Operator’s
Guide
The Printronix L5020 Multifunction Printer
Consumables Information
Printronix® has years of experience designing printer imaging
systems. For the best possible performance of your Printronix
printer, always use Genuine Printronix parts and consumables.
For the name of your nearest Printronix full service distributor, call:
United States (800) 733-1900 or (714) 368-2300
Europe (33) 1-46-25-1900
Singapore (65) 548-4116
Consumable Item Part Number
Toner cartridge 703532-001 21,000
Waste toner bottle 202984-001 150,000
Photoreceptor drum 703535-001 150 - 300,000
Developer 703548-001 150,000
Developing Unit 705739-001 600,000
Note 1: Varies with paper size, media type, and toner coverage.
Note 2: Inspect every 150,000 pages; clean if needed. Replace
at 300,000 pages or sooner of print quality is no longer
acceptable. Drum life is dependent upon media used and proper
maintenance and operation of the printer. Print media other than
bond paper (e.g., labels, card stock, plastic, or vinyl) may reduce
drum life as much as 50%.
For more information, please go to our website at
www.printronix.com.
Replacement Interval
(in Pages)
See Note 2
1
L5020 Mu ltifunc tion P rin ter
Operator’s Guide
706593-001C
Software License Ag re emen t
CAREFULLY READ THE FOLLOWING TERMS AND
CONDITIONS BEFORE USING THIS PRINTER. USING THIS
PRINTER INDICATES YOUR ACCEPTANCE OF THESE TERMS
AND CONDITIONS. IF YOU DO NOT AGREE TO THESE TERMS
AND CONDITIONS, PROMPTLY RETURN THE PRINTER AND
ALL ACCOMPANYING HARDWARE AND WRITTEN MATERIALS
TO THE PLACE YOU OBTAINED THEM, AND YOUR MONEY
WILL BE REFUNDED.
Definitions.
“Software” shall mean the digitally encoded, machine-readable
data and program. The term “Software Product” includes the
Software resident in the printer and its documentation. The
Software Product is licensed (not sold) to you, and Printronix, Inc.
either owns or licenses from other vendors who own, all copyright,
trade secret, patent and other proprietary rights in the Software
Product.
License.
1.
Authorized Use. You agree to accept a non-exclusive license
to use the Software resident in the printer solely for your own
customary business or personal purposes.
2.
Restrictions.
a. To protect the proprietary rights of Printronix, Inc., you
agree to maintain the Software Product and other
proprietary information concerning the typefaces in strict
confidence.
b. You agree not to duplicate or copy the Software Product.
c. You shall not sublicense, sell, lease, or otherwise transfer
all or any portion of the Software Product separate from the
printer, without the prior written consent of Printronix, Inc.
d. You may not modify or prepare derivative works of the
Software Product.
e. You may not transmit the Software Product over a network,
by telephone, or electronically using any means; or reverse
engineer, decompile or disassemble the Software.
f. You agree to keep confidential and use your best efforts to
prevent and protect the contents of the Software Product
from unauthorized disclosure or use.
3. Transfer. You may transfer the Software Product with the
printer, but only if the recipient agrees to accept the terms and
conditions of this Agreement. Your license is automatically
terminated if you transfer the Software Product and printer.
Limited Software Product Warranty
Printronix, Inc. warrants that for ninety (90) days after delivery, the
Software will perform in accordance with specifications published
by Printronix, Inc. Printronix, Inc. does not warrant that the Software
is free from all bugs, errors and omissions.
Remedy
Your exclusive remedy and the sole liability of Printronix, Inc. in
connection with the Software is replacement of defective software
with a copy of the same version and revision level.
Disclaimer of Warranties and Limitation of Remedies
1. THE PARTIES AGREE THAT ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF
FITNESS FOR A PARTICULAR PURPOSE AND
MERCHANTABILITY ARE EXCLUDED.
Printronix, Inc. does not warrant that the functions contained in
the Software will meet your requirements or that the operation
of the Software will be uninterrupted or error free.
Printronix, Inc. reserves the right to make changes and/or
improvements in the Software without notice at any time.
2. IN NO EVENT WILL PRINTRONIX, INC. BE LIABLE FOR
LOST PROFITS, LOST DATA, BUSINESS INTERRUPTIONS,
OR ANY OTHER DIRECT, INDIRECT, INCIDENTAL OR
CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE
OF OR INABILITY TO USE THIS PRODUCT, EVEN IF
PRINTRONIX, INC. HAS BEEN ADVISED OF THE
POSSIBILITY OF SUCH DAMAGES, OR ANY DAMAGES
CAUSED BY THE ABUSE OR MANIPULATION OF THE
SOFTWARE. SOME STATES DO NOT ALLOW THE
EXCLUSION OR LIMITATION OF LIABILITY FOR
CONSEQUENTIAL OR INCIDENTAL DAMAGES, SO THE
ABOVE LIMITATION MAY NOT APPLY TO YOU.
3. Printronix, Inc. will not be liable for any loss or damage caused
by delay in furnishing a Software Product or any other
performance under this Agreemen t.
4. Our entire liability and your exclusive remedies for our liability
of any kind (including liability for negligence except liability for
personal injury caused solely by our negligence) for the
Software Product covered by this Agreement and all other
performance or nonperformance by us under or related to this
Agreement are limited to the remedies specified by this
Agreement.
5. California law governs this Agreement.
Termination of License Agreement
This License shall continue until terminated. This license may be
terminated by agreement between you and Printronix, Inc. or by
Printronix, Inc. if you fail to comply with the terms of this License
and such failure is not corrected within thirty (30) days after notice.
When this License is terminated, you shall return to the place you
obtained them, the printer and all copies of the Software and
documentation.
U.S. Government Restricted Rights
Use, duplication or disclosure by the Government is subject to
restrictions as set forth in the Rights in Technical Data and
Computer Software clause at FAR 242.227-7013, subdivision (b)
(3) (ii) or subparagraph (c) (1) (ii), as appropriate. Further use,
duplication or disclosure is subject to restrictions applicable to
restricted rights software as set forth in FAR 52.227-19 (c) (2).
Acknowledgement of Terms and Conditions
YOU ACKNOWLEDGE THAT YOU HAVE READ THIS
AGREEMENT, UNDERSTAND IT, AND AGREE TO BE BOUND
BY ITS TERMS AN D CON DI TI ONS. N EIT HER PA RT Y SHAL L BE
BOUND BY ANY STATEMENT OR REPRESENTATION NOT
CONTAINED IN THIS AGREEMENT. NO CHANGE IN THIS
AGREEMENT IS EFFECTIVE UNLESS WRITTEN AND SIGNED
BY PROPERLY AUTHORIZED REPRESENTATIVES OF EACH
PARTY. BY USING THIS PRINTER, YOU AGREE TO ACCEPT
THE TERMS AND CONDITIONS OF THIS AGREEMENT.
Communication Notices
Federal Communications Commission (FCC) Statement: This
equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These
limits are designed to provided reasonable protection against
harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can
radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful
interference to radio communications.
Operation of this equipment in a residential area is likely to cause
harmful interference, in which case the user will be required to
correct the interference at his own expense.
Properly shielded and grounded cables and connectors must be
used in order to meet FCC emission limits. Printronix is not
responsible for any radio or television interference caused by using
other than recommended cables and connectors or by any
unauthorized changes or modifications to this equipment.
Unauthorized changes or modifications could void the user’s
authority to operate the equipment.
This device complies with Part 15 of the FCC Rules. Operation is
subject to the following two conditions: (1) this device may not
cause harmful interference, and (2) this device must accept any
interference received, including interference that may cause
undesired operation.
Canadian Department of Communications Compliance
Statement: This Class A digital apparatus complies with Canadian
ICES-003.
Avis de conformite aux normes du ministere des
Communcations du Canada: Cet appareil numerique de la classe
A est conform á norme NMB-003 du Canada.
European Community (EC) Conformity Statement:
This product is in conformity with the protection requirements of EC
Council Directive 89/336/EEC on the approximation of the laws of
the Member States relating to electromagnetic compatibility.
Printronix cannot accept responsibility for any failure to satisfy the
protection requirements resulting from a non-recommended
modification of the product, including the fitting of non-Printronix
option cards.
German Conformity Statement:
Zulassungsbescheinigung Gesetz über die elektromagnetische
Verträglichkeit von Geraten (EMVG) vom 30. August 1995
Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen
das EG-Konformitätszelchen - CE - zu führen.
Der Außteller der Konformitätserklärung ist die Printronix......(1)
Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2:
Das Gerät erfüllt die Schutzanforderungen nach EN 50082-1 und
EN 55022 Klasse A.
EN 55022 Klasse A Geräte bedürfen folgender Hinweise:
Nach dem EMVG: “Geräte dürfen an Orten, für die sie nicht
asreichend entstört sind, nur mit besonderer Genehmigung des
Bundesminester s für Po st und Teleko mmu nik at ion oder des
Bundesamtes für Post und Telekommunikation betrieben werden.
Die Genehmigung wird erteilt, wenn keine elektromagnetischen
Störungen zu erwarten sind.” (Auszug aus dem EMVG, Paragraph
3, Abs. 4) Dieses Genehmigungsverfahren ist nach Paragraph 9
EMVG in Verbindung mit der entsprechenden Kostenverordnung
(Amtsblatt 14/93) kostenpflichtig.
Nach der EN 55022: “Dies ist eine Einrichtung der Klasse A. Diese
Einrichtung kann im Wohnbereich Funkstörungen verursachen; in
diesem Fall kann vom Betreiber verlangt werden, angemessene
Maßnahmen durchzuführen und dafür aufzkommen.”
Anmerkung: Um die Einhaltung des EMVG sicherzustellen sind die
Geräte, wie in den Handbüchern angegeben, zu installieren und zu
betreiben.
This product has been tested and found to comply with the limits for
Class A Information Technology Equipment according to European
Standard EN 55022. The limits for Class A equipment were derived
for commercial and industrial environments to provide reasonable
protection against interference with licensed communication
equipment.
Warning
This is a Class A product. In a domestic
environment this product may cause radio
interference in which case the user may be
required to take adequate measures.
T radem ark Acknowledge ment s
Centronics is a registered trademark of Genicom Corporation.
CSA is a registered certification mark of The Canadian Standards
Association.
Dataproducts is a registered trademark of Dataproducts
Corporation.
EIA is a registered service mark of the Electronic Industries
Association.
Epson is a registered trademark of Seiko Epson Corporation.
Ethernet is a trademark of Xerox Corporation.
Hitachi is a registered trademark of Kabushiki Kaisha Hitachi
Seisakusho DBA Hitachi, Ltd.
IBM, OS/2, and Proprinter are registered trademarks, PC-DOS and
IPDS are trademarks of International Business Machines
Corporation.
IGP, LaserLine, LinePrinter Plus, PGL, PSA, and Printronix are
registered trademarks, and FlashFusion, is a trademark of
Printronix, Inc.
MS-DOS and Windows are registered trademarks of Microsoft
Corporation.
PhoenixPage PCL 5 is a registered trademark of Phoenix
Technologies LTD.
PKUNZIP is a registered trademark of PKWARE, Inc.
SELFOC is a registered trademark of Nippon Sheet Glass Co., Ltd.
3M is a registered trademark of the Minnesota Mining and
Manufacturing Company.
Toray is a registered trademark, and Toraysee is a trademark of
Toray Industries, Inc.
UL is a registered certification mark of Underwriters Laboratories
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.
Hiroshige and Marigold are trademarks of AlphaOmega
Typography, Inc.
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 2000, Printronix, Inc. All rights reserved.
Table of Contents
1 Introduction.............................................17
About This Manual...............................................................17
Important Safety Precautions.... ...... ...... ....... .................18
Components And Labels .....................................................20
About The Printer ................................................................24
Features........................................................................24
Emulations ....................................................................24
Fonts And Forms...........................................................25
2 Initial Setup............................................. 27
Installation Overview ...........................................................27
Loading Paper .....................................................................28
Powering On The Printer.....................................................31
Power Paper Stacker (Option).............................................33
Control Panel Commands.............................................34
Using The Control Panel .....................................................35
Control Panel ...............................................................35
Liquid Crystal Display (LCD).........................................36
Function Keys ...............................................................37
3 Consumables Replacement.................... 41
Consumable Replacement ..................................................41
Replacement Intervals ..................................................41
Opening The Upper Doors............................................42
Replacing The Toner Cartridge.....................................42
Replacing The Waste Toner Bottle ...............................46
Replacing The Photoreceptor Drum..............................48
Photoreceptor Drum Installation....................................53
Proper Disposal Of A Drum Unit ...................................55
13
Table of Contents
Replacing The Developing Unit.....................................56
Replacing Developer.....................................................60
4 Scheduled Maintenance .........................67
Maintaining Print Quality......................................................67
Maintenance Tools........................................................68
Service Level Page Counts...........................................68
Clearing Service Level Messages.................................70
Maintenance Schedules......................................................70
Cleaning Schedule........................................................70
Replacement Schedule.................................................71
Tech Service Maintenance Level Kits...........................72
General Cleaning.................................................................77
Vacuuming....................................................................77
Cleaning The Chargers.................................................85
Cleaning The Fuser Unit Cover Glass ..........................90
Major Cleaning ....................................................................95
Cleaning Unit ................................................................95
Cleaning The Photoreceptor Drum ...............................98
14
5 Troubleshooting ....................................101
Troubleshooting.................................................................101
Diagnostics .................................................................101
Paper Jams ......................................................................102
Paper Jam Near The Tractor ......................................102
Paper Jam Near The Paper Output Section ...............104
Paper Jam In The Transport Input Section.................109
Paper Jam In The Transport Output Section ..............111
Paper Jam In The Power Paper Stacker.....................112
System Status And Error Messages..................................114
Reprinting Pages After Fault Condition.......................115
Error Messages...........................................................119
Table of Contents
A Maintenance Log Sheets................ .....125
Maintenance Log Sheets.................................... ...... ....... ..125
Level A Maintenance - 15,000 Pages (User) ..............126
Level B Maintenance -150,000 Pages (User) .............127
Level C Maintenance - 600,000 Pages (User)............128
B Specifications.......................................129
Specifications ....................................................................129
Paper Specifications ...................................................129
Performance Characteristics.......................................132
Host Interfaces............................................................133
Emulations ..................................................................133
Memory Requirements................................................134
Safety Regulations......................................................134
Electromagnetic Interference......................................134
Physical Characteristics And Environment .................135
15
Table of Contents
16
1 Introduction
About This Manual
This manual explains how to use your printer.
Safety Notices And Special Information
For your safety and to protect valuable equipment, it is very
important that you read and comply with all information highlighted
under the following special headings.
WARNING
CAUTION
A warning notice calls attention to a condition that could harm
you.
WARNUNG
Ein Warhinweis dieser Art weist auf Verletzungsgefahr hin.
AVISO
Las notas de adviso llaman la atención sobre una condición
que puede causar lesiones.
ATTENTION
Attire votre attention sur une opération pouvant présenter un
danger.
AVVERTENZA
Un’indicazione di avvertenza segnala una condizione di
pericolo suscttibile causare lesioni all’operatore.
A caution notice calls attention to a condition that could
damage the printer.
17
Chapter 1 About This Manual
IMPORTANT
An important notice provides information that is vital to proper
operation of the printer.
NOTE: A note provides information and helpful tips about printer
operation.
Control Panel Keys And Display Messages
Keys and indicators that are labeled on the printer are printed in
uppercase letters. For example:
Press ENTER to select the value shown on the LCD.
Messages that appear on the control panel message display (called
the Liquid Crystal Display, or LCD), are printed in uppercase letters
and enclosed in quotation marks. For example:
“ENTER SWITCH LOCKED” appears on the LCD.
Important Safety Precautions
Observe the following precautions at all times to ensure safe
operation of the printer.
Read all instructions and save them for future use.
Follow all safety notices and instructions printed in this manual and
marked on the printer.
18
The operator-accessible power switch does not shut off all power to
the printer. You must unplug the power cord to shut off all power to
the printer.
The power outlet must be near the equipment and easily
accessible.
The printer relies on protective devices in the building installation
for protection. The printer must be connected to a 30 Amp, 250 V
outlet.
Do not operate the printer in a room that is not properly ventilated.
The room should be at least 1,000 cubic feet with a complete air
exchange every two hours.
Important Safety Precautions
Remove packaging materials carefully and save them for possible
future use. If the printer is powered on without removing all internal
tape and packing, the printer may be damaged.
Keep combustible materials away from the printer. Dispose of used
toner properly, as it is flammable.
Keep away from components in the printer that are potentially
hazardous. For example, the fuser unit becomes very hot under
normal operating conditions, and several components use high
voltage.
Handle the photoreceptor drum properl y, due to the nature of the
material. Do not put used drums in the trash; ship them to the
appropriate disposal facility for recycling.
Do not block or obstruct any cabinet ventilation slots.
Never spill liquid on or in the printer. Use only approved cleaning
agents and methods.
Put nothing on the power cord. Do not locate the power cord where
people can walk on it. Do not place the power cord under any
carpet.
Do not lean on or put heavy objects on top of the printer.
Turn off the power immediately if the printer emits an unusual noise
or smell.
Do not look directly at the flash lamp light.
19
Chapter 1 Components And Labels
Component s And Labels
Rear of Printer
Front of Printer
1
20
2
Legend:
1) Control Panel
2) CAUTION
Figure 1: Front and Rear Views
Important Safety Precautions
$
2
1
Legend:
1) WARNING
2) CAUTION
Figure 2: Safety Labels Behind Front Upper Doors
$
21
Chapter 1 Components And Labels
2
1
11
10
4
3
5
8
9
6
7
22
Legend:
1) Scuff Roller
2) Fuser Unit
3) Cleaning Unit
4) Main Charger
5) Toner Cartridge
6) Control Panel
7) Paper Feed Tractor
8) Developing Unit
9) Waste Toner Recovery Unit
10) Flash Power Supply
11) Transport Unit
Figure 3: Printer Components
$
Important Safety Precautions
1
$
2
3
5
6
Legend:
1) Power Switch
2) Diagnostic Port
3) Serial Port
4) Optional Coax/Twinax Port
5) 232/422 Toggle Switch
6) Parallel Port
Figure 4: Power Switch and Printer Interfaces
4
23
Chapter 1 About The Printer
About The Printe r
Features
Printing speed is 20 pages per minute on continuous letter size and
A4 size fanfold forms (long edge fed). The printer produces printed
output with a 300 x 300, (or optionally) 240 x 240, or 400 x 400
dots-per-inch (dpi) resolution. See Appendix B for printer
specifications.
Features include the following:
• Continuous fanfold paper
• User-replaceable toner cartridge
• FlashFusion™ fusing technology
• Two-line, 16-character alphanumeric display that provides
operating and error messages
• Flash Memory which stores preset conf igu ra tio ns and
emulations
24
• Serial and parallel inter fac es
• Coax/Twinax interface (optional)
• Power stacker (optional)
Emulations
Your printer comes equipped with the Printronix® LinePrinter Plus®
emulation software (which emulates an impact printer). Printronix
LinePrinter Plus includes the following printer protocols:
• P-Series
• P-Series XQ
• Serial Matrix
• Proprinter
• Epson
®
III XL
®
FX-1050
Fonts And Forms
Printronix LinePrinter Plus provides portrait and landscape image
orientation. Automatic 1-up, 2-up, 4-up, and gray bar overprinting
are also provided. The emulation also offers optional proportional
(scalable) fonts.
The following optional emulations are also available:
®
• IGP
/PGL
®
• IGP/VGL
• PCL5
• IPDS
For specific information on each emulation, see the appropriate
emulation manual.
®
™
Fonts An d Forms
The printer provides a variety of resident fonts. The emulation you
are using determines what resident fonts are available. For
example, the LinePrinter Plus emulation provides CG Times, Letter
Gothic, Courier, OCR-A, and OCR-B as standard sets of fonts.
With either the LinePrinter Plus or PCL 5 emulations, you can load
additional fonts into printer memory. Once any additional fonts are
in printer memory, you can then access them in the same way as
the resident fonts. Note that if you download fonts from the host
computer and do not save them, the downloaded fonts are lost
when the printer is powered off.
You can store forms together with fonts. The storage space for
forms and fonts depends upon the amount of printer memory
available. You can manipulate different fonts and/or forms
depending upon the emulation installed.
25
Chapter 1 About The Printer
26
2 Initial Setup
Installation Overview
This chapter explains how to load paper, power on the printer, use
the optional power stacker, and how to use the control panel.
The installation and setup of your printer should be performed by a
service pr ovider trained and authorized by Printronix. Your service
provider is also responsible for doing a preinstallation site survey,
unpacking the printer, connecting the power and host data cables,
and installing the first set of consumable items in the printer.
Depending on the terms of your service contract, your service
provider might also power on your printer and configure it.
As the owner of the printer, it is your responsibility to prepare the
printer site. This includes providing adequate ventilation and power
for the printer.
27
Chapter 2 Loading Paper
Loading Paper
Do the following steps whenever top-of-form must be reset (after
clearing a paper jam, loading new paper, etc.).
NOTE: You do not need to power off the printer power to replace
paper. If you leave the printer on and replace the paper it
will resume printing where it left off when you put it on line.
1. Place the paper box under the tractor unit with the first paper fold toward the printer.
IMPORTANT
Be sure the leading edge of the paper has a clean, separated
perforation without ragged edges.
2. Pass the leading edge of the paper between the lower paper
guides to prevent jams. Put the first fold of the paper facing the
printer as shown.
3
1
2
Legend:
1) Paper Guides
2) First paper fold is toward printer
3) Tractor Unit
28
3. Unlock only the right tractor by pushing forward on the tractor lock.
4. Open the left and right tractor gates and place the paper about
half-way onto the tractor pins. Do not push the paper past the
tractors; a paper jam sensor will detect a paper jam if the paper
is pushed too far.
5. Close the left tractor gate.
3
Legend:
1) Tractor Pins
2) Tractor Lock
3) Tractor Gate
1
2
6. Move the right tractor until its pins line up with the holes in the
right edge of the paper, put the paper on the pins, then close
the right tractor gate.
29
Chapter 2 Loading Paper
7. Introduce a slight amount of side-to-side tension into the paper
by setting the right tractor far enough to the right so that there is
no looseness or wrinkles in the paper. Be careful not to set the
right tractor too far to the right, however, as too much tension
may cause the paper holes to tear away from the tractor pins.
8. Tighten the paper by moving the right tractor slightly outward
and lock the right tractor with the tractor lock.
9.
If you are reloading paper following a “PAPER EMPTY”
message with the printer power on, press ONLINE to place the
printer online. The printer automatically sets the physical top of
form at the leading edge of the paper and resumes printing.
30
Powering On The Printe r
3
Legend:
1) Power Switch
2) Strain Relief
3) Door Latch
1
2
CAUTION
Figure 5: Power Switch
The printer must be connected to the proper power source:
220-240 VAC and 50-60 Hz, as shown on the rear panel label.
Using an incorrect power source may damage the printer.
1. Open the cabinet door by turning the key and flipping up the latch.
2. Route all cables through the hole in the bottom of the cabinet
and secure them with the strain relief.
3. Make sure the printer is plugged into the appropriate power
source, the interface cables are connected, and the host
computer is on.
4. Close the cabinet door and flip down the latch.
31
Chapter 2 Powering On The Printer
5. Turn on the printer by setting the power switch to | (on). When
you power on the printer, the following occurs:
a. The printer reads the emulation boot file and displays the
message:
H0: TEST HARDWARE
PLEASE WAIT...
b. The ONLINE indicator lights continuously and STAND BY
goes out.
NOTE: The printer can be set to power on in the OFFLINE state
instead of the ONLINE state. To print, ONLINE must be lit;
if it is not, press ONLINE.
If other messages and prompts appear on the control panel,
answer the prompts and follow the directions as explained on page
120.
32
Power Paper Stacker (Option)
$
$
1
1
2
2
Legend:
1) Heavy Mode/Light Mode Switch
2) Stacker Cover
Figure 6: Power Paper Stacker
33
Chapter 2 Power Paper Stacker (Option)
The L5020 Paper Stacker works with a specially designed basket.
The stacker can stack any paper in the following weight and width
ranges:
Weight: 8 to 44 lbs/ream (68 to 165 g/m
fanfold.
Width: 7 to 17.5 inches (178 to 445 mm) edge to edge.
As fanfold paper moves through the stacker, it is folded, allowing
the paper to stack evenly as it falls into the basket. The basket is
designed to stack approximately 1 box (3,000) sheets of paper. The
basket is also designed to compensate for the natural tendency of
the paper to crown as the height of the paper increases.
NOTE: Load the paper with the first perforation facing the printer.
This allows the stacker to re-fold the paper as it was
originally folded in the box.
Control Panel Commands
When setting up the operation of the stacker through the control
panel there are two options:
2
) bond (17 inch x 22 inch),
34
• Into Stacker
• Bypass Stacker
If Bypass Stacker is chosen, paper travels over the stacking
mechanism; the perforation on the paper is not broken.
The Control Panel path to these options is:
Paper Control > Paper Output > Into Stacker or Bypass Stacker
Heavy Mode/Light Mode Switch
The stacker has a manual switch to adjust its operation depending
on the weight of the paper. If the paper is less than or equal to 34
pounds, set the switch to Light Mode. If the paper is heavier than 34
pounds set the switch to Heavy Mode. In Heavy Mode the stacker
passes the paper through without actively breaking the perforation.
To activate the switch, open the stacker cover, as shown on page
33.
Using The Control Panel
Control Panel
Control Panel
1
JOB IN
SYS
SYNC
ONLINE FAULT
ONLINE CLEAR TEST SHIFT
AVAIL
PROCESS
STAND BYLINE
The control panel (Figure 7), is located on the top right side of the
front cover and consists of the following:
• A Liquid Crystal Display (LCD)
CANCEL
PAGE
EJECT
ENTER
PREV
4
Legend:
1) Status Indicators
2) Liquid Crystal Display (LCD)
3) Paper Path Diagram
4) Function Keys
Figure 7: Control Panel
2
UP
DOWN
3
NEXT
• Six status indicators
• Eleven function keys
• Paper path diagram
The LCD, status indicators, and function keys are described in the
following sections.
35
Chapter 2 Using The Control Panel
Liquid Crystal Display (LCD)
The liquid crystal display (LCD) displays printer status, messages,
configuration options, and error codes.
Status Indicators
The status indicators display the current operational status of the
printer.
LINE SYNC
Twinax interface only. Indicates there is activity on the line from the
host computer.
SYS A VAIL
Twinax interface only. Indicates there is activity to the current
address on the line.
JOB IN PROCESS
IMPORTANT
36
When the printer is receiving data or processing data, JOB IN
PROCESS flashes. If data has been processed and is waiting to be
printed, or has been printed but not yet fused and ejected by the
printer, JOB IN PROCESS lights continuously.
JOB IN PROCESS does not light when the printer is not processing
data, no data exists in the buffer, and the printer is not receiving
data.
STAND BY
Do not press any control panel key when STAND BY is
flashing. The printer may carry out unwanted commands.
STAND BY flashes while the printer is executing any control panel
command, and while the printer is unavailable for printing due to its
normal system activities, such as booting, printing its configuration,
writing status information, and loading applications.
Function Keys
ONLINE
ONLINE is lit continuously when the printer is online (when the
printer is ready to print and accept data from the host). It flashes
when the printer is offline or when the printer stops because of an
error.
F AULT
FAULT flashes when the printer is unavailable for printing because
of an internal error.
Function Keys
The pressure-sensitive function keys are located directly below the
status indicators. When pressing the keys, a “beep” verifies
contact.
The function keys permit you to configure the options of the printer.
You can access these options via a structured menu which is
displayed on the LCD. To navigate through the options, use the UP,
DOWN, NEXT, and PREV keys. Press ENTER to select an option
that appears on the LCD.
The purpose of each function key (under normal printing mode) is
defined below.
For specific procedures and information regarding the configuration
menu, see Chapter 3 in the
NOTE: You can enable or disable the panel key sound via the
configuration menu.
User’s Manual
.
ONLINE Key
The ONLINE key toggles the printer online and offline.
• To place the printer online, press ONLINE until the ONLINE
status indicator remains continuously lit. The LCD displays
“ONLINE,” along with the name of the current emulation. The
printer can now receive and process data and print.
37
Chapter 2 Using The Control Panel
• To place the printer offline, press ONLINE until the ONLINE
status indicator blinks. The LCD displays “OFFLINE.” The
printer stops processing and printing any new data, except for
any pages in process.
• To start downloading files to the printer, hold down the ONLINE
+ PAGE EJECT keys while cycling power. (See Chapter 3 in
User’s Manual.
the
NOTE: When the printer is not in an error state, pressing ONLINE
in any level of the configuration menu causes the printer to
accept any configuration changes you have entered and
return to online status.
When the printer is in an error state, pressing ONLINE in
any level of the configuration menu causes the printer to redisplay the fault message.
)
CLEAR Key
In the fault state, press the CLEAR key to clear errors and reset the
printer to the offline state (if all errors are cleared).
IMPORTANT
38
TEST Key
When the printer is offline, you can run a test print, as configured
under the Test Print menu (see Chapter 3 in the
pressing the TEST key. To stop the test print, press TEST again.
Pressing TEST when the printer is online has no effect.
User’s Manual
), by
SHIFT Key
This key does not have a function of its own. It is combined with
other keys to modify their functions.
PAGE EJECT Key
Do not press PAGE EJECT while JOB IN PROCESS is flashing,
or your print job might become misaligned.
The PAGE EJECT key performs the following functions when the
printer is online:
Function Keys
When the JOB IN PROCESS status indicator lights steadily,
pressing PAGE EJECT causes the printer to print all data in the
printer. The page is then cut at the perforation (unless the Burst On
Eject option is disabled).
When the JOB IN PROCESS status indicator flashes, pressing
PAGE EJECT causes the printer to attempt to print any data in the
buffer. The paper motion caused by the page eject operation may
interrupt the printing of data that is not currently in the buffer. Once
the paper motion has occurred, the data that was not yet in the
buffer should print. The page is then cut at the perforation (unless
the Burst On Eject option is disabled).
To start downloading files to the printer, hold down the ONLINE +
PAGE EJECT keys while cycling power. (See Chapter 3 in the
User’s Manual.
When the JOB IN PROCESS status indicator is not lit or flashing,
PAGE EJECT has no effect.
Pressing the SHIFT + PAGE EJECT keys together moves the
paper one page length without printing or cutting the paper. It can
be used to feed the paper into (customer-supplied) postprocessing
equipment.
)
ENTER Key
When you enter parameters in the configuration menu, press
ENTER to select the value shown in the LCD. The printer confirms
your selection by placing an asterisk (*) next to the value in the
display. However, i f the ENTER key is locked, “ENTER SWITCH
LOCKED” appears and the value is not accepted.
CANCEL Key
The CANCEL key performs the following functions when the printer
is offline:
• Cancels the current page in process
• Cancels any pages queued to print but not yet printed
• Cancels any input data not yet processed
39
Chapter 2 Using The Control Panel
• Clears the reprint buffers
• Cancels a download if one is in process. See Chapter 3 in the
User’s Manual
.
UP And DOWN Keys
The UP and DOWN keys are used for the configuration menu:
• To unlock or lock the ENTER key, press UP + DOWN at the
same time when the printer is offline
• To enter the configuration menu, press DOWN when the printer
is offline
• To move between the different levels in the configuration menu,
either press UP or DOWN as needed
NEXT And PREV Keys
The NEXT and PREV keys are used to move between the
parameter options on the current level of the configuration menu.
Press NEXT or PREV to move forward or backward through
parameter options.
40
3 Consumables
Replacement
Consumable Replacement
Replacement Intervals
For the best print quality, replace the printer consumables at the
intervals specified below. The yield of the supplies is based on a
4% coverage of letter size (8.5 inch x 11 inch) paper. However, the
yield may vary according to your print applications, environmental
conditions, and toner density setting.
Consumable Item Part Number Replacement Interval (in Pages)
Toner Cartridge 703532-001 25,000
Waste toner bottle 703539-001 150,000
Photoreceptor drum 703535-001 150 - 300,000
See Note 2
Developer 703548-001 150,000
Developing unit 705739-001 600,000
Note 1: Will vary with paper size, media type, and toner coverage.
Note 2: Replace at 300,000 pages or sooner if print quality is no longer acceptable.
Drum life is dependent upon media used and proper maintenance and
operation of the printer. Print media other than bond paper (e.g., labels, card
stock, plastic, or vinyl) may reduce drum life as much as 50%.
1
41
Chapter 3 Consumable Replacement
Opening The Upper Doors
1. Take the printer offline.
2. When paper motion stops, wait 15 seconds, then open the printer upper doors.
1
42
Legend:
1) Upper Door
Replacing The Toner Cartridge
NOTE: When replacing the toner cartridge, place the old cartridge
in a disposable wrapper (e.g., a plastic bag, paper towels,
newspaper) to minimize toner spillage.
You can wear vinyl gloves to prevent toner from contacting
the skin. If necessary, use only cold water to remove toner
from skin or clothing.
Replacing The Toner Cartridge
3. Rotate the toner cartridge counterclockwise until the notch is
aligned with the pin in the toner hopper, and remove the
cartridge.
1
Legend:
1) Notch
2) Toner Cartridge
3) Positioning Pin
2
3
4. Put the old cartridge into a plastic bag and discard it.
5. Keep the new toner cartridge in its package. Hold it level and
shake it back and forth several times as shown. This loosens
the toner in the cartridge.
1
Legend:
1) Toner Cartridge
43
Chapter 3 Consumable Replacement
6. Remove the new toner cartridge from its package.
7. With the cover tape facing up, insert the cartridge into the toner
hopper, and slowly pull off the cover tape in the direction of the
arrow. Remove the last of the tape just as the cartridge is
completely inside the hopper.
1
2
3
4
44
Legend:
1) Pin
2) Toner Hopper
3) Cover Tape
4) Notch
8. Fit the notch to the pin on the developing unit. Push the new
toner cartridge as far as possible into the toner hopper.
Replacing The Toner Cartridge
9. Rotate the cartridge clockwise as far as it will turn.
1
Legend:
1) Toner Cartridge
10. If any toner has spilled, remove it with wet tissue paper or a toner vacuum.
11. Close the upper doors.
45
Chapter 3 Consumable Replacement
Replacing The Waste Toner Bottle
When the “WASTE TONER FULL” message appears on the control
panel, replace the waste toner bottle by doing the following steps,
and discard the empty bottle. Do not reuse the bottle.
1.
When paper motion stops, wait 15 seconds, then open the printer upper doors. (See page 42.)
2.
Open the waste toner recovery unit by pressing down on the
opening lever and pulling the door toward you.
1
46
2
Legend:
1) Waste Toner Recovery Door
2) Opening Lever
Replacing The Waste Toner Bottle
3. Remove the cap from the outside of the waste toner bottle, and cap the toner bottle.
1
Legend:
1) Cap
2) Waste Toner Bottle
2
4. Remove the waste toner bottle from the unit and discard it.
5. Install a new waste toner bottle.
6. Close the printer upper doors.
7. Clear Error 28, “WASTE TONER FULL,” as follows:
a. Press CLEAR.
b. Press UP + DOWN to unlock the configuration menu.
+
c. Enter the configuration menu and select the Paper Control
menu.
d. Select the “RESET TONER FULL” option and press
ENTER.
e. Exit the configuration menu .
f. Press ONLINE.
47
Chapter 3 Consumable Replacement
Replacing The Photoreceptor Drum
Drum life is dependent upon media used and proper maintenance
and operation of the printer. Print media other than bond paper
(e.g., labels, card stock, plastic, or vinyl) may reduce drum life as
much as 50%.
To replace the drum, you need a drum auxiliary rod. Please read all
steps before beginning the replacement procedure.
Removal
CAUTION
Do not do this procedure unless you have had the appropriate
training. Do not do this procedure without the drum auxiliary
rod (P/N 703531-170), as you may damage the drum.
1. Turn the power switch OFF.
2. Open the printer upper doors. (See page 42.)
3. Open the waste toner recovery unit. (See page 46.)
4. Remove the developing unit. (See page 56.)
5. Vacuum any spilled toner.
48
Replacing The Photoreceptor Drum
CAUTION
The transfer charger must be in the down position to avoid
scratching the drum. Failure to perform steps 6 and 7 damages
the drum.
6. Rotate the transfer elevator drive shaft counterclockwise. Watch the charger movement:
a. If the charger starts to move up, it is already in the down
position.
b. If the charger starts to move down, continue to rotate the
drive shaft until the charger reaches the complete down
position.
1
2
Legend:
1) Transfer Charger
2) Transfer Elevator Drive Shaft
49
Chapter 3 Consumable Replacement
CAUTION
To avoid damaging the printer or causing false paper jams, the
transport lever must be in the fully down position before
closing the transport unit.
7. Lower the transport unit by turning the green lever on the transport unit to the left.
1
Legend:
1) Green Lever
50
Replacing The Photoreceptor Drum
8. Loosen the three thumbscrews securing the drum plate and remove the drum plate.
1
2
Legend:
1) Drum Plate
2) Thumbscrews (3)
9. Remove the nut from the end of the drum shaft.
1
Legend:
1) Nut
51
Chapter 3 Consumable Replacement
10. Screw the drum auxiliary rod onto the drum shaft.
2
1
52
Legend:
1) Drum Auxiliary Rod
2) Drum Shaft
Photoreceptor Drum Installation
11. Pull the drum out along the drum auxiliary rod. Hold the front
and back ends when the drum is nearly out of the printer, and
remove it with both hands.
1
Legend:
1) Drum
12. Pack the old drum for shipment using the original packaging
material, and close the cover of the box.
CAUTION
13. Wipe the drum shaft clean with a cloth.
Photoreceptor Drum Installation
Avoid touching the surface of the drum with your hands. It
reduces the life of the drum
1. Remove the new photoreceptor drum from its package. Do not
discard the packaging material; as you need it for future drum
disposal. The ends of the drum are identical; there are no front
or back ends.
2. Wipe inside the endcaps of the drum with a cloth to ensure that they are clean.
53
Chapter 3 Consumable Replacement
CAUTION
CAUTION
CAUTION
Exposing the drum to light shortens its life. Do not expose the
drum to direct sunlight, and install it within five minutes under
typical room lighting conditions. When removing the drum
from its packaging, do not touch the surface of the drum.
Fingerprints and scratches can damage the surface and cause
poor print quality.
3. Using both hands, slowly slide the drum onto the drum auxiliary
rod. When the drum reaches the area where the auxiliary rod
connects to the drum shaft, lift the drum very gently over the
connection. Let the drum rest on the rubber rollers as you
gently guide it into the printer.
The drum must rest on the rubber rollers to avoid being
scratched.
4. When the drum is fully inserted into the printer, the end of the
drum is slightly recessed relative to the front of the printer and
the rubber guide rollers should be visible. Slightly lift the drum
up off of the rubber rollers and rotate the drum by hand while
applying inward pressure, until the drum moves slightly farther
into the printer and locks in place.
In order to position the drum slot and the drum shaft pin, push
the drum in all the way to the back and rotate it until you fe el it
drop in place. Failure to lock the drum in place properly can
severely damage the printer.
54
Never force t he dr um onto t he sha ft. If it feels as thoug h the dr um is
not seating properly, remove the drum and inspect the shaft for
foreign material or burrs.
5. Remove the drum auxiliary rod from the drum shaft.
6. Install the nut on the drum shaft and tighten it securely by hand.
7. Install the drum plate and tighten the thumbscrews. While
installing the drum plate, hold the copper grounding clip with
your thumb. Otherwise the grounding clip can be bent, making
no contact with the drum shaft.
Proper Disposal Of A Drum Unit
8. After installing the drum plate, visually verify good electrical
contact between the copper grounding clip and the end of the
drum shaft.
Alternatively, measure the resistance. Connect one lead of an
ohmmeter to the bracket on the drum plate, and touch the other
lead to the edge of the drum. Normal resistance should be 0
9. Install the developing unit.
10. Raise the transport unit by turning the green lever on the transport unit to the right.
11. Close the waste toner recovery unit and ensure that it latches.
12. Close the printer upper doors.
Proper Disposal Of A Drum Unit
Federal regulations prohibit inappropriate disposal of laser print
drums. Dispose of used drums by shipping them to one of the
following organizations:
Ω.
Within U.S.A.
U.S. Fuji Electric, Inc.
240 Circle Drive N.
Piscataway, NJ 08854
Attn: Rod Storm
Phone: (732) 560-9410
Outside U.S.A.
Fuji Distribution Europe B.V.
Attn: Mr. Asada
Leisteen 7,2132 ME Hoofddorp,
The Netherlands.
TEL: 20-6534790
55
Chapter 3 Consumable Replacement
Replacing The Developing Unit
CAUTION
Do not replace the developing unit unless you have been
trained to do so. Be careful not to damage the sensors while
cleaning the developing unit. (If damage occurs, contact your
service representative.)
Removal
1. Turn the power switch OFF.
2. Open the printer upper doors. (See page 42.)
3. Open the waste toner recovery unit. (See page 46.)
4. Rotate the developing unit lever fully clockwise so that it is
pointing straight up. This separates the developing unit from
the photoreceptor drum.
1
56
Legend:
1) Lever
Replacing The Developing Unit
5. Remove the developing unit by holding the lever in one hand
and pulling the developing unit partially out of the printer.
1
2
Legend:
1) Developing Unit
2) Lever
57
Chapter 3 Consumable Replacement
6. With your other hand, grasp the hanger and remove the developing unit from the printer.
1
58
Legend:
1) Hanger
7. Place the old developing unit in a plastic bag and dispose of it properly.
8. Vacuum any spilled toner.
9. Remove the new developing unit from its package, and add developer to the unit. (See page 63.)
Replacing The Developing Unit
1
9
8
Legend:
1) Toner Cartridge
2) Developing Unit
3) Auger
4) Toner Sensor
5) Developing Tank
6) Developing Roller
7) Toner Supply Roller
8) Screws (3)
9) Cover
Cross Section
of Developing
Unit
7
6
2
3
4
4
5
59
Chapter 3 Consumable Replacement
Replacing Developer
The toner sensor is sensitive to both electrostatic discharge
(ESD) and positional adjustment. Do not touch the sensor with
your hand or jar it from its factory-set position. (See page 59.)
1. Turn the power switch OFF.
2. Open the printer upper doors. (See page 42.)
3. Prepare a large plastic bag in which to put the developing unit.
4. Remove the developing unit (See page 56.) and place it in the
plastic bag, making sure it is still accessible.
IMPORTANT
When replacing developer in an existing developing unit, you
must empty and clean the unit before adding new developer
Do this every 150,000 pages.
5. Turn the toner cartridge knob counterclockwise until it stops,
then remove the cartridge from the developing unit.
1
2
5
3
4
Legend:
1) Developing Unit
2) Toner Cartridge
3) Toner Cartridge Knob
4) Cover
5) Screws (3)
60
Replacing Developer
6. Remove the three screws on the developing unit cover and detach the cover.
7. Put the developing unit in the plastic bag and do the following: a. Remove the developer and toner in the toner hopper by
gently shaking the developing unit up and down with the
opening of the toner cartridge facing downward.
b. Rotate the developing unit and gently shake it, to allow any
remaining developer or toner to fall out of the cover slot.
8. Remove the developing unit from the plastic bag and place it on a protected surface.
9. Vacuum up any developer and toner which remains on the
toner supply roller and the auger with a toner vacuum cleaner
equipped with a narrow nozzle.
1
2
Legend:
1) Toner Hopper
2) Toner Spray-Guard Brush
10. Vacuum the toner from the toner spray-guard brush on the developing unit.
11. Shake the new developer bottle several times, remove the
bottle cap, and screw the nozzle tightly onto the bottle.
61
Chapter 3 Consumable Replacement
12. While rotating the new developing roller knob
counterclockwise, evenly pour the entire bottle of developer
powder into the developing unit.
1
2
IMPORTANT
62
Legend:
1) Bottle of new Developer
2) Developing Roller Knob
13. Replace the cover and tighten the screws.
If toner or developer spills on clothing, use cold water to
remove it.
14. Install the developing unit.
Replacing Developer
Install The Developing Unit
1. On the developing unit, rotate the lever fully clockwise so that it is pointing straight up.
3
1
2
Legend:
1) Hanger
2) Lever
3) Guide Rail
2. Holding the lever in one hand and the hanger in the other hand,
insert the developing unit on the guide rail.
3. Rotate the hanger to the right so that it rests against the
developing unit, and push the developing unit in.
63
Chapter 3 Consumable Replacement
4. Rotate the developing roller knob counterclockwise until the
unit drops into its final resting position. The developing unit
lever should protrude through the main body of the developing
unit.
1
2
64
Legend:
1) Lever
2) Developing Roller Knob
Replacing Developer
5. Rotate the developing unit lever fully counterclockwise to lock the developing unit in place.
1
Legend:
1) Lever
6. Close the waste toner recovery unit and ensure that it latches.
7. Close the printer upper doors.
65
Chapter 3 Consumable Replacement
66
4 Scheduled
Maintenance
Maint aini ng Print Qua lity
To maintain good print quality, clean the printer according to the
schedules and information listed in this chapter.
1. Do a General Cleaning. (See page 77.)
2. Clean the main charger, precharger, and transfer charger. For
cleaning instructions, see page 85 for the main charger, and
page 89 for the precharger and transfer charger.
3. If print quality problems occur, clean the following areas (see page 68 for tool part numbers):
a. Clean the drum with the drum freshener (only when smears
appear on print samples due to the drum).
b. Clean the LED array and the SELFOC
head) with the Toraysee™ cloth.
®
lens (LED print
c. Clean the fuser cover glass with a razor blade or the cover
glass scraper.
If the print quality is still poor after cleaning the printer, the chargers
may need to be replaced. Contact your authorized service
representative for further assistance.
NOTE: For replacement intervals, see the maintenance schedules
that begin on page 70.
67
Chapter 4 Maintaining Print Quality
Maintenance Tools
To maintain the printer, you need the following tools:
Item Part Number
Brush Cleaner 703531-169
Drum Auxiliary Rod 703531-170
Drum Freshener Pad 703531-171
Fuser Cover Glass Scraper 703531-187
Special Dry Tissue Paper 703531-188
Standard Toner Vacuum Cleaner See below for
Toraysee Cloth 703531-183
Wire Cleaner 703531-168
recommended models
IMPORTANT
68
9 inch Phillips #1 Screwdriver N/A
Recommended toner vacuum cleaner models are:
• 3M
®
model 497-AJM standard VAC with Type 1 filter
• 3M model 497-AB 220V with Type 1 filter
• Hitachi
®
CV-TN10 with TN-15 filter
Service Level Page Counts
Keep a record of all maintenance done on your printer.
Maintenance log sheets are provided in Appendix A.
Photocopy the pages and keep your maintenance log in a
binder near the printer. Every time you or your service
provider do printer maintenance make an entry in the log.
Each time you complete a level of preventive maintenance, you
must reset the service level page count by selecting the User
Maintenance option on the Mainte nanc e men u.
Service Level Page Counts
(See the Maintenance menu in Chapter 3 of the
Levels A, B, and C are your responsibility, while levels D through H
are the responsibility of your service provider.
When the page count reaches one of the maintenance intervals
listed below, the control panel displays one of the following
messages:
User Maint
X
Level X
Tech Service
Level X
X
X
Service Level
represents the level of service required:
User’s Manual
(User)
(Service
Technician)
.)
• Level A= every 15,000 pages
• Level B= every 150,000 pages
• Level C= every 600,000 pages
• Level D= every 300,000 pages
• Level E= every 600,000 pages
• Level F= every 900,000 pages
• Level G= every 1,200,000 pages
• Level H= every 2,400,000 pages
A service level includes all the levels that precede it. For example,
and
at 150,000 pages, you do Level B
pages, your service provider will do Level F, Level E, and Level D
service.
Note that this condition does not cause the printer to stop printing.
When one of the above messages appears, you should perform the
appropriate scheduled maintenance or call your factory-trained
service representative to perform the maintenance.
Level A service. At 900,000
69
Chapter 4 Maintenance Schedules
Clearing Service Level M essages
When you have done a level of service, clear the page count for
that service level. Note that when you clear a lower service level,
the levels above it are also cleared. For example, clearing level C
also clears levels A and B.
To clear a service level (level A, for example), select the
Maintenance menu from the control panel, select the User Maint
option, then select “Clear Level A” by pressing ENTER.
Maintenance Schedules
Cleaning Schedule
Each time you do maintenance, you must reset the service level
page count by selecting the User Maintenance option on the
Maintenance menu. (See the Maintenance menu in Chapter 3 of
User’s Manual
the
.) This removes the maintenance error message.
Do the following actions in Table 2 after the specified number of
letter size pages (4% coverage) have been printed. Appendix A,
“Maintenance Log Sheets,” contains log sheets you can photocopy.
Table 1. User Cleaning Responsibility
Action Frequency (Pages) Servi ce Level
General cleaning 15,000; See Note 1 A
Major cleaning 150,000 B
Note 1:
70
Every 15,000 pages or 6 paper jams, whichever occurs first.
Replacement Schedule
Replacement Schedule
Replace the following items after the specified number of letter size
pages (4% coverage) have printed. Appendix A, “Maintenance Log
Sheets,” contains log sheets you can photocopy.
Table 2. User Responsibility - Replacement
Item Part Number
Toner cartridge 703532-001 21,000
Waste toner bottle 202984-001 1 50,0 00
Photoreceptor drum 703535-001 150 - 300,000
Developer 703548-001 150,000 B
Developing Unit 705739-001 600,000 C
Note 1: Replace when the “TONER EMPTY” message displays. A guideline for the
replacement is 21,000 pages (A4 size, 4% coverage).
Note 2: Replace when the “WASTE TONER FULL” message appears. A guideline for
the replacement is every 90,000 pages (A4 size, 4% coverage).
Note 3: Inspect every 150,000 pages; clean if needed. Replace at 300,000 pages or
sooner if print quality is no longer acceptable. Drum life depends upon media used
and proper maintenance and operation of the print er. Print media other than bond
paper (e.g. labels, card stock, plastic or vinyl) can reduce drum life as much as 50%.
Frequency
(Pages)
See Note 1
See Note 2
See Note 3
Service Level
As Needed
As needed
B (as needed)
71
Chapter 4 Maintenance Schedules
Tech Service Maintenance Leve l Kits
The following maintenance kits should be used after the specified
letter size pages (4% coverage) have been printed.
Level D kit is used at 300,000 pages.
Item Part Number
Maintenance Kit, Level D, L5020 706802-001
• Main charger
• Precharger
• Transfer charger
• Smoke filter
72
Tech Service Maintenance Level Kits
Use Level E kit after printing 600,000 letter size pages.
Item Part Number
Maintenance Kit, Level E, L5020 706806-001
• Main charger
• Precharger
• Transfer charger
• Smoke filter
• Cleaning unit
• Transport belt (set of 3)
• Cutter motor
73
Chapter 4 Maintenance Schedules
Use Level F kit after printing 900,000 letter size pages.
Item Part Number
Maintenance Kit, Level F, L5020 706812-001
• Main charger
• Precharger
• Transfer charger
• Smoke filter
• Xenon (flash) lamp
74
Tech Service Maintenance Level Kits
Use Level G kit after printing 1,200,000 letter size pages.
Item Part Number
Maintenance Kit, Level G, L5020 706818-001
• Main charger
• Precharger
• Transfer charger
• Smoke filter
• Cleaning unit
• Transport belt (set of 3)
• Cutter motor
• Trigger coil unit
• Developing motor unit
• Exit feed roller belt
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Chapter 4 Maintenance Schedules
Use Level H kit after printing 2,400,000 letter size pages.
Item Part Number
Maintenance Kit, Level H, L5020 706830-001
The kit includes the following items:
• Main charger
• Precharger
• Transfer charger
• Smoke filter
• Cleaning unit
• Transport belt (set of 3)
• Cutter motor
• Trigger coil unit
• Developing motor unit
76
• Exit feed roller belt
• Lamp housing filter
• EPS3
• EPS4
• Capacitor
• Discharge LEDs (PEL)
General Cleaning
To maintain optimum print quality, clean the printer regularly.
Depending upon the density of your print jobs, the printer may
require cleaning every 10,000 - 20,000 sheets.
Vacuuming
1. Turn the power switch OFF.
2. Open the printer upper doors. (See page 42.)
3. Using a vacuum, clean up the toner, paper dust, etc. inside the upper doors.
Vacuuming
1
2
Legend:
1) Vacuum
2) Upper Door
4. Open the waste toner recovery unit. (See page 46).
77
Chapter 4 General Cleaning
5. Vacuum the developing unit and toner hopper.
1
2
78
Legend:
1) Developing Unit and Toner Hopper
2) Vacuum
6. Vacuum the cleaning unit.
1
Vacuuming
2
Legend:
1) Cleaning Unit
2) Vacuum
79
Chapter 4 General Cleaning
7. Vacuum the fuser unit.
8. Vacuum the lamp housing filter on the end of the fuser unit.
1
2
80
Legend:
1) Fuser Unit
2) Vacuum
Vacuuming
CAUTION
The transfer charger must be in the down position to avoid
scratching the drum. Failure to perform steps 9 and 10
damages the drum.
9. Rotate the transfer elevator drive shaft counterclockwise. Watch the charger movement:
a. If the charger starts to move up, it is already in the down
position.
b. If the charger starts to move down, continue to rotate the
drive shaft until the charger reaches the complete down
position.
1
2
CAUTION
Legend:
1) Transfer Charger
2) Transfer Elevator Drive Shaft
To avoid damaging the printer or causing false paper jams, the
transport lever must be in the fully down position before
closing the transport unit.
10. Lower the transport surface by turning the green lever on the transport unit to the left.
11. Pull the transport unit toward you until it stops.
81
Chapter 4 General Cleaning
12. Vacuum the toner, paper dust, etc. Be sure to clean under the transport unit as well.
3
1
2
82
Legend:
1) Transport Surface
2) Green Lever
3) Vacuum
13. Wipe off the dirt on the transport surface with wet tissue paper.
Make sure no paper debris is left on the surface
14. Using an ammonia-based wax-free cleaner or rubbing alcohol,
clean the belts to remove residue buildup and restore their
tacky surface.
Vacuuming
15. Push the transport unit into the printer while holding down the
green lever. Raise the green lever to the right to raise the
transport surface.
1
Legend:
1) Transport Surface
2) Green Lever
2
83
Chapter 4 General Cleaning
16. Vacuum the toner, paper dust, etc. in the tractor area.
1
3
Legend:
1) Tractor
2) Vacuum
3) Paper Guide
2
84
Cleaning The Chargers
Cleaning The Ch arge rs
1. Turn the power switch OFF.
2. Open the printer upper doors. (See page 42.)
Main Charger
CAUTION
Handle the charger carefully to avoid damaging or breaking
the charger wires.
3. Loosen the thumbscrew and remove the main charger by pulling it toward you.
2
1
Legend:
1) Main Charger
2) Thumbscrew
4. Place the main charger on a flat, clean work surface.
85
Chapter 4 General Cleaning
5. Using the brush cleaner (listed on page 68), clean the exposed
side of the charger grid and the body of the main charger to
remove paper dust, etc., as shown below.
1
Legend:
1) Charger Grid
2) Brush Cleaner
3) Main Charger
2
3
86
Cleaning The Chargers
1
6. Position the main charger with the charger grid up and the front
end of the charger toward you, as shown in the following figure.
Remove the charger grid from the main charger as follows:
a. While pressing the front retaining tab toward the rear of the
charger, unhook the rear end of the charger grid from the
rear retaining tab.
b. Release the front retaining tab, then remove the charger
grid from it.
4
Legend:
1) Front Retaining Tab
2) Charger Grid
3) Main Charger
4) Rear Retaining Tab
2
1
3
87
Chapter 4 General Cleaning
7. Using the brush cleaner, clean both sides of the charger grid.
Legend:
1) Brush Cleaner
2) Charger Grid
1
2
88
8. Using the wire cleaner (listed on page 68), clean the two wires
in the main charger. When clean, the wires feel smooth.
1
2
Legend:
1) Wire Cleaner
2) Main Charger
Cleaning The Chargers
9. Install the charger grid.
10. Return the main charger to its original position. Fasten the main charger screw to secure it.
Precharger And Transfer Charger
11. Open the waste toner recovery unit.
12. Loosen the precharger thumbscrew and transfer/separator
charger thumbscrew, and remove the chargers by pulling them
toward you.
3
1
2
Legend:
1) Transfer/Separator Charger
2) Thumbscrews
3) Precharger
13. Place the chargers on a flat, clean work surface.
89
Chapter 4 General Cleaning
14. Using the brush cleaner and the wire cleaner (listed on page
68), remove the dust and dirt on the wires. The precharger
contains one wire, while the transfer/separator charger
contains two wires. When clean, the wires feel smooth.
15. After cleaning, return the chargers to their original positions.
Fasten the charger screws to secure them.
Cleaning The Fuser U nit Cover Glass
WARNING
The fuser unit remains hot after operation. Wait until it has
completely
cooled down before handling it.
WARNUNG
Die Einbrennvorrichtung behält auch nach dem Betrieb ihre
Temperatur bei. Fassen Sie sie erst an, wenn sie
abgekuhlt ist.
vollständig
AVISO
La unidad de fusor estará a alta temperatura después de
funcionar. Espere a que se haya en friado
de manipularia.
por completo
antes
ATTENTION
L’unité de four est encore trés chaude aprés chaque
opération. Attendez qu’elle refroidisse complétement avant de
la manipuler.
AVVERTENZA
Dopo l’uso, l’unitá fusore é calda. Attendere il
raffeddamento dell’unitá prima di intervenir sulla medesima.
completo
IMPORTANT
90
Do not scratch or place your hands directly on the cover glass.
Do not use any cleaners or chemicals on the Fuser Unit Cover
Glass. Use only the scraper.
1. Turn the power switch OFF.
2. Open the printer upper doors. (See page 42.)
Cleaning The Fuser Unit Cover Glass
3. Open the waste toner recovery unit.
CAUTION
The transfer charger must be in the down position to avoid
scratching the drum. Failure to perform steps 4 and 5 damages
the drum.
4. Rotate the transfer elevator drive shaft counterclockwise. Watch the charger movement:
a. If the charger starts to move up, it is already in the down
position.
b. If the charger starts to move down, continue to rotate the
drive shaft until the charger reaches the complete down
position.
1
2
CAUTION
Legend:
1) Transfer Charger
2) Transfer Elevator Drive Shaft
To avoid damaging the printer or causing false paper jams, the
transport lever must be in the fully down position before
closing the transport unit.
5. Lower the transport surface by turning the green lever on the transport unit to the left.
91
Chapter 4 General Cleaning
6. Loosen the thumbscrews (2) on the right and left fuser unit holding plates.
2
1
6
5
3
4
92
Legend:
1) Thumbscrew (not visible)
2) Handle
3) Holding Plate
4) Thumbscrew
5) Green Lever
6) Fuser Unit
7. Grasp the handle and pull out the fuser unit until the second handle is visible.
8. With the other hand, grasp the second handle and remove the fuser from the printer.
Cleaning The Fuser Unit Cover Glass
CAUTION
Do not scratch or place your hands directly on the cover glass.
Fingerprints on the cover glass or lamps will cause them to
break.
9. Place the fuser on a clean, flat surface with the cover glass facing up.
10. Using the fuser cover glass scraper (listed on page 68), remove
the dirt and toner buildup on the cover glass surface.
1
Legend:
1) Scraper
11. Wipe away any remaining toner or dirt with a Toraysee cloth (listed on page 68).
93
Chapter 4 General Cleaning
12. Remove the two screws that secure the filter housing to the filter, then remove the filter.
5
4
94
1
2
Legend:
1) Fuser Unit
2) Filter Holding Plate
3) Filter
4) Screws (2)
5) Filter Housing
3
4
13. Vacuum the filter, then install it.
14. Vacuum any paper dust from the printer frame.
15. Install the fuser, making sure that the guide pins in the screw
bracket align with the holes in the side frame of the printer.
Major Cleaning
Do a major cleaning every 150,000 pages to keep your printer in
the best working order.
Cleaning Unit
1. Turn the power switch OFF.
2. Open the printer upper doors. (See page 42.)
3. Open the waste toner recovery unit. (See page 46.)
4. Loosen the three thumbscrews securing the drum plate and
5. Remove the cleaning unit by grasping its handle and pulling it
Cleaning Unit
remove the drum plate.
toward you.
Legend:
1) Thumbscrews (3)
2) Drum Plate
3) Cleaning Unit Handle
1
3
2
95
Chapter 4 Major Cleaning
IMPORTANT
CAUTION
To avoid spilling toner, do not turn the cleaning unit upside
down.
6. Vacuum the brush on the cleaning unit. Turn the end of the
shaft to rotate the brush. Continue to rotate and vacuum the
brush until the entire brush surface has been cleaned.
Do not touch the brush surface with your hand.
1
2
4
3
96
Legend:
1) Cleaning Unit
2) Cleaning Unit Handle
3) Rotate Shaft
4) Brush
Cleaning Unit
CAUTION
Do not flex the discharge LED, or it may break.
7. Remove the discharge LED screw.
1
2
Legend:
1) Screw
2) Discharge LED
8. Remove the discharge LED by pulling it toward you.
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Chapter 4 Major Cleaning
9. Using a Toraysee cloth (listed on page 68), wipe off the dirt on the discharge LED.
1
Legend:
1) Discharge LED
10. Install the discharge LED.
Cleaning The Photoreceptor Drum
CAUTION
98
When cleaning the photoreceptor drum, observe the following
precautions:
• Do not touch the drum surface with your hands.
• To prevent the drum surface from being scratched,
clean it in a location free of dust.
• Cleaning the drum may result in wiping stains. A drum
left unused in the printer for a long time after cleaning
may especially be affected. Therefore, after cleaning
and installing the drum in the printer, use maximum
size paper to print an image repeatedly until no stains
remain. Stains usually clear after printing a few dozen
pages.
1. Remove the photoreceptor drum from the printer. (See page
115.)
2. Place the drum on a covered work surface.
Cleaning The Photoreceptor Drum
3. If the drum is only slightly dirty, clean it with ethanol or isopropyl
alcohol. Do not use acetone.
4. If the drum has toner buildup, clean it with the drum freshener
pad. (See page 68.) Turn the drum little by little while polishing
the drum surface with the freshener pad. Polish with a slight
force in the direction of the drum circumference, using a
circular motion. Let the polished areas slightly overlap each
other, and polish the entire drum surface two or three times.
CAUTION
Press lightly when polishing the drum surface, as too much
pressure can damage the drum.
5. Using the special dry tissue paper (see page 68), thoroughly
wipe the drum freshener off the drum surface.
6. To avoid exposing the drum to light for too long, temporarily
pack the drum in its original packaging material, and close the
box cover. Set the drum aside.
7. Remove the drum auxiliary rod from the drum shaft.
8. Wipe the drum shaft clean with a cloth.
9. Loosen the thumb screw and remove the main charger by pulling it toward you.
10. Clean the developing unit area with a vacuum cleaner and a soft cloth.
2
1
Legend:
1) Main Charger
2) Thumbscrew
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Chapter 4 Major Cleaning
CAUTION
When wiping the SELFOC® lens, be certain not to apply
excessive force to the drum surface potential sensor located
near the SELFOC lens, as this may cause the sensor to be
dislocated. (If this happens, contact your service
representative.)
11. Wipe the SELFOC lens by moving a Toraysee cloth (see page
68) from the inner part of the printer toward you. Wipe the lens
in this manner several times until there is no more dirt on the
cloth.
NOTE: Always wipe the SELFOC lens with the unused side of the
Toraysee.
2
1
100
Legend:
1) SELFOC Lens
2) Drum Surface Potential Sensor
12. Install the main charger.
13. Install the photoreceptor drum. (See page 53.)
14. Install the developing unit. (See page 63.)
15. Install the cleaning unit.
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