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Cut Sheet Printers Maintenance Manual Model C40D
E1195 HP Part No. C4672-90005
Notice
Hewlett-Packard makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Hewlett-Packard shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. Hewlett-Packard assumes no responsibility for the use or reliability of its software on equipment that is not furnished by Hewlett-Packard. This document contains proprietary information which is protected by copyright. All rights are reserved. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Hewlett-Packard Company. The information contained in this document is subject to change without notice.
Hewlett-Packard Company System Peripherals Operation MS 44MC 19111 Pruneridge Avenue Cupertino, CA 95014
Printing History
New editions are complete revisions of the manual. Update pages, which are issued between editions, contain additional and replacement pages to be merged into the manual by the customer. The date on the title page changes only when a new edition or a new update is published. No information is incorporated into a reprinting unless it appears as a prior update; the edition does not change when an update is incorporated. The software code printed alongside the date indicates the version level of the software product at the time the manual or update was issued. Many product updates and fixes do not require manual changes and, conversely, manual corrections may be done without accompanying product changes. Therefore, do not expect a one-to-one correspondence between product updates and manual updates. Edition 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .November 1995 Edition 2. . . . . . . . . . . . . . . . . . . . . . . . . . .June 1999
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Preface
The C40D Maintenance Manual contains all the information needed to maintain and service Hewlett Packard C40D printers. The C40D printer series are high-speed, non-impact printers utilizing electrophotographic imaging technology. The information in this manual is for authorized field representatives who are familiar with basic printer operations. It serves as a supplement to training classes and provides a basis for discussion with regional field service engineers and customer support representatives.
Using This Manual
This manual is organized into the following sections: Section 1, Troubleshooting Reviews the organization of the manual, the way the printer works, and how to troubleshoot the printer, including some standard procedures to follow when troubleshooting. This chapter also includes a chart detailing exactly what each causes each error code, illustrations of all sensors in the printer, and a list of abbreviations used throughout the manual. Section 2, TAG Cross- Reference Tables Provides cross-reference tables; look up specific printer problem description (in either the mechanical malfunction, error code, or print quality description tables), then turn to the TAG indicated on the chart to troubleshoot the problem. Section 3, Troubleshooting Analysis Guides Detailed step-by-step procedures to help you isolate and resolve specific printer problems. If you are not sure which TAG to start with, begin with the overview, TAG 001. Section 4, Print Quality Samples Shows print test patterns indicating specific problems, and referencing the TAG that treats each problem. Section 5, Diagnostic Tests Reviews each printer software diagnostic. Section 6, Wiring Diagrams and Electrical Data Shows printer schematics and locations of individual components. Section 7, Removal/Replacement Procedures Outlines procedures to follow when removing and replacing printer parts, also called FRUs (Field-Replaceable Units).
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Section 8, Options Provides information about the optional High Capacity Input and High Capacity Output bins. Section 9, General Printer Maintenance Reviews printer maintenance procedures to complete during service calls. Index Provides a list of references to topics mentioned in this manual.
Other Manuals
The C-Series Illustrated Parts Catalog shows every FRU and CRU (customer-replaceable unit) in the printer, including part number information. This information is frequently updated. The C40D Installation Manual, C4672-90007, guides you through unpacking, setup, testing, and network configuration of your C40D printer. The C40D Operator's Manual, C4672-90006, contains all the information needed to operate Hewlett Packard C40D printers. The C40D Technical Reference Manual, C4672-60012, is a complete guide to using fonts and the PJL and PostScript emulations on the C40D. It also documents aspects of printer usage in detail. The Cut Sheet Printers Paper Specifications Guide, C4672-90002, explains the various kinds of papers usable in the printer, how to care for them, and how to minimize paperrelated problems with the C40D.
Copyright ©1999 Hewlett Packard, Inc. All rights reserved. November 1995 Please address any comments or questions with respect to this document to:
Publications Manager System Peripherals Operation MS 44MC Hewlett-Packard Company 19111 Pruneridge Avenue Cupertino, CA 95014
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Contents
Contents
Troubleshooting
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 The Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Paper Path and Cycle Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Simplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Sensors and Switches Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Sensor and Switch Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 General Troubleshooting Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 The Problem: Printer or Host?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Running Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Protocol Converters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Reading the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Confirming Line Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Using the Troubleshooting Analysis Guide (TAG) . . . . . . . . . . . . . . . . . . . . 1-15 Sample TAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Standard Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Power-on-reset (POR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Checking Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Installing the Interlock By-pass Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Producing a Developed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Producing a Toner Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Completing a Service Call. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Error Message and Code Technical Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
TAG Cross-Reference Tables
Error Code/TAG Cross-Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Print Quality/TAG Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Mechanical Malfunction/TAG Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Troubleshooting Analysis Guides
TAG 001: Troubleshooting a Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 TAG 002: Check Problem Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 TAG 010: Upper Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
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TAG 011: Lower Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 TAG 012: Upper Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 TAG 013: Lower Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 TAG 020: Paper Jam/Misfeed in Upper Cassette Area . . . . . . . . . . . . . . . . . . . . . 3-19 TAG 021: Paper Jam/Misfeed in Lower Cassette Area . . . . . . . . . . . . . . . . . . . . . 3-22 TAG 022: Paper Jam in the Transfer or Fuser Area. . . . . . . . . . . . . . . . . . . . . . . . 3-26 TAG 023: Paper Jam in the Output Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 TAG 025: Paper in Input Area Before Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 TAG 026: Paper in Output Area Before Printing. . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 TAG 030: Developer Bias Short/Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 TAG 031: Toner Patch Reference Level Incorrect. . . . . . . . . . . . . . . . . . . . . . . . . 3-39 TAG 032: Toner Patch Too Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 TAG 035: Out of Toner or ADD TONER Indication . . . . . . . . . . . . . . . . . . . . . . 3-43 TAG 036: Developer Not Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 TAG 040: Photoconductor Seam Sensor Malfunction. . . . . . . . . . . . . . . . . . . . . .3-46 TAG 044: Charge Corona/Transfer Corona Circuit Open . . . . . . . . . . . . . . . . . . . 3-49 TAG 045: Charge Corona Circuit Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52 TAG 047: PC Life Data Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 TAG 048: Developer Life Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 TAG 050: Transfer Corona Circuit Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 TAG 055: Erase Lamp Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58 TAG 070: Fuser Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 TAG 071: Open Fuser/Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65 TAG 072: Fuser Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66 TAG 097: +12 Vdc Power Shorted or Sensing Problem . . . . . . . . . . . . . . . . . . . . 3-68 TAG 098: -12 Vdc Power Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78 TAG 099: +24 Vdc Power Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80 TAG 100: VPCL Board Interface Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89 TAG 130: Disk Drive Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90 TAG 200: RIGS Internal Communication Malfunction. . . . . . . . . . . . . . . . . . . . . 3-95 TAG 201: RIGS-VPCL Interface Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97 TAG 405: RIGS Bit-Map RAM Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99 TAG 500: +5 Vdc Power Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100 TAG 600: Vac Power Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105 TAG 610: Operator Panel Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
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TAG 700: Output Tray Circuit Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115 TAG 702: Paper Size Detection Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117 Wiring for the Upper Paper Size Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119 Wiring for the Lower Paper Size Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119 TAG 703: Upper Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120 TAG 704: Lower Cassette Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121 TAG 705: Multiple Paper Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122 TAG 706: Paper Damaged or Wrinkled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123 TAG 707: Upper Paper Guide Assembly Not Closing . . . . . . . . . . . . . . . . . . . . 3-124 TAG 750: Counter Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125 TAG 751: Main Drive Motor Runs Continuously. . . . . . . . . . . . . . . . . . . . . . . . 3-127 TAG 753: Async IO Communications Malfunction . . . . . . . . . . . . . . . . . . . . . . 3-128 TAG 754: Smart I/O Card Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131 TAG 800: Prints Blank or With Dark Horizontal Bands. . . . . . . . . . . . . . . . . . . 3-133 TAG 801: Prints Light or Light With Carrier Particles . . . . . . . . . . . . . . . . . . . . 3-137 TAG 802: Prints With Voids or White Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142 TAG 803: Prints With Light or White Vertical Streaks . . . . . . . . . . . . . . . . . . . 3-144 TAG 804: Prints With Light Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145 TAG 805: Black Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146 TAG 806: Prints with Dark Spots or Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148 TAG 807: Misregistered/Skewed Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-150 TAG 808: Prints Overtoned/Dark Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . 3-153 TAG 809: Blurred or Smeared Vertical Streaks on Prints. . . . . . . . . . . . . . . . . . 3-157 TAG 810: Uneven Density or Dark Areas on Prints . . . . . . . . . . . . . . . . . . . . . . 3-161 TAG 811: Background/Residual Images/Dark Prints . . . . . . . . . . . . . . . . . . . . . 3-162 TAG 812: Uneven or No Fusing on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166 TAG 813: Residual Images on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168 TAG 815: Prints Resulting From Printhead Malfunctions . . . . . . . . . . . . . . . . . 3-170 TAG 900: Top Cover Interlock Malfunction, Duplex . . . . . . . . . . . . . . . . . . . . . 3-171 TAG 901: Misregistration/Skewed Prints (Duplex) . . . . . . . . . . . . . . . . . . . . . . 3-173 TAG 902: Paper Jam in Duplex Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-177
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
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Sample 5: Light Print With Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Sample 6: Voids or White Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Sample 7: Light Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Sample 8: Blank Vertical Bands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Sample 9: Light Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Sample 10: Black or Dark Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Sample 11: Dark Specks, Lines, or Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Sample 12: Dark Vertical Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Sample 13: Skewed Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Sample 14: Misregistration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Sample 15: Overtoned Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Sample 16: Blurred Images or Characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Sample 17: Varying Print Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Sample 18: Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Sample 19: Residual Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Sample 20: Wrinkles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Sample 21: Fusing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Diagnostic Tests
How to Run Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Operator Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Upper Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Lower Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Fuser Thermistor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Roller Clutch Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Counter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Jogging Motor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Photoconductor Seam Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Toner Supply Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Charge Corona Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Transfer Corona Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Erase Lamp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Toner Empty Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Negative Developer Bias Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Duplex Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Duplex Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Duplex Clutch Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Duplex Tray Paper-Guide Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
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High-Capacity Output (HCO) Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 High-Capacity Input (HCI) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 LED Printhead Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 RIGS Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Com. Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Display File Version Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Format Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Clear Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Disk Drive Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Wiring Diagrams and Electrical Data
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Printhead Circuit Board Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Connector (J/P) Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Connectors Inside the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Connectors Inside the Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Connectors on the Duplex Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Connectors Inside the Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Connectors Inside the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Connectors on the Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Connectors Inside the Back Cover (J/P2-14). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Connectors Inside the Back Cover (Continued) J/P 18-62 . . . . . . . . . . . . . . . . . . 6-19 Connectors Inside the Back Cover (Continued) J/P 64-85 . . . . . . . . . . . . . . . . . . 6-20 Connectors Inside the Back Cover (Continued) J/P 90-800 . . . . . . . . . . . . . . . . . 6-21 Voltage Isolation Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 -12 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 +5 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 +12 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 +24 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Ground System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Host Interface Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 RS-232C Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Standard DCE to DTE RS-232C Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Special Considerations for RS-232 Host Interface Users . . . . . . . . . . . . . . . . 6-29 DTE Host to Printer (Option 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 DTE Host to Printer (Option 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 IBM PC/XT to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 IBM PC/AT to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Macintosh Communication Port to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
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Centronics Parallel Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 IBM Parallel to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Removal/Replacement Procedures
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Photoconductor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Back Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Left Side Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Right Side Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Vacuum Transport Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Rear Duplex Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Front Duplex Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Operator Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Counter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 RIGS Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 VPCL Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Printhead Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Printhead Circuit Board (ARIF) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Hard Disk Drive Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Floppy and Hard Disk Drive Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Cooling Fan Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Toner Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 This space left blank intentionally. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 AC Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 DC Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 High Voltage Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Photoconductor Seam Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 Photoconductor Rear Guide Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30 Power Control Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33 Upper or Lower Paper Size Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Upper Cassette Mount Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 This space left blank intentionally. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 Lower Cassette Mount Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 This space left blank intentionally. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Upper Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45 Upper Paper Guide Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
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ULower Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 Paper Timing Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 Cleaner Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51 Cleaner Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52 Fuser Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53 Fuser Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54 Paper Feed Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55 Paper Timing Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56 Upper Feed Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 Lower Feed Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58 Upper Pick-Up Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59 Pick-Up Roller Drive Idler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60 Pick-Up Roller Drive Gear Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61 Lower Pick-Up Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62 Exit Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63 Exit Pinch Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65 Upper Static Brush Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67 Lower Static Brush Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68 Exit Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69 Exit Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71 Paper Exit Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73 Paper Full Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74 Front Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75 Back Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76 Top Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77 Erase Lamp Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78 EP Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79 Main Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82 Main Gear Drive Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85 Duplex Control Board #1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86 Duplex Control Board #2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87 Duplex Tray Registration Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88 Duplex Skew Correction Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89 Upper Duplex Drive/Clutch Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 7-91 Duplex Route Motor/Solenoid Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 7-92 "A" Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
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"B" Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94 "C" Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-96 "C" Roller Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97 Duplex Route Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98 Duplex Paper Path Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
Options
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 1200-Sheet/2500-Sheet Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4 Guide to Component Acronyms/Physical Locations. . . . . . . . . . . . . . . . . . . . . 8-4 Bench Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Prefeed Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7 1200-Sheet Feeder Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 2500-Sheet Feeder Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Connection Diagram for 1200-Sheet/2500-Sheet Feeder. . . . . . . . . . . . . . . . . . . . . 8-8 Connection Diagram for 1200-Sheet /2500-Sheet Feeder . . . . . . . . . . . . . . . . . . . . 8-8 Input Control Board Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 1400-Sheet Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 Guide to Component Abbreviations/Physical Locations. . . . . . . . . . . . . . . . . 8-10 Bench Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Front View (cover removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Left Side View (left cover removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Rear Side View (cover removed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Top View (top cover removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Connection Diagram for the 1400-Sheet Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Output Control Board Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
General Printer Maintenance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Tool Requirements: Service Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Tools/Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Printer/Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Printer Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Every-Call Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Adjusting Paper Feed Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Adjusting Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
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Front View Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13 Front View Lubrication Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Rear View Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15 Rear View Lubrication Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16 Top View Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17 Duplex Holding Tray Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 Tune-Up Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
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June 1999
Section 1
Troubleshooting
Section 1 Troubleshooting
June 1999
Troubleshooting
1-1
Contents
Troubleshooting
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 The Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Paper Path and Cycle Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 Simplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 Sensors and Switches Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 Sensor and Switch Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11 General Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 The Problem: Printer or Host? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Running Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Protocol Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Reading the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Confirming Line Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 Using the Troubleshooting Analysis Guide (TAG) . . . . . . . . . . . . . . . . . . . . . 1-15 Sample TAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15 Standard Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Power-on-reset (POR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17 Checking Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17 Installing the Interlock By-pass Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17 Producing a Developed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 Producing a Toner Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 Completing a Service Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19 Error Message and Code Technical Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
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Troubleshooting
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Theory of Operation
Section 1
Troubleshooting
The information in this Field Service Manual is directed toward authorized field representatives who are familiar with basic printer operations. It serves as a supplement to training classes and provides a basis for discussion with regional field service engineers and customer support representatives.
Theory of Operation
The printer uses an electrophotographic imaging system, which is based on LED array technology. Two key components of the printer are the image generation system (RIGS) controller and the printer control logic (AVPCL) board. A brief description of the function of each of these components follows. Risc Image Generation System (RIGS) controller: Each printer is equipped with an RIGS controller, which provides the interface between the host computer, the AVPCL board, the interface cards, and the disk drives. Video Printer Control Logic (AVPCL) board: The AVPCL board directs the mechanical functions of the printer and print cycle timing, and controls the LED printhead. The AVPCL board also receives initial machine information, such as empty paper cassettes, paper jams, and fuser problems.
The Printing Process
The illustration on the following page details the printing process. The numbers represent the sequence of events from the time that the RIGS controller receives data, through the production of a print image, to the preparation for another print. 1 Receiving data Host data is received through the Signal Interface PCA and passed to the RISC Image Generating System (RIGS) PCA, which temporarily stores the data in RAM. The data may consist of information generated on the host computer and sent over the host communication interface or it may consist of information generated by printer software, such as a request for test prints or to print the directory of the hard disk.
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Troubleshooting
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Theory of Operation
2
Bit Image The RIGS transforms the host file into a bit map image of 1s and 0s and stores them in bitmap RAM. Charging the photoconductor belt When the IGS controller receives data, it causes the AVPCL board to turn on the main motor, which rotates the photoconductor belt. As the photoconductor belt rotates, the charge corona applies a high negative charge to it, which repels toner from the photoconductor belt. Exposing the image The negatively charged belt then passes the LED printhead, where the AVPCL drives the LEDs on and off to discharge the areas of the belt at a density of 300 dots per inch. The 1s in the memory turn the LEDs on; 0s turn the LEDs off. The discharged areas create a latent mirror image of the print on the photoconductor belt. Developing the image As the photoconductor belt continues to rotate, it brings the latent image to the developer. A negative developer bias is applied to toner and the toner is transferred to the surface of the photoconductor belt. The negatively charged toner (which clings to small metal carrier beads) is attracted to the discharged areas of the belt; the carrier beads do not transfer. The belt, with the developed image on its surface, then rotates out of the developer. At this time you can remove the photoconductor belt and read what is printed on it, which you may need to do when troubleshooting print problems. Activating paper As the image is being developed, a sheet of paper is transported to the photoconductor belt. The AVPCL 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. Transferring the image to the paper Next, the paper contacts the surface of the photoconductor belt. Above the paper and the belt is the transfer corona, which has a high positive charge, and attracts the developed image from the belt to the surface of the paper. At this point, you can remove the printed image to verify print quality, but the toner is not yet fused. Fusing the image to the paper The vacuum transport advances the paper with the image to the fuser where heat and pressure bond the toner to the paper. The print then arrives at the paper output tray. Cleaning routine After a print is made, the photoconductor belt must be cleaned for the next print. The belt first passes the erase lamp where any remaining latent image is erased. The belt continues to the cleaner where a charged brush rotates against the surface to remove any residual toner. This toner is recycled to the developer for reuse.
3
4
5
6
7
8
9
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Paper Path and Cycle Sequence
Paper Path and Cycle Sequence
Transfer Corona Vacuum Transport Fuser
6
Paper Input
7
Erase Lamp
8
Paper Output
9
Photoconductor
Cleaner
3
Charge Corona
Toner
4 5
LED Printhead
AVPCL
Developer
RIGS
Interface
HOST
2
1
The RIGS board signals the AVPCL board that a page of data is ready to be printed. When this happens the following sequence takes place.
Simplex Printing
1 2 3 4 AVPCL software downloaded to the AVPCL board from the disk drive system turns on the main motor. The AVPCL board engages the paper pick clutch which causes the roller to feed a sheet of paper. The paper is passed to the feed roller where the AVPCL board has engaged the feed roller clutch. The feed roller passes the paper to the paper timing roller. Prior to reaching the paper timing roller, the paper passes over the paper timing sensor. If the paper does not energize this sensor in a specified amount of time, a jam error (020/021) will occur. The leading edge of the paper is registered against the paper timing roller. The paper timing clutch is engaged and the paper is passed over the photoconductor for transfer. This registers the paper to the printer and the image to the paper. The paper timing sensor also signals the AVCPL to begin sending data. The AVPCL board engages the paper timing roller clutch and, at the same time, turns on the transfer corona to provide a high positive voltage. The developed image on the photoconductor comes in contact with the paper and the high positive voltage causes the image to transfer to the paper.
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Troubleshooting
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Paper Path and Cycle Sequence
6
Because the toner is not yet fixed to the paper, a vacuum transport assembly, gripping the paper from the back side, moves the paper to the fuser, where heat and pressure bond the toner to the paper. Upon leaving the fuser, the paper comes in contact with the paper exit sensor. (If the paper does not energize this sensor in a given amount of time after leaving the paper timing sensor [step 4], a jam error (022) will occur.) The exit roller moves the paper to the exit tray. (If the exit sensor is not cleared in a specified amount of time, a jam error (023) will occur.)
7
8
Duplex Printing
When duplex is selected, the AVPCL board controls the paper motion with page scheduling assistance from the RIGS board. The duplex page router is engaged. When in duplex mode, it is important to note that the printer runs multiple pages through the paper path at the same time to increase speed.
1
In a duplex job, the duplex router solenoid behind the fuser is engaged and mechanical fingers route the paper to the duplex area. Also, the "A" roller clutch engages to turn the "A" and "B" rollers (connected via a belt). 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, a jam error (060) will occur.) 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, a jam error (061) will occur.)
2
3
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Paper Path and Cycle Sequence
4 5
At this time the solenoid for the router at the turnaround tray engages so the paper can be routed to be printed on the duplex side. In a given amount of time after the paper energizes the paper sensor in the turnaround tray, the bidirectional motor reverses and passes the paper to the paper timing roller. (If the paper does not energize the paper timing sensor in a given amount of time after leaving the turnaround sensor, a jam error (062) will occur.) At this point, the same steps happen as during a simplex cycle.
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Sensors and Switches Illustrations
Sensors and Switches Illustrations
The following pages illustrate the locations of the printer's sensors and switches.
Sensor and Switch Listing
Sensor/Switch Name
Cassette paper present sensors, upper and lower Cassette present micro switches, upper and lower Duplex registration sensor Duplex paper path sensor Interlock switch, duplex cover Interlock switch, front Interlock switch, rear Interlock switch, top
.
Page
1-8 1-8 1-8 1-9 1-9 1-11 1-9 1-10
Sensor/Switch Name
Paper exit sensor Paper full sensor Paper size sensors, upper and lower Paper timing sensor Photoconductor seam sensor Automatic toner control Toner empty sensor Toner patch sensor
Page
1-10 1-10 1-9 1-9 1-9 1-10 1-10 1-9
Front left view
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Sensors and Switches Illustrations
Rear view
Left end view
Top view
Front view
Developer right view
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Troubleshooting
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Sensors and Switches Illustrations
Top view
Developer left view
Right side view
Top left, duplex tray view
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Troubleshooting
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Troubleshooting
Front view
Troubleshooting
Throughout the printer's life problems occur, such as when it produces poor quality prints or malfunctions in another way. 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 Problem explains how to use TAGs. Cross reference tables, which link error messages, print quality problems, and mechanical malfunctions to specific TAGs. Print quality samples, which help identify a printing problem and its associated TAGs. Diagnostics, which can uncover a range of problems.
The next several pages review troubleshooting basics and standard procedures followed in every troubleshooting session, including:
· · · · · · · · · · · · ·
Identifying whether a problem belongs to the printer or host Isolating protocol converter problems Running test prints Reading the error log Confirming line power Using TAGs Power-On Reset Installing the interlock by-pass tool Checking continuity Producing a developed image Producing a toner patch Completing a service call Clearing the error log
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Troubleshooting
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Troubleshooting
General Troubleshooting Tips
When a printer problem arises, swapping out all printer supplies may temporarily mask the problem. This is an unsatisfactory, short-term, and expensive solution to correcting the problem. Dust and other contamination, rather than printer supplies, are more often the causes of problems. Clean consumable connectors, alignment guides, and areas before changing consumables. Many failures add excess toner to the printer's engine. When you are advised to de-tone the printer as part of a problem fix, run at least 200 test prints before deciding that the problem is resolved. When you replace the photoconductor, run at least 500 prints before checking print quality. This number of prints is required to "synch" the new PC belt to the developer.
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 glance, they appear to be printer problems. For instance, text printed in the wrong location on a page, improper page breaks, and missing segments of data strongly indicate a host, not a printer, problem. The first step in troubleshooting any problem is to isolate the printer from the host system; you can then run test prints. Producing test prints exercises the printer as a stand-alone machine, ensuring that the basic printer software and all mechanical functions of the printer are working.
Running Test Prints
1 2 3 4 5 6 7 8 9 Disconnect the host interface. Make sure "Ready" displays on the panel. Press ONLINE. Press MENU Press Press to highlight "Test Print" to select "Test Print" to choose simplex.)
Choose "Simplex" or "Duplex" (Duplex is the default. Press
Press to start. A directory of the boot device and multiple listings of fonts prints. A continuous flow of the test pattern then prints. To stop printing the test pattern, press the printer's buffer, then stop. . The printer will print all test prints stored in
If the test pattern prints successfully, the problem probably originates with the host system or a protocol converter connected to the host.
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Troubleshooting
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) the problem may belong to the host or the protocol converter.
Reading the Error Log
The formatted error log is maintained by the printer in a file named "Error.log." You have the option to print this log when you are at the same panel used to print test prints. See "Running Test Prints" on page 1-12.
· ·
The first section lists the numbers and text of the last 15 errors. The second section of the formatted log lists paper jams. A 3-digit error code (or codes) is followed by the error text and a 4-digit number indicating how many times the error has occurred since the error log was last cleared. (Clearing the error log is described on page 1-19.) The third section provides a complete error history since the error log was last cleared. Errors are listed in numeric order in the first column, with the number of times each error occurred listed in the second column. The fourth section indicates the last error that required a power-on-reset (POR).
· ·
The error log is two pages long. This partial illustration shows the main components of the log.
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Troubleshooting
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Troubleshooting
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 outlined on the following chart.
Probe connections red to AC hot black to AC neutral red to AC neutral black to ground red to AC hot black to ground 120v printer 120v +/- 10% 3 vac or less 120v +/- 10% 230v printer 230v +/- 10% 3 vac or less 230 +/- 10%
Please see Section 5, Diagnostic Tests, for additional information about troubleshooting specific printer problems. Please see Section 6, Wiring Diagrams and Electrical Data, for additional information about the printer's electrical systems.
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Troubleshooting
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 message of the printer. The TAG number often matches an error message code displayed on the printer's operator panel.
TAG Number TAG Name
Sample TAG
TAG 001: Troubleshooting a Problem
Error Message:
All related error messages are listed here.
Possible Causes: All possible causes are listed here. Possible Defects: All possible defective parts are listed here. (In no particular order.)
1
Starting actions Yes/No Question
To start:
· ·
Disconnect all peripheral cables Power-on-reset the printer.
Is an error message displayed? No: Run test prints, following the procedure outlined in Section 1, then repeat this step. If the
To Do
answer is still no, refer to the mechanical malfunctions cross-reference chart in Section 2 to determine which TAG to follow. Then turn to that TAG.
Yes: Note the error message and continue.
2
Power-on-reset the printer.
Did the power-on-reset end with an error message? No: Continue. Yes: Refer to the error message cross-reference table in Section 2, using either the code that dis-
played after steps 1 and 2, or if multiple error messages continue to appear, the first error message that displays. Turn to the TAG associated with the message.
Each TAG walks through a comprehensive procedure specific to a single problem. As you progress through a TAG and eliminate possible causes, you may be directed to another step out of sequence in the same TAG or to another TAG altogether. The TAG number and its title may be followed by a listing of possible error messages, possible causes, or possible defective parts related to the TAG. 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.
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Troubleshooting
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Troubleshooting
If it's not clear how to diagnose a problem you're working on, follow the steps outlined in TAG 001, which includes references to the cross reference tables contained in Section 2, TAG Cross- Reference Tables. Or, you may turn directly to the tables to get started. As you use TAGs, you will sometimes refer to other sections of this manual for additional information:
· · · · · ·
Section 4, Print Quality Samples, contains print quality samples you'll use to compare the customer's test prints with flawed and good print samples. Section 5, Diagnostic Tests, outlines how to conduct printer diagnostic tests. Section 6, Wiring Diagrams and Electrical Data, provides all wiring and connector diagrams. Section 7, Removal/Replacement Procedures, provides step-by-step procedures for removing and replacing all field-replaceable parts on the printer. Section 8, Options, reviews printer options (HCI, HCO) information. Section 9, General Printer Maintenance, presents general printer maintenance procedures.
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Standard Procedures
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 2 3 Turn off the printer. Wait at least 5 seconds. Turn the power back on.
Checking Continuity
Make sure the printer is turned off and the power disconnected. Failure to do so may result in personal injury, equipment damage, or both. To perform a continuity check: 1 2 3 Turn off the printer and disconnect the power cord. Set your meter to the lowest ohm setting. Interpret the results as follows: · An infinite reading indicates an open circuit.
·
4
A zero or specific reading indicates continuity.
To check an open or short circuit to ground: · Turn off the printer and disconnect the power cord.
· ·
Locate the circuit in question. (Refer to Section 6, Wiring Diagrams and Electrical Data, for circuit locations.) Check all connectors and wiring on each side for corrosion, foreign objects, bent pins, loose socket housings, and/or loose wires.
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 in "Sensors and Switches Illustrations" on page 1-8). Squeeze the tool between thumb and forefinger and insert it into the interlock switch. The printer ships with two spare interlock by-pass tools concealed behind the right cover. Replace them when you are finished using them. Do not attempt to close the printer cover while the interlock by-pass tool is in place.
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Troubleshooting
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Standard Procedures
Producing a Developed Image
Producing a developed image helps determine where exactly in the print cycle a problem may be occurring. To produce a developed image: 1 2 3 4 5 6 7 Open the top cover and install an interlock by-pass tool. Power-on-reset the printer. Run a series of test prints. See "Running Test Prints" on page 1-12. As test patterns print, observe paper moving from the upper paper tray to the paper timing roller where it pauses briefly. As soon as a sheet of paper begins to move from the paper timing roller, remove the interlock by-pass tool. Remove the photoconductor. Examine the photoconductor belt to verify that a developed image was produced. Caution: Do not touch the surface of the photoconductor belt; this damages the belt and results in poor print quality.
Producing a Toner Patch
To produce a toner patch: 1 2 3 4 5 Turn off the printer. Open the top cover and install an interlock by-pass tool. Turn on the printer. Start running test prints. When the leading edge of the first print enters the fuser, wait one second then remove the interlock by-pass tool. Remove the photoconductor.
Producing a toner patch on the photoconductor.
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Standard Procedures
6
Examine the photoconductor 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 2 3 4 5 6 Reassemble the printer. Perform the every-call cleaning procedure, described in Section 9, General Printer Maintenance. Power-on-reset the printer. Clear the error log. (See the procedure described next.) Run test prints in both the simplex and duplex mode from both the upper and lower paper cassettes. Fill in the Repair/Maintenance record taped inside the front cover. Make sure the problem description and steps taken to resolve the problem are clearly documented.
Clearing the Error Log
1 Enter the diagnostic mode of the printer:
· ·
2 3 4 5 6 7 8 9
Turn off the printer and wait 5 seconds. Hold down the MENU and STATUS keys simultaneously as you turn the printer back on. Wait for all three LEDs to come on. This takes approximately 30 seconds. to display the first available test. key to move through the available tests.
Press
Once a test name is displayed, use the Press the Press
key until "Clear Error Log" shows on the display. to activate the procedure.
Press to advance to the drive where the error log is maintained. This is usually the boot drive. Press Press to clear the error log on the selected drive. to exit the procedure.
Confirm that the error log has been cleared.
10 Exit diagnostic mode (power-on reset) 11 Print the error log. All errors in all sections should be reset to zero.
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Error Message and Code Technical Definitions
Error Message and Code Technical Definitions
Error messages/codes are listed here alphanumerically. Sensor and switch locations referred to throughout these descriptions are illustrated on page 1-8.
Type Message Description 1. There is no text associated with the error. 2. The error is not included in the error look-up tables. AVPCL board detected that the paper being fed from the upper cassette did not reach the timing paper sensor within the allotted time. AVPCL board detected that the paper being fed fro