Xerox WORKCENTRE 3119 Service Manual

WORKCENTRE 3119

SERVICE MANUAL

Part Number 708P88471 06/06

Service Documentation

708P88471

June 2006

Prepared by:

Xerox Europe,

Global Knowledge & Language Services,

Enterprise Centre,

P.O. Box 17,

Bessemer Road,

Welwyn Garden City,

Hertfordshire,

AL7 1BU, England.

Xerox, and all identifying numbers used in connection with the Xerox products mentioned in this publication are registered trademarks of Xerox. Other company trademarks are also acknowledged.

NOTICE

While every care has been taken in the preparation of this manual, no liability will be accepted by Xerox Europe arising out of any inaccuracies or omissions.

All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product trained service personnel only. Xerox does not warrant or represent that it will notify or provide to such customer any future change to this documentation. Customer performed service of equipment, or modules, components or parts of such equipment may affect whether Xerox is responsible to fix machine defects under 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.

06/06 WorkCentre 3119

Introduction

Precautions .............................................................................................................................. iii

1. Service Call Procedures

Section Contents................................................................................................................... 1-1

2. Repair Analysis Procedures

Section Contents................................................................................................................... 2-1

3. Image Quality

Section Contents................................................................................................................... 3-1

4. Repairs/Adjustments

Section Contents................................................................................................................... 4-1

5. Parts List

Section Contents................................................................................................................... 5-1

6. General Procedures/Information

Section Contents................................................................................................................... 6-1

7. Wiring Data

Section Contents................................................................................................................... 7-1

WorkCentre 3119 06/06 i

Introduction

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ii 06/06 WorkCentre 3119

Introduction

Precautions

In order to prevent accidents and to prevent damage to the equipment, please read the precautions listed below carefully before servicing the machine and follow them closely.

Warnings, Cautions and Notes

WARNING

A warning is used whenever an operating or maintenance procedure, practice, condition or statement, if not strictly observed, could result in personal injury.

CAUTION

A caution is used whenever an operation or maintenance procedure, practice, condition or statement, if not strictly observed, could result in damage to the equipment.

Note: A note is used where it is essential to highlight a procedure, practice, condition or statement.

Safety Warning

1. Only to be serviced by appropriately qualified service engineers. High voltages and lasers inside this product are dangerous. This machine should only be serviced

by a suitably trained and qualified service engineer.

2. Use only Xerox replacement parts There are no user serviceable parts inside the machine. Do not make any unauthorized changes

or additions to the machine, these could cause the machine to malfunction and create electric shock or fire hazards.

3. Laser Safety Statement The machine is certified in the U.S. to conform to the requirements of DHHS 21 CFR, chapter 1

Subchapter J for Class 1(1) laser products, and elsewhere, it is certified as a Class I laser product conforming to the requirements of IEC 825. Class I laser products are not considered to be haz-

ardous. The laser system and machine are designed so there is never any human access to laser radiation above a Class I level during normal operation, user maintenance, or prescribed service condition.

WorkCentre 3119 06/06 iii

Introduction

CAUTION - INVISIBLE LASER RADIATION

WHEN THIS COVER OPEN. DO NOT OPEN THIS COVER.

VORSICHT - UNSICHTBARE LASERSTRAHLUNG,

WENN ABDECKUNG GE FFNET . NICHT DEM STRAHL AUSSETZEN.

ATTENTION - RAYONNEMENT LASER INVISIBLE EN CAS

D OUVERTURE. EXPOSITION DANGEREUSE AU FAISCEAU.

ATTENZIONE - RADIAZIONE LASER INVISIBILE IN CASO DI

APERTURA. EVITARE LESPOSIZIONE AL FASCIO.

PRECAUCION - RADIACION LASER IVISIBLE CUANDO SE ABRE.

EVITAR EXPONERSE AL RAYO.

ADVARSEL. - USYNLIG LASERSTR LNING VED BNING, N R

SIKKERHEDSBRYDERE ER UDE AF FUNKTION. UNDG UDSAETTELSE FOR STR LNING.

ADVARSEL. - USYNLIG LASERSTR LNING N R DEKSEL

PNES. STIRR IKKE INN I STR LEN.

UNNG EKSPONERING FOR STR LEN.

VARNING - OSYNLIG LASERSTR LNING N R DENNA DEL

R PPNAD OCH SP RREN R URKOPPLAD.

BETRAKTA EJ STRLEN. STR LEN R FARLIG.

VARO! - AVATTAESSA JA SUOJALUKITUS OHITETTAESSA

OLET ALTTIINA N KYM TT M LLE LASERS TEILYLLE L KATSO S TEESEEN.

WARNING

Avoid exposure to laser beam. Invisible laser radiation.

Caution for safety

Toxic material

This product contains toxic materials that could cause illness if ingested.

1. If the LCD control panel is damaged, it is possible for the liquid inside the display to leak. This liquid is toxic. Contact with skin should be avoided, wash any splashes from eyes or skin immediately and contact your doctor. If the liquid gets into the mouth or is swallowed see a doctor immediately.

2. Please keep print cartridges away from children. The toner powder contained in the print car-

iv 06/06 WorkCentre 3119

tridge may be harmful. If swallowed, contact a doctor immediately.

Introduction

Electric Shock and Fire Safety Precautions

Failure to follow the following instructions could cause electric shock or potentially cause a fire.

1. Use only the correct voltage, failure to do so could damage the machine and potentially cause a fire or electric shock.

2. Use only the power cable supplied with the machine. Use of an incorrectly specified cable could cause the cable to overheat and potentially cause a fire.

3. Do not overload the power socket, this could lead to overheating of the cables inside the wall and could lead to a fire.

4. Do not allow water or other liquids to spill into the machine, this can cause electric shock. Do not allow paper clips, pins or other foreign objects to fall into the machine these could cause a short circuit leading to an electric shock or fire hazard.

5. Never touch the plugs on either end of the power cable with wet hands, this can cause electric shock. When servicing the machine, remove the power plug from the wall socket.

6. Use caution when inserting or removing the power connector. The power connector must be inserted completely otherwise a poor contact could cause overheating and possibly leading to a fire. When removing the power connector grip it firmly and pull.

7. Take care of the power cable. Do not allow it to become twisted, bent sharply round corners or otherwise damaged. Do not place objects on top of the power cable. If the power cable is damaged, it could overheat and cause a fire or exposed cables could cause an electric shock. Replace a damaged power cable immediately, do not reuse or repair the damaged cable. Some chemicals can corrode the coating on the power cable, weaken the cover or exposing cables causing fire and shock risks.

8. Ensure that the power sockets and plugs are not cracked or broken in any way. Any such defects should be repaired immediately. Take care not to cut or damage the power cable or plugs when moving the machine.

9. Use caution during thunder or lightning storms. Xerox recommend that this machine be disconnected from the power source when such weather conditions are expected. Do not touch the machine or the power cord if it is still connected to the wall socket in these weather conditions.

10. Avoid damp or dusty areas, install the machine in a clean well ventilated location. Do not position the machine near a humidifier. Damp and dust build up inside the machine can lead to overheating and cause a fire.

11. Do not position the machine in direct sunlight. This will cause the temperature inside the machine to rise possibly leading to the machine failing to work properly and in extreme conditions could lead to a fire.

12.Do not insert any metal objects into the machine through the ventilator fan or other part of the casing, it could make contact with a high voltage conductor inside the machine and cause an electric shock.

WorkCentre 3119 06/06 v

Introduction

Handling Precautions

The following instructions are for your own personal safety, to avoid injury and so as not to damage the machine

1. Ensure the machine is installed on a level surface, capable of supporting its weight. Failure to do so could cause the machine to tip or fall.

2. The machine contains many rollers, gears and fans. Take great care to ensure that you do not catch your fingers, hair or clothing in any of these rotating devices.

3. Do not place any small metal objects, containers of water, chemicals or other liquids close to the machine which if spilled could get into the machine and cause damage or a shock or fire hazard.

4. Do not install the machine in areas with high dust or moisture levels, beside on open window or close to a humidifier or heater. Damage could be caused to the machine in such areas.

5. Do not place candles, burning cigarettes, etc. on the machine, these could cause a fire.

Assembly / Disassembly Precautions

Replace parts carefully, always use Xerox parts. Take care to note the exact location of parts and also cable routing before dismantling any part of the machine. Ensure all parts and cables are replaced correctly.

Please carry out the following procedures before dismantling the machine or replacing any parts.

1. Check the contents of the machine memory and make a note of any user settings. These will be erased if the mainboard is replaced.

2. Ensure that power is disconnected before servicing or replacing any electrical parts.

3. Disconnect printer interface cables and power cables.

4. Be sure to remove the print cartridge before you disassemble any parts.

5. Only use approved spare parts. Ensure that part number, product name, any voltage, current or temperature rating are correct.

6. When removing or re-fitting any parts do not use excessive force, especially when fitting screws into plastic.

7. Take care not to drop any small parts into the machine.

8. Handling of the OPC Drum

- The OPC Drum can be irreparably damaged if it exposed to light. Take care not to expose the OPC Drum either to direct sunlight or to fluorescent or incandes-

cent room lighting. Exposure for as little as 5 minutes can damage the surface’s photoconductive properties and will result in print quality degradation. Take extra care when servicing the machine. Remove the OPC Drum and store it in a black bag or other lightproof container. Take care when working with the covers (especially the top cover) open as light is admitted to the OPC area and can damage the OPC Drum.

- Take care not to scratch the green surface of OPC Drum Unit. If the green surface of the Drum Cartridge is scratched or touched the print quality will be

compromised.

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Introduction

Releasing Plastic Latches

Many of the parts are held in place with plastic latches. The latches break easily; release them carefully. To remove such parts, press the hook end of the latch away from the part to which it is latched.

Figure 1

Disregarding this warning may cause bodily injury

1. The fuser unit works at a high temperature. Use caution when working on the machine. Wait for the fuser to cool down before disassembly.

2. Do not put fingers or hair into the rotating parts (paper feeding entrance, motor, fan, etc.). Doing so may cause injury.

3. When you move the machine. This machine weighs 12kg (26.7lb) including packaging. Use safe lifting and handling tech-

niques. Back injury could be caused if you do not lift carefully.

4. Ensure the machine is installed safely. The machine weighs 9.7kg (21.4lb) including toner cartridge, ensure the machine is installed

on a level surface, capable of supporting its weight. Failure to do so could cause the machine to tip or fall possibly causing personal injury or damaging the machine.

5. Do not install the machine on a sloping or unstable surface. After installation, double check that the machine is stable.

ESD Precautions

Certain semiconductor devices can be easily damaged by static electricity. Such components are commonly called “Electrostatically Sensitive (ES) Devices”, or ESDs. Examples of typical ESDs are: integrated circuits, some field effect transistors, and semiconductor “chip” components.

The techniques outlined below should be followed to help reduce the incidence of component damage caused by static electricity.

CAUTION

Be sure no power is applied to the chassis or circuit, and observe all other safety precautions.

1. Immediately before handling a semiconductor component or semiconductor-equipped assembly, drain off any electrostatic charge on your body by touching a known earth ground. Alternatively, employ a commercially available wrist strap device, which should be removed for your personal safety reasons prior to applying power to the unit under test.

WorkCentre 3119 06/06 vii

Introduction

2. After removing an electrical assembly equipped with ESDs, place the assembly on a conductive surface, such as aluminium or copper foil, or conductive foam, to prevent electrostatic charge buildup in the vicinity of the assembly.

3. Use only a grounded tip soldering iron to solder or desolder ESDs.

4. Use only an “anti-static” solder removal device. Some solder removal devices not classified as “anti-static” can generate electrical charges sufficient to damage ESDs.

5. Do not use Freon-propelled chemicals. When sprayed, these can generate electrical charges sufficient to damage ESDs.

6. Do not remove a replacement ESD from its protective packaging until immediately before installing it. Most replacement ESDs are packaged with all leads shorted together by conductive foam, aluminium foil, or a comparable conductive material.

7. Immediately before removing the protective shorting material from the leads of a replacement ESD, touch the protective material to the chassis or circuit assembly into which the device will be installed.

8. Maintain continuous electrical contact between the ESD and the assembly into which it will be

installed, until completely plugged or soldered into the circuit.

9. Minimize bodily motions when handling unpackaged replacement ESDs. Normal motions, such

as the brushing together of clothing fabric and lifting one’s foot from a carpeted floor, can generate static electricity sufficient to damage an ESD.

Super Capacitor or Lithium Battery Precautions

1. Exercise caution when replacing a super capacitor or Lithium battery. There could be a danger of explosion and subsequent operator injury and/or equipment damage if incorrectly installed.

2. Be sure to replace the battery with the same or equivalent type recommended by the manufacturer.

3. Super capacitor or Lithium batteries contain toxic substances and should not be opened, crushed, or burned for disposal.

4. Dispose of used batteries according to the manufacturers instructions.

Toner Cartridge Service

Only toner cartridges supplied by Xerox should be used. Printing defects or set damage caused by the use of non-approved print cartridges or un-licensed toner refills are not covered by the guarantee.

Precautions on Safe-keeping of Print Cartridge

Excessive exposure to direct light for more than a few minutes may cause damage to the cartridge.

Service for the Life of Print Cartridge

If the printed image is light due to the toner supply becoming low you can temporarily improve the print quality by redistributing the toner (Shake the print cartridge), however you should replace the print cartridge to solve the problem permanently.

viii 06/06 WorkCentre 3119

Introduction

Redistributing Toner

When the print cartridge is near the end of its life, white streaks or light print occurs. The LCD displays the warning message, “Toner Low.” You can temporarily re-establish the print quality by redistributing the remaining toner in the cartridge.

1. Open the Front Cover.

2. Lightly pushing the used cartridge down, pull it out.

Note: Help the environment by recycling your used toner cartridge. Refer to the recycling brochure packed with the toner cartridge for details.

3. Unpack the new toner cartridge and gently shake it horizontally four or five times to distribute the toner evenly inside the cartridge.

4. Save the box and the cover for shipping. Slide the new toner cartridge in until it locks into place.

Standard of guarantee for consumable parts.

Please refer to User Manual or Instructions on Fax/Printer Consumables SVC manual for the criteria for judging the quality of consumable parts the standard of guarantee on those parts.

How to identify a refilled toner cartridge.

One way security screws are used in the manufacture of the cartridge – check if these are damaged.

WorkCentre 3119 06/06 ix

Introduction

Health and Safety Incident Reporting

I. Summary

This section defines requirements for notification of health and safety incidents involving Xerox products (equipment and materials) at customer locations.

II. Scope

Xerox Corporation and subsidiaries worldwide.

III. Objective

To enable prompt resolution of health and safety incidents involving Xerox products and to ensure Xerox regulatory compliance.

IV. Definitions

Incident:

An event or condition occurring in a customer account that has resulted in injury, illness or property damage. Examples of incidents include machine fires, smoke generation, physical injury to an operator or service representative. Alleged events and product conditions are included in this definition.

V. Requirements

Initial Report:

1. Xerox organisations shall establish a process for individuals to report product incidents to Xerox Environment Health & Safety within 24 hours of becoming aware of the event.

2. The information to be provided at the time of reporting is contained in Appendix A (Health and Safety Incident Report involving a Xerox product).

3. The initial notification may be made by any of the following methods:

• For incidents in North America and Developing Markets West (Brazil, Mexico, Latin Amer-

ican North and Latin American South):

- Phone* Xerox EH&S at: 1-800-828-6571.

- Electronic mail Xerox EH&S at: Doris.Bush@usa.xerox.com.

- Fax Xerox EH&S at: 1-585-422-6449 [intelnet 8*222 6449].

• For incidents in Europe and Developing Markets East (Middle East, Africa, India, China

and Hong Kong):

- Phone* Xerox EH&S at: +44 (0) 1707 353434.

- Electronic mail Xerox EH&S at: Elaine.Grange@GBR.xerox.com.

- Fax Xerox EH&S at: +44 (0) 1707 353914 [intelnet 8*668 3914]. *Initial notification made by phone must be followed within 24 hours by a completed incident report and sent to the indicated electronic mail address or fax number.

Note: If sending a fax, please also send the original via internal mail.

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Introduction

Responsibilities for Resolution:

1. Business Groups/Product Design Teams responsible for the product involved in the incident shall:

a. Manage field bulletins, customer correspondence, product recalls, safety retrofits. b. Fund all field retrofits.

1. Field Service Operations shall: a. Preserve the Xerox product involved and the scene of the incident inclusive of any associ-

ated equipment located in the vicinity of the incident.

b. Return any affected equipment/part(s) to the location designated by Xerox EH&S and/or

the Business Division.

c. Implement all safety retrofits.

2. Xerox EH&S shall: a. Manage and report all incident investigation activities.

b. Review and approve proposed product corrective actions and retrofits, if necessary. c. Manage all communications and correspondence with government agencies. d. Define actions to correct confirmed incidents.

VI. Appendices

The Health and Safety Incident Report involving a Xerox Product (Form # EH&S-700) is available at the end of the manual.

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Introduction

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xii 06/06 WorkCentre 3119

Service Call Procedures

1. Service Call Procedures

SCP 1 Service Call Actions .......................................................................................................1-3

SCP 2 Final Actions .................................................................................................................1-4

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Service Call Procedures

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1-2 06/06 WorkCentre 3119

Service Call Procedures

SCP 1 Service Call Actions

Procedure

Throughout this manual, observe the following Warnings:

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

WARNING

Do not touch the fuser while it is hot.

WARNING

Take care during this procedure. Sharp edges may be present that can cause injury.

1. Take note of symptoms or error messages.

2. Ask the operator to describe or demonstrate the problem.

3. Make sure that:

• The power cord is connected to the wall outlet and to the machine.

• All cables are connected correctly.

4. If available, check the machine service log book for any previous actions that may be relevant to the call.

5. Review any defective print or copy samples.

6. Perform ‘1 Initial Checks RAP’.

WorkCentre 3119 06/06 1-3

Service Call Procedures

SCP 2 Final Actions

Final Actions are used to evaluate the total operation of the system and to identify the actions required to complete the service call.

Procedure

• Exercise the machine in all modes.

• Make a proof copy or print of a customer document.

• If any of the customers selections were changed, return them to the customers preferred settings.

• Mark off any hardware/software options and modifications installed and/or enabled in the Service Log book.

• At the first service and at any subsequent service where changes are made or options are added, print the configuration report and store it with the machine log book. Discard any previous versions of the configuration report.

• Remove and destroy any copies of test patterns.

• Complete the machine service log book, refer to GP 17 Service Log.

• Ensure the machine and service area are clean before leaving the customer premises.

• Provide customer training if required.

1-4 06/06 WorkCentre 3119

Status Indicator RAPs

2. Status Indicator RAPs

1 Initial Checks RAP ..................................................................................................................2-3

2 JAM 0 RAP .............................................................................................................................2-5

3 JAM 1 RAP .............................................................................................................................2-7

4 JAM 2 RAP .............................................................................................................................2-8

5 Multi-Feeding RAP .................................................................................................................2-9

6 Fuser Jam RAP ....................................................................................................................2-10

7 Paper rolled in the Print Cartridge (OPC Drum) RAP ...........................................................2-11

8 Fuser Error RAP ..................................................................................................................2-12

9 LSU Error RAP .....................................................................................................................2-13

10 Melting Fuser Gear RAP ....................................................................................................2-14

11 Paper Empty RAP ..............................................................................................................2-15

12 Cover Open RAP ................................................................................................................2-16

13 No Power RAP ...................................................................................................................2-17

14 SPOOL Error RAP ..............................................................................................................2-18

15 Abnormal Noise RAP .........................................................................................................2-19

16 Scanning RAP ....................................................................................................................2-20

17 Print Cartridge Problems RAP ............................................................................................2-21

18 Software Problems RAP .....................................................................................................2-22

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Status Indicator RAPs

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2-2 06/06 WorkCentre 3119

Status Indicator RAPs

1 Initial Checks RAP

WARNING

Basic Check List

1. Check the Power.

• Does "Warming Up" appear on the display?

--> If not check power cable, switch or SMPS/HVPS, PL 1.

--> Does the wall socket work?

• Do the motors or other components initialize (listen for the main motor, fan and LSU, PL 1 sounds)?

--> If not or there are none of the normal startup sounds, check the cable, switch and/or SMPS/HVPS, PL 1.

--> Does the wall socket work?

2. Check the LCD Panel.

• Refer to General Procedures.

• Is there any display at all?

--> If not, check the power cable, switch and/or SMPS/HVPS, PL 1.

• Is the display showing an error message? Are there any broken or badly formed characters?

• Is the message on the LCD Panel, PL 8 a standard error message? Refer to GP 9.

--> Does the wall socket work?

--> Check the main PBA and cable harness, PL 1.

--> Check for paper jams, refer to GP 6.

3. Check the Paper Path

• Is there a Paper Jam?

--> Remove any paper fragments caught in the paper path, refer to GP 6.

• Paper Jam occurs repeatedly at a specific point in the Paper Path

--> Open the fuser cover, REP 9 and clear the jam, refer to GP 6.

--> Dismantle the machine and carefully inspect the region where the jam occurs. Check if paper fragments are caught in the Fuser, refer to GP 6.

4. Print a test page.

• Try printing a test page from a computer.

--> If there is an error, check cables and driver installation.

5. Check the Print Quality.

• Is there a Print Quality Problem?

--> Go to Section 3, Image Quality.

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6/06 2-3

Status Indicator RAPs

6. Check consumables (toner etc.).

• Using the keys print the Test Pattern.

--> Expected life of various consumable parts, compare this with the figures printed and install new parts as required, GP 7. If necessary, install a new toner cartridge, PL 1.

Initial Inspection

1. Check the power.

1. The machine does not work no matter how long you wait. A. Is the Power Switch (machine and wall socket) turned on? B. Is the Power Cord connected to the machine correctly? C. Is the Power cord connected to the wall socket correctly? D. Is wall socket working? E. Is the unit rated at the same voltage as the supply?

2. Does the Fan work when power is turned on? A. Check the connectors on the SMPS/HVPS, PL 1. B. Check the fuses in the SMPS/HVPS, PL 1.

2. Check the Installation Environment.

1. Ensure the installation surface is flat, level and free from vibration. If necessary move the machine.

2. Ensure that the temperature and humidity of the surroundings are within specification If necessary move the machine.

3. Ensure that the machine is positioned away from any air conditioning or other heating or cooling equipment. Also ensure that is not positioned in a direct draft from any air conditioning, fan or open window.

If necessary move the machine.

4. Ensure the machine is not positioned in direct sunlight. If it is unavoidable use a curtain to shade the machine.

5. Ensure the machine is installed in a clean dust free environment. Move the machine to clean area if necessary.

6. Some industrial or cleaning processes give of fumes which can affect the machine. Move the machine away from this type of air pollution

3. Check the paper type.

1. Use only paper which is of suitable quality, weight and size. See the user guide.

4. Check the overall condition of the machine

1. Clean the Paper Transport areas. Any rollers with dirt surfaces should be cleaned. If necessary, install new rollers.

2-4 0

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Status Indicator RAPs

2 JAM 0 RAP

WARNING

Description

Paper is not fed from the cassette. Jam-0 occurs if the paper feeds into the machine.

Check and Cause Solution

1. If continuous jams occur, check the following parts:

• Pickup roller, PL 1

• Paper feed sensor, PL 1

• Feed roller, PL 4

• Feed roller 1, PL 4

Note: The Paper Feed Sensor is mounted onto the Main PBA, PL 1.

2. Check the RPR-friction pad and IPR plate, PL 9.

3. Check the pickup roller, PL 4 for contamination or damage.

4. Check the solenoid HB (Pickup), PL 3 by using ‘Pickup Test’ in Engine Test Mode, GP

1. Ensure all rollers are clean and operate correctly, PL 4.

2. Clean with soft cloth dampened with IPA (Isopropyl Alcohol) or water. Install new parts as necessary:

• RPR-friction pad, PL 9

• IPR plate, PL 9

3. Clean with soft cloth dampened with IPA (Isopropyl Alcohol) or water. Install a new pickup roller, PL 4 if necessary.

4. Install a new solenoid HB (Pickup), PL 3 if damaged.

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Status Indicator RAPs

Check and Cause Solution

5. Check the following parts:

• Cassette assembly, PL 9

• Paper guides, PL 4

• Spring-ETC TR, PL 4

6. If the paper feeds into the machine and Jam 0 occurs, perform ‘Feed Sen Test’ in Engine Test Mode, GP 4 to check the feed sensor.

Note: The feed sensor is mounted on the SMPS/HVPS, PL 1.

7. Check the motor operation using Engine Test Mode, GP 4. Check the motor harness and connectors, PL 1 and stepper motor (drive), PL 6.

5. Adjust or install new parts as necessary:

• Guide paper, PL 4

• IPR-Plate, PL 9

• RPR-Friction Pad, PL 9

• Cassette assembly, PL 9

6. Install new parts as necessary:

• Feed sensor actuator, PL 4

• SMPS/HVPS, PL 1

• Main PBA, PL 1

7. Install new parts as necessary.

• Motor harness, PL 1

• Drive assembly, PL 6

• Main PBA, PL 1

2-6 0

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Status Indicator RAPs

3 JAM 1 RAP

WARNING

Description

Paper is jammed in front of or inside the fuser. Paper is jammed in the exit roller and in the fuser after passing through the feed sensor actuator.

Check and Cause Solution

1. If paper is jammed in the exit roller, PL 3 and the fuser, PL 5 after passing through the feed sensor actuator, PL 4, the feed sensor actuator may be defective.

2. If paper is jammed in front of or inside the fuser, PL 5.

1. Check the feed sensor actuator, PL 4 for damage, install a new feed sensor actuator if necessary.

2. Install new parts as necessary:

• Exit sensor actuator, PL 4

• SMPS/HVPS, PL 1

• Main PBA., PL 1

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Status Indicator RAPs

4 JAM 2 RAP

WARNING

Description

Paper is jammed in front of or inside the fuser. Paper is jammed in the discharge roller and in the fuser after passing through the Actuator-Feed.

Check and Cause Solution

1. If the paper is completely fed out of the machine, but Jam 2 occurs:

• The exit sensor is defective.

Note: The exit sensor is mounted onto the SMPS/HVPS, PL 1.

• After the paper is completely fed out, the exit sensor actuator, PL 5 should return to its original position to deactivate the photo-sensor. Sometimes it takes longer than it should and does not return to its original position.

2. If the paper is rolled up in the fuser , PL 5:

• A stripper finger, PL 5 is damaged.

• The heat roller or pressure roller, PL 5 is seriously contaminated,

1. Check the exit sensor actuator, PL 5.

2. Disassemble the fuser, refer to REP 9. Remove the jammed paper and clean the surface of the pressure roller, heat roller, and the stripper fingers, PL 5. Install new parts as necessary:

• Heat roller, PL 5

• Pressure roller, PL 5

•Fuser, PL 5

2-8 0

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Status Indicator RAPs

5 Multi-Feeding RAP

WARNING

Description

Multiple sheets of paper are fed together.

Check and Cause Solution

1. Ensure that the paper size guides, PL 9 are

1. Adjust the paper guides, PL 9.

set correctly.

2. The RPR-friction pad and/or IPR plate, PL 9 is contaminated with foreign matter (e.g oil).

2. Clean with soft cloth dampened with IPA (Isopropyl Alcohol) or water. Install new parts as necessary:

• RPR-friction pad, PL 9

• IPR plate, PL 9

3. Paper has a rough surface texture 3. Use paper with a smoother surface finish.

4. Check the solenoid HB (pickup) operation using Engine Test Mode, GP 4.

4. Install new parts as necessary:

• Solenoid HB (Pickup), PL 3

• Main PBA, PL 1

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Status Indicator RAPs

6 Fuser Jam RAP

WARNING

Description

Paper rolled around fuser rollers or ‘Concertina’ jam.

Check and Cause Solution

1. Contamination of the pressure roller or heat roller, PL 5.

2. Damaged stripper fingers or stripper finger springs, PL 5.

1. Disassemble the fuser, REP 9 and clean the surfaces of the rollers with IPA or water. Clean the contamination between the heat roller and thermistor, PL 5.

2. Check the stripper fingers for damage. Install a new fuser, PL 5 if necessary.

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Status Indicator RAPs

7 Paper rolled in the OPC Drum RAP

WARNING

Description

Paper is rolled up in the Toner Cartridge.

Check and Cause Solution

1. Paper is out of specification. 1. Clear the jam, refer to GP 6. Use paper within specification. Refer to the User Guide. Recommend the use of good quality ‘long grain’ paper.

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Status Indicator RAPs

8 Fuser Error RAP

WARNING

Description

A message “Open Heat Error/Over heat/Heating Error” is displayed.

Check and Cause Solution

1. Drive gear, PL 6 has melted. 1. Check the drive assembly, PL 6. Install a new drive assembly if necessary.

2. Check the halogen lamp operation using

Engine Test Mode, GP 4.

2. Install new parts as necessary:

• Halogen lamp, PL 5

•Fuser, PL 5

3.Check the thermistor, PL 5 for damage. 3. Install new parts as necessary:

• Thermistor, PL 5

• Fuser, PL 5

4. Check the following parts:

• Thermostat, PL 5

• Fuser harness, PL 5

• Halogen lamp, PL 5

4. Install new parts as necessary:

• Fuser harness, PL 5

• Thermostat, PL 5

• Halogen lamp, PL 5

•Fuser, PL 5

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