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9-4magicolor 330 - Base Engine Service Manual

Removal and Replacement Procedures

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Main Page Page FEDERAL COMMUNICATIONS COMMISSION NOTICE CLASS 1 LASER PRODUCT Contents Service Section Technical Reference Section Page Page Safety information Page 1-4 magicolor 330 - Base Engine Service Manual Installation Procedure (FIP) Flowchart and proceed from there. Inspect and Clean the Printer Final Checkout Find the Cause of the Problem Correct the Problem Identify the Problem Section 2. The FIP Flowchart How to Use the FIP Flowchart How to Follow a FIP 2 General Notes on Using FIPs 2-4 magicolor 330 - Base Engine Service Manual Fault Isolation Procedures Error M ess a g e FIP Flowchart Printer Performance Section 6 Secondary FIPS Primary FIPS may direct you to a specific Secondary FIP Erro r M e s sa g e Section 3 - Primary FIPs: Error Messages Contents Page 3 - Primary FIPs: Error Messages 3.1 - Error Message: Replace Fuser Oil Roller 1 3.2 - Error Message: Waste Toner Box Full 2 3.3 - Error Message: Black Toner Empty 1 3.4 - Error Message: Cyan Toner Empty 1 3.5 - Error Message: Magenta Toner Empty 1 3.6 - Error Message: Yellow Toner Empty 1 3.7 - Error Message: Put <Size> Paper in OPT3 Bin 3.8 - Error Message: Put <Size> Paper in MPT 2 3 3.9 - Error Message: Put <Size> paper in OPT2 Bin 3.10 - Error Message: Put <Size> Paper in OPT1 Bin 3.11 - Error Message: Put <Size> Paper in Upper Bin 1 3.12 - Error Message: Incorrect OPC Drum 2 2 3 3.13 - Error Message: Incorrect OPC Drum 1 1 3.14 - Error Message: OPC Count Error 3 3.15 - Error Message: Incorrect OPC Drum ID 1 3.16 - Error Message: Used OPC End of Life 1 3.17 - Error Message: OPC Verify Error 3 3.18 - Error Message: OPC Comm Error 2 3.22 - Error Message: Paper Size Mismatch 1 2 3 3.23 - Error Message: Paper Jam Fuser 2 4 5 3.23 - Error Message: Paper Jam Fuser, continued 6 7 8 9 10 2 3 4 3.24 - Error Message: Paper Jam Registration, continued 6 7 8 3.25 - Error Message: Paper Jam Exit 2 4 5 3.25 - Error Message: Exit Jam, continued 6 7 3.26 - Error Message: Adjust OPT3 Bin 1 2 3.27 - Error Message: Black Toner Missing 1 2 3.28 - Error Message: Cyan Toner Missing 1 2 3.29 - Error Message: Magenta Toner Missing 1 2 3.30 - Error Message: Yellow Toner Missing 1 2 3.31 - Error Message: Call for Service Engine Memory 2 3.32 - Error Message: Waste Toner Box Missing 1 3 4 3.33 - Error Message: Call for Service Fuser Temp Low 1 2 3 4 6 2 3 4 3.35 - Error Message: Call for Service Environment Sensor 1 3.36 - Error Message: Call for Service Paper Motor 3 4 3.37 - Error Message: Call for Service Low Density 1 3 4 6 3.37 - Error Message: Call for Service Low Density, continued 7 8 3.38 - Error Message: Call for Service High Density 1 3 4 3.38 - Error Message: Call for Service High Density, continued 6 7 8 3.39 - Error Message: Adjust Upper Bin 1 2 3.40 - Error Message: Call for Service Fuser Lamp 1 3 3.41 - Error Message: Adjust Opt2 Bin 1 2 3.42 - Error Message: Adjust Opt1 Bin 1 2 4 3.43 - Error Message: Call for Service Main Motor 1 2 3 5 6 1 3 3.45 - Error Message: Call for Service Fuser Temp High 2 3 4 5 6 2 3.47 - Error Message: Fuser Missing 1 2 3 3.48 - Error Message: Fuser Oil Roll Missing 1 2 3 3.49 - Error Message: Call for Service Fuser Warm-up 1 2 3 4 6 1 3 4 3.52 - Error Message: Replace Fuser 1 3.53 - Error Message: Replace IBT Belt Cleaner 1 3.54 - Error Message: Replace BTR2 1 3.55 - Error Message: Replace OPC Drum 1 3.56 - Error Message: Feeder Cover Missing 2 3 4 5 6 1 2 3.58 - Error Message: Exit Cover Open 1 2 3 3.59 - Error Message: MPT Tray Open 1 2 3.60 - Error Message: Front Cover Open 1 2 3 4 3.61 - Error Message: Top Stack Full 1 2 3 3.66 - Error Message: Call For Service Engine NVR 3.67 - Error Message: BTR2 Life Low 3.68 - Error Message: Belt Cleaner Life Low 1 3.69 - Error Message: Replace OPC Drum 2 3.70 - Error Message: Fuser Life Low 3.71 - Error Message: Fuser Oil Low 1 3.72 - Error Message: Waste Toner Nearly Full 2 3.73 - Error Message: Black Toner Low 1 3.74 - Error Message: Cyan Toner Low 1 3.75 - Error Message: Magenta Toner Low 1 3.76 - Error Message: Yellow Toner Low Page 4 - Printer Performance Problem FIPs Printer Performance Problem Flow Chart 4.1 - Inoperative Printer 1 2 3 4 5 7 8 9 10 11 1 2 3 4 5 Section 5 - Primary FIPs: Image Quality Contents 5-Image Quality FIPs The Use of Diagnostics Test Print 5.1 - Light (Undertoned) Prints 5.1 - Light (Undertoned) Prints, continued 6 5.2 - Blank Prints 4 5 5.2 - Blank Prints, continued 6 7 5.3 - Black Prints 3 5.3 - Black Prints, continued 5 6 5.4 - Vertical Band Deletions 5.4 - Vertical Band Deletions, continued 5.5 - Horizontal Band Deletions 5.5 - Horizontal Band Deletions, continued 9 10 5.6 - Vertical Streaks 5.6 - Vertical Streaks, continued 5.7 - Horizontal Streaks 5.7 - Horizontal Streaks, continued 6 5.8 - Spot Deletions 5.8 - Spot Deletions, continued 5.9 - Spots 5.9 - Spots, continued 5.10 - Residual Image or Ghosting 1 5.10 - Residual Image or Ghosting, continued 5.11 - Background 4 5.11 - Background, continued 5.12 - Toner on Back of Print 5.12 - Toner on Back of Print, continued 5.13 - Skewed Image 5.13 - Skewed Image, continued 5.14 - Damaged Prints 2 3 4 5 7 Page 5.14 - Damaged Prints, continued 13 14 5.15 - Unfused Image or Image Easily Rubs Off of Page 1 2 3 5.16 - A Repetitive Mark Appears on Each Print 1 5.17 - The Printed Image is Mottled 3 4 5 5.18 - Image Not Registered Correctly on the Page 1 2 3 4 5.19 - Color Layers are not Registered Correctly 1 2 3 4 5.20 - Color Representation Not Correct 1 2 3 4 Page 6 - Secondary FIPs 6.1 - Electrical Noise 1 2 3 4 5 7 8 9 Page Connecting to Engine Diagnostics Required Equipment Portable Computer to Printer Setup Procedure Terminal Program Setup HyperTerminal (Windows 95 O/S) VTERM (DOS O/S) Page Page Life Counters Overview Retrieving the Life Counters Data Page Page Page Page Removal and Replacement Procedures (RRPs) Preparation Work Notes Notations in the RRP text RRP 9.1 Front Cover Assembly (PL1.1.1 RRP 9.1 Front Cover Assembly (PL1.1.1) Page RRP 9.2 Inner Cover Assembly (PL1.1.10) Page RRP 9.3 Top Cover Assembly (PL1.1.20) Page RRP 9.4 Rear Cover (PL1.1.31) Page RRP 9.5 Front Lower Cover (PL1.1.5) Page RRP 9.6 Filter Assembly (PL1.1.32) Page RRP 9.7 Left Lower Cover (PL1.1.40) Page RRP 9.8 Right Cover Assembly (PL1.1.50) Page RRP 9.9 Operation Panel (PL1.1.60) Page RRP 9.10 Front Snubber (PL2.2.9) Page RRP 9.11 End Guide (PL2.2.16) Page RRP 9.12 Sector Gear (PL2.2.17) Page RRP 9.13 Feed Roll Assembly (PL3.1.1) Page RRP 9.14 Feed Roll (PL3.1.3) Page RRP 9.15 Feed Solenoid (PL3.1.9) Page RRP 9.16 Turn Roll Assembly (PL3.1.11) Page RRP 9.17 Size Switch Assembly (PL3.1.23) Page RRP 9.18 No Paper Sensor Assembly (PL3.1.30) Page RRP 9.19 Low Paper Sensor (PL3.1.35) Page RRP 9.20 Turn IN Chute (PL3.1.18) Page RRP 9.21 Universal Paper Tray (PL2.1.1) Page RRP 9.22 MSI Assembly (PL4.1.1) Page RRP 9.23 MSI Front Cover (PL4.1.3) Page RRP 9.24 MSI Rear Cover (PL4.1.4) Page RRP 9.25 MSI Tray Assembly (PL4.1.10) Page RRP 9.26 MSI Top Cover Assembly (PL4.2.4) Page RRP 9.27 MSI Edge Sensor (PL4.2.6) Page RRP 9.28 MSI Short No Paper Sensor (PL4.2.7) Page RRP 9.29 MSI Pick Up Roll (PL4.2.11) Page RRP 9.30 MSI Roll Assembly (PL4.2.9) Page RRP 9.31 MSI Pick Up Solenoid (PL4.2.21) Page RRP 9.32 MSI Clutch (PL4.2.26) Page RRP 9.33 MSI Retard Pad Assembly (PL4.3.3) Page RRP 9.34 MSI Bottom Assembly (PL4.3.9) Page RRP 9.35 MSI Long No Paper Sensor (PL4.3.16) Page RRP 9.36 Main Paper Handling Assembly (PL5.1.1) Page RRP 9.37 Paper Handling Turn Chute Assembly (PL5.1.4) Page RRP 9.38 Pre-Registration Chute Assembly (PL5.1.5) Page RRP 9.39 Registration Chute Assembly (PL5.1.6) Page RRP 9.40 Pre-Registration Roll Assembly (PL5.2.4) Page RRP 9.41 Pre-Registration Clutch (PL5.2.8) Page RRP 9.42 Registration Clutch (PL5.2.15) Page RRP 9.43 Metal Registration Roll (PL5.2.16) Page RRP 9.44 Rubber Registration Roll (PL5.2.24) Page RRP 9.45 Registration Sensor (PL5.2.28) Page RRP 9.46 Registration Brake Clutch (PL5.2.20) Page RRP 9.47 ROS Assembly (PL6.1.1) Page RRP 9.48 Xerographic Cartridge (PL6.1.11) Page RRP 9.49 Waste Toner Box (PL6.1.12) Page RRP 9.50 ADC Sensor Assembly (PL6.1.20) Page RRP 9.51 Erase Lamp Assembly (PL6.1.30) Page RRP 9.52 XL Rail Assembly (PL6.1.40) Page RRP 9.53 Waste Toner Sensor (PL6.1.42) Page RRP 9.54 Toner Box Sensor (PL6.1.43) Page RRP 9.55 Yellow (Y) Toner Cartridge (PL7.1.1) Page RRP 9.56 Magenta (M) Toner Cartridge (PL7.1.2) Page RRP 9.57 Cyan (C) Toner Cartridge (PL7.1.3) Page RRP 9.58 Black (K) Toner Cartridge (PL7.1.4) Page RRP 9.59 Yellow (Y) Developer Assembly (PL7.1.10) Page RRP 9.60 Yellow (Y) Developer (PL7.1.13) Page RRP 9.61 Magenta (M) Developer Assembly (PL7.1.20) Page RRP 9.62 Magenta (M) Developer (PL7.1.23) Page RRP 9.63 Cyan (C) Developer Assembly (PL7.1.30) Page RRP 9.64 Cyan (C) Developer (PL7.1.33) Page RRP 9.65 Black (K) Developer Assembly (PL7.1.40) Page RRP 9.66 Black (K) Developer (PL7.1.43) Page RRP 9.67 Rotary Frame Assembly (PL7.2.2) Page RRP 9.68 Rotary Sensor (PL7.2.22) Page RRP 9.69 Cartridge Sensor (PL7.2.26) Page RRP 9.70 Used Cartridge Sensor (PL7.2.30) Page RRP 9.71 Transfer Assembly (PL8.1.3) Page RRP 9.72 Tension Lever (PL8.1.4) Page RRP 9.73 2nd BTR Cam Assembly (PL8.1.10) Page RRP 9.74 BTR Cam Solenoid (PL8.1.15) Page RRP 9.75 2nd BTR Assembly (PL8.1.20) Page RRP 9.76 Belt Cleaner Assembly (PL8.1.30) Page RRP 9.77 Auger Assembly (PL8.1.40) Page RRP 9.78 IBT Belt Assembly (PL8.2.2) Page RRP 9.79 TR0 Sensor (PL8.2.12) Page RRP 9.80 Fuser Assembly (PL9.1.1) Page RRP 9.81 Main Fuser Assembly (PL9.1.2) Page RRP 9.82 Oil Roll Assembly (PL9.1.10) Page RRP 9.83 Pressure Roll (PL9.2.9) Page RRP 9.84 Heat Roll (PL9.2.12) Page RRP 9.85 Pressure Roll Heat Rod (PL9.2.19) Page RRP 9.86 Heat Roll Heat Rod (PL9.2.20) Page RRP 9.87 Upper Fuser Assembly (PL9.2.23) Page RRP 9.88 Temperature Sensor Assembly (PL9.2.24) Page RRP 9.89 Fuser Exit Sensor (PL9.2.25) Page RRP 9.90 Exit-1 Roll Assembly (PL9.3.7) Page RRP 9.91 Exchange Chute (PL9.3.10) Page RRP 9.92 Exchange Solenoid (PL9.3.16) Page RRP 9.93 Oil Cam Solenoid (PL9.3.21) Page RRP 9.94 Oil Cam Assembly (PL9.3.22) Page RRP 9.95 CRU Switch Assembly (PL9.3.25) Page RRP 9.96 Cleaner Cam Solenoid (PL9.4.23) Page RRP 9.97 Cleaner Cam Assembly (PL9.4.26) Page RRP 9.98 Upper Guide Assembly (PL9.2.32) Page RRP 9.99 Lower Guide Assembly (PL9.2.26) Page RRP 9.100 Exit Tray (PL10.1.10) Page RRP 9.101 Lower Exit Assembly (PL10.1.1) Page RRP 9.102 Upper Exit Assembly (PL10.1.2) Page RRP 9.103 Full Stack Sensor (PL10.2.21) Page RRP 9.104 Exit-2 Roll Assembly (PL10.2.5) Page RRP 9.105 Exit-3 Roll Assembly (PL10.2.7) Page RRP 9.106 Top Exit Sensor (PL10.2.12) Page RRP 9.107 Exit Chute Switch (PL10.2.13) Page RRP 9.108 Fuser Fan (PL10.2.15) Page RRP 9.109 Paper Handling Drive Assembly (PL11.1.1) Page RRP 9.110 Fuser Drive Assembly (PL11.1.2) Page RRP 9.111 Paper Handling Motor Assembly (PL11.1.3) Page RRP 9.112 Process Motor Assembly (PL11.1.12) Page RRP 9.113 Process Drive Assembly (PL11.1.10) Page RRP 9.114 Rotary Motor Assembly (PL11.1.20) Page RRP 9.115 Rotary Motor PWB (PL11.1.21) Page RRP 9.116 Dispense Motor Assembly (PL11.1.22) Page RRP 9.117 Developer Clutch Assembly (PL11.1.23) Page RRP 9.118 Developer Tie Plate (PL12.1.4) Page RRP 9.119 Low Voltage Power Supply (LVPS) (PL13.1.1) Page RRP 9.120 High Voltage Power Supply (HVPS) (PL13.1.2) Page RRP 9.121 Top Cover Switch (PL13.1.3) Page RRP 9.122 Developer Fan (PL13.1.5) Page RRP 9.123 MCU PWB (PL13.2.1) Page RRP 9.124 Front Cover Switch R (PL13.2.3) Page RRP 9.125 Front Cover Switch L (PL13.2.4) Page RRP 9.126 Environment Sensor (PL13.2.5) Page RRP 9.127 Controller Chassis Assembly (PL14.1.1) Page RRP 9.128 Controller Fan (PL14.1.2) Page RRP 9.129 Controller PWB (PL14.1.10) Page RRP 9.130 Fuser Entrance Sensor (PL9.4.4) Page RRP 9.131 Fuser Chute Fan (PL9.4.10) Page Section 10 - Locating P/J Connectors Contents Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Section 11 - Parts List Contents Section 11 - Parts List Page Page PL1.1 Cover Page Page Page PL2.2 Paper Tray II Page PL3.1 Paper Feeder Page Page Page PL4.2 Multi Sheet Inserter II (MSI) Page PL4.3 Multi Sheet Inserter III (MSI) Page PL5.1 Paper Transportation l Page PL5.2 Paper Transportation ll Page PL6.1 Xerographics Page PL7.1 Development l Page PL7.2 Development ll Page PL8.1 IBT l Page PL8.2 IBT ll Page PL8.3 IBT lll Page PL8.4 IBT lV Page Page Page PL9.2 Fusing ll Page PL9.3 Fusing lll Page PL9.4 Fusing IV Page PL10.1 Paper Exit l Page PL10.2 Paper Exit ll Page PL11.1 Drive Page PL12.1 Frame Page PL13.1 Electrical l Page PL13.2 Electrical ll Page PL14.1 Controller Page Page Page PL30.2 Option Tray II Page Section 12 - Wiring Diagrams and Signal Information Contents 12-2 magicolor 330 - Base Engine Service Manual Wiring Diagrams and Signal Information Wiring Diagram Notations magicolor 330 - Base Engine Service Manual 12-3 Wiring Diagrams and Signal Information A C Master Wiring Diagram BD13 BD12 BD9 BD8 Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page General Specifications Page General Specifications continued Speeds for Continuous Printing After the First Sheet Out Image Registration and Reproduction Tolerances Paper Input Devices Paper Output Devices

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