HP C30D, C30 User Manual

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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.

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

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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

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

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

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

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.

Paper Input

Toner

Developer Unit

Transfer Charger

Photoconductor

Vac uu m Transport

Erase Lamp

Cleaner

Charge Corona

LED Printhead

Bitmap

RAM

IGS

Fuser Unit

Paper

Output

Host

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

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

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

Protocol Converters

Many protocol converters have a self-test function or configuration mode that enables the user to check the proper functioning of the control. You can reconnect the host interface and ask the customer to exercise this function of the converter. If the printer receives data and prints it (even if the output is garbled) you have isolated the problem as one that belongs to the host or the prot ocol con verte r. The problem is not a printer problem and the customer must seek assistance elsewhere in resolving the problem.

Reading the Error Log

One of the sheets printed prior to the test pattern is the formatted error log maintained by the printer in a file named ERROR.LOG.

• The first line of the formatted log lists paper jams. A 3-dig it error code (or codes) is

followed by a 4-digit number indicating how many times the error has occurred since the error lo g was last cleared. (See “Clearing the Error Log” on page 1-24.)

• The second line lists the last 15 errors.

• The last line indicates the last error that required a power-on-reset (POR).

Paper Jams

020 0001 021 0000 022 0001 023 020 020 022 022 022 022 071 042 000 000 000 000 000 000 000

Last error requiring POR (not used)

Figure 1-3. Sample Simplex Printer Error Log

Last 15 errors

Printer and Troubleshooting Overview 1-17

Confirming Line Power

Erratic printer problems can be caused by improper line power. As a rule, the voltage of the outlet should be checked at installation. However, if you are unable to isolate an inter-

mittent problem, the power shoul d be chec ked agai n. Consul t your co untry’s national electric code for the proper procedures to check for acceptable voltages, as shown in Table 1-

3, “Acceptable Voltages”.

Table 1-3. Acceptable Voltages

Probe connections 100-127v printer 200-240v printer

red to AC hot black to AC neutral

red to AC neutral black to ground

red to AC hot black to ground

120v +/- 10% 230v +/- 10%

3 vac or less 3 vac or less

120v +/- 10% 230v +/- 10%

Please see Chapter 5, “Dia gnostic Test s” for additional information about running diagnostic printer tests.

Please see Chapter 6, “Wiring Diagrams and Electrical Data” for additional information about the printer’s electrical systems.

1-18 Printer and Troubleshooting Overview

Using the Troubleshooting Analysis Guide (TAG)

The Troubleshooting Analysis Guide provides problem-solving sequences to help you identify and resolve printer problems. Each TAG addresses a particular symptom or error code of the printer. The TAG number often matches an error code displayed on the

printer’s operator panel.

Sample TAG

TAG 001: Troubleshooting a Problem

Error Code: All related error messages are listed here. Possible Causes: All possible causes are listed here. Possible Defects: All possible defective parts are listed here. (In no particular order.)

To start:

• Disconnect all peripheral cables

• Power-on-reset the printer.

Did all of the status lights come on, followed by 888 flashing briefly and an error code? Yes: Run test prints, following the procedure outlined in Section 1, then repeat this step. If the

answer is still no, refer to the mechanical malfunctions cross-reference chart in Section 2 to determine which TAG to follow. Then turn to that TAG.

Yes: Note the error message and continue.

Power-on-reset the printer.

Did the power-on-reset end with an error code? No:

Continue.

Yes: Refer to the error code cross-reference table in Section 2, using either the code that dis-

played after steps 1 and 2, or if multiple error codes conti nue to appear, the first error code that displays. Turn to the TAG associated with the code.

Did only the READY light come on with no numeric display? No: Continue Yes: Go to TAG 753

Each TAG walks through a comprehensive procedure specifi c to a si ngle pr oblem. As y ou progress through a TAG and eliminate possible causes, you may be directed to another step out of sequence in the same TAG or to another TAG altogether.

The TAG number and its title may be followed by a listing of possible error messages, possible causes, or possible defective parts related to the TAG.

Printer and Troubleshooting Overview 1-19

The TAG then directs you to perform cert ai n t as ks. Based on the resul ts of t hes e tasks, the TA G poses questions that can be answered by either yes or no. For yes answers, you follow one path; for no answers, follow another path. Some of the paths may lead you to other TAGs, so that you can methodically diagnose and re solve problems . When you ha ve corrected a problem, you will be directed to TAG 002 to confirm that the problem has been completely resolved and standard cleanup procedures observed.

If it’s not clear how t o diagnose a problem y ou’r e work ing on, follow the ste ps outlined in TA G 001, which includes references to the cross reference tables contained in Chapter 2,

“TAG Cross- Reference Tables”. Or, you may turn directly to the tables to get started.

As you use TAGs, you will sometimes refer to othe r s ect i ons of this manual for addi ti onal information:

• Chapter 4, “Print Quality Samples” contains print quality samples you’ll use to com-

pare the customer’s test prints with flawed and good print samples.

• Chapter 5, “Diagnostic Tests” outlines how to conduct printer diagnostic tests.

• Chapter 6, “Wiring Diagrams and Electrical Data” provides all wiring and connector

diagrams.

• Chapter 7, “Removal/Replacement Procedures” provides step-by-step procedures for

removing and replacing all field-replaceable parts on the printer.

• Chapter 8, “Options” reviews printer options (HCI, HCO) information.

• Chapter 9, “Gener al Pri nter M aint enance” presents general printer maintenance pr oce-

dures.

1-20 Printer and Troubleshooting Overview

Standard Procedures

While using the TAGs, you may be asked to perform some of the following procedures. Specific instructions for completing these procedures are included here, rather than repeated in the body of each TAG. Please read this information before following any TAG.

Power-on-reset (POR)

When directed to power-on-reset the printer:

1 Turn of f the printer. 2 Wait at least 5 seconds. 3 Turn the power back on.

Checking Continuity

Make sure the printer is turned off and the power disconnected. Failure to do so may result in personal injury, equipment damage,

or both.

Warning

To perform a continuity check:

1 Turn off the printer and disconnect the power cord. 2 Set your meter to the lowest ohm setting. 3 Interpret the results as follows:

• An infinite reading indicates an open circuit.

• A zero or specific reading indicates continuity.

4 To check an open or short circuit to ground:

• Turn off the printer and disconnect the power cord.

• Locate the circuit in que stion. (Refer to Chapter 6, “Wiring Diagrams and Electri-

cal Data”, for circuit loca tions.)

• Check all connectors and wiring on each side for corrosion, foreign objects, bent

pins, loose socket housings, and/or loose wires.

Warning

The printer is equipped with safety interlock switches on all of its covers. These switches disable parts of the printer when the

covers are opened. These areas present the risk of electrical shock, burns, and injury from mechanical hazards.

Printer and Troubleshooting Overview 1-21

Installing the Interlock By-pass Tool

The interlock by-p ass tool overri des the cover i nterlock switches , allowin g you to operate

the printer with the c overs open . The interl ock by-pas s tool is a whit e plasti c, “V”-sh aped tool with two finger pads. To use the tool, open the cover and locate the interlock switch (for locations, se e il lustr ation s begi nning p age 1- 11). Squeeze the tool between thumb and fore finger and insert it into the interlock switch.

The printer ships with two spare interlock by-pass tools concealed behind the right cover. Replace them when you are finished using them.

Caution

Do not attempt to close the printer cover while the interlock bypass tool is in place.

Producing a Developed Image

Producing a developed image helps determine where exactly in the print cycle a problem may be occurring. To produce a developed image:

1 Open the top cover and install an interlock by-pass tool. 2 Power-on-reset the printer. 3 Run a series of test prin ts. The direc tory o f the boot de vice wi ll pr int, f ollowe d by con -

tinuous test patterns.

4 As test patterns print, observe paper moving from the upper paper tray to the paper

timing roller w here it pauses briefly.

5 When a sheet of paper be gin s to move from th e pape r timing r oller, turn off the printer. 6 Remove the photoconductor unit. 7 Examine the photoconductor belt to verify that a developed image was produced.

Producing a Toner Patch

To produce a toner patch:

1 Turn of f the printer. 2 Open the top cover and install an interlock by-pass tool. 3 Turn on the printer. 4 Start running test prints using Simplex Print mode. When the leading edge of the first

print enters the fuser unit, remove the interlock by-pass tool.

1-22 Printer and Troubleshooting Overview

5 Remove the photoconductor unit.

Figure 1-4. Producing a Toner Patch on the Photoconductor Unit 6 Examine the photoconductor unit to verify that a toner patch has been produced. You

may have to rotate the belt slightly to observe the patch.

Caution

Do not touch the surface of the photoconductor belt; this damages the belt and results in poor print quality.

Completing a Service Call

After resolving any printer problem, complete the service call as follows:

1 Reassemble the printer. 2 Perform the every-call cleaning procedure, described in Chapter 9, “General Printer

Maintenance”.

3 If you have removed the printer’s diskette(s), reinstall them. 4 Power-on-reset the printer. 5 Clear the error log. (See the procedure described next.) 6 Run test prints in both the simplex and duplex mode from both the upper and lower

paper cassettes.

7 Fill in the Repair/ Maintenance log. Make sure the probl em descri ption and s teps take n

to resolve the problem are clearly documented.

Printer and Troubleshooting Overview 1-23

Clearing the Error Log

1 Enter the dia gnostic mode of the printer:

• Turn off the printer and wait 5 seconds.

• Hold down the STOP and TEST keys simultaneously as you turn the printer back

on.

• The tone, followed by “00” on the di spla y, indicates you are in the test mode. Th is

takes approximately 1 minute.

2 Press: CANCEL to advance the counter to “110.” 3 Press READY to activate the procedure. “0” appears on the display, indicating the A:

drive.

4 Press: CANCEL to advance to the drive where the error l og is maint ained. This i s usu-

ally the boot drive.

Table 1-4. Drive Indication

Display Indication

0 Diskette drive A: 1 Diskette drive B: 2 Hard drive C:

5 Press: READY to select the drive specified. “1-0” appears on the display.

Caution

At this point, be careful! “1-0” represents the clear error log function. Do not advance the counter to “1-1,” which represents

the format disk option.

6 Press: READY to select the clear error log function. “6-0” appears on the display.

Caution

If “7-0” appears, press STOP immediately. DO NOT CONTINUE WITH THIS PROCEDURE. POR the printer and start over.

7 Press: CANCEL to clear the error log. “6-1” appears on the display. 8 Press: STOP to exit the procedure. 9 Cycle printer power to exit diagnostic mode. 10 Confirm that the error log has been cleared. When you run your test prints, check to

make sure the error log entries appear as “0000.”

1-24 Printer and Troubleshooting Overview

Chapter 2

TAG Cross-

Reference Tables

TAG Cross- Reference Tables 2-1

TAG Cross-Reference Tables

This section contains the three cross reference charts for troubleshooting print problems:

Error Code/TAG Cross-Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Print Quality/TAG Cross-Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Mechanical Malfunction/TAG Cross-Reference Chart . . . . . . . . . . . . . . . . . . . . .2-12

2-2 TAG Cross- Reference Tables

Error Code/TAG Cross-Ref erence

Error Code/TAG Cross-Reference

Error codes, which appear on the 3-digit display of the operator’s panel, indicate a wide variety of printer problems related to the control boards, software, and/or host communication problems. On th e chart fi nd the e rror c ode in qu est ion, th en turn to TAG associated with the code.

Table 2-1. Printer Error Codes

Code Printer Error Code Meaning Go to TAG

010 Upper paper tray out of paper 010 011 Lower paper tray out of paper 011 E10 Envelope feeder out of envelopes E10 012 Upper paper tray not plugged in 012 013 Lower paper tray not plugged in 013 E12 Envelope feeder not plugged in E12 020 Upper paper tray paper jam 020 021 Lower paper tray paper jam 021 022 Transfer or fuser area paper jam 022 023 Exit area paper jam 023 025 Transfer or fuser area paper jam not cleared 025 026 Exit area paper jam not cleared 026 027 Duplex area paper jam 902 030 Developer bias short 030 031 Toner patch sensor reference level too low 031 032 Toner patch sensor black patch too light 032 035 No toner 035 036 No developer 036 040 Photoconductor seam sensor malfunction 040 041 Photoconductor seam sensor short 040 042 Photoconductor seam sensor open 040 044 Main charger open 044 045 Main charger short 045 046 Main charger open 044 050 Transfer charger short 050 055 Eraser lamp malfunction 055 057 Fan stopped sensor 752 060 Duplex area 1 paper jam 902 061 Duplex area 2 paper jam 902 062 Duplex area 3 paper jam 902 069 Duplex tray not plugged in 900 070 Fuser lamp or thermal fuse malfunction 070

TAG Cross- Reference Tables 2-3

Table 2-1. Printer Error Codes (Continued)

Code Printer Error Code Meaning Go to TAG

071 Fuser thermistor open or no fuser 071 072 Fuser temperature too high 072 073 Fuser temperature too low 070 081 No front job offset sensor 083 082 No back job offset sensor 083 083 Job offset mechanism malfunction 083 084 Duplex tray registration sensor not activated 901 085 Duplex tray registration sensor not deactivated 901 086 Duplex registration tray malfunction 901 090 Cover open 900 097 DC +12v power failure 097 098 DC -12v power failure 098 099 DC +24v power failure 099 100 PCL board command timeou 100 101 IGS controller diagnostic failure 101

Table 2-2. PCL/IGS Communication Error Codes

Code PCL/IGS Communication Error Code Meaning Go to TAG

121 No controller command; PCL board VSC command asserted 201 122 Command tag asserted; VSC command not asserted 201 123 VSS not asserted; PCL board status tag asserted 201 124 VSS asserted after PCL board sent status 201 125 VSS not asserted again though PCL board expects it 201 126 Command tag asserted during data byte sequence 201 127 PCL board detected parity/overrun on command line 201

Table 2-3. PCL Error Codes

Code PCL Error Code Meaning Go to TAG

130 Address or length error at initial microcode load 130 131 Checksum error at initial microcode load 130 132 RAM error at initial microcode load 100 133 No next block at initial microcode load 130 134 Incorrect format in initial microcode load file 130 140 PCL board ROM checksum error at power on diagnostic 100 145 PCL board RAM error at power on diagnostic 100

2-4 TAG Cross- Reference Tables

Table 2-3. PCL Error Codes (Continued)

Code PCL Error Code Meaning Go to TAG

160 PCL board PIA1 register error after reset 100 161 PCL board PIA1 registers read/write error 100 162 PCL board PIA1 PA or PB read/write error 100 170 PCL board PIA2 register error after reset 100 171 PCL board PIA2 register read/write error 100 172 PCL board PIA2 PB read/write error 100 180 PCL board PTM register error after reset 100 181 PCL board PTM read/write error 100 182 No IRQ generation on PTM 100

Table 2-4. PCL/IGS Communication Error Codes

Code PCL/IGS Communication Error Code Meaning Go to TAG

199 VSS not asserted before communication test 201 200 Status tag not asserted 201 201 Timeout waiting for a failed IGS controller 201 202 No data received after VSS line asserted 201 203 VSS asserted after PCL board sent status 201 204 Status tag asserted after VSS not asserted 201 205 No command tag after status tag not asserted 201 206 VSC command not asserted after command tag asserted 201 207 No data r eceived after VSC asserted 201 208 VSC command asserted after command line asserted 201 209 Command tag asserted after VSC not asserted 201 210 No RQI after “request RQI” command 201

211 Parity error on command line 201 212 Parity or overrun sensed by PCL board 201 213 Incorrect command received from PCL board 201 214 Incorrect command received from IGS controller 201 215 No transfer buffer empty on asynchronous communications

interface adapter after PCL board sent data

201

TAG Cross- Reference Tables 2-5

Table 2-5. IGS Firmware Error Codes

IGS Firmware Error Code Meaning

Code

These error codes signal a problem with the IGS controller

firmware. No TAGs address these problems; report them to the

printer’s manufacturer.

301 Status received after VSS asserted No T AG 302 Status tag asserted after VSS not asserted No TAG 303 VSC command not asserted after command tag asserted No TAG 304 VSC command asserted after data was sent No T AG 305 VSC command not asserted for next data byte No T AG 306 Status tag asserted while data was being sent No TAG 307 Parity error on command line No T AG

Table 2-6. PCL Failure Error Codes

Code PCL Failure Error Code Meaning Go to TAG

380 PCL board failure - command retries 201 381 PCL board failure - command rejected 201 382 PCL board failure - bad command received 201 383 PCL board failure - unexpected byte received 201 384 PCL board failure - no status received 201 385 PCL board failure - bad status information block count 201 386 PCL board failure - bad status information block offset 201 387 PCL board failure - parity error 201 389 Floppy disk retry 130

Go to TAG

Table 2-7. IGS Software Error Codes

IGS Software Error Code Meaning

These error codes signal a problem with the IGS controller

Code

software. No TAGs address these problems; to determine

Go to TAG

whether the faulty software is the customer’s or the

manufacturer’s, contact the printer’s manufacturer.

397 IGS software trap No TAG 398 IGS software trap No TAG 399 IGS software trap No TAG

2-6 TAG Cross- Reference Tables

Table 2-8. IGS/Disk Drive Error Codes

Code Disk Drive Error Code Meaning Go to TAG

401 Fatal IGS PB error No TAG 450 Incorrect diskette 130 451 Diskette format error or incorrect disk 130 454 Fatal trap 200 455 Trap 200 500 Incorrect PIT0 registers contents; no reset 200 501 PIT0 register read/write error 200 502 No countdown/zero detection in PIT0 timer 200 503 PIT0 timer; no halt 200 504 No PIT0 timer interrupt 200 505 Incorrect PIT2 registers contents; no reset 200 506 PIT2 register read/write error 200 507 No countdown/zero detection in PIT2 timer 200 508 PIT2 timer; no halt 200 509 No PIT2/timer interrupt 200 520 No DMAC reset 200 521 DMAC registers read/write error 200 522 No DMA transfer 200 523 No DMA transfer termination 200 524 No DMAC termination interrupt 200 525 No software abort operation 200 526 No software abort interrupt 200 527 DMAC operation error 200 528 DMA transfer error 200 529 Two-channel DMA transfer error 200 530 No two-channel DMA transfer 200 540 PCL board serial controller registers read/write error 200 541 PCL board break condition detected 200 542 PCL board serial controller transmitter not ready 200 543 No PCL board serial controller transfer 200 544 PCL board serial controller transfer error 200 545 Host serial controller registers read/write error 200 546 Host transmitter not ready 200 547 No serial controller interrupts 200 548 Host serial controller/PCL board parity error 200 549 Serial controller unexpected interrupt 200

TAG Cross- Reference Tables 2-7

Table 2-8. IGS/Disk Drive Error Codes (Continued)

Code Disk Drive Error Code Meaning Go to TAG

550 Two-channel transfer error 200 551 No PCL board/serial controller interrupt on break 200 552 No serial contr oller /DM AC int er action 2 00 553 Serial controller/DMAC transfer count error 200 554 Serial controller/DMAC transfer error 200 555 RS232 se nd/rec ei ve path error 200 556 RS232 DTR/DTC path error 200 557 RS232 RTS/CTS path error 200 558 RS422 se nd/rec ei ve path error 200 559 RS422 send clock/receive clock path error 200 560 CRTC register read/wri te error 200 561 No page begin (PIT2) interrupt 200 562 No CRTC address generation 200 563 No VSYNC generation (end of page) 200 564 No end of page (PIT2) interrupt 200 565 No CRTC count termination 200 566 VSYNC timeout error 200 570 Drive controller/SCSI read/write error 200 571 Drive controller busy timeout 200 572 Diskette is write protected 130 573 Drive not ready 130 574 Drive controller restore error 130 575 Drive controller seek error 130 576 Drive controller read sector error 130 577 Drive controller read sector data/checksum error 200 578 Drive controller write sector error 200 579 Drive controller read/modify/write error 200 580 No drive controller/PIT0 interrupt 200 581 No drive controller-DMA interaction 200 582 Drive controller/DMAC transfer error 200 583 Drive controller/DMAC transfer count error 200 584 Drive controller/DMAC read sector error 200 585 Drive controller/DMAC write sector error 200 586 Drive hard error 130

2-8 TAG Cross- Reference Tables

Print Quality/TAG Cross-Reference

Table 2-9. Bit Map RAM Error Codes

Code Bit Map RAM Error Code Meaning Go to TAG

600 Bit-map RAM data path error 200 601 Bit-map RAM bank selection error 200 602 Bit-map RAM refresh error 200 603 Bit-map RAM address path error 200 604 Incorrect ALU operation in bit-map RAM data path 200 605 Incorrect origin data modifications 200 606 Total bit-map RAM bank fault 405 610 Bit-map RAM chip error 405

Table 2-10. Host Communication Error Codes

Code Host Communication Error Code Meaning Go to TAG

701 No communication with host 753 702 Host communication protocol error 753 703 Host communication recoverable error 753

770-784 Ethernet communication error No TAG; con-

tact software

support

Print Quality/TAG Cross-Reference

Poor quality prints are another indication of printer problems. Begin by running a set of test prints. Then, compare the test prints to the samples located in Chapter 4, “Print Qual-

ity Samples”. The chart summarizes the possible print quality problems you may encoun-

ter and recommends a TAG to follow to address the problem.

Table 2-11. Blank Print TAGs

Blank Prints Go to T AG

Complete 800 Partial 800 With dark horizontal bands 800

TAG Cross- Reference Tables 2-9

Print Quality/TAG Cross-Reference

Table 2-12. Light Print TAGs

Light Prints Go to TAG

With carrier particles 801 With background 811 With voids/white spots 802 With light vertical streaks 803 With blank or white vertical lines 803 With light horizontal bands 804

T able 2-13. Dark Print TAGs

Dark Prints Go to TAG

Dark black prints 805 With dark spots or scratches 806 With dark blotches 810 With dark vertical streaks (without fusing) 812 With dark vertical streaks (with fusing) 808

Table 2-14. Skewed Path TAGs

Simplex 807 Duplex 901

Table 2-15. Misregistration TAGs

Misregistered Prints Go to TAG

Simplex 807 Duplex 901

Skewed Prints Go to TAG

2-10 TAG Cross- R eference Tables

Print Quality/TAG Cross-Reference

Table 2-16. Smeared, Blurred, and Uneven Print TAGs

Smeared, Blurred, Uneven Prints Go to TAG

Smeared vertical streaks 809 Blurred prints 809 Uneven density 810 Prints with background 811 Prints with background and residual images 811 Prints with residual images 813 Prints with offset images 814

Table 2-17. Additional Print Quality Problem TAGs

Additional Print Quality Problems Go to TAG

Wrinkled or torn prints 706 Prints improperly fused 812 Prints exhibiting printhead problems 815

TAG Cross- Reference Tables 2-11

Print Quality/TAG Cross-Reference

Mechanical Malfunction/TAG Cross-Reference

The chart below outlines possible mechanical malfunctions and recommends an appropriate TAG to follow to resolve the problem.

Table 2-18. Operator Panel Problems TAGs

Operator Panel Problems Go to TAG

Blank with AC power fan and cooling fan on 500 Blank with AC power fan on 500 Blank with no fans on 600 All lights on 610 Incomplete display immediately after POR 610 Close cover light remains on 6 00 Remove prints light remains on or lights 700 Add toner light remains on 035 Machine check light is on with no numerical Display 201 One or more lights are off at POR 610 Tone not working 610 Incorrect paper size 702 Other operator panel malfunctions 610

Table 2-19. Output Tray Problem TAGs

Output Tray Problems Go to TAG

Sensor not sensing condition 701 Jogging incorrectly 083 Will not stop jogging 083 Job offset incorrect 083

Table 2-20. Cassette Problem TAGs

Cassette Problems Go to TAG

Upper cassette 703 Lower cassette 704

2-12 TAG Cross- R eference Tables

Table 2-21. Paper Handling Problem TAGs

Paper Handling Problems Go to TAG

Multiple paper feed 705 Multiple sheet feeds and jams 705 Wrinkled or torn paper 706 Simplex: misregistration and paper skew 807 Duplex: misregistration and paper skew 901 Paper will not feed from upper cassette 012 Paper jam in duplex area 902 Upper paper guide not closing 707

Table 2-22. Counter Problem TAGs

Counter Problems Go to TAG

Print Quality/TAG Cross-Reference

Supplies seem to have short life span 750 Incorrect counting 750

Table 2-23. Communication Problem TAGs

Communication Problems Go to TAG

Printer will produce test prints 753 Incorrect data being printed 753

Table 2-24. Additional Mechanical Malfunction TAGs

Additional Mechanical Malfunctions Go to TAG

Test prints won’t run after POR 130 Cooling fan not running 752 Vacuum transport unit fan not running 752 Circuit breaker trip 600 Main drive motor not turning off 751

TAG Cross- Reference Tables 2-13

Print Quality/TAG Cross-Reference

2-14 TAG Cross- R eference Tables

Chapter 3

Troubleshooting

Analysis Guide

(TAGs)

Troubleshooting Analysis Guide (TAGs) 3-1

Troubleshooting Analysis Guide (TAGs)

TAG 001: Troubleshooting a Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

TAG 002: Check &Problem Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

TAG 010: Upper Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

E10: Envelope Tray Out of Envelopes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

TAG 011: Lower Cassette Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

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

3-2 Troubleshooting Analysis Guide (TAGs)

TAG 101: IGS Controller Diagnostic Failure . . . . . . . . . . . . . . . . . . . . . . . . . . .3-103

TAG 130: Diskette/Disk Drive Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104

TAG 200: IGS Internal Communication Malfunction. . . . . . . . . . . . . . . . . . . . . 3-108

TAG 201: IGS-PPCL Interface Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-110

TAG 405: IGS Bit-Map RAM Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-112

TAG 500: +5 Vdc Power Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113

TAG 600: Vac 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

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

Troubleshooting Analysis Guide (TAGs) 3-3

Troubleshooting Analysis Guide (TAGs)

This chapter describes each of the TAGs used to diagnose and resolve specific printer problems related to error codes, print quality, and mechanical malfunctions.

Chapter 1, “Printer and Troubleshooting Overview”, is an overview of how the TAGs are

organized and how to use them. If you are using a TAG for the first time, please refer to this chapter for more specif ic instructions.

Chapter 2, “TAG Cross- Reference Tables”, provides comprehensive tables which cross

reference specific error codes, print quality problems, and mechanical malfunctions to the TA Gs contained in this chapter.

As you use these TAGs, you may need to refer to other chapters of this manual for additional information. Please turn to these chapters as required.

3-4 Troubleshooting Analysis Guide (TAGs)

TAG 001: Troubleshooting a Problem

If you are not sur e how t o t ro ubl esh oot a pri nt er pr obl em, s ta rt wi th thi s TAG. This and all TA Gs assume you are familiar with standard procedures, such as power-on-reset, presented in Chapter 1, “Printer and Troubleshooting Over view ”. In addit ion, TAG may refer

you to Chapter 2, “TAG Cross- Reference Tables”, which contain:

• Error code cross-reference table

Arranged by error code; refers you to the TAG associated with the code.

• Print quality cross-reference table

Arranged by description of print-quality problem; refers you to the TAG associated with the problem.

• Mechanical malfunction cross-reference table

Arranged by description of the mechanical malfunction; refers you to the TAG associated with the malfunction.

To start:

• Disconnect all peripheral cables.

• Power-on-reset the printer.

Did all of the status lights come on, followed by 888 flashing briefly and an error code?

No: Run test prints, following the procedure described in Chapter 1, “Printer and Trouble-

shooting Overview”, then repeat this step. If the answer is still no, refer to the mechanical

malfunctions cross-reference table in Chapter 2, “TAG Cross- Reference Tables” to determine which TAG to follow. Then turn to that TAG.

Yes: Note the error code and continue.

Power-on-reset the printer.

Did the power-on-reset end with an error code?

No: Continue. Yes: Refer to the error code cross-reference table in Chapter 2, “TAG Cross- Reference

Tables”, using either the code that displayed after steps 1 and 2, or if multiple error codes

continue to appear, the first error code that disp lays. Turn to the T AG associated with the code.

Did only the READY light come on with no numeric display?

No: Continue. Yes: Go to TAG 753: External Communications Malfunction.

Troubleshooting Analysis Guide (TAGs) 3-5

Did only the READY and ON LINE lights come on with no numeric display?

No: Continue. Yes: Go to TAG 753: External Communications Malfunction.

Did the READY, ON LINE, and JOB IN PROCESS lights come on with no numeric

display?

No: Refer to Chapter 2, “TAG Cross- Reference Tables” to determine which TAG to follow,

then turn to that TAG.

Yes: Continue.

Run test prints from the upper cassette by completing the following:

• Power-on-reset the printer.

• Run test prints from the upper cassette.

Did an error code appear while running the prints?

No: Continue. Yes: Look up the code in Chapter 2, “TAG Cross- Reference Tables” to determine which T AG

to follow, and then turn to that TAG.

Run test prints from the lower cassette by completing the followin g:

• Press STOP and allow the cycle to finish.

• Remove the upper cassette.

• Power-on-reset the printer.

• Run test prints from the lower cassette.

Did an error code appear while running test prints?

No: Continue. Yes: Look up the code in Chapter 2, “TAG Cross- Reference Tables” to determine which T AG

to follow, then turn to that T AG.

Check communications by completing the following:

• Turn the printer off.

• Reinstall all communication cables.

• Reinstall the upper cassette.

• Power-on-reset the printer.

• Re-run the customer’s problem print job.

Does the job fail?

No: Continue. Yes: Go to TAG 753: External Communications Malfunction.

3-6 Troubleshooting Analysis Guide (TAGs)

Complete the following:

• Run test prints.

• Re-run the customer’s problem print job.

Does an error code appear?

No: Continue. Yes: Look up the code in Chapter 2, “TAG Cross- Reference Tables”, then turn to TAG indi-

cated in the table.

Run a job which is known to be good.

• Compare the output from the problem pri nt job to the output from the good print job.

Can you identify the problem?

No: Return to the beginning of the TAG, following the procedures carefully to determine the

kind of problem your customer has.

Yes: Identify the problem as either a print quality problem or a mechanical malfunction, find

the problem in the appropriate cross-reference table, identify a TAG addressing that problem, then turn to that TAG.

Troubleshooting Analysis Guide (TAGs) 3-7

TAG 002: Check & Problem Resolution

Note

Follow the procedure described in this TAG when you have completed an action to resolve a problem, and are sent to this TAG from another TAG

Complete any actions directing you to this TAG.

• Make sure all connectors, covers, parts, and hardware have been reinstalled.

In the course of resolving the printer problem, did you complete the every-call cleaning procedure?

No: Continue. Yes: Go to #3 in this TAG.

Clean the printer thoroughly, following the every-call cleaning procedure described below.

1 Remove these major printer supplies:

• Photoconductor unit; place it in its protective packaging

• Cleaner unit

• Developer unit

•Fuser unit

2 Inspect and vacuum the printer:

• Inspect the areas in the printer around the developer unit, cleaner unit, photoconductor unit, and fuser unit for damage and wear.

• Vacuum these areas to remove all excess toner, contamination, and/or foreign objects.

3 Clean internal areas:

• Clean the erase lamp with a cotton swab.

• Clean the printhead bias plates with a soft cloth.

• Clean the LED lens with a cotton swab, ma king sure no lint remains on the lens.

4 Inspect and clean the fuser unit:

Warning

The fuser unit may be hot

• Inspect the unit for damage and contamination; repair or replace as necessary.

• Clean the fuser unit connector , both on the fuser unit and in the p rinter, with a cotton swab.

• Vacuum in and around the rollers to remove excess toner, contamination, and any foreign objects.

• Reinstall the fuser unit.

5 Inspect and clean the developer unit:

• Inspect the unit for damage or contamination; repair or replace as necessary.

• Clean any excess toner from the developer unit with a soft cloth.

• Clean the toner patch sensor lens with a cotton swab, making sure no lint remains on the lens.

• Vacuum the felt areas around the magnetic roller, being careful not to vacuum toner from

3-8 Troubleshooting Analysis Guide (TAGs)

the magnetic roller.

• Reinstall the developer unit.

6 Inspect and clean the cleaner unit/main charger:

Caution

Handle gently to avoid breaking the charger wire

• Inspect the unit for damage or contamination; repair or replace as necessary.

• Remove the main charger from the cleaner unit.

• Clean the grid with the cleaner brush.

• Remove the grid to expose the charger wire.

• Clean the charger wire with a cotton swab or charger cleaning tool.

• Reinstall the grid.

• Clean any excess toner from the cleaner unit with a soft cloth.

• Reinstall the main charger in the cleaner unit.

• Reinstall the cleaner unit.

7 Clean and inspect the photoconductor unit area

Caution

Do not touch the photoconductor belt as this

permanently

• Clean the photoconductor seam sensor inside the printer with a cotton swab or compressed air.

• Remove the photoconductor from its protective packaging.

• Inspect the photoconductor for damage or contamination; repair or replace as necessary.

• Reinstall the photoconductor unit.

damages the unit

8 Clean the transfer charger

Caution

Handle gently to avoid breaking the charger wire

• Remove the transfer charger.

• Clean the transfer charger housing with a soft cloth.

• Clean the transfer charger wire with a cotton swab.

• Reinstall the transfer charger.

Have you completed the every-call cleaning procedure?

No: Complete the procedure, then continue. Yes: Continue.

Troubleshooting Analysis Guide (TAGs) 3-9

Run test prints to confirm print quality, in both simplex and duplex modes and from upper and lower paper cassettes. When you enter test print mode by pressing the keys listed below, the follow-

ing items print in the order listed: a directory of the boot device and multiple listings of fonts; a formatted and unformatted error log; a continuou s flo w of te st pr int s.

1 Power-on-reset the printer. 2 Run test prints:

• For simplex printers, press: STOP TEST

• For duplex printers, press: STOP DUPLEX TEST

3 Stop printing the pattern by pressing STOP. On pressing STOP, the printer will stop generating

test prints. The printer will print all test prints stored in the printer’s buffer, then stop.

Are the test prints clean and printing correctly?

No: Go to Chapter 4, “Print Quality Samples”; identify a sample with the problem you see in

the test print; then turn to the TAG indicated.

Yes: Continue.

Clear the error log:

Caution

With this procedure you can either clear the error log or

format a disk. Pay careful attention to the options you select.

1 Enter the diagnostic mode of the printer:

• Turn off the printer and wait 5 seconds.

• Hold down the STOP and TEST keys simultaneously as you turn the printer back on.

• The tone, followed by 001 on the display, indicates you are in the test mode. This takes about 1 minute.

2 Press: CANCEL to advance the counter to 110. 3 Press: START to activate the procedure. 0 appears on the display, indicating the A: drive. 4 Press: CANCEL to advance to the drive where the error log is maintained. This is usually the

boot drive.

Display Indication

0 Diskette drive A: 1 Diskette drive B: 2 Hard drive C:

3-10 Troubleshooting Analysis Guide (TAGs)

5 Press: START to select the drive specified. 1-0 appears on the display

Caution

1-0 represents the clear error log function. Do not advance the counter

to 1-1, which represents the format disk option, described in the

Guide to Operations

6 Press: START to select the clear error log function. 6-0 appears on the display.

Caution

If 7-0 appears, press STOP immediately. DO NOT PROCEED

7 Press: CANCEL to clear the error log. 6-1 appears on the display. 8 Press: STOP to exit the procedure. 9 Confirm that the error log has been cleared; to do this, power-on-reset the pr inter and run test

prints, checking to make sure the error log entries appear as 0000.

Do the error log entries appear as 0000?

No: Return to the beginning of this step. Yes: Continue.

Fill in the Repair/Maintenance record taped inside the printer’s front cover.

• Make sure the problem description and steps taken to resolve the problem are clearly documented.

• Reinstall all connectors, covers, parts, and hardware.

You have successfully resolved the printer’s problem. Congratulations!

Troubleshooting Analysis Guide (TAGs) 3-11

TAG 010: Upper Cassette Malfunction

Error Code: 010 Possible Causes: Cassette empty

Paper incorrectly loaded

Possible Defects: Upper paper empty actuator

Upper paper empty sensor Upper cassette tray Upper pressure lever Upper cassette release cam Upper cassette release latch Upper cassette release lever Spring Connectors/wiring PCL board

Make sure paper is in the upper cassette.

• Make sure the paper is loaded correctly so that the side and rear guides are positioned securely against the paper in the cassettes.

• Power-on-reset the printer.

• Run test prints.

Is error code 010 displayed?

No: The paper was loaded incorrectly. Turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Check upper cassette:

• Remove the upper cassette.

• Inspect the upper paper empty sensor actuator for binding, or for a damaged or broken part.

Is it in good working order?

No: Replace the actuator, then turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Check voltage:

• Open the rear door and install an interlock by-pass tool.

• Check the voltage from TP3-15 to ground on the PCL board.

• Activate the upper paper sensor actuator manually.

Does the voltage change from 0 Vdc to +12Vdc?

No: Replace the upper paper empty sensor, then turn to TAG 002: Check & Problem Resolu-

tion.

Yes: Continue.

3-12 Troubleshooting Analysis Guide (TAGs)

Check pressure lever:

• Reinsert the upper cassette.

• Watch the pressure lever as the cassette is inserted.

Does the pressure lever elevate the paper to the correct feeding position?

No: Check the following for defects or incorrect mounting:

• Cassette tray

• Damper assembly

• Upper pressure lever

• Upper cassette release cam

• Upper cassette release latch

• Wire cable, pulley and spring

• Upper cassette release lever Replace the defective part, then turn to TAG 002: Check & Problem Resolution.

Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.

Troubleshooting Analysis Guide (TAGs) 3-13

E10: Envelope Tray Out of Envelopes

This TAG refers to the error code for the envelope tray, which handles 75 envelopes.

Error Code: E10 Possible Causes: Cassette empty

Envelopes incorrectly loaded

Possible Defects: Upper paper empty actuator

Upper paper empty sensor Paper size sensor assembly Envelope cassette tray Upper pressure lever Upper cassette release cam Upper cassette release latch Upper cassette release lever Spring Connectors/wiring PCL board

Make sure envelopes are in the envelope cassette.

• Make sure the envelopes are correctly loaded.

• Power-on-reset the printer.

• Remove and insert the envelope cassette while watching the operator panel.

Does 1-8 appear on the operator panel?

No: Replace the upper paper size sensor assembly, then turn to TAG 002: Check & Problem

Resolution.

Yes: Continue.

Run a job in which you are using envelopes.

Is error code E10 displayed?

No: The cassette was loaded incorrectly. Turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Remove the envelope cassette.

• Inspect the paper empty sensor actuator.

Is it in good working order?

No: Replace the actuator, then turn to TAG 002: Check & Problem Resolution. Yes: Continue.

3-14 Troubleshooting Analysis Guide (TAGs)

Open the rear door and install an interlock by-pass tool.

• Check the voltage from TP3-15 to ground on the PCL board.

• Activate the upper paper sensor actuator manually.

Does the voltage change from 0Vdc to +12Vdc?

No: Replace the upper paper empty sensor, then turn to TAG 002: Check & Problem Resolu-

tion.

Yes: Continue.

Reinsert the envelope cassette.

• Watch the pressure lever as the cassette is inserted.

Does the pressure lever elevate the envelopes to the correct feeding position?

No: Check the following for defects or incorrect mounting:

• Cassette tray

• Damper assembly

• Upper pressure lever

• Upper cassette release cam

• Upper cassette release latch

• Wire cable, pulley and spring

• Upper cassette release lever Replace the defective part, then turn to TAG 002: Check & Problem Resolution.

Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.

Troubleshooting Analysis Guide (TAGs) 3-15

TAG 011: Lower Cassette Malfunction

Error Code: 011 Possible Causes: Cassette empty

Paper incorrectly loaded

Possible Defects: Lower paper empty actuator

Lower paper empty sensor Lower cassette tray Lower pressure lever Lower cassette release cam Lower cassette release latch Lower cassette release lever Spring Connectors/wiring PCL board

Make sure paper is in the lower cassette.

• Make sure the paper is loaded correctly so that the side and rear guides are positioned securely against the paper in the cassettes.

• Power-on-reset the printer.

• Run test prints.

Is error code 011 displayed?

No: The paper was loaded incorrectly. Turn to TAG 002: Check & Problem Resolution Yes: Continue.

Remove the lower cassette.

• Inspect the lower paper empty sensor actuator for binding, or for a damaged or broken part.

Is it in good working order?

No: Replace the actuator, then turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Open the rear door and install an interlock by-pass tool.

• Check the voltage from TP3-14 to ground on the PCL board.

• Activate the lower paper sensor actuator manually.

Does the voltage change from 0 Vdc to +12Vdc?

No: Replace the lower paper empty sensor, then turn to TAG 002: Check & Problem Resolu-

tion.

Yes: Continue.

3-16 Troubleshooting Analysis Guide (TAGs)

Reinsert the lower cassette.

• Watch the pressure lever as the cassette is inserted.

Does the pressure lever elevate the paper to the correct feeding position?

No: Check the following for defects or incorrect mounting:

• Cassette tray

• Lower pressure lever

• Lower cassette release cam

• Lower cassette release latch

• Wire cable, pulley and spring

• Lower cassette release lever Replace the defective part, then turn to TAG 002: Check & Problem Resolution.

Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.

Troubleshooting Analysis Guide (TAGs) 3-17

TAG 012: Upper Cassette Not Latched

Error Code: 012 Possible Defects: Upper cassette release cam

Upper cassette release latch Upper cassette in latch Upper pressure lever Spring Wire cable and pulley Upper cassette Upper cassette in switch Upper paper size sensor Lower paper size sensor Connectors or wiringr PCL board

Turn off the printer and unplug the power cord.

• Verify that J/P40 and J/P52 are connected properly.

• Remove the upper cassette.

• Inspect it fo r damage.

• Reinsert the cassette.

Is the upper cassette properly latched?

No: Continue. Yes: Go to #3 in this TAG.

Check for damage:

• Upper cassette release cam

• Upper cassette release latch

• Upper cassette in latch

• Upper pressure lever

•Spring

• Wire cable and pulley

Are any of these parts damaged?

No: Return to the beginning of this TAG. Yes: Replace the damaged parts, then turn to TAG 002: Check & Problem Resolution.

3-18 Troubleshooting Analysis Guide (TAGs)

Remove the upper cassette.

• Make sure the upper cassette in switch actuator is functioning p roperly.

Is it in good working order?

No: Replace the actuator, then turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Run diagnostic test 002.

Is 1-0 displayed?

No: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Install the upper cassette.

Is a value other than 1-0 displayed?

No: Continue. Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.

Turn the printer off and unplug the power cord.

• Remove the upper cassette.

• Loosen the upper paper size sensor assembly for access to the circuit board.

• Disconnect J/P46.

• Activate the cassette in switch.

• Check P46-1 to P46-2 for continui ty.

Is there continuity?

No: Replace the upper cassette in switch or wire hardness W58, then turn to TAG 002: Check

& Problem Resolution.

Yes: Continue.

Reconnect J/P46.

• Disconnect J/P40 and J/P 45.

• Check P40-49 to P45-2 for continuity.

Is there continuity?

No: Go to #10 in this TAG. Yes: Continue.

Troubleshooting Analysis Guide (TAGs) 3-19

Check P40-48 to P45-3 for continu ity.

Is there continuity?

No: Continue. Yes: Replace the upper paper size sensor assembly. If this does not resolve the problem,

replace the PCL board. Turn to TAG 002: Check & Problem Resolution.

Reconnect J/P40 and J/P45.

• Remove the lower cassette.

• Loosen the lower paper size sensor assembly for access to the circuit board.

• Disconnect J/P43 and J/P 47.

• Check J43-8 to J47-3 for continuity.

Is there continuity?

No: Replace lower paper size sensor assembly, then turn to TAG 002: Check & Problem Res-

olution.

Yes: Repair or replace the connectors or wiring from:

P45-3 to P47-3, P43-8 to J52-3, or P40-48 to P52-3.

If this does not resolve the problem, replace the upper paper size sensor assembly. Then turn to TAG 002: Check & Problem Resolution

Reconnect J/P40 and J/P45.

• Remove the lower cassette.

• Loosen the lower paper size sensor assembly for access to the circuit board.

• Disconnect J/P43 and J/P 47.

• Check J43-9 to J47-2 for continuity.

Is there continuity?

No: Replace the lower paper size sensor assembly. Yes: Repair or replace the connectors or wiring from:

P45-2 to P47-2, P43-9 to J52-2 or P40-49 to P52-2.

If this does not resolve the problem, replace the upper paper size sensor assembly. Then turn to TAG 002: Check & Problem Resolution

3-20 Troubleshooting Analysis Guide (TAGs)

TAG E12: Envelope Tray or Feeder Not Latched

Error Code: E12 Possible Defects: Upper cassette release cam

Upper cassette release latch Upper cassette in latch Upper pressure lever Spring Wire cable and pulley Envelope cassette or high capacity envelope feeder Upper cassette in switch Upper paper size sensor Lower paper size sensor Connectors or wiring PCL board

Turn off the printer and unplug the power cord.

• Confirm that J/P40 and J/P52 are connected properly.

• Remove the envelope tray or high capacity envelope feeder.

• Inspect it fo r damage.

• Reinsert the envelope tray or feeder.

Is the upper cassette properly latched?

No: Continue. Yes: Go to #3 in this TAG.

Check for damage:

• Upper cassette release cam

• Upper cassette release latch

• Upper cassette in latch

• Upper pressure lever

•Spring

• Wire cable and pulley

Are any of these parts damaged?

No: Return to the beginning of this TAG. Yes: Replace the damaged parts, then turn to TAG 002: Check & Problem Resolution.

Troubleshooting Analysis Guide (TAGs) 3-21

Remove the envelope tray or feeder.

• Make sure the upper in switch actuator is functioning prop erly.

Is it in good working order?

No: Replace the actuator, then turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Run diagnostic test 002.

Is 1-0 displayed?

No: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Install the envelope tray.

Is a value other than 1-0 displayed?

No: Continue. Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.

Turn the printer off and unplug the power cord.

• Remove the envelope tray or feeder.

• Loosen the upper paper size sensor assembly for access to the circuit board.

• Disconnect J/P46.

• Activate the cassette in switch.

• Check P46-1 to P46-2 for continui ty.

Is there continuity?

No: Replace the upper cassette in switch or wire harness W58, then turn to TAG 002: Check

& Problem Resolution.

Yes: Continue.

Reconnect J/P46.

• Disconnect J/P40 and J/P 45.

• Check P40-49 to P45-2 for continuity.

Is there continuity?

No: Go to #10 in this TAG. Yes: Continue.

3-22 Troubleshooting Analysis Guide (TAGs)

Check P40-48 to P45-3 for continuity.

Is there continuity?

No: Continue. Yes: Replace the upper paper size sensor assembly. If this does not resolve the problem,

replace the PCL board. Then turn to TAG 002: Check & Problem Resolution.

Reconnect J/P40 and J/P45.

• Remove the lower cassette.

• Loosen the lower paper size sensor assembly for access to the circuit board.

• Disconnect J/P43 and J/P 47.

• Check J43-8 to J47-3 for continuity.

Is there continuity?

No: Replace the lower paper size assembly, then turn to TAG 002: Check & Problem Resolu-

tion.

Yes: Repair or replace the connectors or wiring from:

P45-3 to P47-3, P43-8 to J52-3, or P40-48 to P52-3.

If this does not resolve the problem, replace the upper paper size sensor assembly. Then turn to TAG 002: Check & Problem Resolution.

Reconnect J/P40 and J/P45.

• Remove the lower cassette.

• Loosen the lower paper size sensor assembly for access to the circuit board.

• Disconnect J/P43 and J/P 47.

• Check J43-9 to J47-2 for continuity.

Is there continuity?

No: Replace the lower paper size sensor assembly. Yes: Repair or replace the connectors or wiring from:

P45-2 to P47-2, P43-9 to J52-2, or P40-49 to P52-2.

If this does not resolve the problem, replace the upper paper size sensor assembly. Then turn to TAG 002: Check & Problem Resolution.

Troubleshooting Analysis Guide (TAGs) 3-23

TAG 013: Lower Cassette Not Latched

Error Code: 013 Possible Defects: Lower cassette release cam

Even Lower cassette release latch Lower cassette in latch Lower pressure lever Spring Lower cassette Lower cassette in switch Lower paper size sensor Connectors or wiring PCL board

Turn the printer off and unplug the power cord.

• Verify that J/P40 and J/P52 are connected properly.

• Remove the lower cassette.

• Inspect it fo r damage.

• Reinsert the cassette.

Is the lower cassette properly latched?

No: Continue. Yes: Go to #3 in this TAG.

Check the following for damage:

• Lower cassette release cam

• Lower cassette release latch

• Lower cassette in latch

• Lower pressure lever

•Spring

Are any of these parts damaged?

No: Return to the beginning of this TAG. Yes: Replace the damaged parts, then turn to TAG 002: Check & Problem Resolution.

Remove the lower cassette.

• Make sure the lower cassette in switch actuator is functioning p rop e rl y.

Is it in good working order?

No: Replace the actuator, then turn to TAG 002: Check & Problem Resolution. Yes: Continue.

3-24 Troubleshooting Analysis Guide (TAGs)

Run self diagnostic test 003.

Is 1-0 displayed?

No: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Install the lower cassette.

Is a value other than 1-0 displayed?

No: Continue. Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.

Turn the printer off and unplug the power cord.

• Remove the lower cassette.

• Loosen the lower paper size sensor assembly for access to the circuit board.

• Disconnect J/P48.

• Activate the cassette in switch.

• Check P48-1 to P48-2 for continui ty.

Is there continuity?

No: Replace the lower cassette in switch or wire harness W59, then turn to TAG 002: Check

& Problem Resolution.

Yes: Continue.

Reconnect J/P48.

• Disconnect J/P43 and J/P 40.

• Check P40-50 to P43-10 for continuity.

Is there continuity?

No: Repair or replace the connectors or wiring from P43-10 to J52-1 or P40-50 to P52-1.

Then turn to TAG 002: Check & Problem Resolution.

Yes: Continue.

Check P43-8 to P40-48 for continuity.

Is there continuity?

No: Repair or replace the connectors or wiring f rom P43-8 to J52-3 or P40-48 to P52- 3. Then

turn to TAG 002: Check & Problem Resolution.

Yes: Replace the lower paper size sensor assembly. If this does not resolve the problem,

replace the PCL board. Then turn to TAG 002: Check & Problem Resolution.

Troubleshooting Analysis Guide (TAGs) 3-25

TAG 020: Paper Jam/Misfeed in Upper Cassette Area

Error Code: 020 Possible Causes: Paper incorrectly loaded

Wrong weight or type of paper loaded Paper path obstructed

Possible Defects: Upper pick-up roller assembly

Upper feed roller assembly Upper pick-up roller drive assembly Upper paper guide assembly Lower paper guide assembly Upper paper cassette Pick pressure adjustment Main drive gear assembly Paper feed drive belt Paper feed drive idler assembly Paper timing sensor. Wiring or connectors PCL board

Check both paper paths and remove any paper jams.

• Make sure paper is loaded properly in both cassettes.

• Make sure the paper guides are positioned properly.

• Make sure the upper pick-up roller, feed roller, and pinch roller assemblies are clean.

• Verify that J/P40, J/P60, J/P66, and J/P68 are connected properly.

• Confirm that the paper in the cassettes meets paper specifications, described in the Guide to Operations manual.

• Power-on-reset the printer.

• Run test prints from the upper cassette.

Is error code 020 still displayed?

No: Go to #14 in this TAG. Yes: Continue.

Turn the printer off and inspect the foll owing for damage or binding:

• Upper paper guide assembly

• Lower paper guide assembly

• Paper feed drive belt

• Paper feed drive pulley

• Paper feed drive idler assembly

• Main drive gear assembly

• Upper pick-up roller drive assembly

Are all the parts in good working order?

No: Replace any damaged parts, then turn to TAG 002: Check & Problem Resolution. Yes: Continue.

3-26 Troubleshooting Analysis Guide (TAGs)

Clear the paper path.

• Remove the upper cassette.

• Power-on-reset the printer.

• Run test prints from the lower cassette.

Is error code 021 displayed?

No: Go to #10 in this TAG. Yes: Continue.

Clear the paper path.

• Inspect the paper timing sensor actuator for dama ge or binding.

Is it in good working order?

No: Replace the paper timing guide assembly , then tur n to TAG 00 2: C heck & P rob l em R e so -

lution.

Yes: Continue.

Check the voltage between TP3-16 and ground on the PCL board.

• With the printer powered on, press and release the paper timing sensor.

• Check for a voltage change from 0 Vdc to +12 Vdc.

Does the voltage change from 0 Vdc to +12 Vdc?

No: Go to #9 in this TAG. Yes: Continue.

Check TP3-11 for +24 Vdc.

Is the voltage +24 Vdc?

No: Continue. Yes: Return to the beginning of this TAG.

Check J/P91-1 for +24 Vdc.

Is the voltage +24 Vdc?

No: Continue. Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.

Troubleshooting Analysis Guide (TAGs) 3-27

Check J/P8-13 for +24 Vdc.

Is the voltage +24 Vdc?

No: Replace the DC power supply, then turn to TAG 002: Check & Problem Resolution. Yes: Repair or replace the connectors or wiring from P91-1 to P8-13, then turn to TAG 002:

Check & Problem Resolution.

Turn the printer off and unplug the power cord.

• Disconnect J/P40 and J/P 57.

• Check the following for continuity:.

P40-16 to P57-2 P40-25 to P57-1 P40-12 to P57-3

Is there continuity on all?

No: Repair or replace the connectors or wiring from P40-25 to J/P58-1 to P57-1, P40-16 to J/

P58-2 to P57-2, or P 40- 12 to J/P58 -3 to P 57-3. Then tu rn to TAG 00 2: Ch eck & Proble m

Resolution.

Yes: Replace the paper timing guide. If this does not resolve the problem, replace the PCL

board. Then turn to TAG 002: Check & Problem Resolution.

Turn the printer off.

• Open the back cover and install an interlock by-pass tool.

• Remove the paper feed cover to expose the upper paper pick roller assembly.

Warning

To avoid the risk of injury, use extreme caution as gears

and belts are exposed

• Run diagnostic test 006, testing the upper pick-up roller clutch.

• Check TP3-9 for a voltage change from +24 Vdc to 0 Vdc.

Does the voltage change from +24 Vdc to 0 Vdc?

No: Continue. Yes: Go to #12 in this TAG.

Turn off the printer and unplug the power cord.

• Disconnect J/P40 and J/P 68.

• Check P40-9 to J68-2 and P40-11 to J68-1 for continuity.

Is there continuity?

No: Repair or replace the connectors or wiring from P40-9 to J68-2 or P40-11 to J68-1. Then

turn to TAG 002: Check & Problem Resolution.

Yes: Replace the upper pick-up roller assembly, then turn to TAG 002: Check & Problem Res-

olution.

3-28 Troubleshooting Analysis Guide (TAGs)

Run diagnostic test 006, testing the upper feed roller clutch.

• Check TP3-6 for a voltage change from +24 Vdc to 0 Vdc.

Does the voltage change from +24 Vdc to 0 Vdc?

No: Continue. Yes: Go to #14 in this TAG.

Turn off the printer and unplug the power cord.

• Disconnect J/P40 and J/P 66.

• Check P40-6 to J66-2 and P40-11 to J66-1 for continuity.

Is there continuity?

No: Repair or replace connectors or wirin g from P40-6 to J66-2 or P40 -11 to J66-1. Then turn

to TAG 002: Check & Problem Resolution.

Yes: Replace the upper feed roller assembly, then turn to TAG 002: Check & Problem Resolu-

tion.

Inspect the upper pick-up roller assembly for damage or binding.

Is it in good working order?

No: Replace the upper pick-up roller assembly, then turn to TAG 002: Check & Problem Res-

olution.

Yes: Continue.

Inspect the upper feed roller assembly for damage or binding.

Is it in good working order?

No: Replace the upper feed roller assembly, then turn to TAG 002: Check & Problem Resolu-

tion.

Yes: The upper pick-up roller or the feed rollers may not be delivering paper to the paper tim-

ing sensor at the correct time. Return to the beginning of this TAG.

Troubleshooting Analysis Guide (TAGs) 3-29

TAG 021: Paper Jam/Misfeed in /Lower Cassette Area

Error Code: 021 Possible Causes: Paper loaded incorrectly

Wrong weight or type of paper loaded Paper path obstruction

Possible Defects: Lower pick-up roller assembly

Lower feed roller assembly Lower pick-up roller drive assembly Upper paper guide assembly Lower paper guide assembly Lower paper cassette Pick pressure adjustment Main drive gear assembly Idler assembly Paper feed drive belt Paper feed drive idler assembly Paper timing sensor Wiring or connectors PCL board

Check both paper paths and remove any jams.

• Make sure paper is loaded properly in both cassettes.

• Make sure the paper guides are positioned properly.

• Check that the pick-up roller, feed roller, and backup roller assemblies are clean.

• Verify that J/P40, J/P62, J/P67, and J/P69 are connected properly.

• Confirm that the paper in the cassettes meets paper specifications, which are described in the Guide to Operations manual.

• Remove the upper cassette.

• Power-on-reset the printer.

• Run test prints from the lower cassette.

Is error code 021 displayed?

No: Go to #14 in this TAG. Yes: Continue.

Turn the printer off and inspect the foll owing for damage or binding:

• Lower paper guide assembly

• Upper paper guide assembly

• Paper feed drive belt

• Paper feed drive pulley

• Paper feed drive idler assembly

• Main drive gear assembly

• Lower pick-up roller drive assembly

Are all the parts in good working order?

No: Replace the damaged parts, then turn to TAG 002: Check & Problem Resolution. Yes: Continue.

3-30 Troubleshooting Analysis Guide (TAGs)

Clear the paper path.

• Reinsert the upper cassette.

• Power-on-reset the printer.

• Run test prints from the upper cassette.

Is error code 020 displayed?

No: Go to #10 in this TAG. Yes: Continue.

Clear the paper path.

• Inspect the paper timing sensor actuator for dama ge or binding.

Is it in good working order?

No: Replace the paper timing guide assembly , then tur n to TAG 00 2: C heck & P rob l em R e so -

lution.

Yes: Continue.

Check the voltage between TP3-16 and ground on the PCL board.

• With the printer powered on, activate the paper timing sensor.

• Check for a voltage change from 0 Vdc to +12 Vdc.

Does the voltage change from 0 Vdc to +12 Vdc?

No: Go to #9 in this TAG. Yes: Continue.

Check TP3-11 for +24 Vdc.

Is the voltage +24 Vdc?

No: Continue. Yes: Return to the beginning of this TAG.

Check J/P91-1 for +24 Vdc.

Is the voltage +24 Vdc?

No: Continue. Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.

Troubleshooting Analysis Guide (TAGs) 3-31

Check J/P8-13 for +24 Vdc.

Is the voltage +24 Vdc?

No: Replace the DC power supply, then turn to TAG 002: Check & Problem Resolution. Yes: Repair or replace the connectors or wiring from P91-1 to P8-13, then turn to TAG 002:

Check & Problem Resolution.

Turn the printer off and unplug the power cord.

• Disconnect J/P40 and J/P 57.

• Check the following for continuity: P40-16 to P57-2

P40-25 to P57-1 P40-12 to P57-3

Is there ground?

No: Repair or replace the connectors or wiring from:

P40-25 to J/P58-1 to P57-1, P40-16 to J/P58-2 to P57-2, or P40-12 to J/P58-3 to P57-3.

Then turn to TAG 002: Check & Problem Resolution.

Yes: Replace the paper timing guide. If this does not correct the problem, replace the PCL

board. Then turn to TAG 002: Check & Problem Resolution.

Turn off the printer.

• Open the back cover and install an interlock by-pass tool.

• Remove the paper feed cover to expose the lower paper pick-up assembly.

Warning

To avoid the risk of injury, use extreme caution as gears

and belts are exposed

• Run diagnostic test 006, testing the lower pick-up roller clutch.

• Check TP3-8 for a voltage change from +24 Vdc to 0 Vdc.

Does the voltage change from +24 Vdc to 0 Vdc?

No: Continue. Yes: Go to #12 in this TAG.

Turn the printer off and unplug the power cord.

• Disconnect J/P40 and J/P 69.

• Check P40-8 to J69-2 and P40-10 to J69-1 for continuity.

Is there continuity?

No: Repair or replace the connectors or wiring from:P40-8 to J69-2 or P40-10 to J69-1. Then

turn to TAG 002: Check & Problem Resolution.

Yes: Replace the lower pick-up roller assembly, then turn to TAG 002: Check & Problem Res-

olution.

3-32 Troubleshooting Analysis Guide (TAGs)

Run diagnostic test 006, testing the lower feed roller clutch.

• Check TP3-5 for a voltage change from +24 Vdc to 0 Vdc.

Does the voltage change from +24 Vdc to 0 Vdc?

No: Continue. Yes: Go to #14 in this TAG.

Turn the printer off and unplug the power cord.

• Disconnect J/P40 and J/P 67.

• Check P40-5 to J67-2 and P40-11 to J67-1 for continuity.

Is there continuity?

No: Repair or replace the connectors or wiring from P40-5 to J67-2 or P40-11 to J67-1. Then

turn to TAG 002: Check & Problem Resolution.

Yes: Replace the lower feed roller assembly, then turn to TAG 002: Check & Problem Resolu-

tion.

Inspect the lower pick-up roller assembly for damage or binding.

Is it in good working order?

No: Replace the lower pick-up roller assembly, then turn to TAG 002: Check & Problem Res-

olution.

Yes: Continue.

Inspect the lower feed roller assembly for damage or binding.

Is it in good working order?

No: Replace the lower feed roller assembly, then turn to TAG 002: Check & Problem Resolu-

tion.

Yes: The lower pick-up roller or lower feed roller may no t be deliv ering the pap er to th e paper

timing sensor at the correct time. Return to the beginning of this TAG.

Troubleshooting Analysis Guide (TAGs) 3-33

TAG 022: Paper Jam in the Transfer or Fuser Area

Error Code: 022 Possible Causes: Paper loaded incorrectly

Wrong weight or type of paper loaded Paper path obstruction

Possible Defects: Fuser unit

Paper supply Paper timing roller assembly Fuser drive assembly Fuser drive belt Vacuum transport unit Exit roller assembly Upper paper guide assembly Lower paper guide assembly Paper timing guide assembly Pick pressure adjustment PCL board Connectors or wiring.

Caution

When clearing this jam, be careful not to get toner on your clothing,

as it may stain. If toner gets on your clothing, rinse your clothes

with cold water immediately to avoid stains

Check the paper path and remove any jammed paper.

Warning

The fuser unit may be very hot

• Check the fuser unit for paper wrapped around the heat roller.

Is paper wrapped around the heat roller?

No: Continue. Yes: If the paper is black or very dark with no printing, go to TAG 805: Black Prints. If the

paper is very dark and does have printing, go to TAG 811: Background/Residual Images/

Dark Prints.

Check both paper paths for damage or obstructions.

• Confirm that J/P13, J/P22, J/P40, J/P58, and J/P65 are connected properly.

• Check that the paper is properly loaded.

• Confirm that the paper in the cassettes meets paper specifications, described in the Guide to

3-34 Troubleshooting Analysis Guide (TAGs)

Operations manual.

• Check that the fuser unit is installed properly.

• Power-on-reset the printer.

• Run test prints.

Is error code 022 still displayed?

No: Paper incorrectly loaded, incorrect paper type in use, or a loose connector was at fault.

Turn to TAG 002: Check & Problem Resolution.

Yes: Continue.

Has the fuser unit been replaced recently?

No: Continue. Yes: Go to #5 in this TAG.

Replace the fuser unit.

• Run test prints.

Has the problem been resolved?

No: Reinstall the original fuser unit and continue. Yes: The fuser unit was at fault. Turn to TAG 002: Check & Problem Resolution.

Inspect the following for damage:

• Upper paper guide assembly

• Paper timing roller assembly

• Lower paper guide assembly

• Paper timing guide assembly

Are any of these parts damaged?

No: Continue. Yes: Replace the damaged part, then turn to TAG 002: Check & Problem Resolution.

Is more than one sheet of paper jamming?

No: Go to #8 in this TAG. Yes: Continue.

Troubleshooting Analysis Guide (TAGs) 3-35

Make sure the natural curl of the paper is turned up in the cassettes.

• Make sure the paper is under the corner separators.

• Make sure the rear and side paper guides are positioned properly.

• Make sure the paper being used does not have a high static charge.

• Run test prints.

Does the multiple feed problem still exist?

No: The paper appears to be at fault. Turn to TAG 002: Check & Problem Resolution. Yes: Adjust the paper tension lever or pick pressure, as described in Chapter 9, “General

Printer Maintenance”, then turn to TAG 002: Check & Problem Resolution.

Check the paper path for jams.

• Open the printer’s front cover and insert the interlock bypass tool.

• Power-on-reset the printer.

• Run test prints.

• Watch the end of the paper timing roller shaft.

Does the paper timing roller shaft turn?

No: Continue. Yes: Go to #14 in this TAG.

Check TP3-11 for +24 Vdc.

Is the voltage +24 Vdc?

No: Continue. Yes: Go to #12 in this TAG.

Check J/P91-1 for +24 Vdc.

Is the voltage +24 Vdc?

No: Continue. Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.

Check J/P8-13 for +24 Vdc.

Is the voltage +24 Vdc?

No: Replace the DC power supply unit, then turn to TAG 002: Check & Problem Resolution. Yes: Repair or replace the connectors or wiring from P91-1 to P8-13, then turn to TAG 002:

Check & Problem Resolution.

Run diagnostic test 006, testing the paper timing roller clutch.

• Check TP3-7 for a voltage change from +24 Vdc to 0 Vdc.

Does the voltage change from +24 Vdc to 0 Vdc?

No: Continue. Yes: Go to #14 in this TAG.

3-36 Troubleshooting Analysis Guide (TAGs)

Turn off the printer and unplug the power cord.

• Disconnect J/P40 and J/P 65.

• Check P40-7 to J65-2 and P40-11 to J65-1 for continuity.

Is there continuity on both?

No: Repair or replace the connectors and wiring from: P40-7 to J65-2 or P40-11 to J65-1.

Then turn to TAG 002: Check & Problem Resolution.

Yes: Replace the paper timing roller assembly, then turn to TAG 0 02: Check & P ro ble m R eso -

lution.

Does paper stop or jam either before or during entry into the fuser unit?

No: Go to #17 in this TAG. Yes: Continue.

Remove the fuser unit.

• Check the fuser unit rollers for damage or toner contamination.

Are they damaged or contaminated with toner?

No: Continue. Yes: Replace the fuser unit, then turn to TAG 002: Check & Problem Resolution.

Inspect the following for damage or binding:

•Fuser unit

• Fuser drive belt

• Fuser drive assembly

Are any of these parts damaged?

No: Go to #22 in this TAG. Yes: Replace the damaged parts, then turn to TAG 002: Check & Problem Resolution.

Turn the printer off.

• Check for paper jams.

• Inspect the exit roller, and exit pinch roller assemblies for damage, binding and contamination.

Are these parts in good working order?

No: Repair or replace the defective parts, then turn to TAG 002: Check & Problem Resolu-

tion.

Yes: Continue.

Run test prints.

• Check the leading edge of the prints for improper registration.

Is there improper registration?

No: Continue. Yes: Go to TAG 807: Misregistered/Skewed Prints (Simplex) or TAG 901: Misregistration/

Skewed Prints (Duplex).

Inspect the vacuum transport unit for damage or binding.

Are the parts in good working order?

Repair or replace the vac uum trans port un it, the n turn t o TAG 002: Check & Pr oblem R esolu -

tion

No: Continue. Yes: Open the top cover and install an interlock by-pass tool.

Troubleshooting Analysis Guide (TAGs) 3-37

Power-on-reset the printer.

• While the main motor is running, cover all o f th e ho les in the vacuu m u nit with a piece o f paper.

Does the vacuum transport unit fan hold the paper in place?

No: Continue. Yes: Return to the beginning of this TAG.

Use extreme caution: Check for 100 Vac from J/P22-1 to J/P22-2.

Is the voltage 100 Vac?

No: Continue. Yes: Replace the vacuum transport assembly.

Power-on-reset the printer. Use extreme caution:

• While the main motor is running, monitor J/P 13-6 and J/P13-3 for 100 Vac.

Is the voltage 100 Vac?

No: Replace the power control board, then turn to TAG 002: Check & Problem Resolution. Yes: Repair or replace the connectors or wiring from J22-1 to P13-6 or J22-2 to P13-3. Then

turn to TAG 002: Check & Problem Resolution.

3-38 Troubleshooting Analysis Guide (TAGs)

TAG 023: Paper Jam in the Output Area

Error Code: 023 Possible Causes: Paper path obstruction

Output tray obstr u c tion

Possible Defects: Exit paper sensor

Fuser drive unit Exit roller assembly Exit pinch roller assembly PCL board Connectors or wiring

If the printer has a high capacity output unit (HCO), unplug and remove it before you begin. Test the printer without the HCO; if t he pro ble m remain s, proc eed wit h th is TAG. If the problem occurs only with the HCO, the HCO is c ausing the problem. Repair or replace the HCO.

Turn the printer off and unplug the power cord.

• Verify that J/P50 and J/P40 are connected properly.

• Check the paper path and remove any paper jams.

• Check the output tray and remove any paper jams.

• Power-on-reset the printer.

• Run test prints.

Is error code 023 displayed?

No: Loose connectors or ob structions were at fault. Turn to TAG 002: Check & Problem Res-

olution.

Yes: Continue.

Is paper stopped or jammed at the output tray?

No: Continue. Yes: Go to #5 in this TAG.

Inspect the exit paper sensor actuator for damage or binding.

Is it in good working order?

No: Repair or replace the exit paper sensor actuator , then tur n to TAG 002: Check & Problem

Resolution.

Yes: Continue.

Troubleshooting Analysis Guide (TAGs) 3-39

Turn the printer off and unplug the power cord.

• Disconnect J/P40 and J/P 49.

• Check the following for continuity: P40-24 to P49-2, P40-26 to P49-1, and

P40-13 to P49-3.

Is there continuity?

No: Repair or replace the connectors or wiring from:

P40-26 to J/P50-1 to P49-1, P40-24 to J/P50-2 to P49-2, or P40-13 to J/P50-3 to P49-3.

Yes: Replace the exit paper sensor.

Turn the printer off and unplug the power cord.

• Open the back cover and install an interlock bypass tool.

• Remove the fuser drive cover.

• Inspect the following for damage, binding, or contamination:

• Exit roller assembly

• Exit roller drive gear

• Exit pinch roller assembl y

Are all the parts in good working order?

No: Replace the defective parts, then turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Remove the fuser unit.

• Inspect the following for damage or binding:

• Fuser drive assembly

• Fuser drive belt

• Main drive gear assembly

Are all the parts in good working order?

No: Replace the defective parts, then turn to TAG 002: Check & Problem Resolution. Yes: Reinstall the fuser unit and continue.

Run diagnostic test 009.

• Watch the fuser drive and the exit roller assembly.

Are they in good working order?

No: Replace the defective parts, then turn to TAG 002: Check & Problem Resolution. Yes: Replace the fuser unit, then turn to TAG 002: Check & Problem Resolution.

3-40 Troubleshooting Analysis Guide (TAGs)

TAG 025: Paper in Input Area Before Printing

Error Code: 025 Possible Defects: Paper timing sensor

PCL board Connectors or wiring

Turn the printer off and unplug the power cord.

• Check the paper path and remove any paper jams.

• Confirm that J/P58 and J/P40 are connected properly.

• Inspect the paper timing sensor actuator for dama ge or binding.

Is it in good working order?

No: Replace the paper timing guide assembly and continue. Yes: Continue.

Power-on-reset the printer.

Is error code 025 displayed?

No: Jammed paper, loose connectors, or the sensor actuator were at fault. Turn to TAG 002:

Check & Problem Resolution.

Yes: Continue.

Check TP3-25 for +12 Vdc.

Is the voltage +12 Vdc?

No: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Loosen the paper timing guide.

• Confirm that J/P57 is connected properly.

Is J/P57 connected properly?

No: Continue. Yes: Go to #6 in this TAG.

Troubleshooting Analysis Guide (TAGs) 3-41

Reconnect J/P57.

• Reinstall the paper timing guide.

• Power-on-reset the printer.

Is error code 025 still displayed?

No: J/P57 was at fault. Turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Turn the printer off and unplug the power cord.

• Loosen the paper timing guide.

• Disconnect J/P57 and J/P 40.

• Check the following for continuity:

• P40-16 to P57-2

• P40-25 to P57-1

• P40-12 to P57-3

Is there continuity?

No: Repair or replace the connectors or wiring from:

• P40-25 to J/P58-1 to P57-1

• P40-16 to J/P58-2 to P57-2

• P40-12 to J/P58-3 to P57-3 Then turn to TAG 002: Check & Problem Resolution.

Yes: Replace the paper timing guide. If that doesn’t resolve the problem, replace the PCL

board. Then turn to TAG 002: Check & Problem Resolution.

3-42 Troubleshooting Analysis Guide (TAGs)

TAG 026: Paper in Output Area Before Printing

Error Code: 026 Possible Defects: Exit paper sensor

PCL board Connectors or wiring

If the printer has a high capacity output unit (HCO), unplug and remove it before beginning this TAG . Test the printer without the HCO; if the problem rema ins, procee d with this T AG. If the problem occurs only wit h the HCO, the HCO is causing the problem. Repai r or replace the HCO.

Turn the printer off and unplug the power cord.

• Check the paper path and remove any paper jams.

• Confirm that J/P50 and J/P40 are connected properly.

• Inspect the exit paper sensor actuator for damage or binding.

Is it in good working order?

No: Replace the exit paper sensor actuator and continue. Yes: Continue.

Power-on-reset the printer.

Is error code 026 displayed?

No: Jammed paper, loose connectors, or sensor actuator were at fault; go to TAG 002: Check

& Problem Resolution.

Yes: Continue.

Check J/P40-26 for +12 Vdc.

Is the voltage +12 Vdc?

No: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution. Yes: Continue

Turn off the printer and unplug the power cord.

• Remove the exit cover.

• Disconnect J/P49 and J/P 40.

• Check the following for continuity: P40-26 to P49-1, P40-24 to P49-2, and P40-13 to P49-3

Is there continuity?

No: Repair or replace the connectors or wiring from:

P40-26 to J/P50-1 to P49-1, P40-24 to J/P50-2 to P49-2, or P40-13 to J/P50-3 to P49-3. Then turn to TAG 002: Check & Problem Resolution.

Yes: Replace the exit paper sensor. If this doesn’t resolv e the p rob lem, r eplace the PCL b oard.

Then turn to TAG 002: Check & Problem Resolution.

Troubleshooting Analysis Guide (TAGs) 3-43

TAG 030: Developer Bias Short/Failure

Error Code: 030 Possible Defects: Cleaner unit

High voltage unit DC power supply Connectors or wiring PCL board Printhead assembly Power control #2 board Developer unit

Turn the printer off and unplug the power cord.

• Verify that J/P23, J/P24, J/P40, J/P41, J/P96, and J/P85 are connected properly.

• Power-on-reset the printer.

Is error code 030 still displayed?

No: A loose connector was at fault. Turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Check the voltages, as described in Chapter 9, “General Printer Maintenance”.

Are the voltages correct?

No: Replace the high voltage power supply unit, then turn to TAG 002: Check & Problem

Resolution.

Yes: Continue.

Has the developer unit been replaced recently?

No: Go to #5 in this TAG. Yes: Continue.

Replace the cleaner unit.

• Run test prints.

Is error code 030 still displayed?

No: The cleaner unit was defective; turn to TAG 002: Check & Problem Resolution. Yes: Reinstall the original cleaner unit and go to #6 in this TAG.

3-44 Troubleshooting Analysis Guide (TAGs)

Replace the developer unit.

• Install a new toner cartridge.

• Run test prints.

Is error code 030 still displayed?

No: The developer unit was defective; turn to TAG 002: Check & Problem Resolution. Yes: Reinstall the original developer un it and continue.

Open the back cover and install an interlock by-pass tool.

• Power-on-reset the printer.

• Check TP4-35 for +24 Vdc.

Is the voltage +24 Vdc?

No: Go to #11 in this TAG. Yes: Continue.

Check J/P23-5 for +24 Vdc.

Is the voltage +24 Vdc?

No: Repair or replace the connectors or wiring from P41-35 to P23-5, then turn to TAG 002:

Check & Problem Resolution.

Yes: Continue.

Turn the printer off and unplug the power cord.

• Disconnect J/P41 and J/P 24.

• Check the following for continuity: P41-31 to P24-1 P41-30 to P24-2 P41-40 to P24-3

Is there continuity?

No: Repair or replace the connectors or wiring from:

P41-31 to P24-1 P41-30 to P24-2 P41-40 to P24-3 Then turn to TAG 002: Check & Problem Resolution.

Yes: Continue.

Disconnect P85 from the high voltage unit.

• Check P85-3 to J25-7 for continuity.

Is there continuity?

No: Repair or replace the connectors or wiring from P85-3 to J25-7, then turn to TAG 002:

Check & Problem Resolution.

Yes: Continue.

Troubleshooting Analysis Guide (TAGs) 3-45

Disconnect J/P96.

• Check P96-1 to J25-7 for continuity.

Is there continuity?

No: Repair or replace the developer power supply lead from J/P96-1 to P85-3, then turn to

TAG 002: Check & Problem Resolution.

Yes: Replace the high voltage unit, then turn to TAG 002: Ch eck & Problem Resolution.

Check TP3-27 for +24 Vdc.

Is the voltage +24 Vdc?

No: Continue. Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.

Check J/P12-1 for +24 Vdc.

Is the voltage +24 Vdc?

No: Continue. Yes: Repair or replace the connectors or wiring from P40-27 to P12-1, then turn to TAG 002:

Check & Problem Resolution.

Check J/P11-1 for +24 Vdc.

Is the voltage +24 Vdc?

No: Continue. Yes: Replace the power control #2 board, then turn to TAG 002: Che ck & Problem Resolu-

tion.

Check J/P8-11 for +24 Vdc.

Is the voltage +24 Vdc?

No: Replace the DC power supply unit, then turn to TAG 002: Check & Problem Resolution. Yes: Repair or replace the connectors or wiring from P8-11 to P11-1, then turn to TAG 002:

Check & Problem Resolution.

3-46 Troubleshooting Analysis Guide (TAGs)

TAG 031: Toner Patch Reference Level Too Low

Error Code: 031 Possible Causes: Contamination of the toner patch sensor or printhead lens Possible Defects: Photoconductor unit

Connectors or wiring PCL board Developer unit

Turn the printer off and unplug the power cord.

• Perform the every-call cleaning procedure, described in Chapter 9, “General Printer Mainte-

nance”.

• Clean the toner patch sensor on the developer unit.

• Clean the printhead lens.

• Run at least 200 test prints to detone the printer’s engine.

Has the problem been resolved?

No: Contamination was at fault. Turn to TAG 002: Check & Problem Resolution. Yes: Continue.

Check the voltages, as described in Chapter 9, “General Printer Maintenance”.

Are the voltages correct?

No: Replace the high voltage power supply unit, then turn to TAG 002: Check & Problem

Resolution.

Yes: Continue.

Have the photoconductor and developer units been replaced recently?

No: Continue. Yes: Go to #6 in this TAG.

Troubleshooting Analysis Guide (TAGs) 3-47

Replace the photoconductor unit.

• Run 200+ test prints to reduce toner concentration in the developer unit.

Has the problem been resolved?

No: Reinstall the original photoconductor unit and continue. Yes: The photoconductor was at fault; turn to TAG 002: Check & Problem Resolution.

Replace the developer unit.

• Run test prints.

Has the problem been resolved?

No: Reinstall the original developer un it and continue. Yes: Turn to TAG 002: Check & Problem Resolution. If the problem reappears, the toner/car-

rier mix may be old or contaminated.

Turn the printer off and unplug the power cord.

• Remove the developer unit.

• Disconnect J/P41.

• Check P41-47 to J25-3 for continuity.

Is there continuity?

No: Repair or replace the connectors or wiring from P41-47 to J25-3. Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.

3-48 Troubleshooting Analysis Guide (TAGs)

HP C30D, C30 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Using This Manual

Printer and Troubleshooting Overview 1-1

Contents

Theory of Operation

Paper Path and Cycle Sequence

Simplex Printing

Duplex Printing

Error Code Technical Definitions

Sensor and Switch Locations

Troubleshooting Overview

General Troubleshooting Tips

The Problem: Printer or Host?

Protocol Converters

Reading the Error Log

Confirming Line Power

Using the Troubleshooting Analysis Guide (TAG)

Sample TAG

Standard Procedures

Power-on-reset (POR)

Checking Continuity

Installing the Interlock By-pass Tool

Producing a Developed Image

Producing a Toner Patch

Completing a Service Call

Clearing the Error Log

TAG Cross- Reference Tables 2-1

TAG Cross-Reference Tables

Error Code/TAG Cross-Ref erence

Print Quality/TAG Cross-Reference

Mechanical Malfunction/TAG Cross-Reference

Troubleshooting Analysis Guide (TAGs) 3-1

Contents

Troubleshooting Analysis Guide (TAGs)

TAG 001: Troubleshooting a Problem

TAG 002: Check & Problem Resolution

TAG 010: Upper Cassette Malfunction

E10: Envelope Tray Out of Envelopes

TAG 011: Lower Cassette Malfunction

TAG 012: Upper Cassette Not Latched

TAG E12: Envelope Tray or Feeder Not Latched

TAG 013: Lower Cassette Not Latched

TAG 020: Paper Jam/Misfeed in Upper Cassette Area

TAG 021: Paper Jam/Misfeed in /Lower Cassette Area

TAG 022: Paper Jam in the Transfer or Fuser Area

TAG 023: Paper Jam in the Output Area

TAG 025: Paper in Input Area Before Printing

TAG 026: Paper in Output Area Before Printing

TAG 030: Developer Bias Short/Failure

TAG 031: Toner Patch Reference Level Too Low