drive shaft counterclockwise. Watch the charger movement: a. If the charger starts to move up, it is already in the down position. b.
Chapter 5 CAUTION Cut Sheet Paper Jams To avoid damaging the printer or causing false paper jams, the transport lever must be in the fully down position before opening or closing the transport unit. 4. To lower the transport route surface, turn the green transport unit lever to the left.
Paper Jam In The Transport Input Section 5. Remove knob A from its place as shown below. Attach knob A to the paper feed shaft, and turn knob A counterclockwise. This causes the jammed paper to be moved to the eject side. Remove any jammed paper, and return knob A to its original position. 1 2 Legend: 1) 2) Original Position of Knob A Knob A 6. Restore the transport unit and the waste toner recovery unit to their original positions, and close the front cover.
Chapter 5 Cut Sheet Paper Jams Paper Jam In The Transport Output Section 1. When paper motion stops, wait 15 seconds, then open the front cover. 2. Pull up the bottom lever to raise the paper guide, and turn the green knob B counterclockwise. This causes the jammed paper to be moved to the paper feed section. Remove any jammed paper. 2 1 Legend: 1) 2) Bottom Lever (#1) Knob B 3. Lower the paper guide by restoring the bottom lever to its original position. Close the front cover.
Paper Jam In The Face Up Or Down Paper Path Paper Jam In The Face Up Or Down Paper Path 1. When paper motion stops, wait 15 seconds, then open the front cover. 2. Push the top and middle levers down. Pull the bottom lever up to raise the paper guide. Turn the green knob C clockwise, and remove any jammed paper. 1 4 2 3 Legend: 1) 2) 3) 4) Top Lever (#3) Knob C Bottom Lever (#1) Middle Lever (#2) 3. Restore the top, middle, and bottom levers to their original positions, and close the front cover.
Chapter 5 System Status and Error Messages System Status and Error Messages When an error occurs, the printer displays an appropriate message on the control panel LCD. Some errors are operator-correctable, some require field service, and others require reprinting. Operator-correctable errors include paper jams, missing consumables, and power paper stacker problems. After correcting the error condition, press CLEAR to remove the message from the display and place the printer offline.
Reprinting Pages After Fault Condition Fanfold paper: the printer reprints all pages that have not completely exited the printer at the time of failure. The exact number of pages that are reprinted is determined by the length of the page and where within the page the fault occurred. Cut sheet paper: the printer determines how many pages did not exit the printer, and reprints all pages that did not exit.
Chapter 5 System Status and Error Messages a. The printer beeps and briefly displays the following message: Faults Not Cleared b. The printer then redisplays the original fault message, or any other uncleared fault message. c. • Attempt to clear the fault condition again, or contact your service representative. If the fault is cleared, and if you do not need to reload the paper into the tractors (for example, the printer ran out of toner): a. The printer goes OFFLINE. b.
Reprinting Pages After Fault Condition 5. Press ONLINE to resume printing. Note that pages have been lost. IMPORTANT If Reprint on Fault is disabled and an error occurs, and if either the “Reload Paper in Tractors” or “Not Reprinting Failed Pages” message appears, then any pages removed from the printer will not be reprinted, and the data on them will be lost. Procedure For Fault Clearing - Reprint On Fault Enabled 1. A fault occurs. 2. Correct the fault condition. 3. Press CLEAR. 4.
Chapter 5 System Status and Error Messages • If the fault is cleared, and if you need to reload paper into the tractors (such as after a paper jam), the following message appears: Clear Paper Path for Reprint a. Reload the paper onto the tractors. b. Press CLEAR. The printer reprints only the pages affected by the fault (even though the message display reads “OFFLINE”). c. • Press ONLINE to resume printing.
Error Messages Error Messages “Error Messages,” on page 152, lists errors by error code and shows which are operator-correctable, which require field service, and which require reprinting. • Operator-correctable errors include paper jams, missing consumables, and power paper stacker problems. • Errors requiring field service are printer failures that require the attention of service personnel. • Errors requiring reprinting are those errors which require reprinting to recover from an error condition.
Chapter 5 System Status and Error Messages Table 1. Error Messages.
Error Messages Field Service Required Error Code Error Message Operator Correctable 68 PAPER JAM AT ENTRANCE (A) á á 69 PAPER JAM AT ENTRANCE (A) á á 6A PAPER JAM AT ENTRANCE (A) á á 6B PAPER JAM AT ENTRANCE (A) á á 73 PAPER JAM AT ENTRANCE (A) á á 09 TRANSPORT MOTOR FAIL á á 14 TRACTOR MTR FWD SPEED ERR á á 15 TRACTOR MTR BKWD SPEED ERR á á 0A CUTTER FAIL á 0B CUTTER FAIL á 18 DRUM MOTOR FAIL á 19 SURFACE VOLTAGE TOO HIGH á 1A SURFACE VOLTAGE TOO HIGH á 1
Chapter 5 Error Code 154 System Status and Error Messages Error Message Operator Correctable Field Service Required á 29 NO WASTE TONER BOX 2A TONER LOW 2B TONER DENSITY TOO HIGH á 2C TONER DENSITY TOO LOW á 2D TONER EMPTY 2E DEVELOPER MOTOR FAIL 32 LED HEAD OVERHEAT á 36 LED FAIL á 37 LED FAIL á 38 ENGINE CPU FAIL á 39 ENGINE CPU FAIL á 3A ENGINE CPU FAIL á 3B ENGINE CPU FAIL á 3C ENGINE CPU FAIL á 3D ENGINE CPU FAIL á 3E ENGINE CPU FAIL á 3F ENGINE CPU
Error Messages Error Code Error Message Operator Correctable Field Service Required Reprint Required 47 ENGINE CPU FAIL á 72 ENGINE CPU FAIL á 48 CONTROLLER COMM. FAIL á 49 CONTROLLER COMM. FAIL á 4A CONTROLLER COMM. FAIL á 4B CONTROLLER COMM. FAIL á 4C CONTROLLER COMM. FAIL á 4D CONTROLLER COMM. FAIL á 4E CONTROLLER COMM.
Chapter 5 Error Code System Status and Error Messages Error Message Field Service Required Reprint Required á 07 SCUFF LEVER OPEN 78 MAIN CHARGER ERROR á á 79 TRANSFER CHARGER ERROR á á 7A PRE-CHARGER ERROR á á 7B CLEANING BIAS ERROR á á 7C DEVELOPING BIAS ERROR á á 7D SEPARATOR CHARGER ERROR á á TRAY MISMATCH 156 Operator Correctable á 5D STACKER FAIL á 5E STACKER FAIL á 5F STACKER FAIL á FILE SYS FULL DELETE FILES á á FILE SYS FULL OPTIMIZE&REBOOT á á FI
Error Messages Error Code Error Message Operator Correctable Field Service Required Reprint Required RELOAD PAPER PIN TRACTORS á á CLEAR PAPER PATH FOR REPRINT á á FRAMING ERROR á á PARITY ERROR á á BUFFER OVERRUN á á BUFFER OVERFLOW á á TABLE NOTES: 1. For any error with Reprint on Fault enabled: If the printer stops while in the middle of printing a page, reloading the paper and reprinting are required.
Chapter 5 158 System Status and Error Messages
A Maintenance Log Sheets Maintenance Log Sheets The maintenance log sheets are for your use. These may be photocopied and kept in a binder near the printer. Be sure to use them each time either you or your service provider perform printer maintenance. Only maintenance levels A through C are presented in this Operator’s Guide. These three levels are done by the user. Levels D through H are done by a service representative and are included in the User’s Manual.
Appendix A Maintenance Log Sheets Level A Maintenance - 15,000 Pages (User) Action Item Part # Clean General cleaning N/A Clean Main charger 705741-001 Clean Precharger 705742-001 Clean Transfer charger 705743-001 Clean See Note 1 Cover glass N/A Replace See Note 2 Toner cartridge 703532-050 Performed By Date Note 1: Every 15,000 pages or 6 paper jams, whichever occurs first.
Level B Maintenance - 150,000 Pages (User) Action Item Part # Clean General cleaning N/A Clean Main charger 705741-001 Clean Precharger 705742-001 Clean Transfer charger 705743-001 Clean See Note 1 Cover glass N/A Clean SELFOC lens N/A Vacuum Lamp housing filter 202985-001 Vacuum Cleaning unit 705740-001 See Note 2 Photoreceptor drum 703535-001 Replace See Note 3 Toner cartridge 703532-001 Replace Developer 703548-001 Replace See Note 4 Waste toner bottle 202984-001 Pe
Appendix A Maintenance Log Sheets Level C Maintenance - 600,000 Pages (User) Action Item Part # Clean General cleaning N/A Clean See Note 1 Cover glass N/A Clean SELFOC lens N/A Clean Flash power supply filter N/A See Note 2 Photoreceptor drum 703535-001 Replace Developing Unit 705739-001 Replace See Note 3 Toner cartridge 703532-001 Replace Waste toner bottle 202984-001 Performed By Date Note 1: Every 15,000 pages or 6 paper jams, whichever occurs first.
B Specifications Paper Specifications Paper type Fanfold Paper size Width 7 to 16 inches Length* 1 to 30 inches, in multiples of 1/6 inch. * Measured from main folding/cutting perforation to main folding/cutting perforation. Tractor pin holes See the table and figure below.
Appendix B 164 Paper Specifications Dimension in Figure Specification Inch Millimeter Pin hole center to folding perforation 1/6, 1/4, 1/ 3, or 1/2 4.23, 6.35, 8.47, 1.20 8 Hole center line to edge of form 0.236 ± 0.028 6.0 ±0.1 1 Hole diameter 0.156 ± 0.004 4.0 ±0.1 N/A Distance between centers of two consecutive holes 0.500 ± 0.002 12.7 ±0.05 5 Max. deviation of holes from their center line 0.004 0.1 6 Max.
1 1 2 9 3 4 8 7 6 5 6 Legend: 1) 2) 3) 4) 5) 6) 7) 8) 9) Hole centerline to edge of form Center Line Main Folding/Cutting Perforation Centerline to Centerline Distance between centers of two consecutive holes Center Line Deviation Tractor Pin Hole Pin hole to perforation Fanfold Paper 165
Appendix B Performance Characteristics Paper thickness .010 inch maximum Paper weight 18 to 44 lb. bond (68-165g/m2), 44-125 lb. tag/label (75-204g/m2) Paper feed Automatic paper parking mechanism incorporated Maximum paper stack size 3000 sheets (18 lb.) Folder Perforation Cut 0.12 inches or 3mm minimum Cut to Tie 3:1 minimum Performance Characteristics Printing density 300 x 300 dpi 400 x 400 dpi or 240 x 240 dpi (options) Printing speed 2.78 inches per second.
Host Interfaces Duty cycle 200,000 total pages/month of fanfold paper (11-in. length) Mechanical life 5 years or 12,000,000 pages (11-inch length) Warm-up time 60 sec. max. First page printing time 25 sec. max. MTBF/MPBF 8,000 hours/2,880,000 pages (letter size) 25% print to power on ratio MTTR 2 hour max. (unit exchange Host Interfaces Standard Centronics parallel, Dataproducts parallel, serial RS-232/422 NOTE: Dataproducts parallel interface requires an adapter cable.
Appendix B Memory Requirements Emulations Standard LinePrinter Plus Optional PCL5/LP+ PCL5/PGL PCL5/VGL IGP/VGL IGP/PGL IPDS CTHI (if installed) Memory Requirements The L5000 series printers have 32 MB (standard) or 64 MB (optional) of RAM (Random Access Memory), and 8 MB (standard) or 16, 32, or 64 (optional) of Flash Memory. This is standard with all new printer shipments, and all upgraded printers.
Electromagnetic Interference Physical Characteristics and Environment Dimensions (H x W x D) 49 inch H x 30 inch W x 34 inch D In crate: 36 inches H x 58 inches W x 61 inches D Weight 353 lbs. (or 441 lbs.) with options Input voltage range 200 - 240 V +10% 50/60 Hz (47 - 62 Hz) single phase Power consumption 3300 W (operating); wall outlet must be on a 30amp breaker.
Appendix B Physical Characteristics and Environment o Temperature (5F) 80 71 Maximum Temperature/ Humidity Limits 50 30 70 80 Sound level 170 Operating 60 db (A-weighted ) max. Full options Standby state 50 dB (A-weighted) Inclination 1° max.
Index A CLEAR function key, 48 AUTO Clearing faults procedure function key, 41 with Reprint on Fault disabled, 147 B Buttons See Function keys, 45 C CANCEL function key, 49 Cassette paper jams at back of, 138 Cassette paper size changing, 34 Caution notice, 17 with Reprint on Fault enabled, 149 Clearing service level messages, 80 Control panel using, 45 Cover glass fuser unit cleaning, 110 Custom tray width, 36 Cut sheet paper loading, 31 Cut sheet paper jams, 138 Cut sheet tray linking, 35 D Chan
Index F Diagrams paper path, 45 Face up or down paper path Discharge LED paper jams in, 145 cleaning, 123 Fanfold paper Disk drives loading, 28 location, 38 Fanfold paper jams, 130 Disposal photoreceptor drum, 68 FAULT status lamp, 46 DOWN function key, 41, 50 Fault clearing procedure with Reprint on Fault disabled, 147 Drum photoreceptor cleaning, 124 with Reprint on Fault enabled, 149 Fault condition Drum photoreceptor reprinting pages after, 146 disposal, 68 E Electromagnetic interfe
Index K TEST, 48 UP, 50 Fuser unit cover glass Keys function, 45 cleaning, 110 G Keys See Function keys, 45 L Glass cover fuser unit cleaning, 110 H LCD See Liquid crystal display, 45 LED discharge cleaning, 123 LINE SYNC HEAVY status lamp, 45 function key, 41 Host interface specifications, 167 I LinePrinter Plus emulation, 25 Linking Cut sheet tray, 35 IGP / PGL Emulation, 25 Liquid crystal display (LCD), 45 IGP / VGL Emulation, 25 Loading cut sheet paper, 31 Impact Printer Emulation, 2
Index M Output section transport paper jams in, 144 Main charger P cleaning, 104 Maintaining print quality, 77 Maintenance log sheets level A, 82, 160 Page counts service level, 79 PAGE EJECT level B, 83 function key, 48 level C, 84 Page length level E, 86 stacker setting, 42 Maintenance schedules, 81 Manual conventions, 18 Memory requirements, 168 Pages reprinting after fault, 146 Paper Message display See Liquid crystal loading, 28 display, 45 cut sheet, 31 Message table fanfold, 28 e
Index Paper size cassette changing, 34 emulations, 168 environment, 169 Paper specifications, 163 host interfaces, 167 Paper stacker memory requirements, 168 power, 39 paper, 163 PCL5 Emulation, 25 performance, 166 Performance specifications, 166 physical, 169 PhoenixPage PCL5 Emulation, 25 Photoreceptor drum safety regulations, 169 Printronix LinePrinter Plus emulation, 25 Q cleaning, 124 disposal, 68 Physical characteristics, 169 Pickup rollers cleaning, 115 Quality print maintaining, 77
Index Stacker full Reverse rollers operator procedure, 44 cleaning, 118 Stacker page length Rollers pickup cleaning, 115 reverse cleaning, 118 S setting, 42 STAND BY status lamp, 46 Status lamps, 45 Safety notices, 17 FAULT, 46 JOB IN PROCESS, 46 Safety regulations, 169 LINE SYNC, 45 Schedule replacement ONLINE, 46 service provider responsibility, 92 Schedules maintenance, 81 Self test power-on, 129 Service levels messages clearing, 80 Setting cassette paper size, 34 STAND BY, 46 SYS AVAIL, 4
Index Tray width custom, 36 U UP function key, 50 V Vacuum cleaners recommended, 78 177
Index 178
PRINTRONIX, INC. 14600 Myford Road P.O. Box 19559 Irvine, CA 92623-9559 Phone: (714) 368-2300 Fax: (714) 368-2600 Technical Support: (714) 368-2686 PRINTRONIX Nederland BV P.O. Box 163, Nieuweweg 283 NL-6600 AD Wijchen The Netherlands Phone: (31) 24 6489489 Fax: (31) 24 6489499 PRINTRONIX Schweiz GmbH 42 Changi South Street 1 Changi South Industrial Estate Singapore 486763 Phone: (65) 542-0110 Fax (65) 543-0220 Visit our website at: www.printronix.
