Replacing the customer-replaceable corona wires

Procedure:

Do this procedure to remove and replace the corona wires. Use this procedure when your printer has customer-replaceable corona wires installed.

The following figure shows the charge corona assembly, and the location of the corona wires (2), the terminal (1), and the corona cartridges (3).

Figure 97. Charge corona assembly
Charge corona assembly

The following figure shows the precharge, preclean, and transfer corona assemblies, and the location of the corona wires (2), the terminal (1), and the corona cartridges (3).

Figure 98. Precharge, preclean, and transfer corona assemblies
Precharge, preclean, and transfer corona assemblies

The following figure shows the corona cartridge (1) and the flexible latch (2) used when installing the cartridge in the corona assembly. The corona cartridge contains the corona wire, which is spring loaded inside the corona cartridge.

Figure 99. Corona cartridge
corona cartridge

The following figure shows the corona cartridge (1), the corona wire (2) and the corona wire ring (4).

Figure 100. Corona cartridge, corona wire, and corona wire ring
corona cartridge, wire, and ring
Note:
When installing the corona wires, make sure that the replacement wire does not bend or kink (3). Do not touch the wire.

  1. Stop all activity on the printer and disable all host attachments.
  2. Open the right front cover of the printer (1).
  3. Do the following to remove the charge corona wires and cartridges from the corona assembly:
    1. Pull the charge corona assembly out of the corona housing.
      Charge corona locations
      Note:
      Grasp the corona assembly from each side of the handle as shown below. If you grasp the assembly at the bottom, the cartridge will pop out and the wire will break.
      Grasping corona assembly from each side
    2. Place the corona assembly on a clean, flat work surface.
    3. Open the two corona wire covers (1) by lifting them in the A and B directions.
      Opening the charge corona wire covers
    4. Remove the corona cartridge (1) from the front wire holder on the corona assembly by pushing the latch (2) toward the cartridge while pulling the cartridge up (3).
      Removing corona-wire cartridge
    5. Remove the corona wire ring (1) from the wire terminal (2) at the rear wire holder (3) on the corona assembly.
      Removing the ring from rear wire holder
  4. Before installing new corona wires, moisten a clean, dust-free cloth with water and remove dust and corrosion from the inner and outer surfaces of the charge corona assembly (1).
    Cleaning the charge corona housing
  5. Do the following to replace the corona wires:
    1. Locate the new corona cartridge.
    2. Attach the corona wire ring (1) to the wire terminal (2) at the rear wire holder (3) on the corona assembly.
      Attaching corona wire ring to wire terminal
      Note:
      When installing corona wires, make sure that the replacement wire does not bend or kink. Do not touch the wire. See Figure 100.
    3. Gently pull the corona cartridge (1) slowly in the A direction, keeping the cartridge and wire close to the corona assembly as you pull.
      Note:
      Do not pull the corona wire with too much force. Do not pull the corona wire beyond the position necessary to insert the cartridge to the front wire holder. There is a small spring inside the cartridge and if too much force is used, the wire can break.
      Lengthening the corona wire
    4. Install the corona cartridge into the corresponding slot in the front wire holder on the corona assembly as follows:
      1. Tilt the cartridge (1) to position it so that the groove (4) slides under the pin (5) on the front wire holder.
      2. Push the cartridge down until the flexible latch on the cartridge (2) snaps into place in the front wire holder (3).
      Installing the corona cartridge
    5. Repeat the above steps to install a corona wire and cartridge into each slot in the corona assembly.
    6. Close the two corona wire covers (1) by pushing them in the E and F directions.
      Closing the corona wire covers
  6. Gently push the corona assembly back into place inside the corona housing. Make sure that the corona assembly is pushed in completely.
    Note:
    The labels on the end of each corona assembly correspond to the labels outside the drum. These indicate the correct location for each corona assembly. When replacing corona wires, make sure that the correct corona assembly is installed in the corresponding corona housing.
  7. Do the following to remove the precharge and preclean corona wires. Do these steps for each corona assembly, one at a time.
    1. Pull the corona assembly out of the corona housing.
      Precharge and preclean corona locations
      Note:
      Grasp the corona assembly from each side of the handle as shown below. If you grasp the assembly at the bottom, the cartridge will pop out and the wire will break.
      Grasping corona assembly from each side
    2. Place the corona assembly on a clean, flat work surface.
    3. Open the corona wire cover (1) by lifting it in the A direction.
      Opening the precharge and preclean corona wire covers
    4. Remove the corona cartridge (1) from the front wire holder on the corona assembly by pushing the latch (2) toward the cartridge while pulling the cartridge up (3).
      Removing corona-wire cartridge
    5. Remove the corona wire ring (1) from the wire terminal (2) at the rear wire holder (3) on the corona assembly.
      Removing the ring from rear wire holder
  8. Before installing new corona wires, moisten a clean, dust-free cloth with water and remove dust and corrosion from the inner and outer surfaces of the precharge and preclean corona assemblies (1).
    Cleaning the precharge and preclean corona housing
  9. Do the following to replace the precharge and preclean corona wires, one at a time:
    1. Locate the new corona cartridge.
    2. Attach the corona wire ring (1) to the wire terminal (2) at the rear wire holder (3) on the corona assembly.
      Attaching corona wire ring to wire terminal
      Note:
      When installing the corona wires, make sure that the replacement wire does not bend or kink. Do not touch the wire. See Figure 100.
    3. Gently pull the corona cartridge (1) slowly in the A direction, keeping the cartridge and wire close to the corona assembly as you pull.
      Note:
      Do not pull the corona wire with too much force. Do not pull the corona wire beyond the position necessary to insert the cartridge to the front wire holder. There is a small spring inside the cartridge and if too much force is used, the wire can break.
      Lengthening the corona wire
    4. Install the corona cartridge into the front wire holder on the corona assembly as follows:
      1. Carefully thread the wire into the slit in the mylar piece (1) at the front end of the corona assembly. The wire must pass through the slit before the cartridge can be snapped into place.
        Threading the corona wire
      2. Tilt the cartridge (1) to position it so that the groove (4) slides under the pin (5) of the front wire holder.
      3. Push the cartridge down until the flexible latch on the cartridge (2) snaps into place in the front wire holder (3).
      Installing the corona cartridge
    5. Close the corona wire cover (1) by pushing it in the A direction.
      Closing the corona wire covers
  10. Gently push each corona assembly back into place. Make sure that the corona assembly is pushed in completely.
    Note:
    The labels on the end of each corona assembly correspond to the labels outside the drum. These indicate the correct location for each corona assembly. When replacing corona wires, make sure that the correct corona assembly is installed in the corresponding corona housing.
  11. Close the right front cover of the printer by lifting the cover hinge bar and sliding the bar toward the printer.
    Lift the cover hinge bar
    Important:
    The printer right front door must be completely closed whenever the printer is running. Light entering the printer can significantly reduce print quality.
  12. Open the printer center front cover (1).
  13. Open the transfer station by pushing the transfer station control lever (2) to the left.
    Opening transfer station and center front cover
  14. Do the following to remove the corona wire:
    1. Pull the transfer corona assembly (1) out of the corona housing.
      Removing the transfer corona assembly
      Note:
      Grasp the corona assembly from each side of the handle as shown below. If you grasp the assembly at the bottom, the cartridge will pop out and the wire will break.
      Grasping corona assembly from each side
    2. Place the corona assembly on a clean, flat work surface.
    3. Open the corona wire cover (1) by lifting it in the A direction.
      Opening the transfer corona wire covers
    4. Remove the corona cartridge (1) from the front wire holder on the corona assembly by pushing the latch toward the cartridge (2) while pulling the cartridge up (3).
      Removing corona-wire cartridge
    5. Remove the corona wire ring (1) from the wire terminal (2) at the rear wire holder (3) on the corona assembly.
      Removing the ring from rear wire holder
  15. Before installing new corona wires, moisten a clean, dust-free cloth with water and remove dust and corrosion from the inner and outer surfaces of the corona assembly (1).
    Cleaning the transfer corona housing
  16. Do the following to replace the corona wires:
    1. Locate the new corona cartridge.
    2. Attach the corona wire ring (1) to the wire terminal (2) at the rear wire holder (3) on the corona assembly.
      Attaching corona wire ring to wire terminal
      Note:
      When installing the corona wires, make sure that the replacement wire does not bend or kink. A Do not touch the wire. See Figure 100.
    3. Gently pull the corona cartridge (1) slowly in the A direction, keeping the cartridge and wire close to the corona assembly as you pull.
      Note:
      Do not pull the corona wire with too much force. Do not pull the corona wire beyond the position necessary to insert the cartridge to the front wire holder. There is a small spring inside the cartridge and if too much force is used, the wire can break.
      Lengthening the corona wire
    4. Install the corona cartridge into the front wire holder on the corona assembly as follows:
      1. Carefully thread the wire into the slit in the mylar piece (1) at the front end of the corona assembly. The wire must pass through the slit before the cartridge can be snapped into place.
        Lengthening the corona wire
      2. Tilt the cartridge (1) to position it so that the groove (4) slides under the pin (5) on the front wire holder.
      3. Push the cartridge down until the flexible latch on the cartridge (2) snaps into place in the front wire holder (3).
      Installing the corona cartridge
    5. Close the corona wire cover (1) by pushing it in the A direction.
      Closing the corona wire covers
  17. Gently push the transfer corona assembly back into place. Make sure that the corona assembly is pushed in completely.
    Note:
    The labels on the end of each corona assembly correspond to the labels outside the drum. These indicate the correct location for each corona assembly. When replacing corona wires, make sure that the correct corona assembly is installed in the corresponding corona housing.
  18. Close the transfer station by gently pushing the transfer station toward the photoconductive drum and latch it in place, using the transfer station control lever (2).
  19. Close the printer center front cover (1).
    Closing transfer station and center front cover
  20. Power on the printer.