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DocuPrint C55/C55mp/[NC60] Color Laser Printer (50/60 Hz) Service Manual
CAUTION
Certain components in the DocuPrint C55/C55mp/ [NC60] Color Laser Printers are susceptible to damage from electrostatic discharge. Observe all ESD procedures to avoid component damage.
701P14760 February, 1999
NOTICE
" Service documentation is supplied to Xerox All external customers for informational purposes only. Xerox Service Documentation is intended for use by certified, product trained personnel only. Xerox does not warrant or represent that such documentation is complete, nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation. Customer performed service of equipment, or modules, may affect the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third party provided service. If the customer services such equipment, modules, components or parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the customer agrees to indemnify, defend and hold Xerox harmless from any third party claims which arise directly or indirectly from such service."
CLASS 1 LASER PRODUCTS
This product is certified as a Class 1 Laser product and complies with DHHS LaserRadiation Standards, 21 CFR Chapter 1 Subchapter J.
WARNING
Use of controls, adjustments, or performances of procedures other than those specified in this manual may result in hazardous radiation exposures. The C55/C55mp/[NC60] each contain an invisible laser. There is no visual indication that the laser beam is present. During servicing, the C55/C55mp/[NC60] remain a Class 1 product because of the interlock system. Do not attempt to cheat the interlock switches on this printer.
Prepared by: Xerox Corporation Multinational Customer and Service Education 780 Salt Road Webster, New York 14580
©1999 by Xerox Corporation. All rights reserved. Xerox and all Xerox products mentioned in this publication are registered trademarks of the Xerox Corporation
Product
Title
Part Number
Date
DocuPrint C55/C55mp/[NC60]
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TABLE OF CONTENTS
TITLE INTRODUCTION About This Manual --------------------------------- ii Organization ----------------------------------------- ii How to use This Manual --------------------------iii Reference Symbology -----------------------------iii SERVICE CALL PROCEDURES Contents ------------------------------------------- 1-1 STATUS INDICATOR RAPS Contents ------------------------------------------- 2-1 IMAGE QUALITY RAPS Contents ------------------------------------------- 3-1 REPAIR/ADJUSTMENT PROCEDURES Contents ------------------------------------------- 4-1 PARTS LIST SECTION Contents ------------------------------------------- 5-1 GENERAL PROCEDURES/INFORMATION Contents ------------------------------------------- 6-1 WIRING DATA Contents ------------------------------------------- 7-1 PAGE
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TABLE OF CONTENTS
INTRODUCTION
ABOUT THIS MANUAL
This manual is part of a multinational documentation system which includes Training. This manual contains information that applies to: · · · · USCO XE XCL ACO Section 1 - SERVICE CALL PROCEDURES This section contains the following: · · · · · · Call Flow Instructions Initial Actions System Checks Every Call Activities Scheduled Maintenance Final Action Section 2 - STATUS INDICATOR REPAIR ANALYSIS PROCEDURES (RAPs) This section contains the Repair Analysis Procedures (RAPs) necessary to repair faults other than image quality faults. Section 3 - IMAGE QUALITY REPAIR ANALYSIS PROCEDURES (RAPs) This section contains the Repair Analysis Procedures (RAPs) necessary to repair image quality faults. Section 4 - REPAIR/ADJUSTMENT PROCEDURES This section contains the Repair and Adjustment procedures for the printer. All unique procedures will be identified as follows: · USCO · XE Section 5 - PARTS LIST This section contains exploded view drawings and referenced replaceable parts lists for the Printer. Section 6 - GENERAL PROCEDURES This section contains Diagnostic procedures, Menus, Product Specifications, ESS/IOT test patterns, and other General Procedures. Section 7 - WIRING DATA This section contains Block Schematic Diagrams (BSDs), Plug/Jack/PWB Location Diagrams and wiring diagrams.
Call Flow The call flow chart shows you how to conduct the service call. Initial Actions The initial actions suggests how to collect data necessary to proceed with the service call. System Checks The System Checks procedures details the steps for effective repair and verification of repair of problems found in Initial Action. Every Call Activities These are cleaning and maintenance activities which are performed on every call. Scheduled Maintenance Scheduled Maintenance consists of checking the life remaining on the CRUs. Final Action Final Action ensures that image quality is acceptable, and that printer performance and appearance is satisfactory. Details are included for completing administrative tasks and closing out the service call.
This service manual covers both the C55 and NC60 product families. Unique NC60 directions will be given in [ ]s. For example: Press the On Line [0] key. The On Line key is unique to the C55 family and the [0] key is unique to the NC60. If the entire procedure is unique to a product family, it will be noted at the top of the page and in the footer at the bottom of the page. " USCO" references apply to 115 Volt printers. " XE" references apply to 220/240 Volt printers. " Dry Ink" means the same as " Toner" and " Tag" means the same as " Mod" .
ORGANIZATION
This manual is divided into seven sections organized as follows: A Publications comment sheet is provided at the end of this manual.
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INTRODUCTION
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DocuPrint C55/C55mp/[NC60]
HOW TO USE THIS MANUAL
Section 1, Service Call Procedures will direct you to each section of the manual necessary to perform a service call. You will begin with Initial Actions which suggest how to collect problem symptoms and evidence to be used in the next section, the System Checks Section. Details in the System Checks are designed to assist you in classifying, repairing and verifying the repair of the problem. From here, you may be directed to any of the other six sections of the service manual depending on the symptoms observed and the results of suggested tests. After a repair has been verified (or during a repair activity) instructions are included to direct you into Every Call Activities.
Descriptions of commonly used graphic symbols are included in order to aid troubleshooting when using the circuit diagrams. Switches/Relays Safety interlock switch, circuit open. Safety interlock switch, circuit closed.
This symbol, used with a number, indicates that the actual number may be equal to or very near the value of the designated number. Triac, used to switch AC power. Light Emitting Diode (LED).
Led/Phototransistor Sensor. Switch/relay with momentary contacts shown normally open. Switch/relay with momentary contacts shown normally closed. Magnetically actuated Switch. Miscellaneous Symbols
GND
MOT
Motor. Thermistor Bead, used to sense temperature. A Driver which is used to switch on DC Components. Analog to Digital Converter. Relay Solenoid
REFERENCE SYMBOLOGY
Reference Symbology provides supportive data for Repairs, Adjustments, and the RAPs. The symbols that refer to this supportive data are shown in the paragraphs that follow. Note:
1
2
This symbol is used to refer to notes, usually found on the same page. [ 8-2 ]
A flag that identifies a wire that has been referred to in the text. Indicates a Diagnostic Code used to check a particular component. Identifies a test point, test hole or test stake on a PWB.
A
A/D
RL
Parts Lists PL 2.4 (example) In the example above, the parts list reference and the exploded view drawing would be found in Section 5 on sub-section 2.4.
Auditron/Key Counter connection.
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INTRODUCTION
Signal Continuation/Flow Indicates the continuation of a signal line interrupted in a horizontal direction. Represents the continuation of a standby power line interrupted in the vertical direction. In all cases, the supply is from Standby Power Indicates a feedback signal. Indicates a common splice of wires.
P/J57 6
Tag Identification This WITH TAG Symbol is used to identify the components or configuration that are part of a printer change covered by the Tag number. This WITHOUT TAG Symbol is used to identify the components or configuration that are not part of a printer change covered by the Tag number
47 47
47
47
Indicates a common splice of wires at a pin. Indicates the direction of signal flow. Indicates that the wire continues to the adjacent page.
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INTRODUCTION
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1. SERVICE CALL PROCEDURES
TITLE PAGE
CALL FLOW---------------------------------------1-2 INITIAL ACTION ---------------------------------1-3 SYSTEM CHECKS ------------------------------1-3 EVERY CALL ACTIVITIES --------------------1-4 SCHEDULED MAINTENANCE ---------------1-4 FINAL ACTION -----------------------------------1-5
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SERVICE CALL PROCEDURES
SECTION CONTENTS
CALL FLOW INITIAL ACTION
This step is used to gather information about the reason for the call, to determine the machine condition, and to run print samples.
SYSTEM CHECKS
This step is used to suggest a direction for using the information, obtained during Initial Action. You can then repair and verify the repair of the problem. This step may also provide information to assist in the identification of new problems and suggest actions to take to repair/resolve them.
EVERY CALL ACTIVITIES
This step consists of every call cleaning and maintenance activities.
SCHEDULED MAINTENANCE
This step is used to check the life remaining on the CRU' s.
FINAL ACTIONS
This step is used to ensure that the print quality, the printer performance, and the printer appearance is satisfactory. It will also provide direction to help complete administrative tasks.
SERVICE CALL PROCEDURES
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CALL FLOW
INITIAL ACTION
Purpose To suggest how to gather information about the service call, the machine condition, and to direct the user through the call. PROCEDURE 1. Ask the customer to describe the problem that causes the service call and the job being run when the problem occurred. 2. Inspect any rejected prints for evidence of defects. 3. Switch the printer power Off/On and check for and note/record any fault codes in the Control Panel Display. 4. Examine the Machine Service Log (under the Left Side Cover) for previous problems or activities that may be related to this service call. 5. Go to (SYSTEM CHECKS).
SYSTEM CHECKS
Purpose To suggest a direction for effective repair and verification of repair of problems found in Initial Action. PROCEDURE 1. Select the appropriate situation from a-g below, then diagnose and repair the problem. a. Replace any obviously broken parts. b. If this is an Image Quality problem, go to IQ1 Image Quality Entry RAP in Section 3. c. If there is a Fault Code, go to Section 2 Table of Contents. Locate and perform the RAP associated with the Fault Code.
f.
If the problem still is not reproduced, check the printer Fault History. (C55/C55mp) Off Line, Menu, then scroll to , , . Scroll through the Fault History and note any repeating faults. Refer to the RAP for these fault codes in Section 2 and read the fault code description to see if the code relates to the customer problem. If so, perform the RAP [NC60] Menu Up until Print Menu. Item Up until Fault History then press Enter. Look through the Fault History and note any repeating faults. Refer to the RAP for these fault codes in Section 2 and read the fault code description to see if the code relates to the customer problem. If so, perform the RAP.
d. If there is NO fault code associated with the problem, go to Section 2 Table of Contents. Locate and perform the RAP which most closely matches the problem described by the customer. e. If the problem is not repeatable, operate the printer in the same job conditions the customer used and recheck for a problem in the categories listed here.
g. If none of the above situations applies go to EVERY CALL ACTIVITIES. 2. Verify that the problem is corrected and go to EVERY CALL ACTIVITIES.
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SERVICE CALL PROCEDURES
INITIAL ACTION/SYSTEM CHECKS
EVERY CALL ACTIVITIES
Purpose To list service activities required for specific subsystems. PROCEDURE 1. Open the printer and Clean the Charge Scorotron using the Scorotron cleaner. 2. Clean the toner loading area. 3. Remove the Following: a. Print Drum Module. (GP I) b. Color Developer Module. (GP 2) c. Black Developer Module (GP 3)
SCHEDULED MAINTENANCE
Purpose To check the life remaining on the CRUs. PROCEDURE 1. Check the life of the Customer Replaceable Units (CRUs). a. (C55/C55mp) Enter the Off Line mode, press Menu and scroll to . [NC60] Menu Up until Service Menu, Item Up until CRU Usage, Value Up to see % remaining on the CRUs. b. Check the life remaining on the following: · Black Developer Cartridge. · Color Developer Cartridge. · Print Drum. · Fuser Module. 2. If any of the CRUs are near end of life, notify the customer.
d. Toner Collector. (GP 4) 4. Vacuum the Drum, Developer, and Toner Collector areas. 5. Replace the Toner Collector if required. 6. Reinstall the following: a. Black Developer Module (GP 3) b. Color Developer Module. (GP 2) c. Print Drum Module. (GP I)
d. Toner Collector. (GP 4) 7. Use Film Remover to clean the Feed Rollers. Do not rotate the Feed Rollers more than 270° while cleaning. Apply Rubber restore if available. 8. Check the Transfer Drum Nip Adjustment (ADJ 11.1) 9. Wipe the outside of the printer.
SERVICE CALL PROCEDURES
EVERY CALL ACTIVITIES/ SCHEDULED MAINTENANCE
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FINAL ACTION
Purpose To ensure the image quality is acceptable, printer performance and appearance is satisfactory and to complete administrative tasks. PROCEDURE 1. Install/close all covers and doors. 2. Run the Print Quality sample set. a. (C55/C55mp) Enter the Off Line mode, press Menu and scroll to . Select , and print the PQ set. [NC60] Menu Up until Service Menu, Item Down until Print PQ Set and press Enter. 3. If possible, ask the customer to print one of their representative prints to examine and comment on.
Wrap-Up Procedure 1. Record your service activities in the service log. 2. Record the Total meter reading (from the Diagnostic Test Pattern) in the service log. 3. Record the ESS software level (from the Diagnostic Test Pattern) in the service log. 4. (C55/C55mp) (Off Line, Print, Settings). Record the NIC software level (from the Settings page) in the service log. 5. Put the Printer PQ set and service log into the service log folder. NOTE: It is very important to save the PQ set. There is information on the Diagnostic sheet (Toner Concentration setpoints) which will be needed if the NVM is reset or the PCU PWB is replaced.
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SERVICE CALL PROCEDURES
FINAL ACTION
Notes:
SERVICE CALL PROCEDURES
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NOTES
2. STATUS INDICATOR RAPs
TITLE PAGE TITLE PAGE TITLE PAGE
TROUBLESHOOTING TIPS ------------------2-2 C1-CHECK TRAY 1 -----------------------------2-3 C2-CHECK TRAY 2 -----------------------------2-3 E1-TRAY 1 JAM----------------------------------2-4 E2-TRAY 2 JAM ---------------------------------2-5 E3-BYPASS JAM --------------------------------2-5 E4-INPUT JAM -----------------------------------2-6 E5 FUSER JAM ----------------------------------2-7 E6-DRUM JAM -----------------------------------2-8 E7-PRINT DRUM JAM------------------------ 2-10 E8-OUTPUT JAM ------------------------------ 2-10 E9-CLOSE PRINTER ------------------------- 2-10 EA-COLOR DEV. MISINSTALLED -------- 2-11 EB-BLACK DEV. MISINSTALLED --------- 2-11 EC-PRINT DRUM MISINSTALLED-------- 2-11 F1-DISK ERROR (FLOPPY) ---------------- 2-12 F2-DISK I/O ERROR (FLOPPY) ----------- 2-12 F3-ACTION FAILED (FLOPPY) ------------ 2-12 H1-HARD DISK ERROR --------------------- 2-13 H2-HARD DISK CONTROLLER ERROR ------------------------------------- 2-13 H3-HARD DISK FULL------------------------- 2-14 H4-FORMAT HARD DRIVE ----------------- 2-14
J1-ADD YELLOW TONER------------------- 2-15 J2-ADD MAGENTA TONER ---------------- 2-16 J3-ADD CYAN TONER----------------------- 2-17 J4-ADD BLACK TONER --------------------- 2-18 J5-REPLACE COLOR DEVELOPER CARTRIDGE -------------------------------- 2-19 J6-REPLACE BLACK DEVELOPER CARTRIDGE -------------------------------- 2-19 J7-TONER COLLECTOR FULL------------ 2-20 J8-REPLACE PRINT DRUM ---------------- 2-20 J9-REPLACE FUSER MODULE ----------- 2-20 JA-REPLACE OIL/PAD----------------------- 2-21 T0-FUSER THERMISTOR ERROR ------- 2-21 T1- UNDER TEMPERATURE -------------- 2-22 T2- OVER TEMPERATURE ---------------- 2-23 U0-IOT ROM ERROR ------------------------ 2-23 U1-IOT RAM ERROR------------------------- 2-24 U2-IOT NVM RAM ERROR ----------------- 2-24 U3-IOT/ESS COMMUNICATION ERROR ------------------------------------- 2-24 U4-OPTICS FAULT --------------------------- 2-25 U5-POLYGON MOTOR FAULT ------------ 2-25 U6-MOTOR FAULT (DEVELOPER) ------ 2-26 U7- MOTOR FAULT (MAIN) ---------------- 2-27
W1-COLOR DEVELOPER MODULE (NEAR END OF USE) ------------------- 2-28 W2-BLACK DEVELOPER MODULE (NEAR END OF USE) ------------------- 2-28 W3-PRINT DRUM (NEAR END OF USE) ----------------------------- 2-28 W4-FUSER MODULE (NEAR END OF USE) ------------------- 2-29 W5-FUSER OIL BOTTLE/PAD (NEAR END OF USE) ------------------- 2-29 OF1 DEAD PRINTER RAP ---------------- 2-30 OF2 CONTROL PANEL RAP ------------- 2-32 OF3 TRAY 1 PAPER SIZE SENSING RAP ------------------------- 2-35 OF4 TRAY 2 PAPER SIZE SENSING RAP ------------------------- 2-36 OF5 LOAD PAPER RAP-------------------- 2-37 OF6AESS RAP (C55/C55mp) -------------- 2-38 OF6BESS RAP [NC60]----------------------- 2-39 OF7 ESS BOOT FAILURE ERROR CODES [NC60] ------------- 2-40 OF8 ARCING RAP --------------------------- 2-41
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STATUS INDICATOR RAPs
SECTION CONTENTS
TROUBLESHOOTING TIPS
The following are some general troubleshooting tips and hints which will help you locate components and test points. 1. The procedures for entering, exiting and using the C55/C55mp/[NC60] diagnostic programs can be found in Section 6, General Procedures. Refer to the Table of Contents found on page 6-1 for the specific program. 2. Figure 2-1 on the right is also located in Section 6 and shows the location of the input electrical components in the printer. It is especially helpful when using the Switch Scan program. Refer to this figure if you are unsure of input component location. The BSDs in Section 7 may also prove helpful when locating the various electrical components. 3. The Connectors can be located in Section 7. Refer to Section 7 Table of contents on page 7-1. The table below shows the location of the most common connectors: Connector Numbers CN100' s CN200' s CN300' s CN400' s CN700' s CN800' s Location PCU PWB/ESS PWB Cassette PWB Connector PWB Control Panel PWB LVPS PWB HVPS PWB Figure 7-1 7-4 7-2 7-2 7-2 7-3
TRANSPARENCY JAM SENSOR CLEANER JAM SWITCH TRANSPARENCY SENSOR REGISTRATION SENSOR OIL SENSOR GAMMA SENSOR +24 V INTERLOCK SWITCH EXIT SENSOR
TRANSFER DRUM HOME SENSOR
PHOTORECEPTOR DETECT
BYPASS SWITCH WASTE TONER BOTTLE SENSOR PS0 TEMPERATURE/ HUMIDITY SENSOR TRAY EMPTY SENSOR PS1 PS2 PS3 PS4
T2 TRAY EMPTY T2 SENSOR S0
T2 S1
T2 S2
T2 S3
T2 S4
Figure 2-1. Input Component Location
STATUS INDICATOR RAPs
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TROUBLESHOOTING TIPS
C1 CHECK TRAY 1 RAP
Cassette 1 is not in the printer. INITIAL ACTION Load paper and insert Cassette 1 into the printer. Switch the power off wait 10 seconds and switch the power on. Recheck for the fault. PROCEDURE Enter IOT normal diagnostics. Scroll to the SWITCH SCAN program and select Scan Row 01, Press Form Feed [1]. Remove Cassette 1. Manually make and break Paper Size Sensor 0 while observing the Cyan LED. (Sensor 0 is the first one on the left when viewed from the front of the printer.) The Cyan LED switches on and off. Y N Go to BSD 7.2 in Section 7 and troubleshoot the Paper Size 0 Sensor signal (CN107-8) for a short to ground. If no short is found, replace the PCU PWB. If the problem still exists, replace the Cassette PWB. Check for a broken Sensor Flag on the Tray 1 Cassette. If the problem still exists, replace the PCU PWB. If the problem still exists, replace the Cassette PWB.
C2 CHECK TRAY 2 RAP
Cassette 2 is not in the printer. INITIAL ACTION Move the length stop to the 11 inch position (Figure 2-2), load paper, and insert Cassette 2 into the printer. Switch the power off wait 10 seconds and switch the power on. Recheck for the fault. PROCEDURE Enter IOT normal diagnostics. Scroll to the SWITCH SCAN program and select Scan Row 03. Press Form Feed [1]. Remove Cassette 2. Manually make and break T2 Paper Size Sensor 0 while observing the Cyan LED. The Cyan LED switches on and off. Y N Refer to BSD T2, 7.2 in Section 7 and check the following: · T2 Paper Size 0 Sensor signal CN1091 for an open. · +5 VDC CN109-5 If no problem is found, replace the PCU PWB. If the problem still exists, replace the T2 Cassette PWB. Check for a broken Sensor Flag on the Tray 2 Cassette. If the problem still exists, replace the PCU PWB. If the problem still exists, replace the Cassette PWB.
10.5" 11", A4 14"
Figure 2-2. Length Stop Location
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STATUS INDICATOR RAPs
C1, C2
E1 TRAY 1 JAM RAP
Paper fed from Tray 1 did not reach the Registration Sensor. INITIAL ACTION Remove the cassette and check that the paper is loaded correctly and is in good condition. Switch the power off wait 10 seconds and switch the power on. Recheck for the fault. PROCEDURE Check the following: · · · · Obstructions in the paper path. Dirty Feed Rolls. Dirty Drive Rollers. Mechanical drive problem.
A The Black LED switches on and off. Y N Go to BSD 7.1 in Section 7 and troubleshoot the Tray Empty Sensor signal (CN102-6) for a short to ground. If no short exists, replace the PCU PWB. If the problem still exists, replace the Tray Empty Sensor. Exit from the SWITCH SCAN program. Close the Printer. Remove the paper cassette. Scroll to the MOTOR TEST program. Press Form Feed [1] to switch on the motors while observing the Paper Feed Motor. The Paper Feed Motor is rotating normally. Y N Go to BSD 7.3 in Section 7 and troubleshoot the +24 VDC Interlocked (CN111-5) and Paper Feed Motor for an open. If the motor was noisy, check the clock lines. If the lines are OK, replace the PCU PWB. If the problem still exists, replace the Paper Feed Motor. Exit from diagnostics. Set up the meter to read +24 VDC. Measure between CN101-5 (+) and ground (- ). Make one print while monitoring the meter. The meter swings from +24 VDC to 0. Y N Go to BSD 7.4 in Section 7 and troubleshoot the Feed Solenoid signal, and +24 VDC Interlocked (CN101-5, 3) for an open. B C
B
C If no open exists, replace the PCU PWB. If the problem still exists, replace the Paper Feed Solenoid.
Check for a mechanical problem with the feed clutch.
Enter IOT normal diagnostics. Scroll to the SWITCH SCAN program and select Scan Row 00. Press Form Feed [1]. Open the Printer. Actuate and deactuate the Registration Sensor while observing the Magenta LED. The Magenta LED switches on and off. Y N Go to BSD 8.1 in Section 7 and troubleshoot the Registration Sensor signal, +5 VDC and GND (CN102-9, 7, 8) for an open. If no open exists, replace the PCU PWB. If the problem still exists, replace the Registration Sensor. Press Media Server [2]. Select Scan Row 01. Press Form Feed [1]. Remove the cassette and actuate and deactuate the Tray Empty Sensor while observing the Black LED. A
STATUS INDICATOR RAPs
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E1
E2 TRAY 2 JAM RAP
Paper fed from Tray 2 did not reach the Registration Sensor. INITIAL ACTION Remove the cassette and check that the paper is loaded correctly and is in good condition. Check the position of the rear stop. Make sure that Tray 1 is pushed all the way in. Switch the power off wait 10 seconds and switch the power on. Recheck for the fault. PROCEDURE Try to run a print from Tray 1. The print feeds OK from Tray 1. Y N Go to E1 TRAY 1 JAM RAP. Check the following: · · · · Obstructions in the paper path. Dirty Feed Rolls. Dirty Drive Rollers. Mechanical drive problem.
A Exit from diagnostics. Set up the meter to read +24 VDC. Measure between CN109-8 (+) and ground (- ). Make one print while monitoring the meter. The meter swings from +24 VDC to 0 and back to +24. Y N Go to BSD T2 7.3 in Section 7 and troubleshoot the T2 Feed Solenoid signal, and +24 VDC Interlocked (CN109-8, 7) for an open. If no open exists, replace the PCU PWB. If the problem still exists, replace the T2 Feed Solenoid. Measure between CN109-9 (+) and ground (- ). Make one print while monitoring the meter. The meter swings from +24 VDC to 0 and back to +24. Y N Go to BSD T2 7.4 in Section 7 and troubleshoot the T2 Drive Clutch signal (CN109-9) for an open. If no open exists, replace the PCU PWB. If the problem still exists, replace the T2 Drive Clutch. Check for a mechanical problem with the Feed Clutch and Drive Clutch
E3 BYPASS JAM RAP
Paper fed from the Bypass Tray did not reach the Registration Sensor. INITIAL ACTION Carefully inspect the bypass opening for paper. Switch the power off wait 10 seconds and switch the power on. Run another print and recheck for the fault. PROCEDURE If paper does not feed from the Bypass but does feed from Tray 1, check for an obstruction in the bypass slot. Check to ensure that the switch is installed correctly and has not fallen out. If no paper is loaded in the Bypass when the E3 occurs, refer to BSD 7.5 in Section 7 and check the Bypass Switch signal (CN312-2) for a short to ground. If no short exists, replace the PCU PWB. If the problem still exists, replace the Bypass Switch.
Enter IOT normal diagnostics. Scroll to the SWITCH SCAN program and select Scan Row 03. Press Form Feed [1]. Remove cassette 2. Actuate and deactuate the Tray 2 Empty Sensor while observing the Black LED. The Black LED switches on and off. Y N Go to BSD T2 7.1 in Section 7 and troubleshoot the T2 Tray Empty Sensor signal (CN109-4) for a short to ground. If no short exists, replace the PCU PWB. If the problem still exists, replace the Tray 2 Empty Sensor. A
2/99 DocuPrint C55/C55mp/[NC60] 2-5
STATUS INDICATOR RAPs
E2, E3
E4 INPUT JAM RAP
Paper was on the Registration Sensor too long. INITIAL ACTION Open the printer and check for any obstruction in the register roller area. Switch the power off wait 10 seconds and switch the power on. Run another print to recheck for the fault. Make sure the Grounding Roller is rotating freely. Perform the Transfer Drum Nip Adjustment (ADJ 11.1) PROCEDURE Enter IOT normal diagnostics. Scroll to the SWITCH SCAN program and select Scan Row 00. Press Form Feed [1]. Open the Printer. Actuate and deactuate the Registration Sensor while observing the Magenta LED. The Magenta LED switches on and off. Y N Go to BSD 8.1 in Section 7 and troubleshoot the Registration Sensor signal (CN102-9) for a short to ground. If no short exists, replace the PCU PWB. If the problem still exists, replace the Registration Sensor. Press Media Server [2]. Select Scan Row 04. Press Form Feed [1]. Actuate and deactuate the Transparency Sensor while observing the Cyan LED. A
A The Cyan LED switches on and off. Y N Go to BSD 8.4 in Section 7 and troubleshoot the Transparency Sensor signal (CN311-1) for a short to ground. If no short exists, replace the PCU PWB. If the problem still exists, replace the Transparency Sensor. Exit from the SWITCH SCAN program. Close the Printer. Remove the paper cassette. Scroll to the MOTOR TEST program and press Form Feed [1] to switch on the motors while observing the Paper Feed Motor. The Paper Feed Motor is rotating normally. Y N Go to BSD 7.3 in Section 7 and troubleshoot the Paper Feed Motor clock lines. If the lines are OK, replace the PCU PWB. If the problem still exists, replace the Paper Feed Motor. Exit from diagnostics. Set up the meter to read +24 VDC. Measure between CN103-4 (+) and ground (- ). Make one print while monitoring the meter. The meter swings from +24 VDC to 0 and back to +24. Y N Go to BSD 9.16 in Section 7 and troubleshoot the Stripper Solenoid signal and +24 VDC Interlocked (CN103-4, CN303-2,1) for an open. If no open exists, replace the PCU PWB. If the problem still exists, replace the Stripper Solenoid. B
B Set up the meter to read +24 VDC. Measure between CN101-5 (+) and ground (- ). Make one print while monitoring the meter. The meter swings from +24 VDC to 0 and back to +24. Y N Go to BSD 7.4 in Section 7 and troubleshoot the Feed Solenoid signal (CN101-5) for a short to ground. If no short exists, replace the PCU PWB. If the problem still exists, replace the Feed Solenoid. Set up the meter to read +24 VDC. Measure between CN101-4 (+) and ground (- ). Make one print while monitoring the meter. The meter swings from +24 VDC to 0 and back to +24. Y N Go to BSD 8.2 in Section 7 and troubleshoot the Registration Clutch signal and +24 VDC Interlocked (CN101-4, 1) for an open. If no open exists, replace the PCU PWB. If the problem still exists, replace the Registration Clutch. Check the following: · Obstructions torn paper etc. in the paper path. · Mechanical drive problem.
STATUS INDICATOR RAPs
2/99 2-6 DocuPrint C55/C55mp/[NC60]
E4
E5 FUSER JAM RAP
Paper did not reach the Exit Sensor. INITIAL ACTION Open the Printer and remove the Fuser Assembly. Check for any obstructions in the fuser paper path. Switch the power off wait 10 seconds and switch the power on. Run another print to recheck for the fault. PROCEDURE Check the following: · Obstructions in the paper path. · Defective stripper fingers. · Mechanical drive problem. Enter IOT normal diagnostics. Scroll to the SWITCH SCAN program and select Scan Row 00. Press Form Feed [1]. Open the Printer, then open the Fuser cover. Actuate and deactuate the Exit Sensor while observing the Yellow LED. The Yellow LED switches on and off. Y N With SCAN ROW 00 still selected, actuate and deactuate the Bypass Switch while observing the Cyan LED. The Cyan LED switches on and off. Y N Go to BSD 10.2 and troubleshoot the Strobe 2 signal CN103-18 for an open. If no open exists replace the PCU PWB. A B
A
B Go to BSD 10.2 in Section 7 and troubleshoot the Exit Sensor signal, +5 VDC and GND (CN308-1, 3, 2) for an open. If no open exists, replace the PCU PWB. If the problem still exists, replace the Exit Sensor.
Exit from the SWITCH SCAN program. Remove the Front Cover and then close the Printer. Scroll to the MOTOR TEST program and press Form Feed [1] to switch on the motors while observing the Fuser Drive Motor. The Fuser Drive Motor is rotating normally. Y N Go to BSD 10.1 in Section 7 and troubleshoot the Fuser Drive Motor clock lines. If the lines are OK, replace the PCU PWB. If the problem still exists, replace the Fuser Drive Motor. · Make sure the Fuser Cover fits correctly. · Check for a Mechanical problem.
2/99 DocuPrint C55/C55mp/[NC60] 2-7
STATUS INDICATOR RAPs
E5
E6 DRUM JAM RAP
Paper is jammed on the Transfer Drum and could be caused by one of the following: · Transfer Drum Cleaner not cleaning the Transfer Drum or resting on the Transfer Drum during the Print cycle. · Paper did not reach the Gamma Sensor. · Paper did not tack to the Transfer Drum and actuated the Transparency Jam Sensor. · Paper did not tack to the Transfer Drum and actuated the Cleaner Jam Switch. · Arcing between the Charge Scorotron connectors and the Print Drum. INITIAL ACTION Open the Printer and check for torn paper or an obstruction in the paper path. Check for a sheet of paper or a transparency actuating the Transparency Jam Sensor or the Cleaner Jam Switch. Check the Toner Collector for " layered" toner (sand-art effect). If layered toner is present, refer to OF8 Arcing RAP. If the problem only occurs when running color prints, check the Stripper Fingers for binding or interference. Open the Printer and position the Transfer Drum Home Position Sensor flag at the 3 o' clock position. The Lead edge of the white patch should be at the tips of the stripper fingers. If not, replace the Transfer Drum. PROCEDURE Switch the Printer off. Remove the front cover and tape the Control Panel up so that you can view the operation of the Transfer Drum Cleaning Solenoid. Switch the Printer on. Observe the Transfer Drum Cleaning Solenoid and the Cleaner Assembly.
If you see solid development during the copy quality setup, go the OF8 Arcing RAP. The Transfer Drum Cleaning Solenoid should energize and move the Cleaner Assembly against the Transfer Drum while the patches are generated during the Copy Quality Setup. When the Copy Quality Setup is complete the Transfer Drum Cleaning Solenoid should deenergize and move the Cleaner Assembly away from the Transfer Drum. If the E6 jam occurs before paper is fed and the patches are not being cleaned the Transfer Drum Cleaner assembly is not camming into the cleaning position. If the machine prints OK when printing black only but jams (E6) when printing color, it is an indication that the Transfer Drum Cleaner assembly is staying cammed against the Transfer Drum. The Transfer Drum Cleaning Solenoid and Transfer Drum Cleaner Assembly are operating correctly. Y N Check that when the solenoid energizes the camshaft turns 180 degrees and is stopped by the outer tab on the cleaner clutch sleeve. Ensure that the solenoid is tight and the actuator catches the inner tab when de-energized, and stops the outer tab when energized. Check for flashing on the plastic assembly, a bent solenoid actuator or other things that could interfere with proper operation. Clean the cams and the cam followers with film remover to minimize friction. Do not attempt to lubricate these cams. Observe the operation several times and look for smooth, consistent operation. Do not attempt to disassemble and adjust the clutch. If the clutch is defective order the new Cleaner Clutch Shaft Assembly. B 2/99 2-8
A
B Set up the meter to read +24 VDC. Measure between CN103-3 (+) and ground (- ). Switch the power off wait 10 seconds and switch the power on while monitoring the meter. The meter swings from +24 VDC to 0 and back to +24. Y N Go to BSD 9.14 in Section 7 and troubleshoot the Transfer Drum Cleaning Solenoid signal and +24 VDC Interlocked (CN103-3, CN316-2, 1) for an open or a short. If 24 VDC is not available at 316-1 on the Connector PWB, go to BSD 1 and troubleshoot the 24 VDC Interlocked (CN114-1, CN103-1). Check the Transfer Drum Cleaning Solenoid and the cleaner assembly for binding.
If the sheet appears to be stopping at the Transfer Drum to Print Drum Nip, check the Transfer Drum Nip Adjustment (ADJ 11.1). Enter IOT normal diagnostics. Scroll to the SWITCH SCAN program and select Scan Row 05. Press Form Feed [1]. Open the Printer. Actuate and deactuate the Transparency Jam Sensor while observing the Black LED. The Black LED switches on and off. Y N Check for an obstruction that is keeping the Transparency Jam Sensor actuator raised. C D
A STATUS INDICATOR RAPs
E6
DocuPrint C55/C55mp/[NC60]
C
D If OK, refer to BSD 9.17 and check the Transparency Jam Sensor signal CN314-2 for a short to ground. If no short exists, replace the PCU PWB. If the problem still exists, replace the Transparency Jam Sensor.
E Set up the meter to read +24 VDC. Measure between CN103-4 (+) and ground (- ). Make one print while monitoring the meter. The meter swings from +24 VDC to 0 and back to +24. Y N Go to BSD 9.16 in Section 7 and troubleshoot the Stripper Solenoid signal and +24 VDC Interlocked (CN103-4, CN303-2, 1) for an open or a short. If no short or open can be found, replace the PCU PWB. If the problem still exists, replace the Stripper Solenoid. Set up the meter to read +5 VDC. Measure between CN103-11 (+) and ground (- ). Switch the power off wait 10 seconds and switch the power on. The meter swings from 3.8 VDC to .5 when the white patch passes in front of the Gamma Sensor. Y N Go to BSD 8.5 in Section 7 and troubleshoot the Gamma Sensor, all lines, for an open. If the lines are OK, replace the PCU PWB. If the problem still exists, replace the Gamma Sensor. Refer to Section 6, GP 9.3 and perform the Transfer Voltage Check. The Transfer voltage is within specification. F
F Y N Go to BSD 9.1 in Section 7 and troubleshoot the following for an open or short. · Black Transfer Lead from the Power Supply. · Transfer On Signal (CN106-3). · Transfer Control Signal (CN106-5). · Bias Control Signal (CN106-6). · +24 VDC to Power Supply (CN106-1). If no wiring problem can be found, replace the PCU PWB. If the problem still exists, replace the High voltage Power Supply. Refer to BSD 9.1 in Section 7 and check the Charge On Signal (CN106-2) for an open. Check the following: · Obstructions in the paper path. · Dirty Feed Rolls. · Mechanical drive problem.
Open the printer and remove the Transfer Discharge Corotron from the left side of the printer. You will need to squeeze the corotron handle to release the corotron. With Scan Row 05 still selected, actuate and deactuate the Cleaner Jam Switch while observing the Magenta LED. The Magenta LED switches on and off. Y N Check for an obstruction that is keeping the Cleaner Jam Switch actuated. If OK, refer to BSD 9.18 and check the Cleaner Jam Switch signal CN318-2 for a short to ground. If no short exists, replace the PCU PWB. If the problem still exists, replace the Cleaner Jam Switch. Exit from the Switch Scan Program. Scroll to the MOTOR TEST program and switch on the motors while observing the Fuser Drive Motor The Fuser Drive Motor is rotating normally. Y N Go to BSD 10.1 in Section 7 and troubleshoot the Fuser Drive Motor for an open. If the motor was noisy, check the clock lines for an open or short If the lines are OK, replace the PCU PWB. If the problem still exists, replace the Fuser Drive Motor. E
2/99 DocuPrint C55/C55mp/[NC60] 2-9
STATUS INDICATOR RAPs
E6
E7 PRINT DRUM JAM RAP
INITIAL ACTION Open the Printer and clear the jam. If problem reoccurs refer to E4 RAP.
E8 OUTPUT JAM RAP
Paper was on the Exit Sensor too long. INITIAL ACTION We have seen some machines where the actuator for the Exit Sensor has become stuck during shipping. When this happens, the sensor does not change state, and the E8 jam occurs. If you remove the sensor cover (PL 2.1) by removing the two screws that secure it, you can ensure that the actuator is free and that the sensor is secured in the proper position in the sensor cover. Open the Printer and remove the Fuser Assembly. Check for any obstructions in the fuser paper path. Switch the power off wait 10 seconds and switch the power on. Run another print to recheck for the fault. PROCEDURE Enter IOT normal diagnostics. Scroll to the SWITCH SCAN program and select Scan Row 00. Press Form Feed [1]. Open the Printer, then open the Fuser Cover. Actuate and deactuate the Exit Sensor while observing the Yellow LED. The Yellow LED switches on and off. Y N Go to BSD 10.2 in Section 7 and troubleshoot the Exit Sensor signal (CN308-1) for a short to ground. If no short exists, replace the PCU PWB. If the problem still exists, replace the Exit Sensor. Check the following: · Obstructions in the paper path. · Mechanical drive problem in the feedout area.
E9 CLOSE PRINTER RAP
The Printer is open. INITIAL ACTION Open and reclose the printer. PROCEDURE Enter IOT normal diagnostics. Scroll to the SWITCH SCAN program and select Scan Row 00. Press Form Feed [1]. Open and close the Printer while observing the Black LED. The Black LED switches on and off. Y N Go to BSD 1 (G1) in Section 7 and troubleshoot the 24 VDC Interlock Switch. If no open exists, replace the PCU PWB. If the problem still exists, replace the 24 VDC Interlock Switch. Replace the PCU PWB.
STATUS INDICATOR RAPs
2/99 2-10 DocuPrint C55/C55mp/[NC60]
E7, E8, E9
EA COLOR DEV. MISINSTALLED RAP
The Color Developer Module was installed incorrectly or overtoning has occurred. INITIAL ACTION Enter IOT normal diagnostics. Scroll to the TEST PRINT program and press Form Feed [1] to run a test print. While the print is running, observe the KT=__, CT=__, MT=__, YT=__ values. If any of the three color (C, M, Y) toner concentration values are below 10, that color is overtoned. Refer to ADJ 9.1 EA " Tone Down" Procedure in Section 4. If the values are NOT too low, continue with this RAP. Remove the Color Developer Module. Check the Developer Module connector to be sure it is clean. Reinstall the Color Developer Module. If the problem persists, check connector CN118 for a good connection or any loose wiring before replacing the Color Developer Module. If the problem still exists, replace the PCU PWB.
EB BLACK DEV. MISINSTALLED RAP
The Black Developer Module was installed incorrectly or the contacts are dirty. INITIAL ACTION Remove the Black Developer Module. Check for binding in the housing. Check to be sure that the seal has been removed. Check the Developer Module connector to be sure it is clean. Reinstall the Black Developer Module. If the problem persists, check connector CN107 for a good connection or any loose wiring before replacing the Black Developer Module. If the problem still exists, replace the PCU PWB.
EC PRINT DRUM MISINSTALLED RAP
The Print Drum Module was installed incorrectly or is not making a good connection. INITIAL ACTION Remove then reinstall the Print Drum Module. This problem is usually caused by a poor connection on the left side of the Print Drum Module. Three contacts are cammed out when the Print Drum Module is installed. These contacts make a connection with the Drum Link PWB located on the left side of the Print Drum Module. Check to make sure there is a good connection and the contacts cam out. Refer to BSD 9.2 in Section 7 and check the Drum Detect (H) signal. If the problem persists, replace the Print Drum Module. If the problem still exists, replace the PCU PWB.
2/99 DocuPrint C55/C55mp/[NC60] 2-11
STATUS INDICATOR RAPs
EA, EB, EC
F1 DISK ERROR (FLOPPY) RAP
The Floppy Disk cannot be read. INITIAL ACTION Note: The Floppy Disk must be a DOS format. Load a different floppy and try to read it. If the floppy still cannot be read, check the following for a good connection: · CN102 between the Floppy drive and the ESS. (BSD 13 in Section 7). · CN103 the flat cable between the Floppy drive and the ESS. (BSD 13 in Section 7). If the problem still exists, replace the Floppy Drive before replacing the ESS PWB.
F2 DISK I/O ERROR (FLOPPY) RAP
The Floppy Disk cannot be read. INITIAL ACTION Note: The Floppy Disk must be a DOS format. Load a different floppy and try to read it. If the floppy still cannot be read, check the following for a good connection: · CN102 between the Floppy drive and the ESS. (BSD 13 in Section 7). · CN103 the flat cable between the Floppy drive and the ESS. (BSD 13 in Section 7). If the problem still exists, replace the Floppy Drive before replacing the ESS PWB.
F3 ACTION FAILED (FLOPPY) RAP
The Floppy Disk cannot be accessed. INITIAL ACTION Note: The Floppy Disk must be a DOS format. Load a different floppy and try to read it. If the floppy still cannot be read, check the following for a good connection: · CN102 between the Floppy drive and the ESS. (BSD 13 in Section 7). · CN103 the flat cable between the Floppy drive and the ESS. (BSD 13 in Section 7). If the problem still exists, replace the Floppy Drive before replacing the ESS PWB.
STATUS INDICATOR RAPs
2/99 2-12 DocuPrint C55/C55mp/[NC60]
F1, F2, F3
H1 HARD DISK ERROR RAP
The Hard Disk cannot be read. C55/C55mp NOTE: If no hard disk is installed on this printer, print a Settings page (Off Line, Print, Settings) to record the customer network settings. Tell the customer that you are going to do a factory reset and they will need to reinstall the printer on their network. Perform a Factory Reset (Off Line, Setup, Factory Reset). [NC60] NOTE: If no hard disk is installed on this printer, print a Config. sheet (Menu Up to Service Menu, Item Up to Config Sheet, Enter) to record the customer network settings. Tell the customer that you are going to do a factory reset and they will need to reinstall the printer on their network. Perform a Factory Reset. Power Off. Press and hold On Line and Enter. Switch the power on. Continue holding the On Line and Enter keys until the display indicates Power On Version X.XX, then release the keys. This will enable the Reset Menu. Menu Up until Reset Menu, Item Up until Factor Defaults, Value Up until Yes, then press Enter.
INITIAL ACTION Switch the power off wait 10 seconds and switch the power on. This will force the ESS to retry reading the Hard Disk. If the Hard Disk still cannot be read, check the following: · (C55/C55mp) Check the Hard Disk to ensure that the new Relay Interface PWB is installed. Look for a small PWB mounted to the left of the hard drive. · All Printers, check for a good connection between the Hard Disk and the ESS (CN101). (BSD 13 in Section 7). If the problem still exists, replace the Hard Disk before replacing the ESS PWB.
H2 HARD DISK CONTROLLER ERROR RAP
The Hard Disk Controller has failed. INITIAL ACTION Switch the power off wait 10 seconds and switch the power on. Retry reading the Hard Disk. If the Hard Disk still cannot be read, check the following for a good connection : · Between the Hard Disk and the ESS (CN101). (BSD 13 in Section 7). If the problem still exists, replace the ESS PWB.
2/99 DocuPrint C55/C55mp/[NC60] 2-13
STATUS INDICATOR RAPs
H1, H2
H3 HARD DISK FULL RAP
The Hard Disk is full. INITIAL ACTION Switch the power off wait 10 seconds and switch the power on. This will force the ESS to retry reading the Hard Disk. If the Hard Disk still does not write, have the customer remove some of the files from the Hard Disk.
H4 REFORMAT HARD DISK RAP
The Hard Disk needs to be formatted. INITIAL ACTION Switch the power off wait 10 seconds and switch the power on to retry reading the Hard Disk. If the H4 occurs again, reformat the hard disk:
STATUS INDICATOR RAPs
2/99 2-14 DocuPrint C55/C55mp/[NC60]
H3, H4
J1 ADD YELLOW TONER RAP
The yellow toner concentration sensor has detected low yellow toner in the yellow developer assembly. When this occurs, the Printer will display " Adjusting Print Quality" and attempt to tone up. NOTE: If a new color developer housing has been installed, make sure the 3 seals have been removed from the left side of the housing. INITIAL ACTION Check with the customer to see if they have already added Yellow Dry Ink. Add Yellow Dry Ink, if required. Adding too much toner can cause the toner to " cake" and not be dispensed. (C55/C55mp) Put the printer in the Off Line mode. Select the SERVICE Menu and print a Diagnostic Test Sheet. Determine the Engine Software version from the Diagnostic Test Sheet. If the Software level is Version 66, replace the PCU PWB. All Printers, switch the power off wait 10 seconds and switch the power on. Allow the Printer to try to tone up to recheck for the fault. PROCEDURE Enter IOT normal diagnostics. Scroll to the MOTOR TEST program and Press Form Feed [1] to switch on the motors while observing the Color Toner Motor. The Color Toner Motor is rotating normally. A
A Y N Refer to BSD 9.11 in Section 7 and troubleshoot the Color Toner Motor lines (CN116-1, 2) for an open or a short to ground. If no wiring problem exists, replace the PCU PWB. If the problem still exists, replace the Color Toner Motor. Exit from diagnostics . Set up the meter to read +24 VDC. Measure between CN115-16 (+) and ground (- ). Switch the power off wait 10 seconds and switch the power on while monitoring the meter. The meter swings from +24 VDC to 0. Y N Go to BSD 9.10 in Section 7 and troubleshoot the Yellow Toner Solenoid signal and +24 VDC Interlocked (CN115-16, 15) for an open. If no open exists, replace the PCU PWB. If the problem still exists, replace the Yellow Toner Solenoid. Check the Yellow Dispense Shaft to see if it rotates when the Solenoid energizes. If not, look for a mechanical problem (gears etc.). Check the ground to the Yellow Toner Concentration Sensor (CN118-4 to CN1009-7) BSD 9.10. If the ground is OK, replace the PCU PWB.
Color Toner Motor Y Disp. Shaft
01/02
2/99 DocuPrint C55/C55mp/[NC60] 2-15
STATUS INDICATOR RAPs
J1
J2 ADD MAGENTA TONER RAP
The magenta toner concentration sensor has detected low magenta toner in the magenta developer assembly. When this occurs, the Printer will display " Adjusting Print Quality" and attempt to tone up. NOTE: If a new color developer housing has been installed, make sure the 3 seals have been removed from the left side of the housing. INITIAL ACTION Check with the customer to see if they have already added Magenta Dry Ink. Add Magenta Dry Ink, if required. Adding too much toner can cause the toner to " cake" and not be dispensed. (C55/C55mp) Put the printer in the Off Line mode. Select the SERVICE Menu and print a Diagnostic Test Sheet. Determine the Engine Software version from the Diagnostic Test Sheet. If the Software level is Version 66, replace the PCU PWB. All Printers, switch the power off wait 10 seconds and switch the power on. Allow the Printer to try to tone up to recheck for the fault. PROCEDURE Enter IOT normal diagnostics. Scroll to the MOTOR TEST program and Press Form Feed [1] to switch on the motors while observing the Color Toner Motor. The Color Toner Motor is rotating normally. A
A Y N Refer to BSD 9.11 in Section 7 and troubleshoot the Color Toner Motor lines (CN116-1, 2) for an open or a short to ground. If no wiring problem exists, replace the PCU PWB. If the problem still exists, replace the Color Toner Motor. Exit from diagnostics. Set up the meter to read +24 VDC. Measure between CN115-14 (+) and ground (- ). Switch the power off wait 10 seconds and switch the power on while monitoring the meter. The meter swings from +24 VDC to 0. Y N Go to BSD 9.10 in Section 7 and troubleshoot the Magenta Toner Solenoid signal and +24 VDC Interlocked (CN115-14, 13) for an open. If no open exists, replace the PCU PWB. If the problem still exists, replace the Magenta Toner Solenoid. Check the Magenta Dispense Shaft to see if it rotates when the Solenoid energizes. If not, look for a mechanical problem (gears etc.). Check the ground to the Magenta Toner Concentration Sensor (CN118-5 to CN100921) BSD 9.10. If the ground is OK, replace the PCU PWB.
01/02
Color Toner Motor
M Disp. Shaft
STATUS INDICATOR RAPs
2/99 2-16 DocuPrint C55/C55mp/[NC60]
J2
J3 ADD CYAN TONER RAP
The cyan toner concentration sensor has detected low cyan toner in the cyan developer assembly. When this occurs, the Printer will display " Adjusting Print Quality" and attempt to tone up. NOTE: If a new color developer housing has been installed, make sure the 3 seals have been removed from the left side of the housing. INITIAL ACTION Check with the customer to see if they have already added Cyan Dry Ink. Add Cyan Dry Ink, if required. Adding too much toner can cause the toner to " cake" and not be dispensed. (C55/C55mp) Put the printer in the Off Line mode. Select the SERVICE Menu and print a Diagnostic Test Sheet. Determine the Engine Software version from the Diagnostic Test Sheet. If the Software level is Version 66, replace the PCU PWB. All Printers, switch the power off wait 10 seconds and switch the power on. Allow the Printer to try to tone up to recheck for the fault. PROCEDURE Enter IOT normal diagnostics. Scroll to the MOTOR TEST program and Press Form Feed [1] to switch on the motors while observing the Color Toner Motor. The Color Toner Motor is rotating normally. A
A Y N Refer to BSD 9.11 in Section 7 and troubleshoot the Color Toner Motor lines (CN116-1, 2) for an open or a short to ground. If no wiring problem exists, replace the PCU PWB. If the problem still exists, replace the Color Toner Motor. Exit from diagnostics. Set up the meter to read +24 VDC. Measure between CN115-12 (+) and ground (- ). Switch the power off wait 10 seconds and switch the power on while monitoring the meter. The meter swings from +24 VDC to 0. Y N Go to BSD 9.10 in Section 7 and troubleshoot the Cyan Toner Solenoid signal and +24 VDC Interlocked (CN115-12, 11) for an open. If no open exists, replace the PCU PWB. If the problem still exists, replace the Cyan Toner Solenoid. Check the Cyan Dispense Shaft to see if it rotates when the Solenoid energizes. If not, look for a mechanical problem (gears etc.). Check the ground to the Cyan Toner Concentration Sensor (CN118-6 to CN100917) BSD 9.10. If the ground is OK, replace the PCU PWB. C Disp. Shaft Color Toner Motor
01/02
2/99 DocuPrint C55/C55mp/[NC60] 2-17
STATUS INDICATOR RAPs
J3
J4 ADD BLACK TONER RAP
The black toner concentration sensor has detected low black toner in the black developer assembly. When this occurs, the Printer will dead cycle and attempt to tone up. NOTE: If a new black developer housing has been installed, make sure the packing material has been removed. INITIAL ACTION Check with the customer to see if they have already added Black Dry Ink. Add Black Dry Ink, if required. Adding too much toner can cause the toner to " cake" and not be dispensed. Check the Black toner hopper to ensure that it is latched closed and is opening the shutter to the developer housing. (C55/C55mp) Put the printer in the Off Line mode. Select the SERVICE Menu and print a Diagnostic Test Sheet. Determine the Engine Software version from the Diagnostic Test Sheet. If the Software level is Version 66, replace the PCU PWB. All Printers, switch the power off wait 10 seconds and switch the power on. Recheck for the fault. PROCEDURE Remove the Printer Rear Cover. There is a hole located at the left rear of the printer. This hole is used to view the gears for the Toner motor. NOTE: In the following steps, we will be operating the Black Toner Motor. Do not allow the motor to run for over 2 seconds or overtoning can result. A
A Enter IOT normal diagnostics. Scroll to the MOTOR TEST program and press Form Feed [1] to switch on the motors. Look through the hole and switch on the Black Toner Motor by pressing On Line [0]. Release On Line [0] to stop the motor. Press Media Server [2] to stop the test. The Motor Runs. Y N Set up the meter to read +24 VDC. Measure between CN107-13 (+) and ground (- ). Press Form Feed [1] to switch on the motors. Press On Line [0] to switch on the Black Toner Motor. Release On Line [0] to stop the motor. Press Media Server [2] to stop the test. The meter reads approximately 12 VDC when On Line [0] was pressed. Y N Go to BSD 9.8 in Section 7 and troubleshoot the Black Toner Motor lines (CN107-13, 14) for an open. If the lines are OK, replace the Black Toner Motor Check the Black toner box for auger binding. Check the ground to the Black Toner Concentration Sensor (CN107-2 to CN1001-4) BSD 9.7. If the ground is OK, replace the PCU PWB. Toner should be dispensed, check the Black toner box for auger binding. Check the ground to the Black Toner Concentration Sensor (CN107-2 to CN1001-4) BSD 9.7. If the ground is OK, replace the PCU PWB.
STATUS INDICATOR RAPs
2/99 2-18 DocuPrint C55/C55mp/[NC60]
J4
J5 REPLACE COLOR DEVELOPER CARTRIDGE RAP
NOTE: This code is normally preceded by a W1 code. The Color Developer Cartridge is at end of life. INITIAL ACTION Check the Color Developer Cartridge life. (C55/C55mp) Press On Line, then press Menu, use Next to scroll to the MAINTENANCE menu, press Enter. Use Next to scroll to COLOR DEV CART, press Enter. [NC60] Press Menu Up until Service, Item Down until CRU Usage. Press Value Up to scroll to the Color Dev. Cart. Check the % remaining on the Color Developer Cartridge. If the cartridge is at end of life, notify the customer and have them install a new Color Developer Cartridge. PROCEDURE Check the developer drive motor, belts and gears to ensure that they are rotating. If the J5 code does not clear when a new Color Developer Cartridge is install, go to BSD 9.10 and check the New Developer Sense signal (CN118-7) for an open or short to ground. If the J5 code exists even though the Color Cartridge has not reached end of life refer to BSD 9.10 and check the following: · Cyan Toner Sense signal for an open or a short to ground (CN118-10). · Cyan Toner +5 VDC for an open (CN118-3). · Magenta Toner Sense signal for an open or a short to ground (CN118-9). · Magenta Toner +5 VDC for an open (CN118-2). A
A · Yellow Toner Sense signal for an open or a short to ground (CN118-8). · Yellow Toner +5 VDC for an open (CN118-1). If all of the above check OK, replace the Color Developer Cartridge. If the problem still exists, replace the PCU PWB.
J6 REPLACE BLACK DEVELOPER CARTRIDGE RAP
NOTE: This code is normally preceded by a W2 code. The Black Developer Cartridge is at end of life. INITIAL ACTION Check the Black Developer Cartridge life. (C55/C55mp) Press On Line, then press Menu, use Next to scroll to the MAINTENANCE menu, press Enter. Use Next to scroll to BLACK DEV CART, press Enter. [NC60] Press Menu Up until Service, Item Down until CRU Usage. Press Value Up to scroll to the Black Dev. Cart. Check the % remaining on the Black Developer Cartridge. If the cartridge is at end of life, notify the customer and have them install a new Black Developer Cartridge. PROCEDURE If the J6 code does not clear when a new Black Developer Cartridge is install, go to BSD 9.7 and check the New Developer Sense signal (CN107-3) for an open or short. If the J6 code exists even though the Black Cartridge has not reached end of life refer to BSD 9.7 and check the following: · Black Toner Sense signal for an open or a short to ground (CN107-4). · Black Toner +5 VDC for an open (CN107-1). If all of the above check OK, replace the Black Developer Cartridge. If the problem still exists, replace the PCU PWB.
2/99 DocuPrint C55/C55mp/[NC60] 2-19
STATUS INDICATOR RAPs
J5, J6
J7 TONER COLLECTOR FULL RAP
The Toner Collector is full or not installed correctly. INITIAL ACTION Remove the Toner Collector and ensure that it is not full. Check to ensure that the channel that the sensor " looks" through is not blocked with toner. Reinstall the Toner Collector. PROCEDURE Enter IOT normal diagnostics. Scroll to the SWITCH SCAN program and select Scan Row 02. Press Form Feed [1]. Open the Printer. Remove and reinstall the Toner Collector while observing the Yellow LED. The Yellow LED switches on and off Y N Go to BSD 9.21 in Section 7 and troubleshoot the Waste Toner Sensor signal, +5 VDC, and GND (CN102-3, 1, 2) for an open. If no open exists, replace the PCU PWB. If the problem still, exists replace the Waste Toner Sensor. Install a new Toner Collector.
J8 REPLACE PRINT DRUM RAP
The Print Drum is at end of life, is not in place, or is not installed correctly. NOTE: This code is normally preceded by a W3 code. INITIAL ACTION Check the Print Drum Cartridge life. (C55/C55mp) Press On Line, then press Menu, use Next to scroll to the MAINTENANCE menu, press Enter. Use Next to scroll to PRINT DRUM, press Enter. [NC60] Press Menu Up until Service, Item Down until CRU Usage. Press Value Up to scroll to the Print Drum. Check the % remaining on the Print Drum Cartridge. If the cartridge is at end of life, notify the customer and have them install a new Print Drum Cartridge. PROCEDURE If the J8 code does not clear when a new Print Drum Cartridge is installed, go to BSD 9.2 and check the New Drum Detect signal (CN107-15) for an open or short to ground. Also check +5 VDC (CN107-17) for an open. If the J8 code exists even though the Print Drum Cartridge has not reached end of life, refer to BSD 9.2 and check the Drum Detect signal (CN107-19). If all of the above check OK, replace the Print Drum Cartridge. If the problem still exists, replace the PCU PWB.
J9 REPLACE FUSER MODULE RAP
The Fuser is at end of life. NOTE: This code is normally preceded by a W4 code. INITIAL ACTION Check the Fuser Cartridge life. (C55/C55mp) Press On Line, then press Menu, use Next to scroll to the MAINTENANCE menu, press Enter. Use Next to scroll to FUSER MODULE, press Enter. [NC60] Press Menu Up until Service, Item Down until CRU Usage. Press Value Up to scroll to the Fuser Module. Check the % remaining on the Fuser Module. If the module is at end of life, notify the customer and install a new Fuser Module. PROCEDURE If the J9 code does not clear when a new Fuser Module is install, go to BSD 10.5 and check the New Fuser Detect signal (CN103-8, CN306-4) for an open or short to ground. Also check +5 VDC (CN306-1) for an open. If all of the above check OK, replace the Fuser Module. If the problem still exists, replace the PCU PWB.
STATUS INDICATOR RAPs
2/99 2-20 DocuPrint C55/C55mp/[NC60]
J7, J8, J9
JA REPLACE OIL/PAD RAP
The Oil/Pad needs to be replaced. INITIAL ACTION Check the Oil Bottle and sump. If required, replace the Wiper Roll and Oil Bottle. If this code persists after a new Oil Bottle is installed or the Oil is OK, continue with this RAP. Paper dust and other contaminants can cause the fuser oil to get cloudy and solidify causing the ball that triggers the Low Oil Sensor to stick. When low oil is detected, the printer will stop and the fuser will be powered off after 50 prints to prevent Fuser damage. If the fuser has the contamination described above, the ball could be stuck in a position that will prevent the fuser from warming up. Check to ensure the fuser sump has oil in it. There have been some reported instances of defective oil bottles failing to dispense oil into the sump. Ensure that the valve stem on the oil bottle is not bent or off center. A bent stem will not engage the plunger in the sump correctly. If the sump is full, check to see if the ball is stuck in the bottom of the channel. If i