Printronix L5535 Maintenance Manual

Company. Postscript is a registered trademark of Adobe Systems, Inc. Hitachi is a registered trademark of Kabushiki Kaisha Hitachi Seisakusho DBA Hitachi, Ltd. IBM is a registered trademark of International Business Machines Corporation. HP and PCL are registered trademarks of Hewlett-Packard Company. Centronics is a registered trademark of Genicom Corporation. Dataproducts is a registered trademark of Dataproducts Corporation. Epson is a registered trademark of Seiko Epson Corporation. DuraFusion, IGP, LaserLine, LinePrinter Plus, PGL, PrintNet, PSA, and Printronix are registered trademarks, and Ribbon Minder is a trademark of Printronix, Inc. Magnum and QMS are registered trademarks, and Code V is a trademark of Quality Micro Systems, Inc. Microsoft, MS, MS-DOS, and Windows are registered trademarks of Microsoft Corporation. Toray is a registered trademark, and Toraysee is a trademark of Toray Industries, Inc. SELFOC is a registered trademark of Nippon Sheet Glass Co., Ltd. PKUNZIP is a registered trademark of PKWARE, Inc. 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. CG Times, based on Times New Roman under license from The Monotype Corporation Plc is a product of Agfa. Univers is a registered trademark of Linotype AG and/or its subsidiaries. Letraset is a registered trademark, and Aachen, Revue and University Roman are trademarks of Esselte Pendaflex Corporation. Futura is a registered trademark of Fundición Tipográfica Neufville, S.A. ITC Avant Garde Gothic, ITC Benguiat, ITC Bookman, ITC Century, ITC Cheltenham, ITC Clearface, ITC Galliard, ITC Korinna, ITC Lubalin Graph, ITC Souvenir, ITC Tiepolo, ITC Zapf Chancery, and ITC Zapf Dingbats are registered trademarks of International Typeface Corporation. Albertus, Gill Sans, and Times New Roman are registered trademarks, and Monotype Baskerville is a trademark of The Monotype Corporation Plc, registered in the U.S. Pat. and TM office and elsewhere.

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. The information in this manual is subject to change without notice. This document contains proprietary information protected by copyright. No part of this document may be reproduced, copied, translated or incorporated in any other material in any form or by any means, whether manual, graphic, electronic, mechanical or otherwise, without the prior written consent of Printronix, Inc. Copyright  1998, 2004, Printronix, Inc. All rights reserved.

About This Manual............................................................................ I–19 How To Locate Information ........................................................ I–19 Safety Notices And Special Information..................................... I–19 Switches And Display Messages ............................................... I–20 Related Documents.................................................................... I–20 General Safety Precautions.............................................................. I–20 Setup Safety Precautions ................................................................. I–22 Printer......................................................................................... I–22 Safety Label Locations And Printer Views........................................ I–23 Printer Features................................................................................ I–28 Tools, Test Equipment, And Supplies............................................... I–29 2 Setup................................................................ I–31 Power Requirements ........................................................................ I–31 Site Selection.................................................................................... I–32 Unpacking And Leveling................................................................... I–35 Cable Connections ........................................................................... I–37 Power Cord ................................................................................ I–37 Interface Cable........................................................................... I–40 Installing The First Photoreceptor Drum........................................... I–41 Adding The Developer...................................................................... I–47 Installing The Developing Unit.......................................................... I–49 Installing The Toner Cartridge And Waste Toner Bottle................... I–52 Loading Fanfold Paper ..................................................................... I–55 Loading Cut Sheet Paper ................................................................. I–57 Setting Cassette Paper Size (Optional Procedure) .......................... I–59 Setting The Power Supply Voltage................................................... I–60 3 Scheduled Maintenance .................................. I–67 Maintaining Print Quality................................................................... I–67 Service Level Page Counts .............................................................. I–68 Clearing Service Level Messages.............................................. I–69 About Page Counter Software ................................................... I–69 Volume I Table of Contents

Maintenance Schedules ................................................................... I–69 User’s Cleaning Schedule.......................................................... I–69 User’s Replacement Schedule................................................... I–70 Tech Service Replacement Schedule ........................................ I–71 Maintenance Kits .............................................................................. I–72 General Cleaning.............................................................................. I–76 Cleaning The Chargers..................................................................... I–82 Cleaning The Fuser Unit Cover Glass And Lamp Filter.................... I–86 Cleaning The Cut Sheet Option Rollers............................................ I–89 Major Cleaning.................................................................................. I–93 Cleaning The Flash Power Supply Filter .......................................... I–99 4 Troubleshooting ............................................. I–101 Overview......................................................................................... I–101 Jam Detection Sensors ............................................................ I–101 System Block Diagram ................................................................... I–102 Hidden Control Menus.................................................................... I–103 Global Memory Adjust Menu.................................................... I–104 Printer Control Menu ................................................................ I–105 Fanfold Paper Jams........................................................................ I–107 Paper Jam Near The Tractor ................................................... I–107 Paper Jam Near The Paper Output Section ............................ I–108 Cut Sheet Paper Jams.................................................................... I–111 Paper Jam At The Back Of The Paper Cassette ..................... I–111 Paper Jam In The Transport Input Section .............................. I–112 Paper Jam In The Transport Output Section ........................... I–114 Paper Jam In The Face Up Or Face Down Paper Path........... I–115 Status Messages And Error Messages .......................................... I–116 Error Message Table................................................................ I–116 Error Message Troubleshooting Procedures ........................... I–128 Error Code 01 — Front Cover Open ........................................ I–128 Error Code 02 — Fan-fold Paper Empty: Upon Power-on ....... I–130 Error Code 02 — Fan-fold Paper Empty: When Loading/Beginning Print ........................................................... I–131 Error Code 03 — Paper Jam at Fuser (C) ............................... I–131 Error Code 04 — Paper Jam at Exit (D) (transport section)..... I–132 Error Code 05 — Paper Jam at Exit (D) (paper output section) .............................................................. I–133 Error Code 07 — Scuff Lever Open (knob "C")........................ I–134 Error Code 08 — Cut-sheet Path Open ................................... I–134 Error Code 09 — Transport Motor Fail (complete stop)........... I–135 Error Code 0A — Cutter Fail (front) ......................................... I–136

Error Code 0B — Cutter Fail (rear) .......................................... I–136 Error Code 0C — Transfer Platform Fail (upper) ..................... I–138 Error Code 0D — Transfer Platform Fail (lower)...................... I–138 Error Code 11 — Paper Jam at Drum (B) ................................ I–140 Error Code 12 — Paper Jam at Fuser (C)................................ I–140 Error Code 13 — Paper Jam at Exit (D): Straight Output (faceup) .................................................................................... I–141 Error Code 13 — Paper Jam at Exit (D) (Cut-sheet Facedown Output).................................................................... I–141 Error Code 14 — Tractor Speed Too High............................... I–142 Error Code 15 — Tractor Speed Too Low................................ I–142 Error Code 16 — Paper Jam at Entrance (A)........................... I–144 Error Code 17 — High Voltage Fail.......................................... I–144 Error Code 18 — Drum Motor Fail (complete stop).................. I–146 Error Code 19 — Surface Voltage Too High............................ I–147 Error Code 1A — Surface Voltage Too Low ............................ I–149 Error Code 1B — Tractor Detent Fail....................................... I–150 Error Code 1E — Fuser Supply Fail......................................... I–151 Error Code 1F — Fuser Failure................................................ I–151 Error Code 20 — Fuser Lamp Overheat .................................. I–152 Error Code 26 — No Cleaning Unit.......................................... I–153 Error Code 28 — Waste Toner Full.......................................... I–153 Error Code 29 — No Waste Toner Box.................................... I–154 Error Code 2A — Toner Low.................................................... I–154 Error Code 2D — Toner Empty................................................ I–154 Error Code 2B — Toner Density Too High............................... I–155 Error Code 2C — Toner Density Too Low ............................... I–155 Error Code 32 — LED Head Overheat..................................... I–155 Error Codes 38 through 47 — MC Board CPU Internal Error .. I–156 Error Codes 48 through 4D — Controller Comm. Fail.............. I–156 Error Codes 50 through 53 and 5B — Stacker Fail.................. I–157 Error Code 5D — Stacker Comm. Fail..................................... I–157 Error Code 54 — Stacker Interlock Fail.................................... I–158 Error Code 55 — Stacker Fail .................................................. I–158 Error Code 56 — Stacker Full .................................................. I–159 Error Code 57 — Stacker Not Ready....................................... I–159 Error Code 58 — Stacker Not Auto Mode................................ I–159 Error Code 59 — Stacker Fail .................................................. I–160 Error Code 5A — Stacker Fail.................................................. I–161 Error Code 5C — Stacker Fail.................................................. I–162 Error Codes 60 through 62, 6E, and 70 — Cut-sheet Comm. Fail............................................................................... I–162

Error Code 63 — Cut-sheet Feeder Fail .................................. I–162 Error Code 64 — Cut-sheet Paper Skew ................................. I–163 Error Code 65 — Cut-sheet Pick Miss ..................................... I–163 Error Code 66 — No Paper Cassette....................................... I–164 Error Codes 67, 69, and 6B — Paper Jam at Entrance (A) ..... I–164 Error Codes 68 and 6A — Paper Jam at Entrance (A) ............ I–165 Error Code 6C — Cut-sheet Cover Open ................................ I–165 Error Code 6D — Cut-sheet Motor Fail.................................... I–166 Error Code 6F — Cut-sheet Paper Empty ............................... I–167 Error Code 78 — Main Charger High Voltage Error................. I–167 Error Code 79 — Transfer Charger High Voltage Error ........... I–168 Error Code 7A — Precharger High Voltage Error .................... I–168 Error Code 7B — Cleaning Bias High Voltage Error................ I–169 Error Code 7C — Developing Bias High Voltage Error............ I–170 Error Code 7D — Separator Charger High Voltage Error ........ I–170 Troubleshooting Other Symptoms.................................................. I–171 Smell Of Toner ......................................................................... I–172 Broken Fuser Unit Cover Glass ............................................... I–173 Incomplete Fusing.................................................................... I–174 Paper Jam................................................................................ I–177 Print Quality.............................................................................. I–179 Transfer (Elevator) Motor Abnormal Error................................ I–184 Abnormal Noises...................................................................... I–184 Developer Overflows................................................................ I–184 Toner Is Discharged................................................................. I–185 Power Stacker.......................................................................... I–185 5 Adjustment Procedures.................................. I–189 MC Board Adjustments................................................................... I–189 MC Board Switches.................................................................. I–191 MC Board Test Points.............................................................. I–195 MC Board Variable Resistors................................................... I–200 MC Board LEDs ....................................................................... I–202 MC Board Fuses ...................................................................... I–204 Setting NVRAM Values ............................................................ I–206 Adjusting Feed Motor Speed.................................................... I–207 Adjusting Drum Motor Speed ................................................... I–207 Adjusting Tractor Motor Gain ................................................... I–207 Adjusting Eraser Lamp Voltage................................................ I–208 Adjusting Toner Density Sensor............................................... I–208 Confirming MC Board Operation .................................................... I–210 Confirming the Developing Bias Voltage Control Circuit.......... I–210

Confirming The Main Charger Current Control Circuit ............. I–211 Confirming The Sleeve Motor Operation.................................. I–212 Confirming The Magroll Motor Operation................................. I–212 Confirming The Toner Supply Clutch Operation ...................... I–212 Confirming The Head Cooling Fan Operation.......................... I–212 Confirming The Head Blower Fan Operation ........................... I–212 Confirming The Vacuum Fan Operation................................... I–212 Confirming The Preheat Lamp Operation ................................ I–213 Confirming The Drum Counter Operation ................................ I–213 Confirming The Drum Surface Potential Sensor Operation ..... I–213 Other Print Engine Adjustments ..................................................... I–215 Adjusting The Drum Surface Potential Sensor......................... I–215 Adjusting The Tractors ............................................................. I–215 Adjusting The Top of Form....................................................... I–219 DC Power Supply Board Adjustments............................................ I–223 DC Power Supply Board Switches........................................... I–223 DC Power Supply Board Variable Resistors ............................ I–223 DC Power Supply Board Fuses................................................ I–225 Flash Power Supply Adjustments................................................... I–227 Loading Flash Memory ................................................................... I–228 The lasr2fls Utility Program ...................................................... I–228 Downloading Into Flash Memory.............................................. I–231 6 Replacement Procedures .............................. I–237 Overview......................................................................................... I–237 Front Cover .............................................................................. I–238 Left Rear Cover........................................................................ I–239 Right Rear Cover ..................................................................... I–240 Top Cover ................................................................................ I–243 Stand Cover ............................................................................. I–246 Inside The Front Cover................................................................... I–247 Waste Toner Recovery Unit ..................................................... I–248 Developing Unit........................................................................ I–252 Toner Cartridge ........................................................................ I–252 Photoreceptor Drum................................................................. I–253 Proper Disposal Of A Drum Unit .............................................. I–259 Drum Peripheral Equipment..................................................... I–260 Fuser Unit................................................................................. I–266 Transfer Assembly ................................................................... I–271 Inside The Rear Cover.................................................................... I–280 MC Board ................................................................................. I–281 DC Power Supply Board .......................................................... I–282

Motors ...................................................................................... I–284 Fans ......................................................................................... I–297 Solenoids ................................................................................. I–301 Miscellaneous .......................................................................... I–303 Under The Top Cover..................................................................... I–314 LED Print Head ........................................................................ I–315 High-Voltage (Corona) Power Supply ...................................... I–319 Cutter Unit ................................................................................ I–320 Sensors And Switches ............................................................. I–323 Gates........................................................................................ I–331 Behind The Stand Cover ................................................................ I–332 Smoke Filter............................................................................. I–332 Flash Power Supply ................................................................. I–333 Capacitor.................................................................................. I–340 Other............................................................................................... I–344 Tractor Removal....................................................................... I–344 Paper Back-Feed Sensor (PBFS) (Top Of Form Sensor)........ I–346 Paper Near-End Sensor (PNES).............................................. I–347 Control Panel ........................................................................... I–349 Controller Module ........................................................................... I–350 Controller Board ....................................................................... I–350 Terminating Resistors .............................................................. I–354 Power Supply (In Controller Module) ....................................... I–356 Cooling Fan.............................................................................. I–358

Overview.......................................................................................... II–19 Illustrated Parts Breakdown............................................................. II–20 8 Principles of Operation.................................. II–111 Printing System Descriptions......................................................... II–111 General ................................................................................... II–111 The Printing Process............................................................... II–111 How Images Are Processed .......................................................... II–112 Bit Mapping ............................................................................. II–112 Job Recovery .......................................................................... II–112 The Printing Mechanisms .............................................................. II–113 Photoconductive Section ............................................................... II–114 Discharge ................................................................................ II–114 Main Charging......................................................................... II–114 Exposure ................................................................................. II–116 Developing Section........................................................................ II–117 Developing Unit....................................................................... II–117 Principles Of Developing......................................................... II–118 Image Transfer/Separation Section............................................... II–120 Transfer................................................................................... II–120 Separation............................................................................... II–120 Fixing Section (Fuser Unit) ............................................................ II–122 Preheating............................................................................... II–122 Flash Fusing............................................................................ II–122 Cleaning Section............................................................................ II–123 Precharging (Precleaning Charging)....................................... II–123 Drum Cleaning ........................................................................ II–123 Paper Feed, Transport, And Output Sections................................ II–124 Paper Detection ...................................................................... II–124 Paper Loading......................................................................... II–126 Paper Transport ...................................................................... II–128 Paper Output........................................................................... II–129 Paper Parking ......................................................................... II–130 Volume II Table of Contents

Drive System Descriptions............................................................. II–132 Drum Drive .............................................................................. II–133 Developing Roller Drive .......................................................... II–134 Main Unit Feed Roller Drive .................................................... II–135 Gate Drive ............................................................................... II–136 Transfer Unit Drive .................................................................. II–137 Tractor Drive ........................................................................... II–137 Perforation Cutter Drive .......................................................... II–138 Separator Claw Drive .............................................................. II–139 Cut Sheet Paper Feed Section Drive ...................................... II–140 Control System Descriptions ......................................................... II–141 Paper Transport System Monitoring ....................................... II–142 Motor Rotation Control ............................................................ II–145 Drum Surface Potential Control .............................................. II–151 Toner Density Control ............................................................. II–152 Remaining Toner Level Monitoring ......................................... II–154 Waste Toner Monitoring.......................................................... II–155 Head Temperature Monitoring ................................................ II–156 Fuser Temperature Monitoring................................................ II–157 Developing Bias Adjustment ................................................... II–158 Operational Sequences ................................................................. II–159 Electronics Initialization........................................................... II–160 Mechanical Initialization .......................................................... II–161 Printing Operations ................................................................. II–162 Command Operations............................................................. II–167 A Electrical and Wire Data................................ II–171 Block Diagram ............................................................................... II–171 Printer Interconnection Diagram.................................................... II–172 Print Engine Interconnection Diagram........................................... II–173 Acronyms For Print Engine Interconnection Diagram.................... II–176 Explanation Of Circuits According To Function ............................. II–179 Drum Surface Potential Control Circuit ................................... II–179 Developing Bias Control Circuit .............................................. II–181 Toner Density And Toner Empty Circuits................................ II–183 Drum Motor Control Circuit ..................................................... II–185 Drum Counter Circuit .............................................................. II–186 Tractor Motor Control Circuit................................................... II–187 Main Unit Feed Motor Control Circuit...................................... II–190 Transfer Elevator Motor Control Circuit................................... II–191 Cutter Motor Control Circuit .................................................... II–193

Input / Output Signals .................................................................... II–194 LVX040 Controller Board Input/Output Signals....................... II–194 MC Board (MC-PCBA) Input/Output Signals........................... II–203 DC Power Supply Board (PS-PCBA) Input/Output Signals..... II–216 Unit Interface ................................................................................. II–221 LED Array................................................................................ II–221 Flash Power Supply ................................................................ II–225 Developing Unit....................................................................... II–228 High-Voltage (Corona) Power Supply ..................................... II–231 B Optional Cut Sheet Feeder ........................... II–235 Physical Description ...................................................................... II–235 Front Side................................................................................ II–235 Back Side ................................................................................ II–236 Rear Side (Board Side) ........................................................... II–237 Paper Feed Cassette..................................................................... II–238 Setup And Connections................................................................. II–239 Setup....................................................................................... II–239 Connections ............................................................................ II–241 Basic Principles ............................................................................. II–242 Drive Principles ....................................................................... II–243 Cassette Principles ................................................................. II–243 Control Principles........................................................................... II–244 Upper Level / Lower Level Paper Size Sensor........................ II–244 Paper Feed Cassettes ............................................................ II–245 Upper Level / Lower Level Paper Empty Sensor (PES1 / PES2) ........................................................................ II–246 Cut Sheet Feed Sensor (PFS), Paper Register Sensor (PRS) ................................................. II–246 Paper Timing Sensor (PTS) .................................................... II–247 Cut Sheet Pickup Motor Encoder (PME)................................. II–248 Cut Sheet Feed Motor Encoder (FME).................................... II–249 Paper Guide Interlock Switch (ICIL)........................................ II–250 Detection Errors............................................................................. II–251 Upper Level Cassette Section Error........................................ II–251 Lower Level Cassette Section Error........................................ II–251 Transfer Unit Error................................................................... II–252 Unit Sequencer Section Errors................................................ II–253 Basic Operation ............................................................................. II–254 Mechanism Initialization .......................................................... II–255 Analog Input Processing ......................................................... II–255 Chattering Absorption Processing........................................... II–255

Status Confirmation Processing.............................................. II–255 Confirmation Processing Of Unit Of Error Occurrence ........... II–255 Communication Processing .................................................... II–255 Driving Actuators..................................................................... II–255 Cut Sheet Output Unit.................................................................... II–256 Physical Description................................................................ II–256 Setup and Connections........................................................... II–258 Basic Principles....................................................................... II–261 C Optional Power Paper Stacker...................... II–263 Physical Description ...................................................................... II–263 Front (Output Side) ................................................................. II–263 Rear (Input Side)..................................................................... II–264 Front (Interior) ......................................................................... II–265 Setup And Connections................................................................. II–266 Setup....................................................................................... II–266 Connections ............................................................................ II–269 Removal......................................................................................... II–270 Operation....................................................................................... II–271 Sensors And Actuators.................................................................. II–274 Drive Principles.............................................................................. II–275 Feed Roller And Transfer Belt................................................. II–275 Swinger ................................................................................... II–277 Assisting Arms ........................................................................ II–278 Elevator Table ......................................................................... II–279 Control Principles........................................................................... II–280 Transfer Unit Paper Sensor (Paper Moving Sensor) (PMS) ... II–280 Jam Sensor (PPS) .................................................................. II–281 Paper Surface Sensor 1 (PSS1), Paper Surface Sensor 2 (PSS2) ............................................. II–282 Stacker Full Sensor (SFS), Elevator Down Sensor (EDS)...... II–283 Stacker Motor Encoder (SME), Elevator Motor Encoder (EME) ............................................... II–284 Swinger Position Sensor (SPS), Assisting Arm Position Sensor (APS1) ................................... II–285 Elevator Upper Limit Switch (LIMT1), Elevator Lower Limit Switch (LIMT2) ...................................... II–286 Safety Sensor 1 (SS1), Safety Sensor 2 (SS2)....................... II–287 Elevator Keys (ESWA / ESWS / ESWD / ESWH)................... II–287 Detection Errors............................................................................. II–288 Operator Call Status Errors..................................................... II–288 Service Call Status Errors....................................................... II–288

Basic Operation ............................................................................. II–289 Status Confirmation Processing.............................................. II–290 Communication Processing..................................................... II–290 Driving The Stacker................................................................. II–290 Driving The Elevator Motor...................................................... II–290 Driving The Swinger Motor...................................................... II–290 Driving The Assisting Arm Drive Motor ................................... II–290 Switch Monitoring.................................................................... II–290 Belt Removal Procedures.............................................................. II–291 Power Stacker Cover .............................................................. II–292 Inside The Left Frame ............................................................. II–293 Inside The Right Frame........................................................... II–299 Swinger Belts .......................................................................... II–303 Elevator Belt............................................................................ II–310 Stacker Motor.......................................................................... II–315 D Engine Checker ............................................ II–319 Overview........................................................................................ II–319 Connecting The Engine Checker................................................... II–320 Disconnecting The Engine Checker .............................................. II–323 Using The Control Panel................................................................ II–323 Operation ................................................................................ II–324 Basic Menu.................................................................................... II–325 Device Check Menu....................................................................... II–326 Selecting A Mode/Item/Device ................................................ II–334 Reading Device Status (Input Device Check) ......................... II–335 Driving/Stopping A Device (Output Device Check) ................. II–335 Volume Adjustment Menu.............................................................. II–337 Surface Potential..................................................................... II–338 Eraser Lamp............................................................................ II–338 Drum Motor ............................................................................. II–338 Feed Motor.............................................................................. II–339 Tractor Motor........................................................................... II–339 Toner Density.......................................................................... II–339 Basic Operation Menu ................................................................... II–340 Fanfold Paper.......................................................................... II–340 Cut Sheet Paper...................................................................... II–341 Memory Operation Menu............................................................... II–342 Reading And Changing Data .................................................. II–343

• Opposite each illustration is a list of the illustrated parts and their part numbers. • You can order any part that has a part number. Part numbers are not listed for common fasteners. Parts marked “Ref” (reference) are not spared, are part of another assembly, or are shown elsewhere. • In illustrations, magnified details are shown with locator arrows and letters: NOTE: For replacement procedures for consumables, see the User’s Manual. For replacement procedures for nonconsumable items, see Chapter 6, “Replacement Procedures.” For maintenance schedules and cleaning procedures, see Chapter 3, “Scheduled Maintenance.” For an illustrated list of installation and maintenance tools, with part numbers, see page I–29. This points to an area . . . A that is magnified here. A 80 85 87 90 To get part 80, 85, or 87, for example, you would order item 90, which is a kit containing all these parts. • Assemblies you can order as kits are shown in the following notation:

Illustrated Parts Breakdown Figure II–14. Front View of Printer ...................................................page II–22 Figure II–15. Printer Front Cover Assembly Open ...........................page II–24 Figure II–16. Developing Unit...........................................................page II–26 Figure II–17. Miscellaneous Details .................................................page II–28 Figure II–18. Cleaning Unit and Photoreceptor Drum ......................page II–30 Figure II–19. Transfer Assembly......................................................page II–32 Figure II–20. Fuser Unit ...................................................................page II–36 Figure II–21. Base, WT (Waste Toner) Assembly............................page II–42 Figure II–22. Back View of Printer....................................................page II–44 Figure II–23. Back View of Printer, Close-up ...................................page II–46 Figure II–24. Cut Sheet Output Assembly........................................page II–50 Figure II–25. LED Print Head (LED Array).......................................page II–52 Figure II–26. Cut Sheet Feeder Assembly.......................................page II–54 Figure II–27. Front View, Left Side...................................................page II–60 Figure II–28. MC PCBA....................................................................page II–64 Figure II–29. PNE (Paper Near–End) Sensor Assembly .................page II–66 Figure II–30. Controller Module........................................................page II–68 Figure II–31. Head Blower Fan Assembly........................................page II–72 Figure II–32. Developing Unit Drive Assembly.................................page II–74 Figure II–33. General Details ...........................................................page II–76 Figure II–34. Smoke Filter Box.........................................................page II–80 Figure II–35. Lamp Cooling Blower Fan (AC Blower Assembly)......page II–82 Figure II–36. Flash Power Supply....................................................page II–84 Figure II–37. Miscellaneous Details .................................................page II–86 Figure II–38. DC (Main) Power Supply ............................................page II–88 Figure II–39. Back View, Left Side...................................................page II–90 Figure II–40. Drum Shaft Assembly and Belts .................................page II–96 Figure II–41. Flash Duct Assembly ..................................................page II–98 Figure II–42. Bracket Assembly, FU (Fuser Unit) Connector.........page II–100 Figure II–43. Back of Printer, Left Side ..........................................page II–102

Figure II–14. Front View of Printer 5 10 15 20 25 30 35 40 45 50 55 60 65 75 70 80 35loc1

Quantity per Assembly 5 703531-003 Cassette (S500-A4) 1 10 703531-004 Cassette (S500-Letter) 1 15 703531-005 Cassette (S250-A4) 1 20 703531-006 Cassette (S250-Letter) 1 25 703531-007 Cassette (S250-B4) 1 30 703531-008 Cassette (S250-A3) 1 35 703531-009 Cassette (S250-Legal) 1 40 703531-010 Cassette (S250-Ledger) 1 45 703531-011 Swing Plate 1 50 703531-166 Face Up Tray Assembly 1 55 703531-524 Cover, Front Stand, Painted 1 60 703531-204 Front Cover Assembly 1 65 ---------- See Figure II–15 For Close-up View 70 706289-001 Rubber Magnet for Cover Interlock Switch 75 203452-001 Drum Counter 80 703531-162 Interlock Switch

Figure II–15. Printer Front Cover Assembly Open 22 20 15 10 5 22 55 25 30 40 45 50 35 65 60

Quantity per Assembly 5 705739-001 Developing Unit (Rebuildable) (See Figure II–16, Item 5, For Details) 1 10 705741-001 Main Charger (See Figure II–17, Item 5, For Details) 1 15 703531-118 Discharge LED Assembly (Erase LEDs) (See Figure II–17, Item 10, For Details) 1 20 705740-001 Cleaning Unit (Rebuildable) (See Figure II–18, Item 5, For Details) 1 22 703531-595 Latch, Front Cover 2 25 703531-137 Transfer Assembly (See Figure II–19 For Details) 1 30 203283-001 Fuser Unit (See Figure II–20 For Details) 1 35 703531-140 Plate, Drum 1 40 705742-001 Precharger (See Figure II–17, Item 15, For Details) 1 45 703535-001 Photoreceptor Drum (See Figure II–18, Item 10, For Details) 1 50 --------- Base, WT (Waste Toner Assembly (See Figure II–21 For Details) 1 55 704912-901 Control Panel Assembly 1 60 Ref Upper Inner Cover (Inner Cover “A”) 1 65 703531-530 Lower Inner Cover (Inner Cover “B”) 1

Quantity per Assembly 5 705739-001 Developing Unit (Rebuildable) 1 10 703532-001 Toner Cartridge 1 15 703548-001 Developer Powder, Bottle (includes Nozzle) 1

Quantity per Assembly 5 705741-001 Main Charger 1 10 703531-118 Discharge LED Assembly (Erase LEDs) 1 15 705742-001 Precharger 1

Figure II–18. Cleaning Unit and Photoreceptor Drum 5 10

Drum Quantity per Assembly 5 705740-001 Cleaning Unit (Rebuildable) 1 10 703535-001 Photoreceptor Drum 1

Figure II–19. Transfer Assembly (Sheet 1 of 3) A 20 5 10 15 16* *Item 16 is not part of this assembly 11

(Sheet 2 of 3) B A 28 29 26 27 26 27 25 26 27 30 30 30 31 31

Figure II–19. Transfer Assembly (Sheet 3 of 3) B 55 65 60 45 40 45 35 50

Quantity per Assembly 5 703531-208 Guide, Paper, Transport (upper) 1 10 703531-103 Varistor Assembly/Transfer Charger 1 11 703531-231 Paper Guide, Input, Lower 1 15 703531-127 High-Voltage Connector Assembly 1 16 705743-001 Transfer Charger 1 20 703531-139 Conveyor Assembly 1 25 703531-212 Transport Unit Shaft “A” Assembly 1 26 703531-554 Bearing, Conveyer 2 27 703531-553 Holder, Bearing 2 28 703531-224 Transport Unit Shaft “B” Assembly 1 29 703531-589 Stop Bracket 3 30 703531-035 Transporting Belt 3 31 706303-001 Bearing, 688AZZNR 1 35 703531-126 EPS4 Assembly 1 40 703531-067 Jam Sensor Lever (EPS4) 1 45 703531-075 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 1 50 703531-109 Vacuum Fan Assembly 1 55 703531-125 EPS3 Assembly 1 60 703531-075 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 1 65 703531-588 Jam Sensor Lever (EPS3) 1

Quantity per Assembly 5 202838-001 Lamp Housing Filter, L5035/L5535 1 10 703531-138 Glass Frame Assembly (This Assembly Includes Six Items) 1 15 703531-066 Fuser Cover Glass 1 16 706309-001 Packing Fuser 2, Glass Frame BK 17 703531-165 Trigger Coil Assembly 20 703531-113 Connector/Fuser FU-Male (2 ea./set) 1 25 703531-102 Fuser Fuse Assembly 1 30 703541-001 Xenon Lamp Assembly 1 35 703531-065 Halogen Lamp 1 40 706314-001 Captive Screw 45 706309-001 Fuser Glass

Figure II–21. Base, WT (Waste Toner) Assembly 10 5 15 20* *Item 20 is not part of this assembly.

Assembly Quantity per Assembly Base, WT (Waste Toner) Assembly 5 703531-153 Sensor A PCBA 1 10 703531-106 Microswitch V-014-1C23 1 15 703531-154 Sensor B PCBA 1 20 703539-001 Waste Toner Bottle 1

Figure II–22. Back View of Printer 5 35 40 30 20 10 15

Quantity per Assembly 5 703531-203 Top Cover Assembly 1 10 703531-202 Rear Cover Assembly, Right 1 15 703531-201 Rear Cover Assembly, Left 1 20 703531-206 Top Cover Holder, C CK 1 30 --------- See Figure II–23 For Close-up Of Printer 35 705733-005 High Voltage (Corona) Power Supply, L5035/L5535 1 40 703531-063 Connectors for High Voltage (Corona) Power Supply (set of 8) 1

Figure II–23. Back View of Printer, Close-up (Sheet 1 of 2) 10 15 5 20 25 30 35 36 A

(Sheet 2 of 2) 75 65 60 55 45 40 120 115 110 95 80 85 90 100 A 50 70

Item No. Part No. Description: Figure II–23. Back View of Printer, Close-up Quantity per Assembly 5 703531-190 Cut Sheet Output Assembly (See Figure II–24 For Details) 1 10 703531-068 Heat Pipe Assembly (See Figure II–25 For Details) 1 15 703531-189 Cut Sheet Feeder Assembly (See Figure II–26 For Details) 1 20 --------- See Figure II–27 For Details Of This Area 1 25 705733-012 MC PCBA, L5035/L5535 (See Figure II–28 For Details) 1 30 703531-167 PNE (Paper Near–End) Sensor Assembly (See Figure II–29 For Details) 1 35 704056-001 Controller Module (See Figure II–30 For Details) 1 36 703531-164 Power Supply Harness Assembly 1 40 --------- Bracket Assembly, FU (Fuser Unit) Connector (See Figure II–42 For Details) 1 45 703531-163 Varistor/High Voltage Cable (not visible in figure) (See Figure II–37, Item 10, For Details) 1 50 Ref Drawer Harness Assembly (See Figure II–33, Item 10, For Details) 1 55 703531-144 Drum Shaft Assembly (See Figure II–40 For Details) 1 60 -------- Head Blower Fan Assembly (See Figure II–31 For Details) 1 65 204228-001 Developing Unit Drive Assembly (See Figure II–32 For Details) 1 70 703700-001 Cable Assembly, Print Engine, External 1 75 703531-141 Elevator Motor Assembly (See Figure II–33, Item 20, For Details) 1 80 703540-001 Smoke Filter Box (See Figure II–34 For Details) 1

(continued) Quantity per Assembly 85 703531-117 Lamp Cooling Blower Fan (VEF1) (AC Blower Assembly) (See Figure II–35 For Details) 1 90 705733-006 Flash Power Supply, L5035/L5535 (behind blower) (See Figure II–36 For Details) 1 95 --------- DC (Main) Power Supply Assembly (See Figure II–38 For Details) 1 100 703531-147 Connector Assembly For Transfer Ozone (not visible in figure) (See Figure II–37, Item 5, For Details) 1 110 --------- See Figure II–39 For Details Of This Side Of Printer 115 --------- Flash Duct Assembly (See Figure II–41 For Details) 1 120 --------- Back View Of Printer, Left Side (See Figure II–39 For Details)

Figure II–24. Cut Sheet Output Assembly 5 25 10 20 15 10 15 10 REF

Quantity per Assembly 5 703531-221 Output Assembly Roller-8 1 10 703531-222 Output Assembly Roller-9 2 15 703531-226 Output Assembly Roller-12 7 20 703531-075 Sensor, Photo Interrupter (PHINT ON1517LA-(A) (Optical Sensor) 1 25 703531-034 Belt, 265MXL4.8 1

Figure II–25. LED Print Head (LED Array) 5 10 15 20

Quantity per Assembly 5 703551-001 LED Print Head, 240 DPI (LED Array) 1 10 703551-002 LED Print Head, 300 DPI (LED Array) 1 15 703551-003 LED Print Head, 400 DPI (LED Array) 1 20 703531-068 Heat Pipe Assembly 1

Figure II–26. Cut Sheet Feeder Assembly (Sheet 1 of 4) A 55 50 40 50 41 40 45 40 25 30 35 10 15 10 15 20 5 A C B D D E E

Figure II–26. Cut Sheet Feeder Assembly (Sheet 3 of 4) Ref 75 70 85 Ref 41 41 70 80 C

Quantity per Assembly 703531-189 Cut Sheet Feeder Assembly 1 5 703531-072 Resist Sensor Assembly 3 10 703531-050 Pickup Roller Assembly 2 11 703531-577 Thumbscrew, In/Out 1 15 703531-051 Reverse Roller Assembly 2 20 703531-071 Cassette Sensor PCBA-1 2 25 705733-014 Feeder Unit PBA, Option 1, L5X35 1 30 703531-069 Feeder ROM-Option 1 1 35 703531-077 Harness Feed P004 (Wire Harness) 1 40 703531-054 Clutch Feeder 3 41 703531-525 Shaft, Cut Sheet Feeder Gear 2 45 703531-075 Sensor, Photo Interrupter (PHINT ON1517LA-(A) 1 50 703531-053 Motor Assembly 2 55 703531-076 Harness Feed P003 (Cable Harness) 1 60 703531-078 Harness Feed P031 (Cable Harness) 1 61 703531-565 Registration Roller, Cut Shaft 1 62 703531-563 Shaft Feed Roller 2 64 703531-594 Pinch Roller Upper Unit 1 65 703531-073 Timing Sensor Assembly 1 70 703531-055 Belt 88MXL 2 75 703531-058 Belt 158MXL 1 80 703531-057 Belt 106MXL 1 85 703531-056 Belt 91MXL 1

Figure II–27. Front View, Left Side (Sheet 1 of 3) 5 20 10 15 A B A C D B

Figure II–27. Front View, Left Side (Sheet 3 of 3) D 45

Quantity per Assembly 5 703531-130 Drum Support Assembly 1 10 703531-111 O-Ring CO-0013-A 2 15 703531-128 Drum Guide Assembly, Front 1 20 703531-114 Tractor Set (Left and Right) 2 25 705733-009 Motor Assembly, Drum, L5035/L5535 1 30 703531-075 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 1 35 703531-041 Motor Assembly, Tractor 1 37 706291-001 Pulley, Drum, 3M-51-28 1 38 706292-001 Pulley, Tractor, 3M-63 1 39 706293-001 Pulley, Two-gang, 3M-64 1 40 703531-031 Belt 60S3M264 3 42 703531-583 Bearing, 8 mm 2 45 703531-232 Sensor, Top-of-Form 1

Quantity per Assembly 5 705733-012 MC PCBA, L5035/L5535 1

Figure II–29. PNE (Paper Near–End) Sensor Assembly 10 5

Assembly Quantity per Assembly 703531-167 PNE (Paper Near-End) Sensor Assembly 5 703531-154 Sensor B PCBA 1 10 703531-153 Sensor A PCBA 1

Figure II–30. Controller Module (Sheet 1 of 3) 10 15 20 25 5 35 30 40 35 Ref. 65

Figure II–30. Controller Module (Sheet 3 of 3) 50 55 60

Quantity per Assembly 171621-001 Controller Module 1 5 172068-001 Controller Assembly, LVX040, L55XX, Spare (PCBA with I/O Panel) 1 10 203560-001 SIMM, DC DRAM, 32 MB (J10 Ref.) 10 203561-001 SIMM, DC DRAM, 64 MB (J10 Ref.) 15 203575-001 SIMM, DC Flash, 8 MB, Unprogrammed (J12 Ref.) 15 203574-001 SIMM, DC Flash, 16 MB, Unprogrammed (J12 Ref.) 15 203593-001 SIMM, DC Flash, 32 MB, Unprogrammed (J12 Ref.) 15 203594-001 SIMM, DC Flash, 64 MB, Unprogrammed (J12 Ref.) 20 172206-001 SIMM, VX Flash, 4 MB, Pre-programmed (J13 Ref.) 25 202412-001 SIMM, VX DRAM, 4 MB (J14 Ref.) 30 170274-001 PCBA, Backplane, Controller 1 35 171254-001 Cable Assembly, Parallel I/O, L5000 1 40 170325-001 PrintNet Module (optional) Ref. 45 171234-001 Fan Assembly, 5VDC 1 50 171333-001 Power Supply, 40W, 5V (in Controller Module) 1 55 171224-001 Cable Assembly, AC Power, LVX040 1 60 171225-001 Cable Assembly, Card Cage Power, LVX040 1 65 703700-001 Cable Assembly, Print Engine, External

Quantity per Assembly 5 703531-104 Head Blower Fan 1 10 703531-001 LED Air Filter 1

Figure II–32. Developing Unit Drive Assembly 5 40 35 30 25 10 15 20

Assembly Quantity per Assembly 204228-001 Developer Drive Unit Assembly 1 5 703531-218 Developing Drive Unit Gear #9 1 10 703531-134 Gear Assembly For Developing Drive Unit, L5035/L5535 1 15 202834-001 Developing Drive Unit Gear #10 1 20 705733-011 Magroll Motor Assembly 1 25 705733-010 Sleeve Motor Assembly 1 30 703531-216 Developing Drive Unit Gear #6 1 35 Ref Developing Drive Unit Gear #5 1 40 703531-033 Belt 60S3M177 1

Quantity per Assembly 5 703531-107 Cable Assembly, Developing Unit (I/O 26 Harness Assy) 1 10 Ref Drawer Harness Assembly 1 15 703531-075 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 2 20 703531-159 Transfer Elevator Motor 1 25 703531-141 Elevator Motor Unit (whole unit includes motor, sensors, bracket) 1

Quantity per Assembly 5 703540-001 Smoke Filter Box (VEFE Assembly) 1 10 703531-116 Smoke Filter Blower Fan (VEF0) (Main Blower Fan) 1

Figure II–35. Lamp Cooling Blower Fan (AC Blower Assembly) 5 10

Blower Assembly) Quantity per Assembly 5 703531-117 Lamp Cooling Blower Fan (VEF1) (AC Blower Assembly) 1 10 706285-001 TC Sensor BK (Blower Thermal Sensor)

Quantity per Assembly 705733-006 Flash Power Supply, L5035/L5535 1 10 703531-561 Capacitor 1

Quantity per Assembly 5 703531-147 Connector Assembly For Transfer Ozone 1 10 703531-163 Varistor/High-Voltage Cable 1

Quantity per Assembly 10 705733-007 DC Power Supply PCBA, L5035/L5535 1 15 202836-001 Fan, DC Power Supply, L5035/L5535 20 202837-001 Relay, DC Power Supply, L5035/L5535

Figure II–39. Back View, Left Side (Sheet 1 of 5) 5 10 15 C A

Figure II–39. Back View, Left Side (Sheet 3 of 5) B 50 55 21

Figure II–39. Back View, Left Side (Sheet 5 of 5) D 105 105 115 120 110 121 122

Quantity per Assembly 5 703531-156 Cutter Solenoid Assembly 1 10 703531-029 Belt 60S3M174 1 15 -------- Exit Assembly 1 20 703531-031 Belt 60S3M264 1 21 706293-001 Ply #M-64-24 2-Gang 1 25 204698-001 Feed Motor Assembly 1 30 703531-075 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 2 35 703531-028 Belt 3M-132-6 1 40 703531-031 Belt 60S3M264 1 45 703531-030 Belt 60S3M210 1 50 703531-123 EGS1 Assembly (Exit Gate Solenoid #1) 1 55 703531-124 EGS2 Assembly (Exit Gate Solenoid #2) 1 60 703531-219 Exit Assembly Roller-14 1 65 703531-122 Gate Rear Block 1 70 703531-225 Exit Assembly Roller-11 1 75 703531-585 Exit Sensor (EPS1) 1 80 703531-075 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 1 85 703531-121 Gate Front Block 1 90 703531-115 Rubber Paper Press 1 4 95 703531-119 Rubber Paper Press 2 2 105 703531-075 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 2 110 703531-027 Belt MXL-535-6.4 1 115 203660-001 Cutter Motor 1 120 703531-026 Belt 67MXL6.4 1 121 705447-001 706299-001 Plate, Cutter (Wide Web option, small) Plate, Cutter (large) 1 1 122 703531-136 Plate Cutter Unit (whole unit includes belt, plate)

Figure II–40. Drum Shaft Assembly and Belts 5 40 10 15 45 20 35 25 30 7 7 65 50 60 55 70

Quantity per Assembly 5 705579-001 Cleaner Driver Coupler (metal) 1 7 706303-001 Bearing, 688AZZNR 2 10 703531-032 Belt 60S3M501 1 15 703531-532 Gear, Cleaner Drive 1 20 703531-031 Belt 60S3M264 1 25 703531-075 Sensor, Photo Interrupter (PHINT) ON1517LA-(A) 1 30 703531-133 Tension Pulley, Drum Assembly 1 35 703531-144 Shaft Assembly, Drum 1 40 703531-234 Holder Blk., Gear Assembly (does not include gears) 1 45 703531-590 Shaft, Pre-Drum 1 50 706297-001 Nut, Drum 55 203437-001 Gear, 1-33 Roller 60 203436-001 Pulley, 3M-47-25 Drum 65 203438-001 Gear, 1-66-22 Drum 70 706298-001 Bearing, 6004ZZ

Quantity per Assembly 5 703531-105 Fuser Cooling Fan 1

Figure II–42. Bracket Assembly, FU (Fuser Unit) Connector 5 10 10