HP C40D Service Manual
Cut Sheet Printers
Maintenance Manual
Model C40D
E1195
HP Part No. C4672-90005
Notice
Hewlett-Packard makes no warranty of any kind with regard to this material, including,
but not 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.
Hewlett-Packard Company
System Peripherals Operation
MS 44MC
19111 Pruneridge Avenue
Cupertino, CA 95014
Printing History
New editions are complete revisions of the manual. Update pages, which are issued
between editions, contain additional and replacement pages to be merged into the manual
by the customer. The date on the title page changes only when a new edition or a new
update is published. No in for mat ion is incorporated into a r eprinting unless it ap pears as a
prior update; the edition does not change when an update is incorporated.
The software code printed alongside the date indicates the version level of the software
product at the time the manual or update was issued. Many product updates and fixes do
not require manual changes and, conversely, manual corrections may be done without
accompanying product changes. Therefore, do not expect a one-to-one correspondence
between product updates and manual updates.
Edition 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .November 1995
Edition 2. . . . . . . . . . . . . . . . . . . . . . . . . . .June 1999
ii June 1999
Preface
The C40D Maintenance Manual contains all the information needed to maintain and service Hewlett Packard C40D printers. The C40D printer series are high-speed, non-impact
printers utilizing electrophotographic imaging technology.
The informati on in this manua l is for authorized field repre sentatives wh o are familiar
with basic printer operations. It serves as a supplement to training classes and provides a
basis for discussi on with regional field se rvice engineers and c ust omer s uppor t representatives.
Using This Manual
This manual is organized into the following sections:
Section 1, Troubleshooting
Reviews the organization of the manual, the way the printer works, and how to troubleshoot the printer, including some standard procedures to follow when troubleshooting.
This chapter also 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.
Section 2, TAG Cross- Reference Tables
Provides cross-refe re nce tables; look up specific printer problem descrip ti on (in either the
mechanical malfunction, error code, or print quality description tables), then turn to the
TAG indicated on the chart to troubleshoot the problem.
Section 3, Troubleshooting Analysis Guides
Detailed step-by-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.
Section 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.
Section 5, Diagnostic Tests
Reviews each printer software diagnostic.
Section 6, Wiring Diagrams and Electrical Data
Shows printer schematics and locations of individual components.
Section 7, Removal/Replacement Procedures
Outlines procedures to follow when removing and replacing printer parts, also called
FRUs (Field-Replaceable Units).
June 1999 iii
Section 8, Options
Provides information about the optional High Capacity Input and High Capacity Output
bins.
Section 9, General Printer Maintenance
Reviews printer maintenance procedures to complete during service calls.
Index
Provides a list of references to topics mentioned in this manual.
Other Manuals
The C-Series Illustrated Parts Catalog shows every FRU and CRU (customer-replaceable
unit) in the printer, including part number information. This information is frequently
updated.
The C40D Installation Manual, C4672-90007, guides you through unpacking, setup, test-
ing, and network configuration of your C40D printer.
The C40D Operator’s Manual, C4672-90006, contains all the informat ion nee ded to oper-
ate Hewlett Packard C40D printers.
The C40D Technical Reference Manual, C4672-60012, is a complete guide to using fonts
and the PJL and PostScript emulations on the C40D. It also documents aspects of printer
usage in detail.
The Cut Sheet Printers Paper Specifications Guide, C4672-90002, explains the various
kinds of papers usable in the printer, how to care for them, and how to minimize paperrelated problems with the C40D.
Copyright ©1999 Hewlett Packard, Inc. All rights reserved.
November 1995
Please address any comments or questions with respect to this document to:
Publications Manager
System Peripherals Operation
MS 44MC
Hewlett-Packard Company
19111 Pruneridge Avenue
Cupertino, CA 95014
iv June 1999
Troubleshooting
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
The Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Paper Path and Cycle Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Simplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Sensors and Switches Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Sensor and Switch Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
General Troubleshooting Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
The Problem: Printer or Host?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Running Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Protocol Converters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Reading the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Confirming Line Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Using the Troubleshooting Analysis Guide (TAG) . . . . . . . . . . . . . . . . . . . . 1-15
Sample TAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Contents
Contents
Standard Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Power-on-reset (POR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Checking Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Installing the Interlock By-pass Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Producing a Developed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Producing a Toner Patch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Completing a Service Call. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Error Message and Code Technical Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
TAG Cross-Reference Tables
Error Code/TAG Cross-Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Print Quality/TAG Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Mechanical Malfunction/TAG Cross-Reference. . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Troubleshooting Analysis Guides
TAG 001: Troubleshooting a Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
TAG 002: Check Problem Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
TAG 010: Upper Cassette Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
June 1999 v
Contents
TAG 011: Lower Cassette Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
TAG 012: Upper Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
TAG 013: Lower Cassette Not Latched. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
TAG 020: Paper Jam/Misfeed in Upper Cassette Area . . . . . . . . . . . . . . . . . . . . .3-19
TAG 021: Paper Jam/Misfeed in Lower Cassette Area . . . . . . . . . . . . . . . . . . . . .3-22
TAG 022: Paper Jam in the Transfer or Fuser Area. . . . . . . . . . . . . . . . . . . . . . . .3-26
TAG 023: Paper Jam in the Output Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
TAG 025: Paper in Input Area Before Printing . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
TAG 026: Paper in Output Area Before Printing. . . . . . . . . . . . . . . . . . . . . . . . . .3-34
TAG 030: Developer Bias Short/Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
TAG 031: Toner Patch Reference Level Incorrect. . . . . . . . . . . . . . . . . . . . . . . . .3-39
TAG 032: Toner Patch Too Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
TAG 035: Out of Toner or ADD TONER Indication . . . . . . . . . . . . . . . . . . . . . .3-43
TAG 036: Developer Not Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
TAG 040: Photoconductor Seam Sensor Malfunction. . . . . . . . . . . . . . . . . . . . . .3-46
TAG 044: Charge Corona/Transfer Corona Circuit Open. . . . . . . . . . . . . . . . . . .3-49
TAG 045: Charge Corona Circuit Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
TAG 047: PC Life Data Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
TAG 048: Developer Life Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55
TAG 050: Transfer Corona Circuit Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
TAG 055: Erase Lamp Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-58
TAG 070: Fuser Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60
TAG 071: Open Fuser/Thermistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65
TAG 072: Fuser Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66
TAG 097: +12 Vdc Power Shorted or Sensing Problem . . . . . . . . . . . . . . . . . . . . 3-68
TAG 098: -12 Vdc Power Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-78
TAG 099: +24 Vdc Power Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-80
TAG 100: VPCL Board Interface Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . .3-89
TAG 130: Disk Drive Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-90
TAG 200: RIGS Internal Communication Malfunction. . . . . . . . . . . . . . . . . . . . .3-95
TAG 201: RIGS-VPCL Interface Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . .3-97
TAG 405: RIGS Bit-Map RAM Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-99
TAG 500: +5 Vdc Power Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-100
TAG 600: Vac Power Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-105
TAG 610: Operator Panel Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-112
vi June 1999
Contents
TAG 700: Output Tray Circuit Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
TAG 702: Paper Size Detection Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
Wiring for the Upper Paper Size Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
Wiring for the Lower Paper Size Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
TAG 703: Upper Cassette Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
TAG 704: Lower Cassette Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -121
TAG 705: Multiple Paper Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
TAG 706: Paper Damaged or Wrinkled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-123
TAG 707: Upper Paper Guide Assembly Not Closing . . . . . . . . . . . . . . . . . . . . 3-124
TAG 750: Counter Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
TAG 751: Main Drive Motor Runs Continuously. . . . . . . . . . . . . . . . . . . . . . . . 3-127
TAG 753: Async IO Communications Malfunction . . . . . . . . . . . . . . . . . . . . . . 3-128
TAG 754: Smart I/O Card Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
TAG 800: Prints Blank or With Dark Horizontal Bands. . . . . . . . . . . . . . . . . . . 3-133
TAG 801: Prints Light or Light With Carrier Particles. . . . . . . . . . . . . . . . . . . . 3-137
TAG 802: Prints With Voids or White Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
TAG 803: Prints With Light or White Vertical Streaks . . . . . . . . . . . . . . . . . . . 3-144
TAG 804: Prints With Light Horizontal Bands. . . . . . . . . . . . . . . . . . . . . . . . . . 3-145
TAG 805: Black Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
TAG 806: Prints with Dark Spots or Scratches. . . . . . . . . . . . . . . . . . . . . . . . . . 3-148
TAG 807: Misregistered/Skewed Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-150
TAG 808: Prints Overtoned/Dark Vertical Streaks. . . . . . . . . . . . . . . . . . . . . . . 3-153
TAG 809: Blurred or Smeared Vertical Streaks on Prints. . . . . . . . . . . . . . . . . . 3 -157
TAG 810: Uneven Density or Dark Areas on Prints . . . . . . . . . . . . . . . . . . . . . . 3-161
TAG 811: Background/Residual Images/Dark Prints . . . . . . . . . . . . . . . . . . . . . 3-162
TAG 812: Uneven or No Fusing on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166
TAG 813: Residual Images on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168
TAG 815: Prints Resulting From Printhead Malfunctions . . . . . . . . . . . . . . . . . 3-170
TAG 900: Top Cover Interlock Malfunction, Duplex. . . . . . . . . . . . . . . . . . . . . 3-171
TAG 901: Misregistration/Skewed Prints (Duplex) . . . . . . . . . . . . . . . . . . . . . . 3-173
TAG 902: Paper Jam in Duplex Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-177
Print Quality Samples
Sample 1: Good Quality Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Sample 2: Washout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Sample 3: Blank Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Sample 4: Light Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
June 1999 vii
Contents
Sample 5: Light Print With Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Sample 6: Voids or White Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Sample 7: Light Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Sample 8: Blank Vertical Bands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Sample 9: Light Horizontal Bands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Sample 10: Black or Dark Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Sample 11: Dark Specks, Lines, or Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Sample 12: Dark Vertical Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Sample 13: Skewed Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
Sample 14: Misregistration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
Sample 15: Overtoned Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Sample 16: Blurred Images or Characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
Sample 17: Varying Print Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
Sample 18: Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
Sample 19: Residual Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
Sample 20: Wrinkles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
Sample 21: Fusing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
Diagnostic Tests
How to Run Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 -3
Operator Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Upper Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Lower Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Fuser Thermistor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Roller Clutch Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Counter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Jogging Motor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Photoconductor Seam Sensor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Toner Supply Motor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Charge Corona Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Transfer Corona Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Erase Lamp Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Toner Empty Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Negative Developer Bias Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Duplex Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Duplex Sensor Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
Duplex Clutch Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -13
Duplex Tray Paper-Guide Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
viii June 1999
High-Capacity Output (HCO) Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
High-Capacity Input (HCI) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
LED Printhead Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
RIGS Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Com. Wrap Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Display File Version Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Format Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Clear Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Disk Drive Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Wiring Diagrams and Electrical Data
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Printhead Circuit Board Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Connector (J/P) Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Connectors Inside the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Contents
Connectors Inside the Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Connectors on the Duplex Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Connectors Inside the Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Connectors Inside the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
Connectors on the Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Connectors Inside the Back Cover (J/P2-14). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Connectors Inside the Back Cover (Continued) J/P 18-62 . . . . . . . . . . . . . . . . . . 6-19
Connectors Inside the Back Cover (Continued) J/P 64-85 . . . . . . . . . . . . . . . . . . 6-20
Connectors Inside the Back Cover (Continued) J/P 90-800 . . . . . . . . . . . . . . . . . 6-21
Voltage Isolation Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
-12 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
+5 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -22
+12 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
+24 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Ground System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Host Interface Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
RS-232C Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Standard DCE to DTE RS-232C Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Special Considerations for RS-232 Host Interface Users. . . . . . . . . . . . . . . . 6-29
DTE Host to Printer (Option 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
DTE Host to Printer (Option 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
IBM PC/XT to Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
IBM PC/AT to Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Macintosh Communication Port to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
June 1999 ix
Contents
Centronics Parallel Host Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33
IBM Parallel to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34
Removal/Replacement Procedures
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Photoconductor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Front Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Back Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Left Side Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Right Side Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Vacuum Transport Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
Rear Duplex Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
Front Duplex Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11
Operator Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
Counter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
RIGS Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
VPCL Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
Printhead Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
Printhead Circuit Board (ARIF) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
Hard Disk Drive Housing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
Floppy and Hard Disk Drive Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20
Cooling Fan Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
Toner Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22
This space left blank intentionally. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
AC Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24
DC Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26
High Voltage Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 -27
Photoconductor Seam Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
Photoconductor Rear Guide Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30
Power Control Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
Upper or Lower Paper Size Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Upper Cassette Mount Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35
This space left blank intentionally. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-39
Lower Cassette Mount Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40
This space left blank intentionally. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44
Upper Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45
Upper Paper Guide Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-47
x June 1999
Contents
ULower Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Paper Timing Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
Cleaner Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
Cleaner Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Fuser Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
Fuser Drive Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
Paper Feed Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
Paper Timing Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Upper Feed Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
Lower Feed Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-58
Upper Pick-Up Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
Pick-Up Roller Drive Idler Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Pick-Up Roller Drive Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
Lower Pick-Up Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
Exit Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Exit Pinch Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
Upper Static Brush Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Lower Static Brush Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Exit Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -69
Exit Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Paper Exit Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Paper Full Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Front Cover Interlock Switch Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Back Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
Top Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Erase Lamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -78
EP Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Main Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
Main Gear Drive Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-85
Duplex Control Board #1 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
Duplex Control Board #2 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
Duplex Tray Registration Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Duplex Skew Correction Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89
Upper Duplex Drive/Clutch Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 7-91
Duplex Route Motor/Solenoid Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 7-92
“A” Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
June 1999 xi
Contents
“B” Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-94
“C” Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-96
“C” Roller Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-97
Duplex Route Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-98
Duplex Paper Path Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-99
Options
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
1200-Sheet/2500-Sheet Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
Guide to Component Acronyms/Physical Locations. . . . . . . . . . . . . . . . . . . . .8-4
Bench Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
Prefeed Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
1200-Sheet Feeder Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
2500-Sheet Feeder Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
Connection Diagram for 1200-Sheet/2500-Sheet Feeder. . . . . . . . . . . . . . . . . . . . .8-8
Connection Diagram for 1200-Sheet /2500-Sheet Feeder . . . . . . . . . . . . . . . . . . . .8-8
Input Control Board Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
1400-Sheet Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
Guide to Component Abbreviations/Physical Locations. . . . . . . . . . . . . . . . .8-10
Bench Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13
Front View (cover removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13
Left Side View (left cover removed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13
Rear Side View (cover removed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 -14
Top View (top cover removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14
Connection Diagram for the 1400-Sheet Stacker . . . . . . . . . . . . . . . . . . . . . . . . . .8-15
Output Control Board Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -16
General Printer Maintenance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -4
Tool Requirements: Service Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4
Tools/Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5
Printer/Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5
Printer Maintenance Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6
Every-Call Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
Adjusting Paper Feed Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10
Adjusting Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11
Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12
xii June 1999
Contents
Front View Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Front View Lubrication Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Rear View Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Rear View Lubrication Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Top View Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Duplex Holding Tray Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Tune-Up Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
June 1999 xiii
Contents
xiv June 1999
Troubleshooting
Section 1 T roubleshooting
Section 1
June 1999 Troubleshooting 1-1
Troubleshooting
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
The Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Paper Path and Cycle Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Simplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Sensors and Switches Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Sensor and Switch Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
General Troubleshooting Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
The Problem: Printer or Host?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Running Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Protocol Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Reading the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
Confirming Line Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
Using the Troubleshooting Analysis Guide (TAG). . . . . . . . . . . . . . . . . . . . .1-15
Sample TAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
Contents
Standard Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
Power-on-reset (POR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
Checking Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
Installing the Interlock By-pass Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
Producing a Developed Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18
Producing a Toner Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18
Completing a Service Call. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19
Clearing the Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19
Error Message and Code Technical Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . .1-20
1-2 Troubleshooting June 1999
Troubleshooting
The information in this Field Service Manual is directe d towa rd aut hor ized field represen-
tatives who are familiar with basic printer operations. It serves as a supplement to training
classes and provides a basis for discussion with regional field service engineers and customer suppor t representatives.
Theory of Operation
Section 1
Theory of Operation
The printer uses an electrophotographic imaging system, which is based on LED array
technology. Two key components of the printer are the image generation system (RIGS)
controller and the pr inte r contr ol lo gic (AVPCL) boar d. A brie f descr ipti on o f the func tion
of each of these components follows.
Risc Image Generation System (RIGS) controller: Each printer is equipped with an
RIGS controller, which provides the interface between the host computer, the AVPCL
board, the interface cards, and the disk drives.
Video Printer Control Logic (AVPCL) board: The AVPCL board directs the mechanical functions of the printer and print cycle timing, and controls the LED printhead. The
AVPCL board also receives initial machine information, such as empty paper cassettes,
paper jams, and fuser problems.
The Printing Process
The illustration on the following page details the printing process. The numbers represent
the sequence of events from the time that the RIGS controller receives data, through the
production of a print image, to the preparation for another print.
1 Receiving data
Host data is receive d t hro ugh the Signal Interf ace PCA and passed to the RISC Imag e
Generating System (RIGS) PCA, which temporar ily st ores the dat a in RAM. The data
may consist of information generated on the host computer and sent over the host
communication interface or it may consist of information generated by printer software, such as a request for test prints or to print the directory of the hard disk.
June 1999 Troubleshooting 1-3
Theory of Operation
2Bit Image
The RIGS transforms the host file into a bit map image of 1s and 0s and stores them in
bitmap RAM.
3 Charging the photoconductor belt
When the IGS controller receives data, it causes the AVPCL board to turn on the main
motor, which rotates the photoconductor belt. As the photoconductor belt rotates, the
charge corona applies a high negative charge to it, which repels toner from the photoconductor belt.
4 Exposing the image
The negatively charged belt then passes the LED printhead, where the AVPCL drives
the LEDs on and of f to dischar g e th e are as of the be lt at a den sity of 300 d ots pe r inch .
The 1s in the memory turn the LEDs on; 0s turn the LEDs off. The discharged areas
create a latent mirror image of the print on th e photoconductor belt.
5 Developing the image
As the photoconductor belt continues to rotate, it brings the latent image to the developer. A negative developer bias is applied to toner and the toner is transferred to the
surface of the photoconductor belt. The negatively charged toner (which clings to
small metal carrier beads) is attracted to the discharged areas of the belt; the carrier
beads do not transfer. The belt, with the developed image on its surface, t hen rotates
out of the developer. At this time you can remove the photoconductor belt and read
what is printed on it, which you may need to do when troubleshooting print problems.
6 Activating paper
As the image is be ing de velope d, a she et of paper is t ransp orted to t he phot oconduct or
belt. The AVPCL board controls thi s act i v it y. A series of paper pick-up, feed , an d ti m ing rollers guide the pa per so th e develo ped ima ge is pr operly reg ister ed with t he lead ing 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 advances the paper with the image to the fuser where heat and
pressure bond the toner to the paper. The print then arrives at the paper output tray.
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 cleaner where a charged brush rotates against th e surface to remove
any residual toner. This toner is recycled to the developer for reuse.
1-4 Troubleshooting June 1999
Paper Path and Cycle Sequence
Paper Path and Cycle Sequence
6
Paper Input
Toner
5
Developer
Transfer Corona
7
Photoconductor
Vac uu m Transport
Erase Lamp
9
Cleaner
3
Charge Corona
4
LED Printhead
AVPCL
Fuser
8
Paper
Output
RIGS
Interface
21
HOST
The RIGS board signals t he AVPCL boar d that a page of dat a is r eady t o be pri nted. When
this happens the following sequence takes place.
Simplex Printing
1 AVPCL software downloaded to the AVPCL board from the disk drive system turns
on the main motor.
2 The AVPCL board engages the paper pick clutch which causes the roller to feed a
sheet of paper.
3 The paper is passed to the feed roller where the AVPCL board has engaged the feed
roller clutch.
4 The feed roller passes the p aper to the pap er timing roller. Prior to rea ching the paper
timing roller, the paper passes over the paper timing s ens or. If the paper does not energize this sensor in a specified amount of time, a jam error (020/021) will occur. The
leading edge of the paper is registered against the paper timing roller. The paper timing clutch is engaged and the paper is passed over the photoconductor for transfer.
This registers the paper to the printer and the image to the paper. The paper timing
sensor also signals the AVCPL to begin sending data.
5 The AVPCL board engages the paper timing roller clutch and, at the same time, turns
on the transfer corona to pr ovi de a hi gh positive voltage. The devel oped image on the
photoconductor comes in contact with the paper and the high positive voltage causes
the image to transfer to the p aper.
June 1999 Troubleshooting 1-5
Paper Path and Cycle Sequence
6 Because the toner is not yet fixed to the paper, a vacuum transport assembly, gripping
the paper from the back side, moves the paper to the fuser, where heat and pressure
bond the toner to the paper.
7 Upon leaving the fuser, the paper comes in contact with the paper exit sensor. (If the
paper does not energize this sensor in a given amount of time after leaving the paper
timing sensor [step 4], a jam error (022) will occur.)
8 The exit roller moves the paper to the exit tray. (If the exit sensor is not cleared in a
specified amount of time, a jam error (023) will occur.)
Duplex Printing
When duplex is selected, the AVPCL board controls the paper motion with page scheduling assistance from the RIGS board. The duplex page router is engaged. When in duplex
mode, it is important to note that the printer runs multiple pages through the paper path at
the same time to increase speed.
1 In a duplex job, the duplex r outer so lenoid be hind the fuser is engaged 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).
2 The paper upon passing through the “B” roller comes in contact with the duplex sen-
sor. (If the paper does not energize this sensor in a given amount of time, a jam error
(060) will occur.)
3 The “C” roller bidirectional motor turns on and passes the paper into the turnaround
tray. The paper sensor in the turnaround tray is activated and the paper is center registered. (If the paper does not energize this sensor in a given amount of time after leaving the duplex sensor, a jam error (061) will occur.)
1-6 Troubleshooting June 1999
Paper Path and Cycle Sequence
4 At this time the s ole noid for the router at the turnaround t ra y engages so the paper can
be routed to be printed on the duplex side.
5 In a given amount of time after t h e pa per energizes the paper sensor in the turnaround
tray, the bidirectional motor reverses and passes the paper 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, a jam error (062) will occur.)
6 At this point, the same steps happen as during a simplex cycle.
June 1999 Troubleshooting 1-7
Sensors and Switches Illustrations
Sensors and Switches Illustrations
The following pages illustrate the locations of the printer’s sensors and switches.
Sensor and Switch Listing
Sensor/Switch Name Page Sensor/Switch Name Page
Cassette paper present sensors, upper and
lower
Cassette present micro switches, upper and
lower
Duplex registration sensor 1-8 Paper size sensors, upper and lower 1-9
Duplex paper path sensor 1-9 Paper timing se nsor 1-9
Interlock switch, duplex cover 1-9 Photoconductor seam sensor 1-9
Interlock switch, front 1-11 Automatic toner control 1-10
Interlock switch, rear 1-9 Toner empty sensor 1-10
Interlock switch, top 1-10 Toner patch sensor 1-9
.
1-8 Paper exit sensor 1-10
1-8 Paper full sensor 1-10
Front left view
1-8 Troubleshooting June 1999
Sensors and Switches Illustrations
Rear view
Left end view
Front view
Top view
Developer right view
June 1999 Troubleshooting 1-9
Sensors and Switches Illustrations
To p view
Developer left view
Right side view
Top left, duplex tray view
1-10 Troubleshooting June 1999
Troubleshooting
Throughout the printer’s life problems occur, such as when it produces poor quality prints
or malfunctions in another way. Use the tools provided in this manual to diagnose and
resolve printer problems. These tools include:
Troubleshooting
Front view
• The Troubleshooting Analysis Guide, which contains troubleshooting procedures
called TAGs. TAG 001: Troubleshooting a Problem explains how to use TAGs.
• Cross reference tables, which link error messages, print quality problems, and
mechanical malfunctions to specific TAGs.
• Print quality samples, which hel p i dentify a printing probl em and its associated TAGs.
• Diagnostics, which can uncover a range of problems.
The next several pages revie w troublesho oting basi cs and standa rd procedur es followed in
every troubleshooting sessi on, inc lud ing:
• 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
June 1999 Troubleshooting 1-11
Troubleshooting
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 deciding that the
problem is resolved.
When you replace the photoconductor, run at least 500 prints before checking print quality. This number of prints is required to “synch” the new PC belt to the developer.
The Problem: Printer or Host?
The printer is one comp onent i n a lar ge host sys tem. Befo re y ou star t any tr oubles hooti ng,
make sure that the problem really belongs to the printer rather than to some other component in the host system. Print quality problems and mechanical malfunctions are almost
always associated with the printer. However, host interface and software emulation problems can be caused by some other component of the host system even though, at first
glance, they 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
machine, ensuring that the basic printer software and all mechanical functions of the
printer are working.
Running Test Prints
1 Disconnect the host interface.
2 Make sure “Ready” displays on the panel.
3 Press
4 Press MENU
5 Press h to highlight “Test Print”
6 Press
7 Choose “Simplex” or “Duplex” (Duplex is the default. Press
8 Press
9 To stop printing the test pattern, press
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.
ONLINE.
e to select “Test Print”
h to choose simplex.)
e to start. A directory of the boot device and multiple listings of fonts prints. A
continuous flow of the test pattern then prints.
f. The printer will print a ll test prints stored in
the printer’s buffer, then stop.
1-12 Troubleshooting June 1999
Troubleshooting
Protocol Converters
Many protocol converters have a self-test function or configuration mode that enables the
user to check the proper functioning of the control. You can reconnect the host interface
and ask the customer to exercise this function of the converter. If the printer receives data
and prints it (even if the output is garbled) the problem may belong to the host or the protocol converter.
Reading the Error Log
The formatted error log is mainta ined by the printer in a file named “Error.log.” You have
the option to print this log when you are at the same panel used to print test prints. See
“Running Test Prints” on page 1-12.
• The first section lists the numbers and text of the last 15 errors.
• The second section of the formatted log lists paper jams. A 3-digit error code (or
codes) is followed by the error text and a 4-digit number indicating how many times
the error has occurred since the error log was last cleared. (Clearing the error log is
described on page 1-19.)
• The third section provides a complete er ror hist ory since the error log was last c leared.
Errors are listed in numeric order in the first column, with the number of times each
error occurred listed in the second column.
• The fourth section indicates the last error that required a power-on-reset (POR).
The error log is two pag es long. This partial ill ustration shows the main co mponents of t he
log.
June 1999 Troubleshooting 1-13
Troubleshooting
Confirming Line Power
Erratic printer problems can be caused by improper line power. As a rule, the voltage of
the outlet should be checked at installation. However, if you are unable to isolate an 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 outlined on the
following chart.
Probe connections 120v printer 230v 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% 230 +/- 10%
Please see Section 5, Diagnostic Tests, for additional information about troubleshooting
specific print er pro b le ms.
Please see Section 6, Wiring Diagrams and Electrical Data, for additional information
about the printer’s electrical systems.
1-14 Troubleshooting June 1999
Troubleshooting
Using the Troubleshooting Analysis Guide (T AG)
The Troubleshooting Analysis Guide provides problem-solving sequences to help you
identify and resolve printer problems. Each TAG addresses a particular symptom or error
message of the printer. The TAG number often matches an error message code displayed
on the printer’s operator panel.
TAG Number
Starting
actions
Yes/ No
Question
To Do
TA G Name
TAG 001: Troubleshooting a Problem
Error Message: All related error messages are listed here.
Possible Causes: All possible causes are listed here.
Possible Defects: All possible defective parts are listed here. (In no particular order.)
1
To start:
• Disconnect all peripheral cables
• Power-on-reset the printer.
Is an error message displayed?
No: Run test prints, following the procedure outlined in Secti on 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.
2
Power-on-reset the printer.
Did the power-on-reset end with an error message?
No:
Continue.
Yes: Refer to the error message cross-reference table in Section 2, using either the code that dis-
played after steps 1 and 2, or if multiple error messages continue to appear, the first error message that displays. Turn to the TAG associated with the message.
Sample TAG
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.
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.
June 1999 Troubleshooting 1-15
Troubleshooting
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 Section 2,
TAG Cross- Reference Tables. Or, you may turn directly to the tables to get started.
As you use TAGs, you will sometimes refer to othe r s ect i ons of this manual for addi ti onal
information:
• Section 4, Print Quality Sample s, contai ns print qual ity samples you’l l use to compare
• Section 5, Diagnostic Tests, outlines how to conduct printer diagnostic tests.
• Section 6, Wiring Diagrams and Electrical Data, provides all wiring and connector
• Section 7, Removal/Replacement Procedures, provides step-by-step procedures for
• Section 8, Options, reviews printer options (HCI, HCO) information.
• Section 9, General Printer Maintenance, presents general printer maintenance proce-
the customer’s test prints with flawed and good print samples.
diagrams.
removing and replacing all field-replaceable parts on the printer.
dures.
1-16 Troubleshooting June 1999
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