HP C30D, C30 User Manual
Cut Sheet Printers
Maintenance Manual
Models C30 and C30D
HP Part No. C4000-90006
Notice
Hewlett-Packard makes no warranty of any kind with regard to this material, including,
but not limit ed to, the implied warranties of merchantabil ity 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.
Printing History
New editions are complete revisions of the manual. The dates on the title page change
only when a new edition is published.
The software code (EXXX) printed below the date indicates th e version level of the software product at the time of publication.
Edition 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .March 1994
Edition 2. . . . . . . . . . . . . . . . . . . . . . . . . . .December 1994
Trademarks
PCL is a trademark of the Hewlett-Packard Company. CG Times, a product of Agfa Corporation, is based o n T imes New Roman, a regi stered tr ademark of Monotype Cor poratio n
PLC. ITC Zapf Dingbats is a U.S. registered trademark of International Typeface Corporation. PostScript is a registered trademark of Adobe Systems, Inc. in the U.S.A. and other
countries. Times Roman and Univers are trademarks of Linotype AG and its subsidiaries.
Centronics is a U.S. registered trademark of Centronics Corporation. PhoenixPage is a
trademark of Phoenix technologi es, Ltd. UNIX is a register ed trad emark of UNIX System
Laboratories Inc. in the U.S.A. and othe r countr ies. DE C LN03+ is a register ed trade mark
of Digital Equipment Corporation. All other trademarks are the properties of their respective owners.
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Warnings and Cautions
A WARNING denotes a hazard. It calls attention to a procedure or practice, which, if not
done correctly or adhered to, could result in personal injury. Do not proceed beyond a
WARNING sign until the indicated conditions are fully understood and met.
A CAUTION denotes a hazard. It calls attention to a procedure which, if done incorrectly
or inattentively, coul d damage or destroy pa rt or all of t he product. Do not proceed beyond
a CAUTION until the indicated conditions are fully understood and met.
Conventions
The following conventions are used throughout this manual:
Notes contain important information set off from the text.
Caution messages indicate procedures which, if not observed,
could result in damage to the equipment.
Note
Caution
Warning
Warning messages call attention to situations that could result
in personal injury.
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Preface
The C30/C30D Maintenance Manual contains all the information needed to maintain and
service Hewlett Packard C30 and C30D printers. The C30 printer series are high-speed,
non-impact printers utilizing electrophotographic imaging technology.
The information in this maintenance manual is for author ized field repr esentative s who are
familiar with bas ic pr inter opera ti ons. It serve s a s a supp leme nt to tr aining class es and pro vides a basis for discussion with regional field service engineers and customer support
representatives.
Using This Manual
This manual is organized into the following sections:
Chapter 1, “Printer and Troubleshooting Overview”
Reviews the organization of the manual, the way the printer works, and how to troubleshoot the printer, including some standard procedures to follow when troubleshooting.
This chapter also inclu des a char t d etail ing ex actly what each c auses e ach error code, i llus trations of all senso rs in the print er, and a list of abbre viati ons use d th roughou t the manual.
Chapter 2, “TAG Cross- Reference Tables”
Provides cross-refe re nce tables; look up specific p ri nter problem description ( in e it her the
mechanical malfunction, error code, or print quality description tables), then turn to the
TAG indicated on the chart to troubleshoot the problem.
Chapter 3, “Troubleshooting Analysis Guide (TAGs)”
Detailed step-by-s tep p rocedu res t o hel p you i solat e and reso lve s peci fic pr inter probl ems.
If you are not sure which TAG to start with, begin with the overview, TAG 001.
Chapter 4, “Print Quality Samples”
Shows print test patte rns in dicat ing spec ific proble ms, and refer encin g the TAG that treats
each problem.
Chapter 5, “Diagnostic Tests”
Reviews each printer software diagnostic.
Chapter 6, “Wiring Diagrams and Electrical Data”
Shows printer schematics and locations of individual components.
Chapter 7, “Removal/Replacement Procedures”
Outlines procedures to follow when removing and replacing printer parts, also called
FRUs (Field-Replaceable U nits).
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Chapter 8, “Options”
Provides information about the optional High Capacity Input and High Capacity Output
bins.
Chapter 9, “General Printer Maintenance”
Reviews printer maintenance procedures to complete during service calls.
Appendix A
Lists the abbreviations and acronyms used in the manual.
Index
Provides a list of references to topics and part numbers mentioned in the Maintenance
Manual
Other Manuals
The C-Series Illustrated Parts Catalog shows every FRU and CRU (customer-replaceable
unit) in the printer, including part number information. This information is frequently
updated.
The HP C30 and C30D Guide to Operations, C4000-96006, contains all the information
needed to operate Hewlett Packard C40D printers.
The HP C30 and C40D Paper Specifications 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 © 1995 Hewlett-Packard Company. All rights reserved. January 1995
Please address any comments or questions with respect to this document to:
Publication Dep artment
Hewlett-Packard Company
HP Printers - MS 44MC
System Peripherals Operation
19111 Pruneridge Avenue
Cupertino, CA 95014
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Contents
Printer and Troubleshooting Overview
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Paper Path and Cycle Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Simplex Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Error Code Technical Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Sensor and Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
General Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
The Problem: Printer or Host? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Protocol Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Reading the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Confirming Line Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Using the Troubleshooting Analysis Guide (TAG) . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Sample TAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Standard Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21
Power-on-reset (POR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Checking Continuity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Installing the Interlock By-pass Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Producing a Developed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Producing a Toner Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Completing a Service Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
TAG Cross-Reference Tables
TAG Cross-Reference Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Error Code/TAG Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Print Quality/TAG Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Mechanical Malfunction/TAG Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Troubleshooting Analysis Guide (TAGs)
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Troubleshooting Analysis Guide (TAGs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
TAG 001: Troubleshooting a Problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
TAG 002: Check & Problem Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
TAG 010: Upper Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
E10: Envelope Tray Out of Envelopes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
TAG 011: Lower Cassette Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
vii
TAG 012: Upper Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
TAG E12: Envelope Tray or Feeder Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
TAG 013: Lower Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
TAG 020: Paper Jam/Misfeed in Upper Cassette Area . . . . . . . . . . . . . . . . . . . . . . . .3-26
TAG 021: Paper Jam/Misfeed in /Lower Cassette Area. . . . . . . . . . . . . . . . . . . . . . . .3-30
TAG 022: Paper Jam in the Transfer or Fuser Area. . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
TAG 023: Paper Jam in the Output Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
TAG 025: Paper in Input Area Before Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
TAG 026: Paper in Output Area Before Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
TAG 030: Developer Bias Short/Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
TAG 031: Toner Patch Reference Level Too Low. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
TAG 032: Toner Patch Too Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
TAG 035: Out of Toner or ADD TONER Indicator On. . . . . . . . . . . . . . . . . . . . . . . .3-51
TAG 036: Developer Unit Not Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53
TAG 040: Photoconductor Seam Sensor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . .3-54
TAG 044: Main Charger/Transfer Charger Circuit Open. . . . . . . . . . . . . . . . . . . . . . .3-58
TAG 045: Main Charger Circuit Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
TAG 050: Transfer Charger Circuit Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63
TAG 055: Erase Lamp Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65
TAG 070: Fuser Unit Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-67
TAG 071: Open Fuser Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72
TAG 072: Fuser Unit Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-73
TAG 083: Job Offset Mechanism Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-75
TAG 097: +12 Vdc Power Shorted or Sensing Problem . . . . . . . . . . . . . . . . . . . . . . .3 -79
TAG 098: -12 Vdc Power Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-90
TAG 099: +24 Vdc Power Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-92
TAG 100: PCL Board Interface Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-102
TAG 101: IGS Controller Diagnostic Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
TAG 130: Diskette/Disk Drive Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-104
TAG 200: IGS Internal Communication Malfunction . . . . . . . . . . . . . . . . . . . . . . . .3-108
TAG 201: IGS-PCL Interface Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -110
TAG 405: IGS Bit-Map RAM Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-112
TAG 500: +5 Vdc Power Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-113
TAG 600: AC Power Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-118
TAG 610: Operator Panel Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-125
TAG 700: Output Tray Circuit Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-130
TAG 702: Paper Size Detection Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-132
TAG 703: Upper Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-135
TAG 704: Lower Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-136
TAG 705: Multiple Paper Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-137
TAG 706: Paper Damaged or Wrinkled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-138
TAG 707: Upper Paper Guide Assembly Not Closing. . . . . . . . . . . . . . . . . . . . . . . .3-139
TAG 750: Counter Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-140
TAG 751: Main Drive Motor Runs Continuously . . . . . . . . . . . . . . . . . . . . . . . . . . .3-142
TAG 753: External Communications Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . .3-143
TAG 754: Attachment Option Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-146
TAG 800: Prints Blank or With Dark Horizontal Bands . . . . . . . . . . . . . . . . . . . . . .3-148
TAG 801: Prints Light or Light With Carrier Particles . . . . . . . . . . . . . . . . . . . . . . .3-152
TAG 802: Prints With Voids or White Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-158
TAG 803: Prints With Light or White Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . .3-160
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TAG 804: Prints With Light Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-162
TAG 805: Black Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163
TAG 806: Prints with Dark Spots or Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166
TAG 807: Misregistered/Skewed Prints (Simplex) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168
TAG 808: Prints Overtoned/Dark Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . 3-172
TAG 809: Blurred or Smeared Vertical Streaks on Prints. . . . . . . . . . . . . . . . . . . . . 3-177
TAG 810: Uneven Density or Dark Areas on Prints . . . . . . . . . . . . . . . . . . . . . . . . . 3-180
TAG 811: Background/Residual Images/Dark Prints . . . . . . . . . . . . . . . . . . . . . . . . 3-182
TAG 812: Uneven or No Fusing on Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-187
TAG 813: Residual Images on Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-189
TAG 815: Prints Resulting From Printhead Malfunctions. . . . . . . . . . . . . . . . . . . . . 3-191
TAG 900: Top Cover Interlock Malfunction, Duplex . . . . . . . . . . . . . . . . . . . . . . . . 3-192
TAG 901: Misregistration/Skewed Prints (Duplex). . . . . . . . . . . . . . . . . . . . . . . . . . 3-194
TAG 902: Paper Jam in Duplex Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-198
Print Quality Samples
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Print Quality Samples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Sample 1: Good Quality Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Sample 2: Washout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Sample 3: Blank Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Sample 4: Light Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
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
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
How to Run Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
ix
001 Operator Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
002 Upper Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
003 Lower Cassette Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
005 Sensor Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
006 Paper Transport Clutch Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
007 Counter Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
008 Jogging Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
009 Photoconductor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
010 Toner Supply Motor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
011 Main Charger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
012 Transfer Charger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
013 Erase Lamp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
015 Negative Developer Bias Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
016 Duplex Feed Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
017 Duplex Input Sensor Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
018 Duplex Clutch Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
019 Duplex Tray Paper-Guide Motor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
020 High-Capacity Output Unit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
021 High-Capacity Input Unit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
022 Envelope Fuser Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
101 EIGS/MIGS Board Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
102 EIGS/MIGS Board Test (Continuous Loop). . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
103 Communication Loop-back Test (Single Loop) . . . . . . . . . . . . . . . . . . . . . . .5-21
104 Communication Loop-back Test (Continuous Loop) . . . . . . . . . . . . . . . . . . .5-22
105 EIGS Program RAM Test (Continuous Loop) . . . . . . . . . . . . . . . . . . . . . . . .5-22
107 EIGS/MIGS Bit Map Test (Single Loop) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
108 EIGS/MIGS Bit Map Test (Continuous Loop) . . . . . . . . . . . . . . . . . . . . . . . .5-23
110Format Disk/Clear Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
111 LED Printhead Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
112 Disk Drive Test (Single Loop With Stop on Error). . . . . . . . . . . . . . . . . . . . .5-25
113 Disk Drive Test (Continuous Loop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
Wiring Diagrams and Electrical Data
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Wiring Diagrams and Electrical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Connector (J/P) Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Connectors Inside the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -6
Connectors Inside the Left Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Connectors on the Duplex Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Connectors Inside the Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Connectors Inside the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
Connectors on the Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Connectors Inside the Back Cover (J/P2-14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
x
Connectors Inside the Back Cover (Continued) J/P18-62 . . . . . . . . . . . . . . . . . . . . . . 6-13
Connectors Inside the Back Cover (Continued) J/P 64-85. . . . . . . . . . . . . . . . . . . . . . 6-14
Connectors Inside the Back Cover (Continued) J/P 90-800. . . . . . . . . . . . . . . . . . . . . 6-15
Voltage Isolation Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
Ground System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
Host Interface Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
RS-232C Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Standard DCE to DTE RS-232C Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Special Considerations for RS-232 Host Interface Users. . . . . . . . . . . . . . . . . . . . . . . 6-23
DTE Host to Printer (Option 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
DTE Host to Printer (Option 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
IBM PC/XT to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
IBM PC/AT to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Macintosh Communication Port to Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
RS-422 Host interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Centronics Parallel Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
IBM Parallel to Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Special Considerations for Centronics Parallel Interface Users. . . . . . . . . . . . . . . . . . 6-29
Circuit Board Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
Signal Interface Board Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
PCL Board Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Printhead Circuit Board Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31
Removal/Replacement Procedures
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Power Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Photoconductor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Back Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Lower Back Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Left Side Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Right Side Cover Removal (Simplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
Right Side Cover Removal (Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
Vacuum Transport Unit Removal (Simplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11
Vacuum Transport Unit Removal (Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
Top Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
Top Cover Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
Top Cover Hinge Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
Rear Duplex Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Front DuplexCover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
Operator Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
xi
Counter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20
IGS Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
PCL Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22
Printhead Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
Disk Drive Housing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
Cooling Fan Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26
Duplex Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
Toner Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
AC Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
DC Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
High Voltage Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32
PhotoconductorSeam Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
Photoconductor Rear Guide Rail Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Signal Interface Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37
Power Control Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38
Jogging Motor Control Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-39
Upper or LowerPaper Size Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40
Upper Cassette Mount Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41
Lower Cassette Mount Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45
Upper Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-48
Upper Paper Guide Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50
Lower Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51
Paper Timing Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-52
Cleaner Drive Belt Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-54
Cleaner Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-55
Fuser Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-56
Fuser Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-57
Paper Feed Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-58
Paper Timing Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-59
Upper Feed Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-60
Lower Feed Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-61
Upper Pick-Up Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-62
Upper Pick-Up Roller Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-63
Lower Pick-Up Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-64
Lower Pick-Up Roller Drive Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
Job Offset Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-66
Exit Pinch Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-68
Upper Static Brush Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-70
Lower Static Brush Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Exit Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-72
Exit Cover Removal (Simplex). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-74
Exit Cover Removal (Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-76
Paper Exit Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-78
Paper Full Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-79
Front Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-80
Back Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-81
xii
Top Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-82
Erase Lamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-83
EP Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-84
Main Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-86
Main Gear Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-88
Duplex Control Board #1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-89
Duplex Control Board #2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-90
Duplex Tray Registration Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-91
Duplex Skew Correction Cable Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-92
Upper Duplex Drive/Clutch Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . .7-94
Duplex Route Motor/Solenoid Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . .7-95
“A” Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-96
“B” Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-97
“C” Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-98
“C” Roller Solenoid Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-99
Duplex Route Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-100
Duplex Paper Path Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-102
Options
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
1200-Sheet/2500-Sheet Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
Bench Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Prefeed Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Input Control Board Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
1400-Sheet Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
Bench Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Output Control Board Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -14
General Printer Maintenance
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2
General Printer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
Every-Call Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Paper Feed Tension Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Lubrication Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Tune-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Tool Requirements: Service Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Tools/Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
End User Cleaning Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
xiii
Printer/Maintenance Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4
Every-Call Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6
Remove Major Consumable Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6
Inspect and Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6
Clean Internal Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6
Clean the Fuser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6
Clean the Developer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
Clean the Cleaner Unit/Main Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
Clean the Photoconductor Unit Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
Clean the Transfer Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
Run Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
Adjusting Paper Feed Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8
Printers With Paper Tension Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8
Printers With Pick Pressure Adjusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9
Lubrication Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11
Front View Lubrication Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13
Duplex Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13
Rear View Lubrication Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15
Duplex Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15
Tune-Up Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18
Abbreviations and Acronyms
xiv
Troubleshooting
Section 1 T roubleshooting
Chapter 1
Printer and
Overview
Printer and Troubleshooting Overview 1-1
Printing and Troubleshooting Overview
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Paper Path and Cycle Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Simplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Error Code Technical Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Sensor and Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Troubleshooting Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
General Troubleshooting Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
The Problem: Printer or Host?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Protocol Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
Reading the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Confirming Line Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18
Using the Troubleshooting Analysis Guide (TAG) . . . . . . . . . . . . . . . . . . . . . . . .1-19
Sample TAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19
Contents
Standard Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21
Power-on-reset (POR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21
Checking Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21
Installing the Interlock By-pass Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
Producing a Developed Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
Producing a Toner Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
Completing a Service Call. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
Clearing the Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
1-2 Printer and Troubleshooting Overview
Theory of Operation
The printer uses an electrophotographic imaging system based on LED array technology.
Two key components of the printer are the image generation system (IGS) controller and
the printer control logic (PCL) board.
Image Generation System (IGS) controller: Each printer is equipped with an IGS controller, which prov ides the interface between the host co mputer, the PCL board, LED
printhead, and the disk drives. The controller may be an EIGS or RIGS board.
Printer Control Logic (PCL) board: The PCL boa rd dire cts th e mechani cal fun ctions of
the printer and print cycle timing. The PCL board also receives initial machine information, such as empty paper cassettes, paper jams, and fuser unit problems.
The illustration on the following page details the printing process. The numbers represent
the sequence of events from the time that the system interface receives data, through the
production of a print image, to the preparation for another print.
1 Receiving da ta
Data from the host is received by the Signal Interface (SI) PCA and is passed to the
Image Generating System (IGS) PCA, whi ch temporarily st ores the da ta in RAM. The
data may consist of i nformat ion ge nerat ed on th e ho st compu ter an d sent over t he host
communication interface or it may consist of information generated by printer soft-
ware, such as a request for test prints or to print the directory of a diskette.
2 Bit Image
The IGS transforms the host file into a bit map image of 1s and 0s and stores them in
user bitmap RAM. Bitmap memory is nothing more than an electronic piece of paper.
3 Charging the photoconductor belt
When the IGS controller has a full page of data, it causes the PCL board to turn on the
main motor, which rotates the photoconductor belt. As the photoconductor belt
rotates, the main charger applies a high negative cha rge to it, which repels toner from
the photoconductor belt except in the areas to print.
4 Exposing the image
The negatively charged belt then passes the LED printhead, w here the IGS c ontroller
turns the LEDs on and off to dischar ge the ar eas of the belt at a densi ty of 300 dots per
inch. The 1s in the bitmap memory turn the LED s on; 0s turn the LEDs off. The dis-
charged areas create a latent mirror image of the print on the photoconductor belt.
5 Developing the image
As the photoconductor belt continues to rotate, it brings the latent image to the devel-
oper unit. A negative developer bias is applied to toner and the toner is transferred to
the surface of the photoconductor belt. The negatively charged toner (which clings to
small metal carrier beads) is attracted to the discharged areas of the belt. The carrier
beads do not transfer. The belt, with the developed image on its sur fa ce, r ota te s out of
the developer unit. At this time you can re move the photoconduct or belt and read what
is printed on it, which you may need to do when troubleshooting print problems.
Printer and Troubleshooting Overview 1-3
6 Activating paper
As the image is be ing de velope d, a she et of paper i s tra nsport ed to the p hotocon ductor
belt. The PCL board controls this activity. A series of paper pick-up, feed, and timing
rollers guide the paper so the developed image is properly registered with the leading
edge of the sheet.
7 Transferring the image to the paper
Next, the paper contacts the surface of the photoconductor belt. Above the paper and
the belt is the transfe r cor ona , whic h has a high positive charge, and attracts the devel oped image from the bel t to th e surf ace of t he pape r. At this point, you can remove the
printed image to verify print quality, but the toner is not yet fused.
8 Fusing the image to the paper
The vacuum transport unit advances the paper with the developed image to the fuser
unit where heat and pressure bond the toner to the paper. The finished print then
arrives at the paper output tray.
9 Cleaning routine
After a print is made, the photoconductor belt must be cleaned for the next print. The
belt first passes the erase lamp where any remaining latent image is erased. The belt
continues to the cleaning unit where a charged brush rotates against the surface to
remove any residual toner. This toner is recycled to the developer unit for reuse.
6
Paper Input
Toner
5
Developer Unit
Transfer Charger
7
Photoconductor
Vac uu m Transport
Erase Lamp
9
Cleaner
3
Charge Corona
4
LED Printhead
Bitmap
RAM
2
8
IGS
Fuser Unit
Paper
Output
SI
Host
1
Figure 1-1. Cycle of Operation
1-4 Printer and Troubleshooting Overview
Paper Path and Cycle Sequence
The IGS board signals the PCL board th at a page of data is ready to be printe d. When thi s
happens the following sequence takes place.
Simplex Printing
1 PCL software downloaded to the PCL board from the disk drive system turns on the
main motor.
2 The PCL board engages the paper pick clutc h which causes the roll er to feed a sheet of
paper .
3 The paper is passed t o the f eed r oller where the PCL bo ard has en gaged t he fee d roll er
clutch.
4 The feed roll er passes the pa per to the paper timing roller. Prior to reaching the paper
timing roller, the paper passes over the paper timing sensor. (If the paper does not
energize this sensor in a specified amount of time, an error 020/021 will occur.) The
leading edge of the paper is registered against the paper timing roller. The paper tim-
ing clutch is engaged and the paper is passed over the photoconductor for transfer.
This registers the paper to the printer and the image to the paper. The paper timing
sensor sign al also alerts the PCL to in form the IGS that it can begin to send the data.
5 The PCL board engages the paper timing roller clutch and, at the same time, turns on
the transfer charger to provide a high positive voltage. The developed image on the
photoconductor comes in contact with the paper and the high positive voltage causes
the image to transfer to the p aper.
6 Because the toner is not yet fix ed to th e pape r, a vacuum transport assembly, gripping
the paper from the back side, moves the paper to the fuser unit, where heat and pres-
sure bond the toner to the paper.
7 Upon leaving the fuser unit, 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], an error 022 will occur.)
8 The exit roller moves the paper to the exit tray. (If the exit sensor is not cleared in a
specified amount of time, an error 023 will occur.)
Duplex Printing
When duplex is selected, the PCL board controls the paper motion with page scheduling
assistance from the IGS b oard. The duplex page rout er is enga ged. When in duplex mode,
it is important to note that th e printer runs mu ltiple pages through the paper path at the
same time to increase speed. (See Figure 1-2, “Paper Path,” on page 1-6.)
1 In a duplex job, the duple x router so lenoid behind t he fuser is engag ed and mecha nical
fingers route the paper to the duplex area. Also, the “A” roller clutch engages to turn
the “A” and “B” rollers (connected via a belt).
Printer and Troubleshooting Overview 1-5
2 The paper upon passing through the “B” roller comes in contact with the duplex sen-
sor . ( If the paper doe s not energize this sensor in a giv en amoun t of ti me, an er ror 060
will occur.)
3 The “C” roller bidirectional motor turns on and passes the paper into the turnaround
tray. The paper sensor in the turnaround tray is activated and the paper is center registered. (If the paper does not energize this sensor in a given amount of time after leaving the duplex sensor, an error 061 will occur.)
4 At this time the solenoid for th e r out er at the turnaround t ra y enga ges so the paper can
be routed to be printed on the duplex side.
5 In a given amount o f time after the paper en ergize s the paper sensor in t he turnaroun d
tray, the bi-directional motor reverses and passes the p aper to the paper timing roller.
(If the paper do es not energize the paper timing sensor in a given am ount o f time after
leaving the turnaround sensor, an error 062 will occur.)
6 At this point, the same steps happen as during a simplex cycle.
Figure 1-2. Paper Path
1-6 Printer and Troubleshooting Overview
Error Code Technical Definitions
The following table lists the printer error codes and their descriptions.
Table 1-1. Error Code Technical Definitions
T y pe Error Description
010, E10 PCL board detected no signal from upper paper cassette empty
011 PCL board detected no signal from lower paper cassette empty
012, E12 PCL board detected no signal from upper cassette in switch
013 PCL board detected no signal from lower cassette in switch
Cassette Errors
020 PCL board detected that the paper being fed from the upper cas-
021 PCL board detected that the paper being fed from the lower cas-
022 PCL board detected that the exit paper sensor did not activate or
023 PCL board detected that either:
sensor indicating no paper present
sensor indicating no paper present
sette did not reach the timing paper sensor within the allotted time
sette did not reach the timing paper sensor within the allotted time
the timing sensor did not deactivate within the allotted time
1. The exit paper sensor (within the printer) became activated but
did not deactivate within the specified time.
2. (HCO only). The paper exit sensor (within the HCO) did not
become activated or deactivated within the allotted time
025 PCL board detected that the timing paper sensor was activated
026 PCL board detected that either the exit paper sensor (within the
Paper Jams in the Primary Paper Path
027 PCL board detected paper in the duplex area after clearing a jam
030 PCL board detected a signal from the high-voltage power supply
031 PCL board detected a signal from the toner patch sensor board
032 PCL board detected a signal from the toner patch sensor board
035 PCL board detected too many successive signals from the toner
Toner Control Errors
036 PCL board detected no developer unit electrical interlock signal
immediately after one of the covers was closed
printer) or the paper exit sensor (within the HCO) was activated
immediately after one of the covers was closed
unit indicating an abnormal load on the bias voltage to either the
developer unit, cleaner unit, or printhead-cleaning bias plates.
indicating that the reference voltage level on the photoconductor
was too low.
indicating that the toner patch on the photoconductor was too light.
patch sensor board for a toner feed.
from the J25 connector.
Printer and Troubleshooting Overview 1-7
Table 1-1. Error Code Technical Definitions (Continued)
Type Error Description
040 PCL board sensed that the signal from the photoconductor seam
sensor either was not of sufficient amplitude or did not show the
proper timing.
041 PCL board detected an abnormally high amount of current needed
to drive the photoconductor seam sensor LED (within the photoconductor unit).
042 PCL board detected an open connection to the photoconductor
seam sensor LED (within the photoconductor unit).
044 PCL board detected a signal from the high-voltage power supply
unit indicating that either the main charger or transfer charger circuits have an open connection.
045 PCL board detected a signal from the high-voltage power supply
OPC Rotation Errors
unit indicating an abnormally high load on the bias voltage to the
main charger.
046 PCL board detected a signal from the high-voltage power supply
unit indicating an open connection in the main charger circuit (diagnostic test only).
050 PCL board detected a signal from the high-voltage power supply
unit indicating an abnormally high load on the bias voltage to the
transfer charger.
051 PCL board detected a signal from the high-voltage power supply
unit indicating an open connection in the transfer charger circuit
(diagnostic test only).
HVPS Errors
055 PCL board detected that the current needed to drive the erase
lamp assembly was either higher or lower than the specified limits.
060 PCL board detected that the exit paper sensor did not deactivate
or the paper path sensor did not activate within the allotted time.
061 PCL board detected that the duplex paper path sensor did not
deactivate, the turnaround tray sensor did not activate in the allotted time, or the duplex paper path sensor activated at POR.
062 PCL board detected that paper leaving the duplex turnaround tray
Duplex Jams
did not reach the timing sensor within the allotted time or the
duplex turnaround sensor was activated at POR.
070 PCL board sensed, via the fuser thermistor, that the temperature of
the fuser unit did not change within the allotted time.
071 PCL board sensed an open connection in the fuser thermistor cir-
cuit
072 PCL board sensed that the resistance of the fuser thermistor was
too low indicating that the temperature of the fuser unit was higher
than the specified limit.
073 PCL board sensed that the resistance of the fuser thermistor was
Fuser Control Errors
too high indicating that the temperature of the fuser unit was lower
than the specified limit.
1-8 Printer and Troubleshooting Overview
Table 1-1. Error Code Technical Definitions (Continued)
Type Error Description
081 PCL board activated the jogging motor but did not detect a change
in the signal from the front sensor in the job offset assembly (diagnostic test only).
082 PCL board activated the jogging motor but did not detect a change
in the signal from the rear sensor in the job offset assembly (diagnostic test only).
083 PCL board activated the jogging motor but did not detect a change
in the signal from either the front or rear sensors in the job offset
assembly.
084 PCL board detected a signal from the duplex control board #2 indi-
cating that the registration side sensor did not activate after command was sent to the duplex control board #2 to turn on the resist
motor (diagnostic test only).
Jogger Errors
085 PCL board detected a signal from the duplex control board #2 indi-
cating that the registration side sensor did not deactivate after a
command was sent to the duplex control board #2 to turn on the
resist motor (diagnostic test only).
086 PCL board detected a signal from the duplex control board #2 indi-
cating that either the registration side sensor was activated and
would not deactivate or was deactivated and would not activate
after a command was sent to the duplex control board #2 to turn on
the resist motor.
090 PCL board detected that one of the cover interlocks was not acti-
vated (diagnostic test only).
097 PCL board detected a signal from the IGS board indicating the
absence of +12 Vdc.
098 PCL board detected a signal from the IGS board indicating the
absence of ‚-12 Vdc.
LVPS Errors
099 PCL board detected a signal from the IGS board indicating the
absence of +24 Vdc.
100, 102 IGS board detected a failure of the PCL board status codes.
101 PCL board detected that the IGS board was in a halt state (diag-
nostic test only).
121-127 PCL board detected an error in the communication between the
PCL board and the IGS board.
130-134 PCL board detected an error during the internal diagnostic testing
of the PCL board.
140 PCL board detected an error during the internal diagnostic testing
of the PCL board.
145 PCL board detected an error during the internal diagnostic testing
of the PCL board.
Controller Errors
160-182 PCL board detected an error during the internal diagnostic testing
of the PCL board.
199-215 PCL board detected an error in the communication between the
PCL board and the IGS board.
301-401 IGS board detected an error during the internal diagnostic testing
of the IGS board.
Printer and Troubleshooting Overview 1-9
Table 1-1. Error Code Technical Definitions (Continued)
Type Error Description
405-409 IGS board detected an error in the program RAM during the inter-
450-566 IGS board detected an error during the internal diagnostic testing
DD Errors
570-586 IGS board detected an error when communicating with the floppy
600-610 IGS board detected an error during the internal diagnostic testing
Errors
Controller
701-703 IGS board detected an error when communicating with a host
770-784 IGS board detected an error when communicating with a host
Errors
888 IGS board detected that the PCL board was in a halt or reset state.
Communication
nal diagnostic testing of the IGS board.
of the IGS board and software.
disk drive.
of the IGS board.
using RS232 communications.
using RS422 communications.
1-10 Printer and Troubleshooting Overview
Sensor and Switch Locations
The following pages illustrate the locations of the printer’s sensors and switches. Table 1-
2, “Sensor and Switch List,” on page 1-14, lists them.
Left end view
Left end view
Front left view
Top view, duplex
Printer and Troubleshooting Overview 1-11
Top view
Front view
Developer right view
Developer left view
1-12 Printer and Troubleshooting Overview
Right side view
Top left, duplex tray view
Front view
Printer and Troubleshooting Overview 1-13
Rear view
Table 1-2. Sensor and Switch List
Sensor/Switch Name Page No.
Automatic toner control sensor 1-12
Cassette paper present sensors, upper and low er 1-11
Cassette present micro switches, upper and lower 1-11
Duplex registration sensor 1-11
Duplex paper path sensor 1-11
Duplex cover interlock switch 1-11
Interlock switch, top 1-13
Interlock switch, front 1-13
Interlock switch, rear 1-14
Paper exit sensor 1-13
Paper full sensor 1-13
Paper size sensors, upper and lower 1-11
Paper timing sensor 1-12
Photoconductor seam sensor 1-12
Toner empty sensor 1-12
Toner patch sensor 1-12
1-14 Printer and Troubleshooting Overview
Troubleshooting Overview
Throughout the printer’s life problems occur, such as those indicated when an error code
displays on the operator panel, a printer produces poor quality prints, or the printer malfunctions. Use the t ool s pr ovi de d in this manual to dia gnos e and resolve printer problems.
These tools include:
• The Troubleshooting Analysis Guide, which contains troubleshooting procedures
called TAGs. TAG 001: Troubleshooting A Printer Problem provides an overview of
how to use TAGs.
• Cross reference tab les, which link e rror codes, prin t quality probl ems, and mechanical
malfunctions to specific TAGs.
• Print quality samples, which you can use to identify a printing problem and its associ-
ated TAGs.
• Diagnostics, through which the printer checks itself for a range of problems.
The next several pages revi ew troubleshoot ing basics and standar d 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
General Troubleshooting Tips
When a printer problem arises, swapping out all printer supplies may temporarily mask
the problem. This is an unsat isfacto ry , short-t erm, and ex pensive solution to correcting the
proble m. Dust and other contamination, rather than printer supplies, are more often the
causes of problems. Clean consumable connectors, alignment guides, and areas before
changing consumables.
Many failures add excess toner to the printer’s engine. When you are advised to de-tone
the printer as part of a problem fix, run at least 200 test prints before evaluating whether
the problem has been resolved.
Printer and Troubleshooting Overview 1-15
The Problem: Printer or Host?
The printer is one component in a lar ge host s ystem. Before you start any troubleshoot ing,
make sure that the problem really belongs to the printer rather than to some other component in the host system. Print quality problems and mechanical malfunctions are almost
always associated with the printer. However, host interface and software emulation problems can be caused by some other component of the host system even though, at first Z
glance, they appea r to be printer probl ems. For ins tance, text print ed in t he wrong lo catio n
on a page, improper page breaks, and missing segments of data strongly indicate a host,
not a printer, problem.
The first step i n trou blesho oting any pr oblem i s to isola te t he pri nter from t he hos t sy stem;
you can then run test prints. Producing test prints exercises the printer as a stand-alone
ones machine, ensuring that the basic printer software and all mechanical functions of the
printer are working.
Running Test Prints
To run test prints:
1 Disconnect the host interface.
2 Run a series of test prints. A di re cto ry of the boot device and multiple listing s of fonts
print, followed by an unformatted and formatted error log. A continuous flow of the
test pattern then prints. To run test prints:
• For simplex printers, press:
STOP
TEST
• For duplex printers, press:
STOP
DUPLEX
TEST
• To stop printing t he test pattern, press:
STOP
On pressing STOP, the printer will print all test prints stored in the printer’s buffer, then
stop.
If the test pattern prints suc cessfull y, the problem probably originates with the host syste m
or a protocol converter connected to the host.
1-16 Printer and Troubleshooting Overview
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