Printronix L1024 User manual

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

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P/N 704792–001, Rev C

WARNING
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 provide 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. The manufacturer is not responsible for any radio or television interference
caused by using other than recommended cables and connectors or by 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.
The input/output (I/O) cable must be shielded for the printer to comply with FCC rules and
regulations Part 15 governing the radiation limits for Class “A” equipment.
This digital apparatus does not exceed the Class A limits for radio noise emissions from digital
apparatus set out in the radio interference regulations of the Canadian Department of
Communications.
Ce matériel numérique n’émet pas de bruits radio–électriques supérieurs aux limites fixées pour
les appareils numériques de la Classe A dans le règlement sur le brouillage radio–électrique
publié par le Ministère des Communications du Canada.
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.
All rights reserved. Revision C. September, 1997.
Trademark Acknowledgements
Printronix is a registered trademark of Printronix, Inc.
COPYRIGHT 1996, 1997 PRINTRONIX, INC.

iiiTable of Contents
Table of Contents
Chapter 1 – Introduction
Scope 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conventions 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Documents 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Overview 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 1–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Users 1–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Technicians 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Methods 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Users 1–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Technicians 1–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 2 – Clamshell
Clamshell Parts List 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top Cover, Latch, and LED Assemblies 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Catch Release Assembly 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left and Right Catch Assemblies 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous Components 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left and Right Hinge Assemblies 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamshell Overview 2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical 2–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 2–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top Cover Assembly 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 2–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 2–13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 2–13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Latch Assembly 2–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 2–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 2–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 2–15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 2–15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Catch Release Assembly 2–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 2–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 2–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 2–18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 2–18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left and Right Catch Assemblies 2–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 2–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 2–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 2–19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 2–19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamshell Hinges 2–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 2–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 2–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 2–22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 2–22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv Table of Contents
Chapter 3 – OPC Drum Unit Subsystem
Overview 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 3–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 3–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 4 – Developer Subsystem
Overview 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 4–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 4–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 5 – Transfer Subsystem
Transfer Charger Parts List 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Corona Parts List 5–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engagement Lever Parts List 5–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Charger Subsystem Overview 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical 5–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 5–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Charger 5–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 5–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 5–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 5–13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 5–13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engagement Lever 5–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 5–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 5–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 5–18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 5–18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 6 – Paper Feed Subsystem
Paper Feed Parts List 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Guides 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tension Roller Assembly 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Gear Assembly 6–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tractor Assembly and Tractor Base 6–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 6–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical 6–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 6–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tension Roller Assembly 6–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 6–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 6–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 6–16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 6–16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Gear Assembly 6–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 6–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 6–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 6–22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 6–22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tractor Assembly 6–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 6–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 6–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vTable of Contents
Adjustment 6–29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 6–30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Paper Guide and Paper Empty Sensor 6–31. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 6–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 6–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 6–32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 6–32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 7 – Fuser Subsystem
Fuser Parts List 7–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuser Assembly 7–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuser Heat Shield Assembly 7–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuser Base Assembly 7–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 7–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical 7–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 7–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuser Assembly 7–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 7–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 7–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 7–21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 7–21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuser Base 7–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 7–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 7–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 7–30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 7–31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 8 – Power Supplies
Power Supplies Parts Lists 8–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low V oltage Power Supply 8–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High V oltage Power Supply 8–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 8–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low V oltage Power Supply 8–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 8–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input V oltage Conversion and Fuse Replacement 8–17. . . . . . . . . . . . . . . . .
Reassembly and Replacement 8–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 8–24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8–24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High V oltage Power Supply 8–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 8–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 8–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 8–31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8–34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 9 – Controllers and Floppy Disk Drives
Data Controller Board Parts List 9–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Controller Board Parts List 9–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stepper Motors Controller Board Parts List 9–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Floppy Disk Drives Parts List 9–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 9–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Controller Board 9–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 9–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 9–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 9–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vi Table of Contents
Troubleshooting 9–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Controller Board 9–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 9–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 9–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 9–16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 9–16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stepper Motors Controller Board 9–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 9–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 9–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 9–25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 9–25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Floppy Disk Drives 9–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 9–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 9–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 9–30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 9–30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion C/T Removal and Installation 9–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 10 – Control Panel
Control Panel Parts List 10–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 10–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical 10–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 10–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel 10–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 10–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 10–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 10–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 11 – Laser Scanning Unit (LSU) Subystem
LSU Parts List 11–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSU Assembly 11–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Erase LED Assembly 11–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 11–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical 11–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 11–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSU Assembly 11–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 11–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 11–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 11–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 11–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Erase LED Assembly 11–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 11–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 11–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 11–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 11–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 12 – Covers, Frame, and Backplane Board
Covers Parts List 12–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Side Frame Parts List 12–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Side Frame Parts List 12–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bottom Frame Parts List 12–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 12–12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Side Frame 12–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

viiTable of Contents
Removal and Disassembly 12–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 12–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 12–17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12–17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Side Frame 12–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 12–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 12–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 12–26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12–26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base Frame 12–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 12–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 12–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 12–46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12–46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backplane Board 12–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 12–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Replacement 12–51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 12–52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12–52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 13 – Troubleshooting Guide
Operation Sequence 13–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power-Up Self-Test 13–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Command 13–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Power-up Sequence 13–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guide to Imaging Errors 13–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index to Imaging Errors 13–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Detailed Troubleshooting Guide 13–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guide to Error Mesages 13–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator-correctable Error Messages 13–26. . . . . . . . . . . . . . . . . . . . . . . . . .
Service Call Error Messages 13–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Detailed Troubleshooting Guide 13–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01 CLOSE THE COVER 13–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02 LOAD P APER 13–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
03 ADD T ONER AND CHK W ASTE BOTTLE 13–30. . . . . . . . . . . . . . . . . . .
04 INSTALL T ONER CUP 13–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
05 INSTALL OPC DRUM 13–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
06 CLEAR JAM A T FUSER INPUT 13–31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
07 CLEAR JAM A T FUSER EXIT 13–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
08 CLEAR JAM NEAR TOF LEVER 13–31. . . . . . . . . . . . . . . . . . . . . . . . . . .
09 CHECK TOF LEVER 13–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 SPEED CTL ERR—Check Paper Path 13–31. . . . . . . . . . . . . . . . . . . . . .
25 ENCODER F AIL—Call Service 13–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 FUSER FAIL—Call Service 13–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 FUSER FAIL—Call Service 13–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 FUSER FAIL—Call Service 13–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 FUSER FAIL—Call Service 13–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 THRMISTR FAIL—Call Service 13–37. . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 THRMISTR FAIL—Call Service 13–38. . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 HEA TER FAIL—Call Service 13–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 HEA TER FAIL—Call Service 13–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 BEAM DET FAIL—Call Service 13–39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 LSU FAIL—Call Service 13–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 LSU FAIL—Call Service 13–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 LSU FAIL—Call Service 13–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

viii Table of Contents
32 MISPRINT ERROR—Call Service 13–41. . . . . . . . . . . . . . . . . . . . . . . . . .
33 REPLACE EEPRM—Call Service 13–41. . . . . . . . . . . . . . . . . . . . . . . . . .
34 REPLACE OPC DRUM—Call Service 13–41. . . . . . . . . . . . . . . . . . . . . . .
35 EC CKSUM FAIL—Call Service 13–41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOF REGISTRA TION ERRORS 13–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A – Printer Specifications
Appendix B – Wire Data
Appendix C – Continuous Form Stacker
Parts Identification C–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly/Reassembly C–16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Basic Frame C–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Tabletop C–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Paddle Drive Motor Assembly C–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Upper Drive Motor Assembly C–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Paddle Drive Belts C–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Paper Shelf C–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Front and Rear Paper Guides C–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Left and Right Vertical Frame Braces C–26. . . . . . . . . . . . . . . . . . . . . . .
The Left and Right Upper Frames C–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Upper Drive Bearing C–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Cable Clamp Screw Mount C–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Paper Shelf (with cable installation) C–35. . . . . . . . . . . . . . . . . . . . . . . . .
Stacker Specifications C–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix D – Principles of Operation

1–1Chapter 1 – Introduction
Chapter 1
Introduction

This manual covers service and parts for the L1024 24-ppm continuous-form laser printer. Each section
covers one major subassembly of the printer, in the following order:
SOverview
SMechanical Explanation
SElectronics Explanation (if appropriate)
SSubassembly Removal from the Printer and Disassembly
SSubassembly Reassembly and Replacement in the Printer
SAdjustment (if needed)
SLimited Troubleshooting (See also Chapter 13 for more troubleshooting)

The use of LEFT and RIGHT always assumes you are viewing the front of the printer. For instance, the
control panel is on the RIGHT side of the front of the printer.
Notes and Notices that you need to pay special attention to are presented in the following way:
WARNING: Possible danger to you or the user.
CAUTION: Possible equipment or data damage may occur.
NOTE: Extra information for you to consider.

This manual does not explain how to operate or configure the printer. For that information, refer to the
Operator’s Guide and Setup Guide that accompany the printer.

The L1024 is a 24-ppm continuous-form laser printer. It contains an internal engine controller and an
internal data controller plus a floppy disk drive.
The printer includes the major subassemblies shown in Figure 1–1.

1–2 Chapter 1 – Introduction
BASE
PAN
FUSER
BASE
FUSER ROLLER
ASSEMBLY
CONTROL
PANEL
TRANSFER
BOTTOM
FRAME
HIGH
VOLTAGE
SUPPLY
TRACTOR
LOW
VOLTAGE
SUPPLY
MAIN
DRIVE
RIGHT
FRAME
LEFT
FRAME
DEVELOPER
TENSION
ROLLER
LSU (LASER SCANNING UNIT)
BOTTOM
COVER
LED ARRAY
STEPPER MOTOR &
CONTROL BOARD
HOUSING
MOTOR
OPC
ENGINE CONTROLLER BOARD
CLAMSHELL
BACKPLANE BOARD
DATA CONTROLLER BOARD
Figure 1–1. Major Subassemblies.

1–3Chapter 1 – Introduction

Users
The printer is designed so that the user can perform the following maintenance tasks without calling a
service technician:
SRemoving and replacing the Toner Cartridge
SRemoving and replacing the Waste Toner Container
SReplacing the Fuser Felt Wiper
SCleaning the Fuser Heat Roller
SCleaning the Transfer Corona Wire
SCleaning the Charge Corona Wire
SRemoving and replacing the OPC Drum Unit
SRemoving and replacing the Developer Unit
SRemoving and replacing the Ozone Filter
SRemoving and replacing the Fuser Unit
When you are called to service the printer, check these items to be sure that the owner is replacing them
according to the schedule below. This user maintenance schedule provides the owner with the best
quality printing.
Service Technicians
Service personnel will provide all other maintenance on these printers according to warranty and service
agreements.
WARNING: Since this unit uses laser light, even though the power is less than 1
milliwatt at 780 nm, it is wise to protect your eyes whenever the top of
the printer (clamshell) is open and the Laser Scanning Unit (LSU) is
exposed and functioning. We recommend that you wear protective
eyewear capable of attenuating laser light at 780 nm to safe levels or
cover the LSU cover glass to prevent the laser light from escaping
during servicing.

1–4 Chapter 1 – Introduction

Cleaning kits are provided in the Developer Kits, as well as being sold separately. These kits include
cotton swabs, several “wet wipe” tissues in foil pouches, a corona wire cleaning brush, and instructions.
Users and service personnel are encouraged to use them on the schedule shown below.
Users
Users should perform the following actions at the frequencies listed below:
When Refilling the Toner (approximately every 8,000 pages)
SReplace the Waste Toner Container.
SReplace the Fuser Felt Wiper.
SClean the Fuser Heat Roller.
SClean the Transfer Corona Wire.
SClean the Charge Corona Wire.
When Replacing the OPC Drum Unit (approximately every 30,000 pages)
SClean inside the printer as needed.
When Replacing the Developer Unit (approximately every 100,000 pages)
SReplace the Ozone Filter.
SClean the Fuser Heat Roller.
SClean the Transfer Corona Wire.
SClean the Charge Corona Wire.
When Using Label Paper and Regular Paper alternately
SClean the Tension Roller (after each 4,000 pages of labels printed—see the information on
the next page).
WARNING: Turn off power to the printer before cleaning it.

1–5Chapter 1 – Introduction
Service Technicians
Service personnel should perform the following actions at or before every 300,000 pages:
SClean the LSU Cover Glass.
SClean other parts as needed inside the printer, including vacuuming the interior of the
printer.
WARNING: Turn off power to the printer before cleaning it.
NOTE: The inside of the printer should be cleaned and vacuumed including
special attention to paper dust on the fuser fan motor. This should be done
whenever the printer is serviced, or at 300,000 pages, whichever comes
first.

1–6 Chapter 1 – Introduction
The following table lists the items needing periodic cleaning and the recommended cleaning procedures:
Cleaning
Area Frequency Cleaning
Tool Method
Tension Roller 4,000 pages
(especially if using
regular paper after
using labels)
Wet Wipe
Tissue Turn off the printer. Open the top and front covers of the printer. Remove the OPC
Drum Unit and the Developer Unit (refer to
the Setup Guide ). Wipe the tension roller
with a wet wipe tissue while rotating the
black gear on the right side as shown in the
illustration below.
Figure 1–2. Cleaning the Tension Roller
(Continued on next page)

1–7Chapter 1 – Introduction
Cleaning
Area Method
Cleaning
ToolFrequency
Fuser
Heat Roller;
Transfer
Corona Wire;
Charge
Corona Wire
When replacing Felt
Wipers and when
replacing Developer
Unit
Refer to the
Setup Guide.
Refer to the Setup Guide.
Inside
Cleaning 30,000 pages Wet Wipe Tissue Remove paper powder and toner from the areas listed below:
STransfer Charger around the mylar sheet
(wipe the mylar first, then use the brush
for the wire)
SAround the Tractor
SInside the right cover
SHigh Voltage Power Supply cover
SFuser paper guide
STransfer paper guide
SPaper guide inlet
SFront paper guide (if installed)
LSU
Cover Glass 300,000 pages Cotton Swab and Rubbing
Alcohol
Wipe the LSU Cover Glass with a cotton
swab containing anhydrous rubbing alcohol.
Rub the glass in one direction only (either
from right-to-left or from left-to-right).
Repeat this process, using a new cotton
swab each time, until the glass is
completely clean.

1–8 Chapter 1 – Introduction

2–1Chapter 2 – Clamshell
Chapter 2
Clamshell
Clamshell and Subassemblies

2–2 Chapter 2 – Clamshell
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2.1.1 Top Cover, Latch, and LED Assemblies
Callout Name Vendor Part No. Printronix Part No.
1 Top Cover and Latch Assembly 202104–501
2 Top Cover Assembly 200864–001 702817–001
3 Cover, Top 200495–001 703108–001
4 Seal, Short 200533–001 702820–001
5 Seal, Medium 200532–001 702819–001
6 Seal, Long 200531–001 702818–001
7 Toner Dust Baffle 200563–001 702730–001
8 Screw, PPH, CLFW, M3x8, Zinc (2) 030129–308
9 Latch Assembly 200489–554 702690–001
10 Spring, Torsion, Lower Latch
11 Lever, Release
12 Button, Release
13 Shaft, Latch (2)
14 Button, Locking
15 Shaft, Locking
16 Frame, Latch
17 E-Ring, 3mm I.D., Zinc (2) 071151–004
18 E-Ring, 4mm I.D., Zinc (2) 071051–006
19 Spring, Torsion, Upper Latch
20 Screw, PPH, CLFW, M3x6, Zinc (2) 030130–306
20 Screw, PPH, CLFW, 3x6mm, Zinc (11) 030130–306
21 LSU Base Plate Assembly
22 LSU Base Plate 202165–001
23 Cover Felt, Clamshell Fuser 202166–001
31 Bushing, LED Wire Harness 202167–001
(not shown)
26 Erase LED Assembly 200542–501 702724–001
27 Cover, LED Assembly 200541–001
28 Mount, LED, Plastic
29 Board Assembly
, LED
30 Screw, PPH, PTC, 3x8mm, Zinc (4) 030129–308
32 Cable, LSU 202294–551
33 LSU 202118–551
34 Seal, LSU Drum 202575–001