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IBM 28P1938 User Guide - Page 309

Scheduled Maintenance, 28P2625 - 115V 875W Models 4540

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IBM Infoprint 1130/1140 Scheduled Maintenance The operator panel displays the message "80 Scheduled Maintenance" at each 300K page count interval. It is necessary to replace the fuser assembly, transfer roller and charge roll at this interval to maintain the print quality and reliability of the printer. The parts are available as a maintenance kit with the following part numbers: 28P2012 - 115V 875W Models 4530 28P2013 - 220V 875W Models 4530 28P2625 - 115V 875W Models 4540 28P2626 - 220V 875W Models 4540 After replacing the kit, the maintenance count must be reset to zero to clear the "80 Scheduled Maintenance" message. Refer to "Maintenance Page Count" on page 3-31. 6-2 Service Manual

Section	Page
Go Back	2
Laser Notices	8
Safety Information	18
Preface	23
1. General Information	24
Options	25
Maintenance Approach	26
Tools Required for Service	26
Acronyms	27
2. Diagnostic Information	28
Start	28
Service Error Codes	29
Sub Error Codes for 9XX and 2XX Error Codes	35
Base Printer Sub Error Codes	37
Envelope Feeder Sub Error Codes	46
Stacker Sub Error Codes	48
Duplex Unit Sub Error Codes	49
StapleSmart Finisher Option Sub Error Codes	49
User Status Screens	51
User Attendance Messages	56
User Line 2 Messages	64
User Line 2 Link Messages	65
Check Device Connection Messages	66
Power-On Self Test (POST)	68
Symptom Tables	69
Symptom Table - Base Printer	69
Symptom Table - High-Capacity Feeder Option (2000 Sheet)	70
Symptom Table: Paper Tray Options	71
Symptom Table - Duplex Option	71
Symptom Table - Envelope Feeder Option	71
Symptom Table - Output Expander	72
Symptom Table - StapleSmart Finisher	72
Service Checks	73
Charge Roll Service Check	74
Cover Open Switch/Cable Service Check	76
Dead Machine Service Check	77
Duplex Option Service Check	80
The printer does not recognize the Duplex Option is attached. The printer does not recognize tray...	80
POST fails, 230 Paper Jam, Check Duplex message displays.	81
230 Paper Jam - Check Duplex message displays. The page is not duplexed and only exits half way o...	82
Envelope Feeder Option Service Check	83
Operator panel displays 260 Paper Jam immediately when envelope feed is requested - POST incomplete.	85
Operator panel displays 260 Paper Jam after attempted feed but before envelopes are put in the ho...	86
990 Service Error, envelopes fail to feed from the hopper.	87
260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper. Kick rolls AR...	87
260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper. Kick rolls AR...	88
260 Paper Jam displays, envelope stops in feeder paper path.	89
Envelope Feeder multifeeds or may not display a 260 Paper Jam message.	89
260 Paper Jam displays an envelope stopped in the paper path of the feeder and an envelope also s...	89
Fan Service Check	90
Printhead Fan Service Check	90
Fan does not run or is noisy.	90
Main Fan Service Check	90
Cartridge Fan Service Check	91
Cold Fuser Service Check	92
Hot Fuser Service Check	94
Fuser Solenoid Service Check	95
Input Sensor Service Check	95
Input Tray(s) Option Service Check	96
250 Sheet and 500 Sheet Trays	96
24X Paper Jam message displays, paper jammed over the Pass Thru Sensor. (The printer displays the...	97
Tray X Low message displays when Tray X is full or has adequate paper in the tray.	98
Tray X Empty message displays when Tray X has paper in the tray.	98
Printer does not recognize Tray X is installed.	99
Paper from Tray X does not reach the Pass Thru Sensor.	99
High-Capacity Feeder Input Tray Service Check	99
The base printer indicates a dead machine condition when the high capacity input tray is installed.	100
The base printer does not recognize that the high-capacity input tray is installed.	101
24X Paper Jam message displays, paper jammed over the Pass Thru Sensor. (X=The printer displays t...	103
Tray X Paper Low Message displays when Tray X is full or has adequate paper in the tray.	104
Tray X empty message displays when there is paper in the high capacity feeder input tray.	104
The elevator tray fails to stop at the correct position and continues to drive into the bottom fr...	105
The elevator tray down button does not operate. The tray moves to the upper position.	105
Paper from the high capacity feeder input tray does not reach the pass thru sensor.	106
The elevator tray does not move up or down. The printer recognizes that the option is installed.	107
The elevator moves in one direction only.	108
Paper size switch not selecting paper size that is selected.	109
24X Paper Jam Check Tray X Message displays when Tray X is empty. No Tray X Message displays.	109
Tray X Empty message displays. Tray does not respond to loading paper. No response from the front...	110
Tray X Paper Low Message displays when the high capacity feeder input tray is full or has adequat...	110
Excessive Noise or Vibration	111
Main Drive Service Check	112
Operator Panel Service Check	113
Operator Panel Buttons Service Check	113
Operator Panel Display Service Check	114
Options Service Check	115
Flash Memory Option(s)	115
DRAM Memory Option(s)	115
Hard Disk Option	116
Network Card Option	116
Error Code 976 - Network Card X (X=Network card 1, 2, or 3)	116
Error Code 977 - Network Card X	116
Output Bin Sensor Standard Tray Service Check	117
Output Expander Service Check	118
Problems with excessive static electricity buildup.	118
Printer does not recognize one or more output expander options as being installed.	118
202 Paper Jam Open Rear Door Message displays. A sheet of paper is jammed prior to the pass thru ...	120
Remove Paper - Output Bin X is displayed, POST incomplete, unable to clear the message.	121
271 Paper Jam - Check Bin X, POST incomplete	121
271 Paper Jam - Check Bin X, POST complete, first sheet of paper feeds into Output Bin X.	121
990 Service - BIN X	122
No indication that Bin X is full OR No indication that Bin X is near full	123
High-Capacity Output Stacker Service Check	123
Problems with excessive static electricity buildup.	124
The printer does not recognize one or more output options as installed.	124
202 Paper Jam Open Rear Door Message displays and a sheet of paper is jammed prior to the pass th...	125
Remove Paper - Output Bin X Full displays. You may not be able to clear the message.	126
271 Paper Jam - Check Bin X, POST incomplete.	126
5-Bin Mailbox Service Check	126
Problems with excessive static electricity buildup.	127
The printer does not recognize one or more output options as installed.	127
271 Paper Jam - Check Bin 1 displays	128
274 Paper Jam - Check Bin 4 displays	128
Ready Bin X Full message displays - May be able to clear message and will feed paper into Bin sel...	129
Bin X is full - No message that Bin X is full displays.	129
Ready - Bin X Full displays and paper feeds into Bin X.	129
Paper does not feed into the bin selected. 271 Paper Jam - Check Bin 1 displays.	130
990 Service Error displays	131
Paper Feed Service Check	132
Auto compensator fails to feed paper. Failures occur randomly throughout the stack of paper.	132
Paper feed failures occur only near the top of the stack of paper.	133
Failures occur mainly near the bottom of the stack of paper.	133
Double Feeding Paper	133
Multipurpose Tray	134
Paper fails to feed from the multipurpose tray.	134
Parallel Port Service Check	134
Printhead Service Check	135
Print Quality Service Check	136
Print Quality - All Black Page	137
Print Quality - Blank Page	137
Print Quality - Random Marks	139
Print Quality - Blurred or Fuzzy Print	139
Print Quality - Evenly spaced horizontal lines or marks.	140
Print Quality - Background	141
Print Quality - Banding	144
Print Quality - Black bands on outer edges of the page.	144
Print Quality - Residual Image	146
Print Quality - Light Print	146
Print Quality - Toner on backside of printed page	147
Smart Cartridge Contact Assembly Service Check	148
Serial Port Service Check	149
Toner Sensor Service Check	149
Transfer Roll Service Check	150
StapleSmart Finisher Service Check	152
Problems with static electricity buildup	152
Printer does not recognize StapleSmart Finisher option as being installed.	153
Close Finisher Top Cover displayed - Unable to clear or reset message. (POST incomplete)	154
Close Finished Side Door displayed - Unable to clear or reset message. (POST incomplete)	154
POST incomplete - Stapler cycles several times.	155
990 Service Error Code - Check Bin X displayed - Post Incomplete	155
Step 1 - During POST the stapler option does not try to home.	156
Step 2 - During POST the stapler option tries to home.	157
281 Paper Jam - The paper feeds partway into the Standard Bin even if Finisher Option selected	157
281 Paper Jam - The paper may jam at the upper deflector.	158
281 Paper Jam - Paper jams into stapler output bin.	158
282 Staple Jam - Check Stapler displayed.	159
Post Incomplete - Insert Stapler Cartridge Displayed (Cartridge Holder is installed and cannot cl...	159
283 Staple Jam - Check Stapler displayed.	162
Paper feeds into finisher option output tray - Paper is not stapled - Paper does not align with t...	162
Misalignment of sheets to be stapled.	164
Sheets are transported into output tray but not stapled.	164
Stapled Sheets are not transported to the output tray.	164
POST incomplete - Stapler cycles several times	164
3. Diagnostic Aids	166
Diagnostic/Configuration Menu	166
Configuration Menu	170
Diagnostic Mode	171
Exiting the Diagnostics Mode	171
Device Tests	171
Quick Disk Test	171
Disk Test/Clean	171
Flash Test	172
Disabling Download Emulations	173
Duplex Tests	173
Duplex Quick Test	173
Duplex Sensor Test	174
Duplex Motor Test	174
Duplex Feed 1 Test	177
Duplex Feed 2 Test	177
Error Log	178
Viewing the Error Log	178
Clearing the Error Log	178
Hardware Tests	179
LCD Test	179
Button Test	179
SDRAM Memory Test	180
ROM Memory Test	180
Parallel Wrap Test	181
Serial Wrap Test	182
Input Tray Tests	184
Input Tray Feed Test	184
Input Tray Sensor Test	184
Output Bin - Feed to all Bins Test	185
Output Bin Feed Test	186
Output Bin Sensor Test	186
Standard Bin:	187
Output Expander:	187
High Capacity Output Stacker	187
5-Bin Mailbox Option	188
Finisher Tests, StapleSmart Finisher Option	189
Feed Tests	189
Sensor Tests	189
Base Sensor Test	191
StapleSmart Finisher Tests	191
StapleSmart Finisher Sensor Test	192
5-Bin Mailbox Diverter Test	193
Registration	193
Printer Setup	195
Setting the Page Count	195
Viewing the Permanent Page Count	195
Maintenance Page Count	196
Setting Configuration ID	196
Restore EP Factory Defaults	197
Fuser Temperature	197
Warm Up Time	197
Transfer	198
Print Contrast	198
Charge Roll	198
Print Tests	198
Print Quality Test Pages	199
Printing Menu Settings Page	201
Auto Compensator Operation	201
Autoconnect System, Paper Tray Options, Envelope Feeder and Output Expander Operations	202
Electrical	202
Autoconnect Cabling and Connectors	202
Duplex Option	203
Option Microcode	203
Fuser Operation	204
Hot Roll Fuser	204
Paper Feed Jams	205
Paper Jams - Base Printer	205
Error Message 200 - Paper Jam - Remove Cartridge	205
Error Message 201 - Paper Jam - Remove Cartridge	205
Error Message 202 - Paper Jam - Open Rear Door	206
Paper Jams - Options	206
Error Message 230 Paper Jam - Check Duplex Option	206
Error Message 24x (x=Tray 1 through 5) Paper Jam Check Tray x	207
Error Message 250 - Paper Jam - Check MP Feeder	207
Error Message 260 Paper Jam - Check Envelope Feeder	207
Error Message 27x Paper Jam - Check Bin x	207
Error Message 28x Paper Jam (x=StapleSmart Finisher)	208
Error Message 282 - Check Stapler	208
Error Message 283 - Check Stapler	208
4. Repair Information	210
Handling ESD-Sensitive Parts	210
Adjustment Procedures	211
Duplex Motor Drive Belts	211
Fuser Solenoid Adjustment	212
Gap Adjustment	212
Printhead Assembly Adjustment	213
Paper Alignment Assembly Adjustment	214
Screw Identification Table	216
Removal Procedures	221
Covers	221
Left Door	221
Right Cover	222
Upper Front Cover	224
Laser Assembly Cover	225
Center Pan Assembly	225
System Board	226
Card Assembly (NAND Flash)	227
Developer Drive Assembly	229
Duplex Board	230
Duplex Front Cover Assembly	230
Duplex Front Cover Door	230
Duplex Motor	231
EMC Shields	232
Inner EMC Shield	232
Outer EMC Shield	233
Fan	234
Main Fan	234
Frames	235
EP Frame Assembly	235
Left Side Frame	235
Right Side Frame	238
Fuser	239
Fuser Cover	240
Fuser Detack Fingers	240
Fuser Detack Housing Assembly	241
Fuser Transfer Plate	242
Fuser Envelope Conditioner Solenoid	243
Fuser Narrow Media Sensor/Flag Assembly	244
Fuser Exit Sensor Flag Assembly	244
Fuser Lamp	244
Fuser Lower Exit Guide Assembly	245
High Voltage Power Supply	246
Integrated Tray Compensator Assembly	246
Integrated Tray Compensator Pick Roll Assembly	247
Interconnect Board Assembly	249
Low Voltage Power Supply	251
Main Drive Assembly	252
Main Drive Motor	254
Multipurpose Tray/Lower Deflector Assembly	255
Operator Panel Assembly	257
Operator Panel Cable/Cover Open Switch Assembly	258
Optional 250/500 Paper Tray Assembly	259
Paper Tray Compensator Assembly	259
Paper Tray Frame Assembly	259
Paper Tray Board	259
Paper Tray Paper Out Sensor Flag	259
Paper Size Spring Comb	259
Paper Alignment Assembly	260
Paper Deflectors	262
Inner Paper Deflector Assembly	262
Upper Paper Deflector Assembly	262
Paper Input Sensor	263
Paper Size Sensing Board	263
Pick Roll	263
Printhead (1130)	264
Printhead (1140)	265
Redrive Assembly	266
Smart Cartridge Contact Assembly	267
Toner Sensor	268
Transfer Roll Assembly	269
Upper Paper Deflector Assembly	269
Upper Front Cover Hinge Assembly	270
Upper Front Cover Interlock Switch Assembly	271
5. Connector Locations	272
Low Voltage Power Supply	272
High Voltage Power Supply	274
Interconnect Board	275
Jumper locations for J8, J9, and J10	277
Envelope Option Board	278
Duplex Option Board	280
Autoconnect - Top	282
Output Expander Control Board	283
High-Capacity Output Stacker Board	285
J6 Connector Jumper Locations	286
System Board Connector Locations	287
System Board Connector Locations	291
StapleSmart Finisher Option - Staple Card Assembly	298
Cables - Base Machine	302
Fuser Cable, DC Internal	302
Autoconnect Cable, (Fuser to LVPS)	302
Deflector Cable	302
Fuser Cable, AC EP Autoconnect to Fuser Top Cover	303
Integrated Tray Cable	303
HSYNC Cable	303
Mirror Motor Cable	304
Main Drive Motor Cable	304
Laser Cable	304
Front Harness Cable	305
Fuser Cable, DC EP Autoconnect to System Board	305
Autoconnect Cable - System Board to Top/Interconnect Board	305
Autoconnect Cable - System Board to Front/Bottom/Interconnect Board	306
6. Preventive Maintenance	308
Safety Inspection Guide	308
Lubrication Specifications	308
Scheduled Maintenance	309
7. Parts Catalog	310
How to Use this Parts Catalog	310
Assembly 1: Covers	311
Assembly 2: Frame	315
Assembly 3: Printhead	319
Assembly 4: Paper Feed (Auto compensator)	321
Assembly 5: Paper Feed - Multipurpose Unit	323
Assembly 6: Paper Feed - Alignment	325
Assembly 7: Paper Feed - Output	327
Assembly 8: Integrated Paper Tray - 500 Sheet	329
Assembly 9: Main Drive	331
Assembly 10: Developer Drive	333
Assembly 11: Hot Roll Fuser	335
Assembly 12: Transfer	339
Assembly 13: Charging	341
Assembly 14: Electronics	343
Assembly 14: Electronics (continued)	345
Assembly 14: Electronics (continued)	357
Assembly 15: 250-Sheet Tray	359
Assembly 16: 500-Sheet Tray	365
Assembly 17: Duplex	369
Assembly 18: Output Expander	375
Assembly 19: Envelope Feeder	379
Assembly 20: High-Capacity Feeder	383
Assembly 21: Kiosk - Vertical Paper Adapter	397
Assembly 22: Kiosk - Horizontal Paper Adapter	399
Assembly 23: High-Capacity Output Stacker	401
Assembly 24: 5-Bin Mailbox	407
Assembly 25: StapleSmart Finisher	411
Assembly 26: Options	419
Assembly 27: Miscellaneous	421