Xerox Synergix 8830 User manual

THEDOCUMENTCOMPANY
XEROX
Xerox8830Printer
Service Manual
701P12720
January1998
CAUTION
Certaincomponentsinthe8830aresusceptibleto
damagefromelectrostaticdischarge.Observeali
ESDproceduresinordertoavoidcomponent
damage

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TitlePage
Introductionvi
AboutThisManualvi
Organizationvi
HowtoUseThisManualvii
Section1 ServiceCallProcedures1 -1
Section2 RepairAnalysisProcedures2-1
Section3 PrintQualityRAPs2-1
Section4 RepairsandAdjustments4-1
Section5 PartsLists5-1
Section6 GeneralProcedures6-1
Section7 WiringData7-1
Section8 Accessories8-1
1/98
vTableofContents

AboutthisManualInitialActions/SystemChecksFinalAction
Thismanualispartofa documentationsystem
thatincludesthetraining.
ThismanualcontainsRepairAnalysis
Procedures(RAPs),RepairProcedures,
AdjustmentProcedures,PartsList,Diagnostic
Procedures,InstallationProcedures,WiringData
andBSDs.
ThismanualwillenabletheService
Representativetorepairthe8830.
Organization
Thismanualconsistsofeightsections.The
titleanddescriptionofeachsectionarelisted
below.
Section1 ServiceCallProcedures
Thissectioncontainsthefollowing:
•CallFlowDiagram
•InitialActions/SystemChecks
•PrinterMaintenance
•StatusCodeEntryChart
•SystemCheckout/FinalAction
CallFlowDiagram
TheCallFlowDiagramisa mapofactivitiesto
beperformedoneachservicecall.
Thisdiagramidentifieshowtocollectthedata
necessarytodecidehowtoproceedwiththe
servicecall.Itclassifiestheproblemandrefers
youtotheappropriateRAP.
StatusCodeEntryChart
Thischartprovidesa listofstatuscodes,the
possiblecause,whetherthereisa RAPin
Section2,componentcontrolcode,anda BSD
reference.
PrinterMaintenance
TheMaintenanceActivitiesproceduresidentify
functionalchecksandcleaningoperationsthat
mustbeperformedoneveryNormalCall.Italso
identifiesthoseactivitiesthatcanbeperformed
asneededorasscheduled.
SubsystemChecks
TheSubsystemChecksconsistofchecksand
activitiesthatmustbeperformedwhena
subsystemisrepairedduringa Callbackorwhen
directedtothemduringNormalCall.
SystemCheckout
TheSystemCheckoutprocedureisusedto
verifythattheprinterisoperatingcorrectlyaftera
repairhasbeenmade.
TheFinalActionprocedureidentifiesthesteps
thatmustbeperformedbeforeclosingoutthe
servicecall.
Section2.- RepairAnalysisProcedures
(RAPs)
ThissectioncontainstheRepairAnalysis
Procedures(RAPs)necessarytorepairthe
faults.Whenusinga RAP,alwaysexitthe
procedurewhenthefaultisfixed.Donot
performtheremainingsteps.
Section3.- ImageQualityRepairAnalysis
Procedures(RAPs)
ThissectioncontainstheRepairAnalysis
Procedures(RAPs)necessarytorepairthe
imagequalityfaults.Referto"HowtoUsethe
ImageDefectDefinitions"tocomparetheimage
defecttothedefinitions.Onceyouhave
determinedthedefinitionthatbestdescribesthe
defect,gotothesectioncontentspagetofind
theappropriateRAP.Whenusinga RAP,
alwaysexittheprocedurewhenthefaultisfixed.
Donotperformtheremainingsteps.
Section4.- Repair/ Adjustment
Thissectioncontainstherepairandadjustment
proceduresforthe8830.
Section5.- PartsList
ThissectioncontainsthedetailedPartsListfor
the8830.
Introduction
1/98
vi
8830

Section6.- GeneralProcedures
ThissectioncontainsDiagnosticProcedures,
InstallationProcedures,andGeneral
Information,whichincludesProduct
Specificationsforthe8830.
Section7.- WiringData
ThissectioncontainsPlug/JackLocationindex,
Plug/JackLocationDrawings,andtheBSDs.
Section6.- Accessories
Thissectioncontainsserviceinformationabout
accessoriesforthe8830Printer.As
accessoriesareaddedtothecustomer
configuration,theywillbeaddedtothissection.
HowtoUseThisManual
TheServiceCallProcedureswilldirectyouto
theappropriateSectionoftheServiceManual.
YoushouldbegintheservicecallwiththeInitial
Actions/SystemChecksProcedure.From
there,youwillbereferredtoeitherSection2,
StatusIndicatorRAPs,Section3,ImageQuality
RAPs,Section7 BSDsorSection8,
Accessories.
IfyouaresenttoSection3,comparetheimage
defecttotheprintqualitydefinitions.Onceyou
havedeterminedthedefinitionthatbest
describesthecopydefect,gotothesection
contents.Thesectioncontentswilldirectyouto
animagequalityRAP.TheRAPhasa listof
probablecausesandcorrectiveactions.From
theseRAPsyou maybereferredtoother
sectionsofthemanualtomakechecks,
adjustments,ortoreplacetheparts.
Whenyouhavemadea repair,alwaysgotothe
CallFlowDiagramtofinishthecall.
1/98
8830viiIntroduction

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Introductionviii8830

1.ServiceCallProcedures
SectionContents
TITLEPAGE
Introduction1-2
CallFlowDiagram1-3
InitialActions/ SystemChecks1-4
PrintDefectIsolationProcedure1-5
WorkstationCheckoutProcedure...1-6
StatusCodeEntryChart1-7
MessageDisplayEntryChart1-18
MaintenanceProcedures1-19
SystemCheckout/ FinalAction1-25
CallBack1-25
8830
1/98
1-1
SectionContents

Introduction
TheServiceCallProceduresaredesignedto
assisttheServiceRepresentativetoidentify
printerfaults,performthenecessarycorrective
actionandperformthecorrectMaintenance
Procedures.TheServiceCallProceduresare
designedtobeusedwiththe8830Service
Manualandistheentrylevelforallservice
calls.
•InitialActions/ SystemChecks- This
diagramisdesignedtoidentifyand
classifytheprinterproblemandtorefer
you totheappropriateRAPinorderto
repairtheproblem.Whentheproblem
hasbeenrepaired,performtheSystem
Checkout/ FinalAction.
•SubsystemChecks- Whentheprinteris
beingserviced,themaintenance/cleaning
shouldbeperformed.
•StatusCodeEntryChart- Thischart
containsa listofStatusCodes,their
relatedcomponents,thecorresponding
RAP(RepairAnalysisProcedure),BSD
(BlockSchematicDiagram),Component
CodeandPartsListreference.Thechart
isdesignedtodirectyou totheappropriate
ClearanceProcedure.WhentheStatus
Codeproblemhasbeenrepaired,referto
theCallFlowDiagramandcontinuethe
ServiceCall.
SystemCheckout/ FinalAction- The
purposeofthisprocedureistorecordthe
mediafeetcountandtomakea recordin
themachinelogbookoftheservice
activitiesthatwereperformed.FinalAction
isdesignedtoensurethattheprintis
transportedcorrectlyandtoensurethat
imagequalityiswithinspecification.
Introduction1/98
1-2
8830

CallFlowDiagram
8830
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1-3CallFlowDiagram

InitialActions/ SystemChecks
InitialActions/ SystemChecks1/98
1-4
8830
1.Asktheoperatortodescribetheproblem.
2.Asktheoperatortohaltallprintjobsandstopcontroller.
3.Checkthelogbook.
4.ChecktheRecentFaultLogfortrends:
a.Witha Controller- PrintouttheconfigurationsheetthroughtheUtilitiesMenu.Thelast25faultsarelistedontheupper-rightsideofthesheet.
b.Withouta Controller- Enter[0391],Thedisplaywillscrollthroughtheerrorcodestwoata time.
5.AnalyzethefrequencyofthefaultcodesandrefertotheStatusCodeEntryCharttotroubleshoottheproblem:
a.C orE codesshouldoccurnomorefrequentlythanonceper1000linearfeet.
b.AllCutterfaultsshouldoccurnomorefrequentlythanonceper10,000linearfeet.
Note: E4-09, Cx-04, and Cx-05 are out-of-media codes and will occuronce per 500 linearfeet Also, 001 and 002 codes are power on/off. Question the
operator if the faults are excessive.
6.Recordthereadingsfromthemedialengthcounter.
7.Attempttoduplicatetheproblem.

PrintDefectIsolationProcedure
8830 1/98
1-5PrintDefectIsolationProcedure

WorkstationCheckoutProcedure
WorkstationCheckoutProcedure1/98
1-6
8830

StatusCodeEntryChart
Status
Code
C1-01
C2-01
C3-01
C1-04
C2-04
C3-04
C1-05
C2-05
C3-05
Description
Positionsensorerror
TheRoll1,2,or3 positionsensordidnot
actuateordeactuate.
Mediaregistrationsensorerror
Themediasensordidnotactuateor
deactuatewhenfeedingfromroil1,2,or3.
Motionsensorerror
Motionwasnotdetectedorthemedia
stoppedmovingwhenfeedingfromroll1,2,
or3.
Components
Roll1 positionsensor(Q1)
Roll2 positionsensor(Q2)
Roll3 positionsensor(Q3)
MainPWB(A3)
NOTE:Thesensorsare
interchangeable.
Mediaregistrationsensor(A21Q1)
MainPWB(A3)
DriverPWB
RegistrationRolls
TransportDriverMotor
MotorDriverPWB
Roll1 motionsensor(Q4)
Roll2 motionsensor(Q5)
Roll3 motionsensor(Q6)
MainPWB(A3)
DriverPWB
MotorDriverPWB
MediaFeedRolls
MediaFeedClutch
MediaFeedDriveMotor
NOTE: The sensors and the clutches
areinterchangeable.
RAP
NO
YES
NO
Comp
Code
Roll1
[0707]
Roll2
[0708]
Roll3
[0709]
[0803]
Roll1
[0710]
Roll2
[0711]
Roll3
[0712]
BSDRef
7.2
7.3
7.4
8.1
7.2
7.3
7.4
7.1
PL
Ref
PL7.1
PL1.3
PL8.2
PL1.3
PL7.1
PL1.3
8830
1/98
1-7StatusCodeEntryChart

StatusCodeEntryChart(cont.)
Status
Code
C3-06
C3-07
C1-09
C2-09
C3-09
C1-19
C2-19
C3-19
C1-29
C2-29
C3-29
C1-39
C2-39
C3-39
Description
Roll2 positionsensorerror
MediawasnotdetectedattheRoll2 position
sensorwhenfeedingfromroll3.
Roll1 positionsensorerror
MediawasnotdetectedattheRoll1 position
sensorwhenfeedingfromRoll3.
Firmwareerror
Thisisa firmwareproblem.Presspoweroff
(0)thenpoweron(1).Ifproblempersists,
replacethefirmware.
ThisIsa Firmwareproblem
Thisisa firmwareproblem.Presspoweroff
(0)thenpoweron(1).Ifproblempersists,
replacethefirmware.
Thisisa Firmwareproblem.
Thisisa firmwareproblem.Presspoweroff
(0)thenpoweron(1).Ifproblempersists,
replacethefirmware.
Thisisa Firmwareproblem.
Thisisa firmwareproblem.Presspoweroff
(0)thenpoweron(1).Ifproblempersists,
replacethefirmware.
Components
Roll2 positionsensor(Q2)
MainPWB(A3)
Roil1 positionsensor(Q1)
MainPWB(A3)
RAP
NO
NO
NO
NO
NO
NO
Comp
Code
[0708]
[0707]
BSD
Ref
7.3
7.2
PL
Ref
PL7.1
PL1.3
PL7.1
PL1.3
StatusCodeEntryChart1/98
1-8
8830

StatusCodeEntryChart(cont.)
Status
Code
C1-59
C2-59
C3-59
C4-24
C4-34
C4-49
E2-01
E2-09
Description
Thisisa Firmwareproblem
Thisisa firmwareproblem.Presspoweroff
(0)thenpoweron(1).Ifproblempersists,
replacethefirmware.
Registrationsensorerror
Thecutsheetdoesnotreachthemedia
registrationsensorintime.
Sheetfeedsensorerror
Thesheetfeedsensordeactuatedtooearly
whilemakinga print.Theoperatormayhave
removedthecutsheetmedia.
Thisisa Firmwareproblem
Thisisa firmwareproblem.Presspoweroff
(0)thenpoweron(1).Ifproblempersists,
replacethefirmware.
Mediaregistrationsensorerror
Themediatrailedgejammedinthemedia
registrationsensorarea.
ThisIsa Firmwareproblem
Thisisa firmwareproblem.Presspoweroff
(0)thenpoweron(1).Ifproblempersists,
replacethefirmware.
Components
Mediaregistrationsensor(A21Q1)
MainPWB(A3)
RegistrationRolls
TransportDriveMotor
TransportMotorDriverPWB
CutSheetFeedClutch/Rolls
DriverPWB
Sheetfeedsensor(Q2)
MainPWB(A3)
Mediaregistrationsensor(A21Q1)
MainPWB(A3)
RAP
NO
NO
NO
NO
NO
NO
Comp
Code
[0801]
[0801]
[0803]
BSDRef
8.1
8.1
8.1
PL
Ref
PL8.4
PL1.3
PL8.4
PL1.3
PL8.2
PL1.3
8830
1/98
1-9StatusCodeEntryChart

StatusCodeEntryChart(cont.)
Status
Code
E2-11
E4-01
E4-02
E4-03
E4-04
E4-09
E4-11
Description
Registrationsensorerror
Themediaregistrationsensorwasdetected
tobeactuatedwhenthemachinepowered
up.
Mediaexitsensorerror
Themediatrailedgejammedinthemedia
exitsensorarea.
Mediaexitsensorerror
Leadedgeofmediadidnotreachthemedia
exitswitchintime.
Stripperfingerjamswitcherror
Thestripperfingerjamswitchwasactuated
duringrun.
StackerFull
TheStackerFullSensorwasactuatedduring
arunorwasdetectedtobeactuatedwhen
themachinepowered
Thisisa Firmwareproblem
Presspoweroff(0)thenpoweron(1).If
problempersists,replacethefirmware.
Mediaexitsensorerror
Themediaexitsensorwasdetectedtobe
actuatedwhenthemachinepoweredup.
Thisrequiresthemediaexitareatobe
opened,andthemediatoberemoved.
Components
Mediaregistrationsensor(A21Q1)
MainPWB(A3)
Mediaexitsensorerror(Q3)
MainPWB(A3)
ExitRollersandDrive
Mediaexitsensorerror(Q3)
MainPWB(A3)
FuserDriveMotor
HeatRoll
Transfer/DetackCorotron
FabricGuide
Stripperfingerjamswitch(A23S1)
MainPWB(A3)
StripperFingerDamaged
StackerFullSensor
Mediaexitsensor(A23S1)
MainPWB(A3)
RAP
NO
NO
NO
NO
NO
NO
NO
Comp
Code
[0803]
[0807]
[0807]
[1005]
[0808]
[0807]
BSDRef
8.1
10.3
10.3
10.3
10.3
PL
Ref
PL8.2
PL1.3
PL8.4
PL1.3
PL8.4
PL1.3
PL10.4
PL1.3
PL8.4
PL1.3
StatusCodeEntryChart1/98
1-10
8830

StatusCodeEntryChart(cont.)
Status
Code
E4-12
E4-13
E4-14
E5-03
E5-04
E5-05
E5-06
Description
Sheetfeedsensorerror
Thesheetfeedsensorwasdetectedtobe
actuatedwhenthemachinepoweredup.
Thisrequiresthemediaexitareatobe
opened,andtoberemoved.
StripperfingerJamswitcherror
Thestripperfingerjamswitchwasactuated
atpoweron.
Mediabucklesensorerror
Themediabucklesensorwasdetectedtobe
actuatedwhenthemachinepoweredup.
Thisrequiresthemediaexitareatobe
opened,andthemediatoberemoved.
Topcoverinterlockswitcherror
Thetopcoverwasopenedduringprint.
Cuttercoverinterlockswitcherror
Thecutterwasopenedduringprint.
Feedshelfinterlockswitcherror
Thesheetfeedshelfwasopenedduring
print.
FrontdoorInterlockswitcherror
Thefrontdoorwasopenedduringprint.
Components
Sheetfeedsensor(A21Q2)
MainPWB(A3)
Stripperfingerjamswitch(A23S1)
MainPWB(A3)
MediabucklesensorA21Q5)
MainPWB(A3)
FabricGuidePosition
Topcoverinterlockswitch(S26)
DriverPWB(A2)
Cuttercoverinterlockswitch(S1)
DriverPWB(A2)
Feedshelfinterlockswitch(S29)
DriverPWB(A2)
Frontdoorinterlockswitch(S21)
DriverPWB(A2)
RAP
NO
NO
NO
NO
NO
NO
NO
Comp
Code
[0801]
[1005]
[0802]
[0911]
[0702]
[0910]
[0101]
BSDRef
8.1
10.3
4.1
1.3
1.3
1.2
1.3
PL
Ref
PL8.4
PL1.3
PL10.4
PL1.3
PL8.4
PL1.3
PL14.5
PL1.1
PL7.6
PL1.1
PL14.3
PL1.1
PL14.3
PL1.1
8830
1/98
1-11StatusCodeEntryChart

StatusCodeEntryChart(cont.)
Status
Code
E6-00
E6-01
E7-01
E7-02
E9-XX
Fx-xx
Description
Frontdoorinterlockswitcherror
TheC buttonwaspressedwhilea printwas
beingmadeintherollfeedmode.An
operatorinducedsoftshutdownresultsina
completeprintbeingmade.Theleftside
doormustbeopenedandthenclosed.
Frontdoorinterlockswitcherror
TheExitbuttonwaspressedwhilea print
was beingmadeintheroilfeedmode.An
operator-inducedhardshutdownresultsina
partialprintbeingmade.Theleftsidedoor
mustbeopenedandthenclosed.
Communicationerror
TheIOTisunabletocommunicatewiththe
ESS.TheIOToff-lineandmediamenuswill
stillfunction,butcannotprintfromtheESS
ornetwork.
Printermessagedisplayerror
Arequiredmessageisnotavailableinthe
languageEPROM.Updatethelanguage
EPROM.
Softwareshutdown
Thiserrorisofunknowncause.Please
contactSoftwareengineering.
RefertotheFolderServiceManualforail
F-codes.
Components
instructthecustomerastothe
appropriatetimetopress"C"
Instructthecustomerastothe
appropriatetimetopress"Exit"
PerformGP5Communication
LoopbackTestlocatedinSection6.
(Forthe6830Folder,refertothe
FolderCommunicationTestinthe
folderservicemanual.)
LanguageEPROM
RAP
NO
Comp
Code
[0211]
BSDRef
2.1
PL
Ref
StatusCodeEntryChart1/98
1-12
8830