Download: Cut Sheet Printers Maintenance Manual Model C40D

Cut Sheet Printers Maintenance Manual Model C40D

E1195 HP Part No. C4672-90005,

Notice

Hewlett-Packard makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Hewlett-Packard shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. Hewlett-Packard assumes no responsibility for the use or reliability of its software on equipment that is not furnished by Hewlett-Packard. This document contains proprietary information which is protected by copyright. All rights are reserved. No part of this document may be photocopied, reproduced, or trans- lated to another language without the prior written consent of Hewlett-Packard Company. The information contained in this document is subject to change without notice. Hewlett-Packard Company System Peripherals Operation MS 44MC 19111 Pruneridge Avenue Cupertino, CA 95014

Printing History

New editions are complete revisions of the manual. Update pages, which are issued between editions, contain additional and replacement pages to be merged into the manual by the customer. The date on the title page changes only when a new edition or a new update is published. No information is incorporated into a reprinting unless it appears as a prior update; the edition does not change when an update is incorporated. The software code printed alongside the date indicates the version level of the software product at the time the manual or update was issued. Many product updates and fixes do not require manual changes and, conversely, manual corrections may be done without accompanying product changes. Therefore, do not expect a one-to-one correspondence between product updates and manual updates. Edition 1 ..November 1995 Edition 2..June 1999 ii June 1999,

Preface

The C40D Maintenance Manual contains all the information needed to maintain and ser- vice Hewlett Packard C40D printers. The C40D printer series are high-speed, non-impact printers utilizing electrophotographic imaging technology. The information in this manual is for authorized field representatives who are familiar with basic printer operations. It serves as a supplement to training classes and provides a basis for discussion with regional field service engineers and customer support representa- tives.

Using This Manual

This manual is organized into the following sections: Section 1, Troubleshooting Reviews the organization of the manual, the way the printer works, and how to trouble- shoot the printer, including some standard procedures to follow when troubleshooting. This chapter also includes a chart detailing exactly what each causes each error code, illus- trations of all sensors in the printer, and a list of abbreviations used throughout the manual. Section 2, TAG Cross- Reference Tables Provides cross-reference tables; look up specific printer problem description (in either the mechanical malfunction, error code, or print quality description tables), then turn to the TAG indicated on the chart to troubleshoot the problem. Section 3, Troubleshooting Analysis Guides Detailed step-by-step procedures to help you isolate and resolve specific printer problems. If you are not sure which TAG to start with, begin with the overview, TAG 001. Section 4, Print Quality Samples Shows print test patterns indicating specific problems, and referencing the TAG that treats each problem. Section 5, Diagnostic Tests Reviews each printer software diagnostic. Section 6, Wiring Diagrams and Electrical Data Shows printer schematics and locations of individual components. Section 7, Removal/Replacement Procedures Outlines procedures to follow when removing and replacing printer parts, also called FRUs (Field-Replaceable Units). June 1999 iii, Section 8, Options Provides information about the optional High Capacity Input and High Capacity Output bins. Section 9, General Printer Maintenance Reviews printer maintenance procedures to complete during service calls. Index Provides a list of references to topics mentioned in this manual.

Other Manuals

The C-Series Illustrated Parts Catalog shows every FRU and CRU (customer-replaceable unit) in the printer, including part number information. This information is frequently updated. The C40D Installation Manual, C4672-90007, guides you through unpacking, setup, test- ing, and network configuration of your C40D printer. The C40D Operator’s Manual, C4672-90006, contains all the information needed to oper- ate Hewlett Packard C40D printers. The C40D Technical Reference Manual, C4672-60012, is a complete guide to using fonts and the PJL and PostScript emulations on the C40D. It also documents aspects of printer usage in detail. The Cut Sheet Printers Paper Specifications Guide, C4672-90002, explains the various kinds of papers usable in the printer, how to care for them, and how to minimize paper- related problems with the C40D. Copyright ©1999 Hewlett Packard, Inc. All rights reserved. November 1995 Please address any comments or questions with respect to this document to: Publications Manager System Peripherals Operation MS 44MC Hewlett-Packard Company 19111 Pruneridge Avenue Cupertino, CA 95014 iv June 1999, Contents

Contents Troubleshooting

Theory of Operation.1-3 The Printing Process .1-3 Paper Path and Cycle Sequence.1-5 Simplex Printing .1-5 Duplex Printing .1-6 Sensors and Switches Illustrations.1-8 Sensor and Switch Listing.1-8 Troubleshooting .1-11 General Troubleshooting Tips.1-12 The Problem: Printer or Host?.1-12 Running Test Prints .1-12 Protocol Converters .1-13 Reading the Error Log.1-13 Confirming Line Power.1-14 Using the Troubleshooting Analysis Guide (TAG) .1-15 Sample TAG .1-15 Standard Procedures.1-17 Power-on-reset (POR) .1-17 Checking Continuity .1-17 Installing the Interlock By-pass Tool .1-17 Producing a Developed Image .1-18 Producing a Toner Patch .1-18 Completing a Service Call.1-19 Clearing the Error Log .1-19 Error Message and Code Technical Definitions .1-20

TAG Cross-Reference Tables

Error Code/TAG Cross-Reference.2-4 Print Quality/TAG Cross-Reference .2-12 Mechanical Malfunction/TAG Cross-Reference .2-14

Troubleshooting Analysis Guides

TAG 001: Troubleshooting a Problem .3-5 TAG 002: Check Problem Resolution .3-7 TAG 010: Upper Cassette Malfunction .3-10 June 1999 v, Contents TAG 011: Lower Cassette Malfunction ..3-12 TAG 012: Upper Cassette Not Latched ..3-14 TAG 013: Lower Cassette Not Latched ..3-17 TAG 020: Paper Jam/Misfeed in Upper Cassette Area ..3-19 TAG 021: Paper Jam/Misfeed in Lower Cassette Area ..3-22 TAG 022: Paper Jam in the Transfer or Fuser Area..3-26 TAG 023: Paper Jam in the Output Area ..3-30 TAG 025: Paper in Input Area Before Printing ..3-32 TAG 026: Paper in Output Area Before Printing..3-34 TAG 030: Developer Bias Short/Failure ..3-36 TAG 031: Toner Patch Reference Level Incorrect..3-39 TAG 032: Toner Patch Too Light ..3-41 TAG 035: Out of Toner or ADD TONER Indication ..3-43 TAG 036: Developer Not Installed ..3-45 TAG 040: Photoconductor Seam Sensor Malfunction..3-46 TAG 044: Charge Corona/Transfer Corona Circuit Open ..3-49 TAG 045: Charge Corona Circuit Shorted..3-52 TAG 047: PC Life Data Error ..3-54 TAG 048: Developer Life Error ..3-55 TAG 050: Transfer Corona Circuit Shorted..3-56 TAG 055: Erase Lamp Malfunction..3-58 TAG 070: Fuser Malfunction ..3-60 TAG 071: Open Fuser/Thermistor ..3-65 TAG 072: Fuser Temperature Too High ..3-66 TAG 097: +12 Vdc Power Shorted or Sensing Problem ..3-68 TAG 098: -12 Vdc Power Shorted ..3-78 TAG 099: +24 Vdc Power Shorted ..3-80 TAG 100: VPCL Board Interface Malfunction ..3-89 TAG 130: Disk Drive Malfunction ..3-90 TAG 200: RIGS Internal Communication Malfunction..3-95 TAG 201: RIGS-VPCL Interface Malfunction ..3-97 TAG 405: RIGS Bit-Map RAM Malfunction ..3-99 TAG 500: +5 Vdc Power Malfunction..3-100 TAG 600: Vac Power Malfunction ..3-105 TAG 610: Operator Panel Malfunction ..3-112 vi June 1999, Contents TAG 700: Output Tray Circuit Malfunction .3-115 TAG 702: Paper Size Detection Malfunction .3-117 Wiring for the Upper Paper Size Sensor .3-119 Wiring for the Lower Paper Size Sensor.3-119 TAG 703: Upper Cassette Malfunction .3-120 TAG 704: Lower Cassette Malfunction.3-121 TAG 705: Multiple Paper Feeding .3-122 TAG 706: Paper Damaged or Wrinkled .3-123 TAG 707: Upper Paper Guide Assembly Not Closing .3-124 TAG 750: Counter Malfunction.3-125 TAG 751: Main Drive Motor Runs Continuously.3-127 TAG 753: Async IO Communications Malfunction .3-128 TAG 754: Smart I/O Card Malfunction.3-131 TAG 800: Prints Blank or With Dark Horizontal Bands.3-133 TAG 801: Prints Light or Light With Carrier Particles .3-137 TAG 802: Prints With Voids or White Spots .3-142 TAG 803: Prints With Light or White Vertical Streaks .3-144 TAG 804: Prints With Light Horizontal Bands .3-145 TAG 805: Black Prints.3-146 TAG 806: Prints with Dark Spots or Scratches .3-148 TAG 807: Misregistered/Skewed Prints .3-150 TAG 808: Prints Overtoned/Dark Vertical Streaks .3-153 TAG 809: Blurred or Smeared Vertical Streaks on Prints.3-157 TAG 810: Uneven Density or Dark Areas on Prints .3-161 TAG 811: Background/Residual Images/Dark Prints .3-162 TAG 812: Uneven or No Fusing on Prints .3-166 TAG 813: Residual Images on Prints .3-168 TAG 815: Prints Resulting From Printhead Malfunctions .3-170 TAG 900: Top Cover Interlock Malfunction, Duplex .3-171 TAG 901: Misregistration/Skewed Prints (Duplex) .3-173 TAG 902: Paper Jam in Duplex Area .3-177

Print Quality Samples

Sample 1: Good Quality Print .4-4 Sample 2: Washout .4-5 Sample 3: Blank Print .4-6 Sample 4: Light Print .4-7 June 1999 vii, Contents Sample 5: Light Print With Background ..4-8 Sample 6: Voids or White Spots ..4-9 Sample 7: Light Vertical Streaks ..4-10 Sample 8: Blank Vertical Bands..4-11 Sample 9: Light Horizontal Bands ..4-12 Sample 10: Black or Dark Print ..4-13 Sample 11: Dark Specks, Lines, or Areas ..4-14 Sample 12: Dark Vertical Lines ..4-15 Sample 13: Skewed Prints ..4-16 Sample 14: Misregistration..4-17 Sample 15: Overtoned Print ..4-18 Sample 16: Blurred Images or Characters ..4-19 Sample 17: Varying Print Density ..4-20 Sample 18: Background ..4-21 Sample 19: Residual Images ..4-22 Sample 20: Wrinkles ..4-23 Sample 21: Fusing Problems ..4-24

Diagnostic Tests

How to Run Diagnostics..5-3 Operator Panel Test ..5-4 Upper Cassette Test ..5-4 Lower Cassette Test ..5-5 Fuser Thermistor Test..5-5 Sensor Tests ..5-6 Roller Clutch Tests ..5-7 Counter Test ..5-7 Jogging Motor Test..5-8 Photoconductor Seam Sensor Test ..5-8 Toner Supply Motor Test ..5-8 Charge Corona Test ..5-9 Transfer Corona Test ..5-9 Erase Lamp Test ..5-10 Toner Empty Test ..5-10 Negative Developer Bias Test ..5-11 Duplex Motor Tests ..5-11 Duplex Sensor Tests ..5-12 Duplex Clutch Tests ..5-13 Duplex Tray Paper-Guide Motor Test ..5-13 viii June 1999, Contents High-Capacity Output (HCO) Sensor Tests .5-14 High-Capacity Input (HCI) Test .5-14 LED Printhead Test .5-15 RIGS Board Test .5-16 Com. Wrap Test .5-16 Display File Version Test .5-17 Format Disk .5-17 Clear Error Log .5-18 Disk Drive Test .5-18

Wiring Diagrams and Electrical Data

Introduction .6-3 Printhead Circuit Board Settings.6-3 Connector (J/P) Index .6-4 Acronyms and Abbreviations .6-9 Connectors Inside the Front Cover .6-12 Connectors Inside the Left Cover .6-13 Connectors on the Duplex Cover.6-14 Connectors Inside the Right Cover .6-15 Connectors Inside the Top Cover .6-16 Connectors on the Back Cover .6-17 Connectors Inside the Back Cover (J/P2-14).6-18 Connectors Inside the Back Cover (Continued) J/P 18-62 .6-19 Connectors Inside the Back Cover (Continued) J/P 64-85 .6-20 Connectors Inside the Back Cover (Continued) J/P 90-800 .6-21 Voltage Isolation Diagrams .6-22 -12 Vdc Circuits .6-22 +5 Vdc Circuits .6-22 +12 Vdc Circuits .6-24 +24 Vdc Circuits .6-26 Ground System.6-27 Host Interface Reference .6-28 RS-232C Host Interface .6-28 Standard DCE to DTE RS-232C Cable.6-29 Special Considerations for RS-232 Host Interface Users .6-29 DTE Host to Printer (Option 1) .6-29 DTE Host to Printer (Option 2) .6-30 IBM PC/XT to Printer .6-30 IBM PC/AT to Printer .6-31 Macintosh Communication Port to Printer .6-31 June 1999 ix, Contents Centronics Parallel Host Interface ..6-33 IBM Parallel to Printer ..6-34

Removal/Replacement Procedures

Before You Begin..7-4 Power Considerations ..7-4 Photoconductor Removal..7-4 Front Cover Removal ..7-5 Back Cover Removal ..7-6 Left Side Cover Removal ..7-7 Right Side Cover Removal..7-8 Vacuum Transport Unit Removal ..7-9 Rear Duplex Cover Removal ..7-10 Front Duplex Cover Removal ..7-11 Operator Panel Removal..7-12 Counter Removal ..7-13 RIGS Board Removal..7-14 VPCL Board Removal ..7-15 Printhead Assembly Removal ..7-16 Printhead Circuit Board (ARIF) Removal ..7-18 Hard Disk Drive Housing Removal ..7-19 Floppy and Hard Disk Drive Removal..7-20 Cooling Fan Removal..7-21 Toner Motor Removal ..7-22 This space left blank intentionally..7-23 AC Power Supply Removal ..7-24 DC Power Supply Removal ..7-26 High Voltage Unit Removal ..7-27 Photoconductor Seam Sensor Removal ..7-28 Photoconductor Rear Guide Rail Removal ..7-30 Power Control Board Removal ..7-33 Upper or Lower Paper Size Sensor Removal ..7-34 Upper Cassette Mount Removal..7-35 This space left blank intentionally..7-39 Lower Cassette Mount Removal ..7-40 This space left blank intentionally..7-44 Upper Paper Guide Removal ..7-45 Upper Paper Guide Roller Removal..7-47 x June 1999, Contents ULower Paper Guide Removal .7-48 Paper Timing Guide Removal .7-49 Cleaner Drive Belt Removal .7-51 Cleaner Drive Removal .7-52 Fuser Drive Belt Removal .7-53 Fuser Drive Removal .7-54 Paper Feed Drive Belt Removal .7-55 Paper Timing Roller Removal .7-56 Upper Feed Roller Removal .7-57 Lower Feed Roller Removal .7-58 Upper Pick-Up Roller Removal.7-59 Pick-Up Roller Drive Idler Removal .7-60 Pick-Up Roller Drive Gear Removal .7-61 Lower Pick-Up Roller Removal .7-62 Exit Assembly Removal .7-63 Exit Pinch Roller Removal .7-65 Upper Static Brush Removal .7-67 Lower Static Brush Removal .7-68 Exit Roller Assembly Removal .7-69 Exit Cover Removal.7-71 Paper Exit Sensor Removal .7-73 Paper Full Sensor Removal .7-74 Front Cover Interlock Switch Removal .7-75 Back Cover Interlock Switch Removal .7-76 Top Cover Interlock Switch Removal .7-77 Erase Lamp Removal.7-78 EP Cover Removal.7-79 Main Motor Removal.7-82 Main Gear Drive Removal.7-85 Duplex Control Board #1 Removal .7-86 Duplex Control Board #2 Removal .7-87 Duplex Tray Registration Motor Removal .7-88 Duplex Skew Correction Cable Removal .7-89 Upper Duplex Drive/Clutch Assembly Removal .7-91 Duplex Route Motor/Solenoid Assembly Removal .7-92 “A” Roller Removal.7-93 June 1999 xi, Contents “B” Roller Removal ..7-94 “C” Roller Removal ..7-96 “C” Roller Solenoid Removal ..7-97 Duplex Route Separator Removal ..7-98 Duplex Paper Path Sensor Removal..7-99

Options

Introduction ..8-3 1200-Sheet/2500-Sheet Feeder..8-4 Guide to Component Acronyms/Physical Locations..8-4 Bench Test Procedure..8-5 Prefeed Adjustment Procedure ..8-7 1200-Sheet Feeder Only ..8-7 2500-Sheet Feeder Only ..8-7 Connection Diagram for 1200-Sheet/2500-Sheet Feeder..8-8 Connection Diagram for 1200-Sheet /2500-Sheet Feeder ..8-8 Input Control Board Logic ..8-9 1400-Sheet Stacker..8-10 Guide to Component Abbreviations/Physical Locations..8-10 Bench Test Procedure..8-11 Connector Locations..8-13 Front View (cover removed) ..8-13 Left Side View (left cover removed) ..8-13 Rear Side View (cover removed)..8-14 Top View (top cover removed) ..8-14 Connection Diagram for the 1400-Sheet Stacker..8-15 Output Control Board Logic..8-16

General Printer Maintenance

Introduction ..9-3 Safety Precautions ..9-4 Tool Requirements: Service Kit..9-4 Tools/Supplies ..9-5 Printer/Maintenance Record ..9-5 Printer Maintenance Record ..9-6 Every-Call Cleaning Procedure ..9-7 Adjusting Paper Feed Tension ..9-10 Adjusting Registration ..9-11 Lubrication Procedure ..9-12 xii June 1999, Contents Front View Lubrication .9-13 Front View Lubrication Table .9-14 Rear View Lubrication.9-15 Rear View Lubrication Table.9-16 Top View Lubrication .9-17 Duplex Holding Tray Lubrication .9-18 Tune-Up Maintenance Procedure .9-19 June 1999 xiii, Contents xiv June 1999, Section 1

Troubleshooting

Section 1 Troubleshooting June 1999 Troubleshooting 1-1,

Contents Troubleshooting

Theory of Operation ..1-3 The Printing Process ..1-3 Paper Path and Cycle Sequence..1-5 Simplex Printing ..1-5 Duplex Printing ..1-6 Sensors and Switches Illustrations ..1-8 Sensor and Switch Listing ..1-8 Troubleshooting ..1-11 General Troubleshooting Tips ..1-12 The Problem: Printer or Host? ..1-12 Running Test Prints ..1-12 Protocol Converters ..1-13 Reading the Error Log ..1-13 Confirming Line Power ..1-14 Using the Troubleshooting Analysis Guide (TAG) ..1-15 Sample TAG ..1-15 Standard Procedures ..1-17 Power-on-reset (POR) ..1-17 Checking Continuity ..1-17 Installing the Interlock By-pass Tool..1-17 Producing a Developed Image ..1-18 Producing a Toner Patch ..1-18 Completing a Service Call ..1-19 Clearing the Error Log ..1-19 Error Message and Code Technical Definitions..1-20 1-2 Troubleshooting June 1999, Theory of Operation

Section 1 Troubleshooting

The information in this Field Service Manual is directed toward authorized field represen- tatives who are familiar with basic printer operations. It serves as a supplement to training classes and provides a basis for discussion with regional field service engineers and cus- tomer support representatives.

Theory of Operation

The printer uses an electrophotographic imaging system, which is based on LED array technology. Two key components of the printer are the image generation system (RIGS) controller and the printer control logic (AVPCL) board. A brief description of the function of each of these components follows. Risc Image Generation System (RIGS) controller: Each printer is equipped with an RIGS controller, which provides the interface between the host computer, the AVPCL board, the interface cards, and the disk drives. Video Printer Control Logic (AVPCL) board: The AVPCL board directs the mechani- cal functions of the printer and print cycle timing, and controls the LED printhead. The AVPCL board also receives initial machine information, such as empty paper cassettes, paper jams, and fuser problems.

The Printing Process

The illustration on the following page details the printing process. The numbers represent the sequence of events from the time that the RIGS controller receives data, through the production of a print image, to the preparation for another print. 1 Receiving data Host data is received through the Signal Interface PCA and passed to the RISC Image Generating System (RIGS) PCA, which temporarily stores the data in RAM. The data may consist of information generated on the host computer and sent over the host communication interface or it may consist of information generated by printer soft- ware, such as a request for test prints or to print the directory of the hard disk. June 1999 Troubleshooting 1-3, Theory of Operation 2 Bit Image The RIGS transforms the host file into a bit map image of 1s and 0s and stores them in bitmap RAM. 3 Charging the photoconductor belt When the IGS controller receives data, it causes the AVPCL board to turn on the main motor, which rotates the photoconductor belt. As the photoconductor belt rotates, the charge corona applies a high negative charge to it, which repels toner from the photo- conductor belt. 4 Exposing the image The negatively charged belt then passes the LED printhead, where the AVPCL drives the LEDs on and off to discharge the areas of the belt at a density of 300 dots per inch. The 1s in the memory turn the LEDs on; 0s turn the LEDs off. The discharged areas create a latent mirror image of the print on the photoconductor belt. 5 Developing the image As the photoconductor belt continues to rotate, it brings the latent image to the devel- oper. A negative developer bias is applied to toner and the toner is transferred to the surface of the photoconductor belt. The negatively charged toner (which clings to small metal carrier beads) is attracted to the discharged areas of the belt; the carrier beads do not transfer. The belt, with the developed image on its surface, then rotates out of the developer. At this time you can remove the photoconductor belt and read what is printed on it, which you may need to do when troubleshooting print problems. 6 Activating paper As the image is being developed, a sheet of paper is transported to the photoconductor belt. The AVPCL board controls this activity. A series of paper pick-up, feed, and tim- ing rollers guide the paper so the developed image is properly registered with the lead- ing edge of the sheet. 7 Transferring the image to the paper Next, the paper contacts the surface of the photoconductor belt. Above the paper and the belt is the transfer corona, which has a high positive charge, and attracts the devel- oped image from the belt to the surface of the paper. At this point, you can remove the printed image to verify print quality, but the toner is not yet fused. 8 Fusing the image to the paper The vacuum transport advances the paper with the image to the fuser where heat and pressure bond the toner to the paper. The print then arrives at the paper output tray. 9 Cleaning routine After a print is made, the photoconductor belt must be cleaned for the next print. The belt first passes the erase lamp where any remaining latent image is erased. The belt continues to the cleaner where a charged brush rotates against the surface to remove any residual toner. This toner is recycled to the developer for reuse. 1-4 Troubleshooting June 1999, Paper Path and Cycle Sequence

Paper Path and Cycle Sequence

Transfer Corona Vacuum Transport Fuser678Paper Input Paper Output Erase Lamp 9 Cleaner Charge Corona Toner 4 LED Printhead AVPCL RIGS Inter- HOST face Developer21The RIGS board signals the AVPCL board that a page of data is ready to be printed. When this happens the following sequence takes place.

Simplex Printing

1 AVPCL software downloaded to the AVPCL board from the disk drive system turns on the main motor. 2 The AVPCL board engages the paper pick clutch which causes the roller to feed a sheet of paper. 3 The paper is passed to the feed roller where the AVPCL board has engaged the feed roller clutch. 4 The feed roller passes the paper to the paper timing roller. Prior to reaching the paper timing roller, the paper passes over the paper timing sensor. If the paper does not ener- gize this sensor in a specified amount of time, a jam error (020/021) will occur. The leading edge of the paper is registered against the paper timing roller. The paper tim- ing clutch is engaged and the paper is passed over the photoconductor for transfer. This registers the paper to the printer and the image to the paper. The paper timing sensor also signals the AVCPL to begin sending data. 5 The AVPCL board engages the paper timing roller clutch and, at the same time, turns on the transfer corona to provide a high positive voltage. The developed image on the photoconductor comes in contact with the paper and the high positive voltage causes the image to transfer to the paper. Photoconductor June 1999 Troubleshooting 1-5, Paper Path and Cycle Sequence 6 Because the toner is not yet fixed to the paper, a vacuum transport assembly, gripping the paper from the back side, moves the paper to the fuser, where heat and pressure bond the toner to the paper. 7 Upon leaving the fuser, the paper comes in contact with the paper exit sensor. (If the paper does not energize this sensor in a given amount of time after leaving the paper timing sensor [step 4], a jam error (022) will occur.) 8 The exit roller moves the paper to the exit tray. (If the exit sensor is not cleared in a specified amount of time, a jam error (023) will occur.)

Duplex Printing

When duplex is selected, the AVPCL board controls the paper motion with page schedul- ing assistance from the RIGS board. The duplex page router is engaged. When in duplex mode, it is important to note that the printer runs multiple pages through the paper path at the same time to increase speed. 1 In a duplex job, the duplex router solenoid behind the fuser is engaged and mechanical fingers route the paper to the duplex area. Also, the “A” roller clutch engages to turn the “A” and “B” rollers (connected via a belt). 2 The paper upon passing through the “B” roller comes in contact with the duplex sen- sor. (If the paper does not energize this sensor in a given amount of time, a jam error (060) will occur.) 3 The “C” roller bidirectional motor turns on and passes the paper into the turnaround tray. The paper sensor in the turnaround tray is activated and the paper is center regis- tered. (If the paper does not energize this sensor in a given amount of time after leav- ing the duplex sensor, a jam error (061) will occur.) 1-6 Troubleshooting June 1999, Paper Path and Cycle Sequence 4 At this time the solenoid for the router at the turnaround tray engages so the paper can be routed to be printed on the duplex side. 5 In a given amount of time after the paper energizes the paper sensor in the turnaround tray, the bidirectional motor reverses and passes the paper to the paper timing roller. (If the paper does not energize the paper timing sensor in a given amount of time after leaving the turnaround sensor, a jam error (062) will occur.) 6 At this point, the same steps happen as during a simplex cycle. June 1999 Troubleshooting 1-7, Sensors and Switches Illustrations

Sensors and Switches Illustrations

The following pages illustrate the locations of the printer’s sensors and switches.

Sensor and Switch Listing

Sensor/Switch Name Page Sensor/Switch Name Page Cassette paper present sensors, upper and 1-8 Paper exit sensor 1-10 lower Cassette present micro switches, upper and 1-8 Paper full sensor 1-10 lower Duplex registration sensor 1-8 Paper size sensors, upper and lower 1-9 Duplex paper path sensor 1-9 Paper timing sensor 1-9 Interlock switch, duplex cover 1-9 Photoconductor seam sensor 1-9 Interlock switch, front 1-11 Automatic toner control 1-10 Interlock switch, rear 1-9 Toner empty sensor 1-10 Interlock switch, top 1-10 Toner patch sensor 1-9 . Front left view 1-8 Troubleshooting June 1999, Sensors and Switches Illustrations Rear view Left end view Top view Developer right view Front view June 1999 Troubleshooting 1-9, Sensors and Switches Illustrations Top view Developer left view Right side view Top left, duplex tray view 1-10 Troubleshooting June 1999, Troubleshooting Front view

Troubleshooting

Throughout the printer’s life problems occur, such as when it produces poor quality prints or malfunctions in another way. Use the tools provided in this manual to diagnose and resolve printer problems. These tools include: • The Troubleshooting Analysis Guide, which contains troubleshooting procedures called TAGs. TAG 001: Troubleshooting a Problem explains how to use TAGs. • Cross reference tables, which link error messages, print quality problems, and mechanical malfunctions to specific TAGs. • Print quality samples, which help identify a printing problem and its associated TAGs. • Diagnostics, which can uncover a range of problems. The next several pages review troubleshooting basics and standard procedures followed in every troubleshooting session, including: • Identifying whether a problem belongs to the printer or host • Isolating protocol converter problems • Running test prints • Reading the error log • Confirming line power • Using TAGs • Power-On Reset • Installing the interlock by-pass tool • Checking continuity • Producing a developed image • Producing a toner patch • Completing a service call • Clearing the error log June 1999 Troubleshooting 1-11, Troubleshooting

General Troubleshooting Tips

When a printer problem arises, swapping out all printer supplies may temporarily mask the problem. This is an unsatisfactory, short-term, and expensive solution to correcting the problem. Dust and other contamination, rather than printer supplies, are more often the causes of problems. Clean consumable connectors, alignment guides, and areas before changing consumables. Many failures add excess toner to the printer’s engine. When you are advised to de-tone the printer as part of a problem fix, run at least 200 test prints before deciding that the problem is resolved. When you replace the photoconductor, run at least 500 prints before checking print qual- ity. This number of prints is required to “synch” the new PC belt to the developer.

The Problem: Printer or Host?

The printer is one component in a large host system. Before you start any troubleshooting, make sure that the problem really belongs to the printer rather than to some other compo- nent in the host system. Print quality problems and mechanical malfunctions are almost always associated with the printer. However, host interface and software emulation prob- lems can be caused by some other component of the host system even though, at first glance, they appear to be printer problems. For instance, text printed in the wrong location on a page, improper page breaks, and missing segments of data strongly indicate a host, not a printer, problem. The first step in troubleshooting any problem is to isolate the printer from the host system; you can then run test prints. Producing test prints exercises the printer as a stand-alone machine, ensuring that the basic printer software and all mechanical functions of the printer are working.

Running Test Prints

1 Disconnect the host interface. 2 Make sure “Ready” displays on the panel. 3 Press ONLINE. 4 Press MENU 5 Press h to highlight “Test Print” 6 Press e to select “Test Print” 7 Choose “Simplex” or “Duplex” (Duplex is the default. Press h to choose simplex.) 8 Press e to start. A directory of the boot device and multiple listings of fonts prints. A continuous flow of the test pattern then prints. 9 To stop printing the test pattern, press f. The printer will print all test prints stored in the printer’s buffer, then stop. If the test pattern prints successfully, the problem probably originates with the host system or a protocol converter connected to the host. 1-12 Troubleshooting June 1999, Troubleshooting

Protocol Converters

Many protocol converters have a self-test function or configuration mode that enables the user to check the proper functioning of the control. You can reconnect the host interface and ask the customer to exercise this function of the converter. If the printer receives data and prints it (even if the output is garbled) the problem may belong to the host or the pro- tocol converter.

Reading the Error Log

The formatted error log is maintained by the printer in a file named “Error.log.” You have the option to print this log when you are at the same panel used to print test prints. See “Running Test Prints” on page 1-12. • The first section lists the numbers and text of the last 15 errors. • The second section of the formatted log lists paper jams. A 3-digit error code (or codes) is followed by the error text and a 4-digit number indicating how many times the error has occurred since the error log was last cleared. (Clearing the error log is described on page 1-19.) • The third section provides a complete error history since the error log was last cleared. Errors are listed in numeric order in the first column, with the number of times each error occurred listed in the second column. • The fourth section indicates the last error that required a power-on-reset (POR). The error log is two pages long. This partial illustration shows the main components of the log. June 1999 Troubleshooting 1-13, Troubleshooting

Confirming Line Power

Erratic printer problems can be caused by improper line power. As a rule, the voltage of the outlet should be checked at installation. However, if you are unable to isolate an inter- mittent problem, the power should be checked again. Consult your country’s national elec- tric code for the proper procedures to check for acceptable voltages, as outlined on the following chart. Probe connections 120v printer 230v printer red to AC hot 120v +/- 10% 230v +/- 10% black to AC neutral red to AC neutral 3 vac or less 3 vac or less black to ground red to AC hot 120v +/- 10% 230 +/- 10% black to ground Please see Section 5, Diagnostic Tests, for additional information about troubleshooting specific printer problems. Please see Section 6, Wiring Diagrams and Electrical Data, for additional information about the printer’s electrical systems. 1-14 Troubleshooting June 1999, Troubleshooting

T

St a Yes/N Que

Using the Troubleshooting Analysis Guide (TAG)

The Troubleshooting Analysis Guide provides problem-solving sequences to help you identify and resolve printer problems. Each TAG addresses a particular symptom or error message of the printer. The TAG number often matches an error message code displayed on the printer’s operator panel. AG Number TAG Name Sample TAG

TAG 001: Troubleshooting a Problem

Error Message: All related error messages are listed here. Possible Causes: All possible causes are listed here. Possible Defects: All possible defective parts are listed here. (In no particular order.) 1 To start: arting • Disconnect all peripheral cables ctions • Power-on-reset the printer. o stion Is an error message displayed? No: Run test prints, following the procedure outlined in Section 1, then repeat this step. If the To Do answer is still no, refer to the mechanical malfunctions cross-reference chart in Section 2 to determine which TAG to follow. Then turn to that TAG. Yes: Note the error message and continue. 2 Power-on-reset the printer. Did the power-on-reset end with an error message? No: Continue. Yes: Refer to the error message cross-reference table in Section 2, using either the code that dis- played after steps 1 and 2, or if multiple error messages continue to appear, the first error mes- sage that displays. Turn to the TAG associated with the message. Each TAG walks through a comprehensive procedure specific to a single problem. As you progress through a TAG and eliminate possible causes, you may be directed to another step out of sequence in the same TAG or to another TAG altogether. The TAG number and its title may be followed by a listing of possible error messages, possible causes, or possible defective parts related to the TAG. The TAG then directs you to perform certain tasks. Based on the results of these tasks, the TAG poses questions that can be answered by either yes or no. For yes answers, you fol- low one path; for no answers, follow another path. Some of the paths may lead you to other TAGs, so that you can methodically diagnose and resolve problems. When you have corrected a problem, you will be directed to TAG 002 to confirm that the problem has been completely resolved and standard cleanup procedures observed. June 1999 Troubleshooting 1-15, Troubleshooting If it’s not clear how to diagnose a problem you’re working on, follow the steps outlined in TAG 001, which includes references to the cross reference tables contained in Section 2, TAG Cross- Reference Tables. Or, you may turn directly to the tables to get started. As you use TAGs, you will sometimes refer to other sections of this manual for additional information: • Section 4, Print Quality Samples, contains print quality samples you’ll use to compare the customer’s test prints with flawed and good print samples. • Section 5, Diagnostic Tests, outlines how to conduct printer diagnostic tests. • Section 6, Wiring Diagrams and Electrical Data, provides all wiring and connector diagrams. • Section 7, Removal/Replacement Procedures, provides step-by-step procedures for removing and replacing all field-replaceable parts on the printer. • Section 8, Options, reviews printer options (HCI, HCO) information. • Section 9, General Printer Maintenance, presents general printer maintenance proce- dures. 1-16 Troubleshooting June 1999, Standard Procedures

Standard Procedures

While using the TAGs, you may be asked to perform some of the following procedures. Specific instructions for completing these procedures are included here, rather than repeated in the body of each TAG. Please read this information before following any TAG.

Power-on-reset (POR)

When directed to power-on-reset the printer: 1 Turn off the printer. 2 Wait at least 5 seconds. 3 Turn the power back on.

Checking Continuity Make sure the printer is turned off and the power disconnected. Failure to do so may

result in personal injury, equipment damage, or both. To perform a continuity check: 1 Turn off the printer and disconnect the power cord. 2 Set your meter to the lowest ohm setting. 3 Interpret the results as follows: • An infinite reading indicates an open circuit. • A zero or specific reading indicates continuity. 4 To check an open or short circuit to ground: • Turn off the printer and disconnect the power cord. • Locate the circuit in question. (Refer to Section 6, Wiring Diagrams and Electrical Data, for circuit locations.) • Check all connectors and wiring on each side for corrosion, foreign objects, bent pins, loose socket housings, and/or loose wires.

Installing the Interlock By-pass Tool

The interlock by-pass tool overrides the cover interlock switches, allowing you to operate the printer with the covers open. The interlock by-pass tool is a white plastic, V-shaped tool with two finger pads. To use the tool, open the cover and locate the interlock switch (for locations, see illustrations in “Sensors and Switches Illustrations” on page 1-8). Squeeze the tool between thumb and forefinger and insert it into the interlock switch. The printer ships with two spare interlock by-pass tools concealed behind the right cover. Replace them when you are finished using them.

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

June 1999 Troubleshooting 1-17, Standard Procedures

Producing a Developed Image

Producing a developed image helps determine where exactly in the print cycle a problem may be occurring. To produce a developed image: 1 Open the top cover and install an interlock by-pass tool. 2 Power-on-reset the printer. 3 Run a series of test prints. See “Running Test Prints” on page 1-12. 4 As test patterns print, observe paper moving from the upper paper tray to the paper timing roller where it pauses briefly. 5 As soon as a sheet of paper begins to move from the paper timing roller, remove the interlock by-pass tool. 6 Remove the photoconductor. 7 Examine the photoconductor belt to verify that a developed image was produced.

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

and results in poor print quality.

Producing a Toner Patch

To produce a toner patch: 1 Turn off the printer. 2 Open the top cover and install an interlock by-pass tool. 3 Turn on the printer. 4 Start running test prints. When the leading edge of the first print enters the fuser, wait one second then remove the interlock by-pass tool. 5 Remove the photoconductor. Producing a toner patch on the photoconductor. 1-18 Troubleshooting June 1999, Standard Procedures 6 Examine the photoconductor to verify that a toner patch has been produced. You may have to rotate the belt slightly to observe the patch.

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

and results in poor print quality.

Completing a Service Call

After resolving any printer problem, complete the service call as follows: 1 Reassemble the printer. 2 Perform the every-call cleaning procedure, described in Section 9, General Printer Maintenance. 3 Power-on-reset the printer. 4 Clear the error log. (See the procedure described next.) 5 Run test prints in both the simplex and duplex mode from both the upper and lower paper cassettes. 6 Fill in the Repair/Maintenance record taped inside the front cover. Make sure the problem description and steps taken to resolve the problem are clearly documented.

Clearing the Error Log

1 Enter the diagnostic mode of the printer: • Turn off the printer and wait 5 seconds. • Hold down the MENU and STATUS keys simultaneously as you turn the printer back on. Wait for all three LEDs to come on. This takes approximately 30 seconds. 2 Press h to display the first available test. 3 Once a test name is displayed, use the h key to move through the available tests. 4 Press the h key until “Clear Error Log” shows on the display. 5 Press e to activate the procedure. 6 Press h to advance to the drive where the error log is maintained. This is usually the boot drive. 7 Press h to clear the error log on the selected drive. 8 Press f to exit the procedure. 9 Confirm that the error log has been cleared. 10 Exit diagnostic mode (power-on reset) 11 Print the error log. All errors in all sections should be reset to zero. June 1999 Troubleshooting 1-19, Error Message and Code Technical Definitions

Error Message and Code Technical Definitions

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

MACHINE CHECK 1. There is no text associated with the error. Unknown Error 2. The error is not included in the error look-up tables. PAPER JAM AVPCL board detected that the paper being fed from the upper

020 Upper Cassette cassette did not reach the timing paper sensor within the allot- ted time.

PAPER JAM AVPCL board detected that the paper being fed from the lower

021 Lower Cassette cassette did not reach the timing paper sensor within the allot- ted time.

PAPER JAM AVPCL board detected that the timing paper sensor was acti-

022 Transfer/Fuser vated immediately after one of the covers were closed or the leading edge of the paper did not activate the exit paper sen- sor within the allotted time.

PAPER JAM AVPCL board detected that the exit paper sensor in the printer

023 At/Near Exit (or in the HCO if installed) did not deactivate within the allotted time.

PAPER JAM AVPCL board detected that the paper did not reach the HCO

024 At/Near HCO Exit exit paper sensor within the allotted time.

PAPER JAM AVPCL board detected that either the exit paper sensor (within

025 At/Near Input the printer) or the paper exit sensor (within the HCO) were acti- vated immediately after one of the covers was closed.

PAPER JAM (HCO only). The paper exit sensor (within the HCO) did not

026 At/Near Output become activated or deactivated within the allotted time.

PAPER JAM The AVPCL board detected paper in the duplex area after

027 In Duplex Area clearing a jam.

PAPER JAM AVPCL board detected that the leading edge of the paper did

060 Duplex Roller not activate the BC sensor within the allotted time.

PAPER JAM AVPCL board detected that the trailing edge of the paper did

061 Duplex Path not deactivate the BC sensor within the allotted time.

PAPER JAM Paper picked from the registration tray did not reach the timing

062 Duplex Tray roller sensor within the allotted time. Paper Jams 1-20 Troubleshooting June 1999, Error Message and Code Technical Definitions Type Message Description

MACHINE CHECK AVPCL board detected a signal from the toner patch sensor

TPS Too Low board indicating that the reference voltage level on the photo- Error #031 conductor was too low.

MACHINE CHECK AVPCL board detected a signal from the toner patch sensor

TPS Too Light board indicating that the toner patch on the photoconductor Error #032 was too light.

MACHINE CHECK AVPCL board detected too many successive signals from the

TPS Signal Overload toner patch sensor board for a toner feed. Error #033

MACHINE CHECK AVPCL board detected no developer electrical interlock signal

No Developer from the J25 connector. Error #036

MACHINE CHECK AVPCL board detected a signal from the toner patch sensor

TPS Too High board indicating that the reference voltage level on the photo- Error #037 conductor was too high. Toner Control Errors June 1999 Troubleshooting 1-21, Error Message and Code Technical Definitions Type Message Description

MACHINE CHECK AVPCL board sensed that the signal from the photoconductor

No Signal from PSS seam sensor either was not of sufficient amplitude or did not Error #040 show the proper timing.

MACHINE CHECK AVPCL board detected an abnormally high amount of current

PSS Sensor Shorted needed to drive the photoconductor seam sensor LED (within Error #041 the photoconductor).

MACHINE CHECK AVPCL board detected an open connection to the photocon-

PSS Sensor Open ductor seam sensor LED (within the photoconductor). Error #042

MACHINE CHECK AVPCL board non-volatile RAM error.

AVPCL NVRAM Error #043

MACHINE CHECK AVPCL board detected a signal from the high-voltage power

Charge Corona Open supply indicating that either the charge corona or transfer Error #044 corona circuits have an open connection.

MACHINE CHECK AVPCL board detected a signal from the high-voltage power

Charge Corona Short supply indicating an abnormally high load on the bias voltage Error #045 to the charge corona.

MACHINE CHECK AVPCL board received invalid life data from the photoconduc-

PC Life Data Error tor serializer board. Error #047

MACHINE CHECK AVPCL board received invalid life data received from the

Developer Life Error developer serializer board. Error #048

MACHINE CHECK AVPCL board detected invalid data from either the photocon-

CRU Series Mismatch ductor or developer units. Verify that the CRUs are correct for Error #049 this printer.

MACHINE CHECK AVPCL board detected a signal from the high-voltage power

Transfer Corona Short supply indicating an abnormally high load on the bias voltage Error #050 to the transfer corona.

MACHINE CHECK AVPCL board detected a signal from the high-voltage power

Transfer Corona Open supply indicating an open connection in the transfer corona cir- Error #051 cuit. (Diagnostic test only.)

MACHINE CHECK AVPCL board detected that the current needed to drive the

Eraser Lamp Error erase lamp assembly was either higher or lower than the spec- Error #055 ified limits. (Diagnostic test only.)

MACHINE CHECK Duplex turnaround tray is not electrically connected to the

Duplex not installed printer. (Diagnostic test only.) Error #069 HVPS Errors OPC Rotation Errors 1-22 Troubleshooting June 1999, Error Message and Code Technical Definitions Type Message Description

MACHINE CHECK AVPCL board sensed, via the fuser thermistor, that the temper-

Fuser/Thermal Fuse ature of the fuser did not change within the allotted time. Error #070

MACHINE CHECK AVPCL board sensed an open connection in the fuser ther-

No Fuser/Thermistor mistor circuit. Error #071

MACHINE CHECK AVPCL board sensed that the resistance of the fuser ther-

Fuser Temp Too High mistor was too low indicating that the temperature of the fuser Error #072 was higher than the specified limit.

MACHINE CHECK AVPCL board sensed that the resistance of the fuser ther-

Fuser Temp Too Low mistor was too high indicating that the temperature of the fuser Error #073 was lower than the specified limit.

MACHINE CHECK AVPCL board detected a signal from the duplex control board

Duplex Registration #2 indicating that either the registration side sensor was acti- Error #086 vated and would not deactivate or was deactivated and would not activate after a command was sent to the duplex control board #2 to turn on the resist motor.

MACHINE CHECK AVPCL board detected that the photoconductor is installed

Bad PC Type improperly, or is of the wrong type. Verify that the photocon- Error #091 ductor is the correct type for the printer.

MACHINE CHECK AVPCL board detected that the developer is installed improp-

Bad Dev Type erly, or is of the wrong type. Verify that the developer is the cor- Error #092 rect type for the printer.

MACHINE CHECK AVPCL board detected a signal from the RIGS board indicat-

+12 DC Power Failure ing the absence of +12 Vdc. Error #097

MACHINE CHECK AVPCL board detected a signal from the RIGS board indicat-

+24 DC Power Failure ing the absence of +24 Vdc. Error #099

MACHINE CHECK RIGS board detected an error when attempting to download

IML Error information to the AVPCL flash EPROM. Error #130

MACHINE CHECK RIGS board detected an error from the AVPCL board during

Bad AVPCL ROM Checksum initial AVPCL diagnostic. Error #140

MACHINE CHECK RIGS board detected an error from the AVPCL board during

AVPCL PIA1 Reset Fail initial AVPCL diagnostic. Error #160

MACHINE CHECK RIGS board detected an error from the AVPCL board during

AVPCL PIA1 R/W at POR initial AVPCL diagnostic. Error #161 Jogger AVPCL Error LVPS Errors Fuser Control Errors Errors June 1999 Troubleshooting 1-23, Error Message and Code Technical Definitions Type Message Description

MACHINE CHECK RIGS board detected an error from the AVPCL board during

AVPCL PIA1 Reset Fail initial AVPCL diagnostic. Error #170

MACHINE CHECK RIGS board detected an error from the AVPCL board during

AVPCL PIA1 R/W at POR initial AVPCL diagnostic. Error #171

MACHINE CHECK RIGS board detected an error from the AVPCL board during

AVPCL PTM Reset Fail initial AVPCL diagnostic. Error #180

MACHINE CHECK RIGS board detected an error from the AVPCL board during

AVPCL PTM Read/Write initial AVPCL diagnostic. Error #181

MACHINE CHECK RIGS board detected an error from the AVPCL board during

AVPCL PTM IRQ Failure initial AVPCL diagnostic. Error #182

MACHINE CHECK RIGS board detected a fatal error from the AVPCL board dur-

I2C Oppanel Fatal ing initial AVPCL diagnostic. Error #260

MACHINE CHECK RIGS board detected an error from the AVPCL board during

I2C Oppanel Warning initial AVPCL diagnostic. Error #261

MACHINE CHECK RIGS board detected transmit failed, lost arbitration, with the

Transmit Failed control panel. Error #270

MACHINE CHECK RIGS board detected transmit failed, no acknowledgment, with

Transmit Failed the control panel. Error #271

MACHINE CHECK RIGS board detected transmit failed, bus always busy, with the

Transmit Failed control panel. Error #272

MACHINE CHECK RIGS board detected a transmit error on the I2C bus, with the

Transmit Error control panel. Error #273

MACHINE CHECK RIGS board detected I2C host not ready.

Error #274 AVPCL Errors (cont.) 1-24 Troubleshooting June 1999, Error Message and Code Technical Definitions Type Message Description

MACHINE CHECK RIGS board detected receiver overruns.

Error #275

MACHINE CHECK RIGS board detected a framing error on receive.

Error #276

MACHINE CHECK RIGS board detected a receive overflow.

Error #277

MACHINE CHECK Control panel has failed to establish communication with the

RIGS board. Verify the cabling between the control panel, the Error #278 RIGS board, and the AVCPL boards.

MACHINE CHECK Control panel has lost communication with the RIGS board.

Verify the cabling between the control panel, the RIGS board, Error #280 and the AVCPL boards

MACHINE CHECK Invalid command sent to the operator panel.

Error #281

MACHINE CHECK RIGS board detected an error from the AVPCL board during

AVPCL No Data VSS High initial AVPCL diagnostic. Error #301

MACHINE CHECK RIGS board detected an error from the AVPCL board during

AVPCL TS High VSS Low initial AVPCL diagnostic. Error #302

MACHINE CHECK RIGS board detected an error from the AVPCL board during

TC High but not VSC initial AVPCL diagnostic. Error #303

MACHINE CHECK RIGS board detected an error from the AVPCL board during

VSC high too long initial AVPCL diagnostic. Error #304

MACHINE CHECK RIGS board detected an error from the AVPCL board during

AVPCL VSC Invalid initial AVPCL diagnostic. Error #305

MACHINE CHECK RIGS board detected an error from the AVPCL board during

TS high and data xfr initial AVPCL diagnostic. Error #306

MACHINE CHECK RIGS board detected an error from the AVPCL board during

AVPCL Parity Error initial AVPCL diagnostic. Error #307 AVPCL Errors (cont.) June 1999 Troubleshooting 1-25, Error Message and Code Technical Definitions Type Message Description

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PCL Cmd Retry Error testing of the RIGS board. Error #380

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PCL Cmd Rejected testing of the RIGS board. Error #381

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PCL Sent Bad Cmd testing of the RIGS board. Error #382

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PCL Sent Bad Byte testing of the RIGS board. Error #383

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PCL Got TS-No Status testing of the RIGS board. Error #384

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PCL SIB/Count Bad testing of the RIGS board. Error #385

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PCL Bad SIB Offset testing of the RIGS board. Error #386

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PCL Parity Error testing of the RIGS board. Error #387

MACHINE CHECK RIGS board detected an internal software error.

Unknown Error Error #397 Controller Errors 1-26 Troubleshooting June 1999, Error Message and Code Technical Definitions Type Message Description

MACHINE CHECK RIGS board detected an internal software error.

Fatal Software Error Error #398

MACHINE CHECK RIGS board detected an internal software error.

Software Error Error #399

MACHINE CHECK RIGS board detected an error during the internal diagnostic

Peripheral Bus Error testing of the peripheral bus. Error #401

MACHINE CHECK RIGS board detected an error in the program RAM during the

RAM Bank Selection internal diagnostic testing of the RIGS board. Error #405

MACHINE CHECK RIGS board detected an error in the program RAM during the

RAM Bank 0 Address internal diagnostic testing of the RIGS board. Error #406

MACHINE CHECK RIGS board detected an error in the program RAM during the

RAM Bank 0 Refresh internal diagnostic testing of the RIGS board. Error #407

MACHINE CHECK RIGS board detected an error in the program RAM during the

RAM Bank 1 Address internal diagnostic testing of the RIGS board. Error #408

MACHINE CHECK RIGS board detected an error in the program RAM during the

RAM Bank 1 Refresh internal diagnostic testing of the RIGS board. Error #409

MACHINE CHECK RIGS board detected an error during the internal diagnostic

Incorrect Diskette testing of the RIGS board and software. Error #450

MACHINE CHECK RIGS board detected an error during the internal diagnostic

Floppy Format Error testing of the RIGS board and software. Error #451

MACHINE CHECK RIGS board detected an error during the internal diagnostic

Fatal Software Trap testing of the RIGS board and software. Error #454

MACHINE CHECK RIGS board detected an error during the internal diagnostic

Software Trap testing of the RIGS board and software. Error #455

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PIT0 Invalid testing of the RIGS board and software. Error #500 Controller Errors Disk Drive Errors Controller Errors (cont.) June 1999 Troubleshooting 1-27, Error Message and Code Technical Definitions Type Message Description

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PIT0 Read/Write Error testing of the RIGS board and software. Error #501

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PIT0 No Countdown testing of the RIGS board and software. Error #502

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PIT0 No Timer Halt testing of the RIGS board and software. Error #503

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PIT0 No Timer Intr testing of the RIGS board and software. Error #504

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PIT2 Invalid testing of the RIGS board and software. Error #505

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PIT2 Read/Write Err. testing of the RIGS board and software. Error #506

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PIT2 No Countdown testing of the RIGS board and software. Error #507

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PIT2 No Timer Halt testing of the RIGS board and software. Error #508

MACHINE CHECK RIGS board detected an error during the internal diagnostic

PIT2 No Timer Intr testing of the RIGS board and software. Error #509

MACHINE CHECK RIGS board detected an error during the internal diagnostic

No DMAC Reset testing of the RIGS board and software. Error #520

MACHINE CHECK RIGS board detected an error during the internal diagnostic

DMAC Read/Write testing of the RIGS board and software. Error #521

MACHINE CHECK RIGS board detected an error during the internal diagnostic

No DMA Transfer testing of the RIGS board and software. Error #522

MACHINE CHECK RIGS board detected an error during the internal diagnostic

No DMA Transfer End testing of the RIGS board and software. Error #523 Controller Errors (cont.) 1-28 Troubleshooting June 1999, Error Message and Code Technical Definitions Type Message Description

MACHINE CHECK RIGS board detected an error during the internal diagnostic

No End DMA Interrupt testing of the RIGS board and software. Error #524

MACHINE CHECK RIGS board detected an error during the internal diagnostic

DMA Software Abort testing of the RIGS board and software. Error #525

MACHINE CHECK RIGS board detected an error during the internal diagnostic

DMA Software Intr. testing of the RIGS board and software. Error #526

MACHINE CHECK RIGS board detected an error during the internal diagnostic

DMA Operation Error testing of the RIGS board and software. Error #527

MACHINE CHECK RIGS board detected an error during the internal diagnostic

DMA Transfer Error testing of the RIGS board and software. Error #528

MACHINE CHECK RIGS board detected an error during the internal diagnostic

DMAC2 Transfer Error testing of the RIGS board and software. Error #529

MACHINE CHECK RIGS board detected an error during the internal diagnostic

No DMAC2 Transfer testing of the RIGS board and software. Error #530

MACHINE CHECK RIGS board detected an error during the internal diagnostic

AVPCL SCC register R/W testing of the RIGS SCC UART. Error #540

MACHINE CHECK RIGS board detected an error during the internal diagnostic

AVPCL break detected testing of the RIGS SCC UART. Error #541

MACHINE CHECK RIGS board detected an error during the internal diagnostic

AVPCL SCC xmit not testing of the RIGS SCC UART. Error #542

MACHINE CHECK RIGS board detected an error during the internal diagnostic

No AVPCL SCC Transfer testing of the RIGS SCC UART. Error #543

MACHINE CHECK RIGS board detected an error during the internal diagnostic

AVPCL SCC Transfer testing of the RIGS SCC UART. Error #544

MACHINE CHECK RIGS board detected an error during the internal diagnostic

Host SCC R/W testing of the RIGS SCC UART. Error #545 Controller Errors (cont.) June 1999 Troubleshooting 1-29, Error Message and Code Technical Definitions Type Message Description

MACHINE CHECK RIGS board detected an error during the internal diagnostic

Host xmit not ready testing of the RIGS SCC UART. Error #546

MACHINE CHECK RIGS board detected an error during the internal diagnostic

No TX/RX interrupt testing of the RIGS SCC UART. Error #547

MACHINE CHECK RIGS board detected an error during the internal diagnostic

SCC HOST/AVPCL Parity testing of the RIGS SCC UART. Error #548

MACHINE CHECK RIGS board detected an error during the internal diagnostic

SCC unexpected Intr. testing of the RIGS SCC UART. Error #549

MACHINE CHECK RIGS board detected an error during the internal diagnostic

SCC Transmission testing of the RIGS board and software. Error #550

MACHINE CHECK RIGS board detected an error during the internal diagnostic

No AVPCL SCC Interrupt testing of the RIGS board and software. Error #551

MACHINE CHECK RIGS board detected an error during the internal diagnostic

SCC-DMAC Interaction testing of the RIGS board and software. Error #552

MACHINE CHECK RIGS board detected an error during the internal diagnostic

SCC-DMAC Transfer # testing of the RIGS board and software. Error #553

MACHINE CHECK RIGS board detected an error during the internal diagnostic

SCC-DMAC Transfer testing of the RIGS board and software. Error #554

MACHINE CHECK RIGS board detected an error during the internal diagnostic

RS232 Send/Rcv testing of the RIGS board and software. Error #555

MACHINE CHECK RIGS board detected an error during the internal diagnostic

RS232 DTR/DCD testing of the RIGS board and software. Error #556

MACHINE CHECK RIGS board detected an error during the internal diagnostic

RS232 RTS/CTS testing of the RIGS board and software. Error #557

MACHINE CHECK RIGS board detected an error during the internal diagnostic

RS422 Send/Rcv testing of the RIGS board and software. Error #558 Controller Errors (cont.) 1-30 Troubleshooting June 1999, Error Message and Code Technical Definitions Type Message Description

MACHINE CHECK RIGS board detected an error during the internal diagnostic

RS422 Send/Rcv Clock testing of the RIGS board and software. Error #559

MACHINE CHECK RIGS board detected an error during the internal diagnostic

CRTC Read/Write testing of the RIGS board and software. Error #560

MACHINE CHECK RIGS board detected an error during the internal diagnostic

No Page Begin Intr. testing of the RIGS board and software. Error #561

MACHINE CHECK RIGS board detected an error during the internal diagnostic

CRTC Address testing of the RIGS board and software. Error #562

MACHINE CHECK RIGS board detected an error during the internal diagnostic

No VSYNC Generation testing of the RIGS board and software. Error #563

MACHINE CHECK RIGS board detected an error during the internal diagnostic

No End of Page Intr. testing of the RIGS board and software. Error #564

MACHINE CHECK RIGS board detected an error during the internal diagnostic

No CRTC Termination testing of the RIGS board and software. Error #565

MACHINE CHECK RIGS board detected an error during the internal diagnostic

VSYNC Timeout Error testing of the RIGS board and software. Error #566

MACHINE CHECK RIGS board detected an error when communicating with the

FDC/SCSI Read/Write floppy disk drive. Error #570

MACHINE CHECK RIGS board detected an error when communicating with the

FDC Busy Timeout floppy disk drive. Error #571

MACHINE CHECK RIGS board detected an error when communicating with the

Write Protected floppy disk drive. Error #572

MACHINE CHECK RIGS board detected an error when communicating with the

Floppy Not Ready floppy disk drive. Error #573

MACHINE CHECK RIGS board detected an error when communicating with the

FDC Restore Error floppy disk drive. Error #574 Disk Drive Errors Controller Errors (cont.) June 1999 Troubleshooting 1-31, Error Message and Code Technical Definitions Type Message Description

MACHINE CHECK RIGS board detected an error when communicating with the

FDC Seek Error floppy disk drive. Error #575

MACHINE CHECK RIGS board detected an error when communicating with the

FDC Read Error floppy disk drive. Error #576

MACHINE CHECK RIGS board detected an error when communicating with the

FDC Checksum Error floppy disk drive. Error #577

MACHINE CHECK RIGS board detected an error when communicating with the

FDC Write Error floppy disk drive. Error #578

MACHINE CHECK RIGS board detected an error when communicating with the

FDC R-M-W-V Error floppy disk drive. Error #579

MACHINE CHECK RIGS board detected an error when communicating with the

FDC/PIT0 Interrupt floppy disk drive. Error #580

MACHINE CHECK RIGS board detected an error when communicating with the

FDC/DMA Interaction floppy disk drive. Error #581

MACHINE CHECK RIGS board detected an error when communicating with the

FDC/DMAC Transfer floppy disk drive. Error #582

MACHINE CHECK RIGS board detected an error when communicating with the

FDC/DMAC Transfer # floppy disk drive. Error #583

MACHINE CHECK RIGS board detected an error when communicating with the

FDC/DMAC Read floppy disk drive. Error #584

MACHINE CHECK RIGS board detected an error when communicating with the

FDC/DMAC Write floppy disk drive. Error #585

MACHINE CHECK RIGS board detected an error when communicating with the

FDC/DMAC Operations floppy disk drive. Error #586 Disk Drive Errors (cont.) 1-32 Troubleshooting June 1999, Error Message and Code Technical Definitions Type Message Description

MACHINE CHECK RIGS board detected an error during internal testing.

Bit Map RAM Data Error #600

MACHINE CHECK RIGS board detected an error during internal testing.

Bit Map RAM Bank Error #601

MACHINE CHECK RIGS board detected an error during internal testing.

Bit Map RAM Refresh Error #602

MACHINE CHECK RIGS board detected an error during internal testing.

Bit Map RAM Address Error #603

MACHINE CHECK RIGS board detected an error during internal testing.

ALU Op in Bit RAM Error #604

MACHINE CHECK RIGS board detected an error during internal testing.

Width/Origin Fault Error #605

MACHINE CHECK RIGS board detected an error during internal testing.

BMRAM Bank Fault Error #606

MACHINE CHECK RIGS board detected an error when communicating with a

Host SCC Error host using serial communications on the ASYNC flex IO card. Error #701–#708

MACHINE CHECK RAM test failure during power-on diagnostics.

Host SCC Error Error #709

MACHINE CHECK RIGS board detected an error when communicating with a

Host SCC Error host using serial communications on the ASYNC flex IO card. Error #710–#722

MACHINE CHECK RIGS board detected an error when communicating with a

Parallel Error host using parallel communications on the ASYNC flex IO Error #725–#741 card.

MACHINE CHECK RIGS board detected an error when communicating with a

Smart flex IO Card Error host using an intelligent flex IO card. Error #745–#784 Interface Controller Interface Errors Controller Errors Error Errors June 1999 Troubleshooting 1-33, Error Message and Code Technical Definitions 1-34 Troubleshooting June 1999, Section 2

TAG Cross- Reference Tables

June 1999 2-1, 2-2 June 1999,

Section 2 TAG Cross-Reference Tables

This section contains the three cross reference charts for troubleshooting print problems: • Error Code/TAG Cross-Reference • Print Quality/TAG Cross-Reference • Mechanical Malfunction/TAG Cross-Reference June 1999 TAG Cross-Reference Tables 2-3, Error Code/TAG Cross-Reference

Error Code/TAG Cross-Reference

Error codes, which display on the operator’s panel, indicate a wide variety of printer prob- lems related to the control boards, software, and/or host communication problems. On the chart find the error code in question, then turn to TAG associated with the code. Code Printer Error Code Meaning Go to TAG 010 Upper paper tray out of paper 010 011 Lower paper tray out of paper 011 012 Upper paper tray not plugged in 012 013 Lower paper tray not plugged in 013 020 Upper paper tray paper jam 020 021 Lower paper tray paper jam 021 022 Transfer or fuser area paper jam 022 023 Exit area paper jam 023 024 Paper jam at/near HCO exit 023 025 Transfer or fuser area paper jam not cleared 025 026 Exit area paper jam not cleared 026 027 Duplex area paper jam 902 030 Developer bias short 030 031 Toner patch sensor reference level too low 031 032 Toner patch sensor black patch too light 032 033 Toner patch sensor overload 032 035 Toner empty error 035 036 No developer 036 037 Toner patch sensor too high 031 040 Photoconductor seam sensor malfunction 040 041 Photoconductor seam sensor short 040 042 Photoconductor seam sensor open 040 044 Charge/transfer corona open 044 045 Charge corona short 045 047 PC life error. Bad PC CRU information 047 048 Developer life error. Bad developer CRU information 048 050 Transfer corona short 050 2-4 TAG Cross-Reference Tables June 1999, Error Code/TAG Cross-Reference Code Printer Error Code Meaning Go to TAG 055 Eraser lamp malfunction 055 057 Fan stopped sensor 752 060 Duplex area 1 paper jam 902 061 Duplex area 2 paper jam 902 062 Duplex area 3 paper jam 902 069 Duplex tray not plugged in 900 070 Fuser lamp or thermal fuse malfunction 070 071 Fuser thermistor open or no fuser 071 072 Fuser temperature too high 072 073 Fuser temperature too low 070 081 No front job offset sensor 083 082 No back job offset sensor 083 083 Job offset mechanism malfunction 083 084 Duplex tray registration sensor not activated 901 085 Duplex tray registration sensor not deactivated 901 086 Duplex registration tray malfunction 901 090 Cover open 900 097 DC +12v power failure 097 098 DC -12v power failure 098 099 DC +24v power failure 099 100 VPCL board command timeout 100 Code VPCL/RIGS Communication Error Codes Go to TAG 121 No controller command; VPCL board VSC command asserted 201 122 Command tag asserted; VSC command not asserted 201 123 VSS not asserted; VPCL board status tag asserted 201 124 VSS asserted after VPCL board sent status 201 125 VSS not asserted again though VPCL board expects it 201 126 Command tag asserted during data byte sequence 201 127 VPCL board detected parity/overrun on command line 201 June 1999 TAG Cross-Reference Tables 2-5, Error Code/TAG Cross-Reference Code VPCL Error Codes Go to TAG 130 Address or length error at initial microcode load 130 131 Checksum error at initial microcode load 130 132 RAM error at initial microcode load 100 133 No next block at initial microcode load 130 134 Incorrect format in initial microcode load file 130 140 VPCL board ROM checksum error at power on diagnostic 100 145 VPCL board RAM error at power on diagnostic 100 160 VPCL board PIA1 register error after reset 100 161 VPCL board PIA1 registers read/write error 100 162 VPCL board PIA1 PA or PB read/write error 100 170 VPCL board PIA2 register error after reset 100 171 VPCL board PIA2 register read/write error 100 172 VPCL board PIA2 PB read/write error 100 180 VPCL board PTM register error after reset 100 181 VPCL board PTM read/write error 100 182 No IRQ generation on PTM 100 Code VPCL/RIGS Communication Error Codes Go to TAG 199 VSS not asserted before communication test 201 200 Status tag not asserted 201 201 Timeout waiting for a failed RIGS controller 201 202 No data received after VSS line asserted 201 203 VSS asserted after VPCL board sent status 201 204 Status tag asserted after VSS not asserted 201 205 No command tag after status tag not asserted 201 206 VSC command not asserted after command tag asserted 201 207 No data received after VSC asserted 201 208 VSC command asserted after command line asserted 201 209 Command tag asserted after VSC not asserted 201 2-6 TAG Cross-Reference Tables June 1999, Error Code/TAG Cross-Reference Code VPCL/RIGS Communication Error Codes Go to TAG 210 No RQI after “request RQI” command 201 211 Parity error on command line 201 212 Parity or overrun sensed by VPCL board 201 213 Incorrect command received from VPCL board 201 214 Incorrect command received from RIGS controller 201 215 No transfer buffer empty on asynchronous communications 201 interface adapter after VPCL board sent data RIGS Firmware Error Codes Code These error codes signal a problem with the RIGS controller firmware. Go to TAG No TAGs address these problems; report to Hewlett-Packard. 301 Status received after VSS asserted No TAG 302 Status tag asserted after VSS not asserted No TAG 303 VSC command not asserted after command tag asserted No TAG 304 VSC command asserted after data was sent No TAG 305 VSC command not asserted for next data byte No TAG 306 Status tag asserted while data was being sent No TAG 307 Parity error on command line No TAG Code VPCL Failure Error Codes Go to TAG 380 VPCL board failure – command retries 201 381 VPCL board failure – command rejected 201 382 VPCL board failure – bad command received 201 383 VPCL board failure – unexpected byte received 201 384 VPCL board failure – no status received 201 385 VPCL board failure – bad status information block count 201 386 VPCL board failure – bad status information block offset 201 387 VPCL board failure – parity error 201 389 Floppy disk retry 130 June 1999 TAG Cross-Reference Tables 2-7, Error Code/TAG Cross-Reference RIGS Software Code Meaning These error codes indicate a problem with the RIGS controller Codes software. No TAGs address these problems; to determine whether the Go to TAG faulty software is the customer’s or the manufacturer’s, contact Hewlett-Packard. 397 RIGS software trap No TAG 398 RIGS software trap No TAG 399 RIGS software trap No TAG Codes RIGS/Disk Drive Error Codes Go to TAG 401 Fatal RIGS PB error No TAG 405 RIGS RAM error 201 406 RIGS RAM error 201 407 RIGS RAM error 201 408 RIGS RAM error 201 409 RIGS RAM error 201 450 Incorrect diskette 130 451 Diskette format error or incorrect disk 130 454 Fatal trap 200 455 Trap 200 500 Incorrect PIT0 registers contents; no reset 200 501 PIT0 register read/write error 200 502 No countdown/zero detection in PIT0 timer 200 503 PIT0 timer; no halt 200 504 No PIT0 timer interrupt 200 505 Incorrect PIT2 registers contents; no reset 200 506 PIT2 register read/write error 200 507 No countdown/zero detection in PIT2 timer 200 508 PIT2 timer; no halt 200 509 No PIT2/timer interrupt 200 520 No DMAC reset 200 521 DMAC registers read/write error 200 2-8 TAG Cross-Reference Tables June 1999, Error Code/TAG Cross-Reference Codes RIGS/Disk Drive Error Codes Go to TAG 522 No DMA transfer 200 523 No DMA transfer termination 200 524 No DMAC termination interrupt 200 525 No software abort operation 200 526 No software abort interrupt 200 527 DMAC operation error 200 528 DMA transfer error 200 529 Two-channel DMA transfer error 200 530 No two-channel DMA transfer 200 540 VPCL board serial controller registers read/write error 200 541 VPCL board break condition detected 200 542 VPCL board serial controller transmitter not ready 200 543 No VPCL board serial controller transfer 200 544 VPCL board serial controller transfer error 200 545 Host serial controller registers read/write error 200 546 Host transmitter not ready 200 547 No serial controller interrupts 200 548 Host serial controller/VPCL board parity error 200 549 Serial controller unexpected interrupt 200 550 Two-channel transfer error 200 551 No VPCL board/serial controller interrupt on break 200 552 No serial controller/DMAC interaction 200 553 Serial controller/DMAC transfer count error 200 554 Serial controller/DMAC transfer error 200 555 RS232 send/receive path error 200 556 RS232 DTR/DTC path error 200 557 RS232 RTS/CTS path error 200 558 RS422 send/receive path error 200 559 RS422 send clock/receive clock path error 200 560 CRTC register read/write error 200 561 No page begin (PIT2) interrupt 200 June 1999 TAG Cross-Reference Tables 2-9, Error Code/TAG Cross-Reference Codes RIGS/Disk Drive Error Codes Go to TAG 562 No CRTC address generation 200 563 No VSYNC generation (end of page) 200 564 No end of page (PIT2) interrupt 200 565 No CRTC count termination 200 566 VSYNC timeout error 200 570 Drive controller/SCSI read/write error 200 571 Drive controller busy timeout 200 572 Diskette is write protected 130 573 Drive not ready 130 574 Drive controller restore error 130 575 Drive controller seek error 130 576 Drive controller read sector error 130 577 Drive controller read sector data/checksum error 200 578 Drive controller write sector error 200 579 Drive controller read/modify/write error 200 580 No drive controller/PIT0 interrupt 200 581 No drive controller-DMA interaction 200 582 Drive controller/DMAC transfer error 200 583 Drive controller/DMAC transfer count error 200 584 Drive controller/DMAC read sector error 200 585 Drive controller/DMAC write sector error 200 586 Drive hard error 130 Code Bit Map RAM Error Codes Go to TAG 600 Bit-map RAM data path error 200 601 Bit-map RAM bank selection error 200 602 Bit-map RAM refresh error 200 603 Bit-map RAM address path error 200 604 Incorrect ALU operation in bit-map RAM data path 200 605 Incorrect origin data modifications 200 2-10 TAG Cross-Reference Tables June 1999, Error Code/TAG Cross-Reference Code Bit Map RAM Error Codes Go to TAG 606 Total bit-map RAM bank fault 405 610 Bit-map RAM chip error 405 Code Host Communication Error codes Go to TAG 701–741 Async flex IO error 753 745–755 Smart flex IO error 754 June 1999 TAG Cross-Reference Tables 2-11, Print Quality/TAG Cross-Reference

Print Quality/TAG Cross-Reference

Poor quality prints are another indication of printer problems. Begin by running a set of test prints. Then, compare the test prints to the samples located in Section 4, Print Quality Samples. The chart below summarizes the possible print quality problems you may encounter and recommends a TAG in Section 3 to follow to address the problem. Blank Prints Go to TAG Complete 800 Partial 800 With dark horizontal bands 800 Light Prints Go to TAG With carrier particles 801 With background 811 With voids/white spots 802 With light vertical streaks 803 With blank or white vertical lines 803 With light horizontal bands 804 Dark Prints Go to TAG Dark black prints 805 With dark spots or scratches 806 With dark blotches 810 With dark vertical streaks (without fusing) 812 With dark vertical streaks (with fusing) 808 Skewed Prints Go to TAG Simplex 807 Duplex 901 2-12 TAG Cross-Reference Tables June 1999, Print Quality/TAG Cross-Reference Misregistration Go to TAG Simplex 807 Duplex 901 Smeared, Blurred, Uneven Prints Go to TAG Smeared vertical streaks 809 Blurred prints 809 Uneven density 810 Prints with background 811 Prints with background and residual 811 images Prints with residual images 813 Prints with offset images 814 Additional Print Quality Problems Go to TAG Wrinkled or torn prints 706 Prints improperly fused 812 Prints exhibiting printhead problems 815 June 1999 TAG Cross-Reference Tables 2-13, Mechanical Malfunction/TAG Cross-Reference

Mechanical Malfunction/TAG Cross-Reference

The chart below outlines possible mechanical malfunctions and recommends an appropri- ate TAG to follow to resolve the problem. Operator Panel Problems Go to TAG Blank with AC power fan and cooling fan on 500 Blank with AC power fan on 500 Blank with no fans on 600 All lights on 610 Incomplete display immediately after POR 610 “Close cover” displayed 600 Remove prints light remains on or lights 700 “Add toner” displayed 035 Machine check light is on with no numerical 201 Display One or more lights are off at POR 610 Tone not working 610 Incorrect paper size 702 Other operator panel malfunctions 610 Output Tray Problems Go to TAG Sensor not sensing condition 701 Jogging incorrectly 083 Will not stop jogging 083 Job offset incorrect 083 Cassette Problems Go to TAG Upper cassette 703 Lower cassette 704 2-14 TAG Cross-Reference Tables June 1999, Mechanical Malfunction/TAG Cross-Reference Paper Handling Problems Go to TAG Multiple paper feed 705 Multiple sheet feeds and jams 705 Wrinkled or torn paper 706 Simplex: misregistration and paper skew 807 Duplex: misregistration and paper skew 901 Paper will not feed from upper cassette 012 Paper jam in duplex area 902 Upper paper guide not closing 707 Counter Problems Go to TAG Supplies seem to have short life span 750 Incorrect counting 750 Communication Problems Go to TAG Printer will produce test prints 753 Incorrect data being printed 753 Additional Mechanical Malfunctions Go to TAG Test prints won’t run after POR 130 Cooling fan not running 752 Vacuum transport fan not running 752 Circuit breaker trip 600 Main drive motor not turning off 751 June 1999 TAG Cross-Reference Tables 2-15, Mechanical Malfunction/TAG Cross-Reference 2-16 TAG Cross-Reference Tables June 1999, Section 3

Troubleshooting Analysis Guides

(TAGs) June 1999 Troubleshooting Analysis Guides (TAGs) 3-1,

Contents Troubleshooting Analysis Guides

TAG 001: Troubleshooting a Problem..3-5 TAG 002: Check Problem Resolution ..3-7 TAG 010: Upper Cassette Malfunction ..3-10 TAG 011: Lower Cassette Malfunction ..3-12 TAG 012: Upper Cassette Not Latched ..3-14 TAG 013: Lower Cassette Not Latched ..3-17 TAG 020: Paper Jam/Misfeed in Upper Cassette Area ..3-19 TAG 021: Paper Jam/Misfeed in Lower Cassette Area ..3-22 TAG 022: Paper Jam in the Transfer or Fuser Area..3-26 TAG 023: Paper Jam in the Output Area ..3-30 TAG 025: Paper in Input Area Before Printing ..3-32 TAG 026: Paper in Output Area Before Printing..3-34 TAG 030: Developer Bias Short/Failure ..3-36 TAG 031: Toner Patch Reference Level Incorrect.3-39 TAG 032: Toner Patch Too Light .3-41 TAG 035: Out of Toner or ADD TONER Indication ..3-43 TAG 036: Developer Not Installed ..3-45 TAG 040: Photoconductor Seam Sensor Malfunction..3-46 TAG 044: Charge Corona/Transfer Corona Circuit Open .3-49 TAG 045: Charge Corona Circuit Shorted..3-52 TAG 047: PC Life Data Error ..3-54 TAG 048: Developer Life Error ..3-55 TAG 050: Transfer Corona Circuit Shorted..3-56 TAG 055: Erase Lamp Malfunction..3-58 TAG 070: Fuser Malfunction ..3-60 TAG 071: Open Fuser/Thermistor .3-65 TAG 072: Fuser Temperature Too High ..3-66 TAG 097: +12 Vdc Power Shorted or Sensing Problem ..3-68 TAG 098: -12 Vdc Power Shorted ..3-78 TAG 099: +24 Vdc Power Shorted .3-80 TAG 100: VPCL Board Interface Malfunction ..3-89 3-2 Troubleshooting Analysis Guides (TAGs) June 1999, TAG 130: Disk Drive Malfunction .3-90 TAG 200: RIGS Internal Communication Malfunction .3-95 TAG 201: RIGS-VPCL Interface Malfunction .3-97 TAG 405: RIGS Bit-Map RAM Malfunction .3-99 TAG 500: +5 Vdc Power Malfunction .3-100 TAG 600: Vac Power Malfunction .3-105 TAG 610: Operator Panel Malfunction .3-112 TAG 700: Output Tray Circuit Malfunction .3-115 TAG 702: Paper Size Detection Malfunction .3-117 TAG 703: Upper Cassette Malfunction .3-120 TAG 704: Lower Cassette Malfunction.3-121 TAG 705: Multiple Paper Feeding .3-122 TAG 706: Paper Damaged or Wrinkled .3-123 TAG 707: Upper Paper Guide Assembly Not Closing .3-124 TAG 750: Counter Malfunction.3-125 TAG 751: Main Drive Motor Runs Continuously.3-127 TAG 753: Async I/O Communications Malfunction.3-128 TAG 754: Smart I/O Card Malfunction.3-131 TAG 800: Prints Blank or With Dark Horizontal Bands.3-133 TAG 801: Prints Light or Light With Carrier Particles .3-137 TAG 802: Prints With Voids or White Spots .3-142 TAG 803: Prints With Light or White Vertical Streaks .3-144 TAG 804: Prints With Light Horizontal Bands .3-145 TAG 805: Black Prints.3-146 TAG 806: Prints with Dark Spots or Scratches .3-148 TAG 807: Misregistered/Skewed Prints .3-150 TAG 808: Prints Overtoned/Dark Vertical Streaks .3-153 TAG 809: Blurred or Smeared Vertical Streaks on Prints.3-157 TAG 810: Uneven Density or Dark Areas on Prints .3-161 TAG 811: Background/Residual Images/Dark Prints .3-162 TAG 812: Uneven or No Fusing on Prints .3-166 TAG 813: Residual Images on Prints .3-168 TAG 815: Prints Resulting From Printhead Malfunctions .3-170 TAG 900: Top Cover Interlock Malfunction, Duplex .3-171 TAG 901: Misregistration/Skewed Prints (Duplex) .3-173 TAG 902: Paper Jam in Duplex Area .3-177 June 1999 Troubleshooting Analysis Guides (TAGs) 3-3,

Section 3 Troubleshooting Analysis Guides

The Troubleshooting Analysis Guides (TAGs) contained in this section outline each of the TAGs used to diagnose and resolve specific printer problems related to error messages, print quality, and mechanical malfunctions. An overview of how the TAGs are organized and how to use them is included in “Print Quality/TAG Cross-Reference” on page 2-12. If you are using a TAG for the first time, please refer to this section for more specific instruc- tions. Also note that Section 2, TAG Cross- Reference Tables, provides comprehensive charts which cross reference specific error messages, print quality problems, and mechan- ical malfunctions to the TAGs contained in this section. As you use these TAGs, you may need to refer to other sections of this manual for addi- tional information. Please turn to these sections as required.

The shorthand convention “MC” is used in place of the words “Machine Check” when

error messages that include this text are shown. 3-4 Troubleshooting Analysis Guides June 1999, TAG 001: Troubleshooting a Problem

TAG 001: Troubleshooting a Problem

If you are not sure how to troubleshoot a printer problem, start with this TAG. This and all TAGs assume you are familiar with standard procedures, such as power-on-reset, presented in Section 1, Troubleshooting. In addition, TAGs may refer you to Section 2, TAG Cross- Reference Tables which contains: • Error message cross-reference table Arranged by error message; refers you to the TAG associated with the message. • Print quality cross-reference table Arranged by description of print-quality problem; refers you to the TAG associated with the problem. • Mechanical malfunction cross-reference table Arranged by description of the mechanical malfunction; refers you to the TAG associated with the malfunction. 1 To start: • Disconnect all peripheral cables. • Power-on-reset the printer. Did the printer display an error message? No: Run test prints, following the procedure outlined in Section 1, Troubleshooting then repeat this step. If the answer is still no, refer to the mechanical malfunctions cross-reference chart in Section 2, TAG Cross- Reference Tables to determine which TAG to follow. Then turn to that TAG. Yes: Note the error message and continue. 2 Power-on-reset the printer. Did the power-on-reset end with an error message? No: Continue. Yes: Refer to the error message cross-reference table in Section 2, TAG Cross- Reference Tables using either the message that displayed after steps 1 and 2, or if multiple error messages con- tinue to appear, the first error message that displays. Turn to the TAG associated with the mes- sage. 3 Did the printer READY light come on with no error message? No: Continue. Yes: Go to TAG 753. 4 Run test prints from the upper cassette by completing the following: • Power-on-reset the printer. • Run test prints from the upper cassette. Did an error message appear while running the prints? No: Continue. Yes: Look up the message in the error message cross-reference chart to determine which TAG to follow, then turn to that TAG. June 1999 Troubleshooting Analysis Guides 3-5, TAG 001: Troubleshooting a Problem 5 Run test prints from the lower cassette by completing the following: • Press STOP and allow the cycle to finish. • Remove the upper cassette. • Power-on-reset the printer. • Run test prints from the lower cassette. Did an error message appear while running test prints? No: Continue. Yes: Look up the message in the error message cross-reference chart to determine which TAG to follow, then turn to that TAG. 6 Check communications by completing the following: • Turn the printer off. • Reinstall all communication cables. • Reinstall the upper cassette. • Power-on-reset the printer. • Re-run the customer’s problem print job. Does the job fail? No: Continue. Yes: Go to TAG 753. 7 Complete the following: • Run test prints. • Re-run the customer’s problem print job. Does an error message appear? No: Continue. Yes: Look up the message in the error message cross-reference chart, then turn to TAG indicated in the chart. 8 Run a job which is known to be good. • Compare the output from the problem print job to the output from the good print job. Can you identify the problem? No: Return to the beginning of the TAG, following the procedures carefully to determine the kind of problem your customer has. Yes: Identify the problem as either a print quality problem or a mechanical malfunction, find the problem in the appropriate cross-reference chart, identify a TAG addressing that problem, then turn to that TAG. 3-6 Troubleshooting Analysis Guides June 1999, TAG 002: Check Problem Resolution

TAG 002: Check Problem Resolution Follow the procedure outlined in this TAG when you have completed an action to resolve a

problem, and are sent to this TAG from another TAG. 1 Complete any actions directing you to this TAG. • Make sure all connectors, covers, parts, and hardware have been reinstalled. In the course of resolving the printer problem, did you complete the every-call cleaning pro- cedure? No: Continue. Yes: Go to #3 in this TAG. 2 Clean the printer thoroughly, following the every-call cleaning procedure described below. 1 Remove these major printer supplies: • Photoconductor; place it in its protective packaging • Cleaner • Developer • Fuser 2 Inspect and vacuum the printer: • Inspect the areas in the printer around the developer, cleaner, photoconductor, and fuser for damage and wear. • Vacuum these areas to remove all excess toner, contamination, and/or foreign objects. 3 Clean internal areas: • Clean the erase lamp with a cotton swab. • Clean the printhead bias plates with a soft cloth. • Clean the LED lens with a cotton swab, making sure no lint remains on the lens. 4 Inspect and clean the fuser:

Caution! The fuser may be hot.

• Inspect the fuser for damage and contamination; repair or replace as necessary. • Clean the fuser connector, both on the fuser and in the printer, with a cotton swab. • Vacuum in and around the rollers to remove excess toner, contamination, and any foreign objects. • Reinstall the fuser. 5 Inspect and clean the developer: • Inspect the developer for damage or contamination; repair or replace as necessary. • Clean any excess toner from the developer with a soft cloth. • Clean the toner patch sensor lens with a cotton swab, making sure no lint remains on the lens. • Vacuum the felt areas around the magnetic roller, being careful not to vacuum toner from the magnetic roller. • Reinstall the developer. Inspect and clean the cleaner/charge corona:

Caution! Handle gently to avoid breaking the charger wire.

• Inspect the charger wire for damage or contamination; repair or replace as necessary. • Remove the charge corona from the cleaner. • Clean the grid with the cleaner brush. • Remove the grid to expose the charger wire. • Clean the charger wire with a cotton swab or charger cleaning tool. • Reinstall the grid. • Clean any excess toner from the cleaner with a soft cloth. June 1999 Troubleshooting Analysis Guides 3-7, TAG 002: Check Problem Resolution • Reinstall the charge corona in the cleaner. • Reinstall the cleaner. 6 Clean and inspect the photoconductor area:

Caution! Do not touch the photoconductor belt, as this permanently damages it.

• Clean the photoconductor seam sensor inside the printer with a cotton swab or compressed air. • Remove the photoconductor from its protective packaging. • Inspect the photoconductor for damage or contamination; repair or replace as necessary. • Reinstall the photoconductor. 7 Clean the transfer corona:

Caution! Handle gently to avoid breaking the charger wire.

• Remove the transfer corona. • Clean the transfer corona housing with a soft cloth. • Clean the transfer corona wire with a cotton swab. • Reinstall the transfer corona. Have you completed the every-call cleaning procedure? No: Complete the procedure, then continue. Yes: Continue. 3 Run test prints to confirm print quality, in both simplex and duplex modes and from upper and lower paper cassettes. When you enter test print mode by pressing the keys listed below, the follow- ing items print: a directory of the boot device and multiple listings of fonts; a continuous flow of test prints. To run test prints: 1 Disconnect the host interface. 2 Make sure “Ready” displays on the panel. 3 Press ONLINE. 4 Press MENU 5 Press h to highlight “Test Print” 6 Press e to select “Test Print” 7 Choose “Simplex” or “Duplex” (Duplex is the default. Press h to choose simplex.) 8 Press e to start. A directory of the boot device and multiple listings of fonts prints. A continu- ous flow of the test pattern then prints. 9 To stop printing the test pattern, press f. The printer will print all test prints stored in the printer’s buffer, then stop. If the test pattern prints successfully, the problem probably originates with the host system or a pro- tocol converter connected to the host. Are the test prints clean and printing correctly? No: Go to Section 4, Print Quality Samples to identify a sample with the problem you see in the test print, then turn to the TAG indicated. Yes: Continue. 3-8 Troubleshooting Analysis Guides June 1999, TAG 002: Check Problem Resolution 4 Clear the error log: 1 Enter the diagnostic mode of the printer: a Turn off the printer and wait 5 seconds. b Hold down the MENU and STATUS keys simultaneously as you turn the printer back on. Wait for all three LEDs to come on. This takes approximately 30 seconds. 2 Press e to display the first available test. Once a test name is displayed, you use the h key to move through the available tests. a Press h until “Clear Error Log” shows on the display. 3 Press e to activate the procedure. 4 Press: e to advance to the drive where the error log is maintained. This is usually the boot drive. 5 Press: e to clear the error log on the selected drive. 6 Press: f to exit the procedure. 7 Confirm that the error log has been cleared. Exit diagnostic mode (POR) and print the error log. All errors in all sections should be reset to zero. Do the error log entries appear as 0000? No: Return to the beginning of this step. Yes: Continue. 5 Fill in the Repair/Maintenance record taped inside the printer’s front cover. • Make sure the problem description and steps taken to resolve the problem are clearly documented. • Reinstall all connectors, covers, parts, and hardware. You have successfully resolved the printer’s problem. Congratulations! June 1999 Troubleshooting Analysis Guides 3-9, TAG 010: Upper Cassette Malfunction

TAG 010: Upper Cassette Malfunction

ERROR MESSAGE:FALSE “UPPER CASSETTE EMPTY” MESSAGE Possible Causes: Cassette empty Paper incorrectly loaded Possible Defects (not listed in any particular order): Upper paper empty actuator Upper paper empty sensor Upper cassette tray Upper pressure lever Upper cassette release cam Upper cassette release latch Upper cassette release lever Spring Connectors/wiring VPCL board 1 Make sure paper is in the upper cassette. • Make sure the paper is loaded correctly so that the side and rear guides are positioned securely against the paper in the cassettes. • Power-on-reset the printer. • Run test prints. Is a false “UPPER CASSETTE EMPTY” message displayed? No: The paper was loaded incorrectly. Turn to TAG 002. Yes: Continue. 2 Check upper cassette: • Remove the upper cassette. • Inspect the upper paper empty sensor actuator for binding, or for a damaged or broken part. Is it in good working order? No: Replace the actuator, then turn to TAG 002. Yes: Continue. 3 Power-on-reset the printer • Run test prints. Is a false “UPPER CASSETTE EMPTY” message displayed? No: The upper paper empty sensor was bad. Yes: Reinstall the old upper paper empty sensor and continue. 3-10 Troubleshooting Analysis Guides June 1999, TAG 010: Upper Cassette Malfunction 4 Check pressure lever: • Reinsert the upper cassette. • Watch the pressure lever as the cassette is inserted. Does the pressure lever elevate the paper to the correct feeding position? No: Check the following for defects or incorrect mounting: • Cassette tray • Damper assembly • Upper pressure lever • Upper cassette release cam • Upper cassette release latch • Wire cable, pulley and spring • Upper cassette release lever Replace the defective part, then turn to TAG 002. Yes: Replace the VPCL board, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-11, TAG 011: Lower Cassette Malfunction

TAG 011: Lower Cassette Malfunction

ERROR MESSAGE:FALSE “LOWER CASSETTE EMPTY” MESSAGE Possible Causes: Cassette empty Paper incorrectly loaded Possible Defects (not listed in any particular order): Lower paper empty actuator Lower paper empty sensor Lower cassette tray Lower pressure lever Lower cassette release cam Lower cassette release latch Lower cassette release lever Spring Connectors/wiring VPCL board 1 Make sure paper is in the lower cassette. • Make sure the paper is loaded correctly so that the side and rear guides are positioned securely against the paper in the cassettes. • Power-on-reset the printer. • Run test prints. Is a false “LOWER CASSETTE EMPTY” message displayed? No: The paper was loaded incorrectly. Turn to TAG 002 Yes: Continue. 2 Remove the lower cassette. • Inspect the lower paper empty sensor actuator for binding, or for a damaged or broken part. Is it in good working order? No: Replace the actuator, then turn to TAG 002. Yes: Continue. 3 Power-on-reset the printer • Run test prints. Is a false “LOWER CASSETTE EMPTY” message displayed? No: The lower paper empty sensor was bad. Yes: Reinstall the old lower paper empty sensor and continue. 3-12 Troubleshooting Analysis Guides June 1999, TAG 011: Lower Cassette Malfunction 4 Reinsert the lower cassette. • Watch the pressure lever as the cassette is inserted. Does the pressure lever elevate the paper to the correct feeding position? No: Check the following for defects or incorrect mounting: • Cassette tray • Lower pressure lever • Lower cassette release cam • Lower cassette release latch • Wire cable, pulley and spring • Lower cassette release lever • Replace the defective part, then turn to TAG 002. Yes: Replace the VPCL board, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-13, TAG 012: Upper Cassette Not Latched

TAG 012: Upper Cassette Not Latched

ERROR MESSAGE:FALSE “UPPER CASSETTE NOT LATCHED” MESSAGE Possible Defects (not listed in any particular order): Upper cassette release cam Upper cassette release latch Upper cassette in latch Upper pressure lever Spring Wire cable and pulley Upper cassette Upper cassette in switch Upper paper size sensor Lower paper size sensor Connectors or wiring VPCL board 1 Turn off the printer and unplug the power cord. • Verify that J/P40 and J/P52 are connected properly. • Remove the upper cassette. • Inspect it for damage. • Reinsert the cassette. Is the upper cassette properly latched? No: Continue. Yes: Go to #3 in this TAG. 2 Check for damage: • Upper cassette release cam • Upper cassette release latch • Upper cassette in latch • Upper pressure lever • Spring • Wire cable and pulley Are any of these parts damaged? No: Return to the beginning of this TAG. Yes: Replace the damaged parts, then turn to TAG 002. 3 Remove the upper cassette. • Make sure the upper cassette in switch actuator is functioning properly. Is it in good working order? No: Replace the actuator, then turn to TAG 002. Yes: Continue. 3-14 Troubleshooting Analysis Guides June 1999, TAG 012: Upper Cassette Not Latched 4 Run diagnostic test “Upper Cassette Test” on page 5-4. Is UPPER CASSETTE TEST “NO CASSETTE” displayed? No: Replace the VPCL board, then turn to TAG 002. Yes: Continue. 5 Install the upper cassette. Is a message other than “NO CASSETTE” displayed? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 6 Turn the printer off and unplug the power cord. • Remove the upper cassette. • Loosen the upper paper size sensor assembly for access to the circuit board. • Disconnect J/P46. • Activate the cassette in switch. • Check P46-1 to P46-2 for continuity. Is there continuity? No: Replace the upper cassette in switch or wire hardness W58, then turn to TAG 002. Yes: Continue. 7 Reconnect J/P46. • Disconnect J/P40 and J/P45. • Check P40-49 to P45-2 for continuity. Is there continuity? No: Go to #10 in this TAG. Yes: Continue. 8 Check P40-48 to P45-3 for continuity. Is there continuity? No: Continue. Yes: Replace the upper paper size sensor assembly. If this does not resolve the problem, replace the VPCL board. Turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-15, TAG 012: Upper Cassette Not Latched 9 Reconnect J/P40 and J/P45. • Remove the lower cassette. • Loosen the lower paper size sensor assembly for access to the circuit board. • Disconnect J/P43 and J/P47. • Check J43-8 to J47-3 for continuity. Is there continuity? No: Replace lower paper size sensor assembly, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P45-3 to P47-3, P43-8 to J52-3, or P40-48 to P52-3. If this does not resolve the problem, replace the upper paper size sensor assembly. Then turn to TAG 002 10 Reconnect J/P40 and J/P45. • Remove the lower cassette. • Loosen the lower paper size sensor assembly for access to the circuit board. • Disconnect J/P43 and J/P47. • Check J43-9 to J47-2 for continuity. Is there continuity? No: Replace the lower paper size sensor assembly. Yes: Repair or replace the connectors or wiring from P45-2 to P47-2, P43-9 to J52-2 or P40-49 to P52-2. If this does not resolve the problem, replace the upper paper size sensor assembly. Then turn to TAG 002 3-16 Troubleshooting Analysis Guides June 1999, TAG 013: Lower Cassette Not Latched

TAG 013: Lower Cassette Not Latched

ERROR MESSAGE:FALSE “LOWER CASSETTE NOT LATCHED” MESSAGE Possible Defects (not listed in any particular order): Lower cassette release cam Lower cassette release latch Lower cassette in latch Lower pressure lever Spring Lower cassette Lower cassette in switch Lower paper size sensor Connectors or wiring VPCL board 1 Turn the printer off and unplug the power cord. • Verify that J/P40 and J/P52 are connected properly. • Remove the lower cassette. • Inspect it for damage. • Reinsert the cassette. Is the lower cassette properly latched? No: Continue. Yes: Go to #3 in this TAG. 2 Check the following for damage: • Lower cassette release cam • Lower cassette release latch • Lower cassette in latch • Lower pressure lever • Spring Are any of these parts damaged? No: Return to the beginning of this TAG. Yes: Replace the damaged parts, then turn to TAG 002. 3 Remove the lower cassette. • Make sure the lower cassette in switch actuator is functioning properly. Is it in good working order? No: Replace the actuator, then turn to TAG 002. Yes: Continue. 4 Run self diagnostic test “Lower Cassette Test” on page 5-5. • Is LOWER CASSETTE TEST “NO CASSETTE” displayed? No: Replace the VPCL board, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-17, TAG 013: Lower Cassette Not Latched 5 Install the lower cassette. Is a message other than “NO CASSETTE” displayed? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 6 Turn the printer off and unplug the power cord. • Remove the lower cassette. • Loosen the lower paper size sensor assembly for access to the circuit board. • Disconnect J/P48. • Activate the cassette in switch. • Check P48-1 to P48-2 for continuity. Is there continuity? No: Replace the lower cassette in switch or wire harness W59, then turn to TAG 002. Yes: Continue. 7 Reconnect J/P48. • Disconnect J/P43 and J/P40. • Check P40-50 to P43-10 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P43-10 to J52-1 or P40-50 to P52-1. Then turn to TAG 002. Yes: Continue. 8 Check P43-8 to P40-48 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P43-8 to J52-3 or P40-48 to P52-3. Then turn to TAG 002. Yes: Replace the lower paper size sensor assembly. If this does not resolve the problem, replace the VPCL board. Then turn to TAG 002. 3-18 Troubleshooting Analysis Guides June 1999, TAG 020: Paper Jam/Misfeed in Upper Cassette Area

TAG 020: Paper Jam/Misfeed in Upper Cassette Area

ERROR MESSAGE:PAPER JAM 020 UPPER CASSETTE Possible Causes: Paper incorrectly loaded Wrong weight or type of paper loaded Paper path obstructed Possible Defects (not listed in any particular order): Upper pick-up roller assembly Upper feed roller assembly Upper pick-up roller drive assembly Upper paper guide assembly Lower paper guide assembly Upper paper cassette Pick pressure adjustment Main drive gear assembly Paper feed drive belt Paper feed drive idler assembly Paper timing sensor Wiring or connectors VPCL board 1 Check both paper paths and remove any paper jams. • Make sure paper is loaded properly in both cassettes. • Make sure the paper guides are positioned properly. • Make sure the upper pick-up roller, feed roller, and pinch roller assemblies are clean. • Verify that J/P40, J/P60, J/P66, and J/P68 are connected properly. • Confirm that the paper in the cassettes meets paper specifications. • Power-on-reset the printer. • Run test prints from the upper cassette. Is error message PAPER JAM 020 UPPER CASSETTE still displayed? No: Go to #12 in this TAG. Yes: Continue. 2 Turn the printer off and inspect the following for damage or binding: • Upper paper guide assembly • Lower paper guide assembly • Paper feed drive belt • Paper feed drive pulley • Paper feed drive idler assembly • Main drive gear assembly • Upper pick-up roller drive assembly Are all the parts in good working order? No: Replace any damaged parts, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-19, TAG 020: Paper Jam/Misfeed in Upper Cassette Area 3 Clear the paper path. • Remove the upper cassette. • Power-on-reset the printer. • Run test prints from the lower cassette. Is error message PAPER JAM 021 LOWER CASSETTE displayed? No: Go to #9 in this TAG. Yes: Continue. 4 Clear the paper path. • Inspect the paper timing sensor actuator for damage or binding. Is it in good working order? No: Replace the paper timing guide assembly, then turn to TAG 002. Yes: Continue. 5 Replace the paper timing guide assembly. • Power-on-reset the printer. • Run test prints from the upper cassette. Is error message PAPER JAM 020 UPPER CASSETTE still displayed? No: Turn to TAG 002. Yes: Reinstall the old paper timing guide assembly and continue. 6 Check J/P91-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 7 Check J/P8-13 for +24 Vdc. Is the voltage +24 Vdc? No: Replace the DC power supply, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P91-1 to P8-13, then turn to TAG 002. 8 Turn the printer off and unplug the power cord. • Disconnect J/P40 and J/P57. • Check the following for continuity: P40-16 to P57-2, P40-25 to P57-1, and P40-12 to P57-3. Is there continuity on all? No: Repair or replace the connectors or wiring from P40-25 to J/P58-1 to P57-1, P40-16 to J/P58-2 to P57-2, or P40-12 to J/P58-3 to P57-3. Then turn to TAG 002. Yes: Replace the paper timing guide. If this does not resolve the problem, replace the VPCL board. Then turn to TAG 002. 3-20 Troubleshooting Analysis Guides June 1999, TAG 020: Paper Jam/Misfeed in Upper Cassette Area 9 Turn the printer off. • Open the back cover and install an interlock by-pass tool. • Remove the paper feed cover to expose the upper paper pick roller assembly.

Use extreme caution as gears and belts are exposed.

• Run diagnostic test “Roller Clutch Tests” on page 5-7 to test the upper pick-up roller clutch. • Check P66 for a voltage change from +24 Vdc to 0 Vdc. Does the voltage change from +24 Vdc to 0 Vdc? No: Continue. Yes: Go to #12 in this TAG. 10 Turn off the printer and unplug the power cord. • Disconnect J/P40 and J/P68. • Check P40-9 to J68-2 and P40-11 to J68-1 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P40-9 to J68-2 or P40-11 to J68-1. Then turn to TAG 002. Yes: Replace the upper pick-up roller assembly, then turn to TAG 002. 11 Turn off the printer and unplug the power cord. • Disconnect J/P40 and J/P66. • Check P40-6 to J66-2 and P40-11 to J66-1 for continuity. Is there continuity? No: Repair or replace connectors or wiring from P40-6 to J66-2 or P40-11 to J66-1. Then turn to TAG 002. Yes: Replace the upper feed roller assembly, then turn to TAG 002. 12 Inspect the upper pick-up roller assembly for damage or binding. Is it in good working order? No: Replace the upper pick-up roller assembly, then turn to TAG 002. Yes: Continue. 13 Inspect the upper feed roller assembly for damage or binding. Is it in good working order? No: Replace the upper feed roller assembly, then turn to TAG 002. Yes: The upper pick-up roller or the feed rollers may not be delivering paper to the paper timing sensor at the correct time. Return to the beginning of this TAG. June 1999 Troubleshooting Analysis Guides 3-21, TAG 021: Paper Jam/Misfeed in Lower Cassette Area

TAG 021: Paper Jam/Misfeed in Lower Cassette Area

ERROR MESSAGE:PAPER JAM 021 LOWER CASSETTE Possible Causes: Paper loaded incorrectly Wrong weight or type of paper loaded Paper path obstruction Possible Defects (not listed in any particular order): Lower pick-up roller assembly Lower feed roller assembly Lower pick-up roller drive assembly Upper paper guide assembly Lower paper guide assembly Lower paper cassette Pick pressure adjustment Main drive gear assembly Idler assembly Paper feed drive belt Paper feed drive idler assembly Paper timing sensor Wiring or connectors VPCL board 1 Check both paper paths and remove any jams. • Make sure paper is loaded properly in both cassettes. • Make sure the paper guides are positioned properly. • Check that the pick-up roller, feed roller, and backup roller assemblies are clean. • Verify that J/P40, J/P62, J/P67, and J/P69 are connected properly. • Confirm that the paper in the cassettes meets paper specifications, outlined in the HP 5000 Cut Sheet Printers Paper Specifications Guide, C4672-90002. • Remove the upper cassette. • Power-on-reset the printer. • Run test prints from the lower cassette. Is error message PAPER JAM 021 LOWER CASSETTE displayed? No: Go to #12 in this TAG. Yes: Continue. 3-22 Troubleshooting Analysis Guides June 1999, TAG 021: Paper Jam/Misfeed in Lower Cassette Area 2 Turn the printer off and inspect the following for damage or binding: • Lower paper guide assembly • Upper paper guide assembly • Paper feed drive belt • Paper feed drive pulley • Paper feed drive idler assembly • Main drive gear assembly • Lower pick-up roller drive assembly Are all the parts in good working order? No: Replace the damaged parts, then turn to TAG 002. Yes: Continue. 3 Clear the paper path. • Reinsert the upper cassette. • Power-on-reset the printer. • Run test prints from the upper cassette. Is error message PAPER JAM 020 UPPER CASSETTE displayed? No: Go to #9 in this TAG. Yes: Continue. 4 Clear the paper path. • Inspect the paper timing sensor actuator for damage or binding. Is it in good working order? No: Replace the paper timing guide assembly, then turn to TAG 002. Yes: Continue. 5 Replace the paper timing guide assembly. • Power-on-reset the printer. • Run test prints from the lower cassette. Is error message PAPER JAM 021 LOWER CASSETTE still displayed? No: Turn to TAG 002. Yes: Reinstall the old paper timing guide assembly and continue. 6 Check J/P91-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 7 Check J/P8-13 for +24 Vdc. Is the voltage +24 Vdc? No: Replace the DC power supply, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P91-1 to P8-13, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-23, TAG 021: Paper Jam/Misfeed in Lower Cassette Area 8 Turn the printer off and unplug the power cord. • Disconnect J/P40 and J/P57. • Check the following for continuity: P40-16 to P57-2, P40-25 to P57-1, and P40-12 to P57-3. Is there ground? No: Repair or replace the connectors or wiring from: P40-25 to J/P58-1 to P57-1, P40-16 to J/P58-2 to P57-2, or P40-12 to J/P58-3 to P57-3. Then turn to TAG 002. Yes: Replace the paper timing guide. If this does not correct the problem, replace the VPCL board. Then turn to TAG 002. 9 Turn off the printer. • Open the back cover and install an interlock by-pass tool. • Remove the paper feed cover to expose the lower paper pick-up assembly.

Use extreme caution as gears and belts are exposed.

• Run diagnostic test “Roller Clutch Tests” on page 5-7 to test the lower pick-up roller clutch. • Check P67 for a voltage change from +24 Vdc to 0 Vdc. Does the voltage change from +24 Vdc to 0 Vdc? No: Continue. Yes: Go to #12 in this TAG. 10 Turn the printer off and unplug the power cord. • Disconnect J/P40 and J/P69. • Check P40-8 to J69-2 and P40-10 to J69-1 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from: P40-8 to J69-2 or P40-10 to J69-1. Then turn to TAG 002. Yes: Replace the lower pick-up roller assembly, then turn to TAG 002. 11 Turn the printer off and unplug the power cord. • Disconnect J/P40 and J/P67. • Check P40-5 to J67-2 and P40-11 to J67-1 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from: P40-5 to J67-2 or P40-11 to J67-1. Then turn to TAG 002. Yes: Replace the lower feed roller assembly, then turn to TAG 002. 3-24 Troubleshooting Analysis Guides June 1999, TAG 021: Paper Jam/Misfeed in Lower Cassette Area 12 Inspect the lower pick-up roller assembly for damage or binding. Is it in good working order? No: Replace the lower pick-up roller assembly, then turn to TAG 002. Yes: Continue. 13 Inspect the lower feed roller assembly for damage or binding. Is it in good working order? No: Replace the lower feed roller assembly, then turn to TAG 002. Yes: The lower pick-up roller or lower feed roller may not be delivering the paper to the paper tim- ing sensor at the correct time. Return to the beginning of this TAG. June 1999 Troubleshooting Analysis Guides 3-25, TAG 022: Paper Jam in the Transfer or Fuser Area

TAG 022: Paper Jam in the Transfer or Fuser Area

ERROR MESSAGE:PAPER JAM 022 TRANSFER/FUSER Possible Causes: Paper loaded incorrectly Wrong weight or type of paper loaded Paper path obstruction Possible Defects (not listed in any particular order): Fuser Paper supply Paper timing roller assembly Fuser drive assembly Fuser drive belt Vacuum transport Exit roller assembly Upper paper guide assembly Lower paper guide assembly Paper timing guide assembly Pick pressure adjustment VPCL board Connectors or wiring

When clearing this jam, be careful not to get toner on your clothing, as it may stain. If toner

gets on your clothes, rinse your clothes with cold water immediately to avoid stains. 1 Check the paper path and remove any jammed paper.

Caution! The fuser may be very hot. Use caution when you:

• Check the fuser for paper wrapped around the heat roller. Is paper wrapped around the heat roller? No: Continue. Yes: If the paper is black or very dark with no printing, go to TAG 805. If the paper is very dark and does have printing, go to TAG 811. 2 Check both paper paths for damage or obstructions. • Confirm that J/P13, J/P22, J/P40, J/P58, and J/P65 are connected properly. • Check that the paper is properly loaded. • Confirm that the paper in the cassettes meets paper specifications. • Check that the fuser is installed properly. • Power-on-reset the printer. • Run test prints. Is error message PAPER JAM 022 TRANSFER/FUSER still displayed? No: Paper incorrectly loaded, incorrect paper type in use, or a loose connector was at fault. Turn to TAG 002. Yes: Continue. 3-26 Troubleshooting Analysis Guides June 1999, TAG 022: Paper Jam in the Transfer or Fuser Area 3 Has the fuser been replaced recently? No: Continue. Yes: Go to #5 in this TAG. 4 Replace the fuser. • Run test prints. Has the problem been resolved? No: Reinstall the original fuser and continue. Yes: The fuser was at fault. Turn to TAG 002. 5 Inspect the following for damage: • Upper paper guide assembly • Paper timing roller assembly • Lower paper guide assembly • Paper timing guide assembly Are any of these parts damaged? No: Continue. Yes: Replace the damaged part, then turn to TAG 002. 6 Is more than one sheet of paper jamming? No: Go to #8 in this TAG. Yes: Continue. 7 Make sure the natural curl of the paper is turned up in the cassettes. • Make sure the paper is under the corner separators. • Make sure the rear and side paper guides are positioned properly. • Make sure the paper being used does not have a high static charge. • Run test prints. Does the multiple feed problem still exist? No: The paper appears to be at fault. Turn to TAG 002. Yes: Adjust the paper tension lever or pick pressure, as outlined in Section 9, General Printer Maintenance, then turn to TAG 002. 8 Check the paper path for jams. • Open the printer’s front cover and insert the interlock bypass tool. • Power-on-reset the printer. • Run test prints. • Watch the end of the paper timing roller shaft. Does the paper timing roller shaft turn? No: Continue. Yes: Go to #13 in this TAG. June 1999 Troubleshooting Analysis Guides 3-27, TAG 022: Paper Jam in the Transfer or Fuser Area 9 Check J/P91-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 10 Check J/P8-13 for +24 Vdc. Is the voltage +24 Vdc? No: Replace the DC power supply, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P91-1 to P8-13, then turn to TAG 002. 11 Run diagnostic test “Roller Clutch Tests” on page 5-7 to test the paper timing roller clutch. • Check P65 for a voltage change from +24 Vdc to 0 Vdc. Does the voltage change from +24 Vdc to 0 Vdc? No: Continue. Yes: Go to #13 in this TAG. 12 Turn off the printer and unplug the power cord. • Disconnect J/P40 and J/P65. • Check P40-7 to J65-2 and P40-11 to J65-1 for continuity. Is there continuity on both? No: Repair or replace the connectors and wiring from: P40-7 to J65-2 or P40-11 to J65-1. Then turn to TAG 002. Yes: Replace the paper timing roller assembly, then turn to TAG 002. 13 Does paper stop or jam either before or during entry into the fuser? No: Go to #16 in this TAG. Yes: Continue. 14 Remove the fuser. • Check the fuser rollers for damage or toner contamination. Are they damaged or contaminated with toner? No: Continue. Yes: Replace the fuser, then turn to TAG 002. 15 Inspect the following for damage or binding: • fuser • Fuser drive belt • Fuser drive assembly Are any of these parts damaged? No: Go to #21 in this TAG. Yes: Replace the damaged parts, then turn to TAG 002. 3-28 Troubleshooting Analysis Guides June 1999, TAG 022: Paper Jam in the Transfer or Fuser Area 16 Turn the printer off. • Check for paper jams. • Inspect the exit roller, and exit pinch roller assemblies for damage, binding and contamination. Are these parts in good working order? No: Repair or replace the defective parts, then turn to TAG 002. Yes: Continue. 17 Run test prints. • Check the leading edge of the prints for improper registration. Is there improper registration? No: Continue. Yes: Go to TAG 807 or TAG 901. 18 Inspect the vacuum transport for damage or binding. Are the parts in good working order? No: Repair or replace the vacuum transport, then turn to TAG 002. Yes: Continue. 19 Open the top cover and install an interlock by-pass tool. • Power-on-reset the printer. • While the main motor is running, cover all of the holes in the vacuum transport with a piece of paper. Does the vacuum transport fan hold the paper in place? No: Continue. Yes: Return to the beginning of this TAG. 20 ! Use extreme caution: Check for 100 Vac from J/P22-1 to J/P22-2. Is the voltage 100 Vac? No: Continue. Yes: Replace the vacuum transport assembly. 21 Power-on-reset the printer. ! Use extreme caution: • While the main motor is running, monitor J/P13-6 and J/P13-3 for 100 Vac. Is the voltage 100 Vac? No: Replace the power control board, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from J22-1 to P13-6 or J22-2 to P13-3. Then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-29, TAG 023: Paper Jam in the Output Area

TAG 023: Paper Jam in the Output Area

ERROR MESSAGE:PAPER JAM 023 AT/NEAR EXIT Possible Causes: Paper path obstruction Output tray obstruction Possible Defects (not listed in any particular order): Exit paper sensor Fuser drive Exit roller assembly Exit pinch roller assembly VPCL board Connectors or wiring

If the printer has a high capacity output unit (HCO), unplug and remove it before you begin.

Test the printer without the HCO; if the problem remains, proceed with this TAG. If the prob- lem occurs only with the HCO, the HCO is causing the problem. Repair or replace the HCO. 1 Turn the printer off and unplug the power cord. • Verify that J/P50 and J/P40 are connected properly. • Check the paper path and remove any paper jams. • Check the output tray and remove any paper jams. • Power-on-reset the printer. • Run test prints. Is error message PAPER JAM 023 AT/NEAR EXIT displayed? No: Loose connectors or obstructions were at fault. Turn to TAG 002. Yes: Continue. 2 Is paper stopped or jammed at the output tray? No: Continue. Yes: Go to #5 in this TAG. 3 Inspect the exit paper sensor actuator for damage or binding. Is it in good working order? No: Repair or replace the exit paper sensor actuator, then turn to TAG 002. Yes: Continue. 3-30 Troubleshooting Analysis Guides June 1999, TAG 023: Paper Jam in the Output Area 4 Turn the printer off and unplug the power cord. • Disconnect J/P40 and J/P49. • Check the following for continuity: P40-24 to P49-2, P40-26 to P49-1, and P40-13 to P49-3. Is there continuity? No: Repair or replace the connectors or wiring from: P40-26 to J/P50-1 to P49-1, P40-24 to J/P50-2 to P49-2, or P40-13 to J/P50-3 to P49-3. Yes: Replace the exit paper sensor. 5 Turn the printer off and unplug the power cord. • Open the back cover and install an interlock bypass tool. • Remove the fuser drive cover. • Inspect the following for damage, binding, or contamination: • Exit roller assembly • Exit roller drive gear • Exit pinch roller assembly Are all the parts in good working order? No: Replace the defective parts, then turn to TAG 002. Yes: Continue. 6 Remove the fuser. • Inspect the following for damage or binding: • Fuser drive assembly • Fuser drive belt • Main drive gear assembly Are all the parts in good working order? No: Replace the defective parts, then turn to TAG 002. Yes: Reinstall the fuser and continue. 7 Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8. • Watch the fuser drive and the exit roller assembly. Are they in good working order? No: Replace the defective parts, then turn to TAG 002. Yes: Replace the fuser, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-31, TAG 025: Paper in Input Area Before Printing

TAG 025: Paper in Input Area Before Printing

ERROR MESSAGE:PAPER JAM 025 AT/NEAR INPUT Possible Defects (not listed in any particular order): Paper timing sensor VPCL board Connectors or wiring 1 Turn the printer off and unplug the power cord. • Check the paper path and remove any paper jams. • Confirm that J/P58 and J/P40 are connected properly. • Inspect the paper timing sensor actuator for damage or binding. Is it in good working order? No: Replace the paper timing guide assembly and continue. Yes: Continue. 2 Power-on-reset the printer. Is error message PAPER JAM 025 AT/NEAR INPUT displayed? No: Jammed paper, loose connectors, or the sensor actuator were at fault. Turn to TAG 002. Yes: Continue. 3 Replace the VPCL board. • Power-on-reset the printer. Is error message PAPER JAM 025 AT/NEAR INPUT displayed? No: Turn to TAG 002. Yes: Reinstall the old VPCL board and continue. 4 Loosen the paper timing guide. • Confirm that J/P57 is connected properly. Is J/P57 connected properly? No: Continue. Yes: Go to #6 in this TAG. 5 Reconnect J/P57. • Reinstall the paper timing guide. • Power-on-reset the printer. Is error message PAPER JAM 025 AT/NEAR INPUT still displayed? No: J/P57 was at fault. Turn to TAG 002. Yes: Continue. 3-32 Troubleshooting Analysis Guides June 1999, TAG 025: Paper in Input Area Before Printing 6 Turn the printer off and unplug the power cord. • Loosen the paper timing guide. • Disconnect J/P57 and J/P40. • Check the following for continuity: P40-16 to P57-2, P40-25 to P57-1, and P40-12 to P57-3. Is there continuity? No: Repair or replace the connectors or wiring from: P40-25 to J/P58-1 to P57-1, P40-16 to J/P58-2 to P57-2, or P40-12 to J/P58-3 to P57-3. Then turn to TAG 002. Yes: Replace the paper timing guide. If that doesn’t resolve the problem, replace the VPCL board. Then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-33, TAG 026: Paper in Output Area Before Printing

TAG 026: Paper in Output Area Before Printing

ERROR MESSAGE:PAPER JAM 026 AT/NEAR OUTPUT Possible Defects (not listed in any particular order): Exit paper sensor VPCL board Connectors or wiring

If the printer has a high capacity output unit (HCO), unplug and remove it before beginning

this TAG. Test the printer without the HCO; if the problem remains, proceed with this TAG. If the problem occurs only with the HCO, the HCO is causing the problem. Repair or replace the HCO. 1 Turn the printer off and unplug the power cord. • Check the paper path and remove any paper jams. • Confirm that J/P50 and J/P40 are connected properly. • Inspect the exit paper sensor actuator for damage or binding. Is it in good working order? No: Replace the exit paper sensor actuator and continue. Yes: Continue. 2 Power-on-reset the printer. Is error message PAPER JAM 026 AT/NEAR OUTPUT displayed? No: Jammed paper, loose connectors, or sensor actuator were at fault; go to TAG 002. Yes: Continue. 3 Check J/P40-26 for +12 Vdc. Is the voltage +12 Vdc? No: Replace the VPCL board, then turn to TAG 002. Yes: Continue. 3-34 Troubleshooting Analysis Guides June 1999, TAG 026: Paper in Output Area Before Printing 4 Turn off the printer and unplug the power cord. • Remove the exit cover. • Disconnect J/P49 and J/P40. • Check the following for continuity: P40-26 to P49-1, P40-24 to P49-2, and P40-13 to P49-3 Is there continuity? No: Repair or replace the connectors or wiring from: P40-26 to J/P50-1 to P49-1, P40-24 to J/P50-2 to P49-2, or P40-13 to J/P50-3 to P49-3. Then turn to TAG 002. Yes: Replace the exit paper sensor. If that doesn’t resolve the problem, replace the VPCL board. Then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-35, TAG 030: Developer Bias Short/Failure

TAG 030: Developer Bias Short/Failure

ERROR MESSAGE:MC DEVELOPER BIAS SHORT #030 Possible Defects (not listed in any particular order): Cleaner High voltage power supply DC power supply Connectors or wiring VPCL board Printhead assembly Power control #2 board Developer 1 Turn the printer off and unplug the power cord. • Verify that J/P23, J/P24, J/P40, J/P41, J/P96, and J/P85 are connected properly. • Power-on-reset the printer. Is error message MC DEVELOPER BIAS SHORT #030 still displayed? No: A loose connector was at fault. Turn to TAG 002. Yes: Continue. 2 Refer to Section 9, General Printer Maintenance and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Has the developer been replaced recently? No: Go to #5 in this TAG. Yes: Continue. 4 Replace the cleaner. • Run test prints. Is error message MC DEVELOPER BIAS SHORT #030 still displayed? No: The cleaner was defective; turn to TAG 002. Yes: Reinstall the original cleaner and go to #6 in this TAG. 5 Replace the developer. • Install a new toner cartridge. • Run test prints. Is error message MC DEVELOPER BIAS SHORT #030 still displayed? No: The developer was defective; turn to TAG 002. Yes: Reinstall the original developer and continue. 3-36 Troubleshooting Analysis Guides June 1999, TAG 030: Developer Bias Short/Failure 6 Open the back cover and install an interlock by-pass tool. • Check J/P23-5 for +24 Vdc. Is the voltage +24 Vdc? No: Repair or replace the connectors or wiring from P41-35 to P23-5, then turn to TAG 002. Yes: Continue. 7 Turn the printer off and unplug the power cord. • Disconnect J/P41 and J/P24. • Check the following for continuity P41-31 to P24-1, P41-30 to P24-2, and P41-40 to P24-3. Is there continuity? No: Repair or replace the connectors or wiring from: P41-31 to P24-1, P41-30 to P24-2, or P41-40 to P24-3. Then turn to TAG 002. Yes: Continue. 8 Disconnect P85 from the high voltage power supply. • Check P85-3 to J25-7 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P85-3 to J25-7, then turn to TAG 002. Yes: Continue. 9 Disconnect J/P96. • Check P96-1 to J25-7 for continuity. Is there continuity? No: Repair or replace the developer power supply lead from J/P96-1 to P85-3, then turn to TAG 002. Yes: Replace the high voltage power supply, then turn to TAG 002. 10 Power-on-reset the printer. Is error message MC DEVELOPER BIAS SHORT #030 still displayed? No: The VPCL board was defective. Go to TAG 002. Yes: Replace the VPCL board and continue. 11 Check J/P12-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Repair or replace the connectors or wiring from P40-27 to P12-1, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-37, TAG 030: Developer Bias Short/Failure 12 Check J/P11-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the power control #2 board, then turn to TAG 002. 13 Check J/P8-11 for +24 Vdc. Is the voltage +24 Vdc? No: Replace the DC power supply, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P8-11 to P11-1, then turn to TAG 002. 3-38 Troubleshooting Analysis Guides June 1999, TAG 031: Toner Patch Reference Level Incorrect

TAG 031: Toner Patch Reference Level Incorrect

ERROR MESSAGE:MC TPS TOO LOW #031 MC TPS TOO HIGH #037 Possible Causes: Contamination of the toner patch sensor or printhead lens Possible Defects (not listed in any particular order): Photoconductor Connectors or wiring VPCL board Developer 1 Turn the printer off and unplug the power cord. • Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce- dure. • Clean the toner patch sensor on the developer. • Clean the printhead lens. • Run at least 200 test prints to detone the printer’s engine. Has the problem been resolved? No: Contamination was at fault. Turn to TAG 002. Yes: Continue. 2 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Have the photoconductor and developers been replaced recently? No: Continue. Yes: Go to #6 in this TAG. 4 Replace the photoconductor. • Run 200+ test prints to reduce toner concentration in the developer. Has the problem been resolved? No: Reinstall the original photoconductor and continue. Yes: The photoconductor was at fault; turn to TAG 002. 5 Replace the developer. • Run test prints. Has the problem been resolved? No: Reinstall the original developer and continue. Yes: Turn to TAG 002. If the problem reappears, the toner/carrier mix may be old or contaminated. June 1999 Troubleshooting Analysis Guides 3-39, TAG 031: Toner Patch Reference Level Incorrect 6 Turn the printer off and unplug the power cord. • Remove the developer. • Disconnect J/P41. • Check P41-47 to J25-3 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-47 to J25-3. Yes: Replace the VPCL board, then turn to TAG 002. 3-40 Troubleshooting Analysis Guides June 1999, TAG 032: Toner Patch Too Light

TAG 032: Toner Patch Too Light

ERROR MESSAGE:MC TPS TOO LIGHT #032 MC TPS SIGNAL OVERLOAD #033 Possible Defects (not listed in any particular order): Photoconductor RIGS board VPCL board 1 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 2 Has the photoconductor been replaced recently? No: Continue. Yes: Go to #4 in this TAG. 3 Replace the photoconductor. • Run 200+ test prints to reduce toner concentration in the developer. Has the problem been resolved? No: Reinstall the original photoconductor and continue. Yes: The photoconductor was at fault. Turn to TAG 002. 4 Turn the printer off and unplug the power cord. • Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce- dure. • Clean the toner patch sensor on the developer. • Clean the printhead lens. • Run at least 55 test prints. Has the problem been resolved? No: Contamination was at fault. Turn to TAG 002. Yes: Continue. 5 Run test prints. Do the test prints appear overtoned, dark, or have background? No: Go to #8 in this TAG. Yes: Continue. 6 Develop a toner patch, as described in Section 1, Troubleshooting. Is the toner patch developed and properly positioned? No: Replace the RIGS board, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-41, TAG 032: Toner Patch Too Light 7 Check the toner patch sensor board in the developer for loose wiring connectors. Are all connectors and wiring connected properly? No: Reconnect the wiring and connectors or replace the developer, then turn to TAG 002. Yes: Go to TAG 808, TAG 811, or both, to identify the problem further. 8 Do the prints appear light or blank? No: Replace the VPCL board, then turn to TAG 002. Yes: Replace the photoconductor, then turn to TAG 002. 3-42 Troubleshooting Analysis Guides June 1999, TAG 035: Out of Toner or ADD TONER Indication

TAG 035: Out of Toner or ADD TONER Indication

ERROR MESSAGE:MC TONER EMPTY ERROR #035 Possible Causes: Photoconductor Toner cartridge seal not removed Toner cartridge empty High print coverage Possible Defects (not listed in any particular order): VPCL board Developer connectors or wiring

An MC TPS SIGNAL OVERLOAD #035 error may occur if the print coverage exceeds 25%.

Do not run high print coverage jobs for extended periods of time. 1 Power-on-reset the printer. • Run test prints. Is error message MC TONER EMPTY ERROR #035 displayed? No: Continue. Yes: Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce- dure. Clean the toner patch sensor and the printhead lens, then continue. 2 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Has the photoconductor been replaced recently? No: Continue. Yes: Go to #5 in this TAG. 4 Replace the photoconductor. • Run 200+ test prints to reduce toner concentration in the developer. Has the problem been resolved? No: Reinstall the original photoconductor and continue. Yes: The photoconductor was at fault. Turn to TAG 002. 5 Has the seal has been removed from the toner cartridge? No: Continue. Yes: Go to #7 in this TAG. June 1999 Troubleshooting Analysis Guides 3-43, TAG 035: Out of Toner or ADD TONER Indication 6 Remove the toner cartridge seal. • Power-on-reset the printer. • Run test prints. Has the problem been resolved? No: Continue. Yes: The toner cartridge seal was at fault. Turn to TAG 002. 7 Turn the printer off and unplug the power cord. • Disconnect J/P41. • Remove the developer. • Check P41-48 to J25-6 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-48 to J25-6, then turn to TAG 002. Yes: Replace the VPCL board. If this resolves the problem, then turn to TAG 002. If the problem is still not resolved, go to TAG 610. 3-44 Troubleshooting Analysis Guides June 1999, TAG 036: Developer Not Installed

TAG 036: Developer Not Installed

ERROR MESSAGE:MC NO DEVELOPER #036 MC DEVELOPER CONN. OPEN #037 Possible Defects (not listed in any particular order): Developer not installed properly Connectors or wiring VPCL board 1 Turn the printer off and unplug the power cord. • Make sure the developer is installed properly. • Confirm that J/P41 is connected properly. • Confirm that the proper developer is installed. • Power-on-reset the printer. Is error message MC NO DEVELOPER #036 displayed? No: A loose connector or improper developer was at fault. Turn to TAG 002. Yes: Continue. 2 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Turn the printer off and unplug the power cord. • Disconnect J/P41. • Check P41-45 to P41-46 for continuity. Is there continuity? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 4 Remove the developer. • Check P41-45 to J25-12 and P41-46 to J25-8 for continuity. Is there continuity on both? No: Repair or replace the connectors or wiring from: P41-45 to J25-12 or P41-46 to J25-8, then turn to TAG 002. Yes: Replace the developer, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-45, TAG 040: Photoconductor Seam Sensor Malfunction

TAG 040: Photoconductor Seam Sensor Malfunction

ERROR MESSAGE:MC NO SIGNAL FROM PSS #040 MC PSS SENSOR SHORTED #041 MC PSS SENSOR OPEN #042 Possible Defects (not listed in any particular order): Photoconductor Main motor gear Main motor gear keys Main drive gear assembly Main drive motor assembly Connectors or wiring VPCL board Software Seam sensor 1 Turn the printer off and unplug the power cord. • Verify that J/P4, J/P9, J/P12, J/P14, J/P20, J/P40, J/P41, J/P63 (photoconductor seam sensor), J/ P64, J/P251, and J/P252 are connected properly. • Remove the photoconductor. • Clean the photoconductor contacts, the guide rail contacts, and the photoconductor cavity. • Clean the seam sensor lens and cavity, and remove any obstructions. • Reinstall the photoconductor. • Power-on-reset the printer. Is error message MC NO SIGNAL FROM PSS #040, MC PSS SENSOR SHORTED #041 or MC PSS SENSOR OPEN #042 still displayed? No: Loose connectors or dirty contacts were at fault. Turn to TAG 002. Yes: Continue. 2 Has the photoconductor been replaced recently? No: Continue. Yes: Go to #4 in this TAG. 3 Replace the photoconductor. • Run test prints. Has the problem been resolved? No: Reinstall the original photoconductor and continue. Yes: The photoconductor was at fault. Turn to TAG 002. 4 Open the top cover and insert an interlock by-pass tool. • Run the dignostic test “Photoconductor Seam Sensor Test” on page 5-8. Does the photoconductor belt rotate? No: Continue. Yes: Go to #11 in this TAG. 3-46 Troubleshooting Analysis Guides June 1999, TAG 040: Photoconductor Seam Sensor Malfunction 5 Is error message MC PSS Sensor Shorted #041 or MC PSS Sensor Open #042 displayed while running “Photoconductor Seam Sensor Test” on page 5-8? No: Continue. Yes: Go to #12 in this TAG. 6 Turn the printer off. • Remove the photoconductor. • Inspect it for damaged drive mechanism or belt slippage. Is it in good working order? No: Replace the photoconductor, then turn to TAG 002. Yes: Continue. 7 Reinstall the photoconductor. • Remove the interlock by-pass tool and close the top cover. • Open the back cover and install an interlock by-pass tool. • Remove the main drive motor assembly cover. • Turn the printer on. • Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8. • Watch the main motor. Does the main motor gear turn while running the Photoconductor Seam Sensor Test? No: Continue. Yes: Replace the main motor gear, main motor gear key, or both, or replace the main drive gear assembly, as needed. Then turn to TAG 002. 8 Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8. ! Use extreme caution: • Check J/P20-2 to J/P20-3 for 100 Vac while the test is running. Is the voltage 100 Vac? No: Continue. Yes: Replace the main drive motor assembly, then turn to TAG 002. 9 Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8. ! Use extreme caution: • Check J/P14-2 to J/P14-3 for 100 Vac while the test is running. Is the voltage 100 Vac? No: Continue. Yes: Repair or replace the connectors or wiring from: P14-2 to P20-3 or P14-3 to P20-2; then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-47, TAG 040: Photoconductor Seam Sensor Malfunction 10 Turn the printer off and unplug the power cord. • Disconnect J/P40 and J/P12. • Check P40-33 to P12-7 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P40-33 to P12-7. Yes: Replace the power control board; if this does not correct the problem, replace the VPCL board. Then turn to TAG 002. 11 Remove the photoconductor. • Inspect the photoconductor belt for damage. • Check the timing hole for contamination or blockage. Are the photoconductor belt and the timing hole both in good working order? No: Replace the photoconductor, then turn to TAG 002. Yes: Continue. 12 Turn the printer off. • Disconnect J/P40. • Turn the printer on. • Check J40-20 for +12 Vdc. Is the voltage +12 Vdc? No: Replace the VPCL board, then turn to TAG 002. Yes: Continue. 13 Check J/P64 pin 2 for between +2 to +6 Vdc.

On J/P64, pin 1 is the top pin.

Is the voltage between +2 to +6 Vdc? No: Replace the VPCL board, then turn to TAG 002. Yes: Continue. 14 Turn the printer off and unplug the power cord. • Remove the photoconductor. • Disconnect J/P63, observing carefully the plug’s orientation before you remove it. • Check the following for continuity: • P40-19 to J/P64-1 to J/P252, which is the center connector contact on the photoconductor guide rail; • P40-21 to J/P64-2 to J/P251, which is the top connector contact on the photoconductor guide rail; • P40-18 to J/P 64-3 to P63-1; • P40-20 to J/P64-4 to P63-2. Is there continuity on all? No: Repair or replace the connectors or wiring that did not have continuity, then turn to TAG 002. Yes: Replace the photoconductor seam sensor, reconnect J/P40 and J/P63, then turn to TAG 002. 3-48 Troubleshooting Analysis Guides June 1999, TAG 044: Charge Corona/Transfer Corona Circuit Open

TAG 044: Charge Corona/Transfer Corona Circuit Open

ERROR MESSAGE:MC MAIN/TRANSFER OPEN #044 Possible Defects (not listed in any particular order): Charge corona Transfer corona Connectors or wiring High voltage power supply Upper paper guide Charge corona terminal assembly VPCL board 1 Turn the printer off and unplug the power cord. • Verify that J/P23 and J/P41 are connected properly. • Make sure the high voltage power supply charge corona lead is connected properly. • Make sure the transfer corona lead is connected properly. • Verify that the charge corona and transfer corona ground circuits are connected properly. • Remove the transfer corona from the upper paper guide. • Clean the transfer corona housing and contacts. • Clean the transfer corona wire. • Inspect the transfer corona socket in the upper paper guide for contamination. • Verify that the transfer corona static eliminator brush on the transfer corona housing is grounded to the transfer corona metal housing. • Reinstall the transfer corona. • Clean the charge corona contacts. • Power-on-reset the printer. • Run test prints. Is error message MC MAIN/TRANSFER OPEN #044 displayed? No: Loose connectors or a dirty transfer corona were at fault. Turn to TAG 002. Yes: Continue. 2 Has the charge corona been replaced recently? No: Continue. Yes: Go to #4 in this TAG. 3 Replace the charge corona and photoconductor. • Power-on-reset the printer. • Run test prints. Has the problem been resolved? No: Reinstall the original charge corona and photoconductor, and continue. Yes: The charge corona was at fault. Turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-49, TAG 044: Charge Corona/Transfer Corona Circuit Open 4 Remove the transfer corona. • Inspect the housing for jammed paper. Is paper jammed inside the transfer corona housing? No: Continue. Yes: Remove the jammed paper and check the transfer corona for damage, then turn to TAG 022. 5 Run diagnostic test “Charge Corona Test” on page 5-9. Is error message 046 displayed? No: Continue. Yes: Go to #11 in this TAG. 6 Run diagnostic test “Transfer Corona Test” on page 5-9. Is error message MC TRANSFER CHRGR OPEN #051 displayed? No: Continue. Yes: Go to #8 in this TAG. 7 Run diagnostic test “Transfer Corona Test” on page 5-9. Is error message MC TRANSFER CHRGR SHORT #050 displayed? No: The problem appears to be intermittent. Go to TAG 050. Yes: Go to TAG 050. 8 Turn the printer off and unplug the power cord. • Remove the transfer corona. • Inspect the transfer corona wire. Is the transfer corona wire damaged? No: Continue. Yes: Replace the transfer corona, then turn to TAG 002. 9 With the upper paper guide assembly in its fully upright position, check the transfer corona's lower receptacle for continuity to ground. Is there continuity? No: Replace or repair the upper paper guide assembly, then turn to TAG 002. Yes: Continue. 10 Disconnect high voltage power supply lead to the transfer corona. • Check the transfer corona's upper receptacle to the lead removed from the high voltage power supply for continuity. Is there continuity? No: Replace the upper paper guide assembly, then turn to TAG 002. Yes: Go to #13 in this TAG. 3-50 Troubleshooting Analysis Guides June 1999, TAG 044: Charge Corona/Transfer Corona Circuit Open 11 Turn the printer off and unplug the power cord. • Disconnect the charge corona lead from the high voltage power supply. • Check for continuity the charge corona lead terminal assembly’s lower contact to the lead removed from the high voltage power supply. Is there continuity? No: Repair or replace the charge corona lead or the charge corona terminal assembly, then turn to TAG 002. Yes: Continue. 12 Remove the cleaner. • Disconnect J/P85. • Check for continuity between the connector for the charge corona terminal assembly’s upper contact and J/P85-10 at the high voltage power supply. Is there continuity? No: Repair or replace the connectors or wiring, then turn to TAG 002. Yes: Continue. 13 Disconnect J/P41 and J/P23. • Check P41-35 to P23-5 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-35 to P23-5, then turn to TAG 002. Yes: Continue. 14 Check P41-39 to P23-1 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-39 to P23-1, then turn to TAG 002. Yes: Continue. 15 Reconnect the power. • Turn the printer on. • Check J/P41-35 for +24 Vdc. Is the voltage +24 Vdc? No: Replace the VPCL board, then turn to TAG 002. Yes: Determine whether the high voltage power supply or the charge corona terminal assembly is at fault, replace the faulty unit, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-51, TAG 045: Charge Corona Circuit Shorted

TAG 045: Charge Corona Circuit Shorted

ERROR MESSAGE:MC MAIN CHARGER SHORT #045 Possible Defects (not listed in any particular order): Charge corona High voltage power supply Charge corona terminal assembly Connectors or wiring VPCL board 1 Turn the printer off and unplug the power cord. • Verify that J/P23, J/P41, J/P85, P124, P143, and the high voltage power supply charge corona lead are connected properly. • Clean the charge corona contacts. • Power-on-reset the printer. • Run test prints. Is error message MC MAIN CHARGER SHORT #045 displayed? No: Loose connectors or dirty contacts were at fault. Turn to TAG 002. Yes: Continue. 2 Has the charge corona been replaced recently? No: Continue. Yes: Go to #4 in this TAG. 3 Replace the charge corona and photoconductor. • Run test prints. Is error message MC MAIN CHARGER SHORT #045 still displayed? No: The charge corona was at fault. Turn to TAG 002. Yes: Reinstall the original charge corona and photoconductor, then continue. 4 Turn the printer off and unplug the power cord. • Disconnect the charge corona lead from the high voltage power supply. • Check for continuity the charge corona terminal assembly’s lower contact to the lead removed from the high voltage power supply. Is there continuity? No: Repair or replace the high voltage lead or the charge corona terminal block, then turn to TAG 002. Yes: Continue. 3-52 Troubleshooting Analysis Guides June 1999, TAG 045: Charge Corona Circuit Shorted 5 Reconnect the charge corona high voltage lead. • Disconnect P23 and J/P41. • Check J/P41-34 to P23-6 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-34 to P23-6, then turn to TAG 002. Yes: Continue. 6 Check P41-35 to P23-5 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-35 to P23-5. Yes: Replace the high voltage power supply. If this corrects the problem, turn to TAG 002. If this does not correct the problem, replace the VPCL board, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-53, TAG 047: PC Life Data Error

TAG 047: PC Life Data Error

ERROR MESSAGE:MC PC LIFE DATA ERROR #047 Possible Defects (not listed in any particular order): Connectors or wiring Photoconductor Software VPCL board 1 Turn the printer off and unplug the power cord. • Make sure the photoconductor is properly installed. • Clean the photoconductor contacts, the guide rail contacts, and the photoconductor cavity • Confirm that the proper photoconductor is installed. • Power-on-reset the printer. Is error message MC PC LIFE DATA ERROR #047 displayed? No: A loose connector or improper photoconductor were at fault. Turn to TAG 002. Yes: Continue. 2 Replace the photoconductor. • Power-on-reset the printer. Is error message MC PC LIFE DATA ERROR #047 displayed? No: The photoconductor was at fault. Turn to TAG 002. Yes: Replace the VPCL board. If the error persists, repair or replace the wiring between J/P251 (photoconductor contacts) and J/P64 and P40 (VPCL board), then turn to TAG 002. 3-54 Troubleshooting Analysis Guides June 1999, TAG 048: Developer Life Error

TAG 048: Developer Life Error

ERROR MESSAGE:MC DEVELOPER LIFE ERROR #048 Possible Defects (not listed in any particular order): Connectors or wiring Developer Software VPCL board 1 Turn the printer off and unplug the power cord. • Make sure the developer is properly installed. • Confirm that the proper developer is installed. • Power-on-reset the printer. Is error message MC DEVELOPER LIFE ERROR #048 displayed? No: A loose connector or improper developer were at fault. Turn to TAG 002. Yes: Continue. 2 Replace the developer. • Power-on-reset the printer. Is error message MC DEVELOPER LIFE ERROR #048 displayed? No: The developer was at fault. Turn to TAG 002. Yes: Replace the VPCL board. If the error persists, repair or replace the wiring between P25 (developer) and P40 (VPCL board), then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-55, TAG 050: Transfer Corona Circuit Shorted

TAG 050: Transfer Corona Circuit Shorted

ERROR MESSAGE:MC TRANSFER CHRGR SHORT #050 Possible Defects (not listed in any particular order): Transfer corona High voltage power supply Connectors or wiring VPCL board Upper paper guide assembly 1 Turn the printer off and unplug the power cord. • Verify that J/P23, J/P41 and the transfer corona high voltage power supply lead are connected properly. • Power-on-reset the printer. • Run test prints. Is error message MC TRANSFER CHRGR SHORT #050 displayed? No: A loose connector was at fault. Turn to TAG 002. Yes: Continue. 2 Turn the printer off and unplug the power cord. • Remove and clean the transfer corona housing and contacts. • Check between the two terminals on the back of the transfer corona for continuity. Is there continuity? No: Continue. Yes: Repair or replace the transfer corona, then turn to TAG 002. 3 Reinstall the transfer corona. • Power-on-reset the printer. • Run test prints. Is error message MC TRANSFER CHRGR SHORT #050 displayed? No: A dirty transfer corona was at fault. Turn to TAG 002. Yes: Continue. 4 Turn the printer off and unplug the power cord. • Disconnect the transfer corona lead from the high voltage power supply. • Check the transfer corona high voltage power supply lead for continuity to ground. Is there continuity to ground? No: Continue. Yes: Repair or replace the upper paper guide assembly or transfer corona, then turn to TAG 002. 3-56 Troubleshooting Analysis Guides June 1999, TAG 050: Transfer Corona Circuit Shorted 5 Reconnect the transfer corona high voltage power supply lead. • Disconnect J/P23 and J/P41. • Check P41-37 to P23-3 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-37 to P23-3, then turn to TAG 002. Yes: Continue. 6 Replace the transfer corona. Has the problem been resolved? No: Replace the high voltage power supply. If this resolves the problem, turn to TAG 002. If the problem has not been resolved, replace the VPCL board, then turn to TAG 002. Yes: Turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-57, TAG 055: Erase Lamp Malfunction

TAG 055: Erase Lamp Malfunction

ERROR MESSAGE:MC ERASER LAMP #055 Possible Defects (not listed in any particular order): Erase lamp assembly Connectors or wiring VPCL board 1 Turn the printer off and unplug the power cord. • Verify that J/P26, J/P40 are connected properly. • Power-on-reset the printer. Is error message MC ERASER LAMP #055 displayed? No: Continue. Yes: Go to #3 in this TAG. 2 Run diagnostic test “Erase Lamp Test” on page 5-10. Is the value displayed less than 220? No: A loose connector was at fault. Turn to TAG 002. Yes: Continue. 3 Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8. • Watch all the LEDs on the erase lamp. Do all the LEDs on the erase lamp come on, even momentarily? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 4 Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8. • Check J/P26-2 for +12 Vdc immediately. After the start of the test, the voltage may drop to 0 Vdc. Did you measure +12 Vdc? No: Continue. Yes: Go to #6 in this TAG. 5 Turn off the printer and unplug the power cord. • Disconnect J/P26 and J/P40. • Check P26-2 to P40-3 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P26-2 to P40-3, then turn to TAG 002. Yes: Replace the VPCL board, then turn to TAG 002. 3-58 Troubleshooting Analysis Guides June 1999, TAG 055: Erase Lamp Malfunction 6 Turn off the printer and unplug the power cord. • Disconnect P26 and P40. • Check P26-1 to P40-2 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P26-1 to P40-2, then turn to TAG 002. Yes: Repair or replace the erase lamp assembly. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the VPCL board, turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-59, TAG 070: Fuser Malfunction

TAG 070: Fuser Malfunction

ERROR MESSAGE:MC FUSER/THERMAL FUSE #070 MC FUSER TEMP TOO LOW #073 Symptoms: No AC power at the fuser Possible Defects (not listed in any particular order): Fuser Power control #2 board AC power supply DC power supply Connectors or wiring VPCL board

A lack of continuity may result in fuser damage. If this has occurred, replace the fuser when

replacing connectors and/or wiring. 1 Turn the printer off and unplug the power cord. • Verify that J/P44, J/P4, J/P10, J/P11, J/P12, J/P70, J/P40, J/P41, J/P8, and J/P5 (bottom of fuser) are connected properly. • Verify that the fuser is installed properly. • Read the following steps before taking further action. • Power-on-reset the printer. • Watch through the output tray opening to see if the fuser lamp comes on.

If the fuser lamp comes on immediately after power on, turn off the printer and replace the AC

power supply. Is error message MC FUSER/THERMAL FUSE #070 or MC FUSER TEMP TOO LOW #073 displayed? No: A loose connector was at fault.Turn to TAG 002. Yes: Continue. 2 Has the fuser been replaced recently? No: Continue. Yes: Go to #4 in this TAG. 3 Replace the fuser. • Power-on-reset the printer. • Watch through the output tray opening to see if the fuser lamp comes on.

If the fuser lamp comes on immediately after power on, turn off the printer and replace the AC

power supply. Has the problem been resolved? No: Reinstall the original fuser and continue. Yes: Turn to TAG 002. 3-60 Troubleshooting Analysis Guides June 1999, TAG 070: Fuser Malfunction 4 Power-on-reset the printer. • Watch through the output tray opening to see if the fuser lamp comes on during the first few minutes after power on.

If the fuser lamp comes on immediately after power on, turn the printer off and replace the AC

power supply. Does the fuser lamp light? No: Go to #9 in this TAG. Yes: Continue. 5 Replace the VPCL board. • Power-on-reset the printer. Is error message MC FUSER/THERMAL FUSE #070 or MC FUSER TEMP TOO LOW #073 displayed? No: Turn to TAG 002. Yes: Replace the VPCL board and continue. 6 Turn the printer off and unplug the power cord. • Remove the fuser. • Disconnect J/P41. • Check P41-22 to P5-6 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-22 to P83-1 or J83-1 to P5-6, then turn to TAG 002. Yes: Continue. 7 Check P41-21 to P5-7 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41- 21 to P83-2 or J83-2 to P5-7, then turn to TAG 002. Yes: Continue. 8 Reinstall the fuser. • Check P41-21 to P41-22 for resistance. Is the resistance between IKΩ and 400 KΩ? No: The new fuser seems to be defective. Replace it with a new fuser, then turn to TAG 002. Yes: Replace the VPCL board, then turn to TAG 002. 9 Power-on-reset the printer. • Check J/P10-2 for +24 Vdc during the 15 seconds following power-on-reset. Is the voltage +24 Vdc? No: Go to #15 in this TAG. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-61, TAG 070: Fuser Malfunction 10 Turn the printer off. • Continue to check J/P10-2 for +24 Vdc. • Power-on-reset the printer. Does the voltage drop from +24 Vdc to 0 Vdc during the first few minutes after power on, while the fuser lamp is on? No: Go to #23 in this TAG. Yes: Continue. 11 Power-on-reset the printer. ! Use extreme caution: • Check J/P44-1 to J/P44-2 for at least 100 Vac during the first few minutes after power on, while the fuser lamp is on. Is the voltage at least 100 Vac? No: Go to #14 in this TAG. Yes: Continue. 12 Turn off the printer. • Remove the fuser. • Clean the contacts of connector J/P5. • Disconnect J/P44. • Check J44-2 to J5-4 and J44-1 to J5-1 for continuity. Is there continuity on both? No: Repair or replace the connectors or wiring as needed, then turn to TAG 002. Yes: Continue. 13 Reinstall the fuser. • Power-on-reset the printer. Has the problem been resolved? No: Replace the fuser, then turn to TAG 002. Yes: Cleaning the contacts resolved the problem. Turn to TAG 002. 14 Power-on-reset the printer. ! Use extreme caution: • Check J/P4-1 to J/P4-2 for at least 100 Vac during the first few minutes after power on, while the fuser lamp is on. Was the voltage at least 100 Vac? No: Replace the AC power supply, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from J/P4-1 to J/P44-1, or J/P4-2 to J/P44-2, then turn to TAG 002. 15 Check J/P10-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Go to #18 in this TAG. 3-62 Troubleshooting Analysis Guides June 1999, TAG 070: Fuser Malfunction 16 Check J/P11-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace power control #2 board, then turn to TAG 002. 17 Check J/P8-11 for +24 Vdc. Is the voltage +24 Vdc? No: Replace the DC power supply, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P11-1 to P8-11, then turn to TAG 002. 18 Turn the printer off and unplug the power cord. • Disconnect J/P70 and J/P10. • Check P70-1 to P10-1 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P70-1 to P10-1, then turn to TAG 002. Yes: Continue. 19 Check P70-2 and P10-2 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P70-2 to P10-2, then turn to TAG 002. Yes: Continue. 20 Reconnect J/P70. • Connect negative lead of meter to P10-2 and positive lead of meter to P10-1. Is the resistance approximately 550KΩ? No: Replace the AC power supply, then turn to TAG 002. Yes: Continue. 21 Disconnect J/P12. • Check J10-2 (power control #2 board) for continuity to ground. Is there continuity? No: Continue. Yes: Replace the power control #2 board, then turn to TAG 002. 22 Reconnect J/P10 and J/P12. • Disconnect J/P40. • Check P40-36 for continuity to ground. Is there continuity? No: Replace the VPCL board, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-63, TAG 070: Fuser Malfunction 23 Replace the VPCL board. • Continue to check J/P10-2 for +24 Vdc. • Power-on-reset the printer. Does the voltage drop from +24 Vdc to 0 Vdc during the first few minutes after power on, while the fuser lamp is on? No: Reinstall the old VPCL board. Repair or replace the wiring between the fuser and the VPCL board, then turn to TAG 002. Yes: The VPCL board was at fault, Turn to TAG 002. 3-64 Troubleshooting Analysis Guides June 1999, TAG 071: Open Fuser/Thermistor

TAG 071: Open Fuser/Thermistor

ERROR MESSAGE:MC NO FUSER/THERMISTOR #071 Possible Defects (not listed in any particular order): Connectors or wiring Fuser VPCL board 1 Turn the printer off and unplug the power cord. • Make sure the fuser is installed properly. • Confirm that J/P41 and J/P44 are connected properly. Has the fuser been replaced recently? No: Continue. Yes: Go to #3 in this TAG. 2 Replace the fuser. • Power-on-reset the printer. Is error message MC NO FUSER/THERMISTOR #071 displayed during power-on-reset? No: The fuser was at fault. Turn to TAG 002. Yes: Reinstall the original fuser and continue. 3 Turn the printer off and unplug the power cord. • Disconnect J/P41. • Remove the fuser. • Check P41-21 to P5-7 and P41-22 to P5-6 for continuity. Is there continuity on both? No: Repair or replace the connectors or wiring as necessary, then turn to TAG 002. Yes: Continue. 4 Check P41-21 and P41-22 for continuity to ground. Is there continuity to ground on either? No: Replace the fuser. If this resolves the problem, then turn to TAG 002. If this does not resolve the problem, replace the VPCL board, then turn to TAG 002. Yes: Repair or replace the connectors or wiring that have continuity to ground: P41-21 to P44-2, J44-2 to P5-7, or P41-22 to P44-1, J44-1 to P5-6; then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-65, TAG 072: Fuser Temperature Too High

TAG 072: Fuser Temperature Too High

ERROR MESSAGE:MC FUSER TEMP TOO HIGH #072 Possible Defects (not listed in any particular order): Connectors or wiring Fuser AC power supply VPCL board

The conditions that cause error message MC FUSER TEMP TOO HIGH #072 often cause the

fuser’s thermal fuse to open. This usually necessitates replacement of the fuser. 1 Turn the printer off and unplug the power cord. • Verify that J/P44, J/P40, J/P10, J/P70, and J/P8 are connected properly. • Make sure the fuser is properly installed. • Read the following steps before taking further actions. • Power-on-reset the printer. • Watch through the output tray opening to see if the fuser lamp comes on.

If the fuser lamp comes on immediately after power on, turn off the printer and replace the AC

power supply. • Run test prints. Has the problem been resolved? No: Continue. Yes: A loose connector was at fault. Turn to TAG 002. 2 Has the fuser been replaced recently? No: Continue. Yes: Go to #4 in this TAG. 3 Replace the fuser. • Power-on-reset the printer. • Watch through the output tray opening to see if the fuser lamp comes on during the first few minutes after power on.

If the fuser lamp comes on immediately after power on, turn off the printer and replace the AC

power supply. Has the problem been resolved? No: Reinstall the original fuser and continue. Yes: The fuser was at fault. Turn to TAG 002. 4 Power-on-reset the printer. • Watch the fuser's lamp. Does the lamp turn on before error message MC FUSER TEMP TOO HIGH #072 is dis- played? No: Replace the VPCL board, then turn to TAG 002. Yes: Continue. 3-66 Troubleshooting Analysis Guides June 1999, TAG 072: Fuser Temperature Too High 5 Turn the printer off and unplug the power cord. • Disconnect J/P41. • Check P41-21 for continuity to ground. Is there continuity? No: Continue. Yes: Repair or replace the connectors or wiring that have continuity to ground: P41-21 to P44-2, or J44-2 to P5-7; then turn to TAG 002. 6 Check P41-21 to P41-22 for resistance. Is the resistance at least 1KΩ? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 7 Remove the fuser. • Check P41-21 to P5-7 for resistance. Is there resistance? No: Continue. Yes: Repair or replace the connectors or wiring that have resistance: P41-21 to P44-2, or J44-2 to P5-7; then turn to TAG 002. 8 Check P41-22 to P5-6 for resistance. Is there resistance? No: Replace the fuser, then turn to TAG 002. Yes: Repair or replace the connectors or wiring that have resistance: P41-22 to P44-1, or J44-1 to P5-6; then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-67, TAG 097: +12 Vdc Power Shorted or Sensing Problem

TAG 097: +12 Vdc Power Shorted or Sensing Problem

ERROR MESSAGE:MC +12 DC POWER FAILURE #097 Possible Defects (not listed in any particular order): DC power supply Connectors or wiring IO card RIGS board Optional external attachment Power control #2 board Power control #3 board Developer Duplex control board #1 Paper timing sensor Duplex control board #2 Upper paper empty sensor Paper path sensor Lower paper empty sensor Cover open sensor Output tray full sensor Restart side sensor Paper exit sensor Restart paper sensor Tray front sensor Tray rear sensor Erase lamp VPCL board 1 Turn off the printer and unplug the power cord. • Verify that J/P303, J/P331, J/P323, J/P305, J/P310, J/P306, J/P32, and J/P33 are connected properly. • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: Loose connectors were at fault. Turn to TAG 002. 2 Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 3 Turn the printer off. • Disconnect J/P330. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Continue. Yes: Go to #35 in this TAG. 3-68 Troubleshooting Analysis Guides June 1999, TAG 097: +12 Vdc Power Shorted or Sensing Problem 4 Turn the printer off. • Disconnect J/P32. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #8 in this TAG. Yes: Continue. 5 Turn the printer off. • Reconnect J/P32. • Disconnect J/P74. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Replace the RIGS board, then turn to TAG 002. Yes: Continue. 6 Turn the printer off. • Remove any IO cards. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Replace the IO card(s) and continue. Yes: Replace the IO card(s), then turn to TAG 002. 7 Turn the printer off. • Reconnect J/P74. • Disconnect the DC cable (J/P73) for the attachment option. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Replace the signal interface board, then turn to TAG 002. Yes: Replace the attachment option, then turn to TAG 002. 8 Turn the printer off. • Reconnect J/P32. • Disconnect J/P91. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #13 in this TAG. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-69, TAG 097: +12 Vdc Power Shorted or Sensing Problem 9 Turn the printer off. • Reconnect J/P91. • Disconnect J/P40 and J/P41. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Replace the VPCL board, then turn to TAG 002. Yes: Continue. 10 Turn the printer off. • Reconnect J/P40. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #15 in this TAG. Yes: Continue. 11 Turn the printer off. • Reconnect J/P41. • Remove the developer. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Continue. Yes: Replace the developer, then turn to TAG 002. 12 Turn the printer off and unplug the power cord. • Disconnect J/P41. • Remove the fuser. • Check P41-49 to P25-4 and P41-50 to P25-1 for continuity to ground. Is there continuity? No: Go to #15 in this TAG. Yes: Repair or replace the appropriate connectors or wiring, then turn to TAG 002. 13 Turn the printer off and unplug the power cord. • Reconnect J/P91. • Disconnect J/P8 and J/P32. • Check J8-6 for continuity to ground. Is there continuity? No: Continue. Yes: Repair or replace the connectors or wiring from P8-6 to P32-10 to P91-3, then turn to TAG 002. 3-70 Troubleshooting Analysis Guides June 1999, TAG 097: +12 Vdc Power Shorted or Sensing Problem 14 Reconnect J/P32 and J/P8. • Disconnect J/P77. • Turn on the printer. • Check J/P8-3 for +12Vdc. Is the voltage +12 Vdc? No: Replace the DC power supply, then turn to TAG 002. Yes: Replace the disk drive assembly, then turn to TAG 002. 15 Turn the printer off. • Reconnect J/P41. • Disconnect J/P58, J/P60, and J/P62. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #21 in this TAG. Yes: Continue. 16 Turn the printer off. • Reconnect J/P58. • Turn on the printer. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #19 in this TAG. Yes: Continue. 17 Turn the printer off. • Reconnect J/P60. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #20 in this TAG. Yes: Continue. 18 Disconnect J/P61. • Check P62-1 to P61-1 for continuity to ground. Is there continuity? No: Replace the lower paper empty sensor, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P62-1 to P61-1, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-71, TAG 097: +12 Vdc Power Shorted or Sensing Problem 19 Disconnect J/P58 and J/P57. • Check P58-1 to P57-1 for continuity to ground. Is there continuity? No: Replace the paper timing sensor. Yes: Repair or replace the connectors or wiring from P58-1 to P57-1, then turn to TAG 002. 20 Disconnect J/P60 and J/P59. • Check P60-1 to P59-1 for continuity to ground. Is there continuity? No: Replace the upper paper empty sensor. Yes: Repair or replace the connectors or wiring from P60-1 to P59-1, then turn to TAG 002. 21 Turn the printer off and unplug the power cord. • Disconnect J/P40. • Check for continuity to ground: P40-25 to J58-1, P40-25 to J60-1, and P40-25 to J62-1. Is there continuity? No: Continue. Yes: Repair or replace the connectors or wiring from P40-25 to J58-1, P40-25 to J60-1, or P40-25 to J62-1, then turn to TAG 002. 22 Turn the printer off. • Reconnect J/P40, J/P58, J/P60, and J/P62. • Disconnect J/P50 and J/P54. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #30 in this TAG. Yes: Continue. 23 Turn the printer off. • Reconnect J/P50. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #27 in this TAG. Yes: Continue. 3-72 Troubleshooting Analysis Guides June 1999, TAG 097: +12 Vdc Power Shorted or Sensing Problem 24 Turn the printer off. • Reconnect J/P54. • Disconnect J/P53. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Continue. Yes: Replace the front tray sensor, then turn to TAG 002. 25 Turn the printer off. • Disconnect J/P55. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Continue. Yes: Replace the rear tray sensor, then turn to TAG 002. 26 Turn the printer off and unplug the power cord. • Disconnect J/P54. • Check J54-1 and J54-4 for continuity to ground. Is there continuity to ground at either? No: You have failed to isolate the problem. Return to the beginning of this TAG. Yes: Repair or replace the connectors or wiring from: J54-1 to P53-1 or J54-4 to P55-1, then turn to TAG 002. 27 Turn the printer off. • Remove the exit cover. • Disconnect J/P49 and J/P51. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #29 in this TAG. Yes: Continue. 28 Turn the printer off. • Reconnect J/P49. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Replace the paper exit sensor, then turn to TAG 002. Yes: Replace the output tray full sensor, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-73, TAG 097: +12 Vdc Power Shorted or Sensing Problem 29 Turn the printer off and unplug the power cord. • Disconnect J/P50. • Check J50-1 and J50-4 for continuity to ground. Is there continuity at either? No: You have failed to isolate the problem. Return to the beginning of this TAG. Yes: Repair or replace the connectors or wiring from: J50-1 to P49-1 or J50-4 To P51-1, then turn to TAG 002. 30 Turn the printer off. • Disconnect J/P40. • Check P40-26 for continuity to ground. Is there continuity to ground? No: Continue. Yes: Repair or replace the connectors or wiring from: P40-26 to P54-1, P40-26 to P54-4, P40-26 to P50-1, or P40-26 to P50-4, then turn to TAG 002 31 Turn the printer off. • Reconnect J/P40, J/P50, and J/P54. • Disconnect J/P12. • Turn the printer on. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Continue. Yes: Replace the power control #2 board, then turn to TAG 002. 32 Turn the printer off and unplug the power cord. • Disconnect J/P40. • Check P40-34 to P12-8 for continuity to ground. Is there continuity? No: Continue. Yes: Repair or replace the connectors or wiring from P40-34 to P12-8, then turn to TAG 002. 33 Reconnect J/P40 and J/P12. • Disconnect J/P102. • Turn on the printer. • Check J/P8-6 for +12 Vdc. Is the voltage +12 Vdc? No: Continue. Yes: Replace the power control #3 board, then turn to TAG 002. 3-74 Troubleshooting Analysis Guides June 1999, TAG 097: +12 Vdc Power Shorted or Sensing Problem 34 Turn off the printer and unplug the power cord. • Disconnect J/P40. • Check P40-35 to P102-1 for continuity to ground. Is there continuity? No: You have failed to isolate the problem. Return to the beginning of this TAG. Yes: Repair or replace the connectors or wiring from P40-35 to P102-1, then turn to TAG 002. 35 Turn off the printer. • Reconnect J/P330. • Disconnect J/P323. • Turn on the printer. • Check J/P330-2 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #40 in this TAG. Yes: Continue. 36 Turn off the printer. • Reconnect J/P323. • Disconnect J/P305. • Turn on the printer. • Check J/P330-2 for +12Vdc. Is the voltage +12 Vdc? No: Go to #39 in this TAG. Yes: Continue. 37 Turn off the printer. • Reconnect J/P305. • Disconnect J/P310 (inside the duplex tray). • Turn on the printer. • Check J/P330-2 for +12 Vdc. Is the voltage +12 Vdc? No: Continue. Yes: Go to #42 in this TAG. 38 Turn the printer off and unplug the power cord. • Disconnect J/P305. • Check P305-2 and P310-2 for continuity to ground. Is there continuity? No: Return to the beginning of this TAG and start again. Yes: Repair or replace connectors or wiring P305-2 to P310-2, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-75, TAG 097: +12 Vdc Power Shorted or Sensing Problem 39 Turn off the printer and unplug the power cord. • Disconnect J/P323. • Check J323-2 and J305-2 for continuity to ground. Is there continuity at either? No: Return to the beginning of this TAG and start again. Yes: Repair or replace the connectors or wiring from J323-2 to J305-2, then turn to TAG 002. 40 Turn off the printer. • Reconnect J/P323. • Disconnect J/P306. • Turn on the printer. • Check J/P330-2 for +12 Vdc. Is the voltage +12 Vdc? No: Continue. Yes: Go to #45 in this TAG. 41 Turn off the printer and unplug the power cord. • Disconnect J/P331. • Check J331-2 to P306-2 for continuity to ground. Is there continuity? No: Repair or replace the connectors or wiring from: P330-2 to P331-2, or P330-2 to P323-2. Yes: Repair or replace the connectors or wiring from J331-2 to P306-2. 42 Turn off the printer. • Reconnect J/P310. • Disconnect J/P320 and J/P322. • Turn on the printer. • Check J/P330-2 for +12 Vdc. Is the voltage +12 Vdc? No: Continue. Yes: Go to #44 in this TAG. 43 Turn off the printer and unplug the power cord. • Disconnect J/P312. • Check for continuity to ground: P312-1 to P320-1, and P312-4 to P322-1 Is there continuity? No: Replace the duplex control board #2, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P312-1 to P320-1, or P312-4 to P322-1, then turn to TAG 002. 3-76 Troubleshooting Analysis Guides June 1999, TAG 097: +12 Vdc Power Shorted or Sensing Problem 44 Turn off the printer. • Reconnect J/P320. • Turn on the printer. • Check J/P330-2 for +12 Vdc. Is the voltage +12 Vdc? No: Replace the restart side sensor, then turn to TAG 002. Yes: Replace the restart paper sensor, then turn to TAG 002. 45 Turn off the printer. • Reconnect J/P306. • Disconnect J/P319 and J/P318. • Turn on the printer. • Check J/P330-2 for +12 Vdc. Is the voltage +12 Vdc? No: Go to #47 in this TAG. Yes: Continue. 46 Turn off the printer. • Reconnect J/P319. • Turn on the printer. • Check J/P330-2 for +12 Vdc. Is the voltage at +12 Vdc? No: Replace the paper path sensor, then turn to TAG 002. Yes: Replace the cover open sensor, then turn to TAG 002. 47 Turn off the printer and unplug the power cord. • Disconnect J/P309. • Check for continuity to ground: P309-4 to P319-1, and P309-3 to P318-1. Is there continuity at either? No: Replace the duplex control board #1, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from: P309-4 to P319-1, or P309-3 to P318-1; then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-77, TAG 098: -12 Vdc Power Shorted

TAG 098: -12 Vdc Power Shorted

ERROR MESSAGE:MC -12 DC POWER FAILURE #098 Possible Defects (not listed in any particular order): Connectors or wiring DC power supply VPCL board RIGS board IO card External attachment option 1 Turn the printer off and unplug the power cord. • Verify that J/P8, J/P32, J/P33, J/P73, and J/P74 are connected properly. • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: Loose connectors were at fault. Turn to TAG 002. 2 Check J/P32-3 for -12 Vdc. Is the voltage -12 Vdc? No: Continue. Yes: Replace VPCL board, then turn to TAG 002. 3 Turn the printer off. • Disconnect J/P32. • Turn the printer on. • Check J/P8-8 for -12 Vdc. Is the voltage -12 Vdc? No: Continue. Yes: Go to #5 in this TAG. 4 Turn the printer off. • Disconnect J/P8. • Check P8-8 to P32-3 for continuity to ground. Is there continuity? No: Replace the DC power supply, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P8-8 to P32-3. 3-78 Troubleshooting Analysis Guides June 1999, TAG 098: -12 Vdc Power Shorted 5 Turn the printer off. • Reconnect J/P32. • Disconnect J/P74. • Turn the printer on. • Check J/P8-8 for -12 Vdc. Is the voltage -12 Vdc? No: Replace the RIGS board, then turn to TAG 002. Yes: Continue. 6 Turn the printer off. • Remove any IO cards. • Check J/P8-8 for -12 Vdc. Is the voltage -12 Vdc? No: Replace the IO card(s) and continue. Yes: Replace the IO card(s), then turn to TAG 002. 7 Turn the printer off. • Reconnect J/P74. • Disconnect the DC cable (J/P73) for the attachment option. • Turn the printer on. Is the voltage at J/P8-8 -12 Vdc? No: Replace the signal interface board, then turn to TAG 002. Yes: Replace the attachment option, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-79, TAG 099: +24 Vdc Power Shorted

TAG 099: +24 Vdc Power Shorted

ERROR MESSAGE:MC +24 DC POWER FAILURE #099 Possible Defects (not listed in any particular order): DC power supply IO card AC power supply Duplex control board #1 Connectors or wiring Duplex control board #2 VPCL board Route motor RIGS board In solenoid Power control #2 board “C” roller solenoid High voltage power supply “A” roller clutch Paper timing clutch Exit solenoid Upper feed roller clutch Restart motor Upper pick-up clutch Lower pick-up clutch Lower feed roller clutch Counter assembly 1 Turn the printer off and unplug the power cord. • Verify that J/P11, J/P8, J/P32, J/P33, J/P91, J/P303, J/P305, J/P306, J/P310, J/P323, and J/P331 are connected properly. • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: A loose connector was at fault. Turn to TAG 002. 2 Check J/P8-11 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 3 Turn the printer off. • Remove any IO cards. • Check J/P8-11 for +24 Vdc. Is the voltage +24 Vdc? No: Replace the IO card(s) and continue. Yes: Replace the IO card(s), then turn to TAG 002. 4 Turn the printer off. • Disconnect J/P330. • Turn the printer on. • Check J/P8-11 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Go to #23 in this TAG. 3-80 Troubleshooting Analysis Guides June 1999, TAG 099: +24 Vdc Power Shorted 5 Turn the printer off. • Reconnect J/P330. • Disconnect J/P11. • Turn the printer on. • Check J/P8-11 for +24 Vdc. Is the voltage +24 Vdc? No: Go to #12 in this TAG. Yes: Continue. 6 Turn the printer off. • Reconnect J/P11. • Disconnect J/P10. • Turn the printer on. • Check J/P8-11 for +24 Vdc. Is the voltage +24 Vdc? No: Go to #8 in this TAG. Yes: Continue. 7 Turn the printer off. • Reconnect J/P10. • Disconnect J/P70. • Turn the printer on. • Check J/P8-11 for +24 Vdc. Is the voltage +24 Vdc? No: Repair or replace the connectors or wiring from P10 to P70, then turn to TAG 002. Yes: Replace the AC power supply, then turn to TAG 002. 8 Turn the printer off. • Reconnect J/P10. • Disconnect J/P12. • Turn the printer on. • Check J/P8-11 for +24 Vdc. Is the voltage +24 Vdc? No: Replace the power control #2 board, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-81, TAG 099: +24 Vdc Power Shorted 9 Turn the printer off. • Reconnect J/P12. • Disconnect J/P41. • Turn the printer on. • Check J/P8-11 for +24 Vdc. Is the voltage +24 Vdc? No: Replace the VPCL board, then turn to TAG 002. Yes: Continue. 10 Turn the printer off. • Reconnect J/P41. • Disconnect J/P23. • Turn the printer on. • Check J/P8-11 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the high voltage power supply, then turn to TAG 002. 11 Turn off the printer and unplug the power cord. • Disconnect J/P41. • Check P41-35 to P23-5 for continuity to ground. Is there continuity? No: You have failed to isolate the problem. Return to the beginning of this TAG. Yes: Repair or replace the connectors or wiring from P41-35 to P23-5, then turn to TAG 002. 12 Turn the printer off. • Reconnect J/P11. • Disconnect J/P91. • Turn the printer on. • Check J/P8-13 for +24 Vdc. Is the voltage +24 Vdc? No: Go to #22 in this TAG. Yes: Continue. 13 Turn the printer off. • Reconnect J/P91. • Disconnect J/P40 and J/P41. • Turn the printer on. • Check J/P8-13 for +24 Vdc. Is the voltage +24 Vdc? No: Replace the VPCL board, then turn to TAG 002. Yes: Continue. 3-82 Troubleshooting Analysis Guides June 1999, TAG 099: +24 Vdc Power Shorted 14 Turn the printer off. • Reconnect J/P40. • Turn the printer on. • Check J/P8-13 for +24 Vdc. Is the voltage +24 Vdc? No: Go to #17 in this TAG. Yes: Continue. 15 Turn the printer off. • Reconnect J/P41. • Disconnect J/P81. • Turn the printer on. • Check J/P8-13 for +24 Vdc. Is the voltage +24 Vdc? No: Repair or replace the connectors or wiring from P41-26 to P81-1, then turn to TAG 002. Yes: Continue. 16 Turn the printer off. • Reconnect J/P81. • Disconnect J/P82. • Turn the printer on. • Check J/P8-13 for +24 Vdc. Is the voltage +24 Vdc? No: Repair or replace the connectors or wiring from J81-1 to P82-1, then turn to TAG 002. Yes: Replace the counter assembly, then turn to TAG 002. 17 Turn the printer off. • Reconnect J/P41. • Disconnect J/P69. • Turn the printer on. • Check J/P8-13 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the lower pick-up roller assembly, then turn to TAG 002. 18 Turn the printer off. • Reconnect J/P69. • Disconnect J/P65. • Turn the printer on. • Check J/P8-13 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the paper timing roller assembly, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-83, TAG 099: +24 Vdc Power Shorted 19 Turn the printer off. • Reconnect J/P65. • Disconnect J/P66. • Turn the printer on. • Check J/P8-13 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the upper feed roller assembly, then turn to TAG 002. 20 Turn the printer off. • Reconnect J/P66. • Disconnect J/P67. • Turn the printer on. • Check J/P8-13 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the lower feed roller assembly, then turn to TAG 002. 21 Turn the printer off. • Reconnect J/P67. • Disconnect J/P68. • Turn the printer on. • Check J/P8-13 for +24 Vdc. Is the voltage +24 Vdc? No: Repair or replace the connectors or wiring from: P40-10 to J69-1, P40-11 to J65-1, P40-11 to J66-1, P40-11 to J67-1, or P40-11 to J 68-1; then turn to TAG 002. Yes: Replace the upper pick-up roller assembly, then turn to TAG 002. 22 Turn the printer off and unplug the power cord. • Disconnect J/P8, J/P11, and J/P91. • Check P8-11 to P11-1 and P8-13 to P91-1 for continuity to ground. Is there continuity? No: Replace the DC power supply, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from: P8-13 to P91-1, or P8-11 to P11-1; then turn to TAG 002. 3-84 Troubleshooting Analysis Guides June 1999, TAG 099: +24 Vdc Power Shorted 23 Turn the printer off. • Reconnect J/P330. • Disconnect J/P323. • Turn the printer on. • Check J/P330-1 for +24 Vdc. Is the voltage +24 Vdc? No: Go to #27 in this TAG. Yes: Continue. 24 Turn the printer off. • Reconnect J/P323. • Disconnect J/P305. • Turn the printer on. • Check J/P330-1 for +24 Vdc. Is the voltage +24 Vdc? No: Go to #25 in this TAG. Yes: Continue. 25 Turn the printer off. • Reconnect J/P305. • Disconnect J/P310 (inside duplex tray). • Turn the printer on. • Check J/P330-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Go to #30 in this TAG. 26 Turn the printer off and unplug the power cord. • Disconnect J/P305. • Check P305-1 and P310-1 for continuity to ground. Is there continuity? No: Return to the beginning of this TAG and start again. Yes: Repair or replace the connectors or wiring from P305-1 to P310-1, then turn to TAG 002. 27 Turn the printer off and unplug the power cord. • Disconnect J/P323. • Check J323-1 and J305-1 for continuity to ground. Is there continuity? No: Return to the beginning of this TAG and start again. Yes: Repair or replace the connectors or wiring from J323-1 to J305-1-1, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-85, TAG 099: +24 Vdc Power Shorted 28 Turn the printer off. • Reconnect J/P323. • Disconnect J/P306. • Turn the printer on. • Check J/P330-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Go to #32 in this TAG. 29 Turn the printer off and unplug the power cord. • Disconnect J/P331. • Check J331-1 and P306-1 for continuity to ground. Is there continuity? No: Repair or replace the connectors or wiring from: P330-1 to P331-1 or P330-1 to P323-1; then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P331-1 to P306-1, then turn to TAG 002. 30 Turn the printer off. • Reconnect J/P310. • Disconnect J/P321. • Turn the printer on. • Check J/P330-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the restart motor, then turn to TAG 002. 31 Turn the printer off. • Reconnect J/P321. • Disconnect J/P312. • Turn the printer on. • Check J/P330-1 for +24 Vdc. Is the voltage +24 Vdc? No: Repair or replace the connectors or wiring from P312 to J321, then turn to TAG 002. Yes: Replace the duplex control board #2, then turn to TAG 002. 3-86 Troubleshooting Analysis Guides June 1999, TAG 099: +24 Vdc Power Shorted 32 Turn the printer off. • Reconnect J/P306. • Disconnect J/P313. • Turn the printer on. • Check J/P330-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the route motor, then turn to TAG 002. 33 Turn the printer off. • Reconnect J/P313. • Disconnect J/P314. • Turn the printer on. • Check J/P330-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the “in” solenoid, then turn to TAG 002. 34 Turn the printer off. • Reconnect J/P314. • Disconnect J/P315. • Turn the printer on. • Check J/P330-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the “C” roller solenoid, then turn to TAG 002. 35 Turn the printer off. • Reconnect J/P315. • Disconnect J/P316. • Turn the printer on. • Check J/P330-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the “A” roller clutch, then turn to TAG 002. 36 Turn the printer off. • Reconnect J/P316. • Disconnect J/P317. • Turn the printer on. • Check J/P330-1 for +24 Vdc. Is the voltage +24 Vdc? No: Continue. Yes: Replace the exit solenoid, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-87, TAG 099: +24 Vdc Power Shorted 37 Turn the printer off. • Reconnect J/P317. • Disconnect J/P308 and J/P309. • Turn the printer on. • Check J/P330-1 for +24 Vdc. Is the voltage +24 Vdc? No: Replace the duplex control board #1, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from: P309-7~10 to J313-1~4, P308-1 to J314-1, P308-2 to J315-1, P308-3 to J316-1, or P308-4 to P317-1; then turn to TAG 002. 3-88 Troubleshooting Analysis Guides June 1999, TAG 100: VPCL Board Interface Malfunction

TAG 100: VPCL Board Interface Malfunction

ERROR MESSAGE:130, 132, 140, 145, 160-162, 170-172, 180-182 Symptoms: VPCL board failure Possible Defects (not listed in any particular order): Connectors or wiring VPCL board 1 Turn off the printer and unplug the power cord. • Verify that J/P40, J/P41, J/P33, and J/P91 are connected properly. • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: A loose connector was at fault. Turn to TAG 002. 2 Was an error message displayed during the power-on-reset? No: Refer to the mechanical malfunctions cross-reference chart in Section 2, TAG Cross-Refer- ence Tables. Yes: Continue. 3 Was the error message the same as the one used to enter this TAG? No: Refer to the error message cross-reference chart in Section 2, TAG Cross-Reference Tables. Yes: Replace the VPCL board, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-89, TAG 130: Disk Drive Malfunction

TAG 130: Disk Drive Malfunction

ERROR MESSAGE:130, 131, 133, 134 MC INCORRECT DISKETTE #450 MC FLOPPY FORMAT #451 MC WRITE PROTECTED #572 TO MC FDC READ #576 MC FDC/DMAC OPERATIONS #586 Symptoms: Test prints do not run Possible Defects (not listed in any particular order): Diskette Disk drive assembly Connectors or wiring VPCL board RIGS board DC power supply

Electrical problems on wires J/P31 to J/P79 and J/P31 to ground may cause diskette and disk

drive malfunctions. If this TAG does not correct the problem, suspect an intermittent failure from the disk drive to the RIGS board cable and replace the cable from J/P31 to J/P79 to J/P30.

The causes of error message MC FDC RESTORE #574 or MC FDC READ #576 can alter

the information on a diskette. You may have to replace the diskette with another known to be good. 1 Turn off the printer. • Verify that J/P8, J/P77, J/P79, and J/P31 are connected properly. • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: Loose connectors were at fault. Turn to TAG 002. 2 Is error message MC FLOPPY FORMAT #451 displayed? No: Go to #5 in this TAG. Yes: Continue. 3 Power-on-reset the printer. Is error message MC FLOPPY FORMAT #451 still displayed? No: Go to #5 in this TAG. Yes: Continue. 4 Remove any diskette from the printer’s disk drive assembly. • Power-on-reset the printer. Is error message MC FLOPPY FORMAT #451 still displayed? No: The diskette was at fault. Turn to TAG 002. Yes: Replace the disk drive assembly and reload the printer’s software onto the hard disk, then turn to TAG 002. 3-90 Troubleshooting Analysis Guides June 1999, TAG 130: Disk Drive Malfunction 5 Is error message MC WRITE PROTECTED #572 displayed? No: Go to #7 in this TAG. Yes: Continue. 6 Turn the printer off and unplug the power cord. • Disconnect J/P31 and J/P79. • Check P31-28 to P79-28 for continuity to ground. Is there continuity? No: Replace the disk drive assembly and reload the printer’s software onto the hard disk. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the RIGS board, then turn to TAG 002. Yes: Replace the wire harness from the drive assembly to the RIGS board, W46, then turn to TAG 002. 7 Is error message MC FLOPPY NOT READY #573 displayed? No: Go to #13 in this TAG. Yes: Continue. 8 Turn the printer on. • Check J/P8-1 for +5 Vdc. Is the voltage +5 Vdc? No: Replace the DC power supply, then turn to TAG 002. Yes: Continue. 9 Check J/P77-4 for +5 Vdc. Is the voltage +5 Vdc? No: Repair or replace the connectors or wiring from P8-1 to P77-4, then turn to TAG 002. Yes: Continue. 10 Check J/P8-3 for +12 Vdc. Is the voltage +12 Vdc? No: Replace the DC power supply, then turn to TAG 002. Yes: Continue. 11 Check J/P77-1 for +12 Vdc. Is the voltage +12 Vdc? No: Repair or replace the connectors or wiring from P8-3 to P77-1, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-91, TAG 130: Disk Drive Malfunction 12 Turn the printer off and unplug the power cord. • Disconnect J/P31 and J/P79. • Check for continuity to ground: P31-34 to P79-34, P31-32 to P79-32, P31-16 to P79-16, and P31-10 to P79-10. Is there continuity on any? No: Replace the disk drive assembly and reload the printer’s software onto the hard disk. If this does not resolve the problem, replace the RIGS board, then turn to TAG 002. Yes: Replace the wire harness from the drive assembly to the RIGS board, W46, then turn to TAG 002. 13 Is error message MC FDC RESTORE #574 displayed? No: Go to #16 in this TAG. Yes: Continue. 14 Turn the printer off and unplug the power cord. • Disconnect J/P31 and J/P79. • Check P31-30 to P79-30 for continuity. Is there continuity? No: Replace the wire harness from the drive assembly to the RIGS board, W46, then turn to TAG 002. Yes: Continue. 15 Check for continuity to ground: P31-18 to P79-18, P31-24 to P79-24, and P31-26 to P79-26. Is there continuity on any? No: Replace the disk drive assembly and reload the printer’s software onto the hard disk. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the RIGS board, then turn to TAG 002. Yes: Replace the wire harness from the drive assembly to the RIGS board, W46, then turn to TAG 002. 16 Is error message MC FDC SEEK #575 displayed? No: Go to #18 in this TAG. Yes: Continue. 3-92 Troubleshooting Analysis Guides June 1999, TAG 130: Disk Drive Malfunction 17 Turn the printer off and unplug the power cord. • Disconnect J/P31 and J/P79. • Check P31-20 to P79-20 and P31-18 to P79-18 for continuity. Is there continuity on each? No: Replace the wire harness from the drive assembly to the RIGS board, W46, then turn to TAG 002. Yes: Replace the disk drive assembly and reload the printer’s software onto the hard disk. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the RIGS board, then turn to TAG 002. 18 Is error message MC FDC READ #576 displayed? No: Go to #21 in this TAG. Yes: Continue. 19 Turn the printer off and unplug the power cord. • Disconnect J/P31 and J/P79. • Check for continuity: P31-22 to P79-22, P31-24 to P79-24, P31-26 to P79-26, P31-28 to P79-28, and P31-32 to P79-32. Is there continuity on each? No: Replace the wire harness from the drive assembly to the RIGS board, W46, then turn to TAG 002. Yes: Continue. 20 Check for continuity to ground: P31-20, P31-22, P31-26, and P31-32. Is there continuity to ground on any? No: Replace the disk drive assembly, then turn to TAG 002. Yes: Replace the wire harness from the drive assembly to the RIGS board, W46. 21 Is error message 130, 131, 133, or 134 displayed? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 22 Can the printer run test prints? No: Continue. Yes: Replace the disk drive assembly and reload the printer’s software onto the hard disk. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the RIGS board, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-93, TAG 130: Disk Drive Malfunction 23 Turn the printer off and unplug the power cord. • Disconnect J/P31 and J/P79. • Check P31-34 to P79-34 for continuity to ground. Is there continuity? No: Replace the disk drive assembly and reload the printer’s software onto the hard disk. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the RIGS board, then turn to TAG 002. Yes: Replace the wire harness from the drive assembly to the RIGS board, W46, then turn to TAG 002. 3-94 Troubleshooting Analysis Guides June 1999, TAG 200: RIGS Internal Communication Malfunction

TAG 200: RIGS Internal Communication Malfunction

ERROR MESSAGE:MC PERIPHERAL BUS #401 MC FATAL SOFTWARE TRAP #454 MC SOFTWARE TRAP #455 MC PIT0 INVALID #500 TO MC PIT2 NO TIMER INTR #509 MC NO DMAC RESET #520 TO MC NO DMAC2 TRANSFER #530 #540 TO MC VSYNC TIMEOUT #566 MC FDC/SCSI READ/WRITE #570 MC FDC BUSY TIMEOUT #571 MC FDC CHECKSUM #577 TO MC FDC/DMAC WRITE #585 #600-#610 Symptoms: RIGS board failure Possible Causes: RIGS program error Possible Defects (not listed in any particular order): Wiring or connectors RIGS board Software I/O card 1 Turn the printer off and unplug the power cord. • Verify that J/P31, J/P32, J/P33, J/P79, and J/P74 are connected properly. • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: A loose connector was at fault. Turn to TAG 002. 2 Was an error message displayed? No: Refer to the mechanical malfunctions cross-reference chart in Section 2, TAG Cross-Refer- ence Tables. Yes: Continue. 3 If the operator panel displayed more than one error message, was it the first mes- sage that displayed on the panel that led you to this TAG? No: Look in Section 2, TAG Cross-Reference Tables’s error message cross-reference chart under the first error message that displayed, then turn to the TAG referenced in the chart. Yes: Continue. 4 Turn the printer off. • Disconnect J/P31 and J/P79. • Check P31-34 for continuity to ground. Is there continuity to ground? No: Continue. Yes: Replace wire harness W46, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-95, TAG 200: RIGS Internal Communication Malfunction 5 Replace the RIGS board, making sure that RIGS EPROM version is correctly matched to the soft- ware release installed on the printer. • Power-on-reset the printer. Has the problem been resolved? No: Reinstall the original RIGS board and continue. Yes: Turn to TAG 002. 6 Reinstall the printer’s software. Follow the instructions for loading software in the C40D Installa- tion Guide. • Power-on-reset the printer. Has the problem been resolved? No: Replace the I/O card, then turn to TAG 002. Yes: Software was at fault. Turn to TAG 002. 3-96 Troubleshooting Analysis Guides June 1999, TAG 201: RIGS-VPCL Interface Malfunction

TAG 201: RIGS-VPCL Interface Malfunction

ERROR MESSAGE:121-127, 199-215 MC PCL CMD RETRY #380 TO MC PCL PARITY #387 Symptoms: Communication failure between the RIGS board and the VPCL board Possible Causes: Insufficient delay period between power off and power on Electrical spikes Possible Defects (not listed in any particular order): Connectors or wiring VPCL board RIGS board DC power supply High voltage power supply 1 Is error message 201 displayed? No: Go to #3 in this TAG. Yes: Continue. 2 Turn the printer off and unplug the power cord. • Verify that J/P33 is connected properly. • Power-on-reset the printer. Has the problem been resolved? No: Confirm that the RIGS firmware is correct for the version of software being used; then replace the RIGS board. Turn to TAG 002. Yes: Turn to TAG 002. 3 Is error message 121 or 123 displayed? No: Go to #6 in this TAG. Yes: Continue. 4 Turn the printer off and unplug the power cord. • Confirm that J/P33 is connected properly. Are the connectors or wiring damaged? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 5 Replace the VPCL board. • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: Turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-97, TAG 201: RIGS-VPCL Interface Malfunction 6 Replace the RIGS board. • Power-on-reset the printer. Has the problem been resolved? No: If error message 121 or 123 brought you to this TAG, replace the DC or high voltage power supply, then turn to TAG 002. For all other error messages, replace the RIGS board, then turn to TAG 002. Yes: Turn to TAG 002. 3-98 Troubleshooting Analysis Guides June 1999, TAG 405: RIGS Bit-Map RAM Malfunction

TAG 405: RIGS Bit-Map RAM Malfunction

ERROR MESSAGE:600-610 Possible Defects (not listed in any particular order): RIGS board 1 The RIGS bit-map RAM has malfunctioned. Replace the RIGS board, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-99, TAG 500: +5 Vdc Power Malfunction

TAG 500: +5 Vdc Power Malfunction

Symptoms: Operator panel blank with AC power supply cooling fan running Possible Defects (not listed in any particular order): DC fuse DC power supply Connectors or wiring Operator panel circuit board VPCL board RIGS board Disk drive assembly LED printhead assembly Attachment option AC power supply Signal interface board Duplex control board #1 Duplex control board #2 1 Turn off the printer and unplug the power cord. • Confirm that J/P94, J/P4, J/P41, J/P91, J/P90, J/P6, and J/P8 are connected properly. • Power-on-reset the printer. Is the operator panel still blank? No: Loose connectors were at fault. Turn to TAG 002. Yes: Continue. 2 Check J/P8-10 for +5 Vdc. Is the voltage +5 Vdc? No: Go to #7 in this TAG. Yes: Continue. 3 Check J/P91-5 for +5 Vdc. Is the voltage +5 Vdc? No: Repair or replace the connectors or wiring from P8-10 to P91-5, then turn to TAG 002. Yes: Continue. 4 Check J/P94-1 for +5 Vdc. Is the voltage +5 Vdc? No: Repair or replace the connectors or wiring from P8-14 to J94-1, then turn to TAG 002. Yes: Continue. 5 Check J/P42-1 for +5 Vdc. Is the voltage +5 Vdc? No: Repair or replace the connectors or wiring from P94-1 to J/P90-1 to P42-1, then turn to TAG 002. Yes: Continue. 3-100 Troubleshooting Analysis Guides June 1999, TAG 500: +5 Vdc Power Malfunction 6 Turn the printer off and unplug the power cord. • Disconnect J/P8 and J/P42. • Check P42-20 to P8-15 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P42-20 to J/P90-20 to J/P94-2 to P8-15, then turn to TAG 002. Yes: Replace the operator panel circuit board. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the VPCL board, wire harness W72, or wire harness W63, then turn to TAG 002. 7 Turn the printer off. • Disconnect J/P330. • Turn the printer on. • Check J/P8-1 for +5 Vdc. Is the voltage +5 Vdc? No: Continue. Yes: Go to #16 in this TAG. 8 Turn the printer off. • Disconnect J/P8. • Turn the printer on. • Check J/P330-3 for +5 Vdc. Is the voltage +5 Vdc? No: Go to #20 in this TAG. Yes: Continue. 9 Turn the printer off. • Reconnect J/P8. • Disconnect J/P77. • Turn the printer on. • Check J/P8-10 for +5 Vdc. Is the voltage +5 Vdc? No: Continue. Yes: Replace the disk drive assembly, then turn to TAG 002. 10 Turn the printer off. • Reconnect J/P77. • Disconnect J/P27. • Turn the printer on. • Check J/P8-10 for +5 Vdc. Is the voltage +5 Vdc? No: Continue. Yes: Replace the LED printhead assembly, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-101, TAG 500: +5 Vdc Power Malfunction 11 Turn the printer off. • Reconnect J/P27. • Disconnect J/P91. • Turn the printer on. • Check J/P8-10 for +5 Vdc. Is the voltage +5 Vdc? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 12 Turn the printer off. • Reconnect J/P91. • Remove the IO card(s). • Turn the printer on. • Check J/P8-10 for +5 Vdc. Is the voltage +5 Vdc? No: Continue. Yes: Replace the IO card(s), then turn to TAG 002. 13 Turn the printer off. • Reinstall the IO card(s). • Disconnect J/P32. • Turn the printer on. • Check J/P8-10 for +5 Vdc. Is the voltage +5 Vdc? No: Continue. Yes: Replace the RIGS board, then turn to TAG 002. 14 Turn the printer off. • Reconnect J/P32. • Disconnect J/P94. • Turn the printer on. • Check J/P8-10 for +5 Vdc. Is the voltage +5 Vdc? No: Replace wire harness W36, then turn to TAG 002. Yes: Continue. 15 Turn the printer off. • Disconnect J/P42. • Check P42-1 for continuity to ground. Is there continuity to ground? No: Replace the operator panel circuit board, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P94-1 to J/P90-1 to P42-1, then turn to TAG 002. 3-102 Troubleshooting Analysis Guides June 1999, TAG 500: +5 Vdc Power Malfunction 16 Turn the printer off. • Reconnect J/P330. • Disconnect J/P331. • Turn the printer on. • Check J/P8-10 for +5 Vdc. Is the voltage +5 Vdc? No: Go to #18 in this TAG. Yes: Continue. 17 Turn the printer off. • Reconnect J/P331. • Disconnect J/P306. • Turn the printer on. • Check J/P8-10 for +5 Vdc. Is the voltage +5 Vdc? No: Repair or replace the connectors or wiring from J331-3 to P306-3, then turn to TAG 002. Yes: Replace the duplex control board #1, then turn to TAG 002. 18 Turn the printer off. • Reconnect J/P333. • Disconnect J/P323. • Turn the printer on. • Check J/P8-10 for +5 Vdc. Is the voltage +5 Vdc? No: Replace wire harness W127 or W128, then turn to TAG 002. Yes: Continue. 19 Turn the printer off. • Disconnect J/P310, found inside the duplex tray. • Check P310-3 for continuity to ground. Is there continuity to ground? No: Replace the duplex control board #2, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from J323-3 to J/P305-3 to P310-3, then turn to TAG 002. 20 Turn the printer on. ! Use extreme caution: • Check from J/P6-1 to J/P6-2 (neutral) for 100 Vac or more. Is the voltage at least 100 Vac? No: Continue. Yes: Replace the DC power supply, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-103, TAG 500: +5 Vdc Power Malfunction 21 ! Use extreme caution: Check from J/P4-7 to J/P4-8 (neutral) for 100 Vac or more. Is the voltage at least 100 Vac? No: Replace the AC power supply. Yes: Repair or replace the connectors or wiring from: P4-7 to P6-1 or P4-8 to P6-2; then turn to TAG 002. 3-104 Troubleshooting Analysis Guides June 1999, TAG 600: Vac Power Malfunction

TAG 600: Vac Power Malfunction

Symptoms: Operator panel blank with fans not running “Close cover” displayed Circuit breaker keeps tripping Possible Defects (not listed in any particular order): Upper fuse in the AC power supply AC power supply DC power supply Connectors or wiring Power control #2 board Power control #3 board Fuser Back cover interlock switch Front cover interlock switch Top cover interlock switch Toner supply motor Cooling fans Jogging motor Main drive motor Vacuum transport Operator panel assembly 1 Turn the printer off and unplug the power cord. • Verify that J/P44, J/P84, J/P4, J/P9, J/P12, J/P40, J/P6, and the AC power cord are connected properly. • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: Loose connectors were at fault. Turn to TAG 002. 2 Turn the printer off. • Open the back cover and install an interlock by-pass tool. • Turn the printer on. ! Use extreme caution: Check from J/P9-2 to J/P9-1 for +100 Vac. Is the voltage +100 Vac? No: Go to #4 in this TAG. Yes: Continue. 3 Turn the printer off and unplug the power cord. • Disconnect J/P40 and J/P12. • Check P40-29 to P12-3 and P40-30 to P12-4 for continuity. Is there continuity on each? No: Repair or replace the connectors or wiring as needed. Yes: Replace the power control #2 board. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the VPCL board, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-105, TAG 600: Vac Power Malfunction 4 Does the CLOSE COVER message display on with all the covers closed? No: Go to #24 in this TAG. Yes: Continue. 5 Operate the top and front cover interlock switch actuators. Are the interlock switch actuators working properly? No: Repair or replace any defective actuator, then turn to TAG 002. Yes: Continue. 6 ! Use extreme caution: Check from J/P4-4 to J/P4-3 for +100 Vac. Is the voltage +100 Vac? No: Continue. Yes: Repair or replace the connectors or wiring from: P9-2 to P4-4 or P9-1 to P4-3. If this is a duplex printer and the problem remains, go to TAG 900. If this corrects the prob- lem, turn to TAG 002. 7 Turn the printer off and unplug the power cord. • Remove the upper fuse in the AC power supply. • Check the fuse for continuity. Does the fuse have continuity? No: Continue. Yes: Go to #10 in this TAG. 8 Replace the upper fuse in the AC power supply. • Reconnect the power. • Power-on-reset the printer. Was the power-on-reset successful? No: Go to #14 in this TAG. Yes: Continue. 9 Remove the developer. • Run diagnostic test “Transfer Corona Test” on page 5-9 for approximately 5 seconds, then stop. • Turn the printer off and unplug the power cord. • Remove the fuse. • Check the fuse for continuity. Does the fuse have continuity? No: Go to #12 in this TAG. Yes: A defective fuse was at fault. Turn to TAG 002. 3-106 Troubleshooting Analysis Guides June 1999, TAG 600: Vac Power Malfunction 10 Reinstall the fuse. • Disconnect J/P4. • Close the top cover. • Check P4-5 to P4-6 for continuity. Is there continuity? No: Go to #33 in this TAG. Yes: Continue. 11 Remove the AC power supply. • Operate the front cover interlock switch. • Check for continuity as you operate the front interlock switch. Does the front cover interlock switch have continuity? No: Repair or replace the front interlock switch, then turn to TAG 002. Yes: Repair or replace the AC power supply, then turn to TAG 002. 12 Disconnect J/P13. • Install a new upper fuse in the AC power supply. • Run diagnostic test “Transfer Corona Test” on page 5-9 for approximately 5 seconds, then stop. • Remove the fuse. • Check the fuse for continuity. Does the fuse have continuity? No: Replace the power control #2 board, then turn to TAG 002. Yes: Continue. 13 Disconnect J/P18. • Check P13-5 to P18-1 for continuity to ground. Is there continuity to ground? No: Replace the toner supply motor, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P18-1 to P13-5, then turn to TAG 002. 14 Turn off the printer. • Disconnect J/P9. • Install a new upper fuse in the AC power supply. • Turn the printer on for 5 seconds, then off. • Remove the upper fuse. • Check the fuse for continuity. Does the fuse have continuity? No: Go to #20 in this TAG. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-107, TAG 600: Vac Power Malfunction 15 Reconnect J/P9. • Install a good upper fuse in the AC power supply. • Disconnect J/P13 and J/P14. • Turn the printer on for 5 seconds, then off. • Remove the fuse. • Check the fuse for continuity. Does the fuse have continuity? No: Replace the power control #2 board, then turn to TAG 002. Yes: Continue. 16 Reconnect J/P13 and J/P14. • Disconnect J/P20, J/P21, J/P22, and J/P326 (duplex printers). • Power-on-reset the printer. • Wait 21/2 minutes, then turn the printer off. • Remove the upper fuse in the AC power supply. • Check the fuse for continuity. Does the fuse have continuity? No: Repair or replace connectors or wiring that have continuity to ground: P21-1 to P13-4, P22-1 to P13-6, J326-1 to P13-4, or P20-2 to P14-6; then turn to TAG 002. Yes: Continue. 17 Turn the printer off. • Reconnect J/P21. • Turn the printer on for 5 seconds, then off. • Remove the upper fuse in the AC power supply. • Check the fuse for continuity. Does the fuse have continuity? No: Replace the large cooling fan assembly, then turn to TAG 002. Yes: Continue. 18 Turn the printer off. • Reconnect J/P20. • Turn the printer on for 2-1/2 minutes, then off. • Remove the upper fuse from the AC power supply. • Check the fuse for continuity. Does the fuse have continuity? No: Replace the main drive motor and power supply, then turn to TAG 002. Yes: Continue. 3-108 Troubleshooting Analysis Guides June 1999, TAG 600: Vac Power Malfunction 19 Turn the printer off. • Reconnect J/P22. • Turn on the printer for 21/2 minutes, then off. Was the power-on-reset successful? No: Replace the vacuum transport, then turn to TAG 002. Yes: Replace the small cooling fan assembly, then turn to TAG 002. 20 Reconnect J/P9. • Disconnect J/P100. • Install a new upper fuse in the AC power supply. • Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8 for approximately five seconds, then turn off the printer. • Remove the fuse. • Check the fuse for continuity. Does the fuse have continuity? No: Go to #22 in this TAG. Yes: Continue. 21 Turn off the printer. • Reconnect J/P100. • Install a good upper fuse in the AC power supply. • Disconnect J/P101. • Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8for approximately five sec- onds, then stop. • Remove the fuse. • Check the fuse for continuity. Does the fuse have continuity? No: Replace the power control #3 board, then turn to TAG 002. Yes: Continue. 22 Disconnect J/P4 and J/P9. • Check P4-4 to P9-2 and P4-4 to P100-1 for continuity to ground. Is there continuity to ground? No: Continue. Yes: Repair or replace the connectors or wiring from P4-4 to P9-2 or P4-4 to P100-1; then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-109, TAG 600: Vac Power Malfunction 23 Close the top cover. • Check P4-5 for continuity to ground. Is there continuity? No: Replace the AC power supply, then turn to TAG 002. Yes: Repair or replace the top cover interlock switch assembly. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, repair or replace the connectors or wiring from: P4-5 to J/P84-1 to P131, or P132 to J/P84-2 to P4-6; then turn to TAG 002. 24 Is the operator panel blank and are the cooling and AC power supply fans off? No: You have chosen an incorrect TAG. Refer to the mechanical malfunctions cross-reference chart in Section 2, TAG Cross-Reference Tables to identify a more appropriate TAG. Yes: Continue. 25 Turn off the printer and unplug the power cord. • Check the wall power outlet for proper voltage. Is the voltage correct? If the circuit breaker was reset after beginning this TAG, answer no. No: Go to #27 in this TAG. Yes: Continue. 26 Unplug power cord from the printer and the wall outlet. • Check the power cord for continuity. Is there continuity? No: Replace the power cord, then turn to TAG 002. Yes: Replace the AC power supply, then turn to TAG 002. 27 Disconnect J/P4. • Check P4-1 for continuity to ground. Is there continuity? No: Go to #29 in this TAG. Yes: Continue. 28 Remove the fuser. • Check P4-1 to J/P44-3 to J5-1 to the fuser for continuity to ground. Is there continuity? No: Replace the fuser, making sure the fuser has the proper voltage rating, then turn to TAG 002. Yes: Repair or replace connectors or wiring that have continuity, then turn to TAG 002. 29 Check J4-1 at the AC power supply for continuity to ground. Is there continuity? No: Continue. Yes: Replace the AC power supply, then turn to TAG 002. 3-110 Troubleshooting Analysis Guides June 1999, TAG 600: Vac Power Malfunction 30 Check P4-7 for continuity to ground. Is there continuity? No: Go to #32 in this TAG. Yes: Continue. 31 Disconnect J/P6. • Check P4-7 to P6-1 for continuity to ground. Is there continuity? No: Replace the DC power supply, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P4-7 to P6-1, then turn to TAG 002. 32 Check J4-7 at the AC power supply for continuity to ground. Is there continuity? No: The customer's circuit breaker may be defective. Verify that the wall outlet has the proper voltage. If it does, continue; otherwise, turn to TAG 002. Yes: Replace the AC power supply, then turn to TAG 002. 33 Disconnect J/P84. • Check P4-5 to P84-1 and P4-6 to P84-2 for continuity. Is there continuity on both? No: Repair or replace the connectors or wiring that lack continuity, then turn to TAG 002. Yes: Continue. 34 Check J84-1 to P131 and J84-2 to P132 for continuity. Is there continuity on both? No: Repair or replace the connectors or wiring that lack continuity, then turn to TAG 002. Yes: Continue. 35 Check J131 to J132 (top interlock switch) for continuity while activating the top cover interlock switch. Is there continuity? No: Repair or replace the top cover interlock switch, then turn to TAG 002. Yes: You have failed to isolate the problem. Return to the beginning of this TAG. June 1999 Troubleshooting Analysis Guides 3-111, TAG 610: Operator Panel Malfunction

TAG 610: Operator Panel Malfunction

Symptoms: One or more message indicators will not light Incomplete numbers are displayed Tone does not work properly All status lights remain on One or more function keys do not work Possible Causes: Operator panel Connectors or wiring VPCL board 1 Turn the printer off and unplug the power cord. • Turn the volume control (on operator panel inside front cover) up fully. • Verify that J/P90, J/P42, J/P8, J/P41, and J/P94 are connected properly. • Run diagnostic test “Operator Panel Test” on page 5-4. Has the problem been resolved? No: Continue. Yes: Loose connectors were at fault. Turn to TAG 002. 2 Do the status lights stay on continuously? No: Continue. Yes: Replace the VPCL board, then turn to TAG 002. 3 Turn the printer off and unplug the power cord. • Disconnect J/P42, J/P91, J/P8, and J/P32. • Check P8-15 to P42-20 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P8-15 to J/P94-2 to J/P90-20 to P42-20, then turn to TAG 002. Yes: Continue. 4 Reconnect J/P42, J/P91, J/P8, and J/P32. • Power-on-reset the printer. • When the “ready” indicator lights, press each function key and listen for the tone.

Test prints may be produced. Press STOP or turn the printer OFF to quit.

Did you hear the tone after pressing each function key? No: Go to #14 in this TAG. Yes: Continue. 5 Is one of the function keys not working properly? No: Go to #16 in this TAG. Yes: Continue. 3-112 Troubleshooting Analysis Guides June 1999, TAG 610: Operator Panel Malfunction 6 Turn the printer off and unplug the power cord. • Disconnect J/P42 and J/P41. • Check P42-18 to P41-3 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P42-18 to J/P90-18 to P41-3, then turn to TAG 002. Yes: Continue. 7 Check P41-3 to P42-18 for continuity to ground. Is there continuity? No: Continue. Yes: Repair or replace the connectors or wiring from P42-18 to J/P90-18 to P41-3, then turn to TAG 002. 8 Check P42-17 to P41-4 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P42-17 to J/P90-17 to P41-4, then turn to TAG 002. Yes: Continue. 9 Check P41-4 to P42-17 for continuity to ground. Is there continuity? No: Continue. Yes: Repair or replace the connectors or wiring from P42-17 to J/P90-17 to P41-4, then turn to TAG 002. 10 Check P42-16 to P41-5 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P42-16 to J/P90-16 to P41-5, then turn to TAG 002. Yes: Continue. 11 Check P41-5 to P42-16 for continuity to ground. Is there continuity? No: Continue. Yes: Repair or replace the connectors or wiring from P42-16 to J/P90-16 to P41-5, then turn to TAG 002. 12 Check P42-15 to P41-6 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P42-15 to J/P90-15 to P41-6, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-113, TAG 610: Operator Panel Malfunction 13 Check P41-6 to P42-15 for continuity to ground. Is there continuity? No: Replace the operator panel. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the VPCL board, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P42-15 to J/P90-15 toP41-6, then turn to TAG 002. 14 Turn the printer off and unplug the power cord. • Disconnect J/P41 and J/P42. • Check P41-18 to P42-3 for continuity to ground. Is there continuity? No: Continue. Yes: Repair or replace the connectors or wiring from P41-18 to J/P90-3 to P42-3, then turn to TAG 002. 15 Check P41-18 to P42-3 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-18 to J/P90-3 to P42-3, then turn to TAG 002. Yes: Replace the operator panel. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the VPCL board, then turn to TAG 002. 16 Run diagnostic test “Operator Panel Test” on page 5-4. Does the combination of lights and display match the description in the diagnostic test? No: Replace the operator panel. Does this resolve the problem? No: Replace the operator panel and continue. Yes: Turn to TAG 002. 17 The problem is the wiring between the VPCL and operator panel. Repair or replace W63 and/or W72, then turn to TAG 002. 3-114 Troubleshooting Analysis Guides June 1999, TAG 700: Output Tray Circuit Malfunction

TAG 700: Output Tray Circuit Malfunction

Symptoms: Invalid REMOVE PRINTS message on display Possible Defects (not listed in any particular order): Output tray full sensor Connectors or wiring Job offset assembly VPCL board High capacity output unit 1 Turn the printer off and unplug the power cord. • Verify that J/P50 and J/P40 are connected properly. • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: Loose connectors were at fault. Turn to TAG 002. 2 Is a high capacity output unit installed on the printer? No: Go to #4 in this TAG. Yes: Continue. 3 Turn off the printer. • Remove the high capacity output unit. • Turn on the printer. Has the problem been resolved? No: Continue. Yes: The high capacity output unit is malfunctioning. Refer to Section 8, Options, for instructions on repairing the high capacity unit. 4 Inspect the output tray full sensor actuator for damage or binding. Is it in good working order? No: Replace the actuator, then turn to TAG 002. Yes: Continue. 5 Turn the printer off and unplug the power cord. • Disconnect J/P51 and J/P40. • Check P40-26 to P51-1 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P40-26 to J/P50-4 to P51-1, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-115, TAG 700: Output Tray Circuit Malfunction 6 Check P40-17 to P51-2 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P40-17 to J/P50-5 to P51-2, then turn to TAG 002. Yes: Continue. 7 Check P40-13 to P51-3 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P40-13 to J/P50-6 to P51-3, then turn to TAG 002. Yes: Continue. 8 Verify that the output tray full sensor is mounted properly. • Verify that it moves down fully. Is the output tray full sensor in good working order? No: Replace the sensor, then turn to TAG 002. Yes: Replace the VPCL board. If this resolves the problem, then turn to TAG 002. If this does not resolve the problem, replace wire harness W71 or W52, then turn to TAG 002. 3-116 Troubleshooting Analysis Guides June 1999, TAG 702: Paper Size Detection Malfunction

TAG 702: Paper Size Detection Malfunction

Symptoms: Incorrect paper size displayed Possible Defects (not listed in any particular order): Upper cassette Lower cassette Upper paper size sensor Lower paper size sensor Connectors or wiring VPCL board 1 Turn the printer off and unplug the power cord. • Verify that J/P52 and J/P40 are connected properly. • Remove the upper and lower cassettes. • Make sure that the rear and side paper guides are securely against the paper. • Power-on-reset the printer. • Insert the cassette exhibiting the problem. Does the display still indicate the incorrect paper size? No: A loose connector or incorrectly positioned paper guides were at fault. Turn to TAG 002. Yes: Continue. 2 Remove the cassette exhibiting the problem. • Take out the paper. • Inspect the two paper size sensing balls on the bottom of the cassette by changing positions of the side and rear paper guides. Is the paper size sensing mechanism in good working order? No: Replace the defective cassette, then turn to TAG 002. Yes: Continue. 3 Inspect the upper and lower paper size sensor assemblies. Is either paper size sensor assembly damaged or improperly mounted? No: Continue. Yes: Remount, repair or replace the faulty paper size sensor assembly, then turn to TAG 002. 4 Remove the upper paper size sensor assembly. • Disconnect the upper circuit board from its mounting. • Inspect the paper size sensor circuit board and mounting for damage or contamination. Is the circuit board or mounting damaged or contaminated? No: Continue. Yes: Repair or replace the upper paper size sensor assembly, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-117, TAG 702: Paper Size Detection Malfunction 5 Remove the lower paper size sensor assembly. • Disconnect the circuit board from its mounting. • Inspect the paper size sensor circuit board and mounting for contamination or damage. Is the circuit board or mounting contaminated or damaged? No: Continue. Yes: Repair or replace the lower paper size sensor assembly, then turn to TAG 002. 6 Is the paper size sensing problem occurring with the upper cassette? No: Go to #8 in this TAG. Yes: Continue. 7 Turn the printer off and unplug the power cord. • Disconnect J/P40 and J/P45. • Refer to the charts at the end of this TAG. • Check the connectors or wiring for the upper paper size sensor. Is there a wiring problem? No: Replace the upper paper size sensor assembly. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the VPCL board, then turn to TAG 002. Yes: Repair or replace the connectors or wiring that are defective, then turn to TAG 002. 8 Turn the printer off and unplug the power cord. • Disconnect J/P40 and J/P43. • Refer to the chart at the end of this TAG. • Check the connectors or wiring for the lower paper size sensor. Is there a wiring problem? No: Replace the lower paper sensor assembly. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the VPCL board, then turn to TAG 002. Yes: Repair or replace the connectors or wiring that are defective, then turn to TAG 002. 3-118 Troubleshooting Analysis Guides June 1999, TAG 702: Paper Size Detection Malfunction

Wiring for the Upper Paper Size Sensor

Refer to the chart when performing continuity checks for an open or short to ground for the upper paper size sensor. Wiring Upper Paper Size Sensor P40-41 to J/P52-10 to J43-1 to J47-10 to J45-10 P40-42 to J/P52-9 to J43-2 to J47-9 to J45-9 P40-43 to J/P52-8 to J43-3 to J47-8 to J45-8 P40-44 to J/P52-7 to J43-4 to J47-7 to J45-7 P40-45 to J/P52-6 to J43-5 to J47-6 to J45-6 P40-46 to J/P52-5 to J43-6 to J47-5 to J45-5 P40-47 to J/P52-4 to J43-7 to J47-4 to J45-4 P40-48 to J/P52-3 to J43-8 to J47-3 to J45-3 P40-49 to J/P52-2 to J43-9 to J47-2 to J45-2

Wiring for the Lower Paper Size Sensor

Refer to the chart when performing continuity checks for an open or short to ground for the lower paper size sensor. Wiring Lower Paper Size Sensor P40-41 to J/P52-10 to J43-1 P40-42 to J/P52-9 to J43-2 P40-43 to J/P52-8 to J43-3 P40-44 to J/P52-7 to J43-4 P40-45 to J/P52-6 to J43-5 P40-46 to J/P52-5 to J43-6 P40-47 to J/P52-4 to J43-7 P40-49 to J/P52-2 to J43-9 P40-50 to J/P52-1 to J43-10 June 1999 Troubleshooting Analysis Guides 3-119, TAG 703: Upper Cassette Malfunction

TAG 703: Upper Cassette Malfunction

Symptoms: Upper cassette does not load or unload properly Upper cassette does not latch properly Possible Defects (not listed in any particular order): Upper cassette Upper pressure lever Upper cassette release latch Upper cassette release Damper assembly Upper cassette release cam Wire cable/roller/spring 1 Inspect the upper cassette for damage. Is the upper cassette in good working order? No: Replace the upper cassette, then turn to TAG 002. Yes: Continue. 2 Inspect the following for damage: • Upper pressure lever • Upper cassette release latch • Upper cassette release • Damper assembly • Upper cassette release cam • Wire cable/roller/spring Are all parts in good working order? No: Repair or replace the damaged part, then turn to TAG 002. Yes: Only mechanical defects and malfunctions can cause this type of problem. Carefully reinspect each part. Repair or replace and defective parts, then turn to TAG 002. 3-120 Troubleshooting Analysis Guides June 1999, TAG 704: Lower Cassette Malfunction

TAG 704: Lower Cassette Malfunction

Symptoms: Lower cassette does not load or unload properly Lower cassette does not latch properly Possible Defects (not listed in any particular order): Lower cassette Lower pressure lever Lower cassette release latch Lower cassette release Lower cassette release cam Spring 1 Inspect the lower cassette for damage. Is the lower cassette in good working order? No: Replace the lower cassette, then turn to TAG 002. Yes: Continue. 2 Inspect the following for damage: • Lower pressure lever • Lower cassette release latch • Lower cassette release • Lower cassette release cam • Spring Are all the parts in good working order? No: Repair or replace the damaged part, then turn to TAG 002. Yes: Only mechanical defects and malfunctions can cause this type of problem. Carefully reinspect each part. Repair or replace the damaged part, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-121, TAG 705: Multiple Paper Feeding

TAG 705: Multiple Paper Feeding

Possible Causes: Wrong weight or type of paper loaded Paper improperly loaded Possible Defects (not listed in any particular order): Upper feed roller assembly Lower feed roller assembly Paper cassette 1 Remove paper from the cassette. • Fan the paper stack and place it in the cassette. • Make sure the paper curl is turned up in the cassette. • Make sure the paper is under the corner separators. • Make sure the rear and side paper guides are positioned properly. • Make sure the paper being used does not have a high static charge. • Confirm that the paper in the cassettes meets paper specifications. • Run at least 20 test prints. Has the problem been resolved? No: Continue. Yes: The paper being used was at fault. Turn to TAG 002. 2 Adjust the paper tension lever or pick pressure as outlined in Section 9, General Printer Mainte- nance. Has the problem been resolved? No: Replace the pick-up roller assembly, then turn to TAG 002. Yes: Turn to TAG 002. 3-122 Troubleshooting Analysis Guides June 1999, TAG 706: Paper Damaged or Wrinkled

TAG 706: Paper Damaged or Wrinkled

Possible Causes: Paper incorrectly loaded Wrong weight or type of paper loaded Paper path obstructed Possible Defects (not listed in any particular order): Fuser Exit roller assembly Exit pinch roller assembly 1 Make sure the paper being used is not damaged. • Make sure the paper is loaded properly. • Make sure the side and rear paper guides in the paper cassettes are positioned properly. • Check both upper and lower paper paths for obstructions or roller contamination. • Confirm that the paper in the cassettes meets paper specifications. • Power-on-reset the printer. • Run test prints from the upper cassette. Are the prints wrinkled or damaged? No: Continue. Yes: Go to #3 in this TAG. 2 Remove the upper cassette. • Power-on-reset the printer. • Run test prints from the lower cassette. Are the prints wrinkled or damaged? No: The paper in use was at fault. Turn to TAG 002. Yes: Continue. 3 Run a test print from the cassette exhibiting the problem. Is the print on the paper skewed? No: Continue. Yes: Go to TAG 807. 4 Remove the exit cover assembly. • Inspect the exit roller assembly for damage, wear, or contamination. • Inspect the exit pinch roller for damage, wear, or contamination. Is either part damaged, worn, or contaminated? No: Replace the fuser, then turn to TAG 002. Yes: Repair or replace the part as needed, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-123, TAG 707: Upper Paper Guide Assembly Not Closing

TAG 707: Upper Paper Guide Assembly Not Closing

Possible Causes: Obstructions Photoconductor front or rear latch arm springs Photoconductor latch arms in incorrect position Upper paper guide latching mechanism damaged or binding Front or rear photoconductor guides damaged Possible Defects (not listed in any particular order): Photoconductor latch arms Upper paper guide latch Photoconductor guide rails 1 Check under the upper paper guide assembly for obstructions. • Remove the photoconductor from the printer. • Inspect the front and rear photoconductor latch arm springs for damage. • Inspect the front and rear photoconductor guide rails for damage. • Make sure there are no obstructions in the mounting area of the photoconductor. • Make sure the upper paper guide latching mechanism is functioning properly. • Make sure the photoconductor latch arms are in the upper position. Are all parts in good working order? No: Repair or replace any malfunctioning parts, then turn to TAG 002. Yes: Continue. Yes: Remove the photoconductor. • Close and lock the upper paper guide. Did the upper paper guide lock into place? No: Replace the upper paper guide, then turn to TAG 002. Yes: Only mechanical defects and malfunctions can cause this type of problem. Go to #1 in this TAG and carefully reinspect each part. 3-124 Troubleshooting Analysis Guides June 1999, TAG 750: Counter Malfunction

TAG 750: Counter Malfunction

Symptoms: Counter does not count Counter counts too often Consumable components require replacement too frequently Possible Defects (not listed in any particular order): Counter assembly Connectors or wiring VPCL board 1 Run diagnostic test “Counter Test” on page 5-7. Is the counter functioning properly? No: Continue. Yes: The counter is working correctly. Turn to TAG 002. 2 Verify that J/P41, J/P81, and J/P82 are connected properly. • Run diagnostic test “Counter Test” on page 5-7. Is the counter functioning properly? No: Continue. Yes: Loose connectors were at fault. Turn to TAG 002. 3 Replace the counter. • Run test prints. Has the problem been resolved? No: Replace the VPCL board, then turn to TAG 002. Yes: The counter was at fault. Turn to TAG 002. 4 Replace the VPCL board. Has the problem been resolved? No: Replace the VPCL board and continue. Yes: The VPCL board was at fault. Turn to TAG 002. 5 Turn the printer off and unplug the power cord. • Disconnect J/P41 and J/P82. • Check P41-26 to J82-1 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-26 to J/P81-1 to J82-1, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-125, TAG 750: Counter Malfunction 6 Check P41-25 to J82-2 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-25 to J/P81-2 to J82-2, then turn to TAG 002. Yes: Replace the counter. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the VPCL board, then turn to TAG 002. 3-126 Troubleshooting Analysis Guides June 1999, TAG 751: Main Drive Motor Runs Continuously

TAG 751: Main Drive Motor Runs Continuously

Possible Defects (not listed in any particular order): Power control #2 board Connectors or wiring VPCL board 1 Turn the printer off and unplug the power cord. • Disconnect J/P12 and J/P40. • Check P40-33 for continuity to ground. Is there continuity? No: Replace the power control #2 board. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the VPCL board, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P40-33 to P12-7, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-127, TAG 753: Async IO Communications Malfunction

TAG 753: Async IO Communications Malfunction

ERROR MESSAGE:MC HOST SCC ERROR #701–#722 Symptoms: Test prints can be made but jobs do not run Jobs do not print correctly Possible Causes: Improper DIP switch settings Host computer Improper application Possible Defects (not listed in any particular order): RIGS board communications cable Cable connectors I/O card Diskette Wrap connector DC power supply

Communication problems may require trial replacement of numerous parts. After each trial

replacement, run the job that exhibited the failure. 1 Turn the printer off and unplug the power cord. • Verify that J/P8, J/P32, J/P74, and J/P92 are connected properly. • Verify that all communication cables are attached properly. • Verify that the correct software is installed in the printer. • Reseat the IO card(s). • Power-on-reset the printer. • Confirm that the printer’s soft configuration is set properly. • Run the failing job. Has the problem been resolved? No: Continue. Yes: Loose connectors or software configuration were at fault. Determine which of these is at fault, correct the problem, then turn to TAG 002. 2 Turn the printer off. • Reload the software on the hard disk. • Power-on-reset the printer. • Confirm that the printer’s software configuration is set correctly to the interface you are using. Has the problem been resolved? No: Continue. Yes: Software or software configuration were at fault. Determine which of these is at fault, correct the problem, then turn to TAG 002. 3-128 Troubleshooting Analysis Guides June 1999, TAG 753: Async IO Communications Malfunction 3 Disconnect the interface cable from the printer. • Install the RS-232C and RS-422 wrap connectors. • Run diagnostic test “LED Printhead Test” on page 5-15. Did the diagnostic test run properly? No: Continue. Yes: Go to #11 in this TAG. 4 Turn the printer off and unplug the power cord. • Inspect J/P71 (RS-232C), J/P72 (RS-422), and J/P74 for connector body cracks or damaged pins. Is there a problem with the connectors or pins? No: Go to #7 in this TAG. Yes: Continue. 5 Replace the I/O card(s). • Run diagnostic test “LED Printhead Test” on page 5-15. Did the diagnostic test run properly? No: Continue. Yes: The I/O card was at fault. Turn to TAG 002. 6 Replace the RIGS board. • Run diagnostic test “LED Printhead Test” on page 5-15. Did the diagnostic test run properly? No: Continue. Yes: The RIGS board was at fault. Turn to TAG 002. 7 Open the back cover and install an interlock by-pass tool. • Power-on-reset the printer. • Check J/P32-10 for +12 Vdc. Is the voltage +12 Vdc? No: Repair or replace the connectors or wiring from P8-6 to P32-10, then turn to TAG 002. Yes: Continue. 8 Check J/P32-3 for -12 Vdc. Is the voltage -12 Vdc? No: Continue. Yes: Replace the signal interface board, then turn to TAG 002. If this does not resolve the problem, replace the RIGS board, then turn to TAG 002. 9 Check J/P8-8 for -12 Vdc. Is the voltage -12 Vdc? No: Replace the DC power supply, then turn to TAG 002. Yes: Repair or replace connectors or wiring from P8-8 to P32-3, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-129, TAG 753: Async IO Communications Malfunction 10 Does the problem appear while using RS-232C communications? No: The problem may be caused by the RIGS board, I/O card, host computer, or host interface cable. Determine which of these are at fault, correct the problem, then turn to TAG 002. Yes: Continue. 11 Turn the printer off and unplug the power cord. • Install a breakout box on the printer to confirm that the host interface cable works as outlined in the chart that follows. • Reconnect all communication lines. • Reconnect any external attachment option. • Power-on-reset the printer. • Run the failing job again. Host Computer Printer Description Signal Pin # Directions Pin # Signal FG11FG SG77SG TD 2 –> <– 2 TD Data OUT (status) TD 2 <– –> 3 RD Data in (CMD/Data) RTS 4 –> <– 4 RTS Optional; continuous positive voltage for host computers that require a “printer present” indication. CTS 5 <– 5 CTS Must go to a positive voltage from the host computer. It is only looked at by DSR 6 <– –> the printer at power-on initialization. DCD 8 <– DTR 20 –> 20 DTR Depends on printer soft configuration option 15. DTR will always be a posi- tive voltage if set to “DTR High”. DTR will change from a positive to a nega- tive voltage if set to “DTR Pacing” and the buffer is full. Does your cable work as outlined in the Cable Reference Chart above? No: The problem appears to be related to the host computer or host interface cable. Correct the problem, then turn to TAG 002. Yes: The problem may be caused by the RIGS board, signal interface board, or outdated printer software. Determine which of these is at fault, correct the problem, then turn to TAG 002. 3-130 Troubleshooting Analysis Guides June 1999, TAG 754: Smart I/O Card Malfunction

TAG 754: Smart I/O Card Malfunction

Symptoms: Job fails only when a smart I/O card is used. Possible Causes: Lack of voltage Possible Defects (not listed in any particular order): Attachment option Communication cables Cable connectors Signal interface board Signal interface board fuse RIGS board Host computer Host interface cable

Communication problems may require trial replacement of numerous parts. After each trial

replacement, run the job that exhibited failure. 1 Turn off the printer and unplug the power cord. • Disconnect all attachment cables. • Open the back cover and install an interlock by-pass tool. • Confirm that J/P8, J/P32, and J/P74 are connected properly. • Reseat the IO card. • Reinstall all communication cables. • Power-on-reset the printer. • Confirm that the printer has been correctly configured using the printer’s soft configuration mode. • Run the failing job. Has the problem been resolved? No: Continue. Yes: Loose or damaged connectors or software configuration were at fault. Turn to TAG 002. 2 Turn on the printer. • Check for the indicated voltages: J73-1 should be +5 Vdc; J73-3 should be +12 Vdc; J73-4 should be -12 Vdc; J73-6 should be +5 Vdc. Are all voltages correct? No: Replace the optional IO card. If this resolves the problem, turn to TAG 002. If this doesn’t resolve the problem, go to the appropriate TAG for the incorrect voltage and continue. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-131, TAG 754: Smart I/O Card Malfunction 3 Turn off the printer and unplug the power cord. • Replace the optional IO card. • Reconnect all communication cables. • Run the failing job. Has the problem been resolved? No: The problem appears to be related to the host computer or the host interface cable. Correct the problem, then turn to TAG 002. Yes: The external attachment option was at fault. Turn to TAG 002. 3-132 Troubleshooting Analysis Guides June 1999, TAG 800: Prints Blank or With Dark Horizontal Bands

TAG 800: Prints Blank or With Dark Horizontal Bands

Possible Defects (not listed in any particular order): Photoconductor Printhead assembly RIGS board Main drive gear assembly Connectors or wiring Transfer corona High voltage power supply Upper paper guide assembly Developer

If there is a developed image on the paper other than dark horizontal bands, follow TAG 804.

1 Turn the printer off and unplug the power cord. • Verify that J/P7, J/P27, J/P41, J/P23, J/P30, J/P31, and transfer corona high voltage power sup- ply lead are connected properly. • Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce- dure. • Run test prints. Has the problem been resolved? No: Continue. Yes: Loose connectors or contamination were at fault. Turn to TAG 002. 2 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Have the photoconductor, charge corona, developer, and toner cartridge been replaced recently? No: Continue. Yes: Go to #6 in this TAG. 4 Replace the photoconductor and charge corona. • Run test prints. Has the problem been resolved? No: Reinstall original photoconductor and charge corona and continue. Yes: The photoconductor was at fault. Turn to TAG 002. 5 Replace the developer and toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer and continue. Yes: Turn to TAG 002. If the problem recurs, the toner carrier mix may be old or contaminated. June 1999 Troubleshooting Analysis Guides 3-133, TAG 800: Prints Blank or With Dark Horizontal Bands 6 Produce a developed image on the photoconductor. Is a developed image on the photoconductor? No: Go to #10 in this TAG. Yes: Continue. 7 Remove and clean the transfer corona. • Clean the transfer corona contacts in the upper paper guide. • Inspect the transfer corona contacts for proper alignment. • Reinstall the transfer corona. • Power-on-reset the printer. • Run test prints. Has the problem been resolved? No: Continue. Yes: Turn to TAG 002. 8 Turn the printer off and unplug the power cord. • Remove the transfer corona. • Check the lower transfer corona contact, with the upper paper guide assembly in its fully upright position, for continuity to ground. Is there continuity? No: Replace the upper paper guide assembly, then turn to TAG 002. Yes: Continue. 9 Replace the transfer corona. • Power-on-reset the printer. • Run test prints. Has the problem been resolved? No: Replace the upper paper guide assembly. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the high voltage power supply, then turn to TAG 002. Yes: The transfer corona was at fault. Turn to TAG 002. 10 Replace the printhead. • Produce a developed image on the photoconductor. Is a developed image on the photoconductor? No: Go to #18 in this TAG. Yes: Continue. 11 Are the prints blank without dark bands? No: Go to #15 in this TAG. Yes: Continue. 3-134 Troubleshooting Analysis Guides June 1999, TAG 800: Prints Blank or With Dark Horizontal Bands 12 Remove the photoconductor and place it in its protective packaging. • Remove the developer. • Inspect the drive coupling on the developer for damage. Is the coupling damaged? No: Continue. Yes: Replace the developer, then turn to TAG 002. 13 Rotate the drive coupling on the developer clockwise. • Watch the magnetic brush. Does the magnetic brush turn? No: Replace the developer, then turn to TAG 002. Yes: Continue. 14 Reinstall the photoconductor. • Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8. • Watch the developer drive coupling at the rear of the developer cavity. Does the developer drive coupling turn? No: Repair or replace the main drive gear assembly, then turn to TAG 002. Yes: Replace the high voltage power supply, then turn to TAG 002. 15 Do the prints have one or more horizontal dark bands? No: The problem has not been identified. Go back to TAG 001 and begin again. Yes: Continue. 16 Turn the printer off and unplug the power cord. • Remove the photoconductor. • Clean the photoconductor contacts and guide rail contacts. • Check the bottom connector contact on the photoconductor guide rail for continuity to ground. Is there continuity? No: Repair or replace the grounding circuit wiring, then turn to TAG 002. Yes: Continue. 17 Reinstall the photoconductor. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Replace the photoconductor, then turn to TAG 002. Yes: Contamination was at fault. Turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-135, TAG 800: Prints Blank or With Dark Horizontal Bands 18 Check J/P27-1, J/P27-2, and J/P27-3 for +5 Vdc. Is there +5 Vdc at each? No: Continue. Yes: Replace wire harness W46. If this resolves the problem, turn to TAG 002. If this doesn’t resolve the problem, replace the RIGS board, then turn to TAG 002. 19 Check J/P7-1 for +5 Vdc. Is the voltage +5 Vdc? No: Replace the DC power supply, then turn to TAG 002. Yes: Replace wire harness W37, then turn to TAG 002. 3-136 Troubleshooting Analysis Guides June 1999, TAG 801: Prints Light or Light With Carrier Particles

TAG 801: Prints Light or Light With Carrier Particles

Possible Defects (not listed in any particular order): Photoconductor Connectors or wiring Main drive gear assembly Transfer corona Power control #2 board Printhead assembly High voltage power supply Toner supply motor VPCL board Upper paper guide assembly Developer

If the problem still exists after completing this TAG, go to TAG 800.

1 Run test prints. • Examine the letters A, V, and W for jaggedness on the diagonal lines. Are they jagged? No: Continue. Yes: Refer to Section 4, Print Quality Samples. Review the printhead problem print samples, iden- tify one similar to the test prints, and turn to the associated TAG. 2 Turn the printer off and unplug the power cord. • Verify that J/P12, J/P13, J/P18, and J/P41 are connected properly. • Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce- dure. • Clean the printhead lens and toner patch sensor located on the developer. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination or loose connectors were at fault. Turn to TAG 002. 3 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 4 Have the photoconductor, charge corona, developer, and toner cartridge been replaced recently? No: Continue. Yes: Go to #7 in this TAG. June 1999 Troubleshooting Analysis Guides 3-137, TAG 801: Prints Light or Light With Carrier Particles 5 Replace the photoconductor and charge corona. • Run test prints. Has the problem been resolved? No: Reinstall the original photoconductor and charge corona and continue. Yes: Run at least 200 test prints to detone the engine, then turn to TAG 002. 6 Replace the developer and toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer and continue. Yes: Turn to TAG 002. 7 Produce a developed image on the photoconductor. Is the developed image on the photoconductor correct? No: Go to #11 in this TAG. Yes: Continue. 8 Remove and clean the transfer corona. • Clean the transfer corona contacts in the upper paper guide. • Inspect the transfer corona contacts for proper alignment. • Reinstall the transfer corona. • Power-on-reset the printer. • Run test prints. Has the problem been resolved? No: Continue. Yes: Turn to TAG 002. 9 Turn the printer off and unplug the power cord. • Remove the transfer corona. • Check the lower transfer corona contact, with the upper paper guide assembly in its fully upright position, for continuity to ground. Is there continuity? No: Repair or replace the upper paper guide assembly, then turn to TAG 002. Yes: Continue. 10 Turn the printer off and unplug the power cord. • Replace the transfer corona. • Power-on-reset the printer. • Run test prints. Has the problem been resolved? No: Replace the upper paper guide assembly. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the high voltage power supply, then turn to TAG 002. Yes: The transfer corona was at fault. Turn to TAG 002. 3-138 Troubleshooting Analysis Guides June 1999, TAG 801: Prints Light or Light With Carrier Particles 11 Open the front cover and install an interlock by-pass tool. • Remove the photoconductor. • Remove the developer. • Run diagnostic test “Toner Supply Motor Test” on page 5-8. • Watch the toner motor coupling in the developer cavity. Does the coupling turn? No: Go to #20 in this TAG. Yes: Continue. 12 Inspect the toner drive coupling on the developer for damage. Is the coupling damaged? No: Continue. Yes: Replace the developer, then turn to TAG 002. 13 Rotate both the drive couplings on the developer clockwise. Do both drive couplings rotate freely? No: Replace the developer, then turn to TAG 002. Yes: Continue. 14 Reinstall the photoconductor. • Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8. • Watch the developer drive coupling in the developer cavity. Does the coupling turn? No: Repair or replace the main drive gear assembly, then turn to TAG 002. Yes: Continue. 15 Turn the printer off and unplug the power cord. • Disconnect J/P41, J/P24, and J/P23. • Check the following for continuity: P41-30 to J24-4, P41-38 to J23-2, P41-43 to J25-5, P41-44 to J25-2, P41-47 to J25-3, P41-48 to J25-6, P41-49 to J25-4, and P41-50 to J25-1. Is there continuity on all? No: Repair or replace the connectors or wiring that do not have continuity, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-139, TAG 801: Prints Light or Light With Carrier Particles 16 Reconnect J/P23, J/P41, and J/P24. • Reinstall the developer. • Power-on-reset the printer. • Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Go to #17 in this TAG. 17 Turn the printer off and unplug the power cord. • Replace the charge corona terminal assembly. • Power-on-reset the printer. • Run test prints. Has the problem been resolved? No: Reinstall the original charge corona terminal assembly and continue. Yes: Turn to TAG 800. 18 Turn the printer off and unplug the power cord. • Replace the printhead assembly. • Power-on-reset the printer. • Run test prints. Has the problem been resolved? No: Reinstall the original printhead assembly and continue. Yes: Turn to TAG 002. 19 Turn the printer off and unplug the power cord. • Replace the RIGS board. • Power-on-reset the printer. • Run test prints. Has the problem been resolved? No: Reinstall the original RIGS board and go to TAG 800. 20 Turn to TAG 002. • Run diagnostic test “Toner Supply Motor Test” on page 5-8. ! Use extreme caution: • Check J/P13-5 to J/P13-2 for 100 Vac while the test is running. Is the voltage 100 Vac? No: Replace the VPCL board. If this does not resolve the problem, repair or replace the wiring from J/P 13 to P40, then turn to TAG 002. Yes: Continue. 3-140 Troubleshooting Analysis Guides June 1999, TAG 801: Prints Light or Light With Carrier Particles 21 Run diagnostic test “Toner Supply Motor Test” on page 5-8. ! Use extreme caution: • Check J/P18-1 to J/P18-2 for 100 Vac while the test is running. Is the voltage 100 Vac? No: Repair or replace the connectors or wiring from P18-1 to P13-5, P18-2 to P13-2, or both. Yes: Replace the toner supply motor, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-141, TAG 802: Prints With Voids or White Spots

TAG 802: Prints With Voids or White Spots

Possible Causes: Wrong weight or type of paper loaded Possible Defects (not listed in any particular order): Photoconductor Developer 1 Perform the every-call cleaning procedure. • Confirm that the paper in the cassettes meets paper specifications. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination was at fault. Turn to TAG 002. 2 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Have the photoconductor, developer, and fuser been replaced recently? No: Continue. Yes: Refer to Section 4, Print Quality Samples. Compare the test prints with the print samples, and identify a sample having the same print flaw as the test prints; turn to the TAG listed under the sample. 4 Replace the photoconductor and charge corona. • Run test prints. Has the problem been resolved? No: Reinstall the original photoconductor and charge corona, and continue. Yes: Turn to TAG 002. 5 Replace the developer and toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer and continue. Yes: Turn to TAG 002. 3-142 Troubleshooting Analysis Guides June 1999, TAG 802: Prints With Voids or White Spots 6 Replace the fuser. • Run test prints. Has the problem been resolved? No: Reinstall the original fuser. Refer to Section 4, Print Quality Samples. Compare the test prints with the print samples, and identify a sample having the same print flaw as the test prints; turn to the TAG listed under the sample. Yes: Turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-143, TAG 803: Prints With Light or White Vertical Streaks

TAG 803: Prints With Light or White Vertical Streaks

Possible Defects (not listed in any particular order): Transfer corona Printhead assembly Photoconductor Developer 1 Turn off the printer and unplug the power cord. • Verify that J/P13, J/P30, and J/P31 are connected properly. • Make sure the customer's paper supply is not at fault. • Refer to Section 9, General Printer Maintenance and perform the every-call cleaning procedure. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue. Yes: Loose connectors or contamination were at fault. Turn to TAG 002. 2 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Have the photoconductor, charge corona, and developer been replaced recently? No: Continue. Yes: Go to #6 in this TAG. 4 Replace the photoconductor and charge corona. • Run test prints. Has the problem been resolved? No: Reinstall the original photoconductor and charge corona, and continue. Yes: Turn to TAG 002. 5 Replace the developer and toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer and continue. Yes: Turn to TAG 002. 6 Turn on the printer. • Produce a developed image on the photoconductor. Are there vertical streaks on the photoconductor belt image? No: Replace the transfer corona, then turn to TAG 002. Yes: Replace the printhead assembly, then turn to TAG 002. 3-144 Troubleshooting Analysis Guides June 1999, TAG 804: Prints With Light Horizontal Bands

TAG 804: Prints With Light Horizontal Bands

Possible Causes: Loose printhead connectors Possible Defects (not listed in any particular order): Transfer corona Photoconductor Charge corona 1 Turn the printer off and unplug the power cord. • Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce- dure. • Verify that J/P30 and J/P31 are connected properly. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination or loose connectors were at fault. Turn to TAG 002. 2 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Have the photoconductor and charge corona have been replaced recently? No: Continue. Yes: Go to #5 in this TAG. 4 Replace the photoconductor and charge corona. • Turn on the printer. • Run test prints. Has the problem been resolved? No: Reinstall the original photoconductor and charge corona, then continue. Yes: Turn to TAG 002. 5 Replace the transfer corona. Has the problem been resolved? No: Replace the photoconductor. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, refer to Section 4, Print Quality Samples. Compare the test prints with the print samples, and identify a sample having the same print flaw as the test prints; turn to the TAG listed under the sample. Yes: Turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-145, TAG 805: Black Prints

TAG 805: Black Prints

Possible Causes: Contaminated toner/carrier mix Possible Defects (not listed in any particular order): Charge corona Printhead assembly Connectors or wiring VPCL board RIGS board High voltage power supply Charge corona lead Photoconductor Developer Charge corona terminal assembly 1 Turn the printer off and unplug the power cord. • Verify that J/P23, J/P24, J/P41, and the charge corona high voltage lead are connected properly. • Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce- dure. • Clean the contacts on the charge corona. • Open the printer’s top cover and install an interlock by-pass tool. • Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8. Is the photoconductor belt covered with toner? No: Loose connectors or contamination were at fault. Turn to TAG 002. Yes: Continue. 2 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Has the photoconductor, charge corona, developer, and cleaner been replaced recently? No: Continue. Yes: Go to #6 in this TAG. 4 Replace the photoconductor and charge corona. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Reinstall the original photoconductor and charge corona, then continue. Yes: Turn to TAG 002. 3-146 Troubleshooting Analysis Guides June 1999, TAG 805: Black Prints 5 Replace the developer, toner cartridge, and cleaner. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Reinstall the original developer and cleaner, then continue. Yes: Turn to TAG 002. If the problem recurs, the toner/carrier mix may be old or contaminated. 6 Turn the printer off and unplug the power cord. • Disconnect J/P41, J/P23, and J/P24. • Check P41-33 to P23-7 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-33 to P23-7, then turn to TAG 002. Yes: Continue. 7 Check P41-30 to P24-4 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-30 to P24-4. Yes: Continue. 8 Replace the charge corona terminal assembly. • Run test prints. Has the problem been resolved? No: Continue. Yes: Turn to TAG 002. 9 Replace the high voltage power supply. • Run test prints. Has the problem been resolved? No: Reinstall the original high voltage power supply and continue. Yes: Turn to TAG 002. 10 Replace the printhead assembly. • Run test prints. Has the problem been resolved? No: Reinstall the original printhead assembly and continue. Yes: Turn to TAG 002. 11 Replace the RIGS board. • Run test prints. Has the problem been resolved? No: Replace the charge corona lead wiring, then turn to TAG 002. Yes: Turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-147, TAG 806: Prints with Dark Spots or Scratches

TAG 806: Prints with Dark Spots or Scratches

Possible Causes: Paper path contamination Paper supply defects Toner Possible Defects (not listed in any particular order): Photoconductor Charge corona Fuser Developer Cleaner 1 Turn the printer off and unplug the power cord. • Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce- dure. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination was at fault. Turn to TAG 002. 2 Refer to Section 9, General Printer Maintenance and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Have the photoconductor, charge corona, fuser, cleaner, and developer with new toner cartridge been replaced recently? No: Continue. Yes: Go to #8 in this TAG. 4 Replace the photoconductor and charge corona. • Run test prints. Has the problem been resolved? No: Reinstall the original photoconductor and charge corona and continue. Yes: Turn to TAG 002. 5 Replace the cleaner. • Run test prints. Has the problem been resolved? No: Reinstall the original cleaner and continue. Yes: Turn to TAG 002. 3-148 Troubleshooting Analysis Guides June 1999, TAG 806: Prints with Dark Spots or Scratches 6 Replace the fuser. • Run test prints. Has the problem been resolved? No: Reinstall the original fuser and continue. Yes: Turn to TAG 002. 7 Replace the developer and toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer and continue. Yes: Turn to TAG 002. If this problem recurs, the toner/carrier mix may be old or contaminated. 8 Inspect the paper being used for scratches or dark spots. Does the paper have any problems? No: Continue. Yes: Replace the paper. Turn to TAG 002. 9 Inspect for damage or binding: • Main drive motor gear • Main drive gear assembly • Developer coupling on the developer and the printer Are these mechanisms in good working order? No: Replace the defective parts, then turn to TAG 002. Yes: Verify that the photoconductor, charge corona, developer, and fusers are new. If these items are new, defective or contaminated toner may be the cause of the problem. Replace the devel- oper and cleaners with units from the printer’s manufacturer, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-149, TAG 807: Misregistered/Skewed Prints

TAG 807: Misregistered/Skewed Prints If this problem occurs in the duplex printing mode only, go to TAG 901.

Possible Causes: Paper incorrectly loaded Wrong weight or type of paper loaded Possible Defects (not listed in any particular order): Upper cassette Lower cassette Upper paper guide assembly Lower paper guide assembly Paper timing guide assembly Paper timing roller assembly Upper pick-up roller assembly Upper feed roller assembly Upper pinch rollers Lower feed roller assembly Lower pick-up roller assembly Lower pinch rollers Paper feed drive belt Paper feed idler assembly Main drive gear assembly VPCL board

If the test pattern has a 20 line indicator at the top of the page, registration is correct when the

twentieth line of the indicator is at the leading edge of the print (+ or - 2).

If the problem varies from print to print, a mechanical binding malfunction may be at fault.

1 Inspect both paper cassettes for damage. • Make sure the paper in the cassettes is loaded properly. • Make sure the side and rear paper guides are positioned properly. • Inspect both paper paths for contamination and remove any obstructions. • Confirm that the paper in the cassettes meets paper specifications. • Power-on-reset the printer. • Remove and insert the cassette causing the problem. Confirm that the message, which displays on the operator’s panel, corresponds to the paper size in the cassette. Refer to TAG 702. • Run test prints from the upper cassette. Is the problem with the upper cassette. No: Go to #5 in this TAG. Yes: Continue. 2 Remove the upper cassette. • Power-on-reset the printer. • Run test prints from the lower cassette. Is the problem also with the lower cassette? No: Go to #4 in this TAG. Yes: Continue. 3-150 Troubleshooting Analysis Guides June 1999, TAG 807: Misregistered/Skewed Prints 3 Turn the printer off and unplug the power cord. • Inspect the following for damage or contamination: • Paper timing roller assembly • Upper paper guide assembly • Lower paper guide assembly • Paper timing guide assembly • Paper feed drive belt • Paper feed idler assembly • Main drive gear assembly Are these parts clean and in good working order? No: Repair or replace the parts as needed, then turn to TAG 002. Yes: Go to #7 in this TAG. 4 Inspect the following for damage and contamination: • Upper pick-up roller assembly • Upper feed roller assembly • Upper pinch rollers • Upper cassette Are these parts clean and in good working order? No: Repair or replace the parts as needed, then turn to TAG 002. Yes: You have not isolated the problem. Return to the beginning of this TAG. 5 Remove the upper cassette. • Power-on-reset the printer. • Run test prints from the lower cassette. Is the problem with the lower cassette? No: Incorrectly loaded paper was at fault. Turn to TAG 002. Yes: Continue. 6 Inspect the following for damage or contamination: • Lower pick-up roller assembly • Lower feed roller assembly • Lower pinch rollers • Lower cassette. Are these parts clean and in good working order? No: Repair or replace the parts as needed, then turn to TAG 002. Yes: You have not isolated the problem. Return to the beginning of this TAG. 7 Is misregistration the symptom of the problem? No: Skew problems can only result from mechanical causes. Return to the beginning of this TAG. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-151, TAG 807: Misregistered/Skewed Prints 8 Run test prints. Is the amount of misregistration within + or - 2 lines of the 20-line indicator from the leading edge of the test print? No: Continue. Yes: The registration is within specification. Turn to TAG 002. 9 Adjust the registration as described in Section 9, General Printer Maintenance. Did adjusting the registration resolve the problem? No: Replace the paper timing roller assembly, then turn to TAG 002. If this does not resolve the problem, replace the upper paper guide assembly or the paper timing guide, then turn to TAG 002. Yes: Turn to TAG 002. 3-152 Troubleshooting Analysis Guides June 1999, TAG 808: Prints Overtoned/Dark Vertical Streaks

TAG 808: Prints Overtoned/Dark Vertical Streaks

Possible Causes: Clogged cleaner Contaminated toner/carrier mix Possible Defects (not listed in any particular order): Cleaner Photoconductor Charge corona High voltage power supply Power control #2 board VPCL board Connectors or wiring Developer

Overtoned print and dark print problems are very similar. If this TAG does not resolve the

problem, go to TAG 811. 1 Turn the printer off and unplug the power cord. • Verify that J/P23, J/P12, J/P25, and J/P41 are connected properly. • Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce- dure. • Power-on-reset the printer. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination or loose connectors were at fault. Turn to TAG 002. 2 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Have the photoconductor, charge corona, cleaner, and developer with toner car- tridge been replaced recently? No: Continue. Yes: Go to #7 in this TAG. 4 Replace the photoconductor and charge corona. • Run test prints. Has the problem been resolved? No: Reinstall the original photoconductor and charge corona, then continue. Yes: Run at least 200 test prints to detone the printer’s engine, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-153, TAG 808: Prints Overtoned/Dark Vertical Streaks 5 Replace the cleaner. • Run test prints. Has the problem been resolved? No: Reinstall the original cleaner and continue. Yes: Turn to TAG 002. 6 Replace the developer with toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer and continue. Yes: Turn to TAG 002. If the problem recurs, the toner/carrier mix may be old or contaminated. 7 Turn the printer off. • Open the front cover and install an interlock by-pass tool. • Remove the developer. • Power-on-reset the printer. • Watch the toner motor coupling at the rear of the developer cavity. Does the coupling turn continuously? No: Go to #9 in this TAG. Yes: Continue. 8 Turn off the printer and unplug the power cord. • Disconnect J/P12 and J/P40. • Check P40-31 to P12-5 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P40-31 to P12-5, then turn to TAG 002. Yes: Replace the power control #2 board. If this resolves the problem, turn to TAG 002. If this doesn’t resolve the problem, replace the VPCL board, then turn to TAG 002. 9 Reinstall the developer. • Replace the VPCL board. • Run test prints. Has the problem been resolved? No: Reinstall the old VPCL board and continue. Yes: VPCL board was the problem. Turn to TAG 002. 3-154 Troubleshooting Analysis Guides June 1999, TAG 808: Prints Overtoned/Dark Vertical Streaks 10 Turn the printer off and unplug the power cord. • Disconnect J/P41. • Remove the developer. • Check for continuity: P41-44 to P25-2, P41-47 to P25-3, and P41-50 to P25-1. Is there continuity at each? No: Repair or replace the connectors or wiring from: P41-44 to P25-2, P41-47 to P25-3, or P41-50 to P25-1; then turn to TAG 002. Yes: Continue. 11 Clean the printhead lens and toner patch sensor. • Reinstall the developer. • Reconnect J/P41. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination was at fault. Turn to TAG 002. 12 Turn the printer off and unplug the power cord. • Disconnect J/P41 and J/P24. • Check P41-30 for continuity to ground. Is there continuity? No: Continue. Yes: Repair or replace the connectors or wiring from P41-30 to P24-2, then turn to TAG 002. 13 Reconnect J/P24. • Disconnect J/P23. • Check P41-38 to P23-2 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-38 to P23-2, then turn to TAG 002. Yes: Continue. 14 Disconnect J/P85. • Remove the developer. • Check P85-8 to J25-7 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P85-8 to J25-7, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-155, TAG 808: Prints Overtoned/Dark Vertical Streaks 15 Reconnect J/P85. • Reinstall the developer. • Replace the high voltage power supply. • Run test prints. Has the problem been resolved? No: Reinstall the original high voltage power supply and continue. Yes: Turn to TAG 002. 16 Repair or replace the VPCL board. • Run test prints. Has the problem been resolved? No: Reinstall the original VPCL board. Confirm that the photoconductor, charge corona, devel- oper, and fusers are new. If these items are new, the toner/carrier mix may be old or contami- nated. Replace the developer and cleaners with units from the printer’s manufacturer. If this resolves the problem, turn to TAG 002. Otherwise, turn to TAG 811. Yes: Turn to TAG 002. 3-156 Troubleshooting Analysis Guides June 1999, TAG 809: Blurred or Smeared Vertical Streaks on Prints

TAG 809: Blurred or Smeared Vertical Streaks on Prints

Possible Defects (not listed in any particular order): Photoconductor Charge corona Cleaner Fuser Vacuum transport Fuser drive gear Fuser drive idler and spring Fuser drive belt Main drive assembly Printhead assembly Power control #2 board 1 Turn the printer off and unplug the power cord. • Verify that J/P23, J/P41, and J/P13 are connected properly. • Refer to Section 9, General Printer Maintenance and perform the every-call cleaning procedure. • Clean the printhead lens. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination or loose connectors were at fault. Turn to TAG 002. 2 Refer to Section 9, General Printer Maintenance and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Have the photoconductor, charge corona, cleaner, or fusers been replaced recently? No: Continue. Yes: Go to #7 in this TAG. 4 Replace the photoconductor and charge corona. • Run test prints. Has the problem been resolved? No: Reinstall the original photoconductor and charge corona and continue. Yes: Turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-157, TAG 809: Blurred or Smeared Vertical Streaks on Prints 5 Replace the fuser. • Run test prints. Has the problem been resolved? No: Reinstall the original fuser and continue. Yes: Turn to TAG 002. 6 Replace the cleaner. • Run test prints. Has the problem been resolved? No: Reinstall the original cleaner and continue. Yes: Turn to TAG 002. 7 Check the following for damage: • Vacuum transport • Vacuum transport assembly ozone filter • fuser drive gear on the fuser and fuser cavity • Fuser drive belt • Main drive assembly • cleaner drive belt • Cleaner drive idler assembly • Cleaner drive assembly Are they in good working order? No: Repair or replace the parts as needed, then turn to TAG 002. Yes: Continue. 8 Open the printer’s top cover and install an interlock by-pass tool. • Turn the printer on. • Wait until the motor turns on, then proceed. • Verify the vacuum transport fan is running by placing a sheet of paper over the holes in the vac- uum transport. Does the vacuum fan hold the paper? No: Go to #10 in this TAG. Yes: Continue. 9 Inspect the vacuum transport belts and gear for damage or binding. Is the vacuum transport in good working order? No: Repair or replace the vacuum transport, then turn to TAG 002. Yes: Go to #12 in this TAG. 10 Run test prints. ! Use extreme caution: 3-158 Troubleshooting Analysis Guides June 1999, TAG 809: Blurred or Smeared Vertical Streaks on Prints • Check J/P22-1 to J/P22-2 for 100 Vac. Is the voltage 100 Vac? No: Continue. Yes: Replace the vacuum transport, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-159, TAG 809: Blurred or Smeared Vertical Streaks on Prints 11 Run test prints. ! Use extreme caution: • Check J/P13-6 to J/P13-3 for 100 Vac. Is the voltage 100 Vac? No: Replace the power control #2 board, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from J22-1 to P13-6 or J22-2 to P13-3, then turn to TAG 002. 12 Inspect the fuser drive assembly and the fuser drive belt for damage or a slipping belt. Are they in good working order? No: Replace the parts that are defective, then turn to TAG 002. Yes: Replace the printhead assembly, then turn to TAG 002. 3-160 Troubleshooting Analysis Guides June 1999, TAG 810: Uneven Density or Dark Areas on Prints

TAG 810: Uneven Density or Dark Areas on Prints

Possible Defects (not listed in any particular order): Photoconductor Charge corona Developer Cleaner 1 Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning procedure. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination was at fault. Turn to TAG 002. 2 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Have the photoconductor, charge corona, cleaner and developer with new toner cartridge been replaced recently? No: Continue. Yes: Go to TAG 811. 4 Replace the photoconductor and charge corona. • Run test prints. Has the problem been resolved? No: Reinstall the original photoconductor and charge corona and continue. Yes: Turn to TAG 002. 5 Replace the cleaner. • Run test prints. Has the problem been resolved? No: Reinstall the original cleaner and continue. Yes: Turn to TAG 002. 6 Replace the developer and toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer and toner cartridge, then turn to TAG 811. Yes: Turn to TAG 002. If the problem recurs, the toner/carrier mix may be old or contaminated. June 1999 Troubleshooting Analysis Guides 3-161, TAG 811: Background/Residual Images/Dark Prints

TAG 811: Background/Residual Images/Dark Prints

Possible Causes: Contaminated toner/carrier mix Possible Defects (not listed in any particular order): Photoconductor Charge corona Cleaner Developer Erase lamp assembly High voltage power supply Power control #2 board Connectors or wiring VPCL board Charge corona terminal assembly Cleaner terminal assembly 1 Turn the printer off and unplug the power cord. • Verify J/P23, J/P24, J/P85, and the charge corona high voltage lead are connected properly. • Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce- dure. • Clean the contacts on the charge corona. • Clean the printhead lens and toner patch sensor located on the developer. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination or a loose connector was at fault. Turn to TAG 002. 2 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Have the photoconductor, charge corona, cleaner and developer with new toner cartridge been replaced recently? No: Continue. Yes: Go to #5 in this TAG. 4 Replace the photoconductor and charge corona. • Run 200+ test prints, then evaluate the test print background. Has the problem been resolved? No: Reinstall the original photoconductor and charge corona and continue. Yes: Turn to TAG 002. 3-162 Troubleshooting Analysis Guides June 1999, TAG 811: Background/Residual Images/Dark Prints 5 Replace the developer and cleaner. • Run test prints. Has the problem been resolved? No: Reinstall the original developer and cleaner and continue. Yes: Turn to TAG 002. 6 Remove the photoconductor from the printer. • Run diagnostic test “Erase Lamp Test” on page 5-10. • Watch the erase lamp while the test is running. Are all the erase lamps on? No: Continue Yes: The VPCL was the problem, Turn to TAG 002. 7 Turn the printer off. • Open the front cover and install an interlock by-pass tool. • Remove the developer. • Power-on-reset the printer. • Watch the toner motor coupling in the developer cavity. Does the coupling turn continuously before error message MC NO DEVELOPER #036 is dis- played? No: Continue. Yes: Go to #17 in this TAG. 8 Reinstall the developer. • Replace the VPCL • Run test prints. Has the problem been resolved? No: Go to #10 in this TAG. Yes: Continue. 9 Turn the printer off and unplug the power cord. • Disconnect J/P41. • Remove the developer. • Check for continuity: P41-44 to J25-2, P41-47 to J25-3, and P41-50 to J25-1. Is there continuity on each? No: Repair or replace the connectors or wiring: P41-44 to J24-2, P41-47 to J25-3, or P41-50 to J25-1; then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-163, TAG 811: Background/Residual Images/Dark Prints 10 Turn the printer off and unplug the power cord. • Disconnect J/P41 and J/P24. • Check P41-30 to P24-2 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-30 to P24-2, then turn to TAG 002. Yes: Continue. 11 Reconnect J/P24. • Disconnect J/P23. • Check P41-33 to P23-7 for continuity. Is there continuity? No: Continue. Yes: Repair or replace the connectors or wiring from P41-33 to P23-7, then turn to TAG 002. 12 Reconnect J/P23. • Disconnect J/P85 from the high voltage power supply. • Check P85-8 to J25-7 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P85-8 to J25-7, then turn to TAG 002. Yes: Continue. 13 Reinstall the developer. • Reconnect J/P85. • Disconnect J/P41 and J/P24. • Check P41-40 to P24-3 for continuity. Is there continuity? No: Repair or replace the connector or wiring from P41-40 to P24-3, then turn to TAG 002. Yes: Continue. 14 Reconnect J/P41 and J/P24. • Turn the printer on. • Run test prints. • Check TP4-40 for 0.5 Vdc while running the prints. Is the voltage 0.5 Vdc? No: Replace the VPCL board, then turn to TAG 002. Yes: Continue. 15 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3-164 Troubleshooting Analysis Guides June 1999, TAG 811: Background/Residual Images/Dark Prints 16 Replace the VPCL board. Has the problem been resolved? No: Reinstall original VPCL board. Go back to #3 in this TAG. If this does not resolve the prob- lem, the RIGS board, cleaner terminal assembly, or charge corona terminal assembly may be at fault. Determine which of these is at fault, correct the problem, then turn to TAG 002. Yes: Turn to TAG 002. 17 Check J/P40-31 for 0 Vdc. Is the voltage 0 Vdc? No: Replace the power control #2 board, then turn to TAG 002. Yes: Continue. 18 Turn the printer off and unplug the power cord. • Disconnect J/P40. • Check P40-31 for continuity to ground. Is there continuity? No: Replace the VPCL board, then turn to TAG 002. Yes: Continue. 19 Disconnect J/P12. • Check P40-31 and P12-5 for continuity to ground. Is there continuity? No: Replace the power control #2 board, then turn to TAG 002. Yes: Repair or replace the connectors or wiring from P40-31 to P12-5, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-165, TAG 812: Uneven or No Fusing on Prints

TAG 812: Uneven or No Fusing on Prints

Possible Causes: Wrong weight or type of paper loaded Possible Defects (not listed in any particular order): Fuser Connectors or wiring AC power supply VPCL board 1 Turn the printer off and unplug the power cord. • Verify that J/P44, J/P4, J/P10, J/P11, J/P12, J/P40, J/P83, J/P91, and J/P8 are connected prop- erly. • Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce- dure. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination or loose connectors were at fault. Turn to TAG 002. 2 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 3 Have the fuser and developer with new toner cartridge been replaced recently? No: Continue. Yes: Go to #6 in this TAG. 4 Replace the fuser. • Run test prints. Has the problem been resolved? No: Reinstall the original fuser and continue. Yes: Turn to TAG 002. 5 Replace the developer and toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer and continue. Yes: Turn to TAG 002. 3-166 Troubleshooting Analysis Guides June 1999, TAG 812: Uneven or No Fusing on Prints 6 Power-on-reset the printer. • Watch through the output tray opening to see if the fuser lamp comes on. Does the lamp light within 1.5 minutes? No: Go to TAG 070. Yes: Continue. 7 Run test prints. Does the print seem to be excessively dark or do the characters feel raised on the paper? No: Continue. Yes: Go to TAG 808. 8 Confirm that the paper in the cassettes meets paper specifications. Is the paper within specification? No: Do not use this paper. Turn to TAG 002. Yes: Continue. 9 Turn the printer off and unplug the power cord. • Remove the fuser. • Disconnect J/P41. • Check P41-22 to P5-6 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-22 to P83-1, or J83-1 to P5-6, then turn to TAG 002. Yes: Continue. 10 Check P41-21 to P5-7 for continuity. Is there continuity? No: Repair or replace the connectors or wiring from P41-21 to P83-2, or J83-2 to P5-7, then turn to TAG 002. Yes: Continue. 11 Reinstall the fuser. • Check P41-21 to P41-22 for resistance. Is the resistance between IKΩ and 400 KΩ? No: Replace the fuser. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the VPCL board, then turn to TAG 002. Yes: Replace the VPCL board, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-167, TAG 813: Residual Images on Prints

TAG 813: Residual Images on Prints

Possible Defects (not listed in any particular order): Cleaner drive belt Cleaner High voltage power supply Photoconductor Erase lamp assembly Developer 1 Turn the printer off and unplug the power cord. • Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce- dure. • Turn the printer on. • Run test prints. Has the problem been resolved? No: Continue. Yes: Contamination was at fault. Turn to TAG 002. 2 Open the printer’s back cover. • Remove the paper feed drive cover. • Check the cleaner drive belt. Is the belt attached? No: Repair or replace the cleaner drive belt, then turn to TAG 002. Yes: Continue. 3 Refer to Section 9, General Printer Maintenance, and check the voltages. Are the voltages correct? No: Replace the high voltage power supply, then turn to TAG 002. Yes: Continue. 4 Have the cleaner, developer with new toner cartridge, and photoconductor been replaced recently? No: Continue. Yes: Go to #8 in this TAG. 5 Replace the cleaner. • Run test prints. Has the problem been resolved? No: Reinstall the original cleaner and continue. Yes: Turn to TAG 002. 3-168 Troubleshooting Analysis Guides June 1999, TAG 813: Residual Images on Prints 6 Replace the developer and toner cartridge. • Run test prints. Has the problem been resolved? No: Reinstall the original developer and continue. Yes: Turn to TAG 002. 7 Replace the photoconductor and charge corona. • Run test prints. Has the problem been resolved? No: Reinstall the original photoconductor and charge corona, then continue. Yes: Turn to TAG 002. If the problem recurs, the toner may be old or contaminated. 8 Turn the printer off and unplug the power cord. • Disconnect J/P40 and J/P24. • Check P40-40 to P24-3 for continuity. Is there continuity? No: Repair or replace the connector or wiring from P40-40 to P24-3, then turn to TAG 002. Yes: Continue. 9 Repair or replace the cleaner terminal assembly. • Run test prints. Has the problem been resolved? No: Reinstall the original cleaner terminal assembly, then go back to #5 in this TAG. Yes: Turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-169, TAG 815: Prints Resulting From Printhead Malfunctions

TAG 815: Prints Resulting From Printhead Malfunctions

Symptoms: Additional lines or missing lines on page. Possible Defects (not listed in any particular order): Printhead assembly Connectors or wiring RIGS board 1 Turn off the printer and unplug the power cord. • Replace wire harness 200. Has the problem been resolved? No: Continue. Yes: Turn to TAG 002. 2 Turn off the printer and unplug the power cord. • Replace the printhead assembly. Has the problem been resolved? No: Continue. Yes: Turn to TAG 002. 3 Turn off the printer and unplug the power cord. • Replace the RIGS board. Has the problem been resolved? No: Replace the RIGS board and continue. Yes: RIGS board was at fault. Turn to TAG 002. 4 Turn off the printer and unplug the power cord. • Replace the VPCL board. Has the problem been resolved? No: This is not a printhead malfunction. Replace the VPCL board and turn to TAG 808. Yes: VPCL board was at fault. Turn to TAG 002. 3-170 Troubleshooting Analysis Guides June 1999, TAG 900: Top Cover Interlock Malfunction, Duplex

TAG 900: Top Cover Interlock Malfunction, Duplex

ERROR MESSAGE:090 Possible Defects (not listed in any particular order): Cover open sensor VPCL board Duplex control board #1 Connectors or wiring

Complete TAG 600 before starting this TAG.

1 Turn the printer off and unplug the power cord. • Verify that J/P306, J/P307, J/P309, and J/P318 are connected properly. • Confirm that the top and front covers are closing completely. • Power-on-reset the printer. Is error message 090 displayed? No: Loose connectors or obstructions were at fault. Turn to TAG 002. Yes: Continue. 2 Open the printer’s top cover and insert the interlock by-pass tool. • Turn on the printer. • Check J/P309-3 on duplex control board #1 for +12 Vdc. Is the voltage +12 Vdc? No: Replace the duplex control board #1, then turn to TAG 002. Yes: Continue. 3 Check J/P309-1 on duplex control board #1 for +12 Vdc. Is the voltage +12 Vdc? No: Continue. Yes: Go to #5 in this TAG. 4 Turn the printer off and unplug the power cord. • Disconnect J/P318 and J/P309. • Check the following for continuity: P309-1 to P318-2, P309-3 to P318-1, and P309-5 to P318-3. Is there continuity? No: Repair or replace the wiring or connectors from: P309-1 to P318-2, P309-3 to P318-1, or P309-5 to P318-3, then turn to TAG 002. Yes: Replace the cover open sensor, then turn to TAG 002. June 1999 Troubleshooting Analysis Guides 3-171, TAG 900: Top Cover Interlock Malfunction, Duplex 5 Turn on the printer. • Check J/P36-1 on the VPCL board for +12 Vdc. Is the voltage +12 Vdc? No: Replace the duplex control board #1, then turn to TAG 002. Yes: Replace the VPCL board, then turn to TAG 002. 3-172 Troubleshooting Analysis Guides June 1999, TAG 901: Misregistration/Skewed Prints (Duplex)

TAG 901: Misregistration/Skewed Prints (Duplex)

Possible Causes: Wrong weight or type of paper loaded Possible Defects (not listed in any particular order): Duplex holding tray sensors Duplex holding tray motor Duplex drive/clutch Pinch rollers A and B Route separator Duplex control board #2 Connectors or wiring VPCL board

Registration is correct when the top (+ or - 2) of the 20-line indicator, found on the top of a test

print, is at the leading edge of the print.

If the problem varies from print to print, suspect a mechanical binding problem. If problems

exist in the simplex mode, go to TAG 807. 1 Verify that the upper and lower paper cassettes are not damaged. • Confirm that the paper in the cassettes meets paper specifications. • Make sure the paper in both paper cassettes is loaded properly. • Make sure the side and rear paper guides in the paper cassettes are positioned properly. • Check both paper paths for obstructions or contamination. • Run test prints. Has the problem been resolved? No: Continue. Yes: Turn to TAG 002. 2 Turn the printer off and unplug the power cord. • Inspect the following for damage or contamination: Duplex drive/clutch assembly Timing belts Upper paper guide assembly Pinch roller springs Route separator and springs Are these parts clean and in good working order? No: Repair or replace any damaged parts as needed, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-173, TAG 901: Misregistration/Skewed Prints (Duplex) 3 Verify that J/P305, J/P310, J/P311, J/P312, J/P320, J/P321, and J/P322 are connected properly to duplex control board #2. • Verify that J/P306, J/P307, J/P308, J/P309, and J/P324 are connected properly to duplex control board #1. • Verify that J/P315 and J/P316 are connected properly to the “A” and “C” roller clutches. • Run test prints in duplex. Did the test indicate an error message? No: Registration or skew problems can only result from mechanical causes. Return to the begin- ning of this TAG. Yes: Continue. 4 Did the side guides in the duplex tray move in and out while the test was running? No: Go to #8 in this TAG. Yes: Continue. 5 Check J/P312-1 on duplex control board #2 for +12 Vdc. Is the voltage +12 Vdc? No: Replace duplex control board #2, then turn to TAG 002. Yes: Continue. 6 Manually move the side guides in the duplex tray to the inside positions. • Check J/P312-2 on duplex control board #2 for 0 Vdc. Is the voltage 0 Vdc? No: Continue. Yes: Replace duplex control board #2, then turn to TAG 002. 7 Turn the printer off and unplug the power cord. • Disconnect J/P320 and J/P312. • Check the following for continuity: P312-1 to P320-1, P312-2 to P320-2, and P312-3 to P320-3. Is there continuity? No: Repair or replace the wiring or connectors from: P312-1 to P320-1, P312-2 to P320-2, or P312-3 to P320-3, then turn to TAG 002. Yes: Replace the side sensor. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace duplex control board #2, then turn to TAG 002. 8 Run diagnostic test “Duplex Sensor Tests” on page 5-12. Did the Duplex Sensor Test indicate a duplex tray paper sensor problem? No: Continue. Yes: Go to #13 in this TAG. 3-174 Troubleshooting Analysis Guides June 1999, TAG 901: Misregistration/Skewed Prints (Duplex) 9 Turn the printer off. • Disconnect J/P312 and J/P321. • Check P312-7 to J321-1 for continuity. Is there continuity? No: Repair or replace the wiring or connectors from P312-7 to J321-1, then turn to TAG 002. Yes: Continue. 10 Check P312-8 to J321-2 for continuity. Is there continuity? No: Repair or replace the wiring or connectors from P312-8 to J321-2, then turn to TAG 002. Yes: Continue. 11 Check P312-9 to J321-3 for continuity. Is there continuity? No: Repair or replace the wiring or connectors from P312-9 to J321-3, then turn to TAG 002. Yes: Continue. 12 Check P312-10 to J321-4 for continuity. Is there continuity? No: Repair or replace the wiring or connectors from P312-10 to J321-4, then turn to TAG 002. Yes: Replace duplex control board #2. If this resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the registration motor, then turn to TAG 002. 13 Check J/P312-4 for +12 Vdc. Is the voltage +12 Vdc? No: Replace duplex control board #2, then turn to TAG 002. Yes: Continue. 14 Manually activate the duplex tray paper sensor. • Check J/P312-5 for 0 Vdc. Is the voltage 0 Vdc? No: Replace the duplex tray paper sensor. If this resolves the problem, turn to TAG 002. If this doesn’t resolve the problem, repair or replace the wiring or connectors from: P312-4 to J322-1, P312-5 to J322-2, or P312-6 to J322-3, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-175, TAG 901: Misregistration/Skewed Prints (Duplex) 15 Manually activate the duplex tray paper sensor. • Check J/P36-6 on the VPCL board for 0 Vdc. Is the voltage 0 Vdc? No: Replace duplex control board #2. If this resolves the problem, turn to TAG 002. If this doesn’t resolve the problem, repair or replace the wiring or connectors from P311-7 to J/P305-11 to P36-4, then turn to TAG 002. Yes: Replace the VPCL board, then turn to TAG 002. 3-176 Troubleshooting Analysis Guides June 1999, TAG 902: Paper Jam in Duplex Area

TAG 902: Paper Jam in Duplex Area

ERROR MESSAGE:PAPER JAM 027 IN DUPLEX AREA PAPER JAM 060 DUPLEX ROLLER PAPER JAM 061 DUPLEX PATH PAPER JAM 062 DUPLEX TRAY Possible Causes: Paper incorrectly loaded Paper path not clear Possible Defects (not listed in any particular order): Duplex drive/clutch “A” roller clutch Duplex input solenoid “C” roller clutch Duplex feed motor Duplex control board #1 Connectors or wiring 1 Turn the printer off and unplug the power cord. • Verify that J/P306, J/P307, J/P308, J/P309, J/P313, J/P314, J/P315, J/P316, J/P317, and J/P319 are connected properly. • Check the following components for damage: Duplex drive/clutch Timing belts Route separator • Power-on-reset the printer. Has the problem been resolved? No: Continue. Yes: Loose connectors were at fault. Turn to TAG 002. 2 Turn on the printer. • Run diagnostic test “Duplex Sensor Tests” on page 5-12. Is the duplex paper path sensor in good working order? No: Continue. Yes: Go to #7 in this TAG. 3 Turn the printer off. • Disconnect J/P309. • Turn on the printer. • Check J309-4 on duplex control board #1 for +12 Vdc. Is the voltage +12 Vdc? No: Replace duplex control board #1, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-177, TAG 902: Paper Jam in Duplex Area 4 Check J/P309-2 on duplex control board #1 for +12 Vdc. Is the voltage +12 Vdc? No: Replace duplex control board #1, then turn to TAG 002. Yes: Continue. 5 Turn the printer off. • Reconnect J/P309. • Disconnect J/P319. • Turn the printer on. • Check J319-1 for +12 Vdc. Is the voltage +12 Vdc? No: Repair or replace the wiring or connectors from P309-4 to J319-1, then turn to TAG 002. Yes: Continue. 6 Check J319-2 for +12 Vdc. Is the voltage +12 Vdc? No: Repair or replace the wiring or connectors from P309-2 to J319-2, then turn to TAG 002. Yes: Replace the paper pass sensor, then turn to TAG 002. 7 Turn the printer on. • Run diagnostic test “Duplex Sensor Tests” on page 5-12. Is the “A” roller clutch in good working order? No: Continue. Yes: Go to #10 in this TAG. 8 Turn the printer off. • Disconnect J/P308. • Turn the printer on. • Check J308-3 on the duplex control board #1 for +24 Vdc. Is the voltage +24 Vdc? No: Replace duplex control board #1, then turn to TAG 002. Yes: Continue. 9 Turn the printer off. • Reconnect J/P308. • Disconnect J/P316. • Turn the printer on. • Check P316-1 for +24 Vdc. Is the voltage +24 Vdc? No: Repair or replace the wiring or connectors from P308-3 to J316-1, then turn to TAG 002. Yes: Replace the “A” roller clutch, then turn to TAG 002. 3-178 Troubleshooting Analysis Guides June 1999, TAG 902: Paper Jam in Duplex Area 10 Turn the printer on. • Run diagnostic test “Duplex Clutch Tests” on page 5-13. Is the input solenoid in good working order? No: Continue. Yes: Go to #13 in this TAG. 11 Turn off the printer. • Disconnect J/P308. • Turn on the printer. • Check J308-1 and J308-5 for +24 Vdc. Is the voltage +24 Vdc? No: Replace duplex control board #1, then turn to TAG 002. Yes: Continue. 12 Disconnect J/P314. • Check for continuity: P308-1 to J314-1, and P308-5 to J314-2. Is there continuity? No: Repair or replace the wiring or connectors from: P308-1 to J314-1, or P308-5 to J314-2, then turn to TAG 002. Yes: Replace the input solenoid, then turn to TAG 002. 13 Turn the printer on. • Run diagnostic test “Duplex Clutch Tests” on page 5-13. Is the C roller solenoid in good working order? No: Continue. Yes: Go to #16 in this TAG. 14 Turn off the printer. • Disconnect J/P308. • Turn on the printer. • Check J308-2 and J308-6 for +24 Vdc. Is the voltage +24 Vdc? No: Replace duplex control board #1, then turn to TAG 002. Yes: Continue. June 1999 Troubleshooting Analysis Guides 3-179, TAG 902: Paper Jam in Duplex Area 15 Disconnect J/P315. • Check the following for continuity: P308-2 to P315-1, and P308-6 to P315-2. Is there continuity? No: Repair or replace the wiring or connectors from: P308-2 to P315-1, or P308-6 to P315-2, then turn to TAG 002. Yes: Replace the “C” roller solenoid, then turn to TAG 002. 16 Turn the printer on. • Run diagnostic test “Duplex Motor Tests” on page 5-11. Is the feed motor in good working order? No: Continue. Yes: Go to #21 in this TAG. 17 Turn the printer off. • Disconnect J/P309. • Check P309-7 to P309-8 for continuity. Is there continuity? No: Go to #19 in this TAG. Yes: Continue. 18 Check P309-9 to P309-10 for continuity. Is there continuity? No: Continue. Yes: Replace duplex control board #1, then turn to TAG 002. 19 Disconnect J/P313. • Check the following for continuity: P309-7 to J313-1, P309-8 to J313-2, P309-9 to J313-3, and P309-10 to J313-4. Is there continuity? No: Repair or replace the wiring or connectors from P309 to J313 that have no continuity, then turn to TAG 002. Yes: Continue. 3-180 Troubleshooting Analysis Guides June 1999, TAG 902: Paper Jam in Duplex Area 20 Check the following for continuity: P313-1 to P313-2, and P313-3 to P313-4. Is there continuity? No: Replace the route motor, then turn to TAG 002. Yes: Replace the duplex control board #1, then turn to TAG 002. 21 Turn the printer on. • Check J/P306-3 to J/P306-4 for +5 Vdc. Is the voltage +5 Vdc? No: Repair or replace the wiring or connectors from P306-3 to J/P331-3 to P330-3, then turn to TAG 002. Yes: Continue. 22 Check J/P306-2 to J/P306-4 for +12 Vdc. Is the voltage +12 Vdc? No: Repair or replace the wiring or connectors from P306-2 to J/P331-2 to P330-2, then turn to TAG 002. Yes: Continue. 23 Check J/P306-1 to J/P306-4 for +24 Vdc. Is the voltage +24 Vdc? No: Repair or replace the wiring or connectors from P306-1 to J/P331-1 to P330-1, then turn to TAG 002. Yes: Return to the beginning of this TAG.

Section 2 Troubleshooting Analysis Guides (TAGs)

June 1999 Troubleshooting Analysis Guides 3-181, TAG 902: Paper Jam in Duplex Area 3-182 Troubleshooting Analysis Guides June 1999, Section 4

Print Quality Samples

Section 3 Print Quality Samples June 1999 Print Quality Samples 4-1,

Contents Print Quality Samples

Sample 1: Good Quality Print ..4-4 Sample 2: Washout..4-5 Sample 3: Blank Print..4-6 Sample 4: Light Print ..4-7 Sample 5: Light Print With Background ..4-8 Sample 6: Voids or White Spots ..4-9 Sample 7: Light Vertical Streaks ..4-10 Sample 8: Blank Vertical Bands..4-11 Sample 9: Light Horizontal Bands ..4-12 Sample 10: Black or Dark Print ..4-13 Sample 11: Dark Specks, Lines, or Areas ..4-14 Sample 12: Dark Vertical Lines ..4-15 Sample 13: Skewed Prints ..4-16 Sample 14: Misregistration..4-17 Sample 15: Overtoned Print ..4-18 Sample 16: Blurred Images or Characters ..4-19 Sample 17: Varying Print Density ..4-20 Sample 18: Background ..4-21 Sample 19: Residual Images ..4-22 Sample 20: Wrinkles ..4-23 Sample 21: Fusing Problems ..4-24 4-2 Print Quality Samples June 1999,

Section 4 Print Quality Samples

This section contains flawed test prints, along with a good test print for comparison. Com- pare print samples from your customer’s print job or from test prints you’ve run with the samples in this section. If you find a match, note the TAG (i.e., troubleshooting procedure) listed under the sample. Turn to that TAG to begin troubleshooting. All of the TAGs are contained in Section 3, Troubleshooting Analysis Guides. If your customer’s prints show more than one problem, resolve them one at a time, in the order in which they are listed in this section. June 1999 Print Quality Samples 4-3, Sample 1: Good Quality Print

Sample 1: Good Quality Print

Description: Good, properly registered print. 4-4 Print Quality Samples June 1999, Sample 2: Washout

Sample 2: Washout

Void Areas Blurs Description: Void areas, light spots, or blurs. This is a composite of the possible symptoms. Go to TAG 801, 802, 809, or 810. June 1999 Print Quality Samples 4-5, Sample 3: Blank Print

Sample 3: Blank Print

Void of Any Image Description: No images or characters. The paper is not discolored. Go to TAG 800, 815. 4-6 Print Quality Samples June 1999, Sample 4: Light Print

Sample 4: Light Print

Light Areas Light Areas Description: Images or characters are lighter than normal. Examine the letters H, T, M, and E; if the vertical strokes are dark enough but the diagonal strokes are stair-stepped, the problem is related to the printhead. Carrier particles may make the print feel gritty. Go to TAG 801. June 1999 Print Quality Samples 4-7, Sample 5: Light Print With Background

Sample 5: Light Print With Background

Light Areas Background Description: Images or characters lighter than normal, ranging from a few dark specks to a large speckled background. Go to TAG 811. 4-8 Print Quality Samples June 1999, Sample 6: Voids or White Spots

Sample 6: Voids or White Spots

White Areas Description: Voids or white spots in image areas. Go to TAG 802. June 1999 Print Quality Samples 4-9, Sample 7: Light Vertical Streaks

Sample 7: Light Vertical Streaks

Light Vertical Streaks Description: One or more light vertical streaked areas of varying widths. Go to TAG 803. 4-10 Print Quality Samples June 1999, Sample 8: Blank Vertical Bands

Sample 8: Blank Vertical Bands

Blank Vertical Bands Description: One or more vertical blank bands of varying widths extend over the entire length. Go to TAG 803. June 1999 Print Quality Samples 4-11, Sample 9: Light Horizontal Bands

Sample 9: Light Horizontal Bands

Light Horizontal Bands Description: One or more light horizontal bands of varying width. Go to TAG 804. 4-12 Print Quality Samples June 1999, Sample 10: Black or Dark Print

Sample 10: Black or Dark Print

Excessively Dark or Black Print Description: Black or very dark with no visible images. Go to TAG 805, 811. June 1999 Print Quality Samples 4-13, Sample 11: Dark Specks, Lines, or Areas

Sample 11: Dark Specks, Lines, or Areas

Dark Specs, Lines, or Areas Description: Dark specks or lines (like scratches), some in the same place on each print. Go to TAG 806, 810. 4-14 Print Quality Samples June 1999, Sample 12: Dark Vertical Lines

Sample 12: Dark Vertical Lines

Dark Vertical Lines Description: One or more dark lines of varying density. If the image can be rubbed off, go to TAG 812. If the image cannot be rubbed off, go to TAG 808. Go to TAG 812, 808. June 1999 Print Quality Samples 4-15, Sample 13: Skewed Prints

Sample 13: Skewed Prints

Image is Crooked on Page Description: The entire image is not located squarely on the paper. Go to TAG 807 for simplex. Go to TAG 901 for duplex. 4-16 Print Quality Samples June 1999, Sample 14: Misregistration

Sample 14: Misregistration

Image not Located Properly from Leading Edge of Paper Description: The entire image is not correctly located from the leading edge of the paper. The top or bottom image area may be missing. Go to TAG 807 for simplex. Go to TAG 901 for duplex. June 1999 Print Quality Samples 4-17, Sample 15: Overtoned Print

Sample 15: Overtoned Print

Gaps Between Images or Characters Filled with Toner Background Description: Similar to dark print quality problems. Narrow gaps between letters and images may be filled with toner. Excess toner may be present on the surface of the print. Extra toner can also cause background in the white areas. Go to TAG 808. 4-18 Print Quality Samples June 1999, Sample 16: Blurred Images or Characters

Sample 16: Blurred Images or Characters

Smeared Images or Characters Description: The images or characters are not clear. The lower edges of images and/or characters are extended and may appear smeared. Go to TAG 809. June 1999 Print Quality Samples 4-19, Sample 17: Varying Print Density ty

Sample 17: Varying Print Density

Dark Density Normal Densi Light Density Description: Some areas of the print are lighter or darker than normal. Examine the letters H, T, M, and E on your test print. If the vertical sections are sufficiently dark, but the diagonal sections appear stair-stepped, the problem may be is related to the printhead. Go to TAG 810, 815. 4-20 Print Quality Samples June 1999, Sample 18: Background

Sample 18: Background

Unprinted Areas have Gray Background Description: White areas on the prints have varying degrees of specks appearing in a specific pattern. Go to TAG 811. June 1999 Print Quality Samples 4-21, Sample 19: Residual Images

Sample 19: Residual Images

Residual Images from Previous Print Description: Images from a previous print are visible. White areas on the print may have varying degrees of specks appearing in a specific pattern. Go to TAG 811, 813. 4-22 Print Quality Samples June 1999, Sample 20: Wrinkles

Sample 20: Wrinkles

Wrinkled Paper Description: Wrinkles or creases, often at the top or bottom. Go to TAG 706. June 1999 Print Quality Samples 4-23, Sample 21: Fusing Problems

Sample 21: Fusing Problems

Description: Images or characters may rub off the surface. Go to TAG 812. 4-24 Print Quality Samples June 1999,

Section 5 Diagnostic Tests

Section 4 Diagnostic Tests June 1999 Diagnostic Tests 5-1,

Contents Diagnostic Tests

How to Run Diagnostics ..5-3 Operator Panel Test ..5-4 Upper Cassette Test ..5-4 Lower Cassette Test ..5-5 Fuser Thermistor Test ..5-5 Sensor Tests ..5-6 Roller Clutch Tests ..5-7 Counter Test ..5-7 Jogging Motor Test ..5-8 Photoconductor Seam Sensor Test ..5-8 Toner Supply Motor Test ..5-8 Charge Corona Test ..5-9 Transfer Corona Test ..5-9 Erase Lamp Test ..5-10 Toner Empty Test ..5-10 Negative Developer Bias Test ..5-11 Duplex Motor Tests ..5-11 Duplex Sensor Tests ..5-12 Duplex Clutch Tests ..5-13 Duplex Tray Paper-Guide Motor Test ..5-13 High-Capacity Output (HCO) Sensor Tests ..5-14 High-Capacity Input (HCI) Test ..5-14 LED Printhead Test ..5-15 RIGS Board Test ..5-16 Com. Wrap Test ..5-16 Display File Version Test ..5-17 Format Disk ..5-17 Clear Error Log ..5-18 Disk Drive Test ..5-18 5-2 Diagnostic Tests June 1999, How to Run Diagnostics

Section 5 Diagnostic Tests

This section provides step-by-step instructions for running each of the diagnostic tests available. Check the contents page to find the page on which a specific test is described. Note that some tests assume the condition set up in a previous test – for example, the “Toner Empty Test” assumes that the developer was removed in the previous “Erase Lamp” test. For this reason, perform the necessary tests in the sequence indicated.

How to Run Diagnostics

Follow these steps to access the self-diagnostic mode of the printer: 1 Turn off the printer and wait five seconds. 2 Hold down MENU and STATUS while turning the printer on until all three LEDs are lit. The printer takes about 1 minute to enter diagnostic mode. When the display reads “Diagnostic Tests” – this is called the base panel – you are ready to runs tests. 3 Press e to display the first test. Once a test name is displayed, use these keys: h to move to the next test g to go back to preceding test to return to the base panel If you press these keys before a test is complete, a long tone sounds and the test con- tinues without interruption. 4 Press e to run the test. 5 Press f to end the test (in most cases; see specific diagnostic procedures for directions on exiting a test). 6 To exit diagnostic mode, cycle printer power. Most errors or conditions reported are valid until you press a key. Note: Only diagnostics useful for field maintenance are documented in this manual. June 1999 Diagnostic Tests 5-3, Operator Panel Test

Operator Panel Test

1 Turn the volume control on the operator panel up fully. 2 At the base panel, press e to enter the “Operator Panel Test.” 3 Press h to run the test. 4 The panel displays alphanumeric characters. Press h to scroll the characters. 5 Press f to exit.

Upper Cassette Test

1 Make sure the upper paper cassette is installed with paper, the side and rear guides securely against the edges of the paper in the cassette. 2 At the base panel, press e to enter the tests. 3 Press h until “Upper Cassette Test” is displayed. 4 Press e to run the test. 5 The chart below gives the displays that show the paper size in the cassette. This indi- cates the paper size sensor is working properly. The following displays indicate paper sizes: Display No Cassette Size A4 Size B5 Letter Size Legal Size Executive 6 Press f to exit. 5-4 Diagnostic Tests June 1999, Lower Cassette Test

Lower Cassette Test

1 Make sure the lower paper cassette is installed with paper, the side and rear guides securely against the edges of the paper in the cassette. 2 At the base panel, press e to enter the tests. 3 Press h until “Lower Cassette Test” is displayed. 4 Press e to run the test. 5 The chart below gives the displays that show the paper size in the cassette. This indi- cates the paper size sensor is working properly. The following displays indicate paper sizes: Display No Cassette Size A4 Size B5 Letter Size Legal Size Executive Note: If you have installed the HCI, it should also cause the C40D to display the correct paper setting during testing. 6 Press f to exit.

Fuser Thermistor Test

1 At the base panel, press e to enter the tests. 2 Press h until “Fuser Thermistor Test” is displayed. 3 Press e to run the test. 4 You will see a response listing the A/D value, such as “A/D Value is nn” 5 Press f to exit. June 1999 Diagnostic Tests 5-5, Sensor Tests

Sensor Tests

Note: Remove the HCO from the printer before running this test. 1 At the base panel, press e to enter the tests. 2 Press h until “Sensor Tests” is displayed. 3 Press e to run the test. The name of the first sensor appears on the display, confirming that the sensor is working properly. Note: No paper moves through the machine, so indications of “Paper Not Hitting” are normal. 4 Press e to advance to the next sensor. The display changes, showing the next sensor as outlined in the chart below. 1st Display Line 2nd Display Line Upper Cassette Not Empty Empty Lower Cassette Not Empty Empty Paper Timing Paper Not Hitting Paper Hitting Paper Exit Paper Not Hitting Paper Hitting Output Tray Full Not Full Full PC Seam PSS is Not Active PSS is Active Developer Unit Developer Connected No Developer 5 To check a specific sensor, press e repeatedly until the name of the sensor you want to check is displayed. Manually activate the sensor. Confirm that the display changes when you activate the sensor. See “Sensors and Switches Illustrations” on page 1-8 for the locations of the sensors. 6 Press f to exit. 5-6 Diagnostic Tests June 1999, Roller Clutch Tests

Roller Clutch Tests

1 At the base panel, press e to enter the tests. 2 Press h until “Roller Clutch Tests” is displayed. 3 Press e to run the test. The first clutch engages and disengages, signaled by a contin- uous clicking sound. “Upper Paper Pick-up” appears on the display, corresponding to the upper pick-up roller clutch. The display also shows “On” and “Off” alternately as the clutch operates. 4 Press h to test the next clutch. The display changes to indicate the next clutch. Listen Output Tray Front Output Tray Back Output Tray Front Output Tray Back for the clicking sound as the next clutch engages. The displays for each of the clutches are listed in the following chart. Display Upper Paper Pick-up Lower Paper Pick-up Upper Paper Feed Lower Paper Feed Paper Timing Roller 5 Repeat Step 4 until you have tested all of the clutches. 6 Press f to exit.

Counter Test

1 Open the front cover. 2 At the base panel, press e to enter the tests. 3 Press h until “Counter Test” is displayed. 4 Press e to run the test. 5 Press g to increment the counter. 6 Confirm that the page counter advances by 1 each time you press g. 7 Press f to exit. June 1999 Diagnostic Tests 5-7, Jogging Motor Test

Jogging Motor Test

Note: This test exercises the HCO. If you have no HCO attached to the C40D, you will not notice any test activity. 1 At the base panel, press e to enter the tests. 2 Press h until “Jogging Motor Test” is displayed. 3 Press e to run the test. 4 The HCO exit rollers jog left and right. 5 Press f to exit.

Photoconductor Seam Sensor Test

1 At the base panel, press e to enter the tests. 2 Press h until “PC Seam Sensor Test” is displayed. 3 Press e to run the test. The main motor rotates the photoconductor belt. Be aware that the following error conditions may occur: • Developer bias short detected • Photoconductor seam sensor not received or detected • Seam sensor (sender) short • Seam sensor (sender) open or the photoconductor is not installed • Erase lamp malfunction 4 Press f to exit.

Toner Supply Motor Test

1 Open the front and top covers. 2 Remove the photoconductor and the developer. Place the photoconductor in its protec- tive packaging. 3 Insert the interlock by-pass tool in the front cover. Close the top cover. 4 At the base panel, press e to enter the tests. 5 Press h until “Toner Motor Test” is displayed. 6 Press e to run the test. The toner supply motor runs continuously. 7 Observe the toner supply motor through the open developer cavity. Confirm that the motor is turning counterclockwise, accompanied by “On” on the display. 5-8 Diagnostic Tests June 1999, Charge Corona Test 8 Press f and e alternately several times to verify the toner supply motor starts and stops. (This stops and restarts the test.) Be aware that the following error conditions may occur: • You forgot to remove the developer • You forgot to insert the interlock by-pass tool 9 Press f to exit. 10 Reinstall the developer and photoconductor. 11 Remove the interlock by-pass tool and close the front cover.

Charge Corona Test

1 Remove the photoconductor and place it in its protective packaging. Close the top cover. 2 At the base panel, press e to enter the tests. 3 Press h until “Main Charger Test” is displayed. 4 Press e to run the test. The charge corona turns on and off repeatedly. 5 Confirm that the display alternates between “Off” and “On,” accompanied each time by a brief tone. Be aware that the following error conditions may occur: • Photoconductor seam sensor short • Charge corona short • Charge corona open • You forgot to remove the photoconductor 6 Press f to exit. 7 Reinstall the photoconductor.

Transfer Corona Test

1 Remove the photoconductor and place it in its protective packaging. Close the top cover. 2 At the base panel, press e to enter the tests. 3 Press h until “Transfer Corona Test” is displayed. 4 Press e to run the test. The transfer corona turns on and off repeatedly. 5 Confirm that the display alternates between “Off” and “On,” accompanied each time by a brief tone. June 1999 Diagnostic Tests 5-9, Erase Lamp Test Be aware that the following error conditions may occur: • Seam sensor (sender) short • Transfer corona short • Transfer corona open or not installed • You forgot to remove the photoconductor 6 Press f to exit. 7 Reinstall the photoconductor.

Erase Lamp Test

1 Open the top cover and insert the interlock by-pass tool. 2 Remove the photoconductor and place it in its protective cover. 3 At the base panel, press e to enter the tests. 4 Press h until “Erase Lamp Test” is displayed. 5 Press e to run the test. The erase lamp turns on with all LEDs lighted. 6 Verify that all LEDs are illuminated. Be aware that the following error conditions may occur: • Seam sensor (sender) short • Erase lamp malfunction • You forgot to remove the photoconductor 7 Press f to exit. 8 Reinstall the photoconductor. 9 Remove the interlock by-pass tool and close the top cover.

Toner Empty Test

1 At the base panel, press e to enter the tests. 2 Press h until “Toner Empty Test” is displayed. 3 Press e to run the test. Verify that the Toner Empty message appears on the display. 4 If the developer is not in the C40D, you will get a “No Developer” message. 5 Press f to exit. 5-10 Diagnostic Tests June 1999, Negative Developer Bias Test

Negative Developer Bias Test

1 Open the top cover and insert the interlock by-pass tool. 2 Remove the photoconductor and place it in its protective packaging. 3 At the base panel, press e to enter the tests. 4 Press h until “Neg Devel Bias Test” is displayed. 5 Press e to run the test. The negative developer bias turns on and off repeatedly. 6 Confirm that the display alternates between “Off” and “On,” accompanied each time by a brief tone. Be aware that the following error conditions may occur: • Developer bias short • Seam sensor (sender) short • You forgot to insert the interlock by-pass tool • You forgot to remove the photoconductor 7 Press f to exit. 8 Reinstall the photoconductor. 9 Remove the interlock by-pass tool and close the top cover.

Duplex Motor Tests

1 At the base panel, press e to enter the tests. 2 Press h until “Duplex Motor Tests” is displayed. 3 Press e to run the test. The duplex feed motor operates at full forward speed as indi- cated on the display. 4 Press h to advance to the next motor speed. 5 Listen for the following motor frequencies and check the display as you move through the test sequence: Display Forward Full Speed Forward Slow Speed Reverse Full Speed Reverse Slow Speed Note: To view the timing roller while running the test, open the printer top cover and bypass the cover interlock. June 1999 Diagnostic Tests 5-11, Duplex Sensor Tests Be aware that the following error conditions may occur: • Duplex is not installed • Cover is open/Close cover 6 Press f to exit. 7 Remove the cover interlock bypass.

Duplex Sensor Tests

1 At the base panel, press e to enter the tests. 2 Press h until “Duplex Sensor Tests” is displayed. 3 Press e to run the test. The name of the first sensor appears on the display, confirming that the sensor is working properly. Note: No paper moves through the machine, so indications of “Paper Not Hitting” are normal. 4 Press h to advance to the next sensor. The display changes, showing the name of the next sensor as outlined in the chart below. 1st Display Line 2nd Display Line B-C Paper Sensor Paper Not Hitting Paper Hitting Duplexer Cover Cover is Closed Cover is Open Duplex Tray Sensor Paper Not Hitting Paper Hitting 5 To check a specific sensor, press h repeatedly until the sensor you want to check is displayed, then manually activate the sensor. Confirm that the display changes when you activate the sensor. See “Sensors and Switches Illustrations” on page 1-8 for the locations of the sensors. Be aware that the following error conditions may occur: • Duplex tray is not installed • Cover is open/Close cover 6 Press f to exit. 5-12 Diagnostic Tests June 1999, Duplex Clutch Tests

Duplex Clutch Tests

1 At the base panel, press e to enter the tests. 2 Press h until “Duplex Clutch Tests” is displayed. 3 Press e to run the test. The first flipper engages, accompanied by a continuous click- ing sound, “Exit Flipper” appears on the display, and the display shows “On” or “Off”, according to the flipper’s state. 4 Press h to activate the next clutch or flipper. Listen for the clicking sound as it engages. The display changes to indicate the next clutch or flipper. Display Exit Flipper A-roller Clutch Re-entry Flipper C-roller 5 To check a specific clutch or flipper, press h repeatedly until the code on the display corresponds to the item you want to check. Manually activate the sensor. Confirm that the display changes when you activate the sensor. See “Sensors and Switches Illustra- tions” on page 1-8 for the locations of the sensors. Be aware that the following error conditions may occur: • Duplex tray is not installed • Cover is open/Close cover 6 Press f to exit.

Duplex Tray Paper-Guide Motor Test

1 At the base panel, press e to enter the tests. 2 Press h until “Duplex Paper Guide” is displayed. 3 Press e to run the test. The paper guide in the duplex tray moves to and from its home position. 4 Confirm that the paper guide in the duplex tray moves back and forth constantly. Be aware that the following error conditions may occur: • Duplex tray not installed • Duplex tray registration sensor not activated • Duplex tray registration sensor activated • Cover is open/Close cover 5 Press f to exit. June 1999 Diagnostic Tests 5-13, High-Capacity Output (HCO) Sensor Tests

High-Capacity Output (HCO) Sensor Tests

1 At the base panel, press e to enter the tests. 2 Press h until “Hi Cap Output Sensor” is displayed. 3 Press e to run the test. The code for the sensor appears on the display, confirming that the sensor is working properly. Note: No paper moves through the machine, so indications of “Paper Not Hitting” are normal. 4 Press h to advance to the next sensor. The sensor appears on the display; codes and their meaning are outlined in the chart below. 1st Display Line 2nd Display Line HCO Unit Sensor Not Installed Output Installed Paper Exit Sensor Paper Not Hitting paper Hitting Paper Full Sensor Output Tray Not Full Output Tray Full Tray Wait Sensor Tray Ready Tray Rising 5 To check a specific sensor, press h repeatedly until the sensor you want to check is displayed. Manually activate the sensor. Confirm that the display changes when you activate the sensor. See “Sensors and Switches Illustrations” on page 1-8 for the loca- tions of the sensors. 6 Press f to exit.

High-Capacity Input (HCI) Test

1 At the base panel, press e to enter the tests. 2 Press h until “Hi Cap Input Size” is displayed. 3 Press e to run the test. The display registers the paper size installed in the unit, as out- lined on the chart (“No Cassette” will appear on the display if a high-capacity input is not installed.) 5-14 Diagnostic Tests June 1999, LED Printhead Test 4 Verify the correct paper size, as displayed. Display No Cassette Size A4 Letter Size Legal Size 5 Press f to exit.

LED Printhead Test

1 Open the top cover and insert the interlock by-pass tool. 2 Remove the photoconductor and place it in its protective packaging. 3 Remove the developer. 4 To help identify the LEDs, place a white sheet of paper in the photoconductor cavity over the printhead’s fiber optics. 5 At the base panel, press e to enter the tests. 6 Press h until “LED Printhead Test” is displayed. 7 Press e to run the test. 8 The LED printhead turns on. 9 Verify that the LEDs cycle on and off. These codes indicate specific error conditions: Display Indication 4-1 You forgot to remove the photoconductor unit. 040 Seam sensor (sender) short 10 Press f to exit. June 1999 Diagnostic Tests 5-15, RIGS Board Test

RIGS Board Test

1 At the base panel, press e to enter the tests. 2 Press h until “RIGS Board Test” is displayed. 3 Press e to run the test. 4 If an error is found: • The error message and code appear. • Look up the code in the “Error Code/TAG Cross-Reference” on page 2-4 to deter- mine which TAG to follow. • Press f to exit. 5 If no errors are found, the message “Test Successful” is displayed. 6 Press f to exit.

Com. Wrap Test

Note: You can run this test successfully without the C40D being configured for RS-232 operation. 1 Remove the interface cable from the printer. 2 Install the RS-232C wrap connector, found in the tool kit mounted inside the right printer cover. If you do not have wrap connectors, jumper the connections as outlined in the follow- ing charts: RS-232 Loopback Connection Reference pin 2 <-> pin 3 pin 4 <-> pin 5 pin 8 <-> pin 20 pin 17 <-> pin 24 3 At the base panel, press e to enter the tests. 4 Press h until “Com. Wrap Test” is displayed. 5 Press e to select the test. 6 Press e to run the test. 7 If an error code appears, check the “Error Code/TAG Cross-Reference” on page 2-4 to determine which TAG to follow. 8 If no error is detected, the test exits automatically. 5-16 Diagnostic Tests June 1999, Display File Version Test 9 Press f to exit, if an error is detected. (For some errors, you may have to power-on- reset the printer.) 10 Remove the wrap connectors. 11 Reinstall the interface cable.

Display File Version Test

1 At the base panel, press e to enter the tests. 2 Press h or g until the desired drive shows on the display. 3 Press e to select the drive. 4 Press h or g to find the file to test. 5 Press e to run the test. You will see “Version Number = nnnn”, where nnnn is the function code version number. 6 Press f to exit.

Format Disk

1 At the base panel, press e to enter the tests. 2 Press h until “Format Disk” shows on the display. 3 Press e to select this function. 4 Press h to “Format Hard Drive C” and press e to select this drive. 5 You will see “Status = Erase Disk”. Press the Status key to format drive C. 6 Press f to exit. Note: When using the FORMAT DISK function of the self-diagnostic mode, any existing data on the specified disk is at risk! Note: If you access this function by mistake, do not proceed. Press f immediately to exit the utility. June 1999 Diagnostic Tests 5-17, Clear Error Log

Clear Error Log

1 At the base panel, press e to enter the tests. 2 Press h until “Clear Error Log” shows on the display. 3 Press e to run the test. 4 Press h to advance to the drive where the error log is maintained. This is usually the boot drive. 5 Press e to clear the error log on the selected drive. 6 Press f to exit. 7 Confirm that the error log has been cleared. 8 Exit diagnostic mode (power-on reset) 9 Print the error log. All errors in all sections should be reset to zero.

Disk Drive Test

Note: This is a non-destructive test. You can use it to test drive A, the 3.25” floppy disk drive (if you have inserted a C40D formatted diskette in it), or drive C, the hard drive. 1 At the base panel, press e to enter the tests. 2 Press h until “Disk Drive Test” is displayed. 3 Press e to run the test. 4 Press h to change the drive parameter. 5 Press e to test the selected drive. 6 Press f to exit. 5-18 Diagnostic Tests June 1999, Section 6

Wiring Diagrams

and Electrical Data Section 5 Wiring Diagrams and Electrical Data June 1999 Wiring Diagrams and Electrical Data 6-1,

Contents Wiring Diagrams and Electrical Data

Introduction ..6-3 Printhead Circuit Board Settings ..6-3 Connector (J/P) Index..6-4 Acronyms and Abbreviations ..6-9 Connectors Inside the Front Cover..6-12 Connectors Inside the Left Cover..6-13 Connectors on the Duplex Cover ..6-14 Connectors Inside the Right Cover..6-15 Connectors Inside the Top Cover ..6-16 Connectors on the Back Cover ..6-17 Connectors Inside the Back Cover (J/P2-14) ..6-18 Connectors Inside the Back Cover (Continued) J/P 18-62.6-19 Connectors Inside the Back Cover (Continued) J/P 64-85.6-20 Connectors Inside the Back Cover (Continued) J/P 90-800.6-21 Voltage Isolation Diagrams ..6-22 -12 Vdc Circuits..6-22 +5 Vdc Circuits ..6-22 +12 Vdc Circuits ..6-24 +24 Vdc Circuits ..6-26 Ground System ..6-27 Host Interface Reference ..6-28 RS-232C Host Interface..6-28 Standard DCE to DTE RS-232C Cable ..6-29 Special Considerations for RS-232 Host Interface Users ..6-29 DTE Host to Printer (Option 1) ..6-29 DTE Host to Printer (Option 2) ..6-30 IBM PC/XT to Printer ..6-30 IBM PC/AT to Printer ..6-31 Macintosh Communication Port to Printer ..6-31 Centronics Parallel Host Interface ..6-32 IBM Parallel to Printer..6-33 6-2 Wiring Diagrams and Electrical Data June 1999, Introduction

Section 6 Wiring Diagrams and Electrical Data Introduction

This section provides a reference guide for all information related to the electrical system of the printer, including: • An index, arranged by connector number, to the connector’s location in the printer and on the schematics, which are found in this chapter. Note: Connectors are referred to by J/P (jack/plug) numbers throughout this manual. Use the J/P number when looking up the connector in the index, schematics, and illus- trations. • Complete connection diagram showing plugs, connectors, and wiring. • Connector locations and illustrations. • Voltage isolation diagrams. • Host interface signal definitions. For a complete list of the abbreviations used in this section, please see page 6-9. Printhead Circuit Board Settings Note: The printhead circuit board uses DIP switches to match printhead characteristics to controller characteristics. Do not change these DIP switch settings; they should remain as set at the factory. June 1999 Wiring Diagrams and Electrical Data 6-3, Connector (J/P) Index

Connector (J/P) Index

Schematic Connector Page Location J/P 2 6-18 F4 J/P 3 6-18 F4 J/P 4 6-18 E6 J/P 5 6-16 E5 J/P 6 6-18 E7 J/P 7 6-18 D8 J/P 8 6-18 D7 J/P 9 6-18 C4 J/P 10 6-18 C4 J/P 11 6-18 B4 J/P 12 6-18 B4 J/P 13 6-18 B3 J/P 14 6-18 C3 J/P 15 6-15 D11 J/P 18 6-19 B3 J/P 20 6-19 C3 J/P 21 6-19 B3 J/P 22 6-15, 6-19 C3 J/P 22-1 6-14 C2 J/P 23 6-19 B7 J/P 25 6-19 C4 J/P 26 6-19 B6 J/P 27 6-19 C6 J/P 30 6-19 C6 J/P 31 6-16 B8 J/P 32 6-16 B8 J/P 33 6-16 B8 J/P 34 6-16 B8 J/P 36 6-16 C8 6-4 Schematic Connector Page Location J/P 37 6-16 C8 J/P 40 6-16 C8 J/P 41 6-16 C8 J/P 42 6-12 B9 J/P 43 6-13 D10 J/P 44 6-19 E5 J/P 45 6-13 C10 J/P 46 6-13 D9 J/P 47 6-13 D10 J/P 48 6-13 D9 J/P 49 6-15 E9 J/P 50 6-19 E9 J/P 51 6-15 E9 J/P 57 6-16 E9 J/P 58 6-19 E9 J/P 59 6-13 E9 J/P 60 6-19 E9 J/P 61 6-13 E10 J/P 62 6-19 E10 J/P 63 6-16 C5 J/P 64 6-20 C5 J/P 65 6-20 F8 J/P 66 6-20 F9 J/P 67 6-20 F9 J/P 68 6-20 F9 J/P 69 6-20 F10 J/P 70 6-20 E4 J/P 76 6-16 B8 J/P 77 6-20 D6 J/P 79 6-20 C6 Section 1: Printer and Troubleshooting Overview, Connector (J/P) Index Schematic Connector Page Location J/P 81 6-20 A5 J/P 82 6-12 A4 J/P 83 6-20 E5 J/P 84 6-20 E6 J/P 85 6-20 B6 J/P 90 6-21 C9 J/P 91 6-16 C8 J/P 94 6-21 C8 J/P 96 6-21 C5 J/P 119 6-13 C9 J/P 120 6-13 C9 J/P 121 6-21 B6 J/P 122 6-21 B6 J/P 124 6-21 B6 J/P 127 6-13 C9 J/P 128 6-13 C9 J/P 131 6-16 E6 J/P 132 6-16 E6 J/P 139 6-21 B6 J/P 140 6-21 B6 J/P 143 6-21 B6 J/P 251 6-21 B5 J/P 252 6-21 B5 J/P 255 6-21 A5 J/P 305 6-16 E3 J/P 306 6-14 E2 J/P 307 6-14 E3 J/P 308 6-14 E2 J/P 309 6-14 E2 J/P 310 6-16 F3 Schematic Connector Page Location J/P 311 6-16 F3 J/P 312 6-16 F3 J/P 313 6-14 F2 J/P 314 6-14 E2 J/P 315 6-14 E2 J/P 316 6-14 E2 J/P 317 6-15 D2 J/P 318 6-12 F1 J/P 319 6-14 E2 J/P 320 6-16 G2 J/P 321 6-16 G2 J/P 322 6-16 F2 J/P 323 6-21 D3 J/P 324 6-21 E3 J/P 330 6-21 E8 J/P 331 6-21 D3 J/P 333 6-21 A8, D2 J/P400 6-14 B9 J/P 600 6-16 C8 J/P 800 6-21 E5 6-5, Connector (J/P) Index

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6-6 Wiring Diagrams and Electrical Data June 1999, Connector (J/P) Index This page indexed as the C40D schematic on page 6-7. Page 6-8 will be blank and the next regular page is 6-9. June 1999 Wiring Diagrams and Electrical Data 6-7, Connector (J/P) Index 6-8 Wiring Diagrams and Electrical Data June 1999, Acronyms and Abbreviations

Acronyms and Abbreviations

ACIA... Asynchronous Communication Interface Adapter ALU ... Arithmetic Logic Unit APA... All Points Addressable ARC ... “A” Roller Clutch ARIF ... Array Interface ATC... Auto Toner Control CLEANER ... Cleaner Unit CNT ... Counter COOLING FA2... Cooling Fan COS... Cover Open Sensor CRS... “C” Roller Solenoid CRT... Cathode Ray Tube CRTC ... CRT Controller CRU ... Customer-Replaceable Unit DB-... Developer Bias Negative DB+... Developer Bias Positive DC P.S.1 ... DC Power Supply DEV ... Developer Unit DMAC ... Direct Memory Access Controller DMC ... Dynamic Memory Controller DRAM ... Dynamic Random Access Memory DUPLEX1... Duplex Control #1 DUPLEX2... Duplex Control #2 EL... Eraser LED EPROM... Erasable Programmable Read Only Memory EPP... Electrophotographic Process EPS... Exit Paper Sensor ERASER ... Erase Lamp EXS... Exit Solenoid FA4... Cooling Fan FDC... Floppy Disk Controller FDD ... Floppy Disk Drive FL... Fuser Halogen Lamp Flex IO ... Flex Input/Output card FRU... Field-Replaceable Unit FUSER ...Fuser Unit HCI ...High Capacity Input HCO ...High Capacity Output HEAD...LED Array Print Head HDD ...Hard Disk Drive HVU ...High Voltage Unit IGS ...Image Generation System I.L. SW Front ...Interlocking Switch (Front) I.L. SW Top...Interlocking Switch (Top) INS ...In Solenoid IPL...Initial Program Load (Bootstrap) L PAPS ...Lower Paper Sensor LN03 ...DEC emulation language LPC ...Lower Paper Feed Clutch LPE...Lower Paper Empty Sensor LPP...Lower Pick Up Clutch LPSS...Lower Tray Interlock Switch Main ...Main Motor MAP ...Maintenance Analysis Procedures MCH...Charge Corona Unit MCS ...Charge Corona Sensor MPU ...Micro Processing Unit MUX ...Multiplexer OPC ...Organic Photoconductor OPPNL ...Operator Panel PC...Photoconductor PCL ...1. Hewlett-Packard Printer Con- trol Language (Software) 2. Printer Control Logic Board (Hardware) PCL5 ...HP Printer Control Language (Version 5) PCU ...Photoconductor Unit PFS ...Paper Full Sensor PH 1...A.C. Power Cord PIA ...Peripheral Interface Adapter PIT...Parallel Interface/Timer 6-9,

Acronyms and Abbreviations

(continued) PMP...Page Map Primitives POR...Power On Reset PPS ...Paper Path Sensor (B-C Sensor) PROM ...Programmable Read Only Memory PS ...PostScript PSS ...Photoconductor Seam Sensor PTM...Programmable Timer Module PTS ...Paper Timing Sensor PW CONT2...Power Control #2 PW CONT3...Power Control #3 PWBA ...Printed Wire Board Assembly RAM...Random Access Memory Resist Motor ...Registration Motor RIGS...RISC Image Generation System ROM...Read Only Memory Root Motor ...“C” Roller Motor RPS...Registration Paper Sensor RSS...Registration Side Sensor SCC ...Serial Communication Controller SIG IF or SIF ...Signal Interface Board SRAM ...Static Random Access Memory SRC ...System Reference Code SRMR2...Side Registration Motor Control #2 Suction FA3...Suction Fan SW5...Upper Cassette In Switch SW6...Lower Cassette In Switch TAGs ...Troubleshooting Analysis Guides TC...Toner Concentration TCH...Transfer Corona Unit TCS ...Transfer Corona Sensor TDS ...Toner Density Sensor 6-10 TES...Toner Empty Sensor TFS ...Tray Front Sensor TH...Thermistor TONER...Toner Motor TPS ...1. Timing Paper Sensor (Schematics) 2. Toner Patch Sensor (Printer) TRC ...Timing Roller Clutch TRS...Tray Rear Sensor U PAPS...Upper Paper Sensor UMT 1–3 ...Usage Meter Drive Signal UPC ...Upper Paper Feed Clutch UPE ...Upper Paper Empty Sensor UPP...Upper Pick Up Clutch UPSS ...Upper Tray Interlock VPCL...Video Printer Control Logic Board Section 1: Printer and Troubleshooting Overview,

Connector Locations

The illustrations that follow show the relative location of all accessible connectors in the printer, and illustrate the connector (except for a few instances in which the connector is so simple that an illustration is unnecessary). For the connector’s schematic location, refer to the chart on the preceding pages. June 1999 Wiring Diagrams and Electrical Data 6-11, Connectors Inside the Front Cover

Connectors Inside the Front Cover

J/P 42 J/P 318 J/P 82 6-12 Wiring Diagrams and Electrical Data June 1999, Connectors Inside the Left Cover

Connectors Inside the Left Cover

J/P 43,45, 47 J/P 59, 61 J/P 46, 48 J/P 119, 120, 127, 128 1 June 1999 Wiring Diagrams and Electrical Data 6-13, Connectors on the Duplex Cover

Connectors on the Duplex Cover

J/P 314 J/P 22-1 J/P 306 J/P 315 J/P 307 J/P 316 J/P 308 J/P 309 J/P 319 J/P 313 6-14 Wiring Diagrams and Electrical Data June 1999, Connectors Inside the Right Cover

Connectors Inside the Right Cover

J/P 15 J/P 49, 51 J/P 22 J/P 317 June 1999 Wiring Diagrams and Electrical Data 6-15, Connectors Inside the Top Cover

Connectors Inside the Top Cover

J/P 5 J/P 310 J/P 311 J/P 57 J/P 312 J/P 63 J/P 320 J/P 131-132 1 J/P 321 J/P 305 J/P 322 6-16 Wiring Diagrams and Electrical Data June 1999, Connectors on the Back Cover

J

J/

J J

J/P

Connectors on the Back Cover

/P 31, 33, 34 J/P 76 J/P 600 /P 36 J/P 91 /P 37 J/P 400 40, 41 June 1999 Wiring Diagrams and Electrical Data 6-17, Connectors Inside the Back Cover (J/P2-14)

Connectors Inside the Back Cover (J/P2-14)

J/P 2, 3 J/P 8 J/P 11 J/P 12 J/P 4 J/P 13 J/P 6 J/P 9 J/P 14 J/P 7 J/P 10 6-18 Wiring Diagrams and Electrical Data June 1999, Connectors Inside the Back Cover (Continued) J/P 18-62

Connectors Inside the Back Cover (Continued) J/P 18-62

J/P 18 J/P 26 J/P 20 J/P 27 J/P 21 J/P 30 J/P 22 J/P 23 J/P 44 J/P 50 J/P 25 J/P 58, 60, 62 June 1999 Wiring Diagrams and Electrical Data 6-19, Connectors Inside the Back Cover (Continued) J/P 64-85

Connectors Inside the Back Cover (Continued) J/P 64-85

J/P 64 J/P 79 J/P 65, 66, 67, 68, 69, 70 J/P 81, 83 J/P 774321J/P 84 J/P 85 6-20 Wiring Diagrams and Electrical Data June 1999, Connectors Inside the Back Cover (Continued) J/P 90-800

Connectors Inside the Back Cover (Continued) J/P 90-800

J/P 3234321J/P 90 J/P 324 J/P 94 J/P 330, 3314321J/P 96 J/P 33321J/P 121, 122, 124 1 139, 140, 143 J/P 800 J/P 251, 252, 255 not illustrated June 1999 Wiring Diagrams and Electrical Data 6-21, Voltage Isolation Diagrams

Voltage Isolation Diagrams

Use the following voltage isolation diagrams to locate the presence or loss of proper DC potentials within the printer. -12 Vdc Circuits DC Power J/P8-8 RIGS Supply Board J/P32-3 +5 Vdc Circuits J/P331-3 J/P306-3 Duplex Control Board #1 DC J/P330-3 Power J/P323-3 J/P305-3 J/P310-3 Supply Duplex Control Board #2 (SRMR2) 6-22 Wiring Diagrams and Electrical Data June 1999,

Voltage Isolation Diagrams

J/P8-1 J/P77-4

Disk Drive

J/P8-10 J/P32-5 RIGS Board

DC Power J/P32-6 Supply

J/P8-14 J/P91-5 VPCL Board J/P90-1 J/P42-1 Operator Panel Board J/P94-1 J/P7-1 J/P27-1 J/P7-2 J/P27-2 Printhead J/P7-3 J/P27-3 Board

June 1999 Wiring Diagrams and Electrical Data 6-23

, Voltage Isolation Diagrams or +12 Vdc Circuits J/P8-3 J/P77-1 Disk Drive DC J/P32-10 RIGS Power Board Supply J/P58-1 J/P57-1 J/P8-6 Paper timing sens J/P91-3 J/P40-25 J/P60-1 J/P59-1 Upper paper empty sensor J/P62-1 J/P61-1 Lower paper empty sensor

VPCL

J/P50-1 J/P49-1 Board Paper exit sensor J/P40-26 J/P50-4 J/P51-1 Output tray full sensor J/P40-34 J/P12-8 Power control board #2 J/P41-49 J/P25-4 Developer J/P41-50 J/P25-1 J/P40-3 J/P26-1 Erase lamp 6-24 Wiring Diagrams and Electrical Data June 1999, Voltage Isolation Diagrams Duplex Control Board #1 J/P309-4 J/P319-1 Paper pass sensor J/P306-2 J/P331-2 J/P309-3 J/P318-1 DC Cover openJ/P330-2 Power sensor Supply Duplex Control Board #2 J/P323-2 J/P312-1 J/P320-1 Registration side sensor J/P310-2 J/P305-2 J/P312-4 J/P322-1 Registration paper sensor June 1999 Wiring Diagrams and Electrical Data 6-25,

Voltage Isolation Diagrams

+24 Vdc Circuits

Duplex Control Board #1

J/P309-7~10 J/P313-1~4

Route motor

J/P306-1 J/P308-1 J/P314-1

In solenoid

J/P331-1 J/P308-2 J/P315-1

DC “C” roller solenoid

J/P330-1

Power Supply J/P308-3 J/P316-1

“A” roller clutch J/P308-4 J/P317-1

Exit solenoid

J/P323-1

Duplex Control

J/P310-1 Board #2 J/P312-7~10 J/P321-1~4

Resist motor

J/P305-1 J/P8-11 J/P10-1 J/P11-1

DC J/P12-2 J/P70-1 AC Power Power Supply Control Power Board #2 J/P12-1 Supply

J/P40-27 J/P40-28 J/P41-35 J/P23-13 High Voltage

Unit

J/P8-13 J/P41-26 J/P81-1 J/P82-1

Counter

J/P91-1 J/P40-10 J/P69-1

Lower pick-up clutch

J/P65-1

Paper timing clutch

J/P40-11 J/P66-1

Upper paper feed clutch VPCL J/P67-1 Board Lower paper feed clutch

J/P68-1

Upper pick-up clutch

6-26 Wiring Diagrams and Electrical Data June 1999, Ground System

Ground System

J/P4-9—AC power supply J/P5-8 —Fuser J/P6-3—DC power supply #1 J/P18-3—Toner supply motor J/P21-3—Large cooling fan J/P23-16—High voltage power supply J/P20-1—DC power supply #2 J/P 255—Photoconductor J/P 305-12—Duplex control board #2 (SRMR2) Transfer corona June 1999 Wiring Diagrams and Electrical Data 6-27, Host Interface Reference

Host Interface Reference

Standard printers support two host interfaces: RS-232C and Centronics Parallel. User- level information about the installation, configuration, and use of these interfaces is included in the The C40D Installation Manual, C4672-90004, guides you through unpack- ing, setup, testing, and network configuration of your C40D printer.

RS-232C Host Interface

The default host interface for the printer is RS-232C. A printer is standard data terminal equipment (DTE), designed specifically for a direct connection to a standard data commu- nication equipment (DCE) host. The standard signal definitions for DTE to DCE equip- ment are outlined on the chart that follows. Pin Name Signal Function 1 FG Frame or chassis ground 2 TD Transmitted data 3 RD Received data 4 RST Request to send 5 CTS Clear to send 6 DSR Data set ready (not used) 7 SG Signal ground 8 DCD Data carrier detect 11 (S)DCD Secondary data carrier detect (not used) 12 (S)CTS Secondary clear to send (not used) 13 (S)CTS Secondary clear to send (not used) 14 (S)TD Secondary transmitted data (not used) 15 TC Transmitter clock 16 (S)RD Secondary received data (not used) 17 RC Receiver clock 18 RDC Receiver debit clock (not used) 19 (S)RTS Secondary receive to send (not used) 20 DTR Data terminal ready 21 SQ Signal quality detect (not used) 22 RI Ring indicator (not used) 23 DRS Data rate select (not used) 24 (TC) External transmitter clock 25 BSY Busy (not used) 6-28 Wiring Diagrams and Electrical Data June 1999, Host Interface Reference

Standard DCE to DTE RS-232C Cable

The standard DCE host to the printer (DTE) pin configuration follows. Host Printer Signal DCE DTE Signal FG 1 - 1 FG TD 2 - 2 TD RD 3 - 3 RD RTS 4 - 4 RTS CTS 5 - 5 CTS DSR66DSR SG 7 - 7 SG DCD88DCD DTR 20 - 20 DTR

Special Considerations for RS-232 Host Interface Users

The host computer may be using a non-DCE RS-232C port. If so, you may have to modify your cable or purchase a new cable with the proper pin assignments. Several possible alternate RS-232C cable configurations follow.

DTE Host to Printer (Option 1)

Host Printer Signal DTE DTE Signal GND11GND TD22TD RD33RD RTS44RTS CTS55CTS DSR66DSR GND77GND DCD88DCD DTR 20 20 DTR June 1999 Wiring Diagrams and Electrical Data 6-29, Host Interface Reference

DTE Host to Printer (Option 2)

Host Printer Signal DTE DTE Signal GND11GND TD22TD RD33RD RTS44RTS CTS55CTS DSR66DSR GND77GND DCD88DCD DTR 20 20 DTR

IBM PC/XT to Printer

Normally, the IBM PC/XT comes with a parallel interface for the printer with a 25-pin female connector. To run RS-232, you must install a serial board, which will have a male connector. PC/XT Printer Signal DTE DTE Signal - 1 1 FG TD22TD RD33RD RTS44RTS CTS55CTS DSR66DSR SG77SG DCD88DCD DTR 20 20 DTR 6-30 Wiring Diagrams and Electrical Data June 1999, Host Interface Reference

IBM PC/AT to Printer

Normally, the IBM AT comes with a 9-pin serial connector. PC/AT Printer Signal DCE DTE Signal DCD11FG RD22TD TD33RD DTR44RTS SG55CTS DSR66- RTS77SG CTS88DCD RI 9 20 DTR

Macintosh Communication Port to Printer

Normally, the Macintosh comes with a 9-pin male connector. Macintosh Printer Signal DCE DTE Signal FG11FG22TD SG33RD44RTS TD55CTS66- DSR77SG88DCD RD 9 20 DTR June 1999 Wiring Diagrams and Electrical Data 6-31, Host Interface Reference

Centronics Parallel Host Interface

The signal definitions defined below are for the 1284 compatible mode. This interface also supports other 1284 compatible modes. Signal Pin Function Name 1 DS Data strobe (active low) 2 DB0 Data bit03DB1 Data bit14DB2 Data bit25DB3 Data bit36DB4 Data bit47DB5 Data bit58DB6 Data bit69DB7 Data bit 7 10 ACK Acknowledge (active low) 11 BSY Busy (active high) 12 PE Paper empty (active high) 13 SEL Select (active high) 14 AF Auto feed 15 Not used 16 SG Signal ground 17 FG Frame or chassis ground 18 PLH Peripheral logic high 19 to 30 Signal ground 31 IP INIT 32 ERR Error (active low) 33 to 35 Not used 36 SI Select input

Special Considerations for Centronics Parallel Interface Users

For DOS host computers, add the following line to the AUTOEXEC.BAT file: MODE PRN,,P To edit the AUTOEXEC.BAT file, use any text editor or the EDLIN facility of DOS. If you do not know how to edit this file, refer to the reference manual that came with the DOS software. 6-32 Wiring Diagrams and Electrical Data June 1999, Host Interface Reference

IBM Parallel to Printer

Host Printer Signal Signal DS 1 - 1 DS DB0 2 - 2 DB0 DB1 3 - 3 DB1 DB2 4 - 4 DB2 DB3 5 - 5 DB3 DB4 6 - 6 DB4 DB5 7 - 7 DB5 DB6 8 - 8 DB6 DB7 9 - 9 DB7 ACK 10 - 10 ACK BSY 11 - 11 BSY PE 12 - 12 PE SEL 13 - 13 SEL AF 14 - 14 AF ERR 15 - 32 ERR IP 6 - 31 IP SI 17 - 36 SI GND 18 - 33 GND GND 19 - 19 GND GND 20 - 21 GND GND 21 - 23 GND GND 22 - 25 GND GND 23 - 27 GND GND 24 - 29 GND GND 25 - 30 GND June 1999 Wiring Diagrams and Electrical Data 6-33, Host Interface Reference 6-34 Wiring Diagrams and Electrical Data June 1999, Section 7

Removal/ Replacement Procedures

Section 6 Removal/Replacement Procedures June 1999 Removal/Replacement Procedures 7-1,

Contents Removal/Replacement Procedures

Before You Begin.7-4 Power Considerations ..7-4 Photoconductor Removal..7-4 Front Cover Removal ..7-5 Back Cover Removal ..7-6 Left Side Cover Removal ..7-7 Right Side Cover Removal..7-8 Vacuum Transport Unit Removal .7-9 Rear Duplex Cover Removal ..7-10 Front Duplex Cover Removal ..7-11 Operator Panel Removal..7-12 Counter Removal ..7-13 RIGS Board Removal..7-14 VPCL Board Removal ..7-15 Printhead Assembly Removal ..7-16 Printhead Circuit Board (ARIF) Removal ..7-18 Hard Disk Drive Housing Removal ..7-19 Floppy and Hard Disk Drive Removal..7-20 Cooling Fan Removal..7-21 Toner Motor Removal ..7-22 AC Power Supply Removal ..7-24 DC Power Supply Removal ..7-26 High Voltage Unit Removal ..7-27 Photoconductor Seam Sensor Removal ..7-28 Photoconductor Rear Guide Rail Removal ..7-30 Power Control Board Removal ..7-33 Upper or Lower Paper Size Sensor Removal ..7-34 Upper Cassette Mount Removal..7-35 Lower Cassette Mount Removal ..7-40 Upper Paper Guide Removal ..7-45 Upper Paper Guide Roller Removal..7-47 Lower Paper Guide Removal ..7-48 Paper Timing Guide Removal ..7-49 Cleaner Drive Belt Removal ..7-51 Cleaner Drive Removal ..7-52 7-2 Removal/Replacement Procedures June 1999, Fuser Drive Belt Removal .7-53 Fuser Drive Removal .7-54 Paper Feed Drive Belt Removal .7-55 Paper Timing Roller Removal .7-56 Upper Feed Roller Removal .7-57 Lower Feed Roller Removal .7-58 Upper Pick-Up Roller Removal.7-59 Pick-Up Roller Drive Idler Removal .7-60 Pick-Up Roller Drive Gear Removal .7-61 Lower Pick-Up Roller Removal .7-62 Exit Assembly Removal .7-63 Exit Pinch Roller Removal .7-65 Upper Static Brush Removal .7-67 Lower Static Brush Removal .7-68 Exit Roller Assembly Removal .7-69 Exit Cover Removal.7-71 Paper Exit Sensor Removal .7-73 Paper Full Sensor Removal .7-74 Front Cover Interlock Switch Removal .7-75 Back Cover Interlock Switch Removal .7-76 Top Cover Interlock Switch Removal .7-77 Erase Lamp Removal.7-78 EP Cover Removal.7-79 Main Motor Removal.7-82 Main Gear Drive Removal.7-85 Duplex Control Board #1 Removal .7-86 Duplex Control Board #2 Removal .7-87 Duplex Tray Registration Motor Removal .7-88 Duplex Skew Correction Cable Removal .7-89 Upper Duplex Drive/Clutch Assembly Removal .7-91 Duplex Route Motor/Solenoid Assembly Removal .7-92 “A” Roller Removal.7-93 “B” Roller Removal .7-94 “C” Roller Removal .7-96 “C” Roller Solenoid Removal .7-97 Duplex Route Separator Removal .7-98 Duplex Paper Path Sensor Removal .7-99 June 1999 Removal/Replacement Procedures 7-3, Before You Begin

Section 7 Removal/Replacement Procedures

This section includes step-by-step instructions for removing all field service replaceable parts in the printer. Each part is addressed under its own heading, as outlined on the pre- ceding contents pages.

Before You Begin

To remove a part, follow the instructions provided. To replace a part, follow the steps in reverse order unless otherwise noted. During reassembly, make sure to reconnect all con- nectors properly and seat gears and other moving parts properly. Power Considerations Before removing a part, make sure the printer is turned off and the power cord is disconnected. Photoconductor Removal If it is necessary to remove the photoconductor as part of a removal procedure, make sure to place it in its protective packaging. When you replace the photoconductor, run at least 500 prints before checking print qual- ity. This number of prints is required to “synch” the new PC belt to the developer. 7-4 Removal/Replacement Procedures June 1999, Front Cover Removal

Front Cover Removal

1 Open the front cover. 2 While holding the cover up halfway, unhook the strap from the right side. 3 Remove the strap from the left side. 4 Slide the front cover to the right off its hinges. June 1999 Removal/Replacement Procedures 7-5, Back Cover Removal

Back Cover Removal

1 Remove all external cables and attachments, including the printer’s power cord. 2 Open the top and back covers. 3 Loosen the two thumb screws on the drive side of the top chassis and pull the back cover down. 4 Disconnect CN31, CN32, CN37, CN40, CN41, CN91, CN600, and CN36. 5 Disconnect the hard drive’s data cable. 6 Remove the mounting screws holding the back cover hinge to the printer. 7 While supporting the back cover, remove the screw holding each strap. Caution: hold the cloth strap to avoid throwing the screw as it comes loose. 8 Lift the back cover up and away from the printer. 7-6 Removal/Replacement Procedures June 1999, Left Side Cover Removal

Left Side Cover Removal

1 Open the top, back, and front covers. 2 Remove the duplex tray by disconnecting P305 and loosening the two thumb screws. 3 Remove the upper and lower paper cassettes. 4 Loosen the two screws for the left side cover. 5 Lift the cover up and away from the printer. Replacement Note: When reinstalling, make sure the inside mounting tabs are properly positioned. June 1999 Removal/Replacement Procedures 7-7, Right Side Cover Removal

Right Side Cover Removal

Note: The service kit is attached inside the right side cover. 1 Remove the paper output tray. 2 Open the top, back, and front covers. 3 Remove the two screws holding the right side cover in place. 4 Close the top cover. 5 Pull the cover out and away from the printer. Replacement Note: Tighten the screws first. Then, gently lift the bottom tabs into place. Note: Hold the top of the right side cover in place as you open the top cover. (This avoids the possibility of damaging the top cover.) 7-8 Removal/Replacement Procedures June 1999, Vacuum Transport Unit Removal

Vacuum Transport Unit Removal

1 Open the top cover. 2 Remove the upper duplex roller cover (four screws). 3 Remove the lower duplex roller cover (four screws). 4 Disconnect CN22. 5 Remove the C-clip from the gas spring on the side marked “up.” Gently move the gas spring out of the way so it does not block the wire harness area. 6 Remove the four harnesses stays holding the cable in place. 7 Remove the three ground screws. 8 Remove the vacuum transport (four screws). June 1999 Removal/Replacement Procedures 7-9, Rear Duplex Cover Removal

Rear Duplex Cover Removal

1 Open the top cover. 2 Remove the lower screw for the rear cover. 3 While supporting the cover, remove the upper screw for the rear cover. Replacement Note: Do not substitute longer screws to hold the rear cover in place. 7-10 Removal/Replacement Procedures June 1999, Front Duplex Cover Removal

Front Duplex Cover Removal

1 Open the top cover. 2 Remove the rear cover. (Refer to page 7-10.) 3 Close the top cover. 4 Open the front cover. 5 Remove the C-clip on each gas spring. 6 While supporting the cover, remove each gas spring from its post and lower it. 7 Close the front cover. 8 Remove the front hinges from the top cover (two screws each). 9 Remove the two screws from each front cover hinge. June 1999 Removal/Replacement Procedures 7-11, Operator Panel Removal

Operator Panel Removal

1 Open the front cover. 2 Remove the two screws holding the operator panel in place. 3 Disconnect CN42. 4 Remove the ground screw. 7-12 Removal/Replacement Procedures June 1999, Counter Removal

Counter Removal

1 Open the front cover. 2 Remove the screw holding the counter in place. 3 Pull out the counter. 4 Disconnect CN82. June 1999 Removal/Replacement Procedures 7-13, RIGS Board Removal

RIGS Board Removal

1 Remove any installed flex IO cards. 2 Open the back cover. 3 Disconnect CN31, CN32, and CN33. 4 Disconnect the hard drive’s data cable. 5 Remove the eight screws holding the board in place. 6 Remove the RIGS board. 7-14 Removal/Replacement Procedures June 1999, VPCL Board Removal

VPCL Board Removal

1 Open the back cover. 2 Disconnect CN34, CN36, CN37, CN40, CN41, CN400, and CN91. 3 Push the two retaining clips away from the board. 4 Remove the VPCL board. June 1999 Removal/Replacement Procedures 7-15, Printhead Assembly Removal

Printhead Assembly Removal

1 Open the front, top, and back covers. 2 Remove the photoconductor and place in its protective packaging. 3 Remove the cleaner. 4 Remove the fuser drive cover (three screws). 5 Remove the main drive cover (one screw). 6 Remove the gear stay cover (one screw). 7 Remove the gear stay (three screws). 8 Disconnect CN27, CN30, and CN96 (see back detail). 9 Remove the two back screws holding the printhead assembly in place. Continued 7-16 Removal/Replacement Procedures June 1999, Printhead Assembly Removal 10 Remove the two front screws holding the printhead assembly in place. 11 Pull the printhead assembly from the front of the printer. June 1999 Removal/Replacement Procedures 7-17, Printhead Circuit Board (ARIF) Removal

Printhead Circuit Board (ARIF) Removal

1 Remove ribbon connector J28 and plug P29 from the ARIF PCA. 2 Remove the screw securing the ARIF PCA to the printhead assembly. 3 Separate the ARIF PCA from the printhead assembly. Note: If you are installing a new ARIF PCA, check the settings of DIP switch U1. The switches should be set to: ON - 1,2,3,5; OFF -4:

ON

12345U1 J29 J28 C2 C1 J30 R4 R5 U4 U2 U5 R6 R7 U3 U6 R3 7-18 Removal/Replacement Procedures June 1999, Hard Disk Drive Housing Removal

Hard Disk Drive Housing Removal

1 Open the front and back covers. 2 Disconnect CN77 and CN79. 3 Disconnect the hard drive’s data cable at the RIGs board. 4 Loosen the thumbscrew on the back of the disk drive housing. 5 Remove the disk drive housing from the front of the printer. Note: Use caution to avoid damaging the hard disk drive ribbon data cable. Replacement Note: For floppy drives, set the jumper on the drive circuit board to 0. June 1999 Removal/Replacement Procedures 7-19, Floppy and Hard Disk Drive Removal

Floppy and Hard Disk Drive Removal

Note: The edges of the drive casing may be rough. Avoid contact with these surfaces.

Floppy drive

1 Remove the casing that surrounds the floppy disk and the hard disk drives. • Loosen the screws located on the casing, one on each side. • Remove the screw at the top rear of the casing. • Lift the casing up and away from the drive. Set it aside in a safe place. 2 Disconnect the power cable from the drive. 3 Disconnect the data cable from the drive. 4 Remove the screws holding the drive in place. Each drive is secured to the frame by one screw on the top and two screws on the bottom. 5 Pull the drive forward to free it from the drive frame. 7-20 Removal/Replacement Procedures June 1999, Cooling Fan Removal

Cooling Fan Removal

1 Open the back cover. 2 Remove the fuser drive cover (three screws). 3 Remove the cooling fan’s two cover screws. Remove cover. 4 Disconnect CN21. 5 Remove the cooling fan (two screws). June 1999 Removal/Replacement Procedures 7-21, Toner Motor Removal

Toner Motor Removal

1 Open the back cover. 2 Disconnect CN18. 3 Remove the toner motor (three screws). 7-22 Removal/Replacement Procedures June 1999, Toner Motor Removal

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June 1999 Removal/Replacement Procedures 7-23, AC Power Supply Removal

AC Power Supply Removal

1 Open the front, back, and top covers. 2 Remove the duplex tray. 3 Remove the upper and lower paper cassettes. 4 Remove the left side cover. (See page 7-7.) 5 Remove the paper feed drive cover (three screws). 6 Remove the power control board cover (one screw). 7 Disconnect CN4 and CN70. 8 From the side of the printer, remove the three screws holding the AC power supply in place. 9 Slide the AC power supply out the side of the printer. 10 Verify that the Voltage Strapping Plug P1 is configured correctly and inserted in the power supply. (Refer to the illustration on page 7-25) 7-24 Removal/Replacement Procedures June 1999, AC Power Supply Removal AC Power Supply Removal369258147Voltage Jumper 100 V 1-3 120 V 1-4 200 V 1-5 220 V 1-6 230 V 1-7 240 V 1-8 Voltage Strapping Plug P1 June 1999 Removal/Replacement Procedures 7-25, DC Power Supply Removal

DC Power Supply Removal

1 Open the front, top and back covers. 2 Remove the cooling fan cover (two screws). 3 Disconnect CN6, CN7, CN8, and CN330. 4 Remove the output tray. 5 Remove the right side cover. (See page 7-8.) 6 Remove the bracket for the output tray guide (two screws). 7 Remove the DC power supply (two screws). Replacement Note: When replacing the output tray bracket, make sure it is seated inside the DC power supply. 7-26 Removal/Replacement Procedures June 1999, High Voltage Unit Removal

High Voltage Unit Removal

1 Open the top and back covers. 2 Remove the EMI grounding plate from the rear of the printer (four screws). 3 From the top, loosen the screw holding the high voltage power supply in place. 4 Pull the high voltage power supply out from the back of the printer. 5 Disconnect CN23, CN85, and the two high voltage leads. 6 Remove the high voltage power supply . June 1999 Removal/Replacement Procedures 7-27, Photoconductor Seam Sensor Removal

Photoconductor Seam Sensor Removal

1 Open the front, back, and top covers. 2 Remove the photoconductor and place in its protective packaging. 3 Remove the developer. 4 Remove the paper feed drive cover (three screws). 5 Remove the bracket holding CN64 in place (one screw). 6 Remove the screw holding the seam sensor bracket in place. It is situated under the bracket for CN64. Continued 7 From inside the empty photoconductor cavity, disconnect CN63. 8 Lift the photoconductor seam sensor and bracket up out of the printer, as shown in the illustration on page 7-29. 7-28 Removal/Replacement Procedures June 1999, Photoconductor Seam Sensor Removal Note: Use caution to avoid bending the bracket. Seam Sensor and Bracket June 1999 Removal/Replacement Procedures 7-29, Photoconductor Rear Guide Rail Removal

Photoconductor Rear Guide Rail Removal

1 Open the front, back, and top covers. 2 Remove the photoconductor and place in its protective packaging. 3 Remove the developer. 4 Remove the paper feed drive cover (three screws). 5 Remove the photoconductor seam sensor. (See page 7-28.) 6 Remove the spring at the base of the guide rail. To do this, gently pull the spring for- ward off its post. 7 Disconnect C64. 8 Remove the ground screw. 7-30 Removal/Replacement Procedures June 1999, Photoconductor Rear Guide Rail Removal 9 Remove CN64 from its bracket. 10 From inside the photoconductor cavity, remove the two screws holding the guide rail in place. 11 Push CN64 and the ground wire through the photoconductor cavity to the front of the printer. June 1999 Removal/Replacement Procedures 7-31, Photoconductor Rear Guide Rail Removal 12 Lift the photoconductor guide rail from the printer. 7-32 Removal/Replacement Procedures June 1999, Power Control Board Removal

Power Control Board Removal

1 Open the back cover. 2 Remove the paper feed drive cover (three screws). 3 Remove the power control board cover (one screw). 4 Disconnect CN9, CN10, CN11, CN12, CN13, and CN14. 5 Remove power control board (two screws). Replacement Note: Be sure that the back of the board is mounted properly in the frame slots. June 1999 Removal/Replacement Procedures 7-33, Upper or Lower Paper Size Sensor Removal

Upper or Lower Paper Size Sensor Removal

1 Remove the duplex tray. 2 Remove the upper and lower paper cassettes. 3 Using a small screwdriver, pry up the paper size sensor. Turn the sensor counterclock- wise and lift up. 4 For the upper paper size sensor, disconnect CN45 and CN46. 5 For the lower paper size sensor, disconnect CN43, CN47, and CN48. Note: Use caution not to break the cables. 7-34 Removal/Replacement Procedures June 1999, Upper Cassette Mount Removal

Upper Cassette Mount Removal

1 Open the front, back, and top covers. 2 Remove the duplex tray. 3 Remove the upper and lower paper cassettes. 4 Remove the left side cover. (See page 7-7.) 5 Remove the paper feed drive cover (three screws). 6 Remove the power control board cover (one screw). 7 From the back, remove the two screws holding the upper cassette mount in place. 8 Loosen the CN62 jack and pull it to the back of the printer. June 1999 Removal/Replacement Procedures 7-35, Upper Cassette Mount Removal 9 Disconnect CN62. 10 Remove the upper paper size sensor. 11 Remove the cassette release cover (two screws). 12 Remove the plastic guide on the vertical edge of the printer. Depress the tabs visible through the cassette housing. Gently turn it and lift from the printer. 13 For the tray releases: •Carefully release the tension spring cable from the pick pressure adjustment lever. •Remove the spring and cable. •Remove the upper and lower levers (one spring and C-clip each). •Remove the upper and lower cams (one screw each). 7-36 Removal/Replacement Procedures June 1999, Upper Cassette Mount Removal •Remove the upper and lower latches (one spring and C-clip each). (Continued on next page). Continued 14 Disengage the top of the damper assembly. Push it to the right out of the way 15 Remove the lower bracket (four screws; two front and two back). 16 Remove the tray (four screws; two front and two back). 17 Remove the upper tray lift arm (two screws with two plastic retainers). 18 Remove the upper bracket (four screws; two front and two back). 19 Remove the screws holding the upper cassette mount in place (two front and 2 side). 20 Pull the upper cassette mount from its front and back mounting pins. June 1999 Removal/Replacement Procedures 7-37, Upper Cassette Mount Removal 21 Rotate the upper cassette mount upwards and out of the printer. 7-38 Removal/Replacement Procedures June 1999, Upper Cassette Mount Removal

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June 1999 Removal/Replacement Procedures 7-39, Lower Cassette Mount Removal

Lower Cassette Mount Removal

1 Open the front, back, and top covers. 2 Remove the duplex tray. 3 Remove the upper and lower paper cassettes. 4 Remove the left side cover. (See page 7-7.) 5 Remove the paper feed drive cover (three screws). 6 Remove the power control board cover (one screw). 7 Remove the power control board. (See page 7-33.) 7-40 Removal/Replacement Procedures June 1999, Lower Cassette Mount Removal 8 From the back, remove the two screws holding the lower cassette mount in place. Continued 9 Remove the lower paper size sensor. 10 Remove the cassette release cover (two screws). 11 Remove the plastic guide on the vertical edge of the printer. Depress the tabs visible through the cassette housing. Gently turn it and lift from the printer. 12 For the lower tray release: •Carefully release the tension spring cable from the pick pressure adjustment lever. •Remove the spring and cable. •Remove the lever (one spring and C-clip). June 1999 Removal/Replacement Procedures 7-41, Lower Cassette Mount Removal •Remove the cam (one screw). •Remove the latch (one spring and C-clip). Continued (Continued on next page) 13 Remove the lower bracket (four screws; two front and two back). 14 Remove the tray (four screws; two front and two back) 15 Remove the AC power supply. (See page 7-23.) 16 Remove the lower tray lift arm (two screws with two plastic retainers). 17 Remove the screws holding the lower cassette mount in place (two front and 2 side). 18 Pull the lower cassette mount from its front and back mounting pins. 7-42 Removal/Replacement Procedures June 1999, Lower Cassette Mount Removal 19 Rotate the lower cassette mount upwards and out of the printer June 1999 Removal/Replacement Procedures 7-43, Lower Cassette Mount Removal

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7-44 Removal/Replacement Procedures June 1999, Upper Paper Guide Removal

Upper Paper Guide Removal

1 Open the front, back, and top covers. 2 Remove the EMI grounding plate from the rear of the printer (four screws). 3 Remove the paper feed drive cover (three screws). 4 Disconnect the transfer corona high voltage lead from the HVPS. 5 Disconnect the ground screw for the transfer corona. 6 Remove the cassette release cover (two screws). 7 Raise the upper paper guide. 8 Remove the back screw holding the upper paper guide in place. 9 Remove the front screw holding the upper paper guide in place. 10 Release the two springs at the base of the upper paper guide. 11 Lift the upper paper guide out of the printer June 1999 Removal/Replacement Procedures 7-45, Upper Paper Guide Removal Upper Paper Guide Removal. 7-46 Removal/Replacement Procedures June 1999, Upper Paper Guide Roller Removal

Upper Paper Guide Roller Removal

1 Open the top cover. 2 Remove the two springs at the ends of the roller. To do this, press down gently on the end of the spring and move it out from under the plastic. 3 Raise the upper paper guide. 4 Remove the roller and bearings from the underside of the upper paper guide. June 1999 Removal/Replacement Procedures 7-47, Lower Paper Guide Removal

Lower Paper Guide Removal

1 Open the top cover. 2 Raise the upper paper guide. 3 Raise the lower paper guide slightly. 4 Push the base of the lower paper guide toward the back of the printer until the front mounting peg is free. 5 Lift the lower paper guide out of the printer. Note: Use caution. This piece is made of plastic and can easily break if mishandled. 7-48 Removal/Replacement Procedures June 1999, Paper Timing Guide Removal

Paper Timing Guide Removal

1 Open the front, back, and top covers. 2 Raise the upper paper guide. 3 Remove the lower paper guide. (See page 7-48.) 4 Remove the front screw holding the paper timing guide in place. June 1999 Removal/Replacement Procedures 7-49, Paper Timing Guide Removal 5 Remove the paper feed drive cover (three screws). 6 Remove the back screw holding the paper timing guide in place. Remove the paper timing guide. 7 Disconnect CN58. Note: When reinstalling the paper timing guide, be sure the guide is properly aligned on the mounting pins. 7-50 Removal/Replacement Procedures June 1999, Cleaner Drive Belt Removal

Cleaner Drive Belt Removal

1 Open the back cover. 2 Remove the fuser drive cover (three screws). 3 Remove the main drive cover (one screw). 4 Lift the idler arm and slide the cleaner drive belt off the gear. June 1999 Removal/Replacement Procedures 7-51, Cleaner Drive Removal

Cleaner Drive Removal

1 Open the back cover. 2 Remove the fuser drive cover (three screws). 3 Remove the main drive cover (one screw). 4 Remove the cleaner drive belt. (See page 7-51.) 5 Remove the two high voltage leads. 6 Remove the cleaner drive (three screws). 7-52 Removal/Replacement Procedures June 1999, Fuser Drive Belt Removal

Fuser Drive Belt Removal

1 Open the back cover. 2 Remove the fuser drive cover (three screws). 3 Remove the main drive cover (one screw). 4 Remove the gear stay cover (one screw). 5 Remove the gear stay (three screws). 6 Remove the main drive gear and bearing (two C-clips and a washer). 7 Remove the single upper left and the two lower screws holding the fuser drive in place. 8 Loosen the upper right screw for the fuser drive and pivot the drive down. 9 Slide the fuser drive belt off the gear. June 1999 Removal/Replacement Procedures 7-53, Fuser Drive Removal

Fuser Drive Removal

1 Open the back cover. 2 Remove the fuser drive cover (three screws). 3 Remove the main drive cover (one screw). 4 Remove the gear stay cover (one screw). 5 Remove the gear stay (three screws). 6 Remove the fuser drive belt. (See page 7-53.) 7 Remove the fuser drive (four screws). 7-54 Removal/Replacement Procedures June 1999, Paper Feed Drive Belt Removal

Paper Feed Drive Belt Removal

1 Open the back cover. 2 Remove the fuser drive cover (three screws). 3 Remove the paper feed drive cover (three screws). 4 Remove the main drive cover (one screw). 5 Remove the cleaner drive belt. (See page 7-51.) 6 Push down on the idler arm and slide the paper feed drive belt off the gear. June 1999 Removal/Replacement Procedures 7-55, Paper Timing Roller Removal

Paper Timing Roller Removal

1 Open the front, back, and top covers. 2 Raise the upper paper guide. 3 Remove the photoconductor and place it in its protective bag. 4 Remove the paper feed drive cover (three screws). 5 Remove the paper feed drive belt from the paper timing roller gear. 6 Disconnect CN65. 7 Unscrew the standoff post from the collar surrounding the end of the roller. 8 Remove the C-clip and bearing from the front of the printer. 9 Slide the paper timing roller out the back of the printer. Replacement Notes: Reinstall the original collar and standoff post with any new paper timing roller. The C-clip should move freely if installed correctly. Be sure to align all of the guide pins or the C-clip will not fit correctly. Be careful not to scratch the surface of the roller when inserting it into the printer. 7-56 Removal/Replacement Procedures June 1999, Upper Feed Roller Removal

Upper Feed Roller Removal

1 Open the front and back covers. 2 Remove the paper feed drive cover (three screws). 3 Disconnect CN66. 4 Remove the paper feed drive belt from the upper feed roller gear. 5 Remove the cassette release cover (two screws). 6 Remove the front C-clip and bearing from the front of the printer. 7 Slide the upper feed roller out the back of the printer. June 1999 Removal/Replacement Procedures 7-57, Lower Feed Roller Removal

Lower Feed Roller Removal

1 Open the front and back covers. 2 Remove the paper feed drive cover (three screws). 3 Disconnect CN67. 4 Remove the paper feed drive belt from the lower feed roller gear. 5 Remove the cassette release cover (two screws). 6 Remove the C-clip and bearing from the front of the printer. 7 Slide the lower feed roller out the back of the printer. 7-58 Removal/Replacement Procedures June 1999, Upper Pick-Up Roller Removal

Upper Pick-Up Roller Removal

1 Open the front and back covers. 2 Remove the paper feed drive cover (three screws). 3 Disconnect CN68. 4 Remove the cassette release cover (two screws). 5 Remove the C-clip and bearing from the front of the printer. 6 Remove the pick-up roller drive belt from the gears. 7 Slide the upper pick-up roller out the back of the printer. Note: You may need to remove the EMI grounding plate. June 1999 Removal/Replacement Procedures 7-59, Pick-Up Roller Drive Idler Removal

Pick-Up Roller Drive Idler Removal

1 Open the front and back covers. 2 Remove the paper feed drive cover (three screws). 3 Remove the pick-up roller drive belt from the pick and feed gears. 4 Remove the pick-up roller drive idler (three screws). 7-60 Removal/Replacement Procedures June 1999, Pick-Up Roller Drive Gear Removal

Pick-Up Roller Drive Gear Removal

1 Open the back cover. 2 Remove the paper feed drive cover (three screws). 3 Remove the pick-up roller drive belt. 4 Remove the pick-up roller drive gear and housing (three screws). Note: You may need to remove the EMI grounding plate. June 1999 Removal/Replacement Procedures 7-61, Lower Pick-Up Roller Removal

Lower Pick-Up Roller Removal

1 Open the front and back covers. 2 Remove the paper feed drive cover (three screws). 3 Disconnect CN69. 4 Remove the cassette release cover (two screws). 5 Remove the front C-clip and bearing. 6 Slide the lower pick-up roller out the back of the printer. 7-62 Removal/Replacement Procedures June 1999, Exit Assembly Removal

Exit Assembly Removal

1 Open the front, top, and back covers. 2 Remove the paper output tray. 3 Remove the right side cover. (See page 7-8.) 4 Remove the operator panel. (See page 7-12.) 5 Remove the DC power supply. (See page 7-26.) 6 Remove the mounting bracket for the DC power supply by removing two screws and prying out the bracket with a small screw driver. 7 Remove the fuser drive cover (three screws). June 1999 Removal/Replacement Procedures 7-63, Exit Assembly Removal 8 Remove the five screws holding the job exit assembly in place (three screws in front; two screws in back). 9 Remove the fuser drive cover mounting post. 10 Remove the mounting pin for the output option (one screw). 11 Remove the job exit assembly. 7-64 Removal/Replacement Procedures June 1999, Exit Pinch Roller Removal

Exit Pinch Roller Removal

1 Open the front, back, and top covers. 2 Remove the fuser. 3 Remove the operator panel. (See page 7-12.) 4 Remove the front screw holding the exit pinch roller in place. 5 Remove the front screw holding the exit guide in place. 6 Remove the fuser drive cover (three screws). 7 Remove the back screw holding the exit pinch roller in place. 8 Lift the exit pinch roller from the printer. June 1999 Removal/Replacement Procedures 7-65, Exit Pinch Roller Removal Note: Use caution so as not to damage the paper full or exit sensors. 7-66 Removal/Replacement Procedures June 1999, Upper Static Brush Removal

Upper Static Brush Removal

1 Open the top and front covers. 2 Remove the fuser. 3 Remove the upper static brush from the exit pinch roller assembly (two screws). June 1999 Removal/Replacement Procedures 7-67, Lower Static Brush Removal

Lower Static Brush Removal

1 Open the top, front and back covers. 2 Remove the fuser. 3 Remove the operator panel. (See page 7-12.) 4 Remove the exit pinch roller assembly. (See page 7-65.) 5 Remove the lower static brush (two screws). 7-68 Removal/Replacement Procedures June 1999, Exit Roller Assembly Removal

Exit Roller Assembly Removal

1 Open the front, back, and top covers. 2 Remove the fuser. 3 Remove the operator panel. (See page 7-12.) 4 Remove the front screw holding the exit guide in place. 5 Remove the fuser drive cover (three screws). 6 Remove the exit pinch roller. (See page 7-65.) 7 Remove the lower duplex drive (three screws). 8 Remove the back screw holding the exit guide in place. June 1999 Removal/Replacement Procedures 7-69, Exit Roller Assembly Removal 9 Tilt the exit guide toward the center of the printer. 10 Remove the front C-clip and bearing. 11 Slide the exit roller out the back of the printer. Note: Use caution so as not to damage the paper full or exit sensors. 7-70 Removal/Replacement Procedures June 1999, Exit Cover Removal

Exit Cover Removal

1 Open the front, top, and back covers. 2 Remove the fuser. 3 Remove the paper output tray. 4 Remove the right side cover. (See page 7-8.) 5 Remove the operator panel. (See page 7-12.) 6 Remove the fuser drive cover (three screws). 7 Remove the exit pinch roller. (See page 7-65.) 8 Disconnect CN49 and CN51. June 1999 Removal/Replacement Procedures 7-71, Exit Cover Removal 9 Remove the wiring harness for CN42, CN49, and CN51 from the exit cover. 10 Disconnect CN317. 11 Remove the four screws holding the exit cover in place (two front and two back). 12 Lift the exit cover from the printer. 13 Remove the solenoid from the exit cover (two screws) 7-72 Removal/Replacement Procedures June 1999, Paper Exit Sensor Removal

Paper Exit Sensor Removal

1 Open the front, back, and top covers. 2 Remove the fuser. 3 Remove the operator panel. (See page 7-12.) 4 Remove the exit pinch roller. (See page 7-69.) 5 Disconnect CN49. 6 Remove the two screws holding the exit cover in place (one front and one back). 7 Tilt the exit cover assembly toward the center of the printer. 8 From the underside, remove the paper exit sensor (one screw). June 1999 Removal/Replacement Procedures 7-73, Paper Full Sensor Removal

Paper Full Sensor Removal

1 Open the front, back, and top covers. 2 Remove the fuser. 3 Remove the operator panel. (See page 7-12.) 4 Remove the exit pinch roller. (See page 7-69.) 5 Disconnect CN51. 6 Remove the two screws holding the exit cover in place (one front and one back). 7 Tilt the exit cover toward the center of the printer. 8 From the underside, remove the paper full sensor (one screw). 7-74 Removal/Replacement Procedures June 1999, Front Cover Interlock Switch Removal

Front Cover Interlock Switch Removal

1 Open the front, top, and back covers. 2 Remove the duplex tray. 3 Remove the upper and lower paper cassettes. 4 Remove the left side cover. (See page 7-7.) 5 Remove the AC power supply. (See page 7-24.) 6 Remove the AC power supply top cover (two screws). 7 Disconnect the two wires connected to the interlock switch. 8 Remove the front interlock switch (two screws). June 1999 Removal/Replacement Procedures 7-75, Back Cover Interlock Switch Removal

Back Cover Interlock Switch Removal

1 Open the front, top, and back covers. 2 Remove the duplex tray. 3 Remove the upper and lower paper cassettes. 4 Remove the left side cover. (See page 7-7.) 5 Remove the AC power supply. (See page 7-24.) 6 Remove the AC power supply side cover (one screw). 7 Disconnect the four wires connected to the interlock switch. 8 Remove the back cover interlock switch (two screws). 7-76 Removal/Replacement Procedures June 1999, Top Cover Interlock Switch Removal

Top Cover Interlock Switch Removal

1 Open the top, front, and back covers. 2 Remove the duplex tray. 3 Remove the upper and lower paper cassettes. 4 Remove the left side cover. (See page 7-7.) 5 Remove the duplex tray mount (four screws). 6 Remove the paper feed drive cover (two screws). 7 Disconnect the two wires connected to the interlock switch. 8 Remove the top cover interlock switch (two screws). June 1999 Removal/Replacement Procedures 7-77, Erase Lamp Removal

Erase Lamp Removal

1 Open the top and back covers. 2 Remove the photoconductor and place it in its protective packaging. 3 Remove the fuser drive cover (three screws). 4 Disconnect CN26. 5 Remove the screw holding the erase lamp in place. 6 Disengage the front of the erase lamp from its guide pin. 7 Slide the unit out the back of the printer. 7-78 Removal/Replacement Procedures June 1999, EP Cover Removal

EP Cover Removal

1 Open the front, back, and top covers. 2 Remove the fuser. 3 Remove the photoconductor and place in its protective packaging. 4 Remove the cleaner. June 1999 Removal/Replacement Procedures 7-79, EP Cover Removal 5 Remove the operator panel. (See page 7-12.) 6 Remove the fuser drive cover (three screws). 7 Remove the two supports for the vacuum transport (one screw each). 8 Remove the four screws holding the EP cover in place (two front and two back). 9 Remove the upper right screw holding the fuser drive in place. 7-80 Removal/Replacement Procedures June 1999, EP Cover Removal 10 Lift the EP cover straight up out of the printer. Replacement Note: The higher of the two drive shaft support arms should be facing the left side of the printer. June 1999 Removal/Replacement Procedures 7-81, Main Motor Removal

Main Motor Removal

1 Disconnect all external cables and attachments. 2 Open the front, back, and top covers. 3 Remove the photoconductor and place in its protective packaging. 4 Remove the cleaner. 5 Remove the back cover. (See page 7-6.) 6 Remove the right side cover. (See page 7-8.) 7 Remove the counter. (See page 7-13.) 7-82 Removal/Replacement Procedures June 1999, Main Motor Removal 8 Remove the main drive cover (one screw). 9 Remove the fuser drive cover (three screws). 10 Remove the gear stay cover. 11 Remove the gear stay (three screws). 12 Remove the hard disk drive housing. (See page 7-19.) 13 Remove the printhead. (See page 7-16.) 14 Remove the DC power supply. (See page 7-26.) 15 Remove the main motor gear and bearing (two C-clips and a washer). June 1999 Removal/Replacement Procedures 7-83, Main Motor Removal 16 Remove key, C-clip, and washer. 17 Disconnect CN20 and remove the female end from the chassis. 18 From the right side, remove the screw holding the D.C. main motor power supply in place. 19 Remove the multicolored cable (PN2) from the D.C. main motor power supply. 20 From the back, remove the three screws holding the main motor in place. Note: Remove the lower screw first. 21 Remove the main motor through the side of the printer. Replacement Notes: Remove the drive shaft key from the old motor. Replacement motors are not supplied with a key. Be sure to reroute CN20 after installation so that the wires do not protrude into the disk drive assembly area. Reroute the counter cable for the same reason. 7-84 Removal/Replacement Procedures June 1999, Main Gear Drive Removal

Main Gear Drive Removal

1 Open the back cover. 2 Remove the lower back cover. (See page 7-6.) 3 Remove the paper feed drive cover (three screws). 4 Remove the fuser drive cover (three screws). 5 Remove the main drive cover (one screw). 6 Remove the gear stay cover (one screw). 7 Remove the gear stay (three screws). 8 Remove the cleaner drive belt. (See page 7-51.) 9 Remove the paper feed drive belt. (See page 7-55.) 10 Remove the main gear drive (three screws). June 1999 Removal/Replacement Procedures 7-85, Duplex Control Board #1 Removal

Duplex Control Board #1 Removal

1 Open the top cover. 2 Remove the duplex control board cover (two screws). 3 Disconnect CN306, CN307, CN308, and CN309. 4 Disengage the duplex control board #1. To do this, pinch the four standoffs on the board, one at a time. 5 Lift the board from the mounting bracket. Note: When reinstalling, make sure the duplex control board is pushed down towards the vacuum transport. 7-86 Removal/Replacement Procedures June 1999, Duplex Control Board #2 Removal

Duplex Control Board #2 Removal

1 Open the top cover. 2 Remove the duplex tray. 3 Remove the paper guide from the duplex tray (four screws). 4 Disconnect CN310, CN311, and CN312. 5 Remove duplex control board #2 (two screws). June 1999 Removal/Replacement Procedures 7-87, Duplex Tray Registration Motor Removal

Duplex Tray Registration Motor Removal

1 Open the top cover. 2 Remove the duplex tray. 3 Remove the paper guide inside the duplex tray (four screws). 4 Disconnect CN321. 5 Remove the registration motor (two screws). 7-88 Removal/Replacement Procedures June 1999, Duplex Skew Correction Cable Removal

Duplex Skew Correction Cable Removal

1 Open the top cover. (See next page for illustration.) 2 Remove the duplex tray. 3 Remove the paper guide inside the duplex tray (four screws). 4 Slide the skew correction guides toward the center of the duplex tray. 5 Remove the bracket holding the shaft in place (two screws). 6 Remove the screw holding the cable mounting plate in place. 7 Lift the skew correction guides and shaft up out of the duplex tray. 8 Remove the two screws holding each pulley assembly in place. 9 Remove the spring from the cable. 10 Lift the skew correction cable and pulley assemblies from the duplex tray. Replacement Notes: The placement of the mounting bead is critical. Set it on precisely. Replace parts in this order: 1 Reinstall the pulley assembly first. 2 Then, wrap the cable three times around the drive gear pulley. 3 Finally, connect the spring. June 1999 Removal/Replacement Procedures 7-89, Duplex Skew Correction Cable Removal 7-90 Removal/Replacement Procedures June 1999, Upper Duplex Drive/Clutch Assembly Removal

Upper Duplex Drive/Clutch Assembly Removal

1 Open the top cover. 2 Remove the rear duplex cover. (See page 7-10.) 3 Remove the lower duplex roller cover (four screws). 4 Disconnect CN316. 5 Remove the upper duplex drive/clutch assembly (three screws). June 1999 Removal/Replacement Procedures 7-91, Duplex Route Motor/Solenoid Assembly Removal

Duplex Route Motor/Solenoid Assembly Removal

1 Open the top cover. 2 Remove the rear duplex cover. (See page 7-10.) 3 Remove the upper duplex roller cover (four screws). 4 Disconnect CN313 and CN314. 5 Remove the duplex route motor/solenoid assembly (three screws). 7-92 Removal/Replacement Procedures June 1999, “A” Roller Removal “A” Roller Removal 1 Open the top cover. 2 Remove the rear duplex cover. (See page 7-10.) 3 Remove the lower duplex roller cover (four screws). 4 Remove the front C-clip and bearing from the “A” roller. 5 Lower the top cover to a 45-degree angle. 6 Slide the “A” roller out the back of the printer. June 1999 Removal/Replacement Procedures 7-93, “B” Roller Removal “B” Roller Removal 1 Open the top cover. 2 Remove the rear duplex cover. (See page 7-10.) 3 Remove the upper duplex roller cover (four screws). 4 Remove the lower duplex roller cover (four screws). 5 Remove the front C-clip and bearing from the “B” roller. 6 Remove the two screws holding the duplex control board cover in place. 7 Move the cover to the left out of the way. 8 Loosen the screw holding the idler roller in place. 9 Remove the duplex drive belt. 10 Remove the drive gear (one C-clip). 7-94 Removal/Replacement Procedures June 1999, “B” Roller Removal 11 Slide the “B” roller out the back of the printer. June 1999 Removal/Replacement Procedures 7-95, “C” Roller Removal “C” Roller Removal 1 Open the top cover. 2 Remove the rear duplex cover. (See page 7-10.) 3 Remove the upper duplex roller cover (four screws). 4 Remove the front mechanism cover (two screws). 5 Remove the front C-clip and bearing from the “C” roller. 6 Slide the “C” roller out the back of the printer. 7-96 Removal/Replacement Procedures June 1999, “C” Roller Solenoid Removal “C” Roller Solenoid Removal 1 Open the top cover. 2 Remove the front mechanism cover (two screws). 3 Disconnect CN315 and cut the cable tie securing the wires to the mounting plate. 4 Remove the two screws holding the “C” roller solenoid in place. 5 Loosen the set screw securing the actuator arm to the “C” roller. 6 Disengage the solenoid from the actuator arm and remove it. Replacement Note: Install a new cable tie to secure the wires from CN315 to the mounting plate. June 1999 Removal/Replacement Procedures 7-97, Duplex Route Separator Removal

Duplex Route Separator Removal

1 Open the top cover. 2 Remove the rear duplex cover. (See page 7-10.) 3 Remove the upper duplex roller cover (four screws). 4 Remove the duplex route motor/solenoid assembly. (See page 7-92.) 5 Remove the front mechanism cover (two screws). 6 Open the duplex cover. 7 Remove the screw holding the return arm in place. 8 Disengage the return spring. 9 Remove the front C-clip from the route separator. 10 Disengage the route separator from its side supports. 11 Lift the route separator out from the duplex cover. 7-98 Removal/Replacement Procedures June 1999, Duplex Paper Path Sensor Removal

Duplex Paper Path Sensor Removal

1 Open the top cover. 2 Remove the two screws holding the duplex control board cover in place. 3 Move the cover to the left out of the way. 4 Disconnect CN319. 5 Remove the duplex paper path sensor (one screw). June 1999 Removal/Replacement Procedures 7-99, Duplex Paper Path Sensor Removal 7-100 Removal/Replacement Procedures June 1999,

Section 8 Options

Section 7 Options June 1999 Options 8-1,

Contents Options

Introduction .8-3 1200-Sheet/2500-Sheet Feeder.8-4 Guide to Component Acronyms/Physical Locations..8-4 Bench Test Procedure ..8-5 Connection Diagram for 1200-Sheet /2500-Sheet Feeder .8-8 Prefeed Adjustment Procedure ..8-7 1200-Sheet Feeder Only ..8-7 2500-Sheet Feeder Only ..8-7 Input Control Board Logic ..8-9 1400-Sheet Stacker ..8-10 Guide to Component Abbreviations/Physical Locations..8-10 Bench Test Procedure ..8-11 Connector Locations..8-13 Front View (cover removed) ..8-13 Left Side View (left cover removed) ..8-13 Rear Side View (cover removed) ..8-14 Top View (top cover removed) ..8-14 Connection Diagram for the 1400-Sheet Stacker ..8-15 Output Control Board Logic ..8-16 8-2 Options June 1999, Introduction

Section 8 Options Introduction

This section provides information about troubleshooting and testing specific printer options not covered elsewhere in the manual. These options include the 1200- and 2500- sheet High Capacity Input (HCI) units, and the 1400-sheet High Capacity Output (HCO) unit. Installation instructions for the sheet feeders and sheet stacker are in the C40D Installation Manual, which is shipped with the C40D. For a complete list of the parts contained in the 1200-sheet feeder, the 2500-sheet feeder, and the 1400-sheet stacker, please see the Illustrated Parts Catalog. June 1999 Options 8-3, 1200-Sheet/2500-Sheet Feeder 1200-Sheet/2500-Sheet Feeder

Guide to Component Acronyms/Physical Locations

Acronym Component DSW Door Switch (magnetic door lock) IEM Input Elevator Motor (M1 - elevator motor) ILLS Input Lower Limit Sensor IPES Input Paper Tray Sensor IPM Input Pick-up Motor (M2 - paper pick-up motor) IULS Input Upper Limit Sensor NF AC Noise Filter NPS No Paper Solenoid PCSW Power Control Switch (slope tray interlock switch) PES Paper End Sensor PHS Paper Head Sensor SOL Solenoid Rear side ILLS M1

NF

Input SOLIULS (1200 HCI) control IULS (2500 HCI) board

PES

Door Printer side

PHS

M2 IPES PCSW Power supply DSW Front side 8-4 Options June 1999, Bench Test Procedure

Bench Test Procedure

1 Turn the printer’s main power switch off, then disconnect the unit’s power cord. 2 Press down the printer’s lower cassette release lever, then remove the unit from the printer and place it on a work bench or other suitable surface. 3 Remove the paper size lever, then lift up the slope tray and place the lever between the slope tray and the frame. This will bypass the interlock switch (PCSW) located under the slope tray, allowing 12Vdc to be applied to the input control board.

The slope tray is normally lifted into operating position by the printer’s lower paper

lift arm. Slope Tray Paper Size Lever Paper Supply Tray Paper Access Door 4 Restore AC power to the unit (either the unit’s power cord or the printer’s power cord may be used). 5 Open the paper access door. The elevator motor (M1) should turn on, moving the paper stock down. There is an actuator attached to the elevator’s chain drive that will activate photosensor ILLS signalling the input control board that the paper supply tray is completely down.

Remove any paper that may be on the unit’s slope tray.

June 1999 Options 8-5, Bench Test Procedure Rear side ILLS M1

SOL

IULS (1200 HCI) IULS (2500 HCI)

PES

Door Printer side

PHS

M2 IPES PCSW DSW Front side 6 Close the paper access door. The elevator motor (M1) should turn on, moving the paper stack up. There are two actuators that must enable two photosensors. Photosen- sor IPES signals the input control board that paper is present on the elevator. Photo- sensor IULS signals the input control board that the upper limit for the paper supply tray and paper stack has been reached. 7 With the paper supply tray all the way up and with no paper present on the slope tray (indicated to the input control board by photosensor PES, located in the middle of the paper path), the pick-up roller assembly motor (M2) will turn on and transport a piece of paper to the slope tray. 8 When the paper in transported to the slope tray, note that the (SOL) solenoid (under the slope tray) energizes.

The solenoid causes contact with the printer’s paper present sensor.

9 By removing the piece of paper from the slope tray, photosensor PHS signals the input control board to turn the pick-up motor (M2) on to replace the piece of paper that was removed. 10 When the last sheet of paper has been fed from the paper supply tray to the slope tray, the actuator arm of photosensor IPES falls through a hole in the paper supply tray. This signals the input control board to turn the elevator motor (M1) on to move the paper supply tray down. The paper supply tray will remain down until the paper access door is reopened (more paper is loaded), then closed. 11 When the last sheet of paper has been removed from the slope tray, confirm that the solenoid (SOL) de-energizes. 8-6 Options June 1999, Prefeed Adjustment Procedure

Prefeed Adjustment Procedure This procedure should only be done if you are replacing the control board or experi-

encing excessive paper jams. 1 Remove the side, top, and throat covers from the unit. 2 Disconnect J509. 3 Using the bench test procedure, feed paper to the slope assembly. 4 Set VR2 fully counter clockwise. 1200-Sheet Feeder Only • Adjust VR1 so that the paper feeds to 20 to 30 mm (approximately 1 inch) past the bend of the slope assembly. 2500-Sheet Feeder Only • Adjust VR1 so that the paper feeds to 10 mm (approximately 3/8-inch) before the bend of the slope assembly. June 1999 Options 8-7, Connection Diagram for 1200-Sheet/2500-Sheet Feeder

Connection Diagram for 1200-Sheet/2500-Sheet Feeder

8-8 Options June 1999 der Input Control Board J519 M2

M Connection Diagram for 1200-Sheet /2500-Sheet Fee NF

W520 J600 J400 W508 Gnd

AC

PH-1 P522 Power + 12Vdc W505 Supply P5 W506 J5 P527 P SW2

PCSW

W510 J509 P518 W507 P529 P500 J518 W514 J529 P512 P513 P514 P515 J500 P530 M1 NP PH ILL PE IUL IPES DSW IEM IP

SOL

, Input Control Board Logic

Input Control Board Logic

The table below indicates switching logic for the unit’s various components. Except for the power control switch (PCSW), each component can be monitored from the various pins of CN508 (located on the input control board).

When performing these checks, use test point TP 1 (located below CN507 on the input

control board). Connector Component Monitored Condition CN508-4 PHS High Paper present Low No paper present CN508-13 PES Low Paper present High No paper present CN508-19 IPES High Paper present Low No paper present CN508-16 IULS Low Limit High No Limit CN508-21 DSW High Door open Low Door closed CN508-10 ILLS High Limit Low No limit CN508-2 NPS High On Low Off CN508-25, 26 IPM (M2) +12Vdc Feed 0Vdc No feed CN508-23 IEM (M1) +12 Vdc Up 0Vdc Off CN508-24 IEM (M1) +12 Vdc Down 0Vdc Off CN507-2 PCSW 0Vdc Unit mounted +12Vdc Unit not mounted June 1999 Options 8-9, 1400-Sheet Stacker 1400-Sheet Stacker

Guide to Component Abbreviations/Physical Locations

Abb Component ERM Exit Roller Motor (M1) EPS Exit Paper Sensor ERS Exit Roller Sensor OEM Out Elevator Motor (M2) OELS Out Elevator Limit Sensor OEPS Out Exit Paper Sensor OJFM Out Jogging Front Motor (M4) OJFS Out Jogging Front Sensor OJRM Out Jogging Rear Motor (M3) OJRS Out Jogging Rear Sensor OLLS Out Lower Limit Sensor OULS Out Upper Limit Sensor OEM (M2) ERM (M1) Top View OEPS OLLS OULS Power supply Printer side Output tray

OJRS OJFS

Paper tray full Output actuator control board OJFM (M4) OJRM (M3)

OELS

8-10 Options June 1999, Bench Test Procedure

Bench Test Procedure

1 Turn the printer’s main power switch off. Stacker Unit Adapter Plate Output Tray Power Cord Output Tray Guide Jack Control Cable Connector 2 Remove the output tray from the stacker unit. 3 Disconnect the stacker unit’s power cord from the printer and from the stacker, then disconnect the unit’s control connector cable from the printer’s jack. 4 Remove the stacker unit from the printer, then place it on a work bench or other suit- able surface. 5 Remove the printer’s power cord from the wall outlet and the printer’s lower back cover. 6 Observe the pin configuration of the stacker unit’s control connector cable plug (shown opposite page). 7 Place a jumper from pin 9 to pin 10 (ground). Using the printer’s power cord in place of the unit’s power cord, plug the printer’s power cord in the stacker unit, then into the wall outlet. 8 With the power applied to the stacker unit, the exit roller motor (ERM-M1) will be off. This will signal the output control board to turn the exit roller motor (ERM-M1) on. 9 Remove the jumper from pin 9 and pin 10. 10 Lift the paper tray full actuator to enable photosensor OLLS to signal the output con- trol board to cause the elevator motor (OEM-M2) to turn on and lower the output tray guide. June 1999 Options 8-11, Bench Test Procedure Rear side

OEM

(M2) ERM (M1) OEPS OLLS OULS Printer side Output tray

OJRS OJFS

Paper tray full actuator OJRM (M3) OJFM1234567

OELS

Front side Plug 9 10XXXXXControl Connector Cable 11 As the output tray guide reaches its lowest allowable position, photosensor OELS is enabled and signals the output control board to turn the elevator motor (OEM-M2) off. 12 Releasing the paper tray full actuator then enables photosensor OULS to signal the output control board to turn the elevator (OEM-M2) on and raise the output tray guide. 13 As the output tray guide reaches its highest allowable position, the paper tray full actu- ator enables both photosensor OLLS and photosensor OULS, which in turn signal the output control board to turn the elevator motor (OEM-M2) off. 14 Disconnect the power cord from the stacker, then place a jumper from pin 3 to pin 6 and a second jumper from pin 2 to pin 7. 15 Reconnect the power cord, then (from the printer side of the unit) insert a folded piece of paper into the unit to trigger the actuator and enable photosensor OEPS. This will signal the output control board to turn the jogging rear motor (OJRM-M3) on. 16 After jogging has occurred, remove the piece of paper then reinsert it. This will again trigger the acturator and enable photosensor OEPS. This will signal the output control board to turn the jogging front motor (OJFM-M4) on. 17 The procedure is completed. Disconnect the power cord, remove the jumpers, then reinstall the unit into the printer. 8-12 Options June 1999, Connector Locations

Connector Locations Front View (cover removed)

CN416 Printer side

Left Side View (left cover removed) Connectors/circuit boards shown with broken lines are concealed from view.

CN409 CN426 CN425 Rear side CN405 CN406 Fuse 1 CN401 Fuse 2 Output control board Power supply CN404 CN402 CN417 CN403 Frame ground CN412 June 1999 Options 8-13, Connector Locations

Rear Side View (cover removed)

Output side Printer side CN415 CN424 (AC power) CN420 (Control connector plug)

Top View (top cover removed) Connectors/circuit boards shown with broken lines are concealed from view.

CN413 Front side CN419 Printer side CN414 CN407 CN408 8-14 Options June 1999, Connection Diagram for the 1400-Sheet Stacker

Connection Diagram for the 1400-Sheet Stacker

June 1999 Options 8-15 P419 J419 W-12 7 P408 P409 S-1 S-2 S-3 OULS OLLS OEPS S-4

OELS

1 P41 P41 1 J41 J41 M2 M3 M4 OEM OJRM OJFM

Output Control Board Logic

PCL board W2 J401 Output W5 interface Control Board P406 P40W7 J406 J405 P425 P426 J404 J402 J403 S-5 S-6 OJFS OJRS P404 P402 P403 W4 W6 P424 P41P417 + – W1 L 12V PH-1 AC Power N J41 J4 100 ~ 240V Supply M1

ERM

, Output Control Board Logic

Output Control Board Logic

The table below details specific stacker actions and which sensors supply the signals needed for each action. Signals from the printer are also included. Action Sensor Input Elevator up OULS (Wait signal to printer) OLLS

OELS

Elevator stop OULS

OLLS OELS

Remove prints OULS (signal to printer) OLLS

OELS

Elevator down OULS

OLLS OELS

paper exit EPS

OEPS

Paper exit jam (023) OEPS Jogging start From printer Jogging ERS (from printer)

OJRS OEPS OJFS

Jogging stop From printer 8-16 Options June 1999, Section 9

General Printer Maintenance

Section 8 General Printer Maintenance June 1999 General Printer Maintenance 9-1,

Contents General Printer Maintenance

Introduction ..9-3 Safety Precautions ..9-4 Tool Requirements: Service Kit..9-4 Tools/Supplies ..9-5 Printer/Maintenance Record ..9-5 Printer Maintenance Record ..9-6 Every-Call Cleaning Procedure ..9-7 Remove Major Consumable Supplies ..9-7 Inspect and Vacuum ..9-7 Clean Internal Areas ..9-7 Clean the Fuser ..9-7 Clean the Developer ..9-8 Clean the Cleaner/Charge Corona ..9-8 Clean the Photoconductor Area ..9-8 Clean the Transfer Corona ..9-8 Run Test Prints ..9-9 Adjusting Paper Feed Tension .9-10 Adjusting Registration ..9-11 Lubrication Procedure ..9-12 Front View Lubrication ..9-13 Front View Lubrication Table ..9-14 Rear View Lubrication ..9-15 Rear View Lubrication Table ..9-16 Top View Lubrication ..9-17 Duplex Holding Tray Lubrication ..9-18 Tune-Up Maintenance Procedure..9-19 9-2 General Printer Maintenance June 1999, Introduction

Section 9 General Printer Maintenance Introduction

This section describes the primary printer maintenance procedures to be completed during service calls. In addition, this introduction reviews safety precautions, tool requirements, and the printer maintenance record. Electrical Checks Step-by-step instructions for performing several of the checks needed to solve printer problems. Every-Call Cleaning Procedure The every-call cleaning procedure, as the name implies, is performed every time the printer is serviced. It includes a thorough cleaning of the printer, requiring the removal of all major components and performance of specific cleaning tasks related to each one. It also includes vacuuming all excess toner and other contamination from the interior of the printer. Paper Feed Tension Adjustment Procedure You may need to adjust the paper feed tension to correct jamming. Lubrication Procedures Lubrication procedures are performed whenever needed, though lubrication should be applied sparingly. The required lubricants, including oil, molycote, red grease, and non- silicon white grease can be purchased from the printer’s manufacturer. Tune-Up Procedure The tune-up maintenance procedure is performed when the printer has yielded sub-stan- dard prints after you’ve completed standard maintenance procedures, or has printed one- to two-million images. A tune-up maintenance kit is required for this procedure. June 1999 General Printer Maintenance 9-3, Introduction

Safety Precautions

Whenever servicing sophisticated electronic/electro-mechanical equipment, common sense, training, caution and experience help in avoiding accidents and mishaps. Be aware of the following safety precautions: • Follow all instructions in this document. • Follow all warnings and instructions marked on the printer. • Unplug the printer when performing any removal, replacement or cleaning procedure. • Ensure that the power source for the printer matches the power specification label located above the power outlet on the back of the printer. • Keep combustible materials away from the printer. • Provide adequate ventilation for the printer so that slots and openings in the cabinet sides are not blocked. • Do not push objects of any kind through the cabinet slots. They may contact danger- ous voltage points or other hazards. • Do not expose the printer to liquids of any kind. • Protect the power cord. Do not place it in a traffic pattern or allow anything to rest on it.

Tool Requirements: Service Kit

A service kit intended for use solely by the service technician is shipped inside the right side cover of the printer. This kit includes: • Interlock by-pass tools (2) • RS-232C loop back assembly • RS-422 loop back assembly • Multimeter jumpers (2) • Charger cleaner brush 9-4 General Printer Maintenance June 1999, Introduction

Tools/Supplies

To service the printer properly, you will also need to carry the following: • Soft cleaning cloth • Cotton swabs • Charger cleaner • Basic set of hand tools suitable for office automation equipment repair • Service vacuum cleaner, properly grounded and equipped with a 10 micron filter End User Cleaning Kit Printers are shipped with an end-user cleaning kit taped inside the front cover. The clean- ing kit consists of: • Cotton swabs • Charger cleaner brush This kit is intended for use by the end user.

Printer/Maintenance Record

A maintenance record must be kept for every printer. During the initial service call or at the time of installation, set up a maintenance record for the customer. A copy of the form, illustrated on the following page, should be in a plastic bag taped inside the front cover so that the maintenance form is always easily accessible. June 1999 General Printer Maintenance 9-5, Printer Maintenance Record

Printer Maintenance Record

Completed by user Completed by HP: Page HP notified Down Operator HP CE on site Date Time Counter Date/Time time Malfunction Description Action Required and Comments Malfunction Description Action Required and Comments Malfunction Description Action Required and Comments 9-6 General Printer Maintenance June 1999, Every-Call Cleaning Procedure

Every-Call Cleaning Procedure

Perform the every-call cleaning procedure every time the printer is serviced. When trou- bleshooting a printer problem, you may be directed to complete this procedure as you iso- late or correct the problem. If the procedure is not specifically called out, always complete it before concluding the service call. The every-call cleaning procedure begins by removing the major consumable supplies from the printer. When the supplies are out, use a toner vacuum to vacuum the printer thor- oughly. Clean each consumable supply, following the instructions listed in this section, before returning it to the printer. Conclude the every-call procedure by running test prints to confirm the print quality. The location of all major printer supplies and instructions for their removal are outlined later in this manual. Remove Major Consumable Supplies • Photoconductor; place it in its protective packaging. • Cleaner • Developer • Fuser Inspect and Vacuum • Inspect the areas in the printer around the developer, cleaner, photoconductor, and fuser for damage and wear. • Vacuum these areas to remove all excess toner, contamination, and/or foreign objects. Clean Internal Areas • Clean the erase lamp with a cotton swab. • Clean the printhead bias plates with a soft cloth. • Clean the LED lens with a cotton swab, making sure no lint remains on the lens. Clean the Fuser

Caution! The fuser may be hot.

• Inspect the fuser for damage and contamination; repair or replace as necessary. • Clean the fuser connector, both on the fuser and in the printer, with a cotton swab. • Vacuum in and around the rollers to remove excess toner, contamination, and any for- eign objects. • Reinstall the fuser. June 1999 General Printer Maintenance 9-7, Every-Call Cleaning Procedure Clean the Developer • Inspect the developer for damage or contamination; repair or replace as necessary. • Clean any excess toner from the developer with a soft cloth. • Clean the toner patch sensor lens with a soft cloth, making sure no lint remains on the lens. • Vacuum the felt areas around the magnetic roller, being careful not to vacuum toner from the magnetic roller. • Reinstall the developer. Clean the Cleaner/Charge Corona

Caution! Handle gently, to avoid breaking the charger wire.

• Inspect the cleaner/charge corona for damage or contamination; repair or replace as necessary. • Remove the charge corona from the cleaner. • Clean the grid with the cleaner brush. • Remove the grid to expose the charger wire. • Clean the charger wire with a cotton swab. • Reinstall the grid. • Clean any excess toner from the cleaner with a soft cloth. • Reinstall the charge corona in the cleaner. • Reinstall the cleaner. Clean the Photoconductor Area

Caution! Do not touch the photoconductor belt, as this permanently damages the

photoconductor. • Clean the photoconductor seam sensor inside the printer. • Remove the photoconductor from its protective packaging. • Inspect the photoconductor for damage or contamination; repair or replace as necessary. • Reinstall the photoconductor. Clean the Transfer Corona

Caution! Handle gently, to avoid breaking the charger wire.

• Remove the transfer corona. • Clean the transfer corona housing with a soft cloth. • Clean the transfer corona wire with a cotton swab. • Reinstall the transfer corona. 9-8 General Printer Maintenance June 1999, Every-Call Cleaning Procedure Run Test Prints • Run test prints to verify print quality. June 1999 General Printer Maintenance 9-9, Adjusting Paper Feed Tension

Adjusting Paper Feed Tension

Pressure tension levers can be found inside the front cover, as illustrated below: Paper feed tension levers To adjust the tension: 1 Open the printer’s front cover. 2 Identify the cassette whose tension is to be adjusted, and select the correct lever. 3 Adjust the tension: • To correct multiple feeds: move the lever toward the minus sign, decreasing the feed pressure. • To ease paper feeds: move the lever toward the plus sign, increasing the feed pressure. 4 Close the front cover, then print paper from the cassette you are adjusting. 5 If the paper is still not feeding properly, repeat Steps 3 and 4 until the feed is properly adjusted. 9-10 General Printer Maintenance June 1999, Adjusting Registration

Adjusting Registration

Registration controls the vertical placement of the printed image on the physical page. Obtain a test print produced by the C40D printer. Note the 20 line registration indicator at the top of the page. Registration is correct when the twentieth line of the indicator is at the leading edge of the print (plus or minus 2).

This procedure uses a large amount of paper.

To display the registration menu, select the registration option from the main menu (labeled menu) by using the fand e keys to move the asterisk to it, then press the e key to confirm it. You will see the following menu:

REGISTRATION

* RELATIVE ALIGNMENT ABSOLUTE ALIGNMENT Relative alignment aligns duplex images with relationship to each other. So when you change the alignment, one image will shift up on the page, while the other image shifts down. Absolute alignment moves both images in the same direction. In this case, when you change the alignment, both images on the page shift either up or down together. They stay the same with relationship to each other, but their position on the physical paper changes. Use the following guidelines when you are checking or changing the registration, no mat- ter which type of alignment you are using: 1 When you select either one of the options on the Registration menu, the printer will immediately begin printing test pages. Wait for about 10-15 pages, then look at an image. 2 To shift the image up, press the gkey. To shift the image down, press the hkey. Wait for about 15 more pages, then review the image to see if it has shifted enough. 3 Continue this until you are satisfied with the result. 4 Press the e key. The printer will complete printing the pages left in the buffer. June 1999 General Printer Maintenance 9-11, Lubrication Procedure

Lubrication Procedure

Complete the lubrication procedure as-needed. Apply lubrication sparingly. Insufficient lubrication may result in unnecessary noise and premature wear of components; excessive lubrication may contaminate printer supplies and make the printer difficult to keep clean. The following printer illustrations indicate where lubrication may be required. Charts fol- lowing the illustrations include symbols that indicate the type of lubricant to use on each component: H Oil P Molycote L Red grease R White grease For part numbers, refer to the “Additional Parts List” in the Illustrated Parts Catalog. 9-12 General Printer Maintenance June 1999, Lubrication Procedure

Front View Lubrication

June 1999 General Printer Maintenance 9-13, Lubrication Procedure

Front View Lubrication Table

Symbol Part LubricantH1Front roller bearings (paper feed, paper Oil pickup, timing and exit rollers) H 2 Vacuum transport drive shaft OilH3Fuser drive bearing OilH4Upper paper guide roller OilL5Fuser drive gear Red greaseL6Vacuum transport drive gear Red greaseL7Vacuum transport gear Red greaseP8Vacuum transport rollers MolycoteH9Duplex roller bearings Oil P 10 Lower duplex drive assembly Molycote 9-14 General Printer Maintenance June 1999, Lubrication Procedure

Rear View Lubrication

June 1999 General Printer Maintenance 9-15, Lubrication Procedure

Rear View Lubrication Table

Symbol Part LubricantH1Clutch shafts: upper pick-up roller, lower pick-up roller, Oil upper feed roller, lower feed roller, paper timing rollerP2Upper and lower pick-up roller drive assemblies MolycoteP3Main drive gear assembly MolycoteP4Main drive gear MolycoteP5Main drive motor gear MolycoteR6Fuser drive gear White GreaseP7Fuser drive assembly MolycoteH8Clutch shaft bearing OilR9Lower duplex drive assembly White Grease P 10 Upper duplex drive assembly Molycote P 11 A roller drive gears Molycote P 12 B roller drive gears Molycote P 13 C roller drive gears Molycote R 14 Main Drive Assembly White Grease R 15 Idler White Grease 9-16 General Printer Maintenance June 1999, Lubrication Procedure

Top View Lubrication

Symbol Part LubricantH1Duplex pinch rollers Oil June 1999 General Printer Maintenance 9-17, Lubrication Procedure

Duplex Holding Tray Lubrication

Symbol Part LubricantP1Drive gears MolycoteL2Tray shaft Red grease 9-18 General Printer Maintenance June 1999, Tune-Up Maintenance Procedure

Tune-Up Maintenance Procedure

The tune-up maintenance procedure should be performed when the printer: jams fre- quently; yields sub-standard print quality even after completing regular maintenance pro- cedures; and has printed more than one- or two-million prints. At this point in the life of the printer, the roller assemblies, transfer corona, and static brushes must be replaced. All of the required components are packaged together in a Tune-Up Maintenance Kit. 1 For detailed instructions on how to replace each of these components, refer to Section 7, Removal/Replacement Procedures. General guidelines follow for unpacking the component, along with an outline of the order in which the components should be replaced. 2 Unpack the maintenance kit, which is shipped in a folded cardboard pack. Remove the shipping carton and unfold the cardboard pack. 3 Make sure that you have received all of these replacement components, shown in the following illustration: • Roller assembly, lower feed • Roller assembly, upper feed • Roller assembly, paper timing • Roller assembly, exit • Roller assembly, upper paper guide • Transfer corona • Roller assembly, upper pick up • Roller assembly, lower pick up • Static brush, upper (in cardboard folder) • Static brush, lower (in cardboard folder) • Label (taped to the top of the package) • Duplex Drive Assembly (Not shown) June 1999 General Printer Maintenance 9-19, Tune-Up Maintenance Procedure Tune-Up Kit Components 4 Unplug the printer. 5 Open the top cover. 6 Remove the photoconductor and place it in its protective packaging in a safe place away from the work area. 7 Replace the component assemblies in this order: • Paper timing roller • Exit roller • Upper pick up roller • Lower pick up roller • Upper feed roller • Lower feed roller • Transfer corona • Lower static brush • Upper static brush • Upper paper guide roller • Duplex Drive Assembly 9-20 General Printer Maintenance June 1999, Tune-Up Maintenance Procedure 8 Perform the every-call cleaning procedure outlined on page 9-7. 9 Plug in the printer and turn it on. 10 Run test prints to ensure that the paper feeds correctly through the printer. 11 Fill in the label with the date and meter count. Affix it inside the front cover next to the printer’s serial number. June 1999 General Printer Maintenance 9-21, Tune-Up Maintenance Procedure 9-22 General Printer Maintenance June 1999,

Index

Symbols bit-map RAM “A” roller error codes 2-10 removal 7-93 “B” roller C removal 7-94 carrier beads 1-4 “C” roller cassette paper present sensor removal 7-96 locations 1-8 “C” roller solenoid cassette present micro switch removal 7-97 locations 1-8 Centronics parallel interface 6-32 Numerics special considerations 6-32 1200/2500-sheet feeder 8-4 charge corona bench test 8-5 diagnostic test 5-9 component acronyms 8-4 TAG 3-49, 3-52 component locations 8-4 cleaner drive connection diagram 8-8 removal 7-52 input control board logic 8-9 cleaner drive belt prefeed adjustment 8-7 removal 7-51 1400-sheet stacker cleaning bench test 8-11 every-call procedure 9-7 component abbreviations 8-10 communications malfunctions component locations 8-10 TAG 3-128 connection diagram 8-15 connector index 6-4 connector locations 8-13 connector locations 6-11 output control board logic 8-15, 8-16 connectors back cover 6-17 A duplex cover 6-14 AC power supply front cover 6-12 removal 7-24 left cover 6-13 acronyms and abbreviations 1-3, 6-9 right cover 6-15 automatic toner control 1-10 top cover 6-16 continuity checks 1-17 B controls back cover automatic toner 1-10 removal 7-6 cooling fan back cover interlock switch removal 7-21 removal 7-76 counter Index-1, diagnostic test 5-7 removal 7-92 removal 7-13 duplex route separator TAG 3-125 removal 7-98 cross references duplex sensors error code to TAG 2-4 diagnostic tests 5-12 mechanical malfunction to TAG 2-14 duplex skew correction cable print quality to TAG 2-12 removal 7-89 duplex tray paper-guide motor D diagnostic test 5-13 DC power supply duplex tray registration motor removal 7-26 removal 7-88 DCE host interface 6-29 de-toning 1-12 E developed image, producing 1-18 electrophotography 1-3 developer end-user cleaning kit 9-5 TAG 3-55 EP cover developer bias removal 7-79 TAG 3-36 erase lamp developer unit diagnostic test 5-10 TAG 3-45 removal 7-78 diagnostic tests TAG 3-58 see Section 5, Diagnostic Tests error code/TAG cross reference 2-4 disk drive error codes diagnostic test 5-18 bit-map RAM 2-10 error codes 2-8 defined 1-20–1-33 TAG 3-90 disk drive 2-8 disk formatting 5-17 host communication 2-11 DTE host interface 6-29 printer 2-4 duplex clutch RIGS board 2-5 diagnostic tests 5-13 VPCL board 2-5, 2-6 duplex control board error log removal 7-86, 7-87 clearing 1-19, 3-9, 5-18 duplex cover interlock switch reading 1-13 location 1-9 exit assembly duplex motor removal 7-63 diagnostic tests 5-11 exit cover duplex paper path sensor removal 7-71 location 1-9 exit pinch roller removal 7-99 removal 7-65 duplex registration sensor exit roller assembly location 1-8 removal 7-69 duplex route motor/solenoid assembly Index-2, F host communication fan error codes 2-11 see cooling fan host interface Flex IO card reference 6-28 TAG 3-131 host system format disk 5-17 troubleshooting 1-12 front cover removal 7-5 I front cover interlock switch image removal 7-75 producing developed 1-18 front interlock switch imaging system 1-3 location 1-11 interfaces function code Centronics parallel 6-32 version number 5-17 IBM parallel 6-33 fuser IBM PC/AT 6-31 TAG 3-26, 3-66 IBM PC/XT 6-30 fuser drive Macintosh 6-31 removal 7-54 RS-232C 6-28 fuser drive belt interlock removal 7-53 by-pass tool 1-17 fuser thermistor TAG 3-171 TAG 3-65 fusing problems L TAG 3-166 LED array technology 1-3 LED printhead G diagnostic test 5-15 ground system 6-27 left side cover removal 7-7 H line power 1-14 hard disk drive housing loopback connector removal 7-19 diagnostic test 5-16 HCI lower cassette see 1200/2500-sheet feeder diagnostic test 5-5 HCO TAG 3-12, 3-17, 3-22, 3-121 see 1400-sheet stacker lower cassette mount high voltage power supply removal 7-40 removal 7-27 lower feed roller high-capacity input unit removal 7-58 diagnostic test 5-14 lower paper guide high-capacity output unit removal 7-48 diagnostic test 5-14 lower pick-up roller Index-3, removal 7-62 removal 7-55 lower static brush paper feed tension removal 7-68 adjusting 9-10 lubrication paper full sensor procedure 9-12 location 1-10 lubrication points removal 7-74 duplex holding tray 9-18 paper jams front view 9-13 fuser area 3-26 rear view 9-15 lower cassette 3-22 top view 9-17 output area 3-30 transfer area 3-26 M upper cassette 3-19 main drive motor paper path 1-5 TAG 3-127 illustrated 1-6 main gear drive paper problems removal 7-85 damaged 3-123 main motor input area 3-32 removal 7-82 multiple feeds 3-122 maintenance output area 3-34 every-call cleaning procedure 9-7 paper size lubrication procedure 9-12 TAG 3-117 paper feed tension 9-10 paper size sensor mechanical malfunction locations 1-9 TAG cross reference 2-14 removal 7-34 paper timing guide N removal 7-49 negative developer bias paper timing roller diagnostic test 5-11 removal 7-56 paper timing sensor O location 1-9 operator panel PC life data diagnostic test 5-4 TAG 3-54 removal 7-12 photoconductor TAG 3-112 cautions 7-4 output tray removal 7-4 TAG 3-115 photoconductor rear guide rail P removal 7-30photoconductor seam sensor paper exit sensor diagnostic test 5-8 location 1-10 location 1-10 removal 7-73 removal 7-28 paper feed drive belt Index-4, TAG 3-46 TAG cross reference 2-12 pick-up roller drive gear printer removal 7-61 error codes 2-4 pick-up roller drive idler printer maintenance removal 7-60 logs 9-6 power control board safety precautions 9-4 removal 7-33 supplies 9-5 power problems tools 9-4 +12 Vdc 3-68 printhead +24 Vdc 3-80 TAG 3-170 +5 Vdc 3-100 printhead assembly -12 Vdc 3-78 removal 7-16 ac input 3-105 printhead circuit board TAG 3-68, 3-78, 3-80, 3-100, 3-105 removal 7-18 power-on-reset 1-17 settings 6-3 print problems printing process 1-3 background 4-21 problem resolution black print 4-13 TAG 3-7 blank print 4-6 protocol converters 1-13 blank vertical bands 4-11 blurring 4-19 R dark areas 4-14 rear duplex cover dark lines 4-14 removal 7-10 dark print 4-13 rear interlock switch dark specks 4-14 location 1-9 dark vertical lines 4-15 right side cover density variations 4-20 removal 7-8 light horizontal bands 4-12 RIGS board light print 4-7, 4-8 diagnostic test 5-16 light vertical streaks 4-10 error codes 2-5 misregistration 4-17 removal 7-14 overtoned print 4-18 RIGS controller residual images 4-22 overview 1-3 skewed prints 4-16 TAG 3-95, 3-97, 3-99 toner fusing 4-24 roller clutch voids 4-9 diagnostic test 5-7 washout 4-5 RS-232C interface 6-28 white spots 4-9 wrinkled sheets 4-23 S print quality safety precautions 9-4 samples, see Section 4 self-diagnostic mode 5-3 Index-5, sensors toner patch diagnostic tests 5-6 producing 1-18 duplex paper path 1-9 TAG 3-39, 3-41 duplex registration 1-8 toner path sensor locations 1-8 location 1-9 lower cassette paper present 1-8 top cover interlock switch lower paper size 1-9 removal 7-77 paper exit 1-10 top interlock switch paper full 1-10 location 1-10 paper timing 1-9 transfer area photoconductor seam 1-10 TAG 3-26 toner empty 1-10 transfer corona toner patch 1-9 diagnostic test 5-9 upper cassette paper present 1-8 TAG 3-49, 3-56 upper paper size 1-9 troubleshooting service call, completing 1-19 general tips 1-12 service kit 9-4 overview 1-11 switches TAG 3-5 bypassing interlock 1-17 tune-up duplex cover interlock 1-9 maintenance procedure 9-19 front interlock 1-11 tune-up kit locations 1-8 components 9-20 lower cassette present 1-8 rear interlock 1-9 U top interlock 1-10 upper cassette upper cassette present 1-8 diagnostic test 5-4 TAG 3-10, 3-14, 3-19, 3-120 T upper cassette mount TAGs removal 7-35 sample 1-15 upper duplex drive/clutch assembly using 1-15 removal 7-91 test prints upper feed roller running 1-12, 3-8 removal 7-57 toner upper paper guide automatic control 1-10 assembly 3-124 TAG 3-43 removal 7-45 toner empty sensor upper pick-up roller location 1-10 removal 7-59 toner motor upper static brush diagnostic test 5-8 removal 7-67 removal 7-22 Index-6,

V

vacuum transport unit removal 7-9 voltage isolation diagrams 6-22–6-26 VPCL board error codes 2-5, 2-6 overview 1-3 removal 7-15 TAG 3-89, 3-97 Index-7]

15