Digital Document

Technical Support 1.800.926.8393

2.28.10

Disassembly Procedure Guide

Rev. 6

Note: For the highest quality output from the Ilumina Press, follow the User
Documentation concerning operating temperature, ideal humidity, and other
helpful hints.

Corporate Headquarters: 2800 Dauphin Street, Mobile, AL 36606

USA 1-800-926-8393 - EU +31 (0) 26.319.3210 - www.xante.com

This document describes the disassembly of the Ilumina printer. This document is not designed to be a selfdirected course. Additional information will be provided during the course. Xant is not responsible for manufacturing changes that may change these procedures.

This document is being provided in conjunction with a Xant sponsored training course. Be aware that the
machine you are working with may have already been disassembled, resulting in parts and/or screws being
incorrectly replaced. You are responsible for your own personal safety as you work through this course. You
are expected to know how to safely operate, disassemble, and repair machines of this type. Xant is providing
disassembly, troubleshooting, and repair and reassembly instructions specific to this printer. Xant assumes that
each student has already demonstrated their knowledge of basic electronics, troubleshooting, disassembly and
reassembly of this type of equipment.
Important Safety Notes:
This product generates potentially lethal voltages. While Xant has made every attempt to insure safe operation and voltage interruption by installing safety circuits, it is possible to by-pass these safety circuits. Xant will
not be responsible for the safety of any attendee who knowingly bypasses any of these safety devices.
These printers are very heavy. The Ilumina weighs approximately 125 pounds without options. Safe lifting
techniques are required and Xant assumes that the attendee knows established safe lifting techniques.
These printers contain large amounts of metal that may have sharp edges or burrs on edges. Xant assumes
no liability for carelessness that results in injuries to attendees.
If you are unsure of something, ask the Xant trainer before continuing.
Follow the disassembly instructions as they are written to insure your safety as well as your successful disassembly/reassembly of the printer(s).

You can take digital photographs and notes at anytime during this course.

Ilumina Disassembly Procedures

Course Instructions:
1. The Ilumina printer weighs almost 125 pounds without options, 160 with options and consumables. Please
use caution and common sense when lifting or moving the printer.
2. Follow the procedures as they are written.
3. If you encounter any problems, notify the instructor.
4. NOTE: steel screws go into metal, black screws go into plastic.
5. Use electrostatic discharge precautions when handling the electronics portion of the disassembly.
6. Pay very close attention to the wiring harnesses and how they are routed.

This will save time when you reassemble your unit.
7. Watch for sharp edges and burrs on the metal covers and support brackets.

This machine contains a lot of metal be careful.
8. Store the removed screws with the appropriate assembly they secure.
9. Notify the instructor if you have any left over parts/screws once youve completed the re-assembly. This is
important since these are training machines and will be used for additional training classes.
10. Take your time and understand what you are doing. Take pictures or notes as needed.
11. We do not booby trap machines prior to disassembly or re-assembly. We may introduce problems after
your unit is reassembled and tested, as this is the best way to learn troubleshooting techniques.

Copyright 2011. Xant Corporation. All Rights Reserved.

Ilumina Disassembly Procedures

Configuration Page

How to print a Configuration Page:

menu to Print Information press enter,
menu to Configuration press enter,
press enter on Execute.

Screw descriptions

PLASTIC
BLACK

METAL
SILVER

Consumable Removal
Remove Toners/Drums from the
printer keeping them locked
together. Place the Toners/Drums
in a light safe box or dark room.
Unlock the Transfer Belt and the
Fuser and remove from the printer.

LED Swap
Open the top lid of the printer. Locate LED
with error. Use a flat screw driver to pry the top of
the LED loose. Unlock top connector. Pull the bottom connector free.

Bottom
Top

Top connector is for the power board Bottom connector is for data from engine
board (PU). Errors are as follows:
131 Yellow / 132 Magenta
133 Cyan / 134 Black

Drum Swap
Place paper or a cloth
along the backside of the
printer. Remove 2 keys and
screws and swap drums.

Drum Basket opening and closing procedure: Press on both handle releases on the basket and lift up. To
close, make sure that the basket locked down completely on both sides in the down locked position.

Waste Container
Waste Assembly
Open the cover door below the
printers display. Press the blue tab
on the right side and pull out.
Look along the printer back wall locate and remove 4 black screws
that hold the down drum waste
receptacle.
Remove the 2 black plastic covers.

looking from the feed side

Remove a total of 9 screws from

the assembly. There are 4 screws
near the motor and 5 along the
right side.

Notice the location and position

of the white arm with gear in the
printer.

Verify that the waste caps / springs / magnets

are located properly in the printer

Right Rear Cover

Open the printer lid and the right
side access door. Remove 2
screws from the cover. Pull the
cover out and let it hang freely
until wires are disconnected.

Notice that some printers will have

a modified cover which has more
wires and connections.

Registration Assembly
Board Cover

Remove the cover that is located

on the inside of the printer on the
right. Pry out slightly in the middle
and pop each bottom corner of
the cover until free.

MPTray

Locate the grey wire on the

Xant controller board, disconnect
and pull it up and through the hole
from the inside of the printer.
Disconnect the second and third
wires from the board.
Xant has 2 styles of MPTrays.
Only the digital envelope printer
has a grey modified wire.

Release the MPTray by lifting the handle and pulling open. Remove 1 screw from the right side of the MPTray.
Notice the metal holding bracket.

Remove 1 screw from the left side

of the MPTray. Notice the position
of the metal holding bracket.
Lower the MPTray at a 90 degree
angle and slide out.
Notice the wire protective splint ensure that it is properly inserted
on reassembly.

DEP / DPP MPTray

MPTray Locking Rail

Be sure that the drum basket

is in the up position.
Remove a total of 4 screws and
then slide the rail to the left.
Notice the switch for detecting
the MPTray open or closed. For
proper sensor communication the
plastic arm on the rail must be in
first then the lever on re-assembly.

Duplex Unit

10

On the left side of the printer, the

duplexor can slide out by pressing
down on the right door handle and
pulling forward.

Registration
Assembly

Remove 2 screws from the back

right corner. Unplug the ribbon
cable from the sensor board.
Push in on the gear coupling and
lift straight up and then pull out of
the printer. Note the inside of the
printer on the right side where the
wires are routed.

11

Low Voltage Cover

Cassette Tray
Right Side Cover
Paper Chute

Remove 5 screws from the back

cover. Remove the cassette tray.
Remove 2 screws from the right
cover.

continued on next page

Pull out on the release tab. Use

a flat screw driver on the 4 tabs.
Note, start at the bottom right
tab then to the top right moving
to the left.
Angle the screw driver in the
slot corner. For the bottom tabs
push UP. For the top tabs push
DOWN.
Open the side door and let it hang
freely. Remove the paper chute by
sliding it to the left and lifting out.
Remove the door by sliding it to the
left and lift out.

12

Exit Door
Exit Assembly

Remove the exit door. Remove the

cover from the inside of the printer.
Use the release tabs starting
from the right to the left.
Disconnect the upper right
connector. Remove 2 screws from
the assembly. Press the release
tabs and lift straight out.

looking from the inside

looking from the exit side

looking straight down at the

back corner

To replace the exit flag sensor,

remove the exit assembly. Flip
upside down, press forward on
the plastic holder and remove
the sensor and housing.
When replacing the flag sensor
make sure that the spring is in
the proper location.
Part # ILM-42759301

13

High Voltage Cover

Left Cover Guard
Registration Shutter Assembly
Remove 2 screws from the cover
and lift off. Remove 3 screws
from cover and use a flat screw
driver to release the tabs. Angle the
screw driver in the slot
corner for release.

Remove 2 screws from the transfer

belt motor, unplug and take off.
Remove 1 screw from behind,
where the motor was located.

Remove protective connector cover

and unplug 1 connector at the
backside of the board.

Remove 7 screws from inside the

printer on the registration assembly.

continued on next page

Continue to remove 7 screws from

the registration assembly.
After all 7 screws are removed pull
the assembly out from the right
side first, then lift up on the left
side to maneuver the angle hook
out of position.

looking from the exit side

14

looking from the inside

looking from the exit side

looking from the inside

High Voltage
Power Supply

Remove 2 screws from the backside of the board. Disconnect 3

connectors and ribbon cable from
the board. Pull the board towards
the back of the printer. As the
board slides out from under the
pass through, lift the board up.

15

Front Cover Guard

Display Panel

Remove 3 screws from the cover.

Release the right side first and
finish removing the left side.

continued on next page

Remove 2 screws from the cover

and lift off.
Flip the cover over and release the
2 latches with a flat screw driver.

Remove the cover and remove 1

screw to release the ribbon cable
holder. Remove ribbon cable.

16

Lower Left Cover

Low Voltage Supply

Remove 4 screws from the cover.

Release the power switch linkage
by lifting up and out. Remove 14
screws from the supply and slide
out.
Notice the 4 connections on the
supply.

Fan Duct

17

Pull from the left side and

straight out.

18

Covers
Controller (CU)
Engine (PU)
Xant Controller
Cage
Drive Motor

Remove 2 screws from the cover.

Loosen 2 thumb screws from the
right side and remove both covers.
Remove 5 screws (9600) from the
(CU) controller - 6 screws (9650).
Remove 1 screw from the bottom
corner and 1 screw from the side
bracket. Disconnect the fan,
remove the fan bracket and
slide the CU to the right.

9650 DEP / DPP / 502

9600

16
R

L
L

Remove 4 screws (9600) from the

(PU) controller - 4 screws (9650).
Carefully remove the ribbon cables.
Disconnect all connections and
remove 1 screw from the LED /
Ribbon protector.
Remove the Xant Proprietary
boards Fuser Modification or the
DEP / DPP Envelope Controller.

9650

9600
R.

Fuser Modification

Envelope Controller

LoR

Remove 11 screws from the board

cage. Pull the cage out straight.
Remove 2 screw the K Y M motor
and disconnect the motor and lay
aside. Remove 2 screw from the
drive motor board. Disconnect all
ribbon and wire connections.
Remove the board from the slot
where it is positioned.

Feed Rollers
The rollers should be cleaned with a lint free cloth and a rubber rejuvenator product such as GooGone as
needed for proper feeding.
The wheels are consumables and should be replaced if the rubber is worn or damaged.

1. Remove the red media block then raise the top bar so the rollers can
be accessed for cleaning or replacement.
2. Remove the plastic roller guard. The guard clips out of place by
pushing to the left.
3. Depress the clip to unlock the blue roller then slide it left to remove
4. Depress the clip to unlock the white roller then slide it left to remove
5. Use a small screw driver to pry the upper left side out of place. The
upper roller clips in on both sides with the gear positioned on the right
side.

ILM-42954401

ILM-42701302

ILM-43013001

Separation Pad
The Separation pad may be used when printing on very thin media which double feeds or misfeeds often.
The separation pad helps to separate the media in the feeder to prevent multiple pieces of media from being
fed at once.
Separation Pad installation
1. Slide the feeder away from the printer.
2. Clip the right side of the separation pad to the printer.
3. Gently press the left side down until the separation pad clips into place.

Separation Pad Removal

1. Slide the feeder away from the printer.
2. Gently pull on the left side of the separation pad to swing it outward
3. Swing the pad to the right until it unclips itself from the printer

Face Up exit Sensor

Part # ILM-42760401

1. The Exit Flag Sensor is located on

the left side of the press where the
conveyor is positioned. The close
up photos show where the sensor
is located, the sensor broken and
also the right flag that has been
broken off.

2. Bend out the sensor slightly

(quarter moon angle) to dis-lodge
the right side from the slot. Lift up
on the sensor and gently maneuver until the it becomes dis-lodged
from the left slot and pulled out
from the eject assembly.

3. Maneuver the sensor back into

the eject assembly and place in
the left slot. Bend out the sensor
slightly (quarter moon angle) to
position the right side into the slot.
Verify that the sensor is in correct
by toggling.

Face Down Exit Sensor

Part # ILM-42767501

1. The Exit Flag Sensor is located on

the top lid of the printer where the
media will exit face down. The
close up photo shows where the
sensor is loacted. Remove the old
sensor from the 2 positioning slots.

2. Push in on the black switch

before step 3 and hold the switch
down in a closed position.

3. Bend out the sensor slightly

(quarter moon angle) to dis-lodge
the right side from the slot. Lift up
on the sensor and gently maneuver until the it becomes dis-lodged
from the left slot and pulled out
from the top lod holder.
To put in a new sensor: Maneuver
the sensor back into the top lid
holder and place in the left slot.
Bend out the sensor slightly
(quarter moon angle) to position
the right side into the slot. Verify
that the sensor is in correct by
toggling.

Waste Cap & Spring

Call Technical Support for Part #

and/or availability

The waste cap and spring are located on the back wall of the printer. These 2 parts allow proper waste flow from
the drums to the waste assembly. Missing caps or springs can cause a dirty printer and color to color registration.
The waste caps can be damaged when the drums are not installed properly. Note that all drums must be placed
into the printer straight down, not at any angle. This will prevent the cap from getting pushed at an angle and either breaking the locking pin or dis-lodging it from it housing. The cap or spring when dis-lodged can be searched
for inside the printer where the transfer is located or where the duplexor is located.