Xerox 8830, 8825 Service Manual

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Transmittal Page

Product

8825/8830 Printer

Status

SUPERSEDES

Replaces 701P15050 dated May 1999

Title

Service Manual

Part Number

701P15051

Date

January 2002

8825/ 8830 Pri nter Service Manual

THE DOCUMENT COMPANY

XEROX

701P15051 January 2002

CAUTION

Cert ain components in the 8825/ 8830 Printer are susceptible to d amage from electrostatic discharge. Observe all ESD procedures to avoid component damage.

NOTICE

While every care has been taken in the preparation of this manual, no liability will be ac cep ted b y Xero x Cor pora tion a rising out o f any ina ccu racie s or omissions.

NOTICE

All service documen tation is suppli ed t o Xe rox ex ternal cus tom ers for informational purposes only. Xerox service documentation is intended for use by certified product trained service personal only. Xerox does not warrant or represent that such documentation is complete, nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation. Cust omer performed service of equipment, or m odules, components or parts of such equipment may affect the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third party provided service. If the cust om er serv ices suc h equipment, modules, c om ponents or parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the cust omer agrees to indemnify, defend and hold Xerox harmless from any third party claims which arise directly or indirectly from such service.

Prepared by: Xerox Corporation 800 Phillips Road Bldg. 845-17S Webster, New York 14580-9791 USA

© 1998, 1999, 2000, 2001, 2002 by Xerox Corporation. All rights reserved. Xerox®, XES®, AccXES®, and The Document Company® are trademarks of Xerox Corporation. Xerox product names mentioned in this publication are trademarks of the XEROX CORPORATIO N.

About this Manual ........................................................................................................... iii

Organization....................................................................................................................iii

How to Use This Manu al ............ .... .... ... ........................... ........................... .................... iv

Repair Analysis Procedures (RAPs) ............................................................................... v

Repair / Adjustme nt Proc e du res .... .... ... .... ............... ................ ............... ........................ v

Introduction

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Introduction

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8825/8 83 0 P rin te r

About this Manual

This manual is part of a documentation system that includes the training.

This manual contains Repair Analysis Procedures (RAPs), Repair Procedures, Adjustment Procedures, Parts List, Diagnostic Procedures, Installation Procedures, Wiring Data and BSDs.

This m anual will enable t he Servic e Repres entative to repai r the 88 25/8830 p rinters. Those service procedures affected by the 8825 configuration differences will be identified using the 8825 product name or Tag number .

Organization

This manual consists of eight sections. The title and description of each section are listed below.

Section 1. - Service Call Procedures

This section contains the following:

• Call Flow Procedure

• Initial Actions/ System Checks

• Print Defect Isolation Procedure

• Workstation Checkout Pr ocedure

• Status Code Entry Chart

• Message Di splay Entry C hart

• Maintenance Procedures

• Callback

• System Checkout/ Final Action

Call Flow Proced ur e

The Call Flow Procedure is a list of activities to be perfor med on each service call.

Initial Actions/ System Checks

This proce du re is de si gn ed to iden ti fy an d cla ssi f y the pr o bl em and to refe r you to th e app rop r iate RAP in order to repair the problem. When the problem has been repaired, perform the Final Action.

Print Defect Isolation Procedure

This proced ure directs the CSE to make test prints, perfo rm test procedures to identify the cause of a print defect.

8825/8830 Printer

Workstation Checkout Procedure

This procedure is designed to ensure that the printer is correctly set up to run and communicate with other elements. It consists of a series of connection checks, configuration test prints, PING tests, and tests made from a laptop PC.

Status Code Entry Chart

This ta ble prov ides a li st of stat us cod es, a des criptio n of the p roble m, the com ponen ts tha t are affected, RAPs that may resolve the pr oblem, a s well as BSD references and Parts List references.

Message Display Entry Chart

This table contains a list of messages that may be generated by the printer, their cause, clearance procedures , and BSD references.

Maintenance Procedures

The Maintenance Procedures identifies functional checks and cleaning operations that must be performed on every Normal Call. It also identifies those activities that can be performed as needed or as scheduled.

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iii

About this Manual, Organization

Introduction

Callback

This service is performed when the CSE has been called back to correct a problem that was thought to have been recently corrected. The Callback is a short procedure performed on only that subsystem that caused the original service cal

System Check out / Fina l Action

This p rocedure is used to verify that the printer is operating correct ly after a repair, and that the correct steps are taken to close out a service call.

Section 2. - Repair Analysis Procedures (RAPs)

This s ection conta ins t he Repa ir An alysis Proc edures (RAP s) ne cessa ry to r epair the f aults. When using a RAP, always exit the procedure when the fault is fixed. Do not perform the remaining steps.

Section 3. - Image Quality Repair Analysis Procedures (RAPs)

This s ection contai ns th e Rep air An alysis Proced ures (RAPs ) nece ssar y to r epair t he im age quality faults. Refer to "How to Use the Image Defect Definitions" to compare the image defect to the definitions. Once you have determined the definition that best describes the defect, go to the sec tion cont ents page to find the appropr iate RAP. When using a RAP, always exi t the procedure when the fault is fixed. Do not perform the remaining steps.

Section 4. - Repair / Adjustment

This section contains the repair and adjustment procedures for the 8825/8830 printers.

Section 5. - Parts List

This section contains the detailed Parts List for the 8825/8830 printers.

How to Use This Manual

The Service Call Procedures will direct you to the appropriate Section of the Servic e Manual.

You should begin the service call with the Initial Actions/ System Checks Procedure. From there, you wil l be r ef err e d to either Section 2, St at us Ind i c at or R APs, Sec tion 3, Image Qual ity RAPs, or Section 7 BSDs.

If you are sent to Section 3, compare the image defect to the print quality definitions. Once you have determined the definition that best describes the copy defect, go to the section contents. The section contents will direct you to an image quality RAP. The RAP has a list of probable causes and corrective actions. From these RAPs you may be referred to other sections of the manual to make checks, Adjustments, or to replace parts.

When you have made a Repair , always go to the Call Flow Procedure to finish the call.

Section 6. - General Procedures

This se ction contain s Diagnost ic Procedu res, Install ation Proc edures, and G eneral Info rmation, which includes Product Spec ifications for t he 8825/8830 printers.

Section 7. - Wiring Data

This section contains the BSDs.

Introduction

Organization, How to Use This Manual

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8825/8 83 0 P rin te r

Repair Analysis Procedures (RAPs)

A RAP is either a table of faults and possible solutions, or a series of steps designed to lead you to the ca use of a pro blem . In ea ch step , yo u wi ll perfo rm an a ctio n or ob ser ve a n oc currence. For fa ult t ree RAP S, at each step, a stat emen t is m ade tha t ha s a Yes (Y) o r No ( N) answer.

If the answe r is N O, p erform the a ctio n following th e NO . If th e a nsw e r is YES , pro c ee d to th e next step.

When several items are listed, perform them in the order listed.

Proceed through the steps only until the observed problem is isolated and solved. Then eva luate the unit f or prope r performance. I f a f u rther de fe ct is observ ed , g o to th e ap propria te RAP and perform the steps it contains un til the ad ditiona l fault is located and repaired.

Repair / Adjustment Procedures

The repair proc ed ur e s provide de t ai le d steps on how to remov e an d replace com p onents. The adjustment procedures provide detailed steps on how to check and adjust components. Some units hav e bee n m odi fied by v ari ous d esi gn chan ges . Ea ch c hang e or mo dific at ion i s lab el ed with a Tag/ MOD (modification) number. The Tag/ MOD numbers are identified in the Change Tag/ MOD Index in Section 6 of this Service Manual.

When a modification affects how a particular procedure is performed, the procedure or steps are ide ntified with either a W/ Tag/ MOD or a W/ O Tag/ MOD statement. Each procedure or step that is affected by a modification is identified with the statement, W/ Tag/ MOD, followed by the modification number. The W/ in the sta tement in dicates th at this step m ust be performed on units that are assembled with

When the procedure or steps are not affected by a particular modification, they are identified with th e sta teme nt, W/ O Tag/ MOD, fo llowe d by the mo dificat ion numb er. The W/ O in the statement indicates that this step must be performed on units assembled without modification.

that specific modification.

that s pecific

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Introduction

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Introduction ..................................................................................................................... 1-3

Call Flow

Call Flow Procedure........................................................................................................ 1-5

Initial Actions/Systems Checks....................................................................................... 1-5

Print Defect Isolation Procedure ..................................................................................... 1-6

Workstation Checkout Procedure ................................................................................... 1-6

Status Code Entry Chart ................................................................................................. 1-7

Message Disp la y Entr y Char t..... .... .... ... ................ .......................... ................ ................ 1-11

Maintena nce Pro ce du res ... .... .... .... .... .......................... ................ .......................... ......... 1-1 2

Callback .......................................................................................................................... 1-15

System Checkout / Final Action

System Checkout / Final Action ...................................................................................... 1-17

1 Service Call Procedures

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Service Call Proce dure s

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Introduction

The Service Call Procedures are designed to assist the Service Representative to identify printer faults, perform the necessary corrective action and perform the correct Maintenance Procedures. The Service Call Procedures are designed to be used with the Printer Service Manual and is the entry level for all service calls.

• Call Flow Procedure - The Call Flow Procedure is a list of activities to be performed on each service call.

• Initial Actions / System Checks - This procedure is designed to identify and classify the printer problem an d to refer you to the appro priate RAP in order to repair the pro blem. When the problem has been repaired, perform the System Checkout / Final Action.

• Print Defect Isolation Procedure - This procedure directs the CSE to make test prints, perform test procedures to identify the cause of a print defect.

• Workst a tion Ch ecko ut Pro ced ur e - Th is proc ed ure i s des ig ne d t o ensur e that th e pri nt er is correctly set up to run an d communica te with other e lements. It c onsists of a se ries of conne ction che cks, con figurati on test prints, P ING test s, and t ests mad e from a laptop PC.

• Status Code Entry Chart - This table contains a list of Status Codes, th eir related components, the corre s pond ing R AP (Rep air A nal ysis Pr oced ure ), B SD (B loc k Sc hema tic Diagram), Component Code and Parts List reference. The chart is designed to direct you to the appropriate Clearance Procedure. When the Status Code problem has been repaired, refer to the Call Flow Diagram and continue the Service Call.

• Message Display Entry Chart - This table contains a list of messages that may be generated by the printer, their cause, clearance procedures, and BSD references.

• Mainte nanc e Pro ced ures - This ta ble co nt ains a list of m essa ges that may be gener ate d by the p rinter, their cause, clearance pr ocedures, and BSD references.

• Callback - This service is performed when the CSE has been called back to correct a problem that was thought to have been recently corrected. The Callback is a short procedure performed on the subsystem that caused the original service call.

• System Checkout / Final Action - The purpose of this procedure is to record the media feet count and to make a record in the machine l og book of the service activities that were perfor med. Th e Final A ction is des igned to ensur e that t he prin t is tra nsporte d cor rectly and to ensu re t h at im ag e quality is wi th in spe cification.

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1-3

Service Call Proce dure s

Introduction

Service Call Proce dure s

Introduction

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8825/8 83 0 P rin te r

Call Flow Procedure

Procedure

Perform the following:

1. Initial Actions.

There h as be en more t h an 5 custo me r w or k da ys o r 50 0 feet (150 met ers) since t he la st service call. YN

Perform the following:

1. Perform the Subsystem Checks for the subsystem that caused the problem.

2. System Checkout \ Final Action

Perform the following:

1. Mainte na nc e P ro ce dure for all su bs ys tems.

2. System Checkout / Final Action.

Initial Actions/Systems Checks

1. Ask the operator to try to duplicate the pr oblem.

2. Ask the operator to cancel all of the prin t jobs in the print queue.

3. Review the lo gbook for previous service on the system.

4. Check the Recent Fault Log for trends: a. With a Controller - Print out the configuration sheet through the Utilities Menu. The

last 25 faults are listed on the upper-right side of the sheet.

b. Withou t a Controller - Ente r [0391]. The display will scro ll through the er ror codes

two at a time.

5. Analyze the frequenc y of the fault codes and refer to the Status Code Entry Chart to troubleshoot the problem:

a. C or E codes should occur no more frequently than once per 1000 linear feet. b. All Cutt er fau lt s shou ld occ ur no more fre que ntl y tha n on ce per 10 ,00 0 li ne ar fee t.

NOTE: E4-09, Cx-04, and Cx-05 are out-of-media codes and will occur once per 500 linear feet. A lso , 001 an d 002 co de s are po we r on/of f. Qu esti on the ope rator if the fa ul ts are ex ces sive.

6. Record the readings from the media length counter.

NOTE: Perform each of the following steps in sequence, unless directed elsew here.

7. If there is a fault indicator displayed, determine the type of fault.

• If a status code is displayed, go to the Status Code Entry Chart in this Section.

• If there is a message displayed, go to the Message Display Entry Chart in this Sec-

tion

8. If ther e is a print qu alit y problem , go to th e Print Def ect Is olation Proced ure in this Section.

9. If the Printer Control Panel is blank, go to OF-1 Control Panel RAP in Section 2 of this servic e manual.

10. If the Printer Control Panel displays numbers during printer warm up, go to

svc.8830prt.2974 in Section 2 of this service manual.

11. If the customers lights flicker when the machine is turned on, go to OF-3 Fuser Ballast

RAP.

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Service Call Proce dure s

Call Flow Procedure, Initial Actions/Systems

Print Defect Isolatio n Procedure

Procedure

1. Go to Special Tests 0955 i n Sec tion 6 of thi s serv ice ma nual. Selec t opti on 5 (6 00 mm print length on 36 inch wide paper) and make an internal test print.

2. If the defec t i s sti ll pr esen t, go to Print Quality Initialization Procedure in Section 3 of this servic e ma nual.

3. Go to Workstation Checkout Procedure located in this Section.

Workstation Checkout Procedure

Initial Actions

1. Ensure that all connectors are seated correctly at the Controller.

2. If 8825 /8830 DDS c onfigurati on, ensure that t he SCSI cabl e from the Sca nner is con nected to the scanner connector on the Controller.

3. The Conf igura tion Test Print prov ides trou blesho oting in forma tion th at will be use d later. Ensure that the communication parameters are set correctly.

Procedure

NOTE: Do each of the steps in sequence, unless directed otherwise.

1. Ask the customer to print a different file from the workstation. If the file prints OK, then the original file might be corrupt.

2. If the work s t at io n is co nnected t o a netw ork, go to 3.. Otherwise, go to 5..

3. Ask the customer to obtain the IP address of another device on the network. Ask the customer to go to the DOS prompt and to use the PING function to test the connection to the other device. If the PING test is successful, then go to 4.. Otherwise, notify the customer that there seems to be a network problem.

4. Obta in the IP addres s for th e Cont roller from th e Conf iguratio n Test Print. As k the Customer to use the PING function to test the connection to the Controller. if the test is successful, then go to step 5. Otherwise, go to FRU (Field Replaceable Unit) Test in Section 2 of the Controller Servi c e Manual.

5. Connect the laptop computer to the parallel port on the Controller. Open the Document Submiss ion Tool. Inse rt th e te st fil e disk in th e la pt op . Se nd a test file to the Prin te r. if the defect is present, go to FRU (Field Replaceable Unit) Test in Section 2 of the Controller Servic e Manual. O therwise , ask the cus tomer to rel oad the pri nt drivers. If the probl em still ex is ts , t he re co uld be a defect i ve cab le .

Service Call Proce dure s

Print Defect Isolation Proced ur e, Wor kst atio n Che ck-

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Status Code Entry Chart

T able 1 Stat us Code Entry Chart

Status Code

C1-01 C2-01 C3-01

No RAP

C1-04 Media registration sensor

C1-05 C2-05 C3-05

No RAP

C3-06 No RAP

C3-07 No RAP

Position sensor error

The Roll 1, 2, or 3 position sensor did not actuate or deactuate.

error

The media sensor did not actuate or deactuate when feedi ng from roll 1, 2, or 3.

Motion sens or error

Motion was not detected or the media stopped moving when feeding from ro ll 1, 2, or

Roll 2 pos ition sen sor error

8825 with Tag/MOD 90 Media was not detecte d at the Roll 2 position sensor when feeding from roll 3.

Roll 1 position sensor error

Media was not detecte d at the Roll 1 position sensor when feeding from Roll 3.

Description Components BSD

Roll 1 position sensor (Q1) Roll 2 position sensor (Q2) 8825 with Tag/ MOD 90 Roll 3 position sensor (Q3) Main PWB (A3)

NOTE: The se nsors a re interchangeable.

Media registration sensor (A21Q1) Main PWB (A3) Driver PWB Registration Rolls Transport Driver Motor Motor Driver PWB

Roll 1 motion sensor (Q4) Roll 2 motion sensor (Q5) 8825 with Tag/MOD 90 Roll 3 motion sensor (Q6) Main PWB (A3) Driver PWB Motor Driver PWB Media Fe ed Ro lls Media Fe ed Clu tc h Media Feed Drive Motor

NOTE: The sensors and the clutches are interchangeable.

Roll 2 position sensor (Q2) 8825 with Tag/MOD 90 Main PWB (A3)

Roll 1 position sensor (Q1) Main PWB (A3)

RefPLRef

BSD

7.2

7.1

BSD

7.3

1.1A

BSD

7.4

BSD

8.1PL8.2 PL

1.1A PL

8.3

BSD

7.2

7.1

BSD

7.3

1.1A

BSD

7.4

7.2

BSD

7.1

BSD

7.3PL7.1 PL

1.1A

BSD

7.2PL7.1 PL

1.1A

Status Code

C1-09 C2-09 C3-09 No RAP

C1-19 C2-19 C3-19 No RAP

C1-29 C2-29 C3-29 No RAP

C1-39 C2-39 C3-39 No RAP

C1-59 C2-59 C3-59 RAP

C4-24

No RAP

C4-34

No RAP

Table 1 Status Code Entry Char t

Description Components BSD

Firmware error

This is a firmware problem. Press power off (0) then power on (1). If problem persists, replace the firmware.

This is a Firmware prob le m

This is a firmware problem. Press power off (0) then power on (1). If problem persists, replace the firmware.

This is a Firmware prob le m.

This is a firmware problem. Press power off (0) then power on (1). If problem persists, replace the firmware.

This is a Firmware prob le m.

This is a firmware problem. Press power off (0) then power on (1). If problem persists, replace the firmware.

Light reflecting off of a piece of media or from rear of drawer or a baffle.

Regi stration sensor error

The cut sheet does no t reac h the med ia registration sensor in time.

Sheet feed sensor error

The sheet feed sensor deactuated too early while making a print. The operator may have removed the cut sheet media.

Roll 1 position sensor (Q1) Roll 2 position sensor (Q2); 8825 with Tag/ MOD 90 Roll 3 position sensor (Q3) Main PWB (A3)

Media registration sensor (A21Q1) Main PWB (A3) Registration Rolls Transport Drive Motor Transport Motor Driver PWB Cut Sh eet Feed Clut ch / Rolls Driver PWB

Sheet feed sensor (Q2) 8825 with Tag/MOD 90 Main PWB (A3)

RefPLRef

1.1A

BSD

7.2

1.1A

BSD

7.3

7.1

BSD

7.4

BSD

8.1PL8.2 PL

1.1A PL

7.2 PL

8.3

BSD

8.1PL8.4 PL

1.1A

8825/8830 Printer

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Service Call Proce dure s

Status Code Entry Chart

Status Code

C4-49 No RAP

E2-01 No RAP

E2-09 No RAP

E2-11 No RAP

E4-01 No RAP

E4-02 No RAP

E4-03 No RAP

E4-04 No RAP

T able 1 Stat us Code Entry Chart

Description Components BSD

This is a Firmware problem

This is a firmware problem. Press power off (0) then power on (1). If problem persists, r eplace the firmware.

Media registration sensor error

The me dia trail edge jamm ed in the media registration sensor area.

This is a Firmware problem

This is a firmware problem. Press power off (0) then power on (1). If problem persists, r eplace the firmware.

Registration sensor error

The media registration sensor was detected to be actuated when the machine powered up.

Media exit sensor error. The logic detected that the media exit sensor (Q3) was actuated at the wrong time. Indic ating that t he media t rail edge is jammed in the area.

Media exit sensor error

Lead edge of media did not reach the media exit switch in time.

Stripper finger jam switch error

The stripper finger jam switch was actuated during run.

Stacker Full

The Stacker Full Sensor was actua ted during a r un or was detected to be actuated when the machine powered up.

RefPLRef

1.1A

Media registration sensor (A21Q1) Main PWB (A3)

Media exit sensor (Q3) Main PWB (A3) Exit Drive Pulley, Belt, Drive Rolls and Idler Rolls Transport Drive Motor Driver PWB (A2)

Media exit sensor (Q3) Main PWB (A3) Fuser Drive Motor Heat Roll Transfer/Detack Corotron Fabric Guid e

Stripper finger jam switch (A23S1) Main PWB (A3) Stripper Finger Damaged

Stacker Full Sensor PL

BSD

8.1PL8.2 PL

1.1A

BSD

8.1PL8.2 PL

1.1A

BSD

10.3

8.4 PL

1.1A

BSD

8.1

BSD

10.3PL8.4 PL

1.1A PL

9.4 PL

10.1

BSD

10.3PL10.4 PL

1.1A

14.1

Status Code

E4-09 No RAP

E4-11 No RAP

E4-12 No RAP

E4-13 No RAP

E4-14 No RAP

E5-03 No RAP

E5-04 No RAP

E5-05 No RAP

E5-06 No RAP

Table 1 Status Code Entry Char t

Description Components BSD

This is a Firmware prob le m

Press power off (0) then power on (1). If problem persists, replace the firmware.

Media exit senso r error

The media exit sensor was detect ed t o b e ac tuat ed when the machine powered up. This requires the media exit area to be opened, and the media to be removed.

Sheet feed sensor error

The sheet feed sensor was detect ed t o b e ac tuat ed when the machine powered up. This requires the media exit area to be opened, and to be removed.

Stripper finger jam switch error

The stri pper fi nger jam switc h was actuated at power on.

Media buckle sensor err or

The media buckle sensor was detect ed t o b e ac tuat ed when the machine powered up. This requires the media exit area to be opened, and the media to be removed.

Top cover interlock switch error

The top cover was opened during print.

Cutter cover interlock switch er ror

The cutter was opened during print.

Feed shelf interlock switch error

The sheet feed shelf was opened during print.

Front door interlock switch error

The front door was opened during print.

Media exit sensor (A23S1) Main PWB (A3)

Sheet feed sensor (A21Q2) 8825 with Tag/ MOD 90 Main PWB (A3)

Stripper finger jam switch (A23S1) Main PWB (A3)

Media buckle sensor A21Q5) Main PWB (A3) Fabric Guide Position

Top cover interlock switch (S26) Driver PWB (A2)

Cutter cover interlock switch (S1) Driver PWB (A2)

Feed shelf inte rlo c k switch (S29) Driver PWB (A2)

Front door interlock switch (S21) Driver PWB (A2)

RefPLRef

1.1A

BSD

10.3PL8.4 PL

1.1A

BSD

8.1PL8.4 PL

1.1A

BSD

10.3PL10.4 PL

1.1A

BSD

4.1PL8.4 PL

1.1A

BSD

1.3PL14.5 PL

1.1A

BSD

1.3PL7.6 PL

1.1A

BSD

1.2PL14.3 PL

1.1A

BSD

1.3PL14.3 PL

1.1A

Service Call Proce dure s

Status Code Entry Chart

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T able 1 Stat us Code Entry Chart

Status Code

E6-00 F ront door interlock switc h

E6-01 F ront door interlock switc h

E7-01 Communication error

E7-02 No RAP

E9-XX Software shutdown

Fx-xx Refer to the Folder Service

J1-01 No RAP

error

The C button was pressed while a pr int was be ing made in the roll feed mode. An operator induced soft shutdown results in a complete print being ma de. Th e l eft sid e do or must be opened and then closed.

error

The Exit button was pressed while a pr int was be ing made in the roll feed mode. An operator-induced hard shutdown result s in a partial print be ing made. The left side door must be open ed and th en closed.

The IO T is un able to com municate with the Controller. The IOT Off-Line and Media menus will still function, but cannot print from the Controller or network.

Printer message display error

A required message is not available in the language EPROM. Update the language EPR OM.

This error is of unknown cause. Please contact Software en gi ne er i ng .

Manual for all F-codes. Toner sensor error

Out of t oner .

Description Components BSD

RefPLRef

Instruct the customer as to the appropriate time to press “C”

Instruct the customer as to the appropriate time to press “Exit”

Go to E701 RAP i n 8830 Controller Service Manual.

Language EPROM BSD

2.1

Toner sensor (A22Q1) Main PWB (A3)

BSD

9.7PL9.9 PL

1.1A

Table 1 Status Code Entry Char t

Status Code

J2-02 No RAP

LL-00 Communication error

LL-02 Check sum test error

LL-05 No RAP

LL-06 No RAP

LL-07 No RAP

LL-10 No RAP

LL-11 No RAP

Cartridge home sensor error

Toner cartridge could not find the home position.

Applies only to printe rs with a bit mapped user interface (FX).

Both message ROMs have failed the checksum test immed ia tel y after pow er up .

Fuser oil web error

NVM count of web encoder pulses indicates the fuser oil web has reac hed end of lif e.

Fuser oil web error

No encoder pulses are being received from the fuser oil web.

Fuser oil web error

Web Oiler Assembly connector not connected.

Module wrap-a round error

The paper transport assembly or the Xerographic module is disconnected.

Communications error

Failed communications between the Driver PWB (A2) and the Mai n PWB (A3).

Description Components BSD

Cartridge Home Sensor (A22Q2) Main PWB (A3) Cartri dge Drive Mo t o r Cartri dg e D r iv e Gear

Web oiler motor (A23MOT1) Driver PWB (A2) CONTROL EPROMS

Web oiler optical switch (A23S2) Web oiler motor (A23MOT1) Driver PWB (A2)

P/J 4, wiring harness, pins Driver PWB (A2)

NOTE: TAG 3 must be installed for this code. If not, disable the fault detecti on using [10-35

Xerographic module (A23) Paper transport assembly (A21) Driver PWB (A2)

Driver PWB (A2) (fuser drive c ircuit) Driver PWB (A2) (drum drive c ircuit) Main PWB (A3) CAUTION: Fuser must be up to temperature before running motors.

RefPLRef

BSD

9.7PL9.9 PL

1.1A PL

9.10

BSD

10.2PL1.1A PL

9.6

BSD

10.2PL1.1A PL

9.6

BSD

10.2PL10.4 PL

1.1A

BSD

7.5PL1.1A

BSD

4.1

1.1A

BSD

4.3

8825/8830 Printer

01/02

1-9

Service Call Proce dure s

Status Code Entry Chart

Status Code

LL-12 No RAP

LL-21 No RAP

LL-22 No RAP

LL-30 No RAP

LL-41 Fuser error

LL-42 Thermal Control RAP

LL-43 Fuser Over Temperature RAP

LL-44 Fuser Too Hot RAP

Photoreceptor motor stall fault

HVPS Charge error

The charge scorotron fault signal was active for 1.5 seconds.

Transfer / Detack HVPS Charge error

The transfer / detack corotron fault signal was active for 1.5 seconds.

Cutter error

The cutter did not leave or reach the home sensor. Turn power off, then on.

The fuser did not reach 110 within one minute.

Fuser temperature error

The fuser roll temperature is greater than the maximum allowable temperature for more than thirty seconds. Maximum temperature is currently 348

Fuser temperature error

Fuser temperature has exceeded the temperature limit. The FUSER OPEN (L) +26 VDC signal is low.

Fuser temperature error

Fuser tempera tu r e ex ce ed ed 420 PERATURE LIMIT signal exceeds it’s limit.

Description Components BSD

° F (215° C). The TEM-

T able 1 Stat us Code Entry Chart

Drum drive motor (A20MOT3) Driver PWB (A2)

ADJ 8.4 Medi a Tran sp ort

Xerographic HVPS (A25) Driver PWB (A2) Scorotron

Xerographic HVPS (A25) Driver PWB (A2) Transfer/Detack Corotron

Cutter ho m e se ns or (A8Q1) Driver PWB (A2) Cutter Drive Motor

Fuser heat rod (HTR1)

°F

Thermistor assembly (A23RT1) Fuser power relay (K1)Triac (Q1) AC Power module (A1) Driver PWB (A2) Main PWB (A3)

Triac (Q1) AC Power module (A1) Driver PWB (A2)

° F (176° C).

Triac (Q1) AC Power module (A1) Driver PWB (A2) Thermal fuse (A23F1)

Triac (Q1) LVPS (A5) Driver PWB (A2) Main PWB (A3)

RefPLRef

BSD

4.3PL1.1A PL

9.1

BSD

9.1PL1.3 PL

1.1A

BSD

9.8PL1.3 PL

1.1A

BSD

7.5PL1.1A PL

7.8

10.1 PL

10.2 PL

10.4 PL

1.1A

10.1 PL

1.2A PL

1.1A

10.1 PL

1.1A PL

1.2A PL

10.4

10.1

1.2

10.4

10.1

1.1A

Table 1 Status Code Entry Char t

Status Code

LL-41 Fuser temperature error

LL-4F No RAP

LL-50 No RAP

LL-51 No RAP

LL-52 No RAP

LL-53 No RAP

LL-54 No RAP

LL-55 No RAP

LL-56 No RAP

LL-57 No RAP

Fuser was in the warm up mode too long.

Fuser fault

Fuser was expected to be warming but is was not.

Power supply error

26 VDC Bulk power supply failure.

Power On Self T est fault

The internal RAM failed POST.

Power On Self T est fault or Main PWB in stalled withou t

CONTROL EPROMS The external RAM failed POST.

Power On Self T est fault

IOT firmware checksum error.

Power On Self T est fault

An unknown device failed POST.

Power On Self Test LVPS fault

The +10 V FW R voltage was detected to be off when it should have been on.

Power On Self Test ADC/ DAC fault

The ADC/DAC failed POST

Power On Self Test SCC fault

Description Components BSD

RefPLRef

Fuser heat rod (HTR1) Fuser power relay (K1) Triac (Q1) Ballast resistors (R1 & R2) Fuser ballast power relay (K3) Driver PWB (A2) Main PWB (A3)

Fuser power relay (1K1) Fuser ballast power relay (A1K3) Fuser Triac (A1Q1) Fuser he ater (A23H R 1)

LVPS (A5) Driver PWB (A2) Main PWB (A3)

Main PWB (A3) PL

Install the Control EPROM Main PWB (A3)

Main PWB (A3) PL

LVPS BSD

Main PWB (A3) Driver PWB (A2)

Main PWB (A3) PL

10.1 PL

10.2 PL

1.1A PL

1.2A PL

1.3

BSD

10.1PL1.2A PL

10.2

BSD

1.2PL1.1A PL

1.3 PL

1.3

1.1A

1.2PL1.1A

1.1A

Service Call Proce dure s

Status Code Entry Chart

01/02

1-10

8825/8 83 0 P rin te r

Status Code

LL-58 No RAP

LL-60 No RAP

LL-61 No RAP

LL-89 No RAP

LL-90 Overtoned Fault RAP

LL-91 Undertoned Fault RAP

U1-01 No RAP

T able 1 Stat us Code Entry Chart

Description Components BSD

Power On Self T es t

Extra “Return Value” from the Operating System. Reboot (Power off / Power On).

Power On Self Test NVM Checksum fault

Recor d the exis ting NVM values. Ru n diagnos tic [036 0] to reset NV M to the default v alues. Manually restore the required NVM values.

Power O n S elf Test revi sion level fault

Power the printer up in diagnostics and run [0360] to reset NVM to default values.

This is a Firmware problem

This is a firmware problem. Press power off (0) then power on (1). If problem persists, r eplace the firmware.

Overtoned fault

Toner concentration of the develo per material is too high.

Undertoned fault

Toner concentration of the develo per material is too low.

Media counter error

Print counter is disconnected.

Install the Control EPROM Main PWB (A3)

Cartridge drive motor (A22MOT1) Cartridge home sensor (A22Q2) Toner sensor (A22Q1) Main PWB (A3)

Media co un ter Main PWB (A3)

RefPLRef

1.1A

3.1

9.7

1.1A

9.7

9.3

9.9

9.7 PL

9.9 PL

1.1A

BSD

3.1PL1.3 PL

1.1A

Message Display Entry Chart

Table 1 Message Display Entry Chart

MESSAGE DIS-

PLAYED

PRINTER IS WARMING UP (Continuously displayed)

ADJUSTING THE PRINT QUALITY (Continuously disp layed)

PLEASE CLOSE THE MEDIA DRAWER X (Refer to Note)

PLEASE CLOSE THE CUT SHEET FEED SHELF

PLEASE CLOSE THE FRONT DOOR

PLEASE CLOSE THE TOP DOOR

PLEASE CLOSE THE CUTTER DRAWER

NVM FAULT CALL FOR ASSISTANCE

Re-feed Roll 1 Re-feed roll 1

Re-feed Roll 2 Re-feed roll 2

Re-feed Roll 3 Re-feed roll 3

Flashing 1, 2, 3, 4, 5, 6 or 7

UNABLE TO CALIBRATE TONER SENSOR

TONER FAULT CALL FOR ASSISTANCE

CAUSE CLEARANCE PROCEDURE BSD

No fuser heat - - - BSD

Toner dispense problem

Drawer X read switch is open.

Cut sheet feed shelf interlock switch (S29) is open.

Front door interlock switch (S21) is open.

Top cover interlo ck switch (S26) is open.

Cutter cover interlock sw itch (S1) is open.

Corrupted data in NVM.

problem.

problem. Copier failed

power on self-tes t.

The sensor did not calibrate when the code [0921-6] was entered.

Excessive toner sensed problem.

Ref

10.1

- - - BSD

9.3

Refer to the display on the control panel and follow the clearance procedure.

Press power off (0) then power on (1). If problem persist run diagnostic program [0363] or [0360]. If problem persist replace the Control EPROMS.

Re-feed the media. If necessary, press power off (0) then power on (1).

Press power off (0) then power on (1). If problem persists, go to

svc.8830prt.2974.

Press power off (0), then power on (1). If problem persists, go to LL-91 Under-

toned Fault RAP .

Press power off (0), then power on (1). If probl em persists, go to LL-90 Over-

toned Fault RAP .

BSD

7.1

BSD

1.2

BSD

1.2

BSD

1.2

BSD

1.2

BSD

7.2

BSD

7.3

BSD

7.4

BSD

9.7

BSD

9.7

8825/8830 Printer

01/02

1-11

Service Call Proce dure s

Status Code Entry Chart, Message Display Entry

Table 1 Message Display Entry Chart

ALL ROLLS ARE EMPTY

NOTE: Substitute 1, 2, or 3 for X dep ending on which status code is displayed.

Media Registration Sens or failed to sense me di a.

Go to C1-04.

Maintenance Procedures

Table 1 Image Module

INTER

VAL

Nor-

mal

Call

Nor-

mal

Call

Nor-

mal

Call

Requir

TASK RE ASON TASK ENA BLE R

Check, clean, or repair spacing wheels as required.

Check and clean, if required, the scorotron.

Clean the image bar.

Repair or replace the sco rot r on/grid.

Contaminated, dirty or worn spacing wheels or drum ends cause print quality defects.

Contaminated grid, bent or contaminated pins. Worn end blocks, are also causes for scorotron failure, which results in print quality defects.

Contamination causes print quality defects.

Clean or replace spacing wheels and the end surface that the wheels ride on.

WARNING

The scorotron pin arrays are very sharp. Use care when handling the assembly.

If contam inated , rem o v e sc oro t ro n assembly and clean both sides of the grid with a brush. Examine pins and clean with brush Only if contaminated. Cleaning with a cloth can deposit lint that will cause print quality problems.

Clean the image bar with a lint free cloth an d len s cl eaner.

WARNING

The scorotron pin arrays are very sharp. Use care when handling the assembly.

Replace the grid and/or pin array. Perform ADJ 9.2 Elect r osta tic Series.

Service Call Proce dure s

Message Display Entry Chart, Maintenance Proce-

01/02

1-12

INTER

VAL

Table 2 Xerographic Module

TASK REASON TASK ENABLER

8825/8 83 0 P rin te r

Nor-

Clean the xero-

mal

graphic module .

Call

Clean the erase lamp. Inspect the photoreceptor for damage. Inspect components for vellum contamination. Inspect all seals for damage. Inspect the Cleaner Blade for damage.

Nor-

Check and clean

mal

or replace the

Call

Stripper Fingers. Clean the Media Guides.

Nor-

Clean/check the

mal

Fuser Roll fabric

Call

guide. Re pl ace th e Fuser Roll.

Nor-

Check the fuser

mal

roll for lack of oil.

Call

Nor-

Inspect/clean the

mal

thermistor pad

Call

Table 2 Xerographic Module

Contamination can cause print quality problems. Contaminants can travel to the LED bar and scorotrons, which results in prin t quality pro blems. Fused toner on the bottom of the module can cause j ams. Contamination reduces the effectiveness of the lamp to discharge the photore c eptor drum . Contaminants from vellum

- Cleaner failure

- Contaminants to prints. Vellum con taminatio n will contam ina te an d plu g t he cleaner auger at the ends.

Bent stripper fingers may cause feed out jams and heat roll damage. Contaminated or damaged media guides can cause print quality defects.

Smooth or worn fuser ro ll loses ability to drive media. Contaminated fabric guide causes too much resistance to media which results in jams/ deletions/wrinkles.

Too little oil can cause media handling and offsetting print quality problems.

Contamination can cause fuser heat problems.

Clean the toner from the housing and cleaner blade with a vacuum cleaner.

NOTE: Ensure that the vacuum cleaner does not co ntact the edge of the cleaner blade that touches the surface of the photoreceptor drum.

Perform the Photoreceptor Cleaning Enhanceme nt p rocedu re in s ecti on 6. Use cleaning solvent to remove any fused toner from the bottom of the module. R ep lace t he p ho tor ec ep tor if damaged. Clean the erase lamp with a brush or dry lint free clot h. Replace any damaged xerographic module seals.

Replace the damaged or contaminated stripper fingers.

Clean the roll with film remover. Clean the fabric guide with formula A and film remover. Perform diagnostic code 1033 every time the oiler is removed.

Check remaining fuser web life [1034] and adjust the web oi ler rate [1032]. If the fuser roll is dry, refer to BSD

10.2.

Clean the thermistor pad with a brush or dry lint free cloth.

Table 2 Xerographic Module

Check/clean the

Requir

photoreceptor.

Check/clean the

Requir

cleaning blade.

Replace with the

*Note 3

NOTE: 1. Ensure that the vacuum does not conta c t the edge of the cleaner blade that touc hes the surface of the photoreceptor drum.

NOTE: 2. Wh e re p os s i b le , du s t th e d r u m a nd t h e c l ea nin g blade w i t h zi nc s tearate a w ay f rom the xerographic module to prevent the charge scorotron from being contaminated. If the drum and cleaning blade must be dusted while in the xerographic module, remove the charge scoro tron. The zin c stearate will contaminate the charge scorotron and caus e print qual ity defects.

NOTE: 3. Install the complete cleaning blade kit when installing a new photoreceptor.

new photoreceptor or as required.

30K ft.

Replace the fabric

9Km

guide.

30K ft.

Clean the inner

9Km

xerographic module comp onents.

INTER

VAL

Nor-

Clean the lower

mal

paper transports,

Call

turnaround baffle, paper feed rolls.

Nor-

Clean the under

mal

side of the trans-

Call

port.

TASK REASON TASK ENABLER

Contamination/wear, scratches, or chips can generate print quality problems.

Residual image, streaks, drum scuffing can occur if the blade is worn or contaminated.

Jams, de le tions, wrink les. Refer to REP 8.9

If the customer is running a high percentage of vellum, outgassing of the vellum contaminates the cleaner auger and lower baffle surface resulting in poor cleaning and high dirt contamination. plugge d cleaner auger

T able 3 Media T ransport

Contaminates can cause the me di a t o sl ip resul tin g in print qu ality def ec ts .

Reduc e the ai rbo rne contaminants.

Inspect photoreceptor surface for deep scratches, chips or excessive wear. Repl ace photor eceptor if damaged. Apply zinc stearate to the cleaning blade and ph ot ore cep t or d r um. * Not e 2 Clean photoreceptor surface with Xerox Film Remover if contaminated. Apply zinc stear a te when surfa ce is dry.

Vacuum cle an the clea ning blade . *Note 1 Apply zinc stearate to the cleaning blade and ph ot ore cep t or d r um. * Not e 2 Replace the blade if damaged.

Remove the fuser roll and photoreceptor t o enable access. NOTE: Use caution not to touch or

damage cleaning blade or seals.

Vacuum the Xero Mod and A uger and then clea n al l con taminated areas with Film Remover.

Clean the transport with antistatic fluid and a lint free cloth. Clean the feed roller wit h Formul a A.

Va cu um cl ea n, th en wip e do wn wit h a lint free cloth.

8825/8830 Printer

01/02

1-13

Service Call Proce dure s

Maintenance Procedures

Nor-

Clean the transfer

mal

corotron

Call

Nor-

Empty the conden-

mal

sation r eclaim bot -

Call

tle.

25K ft.

Repair or replace

7Km

the transfer corotron.

INTER

VAL

1st

Remove the drive

10K ft.

chain slack.

or 3K

40K ft.

Remove the drive

or 13K

chain slack.

INTER

VAL Nor-

Brush the devel-

mal

oper from the

Call

Developer Seal and lower edge of the Developer Housing back into the Developer Mag Roll and then clean the Seal.

Nor-

Check that the

mal

developer housing

Call

is level.

Nor-

Check the canis-

mal

ter for proper rota-

Call

tion.

Nor-

Check the devel-

mal

oper drive s.

Call

Table 3 Media Transport

Improv e toner tra nsfer to media. Improve media tack.

Prevent the bottle from overflowing.

Contamination causes print quality defects.

Table 4 Media Feed

TASK REASON TASK ENABLER

Feedin g problems . Loosen the feed motor ha rdware to

T able 5 Developer Modu le

TASK REASON TASK ENABLER

Image quality problems can occur.

If the developer is not level, densit y may not be uniform side to side .

If the cani ster i s no t ro tat ing correctly, the copies will be light.

Worn gears will cause the housing to move up or down, which will cause print quality defects.

Remove the transfer corotron. Clean loose toner/debris with a brush. Use only a water-dampened cloth to remove contaminants from the extrusion.

NOTE: Some of the coating may come off onto the cloth.

Empty the bottle into a sink.

Clean (same as the step above).

allow the spring to tension the chain. Tighten the hardware.

Clean as re qu ire d.

Developer material s hould not be uniform from end to end. Check the level of the copier.

Check t h e dry in k di sp ense motor fo r binding. Check that the cartridge is locked i n the driv e hub.

Check the gears fo r worn or brok en teeth; replace the gears, if necessary. Ensure that the drive coupling is engaged.

Table 5 Developer Module

Nor-

Check, clean, or

mal

replace the devel-

Call

oper housing spacin g wheels, as required.

30K ft.

Check the trickle

9Km

tube and toner Y tube for obstruction.

30K ft.

Check the pres-

9Km

sure equalizing tubes.

INTER

VAL

Nor-

mal

Call

INTER

VAL

Nor-

mal

Call

Nor-

mal

Call

INTER

VAL

Nor-

mal

Call

INTER

VAL

Nor-

mal

Call

TASK REASON TASK ENABLER

Clean the covers. Cus tomer satisfaction . Formul a A an d antis tatic f luid on the

TASK REASON TASK ENABLER

Check the cam for lubrication.

Clean the cutter. To ensure a straight,

TASK REASON TASK ENABLER

Clean the media drawer.

TASK REASON TASK ENABLER

Check and replace the Ozone Filter if necessary.

Contaminated or worn spacing wheels will cause print quality defects.

An obstructed Y tube or trickle tube will clog the cleaning/trickle system.

Increased contamination due to poor air flow in the develop er housing.

Table 6 Covers

T able 7 Cut ter

To ensure the correct cutter operation. The cutter will n ot p rovide a stra ight cut.

smooth cut on the lead edge of the media.

T able 8 Media Drawers

Customer satisfaction. Clean the media dust and contamina-

Table 9 Ozone Fil ter

To ensure correct air flow through machine, and to keep heat that is generated to a minimum.

Clean or replace spacing wheels.

Clean as required.

Remove developer hous in g. R em ov e and vacuum tubes, vacuum lower holes for toner.

and cut sheet feed-in shelf.

Place a l ig ht fil m of lubri ca ti on on the cam surface.

Vacuum the medi a dust and co n tam ination from the cutter blade area.

tion from each of the media drawers with a vacuum cleaner.

Check th eOzo ne Fil ter at 40 K print s, clean or replace as required. Replace the Ozone Filter at 120K pr ints.

Service Call Proce dure s

Maintenance Procedures

01/02

1-14

8825/8 83 0 P rin te r

Callback

Procedure

1. Perform the Subsystem Checks for the subsystem that caused the problem.

2. Functional Checks: a. Perform the Initial Actions. b. Check the Recent Faults listing (see Section 6 - under System Information). If any of

the faul ts desc ribe d i n that se ctio n ar e lis ted, tak e the rec omm end ed step s t o cle ar the fault.

c. Replace any part or supply that is past its lif e.

3. Perform th e Final Action. Do Not perform the Maintenance Procedures.

8825/8830 Printer

01/02

1-15

Service Call Proce dure s

01/02

1-16

8825/8 83 0 P rin te r

System Checkout / Final Action

Procedure

Enter diagnostic mode and make three (3) prints of internal test pattern from the controller (if present). If a controller is not present, print [0955-5] from the IOT. Prints are delivered to the

exit tray. YN

Go to the Initial Actions to begin yo ur repair.

Evaluate the prints using Print D efec ts in Section 3. The print quality is acceptable.

Go to the Print Defects in Section 3 an d go to the ap propriate print quality RA P.

Perform the following:

1. Clean the exterior of the printer and provide print samples to the customer.

2. (Figure 1 ): Fill out the Service Call Report form including: Enter th e Prin te r M en u, a nd s cr oll t o Bil lin g M ete rs . E nte r B ill in g Me te r a nd re c ord M et er

A and Meter B readi ngs on the S ervice Call Report form.

Enter the re ading from the Media Counter here

3. Record all activities in the Servic e Log.

4. Record the Print Count Readings on the Ser vice Cal l Report.

5. Give appropriate credit to the Customer.

8825/8830 Printer

Access the Control Panel me nu an d reco rd the Meter A reading

Figure 1 Recording the Print Count Readings

(8830 printer only:) Access the Control Pa nel menu and record the Meter B reading.

01/02

1-17

Service Call Proce dure s

System Checkout / Final Action

Service Call Proce dure s

System Checkout / Final Action

01/02

1-18

8825/8 83 0 P rin te r

Repair Analysis Procedures

C1-04/C2-0 4/ C3-0 4 R AP ...................... ........................... ............... ........................... ..... 2 -3

C1-59/ C2-59/ C3-59 RAP .............................................................................................. 2-4

LL-41/LL-45 Fuser Warm-up Fault RAP ......................................................................... 2-5

LL-42 Thermal Control RAP............................................................................................ 2-6

LL-43 Fuser Over Temperature RAP.............................................................................. 2-7

LL-44 Fuser Too Hot RAP............................................................................................... 2-8

LL-60/LL-61 NVM Fault RAP .......................................................................................... 2-9

LL-90 Overtoned Fault RAP............................................................................................ 2-10

LL-91 Undertoned Fault RAP.......................................................................................... 2-11

Other Faults

OF-1 Control Panel RAP................................................................................................. 2-15

OF-2 Power On Self Test (POST) RAP .......................................................................... 2-15

OF-3 Fuser Ballast RAP.................................................................................................. 2-16

Generic RAPs

Generic Clutc h RA P ............... ............... ................ .......................... ........................... ..... 2-17

Generic Sens or RAP.............. ........................... ........................... ............... .................... 2-1 8

Generic Swit ch RAP....... .... ................ ............... ........................... .......................... ......... 2-1 9

2 Status Indicator RAPs

8825/8830 Printer

01/02

2-1

Status Indicator RAPs

01/02

2-2

8825/8 83 0 P rin te r

C1-04/C2-04/C3-04 RAP

NOTE: Roll x means Roll 1, 2, or 3.

The Media Drive Motor (MOT1, BSD 7.1) was trying to feed the Roll x Media for ward to the registration p os it ion but the Media R eg is tr a ti on Sens o r ( A 21 Q 1, BSD 8.1) fa iled t o se nse th e media.

Initial Actions

• Check the Media Roll (in the Drawer that was in use when the f ault occurred).

Table 1 Media Roll

Roll 1 BSD 7.2 Roll 2 BSD 7.3 Roll 3 BSD 7.4

• Check that the Drive Chai n, PL 7.2, is OK ( BSD 7.1).

Procedure

Enter DIAGNOSTICS (Gen eral Procedures). Enter [0703] (ROLL FEED M OTOR FOR-WARD) and observe the Media Drive Motor. The Media Drive Motor runs.

Check that the Media Drawers are closed. Check the operation of the Drawer Interlock Switched as follows:

Enter [0713] for Drawe r 1 Enter [0714] for Drawe r 2 Enter [0715] for Drawe r 3

Each Drawer Interlock switch functions co rrectly. YN

Go to BSD 7.1 and check the ci rcuit o f the Draw er Inte rlock Switch that does n ot function correctly. Check that the actuating magnet is not missing.

Go to BSD 8.1. Enter [0917 and then enter [1] on the keypad. Observe the Transport Drive Motor (A21MOT1). The Transport Drive Motor (A21MOT1) runs.

Go to BSD 8. 1, NOTE 4, and check the resistances of the windings of the Transport Drive Motor (A21MOT1). The resistances of the windings of the Transport Drive

Motor (A21MOT1) are O K. YN

Replace the Transport Drive Motor (A21MOT1), PL 8.1.

Go to BSD 8.1, NOTE 2, and check the voltages at A24P1. The voltages at A24P1 are

OK. YN

Check all wiring between A2P210 and A24P1. If the wiring is OK, replace the Driver PWB (A2), PL 1.1A.

NOTE: Drive Motor PWBs (A24) and (A7), BSD 7.1, are identical and can be exchanged with each other.

Replace the Drive Motor PWB (A24), PL 7.2.

Go to BSD 8.1. Enter [0803 and check the Media Registration Sensor. The Media Registra-

tion Sensor is OK. YN

Check the circuit of the Media Registration Sensor (A21Q1).

Check for mechanical binding or broken parts in the area of the Registration Drive Rolls and Pinch Rolls.

Go to BSD 7.1, NO TE 2 , an d ch eck th e res ista nc es o f the win ding s of th e Me dia Driv e Motor (MOT1) The resistances of the windings of the Media Drive Motor (MOT1) are

OK. YN

Replace the Medi a Drive Motor (MOT1) , PL 7.2.

Go to BSD 7.1, NO TE 1, and check the voltages at A7P1. The voltages at A7P1 are

OK. YN

Check all wiring between A2P208 and A7P1. If the wiring is OK, replace the Driver PWB (A2), PL 1.1A

NOTE: Drive Motor PWBs (A24), BSD 8.1, and (A7) are identical and can be exchanged with each other.

Replace the Drive Motor PWB (A7), PL 7.2.

8825/8830 Printer

01/02

2-3

Status Indicator RAPs

C1-04/C2-04/C3-04 RAP

C1-59/ C2-59/ C3-59 RAP

NOTE: C1, C2, C3 means Roll 1, 2, or 3.

The Media Drive Motor (MOT1, BSD 7.1) was trying to feed the Roll x Media for ward to the regist rat i on p osit io n bu t the Posi ti on Sens or (Q1, Q2, or Q3 , BSD 7. 2, 7. 3, 7.4) se nse d tha t the media jammed . Th e pro bl em may be caus ed by lig ht ref l ecti ng of f of med ia , the me di a dra wer, or baffles an d returning to the media Position Sens or.

Initial Actions

• Check that the Roll 1, 2, or 3 (the Drawer that was in use when the fault occurred) Position Sensor Q1, Q 2, or Q3 is not blocked by a piece of media.

• Ensure that there are no strips or pieces of media in the area of the Position Sensor Q1, Q2, or Q3.

Table 1 Media Roll

Roll 1 BSD 7.2 Roll 2 BSD 7.3 Roll 3 BSD 7.4

Procedure

Enter DIAGNOSTICS (Gen eral Procedures). Enter [0703] (ROLL FEED M OTOR FOR-WARD) and observe the Media Drive Motor. The Media Drive Motor runs.

Check that the Media Drawers are closed. Check the operation of the Drawer Interlock Switched as follows:

Enter [0713] for Drawe r 1 Enter [0714] for Drawe r 2 Enter [0715] for Drawe r 3

Repair the Interlock Switch as required.

Check th e rea r of th e appro pri ate D rawe r an d the ba ffle s that ar e lo cate d aro und th e open in g of the Positio n Sens or for s hinny o r reflec tive sur faces. If thes e condi tions ex ist co rrect th e problem by painting the surfa c e with flat black paint or use a black mar k er to cover the surface.

Status Indicator RAPs

C1-59/ C2-59/ C3-59 RAP

01/02

2-4

8825/8 83 0 P rin te r

LL-41/LL-45 Fuser Warm-up Fault RAP

NOTE: Go to BSD 10.1 whi le us in g t hi s RA P.

This RAP is used when the Fuser does not warm up when the control logic attempts to increase the heat.

LL-41 is displayed when the Fuser heat does not increase to 110º F (43º C) within one minute.

LL-45 is displayed when the Fuser temperature is greater than 110º F (43 º C) but does not reach the setpoint temperature within the specified time period.

Initial Actions

• Ensure that the following connectors are correctly seated:

1. Thermistor Assembly RT1J5 / A23P5

2. Thermal Fuse A23XF1

3. Xerographic Module A23J2 / A23P2

4. Fuser Heat Rod A23HR1P2 (blue wire)

5. Fuser Heat Rod A23HR1P1 (brown wire)

• Ensure that the correct Fuse r Heat Rod is installed.

• Check the wa ll ou tle t for co rrec t lin e vo lt ag e.

WARNING

Dangerous Voltage

Procedure

NOTE: After ent ering the code [1004], the Fuser Power Re lay, A1K1, and th e Fuser Power LED, (A2CR15 without Tag 25 or A2CR31 with Tag 25) on the Driver PWB, are energized for approximately five minutes.

Enter DIAGNOSTICS (General Procedures). Enter [1004] to test the operation of the Fuser.

After 10 seconds, the Fuser Heat Rod is still on. YN

Switch off t h e pr in te r an d d is c onnect t he po w er c ord. Me as ur e t h e resistance of t he H e at Rod as follows: Disconnect A23P1/A23J1. Connect the meter leads to A23J1-1 and A23J1-3. The resistance is less than 30 Ohms.

Check the wiring between A23J1 and t he Fuser Heat Rod (HR1). The wires have continuity YN

Repair the wires

Check for AC p ower from th e Fuse r Pow er Rela y as fo llows: Recon nect A 23P1/A 23J1 . Set the meter to read AC voltage and connect the meter leads to A1K1-4 and A1K1-8. Cheat the front door interlock. Connect the Power Cord and switch on the printer. Wait 10 seconds. AC power is present.

Set the meter to read 26 VDC and connect the (+) meter lead to A1K1-1 and the (-) meter lead to A1K1-0. Switch off, then switch on, the printer. 26 VDC is present.

Check the Fuser Power Relay On signal from the Driver PWB, A2, as follows: Connect the (+) meter lead to A2J213-1 and the (-) meter lead to A2J213-3.

26 VDC is present. YN

PL 1.1A Replace the Driver PWB, A2.

Check and repair the wiring between the Driver PWB, A1, and the Fuser Power Relay, A1K1.

Replace the Fuser Power Relay, A1K1, PL 1.2A.

Switch off the printer and disconnect the power cord. Check the following wires for continuity.

Table 1

From To Color A1K1-8 A1Q1MT1-A WHT A1Q1MT2-A A23P1-1 BLU A1K1-4 A23P1-3 BLK & BRN

The wires have continuity. YN

Repair the wires

Set the meter to read +2 VDC. Connect the (+) lead to A1Q1 -G (BRN wire) and the (-) lead t o A1Q1-M T1 (WHT w ires). R econnec t the Powe r Cord an d switch on the prin ter. Wait 10 seconds. Set the voltage meter to Peak Hold. The Peak Voltage exceeds 0.9

VDC. YN

Connect the (+) mete r lead to A2P 213-11 and leave the (-) met er lead c onn ected to A1Q1-MTI. Pulses are present.

Replace the Driver PWB, A2, PL 1.1A

Replace the Fuser Heat Rod, HR1 ( PL 10.2)

8825/8830 Printer

01/02

2-5

The machine has TAG 50 (50Hz only) installed. YN

Repair the wi re be t wee n termina l G an d A1Q 1 and A2 P21 3- 11 (wire no . 31)

C D

Status Indicator RAPs

LL-41/LL-45 Fuser Warm-up Fault RAP

A C D

Connect the (+) meter lead to A9P1-2 and leave the (-) meter lead connected to A1Q1-MTI. Pulses are present.

Repair the wires.

Check the wiri ng between the Heat Rod Control PWB (A9) and the Fuser Triac (Q1). If OK, replace the Heat Rod Control PWB.

Switch off the printer and disconnect the power cord. Replace the Fuser Triac, A1Q1, PL

1.2A. Then go to OF-3 Fuser Ballast RAP to check that the ball ast cir cuit is operating cor-

rectly.

LL-42 Thermal Control RAP

NOTE: Go to BSD 10.1 while using this RAP.

This RAP is used to locate certain problems in the thermal control circuitry in the Fuser area.

WARNING

Dangerou s Voltage

Initial Actions

Switch off, then switch on the printer. If the problem still exists, perform the procedure below.

The Thermistor Pad on the Thermistor Pad Assembly touches the Fuser Roll. YN

Replace the Thermistor Pad Assembly, PL 10.4.

The Thermistor Pad is free of contamination. YN

Clean the Thermi stor Pad with a clean c loth.

Check th e wires between th e Fuser Th ermistor, RT1, and the Main PWB, A1, for contin uity.

The wires have continuity. YN

Repair the wires.

Replace the Thermistor Pad Assembly, PL 10.4.

Procedure

Switch off the printer and disconnect the Power Cord. Disconnect the orange wire from the Fuser Triac, A1Q1-G. Reconnect the Power Cord and switch on the printer. Wait 10 seconds.

After 5 seconds, the Fuser Heat Rod is off. YN

Replac e the Fu ser Triac, ATQ1, PL 1.2A. Switch off the printer. Disconnect A23P5 from the Therm isto r Pad As sem bl y J5 . Se t th e met er to re ad 10 0ohm s . Con nec t th e (+ ) me te r lead to J5-1. Connect the (-) meter lead to J5-2.

The resistance is greater than 100 ohms. YN

Replace the Thermistor Pad Assembly, PL 10.4.

Check the wiring between Fuser Thermistor, RT1, and the Main PWB, A2 . The wires have

continuity. YN

Repair the wires.

Replace the Main PWB, A2, PL 1.1A.

Status Indicator RAPs

LL-41/LL-45 Fuser Warm-up Fault RAP, LL-42 Ther-

01/02

2-6

8825/8 83 0 P rin te r

LL-43 Fuser Over Temperature RAP

NOTE: Refer to BSD 10.1 while us ing this RAP.

WARNING

Dangerous Voltage

LL-43 is displayed when the logic detects that there is a problem with the Fuser temperature and an o v ertemperature condition has caused the Thermal Fuse, A2 3F1, to open.

Initial Actions

• Ensure that the following connectors are correctly seated:

1. Driver PWB A2J213 / A2P213

2. Driver PWB A2J201 / A2P201

3. Xerographics Module A23J2 / A23P2

4. Thermistor Pad Assembly J5 / A23P5

• Ensure that both cooling fans are working. If not, go to BSD 1.3 to repair the cooling fans circuit.

• Ensure that all interloc ks are closed.

Procedure

Connect the (+) m eter lead to the Driver PWB A2P201-1 and the (-) meter lead to ground.

There is +26 VDC pres ent. YN

Check continuity through the Overtemperature Fuse, A23F1, as follows:

1. Disconnect the BLU and G RY wires from the fuse.

2. Set the meter to measure continuity.

3. Connect the meter across the fuse terminals.

The fuse has continuity YN

Switch off the printer and disconnect the Power Cord. Replace the Thermal Fuse, A23F1, PL 10.4 . Perform the following steps to determine the cause for the fuse to open:

1. Disconnec t the BLU and WH T wires from the Fuser Tria c, A1Q1.

2. Set the meter to measure 2K ohms. Measure the resistance across the Fuser Triac connections from which the wires were removed. If the resistance is not infinite, replace the Fuser Triac, A1Q1, PL 1.2A.

3. Measure the resistance from each of the Fuser Triac connections from which the wire s were remov ed to ground . If t he re sistan ce i s not i nfin ite, re place the Fuser Triac, A23Q1, PL 1.2A.

Check the BLU a nd GRY wir es b etween t he T h erm al Fuse . A 23F1, an d t he Drive r PWB, A2 for continuity. The wires have c ontinuity.

Repair the wires.

Disconnect A23P5 from the Thermistor Pad Assembly JS. Set the meter to measure 200K ohms. Connect the (+) meter lead to the Thermistor Pad Assembly J5-1 and the (-) meter lead to J5-2. The resistance is less that 200K ohms.

Replace the Thermistor Pad Assembly PL 10.4.

Check the YEL and GRN wires between the Fuser Thermistor and the Main PWB, A1 for continuity. The wires have continuity.

Repair the wires.

Replace t he D riv er PWB, A2 , PL 1.1A. If the problem persists, replace the Main PWB A1,

PL 1.1A.

Connect the (+) meter lea d to the Driver PWB, A2P213-3 and the (-) m eter lead to ground. Enter Diagnostic code [1009] to turn on the Fuser Power Relay, A1K1. The voltage changes

from +26 VD C to less than 1 VDC when the Fuser Power Relay is turned on. YN

Check the BRN and ORN wires between the Fuser Power Relay, A1K1, and the Driver PWB, A2 for contin ui ty. The wires have continuity.

Repair the wires.

Replace t he D riv er PWB, A2 , PL 1.1A. If the problem persists, replace the Main PWB, A1

PL 1.1A.

Replace the Fuser Power Relay, A1K1, PL 1.2A.

Connect the (+) meter lead to the Driver PWB, A2P201-3 and the (-) meter lead to ground. There is +26 VDC present.

Replace the Driver PWB, A2, PL 1.1A.

AAB

8825/8830 Printer

01/02

2-7

Status Indicator RAPs

LL-43 Fuser Over Temperature RAP

LL-44 Fuser Too Hot RAP

NOTE: Refer to BSD 10.1 while using this RAP.

WARNING

Dangerous Voltage

LL-44 is displayed when the Fuser temperature exceeds 420º F (216º C), the maximum allowed temperature.

The stat us code ma y also be displaye d if the Temperature Limit Ther mistor, A23R T2, has a malfunction or is contaminated.

Initial Actions

Switch off the printer and allow the fuser to cool. Switch on the printer. If the problem still exists, perform the following pr ocedure .

Procedure

Check the Fuser Triac, A1 Q1, as follows:

1. Switch off the pri nter and disconnect the Power Cord.

2. Disconnec t the BLU and WH T wires from the Fuser Tria c, A1Q1

3. Set the meter to measure 2K ohms.

4. Measure the resistance across the Fuser Triac connections from which the wires were removed.

The resistance is infinite. YN

Replace the Fus er Triac, A1Q1, PL 1.2A.

Measu re the re sistan ce from each of the Fus er Triac connec tions fr om whic h the wir es we re removed from the ground. Th e resistance is inf inite.

Replace the Fus er Triac, A1Q1, PL 1.2A.

Disconnect A2P201 from the Driver PWB A2J201. Set the meter to measure 5 VDC. Connect the (+) meter lead to the Driver PWB A2J2-9 and the (-) meter lead to A2J2-10. There is +5

VDC present. YN

Replace the Driver PWB, A2, PL 1.1A.

Check the YEL and GRN wires between the Temperature Limit Thermistor and the Driver PWB, A2, f or co ntinuit y an d for a short to ground. The wires are OK.

Repair the wires.

Replace the Thermistor Pad Assembly, PL 10.4.

Status Indicator RAPs

LL-44 Fuser Too Hot RAP

01/02

2-8

8825/8 83 0 P rin te r

LL-60/LL-61 NVM Fault RAP

This RAP is used for NVM (Non-Volatile Memory) problems that are indicated by a status code or a message display. The control panel displays the message NVM Fault Call For A ssistance. LL-60 or LL-61 may also be displayed. The problem may be caused when the NVM data are corrupted or partially corrupted. The contents of the NVM do not agree with the checksum, or the contents of the NVM do not agree with the shadow content s.

LL-60 - Th is status co de indicate s corrup ted data in NVM . Perform steps 1 throug h 4 of the procedure.

LL-61 - T his sta tus c ode i s an i ndic at ion th at an ol der v ersio n of firm ware has been in stal led. Ensure that the newest version of firmware is installed. If the problem persists, perform steps 1 through 4 of the procedure.

Procedure

The purpose of this procedure is to restore the printer to normal operation condition. Go to To

Enter The Diagnostic Mode locate d in Se c ti on 6 whe n pe r fo r mi ng this proced u re.

1. Enter t he f ol lo w in g d iagnost ic c od es an d r e co r d the corre sponding data va lu es di sp layed on the control panel:

Table 1

[02-61] Country Configuration [0360-2] Electronic Billing Meters value [0760] Delay Between Film Prints [0860] Lead Edge Registration value [0862] Cut length value [0903] Image Module Output Light Value [0921-2] Vhigh [0921-3] Illumi na t io n (E x po su r e) va lue [1034] Remaining Oiler Web Life [1060] Fuser Temperature [1062] Fuser Temperature [1063] Fuser Temperature

T able 2

ADJ 8.2 Lead Edge Registration ADJ 8.3 Cut Length ADJ 9.2 Electrostatic Series ADJ 10.1 Fuser Temperature

NOTE: If the values entered are not retained, replace the NVM (PL 1.1A) and perform steps 2- 4 again.

2. Enter [0360-1] for NACO printers or [0360-3] for EO printers to reset the contents of the NVM to the factory default values.

3. Enter [ 0921-6] and then c ompare t he valu es recorde d in step 1 to prev iously rec orded values for this printer. Enter the codes listed in step 1 and change the default values as required.

NOTE: If any va lue reco rded in st ep 1 appe ars to be i ncorrect , use the p reviously recorde d value. If there is no prev iously recorded value, retain the default value.

4. Check/adjust the following:

Table 2

ADJ 8.1 Vertical Ma gn if ic ati on

8825/8830 Printer

01/02

2-9

Status Indicator RAPs

LL-60/LL-61 NVM Fault RAP

LL-90 Overtoned Fault RAP

NOTE: Go to BSD 9.7 while using this RAP.

The status code LL-90 is displayed when the logic detects that the toner concentration is significantly greater than the Control Point v alue.

The Toner Contr ol Syst em is desi gned to m ai ntain the Toner Con cent rat ion w ithi n an acc ept able operating range. The Control Point operating range is from 5.2 VDC to 6.0 VDC. The Toner Sensor continuously senses the Toner Concentration. A change in the Toner Concentration results in a corresponding change of the Sensor signal. As the toner concentration increases, the Toner Sensor signal voltage decreases. The logic monitors the Sensor signal.

LL-90 indicates that the logic detected that the toner concentration increased greater than the allowable limit.

The problem may occur if there is a problem with the toner dispensing or the developer mixing systems.

Initial Actions

• Clean the Pressure Equalizing Tubes with a vacuum cleaner in order to remove toner from inside the tubes. Clean the Augers and Magnetic Roll

• Examine the Developer Housing and check for a large amount of toner in the area of the Toner Dispenser.

• Ensure that the printer is level.

• Ensure that the Toner Cartridge is not damaged and that the seal is secured to the Car-

tridge in the correct location.

• Check that all the connectors between the Toner Sensor, A22Q1, and the Main PWB, A2, are seated correctly.

• (Figure 1): Ensure that the Developer Housing Auger and Drive Gears are not damaged and are installed correctly.

Ensure that the Rear Auger Drive Gear is positioned with the flange as shown.

Ensure that the Developer Housing Drive Gear is positioned with the flange as shown.

Ensure that the Front Auger Drive Gear is captured in position by the Rear Auger Drive Gear Flange and the Developer Housing Drive Gear flange.

Flange

Cartridge Drive Motor removed for clarity

Status Indicator RAPs

LL-90 Overto ned Fault RAP

01/02

2-10

Developer Housin g D riv e Gear

Rear Auger Drive Gear

Front Auger Drive Gear

Figure 1 Developer Housing and Auger Drive Gears

8825/8 83 0 P rin te r

Procedure

With the printer in an LL-90 fault condition, enter diagnostic code [9-22] and then press YES, in order to enable the printer to function with an LL-90 fault condition. Enter the code [0361] in order to exit the diagnostics mode. Run 3 test prints [9-55 Pattern 5]. The LL-90 code is dis-

played as the print is being made. YN

Complete the service call.

Use the last print to check the image d ensity. The ima ge densi ty of th e 1.0 Sol id Squar e in

the center of the Test Pattern [0955-5] is equal to or less than the 1.20 Density Square on the Output Reference SIR 495.1. YN

Perform th e Tone-Dow n P roc e dure [09- 06 . If the prin te r does not t o ne -down, perform th e Image Density Adjustment. Go to ADJ 9.3.

Enter the code [9-21-4] in order to switch on the Main Drive Motor and the T oner Sensor circuit. Connect the (+) meter lead to the Toner Sensor A22Q1P1-2 and the (-) meter lead to A22Q1P1-4. There is +15 VDC pr esent.

heck fo r an open or s hort circu it to ground in the wires c onnected to A22Q1P1-2 and A22Q1P1-4. If the wires are ok, replace the Main PWB, A3, PL 1.1A.

Connect the (+) meter lead to the Ma in PWB A3J303-4 and the (-) meter lead to ground.

There is +5.2 to +6.0 VDC is present. YN

Connect the (+) meter lead to the Toner Sensor A22Q1-1 and the (-) meter lead to ground. There is greater than +0.2 VDC present.

Discon nect Toner Sensor A22 Q1P1 from A22Q1J1 . Connect th e (+) meter lead to the Main PWB A3J303-16 and the (-) meter lead to ground. There is greater than

+0.2 VDC present. YN

Replace the LVPS, A5, PL 1.1APL 1.1A. If the probl em persists, r eplace th e Main PWB, A3,

Check for an open or short circuit to ground in the wires connected to A22Q1-2 and A22Q1 -4. If the wires are OK, replace the Toner Sensor A22Q1, PL 9.9. Run [9-21-6 Toner Sensor Calibration.

LL-91 Undertoned Fault RAP

NOTE: Go to BSD 9.7 while us in g this RAP.

The statu s cod e LL -91 is di spla ye d when th e lo gi c det ect s tha t t he ton er co nc ent ra ti on is sign if icantl y less than the Control Point va lue.

The Toner Control System is designed to maintain the Toner Concentration within an acceptable o perating r ange. Th e Contr ol Point ope rating ra nge is fr om 5.2 to 6 .0 VDC. Th e Toner Sensor continuously senses the Toner Concentration. A change in the Toner Concentration results in a corresponding change of the Sensor signal. As the Toner Concentration decreases, the Toner Sensor signal voltage increases. The logic moni tors the Toner Sensor signal.

LL-91 indicates that the logic detected that the toner concentration decreased greater than the allowable limit.

The problem may occur if there is a problem with the ton er dispensing or the developer m ixing systems.

Initial Actions

• Examin e the Toner Cartr i dge to ensu r e that th e Car tr id ge is no t empt y an d is ins tall e d correctly.

• Check the Cart ridge fo r dam age and e nsure that the s eal is se cure d to the Cartridg e in the correct location.

• (Figure 1 ) Ensure th at the D ev e loper Dri ve Coupling is in go o d co nd ition and is engaged fully.

• (Figure 2) Ensure that the Developer Housing Auger and Drive Gears are not damaged and are installed correctly.

• Check that all the connectors between the Toner Sensor, A22Q1, and the Main PWB, A2, are seated corre c tly.

Procedure

With the printer in an LL-91 fault condition, enter diagnostic code [9-22] and press Yes, in order to enable the pri nte r to fun cti on with an LL- 91 fau lt con di tio n. E nter the code [03 61 ] in ord er to exit the diagnostics mode.

Check for an open or short circuit to ground in the wire connected to A22Q1P1-3. If the wire i s OK, repl ac e the Toner Sens or A22Q 1 , PL 9 .9. Run [ 9- 2 1-6 Toner Sensor C al ibration.

Replace the Mai n PWB, A3, PL 1.1A.

8825/8830 Printer

01/02

2-11

Status Indicator RAPs

LL-90 Overtoned Fault RAP, LL-91 Undertoned

Main Drive Gear

Drum Drive Gear

Go to BSD 4.3, Drum Dr iv e, to r ep ai r the drive circui t .

The LL-91 code is displayed as the prints are being made. YN

Complete the Service Call.

Developer Drive Coupling

Cartri dg e D r iv e Motor

Developer Drive Gears

Use the last print to check the image density. The image density of the 1.0 Solid Square in

the center of the Test Pattern [0955-5] is equal to or less than the 1.20 Density Square on the Output Reference SIR 495.1. YN

Perform the Tone-Up procedure [09-06. If the printer does not tone up, perform the Image Density Adjus tm e nt . Go to ADJ 9.3

NOTE: : If unable to perform ADJ 9.3, replace the Developer and repeat ADJ 9.3.

Enter the code [9-21-4]in order to switch on the Main Drive Motor and the Toner Sensor circuit. Connect the (+) m eter l ead t o the Ma in PW B A3 J30 3-14 and th e (-) met er lea d to A 3J303- 13.

There is between +5.2 and +6.0 VDC pr esent. YN

Connect the (+) meter lead to the Toner Sensor A22Q1P1-1 and the (-) meter lead to ground. There is less than +10 VDC present.

Disconnect Toner Sensor A22Q1P1 from A22Q1J1. Connect the (+) meter lead to the Main PWB A3J303 -16 and the (-) meter lead to ground. There is less than

+10.0 VDC present. YN

Replace the LVPS, A5, PL 1.1A. If the proble m persists, replace the Main PWB, A3, PL 1.1A.

Check for an o pen or sh ort circ uit to ground i n the wi res co nnecte d to A2 2Q1P1- 3 (BRN) and A22Q1P1-4 (YEL). If the wires are OK, replace the Toner Sensor, A22Q1, PL 9.9. Then run [9-21-6] Toner Sensor Calibration.

Check for an open or short ci rcuit to gro und in the wire conne cted to the A22Q1P1-3 (ORN). If the wire is OK, replace the Toner Sensor Calibration.

Figure 1 Location of Developer Drive Coupling

The Developer Housing Auger and Drive Gears are rotating as the prints are being made.

Status Indicator RAPs

LL-91 Undertoned Fault RAP

Replace the Main PWB, A3, PL 1.1A. If the problem persists, enter the code [0926 to reset the NVM.

01/02

2-12

8825/8 83 0 P rin te r

Ensure that the R ear Auger Drive Gear is positioned with the flange as shown.

Ensure that the Developer Housing Drive Gear is positioned with the flange as shown.

Ensure that the Front Auger D rive Gear is captur ed in position by the Rear Aug er Drive Gear Flange and the Developer Housing Drive Gear flange.

Flange

Cartri dge D rive Motor removed for clarity

Developer Housin g D riv e Gear

8825/8830 Printer

Rear Auger Drive Gear

Front A ug er D r iv e Gear

Figure 2 Developer Housing and Auger Drive Gears

01/02

2-13

Status Indicator RAPs

LL-91 Undertoned Fault RAP

Status Indicator RAPs

LL-91 Undertoned Fault RAP

01/02

2-14

8825/8 83 0 P rin te r

OF-1 Control Panel RAP

OF-2 Power On Self Test (POST) RAP

NOTE: Go to BSD 2.1 while using this RAP, unless otherwise directed.

This RAP is used when the Control Panel does not operate, or when the Control Panel operates incorrectly.

Initial Actions

• Make sure that AC power is applied to the machine.

• Ensure that the 26 -condu ctor ribb on cable, connect ed betw een the Ma in PWB A3J 301

and the U s er Interfac e P WB A 32 J 1 (located in the Control Pan el ), is s e ate d f ul ly a t each connector.

Procedure

Table 1 Control Panel Probable Cause / Corrective Action

Control Panel Probable Cause Corrective Action

The Message Display is blank, no characters are displayed.

The Message Display LEDs ar e on but no characters are displ ayed.

The Message Display LEDs ar e on but no characters, random c haracters, or black squa res appear.

There is no +5 VDC to the Main PWB, A3. There is an open circuit in the ribbon cable between the Main PWB A3J301 and the User Interface PWB A32J1. There is an internal fault in the Control Panel or in the Main PWB A3.

There is no +15 VDC to the Main PWB, A3. There is no +5 VDC (Bulk ) to the Main PWB, A3.

There is an open circuit in the ribbon cable between the Main PWB A3J301 and the User Interface PWB A32J1. There is an internal fault in the Control Panel or in the Main PWB A3.

Go to BSD 1.2 to trou bleshoot the +5 VDC power to the Main PWB, A3. Check for continuity in all wires in the ribbon cable. Replace the Control Panel, PL 1.4. If the problem persists, replace the Main PWB, A3, PL 1.1A.

Go to BSD 1.2 to trou bleshoot the +15 VDC power to the Main PWB, A3. Go to BSD 1.2 to trou bleshoot the +5 VDC (Bulk) power to the Main PWB, A3.

Check for continuity in all wires in the ribbon cable. Replace the Control Panel, PL 1.4. If the probl em persists, re place the Main PWB, A3, PL 1.1A.

NOTE: Go to BSD 1.2 and BSD 2.1 while using this RAP.

This RAP is used when the logic detects a fault during the Power On Self-test (POST). The printer does not initialize and th e Control Panel displays a 1, 2, 3, 4, 5, 6, or 7.

Initial Actions

• Ensure that the EPROMs and the NVM are seated fully on the Main PWB, A3.

• Ensure that the 40-conductor ribbon cable, connected between the Driver PWB A2J206

and the Main PWB A3J313, is seated fully at each conne ctor.

• Ensure that the power cable, connected between the Driver PWB A2J207 and the Main PWB A3J312 is seated fully at each connector.

• Ensure that the 26-conductor ribbon cable, connected between the Main PWB A3J301 and the Control Pa nel User Interface PWB A32J1, is seate d fully at each connector .

Procedure

Table 1 Power On Self Test (POST) Probable Cause / Corrective Action

The number that is

Displa yed on the

Control Panel.

1 or 2 There is a fault in the RAM

3 The contents of the Control

4 There is a faul t tn th e An alog -

5 There is a fault in the Main

6 There is a fault in the Digital-

7 There is a fault in the printer

Probable Cause Corrective Action

Replace the Mai n PWB, A3, PL 1.1A.

memory.

EPROMs does n ot ag ree w ith the chec k su m . The Main PWB is defective.

to-Digital Converter or the Digital-to-A na lo g C on ve rter.

PWB, A3.

to-Analog Converter .

port ou tp ut circuit r y.

Replace both Control EPROMs on the Main PWB, A3. Replace the Mai n PWB, A3, PL 1.1A.

Replace the Mai n PWB, A3, PL 1.1A.

Replace the Driver PWB, A2, PL

1.1A.

If the problem persists, replace the Main PWB, A3, PL 1.1A.

Replace the Mai n PWB, A3, PL 1.1A.

8825/8830 Printer

01/02

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Status Indicator RAPs

OF-1 Control Panel RAP, OF-2 Power On Self Test

OF-3 Fuser Ballast RAP

Procedure

The customers lights flicker when the Machin e is switc hed on. YN

The fuser ballast is operating properly.

The machine has TAG 50 (50Hz only) installed. YN

Switch off the printer and disconnect the power co rd. Perform th e following s teps to check t hat the ballast resistor circuit is operating correctly:

1. Disconnect the BRN wire from A1Q1-G.

2. Set the meter to read 60 VAC (USO) or 120 VAC (XR).

3. Connect the (+) meter lead to A1Q1-MT2 (BLU wires).

4. Connect the (-) meter lead to A1Q1-MT1 (WHT wires).

5. Connect the Power Cord and switch on the printer.

At lea st 60 VAC (USO) or 120 VAC (RX ) is presen t. YN

Switch off the printer and disconnect the power cord. Set the meter to read 8 to 21 ohms of resistance. Disconnect the wires on each Ballast Resistor, A1R1 and A1R2R2, before measuring the resista nce. The re sista nc e of ea ch B all ast Resi s-

tor, A1R1 and A1R2, is 7 to 9 ohms (USO) or 19 to 21 ohms (RX) YN

Replace both Ballast Resistors, A1R 1 and A1R2, PL 1.2A.

Check the following Ballast Resistor wires for continuity;

Repair the wires.

Replace the Ballast Relay, A1K3, PL 1.2A.

Replace the Heat Rod Control PWB PL 1.2A.

Table 1 Ballast Resistor Wires

From T o Color A1R1-1 A1K3-8 RED A1R1-2A A1Q1-B BLU A1R2-1 A1K3-4 RED A1R2-2A A1R1-2B BLU

The wires have continuity. YN

Repair the wires.

Set the meter to read +26 VDC. C onnect the (+) meter l ead to the Fuser Ballas t Power Rela y. A1K3-1. Connect th e (-) mete r lead to A1K3-0. Recon nect the Power Cord and switch on the printer. There is +26 VDC present for approximately 5

seconds. YN

Connect the (+) meter lead to A2P213-6. Connect the (-) meter lead to A2P213-7. Reconnect the Power Cord and switch on the printer. There is +26

VDC present for approximately 5 seconds. YN

Replace the Driver PWB, A2, PL 1.1A.

AABBCCD

Status Indicator RAPs

OF-3 Fuser Ballast RAP

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Generic Clutch RAP

Initial Actions

NOTE: This procedure can be used to check any clutch. Due to the generic format of this RAP there w ill be no specific AD J, PL or Di agnostic codes ide ntified .

Procedure

( Figure 1): Enter DIAGNOSTIC S (General Proce dures). Enter code [x xxx to test the Clutch (Refer to appropriate BSD for the specific code). Actuate the Clutch. The Clutch energizes.

Deactuate the clutch. There is +26 VDC at J209-12 (use the actual connector/pin number on the BSD) on the Driver PWB (A2). YN

Check the wir e for an open cir c uit. If the wir es are good, replace the Clutch (PL X.X ).

Actuate the Clutch. The voltage decreased to approximately 0 VDC.

Replace the Mai n PWB (PL X.X).

Check the adjustment of th e Clutch (ADJ X.X). If the ad justment is good , rep lace the Clutch (PL X.X).

The Clutch and its circuit appear to be operating normally. Check the adjustment or alignment of the Clutch.

8825/8830 Printer

Figure 1 Clutch (Generic)

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Status Indicator RAPs

Generic Clutch RAP

Generic Sensor RAP

Initial Actions

NOTE: This procedure can be used to check any sensor. Due to the generic format of this RAP there w ill be no specific AD J, PL or Di agnostic codes ide ntified .

• Ensure that the Sensor is not blocked.

• Clean the Sensor surfaces before using thi s procedure.

Procedure

( Figure 1): Enter DI AGNOST ICS (G eneral Proced ures) . Enter c ode [xx xx to tes t the Se nsor (Refer to appropriate BSD for the specific code). Block and unblock the Sensor. The Display

toggles between [1] and [0]. YN

Block the sensor. There is +5 YN

Check the wire at J1/P1 pin 3 for an open circuit. If the wire is good, replace the main PWB.

± 0.3 VDC at J1 pin 3 of the sensor.

There is +1.4 YN

Check the wire at J1/P1 pin 1 for an open circuit. If the w ire is goo d, replace the Sens or before replacing the main PWB.

Unblock the sens or. There is approximately 0 VDC at J1 pin 3 of the sensor.

Replace the sensor.

Replace the mai n PWB.

The Sens or and it s c ircuit ap p ea r t o b e o pe r at ing norm al ly, chec k t he adjustment or al ig nm ent of the Sensor.

± 0.2 VDC at J1/P1 pin 1 of the sensor.

Figure 1 Sensor (G ener ic )

Status Indicator RAPs

Generic Sensor RAP

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Generic Switch RAP

Initial Actions

NOTE: This procedure can be us ed to che c k any swi tch. Due to the generic format of this RAP there w ill be no specific AD J, PL or Di agnostic codes ide ntified .

Procedure

( Figure 1) : Enter D IAGNOST ICS (Gene ral Proced ures). Enter cod e [xxxx to test the swi tch (Refer to appropriate BSD for the specific code). Actuate the switch. The switch toggles

from H to L or from L to H. YN

The message display indicates LOW all the time. YN

Actuate the switch. The volta ge at J1-1 (use the actual connector /pin number from the appropriate BSD) goes to less than 0.4 VDC. YN

Check the wiring between the switch and the Main PWB (A2). If the wiring is OK, replace the switch.

Replace the Mai n PWB (A2) (PL X.X)

Replace the Switch (PL X.X)

The swit ch and its cir cui t appe ar to be op era ting n orm all y. check the adju st ment or al ignm ent of the switch.

8825/8830 Printer

Figure 1 Switch (Generic)

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Status Indicator RAPs

Generic Switch RAP

Status Indicator RAPs

Generic Switch RAP

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Print Quality

Print Quality Initialization Procedure ............................................................................... 3-3

Print Defects........ .... .... .......................... ........................... ........................... ............... ..... 3-3

Print Qualit y Defi nitio ns.................. .......................... ........................... ........................... . 3-4

Print Quality General Diagnostics ................................................................................... 3-5

Print Qualit y Spe cific a tio ns ........ .... .... .......................... ...................................... ............. 3-5

Damaged Media.............................................................................................................. 3-8

Media Handlin g Prob le m s .............. .... ............... ........................... .......................... ......... 3-8

Print Quality RAPs

PQ 1 Background............................................................................................................ 3-9

PQ 2 Bands..................................................................................................................... 3-9

PQ 3 Bands..................................................................................................................... 3-10

PQ 4 Black Lines............................................................................................................. 3-10

PQ 5 Black Prints............................................................................................................ 3-11

PQ 6 Blank Prints / Partial Image.................................................................................... 3-11

PQ 7 Blurred Image ........................................................................................................ 3-12

PQ 8 Deletions (bands)................................................................................................... 3-12

PQ 9 Deletions (bands)................................................................................................... 3-13

PQ 10 Deletions (in solid and halftone areas)................................................................. 3-13

PQ 11 Deletions (spots).................................................................................................. 3-14

PQ 12 Finger Marks ........................................................................................................ 3-14

PQ 13 Light Image .......................................................................................................... 3-15

PQ 14 Misregistration...................................................................................................... 3-15

PQ 15 Residual Image .................................................................................................... 3-16

PQ 16 Skewed Image ..................................................................................................... 3-16

PQ 17 Smears................................................................................................................. 3-17

PQ 17A Smudge ............................................................................................................. 3-17

PQ 18 Spots.................................................................................................................... 3-18

PQ 19 Uneven Density.................................................................................................... 3-18

PQ 20 Unfused Prints ..................................................................................................... 3-19

PQ 21 Wrinkle................................................................................................................. 3-19

PQ 22 Offsetting.............................................................................................................. 3-20

3 Print Quality

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Print Quality

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Print Quality Initializatio n Procedu re

Prior to any print quality troubleshooting, validate that the problem is in the IOT by entering [955]. Sele ct te st pa tte rn 5. Examine t he te st pr int fo r d ef ects . If d ef ec ts a pp ea r, comple te th e followin g checklist. If the de fects are still pr esent after com pleting the che cklist, refer to th e Image Q uality Defe cts and Class ification information on the follow ing pages to classify an d repair the problem.

Print Defects

Print quality refers to the entire print. Defects can occur anywhere on the print. These defects could be da ma ge d media or pri nt qu al ity def e c ts .

Always eliminate problems that cau s e the dama ged media before at tempting to fix print quality problems. Some damaged media problems could cause print quality problems.

1. Drum life (Refer to Section 1)

2. Ensure that the Charge Scorot ron is not damaged or contaminated.

3. Ensure that the Image Module Roller fully contacts the drum and does not exhibit abnormal wear or contam ination .

4. Refer to ADJ 9.2, Electrostatic Series and check that the following voltages are within specification:

• Charge Scorotron (V High)

• Image Module LED Duty Cycle (V Low)

5. Check that the Toner Concentration (TC) is cali brated correctly [9-21-4]

If the print quality defect is still present, go to the Print Defects in this section.

Compare the print defect to the definitions on this page and the next page. After you have determined the definiti on that be st descri bes the pri nt defect, go to the Section Contents page. The Section Contents page will direct you to a Print Quality P roblem / Cause Table. The Problem / Cause Table lists the probable causes and corrective actions.

The PROBAB LE CAUSES are arranged in ord er of most probable cause to least probable cause or the ease of the check. CORRECTIVE ACTIONS are given for each cause. Read all of the probable causes before taking any corrective action.

1. Start with the first PROBABLE CAUSE and continue through the list until you come to the cause that best applies to the image def ect.

2. Perform the CORRECTIVE ACTION.

3. If the defect has been corrected, go to the Maintenance Activities in the Service Call Procedures in Section 1. If the defect is still present, continue with the other PROBABLE CAUSES.

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Print Quality

Print Quality Initialization Procedure, Print Defects

Print Quality Definitions

The following terms are some of the most commonly used terms that describe image quality problems.

Offsetting

This is th e transfe r of tone r from th e prin t to the hea t roll. So metime s the toner is tra nsfe rred back to the print or cons ec u tiv e pr i nts .

Background

Backg round occurs as dark ness or dirtiness on the non-image areas of the print.

Black Print

This is a print that is entirely black except for the lead edge, trail edge and possibly the left and right edges.

Blank Print

This i s a print en tirely without an image.

Deletions

An area of the image where information has been lost. The areas of deletions could be localized or bands from top to bottom or side to side.

Density

The relative blackness between the image an d non-ima ge areas.

Fuser Fix

This is a m e as ure of how th e toner pa r tic le s ad here to t he me dia as a r e s ul t of the fu s ing p r ocess.

Print Displacement

Part of the image information is being placed elsewhere on the print or it is completely missing. The area of the mis sing information is shar ply defined. This is unlike de letions where the image is not sharply defined or clear.

Print Distortion or Skew

The image is skewed on the media. The image from side to side or lead edge to trail edge is not parallel to the edges of the print. There is also distortion of the image from one side of the copy to the other. These de fects are a resul t of a misa djustm ent of th e media tr anspo rtatio n system components.

Media Damage

This is any physical distortion to the media that is used in making a print. This distortion may includ e folds, wrinkles, etc.

Media Handling

This i s the proc ess of transporting the media from the su pply are a through the xerographic and the fusing subsystems.

Resolution

The uniformity or clarity of fine line detail.

Residual Image

This is an image that is repeated onto the same print or consecutive prints. The image can eithe r be a ghosti ng of the origina l image or a t oner image . The repe ated im age is usual ly spaced 10.375 inches (265 mm) from the original image. This problem can be caused by poor cleani ng of the drum, a drum that is wor n, or offsetting by the Fuser.

Smear

This is any image defect that occurs in the direction that is perpendicular to media feed and caused by a difference in the relative motion between the drum and media.

Spots

These are defects that are 0. 2 inches (5 mm) or smaller in diameter.

Streak

This is any image defect that occurs in the direction of media feed.

Unfused Print

This is a print where the image can ea sily be wiped off the media. The image has not adhered to the media.

Light Image

These are prints where the density is lighter than the specified density for the printer.

Line Darkne ss

This i s the darkn ess and uniformity for a line.

Misregistration

This is when the distance from the lead ed ge of the image to the lead edge of the media is not within specification.

Print Quality

Print Quality Definitions

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Print Quality General Diagnostics

It is important to understand the orientation of prints in order to troubleshoot image quality problems. The following terms will be used when referring to prints made on the printer:

1. Proces s dir e ct i on is in the media feed direc tion.

2. Cross -process direction is in the side-to -side direction. Determ ining the dista nce betwe en defe cts coul d help isolate problems to a sp ecific c ompo-

nent. Defe cts that are 10. 3 75 inc he s ( 26 5 mm ) ap art (le ad edge of de fec t t o le ad edge of nex t defect) in the process direction could be caused by the drum. The circumference of the Drum is 10.375 inches ( 265 mm).

Defects that are 10.375 inches (265 mm) apart (lead edge of defect to lead edge of next defect ) in the pr o ce s s direction could be cau sed by the heat rol l.

NOTE: The Heat Roller and Drum are the same circumference. Perform a hard stop to examine the Heat Roll er or the D rum to isol ate the ca use of the problem.

Print Quality Specifications

Test Patterns

There are nine internal test patterns that can be run from diagnostic mode [9-55]. (refer to Section 6 for details)

Test Pattern 1 is used whil e adjusting lead edge. trail edge and s ide edge er ase.

Test Pattern 2 is used to produce horizontal black and white horizontal/vertical bands and resolution targets.

Test Pattern 3 is used to produce ROGM image targets and 1.25” solid area squa res that ar e

97.5 mm apart.

Test Pa ttern 4 is used to produce a 49 mm wide horizontal blac k band that is 450 mm from the lead edge of the print.

Test P atter n 5 i s use d to p rod uce s olid area s qua res , ROG M im age t arg ets a nd a g rid of thin horizontal and vertical lines.

T est Pattern 6 is used to produce diagonally placed small ROGM targets.

Test Pattern 7 is used to produce diagonal horizontal and vertical lines that are 16.25 mm apart.

Test Pa ttern 8 is used to produce solid blank vertical ba nds that are 93.5 mm wide.

T est Pattern 9 is used to produce various small ROGM patterns.

Solid Area Density (A)

This term refers to the image density of a totally black portion of the print.

8825/8830 Printer

Figure 1 Use a wide roll of media and run test pattern

[9-55- 5]. Select the black squares (A) and use the SIR 495.01 (PN 82P520) reference scale to measure the density.

SPECIFICATION:

Media - All sites between 1.0 and 1.3 Solid Area Density (SAD)

Film - All sites equal to or greater than .85 SAD

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Print Quality General Diagnostics, Print Quality

Print Quality

Background

This term refers to the density of the print in any non-image area.

Use a wide roll of media and run test pattern

[9-55-5]. Exami ne the print using the Backgr ound Reference Scale 302.02.

SPECIFICATION:

All non-image area should be no greater than 3.7 at printer installation and no greater than 5.9 over the life of the developer.

Skips

This te rm means that a p rin t image i s p ar t ially del eted or ap pe ar s s tretched at a rig ht angle to the media feed direction .

Use a wide roll of media and run test pattern

[9-55- 5] . E x am in e the 2.0 LP/mm v er t ic al ba nd lo cated n ea r t h e c en ter o the p rin t fo r s ki ps or smears.

SPECIFICATION:

The 2.0 LP/mm lines should be resolved.

Resolution

This ter m refers t o the de gree to wh ich fine de tails o f a print a re reprod uced, for exampl e, lines.

Figure 1 Use a wide roll of media and run test pattern [9-55-5. Evaluate the resolution targets

(B) at each corner and three central locations for a total of seven targets.

SPECIFICATION:

The vertical and horizontal resolution for all targets should be equal to or greater than 4.0 LP/ mm.

Print Quality

Print Quality Specifications

Figure 1 Test Pattern [9-55-5]

Lead Edge Registration (A)

This is th e deg re e to w hic h th e lea d ed ge of a print im age is wit hi n a s pec ified dis tan ce f rom the lead edge of th e media.

Use a wide roll of media and run 4 prints of test pattern [9-55-7] and use the fourth print. Measure the distance from the lead edge of the media to the first horizontal line at the right side of the print and the center of the print.

SPECIFICATION:

16.25 +/- 2.0 mm

Skew (B)

This is t he degree to which media is fed at an angle to the print image .

Use a wide roll of media and run test pattern

[9-55- 7]. Measure the distance at B (bo th places) 70 blocks apart.

SPECIFICATION:

+/- 0.5% or less

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Linearity of Li nes

Linearity of lines refers to the straightness of the horizontal, vertical and diagonal lines.

Use a wide roll of media and run test pattern

[9-55- 7]. Measure the straightne ss of a 50 block length in all three direct ions.

SPECIFICATION:

1 mm or less

Side Edge Registration (C)

This i s the degree to which the center of the image of a print i s within a specified distance from the center of the media.

Figure 2 Use a wide roll of m edia and run test pattern [9-55-7. Fol d the print in half. At the fold

mark, measure the distance between the fold line and the center line of the image.

SPECIFICATION:

6 mm or less

Magnifi ca t io n ( D1 , D2)

Magnif icatio n refe rs to the rate a t whic h an orig inal im age is enlar ged or r educe d on a p rint. The cha nge in im age len gth is eit her in the medi a feed dir ectio n (ver tical) or t he sid e-to-s ide direction (horizontal).

Measur e the leng th of 50 blo cks (D1) from sid e-t o-si de (ho riz onta l) and o ne bl ock dow n fro m the lead edge.

Figure 2 Test Pattern [9-55-7]

Measure the len gth of 60 blocks in the media feed di rection (vertical) and one block in from the side.

SPECIFICATION:

Horizontal (D1) 812.8 mm +/- 4.06 mm

Vertical (D2) 975.4 mm +/- 4.88 mm

Cut Accuracy

This is the dimension of var iance from a true, horizontal cut.

SPECIFICATION:

+/- 4 mm

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Print Quality

Print Quality Specifications

Damaged Media Media Handling Problems

Introduction

Table 1 Damaged Me dia

Defect probable cause correc tive action

1. Crease Marks

A thin irregular line on the media ca used by stressing the media.

2. Dog Ears

This is a corner of the lead edge of the print that has been bent back.

3. Frayed Side Edge

This is dama ge to t he si des of the print.

4. Wrinkle

This is damage that is probably caused by the fuser subsystem. This is a severe case of creases that runs in the direction of media travel.

5. Cockle

The media has a rough surface like an orange peel. This damage could be caused by the fuser subsystem.

6. Other Damage 6. If there are other defects on

1. Thi s de fe ct c an be ca used by incorrect handling of the media.

2. Curled media caused by a failed or damage d Detack Corotron.

3. Incorrect media side to side registration

Damag e or obst ructi on in the media path Damp media Incorrect fuser pressure Heat roller is damaged or contaminated.

5. Damage or obstruction in the media path Fuser is too ho t. Damp media . Pressure Plates or Fabric Guide damaged / installed incorrectly

1. Ensure that the media is stored correctly and is not damaged when inserted in the printer.

2a. Ensure that TAG 1 2 is installed. 2b. Try using a new roll of media. 2c. Check for an obstruction caused by a detack corotron.

3. Ensure that the media is loaded correctly. Check the media path for an obstruction.

Clear the media path of obstructions Refer to BSD 7.1 and BSD 7.3 to check for correct operation of the Paper heaters. Ensure that the Customer is storing the media correctly. Check the Fabric Guide ( REP

8.9) and the Pres sur e Pla tes ( REP 8.5).

Replace the heat roll ( REP

10.2).

Clear the media path of obstructions. Check Fuser Temperature (

ADJ 10.1)

Refer to BSD 7.1 and BSD 7.3 to check for correct operation of the Paper heaters. Ensure that the Customer is storing the media correctly. Check the Fabric Guide ( REP

8.9) and the Pres sur e Pla tes ( REP 8.5).

the print, go to Media Handling Problems on, following page.

Experience has shown that many media transportation problems have more than one cause and must be handled using a systematic approach. Media transportation problems appear as one of the following symptoms:

• Pre-fuser jams

• Print qu ality defects

• Physic al distortion of media

When these symptoms occur, perform the following checks of the media and printer and perform the correctiv e action s.

T able 1 Media Check

Media Check Corrective Action

1. Check the type of media: a. Bond media less than 20 lb may perform with less reliability than Xerox 20 lb. b. Other brands of media may have different design specifications than Xerox media and may not give acceptable performance in the printer.

2. Check the sto r ag e of me dia: a. Media that is exposed to the environment may have damp areas. b. Media may have curled ends because of incor rec t st or a ge.

Table 2 Printer Check

Printer Check Corrective Action

1. Contaminated or damaged transfer/ detack Corotron.

2. An incor rect elect rostatic va lue can cause jams or deletions.

3. Detack Corotron shield incorrectly installed.

a. Use Xero x-qualified media. b. After all media checks, test with fresh Xerox media.

a. Sugg est kee ping the me dia in the pack age in which the Xerox media is shipped until the media is to be used. b. Sug gest that th e media shou ld be stored correctly. c. Recommend keeping the printer switched on overnight to help eliminate moisture buildup.

1. Clean or replace if necessary ( PL 9.4).

2. Check the following: a. Clean or replace the Corotron as required (

PL 9. 4).

b. Perform GP 1, HVPS Checkout Procedure.

3. Check for correct installation

Print Quality

Damage d Media, Media Handling Problems

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PQ 1 Background PQ 2 Bands

Table 1 Background Symptom / Check

Symptom / check

Contamination of the blank area by toner particles on the print

Probable Cause Corrective Action

1. An incorrect electrostatic value

2. Developer Bias incorrect. 2A. Perform GP 1 HVPS

3. Toner concentration too high.

4. Erase Lam p operatio n. 4. Re fer to BSD 9.6 and

5. Contaminated charge scorotron

6. Defective Cleaner Blade 6. Replace the Cleaner Blade

7. Web O il s y ste m not op er ating correctly.

8. Contaminated or defective drum.

1A. Perform Electrostatic Series ( ADJ 9.2). 1B. Perform GP 1 HVPS Checkout Procedure. 1C. Clean/Replace/Repair the coro t rons.

Checkout Procedure. 2B. Ensure that TAG 19 is installed.

3. Perform Image Density (

ADJ 9.3).

check for correct operation of the Erase Lamp.

5, Clean or replace if necessary ( PL 9.3).

( REP 9.4).

7. Refer to BSD 10.2 and check Web Oil system for correct operation.

8. Replace the drum ( REP

9.3).

Symptom/ checks

Bands are 1 mm or more w ide and are in the media feed directi on. High de nsit y bands are called black lines.

Table 1 Bands Symp tom / Check

Probable Cause Corrective Action

1. Contaminated charge scorotron

2. Defect ive Cleaner Blade 2. Replace the Cleaner Blade

3. Contaminated magnetic roll.

4. Incorrect Electrostatic value.

5. Toner cloud from the Developer Module contaminating the Drum and corotrons.

6. T/DT Corotron contaminated.

7. Contaminated or defective drum.

8. Image Module LEDs operating in co rr ec tl y.

9. LED Bar without Tag 28 incorr ectly connected to Main PWB.

10. Toner buildup on Magnetic Roll.

1. Clean / replace screen / pins ( REP 9.8).

( REP 9.4).

3. Check for foreign objects on the mag roll.

4A. Ensure that TAG 19 is installed. 4B. Perform Electrostatic Series ( ADJ 9.2). 4C. Perform GP 1 HVPS Checkout Procedure. 4D. Clean / replace / repair the corotrons.

5A. Ensure that the Air Pressure Tubes are clean ( REP

9.18).

5B. Check f or tone r buil dup on the lowe r edge of the Developer Hou si ng .

6. Check / clean / repair

7. Replace the drum ( REP

9.3).

8. Enter [9- 21 -5 an d chec k for correct operation. (Refer to

BSD 6.1, BSD 6. 2 and check

for correct electrical connections to/from the Receiver PWB and the LED Image Bar).

9. Connect to J307A.

10. Go to Technical Services Bulletin (TSB 98116) for toner removal procedure.

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Print Quality

PQ 1, PQ 2

PQ 3 Bands PQ 4 Black Lines

Sympto m/ check

Bands are 1 mm o r more and are perpendicular to the media feed direction. High densit y bands are called black lines.

T able 1 Bands Symptom / Check

Probable Cause Corrective Action

1. Defective or intermittent Charge Scorotron.

2. Defe ctiv e Trans fer / Det ack Corotron.

3. Poor cleaning 3. Replace the Cleaner Blade

4. Def ectiv e or co ntam inated Drum.

1. Check / clean / replace the connections to the Charge Scorotron ( PL 9.3).

2A. Check / replace the Transfer / Deta ck Corotr on. (

REP 9.9).

2B. Ensure th at the Corotron is inst alle d in t he cor rect posi tion.

( REP 9.4).

4. Determine and fix the cause of the damage to the drum. Replace the Drum (

REP 9.3).

T able 1 Black Lines Symptom / Check

Symptom/ check

Black lines appear in the direction of media feed.

Probable Cause Corrective Action

1. Developer Bias and Transfer Corotr on volt age se t incorrectly

2. Contaminated, damaged or disconnected Charge Scorotron

3. Poor cleaning 3. Replace the Cleaner Blade

4. The surface of the heat roll is damaged.

5. The drum surface is contamin ate d or da ma ged.

6. The fuser temperature is too high .

7. Contaminated or damaged mag roll.

8. Defective Transfer/Detack Corotron.

1. Ensure that TAG 19 is installed.

2. Clean /replace or check the connections to the charge scoro tron ( PL 9.3).

( REP 9.4).

4. Determine and fix the cause of the damage to the heat roll. Replace the heat roll ( REP 10.2).

5. Determine and fix the cause of the damage to the drum. Replace the Drum (

REP 9.3).

6. Adjust the Fuser temperature ( ADJ 10.1)

7. Check for foreign objects on the mag roll.

8. Check / repl ac e the Transfer / Detack Corotron. ( REP

9.1).

Print Quality

PQ 3, PQ 4

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PQ 5 Black Prints PQ 6 Blank Prints / Partial Image

T able 1 Black Prints Symptom / Check

Sympto m/ check

The pri nt is totally black w ith no image.

Probable Cause Corrective Action

1. Defective Charge Scorotron

2. Charge control circuit/ defective Harness

1. Clean or replace the screen/pins ( REP 9.8).

2. Perform GP 1 HVPS Checkout Procedure.

Table 1 Blank Prints / Partial Image Symptom / Check

Symptom/ check

No image or a partial image is produced when making a print.

Probable Cause Corrective Action

1. Developer Housing 1A. Ensure that the Devel-

2. Transfer Corotron 2A. Check the Transfer

3. Defective HVPS 3. Perform GP 1, HVPS

4. Image Module LEDs inoperative

5. No drum drive / defective drum.

6. PJ 330 (Tag 28) or 307A (with out Tag 28) is not correctly seated.

oper Housing Module drive gears are engaged and the developer housing is turning. 1B. Ensure that the gear lock is released from the Developer Housing Drive Gear.

Corotron for damage / contamination. 2B. Perform GP 1, HVPS Checkout Procedure.

Checkout procedure. 4A. Enter [9-21-5 and check

for correct operation. (Refer to BSD 6.1, BSD 6.2 and check for correct electrical connections to/from the Receiver PWB and the LED Image Bar.) 4B. Ensure that all connectors are seated and voltages are correct to the LED, 5VDC, RS422, Signal Harness, Receiver PWB.

5. Refer to BSD 4.3 and check for correct drum drive. Replace the drum ( REP 9.3).

6. Reseat the connector.

8825/8830 Printer

01/02

3-11

Print Quality

PQ 5, PQ 6

PQ 7 Blurred Image PQ 8 Deletions (bands)

T able 1 Blurred Image Symptom / C heck

Sympto m/ check

The image is not clear or sharp.

Probable Cause Corrective Action

1. Defective/contaminated Image Module.

2. Contamination on Transfer/ Detack Corotron

3. Defective drive gear 3. Check the following drive

4. Defective registration roller 4. Replace as required ( PL

5. Media transport 5. Check the Media Transport

6. D efecti ve buckle control 6 . Repl ace the buckl e swi tch

1A. Ensure the spacing rollers and drum ends are not contaminated/defective. 1B. Clean the LED Array with a lint-free cloth.

2A. Clean or replace as required. 2B. Perform GP 1, HVPS Checkout Procedure.

gears for damage: a. drum drive gear b. deve loper drive gear c. cleaner drive gear

8.2).

gap ( ADJ 8.4).

( PL 8.4).

Table 1 Deletions (bands) Symptom / Check

Symptom/ check

Deletion bands or very low image de ns i ty in t he print feed direction.

Probable Cause Corrective Action

1. Damp media 1A. Refer to BSD 7.1 and

2. Corotrons 2A. Clean / replace or repair

3. Defective HVPS 3. Perform GP 1, HVPS

4. Developer Housing 4A. Ensure that the Devel-

5. Defective or contaminated LED Image Bar.

6. Contaminated Erase Lamp.

7. M edia transpo rt 7. Ensure th at the gap ( ADJ

8. Heat Roll 8. Check for surface damage.

9. Defective drum 9. Replace the drum ( REP

BSD 7.3 to check f or correct

operation of the Paper heaters. 1B. Ensure that the Customer is storing the media correctly.

the T/DT corotrons ( REP

9.9).

Checkout Procedure.

oper Housing is latched securely. 4B. Check the mag roll for foreign mate rial or cont amin ation. Ensure that there is an even coating of developer material on the mag roll.

5. Check / clean the LED Image Bar [ 9- 21-5. ( PL 9.3)

6. Clean with a lint free cloth.

8.4) is set correctly.

( PL 10.2)

9.3).

Print Quality

PQ 7, PQ 8

01/02

3-12

8825/8 83 0 P rin te r

PQ 9 Deletions (bands) PQ 10 Deletions (in solid and halftone areas)

Table 1 Deletions (bands) Symptom / Check

Sympto m/ check

Deletion bands or very low image density perpendicular to the print feed direction.

Probable Cause Corrective Action

1. Damp media 1A. Refer to BSD 7.1 and

2. Incorrect Corotron operation.

4. Defe c tiv e drum or n o dru m drive.

5. Magnetic roll 5A. Ensure that the housing

6. Image Module Roller not contac ting drum

7. Media Transport. 7. Ensure that the Media

BSD 7.3 to check for correct

operation of the Paper heaters. 1B. Ensure tha t the Customer is storing the media correctly.

2A. Check / Clean or replace the T/DT corotrons as required ( PL 9.4). 2B. Perform GP 1 HVPS Checkout Procedure.

4A. Check for correct operation of the drive system. 4B. Re place t he dru m ( REP

9.3).

is latched securely. 5B. Check the mag roll for damag e or bi nd ing.

6. Check/clean/replace as required ( PL 9.3).

Transport gap ( ADJ 8.4) is set correctly.

Table 1 Deletions (in solid and halftone areas) Symptom / Check

Symptom/ check

Bands of deletion in the solid or halftone areas in the print feed direction.

Probable Cause Corrective Action

1. Damp media 1A. Refer to BSD 7.1 and

2. Exposure 2A. Clean the Image Bar.

3. Incorrect Corotron operation

4. Magnetic roll 4. Check the mag roll for

5. The surface of the heat roll is damaged.

6. Media Transport. 6. Ensure that the Media

BSD 7.3 to check f or correct

operation of the Paper heaters. 1B. Ensure that the Customer is storing the media correctly.

Check / cl ea n the A ir P ress ur e Tubes ( REP 9.18). 2B. Enter [9-21-5 and check for correct operation. (Refer to BSD 6.1, BSD 6.2 and check for correct electrical connections to/from the Receiver PWB and the LED Image Bar) .

3. Perform GP 1, HVPS Checkout Procedure.

damage or binding.

5. Determine and fix the cause of the damage to the heat roll. Replace the heat roll ( REP 10.2).

Transport gap ( ADJ 8.4) is set correctly.

8825/8830 Printer

01/02

3-13

Print Quality

PQ 9, PQ 10

PQ 11 Deletions (spots) PQ 12 Finger Marks

Table 1 Deletions (spots) Symptom / Check

Sympto m/ check

Localized areas of deletion in the sol id or halftone ar eas in the print f e ed dir ec ti on .

Probable Cause Corrective Action

1. Damp media 1A. Refer to BSD 7.1 and

2. T/DT Corotrons 2. Perform GP 1, HVPS

3. Develo per Housin g 3A. Ensure that the hou sing

4. Insuffic ient toner r esulting in developer bead carryover.

5. The surface of t he he at r o ll is dama ged.

6. Defective drum 6. Replace the drum ( REP

7. Media transport 7. Check for correct gap (

8. The Fa bric Guide is contaminated, wrinkled or incorrectly tensioned.

BSD 7.3 to check for correct

operation of the Paper heaters. 1B. Ensure tha t the Customer is storing the media correctly.

Checkout Procedure.

is latched securely. 3B. Check the mag roll for damag e or bi nd ing.

4A. Perform Electrostatic Series ( ADJ 9.2). 4B. Perform Image Density (

ADJ 9.3).

5. Determine and fix the cause of the damage to the heat roll. Replace the heat roll ( REP 10.2)

9.3)

ADJ 8.4).

8. Check/replace the Fabric Guide ( PL 10.2).

T able 1 Finger Marks Symptom / Ch eck

Symptom/ check

Toner marks on the lead edge or trail edge of the print.

Probable Cause Corrective Action

1. Defective or dirty transfer/ detack Coro tro n

2. Cleaner Seal 2. Check / clean as required.

3. Web Oiler 3. Check / replace ( REP

4. Turnaround Baffle 4. Ensure that the baffle is

5. Heat Roll 5. Check / replace ( REP

6. Fabric Guide 6. Check / replace ( REP 8.9)

1A. Clean or replace the Corotron wire ( PL 9.4). 1B. Perform GP 1, HVPS Checkout Procedure.

( PL 9.5A)

10.9)

free of contamination ( PL

8.2).

10.2)

Print Quality

PQ 11, PQ 12

01/02

3-14

8825/8 83 0 P rin te r

PQ 13 Light Image PQ 14 Misregistration

Table 1 Light Ima ge Sym p to m / Check

Sympto m/ check

Image area of a print has low density.

Probable Cause Corrective Action

1. Damp media 1A. Refer to BSD 7.1 and

BSD 7.3 to check for correct

operation of the Paper heaters. 1B. Ensure tha t the Customer is storing the media correctly.

2. Incorrect Image Module

LED duty cycle

3. Incorrect Corotron opera-

tion

4. Incorrect Image Density

adjustment

5. Defective drum ground. 5. Ensure that the drum is cor-

6. Defective drum. 6. Replace the drum ( REP

7. Media Transport 7. Ensure that the Media

8. Developer Housing 8. Ensure the housing is

2. Perform Electrostatic Series ( ADJ 9.2).

3. Perform GP 1, HVPS Checkout Procedure.

4A. Perform Image Density (

ADJ 9.3).

4B. Replace the sensor ( PL

9.9).

rectly grounded.

9.3).

Transport gap ( ADJ 8.4) is set correctly.

latch ed securel y.

T able 1 Misregistration Symptom / Check

Symptom/ check

The regis tration of the im age on the prints is incorrect from top to bottom or side to side.

Probable Cause Corrective Action

1. Incorrect registration adjustment

2. Damaged or worn components in the media feeding area

3. Defective registration sensor

4. Incorrect registration roller nip

5. Incorrectly loaded media 5. Instruct the operator on

1. Adjust Lead Edge Registration ( ADJ 8.2).

2. Check the components for damage or wear.

3. Refer to BSD 8.1 and check the operation of the registration sensor. Replace the sensor if required ( REP

8.8).

4. Clean or replace the registration r ol ler ( PL 8.2).

loading the media correctly .

8825/8830 Printer

01/02

3-15

Print Quality

PQ 13, PQ 14

PQ 15 Residual Image PQ 16 Skewed Image

Table 1 Residual Image Symptom / Check

Sympto m/ check

This is an image that is repeat ed on the sam e pri nt o r consecutive prints. The image can either be a ghosting of the original image or a toner image. The repeated image is usually spaced 10.38 inches (265 mm) from the origin al im ag e.

Perform Panic Stop / Image on Drum procedure (Section

6), and e xamine th e drum fo r the defec t.

Probable Cause Corrective Action

1. The Cleaner Blade m akes

poor contact with dr u m .

2. Defective erase lamp 2. Refer to BSD 9.6 and

3. Contaminated drum 3. Replace the drum ( REP

1. Replace the Cleaner Blade ( REP 9.4).

check the erase lamp. Replace the lamp if necessary ( PL 9.5A).

9.3).

Table 1 Skewed Im ag e Symptom / Ch ec k

Symptom/ check

The image is skewed to one side on the print because th e media is ske wed.

Probable Cause Corrective Action

1. Media is not loaded correctly.

2. Media Transport. 2. Ensure that the Media

3. Defective or contaminated rollers in the media feed area

4. Incorrect registration roller nip

5. Obstruction in media path 5. Check media path.

1. Load the media correctly and instruct the operator on loading the media correctly .

Transport gap ( ADJ 8.4) is set correctly.

3. Check the r oll ers a nd other components in the media feed area.

4. Clean or replace the registration r ol ler ( PL 8.2).

Print Quality

PQ 15, PQ 16

01/02

3-16

8825/8 83 0 P rin te r

PQ 17 Smears PQ 17A Smudge

Sympto m/ check

Areas of the image on the print are blurred. This occurs at the image transfer area and is caused by a difference of speed between the drum and the media.

Table 1 Smears Symptom / Check

Location of Smear Probable Cause Corrective Action

20 - 25 mm from the Lead Edge of the print

40 - 50 mm from the Lead Edge of the print

106 - 126 mm from the Lead Edge of the print

150 - 170 mm from the Lead Edge of the print

140 - 160 mm from the Trail Edge of the print

66 - 86 mm from the Trail Edge of the print (Register Roll Exit Smear)

Random smears Media Transport Ensure that the

Transfer/Detack Shield incorrectly installed.

Fabric Guide worn, contaminated or incorrectly installed.

1. Worn (smooth) Heat Roll ( PL 10.2)

2. Worn Contaminated Fabric Guide ( PL 10.3)

3. Pressure Plate A installed incorrectly or deformed ( PL

10.3).

Pressure Plate B installed incorrectly or deformed.

Cutter Check for loose

Buckle Switch Enter [8-2 and

Check / replace (

PL 9.4)

Check / replace (

REP 8.9).

Check / replace (

REP 10.2)

Check / replace (

REP 8.9)

3. Check / rep lace ( REP 8.5)

Check / replace (

REP 8.5)

Cutter Drive Pulley, Shim / re place ( PL

7.8)

check for correct operation ( PL 8.4)

Media Transport gap ( ADJ 8.4) is set correctly.

Symptom/ check

A smudge is a displacement of the toner image on the drum or the media.

Perform GP 2, Image on Drum to determine if the Smudge occurs on the media or the drum.

Vellum Smud ge is a spec ial defect tha t exhibits ma rginal fusing fix. Toner can chip off of the media and horizontal lines a re broken (image displacement).

T able 1 Smudge Symptom / Check

Location of Smudge

Media Heat Roll Check for a worn

Media Fabric Guide Check for a worn /

Media Excessive media

Media Detack Corotr o n Check for contami-

Media Buckle Switch Ch eck the Buck le

Combination of Vellum beam strength and low Heat Roll drive force. (The media is flexible enough that it buckles between Pressure Plates A and B. The toner then melts and partially sticks to the Heat Roll. As the media enters the Pressure Pla te B, it flatt ens and the im age is displaced in front of it’s correct posi tion. The toner can also become a clump on the media and easily chip off of the media.)

Drum Mechanical interfer-

Drum Buildup of devel-

Probable Cau se Corr ec tiv e Actio n

(smooth) Heat Roll. Replace ( REP

10.2)

contaminated Fabric Guide. ( REP

8.9)

curl (smudge appears 100 mm from lead or trail edge)

ence with the image on the drum

oper ma ter i al on t he lower extrusion of the dev elop er ho using rubbing the developed image on the drum.

Ask the customer to replace the media.

nation or signs of arcing. Clean / replace ( PL 9. 4)

Switch for correct operatio n ( PL 8.4)

Replace the Fa bric Guid e ( REP 8.9) and the Heat Roll (

REP 10.2).

Check for interference.

Push excess developer material back into the housing.

8825/8830 Printer

01/02

3-17

Print Quality

PQ 17, PQ 17A

PQ 18 Spots PQ 19 Uneven Density

Table 1 Spots Symptom / Ch e ck

Sympto m/ check

Circular black spots on the print.

Perform Panic Stop/Image on Drum procedure (Section 6), and examine the drum for the defect.

Repetitive spots 2. Contaminated heat roll 2. Clean or replace the heat

Repetitive spots 3. Contaminated fuser ther-

Random spots 4. Contaminated Web Oiler 4A. Check / replace ( REP

Random spots 5. Defective Lower Cleaning

Random spots 6. Charge scorotron 6. Clean or replace the

Probable Cause Corrective Action

1. Defective, damaged or con-

taminated drum

mistor

Seal

1. If the drum is damaged, determine and f ix the cause of the damage to the drum. Replace the drum ( REP 9.3).

roll ( REP 10.2).

3. Clean the thermistor ( PL

10.4).

10.9)

4B. Check / adjust oil dispense r ate [10-32].

5. Check / replace ( PL 9.10).

scorotron ( REP 9.8).

Table 1 Uneven De ns it y Sym p t o m / Chec k

Symptom/ check

Density and line thickness vary across the print.

Probable Cause Corrective Action

1. Incorrect Corotron operation

2. Contaminated LED Image Bar

3. Machine level 3. Check the level of the

4. Developer mag brush not contac ting the d rum evenly.

5. Defective drum 5. Clean or replace the drum (

1. Perform GP 1, HVPS Checkout Procedure.

2. Check / clean the Image Bar. Check / clean the Air Pressure Tubes ( PL 9.9).

machine. (See Installation

Procedure in Section 6.

4A. Clea n drum en ds and th e Spacer Rolls on the Developer Hou si ng ( PL 9.10). 4B. E nsure that th e housing is latched securely.

REP 9.3).

Print Quality

PQ 18, PQ 19

01/02

3-18

8825/8 83 0 P rin te r

PQ 20 Unfused Prints PQ 21 Wrinkle

Table 1 Unfused Prints Symptom / Check

Sympto m/ check

Characters and image are easily rubbed off a print .

Probable Cause Corrective Action

1. Damp media 1A. Refer to BSD 7.1 and

BSD 7.3 to check for correct

operation of the Paper heaters. 1B. Ensure tha t the Customer is storing the media correctly.

2. Incorrect fuser temperature 2. Adjust the fuser temperature ( ADJ 10.1).

3. Incorrect fuser pressur e 3. Check pressure plates for damage or deformation ( REP

8.5).

4. Defective heat roll 4. Replace the Heat Roll (

REP 10.2)

5. Fabric Guide. 5. Ensure Fabric Guide is installed correctly ( REP 8.9).

Symptom/ check

This is damage that is probably caused by the fuser subsystem. This is a seve re case of creases that runs in the direction of media travel.

Table 1 Wrinkle Sym pt o m / Ch ec k

Probable Cause Corrective Action

1. Damp media 1A. Refer to BSD 7.1 and

BSD 7.3 to check f or correct

operation of the Paper heaters. 1B. Ensure that the Customer is storing the media correctly.

2. Damaged or contaminated

pinch rolls

3. Damaged or contaminated

heat roll

4. Incorrect fuser contact

pressure

5. Incorrect fuser temperatur e 5. Adjust Fuser Temperature (

6. Registration Rolls mis-

aligned.

2. Clea n / repla ce the pinc h rolls ( REP 7.3).

3. Clean / replace the Heat Roll ( REP 10.2).

4. Check the Pressure Plates ( REP 8.5) and Fabric Guide (

REP 8.9) for damage.

ADJ 10.1).

6. Replace the rolls as required ( PL 8.2).

8825/8830 Printer

01/02

3-19

Print Quality

PQ 20, PQ 21

PQ 22 Offsetting

Sympto m/ check

Offsetting is the result of toner adhering to the Fuser Heat Roll and transferring to subsequent prints.

Tab le 1 Offsetting Symptom / Check

Probable Cause Corrective Action

1. There is ins ufficient fus er oil on the Heat Roll.

2. The fuser temperature is out of specific ation.

3. The Fabric Guide is not contacting the Fuser Heat Roll uniformly.

4. Media is damp. 4A. Ensure that the media is

5. Damage d or contamin ated heat roll

1A. Check/replace the Web Oiler ( REP 10.7). 1B. Check/adjust oil dispense rate [10-32].

2. Check Fuser Temperature ( ADJ 10.1).

3. Check / replace the Fabric Guide ( REP 8.9) and Pressure Plates ( REP 8.5).

stored co rrectly. 4B. Refer to BSD 7.1 and

BSD 7.3 to check for correct

operation of the paper heaters.

5. Clean or replace the Heat Roll ( REP 10.2).

Print Quality

PQ 22

01/02

3-20

8825/8 83 0 P rin te r

Repairs/Adjustments

Repairs Electrical

REP 3.1 Main PWB. .... ... ................ .......................... ................ ............... ........................ 4-3

REP 3.2 High Voltage Power Supply.............................................................................. 4-7

RFC

REP 7.1 Media Supply Drawer ....................................................................................... 4-8

REP 7.2 Rewind Gear and Rewind Internal Gear........................................................... 4-9

REP 7.3 Roll Feed Pinc h Roll s .......... ... .... ............... ........................... ............... ............. 4-10

REP 7.4 Roll Feed Drive Rolls ........................................................................................ 4-11

REP 7.5 Feed Clutch ...................................................................................................... 4-12

REP 7.6 Rewind Clutch................................................................................................... 4-13

REP 7.7 Motion Sensor................................................................................................... 4-14

REP 7.9 Roll Drive Moto r ........... .... .... .......................... ........................... ............... ......... 4-1 5

REP 7.10A Lower Media Roll Heater.............................................................................. 4-16

REP 7.10B Upper Media Roll Heater.............................................................................. 4-18

REP 7.11 Encoder Disk ......... .... .... .... ... ................ ............... ........................... ............... . 4-18

Paper Transportation

REP 8.1 Media Transport Assembly............................................................................... 4-20

REP 8.2 Media Exit Switch ............................................................................................. 4-23

REP 8.3 Buckle Switch ................................................................................................... 4-24

REP 8.4 Cut Sheet Media Feed Clutch - 8830 and 8825 with Tag/MOD 90 .................. 4-25

REP 8.5 Pressure Pla te s ........... .... .... ... ................ ............... ........................... ............... . 4-26

REP 8.6 Sheet Drive Roll - 8830 and 8825 with Tag/MOD 90........................................ 4-28

REP 8.7 Sheet Pinch Rolls - 8830 and 8825 with Tag/MOD 90 ..................................... 4-29

REP 8.8 Media Registration Sensor ............................................................................... 4-30

REP 8.9 Fabric Guide ..................................................................................................... 4-31

REP 8.10 Media Tra nspo rt Dr iv e Motor ............ ........................... ............... .................... 4-3 2

REP 8.11 Sheet Feed Switch - 8830 and 8825 with Tag/MOD 90 ................................. 4-34

REP 8.12 Registra tio n Pin ch Roll s..... ... .... .... .... ............... ........................... ............... ..... 4-34

REP 8.13 Media Feed Drive Belt .................. ........................... ............... ........................ 4-37

REP 8.15 Cutter Home Sen s or ............. .... ............... ........................... ............... ............. 4-39

REP 8.16 Exit Roll ... ............... ........................... ............... ........................... ............... ..... 4-40

REP 8.17 Registra tio n Dr ive R oll .......... .... .... .... .... ............... ........................... ................ 4-41

Xerographics

REP 9.1 Xerog rap hic Mo dule... .... ............... ........................... ............... .......................... 4 -43

REP 9.2 Drum Assembly................................................................................................. 4-46

REP 9.3 Drum ................................................................................................................. 4-49

REP 9.4 Cleaner Bla de Kit................... ........................... ............... ........................... ...... 4-50

REP 9.5 Develop er Mo d ule............................. ........................... ............... ...................... 4-54

REP 9.6 Cartridge Drive Motor........................................................................................ 4-58

REP 9.7 Develop er Ma te ria l..... .... .... .... .... .......................... ........................... ............... ... 4 -59

REP 9.8 Scorotron Pin Kit............................................................................................... 4-66

REP 9.9 Transfer / Detack Corotron ............................................................................... 4-68

REP 9.11 Toner Sensor.................................................................................................. 4-69

REP 9.12 Toner Cartridge Home Sensor........................................................................ 4-70

REP 9.13 Sump Shield.................................................................................................... 4-72

REP 9.14 Cartridge Drive Plate....................................................................................... 4-74

REP 9.17 Photoreceptor Seal ......................................................................................... 4-78

REP 9.18 Air Pressure Tubes ......................................................................................... 4-79

REP 9.19 Roller Kit ......................................................................................................... 4-81

REP 9.20 Image Module................................................................................................. 4-81

Fuser

REP 10.1 Heat Rod......................................................................................................... 4-88

REP 10.2 Heat Roll......................................................................................................... 4-92

REP 10.3 Fuser Triac...................................................................................................... 4-92

REP 10.7 Web Oiler Assembly ....................................................................................... 4-93

REP 10.8 Stripper Fingers .............................................................................................. 4-93

REP 10.9 Web Oiler........................................................................................................ 4-94

Adjustments

ADJ 3.2 Country Configuration........................................................................................ 4-97

ADJ 8.1 Vertical Magnification ........................................................................................ 4-97

ADJ 8.2 Lead Edge Registration..................................................................................... 4-99

ADJ 8.3 Cut Length......................................................................................................... 4-100

ADJ 8.4 Media Transport ................................................................................................ 4-101

ADJ 9.2 Electrostatic Series............................................................................................ 4-103

ADJ 9.3 Image Density.................................................................................................... 4-111

ADJ 9.6 Augers ......... .... ............... ........................... ........................... ............... .............. 4-112

ADJ 9.5 Toner Car tri dg e Home Sen s or ... ... ........................... ............... .......................... 4-113

ADJ 10.1 Fuse r Tem per at ure (NVM) ... ........................... .......................... ................ ...... 4-1 15

ADJ 10.2 Fuse r Tem per at ure (with Prob e) . .... ........................... ............... ...................... 4-116

ADJ 10.3 Fuse r Tem per at ure (with Tap e )....... .... .... ............... ........................... .............. 4-118

8825/8830 Printer

01/02

4-1

Repairs and Adjustments

01/02

4-2

8825/8 83 0 P rin te r

REP 3.1 Main PWB

Parts List on PL 1.1A

WARNING

Switch off the Controller and the Printer Main Power S witches. Disconnect the Printer Power Cord.

CAUTION

Electrostatic Discharge Damage (ESD) may occur. Use ESD procedures and Antistatic Wrist Strap to avoid damage to PWBs or components.

Removal

1. Check the Printer Tag Matrix to see if Tag 28 is installed. This information will be needed later in this procedure.

2. (Figure 1): Prepare to remove the Controller.

Remove 2 screws from the Printer Right Lower Cover, and tilt the cover back slightly.

Lift out the Controller and set it on the floor.

A3 p307 B

8825/8830 Printer

A1P3

Disconnect connectors A3P 307B and A1P3.

Figure 1 Removing the Controller

3. Attach a Static Wrist Strap between your wrist and the unpainted metal chassis of the Controller.

01/02

4-3

Repairs and Adjustments

REP 3.1

4. (Figure 2): Disco nn e ct the 10 conn ec to rs from the Prin ter Ma in PWB.

Disconnect Image Bar connector

NOTE: Position the Pin 1 Locating Dot as shown.

Disconnect connectors (8)

Figure 2 Ground Connector location on Main PWB

5. Pull the 8 plastic fasteners outward and remove the Printer Main PWB.

6. (Figure 3): Remove the NVM integrated circuit from the existing Main PWB.

Pin 1 locating dot

Disconn e ct G r ou nd Co nn ec to r

NVM Int egrated Circ uit

Repairs and Adjustments

REP 3.1

Figure 3 NVM Integra ted Circ uit

01/02

4-4

8825/8 83 0 P rin te r

7. (Figure 4): Install the existing NVM integrated circuit into the socket on the new Main PWB.

NOTE: Position the Pin 1 locating dot as shown.

Pin 1 loca tin g dot

Figure 4 Installing the NVM Integrated Circuit on the new Main PWB

8. Install the new Main PWB over the 8 plastic fasteners. (Press down each plastic fastener to secure the Main PWB.)

8825/8830 Printer

01/02

4-5

NVM Int egrated Circ uit

Repairs and Adjustments

REP 3.1

9. (Figure 5): C on ne ct th e co nn ec t o rs :

Connect th e conn ec to rs ( 8)

With Tag 28: Connect Image Bar Connector to J330

Without Tag 28: Connec t Im ag e Bar Connector to J307A

Connect th e ground connector

• If the firmware version IS the current version, switch off the printer and continue on with this procedure.

13. Connect Connectors A3P307B and A1P3.

14. Reinstall the Contr oller.

15. While holding down the 0 key on the Printer Control Panel, switch on the printer and the controller. Continue to hold down the key until two beeps are heard.

16. Enter the diagnostic code Chain 09 Test 00, and select Plot 5. A test print should be generated.

17. Enter the diagnostic code Chain 03 Test 00 to leave the Diagnostic Mode and resume normal operati on.

18. Mark Tag/MOD 27 on the Printer Tag Matrix.

Figure 5 Connecting P307A to new Main PWB

10. Connect the remaining connectors and the ground connector to the Main PWB.

11. Check the Xerox BBS to determine the current version of software to be installed on the Main PWB.

12. Check th e versio n of the firmwa re tha t is curr ently lo aded on to the n ewly ins talled M ain PWB by performing the following:

a. Connect the Printer Power Cord. b. Hold down the 0 (zero) button on the Printer Control Panel and switch on the Printer.

Contin ue to hold dow n the 0 but ton u ntil t he Co nt rol P anel has e mitte d t wo bee ps ;. The printer is now in the Diagnostic Mode.

c. Obser v e the Print er Control Panel Display during the pow er-up sequence:

• If the fir mware version IS NOT the cu rrent versi on, go to GP 6 Downloading Firmware From a Laptop.

Repairs and Adjustments

REP 3.1

01/02

4-6

8825/8 83 0 P rin te r

REP 3.2 High Voltage Power Supply

Parts List on PL 1.3

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal

1. Loosen the screws and open the Rear Door.

2. (Figure 1): R em o ve the H igh Voltage Pow er Sup ply.

Replacement

1. If a new Hig h Voltage Pow er Supply is being ins talled, per form the E lectrosta tic Serie s (ADJ 9.2).

Pull the HVPS off the pins

Disconnect J30

Disconnect the Grid wire

Disconnect the Charge Scorotron wire

Disconne ct the T ransfe r Corotron wire (small connector)

Disconnect the Detack Corotron wire (larg e co nn ec t o r)

8825/8830 Printer

Remove th e thre e screws (7 mm hex head)

01/02

4-7

Disconnect A25P1

Figure 1 Removing the High Voltage Power Supply

Repairs and Adjustments

REP 3.2

REP 7.1 Media Supply Drawer

Parts List on PL 7.1

3. (Fi g ure 2): Remove the Media Supply Drawer.

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

NOTE: All thre e R ol l S up pl y D ra w er A s se m bli es ar e re m ov ed the sam e wa y. The 8825 comes with Media Supply Drawer 1 or 2. The customer can order it with 2 drawers or have Drawer 2 retrofitted on site. (Drawer 2 is TAG 90.)

Removal

1. Open the Media Supply D rawer that is to be removed.

2. (Figure 1): Remove the Cover.

Remove the Media Roll

Remove the screws (one each side)

Remo ve the sc r e w s ( on e at each end)

Remove the Media Supply Drawer

Remove the Cover

Repairs and Adjustments

REP 7.1

Loosen the screws (one ea ch side)

Figure 1 Removing the Cover

01/02

4-8

Figure 2 Removing the Media Supply Drawer

8825/8 83 0 P rin te r

REP 7.2 Rewind Gear and Rewind Internal Gear

Parts List on PL 7.3

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

NOTE: All three Rewind Gears and Rewind Internal Gear Assemblies are removed the same way.

Removal

1. Pull out the Media Sup pl y Drawer.

2. Remove the roll of media.

3. (Figure 1): Remove the Rewind Gear and the Rewind Internal Gear.

Remove the E-ring

Remove the Rewind Gear

8825/8830 Printer

01/02

4-9

Remove the Rewind Internal Ge a r

Figure 1 Removing the Rewind Gears

Remove the E-ring

Repairs and Adjustments

REP 7.2

REP 7.3 Roll Feed Pinch Rolls

Parts List on PL 7.5

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

NOTE: All three Roll Feed Pinch Roll Assemblies are removed the same way.

Removal

1. Open the Media Supply Drawer and remove the Media Roll.

2. (Figure 1): Remove the Roll Feed Pinch Rol ls.

Remove the springs (two each Pinch Roll)

Remov e the Pi nc h Rolls

Remove t he E-rings and the shafts

Repairs and Adjustments

REP 7.3

01/02

4-10

Figure 1 Removing the Roll Feed Pinch Rolls

8825/8 83 0 P rin te r

REP 7.4 Roll Feed Drive Rolls

Parts List on PL 7.1

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

NOTE: All three Roll Feed Drive Roll assemblies are r emoved the same way.

Removal

1. Remove the appropriate Media Supply Drawer (REP 7.1).

Remove the bearing

Remove the Ering

2. Remove the Feed Clutch (REP 7.5).

3. Remove the Toner Waste Contain er.

4. (Fi g ure 1): Remove the Roll Feed Drive Rolls.

Remove the bearing

Remove the E-Ring

8825/8830 Printer

Figure 1 Removing the Roll Feed Drive Rolls

01/02

4-11

Remove the Drive Rolls

Repairs and Adjustments

REP 7.4

REP 7.5 Feed Clutch

Parts List on PL 7.2

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal

1. Loosen the screws and open the Rear Door.

2. (Fi g ure 1): Remove the Feed Clu tch.

Remove the Feed Clutch

Remove th e chain

Move the Motor Brack et to relieve the tension on the chain

Loosen the screws (2)

Disconnect the connector

Remove the E-Ring

Remove the sprocket

Repairs and Adjustments

REP 7.5

Figure 1 Removing the Feed Clutch

01/02

4-12

8825/8 83 0 P rin te r

REP 7.6 Rewind Clutch

Parts List on PL 7.2

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal

1. Loosen the screws and open the Rear Door.

Remove the Rewind Clutch

Remove the chain

2. (Fi g ure 1): Remove the Rewind Clutch.

Disconnect the connector

Remove the E-ring

Move the Motor Bracket to relieve the tension on the chain

Loosen t he screws (2)

8825/8830 Printer

Figure 1 Removing the Rewind Clutch

01/02

4-13

Remove the sprocket

Remove the E-ring

Repairs and Adjustments

REP 7.6

REP 7.7 Motion Senso r

Parts List on PL 7.2

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal

1. Loosen the screws and open the Rear Door.

2. Remove the Rewind Clutch (REP 7.6).

3. (Figure 1): R em o ve th e Mo tion Sens or.

Remove the Motion Sensor

Disconnect the connector

Press the Motion Sensor tabs outwa rd through the slots

Remove the Rewind Housing

Replacement

1. Reinstall the Motio n Sensor and the Rewi nd Housin g.

2. (Fi g ure 2): Reinstall the Encoder Disk.

Ensue th at the s lo t i n the encoder Disk aligns with the pin in the sha ft

Reinstall the Encoder Disk

Align the open sl ot in the Enco der Disk with the op ening the housi ng

Figure 2 Reinstalling the Encoder Disk

Repairs and Adjustments

REP 7.7

Remove the screws (3)

Remove the Encoder Disk

Figure 1 Removing the Motion Sensor

01/02

4-14

8825/8 83 0 P rin te r

REP 7.9 Roll Drive Motor

Parts List on PL 7.2

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal

1. Loosen the screws and open the Rear Door.

2. (Fi g ure 1): Remove the Roll Drive Motor Assembly.

Remove the Roll Drive Motor Assembly

Remove the screws (2)

Disconnect P/J 2

3. (Figure 2): Remove the bracket from the Roll Drive Motor.

8825/8830 Printer

Remove the spring

Loosen the screws

Figure 1 Removing the Roll Drive Assembly

Move the br acke t a nd di sc on ne ct t he ch ain from the drive spr ocket

01/02

4-15

Repairs and Adjustments

REP 7.9

Remove th e bracket from the mo tor

Remove the screws (4)

Figure 2 Removing the Roll Drive Motor Bracket

REP 7.10A Lower Media Roll Heater

Parts List on PL 7.2

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal

1. Lo osen the screws and open the Rear Door.

Repairs and Adjustments

REP 7.9, REP 7.10A

01/02

4-16

8825/8 83 0 P rin te r

2. (Figure 1): R em o ve the Lower Media Roll He at er.

8825/8830 Printer

Remove the screw

Disconnect the conn ec t o r

Figure 1 Removing the Lower Me dia Roll Heater

Remove the Lower Media Roll Heater

01/02

4-17

Repairs and Adjustments

REP 7.10A

REP 7.10B Upper Media Roll Heater

Parts List on PL 7.2

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal

1. Remove Media Supply Drawer 1 (REP 7.1).

CAUTION

Be sure to s upp ort t he Me dia R oll Hea ter/ Gua rd wi th you r ha nd wh ile remo ving the mou nting screws in the next step.

2. (Fi g ure 1): Remove the Upper Me dia Roll Heater.

Upper Media Roll Heater and Guard

Disconnect the connector

REP 7.11 Encoder Disk

Repairs and Adjustments

REP 7.10B, REP 7.11

Remove the screws (2) and lift out the Upper Media Roll Heater and Guard

Slide the Media Roll Heater out from Heater Guard

Figure 1 Removing the Upper Media Roll Heater

01/02

4-18

8825/8 83 0 P rin te r

Parts List on PL 7.2

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal

1. Loosen the screws and open the Rear Door.

2. Remove the Rewind Clutch (REP 7.6).

3. (Figure 1): Remove the Encoder Disk.

2. (Fi g ure 2): Reinstall the Encoder Disk.

Align the open sl ot in the Encoder Disk with the opening in the housing

Figure 2 Reinstalling the Encoder Disk

Ensure that the slot in the Encoder Disk aligns with the pi n in the shaft

Reinstall the Encoder Disk

Remove t he Encoder

Figure 1 Removing the Encoder Disk

Replacement

1. Reinstall the Motion Sensor and the Rewind Housing.

8825/8830 Printer

01/02

4-19

Repairs and Adjustments

REP 7.11

REP 8.1 Media Transport Assembly

Parts List on PL 8.1

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8 830 configuratio n exactly.

Removal

1. L atch the Xerographic Module at the Service Position (REP 9.2).

2. Open the Cutter Drawer.

3. (Figure 1): Disconnect the connectors at the rear of the printer.

Disconnect the Transfer and the Detack Corotron leads

Disconnect the tube

Figure 2 Disconnecting the Moisture Collection Tube

Disconnect A21P1

Figure 1 Disconnecting the Connectors

4. (Figure 2): Disconnect the Moisture Collection Tube.

Repairs and Adjustments

REP 8.1

01/02

4-20

8825/8 83 0 P rin te r

5. (Figure 3): R em o ve th e Me di a Tran sp ort Assem bly.

Remove the Media Transport Assembly

Disconnect the Latch Arms from the Transport (Both sides)

Move the Medi a Trans port pin out of the l ocatin g hole and onto the ramp

Ensure that the Moisture Collection Tube is out of the hole in the frame

Pull the pin and hold it out of the Transport

Loosen the screw and rotate the bracket downward

Figure 3 Removing the Media Transport As sembly

Replacement

1. If a new Media Transport Assembly is being installed, perform the Media Tr ansport to Drum Spacing (ADJ 8.4).

2. Open the Cutter Drawer.

8825/8830 Printer

01/02

4-21

Ensure that the pin is free of the bushing, then move the Right Side of the Media Transport towards you

Repairs and Adjustments

REP 8.1

3. (Figure 4): Reinstal l the Medi a Transport Assembly.

Reconnect the Corotron Leads and Con nector A21 P 1

Place the pin on the ramp

Move the pin into the locating hole

Route th e Dr ai n H os e and reconnect it

Install the Turnaround Baffle under the Developer Assembly Shelf (both ends)

Rotate and loc k the bracket

Pull and hold the pin

Move the Transport in, aligning the pin with the bushing, and release the pin

Repairs and Adjustments

REP 8.1

Figure 4 Rein st a lling the Med i a Transp or t A ss em b ly

01/02

4-22

8825/8 83 0 P rin te r

REP 8.2 Media Exit Switch

Parts List on PL 8.4

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal

1. L atch the Xerographic Module at the Service Position (REP 9.2).

2. Remove the Media Transport Assembly (REP 8.1).

3. Remove the Fabric Guide (REP 8.9).

4. (Figure 1): Remo ve the Front Piv ot Assem bly.

5. Turn the Front Pivot Assembly over and remove the Media Exit Switch. a. Disconnect the Switch Assembly Connector Q3. b. Remove the screw and the Stacker Support. c. Remove the Media Exit Switch from the bracket.

Front Pivot Assembly

Disconnect the connector from the clutch

8825/8830 Printer

Remove the Front Pivot Assembly

01/02

4-23

Loosen the screws ( both sides)

Remove the screws (both sides)

Figure 1 Removing the Front Pivot Assembly

Repairs and Adjustments

REP 8.2

REP 8.3 Buckle Switch

Parts List on PL 8.4

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal

1. L atch the Xerographic Module at the Service Position (REP 9.2).

2. Remove the Media Transport Assembly (REP 8.1).

3. Remove the Fabric Guide (REP 8.9).

4. Remove the Pressure Plates (REP 8.5).

5. (Figure 1): Remo ve the Buck le Switch. a. Remove the screw. b. Carefully pull the B uckle Switch Assembly until the connector can be disconnected. c. Disconnect the connector. d. Remove the Buckle Switch from the bracket.

Screw

Buckle S witch

Repairs and Adjustments

REP 8.3

01/02

4-24

Buckle Switch Assembly

Figure 1 Removing the Buckle Switch

8825/8 83 0 P rin te r

REP 8.4 Cut S hee t M edia Fee d C lu tch - 8830 and 8825 with Tag/MOD 90

Parts List on PL 8.1

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal

1. L atch the Xerographic Module at the Service Position (REP 9.2).

2. Remove the Media Transport Assembly (REP 8.1).

3. (Figure 1): Remove the Cut Sheet Media Feed Clutch.

Remove the screw and the bracket

Pull the clutc h off the shaft

Disconnect the connector from the clutch

Remove the E-ring

8825/8830 Printer

01/02

4-25

Figure 1 Remo vi ng the Cut She et Me dia Feed Cl utch

Repairs and Adjustments

REP 8.4

REP 8.5 Pressure Plates

Parts List on PL 10.3

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8 830 configuratio n exactly.

Removal

1. L atch the Xerographic Module at the Service Position (REP 9.2).

2. Remove the Media Transport Assembly (REP 8.1).

3. Remove the Fabric Guide (REP 8.9).

CAUTION

Be sure to push the Buckle Switch Actuator down while starting to remove the Upper Pressure Plate in order to prevent damage to the actuator.

4. (Figure 1): Remove the Upper and Lower Pressure Plates.

Push the Buckle Switch Actuator down (n ot shown)

Remove the Upper Pressure Plate

Repairs and Adjustments

REP 8.5

01/02

4-26

Remove the Lower Pressure Plate

Figure 1 Removing the Pressure PLates

8825/8 83 0 P rin te r

Replacement

CAUTION

Be caref ul not to da mag e the S he et Me dia S witc h A ctua tor w hil e rein stal li ng the Low er P ressure Plate.

1. (Figure 2): Reinstall the Lower Pressure Plate.

2. (Fi g ure 3): Reinstall the Upper Pressure Plate.

Push the Buckle Switch Actuator down ( not shown)

Reinstall the Upper Pressure Plate

Reinstall the Lower Pressure Plate

Figure 2 Reinstalling the Lower Pressure Pl ate

CAUTION

Be sure t o push t he Buck le S wit ch Actu at or do wn w hile re inst al l ing th e Upp er Pre ss ure P la te in order to prevent damage to the actuator.

8825/8830 Printer

01/02

4-27

Figure 3 Reinstalling the Upper Pressure Plate

Repairs and Adjustments

REP 8.5

REP 8.6 Sheet Drive Roll - 8830 and 8825 with Tag/MOD 90

Parts List on PL 8.3

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

NOTE: The art used for this procedure was developed for previous products and may not match the 8825\8 830 configuratio n exactly.

Removal

1. L atch the Xerographic Module at the Service Position (REP 9.2).

2. Remove the Media Transport Assembly (REP 8.1).

3. Remove the Fabric Guide (REP 8.9).

4. Remove the Pressure Plates (REP 8.5).

5. Remove the Cut Sheet Media Feed Clutch (REP 8.4).

6. (Figure 1): R em o ve the Tim in g Belt and the be arings.

Remove the E-ring and pulley (not shown)

7. (Fi g ure 2): Remove the Sheet Drive Roll.

Remove the Sheet Drive Roll

Figure 2 Removing the Sheet Drive Rol l

Remove the Pulley Clutch and Timing Belt

Remove the E-ring, Drag Brake, E-ring and bearing at the opposite end of the Drive Roll (not shown)

Figure 1 Removing the Bearings

Repairs and Adjustments

REP 8.6

Remove the E-ring and bearing

01/02

4-28

8825/8 83 0 P rin te r

REP 8.7 Sheet Pinch Rolls - 8830 and 8825 with Tag/MOD 90

Parts List on PL 8.3

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8 830 configuratio n exactly.

Removal

1. L atch the Xerographic Module at the Service Position (REP 9.2).

2. Remove the Media Transport Assembly (REP 8.1).

3. Remove the Fabric Guide (REP 8.9).

4. Remove the Pressure Plates (REP 8.5).

5. Turn the Media T ransport over.

6. (Figure 1): Remove the Sheet Pinch Rolls.

Remove the spring from under the edge of the channel

Remove the Sheet Pinch Rolls (one each end)

Unlat ch th e spri ng (bot h ends)

8825/8830 Printer

01/02

4-29

Remove the E-rings and bearings (one each end)

Figure 1 Removing the Sheet Pinch Rolls

Remove the Sheet Pinch Roll Assembly

Repairs and Adjustments

REP 8.7

REP 8.8 Media Registration Sensor

Parts List on PL 8.2

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8 830 configuratio n exactly.

Removal

1. L atch the Xerographic Module at the Service Position (REP 9.2).

2. Remove the Media Transport Assembly (REP 8.1).

3. (Figure 1): Remove the Media Registration Sensor.

Sensor Window

Remove the two screws and the Media Registration Sensor

Push down the tab and disconnect the connector

Remove t he two scr ew s and the assembly

Repairs and Adjustments

REP 8.8

01/02

4-30

Figure 1 Removing the Media Registration Sensor

8825/8 83 0 P rin te r

REP 8.9 Fabric Guide

Parts List on PL 10.3

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8 830 configuratio n exactly.

Removal

1. Lower the Media Transport Cover.

2. (Figure 1): Carefully reach into the Printer and remove the Fabric Guide.

Remove the Fabric Guid e

8825/8830 Printer

01/02

4-31

Raise the Retaining Bar 90 degrees

Figure 1 Removing the Fabric Guide

Repairs and Adjustments

REP 8.9

Replacement

1. (Figure 2): Rei ns tall the Fabr ic Guide .

REP 8.10 Media Transport Drive Motor

Parts List on PL 8.1

Ensure that the edge of the hand le is inside the edge of the frame

Frame

Latch the Retainer Bar

WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal

1. Latch the Xerographic Modul e at the Service Position (REP 9.2).

2. Remove the Media Transport Ass embly (REP 8.1).

3. Remove the Fabric Guid e (REP 8.9).

4. Remove the Pressure Plates (REP 8.5).

5. Turn the Media Transport Assembly over.

Figure 2 Reinstalling the Fabric Guide

Repairs and Adjustments

REP 8.9, REP 8.10

01/02

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8825/8 83 0 P rin te r

Xerox 8830, 8825 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Transmittal Page

Introduction

About this Manual

Organization

How to Use This Manual

Repair Analysis Procedures (RAPs)

Repair / Adjustment Procedures

1 Service Call Procedures

Introduction

Call Flow Procedure

Initial Actions/Systems Checks

Print Defect Isolatio n Procedure

Workstation Checkout Procedure

Status Code Entry Chart

Message Display Entry Chart

Maintenance Procedures

System Checkout / Final Action

2 Status Indicator RAPs

C1-04/C2-04/C3-04 RAP

C1-59/ C2-59/ C3-59 RAP

LL-41/LL-45 Fuser Warm-up Fault RAP

LL-42 Thermal Control RAP

LL-43 Fuser Over Temperature RAP

LL-44 Fuser Too Hot RAP

LL-60/LL-61 NVM Fault RAP

LL-90 Overtoned Fault RAP

LL-91 Undertoned Fault RAP

OF-1 Control Panel RAP

OF-2 Power On Self Test (POST) RAP

OF-3 Fuser Ballast RAP

Generic Clutch RAP

Generic Sensor RAP

Generic Switch RAP

3 Print Quality

Print Quality Initializatio n Procedu re

Print Defects

Print Quality Definitions

Print Quality General Diagnostics

Print Quality Specifications

Damaged Media Media Handling Problems

PQ 22

Repairs/Adjustments

REP 3.1

REP 3.2

REP 7.1

REP 7.2

REP 7.3

REP 7.4

REP 7.5

REP 7.6

REP 7.7

REP 7.9

REP 8.1

REP 8.2

REP 8.3

REP 8.4

REP 8.5

REP 8.6

REP 8.7

REP 8.8

REP 8.9