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701P15051 8825-30 Service Manual

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0% found this document useful (0 votes)

659 views396 pages

701P15051 8825-30 Service Manual

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Andrei Alex

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Transmittal Page Product Title Part Number

8825/8830 Printer

Service Manual

701P15051

Status

Date

SUPERSEDES
Replaces 701P15050 dated May 1999

January 2002

THE DOCUMENT COMPANY

XEROX

8825/ 8830 Printer Service Manual

CAUTION
Certain components in the 8825/ 8830 Printer are susceptible to damage from electrostatic discharge. Observe all ESD procedures to avoid component damage.

701P15051 January 2002

NOTICE
While every care has been taken in the preparation of this manual, no liability will be accepted by Xerox Corporation arising out of any inaccuracies or omissions.

NOTICE
All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified product trained service personal only. Xerox does not warrant or represent that such documentation is complete, nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation. Customer performed service of equipment, or modules, components or parts of such equipment may affect the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third party provided service. If the customer services such equipment, modules, components or parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the customer agrees to indemnify, defend and hold Xerox harmless from any third party claims which arise directly or indirectly from such service.

Prepared by: Xerox Corporation 800 Phillips Road Bldg. 845-17S Webster, New York 14580-9791 USA 1998, 1999, 2000, 2001, 2002 by Xerox Corporation. All rights reserved. Xerox, XES, AccXES, and The Document Company are trademarks of Xerox Corporation. Xerox product names mentioned in this publication are trademarks of the XEROX CORPORATION.

Introduction
About this Manual ........................................................................................................... Organization .................................................................................................................... How to Use This Manual ................................................................................................. Repair Analysis Procedures (RAPs) ............................................................................... Repair / Adjustment Procedures ..................................................................................... iii iii iv v v

8825/8830 Printer

01/02 i

Introduction

01/02 ii

8825/8830 Printer

About this Manual

This manual is part of a documentation system that includes the training. This manual contains Repair Analysis Procedures (RAPs), Repair Procedures, Adjustment Procedures, Parts List, Diagnostic Procedures, Installation Procedures, Wiring Data and BSDs. This manual will enable the Service Representative to repair the 8825/8830 printers. Those service procedures affected by the 8825 configuration differences will be identified using the 8825 product name or Tag number.

Organization
This manual consists of eight sections. The title and description of each section are listed below.

Section 1. - Service Call Procedures

This section contains the following: Call Flow Procedure Initial Actions/ System Checks Print Defect Isolation Procedure Workstation Checkout Procedure Status Code Entry Chart Message Display Entry Chart Maintenance Procedures Callback System Checkout/ Final Action

Call Flow Procedure The Call Flow Procedure is a list of activities to be performed on each service call. Initial Actions/ System Checks This procedure is designed to identify and classify the problem and to refer you to the appropriate RAP in order to repair the problem. When the problem has been repaired, perform the Final Action. Print Defect Isolation Procedure This procedure directs the CSE to make test prints, perform test procedures to identify the cause of a print defect. Workstation Checkout Procedure This procedure is designed to ensure that the printer is correctly set up to run and communicate with other elements. It consists of a series of connection checks, configuration test prints, PING tests, and tests made from a laptop PC. Status Code Entry Chart This table provides a list of status codes, a description of the problem, the components that are affected, RAPs that may resolve the problem, as well as BSD references and Parts List references. Message Display Entry Chart This table contains a list of messages that may be generated by the printer, their cause, clearance procedures, and BSD references. Maintenance Procedures The Maintenance Procedures identifies functional checks and cleaning operations that must be performed on every Normal Call. It also identifies those activities that can be performed as needed or as scheduled.

8825/8830 Printer

01/02 iii

Introduction

About this Manual, Organization

Callback This service is performed when the CSE has been called back to correct a problem that was thought to have been recently corrected. The Callback is a short procedure performed on only that subsystem that caused the original service cal System Checkout / Final Action This procedure is used to verify that the printer is operating correctly after a repair, and that the correct steps are taken to close out a service call.

How to Use This Manual

The Service Call Procedures will direct you to the appropriate Section of the Service Manual. You should begin the service call with the Initial Actions/ System Checks Procedure. From there, you will be referred to either Section 2, Status Indicator RAPs, Section 3, Image Quality RAPs, or Section 7 BSDs. If you are sent to Section 3, compare the image defect to the print quality definitions. Once you have determined the definition that best describes the copy defect, go to the section contents. The section contents will direct you to an image quality RAP. The RAP has a list of probable causes and corrective actions. From these RAPs you may be referred to other sections of the manual to make checks, Adjustments, or to replace parts. When you have made a Repair, always go to the Call Flow Procedure to finish the call.

Section 2. - Repair Analysis Procedures (RAPs)

This section contains the Repair Analysis Procedures (RAPs) necessary to repair the faults. When using a RAP, always exit the procedure when the fault is fixed. Do not perform the remaining steps.

Section 3. - Image Quality Repair Analysis Procedures (RAPs)

This section contains the Repair Analysis Procedures (RAPs) necessary to repair the image quality faults. Refer to "How to Use the Image Defect Definitions" to compare the image defect to the definitions. Once you have determined the definition that best describes the defect, go to the section contents page to find the appropriate RAP. When using a RAP, always exit the procedure when the fault is fixed. Do not perform the remaining steps.

Section 4. - Repair / Adjustment

This section contains the repair and adjustment procedures for the 8825/8830 printers.

Section 5. - Parts List

This section contains the detailed Parts List for the 8825/8830 printers.

Section 6. - General Procedures

This section contains Diagnostic Procedures, Installation Procedures, and General Information, which includes Product Specifications for the 8825/8830 printers.

Section 7. - Wiring Data

This section contains the BSDs.

Introduction

Organization, How to Use This Manual

01/02 iv

8825/8830 Printer

Repair Analysis Procedures (RAPs)

A RAP is either a table of faults and possible solutions, or a series of steps designed to lead you to the cause of a problem. In each step, you will perform an action or observe an occurrence. For fault tree RAPS, at each step, a statement is made that has a Yes (Y) or No (N) answer. If the answer is NO, perform the action following the NO. If the answer is YES, proceed to the next step. When several items are listed, perform them in the order listed. Proceed through the steps only until the observed problem is isolated and solved. Then evaluate the unit for proper performance. If a further defect is observed, go to the appropriate RAP and perform the steps it contains until the additional fault is located and repaired.

Repair / Adjustment Procedures

The repair procedures provide detailed steps on how to remove and replace components. The adjustment procedures provide detailed steps on how to check and adjust components. Some units have been modified by various design changes. Each change or modification is labeled with a Tag/ MOD (modification) number. The Tag/ MOD numbers are identified in the Change Tag/ MOD Index in Section 6 of this Service Manual. When a modification affects how a particular procedure is performed, the procedure or steps are identified with either a W/ Tag/ MOD or a W/ O Tag/ MOD statement. Each procedure or step that is affected by a modification is identified with the statement, W/ Tag/ MOD, followed by the modification number. The W/ in the statement indicates that this step must be performed on units that are assembled with that specific modification. When the procedure or steps are not affected by a particular modification, they are identified with the statement, W/ O Tag/ MOD, followed by the modification number. The W/ O in the statement indicates that this step must be performed on units assembled without that specific modification.

8825/8830 Printer

01/02 v

Introduction

01/02 vi

8825/8830 Printer

1 Service Call Procedures

Introduction ..................................................................................................................... 1-3 1-5 1-5 1-6 1-6 1-7 1-11 1-12 1-15 1-17

If there is a print quality problem, go to the Print Defect Isolation Procedure in this Section. If the Printer Control Panel is blank, go to OF-1 Control Panel RAP in Section 2 of this service manual.

10. If the Printer Control Panel displays numbers during printer warm up, go to svc.8830prt.2974 in Section 2 of this service manual. 11. If the customers lights flicker when the machine is turned on, go to OF-3 Fuser Ballast RAP.

8825/8830 Printer

01/02 1-5

Service Call Procedures

Call Flow Procedure, Initial Actions/Systems

Print Defect Isolation Procedure

Procedure
1. 2. 3. Go to Special Tests 0955 in Section 6 of this service manual. Select option 5 (600 mm print length on 36 inch wide paper) and make an internal test print. If the defect is still present, go to Print Quality Initialization Procedure in Section 3 of this service manual. Go to Workstation Checkout Procedure located in this Section.

Workstation Checkout Procedure

Initial Actions
1. 2. 3. Ensure that all connectors are seated correctly at the Controller. If 8825/8830 DDS configuration, ensure that the SCSI cable from the Scanner is connected to the scanner connector on the Controller. The Configuration Test Print provides troubleshooting information that will be used later. Ensure that the communication parameters are set correctly.

Procedure
NOTE: Do each of the steps in sequence, unless directed otherwise. 1. 2. 3. Ask the customer to print a different file from the workstation. If the file prints OK, then the original file might be corrupt. If the workstation is connected to a network, go to 3.. Otherwise, go to 5.. Ask the customer to obtain the IP address of another device on the network. Ask the customer to go to the DOS prompt and to use the PING function to test the connection to the other device. If the PING test is successful, then go to 4.. Otherwise, notify the customer that there seems to be a network problem. Obtain the IP address for the Controller from the Configuration Test Print. Ask the Customer to use the PING function to test the connection to the Controller. if the test is successful, then go to step 5. Otherwise, go to FRU (Field Replaceable Unit) Test in Section 2 of the Controller Service Manual. Connect the laptop computer to the parallel port on the Controller. Open the Document Submission Tool. Insert the test file disk in the laptop. Send a test file to the Printer. if the defect is present, go to FRU (Field Replaceable Unit) Test in Section 2 of the Controller Service Manual. Otherwise, ask the customer to reload the print drivers. If the problem still exists, there could be a defective cable.

Service Call Procedures

Print Defect Isolation Procedure, Workstation Check-

01/02 1-6

8825/8830 Printer

Status Code Entry Chart

Status Code Table 1 Status Code Entry Chart Status Code C1-01 C2-01 C3-01 No RAP Description Position sensor error The Roll 1, 2, or 3 position sensor did not actuate or deactuate. Components BSD Ref PL Ref C1-09 C2-09 C3-09 No RAP C1-19 C2-19 C3-19 No RAP C1-29 C2-29 C3-29 No RAP C1-39 C2-39 C3-39 No RAP C1-59 C2-59 C3-59 RAP

Table 1 Status Code Entry Chart Description Firmware error This is a firmware problem. Press power off (0) then power on (1). If problem persists, replace the firmware. This is a Firmware problem This is a firmware problem. Press power off (0) then power on (1). If problem persists, replace the firmware. This is a Firmware problem. This is a firmware problem. Press power off (0) then power on (1). If problem persists, replace the firmware. This is a Firmware problem. This is a firmware problem. Press power off (0) then power on (1). If problem persists, replace the firmware. Components BSD Ref PL Ref PL 1.1A

Roll 1 position sensor BSD PL (Q1) 7.2 7.1 Roll 2 position sensor BSD PL (Q2) 8825 with Tag/ 7.3 1.1A MOD 90 BSD Roll 3 position sensor 7.4 (Q3) Main PWB (A3) NOTE: The sensors are interchangeable. Media registration sensor BSD PL (A21Q1) 8.1 8.2 Main PWB (A3) PL Driver PWB 1.1A Registration Rolls PL Transport Driver Motor 8.3 Motor Driver PWB Roll 1 motion sensor (Q4) Roll 2 motion sensor (Q5) 8825 with Tag/MOD 90 Roll 3 motion sensor (Q6) Main PWB (A3) Driver PWB Motor Driver PWB Media Feed Rolls Media Feed Clutch Media Feed Drive Motor NOTE: The sensors and the clutches are interchangeable. BSD 7.2 BSD 7.3 BSD 7.4 BSD 7.1 PL 7.1 PL 1.1A PL 7.2

PL 1.1A

C1-04

Media registration sensor error The media sensor did not actuate or deactuate when feeding from roll 1, 2, or 3.

PL 1.1A

C1-05 C2-05 C3-05 No RAP

Motion sensor error Motion was not detected or the media stopped moving when feeding from roll 1, 2, or 3.

Light reflecting off of a Roll 1 position sensor BSD PL piece of media or from rear (Q1) 7.2 1.1A of drawer or a baffle. Roll 2 position sensor BSD PL (Q2); 8825 with Tag/ 7.3 7.1 MOD 90 BSD Roll 3 position sensor 7.4 (Q3) Main PWB (A3) Registration sensor error The cut sheet does not reach the media registration sensor in time. Media registration sensor BSD PL (A21Q1) 8.1 8.2 Main PWB (A3) PL Registration Rolls 1.1A Transport Drive Motor PL Transport Motor Driver 7.2 PWB PL Cut Sheet Feed Clutch / 8.3 Rolls Driver PWB

C4-24 No RAP

C3-06 No RAP

Roll 2 position sensor error 8825 with Tag/MOD 90 Media was not detected at the Roll 2 position sensor when feeding from roll 3.

Roll 2 position sensor BSD PL (Q2) 8825 with Tag/MOD 7.3 7.1 90 PL Main PWB (A3) 1.1A

C4-34 No RAP

C3-07 No RAP

Roll 1 position sensor error Roll 1 position sensor BSD PL Media was not detected at the (Q1) 7.2 7.1 Roll 1 position sensor when Main PWB (A3) PL feeding from Roll 3. 1.1A

Sheet feed sensor error Sheet feed sensor (Q2) BSD PL The sheet feed sensor deac- 8825 with Tag/MOD 90 8.1 8.4 tuated too early while making Main PWB (A3) PL a print. The operator may 1.1A have removed the cut sheet media.

8825/8830 Printer

01/02 1-7

Service Call Procedures

Status Code Entry Chart

Table 1 Status Code Entry Chart Status Code C4-49 No RAP Description This is a Firmware problem This is a firmware problem. Press power off (0) then power on (1). If problem persists, replace the firmware. Components BSD Ref PL Ref PL 1.1A Status Code E4-09 No RAP E4-11 No RAP

Table 1 Status Code Entry Chart Description This is a Firmware problem Press power off (0) then power on (1). If problem persists, replace the firmware. Media exit sensor error Media exit The media exit sensor was (A23S1) detected to be actuated when Main PWB (A3) the machine powered up. This requires the media exit area to be opened, and the media to be removed. Sheet feed sensor error The sheet feed sensor was detected to be actuated when the machine powered up. This requires the media exit area to be opened, and to be removed. Components BSD Ref PL Ref PL 1.1A

E2-01 No RAP

Media registration sensor Media registration sensor BSD PL error (A21Q1) 8.1 8.2 The media trail edge jammed Main PWB (A3) PL in the media registration sen1.1A sor area. This is a Firmware problem This is a firmware problem. Press power off (0) then power on (1). If problem persists, replace the firmware. Registration sensor error Media registration sensor BSD PL The media registration sen- (A21Q1) 8.1 8.2 sor was detected to be actu- Main PWB (A3) PL ated when the machine 1.1A powered up. Media exit sensor error. The logic detected that the media exit sensor (Q3) was actuated at the wrong time. Indicating that the media trail edge is jammed in the area. Media exit sensor error Lead edge of media did not reach the media exit switch in time. Media exit sensor (Q3) BSD PL Main PWB (A3) 10.3 8.4 Exit Drive Pulley, Belt, PL Drive Rolls and Idler 1.1A Rolls Transport Drive Motor BSD PL Driver PWB (A2) 8.1 8.1 Media exit sensor (Q3) Main PWB (A3) Fuser Drive Motor Heat Roll Transfer/Detack Corotron Fabric Guide BSD PL 10.3 8.4 PL 1.1A PL 9.4 PL 10.1

sensor BSD PL 10.3 8.4 PL 1.1A

E2-09 No RAP

E4-12 No RAP

Sheet feed sensor BSD PL (A21Q2) 8825 with Tag/ 8.1 8.4 MOD 90 PL Main PWB (A3) 1.1A

E2-11 No RAP

E4-01 No RAP

E4-13 No RAP E4-14 No RAP

Stripper finger jam switch Stripper finger jam switch BSD PL error (A23S1) 10.3 10.4 The stripper finger jam switch Main PWB (A3) PL was actuated at power on. 1.1A Media buckle sensor error The media buckle sensor was detected to be actuated when the machine powered up. This requires the media exit area to be opened, and the media to be removed. Media buckle sensor BSD PL A21Q5) 4.1 8.4 Main PWB (A3) PL Fabric Guide Position 1.1A

E4-02 No RAP

E5-03 No RAP E5-04 No RAP E5-05 No RAP E5-06 No RAP

Top cover interlock switch Top cover interlock error switch (S26) The top cover was opened Driver PWB (A2) during print. Cutter cover interlock Cutter cover interlock switch error switch (S1) The cutter was opened during Driver PWB (A2) print. Feed shelf interlock switch Feed shelf interlock error switch (S29) The sheet feed shelf was Driver PWB (A2) opened during print.

BSD PL 1.3 14.5 PL 1.1A BSD PL 1.3 7.6 PL 1.1A BSD PL 1.2 14.3 PL 1.1A

E4-03 No RAP E4-04 No RAP

Stripper finger jam switch error The stripper finger jam switch was actuated during run.

Stripper finger jam switch BSD PL (A23S1) 10.3 10.4 Main PWB (A3) PL Stripper Finger Damaged 1.1A PL 14.1

Stacker Full Stacker Full Sensor The Stacker Full Sensor was actuated during a run or was detected to be actuated when the machine powered up.

Front door interlock switch Front door interlock BSD PL error switch (S21) 1.3 14.3 The front door was opened Driver PWB (A2) PL during print. 1.1A

Service Call Procedures

Status Code Entry Chart

01/02 1-8

8825/8830 Printer

Table 1 Status Code Entry Chart Status Code E6-00 Description Components BSD Ref PL Ref Status Code J2-02 No RAP

Table 1 Status Code Entry Chart Description Components BSD Ref PL Ref

Front door interlock switch Instruct the customer as error to the appropriate time to The C button was pressed press C while a print was being made in the roll feed mode. An operator induced soft shutdown results in a complete print being made. The left side door must be opened and then closed. Front door interlock switch Instruct the customer as error to the appropriate time to The Exit button was pressed press Exit while a print was being made in the roll feed mode. An operator-induced hard shutdown results in a partial print being made. The left side door must be opened and then closed. Communication error Go to E701 RAP in 8830 The IOT is unable to commu- Controller Service Mannicate with the Controller. The ual. IOT Off-Line and Media menus will still function, but cannot print from the Controller or network. Printer message display Language EPROM error A required message is not available in the language EPROM. Update the language EPROM. Software shutdown This error is of unknown cause. Please contact Software engineering. Refer to the Folder Service Manual for all F-codes. Toner sensor error Out of toner. Toner sensor (A22Q1) Main PWB (A3) BSD PL 9.7 9.9 PL 1.1A BSD 2.1

Cartridge home sensor Cartridge Home Sensor BSD PL error (A22Q2) 9.7 9.9 Toner cartridge could not find Main PWB (A3) PL the home position. Cartridge Drive Motor 1.1A Cartridge Drive Gear PL 9.10 Communication error Applies only to printers with a bit mapped user interface (FX). Check sum test error Both message ROMs have failed the checksum test immediately after power up. Fuser oil web error NVM count of web encoder pulses indicates the fuser oil web has reached end of life. Fuser oil web error No encoder pulses are being received from the fuser oil web. Web oiler motor (A23MOT1) Driver PWB (A2) CONTROL EPROMS Web oiler optical switch (A23S2) Web oiler motor (A23MOT1) Driver PWB (A2) BSD PL 10.2 1.1A PL 9.6 BSD PL 10.2 1.1A PL 9.6 BSD PL 10.2 10.4 PL 1.1A

LL-00

E6-01

LL-02

LL-05 No RAP LL-06 No RAP

E7-01

E7-02 No RAP

LL-07 No RAP

Fuser oil web error P/J 4, wiring harness, Web Oiler Assembly connec- pins tor not connected. Driver PWB (A2) NOTE: TAG 3 must be installed for this code. If not, disable the fault detection using [10-35 Module wrap-around error The paper transport assembly or the Xerographic module is disconnected. Communications error Failed communications between the Driver PWB (A2) and the Main PWB (A3). Xerographic module (A23) Paper transport assembly (A21) Driver PWB (A2) Driver PWB (A2) (fuser drive circuit) Driver PWB (A2) (drum drive circuit) Main PWB (A3) CAUTION: Fuser must be up to temperature before running motors.

E9-XX

LL-10 No RAP

BSD PL 7.5 1.1A

Fx-xx J1-01 No RAP

LL-11 No RAP

BSD PL 4.1 1.1A BSD 4.3

8825/8830 Printer

01/02 1-9

Service Call Procedures

Status Code Entry Chart

Table 1 Status Code Entry Chart Status Code LL-12 No RAP LL-21 No RAP LL-22 No RAP Description Components BSD Ref PL Ref Status Code LL-41

Table 1 Status Code Entry Chart Description Components BSD Ref 10.1 PL Ref PL 10.2 PL 1.1A PL 1.2A PL 1.3

Photoreceptor motor stall Drum drive motor fault (A20MOT3) Driver PWB (A2) ADJ 8.4 Media Transport HVPS Charge error Xerographic HVPS (A25) The charge scorotron fault Driver PWB (A2) signal was active for 1.5 sec- Scorotron onds. Transfer / Detack HVPS Charge error The transfer / detack corotron fault signal was active for 1.5 seconds. Cutter error The cutter did not leave or reach the home sensor. Turn power off, then on. Xerographic HVPS (A25) Driver PWB (A2) Transfer/Detack Corotron Cutter home sensor (A8Q1) Driver PWB (A2) Cutter Drive Motor

BSD PL 4.3 1.1A PL 9.1 BSD PL 9.1 1.3 PL 1.1A BSD PL 9.8 1.3 PL 1.1A BSD PL 7.5 1.1A PL 7.8 10.1 PL 10.2 PL 10.4 PL 1.1A

Fuser temperature error Fuser heat rod (HTR1) Fuser was in the warm up Fuser power relay (K1) mode too long. Triac (Q1) Ballast resistors (R1 & R2) Fuser ballast power relay (K3) Driver PWB (A2) Main PWB (A3) Fuser fault Fuser power relay (1K1) Fuser was expected to be Fuser ballast power relay warming but is was not. (A1K3) Fuser Triac (A1Q1) Fuser heater (A23HR1) Power supply error LVPS (A5) 26 VDC Bulk power supply Driver PWB (A2) failure. Main PWB (A3)

LL-4F No RAP

BSD PL 10.1 1.2A PL 10.2 BSD PL 1.2 1.1A PL 1.3 PL 1.3 PL 1.1A

LL-30 No RAP LL-41

LL-50 No RAP

Fuser heat rod (HTR1) Fuser error The fuser did not reach 110F Thermistor assembly within one minute. (A23RT1) Fuser power relay (K1)Triac (Q1) AC Power module (A1) Driver PWB (A2) Main PWB (A3) Triac (Q1) Fuser temperature error The fuser roll temperature is AC Power module (A1) greater than the maximum Driver PWB (A2) allowable temperature for more than thirty seconds. Maximum temperature is currently 348 F (176 C). Fuser temperature error Fuser temperature has exceeded the temperature limit. The FUSER OPEN (L) +26 VDC signal is low. Triac (Q1) AC Power module (A1) Driver PWB (A2) Thermal fuse (A23F1)

LL-51 No RAP LL-52 No RAP

Power On Self Test fault Main PWB (A3) The internal RAM failed POST. Power On Self Test fault Install the or EPROM Main PWB installed without Main PWB (A3) CONTROL EPROMS The external RAM failed POST. Power On Self Test fault Install the IOT firmware checksum error. EPROM Main PWB (A3) Power On Self Test fault Main PWB (A3) An unknown device failed POST. Power On Self Test LVPS LVPS fault The +10 V FWR voltage was detected to be off when it should have been on. Power On Self Test ADC/ Main PWB (A3) DAC fault Driver PWB (A2) The ADC/DAC failed POST Power On Self Test SCC Main PWB (A3) fault Control

PL 1.1A

LL-42 Thermal Control RAP LL-43 Fuser Over Temperature RAP LL-44 Fuser Too Hot RAP

10.1

PL 1.2A PL 1.1A

LL-53 No RAP 10.1 PL 1.1A PL 1.2A PL 10.4 PL 10.4 PL 1.1A LL-54 No RAP LL-55 No RAP

Control

PL 1.1A PL 1.1A BSD PL 1.2 1.1A

Fuser temperature error Fuser temperature exceeded 420 F (215 C). The TEMPERATURE LIMIT signal exceeds its limit.

Triac (Q1) LVPS (A5) Driver PWB (A2) Main PWB (A3)

10.1 1.2 10.1 10.1

LL-56 No RAP LL-57 No RAP

PL 1.1A PL 1.1A

Service Call Procedures

Status Code Entry Chart

01/02 1-10

8825/8830 Printer

Table 1 Status Code Entry Chart Status Code LL-58 No RAP LL-60 No RAP Description Components Control BSD Ref PL Ref PL 1.1A

Message Display Entry Chart

Table 1 Message Display Entry Chart MESSAGE DISPLAYED CAUSE --CLEARANCE PROCEDURE BSD Ref BSD 10.1 BSD 9.3

Power On Self Test Install the Extra Return Value from the EPROM Operating System. Reboot Main PWB (A3) (Power off / Power On). Power On Self Test NVM Checksum fault Record the existing NVM values. Run diagnostic [0360] to reset NVM to the default values. Manually restore the required NVM values. Power On Self Test revision level fault Power the printer up in diagnostics and run [0360] to reset NVM to default values. This is a Firmware problem This is a firmware problem. Press power off (0) then power on (1). If problem persists, replace the firmware.

PRINTER IS WARM- No fuser heat ING UP (Continuously displayed)

ADJUSTING THE Toner dispense - - PRINT QUALITY (Con- problem tinuously displayed)

PLEASE CLOSE THE Drawer X read Refer to the display on the control panel BSD MEDIA DRAWER X switch is open. and follow the clearance procedure. 7.1 (Refer to Note) PLEASE CLOSE THE Cut sheet feed Refer to the display on the control panel BSD CUT SHEET FEED shelf interlock and follow the clearance procedure. 1.2 SHELF switch (S29) is open. PL 1.1A PLEASE CLOSE THE Front door inter- Refer to the display on the control panel BSD FRONT DOOR lock switch (S21) and follow the clearance procedure. 1.2 is open. PLEASE CLOSE THE Top cover interlock Refer to the display on the control panel BSD TOP DOOR switch (S26) is and follow the clearance procedure. 1.2 open. 3.1 9.7 9.7 9.3 PL 1.1A PL 9.9 PLEASE CLOSE THE Cutter cover inter- Refer to the display on the control panel BSD CUTTER DRAWER lock switch (S1) is and follow the clearance procedure. 1.2 open. NVM FAULT CALL FOR Corrupted data in Press power off (0) then power on (1). If ASSISTANCE NVM. problem persist run diagnostic program [0363] or [0360]. If problem persist replace the Control EPROMS. Re-feed Roll 1 Re-feed Roll 2 BSD PL 3.1 1.3 PL 1.1A Re-feed Roll 3 Re-feed problem. Re-feed problem. Re-feed problem. roll roll roll 1 Re-feed the media. If necessary, press BSD power off (0) then power on (1). 7.2 2 Re-feed the media. If necessary, press BSD power off (0) then power on (1). 7.3 3 Re-feed the media. If necessary, press BSD power off (0) then power on (1). 7.4

LL-61 No RAP

LL-89 No RAP

LL-90 Overtoned Fault RAP

Overtoned fault Cartridge drive motor Toner concentration of the (A22MOT1) developer material is too high. Cartridge home sensor (A22Q2) Toner sensor (A22Q1) Main PWB (A3) Cartridge drive motor (A22MOT1) Cartridge home sensor (A22Q2) Toner sensor (A22Q1) Main PWB (A3)

LL-91 Undertoned fault Under- Toner concentration of the toned developer material is too low. Fault RAP U1-01 No RAP

9.7

PL 9.9 PL 1.1A

Media counter error Media counter Print counter is disconnected. Main PWB (A3)

Flashing 1, 2, 3, 4, 5, 6 Copier failed Press power off (0) then power on (1). If or 7 power on self-test. problem persists, go to svc.8830prt.2974. UNABLE TO CALI- The sensor did not Press power off (0), then power on (1). BSD BRATE TONER SEN- calibrate when the If problem persists, go to LL-91 Under- 9.7 SOR code [0921-6] was toned Fault RAP. entered. TONER FAULT CALL Excessive toner Press power off (0), then power on (1). BSD FOR ASSISTANCE sensed problem. If problem persists, go to LL-90 Over- 9.7 toned Fault RAP.

8825/8830 Printer

01/02 1-11

Service Call Procedures

Status Code Entry Chart, Message Display Entry

Table 1 Message Display Entry Chart ALL ROLLS ARE EMPTY Media Registration Go to C1-04. Sensor failed to sense media.

Maintenance Procedures
Table 1 Image Module INTER VAL Normal Call Normal Call TASK Check, clean, or repair spacing wheels as required. REASON TASK ENABLER

NOTE: Substitute 1, 2, or 3 for X depending on which status code is displayed.

Contaminated, dirty or Clean or replace spacing wheels and worn spacing wheels or the end surface that the wheels ride drum ends cause print on. quality defects.

Check and clean, if Contaminated grid, bent required, the or contaminated pins. scorotron. Worn end blocks, are also causes for scorotron failure, which results in print quality defects.

WARNING
The scorotron pin arrays are very sharp. Use care when handling the assembly. If contaminated, remove scorotron assembly and clean both sides of the grid with a brush. Examine pins and clean with brush Only if contaminated. Cleaning with a cloth can deposit lint that will cause print quality problems.

Normal Call

Clean the image Contamination causes Clean the image bar with a lint free bar. print quality defects. cloth and lens cleaner.

As Repair or replace Contamination causes WARNING Requir the scorotron/grid. print quality defects. The scorotron pin arrays are very ed sharp. Use care when handling the assembly. Replace the grid and/or pin array. Perform ADJ 9.2 Electrostatic Series. Table 2 Xerographic Module INTER VAL TASK REASON TASK ENABLER

Service Call Procedures

Message Display Entry Chart, Maintenance Proce-

01/02 1-12

8825/8830 Printer

Table 2 Xerographic Module Normal Call Clean the xerographic module. Clean the erase lamp. Inspect the photoreceptor for damage. Inspect components for vellum contamination. Inspect all seals for damage. Inspect the Cleaner Blade for damage. Contamination can cause print quality problems. Contaminants can travel to the LED bar and scorotrons, which results in print quality problems. Fused toner on the bottom of the module can cause jams. Contamination reduces the effectiveness of the lamp to discharge the photoreceptor drum. Contaminants from vellum - Cleaner failure - Contaminants to prints. Vellum contamination will contaminate and plug the cleaner auger at the ends. Clean the toner from the housing and cleaner blade with a vacuum cleaner. NOTE: Ensure that the vacuum cleaner does not contact the edge of the cleaner blade that touches the surface of the photoreceptor drum. Perform the Photoreceptor Cleaning Enhancement procedure in section 6. Use cleaning solvent to remove any fused toner from the bottom of the module. Replace the photoreceptor if damaged. Clean the erase lamp with a brush or dry lint free cloth. Replace any damaged xerographic module seals.

Table 2 Xerographic Module As Check/clean the Contamination/wear, Requir photoreceptor. scratches, or chips can ed generate print quality problems. Inspect photoreceptor surface for deep scratches, chips or excessive wear. Replace photoreceptor if damaged. Apply zinc stearate to the cleaning blade and photoreceptor drum. *Note 2 Clean photoreceptor surface with Xerox Film Remover if contaminated. Apply zinc stearate when surface is dry. Vacuum clean the cleaning blade. *Note 1 Apply zinc stearate to the cleaning blade and photoreceptor drum. *Note 2 Replace the blade if damaged.

As Requir ed *Note 3

Check/clean the cleaning blade. Replace with the new photoreceptor or as required.

Residual image, streaks, drum scuffing can occur if the blade is worn or contaminated.

30K ft. Replace the fabric Jams, deletions, wrinkles. Refer to REP 8.9 9Km guide. 30K ft. Clean the inner If the customer is running 9Km xerographic mod- a high percentage of velule components. lum, outgassing of the vellum contaminates the cleaner auger and lower baffle surface resulting in poor cleaning and high dirt contamination. plugged cleaner auger Remove the fuser roll and photoreceptor to enable access. NOTE: Use caution not to touch or damage cleaning blade or seals. Vacuum the Xero Mod and Auger and then clean all contaminated areas with Film Remover.

Normal Call

Check and clean or replace the Stripper Fingers. Clean the Media Guides.

Bent stripper fingers may Replace the damaged or contamicause feed out jams and nated stripper fingers. heat roll damage. Contaminated or damaged media guides can cause print quality defects. Smooth or worn fuser roll loses ability to drive media. Contaminated fabric guide causes too much resistance to media which results in jams/ deletions/wrinkles. Clean the roll with film remover. Clean the fabric guide with formula A and film remover. Perform diagnostic code 1033 every time the oiler is removed.

Normal Call

Clean/check the Fuser Roll fabric guide. Replace the Fuser Roll.

NOTE: 1. Ensure that the vacuum does not contact the edge of the cleaner blade that touches the surface of the photoreceptor drum. NOTE: 2. Where possible, dust the drum and the cleaning blade with zinc stearate away from the xerographic module to prevent the charge scorotron from being contaminated. If the drum and cleaning blade must be dusted while in the xerographic module, remove the charge scorotron. The zinc stearate will contaminate the charge scorotron and cause print quality defects. NOTE: 3. Install the complete cleaning blade kit when installing a new photoreceptor. Table 3 Media Transport INTER VAL Normal Call Normal Call TASK REASON TASK ENABLER

Normal Call

Check the fuser Too little oil can cause roll for lack of oil. media handling and offsetting print quality problems.

Check remaining fuser web life [1034] and adjust the web oiler rate [1032]. If the fuser roll is dry, refer to BSD 10.2.

Normal Call

Inspect/clean the Contamination can cause Clean the thermistor pad with a brush thermistor pad fuser heat problems. or dry lint free cloth.

Clean the lower Contaminates can cause Clean the transport with antistatic paper transports, the media to slip resulting fluid and a lint free cloth. turnaround baffle, in print quality defects. Clean the feed roller with Formula A. paper feed rolls. Clean the under Reduce the airborne con- Vacuum clean, then wipe down with a side of the trans- taminants. lint free cloth. port. Service Call Procedures

8825/8830 Printer

01/02 1-13

Maintenance Procedures

Table 3 Media Transport Normal Call Clean the transfer Improve toner transfer to Remove the transfer corotron. Clean corotron media. loose toner/debris with a brush. Use Improve media tack. only a water-dampened cloth to remove contaminants from the extrusion. NOTE: Some of the coating may come off onto the cloth. Normal Call Empty the conden- Prevent the bottle from Empty the bottle into a sink. sation reclaim bot- overflowing. tle. Normal Call

Table 5 Developer Module Check, clean, or Contaminated or worn Clean or replace spacing wheels. replace the devel- spacing wheels will cause oper housing print quality defects. spacing wheels, as required.

30K ft. Check the trickle An obstructed Y tube or Clean as required. 9Km tube and toner Y trickle tube will clog the tube for obstruc- cleaning/trickle system. tion. 30K ft. Check the pres- Increased contamination Remove developer housing. Remove 9Km sure equalizing due to poor air flow in the and vacuum tubes, vacuum lower tubes. developer housing. holes for toner. Table 6 Covers INTER VAL Normal Call TASK Clean the covers. REASON Customer satisfaction. TASK ENABLER Formula A and antistatic fluid on the and cut sheet feed-in shelf.

25K ft. Repair or replace Contamination causes Clean (same as the step above). 7Km the transfer print quality defects. corotron. Table 4 Media Feed INTER VAL TASK REASON TASK ENABLER Loosen the feed motor hardware to allow the spring to tension the chain. Tighten the hardware. Loosen the feed motor hardware to allow the spring to tension the chain. Tighten the hardware.

1st Remove the drive Feeding problems. 10K ft. chain slack. or 3K m 40K ft. Remove the drive Feeding problems. or 13K chain slack. m

Table 7 Cutter INTER VAL Normal Call Normal Call TASK REASON TASK ENABLER

Table 5 Developer Module INTER VAL Normal Call TASK REASON TASK ENABLER

Check the cam for To ensure the correct cut- Place a light film of lubrication on the lubrication. ter operation. The cutter cam surface. will not provide a straight cut. Clean the cutter. To ensure a straight, Vacuum the media dust and contamismooth cut on the lead nation from the cutter blade area. edge of the media. Table 8 Media Drawers

Brush the devel- Image quality problems Clean as required. oper from the can occur. Developer Seal and lower edge of the Developer Housing back into the Developer Mag Roll and then clean the Seal. Check that the If the developer is not Developer material should not be unideveloper housing level, density may not be form from end to end. Check the level is level. uniform side to side. of the copier. Check the canis- If the canister is not rotat- Check the dry ink dispense motor for ter for proper rota- ing correctly, the copies binding. Check that the cartridge is tion. will be light. locked in the drive hub. Check the devel- Worn gears will cause the oper drives. housing to move up or down, which will cause print quality defects. Check the gears for worn or broken teeth; replace the gears, if necessary. Ensure that the drive coupling is engaged.

INTER VAL Normal Call

TASK

REASON

TASK ENABLER Clean the media dust and contamination from each of the media drawers with a vacuum cleaner.

Clean the media Customer satisfaction. drawer.

1
Access the Control Panel menu and record the Meter A reading

2
(8830 printer only:) Access the Control Panel menu and record the Meter B reading.

Figure 1 Recording the Print Count Readings 3. 4. 5. Record all activities in the Service Log. Record the Print Count Readings on the Service Call Report. Give appropriate credit to the Customer.

8825/8830 Printer

01/02 1-17

Service Call Procedures

System Checkout / Final Action

Service Call Procedures

C1-04/C2-04/C3-04 RAP

C1-59/ C2-59/ C3-59 RAP

NOTE: C1, C2, C3 means Roll 1, 2, or 3. The Media Drive Motor (MOT1, BSD 7.1) was trying to feed the Roll x Media forward to the registration position but the Position Sensor (Q1, Q2, or Q3, BSD 7.2, 7.3, 7.4) sensed that the media jammed. The problem may be caused by light reflecting off of media, the media drawer, or baffles and returning to the media Position Sensor.

Initial Actions
Check that the Roll 1, 2, or 3 (the Drawer that was in use when the fault occurred) Position Sensor Q1, Q2, or Q3 is not blocked by a piece of media. Ensure that there are no strips or pieces of media in the area of the Position Sensor Q1, Q2, or Q3. Table 1 Media Roll Roll 1 Roll 2 Roll 3 BSD 7.2 BSD 7.3 BSD 7.4

Status Indicator RAPs

C1-59/ C2-59/ C3-59 RAP

01/02 2-4

8825/8830 Printer

LL-41/LL-45 Fuser Warm-up Fault RAP

NOTE: Go to BSD 10.1 while using this RAP. This RAP is used when the Fuser does not warm up when the control logic attempts to increase the heat. LL-41 is displayed when the Fuser heat does not increase to 110 F (43 C) within one minute. LL-45 is displayed when the Fuser temperature is greater than 110 F (43 C) but does not reach the setpoint temperature within the specified time period.

Initial Actions
Ensure that the following connectors are correctly seated: 1. 2. 3. 4. 5. Thermistor Assembly RT1J5 / A23P5 Thermal Fuse A23XF1 Xerographic Module A23J2 / A23P2 Fuser Heat Rod A23HR1P2 (blue wire) Fuser Heat Rod A23HR1P1 (brown wire)

B Check for AC power from the Fuser Power Relay as follows: Reconnect A23P1/A23J1. Set the meter to read AC voltage and connect the meter leads to A1K1-4 and A1K1-8. Cheat the front door interlock. Connect the Power Cord and switch on the printer. Wait 10 seconds. AC power is present. Y N Set the meter to read 26 VDC and connect the (+) meter lead to A1K1-1 and the (-) meter lead to A1K1-0. Switch off, then switch on, the printer. 26 VDC is present. Y N Check the Fuser Power Relay On signal from the Driver PWB, A2, as follows: Connect the (+) meter lead to A2J213-1 and the (-) meter lead to A2J213-3. 26 VDC is present. Y N PL 1.1A Replace the Driver PWB, A2. Check and repair the wiring between the Driver PWB, A1, and the Fuser Power Relay, A1K1. Replace the Fuser Power Relay, A1K1, PL 1.2A. Switch off the printer and disconnect the power cord. Check the following wires for continuity. Table 1 From A1K1-8 A1Q1MT2-A A1K1-4 The wires have continuity. Y N Repair the wires Set the meter to read +2 VDC. Connect the (+) lead to A1Q1-G (BRN wire) and the (-) lead to A1Q1-MT1 (WHT wires). Reconnect the Power Cord and switch on the printer. Wait 10 seconds. Set the voltage meter to Peak Hold. The Peak Voltage exceeds 0.9 VDC. Y N Connect the (+) meter lead to A2P213-11 and leave the (-) meter lead connected to A1Q1-MTI. Pulses are present. Y N Replace the Driver PWB, A2, PL 1.1A The machine has TAG 50 (50Hz only) installed. Y N Repair the wire between terminal G and A1Q1 and A2P213-11 (wire no. 31) To A1Q1MT1-A A23P1-1 A23P1-3 Color WHT BLU BLK & BRN

Ensure that the correct Fuser Heat Rod is installed. Check the wall outlet for correct line voltage.

WARNING
Dangerous Voltage

Procedure
NOTE: After entering the code [1004], the Fuser Power Relay, A1K1, and the Fuser Power LED, (A2CR15 without Tag 25 or A2CR31 with Tag 25) on the Driver PWB, are energized for approximately five minutes. Enter DIAGNOSTICS (General Procedures). Enter [1004] to test the operation of the Fuser. After 10 seconds, the Fuser Heat Rod is still on. Y N Switch off the printer and disconnect the power cord. Measure the resistance of the Heat Rod as follows: Disconnect A23P1/A23J1. Connect the meter leads to A23J1-1 and A23J1-3. The resistance is less than 30 Ohms. Y N Check the wiring between A23J1 and the Fuser Heat Rod (HR1). The wires have continuity Y N Repair the wires Replace the Fuser Heat Rod, HR1 ( PL 10.2)

A 01/02 2-5

D Status Indicator RAPs

8825/8830 Printer

LL-41/LL-45 Fuser Warm-up Fault RAP

D Connect the (+) meter lead to A9P1-2 and leave the (-) meter lead connected to A1Q1-MTI. Pulses are present. Y N Repair the wires. Check the wiring between the Heat Rod Control PWB (A9) and the Fuser Triac (Q1). If OK, replace the Heat Rod Control PWB.

LL-42 Thermal Control RAP

NOTE: Go to BSD 10.1 while using this RAP. This RAP is used to locate certain problems in the thermal control circuitry in the Fuser area.

WARNING
Dangerous Voltage

Switch off the printer and disconnect the power cord. Replace the Fuser Triac, A1Q1, PL 1.2A. Then go to OF-3 Fuser Ballast RAP to check that the ballast circuit is operating correctly. The Thermistor Pad on the Thermistor Pad Assembly touches the Fuser Roll. Y N Replace the Thermistor Pad Assembly, PL 10.4. The Thermistor Pad is free of contamination. Y N Clean the Thermistor Pad with a clean cloth. Check the wires between the Fuser Thermistor, RT1, and the Main PWB, A1, for continuity. The wires have continuity. Y N Repair the wires. Replace the Thermistor Pad Assembly, PL 10.4.

Initial Actions
Switch off, then switch on the printer. If the problem still exists, perform the procedure below.

Procedure
Switch off the printer and disconnect the Power Cord. Disconnect the orange wire from the Fuser Triac, A1Q1-G. Reconnect the Power Cord and switch on the printer. Wait 10 seconds. After 5 seconds, the Fuser Heat Rod is off. Y N Replace the Fuser Triac, ATQ1, PL 1.2A. Switch off the printer. Disconnect A23P5 from the Thermistor Pad Assembly J5. Set the meter to read 100ohms. Connect the (+) meter lead to J5-1. Connect the (-) meter lead to J5-2. The resistance is greater than 100 ohms. Y N Replace the Thermistor Pad Assembly, PL 10.4. Check the wiring between Fuser Thermistor, RT1, and the Main PWB, A2. The continuity. Y N Repair the wires. Replace the Main PWB, A2, PL 1.1A. wires have

Status Indicator RAPs

LL-41/LL-45 Fuser Warm-up Fault RAP, LL-42 Ther-

01/02 2-6

8825/8830 Printer

LL-43 Fuser Over Temperature RAP

NOTE: Refer to BSD 10.1 while using this RAP.

B Check the BLU and GRY wires between the Thermal Fuse. A23F1, and the Driver PWB, A2 for continuity. The wires have continuity. Y N Repair the wires. Disconnect A23P5 from the Thermistor Pad Assembly JS. Set the meter to measure 200K ohms. Connect the (+) meter lead to the Thermistor Pad Assembly J5-1 and the (-) meter lead to J5-2. The resistance is less that 200K ohms. Y N Replace the Thermistor Pad Assembly PL 10.4. Check the YEL and GRN wires between the Fuser Thermistor and the Main PWB, A1 for continuity. The wires have continuity. Y N Repair the wires. Replace the Driver PWB, A2, PL 1.1A. If the problem persists, replace the Main PWB A1, PL 1.1A.

WARNING
Dangerous Voltage LL-43 is displayed when the logic detects that there is a problem with the Fuser temperature and an overtemperature condition has caused the Thermal Fuse, A23F1, to open.

Initial Actions
Ensure that the following connectors are correctly seated: 1. 2. 3. 4. Driver PWB A2J213 / A2P213 Driver PWB A2J201 / A2P201 Xerographics Module A23J2 / A23P2 Thermistor Pad Assembly J5 / A23P5

Ensure that both cooling fans are working. If not, go to BSD 1.3 to repair the cooling fans circuit. Ensure that all interlocks are closed.

Procedure
Connect the (+) meter lead to the Driver PWB A2P201-1 and the (-) meter lead to ground. There is +26 VDC present. Y N Check continuity through the Overtemperature Fuse, A23F1, as follows: 1. 2. 3. Disconnect the BLU and GRY wires from the fuse. Set the meter to measure continuity. Connect the meter across the fuse terminals.

Connect the (+) meter lead to the Driver PWB, A2P213-3 and the (-) meter lead to ground. Enter Diagnostic code [1009] to turn on the Fuser Power Relay, A1K1. The voltage changes from +26 VDC to less than 1 VDC when the Fuser Power Relay is turned on. Y N Check the BRN and ORN wires between the Fuser Power Relay, A1K1, and the Driver PWB, A2 for continuity. The wires have continuity. Y N Repair the wires. Replace the Driver PWB, A2, PL 1.1A. If the problem persists, replace the Main PWB, A1 PL 1.1A. Replace the Fuser Power Relay, A1K1, PL 1.2A.

The fuse has continuity Y N Switch off the printer and disconnect the Power Cord. Replace the Thermal Fuse, A23F1, PL 10.4. Perform the following steps to determine the cause for the fuse to open: 1. 2. Disconnect the BLU and WHT wires from the Fuser Triac, A1Q1. Set the meter to measure 2K ohms. Measure the resistance across the Fuser Triac connections from which the wires were removed. If the resistance is not infinite, replace the Fuser Triac, A1Q1, PL 1.2A. Measure the resistance from each of the Fuser Triac connections from which the wires were removed to ground. If the resistance is not infinite, replace the Fuser Triac, A23Q1, PL 1.2A.

Y N Connect the (+) meter lead to the Driver PWB, A2P201-3 and the (-) meter lead to ground. There is +26 VDC present. Y N Replace the Driver PWB, A2, PL 1.1A.

B 01/02 2-7 Status Indicator RAPs

8825/8830 Printer

LL-43 Fuser Over Temperature RAP

LL-44 Fuser Too Hot RAP

NOTE: Refer to BSD 10.1 while using this RAP.

WARNING
Dangerous Voltage LL-44 is displayed when the Fuser temperature exceeds 420 F (216 C), the maximum allowed temperature. The status code may also be displayed if the Temperature Limit Thermistor, A23RT2, has a malfunction or is contaminated.

Initial Actions
Switch off the printer and allow the fuser to cool. Switch on the printer. If the problem still exists, perform the following procedure.

Procedure
Check the Fuser Triac, A1Q1, as follows: 1. 2. 3. 4. Switch off the printer and disconnect the Power Cord. Disconnect the BLU and WHT wires from the Fuser Triac, A1Q1 Set the meter to measure 2K ohms. Measure the resistance across the Fuser Triac connections from which the wires were removed.

The resistance is infinite. Y N Replace the Fuser Triac, A1Q1, PL 1.2A. Measure the resistance from each of the Fuser Triac connections from which the wires were removed from the ground. The resistance is infinite. Y N Replace the Fuser Triac, A1Q1, PL 1.2A. Disconnect A2P201 from the Driver PWB A2J201. Set the meter to measure 5 VDC. Connect the (+) meter lead to the Driver PWB A2J2-9 and the (-) meter lead to A2J2-10. There is +5 VDC present. Y N Replace the Driver PWB, A2, PL 1.1A. Check the YEL and GRN wires between the Temperature Limit Thermistor and the Driver PWB, A2, for continuity and for a short to ground. The wires are OK. Y N Repair the wires. Replace the Thermistor Pad Assembly, PL 10.4.

Status Indicator RAPs

LL-44 Fuser Too Hot RAP

01/02 2-8

8825/8830 Printer

LL-60/LL-61 NVM Fault RAP

ADJ 8.2 This RAP is used for NVM (Non-Volatile Memory) problems that are indicated by a status code or a message display. The control panel displays the message NVM Fault Call For Assistance. LL-60 or LL-61 may also be displayed. The problem may be caused when the NVM data are corrupted or partially corrupted. The contents of the NVM do not agree with the checksum, or the contents of the NVM do not agree with the shadow contents. LL-60 - This status code indicates corrupted data in NVM. Perform steps 1 through 4 of the procedure. LL-61 - This status code is an indication that an older version of firmware has been installed. Ensure that the newest version of firmware is installed. If the problem persists, perform steps 1 through 4 of the procedure. ADJ 8.3 ADJ 9.2 ADJ 10.1

Table 2 Lead Edge Registration Cut Length Electrostatic Series Fuser Temperature

NOTE: If the values entered are not retained, replace the NVM (PL 1.1A) and perform steps 24 again.

Procedure
The purpose of this procedure is to restore the printer to normal operation condition. Go to To Enter The Diagnostic Mode located in Section 6 when performing this procedure. 1. Enter the following diagnostic codes and record the corresponding data values displayed on the control panel: Table 1 [02-61] [0760] [0860] [0862] [0903] Country Configuration Delay Between Film Prints Lead Edge Registration value Cut length value Image Module Output Light Value [0360-2] Electronic Billing Meters value

[0921-2] Vhigh [0921-3] Illumination (Exposure) value [1034] [1060] [1062] [1063] 2. 3. Remaining Oiler Web Life Fuser Temperature Fuser Temperature Fuser Temperature

Enter [0360-1] for NACO printers or [0360-3] for EO printers to reset the contents of the NVM to the factory default values. Enter [0921-6] and then compare the values recorded in step 1 to previously recorded values for this printer. Enter the codes listed in step 1 and change the default values as required.

NOTE: If any value recorded in step 1 appears to be incorrect, use the previously recorded value. If there is no previously recorded value, retain the default value. 4. Check/adjust the following: Table 2 ADJ 8.1 Vertical Magnification Status Indicator RAPs

8825/8830 Printer

01/02 2-9

LL-60/LL-61 NVM Fault RAP

LL-90 Overtoned Fault RAP

NOTE: Go to BSD 9.7 while using this RAP. The status code LL-90 is displayed when the logic detects that the toner concentration is significantly greater than the Control Point value. The Toner Control System is designed to maintain the Toner Concentration within an acceptable operating range. The Control Point operating range is from 5.2 VDC to 6.0 VDC. The Toner Sensor continuously senses the Toner Concentration. A change in the Toner Concentration results in a corresponding change of the Sensor signal. As the toner concentration increases, the Toner Sensor signal voltage decreases. The logic monitors the Sensor signal. LL-90 indicates that the logic detected that the toner concentration increased greater than the allowable limit. The problem may occur if there is a problem with the toner dispensing or the developer mixing systems. Ensure that the Developer Housing Drive Gear is positioned with the flange as shown. Ensure that the Rear Auger Drive Gear is positioned with the flange as shown.

Ensure that the Front Auger Drive Gear is captured in position by the Rear Auger Drive Gear Flange and the Developer Housing Drive Gear flange.

Flange

Initial Actions
Clean the Pressure Equalizing Tubes with a vacuum cleaner in order to remove toner from inside the tubes. Clean the Augers and Magnetic Roll Examine the Developer Housing and check for a large amount of toner in the area of the Toner Dispenser. Ensure that the printer is level. Ensure that the Toner Cartridge is not damaged and that the seal is secured to the Cartridge in the correct location. Check that all the connectors between the Toner Sensor, A22Q1, and the Main PWB, A2, are seated correctly. (Figure 1): Ensure that the Developer Housing Auger and Drive Gears are not damaged and are installed correctly. Cartridge Drive Motor removed for clarity Flange

Developer Housing Drive Gear

Rear Auger Drive Gear

Front Auger Drive Gear

Figure 1 Developer Housing and Auger Drive Gears

Status Indicator RAPs

LL-90 Overtoned Fault RAP

01/02 2-10

8825/8830 Printer

Procedure
With the printer in an LL-90 fault condition, enter diagnostic code [9-22] and then press YES, in order to enable the printer to function with an LL-90 fault condition. Enter the code [0361] in order to exit the diagnostics mode. Run 3 test prints [9-55 Pattern 5]. The LL-90 code is displayed as the print is being made. Y N Complete the service call. Use the last print to check the image density. The image density of the 1.0 Solid Square in the center of the Test Pattern [0955-5] is equal to or less than the 1.20 Density Square on the Output Reference SIR 495.1. Y N Perform the Tone-Down Procedure [09-06. If the printer does not tone-down, perform the Image Density Adjustment. Go to ADJ 9.3. Enter the code [9-21-4] in order to switch on the Main Drive Motor and the Toner Sensor circuit. Connect the (+) meter lead to the Toner Sensor A22Q1P1-2 and the (-) meter lead to A22Q1P1-4. There is +15 VDC present. Y N heck for an open or short circuit to ground in the wires connected to A22Q1P1-2 and A22Q1P1-4. If the wires are ok, replace the Main PWB, A3, PL 1.1A. Connect the (+) meter lead to the Main PWB A3J303-4 and the (-) meter lead to ground. There is +5.2 to +6.0 VDC is present. Y N Connect the (+) meter lead to the Toner Sensor A22Q1-1 and the (-) meter lead to ground. There is greater than +0.2 VDC present. Y N Disconnect Toner Sensor A22Q1P1 from A22Q1J1. Connect the (+) meter lead to the Main PWB A3J303-16 and the (-) meter lead to ground. There is greater than +0.2 VDC present. Y N Replace the LVPS, A5, PL 1.1APL 1.1A. If the problem persists, replace the Main PWB, A3, Check for an open or short circuit to ground in the wires connected to A22Q1-2 and A22Q1-4. If the wires are OK, replace the Toner Sensor A22Q1, PL 9.9. Run [9-21-6 Toner Sensor Calibration. Check for an open or short circuit to ground in the wire connected to A22Q1P1-3. If the wire is OK, replace the Toner Sensor A22Q1, PL 9.9. Run [9-21-6 Toner Sensor Calibration. Replace the Main PWB, A3, PL 1.1A.

LL-91 Undertoned Fault RAP

NOTE: Go to BSD 9.7 while using this RAP. The status code LL-91 is displayed when the logic detects that the toner concentration is significantly less than the Control Point value. The Toner Control System is designed to maintain the Toner Concentration within an acceptable operating range. The Control Point operating range is from 5.2 to 6.0 VDC. The Toner Sensor continuously senses the Toner Concentration. A change in the Toner Concentration results in a corresponding change of the Sensor signal. As the Toner Concentration decreases, the Toner Sensor signal voltage increases. The logic monitors the Toner Sensor signal. LL-91 indicates that the logic detected that the toner concentration decreased greater than the allowable limit. The problem may occur if there is a problem with the toner dispensing or the developer mixing systems.

Initial Actions
Examine the Toner Cartridge to ensure that the Cartridge is not empty and is installed correctly. Check the Cartridge for damage and ensure that the seal is secured to the Cartridge in the correct location. (Figure 1 ) Ensure that the Developer Drive Coupling is in good condition and is engaged fully. (Figure 2) Ensure that the Developer Housing Auger and Drive Gears are not damaged and are installed correctly. Check that all the connectors between the Toner Sensor, A22Q1, and the Main PWB, A2, are seated correctly.

Procedure
With the printer in an LL-91 fault condition, enter diagnostic code [9-22] and press Yes, in order to enable the printer to function with an LL-91 fault condition. Enter the code [0361] in order to exit the diagnostics mode.

8825/8830 Printer

01/02 2-11

Status Indicator RAPs

LL-90 Overtoned Fault RAP, LL-91 Undertoned

Y Main Drive Gear Drum Drive Gear

N Go to BSD 4.3, Drum Drive, to repair the drive circuit.

The LL-91 code is displayed as the prints are being made. Y N Complete the Service Call. Use the last print to check the image density. The image density of the 1.0 Solid Square in the center of the Test Pattern [0955-5] is equal to or less than the 1.20 Density Square on the Output Reference SIR 495.1. Y N Perform the Tone-Up procedure [09-06. If the printer does not tone up, perform the Image Density Adjustment. Go to ADJ 9.3 NOTE: : If unable to perform ADJ 9.3, replace the Developer and repeat ADJ 9.3. Enter the code [9-21-4]in order to switch on the Main Drive Motor and the Toner Sensor circuit. Connect the (+) meter lead to the Main PWB A3J303-14 and the (-) meter lead to A3J303-13. There is between +5.2 and +6.0 VDC present. Y N Connect the (+) meter lead to the Toner Sensor A22Q1P1-1 and the (-) meter lead to ground. There is less than +10 VDC present. Y N Disconnect Toner Sensor A22Q1P1 from A22Q1J1. Connect the (+) meter lead to the Main PWB A3J303-16 and the (-) meter lead to ground. There is less than +10.0 VDC present. Y N Replace the LVPS, A5, PL 1.1A. If the problem persists, replace the Main PWB, A3, PL 1.1A. Check for an open or short circuit to ground in the wires connected to A22Q1P1-3 (BRN) and A22Q1P1-4 (YEL). If the wires are OK, replace the Toner Sensor, A22Q1, PL 9.9. Then run [9-21-6] Toner Sensor Calibration. Check for an open or short circuit to ground in the wire connected to the A22Q1P1-3 (ORN). If the wire is OK, replace the Toner Sensor Calibration. Replace the Main PWB, A3, PL 1.1A. If the problem persists, enter the code [0926 to reset the NVM.

Developer Drive Coupling

Cartridge Drive Motor

Developer Drive Gears

Figure 1 Location of Developer Drive Coupling The Developer Housing Auger and Drive Gears are rotating as the prints are being made.

Status Indicator RAPs

LL-91 Undertoned Fault RAP

01/02 2-12

8825/8830 Printer

Ensure that the Rear Auger Drive Gear is positioned with the flange as shown.

Ensure that the Developer Housing Drive Gear is positioned with the flange as shown.

Ensure that the Front Auger Drive Gear is captured in position by the Rear Auger Drive Gear Flange and the Developer Housing Drive Gear flange.

Flange

Cartridge Drive Motor removed for clarity

Rear Auger Drive Gear Developer Housing Drive Gear Front Auger Drive Gear

Figure 2 Developer Housing and Auger Drive Gears

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01/02 2-13

Status Indicator RAPs

LL-91 Undertoned Fault RAP

Status Indicator RAPs

LL-91 Undertoned Fault RAP

01/02 2-14

8825/8830 Printer

OF-1 Control Panel RAP

NOTE: Go to BSD 2.1 while using this RAP, unless otherwise directed. This RAP is used when the Control Panel does not operate, or when the Control Panel operates incorrectly.

OF-2 Power On Self Test (POST) RAP

NOTE: Go to BSD 1.2 and BSD 2.1 while using this RAP. This RAP is used when the logic detects a fault during the Power On Self-test (POST). The printer does not initialize and the Control Panel displays a 1, 2, 3, 4, 5, 6, or 7.

Initial Actions
Make sure that AC power is applied to the machine. Ensure that the 26-conductor ribbon cable, connected between the Main PWB A3J301 and the User Interface PWB A32J1 (located in the Control Panel), is seated fully at each connector.

Initial Actions
Ensure that the EPROMs and the NVM are seated fully on the Main PWB, A3. Ensure that the 40-conductor ribbon cable, connected between the Driver PWB A2J206 and the Main PWB A3J313, is seated fully at each connector. Ensure that the power cable, connected between the Driver PWB A2J207 and the Main PWB A3J312 is seated fully at each connector. Ensure that the 26-conductor ribbon cable, connected between the Main PWB A3J301 and the Control Panel User Interface PWB A32J1, is seated fully at each connector.

Procedure
Table 1 Control Panel Probable Cause / Corrective Action Control Panel The Message Display is blank, no characters are displayed. Probable Cause There is no +5 VDC to the Main PWB, A3. There is an open circuit in the ribbon cable between the Main PWB A3J301 and the User Interface PWB A32J1. There is an internal fault in the Control Panel or in the Main PWB A3. Corrective Action Go to BSD 1.2 to troubleshoot the +5 VDC power to the Main PWB, A3. Check for continuity in all wires in the ribbon cable. Replace the Control Panel, PL 1.4. If the problem persists, replace the Main PWB, A3, PL 1.1A.

Procedure
Table 1 Power On Self Test (POST) Probable Cause / Corrective Action The number that is Displayed on the Control Panel. 1 or 2 3 Probable Cause Corrective Action

There is a fault in the RAM memory.

Replace the Main PWB, A3, PL 1.1A.

The Message Display There is no +15 VDC to the LEDs are on but no char- Main PWB, A3. acters are displayed. There is no +5 VDC (Bulk) to the Main PWB, A3.

Go to BSD 1.2 to troubleshoot the +15 VDC power to the Main PWB, A3. Go to BSD 1.2 to troubleshoot the +5 VDC (Bulk) power to the Main PWB, A3. Check for continuity in all wires in the ribbon cable. Replace the Control Panel, PL 1.4. If the problem persists, replace the Main PWB, A3, PL 1.1A.

The contents of the Control Replace both Control EPROMs on EPROMs does not agree with the Main PWB, A3. the checksum. Replace the Main PWB, A3, PL 1.1A. The Main PWB is defective. There is a fault tn the Analog- Replace the Main PWB, A3, PL 1.1A. to-Digital Converter or the Digital-to-Analog Converter. There is a fault in the Main Replace the Main PWB, A3, PL 1.1A. PWB, A3. There is a fault in the Digitalto-Analog Converter . Replace the Driver PWB, A2, PL 1.1A. If the problem persists, replace the Main PWB, A3, PL 1.1A. Replace the Main PWB, A3, PL 1.1A.

5 6

The Message Display LEDs are on but no characters, random characters, or black squares appear.

There is an open circuit in the ribbon cable between the Main PWB A3J301 and the User Interface PWB A32J1. There is an internal fault in the Control Panel or in the Main PWB A3.

There is a fault in the printer port output circuitry.

8825/8830 Printer

01/02 2-15

Status Indicator RAPs

OF-1 Control Panel RAP, OF-2 Power On Self Test

OF-3 Fuser Ballast RAP

Procedure
The customers lights flicker when the Machine is switched on. Y N The fuser ballast is operating properly. The machine has TAG 50 (50Hz only) installed. Y N Switch off the printer and disconnect the power cord. Perform the following steps to check that the ballast resistor circuit is operating correctly: 1. 2. 3. 4. 5. Disconnect the BRN wire from A1Q1-G. Set the meter to read 60 VAC (USO) or 120 VAC (XR). Connect the (+) meter lead to A1Q1-MT2 (BLU wires). Connect the (-) meter lead to A1Q1-MT1 (WHT wires). Connect the Power Cord and switch on the printer.

D Repair the wires.

Replace the Ballast Relay, A1K3, PL 1.2A. Replace the Heat Rod Control PWB PL 1.2A.

At least 60 VAC (USO) or 120 VAC (RX) is present. Y N Switch off the printer and disconnect the power cord. Set the meter to read 8 to 21 ohms of resistance. Disconnect the wires on each Ballast Resistor, A1R1 and A1R2R2, before measuring the resistance. The resistance of each Ballast Resistor, A1R1 and A1R2, is 7 to 9 ohms (USO) or 19 to 21 ohms (RX) Y N Replace both Ballast Resistors, A1R1 and A1R2, PL 1.2A. Check the following Ballast Resistor wires for continuity; Table 1 Ballast Resistor Wires From A1R1-1 A1R1-2A A1R2-1 A1R2-2A To A1K3-8 A1Q1-B A1K3-4 A1R1-2B The wires have continuity. Y N Repair the wires. Set the meter to read +26 VDC. Connect the (+) meter lead to the Fuser Ballast Power Relay. A1K3-1. Connect the (-) meter lead to A1K3-0. Reconnect the Power Cord and switch on the printer. There is +26 VDC present for approximately 5 seconds. Y N Connect the (+) meter lead to A2P213-6. Connect the (-) meter lead to A2P213-7. Reconnect the Power Cord and switch on the printer. There is +26 VDC present for approximately 5 seconds. Y N Replace the Driver PWB, A2, PL 1.1A. A B C D 01/02 2-16 8825/8830 Printer Color RED BLU RED BLU

Status Indicator RAPs

OF-3 Fuser Ballast RAP

Generic Clutch RAP

Initial Actions
NOTE: This procedure can be used to check any clutch. Due to the generic format of this RAP there will be no specific ADJ, PL or Diagnostic codes identified.

Procedure
( Figure 1): Enter DIAGNOSTICS (General Procedures). Enter code [xxxx to test the Clutch (Refer to appropriate BSD for the specific code). Actuate the Clutch. The Clutch energizes. Y N Deactuate the clutch. There is +26 VDC at J209-12 (use the actual connector/pin number on the BSD) on the Driver PWB (A2). Y N Check the wire for an open circuit. If the wires are good, replace the Clutch (PL X.X). Actuate the Clutch. The voltage decreased to approximately 0 VDC. Y N Replace the Main PWB (PL X.X). Check the adjustment of the Clutch (ADJ X.X). If the adjustment is good, replace the Clutch (PL X.X). The Clutch and its circuit appear to be operating normally. Check the adjustment or alignment of the Clutch.

Figure 1 Clutch (Generic)

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01/02 2-17

Status Indicator RAPs

Generic Clutch RAP

Generic Sensor RAP

Initial Actions
NOTE: This procedure can be used to check any sensor. Due to the generic format of this RAP there will be no specific ADJ, PL or Diagnostic codes identified. Ensure that the Sensor is not blocked. Clean the Sensor surfaces before using this procedure.

Procedure
( Figure 1): Enter DIAGNOSTICS (General Procedures). Enter code [xxxx to test the Sensor (Refer to appropriate BSD for the specific code). Block and unblock the Sensor. The Display toggles between [1] and [0]. Y N Block the sensor. There is +5 0.3 VDC at J1 pin 3 of the sensor. Y N Check the wire at J1/P1 pin 3 for an open circuit. If the wire is good, replace the main PWB. There is +1.4 0.2 VDC at J1/P1 pin 1 of the sensor. Y N Check the wire at J1/P1 pin 1 for an open circuit. If the wire is good, replace the Sensor before replacing the main PWB. Unblock the sensor. There is approximately 0 VDC at J1 pin 3 of the sensor. Y N Replace the sensor. Replace the main PWB. The Sensor and its circuit appear to be operating normally, check the adjustment or alignment of the Sensor. Figure 1 Sensor (Generic)

Status Indicator RAPs

Generic Sensor RAP

01/02 2-18

8825/8830 Printer

Generic Switch RAP

Initial Actions
NOTE: This procedure can be used to check any switch. Due to the generic format of this RAP there will be no specific ADJ, PL or Diagnostic codes identified.

Procedure
( Figure 1): Enter DIAGNOSTICS (General Procedures). Enter code [xxxx to test the switch (Refer to appropriate BSD for the specific code). Actuate the switch. The switch toggles from H to L or from L to H. Y N The message display indicates LOW all the time. Y N Actuate the switch. The voltage at J1-1 (use the actual connector/pin number from the appropriate BSD) goes to less than 0.4 VDC. Y N Check the wiring between the switch and the Main PWB (A2). If the wiring is OK, replace the switch. Replace the Main PWB (A2) (PL X.X) Replace the Switch (PL X.X) The switch and its circuit appear to be operating normally. check the adjustment or alignment of the switch.

Figure 1 Switch (Generic)

8825/8830 Printer

01/02 2-19

Status Indicator RAPs

Generic Switch RAP

Status Indicator RAPs

Generic Switch RAP

01/02 2-20

8825/8830 Printer

3 Print Quality
Print Quality
Print Quality Initialization Procedure ............................................................................... Print Defects.................................................................................................................... Print Quality Definitions ................................................................................................... Print Quality General Diagnostics ................................................................................... Print Quality Specifications ............................................................................................. Damaged Media.............................................................................................................. Media Handling Problems ............................................................................................... 3-3 3-3 3-4 3-5 3-5 3-8 3-8 3-9 3-9 3-10 3-10 3-11 3-11 3-12 3-12 3-13 3-13 3-14 3-14 3-15 3-15 3-16 3-16 3-17 3-17 3-18 3-18 3-19 3-19 3-20

Print Quality RAPs

PQ 1 Background ............................................................................................................ PQ 2 Bands..................................................................................................................... PQ 3 Bands..................................................................................................................... PQ 4 Black Lines............................................................................................................. PQ 5 Black Prints ............................................................................................................ PQ 6 Blank Prints / Partial Image.................................................................................... PQ 7 Blurred Image ........................................................................................................ PQ 8 Deletions (bands)................................................................................................... PQ 9 Deletions (bands)................................................................................................... PQ 10 Deletions (in solid and halftone areas)................................................................. PQ 11 Deletions (spots) .................................................................................................. PQ 12 Finger Marks ........................................................................................................ PQ 13 Light Image .......................................................................................................... PQ 14 Misregistration...................................................................................................... PQ 15 Residual Image .................................................................................................... PQ 16 Skewed Image ..................................................................................................... PQ 17 Smears................................................................................................................. PQ 17A Smudge ............................................................................................................. PQ 18 Spots .................................................................................................................... PQ 19 Uneven Density.................................................................................................... PQ 20 Unfused Prints ..................................................................................................... PQ 21 Wrinkle ................................................................................................................. PQ 22 Offsetting..............................................................................................................

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01/02 3-1

Print Quality

01/02 3-2

8825/8830 Printer

Print Quality Initialization Procedure

Prior to any print quality troubleshooting, validate that the problem is in the IOT by entering [955]. Select test pattern 5. Examine the test print for defects. If defects appear, complete the following checklist. If the defects are still present after completing the checklist, refer to the Image Quality Defects and Classification information on the following pages to classify and repair the problem. 1. 2. 3. 4. Drum life (Refer to Section 1) Ensure that the Charge Scorotron is not damaged or contaminated. Ensure that the Image Module Roller fully contacts the drum and does not exhibit abnormal wear or contamination. Refer to ADJ 9.2, Electrostatic Series and check that the following voltages are within specification: 5. Charge Scorotron (V High) Image Module LED Duty Cycle (V Low)

Print Defects
Print quality refers to the entire print. Defects can occur anywhere on the print. These defects could be damaged media or print quality defects. Always eliminate problems that cause the damaged media before attempting to fix print quality problems. Some damaged media problems could cause print quality problems. Compare the print defect to the definitions on this page and the next page. After you have determined the definition that best describes the print defect, go to the Section Contents page. The Section Contents page will direct you to a Print Quality Problem / Cause Table. The Problem / Cause Table lists the probable causes and corrective actions. The PROBABLE CAUSES are arranged in order of most probable cause to least probable cause or the ease of the check. CORRECTIVE ACTIONS are given for each cause. Read all of the probable causes before taking any corrective action. 1. 2. 3. Start with the first PROBABLE CAUSE and continue through the list until you come to the cause that best applies to the image defect. Perform the CORRECTIVE ACTION. If the defect has been corrected, go to the Maintenance Activities in the Service Call Procedures in Section 1. If the defect is still present, continue with the other PROBABLE CAUSES.

Check that the Toner Concentration (TC) is calibrated correctly [9-21-4]

If the print quality defect is still present, go to the Print Defects in this section.

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01/02 3-3

Print Quality

Print Quality Initialization Procedure, Print Defects

Print Quality Definitions

The following terms are some of the most commonly used terms that describe image quality problems.

Offsetting
This is the transfer of toner from the print to the heat roll. Sometimes the toner is transferred back to the print or consecutive prints.

Background
Background occurs as darkness or dirtiness on the non-image areas of the print.

Media Damage
This is any physical distortion to the media that is used in making a print. This distortion may include folds, wrinkles, etc.

Black Print
This is a print that is entirely black except for the lead edge, trail edge and possibly the left and right edges.

Media Handling
This is the process of transporting the media from the supply area through the xerographic and the fusing subsystems.

Blank Print
This is a print entirely without an image.

Resolution
The uniformity or clarity of fine line detail.

Deletions
An area of the image where information has been lost. The areas of deletions could be localized or bands from top to bottom or side to side.

Residual Image
This is an image that is repeated onto the same print or consecutive prints. The image can either be a ghosting of the original image or a toner image. The repeated image is usually spaced 10.375 inches (265 mm) from the original image. This problem can be caused by poor cleaning of the drum, a drum that is worn, or offsetting by the Fuser.

Density
The relative blackness between the image and non-image areas.

Fuser Fix
This is a measure of how the toner particles adhere to the media as a result of the fusing process.

Smear
This is any image defect that occurs in the direction that is perpendicular to media feed and caused by a difference in the relative motion between the drum and media.

Print Displacement
Part of the image information is being placed elsewhere on the print or it is completely missing. The area of the missing information is sharply defined. This is unlike deletions where the image is not sharply defined or clear.

Spots
These are defects that are 0.2 inches (5 mm) or smaller in diameter.

Streak
This is any image defect that occurs in the direction of media feed.

Print Distortion or Skew

The image is skewed on the media. The image from side to side or lead edge to trail edge is not parallel to the edges of the print. There is also distortion of the image from one side of the copy to the other. These defects are a result of a misadjustment of the media transportation system components.

Unfused Print
This is a print where the image can easily be wiped off the media. The image has not adhered to the media.

Light Image
These are prints where the density is lighter than the specified density for the printer.

Line Darkness
This is the darkness and uniformity for a line.

Misregistration
This is when the distance from the lead edge of the image to the lead edge of the media is not within specification.

Print Quality

Print Quality Definitions

01/02 3-4

8825/8830 Printer

Print Quality General Diagnostics

It is important to understand the orientation of prints in order to troubleshoot image quality problems. The following terms will be used when referring to prints made on the printer: 1. 2. Process direction is in the media feed direction. Cross-process direction is in the side-to-side direction.

Print Quality Specifications

Test Patterns
There are nine internal test patterns that can be run from diagnostic mode [9-55]. (refer to Section 6 for details) Test Pattern 1 is used while adjusting lead edge. trail edge and side edge erase. Test Pattern 2 is used to produce horizontal black and white horizontal/vertical bands and resolution targets. Test Pattern 3 is used to produce ROGM image targets and 1.25 solid area squares that are 97.5 mm apart. Test Pattern 4 is used to produce a 49 mm wide horizontal black band that is 450 mm from the lead edge of the print. Test Pattern 5 is used to produce solid area squares, ROGM image targets and a grid of thin horizontal and vertical lines. Test Pattern 6 is used to produce diagonally placed small ROGM targets. Test Pattern 7 is used to produce diagonal horizontal and vertical lines that are 16.25 mm apart. Test Pattern 8 is used to produce solid blank vertical bands that are 93.5 mm wide. Test Pattern 9 is used to produce various small ROGM patterns.

Determining the distance between defects could help isolate problems to a specific component. Defects that are 10.375 inches (265 mm) apart (lead edge of defect to lead edge of next defect) in the process direction could be caused by the drum. The circumference of the Drum is 10.375 inches ( 265 mm). Defects that are 10.375 inches (265 mm) apart (lead edge of defect to lead edge of next defect) in the process direction could be caused by the heat roll. NOTE: The Heat Roller and Drum are the same circumference. Perform a hard stop to examine the Heat Roller or the Drum to isolate the cause of the problem.

Solid Area Density (A)

This term refers to the image density of a totally black portion of the print. Figure 1 Use a wide roll of media and run test pattern [9-55-5]. Select the black squares (A) and use the SIR 495.01 (PN 82P520) reference scale to measure the density. SPECIFICATION: Media - All sites between 1.0 and 1.3 Solid Area Density (SAD) Film - All sites equal to or greater than .85 SAD

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Print Quality

Print Quality General Diagnostics, Print Quality

Background
This term refers to the density of the print in any non-image area. Use a wide roll of media and run test pattern [9-55-5]. Examine the print using the Background Reference Scale 302.02. SPECIFICATION: All non-image area should be no greater than 3.7 at printer installation and no greater than 5.9 over the life of the developer.

Skips
This term means that a print image is partially deleted or appears stretched at a right angle to the media feed direction . Use a wide roll of media and run test pattern [9-55-5]. Examine the 2.0 LP/mm vertical band located near the center o the print for skips or smears. SPECIFICATION: The 2.0 LP/mm lines should be resolved.

Resolution
This term refers to the degree to which fine details of a print are reproduced, for example, lines. Figure 1 Use a wide roll of media and run test pattern [9-55-5. Evaluate the resolution targets (B) at each corner and three central locations for a total of seven targets. SPECIFICATION: The vertical and horizontal resolution for all targets should be equal to or greater than 4.0 LP/ mm.

Figure 1 Test Pattern [9-55-5]

Lead Edge Registration (A)

This is the degree to which the lead edge of a print image is within a specified distance from the lead edge of the media. Use a wide roll of media and run 4 prints of test pattern [9-55-7] and use the fourth print. Measure the distance from the lead edge of the media to the first horizontal line at the right side of the print and the center of the print. SPECIFICATION: 16.25 +/- 2.0 mm

Skew (B)
This is the degree to which media is fed at an angle to the print image. Use a wide roll of media and run test pattern [9-55-7]. Measure the distance at B (both places) 70 blocks apart. SPECIFICATION: +/- 0.5% or less

Print Quality

Print Quality Specifications

01/02 3-6

8825/8830 Printer

Linearity of Lines
Linearity of lines refers to the straightness of the horizontal, vertical and diagonal lines. Use a wide roll of media and run test pattern [9-55-7]. Measure the straightness of a 50 block length in all three directions. SPECIFICATION: 1 mm or less

Side Edge Registration (C)

This is the degree to which the center of the image of a print is within a specified distance from the center of the media. Figure 2 Use a wide roll of media and run test pattern [9-55-7. Fold the print in half. At the fold mark, measure the distance between the fold line and the center line of the image. SPECIFICATION: 6 mm or less

Magnification (D1, D2)

Magnification refers to the rate at which an original image is enlarged or reduced on a print. The change in image length is either in the media feed direction (vertical) or the side-to-side direction (horizontal). Measure the length of 50 blocks (D1) from side-to-side (horizontal) and one block down from the lead edge. Measure the length of 60 blocks in the media feed direction (vertical) and one block in from the side. SPECIFICATION: Horizontal (D1) Vertical (D2) 812.8 mm +/- 4.06 mm 975.4 mm +/- 4.88 mm Figure 2 Test Pattern [9-55-7]

Cut Accuracy
This is the dimension of variance from a true, horizontal cut. SPECIFICATION: +/- 4 mm

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01/02 3-7

Print Quality

Print Quality Specifications

Damaged Media
Table 1 Damaged Media Defect probable cause corrective action 1. Ensure that the media is stored correctly and is not damaged when inserted in the printer. 2a. Ensure that TAG 12 is installed. 2b. Try using a new roll of media. 2c. Check for an obstruction caused by a detack corotron.

Media Handling Problems

Introduction
Experience has shown that many media transportation problems have more than one cause and must be handled using a systematic approach. Media transportation problems appear as one of the following symptoms: Pre-fuser jams Print quality defects Physical distortion of media

1. Crease Marks 1. This defect can be caused A thin irregular line on the by incorrect handling of the media caused by stressing the media. media. 2. Dog Ears 2. Curled media caused by a This is a corner of the lead failed or damaged Detack edge of the print that has been Corotron. bent back.

When these symptoms occur, perform the following checks of the media and printer and perform the corrective actions. Table 1 Media Check Media Check Corrective Action

3. Frayed Side Edge 3. Incorrect media side to 3. Ensure that the media is This is damage to the sides of side registration loaded correctly. the print. Check the media path for an obstruction. 4. Wrinkle This is damage that is probably caused by the fuser subsystem. This is a severe case of creases that runs in the direction of media travel. Damage or obstruction in the media path Damp media Incorrect fuser pressure Heat roller is damaged or contaminated. Clear the media path of obstructions Refer to BSD 7.1 and BSD 7.3 to check for correct operation of the Paper heaters. Ensure that the Customer is storing the media correctly. Check the Fabric Guide ( REP 8.9) and the Pressure Plates ( REP 8.5). Replace the heat roll ( REP 10.2). Clear the media path of obstructions. Check Fuser Temperature ( ADJ 10.1) Refer to BSD 7.1 and BSD 7.3 to check for correct operation of the Paper heaters. Ensure that the Customer is storing the media correctly. Check the Fabric Guide ( REP 8.9) and the Pressure Plates ( REP 8.5). 6. If there are other defects on the print, go to Media Handling Problems on, following page.

1. Check the type of media: a. Use Xerox-qualified media. a. Bond media less than 20 lb may perform b. After all media checks, test with fresh Xerox with less reliability than Xerox 20 lb. media. b. Other brands of media may have different design specifications than Xerox media and may not give acceptable performance in the printer. 2. Check the storage of media: a. Media that is exposed to the environment may have damp areas. b. Media may have curled ends because of incorrect storage. a. Suggest keeping the media in the package in which the Xerox media is shipped until the media is to be used. b. Suggest that the media should be stored correctly. c. Recommend keeping the printer switched on overnight to help eliminate moisture buildup.

Table 2 Printer Check Printer Check 1. Contaminated or damaged transfer/ detack Corotron. 2. An incorrect electrostatic value can cause jams or deletions. 3. Detack Corotron shield incorrectly installed. Corrective Action 1. Clean or replace if necessary ( PL 9.4). 2. Check the following: a. Clean or replace the Corotron as required ( PL 9.4). b. Perform GP 1, HVPS Checkout Procedure. 3. Check for correct installation

5. Cockle The media has a rough surface like an orange peel. This damage could be caused by the fuser subsystem.

5. Damage or obstruction in the media path Fuser is too hot. Damp media. Pressure Plates or Fabric Guide damaged / installed incorrectly

6. Other Damage

Print Quality

Damaged Media, Media Handling Problems

01/02 3-8

8825/8830 Printer

PQ 1 Background
Table 1 Background Symptom / Check Symptom / check Probable Cause Contamination of the blank area by toner particles on the print Corrective Action

PQ 2 Bands
Table 1 Bands Symptom / Check Symptom/ checks Probable Cause Bands are 1 mm or more wide and are in the media feed direction. High density bands are called black lines. 1. Contaminated scorotron Corrective Action

1. An incorrect electrostatic 1A. Perform Electrostatic value Series ( ADJ 9.2). 1B. Perform GP 1 HVPS Checkout Procedure. 1C. Clean/Replace/Repair the corotrons. 2. Developer Bias incorrect. 2A. Perform GP 1 HVPS Checkout Procedure. 2B. Ensure that TAG 19 is installed.

charge 1. Clean / replace screen / pins ( REP 9.8). 2. Replace the Cleaner Blade ( REP 9.4).

2. Defective Cleaner Blade 3. Contaminated roll. 4. Incorrect value.

magnetic 3. Check for foreign objects on the mag roll.

3. Toner concentration too 3. Perform Image Density ( high. ADJ 9.3). 4. Erase Lamp operation. 4. Refer to BSD 9.6 and check for correct operation of the Erase Lamp.

Electrostatic 4A. Ensure that TAG 19 is installed. 4B. Perform Electrostatic Series ( ADJ 9.2). 4C. Perform GP 1 HVPS Checkout Procedure. 4D. Clean / replace / repair the corotrons.

5. Contaminated scorotron

charge 5, Clean or replace if necessary ( PL 9.3). 6. Replace the Cleaner Blade ( REP 9.4).

6. Defective Cleaner Blade

7. Web Oil system not operat- 7. Refer to BSD 10.2 and ing correctly. check Web Oil system for correct operation. 8. Contaminated or defective 8. Replace the drum ( REP drum. 9.3).

5. Toner cloud from the Devel- 5A. Ensure that the Air Presoper Module contaminating sure Tubes are clean ( REP the Drum and corotrons. 9.18). 5B. Check for toner buildup on the lower edge of the Developer Housing. 6. T/DT Corotron contami- 6. Check / clean / repair nated. 7. Contaminated or defective 7. Replace the drum ( REP drum. 9.3). 8. Image Module LEDs oper- 8. Enter [9-21-5 and check for ating incorrectly. correct operation. (Refer to BSD 6.1, BSD 6.2 and check for correct electrical connections to/from the Receiver PWB and the LED Image Bar). 9. LED Bar without Tag 28 9. Connect to J307A. incorrectly connected to Main PWB. 10. Toner buildup on Magnetic Roll. 10. Go to Technical Services Bulletin (TSB 98116) for toner removal procedure.

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01/02 3-9

Print Quality

PQ 1, PQ 2

PQ 3 Bands
Table 1 Bands Symptom / Check Symptom/ check Probable Cause Bands are 1 mm or more and are perpendicular to the media feed direction. High density bands are called black lines. Corrective Action

PQ 4 Black Lines
Table 1 Black Lines Symptom / Check Symptom/ check Probable Cause Black lines appear in the direction of media feed. Corrective Action

1. Developer Bias and Trans- 1. Ensure that fer Corotron voltage set incor- installed. rectly

TAG 19 is

1. Defective or intermittent 1. Check / clean / replace the Charge Scorotron. connections to the Charge Scorotron ( PL 9.3). 2. Defective Transfer / Detack 2A. Check / replace the Corotron. Transfer / Detack Corotron. ( REP 9.9). 2B. Ensure that the Corotron is installed in the correct position. 3. Poor cleaning 3. Replace the Cleaner Blade ( REP 9.4).

2. Contaminated, damaged 2. Clean/replace or check the or disconnected Charge connections to the charge Scorotron scorotron ( PL 9.3). 3. Poor cleaning 3. Replace the Cleaner Blade ( REP 9.4).

4. The surface of the heat roll 4. Determine and fix the is damaged. cause of the damage to the heat roll. Replace the heat roll ( REP 10.2). 5. The drum surface is con- 5. Determine and fix the taminated or damaged. cause of the damage to the drum. Replace the Drum ( REP 9.3). 6. The fuser temperature is 6. Adjust the Fuser temperatoo high. ture ( ADJ 10.1) 7. Contaminated or damaged 7. Check for foreign objects mag roll. on the mag roll. 8. Defective Transfer/Detack Corotron. 8. Check / replace the Transfer / Detack Corotron. ( REP 9.1).

4. Defective or contaminated 4. Determine and fix the Drum. cause of the damage to the drum. Replace the Drum ( REP 9.3).

Print Quality

PQ 3, PQ 4

01/02 3-10

8825/8830 Printer

PQ 5 Black Prints
Table 1 Black Prints Symptom / Check Symptom/ check Probable Cause The print is totally black with no image. 1. Defective Scorotron Corrective Action

PQ 6 Blank Prints / Partial Image

Table 1 Blank Prints / Partial Image Symptom / Check Symptom/ check Probable Cause No image or a partial image is produced when making a print. 1. Developer Housing Corrective Action

Charge 1. Clean or replace screen/pins ( REP 9.8).

the

2. Charge control circuit/ 2. Perform GP 1 HVPS defective Harness Checkout Procedure.

1A. Ensure that the Developer Housing Module drive gears are engaged and the developer housing is turning. 1B. Ensure that the gear lock is released from the Developer Housing Drive Gear. 2A. Check the Transfer Corotron for damage / contamination. 2B. Perform GP 1, HVPS Checkout Procedure. 3. Perform GP 1, HVPS Checkout procedure.

2. Transfer Corotron

3. Defective HVPS

4. Image Module LEDs inop- 4A. Enter [9-21-5 and check erative for correct operation. (Refer to BSD 6.1, BSD 6.2 and check for correct electrical connections to/from the Receiver PWB and the LED Image Bar.) 4B. Ensure that all connectors are seated and voltages are correct to the LED, 5VDC, RS422, Signal Harness, Receiver PWB. 5. No drum drive / defective 5. Refer to BSD 4.3 and drum. check for correct drum drive. Replace the drum ( REP 9.3). 6. PJ 330 (Tag 28) or 307A (without Tag 28) is not correctly seated. 6. Reseat the connector.

8825/8830 Printer

01/02 3-11

Print Quality

PQ 5, PQ 6

PQ 7 Blurred Image
Table 1 Blurred Image Symptom / Check Symptom/ check Probable Cause The image is not clear or sharp. Corrective Action

PQ 8 Deletions (bands)
Table 1 Deletions (bands) Symptom / Check Symptom/ check Probable Cause Deletion bands or very low image density in the print feed direction. 1. Damp media Corrective Action

1. Defective/contaminated 1A. Ensure the spacing rollers Image Module. and drum ends are not contaminated/defective. 1B. Clean the LED Array with a lint-free cloth. 2. Contamination on Transfer/ 2A. Clean or replace as Detack Corotron required. 2B. Perform GP 1, HVPS Checkout Procedure. 3. Defective drive gear 3. Check the following drive gears for damage: a. drum drive gear b. developer drive gear c. cleaner drive gear

1A. Refer to BSD 7.1 and BSD 7.3 to check for correct operation of the Paper heaters. 1B. Ensure that the Customer is storing the media correctly. 2A. Clean / replace or repair the T/DT corotrons ( REP 9.9). 3. Perform GP 1, HVPS Checkout Procedure. 4A. Ensure that the Developer Housing is latched securely. 4B. Check the mag roll for foreign material or contamination. Ensure that there is an even coating of developer material on the mag roll.

2. Corotrons

3. Defective HVPS 4. Developer Housing

4. Defective registration roller 4. Replace as required ( PL 8.2). 5. Media transport 6. Defective buckle control 5. Check the Media Transport gap ( ADJ 8.4). 6. Replace the buckle switch ( PL 8.4).

5. Defective or contaminated 5. Check / clean the LED LED Image Bar. Image Bar [9-21-5. ( PL 9.3) 6. Contaminated Lamp. 7. Media transport 8. Heat Roll 9. Defective drum Erase 6. Clean with a lint free cloth. 7. Ensure that the gap ( ADJ 8.4) is set correctly. 8. Check for surface damage. ( PL 10.2) 9. Replace the drum ( REP 9.3).

Print Quality

PQ 7, PQ 8

01/02 3-12

8825/8830 Printer

PQ 9 Deletions (bands)
Table 1 Deletions (bands) Symptom / Check Symptom/ check Probable Cause Deletion bands or very low image density perpendicular to the print feed direction. 1. Damp media Corrective Action

PQ 10 Deletions (in solid and halftone areas)

Table 1 Deletions (in solid and halftone areas) Symptom / Check Symptom/ check Probable Cause Bands of deletion in the solid or halftone areas in the print feed direction. 1. Damp media Corrective Action

1A. Refer to BSD 7.1 and BSD 7.3 to check for correct operation of the Paper heaters. 1B. Ensure that the Customer is storing the media correctly.

1A. Refer to BSD 7.1 and BSD 7.3 to check for correct operation of the Paper heaters. 1B. Ensure that the Customer is storing the media correctly. 2A. Clean the Image Bar. Check / clean the Air Pressure Tubes ( REP 9.18). 2B. Enter [9-21-5 and check for correct operation. (Refer to BSD 6.1, BSD 6.2 and check for correct electrical connections to/from the Receiver PWB and the LED Image Bar).

2. Incorrect Corotron opera- 2A. Check / Clean or replace tion. the T/DT corotrons as required ( PL 9.4). 2B. Perform GP 1 HVPS Checkout Procedure. 4. Defective drum or no drum 4A. Check for correct operadrive. tion of the drive system. 4B. Replace the drum ( REP 9.3). 5. Magnetic roll 5A. Ensure that the housing is latched securely. 5B. Check the mag roll for damage or binding.

2. Exposure

3. Incorrect Corotron opera- 3. Perform GP 1, HVPS tion Checkout Procedure. 4. Magnetic roll 4. Check the mag roll for damage or binding.

6. Image Module Roller not 6. Check/clean/replace as contacting drum required ( PL 9.3). 7. Media Transport. 7. Ensure that the Media Transport gap ( ADJ 8.4) is set correctly.

5. The surface of the heat roll 5. Determine and fix the is damaged. cause of the damage to the heat roll. Replace the heat roll ( REP 10.2). 6. Media Transport. 6. Ensure that the Media Transport gap ( ADJ 8.4) is set correctly.

8825/8830 Printer

01/02 3-13

Print Quality

PQ 9, PQ 10

PQ 11 Deletions (spots)
Table 1 Deletions (spots) Symptom / Check Symptom/ check Probable Cause Localized areas of deletion in the solid or halftone areas in the print feed direction. 1. Damp media Corrective Action

PQ 12 Finger Marks
Table 1 Finger Marks Symptom / Check Symptom/ check Probable Cause Toner marks on the lead edge or trail edge of the print. Corrective Action

1A. Refer to BSD 7.1 and BSD 7.3 to check for correct operation of the Paper heaters. 1B. Ensure that the Customer is storing the media correctly. 2. Perform GP 1, HVPS Checkout Procedure. 3A. Ensure that the housing is latched securely. 3B. Check the mag roll for damage or binding.

1. Defective or dirty transfer/ 1A. Clean or replace the detack Corotron Corotron wire ( PL 9.4). 1B. Perform GP 1, HVPS Checkout Procedure. 2. Cleaner Seal 3. Web Oiler 4. Turnaround Baffle 2. Check / clean as required. ( PL 9.5A) 3. Check / replace ( REP 10.9) 4. Ensure that the baffle is free of contamination ( PL 8.2). 5. Check / replace ( REP 10.2) 6. Check / replace ( REP 8.9)

2. T/DT Corotrons 3. Developer Housing

5. Heat Roll 6. Fabric Guide

4. Insufficient toner resulting 4A. Perform Electrostatic in developer bead carryover. Series ( ADJ 9.2). 4B. Perform Image Density ( ADJ 9.3). 5. The surface of the heat roll 5. Determine and fix the is damaged. cause of the damage to the heat roll. Replace the heat roll ( REP 10.2) 6. Defective drum 7. Media transport 6. Replace the drum ( REP 9.3) 7. Check for correct gap ( ADJ 8.4).

8. The Fabric Guide is con- 8. Check/replace the Fabric taminated, wrinkled or incor- Guide ( PL 10.2). rectly tensioned.

Print Quality

PQ 11, PQ 12

01/02 3-14

8825/8830 Printer

PQ 13 Light Image
Table 1 Light Image Symptom / Check Symptom/ check Probable Cause Image area of a print has low density. 1. Damp media Corrective Action

PQ 14 Misregistration
Table 1 Misregistration Symptom / Check Symptom/ check Probable Cause The registration of the image on the prints is incorrect from top to bottom or side to side. 1. Incorrect adjustment Corrective Action

1A. Refer to BSD 7.1 and BSD 7.3 to check for correct operation of the Paper heaters. 1B. Ensure that the Customer is storing the media correctly.

registration 1. Adjust Lead Edge Registration ( ADJ 8.2).

2. Damaged or worn compo- 2. Check the components for nents in the media feeding damage or wear. area 3. Defective registration sen- 3. Refer to BSD 8.1 and sor check the operation of the registration sensor. Replace the sensor if required ( REP 8.8). 4. Incorrect registration roller 4. Clean or replace the regisnip tration roller ( PL 8.2). 5. Incorrectly loaded media 5. Instruct the operator on loading the media correctly.

2. Incorrect Image Module 2. Perform Electrostatic LED duty cycle Series ( ADJ 9.2). 3. Incorrect Corotron opera- 3. Perform GP 1, HVPS tion Checkout Procedure. 4. Incorrect Image Density 4A. Perform Image Density ( adjustment ADJ 9.3). 4B. Replace the sensor ( PL 9.9). 5. Defective drum ground. 6. Defective drum. 7. Media Transport 5. Ensure that the drum is correctly grounded. 6. Replace the drum ( REP 9.3). 7. Ensure that the Media Transport gap ( ADJ 8.4) is set correctly. 8. Ensure the housing is latched securely.

8. Developer Housing

8825/8830 Printer

01/02 3-15

Print Quality

PQ 13, PQ 14

PQ 15 Residual Image
Table 1 Residual Image Symptom / Check Symptom/ check Probable Cause This is an image that is repeated on the same print or consecutive prints. The image can either be a ghosting of the original image or a toner image. The repeated image is usually spaced 10.38 inches (265 mm) from the original image. Corrective Action

PQ 16 Skewed Image
Table 1 Skewed Image Symptom / Check Symptom/ check Probable Cause The image is skewed to one side on the print because the media is skewed. Corrective Action

1. Media is not loaded cor- 1. Load the media correctly rectly. and instruct the operator on loading the media correctly. 2. Media Transport. 2. Ensure that the Media Transport gap ( ADJ 8.4) is set correctly.

Perform Panic Stop / Image 1. The Cleaner Blade makes 1. Replace the Cleaner Blade on Drum procedure (Section poor contact with drum. ( REP 9.4). 6), and examine the drum for the defect. 2. Defective erase lamp 2. Refer to BSD 9.6 and check the erase lamp. Replace the lamp if necessary ( PL 9.5A). 3. Replace the drum ( REP 9.3).

3. Defective or contaminated 3. Check the rollers and other rollers in the media feed area components in the media feed area. 4. Incorrect registration roller 4. Clean or replace the regisnip tration roller ( PL 8.2). 5. Obstruction in media path 5. Check media path.

3. Contaminated drum

Print Quality

PQ 15, PQ 16

01/02 3-16

8825/8830 Printer

PQ 17 Smears
Table 1 Smears Symptom / Check Symptom/ check Location of Smear Probable Cause Areas of the image on the print are blurred. This occurs at the image transfer area and is caused by a difference of speed between the drum and the media. 20 - 25 mm from the Transfer/Detack Lead Edge of the Shield incorrectly print installed. Corrective Action

PQ 17A Smudge
Table 1 Smudge Symptom / Check Symptom/ check Location A smudge is a displacement Smudge of the toner image on the drum or the media. Perform GP 2, Image on Media Drum to determine if the Smudge occurs on the media or the drum. Media of Probable Cause Corrective Action

Heat Roll

Check / replace ( PL 9.4)

Check for a worn (smooth) Heat Roll. Replace ( REP 10.2) Check for a worn / contaminated Fabric Guide. ( REP 8.9)

Fabric Guide

40 - 50 mm from the Fabric Guide worn, Check / replace ( Lead Edge of the contaminated or REP 8.9). print incorrectly installed. 106 - 126 mm from 1. Worn (smooth) the Lead Edge of Heat Roll ( PL 10.2) the print 2. Worn Contaminated Fabric Guide ( PL 10.3) 3. Pressure Plate A installed incorrectly or deformed ( PL 10.3). Check / replace ( REP 10.2) Check / replace ( REP 8.9) 3. Check / replace ( REP 8.5)

Media

Excessive media Ask the customer to curl (smudge replace the media. appears 100 mm from lead or trail edge) Detack Corotron Check for contamination or signs of arcing. Clean / replace ( PL 9.4) Check the Buckle Switch for correct operation ( PL 8.4) Replace the Fabric Guide ( REP 8.9) and the Heat Roll ( REP 10.2).

Media

Buckle Switch

150 - 170 mm from Pressure Plate B Check / replace ( the Lead Edge of installed incorrectly REP 8.5) the print or deformed. 140 - 160 mm from Cutter the Trail Edge of the print 66 - 86 mm from the Buckle Switch Trail Edge of the print (Register Roll Exit Smear) Random smears Media Transport Check for loose Cutter Drive Pulley, Shim / replace ( PL 7.8) Enter [8-2 and check for correct operation ( PL 8.4) Ensure that the Media Transport gap ( ADJ 8.4) is set correctly.

Vellum Smudge is a special defect that exhibits marginal fusing fix. Toner can chip off of the media and horizontal lines are broken (image displacement).

Combination of Vellum beam strength and low Heat Roll drive force. (The media is flexible enough that it buckles between Pressure Plates A and B. The toner then melts and partially sticks to the Heat Roll. As the media enters the Pressure Plate B, it flattens and the image is displaced in front of its correct position. The toner can also become a clump on the media and easily chip off of the media.) Drum

Mechanical interfer- Check for interference with the image ence. on the drum Buildup of devel- Push excess developer material on the oper material back lower extrusion of into the housing. the developer housing rubbing the developed image on the drum. Print Quality

Drum

8825/8830 Printer

01/02 3-17

PQ 17, PQ 17A

PQ 18 Spots
Table 1 Spots Symptom / Check Symptom/ check Probable Cause Circular black spots on the print. Corrective Action

PQ 19 Uneven Density
Table 1 Uneven Density Symptom / Check Symptom/ check Probable Cause Density and line thickness vary across the print. Corrective Action

Perform Panic Stop/Image on 1. Defective, damaged or con- 1. If the drum is damaged, Drum procedure (Section 6), taminated drum determine and fix the cause of and examine the drum for the the damage to the drum. defect. Replace the drum ( REP 9.3). Repetitive spots Repetitive spots Random spots 2. Contaminated heat roll 2. Clean or replace the heat roll ( REP 10.2).

1. Incorrect Corotron opera- 1. Perform GP 1, HVPS tion Checkout Procedure. 2. Contaminated LED Image 2. Check / clean the Image Bar Bar. Check / clean the Air Pressure Tubes ( PL 9.9). 3. Machine level 3. Check the level of the machine. (See Installation Procedure in Section 6.

3. Contaminated fuser ther- 3. Clean the thermistor ( PL mistor 10.4). 4. Contaminated Web Oiler 4A. Check / replace ( REP 10.9) 4B. Check / adjust oil dispense rate [10-32].

Random spots Random spots

5. Defective Lower Cleaning 5. Check / replace ( PL 9.10). Seal 6. Charge scorotron 6. Clean or replace scorotron ( REP 9.8). the

4. Developer mag brush not 4A. Clean drum ends and the contacting the drum evenly. Spacer Rolls on the Developer Housing ( PL 9.10). 4B. Ensure that the housing is latched securely. 5. Defective drum 5. Clean or replace the drum ( REP 9.3).

Print Quality

PQ 18, PQ 19

01/02 3-18

8825/8830 Printer

PQ 20 Unfused Prints
Table 1 Unfused Prints Symptom / Check Symptom/ check Probable Cause Characters and image are easily rubbed off a print. 1. Damp media Corrective Action

PQ 21 Wrinkle
Table 1 Wrinkle Symptom / Check Symptom/ check Probable Cause This is damage that is probably caused by the fuser subsystem. This is a severe case of creases that runs in the direction of media travel. 1. Damp media Corrective Action

1A. Refer to BSD 7.1 and BSD 7.3 to check for correct operation of the Paper heaters. 1B. Ensure that the Customer is storing the media correctly.

2. Incorrect fuser temperature 2. Adjust the fuser temperature ( ADJ 10.1). 3. Incorrect fuser pressure 3. Check pressure plates for damage or deformation ( REP 8.5). 4. Replace the Heat Roll ( REP 10.2) 5. Ensure Fabric Guide is installed correctly ( REP 8.9).

1A. Refer to BSD 7.1 and BSD 7.3 to check for correct operation of the Paper heaters. 1B. Ensure that the Customer is storing the media correctly.

2. Damaged or contaminated 2. Clean / replace the pinch pinch rolls rolls ( REP 7.3). 3. Damaged or contaminated 3. Clean / replace the Heat heat roll Roll ( REP 10.2). 4. Incorrect fuser contact 4. Check the Pressure Plates pressure ( REP 8.5) and Fabric Guide ( REP 8.9) for damage. 5. Incorrect fuser temperature 5. Adjust Fuser Temperature ( ADJ 10.1). 6. Registration Rolls mis- 6. Replace the rolls as aligned. required ( PL 8.2).

4. Defective heat roll 5. Fabric Guide.

8825/8830 Printer

01/02 3-19

Print Quality

PQ 20, PQ 21

PQ 22 Offsetting
Table 1 Offsetting Symptom / Check Symptom/ check Probable Cause Offsetting is the result of toner adhering to the Fuser Heat Roll and transferring to subsequent prints. Corrective Action

1. There is insufficient fuser 1A. Check/replace the Web oil on the Heat Roll. Oiler ( REP 10.7). 1B. Check/adjust oil dispense rate [10-32]. 2. The fuser temperature is 2. Check Fuser Temperature out of specification. ( ADJ 10.1). 3. The Fabric Guide is not 3. Check / replace the Fabric contacting the Fuser Heat Roll Guide ( REP 8.9) and Presuniformly. sure Plates ( REP 8.5). 4. Media is damp. 4A. Ensure that the media is stored correctly. 4B. Refer to BSD 7.1 and BSD 7.3 to check for correct operation of the paper heaters.

5. Damaged or contaminated 5. Clean or replace the Heat heat roll Roll ( REP 10.2).

Print Quality

PQ 22

01/02 3-20

8825/8830 Printer

Repairs/Adjustments
Repairs Electrical
REP 3.1 Main PWB ......................................................................................................... REP 3.2 High Voltage Power Supply .............................................................................. 4-3 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-18 4-18 4-20 4-23 4-24 4-25 4-26 4-28 4-29 4-30 4-31 4-32 4-34 4-34 4-37 4-39 4-40 4-41

Xerographics
REP 9.1 Xerographic Module.......................................................................................... REP 9.2 Drum Assembly................................................................................................. REP 9.3 Drum ................................................................................................................. REP 9.4 Cleaner Blade Kit .............................................................................................. REP 9.5 Developer Module............................................................................................. REP 9.6 Cartridge Drive Motor........................................................................................ REP 9.7 Developer Material............................................................................................ REP 9.8 Scorotron Pin Kit ............................................................................................... REP 9.9 Transfer / Detack Corotron ............................................................................... REP 9.11 Toner Sensor .................................................................................................. REP 9.12 Toner Cartridge Home Sensor........................................................................ REP 9.13 Sump Shield.................................................................................................... REP 9.14 Cartridge Drive Plate....................................................................................... REP 9.17 Photoreceptor Seal ......................................................................................... REP 9.18 Air Pressure Tubes ......................................................................................... REP 9.19 Roller Kit ......................................................................................................... REP 9.20 Image Module ................................................................................................. 4-43 4-46 4-49 4-50 4-54 4-58 4-59 4-66 4-68 4-69 4-70 4-72 4-74 4-78 4-79 4-81 4-81 4-88 4-92 4-92 4-93 4-93 4-94 4-97 4-97 4-99 4-100 4-101 4-103 4-111 4-112 4-113 4-115 4-116 4-118

RFC
REP 7.1 Media Supply Drawer ....................................................................................... REP 7.2 Rewind Gear and Rewind Internal Gear ........................................................... REP 7.3 Roll Feed Pinch Rolls ....................................................................................... REP 7.4 Roll Feed Drive Rolls ........................................................................................ REP 7.5 Feed Clutch ...................................................................................................... REP 7.6 Rewind Clutch................................................................................................... REP 7.7 Motion Sensor................................................................................................... REP 7.9 Roll Drive Motor ................................................................................................ REP 7.10A Lower Media Roll Heater .............................................................................. REP 7.10B Upper Media Roll Heater .............................................................................. REP 7.11 Encoder Disk ..................................................................................................

Paper Transportation
REP 8.1 Media Transport Assembly ............................................................................... REP 8.2 Media Exit Switch ............................................................................................. REP 8.3 Buckle Switch ................................................................................................... REP 8.4 Cut Sheet Media Feed Clutch - 8830 and 8825 with Tag/MOD 90 .................. REP 8.5 Pressure Plates ................................................................................................ REP 8.6 Sheet Drive Roll - 8830 and 8825 with Tag/MOD 90........................................ REP 8.7 Sheet Pinch Rolls - 8830 and 8825 with Tag/MOD 90 ..................................... REP 8.8 Media Registration Sensor ............................................................................... REP 8.9 Fabric Guide ..................................................................................................... REP 8.10 Media Transport Drive Motor .......................................................................... REP 8.11 Sheet Feed Switch - 8830 and 8825 with Tag/MOD 90 ................................. REP 8.12 Registration Pinch Rolls.................................................................................. REP 8.13 Media Feed Drive Belt .................................................................................... REP 8.15 Cutter Home Sensor ....................................................................................... REP 8.16 Exit Roll........................................................................................................... REP 8.17 Registration Drive Roll ....................................................................................

Fuser
REP 10.1 Heat Rod......................................................................................................... REP 10.2 Heat Roll ......................................................................................................... REP 10.3 Fuser Triac...................................................................................................... REP 10.7 Web Oiler Assembly ....................................................................................... REP 10.8 Stripper Fingers .............................................................................................. REP 10.9 Web Oiler ........................................................................................................

Adjustments
ADJ 3.2 Country Configuration........................................................................................ ADJ 8.1 Vertical Magnification ........................................................................................ ADJ 8.2 Lead Edge Registration ..................................................................................... ADJ 8.3 Cut Length ......................................................................................................... ADJ 8.4 Media Transport ................................................................................................ ADJ 9.2 Electrostatic Series............................................................................................ ADJ 9.3 Image Density.................................................................................................... ADJ 9.6 Augers ............................................................................................................... ADJ 9.5 Toner Cartridge Home Sensor .......................................................................... ADJ 10.1 Fuser Temperature (NVM) .............................................................................. ADJ 10.2 Fuser Temperature (with Probe) ..................................................................... ADJ 10.3 Fuser Temperature (with Tape).......................................................................

8825/8830 Printer

01/02 4-1

Repairs and Adjustments

01/02 4-2

8825/8830 Printer

REP 3.1 Main PWB

Parts List on PL 1.1A WARNING
Switch off the Controller and the Printer Main Power Switches. Disconnect the Printer Power Cord. CAUTION Electrostatic Discharge Damage (ESD) may occur. Use ESD procedures and Antistatic Wrist Strap to avoid damage to PWBs or components.

1
Remove 2 screws from the Printer Right Lower Cover, and tilt the cover back slightly.

Removal
1. 2. Check the Printer Tag Matrix to see if Tag 28 is installed. This information will be needed later in this procedure. (Figure 1): Prepare to remove the Controller.

3
Lift out the Controller and set it on the floor.

A3 p307B

A1P3

2
Disconnect connectors A3P 307B and A1P3.

Figure 1 Removing the Controller 3. Attach a Static Wrist Strap between your wrist and the unpainted metal chassis of the Controller.

8825/8830 Printer

01/02 4-3

Repairs and Adjustments

REP 3.1

(Figure 2): Disconnect the 10 connectors from the Printer Main PWB.

NOTE: Position the Pin 1 Locating Dot as shown.

3
Disconnect Image Bar connector

1
Disconnect connectors (8)

2
Disconnect Ground Connector

Figure 2 Ground Connector location on Main PWB 5. 6. Pull the 8 plastic fasteners outward and remove the Printer Main PWB. (Figure 3): Remove the NVM integrated circuit from the existing Main PWB.

NVM Integrated Circuit Pin 1 locating dot Figure 3 NVM Integrated Circuit

Repairs and Adjustments

REP 3.1

01/02 4-4

8825/8830 Printer

(Figure 4): PWB.

Install the existing NVM integrated circuit into the socket on the new Main

NOTE: Position the Pin 1 locating dot as shown.

Pin 1 locating dot

NVM Integrated Circuit

Figure 4 Installing the NVM Integrated Circuit on the new Main PWB 8. Install the new Main PWB over the 8 plastic fasteners. (Press down each plastic fastener to secure the Main PWB.)

8825/8830 Printer

01/02 4-5

Repairs and Adjustments

REP 3.1

(Figure 5): Connect the connectors:

If the firmware version IS the current version, switch off the printer and continue on with this procedure.

1
Connect the connectors (8)

13. Connect Connectors A3P307B and A1P3. 14. Reinstall the Controller. 15. While holding down the 0 key on the Printer Control Panel, switch on the printer and the controller. Continue to hold down the key until two beeps are heard. 16. Enter the diagnostic code Chain 09 Test 00, and select Plot 5. A test print should be generated. 17. Enter the diagnostic code Chain 03 Test 00 to leave the Diagnostic Mode and resume normal operation. 18. Mark Tag/MOD 27 on the Printer Tag Matrix.

2
With Tag 28: Connect Image Bar Connector to J330 Without Tag 28: Connect Image Bar Connector to J307A

3
Connect the ground connector

Figure 5 Connecting P307A to new Main PWB 10. Connect the remaining connectors and the ground connector to the Main PWB. 11. Check the Xerox BBS to determine the current version of software to be installed on the Main PWB. 12. Check the version of the firmware that is currently loaded onto the newly installed Main PWB by performing the following: a. b. Connect the Printer Power Cord. Hold down the 0 (zero) button on the Printer Control Panel and switch on the Printer. Continue to hold down the 0 button until the Control Panel has emitted two beeps;. The printer is now in the Diagnostic Mode. Observe the Printer Control Panel Display during the power-up sequence: If the firmware version IS NOT the current version, go to GP 6 Downloading Firmware From a Laptop.

Repairs and Adjustments

REP 3.1

01/02 4-6

8825/8830 Printer

REP 3.2 High Voltage Power Supply

Parts List on PL 1.3 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

7
Pull the HVPS off the pins

6
Disconnect J30

5
Disconnect the Grid wire

4
Disconnect the Charge Scorotron wire

Removal
1. 2. 1. Loosen the screws and open the Rear Door. (Figure 1): Remove the High Voltage Power Supply. If a new High Voltage Power Supply is being installed, perform the Electrostatic Series (ADJ 9.2).

Replacement 3
Disconnect the Transfer Corotron wire (small connector)

2
Disconnect the Detack Corotron wire (large connector)

8
Remove the three screws (7 mm hex head)

1
Disconnect A25P1

Figure 1 Removing the High Voltage Power Supply

8825/8830 Printer

01/02 4-7

Repairs and Adjustments

REP 3.2

REP 7.1 Media Supply Drawer

Parts List on PL 7.1 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: All three Roll Supply Drawer Assemblies are removed the same way. The 8825 comes with Media Supply Drawer 1 or 2. The customer can order it with 2 drawers or have Drawer 2 retrofitted on site. (Drawer 2 is TAG 90.)

(Figure 2): Remove the Media Supply Drawer.

1
Remove the screws (one at each end)

Removal
1. 2. Open the Media Supply Drawer that is to be removed. (Figure 1): Remove the Cover.

1
Remove the Media Roll

3
Remove the screws (one each side)

2
Remove the Media Supply Drawer

Figure 2 Removing the Media Supply Drawer

4
Remove the Cover

2
Loosen the screws (one each side)

Figure 1 Removing the Cover

Repairs and Adjustments

REP 7.1

01/02 4-8

8825/8830 Printer

REP 7.2 Rewind Gear and Rewind Internal Gear

Parts List on PL 7.3 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: All three Rewind Gears and Rewind Internal Gear Assemblies are removed the same way.

3
Remove the E-ring

4
Remove the Rewind Gear

Removal
1. 2. 3. Pull out the Media Supply Drawer. Remove the roll of media. (Figure 1): Remove the Rewind Gear and the Rewind Internal Gear.

2
Remove the Rewind Internal Gear

1
Remove the E-ring

Figure 1 Removing the Rewind Gears

8825/8830 Printer

01/02 4-9

Repairs and Adjustments

REP 7.2

REP 7.3 Roll Feed Pinch Rolls

Parts List on PL 7.5 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: All three Roll Feed Pinch Roll Assemblies are removed the same way.

2
Remove the Pinch Rolls

Removal
1. 2. Open the Media Supply Drawer and remove the Media Roll. (Figure 1): Remove the Roll Feed Pinch Rolls.

1
Remove the springs (two each Pinch Roll)

3
Remove the E-rings and the shafts

Figure 1 Removing the Roll Feed Pinch Rolls

Repairs and Adjustments

REP 7.3

01/02 4-10

8825/8830 Printer

REP 7.4 Roll Feed Drive Rolls

Parts List on PL 7.1 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: All three Roll Feed Drive Roll assemblies are removed the same way.

2. 3. 4.

Remove the Feed Clutch (REP 7.5). Remove the Toner Waste Container. (Figure 1): Remove the Roll Feed Drive Rolls.

Removal
1. Remove the appropriate Media Supply Drawer (REP 7.1).

2
Remove the bearing

4
Remove the bearing

1
Remove the Ering

3
Remove the E-Ring

5
Remove the Drive Rolls

Figure 1 Removing the Roll Feed Drive Rolls

8825/8830 Printer

01/02 4-11

Repairs and Adjustments

REP 7.4

REP 7.5 Feed Clutch

Parts List on PL 7.2 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

(Figure 1): Remove the Feed Clutch.

Removal
1. Loosen the screws and open the Rear Door.

8
Remove the Feed Clutch

6
Disconnect the connector

7
Remove the E-Ring

3
Remove the chain

4
Remove the E-Ring

2
Move the Motor Bracket to relieve the tension on the chain

5
Remove the sprocket

1
Loosen the screws (2)

Figure 1 Removing the Feed Clutch

Repairs and Adjustments

REP 7.5

01/02 4-12

8825/8830 Printer

REP 7.6 Rewind Clutch

Parts List on PL 7.2 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

(Figure 1): Remove the Rewind Clutch.

Removal
1. Loosen the screws and open the Rear Door.

8
Remove the Rewind Clutch

3
Remove the chain

6
Disconnect the connector

7
Remove the E-ring

2
Move the Motor Bracket to relieve the tension on the chain

5
Remove the sprocket

1
Loosen the screws (2)

4
Remove the E-ring

Figure 1 Removing the Rewind Clutch

8825/8830 Printer

01/02 4-13

Repairs and Adjustments

REP 7.6

REP 7.7 Motion Sensor

Parts List on PL 7.2 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

Replacement
1. 2. Reinstall the Motion Sensor and the Rewind Housing. (Figure 2): Reinstall the Encoder Disk.

Removal
1. 2. 3. Loosen the screws and open the Rear Door. Remove the Rewind Clutch (REP 7.6). (Figure 1): Remove the Motion Sensor.

3
Ensue that the slot in the encoder Disk aligns with the pin in the shaft

5
Press the Motion Sensor tabs outward through the slots

6
Remove the Motion Sensor

2
Reinstall the Encoder Disk

1
Align the open slot in the Encoder Disk with the opening the housing

1
Disconnect the connector

4
Remove the Rewind Housing

Figure 2 Reinstalling the Encoder Disk

3
Remove the screws (3)

2
Remove the Encoder Disk

Figure 1 Removing the Motion Sensor

Repairs and Adjustments

REP 7.7

01/02 4-14

8825/8830 Printer

REP 7.9 Roll Drive Motor

Parts List on PL 7.2 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

(Figure 1): Remove the Roll Drive Motor Assembly.

Removal
1. Loosen the screws and open the Rear Door.

6
Remove the Roll Drive Motor Assembly

5
Remove the screws (2)

1
Disconnect P/J 2

2
Remove the spring

3
Loosen the screws

4
Move the bracket and disconnect the chain from the drive sprocket

Figure 1 Removing the Roll Drive Assembly 3. (Figure 2): Remove the bracket from the Roll Drive Motor.

8825/8830 Printer

01/02 4-15

Repairs and Adjustments

REP 7.9

REP 7.10A Lower Media Roll Heater

2
Remove the bracket from the motor

Parts List on PL 7.2 WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal
1. Loosen the screws and open the Rear Door.

1
Remove the screws (4)

Figure 2 Removing the Roll Drive Motor Bracket

Repairs and Adjustments

REP 7.9, REP 7.10A

01/02 4-16

8825/8830 Printer

(Figure 1): Remove the Lower Media Roll Heater.

2
Remove the screw

1
Disconnect the connector

3
Remove the Lower Media Roll Heater

Figure 1 Removing the Lower Media Roll Heater

8825/8830 Printer

01/02 4-17

Repairs and Adjustments

REP 7.10A

REP 7.10B Upper Media Roll Heater

Parts List on PL 7.2 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. 2.

CAUTION Be sure to support the Media Roll Heater/Guard with your hand while removing the mounting screws in the next step. (Figure 1): Remove the Upper Media Roll Heater.

Removal
1. Remove Media Supply Drawer 1 (REP 7.1).

Upper Media Roll Heater and Guard

1
Disconnect the connector

2
Remove the screws (2) and lift out the Upper Media Roll Heater and Guard

3
Slide the Media Roll Heater out from Heater Guard

Figure 1 Removing the Upper Media Roll Heater

REP 7.11 Encoder Disk

Repairs and Adjustments

REP 7.10B, REP 7.11

01/02 4-18

8825/8830 Printer

Parts List on PL 7.2 WARNING

Switch off the Main Power Switch. Disconnect the Power Cord.

(Figure 2): Reinstall the Encoder Disk.

Removal
1. 2. 3. Loosen the screws and open the Rear Door. Remove the Rewind Clutch (REP 7.6). (Figure 1): Remove the Encoder Disk.

3
Ensure that the slot in the Encoder Disk aligns with the pin in the shaft

2 1
Align the open slot in the Encoder Disk with the opening in the housing Reinstall the Encoder Disk

Figure 2 Reinstalling the Encoder Disk

1
Remove the Encoder

Figure 1 Removing the Encoder Disk

Replacement
1. Reinstall the Motion Sensor and the Rewind Housing.

8825/8830 Printer

01/02 4-19

Repairs and Adjustments

REP 7.11

REP 8.1 Media Transport Assembly

Parts List on PL 8.1 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly. Disconnect the tube

Removal
1. 2. 3. Latch the Xerographic Module at the Service Position (REP 9.2). Open the Cutter Drawer. (Figure 1): Disconnect the connectors at the rear of the printer.

1
Disconnect the Transfer and the Detack Corotron leads

Figure 2 Disconnecting the Moisture Collection Tube

2
Disconnect A21P1

Figure 1 Disconnecting the Connectors 4. (Figure 2): Disconnect the Moisture Collection Tube.

Repairs and Adjustments

REP 8.1

01/02 4-20

8825/8830 Printer

(Figure 3): Remove the Media Transport Assembly.

1
Disconnect the Latch Arms from the Transport (Both sides)

5
Ensure that the Moisture Collection Tube is out of the hole in the frame

2
Loosen the screw and rotate the bracket downward

7
Remove the Media Transport Assembly

3
Pull the pin and hold it out of the Transport

6
Move the Media Transport pin out of the locating hole and onto the ramp

4
Ensure that the pin is free of the bushing, then move the Right Side of the Media Transport towards you

Figure 3 Removing the Media Transport Assembly

Replacement
1. 2. If a new Media Transport Assembly is being installed, perform the Media Transport to Drum Spacing (ADJ 8.4). Open the Cutter Drawer.

8825/8830 Printer

01/02 4-21

Repairs and Adjustments

REP 8.1

(Figure 4): Reinstall the Media Transport Assembly.

7
Route the Drain Hose and reconnect it

6
Rotate and lock the bracket

8
Reconnect the Corotron Leads and Connector A21P1

4
Pull and hold the pin

1
Place the pin on the ramp

2
Install the Turnaround Baffle under the Developer Assembly Shelf (both ends)

5 3
Move the pin into the locating hole Move the Transport in, aligning the pin with the bushing, and release the pin

Figure 4 Reinstalling the Media Transport Assembly

Repairs and Adjustments

REP 8.1

01/02 4-22

8825/8830 Printer

REP 8.2 Media Exit Switch

Parts List on PL 8.4 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

Removal
1. 2. 3. 4. 5. Latch the Xerographic Module at the Service Position (REP 9.2). Remove the Media Transport Assembly (REP 8.1). Remove the Fabric Guide (REP 8.9). (Figure 1): Remove the Front Pivot Assembly. Turn the Front Pivot Assembly over and remove the Media Exit Switch. a. b. c. Disconnect the Switch Assembly Connector Q3. Remove the screw and the Stacker Support. Remove the Media Exit Switch from the bracket.

Front Pivot Assembly

1
Disconnect the connector from the clutch

4
Remove the Front Pivot Assembly

2
Loosen the screws (both sides)

3
Remove the screws (both sides)

Figure 1 Removing the Front Pivot Assembly

8825/8830 Printer

01/02 4-23

Repairs and Adjustments

REP 8.2

REP 8.3 Buckle Switch

Parts List on PL 8.4 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

Removal
1. 2. 3. 4. 5. Latch the Xerographic Module at the Service Position (REP 9.2). Remove the Media Transport Assembly (REP 8.1). Remove the Fabric Guide (REP 8.9). Remove the Pressure Plates (REP 8.5). (Figure 1): Remove the Buckle Switch. a. b. c. d. Remove the screw. Carefully pull the Buckle Switch Assembly until the connector can be disconnected. Disconnect the connector. Remove the Buckle Switch from the bracket. Screw Buckle Switch

Buckle Switch Assembly

Figure 1 Removing the Buckle Switch

Repairs and Adjustments

REP 8.3

01/02 4-24

8825/8830 Printer

REP 8.4 Cut Sheet Media Feed Clutch - 8830 and 8825 with Tag/MOD 90
Parts List on PL 8.1 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

2
Remove the screw and the bracket

1
Disconnect the connector from the clutch

Removal
1. 2. 3. Latch the Xerographic Module at the Service Position (REP 9.2). Remove the Media Transport Assembly (REP 8.1). (Figure 1): Remove the Cut Sheet Media Feed Clutch.

4
Pull the clutch off the shaft

3
Remove the E-ring

Figure 1 Removing the Cut Sheet Media Feed Clutch

8825/8830 Printer

01/02 4-25

Repairs and Adjustments

REP 8.4

REP 8.5 Pressure Plates

Parts List on PL 10.3 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly.

1
Push the Buckle Switch Actuator down (not shown)

Removal
1. 2. 3. Latch the Xerographic Module at the Service Position (REP 9.2). Remove the Media Transport Assembly (REP 8.1). Remove the Fabric Guide (REP 8.9). CAUTION Be sure to push the Buckle Switch Actuator down while starting to remove the Upper Pressure Plate in order to prevent damage to the actuator. 4. (Figure 1): Remove the Upper and Lower Pressure Plates.

2
Remove the Upper Pressure Plate

3
Remove the Lower Pressure Plate

Figure 1 Removing the Pressure PLates

Repairs and Adjustments

REP 8.5

01/02 4-26

8825/8830 Printer

Replacement
CAUTION Be careful not to damage the Sheet Media Switch Actuator while reinstalling the Lower Pressure Plate. 1. (Figure 2): Reinstall the Lower Pressure Plate.

(Figure 3): Reinstall the Upper Pressure Plate.

1
Push the Buckle Switch Actuator down (not shown)

2
Reinstall the Upper Pressure Plate

Reinstall the Lower Pressure Plate

Figure 3 Reinstalling the Upper Pressure Plate

Figure 2 Reinstalling the Lower Pressure Plate CAUTION Be sure to push the Buckle Switch Actuator down while reinstalling the Upper Pressure Plate in order to prevent damage to the actuator.

8825/8830 Printer

01/02 4-27

Repairs and Adjustments

REP 8.5

REP 8.6 Sheet Drive Roll - 8830 and 8825 with Tag/MOD 90
Parts List on PL 8.3 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825\8830 configuration exactly.

(Figure 2): Remove the Sheet Drive Roll.

Remove the Sheet Drive Roll

Removal
1. 2. 3. 4. 5. 6. Latch the Xerographic Module at the Service Position (REP 9.2). Remove the Media Transport Assembly (REP 8.1). Remove the Fabric Guide (REP 8.9). Remove the Pressure Plates (REP 8.5). Remove the Cut Sheet Media Feed Clutch (REP 8.4). (Figure 1): Remove the Timing Belt and the bearings.

1
Remove the E-ring and pulley (not shown) Figure 2 Removing the Sheet Drive Roll

2
Remove the Pulley Clutch and Timing Belt

4
Remove the E-ring, Drag Brake, E-ring and bearing at the opposite end of the Drive Roll (not shown)

3
Remove the E-ring and bearing

Figure 1 Removing the Bearings

Repairs and Adjustments

REP 8.6

01/02 4-28

8825/8830 Printer

REP 8.7 Sheet Pinch Rolls - 8830 and 8825 with Tag/MOD 90
Parts List on PL 8.3 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly.

2
Remove the spring from under the edge of the channel

1
Unlatch the spring (both ends)

Removal
1. 2. 3. 4. 5. 6. Latch the Xerographic Module at the Service Position (REP 9.2). Remove the Media Transport Assembly (REP 8.1). Remove the Fabric Guide (REP 8.9). Remove the Pressure Plates (REP 8.5). Turn the Media Transport over. (Figure 1): Remove the Sheet Pinch Rolls.

5
Remove the Sheet Pinch Rolls (one each end)

4
Remove the E-rings and bearings (one each end)

3
Remove the Sheet Pinch Roll Assembly

Figure 1 Removing the Sheet Pinch Rolls

8825/8830 Printer

01/02 4-29

Repairs and Adjustments

REP 8.7

REP 8.8 Media Registration Sensor

Parts List on PL 8.2 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly. Sensor Window

Removal
1. 2. 3. Latch the Xerographic Module at the Service Position (REP 9.2). Remove the Media Transport Assembly (REP 8.1). (Figure 1): Remove the Media Registration Sensor.

3
Remove the two screws and the Media Registration Sensor

1
Push down the tab and disconnect the connector

2
Remove the two screws and the assembly

Figure 1 Removing the Media Registration Sensor

Repairs and Adjustments

REP 8.8

01/02 4-30

8825/8830 Printer

REP 8.9 Fabric Guide

Removal
1. 2. Lower the Media Transport Cover. (Figure 1): Carefully reach into the Printer and remove the Fabric Guide.

2
Remove the Fabric Guide

1
Raise the Retaining Bar 90 degrees

Figure 1 Removing the Fabric Guide

8825/8830 Printer

01/02 4-31

Repairs and Adjustments

REP 8.9

Replacement
1. (Figure 2): Reinstall the Fabric Guide.

REP 8.10 Media Transport Drive Motor

Parts List on PL 8.1 WARNING 2
Latch the Retainer Bar Switch off the Main Power Switch. Disconnect the Power Cord.

1
Ensure that the edge of the handle is inside the edge of the frame

Frame

Figure 2 Reinstalling the Fabric Guide

Repairs and Adjustments

REP 8.9, REP 8.10

01/02 4-32

8825/8830 Printer

6. 7.

(Figure 1): Remove the Media Transport Drive Motor Assembly. (Figure 2): Remove the motor from the mounting plate.

Replacement
1. 2. Ensure that the belt is over the Idler Pulley. (Figure 2): If a new motor is being installed, use the Drive Pulley from the old assembly.

1 2
Remove the screws (3) Disconnect the connector

1
Remove the ground wire and the screw

2
Remove the retaining clip and the Drive Pulley

4
Remove the mounting plate

3
Remove the screws and washers (3)

Figure 2 Removing the Media Transport Drive Motor Assembly

Idler Pulley

3
Remove the Motor Assembly

Figure 1 Removing the Motor

8825/8830 Printer

01/02 4-33

Repairs and Adjustments

REP 8.10

REP 8.11 Sheet Feed Switch - 8830 and 8825 with Tag/MOD 90
Parts List on PL 8.4

REP 8.12 Registration Pinch Rolls

Parts List on PL 8.2 WARNING

WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly.

Removal
1. 2. 3. 4. 5. 6. 7. Latch the Xerographic Module at the Service Position (REP 9.2). Remove the Media Transport Assembly (REP 8.1). Remove the Fabric Guide (REP 8.9). Remove the Pressure Plates (REP 8.5). Remove the Front Pivot Assembly using REP 8.2. Remove the Sheet Drive Roll (REP 8.6). (Figure 1): Remove the Sheet Feed Switch.

Removal
1. 2. Latch the Xerographic Module at the Service Position (REP 9.2). Remove the Media Transport Assembly (REP 8.1).

1
Disconnect the connector

3
Remove the Sheet Feed Switch

2
Squeeze the tabs

Figure 1 Removing the Sheet Feed Switch

Repairs and Adjustments

REP 8.11, REP 8.12

01/02 4-34

8825/8830 Printer

(Figure 1): Remove the Baffle.

(Figure 2): Remove the Registration Pinch Rolls.

4
Remove the two retainers (one each end)

3
Remove the Registration Pinch Roll Assembly

REP 8.12, REP 8.13

(Figure 1): Remove the Media Feed Drive Belt.

Replacement
1. Ensure that the belt is over the Idler Pulley.

1
Disconnect the connector

2
Remove the screws (3)

4
Remove the Media Feed Drive Belt

Idler Pulley

3
Remove the Motor Assembly

Figure 1 Removing the Media Feed Drive Belt

Repairs and Adjustments

REP 8.13

01/02 4-38

8825/8830 Printer

REP 8.15 Cutter Home Sensor

Parts List on PL 7.8 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly.

3
Rotate the sensor and remove it

Removal
1. 2. Open the Cutter Drawer. (Figure 1): Remove the Cutter Home Sensor.

Cutter Drive Pulley

2
Squeeze the tabs

1
Disconnect the connector

Figure 1 Removing the Cutter Home Sensor

Replacement
1. Center the Disc of the Cutter Drive Pulley in the sensor during reassembly.

8825/8830 Printer

01/02 4-39

Repairs and Adjustments

REP 8.15

REP 8.16 Exit Roll

Parts List on PL 8.4 3 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. Remove the E-ring

1
Remove the E-ring

Removal
1. 2. 3. 4. Latch the Xerographic Module at the Service Position (REP 9.2). Remove the Media Transport Assembly (REP 8.1). Remove the Media Exit Switch (REP 8.2). (Figure 1): Remove the Exit Roll from the Front Pivot Assembly.

2
Remove the belt, the E-ring and the pulley

Left Side Exit Roll

Front Pivot Assembly

4
Remove the Exit Roll by moving it to the right until it is free of the bushing on the left side, then lift the roll out of the Front Pivot Assembly Figure 1 Removing the Exit Roll

Repairs and Adjustments

REP 8.16

01/02 4-40

8825/8830 Printer

REP 8.17 Registration Drive Roll

Parts List on PL 8.2 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

1
Disconnect the connector

2
Remove the screws (3)

4
Remove the Media Feed Drive Belt

Removal
1. 2. 3. 4. 5. 6. 7. Latch the Xerographic Module at the Service Position (REP 9.2). Remove the Media Transport Assembly (REP 8.1). Remove the Fabric Guide (REP 8.9). Remove the Pressure Plates (REP 8.5). Turn the Media Transport Assembly over. (Figure 1): Remove the Media Feed Drive Belt. Turn the Media Transport over and remove the screws (2 each side) and the baffle that they secure.

3
Remove the motor Assembly

Idler Pulley

Figure 1 Removing the Media Feed Drive Belt

8825/8830 Printer

01/02 4-41

Repairs and Adjustments

REP 8.17

8. 9.

(Figure 2): Remove the Baffle. Remove the Registration Drive Roll by pushing the bearings out of the frame and moving the roll as required for removal.

2
Remove the two screws (one each end)

3
Remove the screws (5)

1 4
Rotate the screw until it is free of the slot Remove the two springs (one each end)

5
Remove the Baffle

6
Rotate the Assembly

Figure 2 Removing the Baffle

Repairs and Adjustments

REP 8.17

01/02 4-42

8825/8830 Printer

REP 9.1 Xerographic Module

Parts List on PL 9.1, PL 10.1 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

1
Lift the bracket at the tab in order to disconnect the spring

2
Pull the spring away from the shaft

3
Push the bracket down to the horizontal position

Removal
1. 2. 3. 4. Loosen the screws and open the Rear Door. Raise and latch the Top Cover. Lift and rotate the Image Module to the Service Position. Lower the Media Transport Cover. Tab

NOTE: Figure 1 shows only the Front Support Bracket. 5. (Figure 1): Prepare the Front and Rear Support Brackets for raising the Xerographic Module to the Service Position.

4 5
Perform Steps 1 through 3 for the Rear Support Bracket Disconnect A23P1

Figure 1 Preparing the Support Bracket 6. Remove the Web Oiler Assembly (REP 10.7).

8825/8830 Printer

01/02 4-43

Repairs and Adjustments

REP 9.1

NOTE: In the following steps, Left and Right describe machine locations as observed when you are facing the Xerographic Module at the left side of the Printer. 7. (Figure 2): Install the Handles onto the Left and Right Side of the Xerographic Module.

(Figure 3): Using the handles, rotate the Xerographic Module 90 degrees so that the latches lock into the holes in the frame.

1 1
Attach the handle into the slot Rotate the Xerographic Module 90 degrees

3
Disconnect A23P2 Handles

2 2
Secure the fastener Ensure that the Xerographic Module is latched to the frame

Figure 2 Installing the Handles (Right Side) NOTE: The latches that secure the Xerographic Module to the Printer Frame are spring-loaded and will automatically engage the holes. The latches have a 1/4 turn lockout feature that may be used to prevent actuation during reinstallation of the Xerographic Module. When performing the following step, ensure that the spring-loaded feature is active. Figure 3 Latching the Xerographic Module at the Service Position

Repairs and Adjustments

REP 9.1

01/02 4-44

8825/8830 Printer

(Figure 4): Move the bearing out of the Xerographic Module Frame (Left Side).

10. (Figure 5): Move the bearing out of the Xerographic Module Frame (Right Side).

2
Lift the Drum Assembly and move the bearing to the right Drum Assembly

Drum Assembly

3
Holding the gearbox out of the grommet, move the Drum Assembly to the right while moving the bearing out of the frame (Without Tag 8)

2
Disconnect P/J 1

3
Carefully lower the Drum Assembly

1
Disconnect the retaining clip that holds the bearing and rotate the clip out of the way

1
Loosen the wing nut and rotate the gearbox to disengage the bracket from the grom-

Figure 4 Moving the Bearing (Left Side)

Figure 5 Moving the Bearing (Right Side)

8825/8830 Printer

01/02 4-45

Repairs and Adjustments

REP 9.1

11. (Figure 6): Carefully remove the Drum Assembly from the Printer and place it, Gear Box down, in a safe place on the floor.

REP 9.2 Drum Assembly

Parts List on PL 9.2 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

Drum Assembly

Removal
1. 2. 3. 4. Loosen the screws and open the Rear Door. Raise and latch the Top Cover. Lift and rotate the Image Module to the Service Position. Lower the Media Transport Cover.

NOTE: Figure 1 shows only the Front Support Bracket.

Gear Box

Figure 6 Removing the Drum Assembly 12. Using the Handles, lift the Xerographic Module out of the Printer and place it on a stable, flat surface.

Repairs and Adjustments

REP 9.1, REP 9.2

01/02 4-46

8825/8830 Printer

(Figure 1): Prepare the Front and Rear Support Brackets for raising the Xerographic Module to the Service Position.

NOTE: The latches that secure the Xerographic Module to the Printer Frame are spring-loaded and will automatically engage the holes. The latches have a 1/4 turn lockout feature that may be used to prevent actuation during reinstallation of the Xerographic Module. When performing the following step, ensure that the spring-loaded feature is active. 6. (Figure 2): Using the handles on the Web Oiler Assembly, rotate the Xerographic Module 90 degrees so that the latches lock into the holes in the frame.

1
Lift the bracket at the tab in order to disconnect the spring

2
Pull the spring away from the shaft

3
Push the bracket down to the horizontal position

1
Rotate the Xerographic Module 90 degrees Handles

Tab

2
Ensure that the Xerographic Module is latched to the frame Figure 2 Latching the Xerographic Module at the Service Position NOTE: In the following steps, Left and Right describe machine locations as observed when you are facing the Xerographic Module at the left side of the Printer.

5
Using the handles on the Web Oiler Assembly, pull back the Xerographic Module so that the groove on the shaft is captured by the Support Bracket ((Front and Rear)

4
Perform Steps 1 through 3 for the Rear Support Bracket

Figure 1 Preparing the Support Bracket

8825/8830 Printer

01/02 4-47

Repairs and Adjustments

REP 9.2

(Figure 3): Move the bearing out of the Xerographic Module Frame (Left Side).

(Figure 4): Move the bearing out of the Xerographic Module Frame (Right Side).

3
Drum Assembly Drum Assembly Holding the gearbox out of the grommet, move the Drum Assembly to the right while moving the bearing out of the frame (Without Tag 8)

2
Lift the Drum Assembly and move the bearing to the right

2
Disconnect P/J 2

3
Carefully lower the Drum Assembly

1 1
Disconnect the retaining clip that holds the bearing and rotate the clip out of the way Loosen the wingnut and rotate the gearbox to disengage the bracket from the grommet

Figure 3 Moving the Bearing (Left Side)

Figure 4 Moving the Bearing (Right Side)

Repairs and Adjustments

REP 9.2

01/02 4-48

8825/8830 Printer

(Figure 5): Carefully remove the Drum Assembly from the Printer and place it, Gear Box down, in a safe place on the floor.

REP 9.3 Drum

Parts List on PL 9.2 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

Drum Assembly

Removal
NOTE: When the Drum is replaced, install a Cleaner Blade Kit (REP 9.4). 1. 2. Remove the Drum Assembly (REP 9.2). (Figure 1): Carefully place the Drum Assembly, Gear Box down, in a safe place on the floor.

Drum Assembly

Gear Box

Figure 5 Removing the Drum Assembly

Figure 1 Securing the Drum Assembly

8825/8830 Printer

01/02 4-49

Repairs and Adjustments

REP 9.2, REP 9.3

(Figure 2): Remove the Drum from the Shaft Assembly.

REP 9.4 Cleaner Blade Kit

Parts List on PL 9.5A

2
Lift off the Bearing/Plate Assembly

1
Remove the wing nut

NOTE: These are the instructions to install the Cleaner Blade Kit. The kit contains the following items: Right-hand Seal (57 mm wide) Left-hand Seal (41 mm wide) Cleaner Blade Photoreceptor Seal Blade Retainer (3)

WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

3
Lift the Drum off the Shaft Assembly

Removal
NOTE: In this procedure, Left and Right describe machine locations as observed when you are facing the Xerographic Module at the left side of the Printer. 1. 2. 3. Figure 2 Removing the drum from the Shaft Assembly Remove the Drum Assembly (REP 9.2). (Figure 1): Remove the Photoreceptor Seal, Right-hand Seal, Left-hand Seal, Cleaner Blade, and the three Blade Retainers from the Xerographic Module. Use a vacuum cleaner to clean the channels and the areas where the new parts will be installed.

4. 5. 6. 7. 8.

If the Drum is being replaced, install a Cleaner Blade Kit (REP 9.4). Reassemble the Drum Assembly. Perform GP 4 Drum Cleaning Enhancement procedure. Reinstall the Drum Assembly. Perform the Electrostatic Series (ADJ 9.2).

Repairs and Adjustments

REP 9.3, REP 9.4

01/02 4-50

8825/8830 Printer

Xerographic Module Frame

Right-hand Seal

Photoreceptor Seal

Blade Retainer (3) Photoreceptor Seal Channel Cleaner Blade

Figure 1 Removing the Cleaner Blade

8825/8830 Printer

01/02 4-51

Repairs and Adjustments

REP 9.4

Replacement
1. (Figure 2): Replace the Photoreceptor Seal. a. b. c. 2. Carefully fold the Photoreceptor Seal along the perforations. Slide the Photoreceptor Seal into the channel, smaller side up, so that the edge of the Photoreceptor Seal forms a seal with the inside lip of the channel. Using a soft, straight tool (a piece of shimstock works well), carefully push the seal into the channel, across the entire width of the Xerographic Module. Insert the red stripe end of the Right-hand Seal underneath the folded Photoreceptor Seal. Install the seal fuzzy side up. Ensure that the seal is flush against the Xerographic Module Frame. Start the Cleaner Blade flush against the left edge of the Right-hand Seal. Ensure that the marking, THIS SIDE TO PHOTORECEPTOR, is to the right. Push the Cleaner Blade into the channel, with the Arrow marking to the left. Ensure that the blade is fully seated in the channel. Photoreceptor Seal Right-hand Seal Photoreceptor Seal Channel

Replace the Right-hand Seal. a. b. c. Xerographic Module Frame

Replace the Cleaner Blade. a. b. c. d.

Install the first of the three Blade Retainers approximately one inch from the Xerographic Module Frame, working to the left.

Blade Retainer (3)

Cleaner Blade

Figure 2 Installing the Cleaner Blade Kit 5. 6. Repairs and Adjustments (Figure 3): Complete the installation of the remaining two Blade Retainers, positioning them, one at a time, to the left of the first one. Replace the Left-hand Seal.

REP 9.4

01/02 4-52

8825/8830 Printer

a. b. c. 7.

Insert the red stripe end of the Left-hand Seal underneath the folded Photoreceptor Seal. Install the seal fuzzy side up. Ensure that the seal is flush against the Xerographic Module Frame. Xerographic Module Frame Left-hand Seal

Perform GP 4 Drum Cleaning Enhancement procedure.

Photoreceptor Seal

Cleaner Blade Blade Retainer (3)

Figure 3 Installing the Cleaner Blade Kit

8825/8830 Printer

01/02 4-53

Repairs and Adjustments

REP 9.4

REP 9.5 Developer Module

Parts List on PL 9.8 1 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly. Slide the cover open

3
Pull the plunger while performing Step 4

Removal
CAUTION Before removing the Developer Module, ensure that there is a clean area on which to place the assembly. 1. 2. 3. 4. Loosen the screws and open the Rear Cover. Raise and latch the Top Cover. Raise and hold the Developer Module Cover while lifting and removing the Developer Module Side Cover. Lower the Top Cover.

NOTE: In the following step, tape the Toner Cartridge dispense holes in order to prevent toner from pouring out when the Toner Cartridge is tipped up for removal. 5. (Figure 1): Remove the Toner Cartridge.

2
Clean the toner from the holes in the dispense area and place a piece of tape over the holes

4
Remove the Toner Cartridge

Figure 1 Removing the Toner Cartridge CAUTION Ensure that the clamp will not cause interference when the Developer Module is removed.

Repairs and Adjustments

REP 9.5

01/02 4-54

8825/8830 Printer

(Figure 2): Remove the Developer Module.

1
Move the lock into the groove on the gear while performing Step 2

5
Remove the Developer Module

3
Disconnect A2PP1

4
Press tab and swing down Clamp Bar (one each end)

2
Move the gear to disengage

Figure 2 Removing the Developer Module

8825/8830 Printer

01/02 4-55

Repairs and Adjustments

REP 9.5

Replacement
1. (Figure 3): Reinstall the Developer Module.

4
Move the lock out of the groove on the gear while performing Step 5

1
Reinstall the Developer Module

3
Reconnect A2PP1

2
Press tab and swing up Clamp Bar until it locks (one each end)

5
Move the gear to engage

Figure 3 Reinstalling the Developer Module CAUTION Ensure that the Developer Module is fully reinstalled in the brackets. CAUTION Ensure that the gear is free to engage the Developer Module drive gears. NOTE: To ensure that the Toner Cartridge is correctly engaged in the Drive Plate, rotate the cartridge in both directions.

Repairs and Adjustments

REP 9.5

01/02 4-56

8825/8830 Printer

(Figure 4): Reinstall the Toner Cartridge.

If new Developer Material has been installed, perform the Toner Sensor Calibration Code [09216].

4
Slide the Top Shield closed

2
Partially rotate the Toner Cartridge in both directions to ensure that the cartridge is locked in the Drive Hub

1
Pull the plunger and then reinstall the Toner Cartridge

3
Remove the tape

Figure 4 Reinstalling the Toner Cartridge

8825/8830 Printer

01/02 4-57

Repairs and Adjustments

REP 9.5

REP 9.6 Cartridge Drive Motor

Parts List on PL 9.10

(Figure 2): Remove the Cartridge Drive Motor from the Mounting Plate.

3 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly. Remove the screws (3)

4
Remove the Mounting Plate

Removal
1. 2. Remove the Developer Module (REP 9.5). (Figure 1): Remove the Cartridge Drive Motor.

1
Remove screws (2) and Ground

2
Remove the gear

1
Remove the E-ring

Figure 2 Removing the Cartridge Drive Motor from the Mounting Plate

2
Remove the Cartridge Drive Motor Ground Wire

Figure 1 Removing the Cartridge Drive Motor

Repairs and Adjustments

REP 9.6

01/02 4-58

8825/8830 Printer

REP 9.7 Developer Material

Parts List on (Refer to svc.8830prt.17324 Machine Consumables, Section 6.) WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly.

2
Loosen the screws (2)

Removal
1. Remove the Developer Module (REP 9.5). CAUTION Do not rotate the Developer Module in the vertical position. This may cause Developer Material to get into the Toner Cartridge Clutch (located at the end of the Developer Module). 2. 3. Place the Developer Module on a drop cloth on the floor. (Figure 1): Remove the Sump Shield from the Developer Module.

1
Remove the screws (2)

3
Remove the Top Shield

5
Remove the Sump Shield

4
Remove the Sump Shield from under the edge (full length)

Figure 1 Removing the Sump Shield from the Developer Module NOTE: Rotate the Developer Module away from the Magnetic Roll in the following step.

8825/8830 Printer

01/02 4-59

Repairs and Adjustments

REP 9.7

(Figure 2): Dump the Developer Material.

Magnetic Roll

2
Rotate the gear counterclockwise

1
Rotate the Developer Module

Figure 2 Dumping the Developer Material

Repairs and Adjustments

REP 9.7

01/02 4-60

8825/8830 Printer

Using a vacuum cleaner, clean the entire Developer Module, Magnetic Roll, and Air Pressure Tubes thoroughly. CAUTION

Ensure that the entire length of the tube on the Developer Module is clear of any developer. 7. Using a vacuum cleaner, clean the housing where the Air Pressure Tubes attach.

3
Remove the Air Pressure Tube

5
Remove the retainer

1
Remove the Grip Ring

2
Remove the gears (3)

4
Remove the screw

6
Remove the Air Pressure Tube

Figure 3 Removing the Air Pressure Tubes

8825/8830 Printer

01/02 4-61

Repairs and Adjustments

REP 9.7

Replacement
NOTE: Pour the Developer Material evenly over the full length of the augers. 1. (Figure 4): Install the Developer Material and record the batch number in the Machine Log.

Pour the Developer Material evenly from end to end and across the augers

Figure 4 Installing the Developer Material CAUTION Do not rotate the Auger Gears individually more than the slight amount required for removal or to mesh the teeth during reinstallation. If the factory setting of the augers is changed during the procedure, perform the adjustment procedure, Augers (ADJ 9.6). NOTE: The gears must be reinstalled with the flanges as shown to ensure that all the gears are secured.

Repairs and Adjustments

REP 9.7

01/02 4-62

8825/8830 Printer

(Figure 5): Reinstall the Air Pressure Tubes.

1
Reinstall the Air Pressure Tube Flanges

7
Reinstall the screw

2
Reinstall the gear

4
Reinstall the gear and the Grip Ring

3
Reinstall the gear

6
Reinstall the Air Pressure Tube Retainer

5
Reinstall the Air Pressure Tube

Figure 5 Reinstalling the Air Pressure Tubes

8825/8830 Printer

01/02 4-63

Repairs and Adjustments

REP 9.7

(Figure 6): Reinstall the Sump Shield in the Developer Module.

3
Tighten the screws (2)

2
Reinstall the screws (2)

2
Reinstall the Sump Shield under the edges on the housing

1
Reinstall the Top Shield

Figure 7 Reinstalling the Top Shield 5. Reinstall the Developer Module (REP 9.5).

NOTE: To ensure that the Toner Cartridge is correctly engaged in the Drive Plate, rotate the cartridge in both directions.

1
Reinstall the Sump Shield

Figure 6 Reinstalling the Sump Shield in the Developer Module 4. (Figure 7): Reinstall the Top Shield, taking care not to overtighten the screws.

Repairs and Adjustments

REP 9.7

01/02 4-64

8825/8830 Printer

6. 7.

(Figure 8): Reinstall the Toner Cartridge. If new Developer Material has been installed, perform Toner Sensor Calibration Code [09216].

Perform the Electrostatic Series (ADJ 9.2).

5
Slide the Top Shield closed

3
Partially rotate the Toner Cartridge in both directions to ensure that the cartridge is locked in the Drive Hub

2
Pull the Plunger

4
Remove the tape

1
Reinstall the Toner Cartridge while performing Step 2

Figure 8 Reinstalling the Toner Cartridge

8825/8830 Printer

01/02 4-65

Repairs and Adjustments

REP 9.7

REP 9.8 Scorotron Pin Kit

Parts List on PL 9.3

(Figure 2): Remove the Grid Channel.

1
NOTE: These are the instructions to install the Scorotron Pin Kit. The kit contains the following items: Pin Array Torsion Spring (2) Container Remove the screws (both ends)

2
Remove the Grid Channel

WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

Removal
1. 2. 3. 4. Loosen the screws and open the Rear Cover. Raise and latch the Top Cover. Rotate the Image Module to the Service Position. (Figure 1): Remove the Charge Scorotron Assembly from the Printer and place it on a flat surface.

1
Disconnect the two connectors

2
Rotate the screws until they are free of the mounting blocks on the Image Module Figure 2 Removing the Grid Channel

3
Remove the Charge Scorotron Assembly

Figure 1 Removing the Charge Scorotron Assembly

Repairs and Adjustments

REP 9.8

01/02 4-66

8825/8830 Printer

WARNING
Disposal of the Pin Array is carefully controlled because it is made of a Beryllium Copper alloy. Package the old Pin Array as a returned part. Also, be especially careful of the very sharp tips on the Pin Array. 6. 7. 1. (Figure 3): Remove the Charge Scorotron Pin Array. Remove the Torsion Springs from the End Blocks.

Replacement
Install the Torsion Springs from the repair kit. CAUTION Be careful not to damage the tips of the new Pin Array. Bent tips can cause Print Quality problems. 2. 3. 4. Install the Pin Array from the repair kit into the End Blocks. Reinstall the End Blocks into the Scorotron Extrusion. Ensure that the Pin Array is positioned in the Center Support (not shown) of the Scorotron Extrusion. After completing the reassembly, package the Pin Array for return. Scorotron Extrusion

1
Torsion Spring Spread open the plastic extrusion and lift out the End Block End Block

2
Pull the Pin Array and lift it off the stud

Stud

Grid Channel Grove

4
Repeat Steps 1-3 at the opposite end and remove the Pin Array

3
Remove the Pin Array from the tangs of the torsion spring

Figure 3 Removing the Charge Scorotron Pin Array

8825/8830 Printer

01/02 4-67

Repairs and Adjustments

REP 9.8

REP 9.9 Transfer / Detack Corotron

Parts List on PL 9.4 4 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly. Remove the Transfer / Detack Corotron

Removal
1. 2. 1. Loosen the screws and open the Rear Cover. (Figure 1): Lower the Media Transport Cover and remove the Transfer / Detack Corotron. Reinstall the Transfer / Detack Corotron against the bottom of the channel, away from the Heat Roll.

3
Move the Corotron

Replacement

2
Lift the Corotron

1
Loosen the screw

Figure 1 Removing the Transfer/Detack Corotron

Repairs and Adjustments

REP 9.9

01/02 4-68

8825/8830 Printer

REP 9.11 Toner Sensor

Parts List on PL 9.9 1 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly. Disconnect Q1P1

2
Remove screws (2)

Removal
1. Remove the Developer Module (REP 9.5). CAUTION The Developer Material must be removed before removing the Toner Sensor, or there will be a mess. 2. 3. 1. Remove the Developer Material (REP 9.7). (Figure 1): Remove the Toner Sensor and the spacer. Reinstall the Toner Sensor and spacer. CAUTION If a new Toner Sensor is being installed, new Developer Material must be installed. 2. Reinstall the Developer Material (REP 9.7). CAUTION Do not run prints before calibrating the Toner Sensor. Running prints before performing the calibration may cause toner faults or print defects. 3. 4. If a new Toner Sensor has been installed, perform Toner Sensor Calibration Code [09216]. Perform the Electrostatic Series (ADJ 9.2). Figure 1 Removing the Toner Sensor

Replacement 3
Remove the Toner Sensor and spacer

8825/8830 Printer

01/02 4-69

Repairs and Adjustments

REP 9.11

REP 9.12 Toner Cartridge Home Sensor

Parts List on PL 9.9 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly.

Removal
1. 2. Remove the Developer Module (REP 9.5). Remove the Cartridge Drive Plate (REP 9.14).

NOTE: The Toner Home Sensor is threaded. The wires must be straightened in order to rotate the sensor for removal. 3. (Figure 1): Remove the Toner Cartridge Home Sensor.

3 4
Remove the Toner Cartridge Home Sensor Straighten the wires

1
Disconnect Q2

2
Remove the wires from the fasteners (2 places) Figure 1 Removing the Toner Cartridge Home Sensor

Replacement
1. 2. Reinstall the Toner Cartridge Home Sensor. Perform the Toner Cartridge Home Sensor Adjustment (ADJ 9.5).

Repairs and Adjustments

REP 9.12

01/02 4-70

8825/8830 Printer

CAUTION To avoid damage to the Drive Plate Seal, always rotate the drive plate in the direction shown in Figure 2. 3. (Figure 2): Reinstall the Cartridge Drive Plate.

1
Reinstall the Cartridge Drive Plate with the seal up Seal

3
Rotate while performing step 4

2
Reinstall the gear

4
Position the tab at the bottom

6 5
Reinstall the retainer Reinstall the motor

7
Reinstall the screws (2) and the Ground Wire

Figure 2 Reinstalling the Cartridge Drive PLate

8825/8830 Printer

01/02 4-71

Repairs and Adjustments

REP 9.12

(Figure 3): Reinstall the Top Shield, taking care not to overtighten the screws.

REP 9.13 Sump Shield

Parts List on PL 9.9

4
Connect M1

3
Tighten the screws (2)

WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly.

Removal
1. Remove the Developer Module (REP 9.5).

2
Reinstall the screws (2)

1
Reinstall the Top Shield

Figure 3 Reinstalling the Top shield 5. Reinstall the Developer Module (REP 9.5).

Repairs and Adjustments

REP 9.12, REP 9.13

01/02 4-72

8825/8830 Printer

(Figure 1): Remove the Sump Shield.

Replacement
CAUTION Ensure that the full length of the edge of the Sump Shield is under the edge of the housing.

2
Loosen the screws (2)

(Figure 2): Reinstall the Sump Shield in the Developer Module.

1
Remove the screws (2)

3
Remove the Top Shield

5
Remove the Sump Shield

4
Remove the Sump Shield from under the edge (full length)

Figure 1 Removing the Sump Shield from the Developer Module

8825/8830 Printer

01/02 4-73

Repairs and Adjustments

REP 9.13

REP 9.14 Cartridge Drive Plate

Parts List on PL 9.9 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

2
Reinstall the Sump Shield under the edges on the housing

NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly.

Removal
1. Remove the Developer Module (REP 9.5).

1
Reinstall the Sump Shield

Figure 2 Reinstalling the Sump Shield in the Developer Module

Repairs and Adjustments

REP 9.13, REP 9.14

01/02 4-74

8825/8830 Printer

(Figure 1): Remove the Cartridge Drive Plate.

Replacement
CAUTION To avoid damage to the Drive Plate Seal, always rotate the drive plate in the direction shown in Figure 2.

8
Remove the Drive Plate

6
Remove the motor

5 7
Remove the retainer and gear Remove the screws (2) and the Ground Plate

2
Loosen the screws (2)

4
Disconnect M1

1
Remove the screws (2)

3
Remove the Top Shield

Figure 1 Removing the Cartridge Drive Plate

8825/8830 Printer

01/02 4-75

Repairs and Adjustments

REP 9.14

(Figure 2): Reinstall the Cartridge Drive Plate.

Seal

1
Reinstall the Cartridge Drive Plate with the seal up

3
Rotate while performing step 4

4
Position the tab at the bottom

2
Reinstall the gear

6
Reinstall the motor

7
Reinstall the screws (2) and the Ground Wire

5
Reinstall the retainer

Figure 2 Reinstalling the Cartridge Drive Plate

Repairs and Adjustments

REP 9.14

01/02 4-76

8825/8830 Printer

(Figure 3): Reinstall the Top Shield, taking care not to overtighten the screws.

4
Connect M1

3
Tighten the screws (2)

2
Reinstall the screws (2)

1
Reinstall the Top Shield

Figure 3 Reinstalling the Top Shield 3. Reinstall the Developer Module.

8825/8830 Printer

01/02 4-77

Repairs and Adjustments

REP 9.14

REP 9.17 Photoreceptor Seal

Parts List on PL 9.5B WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. Photoreceptor Seal Channel

Removal
1. 2. 3. 1. Remove the Drum Assembly (REP 9.2). (Figure 1): Remove the Right-hand Seal, the Left-hand Seal (not shown), and the Photoreceptor Seal. Thoroughly clean the Photoreceptor Seal channel using a vacuum cleaner. Replace the Photoreceptor Seal. a. b. c. 2. Carefully fold the Photoreceptor Seal along the perforations. Slide the Photoreceptor Seal into the channel, smaller side up, so that the edge of the Photoreceptor Seal forms a seal with the inside lip of the channel. Using a soft, straight tool (a piece of shimstock works well), carefully push the seal into the channel, across the entire width of the Xerographic Module. Insert the red stripe end of the Right-hand Seal underneath the fold of the Photoreceptor Seal. Install the seal fuzzy side up. Ensure that the seal is flush against the Xerographic Module Frame. Photoreceptor Seal Right-hand Seal Xerographic Module Frame

Replacement

Reinstall the Right-hand Seal. a. b. c.

Reinstall the Left-hand Seal in the same manner.

Blade Retainer (3)

Cleaner Blade

Figure 1 Removing and Replacing the Photoreceptor Seal

Repairs and Adjustments

REP 9.17

01/02 4-78

8825/8830 Printer

REP 9.18 Air Pressure Tubes

Parts List on PL 9.9, PL 9.10 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly.

CAUTION Do not rotate the Auger Gears individually more than the slight amount required for removal or to mesh the teeth during reinstallation. If the factory setting of the augers is changed during the procedure, perform the adjustment procedure, Augers (ADJ 9.6). 2. 3. (Figure 1): Remove the Air Pressure Tubes. Using a vacuum cleaner, remove the impacted Developer Material from the Housing where the Air Pressure Tubes are attached. Pay special attention to the inside of the bottom channel.

Removal
1. Remove the Developer Module (REP 9.5).

3
Remove the Air Pressure Tube

5
Remove the retainer

1
Remove the Grip Ring

2
Remove the gears (3)

4
Remove the screw

6
Remove the Air Pressure Tube

Figure 1 Removing the Air Pressure Tubes

8825/8830 Printer

01/02 4-79

Repairs and Adjustments

REP 9.18

Replacement
CAUTION Do not rotate the Auger Gears individually more than the slight amount required for removal or to mesh the teeth during reinstallation. If the factory setting of the augers is changed during the procedure, perform the adjustment procedure, Augers (ADJ 9.6). NOTE: The gears must be reinstalled with the flanges as shown in order to ensure that all the gears are secured. 1. (Figure 2): Reinstall the Air Pressure Tubes.

1
Reinstall the Air Pressure Tube

Flanges

7
Reinstall the screw

2
Reinstall the gear

4
Reinstall the gear and the Grip Ring

3
Reinstall the gear

6
Reinstall the Air Pressure Tube Retainer

5
Reinstall the Air Pressure Tube

Figure 2 Reinstalling the Air Pressure Tubes

Repairs and Adjustments

REP 9.18

01/02 4-80

8825/8830 Printer

REP 9.19 Roller Kit

Parts List on PL 9.3
NOTE: These are the instructions to install Roller Kit 600K58740. The kit contains the following items: Rollers (2) Pins (2)

REP 9.20 Image Module

Parts List on PL 9.3
NOTE: These are the instructions to install the Image Module Assembly Kit 600K58760. The kit contains the following: Image Module Assembly

WARNING WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

Switch off the Main Power Switch. Disconnect the Power Cord.

Removal
1. 2. 3. Remove the Developer Module (REP 9.5). Remove the Developer Baffle (PL 9.8). Remove the following: a. b. c. d. e. f. Rear Door (PL 14.1) Front Door (PL 14.2) Right Side, Left Lower Cover (PL 14.2) Right Side, Right Lower Cover (PL 14.2) Right Side, Left Cover (three screws, two top, one bottom) (PL 14.2) Right Side, Right Cover (three screws, one top, two bottom) (PL 14.2)

Removal
1. 2. 3. 1. 2. Raise and secure the Top Cover. Open the Image Module. (Figure 1): Using pliers, pull out the pin and remove the roller. Replace the roller and pin with parts from the kit. Repeat the procedure at the rear of the Image Module.

Replacement

Pin Roller

Remove the High Voltage Power Supply (REP 3.2).

NOTE: In the following steps, cut cable ties as necessary in order to remove the harness.

Figure 1 Removing the Front Roller

8825/8830 Printer

01/02 4-81

Repairs and Adjustments

REP 9.19, REP 9.20

(Figure 1): Prepare to remove the Top Cover (Front). Top Cover Pivot Pin (Will be removed in step 6) interlock Plate

3
Remove the Pin

2
Disconnect A32P1

Top Cover Pivot Pin (will be removed in Step 6)

1
Release the cable Figure 2 Top Cover Interlock Plate

Figure 1 Preparing to Remove the Top Cover (Front) 7. NOTE: (Figure 2): Observe the way that the Top Cover Pivot Pin engages the hole in the Interlock Plate. This may be a difficult area during reassembly. 6. Close the Top Cover, open the Developer Module Cover, and remove the two pivot pins shown in Figure 1 andFigure 2. 8. Close the Developer Module Cover and lift off the Top Cover, being careful to disengage the small pin from the Interlock Plate. Open the Cutter Drawer.

Repairs and Adjustments

REP 9.20

01/02 4-82

8825/8830 Printer

(Figure 3): Disconnect the Video Cable Connector J307A from the Main PWB and push the connector through the hole in the frame.

10. (Figure 4): Release the Video Cable from the cable clamps and push it through the hole in the frame.

1
Disconnect J307A

2
Push the Video Cable through the hole

2
Remove the cable from the clamps

3
Push the cable through the hole

1
Figure 3 Disconnecting the video cable Release the Video Cable from the cable clamps

Figure 4 Preparing the Video Cable for Removal

8825/8830 Printer

01/02 4-83

Repairs and Adjustments

REP 9.20

11. (Figure 5): Release the Video Cable from the cable clamps and pull it through the hole in the frame.

12. (Figure 6): Continue to pull the Video Cable through the hole after releasing it from the cable guides.

1
Release the Video Cable from the cable clamps

2 2
Pull the Video Cable through the hole Pull the cable up to the level of the Image Module

1
Release the cable

Figure 5 Preparing the Video Cable for Removal

Figure 6 Preparing the Video Cable

Repairs and Adjustments

REP 9.20

01/02 4-84

8825/8830 Printer

13. (Figure 7): Disconnect A5P2 from the Low Voltage Power Supply and release the harness from the cable clamps.

01/02 4-87

Repairs and Adjustments

REP 9.20

REP 10.1 Heat Rod

Parts List on PL 10.2 2 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. Allow the Fuser Assembly to cool before the procedure is performed. Disconnect the connector and straighten the Heat Rod Wire

1
Remove the Heat Rod Wire from the clamp

Removal
1. 2. Remove the Stripper Finger Assembly. Perform the Xerographic Module procedure (REP 9.1) through Step 11. This will leave the Xerographic Module at the Service Position, handles installed, and the Drum Assembly removed.

NOTE: In the following steps, Left and Right describe machine locations as observed when you are facing the Xerographic Module at the left side of the Printer. 3. (Figure 1): Disconnect the Heat Rod (Right Side).

3
Remove the screw

4
Remove the bracket from the grommet Grommet

5
Remove the grommet from the Heat Rod Wire

Figure 1 Removing the Bracket and Grommet (Right Side)

Repairs and Adjustments

REP 10.1

01/02 4-88

8825/8830 Printer

(Figure 2): Disconnect the Heat Rod and remove the bracket (Left side).

(Figure 3): Remove the Heat Rod.

2
Remove the screws (2) and the bracket

1
Remove the Heat Rod

2
Push the pin while removing the Fuser Hub Assembly

Bracket Fuser Hub Assembly

1
Disconnect the connector Pin

Figure 2 Removing the Bracket (Left side) CAUTION Wear gloves or wrap a sheet of paper around the Heat Rod when handling the Heat Rod. Do not touch the glass section of the Heat Rod. Oil from fingers can cause damage to the Heat Rod.

Figure 3 Removing the Heat Rod and Fuser Hub Assembly

Replacement
CAUTION Wear gloves or wrap a sheet of paper around the Heat Rod when handling the Heat Rod. Do not touch the glass section of the Heat Rod. Oil from fingers can cause damage to the Heat Rod.

8825/8830 Printer

01/02 4-89

Repairs and Adjustments

REP 10.1

(Figure 4): Reinstall the Heat Rod.

NOTE: Do not remove the connectors from the wires on the ends of the Heat Rod. a. b. c. Insert the red connector into the Heat Roll. While looking into the roll, push the red connector through the hole in the Fuser Drive Gear at the opposite end. If the previous step is too difficult, use the rod that secures the Fabric Guide as a tool. Insert that rod through the right side of the Heat Roll, secure the red connector to it, and pull the Heat Rod through the Heat Roll.

1
Straighten the wire at the red connector end (as straight as possible)

2
Reinstall the Heat Rod

3
Insert the connector into the Hub Assembly

4
Reinstall the hub Assembly with the flat sides positioned as shown

Figure 4 Reinstalling the Heat Rod

Repairs and Adjustments

REP 10.1

01/02 4-90

8825/8830 Printer

(Figure 5): Reinstall the bracket (Left side).

(Figure 6): Reinstall the grommet and the bracket (Right side).

2
Reinstall the screws and the bracket

2
Reinstall the bracket onto the grommet

1
Reinstall the grommet onto the Heat Rod wire

1
Connect the connector

3
Reinstall the screw and the bracket

4
Connect the connector and put the wire into the clamp

Figure 5 Reinstalling the Bracket (Left side) 4.

Figure 6 Reinstalling the Bracket (Right side) Ensure that the Thermistor Pad is clean.

8825/8830 Printer

01/02 4-91

Repairs and Adjustments

REP 10.1

REP 10.2 Heat Roll

Parts List on PL 10.2 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. Allow the Fuser Assembly to cool before the procedure is performed. NOTE: The art used for this procedure was developed for previous products and may not match the 8825/8830 configuration exactly.

REP 10.3 Fuser Triac

Parts List on PL 1.2A WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

Removal
1. 2. Remove the two Right Side Covers. (Figure 1): Remove the Fuser Triac.

3
Remove the Fuser Triac Blue

WARNING
Wear protective gloves when handling parts with silicone oil on them. Do not allow silicone oil to contact your eyes. Silicone oil can cause severe eye irritation. Wash your hands immediately after handling any component covered with silicone oil. 4. (Figure 1): Remove the Heat Roll. White

1
Push the pin while removing the Heat Roll from the Hub Assembly View from Right Side of Printer, Top Cover removed for clarity

2
Disconnect the connectors (3) Thermal Insulator

1
Remove the screws (2)

Figure 1 Removing the Fuser Triac

Replacement
1. Cover the entire surface where the Fuser Triac mounts to the frame with a film of thermal compound or install a new Thermal Insulator.

2
Remove the Heat Roll

Figure 1 Removing the Heat Roll

Repairs and Adjustments

REP 10.2, REP 10.3

01/02 4-92

8825/8830 Printer

REP 10.7 Web Oiler Assembly

Parts List on PL 9.6 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

REP 10.8 Stripper Fingers

Parts List on PL 10.4 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. Allow the Fuser Assembly to cool before the procedure is performed.

Removal
1. 2. 3. 4. Loosen the screws and open the Rear Door. Raise and latch the Top Cover. Ensure that there is a clean, flat surface on which to place the Web Oiler Assembly after it is removed. (Figure 1): Remove the Web Oiler Assembly and place it top down, resting on the handles, on a flat surface. At reinstallation, engage the rear lip of the Web Oiler Housing over the metal bracket of the Xerographic Module. After completing the reassembly, enter diagnostics and perform one of the following actions. a. b. If a new Web Oiler has been installed, initialize the Web Oiler using [1030]. If the old Web Oiler is still in the assembly, remove the slack in the web by running [1033] until the display shows the following: Count = 001

Removal
1. 2. Remove the Stripper Finger Assembly. (Figure 1): Remove the Stripper Fingers.

1
Stripper Finger Remove the Stripper Finger while pushing the tab

Replacement
1. 2.

Tab

3
Holding the handles, rotate the rear upward. Lift it and remove.

1
Loosen the two thumbscrews

Figure 1 Removing the Stripper Fingers

2
Disconnect P/J4

Figure 1 Removing the Web Oiler Assembly

8825/8830 Printer

01/02 4-93

Repairs and Adjustments

REP 10.7, REP 10.8

Replacement
CAUTION Do not bend the Stripper Finger too far or it will break. 1. (Figure 2): Reinstall the Stripper Fingers.

REP 10.9 Web Oiler

Parts List on PL 9.7 WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

3
Align the tabs to straighten the finger

1
Squeeze the Stripper Finger

Removal
1. 2. Remove the Web Oiler Assembly and place it top down, resting on the handles, on a flat surface (REP 10.7). (Figure 1): Remove the Supply Roll.

1
Pull the knob to release the Supply Roll (rotate to lock)

2
Push the Stripper Finger on until the tab snaps up

Supply Roll

RH Side Plate

Figure 1 Removing the Supply Roll

Figure 2 Reinstalling the Stripper Fingers

Repairs and Adjustments

REP 10.8, REP 10.9

01/02 4-94

8825/8830 Printer

(Figure 2): Remove the Takeup Roll.

1
Mount the opposite end of the Supply Roll onto the LH Side Plate

RH Side Plate

3
Pull the Takeup Roll off the RH Side Plate (far side)

2
Pull the Stub Shaft / Gear Assembly from the LH Side Plate

LH Side Plate Supply Roll

2
Pull the knob and lock on the Supply Roll Figure 3 Reinstalling the Takeup Roll

4
Pull the Stub Shaft/ Gear Assembly from the Takeup Roll

Spring Stop

1
Disengage the spring from the stop on the Side Plate

Figure 2 Removing the Takeup Roll

Replacement
1. (Figure 3): Reinstall the Supply Roll. 01/02 4-95 Repairs and Adjustments

8825/8830 Printer

REP 10.9

2. 3.

(Figure 4): Reinstall the Takeup Roll. After reinstallation or replacement of the Web Oiler into the assembly, follow the replacement instructions in Web Oiler Assembly (REP 10.7).

2
Push the Stub Shaft / Gear Assembly into the Takeup Roll

1
Mount the opposite end of the Takeup Roll onto the RH Side Plate

LH Side Plate

3
Push the Stub Shaft / Gear Assembly onto the LH Side Plate

4
Rotate the gear counterclockwise until the spring is next to the stop

5
Engage the spring with the stop on the LH side Plate

Spring Stop

Figure 4 Reinstalling the Takeup Roll

Repairs and Adjustments

REP 10.9

01/02 4-96

8825/8830 Printer

ADJ 3.2 Country Configuration

01/02 4-99

Repairs and Adjustments

ADJ 8.2

ADJ 8.3 Cut Length

Purpose
The purpose is to calibrate the Printer to produce the correct length prints for each media type.

Prerequisite
1. Check the following: a. b. c. 1. 2. 3. 4. Fuser Temperature (NVM) ( ADJ 10.1) Vertical Magnification ( ADJ 8.1) Lead Edge Registration ( ADJ 8.2) 7. Figure 2 Media Select ( Figure 3): Enter the measurement of the 600 mm print and press the Enter button. The following message is displayed.

Adjustment
Enter diagnostics. Enter code [ 0955] and make one 600 mm print and one 1200 mm print of Test Pattern #7. Allow the prints to cool for five minutes. ( Figure 1): Measure the two prints in the paper feed direction.

Figure 3 Print Length 8. ( Figure 4): Enter the measurement of the 1200 mm print and press the Enter button. The following message is displayed.

Figure 4 Print Measurement 9. Figure 1 Checking the Print Length 5. 6. Enter code [ 0700] in order to adjust the Cut Length. Enter [ 1] to adjust. ( Figure 2): Select the type of media. The following message is displayed. (In this example, bond paper media has been selected.) Complete the adjustment as appropriate.

10. Repeat the check for all the types of media used by the customer.

Repairs and Adjustments

ADJ 8.3

01/02 4-100

8825/8830 Printer

ADJ 8.4 Media Transport

Purpose
The purpose is to set the correct spacing between the Media Transport and the Drum when a new Media Transport is installed. The correct spacing is obtained by adjusting the position of the Lower Turnaround Baffle. NOTE: The art used for this procedure was developed for previous products and may not match the printer configuration exactly. View from Top Lower Baffle Drum

2
Shim should just fit in the Lower Baffle to Drum gap

WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

Check
1. 2. 3. 4. 5. Remove the Developer Module ( REP 9.5). Remove the white toner shield. Prepare two strips of 0.030 inch (coral) shimstock 0.75 inches (20 mm) wide. Ensure that the Media Transport Cover is closed. ( Figure 1): Check that the Media Transport to Drum spacing is 0.030 +/- 0.005 inches (0.76 +/- 0.1 ).

Upper Baffle

Turnaround Baffle Notch

Drum

1
Position shims in notches of Turnaround Baffle Turnaround Baffle iew from Right ide of Printer Figure 1 Checking the Media Transport to Drum Spacing

8825/8830 Printer

01/02 4-101

Repairs and Adjustments

ADJ 8.4

Adjustment WARNING
Switch off the Main Power Switch. Disconnect the Power Cord. 1. 2. 3. 4. 5. Remove the Transfer / Detack Corotron ( REP 9.9). Remove the Developer Module ( REP 9.5). Remove the white Toner Shield. ( Figure 2): Position the Lower Turnaround Baffle. Close the Media Transport Cover. Shim

1
Place the shims into the notches of the Turnaround Baffle, one on each side Drum

2
Ensure that the shims are positioned between the Lower Baffle and the Drum

2
Push down the Lower Turnaround Baffle, front and rear

This view is of the Media Transport as seen at the front of the printer Media Transport

Upper Baffle

Lower Baffle

Media Transport

1
Loosen the two Turnaround Baffle retaining screws, front and rear Figure 2 Positioning the Lower Turnaround Baffle NOTE: The position of the Lower Turnaround Baffle determines the position of the Upper Turnaround Baffle. When the position of the Lower Turnaround Baffle is correctly set, the Upper Turnaround Baffle is correctly positioned. 6. 7. Cut two strips of 0.030 inch (coral) shimstock 0.75 inches (20 mm) wide. ( Figure 3): Adjust the Media Transport to Drum spacing to 0.030 0.005 inch (0.76 0.1 ). Retaining Screws (2)

3
Use a screwdriver to push the Turnaround Baffle fully against the shims and tighten the retaining screws (front and rear)

This view is of the Media Transport as seen at the rear of the printer

Figure 3 Adjusting the Media Transport to Drum Spacing 8. Reinstall the Transfer / Detack Corotron. Push the corotron down and in the direction of the Developer Module before tightening the securing screw.

Repairs and Adjustments

ADJ 8.4

ADJ 9.2

Table 1 Average Light Output Values Bar # 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 Repairs and Adjustments Value 1.05 1.01 .95 .95 .95 .92 .89 .99 .98 .97 .91 .88 .92 .97 .88 .93 .83 .87 .93 .97 1.04 1.00 .94 .99 .99 .84 .93 .93 .91 .84 .86 .89 .90 .97 .95 1.02 .98 .82 .84 .84 .88 Bar # 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 178 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201

Table 1 Average Light Output Values Value .83 .90 .93 .93 .92 .94 .95 .81 1.02 .85 .83 .93 .91 .92 .79 .77 .91 1.00 .93 .77 .75 .72 .74 .64 .63 .96 .88 .95 .75 .72 .73 .78 .73 .72 .73 .71 .73 .64 .68 .79 .74

ADJ 9.2

01/02 4-106

8825/8830 Printer

Table 1 Average Light Output Values Bar # 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 Value 1.19 1.00 .86 .85 .69 .75 .76 .71 .77 .72 .78 .58 .60 .66 .71 .75 .72 .75 .73 .76 .85 .59 .71 .59 1.03 .89 .91 .72 .69 .82 .85 1.00 .92 1.00 .90 .97 .94 .95 .78 .79 .69 Bar # 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294

Table 1 Average Light Output Values Value .68 .81 .67 .65 .78 .95 1.01 .97 .98 .75 .63 .74 .96 .92 .94 .95 .67 .79 .92 .65 .72 .99 .94 .68 .66 .84 .86 .89 .89 .90 .66 .71 .76 .81 .81 .93 .60 .63 .64 .69 .66 Repairs and Adjustments

8825/8830 Printer

01/02 4-107

ADJ 9.2

Table 1 Average Light Output Values Bar # 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 Repairs and Adjustments Value .71 .85 .82 .86 .81 .92 1.01 .58 .60 .67 .72 .62 .83 .63 .64 .78 .67 .76 .80 .58 .86 .60 .66 .69 .70 .76 .74 .57 .63 .75 .80 .90 .72 .76 .80 .72 .65 .74 .62 .70 .58 Bar # 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376

Table 1 Average Light Output Values Value .72 .81 .56 .73 .96 .75 .82 .56 .65 .77 .77 .66 .63 .67 .66 .82 .89 .58 .61 .67 .73 .65 .71 .88 .79 .69 .78 .74 .79 .99 .84 .98 .81 .82 .95 .71 .65 .73 .99 .74 .77

ADJ 9.2

01/02 4-108

8825/8830 Printer

Table 1 Average Light Output Values Bar # 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 Value .72 .90 .73 .97 1.06 .75 .58 .63 .66 .66 .69 .95 .95 .75 .95 1.00 1.06 1.07 .69 .70 .74 .62 .79 .93 .80 .66 .84 .74 .73 .78 .94 .65 .70 .71 .77 .96 .95 .84 .70 .96 .93 Bar # 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458

Table 1 Average Light Output Values Value .95 .70 .88 .93 .80 .76 .89 .78 .76 .75 .93 .97 .78 .87 .59 .99 .92 .90 .96 1.01 .97 .93 1.01 .99 .99 .79 .73 .98 .96 .99 .99 .77 .98 .94 .94 1.10 1.03 1.00 .98 .96 1.01 Repairs and Adjustments

8825/8830 Printer

01/02 4-109

ADJ 9.2

Table 1 Average Light Output Values Bar # 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 499 Repairs and Adjustments Value 1.01 .73 .83 .79 .81 .83 .88 1.07 1.08 1.00 .82 .67 .79 .80 .86 .85 .89 .89 .82 .93 1.11 1.03 1.06 .98 .89 .69 .86 .84 1.04 .95 .96 1.03 1.10 .82 .87 1.00 .97 .95 .95 .90 .98 Bar # 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523

Table 1 Average Light Output Values Value .65 .68 .72 .96 .90 .89 .94 .85 .82 1.05 .91 1.02 .94 .97 .88 .86 1.02 .95 1.06 .69 .87 .83 .88 .85

ADJ 9.2

01/02 4-110

8825/8830 Printer

ADJ 9.3 Image Density

Purpose
The purpose is to set the toner concentration to obtain good print quality as specified in Section 3 of this Service Manual. NOTE: Electrostatic Series ADJ 9.2 must be performed before the Image Density is adjusted.

Check
1. 2. 3. 4. 1. 2. Enter diagnostics. Enter code [0955] and make one print of Test Pattern #5. Using S.I.R. 495.01 (82P520), evaluate the darkness squares at the lower right center and the upper left from the lead edge. If the darkness square is not between 1.0 and 1.2, perform the adjustment. Enter diagnostics. ( Figure 1): Enter code [ 0921-4. The following message is displayed.

Adjustment

Figure 1 Message Display 3. Adjust the Image Density Control Point (STD CP X.X) using the Previous / Next buttons. a. b. c. d. 4. 5. Use the Next button to increase the Image Density Control Point (decrease the Image Density). Use the Previous button to decrease the Image Density Control Point (increase the Image Density). Press the Enter button in order to store the value in NVM. Press the Exit button two times.

Run the Automatic Tone-up / Tone-down Routine [ 0906]. Repeat the Check.

8825/8830 Printer

01/02 4-111

Repairs and Adjustments

ADJ 9.3

ADJ 9.6 Augers

Purpose
The purpose is to set the Developer Auger and the Mix Auger to the correct angles in order to ensure proper operation of the Developer Module.

Adjustment
NOTE: In order to position the flats on the augers, the Developer Material must be removed. In order to rotate the augers individually, the gears at the drive end of the Developer Module must be removed. 1. 2. Remove the Developer Material ( REP 9.7). ( Figure 1): Position the flats on the augers by rotating the appropriate gear at the drive end of the Developer Module. a. b. c. The flats are at the end opposite the gears, approximately one inch from the ends of the augers. Looking down on the augers, position the Developer Auger to point toward the Magnetic Roll at an approximate 45 degree angle. Position the Mix Auger to point away from the Magnetic Roll, approximately horizontal.

WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

Check
NOTE: In order to see the flats on the augers, remove the Sump Shield using the Developer Material removal procedure ( REP 9.7). 1. 2. Remove the Sump Shield. ( Figure 1): Check the flats on the augers. a. b. c. d. The flats are at the end opposite the gears, approximately one inch from the ends of the augers. Expose the flats using a brush to move the Developer Material. Looking down on the augers, check that the Developer Auger is pointing toward the Magnetic Roll at an approximate 45 degree angle. Check that the Mix Auger is pointing away from the Magnetic Roll and is approximately horizontal.

Developer Auger

Mix Auger

Magnetic Roll

Figure 1 The Correct auger Orientation

Repairs and Adjustments

ADJ 9.6

01/02 4-112

8825/8830 Printer

ADJ 9.5 Toner Cartridge Home Sensor

Purpose
The purpose is to set the Toner Cartridge Home Sensor to the correct distance from the magnet on the Toner Cartridge.

WARNING
Switch off the Main Power Switch. Disconnect the Power Cord.

Check
1. 2. 3. Remove the Developer Module ( REP 9.5). Remove the Cartridge Drive Plate ( REP 9.14). ( Figure 1): Check that the tip of the Toner Cartridge Home Sensor is 2.5 0.5 mm from the plate.

2.5 +/- 0.5 mm

Toner Cartridge Home Sensor

Figure 1 Checking the Position of the Toner Cartridge Home Sensor

Adjustment
1. Perform the check. NOTE: The Toner Cartridge Home Sensor is threaded. The wires must be disconnected and straightened in order to rotate the sensor for adjustment.

8825/8830 Printer

01/02 4-113

Repairs and Adjustments

ADJ 9.5

( Figure 2): Adjust the Toner Cartridge Home Sensor to 2.5 0.5 mm from the plate.

2.5 +/- 0.5 mm

3
Straighten the wires and adjust the sensor

2
Remove the wires from the clamps (2 places)

1
Disconnect Q2

Figure 2 Adjusting the Toner Cartridge Home Sensor

Repairs and Adjustments

ADJ 9.5

01/02 4-114

8825/8830 Printer

ADJ 10.1 Fuser Temperature (NVM)

Purpose
The purpose is to adjust the temperature of the Heat Roll in order to obtain the correct fusing. NOTE: Fuser temperature may also be checked using ADJ 10.2 Fuser Temperature (with Probe) or ADJ 10.3 Fuser Temperature (with Heat Sensitive Tape).

Check
1. 2. 3. Ensure that the Fuser Thermistor is in positive contact with the Heat Roll. Enter diagnostics. ( Figure 1): Enter code [ 1004 in order to switch on the Heat Rod and bring the Heat Roll to the run temperature. The following message is displayed. Figure 3 Fuser Setpoint Screen NOTE: The default Set Point for bond media is 30. Adjust for 300 degrees F. 3. Adjust the bond paper fusing temperature using the Previous / Next buttons. a. b. c. d. 4. Use the Previous button to decrease the Set Point, lowering the fusing temperature. Use the Next button to increase the Set Point, raising the fusing temperature. Press the Enter button in order to store the value in NVM. Press the Exit button two times.

( Figure 4): Enter code [ 1062 in order to adjust the Fuser Temperature for vellum. The following message is displayed.

Figure 1 Fuser Warm Up 4. ( Figure 2): Check the bond paper fusing temperature when the following message is displayed.

Figure 4 Vellum Temperature Setpoint NOTE: The default Set Point for vellum media is 24. Adjust for 294 degrees F. 5. Figure 2 Temperature Test Screen NOTE: The temperature shown on the Display is 270 degrees F + the adjustment value. 5. 1. 2. Press the Exit button three times. Ensure that the Fuser Thermistor is in positive contact with the Heat Roll. ( Figure 3): Enter code [ 1060 in order to adjust the Fuser Temperature for bond paper. The following message is displayed. 6. Adjust the vellum fusing temperature using the Previous / Next buttons. a. b. c. d. Use the Previous button to decrease the Set Point, lowering the fusing temperature. Use the Next button to increase the Set Point, raising the fusing temperature. Press the Enter button in order to store the value in NVM. Press the Exit button two times.

Adjustment

( Figure 5): Enter code [ 1063 in order to adjust the Fuser Temperature for film. The following message is displayed.

8825/8830 Printer

01/02 4-115

Repairs and Adjustments

ADJ 10.1

ADJ 10.2 Fuser Temperature (with Probe)

Purpose
The purpose is to check the temperature of the Heat Roll, using the Temperature Probe, in order to obtain the correct fusing.

Check
1. 2. Figure 5 Film Temperature NOTE: The default Set Point for film media is 30. Adjust for 300 degrees F. 7. Adjust the film fusing temperature using the Previous / Next buttons. a. b. c. d. 8. a. b. c. Use the Previous button to decrease the Set Point, lowering the fusing temperature. Use the Next button to increase the Set Point, raising the fusing temperature. Press the Enter button in order to store the value in NVM. Press the Exit button two times. Vertical Magnification ( ADJ 8.1) Lead Edge Registration ( ADJ 8.2) Cut Length ( ADJ 8.3) Temperature Probe Ensure that the Fuser Thermistor is in positive contact with the Heat Roll. ( Figure 1): Connect the Thermal Sensor to the Temperature Probe.

Check the following:

Thermal Sensor

Figure 1 Connecting the Thermal Sensor to the Temperature Probe

Repairs and Adjustments

ADJ 10.1, ADJ 10.2

01/02 4-116

8825/8830 Printer

( Figure 2): Connect the Temperature Probe to the DMM.

11. ( Figure 4): Check the bond paper fusing temperature, using the Temperature Probe, when the following message is displayed.

Red Adaptor

Red Jack

Figure 4 Fuser Temperature Test Screen Black Adaptor Black Jack 12. Open the Media Transport Latching Cover and press the tip of the Thermal Sensor firmly to the surface of the Heat Roll NOTE: As an example, a reading of 143 on the 200mV scale is 143 C (290 F). 13. Press the Exit button three times.

Temperature Probe

Figure 2 Connecting the Temperature Probe to the DMM 4. 5. 6. 7. 8. 9. Switch on the DMM and then switch on the Temperature Probe. Set the DMM to measure DC voltage. Press the 20 Volt range switch on the DMM. Rotate the select switch of the Temperature Probe to BATT TEST. If the voltage is lower than 1.7V, replace the battery of the Temperature Probe. Rotate the select switch of the Temperature Probe to the o C position and press the 200mV range switch of the DMM. Enter diagnostics.

10. ( Figure 3): Enter code [ 1004 in order to turn on the Heat Rod and bring the Heat Roll to the run temperature. The following message is displayed.

Figure 3 Fuser Warm Up Screen

8825/8830 Printer

01/02 4-117

Repairs and Adjustments

ADJ 10.2

ADJ 10.3 Fuser Temperature (with Tape)

Purpose
The purpose is to check the temperature of the Heat Roll, using Temperature Sensitive Tape, in order to obtain the correct fusing.

( Figure 3): Check the bond paper fusing temperature, using the Temperature Sensitive Tape, when the following message is displayed.

Check
1. 2. Ensure that the Fuser Thermistor is in positive contact with the Heat Roll. ( Figure 1): Prepare one strip of tape from the Temperature Sensitive Tape Kit.

Figure 3 Fuser Temperature Test Screen 6. 7. Attach a strip of tape to the holder Open the Media Transport Latching Cover and press the tape firmly to the surface of the Heat Roll. Press the Exit button three times.

Figure 1 Preparing the Tape 3. 4. Enter diagnostics. ( Figure 2): Enter code [ 1004 in order to turn on the Heat Rod and bring the Heat Roll to the run temperature. The following message is displayed .

Figure 2 Fuser Warm Up Screen

Repairs and Adjustments

ADJ 10.3

01/02 4-118

8825/8830 Printer

Parts Lists
Overview
Introduction ..................................................................................................................... Subsystem Information ................................................................................................... Symbology ...................................................................................................................... 5-3 5-4 5-5 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 5-20 5-21 5-22 5-23 5-24 5-25 5-26 5-27 5-28 5-29 5-30 5-31 5-32 5-33 5-34 5-35 5-36

Fuser
PL 10.1 Xerographic Module Assembly .......................................................................... PL 10.2 Fuser Components ............................................................................................ PL 10.3 Fuser Pressure Components And Moisture Collection ...................................... PL 10.4 Fuser Heat Control And Stripper Fingers........................................................... 5-37 5-38 5-39 5-40 5-41 5-42 5-43 5-44 5-45 5-46 5-47 5-48

Electrical Components
PL 1.1A Electrical Control Components/DC Power Generation (W/O TAG 27).............. PL 1.1B Electrical Control Components/DC Power Generation (W/TAG 27) ................. PL 1.2A AC Electrical Components (W/O TAG 25) ........................................................ PL 1.2B AC Electrical Components (W/TAG 25) ............................................................ PL 1.3 DC Electrical Components................................................................................... PL 1.4 Control Console ...................................................................................................

Covers and Interlock Switches

PL 14.1 Transport Latching Cover And Rear Door ......................................................... PL 14.2 Front Door And Right Side Covers .................................................................... PL 14.3 Developer Cover And Catch Tray ...................................................................... PL 14.4 Top Cover And Catch Tray Brackets ................................................................. PL 14.5 Left Side Covers (8825 Only).............................................................................

Media Roll Feed

PL 7.1 Roll Supply Feed Assembly ................................................................................. PL 7.2 Roll Supply Drives ............................................................................................... PL 7.3 Roll Supply Drawer Components (Part 1 of 4)..................................................... PL 7.4 Roll Supply Drawer Components (Part 2 of 4)..................................................... PL 7.5 Roll Supply Drawer Components (Part 3 of 4)..................................................... PL 7.6 Roll Supply Drawer Components (Part 4 of 4)..................................................... PL 7.7 Media Cutter Assembly........................................................................................ PL 7.8 Media Cutter Components...................................................................................

Electrical Connectors and Fasteners

PL 15.1 Miscellaneous Electrical Connectors And Fasteners.........................................

Common Hardware
Common Hardware ......................................................................................................... Part Number Index ..........................................................................................................

Media Transport
PL 8.1 Media Transport Assembly .................................................................................. PL 8.2 Media Registration Components ......................................................................... PL 8.3 Cut Sheet Feed Components .............................................................................. PL 8.4 Media Transport Components .............................................................................

Xerographic Module
PL 9.1 Xerographic Module Assembly ............................................................................ PL 9.2 Photoreceptor ...................................................................................................... PL 9.3 Image Module Assembly ..................................................................................... PL 9.4 Transfer/Detack Corotron .................................................................................... PL 9.5A Drum Cleaning (Part 1 of 3) .............................................................................. PL 9.5B Drum Cleaning (Part 2 of 3) .............................................................................. PL 9.5C Drum Cleaning (Part 3 of 3) .............................................................................. PL 9.6 Web Oiler Assembly ............................................................................................ PL 9.7 Web Oiler Components .......................................................................................

DEVELOPER Module
PL 9.8 Developer Module Assembly ............................................................................... PL 9.9 Developer Module Components (Part 1 of 2) ...................................................... PL 9.10 Developer Module Components (Part 2 of 2) ....................................................

8825/8830 Printer

01/02 5-1

Parts Lists

01/02 5-2

8825/8830 Printer

Introduction
Overview
The Parts List section identifies all part numbers and the corresponding location of all spared subsystem components. Abbreviation R/E REF: SCSI W/ W/O Refer to

Table 1 Meaning Reduction/Enlargement Small Computer Systems Interface With Without Table 2 Operating Companies Abbreviation AO NASG - US NASG Canada XE Meaning Americas Operations North American Solutions Group - US North American Solutions Group Canada Xerox Europe

Organization
Parts Lists Each item number in the part number listing corresponds to an item number in the related illustration. All the parts in a given subsystem of the machine will be located in the same illustration or in a series of associated illustrations. Electrical Connectors and Fasteners This section contains the illustrations and descriptions of the plugs, jacks, and fasteners used in the machine. A part number listing of the connectors is included. Common Hardware The common hardware is listed in alphabetical order by the letter or letters used to identify each item in the part number listing and in the illustrations. Dimensions are in millimetres unless otherwise identified. Part Number Index This index lists all the spared parts in the machine in numerical order. Each number is followed by a reference to the parts list on which the part may be found.

Symbology
Symbology used in the Parts List section is identified in the Symbology section.

Service Procedure Referencing

If a part or assembly has an associated repair or adjustment procedure, the procedure number will be listed at the end of the part description in the parts lists e.g. (REP 5.1, ADJ 5.3)

Other Information
Abbreviations Abbreviations are used in the parts lists and the exploded view illustrations to provide information in a limited amount of space. The following abbreviations are used in this manual: Table 1 Abbreviation A3 A4 A5 AD AWG EMI GB KB MB MM MOD NOHAD PL P/O Meaning 297 x 594 Millimetres 210 x 297 Millimetres 148 x 210 Millimetres Auto Duplex American Wire Gauge Electro Magnetic Induction Giga Byte Kilo Byte Mega Byte Millimetres Magneto Optical Drive Noise Ozone Heat Air Dirt Parts List Part of

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Parts Lists

Introduction

Subsystem Information
Use of the Term "Assembly"
The term "assembly" will be used for items in the part number listing that include other itemized parts in the part number listing. When the word "assembly is found in the part number listing, there will be a corresponding item number on the illustrations followed by a bracket and a listing of the contents of the assembly.

Brackets
A bracket is used when an assembly or kit is spared, but is not shown in the illustration. The item number of the assembly or kit precedes the bracket; the item numbers of the piece parts follow the bracket.

Tag
The notation "W/Tag" in the parts description indicates that the part configuration has been updated. Check the change Tag index in the General Information section of the Service Data for the name and purpose of the modification. In some cases, a part or assembly may be spared in two versions: with the Tag and without the Tag. In those cases, use whichever part is appropriate for the configuration of the machine on which the part is to be installed. If the machine does not have a particular Tag and the only replacement part available is listed as "W/Tag," install the Tag kit or all of the piece parts. The Change Tag Index tells you which kit or piece parts you need. Whenever you install a Tag kit or all the piece parts that make up a Tag, mark the appropriate number on the Tag matrix.

Parts Lists

Subsystem Information

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8825/8830 Printer

Symbology
A Tag number within a circle pointing to an item number shows that the part has been changed by the tag number within the circle (Figure 1). Information on the modification is in the Change Tag Index.

A Tag number within a circle having a shaded bar and pointing to an item number shows that the configuration of the part shown is the configuration before the part was changed by the Tag number within the circle (Figure 2).

Figure 2 Without Tag Symbol Figure 1 With Tag Symbol

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Parts Lists

Symbology

A tag number within a circle with no apex shows that the entire drawing has been changed by the tag number within the circle (Figure 3). Information on the modification is in the Change Tag Index.

A tag number within a circle with no apex and having a shaded bar shows that the entire drawing was the configuration before being changed by the tag number within the circle (Figure 4).

Figure 3 Entire Drawing With Tag Symbol

Figure 4 Entire Drawing Without Tag Symbol

Parts Lists

Symbology

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8825/8830 Printer

PL 1.1A Electrical Control Components/DC Power Generation (W/O TAG 27)

Item 1 2 3 4 5 6 7 Part 160K37310 162K28840 162K41460 162K41440 105K15863 160K33322 600K75311 600K81881 Description A/B Switch PWB (8830) (W/TAG 90) VPI Harness (8830) (W/TAG 90) A/B Switch to IOT Harness (8830) (W/TAG 90) Power Driver Harness (8830) (W/ TAG 90) DC Low Voltage Power Supply Driver PWB (A2) (W/O TAG 25) Driver PWB (A2) (W/TAG 25) Circuit Assembly Kit (EO) (W/TAG 4, TAG 16, TAG 17, TAG 26, (W/O TAG 53) Circuit Assembly Kit (EO) (W/TAG 4, TAG 16, TAG 17, TAG 26, TAG 53, ) Circuit Assembly Kit (NACO) (W/ TAG 4, TAG 16, TAG 17, TAG 26, TAG 53, TAG 87) Control Eprom Kit Language Eprom No. 1 (P/O PL 1.1A Item 3) Language Eprom No.2 Kit (Not Spared) AO Portuguese Language Eprom AO Spanish Language Eprom Controller Connector (See Note 1) Main PWB (A3) (Not Spared) (See Note 2) (W/TAG 3, TAG 10) (W/O TAG 27) (REP 3.1)

600K81882

600K81873

8 9 10 11 12 13

600K88890 537K51151 537K51161 162K29730

NOTE: 1:- Cable supplied for non-imbeded controllers only. NOTE: 2:- See PL1.1B Item 4. NOTE:

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Parts Lists

PL 1.1A

PL 1.1B Electrical Control Components/DC Power Generation (W/TAG 27)

Item 1 2 3 4 5 6 7 8 9 10 11 Part 105K18273 160K33322 600K75311 162K29730 600K75321 117K32660 105E13850 105E13863 152K36231 162K23453 Description DC Low Voltage Power Supply Assembly (W/TAG 25) Driver PWB (A2) (W/O TAG 25) Driver PWB Kit (A2) (W/TAG 25) Controller Connector (See Note) Main PWB Kit (A3) (W/TAG 27) Power Module Mounting Bracket (P/O PL 1.1B Item 1) Power Cord (5V PS) (P/O PL 1.1B Item 1) Power Cord (25V PS) Power Supply (5V) Power Supply (25V) Jumper Harness (14 Conductor) Motor Control Harness

Item 1 2 3 4 Part 423W72201 020E13853 026E11970 022K63750 022K49205 Description Sheet Drive Belt Sheet Drive Pulley Shoulder Screw Media Transport Assembly (8825) (W/O TAG 89) (REP 8.1,ADJ 8.1) Media Transport Assembly (8830) (W/TAG 15), Media Transport Assembly (8825) (W/TAG 89) (REP 8.1,ADJ 8.1) Transport Drive Motor Assembly (Not Spared) Drive Motor Pulley Motor Mounting Plate (P/O PL 8.1 Item 5) Transport Drive Motor (MOT1) (REP 8.10) Idler Roller Registration Drive Pulley Registration Drive Belt (REP 8.13) Twist Clamp Moisture Collection Tube Moisture Collection Bottle Pin Bracket (Not Spared) Clutch (REP 8.4) Bottle Cap (Not Spared) Compression Spring Clutch Brake Gear Pulley Exit Drive Pulley Belt Clutch Pulley

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

020E13603 127K04293 022E11441 020E12353 423W64001 120E02160 052E07910 093E01501 029K01111 121K10612 009E32510 017E07221 020E26340 020E26350 423W59001 020K08080

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Parts Lists

PL 8.1

PL 8.2 Media Registration Components

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part 130E05990 030K37830 016E06020 022E10531 006E42300 009E32500 009E32480 006K17441 413W31054 016E08931 Description Part of Media Transport Assembly (REF: PL 8.1 Item 4) Registration Support Assembly (P/ O PL 8.2 Item 1) Registration Support (P/O PL 8.2 Item 2) Media Registration Sensor (Q1) (REP 8.8) Registration Sensor Bracket Bushing Registration Pinch Roll (REP 8.12) Pinch Roll Shaft Pinch Roll Spring Turnaround Baffle (P/O PL 8.2 Item 2) Registration Support Spring Registration Drive Roll (REP 8.17) Bearing Media Transport Frame (P/O PL 8.2 Item 1) Bushing

Parts Lists

PL 8.2

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PL 8.3 Cut Sheet Feed Components

Item 1 2 3 4 Part 019E14350 006K15682 Description Part of Media Transport Assembly (REF: PL 8.1 Item 4) Media Transport Frame (P/O PL 8.3 Item 1) Drag Brake (8830), Drag Brake (8825) (W/TAG 90) Sheet Drive Roll (8830) (REP 8.7), Sheet Drive Roll (8825) (W/TAG 90) (REP 8.7) Sheet Support Assembly (P/O PL 8.3 Item 1) Sheet Lower Baffle (P/O PL 8.3 Item 5) Bushing (8830), Bushing (8825) (W/TAG 90) Sheet Pinch Roll (8830) (REP 8.6), Sheet Pinch Roll (8825) (W/TAG 90) (REP 8.6) Sheet Pinch Spring (8830), Sheet Pinch Spring (8825) (W/TAG 90) Sheet Pinch Shaft (8830), Sheet Pinch Shaft (8825) (W/TAG 90) Top Guide (P/O PL 8.3 Item 1) Shield (P/O PL 8.3 Item 1)

5 6 7 8

016E06020 022E09390

9 10 11 12

009E32490 006E23540

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Parts Lists

PL 8.3

PL 8.4 Media Transport Components

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Part 110K08711 019E07100 110K03731 049E54980 006K15670 032E10830 Description Part of Media Transport Assembly (REF: PL 8.1 Item 4) Buckle Switch (Upper) (REP 8.4), Buckle Switch (Lower) (REP 8.2) Sensor Bracket (P/O PL 8.4 Item 1) Transport Frame (P/O PL 8.4 Item 1) Cable Clip Sheet Upper Baffle (P/O PL 8.4 Item 1) Sheet Feed Switch (8830), Sheet Feed Switch (8825) (W/TAG 90) Switch Bracket (P/O PL 8.4 Item 1) Sensor Bracket Exit Support (P/O PL 8.4 Item 1) Exit Roll (REP 8.16) Stacker Support Bushing (P/O PL 8.4 Item 1)

Parts Lists

PL 8.4

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PL 9.1 Xerographic Module Assembly

Item 1 2 3 4 5 Part 127K17882 005K04151 126K05992 126K07152 053E04750 Description Photoreceptor Drive Assembly Photoreceptor Drive (P/O PL 9.1 Item 1) Coupling Xerographic Module Assembly (60 Hz) (REP 9.1) Xerographic Module Assembly (50 Hz) (REP 9.1) Ozone Filter

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Parts Lists

PL 9.1

PL 9.2 Photoreceptor
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part 006K15640 013K00380 028E11470 005K04131 005K04201 230W00652 007E01340 030E16161 001R00535 604K00440 Description Part of Xerographic Module Assembly (REF: PL 9.1 Item 4) Xerographic Frame (P/O PL 9.2 Item 1) Shaft Assembly Bearing Bearing Retainer Bearing (P/O PL 9.2 Item 3) RH End Cap Shaft (P/O PL 9.2 Item 3) LH Hub Wing Nut Toner Auger Drive Gear Ground Clip Bearing (P/O PL 9.2 Item 1) Photoreceptor (REP 9.3) Foam Damper Kit (3/Kit)

Parts Lists

PL 9.2

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PL 9.3 Image Module Assembly

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part 125K02220 026E57690 062E08051 600K58750 600K58730 035E41210 600K58761 600K58740 160K30980 160K63410 021E07660 035E37240 Description Part of Xerographic Module Assembly (REF: PL 9.1 Item 4) Scorotron Assembly Screw (M4 X 30) Screen Right End Block (P/O PL 9.3 Item 2) Pin Array Kit (REP 9.8) Spring (P/O PL 9.3 Item 6) Pin Array (P/O PL 9.3 Item 6) Center Support (P/O PL 9.3 Item 2) Scorotron Extrusion (P/O PL 9.3 Item 2) Left End Block Kit Left End Block (P/O PL 9.3 Item 11) Seal Image Module Assembly Kit (W/ TAG 28) Roller Kit Roller (P/O PL 9.3 Item 15) Pin (P/O PL 9.3 Item 15) Cover (P/O PL 9.3 Item 14) Harness (P/O PL 9.3 Item 14) Circuit Board (W/O TAG 28) Circuit Board (W/TAG 28) Cap Plug Gasket

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Parts Lists

PL 9.3

PL 9.4 Transfer/Detack Corotron

Item 1 2 3 4 5 6 7 8 9 Part 019E16080 019E19971 125K02580 038E06610 038E06620 004E00502 600K37740 Description Part of Media Transport Assembly (REF: PL 8.1 Item 4) Transport Frame (P/O PL 9.4 Item 1) Left Corotron Clamp Right Corotron Clamp Transfer/Detack Corotron (REP 9.9) Rear Detack Corotron Shield Front Detack Corotron Shield Foam Damper Corotron Repair Kit

Parts Lists

PL 9.4

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8825/8830 Printer

PL 9.5A Drum Cleaning (Part 1 of 3)

Item 1 2 3 4 5 6 7 8 Part 600K59060 101K25780 Description Part of Xerographic Module Assembly (REF: PL 9.1 Item 4) Xerographic Frame (P/O PL 9.5A Item 1) Cleaning Blade Kit (REP 9.4) Blade Seal (P/O PL 9.5A Item 3) Cleaner Blade Retainer (P/O PL 9.5A Item 3) Cleaner Blade (P/O PL 9.5A Item 3) Discharge LED Blade Seal (P/O PL 9.5A Item 3)

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Parts Lists

PL 9.5A

PL 9.5B Drum Cleaning (Part 2 of 3)

Item 1 2 3 4 5 6 7 Part 007E05221 023E01620 020E04350 013E00803 094K00085 035K05790 Description Part of Xerographic Module Assembly (REF: PL 9.1 Item 4) Auger Gear Pulley Auger Drive Belt Auger Pulley Auger Bearing Waste Toner Auger Photoreceptor Seal (Part of Cleaning Blade Kit) (REF: PL 9.5A Item 3) (REP 9.17) Media Deflector Kit (7/Kit) Media Guide (P/O PL 9.5B Item 8) Xerographic Frame (P/O PL 9.5B Item 1) Housing (P/O PL 9.5B Item 1)

8 9 10 11

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Table 1 Part Number Index Part Number 891E70530 891E70531 Part List PL 1.4 PL 1.4

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Parts Lists

Part Number Index

Parts Lists

Part Number Index

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8825/8830 Printer

6 General Procedures
Diagnostics
To Enter The Diagnostic Mode ....................................................................................... To Exit The Diagnostic Mode .......................................................................................... Input Diagnostic Test Procedure ..................................................................................... Input Diagnostic Test Codes ........................................................................................... Output Diagnostic Test Procedure .................................................................................. Output Diagnostic Test Codes ........................................................................................ Stepper Motor Commands .............................................................................................. To Enter Multiple Tests (Chaining).................................................................................. To Exit from Multiple Tests.............................................................................................. Special Tests................................................................................................................... 6-3 6-4 6-4 6-5 6-5 6-6 6-7 6-7 6-8 6-8 6-11 6-11 6-12 6-13 6-13 6-14 6-15 6-17 6-18 6-18 6-19 6-19 6-20 6-20 6-21 6-21 6-22 6-22 6-23 6-24 6-24 6-25 6-25 6-26 6-26 6-29 6-40 6-41 6-43

Tools
General Tools and Supplies (NACO) .............................................................................. General Tools and Supplies (EO) ................................................................................... Molex Connector Repair Procedure ................................................................................ 6-47 6-48 6-50 6-53 6-55 6-59

Product Specifications
Product Specifications.....................................................................................................

8825 Change Tag

8825 Change Tag Information.........................................................................................

8830 Change Tag

8830 Change Tag Information.........................................................................................

General Procedures
GP 1 HVPS Checkout ..................................................................................................... GP 2 Image on Drum (Panic Stop) Procedure................................................................ GP 3 Drum Maintenance................................................................................................. GP 4 Drum Cleaning Enhancement................................................................................ GP 5 Communication Loopback Test ............................................................................. GP 6 Downloading Firmware from a Laptop ................................................................... GP 7 NVM Dump of Adjustable Settings.........................................................................

Service Notes
Transfer and Developer Bias Voltages incorrect (Tag 19) .............................................. Power Cord Outlet Pulls Out Of AC Module ................................................................... PRE-TAG 9 Maximum Length Shortfall .......................................................................... Wavy Lines When Connected To XPC or Non Xerox Controller .................................... LL-52 Errors After Installing New Control PWB .............................................................. Cooling Fan Not Running ................................................................................................ Cleaning Blade Squeals During Print Cycle .................................................................... Toner Cleaning Auger Bound Up .................................................................................... LL-22 Caused By Metal Filings ....................................................................................... Intermittent Black Lines Or Background Bands .............................................................. Bent Corners (Dog Ears) On Lead Edge Of Narrow Media ............................................ Problems With Film Stacking .......................................................................................... Low Solid Area Density At Install .................................................................................... Intermittent Extra Print .................................................................................................... Loud Noise From HVPS.................................................................................................. Troubleshooting Photoreceptor Drive Problems ............................................................. Photoreceptor Damage ................................................................................................... Image Displacement (Rollover) On Vellum Or Film ........................................................

Installation
Installation Procedure ..................................................................................................... Product Demonstration ................................................................................................... Installation Checklist .......................................................................................................

Removal
Removal Procedure ........................................................................................................

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General Procedures

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8825/8830 Printer

To Enter The Diagnostic Mode

The diagnostic mode is entered by pressing and holding the zero (0) button while switching on the printer. The Diagnostic Mode may also be entered from the Control Panel by entering the Printer Menu > Diagnostics, and entering the password (6789). When entering the diagnostic mode, the Message Display will indicate the Copyright message, the message ROM configuration, and the software revision level. ( Figure 1): The following message will be displayed when the diagnostic mode is entered.

The Exit button is used to stop the tests. The Exit button is used to clear the entry. The Test Codes consist of a chain number and a test number. The chain numbers correspond to the same chain numbers that are used in the Service Manual to identify functional areas in the printer. The test numbers are sequential numbers to identify the tests within a chain. The chain numbers used are listed below Table 1 Chain Number 01 02 03 04 06 07 08 09 10 11 14 Standby Power User Interface (Control Panel) Printer Run Control Drives Exposure Media Supply Media Transportation Xerographics Fusing/Print Transportation Finishing Communication Functional Area

Figure 1 Control Panel Buttons Enter the first two digits of the code and press Enter button, then enter the second two digits of the code, and press the Enter button to begin the test. (Figure 2): The Control Panel buttons are identified in the following diagram:

Figure 2 Control Panel Buttons The code entered will be displayed on the Control Panel. The test name will be in the bottom line of the display along with test feedback information. There also may be additional information displayed depending on the test being run.

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General Procedures

To Enter The Diagnostic Mode

To Exit The Diagnostic Mode

Enter the test [0361] or switch the printer power off, wait 5 seconds, then switch it on.

Input Diagnostic Test Procedure

1. 2. 3. 4. 5. 6. 7. Enter the Diagnostic Mode Enter the Test Code Press the Enter button to begin the test. Manually operate the component that is to be tested. The condition of the component will be indicated in the message display window. The state of the component is indicated by a 0 for low state and a 1 for high state Press the Exit button to stop the diagnostic test Press the Exit button again to clear the chain

General Procedures

To Exit The Diagnostic Mode, Input Diagnostic Test

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Input Diagnostic Test Codes

Table 1 Code [0101] [0102] [0103] [0104] [0105] [0106] [0202] [0211] [0701] [0702] [0707] [0708] [0709] [0710] [0711] [0712] [0713] [0714] [0715] [0721] [0801] [0802] [0803] [0807] [0808] [0901] [0902] [1005] [1008] [1010] Front Door Interlock Line Voltage Sense Line Frequency Sense Line Voltage High/Low Cut Sheet Feed Shelf Interlock Top Cover Interlock Keyboard Test Message ROM Test Module Loop Interlock (Media Transport and Xero Mod installed) Cutter Drawer Interlock Roll 1 Sensor Input Roll 2 Sensor Input (8830 and 8825 with Tag/MOD 89) Roll 3 Sensor Input Roll 1 Motion Sensor Input Roll 2 Motion Sensor Input (8830 and 8825 with Tag/MOD 89) Roll 3 Motion Sensor Input Roll 1 Drawer Sensor Input Roll 2 Drawer Sensor Input (8830 and 8825 with Tag/MOD 89) Roll 3 Drawer Sensor Input Cutter Home Sensor Bypass Sensor (8830 and 8825 with Tag/MOD 90) Buckle Sensor Media Registration Sensor Exit Sensor Catch Tray Full Sensor (Stacker) Toner (Cartridge) Home Sensor Drum Motor Stall Sensor Fuser Jam Switch Fuser Open Sensor Fuser Scorch Sensor (To reset, power OFF then ON) Component Tested

Output Diagnostic Test Procedure

The Output Diagnostic Test is used verify correct operation of output components. The output diagnostic test allows the operation of the individual or multiple (chaining) output component(s) in order to verify operation. Go to svc.8830prt.16073 for instructions on how to enter multiple tests. 1. 2. 3. 4. 5. 6. Enter the Diagnostic mode. Enter the chain number (first two numbers on the code). Press the Enter button. Enter the test number (last two numbers of the code). Press the Enter button to begin the test. Observe the component for the correct operation. If the component and its circuitry are functioning correctly, the component will operate. If they are not, refer to the documentation to isolate the problem. Press the Exit button to stop the Diagnostic Test. To exit the diagnostic mode, enter the test [0361] or switch the printer power off, wait 5 seconds, then switch it on.

7. 8.

NOTE: The Fuser must be at operating temperature before making voltage checks or operating the diagnostics.

NOTE: 8825: The Media Drawer 3 is not available on the 8825. The Media Roll Drawer 2 is optional and is identified as Tag/MOD 89.

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General Procedures

Input Diagnostic Test Codes, Output Diagnostic

Output Diagnostic Test Codes

NOTE: 8825: The Media Drawer 3 is not available on the 8825. The Media Roll Drawer 2 is optional and is identified as Tag/MOD 89. CAUTION Do not run diagnostic code [0403] if the fuser is cold. Printer damage can occur. Diagnostic code [0403] runs the fuser motor, the developer motor, and the drum motor. The fuser heater is turned off while the printer is in the diagnostic mode. Table 1 Code [0201] [0203] [0210] [0403] [0703] [0704] [0716] [0717] [0718] [0720] [0723] [0727] [0728] [0729] [0730] [0731] [0732] [0733] [0905] [0914] [0917] [0925] [0956] [0957] [0966] [1009] Component Tested Display Test (individual LEDs) Service Meter (half clicks meter on ENTER, completes click on EXIT) Control Panel LEDs Runs Drum, Developer and Fuser Motors (See CAUTION above). Roll Feed Stepper - Forward Roll Feed Stepper - Reverse Roll Drive Motor and Roll 1 Feed Clutch (CL1) Roll Drive Motor/Roll 2 Feed Clutch (CL3) (8830/8825 with Tag/MOD 89) Roll Drive Motor and Roll 3 Feed Clutch (CL5) Cutter Brake Cutter Drive Motor (1 cycle) Roll 1 Rewind Clutch (CL2) Roll 2 Rewind Clutch (CL4) (8830 and 8825 with Tag/MOD 89) Roll 3 Rewind Clutch (CL6) Roll 1 Forward (Feed) Clutch (CL1) Roll 2 Forward (Feed) Clutch (CL3) (8830 and 8825 with Tag/MOD 89) Roll 3 Forward (Feed) Clutch (CL5) Bypass Clutch (8830 and 8825 with Tag/MOD 90) Toner Dispense Motor Cooling Fans ON at slow speed if Fuser is cold Transport Drive Motor Toner Cartridge (1 revolution) Test Pattern - additional delay Display area coverage of last print made. Erase Lamp Fuser Power Relay ON

3. 4. 5.

Codes [0729] and [0732] must be chained with [0703] in order to check the operation of the Feed and Rewind Clutches for Roll 3. The fuser must be at the run temperature before the Drive Motors are switched ON to prevent damage to the printer. Codes [0703] and [0704]: These Stepper Motor codes have output control tests that are capable of driving the motors forward or backward at any speed. These tests are entered using the correct chain and test number, and then entering one of the numbers in the Stepper Motor Command table shown on the right.

ADDITIONAL INFORMATION:
1. 2. Codes [0728] and [0731] must be chained with [0704] in order to check the operation of the Feed and Rewind clutches for Roll 2. Codes [0727] and [0730] must be chained with [0703] in order to check the operation of the Feed and Rewind Clutches for Roll 1.

General Procedures

Output Diagnostic Test Codes

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Stepper Motor Commands

Table 1 Button Pressed 0 1 2 3 4 5 Next Previous Enter Exit Media Switches stepper motor OFF. Switches the stepper motor ON, in the forward direction, at the NVM rate for Bond media. Switches the stepper motor ON, in the forward direction, at the NVM rate for Vellum media. Switches the stepper motor ON, in the forward direction, at the NVM rate for Film media. Switches the stepper motor ON, in the reverse direction, at the current NVM rate for reverse. Holds the stepper motor at the current position, low current. Makes the currently outputted stepper motor rate one count longer, slowing the actual feed rate. Makes the currently outputted stepper motor rate one count shorter, increasing the actual feed rate. Enters the currently outputted stepper motor rate into NVM Switches the stepper motor OFF and returns the printer to the Test Entry Mode. Does not affect the stepper motor, and returns the printer to the Test Entry Mode. Response

To Enter Multiple Tests (Chaining)

The Media button is used when entering more than one test. To chain one code to another, perform the following: 1. 2. Enter the desired code for the first test. Press the MEDIA button, then enter the additional code(s) for additional tests.

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General Procedures

Stepper Motor Commands, To Enter Multiple Tests

To Exit from Multiple Tests

Multiple tests can be switched off by two methods. 1. 2. Enter the codes in the reverse sequence from the way they were initially entered, pressing the EXIT button after each code. Press and hold the DOT (.) button while pressing the EXIT button. This will clear all of the codes that were entered.

Special Tests
The following tables give special diagnostic tests that are used to enable or disable features or to change the operating parameters of the printer. To enter a Special Test, the printer must first be in the diagnostic mode Each special test has a value that is stored in non-volatile memory (NVM). If there is a default value, it is found in the Value column. NVM values may be changed by entering the Special Test mode, pressing the ENTER button, and then using the PREVIOUS and NEXT arrow keys to select the desired NVM value. To enter the selected value, press the ENTER button again. To exit the test, press the EXIT button. NOTE: If there is a reference to a procedure, the procedure must be followed in order to perform the test correctly. Table 1 Code [0211] Description Language ROM Test 0 = Both Language ROMs are defective. 1 = Primary Language ROM is OK 2 = Secondary Language ROM is OK 3 = Both Language ROMs are OK Country Configuration 0 = 115 volts 1 = 240 volts 2 = 220 volts Media Width Detect 0 = 8830 DDS sizes 1 = Finesse 1.0 sizes 2 = FX sizes 5 = All sizes Billing Meter Count This code is used to select the billing in meters or inches. 0 = inch 1 = metric (decimeter) Jump 0. Restarts the IOT. NVM Reset to Default. Entering the number 1 or 3 resets all the NVM values to the default values. Entering the number 2 allows the electronic billing to be reset to any desired value. 1 = NACO NVM Default 2 = Billing 3 = EO NVM Defaults Watchdog Timer Test. This code can be used to exit the Diagnostic mode NACO 0 EO 1 Value

[0261]

[0262]

[0263]

[0300] [0360]

[0361]

General Procedures

To Exit from Multiple Tests, Special Tests

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8825/8830 Printer

Table 1 Code [0362] Description Value [0921] Code

Table 1 Description Electrostatic Setup This code is used adjust the electrostatics. When in this code, additional tests can be run by pressing the following buttons: 1 Transfer/Detack Corotrons ON 2 Adjust Vhigh 3 Adjust Vlow 4 Adjust Image Density ( ADJ 9.3) 5 Illuminates the LED Image Bar for observation purposes. 6 Calibrates the Toner Control Sensor. 7 Humidity Sensor control point setting. Next/Previous Pressing these buttons affects the Duty Cycle value in Tests 2 and 3, and changes Vhigh in [ 0921-2]. When running Tests 2 and 3, pressing the Enter button copies the current duty cycle value to NVM. This code disables toner faults so that the printer will continue to operate. While in Diagnostics, enter the code [0922] and select [Yes] for running with toner faults. Enter the code [0361] to exit the diagnostic mode. Resets the Toner Control Bias to default value IOT Internal Test Pattern Print 9 test patterns are available. The following parameters can be selected: Paper source (roll) Length of print Print quantity Folder program (if folder is available) Fuser Run Temperature Display. This code switches the fuser heat rod on and increases the fuser heat roll temperature to the run temperature. The run temperature is displayed in degrees (F) and degrees (C). At run temperature, the Drum/Developer and Fuser Drive Motors are switched on. The following conditions may exist when the message FUSER CAN NOT BE TURNED ON, CONDITION XX is displayed: 03 Developer Cover is open. 04 Cutter Cover is open 05 Xerographic Interlock is open. 06 Right side door is open. 07 Document Handler interlock is open. 08 Fuser status problem. Turn power off and try again. 09 Illumination status problem. Turn power off and try again. Display Fuser Temperature (Analog) Value

Diagnostic Time-out interval. This code allows the 5 min. adjustment of the time interval that the printer will stay in the Diagnostic mode. The time interval range is 5 to 50 minutes. NVM Reset This code allows the NVM values to be reset to the previously adjusted values. The software compares the NVM values to a backup file and will reset the values that are not the same as the values in the backup file. Reset NVM Check Sum NVM Printout of NVM contents in hex format. NVM Dump of Adjustable Settings. NOTE: This information is accessible through the Printer Main PWB, P308. Refer to GP 7, NVM Dump of Adjustable Settings. Recent Fault Log Displays the last 99 faults that have occurred. Displays the fault code, how many events ago it occurred, and the billing meter reading at the time the fault was originally displayed. Log entries are numbered from 1 to 99, with 1 being the most recent. Fault History Log Displays, in alphabetical order, the number of occurrences of each of the fault codes since the log was last cleared. Display Checksums Vertical Magnification Go to ADJ 8.1 Vertical Magnification Adjustment Cut Length Adjustment Go to ADJ 8.3 Cut Length. Delay Between Prints (Film) Increases the time delay between making prints on Film Media Enable/Disable Stacker Full Sensor Image Registration Go to ADJ 8.2 Lead Edge Registration. Input LED Output Value Tone Up/Tone Down (Automatically adjusts toner concentration until the control set point is reached). Transport Drive Motor Speed Adjustment. Note: This is not a recommended field adjustment. Displays Run Time. 10 (8 mm) 10 (8 mm)

[0363]

[0364] [0365] [0366]

[0921] (contd)

[0391]

[0922]

[0392]

[0926] [0955]

[0398] [0602] [0700] [0760] [0809] [0860] [0903] [0906] [0917] [0920]

[1004] 1-30 Secs

[1006]

8825/8830 Printer

01/02 6-9

General Procedures

Special Tests

Table 1 Code [1010] Description Fuser Scorch Sensor (Thermistor RT2) 1 = Fuser temperature less than or equal to 420 F (215C) 0 = Fuser temperature greater than 420 F (215C) NOTE: Power must be switched OFF then ON, in order to reset signal. [1026] [1030] Reset the Fuser Control NVM to default values. Reset Oil Web. Resets the web counter when a new web has been installed. Specify Oil Web Position. Used if the NVM fails or is reset. This sets the controls for web use. (Enter the diameter of the supply spool in millimeters.) Specify Web Oil Rate. This is used to adjust the web oil rate from 50% to 200%. (A 100% setting is nominal.) This setting directly impacts the life of the Oil Web. 50% means that 1/2 as much web is used. Advance Oil Web. Used to tension the web correctly when the oil assembly is removed and reinstalled. Estimate Oiler Web Life. Displays the remaining web life in print feet or meters. Disable LL-07 Oiler Fault Detection Disable LL-12 Fault Detection (Drum Stall) Fuser Temperature bond media adjustment. Allows the adjustment of the Fuser Run Temperature: 300 F (149C) with 36 inch wide bond media. Go to ADJ 10.1 Fuser Temperature. Fuser Temperature vellum media adjustment: 294F (146C). Go to ADJ 10.1 Fuser Temperature. Fuser Temperature film media adjustment: 300F (149C). Go to ADJ 10.1 Fuser Temperature. Folder Status Loopback Test for Remote Access Interface Loopback Test for Controller Command / Status Loopback Test for Finisher Port Value

[1031]

[1032]

[1033]

[1034] [1035] [10-36] [1060]

[1062] [1063] [1101] [1401] [1402] [1403]

General Procedures

Special Tests

01/02 6-10

8825/8830 Printer

GP 1 HVPS Checkout
The purpose of this checkout procedure is to verify correct operation of the High Voltage Power Supply. ( Figure 1): The location of the HVPS Test Points is shown in the drawing at right. NOTE: Use the 26V RTN test point when measuring all voltages. Failure to use this test point can cause incorrect readings.

GP 2 Image on Drum (Panic Stop) Procedure

This procedure allows the isolation of print quality problems by observing the image on the Drum before the transfer of the toner to the media. If the defect is visible on the Drum before the transfer, the defect is related to the charge, the imaging, or the developer. If the defect is visible on the print after the transfer, the defect is related to the transfer or fuser. 1. 2. 3. Make a test print. Open the right door interlock when the test pattern is almost half way beyond the Drum (Print is just starting to exit from the printer). Remove the Developer Module. If the defect is visible on the developed image, the defect cause is related to the charge, the imaging or the developer. If the defect is not visible, the defect cause is related to the transfer or the fuser.

Figure 1 Location of HVPS Test Points Perform the voltage checks shown in Table 1. Table 1 HVPS Voltage Checks COM Meter Lead V-Ohms Meter Lead Standby Measured Voltage 26.5 VDC Less than 0.05 VDC N/A In Print Measured Voltage 26.5 VDC 2.3 0.05 VDC N/A Diagnostic Code

26V RTN 26V 26V RTN PIN I 26V RTN GRID V 26V RTN DEV V

Less than 0.05 VDC (NOTE: -4.20 0.05 VDC -240 VAC at the Developer Housing) Less than 0.05 VDC Less than 0.05 VAC 0.6 0.1 VDC 1.0 VAC [921-1] [921-1]

26V RTN TFR I 26V RTN DET I

8825/8830 Printer

01/02 6-11

General Procedures

GP 1, GP 2

GP 3 Drum Maintenance
WARNING
When performing this drum maintenance, do the following: Ensure that there is adequate ventilation in the area. Use protective gloves at all times. Do not smoke. Wash your hands when the procedures are completed. CAUTION These procedures must be completed in the shortest possible time in order to reduce the effects of light shock.

NOTE: Ensure that the ends of the drum are washed. 6. 7. 8. 9. Using the clean side of the polyurethane pad, continue washing the drum until the entire surface of the drum is covered with film remover. Allow enough time for the air to dry the surface of the drum. Use the dusting pouch to apply a thin layer of Zinc Stearate (8R181) over the entire surface of the drum. Buff the surface of the drum using the clean side of the dry polyurethane pad.

NOTE: Ensure that the ends of the drum are buffed as well as the center of the drum. 10. Continue to buff the surface of the drum for three complete revolutions of the drum. 11. Apply a final thin layer of Zinc Stearate over the entire surface of the drum. 12. Reinstall the drum. 13. Enter the diagnostic mode. Enter test [1004] and allow the printer to run for five more minutes. 14. Place the used washing materials in the disposal bag. 15. Wash your hands.

Washing Procedure
Washing Materials: 1. 2. 3. 4. 5. Drum Maintenance Kit Film Remover Remove the Drum Assembly from the Xerographic Module ( REP 9.2). Put on gloves. Gently remove any dry ink/toner and developer from the surface of the drum, using a dry polyurethane pad. Apply Film Remover to a clean polyurethane pad. ( Figure 1 ): Wash the drum from end to end, using a circular motion.

Minimum Pressure

Polyurethane pad

Figure 1 Washing the Drum

General Procedures

GP 3

01/02 6-12

8825/8830 Printer

GP 4 Drum Cleaning Enhancement

1. 2. 3. Remove the Drum Assembly (REP 9.2). Use the dusting pouch (8R181) to apply a thin layer of Zinc Stearate over the entire surface of the drum. With a new lint-free cloth (600S4372), wipe the entire surface of the drum, using moderately heavy pressure. Use a back and forth motion of 6 - 10 strokes while revolving the drum three revolutions. Repeat steps 2 and 3 one time and then continue with step 5. Apply a thin layer of Zinc Stearate over the entire surface of the drum.

GP 5 Communication Loopback Test

NOTE: in order to perform this test, it is necessary to use the Loopback Kit (600K43210).

For printers with a Controller:

1. 2. 3. 4. 5. 6. 1. 2. 3. 4. 5. 6. 7. Remove the Controller and disconnect the ribbon cable (J307B) from the IOT Main PWB. Connect the loopback cable (152K59420) to J307B on the IOT Main PWB. Connect the loopback tool (114E4680) to the loopback cable. Enter [1402} to run the communication test. If the test passes, a 0 will be displayed. The problem is then in the ribbon cable or the Controller. Go to the E-701 RAP in the 8825/8830 Controller Service Manual. If the test fails (1), replace the IOT Main PWB ( PL 1.1A). Connect the loopback tool to the lower connector located on the rear right side of the IOT. Enter [1402]. If the test passes (0), the problem is the XPC or the connection between the XPC and the printer. If the test fails (1), remove the right rear lower cover and disconnect the cable at J308 on the Main PWB. Connect the loopback cable (152K59420) into J308 and connect the loopback tool (114E04680) to the loopback cable and repeat the test. If the test passes, replace the cable. If the test fails, replace the IOT Main PWB ( PL 1.1A).

4. 5.

Reinstall the drum assembly. Rotate the Drum manually to clean off excess zinc stearate.

For printers without a Controller:

8825/8830 Printer

01/02 6-13

General Procedures

GP 4, GP 5

GP 6 Downloading Firmware from a Laptop

NOTE: A point-to-point RS232 9-pin adaptor is required for this procedure. 1. 2. Power on the Printer, but do not power on the Controller. (Figure 1 ): Connect a null-modem cable between the serial port of the laptop computer and the serial port J-308 on the Printer Main PWB.

10. Wait until the display indicates: FILE SUCCESSFULLY PROGRAMMED. The computer displays ONE FILE COPIED and then the A:> prompt. 11. If a language is to be downloaded, type: DOWNLOAD LP XXYY.IOT COM1 for the primary language, or DOWNLOAD LS XXYY.IOT COM1 for the secondary language, where XX is the language identifier in the file name, and YY is the revision indicator. The language indicators are: 00yy.IOT (US English) 01yy.IOT (EO English) 02yy.IOT (AO Portuguese) 07yy.IOT (EO Dutch) 09yy.IOT (EO French) 10yy.IOT (EO German) 12yy.IOT (EO Italian) 18yy.IOT (EO Swedish) 19yy.IOT (EO Spanish)

NOTE: If the display indicates COMMUNICATIONS ERROR, recover as follows: a. b. c. d. e. f. P-308 g. Press EXIT on the Printer Control Panel. Type A: Check that you have sent the correct file. Recheck that the serial cable is seated correctly. Switch off the Printer. Hold down the 9 and 0 keys on the Printer Control Panel, while switching on the Printer. Restart the download as described above. If the problem still exists, or a file cannot be downloaded, try the procedure using COM2 on the computer.

NOTE: If the display indicates FLASH PROGRAMMING ERROR, recover as follows: Figure 1 Serial Port Connection - Printer Main PWB 3. 4. 5. 6. Enter the diagnostic code Chain 03 Test 01. The display indicates: DOWNLOAD FILE(S) TO PORT. EXIT TO RESET PRINTER. Insert the floppy disk containing the printer firmware into the floppy disk drive on the laptop computer. Obtain the MS-DOS prompt from within Windows (START/ PROGRAMS/ MSDOS COMMAND). Type A: <CR> The A> prompt is then displayed. NOTE: The batch file on the floppy disk will automatically set the COM1 port parameters on the laptop computer to 8 bits, 1 stop bit, odd parity, and 19,200 baud (bits per second). 7. 8. 9. Exercise the download.bat file. Type DIR to determine the name of the files contained on the disk. Type: DOWNLOAD F xxxxxxxx.iot COM1 (where xxxxxxxx is the file name of the firmware to be downloaded, and COM1 is the serial port to which the null modem cable is connected on the laptop computer. The control panel display indicates the version number of the firmware, and shows: RECEIVING RECORD XXXXX. a. b. Retry the download as described above. If the problem still exists, replace the Printer Main PWB (REP 3.1 in Section 6 of this service manual) and try the download again.

12. After the downloadings are complete, power off the printer. 13. Disconnect the Printer Power Cord. 14. Disconnect the null-modem cable.

General Procedures

GP 6

01/02 6-14

8825/8830 Printer

GP 7 NVM Dump of Adjustable Settings

The purpose of this procedure is to enable the service representative to access a listing of current NVM (Non-Volatile Memory) settings resident in the 8825/8830 Printer. If desired, this information can then be transferred to a computer, printed out and saved. This information can be of great value in recreating the customers printer settings in the event of a component failure. Information can also be recorded in the Service Log. 1. 2. 3. Power on the Printer, but do not power on the Controller. Remove the two screws at either side of the printer Lower Right Side Cover. Tilt the cover (with Controller attached) backward and gently set the Controller on the floor. (Figure 1): Connect a null-modem cable between the Serial Port of the computer and either the Diagnostic Remote Port of the printer (if installed) or J-308 on the Printer Main PWB.

The NVM settings are now displayed on the computer screen. This information can be downloaded to a file in the computer memory and saved for future use.

U38

P-308

Figure 1 Serial Port Connection - Printer Main PWB 4. 5. Access the terminal emulator software on the computer being used. Using the terminal emulator software on the computer, set the Serial Port up for the following: 6. 7. Baud rate: 19, 200 1 Stop Bit Even parity Data bit: 8

Hold down the zero button on the 8825/8830 Printer Control Panel, and turn on the controller and the printer. Enter the diagnostic code [0366] and hit the Enter key.

8825/8830 Printer

01/02 6-15

General Procedures

GP 7

General Procedures

GP 7

01/02 6-16

8825/8830 Printer

Transfer and Developer Bias Voltages incorrect (Tag 19)

PROBLEM
Transfer and developer voltages are set incorrectly.

CAUTION The tolerance window for electrostatics on the printer is very narrow. This printer must be set to specifications using the electrometer to ensure proper performance. If electrostatics are set incorrectly the printer will exhibit print quality problems, excessive dirt levels, and increased toner consumption.

CAUSE
Late in the program it was determined that the developer bias should be set at -420 VDC and transfer should be set at .6 ma DC . Inadvertently the change was never cut in on the manufacturing line. The current settings can cause intermittent broken black lines or background bands in the process direction.

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION N/A TAG 19 PART NUMBERS N/A CUT IN SERIAL NUMBER N/A

SOLUTION
PLEASE MAKE THE FOLLOWING ADJUSTMENT CHANGES TO THE printer ON THE NEXT SERVICE CALL: 1. ADJUST the Transfer output to + 0.6 VDC Go to GP 1 HVPS Checkout in this section. Locate the Transfer potentiometer (TRF I) nearest the center of the HVPS (closest to the transfer output transformer module). Carefully remove the RTV. Using the 26V return on the HVPS as the common and the TFR I test point, adjust the potentiometer to obtain + 0.6 +/- 0.1 VDC during a print. Mark appropriate change in manual (Table 1 on page 6-10).

CHANGE the Developer Bias default Enter diagnostic mode - Go to . Input diagnostic test code 84. ENTER 1E (E is obtained by holding down the period(.) button and striking the 4 button). ENTER Message: chain 84; address 01E is 4E. Using the Previous Button scroll down six (6) times or until the display reads chain 84; address 01E is 48. ENTER EXIT EXAMINE Developer bias output level - Go to GP 1 HVPS Checkout in Section 6 of this manual; . Using the 26V return on the HVPS as the common and the DEV V test point. In the print mode the output should be (-) 4.20 +/- 0.05 VDC. Mark appropriate change in manual (Table 1 on page 6-10). Mark off TAG 19 on the TAG matrix Once these adjustments are made you may see a slight increase in toner consumption. The benefits of doing these adjustments are: 1. Increase Cleaning Field latitude 2. Reduced occurrence of background bands in the process direction. Reduced occurrence of intermittent broken black lines in the process direction.

Provides additional lubrication for the cleaning blade.

8825/8830 Printer

01/02 6-17

General Procedures

Transfer and Developer Bias Voltages incorrect

Power Cord Outlet Pulls Out Of AC Module

PROBLEM
The power cord outlet may pull out of the AC module when trying to unplug the AC Power Cord.

PRE-TAG 9 Maximum Length Shortfall

PROBLEM
Pre-Tag 9 firmware is has a maximum length shortfall. No matter what length you tell the printer to print, it will only print a maximum length of 33 ( m).

CAUSE
The cut out in the AC Power Module for the power cord socket is too large.

CAUSE
Error in the firmware.

SOLUTION
Order and install the AC Mod kit.

SOLUTION
Ensure that the IOT firmware is at least TAG 9.

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION N/A TAG 5 PART NUMBERS 600K606610 AC Mod Kit CUT IN SERIAL NUMBER U.S - 8YG060517 E.O - 110907119-2

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION N/A TAG N/A PART NUMBERS N/A CUT IN SERIAL NUMBER N/A

General Procedures

Power Cord Outlet Pulls Out Of AC Module, PRE-TAG

01/02 6-18

8825/8830 Printer

Wavy Lines When Connected To XPC or Non Xerox Controller

PROBLEM
The printer produces prints with wavy lines when connected to a Xerox XPC or a non Xerox controller. This problem does not occur with a Xerox controller due to the short interface cable.

LL-52 Errors After Installing New Control PWB

PROBLEM
LL-52 errors after installing a new control pwb.

CAUSE
NVM eprom was not moved from the original Control PWB to the new Control PWB.

CAUSE
There is a timing problem in the P193R interface.

SOLUTION
Ensure that when the Control PWB is changed, that the NVM eprom (Component U40) is transferred to the new PWB. Ensure that the NVM eprom is installed onto the Control PWB with the dot in the lower left corner.

SOLUTION
Order and install a TAG 10 IOT Control PWB. This part is on j control you must call tech support to get approval before placing an order.

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION REP 3.1 TAG N/A PART NUMBERS N/A CUT IN SERIAL NUMBER

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION N/A TAG 10 PART NUMBERS 600K62420 TAG 10 UPGRADE KIT CUT IN SERIAL NUMBER US - 8YG060517 EO - 110907207-5

8825/8830 Printer

01/02 6-19

General Procedures

Wavy Lines When Connected To XPC , LL-52 Errors

Cooling Fan Not Running

PROBLEM
Cooling fan not running.

Cleaning Blade Squeals During Print Cycle

PROBLEM
Squealing noise from cleaning blade during print cycle.

CAUSE
Early IOT firmware could cause a cooling fan to start improperly. This problem only occurs with Delta cooling fans.

CAUSE
Excessive heat build up in the printer.

SOLUTION SOLUTION
Check the label on the cooling fans. If the label reads Delta DC Brushless install TAG 11 Firmware (Ver 1.03). If Japan Servo is the manufacturer replace the cooling fan assembly. If not noticed, the temperature inside the printer would increase on long runs. The first indication would be cleaning blade squeal during operation. Then the next probable failure would be a bound up toner auger from solidified toner. Make sure both cooling fans are functioning properly. If they are not see the article titled Cooling Fan Not Running in this section.

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION N/A TAG 11 PART NUMBERS U.S. - 600K59933 E.O. - 600K59953 CUT IN SERIAL NUMBER U.S. - 8YG060368 and up E.O. - 110907114-1 and up

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION N/A TAG 11 PART NUMBERS U.S. - 600K59933 E.O. - 600K59953 CUT IN SERIAL NUMBER U.S. - 8YG060368 and up E.O. - 110907114-1 and up

General Procedures

Cooling Fan Not Running, Cleaning Blade Squeals

01/02 6-20

8825/8830 Printer

Toner Cleaning Auger Bound Up

PROBLEM
Toner cleaning auger is bound up due to solidified toner.

LL-22 Caused By Metal Filings

PROBLEM
LL-22 errors or metal filings are accumulating in the cutter area.

CAUSE
Excessive heat build up in the printer.

CAUSE
Metal filings are shorting the Transfer/Detack. These metal filings may be generated in the media transport.

SOLUTION
Make sure both cooling fans are functioning properly. If they are not see the article titled Cooling Fan Not Running in this section.

SOLUTION
Check to see if the transport is the cause of the metal fillings by doing the following: 1. Remove the paper transport. Access the registration roll by removing the springs on the turn baffle and tipping it back. Inspect the registration roll shaft. If it appears that something is scraping it, replace the media transport assembly. 2. 3.

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION N/A TAG 11 PART NUMBERS U.S. - 600K59933 E.O. - 600K59953 CUT IN SERIAL NUMBER U.S. - 8YG060368 and up E.O. - 110907114-1 and up

Please report the serial number of any machine that has to have the transport replaced to Tech Support

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION N/A TAG N/A PART NUMBERS 22K49201 Media Transport Assembly P.L. 8.1 Item 4 CUT IN SERIAL NUMBER N/A

8825/8830 Printer

01/02 6-21

General Procedures

Toner Cleaning Auger Bound Up, LL-22

Intermittent Black Lines Or Background Bands

PROBLEM
Intermittent broken black lines or background bands in the process direction.

Bent Corners (Dog Ears) On Lead Edge Of Narrow Media

PROBLEM
Bent lead edge corners (dog ears) on A (A4) and B (A3) -short edge feed size media may occur on some printers. This happens primarily when close to the end of the media roll when the curl is the worst.

CAUSE
Developer bias and Transfer voltage set incorrectly at manufacturing.

CAUSE
This problem occurs in the media transport at the point where the media turns and meets the registration roll shaft. Because there is no registration feed roll in this area of the transport. the media catches the edge of the inner extrusion of the media transport.

SOLUTION
Set the values correctly.

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION N/A TAG 19 PART NUMBERS N/A CUT IN SERIAL NUMBER N/A

SOLUTION
( Figure 1): Order a dog ear repair kit 600K62600, remove the transport and install mylar strips in the area shown in the illustration. The registration roll and transport design was changed to add an additional set of registration feed rolls ( TAG 12). Some early machine with this tag did not get marked on the tag matrix. This transport may be identified in the following manner, without removing it from the machine: 1. 2. Open the cutter drawer . Check the left side of the transport. If the label is marked 12 roll this kit is not needed and something else in the media path is causing the problem.

General Procedures

Intermittent Black Lines Or Background Bands, Bent

01/02 6-22

8825/8830 Printer

Problems With Film Stacking

PROBLEM
Adhesive When running multiple prints on film, stacking problems may occur.

CAUSE
Inner Extension When film exits the machine it is very hot and flexible. After the first film print exits the machine, the film that follows may stick to the previous print. This can cause the film to roll up and block the exit.

Registration Roll Shaft

SOLUTION
Film Stripper Adjust diagnostic code 0760 to increase the delay between film copies. throughput of film only. This will impact

Registration Roll

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION N/A TAG 9, TAG 11 PART NUMBERS N/A CUT IN SERIAL NUMBER N/A

3
Install Mylar strips in location shown

Transport Clam Shell Full Open

2
Back out the Retaining Screw

1
Remove the two (2) Springs that hold the Turn Baffle down

Figure 1 Installation of Mylar Strips

8825/8830 Printer

01/02 6-23

General Procedures

Bent Corners (Dog Ears) On Lead Edge , Problems

Low Solid Area Density At Install

PROBLEM
At install it is difficult to attain 1.0 solid area density.

Intermittent Extra Print

PROBLEM
Intermittently an extra print is printed. The extra print will be partially the requested print and partially one of the internal test patterns.

CAUSE
This symptom is a developer/toner materials package phenomena that has to do with aging.

CAUSE
Electrical noise that is being injected into the system is causing the system to print this strange print. This noise is caused by either a contaminated scorotron that is arcing or the scorotron leads breaking down. No error code is produced but the system prints a second print correctly because it knows the first one failed.

SOLUTION
There is no fix for this problem other than to allow the material to age. After 500 to 1000 linear feet the solid area coverage will recover. NOTE: DO NOT USE 09 21 6 to adjust image density!!! Adjust only the image density in diagnostic 09 21 4.

SOLUTION
Clean the suspect scorotron and grid. Replace the grid or pins if required. Replace the Scorotron endblock and leads by installing a scorotron end block kit (600K58730)

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION N/A TAG N/A PART NUMBERS N/A CUT IN SERIAL NUMBER N/A

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION N/A TAG N/A PART NUMBERS 600K58730 Scorotron Endblock Kit CUT IN SERIAL NUMBER N/A

General Procedures

Low Solid Area Density At Install, Intermittent Extra

01/02 6-24

8825/8830 Printer

Loud Noise From HVPS

PROBLEM
Loud noise or squeal coming from the High Voltage Power Supply.

Troubleshooting Photoreceptor Drive Problems

PROBLEM
Photoreceptor drive may stall causing blank prints

CAUSE
Poor connection between the High Voltage Power Supply and the Charge Scorotron.

CAUSE
There is more than one cause of this problem, other than hard failure. Check the items listed below before troubleshooting the circuit or replacing components:

SOLUTION
Check the Charge Scorotron leads for an open or poor connection. If damaged repair or replace the Charge Leads (part of the Charge Scorotron Endblock Kit)

SOLUTION
NOTE: The photoreceptor drive circuit has an overcurrent protection built into it. If the circuit detects no drum drive or high current the drive system will shut down. When this occurs, the printer must be powered off then on to reset the circuit. 1. A poorly lubricated cleaning blade and photoreceptor can cause photoreceptor stalls or squealing. Use the double buff procedure when servicing the cleaning components.

REQUIREMENTS FOR FIELD RESOLUTION

DOCUMENTATION N/A TAG N/A PART NUMBERS 600K58730 Scorotron Endblock Kit CUT IN SERIAL NUMBER N/A

NOTE: Excessive zinc stearate can cause print quality problems but the photoreceptor will recover back to normal performance. 2. 3. Ensure that the screws that hold the scorotron in place are fully seated . If they are not they can touch the ends of the photoreceptor and stall it. Ensure that the plastic skis that are located on the top of the turn baffle do not contact the photoreceptor. To check this remove the developer housing and place a piece of paper between the skis and the photoreceptor. The paper should pass freely between them. If it does not perform the transport adjustment. Ensure that the Photoreceptor drive coupling is securely fastened to the motor and drive shaft. Rotate the shaft, if the coupling appears to wobble replace it. DOCUMENTATION N/A TAG N/A PART NUMBERS N/A CUT IN SERIAL NUMBER N/A

REQUIREMENTS FOR FIELD RESOLUTION

Image Displacement (Rollover) On Vellum Or Film

01/02 6-28

8825/8830 Printer

Installation Procedure
Prepare to Install the Printer
CAUTION Before installing the Printer, check for the correct voltage, polarity, and the grounding of the AC outlet that is provided by the customer. Use the Digital Multimeter. Incorrect voltage applied to the Printer could result in poor performance or damage to the Printer. NOTE: The power line outlet must be a 20 amp dedicated line (wired directly to the circuit breaker panel) with no shared neutral and a different phase from the lighting circuits. CAUTION If the supply AC voltage specifications are not met, the AC outlet may be wired or grounded incorrectly. Inform the customer and request that a licensed electrician correct the problem. DO NOT attempt to make the correction yourself. NOTE: The Power Cord is the disconnect device for this equipment. Ensure that the installation is near the outlet and is easily accessible. 1. ( Figure 1): Check the Ground and AC voltages.

On 50 Hz Printers, perform the following: a. b. c. Check for 220-240 VAC between AC Hot and AC Neutral. Check for 220-240 VAC between AC Hot and AC ground. Check for less than 2 VAC between AC Neutral and ground.

Floor Space Requirements WARNING

This product will produce ozone during operation. The ozone that is produced is dependent on the print volume and is heavier than air. Providing the correct environmental parameters as specified in Xerox installation procedures will ensure that concentration levels meet safe limits The minimum space requirement is 116.75 inches (292 cm) x 85 inches (212.5 cm). USO Only: If additional information concerning ozone is needed, request the Xerox publication 600P83222, Ozone by calling 1-800-828-6571. ( Figure 2): IOT Dimensions.

Rear Neutral (ACN) White Wire Hot (ACH) Black Wire

Front

43.5 (108 cm)

Ground Green Wire

56.75 (141.25 cm) 20 AMP 600S3703 NEMA = 5 - 20R 600S3703 Preferred

Figure 1 Checking the Ground and AC voltages On 60 Hz Printers, perform the following: a. b. c. Check for 105-125 VAC between AC Hot and AC Neutral. Check for 105-125 VAC between AC Hot and AC ground. Check for less than 2 VAC between AC Neutral and ground.

Figure 2 IOT Front Dimensions ( Figure 3): Minimum Space Requirements.

8825/8830 Printer

01/02 6-29

General Procedures

Installation Procedure

24 (60 cm)

1
36 Lift Stripper Bar slightly

2
Cut and remove cable tie. (8825 has two cable ties.)

89 222.5 cm

36 (90 cm)

3
Allow bar to return to normal position

Fuser Heat Roll

Figure 3 Minimum Space Requirements

Figure 4 Removing the Cable Tie 3. 4. 5. 6. Close the Media Transport Cover. Open the Media Drawers and remove the packaging material from the Media Tubes. (8830 has 3 Media Drawers; 8825 has either 1 or 2 Media Drawers.) Remove the Scorotron from the Media Drawer and carefully remove the packing material from the Scorotron. Lift and rotate the Image Module to the Service Position. Install the Scorotron on the Image Bar, making sure that the connector end of the Scorotron is to the left (machine rear). Attach the connectors to the Scorotron, taking care to join like-sized connectors. ( Figure 5): Remove the shipping pads located near the ends of the Image Module.

Install the Printer

1. Prepare to remove the internal packing material from the Printer. a. b. c. d. e. 2. Remove all external shipping tape. Loosen the two locking screws and open the Rear Door. Raise and latch the Top Cover. Lower the Media Transport Cover. Hold open the Developer Module Door while lifting and removing the Developer Module Side Cover.

7. 8.

( Figure 4): Remove the cable tie from the Stripper Finger Assembly.

General Procedures

Installation Procedure

01/02 6-30

8825/8830 Printer

1
Image Module at Service Position Remove the shipping pads, one from each end of drum

1
Loosen screw

2
Slide bracket off shaft

2
Remove the shipping pads, one from each side

4
Repeat steps 1 through 3 on the other side Figure 5 Removing the Shipping Pads 9. ( Figure 6): Disengage the Developer Module shipping brackets.

3
Retighten screw

Figure 6 Disengaging the Shipping Brackets 10. Close the Image Module and the Top Cover. 11. Lift open the Developer Module door, located on the top right side of the printer. 12. Remove the Toner Cartridge from the Developer Module. 13. ( Figure 7 ): Prepare to remove the Developer Module.

8825/8830 Printer

01/02 6-31

General Procedures

Installation Procedure

Gear Lock

1
Slide gear to left and lock into position with Gear Lock

1
Disconnect A22

2
Press in and rotate Retaining Clip to DOWN position Remove the Developer Module and place upon a flat surface

2
Press in and rotate the Developer Module Retaining Clip to the DOWN position

Figure 7 Removing the Developer Module 14. ( Figure 8 ): Remove the Developer Module.

Figure 8 Preparing to Remove the Developer Module 15. ( Figure 9): Remove the Sump Shield.

General Procedures

Installation Procedure

01/02 6-32

8825/8830 Printer

1 3
Remove the Top Shield Install the Developer Material

2
Loosen rear screws

1
Remove front screws

2
Record the batch number of the Developer Material on the Printer Log Augers

Figure 10 Installing the Developer Material 18. ( Figure 11): Reinstall the Sump Shield, rear edge first.

6
Rotate and remove the Sump Shield

5
Use a straight edge to separate the Sump Shield from the Rear Edge, then rotate the Sump Shield to remove.

Sump Shield

4
Remove full length of Sump Shield lip from under the Front Edge of the Developer Module.

Figure 9 Removing the Sump Shield 16. Remove the bottle of Developer Material from the Supply Kit. 17. ( Figure 10): Install the Developer Material evenly along the entire length of the augers.

8825/8830 Printer

01/02 6-33

General Procedures

Installation Procedure

2
Reinstall the edges of the shield under the edge on the housing

1
Reinstall the Top Shield

3
Tighten the screws

2
Reinstall the screws

1
Position the Sump Shield Figure 11 Reinstalling the Sump Shield 19. ( Figure 12): Reinstall the Top Shield, rear edge first. Figure 12 Reinstalling the Top Shield CAUTION Ensure that the Developer Module is kept close to the Printer frame during reinstallation in order to avoid damage to the Toner Dispenser Motor. 20. (Figure 13 ): Reinstall the Developer Module.

General Procedures

Installation Procedure

01/02 6-34

8825/8830 Printer

Support Block

3
Pull to remove Gear Lock from Drive Gear

2
Press in and rotate Retaining Clip to UP position

1 1
Place Developer Module Support Shaft onto Support Block (one each end) and slide in the Developer Module

2
Connect the connector

Press in and rotate Developer Module Retaining Clip to UP position

Figure 13 Reinstalling the Developer Module 21. (Figure 14 ): Reinstall the Developer Module.

Figure 14 Reinstalling the Developer Module 22. (Figure 15 ): Reinstall the Toner Cartridge.

8825/8830 Printer

01/02 6-35

General Procedures

Installation Procedure

1
Toner Cartridge insert left end of Toner Cartridge into Developer Module. Then, pull plunger back and guide the right side of cartridge into place

1
Remove the tape

3
Rock the Toner Cartridge back and forth to ensure correct engagement of cartridge to motor

2
Close the cover

Figure 15 Reinstalling the Toner Cartridge 23. Figure 16 : Complete the Toner Cartridge installation.

Figure 16 Completing the Toner Cartridge installation 24. Close the Developer Module Cover. 25. Raise the Printer Top Cover. 26. Raise and hold the Developer Module Cover while reinstalling the Developer Module Side Cover. 27. Figure 17 : Prepare to level the Printer. Rotate the leveling bolts (located inside the front and rear doors) fully counterclockwise.

General Procedures

Installation Procedure

01/02 6-36

8825/8830 Printer

3
Repeat the side-to-side level check at the other end of the printer

1
Rotate bolts fully counterclockwise Place the level as shown and check the front-to-rear level of the printer

2
Check the side-to-side level at base of printer

Figure 17 Preparing to Level the Printer 28. Figure 18: Check the level of the Printer.

Figure 18 Checking the Level of Printer NOTE: To ensure that the Printer frame is not twisted, use a level to perform the side-to-side level check on both end frames. NOTE: Adjust the end that is farthest out of level first. 29. Figure 19: Adjust the side-to-side level of the Printer.

8825/8830 Printer

01/02 6-37

General Procedures

Installation Procedure

1
Rotate the bolts to adjust the level of the printer

2
Repeat Step 1 at the other end of the printer

Rotate the bolts equally to adjust the level of the printer

Figure 19 Adjusting the side-to-side level 30. Figure 20: Adjust the front-to-rear level of the Printer.

Figure 20 Adjusting the Front-to-Rear Level of Printer 31. Figure 21: Check the level of the printer.

Determine level of printer

Figure 21 Checking and Adjusting the Printer Level 32. Repeat the Printer leveling (Steps 27 through 30) until the Printer is level.

General Procedures

Installation Procedure

01/02 6-38

8825/8830 Printer

33. Lock the printer casters. 34. Close the Top Cover. 35. Close the Rear Door and tighten the locking screw. 36. Install a roll of 36 inch (A0) Bond media in Roll 1 Media Supply. Refer to the User Guide as required. 37. Install the Second Language EPROM on the Main PWB (if required). 38. Install the Catch Tray or Folder. Go to the particular Installation Procedure of that service manual. 39. If the printer is being installed as part of the 8825/8830 DDS, proceed to the Functional Checks. Otherwise, continue on with the next step. NOTE: The printer comes with either a plain cover to attach to the right side of the printer, or with the Controller (which covers the same area). 40. If the Printer you are installing does not have the Controller (just a plain cover), perform the following: a. b. Attach the ribbon cable affixed to the Side Cover to A1P3 on the Main PWB. Place the Side Cover into the groove at the bottom of the Printer and secure it with the two screws provided. Connect the Controller ribbon cable to J307B on the Main PWB. Connect A1J3 on the controller panel to A1P3 on the Main PWB. Attach the Controller to the Printer by sliding it into the groove at the bottom of the Printer and secure it with the two screws provided. 5. 6. 7. 8. 9.

NOTE: New developer material requires that it be run for 500 to 1500 linear meters (1524 to 4572 linear feet) in order to break-in the developer material. As the developer material approaches break-in, the image density will increase. Check the image density. If the image density is at 1.3 or greater, reduce it to 1.2. If the image density is below 1.0, increase it to 1.0. Make three test prints using [9-55-5] and [9-55-7]. Check the print quality. Go to Print Quality Initialization Procedure in Section 3 of this Service Manual. If there is a controller installed, run a test print from the controller (special test). Exit the Diagnostic mode. Inform the operator that the following adjustments are Operator Adjustments and can be changed to fit individual needs. Refer to the User Guide and demonstrate the following adjustments. Power Saver Mode (EO: Low Power Mode) Standby Mode Timers Audible indicators Print density Controller (if present): Settings, Menu, Printing a Test Pattern

41. If the Printer you are installing has the Controller, perform the following: a. b. c.

10. Place a print of the Configuration Sheet inside the Front Door. 11. (Figure 22): Read the number of prints made on the Media Counter.

42. Provide following to the Systems Administrator (required for obtaining the software keys for options): 1. Printer serial number Controller serial number (if Controller present) Hardware address of the Ethernet Advanced Port (if Controller present)

Functional Checks
Check to ensure that the latest software is available and compatible for installation on the 8825/8830 Printer. Reference the Configuration Matrix Technical Services Bulletin (TSB) for the 8825/8830 Printer, or reference the Bulletin Board System (BBS). Connect the Power Cord. Switch on the Controller and the Printer. Then enter the Diagnostic mode. CAUTION When starting to operate the Printer, do not run 9-21-6. The Developer Material in this machine has already been initialized. There is no need to run this program again. 4. Go to the Service Manual and perform the following adjustments. Country configuration (ADJ 3.2) Initialize the Web Oiler [1030] Vertical Magnification (ADJ 8.1) Lead Edge Registration (ADJ 8.2) Cut Length (ADJ 8.3) Electrostatic Series (ADJ 9.2) Figure 22 Media Counter Location Media Counter

2. 3.

8825/8830 Printer

01/02 6-39

General Procedures

Installation Procedure

12. Figure 23): Record the Media Counter readings onto the Service Call Report. Record and report any accessory Serial Numbers (i.e., Finisher, Controller). 13. Separate the First Call Report card from the Installation Quality Report card and insert the First Call Report card into the Machine Log.

Product Demonstration
CAUTION 50 Hz machines only:. Do not run program 3-60-3 as this will cause all settings on the Printer to be lost. To demonstrate the capabilities of the Printer, refer to the User Guide. Perform the following procedures to train an operator. 1. 2. 3. 4. 5. 6. 7. Getting to know your Printer Control Console Loading the media Making prints using roll media Adding Toner and how to clear the J1 Status Code Problem solving status codes Clearing the Printer

3
Enter the reading from the Media Counter here

1
Access the Control Panel menu and record the Meter A reading

2
(8830 only) Access the Control Panel menu and record the Meter B reading

Figure 23 Recording the Print Count Readings 14. Record the following on the Printer Installation Quality Report card: Print count readings 8830: Media Counter, Meter A and Meter B 8825 Media Counter, Meter A

Printer serial number Installation date Comments

15. Mail the Printer Installation Quality Report Card.

General Procedures

Installation Procedure, Product Demonstration

01/02 6-40

8825/8830 Printer

Installation Checklist
Site Preparation
1. 2. 1. 2. 3. 4. 5. 6. 7. Supply voltage check Space requirements Remove the packing material Remove the Toner Cartridge Adding Developer Material Install the Toner Cartridge Level the Printer EO Only: Set the 220/240 switch Enable the correct language CAUTION When starting to operate the Printer, do not run 9-21-6. The Developer Material in this machine has already been initialized. There is no need to run this program again. 1. 2. 3. 4. 5. 6. 7. Switch on the Printer and allow the Printer to warm up. Set the Country Configuration ( ADJ 3.2). Initialize the Web Oiler [1030]. Set the Vertical Magnification ( ADJ 8.1). Set the Lead Edge Registration ( ADJ 8.2). Set the Cut Length ( ADJ 8.3). Perform the Electrostatic Series ( ADJ 9.2). NOTE: New developer material requires that it be run for 500 to 1500 linear feet (1524 to 4572 linear meters) in order to break-in the developer material. As the developer material approaches break-in, the image density will increase. Check the image density. If the image density is at 1.3 or greater, reduce it to 1.2. If the image density is below 1.0, increase it to 1.0. 8. 9. Perform the Image Density adjustment. (ADJ 9.3). Make three test prints using [9-55-5] and [9-55-7].

Installation

Functional Check

10. Check the print quality using Section 3 of this Service Manual. 11. Check the operator adjustments.

Product Demonstration Checklist

1. 2. 3. 4. 5. ON/OFF switch, Print Count Meter, and serial number plate Control Console Replacing the Toner Cartridge Problem solving status codes Clearing the Printer

8825/8830 Printer

01/02 6-41

General Procedures

Installation Checklist

General Procedures

Installation Checklist

01/02 6-42

8825/8830 Printer

Removal Procedure
Purpose
The purpose is to repack the Printer and the Controller (if present) for removal by Delivery / Removal Carriers. Printer Repack Kit 600K59540 Kit Contents Inspect the shipment for the following items: Poly Tape Bubble Pack Foam Pads (2 Cable Ties (2) Tape Box Bag (Poly) Bag (36 x 36) Bag (Jiffy) Photoreceptor End Caps (L & R)

Using the Developer Material procedure ( REP 9.7), remove the Developer Material.

10. Reassemble the Developer Module and reinstall it into the Printer. Engage the Gear Lock. 11. Reinstall the Developer Module Side Cover. 12. Unlock the casters. 13. Open the Front Door and the Rear Door. 14. ( Figure 1): Raise the leveling bolts.

Controller Repack Kit 673K34340 Kit Contents Inspect the shipment for the following items: 1. 2. 3. 4. 5. 6. 7. 8. Tape Box Bag (Anti-static) End Caps (Top & Bottom) Switch off the Main Power Switch and disconnect the Power Cord. Remove all rolls of media and leave them with the customer. Tape down the Roll Support Tubes in their respective Drawer. Remove the Power Cord and place it in a Media Supply Drawer. Remove the Catch Tray and the Catch Tray Supports. Place the Catch Tray into the (36 x 36)bag and secure the bag with tape in three places. Put the bag in the box and seal the flaps with tape. Put the two Catch Tray Supports into the Poly Bag, close the flap, and secure the bag with tape. Put the bag into the Jiffy bag, close the flap, and secure the bag with tape in three places. If the Printer you are removing has the Controller, perform the following: a. b. c. d. e. Remove the Controller by removing the two screws and lifting it off the groove at the bottom of the of Printer. Disconnect A1J3 on the Controller panel from A1P3 on the Main PWB. Disconnect the Controller ribbon cable from J307B on the Main PWB. Place the Controller in the Anti-static Bag, install the Top and Bottom End Caps, and place the assembly into the box. Secure the box with tape. General Procedures Figure 1 Raising the Leveling Bolts 15. Raise and latch the Top Cover. 16. ( Figure 2): Raise the Image Module to engage the Developer Module shipping brackets .

1
Rotate bolts fully clockwise

2
Repeat this step at other end of printer

Preparation

8825/8830 Printer

01/02 6-43

Removal Procedure

1
Loosen screw

2
Slide bracket onto the shaft

Image Module at Service Position

1
Install the shipping pads, one on each end of photoreceptor

2
Install the foam pads, one on each side

4
Repeat steps 1 through 3 on other side

3
Retighten screw

Figure 2 Engaging the Shipping Brackets 17. ( Figure 3): Install the shipping pads.

Figure 3 Installing the Shipping Pads 18. Remove the Charge Scorotron Assembly ( REP 9.8), wrap the assembly in bubble pack, and place it in a Media Supply Drawer. 19. ( Figure 4): Open the Media Transport Cover and secure the Stripper Finger Assembly with a cable tie.

General Procedures

Removal Procedure

01/02 6-44

8825/8830 Printer

1
Lift Stripper Bar slightly

2
Install a cable tie

3
Allow bar to return to normal position Fuser Heat Roll

Figure 4 Installing the Cable Tie

8825/8830 Printer

01/02 6-45

General Procedures

Removal Procedure

General Procedures

Removal Procedure

01/02 6-46

8825/8830 Printer

General Tools and Supplies (NACO)

Cleaning Brush Table 1 Supplies Supplies Description Service Manual Binder Table 2 Tools Tools Description Basic Multinational Tool Kit Supplemental Tool Kit Metric Supplemental Tool Kit Digital Multimeter DMM Test Lead Kit Test Leads (required for 600T2020) Red Adapter Plug Black Adapter Plug Electrometer Temperature Probe Set (Probe and Sensor) Thermal Sensor (straight) Light Shield Stackable Jumper Lead (Electrometer) Interlock Tool Vacuum Cleaner Vacuum Cleaner Bags (10) Vacuum Cleaner Filter Module Electrometer Probe Wing Screwdriver Blade (6 x 3/16) Pocket Screwdriver 5.5 mm Wrench 7 mm Wrench 5.5 mm Socket 7 mm Socket Longnose Pliers Diagonal Cutting Pliers Metric Hex Key Set Retaining Ring Pliers 150 mm Rule 2 Meter Tape Measure Line Level Round File, 6 inch Flat File, 6 inch 600T1835 600T1837 600T1836 600T2020 600T1923 600T1660 499T9567 499T9568 600T1620 499T9570 499T9572 600T1198 600T1652 600T91616 600T1820 93E3270 600T1832 600T1728 600T40203 600T40205 600T40501 600T40502 600T40701 600T40702 600T40901 600T40903 600T41101 600T41401 600T41503 600T41505 600T41510 600T41801 600T41802 20 lb Roll Bond Media Oil Tube (8 cc) Log Holder Media Message Description Cleaning Solvent Disposable Gloves Drop Cloth Film Remover Formula A Heavy Duty Towels Lint-free Cloth Polyurethane Pads (40) Photoreceptor Maintenance Kit Photoreceptor Toner Cartridge (with Reclaim Bottle) Developer (7 lb bottle) Dusting Pouch Solid Area Fill Image Darkness Background Part 600P88124 Part Scribing Tool Magnetic Pickup and Mirror Socket Driver Metric Feeler Gauge Set Screwdriver Handle 13 mm Wrench 10 mm Wrench

Table 2 Tools 600T41901 600T41903 600T41911 600T1751 600T41509 600T40212 600T40505 600T40504 Table 3 Image Reference Pattern Image Reference Pattern 82P520 82E7030 82P502 Table 4 Machine Consumables Machine Consumables Description 1R535 6R880 5R310 8R181 Table 5 Cleaning Materials Cleaning Materials Part 43P10 99P3024 35P1638 43P45 43P48 35P3191 600S4372 600S4653 600S5838 Part

Table 6 Other Tools and Supplies Other Tools and Supplies Description 22E630 93E811 600P293 600P60017 General Procedures Part

01/02 6-49

General Procedures

General Tools and Supplies (EO)

Molex Connector Repair Procedure

Purpose
The purpose of this procedure is to show the approved method of repair or replacement of the wire terminals in either the Pin Housing Connectors or the Socket Housing Connectors without damaging them. CAUTION The Molex connectors will break easily. Use only approved tools and procedures when extracting modules or terminals, or resetting the terminal locking tabs.

CAUTION Note the location of the individual module connectors in the housing before removing them. This will ensure that they are reinstalled correctly after the repair to the terminals is complete. Failure to position the individual connectors correctly will cause the printer to malfunction, causing damage. CAUTION Use caution when forcing the housing body away from the module connector. Too much force could cause damage to the housing body. 2. ( Figure 2): Remove the individual module connectors from the housing.

Items Required
600T1825 Extraction Tool

4
Remove the module connectors from the housing body

Procedure
1. ( Figure 1): Familiarize yourself with the Molex Extraction Tool components.

This hook is used to reform the locking tab on the pin before inserting the pin into the connector

1 3
Flat tabs Extender Ensure that the tabs on the housing are moved clear of the module connectors Insert the Extractor Tool between the housing and the individual module connectors

2
Module connectors Force the housing body away from the module connectors while performing the step 3

This protruding tab is used to release the locking tabs on the pins while the individual module connectors remain in the housing

This protruding tab is used to release the locking tabs on the pins when the individual module connectors are removed from the housing

These flat tabs and extender are used to remove the individual module connectors from within the housing

Figure 2 Removing the Module Connectors NOTE: Insert the Extractor Tab until the face of the tool is flush with the connector housing. 3. ( Figure 3):Remove the terminal from the connector.

Figure 1 Molex Extraction Tool Components

General Procedures

Molex Connector Repair Procedure

01/02 6-50

8825/8830 Printer

Long Extractor Tab (working edge of tool)

2
Remove the terminal from the housing

(Terminal shown rotated 90 degrees)

1
Insert the long Extractor Tab through the window in the housing Terminal removal through the housing

2
Short Extractor Tab (working edge of tool) Remove the terminal

(Terminal shown rotated 90 degrees)

1
Insert the short Extractor Tab through the window in the module connector Terminal removal through the connector Figure 3 Removing the Terminal from the Connector 4. ( Figure 4): Reform the Terminal Locking Tab.

8825/8830 Printer

01/02 6-51

General Procedures

Molex Connector Repair Procedure

2
Rotate the terminal until it is parallel with the line on the tool

1
Insert the locking tab on the terminal over the hook on the Extractor Tool

Figure 4 Removing the Locking Tab 5. 6. Reinstall the terminal to the pin position from which it was removed. Reinstall the individual module connectors to the correct locations noted at the beginning of this procedure. Refer to Section 7 for detail of connector configuration.

General Procedures

Molex Connector Repair Procedure

01/02 6-52

8825/8830 Printer

Product Specifications
Physical Characteristics
Table 1 Printer Dimensions Weight 8830 650 lbs (295 kg) 8825 (1 drawer) 620 lbs (281 kg) 8825 (2 drawer) 635 lbs (286 kg) 43 inches (1092 mm) 23 inches (584 mm) 57 inches (1448 mm) 8YG 36 (914 mm) 24 (610 mm) 36 (914 mm) 83 (2108 mm) 24 (610 mm)

Height Width Depth Product Code

( Figure 1): Printer front dimensions

117 (2972 mm) Figure 2 Printer Footprint 43 (1092 mm)

Electrical Specifications
The printer is designed to operate on a 20 Amp, 105 - 125 VAC, 60 Hz single phase dedicated line protected by a circuit breaker. Table 2 Current Consumption: Rest 1.0 Amps 1.4 Amps 6.0 Amps 16.0 Amps Table 3 Power Consumption: Rest Standby Ready Running Power Cord Length: 10 feet (3 m) 120 Watts 1000 Watts 690 Watts 1840 Watts

57 (1448 mm)

Standby Ready Running

Figure 1 Printer Front Dimensions

Minimum Space Requirements

( Figure 2): Printer footprint

8825/8830 Printer

01/02 6-53

General Procedures

Product Specifications

Environmental Conditions
Temperature: Maximum 80F (27C) Minimum 60F (10C) Humidity: Maximum 80% Minimum 20% Maximum Elevation: 7000 feet (2133 m) Table 4 Heat Emission (BTU/Hr): Rest Standby Ready Running 393 550 2350 6270 Table 5 Media Specifications Bond Vellum Film Tracing 20 Lb 20 Lb 4 mil 4 mil

Roll Size Width: 11 (279.4 mm) 36 (914.4 mm) Roll Size Diameter: 3 (76.2 mm) to 6.7 (170.2 mm) Output Print Specifications: Cut Sheet Minimum Size - 8.5 X 11 (216 X 279 mm) Portrait) Roll Sheet Minimum Size - 11 X 8.5 (279 X 216 mm) Landscape Maximum Size 36 X 48 feet (914 mm X 12.2 m) 80 feet (24.4 m) Optional

General Procedures

Product Specifications

01/02 6-54

8825/8830 Printer

8825 Change Tag Information

Introduction
The purpose of this section is to list the Change Tag Index for the 8825 Printer. All important modifications are identified by a Tag number on a matrix card attached to the machine. This section describes all of the Tags as well as multinational applicability, classification codes, and permanent or temporary modification information.

TAG:
CLASS: USE:

26
O All US-8YG064000/2/5/6/7 & 8YG064048 Cut-in: 11/17/98 133K19970 DUO-059110 Through DUO-059114 T5R-030065; T4R-112-047534-3; DT9-030282; 8YG-064107; 7YG-909551-2

MFG SERIAL NUMBERS:

NAME: Classification Codes A Tag number may be required to identify differences between parts that cannot be interchanged, or differences in diagnostic, repair, installation, or adjustment procedures. A Tag number may also be required to identify the presence of optional hardware, special non-volatile memory programming, or if mandatory modifications have been installed. Each Tag number is given a classification code to identify the type of change the Tag has made: M - Mandatory N - Not installed in the field O - Optional R - Repair PURPOSE:

Firmware Version 01.07.00-16 U.S - 600K59938 E.O - 600K59958

KIT NUMBER: REFERENCE:

TAG:
CLASS: USE:

27
O All Cut-in: 4/22/99 - 160K63940 DT9-031050 - DT9031054 8YG-065142; T5R-030359; T4R-112047751-6, DU0-112-059620-5

MFG SERIAL NUMBERS:

TAG:
CLASS: USE:

25
M Cut in 4/21/99: 101K40580/101K40570/105K18270/ 160K54570 7YG-90999 Through 7YG-910003 DT9-031032, 031033, 031035, 031036, 031037 8YG-065142; T5R-030359; T4R-112-047751-6; DU0-112-059620-5 NAME: PURPOSE: KIT NUMBER: REFERENCE:

New IOT Control PWB Change in IOT Control PWB design replaces EPROMS with Flash ROM. Enables Controller IOT firmware upgrades. U.S - 600K75320

MFG SERIAL NUMBERS:

NAME: PURPOSE:

8825/8830 AC/DC Power Distribution Changes Consists of: DC Power Harness, DC Power Module, 10 Volt Power Supply, Circuit Breaker replacement for current Ground Fault Indicator, Driver PWB.

KIT NUMBER: REFERENCE:

8825/8830 Printer

01/02 6-55

General Procedures

8825 Change Tag Information,

TAG:
CLASS: USE:

28
O All Cut-in: 5/21/99 62K7893 DT9-031264 Through DT9-031267 8YG-065294; 7YG-910059-1; T4R-112-047928-4; DU0-112-059668-0

TAG:
CLASS: USE: NAME: PURPOSE:

32
O All Printer Process Speed Problem Fix Firmware To Eliminate Process Speed Problem

MFG SERIAL NUMBERS:

KIT NUMBER: REFERENCE:

NAME: PURPOSE:

New Image Module Assembly Removal of RS 422 board enables downward compatiblity by removing the connector PWB and replacing it with the RS422 PWB from the existing bar. (Tag 28 on machine without the RS422 PWB.) U.S - 600K58761

KIT NUMBER: REFERENCE:

TAG:
CLASS: USE: NAME: PURPOSE:

50
O (50 Hz) Only Cut-in: 12/ 2000 Light Flicker Modification for use on (50 Hz) Printers To reduce the customer light flicker problem caused by the Fuser System. Required compliance with European Regulatory Authority standard EMC Directive 89/ 336/ EEC.) Manufacturing Build only PL

MFG SERIAL NUMBERS:

TAG:
CLASS: USE: NAME: PURPOSE:

29
All

MFG SERIAL NUMBERS: Common AC Chassis Assembly and New GFI Provide common chassis assembly. Manufacturing Build Only

KIT NUMBER: REFERENCE:

TAG:
CLASS: USE:

TAG:
CLASS: USE: NAME: PURPOSE:

31
O All Tracing Paper Problem Fix Eliminates Tracing Paper Problem 600K89510

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE: PL Firmware Upgrade

MFG SERIAL NUMBERS:

KIT NUMBER: REFERENCE:

General Procedures

01/02 6-56

8825/8830 Printer

TAG:
CLASS: USE:

55
O

TAG:
CLASS: USE:

89
O All N/A Transport Assembly Kit Provides a Media Transport Assembly with single sheet bypass capability. 98K72830 Customer purchased kit

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE: PL 10V FWR PWB To PROVIDE A NEW PWB.

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE:

TAG:
CLASS: USE:

87
O

TAG:
CLASS: USE:

90
O All Optional Drawer Kit Provides an optional second drawer to meet customer printing requirements. 98K72820 Customer purchased kit

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE: PL Firmware Upgrade

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE:

TAG:
CLASS: USE:

88
O

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE: PL Firmware Upgrade

8825/8830 Printer

01/02 6-57

General Procedures

01/02 6-58

8825/8830 Printer

8830 Change Tag Information

Introduction
The purpose of this section is to list the Change Tag Index. All important modifications are identified by a Tag number on a matrix card attached to the machine. This section describes all of the Tags as well as multinational applicability, classification codes, and permanent or temporary modification information. Classification Codes A Tag number may be required to identify differences between parts that cannot be interchanged, or differences in diagnostic, repair, installation, or adjustment procedures. A Tag number may also be required to identify the presence of optional hardware, special non-volatile memory programming, or if mandatory modifications have been installed. Each Tag number is given a classification code to identify the type of change the Tag has made: M - Mandatory N - Not installed in the field O - Optional R - Repair

2
M All US - 8YG060018 and up - - -EO - 110907020-0 IOT Firmware update Updates US Firmware 133K15992 version # 00.32.01-10 Updates EO Firmware 133K16161 version # 00.32.01-10 KIT NUMBER: REFERENCE:

MFG SERIAL NUMBERS:

KIT NUMBER: REFERENCE:

8825/8830 Printer

01/02 6-59

General Procedures

KIT NUMBER: REFERENCE:

N/A P/N US - 126K30385 - -EO - 126K07152 KIT NUMBER: REFERENCE:

US Upgrade Kit - 600K59933 EO Upgrade Kit - 600K59953 ization Kit US 650K06201

National-

General Procedures

01/02 6-60

8825/8830 Printer

TAG:
CLASS: USE: NAME: PURPOSE:

12
M All US - 8YG060368 and up - -EO - 110907165 and up Transport Assembly

TAG:
CLASS: USE:

15
M US - 8YG060-824, EO - 110-907492-2

MFG SERIAL NUMBERS:

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER:

Transport Assembly New Corotron Endblocks 022K49203

KIT NUMBER: REFERENCE: PN 22K49201

REFERENCE:

TAG:
CLASS: USE: NAME: PURPOSE:

13
M All -EO - 110907210-3 Transport Assembly New handle to secure the Fabric Belt N/A PN 22K49202

TAG:
CLASS: USE: NAME: PURPOSE:

16
M All Firmware US Firmware 133K15997 version #01.04.00-10 EO Firmware 133K16166 version #01.04.00-10 US - Upgrade Kit - 600K59934 EO Upgrade Kit - 600K59954 Nationalization Kit - US 650K06202

MFG SERIAL NUMBERS:

KIT NUMBER: REFERENCE:

TAG:
CLASS: USE: NAME: PURPOSE:

14
M All MFG. SERIAL NUMBERS - EO 110907210-3 and up Media Roll Label New label reflects 11. 052K03191 reworked with new Label (or) 052K03580 cut-in six (6) per machine. 600K62460 P/N 052K03191 reworked with new Label (or) 052K03580 cut-in six (6) per machine.

TAG:
CLASS: USE: NAME: PURPOSE:

17
M All IOT Firmware US Firmware 133K15998 version #01.04.07-10 EO Firmware 133K16167 version #01.04.07-10 US Upgrade Kit - 600K59935EO Upgrade Kit - 600K59955Nationalization Kit (US) - 650K06203

MFG SERIAL NUMBERS:

KIT NUMBER: REFERENCE:

8825/8830 Printer

01/02 6-61

General Procedures

TAG:
CLASS: USE: NAME: PURPOSE:

18
M All Data Plate Change to Data Plate to enable Korea sales. PN 891E15361

TAG:
CLASS: USE: NAME: PURPOSE:

21
M All New Front Panel Enables installation of Stacker Full Switch 30K55633 ( n/h 50K32171 )

MFG SERIAL NUMBERS:

KIT NUMBER: REFERENCE:

TAG:
CLASS: USE: NAME: PURPOSE:

19
M All US - 8YG061469 to 474/688 to 670 Output Current Adjustment Establishes the correct electrostatic setup voltages for the Printer. 105K13542

TAG:
CLASS: USE:

23
M 60 Hz 8YG061952 / 8YG061955 50 Hz 110908411/13/27/28/29

MFG SERIAL NUMBERS:

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE:

IOT Firmware ver 01.05.06-13 Enables 8830 DDS System NACO - 600K59936EO - 600K59956 537K47148

KIT NUMBER: REFERENCE:

TAG:
CLASS: USE: NAME: PURPOSE:

20
M All New Fuser Oil Assembly with new Timing Disk Improved Performance 94K0330

TAG:
CLASS: USE:

24
M 8YG063270-063274 8YG-063512 to524

MFG SERIAL NUMBERS:

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE:

Firmware Ver 01.06.09-16 U.S - 600K59937 E.O - 600K59957

KIT NUMBER: REFERENCE:

General Procedures

01/02 6-62

8825/8830 Printer

TAG:
CLASS: USE:

25
M Cut in 4/21/99: 101K40580/101K40570/105K18270/ 160K54570 7YG-90999 Through 7YG-910003 DT9-031032, 031033, 031035, 031036, 031037 8YG-065142; T5R-030359; T4R-112-047751-6; DU0-112-059620-5

TAG:
CLASS: USE:

27
O All Cut-in: 4/22/99 - 160K63940 DT9-031050 - DT9031054 8YG-065142; T5R-030359; T4R-112047751-6, DU0-112-059620-5

MFG SERIAL NUMBERS:

NAME: PURPOSE:

New IOT Control PWB Change in IOT Control PWB design replaces EPROMS with Flash ROM. Enables Controller IOT firmware upgrades. U.S - 600K75320

NAME: PURPOSE:

8825/8830 AC/DC Power Distribution Changes Consists of: DC Power Harness, DC Power Module, 10 Volt Power Supply, Circuit Breaker replacement for current Ground Fault Indicator, Driver PWB. KIT NUMBER: REFERENCE:

KIT NUMBER: REFERENCE:

TAG: TAG:
CLASS: USE:

28
O All Cut-in: 5/21/99 62K7893 DT9-031264 Through DT9-031267 8YG-065294; 7YG-910059-1; T4R-112-047928-4; DU0-112-059668-0

26
O All US-8YG064000/2/5/6/7 & 8YG064048 Cut-in: 11/17/98 133K19970 DUO-059110 Through DUO-059114 T5R-030065; T4R-112-047534-3; DT9-030282; 8YG-064107; 7YG-909551-2

CLASS: USE:

MFG SERIAL NUMBERS:

NAME: PURPOSE:

New Image Module Assembly Removal of RS 422 board enables downward compatibility by removing the connector PWB and replacing it with the RS422 PWB from the existing bar. (Tag 28 on machine without the RS422 PWB.) U.S - 600K58761

NAME: PURPOSE:

Firmware Version 01.07.00-16 KIT NUMBER: U.S - 600K59938 E.O - 600K59958 REFERENCE:

KIT NUMBER: REFERENCE:

TAG:
CLASS: USE: NAME: PURPOSE:

29
All 8YG061364 to 367 Common AC CHassis and new design GFI Improved Performance

MFG SERIAL NUMBERS:

KIT NUMBER: REFERENCE:

8825/8830 Printer

01/02 6-63

General Procedures

TAG:
CLASS: USE: NAME: PURPOSE:

31
O All Eliminate Tracing Paper Problem Improved Performance

TAG:
CLASS: USE: NAME: PURPOSE:

50
(50 Hz) Only Cut-in: Light Flicker Modification for use on (50 Hz) Printers To reduce the customer light flicker problem caused by the Fuser System. Required compliance with European Regulatory Authority standard EMC Directive 89/ 336/ EEC.) Manufacturing Build only PL

MFG SERIAL NUMBERS:

KIT NUMBER: REFERENCE: KIT NUMBER: REFERENCE:

TAG:
CLASS: USE: NAME: PURPOSE:

32
O All Process Speed Upgrade Improved Performance

TAG:
CLASS: USE:

MFG SERIAL NUMBERS:

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE: PL Firmware Upgrade

KIT NUMBER: REFERENCE:

TAG:
CLASS: USE: NAME: PURPOSE:

40
M All 8YG061364 to 367 New Cutter Motor Improved Performance- New Pittman Motor in Cutter 50K32172

TAG:
CLASS: USE:

55
O

MFG SERIAL NUMBERS:

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE: PL 10V FWR PWB To PROVIDE A NEW PWB.

KIT NUMBER: REFERENCE:

General Procedures

01/02 6-64

8825/8830 Printer

TAG:
CLASS: USE:

87
O

TAG:
CLASS: USE:

90
M All A/B Switch Enables the Printer to be connected to the XPC and to the 8830 Controller. 98K65670 Spares - 162K41460, 162K41440, 162K28840

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE: PL Firmware Upgrade

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE:

TAG:
CLASS: USE:

88
O

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE: PL Firmware Upgrade

TAG:
CLASS: USE:

89
M

MFG SERIAL NUMBERS: NAME: PURPOSE: KIT NUMBER: REFERENCE: Firmware

8825/8830 Printer

01/02 6-65

General Procedures

01/02 6-66

8825/8830 Printer

7 Wiring Data
Block Schematic Diagrams Level 1 BSD
How To Use BSDs .......................................................................................................... Level 1 BSD .................................................................................................................... 7-3 7-4

Xerographics
BSD 9.1 Charging ........................................................................................................... BSD 9.2 Exposure........................................................................................................... BSD 9.3 Development..................................................................................................... BSD 9.4 Image Transfer and Media Stripping................................................................. BSD 9.5 Drum Cleaning .................................................................................................. BSD 9.6 Drum Discharging ............................................................................................. BSD 9.7 Toner/Developer Dispense ............................................................................... BSD 9.8 Corotron and Developer Bias Power ................................................................ 7-61 7-63 7-64 7-66 7-67 7-69 7-71 7-73 7-75 7-78 7-81 7-84 7-86 7-89

Standby Power
BSD 1.1A Main Power On (With Delta Noise Filter) (50 and 60 HZ) ............................ 7-9 BSD 1.1B Main Power On (With CORCOM Noise Filter) (50 and 60 HZ) .................... 7-11 BSD1.2 Power Generation (1 of 3) (Without Tag/ MOD 25) ........................................... 7-13 BSD 1.2 DC Power Generation (1 of 3) (With TAG/ MOD 25) and (50 Hz With TAG/ MOD 50) 7-16 BSD 1.2 DC Power Generation (1 of 3) (W/ Tag 25 Driver PWB Only) .......................... 7-19 BSD 1.2 DC Power Generation (1 of 3) (With Tag 25 and Updated Driver PWB) .......... 7-22 BSD 1.3 Interlock Monitoring .......................................................................................... 7-25 BSD 1.4 Machine Cooling ............................................................................................... 7-27

Print Transportation and Fusing

BSD 10.1 Fuser Heat (W/ O TAG/ MOD 25 AND 50) ..................................................... BSD 10.1 Fuser Heat (W/TAG25) AND (W/ O TAG 50) ................................................. BSD 10.1 Fuser Heat (W/25 AND TAG 50) .................................................................. BSD 10.2 Fuser Oil Dispensing....................................................................................... BSD 10.3 Fusing and Media Exit ....................................................................................

Mode Control
BSD 2.1 Mode Selection ................................................................................................. 7-29 7-31 7-33 7-35 7-37 7-39 7-41 7-43 7-45 7-47 7-49 7-51 7-53 7-55 7-57

Plug/Jack
Plug/Jack List ..................................................................................................................

Machine Run Control

BSD 3.1 Machine Run Control ........................................................................................

Print Power
BSD 4.1 Fuser Roll Drive ................................................................................................ BSD 4.2 Developer Drive ................................................................................................ BSD 4.3 Drum Drive........................................................................................................

Imaging Imaging (Right Side)

BSD BSD BSD BSD BSD BSD BSD BSD BSD 6.1 Imaging Right Side (W/ O TAGS 27 and 28) (Differential) ............................... 6.1 Imaging Right Side (1 of 2) (With TAGS 27 and 28) (Single Ended) ................ 6.2 Imaging Left Side (1 of 2) (Without TAGS 27 and 28) (Differential) ................. 6.2 Imaging Left Side (1 of 2) (With TAGS 27 and 28) (Single Ended) .................. 7.1 Media Drive....................................................................................................... 7.2 Media Feed, Roll 1............................................................................................ 7.3 Media Feed, Roll 2............................................................................................ 7.4 Media Feed, Roll 3............................................................................................ 7.5 Media Cutting....................................................................................................

Paper Supplying

Paper Feeding
BSD 8.1 Media Registration and Transportation.............................................................

8825/8830 Printer

01/02 7-1

Wiring Data

01/02 7-2

8825/8830 Printer

How To Use BSDs

Normally, you will be directed to a specific BSD, (Block Schematic Diagram) from the Level 1 Entry Procedure. If you have a problem that is not identified in Level 1, then refer to the following Level 1 BSD to determine an entry point for troubleshooting. Note that the Level 1 BSD shows the standard Chains 1, 2, 3, 4, 6, 7, 8, 9, and 10. Each Level 2 BSD is shown within the Level 1 BSD. For example, Chain 6, Imaging, contains two Level 2 Chains: Chain 6.1 Imaging (Right Side) and Chain 6.2, Imaging (Left Side). All of the necessary inputs and outputs for each Chain and for each Level 2 BSD are shown in the Level 1 BSD. For example, if the User Interface is not functioning properly, refer to the Level 1 BSD, Sheet 1, and observe that Chain 2, Mode Selection is the most likely place to start. Then, you should proceed to BSD 2.1 and use that information to diagnose your problem. Each BSD contains the necessary wiring information, physical location of components information, and Diagnostic Code information to assist you in identifying the specific fault. NOTE: In the Block Schematic Diagrams that follow, the term FOR = Forever or unswitched voltage.

8825/8830 Printer

8825/8830 Printer

01/02 7-7

Wiring Data

Level 1 BSD

Wiring Data

Level 1 BSD

01/02 7-8

8825/8830 Printer

BSD 1.1A Main Power On (With Delta Noise Filter) (50 and 60 HZ)

8825/8830 Printer

01/02 7-9

Wiring Data

BSD 1.1A

Wiring Data

BSD 1.1A

01/02 7-10

8825/8830 Printer

BSD 1.1B Main Power On (With CORCOM Noise Filter) (50 and 60 HZ)

8825/8830 Printer

01/02 7-11

Wiring Data

BSD 1.1B

Wiring Data

BSD 1.1B

01/02 7-12

8825/8830 Printer

BSD1.2 Power Generation (1 of 3) (Without Tag/ MOD 25)

8825/8830 Printer

01/02 7-13

Wiring Data

BSD1.2

Wiring Data

BSD1.2

01/02 7-14

8825/8830 Printer

01/02 7-15

Wiring Data

BSD1.2

BSD 1.2 DC Power Generation (1 of 3) (With TAG/ MOD 25) and (50 Hz With TAG/ MOD 50)

Wiring Data

BSD 1.2

01/02 7-16

8825/8830 Printer

01/02 7-17

Wiring Data

BSD 1.2

Wiring Data

BSD 1.2

01/02 7-18

8825/8830 Printer

BSD 1.2 DC Power Generation (1 of 3) (W/ Tag 25 Driver PWB Only)

8825/8830 Printer

01/02 7-19

Wiring Data

BSD 1.2

Wiring Data

BSD 1.2

01/02 7-20

8825/8830 Printer

01/02 7-21

Wiring Data

BSD 1.2

BSD 1.2 DC Power Generation (1 of 3) (With Tag 25 and Updated Driver PWB)

Wiring Data

BSD 1.2

01/02 7-22

8825/8830 Printer

01/02 7-23

Wiring Data

BSD 1.2

Wiring Data

BSD 1.2

01/02 7-24

8825/8830 Printer

BSD 1.3 Interlock Monitoring

8825/8830 Printer

01/02 7-25

Wiring Data

BSD 1.3

Wiring Data

BSD 1.3

01/02 7-26

8825/8830 Printer

BSD 1.4 Machine Cooling

8825/8830 Printer

01/02 7-27

Wiring Data

BSD 1.4

Wiring Data

BSD 1.4

01/02 7-28

8825/8830 Printer

BSD 2.1 Mode Selection

8825/8830 Printer

01/02 7-29

Wiring Data

BSD 2.1

Wiring Data

BSD 2.1

01/02 7-30

8825/8830 Printer

BSD 3.1 Machine Run Control

8825/8830 Printer

01/02 7-31

Wiring Data

BSD 3.1

Wiring Data

BSD 3.1

01/02 7-32

8825/8830 Printer

BSD 4.1 Fuser Roll Drive

8825/8830 Printer

01/02 7-33

Wiring Data

BSD 4.1

Wiring Data

BSD 4.1

01/02 7-34

8825/8830 Printer

BSD 4.2 Developer Drive

8825/8830 Printer

01/02 7-35

Wiring Data

BSD 4.2

Wiring Data

BSD 4.2

01/02 7-36

8825/8830 Printer

BSD 4.3 Drum Drive

8825/8830 Printer

01/02 7-37

Wiring Data

BSD 4.3

Wiring Data

BSD 4.3

01/02 7-38

8825/8830 Printer

BSD 6.1 Imaging Right Side (W/ O TAGS 27 and 28) (Differential)

8825/8830 Printer

01/02 7-39

Wiring Data

BSD 6.1

Wiring Data

BSD 6.1

01/02 7-40

8825/8830 Printer

BSD 6.1 Imaging Right Side (1 of 2) (With TAGS 27 and 28) (Single Ended)

8825/8830 Printer

01/02 7-41

Wiring Data

BSD 6.1

Wiring Data

BSD 6.1

01/02 7-42

8825/8830 Printer

BSD 6.2 Imaging Left Side (1 of 2) (Without TAGS 27 and 28) (Differential)

8825/8830 Printer

01/02 7-43

Wiring Data

BSD 6.2

Wiring Data

BSD 6.2

01/02 7-44

8825/8830 Printer

BSD 6.2 Imaging Left Side (1 of 2) (With TAGS 27 and 28) (Single Ended)

8825/8830 Printer

01/02 7-45

Wiring Data

BSD 6.2

Wiring Data

BSD 6.2

01/02 7-46

8825/8830 Printer

BSD 7.1 Media Drive

8825/8830 Printer

01/02 7-47

Wiring Data

BSD 7.1

Wiring Data

BSD 7.1

01/02 7-48

8825/8830 Printer

BSD 7.2 Media Feed, Roll 1

8825/8830 Printer

01/02 7-49

Wiring Data

BSD 7.2

Wiring Data

BSD 7.2

01/02 7-50

8825/8830 Printer

BSD 7.3 Media Feed, Roll 2

8825/8830 Printer

01/02 7-51

Wiring Data

BSD 7.3

Wiring Data

BSD 7.3

01/02 7-52

8825/8830 Printer

BSD 7.4 Media Feed, Roll 3

8825/8830 Printer

01/02 7-53

Wiring Data

BSD 7.4

Wiring Data

BSD 7.4

01/02 7-54

8825/8830 Printer

BSD 7.5 Media Cutting

8825/8830 Printer

01/02 7-55

Wiring Data

BSD 7.5

Wiring Data

BSD 7.5

01/02 7-56

8825/8830 Printer

BSD 8.1 Media Registration and Transportation

8825/8830 Printer

01/02 7-57

Wiring Data

BSD 8.1

Wiring Data

BSD 8.1

01/02 7-58

8825/8830 Printer

01/02 7-59

Wiring Data

BSD 8.1

Wiring Data

BSD 8.1

01/02 7-60

8825/8830 Printer

BSD 9.1 Charging

8825/8830 Printer

01/02 7-61

Wiring Data

BSD 9.1

Wiring Data

BSD 9.1

01/02 7-62

8825/8830 Printer

BSD 9.2 Exposure

8825/8830 Printer

01/02 7-63

Wiring Data

BSD 9.2

BSD 9.3 Development

Wiring Data

BSD 9.3

01/02 7-64

8825/8830 Printer

8825/8830 Printer

01/02 7-75

Wiring Data

BSD 10.1

Wiring Data

BSD 10.1

01/02 7-76

8825/8830 Printer

01/02 7-77

Wiring Data

BSD 10.1

BSD 10.1 Fuser Heat (W/TAG25) AND (W/ O TAG 50)

Wiring Data

BSD 10.1

01/02 7-78

8825/8830 Printer

01/02 7-79

Wiring Data

BSD 10.1

Wiring Data

BSD 10.1

01/02 7-80

8825/8830 Printer

BSD 10.1 Fuser Heat (W/25 AND TAG 50)

8825/8830 Printer

01/02 7-81

Wiring Data

BSD 10.1

Wiring Data

BSD 10.1

01/02 7-82

8825/8830 Printer

01/02 7-83

Wiring Data

BSD 10.1

BSD 10.2 Fuser Oil Dispensing

Wiring Data

BSD 10.2

01/02 7-84

8825/8830 Printer

01/02 7-85

Wiring Data

BSD 10.2

BSD 10.3 Fusing and Media Exit

Wiring Data

BSD 10.3

01/02 7-86

8825/8830 Printer

01/02 7-87

Wiring Data

BSD 10.3

Wiring Data

BSD 10.3

01/02 7-88

8825/8830 Printer

Plug/Jack List
The following list is provided as an aid in locating plugs and jacks and other components. Refer to the referenced Block Schematic Diagram (BSD) for component location. Table 1 Plug/Jack Plug/Jack or Component A1 A1FL1 A1FL1 A1GFP1 A1K1 A1K3 A1P2/J2 A1P3/J3 A1Q1 A1R1 A1S1 A2P201/J201 A2P202/J202 A2P203/J203 A2P203/J203 A2P204/J204 A2P205/J205 A2P206/J206 A2P207/J207 A2P208/J208 A2P209/J209 A2P210/J210 A2P210/J210 A2P213/J213 A2P214/J214 A2P215/J215 A2P216/J216 A3P301/J301 A3P303/J303 A3P305/J305 A3P306/J306 A3P307A/J307A A3P307B/J307B A3P312/J312 A3P313/J313 A5P1/J1 A5P2/J2 Brief Description AC Module Noise Filter Delta Noise Filter Corcom Ground Fault Protector Fuser Power Relay Fuser Ballast Power Relay AC Power Module Controller Power Cord Fuser Triac Fuser Ballast Resistor Main Power Switch Driver PWB Print Length Meter Driver PWB Cutter Interlock Driver PWB Xerographic HVPS Driver PWB to Main PWB Driver PWB Driver PWB Feed/Rewind Clutches Media Drive Motor Transport Drive Driver PWB (Fuser Control) Driver PWB Driver PWB Driver PWB Main PWB Main PWB Main PWB to Media Buckle Sensor Main PWB Main PWB to Image Bar Assembly Main PWB to Controller Main PWB Main PWB to Driver PWB LVPS LVPS BSD BSD 1.1A BSD 1.1A BSD 1.1B BSD 1.1A BSD 10.1 BSD 10.1 BSD 10.1 BSD 1.1A BSD 10.1 BSD 10.1 BSD 1.1A BSD 7.5 BSD 3.1 BSD 7.5 BSD 7.5 BSD 1.4 BSD 9.1 BSD 3.1 BSD1.2 BSD 1.2 BSD 7.2 BSD 7.1 BSD 8.1 BSD 10.1 BSD 1.2 BSD 4.3 BSD 1.2 BSD 2.1 BSD 9.7 BSD 4.1 BSD 10.1 BSD 6.1 BSD 3.1 BSD 1.2 BSD 3.1 BSD 1.2 BSD 1.2 Plug/Jack or Component A5P3/J3 A7P1/J1 A7P2/J2 A8MOT1P1/J1 A8Q1P1/J1 A20MOT1P1/J1 A20MOT2P1/J1 A20MOT3P1/J1 A21-GRN A21-ORN A21CL1P1/J1 A21Q1P1 A21Q2P1/J1 A21Q5P1/J1 A21Q5P2/J2 A22MOT1P1/J1 A22P1/J1 A22Q1P1/J1 A23DS1P1/J1 A23F1 A23HR1 A23P1/J1 A23P5/J5 A24P1/J1 A24P2/J2 A25P1/J1 A25P2/J2 (CHARGE) A25P3/J3 (GRID) A25P5/J5 (TRANSFER) A25P6/J6 (DETACK) A29CN2/A30P2 A29CN3/A30J3 A29P1/CN1 A29P4/CN4 A30J3/A29CN3 A30P1/J1 A30P2/A29CN2 A32P1/J1 A32P2/J2 CL1P1/J1 CL2P1/J1

Table 1 Plug/Jack Brief Description LVPS Media Drive Motor PWB Media Drive Motor PWB Cutter Drive Motor Cutter Home Sensor Fuser Roll Drive Motor Developer Drive Motor Drum Drive Motor Transfer Current Detack Current Cut Sheet Roll Drive Clutch Media Registration Sensor Sheet Feed Sensor Media Buckle Sensor Media Buckle Sensor Cartridge Drive Motor Developer Assembly Toner Sensor Erase Lamps Thermal Fuse Fuser Heat Rod Fuser Heater Thermistor Pad Assembly Transport Drive Transport Drive Xerographic HVPS Xerographic HVPS Xerographic HVPS Xerographics HVPS Xerographics HVPS LED Driver (Data) LED Driver (Data) LED Drive (Power) LED Driver (Power) LED Driver (Data) Receiver PWB to Main PWB Receiver PWB to LED Driver PWB User Interface PWB to Main PWB Roll 1 Feed Clutch Roll 1 Rewind Clutch BSD BSD 1.2 BSD 7.1 BSD 7.1 BSD 7.5 BSD 7.5 BSD 4.1 BSD 4.2 BSD 4.3 BSD 9.4 BSD 9.4 BSD 8.1 BSD 8.1 BSD 8.1 BSD 4.1 BSD 4.1 BSD 9.7 BSD 9.7 BSD 9.7 BSD 9.6 BSD 10.1 BSD 10.1 BSD 10.1 BSD 10.1 BSD 8.1 BSD 8.1 BSD 9.1 BSD 9.1 BSD 9.1 BSD 9.8 BSD 9.8 BSD 6.1 BSD 6.2 BSD 6.1 BSD 6.2 BSD 6.2 BSD 6.1 BSD 6.1 BSD 2.1 BSD 7.2 BSD 7.2 Wiring Data

User Interface PWB to 2x40 Display BSD 2.1

8825/8830 Printer

01/02 7-89

Plug/Jack List

Table 1 Plug/Jack Plug/Jack or Component CL3P1/J1 CL4P1/J1 CL5P1/J1 CL6P1/J1 MOT1-3 and -4 MOT2-1 and -2 Q1P1/J1 Q2P1/J1 Q3P1/J1 Q4P1/J1 Q5P1/J1 Q6P1/J1 S1 S1 S2 S3 S21 S26 S29 Brief Description Roll 2 Feed Clutch Roll 2 Rewind Clutch Roll 3 Feed Clutch Roll 3 Rewind Clutch Cooling Fan Motor Cooling Fan Motor Roll 1 Position Sensor Roll 2 Position Sensor Roll 3 Position Sensor Roll 1 Motion Sensor Roll 2 Motion Sensor Roll 3 Motion Sensor Cutter Cover Interlock Switch Drawer 1 Reed Switch Drawer 2 Reed Switch Drawer 3 Reed Switch Front Door Interlock Switch Top Cover Interlock Switch Feed Shelf Interlock Switch BSD BSD 7.3 BSD 7.3 BSD 7.4 BSD 7.4 BSD 1.4 BSD 1.4 BSD 7.2 BSD 7.3 BSD 7.4 BSD 7.2 BSD 7.3 BSD 7.4 BSD 1.3 BSD 7.1 BSD 7.1 BSD 7.1 BSD 1.3 BSD 1.3 BSD 1.2

Wiring Data

Plug/Jack List

01/02 7-90

8825/8830 Printer

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