HP C40D Service Manual

Download

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.

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

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 Input

Toner

Developer

Transfer Corona

Photoconductor

Vac uu m Transport

Erase Lamp

Cleaner

Charge Corona

LED Printhead

AVPCL

Fuser

Paper

Output

RIGS

Interface

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

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.)

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.

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

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 off 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 disconnecte d. Failure to do s o may

result in personal injury, equipment damage, or both.

To perform a continuity check:

Standard Procedures

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 question. (Refer to Section 6, Wiring Diagrams and Electri cal

Data, for circuit locations.)

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

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

Installing the Interlock By-pass Tool

The interlock by-pass tool overrides the cover interlock switches, allowing you to operate the printer with the covers open. The interlock by-pass tool is a white plastic, V-shaped tool with two finger pads. To use the tool, open the cover and locate the interlock switch (for locations, see illustrations in “Sensors and Switches Illustrations” on page 1-8).

Squeeze the tool between thumb and forefinger and insert it into the interlock switch. The printer ships with two spare interlock by-pass tools concealed behind the right cover.

Replace them when you are finished using them.

 Do not attempt to close the printer cover while the interlock by-pass too l is in place.

June 1999 Troubleshooting 1-17

Standard Proced ures

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 prints. See “Running Test Prints” on page 1-12.

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

timing roller w here it pauses briefly.

5 As soon as a sheet of paper begins to move from the paper timing roller, remove the

interlock by-pass tool.

6 Remove the photoconductor. 7 Examine the photoconductor belt to verify that a developed image was produced.

 Caution: Do not touch the surface of the photoconductor belt; this damages the belt

and results in poor print quality.

Producing a Toner Patch

To produce a toner patch:

1 Turn off the printer. 2 Open the top cover and install an interlock by-pass tool. 3 Turn on the printer. 4 Start running test prints. When the leading edge of the first print enters the fuser, wait

one second then remove the interlock by-pass tool.

5 Remove the photoconductor.

Producing a toner patch on the photoconductor.

1-18 Troubleshooting June 1999

Standard Procedures

6 Examine the photoconductor to verify that a toner patch has been produced. You may

have to rotate the belt slightly to observe the patch.

 Caution: Do not touch the surface of the photoconductor belt; this damages the belt

and results in poor print quality.

Completing a Service Call

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

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

Maintenance.

3 Power-on-reset the printer. 4 Clear the error log. (See the procedure described next.) 5 Run test prints in both the simplex and duplex mode from both the upper and lower

paper cassettes.

6 Fill in the Repair/Maintenance record taped inside the front cover. Make sure the

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

Clearing the Error Log

1 Enter the diagnostic mod e of the printer:

• Turn off the printer and wait 5 seconds.

• Hold down the MENU and STATUS keys simult aneously as you t urn the printer back

on. Wait for all three LEDs to come on. This takes approximately 30 seconds.

2 Press 3 Once a test name is di splayed, use the 4 Press the 5 Press 6 Press

7 Press 8 Press 9 Confirm that the error log has been cleared. 10 Exit diagnostic mode (power-on reset)

h to display the first available test.

h key to move through the available tests.

h key until “Clear Error Log” shows on the display.

to activate the procedure.

h to advance to the drive where the error log is maintained. This is usually the

boot drive.

h to clear the error log on the selected drive. f to exit the procedure.

11 Print the error log. All errors in all sections should be reset to zero.

June 1999 Troubleshooting 1-19

Error Message and Code Technical Definitions

Error messages/codes are listed here alphanumerically. Sensor and switch locations referred to throughout these descriptions are illustrated on page 1-8.

Type Message Description

MACHINE CHECK Unknown Error

PAPER JAM

020 Upper Cassette

PAPER JAM

021 Lower Cassette

PAPER JAM

022 Transfer/Fuser

PAPER JAM

023 At/Near Exit

PAPER JAM

024 At/Near HCO Exit

PAPER JAM

Paper Jams

025 At/Near Input

1. There is no text associated with the error.

2. The error is not included in the error look-up tables. A VPCL board detected that the paper being fed from the upper

cassette did not reach the timing paper sensor within the allotted time.

A VPCL board detected that the paper being fed from the lower cassette did not reach the timing paper sensor within the allotted time.

AVPCL board detected that the timing paper sensor was activated immediately after one of the covers were closed or the leading edge of the paper did not activate the exit paper sensor within the allotted time.

A VPCL board detected that the exit paper sensor in the printer (or in the HCO if installed) did not deactivate within the allotted time.

AVPCL board detected that the paper did not reach the HCO exit paper sensor within the allotted time.

A VPCL board detected that either the exit paper sensor (within the printer) or the paper exit sensor (within the HCO) were activated immediately after one of the covers was closed.

PAPER JAM

026 At/Near Output

PAPER JAM

027 In Duplex Area

PAPER JAM

060 Duplex Roller

PAPER JAM

061 Duplex Path

PAPER JAM

062 Duplex Tray

1-20 Troubleshooting June 1999

(HCO only). The paper exit sensor (within the HCO) did not become activated or deactivated within the allotted time.

The AVPCL board detected paper in the duplex area after clearing a jam.

AVPCL board detected that the leading edge of the paper did not activate the BC sensor within the allotted time.

AVPCL board detected that the trailing edge of the paper did not deactivate the BC sensor within the allotted time.

Paper picked from the registration tray did not reach the timing roller sensor within the allotted time.

Error Message and Code Technical Definitions

Type Message Description

MACHINE CHECK

TPS Too Low Error #031

MACHINE CHECK

TPS Too Light Error #032

MACHINE CHECK

TPS Signal Overload Error #033

MACHINE CHECK

Toner Control Errors

No Developer Error #036

MACHINE CHECK

TPS Too High Error #037

AVPCL board detected a signal from the toner patch sensor board indicating that the reference voltage level on the photoconductor was too low.

AVPCL board detected a signal from the toner patch sensor board indicating that the toner patch on the photoconductor was too light.

AVPCL board detected too many successive signals from the toner patch sensor board for a toner feed.

AVPCL board detected no developer electrical interlock signal from the J25 connector.

AVPCL board detected a signal from the toner patch sensor board indicating that the reference voltage level on the photoconductor was too high.

June 1999 Troubleshooting 1-21

Error Message and Code Technical Definitions

Type Message Description

MACHINE CHECK

No Signal from PSS Error #040

MACHINE CHECK

PSS Sensor Shorted Error #041

MACHINE CHECK

PSS Sensor Open Error #042

MACHINE CHECK

AVPCL NVRAM Error #043

MACHINE CHECK

Charge Corona Open Error #044

MACHINE CHECK

OPC Rotation Errors

Charge Corona Short Error #045

MACHINE CHECK

PC Life Data Error Error #047

AVPCL board sensed that the signal from the photoconductor seam sensor either was not of sufficient amplitude or did not show the proper timing.

AVPCL board detected an abnormally high amount of current needed to drive the photoconductor seam sensor LED (within the photoconductor).

AVPCL board detected an open connection to the photoconductor seam sensor LED (within the photoconductor).

AVPCL board non-volatile RAM error.

AVPCL board dete cted a sign al f rom the hig h-vo ltage power supply indicatin g th at eith er the ch ar g e coro na or tra nsf e r corona circuits have an open connecti on.

AVPCL board detected a signal from the high-voltage power supply indicating an abnormally high load on the bias voltage to the charge corona.

AVPCL board received invalid life data from the photoconductor serializer board.

MACHINE CHECK

Developer Life Error Error #048

MACHINE CHECK

CRU Series Mismatch Error #049

MACHINE CHECK

Transfer Corona Short Error #050

MACHINE CHECK

Transfer Corona Open Error #051

HVPS Errors

MACHINE CHECK

Eraser Lamp Error Error #055

MACHINE CHECK

Duplex not installed Error #069

AVPCL board received invalid life data received from the developer serializer board.

AVPCL board detected invalid data from either the photoconductor or developer units. Verify that the CRUs are correct for this printer.

AVPCL board detected a signal from the high-voltage power supply indicating an abnormally high load on the bias voltage to the transfer corona.

AVPCL board detected a signal from the high-voltage power supply indicating an open connection in the transfer corona circuit. (Diagnostic test only.)

AVPCL board detected that the current needed to drive the erase lamp assembly was either higher or lower than the specified limits. (Diagnostic test only.)

Duplex turnaround tray is not electrically connected to the printer. (Diagnostic test only.)

1-22 Troubleshooting June 1999

Error Message and Code Technical Definitions

Type Message Description

MACHINE CHECK

Fuser/Thermal Fuse Error #070

MACHINE CHECK

No Fuser/Thermistor Error #071

MACHINE CHECK

F user Temp Too High Error #072

Fuser Control Errors

MACHINE CHECK

F user Temp Too Low Error #073

MACHINE CHECK

Duplex Registration Error #086

Errors

Jogger

MACHINE CHECK

Bad PC Type Error #091

A VPCL board sensed, via the fuser thermistor, that the temperature of the fuser did not change within the allotted time.

A VPCL board sensed an open connection in the fuser thermistor circuit.

AVPCL board sensed that the resistance of the fuser thermistor was too low indicating that the temperature of the fuser was higher than the specified limit.

AVPCL board sensed that the resistance of the fuser thermistor was too high indicating that the temperature of the fuser was lower than the specified limit.

AVPCL board detected a signal from the duplex control board #2 indicating 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.

AVPCL board detected that the photoconductor is installed improperly, or is of the wrong type. Verify that the photoconductor is the correct type for the printer.

MACHINE CHECK

Bad Dev Type Error #092

MACHINE CHECK

+12 DC Power Failure

LVPS Errors

Error #097

MACHINE CHECK

+24 DC Power Failure Error #099

MACHINE CHECK

IML Error Error #130

MACHINE CHECK

Bad AVPCL ROM Checksum Error #140

MACHINE CHECK

AVPCL PIA1 Reset Fail

AVPCL Error

Error #160

MACHINE CHECK

AVPCL PIA1 R/W at POR Error #161

AVPCL board detected that the developer is installed improperly, or is of the wrong type. Verify that the developer is the correct type for the printer.

AVPCL board detected a signal from the RIGS board indicating the absence of +12 Vdc.

AVPCL board detected a signal from the RIGS board indicating the absence of +24 Vdc.

RIGS board detected an error when attempting to download information to the AVPCL flash EPROM.

RIGS board detected an error from the AVPCL board during initial AVPCL diagnostic.

June 1999 Troubleshooting 1-23

Error Message and Code Technical Definitions

Type Message Description

MACHINE CHECK

AVPCL PIA1 Reset Fail Error #170

MACHINE CHECK

AVPCL PIA1 R/W at POR Error #171

MACHINE CHECK

AVPCL PTM Reset Fail Error #180

MACHINE CHECK

AVPCL PTM Read/Write Error #181

MACHINE CHECK

AVPCL PTM IRQ Failure Error #182

MACHINE CHECK

I2C Oppanel Fatal Error #260

MACHINE CHECK

I2C Oppanel Warning Error #261

A VPCL Errors (cont.)

MACHINE CHECK

Transmit Failed Error #270

RIGS board detected an error from the AVPCL board during initial AVPCL diagnostic.

RIGS board detected a fatal error from the AVPCL board during initial AVPCL diagnostic.

RIGS board detected an error from the AVPCL board during initial AVPCL diagnostic.

RIGS board detected transmit failed, lost arbitration, with the control panel.

MACHINE CHECK

Transmit Failed Error #271

MACHINE CHECK

Transmit Failed Error #272

MACHINE CHECK

Transmit Error Error #273

MACHINE CHECK

Error #274

1-24 Troubleshooting June 1999

RIGS board detected transmit failed, no acknowledgment, with the control panel.

RIGS board detected transmit failed, bus always busy, with the control panel.

RIGS board detected a transmit error on the I control panel.

RIGS board detected I

C host not ready.

C bus, with the

Error Message and Code Technical Definitions

Type Message Description

MACHINE CHECK

Error #275

MACHINE CHECK

Error #276

MACHINE CHECK

Error #277

MACHINE CHECK

Error #278

MACHINE CHECK

Error #280

MACHINE CHECK

Error #281

MACHINE CHECK

AVPCL No Data VSS Hig h Error #301

RIGS board detected receiver overruns.

RIGS board detected a framing error on receive.

RIGS board detected a receive overflow.

Control panel has failed to establish communication with the RIGS board. Verify the cabling between the control panel, the RIGS board, and the AVCPL boards.

Control panel has lost communication with the RIGS board. Verify the cabling between the control panel, the RIGS board, and the AVCPL boards

Invalid command sent to the operator panel.

RIGS board detected an error from the AVPCL board during initial AVPCL diagnostic.

MACHINE CHECK

AVPCL Errors (cont.)

AVPCL TS High VSS Low Error #302

MACHINE CHECK

TC High but not VSC Error #303

MACHINE CHECK

VSC high too long Error #304

MACHINE CHECK

AVPCL VSC Invalid Error #305

MACHINE CHECK

TS high and data xfr Error #306

MACHINE CHECK

AVPCL Parity Error Error #307

RIGS board detected an error from the AVPCL board during initial AVPCL diagnostic.

June 1999 Troubleshooting 1-25

Error Message and Code Technical Definitions

Type Message Description

MACHINE CHECK

PCL Cmd Retry Error Error #380

MACHINE CHECK

PCL Cmd Rejected Error #381

MACHINE CHECK

PCL Sent Bad Cmd Error #382

MACHINE CHECK

PCL Sent Bad Byte Error #383

MACHINE CHECK

PCL Got TS-No Status Error #384

MACHINE CHECK

Controller Errors

PCL SIB/Count Bad Error #385

MACHINE CHECK

PCL Bad SIB Offset Error #386

RIGS board detected an error during the internal diagnostic testing of the RIGS board.

MACHINE CHECK

PCL Parity Error Error #387

MACHINE CHECK

Unknown Error Error #397

RIGS board detected an error during the internal diagnostic testing of the RIGS board.

RIGS board detected an internal software error.

1-26 Troubleshooting June 1999

Error Message and Code Technical Definitions

Type Message Description

MACHINE CHECK

Fatal Software Error Error #398

MACHINE CHECK

Software Error Error #399

MACHINE CHECK

Peripheral Bus Error Error #401

MACHINE CHECK

RAM Bank Selection Error #405

MACHINE CHECK

RAM Bank 0 Address Error #406

Controller Errors (cont.)

MACHINE CHECK

RAM Bank 0 Refresh Error #407

MACHINE CHECK

RAM Bank 1 Address Error #408

RIGS board detected an internal software error.

RIGS board detected an error during the internal diagnostic testing of the peripheral bus.

RIGS board detected an error in the program RAM during the internal diagnostic testing of the RIGS board.

MACHINE CHECK

RAM Bank 1 Refresh Error #409

MACHINE CHECK

Incorrect Diskette Error #450

MACHINE CHECK

Floppy Format Error Error #451

Disk Drive Errors

MACHINE CHECK

Fatal Software Trap Error #454

MACHINE CHECK

Software Trap Error #455

MACHINE CHECK

Controller Errors

PIT0 Invalid Error #500

RIGS board detected an error in the program RAM during the internal diagnostic testing of the RIGS board.

RIGS board detected an error during the internal diagnostic testing of the RIGS board and software.

June 1999 Troubleshooting 1-27

Error Message and Code Technical Definitions

Type Message Description

MACHINE CHECK

PIT0 Read/Write Error Error #501

MACHINE CHECK

PIT0 No Countdown Error #502

MACHINE CHECK

PIT0 No Timer Halt Error #503

MACHINE CHECK

PIT0 No Timer Intr Error #504

MACHINE CHECK

PIT2 Invalid Error #505

MACHINE CHECK

PIT2 Read/Write Err. Error #506

MACHINE CHECK

PIT2 No Countdown Error #507

RIGS board detected an error during the internal diagnostic testing of the RIGS board and software.

MACHINE CHECK

PIT2 No Timer Halt

Controller Errors (cont.)

Error #508

MACHINE CHECK

PIT2 No Timer Intr Error #509

MACHINE CHECK

No DMAC Reset Error #520

MACHINE CHECK

DMAC Read/Write Error #521

MACHINE CHECK

No DMA Transfer Error #522

MACHINE CHECK

No DMA Transfer End Error #523

RIGS board detected an error during the internal diagnostic testing of the RIGS board and software.

1-28 Troubleshooting June 1999

Error Message and Code Technical Definitions

Type Message Description

MACHINE CHECK

No End DMA Interrupt Error #524

MACHINE CHECK

DMA Software Abort Error #525

MACHINE CHECK

DMA Software Intr. Error #526

MACHINE CHECK

DMA Operation Error Error #527

MACHINE CHECK

DMA Transfer Error Error #528

MACHINE CHECK

DMAC2 Transfer Error Error #529

MACHINE CHECK

No DMAC2 Transfer Error #530

RIGS board detected an error during the internal diagnostic testing of the RIGS board and software.

MACHINE CHECK

AVPCL SCC register R/W

Controller Errors (cont.)

Error #540

MACHINE CHECK

AVPCL break detected Error #541

MACHINE CHECK

AVPCL SCC xmit not Error #542

MACHINE CHECK

No AVPCL SCC Transfer Error #543

MACHINE CHECK

AVPCL SCC Transfer Error #544

MACHINE CHECK

Host SCC R/W Error #545

RIGS board detected an error during the internal diagnostic testing of the RIGS SCC UART.

June 1999 Troubleshooting 1-29

Error Message and Code Technical Definitions

Type Message Description

MACHINE CHECK

Host xmit not ready Error #546

MACHINE CHECK

No TX/RX interrupt Error #547

MACHINE CHECK

SCC HOST/AVPCL Parity Error #548

MACHINE CHECK

SCC unexpected Intr. Error #549

MACHINE CHECK

SCC Transmission Error #550

MACHINE CHECK

No AVPCL SCC Interrupt Error #551

MACHINE CHECK

SCC-DMAC Interaction Error #552

RIGS board detected an error during the internal diagnostic testing of the RIGS SCC UART.

RIGS board detected an error during the internal diagnostic testing of the RIGS board and software.

MACHINE CHECK

SCC-DMAC Transfer #

Controller Errors (cont.)

Error #553

MACHINE CHECK

SCC-DMAC Transfer Error #554

MACHINE CHECK

RS232 Send/Rcv Error #555

MACHINE CHECK

RS232 DTR/DCD Error #556

MACHINE CHECK

RS232 RTS/CTS Error #557

MACHINE CHECK

RS422 Send/Rcv Error #558

RIGS board detected an error during the internal diagnostic testing of the RIGS board and software.

1-30 Troubleshooting June 1999

Error Message and Code Technical Definitions

Type Message Description

MACHINE CHECK

RS422 Send/Rcv Clock Error #559

MACHINE CHECK

CRTC Read/Write Error #560

MACHINE CHECK

No Page Begin Intr. Error #561

MACHINE CHECK

CR TC Address Error #562

MACHINE CHECK

No VSYNC Generation Error #563

Controller Errors (cont.)

MACHINE CHECK

No End of Page Intr. Error #564

MACHINE CHECK

No CRTC Termination Error #565

RIGS board detected an error during the internal diagnostic testing of the RIGS board and software.

MACHINE CHECK

VSYNC Timeout Error Error #566

MACHINE CHECK

FDC/SCSI Read/Write Error #570

MACHINE CHECK

FDC Busy Timeout Error #571

MACHINE CHECK

Write Protected Error #572

MACHINE CHECK

Disk Drive Errors

Floppy Not Ready Error #573

MACHINE CHECK

FDC Restore Error Error #574

RIGS board detected an error during the internal diagnostic testing of the RIGS board and software.

RIGS board detected an error when communicating with the floppy disk drive.

June 1999 Troubleshooting 1-31

Error Message and Code Technical Definitions

Type Message Description

MACHINE CHECK

FDC Seek Error Error #575

MACHINE CHECK

FDC Read Error Error #576

MACHINE CHECK

FDC Checksum Error Error #577

MACHINE CHECK

FDC Write Error Error #578

MACHINE CHECK

FDC R-M-W-V Error Error #579

MACHINE CHECK

FDC/PIT0 Interrupt Error #580

MACHINE CHECK

FDC/DMA Interaction Error #581

RIGS board detected an error when communicating with the floppy disk drive.

Disk Drive Errors (cont.)

MACHINE CHECK

FDC/DMAC Transfer Error #582

MACHINE CHECK

FDC/DMAC Transfer # Error #583

MACHINE CHECK

FDC/DMAC Read Error #584

MACHINE CHECK

FDC/DMAC Write Error #585

MACHINE CHECK

FDC/DMAC Operations Error #586

RIGS board detected an error when communicating with the floppy disk drive.

1-32 Troubleshooting June 1999

Error Message and Code Technical Definitions

Type Message Description

MACHINE CHECK

Bit Map RAM Data Error #600

MACHINE CHECK

Bit Map RAM Bank Error #601

MACHINE CHECK

Bit Map RAM Refresh Error #602

MACHINE CHECK

Bit Map RAM Address Error #603

MACHINE CHECK

Controller Errors

ALU Op in Bit RAM Error #604

MACHINE CHECK

Width/Ori gin Fau l t Error #605

MACHINE CHECK

BMRAM Bank Fault Error #606

RIGS board detected an error during internal testing.

Interface

MACHINE CHECK

Host SCC Error

Error #701–#708

Errors

Interface

MACHINE CHECK

Host SCC Error Error #709

Error

Controller

MACHINE CHECK

Host SCC Error Error #710–#722

MACHINE CHECK

Parallel Error

Errors

Error #725–#741

MACHINE CHECK

Smart flex IO Card Error Error #745–#784

RIGS board detected an error when communicating with a host using serial communications on the ASYNC flex IO card.

RAM test failure during power-on diagnostics.

RIGS board detected an error when communicating with a host using serial communications on the ASYNC flex IO card.

RIGS board detected an error when communicating with a host using parallel communications on the ASYNC flex IO card.

RIGS board detected an error when communicating with a host using an intelligent flex IO card.

June 1999 Troubleshooting 1-33

Error Message and Code Technical Definitions

1-34 Troubleshooting June 1999

Section 2

TAG Cross-

Reference Tables

June 1999 2-1

2-2 June 1999

TAG Cross-Reference Tables

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

• Error Code/TAG Cross-Reference

• Print Quality/TAG Cross-Reference

• Mechanical Malfunction/TAG Cross-Reference

Section 2

June 1999 TAG Cross-Reference Tables 2-3

Error Code/TAG Cross-Reference

Error codes, which display on the operator’s panel, i ndi cate a wide variety of printer prob lems related to the con tr ol b oards, software, and/or host communication problems. On t he chart find the error code in question, then turn to TAG associated with the code.

Code Printer Error Code Meaning Go to TAG

010 Upper paper tray out of paper 010 011 Lower paper tray out of paper 011 012 Upper paper tray not plugged in 012 013 Lower paper tray not plugged in 013 020 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 023 024 Paper jam at/near HCO exit 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 T oner patch sensor reference level too low 031 032 T oner patch sensor black patch too light 032 033 T oner patch sensor overload 032 035 T oner empty error 035 036 No developer 036 037 T oner patch sensor too high 031 040 Photoconduc tor seam sensor malfunction 040 041 Photoconductor seam sensor short 040 042 Photoconductor seam sensor open 040 044 Charge/transfer corona open 044 045 Charge corona short 045 047 PC life error . Bad PC CRU information 047 048 Developer life error. Bad developer CRU information 048 050 Transfer corona short 050

2-4 TAG Cross-Reference Tables June 1999

Error Code/TAG Cross-Reference

Code Printer Error Code Meaning Go to TAG

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 070 071 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 VPCL board co mmand timeout 100

Code VPCL/RIGS Communication Error Codes Go to TAG

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

June 1999 TAG Cross-Reference Tables 2-5

Error Code/TAG Cross-Reference

Code VPCL Error Codes 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 VPCL board ROM checksum error at power on diagnostic 100 145 VPCL board RAM error at power on diagnostic 100 160 VPCL board PIA1 register error after reset 100 161 VPCL board PIA1 registers read/write error 100 162 VPCL board PIA1 PA or PB read/write error 100 170 VPCL board PIA2 register error after reset 100 171 VPCL board PIA2 register read/write error 100 172 VPCL board PIA 2 PB re ad/w rite error 100 180 VPCL board PTM register error after reset 100 181 VPCL board PTM read/wr ite error 100 182 No IRQ generation on PTM 100

Code VPCL/RIGS Communication Error Codes Go to TAG

199 VSS not asserted before communication test 201 200 Status tag not asserted 201 201 Timeout waiting for a failed RIGS controller 201 202 No data received after VSS line asserted 201 203 VSS asserted after VPCL 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 received after VSC asserted 201 208 VSC command asserted after command line asserted 201 209 Command tag asserted after VSC not asserted 201

2-6 TAG Cross-Reference Tables June 1999

Error Code/TAG Cross-Reference

Code VPCL/RIGS Communication Error Codes Go to TAG

210 No RQI after “request RQI” command 201 211 Parity error on command line 201 212 Parity or overrun sensed by VPCL board 201 213 Incorrect command received from VPCL board 201 214 Incorrect command received from RIGS controller 201 215 No transfer buffer empty on asynchronous communications

201

interface adapter after VPCL board sent data

RIGS Firmware Error Codes

Code

These error codes signal a prob lem with the RIGS co ntroller firmware.

No TAGs address these problems; report to Hewlett-Packard.

Go to TAG

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

Code VPCL Failure Error Codes Go to TAG

380 VPCL board fai lure – comm and retrie s 201 381 VPCL board fai lure – comm and reje ct ed 201 382 VPCL board fai lure – bad comm and receiv ed 201 383 VPCL board fai lure – unex pec ted byte recei ved 201 384 VPCL board fai lure – no status recei ved 201 385 VPCL board failure – bad status information block count 201 386 VPCL board failure – bad status information block offset 201 387 VPCL board fai lure – parity error 201 389 Floppy disk retry 130

June 1999 TAG Cross-Reference Tables 2-7

Error Code/TAG Cross-Reference

RIGS Software Code Meaning

These error codes indicate a problem with the RIGS controller

Codes

software. No T AGs address these pr oblems; to de termine whether t he

faulty software is the customer’s or the manufacturer’s, contact

Hewlett-Packard.

Go to TAG

397 RIGS software trap No T AG 398 RIGS software trap No T AG 399 RIGS software trap No T AG

Codes RIGS/Disk Drive Error Codes Go to TAG

401 Fatal RIGS PB error No TAG 405 RIGS RAM error 201 406 RIGS RAM error 201 407 RIGS RAM error 201 408 RIGS RAM error 201 409 RIGS RAM error 201 450 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

2-8 TAG Cross-Reference Tables June 1999

Error Code/TAG Cross-Reference

Codes RIGS/Disk Drive Error Codes Go to TAG

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 VPCL board serial controller registers read/write error 200 541 VPCL board br eak conditi on dete cte d 200 542 VPCL board serial controller transmitter not ready 200 543 No VPCL board serial controller transfer 200 544 VPCL 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/V PCL board parity error 200 549 Serial controller unexpected interrupt 200 550 Two-channel transfer error 200 551 No VPCL board/serial controller interrupt on break 200 552 No serial con tr ol ler/DM AC int er action 200 553 Serial contr oller/DMAC transfer count error 200 554 Serial controller/DMAC transfer error 200 555 RS2 32 se nd/rec ei ve path error 200 556 RS232 DTR/DTC path error 200 557 RS232 RTS/CTS path error 200 558 RS4 22 se nd/rec ei ve path error 200 559 RS422 send clock/receive clock path error 200 560 CRTC register read/write error 200 561 No page begin (PIT2) interr upt 200

June 1999 TAG Cross-Reference Tables 2-9

Error Code/TAG Cross-Reference

Codes RIGS/Disk Drive Error Codes Go to TAG

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 writ e 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

Code Bit Map RAM Error Codes 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

2-10 TAG Cross- Reference Tables June 1999

Error Code/TAG Cross-Reference

Code Bit Map RAM Error Codes Go to TAG

606 T otal bit-map RAM bank fault 405 610 Bit-map RAM chip error 405

Code Host Communication Error codes Go to TAG

701–741 Async flex IO error 753 745–755 Smart flex IO error 754

June 1999 TAG Cross-Reference Tables 2-11

Print Quality/TAG Cross-Reference

Poor quality prints are another indication of printer problems. Begin by running a set of test prints. Then, compare th e te st prints to the samples located in Sect ion 4, Print Quality

Samples. The chart below summarizes the possible print quality problems you may

encounter and recommends a TAG in Section 3 to follow to address the problem.

Blank Prints Go to TAG

Complete 800 Partial 800 With dark horizontal bands 800

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

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

Skewed Prints Go to TAG

Simplex 807 Duplex 901

2-12 TAG Cross- Reference Tables June 1999

Misregistration Go to TAG

Simplex 807 Duplex 901

Smeared, Blurred, Uneven Prints Go to TAG

Smeared vertical streaks 809 Blurred prints 809 Uneven density 810 Prints with background 811

Print Quality/TAG Cross-Reference

Prints with background and residual

811

images Prints with residual images 813 Prints with offset images 814

Additional Print Quality Problems Go to TAG

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

June 1999 TAG Cross-Reference Tables 2-13

Mechanical Malfunction/TAG Cross-Reference

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

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” displayed 600 Remove prints light remains on or lights 700 “Add toner” displayed 035 Machine check light is on with no numerical

Display One or more lights are off at POR 610 Tone not working 610 Incorrect paper size 702 Other operator panel malfunctions 610

Output Tray Problems Go to TAG

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

Cassette Problems Go to TAG

201

Upper cassette 703 Lower cassette 704

2-14 TAG Cross- Reference Tables June 1999

Mechanical Malfunction/TAG Cross-Reference

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

Counter Problems Go to TAG

Supplies seem to have short life span 750 Incorrect counting 750

Communication Problems Go to TAG

Printer will produce test prints 753 Incorrect data being printed 753

Additional Mechanical Malfunctions Go to TAG

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

June 1999 TAG Cross-Reference Tables 2-15

Mechanical Malfunction/TAG Cross-Reference

2-16 TAG Cross- Reference Tables June 1999

Section 3

Troubleshooting

Analysis Guides

(TAGs)

June 1999 Troubleshooting Analysis Guides (TAGs) 3-1

Troubleshooting Analysis Guides

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

TAG 002: Check Problem Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

TAG 010: Upper Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

TAG 011: Lower Cassette Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12