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Diagnostic Information, Diagnostic/Maintenance Approach

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5045-001 2. Diagnostic Information Diagnostic/Maintenance Approach This printer can be serviced without being connected to a host computer. This printer will display both operator correctable errors and service errors on the front (operator) panel. In addition, there are tests available from the density adjustment panel on the back of the machine that bypass the video controller board. These basic engine function tests to enable you to eliminate potential software problems. These tests are covered in Chapter 3, "Diagnostic Aids". Using the diagnostic information in this manual leads you to the correct field replaceable unit (FRU), or part. Before replacing an entire FRU, determine if just the defective part is available in the parts section, Chapter 7. Always replace the smallest possible part. Use the error code charts, symptom index, service checks and the diagnostic aids chapter to determine the symptom and repair the failure. After you complete the repair, perform the appropriate tests to verify the repair. DO NOT swap parts as a diagnostic technique. Certain parts work as a system and unnecessary swapping of these parts may lead to print quality. Diagnostic Information 2-1

Section	Page
1. General Information	27
Power Consumption	27
Options	27
Maintenance Approach	28
Tools	31
Abbreviations	32
2. Diagnostic Information	33
Diagnostic/Maintenance Approach	33
Start	36
Operator Codes	37
Power-On Self Test (POST)	40
Error Message Table	42
Symptom Table	44
Service Checks	46
Error (46) Toner Cartridge Not Installed Correctly	46
Error (111/112) Fuser, Warm-Up/Temperature Low	47
Error (113) Fuser Temperature High	48
Error (114) Fuser Failure	48
Error (115) Fuser Heater Off	49
Error (116) Fuser Unit Missing	49
Error (117) Fuser Pump Failure	50
Error (121/125) Laser Board Failure	52
Error (122) Laser Failure	52
Error (123/124) Mirror Motor Start-up or Rotation	53
Error (126/131) Transfer Drum Motor Failure	54
Error (130) Service Motor Error	54
Error (132/133) Main Motor (M2) Start-Up or Rotation	55
Error (134) Controller Fan Motor Failure	55
Error (135) Fuser Unit Fan Motor Failure	56
Error (136) Electrical Unit Fan Motor Failure	56
Error (141) Power Supply Failure (LVPS 110V or 220V)	57
Error (142) Engine Board Memory Failure	57
Error (143) 5 V / 24 V Supply Failure	58
Error (144) Temperature/Humidity Sensor Failure	58
Error (145) Density Sensor Failure	58
Error (146) Printer Communication Failure	59
Error (147) Engine Board IC Failure	59
Error (148) Developer Unit Rotation Failure	60
Error (149) Developer Unit Pressure Failure	61
Error (152) Tray 2 Power Failure	61
No AC Power/Dead Machine	62
No DC Power	63
No Pickup (Manual Feed)	63
No Pickup (Cassette Feed)	64
No Pickup (Optional Paper Feeder Pickup)	64
Registration Roller Does Not Rotate	65
High-Voltage Power Supply Output	65
Pickup / Feed System Theory	66
Paper Feed Troubleshooting	70
Pickup Unit	70
Transfer Drum Unit	72
Fuser/Delivery Unit	73
Fuser	74
Multi-Feed	75
Wrinkles	76
Leading-Edge Fold	76
Skewing	77
Error Codes - 9XX	78
Error (900) Software Error	78
Error (941) Service ROM SIMM	78
Error (939, 942, 943, 944) Service RIP Board	78
Error (945) Service RIP Board	78
Error (946) Service RIP Board	79
Error (947) Service RIP Board	79
Error (948) Service RIP Board	79
Error (949) Service RIP Board	79
Error (950) Service RIP Board	80
Error (953) Service RIP Board	80
Error (955) Service Video RAM Error	80
Error (956) Service L2 Cache Error	80
Error (960) Service Memory Error	80
Error (961) Bad / Missing DRAM	81
Error (970/979) INI Failure	81
Error (977) Service Network Board	81
Print Quality	82
Print Quality Start Of Call	82
Horizontal Variation (“Jitter”) Example	84
Print Quality Troubleshooting	86
Background	86
Black Horizontal Lines	86
Black Vertical Lines	87
Blur at Bottom of Page	87
Laser Failures	88
Low Color Coverage or Usage	88
Oil Soaking	89
Random Oil Spots on Page	90
Spew	90
Vertical Streaks	91
Print Quality Service Checks	93
Black Service Check	93
Blank Page Service Check	94
Blank Spots Service Check	95
Color Aberration Service Check	95
Dark Image Service Check	96
Dirt On Back Of Paper Service Check	97
Dirty Print Service Check	98
Distortion Service Check	99
Horizontal Voids Service Check	99
Light Image Service Check	100
Poor Fusing Service Check	101
Spacing Table Service Check	101
Streaking Service Check	102
Toner Scattered Service Check	103
Vertical Lines Service Check	104
Vertical Voids Service Check	105
3. Diagnostic Aids	106
Basic Engine Test	106
Diagnostics Mode	107
Diagnostics Mode Menu Structure	108
Diagnostics Mode Tests	109
Button Test	109
Compressor	109
Defaults	110
Disk Test/Clean	110
Error Log	111
Flash Test	111
LCD Test	112
Memory Tests	112
Page Count	112
Permanent Page Count	113
Print Test 1	113
Print Test 2	114
Print Test 3	114
Quick Disk Test	115
Wrap Tests	116
Other Tests	117
Density Adjustment Panel	117
LAN Information	126
4. Repair Information	127
Handling ESD-Sensitive Parts	127
Adjustments	128
Service Information	128
Releasing Plastic Latches	128
Screws	128
Removal Procedures	129
Attraction Roller Drive Assembly	129
Cassette Paper Pickup Drive Motor	130
Registration Roller Drive Clutch	130
Cassette Paper Pickup PCB	131
Cassette Paper Pickup Assembly	131
Cassette Paper Pickup D-rollers	132
Cassette Paper Pickup Roller Assembly, Front	132
Cassette Paper Pickup Roller Assembly, Rear	132
Cassette Paper Pickup Solenoid	133
Corona Assembly	133
Cover Removals	134
DC Controller PCB	140
Density Adjustment Panel	149
Density Sensor	149
Developing Rotary Assembly	150
Discharge Roller Drive Assembly	151
Drive Gear Solenoid Assembly	152
Drum Cleaner Assembly	153
Drum Lift Assembly	154
Fuser Assembly	155
Fuser Oil Bottle Case Assembly	156
Fuser Hot Rollers	157
Fuser Thermo Switch	158
Fuser Cleaner Assembly	159
Fuser Oil Apply Assembly	160
Fuser Thermistor	161
Fuser Lamps	163
Fuser Oil Applying Input Assembly	165
Fuser Delivery Assembly	165
High Voltage Power Supply	166
High Voltage Converter	166
Low Voltage Power Supply	167
Main Drive Motor and Board	167
Mechanical Controller PCB	168
Multipurpose Feeder Paper Pickup, D-Roller	168
Multipurpose Feeder Paper Sensor	168
Multipurpose Feeder U-Turn Roller Assembly	169
Multipurpose Feeder D-Roller Solenoid	169
Paper Delivery Assembly	170
Printhead and Printhead Board	171
Printer Drive Assembly	174
Rotary Manual Feed Assembly	175
Rear Cooling Fan	175
Rear Cooling Duct	176
Transfer Drum Motor and Developer Drive Motor	176
Transfer Drum and Holder Assembly	177
Transfer Drum Separation Claw	178
Transfer Drum Knob Assembly	178
Transfer Drum Attraction Roller	179
Transfer Drum Sheet	180
Transfer Drum Front and Rear Slide Assemblies	181
Transfer Drum Discharge Roller	181
Transfer Drum HV Contact Assembly	181
Transfer Drum Gripper Assembly	182
Transfer Drum Solenoid	183
Transfer Drum Sensors	184
Transfer Drum Assembly	185
Transfer Drum Cleaning Drive Assembly	187
Toner Cartridge Ejector	188
Upper Cooling Fan	189
Upper Output Drive Assembly	189
Video Controller Board	189
Optional Paper Feeder Removals	190
5. Locations	195
Switches	196
Sensors	198
Clutches and Solenoids	201
Motors and Fuser Heaters	203
PCBs	205
Connector Locations	208
DC Controller Board Connector Locations	211
DC Controller Board Connector Locations (Graphic)	212
Mechanical Controller Board Connector Locations	218
Mechanical Controller Board Connectors (Graphic)	219
Paper Pickup Board	224
Terminal Board	226
Optional Paper Feeder (Driver Board)	227
Optional Paper Feeder (Miscellaneous)	228
High Voltage Power Supply PCB	228
Separation HVT PCB	229
Ejection Sensing PCB	229
Cassette Size Sensing PCB	229
Paper Feed Driver PCB	230
Fuser Connector (J21)	231
6. Preventive Maintenance	232
Safety Inspection Guide	232
Lubrication Specifications	233
Lubricants and Cleaners	233
Maintenance, Customer Checks	234
7. Parts Catalog	235
How To Use This Parts Catalog	235
Assembly 1: Covers	236
Assembly 2: Major Components	238
Assembly 3: Toner (used) Reservoir/ HV	240
Assembly 4: Major Assemblies (Top/Bottom)	242
Assembly 5: DC Controller / Video Controller Board	244
Assembly 6: Laser	246
Assembly 7: Drive, Main	248
Assembly 8: Density Adjustment Panel	250
Assembly 9: Bottom Plate	252
Assembly 10: Door Switch, Upper	254
Assembly 11: Door Switch, Lower	256
Assembly 12: Ejector Lever	258
Assembly 13: Solenoid Plate	260
Assembly 14: Cleaning Belt Drive Solenoid	262
Assembly 15: Rotary Manual Feed	264
Assembly 16: Printer Drive	266
Assembly 17: Transfer Drum Cleaning Drive	268
Assembly 18: Discharge Roller Drive	270
Assembly 19: Drum Lift	272
Assembly 20: Attraction Roller Drive	274
Assembly 21: Paper Drive	276
Assembly 22: Universal Cassette	278
Assembly 23: Paper Pickup	280
Assembly 24: Cassette Paper Pickup Asm	282
Assembly 25: Multipurpose Feeder Pickup Asm	286
Assembly 26: Paper, Side Exit Asm	288
Assembly 27: Developing Rotary Asm	290
Assembly 28: Transfer Drum Mounting Asm	292
Assembly 29: Transfer Drum	294
Assembly 30: Density Sensor Asm	298
Assembly 31: Transfer Drum Cleaning	300
Assembly 32: Fuser	302
Assembly 33: Video Controller Board	306
Assembly 34: Optional Paper Feeder (Main Body)	308
Assembly 35: Optional Paper Feeder (Front)	310
Assembly 36: Paper Pickup Asm (Base)	314
Assembly 37: Paper Pickup Asm (Rear)	316
Assembly 38: Options	318
Wiring Diagram	320
Index	321
A	321
B	321
C	321
D	321
E	321
F	322
H	322
L	322
M	322
N	322
O	322
P	323
Q	323
R	324
S	325
T	326
U	326
V	326