Cut Sheet Printers Maintenance Manual Models C30 and C30D HP Part No.
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.
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.
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.
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.
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Contents Printer and Troubleshooting Overview Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Paper Path and Cycle Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Simplex Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAG 012: Upper Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 TAG E12: Envelope Tray or Feeder Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 TAG 013: Lower Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 TAG 020: Paper Jam/Misfeed in Upper Cassette Area . . . . . . . . . . . . . . . . . . . . . . . . 3-26 TAG 021: Paper Jam/Misfeed in /Lower Cassette Area. . . . . . . . . . . . . .
TAG 804: Prints With Light Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-162 TAG 805: Black Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163 TAG 806: Prints with Dark Spots or Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166 TAG 807: Misregistered/Skewed Prints (Simplex) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168 TAG 808: Prints Overtoned/Dark Vertical Streaks . . . . . . . . .
001 Operator Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 002 Upper Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 003 Lower Cassette Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 005 Sensor Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connectors Inside the Back Cover (Continued) J/P18-62 . . . . . . . . . . . . . . . . . . . . . . 6-13 Connectors Inside the Back Cover (Continued) J/P 64-85. . . . . . . . . . . . . . . . . . . . . . 6-14 Connectors Inside the Back Cover (Continued) J/P 90-800. . . . . . . . . . . . . . . . . . . . . 6-15 Voltage Isolation Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Ground System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 IGS Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 PCL Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Printhead Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Disk Drive Housing Removal. . . . . . .
Top Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82 Erase Lamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83 EP Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84 Main Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86 Main Gear Drive Removal . . . . . . . . . . . .
Printer/Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Every-Call Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Remove Major Consumable Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Inspect and Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Clean Internal Areas . . . . . .
Chapter 1 Printer and Troubleshooting Overview Section 1 Troubleshooting Printer and Troubleshooting Overview 1-1
Contents Printing and Troubleshooting Overview Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Paper Path and Cycle Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 Simplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 Generation System (IGS) controller: Each printer is equipped with an IGS controller, 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.
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 paper 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.
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 sequence takes place. Simplex Printing 1 PCL software downloaded to the PCL board from the disk drive system turns on the main motor. 2 The PCL board engages the paper pick clutch which causes the roller to feed a sheet of paper. 3 The paper is passed to the feed roller where the PCL board has engaged the feed roller clutch.
2 The paper upon passing through the “B” roller comes in contact with the duplex sensor. (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 registered. (If the paper does not energize this sensor in a given amount of time after leaving the duplex sensor, an error 061 will occur.
Error Code Technical Definitions The following table lists the printer error codes and their descriptions. Table 1-1.
Table 1-1. Error Code Technical Definitions (Continued) Fuser Control Errors Duplex Jams HVPS Errors OPC Rotation Errors Type 1-8 Error Description 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 photoconductor unit).
Table 1-1. Error Code Technical Definitions (Continued) Controller Errors LVPS Errors Jogger Errors Type Error Description 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 (diagnostic 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 (diagnostic test only).
Table 1-1. Error Code Technical Definitions (Continued) 1-10 DD Errors Description 405-409 IGS board detected an error in the program RAM during the internal diagnostic testing of the IGS board. 450-566 IGS board detected an error during the internal diagnostic testing of the IGS board and software. Controller Errors Error 570-586 IGS board detected an error when communicating with the floppy disk drive.
Sensor and Switch Locations The following pages illustrate the locations of the printer’s sensors and switches. Table 12, “Sensor and Switch List,” on page 1-14, lists them.
Top view Front view Developer right view Developer left view 1-12 Printer and Troubleshooting Overview
Right side view Top left, duplex tray view Front view Printer and Troubleshooting Overview 1-13
Rear view Table 1-2. Sensor and Switch List Sensor/Switch Name 1-14 Page No.
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 malfunctions. 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 TAGs.
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 component in the host system. Print quality problems and mechanical malfunctions are almost always associated with the printer. However, host interface and software emulation problems can be caused by some other component of the host system even though, at first Z glance, they appear to be printer problems.
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.
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 intermittent problem, the power should be checked again. Consult your country’s national electric code for the proper procedures to check for acceptable voltages, as shown in Table 13, “Acceptable Voltages”. Table 1-3.
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 printer’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.
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 follow 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.
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 Turn off the printer. 2 Wait at least 5 seconds. 3 Turn the power back on.
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.
5 Remove the photoconductor unit. 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: 1 Reassemble the printer.
Clearing the Error Log 1 Enter the diagnostic mode of the printer: • • Turn off the printer and wait 5 seconds. • The tone, followed by “00” on the display, indicates you are in the test mode. This takes approximately 1 minute. Hold down the STOP and TEST keys simultaneously as you turn the printer back on. 2 Press: CANCEL to advance the counter to “110.” 3 Press READY to activate the procedure. “0” appears on the display, indicating the A: drive.
Chapter 2 TAG CrossReference 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Print Quality/TAG Cross-Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 Mechanical Malfunction/TAG Cross-Reference Chart . . . . . . . . . . . . . . . . . . . . .
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 communication problems. On the chart find the error code in question, then turn to TAG associated with the code. Table 2-1.
Table 2-1.
Table 2-3.
Table 2-5. IGS Firmware Error Codes Code IGS Firmware Error Code Meaning These error codes signal a problem with the IGS controller firmware. No TAGs address these problems; report them to the printer’s manufacturer.
Table 2-8.
Table 2-8.
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.
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.
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 density 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.
Print Quality/TAG Cross-Reference Mechanical Malfunction/TAG Cross-Reference The chart below outlines possible mechanical malfunctions and recommends an appropriate TAG to follow to resolve the problem. Table 2-18.
Print Quality/TAG Cross-Reference Table 2-21. Paper Handling Problem TAGs 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 Table 2-22.
Print Quality/TAG Cross-Reference 2-14 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 TAG 002: Check &Problem Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 TAG 010: Upper Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12 E10: Envelope Tray Out of Envelopes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 TAG 011: Lower Cassette Malfunction . . .
TAG 101: IGS Controller Diagnostic Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103 TAG 130: Diskette/Disk Drive Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104 TAG 200: IGS Internal Communication Malfunction. . . . . . . . . . . . . . . . . . . . . 3-108 TAG 201: IGS-PPCL Interface Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110 TAG 405: IGS Bit-Map RAM Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Analysis Guide (TAGs) 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.
TAG 001: 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, presented in Chapter 1, “Printer and Troubleshooting Overview”. In addition, TAG may refer you to Chapter 2, “TAG Cross- Reference Tables”, which contain: 1 • Error code cross-reference table Arranged by error code; refers you to the TAG associated with the code.
display? No: Refer to Chapter 2, “TAG Cross- Reference Tables” to determine which TAG to follow, then turn to that TAG. Yes: Continue. 6 Run test prints from the upper cassette by completing the following: • Power-on-reset the printer. • 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.
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 problem, then turn to that TAG.
TAG 002: Check & 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. • Make 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.
6 the magnetic roller. • Reinstall the developer unit. Inspect and clean the cleaner unit/main charger: Caution Handle gently to avoid breaking the charger wire 7 • 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.
3 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 following items print in the order listed: a directory of the boot device and multiple listings of fonts; a formatted and unformatted error log; a continuous flow of test prints. 1 Power-on-reset the printer.
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.
TAG 010: Upper Cassette Malfunction Error Code: 010 Possible Causes: Cassette empty Paper incorrectly loaded Possible Defects: Upper paper empty actuator Upper paper empty sensor Upper cassette tray Upper pressure lever Upper cassette release cam Upper cassette release latch Upper cassette release lever Spring Connectors/wiring PCL board 1 Make sure paper is in the upper cassette.
4 Check pressure lever: • 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: • Cassette tray • Damper assembly • Upper pressure lever • Upper cassette release cam • Upper cassette release latch • Wire cable, pulley and spring • Upper cassette release lever Replace the defective part, then turn to TAG 002: Check & Problem Resolution.
E10: Envelope Tray Out of Envelopes This TAG refers to the error code for the envelope tray, which handles 75 envelopes.
5 Reinsert the envelope cassette. • 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: • Cassette tray • Damper assembly • Upper pressure lever • Upper cassette release cam • Upper cassette release latch • Wire cable, pulley and spring • Upper cassette release lever Replace the defective part, then turn to TAG 002: Check & Problem Resolution.
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.
4 Reinsert the lower 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: • 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 & Problem Resolution.
TAG 012: Upper Cassette Not Latched Error Code: 012 Possible Defects: Upper cassette release cam Upper cassette release latch Upper cassette in latch Upper pressure lever Spring Wire cable and pulley Upper cassette Upper cassette in switch Upper paper size sensor Lower paper size sensor Connectors or wiringr PCL board 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.
4 Run diagnostic test 002. Is 1-0 displayed? No: Replace the PCL board, then turn to TAG 002: Check & 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 & 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. • Disconnect J/P46.
9 Reconnect J/P40 and J/P45. • Remove the lower cassette. • Loosen the lower paper size sensor assembly for access to the circuit board. • 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 & 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.
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 lever 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. • Confirm that J/P40 and J/P52 are connected properly.
4 Run diagnostic test 002. Is 1-0 displayed? No: Replace the PCL board, then turn to TAG 002: Check & 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 & Problem Resolution. 6 Turn the printer off and unplug the power cord. • Remove the envelope tray or feeder. • Loosen the upper paper size sensor assembly for access to the circuit board. • Disconnect J/P46.
9 Reconnect J/P40 and J/P45. • Remove the lower cassette. • Loosen the lower paper size sensor assembly for access to the circuit board. • Disconnect J/P43 and J/P47. • Check J43-8 to J47-3 for continuity. Is there continuity? No: Replace the lower paper size assembly, then turn to TAG 002: Check & 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.
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. • Verify that J/P40 and J/P52 are connected properly. • Remove the lower cassette. • Inspect it for damage. • Reinsert the cassette.
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 & 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. • Disconnect J/P48. • Activate the cassette in switch. • Check P48-1 to P48-2 for continuity.
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.
3 Clear the paper path. • Remove the upper cassette. • Power-on-reset the printer. • Run test prints from the lower cassette. Is error code 021 displayed? No: Go to #10 in this TAG. Yes: Continue. 4 Clear the paper path. • Inspect the paper timing sensor actuator for damage or binding. Is it in good working order? No: Replace the paper timing guide assembly, then turn to TAG 002: Check & Problem Reso- lution. Yes: Continue. 5 Check the voltage between TP3-16 and ground on the PCL board.
9 Turn the printer off and unplug the power cord. • 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 & Problem Resolution. Yes: Replace the paper timing guide. If this does not resolve the problem, replace the PCL board.
13 Turn off the printer and unplug the power cord. • Disconnect J/P40 and J/P66. • 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 & Problem Resolution. Yes: Replace the upper feed roller assembly, then turn to TAG 002: Check & Problem Resolu- tion. 14 Inspect the upper pick-up roller assembly for damage or binding.
TAG 021: Paper Jam/Misfeed in /Lower Cassette Area 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 conn
3 Clear the paper path. • Reinsert the upper cassette. • Power-on-reset the printer. • 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 it in good working order? No: Replace the paper timing guide assembly, then turn to TAG 002: Check & Problem Reso- lution. Yes: Continue. 5 Check the voltage between TP3-16 and ground on the PCL board.
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 & 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 & Problem Resolution. 10 Turn off the printer. • Open the back cover and install an interlock by-pass tool.
13 Turn the printer off and unplug the power cord. • 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 & Problem Resolution. Yes: Replace the lower feed roller assembly, then turn to TAG 002: Check & Problem Resolu- tion. 14 Inspect the lower pick-up roller assembly for damage or binding.
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 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.
• • • Operations manual. Check that the fuser unit is installed properly. Power-on-reset the printer. Run test 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 & Problem Resolution. Yes: Continue. 3 Has the fuser unit been replaced recently? No: Continue. Yes: Go to #5 in this TAG. 4 Replace the fuser unit. • Run test prints.
8 Check the paper path for jams. • Open the printer’s front cover and insert the interlock bypass tool. • Power-on-reset the printer. • Run test prints. • 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. 9 Check TP3-11 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Go to #12 in this TAG. 10 Check J/P91-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue.
14 Does paper stop or jam either before or during entry into the fuser unit? No: Go to #17 in this TAG. Yes: Continue. 15 Remove the fuser unit. • 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 & Problem Resolution.
20 Power-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. 21 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. 22 Power-on-reset the printer.
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.
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. • Open the back cover and install an interlock bypass tool. • Remove the fuser drive cover.
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. • Check the paper path and remove any paper jams. • Confirm that J/P58 and J/P40 are connected properly. • Inspect the paper timing sensor actuator for damage or binding. Is it in good working order? No: Replace the paper timing guide assembly and continue. Yes: Continue. 2 Power-on-reset the printer.
6 Turn the printer off and unplug the power cord. • Loosen the paper timing guide. • Disconnect J/P57 and J/P40. • Check the following for continuity: • P40-16 to P57-2 • P40-25 to P57-1 • P40-12 to P57-3 Is there continuity? 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 • P40-12 to J/P58-3 to P57-3 Then turn to TAG 002: Check & Problem Resolution. Yes: Replace the paper timing guide.
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 beginning 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 replace the HCO. 1 Turn the printer off and unplug the power cord.
TAG 030: Developer Bias Short/Failure Error Code: 030 Possible Defects: Cleaner unit High voltage unit DC power supply Connectors or wiring PCL board Printhead assembly Power control #2 board Developer unit 1 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. • Power-on-reset the printer. Is error code 030 still displayed? No: A loose connector was at fault. Turn to TAG 002: Check & Problem Resolution. Yes: Continue.
6 Open the back cover and install an interlock by-pass tool. • Power-on-reset the printer. • Check TP4-35 for +24 Vdc. Is the voltage +24 Vdc? No: Go to #11 in this TAG. Yes: Continue. 7 Check J/P23-5 for +24 Vdc. Is the voltage +24 Vdc? No: Repair or replace the connectors or wiring from P41-35 to P23-5, then turn to TAG 002: Check & Problem Resolution. Yes: Continue. 8 Turn the printer off and unplug the power cord. • Disconnect J/P41 and J/P24.
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 & 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 & Problem 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 & Problem Resolu- tion.
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 Maintenance”. • Clean the toner patch sensor on the developer unit. • Clean the printhead lens.
6 Turn the printer off and unplug the power cord. • Remove the developer unit. • Disconnect J/P41. • 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 & Problem Resolution.
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 & Problem Resolution. Yes: Continue. 2 Have the photoconductor unit been replaced recently? No: Continue. Yes: Go to #4 in this TAG. 3 Replace the photoconductor unit.
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 & Problem Resolution. Yes: Go to TAG 808: Prints Overtoned/Dark Vertical Streaks, TAG 811: Background/Resid- ual Images/Dark Prints, or both, to identify the problem further.
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. • Run test prints. Is error code 035 displayed? No: Continue.
6 Remove the toner cartridge seal. • Power-on-reset the printer. • Run test prints. Has the problem been resolved? No: Continue. Yes: The toner cartridge seal was at fault. Turn to TAG 002: Check & Problem Resolution. 7 Turn the printer off and unplug the power cord. • Disconnect J/P41. • Remove the developer unit. • 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 & Problem Resolution.
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. • Confirm that J/P41 is connected properly. • Confirm that the proper developer unit is installed. • Power-on-reset the printer. Is error code 036 displayed? No: A loose connector or improper developer unit was at fault.
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 1 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 unit.
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 & 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 interlock by-pass tool. • Remove the main drive motor assembly cover. • Turn the printer on. • Run diagnostic test 009.
11 Remove the photoconductor unit. • Inspect the photoconductor belt for damage. • 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 & Problem Resolution. Yes: Continue. 12 Turn the printer off. • Disconnect J/P40. • Turn the printer on. • Check TP3-20 for +12 Vdc.
16 Clean both the photoconductor LED and seam sensor using a cotton swab or compressed air. • 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 0v; you may have to settle for less.
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. • 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 lead is connected properly.
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 Transfer 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.
continuity. Is there continuity? No: Replace the upper paper guide assembly, then turn to TAG 002: Check & Problem Reso- lution. Yes: Go to #13 in this TAG. 11 Turn the printer off and unplug the power cord. • Disconnect the main charger lead from the high voltage unit. • Check for continuity the main charger lead terminal assembly’s lower contact to the lead removed from the high voltage unit.
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. • Verify that J/P23, J/P41, J/P85, P124, P143, and the high voltage unit main charger lead are connected properly. • Clean the main charger contacts. • Power-on-reset the printer. • Run test prints. Is error code 045 displayed? No: Loose connectors or dirty contacts were at fault.
5 Reconnect the main charger high voltage lead. • 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 & 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.
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. • Power-on-reset the printer. • Run test prints. Is error code 050 displayed? No: A loose connector was at fault. Turn to TAG 002: Check & Problem Resolution. Yes: Continue.
5 Reconnect the transfer charger high voltage unit lead. • 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 & 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 & Problem Resolution.
TAG 055: Erase Lamp Malfunction Error Code: 055 Possible 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. • 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 & Problem Resolution. Yes: Continue.
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 P26-1 to P40-2, then turn to TAG 002: Check & Problem Resolution. Yes: Repair or replace the erase lamp assembly. If this resolves the problem, turn to TAG 002: Check & Problem Resolution. If this does not resolve the problem, replace the PCL board, turn to TAG 002: Check & Problem Resolution.
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 1 Turn the printer off and unplug the power cord.
4 Power-on-reset the printer. • Watch through the output tray opening to see if the fuser lamp comes on during the 15 seconds following the output tray jogging test. • If the 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. • Power-on-reset the printer.
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 & Problem Resolution. Yes: Continue. 9 Reinstall the fuser unit. • Check P41-21 to P41-22 for resistance. Is the resistance between I KΩ and 400 KΩ? No: The new fuser unit seems to be defective. Replace it with a new fuser unit, then turn to TAG 002: Check & Problem Resolution.
13 Turn off the printer. • Remove the fuser unit. • Clean the contacts of connector J/P5. • Disconnect J/P44. • 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 & Problem Resolution. Yes: Continue. 14 Reinstall the fuser unit. • Power-on-reset the printer. Has the problem been resolved? No: Replace the fuser unit, then turn to TAG 002: Check & Problem Resolution.
19 Turn the printer off and unplug the power cord. • 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 & Problem Resolution. Yes: Continue. 20 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 & Problem Resolution. Yes: Continue. 21 Reconnect J/P70.
TAG 071: Open Fuser Thermistor Error Code: 071 Possible Defects: Connectors or wiring Fuser unit PCL board 1 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. 2 Replace the fuser unit. • Power-on-reset the printer. Is error code 071 displayed during power-on-reset? No: The fuser unit was at fault.
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. • Verify that J/P44, J/P40, J/P10, J/P70, and J/P8 are connected properly. • Make sure the fuser unit is properly installed.
5 Turn the printer off and unplug the power cord. • Disconnect J/P41. • 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 & Problem Resolution. 6 Check P41-21 to P41-22 for resistance. Is the resistance at least 1K‡WW? No: Continue. Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution. 7 Remove the fuser unit.
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. • Verify that J/P100, J/P101, J/P102, J/P19, J/P40, J/P54, J/P53, and J/P55 are connected properly. • Power-on-reset the printer. Has the problem been resolved? No: Continue.
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 & Problem Resolution. Yes: Continue. 8 Check P101-1 to P19-3 for continuity.
11 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 & Problem Resolu- tion. 12 Run diagnostic test 008. • 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 & Problem Resolution.
17 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 & Problem Resolution. Yes: Continue. 18 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 & Problem Resolution. Yes: Continue. 19 Check P40-13 to P55-3 for continuity.
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 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 pa
3 Turn the printer off. • 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. • 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. • Reconnect J/P32. • Disconnect J/P74. • Turn the printer on. • Check J/P8-6 for +12 Vdc.
8 Turn the printer off. • Reconnect J/P32. • 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. • Reconnect J/P91. • Disconnect J/P40 and J/P41. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution. Yes: Continue. 10 Turn the printer off. • Reconnect J/P40. • Turn the printer on.
12 Turn the printer off and unplug the power cord. • Reconnect J/P41. • Remove the fuser unit. • Check P41-49 to P25-4 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 & Problem Resolution. 13 Turn the printer off and unplug the power cord. • Reconnect J/P91. • Disconnect J/P8 and J/P32. • Check J8-6 for continuity to ground. Is there continuity? No: Continue.
17 Turn the printer off. • 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. 18 Disconnect J/P61. • 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 & Problem Resolu- tion. Yes: Repair or replace the connectors or wiring from P62-1 to P61-1, then turn to TAG 002: Check & Problem Resolution. 19 Disconnect J/P58 and J/P57.
22 Turn the printer off. • Reconnect J/P40, J/P58, J/P60, and J/P62. • 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 this TAG. Yes: Continue. 23 Turn the printer off. • 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. 24 Turn the printer off. • Reconnect J/P54. • Disconnect J/P53. • Turn the printer on. • Check J/P8-6 for +12 Vdc.
27 Turn the printer off. • Remove the exit cover. • Disconnect J/P49 and J/P51. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #29 in this TAG. Yes: Continue. 28 Turn the printer off. • Reconnect J/P49. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Replace the paper exit sensor, then turn to TAG 002: Check & Problem Resolution. Yes: Replace the output tray full sensor, then turn to TAG 002: Check & Problem Resolution.
32 Turn the printer off and unplug the power cord. • 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 & Problem Resolution. 33 Reconnect J/P40 and J/P12. • Disconnect J/P102. • Turn on the printer. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Continue.
37 Turn off the printer. • Reconnect J/P305. • 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. • 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.
42 Turn off the printer. • Reconnect J/P310. • 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. • Disconnect J/P312. • 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 & Problem Resolu- tion.
47 Turn off the printer and unplug the power cord. • Disconnect J/P309. • 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 & 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 & Problem Resolution.
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. • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: Loose connectors were at fault. Turn to TAG 002: Check & Problem Resolution. 2 Check J/P32-3 for -12 Vdc.
5 Turn the printer off. • Reconnect J/P32. • 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 & Problem Resolution. Yes: Continue. 6 Does the printer have an attachment option? No: Replace the signal interface board, then turn to TAG 002: Check & Problem Resolution. Yes: Continue. 7 Turn the printer off. • Reconnect J/P74. • Disconnect the DC cable (J/P73) for the attachment option. • Turn the printer on.
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 1 Turn the prin
4 Turn the printer off. • Reconnect J/P330. • 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. • Reconnect J/P11. • 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. • Reconnect J/P10. • Disconnect J/P70. • Turn the printer on. • Check J/P8-11 for +24 Vdc.
8 Turn the printer off. • Reconnect J/P12. • 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 & Problem Resolution. Yes: Continue. 9 Turn the printer off. • Reconnect J/P41. • 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 & Problem Resolution.
12 Turn the printer off. • Reconnect J/P91. • 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 & Problem Resolution. Yes: Continue. 13 Turn the printer off. • 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. • Reconnect J/P41. • Disconnect J/P81. • Turn the printer on.
16 Turn the printer off. • Reconnect J/P41. • 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 & Problem Res- olution. 17 Turn the printer off. • Reconnect J/P69. • 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 & Problem Reso- lution.
20 Turn the printer off. • Reconnect J/P67. • 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 & Problem Resolution. Yes: Replace the upper pick-up roller assembly, then turn to TAG 002: Check & Problem Res- olution. 21 Turn the printer off and unplug the power cord.
24 Turn the printer off. • Reconnect J/P305. • Disconnect J/P310 (inside duplex tray). • Turn the printer on. • 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. • 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.
28 Turn the printer off and unplug the power cord. • 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 & Problem Resolution. Yes: Repair or replace the connectors or wiring from P331-1 to P306-1, then turn to TAG 002: Check & Problem Resolution. 29 Turn the printer off. • Reconnect J/P310. • Disconnect J/P321. • Turn the printer on.
32 Turn the printer off. • Reconnect J/P313. • 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 & Problem Resolution. 33 Turn the printer off. • Reconnect J/P314. • 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 002: Check & Problem Resolution.
36 Turn the printer off. • Reconnect J/P317. • Disconnect J/P308 and J/P309. • Turn the printer on. • Check J/P330-1 for +24 Vdc. Is the voltage +24 Vdc? No: Repair the duplex control board #1, then turn to TAG 002: Check & 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 & Problem Resolution.
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. • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: A loose connector was at fault. Turn to TAG 002: Check & Problem Resolution.
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 & Problem Resolution. Yes: Replace the IGS controller, then turn to TAG 002: Check & Problem Resolution.
TAG 130: Diskette/Disk Drive Malfunction 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.
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. • 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 problem, turn to TAG 002: Check & Problem Resolution. If this does not resolve the problem, replace the IGS board, then turn to TAG 002: Check & Problem Resolution.
P31-10 to P79-10. Is there continuity on any? No: Replace the disk drive assembly. If this does not resolve the problem, replace the IGS board, then turn to TAG 002: Check & Problem Resolution. Yes: Replace wire harness W46, then turn to TAG 002: Check & Problem Resolution. 13 Is error code 574 displayed? No: Go to #16 in this TAG. Yes: Continue. 14 Turn the printer off and unplug the power cord. • Disconnect J/P31 and J/P79. • Check P31-30 to P79-30 for continuity.
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 & Problem Resolution. Yes: Continue. 20 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 & Problem Resolution. Yes: Replace wire harness W46. 21 Is error code 130, 131, 133, or 134 displayed? No: Continue.
TAG 200: IGS Internal Communication Malfunction 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 1 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. • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: A loose connector was at fault.
7 Replace the software diskettes in drives A and B. • Power-on-reset the printer. Has the problem been resolved? No: Replace the signal interface board, then turn to TAG 002: Check & Problem Resolution. Yes: Software diskettes were at fault. Turn to TAG 002: Check & Problem Resolution. 8 Disconnect J/P76 (hard drive cable). • Insert the emulation diskette into drive A. • Power-on-reset the printer.
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 between 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.
6 Replace the IGS board. • 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 & Problem Resolution. For all other error codes, replace the IGS board, then turn to TAG 002: Check & Problem Resolution. Yes: Turn to TAG 002: Check & Problem Resolution.
TAG 405: IGS Bit-Map RAM Malfunction Error Code: 606, 600, 610 Possible Defects: IGS board 1 3-112 The IGS bit-map RAM has malfunctioned. Replace the IGS board, then turn to TAG 002: Check & Problem Resolution.
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.
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 & Problem Resolution. Yes: Continue. 6 Turn the printer off and unplug the power cord. • 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 & Problem Resolution.
10 Turn the printer off. • Reconnect J/P77. • 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 & Problem Resolu- tion. 11 Turn the printer off. • Reconnect J/P27. • 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 & Problem Resolution. 12 Turn the printer off.
14 Turn the printer off. • 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 & Problem Reso- lution. Yes: Repair or replace the connectors or wiring from P94-1 to J/P90-1 to P42-1, then turn to TAG 002: Check & Problem Resolution. 15 Turn the printer off. • Reconnect J/P330. • Disconnect J/P331. • Turn the printer on. • Check J/P8-10 for +5 Vdc.
19 Turn the printer off. • 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 & Problem Resolution. Yes: Replace the attachment option, then turn to TAG 002: Check & Problem Resolution. 20 Turn the printer off. • Reconnect J/P333. • Disconnect J/P323. • Turn the printer on. • Check J/P8-10 for +5 Vdc.
TAG 600: AC Power Malfunction 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 board 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 p
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 actuators. Are the interlock switch actuators working properly? No: Repair or replace any defective actuator, then turn to TAG 002: Check & 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.
10 Reinstall the fuse. • Disconnect J/P4. • Close the top cover. • Check P4-5 to P4-6 for continuity. Is there continuity? No: Go to #34 in this TAG. Yes: Continue. 11 Remove the AC power supply unit. • Operate the front cover interlock switch. • 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 & Problem Resolution.
15 Reconnect J/P9. • Install a good upper fuse in the AC power supply unit. • Disconnect J/P13 and J/P14. • Turn the printer on for 5 seconds, then off. • Remove the fuse. • Check the fuse for continuity. Does the fuse have continuity? No: Replace the power control #2 board, then turn to TAG 002: Check & Problem Resolu- tion. Yes: Continue. 16 Reconnect J/P13 and J/P14. • Disconnect J/P20, J/P21, J/P22, and J/P326 (duplex printers). • Power-on-reset the printer.
19 Turn the printer off. • Reconnect J/P22. • 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 & Problem Resolution. Yes: Replace the small cooling fan assembly, then turn to TAG 002: Check & Problem Reso- lution. 20 Reconnect J/P9. • Disconnect J/P100. • Install a new upper fuse in the AC power supply unit. • Run diagnostic test 008 for approximately five seconds, then turn off the printer.
24 Close the top cover. • Check P4-5 for continuity to ground. Is there continuity? No: Replace the AC power supply, then turn to TAG 002: Check & Problem Resolution. Yes: Repair or replace the top cover interlock switch assembly. If this resolves the problem, turn to TAG 002: Check & 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 & Problem Resolution.
30 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 & Problem Resolution. 31 Check P4-7 for continuity to ground. Is there continuity? No: Go to #33 in this TAG. Yes: Continue. 32 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 & Problem Resolution.
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 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. • Verify that J/P90, J/P42, J/P8, J/P41, and J/P94 are connected properly.
6 Turn the printer off and unplug the power cord. • Disconnect J/P42 and J/P41. • 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 & Problem Resolution. Yes: Continue. 7 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 & Problem Resolution.
13 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 & Prob- lem Resolution. If this does not resolve the problem, replace the PCL board, then turn to TAG 002: Check & 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 & Problem Resolution. 14 Turn the printer off and unplug the power cord. • Disconnect J/P41 and J/P42.
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.
Table 3-1.
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. • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: Loose connectors were at fault.
6 Turn the printer off and unplug the power cord. • Disconnect J/P51 and J/P40. • 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 & 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 & Problem Resolution. Yes: Continue.
TAG 702: Paper Size Detection Malfunction 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 1 Turn the printer off and unplug the power cord. • 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. • Power-on-reset the printer.
5 Remove the lower paper size sensor assembly. • 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 & Problem Resolution. 6 Is the paper size sensing problem occurring with the upper cassette? No: Go to #8 in this TAG. Yes: Continue.
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.
TAG 703: Upper Cassette Malfunction Error Code: 703 Symptoms: Upper cassette does not load or unload properly Upper cassette does not latch properly Possible Defects: Upper cassette Upper pressure lever Upper cassette release latch Upper cassette release Damper assembly Upper cassette release cam Wire cable/roller/spring 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 & Problem Resolution. Yes: Continue.
TAG 704: Lower Cassette Malfunction Error Code: 704 Symptoms: Lower cassette does not load or unload properly 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 1 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 & Problem Resolution. Yes: Continue.
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.
TAG 706: Paper Damaged or Wrinkled Error Code: 706 Possible Causes: Paper incorrectly loaded Wrong weight or type of paper loaded Paper path obstructed Possible 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. • Check both upper and lower paper paths for obstructions or roller contamination.
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.
TAG 750: Counter Malfunction 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 1 Run diagnostic test 007. Is the counter functioning properly? No: Continue. Yes: The counter is working correctly. Turn to TAG 002: Check & Problem Resolution. 2 Verify that J/P41, J/P81, and J/P82 are connected properly. • Run diagnostic test 007.
7 Run test prints. • 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: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution. Yes: Replace the counter, then turn to TAG 002: Check & Problem Resolution. 8 Turn the printer off and unplug the power cord. • Disconnect J/P41 and J/P82. • Check P41-26 to J82-1 for continuity.
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. • 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 & Problem Resolution. If this does not resolve the problem, replace the PCL board, then turn to TAG 002: Check & Problem Resolution.
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.
3 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 & 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 & Problem Resolution. Yes: Continue. 4 Disconnect the interface cable from the printer.
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 & Problem Resolution. Yes: Repair or replace connectors or wiring from P8-8 to P32-3, then turn to TAG 002: Check & 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.
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.
4 Reconnect the attachment cables. • Turn on the printer for five seconds, then turn it off. • Check the signal interface board fuse for continuity. Does the fuse have continuity? No: Replace the attachment option, then turn to TAG 002: Check & Problem Resolution. Yes: The signal interface board fuse was at fault. Turn to TAG 002: Check & Problem Resolu- tion. 5 Turn on the printer.
TAG 800: Prints Blank or With Dark Horizontal Bands 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. 1 Turn the printer off and unplug the power cord.
5 Replace the developer unit and toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer unit and continue. Yes: Turn to TAG 002: Check & 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.
10 Run diagnostic test 111. • Watch the printhead LEDs while the test is running. Do the LEDs illuminate? No: Go to #18 in this TAG. Yes: Continue. 11 Are the prints blank without dark bands? No: Go to #15 in this TAG. Yes: Continue. 12 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.
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 & Problem Resolution. Yes: Continue. 17 Reinstall the photoconductor unit. • Turn the printer on. • Run test prints.
TAG 801: Prints Light or Light With Carrier Particles 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 Blank or With Dark Horizontal Bands. 1 Run test prints.
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 prints to detone the engine, then turn to TAG 002: Check & Problem Resolution. 6 Replace the developer unit and toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer unit and continue. Yes: Turn to TAG 002: Check & Problem Resolution.
10 Turn the printer off and unplug the power cord. • Replace the transfer charger unit. • Power-on-reset the printer. • Run test prints. Has the problem been resolved? No: Replace the upper paper guide assembly. If this resolves the problem, turn to TAG 002: Check & Problem Resolution. If this does not resolve the problem, replace the high voltage unit, then turn to TAG 002: Check & Problem Resolution. Yes: The transfer charger unit was at fault. Turn to TAG 002: Check & Problem Resolution.
15 Turn the printer off and unplug the power cord. • Disconnect J/P41, J/P24, and J/P23. • Check the following for continuity: 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 & Problem Resolution. Yes: Continue. 16 Reconnect J/P23, J/P41, and J/P24. • Reinstall the developer unit.
20 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 voltage 100 Vac? No: Go to #22 in this TAG. Yes: Continue. 21 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 & Problem Resolution.
26 Turn the printer off and unplug the power cord. • Replace the printhead assembly unit. • Power-on-reset the printer. • Run test prints. Has the problem been resolved? No: Reinstall the original printhead assembly unit and continue. Yes: Turn to TAG 002: Check & Problem Resolution. 27 Turn the printer off and unplug the power cord. • Replace the IGS board. • Power-on-reset the printer. • Run test prints.
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. • Confirm that the paper in the cassettes meets paper specifications, outlined in the Guide to Operations manual. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination was at fault. Turn to TAG 002: Check & Problem Resolution.
6 Replace the fuser unit. • 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 & Problem Resolution.
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. • Verify that 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 Maintenance”. • Turn the printer on. • Run test prints.
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 TAG 002: Check & Problem Resolution. Yes: Replace the printhead assembly unit, then turn to TAG 002: Check & Problem Resolu- tion.
TAG 804: Prints With Light Horizontal Bands Error Code: 804 Possible Causes: Loose printhead connectors Possible Defects: Transfer charger unit Photoconductor unit Main charger 1 Turn the printer off and unplug the power cord. • Perform the every-call cleaning procedure, described in Chapter 9, “General Printer Maintenance”. • Verify that J/P30 and J/P31 are connected properly. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue.
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 1 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.
5 Replace the developer unit, toner cartridge, and cleaner unit. • Turn the printer on. • 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 & 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/P41, J/P23, and J/P24. • Check P41-33 to P23-7 for continuity.
11 Replace the IGS board. • Run test prints. Has the problem been resolved? No: Replace the main charger lead wiring, then turn to TAG 002: Check & Problem Resolu- tion. Yes: Turn to TAG 002: Check & Problem Resolution.
TAG 806: Prints with Dark Spots or Scratches Error Code: 806 Possible Causes: Paper path contamination Paper supply defects Toner Possible Defects: Photoconductor unit Main charger Fuser unit Developer unit Cleaner unit 1 Turn the printer off and unplug the power cord. • Perform the every-call cleaning procedure, described in Chapter 9, “General Printer Maintenance”. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination was at fault.
6 Replace the fuser unit. • Run test prints. Has the problem been resolved? No: Reinstall the original fuser unit and continue. Yes: Turn to TAG 002: Check & Problem Resolution. 7 Replace the developer unit and toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer unit and continue. Yes: Turn to TAG 002: Check & Problem Resolution. If this problem recurs, the toner/carrier mix may be old or contaminated.
TAG 807: Misregistered/Skewed Prints (Simplex) If this problem occurs in the duplex printing mode only, go to TAG 901: Misregistration/ Skewed Prints (Duplex).
2 Remove the upper cassette. • Power-on-reset the printer. • 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.
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 & 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.
Table 3-5.
TAG 808: Prints Overtoned/Dark Vertical Streaks 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. 1 Turn the printer off and unplug the power cord.
5 Replace the cleaner unit. • Run test prints. Has the problem been resolved? No: Reinstall the original cleaner unit and continue. Yes: Turn to TAG 002: Check & Problem Resolution. 6 Replace the developer unit with toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer unit and continue. Yes: Turn to TAG 002: Check & Problem Resolution. If the problem recurs, the toner/carrier mix may be old or contaminated. 7 Turn the printer off.
10 Reinstall the developer unit. • Run test prints. • Check TP3-31 for a voltage change from +12 Vdc to 0Vdc while running test prints. Does the voltage change from +12 Vdc to 0Vdc every other print cycle? No: Go to #14 in this TAG. Yes: Continue. 11 Turn the printer off and unplug the power cord. • Disconnect J/P41. • Remove the developer unit. • Check for continuity: P4 P41-44 to P25-2, P41-47 to P25-3, and P41-50 to P25-1.
15 Reconnect J/P24. • 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 & Problem Resolution. Yes: Continue. 16 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 & Problem Resolution. Yes: Continue.
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 & Problem Resolution.
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. • Verify that J/P23, J/P41, and J/P13 are connected properly.
5 Replace the fuser unit. • Run test prints. Has the problem been resolved? No: Reinstall the original fuser unit and continue. Yes: Turn to TAG 002: Check & Problem Resolution. 6 Replace the cleaner unit. • Run test prints. Has the problem been resolved? No: Reinstall the original cleaner unit and continue. Yes: Turn to TAG 002: Check & Problem Resolution.
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 & 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 & Problem Resolu- tion.
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. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination was at fault. Turn to TAG 002: Check & Problem Resolution. 2 Check the voltages, as outlined in Chapter 9, “General Printer Maintenance”.
6 Replace the developer unit and toner cartridge. • 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 & Problem Resolution. If the problem recurs, the toner/carrier mix may be old or contaminated.
TAG 811: Background/Residual Images/Dark Prints 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 1 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.
5 Replace the developer unit and cleaner unit. • 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 & Problem Resolution. 6 Remove the photoconductor unit from the printer. • Run diagnostic test 013. • 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 & Problem Resolution. Yes: Continue. 7 Turn the printer off.
10 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 & Problem Resolution. Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution. 11 Turn the printer off and unplug the power cord. • Disconnect J/P41 and J/P24. • Check P41-30 to P24-2 for continuity.
15 Reconnect J/P41 and J/P24. • Turn the printer on. • 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 & Problem Resolution. Yes: Continue. 16 Is a meter with a high voltage probe available? No: Go to #19 in this TAG. Yes: Continue. 17 Using a high voltage probe, check J/P25-7 for the proper voltage, as described in Chapter 9, “General Printer Maintenance”.
22 Turn the printer off and unplug the power cord. • Disconnect J/P40. • Check P40-31 for continuity to ground. Is there continuity? No: Replace the PCL board, then turn to TAG 002: Check & 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 & Problem Resolu- tion.
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 properly. • Perform the every-call cleaning procedure, described in Chapter 9, “General Printer Maintenance”. • Turn the printer on. • Run test prints.
6 Power-on-reset the printer. • 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. 7 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. 8 Confirm that the paper in the cassettes meets paper specifications, outlined in the Guide to Operations manual.
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. • Perform the every-call cleaning procedure, described in Chapter 9, “General Printer Maintenance”. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination was at fault. Turn to TAG 002: Check & Problem Resolution.
6 Replace the developer unit and toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer unit and continue. Yes: Turn to TAG 002: Check & Problem Resolution. 7 Replace the photoconductor unit and main charger. • 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 & Problem Resolution. If the problem recurs, the toner may be old or contaminated.
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 & Problem Resolution. 2 Turn off the printer and unplug the power cord. • Replace the printhead assembly.
TAG 900: Top Cover Interlock Malfunction, Duplex 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. 1 Turn the printer off and unplug the power cord. • Verify that J/P306, J/P307, J/P309, and J/P318 are connected properly. • Confirm that the top and front covers are closing completely. • Power-on-reset the printer.
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 & Problem Resolu- tion. Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.
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.
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. • Verify that J/P315 and J/P316 are connected properly to the “A” and “C” roller clutches. • 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.
8 Run diagnostic test 017. Did diagnostic test 017 indicate a duplex tray paper sensor problem? No: Continue. Yes: Go to #13 in this TAG. 9 Turn the printer off. • 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 & Problem Resolution. Yes: Continue. 10 Check P312-8 to J321-2 for continuity.
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 & 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 & Problem Resolution. Yes: Continue. 15 Manually activate the duplex tray paper sensor.
TAG 902: Paper Jam in Duplex Area 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 1 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.
5 Turn the printer off. • Reconnect J/P309. • Disconnect J/P319. • Turn the printer on. • 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 & 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 & Problem Resolution.
10 Turn the printer on. • Run diagnostic test 018. Is the input solenoid in good working order? No: Continue. Yes: Go to #13 in this TAG. 11 Turn off the printer. • 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 & Problem Resolution. Yes: Continue. 12 Disconnect J/P314.
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 & Problem Resolution. Yes: Replace the “C” roller solenoid, then turn to TAG 002: Check & Problem Resolution. 16 Turn the printer on. • Run diagnostic test 016. Is the feed motor in good working order? No: Continue. Yes: Go to #21 in this TAG. 17 Turn the printer off. • Disconnect J/P309. • Check P309-7 to P309-8 for continuity.
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 & 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 from P306-2 to J/P331-2 to P330-2, then turn to TAG 002: Check & Problem Resolution. Yes: Continue. 23 Check J/P306-1 to J/P306-4 for +24 Vdc.
Chapter 4 Print Quality Samples Section 2 Print Quality Samples Troubleshooting 4-1
Contents Print Quality Samples Sample 1: Good Quality Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 Sample 2: Washout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 Sample 3: Blank Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Sample 4: Light Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Quality Samples This section contains flawed test prints, along with a good test print for comparison. Compare 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.
Sample 1: Good Quality Print Figure 4-1. Good Quality Print Description: Good, properly registered print.
Sample 2: Washout 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.
Sample 3: ;:Blank Print Figure 4-3. Blank 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.
Sample 4: Light Print 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.
Sample 5: Light Print With Background 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.
Sample 6: Voids or White Spots 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.
Sample 7: Light Vertical Streaks Figure 4-7. Light Vertical Streaks Description: One or more light vertical streaked areas of varying widths. Go to TAG 803: Prints With Light or White Vertical Streaks.
Sample 8: Blank Vertical Bands Figure 4-8. Blank Vertical Bands 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.
Sample 9: Light Horizontal Bands 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.
Sample 10: Black or Dark Print Figure 4-10. Black or Dark Print Description: Black or very dark with no visible images. Go to TAG 805: Black Prints, TAG 811: Background/Residual Images/Dark Prints.
Sample 11: Dark Specks, Lines, or Areas 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.
Sample 12: Dark Vertical Lines 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 Vertical Streaks.
Sample 13: Skewed Prints Figure 4-13. Skewed prints Description: The entire image is not located squarely on the paper. Go to TAG 807: Misregistered/Skewed Prints (Simplex) or TAG 901: Misregistration/ Skewed Prints (Duplex).
Sample 14: Misregistration 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).
Sample 15: Overtoned Print 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.
Sample 16: Blurred Images or Characters 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 to TAG 809: Blurred or Smeared Vertical Streaks on Prints.
Sample 17: Varying Print Density 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 diagonal 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.
Sample 18: Background Figure 4-18. Background Description: White areas on the prints have varying degrees of specks appearing in a specific pattern. Go to TAG 811: Background/Residual Images/Dark Prints.
Sample 19: Residual Images Figure 4-19. Residual Images 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.
Sample 20: Wrinkles Figure 4-20. Wrinkles Description: Wrinkles or creases, often at the top or bottom. Go to TAG 706: Paper Damaged or Wrinkled.
Sample 21: Fusing Problems Figure 4-21. Fusing Problems Description: Images or characters may rub off the surface. Go to TAG 812: Uneven or No Fusing on Prints.
Chapter 5 Diagnostic Tests Section 3 Diagnostic Tests Troubleshooting 5-1
Contents How to Run Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 001 Operator Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 002 Upper Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 003 Lower Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 005 Sensor Test Sequence . . . . . .
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 number. 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 Turn off the printer and wait five seconds.
How to Run Diagnostics 001 002 Operator Panel Test 1 Turn the volume control on the operator panel up fully. 2 Go to: 001 3 Press: READY to run the test. 4 Confirm that the tone sounds and all lights turn on and off continuously. 5 Press: STOP to exit. 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. 2 Go to: 002 3 Press: READY to run the test.
(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. 2 Go to: 003 3 Press: READY to run the test. 4 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.
(004 intentionally excluded) 005 Sensor Test Sequence 1 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.
(004 intentionally excluded) 006 Paper Transport Clutch Test Sequence 1 Go to: 006 2 Press: READY to run the test. The first clutch engages, signaled by a continuous 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.
(004 intentionally excluded) 008 Jogging Motor Test 1 Go to: 008 2 Press: READY to run the test. The output tray jogs back and forth. 3 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.
(004 intentionally excluded) 010 Toner Supply Motor Test 1 Open the front and top covers. 2 Remove the photoconductor unit and the developer unit. Place the photoconductor unit in its protective packaging. 3 Insert the interlock by-pass tool in the front cover. Close the top cover. 4 Go to: 010 5 Press: READY to run the test. The toner supply motor runs continuously. 6 Observe the toner supply motor through the open developer unit cavity.
(004 intentionally excluded) 011 Main Charger Test 1 Remove the photoconductor unit and place it in its protective packaging. Close the top cover. 2 Go to: 011 3 Press: READY to run the test. The main charger turns on and off repeatedly. 4 Confirm that the display alternates between “0” and “1,” accompanied each time by a brief tone. The display indicates the following: Table 5-7.
(004 intentionally excluded) 012 Transfer Charger Test 1 Remove the photoconductor unit and place it in its protective packaging. Close the top cover. 2 Go to: 012 3 Press: READY to run the test. The transfer charger turns on and off repeatedly. 4 Confirm that the display alternates between “0” and “1,” accompanied each time by a brief tone. The display indicates the following: Table 5-9.
(014 intentionally excluded) 013 Erase Lamp Test 1 Open the top cover and insert the interlock by-pass tool. 2 Remove the photoconductor unit and place it in its protective cover. 3 Select: 013 4 READY to run the test. The erase lamp turns on with all LEDs lighted. 5 Verify that all LEDs are illuminated and a number(s) appears on the display. The number 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.
(014 intentionally excluded) 015 Negative Developer Bias Test 1 Open the top cover and insert the interlock by-pass tool. 2 Remove the photoconductor unit and place it in its protective packaging. 3 Go to: 015 4 Press: READY to run the test. The negative developer bias turns on and off repeatedly. 5 Confirm that the display alternates between “0” and “1,” accompanied each time by a brief tone. The display indicates the following: Table 5-12.
(014 intentionally excluded) 016 Duplex Feed Motor Test 1 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. 3 Press: READY to advance to the next motor speed. 4 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.
(014 intentionally excluded) 017 Duplex Input Sensor Test Sequence 1 Go to: 017 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 the chart below. Table 5-16.
(014 intentionally excluded) 018 Duplex Clutch Test Sequence 1 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.
(014 intentionally excluded) 019 Duplex Tray Paper-Guide Motor Test 1 Go to: 019 2 Press: READY to run the test. 3 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 time you press READY. These codes may indicate specific error conditions: Table 5-20.
(014 intentionally excluded) 020 High-Capacity Output Unit Test 1 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.
(023-100 intentionally excluded) 021 High-Capacity Input Unit Test 1 Go to: 021 2 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.) 3 Verify the correct paper size, as follows: Table 5-22. High-Capacity Input Unit Test Displays Display 4 022 Indication 1-1 A4-size paper in use 1-3 Letter-size paper in use Press: STOP to exit.
(023-100 intentionally excluded) 101 EIGS/MIGS Board Test 1 Select: 101 2 Press: READY to run the test. 3 If an error is found: • • • 4 Power-on-reset to exit. The test continues to run. After about five minutes, press STOP to exit. EIGS/MIGS Board Test (Continuous Loop) 1 Go to: 102 2 Press: READY to run the test. 3 If an error is found: • • • 4 The error code is displayed for at least 1 second.
(023-100 intentionally excluded) 103 Communication Loop-back Test (Single Loop) 1 Remove the interface cable from the printer. 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. 3 Install the RS-232C and RS-422 loop-back connectors, found in the tool kit mounted inside the right printer cover.
(106 intentionally excluded) 104 Communication Loop-back Test (Continuous Loop) 1 Remove the interface cable from the printer. 2 Make sure the DIP switches on the signal interface board have been pulled toward the printer’s back cover. Close the back cover. 3 Install the RS-232C and RS-422 loop-back connectors, found in the tool kit mounted inside the right printer cover.
(109 intentionally excluded) 107 108 EIGS/MIGS Bit Map Test (Single Loop) 1 Go to: 107 2 Press: READY to run the test. 3 If no error is detected, the test exits automatically. 4 If an error code appears, look it up in “Error Code/TAG Cross-Reference” on page 23 to determine which TAG to follow. 5 Press: STOP to exit, if an error is reported. EIGS/MIGS Bit Map Test (Continuous Loop) 1 Go to: 108 2 Press: READY to run the test. 3 If no errors are detected: • • 4 The test continues to loop.
(109 intentionally excluded) 110 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.
(109 intentionally excluded) 112 Disk Drive Test (Single Loop With Stop on Error) 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 Go to: 112 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.
(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 disk format. 5-26 1 Go to: 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.
Chapter 6 Wiring Diagrams and Electrical Data Section 4 Troubleshooting
Contents Wiring Diagrams and Electrical Data Wiring Diagrams and Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3 Connector (J/P) Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Connectors Inside the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams and Electrical Data This section provides a reference guide for all information related to the electrical system of the printer, including: • An index, arranged by connector number, to the connector’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.
Connector (J/P) Index Connector Page Schematic Location Connector Page Schematic 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 E6 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
Connector Page Schematic Location Connector Page Schematic Location 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
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 Left Cover J/P 43, 45, 47 J/P 59, 61 10 J/P 46, 48 2 9 8 7 1 Wiring Diagrams and Electrical Data 6 5 4 3 2 1 2 3 1 J/P 119, 120, 127, 128 1 6-7
Connectors on the Duplex Cover J/P 22-1 J/P 306 J/P 307 J/P 308 6-8 3 1 2 1 3 2 J/P 309 1 J/P 313 1 2 3 2 4 3 2 1 J/P 315 1 J/P 316 1 2 J/P 319 1 2 2 4 1 2 3 4 5 6 1 J/P 314 7 8 5 4 3 6 5 9 10 11 12 13 14 7 6 2 8 7 8 9 10 3 4 Wiring Diagrams and Electrical Data
Connectors Inside the Right Cover 54 53 55 8 7 6 5 4 3 2 1 J/P 54 J/P 15 15 14 13 12 11 10 J/P 22 J/P 49, 51, 53 3 1 2 2 1 3 Wiring Diagrams and Electrical Data 1 2 3 4 5 6 9 J/P 55 J/P 317 1 2 1 3 2 6-9
Connectors Inside the Top Cover + J/P 5 + J/P 57 J/P 63 1 1 2 3 4 5 6 7 8 2 J/P 131-132 1 J/P 311 1 6-10 2 J/P 312 1 J/P 320 1 3 3 4 4 5 6 7 8 2 3 4 2 5 6 7 8 9 10 3 1 J/P 321 J/P 305 2 3 2 1 J/P 310 3 6 9 12 2 5 8 11 1 4 7 10 J/P 322 1 2 1 3 2 4 3 Wiring Diagrams and Electrical Data
Connectors on the Back Cover 74 32 31 40 41 76 36 91 37 33 87 2 4 6 8 10 12 14 16 18 20 22 2426 28 30 3234 36 38 40 42 44 46 48 50 52 54 56 58 60 J/P 31 1 3 5 7 9 11 1315 17 19 2123 25 27 29 3133 35 37 39 41 43 45 47 49 51 53 55 57 59 2 11 10 6 5 9 8 7 3 2 1 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 J/P 74 J/P 32 4 15 13 11 9 7 1 3 5 3 1 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 2 4 6 8 10 12 14 16 18 20 22 2426 28 30 32 34 36 38 40 42 44 46 48 50 J/P 3
Connectors Inside the Back Cover (J/P2-14) 56 24 19 Jogging Motor Control Board 54 102 101 100 52 Signal Interface Board 71 72 73 500 J/P 8 J/P 2, 3 10 1 11 2 12 3 13 4 J/P 11 1 2 5 3 J/P 4 J/P 6 9 6 2 5 8 1 4 7 3 2 14 6 15 7 16 8 17 9 1 2 5 1 4 2 7 8 9 10 6 5 4 3 2 1 3 2 1 1 J/P 7 6-12 6 J/P 13 J/P 9 6 3 4 5 J/P 12 1 3 2 J/P 10 2 1 J/P 14 Wiring Diagrams and Electrical Data
Connectors Inside the Back Cover (Continued) J/P18-62 3 J/P 18 2 1 J/P 26 J/P 19, 20 4 3 2 1 J/P 27 J/P 21, 22 3 2 1 2 1 3 6 2 5 1 4 J/P 23 8 7 6 5 4 3 2 1 J/P 30 J/P 24 1 2 3 4 + J/P 25 6 12 5 11 4 10 3 9 2 8 1 7 J/P 44 1 J/P 50 1 J/P 52 1 26 25 24 23 22 21 20 19 18 16 17 14 13 12 10 11 9 8 7 6 4 5 2 1 15 3 2 2 2 3 3 4 4 5 5 6 6 7 8 9 10 + J/P 54 J/P 44 1 2 Wiring Diagrams and Electrical Data J/P 56, 58, 60, 62
Connectors Inside the Back Cover (Continued) J/P 64-85 56 24 19 Jogging Motor Control Board 54 101 100 102 52 Signal Interface Board 71 J/P 64 1 2 73 72 3 500 J/P 77 4 J/P 65, 66, 67, 68, 69, 70 4 3 2 1 2 1 J/P 79 13 12 11 10 9 8 7 6 5 4 3 2 1 J/P 71 (RS-232C) 2 1 J/P 81, 83 25 24 23 22 21 20 19 18 17 16 15 14 8 7 6 5 4 3 2 1 J/P 72 (RS-422) J/P 84 15 14 13 12 11 10 5 4 3 2 6-14 7 31 30 28 29 26 25 24 23 22 21 20 19 18 16 17 14 13 12 10 11
Connectors Inside the Back Cover (Continued) J/P 90-800 21 17 13 9 5 1 22 18 14 10 6 2 23 19 15 11 7 3 24 20 16 12 8 4 J/P 323 4 3 2 1 J/P 90 J/P 324 J/P 94 3 6 9 12 2 5 8 11 1 4 7 10 1 2 1 J/P 96 J/P 330, 331 J/P 100 3 2 1 2 1 2 1 J/P 333 J/P 101 4 1 2 18 17 16 15 14 13 12 11 10 9 8 3 7 6 5 4 3 2 1 J/P 500 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 J/P 102 2 1 J/P 800 J/P 121, 122, 124 139, 140, 143 J/P 251, 252, 255 1 2
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 DC Power Supply IGS J/P32-3 J/P74-32 Board J/P88-32 Signal Interface Board J/P73-4 External Attachment Connector Figure 6-1.
J/P8-3 DC Power Supply J/P32-10 J/P77-1 J/P74-34 IGS Board J/P8-6 J/P58-1 J/P91-3 Disk drive J/P40-25 PCL Board J/P40-26 Signal interface board J/P57-1 J/P60-1 J/P59-1 J/P62-1 J/P61-1 J/P50-1 J/P49-1 J/P50-4 J/P51-1 J/P54-1 J/P53-1 J/P54-4 J/P55-1 J/P40-34 J/P12-8 J/P40-35 J/P12-1 J/P41-49 J/P25-4 J/P41-50 J/P25-1 J/P40-3 J/P26-1 Paper timing sensor J/P73-3 External attachment connector Upper paper empty sensor Lower paper empty sensor Paper exit sensor Output tray full
J/P10-1 J/P8-11 J/P11-1 Power Control Board #2 J/P70-1 J/P12-2 AC Power Supply J/P12-1 DC Power Supply J/P40-27 J/P40-28 J/P23-5 J/P41-35 PCL Board J/P8-13 J/P41-26 J/P81-1 High Voltage Unit J/P82-1 Counter J/P91-1 J/P40-10 J/P69-1 J/P40-11 J/P65-1 Lower pick-up clutch 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.
J/P331-3 DC Power Supply J/P330-3 J/P323-3 J/P305-3 J/P306-3 Duplex Control Board #1 J/P310-3 Duplex Control Board #2 J/P333-1 Fuse (FH2) J/P73-1 J/P73-6 ( ) ) ( Signal Interface Board External Attachment Connector Figure 6-5.
Duplex Control Board #1 J/P309-4 J/P319-1 Paper pass sensor J/P309-3 J/P318-1 Cover open sensor J/P312-1 J/P320-1 Registration side sensor J/P312-4 J/P322-1 Registration paper sensor J/P306-2 J/P331-2 DC Power Supply J/P330-2 Duplex Control Board #2 J/P323-2 J/P310-2 J/P305-2 Figure 6-7.
Ground System 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 Wiring Diagrams and Electrical Data 6-21
Host Interface Reference Standard printers support three host interfaces: RS-232C, RS-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.
Standard DCE to DTE RS-232C Cable The standard DCE host to the printer (DTE) pin configuration follows.. Table 6-2.
DTE Host to Printer (Option 1) Table 6-3. DTE Host to Printer Connector Wiring (Option 1) Host Signal DCE DTE Printer Signal GND 1 1 GND GND 7 7 GND DTR 20 20 DTR DCD 8 8 DCD DSR 6 6 DSR RTS 4 4 RTS CTS 5 5 CTS TD 2 2 TD RD 3 3 RD DTE Host to Printer (Option 2) Table 6-4.
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.
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 Signal DCE DTE Printer Signal FG 1 1 FG 2 2 TD 3 3 RD 4 4 RTS 5 5 CTS 6 6 ------ 7 7 SG 8 8 DCD 9 20 DTR SG TD DSR RD RS-422 Host interface The RS-422 host interface uses the signal definitions defined below.
Centronics Parallel Host Interface The Centronics Parallel host interface uses the signal definitions defined below. Table 6-9.
IBM Parallel to Printer Table 6-10.
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.
Circuit Board Settings Several of the circuit boards in the printer have jumpers and/or DIP switches used to control 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 interface interactions. In general, the four jumpers on the signal interface board should remain as set at the factory. The jumpers control the following: Table 6-11.
ON For a Centronics Parallel Host Interface: set all four DIP switches to OFF by pushing them toward the interior of the printer, as illustrated. 1 2 3 4 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 settings only if directed to do so when following TAG #807.
6-32 Wiring Diagrams and Electrical Data
Chapter 7 Removal/Replacement Procedures Section 5 Troubleshooting Removal/Replacement Procedures 7-1
Contents Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 Back Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6 Lower Back Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Left Side Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Right Side Cover Removal (Simplex) . .
Fuser Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 Paper Feed Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58 Paper Timing Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59 Upper Feed Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60 Lower Feed Roller Removal . . . . . . . . . . . . . . . . .
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 preceding 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 To remove a part, follow the instructions provided.
Front Cover Removal Front Cover Removal To remove the front cover: 1 Open the front cover. 2 While holding the cover up halfway, unhook the strap from the right side. 3 Duplex only: Remove the strap from the left side. 4 Slide the front cover to the right off its hinges.
Back Cover Removal Back Cover Removal To remove the back cover: 1 Remove all external cables and attachments. 2 Open the top and back covers. 3 Disconnect CN31, CN32, CN37, CN40, CN41, CN74, and CN91. 4 Duplex only: Disconnect CN36. 5 For the hard drive option, disconnect the drive’s data cable. 6 Remove the ground screw from the back cover. 7 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.
Lower Back Cover Removal Lower Back Cover Removal To remove the lower back cover: 1 Disconnect all external cables and attachments. 2 Open the back cover. 3 Loosen the two screws holding the lower back cover in place. 4 Lift the back cover off its hinges. 5 While supporting the back cover, lift the lower back cover out and away from the printer. 6 Return the back cover to its hinges.
Left Side Cover Removal Left Side Cover Removal To remove the left side cover: 1 Open the top, back, and front covers. 2 Duplex only: Remove the duplex tray by disconnecting P305 and loosening the two thumb screws. 3 Remove the upper and lower paper cassettes. 4 Loosen the two screws for the left side cover. 5 Lift the cover up and away from the printer. Replacement Note: When reinstalling, make sure the inside mounting tabs are properly positioned.
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: 1 Remove the paper output tray. 2 Open the top and front covers. 3 Loosen the two screws holding the right side cover. 4 Pull the cover out and away from the printer. Replacement Note: When reinstalling, make sure the inside mounting tabs are properly positioned.
Right Side Cover Removal (Duplex) Right Side Cover Removal (Duplex) Note The service kit is attached inside the right side cover. To remove the right side cover: 1 Remove the paper output tray. 2 Open the top, back, and front covers. 3 Remove the two screws holding the right side cover in place. 4 Close the top cover. 5 Pull the cover out and away from the printer. Replacement Note: Tighten the screws first. Then, gently lift the bottom tabs into place.
Vacuum Transport Unit Removal (Simplex) Vacuum Transport Unit Removal (Simplex) To remove the simplex vacuum transport unit: 1 Open the top and back cover. 2 Disconnect CN22A. 3 Remove the retaining clip holding the cable in place. 4 Remove the ground screw on the left side of the back cover. 5 Remove the harness stays holding the cable in place. 6 Remove the vacuum transport unit (four screws).
Vacuum Transport Unit Removal (Simplex) Mounting Screws Vacuum Transport Detail 7-12 Removal/Replacement Procedures
Vacuum Transport Unit Removal (Duplex) Vacuum Transport Unit Removal (Duplex) To remove the duplex vacuum transport unit: 1 Open the top cover. 2 Remove the upper duplex roller cover (four screws). 3 Remove the lower duplex roller cover (four screws). 4 Disconnect CN22. 5 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. 6 Remove the four harnesses stays holding the cable in place.
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.) 3 Remove the four screws for each support assembly. 4 Lift the top cover up and away from the printer.
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.
Top Cover Hinge Removal Top Cover Hinge Removal To remove the top cover hinge: 1 Open the top cover. 2 Remove the two screws holding the hinge/support to the top cover. 3 Remove the two screws holding the hinge/support to the printer base. 4 While supporting the top cover, loosen the top two screws. 5 Remove the hinge. Replacement Note: Replace one hinge at a time so that one always remains in place to support the top cover.
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.
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 each front cover hinge.
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.
Counter Removal Counter Removal To remove the counter: 1 Open the front cover. 2 Remove the screw holding the counter in place. 3 Pull out the counter. 4 Disconnect connector CN82.
IGS Board Removal IGS Board Removal To remove the IGS board: 1 Open the back cover. 2 Disconnect connectors CN31, CN32, CN33, and CN74. 3 For the hard drive option, disconnect the drive’s data cable. 4 Push the two retaining clips away from the board. 5 Remove the IGS board.
PCL Board Removal PCL Board Removal To remove the PCL board: 1 Open the back cover. 2 Disconnect connectors CN33, CN37, CN40, CN41, and CN91. 3 Duplex only: also disconnect connector CN36. 4 Push the two retaining clips away from the board. 5 Remove the PCL board. 6 Change the settings of the DIP switches on the replacement PCL to match the switch settings on the original PCL.
Printhead Assembly Removal Printhead Assembly Removal To remove the printhead assembly: 1 Open the front, top, and back covers. 2 Remove the photoconductor unit and place in its protective packaging. 3 Remove the cleaner unit. 4 Remove the fuser drive cover (three screws). 5 Remove the main drive cover (one screw). 6 Remove the gear stay cover (one screw). 7 Remove the gear stay (three screws). 8 Disconnect connectors CN27, CN30, and CN96 (see back detail).
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.
Disk Drive Housing Removal Disk Drive Housing Removal To remove the disk drive housing: 1 Open the front and back covers. 2 Remove the diskette(s). 3 Disconnect CN77 and CN79. 4 For the hard drive option, disconnect the drive’s data cable. 5 Loosen the thumbscrew on the back of the disk drive housing. 6 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.
Cooling Fan Removal Cooling Fan Removal To remove the cooling fan: 1 Open the back cover. 2 Remove the fuser drive cover (three screws). 3 Disconnect CN21. 4 Remove the cooling fan (four screws).
Duplex Fan Removal Duplex Fan Removal To remove the duplex fan: 1 Open the back and top covers. 2 Remove the fuser drive cover (three screws). 3 Remove the EMI grounding plate (if present) from the rear of the printer (four screws). 4 Remove the four screws holding the duplex fan in place. 5 Disconnect CN326. 6 Lift the duplex fan from the printer.
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).
AC Power Supply Removal AC Power Supply Removal To remove the AC power supply: 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 Disconnect CN4 and CN70.
AC Power Supply Removal 7-30 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.
DC Power Supply Removal DC Power Supply Removal To remove the DC power supply: 1 Open the front, top, and back covers. 2 Disconnect CN6, CN7, CN8, and CN330. 3 Remove the output tray. 4 Remove the right side cover. (See page 7-9.) 5 Remove the bracket for the output tray guide (two screws). 6 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.
High Voltage Unit Removal High Voltage Unit Removal To remove the high voltage unit: 7-32 1 Open the top and back covers. 2 Remove the EMI grounding plate (if present) from the rear of the printer (four screws). 3 From the top, loosen the screw holding the high voltage unit in place. 4 Pull the high voltage unit out from the back of the printer. 5 Disconnect connectors CN23, CN24, CN85, and the two high voltage leads. 6 Remove the high voltage unit.
Photoconductor Seam Sensor Removal PhotoconductorSeam Sensor Removal To remove the photoconductor seam sensor: 1 Open the front, back, and top covers. 2 Remove the photoconductor and place in its protective packaging. 3 Remove the developer unit. 4 Remove the paper feed drive cover (three screws). 5 Remove the bracket holding CN64 in place (one screw). 6 Remove the screw holding the seam sensor bracket in place. It is situated under the bracket for CN64.
Photoconductor Seam Sensor Removal 7 From inside the empty photoconductor cavity, disconnect connector CN63. 8 Lift the photoconductor seam sensor and bracket up out of the printer. Note: Use caution not to bend the bracket.
Photoconductor Rear Guide Rail Removal Photoconductor Rear Guide Rail Removal To remove the photoconductor rear guide rail: 1 Open the front, back, and top covers. 2 Remove the photoconductor and place in its protective packaging. 3 Remove the developer unit. 4 Remove the paper feed drive cover (three screws). 5 Remove the photoconductor seam sensor. (See illustration on page 7-33.) 6 Remove the spring at the base of the guide rail. To do this, gently pull the spring forward off its post.
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.
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.
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 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.
Jogging Motor Control Board Removal Jogging Motor Control Board Removal To remove the jogging motor control board: 1 Open the back cover. 2 Remove the paper feed drive cover (three screws). 3 Remove the power control board cover (one screw). 4 Disconnect CN100, CN101, and CN102. 5 Disengage the board. To do this, pinch the two standoffs on the board. 6 Lift the board from its mounting bracket.
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. 2 Remove the upper and lower paper cassettes. 3 Using a small screwdriver, pry up the paper size sensor. Turn the sensor counterclockwise and lift up. 4 For the upper paper size sensor, disconnect CN45 and CN46. 5 For the lower paper size sensor, disconnect CN43, CN47, and CN48.
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.
Upper Cassette Mount Removal 10 Remove the upper paper size sensor. (See page 7-40.) 11 Remove the cassette release cover (two screws). 12 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. 13 For the tray releases: 7-42 • 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.
Upper Cassette Mount Removal 14 Disengage the top of the damper assembly. Push it to the right out of the way.
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.
Lower Cassette Mount Removal Lower Cassette Mount Removal To remove the lower 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 Remove the power control board. (See page 7-38.
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.
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.
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.
Upper Paper Guide Removal 5 Remove the cassette release cover (two screws). 6 Raise the upper paper guide. 7 Remove 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.
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. 3 Raise the upper paper guide. 4 Remove the roller and bearings from the underside of the upper paper guide.
Lower Paper Guide Removal Lower Paper Guide Removal To remove the lower paper guide: 1 Open the top cover. 2 Raise the upper paper guide. 3 Raise the lower paper guide slightly. 4 Push the base of the lower paper guide toward the back of the printer until the front mounting peg is free. 5 Lift the lower paper guide out of the printer. Note: Use caution. This piece is made of plastic and can easily break if mishandled.
Paper Timing Guide Removal Paper Timing Guide Removal To remove the paper timing guide: 1 Open the front, back, and top covers. 2 Raise the upper paper guide. 3 Remove the lower paper guide. (See page 7-51.
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.
Cleaner Drive Belt Removal Cleaner Drive Belt Removal To remove the cleaner drive belt: 1 Open the back cover. 2 Remove the fuser drive cover (three screws). 3 Remove the main drive cover (one screw). 4 Lift the idler arm and slide the cleaner drive belt off the gear.
Cleaner Drive Removal Cleaner Drive Removal To remove the cleaner drive: 1 Open the back cover. 2 Remove the fuser drive cover (three screws). 3 Remove the main drive cover (one screw). 4 Remove the cleaner drive belt. (See page 7-54.) 5 Remove the two high voltage leads. 6 Remove the cleaner drive (three screws).
Fuser Drive Belt Removal Fuser Drive Belt Removal To remove the fuser drive belt: 1 Open the back cover. 2 Remove the fuser drive cover (three screws). 3 Remove the main drive cover (one screw). 4 Remove the gear stay cover (one screw). 5 Remove the gear stay (three screws). 6 Remove the main drive gear and bearing (single C-clip). 7 Remove the single upper left screw and the two lower screws holding the fuser drive in place.
Fuser Drive Removal Fuser Drive Removal To remove the fuser drive: 1 Open the back cover. 2 Remove the fuser drive cover (three screws). 3 Remove the main drive cover (one screw). 4 Remove the gear stay cover (one screw). 5 Remove the gear stay (three screws). 6 Remove the fuser drive belt. (See page 7-56.) 7 Remove the fuser drive (four screws).
Paper Feed Drive Belt Removal Paper Feed Drive Belt Removal To remove the paper feed drive belt: 1 Open the back cover. 2 Remove the fuser drive cover (three screws). 3 Remove the paper feed drive cover (three screws). 4 Remove the main drive cover (one screw). 5 Remove the cleaner drive belt. (See page 7-54.) 6 Push down on the idler arm and slide the paper feed drive belt off the gear.
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.
Upper Feed Roller Removal Upper Feed Roller Removal To remove the upper feed roller: 1 Open the front and back covers. 2 Remove the paper feed drive cover (three screws). 3 Disconnect CN66. 4 Remove the paper feed drive belt from the upper feed roller gear. 5 Remove the cassette release cover (two screws). 6 Remove the front C-clip and bearing. 7 Slide the upper feed roller out the back of the printer.
Lower Feed Roller Removal Lower Feed Roller Removal To remove the lower feed roller: 1 Open the front and back covers. 2 Remove the paper feed drive cover (three screws). 3 Disconnect CN67. 4 Remove the paper feed drive belt from the lower feed roller gear. 5 Remove the cassette release cover (two screws). 6 Remove the front C-clip and bearing. 7 Slide the lower feed roller out the back of the printer.
Upper Pick-Up Roller Removal Upper Pick-Up Roller Removal To remove the upper pick-up roller: 1 Open the front and back covers. 2 Remove the paper feed drive cover (three screws). 3 Disconnect CN68. 4 Remove the cassette release cover (two screws). 5 Remove the front C-clip and bearing. 6 Slide the upper pick-up roller out the back of the printer. Note: You may need to remove the EMI grounding plate.
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 screws). 3 Remove the upper pick-up roller drive (three screws). Note: You may need to remove the EMI grounding plate.
Lower Pick-Up Roller Removal Lower Pick-Up Roller Removal To remove the lower pick-up roller: 1 Open the front and back covers. 2 Remove the paper feed drive cover (three screws). 3 Disconnect CN69. 4 Remove the cassette release cover (two screws). 5 Remove the front C-clip and bearing. 6 Slide the lower pick-up roller out the back of the printer.
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).
Job Offset Assembly Removal Job Offset Assembly Removal To remove the job offset assembly: 1 Open the front, top, and back covers. 2 Remove the paper output tray. 3 Remove the right side cover. (See page 7-10.) 4 Remove the operator panel. (See page 7-19.
Job Offset Assembly Removal 5 Remove the DC power supply (See page 7-31.) 6 Remove the mounting bracket for the DC power supply (two screws). 7 Remove the fuser drive cover (three screws). 8 Disconnect CN19 and CN54. 9 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.
Exit Pinch Roller Removal Exit Pinch Roller Removal To remove the exit pinch roller: 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 pinch roller in place. 5 Remove the front screw holding the exit guide in place.
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.
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).
Lower Static Brush Removal Lower Static Brush Removal To remove the lower static brush: 1 Open the top, front and back covers. 2 Remove the fuser. 3 Remove the operator panel. (See page 7-19.) 4 Remove the exit pinch roller assembly. (See page 7-68.) 5 Remove the lower static brush (two screws).
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.
Exit Roller Assembly Removal 5 Remove the fuser drive cover (three screws). 6 Remove the exit pinch roller. (See page 7-68.) 7 Duplex only: Remove the lower duplex drive (3 screws). 8 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 printer. Note: Use caution so as not to damage the paper full or exit sensors.
Exit Cover Removal (Simplex) Exit Cover Removal (Simplex) To remove the simplex exit cover: 1 Open the front, back, and top covers. 2 Remove the fuser. 3 Remove the right side cover. (See page 7-9.) 4 Remove the paper output tray. 5 Remove the operator panel. (See page 7-19.
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.
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.) 5 Remove the operator panel. (See page 7-19.
Exit Cover Removal (Duplex) 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 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).
Paper Exit Sensor Removal Paper Exit Sensor Removal To remove the paper exit sensor: 1 Open the front, back, and top covers. 2 Remove the fuser. 3 Remove the operator panel. (See page 7-19.) 4 Remove the exit pinch roller. (See page 7-68.) 5 Disconnect CN49. 6 Remove the two screws holding the exit cover in place (one front and one back). 7 Tilt the exit cover assembly toward the center of the printer. 8 From the underside, remove the paper exit sensor (single screw).
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. 3 Remove the operator panel. (See page 7-19.) 4 Remove the exit pinch roller. (See page 7-68.) 5 Disconnect CN51. 6 Remove the two screws holding the exit cover in place (one front and one back). 7 Tilt the exit cover toward the center of the printer. 8 From the underside, remove the paper full sensor (single screw).
Front Cover Interlock Switch Removal Front Cover Interlock Switch Removal To remove the front cover interlock switch: 1 Open the front, top, and back 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 AC power supply. (See page 7-29.) 6 Remove the AC power supply top cover (two screws). 7 Disconnect the two wires connected to the interlock switch.
Back Cover Interlock Switch Removal Back Cover Interlock Switch Removal To remove the back cover interlock switch: 1 Open the front, top, and back 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 AC power supply. (See page 7-29.) 6 Remove the AC power supply side cover (one screw). 7 Disconnect the four wires connected to the interlock switch.
Top Cover Interlock Switch Removal Top Cover Interlock Switch Removal To remove the top cover interlock switch: 1 Open the top, front, and back 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 Duplex only: Remove the duplex tray mount (four screws). 6 Remove the paper feed drive cover (three screws; duplex two screws). 7 Disconnect the two wires connected to the interlock switch.
Erase Lamp Removal Erase Lamp Removal To remove the erase lamp: 1 Open the top and back covers. 2 Remove the photoconductor and place it in its protective packaging. 3 Remove the fuser drive cover (three screws). 4 Disconnect CN26. 5 Remove the screw holding the erase lamp in place. 6 Disengage the front of the erase lamp from its guide pin. 7 Slide the unit out from the back of the printer.
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).
EP Cover Removal 6 Remove the fuser drive cover (three screws). 7 Remove the two supports for the vacuum transport unit (one screw each). 8 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.
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: 1 Disconnect all external cables and attachments. 2 Open the front, back, and top covers. 3 Remove the photoconductor and place it in its protective packaging. 4 Remove the cleaner unit. 5 Remove the back cover. (See page 7-6.) 6 Remove the lower back cover. (See page 7-7.) 7 Remove the signal interface board. (See page 7-37.
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 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.
Main Gear Drive Removal Main Gear Drive Removal To remove the main gear drive: 1 Open the back cover. 2 Remove the lower back cover. (See page 7-7.) 3 Remove the paper feed drive cover (three screws). 4 Remove the fuser drive cover (three screws). 5 Remove the main drive cover (one screw). 6 Remove the gear stay cover (one screw). 7 Remove the gear stay (three screws). 8 Remove the cleaner drive belt. (See page 7-54.) 9 Remove the paper feed drive belt. (See page 7-58.
Duplex Control Board #1 Removal Duplex Control Board #1 Removal To remove duplex control board #1: 1 Open the top cover. 2 Remove the duplex control board cover (two screws). 3 Disconnect CN306, CN307, CN308, and CN309. 4 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.
Duplex Control Board #2 Removal Duplex Control Board #2 Removal To remove duplex control board #2: 1 Open the top cover. 2 Remove the duplex tray. 3 Remove the paper guide from the duplex tray (four screws). 4 Disconnect CN310, CN311, and CN312. 5 Remove duplex control board #2 (two screws).
Duplex Tray Registration Motor Removal Duplex Tray Registration Motor Removal To remove the duplex tray registration motor: 1 Open the top cover. 2 Remove the duplex tray. 3 Remove the paper guide inside the duplex tray (four screws). 4 Disconnect CN321. 5 Remove the registration motor (two screws).
Duplex Skew Correction Cable Removal Duplex Skew Correction Cable Removal To remove the duplex skew correction cable: 1 Open the top cover. 2 Remove the duplex tray. 3 Remove the paper guide from inside the duplex tray (four screws). 4 Slide the skew correction guides toward the center of the duplex tray. 5 Remove the bracket holding the shaft in place (two screws). 6 Remove the screw holding the cable mounting plate in place.
Duplex Skew Correction Cable Removal Paper Guide Skew Correction Guides Mounting Plate Screw Shaft Bracket Shaft Mounting Bead Skew Correction Cable Drive Gear Pulley Cable Mounting Plate Tension Spring Pulley Assembly Skew Correction Cable Detail Removal/Replacement Procedures 7-93
Upper Duplex Drive/Clutch Assembly Removal Upper Duplex Drive/Clutch Assembly Removal To remove the upper duplex drive/clutch assembly: 1 Open the top cover. 2 Remove the rear duplex cover. (See page 7-17.) 3 Remove the lower duplex roller cover (four screws). 4 Disconnect CN316. 5 Remove the upper duplex drive/clutch assembly (three screws).
Duplex Route Motor/Solenoid Assembly Removal Duplex Route Motor/Solenoid Assembly Removal To remove the duplex route motor/solenoid assembly: 1 Open the top cover. 2 Remove the rear duplex cover. (See page 7-17.) 3 Remove the upper duplex roller cover (four screws). 4 Disconnect CN313 and CN314. 5 Remove the duplex route motor/solenoid assembly (three screws).
“A” Roller Removal “A” Roller Removal To remove the “A” roller: 1 Open the top cover. 2 Remove the rear duplex cover. (See page 7-17.) 3 Remove the lower duplex roller cover (four screws). 4 Remove the front C-clip and bearing from the “A” roller. 5 Lower the top cover to a 45 degree angle. 6 Slide the “A” roller out the back of the printer.
“B” Roller Removal “B” Roller Removal To remove the “B” roller: 1 Open the top cover. 2 Remove the rear duplex cover. (See page 7-17.) 3 Remove the upper duplex roller cover (four screws). 4 Remove the lower duplex roller cover (four screws). 5 Remove the front C-clip and bearing from the “B” roller. 6 Remove two screws holding the duplex control board cover in place. 7 Move the cover to the left out of the way. 8 Loosen the screw holding the idler roller in place.
“C” Roller Removal “C” Roller Removal To remove the “C” roller: 1 Open the top cover. 2 Remove the rear duplex cover. (See page 7-17.) 3 Remove the upper duplex roller cover (four screws). 4 Remove the front mechanism cover (two screws). 5 Remove the front C-clip and bearing from the “C” roller. 6 Slide the “C” roller out from the back of the printer.
“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 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.
Duplex Route Separator Removal Duplex Route Separator Removal To remove the duplex route separator: 1 Open the top cover. 2 Remove the rear duplex cover. (See page 7-17.) 3 Remove the upper duplex roller cover (four screws). 4 Remove the duplex route motor/solenoid assembly. (See page 7-95.) 5 Remove the front mechanism cover (two screws). 6 Open the duplex cover. 7 Remove screw holding the return arm in place. 8 Disengage the return spring.
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.
Duplex Paper Path Sensor Removal Duplex Paper Path Sensor Removal To remove the duplex paper path sensor: 1 Open the top cover. 2 Remove the two screws holding the duplex control board cover in place. 3 Move the cover to the left out of the way. 4 Disconnect CN319. 5 Remove the duplex paper path sensor (single screw).
Chapter 8 Options Section 6 Options Troubleshooting 8-1
Contents Options Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 1200-Sheet/2500-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4 Bench Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Prefeed Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6 Input Control Board Logic . . . . . .
Introduction 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 Illustrated Parts Catalog.
1200-Sheet/2500-Sheet Feeder Table 8-1.
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.
sor IPES signals the input control board that paper is present on the elevator. Photosensor 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.
Input Control Board Logic The table below indicates switching logic for the unit’s various components. Except for the power control switch (PCSW), each 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.
8-8 J600 W520 W508 J400 P507 Gnd AC PH-1 P522 W505 Power Supply + 12Vdc P506 P523 W506 J506 P527 P528 Input Control Board SW2 PCSW P508 W510 P509 J509 W507 P500 P529 J529 W514 SOL Figure 8-4.
1400-Sheet Stacker Table 8-3.
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. Figure 8-6. 1400-Sheet Stacker Bench Test Preparation To bench test the 1400-sheet stacker: 1 Turn the printer’s main power switch off. 2 Remove the output tray from the stacker unit. 3 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.
7 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. 8 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. 9 Remove the jumper from pin 9 and pin 10.
Connector Locations CN416 Printer side Figure 8-7. Connector Locations (front view, cover removed) Connectors/circuit boards shown with broken lines are concealed from view. CN409 CN426 CN425 Rear side CN405 CN406 Fuse 1 CN401 Fuse 2 Power supply Output control board Front side CN404 CN402 CN417 Frame ground CN403 CN412 Figure 8-8.
Printer side Output side CN415 CN424 (AC power) 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 Output side Printer side CN414 CN407 CN408 Figure 8-10.
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.
Options Figure 8-11.
8-16 Options
Chapter 9 General Printer Maintenance Section 7 Troubleshooting General Printer Maintenance 9-1
Contents General Printer Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3 Every-Call Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6 Adjusting Paper Feed Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 (page 7-6) The every-call cleaning procedure, as the name implies, is performed every time the printer is serviced.
Introduction • Do not push objects of any kind through the cabinet slots. They may contact dangerous 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.
General Printer Maintenance HISTORY LOG To Be Completed By User Page Counter Operator To Be Completed By HP HP Notified Date/Time Down-Time HP Customer Engineer On Site Malfunction Description: Action Required and Comments: Malfunction Description: Action Required and Comments: Malfunction Description: Action Required and Comments: Date Time Introduction 9-5
Introduction Every-Call Cleaning Procedure Perform the every-call cleaning procedure every time the printer is serviced. When troubleshooting a printer problem, you may be directed to complete this procedure as you isolate 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 printer.
Introduction Clean the Developer Unit • • • Inspect the unit for damage or contamination; repair or replace as necessary. • Vacuum the felt areas around the magnetic roller, being careful not to vacuum toner from the magnetic roller. • Reinstall the developer unit. 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.
Introduction Adjusting Paper Feed Tension Printers With Paper Tension Levers Recently released simplex and duplex printers have pressure tension levers inside the front cover, as illustrated in Figure 9-1, Paper Feed Tension Levers, below: Figure 9-1. Paper Feed Tension Levers To adjust the tension: 9-8 1 Open the printer’s front cover. 2 Identify the cassette whose tension is to be adjusted, and select the correct lever.
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 printers: 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.
Introduction This reveals the pick pressure adjusters, illustrated in Figure 9-3, Paper Pick Pressure Adjusters, below: Figure 9-3. Paper Pick Pressure Adjusters 3 4 9-10 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.
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 illustrations indicate where lubrication may be required.
Introduction Figure 9-4.
Introduction Front View Lubrication Tables Table 9-1. All Printers – Front View Lubrication Symbol Part Lubricant H1 Front roller bearings (paper feed, paper pickup, timing and exit rollers) oil H2 Vacuum transport drive shaft oil H3 Fuser drive bearing oil H4 Upper paper guide roller oil L5 Fuser drive gear red grease L6 Vacuum transport drive gear red grease L7 Vacuum transport gear red grease P8 Vacuum transport rollers Molycote Duplex Only Table 9-2.
Introduction Figure 9-5.
Introduction Rear View Lubrication Tables Table 9-3. All Printers – Rear View Lubrication Symbol Part Lubricant H1 Clutch shafts: upper pick-up roller, lower pick-up roller, upper feed roller, lower feed roller, paper timing roller oil P2 Upper and lower pick-up roller drive assemblies Molycote P3 Main drive gear assembly Molycote P4 Main drive gear Molycote P5 Main drive motor gear Molycote P6 Fuser drive gear Molycote P7 Fuser drive assembly Molycote Duplex Only Table 9-4.
Introduction Figure 9-6. Duplex Only: Top View Lubrication Table 9-5.
Introduction Figure 9-7. Duplex Only: Duplex Holding Tray Lubrication Table 9-6.
Introduction Tune-Up Maintenance Procedure The tune-up maintenance procedure should be performed when the printer: jams frequently; yields sub-standard print quality even after completing regular maintenance procedures; 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.
Introduction 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 Plug in the printer and turn it on. 10 Run test prints to ensure that the paper feeds correctly through the printer.
Introduction 9-20 General Printer Maintenance
Appendix A Abbreviations and Acronyms ACIA . . . . . . . . . Asynchronous Communication Interface Adapter EPROM. . . . . . . Erasable Programmable Read Only Memory ALU . . . . . . . . . . Arithmetic Logic Unit EPP . . . . . . . . . . Electrophotographic Process APA . . . . . . . . . . All Points Addressable EPS . . . . . . . . . . Exit Paper Sensor ARC . . . . . . . . . . “A” Roller Clutch (Duplex only) ERASER . . . . . . Erase Lamp ARIF. . . . . . . . . . Array Interface EXS . . . . . . . . . .
MCH . . . . . . . . . .Main Charger Unit MCS . . . . . . . . . .Main Charger Sensor RPS . . . . . . . . . . Registration Paper Sensor (Duplex only) MIGS . . . . . . . . .Minter Image Generation System RSS . . . . . . . . . . Registration Side Sensor (Duplex only) MPU . . . . . . . . . .Micro Processing Unit SCC . . . . . . . . . . Serial Communication Controller MUX . . . . . . . . . .Multiplexer OPC. . . . . . . . . . .Organic Photoconductor OPPNL . . . . . . . .Operator Panel PC . . . . . . . . . .
Index 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 soleno
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-
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 testing 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 communicati
overriding 1-22 top cover 3-192 J job offset assembly problems 3-75 removal 7-66 jogging motor testing 5-8 jogging motor control board removal 7-39 jumpers signal interface board 6-30 L left side cover connectors 6-7 removal 7-8 locating connectors 6-6 lower back cover removal 7-7 lower cassette latch problems 3-24 paper jams/misfeeds 3-30 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 lo
paper exit sensor removal 7-78 paper feed drive belt removal 7-58 paper feed tension adjusting 9-8 paper full sensor removal 7-79 paper handling problems 2-13 paper 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
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 re
too light 3-49 toner supply motor testing 5-9 tool kit 9-4 top cover connectors 6-10 removal 7-14 top cover hinge removal 7-16 top cover interlock switch removal 7-82 top cover support removal 7-15 transfer charger circuit problems 3-58, 3-63 testing 5-11 troubleshooting analysis guide (TAG) 1-19 tune-up maintenance procedure 9-18 removal 7-11, 7-13 voltage isolation diagrams 6-16–6-20 voltage ranges operating 1-18 W wrinkled paper 3-138 U upper cassette latch problems 3-18 paper jams/misfeeds 3-26 probl
