Olivetti PG L22 Special User manual

PG L22 Special
Printer
SERVICE MANUAL
Code Y103920-3

PUBLICATION ISSUED BY:
Olivetti Tecnost S.p.A.
77, Via Jervis - 10015 Ivrea (TO)
Italy
Copyright © 2004, Olivetti
All rights reserved

Y103920-3 Service Manual 3
PREFACE
This Maintenance Manual describes the field maintenance methods for this Monochrome LED Page Printer
model.
This manual is written for use by service persons. Please note that you should refer to the Printer Handbook
for the handling and operating methods of the equipment.

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CONTENTS
1. CONFIGURATION .................................................................................................... 7
1.1 System Configuration........................................................................................ 7
1.2 Printer Configuration ......................................................................................... 8
1.3 Optional Configuration ...................................................................................... 9
1.4 Specification ................................................................................................... 11
1.5 Safety Standards ............................................................................................ 13
1.5.1 Certification Label ..................................................................................................... 13
1.5.2 Warning Label ........................................................................................................... 13
1.5.3 Warning/Caution Marking ......................................................................................... 14
2. PARTS REPLACEMENT ........................................................................................ 15
2.1 Precautions for Parts Replacement ................................................................ 15
2.2 Parts Layout .................................................................................................... 17
2.3 How to Change Parts ...................................................................................... 20
2.3.1 Upper Cover Assy ..................................................................................................... 21
2.3.2 LED Head ................................................................................................................. 22
2.3.3 Operator Panel Assy ................................................................................................. 23
2.3.4 Lower Base Unit........................................................................................................ 24
2.3.5 Pulse Motor (Main/Drum) .......................................................................................... 25
2.3.6 Pulse Motor (Registration) ........................................................................................ 26
2.3.7 Pulse Motor (Hopping) .............................................................................................. 27
2.3.8 Face Up Stacker Assy .............................................................................................. 28
2.3.9 Eject Roller Assy ....................................................................................................... 29
2.3.10 Motor Assy ................................................................................................................30
2.3.11 Hopping Roller Shaft Assy ........................................................................................ 31
2.3.12 Stacker Cover Assy .................................................................................................. 32
2.3.13 Registration Roller .................................................................................................... 33
2.3.14 Roller Transfer Assy ................................................................................................. 34
2.3.15 Fusing Unit ................................................................................................................ 35
2.3.16 Back-up Roller .......................................................................................................... 36
2.3.17 Sensor Plate (Inlet) ................................................................................................... 37
2.3.18 Sensor Plate (Outlet), Sensor Wire Assy .................................................................. 38
2.3.19 Manual Feed Guide Assy .......................................................................................... 39
2.3.20 Sensor Plate (Paper Supply) .................................................................................... 40
2.3.21 GRV-2 PCB ............................................................................................................... 41
2.3.22 Power Supply Board and High Voltage/Sensor Board .............................................. 42
2.3.23 Cassette Guide L Assy ............................................................................................. 43
2.3.24 Cassette Guide R Assy ............................................................................................. 44
3. ADJUSTMENT ........................................................................................................ 45
3.1 Maintenance Modes and Functions ................................................................ 45
3.1.1 User Maintenance Mode (Administrator Menu)......................................................... 45
3.1.2 System Maintenance Mode (System Maintenance Menu) ........................................ 46
3.1.3 EEPROM Initial Setting Range for Events ................................................................ 48
3.2 Adjustment When Replacing a Part ................................................................ 49
3.2.1 Uploading/Downloading EEPROM data .................................................................... 49
4. PERIODICAL MAINTENANCE ............................................................................... 50
4.1 Periodical Replacement Parts......................................................................... 50

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4.2 Cleaning .......................................................................................................... 50
4.2.1 Cleaning of LED Lens Array ..................................................................................... 50
4.2.2 Cleaning Page Function ............................................................................................ 51
5. TROUBLESHOOTING PROCEDURES.................................................................. 52
5.1 Troubleshooting Tips ...................................................................................... 52
5.2 Points to Check before Correcting Image Problems ....................................... 52
5.3 Tips for Correcting Image Problems ............................................................... 52
5.4 Preparation for Troubleshooting ..................................................................... 53
5.5 Troubleshooting Flow...................................................................................... 53
5.5.1 LCD Status Message/Problem List ........................................................................... 53
5.5.2 LCD Message Troubleshooting ................................................................................. 59
5.5.3 Image Troubleshooting ............................................................................................. 67
6. WIRING DIAGRAM ................................................................................................ 76
6.1 Interconnect Signal Diagram ........................................................................... 76
6.2 PCB Layout and Connector Signal List ........................................................... 77
6.3 Resistance Check ........................................................................................... 89
APPENDIX A RS-232C SERIAL INTERFACE (OPTION) .......................................... 91
APPENDIX B CENTRONICS PARALLEL INTERFACE ............................................ 96
APPENDIX C UNIVERSAL SERIAL BUS (USB) ..................................................... 105
APPENDIX D LOOP TEST (RS-232C INTERFACE) ............................................... 111
APPENDIX E DIAGNOSTICS TEST ........................................................................ 112
APPENDIX F MULTI PURPOSE FEEDER MAINTENANCE ................................... 122
1. OUTLINE ...................................................................................................... 122
1.1 Functions ................................................................................................................ 122
1.2 External View and Component Names ................................................................... 122
2. MECHANISM DESCRIPTION ...................................................................... 123
2.1 General Mechanism ................................................................................................ 123
2.2 Hopper Mechanism ................................................................................................. 123
3. PARTS REPLACEMENT .............................................................................. 124
3.1 Precautions Concerning Parts Replacement .......................................................... 124
3.2 Parts Layout ............................................................................................................ 125
3.3 Parts Replacement Methods ................................................................................... 126
3.3.1 Link ........................................................................................................... 126
3.3.2 Separator .................................................................................................. 127
3.3.3 OLEV-11-PCB .......................................................................................... 128
3.3.4 Pulse Motor ............................................................................................... 129
3.3.5 Planet Gear ............................................................................................... 130
3.3.6 Roller-A and B .......................................................................................... 131
4. TROUBLESHOOTING .................................................................................. 132
4.1 Precautions Prior to the Troubleshooting ................................................................ 132
4.2 Preparations for the Troubleshooting ...................................................................... 132
4.3 Troubleshooting Method ......................................................................................... 133
4.3.1 LCD Status Message List ......................................................................... 133

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5. CONNECTION DIAGRAM ............................................................................ 135
5.1 Interconnection Diagram ......................................................................................... 135
5.2 PCB Layout ............................................................................................................. 135
6. PARTS LIST ................................................................................................. 136
APPENDIX G HIGH CAPACITY SECOND PAPER FEEDER .................................. 138
1. OUTLINE ...................................................................................................... 138
1.1 Functions ................................................................................................................ 138
1.2 External View and Component Names ................................................................... 138
2. MECHANISM DESCRIPTION ...................................................................... 139
2.1 General Mechanism ................................................................................................ 139
2.2 Hopper Mechanism ................................................................................................. 139
3. PARTS REPLACEMENT .............................................................................. 140
3.1 Precautions Concerning Parts Replacement .......................................................... 140
3.2 Parts Layout ............................................................................................................ 141
3.3 Parts Replacement Methods ................................................................................... 142
3.3.1 Stepping Motor (Hopping) ......................................................................... 143
3.3.2 TQSB-2 PCB ............................................................................................ 145
3.3.3 Hopping Roller Shaft Assy and One-way Clutch Gear .............................. 145
4. TROUBLESHOOTING .................................................................................. 146
4.1 Precautions Prior to the Troubleshooting ................................................................ 146
4.2 Preparations for the Troubleshooting ...................................................................... 146
4.3 Troubleshooting Method ......................................................................................... 147
4.3.1 LCD Status Message List ......................................................................... 147
5. CONNECTION DIAGRAM ............................................................................ 149
5.1 Interconnection Diagram ......................................................................................... 149
5.2 PCB Layout ............................................................................................................. 149
6. PARTS LIST ................................................................................................. 150
APPENDIX H NETWORK INTERFACE (OPTION) .................................................. 156

Y103920-3 Service Manual 7
1. CONFIGURATION
1.1 System Configuration
This printer model consists of control and engine blocks in the standard configuration, as shown
in Figure 1-1.
In addition, the options marked with asterisk(*) are available.
Figure 1-1
Operator Panel
LCD : 1
LED : 1
SW : 8
Drum Motor
Paper
Cassette
ID
Unit
Paper Feeding
Mechanism
(First Tray Unit)
Registration
Motor
Hopping Motor
LED Head
Electrophotogarphic
Processing Unit
Fuser Unit
Halogen-Lamp
High Voltage /
Sensor Board
ROM DIMM
*
High Capacity
Second Paper
Feeder
*
Multi Purpose
Feeder
IEEE1284
USB
Network
RS232C
*
Network
Board
OR
*
RS232C
Board
** : Optional
AC
INPUT
Power Supply
Board
Face Down
Stacker
FAN
RAM
DIMM
*
Main Control Board

Y103920-3 Service Manual 8
1.2 Printer Configuration
The printer unit consists of the following hardware components:
• Electrophotographic Processor
• Paper Feeder
• Controller
• Operator Panel
• Power Supply Unit
The printer unit configuration is shown in Figure 1-2.
Figure 1-2
Upper cover
Operator panel assy
Stacker assy
Optional board
Legal/universal paper cassette
Image drum unit(Type 9)
(consumable)
Toner-cartridge(Type 9)
(consumable)
Power supply
High Voltage / Sensor board
Main control board

Y103920-3 Service Manual 9
1.3 Optional Configuration
The options shown below are available for this printer model. These are available separately from the
printer unit.
(1) High Capacity Second Paper Feeder
(2) Multi Purpose Feeder
(3) RS-232C Serial Interface Board

Y103920-3 Service Manual 10
(5) SDRAM DIMM
(6) Flash DIMM
(4) Network Interface Board(Soft NIC CARD)
(7) Postscript 3 Emulation DIMM
(i) 16MB (ii) 32MB (iii) 64MB
(iv) 128MB (v) 256MB
(i) 8MB (ii) 16MB

Y103920-3 Service Manual 11
1.4 Specification
(1) Type Desktop
(2) External dimensions Height 8.5” (215 mm)
Width 14.0” (355 mm)
Depth 15.7” (400 mm)
(3) Weight Approx. 9 kg
(4) Developing method Dry electrophotography
Exposing method LED stationary head
(5) Paper used <Type>
• Standard paper
– Xerox 4200 (20 lbs)
• Application paper (manual face-up feed)
– Label
– Envelope
– OHP paper (transparency)
<Size>
• Standard sizes
– Letter
– Legal* [* Without Multi Purpose Feeder (Option)]
– Legal-13*
– Executive
– COM-9 **
– COM-10** [** manual feed and Multi Purpose Feeder
– Monarch** (option) only]
– DL**
– C5**
– A4
– A5
– B5 (JIS)
– A6
• Applicable sizes
– Width : 3.5” to 8.5” (90 to 216 mm)
– Length : 5.8” to 14” (148 to 355.6 mm)
<Thickness>
– Automatic feed : 16 to 28 lbs (60 to 105 g/m2)
– Manual feed : Label, OHP paper (transparency)
Envelope (24 to 28 lbs)
(6) Printing speed Continuous printing : 23 pages per minute with Letter size paper.
22 pages per minute with A4 size paper.
[Except, Multi purpose Feeder (14ppm) with
Letter size paper]
Warm-up time : 35 seconds typical at room temperature
[68½F (20½C), AC 120/230 V].
First page print time : 6.0 seconds typical for the Letter size paper
(6.2 seconds for the A4 size) after warm-up.
(7) Paper feeding method Automatic feed or manual feed
(8) Paper delivery method Face down/face up
(9) Resolution 600 ∞600 dots/inch
600 ∞1200 dots/inch

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(10) Power input 110~127 VAC ± 10%
220~240 VAC ± 10%
(11) Power consumption 120VAC 230VAC
Peak : Approx. 700W Approx. 700W
Typical operation : Approx. 360W Approx. 360W
Idle : Approx. 68W Approx. 66W
Power save mode : Approx. 9W Approx. 10W
(Without option)
Power save mode : Approx. 13W Approx. 14W
(With full option)
(12) Temperature and humidity
1. Storage conditions specified above apply to printers in packed condition.
2. Temperature and humidity must be in the range where no condensation occurs.
In operation Power off mode During Storage Unit
Temperature
Humidity
Maximum wet bulb
temperature
Minimum diference
between wet and dry
bulb temperatures
50-90
(10-32)
20-80
77
(25)
35.6
(2)
°F
(°C)
%RH
°F
(°C)
°F
(°C)
32-110
(0-43)
10-90
80.4
(26.8)
35.6
(2)
14-110
(–10-43)
10-90
(13) Noise During operation : 53 dB (A) or less
Standby : 38 dB (A) or less
Quiet mode : Back ground level
(14) Consumables Toner cartridge kit 2,500 (5% duty) 6,000 (Optional 6K Toner 5%
duty)
Image drum cartridge 25,000 (at continuouts printing)
17,000 (3 page/job) without Power Save
11,000 (1 page/job) without Power Save
7,000 (1 page/job) with Power Save
(Minimum)
10
28
32
Temperature
(
° C)
20 80 Humidity (%)
Operation range

Y103920-3 Service Manual 13
1.5 Safety Standards
1.5.1 Certification Label
The safety certification label is affixed to the printer in the position described below.
1.5.2 Warning Label
The warning labels are affixed to the sections which may cause bodily injury.
Follow the instructions on warning labels during maintenance.
Serial No.
Made In China

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1.5.3 Warning/Caution Marking
The following warning and caution markings are made on the power supply/sensor board.
ENGLISH
Heatsink and transformer core present risk of electric shock. Test before touching.
FRENCH
Le dissipateur thermique et le noyau du transformateur présentent des risques de choc électrique.
Testez avant de manipuler.
SPANISH
Las disipadores de color el núcel del transformador pueden producir un choque eléctrico. Compruebe
antes de tocar.
PORTUGUESE
O dissipador de calor e o núcleo do fransiormador apresentam risco de choque elétrico. Teste antes de
focar.
ENGLISH
Circuits maybe live after fuses open.
FRENCH
Il se peut que les circuits soient sous tension une fois que les fusibles ont éfé rerirés.
SPANISH
Las circuitos pueden estar activos una vez que se hayan abierio los fusibles.
PORTUGUESE
Os circuitos podem estar energizados após os fusiveis se queimarem.
CAUTION

Y103920-3 Service Manual 15
2. PARTS REPLACEMENT
The section explains the procedures for replacement of parts, assemblies, and units in the field. Only
the disassembly procedures are explained here. For reassembly, reverse the disassembly procedure.
2.1 Precautions for Parts Replacement
(1) Before starting to replace parts, remove the AC cord and interface cable.
(a) Remove the AC cord in the following sequence:
i) Turn off (“o”) the power switch of the printer
ii) Disconnect the AC inlet plug of the AC cord from the AC receptacle.
iii) Disconnect the AC cord and interface cable from the printer.
(b) Reconnect the printer in the following procedure.
i) Connect the AC cord and interface cable to the printer.
ii) Connect the AC inlet plug to the AC receptacle.
iii) Turn on (“l”) the power switch of the printer.
(2) Do not disassemble the printer as long as it is operating normally.
(3) Do not remove parts which do not have to be touched; try to keep the disassembly to a minimum.
(4) Use specified service tools.
(5) When disassembling, follow the laid out sequences. Parts may be damaged if these sequences are
not followed.
(6) Since screws, collars and other small parts are likely to be lost, they should temporarily be attached
to the original positions during disassembly.
(7) When handling IC’s such as microprocessors, ROMs and RAMs, or circuit boards, do not wear
gloves that are likely to generate static electricity.
(8) Do not place printed circuit boards directly on the equipment or floor.
Disconnect
Reconnect
OFF
ON

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[Service Tools]
The tools required for field replacement of printed circuit boards, assemblies and units are listed in Table
2-1.
Table 2-1 Service Tools
No. Q’ ty Application RemarksService Tools
1
2
3
4
5
6
7
8
1
1
1
1
1
1
1
1
2~2.5 mm screws
3~5 mm screws
Cleans LED head
No. 1-100 Philips screwdriver
No. 2-100 Philips screwdriver
No. 3-100 screwdriver
No. 5-200 screwdriver
Digital multimeter
Pliers
Handy cleaner
LED Head cleaner

Y103920-3 Service Manual 17
2.2 Parts Layout
This section explains the layout of main components of the equipment.
[Lower base unit]
Figure 2-1
Image drum unit (Type 9)
(consumable)
Toner cartridge (Type 9)
(consumable)
LED head
Stacker cover assy
View A
Pulse motor
(main/drum)
Pulse motor
(registration)
Pulse motor
(hopping)
Stacker cover assy
Eject roller assy
Registration
roller Assy
Back-up roller
Diselectrification bar Transfer roller
Lower base unit
Hopping roller rubber
Hopping roller shaft
Manual feed guide assy
View A

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[Upper cover unit]
Figure 2-2
Upper cover

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[Base unit]
Figure 2-3
Paper cassette
Cassette guide (L) Assy
Cassette guide (R) Assy
DC fan assy
Face up stacker assy
Operator panel assy
Power supply/sensor board
(Low voltage)
High voltage /
sensor board
Main control board
Network Interface board

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2.3 How to Change Parts
This section explains how to change parts and assemblies listed in the disassembly diagram below.
In the parts replacement procedure, those parts marked with the part number inside ●with white letters
are RSPL parts.
Printer unit Upper cover assy
(2.3.1)
LED head
(2.3.2)
Transfer roller
(2.3.14)
Face up stacker assy
(2.3.8)
Lower base unit
(2.3.4)
Operator panel assy
(2.3.3)
Manual feed guide assy
(2.3.19)
Pulse motor (main/drum)
(2.3.5)
Pulse motor (registration)
(2.3.6)
Pulse motor (hopping)
(2.3.7)
Eject roller assy
(2.3.9)
Motor assy
(2.3.10)
Sensor plate (inlet)
(2.3.17)
Sensor plate (outlet),
sensor wire assy
(2.3.18)
Sensor plate (paper supply)
(2.3.20)
GRV-2 PCB
(2.3.21)
1 Hopping roller shaft assy
(2.3.11)
Stacker cover assy
(2.3.12)
Registration roller
(2.3.13)
Fusing unit
(2.3.15)
Back up roller
(2.3.16)
2 Power supply board, high voltage / sensor board
(2.3.22)
Cassette guide (L)
(2.3.23)
Cassette guide (R)
(2.3.24)
To
1
To
2