HP C30D manual

Cut Sheet Printers Maintenance Manual Models C30 and C30D HP Part No. C 4000-900 06[...]

-ii Notice Hewlett- Packard make s no warran ty of any ki nd wit h regard t o this mat erial, i ncluding, but no t limit ed to, th e implie d warra nties of merch antabil ity an d fitnes s for a pa rticu lar purpose. Hewlett -Packard shal l not be liable f or errors conta ined here in or for inc idental or conse quential damages in c onnection with[...]

-iii Warnings and Cautions A W ARNING denotes a hazard. It c alls atten tion to a procedure or practice , which, if not done corr ectly or adhered to, c ould resul t in persona l injury . Do not pr oceed beyond a W ARNING sign unt il the i ndicated c ondition s are ful ly underst ood and me t. A CAUTION denot es a h azard. I t calls attenti on to a[...]

-iv Preface The C3 0/C30 D Mainte nance Manua l cont ai ns all the info rmatio n nee de d to ma in tain a n d servic e Hewlett Pa ckard C30 an d C30D printe rs. The C30 printer series are high- speed, non-im pact printe rs uti lizing ele ctrophot ographic i maging tec hnology . The infor mation in this maint enance manual is for authoriz ed field r[...]

-v Chapter 8, “Opt ions” Provides inform ation abou t the opt ional High Capacit y Input an d High Capaci ty Outpu t bins. Chapter 9, “Ge neral Print er Maintenanc e” Reviews pr inter mai ntenance p rocedures to compl ete during s ervic e calls. Appendix A Lists t he abbrevi ations a nd acronyms u sed in th e manual. Index Provides a list o[...]

-vi[...]

Contents vii Printer and Troubleshooting Overview Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Paper Path and Cycle Sequence . . . . . . . . . .[...]

viii TAG 012: Upper Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 TAG E12: Envelope Tray or Feeder Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 TAG 013: Lower Cassette Not La tched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 TAG 020: Pap[...]

ix TAG 804: Pri nts With Light Hori zontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-162 TAG 805: Blac k Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163 TAG 806: Pri nts with Dark Spots or Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166 TA[...]

x 001 Operator Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 002 Upper Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 003 Lower Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

xi Connectors I nside the Back Cover (Cont inued) J/P18- 62 . . . . . . . . . . . . . . . . . . . . . . 6-13 Connectors I nside the Back Cover (Cont inued) J/P 64- 85 . . . . . . . . . . . . . . . . . . . . . . 6-14 Connectors I nside the Back Cover (Cont inued) J/P 90- 800 . . . . . . . . . . . . . . . . . . . . . 6-15 Voltage Isolation Diagrams .[...]

xii Counter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 IGS Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 PCL Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

xiii Top Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82 Erase Lamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83 EP Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84[...]

xiv Printer /Maintenance Reco rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Every-Call Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Remove Major Consumable Suppli es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

Printer an d Troubl eshootin g Overview 1-1 Chapter 1 Printer and T roubleshooting Overview Section 1 T roubleshooting[...]

1-2 Printer and Tro ubleshoo ting Ove rview Contents Printing and Troubleshoo ting Overview Theory of Operat ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Paper Path a nd Cycle Seque nce. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Simplex Print ing . [...]

Printer an d Troubl eshootin g Overview 1-3 Theory of Operation The print er uses a n electr ophotograp hic ima ging syste m based o n LED array t echnology . T wo key compon ents of the p rinter are th e image gene ration sy stem (IGS) c ontroll er and the pri nter cont rol logi c (PCL) b oard. Image Generat ion System (IGS) contr oller: Each prin[...]

1-4 Printer and Tro ubleshoo ting Ove rview 6 Activati ng paper As the i mage is be ing de velope d, a she et of pa per i s tra nsport ed to the p hotocon ductor belt. The PCL board cont rols th is act ivity . A seri es of pape r pick-up , feed, and timing roller s guide t he paper so the de veloped imag e is prope rly regi stered wi th the le adin[...]

Printer an d Troubl eshootin g Overview 1-5 Paper Path and Cycle Sequence The IGS board si gna ls the PCL board th at a page of dat a is read y to be printe d. When this happens t he follo wing seq uence take s place. Simplex Pr inting 1 PCL softwar e downloade d to th e PCL board fr om the disk drive sys tem turns o n the main motor . 2 The PCL bo[...]

1-6 Printer and Tro ubleshoo ting Ove rview 2 The paper upon passing t hrough the “B” rolle r comes in cont act with the duplex sen- sor . (If the paper doe s not ener gize this senso r i n a giv en amoun t of ti me, an er ror 060 will occ ur .) 3 The “C” rol ler bidi rectio nal moto r turns on and passes the pa per into t he turna round tr[...]

Printer an d Troubl eshootin g Overview 1-7 Error Code T echnical Definitions The foll owing tabl e lists the print er error codes and their de scripti ons. T able 1 -1. Error Code T echnical Definitions T ype E rror Description Cassette E rrors 010, E10 PCL boar d detected no signal f rom upper paper cassette empty sensor i ndicatin g no paper pre[...]

1-8 Printer and Tro ubleshoo ting Ove rview OPC Rotation Errors 040 PCL boar d sensed tha t the sign al from the p hotocondu ctor seam sensor ei ther was not of sufficient amp litude or did not sho w the proper ti ming. 041 PCL boar d detected an abnor mally hig h amount o f current needed to driv e the photo conductor seam senso r LED (withi n the[...]

Printer an d Troubl eshootin g Overview 1-9 Jogger Errors 081 PCL boar d activate d the jogg ing motor b ut did not detect a change in the s ignal from t he front sens or in the j ob offset assembl y (diag- nostic test only). 082 PCL boar d activate d the jogg ing motor b ut did not detect a change in the s ignal from t he rear se nsor in the job o[...]

1-10 Printer and Troubl eshootin g Overview DD Er rors 405-409 IGS boa rd detected an error in th e program R AM durin g the inter- nal d iagnostic t esting of the IGS b oard. 450-566 IGS boa rd detected an error d uring the in ternal diag nostic testi ng of the IG S board a nd software. Controller Error s 570-586 IGS boa rd detected an error wh en[...]

Printer an d Troubl eshootin g Overview 1-11 Sensor and Switch Locations The follow ing pa ges il lustra te the locat ions of the pr inter ’ s se n sors a nd sw it ches . Table 1- 2, “Sensor a nd Switch List ,” on page 1- 14 , list s th em. Left end view Left end view Fron t lef t vi ew Top view , duplex[...]

1-12 Printer and Troubl eshootin g Overview Top view Front view Developer right view Developer left view[...]

Printer an d Troubl eshootin g Overview 1-13 Right side view Top left, duplex tray view Front view[...]

1-14 Printer and Troubl eshootin g Overview T able 1 -2. Sensor and Switch List Sensor/Switch Name Page No. Auto mati c tone r contr ol sens or 1-12 Cassette paper present sen so rs, uppe r and lower 1-1 1 Cassette present mic ro switch es, upper an d lower 1-1 1 Dupl ex re gistr ati on sens or 1-1 1 Duplex paper path s ensor 1-1 1 Duple x cover in[...]

Printer an d Troubl eshootin g Overview 1-15 T r oubleshooting Overview Throughout the prin ter’ s life problems oc cur , such as th ose ind icated whe n an error code display s on th e operator panel, a p rinter p roduces poo r qual ity prin ts, or the printer mal- functi ons. Use the t ool s pr ovi de d in t his manu al to dia gnos e a nd r es [...]

1-16 Printer and Troubl eshootin g Overview The Problem: Printer or Host? The pri nter is one component in a larg e host s ystem. Before you start any troubleshoot ing, make su re that t he proble m reall y belo ngs to the printer rather t han to som e other c ompo- nent in the host s ystem. Prin t qual ity probl ems and mechani cal malfunct ions a[...]

Printer an d Troubl eshootin g Overview 1-17 Protocol Converters Many proto col conver ters ha ve a s elf-test function or confi guration mode that enabl es the user to check the p roper fun ctioning of the control. Y ou ca n reconnec t the host interf ace and ask t he customer to exe rcise this funct ion of the converte r . If the printer re ceive[...]

1-18 Printer and Troubl eshootin g Overview Confirming Line Power Errati c printe r problems can be c aused by impr oper lin e power . As a rul e, the v oltage of the outl et shoul d be che cked at in stallat ion. However , if you a re unable to isola te an int er- mittent proble m, the power shoul d be chec ked agai n. Consul t your co untry’ s [...]

Printer an d Troubl eshootin g Overview 1-19 Using the Troubleshooting Analysis Guide (T AG) The T roubleshoot ing Analys is Guide pr ovides pr oblem-solv ing sequenc es to h elp you identi fy and res olve prin ter pr oblems. Each T AG addresse s a particul ar symp tom or erro r code of t he print er . The T AG number often mat ches an er ror code [...]

1-20 Printer and Troubl eshootin g Overview The T AG then direct s you to per fo rm c ert ai n t as ks. Based o n t he results of thes e t as ks, the T AG poses qu estio ns that c an be answer ed by eithe r yes or n o. For ye s answers, y ou fol- low one pat h; for no answers, f ollow another path. Some of the paths may lead you to other T AGs, so [...]

Printer an d Troubl eshootin g Overview 1-21 S tandard Procedures While usi ng the T AGs, you may be asked to perform some of the foll owing proce dures. Specifi c instru ctions f or compl eting the se procedu res are i ncluded he re, rathe r than repeat ed in the body of eac h T AG . Please read thi s inf or mati on bef ore fol lowi ng any T AG . [...]

1-22 Printer and Troubl eshootin g Overview Inst alling the Inter lock By-p ass T ool The int erlock b y-pass t ool over rides t he cover interl ock switc hes, all owing you to opera te the pri nter with t he covers open. The int erlock by- pass tool is a white plas tic, “V”-s haped tool wit h two finge r pads. T o use the tool, open the cover [...]

Printer an d Troubl eshootin g Overview 1-23 5 Remove the p hotoconduct or unit. Figure 1 -4. Pr oducing a T oner Patch on the Photoconductor Unit 6 Examine the photoc onductor u nit to verify t hat a ton er patch h as been pr oduced. Y ou may have to rotat e the bel t slightly to obse rve the patc h. Completing a Service Call After r esolving a ny[...]

1-24 Printer and Troubl eshootin g Overview Clearing the Error Log 1 Ente r th e dia gn osti c mo de of th e prin te r: • T urn off the prin ter and wait 5 seconds . • Hold down t he ST OP and TEST keys simultane ously as you tu rn the pr inter back on. • The tone , fol lowed by “00” on the di spla y , indica tes y ou are in t he te st mo[...]

TAG Cr oss- Re ferenc e Tabl es 2-1 Chapter 2 T AG Cross- Reference T a bles[...]

T AG Cross-Reference T ables 2-2 TAG Cros s- Refe r ence T ables T AG Cross-Reference T ables This sec tion cont ains the t hree cro ss refer ence char ts for tr ouble shooting pr int prob lems: Error Cod e/TAG Cross-Referen ce Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Print Qua lity/TAG Cross-Referenc e Chart . . [...]

Error Code/T A G Cross-Ref erence TAG Cr oss- Re ferenc e Tabl es 2-3 Error Code/T AG Cross-Re ference Error co des, whi ch appear o n the 3-di git displ ay of the operator’ s panel, indi cate a wid e variet y of printer problems rel ated to the c ontrol bo ards, soft ware, and/or h ost communi- cation p roblem s. On th e chart find th e error c [...]

2-4 TAG Cros s- Refe r ence T ables 071 Fuser the rmistor open or no fus er 071 072 Fuser tem perature too high 072 073 Fuser tem perature too low 070 081 No front j ob offset sensor 083 082 No back job of fset se nsor 083 083 Job offset mecha nism mal function 083 084 Duplex tray reg istration sen sor not activated 901 085 Duple x tray regi st rat[...]

TAG Cr oss- Re ferenc e Tabl es 2-5 160 PCL boar d PIA1 regi ster error after reset 100 161 PCL boar d PIA1 regi sters rea d/write error 1 00 162 PCL board PIA1 P A or PB rea d/write error 100 170 PCL boar d PIA2 regi ster error after reset 100 171 PCL boar d PIA2 regi ster read/w rite error 100 172 PCL boar d PIA2 PB r ead/write er ror 100 180 PCL[...]

2-6 TAG Cros s- Refe r ence T ables T able 2-5. IGS Firmwa re Error Codes Code IGS Firmw are Error Code Me aning These e rror codes signal a problem with the IG S contr oller firmware. No T AGs addre ss these problem s; report them to the printer ’s man ufacturer . Go t o T AG 301 S tatus rec eived afte r VSS asserte d No T AG 302 S tatus tag as [...]

TAG Cr oss- Re ferenc e Tabl es 2-7 T able 2 -8. IGS/Disk Dr ive Error Codes Code Disk Drive E rror Code Meaning Go to T AG 401 Fatal IGS PB error No T AG 450 Incorrec t diskette 130 451 Diske tte format error or incorr ect disk 130 454 Fatal trap 200 455 T rap 200 500 Incorrec t PIT0 regis ters conten ts; no reset 200 501 PIT0 regi ster read/ writ[...]

2-8 TAG Cros s- Refe r ence T ables 550 T wo-cha nnel tran sfer error 200 551 No PCL board/seri al control ler interru pt on break 200 552 No serial con troll er /DM AC int erac tion 2 00 553 Seria l cont roll er/ DM AC tra nsf er coun t er ror 200 554 Serial co ntroller/D MAC transfer e rror 200 555 RS232 se nd/r ec eive path error 200 556 RS232 D[...]

Print Quality/T AG Cross-Reference TAG Cr oss- Re ferenc e Tabl es 2-9 Print Quality/T AG C ross-Refe rence Poor qu ality prin ts ar e another indicati on of pri nter probl ems. Begin by runnin g a set of test pr ints. Then , compare th e test pr ints to t he samples located i n Cha pter 4, “Pr int Qual- ity Sa mp les” . The chart summar izes t[...]

Print Quality /T AG Cross-Referenc e 2-10 TA G Cros s- Re ferenc e Tabl es T able 2 -12. Light Print T AGs Light Print s Go to T AG With carrier p articles 801 With backg ro und 81 1 With voids /wh ite sp ots 8 02 With li ght vertica l streaks 803 With bla nk or white vertical l ines 803 With light hor izo n tal bands 804 T able 2 -13. Dark Print T[...]

Print Quality/T AG Cross-Reference TAG Cr oss- Re ferenc e Tabl es 2-11 T able 2 -16. Smeare d, Blurred, and U neven Print T AGs Smeared, Blurr ed, Uneven Prints Go to T AG Smeared vertical streak s 809 Blurred p rints 809 Uneven de nsity 810 Prints with ba ckgrou nd 81 1 Prints with ba ckgrou nd and residual images 81 1 Prints with r esidual im ag[...]

Print Quality /T AG Cross-Referenc e 2-12 TA G Cros s- Re ferenc e Tabl es Mechanical Malfunction/T AG Cross-Reference The chart below ou tlines possible mechanical malfunc tions and recommends an appropri- ate T AG to follow to resol ve the pro blem. T able 2 -18. Operat or Panel Problems T AGs Operator Panel Problems Go to T AG Blank wi th AC pow[...]

Print Quality/T AG Cross-Reference TAG Cr oss- Re ferenc e Tabl es 2-13 f T able 2-21. Paper Handling Problem T AGs Paper Handling Problems Go to T AG Mul tipl e p aper feed 70 5 Multiple sheet fee ds and jams 705 Wrinkled or torn paper 7 06 Simplex : misregi stration an d paper skew 807 Duplex: m isregistra tion and paper s kew 901 Paper will not [...]

Print Quality /T AG Cross-Referenc e 2-14 TA G Cros s- Re ferenc e Tabl es[...]

Troub leshootin g Analys is Guid e (TAGs) 3-1 Chapter 3 T roubleshooting Analysis Guide (T AGs)[...]

3-2 Tro ubles ho otin g Analy sis Guid e (TAG s) Contents Troubleshooting Analysis Guide (TAGs) TAG 001: Trou bleshooting a Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 TAG 002: Check &Problem Resoluti on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 TAG 010: Upper Cassette Malf unctio[...]

Troub leshootin g Analys is Guid e (TAGs) 3-3 TAG 101: IGS Cont roller Dia gnostic Fail ure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103 TAG 130: Disk ette/Disk Dri ve Malfuncti on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104 TAG 200: IGS I nternal Communica tion Malfunctio n . . . . . . . . . . . . . . . . . . . . .[...]

3-4 Tro ubles ho otin g Analy sis Guid e (TAG s) T r oubleshooting Analysis Guide (T A Gs) This chap ter descr ibes eac h of th e T AGs used t o diagnose and resolv e specif ic print er problems related to e rror code s, print qual ity , and mechanica l malfunctio ns. Chapter 1 , “Prin ter and Troubl eshootin g Overvi ew” , is a n overvie w of [...]

Troub leshootin g Analys is Guid e (TAGs) 3-5 T AG 001: T roubleshooting a Problem If you ar e no t sure how t o t ro ubl esh oot a pri nt er pr obl em, s ta rt wi th thi s T AG . This an d a ll T AGs assume y ou are fami liar wit h standar d proce dures, suc h as power -on-reset, pre - sente d in Chapter 1, “Pri nter a nd Troublesh oot ing Over [...]

3-6 Tro ubles ho otin g Analy sis Guid e (TAG s) display? No: Refer to Chapter 2, “TAG Cr oss- Reference Tables” to determine which T AG to follow , then turn to that T AG . Ye s : Co ntinue. 6 Run tes t prin ts from t he upper cass ette by completin g the foll owing: • Power-on-reset the printer . • Run tes t prin ts from the upper cass et[...]

Troub leshootin g Analys is Guid e (TAGs) 3-7 10 Run a j ob which is known to be good. • Compare the ou tp ut from the problem pri nt jo b to the output from the go o d print job. Can you identify the problem? No: Return to the beginning of the T AG , following the procedures carefully to determine the kind o f problem your custom er has. Ye s : [...]

3-8 Tro ubles ho otin g Analy sis Guid e (TAG s) T AG 002: Check & Pr oblem Resoluti on 1 Complete any actio ns directing you to this T AG . • Make sure all connector s, covers, parts, and hardware have be en reinstalled. In the course of resolving the printer problem, did you complete the eve ry-call cleaning procedure? No: Continue. Ye s : [...]

Troub leshootin g Analys is Guid e (TAGs) 3-9 the magnetic roller . • Reinstall th e developer unit. 6 Inspect and clean the cleaner un it/m ain charger: • Inspect the unit for damage or con tamination; repair or rep lace as necessary . • Remove the main charger from the cleaner unit. • Clean the grid with the cleaner brush. • Remove the [...]

3-10 Troublesh ooting Anal ysis Guide (T AGs) 3 Run tes t prin ts to con firm print quality , in bo th simpl ex and dupl ex modes an d from upper and lower paper cassettes . When you enter test p rint mode by pressing the keys listed belo w , the follo w- ing items print in the order listed: a directory of th e boot device and mu ltiple listings of[...]

Troub leshootin g Analys is Guid e (TAGs) 3-11 5 Press: ST AR T to select the drive specified. 1-0 appear s on the display 6 Press: ST AR T to select the clear error log function. 6- 0 appears on the display . 7 Press: CANCEL to clear the error log. 6-1 appears on the display . 8 Press: STOP to exit the p rocedure. 9 Confirm that the error log h as[...]

3-12 Troublesh ooting Anal ysis Guide (T AGs) T AG 010: Upper Cassette Malfunction Error Code: 010 Possible Ca uses: Cassette empty Paper incorrectly loaded Possible De fect s: Upper paper empty actuator Upper paper empty sensor Upper cassette tray Upper pressure lev er Upper cassette relea se cam Upper cassette relea se latch Upper cassette releas[...]

Troub leshootin g Analys is Guid e (TAGs) 3-13 4 Check pressure lever: • Reinsert the upper cassette. • W atch the pressure lever as the cassette is inserted. Does the pres sure lever e levate the paper to the co rrect feeding position? No: Check the fo llowing for defects or in correct moun ting: • Cassette tray • Damper assembly • Upper[...]

3-14 Troublesh ooting Anal ysis Guide (T AGs) E10: Envelop e T ray Out of Enve lopes This T AG refers to t he error code for t he envelo pe tray , which handl es 75 enve lopes. Error Code: E10 Possible Ca uses: Cassette empty Envelopes incorrectly lo aded Possible De fect s: Upper paper empty actuator Upper paper empty sensor Paper size sensor asse[...]

Troub leshootin g Analys is Guid e (TAGs) 3-15 5 Reinsert the envelo p e cassette. • W atch the pressure lever as the cassette is inserted. Does the pres sure lever e levate the env elopes to the corre ct feeding position? No: Check the fo llowing for defects or in correct moun ting: • Cassette tray • Damper assembly • Upper pressure lever [...]

3-16 Troublesh ooting Anal ysis Guide (T AGs) T AG 01 1: Lower Cassett e Malfun ction Error Code: 01 1 Possible Ca uses: Cassette empty Paper incorrectly loaded Possible De fect s: Lower paper empty ac tuator Lower paper empty sensor Lower cassette tray Lower pressur e lever Lower cassette r elease cam Lower cassette r elease latch Lower cassette r[...]

Troub leshootin g Analys is Guid e (TAGs) 3-17 4 Reinsert the lower cassette. • W atch the pressure lever as the cassette is inserted. Does the pres sure lever e levate the paper to the co rrect feeding position? No: Check the fo llowing for defects or in correct moun ting: • Cassette tray • Lower pressure lever • Lower cassette release cam[...]

3-18 Troublesh ooting Anal ysis Guide (T AGs) T AG 012: Upper Cassette Not Latched Error Code: 012 Possible De fect s: Upper cassette relea se cam Upper cassette relea se latch Upper cassette in latch Upper pressure lev er Spring Wir e cable and pulley Upper cassette Upper cassette in switch Upper paper s ize sensor Lower paper size sensor Connecto[...]

Troub leshootin g Analys is Guid e (TAGs) 3-19 4 Run di agnostic test 002 . Is 1-0 displayed? No: Replace the PCL board, then turn to TAG 002: Check & Problem Reso lution . Ye s : Co ntinue. 5 Install the upper cassette. Is a value other t han 1-0 displayed? No: Continue. Ye s : Replace the PCL board, then turn to TAG 00 2: Check & Problem [...]

3-20 Troublesh ooting Anal ysis Guide (T AGs) 9 Reconnect J/P40 and J/P45. • Remove the lower cassette. • Loosen the lower paper size sensor assembly f or access to the circuit board. • Disconn ect J/P43 and J/ P 47. • Check J4 3-8 to J 47-3 for co ntinuit y . Is there continuity? No: Replace lower paper size sensor assembly , then turn to [...]

Troub leshootin g Analys is Guid e (TAGs) 3-21 T AG E12: Envelope T ray or Feeder Not Latched Error Code: E12 Possible De fect s: Upper cassette release cam Upper cassette release latch Upper cassette in latch Upper pressure lev er Spring Wir e cable and pulley Envelope cassette or high capacity env elope feeder Upper cassette in switch Upper paper[...]

3-22 Troublesh ooting Anal ysis Guide (T AGs) 4 Run di agnostic test 00 2. Is 1-0 displayed? No: Replace the PCL board, then turn to TAG 002: Check & Problem Reso lution . Ye s : Co ntinue. 5 Install the envelope tray . Is a value other t han 1-0 displayed? No: Continue. Ye s : Replace the PCL board, then turn to TAG 00 2: Check & Problem R[...]

Troub leshootin g Analys is Guid e (TAGs) 3-23 9 Reconnect J/P40 and J/P45. • Remove the lower cassette. • Loosen the lower paper size sensor assembly f or access to the circuit board. • Disconn ect J/P43 and J/ P 47. • Check J4 3-8 to J 47-3 for co ntinuit y . Is there continuity? No: Replace the lower p aper size assembly , then turn to T[...]

3-24 Troublesh ooting Anal ysis Guide (T AGs) T AG 013: Lower Cassette Not Latched Error Code: 013 Possible De fect s: Lower cassette r elease cam Even Lower cassette r elease latch Lower cassette in latch Lower pressur e lever Spring Lower cassette Lower cassette in switch Lower paper size sensor Connectors or wiring PCL board 1 T urn th e printer[...]

Troub leshootin g Analys is Guid e (TAGs) 3-25 5 Install the lower cassette. Is a value other t han 1-0 displayed? No: Continue. Ye s : Replace the PCL board, then turn to TAG 00 2: Check & Problem Resolutio n . 6 T urn th e printer off an d unplug t he power cord . • Remove the lower cassette. • Loosen the lower paper size sensor assembly [...]

3-26 Troublesh ooting Anal ysis Guide (T AGs) T AG 020: Paper Jam/Misfeed i n Upper Cassette Area Error Code: 020 Possible Ca uses: Paper incorrectly loaded Wr ong weight or t ype of pa per loaded Paper path obstructed Possible De fect s: Upper pick-up roller assembly Upper feed roller assembly Upper pick-up roller drive assembly Upper paper gui de[...]

Troub leshootin g Analys is Guid e (TAGs) 3-27 3 Clear the p aper path. • Remove the upper cassette. • Power-on-reset the printer . • Run test prints from the lower cassette. Is error code 021 displayed? No: Go to #1 0 in this T AG . Ye s : Co ntinue. 4 Clear the paper path. • Ins pe ct the pap er timing sensor actuato r for dam a ge or bi [...]

3-28 Troublesh ooting Anal ysis Guide (T AGs) 9 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P40 and J/ P 57. • Check the follow ing for continu ity :. P40-16 to P5 7-2 P40-25 to P5 7-1 P40-12 to P5 7-3 Is there continuity on all? No: Repair or repl ace the connectors or wirin g from P40-25 to J/P5 8-1 to P57-1, P4 0-16 [...]

Troub leshootin g Analys is Guid e (TAGs) 3-29 13 T urn of f the printer an d unplug the power cord. • Disconn ect J/P40 and J/ P 66. • Check P4 0-6 to J 66-2 and P 40-1 1 to J66-1 f or continui ty . Is there continuity? No: Repair or replace conn ectors or wirin g from P40-6 to J66- 2 or P40 -1 1 to J66-1. Then turn to TAG 002: Check & Pro[...]

3-30 Troublesh ooting Anal ysis Guide (T AGs) T AG 021: Paper Jam/Misfeed i n /Lower Casse tte Area Error Code: 021 Possible Ca uses: Paper loaded incorrectly Wr ong weight or t ype of pa per loaded Paper path obstruction Possible De fect s: Lower pick-up roller assembly Lower feed roller assembly Lower pick-up roller drive assembly Upper paper gui[...]

Troub leshootin g Analys is Guid e (TAGs) 3-31 3 Clear the paper path. • Reinsert the upper cassette. • Power-on-reset the printer . • Run tes t prin ts from the upper cass ette. Is error code 020 displayed? No: Go to #1 0 in this T AG . Ye s : Co ntinue. 4 Clear the paper path. • Ins pe ct the pap er timing sensor actuato r for dam a ge or[...]

3-32 Troublesh ooting Anal ysis Guide (T AGs) P40-25 to P5 7-1 P40-12 to P5 7-3 Is there ground? No: Repair or repl ace the connectors or wirin g from: P40-25 to J/P58-1 to P57-1, P40-16 to J/ P58-2 t o P57-2, or P40-12 to J/P58-3 to P57-3. Then turn to TAG 002: Check & Problem Resolution . Ye s : Replace the paper timing guide. If this does no[...]

Troub leshootin g Analys is Guid e (TAGs) 3-33 13 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P40 and J/ P 67. • Check P4 0-5 to J 67-2 and P 40-1 1 to J67-1 f or continui ty . Is there continuity? No: Repair or replace the connectors or wiring from P40-5 to J67-2 or P40-1 1 to J67-1. Then turn to TAG 002: Ch eck & [...]

3-34 Troublesh ooting Anal ysis Guide (T AGs) T AG 022: Paper Jam in the T ransfer or Fuser Area Error Code: 022 Possible Ca uses: Paper loaded incorrectly Wr ong weight or t ype of pa per loaded Paper path obstruction Possible De fect s: Fuser unit Paper supply Paper timing r oller assembly Fuser drive assembly Fuser drive belt V acuum transp ort [...]

Troub leshootin g Analys is Guid e (TAGs) 3-35 Operations manual. • Check that the fu ser unit is installed proper ly . • Power-on-reset the printer . • Run test pr ints. Is error code 022 still disp layed? No: Paper incorrectly load ed, incorrect paper type in use, or a loose conn ector was at fault. Tu r n t o TAG 0 0 2: Check & Problem[...]

3-36 Troublesh ooting Anal ysis Guide (T AGs) 8 Check the pap er path for jams. • Open the prin ter ’ s front cover and in sert the interlock by pas s to ol. • Power-on-reset the printer . • Run test pr ints. • W atch the end of the p aper timing roller shaft. Does the p aper timing roller sha ft tur n? No: Continue. Ye s : Go to #14 i n [...]

Troub leshootin g Analys is Guid e (TAGs) 3-37 14 Does pa per stop or jam either before or during entry into the fuser unit? No: Go to #1 7 in this T AG . Ye s : Co ntinue. 15 Remo ve the fus er uni t. • Check the fuser unit rollers for damage or toner contamination. Are they damaged or cont aminated with toner? No: Continue. Ye s : Replace the f[...]

3-38 Troublesh ooting Anal ysis Guide (T AGs) 20 Power-o n-reset the printer . • While the main m otor is run ning, cov er all o f the ho les in the vacuu m unit with a piece o f p aper . Does the vacuum transport unit fan hold the paper in place? No: Continue. Ye s : Retu rn to the beginning of this T A G . 21 Use extreme caution: Check fo r 100[...]

Troub leshootin g Analys is Guid e (TAGs) 3-39 T AG 023: Paper Jam in the Output Area Error Code: 023 Possible Ca uses: Paper path obstruction Output t ray obst r uction Possible De fect s: Exit paper sens or Fuser drive unit Exit roller assembly Exi t pi nch r oller ass embl y PCL board Connectors or wiring If the printer has a high c apacity o ut[...]

3-40 Troublesh ooting Anal ysis Guide (T AGs) P40-13 to P4 9-3. Is there continuity? No: Repair or repl ace the connectors or wirin g from: P40-26 to J/P50-1 to P49-1, P40-24 to J/ P50-2 t o P49-2, or P40-13 to J/P50-3 to P49-3. Ye s : Replace the exit paper sensor . 5 T urn th e printer off an d unplug t he power cord . • Open the back cover an [...]

Troub leshootin g Analys is Guid e (TAGs) 3-41 T AG 025: Paper in Input Area Befor e Printing Error Code: 025 Possible De fect s: Paper timing sens or PCL board Connectors or wiring 1 T urn th e printer off an d unplug t he power cord . • Check the pap er path and remo ve any paper jams. • Confirm that J/P58 an d J/P40 are connected p roperly .[...]

3-42 Troublesh ooting Anal ysis Guide (T AGs) 6 T urn th e printer off an d unplug t he power cord . • Loosen the paper timin g guide. • Disconn ect J/P57 and J/ P 40. • Check the fo llowing for continuity: • P40-1 6 to P57- 2 • P40-2 5 to P57- 1 • P40-1 2 to P57- 3 Is there continuity? No: Repair or repl ace the connectors or wirin g f[...]

Troub leshootin g Analys is Guid e (TAGs) 3-43 T AG 026: Paper in Output Area Befo re Print ing Error Code: 026 Possible De fect s: Exit paper sens or PCL board Connectors or wiring If the printer has a high c apacity o utput unit (HCO), un plug an d remove it before beg in- ning this T AG . T est the print er without the HCO; if the probl em remai[...]

3-44 Troublesh ooting Anal ysis Guide (T AGs) T AG 030: Developer Bias Short/Failure Error Code: 030 Possible De fect s: Cleaner unit High vo ltage uni t DC power supply Connectors or wiring PCL board Printhead assembly Power contr ol #2 board Developer u nit 1 T urn th e printer off an d unplug t he power cord . • V erify that J/P23, J/P24, J/P4[...]

Troub leshootin g Analys is Guid e (TAGs) 3-45 6 Open the back co ver and install an interlock by-pass tool . • Power-on-reset the printer . • Check TP4 -35 for +24 Vdc. Is the voltage +24 Vdc? No: Go to #1 1 in this T AG . Ye s : Co ntinue. 7 Check J/ P23-5 fo r +24 Vdc. Is the voltage +24 Vdc? No: Repair or repl ace the connectors or wirin g [...]

3-46 Troublesh ooting Anal ysis Guide (T AGs) 11 Check TP3-27 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Ye s : Replace the PCL board, then turn to TAG 00 2: Check & Problem Resolutio n . 12 Check J/ P12-1 fo r +24 Vdc. Is the voltage +24 Vdc? No: Continue. Ye s : Repair or replace the connecto rs or wiring from P40 -27 to P12-1, then t[...]

Troub leshootin g Analys is Guid e (TAGs) 3-47 T AG 031: T oner Patch Ref erence Le vel T oo Low Error Code: 031 Possible Ca uses: Contamina tion of the toner pat c h sens or or printhead lens Possible De fect s: Photocond uctor unit Connectors or wiring PCL board Developer u nit 1 T urn th e printer off an d unplug t he power cord . • Perform th[...]

3-48 Troublesh ooting Anal ysis Guide (T AGs) 6 T urn th e printer off an d unplug t he power cord . • Remove t he developer unit. • Disconn ect J/P41. • Check P41-47 t o J25-3 for continu ity . Is there continuity? No: Repair or repl ace the connectors or wirin g from P41-47 to J25 -3. Ye s : Replace the PCL board, then turn to TAG 00 2: Che[...]

Troub leshootin g Analys is Guid e (TAGs) 3-49 T AG 032: T oner Patch T oo Light Error Code: 032, 033 Possible De fect s: Photocond uctor unit IGS boar d PCL board 1 Check the voltages, as described in Chapter 9, “General Printer Maintenance” . Are the voltages correct ? No: Replace the high voltage power supply unit, then tur n to TAG 002: Che[...]

3-50 Troublesh ooting Anal ysis Guide (T AGs) 7 Check the toner p atch se nsor boa r d in the de veloper unit for lo ose wir ing conn ector s. Are all connectors and wiring co nnected properly? No: Reconnect the wiring an d connectors or r eplace the deve loper unit, then tur n to TAG 00 2: Check & Problem R esolution . Ye s : Go t o TAG 808: P[...]

Troub leshootin g Analys is Guid e (TAGs) 3-51 T AG 035: Out of T oner or ADD T ONER Indicator On Error Code: 035 Possible Ca uses: Photocond uctor unit T oner cartridge seal not r emoved T oner cartridge empty High print coverage Possible De fect s: PCL board Developer unit connectors or wiring An 035 error may occur i f the print cov erage excee [...]

3-52 Troublesh ooting Anal ysis Guide (T AGs) 6 Remove the toner cartr idge seal. • Power-on-reset the printer . • Run test pr ints. Has the problem been resolved? No: Continue. Ye s : The toner cartridge seal was at fault. T urn to TAG 002: C heck & Problem Resolution . 7 T urn th e printer off an d unplug t he power cord . • Disconn ect[...]

Troub leshootin g Analys is Guid e (TAGs) 3-53 T AG 036: Developer Unit Not Inst alled Error Code: 036 Possible De fect s: Developer unit no t in sta lled properly Connectors or wiring PCL board 1 T urn th e printer off an d unplug t he power cord . • Make sure the developer un it is installed properly . • Confirm that J/P41 is con nected prope[...]

3-54 Troublesh ooting Anal ysis Guide (T AGs) T AG 040: Photo conductor Se am Sensor Mal function Error Code: 040, 041 , 042 Possible De fect s: Photocond uctor unit Main m otor gear Main mo tor gear keys Main driv e gear assemb ly Main d rive motor as sembly Connectors or wiring PCL board Software Seam s ensor 1 T urn th e printer off an d unplug [...]

Troub leshootin g Analys is Guid e (TAGs) 3-55 6 T urn the printer off. • Remove the p hotoconduct or unit. • Inspect i t for damaged d rive mechanis m or belt s lippage. Is it in good working order? No: Replace the photocond uctor unit, then turn to TAG 002: Check & Problem Resolutio n . Ye s : Co ntinue. 7 Reinstall the photoco nd uctor u[...]

3-56 Troublesh ooting Anal ysis Guide (T AGs) 11 Remove t he photocond uctor unit. • Inspect t he photocond uctor belt for damage. • Check th e timing hole for co ntamination or block age. Are the photoconductor belt and the timing hole both in good working order? No: Replace the photocond uctor unit, then turn to TAG 002: Check & Problem R[...]

Troub leshootin g Analys is Guid e (TAGs) 3-57 16 Clean bo th the photo conductor LED and seam sens or using a co tton swab or com pressed air . • Run diagnosti c 009. • Using an oscilloscope connected to TP3- 20 on the PCL b oard, adjust the signal so that it matches f igure A by moving the sen sor bracket cl oser or far ther from the photoco [...]

3-58 Troublesh ooting Anal ysis Guide (T AGs) T AG 044: Main Char ger/T ransfer Charger Circuit Open Error Code: 044 Possible De fect s: Main c harge r T ransfer charger Connectors or wiring High vo ltage uni t Upper paper guide Main charger terminal assembly PCL board 1 T urn th e printer off an d unplug t he power cord . • V erify that J/P23 an[...]

Troub leshootin g Analys is Guid e (TAGs) 3-59 4 Remove the tran sfer charge r . • Inspect t he housing for jammed p aper . Is paper jammed inside the transfer charger housing? No: Continue. Ye s : Remove the jammed paper an d check the transfer ch arger fo r damage, then tu rn to TAG 022: Paper Jam in the Transfer or Fuser Area . 5 Run di agnost[...]

3-60 Troublesh ooting Anal ysis Guide (T AGs) continuity . Is there continuity? No: Replace the upper pap er guide assembly , then turn to TAG 002: Check & Prob lem Reso- lution . Ye s : Go to #13 i n thi s T AG . 11 T urn th e printer off an d unplug t he power cord . • Disconn ect the mai n char ger lead from the high volt age unit. • Che[...]

Troub leshootin g Analys is Guid e (TAGs) 3-61 T A G 045: Main Charger Circuit Shorted Error Code: 045 Possible De fect s: Main c harge r High vo ltage uni t Main charger terminal assembly Connectors or wiring PCL board 1 T urn th e printer off an d unplug t he power cord . • V erify that J/P2 3, J/P 41, J/P 85, P1 24, P1 43, and the hi gh vol ta[...]

3-62 Troublesh ooting Anal ysis Guide (T AGs) 5 Reconnect the main char ger high voltage lead. • Disconn ect P23 and J/P4 1. • Check J/P41-34 to P23- 6 for continuit y . Is there continuity? No: Repair or repl ace the connectors or wirin g from P41-34 to P23 -6, then turn to TAG 002: Check & Problem R esolution . Ye s : Co ntinue. 6 Check P[...]

Troub leshootin g Analys is Guid e (TAGs) 3-63 T AG 050: T ransfer Charger Circuit Shorted Error Code: 050 Possible De fect s: T ransfer charger High vo ltage uni t Connectors or wiring PCL board Upper paper gui de assembly 1 T urn th e printer off an d unplug t he power cord . • V erify that J/P23, J/P41 and the transfer char ger high vo ltage u[...]

3-64 Troublesh ooting Anal ysis Guide (T AGs) 5 Reconnect the transf er charg er high voltage un it lead. • Disconn ect J/P23 and J/ P 41. • Check P4 1-37 to P 23-3 for continui ty . Is there continuity? No: Repair or repl ace the connectors or wirin g from P41-37 to P23 -3, then turn to TAG 002: Check & Problem R esolution . Ye s : Co ntin[...]

Troub leshootin g Analys is Guid e (TAGs) 3-65 T AG 055: Erase L amp Malfunction Error Code: 055 Possible De fect s: Erase lamp as sembly Connectors or wiring PCL board 1 T urn th e printer off an d unplug t he power cord . • V erify that J/P26, J/P40 are connected properly . • Power-on-reset the printer . Is error code 055 displayed? No: Conti[...]

3-66 Troublesh ooting Anal ysis Guide (T AGs) 6 T urn of f the printer an d unplug the power cord. • Disconn ect P26 and P40 . • Check P26-1 to P4 0-2 for continui ty . Is there continuity? No: Repair or repl ace the connectors or wirin g from P26-1 to P40-2, then tur n to TAG 002: Check & Problem R esolution . Ye s : Repair or replace the [...]

Troub leshootin g Analys is Guid e (TAGs) 3-67 T AG 070: Fuser Unit Malfunction Error Code: 070, 073 Symptoms: No AC power at the fuser Possible De fect s: Fuser unit Power contr ol #2 board AC power supply uni t DC power supply uni t Connectors or wiring PCL board 1 T urn th e printer off an d unplug t he power cord . • V eri fy that J/P44, J/P4[...]

3-68 Troublesh ooting Anal ysis Guide (T AGs) 4 Power-o n-reset the printer . • W atch through the output tr ay opening to see if the fuser lamp comes on during the 1 5 seconds followi ng the outp ut tray jogging t est. • If the fuser lamp comes on immediately after po wer on, turn the printer of f and replace the AC power supply . Does the fus[...]

Troub leshootin g Analys is Guid e (TAGs) 3-69 8 Check P41-21 to P5-7 for continui ty . Is there continuity? No: Repair or repl ace the connectors or wirin g from P41- 21 to P83 -2 or J83-2 to P5-7, then turn to TAG 002: Ch eck & Prob lem Resolution . Ye s : Co ntinue. 9 Reinstall the fuser unit. • Check P41-2 1 to P41-22 for resistan ce. Is [...]

3-70 Troublesh ooting Anal ysis Guide (T AGs) 13 T urn off the printer . • Remove the fu ser unit. • Clean the contacts of c onnector J/P5. • Disconn ect J/P44. • Check J4 4-2 to J5-4 and J44-1 to J5-1 for con tinuity . Is there continuity on both? No: Repair or replace the co nnectors or wiring as needed, th en turn to TAG 002: Check &[...]

Troub leshootin g Analys is Guid e (TAGs) 3-71 19 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P70 and J/ P 10. • Check P70-1 to P1 0-1 for continui ty . Is there continuity? No: Repair or repl ace the connectors or wirin g from P70-1 to P10-1, then tur n to TAG 002: Check & Problem R esolution . Ye s : Co ntinue. 20[...]

3-72 Troublesh ooting Anal ysis Guide (T AGs) T AG 071: Open Fuser Thermistor Error Code: 071 Possible De fect s: Connectors or wiring Fuser unit PCL board 1 T urn th e printer off an d unplug t he power cord . • Make sure the fuser unit is ins talled properly . • Confirm that J/P41 an d J/P44 are connected p roperly . Has t he fuser unit been [...]

Troub leshootin g Analys is Guid e (TAGs) 3-73 T AG 072: Fuser Unit T emperature T oo High Error Code: 072 Possible De fect s: Connectors or wiring Fuser unit AC power supply uni t PCL board The condi tions t hat cause error code 07 2 often c ause the fuser un it’ s ther mal fuse t o open. This usua lly neces sitate s replace ment of the fuser un[...]

3-74 Troublesh ooting Anal ysis Guide (T AGs) 5 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P41. • Check P41-21 fo r conti nuity to groun d. Is there continuity? No: Continue. Ye s : Repair or replace the connecto rs or wiring that have co ntinuity to groun d: P41-21 to P44-2, or J4 4-2 to P5-7; then turn to TAG 002: Ch[...]

Troub leshootin g Analys is Guid e (TAGs) 3-75 T AG 083: Job Offset Mechanism Malfunction Error Code: 081, 082 , 083 Symptoms: Jobs not offsetting Jobs off set t ing improperly Continuous jogging Possible De fect s: Job offset mechanism Jogg in g mo tor Connectors or wiring T ray fro nt sensor T ray rea r sensor Power contr ol #3 board 1 T urn th e[...]

3-76 Troublesh ooting Anal ysis Guide (T AGs) 6 Run di agnostic test 00 8. Is the voltage 100 V ac? No: Go to #9 in this T AG . Ye s : Co ntinue. 7 T urn the printer off. • Disconn ect J/P 101 and J/P 19. • Check P1 01-2 to P 19-1 for continui ty . Is there continuity? No: Repair or repl ace the connectors or wirin g from P101-2 to P19 -1, then[...]

Troub leshootin g Analys is Guid e (TAGs) 3-77 11 Run di agnostic test 008 . • Check J/P102-1 for +1 2 Vdc while the test is running. Is the voltage +12 Vdc? No: Continue. Ye s : Replace the power control #3 board, then turn to TAG 002: C h eck & Pr oblem Re solu- tion . 12 Run di agnostic test 008 . • Check TP3-35 on the PCL boar d for +12[...]

3-78 Troublesh ooting Anal ysis Guide (T AGs) 17 Check P40 -26 to P 55-1 for continuity . Is there continuity? No: Repair or repl ace the connectors or wirin g from P40-26 to J/P5 4-4 to P55-1, then tu rn to TAG 002: C heck & Probl em Resolu tion . Ye s : Co ntinue. 18 Check P40 -22 to P 55-2 for continuity . Is there continuity? No: Repair or [...]

Troub leshootin g Analys is Guid e (TAGs) 3-79 T AG 097: +12 Vd c Power Sho rted or Sensing Pr oblem Error Code: 097 Possible De fect s: DC power supply uni t Connectors or wiring Signal interface board IGS boar d Optional external attachment Power contr ol #2 board Power contr ol #3 board Developer u nit Paper timing sens or Upper paper empty sens[...]

3-80 Troublesh ooting Anal ysis Guide (T AGs) 3 T urn the printer off. • Disconn ect J/P330 . • T urn the printer on. • Check J/P8-6 for +12 Vdc. No: Is the voltage +12 Vdc? No: Continue. Ye s : Go to #35 i n thi s T AG . 4 T urn the printer off. • Disconn ect J/P32. • T urn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12[...]

Troub leshootin g Analys is Guid e (TAGs) 3-81 8 T urn the printer off. • Reconnect J/P32. • Disconn ect J/P91. • T urn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #1 3 in this T AG . Ye s : Co ntinue. 9 T urn the printer off. • Reconnect J/P91. • Disconn ect J/P40 and J/ P 41. • T urn the printer on.[...]

3-82 Troublesh ooting Anal ysis Guide (T AGs) 12 T urn th e printer off an d unplug t he power cord . • Reconnect J/P41. • Remove the fu ser unit. • Check P41-49 t o P25-4 and P41-5 0 to P2 5-1 for continui ty to grou nd. Is there continuity? No: Go to #1 5 in this T AG . Ye s : Repair or replace the appro priate connectors or wiring, then tu[...]

Troub leshootin g Analys is Guid e (TAGs) 3-83 17 T urn the printer off. • Reconnect J/P60. • T urn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #2 0 in this T AG . Ye s : Co ntinue. 18 Disconn ect J/P 61. • Check P6 2-1 to P 61-1 for co ntinuity to groun d. Is there continuity? No: Replace the lower pap er [...]

3-84 Troublesh ooting Anal ysis Guide (T AGs) 22 T urn the printer off. • Reconnect J/P40, J /P58, J/ P60, and J /P62. • Disconn ect J/P50 and J/ P 54. • T urn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #3 0 in this T AG . Ye s : Co ntinue. 23 T urn the printer off. • Reconnect J/P50. • T urn the print[...]

Troub leshootin g Analys is Guid e (TAGs) 3-85 27 T urn the printer off. • Remove the ex it cover . • Disconn ect J/P49 and J/ P 51. • T urn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #2 9 in this T AG . Ye s : Co ntinue. 28 T urn the printer off. • Reconnect J/P49. • T urn the printer on. • Check J/[...]

3-86 Troublesh ooting Anal ysis Guide (T AGs) 32 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P40. • Check P4 0-34 to P 12-8 for continui ty to grou nd. Is there continuity? No: Continue. Ye s : Repair or replace the connecto rs or wiring from P40 -34 to P12-8, then tu rn to TAG 002: Check & Problem R esolution . 33 [...]

Troub leshootin g Analys is Guid e (TAGs) 3-87 37 T urn off the printer . • Reconnect J/P305. • Disconn ect J/P 310 (insi de the dupl ex tray). • T urn on the prin ter . • Check J/P330 -2 for +12 Vdc. Is the voltage +12 Vdc? No: Continue. Ye s : Go to #4 in this T AG . 38 T urn th e printer off an d unplug t he power cord . • Disconn ect [...]

3-88 Troublesh ooting Anal ysis Guide (T AGs) 42 T urn off the printer . • Reconnect J/P310. • Disconn ect J/P 320 and J/P 322. • T urn on the prin ter . • Check J/P330 -2 for +12 Vdc. Is the voltage +12 Vdc? No: Continue. Ye s : Go to #44 i n thi s T AG . 43 T urn of f the printer an d unplug the power cord. • Disconn ect J/P312 . • Ch[...]

Troub leshootin g Analys is Guid e (TAGs) 3-89 47 T urn of f the printer an d unplug the power cord. • Disconn ect J/P309 . • Check for continu ity to g round: P309- 4 to P319 - 1, an d P309-3 to P3 18-1 Is there c ontinuity at either? No: Replace duplex control board #1, th en turn to TAG 002: Check & Problem Resolutio n . Ye s : Repair or[...]

3-90 Troublesh ooting Anal ysis Guide (T AGs) T AG 098: -12 V dc Power Sh orted Error Code: 098 Possible De fect s: Connectors or wiring DC power supply uni t PCL board IGS boar d Signal interface board External atta chment option 1 T urn th e printer off an d unplug t he power cord . • V erify that J/P8, J/P32, J/P33, J/P73, and J/P74 are connec[...]

Troub leshootin g Analys is Guid e (TAGs) 3-91 5 T urn the printer off. • Reconnect J/P32. • Disconn ect J/P74. • T urn the printer on. • Check J/P 8-8 for -1 2 Vdc. Is the voltage -12 Vdc? No: Replace the IGS board , then turn to TAG 002: Check & Problem Reso luti on . Ye s : Co ntinue. 6 Does the printer have an att a chment option? N[...]

3-92 Troublesh ooting Anal ysis Guide (T AGs) T AG 099: +24 Vdc Power Shorted Error Code: 099 Possible De fect s: DC power supply uni t AC power supply uni t Connectors or wiring PCL board IGS boar d Power contr ol #2 board High vo ltage uni t Paper timing clutch Upper feed roller clutch Upper pick-up clutch Lower pick-up clutch Lower feed roller c[...]

Troub leshootin g Analys is Guid e (TAGs) 3-93 4 T urn the printer off. • Reconnect J/P330. • Disconnect J/P1 1 . • T urn the printer on. • Check J/P8-1 1 for +24 Vdc. Is the voltage +24 Vdc? No: Go to #1 1 in this T AG . Ye s : Co ntinue. 5 T urn the printer off. • Reconnect J/P1 1. • Disconn ect J/P10. • T urn the printer on. • Ch[...]

3-94 Troublesh ooting Anal ysis Guide (T AGs) 8 T urn the printer off. • Reconnect J/P12. • Disconn ect J/P41. • T urn the printer on. • Check J/P8-1 1 for +24 Vdc. Is the voltage +24 Vdc? No: Replace the PCL board, then turn to TAG 002: Check & Problem Reso lution . Ye s : Co ntinue. 9 T urn the printer off. • Reconnect J/P41. • Di[...]

Troub leshootin g Analys is Guid e (TAGs) 3-95 12 T urn the printer off. • Reconnect J/P91. • Disconn ect J/P40 and J/ P 41. • T urn the printer on. • Check J/P8-1 3 for +24 Vdc. Is the voltage +24 Vdc? No: Replace the PCL board, then turn to TAG 002: Check & Problem Reso lution . Ye s : Co ntinue. 13 T urn the printer off. • Reconnec[...]

3-96 Troublesh ooting Anal ysis Guide (T AGs) 16 T urn the printer off. • Reconnect J/P41. • Disconn ect J/P69. • T urn the printer on. • Check J/P8-1 3 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Ye s : Replace the lower pick-up roller assem bly , then turn to TAG 002: Ch eck & Problem Res - oluti on . 17 T urn the printer off. [...]

Troub leshootin g Analys is Guid e (TAGs) 3-97 20 T urn the printer off. • Reconnect J/P67. • Disconn ect J/P68. • T urn the printer on. • Check J/P8-1 3 for +24 Vdc. Is the voltage +24 Vdc? No: Repair or repl ace the connectors or wirin g from: P40-10 to J69-1, P40-11 to J65-1 , P40-11 to J66-1 , P40-11 to J67-1 , or P40-11 to J 68-1; then[...]

3-98 Troublesh ooting Anal ysis Guide (T AGs) 24 T urn the printer off. • Reconnect J/P305. • Disconnect J/P310 (inside d uplex tray). • T urn the printer on. • Check J/P330 -1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Ye s : Go to #29 i n thi s T AG . 25 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P305 .[...]

Troub leshootin g Analys is Guid e (TAGs) 3-99 28 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P331 . • Check J3 31-1 and P306-1 f or continu ity to g round. Is there continuity? No: Repair or repl ace the connectors or wirin g from: P330-1 to P3 31-1 or P330-1 to P3 23-1; then turn to TAG 00 2 : Check & Problem Res [...]

3-100 Troublesh ooting Anal ysis Guide (T AGs) 32 T urn the printer off. • Reconnect J/P313. • Disconn ect J/P314 . • T urn the printer on. • Check J/P330 -1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Ye s : Replace the “in” solenoid, then turn to TAG 002: Check & Prob lem Resoluti on . 33 T urn the printer off. • Reconnec[...]

Troub leshootin g Analys is Guid e (TAGs) 3-101 36 T urn the printer off. • Reconnect J/P317. • Disconn ect J/P 308 and J/P 309. • T urn the printer on. • Check J/P330 -1 for +24 Vdc. Is the voltage +24 Vdc? No: Repair the duplex control board #1, then turn to TAG 002: Check & Pr oblem Res ol u ti o n . Ye s : Repair or replace the conn[...]

3-102 Troublesh ooting Anal ysis Guide (T AGs) T AG 100: PCL Bo ard Interf ace Malfunct ion Error Code: 100, 132 , 140, 145, 160-1 62, 170-17 2, 180-182 Symptoms: PCL board failure Possible De fect s: Connectors or wiring PCL board 1 T urn of f the printer an d unplug the power cord. • V erify that J/P40, J/P41, J/P33 , and J/P91 are connected pr[...]

Troub leshootin g Analys is Guid e (TAGs) 3-103 T AG 101: IGS Cont roller Diagnostic Fai lure Error Code: 101 Possible De fect s: IGS boar d 1 Power-o n-reset the printer . Is error 10 1 displayed on the operator panel. No: The pr oblem may be cau se d by pow e r fluctu ation. Turn to TAG 002: Check & P roblem Resolution . Ye s : Replace the IG[...]

3-104 Troublesh ooting Anal ysis Guide (T AGs) T AG 130: Diskette/Disk Drive Malfuncti on Error Code: 130, 131 , 133, 134, 450, 451, 572-57 6, 586 Symptoms: T est print s do not run Possible De fect s: Diskette Disk drive as semb ly Connectors or wiring PCL board IGS boar d DC power supply Electr ical prob lems on wire s J/P31 to J/P79 a nd J/P31 t[...]

Troub leshootin g Analys is Guid e (TAGs) 3-105 5 Is error code 572 displayed? No: Go to #7 in this T AG . Ye s : Co ntinue. 6 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P31 and J/ P 79. • Check P31-28 to P79-28 for contin u ity to ground . Is there continuity? No: Replace the disk drive assembly . If this resolves the[...]

3-106 Troublesh ooting Anal ysis Guide (T AGs) P31-10 to P7 9-10. Is there continuity on any? No: Replace the disk driv e assembly . If this does not r esolve the problem, replace the I GS boar d, th en t urn t o TAG 002: Check & P roblem Resol ution . Ye s : Replace wire harness W46, then turn to TAG 002: C heck & Prob lem Resolu tion . 13[...]

Troub leshootin g Analys is Guid e (TAGs) 3-107 P31-22 to P79-22, P31-24 to P79-24, P31-26 to P79-26, P31-2 8 to P79-28 , and P31-32 to P79-32. Is there continuity on each? No: Replace wire harness W46, then turn to TAG 002: Check & Probl em Resoluti on . Ye s : Co ntinue. 20 Check for continui ty to gr ound: P31-20, P31-22, P31-2 6, and P31-3 [...]

3-108 Troublesh ooting Anal ysis Guide (T AGs) T AG 200: IGS Internal Communication Malfunct ion Error Code: 401, 454 , 455, 500- 509, 5 20-530, 54 0-566, 570 , 571, 577-585, 6 00-605 Symptoms: IGS board failure Possible Ca uses: IGS program error Possible De fect s: Wiring or connectors IGS boar d Software Signal i nterface 1 T urn th e printer of[...]

Troub leshootin g Analys is Guid e (TAGs) 3-109 7 Replace the software diskettes in drives A and B . • Power-on-reset the printer . Has the problem been resolved? No: Replace the signal interface board, then turn to TAG 002 : Check & Problem Reso lution . Ye s : Software diskettes were at fault. T urn to TAG 00 2: Check & P roblem Resolut[...]

3-110 Troublesh ooting Anal ysis Guide (T AGs) T AG 201: IGS- PCL Interface Malf unction Error Code: 121-127 , 199-215, 380-38 7 Symptoms: Communication failure between t he IG S bo ard and the PCL b oa r d Possible Ca uses: Insufficient delay period between power off and power on Electrical spikes Possible De fect s: Connectors or wiring PCL board[...]

Troub leshootin g Analys is Guid e (TAGs) 3-111 6 Replace the IGS board. • Power-on-reset the printer . Has the problem been resolved? No: If error co de 121 or 123 b rought you to this T AG , replace the DC or high v oltage power supply , then turn t o TAG 002: Check & Problem Resoluti on . For all other error cod es, replace the IGS board, [...]

3-112 Troublesh ooting Anal ysis Guide (T AGs) T AG 405: IGS Bit-Map RAM Malfunction Error Code: 606, 600 , 610 Possible De fect s: IGS boar d 1 The IGS bit-map RAM has malfunction ed. Replace the IGS boar d, then tur n to TAG 002: Check & Problem Res ol ution .[...]

Troub leshootin g Analys is Guid e (TAGs) 3-113 T AG 500: +5 Vdc Power Malfunction Error Code: 500 Symptoms: Operator panel blank with AC power supply coo ling fan running Possible De fect s: DC fuse DC power supply uni t Connectors or wiring Operator panel circuit board PCL board IGS boar d Disk drive as semb ly LED printhead assembly Atta chm e n[...]

3-114 Troublesh ooting Anal ysis Guide (T AGs) 5 Check J/P42- 1 for +5 Vdc. Is the voltage +5 Vdc? No: Repair or repl ace the connectors or wirin g from P94-1 to J/P90-1 to P42-1, th en turn to TAG 002: C heck & Probl em Resolu tion . Ye s : Co ntinue. 6 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P 8 and J/ P42. • [...]

Troub leshootin g Analys is Guid e (TAGs) 3-115 10 T urn the printer off. • Reconnect J/P77. • Disconn ect J/P27. • T urn the printer on. • Check J/P8-1 0 for +5 Vdc. Is the voltage +5 Vdc? No: Continue. Ye s : Replace the LED printhead assembly , then turn to TAG 002: Check & P roblem Resolu - tion . 11 T urn the printer off. • Recon[...]

3-116 Troublesh ooting Anal ysis Guide (T AGs) 14 T urn the printer off. • Disconn ect J/P42. • Check P4 2-1 for continuit y to gro und. Is there continuity to ground? No: Replace the operator pa nel circuit board, then turn to TAG 002: Check & Prob lem Reso- lution . Ye s : Repair or replace the connecto rs or wiring from P94 -1 to J/P90-1[...]

Troub leshootin g Analys is Guid e (TAGs) 3-117 19 T urn the printer off. • Reconnect J/P333. • Disconnect J/P73, the DC cable for the attachment o ption. • T urn the printer on. • Check J/P8-1 0 for +5 Vdc. Is the voltage +5 Vdc? No: Replace the signal interface board, then turn to TAG 002 : Check & Problem Reso lution . Ye s : Replace[...]

3-118 Troublesh ooting Anal ysis Guide (T AGs) T AG 600: AC Power Malfunction Error Code: 600 Symptoms: Operator panel blank with fans not running Printer Open indicator on Circuit breaker keeps tripping Possible De fect s: Upper fuse in the AC power supply AC power supply uni t DC power supply uni t Connectors or wiring Power contr ol #2 board Pow[...]

Troub leshootin g Analys is Guid e (TAGs) 3-119 4 Does the PRINTER OPEN light come on with all the covers closed? No: Go to #2 5 in this T AG . Ye s : Co ntinue. 5 Operate the top and front cover interlock switch actuator s. Are the interlock switch actuators working properly? No: Repair or repl ace any defective actuator , then turn to TAG 002: Ch[...]

3-120 Troublesh ooting Anal ysis Guide (T AGs) 10 Reinstall the fuse. • Disconnect J/P4. • Clo se th e top cove r . • Check P4-5 to P4-6 for continuity . Is there continuity? No: Go to #3 4 in this T AG . Ye s : Co ntinue. 11 Remove the AC power su pply uni t. • Operat e the front co ver in terlock swi tch. • Check for continuity as you o[...]

Troub leshootin g Analys is Guid e (TAGs) 3-121 15 Reconnect J/P9. • Install a goo d uppe r fuse in th e AC power supply unit. • Disconn ect J/P13 and J/ P 14. • T urn the printer on for 5 s econds, then of f. • Remove the fu se. • Check the fu se for continuity . Does the fuse have continuity? No: Replace the power control #2 boar d, the[...]

3-122 Troublesh ooting Anal ysis Guide (T AGs) 19 T urn the printer off. • Reconnect J/P22. • T urn on the printer for 2-1/2 m inutes, then off. W a s the power-on-res et successful? No: Replace the vacuu m transport unit, then turn to TAG 00 2: Check & Problem Resolution . Ye s : Replace the small cooling fan assembly , then turn to TAG 00[...]

Troub leshootin g Analys is Guid e (TAGs) 3-123 24 Close the top cove r . • Check P4-5 for continui ty to ground. Is there continuity? No: Replace the AC power supp ly , then turn to TAG 002: Check & Problem Resolu tio n . Ye s : Repair or replace the top cover interlo ck switch assembly . If this resolves the problem, turn to TAG 002: Ch eck[...]

3-124 Troublesh ooting Anal ysis Guide (T AGs) 30 Check J4-1 at the AC power su pply unit for conti nuity to ground. Is there continuity? No: Continue. Ye s : Replace the AC power supply unit, then turn to TAG 002: Check & Problem Resoluti on . 31 Check P4-7 for continui ty to ground. Is there continuity? No: Go to #3 3 in this T AG . Ye s : Co[...]

Troub leshootin g Analys is Guid e (TAGs) 3-125 T AG 610: Operator Panel Malfunction Error Code: 610 Symptoms: One o r more message indicators will not light Incomplete numbers are displayed T one does not work pro perly All status lights remain on One or m ore func tion ke ys do not work Possible Ca uses: Operator panel Connectors or wiring PCL bo[...]

3-126 Troublesh ooting Anal ysis Guide (T AGs) 6 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P42 and J/ P 41. • Check P4 2-18 to P 41-3 for continui ty . Is there continuity? No: Repair or r eplace the con nectors or wirin g from P42-18 to J/P90-18 to P41-3, then tu rn to TAG 002: C heck & Probl em Resolu tion . Ye [...]

Troub leshootin g Analys is Guid e (TAGs) 3-127 13 Check P4 1-6 to P42 -15 for continuit y to grou nd. Is there continuity? No: Replace the operator panel. If this resolves the problem, turn to TAG 002: Check & P rob - lem Resolution . If this does no t resolve the problem, r eplace the PCL board, then tu rn to TAG 002: C heck & Probl em Re[...]

3-128 Troublesh ooting Anal ysis Guide (T AGs) Wiring T a ble Refer t o the tabl e below to c heck t he wiring f or an open o r short t o ground. I n the displ ay panel i llustra tions, “on ” status lights ( which may b e dimly li t) are blac k. T able 3 -1. Drive Indication Wiring Failure Des cription Oper ator Panel J/P 42- 7 to J/P 90- 7 to [...]

Troub leshootin g Analys is Guid e (TAGs) 3-129 J/P 42- 10 to J/P 90- 10 to J/P41 -1 1 Open J/P 42- 10 to J/P 90- 10 to J/P41 -1 1 Short to ground CLR P APE R light may be very dim J/P42 -1 1 to J/P90 -1 1 to J/P 41- 10 Short to ground J/P 42- 12 to J/P 90- 12 to J/P41 -9 Short to ground J/P 42- 13 to J/P 90- 13 to J/P41 -8 Short to ground J/P 42- [...]

3-130 Troublesh ooting Anal ysis Guide (T AGs) T AG 700: Output T ray Circuit Malfunction Error Code: 700 Symptoms: Output T ray Full light remains on , will not light, or ligh ts prematurely Possible De fect s: Output tray full sensor Connectors or wiring Job offs et a ss embly PCL board High capacity output unit 1 T urn th e printer off an d unpl[...]

Troub leshootin g Analys is Guid e (TAGs) 3-131 6 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P51 and J/ P 40. • Check P4 0-26 to P 51-1 for continui ty . Is there continuity? No: Repair or repl ace the connectors or wirin g from P40-26 to J/P5 0-4 to P51-1, then tu rn to TAG 002: C heck & Probl em Resolu tion . Ye [...]

3-132 Troublesh ooting Anal ysis Guide (T AGs) T AG 702: Paper Size Detection Malfunct ion Error Code: 702 Symptoms: Incorr ect paper size displayed Possible De fect s: Upper cassette Lower cassette Upper paper s ize sensor Lower paper size sensor Connectors or wiring PCL board 1 T urn th e printer off an d unplug t he power cord . • V erify that[...]

Troub leshootin g Analys is Guid e (TAGs) 3-133 5 Remove the lower paper size sensor assembly . • Disconnect the circuit board fro m its mounting. • Inspect t he paper size se nsor circui t board and mo unting fo r contaminati on or damage. Is the circuit board or mounting contaminated or damaged? No: Continue. Ye s : Repair or replace the lowe[...]

3-134 Troublesh ooting Anal ysis Guide (T AGs) Wiring for the Upper Paper Size Sensor Refer t o the foll owing tabl e when perf orming cont inuity ch ecks for a n open or short t o ground fo r the upper paper size sen sor . Wiring for the Lower Paper Size S ensor Refer t o the foll owing tabl e when perf orming cont inuity ch ecks for a n open or s[...]

Troub leshootin g Analys is Guid e (TAGs) 3-135 T AG 703: Upper Cassette Malfunction Error Code: 703 Symptoms: Upper cassett e does not load or unload properly Upper cassette does not latch pr operly Possible De fect s: Upper cassette Upper pressure lev er Upper cassette release latch Upper cassette release Damper assembly Upper cassette release ca[...]

3-136 Troublesh ooting Anal ysis Guide (T AGs) T AG 704: Lower Cassette Malfunction Error Code: 704 Symptoms: L ower cassette does not load or unload pr operly Lower cassette does not latch pro perly Possible De fect s: Lower cassette Lower pressur e lever Lower cassette r elease latch Lower cassette r elease Lower cassette r elease cam Spring 1 In[...]

Troub leshootin g Analys is Guid e (TAGs) 3-137 T AG 705: Multiple Paper Feeding Error Code: 705 Possible Ca uses: Wr ong weight or t ype of pa per loaded Paper improperly loaded Possible De fect s: Upper feed roller assembly Lower feed roller assembly Paper cassette 1 Remove pape r from the cassette. • Fan the paper stack and place it in the cas[...]

3-138 Troublesh ooting Anal ysis Guide (T AGs) T AG 706: Paper Damaged or Wrinkled Error Code: 706 Possible Ca uses: Paper incorrectly loaded Wr ong weight or t ype of pa per loaded Paper path obstructed Possible De fect s: Fuser unit Exit roller assembly Exi t pi nch r oller ass embl y 1 Make sure t he paper being used is no t damaged. • Make su[...]

Troub leshootin g Analys is Guid e (TAGs) 3-139 T AG 707: Upper Paper Guide Assembly Not Closing Error Code: 707 Possible Ca uses: Obstructions Photocondu ctor uni t front or rear latch arm springs Photoconductor unit latch arms in incorrect position Upper paper guide lat c hi ng mechanism da ma ged or bindin g Front or re ar photo conduct or unit [...]

3-140 Troublesh ooting Anal ysis Guide (T AGs) T AG 750: Counter Malfunction Error Code: 750 Symptoms: Counter does not count Counter counts to o often Consumable compo nents requir e replacement too frequently Possible De fect s: Counter assem bly Connectors or wiring PCL board 1 Run di agnostic test 00 7. Is the counter functioning properly? No: [...]

Troub leshootin g Analys is Guid e (TAGs) 3-141 7 Run tes t prin ts. • Check TP4 -25 for a vo ltage change f rom +24 Vdc to 0 Vdc whil e running t he print s. Does the voltage change f rom +24 Vdc to 0 Vdc? No: Replace the PCL board, then turn to TAG 002: Check & Problem Reso lution . Ye s : Replace the counter , then turn to TAG 002: Check &[...]

3-142 Troublesh ooting Anal ysis Guide (T AGs) T AG 751: Main Drive Motor Runs Conti nuously Error Code: 751 Possible De fect s: Power contr ol #2 board Connectors or wiring PCL board 1 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P12 and J/ P 40. • Check P40-33 fo r conti nuity to groun d. Is there continuity? No: Repla[...]

Troub leshootin g Analys is Guid e (TAGs) 3-143 T AG 753: Externa l Communications Malfunction Error Code: 753 Symptoms: T est p rin ts c an b e made but job s do not r un Jobs do not print corr ectly Possible Ca uses: Improper DIP switch settings Host computer Improper applicatio n Possible De fect s: IGS boar d co mmunication s cable Cable connec[...]

3-144 Troublesh ooting Anal ysis Guide (T AGs) 3 T urn of f the printer an d unplug the power cord. • Remove fuse FH2, which is mou nted to the signal interface board, and check for contin uity . Is there continuity? No: Install a new fuse and retes t. If the fuse is okay , turn to TAG 002: Chec k & Pro bl em Res - oluti on . If the new fuse [...]

Troub leshootin g Analys is Guid e (TAGs) 3-145 9 Check J/P8-8 for -12 Vdc. Is the voltage -12 Vdc? No: Replace the DC power supp ly unit, then turn to TAG 00 2: Check & Pr oblem Res olution . Ye s : Repair or replace connectors or wiring from P8-8 to P32-3, then turn to TAG 002: Check & Problem Resolu tion . 10 Does the problem appear whil[...]

3-146 Troublesh ooting Anal ysis Guide (T AGs) T AG 754: Atta chmen t Option Malfunction Error Code: 754 Symptoms: J ob fails only when an attachme nt opti on is us ed. Possible Ca uses: Lack of voltage Possible De fect s: Atta chm e nt op tion Communicat ion cables Cable connectors Signal interface board Signal interface board fuse IGS boar d Host[...]

Troub leshootin g Analys is Guid e (TAGs) 3-147 4 Reconnect the attachment cables. • T urn on the printer for five seco nd s, then turn it off. • Check the signal interf ace board fuse fo r continuity . Does the fuse have continuity? No: Replace the attachment option, then turn to TAG 002: Check & Problem Resolu tio n . Ye s : The signal in[...]

3-148 Troublesh ooting Anal ysis Guide (T AGs) T AG 800: Print s Blank or Wit h Dark Horizont al Bands Error Code: 800 Possible De fect s: Photocond uctor unit, Printhead assembly IGS boar d Main driv e gear assemb ly Connectors or wiring T ransfer charger High vo ltage uni t Upper paper gui de assembly Developer u nit If ther e is a de veloped ima[...]

Troub leshootin g Analys is Guid e (TAGs) 3-149 5 Replace the developer u nit and toner cartridge. • Run test pr ints. Has the problem been resolved? No: Reinstall the orig inal developer un it and continu e. Ye s : Tu r n t o TAG 002: Check & Problem Reso lution . If the problem recurs, th e toner carrier mix may be old or contaminated . 6 P[...]

3-150 Troublesh ooting Anal ysis Guide (T AGs) 10 Run di agnostic test 1 1 1. • W atch the printhead LEDs while the test is running. Do the LEDs illuminate? No: Go to #1 8 in this T AG . Ye s : Co ntinue. 11 Are the prints blank without dark bands? No: Go to #1 5 in this T AG . Ye s : Co ntinue. 12 Remove the photoco nductor unit and place it in [...]

Troub leshootin g Analys is Guid e (TAGs) 3-151 16 T urn th e printer off an d unplug t he power cord . • Remove the p hotoconduct or . • Cle an the photo conductor unit cont acts and guide rail contacts. • Check the bo ttom connector contact on th e photoconducto r guide rail for co ntinuity to groun d. Is there continuity? No: Repair or rep[...]

3-152 Troublesh ooting Anal ysis Guide (T AGs) T AG 801: Print s Light or Lig ht Wit h Carrier Particles Error Code: 801 Possible De fect s: Photocond uctor unit Connectors or wiring Main driv e gear assemb ly T ransfer charger unit Power contr ol #2 board Print-head assembly High vo ltage uni t T oner supply motor PCL board Upper paper gui de asse[...]

Troub leshootin g Analys is Guid e (TAGs) 3-153 5 Replace the photocond uctor unit an d main char ger . • Run test pr ints. Has the problem been resolved? No: Reinstall the original photoconductor unit and main charger and continue. Ye s : Ru n at least 200 test prints to de tone the engine, then turn to TAG 002 : Ch eck & P roblem Resolution[...]

3-154 Troublesh ooting Anal ysis Guide (T AGs) 10 T urn th e printer off an d unplug t he power cord . • Replace the transfer char ger unit. • Power-on-reset the printer . • Run test pr ints. Has the problem been resolved? No: Replace the upper pap er guide assembly . If this resolves the problem, turn to TAG 002: Check & Problem R esolut[...]

Troub leshootin g Analys is Guid e (TAGs) 3-155 15 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P 41, J/P 24, and J/P23. • Check the follow ing for continu ity : P41-30 to J24-4, P41-38 to J23-2, P41-43 to J25-5, P41-44 to J25-2, P41-47 to J25-3, P41-48 to J25-6, P41-49 to J25-4, an d P41-50 to J25-1. Is there continuity[...]

3-156 Troublesh ooting Anal ysis Guide (T AGs) 20 Run diagno stic tes t 010. Use ext reme caution: • Check J/ P13-5 to J/P13- 2 for 100 V ac while the tes t is runn ing. Is the voltage 100 V ac? No: Go to #2 2 in this T AG . Ye s : Co ntinue. 21 Run diagno stic tes t 010. Use ext reme caution: • Check J/ P18-1 to J/P18- 2 for 100 V ac while the[...]

Troub leshootin g Analys is Guid e (TAGs) 3-157 26 T urn th e printer off an d unplug t he power cord . • Replace the printhead assembly u nit. • Power-on-reset the printer . • Run test pr ints. Has the problem been resolved? No: Reinstall the orig inal printhead ass embly unit and co nt inue. Ye s : Tu r n t o TAG 002: Check & Problem Re[...]

3-158 Troublesh ooting Anal ysis Guide (T AGs) T AG 802: Prints Wi th Vo ids or White Spots Error Code: 802 Possible Ca uses: Wr ong weight or t ype of pa per loaded Possible De fect s: Photocond uctor unit Developer u nit 1 Perform the every -call cleaning procedure. • Confirm that the pap er in the cassettes meets paper sp ecifi cation s, outli[...]

Troub leshootin g Analys is Guid e (TAGs) 3-159 6 Replace the fuser unit. • Run test pr ints. Has the problem been resolved? No: Reinstall the original fuser unit. Refer to the Chapter 4, “Print Quality Samples” . Com- pare the test prints with the p rint samples, and identify a sample h a vin g the same print flaw as the test prints; turn to[...]

3-160 Troublesh ooting Anal ysis Guide (T AGs) T AG 803: Prints Wi th Light or White V ertical S treaks Error Code: 803 Possible De fect s: T ransfer charger unit Printhead assembly unit Photocond uctor unit Developer u nit 1 T urn of f the printer an d unplug the power cord. • V erify that J/P13, J/P30, and J/P31 are co nnected properly . • Ma[...]

Troub leshootin g Analys is Guid e (TAGs) 3-161 6 T urn on the printer . • Produce a developed im age on the phot oconductor . Are there vertical s treaks on the photoconductor belt image? No: Replace the transfer char ger unit, then turn to TAG 002: Check & Proble m Resolu tion . Ye s : Replace the printhead assembly unit, then turn to TAG 0[...]

3-162 Troublesh ooting Anal ysis Guide (T AGs) T AG 804: Prints Wi th Light Horizontal Bands Error Code: 804 Possible Ca uses: Loose printhead connectors Possible De fect s: T ransfer charger unit Photocond uctor unit Main c harge r 1 T urn th e printer off an d unplug t he power cord . • Perform the every -call cleaning procedu re, described in [...]

Troub leshootin g Analys is Guid e (TAGs) 3-163 T AG 805: Black Print s Error Code: 805 Possible Ca uses: Contaminated toner/carrier mix Possible De fect s: Main c harge r Printhead assembly Connectors or wiring PCL board IGS boar d High vo ltage uni t Main charger lead Photocond uctor unit Developer u nit Main charger terminal assembly 1 T urn th [...]

3-164 Troublesh ooting Anal ysis Guide (T AGs) 5 Replace the develop er unit, toner cartridge, an d cleaner unit. • T urn the printer on. • Run test pr ints. Has the problem been resolved? No: Reinstall the original developer unit and clean er unit, then continue. Ye s : Tu r n t o TAG 002: Check & Problem Reso lution . If the problem recur[...]

Troub leshootin g Analys is Guid e (TAGs) 3-165 11 Replace the IGS board. • Run test pr ints. Has the problem been resolved? No: Replace the main char ger lead wiring, th en turn to TA G 002: Ch eck & Pr ob lem Res olu- tion . Ye s : Tu r n t o TAG 002: Check & Problem Reso lution .[...]

3-166 Troublesh ooting Anal ysis Guide (T AGs) T AG 806: Print s with Dark Spot s or Scratches Error Code: 806 Possible Ca uses: Paper path contamination Paper supply d efects To n e r Possible De fect s: Photocond uctor unit Main c harge r Fuser unit Developer u nit Cleaner unit 1 T urn th e printer off an d unplug t he power cord . • Perform th[...]

Troub leshootin g Analys is Guid e (TAGs) 3-167 6 Replace the fuser unit. • Run test pr ints. Has the problem been resolved? No: Reinstall the orig inal fuser unit and cont inue. Ye s : Tu r n t o TAG 002: Check & Problem Reso lution . 7 Replace the developer u nit and toner cartridge. • Run test pr ints. Has the problem been resolved? No: [...]

3-168 Troublesh ooting Anal ysis Guide (T AGs) T AG 807: Misregistered/Skewed Prin t s (Simplex) If this proble m occu rs in the duple x printin g mode o nly , go to TAG 901 : Misregis tration / Skewed P rints (Dup lex) . Error Code: 807 Possible Ca uses: Paper incorrectly loaded Wr ong weight or t ype of pa per loaded Possible De fect s: Upper cas[...]

Troub leshootin g Analys is Guid e (TAGs) 3-169 2 Remove the upper cassette. • Power-on-reset the printer . • Run test prints from the lower cassette. Is the problem a lso with the low er cassette? No: Go to #4 in this T AG . Ye s : Co ntinue. 3 T urn th e printer off an d unplug t he power cord . • Inspect t he following f or damage or c ont[...]

3-170 Troublesh ooting Anal ysis Guide (T AGs) 6 Inspect t he following f or damage or c ontamina tion: • Lower pick-up roller assembly • Lower feed roller assembly • Lower pinch r ollers • Lower cassette. Are these part s clean and in good working order? No: Repair or repl ace the parts as needed, then turn to TAG 002: Check & Problem [...]

Troub leshootin g Analys is Guid e (TAGs) 3-171 7 OFF ON ON ON 8 ON OFF OFF OFF 9O N O F F O F F O N 10 ON OFF ON OFF 1 1 ON OFF ON ON 12 ON ON OFF OFF 13 ON ON OFF ON 14 ON ON ON OFF 15 ON ON ON ON T able 3-5. PCL Board Swit ch Settings Settin g Number DIP Sw itches 1234[...]

3-172 Troublesh ooting Anal ysis Guide (T AGs) T AG 808: Print s Overtoned/ Dark V ertical S treaks Error Code: 808 Possible Ca uses: Clogged clean er Contaminated toner/carrier mix Possible De fect s: Cleaner unit Photocond uctor unit Main c harge r High vo ltage uni t Power contr ol #2 board PCL board Connectors or wiring Developer u nit Overtone[...]

Troub leshootin g Analys is Guid e (TAGs) 3-173 5 Replace the cleaner unit. • Run test pr ints. Has the problem been resolved? No: Reinstall the original cleaner u nit and continue. Ye s : Tu r n t o TAG 002: Check & Problem Reso lution . 6 Replace the developer u nit with toner cartridge. • Run test pr ints. Has the problem been resolved? [...]

3-174 Troublesh ooting Anal ysis Guide (T AGs) 10 Reinstall the dev eloper unit. • Run test pr ints. • Check TP3 -31 for a voltage chan ge from +12 Vdc to 0 Vdc while ru nning t est prin ts. Does the voltage change f rom +12 Vdc to 0 Vdc every other print cycle? No: Go to #1 4 in this T AG . Ye s : Co ntinue. 11 T urn th e printer off an d unpl[...]

Troub leshootin g Analys is Guid e (TAGs) 3-175 15 Reconnect J/P24. • Disconn ect J/P23. • Check P4 1-38 to P 23-2 for continui ty . Is there continuity? No: Repair or repl ace the connectors or wirin g from P41-38 to P23 -2, then turn to TAG 002: Check & Problem R esolution . Ye s : Co ntinue. 16 Remove the developer unit. • Check P8 5-8[...]

3-176 Troublesh ooting Anal ysis Guide (T AGs) 20 Repair or replace the PCL board. • Run test pr ints. Has the problem been resolved? No: Reinstall the original PCL board. Confirm that the photocon ductor , m ain charger , devel- oper unit, and fuser units are new . If these items ar e new , the toner/carrier mix may be old or contaminated. Repla[...]

Troub leshootin g Analys is Guid e (TAGs) 3-177 T AG 809: Blurred or Smeared V ertical S treaks on Prints Error Code: 809 Possible De fect s: Photocond uctor unit Main c harge r Cleaner unit Fuser unit V acuum transp ort un it Fuser unit drive gear Fuser drive idler and sprin g Fuser drive belt Main d rive ass embly Printhead assembly Power contr o[...]

3-178 Troublesh ooting Anal ysis Guide (T AGs) 5 Replace the fuser u nit. • Run test pr ints. Has the problem been resolved? No: Reinstall the orig inal fuser unit and cont inue. Ye s : Tu r n t o TAG 002: Check & Problem Reso lution . 6 Replace the cleaner unit. • Run test pr ints. Has the problem been resolved? No: Reinstall the original [...]

Troub leshootin g Analys is Guid e (TAGs) 3-179 10 Run test prints. Use extreme cau tion: • Check J/P22- 1 to J/P22- 2 for 100 V ac. Is the voltage 100 va c? No: Continue. Ye s : Replace the vacuum transport unit, then turn to TAG 002: Ch eck & Probl em Resoluti on . 11 Run test prints. Use extreme cau tion: • Check J/P13- 6 to J/P13- 3 for[...]

3-180 Troublesh ooting Anal ysis Guide (T AGs) T AG 810: Uneven Densit y or Dark Ar eas on Pr ints Error Code: 810 Possible De fect s: Photocond uctor unit Main c harge r Developer u nit Cleaner unit 1 Perform the every -call cleaning procedure, d escribed in Chapter 9, “General Printer Maintenan ce” . • T urn the printer on. • Run test pr [...]

Troub leshootin g Analys is Guid e (TAGs) 3-181 6 Replace the developer u nit and toner cartridge. • Run test pr ints. Has the problem been resolved? No: Reinstall the orig inal developer un it and toner cartridge, th en turn to TAG 811: Back- ground/Residu al Images/Dark Prints . Ye s : Tu r n t o TAG 002: Check & Problem Reso lution . If th[...]

3-182 Troublesh ooting Anal ysis Guide (T AGs) T AG 81 1: Background/Residua l Images/Dark Print s Error Code: 81 1 Possible Ca uses: Contaminated toner/carrier mix Possible De fect s: Photocond uctor unit Main c harge r Cleaner unit Developer u nit Erase lamp as sembly High vo ltage uni t Power contr ol #2 board Connectors or wiring PCL board Main[...]

Troub leshootin g Analys is Guid e (TAGs) 3-183 5 Replace the developer u nit and cleaner unit. • Run test pr ints. Has the problem been resolved? No: Reinstall the orig inal developer un it and cleaner unit and co ntin ue. Ye s : Tu r n t o TAG 002: Check & Problem Reso lution . 6 Remove t he photocond uctor unit fr om the prin ter . • Run[...]

3-184 Troublesh ooting Anal ysis Guide (T AGs) 10 V erify that th e toner patch sensor bo ard connector , mounted o n the deve loper unit , is connected proper ly . Is it connected properly? No: A loose connection was at fau lt. T urn to TAG 002: C heck & Prob lem Resolu tion . Ye s : Replace the PCL board, then turn to TAG 00 2: Check & Pr[...]

Troub leshootin g Analys is Guid e (TAGs) 3-185 15 Reconnect J/P41 and J/P24. • T urn the printer on. • Run test pr ints. • Check TP4 -40 for 0.5 Vdc whil e running the pr ints. Is t he vol t age 0.5 V dc? No: Replace the PCL board, then turn to TAG 002: Check & Problem Reso lution . Ye s : Co ntinue. 16 Is a meter w ith a high voltage pr[...]

3-186 Troublesh ooting Anal ysis Guide (T AGs) 22 T urn th e printer off an d unplug t he power cord . • Disconn ect J/P40. • Check P40-31 fo r conti nuity to groun d. Is there continuity? No: Replace the PCL board, then turn to TAG 002: Check & Problem Reso lution . Ye s : Co ntinue. 23 Disconn ect J/P 12 . • Check P4 0-31 and P 12-5 for[...]

Troub leshootin g Analys is Guid e (TAGs) 3-187 T AG 812: Uneven or No Fusing on Print s Error Code: 812 Possible Ca uses: Wr ong weight or t ype of pa per loaded Possible De fect s: Fuser unit Connectors or wiring AC power supply uni t PCL board 1 T urn th e printer off an d unplug t he power cord . • V erify that J/P44, J/P4, J/ P10, J/P 1 1, J[...]

3-188 Troublesh ooting Anal ysis Guide (T AGs) 6 Power-o n-reset the printer . • W atch through the ou tput tray opening to see if the fuser lamp comes o n. Does the lamp light within 1.5 minutes? No: Go to TAG 070: Fuser Unit Malfun ction . Ye s : Co ntinue. 7 Run tes t prin ts. Does the print se em to be exces sively dark or do the characters f[...]

Troub leshootin g Analys is Guid e (TAGs) 3-189 T AG 813: Residual I mages on Print s Error Code: 813 Possible De fect s: Cleaner unit drive belt Cleaner unit High vo ltage uni t Photocond uctor unit Erase lamp as sembly Developer u nit 1 T urn th e printer off an d unplug t he power cord . • Perform the every -call cleaning procedu re, described[...]

3-190 Troublesh ooting Anal ysis Guide (T AGs) 6 Replace the develop er unit and toner cartridg e. • Run test pr ints. Has the problem been resolved? No: Reinstall the orig inal developer un it and continu e. Ye s : Tu r n t o TAG 002: Check & Problem Reso lution . 7 Replace the pho toconductor unit and ma in charger . • Run test pr ints. H[...]

Troub leshootin g Analys is Guid e (TAGs) 3-191 T AG 815: Prints Resulting From Print head Malfunctions Error Code: 815 Possible Ca uses: Addition al lines or miss ing lines on pag e. Possible De fect s: Printhead assembly Connectors or wiring IGS boar d 1 T urn of f the printer an d unplug the power cord. • Replace wire harness 46. Has the probl[...]

3-192 Troublesh ooting Anal ysis Guide (T AGs) T AG 900: T op Cover I nterlock Malfunction, Duplex Error Code: 900 Possible De fect s: Cover open sensor PCL board Duplex control boar d #1 Connectors or wiring Comple te TAG 600: AC P ower Malfunct ion before s tartin g this T AG . 1 T urn th e printer off an d unplug t he power cord . • V erify th[...]

Troub leshootin g Analys is Guid e (TAGs) 3-193 5 T urn on the printer . • Check J/ P36-1 on t he PCL board f or +12 Vdc. Is the voltage +12 Vdc? No: Replace the duplex con trol board #1, then turn to TAG 00 2: Check & Problem Resolu- tion . Ye s : Replace the PCL board, then turn to TAG 00 2: Check & Problem Resolutio n .[...]

3-194 Troublesh ooting Anal ysis Guide (T AGs) T AG 901: Misregistration/Skewed Print s (Duplex) Error Code: 901 Possible Ca uses: Wr ong weight or t ype of pa per loaded Possible De fect s: Duplex h olding t ray sensors Duplex holding t ray mo tor Duplex drive/clutch Pinch rollers A and B Route sepa rator Duplex control boar d #2 Connectors or wir[...]

Troub leshootin g Analys is Guid e (TAGs) 3-195 3 V erify that J /P305, J /P310, J/ P31 1, J/P312, J/P320, J/ P321, and J/P322 are connected p roperly t o duplex contro l board #2. • V erify that J/P3 06, J/P 307, J/P 308, J /P309, an d J/ P324 ar e connected pro perly to du plex con trol boar d #1. • V erify that J/P315 and J/P31 6 are connect[...]

3-196 Troublesh ooting Anal ysis Guide (T AGs) 8 Run di agnostic test 01 7. Did diagnostic test 017 indic ate a duplex tray pa per sensor problem ? No: Continue. Ye s : Go to #13 i n thi s T AG . 9 T urn the printer off. • Disconn ect J/P 312 and J/P 321. • Check P312-7 t o J321-1 for cont inuity . Is there continuity? No: Repair or replace the[...]

Troub leshootin g Analys is Guid e (TAGs) 3-197 14 Manually activate the duplex tray p aper sensor . • Check J/P312 -5 for 0 Vdc. Is the voltage 0 Vdc? No: Replace the duplex tray paper sensor . If this resolves the pr oblem, turn to TAG 002: Check & Problem R esolution . If this doesn’t resolv e the problem, repair or replace the wiring or[...]

3-198 Troublesh ooting Anal ysis Guide (T AGs) T AG 902: Paper Jam in Duplex Area Error Code: 027, 060 , 061, 062 Possible Ca uses: Paper incorrectly loaded Paper path not clear Possible De fect s: Duplex drive/clutch “A” roll er clu tch Duplex input so lenoid “C” roll er clu tch Duplex feed motor Duplex control boar d #1 Connectors or wiri[...]

Troub leshootin g Analys is Guid e (TAGs) 3-199 5 T urn the printer off. • Reconnect J/P309. • Disconn ect J/P319 . • T urn the printer on. • Check J3 19-1 for +12 Vdc. Is the voltage +12 Vdc? No: Repair or replace the wiring or connectors from P309-4 to J319-1, then turn to TAG 002: Check & Problem R esolution . Ye s : Co ntinue. 6 Che[...]

3-200 Troublesh ooting Anal ysis Guide (T AGs) 10 T urn the printer on. • Run diagnosti c test 018. Is the input solenoid in good working order? No: Continue. Ye s : Go to #13 i n thi s T AG . 11 T urn off the printer . • Disconn ect J/P308 . • T urn on the prin ter . • Check J3 08-1 and J 308-5 for +2 4 Vdc. Is the voltage +24 Vdc? No: Rep[...]

Troub leshootin g Analys is Guid e (TAGs) 3-201 P308-6 to P3 15-2. Is there continuity? No: Repair or repl ace the wiring or conn ectors from: P308-2 to P3 15-1, or P308-6 to P3 15-2, then turn to TAG 00 2 : Check & Problem Res o lution . Ye s : Replace the “C” roller solenoid, then turn to TAG 00 2: Check & P roblem Resol ution . 16 T [...]

3-202 Troublesh ooting Anal ysis Guide (T AGs) 21 T urn the printer on. • Check J/P306 -3 to J/P306-4 for +5 Vdc. Is the voltage +5 Vdc? No: Repair or repl ace the wiring or conn ectors from P306-3 to J/P331- 3 to P330- 3, then turn to TAG 002: Check & Problem Resolution . Ye s : Co ntinue. 22 Check J/P306 -2 to J/P30 6-4 for +12 Vdc. Is the [...]

Print Quali ty Samples 4-1 Chapter 4 Print Quality Samples Section 2 T roubleshooting[...]

4-2 Print Quality Sample s Contents Prin t Q u a lity Sa m p le s Sample 1: Good Quality Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Sample 2: Washout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Sample 3: Blank Print . . . . . . . . . . . . . .[...]

Print Quali ty Samples 4-3 Prin t Q u a lity Sa m p le s This sect io n con tains fl awed t es t prints, along wit h a go od test pri n t for compa ri son . Com- pare pri nt samp les from yo ur customer’ s print job or from te st print s you’ve r un with the samples in thi s section. If you find a match, note the T AG (i.e., troubl eshooting pr[...]

4-4 Print Quality Sample s Sample 1: Good Qualit y Print Figure 4-1. Good Quality Print Descripti on: Good, prop erly regist ered print .[...]

Print Quali ty Samples 4-5 Sample 2: Washout Figure 4 -2. W ashout Descripti on: V oid areas, light spo ts, or blurs . This is a composite o f possible s ymptoms. Go to TAG 801: Prints Light o r Light With Ca rrie r Part icle s , TAG 802: Pr ints Wi th Voids or White Sp ots , TAG 809: Bl urred or Smeared Vert ical Str eaks on Pri nts , or TAG 810: [...]

4-6 Print Quality Sample s Sample 3: ;: Blan k Prin t Figure 4-3. Blank Print Descripti on: No images or charac ters. The p aper is not di scolore d. Go to TAG 800: Prints Blank or With Dark Hor izontal Ba nds , TAG 815: Pr int s Re sul ting From Print head Malfuncti ons .[...]

Print Quali ty Samples 4-7 Sample 4: Light Print Figure 4 -4. Light P rint Descript ion: Imag es or char acters a re light er than no rmal. Examin e the le tters H, T , M, and E; if t he vertical st rokes are dark enough but the di agonal strokes ar e stair -stepped, t he prob le m is re la ted to th e prin t head . C arrie r partic les may make th[...]

4-8 Print Quality Sample s Sample 5: Light Print With B ackground Figure 4-5. Light Print With Background Descript ion: Image s or character s lighte r than normal , ranging fr om a few dark spec ks to a lar ge speckl ed backgr ound. Go to TAG 811: Background/ Residual I mages/Da rk Prints .[...]

Print Quali ty Samples 4-9 Sample 6: V oids or White Spots Figure 4 -6. V oids of White Spot s Desc riptio n: V oid s o r whi t e spots in imag e area s. Go to TAG 802 : Prints With Vo ids or White Sp ots .[...]

4-10 Print Quality Samples Sample 7: Light V ertical S treaks Figure 4-7. Light V ertical Streaks Descript ion: One or more light ve rtical streaked areas of varyi ng widths. Go to TAG 803 : Prints With L ig ht or W h ite Ve rt ical S treaks .[...]

Print Quali ty Samples 4-11 Sample 8: Blank V ertical Bands Figure 4- 8. Blank V ertical Bands Descript ion: One or more verti cal blank bands o f varying widths ext end over th e entire length. Go to TAG 803: Pr ints Wi th Light o r White Ve rtical Streaks .[...]

4-12 Print Quality Samples Sample 9: Light Horizontal Bands Figure 4-9. Light Horizont al Bands Descripti on: One or mor e light hori zontal bands of varyin g width. Go to TAG 804: Prints With Li ght Horizon tal Bands .[...]

Print Quali ty Samples 4-13 Sample 10: Black or Dark Print Figure 4 -10. Black or Dark Print Descripti on: Black or very dark wit h no visib le images. Go to TAG 805: Black Print s , TAG 811: Background/Residu al Image s/ Dark Prints .[...]

4-14 Print Quality Samples Sample 1 1: Dark Specks, Lines, or Areas Figure 4-1 1. Dar k Specks, Line s, or Areas Descript ion: Dark specks or lines (l ike scra tches), s ome in the s ame place on each prin t. Go to TAG 806: Prints with Da rk Spots or Scratches , TAG 81 0: Uneven Dens ity or Dark Areas on Pr ints .[...]

Print Quali ty Samples 4-15 Sample 12: Dark V ertical Lines Figure 4 -12. Dark V ertica l Lines Descript i on: One or more dark l ines of var yi ng density . If the image c an be ru bbed of f, go to TAG 812: Une ven or No Fus ing on Prin ts . If th e image cann ot be rubbe d off , go to TAG 808: Pri nts Overto ned/Dark Verti cal Streaks . Go to TAG[...]

4-16 Print Quality Samples Sample 13: Skewed P rints Figure 4-13. Skewed prints Desc riptio n: The entire imag e is not locate d squ a rely o n the p a per . Go to TAG 80 7 : Mis regis tered /S kew ed Prin ts (Si m plex) or TAG 901: M isregi stratio n/ Skewed P rints (Dup lex) .[...]

Print Quali ty Samples 4-17 Sample 14: Misre gistration Figure 4 -14. Misregistration Descript ion: The entire image is not cor rectly lo cat ed from the lea ding edge of the pape r . The top or bottom image area may be miss ing. Go to TAG 8 07 : Mis regis te red/S kew ed Prin ts (Si m plex) or TAG 901: M isregi stratio n/ Skewed P rints (Dup lex) [...]

4-18 Print Quality Samples Sample 15: Overtoned Print Figure 4-15. Overtoned Pr int Descript ion: Simi lar to da rk print quality p roblems. Nar row gaps bet ween lett ers an d image s may be fi lled w i th ton er . Exc e ss ton er may be pr esen t o n the s u rface of the pr int. Extra t oner can al so cause b ackgrou nd in the whi te area s. Go t[...]

Print Quali ty Samples 4-19 Sample 16: Blurred Images or Characters Figure 4 -16. Blurred Images or Character s Descript ion: The i mages or ch aracter s are not c lear . The lower e dges of imag es and/or charact ers are extended an d may appear smeared . Go to TAG 809: Blurred or Smeared Vert ical Str eaks on Prints .[...]

4-20 Print Quality Samples Sample 17: V ar ying Print Density Figure 4-17. V arying Print Density Desc riptio n: Some areas of the print a re lig hter o r dark er than n ormal . Exam ine th e lette rs H, T , M, and E on y our te st pr int . I f the ver tical sec tions ar e s uf ficiently da rk, but th e diag - onal sec tions app ear stai r- stepped[...]

Print Quali ty Samples 4-21 Sample 18: Background Figure 4 -18. Background Descript ion: Whit e areas on the print s have var ying degre es of s pecks appe aring in a spe- cifi c p atter n. Go to TAG 811: Background/ Residual I mages/Da rk Prints .[...]

4-22 Print Quality Samples Sample 19: Residual Images Figure 4-19. Residual Images Descript ion: Imag es from a pr evious pri nt are vi sible. Whi te areas on the pri nt may have varying degrees of specks appeari ng in a spec ific pat tern. Go to TAG 811: Background/Resi dual Image s/Dark Print s , TAG 813 : Residual Images o n Prints .[...]

Print Quali ty Samples 4-23 Sample 20: W rinkles Figure 4 -20. W rinkles Descripti on: W rinkles or cre ases, oft en at the top or bottom. Go to TAG 706: Paper Damaged o r Wrinkled .[...]

4-24 Print Quality Samples Sample 21: Fusing Problems Figure 4-21. Fusing Problems Descript ion: Imag es or char acters may rub of f the su rface . Go to TAG 812: Uneven or No Fus ing on Prints .[...]

Diagn ostic Tes ts 5-1 Chapter 5 Diagnostic Te s t s Section 3 T roubleshooting[...]

5-2 Diagnostic Tests Contents How to Run Diagnos tics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 001 Operat or Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 002 Upper Ca ssette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

How to Run Diagnostics Diagn ostic Tes ts 5-3 Diagnostic T ests This sec tion provi des step -by-step instruct ions for running ea ch of the diagnos tic tests availa ble throu gh the s elf-dia gnostic mod e of the pr inter . Each test i s refer enced by num- ber . Check the co ntents page to f ind the pag e on which a s pecific test is describe d. [...]

How to Run Diagnostics 5-4 Diagnostic Tests 001 Operator Panel T est 1 T urn the volume c ontrol on t he operat or panel up full y . 2 Go to: 0 01 3 Press: READY to run the test. 4 Confirm t hat the t one sounds a nd all li ghts tur n on and of f continuously . 5 Press: STOP to e xit. 002 Upper Cassette T est 1 Make sure t he upper p aper cass ette[...]

(004 intentionally excluded) Diagn ostic Tes ts 5-5 003 Lower Cassette T est 1 Make sure t he lower pa per cass ette is i nstall ed with pape r , the side an d rear gui des securel y against the edges of the pap er in the casse tte. 2 Go to: 0 03 3 Press: READY to run the test. 4 Refe r to the c hart b el ow to co nfirm t h at the c ode tha t displ[...]

(004 intentionally excluded) 5-6 Diagnostic Tests 005 Sensor T est Sequence 1 Go to: 0 05 2 Press: READY to run the test. The code for the fir st sensor (i.e., “0- 0” or “ 0-1”) appears on the dis play , confir ming that t he sensor is working proper ly . 3 Press: READY to advan ce to the next senso r . The displ ay changes , showing the co[...]

(004 intentionally excluded) Diagn ostic Tes ts 5-7 006 Paper T ransport Clutch T est Sequence 1 Go to: 0 06 2 Press: READY to run the test. The first cl utch engag es, si gnaled by a continuous clicki ng sound. “3-0” appea rs on the display , correspo nding to the upper pick- up roller clutc h. 3 Press: READY to test the n ext clutch. Li sten [...]

(004 intentionally excluded) 5-8 Diagnostic Tests 008 Jogging Motor T est 1 Go to: 0 08 2 Press: READY to run the test. The o utput tray j ogs back and forth. 3 Confirm that a tone sou nds each time t he tray c ontacts the s ensor at eac h side. The codes in the following table in dicate sp ecific e rror cond itions: 4 Press: STOP to e xit. 009 Pho[...]

(004 intentionally excluded) Diagn ostic Tes ts 5-9 010 T oner Supply Motor T est 1 Open the f ront and top c overs. 2 Remove the p hotoconduct or unit a nd the developer unit. Plac e the phot oconducto r unit in its prot ective p ackagi ng. 3 Insert the inte rlock by-pass tool in the front co ver . Close the top cover . 4 Go to: 0 10 5 Press: READ[...]

(004 intentionally excluded) 5-10 Diagnostic Te sts 01 1 Main Charg er T est 1 Remove the p hotoconduct or unit a nd place i t in its protective p ackaging. Cl ose the t op cover . 2 Go to: 0 1 1 3 Press : REA D Y to run th e test . The ma in charger tu rns on an d off repea t edly . 4 Confirm t hat the display altern ates bet ween “ 0” and “[...]

(004 intentionally excluded) Diagn ostic Tes ts 5-11 012 T ransfer Ch arger T est 1 Remove the pho toconducto r unit and place it in its pr otectiv e packagin g. Close the top cover . 2 Go to: 012 3 Press: READY to run th e test. The transfe r char ger tur ns on and of f repeatedl y . 4 Confirm t hat the displ ay alte rnates b etween “0” and ?[...]

(014 intentionally excluded) 5-12 Diagnostic Te sts 013 Erase Lamp T est 1 Open the t op cover an d inse rt the in terlock by-pass to ol. 2 Remove the p hotoconduct or unit and p lace it in i ts prote ctive cover . 3 Select: 013 4 READY to run th e test. The erase l amp turn s on with al l LEDs light ed. 5 V erify th at all LEDs are il lu mi na ted[...]

(014 intentionally excluded) Diagn ostic Tes ts 5-13 015 Negative Developer Bias T est 1 Open the t op cover an d insert the in terlock by-pass to ol. 2 Remove the p hotoconduct or unit a nd plac e it in its protect ive packag ing. 3 Go to: 0 15 4 Press: READY to run t he tes t. The neg ative devel oper bi as t urns on and of f repeatedl y . 5 Conf[...]

(014 intentionally excluded) 5-14 Diagnostic Te sts 016 Duplex Feed Motor T est 1 Go to: 0 16 2 Press: READY to run the test. The d uplex feed moto r opera tes at full f orward spee d and “7-0” appears o n the di splay . 3 Press: READY to advance t o the next motor speed. 4 Listen f or the f ollowing mot or freque ncies and c heck t he code tha[...]

(014 intentionally excluded) Diagn ostic Tes ts 5-15 017 Duplex In put Sensor T est Sequence 1 Go to: 0 17 2 Press: READY to run the test. The code for the fir st sensor (i.e., “0- 0” or “ 0-1”) appears on the dis play , confir ming that t he sensor is worki ng proper ly . 3 Press: READY to advan ce to the next senso r . The displ ay change[...]

(014 intentionally excluded) 5-16 Diagnostic Te sts 018 Duplex Clutch T est Sequence 1 Go to: 0 18 2 Press: READY to run t he test . The fi rst f lipper e ngag es, acc ompanied by a con tinuou s clicking s ound, and “7- 0” appears on the di splay . 3 Press: READY to ac tiva te the ne xt clut ch or fl ipper . Listen for t he clic king sou nd as [...]

(014 intentionally excluded) Diagn ostic Tes ts 5-17 019 Duplex T ray Paper- Guide Motor T est 1 Go to: 0 19 2 Press: READY to run the test. 3 Press: READY again. Th e pape r guide in the d uplex tray moves to and from its home positi on. 4 Confirm that the paper guide in the duplex tr ay moves back and forth each time you press READY . These code [...]

(014 intentionally excluded) 5-18 Diagnostic Te sts 020 High-Capacity Output Unit T est 1 Go to: 0 20 2 Press: READY to run the test. The code for the fir st sensor (i.e., “0- 0” or “ 0-1”) appears on the dis play , confir ming that t he sensor is working proper ly . 3 Press: READY to advan ce to the next senso r . The senso r ’ s code ap[...]

(023-100 intentionally excluded) Diagn ostic Tes ts 5-19 021 High-Capacity Input Unit T est 1 Go to: 0 21 2 Press: READY to run t he test. The disp lay regist ers the paper siz e install ed in the unit, as outl ined on the chart (“ 1-0” will appear on t he displ ay if a hi gh-capaci ty input unit is not install ed.) 3 V er if y the c orrec t pa[...]

(023-100 intentionally excluded) 5-20 Diagnostic Te sts 101 EIGS/MI GS Board T est 1 Select: 101 2 Press: READY to run the test. 3 If an er ror is f ound: • The erro r code appe ars. • Look up the c ode in “Erro r Code/TAG Cross -Referenc e” on page 2-3 to determine which T AG to follow . • Power -on-res et to exit. 4 If no er rors are fo[...]

(023-100 intentionally excluded) Diagn ostic Tes ts 5-21 103 Comm unication Loop-back T est (Single Loop) 1 Remo ve the in te rface cable fr om the printer. 2 Check to mak e sure the four DI P switches on the si gnal inte rface boa rd have bee n pulled t oward the print er ’ s back cover . Close th e back c over . 3 Instal l the RS-23 2C and RS-4[...]

(106 intentionally excluded) 5-22 Diagnostic Te sts 104 Comm unication Loop-back T est (Continuous Lo op) 1 Remo ve the in te rface cable fr om the printer. 2 Make s ure t he DIP swi tch es on th e sig nal i nt erf ac e boar d h ave be en pulle d t owar d t he printe r ’ s back co ver . Close the bac k cover . 3 Instal l the RS-23 2C and RS-4 22 [...]

(109 intentionally excluded) Diagn ostic Tes ts 5-23 107 EIGS/MIGS Bit Map T est (Single Loop) 1 Go to: 1 07 2 Press: READY to run the test. 3 If no e rror is d etecte d, the te st exit s automa tical ly . 4 If an er ror code a ppears, look it up in “Erro r Code/TAG Cross- Reference” on page 2- 3 to det ermine wh ich T AG to fo llow . 5 Press: [...]

(109 intentionally excluded) 5-24 Diagnostic Te sts 1 10 Format Disk/Clear Error Log • T o fo rma t a disk , ref er to the Guide to Operations manual. 5 T o clear the err or log, follow t he proce dure on cl earing t he log f ound in “Cle aring the Error Log ” on page 1- 24 . 1 1 1 LED Printhead T est 1 Open the t op cover . 2 Remove the p ho[...]

(109 intentionally excluded) Diagn ostic Tes ts 5-25 1 12 Disk D rive T est (Sin gle Loop With S t op on Error ) This te st r eads d ata f rom the dr iv e sel ect ed . I t chec ks th e s eek f unction, c ycle re dunda ncy , parity , checksum, directo ry and all ocation t able int egrity , and disk format . 1 Go to: 112 2 Insert a disket te or d isk[...]

(109 intentionally excluded) 5-26 Diagnostic Te sts 1 13 Disk D rive T est (Continu ous Loop) This tes t reads d ata dire ctly fro m the drive selecte d. It check s the s eek funct ion, cycle redundan cy , parity , checksum, di recto ry and alloca tion tab le integr ity , and dis k format. 1 Go to: 113 2 Insert a disket te or d iskette s in the di [...]

Chapter 6 W i ring Diagrams and Electrical Data Section 4 T roubleshooting[...]

6-2 Wir ing Di agra ms and E lect rical Data Contents Wiring Diagrams and Electri cal Data Wiring Diagra ms and Electri cal Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Connector (J /P) Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Connector Loc ations . . .[...]

Wiring D iagrams an d Electric al Data 6-3 Wiring Diag rams and Electrical D ata This se ction p rovides a refe rence g uide f or all in fo rmat io n rela te d to the electr ical sy s tem of the pr inter , including: • An index, a rranged b y connector number , to the connector’ s l ocation in the pr inter an d on the si mplex an d duplex sc he[...]

6-4 Section 1 : Printer and Troubl eshootin g Overview Connector (J/P) Index Connector Page Schematic Location J/P 2 6-12 simp lex/du plex F4 J/P 3 6-12 simp lex/du plex F4 J/P 4 6-12 simplex/d uplex E6 J/P 5 6-10 simplex/d uplex E5 J/P 6 6-12 simplex/d uplex E7 J/P 7 6-12 simplex/du ple x D8 J/P 8 6-12 simplex/du ple x D7 J/P 9 6-12 simplex/du ple[...]

Section 1: Printer and Troub leshootin g Overview 6-5 J/P 8 2 6-6 simple x/duplex A4 J/P 8 3 6-14 s implex/d uplex E5 J/P 8 4 6-14 s implex/d uplex E6 J/P 8 5 6-14 s implex/d uplex B6 J/P 8 7 6-11 si mpl ex /du ple x C8 J/P 9 0 6-15 s implex/d uplex B9 J/P 9 1 6-11 si mpl ex /du ple x C8 J/P 9 4 6-15 s implex/d uplex B8 J/P 9 5 6-6 simplex /du p le[...]

6-6 Wir ing Di agra ms and E lect rical Data Connector Lo cations The ill ustrati ons that f ollow show t he relat ive loca tion of al l access ible conn ectors i n the printe r , a nd illu strate the conn ector ( except for a fe w instanc es in wh ich the connector is so simple t ha t a n i l lustrat ion is unnec essar y). For t he conn ect or’ [...]

Wiring D iagrams an d Electric al Data 6-7 Connectors Inside the Left Cover J/P 43, 45, 47 J/P 46, 48 J/P 59, 61 J/P 1 19, 120, 127, 128 2 3 4 5 6 7 8 9 10 1 12 3 1 2 1[...]

6-8 Wir ing Di agra ms and E lect rical Data Connectors on the Duplex Cover J/P 316 J/P 22-1 J/P 307 J/P 315 J/P 319 J/P 306 J/P 309 J/P 308 J/P 314 J/P 313 1 2 1 2 1 2 3 1 2 1 2 3 4 1 2 3 4 5 6 7 8 9 1 01 11 21 3 1 4 12345678 1 2 34 56 7 8 9 1 0 1234 1 2 3[...]

Wiring D iagrams an d Electric al Data 6-9 Connectors Inside the Right Cover J/P 49, 51, 53 J/P 22 J/P 31 7 J/P 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 12 3 12 3 1 2 J/P 5 5 1 2 34 56 J/P 54 53 55 54[...]

6-10 Wiri ng Di ag rams and El ectr ical Dat a Connectors Inside the Top Cover J/P 305 J/P 322 J/P 310 J/P 31 1 J/P 312 J/P 321 J/P 5 J/P 5 7 J/P 320 J/P 63 J/P 131-132 1 2 3 4 5 6 7 8 9 10 11 12 1 1 2 12 3 12345678 1 2 34 56 7 8 9 1 0 12 3 12 3 4 1234 1 2 3 1 2 3 4 5 6 7 8 + +[...]

Wiring D iagrams an d Electric al Data 6-11 Connectors on the Back Cover J/P 32 J/P 31 J/P 36 J/P 40, 41 J/P 37 J/P 76 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 2 4 6 8 10 12 1 6 14 18 20 22 24 26 28 30 32 34 36 38 40 42 41 43 44 45 46 47 48 49 50 1 3 5 7 9 1 1 13 1 5 17 1 9 21 23[...]

6-12 Wiri ng Di ag rams and El ectr ical Dat a Connectors Inside the Back Cover (J/P2-14) J/P 2, 3 J/P 4 J/P 6 J/P 7 J/P 8 J/P 9 J/P 10 J/P 13 J/P 14 J/P 1 1 J/P 12 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 1 2 3 1 2 3 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 1 2 12 3 4 56 7 8 9 1 0 1 2 72 71 102 73 100 101 500 56 19 54 24 Joggi ng Motor Contr[...]

Wiring D iagrams an d Electric al Data 6-13 Connectors Inside the Back Cover (Continued) J/P18-62 J/P 18 J/P 19, 20 J/P 21, 22 J/P 23 J/P 25 J/P 2 6 J/P 2 7 J/P 50 J/P 56 , 58, 60 , 62 J/P 3 0 J/P 44 1 2 3 1 2 3 1 2 3 4 5 6 1 2 1 2 3 4 1 2 1 2 3 4 J/P 24 2 3 4 5 6 7 8 1 + + 1 2 3 4 5 6 7 8 9 10 11 12 1 2 34 56 1 2 3 1 2 34 56 7 8 9 1 0 1 2 34 56 J/[...]

6-14 Wiri ng Di ag rams and El ectr ical Dat a Connectors Inside the Back Cover (Continued) J/P 64-85 72 71 102 73 101 500 56 19 54 24 Jogg ing Motor Contro l Board Signa l Interface Board 52 100 J/P 77 J/P 79 J/P 81, 83 J/P 84 J/P 65, 66, 6 7, 68, 69, 70 J/P 64 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 [...]

Wiring D iagrams an d Electric al Data 6-15 Connectors Inside the Back Cover (Continued) J/P 90-800 J/P 90 J/P 9 4 J/P 96 J/P 121, 12 2, 124 J/P 323 J/P 33 3 139, 140, 1 43 J/P 251, 2 52, 255 not illustrat ed J/P 800 J/P 330, 331 J/P 324 1 2 1 2 3 4 1 2 3 4 1 2 1 2 3 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8[...]

6-16 Wiri ng Di ag rams and El ectr ical Dat a V oltage Isolation Diagrams Use the f ollowing vo ltage is olation d iagra ms to locat e the pre sence o r loss of pro per DC poten t ials w it hin th e printe r . Simp lex circ uit are shown first, f ollowe d by dup l ex cir cuits . Figure 6-1. (Simplex) -12 Vdc Circuits Figure 6-2. (Simplex) +5 V dc [...]

Wiring D iagrams an d Electric al Data 6-17 Figure 6 -3. (Simplex) +12 Vdc Circuit s J/P8-3 J/P32- 10 J/P91-3 J/P8-6 J/P77-1 J/P40- 25 J/P40-26 J/P40-34 J/P50- 4 J/P50-1 J/P62-1 J/P60- 1 J/P58- 1 J/P57-1 J/P59-1 J/P61- 1 J/P49- 1 J/P51-1 J/P12- 8 J/P41- 50 J/P25-1 J/P41-49 J/ P25-4 J/P40-3 J/P 26-1 DC IGS PCL Board Power Supply Board Disk drive Sig[...]

6-18 Wiri ng Di ag rams and El ectr ical Dat a Figure 6-4. (Simplex) +24 Vdc Circuits PCL Board Power Control Board #2 Coun ter High V ol tage Unit AC Power Lower pi ck-up clu tch Pap er timi ng clut ch Upper p aper feed clutch Lower p aper f eed clutc h Upper pi ck-up clu tch Supply DC Power Supply J/P8-1 1 J/P1 1-1 J/P8-13 J/P91-1 J/P10-1 J/P12-2[...]

Wiring D iagrams an d Electric al Data 6-19 Figure 6 -5. (Duplex) +5 Vdc Circuit Figure 6 -6. (Duplex) +24 Vdc Circuit s DC Power Supply Signal Interface Board Duplex Control Boar d #1 Duplex Control Boar d #2 J/P330-3 J/P331-3 J/P323-3 J/P333-1 J/P305-3 J/P306-3 J/P310-3 Fuse (FH 2) J/P73-1 J/P73 -6 External Attach ment Connector ( ) ) ( J/P331-1 [...]

6-20 Wiri ng Di ag rams and El ectr ical Dat a Figure 6-7. (Duplex) +12 Vdc Circuits J/P331-2 J/P330-2 J/P323-2 J/P306-2 J/P310- 2 J/P305- 2 Duplex Duplex Control Board #2 DC Power Supply Board #1 Control J/P319-1 Paper pass J/P309- 4 J/P318- 1 Cover o pen J/P309 -3 J/P320- 1 Regis tratio n side J/P312 -1 J/P322- 1 Regis trat ion pape r J/P312-4 se[...]

Wiring D iagrams an d Electric al Data 6-21 Ground System J/P4-9 – AC power supp ly J/P5-8 – Fus er unit J/P6-3 – DC power supply J/P18-3 – T oner supply motor J/P19-4 – Jogging motor J/P21-3 – Large co oling fan J/P326-3 – Small c ooling fa n J/P22-3 – V acuum transport unit J/P23-8 – High vol tage unit J/P20-1 – Main m otor J/[...]

6-22 Wiri ng Di ag rams and El ectr ical Dat a Host Interface Refe rence S tandard print ers support three host i nterfaces: RS- 232C, RS-422, an d Centronics P arallel. User-lev e l info rmation about th e inst al latio n, conf igurat ion, an d use of these in terfa ces is include d in the pr inte r ’ s Guide to Oper ations . RS-232C Host Interf[...]

Wiring D iagrams an d Electric al Data 6-23 S tandard DCE to DT E RS-232C Cab le The s tanda rd DCE h ost to the pr inter (DTE) p in co nf igura tion follow s.. Spec ia l Conside r ations for RS -232 Host Interface Users If the READY light comes on and the ON-LINE l ight does not come on whe n you are instal ling t he prin ter , one or more of the [...]

6-24 Wiri ng Di ag rams and El ectr ical Dat a DTE Host to Printer (Option 1) DTE Host to Printer (Option 2) T able 6-3. DTE Host to Printer Connector W iring (Option 1) Host Signal DCE DTE Printer Signa l GND 1 1 GND GND 7 7 GND DTR 20 20 DTR DCD 8 8 DCD DSR 6 6 DSR RTS 4 4 RTS CTS 5 5 CTS TD 2 2 TD RD 3 3 RD T able 6-4. DTE Host to Printer Connec[...]

Wiring D iagrams an d Electric al Data 6-25 IBM PC/XT to P rinter Normally , the IBM PC/XT comes with a par allel i nterface for the p rinter wi th a 25 -pin female c onnector . T o run RS-232 , you must i nstall a seria l boar d, which wi ll have a male connecto r . IBM PC/A T to P rinter Normally , the IBM A T comes wi th a 9-pi n serial connecto[...]

6-26 Wiri ng Di ag rams and El ectr ical Dat a Macintosh Communication Port to Printer Normally , the Macintosh c omes with a 9-pin male c onnecto r . RS-422 Host int erface The RS-422 ho st in terface uses the s ignal def initions de fined bel ow . A shielde d cable is requir ed with the shield c onnected on one end o nly , preferab ly at th e pri[...]

Wiring D iagrams an d Electric al Data 6-27 Centronics Paralle l Host Interface The Centr onics Para llel hos t interf ace uses the signal defini tions def ined below . T able 6 -9. Centronics Parallel Signal Definitions Pin Signal Name Function 1 DS Data strobe (active l ow) 2 DB0 Data bit 0 3 DB1 Data bit 1 4 DB2 Data bit 2 5 DB3 Data bit 3 6 DB4[...]

6-28 Wiri ng Di ag rams and El ectr ical Dat a IBM Parallel to Printer T able 6-10. IBM Parallel to Pr inter Connector Wiring Host Sign al Prin ter Signa l DS 1 1 DS DB0 2 2 DB0 DB1 3 3 DB1 DB2 4 4 DB2 DB3 5 5 DB3 DB4 6 6 DB4 DB5 7 7 DB5 DB6 8 8 DB6 DB7 9 9 DB7 ACK 10 10 AC K BSY 1 1 1 1 BS Y PE 12 12 PE SEL 13 13 SEL AF 14 14 AF ERR 15 32 ERR IP 6[...]

Wiring D iagrams an d Electric al Data 6-29 Special Considera tions for Centronics Parallel Interface Users For DOS host computers, a dd the fol lowing li ne to the AUT OEXEC.BA T file: MODE PRN,,P T o edit th e AUTOEXEC.BA T file, use any text edi tor or th e EDLIN facili ty of DOS. If you do not know how to edi t this fil e, refer to the refe ren[...]

6-30 Wiri ng Di ag rams and El ectr ical Dat a Circuit Board Settin gs Several of the ci rcuit boa rds in th e prin ter have j umpers and/ or DIP swit ches used t o con- trol t he functi onality of the boar d. These se tting s are desc ribed th e followin g section . Signal Interface Board Settings The signa l inter face board has both j umpers and[...]

Wiring D iagrams an d Electric al Data 6-31 For a Centr onics Parall el Host Interf ace: set al l four DIP switches t o OFF by pu shing them to ward th e inter ior of t he prin ter , as ill u strate d. Figure 6 -9. Centronics Parallel Host Inter face DIP Settings PCL Board Settings The PCL board uses DIP swi tches to contro l the reg istration of p[...]

6-32 Wiri ng Di ag rams and El ectr ical Dat a[...]

Removal /Replacem ent Proced ures 7-1 Chapter 7 Removal/Replacement Procedures Section 5 T roubleshooting[...]

7-2 Remova l/Replac ement Proc edures Contents Front Cover Re moval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Back Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Lower Back Cover Removal . . . . . . . . . . . . . . . . . . . . [...]

Removal /Replacem ent Proced ures 7-3 Fuser Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 Paper Fee d Drive Belt Remov al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58 Paper Timing Rol ler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

Remo val 7-4 Remova l/Replac ement Proc edures Removal This sec tion incl udes step -by-step instruc tions for removing al l fiel d service replacea ble parts i n the pri nter . Each part i s addres sed under i ts own headi ng, as outl ined o n the pre- ceding c ontents pages . Most of the procedure s are appli cable to both the simple x and duplex[...]

Front Cover R emoval Removal /Replacem ent Proced ures 7-5 Front Cover Removal T o remove the fr ont cover : 1 Open the f ront cover . 2 While hol ding the co ver up h alfway , unhook the s trap fro m the right side. 3 Duplex only: Remov e the str ap from the left side. 4 Slide the fr ont co ver to th e righ t off its h inges . Left Strap Right Str[...]

Back C over R emov al 7-6 Remova l/Replac ement Proc edures Back Cover Removal T o remove the bac k cover: 1 Remove all ext ernal ca bles and att achments. 2 Open the t op and back c overs. 3 Disconnec t CN31, CN32, CN37, CN40, CN41, CN74, a nd CN91. 4 Duplex onl y: Disconnect CN36. 5 For the h ard drive optio n, disconnec t the dri ve’ s data ca[...]

Lower Ba ck Cover Re moval Removal /Replacem ent Proced ures 7-7 Lower Back Cover Removal T o remove the lower b ack cover: 1 Disconnec t all ex ternal c ables and a ttachment s. 2 Open the ba ck cover . 3 Loosen th e two sc rews holdi ng the lower back cover in place . 4 Lift t he back cove r of f its hi nges. 5 While supp orting the ba ck cover ,[...]

Left Side Cover Removal 7-8 Remova l/Replac ement Proc edures Left Side Cover Removal T o remove the left si de cover: 1 Open the t op, back, and front cov ers. 2 Duplex only: Re move the dupl ex tray by discon necting P30 5 and loose ning th e two thumb scr ews. 3 Remove the u pper and lo wer pape r casset tes. 4 Loosen th e two sc rews for t he l[...]

Right Side Cover Removal (Simplex) Removal /Replacem ent Proced ures 7-9 Right Side Cover Removal (Simplex) T o remove the right si de cover: 1 Rem o ve the paper outp ut tray . 2 Open the t op and fron t covers. 3 Loosen th e two sc rews holdi ng the rig ht side co ver . 4 Pull the cover out and away from the pr inter . Replacement Note: When rein[...]

Right Side Cover Removal (Duplex) 7-10 Removal/R eplacemen t Proced ures Right Side Cover Removal (Duplex) T o rem ove th e right side c over: 1 Remove the pa per output tr ay . 2 Open the to p, back, a nd front c overs. 3 Remove the t wo screws hol ding t he right s ide cover in place. 4 Close the top cove r . 5 Pull the cov er out an d away from [...]

V acuum T ransport Unit Removal (Simplex) Removal /Replacem ent Proced ures 7-11 V acuum Tr ansport Unit Removal (Simplex) T o remove the simplex vac uum transpo rt unit: 1 Open the t op and back c over . 2 Disconnec t CN22A. 3 Remove the r etainin g clip hol ding the c able in pl ace. 4 Remove the g round screw on t he left side of the ba ck cover[...]

V a cuum T ransport Unit Removal (Simplex) 7-12 Removal/R eplacemen t Proced ures Vacuum Transport Detail Mounting Sc rews[...]

V a cuum T ransport Unit Removal (Duplex) Removal /Replacem ent Proced ures 7-13 V acuum Transport Unit Removal (Duplex) T o remove the duplex vac uum transpor t unit: 1 Open the t op cover . 2 Remove the u pper duple x roll er cover ( four scr ews). 3 Remove the l ower duple x roll er cover ( four scr ews). 4 Disconnec t CN22. 5 Remove the C-c lip[...]

T op Cover Re moval 7-14 Removal/R eplacemen t Proced ures T op Cover Removal T o remove the top cover : 1 Open the t op cover . 2 Remove the vacuum tr ans por t unit from the top cover . It is not necess ary to remov e it comple tely fro m the print er . (Refer to page 7 -11 .) 3 Remove the f our scre ws for e ach support assemb ly . 4 Lift t he t[...]

T op Cover Support R emoval Removal /Replacem ent Proced ures 7-15 T op Cover Su ppor t Removal T o remove the top cover support: 1 Open the t op cover . 2 Remove the s pring fr om the top co ver sup port (singl e screw). 3 Remove the s crews hold ing the support t o the base of the pr inter . Replacement Note: Replace o ne suppo rt at a time so th[...]

T op Cover Hinge Removal 7-16 Removal/R eplacemen t Proced ures T op Cover Hinge Removal T o remove the top cover hinge: 1 Open the t op cover . 2 Remove the t wo screws ho lding t he hinge/ support t o the top c over . 3 Remo ve the two screw s holdin g the hi nge/s upport to the pr inter base. 4 While supp orting t he top cover , loosen th e top [...]

Rear Duplex Cov er Re mova l Removal /Replacem ent Proced ures 7-17 Rear Duplex Cover R emoval T o remove the rear dupl ex cover: 1 Open the t op cover . 2 Remo ve the lo w er scr ew for the rear d u plex c ov er . 3 While supp orting t he cover , remove the uppe r screw for the rea r duplex co ver . Replacement Note: Do not substitu te longer scre[...]

Front Duplex Cover Removal 7-18 Removal/R eplacemen t Proced ures Front DuplexCover Removal T o remove the front dup lex cover: 1 Open the t op cover . 2 Rem o ve the rear d uplex c over . (Ref er to page 7-17 .) 3 Close th e top cover . 4 Open the f ront duplex c over . 5 Remove the C- clip fr om each gas s pring. 6 While supp orting t he cover , [...]

Operator Panel Removal Removal /Replacem ent Proced ures 7-19 Operator Panel Removal T o remove the operator panel: 1 Open the f ront cover . 2 Remo ve the two screw s holdin g the op erato r p anel in plac e . 3 Disconnec t connector CN4 2. 4 Remove the g round scre w . Ground S crew CN4 2[...]

Counter Removal 7-20 Removal/R eplacemen t Proced ures Counte r Removal T o remove the counte r: 1 Open the f ront cover . 2 Remove the s crew holding t he counter in place. 3 Pull out the count er . 4 Disconnec t connect or CN82. CN82[...]

IGS Bo ard Re moval Removal /Replacem ent Proced ures 7-21 IGS Board Removal T o remove the IGS b oard: 1 Open the ba ck cover . 2 Disconnec t connectors CN31, CN32, CN33, a nd CN74. 3 For the h ard drive optio n, disconnec t the dri ve’ s data cabl e. 4 Push the t wo retai ning clip s away fr om the boar d. 5 Remove the IGS b oard. Retain ing Cl[...]

PCL Board Removal 7-22 Removal/R eplacemen t Proced ures PCL Board Removal T o remove the PCL boa rd: 1 Open the ba ck cover . 2 Disconnec t connectors CN33, CN37, CN40, CN41 , and CN91. 3 Duplex only: a lso disconnec t connect or CN36. 4 Push the t wo retai ning clip s away fr om the boar d. 5 Remove the PCL board. 6 Change the setting s of the DI[...]

Printh ead As se mbly Re mova l Removal /Replacem ent Proced ures 7-23 Printhead Assembly Removal T o remove the printhea d assemb ly: 1 Open the f ront, top, and back cov ers. 2 Remove the p hotoconduct or unit a nd plac e in its pro tective packaging. 3 Rem o ve the clean er uni t. 4 Remove the f user dri ve cover ( three sc rews). 5 Remo ve the [...]

Printhead Assembly Removal 7-24 Removal/R eplacemen t Proced ures 10 Remove the t wo front s crews holdi ng the printhea d assembly i n place. 11 Pull the printhe ad assemb ly fr om the front of the pr inter . Replacement Note: Do not change the DIP switch s etting on the repl acement pri nthea d circuit board. The se are set at the f actory . Moun[...]

Disk D rive Housi ng Re moval Removal /Replacem ent Proced ures 7-25 Disk Drive Housing Removal T o remove the di sk drive ho using: 1 Open the f ront and ba ck cove rs. 2 Rem o ve the diske tte(s ). 3 Disconnec t CN77 and CN79. 4 For the h ard drive optio n, disconnec t the dri ve’ s data cable. 5 Loosen th e thumbsc rew on the b ack of the disk[...]

Cooling Fan Removal 7-26 Removal/R eplacemen t Proced ures Cooling Fan Rem oval T o remove the coo ling fan: 1 Open the ba ck cover . 2 Remo ve the fu se r driv e cover (thre e scre w s). 3 Disconnec t CN21. 4 Remove the c ooling fa n (four sc rews). Fuser Drive Cover CN21 Cooling Fan Detail[...]

Duplex Fan Removal Removal /Replacem ent Proced ures 7-27 Duplex Fan Removal T o remove the dupl ex fan: 1 Open the ba ck and top c overs. 2 Remove the f user dri ve cover ( three sc rews). 3 Remove the EMI grounding p late (i f present ) from the rear of the pri nter (f our scr ews). 4 Remove the f our screws hol ding the d uplex fan in place. 5 D[...]

T oner Motor Remova l 7-28 Removal/R eplacemen t Proced ures T oner Motor Removal T o remove the toner motor: 1 Open the ba ck cover . 2 Disconnec t CN18. 3 Remove the ton er motor ( three sc re ws). T oner Motor Det ai l CN18[...]

AC Power Supply Removal Removal /Replacem ent Proced ures 7-29 AC Power Supply Removal T o remove the AC power supply: 1 Open the f ront, back , and top covers. 2 Duplex only: Remov e the duplex t ray . 3 Remove the u pper and lo wer pape r casset tes. 4 Remove the l eft sid e cover . (See p age 7-8 .) 5 Remove the p aper feed drive cover (th ree s[...]

AC Power Supply Removal 7-30 Removal/R eplacemen t Proced ures 8 From the side of the prin ter , remove t he thre e screws hol ding the AC power s upply in place. 9 Slide t he AC power supply out from the si de of the printer .[...]

DC Power Supply Removal Removal /Replacem ent Proced ures 7-31 DC Power Supply Removal T o remove the DC power supply: 1 Open the f ront, top, and back cov ers. 2 Disconnec t CN6, CN7, CN8, and CN330. 3 Remo ve the ou t put tra y . 4 Remove the r ight sid e cover . (See p age 7-9 .) 5 Remo ve the br acket fo r the o u tput tra y gui de (two screws [...]

High V olt a ge Unit Removal 7-32 Removal/R eplacemen t Proced ures High V oltage Unit Remo val T o remove the high volt age unit: 1 Open the t op and back c overs. 2 Remove the EMI grounding p late (i f present ) from the rear of the pri nter (f our scr ews). 3 From the t op, loosen t he screw ho lding the high vo ltage uni t in plac e. 4 Pull the[...]

Photoconductor Seam Sensor Removal Removal /Replacem ent Proced ures 7-33 PhotoconductorSeam Senso r Removal T o remove the phot oconducto r seam senso r: 1 Open the f ront, back , and to p covers. 2 Remove the p hotoconduct or and place in its prot ective pa ckaging. 3 Rem ove th e dev elope r uni t. 4 Remove the p aper feed drive cover (th ree sc[...]

Photoconductor Seam Sensor R emoval 7-34 Removal/R eplacemen t Proced ures 7 From insi de the empty photoc onductor ca vity , disconnect connec tor CN63. 8 Lift t he photocond uctor sea m sensor and bracke t up out of the pr inter . Note : Use cauti on not to be nd the b racket. Seam Sens or and Br acket CN63 Front Det ail[...]

Photoconductor Rear Guide Rail Removal Removal /Replacem ent Proced ures 7-35 Photoconductor Rear Guide Rail Removal T o remove the photoconduc tor rear guide ra il: 1 Open the f ront, back , and to p covers. 2 Remove the p hotoconduct or and place in its prot ective pa ckaging. 3 Rem ove th e dev elope r uni t. 4 Remove the p aper feed drive cover[...]

Photoconductor Rear Guide Rail Removal 7-36 Removal/R eplacemen t Proced ures 10 From insi de the phot oconduc tor cavit y , remove the two sc rews holdi ng the gu ide rail in plac e. 11 Push CN64 and the ground wire thro ugh the photoc onductor c avity to t he front of the printe r . 12 Lift th e phot ocondu ctor gu ide ra il from th e prin te r .[...]

Signal Interfac e Boar d Remova l Removal /Replacem ent Proced ures 7-37 Signal Inte rface Board Removal T o remove the signal i nterfac e board: 1 Disc onne ct all e xt ernal cable s and attach m ents . 2 Open the ba ck cover . 3 Remo ve the lo w er back cover . (See page 7- 7 .) 4 Disconnec t CN74 and P333. 5 Remove the s ignal in terface board ([...]

Power Control Board Removal 7-38 Removal/R eplacemen t Proced ures Power Contro l Boa rd Removal T o remove the power control board: 1 Open the ba ck cover . 2 Remove the p aper feed drive cover (th ree screws). 3 Remo ve the po w er con trol bo a rd cove r (one screw) . 4 Disconnec t CN9, CN10, CN1 1, CN12, CN13, and CN14. 5 Remove po wer contro l[...]

Jogging Motor Control Board Removal Removal /Replacem ent Proced ures 7-39 Jogging Motor Control Board Removal T o remove the jogging mot or contro l board: 1 Open the ba ck cover . 2 Remove the p aper feed drive cover (th ree screws). 3 Remo ve the po w er con trol bo a rd cove r (one screw) . 4 Disconnec t CN100, CN101, and CN102. 5 Disengage the[...]

Upper or Lower Paper S ize Sensor Removal 7-40 Removal/R eplacemen t Proced ures Upper or Lo werPaper Size Sen sor Removal T o remove the upper or l ower paper size sens or: 1 Duplex only: Remov e the duplex t ray . 2 Remove the u pper and lo wer pape r casset tes. 3 Using a small scr ewdriv er , pry up th e paper s ize sensor . T urn the se nsor c[...]

Upper Cassette Mount R emoval Removal /Replacem ent Proced ures 7-41 Upper Cassette Mount Removal T o remove the upper cass ette mount : 1 Open the f ront, back , and to p covers. 2 Duplex only: Re move the duplex t ray . 3 Remove the u pper and lo wer pape r casset tes. 4 Remove the l eft sid e cover . (See p age 7-8 .) 5 Remove the p aper feed dr[...]

Upper Cassette Mount Removal 7-42 Removal/R eplacemen t Proced ures 10 Remove the u pper paper size sens or . (See pa ge 7-40 .) 11 Remove the c assette release cover ( two screws ). 12 Remove the p lastic g uide on the vert ical edge of the pri nter . Depress the t abs visi ble through t he casse tte ho using. Gentl y turn it and lif t from the pr[...]

Upper Cassette Mount R emoval Removal /Replacem ent Proced ures 7-43 14 Disengage the top of the damper as sembly . Push it to t he right out of the way . Cable T ension Cable Edge Guid e Damper A ssembly Cable T ension Spring Lower Paper T ens ion Lever Lowe r Cam Lower Latc h Upper Cam Upper Lat ch Upper Pape r T en si on Lever Spring Upper Paper[...]

Upper Cassette Mount Removal 7-44 Removal/R eplacemen t Proced ures 15 Remove the l ower brack et (four screws; t wo front a nd two bac k). 16 Remove the t ray (fou r screws; two front and two back) . 17 Remove the u pper tray lift ar m (two scre ws with tw o plastic r etainer s). 18 Remove the u pper brack et (four screws; t wo front a nd two bac [...]

Lower Cassette Mount R emoval Removal /Replacem ent Proced ures 7-45 Lower Cassette Mount Removal T o remove the lower cass ette mount: 1 Open the f ront, back , and to p covers. 2 Duplex only: Re move the duplex t ray . 3 Remove the u pper and lo wer pape r casset tes. 4 Remove the l eft sid e cover . (See p age 7-8 .) 5 Remove the p aper feed dri[...]

Lower Cassette Mount Removal 7-46 Removal/R eplacemen t Proced ures 9 Remove the l ower paper size sens or . (See page 7-40 .) 10 Remove the c assette release cover ( two screws ). 11 Remove the p lastic g uide on the vert ical edge of the pri nter . Depress the t abs visi ble through t he casse tte ho using. Gentl y turn it and lif t from the prin[...]

Lower Cassette Mount R emoval Removal /Replacem ent Proced ures 7-47 13 Remove the l ower brack et (four screws; t wo fron t and two bac k). 14 Remove the t ray (four s crews, two fron t and two bac k) 15 Remove the AC p ower supply . (See pa ge 7-29 .) 16 Remove the low e r tray l if t arm (two s crews w i th two p la stic reta iners) . 17 Remove [...]

Upper Paper Guide Removal 7-48 Removal/R eplacemen t Proced ures Upper Paper Gu ide Removal T o remove the upper pape r guide: 1 Open the f ront, back , and top covers. 2 Remove the p aper feed drive cover (th ree screws). 3 Disconnec t the tr ansfer co rona high v oltag e lead fr om the HVPS. 4 Disconnec t the gro und screw fo r the transfer co ro[...]

Upper Paper Guide Removal Removal /Replacem ent Proced ures 7-49 5 Remove the c assette release cover ( two screws ). 6 Raise th e upper pap er guid e. 7 Remove the b ack screw ho lding the upper p aper guide in place . 8 Remove the f ront scr ew holding t he uppe r paper gui de in pla ce. 9 Release the two spr ings at t he base of the upp er paper[...]

Upper Paper Gui de Roller Removal 7-50 Removal/R eplacemen t Proced ures Upper Pa per Gu ide Rolle r Removal T o remove the upper pape r guide ro ller: 1 Open the t op cover . 2 Remove the t w o sp ri ngs at eac h end of t he rol ler . T o do this, pre ss down ge nt ly on th e end of th e spring a nd move it ou t from u nder the pl astic. 3 Raise t[...]

Lower Paper Guide Removal Removal /Replacem ent Proced ures 7-51 Lower Paper Gui de Removal T o remove the lower p aper guide : 1 Open the t op cover . 2 Raise th e upper pap er guid e. 3 Raise th e lower pap er guid e slightly . 4 Push the b ase of the lower paper guid e toward the back o f the pri nter unti l the fr ont mounting p eg is free. 5 L[...]

Paper T iming Guide Remov al 7-52 Removal/R eplacemen t Proced ures Paper Timing Guide Removal T o remove the paper ti ming guid e: 1 Open the f ront, back , and top covers. 2 Raise th e upper pap er guid e. 3 Remove the l ower paper gui de. (See pa ge 7-51 .) Lower P aper Guide Paper Timing Guide Mountin g Screw Front Deta il[...]

Paper T iming Guide Removal Removal /Replacem ent Proced ures 7-53 4 Remove the p aper feed drive cover (th ree screws). 5 Remove the b ack screw ho lding the paper ti ming guide i n place. Remove t he paper timing gu ide. 6 Disconnec t CN58. Mounting Screw CN58 Back Detail Paper Feed Drive Cov er[...]

Cleaner Drive Belt Remov al 7-54 Removal/R eplacemen t Proced ures Cleaner Drive Bel t Removal T o remove the cleaner dri ve bel t: 1 Open the ba ck cover . 2 Remove the f user dri ve cover ( three sc rews). 3 Remo ve the ma in drive cove r (o ne scre w). 4 Lift th e idler arm and slide th e clea ner dr iv e bel t o ff the gear . Idler Arm Cleaner [...]

Cleaner Dri ve Re mova l Removal /Replacem ent Proced ures 7-55 Cleaner Drive Removal T o remove the cleaner dri ve: 1 Open the ba ck cover . 2 Remo ve the fu se r driv e cover (thre e scre w s). 3 Remove the ma in drive cover (one scr ew). 4 Remove the c leaner dr ive belt . (See p age 7-54 .) 5 Remove the t wo high v oltage l eads. 6 Remove the c[...]

Fuser Drive Belt Removal 7-56 Removal/R eplacemen t Proced ures Fuser Drive Belt Removal T o remove the fuser dr ive belt: 1 Open the ba ck cover . 2 Remove the f user dri ve cover ( three sc rews). 3 Remo ve the ma in drive cove r (o ne scre w). 4 Remove the g ear stay cover (one screw). 5 Remove the g ear stay (three s crews). 6 Remove the mai n [...]

Fuser Dri ve Remova l Removal /Replacem ent Proced ures 7-57 Fuser Drive Removal T o remove the fuser drive: 1 Open the ba ck cover . 2 Remo ve the fu se r driv e cover (thre e scre w s). 3 Remove the ma in drive cover (one scr ew). 4 Remove the g ear stay cover (one screw). 5 Remove the g ear stay (three s crews). 6 Remo ve the fu se r driv e belt[...]

Paper Feed Drive Belt Re moval 7-58 Removal/R eplacemen t Proced ures Paper Feed Drive Belt Removal T o remove the paper feed driv e belt: 1 Open the ba ck cover . 2 Remove the f user dri ve cover ( three sc rews). 3 Remove the p aper feed drive cover (th ree screws). 4 Remo ve the ma in drive cove r (o ne scre w). 5 Remove the c leaner dr ive belt[...]

Paper Timi ng Roller Removal Removal /Replacem ent Proced ures 7-59 Paper T iming Roller Removal T o remove the paper ti ming rolle r: 1 Open the f ront, back , and to p covers. 2 Raise th e upper pap er guid e. 3 Remove the p hotoconduct or and place it in its p rotecti ve bag. 4 Remove the p aper feed drive cover (th ree screws). 5 Remove the p a[...]

Upper Feed Roller Re mova l 7-60 Removal/R eplacemen t Proced ures Upper Feed Roller Removal T o remove the upper fee d roller : 1 Open the f ront and ba ck cove rs. 2 Remove the p aper feed drive cover (th ree screws). 3 Disconnec t CN66. 4 Remove the p aper feed drive belt from the upper f eed roll er gear . 5 Remove the c assette release cover ([...]

Lower Feed Roller Re mova l Removal /Replacem ent Proced ures 7-61 Lower Feed Roller Removal T o remove the lowe r feed ro ller : 1 Open the f ront and ba ck cove rs. 2 Remove the p aper feed drive cover (th ree screws). 3 Disconnec t CN67. 4 Remove t he paper f eed drive belt fro m the lowe r feed ro ller gea r . 5 Remove the c assette release cov[...]

Upper Pick-Up Roller Removal 7-62 Removal/R eplacemen t Proced ures Upper Pick-Up Rol ler Removal T o remove the upper pic k-up ro ller: 1 Open the f ront and ba ck cove rs. 2 Remove the p aper feed drive cover (th ree screws). 3 Disconnec t CN68. 4 Remove the c assette release cover ( two screws ). 5 Remove the f ront C-cl ip and bearing. 6 Slide [...]

Upper Pick -Up Roll er Drive Removal Removal /Replacem ent Proced ures 7-63 Upper Pick-Up Roller Drive Removal T o remove the upper pic k-up ro ller drive: 1 Open the ba ck cover . 2 Remove the p aper feed drive cover (th ree screws). 3 Remo ve the up p er pic k -up roll er driv e (thre e scre w s). Note : Y ou may need t o remove the EMI grounding[...]

Lower Pick-Up Roller Removal 7-64 Removal/R eplacemen t Proced ures Lower Pick-Up Roller Removal T o remove the lowe r pick-up roll er: 1 Open the f ront and ba ck cove rs. 2 Remove the p aper feed drive cover (th ree screws). 3 Disconnec t CN69. 4 Remove the c assette release cover ( two screws ). 5 Remove the f ront C-cl ip and bearing. 6 Slide t[...]

Lower P ick-Up Roll er Dri ve Remova l Removal /Replacem ent Proced ures 7-65 Lower Pick-Up Roller Drive Removal T o remove the lowe r pick-up roll er drive: 1 Open the ba ck cover . 2 Remove the p aper feed drive cover (th ree screws). 3 Remo ve the lo w er pick -up roll er driv e (thre e scre ws). Pa pe r Fe ed Drive Cover Lower Pick-up Roller Dr[...]

Job Offs et Assembly Re moval 7-66 Removal/R eplacemen t Proced ures Job Of fset Asse mbly Removal T o remove the job of fset as sembly: 1 Open the f ront, top, and back cov ers. 2 Rem o ve the paper outp ut tray . 3 Remove the r ight sid e cover . (See p age 7-10 .) 4 Remove the o perator p anel. (S ee page 7-19 .) Outpu t Opti on Mountin g Pin Mo[...]

Job Offset Assembly Removal Removal /Replacem ent Proced ures 7-67 5 Remove the DC p ower supply (See page 7- 31 .) 6 Remove the mou nting bracket for the DC power supply (t wo screws) . 7 Remo ve the fu se r driv e cover (thre e scre w s). 8 Disconnec t CN19 and CN54. 9 Remove the f ive scre ws holding t he job of fset assembl y in plac e (three f[...]

Exit Pinch Rolle r Removal 7-68 Removal/R eplacemen t Proced ures Exit Pi nch Roller Removal T o remove the exit pinch roller : 1 Open the f ront, back , and top covers. 2 Remove the fus er . 3 Remove the o perator p anel. (S ee pag e 7-19 .) 4 Remove the f ront scr ew holding t he exi t pinch roll er in pl ace. 5 Remove the f ront scr ew holding t[...]

Ex it Pi nch Roll er R emo val Removal /Replacem ent Proced ures 7-69 6 Remo ve the fu se r driv e cover (thre e scre w s). 7 Remove the b ack screw ho lding the exit pin ch roller in pl ace. 8 Lift t he exit pi nch rolle r from the printer . Note : Use cauti on so as not to damag e the paper full or exit sen sors. Mountin g Screw Back Detail Fuser[...]

Upper St at ic Brush Removal 7-70 Removal/R eplacemen t Proced ures Upper Static Brush Removal T o remove the uppe r stati c brush: 1 Open the t op and front c overs. 2 Remove the fus er . 3 Remove the u pper stat ic brush from the exi t pin ch roller as sembly ( two screws ). Upper S tatic Brush Detail[...]

Lower St at ic Brush Removal Removal /Replacem ent Proced ures 7-71 Lower S tatic Brush Removal T o remove the lower sta tic brus h: 1 Open the t op, front and back covers. 2 Remo ve the fu se r . 3 Remove the o perator p anel. (S ee pag e 7-19 .) 4 Remove the e xit pinch roller assembly . (See page 7-6 8 .) 5 Remove the l ower stat ic brush (two s[...]

Exit Roller Assembl y Removal 7-72 Removal/R eplacemen t Proced ures Exit Roller Assembly Removal T o re move th e exit roller as sembl y: 1 Open the f ront, back , and top covers. 2 Remove the fus er . 3 Remove the o perator p anel (S ee page 7-19 ). 4 Remove the f ront scr ew holding t he exi t guide i n place. Exit P inch Roller S crew C-Clip an[...]

Ex it R olle r Ass embl y R emov al Removal /Replacem ent Proced ures 7-73 5 Remo ve the fu se r driv e cover (thre e scre w s). 6 Remove the e xit pinch roller . (See page 7-68 .) 7 Duplex only: Re move the lower duplex dr ive (3 screws). 8 Remove the b ack screw ho lding the exit guide in pl ace. 9 T ilt th e exit g uide t owar d t he cen ter of [...]

Exit Cover Rem oval (Simple x) 7-74 Removal/R eplacemen t Proced ures Exit Cover Removal (Si mplex) T o remove the simplex exi t cover: 1 Open the f ront, back , and top covers. 2 Remove the fus er . 3 Remove the r ight sid e cover . (See p age 7-9 .) 4 Rem o ve the paper outp ut tray . 5 Remove the o perator p anel. (S ee pag e 7-19 .) Mountin g S[...]

Exit Cover Remova l (Simplex) Removal /Replacem ent Proced ures 7-75 6 Remo ve the fu se r driv e cover (thre e scre w s). 7 Remove the e xit pinch roller . (See page 7-68 .) 8 Disconnec t CN49 and CN51. 9 Remove the f our screws hol ding the e xit cover i n place (t wo front and t wo back). 10 Remove the wi ring harness for CN42, CN49, a nd CN51 f[...]

Exit Cover Remova l (Duplex) 7-76 Removal/R eplacemen t Proced ures Exit Cover Removal (Duplex) T o remove the dupl ex exit c over: 1 Open the f ront, top, and back cov ers. 2 Remove the fus er . 3 Rem o ve the paper outp ut tray . 4 Remove the r ight sid e cover . (See p age 7-10 .) 5 Remove the o perator p anel. (S ee pag e 7-19 .) CN317 Solen oi[...]

Exit Cove r Removal (Duplex) Removal /Replacem ent Proced ures 7-77 6 Remo ve the fu se r driv e cover (thre e scre w s). 7 Remove the e xit pinch roller . (See page 7-68 .) 8 Disconnec t CN49 and CN51. 9 Remove the wi ring harness for CN42, CN49, a nd CN51 from the exit cov er . 10 Disconnec t CN317. 11 Remove the f our screws hol ding the e xit c[...]

Paper Exit Sensor Removal 7-78 Removal/R eplacemen t Proced ures Pape r Exi t Sensor Removal T o remove the paper exi t sensor: 1 Open the f ront, back , and top covers. 2 Remove the fus er . 3 Remove the o perator p anel. (S ee pag e 7-19 .) 4 Remove t he exit pi nch roll er . (See page 7-68 .) 5 Disconnec t CN49. 6 Remove the t wo screws ho lding[...]

Paper Full S ensor Removal Removal /Replacem ent Proced ures 7-79 Paper Fu ll Sensor Removal T o remove the paper ful l sensor : 1 Open the f ront, back , and to p covers. 2 Remo ve the fu se r . 3 Remove the o perator p anel. (S ee pag e 7-19 .) 4 Remove the e xit pinch roller . (See page 7-68 .) 5 Disconnec t CN51. 6 Remove the t wo screws ho ldi[...]

Front Cover Interlock Switch Removal 7-80 Removal/R eplacemen t Proced ures Front Cover Interlock Switch Removal T o re move the fro nt co ve r inte rlock switc h: 1 Open the f ront, top, and back cov ers. 2 Duplex only: Remov e the duplex t ray . 3 Remove the u pper and lo wer pape r casset tes. 4 Remove the l eft sid e cover . (See p age 7-8 .) 5[...]

Back C over Interl ock Switc h Remova l Removal /Replacem ent Proced ures 7-81 Back Cover Interlock Switch Removal T o remove the back co ver inter lock swit ch: 1 Open the f ront, top, and back cov ers. 2 Duplex only: Re move the duplex t ray . 3 Remove the u pper and lo wer pape r casset tes. 4 Remove the l eft sid e cover . (See p age 7-8 .) 5 R[...]

T o p Cover Interlock S witch Removal 7-82 Removal/R eplacemen t Proced ures T op Cover Interlock Switch Removal T o re move the top c over i nterl ock sw i tch: 1 Open the t op, front, and back covers. 2 Duplex only: Remov e the duplex t ray . 3 Remove the u pper and lo wer pape r casset tes. 4 Remove the l eft sid e cover . (See p age 7-8 .) 5 Du[...]

Erase Lamp Remova l Removal /Replacem ent Proced ures 7-83 Erase Lamp Removal T o remove the erase la mp: 1 Open the t op and back c overs. 2 Remove the p hotoconduct or and place it in its p rotecti ve packagi ng. 3 Remo ve the fu se r driv e cover (thre e scre w s). 4 Disconnec t CN26. 5 Remove the s crew holdi ng the era se lamp in place. 6 Dise[...]

EP Cover Removal 7-84 Removal/R eplacemen t Proced ures EP Cover Removal T o remove the EP co ver: 1 Open the f ront, back , and top covers. 2 Remove the fus er . 3 Remove the p hotoconduct or and place it in its p rotecti ve packagi ng. 4 Rem o ve the clean er uni t. 5 Remove the o perator p anel. (S ee pag e 7-19 ). Support S crew EP Cover Sc rew[...]

EP Cover Removal Removal /Replacem ent Proced ures 7-85 6 Remo ve the fu se r driv e cover (thre e scre w s). 7 Remove the t wo supports for t he vacuum tr ansport u nit (one screw each) . 8 Duplex only: Re move the duplex f an. (See page 7-27 ). 9 Remove the f our scre ws holding t he EP cov er in pla ce (two fr ont and two b ack). 10 Remove the u[...]

Main Motor Remov al 7-86 Removal/R eplacemen t Proced ures Main Motor Removal T o remove the main moto r: 1 Disc onne ct all e xt ernal cable s and attach m ents . 2 Open the f ront, back , and to p covers. 3 Remove the p hotoconduct or and place it in its p rotecti ve packagi ng. 4 Rem o ve the clean er uni t. 5 Remove the b ack cover . (See page [...]

Main Motor Removal Removal /Replacem ent Proced ures 7-87 8 Remove the r ight sid e cover . (See p age 7-9 .) 9 Remove the c ounter . (See page 7-20 .) 10 Remo ve the ma in drive cove r (o ne scre w). 11 Remove the f user dri ve cover ( three sc rews). 12 Remove the g ear stay cover . 13 Remove the g ear stay (three s crews). 14 Remove the d isk dr[...]

Main Gear Driv e Removal 7-88 Removal/R eplacemen t Proced ures Main Gear Dri ve Removal T o remove the main gear dri ve: 1 Open the ba ck cover . 2 Remo ve the lo w er back cover . (See page 7- 7 .) 3 Remove the p aper feed drive cover (th ree screws). 4 Remove the f user dri ve cover ( three sc rews). 5 Remo ve the ma in drive cove r (o ne scre w[...]

Duplex Control Board #1 Removal Removal /Replacem ent Proced ures 7-89 Duplex Control Board #1 Removal T o remove dupl ex contro l board #1: 1 Open the t op cover . 2 Remove the d uplex control board cove r (two scr ews). 3 Disconnec t CN306, CN307, CN308, and CN30 9. 4 Disengage duplex control b oard #1. T o do t his, pinch the four standof fs on [...]

Duplex Control Board #2 Removal 7-90 Removal/R eplacemen t Proced ures Duplex Control Board #2 Removal T o remove dupl ex contro l board #2: 1 Open the t op cover . 2 Remove the d uplex tray . 3 Remove t he paper gu ide from th e duple x tray (f our screws ). 4 Disconnec t CN310, CN31 1, and CN312. 5 Remove duple x control board #2 (t wo screws). C[...]

Duplex T ray Regist ration Motor Removal Removal /Replacem ent Proced ures 7-91 Duplex T r ay Registration Motor R emoval T o remove the duplex tr ay regist ration mot or: 1 Open the t op cover . 2 Remove the d uplex tray . 3 Remove the p aper guide insi de the dupl ex tray ( four scre ws). 4 Disconnec t CN321. 5 Remove the reg istratio n motor ( t[...]

Duplex Skew Correction Cable Removal 7-92 Removal/R eplacemen t Proced ures Duplex Skew Correc tion Cable Removal T o remove the duplex ske w correcti on cable: 1 Open the t op cover . 2 Remove the d uplex tray . 3 Remove the p aper guide from in side the duplex tr ay (four s crews). 4 Slide t he skew co rrecti on guides t oward the c enter of the [...]

Duplex Sk ew Cor recti on Cable Remova l Removal /Replacem ent Proced ures 7-93 Paper G uide Ske w Correctio n Guides Mounting P late Shaft Bracket Shaft Mount ing Bead Skew Cor rection Cable Driv e Gear Pulley Cable M ounting Pl ate Pulle y Asse mbly Tension Spr ing Skew Corr ection Cable Detail Screw[...]

Upper Duplex Drive/Clutch Assembly Remov a l 7-94 Removal/R eplacemen t Proced ures Upper Duplex Drive/Clutch Assembly Removal T o remove the upper dupl ex drive/ clutch as sembly: 1 Open the t op cover . 2 Remove the r ear duplex co ver . (See page 7-17 .) 3 Remove the l ower duple x roll er cover ( four scr ews). 4 Disconnec t CN316. 5 Remove the[...]

Duplex Route Motor/Solenoid Assembly Remova l Removal /Replacem ent Proced ures 7-95 Duplex Route Motor/Sol enoid Assembly Removal T o remove the dupl ex route motor/sol enoid assembly: 1 Open the t op cover . 2 Remove the r ear duplex co ver . (See page 7-17 .) 3 Remove the u pper duple x roll er cover ( four scr ews). 4 Disconnec t CN313 and CN31[...]

“A” Roll er Removal 7-96 Removal/R eplacemen t Proced ures “A” Roller Removal T o re move th e “A” ro ller: 1 Open the t op cover . 2 Remove the r ear duplex co ver . (See page 7-17 .) 3 Remove the l ower duple x roll er cover ( four scr ews). 4 Remove the f ront C-cl ip and bearing f rom the “A” r oller . 5 Lower the top cove r to [...]

“B” Roller Removal Removal /Replacem ent Proced ures 7-97 “B” Roller Removal T o remove the “B” rolle r: 1 Open the t op cover . 2 Remove the r ear duplex co ver . (See page 7-17 .) 3 Remove the u pper duple x roll er cover ( four scr ews). 4 Remove the l ower duple x roll er cover ( four scr ews). 5 Remove the f ront C-cl ip and bearin[...]

“C” Roll er Removal 7-98 Removal/R eplacemen t Proced ures “C” Roller Removal T o remove the “C” rolle r: 1 Open the t op cover . 2 Remove the r ear duplex co ver . (See page 7-17 .) 3 Remove the u pper duple x roll er cover ( four scr ews). 4 Remove the f ront me chanism cove r (two scr ews). 5 Remove the f ront C-cl ip and bearing f r[...]

“C” Roller Solenoid Removal Removal /Replacem ent Proced ures 7-99 “C” Roller Sole no id Re mo val T o remove the “C” rolle r solenoi d: 1 Open the t op cover . 2 Remove the f ront me chanism cove r (two scr ews). 3 Disconnec t CN315 and cut the c able tie se curing th e wires to the mountin g plat e. 4 Remove the t wo screws ho lding t[...]

Duplex Route Sep a rat or Removal 7-100 Remo val/Rep lacemen t Procedure s Duplex Route Separator Removal T o remove the duplex rou te separa tor: 1 Open the t op cover . 2 Remove the r ear duplex co ver . (See page 7-17 .) 3 Remove the u pper duple x roll er cover ( four scr ews). 4 Remove the d uplex route mot or/sole noid assembly . (See page 7-[...]

Duplex Route Sep a rat or Removal Remo val/Re place m e nt Pro cedure s 7-101 9 Remove the f ront C-cl ip fr om the rout e separat or . 10 Disengage the rout e separat or from it s side su pports. 11 Lift t he route s eparator out from th e duplex co ver . C-Clip Location[...]

Duplex Paper Path Sensor Removal 7-102 Remo val/Rep lacemen t Procedure s Duplex Paper Path Sensor Rem oval T o remove the duplex pape r path se nsor: 1 Open the t op cover . 2 Remove the t wo screws ho lding t he duplex control b oard cover in pla ce. 3 Move the cover to the left out of th e way . 4 Disconnec t CN319. 5 Remove the d uplex paper pa[...]

Options 8-1 Chapter 8 Options Section 6 T roubleshooting[...]

8-2 Optio ns Contents Options Introduct ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 1200-Shee t/2500-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Bench Test Pro cedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Options 8-3 Introduction This sec tion provi des info rmation about spec ific pr inter opt ions no t covered elsewhere in the ma nual. These op tions incl ude the 12 00-shee t and 2500-s heet f eeder s, the 1400-s hee t stacker , and the en hanced vide o model of t he printe r . For a complete list of the part s contained i n the 1200-shee t feeder[...]

8-4 Optio ns 1200-Sheet/250 0-Sheet Feeder Figure 8-1. 1200-Sheet /2500-Sheet Physical Locations T able 8 -1. 1200-Sheet/2 500-Sheet Component Acronyms Acronym Component DSW Door Switch (magnetic doo r lock) IEM Input E levator Mo tor (M1 – el evator moto r) ILLS Input Lower Li mit Sensor IPES Inp ut Paper T ray Sensor IPM Inp ut Pick-up Mo tor ([...]

Options 8-5 Bench T est Procedure The bench t est procedur e referenc es the compon ent acronyms i n Table 8-1 on page 8-4 and the c omponent locations i n Figur e 8-1 on page 8-4 . T o be nch te st the printe r : 1 T urn the print er ’ s main power switch of f, then di sconnect the unit ’ s power cor d. 2 Press down the print er ’ s lower ca[...]

8-6 Optio ns sor IPES s ignals t he input c ontrol boa rd tha t paper is pr esent on t he ele vator . Photo- sensor I ULS signals the i nput contro l board t hat the u pper limit for the paper suppl y tray an d paper st ack has been reach ed. 7 W ith the paper supply tray all the way up a nd with no pa per prese nt on the s lope tra y (indic ated t[...]

Options 8-7 Input Control Board Logic The tabl e below indi cates swi tching l ogic for t he unit’ s various component s. Except f or the power control s witch (PCSW), each compo nent ca n be monitor ed from the various pins of CN508 (loc ated on th e input co ntrol boa rd). When perfor ming these checks, use t est point TP 1 (located below CN507[...]

8-8 Options Figure 8-4. Connection Diagram for 1200-Sheet/2500-Sheet Feede r NPS PHS ILLS PES IULS IPES DSW IEM IPM J529 W514 P530 P529 W507 J509 P509 P512 P513 P514 P515 J5 00 P500 M 1 M 2 P518 P519 J518 J519 W510 PCSW SW2 P508 P507 W508 J400 + 12Vdc P527 P528 J506 W506 P506 Gnd Input Cont rol Board Power Supply J600 W520 P522 W505 NF P523 PH-1 AC[...]

Options 8-9 1400-Sheet S tacker Figure 8 -5. 1400-Sheet S tacker Component Locations T able 8-3. 1400-Sheet Stacker Component Acronyms Acronym Component ERM Exi t Roller Moto r (M1) EPS Exi t Paper Sens or ERS Exit R oller Sensor OEM O ut Elevator Motor (M2) OELS Out E levator Limi t Sensor OEPS Ou t Exit Paper Sens or OJFM Out Jogging Front Moto r[...]

8-10 Op tions Bench T est Procedure The bench t est procedur e referenc es the compon ent acronyms i n Table 8-3 on page 8-9 and the c omponent locations i n Figur e 8-5 on page 8-9 . Figure 8-6. 1400-Sheet St ack er Bench T est Pre p ar ation T o bench tes t the 1400 -sheet st acker: 1 T urn th e printe r ’ s ma in powe r swi tc h off. 2 Remo ve[...]

Options 8-11 7 Place a j umper from pin 9 to pin 10 ( ground). Using the print er ’ s power cor d in place of the unit’ s power cord, plug the printer’ s power cord in the stacker uni t, then into the wall out let. 8 W ith the power ap plied to the stack er uni t, the exi t roller mo tor (ERM -M1) will be off. This will si gnal th e outp ut c[...]

8-12 Op tions Connector Locations Figure 8-7. Connector Locations (front view , cover removed) Connector s/circu it boards shown with b roken line s are conc ealed fr om view . Figure 8-8. Connector Locations (left side view , left cover removed) CN416 Printer s ide CN409 CN426 CN4 25 CN405 CN406 CN401 CN404 CN402 CN403 CN412 Fuse 1 Fuse 2 Power su[...]

Options 8-13 Figure 8 -9. Rear Side View (cover removed) Connector s/circu it boards shown with b roken line s are conc ealed fr om view . Figure 8 -10. T op View (top cover removed) CN415 Printer side Output sid e CN4 24 (A C po wer) CN420 (Co ntrol conne ctor plu g) CN413 CN419 CN414 CN408 CN407 Printe r side Output s ide[...]

8-14 Op tions Output Control Board Logic The tabl e below det ails spec ific st acker act ions a nd which sen sors suppl y the sig nals needed f or each action. Signa ls fr om the prin ter are a lso incl uded. T able 8 -4. St ack er Actions and Sensor Inputs Action Sensor Input Elevato r up (W ait signal to print er) OULS OLLS OELS Elevato r stop O[...]

Options 8-15 Figure 8-1 1. Connection Diagram for the 1400-Sheet St acke r OULS ERM P407 M 1 J41 Outpu t Contr ol Board PH-1 12V Power Supply OEM M 2 J41 OJRM M 3 J41 OJFM M 4 J41 OELS P412 S-1 OLLS P408 S-2 OEPS P409 S-3 W5 P419 J419 W- P403 P402 P404 J404 J402 J403 J406 J405 J401 P401 P420 W2 P406 W7 P425 P426 OJFS S-5 OJRS S-6 AC 100 ~ 240V P424[...]

8-16 Op tions[...]

Gener al Pri nter Mai nten ance 9-1 Chapter 9 General Printer Maintenance Section 7 T roubleshooting[...]

9-2 General Pri nter Main tenance Contents General P rinter Maintena nce Introduct ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Every-Call Cleaning Procedur e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Adjusting Pa per Feed Tension . . [...]

Introduction Gener al Pri nter Mai nten ance 9-3 General P rinter Maintena nce Introduction This sec tion descri bes t he pri mary print er main tenan ce pro cedure s to be comp leted durin g servic e calls. I n additi on, this i ntroduct ion re views safe ty precau tions, tool requ irements, and th e print er main te nance r ecord . Ever y- Ca ll [...]

Introduction 9-4 General Pri nter Main tenance • Do not push object s of any ki nd through the cabin et slots . They may c ontact da nger- ous volt age points or other hazards. • Do not expose the printer to liqui ds of any ki nd. • Protect the power cord. Do not pla ce it i n a traf fic patter n or all ow anythin g to rest on it. T ool Requi[...]

Introduction Genera l Printe r Mainten ance 9-5 HISTORY LOG To Be Completed By User To Be Completed By HP Page Counte r Operator HP Not ified Date/Time Down-Time HP Cu stomer Enginee r On Site Date Time Malfunc tion Descrip tion: Action Requ ired and Co mments: Malfun ction D es cripti on: Malfun ction D es cripti on: Action Requ ired and Co mments[...]

Introduction 9-6 General Pri nter Main tenance Every-Call Cleaning Proced ure Perform t he every- call cle aning proc edure every time the printer is servi ced. When trou- bleshoot ing a pri nter prob lem, you may be direct ed to complete this proced ure as you iso- late o r corr ect the pr oblem. I f the proce dure i s not speci fica lly c alled o[...]

Introduction Gener al Pri nter Mai nten ance 9-7 Clean the Developer Unit • Inspect the un it for da mage or cont amination; repair or repla ce as neces sary . • Clean any excess to ner fr om the devel oper unit with a sof t cloth. • Clean the tone r patch se nsor le ns wi th a sof t cl ot h, maki ng s u re no li nt re ma ins on t he lens. ?[...]

Introduction 9-8 General Pri nter Main tenance Adjusting Paper Feed T ension Printers With P aper T ension Levers Rece ntly re lease d simpl ex and duplex printe rs hav e press ure tens ion le vers in side th e fron t cover , as illustrat ed in Figur e 9-1, Pape r Feed T ensio n Levers, be low: Figure 9-1. Paper Feed T ension Levers T o adjust t he[...]

Introduction Gener al Pri nter Mai nten ance 9-9 Printe rs With Pic k Pressur e Adjust ers Older simpl ex and dup lex print ers have two pi ck pr es sur e adj us ter s i n si de t he f ron t cov er , behind t he casset te relea se cover i llustr ated belo w . T o adjust pick p ressure i n these pr int- ers : 1 Open th e prin ter ’ s fro n t cove [...]

Introduction 9-10 General Printe r Maintena nce This rev eals the pick pr essure ad justers, illust rated in Figure 9-3 , Paper P ick Press ure Adjuster s, below: Figure 9-3. Paper Pick Pressure Adjusters 3 T o adjust paper pic k ten sion for t he upper cass ette, ident ify the adjust er c orres pond ing to that cassett e, then: • T o decreas e t[...]

Introduction Gener al Pri nter Mai nten ance 9-11 Lubr ic a ti o n Proc edur e Complete t he lubri cation pr ocedure as -needed. Appl y lubric ation spa ringly . Insuf ficient lubric ation may result in unnec essar y noise and premat ure wear of compone nts; ex cessi ve lubric ation may co ntamina te print er suppli es and ma ke the pri nter dif fi[...]

Introduction 9-12 General Printe r Maintena nce Figure 9-4. Front V iew Lubrication Point s[...]

Introduction Gener al Pri nter Mai nten ance 9-13 Front V iew Lubrication T ables Duplex Only T able 9-1. All Printers – Front View Lubrication Symbol Part Lubricant H 1 Front roller be arings (paper feed, paper pic kup, timing and exit rollers) oil H 2 V a cuum tra nsport dri ve shaft oil H 3 Fuser drive bear ing oil H 4 Upper paper guide roll e[...]

Introduction 9-14 General Printe r Maintena nce Figure 9-5. Rear View Lubrication[...]

Introduction Gener al Pri nter Mai nten ance 9-15 Rear V iew Lubrication T ables Duplex Only T able 9-3. All Printers – Re ar View Lubrication Symbol Part Lubricant H 1 Clutc h shafts: upper pick-u p roller , lower pi ck-up r oller , upper fee d roller , lower feed r oller , paper timing rolle r oil P 2 Upper and lower pick-up roller driv e assem[...]

Introduction 9-16 General Printe r Maintena nce Figure 9-6. Duplex Only: T op View Lubrication T able 9 -5. Duplex T op View Lubrication Symbol Part Lubricant H 1 Dup lex pinch r ollers oil[...]

Introduction Gener al Pri nter Mai nten ance 9-17 Figure 9 -7. Duplex Only: Duplex Holding T r ay Lubrication T able 9-6. Duplex Front View Lubrication Symbol Part Lubricant P 9 Drive g ears M olycote L 1 0 T ray shaft red grease[...]

Introduction 9-18 General Printe r Maintena nce Tune-Up Maintenance Procedur e The tune- up maintena nce proced ure sho uld be per formed when t he printe r: jams fre- quently ; yields sub-stand ard print quality even afte r completi ng reg ular maint enance pro - cedures ; and has pr inted more than o ne- or two- million pri nts. At this poin t in[...]

Introduction Gener al Pri nter Mai nten ance 9-19 Figure 9 -8. T une-Up Kit Component s 7 Replace t he component assemblie s in th is order : • Paper ti ming ro ller • Exit r oller • Upper pic k up rol ler • Low er pic k u p roll er • Upper feed roll er • Lower fee d roller • T ransfer ch arg er • Low er stat ic brush • Uppe r sta[...]

Introduction 9-20 General Printe r Maintena nce[...]

Abbrevia tions and Acronyms A-1 Appendix A Abbreviations and Acronyms ACIA . . . . . . . . . Asynchronous Communication Inte rface Adap ter ALU . . . . . . . . . . Arithmetic Logic Unit AP A . . . . . . . . . . All Points Addressa ble ARC . . . . . . . . . . “A ” Rolle r Clut ch (Duplex on ly) ARIF . . . . . . . . . . Array Interfa ce A TC . . [...]

A-2 Abbrevia tions and Acronyms MCH . . . . . . . . . .Main Cha rger Unit MCS . . . . . . . . . .Main Char ger Sensor MIGS . . . . . . . . .Minter Image Gener ation System MPU . . . . . . . . . .Micro Process ing Unit MUX . . . . . . . . . .Multiplexer OPC. . . . . . . . . . .Organic Photoc onductor OPPNL . . . . . . . .Opera tor Panel PC . . . . .[...]

Index Index-1 A "A" roller removal 7- 96 abbreviations A-1 AC power malfunctions 3-118 AC power supply removal 7-29 acronyms A-1 add toner indicator problems 3-51 B "B" roller removal 7-97 back cover connectors 6-11 removal 7-6 back cover interlock switch removal 7-81 basic troubleshooting 3-5 belts removing cleaner drive 7-54 r[...]

Index-2 removal 7-26 counter malfunctions 3-140 problems 2-13 removal 7-20 testing 5-7 covers removing back 7-6 removing EP 7-8 4 removing exit 7-74 , 7-76 removing front 7-5 removing front duplex 7-18 removing left side 7-8 removing lower back 7-7 removing rear duplex 7-17 removing right side 7-9 , 7-10 removing top 7-14 cross reference s error co[...]

Index-3 removal 7-92 duplex tray paper guide motor testing 5-17 duplex tray registration motor removal 7-91 E EIGS program RAM testing 5-22 EIGS/MIGS bit map testing 5-23 envelope fuser solenoid testing 5-19 envelope tray latch problems 3-21 problems 3-14 EP cover removal 7-84 erase l amp malfunctions 3-65 removal 7-83 testing 5-12 error code /TAG [...]

Index-4 overriding 1-22 top cover 3-192 J job offset assembly problems 3-75 removal 7-66 jogging motor testing 5-8 jogging motor control board removal 7-39 jumpers signal interface board 6-30 L left side cover connectors 6-7 removal 7-8 locating connectors 6-6 lower back cover removal 7-7 lower cassette latch problems 3-24 paper jams/ misfeeds 3-30[...]

Index-5 paper exit sensor removal 7-78 paper feed drive belt removal 7-58 paper feed tension adjusting 9-8 paper full sensor removal 7-79 paper handling problems 2-13 paper inp ut timing problems 3-41 paper jams duplex area 3-198 fuser area 3-34 lower cassette 3-30 output area 3-39 transfer ar ea 3-34 upper cassette 3-26 paper output timi ng proble[...]

Index-6 smearing 2-11 uneven print density 2-11 , 3-180 varying print density example 4- 20 voids example 4- 9 voids or white spots 3-158 washout example 4-5 white spots example 4- 9 wrinkle example 4-23 print quality/TAG cross refe rence 2-9 printer operation 1-3 printhead ass embly malfunctions 3-191 removal 7-23 testing 5-24 problem resolution 3[...]

Index-7 too light 3-49 toner supply motor testing 5-9 tool kit 9-4 top cover connectors 6-10 removal 7-14 top cover hinge removal 7-16 top cover interlock switch removal 7-82 top cover support removal 7-15 transfer charger circuit problems 3-58 , 3-63 testing 5-11 troubleshooting analysis guide (TAG) 1-19 tune-up maintenance procedure 9-18 U upper [...]