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6HUYLFH 0DQXDO
Code: 686680G-00
P8e_100
720P4170
PREFACE
This manual is addressed to the field engineers who will install and service the PG L8L laser printer. It provides all the information needed for a correct product maintenance.
SUMMARY
This manual is divided into seven chapters. The Chapter 3 holds the SPARE PARTS CATALOGUE.
PREREQUISITES
The topics described in this manual require knowledge of similar products.
REFERENCE DOCUMENTATION
Instruction Manual - (provided with the product)
DISTRIBUTION: GENERAL
FIRST EDITION: December 1998
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Warning
This equipment complies with the requirements in Part 15 of FCC rules for a class A computing device. Operation of the equipment in a residential area may cause unacceptable interference to radio and TV reception, requiring the operator to take whatever steps are necessary to correct the interference.
The laser and output of the laser scanner unit produces a beam that, if looked into, could cause eye damage. Service procedures must be followed exactly as written without change. When servicing the machine or laser module, follow the procedures specified in the manual and there will be no hazards from the laser. Laser (FDA): Any laser label visible to service must be reproduced in the service manual with location shown or indicated. Safe working procedures and clear warnings concerning precautions to avoid possible exposure must also be included. The Laser contained in the PG L8L meets the following standard: Laser class 3B, maximum 5mW, wavelength 780nm. The following LASER symbol will be displayed at the start of any procedure where possible exposure to the laser beam exists.
Product Safety
Electrostatic Discharge This caution indicates that there are components which are sensitive to damage caused by electrostatic discharge. CAUTION
These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage.
Shock Hazard
DP8_006
This symbol indicates the presence of potentially hazardous voltages.
LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT Each PG L8L laser printer has the following laser warning label on the Laser Assembly.
DP8_001
CLASS 1 LASER PRODUCT
The PG L8L laser printers are certified to comply with Laser Product Performance Standards set by the U.S. Department of Health and Human Services as a Class 1 Laser Product. This means that this is a class of laser product that does not emit hazardous laser radiation; this is possible only because the laser beam is totally enclosed during all modes of customer operation.
DP8_009
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The Laser Label is visible when the Top Cover is removed (Figure 1).
Figure 1. Laser Safety Label
Laser Label.
P8e_321
Finland Laser Safety
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Table of Contents
Title Page
Introduction
The PG L8L Service Manual is the primary document used for repairing and maintaining the Laser Printers. This manual contains Service Call Procedures, Diagnostic Procedures, General Information, Repair Analysis Procedures, Copy Quality Analysis Procedures, Wiring Data, and Parts Lists that will enable the Service Representative to repair Printer failures.
Introduction .............................................. v Organization ............................................ vi Service Call Procedures .......................1-1 Printer Specifications ...........................2-1 Parts Lists ..............................................3-1 Repair Procedures ................................4-1 General Procedures ..............................5-1 Wiring Data ............................................6-1 Repair Analysis Procedures.................7-1
NOTE: In some of the Printer documentation the Print Cartridge is referred to as the Image Cartridge. Print Cartridge is the correct term.
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Organization
This manual is divided into seven sections. The title and description of each section of the manual is as follows: Section 1 - SERVICE CALL PROCEDURES This section is used to identify a suspected problem. It contains Call Flow, Initial Actions, and Final Actions. This part of the service manual should always be used to start the service call. Section 2 - PRINTER SPECIFICATIONS This section contains all the specifications for the PG L8L printers. Section 3 - PARTS LISTS This section contains illustrations of disassembled subsystems and a listing of the spared parts. Part names are listed in this section of the manual even if the part itself is not spared. All the parts that are spared will have the part number listed. Parts that are not spared will not have a number listed. Section 4 - REPAIR PROCEDURES This section contains the instructions for removal, replacement, and adjustment of the spared parts. Section 5 - GENERAL PROCEDURES This section contains diagnostic routines, printer setup procedures, and a listing of tools and supplies. Section 6 - WIRING DATA This section contains illustrations of the plug/jack locations and the routing of power and signal cables. Section 7 - REPAIR ANALYSIS PROCEDURES (RAPs) This section contains the procedures necessary to repair failures in the printer. This section also contains the procedures necessary to troubleshoot print quality problems.
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Section 1
Service Call Procedures
1
1.1 Call Flow Diagram........................................................................... 1-2 1.2 Initial Actions .................................................................................. 1-3 1.3 Corrective Actions.......................................................................... 1-3 1.4 Final Actions ................................................................................... 1-4
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1.1 Call Flow Diagram
The basic troubleshooting steps are outlined in the Call Flow Diagram (Figure 1.1). All service calls begin with Initial Actions and end with Final Actions.
Figure 1.1 Call Flow Diagram.
Initial Actions
Corrective Actions
Parts List
RAPs
Repair Procedures
Wiring Data
General Procedures
Final Actions Image Quality
Correct Any Secondary Problems
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1.2 Initial Actions
1 Question the operator and verify the problem. 2 Check that the printer paper path is clear of foreign matter such as staples, paper clips, and paper scraps. 3 After you have identified the problem symptom, check the following items: · The printer is connected to a wall power outlet, and the outlet is supplying the correct voltage. · The printer power cord is not frayed or broken. · The printer is correctly grounded / earthed. · The printer is in an appropriate operating environment, with no extremes of heat, humidity, or dirt. · The printer is not exposed to direct sunlight. · The printer is on a level and stable surface.
1.3 Corrective Actions
1 If the printer has an obvious failure or fault, you can go directly to the appropriate Repair Procedure (Section 4) or Repair Analysis Procedure (RAP) (Section 7) and begin corrective action. 2 If the fault is not obvious, follow the Entry Level RAP (Section 7) to identify the problem and begin corrective action. 3 After all corrective actions have been made, perform Final Actions.
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1.4 Final Actions
1 Run Test Prints to evaluate print quality. 2 Perform the Image Quality Checkout procedures in section 7 to correct any print quality defects. 3 Correct any secondary problems (return to Corrective Actions, if necessary). 4 Reinstall the machine covers. 5 Clean the machine and the work area. 6 Ask the customer to send a print job to verify printer operation. 7 Provide operator training as required. 8 Close the call.
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Section 2
Printer Specifications
2
2.1 Electrical Specifications ................................................................ 2-2 2.1.1 Power Sources and Consumption ........................................... 2-2 2.1.2 Power On/Off ........................................................................... 2-2 2.1.3 Power Saver ............................................................................ 2-2 2.1.4 Mechanical............................................................................... 2-2 2.1.5 Consumables ........................................................................... 2-2 2.2 Physical Location ........................................................................... 2-3 2.3 Functional Specifications .............................................................. 2-3 2.4 Environment.................................................................................... 2-4 2.5 Options ............................................................................................ 2-4 2.6 Paper Specifications ...................................................................... 2-4 2.6.1 Paper limitations ...................................................................... 2-4 2.7 Operating Language and Emulation ............................................. 2-6 2.8 Communication Interfaces ............................................................ 2-6 2.9 Status Display / Controls ............................................................... 2-6
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2.1 Electrical Specifications
Video Controller (Video I/F) Video Controller Board (Video I/F) is installed in the printer. Video Interface Specification to be provided, if necessary.
2.1.1 Power Sources and Consumption
The Printers are available in either a 110 or a 220 volt configuration. Line Voltage
100/115 VAC 220/240 VAC
Line Voltage Tolerance
90 - 132 VAC 198 - 264 VAC
Frequency
60 Hz 50 Hz
Frequency Tolerance
57 - 63 Hz 47 - 53 Hz
Running Power Consumption
450 Watts max (200W average) 450 Watts (200W average)
Power Saver
25 Watts 25 Watts
2.1.2 Power On/Off
The Printers have an on/off power switch located on left rear corner of machine. The machine is equipped with a grounded power socket. Printer will power down automatically when not used for a period of time (see Power Saver).
2.1.3 Power Saver
The Power Saver reduces power automatically when the printer does not receive data for a period of time. Power Saver is a menu selection in the Remote Control Panel (RCP) software which provides the user with the ability to control, when the printer enters the power saver state. The default value is 30 minutes. In Power Save mode, the power consumption is under 25 watts.
2.1.4 Mechanical
Unit
Metric SAE
Width
345 mm 13.58 in.
Depth
364.9 mm 14.36 in.
Height
224 mm 8.8 in
Weight
7.5 Kg 15.4 lbs
2.1.5 Consumables
PRINTER CARTRIDGE: 5000 pages at 5% coverage; more with use of the toner saving Econo Mode. The starter kit cartridge shipped with the printer is 2.5 K pages with 5% coverage.
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2.2 Physical Location
224 mm 370 mm 8.8 in 14,5 in
345 mm 13.6 in
367 mm 14.36 in
P8e_100
Place your printer on a flat, stable surface near your workstation. Leave enough space around the printer, so that you can easily: · · · · · open the printer cover load the paper retrieve paper open the front single sheet output tray and retrieve the paper in the front output tray allow air circulation around the vents to prevent the printer from overheating
2.3 Functional Specifications
Warm Up Time
From Sleep mode to Standby mode under 30 seconds
First Print Out
From Standby mode 20 seconds From Power save mode 30 seconds
Print Speed - ppm (pages per minute)
8 ppm
Resolution - dpi (Dots per inch)
True 600 x 600 dpi
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2.4 Environment
Temperature
Operating 10o - 32o C 50 o - 90.5o F -20o - 40o C -4o - 104o F
Humidity
20 - 80% RH
Noise
Sleep (Power Saver) - Background Standby - Under 29 dB Printing - Under 47 dB ------
Level
Within 5o
Shipping
10 - 95% RH
------
The printer must not be exposed to: · · · · · · abrupt changes in temperature or humidity any condensation direct sunlight chemicals vibration dusty or dirty environments.
2.5 Options
MEMORY/DRAM: 4MB on board memory standard. · · With the one available memory expansion slot, memory can expand to include a 4, 8, 16, or 32MB SIMM. Maximum memory is 36 MB. The SIMM is a customer supplied item (72 pin, 60ns, 32 bit, No Parity, EDO SIMM).
2.6 Paper Specifications
Papers that meet the specifications may be fed either through the Multipurpose Paper Feeder, or the Manual Single Sheet Feeder. If you use thick paper with a weight of more than 90 g/m2 (40lb), or envelope, you must insert paper into the Manual Single Sheet Feeder and select Thick Paper. The Multipurpose Paper Feeder will hold 150 sheets of 60 - 90 g/m 2 (16 - 24 lb), or 10 envelopes, 10 labels, 10 transparency films. The Manual Single Sheet Feeder capacity is 1 sheet 60 - 135 g/m 2 paper.
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2.6.1 Paper Limitations
The following are recommended for optimum performance: · · · · Adhesive label sheets specifically designed for laser printers. Transparencies specifically designed for laser printers Envelopes with peel-off adhesive strips or more than one fold-over flap to seal must have adhesives compatible with the heat and pressure of the printer's fusing process. Avoid: -- Paper with embossed lettering, perforations, or rough texture. -- Paper to which color was added after the paper was made. -- Printed forms whose ink is not for laser printing. Most papers that meet the above specifications may be fed either through the multisheet or the single sheet paper feeder. Some media meets the specifications but is not ideal for feeding, e.g., paper that is either highly textured, thicker than normal for its weight, or unusually smooth. Paper types
Paper Type
A4/Letter Letter Executive, Legal B5 A5 Monarch (7 3/4) COM10 #9 C5 D5 DL
Capacity (Sheets)
150
10
2.7 Operating Language and Emulation
The Printer uses the enhanced PCL5 language (PCL 5e). The Printer emulates the HP LJ 6L.
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2.8 Communication Interfaces
Parallel port - Centronics IEEE V1284 compatible bi-directional (Nibble, Byte and ECP).
2.9 Status Display/Controls
The printer's status is controlled and displayed by both: · 1) 2) 3) 4) · a panel with a Front Panel Key and three LED's Error Light Paper light On-Line light On-Line / Reset Key software programs that enable the user to: -- monitor the printer's status on the computer screen (the Status Monitor). The Status Monitor is a program that runs in background and automatically displays a message(s) on your computer screen whenever the printer status changes (not available for NT 4.0). -- change printer settings from the computer screen (Remote Control Panel). The Remote Control Panel (RCP) program allows you to view and change print settings for the following operating systems; DOS, Windows 3.1, Windows 95, Windows 98, and NT 4.0.
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Section 3
Parts Lists
3
PL 1 Covers ........................................................................................... 3-2 PL 2 Front Cover................................................................................... 3-4 PL 3 Paper Trays................................................................................... 3-6 PL 4 Feeder ........................................................................................... 3-8 PL 5 Paper Transport ......................................................................... 3-10 PL 6 Frame Assembly (1 of 2) ........................................................... 3-12 PL 7 Frame Assembly (2 of 2) ........................................................... 3-14 PL 8 Fuser ........................................................................................... 3-16 PL 9 Main Drive Motor........................................................................ 3-18 PL 10 Electronics................................................................................ 3-20
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PL 1 Covers
Item 1) 2) 3) 4) 5) 6) 7) 8) Part Number -----127550U ----------127560W 127556N ----------Description Top Cover} Rear Cover Right Side Cover Bottom Cover Face Up Cover Front Cover Left Side Cover Print Cartridge
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8
6
2
3
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PL 2 Front Cover
Item 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) Part Number --------------------127556N ----------127557P 127558Y 127559Z -----127560W Description Front Cover {Includes Items 2 through 7} Stacker Extender Stacker Duct Front Cover Stacker Guide Stopper Key LED Control Panel Control Panel Cover Face Up Exit Cover
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6
4
5
9 10 12 8
11
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PL 3 Paper Trays
Item 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) Part Number ------------------------------------------------------------127561K 127550U Description Media (Paper) Tray {Includes Items 2 through 12} Gear Adjust Rack, Left Gear Adjust Rack, Right Pinion Gear Auto Tray Adjust, Right Manual Tray Adjust, Right Film Guide Sheet Manual Tray Adjust, Left Manual Paper Tray Auto Tray Adjust, Left Paper Guide Plate Rear Cover Assembly {Includes Items 13 & 14} Tray Extender Rear Cover
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9
3 4
8 5 7 6
12
13
14
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PL 4 Feeder
Item 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) 30) 31) 32) Part Number 127530Q ----------127532E 127533F ---------------127527H -------------------------127504K ----------------------------------------127516E 127475M --------------------127478Y ----------Description Paper Separator Unit {Includes Items 2 & 3} Separator Pad Separator Holder Knock Up Spring Knock Up Spring Holder Assembly {Includes Items 6 & 7} Knock Up Spring Holder Knock Up Ground Separator Spring Media Unit Knock Up Assembly {Includes Items 10 through 13} Knock Up Holder, Right Knock Up Pad Knock Up Holder, Left Knock Up Plate Extension Spring Media Unit Clutch {Includes Items 16 through 19} Clutch Hub Clutch Spring Clutch Collar Pick Up Gear Media Unit Pick Up Assembly {Includes Items 21 through 31} Knock Up Cam Paper Guide Roll E-Ring Paper Feed Guide Pick Up Rubber Pick Up Housing Knock Up Cam, Right Pick Up Shaft Pin Feed Idler Shaft Feed Roller, Left Pick Up Shaft Shaft Lock Bushing
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1 3 13 14 32 21 22 23 24 22 25 28 30 20 28 30 31 29 23 26 22 8 11 7 2 4
5 6
12
24 22 27 16 17 10 14 18 19
9
29 28
15
P8e_303
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PL 5 Paper Transport
Item 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) Part Number 037456K ------------------------------037457L -----037458V Description Media Frame Support Unit {Includes Items 2 through 6} Feed Rubber Idler Feed Shaft Feed Shaft Bearing Feed Spring Feed Support Frame Media Feed Gear Unit Paper Empty Actuator Paper Separator Paper Empty Assembly
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1 2 3
4
2 7
5 8 9
10
6
P8e_304
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PL 6 Frame Assembly (1 of 2)
Item 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) Part Number 037459W 037460T ----------------------------------------037461Q Description LSU (Laser) Unit Upper Frame Unit Cover Open Actuator Spring Cover Open Actuator Cover Open Micro Switch Developer Plate, Left Developer Plate Spring Developer Plate, Right Cover Open Sensor Cover Upper Frame Paper Feed Solenoid
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2 3 4 9
5
10
6 7 8
P8e_305
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PL 7 Frame Assembly (2 of 2)
Item 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) 30) 31) 32) 33) 34) 35) 36) 37) 38) 39) 40) 41) Part Number 037462R 037463J ---------------------------------------------037464K --------------------------------------------------037465L 037466M -----------------------------------037467N ---------------037468X ---------------037469Y 037517G Description Transfer Roller Transfer Unit Holder Right {Includes Items 3, 4, & 5} Transfer Roller Bushing Transfer Roller Spring Transfer Roller Holder Media Unit Operator, Left {Includes Items 7 & 8} Pad Holder, Left Separator Pad, Left Media Unit Operator, Right {Includes Items 10 & 11} Separator Pad, Right Pad Holder, Right Transfer Gear Lower Frame Unit Base Frame
Rubber Foot Saw Plate Saw Plate Holder Feed Sensor Assembly Exit Actuator Fuser Cover Transfer Roller Terminal Unit {Includes Items 27 & 28} High Voltage Shaft, Large High Voltage Spring, Large High Voltage Terminal Unit High Voltage Shaft, Small Developer Unit Fuse {Includes Items 32, 33, & 34} Developer Unit Fuse Contact, Upper Developer Unit Fuse Plate Developer Unit Fuse Contact, Lower Off / On Switch ELA Unit-PTL
DC Fan Motor Transfer Unit Holder Left {Includes Items 3, 4, & 5}
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41 2
4 5
1
2 3 4 38 7 8 5 6 9 35 31 32 33 29 26 28 27 25 14 13 34 30 21 22 11 10
36 37
39
15 24 20 18 19 17 16
23
40
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PL 8 Fuser
Item 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) Part Number -----037470V --------------------------------------------------037471J ---------------037472K --------------------037473L ---------------037474M 037475N ---------------037476P Description Fuser Unit Assembly (115 VAC) {Includes Items 2 through 19} Fuser Unit Assembly (220 VAC) {Includes Items 2 through 19} Rubber Exit Roller Exit Bearing Exit Gear Roller Fuser Cover AC Electrode, Left AC Electrode, Right Thermostat Fuser Frame Bracket Thermistor Bracket Exit Spring Halogen Lamp (115 VAC) Halogen Lamp (220 VAC) Heat Roll Bearing, Left Heat Roller Heat Roll Bearing, Right Fuser Gear Pressure Roller Holder Assembly {Includes Items 21, 22, & 23} Pressure Roller Bearing Pressure Roller Bearing Holder Pressure Roller Bearing Spring Pressure Roller Exit Roller Assembly {Includes Items 26, 27, 28, & 29} Rubber Exit Roll F/Up Exit Shaft F/Up Exit Gear Exit Shaft Bushing - TX
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8 14
9 10
13 12 16 17 11 15 20 26 27 22 23 18 19 24 28 25 20 21
29
26
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PL 9 Main Drive Motor
Item 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) Part Number 037477Q ---------------------------------------------Description Main Drive Motor Assembly {Includes Items 2 through 12} Main Drive Motor Motor bracket Motor Drive Gear Feed Drive Gear Gear Bracket Gear-Drive 1 Gear-Drive 2 Gear-Pulley RCT-Belt Impeller
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2 3
4
5
10 6
9 8
7
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PL 10 Electronics
Item 1) 2) 3) 4) 5) 6) 7) Part Number 037478Z ----------037479S ----------037480Q ----------037481D Description High Voltage Power Supply PWB AC Plug Assembly Controller PWB (115 VAC) Controller PWB (220 VAC) SIMM Engine Controller PWB (115 VAC) Engine Controller PWB (220 VAC) Joint PWB Fuse (115 VAC / T8A) Fuse (220 VAC / T5A)
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6
7
2
3 5
4
P8e_310a
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.
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Section 4
Repair Procedures
REP 4.1 Covers
4
4.0 Overview.......................................................................................... 4-3
REP 4.1.1 Face Up Cover................................................................. 4-4 REP 4.1.2 Front Cover...................................................................... 4-5 REP 4.1.3 Rear Cover ...................................................................... 4-6 REP 4.1.4 Top Cover ........................................................................ 4-7 REP 4.1.5 Left and Right Side Covers.............................................. 4-8 REP 4.2 Paper Feed REP 4.2.1 Paper Feed Solenoid....................................................... 4-9 REP 4.2.2 Upper Frame Assembly................................................. 4-10 REP 4.2.3 Paper Feeder Assembly ................................................ 4-12 REP 4.3 Paper Transportation and Sensing REP 4.3.1 Pfeed Sensor................................................................. 4-14 REP 4.3.2 Paper Empty Sensor ..................................................... 4-15
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REP 4.4 Fuser REP 4.4.1 Fuser Assembly............................................................. 4-16 REP 4.4.2 Fuser Pressure Roller ................................................... 4-18 REP 4.4.3 Halogen Lamp (Fuser Heat Rod) .................................. 4-19 REP 4.4.4 Fuser Thermistor ........................................................... 4-20 REP 4.5 Drive and Xerographic Modules REP 4.5.1 Print Cartridge ............................................................... 4-21 REP 4.5.2 Gear Bracket ................................................................. 4-22 REP 4.5.3 Main Drive Motor Assembly........................................... 4-23 REP 4.5.4 Transfer Roller ............................................................... 4-24 REP 4.5.5 DC Fan Motor ................................................................ 4-25 REP 4.5.5 DC Fan Motor REP 4.6.1 Bottom Shield ................................................................ 4-26 REP 4.6.2 Engine Controller PWB ................................................. 4-27 REP 4.6.3 Controller PWB.............................................................. 4-29 REP 4.6.4 LSU (Laser) Assembly .................................................. 4-30 REP 4.6.5 HVPS (High Voltage Power Supply) PWB..................... 4-31 REP 4.6.6 Joint PWB...................................................................... 4-32
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4.0 Overview
Locations given in the Repair Procedures are always referenced from the front of the printer as you are facing the Control Panel. See figure 4.0.1.
Figure 4.0.1 Printer Orientation.
Left Rear
Front
Right
P8e_300
The following notations apply: · · Arrows in the illustrations show direction of movement. Numbers in an illustration refer to the corresponding steps in the procedure being performed. Example, REP 4.1.1, step 2 indicates to press on the two locking tabs. Notice that the two locking tabs in the illustration are labeled 2. At the bottom of each illustration is a number. In the illustration above the number is P8e_300. This is the art number and is used by the developers for tracking and control of the art.
·
There are a number of steps you should follow each time before you begin a procedure: 1 Do not use force to remove or install printer components. 2 Use only the screw size and type designated in the REP. The wrong screw could easily damage tapped holes. 3 Wear a wrist strap to dissipate static electricity, which may damage sensitive electronic parts, and use a grounded mat when working with PWBs. 4 See Section 6 for the precise location of electrical connectors in the printer.
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REP 4.1 Covers
REP 4.1.1 Face Up Cover
Removal
1 Switch the printer power off and disconnect the AC power cord. 2 Press on the two locking tabs and open the cover (Figure 4.1.1a). 3 Carefully bend the cover in the middle until the hinge pin is free of the printer frame (Figure 4.1.1b). 4 Remove the Face Up Cover.
Figure 4.1.1a. Face Up Cover Locking Tabs.
2
P8e_257
Figure 4.1.1b. Face Up Cover Removal.
3
4
P8e_258
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.1.2 Front Cover
Removal
Switch the printer power off and disconnect the AC power cord. Remove the Face Up Cover (REP 4.1.1). Open the Front Cover and remove the Print Cartridge (REP 4.5.1). Remove the screw that secures the Limit Strap (Figure 4.1.2a). Remove the strap from the left side cover. 5 Carefully push the right side of the Front Cover out until it is free of the hinge pin. Remove the Front Cover (Figure 4.1.2a). 6 Unplug the Control Panel connector. 1 2 3 4
Figure 4.1.2a. Front Cover Removal.
P8e_223
4
Left Side
5
P8e_210a
Right Side
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.1.3 Rear Cover
Removal
1 2 3 4 Switch the printer power off and disconnect the AC power cord. Remove the three screws that secure the Rear Cover (Figure 4.1.3a). Release the two lock tabs that secure the bottom of the cover (Figure 4.1.3a). Slide the cover up and remove.
Figure 4.1.3a. Rear Cover.
3 2
P8e_236
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.1.4 Top Cover
Removal
1 2 3 4 5 Switch the printer power off and disconnect the AC power cord. Remove the Rear Cover (REP 4.1.3). Open the Front Cover and remove the Print Cartridge (REP 4.5.1). Remove the two screws that secure the front of the Top Cover (Figure 4.1.4a). Lift the Top Cover to remove (Figure 4.1.4a).
Figure 4.1.4a. Top Cover Removal.
4
P8e_315
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.1.5 Left and Right Side Covers
Removal
1 2 3 4 5 6 7 8 9 Switch the printer power off and disconnect the AC power cord. Remove the Face Up Cover (REP 4.1.1). Open the Front Cover and remove the Print Cartridge (REP 4.5.1). Remove the Front Cover (REP 4.1.2). Remove the Rear Cover (REP 4.1.3). Remove the Top Cover (REP 4.1.4). Remove the screw securing the side cover (Figure 4.1.5a). Release the locking tab located at the top of the side cover (Figure 4.1.5a). Remove the side cover.
Figure 4.1.5a. Left and Right Side Cover Removal.
8
7
8
8
7
8
P8e_238
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.2 Paper Feed
REP 4.2.1 Paper Feed Solenoid
Removal
1 2 3 4 5 6 7 8 9 10 11 12 13 Switch the printer power off and disconnect the AC power cord. Remove the Face Up Cover (REP 4.1.1). Open the Front Cover and remove the Print Cartridge (REP 4.5.1). Remove the Front Cover (REP 4.1.2). Remove the Rear Cover (REP 4.1.3). Remove the Top Cover (REP 4.1.4). Remove the Right Side Covers (REP 4.1.5). Remove the Bottom Shield (REP 4.6.1). Remove the Gear Bracket (REP 4.5.2). Remove the Controller PWB (REP 4.6.3). Remove the Engine Controller PWB (REP 4.6.2). Remove the solenoid connector from CN 402 of the Joint PWB. Remove the two screws (and ground strap) that secure the Paper Feed Solenoid to the printer frame (Figure 4.2.1a).
Figure 4.2.1a. Paper Feed Solenoid Removal.
13
P8e_311a 1
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.2.2 Upper Frame Assembly
Removal
Switch the printer power off and disconnect the AC power cord. Remove the Face Up Cover (REP 4.1.1). Open the Front Cover and remove the Print Cartridge (REP 4.5.1). Remove the Front Cover (REP 4.1.2). Remove the Rear Cover (REP 4.1.3). Remove the Top Cover (REP 4.1.4). Remove the Left and Right Side Covers (REP 4.1.5). Remove the Gear Bracket (REP 4.5.2). Remove the HVPS (REP 4.6.5). Remove the two screws that secure the Paper Feed Solenoid to the printer frame (Figure 4.2.2a). Remove the solenoid from the frame but do not disconnect the solenoid harness. 11 Remove the six screws that secure the Upper Frame Assembly (Figure 4.2.2a). 12 Lift-up the left side of the Upper Frame Assembly approximately 12 mm (0.5 in). Lift-up the rear of the right side of the Upper Frame Assembly. Move the Upper Frame Assembly to the right to disconnect the front hinge pin and remove (Figure 4.2.2b). 1 2 3 4 5 6 7 8 9 10
Figure 4.2.2a. Upper Frame Assembly Removal.
11
10
P8e_244
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Figure 4.2.2b. Upper Frame Assembly Removal.
P8e_245
12
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.2.3 Paper Feeder Assembly
Removal
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Switch the printer power off and disconnect the AC power cord. Remove the Face Up Cover (REP 4.1.1). Open the Front Cover and remove the Print Cartridge (REP 4.5.1). Remove the Front Cover (REP 4.1.2). Remove the Rear Cover (REP 4.1.3). Remove the Top Cover (REP 4.1.4). Remove the Left and Right Side Covers (REP 4.1.5). Remove the Gear Bracket (REP 4.5.2). Remove the HVPS (REP 4.6.5). Remove the Upper Frame Assembly (REP 4.2.2). Remove the screw that secures the earth (ground) strap to the left end of the paper feed shaft (Figure 4.2.3a). Pull out on the locking tab of the left bearing and rotate the bearing 45 degrees clockwise (Figure 4.2.3a). Press the locking tab and remove the frame insert. Remove the E-Ring that secures the drive gear and clutch to the right end of the paper feed shaft (Figure 4.2.3a). remove the Gear and Clutch. Move the left end of the Paper Feeder Assembly toward the front of the printer and remove the assembly.
Figure 4.2.3a. Paper Feeder Assembly Removal.
12
15
11
14
P8e_314
14
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Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.3 Paper Transportation and Sensing
REP 4.3.1 Pfeed Sensor
Removal
1 2 3 4 5 6 7 8 Switch the printer power off and disconnect the AC power cord. Remove the Print Cartridge (REP 4.5.1). Remove the Rear Cover (REP 4.1.3). Turn the printer up side down. Remove the Bottom Shield (REP 4.6.1). Remove the Engine Controller PWB (REP 4.6.2). Disconnect CN401 from the Joint PWB (Figure 4.3.1a). Remove the two screws that secure the Pfeed Sensor to the printer frame (Figure 4.3.1a). Remove the Pfeed Sensor.
Figure 4.3.1a. Pfeed Sensor Removal.
8
7
P8e_318
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.3.2 Paper Empty Sensor
Removal
Switch the printer power off and disconnect the AC power cord. Remove the Print Cartridge (REP 4.5.1). Remove the Rear Cover (REP 4.1.3). Turn the printer up side down. Remove the Bottom Shield (REP 4.6.1). Remove the Engine Controller PWB (REP 4.6.2). Remove the Controller PWB (REP 4.6.3). Remove the Pfeed Sensor (REP 4.3.1). Disconnect CN403 from the Engine Controller PWB (Figure 4.3.2a). Remove the two screws that secure the Paper Empty Sensor to the printer frame (Figure 4.3.2a). Lift the front end of the Sensor Assembly and move the assembly to free the three tabs (Figure 4.3.2a). 12 Move the assembly to the left and disconnect the drive shaft. Remove the Paper Empty Sensor Assembly. 13 Press the lock tab and remove the Paper Empty Sensor from the assembly. 1 2 3 4 5 6 7 8 9 10 11
Figure 4.3.2a. Paper Empty Sensor Removal.
10
13
9
P8e_317 P8e_316
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.4 Fuser
REP 4.4.1 Fuser Assembly
Removal
Switch the printer power off and disconnect the AC power cord. Remove the Print Cartridge (REP 4.5.1). Remove the Face Up Cover (REP 4.1.1). Remove the Front Cover (REP 4.1.2). Remove the Rear Cover (REP 4.1.3). Remove the Top Cover (REP 4.1.4). Remove the Left Side Cover (REP 4.1.5). Remove the screw that secures the Wire Cap (Figure 4.4.1a). Remove the Wire Cap. Disconnect the Fuser Harness from CN1 on the Engine Controller PWB (Figure 4.4.1a). Remove the two screws that secure the AC power wires to the Fuser Assembly (Figure 4.4.1a). Remove the two screws that secure the Fuser Assembly to the printer frame (Figure 4.4.1a). Use a small screwdriver to carefully release the two locking tabs on the front of the Fuser Assembly (Figure 4.4.1a). 13 Move the Fuser Assembly to the left until right hinge pin is free of the printer frame. 14 Lift the right end of the Fuser Assembly up approximately 25mm (1in.), and move the right end toward the rear of the printer. (Figure 4.4.1a) 15 Continue to move the right end toward the rear of the printer until the left end is free of the printer frame. Remove the Fuser Assembly. 1 2 3 4 5 6 7 8 9 10 11 12
Figure 4.4.1a. Fuser Assembly Removal.
14
12
8 10 9 12
11
P8e_225
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Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.4.2 Fuser Pressure Roller
Removal
1 2 3 4 5 6 7 8 9 Switch the printer power off and disconnect the AC power cord. Remove the Print Cartridge (REP 4.5.1). Remove the Face Up Cover (REP 4.1.1). Remove the Front Cover (REP 4.1.2). Remove the Rear Cover (REP 4.1.3). Remove the Top Cover (REP 4.1.4). Remove the Right Side Cover (REP 4.1.5). Remove the Fuser Assembly (REP 4.4.1). Remove the Fuser Pressure Roller from the bearings (Figure 4.4.2a).
Figure 4.4.2a. Fuser Pressure Roller Removal.
P8e_313
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.4.3 Halogen Lamp (Fuser Heat Rod)
Removal
1 2 3 4 5 6 7 8 9 10 11 12 13 Switch the printer power off and disconnect the AC power cord. Remove the Print Cartridge (REP 4.5.1). Remove the Face Up Cover (REP 4.1.1). Remove the Front Cover (REP 4.1.2). Remove the Rear Cover (REP 4.1.3). Remove the Top Cover (REP 4.1.4). Remove the Right Side Cover (REP 4.1.5). Remove the Fuser Assembly (REP 4.4.1). Turn the Fuser Assembly up side down and remove the earth (ground) strap from the right end of the Fuser (Figure 4.4.3a). Remove the two screws that secure the Halogen Lamp to the AC Terminals (Figure 4.4.3a). Carefully lift the Fuser Roll and bearings out of the Fuser Assembly. Remove the Halogen Lamp and Fuser Drive Gear from the Fuser Roll (Figure 4.4.3a). Remove the drive gear from the Halogen Lamp (Figure 4.4.3a).
Figure 4.4.3a. Halogen Lamp Removal.
10
12 9
10
P8e_319
13
Replacement
1 Assemble in reverse order. 2 Ensure the four Fuser Stripper Fingers are on top of the Fuser Roll. 3 Verify proper operation.
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REP 4.4.4 Fuser Thermistor
Removal
Switch the printer power off and disconnect the AC power cord. Remove the Print Cartridge (REP 4.5.1). Remove the Face Up Cover (REP 4.1.1). Remove the Front Cover (REP 4.1.2). Remove the Rear Cover (REP 4.1.3). Remove the Top Cover (REP 4.1.4). Remove the Right Side Cover (REP 4.1.5). Remove the Fuser Assembly (REP 4.4.1). Remove the Fuser Heat Roll (REP 4.4.3). Remove the two screws that secure the Overheat Thermostat (Figure 4.4.4a). Remove the Thermostat. 11 Release the six locking tabs (Figure 4.4.4a) and remove the Fuser Cover (the AC Electrodes are attached to the bottom of the Fuser Cover). 12 Remove the screw that secures the Thermistor to the Fuser Assembly (Figure 4.4.4a). Remove the Thermistor. 1 2 3 4 5 6 7 8 9 10
Figure 4.4.4a. Fuser Thermistor Removal.
11
10
12
P8e_320
Replacement
1 Assemble in reverse order. 2 Ensure the four Fuser Stripper Fingers are on top of the Fuser Roll. 3 Verify proper operation.
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REP 4.5 Drive and Xerographic Modules
REP 4.5.1 Print Cartridge
Removal
1 Switch the printer power off and disconnect the AC power cord. 2 Open the printer's front cover. 3 Grasp the Print Cartridge Handle as shown in Figure 4.5.1a. Pull the Printer Cartridge up and out of the printer.
Figure 4.5.1a. Printer Cartridge Removal.
3 2
P8e_268
4 If the Printer Cartridge will be out for longer then a few minutes, cover the Cartridge with several sheets of paper to protect it from light.
Replacement
1 Assemble in reverse order.
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REP 4.5.2 Gear Bracket
Removal
1 2 3 4 5 6 7 8 Switch the printer power off and disconnect the AC power cord. Remove the Face Up Cover (REP 4.1.1). Remove the Print Cartridge (REP 4.5.1). Remove the Front Cover (REP 4.1.2). Remove the Rear Cover (REP 4.1.3). Remove the Top Cover (REP 4.1.4). Remove the Right Side Cover (REP 4.1.5). Remove the six screws that secure the Gear Bracket to the printer frame along with the Red and Green ground wires (Figure 4.5.2a).
Figure 4.5.2a. Gear Bracket Removal.
9
P8e_200a
8
9 Lower the Gear Bracket to access the Drive Motor. Disconnect the Drive Motor Harness from the Drive Motor (Figure 4.5.2a). 10 Remove the Gear Bracket.
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.5.3 Main Drive Motor Assembly
Removal
1 2 3 4 5 6 7 8 9 Switch the printer power off and disconnect the AC power cord. Remove the Face Up Cover (REP 4.1.1). Remove the Print Cartridge (REP 4.5.1). Remove the Front Cover (REP 4.1.2). Remove the Rear Cover (REP 4.1.3). Remove the Top Cover (REP 4.1.4). Remove the Right Side Cover (REP 4.1.5). Remove the Gear Bracket (REP 4.5.2). Remove the three screws that secure the Drive Motor Assembly to the Gear Bracket (Figure 4.5.3a).
Figure 4.5.3a. Drive Motor Assembly.
10
9
P8e_234a
10 Remove the two gears from the Drive Motor Assembly (Figure 4.5.3a).
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.5.4 Transfer Roller
Removal
1 Switch the printer power off and disconnect the AC power cord. 2 Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
NOTE: Wear rubber gloves when removing the Transfer Roller. Touching the rubber part of the roller can cause print quality problems.
3 Press the locking tabs on the bushings on each end of the Transfer Roller. Remove the Transfer Roller and the bushings.
Figure 4.5.4a. Transfer Roller Removal.
3
P8e_243
Replacement
1 If installing a new Transfer Roller, remove the gear and bushings from the old roller and place on the new roller. 2 The high voltage contact for the roller is located in the left side frame. Slide the Transfer Roller to the right and insert the left bushing and gear into position. 3 Slide the roller to the left against the high voltage contact and insert the right bushing. 4 Assemble remaining components in reverse order. 5 Verify proper operation.
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REP 4.5.5 DC Fan Motor
Removal
1 2 3 4 5 6 7 8 9 10 11 12 13 Switch the printer power off and disconnect the AC power cord. Remove the Face Up Cover (REP 4.1.1). Open the Front Cover and remove the Print Cartridge (REP 4.5.1). Remove the Front Cover (REP 4.1.2). Remove the Rear Cover (REP 4.1.3). Remove the Top Cover (REP 4.1.4). Remove the Right Side Covers (REP 4.1.5). Remove the Bottom Shield (REP 4.6.1). Remove the Gear Bracket (REP 4.5.2). Remove the Controller PWB (REP 4.6.3). Remove the Engine Controller PWB (REP 4.6.2). Remove the fan connector from CN 408 of the Joint PWB. Remove the two screws securing the DC Fan Motor to the printer frame (Figure 4.5.5a).
Figure 4.5.5a. DC Fan Motor Removal.
P8e_400
13
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.6 Electrical Modules
REP 4.6.1 Bottom Shield
Removal
1 2 3 4 5 Switch the printer power off and disconnect the AC power cord. Remove the Print Cartridge (REP 4.5.1). Turn the printer up side down (Figure 4.6.1a). Remove the three screws that secure the Shield to the bottom of the printer (Figure 4.6.1a). Lift and remove the shield (Figure 4.6.1a).
Figure 4.6.1a. Bottom Shield.
4
5
P8e_239
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.6.2 Engine Controller PWB
Removal
CAUTION
These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage.
Switch the printer power off and disconnect the AC power cord. Remove the Print Cartridge (REP 4.5.1). Remove the Rear Cover (REP 4.1.3). Turn the printer up side down. Remove the Bottom Shield (REP 4.6.1). Disconnect J5 from the Controller PWB (Figure 4.6.2a). Remove the five screws that secure the Engine Controller PWB to the bottom of the printer (Figure 4.6.2a). 8 Lift the edge of the Engine Controller PWB that is next to the Controller PWB approximately 40 mm (1.5 in.) and disconnect CN406 from the Joint PWB (Figure 4.6.2a). 9 Continue to lift the Engine Controller PWB and disconnect CN1, CN2, CN201, CN202, and the AC inline connector (Figure 4.6.2a). 10 Remove the Engine Controller PWB. 1 2 3 4 5 6 7
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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Figure 4.6.2a. Engine Controller Removal.
7
6 8 9
P8e_240
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REP 4.6.3 Controller PWB
Removal
CAUTION
These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage.
1 2 3 4 5 6 7
Switch the printer power off and disconnect the AC power cord. Remove the Print Cartridge (REP 4.5.1). Remove the Rear Cover (REP 4.1.3). Turn the printer up side down. Remove the Bottom Shield (REP 4.6.1). Disconnect J2 and J5 from the Controller PWB (Figure 4.6.3a). Remove the four screws that secure the Controller PWB to the printer frame (Figure 4.6.3a). Remove the Controller PWB.
Figure 4.6.3a. Controller PWB Removal.
6 6 7 7 7 7
P8e_312
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.6.4 LSU (Laser) Assembly
Removal
1 2 3 4 5 6 7 8 9 10 Switch the printer power off and disconnect the AC power cord. Remove the Face Up Cover (REP 4.1.1). Remove the Print Cartridge (REP 4.5.1). Remove the Front Cover (REP 4.1.2). Remove the Rear Cover (REP 4.1.3). Remove the Top Cover (REP 4.1.4). Disconnect the harness connected to the left side of the Laser Assembly (Figure 4.6.4a). Remove the screw that secures the ground wire to the Laser (Figure 4.6.4a). Remove the four mounting screws that secure the Laser to the printer frame (Figure 4.6.4a). Turn the Laser up side down and disconnect the harness connected to the right side of the Laser (Figure 4.6.4a).
Figure 4.6.4a. Laser Assembly Removal.
9 8 7
10
P8e_231a
Replacement
1 Clean the Laser window. 2 Assemble in reverse order. 3 Verify proper operation.
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REP 4.6.5 HVPS (High Voltage Power Supply) PWB
CAUTION
These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage.
Removal
1 2 3 4 5 6 7 8 9 10 Switch the printer power off and disconnect the AC power cord. Remove the Face Up Cover (REP 4.1.1). Remove the Print Cartridge (REP 4.5.1). Remove the Front Cover (REP 4.1.2). Remove the Rear Cover (REP 4.1.3). Remove the Top Cover (REP 4.1.4). Remove the Left Side Cover (REP 4.1.5). Disconnect the following from the top of the HVPS PWB, CN2, CN3, and CN4 (Figure 4.6.5a). Remove the five screws that secure the HVPS to the printer frame (Figure 4.6.5a). Lower the HVPS PWB to access connector CN1. Disconnect CN1 from the HVPS PWB (Figure 4.6.5a).
NOTE: With the HVPS PWB removed, the four high voltage contacts can be removed. The three top contacts are the same size. The bottom contact (transfer) is longer than the other three (Figure 4.6.5a).
Figure 4.6.5a. High Voltage Power Supply Removal.
9
7
8
P8e_227
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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REP 4.6.6 Joint PWB
CAUTION
These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage.
Removal
Switch the printer power off and disconnect the AC power cord. Remove the Print Cartridge (REP 4.5.1). Remove the Rear Cover (REP 4.1.3). Turn the printer up side down. Remove the Bottom Shield (REP 4.6.1). Remove the Engine Controller PWB (REP 4.6.2). Disconnect CN401, CN402, CN403, CN404, CN405, CN407 and CN408 from the Joint PWB (Figure 4.6.6a). 8 Remove the three screws securing the Joint PWB to the Printer Frame (Figure 4.6.6a). Remove the Joint PWB. 1 2 3 4 5 6 7
Figure 4.6.6a. Joint PWB Removal.
8
7
P8e_229
Replacement
1 Assemble in reverse order. 2 Verify proper operation.
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Section 5
General Procedures and Information
5
5.1 Precautions ..................................................................................... 5-3 5.1.1 General Safety Precautions ..................................................... 5-3 5.1.2 Service Precautions................................................................. 5-3 5.1.3 ESD Precautions ..................................................................... 5-4 5.1.4 Laser Safety............................................................................. 5-4 5.2 Printer Operations .......................................................................... 5-5 5.2.1 Control Panel ........................................................................... 5-5 5.2.2 Printer Modes .......................................................................... 5-6 5.2.2.1 Ready Mode (Online)...................................................... 5-6 5.2.2.2 Test Mode ....................................................................... 5-6 5.2.3 Clearing Printer Memory.......................................................... 5-7 5.2.4 Print Cartridge Cleaning Procedure......................................... 5-7 5.3 Printer Software .............................................................................. 5-7 5.3.1 Installing Software ................................................................... 5-8 5.3.1.1 Installing Printer Drivers.................................................. 5-8 5.3.1.2 Installing Status Monitor and Remote Control Panel ........ 585.3.2 The Status Monitor .......................................................... 5-9 5.3.3 Remote Control Panel (RCP)................................................. 5-10
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5.3.3.1 Total View Tab ............................................................... 5-12 5.3.3.2 Printer Tab .................................................................... 5-13 5.3.3.3 Page Tab ....................................................................... 5-14 5.3.3.4 Font Tab ........................................................................ 5-15 5.3.3.5 Quality Tab .................................................................... 5-16 5.3.3.6 Test Tab......................................................................... 5-17 5.4 Diagnostic Control Unit (DCU) .................................................... 5-17 5.4.1 Connecting the DCU .............................................................. 5-18 5.4.2 The DCU's Operating Modes ................................................. 5-18 5.4.2.1 Status Mode.................................................................. 5-20 5.4.2.2 Diagnostic Mode ........................................................... 5-21 5.4.3 General Test Procedures ....................................................... 5-22 5.5 Engine Controller PWB ................................................................ 5-25 5.6 Installing Additional Memory....................................................... 5-25 5.7 EPROM Update Procedure........................................................... 5-27 5.8 Supplemental Tools and Supplies .............................................. 5-29 5.8.1 Tools ...................................................................................... 5-29 5.9 Abbreviations................................................................................ 5-30
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5.1 Precautions
The three subsections below focus on three kinds of precautions important to service persons: · · · General safety precautions needed by everyone using or handling the printer. Precautions needed by anyone servicing the printer. Additional service precautions specifically related to Electrostatically Sensitive Devices (ESDs).
Read each of these precautions carefully.
5.1.1 General Safety Precautions
1 Do not use this printer near water, or where any kind of liquid can spill on it, and do not expose it to inclement weather. 2 Make sure the printer is on a stable surface, and that the surface is large enough to keep the printer from being accidentally knocked to the floor. 3 The printer's ventilation slots are designed to prevent overheating. Make sure these slots are not covered or blocked. Don't put the printer in any enclosure that doesn't permit full ventilation. 4 Never insert objects of any kind into the printer through the ventilation slots. Such objects may touch dangerous high voltage points, causing electric shock, a short circuit, or a fire. 5 Use only a grounded / earthed power source. If you are not sure of the type of power available, consult your dealer or the local power company. 6 Make sure no one can trip on the power cord or communication cable, and that no weight is placed on them. 7 Avoid touching the surface of the photo-sensitive drum. The surface is easily marked, and any scratch or mark can affect print quality. 8 Don't expose the print cartridge to direct light for long periods. 9 Follow the directions in Section 2, "Paper Specifications," on the proper choice of paper. 10 Before cleaning, disconnect the AC power. Use only a damp cloth for cleaning. Do not use liquid cleaners or aerosol sprays.
5.1.2 Service Precautions
1 Before disassembly, disconnect the AC power. 2 Replace parts only with the same parts. 3 Pay attention to the proper orientation of parts when mounting or inserting them. 4 Pay particular attention to the Electrostatically Sensitive Device (ESD) precautions, since failure to follow them can seriously damage the unit.
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5.1.3 ESD Precautions
CAUTION
These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage.
Semiconductor (solid state) devices that are easily damaged by static electricity are called Electrostatically Sensitive Devices. Examples are integrated circuits (ICs), large-scale integrated circuits (LSIs), semiconductor chip components, and some field-effect transistors. The following techniques are designed to reduce the danger of damage to printer components as a result of static electricity. 1 Check and observe all the safety and servicing precautions. 2 Before handling any circuit board or wiring assembly, perform the ESD procedures.
NOTE: to avoid the danger of shock, be sure to remove the wrist strap before powering up the unit under test.
3 Place any sensitive assemblies on a conductive surface. This will prevent accumulation of static electricity. 4 Do not use freon-propelled chemicals. These can generate enough static charge to damage sensitive components. 5 Do not remove a replacement component from its protective package until you are ready to install it. Most replacement components are packaged with leads that are electrically shorted together by conductive foam, aluminum foil, or other conductive material. 6 Immediately before removing the protective material from the component, touch the protective material to the printer chassis or the circuit assembly in which the device will be installed. 7 Minimize body motions when handling unpackaged replacement components. Even such simple motions as clothes brushing together or a foot being lifted from a carpet can generate enough static electricity to cause damage.
5.1.4 Laser Safety
The laser printer contains a Class IIIb laser. All laser safety information is contained on pages iii and iv in the front of this manual.
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5.2 Printer Operations
5.2.1 Control Panel
The Control Panel (Figure 5.2.1) is located on the right forward corner of the Front Cover Assembly. The Control Panel includes a single On/Off-line button and three indicator LEDs. The On/Off-line button has multiple functions that enable the user to select the desired operation. The three Indicator LEDs: red (Error), amber (Paper), and green (Ready). These LEDs indicate the printer's status. (More detailed information about printer status is available through the Status Monitor software utility.)
Figure 5.2.1 Control Panel.
Error LED Paper LED Ready LED
On/Off-line Button
sm5_007a
The table below provides various LED conditions and describes their significance.
Indicator Error LED (on) Description There is no print cartridge. The cover is open. There is a paper jam (if the Paper LED is on). Other error condition. Printer memory is insufficient for print job. The paper tray is empty. There is a paper jam (if Error LED is also on). The printer is on manual feed mode (push On/Off-line button to feed paper from manual feeder). The printer is ready to receive and process data. The printer is receiving or processing data. The printer is offline Possible printer failure.
Error LED (blink) Paper LED (on) Paper LED (blink) Ready LED (on) Ready LED (blink) Ready LED (off) All LEDs (blink)
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5.2.2 Printer Modes
The Printer has two modes of operation, each with its own set of options. 1 Ready Mode (online) 2 Test Mode
5.2.2.1 Ready Mode (Online)
The Ready Mode (Online) is the printer's normal operating mode. In this mode the printer is online and ready to print. Ready Mode occurs automatically when the printer is switched on. The printer can be taken Offline by pressing the On/Off-line button. When the button is pressed the Ready LED will go off. Ready Mode may be restored by pressing the On/Off-line button again. When the printer is in Ready Mode, the "Ready" LED on the Control Panel is lit. When the "Ready" LED is blinking, the printer is receiving/processing data, or printing. When the Ready LED is OFF, the printer is Offline.
5.2.2.2 Test Mode
In Test Mode, the printer is able to print a one page configuration sheet.
Local Test Mode To initiate a printer self-test and print a configuration sheet, follow these steps: 1) Make sure the printer in on-line. 2) Press and hold the On/Off-line button until all three LEDs are blinking (approximately four seconds), then release the button. The configuration sheet will be printed. Remote Test Mode The Remote Control Panel software can be used to tell the printer to print a one page printer configuration sheet, although it cannot make the printer do a self-test.
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5.2.3 Clearing Printer Memory
This function resets the printer, restoring user default settings and clearing all data from the printer's memory except permanent fonts and macros. To clear printer memory, while the "Ready" LED is OFF (the On/Off-line button has been pressed to take the printer off line), press and hold the On/Off-line button until all three LED's are blinking. When the button is released, all the LEDs except the Ready LED go out.
5.2.4 Print Cartridge Cleaning Procedure
This procedure is used to remove excess toner from the Print Cartridge. To initiate this procedure, the "Ready" LED must be ON. Press and Hold the On/Off-line button until all four LED's remain lit (not blinking) and the Printer begins to cycle up (starts the feed of the page). The printer will produce one page. Depending on the contamination, the page may contain a heavy concentration of background. More than one cleaning cycle may be required to remove contamination. Replace Printer Cartridge if cleaning cycles do not resolve the print quality problem.
5.3 Printer Software
The customer has a choice of different software configurations depending upon their needs. The Printer can be configured for Windows 3.1x, Windows 95/98 or Windows NT 4.0. The printer software includes: Print Drivers, Remote Control Panel (RCP), and Status Monitor. This section describes each of the software selections. These programs enable the user to: · · · · · be alerted of any printer changes (Status Monitor) configure the printer (driver) (RCP for DOS programs inside Windows) set default parameters for the current print job (driver) (RCP for DOS programs inside Windows) adjust toner usage (RCP) print a configuration sheet, handle printer fonts and print a demo page (RCP)
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5.3.1 Installing Software
To install the software, the printer does not need to be connected to the computer or be on. However, in order to start the RCP or SM programs, the printer must be powered on and properly connected by a IEEE-1284 compliant parallel printer cable.
5.3.1.1 Installing Printer Drivers
Installing the software for Windows 95/98
1 Start Windows. If Windows detects new hardware, click cancel. 2 Insert the disk labeled "PG L8L Driver Disk" into your computer's floppy drive. 3 From the Start menu, select Run. 4 In the Run dialog box, type a:\setup (or b:\setup) and press Enter. 5 Follow the on-screen instructions to complete the installation. 6 Remove the diskette before restarting Windows. 7 Restart Windows, as prompted, when the installation is complete.
Installing the software for Windows 3.1x
1 Start Windows. 2 Insert the disk labeled "PG L8L Driver Disk" into your computer's floppy drive. 3 From the Program Manager, select Run from the File menu. 4 In the Run dialog box, type a:\setup (or b:\setup) and press Enter. 5 Follow the on-screen instructions to complete the installation. 6 Remove the diskette before restarting Windows. 7 Restart Windows, as prompted, when the installation is complete.
Installing software for Windows NT 4.0
1 Start Windows. 2 Insert the disk labeled "PG L8L Driver NT 4.0 Disk" into your computer's floppy drive. 3 From the Windows NT 4.0 Start menu, select Settings, then Printers. 4 Double click on the Add Printer icon. 5 Click on My Computer and Next. 6 Select the port you are using, typically LPT1, then click on Next. 7 The computer will list different printer manufactures and models. Click on Have Disk. 8 In the Install from Disk dialog box, in the input box marked "Copy Manufacturer's Files From:", make sure it says "a:\". Click on OK 9 Olivetti PG L8L will be listed. Click on Next. 10 Follow the on-screen instructions to complete the installation.
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5.3.1.2 Installing Status Monitor and Remote Control Panel
Installing the software for Windows 95/98
1 Insert the diskette labeled "PG L8L RCP and SM Disk" into your computer's floppy drive. 2 From the Start Menu, select Run. 3 Type A:\setup and press Enter. Follow the on-screen instructions to complete the installation.
Installing the software for Windows 3.1x
1 Insert the diskette labeled "PG L8L RCP and SM Disk" into your computer's floppy drive. 2 From the Program Manager, select File, Rum. 3 Type a:\setup and press Enter. Follow the on-screen instructions to complete the installation.
Installing software for Windows NT 4.0 (RCP only)
1 Insert the diskette labeled "PG L8L NT 4.0 Disk" into your computer's floppy drive. 2 From the Start Menu, select Run. 3 Type A:\ntrcp\setup and press Enter. Follow the on-screen instructions to complete the installation.
Installing software for DOS
1 Insert the diskette labeled "PG L8L RCP and SM Disk" into your computer's floppy driver. 2 At the DOS prompt, enter the following commands: > md dosrcp > cd dosrcp > copy a:\dosutil\*.* > dosp8e.bat
5.3.2 Status Monitor
NOTE: The Status Monitor is not available with Windows NT 4.0.
The Status Monitor program runs in background mode. When selected, the Status Monitor automatically displays messages from the printer on the computer screen whenever the printer's status changes.
NOTE: On some machines Window's Print Manager must be disabled to get the Status Monitor to operate correctly.
Status Monitor Messages
ON-LINE: The printer is in Ready Mode, online and is ready to receive print data. The printer may be in standby mode or Power Save mode. When first turned on, the printer goes to this mode. OFF-LINE: The printer is off-line and not ready to receive print data. The user needs to press the On/Offline button in order to go to ON-LINE mode.
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Cover Open or Missing Cartridge: This message could either mean one or both of the following conditions have occurred: · · The printer's front cover is not closed properly The image cartridge is not installed or installed improperly.
Can't communicate with printer. Please check printer.: This error usually indicates some sort of hardware-related problem such as: · · · · The printer is turned off. The printer cable is not connected or not connected properly. The printer cable is defective. The printer port and software driver settings don't match.
Technician's Note: In the current release of the printer and software, sometimes this message pops up for a few seconds and goes back down again when the printer is busy: i.e. printing a job or warming up the fuser. Paper Tray Open or Empty.: There is no paper either in the Multipurpose Paper Feeder or Manual Feeder. Paper jam near input feeder.: The printer had problems grabbing paper from either the Multipurpose Paper Feeder or Manual Feeder. Paper should be pulled out, arranged carefully, and put back into the feeder. If there are only a few sheets of paper in the MPF and/or the paper in there has excessive curl, paper jams of this type will occur. Paper jam near inside rear of printer.: The printer had a jam while feeding paper into the xerographic area. To remedy the problem, the user should open the cover, remove the image cartridge, and paper cleared. Paper jam near front of printer.: The printer had a jam in the area from the fuser to face-up stacker or fuser to face-down stacker. To remedy the problem, the user should clear any paper from the stackers, open the cover, tear off any jammed paper, remove the image cartridge, and clear any remaining paper without using excessive force. If any paper is still jammed in the roller assembly to the face-down stacker, this will clear when the printer cover is closed and the printer warmed-up. Memory Full.: The printer is unable to print the current print job because of insufficient memory due to the complexity of the print job or too many fonts. Unknown Error.: A catastrophic printer failure such as a laser or fuser error has occurred. For this current release, it is not known whether this error message has been implemented.
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5.3.3 Remote Control Panel (RCP)
The Remote Control Panel (RCP) has several different functions. As opposed to the driver which allows the user to control how Windows applications drive the printer, the RCP is used to control printer de