Tektronix PHASER 380 Service Manual Download Page 1 | Manualshive

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Service Manual

Phaser

®

380

Color Printer

Warning
The following servicing instructions are for
use by qualified service personnel only. To
avoid personal injury, do not perform any
servicing other than that contained in
operating instructions unless you are qualified
to do so.

This printing June 1999
070-9661-00

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Summary of Contents for PHASER 380

Page 1: ...llowing servicing instructions are for use by qualified service personnel only To avoid personal injury do not perform any servicing other than that contained in operating instructions unless you are...

Page 2: ...ies Micronta is a registered trademark of Radio Shack Microsoft and Microsoft Windows are registered trademarks of Microsoft Corporation Novell and NetWare are registered trademarks of Novell Inc OS 2...

Page 3: ...he product into a power source Terms on product CAUTION A personal injury hazard exists that may not be apparent For example a panel may cover the hazardous area Also applies to a hazard to property i...

Page 4: ...ch exposed connections and components while power is on Disconnect power before removing the power supply shield soldering or replacing components Do not wear jewelry Remove jewelry prior to servicing...

Page 5: ...Networked connection to a PC using the printer s Ethernet port 2 11 Connecting the printer to a workstation 2 11 Direct connection to a workstation 2 11 Networked connection to a workstation 2 11 Ins...

Page 6: ...the printer 2 42 NDS method 2 42 Bindery method 2 42 Configuring TCP IP on a UNIX host 2 43 3 Verifying the Printer and Host Connections Verifying printing from a PC 3 1 Direct DOS connection verifica...

Page 7: ...onix Color Printer Information Server 4 7 Using the automated fax systems 4 8 Customer Support Hotline 4 9 Service support 4 10 Accessing the printer s web page 4 10 5 Theory of Operation Overview 5 1...

Page 8: ...Troubleshooting System power up sequence 6 1 Print engine troubleshooting 6 4 Verifying main board CPU operation 6 4 Verifying print engine operation by using its test print 6 6 Verifying power suppl...

Page 9: ...Error codes and messages 6 16 PC based diagnostics 6 24 Requirements 6 24 Starting the diagnostics 6 25 Selecting tests 6 28 Running tests 6 30 Saving and restoring test selections 6 34 Saving and re...

Page 10: ...the lower pick roller manually 7 21 Cleaning the lower tray paper feed rollers 7 21 Moving the printer 7 23 Wait 45 minutes after power off before moving 7 23 Removing the maintenance tray 7 23 Locki...

Page 11: ...er finger assemblies 8 51 Rollers 8 53 Exit roller 8 53 Lower feed roller assembly and lower feed roller electric clutch 8 55 Pick roller and pick roller solenoid clutch 8 57 Maintenance tray cam roll...

Page 12: ...drive belts 9 12 Paper pick adjustment 9 13 X axis rails to drum parallelism adjustment 9 14 Printhead to drum spacing adjustment 9 16 Transfix roller pressure spring adjustment 9 18 Drum position en...

Page 13: ...onal Ethernet card 1 14 Figure 1 13 Printer front panel 1 15 Figure 2 1 The printer packaging 2 7 Figure 2 2 Unlocking the transit restraint lock 2 8 Figure 2 3 Connecting a SCSI hard disk drive to a...

Page 14: ...6 11 The Fault History 6 34 Figure 7 1 Removing the separator pad 7 2 Figure 7 2 Removing the separator pad 7 3 Figure 7 3 Light stripes in a print 7 5 Figure 7 4 Light stripes test print 7 6 Figure...

Page 15: ...8 24 Figure 8 18 Removing the pressure springs and transfix roller 8 27 Figure 8 19 Removing the drum transfix assembly left side 8 29 Figure 8 20 Removing the drum transfix assembly right side 8 31...

Page 16: ...g process motor belt tension 9 7 Figure 9 4 Setting the Y axis belt tension 9 9 Figure 9 5 Aligning the cap wipe purge unit to the printhead 9 11 Figure 9 6 Tensioning the cap wipe purge assembly driv...

Page 17: ...7 Figure C 1 Print engine wiring diagram C 1 Figure C 2 Wire dressing around the front right of the printer C 2 Figure C 3 Wire dressing around the rear right of the printer C 2 Figure C 4 Wire dress...

Page 18: ...s 6 5 Table 6 3 Power supply test point on the power control board 6 8 Table 6 4 Motor and solenoid resistances 6 10 Table 6 5 Front panel and fault history log error codes and messages 6 16 Table 6 6...

Page 19: ...rmation on installing and verifying the printer and training printer customers as a part of the Option S0 printer installation procedure The latter half of the manual includes troubleshooting guides a...

Page 20: ...24 Mbytes of standard RAM Both printers features a 250 sheet Universal paper tray An optional Lower Tray Assembly is available which gives the printer a dual tray capability The Lower Paper Tray Assem...

Page 21: ...Memory considerations There are four basic printer configurations With the addition of the Extended Feature ROM SIMM the printer receives 69 on board fonts Check Print and PhaserMatch capabilities Mo...

Page 22: ...ssemblies Figure 1 2 Internal features of the print engine Ink load assembly Print head Cap wipe purge unit raised position Drum Transfix roller Process motor Paper preheater Media width sensor assemb...

Page 23: ...front panel solenoids and sensors The main board contains the printer s two CPU processors a 29K processor which executes the PostScript image processing and a 68K processor which controls the print...

Page 24: ...1 6 Phaser 380 Color Printer 1 General Information Figure 1 4 Circuit boards of the print engine left front view I O board 1 Power supply Main board Network card Power control board 9661 53...

Page 25: ...ontrol board Through this single bus the main board can poll the I O boards for the state of the printer s sensors as well as actuate the printer s solenoids This data bus greatly simplifies the wirin...

Page 26: ...e printhead faceplate and clear clogs from the printhead nozzles The system consists of a vacuum pump a vacuum accumulator a solenoid valve and a cap wipe purge assembly Figure 1 6 Printhead maintenan...

Page 27: ...of many other assemblies such as the printhead paper preheater and the drum Figure 1 7 Left side sensors and switches on the print engine Ink stick low sensor Preheater exit sensor Ink stick out senso...

Page 28: ...ight side sensors and switches on the print engine Paper exit sensor Printhead lock sensor Exit cover open sensor Maintenance tray blade position sensor Cap wipe purge assembly home sensor Media type...

Page 29: ...Figure 1 9 Solenoids and clutches on the print engine Head tilt solenoid Transfix cam solenoid Air valve Maintenance tray electric clutch Paper pick solenoid clutch Lower feed roller electric clutch...

Page 30: ...ia tray indicating the type of media in the tray Another set of sensors on the media size board detect the position of the paper back stop to determine the length of the media The media width sensor l...

Page 31: ...is located next to the main processor of the main board Next to it are the two optional RAM SIMMs which may be 8 16 or 32 Mbyte RAM SIMMs Network connection is provided through the plug in network ca...

Page 32: ...normally Both LEDs blink irregularly during diagnostics If a soft error occurs the image processor s 29K operates but in a reduced capacity Soft failures include failure of expansion memory SIMMs or a...

Page 33: ...interactive menu has two modes review and modify Customers can review and modify certain NVRAM I O ports and peripheral parameters Using the front panel to review and change parameters is discussed in...

Page 34: ...wer Paper Tray Assembly Table 1 3 Printer clearances Clearances Value Top 46 cm 18 ins Left 10 cm 4 ins Right 10 cm 4 ins Front Unrestricted to replace trays and clear paper jams Rear 10 cm 4 ins Bott...

Page 35: ...Standard mode 48 seconds per print Enhanced mode The time it takes from loading to ejecting on Tabloid Maximum size paper 30 seconds per print Fast Color Mode mode 46 seconds per print Standard mode...

Page 36: ...5 watts during Energy Star mode Current rating 115 VAC configuration 12 amp max 1 amp min 220 VAC configuration 6 amp max 1 amp min Fusing F1 DC switcher 6 3 amp slo blo F2 Drum heater 1 reservoir hea...

Page 37: ...ration Non operating shock Operating shock Will withstand 0 15G excitation 5 to500 Hz 3 axes for up to 10 minutes with no impairment or subsequent damage 0 5 g 25 minute sweep 5 500 Hz 100 200 sec swe...

Page 38: ...VAC equipment EN55022 CISPR 22 Class B VCCI CISPR 22 Class B The packaged product meets National Safe Transit Committee Test Procedures Listed UL 1950 Information Technology Equipment Certified to CS...

Page 39: ...ce such as network system administration will be available for the scheduled installation and that all necessary cables will be available Unpacking This is the procedure for taking the printer out of...

Page 40: ..._ Which type of host to printer connection will be used serial parallel network What kind of network environment will the printer be installed into Hardware Protocols LocalTalk EtherTalk Token Ring TC...

Page 41: ...t power cord _______ U S Standard 161 0230 01 _______ European Option A1 161 0104 06 _______ United Kingdom Option A2 161 0066 10 _______ Australian Option A3 161 0104 05 _______ Swiss Option A5 161 0...

Page 42: ...l the paper tray The extra height is to install the ink sticks Weight support 90 kgs 200 lbs Weight support 115 kgs 255 lbs with lower feeder installed Driver software must be installed on the host co...

Page 43: ...ek com for the latest information regarding installing servicing and supporting the printer Additionally you can access the Tektronix Highly Automated Library HAL during business hours at 1 800 835 61...

Page 44: ...lope includes a printer registration card Cleaning kit Supplies information sheet Ink sticks Maintenance tray Paper sampler User manual Installation instructions Phaser printing utilities and driver d...

Page 45: ...Service Manual 2 7 Installing the Printer and Drivers 2 Figure 2 1 The printer packaging 220 lbs 100 kg 9661 62...

Page 46: ...lace it in its working location If the Lower Paper Tray Assembly was also purchased place the Lower Paper Tray Assembly in the working location and then install the printer on top of it 2 Install the...

Page 47: ...ork Interface plug in cards The LocalTalk Serial Card supports AppleTalk LocalTalk protocols and RS 232 serial connectors The Ethernet Interface Card supports the EtherTalk Novell NetWare and TCP IP p...

Page 48: ...alTalk port The port has a printer icon printed next to it Attach the other end to the printer s LocalTalk port For a LocalTalk network connection attach the network adapter to the printer s LocalTalk...

Page 49: ...network in the same manner as workstations using an Ethernet connection 1 Turn off the printer 2 Connect the interface cable to the printer s Ethernet connector 3 Turn on the printer Connecting the p...

Page 50: ...n SCSI connector to the smaller high density SCSI connector on the printer s rear panel 3 Attach the other end of the SCSI cable to the SCSI drive 4 Attach a terminator to the SCSI drive s second conn...

Page 51: ...ation s SCSI cable to the printer s SCSI port The SCSI drive may require the SCSI cable part numbered 013 1465 00 to connect the drive s standard 50 pin SCSI connector to the smaller high density SCSI...

Page 52: ...startup page provides valuable information about the printer Fonts Ports Serial Parallel LocalTalk Ethernet Printer name Ethernet protocols TekColor corrections and print quality mode Pages printed R...

Page 53: ...and total memory Color settings such as Vivid Color Serial port settings if installed Parallel port settings LocalTalk port settings if installed EtherTalk settings if installed TCP IP settings if in...

Page 54: ...hours 0 means unlimited amount of time Media tray Indicates the default media tray yes Upper Lower Auto RAM memory Total amount of RAM on the image processor board no 16 MBytes 24 48 or 64 Mbytes Col...

Page 55: ...ial port interpreter Indicates the type of interpreters in use at the port yes PostScript Level 2 Not installed Disabled interpreter Serial port encoding Data byte encoding for communication yes ASCII...

Page 56: ...data Transparent no source routing SourceRoute use source routing All Routes Broadcast The printer sends response packets back to the host indicating all possible routes to the printer yes False True...

Page 57: ...set to True Network Mask Indicates which fields of the IP Address designates the network portion and which designates the node portion If null the mask will be determined from the printer s IP address...

Page 58: ...to send data The actual window size is established when the connection is made and may be smaller to accommodate the host yes 0 1024 through 59392 Syslog Protocol that acts as a remote front panel to...

Page 59: ...If enabled the printer sends a trap for SNMP authentication failure yes Enabled Disabled HTTP Indicates if HTTP support has been enabled yes Enabled Disabled Auto Transmit Enabled Disabled Local URL A...

Page 60: ...ng 1 Insert either the printer s CD ROM or the first Macintosh diskette into the appropriate drive on your computer 2 Double click the Phaser 380 Installer icon Click Continue until the Easy Install w...

Page 61: ...selected in the Chooser 5 Close the Chooser Setting up the Apple LaserWriter 8 printer driver 1 Select Chooser from the Apple menu after installing the printer s software 2 Click on the icon of the La...

Page 62: ...ck on the Zone for your printer See your network administrator if you have questions 4 Select your printer from the list of printers on the right side of the Chooser If it is not in the list check you...

Page 63: ...e two introduction screens in the Installer 5 In the Select Installation Type dialog box select either Easy Installation or Custom Installation and click Next Easy Installation Custom Installation The...

Page 64: ...OM or diskette and click OK 11 Select the printer and click Next 12 Tektronix Phaser 380 standard printer configuration 13 Tektronix Phaser 380 Extended Extended Features option If you are not sure of...

Page 65: ...g box click Have Disk 11 Type in the drive for the CD ROM or diskette and click OK Easy Installation Custom Installation The following files are copied to the hard disk QuarkXPress PDF installs an app...

Page 66: ...rtup page for Extended Features Yes or No 13 Enter a name for the printer and select the Phaser 380 as the default printer if desired and click Next 14 Determine if the printer is to be shared Shared...

Page 67: ...Custom Install The following files are copied to the hard disk QuarkXPress PDF installs an application specific printer description file PhaserPrint Plug in for Photoshop installs an application spec...

Page 68: ...configuration If you are not sure of the printers s version check the printer s startup page for Extended Features Yes or No 11 In the Create Printer dialog box fill in the other fields as desired th...

Page 69: ...r Custom Installation 1 In the Driver Installation dialog box select from the following options Drivers PPDs installs driver files and printer description files QuarkXPress PDF installs an application...

Page 70: ...instructions If you selected the AdobePS 3 Driver for Windows 3 1 in the Custom Installation continue with the following instructions 1 In the Adobe installer click Read or Skip in the README WRI dia...

Page 71: ...t Create a new printer in the Print Manager select the appropriate printer driver 2 Select Other in the Print to field of the From the Printer Properties dialog box 3 Select LPR Port for Available Pri...

Page 72: ...Print Manager select the appropriate printer driver 2 Select Other in the Print to field of the From the Printer Properties dialog box 3 Select AppleTalk Printing Devices for Available Print Monitors...

Page 73: ...1 If this is a locally connected printer click on the port that the printer is connected to LPTx Parallel printer connection COM Serial connected printer Add Port Networked printer For mixed environme...

Page 74: ...appropriate box to use this printer as the default Click Next 11 Check one of the following options then click Next Shared To share the printer on the network click on all platforms that may use this...

Page 75: ...on specific files Mount the printer s PC diskette 1 and copy the files to your workstation s hard drive Access the Tektronix anonymous ftp site on the Internet at ftp tek com Download utility files fr...

Page 76: ...the snippet is available on the Tektronix web page bulletin board and the printer s CD ROM To check or set the printer s IP address 1 Press the front panel s Menu button and scroll to the menu item Ne...

Page 77: ...bits to 2 and the baud rate to 9600 In the example below the changes are persistent across print jobs and across power cycles they remain in effect until specifically changed again CTRL D systemdict l...

Page 78: ...and to send DEVPARAM PS to the printer for example COPY DEVPARAM PS COM1 Substitute the appropriate port for COM1 3 Similarly use the DOS COPY command to send CTRLD PS to the printer Table 2 2 Values...

Page 79: ...inter s print server name is displayed The default name is TEKxxxxxx where xxxxxx is the last six hex digits of the printer s Ethernet address Select the printer If the printer is not displayed refer...

Page 80: ...ation Tool ACT onto the file server through a workstation 2 Log on to a file server as supervisor with supervisor privileges 3 Run ACT and select Quick Configuration 4 Enter the print server name TEKx...

Page 81: ...d add a spool directory for example to usr spool lpr For System V hosts configure the queue as a remote BSD print queue support for TCP IP LPR is required Note Some UNIX hosts report an error when you...

Page 82: ...g the front panel on page 2 38 FTP An ftp session is opened with the ftp command followed by the printer s IP address The put command is used to send the file sample file ps to the printer The bye com...

Page 83: ...rcase the following echo showpage port Substitute port with LPT1 LPT2 or COM1 etc or whichever corresponds to the port the printer is attached to The printer should respond by picking processing and e...

Page 84: ...ssories icon 4 Double click on the Write icon If Write is not available you can use any other text editor type program 5 Type in a line of text such as THIS IS A TEST 6 Click the File menu item and se...

Page 85: ...turn finds all file servers with Phaser 380 queues and extracts its print files from them You must determine if a computer can communicate a print file to the file server Generally as outlined in the...

Page 86: ...e name 3 Then type echo showpage LPT1 Using the Error Handler utility If the PC does not print to the printer reset the printer and then load the error handling utility into the printer s memory using...

Page 87: ...f the dialog box are icons representing the printer drivers installed on the Macintosh Select the driver icon Phaser 380 by clicking on it once If the host and the printer are a part of a zone you sho...

Page 88: ...to the printer This verifies that the Macintosh and the printer driver can send a file to the printer If the printer does not make a print then there may be a problem with the printer driver In this c...

Page 89: ...inter s memory using the front panel menu item Printer Defaults PS Error Handler Alternatively reset the printer and then download one of the Tek Error Handler utility files to the printer or enable t...

Page 90: ...m the host you must first have the printer s queue established This is site dependent and requires the aid of the site s network administrator After the queue is in place you can proceed to the next s...

Page 91: ...queue name is the printer s queue and file nam is any PostScript file Using the Error Handler utility If the workstation host does not print to the printer reset the printer and then load the error h...

Page 92: ......

Page 93: ...vers the last portion of the Tektronix Service Option S0 installation Training the printer s key operator The steps you follow here place an emphasis on encouraging the key operator to read and use th...

Page 94: ...ons and how they correspond to the display Error reporting Explain how error conditions are displayed on the front panel Show where error conditions are explained in the user manual and Quick Referenc...

Page 95: ...should be fed using the same prompt to avoid jams at the manual feeder Explain the advantages of purchasing a separate dedicated transparency tray and a Lower Paper Tray Assembly Show where media load...

Page 96: ...ams inside the exit cover inside the front cover at the manual feed slot at the media tray Show the location of the jam clearing information in the user manual Duplex printing Explain to the customer...

Page 97: ...y is tipped or left tilted Due to the weight of the printer emphasize the need to use four people to move the printer Explain the use of the retractable handles for moving the printer Warranty informa...

Page 98: ...Norway 800 11782 Spain 900 97 4499 Sweden 020 795 177 Switzerland 155 9493 The Netherlands 06 0221647 UK 0800 558668 Monday through Friday 6 00 am to 5 00 pm PST Printer service U S and Canada 1 800 8...

Page 99: ...print quality modes color correction modes and other features If you don t have the means of transferring these files from the PC diskette you can request files from the Tektronix Color Printer Infor...

Page 100: ...ore calling instruct customers to write down the area code and telephone number for customers fax machine HAL will ask customers to key this number through the keypad on their voice telephone If they...

Page 101: ...le using their printer they can call toll free at 1 800 835 6100 ask for the Customer Support Hotline The Hotline can answer technical question regarding using the printer ranging from printing from a...

Page 102: ...printer s web page PhaserLink the Tektronix implementation of a World Wide Web server inside the printer allows a customer to communicate to the printer using a web browser With PhaserLink a customer...

Page 103: ...ion of each subsystem within the printer Functional block diagram Printer electronics Printhead X axis system Cap wipe purge assembly Drum transfix assembly Drum maintenance tray Ink loader Paper preh...

Page 104: ...ap wipe purge assembly Drum transfix assembly Drum maintenance tray Ink loader Paper preheater Media width unit Paper tray Exit unit Power supply Figure 5 1 Overview of the printer 9661 67 Transfix ro...

Page 105: ...and 68330 self tests are stored in ROM Stored engine parameters are saved in EEPROM A digital motion control DMC ASIC controls the I2C Inter Integrated Circuit bus which links all the printer sensors...

Page 106: ...under the control of the digital motion control ASIC of the main board In addition is functions as a motherboard or interconnect for the power supply main board printhead network card and I O boards...

Page 107: ...rd card provides a Token Ring interface supporting Novel NetWare TokenTalk and TCP IP Table 5 1 I O board functions I O board 1 left side of printer I O board 2 lower right side of printer I O board 3...

Page 108: ...s means if the print engine firmware should fail the heaters automatically shut off The printer is also protected by five thermal fuses located inside these assemblies the drum heater the printhead s...

Page 109: ...V 12V 12V Drum heater 1 Reservoir heater 1 Black ink melter Magenta ink melter Cyan ink melter Yellow ink melter Jet stack left Paper pre heater Jet stack right Reservoir heater 2 Triac control lines...

Page 110: ...e printhead face the nozzles are arranged in four rows with the yellows nozzles forming the top row the magenta nozzles forming the next row 24 pixels below and the cyan row forming the third row 24 p...

Page 111: ...er end of the arm is a cam following bearing The bearing rides in a cam shaped groove in the head tilt cam gear As the gear rotates the arm follows the motion and tilts back the printhead The printhea...

Page 112: ...y when manually actuated which locks the printhead in its tilted back position There is a mechanical interlock which prohibits the X axis from disengaging the head tilt arm when the printhead is tilte...

Page 113: ...exible split metal band which attaches to each end of a frame supporting the printhead As the capstan turns it moves the printhead along a pair of X axis rails parallel to the axis of the drum Two ste...

Page 114: ...he wipe and purge operations The cap wipe purge assembly is attached to a pair of parallel belts on a rotating shaft To perform a printhead maintenance cycle the printhead is first tilted away from th...

Page 115: ...ubbles out of the printhead nozzles With the air valve once again de energized air is metered through the 7 mil orifice to gradually release the vacuum at the faceplate Figure 5 8 The cap wipe purge a...

Page 116: ...uch more slowly and the transfix roller The transfix cam solenoid on I O board 3 is energized to release the spring loaded eccentric shaft cam to engage the transfix gear The process gear drives the t...

Page 117: ...rom the drum drive system it uses a closed loop drive system This closed loop servo drive system is dangerous since the motor torque increases if it senses the drum slowing down Fingers caught in the...

Page 118: ...e always open when the maintenance tray is installed in the printer The oil can leak out if the printer does not remain level Prior to each print a cam driven by the process motor raises the wick agai...

Page 119: ...when to activate the ink melters As ink is required by the printhead the printer positions the printhead under the ink loader Once the printhead is positioned the appropriate color s melting element...

Page 120: ...dth sensor detects grossly skewed media If such conditions arise the print job is aborted to prevent any of the latent image on the drum from being inadvertently transferred onto the transfix pressure...

Page 121: ...of media as it travels from the paper tray to the exit tray Figure 5 12 The paper path Upper feed rollers Media width sensor Paper pick handfeed sensor Lower feed rollers Exit rollers Transfix roller...

Page 122: ...e compound gear drives the head tilt cam gear clockwise A cam follower mounted on the lower end of the head tilt arm follows a groove in the inside surface of the rotating cam gear tilting the printhe...

Page 123: ...re 5 13 Tilting the printhead 9661 83 Head tilt cam gear Head tilt cam gear latched by head tilt solenoid Head tilt cam gear disengaged from drive gear Head tilt solenoid Process motor Process drive b...

Page 124: ...rd to the paper preheater Measurement Having detected the leading edge of the paper the media width sensor driven by the media width sensor motor through a screw drive travels to the left until it det...

Page 125: ...ositioning for transfixing Paper pick solenoid Lower feed roller electric clutch Upper feed roller electric clutch Lower feed roller Upper feed roller Pick roller Pick roller clutch 9661 87 Upper feed...

Page 126: ...nergized clutch holds the camshaft in this position As the drum nears the end of its rotation the maintenance cam electric clutch energizes for a moment allowing the camshaft to rotate further this lo...

Page 127: ...aration for printing Drum Drum Cam pushes wick and blade against drum Cam lowers wick but leaves blade against drum 9661 84 Maintenance tray electric clutch Camshaft home position flag Drum maintenanc...

Page 128: ...ep 4 columns to the right print 9th column step 4 columns to the right Repeat until 7 columns are laid down total of 14 so far 4 Step 1 additional column to the right 5 Print the 15th column step 4 co...

Page 129: ...ps spread over a 224 pixel wide field The drum rotates 56 times to receive the pixel columns The same interlace method is used except 14 pixel columns are printed between the intermediate 2 step 1 ste...

Page 130: ...uced by four adjacent jets are interlaced together for 300 dpi printing Each jet produces 28 pixel columns For 600 dpi printing each jet produces 56 pixel columns Columns of pixel dots produced by pre...

Page 131: ...can on the drum Jets columns 1 through 71 deposit the left half scan Jet 18 through 20 of the right side scan interleave with jet columns 69 through 71 of the left side scan to seamlessly join the two...

Page 132: ...proper position as detected by the compound gear position sensor the transfix cam solenoid located on I O board 3 energizes to release the spring loaded transfix cam on the right end of the transfix...

Page 133: ...drum by additional rotation of the process motor until the transfix cam is once again captured by the transfix cam solenoid The rotating drum driving the exit rollers pushes the remainder of the sheet...

Page 134: ...detected the transfix operation is aborted and a paper jam is reported After the user removes the jammed media a chase sheet is passed through the printer to remove the image from the drum As the tra...

Page 135: ...nance cycle Paper preheater cleaning Transfix roller oiling Pick roller cleaning Drum cleaning chase page Printhead maintenance cycle This topic describes the cleaning cycles used to clean jets of bub...

Page 136: ...faceplate to the vacuum The vacuum bleeds off after about 8 seconds through a 7 mil orifice on the air vale Then the printhead is tilted backward to break the seal and the printer waits for 10 second...

Page 137: ...the cap wipe purge assembly is stored in its standby position Then the printhead is tilted forward into its print position and a flush page is printed The flush page allows each jet to eject ink that...

Page 138: ...ser a chance to continue or cancel 2 If continued the printer heats the paper preheater to 110o C softening ink trapped inside the paper preheater Ordinarily the paper preheater runs at temperatures o...

Page 139: ...as it would be during a print cycle Then the transfix roller is lowered against the drum and the drum rotates this transfers the oil to the transfix roller then the transfix roller is raised to its st...

Page 140: ...drum and home the drum maintenance system 6 If the print engine was performing head maintenance stop jet firing pump and cap motion Tilt the head to its standby position Return the cap wipe purge uni...

Page 141: ...ead and the cap wipe purge assembly Power switch turned on 1 Low level power on self test POST diagnostics are performed by both the print engine 68K and PostScript 29K processors The two status LEDs...

Page 142: ...lready forward rotate all the rollers to their ready positions disengage the transfix roller and lower the maintenance tray blade and wiper g The printhead is moved to its X axis home position and the...

Page 143: ...stall the motors 6 The printhead is tilted back to the standby position 7 The front panel displays a warm up message 8 The heaters are enabled and the drum begins to rotate 9 After the printhead reac...

Page 144: ...s encoded as a series of short flashes representing 1 through 4 or a long flash representing 5 followed by 1 or 2 short flashes representing 6 or 7 The possible LED encoded error codes are listed here...

Page 145: ...rn Table 6 2 68K processor power up self test error codes Right LED flashes Long flash 5 Short flash 1 3L 1S 16 Meaning 1 CPU Interrupt 2 Instruction ROM Data Bus 3 Instruction ROM Checksum 4 SRAM Val...

Page 146: ...sections the AC section used for heaters and the DC section for control logic printhead drivers and motors Verifying the power supply involves five steps Checking for proper AC voltage Inspecting the...

Page 147: ...e printer and remove the power cord 2 Remove the four screws securing the power supply Pull out the power supply 3 With a VOM determine that the fuse F1 is functional If the fuse is good but the print...

Page 148: ...e fluctuating intermediate value less than 30 Hz 2 DC Output Refer to test points located along top edge of the power control board These points are listed in the above table If you do not measure the...

Page 149: ...s failed Checking the motors and solenoids reduces the change that a driver will be damaged by a defective motor 3 Disconnect the two I2C bus cables J108 and J206 from the power control board this iso...

Page 150: ...general if you measure any low resistance from a motor winding to ground while the motor is installed replace that motor Table 6 4 Motor and solenoid resistances Motor or solenoid Resistance approxima...

Page 151: ...aper trays For manual feeding use 16 32 lb Bond 60 120 g m2 or 50 80 lb Cover 135 220 gm2 Paper pick errors Paper pick errors occur when the media in the paper tray mispicks or the printer double pick...

Page 152: ...tics on page 6 24 If the sensor fails the test replace the paper pre heater 2 Inspect the process idler rollers on the left side of the printer they should rotate freely 3 Inspect the wiring harness l...

Page 153: ...d smoothly and evenly 4 Check the upper and lower feed rollers operate correctly Also make sure that the front door is properly closed 5 Test the media width sensor assembly using the diagnostics disc...

Page 154: ...adjusted Scratches in the transparency parallel to the long axis of printing 1 Usually caused by foreign debris in the paper path Run a transparency through the manual feed to see if the scratch appea...

Page 155: ...connector leading to the printhead 2 Run PC based diagnostics 3 Replace the power control board 4 Replace the printhead Printing too light or too dark 1 Perform the procedure Adjustments on page 9 6 I...

Page 156: ...4 004 43 0x2404 PC_DEV_FAULT_HEAD_CHECK SUM Printhead NVRAM checksum failure the data within the printhead NVRAM has been corrupted Check the hardware The printhead may need to be renormalized a manuf...

Page 157: ...ensors indicate that media is in the paper path at an unexpected time Remove the media If no media is present check for a stuck or defective paper path sensor 4 080 36 0x2350 PC_JAM_X_OFFSET_ STD_TRAY...

Page 158: ...n The sensor has failed the motor control is moving the printhead in the wrong direction or the user has engaged the printhead restraint mechanism 6 003 44 0x3803 XA_FAULT_LOST A verify of the home ca...

Page 159: ...eck for sticky or defective sensors Check for a defective media width sensor mechanism 7 005 47 0x3c05 PM_FAULT_ECC_NOT_HOME The eccentric roller was not home when a command requiring it to be home wa...

Page 160: ...block in it s linked list The block was not found We have no explanation for this behavior 11 013 30 0x5b0d DMC_STATUS_STD_TRAY_ TYPE_AJAR Jam The specified tray was removed during a print or drum cl...

Page 161: ...7 47 0x6c11 TCH_JS_RIGHT_OPEN The thermistor in the right jetstack appears to be open Replace the printhead 13 018 48 0x6c12 TCH_JS_RIGHT_SHORT The thermistor in the right jetstack appears to be short...

Page 162: ...open Replace the paper preheater 16 002 44 0x8402 TCP_THERMISTOR_SHORT The preheater thermistor appears to be shorted Replace the paper preheater 16 003 45 0x8403 TCP_THERMISTOR_HOT The preheater hea...

Page 163: ...24 021 11 Engine is stuck while cooling down 24 022 12 Engine is stuck while in cool state 24 023 13 Engine is stuck while in printhead adjust state 24 024 14 Engine is stuck while flushing the print...

Page 164: ...ortable computer in use by the field service organization Requirements Printer serial cable adapter level shifter part number 174 3493 00 For PCs use serial null modem cable part number 012 1535 00 Fo...

Page 165: ...ntosh plug the serial cable from the printer into the Mac s serial port marked Modem 2 Service switch Push down the service mode dip switch The switch is the left most of the two dip switches on the r...

Page 166: ...ired version diagnostic software Launch the diagnostics program by typing DIAGS xxx where xxx is the engine ROM version Once launched the program repeatedly attempts to communicate with the printer Th...

Page 167: ...field it contains descriptive text summarizing the operation of tests in progress and of the diagnostics program itself Next is the completion indicator When downloading test files to the printer thi...

Page 168: ...PgDn move the display of tests one screen full at a time The highlight generally stays in place on the screen so this also changes the highlighted test In the Individual Test column Up Down arrows mov...

Page 169: ...Press Escape or Enter to make it go away F1 Brings up a more complete description about the currently highlighted test Esc and Enter Return either key replaces the selection screen with the current st...

Page 170: ...ile has been loaded A different message is issued for ROM resident 29K processor image processor tests and there is no downloading 1 Press the Return key to enter the test group selection window Choos...

Page 171: ...s as you like 4 Once selected press Ctrl R to start the test s Depending on the test a screen may be displayed to modify how the tests run The solenoid test shown above allows you to selectively actua...

Page 172: ...ighting an individual test to display a help message that describes the test The Sensor Test shows you the real time state of the printer s sensors You can manually interrupt the sensors to determine...

Page 173: ...mple graphic of a vertical bar between two brackets show that the temperature is within its expected range If the symbol is replaced by a or outside the bracket the temperature is too cold or too hot...

Page 174: ...er The result of loading a saved test selection file is exactly the same as if the settings were re specified manually It provides a way to pre select tests for particular audiences Default file name...

Page 175: ...e 29K processor 68K Tests switch to the 68K window to show results of test running on the 68K processor Erase Screen erases all the characters from the currently selected window it has no affect on th...

Page 176: ...rrent test selections in a particular file eXit Alt X exit the diagnostic program Options Menu Provides for customizing of program operation This menu contains some sub menus Communications provide fo...

Page 177: ...re that the correct Phaser 380 icon was selected in the Chooser Try printing the job again In the Chooser switch background printing to off Try printing the job again Enable the Error Handler and try...

Page 178: ...r the correct port This turns on printer retry indefinitely Is the printer in PostScript mode Check this by sending the file TESTHPGL PLT located on the Tektronix Utilities diskette HP GL directory to...

Page 179: ...s this option select Printer Setup Options Printer Features Media Selection You are now at the TekColor Options window select Vivid Color This TekColor Options window can also be accessed through the...

Page 180: ...startup page had been turned off Soft errors include failures of the expansion SIMMs as well as the SCSI serial LocalTalk parallel and Ethernet ports and their cabling or connections Table 6 11 Workst...

Page 181: ...ollowing symptoms occur Light stripes or missing colors appear in prints Ink smears or random streaks appear on the front or back of prints Oily spots appear along the top of prints Mispicks or multip...

Page 182: ...eplace the media tray separator pad A visible wear pattern on the separator pad is also an indication that it is time to replace it A replacement separator pad and installation instructions are includ...

Page 183: ...or pad and install the new replacement separator pad An alignment guide on the separator pad assembly ensures proper installation 6 Replace media into the tray and install the tray into the printer Fi...

Page 184: ...best to use the purest isopropyl alcohol 99 available You can use 90 pure isopropyl alcohol but if you do you must wait after cleaning to make sure that printer parts are completely dry 99 isopropyl a...

Page 185: ...eady message or the printer s name appears press the Clean button The printer displays the first selection in the menu Clean Light Stripes Clean Test 2 Press the Clean button once again 3 A series of...

Page 186: ...ning service is required Figure 7 4 Light stripes test print 9661 139 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47...

Page 187: ...en the printer is on and the Ready message or the printer s name appears press the Clean button The printer displays the first selection in the menu Clean Light Stripes Clean Test 2 Press the left arr...

Page 188: ...eration by pressing the Exit button If the ink smears problem persists after running clean sheets of paper through the paper path refer to the following two procedures for directions on cleaning paper...

Page 189: ...Light Stripes Clean Test 2 Press the left arrow button until the following message appears Clean Feed Rollers Cancel Menu 3 Press the Clean button and the following message appears Clean Upper Feed R...

Page 190: ...feed rollers press an alcohol soaked cleaning card both sides between the white and black lower rollers 7 Use the Clean button on the front panel to operate the upper feed rollers Press the Clean but...

Page 191: ...e plastic Both sets of lower rollers are located below the maintenance tray To clean the lower media feed rollers press an alcohol soaked cleaning card between the white and black lower rollers 13 Use...

Page 192: ...the exit cover causing ink streaks or marks on the top edge front or back of prints When this occurs you must clean these parts using both dry and alcohol soaked swabs or cloths Sample ink smear pape...

Page 193: ...press an alcohol soaked cleaning card against each roller and turn it several times to clean each roller individually Note You may notice some staining of the exit rollers while performing the cleani...

Page 194: ...r tray jams media pick roller If you are experiencing media feeding problems including mispicks and multiple picks at the standard upper media tray you can generally correct the problem by cleaning th...

Page 195: ...the media tray b Remove the cleaning tray from the cleaning kit and open the tray lid to reveal the cleaning tray sponge c Wet the cleaning tray sponge with isopropyl alcohol A a bottle is provided in...

Page 196: ...r media tray with the cleaning tray into the printer 4 Press the Clean button The printer cleans the media pick roller while displaying the following message Cleaning 5 When the cleaning operation is...

Page 197: ...n the media tray Replace the upper media tray in the printer 10 The front panel re displays the following message Clean Media Tray Jams Clean Test 11 Press the Exit button to return to normal operatio...

Page 198: ...r with isopropyl alcohol The printer guides you through the necessary steps to perform automatic cleaning procedures You will need the pick roller cleaning tray included in the cleaning kit when you r...

Page 199: ...l because it can contain water and oils that leave undesirable residue on the printer parts Never use water to clean the printer s internal components Failure to follow these instructions may invalida...

Page 200: ...e paper tray Replace the paper tray in the Lower Paper Tray Assembly 10 The front panel re displays the following message Clean Media Tray Jams Clean Test 11 Press the Exit button to return to normal...

Page 201: ...ng the lower tray paper feed rollers 1 Press the Clean button The printer displays the first selection in the menu Clean Light Stripes Clean Test 2 Press the left arrow button until the following mess...

Page 202: ...rinter push the cleaning card down into the slot until it contacts the rubber transport rollers Note Guide marks molded into the Lower Paper Tray Assembly indicate the left and right boundaries of the...

Page 203: ...ance tray from the printer keeping it level Remove empty and replace the waste liner 2 Place the maintenance tray in a plastic bag and seal the bag If the maintenance tray is to be transported restrai...

Page 204: ...our printer s warranty 2 Locate the transit restraint on the right side of the printer and insert a wide flat blade screwdriver or coin into the transit restraint slot 3 While pressing inward with med...

Page 205: ...r path and attract dust so apply lubrication sparingly Lubricate the following only when needed Bushings Apply a drop of light oil to a bushing if it is noisy or running dry Plastic gear train This ge...

Page 206: ...re seven rubber belts in the printer a belt from the process motor to the compound gear two belts from the y axis motor drive two belts on the cap wipe purge drive and two belts in the x axis drive Lo...

Page 207: ...st 0031712 00 Cap wipe purge alignment spacer 003 1714 00 Dial caliper 0 6 in 003 1719 00 Loupe optical comparator 003 1720 00 L wrench 6 mm hex drive ball driver 003 1721 00 Bit hex 3 32 x 1 4 in dri...

Page 208: ...se 006 7997 00 Oil 006 2530 00 Antistatic mat 006 7056 00 Cable adapter level shifter service diags 174 3493 00 Cable Serial Mini DIN8 to DB25M service diags via Macintosh 012 1498 00 Cable Serial DB9...

Page 209: ...ear of the printer 3 Extend the four lifting handles from the underside of the printer Warning The printer is heavy Four people one holding each handle should lift the printer in the next step 4 Lift...

Page 210: ...ight side panel in place Also remove the screw securing the rear of the panel c Lift up the upper edge of the right side panel and pull it over the printer s metal frame Remove the right side panel 4...

Page 211: ...mbly 8 c Lift up the upper edge of the left side cover and pull it over the printer s metal frame Remove the left side cover Figure 8 2 Removing the printer side covers 9661 02 Remove 4 screws Left si...

Page 212: ...nel b Slide the ink loader s spring crossarm to the center of the ink loader You may need to remove some ink sticks c Remove the two screws on each side of the ink loader slots securing the top panel...

Page 213: ...r c Pull the front cover off of the two pivots 3 Front panel a Remove the left and right side panels b Lift out the front panel and disconnect the front panel display wiring harness from the underside...

Page 214: ...the exit cover b Carefully remove the E clip securing each of exit cover s two brass bushing at each end of the exit roller Slide the bushings inward to free the exit cover Lift and remove the exit co...

Page 215: ...harnesses leading to the ink loader One leads to the power supply the other leads to I O board 3 Caution Be careful not to break the ink melt elements of the ink loader they are made of a fragile cer...

Page 216: ...on a residual amount of liquid ink may flow down the felt lined ink stick chutes and damage the felt Reverse these steps to install the ink loader Refer to Appendix C Wiring Diagrams for illustrations...

Page 217: ...ant layer of dust has accumulated on the ink loader support vacuum the dust off before removing the support This prevents dust from falling into the ink reservoirs and onto the face of the printhead 2...

Page 218: ...r to the later procedure Main board on page 8 68 3 Remove the network card and its frame 4 Disconnect the wiring harnesses leading from the rear fan to J21 of the power control board 5 Remove the thre...

Page 219: ...Remove the main board and network card and frame Refer to the later topic Circuit boards on page 8 62 4 Disconnect the wiring harnesses leading from the vacuum pump to J16 of the power control board...

Page 220: ...d covers on page 8 4 3 Disconnect the two vacuum hoses leading to the accumulator 4 Remove the two screws securing the accumulator bracket to the printer frame 5 Remove the two screws securing the acc...

Page 221: ...iring harnesses leading to the solenoid valve from I O board 2 4 Disconnect the vacuum hoses leading to the solenoid valve 5 Remove the two screws securing the solenoid valve Remove the solenoid valve...

Page 222: ...on the drum pulley in the same position A mark on the ring rear should line up with a mark on the drum pulley Note Shim washers on pre production units Shim washers may be used to achieve optimum belt...

Page 223: ...0 5 mm 0 020 in and d 0 30 mm 0 012 in Standard serial numbered printer drive assemblies will not use shims but instead will feature bosses of the correct height Tension the drive belts using the proc...

Page 224: ...lease the tension on the wiring harness Note for reassembly that the ribbon cables contacts face out towards the I O board 1 5 Remove the one screw and bushing on the left side of the printer frame se...

Page 225: ...Remove the right side panel as explained in the earlier topic Cabinet panels and covers on page 8 4 3 Disconnect the wiring harnesses leading from the drum fan to J22 of the power control board Loose...

Page 226: ...the drum heater fan assembly to the drum heater bracket Reverse the steps to reinstall the drum heater fan assembly Ensure the drum fan is oriented so its airflow blows inward Figure 8 14 Removing the...

Page 227: ...d The paper preheater s ground wire connected to the engine frame below the exit drive gear train The heater s power wiring harness near the I O Board 2 7 At the left side of the printer remove the E...

Page 228: ...Reverse these steps to reinstall the paper preheater Perform the procedure Adjusting the image position margins on page 9 26 Figure 8 15 Removing the paper preheater Upper feed roller electric clutch...

Page 229: ...105 RED of I O board 1 Disconnect the drum position encoder sensor s wiring harness locking style at the drum position assembly 5 Precisely mark the end of the drum shaft relative to the drum home fla...

Page 230: ...ging the encoder wheel 8 Remove the two screws securing the drum position sensor assembly housing to the print engine Slide the assembly off the drum shaft If necessary use the small flat blade screwd...

Page 231: ...sor assembly was removed 1 If removed earlier slide the drum bearing on the drum shaft 2 Place the retaining spring in the groove of the encoder wheel and install the encoder wheel on the drum shaft p...

Page 232: ...remove the two bolts securing the two spring retainers at each end of the transfix module Set the spring retainers aside Note Do not confuse the left side spring with the right side spring their pres...

Page 233: ...ings stacks so their height marking are visible for a later adjustment Note the embossed orientation arrows on the spring retainers they should face forward Do not reinstall I O board 3 except as a pa...

Page 234: ...e power control board Remove the access plate so you can disconnect the wiring harness from J14 and J17 of the power control board the two upper connectors 8 Remove the drum position sensor assembly I...

Page 235: ...at also secure the left side of the drum assembly to the print engine Carefully remove the rubber tips of the supports before removing the supports using the standoff support removal tool Figure 8 19...

Page 236: ...f the power control board Free the wiring harness from it cable retainers 23 Remove the exit roller gear train it is held onto the exit roller shaft by two E clips Note the position of the two flat wa...

Page 237: ...8 31 Field Replaceable Unit Disassembly Assembly 8 Figure 8 20 Removing the drum transfix assembly right side 9661 21 Screws Shoulder screw Cover standoff supports 5 total Exit cover spring assembly E...

Page 238: ...tray with Tabloid Maximum paper a Power up the printer in Bypass mode refer to Bypass mode on page 9 4 b Navigate to the Extended Service Support menu and select the Seal Drum menu item c Wait for th...

Page 239: ...er preheater as explained in the previous procedure Paper preheater on page 8 21 6 Disconnect the motor s wiring harnesses from the power control board The process motor connects to J14 and J17 Remove...

Page 240: ...paper preheater as explained in the previous procedure Paper preheater on page 8 21 6 Disconnect the motor s wiring harnesses from the power control board The Y axis motor connect to J15 7 Remove the...

Page 241: ...the topic Cabinet panels and covers on page 8 4 3 Remove the access plate so you can disconnect the motor s wiring harness from J18 of the power control board 4 Remove the two screws securing the cap...

Page 242: ...as explained in the earlier topic Cabinet panels and covers on page 8 4 3 Remove the ink loader as explained in the earlier topic Ink loader on page 8 9 4 Remove the metal dust cover as described in...

Page 243: ...ertently tip the printhead 8 Manually unlatch the tilt cam solenoid and rotate the process motor to tilt the printhead back to its maximum tilt back position Also make sure that cap wipe purge assembl...

Page 244: ...rocess motor to tilt the printhead forward about 2 5 cm 1 inch 11 Slide the standoff locks outward to secure the tool to the printhead 12 Loosen the two mounting screws securing the printhead in place...

Page 245: ...nd no changes or adjustments were made to the x axis drive system then you do not need to make the following cold printhead to drum adjustment 4 At the left end of the printhead slide the printhead ga...

Page 246: ...thead to drum spacing adjustment on page 9 16 to set the gap between the hot printhead and the drum 10 Perform the procedure Adjusting the vertical interleave scan shift on page 9 34 and Adjusting the...

Page 247: ...xplained in the earlier topic Cabinet panels and covers on page 8 4 3 Remove the ink loader as explained in the earlier topic Ink loader on page 8 9 4 Disconnect the printhead s power wiring harness a...

Page 248: ...shings Note In the next step mark the location of the restrain pin guide on the chassis This simplifies reinstallation and ensure the guide is correctly adjusted 7 At the left side of the printer remo...

Page 249: ...rocedure as described in the topic Printhead transit restraint adjustment on page 9 22 Note the two slotted screw holes on the restraint pin guide By sliding the restraint pin guide forward or backwar...

Page 250: ...in plate Caution Do not remove the black plastic plugs on the sides of the printer frame covering the access hole for the X axis roll adjustment 10 Remove the printhead cable and restraint sensor rest...

Page 251: ...nd scan refer to Adjusting the vertical interleave scan shift on page 9 34 and Adjusting the horizontal image interleave skip on page 9 32 Scale factor refer to Adjusting scale and skip factors on pag...

Page 252: ...harness leading from the cap wipe purge unit to the power control board Remove the small two part white plastic panel to free the wiring harness Disconnect the vacuum hose leading to the cap wipe purg...

Page 253: ...toward the drum remove the pin screw from the right end of the cap wipe purge unit 11 Slide the cap wipe purge unit slightly to the printer s right to free its left end and remove the cap wipe purge...

Page 254: ...from the cap wipe purge assembly to the power control board Remove the small two part white plastic panel to free the wiring harness Disconnect the vacuum hose leading to the cap wipe purge assembly 6...

Page 255: ...nder the tilt cam gear is an extra unused screwhole used for manufacturing It is located about 1 75 cm 5 8 in from the correct screwhole Both screwholes can be accessed through a hole in the tilt cam...

Page 256: ...p wipe purge drive assembly Make these adjustments Left and right belt tensioners refer to Tensioning the cap wipe purge drive belts on page 9 12 Cap wipe purge to printhead parallelism refer to Setti...

Page 257: ...ve train by removing the two E clips securing it in place Note for reassembly how it is spring loaded to the engine frame 5 Remove the white plastic lower stripper finger push lever 6 Note for reassem...

Page 258: ...e 8 33 Removing the upper and lower stripper finger assemblies Upper stripper finger assembly Upper stripper finger shaft Lower stripper finger shaft Lower stripper finger assembly C clip C clip Lever...

Page 259: ...procedure Cabinet panels and covers on page 8 4 4 Disconnect the cables from I O board 3 and then remove it Removing I O board 3 is discussed in the later topic I O board 2 and I O board 3 on page 8 6...

Page 260: ...d bushing the right end bearing from the shaft Remove the exit roller Reverse these steps to install the exit roller assembly Figure 8 34 Removing the exit roller Exit roller drive train assembly Righ...

Page 261: ...iring harness leading from the clutch to I O board 1 5 At the electric clutch remove the left side E clip securing the left end of lower feed roller shaft 6 Remove the feed roller magnetic clutch 7 Ri...

Page 262: ...Printer 8 Field Replaceable Unit Disassembly Assembly Reverse these steps to install the feed roller Figure 8 35 Removing the feed roller I O board 2 Lower feed roller electric clutch C clip Bushing C...

Page 263: ...arness from the pick roller solenoid leading to I O board 1 5 Remove the process drive belt tensioner and its spring 6 Remove the process belt and the paper path drive gear it is held in place with an...

Page 264: ...ll the pick roller pick roller solenoid and clutch Make the pick roller alignment adjustment as described in the topic Paper pick adjustment on page 9 13 Figure 8 36 Removing the pick roller Process d...

Page 265: ...e four screws securing it in place 5 Remove the sensor flag mounted on the right end of the maintenance tray cam roller 6 Remove the electric clutch mounted in the left end of the maintenance tray cam...

Page 266: ...e 8 64 7 Remove the E clip securing the head tilt cam gear to the its printer frame shaft Remove the cam gear Reverse these steps to install the tilt cam gear Be sure to position the new tilt cam gear...

Page 267: ...white plastic maintenance tray lift arm to the maintenance tray guide 4 For each maintenance tray guide remove the three screws securing it to the inside of the printer side frame Remove the guide Re...

Page 268: ...n the earlier topic Cabinet panels and covers on page 8 4 3 Disconnect the heater wiring harnesses leading to the power supply 4 Remove the four screws securing the power supply to the rear of the pri...

Page 269: ...securing the bracket to the rear printer frame Remove the bracket 5 Disconnect the wiring harness leading to the media size sensor board 6 Through two access holes on the lower rear printer frame remo...

Page 270: ...reassembly that the ribbon cables contacts face out towards the I O board 1 4 Remove the six screws securing I O board 1 to the engine frame Remove the interconnect board Caution After reinstalling I...

Page 271: ...lier topic Cabinet panels and covers on page 8 4 3 I O board 2 a Disconnect the wiring harnesses leading to I O board 2 b Remove the four screws securing I O board 2 to the engine frame c Remove the b...

Page 272: ...ve the board Note Refer to Appendix C Wiring Diagrams for details on where each wiring harness connector plugs into the I O boards Additionally each connector receptacle on the boards is labeled for i...

Page 273: ...ver as explained in the earlier topic Cabinet panels and covers on page 8 4 3 Disconnect the wiring harnesses leading to the media sensor board 4 Remove the three screws securing the media sensor boar...

Page 274: ...le and slide out the main board Reverse these steps to reinstall the main board If you are replacing the main board swap the socketed printer ID chip and the NVRAM chip with the new board so the print...

Page 275: ...ard and its frame It is held in place to the printer s back frame by six screws 4 Remove the main board It is secured to the printer back frame by two screws 5 Disconnect the two power harnesses leadi...

Page 276: ...and remove the power control board Reverse these steps to install the power control board NVRAM Transfer IC M15 from the old board to the new board to preserve printer NVRAM settings and calibration...

Page 277: ...SIMM can be replaced with a larger SIMM 3 Insert a memory module 16 Mbyte or 32 Mbyte in connector J9 a next to J88 and tilt the module down until it locks in place b If J9 is already occupied by a S...

Page 278: ...IMM in connector P71 ROM SIMM Remove the SIMM 5 Insert a replacement code ROM SIMM in connector P71 a and tilt the SIMM down until it locks in place b When properly inserted a tab on each end of the c...

Page 279: ...securing each end of the SIMM in connector J25 FONT SIMM Remove the SIMM 6 Insert a replacement optional font SIMM in connector J25 a and tilt the SIMM down until it locks in place b When properly ins...

Page 280: ...eplacement network card and tighten the two thumb screws 4 Swap the socketed NVRAM chip on the new network card with the old card so that the printer s network parameters are retained 5 Reconnect the...

Page 281: ...003 1720 00 Bit hex 3 32 x 1 4 in drive 003 1726 00 Bit hex 4 mm x 1 4 in drive 003 1734 00 Printhead to drum gap tool 003 1499 00 Y axis encoder disk spacer 003 1710 00 Cleaning cards pack of five 0...

Page 282: ...enu item Service Support and then press the Menu and then Exit button together Pressing Menu alone allows you to access the printer copy counts fault history and the printer s altitude setting The fol...

Page 283: ...e FW Version Serial Settings Baud Rate Data Bits Flow Control Stop Bits Parity Fault History Purge Volume Engine Copy Count Test Print Head To Drum Adjust Reset Printer Reset NVRAM Head Adjust Deep Cl...

Page 284: ...ess and hold front panel buttons 1 and 2 Turn on the printer 2 Wait for the message Entering Bypass Mode to be displayed 3 Release buttons 1 and 2 Cool down mode Using this menu item accelerates the c...

Page 285: ...to the menu item Test Prints and press the Menu button to access it list of test prints 6 Scroll to the desired test print and press the Print button Refer to Appendix B Test Patterns it discusses eac...

Page 286: ...nels and covers on page 8 4 2 Loosen the process motor belt tensioner screw allow the spring loaded belt tensioner to adjust its position for proper belt tension With one finger on the pivot point to...

Page 287: ...Service Manual 9 7 Checks and Adjustments 9 Figure 9 3 Setting process motor belt tension Process motor drive belt Belt tensioner Set screw 9661 105...

Page 288: ...ishhook should engage the eyelet on the underside of the Y axis drive assembly 5 Pull forward and down on the lever arm of the tension tool to apply tension to the Y axis belts 6 Connect a PC to the p...

Page 289: ...9 Figure 9 4 Setting theY axis belt tension 9661 106 4 mounting bolts Rotate belt 10 times while tensioning Y axis belt tensioning tool Minimum radius mark Radius mark and both axes in line Mounting b...

Page 290: ...f the printer Remove the left and right side panels and the top panel as described in the topic Cabinet panels and covers on page 8 4 Remove the ink loader support as described in the topic Ink loader...

Page 291: ...s skewed to the printhead faceplate use a 2 mm hex wrench to loosen the two set screws on the right cap wipe purge shaft pulley Rotate the shaft to bring the cap wipe purge unit into alignment and tig...

Page 292: ...pic Ink loader support cross member on page 8 11 2 Loosen each cap wipe purge belt tensioner set screw You can reach each set screw through an access hole in the left and right side frame 3 Gently rot...

Page 293: ...te the front orientation of the tool marked F The paper pick roller should rotate slightly between the two positions denoted by the alignment tools 4 If an adjustment is needed loosen the paper pick s...

Page 294: ...gn the X axis rails to the drum loosen the 4 large bolts or nuts securing the X axis drive assembly to the chassis enough to allow the drive assembly to slide For the adjustment the assembly will pivo...

Page 295: ...m so the difference between the left and right alignment readings is less than 0 003 inches 16 Carefully remove the alignment tool 17 Reassemble the printer and make a test print Perform the calibrati...

Page 296: ...until they are just snug in place 5 Using the front panel menu move the printhead to its right most position At the right end of the printhead slide the printhead gap tool between the printhead and t...

Page 297: ...shift on page 9 34 and Adjusting the horizontal image interleave skip on page 9 32 Figure 9 9 Spacing the printhead to the drum 5 4 3 2 1 COLD HOT 5 4 3 COLD Gap tool Align gap tool mark to top of rai...

Page 298: ...th the printer 3 Connect a PC to the printer and start diagnostics as described in the topic PC based diagnostics on page 6 24 turn on the printer and start the service diagnostics program on the PC C...

Page 299: ...365 35 16 1 384 35 66 1 404 33 18 1 306 33 68 1 326 34 18 1 346 34 68 1 365 35 18 1 385 35 68 1 405 33 2 1 307 33 7 1 327 34 2 1 346 34 7 1 366 35 2 1 386 35 7 1 406 33 22 1 308 33 72 1 328 34 22 1 34...

Page 300: ...out of the drum position sensor assembly s encoder wheel groove This ensures that the encoder wheel is not tensioned and slides easily on the drum shaft 4 Through the access hole in the drum position...

Page 301: ...Service Manual 9 21 Checks and Adjustments 9 Figure 9 11 Setting the drum position encoder gap 9661 112 Gap tool Groove Retaining spring...

Page 302: ...t engages the fixed restraint on the left side of the printer frame Tilt the printhead forward slightly to the restraint position 24 6o 5 Engage the printhead restraint to the printhead 6 When properl...

Page 303: ...e 9 12 Adjusting the printhead restraint 0 5 mm 02 in Center pin Rotate this nut to adjust the pin depth 5 mm left right Locknut for pin depth 9661 114 0 66 mm 0 2 mm 026 in 008 Lock nut for pin cente...

Page 304: ...uum gauge to the inlet side of the pump the hose running between the pump and the accumulator This allows you to check the action of the vacuum pump and accumulator 4 Turn on the printer and enable th...

Page 305: ...allows you to check the action of the vacuum as it is applied to the printhead the cap wipe purge assembly should be sharply sucked against the printhead faceplate If it is not there may be an ink clo...

Page 306: ...e Support and then pressing buttons 1 and 4 together 5 Scroll to the menu item Calibrate Paper Margins At the sub menu item Select Media Size choose the selected size of paper in the paper tray Letter...

Page 307: ...s 4 through 10 The left and right margins should differ by no more than 0 4 mm from the front panel displayed value Likewise the top and bottom margins should differ by no more than 1 mm from the fron...

Page 308: ...image on the drum Due to jet interlacing traveling an incorrect distance actually results in a series of dark lines or light lines where the adjacent jets produce lines that are to close or too far fr...

Page 309: ...or stitch where the two image halves join The skip adjustment ensures the jets interlace correctly Perform the scale and skip adjustments after replacing the X axis drive unit the printhead or the pow...

Page 310: ...the 1st line of the next set dark lines or light lines respectively will appear in the print 7 If a correction is needed scroll to the menu item Set Scale Factor A Press the menu button Lower the dis...

Page 311: ...and eliminate dark lines Increase the displayed value to increase underscan and eliminate light lines 12 Perform the following procedure Adjusting the horizontal image interleave skip on page 9 32 Whe...

Page 312: ...tion Image print two test prints Discard the first print and use the second print Note For this test the scan value is temporarily offset by 40 automatically to make it easier to see the horizontal mi...

Page 313: ...o verify if the adjustment is correct Repeat Steps 5 through 9 as necessary 11 Exit the menus When you exit the calibration menu the new skip value is stored in NVRAM located on the power control boar...

Page 314: ...y Letter size or A4 size paper 4 Scroll to the extended service support menu by first scrolling to the front panel menu item Service Support and then pressing buttons 1 and 4 together 5 Scroll to the...

Page 315: ...adjustment is correct 10 Exit the menus When you exit the calibration menu the new scan shift value is stored in NVRAM located on the power control board Figure 9 20 Examining a test print for vertic...

Page 316: ...the printer before turning on the printer you should always make sure that the head tilt cam gear is latched by the head tilt solenoid and that the head tilt cam gear is disengaged via its missing tee...

Page 317: ...firmware serial number If you do not wish to reset the NVRAM stored parameters of an installed Phaser Share card then remove the card before performing this procedure To reset the printer to its fact...

Page 318: ......

Page 319: ...e number of the printer produced on that day The serial number is coded as follows JLxxDMY J indicates the headquarter country of the manufacturing company Japan L indicates the modification level of...

Page 320: ...9356 00 1 Cover Front Jam Access 2 118 9359 00 2 Pivot Hinge Front Cover 3 118 9357 00 1 Handle Release Lever 4 118 9353 00 1 Cabinet Panel Side Left 5 650 3531 00 Front panel with display board 6 11...

Page 321: ...Service Manual A 3 Field Replaceable Units List A Figure A 1 The printer exterior FRUs 9661 120 1 3 2 9 2 4 6 7 8 5 10...

Page 322: ...ear Compound Eccentric Par t of Gear Kit 650 3499 00 7 Process Gear Position Sensor Par t of Sensor Kit 650 3497 00 8 118 9383 00 1 Drum Position Sensor Assembly 9 Gear Paper Path Par t of Gear Kit 65...

Page 323: ...or Assembly 11 118 9370 00 1 Transfix Roller Pressure Spring Stack 12 118 9368 00 1 Transfix Roller w Shaft and C clips 13 118 9372 00 1 Stripper Finger Assys Upper and Lower 14 118 9371 00 1 Exit Rol...

Page 324: ...Door Switch Sensor 42 118 9374 00 1 Maintenance Tray Guides Left and Right 43 118 9375 00 1 Maintenance Tray Lift Spring Lifter 44 650 3343 00 1 Cap Wipe Purge Unit 45 118 9369 00 2 Transfix Roller Be...

Page 325: ...Replaceable Parts List Figure A 3 The printer interior FRUs right side 18 17 19 14 15 13 9 10 3 4 2 1 33 32 31 21 24 22 20 12 11 23 16 29 30 28 40 43 42 36 35 34 26 27 37 8 7 6 38 39 41 5 25 9661 121...

Page 326: ...ware 065 0564 00 Shipping Box 070 9538 01 Network Admin SW Manual 070 9539 01 PhaserShare SW Manual 070 9661 00 Phaser 380 Service Manual 070 9662 00 Phaser 380 User Manual English 070 9662 10 Phaser...

Page 327: ...er Tray Assembly w A size Tray Table A 5 Lower paper tray assembly FRUs Part number Serial number Effective Discontinued Quantity Name and description 1 437 0461 00 Aux feeder assembly exchange module...

Page 328: ......

Page 329: ...paper Look for misconverged vertical lines running thru the centerline of the print perform Adjusting the horizontal image interleave skip on page 9 32 Ensure the tops ends of the lines are horizonta...

Page 330: ...to color misregistration inherent in the fabrication of the jet Make sure that the drum temperature sensor is correctly mounted and in proper even contact with the drum Ensure the printhead to spacing...

Page 331: ...qrstuvwxyz1234567890 10 point Times Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 8 point Times Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 6 point Time...

Page 332: ...led Causes Use the PC diagnostics to check the printhead and drum for good thermal regulation Also check the printhead to drum gap Ensure the drum fan is running properly A vertical band running the l...

Page 333: ...colors A slight amount of wrinkling in green fills at 600 dpi is normal But there should be no wrinkling in 600 dpi blue fills Causes Weak jets or uneven drum heating may cause uneven fills To solve...

Page 334: ......

Page 335: ...upplies illustrated 7 4 swab 7 4 upper pick rollers 7 14 upper tray jams 7 14 clearances 1 16 installation 2 4 clutches inspecting 7 26 code ROM SIMM installing 8 72 Color Correction 2 16 Color Printe...

Page 336: ...7 ink smears cleaning 7 7 identifying 7 7 inspecting the printer 7 26 installation printer software Macintosh 2 22 interface cables required 2 3 interleave shift adjusting 9 34 Internet 4 7 IP address...

Page 337: ...13 PhaserLink 2 38 accessing printer s web page 4 10 physical dimensions 1 16 power problems 6 37 power supply theory 5 6 verifying 6 6 power up error codes rear panel 6 4 power up sequence 6 1 pre i...

Page 338: ...ard Service BBS 2 37 terminator SCSI 2 12 Test button 7 6 test patterns descriptions B 1 things affecting 4 4 tools for checks and adjustments 9 1 required for disassembly 8 1 transit restraint lockin...

Page 339: ...upplies illustrated 7 4 swab 7 4 upper pick rollers 7 14 upper tray jams 7 14 clearances 1 16 installation 2 4 clutches inspecting 7 26 code ROM SIMM installing 8 72 Color Correction 2 16 Color Printe...

Page 340: ...7 ink smears cleaning 7 7 identifying 7 7 inspecting the printer 7 26 installation printer software Macintosh 2 22 interface cables required 2 3 interleave shift adjusting 9 34 Internet 4 7 IP address...

Page 341: ...13 PhaserLink 2 38 accessing printer s web page 4 10 physical dimensions 1 16 power problems 6 37 power supply theory 5 6 verifying 6 6 power up error codes rear panel 6 4 power up sequence 6 1 pre i...

Page 342: ...ard Service BBS 2 37 terminator SCSI 2 12 Test button 7 6 test patterns descriptions B 1 things affecting 4 4 tools for checks and adjustments 9 1 required for disassembly 8 1 transit restraint lockin...

Page 343: ...r Electric Clutch Rear Fan Drum Heater Paper Exit Sensor Front Cover Sensor Exit Cover Sensor MediaType Sensor Board Air Valve Solenoid GRAY GRN BRN RED Vacuum Pump none ORG J206 Op Panel WHT ORG VIO...

Page 344: ...oper means of routing and dressing printer wiring Incorrect wiring dressing can result in wires pinched by cabinet panels or damaged by moving parts of the printer Figure C 2 Wire dressing around the...

Page 345: ...C Wiring Diagrams Phaser 380 Service Manual C 3 Figure C 4 Wire dressing around the bottom right of the printer Figure C 5 Wire dressing around the left side of the printer...

Page 346: ...C 4 Phaser 380 Color Printer C Wiring Diagrams Figure C 6 Wire dressing behind the printhead...

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