Home

HP C30D User's Manual

1. Acronym Component DSW Door Switch magnetic door lock IEM Input Elevator Motor M1 elevator motor ILLS Input Lower Limit Sensor IPES Input Paper Tray Sensor IPM Input Pick up Motor M2 paper pick up motor IULS Input Upper Limit Sensor NF AC Noise Filter NPS No Paper Solenoid PCSW Power Control Switch slope tray interlock switch PES Paper End Sensor PHS Paper Head Sensor SOL Solenoid uS Bear side M1 IEM Sn NF Input zu IULS control board PES Door val PHS M2 IPM IPES Power supply T d Front side Figure 8 1 1200 Sheet 2500 Sheet Physical Locations 84 SOL Printer side PCSW Options Bench Test Procedure The bench test procedure references the component acronyms in Table 8 1 on page 8 4 and the component locations in Figure 8 1 on page 8 4 To bench test the printer 1 Turn the printer s main power switch off then disconnect the unit s power cord 2 Press down the printer s lower cassette release lever then remove the unit from the printer and place it on a work bench or other suitable surface 3 Remove the paper size lever then lift up the slope tray and place the lever between the slope tray and the frame This will bypass the interlock switch PCSW located under the slope tray allowing 12 Vdc to be applied to the input control board Note The slope t
2. Connector Page aa Connector Page seca J P 82 6 6 simplex duplex A4 J P 315 6 8 duplex E2 J P 83 6 14 simplex duplex E5 J P 316 6 8 duplex E2 J P 84 6 14 simplex duplex E6 J P 317 6 9 duplex D2 J P 85 6 14 simplex duplex B6 J P 318 6 6 duplex F1 J P 87 6 11 simplex duplex C8 J P 319 6 8 duplex F2 J P 90 6 15 simplex duplex B9 J P 320 6 10 duplex G2 J P 91 6 11 simplex duplex C8 J P 321 6 10 duplex G2 J P 94 6 15 simplex duplex B8 J P 322 6 10 duplex F2 J P 95 6 6 simplex duplex C3 J P 323 6 15 duplex D3 J P 96 6 15 simplex duplex C5 J P 324 6 15 duplex E3 J P 100 6 15 simplex duplex D4 J P 330 6 15 simplex duplex E8 J P 101 6 15 simplex duplex D3 J P 331 6 15 duplex D3 J P 102 6 15 simplex duplex C4 J P 333 6 15 simplex duplex A8 J P 119 6 7 simplex duplex C9 simplex duplex D2 J P 120 6 7 simplex duplex C9 J P 500 6 15 simplex duplex A8 J P 121 6 15 simplex duplex B6 J P 800 6 15 simplex duplex E5 J P 122 6 15 simplex duplex B6 J P 124 6 15 simplex duplex B6 J P 127 6 7 simplex duplex C9 J P 128 6 7 simplex duplex C9 J P 131 6 10 simplex duplex E6 J P 132 6 10 simplex duplex E6 J P 139 6 15 simplex duplex B6 J P 140 6 15 simplex duplex B6 J P 143 6 15 simplex duplex B6 J P 251 6 15 simplex duplex B5 J P 252 6 15 simplex duplex B5 J P 255 6 15 simplex duplex A5 J P 305 6 10 duplex E3 J P 306 6 8 duplex E2 J P 307 6 8 duplex E
3. Code PCL Error Code Meaning Go to TAG 160 PCL board PIA1 register error after reset 100 161 PCL board PIA1 registers read write error 100 162 PCL board PIA1 PA or PB read write error 100 170 PCL board PIA register error after reset 100 171 PCL board PIA2 register read write error 100 172 PCL board PIA2 PB read write error 100 180 PCL board PTM register error after reset 100 181 PCL board PTM read write error 100 182 No IRQ generation on PTM 100 Table 2 4 PCL IGS Communication Error Codes Code PCL IGS Communication Error Code Meaning Go to TAG 199 VSS not asserted before communication test 201 200 Status tag not asserted 201 201 Timeout waiting for a failed IGS controller 201 202 No data received after VSS line asserted 201 203 VSS asserted after PCL board sent status 201 204 Status tag asserted after VSS not asserted 201 205 No command tag after status tag not asserted 201 206 VSC command not asserted after command tag asserted 201 207 No data received after VSC asserted 201 208 VSC command asserted after command line asserted 201 209 Command tag asserted after VSC not asserted 201 210 No RQI after request RQI command 201 211 Parity error on command line 201 212 Parity or overrun sensed by PCL board 201 213 Incorrect command received from PCL board 201 214 Incorrect command received from IGS controller 201 215 No transfer buffer empty on asynchronous communication
4. J P 321 2 G J P 322 OG J P 305 2 s CO 9 6 10 Wiring Diagrams and Electrical Data J P 31 J P 32 J P 33 J P 36 J P 37 2 Connectors on the Back Cover HARA N ARTAN E TA 4 6 81012141618 2022242628 30 3234 36 38 40 42 44 46 48 50 52 54 56 58 60 6 6 6 6 O6 6 6 6 6 6 e eeeeeseeseensveeeeeeeeeeeeeeeeeeee I 1 3 5 7 9 11131517 19 2123 2527 29 313335 37 3941 4345 47 49 51 53 55 5759 11 10 9 8 7 J P 74 6 5 4 3 2 1 1513 119 7 5 3 1 eeccc060090 J P 76 e e2e2ee eee I 1 I 1 16141210 8 6 4 2 19 17 15 13 7 5 3 1 20 18 16 14 12 10 8 6 4 2 15 13 11 5 3 1 16 14 12 10 8 6 4 2 2 4 6 8 1012 14 16 18 20 22 24 26 28 30 32 34 36 38 40 1 3 5 7 9 1113 15 17 19 21 23 25 27 29 31 33 35 37 39 2 4 6 81012141618 20222426 28 30 3234 36 38 4042 444648 50 SE SE 9 9 9 9
5. yes 3 B 3 3 5 8 J P 56 58 60 62 Connectors Inside the Back Cover Continued J P 64 85 Ew Pl 1 24 LJ 28 ug es 68 a3 67 19 fs as 84 e2 252 Jogging Mot E us E Beard EEA m EJE Signal Interface ias Board psv Control Board J P 77 4 3 2 1 34 e e 33 J P 64 t B Bm glee ede 7 v 30 e e 29 28 e 27 260 e e 25 J P 65 66 67 68 69 70 24 e e z3 J P 79 SE tibl es 20 e Ms 18 e e 17 13 1211 109 8 7 6 5 4 3 2 1 16 e e 15 pue SOOOOO OOVOO OO 14 9 e 118 m 12 e 11 97 OOOO00000000 asus fj heals 25 24 23 22 21 20 19 18 17 16 15 14 8 ee 7 6 e oe 5 8 76 5 4 3 21 4 e 3 C 2 J P 72 OQODOOOOCO CQ nl i Rei dO CHOQDUODO vesa Sp 15 14 13 12 11 10 9 5 4 3 2 1 c4 ee JP7233 OOOOO n 5 DC OOOOQ JP85 Hollol eal 7I el sI al sI 2l 9 8 7 6 6 14 Wiring Diagrams and Electrical Data Connectors Inside the Back Cover Continued J P 90 800
6. gt uo 4 ees 7 79 Removal Replacement Procedures Front Cover Interlock Switch Removal Front Cover Interlock Switch Removal To remove the front cover interlock switch Open the front top and back covers Duplex only Remove the duplex tray Remove the upper and lower paper cassettes Remove the left side cover See page 7 8 Remove the AC power supply See page 7 29 Remove the AC power supply top cover two screws Disconnect the two wires connected to the interlock switch ON Oat WD a Remove the front interlock switch two screws 7 80 Removal Replacement Procedures Back Cover Interlock Switch Removal Back Cover Interlock Switch Removal To remove the back cover interlock switch Open the front top and back covers Duplex only Remove the duplex tray Remove the upper and lower paper cassettes Remove the left side cover See page 7 8 Remove the AC power supply See page 7 29 Remove the AC power supply side cover one screw Disconnect the four wires connected to the interlock switch ON Oat WD a Remove the back cover interlock switch two screws AC Power Supply Removal Replacement Procedures 7 81 Top Cover Interlock Switch Removal Top Cover Interlock Switch Removal To remove the top cover interlock switch Open the top front and back covers Duplex only Remove the duplex tray Remove the upper and lower paper cassettes Remove the left side
7. o N Oo Duplex only Remove the duplex fan See page 7 27 9 Remove the four screws holding the EP cover in place two front and two back 10 Remove the upper right screw holding the fuser drive in place 11 Lift the EP cover straight up and out of the printer Replacement Note The higher of the two drive shaft support arms should be facing the left side of the printer Support Screw Fuser Drive Screw Fuser Drive Cover EP Cover Screws Back Detail Removal Replacement Procedures 7 85 Main Motor Removal Main Motor Removal Caution Do not allow the capacitor contacts to short out against your body or the printer frame To remove the main motor Disconnect all external cables and attachments Open the front back and top covers Remove the photoconductor and place it in its protective packaging Remove the cleaner unit Remove the back cover See page 7 6 Remove the lower back cover See page 7 7 o0 FB OND Remove the signal interface board See page 7 37 Drive Shaft Key Main Motor Gear Gear Stay Cover hm Gear Stay Fuser Drive Cover Back Detail 7 86 Removal Replacement Procedures Main Motor Removal 8 Remove the right side cover See page 7 9 9 Remove the counter See page 7 20 10 Remove the main drive cover one screw 11 Remove the fuser drive cover three screws 12 Remove the gear stay cover 13 Remove the gear stay three
8. 6 29 Circuit Board S ttingS a 6 ins cede RAO oe EAR APER ae EA see hee 6 30 Signal Interface Board Settings 2e 6 30 PCL Board Settings 1 osi mo noe eben o Eel oboe ies 6 31 Printhead Circuit Board Settings 0 0 0 cece eens 6 31 Removal Replacement Procedures CONTENTS ice dd eio Aa ae op eee Raw ak eed xaee aen Dee ee diede iss 7 2 Rermoxdl esent s tat SD 11x cut du cte M Bela el SNA Dads chal DE at 7 4 Before You Begin te vt odd ob ee Rae Go td all viae ta deos a o 7 4 Power Considerations 0 20 a eai cece a O E nen ene neas 7 4 Photoconductor Removal 0 0 0 0 cece eee e 7 4 Front Cover Removal aca v use M oh ee ges ea E ia RC Ee 7 5 Back Cover Removal n o uso eo e re ears ow eae ee oy Hee SSNs GER E 7 6 Lower Back Cover Removal a ore ove eee E iced owe re es 7 7 Lett Side Gover Removal oc cose bee ova tae en Ge aw eae tae ES 7 8 Right Side Cover Removal Simplex 0 0 0 ee eee eee eee eee 7 9 Right Side Cover Removal Duplex 0 cece ee eee nee 7 10 Vacuum Transport Unit Removal Simplex 0 0 0 7 11 Vacuum Transport Unit Removal Duplex 0 0 0 0 ee eee eee 7 13 Top Cover Removal ore des vet ah uh AR P RH IR RR at SA A oe wa ee 7 14 Top Cover Support Removal 1 oi lp EA RREER RENE 7 15 Top Cover Hinge Removal ssa css Xx X EXAM a aR ee ME ESE CHR 7 16 Rear Duplex Cover Removal 0 0 eee e cece eee eee 7 17 Front DuplexCover Removal
9. 9999 99906 999999999999999 99 I 1 1 1 3 5 7 9 11131517 19212325 27 29 313335 37 3941 43 45 47 49 J P 87 1513 119 7 5 31 EE EE E EE EE EE EE eeeoeeee 9 7 D 161412108 64 2 J P 91 1 4 6 8101214 1618 20 2224 2628 30 3234 36 38 404244 46 48 50 J P 40 41 3579 Wiring Diagrams and Electrical Data Ll 1517 19 21232527 29313335 H 41 434547 49 6 11 Connectors Inside the Back Cover J P2 14 BL 1 Jogging Motor Control Board 3 24 EJ g eB 7143 67 19 Fal 5 285 30 96 T 50 331 Signal Interface 5i 25 Board 10 1 J P 8 J P 2 3 11 2 12
10. Turn the printer on e Check J319 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 amp Problem Resolution Yes Continue 6 Check J319 2 for 12 Vdc Is the voltage 12 Vdc No Repair or replace the wiring or connectors from P309 2 to J319 2 then turn to TAG 002 Check amp Problem Resolution Yes Replace the paper pass sensor then turn to TAG 002 Check amp Problem Resolution 7 Turn the printer on Run diagnostic test 018 Is the A roller clutch in good working order No Continue Yes Go to 10 in this TAG 8 Turn the printer off e Disconnect J P308 Turn the printer on Check J308 3 on the duplex control board 1 for 24 Vdc Is the voltage 24 Vdc No Replace duplex control board 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue 9 Turn the printer off e Reconnect J P308 e Disconnect J P316 Turn the printer on e Check P316 1 for 24 Vdc Is the voltage 24 Vdc No Repair or replace the wiring or connectors from P308 3 to J316 1 then turn to TAG 002 Check amp Problem Resolution Yes Replace the A roller clutch then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 199 10 11 12 13 14 15 3 200 Turn the printer on Run diagnostic test 018 Is the input solenoid in good working order No Contin
11. Unplug power cord from the printer and the wall outlet e Check the power cord for continuity Is there continuity No Replace the power cord then turn to TAG 002 Check amp Problem Resolution Yes Replace the AC power supply then turn to TAG 002 Check amp Problem Resolution Disconnect J P4 e Check P4 1 for continuity to ground Is there continuity No Go to 30 in this TAG Yes Continue Remove the fuser unit Check P4 1 to J P44 3 to J5 1 to the fuser unit for continuity to ground Is there continuity No Replace the fuser unit making sure the fuser has the proper voltage rating then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace connectors or wiring that have continuity then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 123 30 31 32 33 34 35 36 3 124 Check J4 1 at the AC power supply unit for continuity to ground Is there continuity No Continue Yes Replace the AC power supply unit then turn to TAG 002 Check amp Problem Resolution Check P4 7 for continuity to ground Is there continuity No Go to 33 in this TAG Yes Continue Disconnect J P6 Check P4 7 to P6 1 for continuity to ground Is there continuity No Replace the DC power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P4 7 to P6 1 then turn to TAG 002
12. While supporting the back cover lift the lower back cover out and away from the printer 6 Return the back cover to its hinges Loosen Screws WA mm emen ne A aG 52 YN cd ANN I dtf Removal Replacement Procedures 7 7 Left Side Cover Removal Left Side Cover Removal To remove the left side cover Open the top back and front covers 2 Duplex only Remove the duplex tray by disconnecting P305 and loosening the two thumb screws Remove the upper and lower paper cassettes Loosen the two screws for the left side cover Lift the cover up and away from the printer Replacement Note When reinstalling make sure the inside mounting tabs are properly positioned Loosen Screws 7 8 Removal Replacement Procedures Right Side Cover Removal Simplex Right Side Cover Removal Simplex Note The service kit is attached inside the right side cover To remove the right side cover Remove the paper output tray Open the top and front covers Loosen the two screws holding the right side cover b amp b WO N 2a Pull the cover out and away from the printer Replacement Note When reinstalling make sure the inside mounting tabs are properly positioned Loosen Screws KAN M 1 AO ANN Service Kit Removal Replacement Procedures 7 9 Right Side Cover Removal Duplex Right Side Cover Removal Duplex Note The service kit is attached inside the right side cove
13. slsseeee BB 5 24 111 LED Printhead Test ululueeeeeeeeeeee eee 5 24 112 Disk Drive Test Single Loop With Stop on Error 0004 5 25 113 Disk Drive Test Continuous Loop 00 cee e 5 26 Diagnostic Tests How to Run Diagnostics Diagnostic Tests This section provides step by step instructions for running each of the diagnostic tests available through the self diagnostic mode of the printer Each test is referenced by num ber Check the contents page to find the page on which a specific test is described How to Run Diagnostics Follow these steps to access the self diagnostic mode of the printer 1 2 Turn off the printer and wait five seconds Hold down the STOP and TEST keys simultaneously as you turn the printer back on Continue to hold the keys down until O appears on the display The STANDBY light flashes as the printer accesses its soft diagnostic mode which takes approximately 1 minute The tone followed by 001 on the display indicates you can now run a test Change the counter to the number of the test you wish to run by pressing CANCEL to increase the counter or TEST to decrease the counter If you press these keys before a test is complete a long tone sounds and the test continues without interruption Press READY to run the test Press STOP to end the test in most cases see specific diagnostic procedures for direc tions on exiting a test To exit diagnostic m
14. 5 Reconnect the main charger high voltage lead e Disconnect P23 and J P41 Check J P41 34 to P23 6 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 34 to P23 6 then turn to TAG 002 Check amp Problem Resolution Yes Continue 6 Check P41 35 to P23 5 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 35 to P23 5 Yes Replace the high voltage unit If this corrects the problem turn to TAG 002 Check amp Problem Resolution If this does not correct the problem replace the PCL board then turn to TAG 002 Check amp Problem Resolution 3 62 Troubleshooting Analysis Guide TAGs TAG 050 Transfer Charger Circuit Shorted Error Code 050 Possible Defects Transfer charger High voltage unit Connectors or wiring PCL board Upper paper guide assembly 1 Turn the printer off and unplug the power cord Verify that J P23 J P41 and the transfer charger high voltage unit lead are connected properly e Power on reset the printer Runtest prints Is error code 050 displayed No A loose connector was at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue 2 Turn the printer off and unplug the power cord Remove and clean the transfer charger housing and contacts e Check between the two terminals on the back of the transfer charger for continuity Is there continuity No Continue Yes Repair or replace t
15. CN405 CN406 CN401 Output control pee board Front side CN404 G CN402 CN403 N CN412 Figure 8 8 Connector Locations left side view left cover removed Options 1 Output side Printer side OM CN415 n CN424 AC power eS CN420 Control connector plug Figure 8 9 Rear Side View cover removed Connectors circuit boards shown with broken lines are concealed from view CN413 CN419 m Printer side Output side e CN44 4 Lo CN407 CN408 Figure 8 10 Top View top cover removed Options 8 13 8 14 Output Control Board Logic The table below details specific stacker actions and which sensors supply the signals needed for each action Signals from the printer are also included Table 8 4 Stacker Actions and Sensor Inputs Action Sensor Input Elevator up OULS Wait signal to printer OLLS OELS Elevator stop OULS OLLS OELS Remove prints OULS signal to printer OLLS OELS Elevator down OULS OLLS OELS Paper exit EPS OEPS Paper exit jam 023 OEPS Jogging start From printer Jogging ERS from printer OJRS OEPS OJFS Jogging stop From printer Options suondo 81 8 JBYIEIS 199uS 00r y 10 WesBeIG uonoeuuo2
16. Check P42 18 to P41 3 for continuity Is there continuity No Repair or replace the connectors or wiring from P42 18 to J P90 18 to P41 3 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P41 3 to P42 18 for continuity to ground Is there continuity No Continue Yes Repair or replace the connectors or wiring from P42 18 to J P90 18 to P41 3 then turn to TAG 002 Check amp Problem Resolution Check P42 17 to P41 4 for continuity Is there continuity No Repair or replace the connectors or wiring from P42 17 to J P90 17 to P41 4 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P41 4 to P42 17 for continuity to ground Is there continuity No Continue Yes Repair or replace the connectors or wiring from P42 17 to J P90 17 to P41 4 then turn to TAG 002 Check amp Problem Resolution Check P42 16 to P41 5 for continuity Is there continuity No Repair or replace the connectors or wiring from P42 16 to J P90 16 to P41 5 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P41 5 to P42 16 for continuity to ground Is there continuity No Continue Yes Repair or replace the connectors or wiring from P42 16 to J P90 16 to P41 5 then turn to TAG 002 Check amp Problem Resolution Check P42 15 to P41 6 for continuity Is there continuity No Repair or replace the connectors or wiring from P42 15 to J P90 15 to P41 6
17. TAG 754 Attachment Option Malfunction Error Code 754 Symptoms Job fails only when an attachment option is used Possible Causes Lack of voltage Possible Defects Attachment option Communication cables Cable connectors Signal interface board Signal interface board fuse IGS board Host computer Host interface cable Communication problems may require trial replacement of numerous parts After each trial replacement run the job that exhibited failure 1 Turn off the printer and unplug the power cord e Disconnect all attachment cables Open the back cover and install an interlock by pass tool Confirm that J P8 J P32 and J P74 are connected properly Confirm that the signal interface board DIP switches are set correctly e Reinstall all communication cables e Power on reset the printer e Confirm that the printer has been correctly configured using the printer s soft configuration mode Runthe failing job Has the problem been resolved No Continue Yes Loose or damaged connectors software configuration or DIP switches were at fault Turn to TAG 002 Check amp Problem Resolution 2 Turn the printer off and unplug the power cord Check the signal interface board fuse for continuity Does the fuse have continuity No Continue Yes Go to 5 in this TAG 3 Disconnect the cables from the attachment option to the printer Replace the signal interface board fuse Turn on the printer for five seco
18. Troubleshooting Analysis Guide TAGs 15 Reconnect J P9 Install a good upper fuse in the AC power supply unit e Disconnect J P13 and J P14 Turn the printer on for 5 seconds then off Remove the fuse e Check the fuse for continuity Does the fuse have continuity No Replace the power control 2 board then turn to TAG 002 Check amp Problem Resolu tion Yes Continue 16 Reconnect J P13 and J P14 e Disconnect J P20 J P21 J P22 and J P326 duplex printers e Power on reset the printer Wait 2 1 2 minutes then turn the printer off Remove the upper fuse in the AC power supply unit e Check the fuse for continuity Does the fuse have continuity No Repair or replace connectors or wiring that have continuity to ground P21 1 to P13 4 P22 1 to P13 6 J326 1 to P13 4 or P20 2 to P14 6 then turn to TAG 002 Check amp Problem Resolution Yes Continue 17 Turn the printer off e Reconnect J P21 Turn the printer on for 5 seconds then off Remove the upper fuse in the AC power supply unit e Check the fuse for continuity Does the fuse have continuity No Replace the large cooling fan assembly then turn to TAG 002 Check amp Problem Resolu tion Yes Continue 18 Turn the printer off e Reconnect J P20 Turn the printer on for 2 1 2 minutes then off Remove the upper fuse from the AC power supply unit e Check the fuse for continuity Does the fuse have continuity No Repl
19. Troubleshooting Analysis Guide TAGs 26 Turn the printer off and unplug the power cord Replace the printhead assembly unit e Power on reset the printer Runtest prints Has the problem been resolved No Reinstall the original printhead assembly unit and continue Yes Turn to TAG 002 Check amp Problem Resolution 27 Turn the printer off and unplug the power cord e Replace the IGS board e Power on reset the printer e Run test prints Has the problem been resolved No Reinstall the original IGS board and go to TAG 800 Prints Blank or With Dark Horizon tal Bands Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 157 TAG 802 Prints With Voids or White Spots Error Code 802 Possible Causes Wrong weight or type of paper loaded Possible Defects Photoconductor unit Developer unit 1 Perform the every call cleaning procedure e Confirm that the paper in the cassettes meets paper specifications outlined in the Guide to Operations manual Turn the printer on e Run test prints Has the problem been resolved No Continue Yes Contamination was at fault Turn to TAG 002 Check amp Problem Resolution 2 Check the voltages as outlined in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Have the photoconduc
20. Upper Paper Size Sensor Lower Paper Size Sensor Pry Slot CN45 Upper Paper Size Sensor Deiail Lower Paper Size Sensor Detail 7 40 Removal Replacement Procedures Upper Cassette Mount Removal Upper Cassette Mount Removal To remove the upper cassette mount 1 Open the front back and top covers 2 Duplex only Remove the duplex tray 3 Remove the upper and lower paper cassettes 4 Remove the left side cover See page 7 8 5 Remove the paper feed drive cover three screws 6 Remove the power control board cover one screw 7 From the back remove the two screws holding the upper cassette mount in place 8 Loosen the CN62 jack and pull it to the back of the printer 9 Disconnect CN62 Power Control Board Cover Back Detail Removal Replacement Procedures 7 41 Upper Cassette Mount Removal 7 42 10 11 12 13 Remove the upper paper size sensor See page 7 40 Remove the cassette release cover two screws Remove the plastic guide on the vertical edge of the printer Depress the tabs visible through the cassette housing Gently turn it and lift from the printer For the tray releases Carefully release the tension spring cable from the pick pressure adjustment lever only on the most recent versions of the printer Remove the spring and cable Remove the upper and lower levers one spring and C clip each Remove the upper and lower cams one screw each Remove the upper and lowe
21. 0123456789 0 283 ABCDEFGHI JKLRNOPQRSTUVWXYZL abcdefghijkisnoperstuvwxyzil pepepepe pap ppap aprapta Figure 4 15 Overtoned Print Description Similar to dark print quality problems Narrow gaps between letters and images may be filled with toner Excess toner may be present on the surface of the print Extra toner can also cause background in the white areas Go to TAG 809 Blurred or Smeared Vertical Streaks on Prints Print Quality Samples Sample 16 Blurred Images or Characters fn Add 444 i a cael 444 444 E m TITTITTITTITTTTTITTTT TTITTITTTTTITITITITT i 4444444 AAA AAA AAA EPROKR A 701234567891 1 25179 ABCDEFGHIJKLMNOPQRSTUVWXYZIN1 abcdefghijkimnoparstuvwxyzii 1 4 4X amp O 012365678911 25 39 ABCDEFGHIJKLMMOPQRSTUYWXYZIN sbedefgnijklanoparstuvyxyz i i Smears pun em LETTER 1 94X amp C t 7 0123456789 1 1 7 T9 ABCDEFBHIJKLMNOPQRSTUVWXYZIN 7 abcdefghijklmnooqrstuvwxyziil 1 84X amp C 9 012345678911 25 ABCDEFGHIJKLMNOPQRSTUVWXYZI abgqefghiikipngpgrstuvwgyg 17 dddddaddaddaddaad 4445 44 444 444A pinnate inept aan neuen neato ets on L m B E B Jf fuse foo jou jp le pfo fen moneo pun Figure 4 16 Blurred Images or Characters Description The images or characters are not clear The lower edges of images and or characters are extended and may appear smeared Go
22. 014 intentionally excluded 018 5 16 Duplex Clutch Test Sequence Go to 018 2 Press READY to run the test The first flipper engages accompanied by a continuous clicking sound and 7 0 appears on the display 3 Press READY to activate the next clutch or flipper Listen for the clicking sound as it engages The number on the display changes to indicate the next clutch or flipper The display codes and the clutch or flipper they represent are listed in the following chart Table 5 18 Duplex Clutch Test Displays Display Indication 7 0 Duplex exit flipper 7 1 Duplex roller clutch A 7 2 Duplex re entry flipper 7 3 Duplex roller C solenoid 4 To check a specific clutch or flipper press READY repeatedly until the code on the display corresponds to the item you want to check Manually activate the sensor Con firm that the display changes when you activate the sensor These codes may indicate specific error conditions Table 5 19 Duplex Clutch Test Error Displays Display Indication 069 Duplex is not installed 090 Cover is open Close cover 5 Press STOP to exit Diagnostic Tests 014 intentionally excluded 019 Duplex Tray Paper Guide Motor Test 1 Goto 019 Press READY to run the test Press READY again The paper guide in the duplex tray moves to and from its home position 4 Confirm that the paper guide in the duplex tray moves back and forth each tim
23. 5 19 023 100 intentionally excluded 101 EIGS MIGS Board Test Select 101 Press READY to run the test If an error is found The error code appears Look up the code in Error Code TAG Cross Reference on page 2 3 to determine which TAG to follow Power on reset to exit 4 fno errors are found The test continues to run After about five minutes press STOP to exit 102 EIGS MIGS Board Test Continuous Loop 1 Goto 102 Press READY to run the test If an error is found The error code is displayed for at least 1 second Look up the code in Error Code TAG Cross Reference on page 2 3 to determine which TAG to follow Ifthe test resumes press STOP to exit if the test does not resume power on reset 4 If noerrors are found The test continues to loop Press STOP to exit 5 20 Diagnostic Tests 103 Communication Loop back Test Single Loop 1 2 Check to make sure the four DIP switches on the signal interface board have been pulled toward the printer s back cover Close the back cover 023 100 intentionally excluded Remove the interface cable from the printer Install the RS 232C and RS 422 loop back connectors found in the tool kit mounted inside the right printer cover If you do not have loop back connectors jumper the connections as outlined in Table 5 24 RS 232 Loopback Connections and Table 5 25 RS 422 Loopback Connec tions Table
24. CN36 C30D only CN33 Retaining Clip 7 22 Removal Replacement Procedures Printhead Assembly Removal Printhead Assembly Removal To remove the printhead assembly Open the front top and back covers Remove the photoconductor unit and place in its protective packaging Remove the cleaner unit Remove the fuser drive cover three screws Remove the main drive cover one screw Remove the gear stay cover one screw Remove the gear stay three screws Disconnect connectors CN27 CN30 and CN96 see back detail oO ON OO A RA O N Remove the two back screws holding the printhead assembly in place Fuser Drive Cover nd PT A Gear Stay Cover Main Drive Cover Back Detail Removal Replacement Procedures 7 23 Printhead Assembly Removal 10 Remove the two front screws holding the printhead assembly in place 11 Pull the printhead assembly from the front of the printer Replacement Note Do not change the DIP switch setting on the replacement printhead circuit board These are set at the factory ah j H ae XO re arm TA n Ny 3 INN Mounting Screws Front Detail Removal Replacement Procedures 7 24 Disk Drive Housing Removal Disk Drive Housing Removal To remove the disk drive housing Open the front and back covers Remove the diskette s Disconnect CN77 and CN79 For the hard drive option disconnect the drive s data cable Lo
25. Check amp Problem Resolution Check J4 7 at the AC power supply unit for continuity to ground Is there continuity No The customer s circuit breaker may be defective Verify that the wall outlet has the proper voltage If it does continue otherwise turn to TAG 002 Check amp Problem Resolution Yes Replace the AC power supply unit then turn to TAG 002 Check amp Problem Resolution Disconnect J P84 e Check P4 5 to P84 1 and P4 6 to P84 2 for continuity Is there continuity on both No Repair or replace the connectors or wiring that lack continuity then turn to TAG 002 Check amp Problem Resolution Yes Continue Check J84 1 to P131 and J84 2 to P132 for continuity Is there continuity on both No Repair or replace the connectors or wiring that lack continuity then turn to TAG 002 Check amp Problem Resolution Yes Continue Check J131 to J132 top interlock switch for continuity while activating the top cover interlock switch Is there continuity No Repair or replace the top cover interlock switch then turn to TAG 002 Check amp Problem Resolution Yes You have failed to isolate the problem Return to the beginning of this TAG Troubleshooting Analysis Guide TAGs TAG 610 Operator Panel Malfunction Error Code 610 Symptoms One or more message indicators will not light Incomplete numbers are displayed Tone does not work properly All status lights remain on One or more function
26. Check the connectors or wiring for the upper paper size sensor Is there a wiring problem No Replace the upper paper size sensor assembly If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring that are defective then turn to TAG 002 Check amp Problem Resolution 8 Turn the printer off and unplug the power cord e Disconnect J P40 and J P43 e Refer to the table at the end of this TAG Check the connectors or wiring for the lower paper size sensor Is there a wiring problem No Replace the lower paper sensor assembly If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring that are defective then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 133 Wiring for the Upper Paper Size Sensor Refer to the following table when performing continuity checks for an open or short to ground for the upper paper size sensor Table 3 2 Wiring for the Upper Paper Size Sensor Wiring Upper Paper Size Sensor P40 41 to J P52 10 to J43 1 to J47 10 to J45 10 P40 42 to J P52 9 to J43 2 to J47 9 to J45 9
27. LVPS Errors 090 PCL board detected that one of the cover interlocks was not acti vated diagnostic test only 097 PCL board detected a signal from the IGS board indicating the absence of 12 Vdc 098 PCL board detected a signal from the IGS board indicating the absence of 12 Vdc 099 PCL board detected a signal from the IGS board indicating the absence of 24 Vdc Controller Errors 100 102 IGS board detected a failure of the PCL board status codes 101 PCL board detected that the IGS board was in a halt state diag nostic test only 121 127 PCL board detected an error in the communication between the PCL board and the IGS board 130 134 PCL board detected an error during the internal diagnostic testing of the PCL board 140 PCL board detected an error during the internal diagnostic testing of the PCL board 145 PCL board detected an error during the internal diagnostic testing of the PCL board 160 182 PCL board detected an error during the internal diagnostic testing of the PCL board 199 215 PCL board detected an error in the communication between the PCL board and the IGS board 301 401 IGS board detected an error during the internal diagnostic testing of the IGS board Printer and Troubleshooting Overview Table 1 1 Error Code Technical Definitions Continued Type Error Description o
28. No Continue Yes Replace the lower feed roller assembly then turn to TAG 002 Check amp Problem Resolu tion 3 96 Troubleshooting Analysis Guide TAGs 20 Turn the printer off e Reconnect J P67 e Disconnect J P68 Turn the printer on Check J P8 13 for 24 Vdc Is the voltage 24 Vdc No Repair or replace the connectors or wiring 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 turn to TAG 002 Check amp Problem Resolution Yes Replace the upper pick up roller assembly then turn to TAG 002 Check amp Problem Res olution 21 Turn the printer off and unplug the power cord e Disconnect J P8 J P11 and J P91 Check P8 11 to P11 1 and P8 13 to P91 1 for continuity to ground Is there continuity No Replace the DC power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P8 13 to P91 1 or P8 11 to P11 1 then turn to TAG 002 Check amp Problem Resolution 22 Turn the printer off e Reconnect J P330 e Disconnect J P323 Turn the printer on Check J P330 1 for 24 Vdc Is the voltage 24 Vdc No Go to 27 in this TAG Yes Continue 23 Turn the printer off e Reconnect J P323 e Disconnect J P305 Turn the printer on Check J P330 1 for 24 Vdc Is the voltage 24 Vdc No Go to 26 in this TAG Yes Continue Troubleshooting Analysis Guide TAGs 3 97
29. S indicating that the toner patch on the photoconductor was too light g 035 PCL board detected too many successive signals from the toner e patch sensor board for a toner feed 036 PCL board detected no developer unit electrical interlock signal from the J25 connector Printer and Troubleshooting Overview Table 1 1 Error Code Technical Definitions Continued Type Error Description OPC Rotation Errors 040 PCL board sensed that the signal from the photoconductor seam sensor either was not of sufficient amplitude or did not show the proper timing 041 PCL board detected an abnormally high amount of current needed to drive the photoconductor seam sensor LED within the photo conductor unit 042 PCL board detected an open connection to the photoconductor seam sensor LED within the photoconductor unit 044 PCL board detected a signal from the high voltage power supply unit indicating that either the main charger or transfer charger cir cuits have an open connection 045 PCL board detected a signal from the high voltage power supply unit indicating an abnormally high load on the bias voltage to the main charger 046 PCL board detected a signal from the high voltage power supply unit indicating an open connection in the main charger circuit diag nostic test only HVPS Errors 050 PCL board detected a signal from the high voltage power supply unit indicating an ab
30. See page 7 68 8 Disconnect CN49 and CN51 9 Remove the wiring harness for CN42 CN49 and CN51 from the exit cover 10 Disconnect CN317 11 Remove the four screws holding the exit cover in place two front and two back 12 Lift the exit cover from the printer 13 Remove the solenoid from the exit cover two screws Fuser Drive Cover Back Detail Removal Replacement Procedures 7 77 Paper Exit Sensor Removal Paper Exit Sensor Removal To remove the paper exit sensor Open the front back and top covers Remove the fuser Remove the operator panel See page 7 19 Remove the exit pinch roller See page 7 68 Disconnect CN49 Remove the two screws holding the exit cover in place one front and one back Tilt the exit cover assembly toward the center of the printer ON o0 5 WD a From the underside remove the paper exit sensor single screw 7 78 Removal Replacement Procedures Paper Full Sensor Removal Paper Full Sensor Removal To remove the paper full sensor 1 Open the front back and top covers 2 Remove the fuser 19 4 Remove the exit pinch roller See page 7 68 5 Disconnect CN51 3 Remove the operator panel See page 7 6 Remove the two screws holding the exit cover in place one front and one back 7 Tiltthe exit cover toward the center of the printer 8 From the underside remove the paper full sensor single screw bra NE NE N Nanay
31. Simplex 12 Vdc Circuits Wiring Diagrams and Electrical Data 6 17 J P8 11 J P10 1 a 4 4 J P11 1 Power J P12 2 J P70 1 AC Control 4 4 gt gt Power Board 2 Supply J P12 1 lt 4 DC Power J P40 27 Supply os J P40 28 e 4 4 J P41 35 J P23 5 4 lt gt gt Ves PCL iu Board J P8 13 J P41 26 J P81 1 J P82 1 a 4 4 gt gt gt gt Counter J P91 1 J P40 10 J P69 1 lt lt 4 4 Lower pick up clutch J P40 11 J P65 1 lt lt a Paper timing clutch J P66 1 Upper paper feed clutch J P67 1 Lower paper feed clutch J P68 1 Upper pick up clutch Figure 6 4 Simplex 24 Vdc Circuits 6 18 Wiring Diagrams and Electrical Data J P331 3 J P306 3 Duplex gt gt gt gt Control Board 1 DC J P330 3 J P323 3 J P305 3 J P310 3 Duplex Power lt lt e gt gt 4 gt gt Control Supply Board 2 J P333 1 gt gt Fuse FH2 Signal J P73 1 Interface e 4 4 l External Board J P73 6 Attachment 4 4 f Connector Figure 6 5 Duplex 5 Vdc Circuit Duplex Control Board 1 J P306 1 J P309 7 10 J P313 1 4 gt gt e lt lt lt lt Route motor J P308 1 J P314 1 e 4 4 4 4 In solenoid A J P331 1 A J P308 2 J P315 1 lt lt lt lt C C roller soleno
32. Yes Continue 2 Inspect the following for damage e Upper pressure lever e Upper cassette release latch e Upper cassette release Damper assembly e Upper cassette release cam Wire cable roller spring Are all parts in good working order No Repair or replace the damaged part then turn to TAG 002 Check amp Problem Resolution Yes Only mechanical defects and malfunctions can cause this type of problem Carefully rein spect each part Repair or replace and defective parts then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 135 TAG 704 Lower Cassette Malfunction Error Code 704 Symptoms Lower cassette does not load or unload properly 3 136 Lower cassette does not latch properly Possible Defects Lower cassette Lower pressure lever Lower cassette release latch Lower cassette release Lower cassette release cam Spring Inspect the lower cassette for damage Is the lower cassette in good working order No Replace the lower cassette then turn to TAG 002 Check amp Problem Resolution Yes Continue Inspect the following for damage Lower pressure lever Lower cassette release latch Lower cassette release Lower cassette release cam Spring Are all the parts in good working order No Repair or replace the damaged part then turn to TAG 002 Check amp Problem Resolution Yes Only mechanical defects and malfunctions can cause this type of problem Careful
33. Yes Repair or replace connectors or wiring P305 2 to P310 2 then turn to TAG 002 Check amp Problem Resolution 39 Turn off the printer and unplug the power cord e Disconnect J P323 Check J323 2 and J305 2 for continuity to ground Is there continuity at either No Return to the beginning of this TAG and start again Yes Repair or replace the connectors or wiring from J323 2 to J305 2 then turn to TAG 002 Check amp Problem Resolution 40 Turn off the printer e Reconnect J P323 e Disconnect J P306 Turn on the printer Check J P330 2 for 12 Vdc Is the voltage 12 Vdc No Continue Yes Go to 45 in this TAG 41 Turn off the printer and unplug the power cord e Disconnect J P331 Check J331 2 to P306 2 for continuity to ground Is there continuity No Repair or replace the connectors or wiring from P330 2 to P331 2 or P330 2 to P323 2 Yes Repair or replace the connectors or wiring from J331 2 to P306 2 Troubleshooting Analysis Guide TAGs 3 87 42 Turn off the printer e Reconnect J P310 e Disconnect J P320 and J P322 Turn on the printer Check J P330 2 for 12 Vdc Is the voltage 12 Vdc No Continue Yes Go to 44 in this TAG 43 Turn off the printer and unplug the power cord e Disconnect J P312 e Check for continuity to ground P312 1 to P320 1 and P312 4 to P322 1 Is there continuity No Replace the duplex control board 2 then turn to TAG 002 Check amp Problem Re
34. 0 0 0c cee es 9 4 Every Call Cleaning Procedure i ngs wd oe ea hod a bole ae ew Lee EN e 9 6 Remove Major Consumable Supplies 9 6 Inspect and Vacuum iei pe thee Vei ta oe aem bere bs 9 6 Clean Internal Areas ok bbe f el E bee LADY 8 See v e ERE i 9 6 Clean the Fuser Unt dk oce Eo weItoRei bSawbr EV PEERS 9 6 Clean the Developer Unit ous uei ER Ree c ped ER a adis 9 7 Clean the Cleaner Unit Main Charger lsleeeleee eee 9 7 Clean the Photoconductor Unit Area 0 2 cece ee 9 7 Clean the Transfer Charger 9 7 Run Test Prints sol es eve en e e CA en Wade e a dU eg ee dei as 9 7 Adjusting Paper Feed Tension i ussocleie RR Re xe lIEkSe T CREER 9 8 Printers With Paper Tension Levers 0 0 cece cece eee eee eee 9 8 Printers With Pick Pressure Adjusters eee 9 9 Li brcation PEOCedufes s etuer mec tenet Cbr Medicae Xe diues dts 9 11 Front View Lubrication Tables llle 9 13 Duplex Only i3 ecu ve wae Gee edo ee ee ge du bee Marte ege eua ds 9 13 Rear View Lubrication Tables llle 9 15 Duplex Only 5 env oe ar ULL best RAE es ep a egt ie pni E 9 15 Tune Up Maintenance Procedure 0 eee eee eee eee 9 18 Abbreviations and Acronyms Printer and Troubleshooting Overview Chapter 1 Printer and Troubleshooting Overview Contents Printing and Troubleshooting Overview Theory of Operation cocco pee eee dn cae gabe e RR a 1 3 Paper Path and Cycle Se
35. 11 9 oJnD1J4 P401 P420 PCL board W2 J401 Output W5 P419 J419 interface Control l Board W Wm P406 P407 P408 P409 ED J406 aS 52 53 OLLS OEPS J405 P425 P426 J404 J402 J403 T TT OJFS OJRS P404 P402 P403 W4 prz OELS W6 P41 P41 P41 P41 D OL 12V LL 4 ZEE E AC ad aig oe J41 J41 J41 J41 100 240V N Supply P418 ms ERM OEM OJRM OJFM 8 16 Options Chapter 9 General Printer Maintenance Genera Printer Maintenance 9 1 Contents General Printer Maintenance Introduction EE 9 3 Every Call Cleaning Procedure 1 2 0 0 uruuru 9 6 Adjusting Paper Feed Tension 9 8 Lubrication Procedure veser eae ee xou ae eoe e er a eee ee 9 11 Tune Up Maintenance Procedure llsleeeeeeelee eee 9 18 General Printer Maintenance Introduction General Printer Maintenance Introduction This section describes the primary printer maintenance procedures to be completed during service calls In addition this introduction reviews safety precautions tool requirements and the printer maintenance record Every Call Cleaning Procedure
36. 2 6 3 5 oees oo ud eR Pee aL PS De 7 74 Exit Cover Removal Duplex vu dedu dun o as Sei Oe Rae oes 7 76 Paper Exit Sensor Removal o2 2c20s casi Sox se Sy tie X ne SY COITU Y 4s 7 78 Paper Full Sensor Removal 3 2 52 2 040 bc eed se besa ELI REESE Rie 7 79 Front Cover Interlock Switch Removal leeeeeeleeeeeees 7 80 Back Cover Interlock Switch Removal 0 0 ee eee eee eee ee 7 81 Top Cover Interlock Switch Removal 0 0 0 cece eee eee 7 82 Erase Lamp Removal sosetan ex MAS ayes RE ON ao Gee Nase Oem 7 83 EP Cover Kemoval ss ce 234400 io d b kp RNR eon ne DU eed eek 7 84 Mam Motor Remo al i566 cosy a utes By oh cn eee BR eee E Ue 7 86 Main Gear Drive Removals 1 een sud eate a eu ut LES 7 88 Duplex Control Board 1 Removal 0 0 cee eee eee eee 7 89 Duplex Control Board 2 Removal 0 0 0 cece eee eee 7 90 Duplex Tray Registration Motor Removal 0 0 0 0 e ee eee eee 7 91 Duplex Skew Correction Cable Removal 0 0 0 0 e ee eee eee 7 92 Upper Duplex Drive Clutch Assembly Removal lesse 7 94 Duplex Route Motor Solenoid Assembly Removal 2 00 5 7 95 x Roller REMOVAL soc aae etit pes pie a A ecd etae sa As 7 96 B Roller Removal 5 cesot Nexus va UOCE E AEN VEG EE AK RR 7 97 e Roller Removal cesse eer wid ache ate eck wd PESIADUPRERA KL qi 7 98 C Roller Solenoid Removal leseseeee ee 7 99 Duplex Route Separator Rem
37. 24 Turn the printer off e Reconnect J P305 e Disconnect J P310 inside duplex tray Turn the printer on e Check J P330 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Go to 29 in this TAG 25 Turn the printer off and unplug the power cord e Disconnect J P305 Check P305 1 and P310 1 for continuity to ground Is there continuity No Return to the beginning of this TAG and start again Yes Repair or replace the connectors or wiring from P305 1 to P310 1 then turn to TAG 002 Check amp Problem Resolution 26 Turn the printer off and unplug the power cord e Disconnect J P323 Check J323 1 and J305 1 for continuity to ground Is there continuity No Return to the beginning of this TAG and start again Yes Repair or replace the connectors or wiring from J323 1 to J305 1 then turn to TAG 002 Check amp Problem Resolution 27 Turn the printer off e Reconnect J P323 e Disconnect J P306 e Turn the printer on Check J P330 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Go to 31 in this TAG 3 98 Troubleshooting Analysis Guide TAGs 28 Turn the printer off and unplug the power cord e Disconnect J P331 Check J331 1 and P306 1 for continuity to ground Is there continuity No Repair or replace the connectors or wiring from P330 1 to P331 1 or P330 1 to P323 1 then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring f
38. 3 J P 11 13 4 5 3 6 9 14 6 JP 4 2 s 8 PiE J P 12 1 4 7 16 8 17 9 J P 6 3 2 i J P 13 J P 9 oll 4 JP 7 ILE J P 14 2 rg JP 10 2 1 1 4 6 12 123 45 6 7 8 9 10 LILILILILIEIEILILIEI Wiring Diagrams and Electrical Data Connectors Inside the Back Cover Continued J P18 62 J P 18 3 2 1 J P 19 20 4 13 2 1 Dll J P 21 22 3 2 1 J P 23 87 65 4383 2 1 J P 24 1 2 3 4 e 6 12 5 11 J P 25 4 10 3 9 2 8 1 7 J P 44 Wiring Diagrams and Electrical Data J P 26 J P 27 J P 30 J P 44 Foi ms oan JiPso i 2 3 4 5 S JP52 53 f 4 f 3 7 8 B f
39. 5 Vdc Is the voltage 5 Vdc No Replace wire harness W127 or W128 then turn to TAG 002 Check amp Problem Resolu tion Yes Continue 21 Turn the printer off e Disconnect J P310 found inside the duplex tray Check P310 3 for continuity to ground Is there continuity to ground No Replace the duplex control board 2 then turn to TAG 002 Check amp Problem Resolu tion Yes Repair or replace the connectors or wiring from J323 3 to J P305 3 to P310 3 then turn to TAG 002 Check amp Problem Resolution 22 Turn the printer on Use extreme caution e Check from J P6 1 to J P6 2 neutral for 100 Vac or more Is the voltage at least 100 Vac No Continue Yes Replace the DC power supply unit then turn to TAG 002 Check amp Problem Resolution 23 Use extreme caution Check from J P4 7 to J P4 8 neutral for 100 Vac or more Is the voltage at least 100 Vac No Replace the AC power supply unit Yes Repair or replace the connectors or wiring from P4 7 to P6 1 or P4 8 to P6 2 then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 117 TAG 600 AC Power Malfunction 3 118 Error Code 600 Symptoms Operator panel blank with fans not running Printer Open indicator on Circuit breaker keeps tripping Possible Defects Upper fuse in the AC power supply AC power supply unit DC power supply unit Connectors or wiring Power control 2 board Power control 3 b
40. Continue Yes Go to 6 in this TAG 4 Replace the photoconductor unit e Run 200 test prints to reduce toner concentration in the developer unit Has the problem been resolved No Reinstall the original photoconductor unit and continue Yes The photoconductor was at fault turn to TAG 002 Check amp Problem Resolution 5 Replace the developer unit e Run test prints Has the problem been resolved No Reinstall the original developer unit and continue Yes Turn to TAG 002 Check amp Problem Resolution If the problem reappears the toner car rier mix may be old or contaminated Troubleshooting Analysis Guide TAGs 3 47 6 Turn the printer off and unplug the power cord Remove the developer unit e Disconnect J P41 e Check P41 47 to J25 3 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 47 to J25 3 Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 3 48 Troubleshooting Analysis Guide TAGs TAG 032 Toner Patch Too Light Error Code 032 033 Possible Defects Photoconductor unit IGS board 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 turn to TAG 002 Check amp Problem Resolution Yes Continue 2 Have the photoconductor unit been replaced recently No Continue Yes Go to 4 in this TAG 3 Re
41. Detailed step by step procedures to help you isolate and resolve specific printer problems If you are not sure which TAG to start with begin with the overview TAG 001 Chapter 4 Print Quality Samples Shows print test patterns indicating specific problems and referencing the TAG that treats each problem Chapter 5 Diagnostic Tests Reviews each printer software diagnostic Chapter 6 Wiring Diagrams and Electrical Data Shows printer schematics and locations of individual components Chapter 7 Removal Replacement Procedures Outlines procedures to follow when removing and replacing printer parts also called FRUS Field Replaceable Units Chapter 8 Options Provides information about the optional High Capacity Input and High Capacity Output bins Chapter 9 General Printer Maintenance Reviews printer maintenance procedures to complete during service calls Appendix A Lists the abbreviations and acronyms used in the manual Index Provides a list of references to topics and part numbers mentioned in the Maintenance Manual Other Manuals The C Series Illustrated Parts Catalog shows every FRU and CRU customer replaceable unit in the printer including part number information This information is frequently updated The HP C30 and C30D Guide to Operations C4000 96006 contains all the information needed to operate Hewlett Packard C40D printers The HP C30 and C40D Paper Specifications
42. OOOO0O0 OOOO J P 90 69 69 60 CO CO 9 G0 69 62 0 C ol I J P 94 E 7 J P 96 J P 100 1 al jH J P 101 1 2 3 H J P 102 2 1 J P 121 122 124 139 140 143 J P 251 252 255 not illustrated Wiring Diagrams and Electrical Data JP 323 al fal fe C C 02 ws OOOO L1 J P 330 331 a fa rz f J P 333 2 1 18 17 16 15 14 1312 11 10 98 76 54 3 2 1 J P 500 BEE EE 2E B E DE S HB BE BEES HH e pee Du O O O O O O 0 000 0000 000 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 J P 800 Voltage Isolation Diagrams Use the following voltage isolation diagrams to locate the presence or loss of proper DC potentials within the printer Simplex circuit are shown first followed by duplex circuits J P8 8 J P74 32 J P73 4 ignal Interf du a Pi bales i nae s J P88 32 J P32 3 External Attachment Connector Figure 6 1 Simplex 12 Vdc Circuits J P8 1 J
43. Oo Run test prints in both the simplex and duplex mode from both the upper and lower paper cassettes 7 Fillin the Repair Maintenance log Make sure the problem description and steps taken to resolve the problem are clearly documented Printer and Troubleshooting Overview 1 23 Clearing the Error Log 1 Enter the diagnostic mode of the printer Turn off the printer and wait 5 seconds Hold down the STOP and TEST keys simultaneously as you turn the printer back on The tone followed by 00 on the display indicates you are in the test mode This takes approximately 1 minute Press CANCEL to advance the counter to 110 Press READY to activate the procedure 0 appears on the display indicating the A drive 4 Press CANCEL to advance to the drive where the error log is maintained This is usu ally the boot drive Table 1 4 Drive Indication Display Indication 0 Diskette drive A 1 Diskette drive B 2 Hard drive C 5 Press READY to select the drive specified 1 0 appears on the display Caution At this point be careful 1 0 represents the clear error log function Do not advance the counter to 1 1 which represents the format disk option 6 Press READY to select the clear error log function 6 0 appears on the display Caution If 7 0 appears press STOP immediately DO NOT CONTINUE WITH THIS PROCEDURE POR the printer and
44. P40 43 to J P52 8 to J43 3 to J47 8 to J45 8 P40 44 to J P52 7 to J43 4 to J47 7 to J45 7 P40 45 to J P52 6 to J43 5 to J47 6 to J45 6 P40 46 to J P52 5 to J43 6 to J47 5 to J45 5 P40 47 to J P52 4 to J43 7 to J47 4 to J45 4 P40 48 to J P52 3 to J43 8 to J47 3 to J45 3 P40 49 to J P52 2 to J43 9 to J47 2 to J45 2 Wiring for the Lower Paper Size Sensor Refer to the following table when performing continuity checks for an open or short to ground for the lower paper size sensor Table 3 3 Wiring for the Lower Paper Size Sensor Wiring for the Lower Paper Size Sensor P40 41 to J P52 10 to J43 1 P40 42 to J P52 9 to J43 2 P40 43 to J P52 8 to J43 3 P40 44 to J P52 7 to J43 4 P40 45 to J P52 6 to J43 5 P40 46 to J P52 5 to J43 6 P40 47 to J P52 4 to J43 7 P40 49 to J P52 2 to J43 9 P40 50 to J P52 1 to J43 10 3 134 Troubleshooting Analysis Guide TAGs TAG 703 Upper Cassette Malfunction Error Code 703 Symptoms pper cassette does not load or unload properly pper cassette does not latch properly Possible Defects Upper cassette pper pressure lever pper cassette release latch pper cassette release Damper assembly Upper cassette release cam Wire cable roller spring U U U U U U 1 Inspect the upper cassette for damage Is the upper cassette in good working order No Replace the upper cassette then turn to TAG 002 Check amp Problem Resolution
45. 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 and P41 50 to J25 1 Is there continuity on all No Repair or replace the connectors or wiring that do not have continuity then turn to TAG 002 Check amp Problem Resolution Yes Continue Reconnect J P23 J P41 and J P24 Reinstall the developer unit e Power on reset the printer e Check TP4 30 for 24 Vdc for one minute Is the voltage 24 Vdc for the first minute after power on reset No Replace the high voltage unit then turn to TAG 002 Check amp Problem Resolution Yes Continue Run test prints Check TP4 30 for 0 Vdc while running the prints Does the voltage change to 0 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue Is a meter with a high voltage probe available No Go to 24 in this TAG Yes Continue Power on reset the printer e Run test prints Using a high voltage probe check J P25 7 for the proper voltage as outlined in Chapter 9 General Printer Maintenance Is the voltage correct No Replace the high voltage unit then turn to TAG 002 Check amp Problem Resolution Yes Go to 25 in this TAG Troubleshooting Analysis Guide TAGs 3 155 20 21 22 23 24 25 3 156 Run diagnostic test 010 Use extreme caution Check J P13 5 to J P13 2 for 100 Vac while the test is running Is the v
46. TAG 902 Paper Jam in Duplex Area 3 198 Error Code 027 060 061 062 Possible Causes Paper incorrectly loaded Paper path not clear Possible Defects Duplex drive clutch A roller clutch Duplex input solenoid C roller clutch Duplex feed motor Duplex control board 1 Connectors or wiring Turn the printer off and unplug the power cord Verify that J P306 J P307 J P308 J P309 J P313 J P314 J P315 J P316 J P317 and J P319 are connected properly Check the following components for damage Duplex drive clutch Timing belts Route separator e Power on reset the printer Has the problem been resolved No Continue Yes Loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution Turn on the printer e Run diagnostic test 017 Is the duplex paper path sensor in good working order No Continue Yes Go to 7 in this TAG Turn the printer off e Disconnect J P309 Turn on the printer e Check J309 4 on duplex control board 1 for 12 Vdc Is the voltage 12 Vdc No Replace duplex control board 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check J P309 2 on duplex control board 1 for 12 Vdc Is the voltage 12 Vdc No Replace duplex control board 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 5 Turn the printer off e Reconnect J P309 e Disconnect J P319
47. Troubleshooting a Problem If you are not sure how to troubleshoot a printer problem start with this TAG This and all TAGs assume you are familiar with standard procedures such as power on reset pre sented in Chapter 1 Printer and Troubleshooting Overview In addition TAG may refer you to Chapter 2 TAG Cross Reference Tables which contain Error code cross reference table Arranged by error code refers you to the TAG associated with the code Print quality cross reference table Arranged by description of print quality problem refers you to the TAG associated with the problem e Mechanical malfunction cross reference table Arranged by description of the mechanical malfunction refers you to the TAG associ ated with the malfunction 1 To start e Disconnect all peripheral cables e Power on reset the printer Did all of the status lights come on followed by 888 flashing briefly and an error code No Run test prints following the procedure described in Chapter 1 Printer and Trouble shooting Overview then repeat this step If the answer is still no refer to the mechanical malfunctions cross reference table in Chapter 2 TAG Cross Reference Tables to determine which TAG to follow Then turn to that TAG Yes Note the error code and continue 2 Power on reset the printer Did the power on reset end with an error code No Continue Yes Refer to the error code cross reference table in Chapter 2 T
48. Warning messages call attention to situations that could result in personal injury Preface The C30 C30D Maintenance Manual contains all the information needed to maintain and service Hewlett Packard C30 and C30D printers The C30 printer series are high speed non impact printers utilizing electrophotographic imaging technology The information in this maintenance manual is for authorized field representatives who are familiar with basic printer operations It serves as a supplement to training classes and pro vides a basis for discussion with regional field service engineers and customer support representatives Using This Manual This manual is organized into the following sections Chapter 1 Printer and Troubleshooting Overview Reviews the organization of the manual the way the printer works and how to trouble shoot the printer including some standard procedures to follow when troubleshooting This chapter also includes a chart detailing exactly what each causes each error code illus trations of all sensors in the printer and a list of abbreviations used throughout the manual Chapter 2 TAG Cross Reference Tables Provides cross reference tables look up specific printer problem description in either the mechanical malfunction error code or print quality description tables then turn to the TAG indicated on the chart to troubleshoot the problem Chapter 3 Troubleshooting Analysis Guide TAGs
49. e Check P4 5 to P4 6 for continuity Is there continuity No Go to 34 in this TAG Yes Continue Remove the AC power supply unit e Operate the front cover interlock switch e Check for continuity as you operate the front interlock switch Does the front cover interlock switch have continuity No Repair or replace the front interlock switch then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the AC power supply unit then turn to TAG 002 Check amp Problem Resolution Disconnect J P13 Install a new upper fuse in the AC power supply unit e Run diagnostic test 010 for approximately 5 seconds then stop Remove the fuse e Check the fuse for continuity Does the fuse have continuity No Replace the power control 2 board then turn to TAG 002 Check amp Problem Resolu tion Yes Continue Disconnect J P18 Check P13 5 to P18 1 for continuity to ground Is there continuity to ground No Replace the toner supply motor then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P18 1 to P13 5 then turn to TAG 002 Check amp Problem Resolution Turn off the printer e Disconnect J P9 Install a new upper fuse in the AC power supply unit Turn the printer on for 5 seconds then off Remove the upper fuse e Check the fuse for continuity Does the fuse have continuity No Go to 20 in this TAG Yes Continue
50. main motor which rotates the photoconductor belt As the photoconductor belt rotates the main charger applies a high negative charge to it which repels toner from the photoconductor belt except in the areas to print 4 Exposing the image The negatively charged belt then passes the LED printhead where the IGS controller turns the LEDs on and off to discharge the areas of the belt at a density of 300 dots per inch The 1s in the bitmap memory turn the LEDs on Os turn the LEDs off The dis charged areas create a latent mirror image of the print on the photoconductor belt 5 Developing the image As the photoconductor belt continues to rotate it brings the latent image to the devel oper unit A negative developer bias is applied to toner and the toner is transferred to the surface of the photoconductor belt The negatively charged toner which clings to small metal carrier beads is attracted to the discharged areas of the belt The carrier beads do not transfer The belt with the developed image on its surface rotates out of the developer unit At this time you can remove the photoconductor belt and read what is printed on it which you may need to do when troubleshooting print problems Printer and Troubleshooting Overview 1 3 6 Activating paper As the image is being developed a sheet of paper is transported to the photoconductor belt The PCL board controls this activity A series of paper pick up feed and timing rollers guide the pap
51. replace the HCO 1 Turn the printer off and unplug the power cord e Check the paper path and remove any paper jams e Confirm that J P50 and J P40 are connected properly Inspect the exit paper sensor actuator for damage or binding Is itin good working order No Replace the exit paper sensor actuator and continue Yes Continue 2 Power on reset the printer Is error code 026 displayed No Jammed paper loose connectors or sensor actuator were at fault go to TAG 002 Check amp Problem Resolution Yes Continue 3 Check J P40 26 for 12 Vdc Is the voltage 12 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue 4 Turn off the printer and unplug the power cord Remove the exit cover e Disconnect J P49 and J P40 e Check the following for continuity P40 26 to P49 1 P40 24 to P49 2 and P40 13 to P49 3 Is there continuity No Repair or replace the connectors or wiring from P40 26 to J P50 1 to P49 1 P40 24 to J P50 2 to P49 2 or P40 13 to J P50 3 to P49 3 Then turn to TAG 002 Check amp Problem Resolution Yes Replace the exit paper sensor If this doesn t resolve the problem replace the PCL board Then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 43 3 44 TAG 030 Developer Bias Short Failure Error Code 030 Possible Defects Cleaner unit High voltage unit DC power supply Connectors or wiring
52. replace the IGS board then turn to TAG 002 Check amp Problem Resolution Yes Replace wire harness W46 then turn to TAG 002 Check amp Problem Resolution Is error code 574 displayed No Go to 16 in this TAG Yes Continue Turn the printer off and unplug the power cord e Disconnect J P31 and J P79 Check P31 30 to P79 30 for continuity Is there continuity No Replace wire harness W46 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check for continuity to ground P31 18 to P79 18 P31 24 to P79 24 and P31 26 to P79 26 Is there continuity on any No Replace the disk drive assembly If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the IGS board then turn to TAG 002 Check amp Problem Resolution Yes Replace wire harness W46 then turn to TAG 002 Check amp Problem Resolution Is error code 575 displayed No Go to 18 in this TAG Yes Continue Turn the printer off and unplug the power cord e Disconnect J P31 and J P79 Check P31 20 to P79 20 and P31 18 to P79 18 for continuity Is there continuity on each No Replace wire harness W46 then turn to TAG 002 Check amp Problem Resolution Yes Replace the disk drive assembly If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the IGS board then turn to TAG 002 Check amp Pr
53. s J P 14 6 12 simplex duplex C3 J P 55 inl simplex duplex D10 J P 15 6 9 simplex duplex D11 J P 56 diis simplex duplex B4 J P 18 6 13 simplex duplex B3 J P 57 9 19 simplex duplex E9 J P 19 6 13 simplex duplex C3 J P 58 T simplex duplex E9 J P 20 6 13 simplex duplex C3 J P 59 eT simplex duplex E9 J P 21 6 13 simplex duplex B3 J P 60 alas simplex duplex E9 J P 22 6 9 simplex duplex C3 J P 61 6 7 simplex duplex E10 6 13 J P 62 6 13 simplex duplex E10 J P 22 1 6 8 duplex C2 J P 63 6 10 simplex duplex C5 J P 23 6 13 simplex duplex A7 J P 64 6 14 simplex duplex C5 J P 24 6 13 simplex duplex B7 J P 65 6 14 simplex duplex F8 J P 25 6 13 simplex duplex C4 J P 66 6 14 simplex duplex F9 J P 26 6 13 simplex duplex B6 J P 67 6 14 simplex duplex F9 J P 27 6 13 simplex duplex C6 J P 68 6 14 simplex duplex F9 J P 30 6 13 simplex duplex B6 J P 69 6 14 simplex duplex F10 J P 31 6 11 simplex duplex B8 J P 70 6 14 simplex duplex E5 J P 32 6 11 simplex duplex B8 J P 71 6 14 simplex duplex A8 J P 33 6 11 simplex duplex B8 J P 72 6 14 simplex duplex A8 J P 36 6 11 duplex C8 J P 73 6 14 simplex duplex A8 J P 37 6 11 simplex duplex C8 J P 74 6 11 simplex duplex B8 J P 40 6 11 simplex duplex C8 J P 76 6 11 simplex duplex B8 J P 41 6 11 simplex duplex C8 J P 77 6 14 simplex duplex C6 J P 42 6 6 simplex duplex B9 J P 79 6 14 simplex duplex C6 J P 43 6 7 simplex duplex D10 J P 81 6 14 simplex duplex A5 6 4 Section 1 Printer and Troubleshooting Overview
54. then turn to TAG 002 Check amp Problem Resolution Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs TAG 011 Lower Cassette Malfunction Error Code 011 Possible Causes Cassette empty Paper incorrectly loaded Possible Defects Lower paper empty actuator Lower paper empty sensor Lower cassette tray Lower pressure lever Lower cassette release cam Lower cassette release latch Lower cassette release lever Spring Connectors wiring PCL board 1 Make sure paper is in the lower cassette Make sure the paper is loaded correctly so that the side and rear guides are positioned securely against the paper in the cassettes e Power on reset the printer Runtest prints Is error code 011 displayed No The paper was loaded incorrectly Turn to TAG 002 Check amp Problem Resolution Yes Continue 2 Remove the lower cassette Inspect the lower paper empty sensor actuator for binding or for a damaged or broken part Is itin good working order No Replace the actuator then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Open the rear door and install an interlock by pass tool Check the voltage from TP3 14 to ground on the PCL board e Activate the lower paper sensor actuator manually Does the voltage change from 0 Vdc to 12Vdc No Replace the lower paper empty sensor then turn to TAG 002 Check amp Problem Resolu ti
55. 002 Check amp Problem Resolution 34 Turn the printer off e Reconnect J P315 e Disconnect J P316 Turn the printer on Check J P330 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the A roller clutch then turn to TAG 002 Check amp Problem Resolution 35 Turn the printer off e Reconnect J P316 e Disconnect J P317 Turn the printer on Check J P330 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the exit solenoid then turn to TAG 002 Check amp Problem Resolution 3 100 Troubleshooting Analysis Guide TAGs 36 Turn the printer off e Reconnect J P317 e Disconnect J P308 and J P309 Turn the printer on Check J P330 1 for 424 Vdc Is the voltage 24 Vdc No Repair the duplex control board 1 then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P309 pins 7 through 10 to J313 pins 1 through 4 P308 1 to J314 1 P308 2 to J315 1 P308 3 to J316 1 or P308 4 to P317 1 then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 101 TAG 100 PCL Board Interface Malfunction Error Code 100 132 140 145 160 162 170 172 180 182 Symptoms PCL board failure Possible Defects Connectors or wiring PCL board 1 Turn off the printer and unplug the power cord Verify that J P40 J P41 J P33 and J P91 are connected properly e Power on reset the printer Has the p
56. 002 Check amp Problem Resolution Yes Replace duplex control board 2 If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the registration motor then turn to TAG 002 Check amp Problem Resolution Check J P312 4 for 12 Vdc Is the voltage 12 Vdc No Replace duplex control board 2 then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 14 Manually activate the duplex tray paper sensor Check J P312 5 for 0 Vdc Is the voltage 0 Vdc No Replace the duplex tray paper sensor If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this doesn t resolve the problem repair or replace the wiring or connectors from P312 4 to J322 1 P312 5 to J322 2 or P312 6 to J322 3 then turn to TAG 002 Check amp Problem Resolution Yes Continue 15 Manually activate the duplex tray paper sensor e Check J P36 6 on the PCL board for 0 Vdc Is the voltage 0 Vdc No Replace duplex control board 2 If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this doesn t resolve the problem repair or replace the wiring or connectors from P311 7 to J P305 11 to P36 4 then turn to TAG 002 Check amp Problem Resolution Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 197
57. 1 19 sample LAG co oup eae ee EM Ae eeu e iab se 1 19 Standard Procedures o2 ox rA ewe CA OEERSAQE AED T EAE 1 21 Power on reset POR aceros aruntata ccc ehh ha 1 21 Checking GContimn lty 2b rueda etes dan Pape da aded ing 1 21 Installing the Interlock By pass Tool 2 2 0 0 cece ce ee eee eee 1 22 Producing a Developed Image 0 0 2 eee ee 1 22 Producing a Toner Patch i2 se onis rans d Meee Re eee 1 22 Completing a Service Call lleeeeeee e 1 23 Clearing the Error Log 2s REESE Xe HR 1 24 TAG Cross Reference Tables TAG Cross Reference Tables 0 0 e 2 2 Error Code TAG Cross Reference 0 0 0 0 ccc eee eens 2 3 Print Quality TAG Cross Reference 0 cee cece eee eee 2 9 Mechanical Malfunction TAG Cross Reference 000 ccc eee eee 2 12 Troubleshooting Analysis Guide TAGs Contents 4 556 Bod sarees Sad EI UH eee gt T ey CaS ee eO Ed M 3 2 Troubleshooting Analysis Guide TAGs 0 0 0 c ee eee eee eee eee 3 4 TAG 001 Troubleshooting a Problem 3 5 TAG 002 Check amp Problem Resolution 3 8 TAG 010 Upper Cassette Malfunction 0 0 0 cee cece eee 3 12 E10 Envelope Tray Out of Envelopes 3 14 TAG 011 Lower Cassette Malfunction lesse 3 16 vii viii TAG 012 Upper Cassette Not Latched 0 0 0 eee eee eee ee 3 18 TAG E12 Envelope Tray or Feeder Not Latched 0 0 3 21 TAG 013 Lower Cassette Not L
58. 16 019 Duplex Tray Paper Guide Motor Test llle 5 17 020 High Capacity Output Unit Test llle 5 18 021 High Capacity Input Unit Test 2 occ 2 40 tesa REIR eee e EN 5 19 022 Envelope Fuser Solenoid Test 2 0 0 0 0 cece eee eee nee 5 19 101 EIGS MIGS Board Test 6 ose goa aos yew teak area ake YS 5 20 102 EIGS MIGS Board Test Continuous Loop 5 20 103 Communication Loop back Test Single Loop 0008 5 21 104 Communication Loop back Test Continuous Loop 5 22 105 EIGS Program RAM Test Continuous Loop 00 20 eee 5 22 107 EIGS MIGS Bit Map Test Single Loop 0 0 e eee eee 5 23 108 EIGS MIGS Bit Map Test Continuous Loop 2005 5 23 T TOPormat Disk C ear Error Log 2 62 3 4 2 yet S RO Sige Poe aE oe 5 24 LL ED Printhead Testaa 4 aoroy o et core AU oed sata d nro 5 24 112 Disk Drive Test Single Loop With Stop on Error 5 25 113 Disk Drive Test Continuous Loop 0 0 0 cece eee eh 5 26 Wiring Diagrams and Electrical Data COMENTS aa a Bett iR Lar Bl EAD an EUM c MAD N modas 6 2 Wiring Diagrams and Electrical Data 2 0 0 ee 6 3 Connector M PI TIBOe Xov sow b ane pine aha OCASION OS aca DR 6 4 Connector Locations 1224 l ee bhxecidekkbiadesideted eri iads Aes 6 6 Connectors Inside the Front Cover 6 6 Connectors Inside the Left Cover 0 2 0 0 ea 6 7 Connectors on the Duplex Cover 0 0 i
59. 180 Troubleshooting Analysis Guide TAGs 6 Replace the developer unit and toner cartridge e Run test prints Has the problem been resolved No Reinstall the original developer unit and toner cartridge then turn to TAG 811 Back ground Residual Images Dark Prints Yes Turn to TAG 002 Check amp Problem Resolution If the problem recurs the toner carrier mix may be old or contaminated Troubleshooting Analysis Guide TAGs 3 181 TAG 811 Background Residual Images Dark Prints 3 182 Error Code 811 Possible Causes Contaminated toner carrier mix Possible Defects Photoconductor unit Main charger Cleaner unit Developer unit Erase lamp assembly High voltage unit Power control 2 board Connectors or wiring PCL board Main charger terminal assembly Cleaner terminal assembly Turn the printer off and unplug the power cord Verify J P23 J P24 J P85 and the main charger high voltage lead are connected properly Perform the every call cleaning procedure described in Chapter 9 General Printer Mainte nance Clean the contacts on the main charger Clean the printhead lens and toner patch sensor located on the developer unit Turn the printer on Runtest prints Has the problem been resolved No Continue Yes Contamination or a loose connector was at fault Turn to TAG 002 Check amp Problem Resolution Check the voltages as outlined in Chapter 9 General Printer Maintenance Are the vo
60. 405 409 IGS board detected an error in the program RAM during the inter o nal diagnostic testing of the IGS board ui 450 566 IGS board detected an error during the internal diagnostic testing A of the IGS board and software i 570 586 IGS board detected an error when communicating with the floppy 32 disk drive e 600 610 IGS board detected an error during the internal diagnostic testing amp ul of the IGS board c 701 703 IGS board detected an error when communicating with a host 2 using RS232 communications 8 2 770 784 IGS board detected an error when communicating with a host g using RS422 communications 888 IGS board detected that the PCL board was in a halt or reset state o o Printer and Troubleshooting Overview Sensor and Switch Locations The following pages illustrate the locations of the printer s sensors and switches Table 1 2 Sensor and Switch List on page 1 14 lists them Upper cassette present micro switch Left end view Upper cassette paper present sensor Upper paper size sensor Lower paper size sensor Lower cassette Lower cassette present paper present sensor micro switch Left end view Duplex registration sensor Duplex cover e interlock switch Duplex paper path sensor Printer and Troubleshooting Overview 1 11 Paper timing sensor Front view ERBEN JF Toner patch sensor TPS Toner empty sensor Automatic toner co
61. 69 Upper Static Brush Removal Upper Static Brush Removal To remove the upper static brush 1 Open the top and front covers 2 Remove the fuser 3 Remove the upper static brush from the exit pinch roller assembly two screws Upper Static Brush Detail Removal Replacement Procedures 7 70 Lower Static Brush Removal Lower Static Brush Removal To remove the lower static brush Open the top front and back covers Remove the fuser Remove the operator panel See page 7 19 Remove the exit pinch roller assembly See page 7 68 a WO N Remove the lower static brush two screws Mounting Screws Removal Replacement Procedures 7 71 Exit Roller Assembly Removal Exit Roller Assembly Removal To remove the exit roller assembly 1 Open the front back and top covers 2 Remove the fuser 3 Remove the operator panel See page 7 19 4 Remove the front screw holding the exit guide in place Front Detail Exit Guide Screw Exit Pinch Roller Screw Removal Replacement Procedures 7 72 Exit Roller Assembly Removal Remove the fuser drive cover three screws Remove the exit pinch roller See page 7 68 Duplex only Remove the lower duplex drive 3 screws oN Oo Oo Remove the back screw holding the exit guide in place 9 Tilt the exit guide toward the center of the printer 10 Remove the front C clip and bearing 11 Slide the exit roller out the back of the printe
62. 7 2 Contents Front Cover Removal 2 212 2 9 tetuer ir p eed 7 5 Back Cover Removal 0 0 ccc cece n 7 6 Lower Back Cover Removal 0 0 0 cece cece eens 7 7 Left Side Cover Removal seco 0 0 eee ccc e 7 8 Right Side Cover Removal Simplex 0 0 0c cece eee eee eee 7 9 Right Side Cover Removal Duplex 0 0 0 eee eee eee 7 10 Vacuum Transport Unit Removal Simplex 0 0 0 0 0 0 eee eee 7 11 Vacuum Transport Unit Removal Duplex 0 0 0 0 ee eee eee 7 13 Top Cover Removal 2 2 2 ntes tpe eee eae pee sane ene 7 14 Top Cover Support Removal 7 15 Top Cover Hinge Removal 20 0 cece eect e 7 16 Rear Duplex Cover Removal 0 0 cece cece eh 7 17 Front Duplex Cover Removal leleseee eA 7 18 Operator Panel Removal 00 cece eee ee eee eens 7 19 Counter Removal sess neta ee eee kaw hae aee de dear die 7 20 IGS Board Removal sseseeeeeee eh 7 21 PCL Board Removal 3 24 enis eter e ee p e ege Fa e os 7 22 Printhead Assembly Removal eleee eA 7 23 Disk Drive Housing Removal 0 0 0 0c cece eee eee 7 25 Cooling Fan Removal ee eee eke eee eee le ee ee e OR 7 26 Duplex Pan Removal 2 i eeeiaieasusa tian Poesia E wea Ra dre 7 27 Toner Motor Removal 0 0 cece cect ene 7 28 AC Power Supply Removal 1 0 0 0 0 0c cece eee eens 7 29 DC Power Supply Removal 0 ccc eee eee eh 7 3
63. Back Cover Continued J P 90 800 6 15 Voltage Isolation Diagrams 0 0 0 eh 6 16 Ground System sass ba dea ees awseratedacntiavawaddaeweoad doa eos 6 21 Host Interface Reference 0 0 0 ccc eee een eens 6 22 RS 232C Host Interface 0 0 ce eee ne nns 6 22 Standard DCE to DTE RS 232C Cable 0 0 0 cece eee 6 23 Special Considerations for RS 232 Host Interface Users 6 23 DTE Host to Printer Option 1 0 0 eee 6 24 DTE Host to Printer Option 2 2 0 cece eens 6 24 IBM PC XT to Printer ines ecsodse emer em eka exa eR a e e Rr eka od 6 25 IBM PC AT to Printet 1 21499 teed RRRRSTG aA 6 25 Macintosh Communication Port to Printer 0 0 0 cc eee ee ee 6 26 RS 422 Host interface 0 ee trairar asa 6 26 Centronics Parallel Host Interface 0 0 0c 6 27 IBM Parallel to Printer 2 0 0 cece eens 6 28 Special Considerations for Centronics Parallel Interface Users 6 29 Circuit Board Settings eiser eee ee ee a ee ee ee ee 6 30 Signal Interface Board Settings 0 eee eee eee 6 30 PCL Board Settings be een ha eh be eee ede DER ee es 6 31 Printhead Circuit Board Settings 6 31 Wiring Diagrams and Electrical Data Wiring Diagrams and Electrical Data This section provides a reference guide for all information related to the electrical system of the printer including Anindex arranged by connector number to the connec
64. Check amp Problem Resolution 3 114 Troubleshooting Analysis Guide TAGs 10 Turn the printer off e Reconnect J P77 e Disconnect J P27 Turn the printer on Check J P8 10 for 5 Vdc Is the voltage 5 Vdc No Continue Yes Replace the LED printhead assembly then turn to TAG 002 Check amp Problem Resolu tion 11 Turn the printer off e Reconnect J P27 e Disconnect J P91 Turn the printer on Check J P8 10 for 5 Vdc Is the voltage 5 Vdc No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 12 Turn the printer off e Reconnect J P91 e Disconnect J P32 Turn the printer on Check J P8 10 for 5 Vdc Is the voltage 5 Vdc No Continue Yes Replace the IGS board then turn to TAG 002 Check amp Problem Resolution 13 Turn the printer off e Reconnect J P32 e Disconnect J P94 Turn the printer on Check J P8 10 for 5 Vdc Is the voltage 5 Vdc No Replace wire harness W36 then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 115 14 15 16 17 18 3 116 Turn the printer off e Disconnect J P42 Check P42 1 for continuity to ground Is there continuity to ground No Replace the operator panel circuit board then turn to TAG 002 Check amp Problem Reso lution Yes Repair or replace the connectors or wiring from P94 1 to J P90 1 to P42 1 then turn to T
65. Continue 3 Has the fuser unit been replaced recently No Continue Yes Go to 5 in this TAG 4 Replace the fuser unit e Run test prints Has the problem been resolved No Reinstall the original fuser unit and continue Yes The fuser unit was at fault Turn to TAG 002 Check amp Problem Resolution 5 Inspect the following for damage e Upper paper guide assembly Paper timing roller assembly Lower paper guide assembly Paper timing guide assembly Are any of these parts damaged No Continue Yes Replace the damaged part then turn to TAG 002 Check amp Problem Resolution 6 Is more than one sheet of paper jamming No Go to 8 in this TAG Yes Continue 7 Make sure the natural curl of the paper is turned up in the cassettes Make sure the paper is under the corner separators Make sure the rear and side paper guides are positioned properly Make sure the paper being used does not have a high static charge Runtest prints Does the multiple feed problem still exist No The paper appears to be at fault Turn to TAG 002 Check amp Problem Resolution Yes Adjust the paper tension lever or pick pressure as described in Chapter 9 General Printer Maintenance then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 35 10 11 12 13 3 36 Check the paper path for jams Open the printer s front cover and insert the interlock bypass tool e Pow
66. Dark Prints or both to identify the problem further 8 Do the prints appear light or blank No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Replace the photoconductor unit then turn to TAG 002 Check amp Problem Resolution 3 50 Troubleshooting Analysis Guide TAGs TAG 035 Out of Toner or ADD TONER Indicator On Error Code 035 Possible Causes Photoconductor unit Toner cartridge seal not removed Toner cartridge empty High print coverage Possible Defects PCL board Developer unit connectors or wiring An 035 error may occur if the print coverage exceeds 25 Do not run high print coverage jobs for extended periods of time 1 Power on reset the printer e Run test prints Is error code 035 displayed No Continue Yes Perform the every call cleaning procedure described in Chapter 9 General Printer Maintenance Clean the toner patch sensor and the printhead lens then continue 2 Check the voltages as described in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Has the photoconductor unit been replaced recently No Continue Yes Go to 5 in this TAG 4 Replace the photoconductor unit e Run 200 test prints to reduce toner concentration in the developer unit Has the problem been resolved No Reinstall the original photo
67. E TTTTTTTTTTTTTTTTTTT tee ee re Pe Pa eae ee 1 96X amp C 0123456789 1 Ta ABCDEFGHIJKLNNOPQRSTUVWXYZ N abcdefghijklmnopqrstuvwxyz i 1 5X amp 034 01234567891 25 te i ABCDEFGHIJKLMNOPQRSTUVWXYZIN abcdefghijkimnopqrstuvwxyzii a Dark specks or areas 4 y i i34 4 AA AA AAA AAA AA AAAS AS john jhe LETTER le 66X amp C t 0123456789 1 513 ABCDEFGHIJKLMMOPQRSTUVWXYZ N 1 abcdefgh jklImnoparstuvwxyziil 1I 99X amp 8 O5 7 0123456789 1 7218 ABCDEFGHIJKLMNOPQRSTUYWXYZIN abcdefghijklanoparstuvwxyz i uu 1 1 1 4 i X tt NE im m imm m ig a _ a aa a Figure 4 11 Dark Specks Lines or Areas Description Dark specks or lines like scratches some in the same place on each print Go to TAG 806 Prints with Dark Spots or Scratches TAG 810 Uneven Density or Dark Areas on Prints 4 14 Print Quality Samples Sample 12 Dark Vertical Lines jd hu ns I 6xR1C x 79 ABCDEFGHIJKLMNOPQRSTU ENERE imbri idt gnu ddp pod Jb pbi nn Z 3456789 lt gt 73 abcdefghijklmnoparstuvwxy 17 995 amp 8 0 701234556789 1 22 1 ABCDEFGHIJKLMNOPQRSTUVWXYZ N 1 abcdefghijklmnopqrstuvwxyz il 1 amp X amp C 0123656789 z25 3 ABCDEFGHIJKLMNOPQRSTUVWXYZIN 1 abedefghijkimnoparstuvwxyz i 7 1 996
68. Error Code 021 Possible Causes Paper loaded incorrectly Wrong weight or type of paper loaded Paper path obstruction Possible Defects Lower pick up roller assembly Lower feed roller assembly Lower pick up roller drive assembly Upper paper guide assembly Lower paper guide assembly Lower paper cassette Pick pressure adjustment Main drive gear assembly Idler assembly Paper feed drive belt Paper feed drive idler assembly Paper timing sensor Wiring or connectors PCL board 1 Check both paper paths and remove any jams Make sure paper is loaded properly in both cassettes Make sure the paper guides are positioned properly Check that the pick up roller feed roller and backup roller assemblies are clean Verify that J P40 J P62 J P67 and J P69 are connected properly Confirm that the paper in the cassettes meets paper specifications which are described in the Guide to Operations manual Remove the upper cassette Power on reset the printer Run test prints from the lower cassette Is error code 021 displayed No Go to 14 in this TAG Yes Continue Turn the printer off and inspect the following for damage or binding Lower paper guide assembly Upper paper guide assembly Paper feed drive belt Paper feed drive pulley Paper feed drive idler assembly Main drive gear assembly Lower pick up roller drive assembly Are all the parts in good working order No Replace the damaged parts then turn to TAG 00
69. Indication 030 Developer bias short detected 040 Photoconductor seam sensor not received or detected 041 Seam sensor sender short 042 Seam sensor sender open or the photoconductor is not installed 055 Erase lamp malfunction 4 Press STOP to exit Diagnostic Tests 004 intentionally excluded 010 Toner Supply Motor Test Open the front and top covers Remove the photoconductor unit and the developer unit Place the photoconductor unit in its protective packaging Insert the interlock by pass tool in the front cover Close the top cover Go to 010 Press READY to run the test The toner supply motor runs continuously o0 5 Oo Observe the toner supply motor through the open developer unit cavity Confirm that the motor is turning counterclockwise accompanied by a 1 on the display 7 Press STOP and READY alternately several times to verify the toner supply motor starts and stops This stops and restarts the test These codes may indicate specific error conditions Table 5 6 Toner Supply Motor Test Error Displays Display Indication 4 0 You forgot to remove the developer unit 090 You forgot to insert the interlock by pass tool 8 Press STOP to exit 9 Reinstall the developer unit and photoconductor unit 10 Remove the interlock by pass tool and close the front cover Diagnostic Tests 5 9 004 intentionally excluded 011 5 10 Main Charger Test 1 Remove th
70. P77 4 i 4 4 gt gt gt gt Disk Drive U P8 10 J P32 5 Ld lt gt gt mr IGS Board gt gt J P8 14 DC Power Supply J P91 5 PCL Board JP90 1 J PA2 1 Operator Panel L b gt Board J P94 1 lt lt J P7 1 J P27 1 a lt gt gt gt gt J P7 2 J P27 2 Printh eae ET PT beg J P7 3 J P27 3 r4 4 gt gt gt gt Figure 6 2 Simplex 5 Vdc Circuit 6 16 Wiring Diagrams and Electrical Data DC Power Supply res J P77 1 P lt lt gt gt gt gt Disk drive J P32 10 IGS J P74 34 Si li f J P73 3 gt gt ignal interface Board h board DER J P8 6 External J P58 1 J P57 1 m attachment 4 9 Paper timing connector di iila sensor PAS J P40 25 J P60 1 J P59 1 Upper paper E lt 4 b Kx x empty sensor ui p os 1 Lower paper empty sensor da J P50 1 J P49 1 Board Paper exit iod i sensor J P40 26 J P50 4 J P51 1 Output tray lt A EE Fr full sensor J P54 1 J P53 1 Tray front ke PS sensor J P54 4 J P55 1 gt D gt Tray rear sensor pa w P12 8 Power control e Sa a board 2 puia P121 Power control 7 neo aic Board 3 9 4 4 gt gt J P41 50 J P25 1 Developer unit e lt 4 gt gt J P40 3 J P26 1 4 4 gt gt Erase lamp Figure 6 3
71. Print Description No images or characters The paper is not discolored Go to TAG 800 Prints Blank or With Dark Horizontal Bands TAG 815 Prints Resulting From Printhead Malfunctions 4 6 Print Quality Samples Sample 4 Light Print Light areas qgUgeutt t 70122656789 17572178 ARCDEFGHTJKLINOPORSTUVHXYZINIT abcdefghijklmnoparstuvwxvz i 7 1 85 5R Ox 701023456 BI cao 78 ARCDEFEHWTJELMNNOPORSTUVHXYZIN T 7 abcriefnohiikIminparstuveuxvziil AG Hee tain pi tnu LETTER 1 955R 9t 7 70123656789 5 77 28 ARCPEF GITE LHINOPORSTUVHXYZIN 7 abcdefohijkImnoparstuvuxvz i J g55R t2 012365678 5 7518 ARCDEL GI T JKLITHDPORSTUVHXYZIN T7 7 abcdefahi jk1mnoparstuvexvz i117 Light areas 1 43 pori a T D om n n 1 1 i t i i li l xol in mele nj ec nt vens en tee tenen nter fo rome roam pnr cun prep arit AMA idit fpe dne Figure 4 4 Light Print Description Images or characters are lighter than normal Examine the letters H T M and E if the vertical strokes are dark enough but the diagonal strokes are stair stepped the problem is related to the printhead Carrier particles may make the print feel gritty Go to TAG 801 Prints Light or Light With Carrier Particles Print Quality Samples 4 7 Sample 5 Light Print With Background ke Wi a a WP T T i t t 1 8 45E 0945 0125 456789 2 13 amp BRCDEFCHIJKLMNDPORSTUVR
72. Refer to the table at the end of this TAG Is the combination of lights and display you noted identified in the table No Replace the operator panel If this resolves the problem then turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue Turn the printer off and unplug the power cord e Disconnect J P41 and J P42 e Check the wiring indicated on the table below Is there an open or short to ground continuity No Replace the operator panel If this resolves the problem then turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the defective connectors or wiring then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 127 Wiring Table Refer to the table below to check the wiring for an open or short to ground In the display panel illustrations on status lights which may be dimly lit are black Table 3 1 Drive Indication Wiring Failure Description Operator Panel J P42 7 to Open J P90 7 to J P41 14 No indications J P42 7 to Short to ground J P90 7 to J P41 14 J P42 11 to Open J P90 11 to J P41 10 J P42 12 to Open J P90 12 to J P41 9 J P42 13 to Open J P90 13 to J P41 8 Sponsi ele All lights ON J P
73. Sample 16 Blurred Images or Characters 0 0 0 0 0 eee eee ee eee 4 19 Sample 17 Varying Print Density 0 0 0 cece eee ee 4 20 Sample 18 Background 0 0 ccc eee tees 4 21 Sample 19 Residual Images 0 0 0 c eee cee eee eee 4 22 sample 20 Wrinkles soss seregno 4e dui ce oe dialed cc wth awe e 4 23 Sample 21 Fusing Problems lsleeeeee ee 4 24 Print Quality Samples Print Quality Samples This section contains flawed test prints along with a good test print for comparison Com pare print samples from your customer s print job or from test prints you ve run with the samples in this section If you find a match note the TAG i e troubleshooting procedure listed under the sample Turn to that TAG to begin troubleshooting All of the TAGs are outlined in Chapter 3 Troubleshooting Analysis Guide TAGs If your customer s prints show more than one problem resolve them one at a time in the order in which they are listed in this section Print Quality Samples 4 3 Sample 1 Good Quality Print 4 4 foc vn abcdefghijklmnopqrstuvwxyz il na abcdefghijk1mnoparstuvwxyzii Bi gt _ I 5 amp x 01234567891 7 9 ABCDEFGHIJKLMNOPQRSTUVWXYZIN 7 abcdefghijklmnoparstuvwxyz J 3 0123456789 5 7 8 ABCDEFGHIJKLMNOPQRSTUVWXYZINI1 7 abcdefghiiklmnoparstuvwxy
74. Standard DCE to DTE Signal Definition Special Considerations for RS 232 Host Interface Users If the READY light comes on and the ON LINE light does not come on when you are Host Printer Signal DCE DTE Signal GND 1 1 GND GND 7 7 GND RI 22 22 RI 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 installing the printer one or more of the pin signals on the RS 232 cable may be incorrect The host computer may be using a non DCE RS 232C port If so you may have to modify your cable or purchase a new cable with the proper pin assignments Several possible alternate RS 232C cable configurations follow Wiring Diagrams and Electrical Data 6 23 DTE Host to Printer Option 1 Table 6 3 DTE Host to Printer Connector Wiring Option 1 Host Printer Signal DCE DTE Signal GND 1 lt gt 1 GND GND 7 lt gt 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 Ill ce 3 RD DTE Host to Printer Option 2 Table 6 4 DTE Host to Printer Connector Wiring Option 2 Host Printer Signal DCE DTE Signal GND 1 4 1 GND GND 7 lt gt 7 GND DTR 20 20 DTR DCD 8 lt lt aa 8 DCD DSR 6 6 DSR RTS 4 4 RTS CTS 5 haue coni 5 CTS TD 2 2 TD RD 3 Mer Lo 3 RD 6 24 Wiri
75. TAG 002 Check amp Problem Resolution Yes Replace the printhead assembly unit then turn to TAG 002 Check amp Problem Resolu tion Troubleshooting Analysis Guide TAGs 3 161 TAG 804 Prints With Light Horizontal Bands 3 162 Error Code 804 Possible Causes Loose printhead connectors Possible Defects Transfer charger unit Photoconductor unit Main charger Turn the printer off and unplug the power cord Perform the every call cleaning procedure described in Chapter 9 General Printer Mainte nance e Verify that J P30 and J P31 are connected properly Turn the printer on e Run test prints Has the problem been resolved No Continue Yes Contamination or loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution Check the voltages as outlined in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue Have the photoconductor unit and main charger have been replaced recently No Continue Yes Go to 5 in this TAG No Replace the photoconductor unit and main charger Yes Turn on the printer Run test prints Has the problem been resolved No Reinstall the original photoconductor unit and main charger then continue Yes Turn to TAG 002 Check amp Problem Resolution Replace the transfer charger unit Has the problem been res
76. amp Problem Resolution 9 Replace the high voltage unit e Run test prints Has the problem been resolved No Reinstall the original high voltage unit and continue Yes Turn to TAG 002 Check amp Problem Resolution 10 Replace the printhead assembly e Run test prints Has the problem been resolved No Reinstall the original printhead assembly and continue Yes Turn to TAG 002 Check amp Problem Resolution 3 164 Troubleshooting Analysis Guide TAGs 11 Replace the IGS board e Run test prints Has the problem been resolved No Replace the main charger lead wiring then turn to TAG 002 Check amp Problem Resolu tion Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 165 TAG 806 Prints with Dark Spots or Scratches 3 166 Error Code 806 Possible Causes Paper path contamination Paper supply defects Toner Possible Defects Photoconductor unit Main charger Fuser unit Developer unit Cleaner unit Turn the printer off and unplug the power cord Perform the every call cleaning procedure described in Chapter 9 General Printer Mainte nance Turn the printer on e Run test prints Has the problem been resolved No Continue Yes Contamination was at fault Turn to TAG 002 Check amp Problem Resolution Check the voltages as outlined in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high vol
77. amp Problem Resolution Troubleshooting Analysis Guide TAGs TAG 045 Main Charger Circuit Shorted Error Code 045 Possible Defects Main charger High voltage unit Main charger terminal assembly Connectors or wiring PCL board 1 Turn the printer off and unplug the power cord e Verify that J P23 J P41 J P85 P124 P143 and the high voltage unit main charger lead are con nected properly Clean the main charger contacts e Power on reset the printer e Run test prints Is error code 045 displayed No Loose connectors or dirty contacts were at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue 2 Has the main charger been replaced recently No Continue Yes Go to 4 in this TAG 3 Replace the main charger and photoconductor unit e Run test prints Is error code 045 still displayed No The main charger was at fault Turn to TAG 002 Check amp Problem Resolution Yes Reinstall the original main charger and photoconductor unit then continue 4 Turn the printer off and unplug the power cord Disconnect the main charger lead from the high voltage unit e Check for continuity the main charger terminal assembly s lower contact to the lead removed from the high voltage unit Is there continuity No Repair or replace the high voltage lead or the main charger terminal block then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 61
78. assembly Fuser drive belt Vacuum transport unit Exit roller assembly Upper paper guide assembly Lower paper guide assembly Paper timing guide assembly Pick pressure adjustment PCL board Connectors or wiring Caution When clearing this jam be careful not to get toner on your clothing as it may stain If toner gets on your clothing rinse your clothes with cold water immediately to avoid stains 1 Check the paper path and remove any jammed paper Warning The fuser unit may be very hot e Check the fuser unit for paper wrapped around the heat roller Is paper wrapped around the heat roller No Continue Yes If the paper is black or very dark with no printing go to TAG 805 Black Prints If the paper is very dark and does have printing go to TAG 811 Background Residual Images Dark Prints 2 Check both paper paths for damage or obstructions Confirm that J P13 J P22 J P40 J P58 and J P65 are connected properly e Check that the paper is properly loaded e Confirm that the paper in the cassettes meets paper specifications described in the Guide to 3 34 Troubleshooting Analysis Guide TAGs Operations manual e Check that the fuser unit is installed properly e Power on reset the printer Runtest prints Is error code 022 still displayed No Paper incorrectly loaded incorrect paper type in use or a loose connector was at fault Turn to TAG 002 Check amp Problem Resolution Yes
79. ce eee eee ee 7 92 Upper Duplex Drive Clutch Assembly Removal 0 0 0005 7 94 Duplex Route Motor Solenoid Assembly Removal 004 7 95 A Roller Removal srece tii enese riiin Resta eee tu elio e ie E 7 96 B Roller Removal seeeeeeeee I 7 97 C Roller Removal sy eS ea dabei id ba ean edu 7 98 C Roller Solenoid Removal 00 cece eee eee eee 7 99 Duplex Route Separator Removal 0 0 eee cee ee 7 100 Duplex Paper Path Sensor Removal 0 0 cee ee eee eee eens 7 102 Removal Replacement Procedures 7 3 Removal Removal This section includes step by step instructions for removing all field service replaceable parts in the printer Each part is addressed under its own heading as outlined on the pre ceding contents pages Most of the procedures are applicable to both the simplex and duplex printer models When the procedures differ between the two printers the word simplex or duplex is included in parentheses Before You Begin 7 4 To remove a part follow the instructions provided To replace a part follow the steps in reverse order unless otherwise noted During reassembly make sure to reconnect all con nectors properly and seat gears and other moving parts properly Power Considerations Before removing a part make sure the printer is turned off and that the power cord is dis connected Photoconductor Removal If it is necessary to remove th
80. connectors or wiring from P41 26 to P81 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue 15 Turn the printer off e Reconnect J P81 e Disconnect J P82 Turn the printer on Check J P8 13 for 24 Vdc Is the voltage 24 Vdc No Repair or replace the connectors or wiring from J81 1 to P82 1 then turn to TAG 002 Check amp Problem Resolution Yes Replace the counter assembly then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 95 16 Turn the printer off e Reconnect J P41 e Disconnect J P69 Turn the printer on Check J P8 13 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the lower pick up roller assembly then turn to TAG 002 Check amp Problem Res olution 17 Turn the printer off e Reconnect J P69 e Disconnect J P65 Turn the printer on Check J P8 13 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the paper timing roller assembly then turn to TAG 002 Check amp Problem Reso lution 18 Turn the printer off e Reconnect J P65 e Disconnect J P66 Turn the printer on Check J P8 13 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the upper feed roller assembly then turn to TAG 002 Check amp Problem Resolu tion 19 Turn the printer off e Reconnect J P66 e Disconnect J P67 Turn the printer on Check J P8 13 for 24 Vdc Is the voltage 24 Vdc
81. developer unit e Run test prints e Check TP3 31 for voltage change from 12 Vdc to 0 Vdc while running test prints Does the voltage change from 12 Vdc to 0 Vdc every other print cycle No Go to 11 in this TAG Yes Continue 9 Turn the printer off and unplug the power cord e Disconnect J P41 Remove the developer unit Check for continuity P41 44 to J25 2 P41 47 to J25 3 and P41 50 to J25 1 Is there continuity on each No Repair or replace the connectors or wiring P41 44 to J24 2 P41 47 to J25 3 or P41 50 to J25 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 183 10 11 12 13 14 3 184 Verify that the toner patch sensor board connector mounted on the developer unit is connected properly Is it connected properly No A loose connection was at fault Turn to TAG 002 Check amp Problem Resolution Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Turn the printer off and unplug the power cord e Disconnect J P41 and J P24 Check P41 30 to P24 2 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 30 to P24 2 then turn to TAG 002 Check amp Problem Resolution Yes Continue Reconnect J P24 e Disconnect J P23 Check P41 33 to P23 7 for continuity Is there continuity No Continue Yes Repair or replace the connectors or wiring from P
82. each front cover hinge Gas Spring C Clip Gas Spring Detail 4 7 18 Removal Replacement Procedures Operator Panel Removal Operator Panel Removal To remove the operator panel 1 Open the front cover 2 Remove the two screws holding the operator panel in place 3 Disconnect connector CN42 4 Remove the ground screw Ground Screw 7 19 Removal Replacement Procedures Counter Removal Counter Removal To remove the counter Open the front cover Remove the screw holding the counter in place Pull out the counter kh UO N Disconnect connector CN82 CN82 7 20 Removal Replacement Procedures IGS Board Removal IGS Board Removal To remove the IGS board Open the back cover Disconnect connectors CN31 CN32 CN33 and CN74 For the hard drive option disconnect the drive s data cable Push the two retaining clips away from the board Remove the IGS board a Q N Retaining Clips Hard Disk Drive CN32 Connector CN31 Removal Replacement Procedures 7 21 PCL Board Removal PCL Board Removal To remove the PCL board Open the back cover Disconnect connectors CN33 CN37 CN40 CN41 and CN91 Duplex only also disconnect connector CN36 Push the two retaining clips away from the board Remove the PCL board oa 5 O N Change the settings of the DIP switches on the replacement PCL to match the switch settings on the original PCL CN91
83. ee Photoconductor PCLE 5 and ies Hewlett Packard Printer Con trol Language Software PCL 222i Printer Control Logic Board Hardware PELS uites HP Printer Control Language Version 5 PCU niter Photoconductor Unit PES oot ee ght Paper Full Sensor PH El Deere A A C Power Cord PIA etc obec Peripheral Interface Adapter PEL 1 ient Parallel Interface Timer PMP Page Map Primitives POR iem Power On Reset PPS LES Paper Path Sensor B C Sensor Duplex only PROM Programmable Read Only Memory PS i Lg RAeL S PostScript PSS ires Photoconductor Seam Sensor PIM jc e Programmable Timer Module PLS oie ee ont oe Paper Timing Sensor PW CONT Power Control 2 PW CONT3 Power Control 3 PWBA Printed Wire Board Assembly RAM Random Access Memory Resist Motor Registration Motor Duplex only ROM Read Only Memory Root Motor C Roller Motor Duplex only A 2 RPS 1 bation Se Registration Paper Sensor Duplex only RSS ees Registration Side Sensor Duplex only SCC uires Serial Communication Controller SIG IF or SIF Signal Interface Board SRAM Static Random Access Memory SRE wo Loewe System Reference Code SRMR2 Side Registration Motor Control 2 Duplex only Suction FA3 Suction Fan SW dive iva Upper Cassette In Switch SW6 Lower Cassette In Switch TAG Troubleshooting Analysis Guide TG es eem Toner Conce
84. eee ee 3 142 TAG 753 External Communications Malfunction 2 0002 eee eee 3 143 TAG 754 Attachment Option Malfunction sse eese 3 146 TAG 800 Prints Blank or With Dark Horizontal Bands 4 3 148 TAG 801 Prints Light or Light With Carrier Particles 0 4 3 152 TAG 802 Prints With Voids or White Spots eene 3 158 TAG 803 Prints With Light or White Vertical Streaks 0004 3 160 TAG 804 Prints With Light Horizontal Bands 0 0 00 0 00000 3 162 TAG 805 Black Prints 2 cece cence eens 3 163 TAG 806 Prints with Dark Spots or Scratches 0 0 0 0 0c eee eee eee 3 166 TAG 807 Misregistered Skewed Prints Simplex 0 00000005 3 168 TAG 808 Prints Overtoned Dark Vertical Streaks 00000 3 172 TAG 809 Blurred or Smeared Vertical Streaks on Prints 04 3 177 TAG 810 Uneven Density or Dark Areas on Prints 00000005 3 180 TAG 811 Background Residual Images Dark Prints 00 3 182 TAG 812 Uneven or No Fusing on Prints 2 0 0 0 eee ee eee eee 3 187 TAG 813 Residual Images on Prints 3 189 TAG 815 Prints Resulting From Printhead Malfunctions 3 191 TAG 900 Top Cover Interlock Malfunction Duplex 0 3 192 TAG 901 Misregistration Skewed Prints Duplex 00 0000 000 3 194 TAG 902 Paper Jam in D
85. from the disk drive to the IGS board cable and replace the cable from J P31 to J P79 to J P30 The causes of error code 574 or 576 may alter the information on the diskette You may have to replace the diskette with another known to be good Verify that a diskette has been inserted properly e Verify that the write protect notch is closed Turn off the printer Verify that J P8 J P77 J P79 and J P31 are connected properly e Power on reset the printer Has the problem been resolved No Continue Yes Loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution Is error code 451 displayed No Go to 5 in this TAG Yes Continue Power on reset the printer Is error code 451 still displayed No Go to 5 in this TAG Yes Continue Replace the diskette with another diskette known to be correct for the customer s system configura tion e Power on reset the printer Is error code 451 still displayed No The diskette was at fault Turn to TAG 002 Check amp Problem Resolution Yes Replace the disk drive assembly then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 5 Is error code 572 displayed No Go to 7 in this TAG Yes Continue 6 Turn the printer off and unplug the power cord e Disconnect J P31 and J P79 Check P31 28 to P79 28 for continuity to ground Is there continuity No Replace the disk drive assembly If this resolves the p
86. full sensor Paper exit sensor Tray front sensor Tray rear sensor Erase lamp PCL board Possible Defects Duplex Printers Duplex control board 1 Duplex control board 2 Paper path sensor Cover open sensor Restart side sensor Restart paper sensor 1 Turn off the printer and unplug the power cord Verify that J P303 J P331 J P323 J P305 J P310 J P306 J P32 and J P33 are connected properly e Power on reset the printer Has the problem been resolved No Continue Yes Loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution 2 Check J P8 6 for 412 Vdc Is the voltage 12 Vdc No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 79 3 Turn the printer off e Disconnect J P330 Turn the printer on Check J P8 6 for 12 Vdc No Is the voltage 12 Vdc No Continue Yes Go to 35 in this TAG 4 Turn the printer off e Disconnect J P32 Turn the printer on Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Go to 8 in this TAG Yes Continue 5 Turn the printer off e Reconnect J P32 e Disconnect J P74 Turn the printer on Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Replace the IGS board then turn to TAG 002 Check amp Problem Resolution Yes Continue 6 Does the printer have an attachment option No Replace the signal interface board then turn to TAG 002 C
87. fuser unit e Check P41 21 to P5 7 and P41 22 to P5 6 for continuity Is there continuity on both No Repair or replace the connectors or wiring as necessary then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P41 21 and P41 22 for continuity to ground Is there continuity to ground on either No Replace the fuser unit If this resolves the problem then turn to TAG 002 Check amp Prob lem Resolution If this does not resolve the problem replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring that have continuity to ground P41 21 to P44 2 J44 2 to P5 7 or P41 22 to P44 1 J44 1 to P5 6 then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs TAG 072 Fuser Unit Temperature Too High Error Code 072 Possible Defects Connectors or wiring Fuser unit AC power supply unit PCL board The conditions that cause error code 072 often cause the fuser unit s thermal fuse to open This usually necessitates replacement of the fuser unit 1 Turn the printer off and unplug the power cord e Verify that J P44 J P40 J P10 J P70 and J P8 are connected properly Make sure the fuser unit is properly installed Read the following steps before taking further actions e Power on reset the printer e Watch through the output tray opening to see if the fuser lamp comes on Ifthe fuser lamp comes on i
88. istration Go to TAG 807 Misregistered Skewed Prints Simplex or TAG 901 Misregistra Skewed Prints Duplex Print Quality Samples 4 16 Sample 14 Misregistration Po ee I eae a ar ct ee ee ee ea ee or 19 BORK C1 0123456789 1 2519 ABCDEFGHIJKLMNOPQRSTUVWXYZIX 1 abcdefghijklmnopqrstuvwxyz il 1 99X amp 5 012368567891 2 8 ABCDEFGHIJKLHNOPQRSTUVWXYZ abcdefghijklmnopqrstuvwxyzii A6 bm dipl rp supp paper e Figure 4 14 Misregistration Description The entire image is not correctly located from the leading edge of the paper The top or bottom image area may be missing Go to TAG 807 Misregistered Skewed Prints Simplex or TAG 901 Misregistration Skewed Prints Duplex Print Quality Samples 4 17 Sample 15 Overtoned Print 4 18 4 44 444 4444454 b 44 43244434353 HaHa d 442ddaduiddadadadad4d Li add 444 LRL MUR NER RE an aa ELM M LR hee DM M IM RADA E M M bi bal a v hehehe aer t Oe RN T pr l t VE E JUS TY TITITPPPTTS TT TPPPTYTTTTTTTTT 190109 0099 70123456789 0502 ABCDEFGHIJKLMNOPORSTUYWXYZUN 1 7 abcdefghijklaneparstuvwxyzii Excess 196084 O49 0125456789 1149233 qp toner ABCDEFGHIJKLNNOPQRSTUVWXYZIN 1 7 abcdefghijkimneparstuvwxyz i Background 1 99A Cer 7 79123456789 90d ABCDEFGHIJKLHNOPQRSTUVWXYZIN abcdefghijklanoperstuvwxyz il 1 95X8 A0
89. lead is connected properly e Verify that the main charger and transfer charger ground circuits are connected properly Remove the transfer charger from the upper paper guide Clean the transfer charger housing and contacts Clean the transfer charger wire Inspect the transfer charger socket in the upper paper guide for contamination e Verify that the transfer charger static eliminator brush on the transfer charger housing is grounded to the transfer charger metal housing Reinstall the transfer charger Clean the main charger contacts e Power on reset the printer Runtest prints Is error code 044 displayed No Loose connectors or a dirty transfer charger were at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue 2 Has the main charger been replaced recently No Continue Yes Go to 4 in this TAG 3 Replace the main charger and photoconductor unit e Power on reset the printer Runtest prints Has the problem been resolved No Reinstall the original main charger and photoconductor unit and continue Yes The main charger was at fault Turn to TAG 002 Check amp Problem Resolution 3 58 Troubleshooting Analysis Guide TAGs 4 Remove the transfer charger Inspect the housing for jammed paper Is paper jammed inside the transfer charger housing No Continue Yes Remove the jammed paper and check the transfer charger for damage then turn to TAG 022 Paper Jam in the T
90. motor gear Main drive gear assembly Developer coupling on the developer unit and the printer Are these mechanisms in good working order No Replace the defective parts then turn to TAG 002 Check amp Problem Resolution Yes Verify that the photoconductor main charger developer and fuser units are new If these items are new defective or contaminated toner may be the cause of the problem Replace the developer and cleaner units with units from the printer s manufacturer then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 167 TAG 807 Misregistered Skewed Prints Simplex If this problem occurs in the duplex printing mode only go to TAG 901 Misregistration Skewed Prints Duplex Error Code 807 Possible Causes Paper incorrectly loaded Wrong weight or type of paper loaded Possible Defects Upper cassette Lower cassette Upper paper guide assembly Lower paper guide assembly Paper timing guide assembly Paper timing roller assembly Upper pick up roller assembly Upper feed roller assembly Upper pinch rollers Lower feed roller assembly Lower pick up roller assembly Lower pinch rollers Paper feed drive belt Paper feed idler assembly Main drive gear assembly PCL board If the test pattern has a 20 line indicator at the top of the page registration is correct when the line of the indicator is at the leading edge of the print or 2 If the problem varies from print
91. needed then turn to TAG 002 Check amp Problem Resolu tion Yes Continue Open the printer s top cover and install an interlock by pass tool Turn the printer on e Wait until the motor turns on then proceed e Verify the vacuum transport fan is running by placing a sheet of paper over the holes in the transport unit Does the vacuum fan hold the paper No Go to 10 in this TAG Yes Continue Inspect the vacuum transport belts and gear for damage or binding Is the vacuum transport unit in good working order No Repair or replace the vacuum transport unit then turn to TAG 002 Check amp Problem Resolution Yes Go to 12 in this TAG Troubleshooting Analysis Guide TAGs 10 Run test prints Use extreme caution Check J P22 1 to J P22 2 for 100 Vac Is the voltage 100 vac No Continue Yes Replace the vacuum transport unit then turn to TAG 002 Check amp Problem Resolution 11 Run test prints Use extreme caution Check J P13 6 to J P13 3 for 100 Vac Is the voltage 100 vac No Replace the power control 2 board then turn to TAG 002 Check amp Problem Resolu tion Yes Repair or replace the connectors or wiring from J22 1 to P13 6 or J22 2 to P13 3 then turn to TAG 002 Check amp Problem Resolution 12 Inspect the fuser drive assembly and the fuser drive belt for damage or a slipping belt Are they in good working order No Replace the parts that are defective then turn to TAG
92. or wiring from P40 33 to P12 7 then turn to TAG 002 Check amp Problem Resolution 3 142 Troubleshooting Analysis Guide TAGs TAG 753 External Communications Malfunction Error Code 753 Symptoms Test prints can be made but jobs do not run Jobs do not print correctly Possible Causes Improper DIP switch settings Host computer Improper application Possible Defects IGS board communications cable Cable connectors Signal interface board Diskette Wrap connector DC power supply unit Attachment options Note Communication problems may require trial replacement of numerous parts After each trial replacement run the job that exhibited the failure 1 Turn the printer off and unplug the power cord Verify that J P8 J P32 J P74 and J P92 are connected properly e Verify that all communication cables are attached properly e Verify that the correct diskette is installed in the printer Confirm that the DIP switches on the signal interface board are set to their proper positions e Power on reset the printer Confirm that the printer s soft configuration is set properly Runthe failing job Has the problem been resolved No Continue Yes Loose connectors software configuration or DIP switches were at fault Determine which of these is at fault correct the problem then turn to TAG 002 Check amp Problem Resolution 2 Turn the printer off e Recheck the diskette for suitability e Verify that t
93. page 7 6 The every call cleaning procedure as the name implies is performed every time the printer is serviced It includes a thorough cleaning of the printer requiring the removal of all major components and performance of specific cleaning tasks related to each one It also includes vacuuming all excess toner and other contamination from the interior of the printer Paper Feed Tension Adjustment Procedure page 7 8 You may need to adjust the paper feed tension to correct jamming Adjustment procedures for older and newer printers are included Lubrication Procedures page 7 11 Lubrication procedures are performed whenever needed though lubrication should be applied sparingly The required lubricants including oil molycote and red grease can be purchased from the printer s manufacturer Tune Up Procedure page 7 18 The tune up maintenance procedure is performed when the printer has yielded sub stan dard prints after you ve completed standard maintenance procedures or has printed one to two million images A tune up maintenance kit is required for this procedure Safety Precautions Whenever servicing sophisticated electronic electro mechanical equipment common sense training caution and experience help in avoiding accidents and mishaps Be aware of the following safety precautions Follow all instructions in this document Follow all warnings and instructions marked on the printer Unplug the printer whe
94. plate 4 Remove the two screws holding the C roller solenoid in place 5 Loosen the set screw securing the actuator arm to the C roller 6 Disengage the solenoid from the actuator arm and remove it Replacement Note Install a new cable tie to secure the wires from CN315 to the mounting plate Actuator Arm CN315 Mounting Screws C Roller Solenoid Detail Removal Replacement Procedures 7 99 Duplex Route Separator Removal Duplex Route Separator Removal To remove the duplex route separator 1 2 3 4 5 6 7 8 Open the top cover Remove the rear duplex cover See page 7 17 Remove the upper duplex roller cover four screws Remove the duplex route motor solenoid assembly See page 7 95 Remove the front mechanism cover two screws Open the duplex cover Remove screw holding the return arm in place Disengage the return spring Duplex Route Motor Solenoid Assembly TTT SENSA Return Arm Screw E RAIA 717 Return Arm Front Side Detail Upper Duplex Roller Cover 7 100 Removal Replacement Procedures Duplex Route Separator Removal 9 Remove the front C clip from the route separator 10 Disengage the route separator from its side supports 11 Lift the route separator out from the duplex cover C Clip Location SN ABA Removal Replacement Procedures 7 101 Duplex Paper Path Sensor Removal Duplex Paper Path Sensor Removal T
95. power cord e Remove the envelope tray or feeder Loosen the upper paper size sensor assembly for access to the circuit board e Disconnect J P46 Activate the cassette in switch Check P46 1 to P46 2 for continuity Is there continuity No Replace the upper cassette in switch or wire harness W58 then turn to TAG 002 Check amp Problem Resolution Yes Continue 7 Reconnect J P46 e Disconnect J P40 and J P45 Check P40 49 to P45 2 for continuity Is there continuity No Go to 10 in this TAG Yes Continue 8 Check P40 48 to P45 3 for continuity Is there continuity No Continue Yes Replace the upper paper size sensor assembly If this does not resolve the problem replace the PCL board Then turn to TAG 002 Check amp Problem Resolution 3 22 Troubleshooting Analysis Guide TAGs 9 Reconnect J P40 and J P45 Remove the lower cassette Loosen the lower paper size sensor assembly for access to the circuit board e Disconnect J P43 and J P47 e Check J43 8 to J47 3 for continuity Is there continuity No Replace the lower paper size assembly then turn to TAG 002 Check amp Problem Resolu tion Yes Repair or replace the connectors or wiring from P45 3 to P47 3 P43 8 to J52 3 or P40 48 to P52 3 If this does not resolve the problem replace the upper paper size sensor assembly Then turn to TAG 002 Check amp Problem Resolution 10 Reconnect J P40 and J P45 Remove the lower cass
96. resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the high volt age unit then turn to TAG 002 Check amp Problem Resolution Yes The transfer charger unit was at fault Turn to TAG 002 Check amp Problem Resolution 11 Open the front cover and install an interlock by pass tool Remove the photoconductor unit Remove the developer unit e Run diagnostic test 010 e Watch the toner motor coupling in the developer unit cavity Does the coupling turn No Go to 20 in this TAG Yes Continue 12 Inspect the toner drive coupling on the developer unit for damage Is the coupling damaged No Continue Yes Replace the developer unit then turn to TAG 002 Check amp Problem Resolution 13 Rotate both the drive couplings on the developer unit clockwise Do both drive couplings rotate freely No Replace the developer unit then turn to TAG 002 Check amp Problem Resolution Yes Continue 14 Reinstall the photoconductor unit e Run diagnostic test 009 e Watch the developer drive coupling in the developer cavity Does the coupling turn No Repair or replace the main drive gear assembly then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 154 Troubleshooting Analysis Guide TAGs 15 16 17 18 19 Turn the printer off and unplug the power cord e Disconnect J P41 J P24 and J P23 e Check the following for continuity
97. screws 14 Remove the disk drive housing See page 7 25 15 Remove the printhead See page 7 23 16 Remove the DC power supply See page 7 31 17 Remove the main motor gear and bearing two C clips 18 Disconnect CN95 19 From the right side remove the two screws holding the main motor in place 20 From the back remove the three screws holding the main motor in place 21 Remove the main motor through the side of the printer Replacement Notes Remove the drive shaft key from the old motor Replacement motors are not sup plied with a key Be sure to tuck the CN95 connector under the motor after installation so that the wires do not protrude into the disk drive assembly area Main Motor Detail Capacitor Capacitor Contacts Removal Replacement Procedures 7 87 Main Gear Drive Removal Main Gear Drive Removal To remove the main gear drive Open the back cover Remove the lower back cover See page 7 7 Remove the paper feed drive cover three screws Remove the fuser drive cover three screws Remove the main drive cover one screw Remove the gear stay three screws Remove the cleaner drive belt See page 7 54 1 2 3 4 5 6 Remove the gear stay cover one screw 7 8 9 Remove the paper feed drive belt See page 7 58 1 0 Remove the main gear drive three screws Paper Feed Drive Cover LE Z Main Drive Cover Gear Stay Cover Gear Stay Main Gear
98. specification No Go to 20 in this TAG Yes Replace the high voltage unit then turn to TAG 002 Check amp Problem Resolution Replace the high voltage unit Has the problem been resolved No Reinstall the original high voltage unit and continue Yes Turn to TAG 002 Check amp Problem Resolution Replace the PCL board Has the problem been resolved No Reinstall original PCL board Go back to 3 in this TAG If this does not resolve the prob lem the IGS board cleaner terminal assembly or main charger terminal assembly may be at fault Determine which of these is at fault correct the problem then turn to TAG 002 Check amp Problem Resolution Yes Turn to TAG 002 Check amp Problem Resolution Check J P40 31 for 0 Vdc Is the voltage 0 Vdc No Replace the power control 2 board then turn to TAG 002 Check amp Problem Resolu tion Yes Continue Troubleshooting Analysis Guide TAGs 3 185 22 Turn the printer off and unplug the power cord e Disconnect J P40 Check P40 31 for continuity to ground Is there continuity No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue 23 Disconnect J P12 Check P40 31 and P12 5 for continuity to ground Is there continuity No Replace the power control 2 board then turn to TAG 002 Check amp Problem Resolu tion Yes Repair or replace the connectors or wiring from P40 31 to P12 5 then turn to TAG 002 Chec
99. this TAG Yes Continue Turn the printer off e Reconnect J P50 Turn the printer on Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Go to 27 in this TAG Yes Continue Turn the printer off e Reconnect J P54 e Disconnect J P53 Turn the printer on Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Continue Yes Replace the front tray sensor then turn to TAG 002 Check amp Problem Resolution Turn the printer off e Disconnect J P55 Turn the printer on Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Continue Yes Replace the rear tray sensor then turn to TAG 002 Check amp Problem Resolution Turn the printer off and unplug the power cord e Disconnect J P54 Check J54 1 and J54 4 for continuity to ground Is there continuity to ground at either No You have failed to isolate the problem Return to the beginning of this TAG Yes Repair or replace the connectors or wiring from J54 1 to P53 1 or J54 4 to P55 1 then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 27 28 29 30 31 Turn the printer off Remove the exit cover e Disconnect J P49 and J P51 Turn the printer on e Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Go to 29 in this TAG Yes Continue Turn the printer off e Reconnect J P49 Turn the printer on e Check J P8 6 for 12 Vdc Is the voltage 12 Vdc N
100. to TAG 809 Blurred or Smeared Vertical Streaks on Prints Print Quality Samples 4 19 Sample 17 Varying Print Density hui ohn Dark density 1 86XE C 9 012365678915 25T8 ABCDEFGHIJKLMNOPQRSTUVWXYZIN abcdefghijklimnoparstuvwxyzii 1I BeXE COou 012345678913 z5 13 ABCBEFCHIJKLNNOPORSTUVWIYI pus abcdefghijRimnopaestuvuxyzil jul Normal density LETTER po die infan 1 5X amp 3 0123456789 2579 ABCDEFGHIJKLMNOPQRSTUYWXYZI N 1 ahbcdafghiiklenoggrstouvwuyzi ai 123456789 bu 4444444 Light density rbd lp hss M Qn Figure 4 17 Varying Print Density Description Some areas of the print are lighter or darker than normal Examine the letters H T M and E on your test print If the vertical sections are sufficiently dark but the diag onal sections appear stair stepped the problem may be is related to the printhead Go to TAG 810 Uneven Density or Dark Areas on Prints TAG 815 Prints Resulting From Printhead Malfunctions 4 20 Print Quality Samples Sample 18 Background T TOT TU TIS TE TITO TIS TTE I p PORK C Hy 0123456789 lt gt a 3 ABGDEFGHIJKLNNOPQRSTUYWXYZINI7_ lt Bos bedefahijkinnoparstuvwxyz i gt v 1 06X amp 99 25 70123456789 Karta AB DEFGHIJKLMNOPQRSTUVWXYZIN lanopqrstuvwxyz i Dark jana background LETTER gt EP OORE C 0123456789 2T ABCDEFGHIJKLMNOPQRSTUVWX
101. top covers 2 Raise the upper paper guide 3 Remove the lower paper guide See page 7 51 Lower Paper Guide Paper Timing Guide LY Ser Hyg NAHI aE p ery y 7 Mounting Screw Front Detail Removal Replacement Procedures 7 52 Paper Timing Guide Removal 4 Remove the paper feed drive cover three screws 5 Remove the back screw holding the paper timing guide in place Remove the paper timing guide 6 Disconnect CN58 Paper Feed Drive Cover Mounting Screw Back Detail 7 53 Removal Replacement Procedures Cleaner Drive Belt Removal Cleaner Drive Belt Removal To remove the cleaner drive belt Open the back cover Remove the fuser drive cover three screws Remove the main drive cover one screw A OO N 2a Lift the idler arm and slide the cleaner drive belt off the gear Main Drive Cover Fuser Drive Cover Cleaner Drive Belt Detail 7 54 Removal Replacement Procedures Cleaner Drive Removal Cleaner Drive Removal To remove the cleaner drive Open the back cover Remove the fuser drive cover three screws Remove the main drive cover one screw Remove the cleaner drive belt See page 7 54 Remove the two high voltage leads o0 fF O N a Remove the cleaner drive three screws Main Drive Cover Fuser Drive Cover Cleaner Drive Detail Removal Replacement Procedures 7 55 Fuser Drive Belt Removal Fuser Dr
102. will print all test prints stored in the printer s buffer then stop If the test pattern prints successfully the problem probably originates with the host system or a protocol converter connected to the host Printer and Troubleshooting Overview Protocol Converters Many protocol converters have a self test function or configuration mode that enables the user to check the proper functioning of the control You can reconnect the host interface and ask the customer to exercise this function of the converter If the printer receives data and prints it even if the output is garbled you have isolated the problem as one that belongs to the host or the protocol converter The problem is not a printer problem and the customer must seek assistance elsewhere in resolving the problem Reading the Error Log One of the sheets printed prior to the test pattern is the formatted error log maintained by the printer in a file named ERROR LOG The first line of the formatted log lists paper jams A 3 digit error code or codes is followed by a 4 digit number indicating how many times the error has occurred since the error log was last cleared See Clearing the Error Log on page 1 24 The second line lists the last 15 errors The last line indicates the last error that required a power on reset POR Paper Jams 020 0001 021 0000 022 0001 023 020 020 022 022 022 022 071 042 000 000 000 000 000 000 000 p Last 15 errors Last e
103. 0 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Go to 19 in this TAG Check J P11 1 for 424 Vdc Is the voltage 24 Vdc No Continue Yes Replace power control 2 board then turn to TAG 002 Check amp Problem Resolution Check J P8 11 for 24 Vdc Is the voltage 24 Vdc No Replace the DC power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P11 1 to P8 11 then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 19 20 21 22 23 24 Turn the printer off and unplug the power cord e Disconnect J P70 and J P10 Check P70 1 to P10 1 for continuity Is there continuity No Repair or replace the connectors or wiring from P70 1 to P10 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P70 2 and P10 2 for continuity Is there continuity No Repair or replace the connectors or wiring from P70 2 to P10 2 then turn to TAG 002 Check amp Problem Resolution Yes Continue Reconnect J P70 Connect negative lead of meter to P10 2 and positive lead of meter to P10 1 Is the resistance approximately 550K 0 No Replace the AC power supply then turn to TAG 002 Check amp Problem Resolution Yes Continue Disconnect J P12 Check J10 2 power control 2 board for continuity to ground Is there continuity No Continue Yes Replace the powe
104. 002 Check amp Problem Resolution Yes Replace the printhead assembly then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 179 TAG 810 Uneven Density or Dark Areas on Prints Error Code 810 Possible Defects Photoconductor unit Main charger Developer unit Cleaner unit 1 Perform the every call cleaning procedure described in Chapter 9 General Printer Maintenance Turn the printer on Runtest prints Has the problem been resolved No Continue Yes Contamination was at fault Turn to TAG 002 Check amp Problem Resolution 2 Check the voltages as outlined in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Have the photoconductor unit main charger cleaner unit and developer unit with new toner cartridge been replaced recently No Continue Yes Go to TAG 811 Background Residual Images Dark Prints 4 Replace the photoconductor unit and main charger e Run test prints Has the problem been resolved No Reinstall the original photoconductor unit and main charger and continue Yes Turn to TAG 002 Check amp Problem Resolution 5 Replace the cleaner unit Runtest prints Has the problem been resolved No Reinstall the original cleaner unit and continue Yes Turn to TAG 002 Check amp Problem Resolution 3
105. 1 High Voltage Unit Removal 0 0 2c ee eens 7 32 Photoconductor Seam Sensor Removal 0 00 cece eee eee eee 7 33 Photoconductor Rear Guide Rail Removal sees 00 e eee 7 35 Signal Interface Board Removal 0 0 c cee eee eects 7 37 Power Control Board Removal leeeeeeeeeeee eee 7 38 Jogging Motor Control Board Removal sees eee 7 39 Upper or Lower Paper Size Sensor Removal eseleleees 7 40 Upper Cassette Mount Removal 0 00 cece eee eh 7 41 Lower Cassette Mount Removal 0 0 0 0 cece eee eee 7 45 Upper Paper Guide Removal seeeeeeeeee eee 7 48 Upper Paper Guide Roller Removal 00 eee eee 7 50 Lower Paper Guide Removal 0 0c eee eee es 7 51 Paper Timing Guide Removal 0 0 eee cece eee 7 52 Cleaner Drive Belt Removal 0 0 0 eee cece eh 7 54 Cleaner Drive Removal 0 0 7 55 Fuser Drive Belt Removal 0 0 0 eee cece eects 7 56 Removal Replacement Procedures Fuser Drive Removal 0 0 0 ccc cee es 7 57 Paper Feed Drive Belt Removal 0 0 0 0 c cee ee ee eee 7 58 Paper Timing Roller Removal 0 0 0 cece eects 7 59 Upper Feed Roller Removal 0 0 0 cee eee eee eee 7 60 Lower Feed Roller Removal 0 0 0 0 cece eee cece teenies 7 61 Upper Pick Up Roller Removal 0 0 0c cece eee eee 7 62 Upper Pick Up Roller Dr
106. 1 1 to P8 13 then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 27 3 28 10 Turn the printer off and unplug the power cord e Disconnect J P40 and J P57 Check the following for continuity P40 16 to P57 2 P40 25 to P57 1 P40 12 to P57 3 Is there continuity on all No Repair or replace the connectors or wiring from P40 25 to J P58 1 to P57 1 P40 16 to J P58 2 to P57 2 or P40 12 to J P58 3 to P57 3 Then turn to TAG 002 Check amp Problem Resolution Yes Replace the paper timing guide If this does not resolve the problem replace the PCL board Then turn to TAG 002 Check amp Problem Resolution Turn the printer off Open the back cover and install an interlock by pass tool Remove the paper feed cover to expose the upper paper pick roller assembly Warning To avoid the risk of injury use extreme caution as gears and belts are exposed 11 12 e Run diagnostic test 006 testing the upper pick up roller clutch e Check TP3 9 for a voltage change from 24 Vdc to 0 Vdc Does the voltage change from 24 Vdc to 0 Vdc No Continue Yes Go to 12 in this TAG Turn off the printer and unplug the power cord e Disconnect J P40 and J P68 e Check P40 9 to J68 2 and P40 11 to J68 1 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 9 to J68 2 or P40 11 to J68 1 Then turn to TAG 002 Check amp Problem
107. 1 to P40 2 then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the erase lamp assembly If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the PCL board turn to TAG 002 Check amp Problem Resolution 3 66 Troubleshooting Analysis Guide TAGs TAG 070 Fuser Unit Malfunction Error Code 070 073 Symptoms No AC power at the fuser Possible Defects Fuser unit Power control 2 board AC power supply unit DC power supply unit Connectors or wiring PCL board Note A lack of continuity can result in fuser unit damage If there is no continuity replace the fuser unit when replacing the connectors and or wiring Turn the printer off and unplug the power cord e Verify that J P44 J P4 J P10 J P11 J P12 J P70 J P40 J P41 J P8 and J P5 bottom of fuser unit are connected properly e Verify that the fuser unit is installed properly Read the following steps before taking further action e Power on reset the printer e Watch through the output tray opening to see if the fuser lamp comes on Note If the fuser lamp comes on immediately after power on turn off the printer and replace the AC power supply Is error code 070 or 073 displayed No A loose connector was at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue Has the fuser unit been replaced recently No Continue
108. 130 576 Drive controller read sector error 130 577 Drive controller read sector data checksum error 200 578 Drive controller write sector error 200 579 Drive controller read modify write error 200 580 No drive controller PITO interrupt 200 581 No drive controller DMA interaction 200 582 Drive controller DMAC transfer error 200 583 Drive controller DMAC transfer count error 200 584 Drive controller DMAC read sector error 200 585 Drive controller DMAC write sector error 200 586 Drive hard error 130 2 8 TAG Cross Reference Tables Print Quality TAG Cross Reference Table 2 9 Bit Map RAM Error Codes Code Bit Map RAM Error Code Meaning Go to TAG 600 Bit map RAM data path error 200 601 Bit map RAM bank selection error 200 602 Bit map RAM refresh error 200 603 Bit map RAM address path error 200 604 Incorrect ALU operation in bit map RAM data path 200 605 Incorrect origin data modifications 200 606 Total bit map RAM bank fault 405 610 Bit map RAM chip error 405 Table 2 10 Host Communication Error Codes Code Host Communication Error Code Meaning Go to TAG 701 No communication with host 753 702 Host communication protocol error 753 703 Host communication recoverable error 753 770 784 Ethernet communication error No TAG con tact software support Print Quality TAG Cross Reference Poor quality prints are another indication of printer problems Begin by run
109. 18 J519 J529 P514 TIj500 w514 S pete jPsta 514 P515 6 8 m Ij NPS PHS ILLS PES IULS IPES DSW IEM IPM Input Control Board 1400 Sheet Stacker Table 8 3 1400 Sheet Stacker Component Acronyms Acronym Component ERM Exit Roller Motor M1 EPS Exit Paper Sensor ERS Exit Roller Sensor OEM Out Elevator Motor M2 OELS Out Elevator Limit Sensor OEPS Out Exit Paper Sensor OJFM Out Jogging Front Motor M4 OJFS Out Jogging Front Sensor OJRM Out Jogging Rear Motor M3 OJRS Out Jogging Rear Sensor OLLS Out Lower Limit Sensor OULS Out Upper Limit Sensor OEM M2 a R re ERM M1 neat Power supply Sh 7 OEPS OLLS OULS OJRS Output tray LI OJFS Mes ipa zh Paper tray Output al full actuator control board 3 oJFM M4 OJRM M3 Eum OELS Front side Figure 8 5 1400 Sheet Stacker Component Locations Options 8 9 Bench Test Procedure The bench test procedure references the component acronyms in Table 8 3 on page 8 9 and the component locations in Figure 8 5 on page 8 9 Adapter plate Il Bl LI Output tray Stacker Unit cord Control connector Output tray Jack cable guide Figure 8 6 1400 Sheet Stacker Bench Test Preparation To bench test the 1400 sheet stacker Turn the printer s main power switch off R
110. 2 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 Clear the paper path Reinsert the upper cassette e Power on reset the printer e Run test prints from the upper cassette Is error code 020 displayed No Go to 10 in this TAG Yes Continue 4 Clear the paper path Inspect the paper timing sensor actuator for damage or binding Is itin good working order No Replace the paper timing guide assembly then turn to TAG 002 Check amp Problem Reso lution Yes Continue 5 Check the voltage between TP3 16 and ground on the PCL board With the printer powered on activate the paper timing sensor e Check for a voltage change from 0 Vdc to 12 Vdc Does the voltage change from 0 Vdc to 12 Vdc No Go to 9 in this TAG Yes Continue 6 Check TP3 11 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Return to the beginning of this TAG 7 Check J P91 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 8 Check J P8 13 for 24 Vdc Is the voltage 24 Vdc No Replace the DC power supply then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P91 1 to P8 13 then turn to TAG 002 Check amp Problem Resolution 9 Turn the printer off and unplug the power cord e Disconnect J P40 and J P57 Check the following for cont
111. 2 error line output disabled JP4 i j PE pin 12 out of paper line enabled j k PE pin 12 out of paper line disabled The four DIP switches on the signal interface board should be changed based on the host interface being used For an RS 232C host interface the DIP switches may be set in either direction they have no effect on an RS 232C interface For an RS 422 host interface set all four DIP swiches to ON by pushing them toward the exterior of the printer as illustrated ON Figure 6 8 RS 422 Host Interface DIP Settings 6 30 Wiring Diagrams and Electrical Data For a Centronics Parallel Host Interface set all four DIP switches to OFF by pushing them toward the interior of the printer as illustrated ON Figure 6 9 Centronics Parallel Host Interface DIP Settings PCL Board Settings The PCL board uses DIP switches to control the registration of prints Change these set tings only if directed to do so when following TAG 807 Printhead Circuit Board Settings The printhead circuit board uses jumpers to match printhead characteristics to controller characteristics Do not change these jumper settings they should remain as set at the fac tory Wiring Diagrams and Electrical Data 6 31 6 32 Wiring Diagrams and Electrical Data Chapter 7 Removal Replacement Procedures Removal Replacement Procedures 7 1
112. 2 to P19 2 then turn to TAG 002 Check amp Problem Resolution Disconnect J P4 and J P9 Check P4 4 to P9 2 and P4 4 to P100 1 for continuity to ground Is there continuity to ground No Continue Yes Repair or replace the connectors or wiring from P4 4 to P9 2 or P4 4 to P100 1 then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 24 25 26 27 28 29 Close the top cover e Check P4 5 for continuity to ground Is there continuity No Replace the AC power supply then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the top cover interlock switch assembly If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem repair or replace the connectors or wiring from P4 5 to J P84 1 to P131 or P132 to J P84 2 to P4 6 then turn to TAG 002 Check amp Problem Resolution Is the operator panel blank and are the cooling and AC power supply fans off No You have chosen an incorrect TAG Refer to the mechanical malfunctions cross reference table in Mechanical Malfunction TAG Cross Reference on page 2 12 to identify a more appropriate TAG Yes Continue Turn off the printer and unplug the power cord Check the wall power outlet for proper voltage Is the voltage correct If the circuit breaker was reset after beginning this TAG answer no No Go to 228 in this TAG Yes Continue
113. 222 a nde ands etes Re IR OHE RN Ret et 7 18 Operator Panel Removals coe dose s e Da erased un 7 19 Xi Xii Counter Removals otto ies eden eet ubi LA be bi Lai 7 20 IGS Board Removal isa xou Mea poat Mes ev bm sr IM dex urs eden de 7 21 PCL Board Removal cick iene iee pend ru pex sweet OL ERT p eis 7 22 Printhead Assembly Removal Js 2x0 Sanyo hee tenes ee wy wR ee eee Eus 7 23 Disk Drive Housing Removal 03 2220525 eat eoa eld ek speres 7 25 Cooling Fan Removal 5 26222 drer eu fends peed ene ecd tke 7 26 D plex Fan Removdl conocer ee OE EPIIT dae eee ee prr aha tales 7 27 Toner Motor Removal 2 22 22 2 9 44 BER ER Gee Rhee A ERIS gee hes 7 28 AC Power supply Removal io eue RR SEXUS aS hee Cw ES ae ea Y ds 7 29 DC Power supply Removal 222 5 peser us Reg ur ID RR RN IER SON da 7 31 High Voltage Unit Removal 22 2a 342 44 22 cave dodo sate ones AYER DE AE 7 32 PhotoconductorSeam Sensor Removal lees 7 33 Photoconductor Rear Guide Rail Removal 0 0 0 cee ee eee eee 7 35 Signal Interface Board Removal 1 iode re Hoesen tees apie sesh 7 3 Power Control Board Removal leeeeeeeee eee 7 38 Jogging Motor Control Board Removal 0 0 0 eee eee eee 7 39 Upper or LowerPaper Size Sensor Removal 0 0 00 eee eee eee 7 40 Upper Cassette Mount Removals uu ex ove xeu m e adeo eas e ees 7 41 Lower Cassette Mount Removal ocio dole SERE MERE eee ex MS 7 45 Upper Paper Guide Remov
114. 3 082 No back job offset sensor 083 083 Job offset mechanism malfunction 083 084 Duplex tray registration sensor not activated 901 085 Duplex tray registration sensor not deactivated 901 086 Duplex registration tray malfunction 901 090 Cover open 900 097 DC 12v power failure 097 098 DC 12v power failure 098 099 DC 24v power failure 099 100 PCL board command timeou 100 101 IGS controller diagnostic failure 101 Table 2 2 PCL IGS Communication Error Codes Code PCL IGS Communication Error Code Meaning Go to TAG 121 No controller command PCL board VSC command asserted 201 122 Command tag asserted VSC command not asserted 201 123 VSS not asserted PCL board status tag asserted 201 124 VSS asserted after PCL board sent status 201 125 VSS not asserted again though PCL board expects it 201 126 Command tag asserted during data byte sequence 201 127 PCL board detected parity overrun on command line 201 Table 2 3 PCL Error Codes Code PCL Error Code Meaning Go to TAG 130 Address or length error at initial microcode load 130 131 Checksum error at initial microcode load 130 132 RAM error at initial microcode load 100 133 No next block at initial microcode load 130 134 Incorrect format in initial microcode load file 130 140 PCL board ROM checksum error at power on diagnostic 100 145 PCL board RAM error at power on diagnostic 100 2 4 TAG Cross Reference Tables Table 2 3 PCL Error Codes Continued
115. 3 J P 308 6 8 duplex E2 J P 309 6 8 duplex E2 J P 310 6 10 duplex F3 J P 311 6 10 duplex F3 J P 312 6 10 duplex F3 J P 313 6 8 duplex F2 J P 314 6 8 duplex E2 Section 1 Printer and Troubleshooting Overview 6 5 Connector Locations The illustrations that follow show the relative location of all accessible connectors in the printer and illustrate the connector except for a few instances in which the connector is so simple that an illustration is unnecessary For the connector s schematic location refer to the chart on the preceding pages Connectors Inside the Front Cover 19 17 15 13 7 5 S3 1 J P 95 4 3 2 1 J P 42 20 18 16 14 12 10 8 6 4 2 J P 318 EMITE J P 82 BEEN 6 6 Wiring Diagrams and Electrical Data Connectors Inside the Left Cover J P 43 45 47 J P 46 48 2 1 Wiring Diagrams and Electrical Data J P 59 61 1 3 J P 119 120 127 128 6 7 Connectors on the Duplex Cover Duplex Control Board 1 J P 22 1 J P 306 J P 307 J P 308 J P 30
116. 40 and J P102 Check P40 32 for continuity to ground Is there continuity to ground No Replace the power control 3 board then turn to TAG 002 Check amp Problem Resolu tion Yes Repair or replace the connectors or wiring from P40 32 to P102 2 then turn to TAG 002 Check amp Problem Resolution 4 Run diagnostic test 008 Does the output tray move back and forth No Continue Yes Go to 15 in this TAG 5 Run diagnostic test 008 Use extreme caution Check J P19 1 to J P19 3 for 100 Vac while the test is running Is the voltage 100 Vac No Continue Yes Replace the jogging motor then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 75 6 Run diagnostic test 008 Caution Check J P101 2 to J P101 1 for 100 Vac while the test is running Is the voltage 100 Vac No Go to 9 in this TAG Yes Continue 7 Turn the printer off Disconnect J P101 and J P19 Check P101 2 to P19 1 for continuity Is there continuity No Repair or replace the connectors or wiring from P101 2 to P19 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue 8 Check P101 1 to P19 3 for continuity Is there continuity No Repair or replace the connector or wiring from P101 1 to P19 3 then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the job offset assembly then turn to TAG 002 Check amp Problem Reso lution 9 Run
117. 41 33 to P23 7 then turn to TAG 002 Check amp Problem Resolution Reconnect J P23 Disconnect J P85 from the high voltage unit Check P85 8 to J25 7 for continuity Is there continuity No Repair or replace the connectors or wiring from P85 8 to J25 7 then turn to TAG 002 Check amp Problem Resolution Yes Continue Reinstall the developer unit e Reconnect J P85 e Disconnect J P41 and J P24 e Check P41 40 to P24 3 for continuity Is there continuity No Repair or replace the connector or wiring from P41 40 to P24 3 then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 15 16 17 18 19 20 21 Reconnect J P41 and J P24 Turn the printer on e Run test prints Check TP4 40 for 0 5 Vdc while running the prints Is the voltage 0 5 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue Is a meter with a high voltage probe available No Go to 19 in this TAG Yes Continue Using a high voltage probe check J P25 7 for the proper voltage as described in Chapter 9 Gen eral Printer Maintenance Is the voltage correct No Replace the high voltage unit then turn to TAG 002 Check amp Problem Resolution Yes Continue Check the main charger transfer charger grid and cleaning bias described in Chapter 9 General Printer Maintenance Are any of the values out of
118. 41 7 CLR PAPER JAM light may be very dim J P42 8 to Open J P90 8 to J P41 13 J P42 8 to Short to ground J P90 8 to J P41 13 CLOSE COVER light may be very dim J P42 9 to Open J P90 9 to J P41 12 J P42 9 to Short to ground J P90 9 to J P41 12 ADD PAPER light may be very dim 3 128 Troubleshooting Analysis Guide TAGs Table 3 1 Drive Indication Wiring Failure Description Operator Panel J P42 10 to Open J P90 10 to J P41 11 J P42 10 to Short to ground J P90 10 to J P41 11 CLR PAPER light may be very dim J P42 11 to Short to ground J P90 11 to J P41 10 J P42 12 to Short to ground J P90 12 to J P41 9 J P42 13 to Short to ground J P90 13 to J P41 8 J P42 14 to Short to ground J P90 14 to J P41 7 Troubleshooting Analysis Guide TAGs 3 129 TAG 700 Output Tray Circuit Malfunction Error Code 700 Symptoms Output Tray Full light remains on will not light or lights prematurely Possible Defects Output tray full sensor Connectors or wiring Job offset assembly PCL board High capacity output unit 1 Turn the printer off and unplug the power cord Verify that J P50 and J P40 are connected properly e Power on reset the printer Has the problem been resolved No Continue Yes Loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution 2 Is a high capacity output unit installed on the printer No
119. 5 24 RS 232 Loopback Connections RS 232 Loopback Connection Reference pin 2 L r pin 3 pin 4 gt pin 5 pin 8 pin 20 pin 17 L LL h pin 24 Table 5 25 RS 422 Loopback Connections 4 5 6 7 8 9 RS 232 Loopback Connection Reference pin 2 ar pin 4 pin 9 gt pin 11 pin 7 4 pin 6 pin 14 LL r pin 13 Go to 103 Press READY to run the test If an error code appears check the Error Code TAG Cross Reference on page 2 3 to determine which TAG to follow If no error is detected the test exits automatically Press STOP to exit if an error is detected For some errors you may have to power on reset the printer Remove the wrap connectors 10 Reinstall the interface cable Diagnostic Tests 5 21 106 intentionally excluded 104 105 Communication Loop back Test Continuous Loop 8 9 Remove the interface cable from the printer Make sure the DIP switches on the signal interface board have been pulled toward the printer s back cover Close the back cover Install the RS 232C and RS 422 loop back connectors found in the tool kit mounted inside the right printer cover If you do not have loop back connectors jumper the connections as outlined in Table 5 24 RS 232 Loopback Connections on page 5 21 and Table 5 25 RS 422 Loopback Connections on page 5 21 Go to 104 Press READY to run the test If
120. 58 C 701234567891 2 8 ABCDEFGHIJKLMNOPQRSTUVWXYZ 1 abedefghijkimnoparstuvwxyz i Dark bands Zr i un TTER PES 444 jae uu apna puppi fp minu enu jp ppm Figure 4 12 Dark Vertical Lines Description One or more dark lines of varying density If the image can be rubbed off go to TAG 812 Uneven or No Fusing on Prints If the image cannot be rubbed off go to TAG 808 Prints Overtoned Dark Vertical Streaks Go to TAG 812 Uneven or No Fusing on Prints TAG 808 Prints Overtoned Dark Verti cal Streaks Print Quality Samples 4 15 Sample 13 Skewed Prints bf m mE H FA AAA A444 4 E e 44 4 d a 44 M H H zal ae nis a 44 pe ES O X8 C 9 7012365678915 co tg ABCDEFGHIJKLMNOPQRSTUVWXYZ N abcdefghijklmnopqrstuvwxyz I0 8X8 Out 7012345678915 23 ABCDEFGHIJKLMNDPQRSTUVWXYZ abcdefahiik lmnoparstuvexyz ooo a aedeaae DOT aman 1 E LETTER ITE X8 X 0125456739 1 2522 ABCDEFGHIJKLMNOPQRSTUYMXYz x abcdefohiikImnopqrstuvwxyz 1 I 86x8 O 5 01234567891 x 73 ABCDEFGHIJKLHNOPQRSTUVWXYZI J _ abcdefghiiklanopqnstuvwxyz jut rna ndun Tivbeirietverisirrbrbebeiee derriere Figure 4 13 Skewed prints Description The entire image is not located squarely on the paper i Mi
121. 7 Remove the lower duplex roller cover four screws Disconnect CN3 16 a Q N Remove the upper duplex drive clutch assembly three screws Side Detail Lower Duplex Roller Cover 7 94 Removal Replacement Procedures Duplex Route Motor Solenoid Assembly Removal Duplex Route Motor Solenoid Assembly Removal To remove the duplex route motor solenoid assembly Open the top cover Remove the rear duplex cover See page 7 17 Remove the upper duplex roller cover four screws Disconnect CN313 and CN314 a Q N Remove the duplex route motor solenoid assembly three screws Mounting Screws Y 2 Titi if CLE Ug Duplex Route Motor Solenoid Detail Upper Duplex Roller Cover Removal Replacement Procedures 7 95 A Roller Removal A Roller Removal To remove the A roller Open the top cover Remove the rear duplex cover See page 7 17 Remove the lower duplex roller cover four screws Remove the front C clip and bearing from the A roller Lower the top cover to a 45 degree angle oa fF O N Slide the A roller out the back of the printer SIMA Side Detail Lower Duplex Roller Cover C Clip and Bearing 7 96 Removal Replacement Procedures B Roller Removal B Roller Removal To remove the B roller 1 2 3 4 5 6 7 8 9 1 1 Open the top cover Remove the rear dup
122. 9 J P 313 6 8 SIEG TCSTCSI ILS LS SAIS d HEABHAL E B 8 4 5 8 7 8 8 fd E B B B LT LT J P 314 J P 315 J P 316 J P 319 Wiring Diagrams and Electrical Data Connectors Inside the Right Cover 8 7 6 5 4 3 2 1 C pig AC OOO0O0O00 0 OOOOQOQOQO 15 14 13 12 11 10 9 J P 22 3 2 1 J P 49 51 53 11 2 3 Wiring Diagrams and Electrical Data yess D BL B 4 5 8 TT LIT J P 55 ZIMIP J P 317 p 6 9 Connectors Inside the Top Cover J5 is located under the fuser J P 5 1 12113114 J P 310 1 2 3 4 J P 311 AERALA J P 57 I 1 JP 312 5 3 3 4 5 9 7 8 9 frd J P 63 is JP320 le2 ls J P 131 132
123. AG 002 Check amp Problem Resolution Turn the printer off e Reconnect J P330 e Disconnect J P331 Turn the printer on Check J P8 10 for 5 Vdc Is the voltage 5 Vdc No Go to 17 in this TAG Yes Continue Turn the printer off e Reconnect J P331 e Disconnect J P306 Turn the printer on Check J P8 10 for 5 Vdc Is the voltage 5 Vdc No Repair or replace the connectors or wiring from J331 3 to P306 3 then turn to TAG 002 Check amp Problem Resolution Yes Replace the duplex control board 1 then turn to TAG 002 Check amp Problem Resolu tion Turn the printer off e Reconnect J P331 e Disconnect J P333 Turn the printer on Check J P8 10 for 5 Vdc Is the voltage 5 Vdc No Go to 20 in this TAG Yes Continue Does the printer have an attachment option No Replace the signal interface board then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 19 Turn the printer off e Reconnect J P333 Disconnect J P73 the DC cable for the attachment option Turn the printer on Check J P8 10 for 5 Vdc Is the voltage 5 Vdc No Replace the signal interface board then turn to TAG 002 Check amp Problem Resolution Yes Replace the attachment option then turn to TAG 002 Check amp Problem Resolution 20 Turn the printer off e Reconnect J P333 e Disconnect J P323 Turn the printer on Check J P8 10 for
124. AG Cross Reference Tables using either the code that displayed after steps 1 and 2 or if multiple error codes continue to appear the first error code that displays Turn to the TAG associated with the code 3 Did only the READY light come on with no numeric display No Continue Yes Go to TAG 753 External Communications Malfunction 4 Did only the READY and ON LINE lights come on with no numeric display No Continue Yes Go to TAG 753 External Communications Malfunction 5 Did the READY ON LINE and JOB IN PROCESS lights come on with no numeric Troubleshooting Analysis Guide TAGs 3 5 display No Refer to Chapter 2 TAG Cross Reference Tables to determine which TAG to follow then turn to that TAG Yes Continue Run test prints from the upper cassette by completing the following e Power on reset the printer e Run test prints from the upper cassette Did an error code appear while running the prints No Continue Yes Look up the code in Chapter 2 TAG Cross Reference Tables to determine which TAG to follow and then turn to that TAG Run test prints from the lower cassette by completing the following e Press STOP and allow the cycle to finish Remove the upper cassette e Power on reset the printer e Run test prints from the lower cassette Did an error code appear while running test prints No Continue Yes Look up the code in Chapter 2 TAG Cross Reference Tables to det
125. Blank or With Dark Horizontal Bands Run test prints Examine the letters A V and W for jaggedness on the diagonal lines Are they jagged No Continue Yes Refer to Chapter 4 Print Quality Samples Review the printhead problem print sam ples identify one similar to the test prints and turn to the associated TAG Turn the printer off and unplug the power cord Verify that J P12 J P13 J P18 and J P41 are connected properly Perform the every call cleaning procedure described in Chapter 9 General Printer Mainte nance Clean the printhead lens and toner patch sensor located on the developer unit Turn the printer on Runtest prints Has the problem been resolved No Continue Yes Contamination or loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution Check the voltages as outlined in Chapter 9 General Printer Maintenance Are the voltages cor rect No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue Have the photoconductor unit main charger developer unit and toner cartridge been replaced recently No Continue Yes Go to 7 in this TAG Troubleshooting Analysis Guide TAGs 5 Replace the photoconductor unit and main charger Run test prints Has the problem been resolved No Reinstall the original photoconductor unit and main charger and continue Yes Run at least 200 test
126. C clip and bearing N Oo oO 5 WO ND Slide the upper feed roller out the back of the printer Paper Feed Drive Cover Front Detail Cassette Release Cover 7 60 Removal Replacement Procedures Lower Feed Roller Removal Lower Feed Roller Removal To remove the lower feed roller Open the front and back covers Remove the paper feed drive cover three screws Disconnect CN67 Remove the paper feed drive belt from the lower feed roller gear Remove the cassette release cover two screws Remove the front C clip and bearing N Oo oO 5 WO ND Slide the lower feed roller out the back of the printer Paper Feed Drive Cover Front Detail Cassette Release Cover Removal Replacement Procedures 7 61 Upper Pick Up Roller Removal Upper Pick Up Roller Removal To remove the upper pick up roller 1 2 3 4 5 6 Note You may need to remove the EMI grounding plate Open the front and back covers Remove the paper feed drive cover three screws Disconnect CN68 Remove the cassette release cover two screws Remove the front C clip and bearing Slide the upper pick up roller out the back of the printer Paper Feed Drive Cover Front Detail Cassette Release Cover 7 62 Removal Replacement Procedures Upper Pick Up Roller Drive Removal Upper Pick Up Roller Drive Removal To remove the upper pick up roller drive 1 Open the back cover 2 Remove the paper feed drive cover three
127. Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 187 10 11 3 188 Power on reset the printer e Watch through the output tray opening to see if the fuser lamp comes on Does the lamp light within 1 5 minutes No Go to TAG 070 Fuser Unit Malfunction Yes Continue Run test prints Does the print seem to be excessively dark or do the characters feel raised on the paper No Continue Yes Go to TAG 808 Prints Overtoned Dark Vertical Streaks Confirm that the paper in the cassettes meets paper specifications outlined in the Guide to Opera tions manual Is the paper within specification No Do not use this paper Turn to TAG 002 Check amp Problem Resolution Yes Continue Turn the printer off and unplug the power cord Remove the fuser unit e Disconnect J P41 Check P41 22 to P5 6 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 22 to P83 1 or J83 1 to P5 6 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P41 21 to P5 7 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 21 to P83 2 or J83 2 to P5 7 then turn to TAG 002 Check amp Problem Resolution Yes Continue Reinstall the fuser unit Check P41 21 to P41 22 for resistance Is the resistance between I KQ and 400 KQ No Replace the fuser unit If this resolves the problem turn to TAG 002 Che
128. Cut Sheet Printers Maintenance Manual Models C30 and C30D U HEWLETT PACKARD HP Part No C4000 90006 Notice Hewlett Packard makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose Hewlett Packard shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Hewlett Packard assumes no responsibility for the use or reliability of its software on equipment that is not furnished by Hewlett Packard This document contains proprietary information which is protected by copyright All rights are reserved No part of this document may be photocopied reproduced or trans lated to another language without the prior written consent of Hewlett Packard Company The information contained in this document is subject to change without notice Printing History New editions are complete revisions of the manual The dates on the title page change only when a new edition is published The software code EXXX printed below the date indicates the version level of the soft ware product at the time of publication Bditton T TRIER Res March 1994 Editli0D 2 oo 2S eek EE December 1994 Trademarks PCL is a trademark of the Hewlett Packard Company CG Times a product of Agfa Cor poration is based on Times New Roman a registered trad
129. Drive Detail Fuser Drive Cover 7 88 Removal Replacement Procedures Duplex Control Board 1 Removal Duplex Control Board 1 Removal To remove duplex control board 1 Open the top cover Remove the duplex control board cover two screws Disconnect CN306 CN307 CN308 and CN309 b amp b OO N 2a Disengage duplex control board 1 To do this pinch the four standoffs on the board one at a time 5 Lift the board from the mounting bracket Standoffs Duplex Control Board 1 Deiail Removal Replacement Procedures 7 89 Duplex Control Board 2 Removal Duplex Control Board 2 Removal To remove duplex control board 2 Open the top cover Remove the duplex tray Remove the paper guide from the duplex tray four screws Disconnect CN310 CN311 and CN312 Remove duplex control board 2 two screws a A Q N Paper Guide Duplex Control Board 2 I e j 7 90 Removal Replacement Procedures Duplex Tray Registration Motor Removal Duplex Tray Registration Motor Removal To remove the duplex tray registration motor Open the top cover Remove the duplex tray Remove the paper guide inside the duplex tray four screws Disconnect CN321 ao A QOQ N Remove the registration motor two screws Paper Guide CN321 X NN 6 B ee e 0 FX s Registration Motor Detail Removal Replacement Procedures 7 91 Duplex Skew Correction Cable Removal Duplex Sk
130. F ERR 15 32 ERR IP 6 31 IP SI 17 36 SI GND 18 33 GND GND 19 19 GND GND 20 21 GND GND 21 23 GND GND 22 25 GND GND 23 27 GND GND 24 29 GND GND 25 30 GND Wiring Diagrams and Electrical Data Special Considerations for Centronics Parallel Interface Users For DOS host computers add the following line to the AUTOEXEC BAT file MODE PRN P To edit the AUTOEXEC BAT file use any text editor or the EDLIN facility of DOS If you do not know how to edit this file refer to the reference manual that came with the DOS software Wiring Diagrams and Electrical Data 6 29 Circuit Board Settings Several of the circuit boards in the printer have jumpers and or DIP switches used to con trol the functionality of the board These settings are described the following section Signal Interface Board Settings The signal interface board has both jumpers and DIP switches used to control host inter face interactions In general the four jumpers on the signal interface board should remain as set at the fac tory The jumpers control the following Table 6 11 Signal Interface Board Jumper Settings Jumper Direction Description JP1 b c Baud rate crystal oscillator on IGS board 3 6854 MHz a b Baud rate crystal oscillator on IGS board 7 3728 MHz JP2 d e Unsolicited status reports enabled after power on reset e f Unsolicited status reports disabled after power on reset JP3 g h ERR pin 32 error line output enabled No jumper ERR pin 3
131. Generation System IGS controller Each printer is equipped with an IGS con troller which provides the interface between the host computer the PCL board LED printhead and the disk drives The controller may be an EIGS or RIGS board Printer Control Logic PCL board The PCL board directs the mechanical functions of the printer and print cycle timing The PCL board also receives initial machine informa tion such as empty paper cassettes paper jams and fuser unit problems The illustration on the following page details the printing process The numbers represent the sequence of events from the time that the system interface receives data through the production of a print image to the preparation for another print 1 Receiving data Data from the host is received by the Signal Interface SI PCA and is passed to the Image Generating System IGS PCA which temporarily stores the data in RAM The data may consist of information generated on the host computer and sent over the host communication interface or it may consist of information generated by printer soft ware such as a request for test prints or to print the directory of a diskette 2 Bit Image The IGS transforms the host file into a bit map image of 1s and Os and stores them in user bitmap RAM Bitmap memory is nothing more than an electronic piece of paper 3 Charging the photoconductor belt When the IGS controller has a full page of data it causes the PCL board to turn on the
132. Go to 4 in this TAG Yes Continue 3 Turn off the printer Remove the high capacity output unit Turn on the printer Has the problem been resolved No Continue Yes The high capacity output unit is malfunctioning Refer to Chapter 8 Options for instructions on repairing the high capacity unit 4 Inspect the output tray full sensor actuator for damage or binding Is itin good working order No Replace the actuator then turn to TAG 002 Check amp Problem Resolution Yes Continue 5 Does Output Tray Full come on too soon No Continue Yes Repair or replace the job offset assembly then turn to TAG 002 Check amp Problem Reso lution 3 130 Troubleshooting Analysis Guide TAGs 6 Turn the printer off and unplug the power cord e Disconnect J P51 and J P40 e Check P40 26 to P51 1 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 26 to J P50 4 to P51 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue 7 Check P40 17 to P51 2 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 17 to J P50 5 to P51 2 then turn to TAG 002 Check amp Problem Resolution Yes Continue 8 Check P40 13 to P51 3 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 13 to J P50 6 to P51 3 then turn to TAG 002 Check amp Problem Resolution Yes Continue 9 Verify t
133. Guide C4672 90002 explains the various kinds of papers usable in the printer how to care for them and how to minimize paper related problems with the C40D Copyright 1995 Hewlett Packard Company All rights reserved January 1995 Please address any comments or questions with respect to this document to Publication Department Hewlett Packard Company HP Printers MS 44MC System Peripherals Operation 19111 Pruneridge Avenue Cupertino CA 95014 Contents Printer and Troubleshooting Overview CODIEDIS suede i a aS RW owe o d e alee ee es ak 1 2 Theory Of Op ration os esse res ha e dead ae a See head Nord Par hes 1 3 Paper Path and Cycle Sequence ke RR ER ei bad owen baw EE XAR 1 5 Simplex Prntitigz sessed w ccs ke REG E Adana Wace eae hares m URN RUE we 1 5 Duplex Printine 24 3 5 c utrsbl bep ue P aer ED Dd TERR qe 1 5 Error Code Technical Definitions i460 i400 0tacawtveskd LERRA E E ds 1 7 Sensor and Switch Locations ids pete Sa eie eM eS ape tse a ened 1 11 Troubleshooting Overview cci va by oa deca pe ea Say yea da WE ea Da 1 15 General Troubleshooting Tips 0 0 0 cece cence eens 1 15 The Problem Printer or Host oani cesarice ene ene eens 1 16 Protocol Converters o gl bins toe eet apie SB Aas OU SY oe BONS 1 17 Reading the Error Log c o Bee ee OE ee ees 1 17 Confirming Line Power 2 ertet beds eroe ub deg a ded ideas 1 18 Using the Troubleshooting Analysis Guide TAG 0 040
134. Guide TAGs 3 193 TAG 901 Misregistration Skewed Prints Duplex Error Code 901 Possible Causes Wrong weight or type of paper loaded Possible Defects Duplex holding tray sensors Duplex holding tray motor Duplex drive clutch Pinch rollers A and B Route separator Duplex control board 2 Connectors or wiring PCL board Registration is correct when the top or 2 of the 20 line indicator found on the top of a test print is at the leading edge of the print If the problem varies from print to print suspect a mechanical binding problem if prob lems exist in the simplex mode go to TAG 807 Misregistered Skewed Prints Simplex 1 Verify that the upper and lower paper cassettes are not damaged Confirm that the paper in the cassettes meets paper specifications outlined in the Guide to Operations manual Make sure the paper in both paper cassettes is loaded properly Make sure the side and rear paper guides in the paper cassettes are positioned properly Check both paper paths for obstructions or contamination Run test prints Has the problem been resolved No Continue Yes Turn to TAG 002 Check amp Problem Resolution 2 Turn the printer off and unplug the power cord Inspect the following for damage or contamination e Duplex drive clutch assembly e Timing belts e Upper paper guide assembly e Pinch roller springs Route separator and springs Are these parts clean and in good working order No Rep
135. PCL board Printhead assembly Power control 2 board Developer unit Turn the printer off and unplug the power cord Verify that J P23 J P24 J P40 J P41 J P96 and J P85 are connected properly e Power on reset the printer Is error code 030 still displayed No A loose connector was at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue Check the voltages as described in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue Has the developer unit been replaced recently No Go to 5 in this TAG Yes Continue Replace the cleaner unit e Run test prints Is error code 030 still displayed No The cleaner unit was defective turn to TAG 002 Check amp Problem Resolution Yes Reinstall the original cleaner unit and go to 46 in this TAG Replace the developer unit Install a new toner cartridge e Run test prints Is error code 030 still displayed No The developer unit was defective turn to TAG 002 Check amp Problem Resolution Yes Reinstall the original developer unit and continue Troubleshooting Analysis Guide TAGs 6 Open the back cover and install an interlock by pass tool e Power on reset the printer Check TP4 35 for 24 Vdc Is the voltage 24 Vdc No Go to 11 in this TAG Yes Continue 7 Check J P23 5 for 24 Vdc Is the volt
136. Problem Resolution Yes Continue 9 Turn the printer off e Reconnect J P41 e Disconnect J P23 Turn the printer on Check J P8 11 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the high voltage unit then turn to TAG 002 Check amp Problem Resolution 10 Turn off the printer and unplug the power cord e Disconnect J P41 Check P41 35 to P23 5 for continuity to ground Is there continuity No You have failed to isolate the problem Return to the beginning of this TAG Yes Repair or replace the connectors or wiring from P41 35 to P23 5 then turn to TAG 002 Check amp Problem Resolution 11 Turn the printer off e Reconnect J P11 e Disconnect J P91 Turn the printer on Check J P8 13 for 24 Vdc Is the voltage 24 Vdc No Go to 21 in this TAG Yes Continue 3 94 Troubleshooting Analysis Guide TAGs 12 Turn the printer off e Reconnect J P91 e Disconnect J P40 and J P41 Turn the printer on Check J P8 13 for 24 Vdc Is the voltage 24 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue 13 Turn the printer off e Reconnect J P40 Turn the printer on Check J P8 13 for 24 Vdc Is the voltage 24 Vdc No Go to 16 in this TAG Yes Continue 14 Turn the printer off e Reconnect J P41 e Disconnect J P81 Turn the printer on Check J P8 13 for 24 Vdc Is the voltage 24 Vdc No Repair or replace the
137. Reinstall the original high voltage unit and continue Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 175 20 Repair or replace the PCL board Run test prints Has the problem been resolved No Reinstall the original PCL board Confirm that the photoconductor main charger devel oper unit and fuser units are new If these items are new the toner carrier mix may be old or contaminated Replace the developer and cleaner units with units from the printer s manufacturer If this resolves the problem turn to TAG 002 Check amp Problem Resolu tion Otherwise turn to TAG 811 Background Residual Images Dark Prints Yes Turn to TAG 002 Check amp Problem Resolution 3 176 Troubleshooting Analysis Guide TAGs TAG 809 Blurred or Smeared Vertical Streaks on Prints Error Code 809 Possible Defects Photoconductor unit Main charger Cleaner unit Fuser unit Vacuum transport unit Fuser unit drive gear Fuser drive idler and spring Fuser drive belt Main drive assembly Printhead assembly Power control 2 board 1 Turn the printer off and unplug the power cord e Verify that J P23 J P41 and J P13 are connected properly Perform the every call cleaning procedure described in Chapter 9 General Printer Mainte nance e Clean the printhead lens Turn the printer on e Run test prints Has the problem been resolved No Continue Yes Contamination or loose conn
138. Resolution 13 Check J P11 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the power control 2 board then turn to TAG 002 Check amp Problem Resolu tion 14 Check J P8 11 for 24 Vdc Is the voltage 24 Vdc No Replace the DC power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P8 11 to P11 1 then turn to TAG 002 Check amp Problem Resolution 3 46 Troubleshooting Analysis Guide TAGs TAG 031 Toner Patch Reference Level Too Low Error Code 031 Possible Causes Contamination of the toner patch sensor or printhead lens Possible Defects Photoconductor unit Connectors or wiring PCL board Developer unit 1 Turn the printer off and unplug the power cord Perform the every call cleaning procedure described in Chapter 9 General Printer Mainte nance Clean the toner patch sensor on the developer unit Clean the printhead lens Runatleast 200 test prints to detone the printer s engine Has the problem been resolved No Contamination was at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue 2 Check the voltages as described in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Have the photoconductor and developer units been replaced recently No
139. Resolution Yes Replace the upper pick up roller assembly then turn to TAG 002 Check amp Problem Res olution Run diagnostic test 006 testing the upper feed roller clutch e Check TP3 6 for a voltage change from 24 Vdc to 0 Vdc Does the voltage change from 24 Vdc to 0 Vdc No Continue Yes Go to 14 in this TAG Troubleshooting Analysis Guide TAGs 13 Turn off the printer and unplug the power cord e Disconnect J P40 and J P66 e Check P40 6 to J66 2 and P40 11 to J66 1 for continuity Is there continuity No Repair or replace connectors or wiring from P40 6 to J66 2 or P40 11 to J66 1 Then turn to TAG 002 Check amp Problem Resolution Yes Replace the upper feed roller assembly then turn to TAG 002 Check amp Problem Resolu tion 14 Inspect the upper pick up roller assembly for damage or binding Is it in good working order No Replace the upper pick up roller assembly then turn to TAG 002 Check amp Problem Res olution Yes Continue 15 Inspect the upper feed roller assembly for damage or binding Is it in good working order No Replace the upper feed roller assembly then turn to TAG 002 Check amp Problem Resolu tion Yes The upper pick up roller or the feed rollers may not be delivering paper to the paper tim ing sensor at the correct time Return to the beginning of this TAG Troubleshooting Analysis Guide TAGs 3 29 3 30 TAG 021 Paper Jam Misfeed in Lower Cassette Area
140. S 422 and Centronics Parallel User level information about the installation configuration and use of these interfaces is included in the printer s Guide to Operations RS 232C Host Interface A printer is standard data terminal equipment DTE designed specifically for a direct connection to a standard data communication equipment DCE host The standard signal definitions for DTE to DCE equipment are outlined in the table that follows Table 6 1 RS 232C DCE to DTE Signal Definitions Pin Rn Function 1 FG Frame or chassis ground 2 TD Transmitted data 3 RD Received data 4 RST Request to send 5 CTS Clear to send 6 DSR Data set ready 7 SG Signal ground 8 DCD Data carrier detect 9 Positive DC test voltage 10 Negative DC test voltage unassigned 11 S DCD Secondary data carrier detect 12 S CTS Secondary clear to send 13 S CTS Secondary clear to send 14 S TD Secondary transmitted data 15 TC Transmitter clock 16 S RD Secondary received data 17 RC Receiver clock 18 RDC Receiver debit clock 19 S RTS Secondary receive to send 20 DTR Data terminal ready 21 SQ Signal quality detect 22 RI Ring indicator 23 DRS Data rate select 24 TC External transmitter clock 25 BSY Busy 6 22 Wiring Diagrams and Electrical Data Standard DCE to DTE RS 232C Cable The standard DCE host to the printer DTE pin configuration follows Table 6 2
141. Sample 20 Wrnkles 22i Re ERAIARRAERI RR RRRERIAGG S heenes 4 23 Sample 21 Fusing Probl mS cot Goes tek goa VERI eels Se Sees aes 4 24 Diagnostic Tests CODIBHIS os uu Gis tee T E oe da Vera dd Ges Bede Mx tee eee da Pers 5 2 Diagnosue Tests i esilikbesieseikdhed4s d iq AERIS AC PER REIR REESE 5 3 How to Run Diagnostics uvis oes as amp RV ER RM ea de v en M 5 3 001 Operator Panel Test i2 kh AR RERRA webu head ee Mhek ad ERERES 5 4 O02 D pper Cassette Tests x os Sao e OS ees cu WAS ER RM De NA de Pes 5 4 003 Lower Cassette Test cnc deena eed Rp DER REEG REESE 5 5 005 Sensor Test SEQUENCE v sess Rute ove oe dm E ete eher puts 5 6 006 Paper Transport Clutch Test Sequence 0 0 cee eee eee eee 5 7 007 Counter Tests ors eor ar naka eee EIE RRIGOEE E reto SES 5 7 008 Jogging Motor Test vua sy LA IE TET ONE ee Er ES NOSE ee 5 8 009 Photoconductor Test 5 2 2224 93 ER I Ru A ERE I RA PASE 5 8 OTO Toner Supply Motor Test cuoexevx SEXUS XE XI EN RE EX EU 5 9 OTI Nam Charter Test oso i eto iai ee te ene RES EIER RO v ida 5 10 012 T ranster Charger TOS soa e de ee Y Edd APER Ee CREE ane 5 11 OL Brase Lamp Fest 15 ode ra tale uro Eras e cde et 5 12 015 Negative Developer Bias Test 25er secl p ein ERPREI RM PE EVRMA 5 13 016 Duplex Feed Motor Testun dersten eho wy SUIS REX RERO PR 5 14 017 Duplex Input Sensor Test Sequence 0 0 00 5 15 018 Duplex Clutch Test Sequence 24 2420 esteso e VER ete ee OR OU 5
142. Transport Clutch Test Sequence 5 7 007 Counter Test 2 0 0 count eee RERO Rae RR C eb ER DICE Cee UE ee Vie 5 7 008 Jogging Motor Test ic onsec dots t Re UR wa ee d e 5 8 009 Photoconductor Test llle III 5 8 010 Toner Supply Motor Test ssseeee III 5 9 011 Main Charger Test 2 0 0 ec III 5 10 012 Transfer Charget Test adds eee etos ae Rb Male aee 5 11 O13 Erase Lamp Test cirios rerna rm ere Ede terms Eae sae ER E dus 5 12 015 Negative Developer Bias Test 0 0 0 eee eee eee 5 13 016 Duplex Feed Motor Test 5 14 017 Duplex Input Sensor Test Sequence 0 0 cece ee eee eee 5 15 018 Duplex Clutch Test Sequence 5 16 019 Duplex Tray Paper Guide Motor Test 0 0 0 02 eee eee eee 5 17 020 High Capacity Output Unit Test 5 18 021 High Capacity Input Unit Test 0 2 ee eee 5 19 022 Envelope Fuser Solenoid Test 0 0 0 0 eee ee eee eee 5 19 101 EIGS MIGS Board Test sseseeeeee eee eee 5 20 102 EIGS MIGS Board Test Continuous Loop 0 0 eee eee 5 20 103 Communication Loop back Test Single Loop 02005 5 21 104 Communication Loop back Test Continuous Loop cesses 5 22 105 EIGS Program RAM Test Continuous Loop 0 00000 5 22 107 EIGS MIGS Bit Map Test Single Loop 0 000005 5 23 108 EIGS MIGS Bit Map Test Continuous Loop 00005 5 23 110 Format Disk Clear Error Log
143. XY21N I _ amp bcdefphijklanoparstuvexyz i 7 1 945 amp 005 7 70123456789 2518 RBCDEFGHIJKLMNOPORSTUVVXYZI N Pe 4 A HHHdHddHdddddddadaa decns abcdefghijklanoparatuvwxyrii PEER CMe y 701236567891 0518 ABCDEF GHI JKLMNOPORSTUVEXYZES _ sbedefghiskimnoparstuvexyz 1T 65XE 1 C285 70123656789 25 3 LO ABCDEFGHIJKLHNDPORSTUYVXYZIN 2 abcdefghijklmnpparstuvwxyzii vi gt sajna Mna nase As URS RUE i i amp uris LETTER Background T p Q oy o Figure 4 5 Light Print With Background Description Images or characters lighter than normal ranging from a few dark specks to a large speckled background Go to TAG 811 Background Residual Images Dark Prints Print Quality Samples Sample 6 Voids or White Spots 1 ida 444 444 Tor vet ot qu qsgu eu uu PEETI jede je D Som 9 dd HHddddadaddadadddadaad SIOCITGTTTTPTITITTTTYTJUFIET 1 89X amp O5 701234567891 9513 ABCDEFGH JKL 4 QRSTUVWXYZIN 1 abedefgh iz clanoogrstuv xyz i 7 1 846977 Y 0123456739 1 25 2 ABCDEF MNOPQRSTU abcdefgh j jklmnopqr ivw I S5XE H 0123456789 5 2 TO ABCDEFGHY KLMNOPQRSTUVWXYZES abc jklmnoparstuv xyz i PPOs Rt OO 7 0123456 59 5 18 ABCo FGHIJKLMNOPQRST 4b YZF abr fghijkl
144. YZ 1 _ gt abcdefghijkimnoporstuvwxyz i 1996X amp n 0123456789 25 T3 ABCDEFGHIJKLMNOPQRSTUVWXYZIN abcdefghijklmnopqrstuvwxyz il m TE Peepar paperean padenejar par arap paoa a pen bee Figure 4 18 Background Description White areas on the prints have varying degrees of specks appearing in a spe cific pattern Go to TAG 811 Background Residual Images Dark Prints Print Quality Samples 4 21 Sample 19 Residual Images 0009 02i 9592 022 0220 4253 G 923 023 02 232 23 222 JEC 22 uou nage uiu Jereys EIRIAU titiad SERA HENN urbi HEIRE ung gp ge ntj inirdi dt abet Hd Ue Dub agpo nuu bu Pn abbia shiv ged reel itid idum OH EE Figure 4 19 Residual Images unt tud Obed abana Heo ipi Description Images from a previous print are visible White areas on the print may have varying degrees of specks appearing in a specific pattern Go to TAG 811 Background Residual Images Dark Prints TAG 813 Residual Images on Prints 4 22 Print Quality Samples Sample 20 Wrinkles W 77 TI i mot TT Bm IM ON POTTERY PRX IdXTTTETOLIJTI bam x a t Pee ery To eel eT ee se RON JTT eae ees E I1 94X amp CI308 012365678915 2519 Toor ABCDEFGHIJKLMNOPQRSTUVWXYZI 17_ Ame s abcdefghijklmenoparstuvwxyz i T TT 1 65 2 C 012265678911 z5 9 E j ABCDEFGHIJKLMNOPQRSTUVWXYZ N T T abcdefghijiklmnopurst
145. Yes Go to 4 in this TAG Replace the fuser unit e Power on reset the printer e Watch through the output tray opening to see if the fuser lamp comes on Ifthe fuser lamp comes on immediately after power on turn off the printer and replace the AC power supply Has the problem been resolved No Reinstall the original fuser unit and continue Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 67 4 Power on reset the printer e Watch through the output tray opening to see if the fuser lamp comes on during the 15 seconds following the output tray jogging test Ifthe fuser lamp comes on immediately after power on turn the printer off and replace the AC power supply Does the fuser lamp light No Go to 10 in this TAG Yes Continue 5 Read this entire step before taking any action e Power on reset the printer e Check the voltage between TP4 21 and ground on the PCL board for a voltage increase during the 15 seconds following the output tray jogging test Caution If the voltage does not increase within 15 seconds turn the printer off immediately or additional damage may occur Did the voltage remain constant for 15 seconds after the output tray jogging test No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue 6 Check TP4 22 on the PCL board for 5 Vdc Caution Do not allow the printer to remain on for mor
146. ace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Replace the counter then turn to TAG 002 Check amp Problem Resolution 8 Turn the printer off and unplug the power cord e Disconnect J P41 and J P82 Check P41 26 to J82 1 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 26 to J P81 1 to J82 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue 9 Check P41 25 to J82 2 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 25 to J P81 2 to J82 2 then turn to TAG 002 Check amp Problem Resolution Yes Replace the counter If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the PCL board then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 141 TAG 751 Main Drive Motor Runs Continuously Error Code 751 Possible Defects Power control 2 board Connectors or wiring PCL board 1 Turn the printer off and unplug the power cord e Disconnect J P12 and J P40 Check P40 33 for continuity to ground Is there continuity No Replace the power control 2 board If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors
147. ace the main drive motor then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 121 19 20 21 22 23 3 122 Turn the printer off e Reconnect J P22 e Turn on the printer for 2 1 2 minutes then off Was the power on reset successful No Replace the vacuum transport unit then turn to TAG 002 Check amp Problem Resolution Yes Replace the small cooling fan assembly then turn to TAG 002 Check amp Problem Reso lution Reconnect J P9 e Disconnect J P100 Install a new upper fuse in the AC power supply unit e Run diagnostic test 008 for approximately five seconds then turn off the printer Remove the fuse e Check the fuse for continuity Does the fuse have continuity No Go to 23 in this TAG Yes Continue Turn off the printer e Reconnect J P100 Install a good upper fuse in the AC power supply unit e Disconnect J P101 e Run diagnostic test 008 for approximately five seconds then stop Remove the fuse e Check the fuse for continuity Does the fuse have continuity No Replace the power control 3 board then turn to TAG 002 Check amp Problem Resolu tion Yes Continue Disconnect J P19 Check P101 2 to P19 2 for continuity to ground Is there continuity to ground No Replace the jogging motor then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P101
148. ach component can be monitored from the various pins of CN508 located on the input control board When performing these checks use test point TP 1 located below CN507 on the input control board Table 8 2 Monitoring Input Control Board Logic at Connector CN508 Connector Component Monitored Condition CN508 4 PHS High Paper present Low No paper present CN508 13 PES High Paper present Low No paper present CN508 19 IPES High Paper present Low No paper present CN508 16 IULS High Limit Low No Limit CN508 21 DSW High Door open Low Door closed CN508 10 ILLS High Limit Low No Limit CN508 2 NPS High ON Low Off CN508 25 26 IPM M2 12 Vdc Feed 0 Vdc No feed CN508 23 IEM M1 12 Vdc Up 0 Vdc Off CN508 24 IEM M1 12 Vdc Down 0 Vdc Off CN507 2 PCSW 0 Vdc Unit mounted 12 Vdc Unit not mounted Options 8 7 8 8 suondo JopoeJ 199us 00S2 199us 00z I 10 Wesbeiq uonoeuuo p g e1nDiJ I RUN W520 J600 J400 W508 P507 x Gnd ct 5P522 Bane 12Vdc w505 Supply P506 P523 g W506 J506 P527 i I P528 LLL LL SW eter PCSW W510 P508 P509 J509 P518 P519 P529 id P500 J5
149. age 24 Vdc No Repair or replace the connectors or wiring from P41 35 to P23 5 then turn to TAG 002 Check amp Problem Resolution Yes Continue 8 Turn the printer off and unplug the power cord e Disconnect J P41 and J P24 e Check the following for continuity P41 31 to P24 1 P41 30 to P24 2 P41 40 to P24 3 Is there continuity No Repair or replace the connectors or wiring from P41 31 to P24 1 P41 30 to P24 2 P41 40 to P24 3 Then turn to TAG 002 Check amp Problem Resolution Yes Continue 9 Disconnect P85 from the high voltage unit Check P85 3 to J25 7 for continuity Is there continuity No Repair or replace the connectors or wiring from P85 3 to J25 7 then turn to TAG 002 Check amp Problem Resolution Yes Continue 10 Disconnect J P96 Check P96 1 to J25 7 for continuity Is there continuity No Repair or replace the developer power supply lead from J P96 1 to P85 3 then turn to TAG 002 Check amp Problem Resolution Yes Replace the high voltage unit then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 45 11 Check TP3 27 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 12 Check J P12 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Repair or replace the connectors or wiring from P40 27 to P12 1 then turn to TAG 002 Check amp Problem
150. air or replace any damaged parts as needed then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 194 Troubleshooting Analysis Guide TAGs 3 Verify that J P305 J P310 J P311 J P312 J P320 J P321 and J P322 are connected properly to duplex control board 2 Verify that J P306 J P307 J P308 J P309 and J P324 are connected properly to duplex control board 1 e Verify that J P315 and J P316 are connected properly to the A and C roller clutches e Run test prints in duplex Did the test indicate an error code No Registration or skew problems can only result from mechanical causes Return to the beginning of this TAG Yes Continue 4 Did the side guides in the duplex tray move in and out while the test was running No Go to 8 in this TAG Yes Continue 5 Check J P312 1 on duplex control board 2 for 12 Vdc Is the voltage 12 Vdc No Replace duplex control board 2 then turn to TAG 002 Check amp Problem Resolution Yes Continue 6 Manually move the side guides in the duplex tray to the inside positions Check J P312 2 on duplex control board 2 for 0 Vdc Is the voltage 0 Vdc No Continue Yes Replace duplex control board 2 then turn to TAG 002 Check amp Problem Resolution 7 Turn the printer off and unplug the power cord e Disconnect J P320 and J P312 e Check the following for continuity P312 1 to P320 1 P312 2 to P320 2 and P312 3 to P320 3 I
151. ake sure the problem description and steps taken to resolve the problem are clearly docu mented e Reinstall all connectors covers parts and hardware You have successfully resolved the printer s problem Congratulations Troubleshooting Analysis Guide TAGs 3 11 TAG 010 Upper Cassette Malfunction Error Code 010 Possible Causes Cassette empty Paper incorrectly loaded Possible Defects Upper paper empty actuator pper paper empty sensor pper cassette tray pper pressure lever pper cassette release cam pper cassette release latch Upper cassette release lever Spring Connectors wiring PCL board U U U U U U 1 Make sure paper is in the upper cassette Make sure the paper is loaded correctly so that the side and rear guides are positioned securely against the paper in the cassettes e Power on reset the printer Runtest prints Is error code 010 displayed No The paper was loaded incorrectly Turn to TAG 002 Check amp Problem Resolution Yes Continue 2 Check upper cassette Remove the upper cassette Inspect the upper paper empty sensor actuator for binding or for a damaged or broken part Is itin good working order No Replace the actuator then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Check voltage Open the rear door and install an interlock by pass tool Check the voltage from TP3 15 to ground on the PCL board e Activate the upper paper sensor actuato
152. al 4 455 i9 eared RR RAI Mee eee ee SEN 7 48 Upper Paper Guide Roller Removal 0 0 eee 7 50 Lower Paper Guide Removal s fase Race Audi pia p xe 7 51 Paper Timing Guide Removal deg lkie eek eee bone RA e Beets e 7 52 Cleaner Drive Belt Removal ool oe ke an doe e us VADER ak due eas lox 7 54 Cleaner Drive Removal 2 21 64 like qe RREEREInRTIAEREE AR EOS 7 55 Fuser Drive Belt Removal sopce evoco piaia Ur T AD DOSE ES eX EEXIAG r 7 56 Fuser Drive Removal 2 2 1222 22 eei iu pepe Re RETI EE RA Rie 7 57 Paper Feed Drive Belt Removal uere oode cae badd ane bees 7 58 Paper Timing Roller Removal e ooa nde eae ied oe eed 7 59 Upper Feed Roller Bemoval i443 4eu veered toad Gege YN ei dE Rege ligue 7 60 Lower Peed Roller Removal into 4 s vetusto d oud be ihek oi i a ek 7 61 Upper Pick Up Roller Removal 0 0 0 0 ce eee eee eee 7 62 Upper Pick Up Roller Drive Removal 0 0 0 0 cece eee eee ee 7 63 Lower Pick Up Roller Removal 2 0 0 0 cee ee cece eee ee nee 7 64 Lower Pick Up Roller Drive Removal 0 0 0 0 e ee ee eee eee 7 65 Job Offset Assembly Removal ested ei Seah EX aca a hatred 7 66 Exit Pinch Roller Removal i10 a ey ea dae REAGAN EAE QUEE CAS 7 68 Upper Static Brush Removal 222eves ev FUP had Y 3 erePRESTROEEN SS 7 70 Lower Static Brush Removal 2 4 25 5i40 uu RR sed eee ERROR d 7 71 Exit Roller Assembly Removal 2 242 4450 RI IR 0A eee tees Bee 7 72 Exit Cover Removal Simplex
153. an error is detected the error code is displayed briefly and the test continues Note the error code and check the Error Code TAG Cross Reference on page 2 3 to determine which TAG to follow If no errors are found the test continues to loop Allow the test to continue for at least one minute Press STOP to exit For some errors you may have to power on reset the printer Remove the loop back connectors 10 Reinstall the interface cable EIGS Program RAM Test Continuous Loop Go to 105 Press READY to run the test If an error code appears before the test has run for five minutes look up the code in Error Code TAG Cross Reference on page 2 3 to determine which TAG to follow Otherwise a 201 may display after about five minutes indicating that the test has run successfully Power on reset the printer to exit Note This test does not run on printers with MIGS boards 106 intentionally excluded 5 22 Diagnostic Tests 109 intentionally excluded 107 EIGS MIGS Bit Map Test Single Loop A Q N a Go to 107 Press READY to run the test If no error is detected the test exits automatically If an error code appears look it up in Error Code TAG Cross Reference on page 2 3 to determine which TAG to follow Press STOP to exit if an error is reported 108 EIGS MIGS Bit Map Test Continuous Loop 1 Go to 108 Press READY to run the test If no errors ar
154. and P41 50 to P25 1 for continuity to ground Is there continuity No Go to 15 in this TAG Yes Repair or replace the appropriate connectors or wiring then turn to TAG 002 Check amp Problem Resolution 13 Turn the printer off and unplug the power cord e Reconnect J P91 e Disconnect J P8 and J P32 Check J8 6 for continuity to ground Is there continuity No Continue Yes Repair or replace the connectors or wiring from P8 6 to P32 10 to P91 3 then turn to TAG 002 Check amp Problem Resolution 14 Reconnect J P32 and J P8 e Disconnect J P77 Turn on the printer e Check J P8 3 for 12Vdc Is the voltage 12 Vdc No Replace the DC power supply then turn to TAG 002 Check amp Problem Resolution Yes Replace the disk drive assembly then turn to TAG 002 Check amp Problem Resolution 15 Turn the printer off e Reconnect J P41 Disconnect J P58 J P60 and J P62 Turn the printer on e Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Go to 21 in this TAG Yes Continue 16 Turn the printer off e Reconnect J P58 Turn on the printer e Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Goto 19 in this TAG Yes Continue 3 82 Troubleshooting Analysis Guide TAGs 17 18 19 20 21 Turn the printer off e Reconnect J P60 Turn the printer on Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Go to 20 in this TAG Yes Continue Disconnect J P61
155. assette 703 Lower cassette 704 TAG Cross Reference Tables Print Quality TAG Cross Reference Table 2 21 Paper Handling Problem TAGs Table 2 22 Counter Problem TAGs f Paper Handling Problems Go to TAG Multiple paper feed 705 Multiple sheet feeds and jams 705 Wrinkled or torn paper 706 Simplex misregistration and paper skew 807 Duplex misregistration and paper skew 901 Paper will not feed from upper cassette 012 Paper jam in duplex area 902 Upper paper guide not closing 707 Counter Problems Go to TAG Supplies seem to have short life span 750 Incorrect counting 750 Table 2 23 Communication Problem TAGs Communication Problems Go to TAG Printer will produce test prints 753 Incorrect data being printed 753 Table 2 24 Additional Mechanical Malfunction TAGs Additional Mechanical Malfunctions Go to TAG Test prints won t run after POR 130 Cooling fan not running 752 Vacuum transport unit fan not running 752 Circuit breaker trip 600 Main drive motor not turning off 751 TAG Cross Reference Tables Print Quality TAG Cross Reference TAG Cross Reference Tables Chapter 3 Troubleshooting Analysis Guide TAGS Troubleshooting Analysis Guide TAGs 3 1 Contents Troubleshooting Analysis Guide TAGs TAG 001 Troubleshooting a Problem 0 0 0 cece eee eee eee 3 5 TAG 002 Check amp Proble
156. at J P13 J P30 and J P31 are connected properly Make sure the customer s paper supply is not at fault Perform the every call cleaning procedure described in Chapter 9 General Printer Mainte nance Turn the printer on e Run test prints Has the problem been resolved No Continue Yes Loose connectors or contamination were at fault Turn to TAG 002 Check amp Problem Resolution 2 Check the voltages as outlined in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Have the photoconductor unit main charger and developer unit been replaced recently No Continue Yes Go to 6 in this TAG 4 Replace the photoconductor unit and main charger Runtest prints Has the problem been resolved No Reinstall the original photoconductor unit and main charger and continue Yes Turn to TAG 002 Check amp Problem Resolution 5 Replace the developer unit and toner cartridge Runtest prints Has the problem been resolved No Reinstall the original developer unit and continue Yes Turn to TAG 002 Check amp Problem Resolution 3 160 Troubleshooting Analysis Guide TAGs 6 Turn on the printer Produce a developed image on the photoconductor Are there vertical streaks on the photoconductor belt image No Replace the transfer charger unit then turn to
157. at the paper being fed from the upper cas us sette did not reach the timing paper sensor within the allotted time S 021 PCL board detected that the paper being fed from the lower cas 5 sette did not reach the timing paper sensor within the allotted time 022 PCL board detected that the exit paper sensor did not activate or n the timing sensor did not deactivate within the allotted time gt G 023 PCL board detected that either E 1 The exit paper sensor within the printer became activated but A did not deactivate within the specified time 2 HCO only The paper exit sensor within the HCO did not become activated or deactivated within the allotted time 025 PCL board detected that the timing paper sensor was activated G immediately after one of the covers was closed 5 026 PCL board detected that either the exit paper sensor within the 2 printer or the paper exit sensor within the HCO was activated A immediately after one of the covers was closed 027 PCL board detected paper in the duplex area after clearing a jam 030 PCL board detected a signal from the high voltage power supply unit indicating an abnormal load on the bias voltage to either the o developer unit cleaner unit or printhead cleaning bias plates g 031 PCL board detected a signal from the toner patch sensor board Lu indicating that the reference voltage level on the photoconductor e was too low E 032 PCL board detected a signal from the toner patch sensor board
158. atched 0 0 0 eee eee ee 3 24 TAG 020 Paper Jam Misfeed in Upper Cassette Area 000 3 26 TAG 021 Paper Jam Misfeed in Lower Cassette Area 0 00005 3 30 TAG 022 Paper Jam in the Transfer or Fuser Area 0 0 eese 3 34 TAG 023 Paper Jam in the Output Area 0 2 eee eee 3 39 TAG 025 Paper in Input Area Before Printing 0 0 00 2 e eee ee 3 41 TAG 026 Paper in Output Area Before Printing 3 43 TAG 030 Developer Bias Short Failure 0 0 0 0 eee eee eee 3 44 TAG 031 Toner Patch Reference Level Too Low 00 0 0 e eee eee 3 47 TAG 032 Toner Patch Too Light 0 0 0 cece eee ene eee 3 49 TAG 035 Out of Toner or ADD TONER Indicator On 0 04 3 51 TAG 036 Developer Unit Not Installed 0 0 llle 3 53 TAG 040 Photoconductor Seam Sensor Malfunction 00005 3 54 TAG 044 Main Charger Transfer Charger Circuit Open 04 3 58 TAG 045 Main Charger Circuit Shorted 2 0 2 0 eee eee ee 3 61 TAG 050 Transfer Charger Circuit Shorted 0 0 0 0 cece eee eee 3 63 TAG 055 Erase Lamp Malfunction sese 3 65 TAG 070 Fuser Unit Malfunction 0 0 0 0 cee eee eee eee 3 67 TAG 071 Open Fuser Thermistor 0 0 0 2 eee I 3 72 TAG 072 Fuser Unit Temperature Too High 0 0 0 cee eee eee 3 73 TAG 083 Job Offset Mechanism Malfunction 0 0 00 cee eee ee
159. ative DB Developer Bias Positive DCPS 1 DC Power Supply DEV eeu Developer Unit DMAC Direct Memory Access Controller DMC Dynamic Memory Controller DRAM Dynamic Random Access Memory DUPLEXI Duplex Control 1 Duplex only DUPLEX2 Duplex Control 2 Duplex only BIGS 2 24 ke Enhanced Image Generation System Bae eerie this Eraser LED Abbreviations and Acronyms IGS CONT LL SW Front LL SW Top Erasable Programmable Read Only Memory Electrophotographic Process Exit Paper Sensor Erase Lamp Enhanced Video K30 printer Exit Solenoid Duplex only Cooling Fan Duplex only Floppy Disk Controller Floppy Disk Drive Fuser Halogen Lamp Field Replaceable Unit Fuser Unit High Capacity Input High Capacity Output LED Array Print Head Hard Disk Drive High Voltage Unit Image Generation System Image Control System Interlocking Switch Front Interlocking Switch Top In Solenoid Duplex only Initial Program Load Jogging Motor Lower Paper Sensor DEC emulation language Lower Paper Feed Clutch Lower Paper Empty Sensor Lower Pick Up Clutch Lower Tray Interlock Switch Main Motor Maintenance Analysis Procedures A 1 MCH Main Charger Unit MCS Main Charger Sensor MIG Sereen Minter Image Generation System MPU em Micro Processing Unit MUX Multiplexer OPC erre Organic Photoconductor OPPNL Operator Panel P uoce nae ok
160. ators Are the interlock switch actuators working properly No Repair or replace any defective actuator then turn to TAG 002 Check amp Problem Reso lution Yes Continue 6 Use extreme caution Check from J P4 4 to J P4 3 for 100 Vac Is the voltage 100 Vac No Continue Yes Repair or replace the connectors or wiring from P9 2 to P4 4 or P9 1 to P4 3 If this is a duplex printer and the problem remains go to TAG 900 Top Cover Interlock Malfunc tion Duplex If this corrects the problem turn to TAG 002 Check amp Problem Resolu tion 7 Turn the printer off and unplug the power cord Remove the upper fuse in the AC power supply unit e Check the fuse for continuity Does the fuse have continuity No Continue Yes Go to 10 in this TAG 8 Replace the upper fuse in the AC power supply unit e Reconnect the power e Power on reset the printer Was the power on reset successful No Go to 14 in this TAG Yes Continue 9 Remove the developer unit e Run diagnostic test 010 for approximately 5 seconds then stop Turn the printer off and unplug the power cord Remove the fuse e Check the fuse for continuity Does the fuse have continuity No Go to 12 in this TAG Yes A defective fuse was at fault Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 119 10 11 12 13 14 3 120 Reinstall the fuse e Disconnect J P4 Close the top cover
161. been resolved No Replace the upper paper guide assembly If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the high volt age unit then turn to TAG 002 Check amp Problem Resolution Yes The transfer charger unit was at fault Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 149 10 11 12 13 14 15 3 150 Run diagnostic test 111 e Watch the printhead LEDs while the test is running Do the LEDs illuminate No Go to 18 in this TAG Yes Continue Are the prints blank without dark bands No Go to 15 in this TAG Yes Continue Remove the photoconductor unit and place it in its protective packaging Remove the developer unit Inspect the drive coupling on the developer unit for damage Is the coupling damaged No Continue Yes Replace the developer unit then turn to TAG 002 Check amp Problem Resolution Rotate the drive coupling on the developer unit clockwise e Watch the magnetic brush Does the magnetic brush turn No Replace the developer unit then turn to TAG 002 Check amp Problem Resolution Yes Continue Reinstall the photoconductor unit e Run diagnostic test 009 e Watch the developer drive coupling at the rear of the developer unit cavity Does the developer drive coupling turn No Repair or replace the main drive gear assembly then turn to TAG 002 Che
162. belt for damage e Check the timing hole for contamination or blockage Are the photoconductor belt and the timing hole both in good working order No Replace the photoconductor unit then turn to TAG 002 Check amp Problem Resolution Yes Continue Turn the printer off e Disconnect J P40 Turn the printer on e Check TP3 20 for 12 Vdc Is the voltage 12 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue Check TP3 21 for between 2 to 6 Vdc Is the voltage between 2 to 6 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue Turn the printer off and unplug the power cord Remove the photoconductor unit e Disconnect J P63 observing carefully the plug s orientation before you remove it e Check the following for continuity e P40 19 to J P64 1 to J P252 which is the center connector contact on the photoconductor guide rail e P40 21 to J P64 2 to J P251 which is the top connector contact on the photoconductor guide rail e P40 18 to J P 64 3 to P63 1 e P40 20 to J P64 4 to P63 2 Is there continuity on all No Repair or replace the connectors or wiring that did not have continuity then turn to TAG 002 Check amp Problem Resolution Yes Continue Repair or replace the photoconductor seam sensor e Reconnect J P40 and J P63 Reinstall the photoconductor e Power on reset the printer Has the prob
163. ble Defects Erase lamp assembly Connectors or wiring PCL board 1 Turn the printer off and unplug the power cord Verify that J P26 J P40 are connected properly e Power on reset the printer Is error code 055 displayed No Continue Yes Go to 3 in this TAG 2 Run diagnostic test 013 Is the value displayed less than 220 No A loose connector was at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Run diagnostic test 009 e Watch all the LEDs on the erase lamp Do all the LEDs on the erase lamp come on even momentarily No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 4 Run diagnostic test 013 Check J P26 2 for 12 Vdc immediately After the start of the test the voltage may drop to 0 Vdc Did you measure 12 Vdc No Continue Yes Go to 6 in this TAG 5 Turn off the printer and unplug the power cord e Disconnect J P26 and J P40 Check P26 2 to P40 3 for continuity Is there continuity No Repair or replace the connectors or wiring from P26 2 to P40 3 then turn to TAG 002 Check amp Problem Resolution Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 65 6 Turn off the printer and unplug the power cord Disconnect P26 and P40 Check P26 1 to P40 2 for continuity Is there continuity No Repair or replace the connectors or wiring from P26
164. blem replace the PCL board Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 19 3 20 10 Reconnect J P40 and J P45 Remove the lower cassette Loosen the lower paper size sensor assembly for access to the circuit board e Disconnect J P43 and J P47 Check J43 8 to J47 3 for continuity Is there continuity No Replace lower paper size sensor assembly then turn to TAG 002 Check amp Problem Res olution Yes Repair or replace the connectors or wiring from P45 3 to P47 3 P43 8 to J52 3 or P40 48 to P52 3 If this does not resolve the problem replace the upper paper size sensor assembly Then turn to TAG 002 Check amp Problem Resolution Reconnect J P40 and J P45 Remove the lower cassette Loosen the lower paper size sensor assembly for access to the circuit board e Disconnect J P43 and J P47 Check J43 9 to J47 2 for continuity Is there continuity No Replace the lower paper size sensor assembly Yes Repair or replace the connectors or wiring from P45 2 to P47 2 P43 9 to J52 2 or P40 49 to P52 2 If this does not resolve the problem replace the upper paper size sensor assembly Then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs TAG E12 Envelope Tray or Feeder Not Latched Error Code E12 Possible Defects Upper cassette release cam Upper cassette release latch Upper cassette in latch Upper pressure l
165. blem Resolution Turn the printer off e Disconnect J P330 Turn the printer on Check J P8 11 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Go to 22 in this TAG Troubleshooting Analysis Guide TAGs 4 Turn the printer off e Reconnect J P330 e Disconnect J P11 Turn the printer on Check J P8 11 for 24 Vdc Is the voltage 24 Vdc No Go to 11 in this TAG Yes Continue 5 Turn the printer off e Reconnect J P11 e Disconnect J P10 Turn the printer on Check J P8 11 for 24 Vdc Is the voltage 24 Vdc No Go to 7 in this TAG Yes Continue 6 Turn the printer off e Reconnect J P10 e Disconnect J P70 Turn the printer on Check J P8 11 for 24 Vdc Is the voltage 24 Vdc No Repair or replace the connectors or wiring from P10 to P70 then turn to TAG 002 Check amp Problem Resolution Yes Replace the AC power supply unit then turn to TAG 002 Check amp Problem Resolution 7 Turn the printer off e Reconnect J P10 e Disconnect J P12 Turn the printer on Check J P8 11 for 24 Vdc Is the voltage 24 Vdc No Replace power control 2 board then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 93 8 Turn the printer off e Reconnect J P12 e Disconnect J P41 Turn the printer on Check J P8 11 for 24 Vdc Is the voltage 24 Vdc No Replace the PCL board then turn to TAG 002 Check amp
166. board cover one screw 4 Disconnect CN9 CN10 CN11 CN12 CN13 and CN14 5 Remove power control board two screws Replacement Note Be sure that the back of the board is mounted properly in the frame slots Power Control Board Cover Mounting Slots cite CN10 Power Control Board Detail 7 38 Removal Replacement Procedures Jogging Motor Control Board Removal Jogging Motor Control Board Removal To remove the jogging motor control board Open the back cover Remove the paper feed drive cover three screws Remove the power control board cover one screw Disconnect CN100 CN101 and CN102 Disengage the board To do this pinch the two standoffs on the board o0 5 O N a Lift the board from its mounting bracket Power Control Board Cover Paper Feed Drive Cover CN100 CN102 Mounting Bracket Jogging Motor Power Conirol Board Deiail Removal Replacement Procedures 7 39 Upper or Lower Paper Size Sensor Removal Upper or LowerPaper Size Sensor Removal To remove the upper or lower paper size sensor 1 Duplex only Remove the duplex tray Remove the upper and lower paper cassettes Using a small screwdriver pry up the paper size sensor Turn the sensor counterclock wise and lift up For the upper paper size sensor disconnect CN45 and CN46 For the lower paper size sensor disconnect CN43 CN47 and CN48 Note Be careful not to damage the cables when disconnecting
167. cation Negative developer bias off 1 Negative developer bias on These codes may indicate specific error conditions Table 5 13 Negative Developer Bias Test Error Displays Display 030 Indication Developer bias short 041 Seam sensor sender short 090 You forgot to insert the interlock by pass tool 4 1 You forgot to remove the photoconductor unit 6 Press STOP to exit 7 Reinstall the photoconductor unit 8 Remove the interlock by pass tool and close the top cover Diagnostic Tests Press READY to run the test The negative developer bias turns on and off repeatedly Confirm that the display alternates between 0 and 1 accompanied each time by a 014 intentionally excluded 016 Duplex Feed Motor Test Go to 016 2 Press READY to run the test The duplex feed motor operates at full forward speed and 7 0 appears on the display Press READY to advance to the next motor speed Listen for the following motor frequencies and check the code that displays as you move through the test sequence The codes and their meaning are outlined in the chart below Table 5 14 Duplex Motor Feed Test Displays Display 7 0 Indication Full forward speed high frequency 7 1 Low forward speed low frequency 7 2 Full reverse speed high frequency 7 3 Half reverse speed low frequency These codes may indicate
168. ck amp Problem Resolution Yes Replace the high voltage unit then turn to TAG 002 Check amp Problem Resolution Do the prints have one or more horizontal dark bands No The problem has not been identified Go back to TAG 001 Troubleshooting a Problem and begin again Yes Continue Troubleshooting Analysis Guide TAGs 16 Turn the printer off and unplug the power cord Remove the photoconductor Clean the photoconductor unit contacts and guide rail contacts Check the bottom connector contact on the photoconductor guide rail for continuity to ground Is there continuity No Repair or replace the grounding circuit wiring then turn to TAG 002 Check amp Problem Resolution Yes Continue 17 Reinstall the photoconductor unit Turn the printer on e Run test prints Has the problem been resolved No Replace the photoconductor unit then turn to TAG 002 Check amp Problem Resolution Yes Contamination was at fault Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 151 TAG 801 Prints Light or Light With Carrier Particles 3 152 Error Code 801 Possible Defects Photoconductor unit Connectors or wiring Main drive gear assembly Transfer charger unit Power control 2 board Print head assembly High voltage unit Toner supply motor PCL board Upper paper guide assembly Developer unit If the problem still exists after completing this TAG go to TAG 800 Prints
169. ck amp Problem Resolution If this does not resolve the problem replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs TAG 813 Residual Images on Prints Error Code 813 Possible Defects Cleaner unit drive belt Cleaner unit High voltage unit Photoconductor unit Erase lamp assembly Developer unit 1 Turn the printer off and unplug the power cord e Perform the every call cleaning procedure described in Chapter 9 General Printer Mainte nance Turn the printer on Runtest prints Has the problem been resolved No Continue Yes Contamination was at fault Turn to TAG 002 Check amp Problem Resolution 2 Open the printer s back cover Remove the paper feed drive cover Check the cleaner unit drive belt Is the belt attached No Repair or replace the cleaner unit drive belt then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Check the voltages as outlined in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue 4 Have the cleaner unit developer unit with new toner cartridge and photoconductor unit been replaced recently No Continue Yes Go to 8 in this TAG 5 Replace the cleaner unit e R
170. ck amp Problem Resolution Replace the IGS board making sure that IGS EPROM version is correctly matched to the software release installed on the printer e Power on reset the printer Has the problem been resolved No Reinstall the original IGS board and continue Yes Turn to TAG 002 Check amp Problem Resolution Does this printer contain a hard drive No Continue Yes Go to 8 in this TAG Troubleshooting Analysis Guide TAGs 7 Replace the software diskettes in drives A and B e Power on reset the printer Has the problem been resolved No Replace the signal interface board then turn to TAG 002 Check amp Problem Resolution Yes Software diskettes were at fault Turn to TAG 002 Check amp Problem Resolution 8 Disconnect J P76 hard drive cable Insert the emulation diskette into drive A e Power on reset the printer Has the problem been resolved No Replace the signal interface board then turn to TAG 002 Check amp Problem Resolution Yes Reconnect J P76 and reload the software onto the hard drive instructions for loading software onto the printer s hard drive are outlined in the Guide to Operations Then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 109 TAG 201 IGS PCL Interface Malfunction Error Code 121 127 199 215 380 387 Symptoms Communication failure between the IGS board and the PCL board Possible Causes Insufficient delay period betwe
171. ck the paper path and remove any paper jams e Check the output tray and remove any paper jams e Power on reset the printer e Run test prints Is error code 023 displayed No Loose connectors or obstructions were at fault Turn to TAG 002 Check amp Problem Res olution Yes Continue 2 Is paper stopped or jammed at the output tray No Continue Yes Go to 5 in this TAG 3 Inspect the exit paper sensor actuator for damage or binding Is it in good working order No Repair or replace the exit paper sensor actuator then turn to TAG 002 Check amp Problem Resolution Yes Continue 4 Turn the printer off and unplug the power cord e Disconnect J P40 and J P49 e Check the following for continuity P40 24 to P49 2 P40 26 to P49 1 and Troubleshooting Analysis Guide TAGs 3 39 P40 13 to P49 3 Is there continuity No Repair or replace the connectors or wiring from P40 26 to J P50 1 to P49 1 P40 24 to J P50 2 to P49 2 or P40 13 to J P50 3 to P49 3 Yes Replace the exit paper sensor 5 Turn the printer off and unplug the power cord e Open the back cover and install an interlock bypass tool Remove the fuser drive cover Inspect the following for damage binding or contamination e Exit roller assembly e Exit roller drive gear e Exit pinch roller assembly Are all the parts in good working order No Replace the defective parts then turn to TAG 002 Check amp Problem Resolution Yes Co
172. conductor unit and continue Yes The photoconductor unit was at fault Turn to TAG 002 Check amp Problem Resolution 5 Has the seal has been removed from the toner cartridge No Continue Yes Go to 7 in this TAG Troubleshooting Analysis Guide TAGs 3 51 6 Remove the toner cartridge seal e Power on reset the printer e Run test prints Has the problem been resolved No Continue Yes The toner cartridge seal was at fault Turn to TAG 002 Check amp Problem Resolution 7 Turn the printer off and unplug the power cord e Disconnect J P41 Remove the developer unit e Check P41 48 to J25 6 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 48 to J25 6 then turn to TAG 002 Check amp Problem Resolution Yes Replace the PCL board If this resolves the problem then turn to TAG 002 Check amp Problem Resolution If the problem is still not resolved go to TAG 610 Operator Panel Malfunction 3 52 Troubleshooting Analysis Guide TAGs TAG 036 Developer Unit Not Installed Error Code 036 Possible Defects Developer unit not installed properly Connectors or wiring PCL board 1 Turn the printer off and unplug the power cord Make sure the developer unit is installed properly e Confirm that J P41 is connected properly e Confirm that the proper developer unit is installed e Power on reset the printer Is error code 036 displayed No A loose connector or impr
173. cover See page 7 8 Duplex only Remove the duplex tray mount four screws Remove the paper feed drive cover three screws duplex two screws Disconnect the two wires connected to the interlock switch ON Oat WD a Remove the top cover interlock switch two screws Duplex Tray Mount C30D only Paper Feed Drive Cover Top Cover Interlock Switch Detail 7 82 Removal Replacement Procedures Erase Lamp Removal Erase Lamp Removal To remove the erase lamp Open the top and back covers Remove the photoconductor and place it in its protective packaging Remove the fuser drive cover three screws Disconnect CN26 Remove the screw holding the erase lamp in place Disengage the front of the erase lamp from its guide pin N Oo oO 5 WO ND Slide the unit out from the back of the printer Fuser Drive Cover Back Detail Removal Replacement Procedures 7 83 EP Cover Removal EP Cover Removal To remove the EP cover 1 Open the front back and top covers 2 Remove the fuser 3 Remove the photoconductor and place it in its protective packaging 4 Remove the cleaner unit 5 Remove the operator panel See page 7 19 Vacuum Transport Supports Support Screw EP Cover Screws Front Detail Removal Replacement Procedures 7 84 EP Cover Removal Remove the fuser drive cover three screws Remove the two supports for the vacuum transport unit one screw each
174. d then turn to TAG 002 Check amp Problem Resolution Yes Continue 7 Turn the printer off e Reconnect J P74 e Disconnect the DC cable J P73 for the attachment option Turn the printer on Is the voltage at J P8 8 12 Vdc No Replace the signal interface board then turn to TAG 002 Check amp Problem Resolution Yes Replace the attachment option then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 91 3 92 TAG 099 24 Vdc Power Shorted Error Code 099 Possible Defects DC power supply unit AC power supply unit Connectors or wiring PCL board IGS board Power control 2 board High voltage unit Paper timing clutch Upper feed roller clutch Upper pick up clutch Lower pick up clutch Lower feed roller clutch Counter assembly Possible Defects Duplex Printers Duplex control board 1 Duplex control board 2 Route motor In solenoid C roller solenoid A roller clutch Exit solenoid Restart motor Turn the printer off and unplug the power cord Verify that J P11 J P8 J P32 J P33 J P91 J P303 J P305 J P306 J P310 J P323 and J P331 are connected properly e Power on reset the printer Has the problem been resolved No Continue Yes A loose connector was at fault Turn to TAG 002 Check amp Problem Resolution Check J P8 11 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Pro
175. d Vertical Streaks on Prints 3 177 Uneven Density or Dark Areas on Prints 04 3 180 Background Residual Images Dark Prints 3 182 Uneven or No Fusing on Prints 0 0 0 eee eee 3 187 Residual Images on Prints 0 0 00 cee eee eee eee 3 189 Prints Resulting From Printhead Malfunctions 3 191 Top Cover Interlock Malfunction Duplex 3 192 Misregistration Skewed Prints Duplex 005 3 194 Paper Jam in Duplex Area 1 0 0 2 eee eee eee 3 198 Troubleshooting Analysis Guide TAGs 3 3 Troubleshooting Analysis Guide TAGs 3 4 This chapter describes each of the TAGs used to diagnose and resolve specific printer problems related to error codes print quality and mechanical malfunctions Chapter 1 Printer and Troubleshooting Overview is an overview of how the TAGs are organized and how to use them If you are using a TAG for the first time please refer to this chapter for more specific instructions Chapter 2 TAG Cross Reference Tables provides comprehensive tables which cross reference specific error codes print quality problems and mechanical malfunctions to the TAGs contained in this chapter As you use these TAGs you may need to refer to other chapters of this manual for addi tional information Please turn to these chapters as required Troubleshooting Analysis Guide TAGs TAG 001
176. detone the printer s engine then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 5 Replace the cleaner unit e Run test prints Has the problem been resolved No Reinstall the original cleaner unit and continue Yes Turn to TAG 002 Check amp Problem Resolution 6 Replace the developer unit with toner cartridge e Run test prints Has the problem been resolved No Reinstall the original developer unit and continue Yes Turn to TAG 002 Check amp Problem Resolution If the problem recurs the toner carrier mix may be old or contaminated 7 Turn the printer off Open the front cover and install an interlock by pass tool Remove the developer unit e Power on reset the printer Watch the toner motor coupling at the rear of the developer cavity Does the coupling turn continuously No Go to 10 in this TAG Yes Continue 8 Check TP3 31 for 0 Vdc Is the voltage 0 Vdc No Replace the power control 2 board then turn to TAG 002 Check amp Problem Resolu tion Yes Continue 9 Turn off the printer and unplug the power cord e Disconnect J P12 and J P40 Check P40 31 to P12 5 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 31 to P12 5 then turn to TAG 002 Check amp Problem Resolution Yes Replace the power control 2 board If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this
177. diagnostic test 008 Check J P102 2 for 12 Vdc while the test is running Is the voltage 12 Vdc No Go to 11 in this TAG Yes Replace the power control 3 board then turn to TAG 002 Check amp Problem Resolu tion 10 Run diagnostic test 008 Check TP3 32 on the PCL board for 12 Vdc while the test is running Is the voltage 12 Vdc No Repair or replace the connectors or wiring from P102 2 to P40 32 then turn to TAG 002 Check amp Problem Resolution Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 3 76 Troubleshooting Analysis Guide TAGs 11 12 13 14 15 16 Run diagnostic test 008 Check J P102 1 for 12 Vdc while the test is running Is the voltage 12 Vdc No Continue Yes Replace the power control 3 board then turn to TAG 002 Check amp Problem Resolu tion Run diagnostic test 008 e Check TP3 35 on the PCL board for 12 Vdc while the test is running Is the voltage 12 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P102 1 to P40 35 then turn to TAG 002 Check amp Problem Resolution Run diagnostic test 008 Does the tone sound steadily while the output tray moves back and forth No Continue Yes Repair or replace the job offset assembly then turn to TAG 002 Check amp Problem Reso lution Turn the printer off and unplug the power c
178. doesn t resolve the problem replace the PCL board then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 173 10 11 12 13 14 3 174 Reinstall the developer unit e Run test prints e Check TP3 31 for a voltage change from 12 Vdc to OVdc while running test prints Does the voltage change from 12 Vdc to OVdc every other print cycle No Goto 14 in this TAG Yes Continue Turn the printer off and unplug the power cord e Disconnect J P41 Remove the developer unit e Check for continuity P4 P41 44 to P25 2 P41 47 to P25 3 and P41 50 to P25 1 Is there continuity at each No Repair or replace the connectors or wiring from P41 44 to P25 2 P41 47 to P25 3 or P41 50 to P25 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue Verify that the connector is securely plugged into the toner patch sensor circuit board which is mounted on the developer unit Is it connected properly No Reconnect the connector then turn to TAG 002 Check amp Problem Resolution Yes Continue Clean the printhead lens and toner patch sensor e Reinstall the developer unit e Reconnect J P41 e Run test prints while checking TP3 31 for a voltage change Does the voltage still change from 12 Vdc to 0 Vdc every other print cycle No Contamination was at fault Turn to TAG 002 Check amp Problem Resolution Yes Replace the developer unit and cleaner unit
179. e 3 113 Vac Power Malfunction 0 0 0 cece eee eee 3 118 Operator Panel Malfunction lesse eee eee 3 125 Output Tray Circuit Malfunction 00 0 eee eee eee 3 130 Paper Size Detection Malfunction 00 0 000 3 132 Upper Cassette Malfunction 0 0 0 c eee eee eee eee 3 135 Lower Cassette Malfunction 00 0 0 c eee eee ee eee 3 136 Multiple Paper Feeding 0 cece eee eee eee 3 137 Paper Damaged or Wrinkled 0 0 0 0 cece ee ee eee 3 138 Upper Paper Guide Assembly Not Closing 3 139 Counter Malfunction sls 3 140 Main Drive Motor Runs Continuously 00 0005 3 142 External Communications Malfunction 05 3 143 Attachment Option Malfunction 0 0 0 ce ee ee eee 3 146 Prints Blank or With Dark Horizontal Bands 3 148 Prints Light or Light With Carrier Particles 3 152 Prints With Voids or White Spots 0 0 000 eee eee 3 158 Prints With Light or White Vertical Streaks 3 160 Prints With Light Horizontal Bands 0 3 162 Black Printsess e oe ae Sawer ERES UPPER EGER ean he eR ee 3 163 Prints with Dark Spots or Scratches 0 0 0 0 0 002 e ee 3 166 Misregistered Skewed Prints Simplex 005 3 168 Prints Overtoned Dark Vertical Streaks 004 3 172 Blurred or Smeare
180. e 3 75 TAG 097 12 Vdc Power Shorted or Sensing Problem 3 79 TAG 098 12 Vde Power Shorted 0 0 0 eee eee ee eee 3 90 TAG 099 24 Vdc Power Shorted 0 0 eee eee eens 3 92 TAG 100 PCL Board Interface Malfunction 0 0 0 ee eee eee ee 3 102 TAG 101 IGS Controller Diagnostic Failure eee ee eee ee 3 103 TAG 130 Diskette Disk Drive Malfunction 0 0 0 0 ee eee eee eee 3 104 TAG 200 IGS Internal Communication Malfunction 00000 3 108 TAG 201 IGS PCL Interface Malfunction 0 0 0 0 cece eee ee eee 3 110 TAG 405 IGS Bit Map RAM Malfunction 0 00 eese 3 112 TAG 500 5 Vdc Power Malfunction l l eee 3 113 TAG 600 AC Power Malfunction sslseeeeeee ee eee 3 118 TAG 610 Operator Panel Malfunction lsseeeee eee 3 125 TAG 700 Output Tray Circuit Malfunction 0 0 0 cee eee eee ee 3 130 TAG 702 Paper Size Detection Malfunction 0 0 0 0 ce eee eee ee 3 132 TAG 703 Upper Cassette Malfunction slseee ee eee 3 135 TAG 704 Lower Cassette Malfunction 0 0 0 c eee eee eee 3 136 TAG 705 Multiple Paper Feeding 3 137 TAG 706 Paper Damaged or Wrinkled 0 0 eee ee eee 3 138 TAG 707 Upper Paper Guide Assembly Not Closing 000000 3 139 TAG 750 Counter Malfunction 0 0 0 ee eee eee 3 140 TAG 751 Main Drive Motor Runs Continuously 00 0000 e
181. e Check P62 1 to P61 1 for continuity to ground Is there continuity No Replace the lower paper empty sensor then turn to TAG 002 Check amp Problem Resolu tion Yes Repair or replace the connectors or wiring from P62 1 to P61 1 then turn to TAG 002 Check amp Problem Resolution Disconnect J P58 and J P57 Check P58 1 to P57 1 for continuity to ground Is there continuity No Replace the paper timing sensor Yes Repair or replace the connectors or wiring from P58 1 to P57 1 then turn to TAG 002 Check amp Problem Resolution Disconnect J P60 and J P59 Check P60 1 to P59 1 for continuity to ground Is there continuity No Replace the upper paper empty sensor Yes Repair or replace the connectors or wiring from P60 1 to P59 1 then turn to TAG 002 Check amp Problem Resolution Turn the printer off and unplug the power cord e Disconnect J P40 e Check for continuity to ground P40 25 to J58 1 P40 25 to J60 1 and P40 25 to J62 1 Is there continuity No Continue Yes Repair or replace the connectors or wiring from P40 25 to J58 1 P40 25 to J60 1 or P40 25 to J62 1 then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 83 3 84 22 23 24 25 26 Turn the printer off e Reconnect J P40 J P58 J P60 and J P62 e Disconnect J P50 and J P54 Turn the printer on Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Go to 30 in
182. e detected The test continues to loop Press STOP to exit If an error is found The error code displays briefly If more than one error is detected the error codes appear sequentially Look up the codes in the Error Code TAG Cross Reference on page 2 3 to deter mine which TAG to follow Power on reset to exit after codes display 109 intentionally excluded Diagnostic Tests 5 23 109 intentionally excluded 110 111 5 24 Format Disk Clear Error Log Caution When using the 110 function of the self diagnostic mode any existing data on the specified disk is at risk To format a disk refer to the Guide to Operations manual 5 To clear the error log follow the procedure on clearing the log found in Clearing the Error Log on page 1 24 Caution If you access this function by mistake do not proceed Press STOP immediately to exit the utility LED Printhead Test A OQ N a 5 6 7 Open the top cover Remove the photoconductor unit and place it in its protective packaging Remove the developer station To help you identify the LEDs place a white sheet of paper in the photoconductor cavity over the printhead s fiber optics Go to 111 Press READY to run the test The LED printhead turns on Verify that the LEDs cycle on and off from front to back These codes may indicate specific error conditions Table 5 26 LED Printhead Test Error Disp
183. e photoconductor unit and place it in its protective packaging Close the top cover Go to O11 Press READY to run the test The main charger turns on and off repeatedly Confirm that the display alternates between 0 and 1 accompanied each time by a brief tone The display indicates the following Table 5 7 Main Charger Test Displays Display 0 Indication Main charger off 1 Main charger on These codes may indicate specific error conditions Table 5 8 Main Charger Test Error Displays Display Indication 041 Photoconductor seam sensor short 045 Main charger short 046 Main charger open 4 1 You forgot to remove the photoconductor 5 Press STOP to exit 6 Reinstall the photoconductor unit Diagnostic Tests 004 intentionally excluded 012 Transfer Charger Test 1 Remove the photoconductor unit and place it in its protective packaging Close the top cover Go to 012 Press READY to run the test The transfer charger turns on and off repeatedly Confirm that the display alternates between 0 and 1 accompanied each time by a brief tone The display indicates the following Table 5 9 Transfer Charger Test Displays Display Indication 0 Transfer charger off 1 Transfer charger on These codes may indicate specific error conditions Table 5 10 Transfer Charger Test Error Displays Display Indication 041 Seam sensor s
184. e photoconductor unit as part of a removal procedure make sure to place it in its protective packaging Removal Replacement Procedures Front Cover Removal Front Cover Removal To remove the front cover Open the front cover While holding the cover up halfway unhook the strap from the right side Duplex only Remove the strap from the left side b amp b OO N 2a Slide the front cover to the right off its hinges Right Strap Removal Replacement Procedures 7 5 Back Cover Removal Back Cover Removal To remove the back cover Remove all external cables and attachments Open the top and back covers Disconnect CN31 CN32 CN37 CN40 CN41 CN74 and CN91 Duplex only Disconnect CN36 For the hard drive option disconnect the drive s data cable Remove the ground screw from the back cover o0 5 WO ND While supporting the back cover remove the screw holding each strap Caution hold the plastic strap to avoid throwing the screw as it comes loose 8 Lift the back cover up and away from the printer CN36 C30D only CN37 CN91 Ground Screw Hard Disk Drive CN74 CN32 Connector CN31 7 6 Removal Replacement Procedures Lower Back Cover Removal Lower Back Cover Removal To remove the lower back cover Disconnect all external cables and attachments Open the back cover Loosen the two screws holding the lower back cover in place Lift the back cover off its hinges a 5 WwW N
185. e printer Remove and insert the envelope cassette while watching the operator panel Does 1 8 appear on the operator panel No Replace the upper paper size sensor assembly then turn to TAG 002 Check amp Problem Resolution Yes Continue Run a job in which you are using envelopes Is error code E10 displayed No The cassette was loaded incorrectly Turn to TAG 002 Check amp Problem Resolution Yes Continue Remove the envelope cassette Inspect the paper empty sensor actuator Is itin good working order No Replace the actuator then turn to TAG 002 Check amp Problem Resolution Yes Continue Open the rear door and install an interlock by pass tool Check the voltage from TP3 15 to ground on the PCL board e Activate the upper paper sensor actuator manually Does the voltage change from OVdc to 12Vdc No Replace the upper paper empty sensor then turn to TAG 002 Check amp Problem Resolu tion Yes Continue Troubleshooting Analysis Guide TAGs 5 Reinsert the envelope cassette e Watch the pressure lever as the cassette is inserted Does the pressure lever elevate the envelopes to the correct feeding position No Check the following for defects or incorrect mounting e Cassette tray e Damper assembly e Upper pressure lever e Upper cassette release cam e Upper cassette release latch Wire cable pulley and spring e Upper cassette release lever Replace the defective part
186. e than five seconds or additional damage may occur Is the voltage approximately 5 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue 7 Turn the printer off and unplug the power cord Remove the fuser unit e Disconnect J P41 Check P41 22 to P5 6 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 22 to P83 1 or J83 1 to P5 6 then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 68 Troubleshooting Analysis Guide TAGs 8 Check P41 21 to P5 7 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 21 to P83 2 or J83 2 to P5 7 then turn to TAG 002 Check amp Problem Resolution Yes Continue 9 Reinstall the fuser unit Check P41 21 to P41 22 for resistance Is the resistance between I KQ and 400 Ko No The new fuser unit seems to be defective Replace it with a new fuser unit then turn to TAG 002 Check amp Problem Resolution Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 10 Power on reset the printer e Check J P10 2 for 24 Vdc during the 15 seconds following power on reset Is the voltage 24 Vdc No Go to 16 in this TAG Yes Continue 11 Turn the printer off Continue to check J P10 2 for 24 Vdc e Power on reset the printer Does the voltage drop from 24 Vdc to 0 Vdc during the 15 seconds followi
187. e upper duplex roller cover four screws Remove the lower duplex roller cover four screws Disconnect CN22 a Ff QOQ N Remove the C clip from the gas spring on the side marked up Gently move the gas spring out of the way so it does not block the wire harness area Remove the four harnesses stays holding the cable in place Remove the three ground screws Remove the vacuum transport unit four screws Upper Duplex Harness Stays Roller Cover Vacuum Transport Ground Screws CN22 Harness Stay Spring Detail Lower Duplex Z4 Roller Cover S Removal Replacement Procedures 7 18 Top Cover Removal Top Cover Removal To remove the top cover 1 Open the top cover 2 Remove the vacuum transport unit from the top cover It is not necessary to remove it completely from the printer Refer to page 7 11 Remove the four screws for each support assembly Lift the top cover up and away from the printer Vacuum Transport Unit Support Assembly Detail 7 14 Removal Replacement Procedures Top Cover Support Removal Top Cover Support Removal To remove the top cover support 1 Open the top cover 2 Remove the spring from the top cover support single screw 3 Remove the screws holding the support to the base of the printer Replacement Note Replace one support at a time so that the other remains in place to stabilize the top cover Spring Screw Support Detail Removal Re
188. e you press READY These codes may indicate specific error conditions Table 5 20 Duplex Tray Paper Guide Motor Test Displays Display 069 Indication Duplex tray not installed 084 Duplex tray registration sensor not active 085 Duplex tray registration sensor active 090 Cover is open Close cover 5 Press STOP to exit Diagnostic Tests 014 intentionally excluded 020 High Capacity Output Unit Test Go to 020 2 Press READY to run the test The code for the first sensor i e 0 0 or 0 1 appears on the display confirming that the sensor is working properly Note No paper moves through the machine so indications of No paper at sensor location are normal 3 Press READY to advance to the next sensor The sensor s code appears on the dis play codes and their meaning are outlined in Table 5 21 High Capacity Output Unit Test Displays below Table 5 21 High Capacity Output Unit Test Displays Sensor Description Display Installation sensor 0 0 Unit not installed 0 1 Unit installed Paper exit sensor 1 0 No paper at sensor location 1 1 Paper at sensor Paper full sensor 2 0 Paper not full 2 1 Paper full Lower limit sensor 3 0 Tray stationary or moving down 3 1 Tray moving up 4 To check a specific sensor press READY repeatedly until the code on the display cor responds to the sensor you want to check Manually activa
189. ect the main charger lead from the high voltage unit e Check for continuity the main charger lead terminal assembly s lower contact to the lead removed from the high voltage unit Is there continuity No Repair or replace the main charger lead or the main charger terminal assembly then turn to TAG 002 Check amp Problem Resolution Yes Continue Remove the cleaner unit Disconnect J P85 Check for continuity between the connector for the main charger terminal assembly s upper contact and J P85 10 at the high voltage unit Is there continuity No Repair or replace the connectors or wiring then turn to TAG 002 Check amp Problem Res olution Yes Continue Disconnect J P41 and J P23 Check P41 35 to P23 5 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 35 to P23 5 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P41 39 to P23 1 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 39 to P23 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue Reconnect the power Turn the printer on e Check J P41 35 for 24 Vdc Is the voltage 24 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Determine whether the high voltage unit or the main charger terminal assembly is at fault replace the faulty unit then turn to TAG 002 Check
190. ectors were at fault Turn to TAG 002 Check amp Problem Resolution 2 Check the voltages as outlined in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Have the photoconductor main charger cleaner or fuser units been replaced recently No Continue Yes Go to 7 in this TAG 4 Replace the photoconductor unit and main charger Runtest prints Has the problem been resolved No Reinstall the original photoconductor and main charger and continue Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 177 3 178 Replace the fuser unit e Run test prints Has the problem been resolved No Reinstall the original fuser unit and continue Yes Turn to TAG 002 Check amp Problem Resolution Replace the cleaner unit e Run test prints Has the problem been resolved No Reinstall the original cleaner unit and continue Yes Turn to TAG 002 Check amp Problem Resolution Check the following for damage e Vacuum transport unit e Vacuum transport assembly ozone filter e Fuser unit drive gear on the fuser unit and fuser unit cavity e Fuser drive belt Main drive assembly Cleaner unit drive belt Cleaner drive idler assembly Cleaner drive assembly Are they in good working order No Repair or replace the parts as
191. ed paper size 5 Press STOP to exit Diagnostic Tests 004 intentionally excluded 003 Lower Cassette Test 1 Make sure the lower paper cassette is installed with paper the side and rear guides securely against the edges of the paper in the cassette Go to 003 Press READY to run the test Refer to the chart below to confirm that the code that displays corresponds to the paper size in the cassette For example if the cassette holds letter size paper 1 3 should appear on the display This indicates the paper size sensor is working properly Table 5 1 Paper Size Codes lists the paper size codes Note A 1 9 is displayed when a high capacity paper feed unit is installed refer to 021 High Capacity Unit Input Test 5 Press STOP to exit 004 intentionally excluded Diagnostic Tests 004 intentionally excluded 005 Sensor Test Sequence Go to 005 2 Press READY to run the test The code for the first sensor i e 0 0 or 0 1 appears on the display confirming that the sensor is working properly Note No paper moves through the machine so indications of No paper at sensor location are normal 3 Press READY to advance to the next sensor The display changes showing the code for the next sensor as outlined in Table 5 2 Sensor Test Displays below Table 5 2 Sensor Test Displays Sensor Description Display Up
192. emark of Monotype Corporation PLC ITC Zapf Dingbats is a U S registered trademark of International Typeface Corpora tion PostScript is a registered trademark of Adobe Systems Inc in the U S A and other countries Times Roman and Univers are trademarks of Linotype AG and its subsidiaries Centronics is a U S registered trademark of Centronics Corporation PhoenixPage is a trademark of Phoenix technologies Ltd UNIX is a registered trademark of UNIX System Laboratories Inc in the U S A and other countries DEC LNO03 is a registered trademark of Digital Equipment Corporation All other trademarks are the properties of their respec tive owners Warnings and Cautions A WARNING denotes a hazard It calls attention to a procedure or practice which if not done correctly or adhered to could result in personal injury Do not proceed beyond a WARNING sign until the indicated conditions are fully understood and met A CAUTION denotes a hazard It calls attention to a procedure which if done incorrectly or inattentively could damage or destroy part or all of the product Do not proceed beyond a CAUTION until the indicated conditions are fully understood and met Conventions The following conventions are used throughout this manual Note Notes contain important information set off from the text Caution Caution messages indicate procedures which if not observed could result in damage to the equipment Warning
193. emove the output tray from the stacker unit Disconnect the stacker unit s power cord from the printer and from the stacker then disconnect the unit s control connector cable from the printer s jack 4 Remove the stacker unit from the printer then place it on a work bench or other suit able surface 5 Remove the printer s power cord from the wall outlet and the printer s lower back COVer 6 Observe the pin configuration of the stacker unit s control connector cable plug 1234567 eeceoc 006090 Pd eeooooo 910XXXXX Control Connector Cable Plug 8 10 Options Options 11 12 13 14 15 16 17 Place a jumper from pin 9 to pin 10 ground Using the printer s power cord in place of the unit s power cord plug the printer s power cord in the stacker unit then into the wall outlet With the power applied to the stacker unit the exit roller motor ERM M1 will be off This will signal the output control board to turn the exit roller motor ERM M1 on Remove the jumper from pin 9 and pin 10 Lift the paper tray full actuator to enable photosensor OLLS to signal the output con trol board to cause the elevator motor OEM M2 to turn on and lower the output tray guide As the output tray guide reaches its lowest allowable position photosensor OELS is enabled and signals the output control board to turn the elevator motor OEM M2 off Releasing the paper tray full actuator then enables photosensor OULS to
194. en power off and power on Electrical spikes Possible Defects Connectors or wiring PCL board IGS board DC power supply High voltage power supply 1 Is error code 201 displayed No Go to 3 in this TAG Yes Continue 2 Turn the printer off and unplug the power cord Verify that J P33 is connected properly e Power on reset the printer Has the problem been resolved No Confirm that the IGS firmware is correct for the version of software being used then replace the IGS board Turn to TAG 002 Check amp Problem Resolution Yes Turn to TAG 002 Check amp Problem Resolution 3 Is error code 121 or 123 displayed No Go to 6 in this TAG Yes Continue 4 Turn the printer off and unplug the power cord e Confirm that J P33 is connected properly Are the connectors or wiring damaged No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 9 Replace the PCL board e Power on reset the printer Has the problem been resolved No Continue Yes Turn to TAG 002 Check amp Problem Resolution 3 110 Troubleshooting Analysis Guide TAGs 6 Replace the IGS board e Power on reset the printer Has the problem been resolved No If error code 121 or 123 brought you to this TAG replace the DC or high voltage power supply then turn to TAG 002 Check amp Problem Resolution For all other error codes replace the IGS board then turn to TAG 002 Check amp Problem Resoluti
195. ender short 050 Transfer charger short 051 Transfer charger open or not installed 4 1 You forgot to remove the photoconductor 5 Press STOP to exit 6 Reinstall the photoconductor unit Diagnostic Tests 5 11 014 intentionally excluded Erase Lamp Test 013 Select 013 a fF OO N Open the top cover and insert the interlock by pass tool Remove the photoconductor unit and place it in its protective cover READY to run the test The erase lamp turns on with all LEDs lighted Verify that all LEDs are illuminated and a number s appears on the display The num ber is a readout from the A D converter and does not affect the erase lamp test These codes may indicate specific error conditions Table 5 11 Erase Lamp Test Error Displays Display Indication 041 Seam sensor sender short 055 Erase lamp malfunction 4 1 You forgot to remove the photoconductor unit 6 Press STOP to exit 7 Reinstall the photoconductor unit 8 Remove the interlock by pass tool and close the top cover 014 intentionally excluded 5 12 Diagnostic Tests 014 intentionally excluded 015 Negative Developer Bias Test Go to 015 a fF OND Open the top cover and insert the interlock by pass tool Remove the photoconductor unit and place it in its protective packaging brief tone The display indicates the following Table 5 12 Negative Developer Bias Test Displays Display 0 Indi
196. eplace as necessary Clean any excess toner from the developer unit with a soft cloth Clean the toner patch sensor lens with a soft cloth making sure no lint remains on the lens Vacuum the felt areas around the magnetic roller being careful not to vacuum toner from the magnetic roller Reinstall the developer unit Clean the Cleaner Unit Main Charger Inspect the unit for damage or contamination repair or replace as necessary Remove the main charger from the cleaner unit Clean the grid with the cleaner brush Remove the grid to expose the charger wire Clean the charger wire with a cotton swab Reinstall the grid Clean any excess toner from the cleaner unit with a soft cloth Reinstall the main charger in the cleaner unit Reinstall the cleaner unit Clean the Photoconductor Unit Area Clean the photoconductor seam sensor inside the printer Remove the photoconductor from its protective packaging Inspect the photoconductor for damage or contamination repair or replace as neces sary Reinstall the photoconductor unit Clean the Transfer Charger Remove the transfer charger Clean the transfer charger housing with a soft cloth Clean the transfer charger wire with a cotton swab Reinstall the transfer charger Run Test Prints Run test prints to verify print quality General Printer Maintenance 9 7 Introduction Adjusting Paper Feed Tension Printers With Paper Tension Levers Recently released
197. eplace the IGS board then turn to TAG 002 Check amp Problem Resolution Yes Replace wire harness W46 then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 107 TAG 200 IGS Internal Communication Malfunction 3 108 Error Code 401 454 455 500 509 520 530 540 566 570 571 577 585 600 605 Symptoms IGS board failure Possible Causes IGS program error Possible Defects Wiring or connectors IGS board Software Signal interface Turn the printer off and unplug the power cord Verify that J P31 J P32 J P33 J P79 and J P74 are connected properly e Power on reset the printer Has the problem been resolved No Continue Yes A loose connector was at fault Turn to TAG 002 Check amp Problem Resolution Was an error code displayed No Refer to the mechanical malfunctions cross reference table in Mechanical Malfunction TAG Cross Reference on page 2 12 Yes Continue If the operator panel displayed more than one error code was it the first code that displayed on the panel that led you to this TAG No Look in Error Code TAG Cross Reference on page 2 3 for the first error code that dis played then turn to the TAG referenced in the table Yes Continue Turn the printer off e Disconnect J P31 and J P79 Check P31 34 for continuity to ground Is there continuity to ground No Continue Yes Replace wire harness W46 then turn to TAG 002 Che
198. er When the supplies are out use a toner vacuum to vacuum the printer thor oughly Clean each consumable supply following the instructions listed in this section before returning it to the printer Conclude the every call procedure by running test prints to confirm the print quality The location of all major printer supplies and instructions for their removal are outlined later in this manual Remove Major Consumable Supplies Photoconductor unit place it in its protective packaging e Cleaner unit Developer unit Fuser unit Inspect and Vacuum Inspect the areas in the printer around the developer unit cleaner unit photoconducto unit and fuser unit for damage and wear Vacuum these areas to remove all excess toner contamination and or foreign objects Clean Internal Areas Clean the erase lamp with a cotton swab Clean the printhead bias plates with a soft cloth e Clean the LED lens with a cotton swab making sure no lint remains on the lens Clean the Fuser Unit Inspect the unit for damage and contamination repair or replace as necessary Clean the fuser unit connector both on the fuser unit and in the printer with a cotton swab Vacuum in and around the rollers to remove excess toner contamination and any for eign objects Reinstall the fuser unit General Printer Maintenance Introduction Clean the Developer Unit Inspect the unit for damage or contamination repair or r
199. er on reset the printer Runtest prints e Watch the end of the paper timing roller shaft Does the paper timing roller shaft turn No Continue Yes Go to 14 in this TAG Check TP3 11 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Go to 12 in this TAG Check J P91 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Check J P8 13 for 24 Vdc Is the voltage 24 Vdc No Replace the DC power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P91 1 to P8 13 then turn to TAG 002 Check amp Problem Resolution Run diagnostic test 006 testing the paper timing roller clutch Check TP3 7 for a voltage change from 24 Vdc to 0 Vdc Does the voltage change from 24 Vdc to 0 Vdc No Continue Yes Go to 14 in this TAG Turn off the printer and unplug the power cord e Disconnect J P40 and J P65 Check P40 7 to J65 2 and P40 11 to J65 1 for continuity Is there continuity on both No Repair or replace the connectors and wiring from P40 7 to J65 2 or P40 11 to J65 1 Then turn to TAG 002 Check amp Problem Resolution Yes Replace the paper timing roller assembly then turn to TAG 002 Check amp Problem Reso lution Troubleshooting Analysis Guide TAGs 14 15 16 17 18 19 Does paper stop or jam either before or during ent
200. er so the developed image is properly registered with the leading edge of the sheet 7 Transferring the image to the paper Next the paper contacts the surface of the photoconductor belt Above the paper and the belt is the transfer corona which has a high positive charge and attracts the devel oped image from the belt to the surface of the paper At this point you can remove the printed image to verify print quality but the toner is not yet fused 8 Fusing the image to the paper The vacuum transport unit advances the paper with the developed image to the fuser unit where heat and pressure bond the toner to the paper The finished print then arrives at the paper output tray 9 Cleaning routine After a print is made the photoconductor belt must be cleaned for the next print The belt first passes the erase lamp where any remaining latent image is erased The belt continues to the cleaning unit where a charged brush rotates against the surface to remove any residual toner This toner is recycled to the developer unit for reuse Transfer Charger Vacuum Transport Fuser Unit s 7i C 2 40 Paper Input Ee Paper Erase Lamp puit Cleaner 3 e Charge Corona LED Printhead Photoconductor Developer Unit Figure 1 1 Cycle of Operation Printer and Troubleshooting Overview Paper Path and Cycle Sequence The IGS board signals the PCL board that a page of data is ready to be printed When this happens the following
201. erlock by pass tool Remove the main drive motor assembly cover Turn the printer on e Run diagnostic test 009 e Watch the main motor Does the main motor gear turn while running diagnostic test 009 No Continue Yes Replace the main motor gear main motor gear key or both or replace the main drive gear assembly as needed Then turn to TAG 002 Check amp Problem Resolution 8 Run diagnostic test 009 Use extreme caution Check J P20 2 to J P20 3 for 100 Vac while the test is running Is the voltage 100 vac No Continue Yes Replace the main drive motor assembly then turn to TAG 002 Check amp Problem Reso lution 9 Run diagnostic test 009 Use extreme caution Check J P14 2 to J P14 3 for 100 Vac while the test is running Is the voltage 100 Vac No Continue Yes Repair or replace the connectors or wiring from P14 2 to P20 3 or P14 3 to P20 2 then turn to TAG 002 Check amp Problem Resolution 10 Turn the printer off and unplug the power cord e Disconnect J P40 and J P12 Check P40 33 to P12 7 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 33 to P12 7 Yes Replace the power control board if this does not correct the problem replace the PCL board Then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 55 3 56 11 12 13 14 15 Remove the photoconductor unit Inspect the photoconductor
202. ermine which TAG to follow then turn to that TAG Check communications by completing the following Turn the printer off e Reinstall all communication cables Reinstall the upper cassette e Power on reset the printer e Re run the customer s problem print job Does the job fail No Continue Yes Go to TAG 753 External Communications Malfunction Complete the following e Run test prints e Re run the customer s problem print job Does an error code appear No Continue Yes Look up the code in Chapter 2 TAG Cross Reference Tables then turn to TAG indi cated in the table Troubleshooting Analysis Guide TAGs 10 Run a job which is known to be good Compare the output from the problem print job to the output from the good print job Can you identify the problem No Return to the beginning of the TAG following the procedures carefully to determine the kind of problem your customer has Yes Identify the problem as either a print quality problem or a mechanical malfunction find the problem in the appropriate cross reference table identify a TAG addressing that prob lem then turn to that TAG Troubleshooting Analysis Guide TAGs 3 7 TAG 002 Check amp Problem Resolution Note Follow the procedure described in this TAG when you have completed an action to resolve a problem and are sent to this TAG from another TAG 1 Complete any actions directing you to this TAG Ma
203. ette Loosen the lower paper size sensor assembly for access to the circuit board e Disconnect J P43 and J P47 e Check J43 9 to J47 2 for continuity Is there continuity No Replace the lower paper size sensor assembly Yes Repair or replace the connectors or wiring from P45 2 to P47 2 P43 9 to J52 2 or P40 49 to P52 2 If this does not resolve the problem replace the upper paper size sensor assembly Then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 23 TAG 013 Lower Cassette Not Latched Error Code 013 Possible Defects Lower cassette release cam Even Lower cassette release latch Lower cassette in latch Lower pressure lever Spring Lower cassette Lower cassette in switch Lower paper size sensor Connectors or wiring PCL board 1 Turn the printer off and unplug the power cord e Verify that J P40 and J P52 are connected properly Remove the lower cassette Inspect it for damage Reinsert the cassette Is the lower cassette properly latched No Continue Yes Go to 3 in this TAG 2 Check the following for damage Lower cassette release cam Lower cassette release latch Lower cassette in latch Lower pressure lever Spring Are any of these parts damaged No Return to the beginning of this TAG Yes Replace the damaged parts then turn to TAG 002 Check amp Problem Resolution 3 Remove the lower cassette Make sure the lower cassette in switc
204. ever Spring Wire cable and pulley Envelope cassette or high capacity envelope feeder Upper cassette in switch Upper paper size sensor Lower paper size sensor Connectors or wiring PCL board 1 Turn off the printer and unplug the power cord e Confirm that J P40 and J P52 are connected properly Remove the envelope tray or high capacity envelope feeder Inspect it for damage Reinsert the envelope tray or feeder Is the upper cassette properly latched No Continue Yes Go to 3 in this TAG 2 Check for damage e Upper cassette release cam e Upper cassette release latch e Upper cassette in latch e Upper pressure lever Spring Wire cable and pulley Are any of these parts damaged No Return to the beginning of this TAG Yes Replace the damaged parts then turn to TAG 002 Check amp Problem Resolution 3 Remove the envelope tray or feeder Make sure the upper in switch actuator is functioning properly Is it in good working order No Replace the actuator then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 21 4 Run diagnostic test 002 Is 1 0 displayed No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue 5 Install the envelope tray Is a value other than 1 0 displayed No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 6 Turn the printer off and unplug the
205. ew Correction Cable Removal To remove the duplex skew correction cable Open the top cover Remove the duplex tray Remove the paper guide from inside the duplex tray four screws Slide the skew correction guides toward the center of the duplex tray Remove the bracket holding the shaft in place two screws 1 2 3 4 5 6 Remove the screw holding the cable mounting plate in place 7 Lift the skew correction guides and shaft up out of the duplex tray 8 Remove two screws holding each pulley assembly in place 9 Remove the spring from the cable 1 0 Lift the skew correction cable and pulley assemblies from the duplex tray Replacement Notes The placement of the mounting bead is critical Set it on precisely Replace parts in this order First reinstall the pulley assembly Then wrap the cable three times around the drive gear pulley Finally connect the spring 7 92 Removal Replacement Procedures Duplex Skew Correction Cable Removal Mounting Plate Shaft Bracket Skew Correction Guides Paper Guide Mounting Bead Cable Mounting Plate Drive Gear Pulley Pulley Assembly Skew Correction Cable Tension Spring Skew Correction Cable Detail 7 93 Removal Replacement Procedures Upper Duplex Drive Clutch Assembly Removal Upper Duplex Drive Clutch Assembly Removal To remove the upper duplex drive clutch assembly Open the top cover Remove the rear duplex cover See page 7 1
206. from P306 2 to J P331 2 to P330 2 then turn to TAG 002 Check amp Problem Resolution Yes Continue 23 Check J P306 1 to J P306 4 for 24 Vdc Is the voltage 24 Vdc No Repair or replace the wiring or connectors from P306 1 to J P331 1 to P330 1 then turn to TAG 002 Check amp Problem Resolution Yes Return to the beginning of this TAG 3 202 Troubleshooting Analysis Guide TAGs Chapter 4 Print Quality Samples Print Quality Samples 4 1 4 2 Contents Print Quality Samples Sample 1 Good Quality Print 0 2 eee cee eee 4 4 Sample 2 Washout 2222s tisse iawadindd oe e ara whee epa egesta 4 5 Sample 3 Blank Print lseeeeeeeeeeeee I II 4 6 Sample 4 Light Print decd bat Sa oe a ee eal ee ae es 4 7 Sample 5 Light Print With Background 0 0 0 e ee eee eee 4 8 Sample 6 Voids or White Spots 20 0c eee ee ee eee eee 4 9 Sample 7 Light Vertical Streaks 0 0 eee cee ees 4 10 Sample 8 Blank Vertical Bands 2 0 eee cece eee eee 4 11 Sample 9 Light Horizontal Bands 0 0 0 ce eee eee eee nee 4 12 Sample 10 Black or Dark Print 0 2 0 0 eee eee ee nee 4 13 Sample 11 Dark Specks Lines or Areas 0 0 0 0 eee eee eee 4 14 Sample 12 Dark Vertical Lines 4 15 Sample 13 Skewed Prints 0 cece eee eee teens 4 16 Sample 14 Misregistration 0 0 0 eee cee tees 4 17 Sample 15 Overtoned Print 0 0 cece eee cece eee 4 18
207. ge change from 24 Vdc to 0 Vdc Does the voltage change from 24 Vdc to 0 Vdc No Continue Yes Go to 14 in this TAG 3 32 Troubleshooting Analysis Guide TAGs 13 Turn the printer off and unplug the power cord e Disconnect J P40 and J P67 Check P40 5 to J67 2 and P40 11 to J67 1 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 5 to J67 2 or P40 11 to J67 1 Then turn to TAG 002 Check amp Problem Resolution Yes Replace the lower feed roller assembly then turn to TAG 002 Check amp Problem Resolu tion 14 Inspect the lower pick up roller assembly for damage or binding Is itin good working order No Replace the lower pick up roller assembly then turn to TAG 002 Check amp Problem Res olution Yes Continue 15 Inspect the lower feed roller assembly for damage or binding Is itin good working order No Replace the lower feed roller assembly then turn to TAG 002 Check amp Problem Resolu tion Yes The lower pick up roller or lower feed roller may not be delivering the paper to the paper timing sensor at the correct time Return to the beginning of this TAG Troubleshooting Analysis Guide TAGs 3 33 TAG 022 Paper Jam in the Transfer or Fuser Area Error Code 022 Possible Causes Paper loaded incorrectly Wrong weight or type of paper loaded Paper path obstruction Possible Defects Fuser unit Paper supply Paper timing roller assembly Fuser drive
208. gure 4 8 Blank Vertical Bands X cd x qm F T Lag PL Blank vertical bands jr rp noaga Ae jun jg LETTER Description One or more vertical blank bands of varying widths extend over the entire length Go to TAG 803 Prints With Light or White Vertical Streaks Print Quality Samples Sample 9 Light Horizontal Bands 4 12 1d 444 BE P IqQ3TITIPLPVTSITLTPLITEI TOGE p ak a a de ie ae fe ee ae PPOOKE CDF 01236567898 3 lt gt 22 T 7r ABCDEFGHIJKLMNOPQRSTUVWXYZIN 7 abcdefghijklimnopqrstuvwxyziil 1 geXE C237 701234567895 142578 ARCDEFO PORRIUVMXTIDV T1 C amp UCGRIORIZKISDDUAGUEKuYWXY nnn none i T E T 9 8 amp 0x 01236567891 3 25 3 T ABCDEFGHIJKLMNOPQRSTUVWXYZIN abcdefghijkImnoparstuvwxyz i T TEENEI Ox 0123456789 1 2578 HT ESTUYWXYZDN I LE r amp tuvexyzil TT um B E Light bands AG 2 fe LETTER jsut ennui Figure 4 9 Light Horizontal Bands Description One or more light horizontal bands of varying width Go to TAG 804 Prints With Light Horizontal Bands Print Quality Samples Sample 10 Black or Dark Print Figure 4 10 Black or Dark Print Description Black or very dark with no visible images Go to j Print Quality Samples Sample 11 Dark Specks Lines or Areas ee E H u E 77 TT E m Ir om
209. h actuator is functioning properly Is it in good working order No Replace the actuator then turn to TAG 002 Check amp Problem Resolution Yes Continue 4 Run self diagnostic test 003 Is 1 0 displayed No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 24 Troubleshooting Analysis Guide TAGs 5 Install the lower cassette Is a value other than 1 0 displayed No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 6 Turn the printer off and unplug the power cord Remove the lower cassette Loosen the lower paper size sensor assembly for access to the circuit board e Disconnect J P48 Activate the cassette in switch e Check P48 1 to P48 2 for continuity Is there continuity No Replace the lower cassette in switch or wire harness W59 then turn to TAG 002 Check amp Problem Resolution Yes Continue 7 Reconnect J P48 e Disconnect J P43 and J P40 Check P40 50 to P43 10 for continuity Is there continuity No Repair or replace the connectors or wiring from P43 10 to J52 1 or P40 50 to P52 1 Then turn to TAG 002 Check amp Problem Resolution Yes Continue 8 Check P43 8 to P40 48 for continuity Is there continuity No Repair or replace the connectors or wiring from P43 8 to J52 3 or P40 48 to P52 3 Then turn to TAG 002 Check amp Problem Resolution Yes Replace the lower paper size sensor assembly If
210. h down on the idler arm and slide the paper feed drive belt off the gear Paper Feed Drive Cover Main Drive Cover Fuser Drive Cover Idler Arm Cleaner Drive Belt Paper Feed Drive Belt Detail 7 58 Removal Replacement Procedures Paper Timing Roller Removal Paper Timing Roller Removal To remove the paper timing roller 1 Open the front back and top covers 2 Raise the upper paper guide 3 Remove the photoconductor and place it in its protective bag 4 Remove the paper feed drive cover three screws 5 Remove the paper feed drive belt from the paper timing roller gear 6 Disconnect CN65 7 Unscrew the standoff post from the collar surrounding the end of the roller 8 Remove the front C clip and bearing 9 Slide the paper timing roller out the back of the printer Replacement Notes e Reinstall the original collar and standoff post with any new paper timing roller Be sure to align all of the guide pins or the C clip will not fit correctly Paper Feed Drive Cover Collar Standoff Post Cassette Release Cover Front Detail Removal Replacement Procedures 7 59 Upper Feed Roller Removal Upper Feed Roller Removal To remove the upper feed roller Open the front and back covers Remove the paper feed drive cover three screws Disconnect CN66 Remove the paper feed drive belt from the upper feed roller gear Remove the cassette release cover two screws Remove the front
211. hat the output tray full sensor is mounted properly e Verify that it moves down fully Is the output tray full sensor in good working order No Replace the sensor then turn to TAG 002 Check amp Problem Resolution Yes Replace the PCL board If this resolves the problem then turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace wire harness W71 or W52 then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 131 TAG 702 Paper Size Detection Malfunction 3 132 Error Code 702 Symptoms Incorrect paper size displayed Possible Defects Upper cassette Lower cassette Upper paper size sensor Lower paper size sensor Connectors or wiring PCL board Turn the printer off and unplug the power cord e Verify that J P52 and J P40 are connected properly Remove the upper and lower cassettes Make sure that the rear and side paper guides are securely against the paper e Power on reset the printer Insert the cassette exhibiting the problem Does the display still indicate the incorrect paper size No Aloose connector or incorrectly positioned paper guides were at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue Remove the cassette exhibiting the problem Take out the paper Inspect the two paper size sensing balls on the bottom of the cassette by changing positions of the side and rear paper guides Is the paper
212. he DIP switch settings on signal interface boards are correct e Power on reset the printer e Confirm that the printer s software configuration is set correctly to the interface you are using Has the problem been resolved No Continue Yes Software configuration or DIP switch settings were at fault Determine which of these is at fault correct the problem then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 143 3 144 Turn off the printer and unplug the power cord Remove fuse FH2 which is mounted to the signal interface board and check for continuity Is there continuity No Install a new fuse and retest If the fuse is okay turn to TAG 002 Check amp Problem Res olution If the new fuse fails replace the signal interface board or attachment option and install a new fuse then turn to TAG 002 Check amp Problem Resolution Yes Continue Disconnect the interface cable from the printer Disconnect any attachment option Install the RS 232C and RS 422 wrap connectors e Run diagnostic test 103 Did the diagnostic test run properly No Continue Yes Go to 11 in this TAG Turn the printer off and unplug the power cord e Inspect J P71 RS 232C J P72 RS 422 and J P74 for connector body cracks or damaged pins Is there a problem with the connectors or pins No Go to 7 in this TAG Yes Continue Replace the signal interface board e Run diagnostic
213. he developer unit Remove the paper feed drive cover three screws Remove the photoconductor seam sensor See illustration on page 7 33 oa 5 O N a Remove the spring at the base of the guide rail To do this gently pull the spring for ward off its post Disconnect CN64 Remove the ground screw Remove CN64 from its bracket Back Detail Removal Replacement Procedures 7 35 Photoconductor Rear Guide Rail Removal 10 From inside the photoconductor cavity remove the two screws holding the guide rail in place 11 Push CN64 and the ground wire through the photoconductor cavity to the front of the printer 12 Lift the photoconductor guide rail from the printer S o a o e L Removal Replacement Procedures 7 36 Signal Interface Board Removal Signal Interface Board Removal To remove the signal interface board 1 Disconnect all external cables and attachments 2 Open the back cover 3 Remove the lower back cover See page 7 7 4 Disconnect CN74 and P333 5 Remove the signal interface board two screws Replacement Note Replicate the DIP switch settings and jumper locations on any new signal interface board Jumpers DIP Switches Removal Replacement Procedures 7 37 Power Control Board Removal Power Control Board Removal To remove the power control board 1 Open the back cover 2 Remove the paper feed drive cover three screws 3 Remove the power control
214. he printer s manufacturer 397 IGS software trap No TAG 398 IGS software trap No TAG 399 IGS software trap No TAG 2 6 TAG Cross Reference Tables Table 2 8 IGS Disk Drive Error Codes Code Disk Drive Error Code Meaning Go to TAG 401 Fatal IGS PB error No TAG 450 Incorrect diskette 130 451 Diskette format error or incorrect disk 130 454 Fatal trap 200 455 Trap 200 500 Incorrect PITO registers contents no reset 200 501 PITO register read write error 200 502 No countdown zero detection in PITO timer 200 503 PITO timer no halt 200 504 No PITO timer interrupt 200 505 Incorrect PIT2 registers contents no reset 200 506 PIT2 register read write error 200 507 No countdown zero detection in PIT2 timer 200 508 PIT2 timer no halt 200 509 No PIT2 timer interrupt 200 520 No DMAC reset 200 521 DMAC registers read write error 200 522 No DMA transfer 200 523 No DMA transfer termination 200 524 No DMAC termination interrupt 200 525 No software abort operation 200 526 No software abort interrupt 200 527 DMAC operation error 200 528 DMA transfer error 200 529 Two channel DMA transfer error 200 530 No two channel DMA transfer 200 540 PCL board serial controller registers read write error 200 541 PCL board break condition detected 200 542 PCL board serial controller transmitter not ready 200 543 No PCL board
215. he transfer charger then turn to TAG 002 Check amp Problem Resolu tion 3 Reinstall the transfer charger e Power on reset the printer e Run test prints Is error code 050 displayed No A dirty transfer charger was at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue 4 Turn the printer off and unplug the power cord e Disconnect the transfer charger lead from the high voltage unit Check the transfer charger high voltage unit lead for continuity to ground Is there continuity to ground No Continue Yes Repair or replace the upper paper guide assembly or transfer charger then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 63 5 Reconnect the transfer charger high voltage unit lead e Disconnect J P23 and J P41 Check P41 37 to P23 3 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 37 to P23 3 then turn to TAG 002 Check amp Problem Resolution Yes Continue 6 Replace the transfer charger Has the problem been resolved No Replace the high voltage unit If this resolves the problem turn to TAG 002 Check amp Problem Resolution If the problem has not been resolved replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Turn to TAG 002 Check amp Problem Resolution 3 64 Troubleshooting Analysis Guide TAGs TAG 055 Erase Lamp Malfunction Error Code 055 Possi
216. heck amp Problem Resolution Yes Continue 7 Turn the printer off e Reconnect J P74 e Disconnect the DC cable J P73 for the attachment option Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Replace the signal interface board then turn to TAG 002 Check amp Problem Resolution Yes Replace the attachment option then turn to TAG 002 Check amp Problem Resolution 3 80 Troubleshooting Analysis Guide TAGs 8 Turn the printer off e Reconnect J P32 e Disconnect J P91 Turn the printer on Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Go to 13 in this TAG Yes Continue 9 Turn the printer off e Reconnect J P91 e Disconnect J P40 and J P41 Turn the printer on e Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue 10 Turn the printer off e Reconnect J P40 Turn the printer on Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Go to 15 in this TAG Yes Continue 11 Turn the printer off e Reconnect J P41 Remove the developer unit Turn the printer on Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Continue Yes Replace the developer unit then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 81 12 Turn the printer off and unplug the power cord e Reconnect J P41 Remove the fuser unit Check P41 49 to P25 4
217. hese parts damaged No Return to the beginning of this TAG Yes Replace the damaged parts then turn to TAG 002 Check amp Problem Resolution 3 Remove the upper cassette Make sure the upper cassette in switch actuator is functioning properly Is it in good working order No Replace the actuator then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 4 Run diagnostic test 002 Is 1 0 displayed No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue 5 Install the upper cassette Is a value other than 1 0 displayed No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 6 Turn the printer off and unplug the power cord Remove the upper cassette Loosen the upper paper size sensor assembly for access to the circuit board e Disconnect J P46 Activate the cassette in switch e Check P46 1 to P46 2 for continuity Is there continuity No Replace the upper cassette in switch or wire hardness W58 then turn to TAG 002 Check amp Problem Resolution Yes Continue 7 Reconnect J P46 e Disconnect J P40 and J P45 Check P40 49 to P45 2 for continuity Is there continuity No Go to 10 in this TAG Yes Continue 8 Check P40 48 to P45 3 for continuity Is there continuity No Continue Yes Replace the upper paper size sensor assembly If this does not resolve the pro
218. ias 5 13 disk drive 5 25 5 26 duplex clutch 5 16 duplex feed motor 5 14 duplex input sensor 5 15 duplex tray paper guide motor 5 17 EIGS program RAM 5 22 EIGS MIGS bit map 5 23 EIGS MIGS board 5 20 envelope fuser solenoid 5 19 Index 2 erase lamp 5 12 input feeder 5 19 jogging motor 5 8 lower cassette 5 5 main charger 5 10 operator panel 5 4 output stacker 5 18 paper transport clutch 5 7 photoconductor 5 8 printhead assembly 5 24 running 5 3 sensor sequence 5 6 toner supply motor 5 9 transfer charger 5 11 upper cassette 5 4 diagrams voltage isolation 6 16 6 20 disk drive formatting 5 24 malfunctions 3 104 testing 5 25 5 26 disk drive housing removal 7 25 diskette drive malfunctions 3 104 duplex clutch test sequence 5 16 duplex control board 1 removal 7 89 duplex control board 2 removal 7 90 duplex cover connectors 6 8 duplex fan removal 7 27 duplex feed motor 5 14 duplex input sensor test sequence 5 15 duplex paper path sensor removal 7 102 duplex print cycle 1 5 duplex route motor solenoid assembly removal 7 95 duplex route separator removal 7 100 duplex skew correction cable 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 lamp malfunctions 3 65 removal 7 83 te
219. id E J P330 1 J P308 3 J P316 1 n ower 4 e e lt lt 4 lt C A roller clutch Supply J P308 4 J P317 1 4 4 4 C Exit solenoid v w P3231 Duplex Control J P310 1 Board 42 J P312 7 10 J P321 1 4 4 4 gt gt 4 4 44 Restart motor J P305 1 Wiring Diagrams and Electrical Data Figure 6 6 Duplex 24 Vdc Circuits 6 19 Duplex Control P309 4 Board 1 p 5 E Paper pass sensor J P306 2 gt gt A J P331 2 J P309 3 J P318 1 A dd bl de Cover open sensor DC J P330 2 Power 44 Supply Duplex Control v Board 2 P323 2 verre ord Mie Registration side 4 lt gt gt sensor J P310 2 44 gt gt LJ J P305 2 J P312 4 J P322 1 as cat Ca Registration paper sensor Figure 6 7 Duplex 12 Vdc Circuits 6 20 Wiring Diagrams and Electrical Data Ground System Wiring Diagrams and Electrical Data J P4 9 AC power supply J P5 8 Fuser unit J P6 3 DC power supply J P18 3 Toner supply motor J P19 4 Jogging motor J P21 3 Large cooling fan J P326 3 Small cooling fan J P22 3 Vacuum transport unit J P23 8 High voltage unit J P20 1 Main motor J P 255 Photoconductor unit J P305 12 Duplex control board 2 Back cover to frame grounding strap Main charger Transfer corona 6 21 Host Interface Reference Standard printers support three host interfaces RS 232C R
220. ide TAGs 3 139 TAG 750 Counter Malfunction 3 140 Error Code 750 Symptoms Counter does not count Counter counts too often Consumable components require replacement too frequently Possible Defects Counter assembly Connectors or wiring PCL board Run diagnostic test 007 Is the counter functioning properly No Continue Yes The counter is working correctly Turn to TAG 002 Check amp Problem Resolution Verify that J P41 J P81 and J P82 are connected properly e Run diagnostic test 007 Is the counter functioning properly No Continue Yes Loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution Is the counter either counting when it shouldn t or counting too many times No Go to 5 in this TAG Yes Continue Replace the counter e Run test prints Has the problem been resolved No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes The counter was at fault Turn to TAG 002 Check amp Problem Resolution Check TP4 26 for 24 Vdc Is the voltage 24 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue Check TP4 25 for 24 Vdc Is the voltage 24 Vdc No Go to 8 in this TAG Yes Continue Troubleshooting Analysis Guide TAGs 7 Run test prints e Check TP4 25 for a voltage change from 24 Vdc to 0 Vdc while running the prints Does the voltage change from 24 Vdc to 0 Vdc No Repl
221. ie a E e e e 6 8 Connectors Inside the Right Cover 0 0 0 eee ee ene 6 9 Connectors Inside the Top Cover 6 10 Connectors on the Back Cover 0 cece eee eens 6 11 Connectors Inside the Back Cover J P2 14 2 0 ccc eens 6 12 Connectors Inside the Back Cover Continued J P18 62 0 0 00 ee eae 6 13 Connectors Inside the Back Cover Continued J P 64 85 0 00000 cee 6 14 Connectors Inside the Back Cover Continued J P 90 800 0 000 0000 6 15 Voltage Isolation Diagrams 4 23 25 seve aides ene EE US EXEEU MESE R 6 16 Ground Systemi ne 852 v ovd sb e p Ba Mose RU a RC duis Cet du eee OU kes 6 21 Host Interface Reference uide kh ik REB IARE BESIL GER EERDAG 6 22 R5 232C Host Interface x 5r E NP n ERA SERA 6 22 Standard DCE to DTE RS 232C Cable 0 0 0 esee 6 23 Special Considerations for RS 232 Host Interface Users 0 6 23 DTE Host to Printer Option 1 0 nen eens 6 24 DTE Host to Printer Option 2 0 ence n eens 6 24 IBM PC XT to Brintet nuuc nis e ERR a wands RATER woke ee e Rt ir ce d 6 25 IBM PC AT to Pinet 2 i bp eq deca diode ld ets 6 25 Macintosh Communication Port to Printer 0 0 0 cc eens 6 26 RS 422 Host interlace senium naa Ie RUP Ge EO oO ahs 6 26 Centronics Parallel Host Interfaces reer re e R cee eens 6 27 IBM Parallel to Printer 0 0 cece eens 6 28 Special Considerations for Centronics Parallel Interface Users
222. in or 2 lines of the 20 line indicator from the leading edge of the test print No Continue Yes The registration is within specification Turn to TAG 002 Check amp Problem Resolution 9 Open the printer s rear cover and insert an interlock by pass tool e Set the four registration switches on the PCL board to off e Run test prints e Based on the test prints increase the registration by changing the switches Refer to the follow ing chart Did resetting the switches resolve the problem No Replace the paper timing roller assembly then turn to TAG 002 Check amp Problem Reso lution If this does not resolve the problem replace the upper paper guide assembly or the paper timing guide then turn to TAG 002 Check amp Problem Resolution Yes Turn to TAG 002 Check amp Problem Resolution Table 3 5 PCL Board Switch Settings Setting DIP Switches Number 1 2 3 s OFF OFF OFF OFF l OFF OFF OFF ON OFF OFF ON OFF 3 OFF OFF ON ON i OFF ON OFF OFF 5 OFF ON OFF ON 6 OFF ON ON OFF 3 170 Troubleshooting Analysis Guide TAGs Table 3 5 PCL Board Switch Settings Setting DIP Switches Number 2 3 7 OFF ON ON ON ON OFF OFF OFF 2 ON OFF OFF ON In ON OFF ON OFF 11 ON OFF ON ON is ON ON OFF OFF 18 ON ON OFF ON 14 ON ON ON OFF 15 ON ON ON ON Troubleshooting Analysis Guide TAGs 3 171 TAG 808 Prints Overtoned Dark Ve
223. 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 problems 3 16 3 136 testing 5 5 lower cassette mount removal 7 45 lower feed roller removal 7 61 lower paper guide removal 7 51 lower paper size sensor removal 7 40 lower pick up roller removal 7 64 lower pick up roller drive removal 7 65 lower static brush removal 7 71 lubrication 9 11 M main charger circuit malfunctions 3 61 problems 3 58 testing 5 10 Index 4 main gear drive removal 7 88 main motor problems 3 142 removal 7 86 maintenance cleaning 9 6 lubricating 9 11 tune up procedure 9 18 maintenance record 9 4 maintenance supplies 9 4 mechanical malfunction TAG cross reference 2 12 misfeeds lower cassette 3 30 upper cassette 3 26 motors problems with main 3 142 removing duplex tray registration 7 91 removing main 7 86 removing toner 7 28 testing duplex feed 5 14 testing duplex tray paper guide 5 17 testing jogging 5 8 testing toner supply 5 9 multiple feeds 3 137 O operator panel malfunctions 3 125 problems 2 12 removal 7 19 testing 5 4 out of toner indicator problems 3 51 output sheet stacker 8 9 output stacker testing 5 18 output tray malfunctions 3 130 problems 2 12 P paper damaged 3 138 multiple feeds 3 137 wrinkled 3 138 paper exit sensor removal 7 78 paper feed drive belt re
224. inuity P40 16 to P57 2 Troubleshooting Analysis Guide TAGs 3 31 P40 25 to P57 1 P40 12 to P57 3 Is there ground No Repair or replace the connectors or wiring from P40 25 to J P58 1 to P57 1 P40 16 to J P58 2 to P57 2 or P40 12 to J P58 3 to P57 3 Then turn to TAG 002 Check amp Problem Resolution Yes Replace the paper timing guide If this does not correct the problem replace the PCL board Then turn to TAG 002 Check amp Problem Resolution 10 Turn off the printer Open the back cover and install an interlock by pass tool Remove the paper feed cover to expose the lower paper pick up assembly Warning To avoid the risk of injury use extreme caution as gears and belts are exposed e Run diagnostic test 006 testing the lower pick up roller clutch e Check TP3 8 for a voltage change from 24 Vdc to 0 Vdc Does the voltage change from 24 Vdc to 0 Vdc No Continue Yes Go to 12 in this TAG 11 Turn the printer off and unplug the power cord e Disconnect J P40 and J P69 e Check P40 8 to J69 2 and P40 10 to J69 1 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 8 to J69 2 or P40 10 to J69 1 Then turn to TAG 002 Check amp Problem Resolution Yes Replace the lower pick up roller assembly then turn to TAG 002 Check amp Problem Res olution 12 Run diagnostic test 006 testing the lower feed roller clutch Check TP3 5 for a volta
225. iring from P8 14 to J94 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 113 5 Check J P42 1 for 5 Vdc Is the voltage 5 Vdc No Repair or replace the connectors or wiring from P94 1 to J P90 1 to P42 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue 6 Turn the printer off and unplug the power cord e Disconnect J P8 and J P42 Check P42 20 to P8 15 for continuity Is there continuity No Repair or replace the connectors or wiring from P42 20 to J P90 20 to J P94 2 to P8 15 then turn to TAG 002 Check amp Problem Resolution Yes Replace the operator panel circuit board If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the PCL board wire harness W72 or wire harness W63 then turn to TAG 002 Check amp Problem Resolution 7 Turn the printer off e Disconnect J P330 Turn the printer on e Check J P8 1 for 5 Vdc Is the voltage 5 Vdc No Continue Yes Go to 15 in this TAG 8 Turn the printer off e Disconnect J P8 Turn the printer on Check J P330 3 for 5 Vdc Is the voltage 5 Vdc No Go to 22 in this TAG Yes Continue 9 Turn the printer off e Reconnect J P8 e Disconnect J P77 Turn the printer on Check J P8 10 for 5 Vdc Is the voltage 5 Vdc No Continue Yes Replace the disk drive assembly then turn to TAG 002
226. it Clean the photoconductor unit contacts the guide rail contacts and the photoconductor cavity Clean the seam sensor lens and cavity and remove any obstructions Reinstall the photoconductor unit e Power on reset the printer Is error code 040 041 or 042 still displayed No Loose connectors or dirty contacts were at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue Has the photoconductor unit been replaced recently No Continue Yes Go to 4 in this TAG Replace the photoconductor unit Runtest prints Has the problem been resolved No Reinstall the original photoconductor unit and continue Yes The photoconductor was at fault Turn to TAG 002 Check amp Problem Resolution Open the top cover and insert an interlock by pass tool e Run diagnostic test 009 Does the photoconductor belt rotate No Continue Yes Go to 11 in this TAG Is error code 041 or 042 displayed while running diagnostic test 009 No Continue Yes Go to 12 in this TAG Troubleshooting Analysis Guide TAGs 6 Turn the printer off Remove the photoconductor unit Inspect it for damaged drive mechanism or belt slippage Is it in good working order No Replace the photoconductor unit then turn to TAG 002 Check amp Problem Resolution Yes Continue 7 Reinstall the photoconductor unit Remove the interlock by pass tool and close the top cover Open the back cover and install an int
227. ity 810 Prints with background 811 Prints with background and residual images 811 Prints with residual images 813 Prints with offset images 814 Table 2 17 Additional Print Quality Problem TAGs Additional Print Quality Problems Go to TAG Wrinkled or torn prints 706 Prints improperly fused 812 Prints exhibiting printhead problems 815 TAG Cross Reference Tables Print Quality TAG Cross Reference Mechanical Malfunction TAG Cross Reference The chart below outlines possible mechanical malfunctions and recommends an appropri ate TAG to follow to resolve the problem Table 2 18 Operator Panel Problems TAGs Table 2 20 Cassette Problem TAGs Operator Panel Problems Go to TAG Blank with AC power fan and cooling fan on 500 Blank with AC power fan on 500 Blank with no fans on 600 All lights on 610 Incomplete display immediately after POR 610 Close cover light remains on 600 Remove prints light remains on or lights 700 Add toner light remains on 035 Machine check light is on with no numerical Display 201 One or more lights are off at POR 610 Tone not working 610 Incorrect paper size 702 Other operator panel malfunctions 610 Table 2 19 Output Tray Problem TAGs Output Tray Problems Go to TAG Sensor not sensing condition 701 Jogging incorrectly 083 Will not stop jogging 083 Job offset incorrect 083 Cassette Problems Go to TAG Upper c
228. ive Belt Removal To remove the fuser drive belt Open the back cover Remove the fuser drive cover three screws Remove the main drive cover one screw Remove the gear stay cover one screw Remove the gear stay three screws Remove the main drive gear and bearing single C clip o0 FB WO ND Remove the single upper left screw and the two lower screws holding the fuser drive in place 8 9 Slide the fuser drive belt off the gear Loosen the upper right screw for the fuser drive and pivot the drive down ain Drive Cover Gear Stay Cover KA Fuser Drive Cover Main En G ear 7 56 Removal Replacement Procedures Fuser Drive Removal Fuser Drive Removal To remove the fuser drive Open the back cover Remove the fuser drive cover three screws Remove the main drive cover one screw Remove the gear stay cover one screw Remove the gear stay three screws Remove the fuser drive belt See page 7 56 o0 5 WO ND Remove the fuser drive four screws Gear Stay Cover Main Drive Cover Fuser Drive Cover Removal Replacement Procedures 7 57 Paper Feed Drive Belt Removal Paper Feed Drive Belt Removal To remove the paper feed drive belt Open the back cover Remove the fuser drive cover three screws Remove the paper feed drive cover three screws Remove the main drive cover one screw Remove the cleaner drive belt See page 7 54 oa 5 O N Pus
229. ive Removal 0 0 0 0 cece eee eee 7 63 Lower Pick Up Roller Removal eeee IA 7 64 Lower Pick Up Roller Drive Removal 0 00 cece eee ee eee 7 65 Job Offset Assembly Removal 0 0 eee cee ee 7 66 Exit Pinch Roller Removal 0 0 0 0 cece eee eee 7 68 Upper Static Brush Removal 0 cece eects 7 70 Lower Static Brush Removal 00 0 cece eee eee eee eee 7 71 Exit Roller Assembly Removal eeee eee ee 7 72 Exit Cover Removal Simplex 0 0 cece ee een 7 74 Exit Cover Removal Duplex 0 0 0 cece eee eens 7 76 Paper Exit Sensor Removal 0 cece eee eects 7 78 Paper Full Sensor Removal eseseseeeee e 7 19 Front Cover Interlock Switch Removal leeeeeeeeeeeesl 7 80 Back Cover Interlock Switch Removal 0 0 eee ee eee eee eee 7 81 Top Cover Interlock Switch Removal 0 0 0 0 c eee eee eee nee 7 82 Erase Lamp Removal 0 cee eect ee ene eens 7 83 EP Cover Removal ation er RE Page eie UR Pese Die ma 7 84 Main Motor Removal seekos teco nauuri nenn nee ee 7 86 Main Gear Drive Removal seeseeeeeee e 7 88 Duplex Control Board 1 Removal 0 0 0 0 cee ee eee ee eee 7 89 Duplex Control Board 2 Removal 0 0 cee eee eee eee 7 90 Duplex Tray Registration Motor Removal 0 0 0 00 eee eee 7 91 Duplex Skew Correction Cable Removal 0 0 00
230. ive idler assembly Main drive gear assembly Upper pick up roller drive assembly Are all the parts in good working order No Replace any damaged parts then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 Clear the paper path Remove the upper cassette e Power on reset the printer e Run test prints from the lower cassette Is error code 021 displayed No Go to 10 in this TAG Yes Continue 4 Clear the paper path Inspect the paper timing sensor actuator for damage or binding Is itin good working order No Replace the paper timing guide assembly then turn to TAG 002 Check amp Problem Reso lution Yes Continue 5 Check the voltage between TP3 16 and ground on the PCL board With the printer powered on press and release the paper timing sensor e Check for a voltage change from 0 Vdc to 12 Vdc Does the voltage change from 0 Vdc to 12 Vdc No Go to 9 in this TAG Yes Continue 6 Check TP3 11 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Return to the beginning of this TAG 7 Check J P91 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 8 Check J P8 13 for 24 Vdc Is the voltage 24 Vdc No Replace the DC power supply then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P9
231. jects bent pins loose socket housings and or loose wires Warning The printer is equipped with safety interlock switches on all of its covers These switches disable parts of the printer when the covers are opened These areas present the risk of electrical shock burns and injury from mechanical hazards Printer and Troubleshooting Overview 1 21 Installing the Interlock By pass Tool The interlock by pass tool overrides the cover interlock switches allowing you to operate the printer with the covers open The interlock by pass tool is a white plastic V shaped tool with two finger pads To use the tool open the cover and locate the interlock switch for locations see illustrations beginning page 1 11 Squeeze the tool between thumb and fore finger and insert it into the interlock switch The printer ships with two spare interlock by pass tools concealed behind the right cover Replace them when you are finished using them Caution Do not attempt to close the printer cover while the interlock bypass tool is in place Producing a Developed Image Producing a developed image helps determine where exactly in the print cycle a problem may be occurring To produce a developed image Open the top cover and install an interlock by pass tool Power on reset the printer Run a series of test prints The directory of the boot device will print followed by con tinuous test patterns 4 As test pattern
232. k amp Problem Resolution 3 186 Troubleshooting Analysis Guide TAGs TAG 812 Uneven or No Fusing on Prints Error Code 812 Possible Causes Wrong weight or type of paper loaded Possible Defects Fuser unit Connectors or wiring AC power supply unit PCL board 1 Turn the printer off and unplug the power cord Verify that J P44 J P4 J P10 J P11 J P12 J P40 J P83 J P91 and J P8 are connected prop erly Perform the every call cleaning procedure described in Chapter 9 General Printer Mainte nance Turn the printer on Runtest prints Has the problem been resolved No Continue Yes Contamination or loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution 2 Check the voltages as outlined in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Have the fuser unit and developer unit with new toner cartridge been replaced recently No Continue Yes Go to 6 in this TAG 4 Replace the fuser unit e Run test prints Has the problem been resolved No Reinstall the original fuser unit and continue Yes Turn to TAG 002 Check amp Problem Resolution 5 Replace the developer unit and toner cartridge Runtest prints Has the problem been resolved No Reinstall the original developer unit and continue Yes Turn to TAG 002
233. k format 1 Goto 113 2 Insert a diskette or diskettes in the diskette drive or drives you wish to test 3 Press READY to run the test 0 appears on the display indicating the A drive 4 Press CANCEL to advance to the drive you wish to test Table 5 27 Disk Drive Test Drive Indications on page 5 25 lists the drive indications 5 Press READY to activate the drive 6 Ifan error code appears look it up in Table 2 8 IGS Disk Drive Error Codes on page 2 7 to determine which TAG to follow 7 Power on reset to exit 5 26 Diagnostic Tests Chapter 6 Wiring Diagrams and Electrical Data Contents Wiring Diagrams and Electrical Data Wiring Diagrams and Electrical Data 0 0 0 ee ee 6 3 Connector JP Index 2 1 cent een ee nas 6 4 Connector Locations cs ecse rotera irer ehh 6 6 Connectors Inside the Front Cover 0 0 00 anaana anann 6 6 Connectors Inside the Left Cover 0 0 0 0c cece nee 6 7 Connectors on the Duplex Cover 0 0 c eee eee ee eee 6 8 Connectors Inside the Right Cover 0 0 0 0c eee eee eee 6 9 Connectors Inside the Top Cover 0 0 c eee eee eee 6 10 Connectors on the Back Cover 0 0 ccc cee nas 6 11 Connectors Inside the Back Cover J P2 14 2 0 0 ccc cee ee 6 12 Connectors Inside the Back Cover Continued J P18 6262 6 13 Connectors Inside the Back Cover Continued J P 64 85 6 14 Connectors Inside the
234. ke sure all connectors covers parts and hardware have been reinstalled In the course of resolving the printer problem did you complete the every call cleaning procedure No Continue Yes Go to 3 in this TAG 2 Clean the printer thoroughly following the every call cleaning procedure described below 1 Remove these major printer supplies e Photoconductor unit place it in its protective packaging e Cleaner unit Developer unit e Fuser unit 2 Inspect and vacuum the printer e Inspect the areas in the printer around the developer unit cleaner unit photoconductor unit and fuser unit for damage and wear e Vacuum these areas to remove all excess toner contamination and or foreign objects 3 Clean internal areas Clean the erase lamp with a cotton swab e Clean the printhead bias plates with a soft cloth Clean the LED lens with a cotton swab making sure no lint remains on the lens 4 Inspect and clean the fuser unit Warning The fuser unit may be hot e Inspect the unit for damage and contamination repair or replace as necessary e Clean the fuser unit connector both on the fuser unit and in the printer with a cotton swab e Vacuum in and around the rollers to remove excess toner contamination and any foreign objects Reinstall the fuser unit 5 Inspect and clean the developer unit Inspect the unit for damage or contamination repair or replace as necessary Clean any excess toner fro
235. keys do not work Possible Causes Operator panel Connectors or wiring PCL board 1 Turn the printer off and unplug the power cord Turn the volume control on operator panel inside front cover up fully e Verify that J P90 J P42 J P8 J P41 and J P94 are connected properly e Run diagnostic test 001 Has the problem been resolved No Continue Yes Loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution 2 Do the status lights stay on continuously No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 3 Turn the printer off and unplug the power cord e Disconnect J P42 J P91 J P8 and J P32 e Check P8 15 to P42 20 for continuity Is there continuity No Repair or replace the connectors or wiring from P8 15 to J P94 2 to J P90 20 to P42 20 then turn to TAG 002 Check amp Problem Resolution Yes Continue 4 Reconnect J P42 J P91 J P8 and J P32 e Power on reset the printer Press each function key and listen for the tone Test prints may be produced Press the STOP key or turn the printer off to quit Did you hear the tone after pressing each function key No Go to 14 in this TAG Yes Continue 5 Is one of the function keys not working properly No Go to 16 in this TAG Yes Continue Troubleshooting Analysis Guide TAGs 3 125 10 11 12 3 126 Turn the printer off and unplug the power cord e Disconnect J P42 and J P41
236. lays Display Indication 4 1 You forgot to remove the photoconductor unit 040 Seam sensor sender short 8 Press STOP to exit 9 Reinstall the photoconductor unit Diagnostic Tests 112 Disk Drive Test Single Loop With Stop on Error 109 intentionally excluded This test reads data from the drive selected It checks the seek function cycle redundancy parity checksum directory and allocation table integrity and disk format 1 2 3 4 Go to 112 Insert a diskette or diskettes in the diskette drive or drives you wish to test Press READY to run the test 0 appears on the display indicating the A drive Press CANCEL to advance to the drive you wish to test Table 5 27 Disk Drive Test Drive Indications Diagnostic Tests Display Indication 0 Floppy drive A 1 Floppy drive B 2 Hard drive C Press READY to activate the drive If no errors are found the test exits automatically If an error code appears refer to the Table 2 8 IGS Disk Drive Error Codes on page 2 7 to determine which TAG to follow Press STOP to exit if errors are found To test another drive repeat this procedure starting with Step 2 5 25 109 intentionally excluded 113 Disk Drive Test Continuous Loop This test reads data directly from the drive selected It checks the seek function cycle redundancy parity checksum directory and allocation table integrity and dis
237. lem Resolution 33 Reconnect J P40 and J P12 e Disconnect J P102 Turn on the printer Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Continue Yes Replace the power control 3 board then turn to TAG 002 Check amp Problem Resolu tion 34 Turn off the printer and unplug the power cord e Disconnect J P40 Check P40 35 to P102 1 for continuity to ground Is there continuity No You have failed to isolate the problem Return to the beginning of this TAG Yes Repair or replace the connectors or wiring from P40 35 to P102 1 then turn to TAG 002 Check amp Problem Resolution 35 Turn off the printer e Reconnect J P330 e Disconnect J P323 Turn on the printer e Check J P330 2 for 12 Vdc Is the voltage 12 Vdc No Go to 40 in this TAG Yes Continue 36 Turn off the printer e Reconnect J P323 e Disconnect J P305 Turn on the printer Check J P330 2 for 12Vdc Is the voltage 12 Vdc No Go to 39 in this TAG Yes Continue 3 86 Troubleshooting Analysis Guide TAGs 37 Turn off the printer e Reconnect J P305 e Disconnect J P310 inside the duplex tray Turn on the printer Check J P330 2 for 12 Vdc Is the voltage 12 Vdc No Continue Yes Go to 4 in this TAG 38 Turn the printer off and unplug the power cord e Disconnect J P305 Check P305 2 and P310 2 for continuity to ground Is there continuity No Return to the beginning of this TAG and start again
238. lem been resolved No Continue Yes Go to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 16 Clean both the photoconductor LED and seam sensor using a cotton swab or compressed air e Run diagnostic 009 Using an oscilloscope connected to TP3 20 on the PCL board adjust the signal so that it matches figure A by moving the sensor bracket closer or farther from the photoconductor unit Figure B illustrates a bad signal Note that 7ms is the recommended minimum length of time the waveform should maintain Ov you may have to settle for less The two small signals prior to the 12v signal are from the smaller holes in the photoconductor unit the larger signal is from the cutout for the PC sensor Figure A Figure B 12V 12V UU UU V 0v 0v 7 ms Is the signal adjusted to match that illustrated in Figure A No Repeat this step until the signal has been adjusted properly Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 57 TAG 044 Main Charger Transfer Charger Circuit Open Error Code 044 Possible Defects Main charger Transfer charger Connectors or wiring High voltage unit Upper paper guide Main charger terminal assembly PCL board 1 Turn the printer off and unplug the power cord e Verify that J P23 and J P41 are connected properly Make sure the high voltage unit main charger lead is connected properly Make sure the transfer charger
239. lex cover See page 7 17 Remove the upper duplex roller cover four screws Remove the lower duplex roller cover four screws Remove the front C clip and bearing from the B roller Remove two screws holding the duplex control board cover in place Move the cover to the left out of the way Loosen the screw holding the idler roller in place Remove the duplex drive belt 0 Remove the drive gear single C clip 1 Slide the B roller out from the back of the printer Duplex Control B Roller Board Cover Drive Gear LITT Loosen Screw Duplex Drive Belt UR 27777 Side Detail Upper Duplex Boller Chyar C Clip and Lower Duplex Bearing Roller Cover Removal Replacement Procedures 7 97 C Roller Removal C Roller Removal To remove the C roller Open the top cover Remove the rear duplex cover See page 7 17 Remove the upper duplex roller cover four screws Remove the front mechanism cover two screws Remove the front C clip and bearing from the C roller oa A OO N a Slide the C roller out from the back of the printer Upper Duplex Roller Cover 7 98 Removal Replacement Procedures C Roller Solenoid Removal C Roller Solenoid Removal To remove the C roller solenoid 1 Open the top cover 2 Remove the front mechanism cover two screws 3 Disconnect CN315 and cut the cable tie securing the wires to the mounting
240. llowed by a listing of possible error messages possible causes or possible defective parts related to the TAG Printer and Troubleshooting Overview 1 19 1 20 The TAG then directs you to perform certain tasks Based on the results of these tasks the TAG poses questions that can be answered by either yes or no For yes answers you fol low one path for no answers follow another path Some of the paths may lead you to other TAGs so that you can methodically diagnose and resolve problems When you have corrected a problem you will be directed to TAG 002 to confirm that the problem has been completely resolved and standard cleanup procedures observed If it s not clear how to diagnose a problem you re working on follow the steps outlined in TAG 001 which includes references to the cross reference tables contained in Chapter 2 TAG Cross Reference Tables Or you may turn directly to the tables to get started As you use TAGs you will sometimes refer to other sections of this manual for additional information Chapter 4 Print Quality Samples contains print quality samples you ll use to com pare the customer s test prints with flawed and good print samples Chapter 5 Diagnostic Tests outlines how to conduct printer diagnostic tests Chapter 6 Wiring Diagrams and Electrical Data provides all wiring and connector diagrams e Chapter 7 Removal Replacement Procedures provides step by step procedures for
241. ltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue Have the photoconductor unit main charger cleaner unit and developer unit with new toner cartridge been replaced recently No Continue Yes Go to 5 in this TAG Replace the photoconductor unit and main charger e Run 200 test prints then evaluate the test print background Has the problem been resolved No Reinstall the original photoconductor unit and main charger and continue Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 5 Replace the developer unit and cleaner unit e Run test prints Has the problem been resolved No Reinstall the original developer unit and cleaner unit and continue Yes Turn to TAG 002 Check amp Problem Resolution 6 Remove the photoconductor unit from the printer Run diagnostic test 013 e Watch the erase lamp while the test is running Are all the erase lamps on No Replace the erase lamp assembly then turn to TAG 002 Check amp Problem Resolution Yes Continue 7 Turn the printer off Open the front cover and install an interlock by pass tool Remove the developer unit e Power on reset the printer e Watch the toner motor coupling in the developer cavity Does the coupling turn continuously before error code 036 is displayed No Continue Yes Go to 21 in this TAG 8 Reinstall the
242. lved No Reinstall the original high voltage unit and continue Yes Turn to TAG 002 Check amp Problem Resolution Repair or replace the cleaner terminal assembly Runtest prints Has the problem been resolved No Reinstall the original cleaner terminal assembly then go back to 5 in this TAG Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs TAG 815 Prints Resulting From Printhead Malfunctions Error Code 815 Possible Causes Additional lines or missing lines on page Possible Defects Printhead assembly Connectors or wiring IGS board 1 Turn off the printer and unplug the power cord Replace wire harness 46 Has the problem been resolved No Continue Yes Turn to TAG 002 Check amp Problem Resolution 2 Turn off the printer and unplug the power cord Replace the printhead assembly Has the problem been resolved No Replace the IGS board then turn to TAG 002 Check amp Problem Resolution Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 191 TAG 900 Top Cover Interlock Malfunction Duplex 3 192 Error Code 900 Possible Defects Cover open sensor PCL board Duplex control board 1 Connectors or wiring Complete TAG 600 AC Power Malfunction before starting this TAG Turn the printer off and unplug the power cord e Verify that J P306 J P307 J P309 and J P318 are connected properly e Confirm
243. ly rein spect each part Repair or replace the damaged part then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs TAG 705 Multiple Paper Feeding Error Code 705 Possible Causes Wrong weight or type of paper loaded Paper improperly loaded Possible Defects Upper feed roller assembly Lower feed roller assembly Paper cassette 1 Remove paper from the cassette Fan the paper stack and place it in the cassette Make sure the paper curl is turned up in the cassette Make sure the paper is under the corner separators Make sure the rear and side paper guides are positioned properly Make sure the paper being used does not have a high static charge Confirm that the paper in the cassettes meets paper specifications outlined in the Guide to Operations at the back of this manual Runatleast 20 test prints Has the problem been resolved No Continue Yes The paper being used was at fault Turn to TAG 002 Check amp Problem Resolution 2 Adjust the paper tension lever or pick pressure as outlined in Chapter 9 General Printer Mainte nance Has the problem been resolved No Replace the pick up roller assembly then turn to TAG 002 Check amp Problem Resolu tion Troubleshooting Analysis Guide TAGs 3 137 TAG 706 Paper Damaged or Wrinkled Error Code 706 Possible Causes Paper incorrectly loaded Wrong weight or type of paper loaded Paper path obstructed P
244. m Resolution 0 0 0 0 eene 3 8 TAG 010 Upper Cassette Malfunction 0 0 0 cece eee e 3 12 E10 Envelope Tray Out of Envelopes 3 14 TAG 011 Lower Cassette Malfunction ls 3 16 TAG 012 Upper Cassette Not Latched 0 0 0 cece eee eee eee 3 18 TAG E12 Envelope Tray or Feeder Not Latched 00 0 3 21 TAG 013 Lower Cassette Not Latched 0 0 cee ee eee eee 3 24 TAG 020 Paper Jam Misfeed in Upper Cassette Area 04 3 26 TAG 021 Paper Jam Misfeed in Lower Cassette Area 00 3 30 TAG 022 Paper Jam in the Transfer or Fuser Area elles 3 34 TAG 023 Paper Jam in the Output Area 0 2 eee ees 3 39 TAG 025 Paper in Input Area Before Printing 00 00 3 41 TAG 026 Paper in Output Area Before Printing 0000 3 43 TAG 030 Developer Bias Short Failure leeleeeeeeeeees 3 44 TAG 031 Toner Patch Reference Level Too Low esee 3 47 TAG 032 Toner Patch Too Light 2 0 0 eee eee eene 3 49 TAG 035 Out of Toner or ADD TONER Indicator On sess 3 51 TAG 036 Developer Unit Not Installed 0 0 0 cece ee eee ee 3 53 TAG 040 Photoconductor Seam Sensor Malfunction 3 54 TAG 044 Main Charger Transfer Charger Circuit Open 3 58 TAG 045 Main Charger Circuit Shorted 0 0 0 0 cee eee eee 3 61 TAG 050 Transfer Cha
245. m the developer unit with a soft cloth e Clean the toner patch sensor lens with a cotton swab making sure no lint remains on the lens e Vacuum the felt areas around the magnetic roller being careful not to vacuum toner from 3 8 Troubleshooting Analysis Guide TAGs the magnetic roller Reinstall the developer unit 6 Inspect and clean the cleaner unit main charger Caution Handle gently to avoid breaking the charger wire Inspect the unit for damage or contamination repair or replace as necessary Remove the main charger from the cleaner unit Clean the grid with the cleaner brush Remove the grid to expose the charger wire Clean the charger wire with a cotton swab or charger cleaning tool Reinstall the grid Clean any excess toner from the cleaner unit with a soft cloth Reinstall the main charger in the cleaner unit Reinstall the cleaner unit 7 Clean and inspect the photoconductor unit area Caution Do not touch the photoconductor belt as this permanently damages the unit Clean the photoconductor seam sensor inside the printer with a cotton swab or compressed air Remove the photoconductor from its protective packaging Inspect the photoconductor for damage or contamination repair or replace as necessary Reinstall the photoconductor unit 8 Clean the transfer charger Caution Handle gently to avoid breaking the charger wire Remove the transfer charger Clean the
246. mmediately after power on turn off the printer and replace the AC power supply Runtest prints Has the problem been resolved No Continue Yes A loose connector was at fault Turn to TAG 002 Check amp Problem Resolution 2 Has the fuser unit been replaced recently No Continue Yes Go to 4 in this TAG 3 Replace the fuser unit e Power on reset the printer Watch through the output tray opening to see if the fuser lamp comes on during the 15 seconds after the output tray jogging test Ifthe fuser lamp comes on immediately after power on turn off the printer and replace the AC power supply Has the problem been resolved No Reinstall the original fuser unit and continue Yes The fuser unit was at fault Turn to TAG 002 Check amp Problem Resolution 4 Power on reset the printer e Watch the fuser unit s lamp Does the lamp turn on before error code 072 is displayed No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 73 5 Turn the printer off and unplug the power cord e Disconnect J P41 e Check P41 21 for continuity to ground Is there continuity No Continue Yes Repair or replace the connectors or wiring that have continuity to ground P41 21 to P44 2 or J44 2 to P5 7 then turn to TAG 002 Check amp Problem Resolution 6 Check P41 21 to P41 22 for resistance Is the resistance at least 1K3WW N
247. mnap vexyz t AG fn fog LETTER Figure 4 6 Voids of White Spots Description Voids or white spots in image areas Go to TAG 802 Prints With Voids or White Spots Print Quality Samples PI n TY TT i a B jid pfi prp p rri 4 9 Sample 7 Light Vertical Streaks 4 10 e XE C Kt 7556789 z214 ABCDEFGHIJKLMKOPZESYUVWXY2IN PO abcdefghijklm 1 9 5 amp 5 Cow ABCDEFGHIJKLMM abcdefghijklmros abcdefghijkins INESE ABCDEFGHIJKLH abcdefghijklm UVWXYZ ssuvexyziil uvwxyziil i9 cz tfa EMOSUR COXe 5 276567B9 2 5 78 ABCDEFGHIJKLHK 2 S7 2tuvwxvz i 7 TUVWXYZ N97 56789 z5 73 UVWXYZIN 7 vstuvwxyzii 7 Light vertical streaks AG mS ij i LETTER nn nanopores aaan ag Figure 4 7 Light Vertical Streaks an Go to TAG 803 Prints With Light or White Vertical Streaks Description One or more light vertical streaked areas of varying widths Print Quality Samples Sample 8 Blank Vertical Bands TIT IT hib bo a ne podere 44444444444 4454554445 T p cpu qu ITTTITTTTTT 446X i 7 012 ABCDEFGHIJKLMNOPQR abcdefghijklanopqr I S 6XK amp O 7 7012 ABCDEFGHIJKLMNOPQR abcdefghijklmnopqtr 1 4 X amp 8 084 012 ABCDEFGHIJKLNNOPQR abcdefghijklmnopqr Inex 84 7012 ABCDEFGHIJKLMNOPQR abcdefghijkimnopar 44d EE Jd nano jp jupe Fi
248. moval 7 58 paper feed tension adjusting 9 8 paper full sensor removal 7 79 paper handling problems 2 13 paper input timing problems 3 41 paper jams duplex area 3 198 fuser area 3 34 lower cassette 3 30 output area 3 39 transfer area 3 34 upper cassette 3 26 paper output timing problems 3 43 paper path 1 6 paper size codes 5 4 paper timing guide removal 7 52 paper timing roller removal 7 59 paper transport clutch test sequence 5 7 parallel interface 6 27 PCL board 1 3 malfunctions 3 102 removal 7 22 PCL to IGS interface malfunctions 3 110 photoconductor testing 5 8 photoconductor rear guide rail removal 7 35 photoconductor seam sensor problems 3 54 removal 7 33 power control board removal 7 38 power supplies 12 Vdc malfunctions 3 79 24 Vdc malfunctions 3 92 5 Vdc malfunctions 3 113 12 Vdc malfunctions 3 90 removing AC 7 29 removing DC 7 31 removing high voltage 7 32 power on reset POR 1 21 print cycle 1 3 print quality background print example 4 21 black print 3 163 example 4 13 blank print 2 9 3 148 example 4 6 blank vertical bands example 4 11 blurred print 2 11 example 4 19 blurred vertical streaks 3 177 dark areas 3 180 dark horizontal bands 3 148 dark print 2 10 3 182 example 4 13 dark speck example 4 14 dark spots 3 166 dark vertical band example 4 15 dark vertical streaks 3 172 fusing problems 3 187 example 4 24 light horizontal bands 3 162 example 4 12 light print 2 10 3 152 exa
249. mple 4 7 light print with background example 4 8 light vertical streaks 3 160 example 4 10 misregistration 2 10 3 168 3 194 example 4 17 overtoned print example 4 18 residual images 3 182 3 189 example 4 22 samples 4 3 scratches 3 166 skewed print 2 10 3 168 3 194 example 4 16 smeared vertical streaks 3 177 Index 5 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 reference 2 9 printer operation 1 3 printhead assembly malfunctions 3 191 removal 7 23 testing 5 24 problem resolution 3 8 R rear duplex cover removal 7 17 right side cover connectors 6 9 removal 7 9 7 10 rollers removing A 7 96 removing B 7 97 removing C 7 98 removing exit pinch 7 68 removing lower feed 7 61 removing lower pick up 7 64 removing paper timing 7 59 removing upper feed 7 60 removing upper paper guide 7 50 removing upper pick up 7 62 S safety precautions 9 3 self diagnostic mode 5 3 Sensors locations 1 11 lower paper size wiring 3 134 malfunctioning photoconductor seam 3 54 removing duplex paper path 7 102 removing lower paper size 7 40 Index 6 removing paper exit 7 78 removing paper full 7 79 removing photoconductor seam 7 33 removing upper paper size 7 40 test sequence 5 6 testing duplex input 5 15 upper paper size wiring 3 134 serial i
250. ms 3 139 removal 7 48 upper paper guide roller removal 7 50 upper paper size sensor removal 7 40 upper pick up roller removal 7 62 upper pick up roller drive removal 7 63 upper static brush removal 7 70 W wrinkled paper 3 138 V vacuum transport unit Index 7
251. n Yes Continue 4 Loosen the paper timing guide e Confirm that J P57 is connected properly Is J P57 connected properly No Continue Yes Go to 6 in this TAG 5 Reconnect J P57 Reinstall the paper timing guide e Power on reset the printer Is error code 025 still displayed No J P57 was at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 41 6 Turn the printer off and unplug the power cord Loosen the paper timing guide e Disconnect J P57 and J P40 e Check the following for continuity e P40 16 to P57 2 e P40 25 to P57 1 e P40 12 to P57 3 Is there continuity No Repair or replace the connectors or wiring from e P40 25 to J P58 1 to P57 1 e P40 16 to J P58 2 to P57 2 e P40 12 to J P58 3 to P57 3 Then turn to TAG 002 Check amp Problem Resolution Yes Replace the paper timing guide If that doesn t resolve the problem replace the PCL board Then turn to TAG 002 Check amp Problem Resolution 3 42 Troubleshooting Analysis Guide TAGs TAG 026 Paper in Output Area Before Printing Error Code 026 Possible Defects Exit paper sensor PCL board Connectors or wiring If the printer has a high capacity output unit HCO unplug and remove it before begin ning this TAG Test the printer without the HCO if the problem remains proceed with this TAG If the problem occurs only with the HCO the HCO is causing the problem Repair or
252. n Table 5 3 Clutch Test Displays Table 5 3 Clutch Test Displays Display 3 0 Indication Upper pick up roller clutch 3 1 Lower pick up roller clutch 3 2 Upper feed roller clutch 3 3 Lower feed roller clutch 3 3 Paper timing roller clutch 4 Repeat Step 3 until you have tested all of the clutches 5 Press STOP to exit 007 Counter Test 1 Open the front cover Go to 007 Press READY to run the test Confirm that the page counter advances by 1 The test then exits automatically Diagnostic Tests 004 intentionally excluded 008 009 5 8 Jogging Motor Test Go to 008 Press READY to run the test The output tray jogs back and forth Confirm that a tone sounds each time the tray contacts the sensor at each side The codes in the following table indicate specific error conditions Table 5 4 Jogging Motor Test Error Displays Display Indication 081 Front tray sensor signal not received 082 Rear tray sensor signal not received 083 No signal received from either sensor 090 Close covers 4 Press STOP to exit Photoconductor Test 1 Goto 009 Press READY to run the test The main motor rotates the photoconductor belt Confirm that a tone sounds repeatedly indicating that the photoconductor belt is rotating These codes may indicate specific error conditions Table 5 5 Photoconductor Error Test Displays Display
253. n performing any removal replacement or cleaning procedure Ensure that the power source for the printer matches the power specification label located above the power outlet on the back of the printer Keep combustible materials away from the printer Provide adequate ventilation for the printer so that slots and openings in the cabinet sides are not blocked General Printer Maintenance 9 3 Introduction 9 4 Do not push objects of any kind through the cabinet slots They may contact danger ous voltage points or other hazards Do not expose the printer to liquids of any kind Protect the power cord Do not place it in a traffic pattern or allow anything to rest on it Tool Requirements Service Kit A service kit intended for use solely by the service technician is shipped inside the right side cover of the printer This kit includes Interlock by pass tools 2 e RS 232C loop back assembly RS 422 loop back assembly e Multimeter jumpers 2 Corona cleaner brush Tools Supplies To service the printer properly you will also need to carry the following Soft cleaning cloth Cotton swabs Corona cleaner Basic set of hand tools suitable for office automation equipment repair Digital multimeter with test leads alligator clips and a high voltage probe Service vacuum cleaner properly grounded and equipped with a 10 micron filter End User Cleaning Kit Printers are shipped with an e
254. nd top covers Duplex only Remove the duplex tray Remove the upper and lower paper cassettes Remove the left side cover See page 7 8 Remove the paper feed drive cover three screws Remove the power control board cover one screw Disconnect CN4 and CN70 N Oo oO FB WO ND Paper Feed Drive Cover 3i Power Control Board Cover Power Control Board CN70 Back Detail Removal Replacement Procedures 7 29 AC Power Supply Removal 8 From the side of the printer remove the three screws holding the AC power supply in place 9 Slide the AC power supply out from the side of the printer Removal Replacement Procedures 7 30 DC Power Supply Removal DC Power Supply Removal To remove the DC power supply Open the front top and back covers Disconnect CN6 CN7 CN8 and CN330 Remove the output tray Remove the right side cover See page 7 9 Remove the bracket for the output tray guide two screws oa 5 O N Remove the DC power supply two screws Replacement Note When replacing the output tray bracket make sure it is seated inside the DC power supply Bracket Screws Ly b ai DC E a Supply Screws CN7 CN8 Right Side Detail Back Detail Removal Replacement Procedures 7 31 High Voltage Unit Removal High Voltage Unit Removal To remove the high voltage unit Open the top and back covers Remove the EMI grounding plate if present from the rear of the printe
255. nd user cleaning kit taped inside the front cover The clean ing kit consists of Cotton swabs Corona cleaner brush This kit is intended for use by the end user Printer Maintenance Record A maintenance record must be kept for every printer During the initial service call or at the time of installation set up a maintenance record for the customer A copy of the form illustrated on the following page should be kept in the Guide to Operations so that the maintenance form is always easily accessible General Printer Maintenance SOUBUBIUIe JOJUL eJeuec S 6 To Be Completed By User HISTORY LOG To Be Completed By HP rece cour Oper it HP Customer SOME TINE Engineer On Site Date Time Malfunction Description Action Required and Comments Malfunction Description Action Required and Comments Malfunction Description Action Required and Comments uononpouu Introduction Every Call Cleaning Procedure 9 6 Perform the every call cleaning procedure every time the printer is serviced When trou bleshooting a printer problem you may be directed to complete this procedure as you iso late or correct the problem If the procedure is not specifically called out always complete it before concluding the service call The every call cleaning procedure begins by removing the major consumable supplies from the print
256. nds Hold down the STOP and TEST keys simultaneously as you turn the printer back on e The tone followed by 001 on the display indicates you are in the test mode This takes about 1 minute 2 Press CANCEL to advance the counter to 110 3 Press START to activate the procedure 0 appears on the display indicating the A drive 4 Press CANCEL to advance to the drive where the error log is maintained This is usually the boot drive Display Indication 0 Diskette drive A 1 Diskette drive B 2 Hard drive C Troubleshooting Analysis Guide TAGs 5 Press START to select the drive specified 1 0 appears on the display Caution 1 0 represents the clear error log function Do not advance the counter to 1 1 which represents the format disk option described in the Guide to Operations 6 Press START to select the clear error log function 6 0 appears on the display Caution If 7 0 appears press STOP immediately DO NOT PROCEED 7 Press CANCEL to clear the error log 6 1 appears on the display 8 Press STOP to exit the procedure 9 Confirm that the error log has been cleared to do this power on reset the printer and run test prints checking to make sure the error log entries appear as 0000 Do the error log entries appear as 0000 No Return to the beginning of this step Yes Continue 5 Fill in the Repair Maintenance record taped inside the printer s front cover M
257. nds then turn it off e Check the signal interface board fuse for continuity Does the fuse have continuity No Replace the signal interface board then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 146 Troubleshooting Analysis Guide TAGs 4 Reconnect the attachment cables Turn on the printer for five seconds then turn it off e Check the signal interface board fuse for continuity Does the fuse have continuity No Replace the attachment option then turn to TAG 002 Check amp Problem Resolution Yes The signal interface board fuse was at fault Turn to TAG 002 Check amp Problem Resolu tion 5 Turn on the printer e Check for the indicated voltages J73 1 should be 5 Vdc J73 3 should be 12 Vdc J73 4 should be 12 Vdc J73 6 should be 5 Vdc Are all voltages correct No Replace the signal interface board If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this doesn t resolve the problem go to TAG 753 External Communications Malfunction step 4 Yes Continue 6 Turn off the printer and unplug the power cord Replace the external attachment option e Reconnect all communication cables e Run the failing job Has the problem been resolved No The problem appears to be related to the host computer or the host interface cable Cor rect the problem then turn to TAG 002 Check amp Problem Resolution Yes The external attachment option wa
258. ng Analysis Guide TAGs TAG 707 Upper Paper Guide Assembly Not Closing Error Code 707 Possible Causes Obstructions Photoconductor unit front or rear latch arm springs Photoconductor unit latch arms in incorrect position Upper paper guide latching mechanism damaged or binding Front or rear photoconductor unit guides damaged Possible Defects Photoconductor latch arms Upper paper guide latch Photoconductor guide rails 1 Check under the upper paper guide assembly for obstructions Remove the photoconductor unit from the printer Inspect the front and rear photoconductor unit latch arm springs for damage Inspect the front and rear photoconductor unit guide rails for damage Make sure there are no obstructions in the mounting area of the photoconductor unit Make sure the upper paper guide latching mechanism is functioning properly Make sure the photoconductor unit latch arms are in the upper position Are all parts in good working order No Repair or replace any malfunctioning parts then turn to TAG 002 Check amp Problem Resolution Yes Continue 2 Remove the photoconductor unit Close and lock the upper paper guide Did the upper paper guide lock into place No Replace the upper paper guide then turn to TAG 002 Check amp Problem Resolution Yes Only mechanical defects and malfunctions can cause this type of problem Go to 1 in this TAG and carefully reinspect each part Troubleshooting Analysis Gu
259. ng Analysis Guide TAGs 3 89 TAG 098 12 Vdc Power Shorted Error Code 098 Possible Defects Connectors or wiring DC power supply unit PCL board IGS board Signal interface board External attachment option 1 Turn the printer off and unplug the power cord Verify that J P8 J P32 J P33 J P73 and J P74 are connected properly e Power on reset the printer Has the problem been resolved No Continue Yes Loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution 2 Check J P32 3 for 12 Vdc Is the voltage 12 Vdc No Continue Yes Replace PCL board then turn to TAG 002 Check amp Problem Resolution 3 Turn the printer off e Disconnect J P32 Turn the printer on Check J P8 8 for 12 Vdc Is the voltage 12 Vdc No Continue Yes Go to 5 in this TAG 4 Turn the printer off e Disconnect J P8 Check P8 8 to P32 3 for continuity to ground Is there continuity No Replace the DC power supply then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P8 8 to P32 3 3 90 Troubleshooting Analysis Guide TAGs 5 Turn the printer off e Reconnect J P32 e Disconnect J P74 Turn the printer on Check J P8 8 for 12 Vdc Is the voltage 12 Vdc No Replace the IGS board then turn to TAG 002 Check amp Problem Resolution Yes Continue 6 Does the printer have an attachment option No Replace the signal interface boar
260. ng Diagrams and Electrical Data IBM PC XT to Printer Normally the IBM PC XT comes with a parallel interface for the printer with a 25 pin female connector To run RS 232 you must install a serial board which will have a male connector Table 6 5 IBM PC XT to Printer Connector Wiring PC XT Printer Signal DTE DTE Signal 1 1 FG TD 2 2 TD RD 3 Mor ek 3 RD RTS 4 gt 4 RTS CTS 5 4 5 CTS DSR 6 6 DSR SG 7 lt 4 gt 7 SG DCD 8 8 DCD DTR 20 e 20 DTR IBM PC AT to Printer Normally the IBM AT comes with a 9 pin serial connector Table 6 6 IBM PC AT to Printer Connector Wiring PC AT Printer Signal DCE DTE Signal DCD 1 4 1 FG RD 2 gt 2 TD TD 3 lt gt 3 RD DTR 4 e 4 RTS SG 5 pL 5 CTS DSR 6 ii a 6 7 0 RTS 7 7 SG CTS 8 8 DCD RI 9 SEA 20 DTR Wiring Diagrams and Electrical Data 6 25 6 26 Macintosh Communication Port to Printer Normally the Macintosh comes with a 9 pin male connector Table 6 7 Macintosh Communication Port to Printer Connector Wiring Macintosh Printer Signal DCE DTE Signal FG 1 gt 1 FG 2 2 TD SG 3 3 RD 4 gt 4 RTS TD 5 5 CTS 6 6 qem DSR 7 7 SG 8 8 DCD RD 9 20 DTR RS 422 Host interface The RS 422 host interface uses the signal definitions defined below A shielded cable is required with the shield connected on one end only preferably at the printer end Table 6 8 RS 422 Host Interface Connect
261. ng the output tray jogging test No Go to 24 in this TAG Yes Continue 12 Power on reset the printer Use extreme caution Check J P44 1 to J P44 2 for at least 100 Vac during the 15 seconds following the output tray jogging test Is the voltage at least 100 Vac No Go to 15 in this TAG Yes Continue Troubleshooting Analysis Guide TAGs 3 69 3 70 13 14 15 16 17 18 Turn off the printer Remove the fuser unit Clean the contacts of connector J P5 e Disconnect J P44 e Check J44 2 to J5 4 and J44 1 to J5 1 for continuity Is there continuity on both No Repair or replace the connectors or wiring as needed then turn to TAG 002 Check amp Problem Resolution Yes Continue Reinstall the fuser unit e Power on reset the printer Has the problem been resolved No Replace the fuser unit then turn to TAG 002 Check amp Problem Resolution Yes Cleaning the contacts resolved the problem Turn to TAG 002 Check amp Problem Resolu tion Power on reset the printer Use extreme caution Check J P4 1 to J P4 2 for at least 100 Vac during the 15 seconds following the output tray jog ging test Was the voltage at least 100 Vac No Replace the AC power supply then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from J P4 1 to J P44 1 or J P4 2 to J P44 2 then turn to TAG 002 Check amp Problem Resolution Check J P1
262. ning a set of test prints Then compare the test prints to the samples located in Chapter 4 Print Qual ity Samples The chart summarizes the possible print quality problems you may encoun ter and recommends a TAG to follow to address the problem Table 2 11 Blank Print TAGs Blank Prints Go to TAG Complete 800 Partial 800 With dark horizontal bands 800 TAG Cross Reference Tables 2 9 Print Quality TAG Cross Reference Table 2 12 Light Print TAGs Light Prints Go to TAG With carrier particles 801 With background 811 With voids white spots 802 With light vertical streaks 803 With blank or white vertical lines 803 With light horizontal bands 804 Table 2 13 Dark Print TAGs Dark Prints Go to TAG Dark black prints 805 With dark spots or scratches 806 With dark blotches 810 With dark vertical streaks without fusing 812 With dark vertical streaks with fusing 808 Table 2 14 Skewed Path TAGs Skewed Prints Go to TAG Simplex 807 Duplex 901 Table 2 15 Misregistration TAGs Misregistered Prints Go to TAG Simplex 807 Duplex 901 TAG Cross Reference Tables Print Quality TAG Cross Reference Table 2 16 Smeared Blurred and Uneven Print TAGs Smeared Blurred Uneven Prints Go to TAG Smeared vertical streaks 809 Blurred prints 809 Uneven dens
263. normally high load on the bias voltage to the transfer charger 051 PCL board detected a signal from the high voltage power supply unit indicating an open connection in the transfer charger circuit diagnostic test only 055 PCL board detected that the current needed to drive the erase lamp assembly was either higher or lower than the specified limits Duplex Jams 060 PCL board detected that the exit paper sensor did not deactivate or the paper path sensor did not activate within the allotted time 061 PCL board detected that the duplex paper path sensor did not deactivate the turnaround tray sensor did not activate in the allot ted time or the duplex paper path sensor activated at POR 062 PCL board detected that paper leaving the duplex turnaround tray did not reach the timing sensor within the allotted time or the duplex turnaround sensor was activated at POR Fuser Control Errors 070 PCL board sensed via the fuser thermistor that the temperature of the fuser unit did not change within the allotted time 071 PCL board sensed an open connection in the fuser thermistor cir cuit 072 PCL board sensed that the resistance of the fuser thermistor was too low indicating that the temperature of the fuser unit was higher than the specified limit 073 PCL board sensed that the resistance of the fuser thermistor was too high indicating that the temperature of the fuser
264. nterface 6 22 service calls completing 1 23 service record 9 4 service tool kit 9 4 sheet feeder 8 4 input control board interface 8 7 prefeed adjustment 8 6 test procedure 8 5 sheet stacker 8 9 connector locations 8 12 output control board interface 8 14 test procedure 8 10 signal interface board removal 7 37 settings 6 30 simplex print cycle 1 5 supplies 9 4 switches locations 1 11 overriding interlock 1 22 PCL board registration 3 170 removing back cover interlock 7 81 removing front cover interlock 7 80 removing top cover interlock 7 82 signal interface board 6 30 top cover interlock 3 192 T test prints 1 16 testing 5 14 timing paper input 3 41 paper output 3 43 toner motor removal 7 28 toner patch low reference level 3 47 producing 1 22 too light 3 49 removal 7 11 7 13 toner supply motor voltage testing 5 9 isolation diagrams 6 16 6 20 tool kit 9 4 voltage ranges top cover operating 1 18 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 cassette latch problems 3 18 paper jams misfeeds 3 26 problems 3 12 3 135 testing 5 4 upper cassette mount removal 7 41 upper duplex drive clutch assembly removal 7 94 upper feed roller removal 7 60 upper paper guide proble
265. nters Rear View Lubrication Introduction Symbol Part Lubricant v 1 Clutch shafts upper pick up roller lower pick up roller oil upper feed roller lower feed roller paper timing roller 2 Upper and lower pick up roller drive assemblies Molycote 3 Main drive gear assembly Molycote 4 Main drive gear Molycote 5 Main drive motor gear Molycote 6 Fuser drive gear Molycote e7 Fuser drive assembly Molycote Duplex Only Table 9 4 Duplex Only Rear Lubrication Symbol Part Lubricant v8 Clutch shaft bearing oil e Lower duplex drive assembly Molycote e 10 Upper duplex drive assembly Molycote e 11 A roller drive gears Molycote e 12 B roller drive gears Molycote e 13 C roller drive gears Molycote General Printer Maintenance Introduction Figure 9 6 Duplex Only Top View Lubrication Table 9 5 Duplex Top View Lubrication Symbol Part Lubricant v 1 Duplex pinch rollers oil General Printer Maintenance Figure 9 7 Duplex Only Duplex Holding Tray Lubrication Table 9 6 Duplex Front View Lubrication Introduction Symbol Part Lubricant 9 Drive gears Molycote B 10 Tray shaft red grease General Printer Maintenance 9 17 Introduction Tune Up Maintenance Procedure The tune up maintenance procedure should be performed when the printer jams fre quently yields sub standard print quality e
266. ntinue 6 Remove the fuser unit Inspect the following for damage or binding e Fuser drive assembly e Fuser drive belt Main drive gear assembly Are all the parts in good working order No Replace the defective parts then turn to TAG 002 Check amp Problem Resolution Yes Reinstall the fuser unit and continue 7 Run diagnostic test 009 e Watch the fuser drive and the exit roller assembly Are they in good working order No Replace the defective parts then turn to TAG 002 Check amp Problem Resolution Yes Replace the fuser unit then turn to TAG 002 Check amp Problem Resolution 3 40 Troubleshooting Analysis Guide TAGs TAG 025 Paper in Input Area Before Printing Error Code 025 Possible Defects Paper timing sensor PCL board Connectors or wiring 1 Turn the printer off and unplug the power cord e Check the paper path and remove any paper jams e Confirm that J P58 and J P40 are connected properly Inspect the paper timing sensor actuator for damage or binding Is itin good working order No Replace the paper timing guide assembly and continue Yes Continue 2 Power on reset the printer Is error code 025 displayed No Jammed paper loose connectors or the sensor actuator were at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Check TP3 25 for 12 Vdc Is the voltage 12 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolutio
267. ntration TCE a eie Transfer Charger Unit TES eee Transfer Charger Sensor TDS snis Toner Density Sensor TES ou mem Toner Empty Sensor TES ak Tray Front Sensor TED nro es Thermistor TO SIG IF To Signal Interface TOSIGIF CENT To Signal Interface Centronics TONER Toner Motor TPS eme Timing Paper Sensor Schematics TPS 22 Toner Patch Sensor Printer TRGC ace Timing Roller Clutch TRS wee c Tray Rear Sensor PADS Upper Paper Sensor UMT 1 3 Usage Meter Drive Signal UPC Len ius Upper Paper Feed Clutch UBER Upper Paper Empty Sensor UPP iniii Upper Pick Up Clutch UPSS Upper Tray Interlock XBGE ns Video Printer Control Logic Board Abbreviations and Acronyms 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 removing fuser drive 7 56 removing paper feed drive 7 58 board tests EIGS MIGS 5 20 brushes removing lower static 7 71 removing upper static 7 70 C C roller removal 7 98 C roller solenoid removal 7 99 cassette mounts removing lower 7 45 removing upper 7 41 cassettes problems 2 12 problems with lower 3 136 Index problems with upper 3 135 testing lower 5 5 testing upper 5 4 circuit boa
268. ntrol ATC 1 12 Printer and Troubleshooting Overview Paper exit sensor Paper full sensor Right side view Top interlock switch Front view Front interlock switch Printer and Troubleshooting Overview 1 13 Rear interlock switch Rear view Table 1 2 Sensor and Switch List Sensor Switch Name Page No Automatic toner control sensor 1 12 Cassette paper present sensors upper and lower 1 11 Cassette present micro switches upper and lower 1 11 Duplex registration sensor 1 11 Duplex paper path sensor 1 11 Duplex cover interlock switch 1 11 Interlock switch top 1 13 Interlock switch front 1 13 Interlock switch rear 1 14 Paper exit sensor 1 13 Paper full sensor 1 13 Paper size sensors upper and lower 1 11 Paper timing sensor 1 12 Photoconductor seam sensor 1 12 Toner empty sensor 1 12 Toner patch sensor 1 12 Printer and Troubleshooting Overview Troubleshooting Overview Throughout the printer s life problems occur such as those indicated when an error code displays on the operator panel a printer produces poor quality prints or the printer mal functions Use the tools provided in this manual to diagnose and resolve printer problems These tools include The Troubleshooting Analysis Guide which contains troubleshooting procedures called TAGs TAG 001 Troubleshooting A Printer Problem provides an overview of how to use TAG
269. nvelope feeder out of envelopes E10 012 Upper paper tray not plugged in 012 013 Lower paper tray not plugged in 013 E12 Envelope feeder not plugged in E12 020 Upper paper tray paper jam 020 021 Lower paper tray paper jam 021 022 Transfer or fuser area paper jam 022 023 Exit area paper jam 023 025 Transfer or fuser area paper jam not cleared 025 026 Exit area paper jam not cleared 026 027 Duplex area paper jam 902 030 Developer bias short 030 031 Toner patch sensor reference level too low 031 032 Toner patch sensor black patch too light 032 035 No toner 035 036 No developer 036 040 Photoconductor seam sensor malfunction 040 041 Photoconductor seam sensor short 040 042 Photoconductor seam sensor open 040 044 Main charger open 044 045 Main charger short 045 046 Main charger open 044 050 Transfer charger short 050 055 Eraser lamp malfunction 055 057 Fan stopped sensor 752 060 Duplex area 1 paper jam 902 061 Duplex area 2 paper jam 902 062 Duplex area 3 paper jam 902 069 Duplex tray not plugged in 900 070 Fuser lamp or thermal fuse malfunction 070 TAG Cross Reference Tables 2 3 Table 2 1 Printer Error Codes Continued Code Printer Error Code Meaning Go to TAG 071 Fuser thermistor open or no fuser 071 072 Fuser temperature too high 072 073 Fuser temperature too low 070 081 No front job offset sensor 08
270. o Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 7 Remove the fuser unit Check P41 21 to P5 7 for resistance Is there resistance No Continue Yes Repair or replace the connectors or wiring that have resistance P41 21 to P44 2 or J44 2 to P5 7 then turn to TAG 002 Check amp Problem Resolution 8 Check P41 22 to P5 6 for resistance Is there resistance No Replace the fuser unit then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring that have resistance P41 22 to P44 1 or J44 1 to P5 6 then turn to TAG 002 Check amp Problem Resolution 3 74 Troubleshooting Analysis Guide TAGs TAG 083 Job Offset Mechanism Malfunction Error Code 081 082 083 Symptoms Jobs not offsetting Jobs offsetting improperly Continuous jogging Possible Defects Job offset mechanism Jogging motor Connectors or wiring Tray front sensor Tray rear sensor Power control 3 board 1 Turn the printer off and unplug the power cord e Verify that J P100 J P101 J P102 J P19 J P40 J P54 J P53 and J P55 are connected properly e Power on reset the printer Has the problem been resolved No Continue Yes Loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution 2 Does the output tray jog continuously No Go to 4 in this TAG Yes Continue 3 Turn the printer off and unplug the power cord e Disconnect J P
271. o Replace the paper exit sensor then turn to TAG 002 Check amp Problem Resolution Yes Replace the output tray full sensor then turn to TAG 002 Check amp Problem Resolution Turn the printer off and unplug the power cord e Disconnect J P50 Check J50 1 and J50 4 for continuity to ground Is there continuity at either No You have failed to isolate the problem Return to the beginning of this TAG Yes Repair or replace the connectors or wiring from J50 1 to P49 1 or J50 4 To P51 1 then turn to TAG 002 Check amp Problem Resolution Turn the printer off e Disconnect J P40 Check P40 26 for continuity to ground Is there continuity to ground No Continue Yes Repair or replace the connectors or wiring from P40 26 to P54 1 P40 26 to P54 4 P40 26 to P50 1 or P40 26 to P50 4 then turn to TAG 002 Check amp Problem Resolution Turn the printer off e Reconnect J P40 J P50 and J P54 e Disconnect J P12 Turn the printer on Check J P8 6 for 12 Vdc Is the voltage 12 Vdc No Continue Yes Replace the power control 2 board then turn to TAG 002 Check amp Problem Resolu tion Troubleshooting Analysis Guide TAGs 3 85 32 Turn the printer off and unplug the power cord e Disconnect J P40 Check P40 34 to P12 8 for continuity to ground Is there continuity No Continue Yes Repair or replace the connectors or wiring from P40 34 to P12 8 then turn to TAG 002 Check amp Prob
272. o remove the duplex paper path sensor Open the top cover Remove the two screws holding the duplex control board cover in place Move the cover to the left out of the way Disconnect CN319 ao A Q N Remove the duplex paper path sensor single screw Duplex Control Board Cover Paper Path Sensor Underside Detail 7 102 Removal Replacement Procedures Chapter 8 Options Contents Options IntfOdUCUOR o2 dete Rea Ge RI Ne Ro e ca RR et e Rp Re 8 3 1200 Sheet 2500 Sheet Feeder 0 0 0 0 cece eee 8 4 Bench Test Procedure 0 c ccc cette ene nee 8 5 Prefeed Adjustment Procedure 0 cece cece eee 8 6 Input Control Board Logic 8 7 1400 Sheet Stacker 0 0 0 ec een een eee nee 8 9 Bench Test Procedure 0 cece ete eens 8 10 Connector Locations esee sere 0 0 eee een eens 8 12 Output Control Board Logic 2 2 ce eee eee 8 14 Options Introduction Options This section provides information about specific printer options not covered elsewhere in the manual These options include the 1200 sheet and 2500 sheet feeders the 1400 sheet stacker and the enhanced video model of the printer For a complete list of the parts contained in the 1200 sheet feeder the 2500 sheet feeder and the 1400 sheet stacker please see the Ilustrated Parts Catalog 8 3 1200 Sheet 2500 Sheet Feeder Table 8 1 1200 Sheet 2500 Sheet Component Acronyms
273. oard Fuser unit Back cover interlock switch Front cover interlock switch Top cover interlock switch Toner supply motor Cooling fans Jogging motor Main drive motor Vacuum transport unit Operator panel assembly Turn the printer off and unplug the power cord Verify that J P44 J P84 J P4 J P9 J P12 J P40 J P6 and the AC power cord are connected properly e Power on reset the printer Has the problem been resolved No Continue Yes Loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution Turn the printer off Open the back cover and install an interlock by pass tool Turn the printer on Use extreme caution e Check from J P9 2 to J P9 1 for 100 Vac Is the voltage 100 Vac No Go to 4 in this TAG Yes Continue Turn the printer off and unplug the power cord e Disconnect J P40 and J P12 Check P40 29 to P12 3 and P40 30 to P12 4 for continuity Is there continuity on each No Repair or replace the connectors or wiring as needed Yes Replace the power control 2 board If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the PCL board then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 4 Does the PRINTER OPEN light come on with all the covers closed No Go to 25 in this TAG Yes Continue 5 Operate the top and front cover interlock switch actu
274. oblem Resolution Is error code 576 displayed No Go to 21 in this TAG Yes Continue Turn the printer off and unplug the power cord e Disconnect J P31 and J P79 e Check for continuity Troubleshooting Analysis Guide TAGs 20 21 22 23 P31 22 to P79 22 P31 24 to P79 24 P31 26 to P79 26 P31 28 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 amp Problem Resolution Yes Continue Check for continuity to ground P31 20 P31 22 P31 26 and P31 32 Is there continuity to ground on any No Replace the disk drive assembly then turn to TAG 002 Check amp Problem Resolution Yes Replace wire harness W46 Is error code 130 131 133 or 134 displayed No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Can the printer run test prints No Continue Yes Replace the disk drive assembly If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the IGS board then turn to TAG 002 Check amp Problem Resolution Turn the printer off and unplug the power cord e Disconnect J P31 and J P79 Check P31 34 to P79 34 for continuity to ground Is there continuity No Replace the disk drive assembly If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem r
275. ode cycle printer power e Most errors or conditions reported are valid for about 90 seconds which is the timeout period set for most of the diagnostic tests described in this section Note Only diagnostics useful for field maintenance are documented in this manual Diagnostic Tests 5 3 How to Run Diagnostics 001 002 5 4 Operator Panel Test Turn the volume control on the operator panel up fully Go to 001 Press READY to run the test Confirm that the tone sounds and all lights turn on and off continuously Press STOP to exit a fF O N Upper Cassette Test 1 Make sure the upper paper cassette is installed with paper the side and rear guides securely against the edges of the paper in the cassette Go to 002 Press READY to run the test Refer to the chart below to confirm that the code that displays corresponds to the paper size in the cassette For example if the cassette holds letter size paper 1 3 should appear on the display This indicates the paper size sensor is working properly The following codes indicate paper sizes Table 5 1 Paper Size Codes Display Indication 1 0 Cassette not installed 1 1 A4 size paper in use 1 2 B5 size paper in use 1 3 Letter size paper in use 1 4 Legal size paper in use 1 5 Executive 1 size paper in use 1 6 Executive 2 size paper in use 1 7 Executive 3 size paper in use 1 8 Envelopes in use 1 9 Undefin
276. oltage 100 Vac No Go to 22 in this TAG Yes Continue Run diagnostic test 010 Use extreme caution Check J P18 1 to J P18 2 for 100 Vac while the test is running Is the voltage 100 Vac No Repair or replace the connectors or wiring from P18 1 to P13 5 P18 2 to P13 2 or both Yes Replace the toner supply motor then turn to TAG 002 Check amp Problem Resolution Run diagnostic test 010 Check TP3 31 for 0 Vdc while the test is running Is the voltage 0 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Continue Turn the printer off and unplug the power cord Check P40 31 to P12 5 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 31 to P12 5 Yes Replace the power control 2 board then turn to TAG 002 Check amp Problem Resolu tion Turn the printer off and unplug the power cord Replace the high voltage unit e Power on reset the printer e Run test prints Has the problem been resolved No Reinstall the original high voltage unit and continue Yes Turn to TAG 002 Check amp Problem Resolution Turn the printer off and unplug the power cord Replace the main charger terminal assembly e Power on reset the printer Runtest prints Has the problem been resolved No Reinstall the original main charger terminal assembly and continue Yes Turn to TAG 800 Prints Blank or With Dark Horizontal Bands
277. olved No Replace the photoconductor unit If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem refer to the Chapter 4 Print Quality Samples Compare the test prints with the print samples and identify a sample having the same print flaw as the test prints turn to the TAG listed under the sample Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs TAG 805 Black Prints Error Code 805 Possible Causes Contaminated toner carrier mix Possible Defects Main charger Printhead assembly Connectors or wiring PCL board IGS board High voltage unit Main charger lead Photoconductor unit Developer unit Main charger terminal assembly Turn the printer off and unplug the power cord Verify that J P23 J P24 J P41 and the main charger high voltage lead are connected properly Perform the every call cleaning procedure described in Chapter 9 General Printer Mainte nance Clean the contacts on the main charger Open the printer s top cover and install an interlock by pass tool e Run diagnostic test 009 Is the photoconductor belt covered with toner No Loose connectors or contamination were at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue Check the voltages as outlined in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply
278. on Yes Continue Troubleshooting Analysis Guide TAGs 4 Reinsert the lower cassette e Watch the pressure lever as the cassette is inserted Does the pressure lever elevate the paper to the correct feeding position No Check the following for defects or incorrect mounting e Cassette tray Lower pressure lever Lower cassette release cam Lower cassette release latch Wire cable pulley and spring Lower cassette release lever Replace the defective part then turn to TAG 002 Check amp Problem Resolution Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs TAG 012 Upper Cassette Not Latched Error Code 012 Possible Defects Upper cassette release cam pper cassette release latch pper cassette in latch pper pressure lever pring Wire cable and pulley Upper cassette Upper cassette in switch Upper paper size sensor Lower paper size sensor Connectors or wiringr PCL board U U U U Un 1 Turn off the printer and unplug the power cord Verify that J P40 and J P52 are connected properly Remove the upper cassette Inspect it for damage Reinsert the cassette Is the upper cassette properly latched No Continue Yes Go to 3 in this TAG 2 Check for damage e Upper cassette release cam e Upper cassette release latch e Upper cassette in latch e Upper pressure lever Spring Wire cable and pulley Are any of t
279. on Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 111 TAG 405 IGS Bit Map RAM Malfunction Error Code 606 600 610 Possible Defects IGS board 1 The IGS bit map RAM has malfunctioned Replace the IGS board then turn to TAG 002 Check amp Problem Resolution 3 112 Troubleshooting Analysis Guide TAGs TAG 500 5 Vdc Power Malfunction Error Code 500 Symptoms Operator panel blank with AC power supply cooling fan running Possible Defects DC fuse DC power supply unit Connectors or wiring Operator panel circuit board PCL board IGS board Disk drive assembly LED printhead assembly Attachment option AC power supply Signal interface board Duplex control board 1 Duplex control board 2 1 Turn off the printer and unplug the power cord Confirm that J P94 J P4 J P41 J P91 J P90 J P6 and J P8 are connected properly e Power on reset the printer Is the operator panel still blank No Loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue 2 Check J P8 10 for 5 Vdc Is the voltage 5 Vdc No Go to 7 in this TAG Yes Continue 3 Check J P91 5 for 5 Vdc Is the voltage 5 Vdc No Repair or replace the connectors or wiring from P8 10 to P91 5 then turn to TAG 002 Check amp Problem Resolution Yes Continue 4 Check J P94 1 for 5 Vdc Is the voltage 5 Vdc No Repair or replace the connectors or w
280. on e Run diagnostic test 016 Is the feed motor in good working order No Continue Yes Go to 21 in this TAG Turn the printer off e Disconnect J P309 Check P309 7 to P309 8 for continuity Is there continuity No Go to 19 in this TAG Yes Continue Check P309 9 to P309 10 for continuity Is there continuity No Continue Yes Replace duplex control board 1 then turn to TAG 002 Check amp Problem Resolution Disconnect J P313 Check the following for continuity P309 7 to J313 1 P309 8 to J313 2 P309 9 to J313 3 and P309 10 to J313 4 Is there continuity No Repair or replace the wiring or connectors from P309 to J313 that have no continuity then turn to TAG 002 Check amp Problem Resolution Yes Continue Check the following for continuity e P313 1 to P313 2 e P313 3 to P313 4 Is there continuity No Replace the route motor then turn to TAG 002 Check amp Problem Resolution Yes Replace the duplex control board 1 then turn to TAG 002 Check amp Problem Resolu tion Troubleshooting Analysis Guide TAGs 3 201 21 Turn the printer on Check J P306 3 to J P306 4 for 5 Vdc Is the voltage 5 Vdc No Repair or replace the wiring or connectors from P306 3 to J P331 3 to P330 3 then turn to TAG 002 Check amp Problem Resolution Yes Continue 22 Check J P306 2 to J P306 4 for 12 Vdc Is the voltage 12 Vdc No Repair or replace the wiring or connectors
281. ontact with the printer s paper present sensor 9 By removing the piece of paper from the slope tray photosensor PHS signals the input control board to turn the pick up motor M2 on to replace the piece of paper that was removed 10 When the last sheet of paper has been fed from the paper supply tray to the slope tray the actuator arm of photosensor IPES falls through a hole in the paper supply tray This signals the input control board to turn the elevator motor M1 on to move the paper supply tray down The paper supply tray will remain down until the paper access door is reopened more paper is loaded then closed 11 When the last sheet of paper has been removed from the slope tray confirm that the solenoid SOL de energizes Prefeed Adjustment Procedure This procedure should only be done if you are replacing the control board or experiencing excessive paper jams Remove the side top and throat covers from the unit Disconnect J509 Using the bench test procedure feed paper to the slope assembly Set VR2 fully counter clockwise a OND Adjust VR1 so that the paper feeds to 20 to 30 mm approximately 1 inch past the bend of the slope assembly Bend of Slope Assembly Paper Present A Sensor l Figure 8 3 Slope Assembly Prefeed Adjustment 8 6 Options Input Control Board Logic The table below indicates switching logic for the unit s various components Except for the power control switch PCSW e
282. oper developer unit was at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue 2 Check the voltages as described in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Turn the printer off and unplug the power cord e Disconnect J P41 e Check P41 45 to P41 46 for continuity Is there continuity No Continue Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 4 Remove the developer unit Check P41 45 to J25 12 and P41 46 to J25 8 for continuity Is there continuity on both No Repair or replace the connectors or wiring from P41 45 to J25 12 or P41 46 to J25 8 then turn to TAG 002 Check amp Problem Resolution Yes Replace the developer unit then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 53 3 54 TAG 040 Photoconductor Seam Sensor Malfunction Error Code 040 041 042 Possible Defects Photoconductor unit Main motor gear Main motor gear keys Main drive gear assembly Main drive motor assembly Connectors or wiring PCL board Software Seam sensor Turn the printer off and unplug the power cord Verify that J P4 J P9 J P12 J P14 J P20 J P40 J P41 J P63 photoconductor seam sensor J P64 J P251 and J P252 are connected properly Remove the photoconductor un
283. or Wiring Host Printer Signal Signal GND 1 gt 1 FG SG 8 gt 8 SG 2 2 TD 9 gt 9 TD 4 4 RD 1 gt RD DCD j DCD 12 12 ST2 ST2 13 13 7 7 ST1 14 gt 14 ST1 DTR E DTR 10 10 Wiring Diagrams and Electrical Data Centronics Parallel Host Interface The Centronics Parallel host interface uses the signal definitions defined below Table 6 9 Centronics Parallel Signal Definitions Wiring Diagrams and Electrical Data Pin Signal Function Name 1 DS Data strobe active low 2 DBO Data bit 0 3 DB1 Data bit 1 4 DB2 Data bit 2 5 DB3 Data bit 3 6 DB4 Data bit 4 7 DB5 Data bit 5 8 DB6 Data bit 6 g DB7 Data bit 7 10 ACK Acknowledge active low 11 BSY Bugsy active high 12 PE Paper empty active high 13 SEL Select active high 14 AF Auto feed 15 Not used 16 SG Signal ground 17 FG Frame or chassis ground 18 PLH Peripheral logic high 19 to 30 Signal ground 31 IP INIT 32 ERR Error active low 33 to 35 Not used 36 SI Select input 6 27 6 28 IBM Parallel to Printer Table 6 10 IBM Parallel to Printer Connector Wiring Host Printer Signal Signal DS 1 1 DS DBO 2 2 DBO 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 ACK BSY 11 11 BSY PE 12 12 PE SEL 13 13 SEL AF 14 14 A
284. ord e Disconnect J P53 J P55 and J P40 Check P40 26 to P53 1 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 26 to J P54 1 to P53 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P40 23 to P53 2 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 23 to J P54 2 to P53 2 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P40 13 to P53 3 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 13 to J P54 3 to P53 3 then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 77 17 18 19 20 21 22 3 78 Check P40 26 to P55 1 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 26 to J P54 4 to P55 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P40 22 to P55 2 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 22 to J P54 5 to P55 2 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P40 13 to P55 3 for continuity Is there continuity No Repair or replace the connectors or wiring from P40 13 to J P54 6 to P55 3 then turn to TAG 002 Check amp Problem Resolution Yes Continue Reconnect J P40 J P53 and J P55 e Run diagn
285. original photoconductor unit and main charger and continue Yes The photoconductor unit was at fault Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 5 Replace the developer unit and toner cartridge e Run test prints Has the problem been resolved No Reinstall the original developer unit and continue Yes Turn to TAG 002 Check amp Problem Resolution If the problem recurs the toner carrier mix may be old or contaminated 6 Produce a developed image on the photoconductor Is a developed image on the photoconductor No Go to 10 in this TAG Yes Continue 7 Remove and clean the transfer charger unit Clean the transfer charger unit contacts in the upper paper guide Inspect the transfer charger contacts for proper alignment Reinstall the transfer charger unit e Power on reset the printer Runtest prints Has the problem been resolved No Continue Yes Turn to TAG 002 Check amp Problem Resolution 8 Turn the printer off and unplug the power cord Remove the transfer charger unit e Check the lower transfer charger unit contact with the upper paper guide assembly in its fully upright position for continuity to ground Is there continuity No Replace the upper paper guide assembly then turn to TAG 002 Check amp Problem Reso lution Yes Continue 9 Replace the transfer charger unit e Power on reset the printer e Run test prints Has the problem
286. osen the thumbscrew on the back of the disk drive housing o0 5 O N Remove the disk drive housing from the front of the printer Be careful not to damage the cables on the sharp edges of the chassis Replacement Note For A drives set the jumper on the drive circuit board to 0 for B drives set the jumper to 1 Hard Disk Drive Connector Thumbscrew Back Detail Removal Replacement Procedures 7 25 Cooling Fan Removal Cooling Fan Removal To remove the cooling fan Open the back cover Remove the fuser drive cover three screws Disconnect CN21 b amp b WO N 2a Remove the cooling fan four screws Fuser Drive Cover 9 7 26 Removal Replacement Procedures Duplex Fan Removal Duplex Fan Removal To remove the duplex fan 1 Open the back and top covers Remove the fuser drive cover three screws Remove the EMI grounding plate if present from the rear of the printer four screws Remove the four screws holding the duplex fan in place Disconnect CN326 Lift the duplex fan from the printer Fuser Drive Cover Removal Replacement Procedures 7 27 Toner Motor Removal Toner Motor Removal To remove the toner motor 1 Open the back cover 2 Disconnect CN18 3 Remove the toner motor three screws Toner Motor Detail 7 28 Removal Replacement Procedures AC Power Supply Removal AC Power Supply Removal To remove the AC power supply Open the front back a
287. ossible Defects Fuser unit Exit roller assembly Exit pinch roller assembly 1 Make sure the paper being used is not damaged Make sure the paper is loaded properly Make sure the side and rear paper guides in the paper cassettes are positioned properly e Check both upper and lower paper paths for obstructions or roller contamination Confirm that the paper in the cassettes meets paper specifications outlined in the Guide to Operations at the back of this manual e Power on reset the printer e Run test prints from the upper cassette Are the prints wrinkled or damaged No Continue Yes Go to 3 in this TAG 2 Remove the upper cassette e Power on reset the printer Runtest prints from the lower cassette Are the prints wrinkled or damaged No The paper in use was at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue 3 Run a test print from the cassette exhibiting the problem Is the print on the paper skewed No Continue Yes Go to TAG 807 Misregistered Skewed Prints Simplex 4 Remove the exit cover assembly e Inspect the exit roller assembly for damage wear or contamination Inspect the exit pinch roller for damage wear or contamination Is either part damaged worn or contaminated No Replace the fuser unit then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the part as needed then turn to TAG 002 Check amp Problem Resolu tion 3 138 Troubleshooti
288. ostic test 008 Is error code 083 displayed No Continue Yes Verify again that J P40 J P53 J P55 and J P54 are connected properly If they re not connect them properly then turn to TAG 002 Check amp Problem Resolution If they are replace the PCL board then turn to TAG 002 Check amp Problem Resolution Interchange P53 and P55 e Run diagnostic test 008 Does the error code change from 081 to 082 No Continue Yes Adjust the tray front sensor position If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the tray front sensor then turn to TAG 002 Check amp Problem Resolution Does the error code change from 082 to 081 No Replace the job offset assembly then turn to TAG 002 Check amp Problem Resolution Yes Adjust the tray rear sensor position If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the tray rear sensor or job offset sensor then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs TAG 097 12 Vdc Power Shorted or Sensing Problem Error Code 097 Possible Defects DC power supply unit Connectors or wiring Signal interface board IGS board Optional external attachment Power control 2 board Power control 3 board Developer unit Paper timing sensor Upper paper empty sensor Lower paper empty sensor Output tray
289. oval sseeeeeeeeeee 7 100 Duplex Paper Path Sensor Removal 22225202 Po Y D iV E 7 102 Options CODIEls o iki bubiebeg eee booth a Res RR Reta bees dude fla Sx ds 8 2 INPOCUCHON eras ted Soe eo oe oe E ee ek AREE Qe ERA id 8 3 1200 Sheet 2500 Sheet Feederz does uz Ply be Ta hex EUR ES RES 8 4 Bench Test Proc dure ooi ope Rem e HERR CY ATO C 8 5 Prefeed Adjustment Procedure 8 6 Input Control Board Logic sseeeeeeeee eee teens 8 7 1400 Sheet SIaCKer nee e res ee E st etna eee ETC EE EP 8 9 Bench Test Procedure sexa ex E EL Edna s Eee 8 10 Connector Loca Ons odio ART eden S UR Rer Ee a teen 8 12 Output Control Board Logic ssseeeeeeeeeeee e 8 14 General Printer Maintenance GOING INES iis ort Nes rk LE oot sot sepe abt A a M dire aM dtu 9 2 General Printer Maintenance 0 0 cee eee ete eee eens 9 3 IntrodUctoll ora bas Fasc e Ces tcp PREDA RENI WE a at de 9 3 Every Call Cleaning Procedure 0 0 eee ccc ee ee 9 3 Paper Feed Tension Adjustment Procedure 0 0 cece eee eee eee 9 3 Lubrication Procedures i sese ei ee eta tea A en 9 3 Pune Wp Procedure s a 04 2 ss E he M EXAMS BO Lut ea 9 3 Safety Precautions ooi sre er suo ee eee I beer eee dea Siw AEA MEE ee 9 3 Tool Requirements Service Kit 2 0 ee eee eee 9 4 ToolS Supplies Er ERROR Pa aa a etre bears 9 4 End User Cleaning Kit 0 0 2 ccc cece cece ee 9 4 xiii xiv Printer Maintenance Record
290. ove the back screw holding the upper paper guide in place 8 Remove the front screw holding the upper paper guide in place 9 Release the two springs at the base of the upper paper guide 10 Lift the upper paper guide out of the printer S o a c o e L Springs Cassette Release Cover 7 49 Removal Replacement Procedures Upper Paper Guide Roller Removal Upper Paper Guide Roller Removal To remove the upper paper guide roller 1 Open the top cover 2 Remove the two springs at each end of the roller To do this press down gently on the end of the spring and move it out from under the plastic Raise the upper paper guide Remove the roller and bearings from the underside of the upper paper guide Upper Paper Guide Underside Springs 7 50 Removal Replacement Procedures Lower Paper Guide Removal Lower Paper Guide Removal To remove the lower paper guide b amp b WO N 2a 5 Open the top cover Raise the upper paper guide Raise the lower paper guide slightly Push the base of the lower paper guide toward the back of the printer until the front mounting peg is free Lift the lower paper guide out of the printer Note Use caution This piece is made of plastic and can easily break if mishandled Removal Replacement Procedures 7 51 Paper Timing Guide Removal Guide Removal ming i Paper Ti To remove the paper timing guide 1 Open the front back and
291. per comes in contact with the paper exit sensor If the paper does not energize this sensor in a given amount of time after leaving the paper timing sensor step 4 an error 022 will occur The exit roller moves the paper to the exit tray If the exit sensor is not cleared in a specified amount of time an error 023 will occur Duplex Printing When duplex is selected the PCL board controls the paper motion with page scheduling assistance from the IGS board The duplex page router is engaged When in duplex mode it is important to note that the printer runs multiple pages through the paper path at the same time to increase speed See Figure 1 2 Paper Path on page 1 6 1 In a duplex job the duplex router solenoid behind the fuser is engaged and mechanical fingers route the paper to the duplex area Also the A roller clutch engages to turn the A and B rollers connected via a belt Printer and Troubleshooting Overview 1 5 2 The paper upon passing through the B roller comes in contact with the duplex sen sor If the paper does not energize this sensor in a given amount of time an error 060 will occur 3 The C roller bidirectional motor turns on and passes the paper into the turnaround tray The paper sensor in the turnaround tray is activated and the paper is center regis tered If the paper does not energize this sensor in a given amount of time after leav ing the duplex sensor an erro
292. per paper cassette 0 0 Cassette full 0 1 Cassette empty Lower paper cassette 1 0 Cassette full 1 1 Cassette empty Paper timing sensor 2 0 No paper at sensor location 2 1 Paper at sensor Paper exit sensor 3 0 No paper at sensor location 3 1 Paper at sensor Paper full sensor 4 0 Tray empty 4 1 Tray full Jogging sensor front 5 0 Tray in front position 5 1 Error tray in rear position Jogging sensor rear 6 0 Tray in rear position 6 1 Error tray in front position PC seam sensor 7 0 Active 7 1 Not active Developer interlock 8 0 Developer unit in place 8 1 Developer unit not in place 4 To check a specific sensor press READY repeatedly until the code on the display cor responds to the sensor you want to check Manually activate the sensor Confirm that the display changes when you activate the sensor Refer to Sensor and Switch Loca tions on page 1 11 for sensor locations 5 Press STOP to exit 5 6 Diagnostic Tests 006 Paper Transport Clutch Test Sequence 1 Goto 006 2 Press READY to run the test The first clutch engages signaled by a continuous 004 intentionally excluded clicking sound 3 0 appears on the display corresponding to the upper pick up roller clutch 3 Press READY to test the next clutch Listen for the clicking sound as the next clutch engages The number on the display changes to indicate the next clutch The display codes and the clutch they represent are listed i
293. place the photoconductor unit e Run 200 test prints to reduce toner concentration in the developer unit Has the problem been resolved No Reinstall the original photoconductor unit and continue Yes The photoconductor was at fault turn to TAG 002 Check amp Problem Resolution 4 Turn the printer off and unplug the power cord Perform the every call cleaning procedure described in Chapter 9 General Printer Mainte nance Clean the toner patch sensor on the developer unit Clean the printhead lens Runatleast 55 test prints Has the problem been resolved No Contamination was at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue 5 Run test prints Do the test prints appear overtoned dark or have background No Go to 8 in this TAG Yes Continue 6 Develop a toner patch as described in Chapter 1 Printer and Troubleshooting Overview Is the toner patch developed and properly positioned No Replace the IGS board then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 49 7 Check the toner patch sensor board in the developer unit for loose wiring connectors Are all connectors and wiring connected properly No Reconnect the wiring and connectors or replace the developer unit then turn to TAG 002 Check amp Problem Resolution Yes Go to TAG 808 Prints Overtoned Dark Vertical Streaks TAG 811 Background Resid ual Images
294. placement Procedures 7 15 Top Cover Hinge Removal Top Cover Hinge Removal To remove the top cover hinge Open the top cover Remove the two screws holding the hinge support to the top cover Remove the two screws holding the hinge support to the printer base While supporting the top cover loosen the top two screws a A QOQ N Remove the hinge Replacement Note Replace one hinge at a time so that one always remains in place to support the top cover Loosen Screws 7 16 Removal Replacement Procedures Rear Duplex Cover Removal Rear Duplex Cover Removal To remove the rear duplex cover 1 Open the top cover 2 Remove the lower screw for the rear duplex cover 3 While supporting the cover remove the upper screw for the rear duplex cover Replacement Note Do not substitute longer screws to hold the rear duplex cover in place LY Upper Screw LASS LIF If II S AAAS VELA Lower Screw Removal Replacement Procedures 7 17 Front Duplex Cover Removal Front DuplexCover Removal To remove the front duplex cover 1 Open the top cover 2 Remove the rear duplex cover Refer to page 7 17 3 Close the top cover 4 Open the front duplex cover 5 Remove the C clip from each gas spring 6 While supporting the cover remove each gas spring from its post and lower it 7 Close the front duplex cover 8 Remove the front hinges from the top cover two screws each 9 Remove the two screws from
295. prints to detone the engine then turn to TAG 002 Check amp Problem Resolution 6 Replace the developer unit and toner cartridge e Run test prints Has the problem been resolved No Reinstall the original developer unit and continue Yes Turn to TAG 002 Check amp Problem Resolution 7 Produce a developed image on the photoconductor Is the developed image on the photoconductor correct No Go to 11 in this TAG Yes Continue 8 Remove and clean the transfer charger unit Clean the transfer charger unit contacts in the upper paper guide Inspect the transfer charger contacts for proper alignment Reinstall the transfer charger unit e Power on reset the printer e Run test prints Has the problem been resolved No Continue Yes Turn to TAG 002 Check amp Problem Resolution 9 Turn the printer off and unplug the power cord Remove the transfer charger unit e Check the lower transfer charger unit contact with the upper paper guide assembly in its fully upright position for continuity to ground Is there continuity No Repair or replace the upper paper guide assembly then turn to TAG 002 Check amp Prob lem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 153 10 Turn the printer off and unplug the power cord Replace the transfer charger unit e Power on reset the printer Runtest prints Has the problem been resolved No Replace the upper paper guide assembly If this
296. quence 0 0 0 e cece eee 1 5 Simplex Printing cc c00a crea che eee beeen deae eda 1 5 Duplex Printing scho neges Maes onda eee we alata nae e nce Ene 1 5 Error Code Technical Definitions 0 00 0 eee eee 1 7 Sensor and Switch Locations seeeeee eh 1 11 Troubleshooting Overview lese Ih 1 15 General Troubleshooting Tips 1 15 The Problem Printer or Host 2 0 eee ee eee 1 16 Protocol Converters iussu edes ccr eee en dee deed ae a 1 17 Reading the Error Log 1 17 Confirming Line Power 0 0 cee cece eee eee nee 1 18 Using the Troubleshooting Analysis Guide TAG 0 000005 1 19 Sample TAG Liuius veda iex sealed rursum uus aae weeds 1 19 Standard Procedures 2 0 0 0 ccc cc eect hrs 1 21 Power on reset POR 0 ccc een tence nee 1 21 Checking Continuity 0 0 eee eects 1 21 Installing the Interlock By pass Tool 20 0 c eee eee eee eee 1 22 Producing a Developed Image 0 0 eee eee eee eee 1 22 Producing a Toner Patch 0 eee ee 1 22 Completing a Service Call 0 eee eect eee 1 23 Clearing the Error Log coepere Mack S HR p LER ee d 1 24 Printer and Troubleshooting Overview Theory of Operation The printer uses an electrophotographic imaging system based on LED array technology Two key components of the printer are the image generation system IGS controller and the printer control logic PCL board Image
297. r To remove the right side cover Remove the paper output tray Open the top back and front covers Remove the two screws holding the right side cover in place Close the top cover a fF OO N Pull the cover out and away from the printer Replacement Note Tighten the screws first Then gently lift the bottom tabs into place Hold the top of the right side cover in place as you open the top cover This avoids the possibility of damag ing the top cover 7 10 Removal Replacement Procedures Vacuum Transport Unit Removal Simplex Vacuum Transport Unit Removal Simplex To remove the simplex vacuum transport unit Open the top and back cover Disconnect CN22A Remove the retaining clip holding the cable in place Remove the ground screw on the left side of the back cover Remove the harness stays holding the cable in place o0 5 O N Remove the vacuum transport unit four screws Ground Screw Removal Replacement Procedures 7 11 Vacuum Transport Unit Removal Simplex E p LI a Lo H BH bg i b Ji f id M 7 ng YA ae o a o Q o c b E 3 Ss o gt Mounting Screws m O CN 4 away A ens Removal Replacement Procedures 7 12 Vacuum Transport Unit Removal Duplex Vacuum Transport Unit Removal Duplex To remove the duplex vacuum transport unit Open the top cover Remove th
298. r Note Use caution so as not to damage the paper full or exit sensors Exit Guide Exit Pinch Roller Screw Exit Guide Screw Lower Duplex Drive C30D only Back Detail Removal Replacement Procedures 7 73 Exit Cover Removal Simplex Exit Cover Removal Simplex To remove the simplex exit cover Open the front back and top covers Remove the fuser Remove the right side cover See page 7 9 Remove the paper output tray a Q N Remove the operator panel See page 7 19 Front Detail 7 74 Removal Replacement Procedures Exit Cover Removal Simplex 6 Remove the fuser drive cover three screws 7 Remove the exit pinch roller See page 7 68 8 Disconnect CN49 and CN51 9 Remove the four screws holding the exit cover in place two front and two back 10 Remove the wiring harness for CN42 CN49 and CN51 from the exit cover 11 Lift the exit cover from the printer Fuser Drive Cover Back Detail Removal Replacement Procedures 7 75 Exit Cover Removal Duplex Exit Cover Removal Duplex To remove the duplex exit cover 1 Open the front top and back covers 2 Remove the fuser 3 Remove the paper output tray 4 Remove the right side cover See page 7 10 19 5 Remove the operator panel See page 7 Removal Replacement Procedures 7 76 Exit Cover Removal Duplex 6 Remove the fuser drive cover three screws 7 Remove the exit pinch roller
299. r four screws From the top loosen the screw holding the high voltage unit in place Pull the high voltage unit out from the back of the printer Disconnect connectors CN23 CN24 CN85 and the two high voltage leads o0 5 Oo Remove the high voltage unit 7 32 Removal Replacement Procedures Photoconductor Seam Sensor Removal PhotoconductorSeam Sensor Removal To remove the photoconductor seam sensor Open the front back and top covers Remove the photoconductor and place in its protective packaging Remove the developer unit Remove the paper feed drive cover three screws Remove the bracket holding CN64 in place one screw o0 5 O N Remove the screw holding the seam sensor bracket in place It is situated under the bracket for CN64 Mounting Screw under CN64 bracket Back Detail Removal Replacement Procedures 7 33 Photoconductor Seam Sensor Removal 7 From inside the empty photoconductor cavity disconnect connector CN63 8 Liftthe photoconductor seam sensor and bracket up out of the printer Note Use caution not to bend the bracket Seam Sensor and Bracket Y Front Detail W Removal Replacement Procedures 7 34 Photoconductor Rear Guide Rail Removal Photoconductor Rear Guide Rail Removal To remove the photoconductor rear guide rail Open the front back and top covers Remove the photoconductor and place in its protective packaging Remove t
300. r 061 will occur 4 Atthis time the solenoid for the router at the turnaround tray engages so the paper can be routed to be printed on the duplex side 5 Inagiven amount of time after the paper energizes the paper sensor in the turnaround tray the bi directional motor reverses and passes the paper to the paper timing roller If the paper does not energize the paper timing sensor in a given amount of time after leaving the turnaround sensor an error 062 will occur 6 Atthis point the same steps happen as during a simplex cycle Roller B Roller C Roller iPaper Timing Roller A Roller Upper Pick up Roller Fuser Unit Exit Roller Exit Flipper Lower Paper Cassette Lower Pick up Roller Photoconductor Belt Lower Feed Roller Figure 1 2 Paper Path 1 6 Printer and Troubleshooting Overview Error Code Technical Definitions The following table lists the printer error codes and their descriptions Table 1 1 Error Code Technical Definitions Type Error Description o 010 E10 PCL board detected no signal from upper paper cassette empty o sensor indicating no paper present ui 011 PCL board detected no signal from lower paper cassette empty 2 sensor indicating no paper present D 012 E12 PCL board detected no signal from upper cassette in switch 013 PCL board detected no signal from lower cassette in switch 020 PCL board detected th
301. r Paper Tension Lever k Cable Tension Damper Assembly Spring Lower Paper Size Sensor Cassette Release Cover Removal Replacement Procedures Lower Cassette Mount Removal 13 Remove the lower bracket four screws two front and two back 14 Remove the tray four screws two front and two back 15 Remove the AC power supply See page 7 29 16 Remove the lower tray lift arm two screws with two plastic retainers 17 Remove the screws holding the lower cassette mount in place two front and two side 18 Pull the lower cassette mount from its front and back mounting pins 19 Rotate the lower cassette mount upwards and out of the printer Tray Lower Bracket Lower Cassette Mount Mounting Screws Cassette Mount Detail Left Side Detail Tray Lower Bracket Lower Cassette Mount Front Mounting Screw Detail Back Mounting Screw Detail Removal Replacement Procedures 7 47 Upper Paper Guide Removal Upper Paper Guide Removal To remove the upper paper guide 1 Open the front back and top covers 2 Remove the paper feed drive cover three screws 3 Disconnect the transfer corona high voltage lead from the HVPS 4 Disconnect the ground screw for the transfer corona Paper Feed Drive Cover Mounting Screw Back Detail 7 48 Removal Replacement Procedures Upper Paper Guide Removal 5 Remove the cassette release cover two screws 6 Raise the upper paper guide 7 Rem
302. r control 2 board then turn to TAG 002 Check amp Problem Resolu tion Reconnect J P10 and J P12 e Disconnect J P40 Check P40 36 for continuity to ground Is there continuity No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P40 36 to P12 1 then turn to TAG 002 Check amp Problem Resolution Power on reset the printer e Check TP3 36 on the PCL board for a voltage change from 24 Vdc to 0 Vdc during the 15 sec onds after the output tray jogging test Does the voltage change from 24 Vdc to 0 Vdc No Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Go to 11 in this TAG Troubleshooting Analysis Guide TAGs 3 71 TAG 071 Open Fuser Thermistor 3 72 Error Code 071 Possible Defects Connectors or wiring Fuser unit PCL board Turn the printer off and unplug the power cord Make sure the fuser unit is installed properly Confirm that J P41 and J P44 are connected properly Has the fuser unit been replaced recently No Continue Yes Go to 3 in this TAG Replace the fuser unit e Power on reset the printer Is error code 071 displayed during power on reset No The fuser unit was at fault Turn to TAG 002 Check amp Problem Resolution Yes Reinstall the original fuser unit and continue Turn the printer off and unplug the power cord e Disconnect J P41 Remove the
303. r latches one spring and C clip each Removal Replacement Procedures Upper Cassette Mount Removal Cassette Release Cover 7 43 14 Disengage the top of the damper assembly Push it to the right out of the way c D b D o o A oe 26 A gt J e I A o oO QO 5 6 YN 58 22 g AA Doo o 5 2 j 2 i oc Ap c fy oc o AV Bpi 57 X s po AAN LES Sa if o yi 7 7 v j et fF n a is o Dr s amp 7 k s Y a ES 2 Pi bey 2L f 24 O S o ga oS a cot N f n Entice em ey ka o ok 52 amp a oR D Eo E a o Q o 2 2 amp E a Q Removal Replacement Procedures Upper Cassette Mount Removal 15 Remove the lower bracket four screws two front and two back 16 Remove the tray four screws two front and two back 17 Remove the upper tray lift arm two screws with two plastic retainers 18 Remove the upper bracket four screws two front and two back 19 Remove the screws holding the upper cassette mount in place two front and two side 20 Pull the upper cassette mount from its front and back mounting pins 21 Rotate the upper cassette mount upwards and out of the printer Mounting Screws Upper Bracket Upper Cassette Mount bores er Rr Tray Lower Bracket Retainers Cassette Mount Detail Left Side Detail Upper Bracket Upper Bracket Upper Cassette Moun Front Mounting Screw Detail Back Mounting Scre
304. r manually Does the voltage change from 0 Vdc to 12Vdc No Replace the upper paper empty sensor then turn to TAG 002 Check amp Problem Resolu tion Yes Continue Troubleshooting Analysis Guide TAGs 4 Check pressure lever e Reinsert the upper cassette Watch the pressure lever as the cassette is inserted Does the pressure lever elevate the paper to the correct feeding position No Check the following for defects or incorrect mounting e Cassette tray e Damper assembly e Upper pressure lever e Upper cassette release cam e Upper cassette release latch Wire cable pulley and spring e Upper cassette release lever Replace the defective part then turn to TAG 002 Check amp Problem Resolution Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs E10 Envelope Tray Out of Envelopes This TAG refers to the error code for the envelope tray which handles 75 envelopes Error Code E10 Possible Causes Cassette empty Envelopes incorrectly loaded Possible Defects Upper paper empty actuator Upper paper empty sensor Paper size sensor assembly Envelope cassette tray Upper pressure lever Upper cassette release cam Upper cassette release latch Upper cassette release lever Spring Connectors wiring PCL board Make sure envelopes are in the envelope cassette Make sure the envelopes are correctly loaded e Power on reset th
305. r on reset the printer While the main motor is running cover all of the holes in the vacuum unit with a piece of paper Does the vacuum transport unit fan hold the paper in place No Continue Yes Return to the beginning of this TAG Use extreme caution Check for 100 Vac from J P22 1 to J P22 2 Is the voltage 100 Vac No Continue Yes Replace the vacuum transport assembly Power on reset the printer Use extreme caution While the main motor is running monitor J P13 6 and J P13 3 for 100 Vac Is the voltage 100 Vac No Replace the power control board then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from J22 1 to P13 6 or J22 2 to P13 3 Then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs TAG 023 Paper Jam in the Output Area Error Code 023 Possible Causes Paper path obstruction Output tray obstruction Possible Defects Exit paper sensor Fuser drive unit Exit roller assembly Exit pinch roller assembly PCL board Connectors or wiring If the printer has a high capacity output unit HCO unplug and remove it before you begin Test the printer without the HCO if the problem remains proceed with this TAG If the problem occurs only with the HCO the HCO is causing the problem Repair or replace the HCO 1 Turn the printer off and unplug the power cord e Verify that J P50 and J P40 are connected properly e Che
306. ransfer or Fuser Area 5 Run diagnostic test 011 Is error code 046 displayed No Continue Yes Go to 11 in this TAG 6 Run diagnostic test 012 Is error code 051 displayed No Continue Yes Go to 8 in this TAG 7 Run diagnostic test 012 Is error code 050 displayed No The problem appears to be intermittent Go to TAG 050 Transfer Charger Circuit Shorted Yes Go to TAG 050 Transfer Charger Circuit Shorted 8 Turn the printer off and unplug the power cord Remove the transfer charger Inspect the transfer charger wire Is the transfer charger wire damaged No Continue Yes Replace the transfer charger then turn to TAG 002 Check amp Problem Resolution 9 With the upper paper guide assembly in its fully upright position check the transfer charger s lower receptacle for continuity to ground Is there continuity No Replace or repair the upper paper guide assembly then turn to TAG 002 Check amp Prob lem Resolution Yes Continue 10 Disconnect high voltage unit lead to the transfer charger e Check the transfer charger s upper receptacle to the lead removed from the high voltage unit for Troubleshooting Analysis Guide TAGs 3 59 3 60 11 12 13 14 15 continuity Is there continuity No Replace the upper paper guide assembly then turn to TAG 002 Check amp Problem Reso lution Yes Go to 13 in this TAG Turn the printer off and unplug the power cord Disconn
307. ray is normally lifted into operating position by the printer s lower paper lift arm Slope tray Paper size lever Paper supply tray Paper access door Figure 8 2 Bench Test Procedure 4 Restore AC power to the unit either the unit s power cord or the printer s power cord may be used 5 Open the paper access door The elevator motor M1 should turn on moving the paper stock down There is an actuator attached to the elevator s chain drive that will activate photosensor ILLS signalling the input control board that the paper supply tray is completely down Note Remove any paper that may be on the unit s slope tray 6 Close the paper access door The elevator motor M1 should turn on moving the paper stack up There are two actuators that must enable two photosensors Photosen Options 8 5 sor IPES signals the input control board that paper is present on the elevator Photo sensor IULS signals the input control board that the upper limit for the paper supply tray and paper stack has been reached 7 With the paper supply tray all the way up and with no paper present on the slope tray indicated to the input control board by photosensor PES located in the middle of the paper path the pick up roller assembly motor M2 will turn on and transport a piece of paper to the slope tray 8 When the paper in transported to the slope tray note that the SOL solenoid under the slope tray energizes Note The solenoid causes c
308. rds IGS 1 3 IGS bit map RAM malfunction 3 112 IGS communication malfunctions 3 108 IGS controller malfunctions 3 103 IGS to PCL interface malfunctions 3 110 PCL 1 3 PCL interface problems 3 102 removing duplex control 1 7 89 removing duplex control 2 7 90 removing IGS 7 21 removing jogging motor 7 39 removing PCL 7 22 removing power control 7 38 removing signal interface 7 37 settings 6 30 cleaner drive removal 7 55 cleaner drive belt removal 7 54 cleaning kit 9 4 cleaning procedure 9 6 communications external problems 3 143 problems 2 13 3 146 testing 5 21 5 22 connector index 6 4 connector locations 6 6 connectors back cover 6 11 duplex cover 6 8 front cover 6 6 left cover 6 7 right cover 6 9 sheet stacker 8 12 top cover 6 10 continuity checks 1 21 cooling fan Index 1 removal 7 26 counter malfunctions 3 140 problems 2 13 removal 7 20 testing 5 7 covers removing back 7 6 removing EP 7 84 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 references error code TAG 2 3 mechanical malfunction TAG 2 12 print quality TAG 2 9 D damaged paper 3 138 DC power supply removal 7 31 developed image producing 1 22 developer bias problems 3 44 testing 5 13 developer unit problems 3 53 diagnostics communication loop back 5 21 5 22 counter 5 7 developer b
309. removing and replacing all field replaceable parts on the printer Chapter 8 Options reviews printer options HCI HCO information Chapter 9 General Printer Maintenance presents general printer maintenance proce dures Printer and Troubleshooting Overview Standard Procedures While using the TAGs you may be asked to perform some of the following procedures Specific instructions for completing these procedures are included here rather than repeated in the body of each TAG Please read this information before following any TAG Power on reset POR When directed to power on reset the printer 1 Tur off the printer 2 Wait at least 5 seconds 3 Turn the power back on Checking Continuity Warning Make sure the printer is turned off and the power disconnected age to do so may result in personal injury equipment damage or both To perform a continuity check Turn off the printer and disconnect the power cord 2 Set your meter to the lowest ohm setting C Interpret the results as follows e An infinite reading indicates an open circuit Azero or specific reading indicates continuity 4 To check an open or short circuit to ground Turn off the printer and disconnect the power cord Locate the circuit in question Refer to Chapter 6 Wiring Diagrams and Electri cal Data for circuit locations Check all connectors and wiring on each side for corrosion foreign ob
310. rface cable works as outlined in the table that follows e Reconnect all communication lines e Reconnect any external attachment option e Power on reset the printer Runthe failing job again Table 3 4 RS 232 Cable Reference Table Host Computer Printer Description Signal Pin Directions Pin Signal FG 1 1 FG SG 7 7 SG TD 2 _ lt 2 TD Data Out status TD 2 lt a 3 RD Data In CMD Data RTS 4 4 RTS Optional continuous positive volt age for host computers that require a printer present indication CTS 5 5 CTS Must go to a positive voltage from the host computer It is only looked at by the printer at power on initial DSR 6 lt ization DTR 20 20 DTR Depends on printer soft configura tion option 15 DTR will always be a positive voltage if set to DTR High DTR will change from a positive to a negative voltage if set to DTR Pac ing and the buffer is full Does your cable work as outlined in the Cable Reference Table above No The problem appears to be related to the host computer or host interface cable Correct the problem then turn to TAG 002 Check amp Problem Resolution Yes The problem may be caused by the IGS board signal interface board or outdated printer software Determine which of these is at fault correct the problem then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 145
311. rger Circuit Shorted 0 0 0 0 00 0 e ee eee 3 63 TAG 055 Erase Lamp Malfunction 0 0 0 0 e eee eee eee 3 65 TAG 070 Fuser Unit Malfunction 0 0 0 0 0 cece eee eee 3 67 TAG 071 Open Fuser Thermistor 2 0 0 cece e eee eee 3 72 TAG 072 Fuser Unit Temperature Too High 0 00 0 arean 3 73 TAG 083 Job Offset Mechanism Malfunction 0 000000 000 3 75 TAG 097 12 Vdc Power Shorted or Sensing Problem 3 79 TAG 098 12 Vdc Power Shorted 0 0 0 eee eee 3 90 TAG 099 24 Vdc Power Shorted 0 0 0 eee eee eee 3 92 TAG 100 PCL Board Interface Malfunction 0 002 esee 3 102 Troubleshooting Analysis Guide TAGs TAG 101 TAG 130 TAG 200 TAG 201 TAG 405 TAG 500 TAG 600 TAG 610 TAG 700 TAG 702 TAG 703 TAG 704 TAG 705 TAG 706 TAG 707 TAG 750 TAG 751 TAG 753 TAG 754 TAG 800 TAG 801 TAG 802 TAG 803 TAG 804 TAG 805 TAG 806 TAG 807 TAG 808 TAG 809 TAG 810 TAG 811 TAG 812 TAG 813 TAG 815 TAG 900 TAG 901 TAG 902 IGS Controller Diagnostic Failure eese 3 103 Diskette Disk Drive Malfunction 0 000008 3 104 IGS Internal Communication Malfunction 3 108 IGS PPCL Interface Malfunction 0 0 0 0008 3 110 IGS Bit Map RAM Malfunction 0 0 0 eee ee eee 3 112 5 Vdc Power Malfunction 0 0 00 cee eee eee ee
312. roblem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the IGS board then turn to TAG 002 Check amp Problem Resolution Yes Replace wire harness W46 then turn to TAG 002 Check amp Problem Resolution 7 Is error code 573 displayed No Go to 13 in this TAG Yes Continue 8 Turn the printer on Check J P8 1 for 5 Vdc Is the voltage 5 Vdc No Replace the DC power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue 9 Check J P77 4 for 5 Vdc Is the voltage 5 Vdc No Repair or replace the connectors or wiring from P8 1 to P77 4 then turn to TAG 002 Check amp Problem Resolution Yes Continue 10 Check J P8 3 for 12 Vdc Is the voltage 12 Vdc No Replace the DC power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue 11 Check J P77 1 for 12 Vdc Is the voltage 12 Vdc No Repair or replace the connectors or wiring from P8 3 to P77 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue 12 Turn the printer off and unplug the power cord e Disconnect J P31 and J P79 Check for continuity to ground P31 34 to P79 34 P31 32 to P79 32 P31 16 to P79 16 and Troubleshooting Analysis Guide TAGs 3 105 13 14 15 16 17 18 19 3 106 P31 10 to P79 10 Is there continuity on any No Replace the disk drive assembly If this does not resolve the problem
313. roblem been resolved No Continue Yes A loose connector was at fault Turn to TAG 002 Check amp Problem Resolution 2 Was an error code displayed during the power on reset No Refer to the mechanical malfunctions cross reference table in Mechanical Malfunction TAG Cross Reference on page 2 12 Yes Continue 3 Was the error code the same as the one used to enter this TAG No Refer to the error code cross reference table in Error Code TAG Cross Reference on page 2 3 Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution 3 102 Troubleshooting Analysis Guide TAGs TAG 101 IGS Controller Diagnostic Failure Error Code 101 Possible Defects IGS board 1 Power on reset the printer Is error 101 displayed on the operator panel No The problem may be caused by power fluctuation Turn to TAG 002 Check amp Problem Resolution Yes Replace the IGS controller then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 103 TAG 130 Diskette Disk Drive Malfunction 3 104 Error Code 130 131 133 134 450 451 572 576 586 Symptoms Test prints do not run Possible Defects Diskette Disk drive assembly Connectors or wiring PCL board IGS board DC power supply Electrical problems on wires J P31 to J P79 and J P31 to ground may cause diskette and disk drive malfunctions If this TAG does not correct the problem suspect an intermittent failure
314. rom P331 1 to P306 1 then turn to TAG 002 Check amp Problem Resolution 29 Turn the printer off e Reconnect J P310 e Disconnect J P321 Turn the printer on Check J P330 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the restart motor then turn to TAG 002 Check amp Problem Resolution 30 Turn the printer off e Reconnect J P321 e Disconnect J P312 Turn the printer on Check J P330 1 for 24 Vdc Is the voltage 24 Vdc No Repair or replace the connectors or wiring from P312 to J321 then turn to TAG 002 Check amp Problem Resolution Yes Replace the duplex control board 2 then turn to TAG 002 Check amp Problem Resolu tion 31 Turn the printer off e Reconnect J P306 e Disconnect J P313 Turn the printer on Check J P330 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the route motor then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 99 32 Turn the printer off e Reconnect J P313 e Disconnect J P314 Turn the printer on Check J P330 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the in solenoid then turn to TAG 002 Check amp Problem Resolution 33 Turn the printer off e Reconnect J P314 e Disconnect J P315 Turn the printer on Check J P330 1 for 24 Vdc Is the voltage 24 Vdc No Continue Yes Replace the C roller solenoid then turn to TAG
315. rror requiring POR not used Figure 1 3 Sample Simplex Printer Error Log Printer and Troubleshooting Overview 1 17 Confirming Line Power Erratic printer problems can be caused by improper line power As a rule the voltage of the outlet should be checked at installation However if you are unable to isolate an inter mittent problem the power should be checked again Consult your country s national elec tric code for the proper procedures to check for acceptable voltages as shown in Table 1 3 Acceptable Voltages Table 1 3 Acceptable Voltages Probe connections 100 127v printer 200 240v printer red to AC hot black to AC neutral 120v 10 230v 10 red to AC neutral black to ground 3 vac or less 3 vac or less red to AC hot black to ground 120v 10 230v 10 Please see Chapter 5 Diagnostic Tests for additional information about running diag nostic printer tests Please see Chapter 6 Wiring Diagrams and Electrical Data for additional information about the printer s electrical systems Printer and Troubleshooting Overview Using the Troubleshooting Analysis Guide TAG The Troubleshooting Analysis Guide provides problem solving sequences to help you identify and resolve printer problems Each TAG addresses a particular symptom or error code of the printer The TAG number often matches an error code displayed on the prin
316. rtical Streaks 3 172 Error Code 808 Possible Causes Clogged cleaner Contaminated toner carrier mix Possible Defects Cleaner unit Photoconductor unit Main charger High voltage unit Power control 2 board PCL board Connectors or wiring Developer unit Overtoned print and dark print problems are very similar If this TAG does not resolve the problem go to TAG 811 Background Residual Images Dark Prints Turn the printer off and unplug the power cord e Verify that J P23 J P12 J P25 and J P41 are connected properly Perform the every call cleaning procedure described in Chapter 9 General Printer Mainte nance e Power on reset the printer Runtest prints Has the problem been resolved No Continue Yes Contamination or loose connectors were at fault Turn to TAG 002 Check amp Problem Resolution Check the voltages as outlined in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue Have the photoconductor unit main charger cleaner unit and developer unit with toner cartridge been replaced recently No Continue Yes Go to 7 in this TAG Replace the photoconductor unit and main charger Runtest prints Has the problem been resolved No Reinstall the original photoconductor unit and main charger then continue Yes Run at least 200 test prints to
317. ry into the fuser unit No Go to 17 in this TAG Yes Continue Remove the fuser unit e Check the fuser unit rollers for damage or toner contamination Are they damaged or contaminated with toner No Continue Yes Replace the fuser unit then turn to TAG 002 Check amp Problem Resolution Inspect the following for damage or binding e Fuser unit e Fuser drive belt e Fuser drive assembly Are any of these parts damaged No Go to 22 in this TAG Yes Replace the damaged parts then turn to TAG 002 Check amp Problem Resolution Turn the printer off Check for paper jams Inspect the exit roller and exit pinch roller assemblies for damage binding and contamination Are these parts in good working order No Repair or replace the defective parts then turn to TAG 002 Check amp Problem Resolu tion Yes Continue Run test prints e Check the leading edge of the prints for improper registration Is there improper registration No Continue Yes Go to TAG 807 Misregistered Skewed Prints Simplex or TAG 901 Misregistration Skewed Prints Duplex Inspect the vacuum transport unit for damage or binding Are the parts in good working order Repair or replace the vacuum transport unit then turn to TAG 002 Check amp Problem Resolu tion No Continue Yes Open the top cover and install an interlock by pass tool Troubleshooting Analysis Guide TAGs 3 37 3 38 20 21 22 Powe
318. s Cross reference tables which link error codes print quality problems and mechanical malfunctions to specific TAGs Print quality samples which you can use to identify a printing problem and its associ ated TAGs Diagnostics through which the printer checks itself for a range of problems The next several pages review troubleshooting basics and standard procedures followed in every troubleshooting session including Identifying whether a problem belongs to the printer or host e Isolating protocol converter problems Running test prints Reading the error log Confirming line power Using TAGs Power On Reset e Installing the interlock by pass tool Checking continuity Producing a developed image Producing a toner patch Completing a service call Clearing the error log General Troubleshooting Tips When a printer problem arises swapping out all printer supplies may temporarily mask the problem This is an unsatisfactory short term and expensive solution to correcting the problem Dust and other contamination rather than printer supplies are more often the causes of problems Clean consumable connectors alignment guides and areas before changing consumables Many failures add excess toner to the printer s engine When you are advised to de tone the printer as part of a problem fix run at least 200 test prints before evaluating whether the problem has been resolved Printer and Trouble
319. s Job Offset Assembly Removal Remove the DC power supply See page 7 31 Remove the mounting bracket for the DC power supply two screws Remove the fuser drive cover three screws Disconnect CN19 and CN54 o ON OD OC Remove the five screws holding the job offset assembly in place three front and two back 10 Remove the fuser drive cover mounting post 11 Remove the output option mounting pin single screw located on the front of the printer 12 Remove the job offset assembly Fuser Drive Cover Mounting Pin Fuser Drive Cover Mounting Post Bracket Mounting Screws Mounting Screws Right Side Detail Back Detail Removal Replacement Procedures 7 67 Exit Pinch Roller Removal Exit Pinch Roller Removal To remove the exit pinch roller Open the front back and top covers Remove the fuser Remove the operator panel See page 7 19 Remove the front screw holding the exit pinch roller in place a Q N Remove the front screw holding the exit guide in place Exit Pinch Roller Screw Exit Guide Screw Front Detail 7 68 Removal Replacement Procedures Exit Pinch Roller Removal 6 Remove the fuser drive cover three screws 7 Remove the back screw holding the exit pinch roller in place 8 Lift the exit pinch roller from the printer Note Use caution so as not to damage the paper full or exit sensors Fuser Drive Cover Back Detail Removal Replacement Procedures 7
320. s 201 interface adapter after PCL board sent data TAG Cross Reference Tables 2 5 Table 2 5 IGS Firmware Error Codes IGS Firmware Error Code Meaning ie nic Ei ene MT ar ee printer s manufacturer 301 Status received after VSS asserted No TAG 302 Status tag asserted after VSS not asserted No TAG 303 VSC command not asserted after command tag asserted No TAG 304 VSC command asserted after data was sent No TAG 305 VSC command not asserted for next data byte No TAG 306 Status tag asserted while data was being sent No TAG 307 Parity error on command line No TAG Table 2 6 PCL Failure Error Codes Code PCL Failure Error Code Meaning Go to TAG 380 PCL board failure command retries 201 381 PCL board failure command rejected 201 382 PCL board failure bad command received 201 383 PCL board failure unexpected byte received 201 384 PCL board failure no status received 201 385 PCL board failure bad status information block count 201 386 PCL board failure bad status information block offset 201 387 PCL board failure parity error 201 389 Floppy disk retry 130 Table 2 7 IGS Software Error Codes IGS Software Error Code Meaning These error codes signal a problem with the IGS controller Code software No TAGs address these problems to determine Go to TAG whether the faulty software is the customer s or the manufacturer s contact t
321. s at fault Turn to TAG 002 Check amp Problem Resolu tion Troubleshooting Analysis Guide TAGs 3 147 TAG 800 Prints Blank or With Dark Horizontal Bands 3 148 Error Code 800 Possible Defects Photoconductor unit Printhead assembly IGS board Main drive gear assembly Connectors or wiring Transfer charger High voltage unit Upper paper guide assembly Developer unit If there is a developed image on the paper other than dark horizontal bands follow TAG 804 Prints With Light Horizontal Bands Turn the printer off and unplug the power cord Verify that J P7 J P27 J P41 J P23 J P30 J P31 and transfer charger high voltage unit lead are connected properly Perform the every call cleaning procedure described in Chapter 9 General Printer Mainte nance e Run test prints Has the problem been resolved No Continue Yes Loose connectors or contamination were at fault Turn to TAG 002 Check amp Problem Resolution Check the voltages as outlined in Chapter 9 General Printer Maintenance Are the voltages correct No Replace the high voltage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue Have the photoconductor unit main charger developer unit and toner cartridge been replaced recently No Continue Yes Go to 6 in this TAG Replace the photoconductor unit and main charger Runtest prints Has the problem been resolved No Reinstall
322. s print observe paper moving from the upper paper tray to the paper timing roller where it pauses briefly When a sheet of paper begins to move from the paper timing roller turn off the printer Remove the photoconductor unit Examine the photoconductor belt to verify that a developed image was produced Producing a Toner Patch To produce a toner patch Turn off the printer Open the top cover and install an interlock by pass tool Turn on the printer A O N 2a Start running test prints using Simplex Print mode When the leading edge of the first print enters the fuser unit remove the interlock by pass tool 1 22 Printer and Troubleshooting Overview 5 Remove the photoconductor unit Toner patch Figure 1 4 Producing a Toner Patch on the Photoconductor Unit 6 Examine the photoconductor unit to verify that a toner patch has been produced You may have to rotate the belt slightly to observe the patch Caution Do not touch the surface of the photoconductor belt this damages the belt and results in poor print quality Completing a Service Call After resolving any printer problem complete the service call as follows Reassemble the printer Perform the every call cleaning procedure described in Chapter 9 General Printer Maintenance If you have removed the printer s diskette s reinstall them Power on reset the printer Clear the error log See the procedure described next o0 5
323. s there continuity No Repair or replace the wiring or connectors from P312 1 to P320 1 P312 2 to P320 2 or P312 3 to P320 3 then turn to TAG 002 Check amp Problem Resolution Yes Replace the side sensor If this resolves the problem turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace duplex control board 2 then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 195 10 11 12 13 3 196 Run diagnostic test 017 Did diagnostic test 017 indicate a duplex tray paper sensor problem No Continue Yes Go to 13 in this TAG Turn the printer off e Disconnect J P312 and J P321 Check P312 7 to J321 1 for continuity Is there continuity No Repair or replace the wiring or connectors from P312 7 to J321 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P312 8 to J321 2 for continuity Is there continuity No Repair or replace the wiring or connectors from P312 8 to J321 2 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P312 9 to J321 3 for continuity Is there continuity No Repair or replace the wiring or connectors from P312 9 to J321 3 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check P312 10 to J321 4 for continuity Is there continuity No Repair or replace the wiring or connectors from P312 10 to J321 4 then turn to TAG
324. screws 3 Remove the upper pick up roller drive three screws Note You may need to remove the EMI grounding plate Paper Feed Drive Cover Upper Pick up Roller Drive Detail Removal Replacement Procedures 7 63 Lower Pick Up Roller Removal Lower Pick Up Roller Removal To remove the lower pick up roller Open the front and back covers Remove the paper feed drive cover three screws Disconnect CN69 Remove the cassette release cover two screws Remove the front C clip and bearing oa 5 O N a Slide the lower pick up roller out the back of the printer Paper Feed Drive Cover Cassette Release Cover C Clip and Bearing Front Detail 7 64 Removal Replacement Procedures Lower Pick Up Roller Drive Removal Lower Pick Up Roller Drive Removal To remove the lower pick up roller drive 1 Open the back cover 2 Remove the paper feed drive cover three screws 3 Remove the lower pick up roller drive three screws Paper Feed Drive Cover Lower Pick up Roller Drive Detail Removal Replacement Procedures 7 65 Job Offset Assembly Removal Job Offset Assembly Removal To remove the job offset assembly Open the front top and back covers Remove the paper output tray Remove the right side cover See page 7 10 b amp b WO N 2 Remove the operator panel See page 7 19 Output Option Mounting Pin Mounting Screws Front Detail 7 66 Removal Replacement Procedure
325. sequence takes place Simplex Printing 1 PCL software downloaded to the PCL board from the disk drive system turns on the main motor The PCL board engages the paper pick clutch which causes the roller to feed a sheet of paper The paper is passed to the feed roller where the PCL board has engaged the feed roller clutch The feed roller passes the paper to the paper timing roller Prior to reaching the paper timing roller the paper passes over the paper timing sensor If the paper does not energize this sensor in a specified amount of time an error 020 021 will occur The leading edge of the paper is registered against the paper timing roller The paper tim ing clutch is engaged and the paper is passed over the photoconductor for transfer This registers the paper to the printer and the image to the paper The paper timing sensor signal also alerts the PCL to inform the IGS that it can begin to send the data The PCL board engages the paper timing roller clutch and at the same time turns on the transfer charger to provide a high positive voltage The developed image on the photoconductor comes in contact with the paper and the high positive voltage causes the image to transfer to the paper Because the toner is not yet fixed to the paper a vacuum transport assembly gripping the paper from the back side moves the paper to the fuser unit where heat and pres sure bond the toner to the paper Upon leaving the fuser unit the pa
326. serial controller transfer 200 544 PCL board serial controller transfer error 200 545 Host serial controller registers read write error 200 546 Host transmitter not ready 200 547 No serial controller interrupts 200 548 Host serial controller PCL board parity error 200 549 Serial controller unexpected interrupt 200 TAG Cross Reference Tables 2 7 Table 2 8 IGS Disk Drive Error Codes Continued Code Disk Drive Error Code Meaning Go to TAG 550 Two channel transfer error 200 551 No PCL board serial controller interrupt on break 200 552 No serial controller DMAC interaction 200 553 Serial controller DMAC transfer count error 200 554 Serial controller DMAC transfer error 200 555 RS232 send receive path error 200 556 RS232 DTR DTC path error 200 557 RS232 RTS CTS path error 200 558 RS422 send receive path error 200 559 RS422 send clock receive clock path error 200 560 CRTC register read write error 200 561 No page begin PIT2 interrupt 200 562 No CRTC address generation 200 563 No VSYNC generation end of page 200 564 No end of page PIT2 interrupt 200 565 No CRTC count termination 200 566 VSYNC timeout error 200 570 Drive controller SCSI read write error 200 571 Drive controller busy timeout 200 572 Diskette is write protected 130 573 Drive not ready 130 574 Drive controller restore error 130 575 Drive controller seek error
327. shooting Overview 1 15 The Problem Printer or Host The printer is one component in a large host system Before you start any troubleshooting make sure that the problem really belongs to the printer rather than to some other compo nent in the host system Print quality problems and mechanical malfunctions are almost always associated with the printer However host interface and software emulation prob lems can be caused by some other component of the host system even though at first Z glance they appear to be printer problems For instance text printed in the wrong location on a page improper page breaks and missing segments of data strongly indicate a host not a printer problem The first step in troubleshooting any problem is to isolate the printer from the host system you can then run test prints Producing test prints exercises the printer as a stand alone ones machine ensuring that the basic printer software and all mechanical functions of the printer are working Running Test Prints To run test prints 1 Disconnect the host interface 2 Runa series of test prints A directory of the boot device and multiple listings of fonts print followed by an unformatted and formatted error log A continuous flow of the test pattern then prints To run test prints For simplex printers press STOP TEST For duplex printers press STOP DUPLEX TEST o stop printing the test pattern press STOP On pressing STOP the printer
328. signal the output control board to turn the elevator OEM M2 on and raise the output tray guide As the output tray guide reaches its highest allowable position the paper tray full actu ator enables both photosensor OLLS and photosensor OULS which in turn signal the output control board to turn the elevator motor OEM M2 off Disconnect the power cord from the stacker then place a jumper from pin 3 to pin 6 and a second jumper from pin 2 to pin 7 Reconnect the power cord then from the printer side of the unit insert a folded piece of paper into the unit to trigger the actuator and enable photosensor OEPS This will signal the output control board to turn the jogging rear motor OJRM M3 on After jogging has occurred remove the piece of paper then reinsert it This will again trigger the acturator and enable photosensor OEPS This will signal the output control board to turn the jogging front motor OJFM MA on The procedure is completed Disconnect the power cord remove the jumpers then reinstall the unit into the printer Connector Locations Printer side CN416 Figure 8 7 Connector Locations front view cover removed Connectors circuit boards shown with broken lines are concealed from view Rear side Fuse 1 Fuse 2 Power supply CN409 CN426 a CN417 Frame ground e CN425
329. simplex and duplex printers have pressure tension levers inside the front cover as illustrated in Figure 9 1 Paper Feed Tension Levers below Lower paper tension lever Upper paper tension lever Figure 9 1 Paper Feed Tension Levers To adjust the tension 1 Open the printer s front cover Identify the cassette whose tension is to be adjusted and select the correct lever Adjust the tension To correct multiple feeds move the lever toward the minus sign decreasing the feed pressure To ease paper feeds move the lever toward the plus sign increasing the feed pres sure Close the front cover then print paper from the cassette you are adjusting If the paper is still not feeding properly repeat Steps 3 through 5 until the feed is prop erly adjusted 9 8 General Printer Maintenance Introduction Printers With Pick Pressure Adjusters Older simplex and duplex printers have two pick pressure adjusters inside the front cover behind the cassette release cover illustrated below To adjust pick pressure in these print ers 1 Open the printer s front cover 2 Remove the cassette release cover by loosening its two screws and lifting The release cover is illustrated in Figure 9 2 Removing the Cassette Release Cover below Figure 9 2 Removing the Cassette Release Cover General Printer Maintenance 9 9 Introduction 9 10 This reveals the pick pressure adjusters illustrated in Figure 9 3 Paper Pick Pre
330. size sensing mechanism in good working order No Replace the defective cassette then turn to TAG 002 Check amp Problem Resolution Yes Continue Inspect the upper and lower paper size sensor assemblies Is either paper size sensor assembly damaged or improperly mounted No Continue Yes Remount repair or replace the faulty paper size sensor assembly then turn to TAG 002 Check amp Problem Resolution Remove the upper paper size sensor assembly e Disconnect the upper circuit board from its mounting Inspect the paper size sensor circuit board and mounting for damage or contamination Is the circuit board or mounting damaged or contaminated No Continue Yes Repair or replace the upper paper size sensor assembly then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 5 Remove the lower paper size sensor assembly e Disconnect the circuit board from its mounting Inspect the paper size sensor circuit board and mounting for contamination or damage Is the circuit board or mounting contaminated or damaged No Continue Yes Repair or replace the lower paper size sensor assembly then turn to TAG 002 Check amp Problem Resolution 6 Is the paper size sensing problem occurring with the upper cassette No Go to 8 in this TAG Yes Continue 7 Turn the printer off and unplug the power cord e Disconnect J P40 and J P45 Refer to the tables at the end of this TAG
331. solu tion Yes Repair or replace the connectors or wiring from P312 1 to P320 1 or P312 4 to P322 1 then turn to TAG 002 Check amp Problem Resolution 44 Turn off the printer e Reconnect J P320 e Turn on the printer e Check J P330 2 for 12 Vdc Is the voltage 12 Vdc No Replace the restart side sensor then turn to TAG 002 Check amp Problem Resolution Yes Replace the restart paper sensor then turn to TAG 002 Check amp Problem Resolution 45 Turn off the printer e Reconnect J P306 e Disconnect J P319 and J P318 Turn on the printer Check J P330 2 for 12 Vdc Is the voltage 12 Vdc No Go to 47 in this TAG Yes Continue 46 Turn off the printer e Reconnect J P319 Turn on the printer e Check J P330 2 for 12 Vdc Is the voltage at 12 Vdc No Replace the paper path sensor then turn to TAG 002 Check amp Problem Resolution Yes Replace the cover open sensor then turn to TAG 002 Check amp Problem Resolution 3 88 Troubleshooting Analysis Guide TAGs 47 Turn off the printer and unplug the power cord e Disconnect J P309 e Check for continuity to ground P309 4 to P319 1 and P309 3 to P318 1 Is there continuity at either No Replace duplex control board 1 then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P309 4 to P319 1 or P309 3 to P318 1 then turn to TAG 002 Check amp Problem Resolution Troubleshooti
332. specific error conditions Table 5 15 Duplex Motor Feed Test Error Displays Display 069 Indication Duplex is not installed 090 Cover is open Close cover 5 Press STOP to exit 5 14 Diagnostic Tests 014 intentionally excluded 017 Duplex Input Sensor Test Sequence 1 2 Go to 017 Press READY to run the test The code for the first sensor i e O 0 or 0 1 appears on the display confirming that the sensor is working properly Note No paper moves through the machine so indications of No paper at sensor location are normal Press READY to advance to the next sensor The display changes showing the code for the next sensor as outlined in the chart below Table 5 16 Duplex Input Sensor Test Displays Sensor Description Display Paper sensor 0 0 No paper 0 1 Paper at sensor Cover sensor 1 0 Cover closed 1 1 Cover open Duplex tray sensor 2 0 No paper 2 1 Paper at sensor To check a specific sensor press READY repeatedly until the code on the display cor responds to the sensor you want to check then manually activate the sensor Confirm that the display changes when you activate the sensor These codes may indicate specific error conditions Table 5 17 Duplex Input Sensor Test Error Displays Display Indication 069 Duplex tray not installed 090 Cover is open Close cover 5 Press STOP to exit Diagnostic Tests
333. ssure Adjusters below Figure 9 3 Paper Pick Pressure Adjusters 3 To adjust paper pick tension for the upper cassette identify the adjuster corresponding to that cassette then To decrease the pressure correcting multiple feeds loosen the screws pivot the adjuster up and tighten the screws To increase the pressure easing the paper feed loosen the screws pivot the adjuster down and tighten the screws To adjust paper pick tension for the lower cassette identify the adjuster corresponding to that cassette then To decrease the pressure correcting multiple feeds loosen the screws pivot the adjuster down and tighten the screws To increase the pressure easing the paper feed loosen the screws pivot the adjuster up and tighten the screws Test the adjustments by closing the front cover and sending paper through the printer You may need to adjust the lever several times repeating Steps 3 or 4 and 5 before the pressure is set properly When the tension is set properly reinstall the cassette release cover and close the printer s front cover General Printer Maintenance Introduction Lubrication Procedure Complete the lubrication procedure as needed Apply lubrication sparingly Insufficient lubrication may result in unnecessary noise and premature wear of components excessive lubrication may contaminate printer supplies and make the printer difficult to keep clean The following printer ill
334. start over Press CANCEL to clear the error log 6 1 appears on the display Press STOP to exit the procedure 9 Cycle printer power to exit diagnostic mode 10 Confirm that the error log has been cleared When you run your test prints check to make sure the error log entries appear as 0000 1 24 Printer and Troubleshooting Overview Chapter 2 TAG Cross Reference Tables TAG Cross Reference Tables 2 1 TAG Cross Reference Tables TAG Cross Reference Tables This section contains the three cross reference charts for troubleshooting print problems Error Code TAG Cross Reference Chart 0 00000 cece eee eee eens 2 3 Print Quality TAG Cross Reference Chart 0 0 0c ee eee eee eee 2 9 Mechanical Malfunction TAG Cross Reference Chart 00 2 12 2 2 TAG Cross Reference Tables Error Code TAG Cross Reference Error Code TAG Cross Reference Error codes which appear on the 3 digit display of the operator s panel indicate a wide variety of printer problems related to the control boards software and or host communi cation problems On the chart find the error code in question then turn to TAG associated with the code Table 2 1 Printer Error Codes Code Printer Error Code Meaning Go to TAG 010 Upper paper tray out of paper 010 011 Lower paper tray out of paper 011 E10 E
335. sting 5 12 error code TAG cross reference 2 3 error codes 1 7 bit map RAM 2 9 host communication 2 9 IGS firmware 2 6 IGS software 2 6 IGS disk drive 2 7 PCL 2 4 PCL failure 2 6 PCL IGS communication 2 4 2 5 printer 2 3 error log 1 17 clearing 1 24 5 24 every call cleaning procedure 9 6 exit cover removal 7 74 7 76 exit pinch roller removal 7 68 exit roller assembly removal 7 72 F fans removing cooling 7 26 removing duplex 7 27 front cover connectors 6 6 removal 7 5 front cover interlock switch removal 7 80 front duplex cover removal 7 18 fuser drive removal 7 57 fuser drive belt removal 7 56 fuser unit high temperature problems 3 73 malfuctions 3 67 thermistor malfunctions 3 72 G ground system 6 21 guides problems with upper paper 3 139 removing lower paper 7 51 removing paper timing 7 52 removing upper paper 7 48 H high voltage unit removal 7 32 IGS board 1 3 bit map RAM malfunction 3 112 communication malfunctions 3 108 malfunctions 3 103 removal 7 21 IGS to PCL interface malfunctions 3 110 input feeder testing 5 19 input sheet feeder 8 4 input tray paper size detection malfunctions 3 132 interfaces 6 22 Centronics parallel 6 27 RS 232C 6 22 RS 422 6 26 interlock by pass tool 1 22 interlock switches Index 3 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
336. tage power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Continue Have the photoconductor unit main charger fuser unit cleaner unit and developer unit with new toner cartridge been replaced recently No Continue Yes Go to 8 in this TAG Replace the photoconductor unit and main charger Runtest prints Has the problem been resolved No Reinstall the original photoconductor unit and main charger and continue Yes Turn to TAG 002 Check amp Problem Resolution Replace the cleaner unit Runtest prints Has the problem been resolved No Reinstall the original cleaner unit and continue Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 6 Replace the fuser unit e Run test prints Has the problem been resolved No Reinstall the original fuser unit and continue Yes Turn to TAG 002 Check amp Problem Resolution 7 Replace the developer unit and toner cartridge e Run test prints Has the problem been resolved No Reinstall the original developer unit and continue Yes Turn to TAG 002 Check amp Problem Resolution If this problem recurs the toner carrier mix may be old or contaminated 8 Inspect the paper being used for scratches or dark spots Does the paper have any problems No Continue Yes Replace the paper Turn to TAG 002 Check amp Problem Resolution 9 Inspect the following for damage or binding Main drive
337. te the sensor Confirm that the display changes when you activate the sensor 5 Press STOP to exit 5 18 Diagnostic Tests 023 100 intentionally excluded 021 High Capacity Input Unit Test 1 2 3 Go to 021 Press READY to run the test The display registers the paper size installed in the unit as outlined on the chart 1 0 will appear on the display if a high capacity input unit is not installed Verify the correct paper size as follows Table 5 22 High Capacity Input Unit Test Displays 4 Display Indication 1 1 A4 size paper in use 1 3 Letter size paper in use Press STOP to exit 022 Envelope Fuser Solenoid Test 1 6 Remove the photoconductor unit and place it in its protective packaging Go to 022 Press READY to run the test The main motor turns on and 0 appears on the dis play Press READY again to activate the envelope fuser solenoid Listen for a clicking sound and confirm that the display alternates between 0 and when the solenoid is activated If you hear no clicking either the machine does not have an envelope fuser installed or the solenoid is not working properly Check for the following conditions Table 5 23 Envelope Fuser Solenoid Test Displays 7 Display Indication 4 1 You forgot to remove the photoconductor unit 090 Cover is open Close cover Press STOP to exit 023 100 intentionally excluded Diagnostic Tests
338. ter s operator panel Sample TAG TAG 001 Troubleshooting a Problem Error Code All related error messages are listed here Possible Causes All possible causes are listed here Possible Defects All possible defective parts are listed here In no particular order 1 To start Disconnect all peripheral cables Power on reset the printer Did all of the status lights come on followed by 888 flashing briefly and an error code Yes Run test prints following the procedure outlined in Section 1 then repeat this step If the answer is still no refer to the mechanical malfunctions cross reference chart in Section 2 to determine which TAG to follow Then turn to that TAG Yes Note the error message and continue 2 Power on reset the printer Did the power on reset end with an error code No Continue Yes Refer to the error code cross reference table in Section 2 using either the code that dis played after steps 1 and 2 or if multiple error codes continue to appear the first error code that displays Turn to the TAG associated with the code 3 Did only the READY light come on with no numeric display No Continue Yes Go to TAG 753 Each TAG walks through a comprehensive procedure specific to a single problem As you progress through a TAG and eliminate possible causes you may be directed to another step out of sequence in the same TAG or to another TAG altogether The TAG number and its title may be fo
339. test 103 Did the diagnostic test run properly No Continue Yes The signal interface board was at fault Turn to TAG 002 Check amp Problem Resolution Open the back cover and install an interlock by pass tool e Power on reset the printer Check J P32 10 for 12 Vdc Is the voltage 12 Vdc No Repair or replace the connectors or wiring from P8 6 to P32 10 then turn to TAG 002 Check amp Problem Resolution Yes Continue Check J P32 3 for 12 Vdc Is the voltage 12 Vdc No Continue Yes Replace the signal interface board then turn to TAG 002 Check amp Problem Resolution If this does not resolve the problem replace the IGS board then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 9 Check J P8 8 for 12 Vdc Is the voltage 12 Vdc No Replace the DC power supply unit then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace connectors or wiring from P8 8 to P32 3 then turn to TAG 002 Check amp Problem Resolution 10 Does the problem appear while using RS 232C communications No The problem may be caused by the IGS board signal interface board host computer or host interface cable Determine which of these are at fault correct the problem then turn to TAG 002 Check amp Problem Resolution Yes Continue 11 Turn the printer off and unplug the power cord Install a breakout box on the printer to confirm that the host inte
340. that the top and front covers are closing completely e Power on reset the printer Is error code 090 displayed No Loose connectors or obstructions were at fault Turn to TAG 002 Check amp Problem Res olution Yes Continue Open the printer s top cover and insert the interlock by pass tool e Turn on the printer Check J P309 3 on duplex control board 1 for 12 Vdc Is the voltage 12 Vdc No Replace the duplex control board 1 then turn to TAG 002 Check amp Problem Resolu tion Yes Continue Check J P309 1 on duplex control board 1 for 12 Vdc Is the voltage 12 Vdc No Continue Yes Go to 5 in this TAG Turn the printer off and unplug the power cord e Disconnect J P318 and J P309 Check the following for continuity P309 1 to P318 2 P309 3 to P318 1 and P309 5 to P318 3 Is there continuity No Repair or replace the wiring or connectors from P309 1 to P318 2 P309 3 to P318 1 or P309 5 to P318 3 then turn to TAG 002 Check amp Problem Resolution Yes Replace the cover open sensor then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 5 Turn on the printer Check J P36 1 on the PCL board for 12 Vdc Is the voltage 12 Vdc No Replace the duplex control board 1 then turn to TAG 002 Check amp Problem Resolu tion Yes Replace the PCL board then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis
341. then turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 13 14 15 16 17 Check P41 6 to P42 15 for continuity to ground Is there continuity No Replace the operator panel If this resolves the problem turn to TAG 002 Check amp Prob lem Resolution If this does not resolve the problem replace the PCL board then turn to TAG 002 Check amp Problem Resolution Yes Repair or replace the connectors or wiring from P42 15 to J P90 15 toP41 6 then turn to TAG 002 Check amp Problem Resolution Turn the printer off and unplug the power cord e Disconnect J P41 and J P42 Check P41 18 to P42 3 for continuity to ground Is there continuity No Continue Yes Repair or replace the connectors or wiring from P41 18 to J P90 3 to P42 3 then turn to TAG 002 Check amp Problem Resolution Check P41 18 to P42 3 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 18 to J P90 3 to P42 3 then turn to TAG 002 Check amp Problem Resolution Yes Replace the operator panel If this resolves the problem turn to TAG 002 Check amp Prob lem Resolution If this does not resolve the problem replace the PCL board then turn to TAG 002 Check amp Problem Resolution Run diagnostic test 001 Note which status lights come on and what is displayed each time the tone sounds Some of the status lights may be very dim
342. then turn to TAG 002 Check amp Problem Resolution Turn the printer off and unplug the power cord e Disconnect J P41 and J P24 Check P41 30 for continuity to ground Is there continuity No Continue Yes Repair or replace the connectors or wiring from P41 30 to P24 2 then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 15 16 17 18 19 Reconnect J P24 e Disconnect J P23 Check P41 38 to P23 2 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 38 to P23 2 then turn to TAG 002 Check amp Problem Resolution Yes Continue Remove the developer unit Check P85 8 to J25 7 for continuity Is there continuity No Repair or replace the connectors or wiring from P85 8 to J25 7 then turn to TAG 002 Check amp Problem Resolution Yes Continue Is a meter with a high voltage probe available No Goto 19 in this TAG Yes Continue Reinstall the developer unit e Reconnect J P85 Runtest prints e Using a high voltage probe check J P25 7 for the proper voltage as outlined in Chapter 9 General Printer Maintenance Is the voltage correct No Replace the high voltage unit then turn to TAG 002 Check amp Problem Resolution Yes Go to 20 in this TAG Reconnect J P85 Reinstall the developer unit Replace the high voltage unit Runtest prints Has the problem been resolved No
343. this does not resolve the problem replace the PCL board Then turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 25 3 26 TAG 020 Paper Jam Misfeed in Upper Cassette Area Error Code 020 Possible Causes Paper incorrectly loaded Wrong weight or type of paper loaded Paper path obstructed Possible Defects Upper pick up roller assembly Upper feed roller assembly Upper pick up roller drive assembly Upper paper guide assembly Lower paper guide assembly Upper paper cassette Pick pressure adjustment Main drive gear assembly Paper feed drive belt Paper feed drive idler assembly Paper timing sensor Wiring or connectors PCL board 1 Check both paper paths and remove any paper jams Make sure paper is loaded properly in both cassettes Make sure the paper guides are positioned properly Make sure the upper pick up roller feed roller and pinch roller assemblies are clean Verify that J P40 J P60 J P66 and J P68 are connected properly Confirm that the paper in the cassettes meets paper specifications described in the Guide to Operations manual Power on reset the printer Run test prints from the upper cassette Is error code 020 still displayed No Go to 14 in this TAG Yes Continue Turn the printer off and inspect the following for damage or binding Upper paper guide assembly Lower paper guide assembly Paper feed drive belt Paper feed drive pulley Paper feed dr
344. to print a mechanical binding malfunction may be at fault 1 Inspect both paper cassettes for damage Make sure the paper in the cassettes is loaded properly Make sure the side and rear paper guides are positioned properly Inspect both paper paths for contamination and remove any obstructions Confirm that the paper in the cassettes meets paper specifications outlined in the Guide to Operations at the back of this manual Power on reset the printer Remove and insert the cassette causing the problem Confirm that the code which displays on the operator s panel corresponds to the paper size in the cassette The codes and the paper sizes to which they correspond are listed in the Guide to Operations Refer to TAG 702 Paper Size Detection Malfunction Run test prints from the upper cassette Is the problem with the upper cassette No Go to 5 in this TAG Yes Continue 3 168 Troubleshooting Analysis Guide TAGs 2 Remove the upper cassette e Power on reset the printer e Run test prints from the lower cassette Is the problem also with the lower cassette No Go to 4 in this TAG Yes Continue 3 Turn the printer off and unplug the power cord Inspect the following for damage or contamination e Paper timing roller assembly e Upper paper guide assembly Lower paper guide assembly e Paper timing guide assembly e Paper feed drive belt e Paper feed idler assembly Main drive gear assembly Are these par
345. tor s location in the printer and on the simplex and duplex schematics which are found in this chapter Note Connectors are referred to by J P jack plug numbers throughout this manual Use the J P number when looking up the connector in the index schematics and illustration Complete connection diagram showing plugs connectors and wiring Connector locations and illustrations Voltage isolation diagrams e Host interface signal definitions and DIP switch settings Wiring Diagrams and Electrical Data 6 3 Connector J P Index Connector Page Schematic Connector Page schematic Location Location J P 2 6 12 simplex duplex F4 J P 44 6 13 simplex duplex E5 J P 3 6 12 simplex duplex F4 J P 45 6 7 simplex duplex C10 J P 4 6 12 simplex duplex EG J P 46 6 7 simplex duplex C9 J P 5 6 10 simplex duplex E5 J P 47 6 7 simplex duplex D10 J P 6 6 12 simplex duplex E7 J P 48 6 7 simplex duplex C10 J P 7 6 12 simplex duplex D8 J P 49 6 9 simplex duplex E9 J P 8 6 12 simplex duplex D7 J P 50 6 13 simplex duplex E9 J P 9 6 12 simplex duplex C4 J P 51 6 9 simplex duplex E9 J P 10 6 12 simplex duplex C4 J P 52 6 13 simplex duplex D9 J P 11 6 12 simplex duplex B4 J P 53 6 9 simplex duplex D10 J P 12 6 12 simplex duplex B4 J P 54 6 9 simplex duplex E10 J P 13 6 12 simplex duplex B3
346. tor unit developer unit and fuser unit been replaced recently No Continue Yes Refer to the Chapter 4 Print Quality Samples Compare the test prints with the print samples and identify a sample having the same print flaw as the test prints turn to the TAG listed under the sample 4 Replace the photoconductor unit and main charger e Run test prints Has the problem been resolved No Reinstall the original photoconductor unit and main charger and continue Yes Turn to TAG 002 Check amp Problem Resolution 5 Replace the developer unit and toner cartridge e Run test prints Has the problem been resolved No Reinstall the original developer unit and continue Yes Turn to TAG 002 Check amp Problem Resolution 3 158 Troubleshooting Analysis Guide TAGs 6 Replace the fuser unit e Run test prints 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 print samples and identify a sample having the same print flaw as the test prints turn to the TAG listed under the sample Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 159 TAG 803 Prints With Light or White Vertical Streaks Error Code 803 Possible Defects Transfer charger unit Printhead assembly unit Photoconductor unit Developer unit 1 Turn off the printer and unplug the power cord e Verify th
347. transfer charger housing with a soft cloth Clean the transfer charger wire with a cotton swab Reinstall the transfer charger Have you completed the every call cleaning procedure No Complete the procedure then continue Yes Continue Troubleshooting Analysis Guide TAGs 3 9 Run test prints to confirm print quality in both simplex and duplex modes and from upper and lower paper cassettes When you enter test print mode by pressing the keys listed below the follow ing items print in the order listed a directory of the boot device and multiple listings of fonts a for matted and unformatted error log a continuous flow of test prints 1 Power on reset the printer 2 Run test prints e For simplex printers press STOP TEST For duplex printers press STOP DUPLEX TEST 3 Stop printing the pattern by pressing STOP On pressing STOP the printer will stop generating test prints The printer will print all test prints stored in the printer s buffer then stop Are the test prints clean and printing correctly No Go to Chapter 4 Print Quality Samples identify a sample with the problem you see in the test print then turn to the TAG indicated Yes Continue Clear the error log Caution With this procedure you can either clear the error log or format a disk Pay careful attention to the options you select 1 Enter the diagnostic mode of the printer e Turn off the printer and wait 5 seco
348. ts clean and in good working order No Repair or replace the parts as needed then turn to TAG 002 Check amp Problem Resolu tion Yes Go to 7 in this TAG 4 Inspect the following for damage and contamination e Upper pick up roller assembly e Upper feed roller assembly Upper pinch rollers e Upper cassette Are these parts clean and in good working order No Repair or replace the parts as needed then turn to TAG 002 Check amp Problem Resolu tion Yes You have not isolated the problem Return to the beginning of this TAG 5 Remove the upper cassette e Power on reset the printer e Run test prints from the lower cassette Is the problem with the lower cassette No Incorrectly loaded paper was at fault Turn to TAG 002 Check amp Problem Resolution Yes Continue Troubleshooting Analysis Guide TAGs 3 169 6 Inspect the following for damage or contamination Lower pick up roller assembly Lower feed roller assembly Lower pinch rollers Lower cassette Are these parts clean and in good working order No Repair or replace the parts as needed then turn to TAG 002 Check amp Problem Resolu tion Yes You have not isolated the problem Return to the beginning of this TAG 7 Is misregistration the symptom of the problem No Skew problems can only result from mechanical causes Return to the beginning of this TAG Yes Continue 8 Run test prints Is the amount of misregistration with
349. uction C Roller assembly paper timing Roller assembly exit Exit pinch roller Roller assembly upper paper guide Roller assembly upper pick P Transfer Charger Label taped to inside top of package Figure 9 8 Tune Up Kit Components 7 Replace the component assemblies in this order Paper timing roller Exit roller Upper pick up roller Lower pick up roller Upper feed roller Lower feed roller Transfer charger Lower static brush Upper static brush Upper paper guide roller 8 Perform the every call cleaning procedure on page 7 6 9 Plugin the printer and turn it on 10 Run test prints to ensure that the paper feeds correctly through the printer 11 Fill in the label with the date and meter count Affix it inside the front cover next to the printer s serial number General Printer Maintenance 9 19 Introduction 9 20 General Printer Maintenance Appendix A Abbreviations and Acronyms ACIA Asynchronous Communication Interface Adapter ALU Arithmetic Logic Unit APA All Points Addressable ARC A Roller Clutch Duplex only ARIF Array Interface AVC va Auto Toner Control CLEANER Cleaner Unit CN od e X on Counter COOLING FA2 Cooling Fan COS ees Cover Open Sensor Duplex only CRS 2v C Roller Solenoid Duplex only CRE ee Cathode Ray Tube CERTO nc CRT Controller CRU vue Customer Replaceable Unit DB ee Developer Bias Neg
350. ue Yes Go to 13 in this TAG Turn off the printer e Disconnect J P308 Turn on the printer Check J308 1 and J308 5 for 24 Vdc Is the voltage 24 Vdc No Replace duplex control board 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue Disconnect J P314 e Check for continuity P308 1 to J314 1 P308 5 to J314 2 Is there continuity No Repair or replace the wiring or connectors from P308 1 to J314 1 or P308 5 to J314 2 then turn to TAG 002 Check amp Problem Resolution Yes Replace the input solenoid then turn to TAG 002 Check amp Problem Resolution Turn the printer on e Run diagnostic test 018 Is the C roller solenoid in good working order No Continue Yes Go to 16 in this TAG Turn off the printer e Disconnect J P308 Turn on the printer Check J308 2 and J308 6 for 24 Vdc Is the voltage 24 Vdc No Replace duplex control board 1 then turn to TAG 002 Check amp Problem Resolution Yes Continue Disconnect J P315 e Check the following for continuity P308 2 to P315 1 and Troubleshooting Analysis Guide TAGs 16 17 18 19 20 P308 6 to P315 2 Is there continuity No Repair or replace the wiring or connectors from P308 2 to P315 1 or P308 6 to P315 2 then turn to TAG 002 Check amp Problem Resolution Yes Replace the C roller solenoid then turn to TAG 002 Check amp Problem Resolution Turn the printer
351. un test prints Has the problem been resolved No Reinstall the original cleaner unit and continue Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 189 10 11 12 3 190 Replace the developer unit and toner cartridge e Run test prints Has the problem been resolved No Reinstall the original developer unit and continue Yes Turn to TAG 002 Check amp Problem Resolution Replace the photoconductor unit and main charger e Run test prints Has the problem been resolved No Reinstall the original photoconductor unit and main charger then continue Yes Turn to TAG 002 Check amp Problem Resolution If the problem recurs the toner may be old or contaminated Turn the printer off and unplug the power cord e Disconnect J P40 and J P24 Check P40 40 to P24 3 for continuity Is there continuity No Repair or replace the connector or wiring from P40 40 to P24 3 then turn to TAG 002 Check amp Problem Resolution Yes Continue Is a meter with a high voltage probe available No Go to 11 in this TAG Yes Continue Check the main charger transfer charger grid and cleaning bias described in Chapter 9 General Printer Maintenance Are any of the values out of specification No Goto 12 in this TAG Yes Replace the high voltage unit then turn to TAG 002 Check amp Problem Resolution Replace the high voltage unit Has the problem been reso
352. unit then turn to TAG 002 Check amp Problem Resolution Yes Continue Has the photoconductor unit main charger developer unit and cleaner unit been replaced recently No Continue Yes Go to 6 in this TAG Replace the photoconductor unit and main charger Turn the printer on e Run test prints Has the problem been resolved No Reinstall the original photoconductor unit and main charger then continue Yes Turn to TAG 002 Check amp Problem Resolution Troubleshooting Analysis Guide TAGs 3 163 5 Replace the developer unit toner cartridge and cleaner unit Turn the printer on e Run test prints Has the problem been resolved No Reinstall the original developer unit and cleaner unit then continue Yes Turn to TAG 002 Check amp Problem Resolution If the problem recurs the toner carrier mix may be old or contaminated 6 Turn the printer off and unplug the power cord Disconnect J PA1 J P23 and J P24 Check P41 33 to P23 7 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 33 to P23 7 then turn to TAG 002 Check amp Problem Resolution Yes Continue 7 Check P41 30 to P24 4 for continuity Is there continuity No Repair or replace the connectors or wiring from P41 30 to P24 4 Yes Continue 8 Replace the main charger terminal assembly e Run test prints Has the problem been resolved No Continue Yes Turn to TAG 002 Check
353. unit was lower than the specified limit Printer and Troubleshooting Overview Table 1 1 Error Code Technical Definitions Continued Type Error Description Jogger Errors 081 PCL board activated the jogging motor but did not detect a change in the signal from the front sensor in the job offset assembly diag nostic test only 082 PCL board activated the jogging motor but did not detect a change in the signal from the rear sensor in the job offset assembly diag nostic test only 083 PCL board activated the jogging motor but did not detect a change in the signal from either the front or rear sensors in the job offset assembly 084 PCL board detected a signal from the duplex control board 2 indi cating that the registration side sensor did not activate after com mand was sent to the duplex control board 2 to turn on the resist motor diagnostic test only 085 PCL board detected a signal from the duplex control board 2 indi cating that the registration side sensor did not deactivate after a command was sent to the duplex control board 2 to turn on the resist motor diagnostic test only 086 PCL board detected a signal from the duplex control board 2 indi cating that either the registration side sensor was activated and would not deactivate or was deactivated and would not activate after a command was sent to the duplex control board 2 to turn on the resist motor
354. uplex Area 3 198 Print Quality Samples Contents crestea Eee Sache Saree ep Seb x iae ED een AA a Dedi ae base 4 2 Print Quality Samples eeen aa usce e 2 fe fs oe A CU AO 4 3 Sample 1 Good Quality Print oou ke Hee ed fs es a ae 4 4 Sample 2 Washout teser bod rep REPERSE SACRE VRERE yaad RIA s 4 5 sample 3 Blank Print 3 2idusi tcn e REEL RR as idea nenebaewndb can 4 6 Sample 4 Light Pris oos poA ees ONEVE Re Oe eae oe ewes 4 7 Sample 5 Light Print With Background 0 0 0 c ee eee eee 4 8 Sample 6 Voids or While Spots 62 60 06 ead ees ee ko E SY wed ae a 4 9 Sample 7 Light Vertical Streaks 2 59 5 gh SSH Hep e ea 4 10 Sample 8 Blank Vertical Bands 0 0 0 cee eee eee eee 4 11 Sample 9 Light Horizontal Bands 0 0 0 0 eee ee eee eee 4 12 Sample 10 Black or Dark Print 2 2 0 ee ee eee eee 4 13 Sample 11 Dark Specks Lines or Areas lees 4 14 sample 12 Dark Vertical Lines 0 esc oo iow hA REIS US TEES 4 15 sample 13 Skewed Prints sdci oid cave RI SURE ene REX CIE AIRE ERE 4 16 Sample 14 Misregistration veuve d ewe ee ECCO A PY IE RUE RS RE 4 17 sample 15 Overtoned Print o dissi pu lex PEE RE Rey 4 18 Sample 16 Blurred Images or Characters 0 0 0 eee eee eee ee 4 19 Sample 17 Varying Print Density 25d ee ee ee eee ERAS 4 20 Sample 18 BackbPrOund e esc tioi Shee Meh RR hei wale SOA RE ae Soe 4 21 Sample 19 Residual Iniages vx aie ad n bua ERA ee wees 4 22
355. ustrations indicate where lubrication may be required Charts fol lowing the illustrations include symbols that indicate the type of lubricant to use on each component v Oil Molycote B Red grease General Printer Maintenance 9 11 Introduction vo rd S N o zm e uA N a Hed et AA GS I i n ST ees ja E i A IR REVEO KOA MEZ LING ING y NN N NN h eS 4 n N ON AVA A A d eA i OE YA A OM SF y Y ce X S Ai n f 73 N as S es Figure 9 4 Front View Lubrication Points General Printer Maintenance 9 12 Front View Lubrication Tables Table 9 1 All Printers Front View Lubrication Introduction Symbol Part Lubricant vi Front roller bearings paper feed paper pickup timing oil and exit rollers v2 Vacuum transport drive shaft oil v3 Fuser drive bearing oil v4 Upper paper guide roller oil m5 Fuser drive gear red grease m6 Vacuum transport drive gear red grease n7 Vacuum transport gear red grease e 8 Vacuum transport rollers Molycote Duplex Only Table 9 2 Duplex Front View Lubrication Symbol Part Lubricant v9 Duplex roller bearings oil e 10 Lower duplex drive assembly Molycote General Printer Maintenance 9 13 Introduction Figure 9 5 Rear View Lubrication 9 14 General Printer Maintenance Rear View Lubrication Tables Table 9 3 All Pri
356. uvwxyzii r4 as Wrinkled t paper FITT AG 4 nna fn T ES LETTER IT44XF C 0123456789 c 512 ES IV TT ABCDERHIJKLMNOPQRSTUVWXYZIN abcdevhiiklmnoparstuvwxyz j T 1 95Xf C4 01234656789 5 c3 a Mia ABCDEEHTUKLMNOPQRSTUVWXY I El abcdethiklanoparstuvwydfzti t TX ai TT TT ga i Re oe odanog inj oogonia i Figure 4 20 Wrinkles Description Wrinkles or creases often at the top or bottom Go to TAG 706 Paper Damaged or Wrinkled Print Quality Samples 4 23 Sample 21 Fusing Problems S TIT ee tc ce de ae T jh t depre 1 B eit 3925 lt gt 7O Ese ay on es WWXYZEIN T T 22 oe70513e Wecocsru v wxyz 17 f 2 3 288556789 475 0 SCJKLNNCP eSTUVNXYZEIN IT 5 vay 17 Kine lu genit uli s RRA AE OAS AAAAAIAINAARAS AL 5 fonipurfonfnlhoaupuunpnon pu opo jpufnjius prj anf l amma dien enun nnd Figure 4 21 Fusing Problems Description Images or characters may rub off the surface Go to TAG 812 Uneven or No Fusing on Prints 4 24 Print Quality Samples Chapter 5 Diagnostic Tests Contents How to Run Diagnostics es ceense dore eee ene eens 5 3 001 Operator Panel Test 12d eere ee Ree eee Re em Seba ee 5 4 002 Upper Cassette Test lleseeeeeee III 5 4 003 Lower Cassette Test eseeeeeeeee eect e eens 5 5 005 Sensor Test Sequence sess rerien ser eiii iei Ea e eene 5 6 006 Paper
357. ven after completing regular maintenance pro cedures and has printed more than one or two million prints At this point in the life of the printer the roller assemblies transfer charger and static brushes must be replaced All of the required components are packaged together in a Tune Up Maintenance Kit 1 For detailed instructions on how to replace each of these components refer to Chapter 7 Removal Replacement Procedures General guidelines follow for unpacking the component along with an outline of the order in which the components should be replaced 2 Unpack the maintenance kit which is shipped in a folded cardboard pack Remove the shipping carton and unfold the cardboard pack 3 Make sure that you have received all of these replacement components shown in Fig ure 9 8 Tune Up Kit Components on page 9 19 Roller assembly lower feed Roller assembly upper feed Roller assembly paper timing Roller assembly exit Roller assembly upper paper guide Transfer charger Roller assembly upper pick up Roller assembly lower pick up Static brush upper in cardboard folder Static brush lower in cardboard folder abel taped to the top of the package Unplug the printer Open the top cover Remove the photoconductor unit Place the unit in its protective packaging in a safe place away from the work area 9 18 General Printer Maintenance In cardboard folder Lower static brush Introd
358. w Detail 7 44 Removal Replacement Procedures Lower Cassette Mount Removal Lower Cassette Mount Removal To remove the lower cassette mount Open the front back and top covers Duplex only Remove the duplex tray Remove the upper and lower paper cassettes Remove the left side cover See page 7 8 Remove the paper feed drive cover three screws Remove the power control board cover one screw Remove the power control board See page 7 38 ON Oat WD a From the back remove the two screws holding the lower cassette mount in place Power Control Board Cover Mounting Screws Paper Feed Drive Cover Power Control Board Back Detail Removal Replacement Procedures 7 45 Lower Cassette Mount Removal 9 Remove the lower paper size sensor See page 7 40 10 Remove the cassette release cover two screws 11 Remove the plastic guide on the vertical edge of the printer Depress the tabs visible through the cassette housing Gently turn it and lift from the printer 12 For the lower tray release Carefully release the tension spring cable from the pick pressure adjustment lever only on the most recent versions of the printer Remove the spring and cable Remove the lever one spring and C clip Remove the cam one screw Remove the latch one spring and C clip Cable Tension EN Upper Paper Spring ere Tension Lever Upper Latch Upper Cam u Lower hl L Latch Lowe
359. z i I amp 52 X 012364567891 72 8 ABCDEFGHIJKLMNOPQRSTUVWXYZIN E 5 amp C X 0123656789 15 5 8 ABCDEFGHIJKLMNOPQRSTUVWXYZINMI uU AG ong ssn LETTER HH 444 E Ei hun jr ipods fo bu jo nuno Figure 4 1 Good Quality Print Description Good properly registered print snp Print Quality Samples Sample 2 Washout TET EE vu I X amp 012365678915 25 T9 ABCDEFGHI JE A QPQRSTUVWXYZI N 1 abcdef ti se qarstuvwxyzti I S 52 01736567891 75 9 ABCLEF bn KLAN PQRSTUVWXYZIX 1 abc k m rpqrstuvwxyz i A6 Jub been LETTER I amp 58 OX 01236567891 5 25 9 ABCDEFGHIJKLMNOPQRST VWXY I gt abcdefghijklmnopqrs wxv 51 7 TESE D p 18789 amp s 5 9 ABCDEFGH Ke MNu CO TUVWXS Ur abcdefghijklauno zootuvw gt 71 UE RC b ftir dno fuor Journ rff joe nao eongo eanga aanp poe Figure 4 2 Washout Description Void areas light spots or blurs This is a composite of possible symptoms Go to TAG 801 Prints Light or Light With Carrier Particles TAG 802 Prints With Voids or White Spots TAG 809 Blurred or Smeared Vertical Streaks on Prints or TAG 810 Uneven Density or Dark Areas on Prints Print Quality Samples 4 5 Sample 3 Blank Print Figure 4 3 Blank

HP C30D User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents