Xerox 8830, 8825 Service Manual

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

8825/8830 Printer

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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.

01/02

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

8825/8830 Printer

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Introduction

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8825/8 83 0 P rin te r

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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8825/8 83 0 P rin te r

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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8825/8 83 0 P rin te r

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

+ 366 hidden pages