CUT SHEET C30, C30D Parts and Service Manual

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Models C30 and C30D
HP Part No. C4000-90006

Notice
Hewlett-Packard makes no warranty of any kind with regard to this material, including,
but not limited to, the implied warranties of merchantability and fitness for a particular
purpose. Hewlett-Packard shall not be liable for errors contained herein or for incidental
or consequential damages in connection with the furnishing, performance, or use of this
material.
Hewlett-Packard assumes no responsibility for the use or reliability of its software on
equipment that is not furnished by Hewlett-Packard.
This document contains proprietary information which is protected by copyright. All
rights are reserved. No part of this document may be photocopied, reproduced, or trans-
lated to another language without the prior written consent of Hewlett-Packard Company.
The information contained in this document is subject to change without notice.
Printing History
New editions are complete revisions of the manual. The dates on the title page change
only when a new edition is published.
The software code (EXXX) printed below the date indicates the version level of the soft-
ware product at the time of publication.
Edition 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .March 1994
Edition 2. . . . . . . . . . . . . . . . . . . . . . . . . . . December 1994
Edition 3. . . . . . . . . . . . . . . . . . . . . . . . . . . June 1999
Trademarks
PCL is a trademark of the Hewlett-Packard Company. CG Times, a product of Agfa Cor-
poration, is based on Times New Roman, a registered trademark of Monotype Corporation
PLC. ITC Zapf Dingbats is a U.S. registered trademark of International Typeface Corpora-
tion. PostScript is a registered trademark of Adobe Systems, Inc. in the U.S.A. and other
countries. Times Roman and Univers are trademarks of Linotype AG and its subsidiaries.
Centronics is a U.S. registered trademark of Centronics Corporation. PhoenixPage is a
trademark of Phoenix technologies, Ltd. UNIX is a registered trademark of UNIX System
Laboratories Inc. in the U.S.A. and other countries. DEC LN03+ is a registered trademark
of Digital Equipment Corporation. All other trademarks are the properties of their respec-
tive owners.
ii June 1999
Warnings and Cautions
A WARNING denotes a hazard. It calls attention to a procedure or practice, which, if not
done correctly or adhered to, could result in personal injury. Do not proceed beyond a
WARNING sign until the indicated conditions are fully understood and met.
A CAUTION denotes a hazard. It calls attention to a procedure which, if done incorrectly
or inattentively, could damage or destroy part or all of the product. Do not proceed beyond
a CAUTION until the indicated conditions are fully understood and met.
Conventions
The following conventions are used throughout this manual:
Note
Notes contain important information set off from the text.
Caution
Caution messages indicate procedures which, if not observed,
could result in damage to the equipment.
Warning
Warning messages call attention to situations that could result
in personal injury.
June 1999 iii

Preface
The C30/C30D Maintenance Manual contains all the information needed to maintain and
service Hewlett Packard C30 and C30D printers. The C30 printer series are high-speed,
non-impact printers utilizing electrophotographic imaging technology.
The information in this maintenance manual is for authorized field representatives who are
familiar with basic printer operations. It serves as a supplement to training classes and pro-
vides a basis for discussion with regional field service engineers and customer support
representatives.
Using This Manual

This manual is organized into the following sections:
Chapter 1, “Printer and Troubleshooting Overview”

Reviews the organization of the manual, the way the printer works, and how to trouble-
shoot the printer, including some standard procedures to follow when troubleshooting.
This chapter also includes a chart detailing exactly what each causes each error code, illus-
trations of all sensors in the printer, and a list of abbreviations used throughout the manual.
Chapter 2, “TAG Cross- Reference Tables”

Provides cross-reference tables; look up specific printer problem description (in either the
mechanical malfunction, error code, or print quality description tables), then turn to the
TAG indicated on the chart to troubleshoot the problem.
Chapter 3, “Troubleshooting Analysis Guide (TAGs)”

Detailed step-by-step procedures to help you isolate and resolve specific printer problems.
If you are not sure which TAG to start with, begin with the overview, TAG 001.
Chapter 4, “Print Quality Samples”

Shows print test patterns indicating specific problems, and referencing the TAG that treats
each problem.
Chapter 5, “Diagnostic Tests”

Reviews each printer software diagnostic.
Chapter 6, “Wiring Diagrams and Electrical Data”

Shows printer schematics and locations of individual components.
Chapter 7, “Removal/Replacement Procedures”

Outlines procedures to follow when removing and replacing printer parts, also called
FRUs (Field-Replaceable Units).
iv June 1999
Chapter 8, “Options”
Provides information about the optional High Capacity Input and High Capacity Output
accessories and the optional hard disk upgrade.
Chapter 9, “General Printer Maintenance”

Reviews printer maintenance procedures to complete during service calls.
Appendix A
Lists the abbreviations and acronyms used in the manual.
Index
Provides a list of references to topics and part numbers mentioned in the Maintenance
Manual
Other Manuals
The C-Series Illustrated Parts Catalog shows every FRU and CRU (customer-replaceable
unit) in the printer, including part number information. This information is frequently
updated.
The HP C30 and C30D Guide to Operations, C4000-96006, contains all the information
needed to operate Hewlett Packard C30 and C30D printers.
The HP C30/30D and C40D Paper Specifications Guide, C4672-90002, explains the vari-
ous papers usable in the printer, how to care for them, and how to minimize paper-related
problems with the C30/30D and C40D.
Copyright © 1999 Hewlett-Packard Company. All rights reserved. May 1999

Please address any comments or questions with respect to this document to:
Publication Department
Hewlett-Packard Company
HP Printers - MS 44MC
System Peripherals Operation
19111 Pruneridge Avenue
Cupertino, CA 95014
June 1999 v
vi June 1999
Contents
Printer and Troubleshooting Overview

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Paper Path and Cycle Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Simplex Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Error Code Technical Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Sensor and Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
General Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
The Problem: Printer or Host? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Protocol Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Reading the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Confirming Line Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Using the Troubleshooting Analysis Guide (TAG) . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Sample TAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Standard Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Power-on-reset (POR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Checking Continuity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Installing the Interlock By-pass Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Producing a Developed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Producing a Toner Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Completing a Service Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
TAG Cross-Reference Tables

TAG Cross-Reference Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Error Code/TAG Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Print Quality/TAG Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Mechanical Malfunction/TAG Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Troubleshooting Analysis Guide (TAGs)

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Troubleshooting Analysis Guide (TAGs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
TAG 001: Troubleshooting a Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
TAG 002: Check & Problem Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
TAG 010: Upper Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
E10: Envelope Tray Out of Envelopes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
TAG 011: Lower Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
June 1999 vii

Contents
TAG 012: Upper Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

TAG E12: Envelope Tray or Feeder Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
TAG 013: Lower Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
TAG 020: Paper Jam/Misfeed in Upper Cassette Area . . . . . . . . . . . . . . . . . . . . . . . . 3-26
TAG 021: Paper Jam/Misfeed in /Lower Cassette Area. . . . . . . . . . . . . . . . . . . . . . . . 3-30
TAG 022: Paper Jam in the Transfer or Fuser Area . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
TAG 023: Paper Jam in the Output Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
TAG 025: Paper in Input Area Before Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
TAG 026: Paper in Output Area Before Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
TAG 030: Developer Bias Short/Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
TAG 031: Toner Patch Reference Level Too Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
TAG 032: Toner Patch Too Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
TAG 035: Out of Toner or ADD TONER Indicator On. . . . . . . . . . . . . . . . . . . . . . . . 3-51
TAG 036: Developer Unit Not Installed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
TAG 040: Photoconductor Seam Sensor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
TAG 044: Charge Corona/Transfer Corona Circuit Open . . . . . . . . . . . . . . . . . . . . . . 3-58
TAG 045: Charge Corona Circuit Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
TAG 050: Transfer Corona Circuit Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
TAG 055: Erase Lamp Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
TAG 070: Fuser Unit Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
TAG 071: Open Fuser Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
TAG 072: Fuser Unit Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
TAG 083: Job Offset Mechanism Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
TAG 097: +12 Vdc Power Shorted or Sensing Problem . . . . . . . . . . . . . . . . . . . . . . . 3-79
TAG 098: -12 Vdc Power Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
TAG 099: +24 Vdc Power Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-92
TAG 100: PCL Board Interface Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
TAG 101: IGS Controller Diagnostic Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
TAG 130: Diskette/Disk Drive Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104
TAG 200: IGS Internal Communication Malfunction . . . . . . . . . . . . . . . . . . . . . . . . 3-108
TAG 201: IGS-PCL Interface Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
TAG 405: IGS Bit-Map RAM Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
TAG 500: +5 Vdc Power Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113
TAG 600: AC Power Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
TAG 610: Operator Panel Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
TAG 700: Output Tray Circuit Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
TAG 702: Paper Size Detection Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
TAG 703: Upper Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
TAG 704: Lower Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
TAG 705: Multiple Paper Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-137
TAG 706: Paper Damaged or Wrinkled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
TAG 707: Upper Paper Guide Assembly Not Closing . . . . . . . . . . . . . . . . . . . . . . . . 3-139
TAG 750: Counter Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140
TAG 751: Main Drive Motor Runs Continuously . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
TAG 753: External Communications Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
TAG 754: Attachment Option Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
TAG 800: Prints Blank or With Dark Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . 3-148
TAG 801: Prints Light or Light With Carrier Particles . . . . . . . . . . . . . . . . . . . . . . . 3-152
TAG 802: Prints With Voids or White Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-158
TAG 803: Prints With Light or White Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . 3-160
viii June 1999

Contents
TAG 804: Prints With Light Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-162

TAG 805: Black Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163
TAG 806: Prints with Dark Spots or Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166
TAG 807: Misregistered/Skewed Prints (Simplex) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168
TAG 808: Prints Overtoned/Dark Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . 3-172
TAG 809: Blurred or Smeared Vertical Streaks on Prints . . . . . . . . . . . . . . . . . . . . . 3-177
TAG 810: Uneven Density or Dark Areas on Prints . . . . . . . . . . . . . . . . . . . . . . . . . 3-180
TAG 811: Background/Residual Images/Dark Prints . . . . . . . . . . . . . . . . . . . . . . . . 3-182
TAG 812: Uneven or No Fusing on Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-187
TAG 813: Residual Images on Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-189
TAG 815: Prints Resulting From Printhead Malfunctions. . . . . . . . . . . . . . . . . . . . . 3-191
TAG 900: Top Cover Interlock Malfunction, Duplex . . . . . . . . . . . . . . . . . . . . . . . . 3-192
TAG 901: Misregistration/Skewed Prints (Duplex). . . . . . . . . . . . . . . . . . . . . . . . . . 3-194
TAG 902: Paper Jam in Duplex Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-198
Print Quality Samples

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Print Quality Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Sample 1: Good Quality Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Sample 2: Washout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Sample 3: Blank Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Sample 4: Light Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Sample 5: Light Print With Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Sample 6: Voids or White Spots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Sample 7: Light Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Sample 8: Blank Vertical Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Sample 9: Light Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Sample 10: Black or Dark Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Sample 11: Dark Specks, Lines, or Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Sample 12: Dark Vertical Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Sample 13: Skewed Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Sample 14: Misregistration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Sample 15: Overtoned Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Sample 16: Blurred Images or Characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Sample 17: Varying Print Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Sample 18: Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Sample 19: Residual Images. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Sample 20: Wrinkles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Sample 21: Fusing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
June 1999 ix
Contents
Diagnostic Tests
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
How to Run Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
001 Operator Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
002 Upper Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
003 Lower Cassette Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
005 Sensor Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
006 Paper Transport Clutch Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
007 Counter Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
008 Jogging Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
009 Photoconductor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
010 Toner Supply Motor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
011 Charge Corona Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
012 Transfer Corona Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
013 Erase Lamp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
015 Negative Developer Bias Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
016 Duplex Feed Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
017 Duplex Input Sensor Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
018 Duplex Clutch Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
019 Duplex Tray Paper-Guide Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
020 High-Capacity Output Unit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
021 High-Capacity Input Unit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
022 Envelope Fuser Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
101 EIGS/MIGS Board Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
102 EIGS/MIGS Board Test (Continuous Loop) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
103 Communication Loop-back Test (Single Loop) . . . . . . . . . . . . . . . . . . . . . . . 5-21
104 Communication Loop-back Test (Continuous Loop) . . . . . . . . . . . . . . . . . . . 5-22
105 EIGS Program RAM Test (Continuous Loop) . . . . . . . . . . . . . . . . . . . . . . . . 5-22
107 EIGS/MIGS Bit Map Test (Single Loop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
108 EIGS/MIGS Bit Map Test (Continuous Loop) . . . . . . . . . . . . . . . . . . . . . . . . 5-23
110 Format Disk/Clear Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
111 LED Printhead Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
112 Disk Drive Test (Single Loop With Stop on Error). . . . . . . . . . . . . . . . . . . . . 5-25
113 Disk Drive Test (Continuous Loop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Wiring Diagrams and Electrical Data

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Wiring Diagrams and Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Connector (J/P) Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Connectors Inside the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Connectors Inside the Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
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Contents
Connectors on the Duplex Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Connectors Inside the Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Connectors Inside the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Connectors on the Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Connectors Inside the Back Cover (J/P2-14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Connectors Inside the Back Cover (Continued) J/P18-62 . . . . . . . . . . . . . . . . . . . . . . 6-13
Connectors Inside the Back Cover (Continued) J/P 64-85. . . . . . . . . . . . . . . . . . . . . . 6-14
Connectors Inside the Back Cover (Continued) J/P 90-800. . . . . . . . . . . . . . . . . . . . . 6-15
Voltage Isolation Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Ground System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Host Interface Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
RS-232C Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Standard DCE to DTE RS-232C Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Special Considerations for RS-232 Host Interface Users. . . . . . . . . . . . . . . . . . . . . . . 6-23
DTE Host to Printer (Option 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
DTE Host to Printer (Option 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
IBM PC/XT to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
IBM PC/AT to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Macintosh Communication Port to Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
RS-422 Host interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Centronics Parallel Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
IBM Parallel to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Special Considerations for Centronics Parallel Interface Users. . . . . . . . . . . . . . . . . . 6-29
Circuit Board Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Signal Interface Board Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
PCL Board Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Printhead Circuit Board Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Power Supply Strapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Removal/Replacement Procedures
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Power Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Photoconductor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Back Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Lower Back Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Left Side Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Replacement Note: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Right Side Cover Removal (Simplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Replacement Note: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Right Side Cover Removal (Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
June 1999 xi
Contents
Replacement Note: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Vacuum Transport Unit Removal (Simplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Vacuum Transport Unit Removal (Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Top Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Top Cover Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Top Cover Hinge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Rear Duplex Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Front Duplex Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Operator Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Counter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
IGS Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
PCL Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Printhead Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Disk Drive Housing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Cooling Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Duplex Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Toner Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
AC Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
DC Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
High Voltage Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Photoconductor Seam Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Photoconductor Rear Guide Rail Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Signal Interface Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Power Control Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Jogging Motor Control Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Upper or Lower Paper Size Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Upper Cassette Mount Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Lower Cassette Mount Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Upper Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
Upper Paper Guide Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
Lower Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Paper Timing Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
Cleaner Drive Belt Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
Cleaner Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Fuser Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
Fuser Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Paper Feed Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
xii June 1999

Contents
Paper Timing Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60

Replacement Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Upper Feed Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
Lower Feed Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
Upper Pick-Up Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Upper Pick-Up Roller Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
Lower Pick-Up Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Lower Pick-Up Roller Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Job Offset Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Exit Pinch Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
Upper Static Brush Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Lower Static Brush Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Exit Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Exit Cover Removal (Simplex). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Exit Cover Removal (Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Paper Exit Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Paper Full Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Front Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Back Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
Top Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
Erase Lamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
EP Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
Main Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
Main Gear Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89
Duplex Control Board #1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90
Duplex Tray Registration Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92
Duplex Skew Correction Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
Upper Duplex Drive/Clutch Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95
Duplex Route Motor/Solenoid Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . 7-96
“A” Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97
“B” Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98
“C” Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
“C” Roller Solenoid Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
Replacement Note: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
Duplex Route Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101
Duplex Paper Path Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-103
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Contents
Options
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
1200-Sheet/2500-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Bench Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Prefeed Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Input Control Board Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
1400-Sheet Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Bench Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Output Control Board Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Hard Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Troubleshooting Hard Disk Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
General Printer Maintenance

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Every-Call Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Paper Feed Tension Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
Tune-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Tool Requirements: Service Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Tools/Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4
End User Cleaning Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Printer/Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Every-Call Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Remove Major Consumable Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Inspect and Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Clean Internal Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Clean the Fuser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Clean the Developer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Clean the Cleaner Unit/Main Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Clean the Photoconductor Unit Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Clean the Transfer Corona . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Run Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
Adjusting Paper Feed Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Printers With Paper Tension Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Lubrication Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Front View Lubrication Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Duplex Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Rear View Lubrication Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
xiv June 1999

Contents
Duplex Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

Tune-Up Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Abbreviations and Acronyms
June 1999 xv
Contents
xvi June 1999

Chapter 1
Printer and
Troubleshooting
Overview
Section 1 Troubleshooting
June 1999 Printer and Troubleshooting Overview 1-1

Chapter Contents
Printing and Troubleshooting Overview

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Paper Path and Cycle Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Simplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Error Code Technical Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Sensor and Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Troubleshooting Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
General Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
The Problem: Printer or Host? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
Protocol Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Reading the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Confirming Line Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18
Using the Troubleshooting Analysis Guide (TAG) . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Sample TAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19
Power-on-reset (POR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21
Checking Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21
Installing the Interlock By-pass Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
Producing a Developed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
Producing a Toner Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
Completing a Service Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
1-2 Printer and Troubleshooting Overview June 1999

Theory of Operation
Theory of Operation
The printer uses an electrophotographic imaging system based on LED array technology.
Two key components of the printer are the image generation system (IGS) controller and
the printer control logic (PCL) board.
Image Generation System (IGS) controller: Each printer is equipped with an IGS con-
troller, which provides the interface between the host computer, the PCL board, LED
printhead, and the disk drives. The controller may be an EIGS or RIGS board.
Printer Control Logic (PCL) board: The PCL board directs the mechanical functions of
the printer and print cycle timing. The PCL board also receives initial machine informa-
tion, such as empty paper cassettes, paper jams, and fuser unit problems.
The illustration on the following page details the printing process. The numbers represent
the sequence of events from the time that the system interface receives data, through the
production of a print image, to the preparation for another print.
1 Receiving data
Data from the host is received by the Signal Interface (SI) PCA and is passed to the
Image Generating System (IGS) PCA, which temporarily stores the data in RAM. The
data may consist of information generated on the host computer and sent over the host
communication interface or it may consist of information generated by printer soft-
ware, such as a request for test prints or to print the directory of a diskette.
2 Bit Image
The IGS transforms the host file into a bit map image of 1s and 0s and stores them in
user bitmap RAM. Bitmap memory is nothing more than an electronic piece of paper.
3 Charging the photoconductor belt
When the IGS controller has a full page of data, it causes the PCL board to turn on the
main motor, which rotates the photoconductor belt. As the photoconductor belt
rotates, the charge corona applies a high negative charge to it, which repels toner from
the photoconductor belt except in the areas to print.
4 Exposing the image
The negatively charged belt then passes the LED printhead, where the IGS controller
turns the LEDs on and off to discharge the areas of the belt at a density of 300 dots per
inch. The 1s in the bitmap memory turn the LEDs on; 0s turn the LEDs off. The dis-
charged areas create a latent mirror image of the print on the photoconductor belt.
5 Developing the image
As the photoconductor belt continues to rotate, it brings the latent image to the devel-
oper unit. A negative developer bias is applied to toner and the toner is transferred to
the surface of the photoconductor belt. The negatively charged toner (which clings to
small metal carrier beads) is attracted to the discharged areas of the belt. The carrier
beads do not transfer. The belt, with the developed image on its surface, rotates out of
the developer unit. At this time you can remove the photoconductor belt and read what
is printed on it, which you may need to do when troubleshooting print problems.

Theory of Operation
6 Activating paper
As the image is being developed, a sheet of paper is transported to the photoconductor
belt. The PCL board controls this activity. A series of paper pick-up, feed, and timing
rollers guide the paper so the developed image is properly registered with the leading
edge of the sheet.
7 Transferring the image to the paper
Next, the paper contacts the surface of the photoconductor belt. Above the paper and
the belt is the transfer corona, which has a high positive charge, and attracts the devel-
oped image from the belt to the surface of the paper. At this point, you can remove the
printed image to verify print quality, but the toner is not yet fused.
8 Fusing the image to the paper
The vacuum transport unit advances the paper with the developed image to the fuser
unit where heat and pressure bond the toner to the paper. The finished print then
arrives at the paper output tray.
9 Cleaning routine
After a print is made, the photoconductor belt must be cleaned for the next print. The
belt first passes the erase lamp where any remaining latent image is erased. The belt
continues to the cleaning unit where a charged brush rotates against the surface to
remove any residual toner. This toner is recycled to the developer unit for reuse.
Transfer Corona Vacuum Transport Fuser Unit
6 7 8
Paper Input Paper
Output
Erase Lamp
9 Cleaner
Photoconductor
3
Charge Corona
Toner
4 LED Printhead
5
Bitmap SI
RAM
Developer Unit IGS Host
2 1
Figure 1-1. Cycle of Operation

Paper Path and Cycle Sequence

The IGS board signals the PCL board that a page of data is ready to be printed. When this
happens the following sequence takes place.
Simplex Printing
1 PCL software downloaded to the PCL board from the disk drive system turns on the
main motor.
2 The PCL board engages the paper pick clutch which causes the roller to feed a sheet of
paper.
3 The paper is passed to the feed roller where the PCL board has engaged the feed roller
clutch.
4 The feed roller passes the paper to the paper timing roller. Prior to reaching the paper
timing roller, the paper passes over the paper timing sensor. (If the paper does not
energize this sensor in a specified amount of time, an error 020/021 will occur.) The
leading edge of the paper is registered against the paper timing roller. The paper tim-
ing clutch is engaged and the paper is passed over the photoconductor for transfer.
This registers the paper to the printer and the image to the paper. The paper timing
sensor signal also alerts the PCL to inform the IGS that it can begin to send the data.
5 The PCL board engages the paper timing roller clutch and, at the same time, turns on
the transfer corona to provide a high positive voltage. The developed image on the
photoconductor comes in contact with the paper and the high positive voltage causes
the image to transfer to the paper.
6 Because the toner is not yet fixed to the paper, a vacuum transport assembly, gripping
the paper from the back side, moves the paper to the fuser unit, where heat and pres-
sure bond the toner to the paper.
7 Upon leaving the fuser unit, the paper comes in contact with the paper exit sensor. (If
the paper does not energize this sensor in a given amount of time after leaving the
paper timing sensor [step 4], an error 022 will occur.)
8 The exit roller moves the paper to the exit tray. (If the exit sensor is not cleared in a
specified amount of time, an error 023 will occur.)
Duplex Printing
When duplex is selected, the PCL board controls the paper motion with page scheduling
assistance from the IGS board. The duplex page router is engaged. When in duplex mode,
it is important to note that the printer runs multiple pages through the paper path at the
same time to increase speed. (See Figure 1-2, “Paper Path,” on page 1-6.)
1 In a duplex job, the duplex router solenoid behind the fuser is engaged and mechanical
fingers route the paper to the duplex area. Also, the “A” roller clutch engages to turn
the “A” and “B” rollers (connected via a belt).

2 The paper upon passing through the “B” roller comes in contact with the duplex sen-
sor. (If the paper does not energize this sensor in a given amount of time, an error 060
will occur.)
3 The “C” roller bidirectional motor turns on and passes the paper into the turnaround
tray. The paper sensor in the turnaround tray is activated and the paper is center regis-
tered. (If the paper does not energize this sensor in a given amount of time after leav-
ing the duplex sensor, an error 061 will occur.)
4 At this time the solenoid for the router at the turnaround tray engages so the paper can
be routed to be printed on the duplex side.
5 In a given amount of time after the paper energizes the paper sensor in the turnaround
tray, the bi-directional motor reverses and passes the paper to the paper timing roller.
(If the paper does not energize the paper timing sensor in a given amount of time after
leaving the turnaround sensor, an error 062 will occur.)
6 At this point, the same steps happen as during a simplex cycle.
Figure 1-2. Paper Path

Error Code Technical Definitions

The following table lists the printer error codes and their descriptions.
Table 1-1. Error Code Technical Definitions
Type Error Description

010, E10 PCL board detected no signal from upper paper cassette empty
Cassette Errors
sensor indicating no paper present

011 PCL board detected no signal from lower paper cassette empty
sensor indicating no paper present
012, E12 PCL board detected no signal from upper cassette in switch
013 PCL board detected no signal from lower cassette in switch
020 PCL board detected that the paper being fed from the upper cas-
sette did not reach the timing paper sensor within the allotted time
Paper Jams in the Primary Paper Path
021 PCL board detected that the paper being fed from the lower cas-
sette did not reach the timing paper sensor within the allotted time
022 PCL board detected that the exit paper sensor did not activate or
the timing sensor did not deactivate within the allotted time
023 PCL board detected that either:
1. The exit paper sensor (within the printer) became activated but
did not deactivate within the specified time.
2. (HCO only). The paper exit sensor (within the HCO) did not
become activated or deactivated within the allotted time
025 PCL board detected that the timing paper sensor was activated
immediately after one of the covers was closed
026 PCL board detected that either the exit paper sensor (within the
printer) or the paper exit sensor (within the HCO) was activated
immediately after one of the covers was closed
027 PCL board detected paper in the duplex area after clearing a jam
030 PCL board detected a signal from the high-voltage power supply
unit indicating an abnormal load on the bias voltage to either the
developer unit, cleaner unit, or printhead-cleaning bias plates.
Toner Control Errors
031 PCL board detected a signal from the toner patch sensor board
indicating that the reference voltage level on the photoconductor
was too low.
032 PCL board detected a signal from the toner patch sensor board
indicating that the toner patch on the photoconductor was too light.
035 PCL board detected too many successive signals from the toner
patch sensor board for a toner feed.
036 PCL board detected no developer unit electrical interlock signal
from the J25 connector.

Table 1-1. Error Code Technical Definitions (Continued)

040 PCL board sensed that the signal from the photoconductor seam
sensor either was not of sufficient amplitude or did not show the
proper timing.
041 PCL board detected an abnormally high amount of current needed
to drive the photoconductor seam sensor LED (within the photo-
OPC Rotation Errors
conductor unit).
042 PCL board detected an open connection to the photoconductor
seam sensor LED (within the photoconductor unit).
unit indicating that either the charge corona or transfer corona cir-
cuits have an open connection.
unit indicating an abnormally high load on the bias voltage to the
charge corona.
unit indicating an open connection in the charge corona circuit
(diagnostic test only).
unit indicating an abnormally high load on the bias voltage to the
HVPS Errors
transfer corona.
unit indicating an open connection in the transfer corona circuit
(diagnostic test only).
055 PCL board detected that the current needed to drive the erase
lamp assembly was either higher or lower than the specified limits.
060 PCL board detected that the exit paper sensor did not deactivate
or the paper path sensor did not activate within the allotted time.
Duplex Jams
061 PCL board detected that the duplex paper path sensor did not
deactivate, the turnaround tray sensor did not activate in the allot-
ted time, or the duplex paper path sensor activated at POR.
062 PCL board detected that paper leaving the duplex turnaround tray
did not reach the timing sensor within the allotted time or the
duplex turnaround sensor was activated at POR.
070 PCL board sensed, via the fuser thermistor, that the temperature of
Fuser Control Errors
the fuser unit did not change within the allotted time.
071 PCL board sensed an open connection in the fuser thermistor cir-
cuit
072 PCL board sensed that the resistance of the fuser thermistor was
too low indicating that the temperature of the fuser unit was higher
than the specified limit.
073 PCL board sensed that the resistance of the fuser thermistor was
too high indicating that the temperature of the fuser unit was lower
than the specified limit.


081 PCL board activated the jogging motor but did not detect a change
in the signal from the front sensor in the job offset assembly (diag-
nostic test only).
in the signal from the rear sensor in the job offset assembly (diag-
nostic test only).
in the signal from either the front or rear sensors in the job offset
Jogger Errors
assembly.
084 PCL board detected a signal from the duplex control board #2 indi-
cating that the registration side sensor did not activate after com-
mand was sent to the duplex control board #2 to turn on the resist
motor (diagnostic test only).
cating that the registration side sensor did not deactivate after a
command was sent to the duplex control board #2 to turn on the
resist motor (diagnostic test only).
cating that either the registration side sensor was activated and
would not deactivate or was deactivated and would not activate
after a command was sent to the duplex control board #2 to turn on
the resist motor.
090 PCL board detected that one of the cover interlocks was not acti-
vated (diagnostic test only).
LVPS Errors
097 PCL board detected a signal from the IGS board indicating the
absence of +12 Vdc.
absence of ‚-12 Vdc.
absence of +24 Vdc.
100, 102 IGS board detected a failure of the PCL board status codes.
101 PCL board detected that the IGS board was in a halt state (diag-
nostic test only).
121-127 PCL board detected an error in the communication between the
PCL board and the IGS board.
130-134 PCL board detected an error during the internal diagnostic testing
Controller Errors
of the PCL board.

140 PCL board detected an error during the internal diagnostic testing
of the PCL board.
145 PCL board detected an error during the internal diagnostic testing
of the PCL board.
160-182 PCL board detected an error during the internal diagnostic testing
of the PCL board.
199-215 PCL board detected an error in the communication between the
PCL board and the IGS board.
301-401 IGS board detected an error during the internal diagnostic testing
of the IGS board.


405-409 IGS board detected an error in the program RAM during the inter-
DD Errors
nal diagnostic testing of the IGS board.
of the IGS board and software.
570-586 IGS board detected an error when communicating with the floppy
Controller
disk drive.
Errors
of the IGS board.
701-703 IGS board detected an error when communicating with a host

Communication
using RS232 communications.

Errors
770-784 IGS board detected an error when communicating with a host

using RS422 communications.
888 IGS board detected that the PCL board was in a halt or reset state.

Sensor and Switch Locations

The following pages illustrate the locations of the printer’s sensors and switches. Table 1-
2, “Sensor and Switch List,” on page 1-14, lists them.
Left end view
Left end view
Front left view
Top view, duplex

Top view
Front view
Developer right view
Developer left view

Right side view
Top left, duplex tray view
Front view

Rear view
Table 1-2. Sensor and Switch List
Sensor/Switch Name Page No.

Automatic toner control sensor 1-12
Cassette paper present sensors, upper and lower 1-11
Cassette present micro switches, upper and lower 1-11
Duplex registration sensor 1-11
Duplex paper path sensor 1-11
Duplex cover interlock switch 1-11
Interlock switch, top 1-13
Interlock switch, front 1-13
Interlock switch, rear 1-14
Paper exit sensor 1-13
Paper full sensor 1-13
Paper size sensors, upper and lower 1-11
Paper timing sensor 1-12
Photoconductor seam sensor 1-12
Toner empty sensor 1-12
Toner patch sensor 1-12

Troubleshooting Overview
Throughout the printer’s life problems occur, such as those indicated when an error code
displays on the operator panel, a printer produces poor quality prints, or the printer mal-
functions. Use the tools provided in this manual to diagnose and resolve printer problems.
These tools include:
• The Troubleshooting Analysis Guide, which contains troubleshooting procedures
called TAGs. TAG 001: Troubleshooting A Printer Problem provides an overview of
how to use TAGs.
• Cross reference tables, which link error codes, print quality problems, and mechanical
malfunctions to specific TAGs.
• Print quality samples, which you can use to identify a printing problem and its associ-
ated TAGs.
• Diagnostics, through which the printer checks itself for a range of problems.
The next several pages review troubleshooting basics and standard procedures followed in
every troubleshooting session, including:
• Identifying whether a problem belongs to the printer or host
• Isolating protocol converter problems
• Running test prints
• Reading the error log
• Confirming line power
• Using TAGs
• Power-On Reset
• Installing the interlock by-pass tool
• Checking continuity
• Producing a developed image
• Producing a toner patch
• Completing a service call
• Clearing the error log
General Troubleshooting Tips

When a printer problem arises, swapping out all printer supplies may temporarily mask
the problem. This is an unsatisfactory, short-term, and expensive solution to correcting the
problem. Dust and other contamination, rather than printer supplies, are more often the
causes of problems. Clean consumable connectors, alignment guides, and areas before
changing consumables.
Many failures add excess toner to the printer’s engine. When you are advised to de-tone
the printer as part of a problem fix, run at least 200 test prints before evaluating whether
the problem has been resolved.

The Problem: Printer or Host?

The printer is one component in a large host system. Before you start any troubleshooting,
make sure that the problem really belongs to the printer rather than to some other compo-
nent in the host system. Print quality problems and mechanical malfunctions are almost
always associated with the printer. However, host interface and software emulation prob-
lems can be caused by some other component of the host system even though, at first Z
glance, they appear to be printer problems. For instance, text printed in the wrong location
on a page, improper page breaks, and missing segments of data strongly indicate a host,
not a printer, problem.
The first step in troubleshooting any problem is to isolate the printer from the host system;
you can then run test prints. Producing test prints exercises the printer as a stand-alone
ones machine, ensuring that the basic printer software and all mechanical functions of the
printer are working.
Running Test Prints
To run test prints:
1 Disconnect the host interface.
2 Run a series of test prints. A directory of the boot device and multiple listings of fonts
print, followed by an unformatted and formatted error log. A continuous flow of the
test pattern then prints. To run test prints:
• For simplex printers, press:
STOP
TEST
• For duplex printers, press:
STOP
DUPLEX
TEST
• To stop printing the test pattern, press:
STOP
On pressing STOP, the printer will print all test prints stored in the printer’s buffer, then
stop.
If the test pattern prints successfully, the problem probably originates with the host system
or a protocol converter connected to the host.

Protocol Converters
Many protocol converters have a self-test function or configuration mode that enables the
user to check the proper functioning of the control. You can reconnect the host interface
and ask the customer to exercise this function of the converter. If the printer receives data
and prints it (even if the output is garbled) you have isolated the problem as one that
belongs to the host or the protocol converter. The problem is not a printer problem and the
customer must seek assistance elsewhere in resolving the problem.
Reading the Error Log

One of the sheets printed prior to the test pattern is the formatted error log maintained by
the printer in a file named ERROR.LOG.
• The first line of the formatted log lists paper jams. A 3-digit error code (or codes) is
followed by a 4-digit number indicating how many times the error has occurred since
the error log was last cleared. (See “Clearing the Error Log” on page 1-24.)
• The second line lists the last 15 errors.
• The last line indicates the last error that required a power-on-reset (POR).
Paper Jams
020 0001 021 0000 022 0001

023 020 020 022 022 022 022 071 042 000 000 000 000 000 000
000
Last 15 errors
Last error requiring POR (not used)
Figure 1-3. Sample Simplex Printer Error Log

Confirming Line Power

Erratic printer problems can be caused by improper line power. As a rule, the voltage of
the outlet should be checked at installation. However, if you are unable to isolate an inter-
mittent problem, the power should be checked again. Consult your country’s national elec-
tric code for the proper procedures to check for acceptable voltages, as shown in Table 1-
3, “Acceptable Voltages”.
Table 1-3. Acceptable Voltages
Probe connections 100-127v printer 200-240v printer
red to AC hot 120v +/- 10% 230v +/- 10%

black to AC neutral
red to AC neutral 3 vac or less 3 vac or less

black to ground
red to AC hot 120v +/- 10% 230v +/- 10%

black to ground
Please see Chapter 5, “Diagnostic Tests” for additional information about running diag-
nostic printer tests.
Please see Chapter 6, “Wiring Diagrams and Electrical Data” for additional information
about the printer’s electrical systems.

Using the Troubleshooting Analysis Guide (TAG)

The Troubleshooting Analysis Guide provides problem-solving sequences to help you
identify and resolve printer problems. Each TAG addresses a particular symptom or error
code of the printer. The TAG number often matches an error code displayed on the
printer’s operator panel.
Sample TAG
TAG 001: Troubleshooting a Problem

Error Code: All related error messages are listed here.
Possible Causes: All possible causes are listed here.
Possible Defects: All possible defective parts are listed here. (In no particular order.)
1 To start:
• Disconnect all peripheral cables
• Power-on-reset the printer.

Did all of the status lights come on, followed by 888 flashing briefly and an error code?
Yes: Run test prints, following the procedure outlined in Section 1, then repeat this step. If the
answer is still no, refer to the mechanical malfunctions cross-reference chart in Section 2
to determine which TAG to follow. Then turn to that TAG.
Yes: Note the error message and continue.
2 Power-on-reset the printer.

Did the power-on-reset end with an error code?
No: Continue.
Yes: Refer to the error code cross-reference table in Section 2, using either the code that dis-
played after steps 1 and 2, or if multiple error codes continue to appear, the first error
code that displays. Turn to the TAG associated with the code.
3 Did only the READY light come on with no numeric display?

No: Continue
Yes: Go to TAG 753
Each TAG walks through a comprehensive procedure specific to a single problem. As you
progress through a TAG and eliminate possible causes, you may be directed to another
step out of sequence in the same TAG or to another TAG altogether.
The TAG number and its title may be followed by a listing of possible error messages,
possible causes, or possible defective parts related to the TAG.

The TAG then directs you to perform certain tasks. Based on the results of these tasks, the
TAG poses questions that can be answered by either yes or no. For yes answers, you fol-
low one path; for no answers, follow another path. Some of the paths may lead you to
other TAGs, so that you can methodically diagnose and resolve problems. When you have
corrected a problem, you will be directed to TAG 002 to confirm that the problem has been
completely resolved and standard cleanup procedures observed.
If it’s not clear how to diagnose a problem you’re working on, follow the steps outlined in
TAG 001, which includes references to the cross reference tables contained in Chapter 2,
“”. Or, you may turn directly to the tables to get started.
As you use TAGs, you will sometimes refer to other sections of this manual for additional
information:
• Chapter 4, “Print Quality Samples” contains print quality samples you’ll use to com-
pare the customer’s test prints with flawed and good print samples.
• Chapter 5, “Diagnostic Tests” outlines how to conduct printer diagnostic tests.
• Chapter 6, “Wiring Diagrams and Electrical Data” provides all wiring and connector
diagrams.
• Chapter 7, “Removal/Replacement Procedures” provides step-by-step procedures for
removing and replacing all field-replaceable parts on the printer.
• Chapter 8, “Options” reviews printer options (HCI, HCO) information.
• Chapter 9, “General Printer Maintenance” presents general printer maintenance proce-
dures.

Standard Procedures
Standard Procedures
While using the TAGs, you may be asked to perform some of the following procedures.
Specific instructions for completing these procedures are included here, rather than
repeated in the body of each TAG. Please read this information before following any TAG.
Power-on-reset (POR)
When directed to power-on-reset the printer:
1 Turn off the printer.
2 Wait at least 5 seconds.
3 Turn the power back on.
Checking Continuity
Warning
Make sure the printer is turned off and the power disconnected.
Failure to do so may result in personal injury, equipment damage,
or both.
To perform a continuity check:

1 Turn off the printer and disconnect the power cord.
2 Set your meter to the lowest ohm setting.
3 Interpret the results as follows:
• An infinite reading indicates an open circuit.
• A zero or specific reading indicates continuity.
4 To check an open or short circuit to ground:
• Turn off the printer and disconnect the power cord.
• Locate the circuit in question. (Refer to Chapter 6, “Wiring Diagrams and Electri-
cal Data”, for circuit locations.)
• Check all connectors and wiring on each side for corrosion, foreign objects, bent
pins, loose socket housings, and/or loose wires.
Warning
The printer is equipped with safety interlock switches on all of
its covers. These switches disable parts of the printer when the
covers are opened. These areas present the risk of electrical
shock, burns, and injury from mechanical hazards.

Standard Procedures
Installing the Interlock By-pass Tool

The interlock by-pass tool overrides the cover interlock switches, allowing you to operate
the printer with the covers open. The interlock by-pass tool is a white plastic, “V”-shaped
tool with two finger pads. To use the tool, open the cover and locate the interlock switch
(for locations, see illustrations beginning page 1-11). Squeeze the tool between thumb and
fore finger and insert it into the interlock switch.
The printer ships with two spare interlock by-pass tools concealed behind the right cover.
Replace them when you are finished using them.
Caution
Do not attempt to close the printer cover while the interlock
bypass tool is in place.
Producing a Developed Image

Producing a developed image helps determine where exactly in the print cycle a problem
may be occurring. To produce a developed image:
1 Open the top cover and install an interlock by-pass tool.
3 Run a series of test prints. The directory of the boot device will print, followed by con-
tinuous test patterns.
4 As test patterns print, observe paper moving from the upper paper tray to the paper
timing roller where it pauses briefly.
5 When a sheet of paper begins to move from the paper timing roller, turn off the printer.
6 Remove the photoconductor unit.
7 Examine the photoconductor belt to verify that a developed image was produced.
Producing a Toner Patch

To produce a toner patch:
3 Turn on the printer.
4 Start running test prints using Simplex Print mode. When the leading edge of the first
print enters the fuser unit, remove the interlock by-pass tool.

Standard Procedures
Figure 1-4. Producing a Toner Patch on the Photoconductor Unit

6 Examine the photoconductor unit to verify that a toner patch has been produced. You
may have to rotate the belt slightly to observe the patch.
Caution
Do not touch the surface of the photoconductor belt; this
damages the belt and results in poor print quality.
Completing a Service Call

After resolving any printer problem, complete the service call as follows:
1 Reassemble the printer.
2 Perform the every-call cleaning procedure, described in Chapter 9, “General Printer
Maintenance”.
3 If you have removed the printer’s diskette(s), reinstall them.
5 Clear the error log. (See the procedure described next.)
6 Run test prints in both the simplex and duplex mode from both the upper and lower
paper cassettes.
7 Fill in the Repair/Maintenance log. Make sure the problem description and steps taken
to resolve the problem are clearly documented.

Standard Procedures
Clearing the Error Log

1 Enter the diagnostic mode of the printer:
• Turn off the printer and wait 5 seconds.
• Hold down the STOP and TEST keys simultaneously as you turn the printer back
on.
• The tone, followed by “00” on the display, indicates you are in the test mode. This
takes approximately 1 minute.
2 Press: CANCEL to advance the counter to “110.”
3 Press READY to activate the procedure. “0” appears on the display, indicating the A:
drive.
4 Press: CANCEL to advance to the drive where the error log is maintained. This is usu-
ally the boot drive.
Table 1-4. Drive Indication
Display Indication
0 Diskette drive A:
1 Diskette drive B:
2 Hard drive C:
5 Press: READY to select the drive specified. “1-0” appears on the display.
Caution
At this point, be careful! “1-0” represents the clear error log
function. Do not advance the counter to “1-1,” which represents
the format disk option.
6 Press: READY to select the clear error log function. “6-0” appears on the display.
Caution
If “7-0” appears, press STOP immediately. DO NOT CONTINUE
WITH THIS PROCEDURE. POR the printer and start over.
7 Press: CANCEL to clear the error log. “6-1” appears on the display.
8 Press: STOP to exit the procedure.
9 Cycle printer power to exit diagnostic mode.
10 Confirm that the error log has been cleared. When you run your test prints, check to
make sure the error log entries appear as “0000.”

Chapter 2
June 1999 2-1

Chapter Contents

This section contains the three cross reference charts for troubleshooting print problems:
Error Code/TAG Cross-Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Print Quality/TAG Cross-Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Mechanical Malfunction/TAG Cross-Reference Chart . . . . . . . . . . . . . . . . . . . . .2-12
2-2 June 1999

Error Code/TAG Cross-Reference

Error codes, which appear on the 3-digit display of the operator’s panel, indicate a wide
variety of printer problems related to the control boards, software, and/or host communi-
cation problems. On the chart find the error code in question, then turn to TAG associated
with the code.
Table 2-1. Printer Error Codes
Code Printer Error Code Meaning Go to TAG

010 Upper paper tray out of paper 010
011 Lower paper tray out of paper 011
E10 Envelope feeder out of envelopes E10
012 Upper paper tray not plugged in 012
013 Lower paper tray not plugged in 013
E12 Envelope feeder not plugged in E12
020 Upper paper tray paper jam 020
021 Lower paper tray paper jam 021
022 Transfer or fuser area paper jam 022
023 Exit area paper jam 023
025 Transfer or fuser area paper jam not cleared 025
026 Exit area paper jam not cleared 026
027 Duplex area paper jam 902
030 Developer bias short 030
031 Toner patch sensor reference level too low 031
032 Toner patch sensor black patch too light 032
035 No toner 035
036 No developer 036
040 Photoconductor seam sensor malfunction 040
041 Photoconductor seam sensor short 040
042 Photoconductor seam sensor open 040
044 Charge corona open 044
045 Charge corona short 045
046 Charge corona open 044
050 Transfer corona short 050
055 Eraser lamp malfunction 055
057 Fan stopped sensor 752
060 Duplex area 1 paper jam 902
069 Duplex tray not plugged in 900
June 1999 2-3

Table 2-1. Printer Error Codes (Continued)

070 Fuser lamp or thermal fuse malfunction 070
071 Fuser thermistor open or no fuser 071
072 Fuser temperature too high 072
073 Fuser temperature too low 070
081 No front job offset sensor 083
082 No back job offset sensor 083
083 Job offset mechanism malfunction 083
084 Duplex tray registration sensor not activated 901
085 Duplex tray registration sensor not deactivated 901
086 Duplex registration tray malfunction 901
090 Cover open 900
097 DC +12v power failure 097
098 DC -12v power failure 098
100 PCL board command timeou 100
101 IGS controller diagnostic failure 101
Table 2-2. PCL/IGS Communication Error Codes
Code PCL/IGS Communication Error Code Meaning Go to TAG

121 No controller command; PCL board VSC command asserted 201
122 Command tag asserted; VSC command not asserted 201
123 VSS not asserted; PCL board status tag asserted 201
124 VSS asserted after PCL board sent status 201
125 VSS not asserted again though PCL board expects it 201
126 Command tag asserted during data byte sequence 201
127 PCL board detected parity/overrun on command line 201
Table 2-3. PCL Error Codes
Code PCL Error Code Meaning Go to TAG

130 Address or length error at initial microcode load 130
131 Checksum error at initial microcode load 130
132 RAM error at initial microcode load 100
133 No next block at initial microcode load 130
134 Incorrect format in initial microcode load file 130
140 PCL board ROM checksum error at power on diagnostic 100
2-4 June 1999

Table 2-3. PCL Error Codes (Continued)
Code PCL Error Code Meaning Go to TAG

145 PCL board RAM error at power on diagnostic 100
160 PCL board PIA1 register error after reset 100
161 PCL board PIA1 registers read/write error 100
162 PCL board PIA1 PA or PB read/write error 100
170 PCL board PIA2 register error after reset 100
171 PCL board PIA2 register read/write error 100
172 PCL board PIA2 PB read/write error 100
180 PCL board PTM register error after reset 100
181 PCL board PTM read/write error 100
182 No IRQ generation on PTM 100
Table 2-4. PCL/IGS Communication Error Codes
Code PCL/IGS Communication Error Code Meaning Go to TAG

199 VSS not asserted before communication test 201
200 Status tag not asserted 201
201 Timeout waiting for a failed IGS controller 201
202 No data received after VSS line asserted 201
203 VSS asserted after PCL board sent status 201
204 Status tag asserted after VSS not asserted 201
205 No command tag after status tag not asserted 201
206 VSC command not asserted after command tag asserted 201
207 No data received after VSC asserted 201
208 VSC command asserted after command line asserted 201
209 Command tag asserted after VSC not asserted 201
210 No RQI after “request RQI” command 201
211 Parity error on command line 201
212 Parity or overrun sensed by PCL board 201
213 Incorrect command received from PCL board 201
214 Incorrect command received from IGS controller 201
215 No transfer buffer empty on asynchronous communications 201
interface adapter after PCL board sent data
June 1999 2-5

Table 2-5. IGS Firmware Error Codes
IGS Firmware Error Code Meaning

These error codes signal a problem with the IGS controller
Code Go to TAG
firmware. No TAGs address these problems; report them to the
printer’s manufacturer.
301 Status received after VSS asserted No TAG
302 Status tag asserted after VSS not asserted No TAG
303 VSC command not asserted after command tag asserted No TAG
304 VSC command asserted after data was sent No TAG
305 VSC command not asserted for next data byte No TAG
306 Status tag asserted while data was being sent No TAG
307 Parity error on command line No TAG
Table 2-6. PCL Failure Error Codes
Code PCL Failure Error Code Meaning Go to TAG

380 PCL board failure - command retries 201
381 PCL board failure - command rejected 201
382 PCL board failure - bad command received 201
383 PCL board failure - unexpected byte received 201
384 PCL board failure - no status received 201
385 PCL board failure - bad status information block count 201
386 PCL board failure - bad status information block offset 201
387 PCL board failure - parity error 201
389 Floppy disk retry 130
Table 2-7. IGS Software Error Codes
IGS Software Error Code Meaning

These error codes signal a problem with the IGS controller
Code software. No TAGs address these problems; to determine Go to TAG
whether the faulty software is the customer’s or the
manufacturer’s, contact the printer’s manufacturer.
397 IGS software trap No TAG
2-6 June 1999

Table 2-8. IGS/Disk Drive Error Codes
Code Disk Drive Error Code Meaning Go to TAG

401 Fatal IGS PB error No TAG
450 Incorrect diskette 130
451 Diskette format error or incorrect disk 130
454 Fatal trap 200
455 Trap 200
500 Incorrect PIT0 registers contents; no reset 200
501 PIT0 register read/write error 200
502 No countdown/zero detection in PIT0 timer 200
503 PIT0 timer; no halt 200
504 No PIT0 timer interrupt 200
509 No PIT2/timer interrupt 200
520 No DMAC reset 200
521 DMAC registers read/write error 200
522 No DMA transfer 200
523 No DMA transfer termination 200
524 No DMAC termination interrupt 200
525 No software abort operation 200
526 No software abort interrupt 200
527 DMAC operation error 200
528 DMA transfer error 200
529 Two-channel DMA transfer error 200
530 No two-channel DMA transfer 200
540 PCL board serial controller registers read/write error 200
541 PCL board break condition detected 200
542 PCL board serial controller transmitter not ready 200
543 No PCL board serial controller transfer 200
544 PCL board serial controller transfer error 200
545 Host serial controller registers read/write error 200
546 Host transmitter not ready 200
547 No serial controller interrupts 200
548 Host serial controller/PCL board parity error 200
549 Serial controller unexpected interrupt 200
550 Two-channel transfer error 200
551 No PCL board/serial controller interrupt on break 200
June 1999 2-7

Table 2-8. IGS/Disk Drive Error Codes (Continued)
Code Disk Drive Error Code Meaning Go to TAG

552 No serial controller/DMAC interaction 200
553 Serial controller/DMAC transfer count error 200
554 Serial controller/DMAC transfer error 200
555 RS232 send/receive path error 200
556 RS232 DTR/DTC path error 200
557 RS232 RTS/CTS path error 200
559 RS422 send clock/receive clock path error 200
560 CRTC register read/write error 200
561 No page begin (PIT2) interrupt 200
562 No CRTC address generation 200
563 No VSYNC generation (end of page) 200
564 No end of page (PIT2) interrupt 200
565 No CRTC count termination 200
566 VSYNC timeout error 200
570 Drive controller/SCSI read/write error 200
571 Drive controller busy timeout 200
572 Diskette is write protected 130
573 Drive not ready 130
574 Drive controller restore error 130
575 Drive controller seek error 130
576 Drive controller read sector error 130
577 Drive controller read sector data/checksum error 200
578 Drive controller write sector error 200
579 Drive controller read/modify/write error 200
580 No drive controller/PIT0 interrupt 200
581 No drive controller-DMA interaction 200
582 Drive controller/DMAC transfer error 200
583 Drive controller/DMAC transfer count error 200
584 Drive controller/DMAC read sector error 200
585 Drive controller/DMAC write sector error 200
586 Drive hard error 130
Table 2-9. Bit Map RAM Error Codes
Code Bit Map RAM Error Code Meaning Go to TAG

600 Bit-map RAM data path error 200
2-8 June 1999

Table 2-9. Bit Map RAM Error Codes (Continued)
Code Bit Map RAM Error Code Meaning Go to TAG

601 Bit-map RAM bank selection error 200
602 Bit-map RAM refresh error 200
603 Bit-map RAM address path error 200
604 Incorrect ALU operation in bit-map RAM data path 200
605 Incorrect origin data modifications 200
606 Total bit-map RAM bank fault 405
610 Bit-map RAM chip error 405
Table 2-10. Host Communication Error Codes
Code Host Communication Error Code Meaning Go to TAG

701 No communication with host 753
702 Host communication protocol error 753
703 Host communication recoverable error 753
770-784 Ethernet communication error No TAG; con-
tact software
support
June 1999 2-9

Print Quality/TAG Cross-Reference

Poor quality prints are another indication of printer problems. Begin by running a set of
test prints. Then, compare the test prints to the samples located in Chapter 4, “Print Qual-
ity Samples”. The chart summarizes the possible print quality problems you may encoun-
ter and recommends a TAG to follow to address the problem.
Table 2-11. Blank Print TAGs
Blank Prints Go to TAG

Complete 800
Partial 800
With dark horizontal bands 800
Table 2-12. Light Print TAGs
Light Prints Go to TAG

With carrier particles 801
With background 811
With voids/white spots 802
With light vertical streaks 803
With blank or white vertical lines 803
With light horizontal bands 804
Table 2-13. Dark Print TAGs
Dark Prints Go to TAG

Dark black prints 805
With dark spots or scratches 806
With dark blotches 810
With dark vertical streaks (without fusing) 812
With dark vertical streaks (with fusing) 808
Table 2-14. Skewed Path TAGs
Skewed Prints Go to TAG

Simplex 807
Duplex 901
2-10 June 1999

Table 2-15. Misregistration TAGs
Misregistered Prints Go to TAG

Simplex 807
Duplex 901
Table 2-16. Smeared, Blurred, and Uneven Print TAGs
Smeared, Blurred, Uneven Prints Go to TAG

Smeared vertical streaks 809
Blurred prints 809
Uneven density 810
Prints with background 811
Prints with background and residual images 811
Prints with residual images 813
Prints with offset images 814
Table 2-17. Additional Print Quality Problem TAGs
Additional Print Quality Problems Go to TAG

Wrinkled or torn prints 706
Prints improperly fused 812
Prints exhibiting printhead problems 815
June 1999 2-11

Mechanical Malfunction/TAG Cross-Reference

The chart below outlines possible mechanical malfunctions and recommends an appropri-
ate TAG to follow to resolve the problem.
Table 2-18. Operator Panel Problems TAGs
Operator Panel Problems Go to TAG

Blank with AC power fan and cooling fan on 500
Blank with AC power fan on 500
Blank with no fans on 600
All lights on 610
Incomplete display immediately after POR 610
Close cover light remains on 600
Remove prints light remains on or lights 700
Add toner light remains on 035
Machine check light is on with no numerical Display 201
One or more lights are off at POR 610
Tone not working 610
Incorrect paper size 702
Other operator panel malfunctions 610
Table 2-19. Output Tray Problem TAGs
Output Tray Problems Go to TAG

Sensor not sensing condition 701
Jogging incorrectly 083
Will not stop jogging 083
Job offset incorrect 083
Table 2-20. Cassette Problem TAGs
Cassette Problems Go to TAG

Upper cassette 703
Lower cassette 704
2-12 June 1999

Table 2-21. Paper Handling Problem TAGs
Paper Handling Problems Go to TAG

Multiple paper feed 705
Multiple sheet feeds and jams 705
Wrinkled or torn paper 706
Simplex: misregistration and paper skew 807
Duplex: misregistration and paper skew 901
Paper will not feed from upper cassette 012
Paper jam in duplex area 902
Upper paper guide not closing 707
Table 2-22. Counter Problem TAGs
Counter Problems Go to TAG

Supplies seem to have short life span 750
Incorrect counting 750
Table 2-23. Communication Problem TAGs
Communication Problems Go to TAG

Printer will produce test prints 753
Incorrect data being printed 753
Table 2-24. Additional Mechanical Malfunction TAGs
Additional Mechanical Malfunctions Go to TAG

Test prints won’t run after POR 130
Cooling fan not running 752
Vacuum transport unit fan not running 752
Circuit breaker trip 600
Main drive motor not turning off 751
June 1999 2-13

2-14 June 1999

Chapter 3
Troubleshooting
Analysis Guide
(TAGs)
June 1999 Troubleshooting Analysis Guide (TAGs) 3-1

Chapter Contents

TAG 001: Troubleshooting a Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
TAG 002: Check &Problem Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
TAG 010: Upper Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
E10: Envelope Tray Out of Envelopes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
TAG 011: Lower Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
TAG 012: Upper Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
TAG E12: Envelope Tray or Feeder Not Latched . . . . . . . . . . . . . . . . . . . . . . . . .3-21
TAG 013: Lower Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
TAG 020: Paper Jam/Misfeed in Upper Cassette Area . . . . . . . . . . . . . . . . . . . . . 3-26
TAG 021: Paper Jam/Misfeed in /Lower Cassette Area . . . . . . . . . . . . . . . . . . . . 3-30
TAG 022: Paper Jam in the Transfer or Fuser Area. . . . . . . . . . . . . . . . . . . . . . . . 3-34
TAG 023: Paper Jam in the Output Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
TAG 025: Paper in Input Area Before Printing . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
TAG 026: Paper in Output Area Before Printing. . . . . . . . . . . . . . . . . . . . . . . . . .3-43
TAG 030: Developer Bias Short/Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
TAG 031: Toner Patch Reference Level Too Low . . . . . . . . . . . . . . . . . . . . . . . . 3-47
TAG 032: Toner Patch Too Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
TAG 035: Out of Toner or ADD TONER Indicator On . . . . . . . . . . . . . . . . . . . .3-51
TAG 036: =Developer Unit Not Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53
TAG 040: Photoconductor Seam Sensor Malfunction. . . . . . . . . . . . . . . . . . . . . .3-54
TAG 044: Charge Corona/Transfer Corona Circuit Open . . . . . . . . . . . . . . . . . . . 3-58
TAG 045: Charge Corona Circuit Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
TAG 050: Transfer Corona Circuit Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63
TAG 055: Erase Lamp Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65
TAG 070: Fuser Unit Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-67
TAG 071: Open Fuser Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
TAG 072: Fuser Unit Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-73
TAG 083: Job Offset Mechanism Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . .3-75
TAG 097: +12 Vdc Power Shorted or Sensing Problem . . . . . . . . . . . . . . . . . . . . 3-79
TAG 098: -12 Vdc Power Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-90
TAG 099: +24 Vdc Power Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
TAG 100: PCL Board Interface Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-102
TAG 101: IGS Controller Diagnostic Failure . . . . . . . . . . . . . . . . . . . . . . . . . . .3-103
3-2 Troubleshooting Analysis Guide (TAGs) June 1999

TAG 130: Diskette/Disk Drive Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104
TAG 200: IGS Internal Communication Malfunction. . . . . . . . . . . . . . . . . . . . . 3-108
TAG 201: IGS-PPCL Interface Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
TAG 405: IGS Bit-Map RAM Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
TAG 500: +5 Vdc Power Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113
TAG 600: Vac Power Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
TAG 610: Operator Panel Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
TAG 700: Output Tray Circuit Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
TAG 702: Paper Size Detection Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
TAG 703: Upper Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
TAG 704: Lower Cassette Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
TAG 705: Multiple Paper Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-137
TAG 706: Paper Damaged or Wrinkled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
TAG 707: Upper Paper Guide Assembly Not Closing . . . . . . . . . . . . . . . . . . . . 3-139
TAG 750: Counter Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140
TAG 751: Main Drive Motor Runs Continuously. . . . . . . . . . . . . . . . . . . . . . . . 3-142
TAG 753: External Communications Malfunction . . . . . . . . . . . . . . . . . . . . . . . 3-143
TAG 754: Attachment Option Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
TAG 800: Prints Blank or With Dark Horizontal Bands. . . . . . . . . . . . . . . . . . . 3-148
TAG 801: Prints Light or Light With Carrier Particles . . . . . . . . . . . . . . . . . . . . 3-152
TAG 802: Prints With Voids or White Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-158
TAG 803: Prints With Light or White Vertical Streaks . . . . . . . . . . . . . . . . . . . 3-160
TAG 804: Prints With Light Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . 3-162
TAG 805: Black Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163
TAG 806: Prints with Dark Spots or Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166
TAG 807: Misregistered/Skewed Prints (Simplex) . . . . . . . . . . . . . . . . . . . . . . . 3-168
TAG 808: Prints Overtoned/Dark Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . 3-172
TAG 809: Blurred or Smeared Vertical Streaks on Prints. . . . . . . . . . . . . . . . . . 3-177
TAG 810: Uneven Density or Dark Areas on Prints . . . . . . . . . . . . . . . . . . . . . . 3-180
TAG 811: Background/Residual Images/Dark Prints . . . . . . . . . . . . . . . . . . . . . 3-182
TAG 812: Uneven or No Fusing on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-187
TAG 813: Residual Images on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-189
TAG 815: Prints Resulting From Printhead Malfunctions . . . . . . . . . . . . . . . . . 3-191
TAG 900: Top Cover Interlock Malfunction, Duplex . . . . . . . . . . . . . . . . . . . . . 3-192
TAG 901: Misregistration/Skewed Prints (Duplex) . . . . . . . . . . . . . . . . . . . . . . 3-194
TAG 902: Paper Jam in Duplex Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-198

This chapter describes each of the TAGs used to diagnose and resolve specific printer
problems related to error codes, print quality, and mechanical malfunctions.
Chapter 1, “Printer and Troubleshooting Overview”, is an overview of how the TAGs are
organized and how to use them. If you are using a TAG for the first time, please refer to
this chapter for more specific instructions.
Chapter 2, “”, provides comprehensive tables which cross reference specific error codes,
print quality problems, and mechanical malfunctions to the TAGs contained in this chap-
ter.
As you use these TAGs, you may need to refer to other chapters of this manual for addi-
tional information. Please turn to these chapters as required.


If you are not sure how to troubleshoot a printer problem, start with this TAG. This and all
TAGs assume you are familiar with standard procedures, such as power-on-reset, pre-
sented in Chapter 1, “Printer and Troubleshooting Overview”. In addition, TAG may refer
you to Chapter 2, “”, which contain:
• Error code cross-reference table
Arranged by error code; refers you to the TAG associated with the code.
• Print quality cross-reference table
Arranged by description of print-quality problem; refers you to the TAG associated
with the problem.
• Mechanical malfunction cross-reference table
Arranged by description of the mechanical malfunction; refers you to the TAG associ-
ated with the malfunction.
1 To start:
• Disconnect all peripheral cables.
Did all of the status lights come on, followed by 888 flashing briefly and an error
code?
No: Run test prints, following the procedure described in Chapter 1, “Printer and Trouble-
shooting Overview”, then repeat this step. If the answer is still no, refer to the mechanical
malfunctions cross-reference table in Chapter 2, “” to determine which TAG to follow.
Then turn to that TAG.
Yes: Note the error code and continue.

Did the power-on-reset end with an error code?
No: Continue.
Yes: Refer to the error code cross-reference table in Chapter 2, “”, using either the code that
displayed after steps 1 and 2, or if multiple error codes continue to appear, the first error
code that displays. Turn to the TAG associated with the code.
3 Did only the READY light come on with no numeric display?

No: Continue.
Yes: Go to TAG 753: External Communications Malfunction.
4 Did only the READY and ON LINE lights come on with no numeric display?
No: Continue.
5 Did the READY, ON LINE, and JOB IN PROCESS lights come on with no numeric
display?
No: Refer to Chapter 2, “” to determine which TAG to follow, then turn to that TAG.
Yes: Continue.

6 Run test prints from the upper cassette by completing the following:
• Run test prints from the upper cassette.
Did an error code appear while running the prints?
No: Continue.
Yes: Look up the code in Chapter 2, “” to determine which TAG to follow, and then turn to
that TAG.
7 Run test prints from the lower cassette by completing the following:
• Press STOP and allow the cycle to finish.
• Remove the upper cassette.
• Run test prints from the lower cassette.
Did an error code appear while running test prints?
No: Continue.
Yes: Look up the code in Chapter 2, “” to determine which TAG to follow, then turn to that
TAG.
8 Check communications by completing the following:

• Turn the printer off.
• Reinstall all communication cables.
• Reinstall the upper cassette.
• Re-run the customer’s problem print job.
Does the job fail?
No: Continue.
9 Complete the following:

• Run test prints.
Does an error code appear?
No: Continue.
Yes: Look up the code in Chapter 2, “”, then turn to TAG indicated in the table.
10 Run a job which is known to be good.

• Compare the output from the problem print job to the output from the good print job.
Can you identify the problem?
No: Return to the beginning of the TAG, following the procedures carefully to determine the
kind of problem your customer has.
Yes: Identify the problem as either a print quality problem or a mechanical malfunction, find
the problem in the appropriate cross-reference table, identify a TAG addressing that prob-
lem, then turn to that TAG.

TAG 002: Check & Problem Resolution

Note
Follow the procedure described in this TAG when you have
completed an action to resolve a problem, and are sent to
this TAG from another TAG
1 Complete any actions directing you to this TAG.

• Make sure all connectors, covers, parts, and hardware have been reinstalled.
In the course of resolving the printer problem, did you complete the every-call
cleaning procedure?
No: Continue.
Yes: Go to #3 in this TAG.
2 Clean the printer thoroughly, following the every-call cleaning procedure described below.
1 Remove these major printer supplies:
• Photoconductor unit; place it in its protective packaging
• Cleaner unit
• Developer unit
• Fuser unit
2 Inspect and vacuum the printer:
• Inspect the areas in the printer around the developer unit, cleaner unit, photoconductor
unit, and fuser unit for damage and wear.
• Vacuum these areas to remove all excess toner, contamination, and/or foreign objects.
3 Clean internal areas:
• Clean the erase lamp with a cotton swab.
• Clean the printhead bias plates with a soft cloth.
• Clean the LED lens with a cotton swab, making sure no lint remains on the lens.
4 Inspect and clean the fuser unit:
Warning
The fuser unit may be hot
• Inspect the unit for damage and contamination; repair or replace as necessary.
• Clean the fuser unit connector, both on the fuser unit and in the printer, with a cotton swab.
• Vacuum in and around the rollers to remove excess toner, contamination, and any foreign
objects.
• Reinstall the fuser unit.
5 Inspect and clean the developer unit:
• Inspect the unit for damage or contamination; repair or replace as necessary.
• Clean any excess toner from the developer unit with a soft cloth.
• Clean the toner patch sensor lens with a cotton swab, making sure no lint remains on the
lens.
• Vacuum the felt areas around the magnetic roller, being careful not to vacuum toner from

the magnetic roller.

• Reinstall the developer unit.
6 Inspect and clean the cleaner unit/charge corona:
Caution
Handle gently to avoid breaking the corona wire

• Remove the charge corona from the cleaner unit.
• Clean the grid with the cleaner brush.
• Remove the grid to expose the corona wire.
• Clean the corona wire with a cotton swab or corona cleaning tool.
• Reinstall the grid.
• Clean any excess toner from the cleaner unit with a soft cloth.
• Reinstall the charge corona in the cleaner unit.
• Reinstall the cleaner unit.
7 Clean and inspect the photoconductor unit area
Caution
Do not touch the photoconductor belt as this
permanently damages the unit
• Clean the photoconductor seam sensor inside the printer with a cotton swab or compressed
air.
• Remove the photoconductor from its protective packaging.
• Inspect the photoconductor for damage or contamination; repair or replace as necessary.
• Reinstall the photoconductor unit.
8 Clean the transfer corona
Caution
Handle gently to avoid breaking the corona wire
• Remove the transfer corona.

• Clean the transfer corona housing with a soft cloth.
• Clean the transfer corona wire with a cotton swab.
• Reinstall the transfer corona.
Have you completed the every-call cleaning procedure?
No: Complete the procedure, then continue.
Yes: Continue.

3 Run test prints to confirm print quality, in both simplex and duplex modes and from upper and
lower paper cassettes. When you enter test print mode by pressing the keys listed below, the follow-
ing items print in the order listed: a directory of the boot device and multiple listings of fonts; a for-
matted and unformatted error log; a continuous flow of test prints.
2 Run test prints:
• For simplex printers, press:
STOP
TEST
• For duplex printers, press:
STOP
DUPLEX
TEST
3 Stop printing the pattern by pressing STOP. On pressing STOP, the printer will stop generating
test prints. The printer will print all test prints stored in the printer’s buffer, then stop.
Are the test prints clean and printing correctly?
No: Go to Chapter 4, “Print Quality Samples”; identify a sample with the problem you see in
the test print; then turn to the TAG indicated.
Yes: Continue.
4 Clear the error log:
Caution
With this procedure you can either clear the error log or
format a disk. Pay careful attention to the options you select.

• Hold down the STOP and TEST keys simultaneously as you turn the printer back on.
• The tone, followed by 001 on the display, indicates you are in the test mode. This takes
about 1 minute.
2 Press: CANCEL to advance the counter to 110.
3 Press: START to activate the procedure. 0 appears on the display, indicating the A: drive.
4 Press: CANCEL to advance to the drive where the error log is maintained. This is usually the
boot drive.
Display Indication
0 Diskette drive A:
1 Diskette drive B:
2 Hard drive C:

5 Press: START to select the drive specified. 1-0 appears on the display
Caution
1-0 represents the clear error log function. Do not advance the counter
to 1-1, which represents the format disk option, described in the
Guide to Operations
6 Press: START to select the clear error log function. 6-0 appears on the display.
Caution
If 7-0 appears, press STOP immediately. DO NOT PROCEED
7 Press: CANCEL to clear the error log. 6-1 appears on the display.
8 Press: STOP to exit the procedure.
9 Confirm that the error log has been cleared; to do this, power-on-reset the printer and run test
prints, checking to make sure the error log entries appear as 0000.
Do the error log entries appear as 0000?
No: Return to the beginning of this step.
Yes: Continue.
5 Fill in the Repair/Maintenance record taped inside the printer’s front cover.
• Make sure the problem description and steps taken to resolve the problem are clearly docu-
mented.
• Reinstall all connectors, covers, parts, and hardware.
You have successfully resolved the printer’s problem. Congratulations!

TAG 010: Upper Cassette Malfunction

Error Code: 010
Possible Causes: Cassette empty
Paper incorrectly loaded
Possible Defects: Upper paper empty actuator
Upper paper empty sensor
Upper cassette tray
Upper pressure lever
Upper cassette release cam
Upper cassette release latch
Upper cassette release lever
Spring
Connectors/wiring
PCL board
1 Make sure paper is in the upper cassette.

• Make sure the paper is loaded correctly so that the side and rear guides are positioned securely
against the paper in the cassettes.
Is error code 010 displayed?
No: The paper was loaded incorrectly. Turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
2 Check upper cassette:

• Inspect the upper paper empty sensor actuator for binding, or for a damaged or broken part.
Is it in good working order?
No: Replace the actuator, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
3 Check voltage:
• Open the rear door and install an interlock by-pass tool.
• Check the voltage from TP3-15 to ground on the PCL board.
• Activate the upper paper sensor actuator manually.
Does the voltage change from 0 Vdc to +12Vdc?
No: Replace the upper paper empty sensor, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: Continue.

4 Check pressure lever:

• Reinsert the upper cassette.
• Watch the pressure lever as the cassette is inserted.
Does the pressure lever elevate the paper to the correct feeding position?
No: Check the following for defects or incorrect mounting:
• Cassette tray
• Damper assembly
• Upper pressure lever
• Upper cassette release cam
• Upper cassette release latch
• Wire cable, pulley and spring
• Upper cassette release lever
Replace the defective part, then turn to TAG 002: Check & Problem Resolution.
Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.

E10: Envelope Tray Out of Envelopes

This TAG refers to the error code for the envelope tray, which handles 75 envelopes.
Error Code: E10
Envelopes incorrectly loaded
Possible Defects: Upper paper empty actuator
Paper size sensor assembly
Envelope cassette tray
Spring
Connectors/wiring
PCL board
1 Make sure envelopes are in the envelope cassette.

• Make sure the envelopes are correctly loaded.
• Remove and insert the envelope cassette while watching the operator panel.
Does 1-8 appear on the operator panel?
No: Replace the upper paper size sensor assembly, then turn to TAG 002: Check & Problem
Resolution.
Yes: Continue.
2 Run a job in which you are using envelopes.

Is error code E10 displayed?
No: The cassette was loaded incorrectly. Turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
3 Remove the envelope cassette.

• Inspect the paper empty sensor actuator.
Yes: Continue.
4 Open the rear door and install an interlock by-pass tool.

• Activate the upper paper sensor actuator manually.
Does the voltage change from 0Vdc to +12Vdc?
No: Replace the upper paper empty sensor, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: Continue.

5 Reinsert the envelope cassette.

Does the pressure lever elevate the envelopes to the correct feeding position?
• Cassette tray
• Damper assembly

TAG 011: Lower Cassette Malfunction

Error Code: 011
Possible Defects: Lower paper empty actuator
Lower paper empty sensor
Lower cassette tray
Lower pressure lever
Lower cassette release cam
Lower cassette release latch
Lower cassette release lever
Spring
Connectors/wiring
PCL board
1 Make sure paper is in the lower cassette.

No: The paper was loaded incorrectly. Turn to TAG 002: Check & Problem Resolution
Yes: Continue.
2 Remove the lower cassette.

• Inspect the lower paper empty sensor actuator for binding, or for a damaged or broken part.
Yes: Continue.
3 Open the rear door and install an interlock by-pass tool.

• Activate the lower paper sensor actuator manually.
Does the voltage change from 0 Vdc to +12Vdc?
No: Replace the lower paper empty sensor, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: Continue.

4 Reinsert the lower cassette.

• Cassette tray
• Lower pressure lever
• Lower cassette release cam
• Lower cassette release latch
• Lower cassette release lever

TAG 012: Upper Cassette Not Latched

Error Code: 012
Possible Defects: Upper cassette release cam
Upper cassette in latch
Spring
Wire cable and pulley
Upper cassette
Upper cassette in switch
Upper paper size sensor
Lower paper size sensor
Connectors or wiringr
PCL board
1 Turn off the printer and unplug the power cord.

• Verify that J/P40 and J/P52 are connected properly.
• Inspect it for damage.
• Reinsert the cassette.
Is the upper cassette properly latched?
No: Continue.
2 Check for damage:

• Upper cassette in latch
• Spring
• Wire cable and pulley
Are any of these parts damaged?
No: Return to the beginning of this TAG.
Yes: Replace the damaged parts, then turn to TAG 002: Check & Problem Resolution.
3 Remove the upper cassette.

• Make sure the upper cassette in switch actuator is functioning properly.
Yes: Continue.

4 Run diagnostic test 002.

Is 1-0 displayed?
No: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
5 Install the upper cassette.

Is a value other than 1-0 displayed?
No: Continue.
6 Turn the printer off and unplug the power cord.

• Loosen the upper paper size sensor assembly for access to the circuit board.
• Disconnect J/P46.
• Activate the cassette in switch.
• Check P46-1 to P46-2 for continuity.
Is there continuity?
No: Replace the upper cassette in switch or wire hardness W58, then turn to TAG 002: Check
& Problem Resolution.
Yes: Continue.
7 Reconnect J/P46.
• Disconnect J/P40 and J/P45.
No: Go to #10 in this TAG.
Yes: Continue.
8 Check P40-48 to P45-3 for continuity.

No: Continue.
Yes: Replace the upper paper size sensor assembly. If this does not resolve the problem,
replace the PCL board. Turn to TAG 002: Check & Problem Resolution.

9 Reconnect J/P40 and J/P45.

• Remove the lower cassette.
• Loosen the lower paper size sensor assembly for access to the circuit board.
• Check J43-8 to J47-3 for continuity.
No: Replace lower paper size sensor assembly, then turn to TAG 002: Check & Problem Res-
olution.
Yes: Repair or replace the connectors or wiring from:
P45-3 to P47-3,
P43-8 to J52-3, or
P40-48 to P52-3.
If this does not resolve the problem, replace the upper paper size sensor assembly. Then
turn to TAG 002: Check & Problem Resolution

No: Replace the lower paper size sensor assembly.
P45-2 to P47-2,
P43-9 to J52-2 or
P40-49 to P52-2.
turn to TAG 002: Check & Problem Resolution

TAG E12: Envelope Tray or Feeder Not Latched

Error Code: E12
Possible Defects: Upper cassette release cam
Spring
Envelope cassette or high capacity envelope feeder
Connectors or wiring
PCL board

• Confirm that J/P40 and J/P52 are connected properly.
• Remove the envelope tray or high capacity envelope feeder.
• Reinsert the envelope tray or feeder.
No: Continue.
2 Check for damage:

• Spring
3 Remove the envelope tray or feeder.

• Make sure the upper in switch actuator is functioning properly.
Yes: Continue.


Is 1-0 displayed?
Yes: Continue.
5 Install the envelope tray.

No: Continue.

• Remove the envelope tray or feeder.
No: Replace the upper cassette in switch or wire harness W58, then turn to TAG 002: Check
Yes: Continue.
7 Reconnect J/P46.
Yes: Continue.

No: Continue.
Yes: Replace the upper paper size sensor assembly. If this does not resolve the problem,
replace the PCL board. Then turn to TAG 002: Check & Problem Resolution.


No: Replace the lower paper size assembly, then turn to TAG 002: Check & Problem Resolu-
tion.
P45-3 to P47-3,
P43-8 to J52-3, or
P40-48 to P52-3.
turn to TAG 002: Check & Problem Resolution.

P45-2 to P47-2,
P43-9 to J52-2, or
P40-49 to P52-2.

TAG 013: Lower Cassette Not Latched

Error Code: 013
Possible Defects: Lower cassette release cam
Even Lower cassette release latch
Lower cassette in latch
Spring
Lower cassette
Lower cassette in switch
PCL board

Is the lower cassette properly latched?
No: Continue.
2 Check the following for damage:

• Lower cassette in latch
• Spring

• Make sure the lower cassette in switch actuator is functioning properly.
Yes: Continue.
4 Run self diagnostic test 003.

Is 1-0 displayed?
Yes: Continue.

5 Install the lower cassette.

No: Continue.

No: Replace the lower cassette in switch or wire harness W59, then turn to TAG 002: Check
Yes: Continue.
7 Reconnect J/P48.
No: Repair or replace the connectors or wiring from P43-10 to J52-1 or P40-50 to P52-1.
Then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

No: Repair or replace the connectors or wiring from P43-8 to J52-3 or P40-48 to P52-3. Then
Yes: Replace the lower paper size sensor assembly. If this does not resolve the problem,
replace the PCL board. Then turn to TAG 002: Check & Problem Resolution.

TAG 020: Paper Jam/Misfeed in Upper Cassette Area

Error Code: 020
Possible Causes: Paper incorrectly loaded
Wrong weight or type of paper loaded
Paper path obstructed
Possible Defects: Upper pick-up roller assembly
Upper feed roller assembly
Upper pick-up roller drive assembly
Upper paper guide assembly
Lower paper guide assembly
Upper paper cassette
Pick pressure adjustment
Main drive gear assembly
Paper feed drive belt
Paper feed drive idler assembly
Paper timing sensor.
Wiring or connectors
PCL board
1 Check both paper paths and remove any paper jams.

• Make sure paper is loaded properly in both cassettes.
• Make sure the paper guides are positioned properly.
• Make sure the upper pick-up roller, feed roller, and pinch roller assemblies are clean.
• Verify that J/P40, J/P60, J/P66, and J/P68 are connected properly.
• Confirm that the paper in the cassettes meets paper specifications, described in the Guide to
Operations manual.
Is error code 020 still displayed?
Yes: Continue.
2 Turn the printer off and inspect the following for damage or binding:
• Upper paper guide assembly
• Lower paper guide assembly
• Paper feed drive belt
• Paper feed drive pulley
• Paper feed drive idler assembly
• Main drive gear assembly
• Upper pick-up roller drive assembly
Are all the parts in good working order?
No: Replace any damaged parts, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

3 Clear the paper path.

Yes: Continue.

• Inspect the paper timing sensor actuator for damage or binding.
No: Replace the paper timing guide assembly, then turn to TAG 002: Check & Problem Reso-
lution.
Yes: Continue.
5 Check the voltage between TP3-16 and ground on the PCL board.
• With the printer powered on, press and release the paper timing sensor.
• Check for a voltage change from 0 Vdc to +12 Vdc.
Does the voltage change from 0 Vdc to +12 Vdc?
Yes: Continue.
6 Check TP3-11 for +24 Vdc.

Is the voltage +24 Vdc?
No: Continue.
Yes: Return to the beginning of this TAG.
7 Check J/P91-1 for +24 Vdc.

No: Continue.

No: Replace the DC power supply, then turn to TAG 002: Check & Problem Resolution.
Yes: Repair or replace the connectors or wiring from P91-1 to P8-13, then turn to TAG 002:
Check & Problem Resolution.


• Check the following for continuity:.
P40-16 to P57-2
P40-25 to P57-1
P40-12 to P57-3
Is there continuity on all?
No: Repair or replace the connectors or wiring from P40-25 to J/P58-1 to P57-1, P40-16 to J/
P58-2 to P57-2, or P40-12 to J/P58-3 to P57-3. Then turn to TAG 002: Check & Problem
Resolution.
Yes: Replace the paper timing guide. If this does not resolve the problem, replace the PCL
board. Then turn to TAG 002: Check & Problem Resolution.
10 Turn the printer off.

• Open the back cover and install an interlock by-pass tool.
• Remove the paper feed cover to expose the upper paper pick roller assembly.
Warning
To avoid the risk of injury, use extreme caution as gears
and belts are exposed
• Run diagnostic test 006, testing the upper pick-up roller clutch.
• Check TP3-9 for a voltage change from +24 Vdc to 0 Vdc.
Does the voltage change from +24 Vdc to 0 Vdc?
No: Continue.

• Check P40-9 to J68-2 and P40-11 to J68-1 for continuity.
No: Repair or replace the connectors or wiring from P40-9 to J68-2 or P40-11 to J68-1. Then
Yes: Replace the upper pick-up roller assembly, then turn to TAG 002: Check & Problem Res-
olution.
12 Run diagnostic test 006, testing the upper feed roller clutch.
No: Continue.


No: Repair or replace connectors or wiring from P40-6 to J66-2 or P40-11 to J66-1. Then turn
to TAG 002: Check & Problem Resolution.
Yes: Replace the upper feed roller assembly, then turn to TAG 002: Check & Problem Resolu-
tion.
14 Inspect the upper pick-up roller assembly for damage or binding.

No: Replace the upper pick-up roller assembly, then turn to TAG 002: Check & Problem Res-
olution.
Yes: Continue.
15 Inspect the upper feed roller assembly for damage or binding.

No: Replace the upper feed roller assembly, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: The upper pick-up roller or the feed rollers may not be delivering paper to the paper tim-
ing sensor at the correct time. Return to the beginning of this TAG.

TAG 021: Paper Jam/Misfeed in /Lower Cassette Area

Error Code: 021
Possible Causes: Paper loaded incorrectly
Paper path obstruction
Possible Defects: Lower pick-up roller assembly
Lower feed roller assembly
Lower pick-up roller drive assembly
Lower paper cassette
Idler assembly
Paper timing sensor
PCL board
1 Check both paper paths and remove any jams.

• Check that the pick-up roller, feed roller, and backup roller assemblies are clean.
• Confirm that the paper in the cassettes meets paper specifications, which are described in the
Guide to Operations manual.
Yes: Continue.
• Lower pick-up roller drive assembly
No: Replace the damaged parts, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.


Yes: Continue.

No: Replace the paper timing guide assembly, then turn to TAG 002: Check & Problem Reso-
lution.
Yes: Continue.
5 Check the voltage between TP3-16 and ground on the PCL board.
• With the printer powered on, activate the paper timing sensor.
• Check for a voltage change from 0 Vdc to +12 Vdc.
Does the voltage change from 0 Vdc to +12 Vdc?
Yes: Continue.

No: Continue.

No: Continue.


• Check the following for continuity:
P40-16 to P57-2

P40-25 to P57-1
P40-12 to P57-3
Is there ground?
No: Repair or replace the connectors or wiring from:
P40-25 to J/P58-1 to P57-1,
P40-16 to J/P58-2 to P57-2, or
P40-12 to J/P58-3 to P57-3.
Yes: Replace the paper timing guide. If this does not correct the problem, replace the PCL

• Remove the paper feed cover to expose the lower paper pick-up assembly.
Warning
To avoid the risk of injury, use extreme caution as gears
and belts are exposed
• Run diagnostic test 006, testing the lower pick-up roller clutch.
No: Continue.

No: Repair or replace the connectors or wiring from:P40-8 to J69-2 or P40-10 to J69-1. Then
Yes: Replace the lower pick-up roller assembly, then turn to TAG 002: Check & Problem Res-
olution.
12 Run diagnostic test 006, testing the lower feed roller clutch.
No: Continue.


No: Repair or replace the connectors or wiring from P40-5 to J67-2 or P40-11 to J67-1. Then
Yes: Replace the lower feed roller assembly, then turn to TAG 002: Check & Problem Resolu-
tion.
14 Inspect the lower pick-up roller assembly for damage or binding.

No: Replace the lower pick-up roller assembly, then turn to TAG 002: Check & Problem Res-
olution.
Yes: Continue.
15 Inspect the lower feed roller assembly for damage or binding.

No: Replace the lower feed roller assembly, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: The lower pick-up roller or lower feed roller may not be delivering the paper to the paper
timing sensor at the correct time. Return to the beginning of this TAG.

TAG 022: Paper Jam in the Transfer or Fuser Area

Error Code: 022
Possible Defects: Fuser unit
Paper supply
Paper timing roller assembly
Fuser drive assembly
Fuser drive belt
Vacuum transport unit
Exit roller assembly
Paper timing guide assembly
PCL board
Connectors or wiring.
Caution
When clearing this jam, be careful not to get toner on your clothing,
as it may stain. If toner gets on your clothing, rinse your clothes
with cold water immediately to avoid stains
1 Check the paper path and remove any jammed paper.
Warning
The fuser unit may be very hot
• Check the fuser unit for paper wrapped around the heat roller.
Is paper wrapped around the heat roller?
No: Continue.
Yes: If the paper is black or very dark with no printing, go to TAG 805: Black Prints. If the
paper is very dark and does have printing, go to TAG 811: Background/Residual Images/
Dark Prints.
2 Check both paper paths for damage or obstructions.

• Confirm that J/P13, J/P22, J/P40, J/P58, and J/P65 are connected properly.
• Check that the paper is properly loaded.
• Confirm that the paper in the cassettes meets paper specifications, described in the Guide to

Operations manual.
• Check that the fuser unit is installed properly.
No: Paper incorrectly loaded, incorrect paper type in use, or a loose connector was at fault.
Turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
3 Has the fuser unit been replaced recently?

No: Continue.
4 Replace the fuser unit.

Has the problem been resolved?
No: Reinstall the original fuser unit and continue.
Yes: The fuser unit was at fault. Turn to TAG 002: Check & Problem Resolution.
5 Inspect the following for damage:

• Paper timing roller assembly
• Paper timing guide assembly
No: Continue.
Yes: Replace the damaged part, then turn to TAG 002: Check & Problem Resolution.
6 Is more than one sheet of paper jamming?

Yes: Continue.
7 Make sure the natural curl of the paper is turned up in the cassettes.
• Make sure the paper is under the corner separators.
• Make sure the rear and side paper guides are positioned properly.
• Make sure the paper being used does not have a high static charge.
Does the multiple feed problem still exist?
No: The paper appears to be at fault. Turn to TAG 002: Check & Problem Resolution.
Yes: Adjust the paper tension lever or pick pressure, as described in Chapter 9, “General
Printer Maintenance”, then turn to TAG 002: Check & Problem Resolution.

8 Check the paper path for jams.

• Open the printer’s front cover and insert the interlock bypass tool.
• Watch the end of the paper timing roller shaft.
Does the paper timing roller shaft turn?
No: Continue.

No: Continue.

No: Continue.

No: Replace the DC power supply unit, then turn to TAG 002: Check & Problem Resolution.
12 Run diagnostic test 006, testing the paper timing roller clutch.
No: Continue.

Is there continuity on both?
No: Repair or replace the connectors and wiring from: P40-7 to J65-2 or P40-11 to J65-1.
Yes: Replace the paper timing roller assembly, then turn to TAG 002: Check & Problem Reso-
lution.

14 Does paper stop or jam either before or during entry into the fuser unit?
Yes: Continue.
15 Remove the fuser unit.

• Check the fuser unit rollers for damage or toner contamination.
Are they damaged or contaminated with toner?
No: Continue.
Yes: Replace the fuser unit, then turn to TAG 002: Check & Problem Resolution.
16 Inspect the following for damage or binding:

• Fuser unit
• Fuser drive belt
• Fuser drive assembly

• Check for paper jams.
• Inspect the exit roller, and exit pinch roller assemblies for damage, binding and contamination.
Are these parts in good working order?
No: Repair or replace the defective parts, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: Continue.
18 Run test prints.

• Check the leading edge of the prints for improper registration.
Is there improper registration?
No: Continue.
Yes: Go to TAG 807: Misregistered/Skewed Prints (Simplex) or TAG 901: Misregistration/
Skewed Prints (Duplex).
19 Inspect the vacuum transport unit for damage or binding.

Are the parts in good working order?
Repair or replace the vacuum transport unit, then turn to TAG 002: Check & Problem Resolu-
tion.
No: Continue.
Yes: Open the top cover and install an interlock by-pass tool.


• While the main motor is running, cover all of the holes in the vacuum unit with a piece of paper.
Does the vacuum transport unit fan hold the paper in place?
No: Continue.
21 Use extreme caution: Check for 100 Vac from J/P22-1 to J/P22-2.
Is the voltage 100 Vac?
No: Continue.
Yes: Replace the vacuum transport assembly.
22 Power-on-reset the printer. Use extreme caution:

• While the main motor is running, monitor J/P13-6 and J/P13-3 for 100 Vac.
No: Replace the power control board, then turn to TAG 002: Check & Problem Resolution.
Yes: Repair or replace the connectors or wiring from J22-1 to P13-6 or J22-2 to P13-3. Then

TAG 023: Paper Jam in the Output Area

Error Code: 023
Possible Causes: Paper path obstruction
Output tray obstruction
Possible Defects: Exit paper sensor
Fuser drive unit
Exit pinch roller assembly
PCL board
If the printer has a high capacity output unit (HCO), unplug and remove it before you
begin. Test the printer without the HCO; if the problem remains, proceed with this TAG. If
the problem occurs only with the HCO, the HCO is causing the problem. Repair or replace
the HCO.

• Check the paper path and remove any paper jams.
• Check the output tray and remove any paper jams.
No: Loose connectors or obstructions were at fault. Turn to TAG 002: Check & Problem Res-
olution.
Yes: Continue.
2 Is paper stopped or jammed at the output tray?

No: Continue.
3 Inspect the exit paper sensor actuator for damage or binding.

No: Repair or replace the exit paper sensor actuator, then turn to TAG 002: Check & Problem
Resolution.
Yes: Continue.

P40-24 to P49-2,
P40-26 to P49-1, and

P40-13 to P49-3.
P40-26 to J/P50-1 to P49-1,
P40-24 to J/P50-2 to P49-2, or
P40-13 to J/P50-3 to P49-3.
Yes: Replace the exit paper sensor.

• Open the back cover and install an interlock bypass tool.
• Remove the fuser drive cover.
• Inspect the following for damage, binding, or contamination:
• Exit roller assembly
• Exit roller drive gear
• Exit pinch roller assembly
No: Replace the defective parts, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

• Inspect the following for damage or binding:
Yes: Reinstall the fuser unit and continue.

• Watch the fuser drive and the exit roller assembly.
Are they in good working order?
Yes: Replace the fuser unit, then turn to TAG 002: Check & Problem Resolution.

TAG 025: Paper in Input Area Before Printing

Error Code: 025
Possible Defects: Paper timing sensor
PCL board

No: Replace the paper timing guide assembly and continue.
Yes: Continue.

No: Jammed paper, loose connectors, or the sensor actuator were at fault. Turn to TAG 002:
Yes: Continue.

Yes: Continue.
4 Loosen the paper timing guide.

• Confirm that J/P57 is connected properly.
Is J/P57 connected properly?
No: Continue.
5 Reconnect J/P57.
• Reinstall the paper timing guide.
No: J/P57 was at fault. Turn to TAG 002: Check & Problem Resolution.
Yes: Continue.


• Loosen the paper timing guide.
• P40-16 to P57-2
• P40-25 to P57-1
• P40-12 to P57-3
• P40-25 to J/P58-1 to P57-1
• P40-16 to J/P58-2 to P57-2
• P40-12 to J/P58-3 to P57-3
Yes: Replace the paper timing guide. If that doesn’t resolve the problem, replace the PCL

TAG 026: Paper in Output Area Before Printing

Error Code: 026
Possible Defects: Exit paper sensor
PCL board
If the printer has a high capacity output unit (HCO), unplug and remove it before begin-
ning this TAG. Test the printer without the HCO; if the problem remains, proceed with this
TAG. If the problem occurs only with the HCO, the HCO is causing the problem. Repair or
replace the HCO.

• Inspect the exit paper sensor actuator for damage or binding.
No: Replace the exit paper sensor actuator and continue.
Yes: Continue.

No: Jammed paper, loose connectors, or sensor actuator were at fault; go to TAG 002: Check
Yes: Continue.

Yes: Continue

• Remove the exit cover.
P40-26 to P49-1,
P40-24 to P49-2, and
P40-13 to P49-3
P40-26 to J/P50-1 to P49-1,
P40-24 to J/P50-2 to P49-2, or
P40-13 to J/P50-3 to P49-3.
Yes: Replace the exit paper sensor. If this doesn’t resolve the problem, replace the PCL board.

TAG 030: Developer Bias Short/Failure

Error Code: 030
Possible Defects: Cleaner unit
High voltage unit
DC power supply
PCL board
Printhead assembly
Power control #2 board
Developer unit

• Verify that J/P23, J/P24, J/P40, J/P41, J/P96, and J/P85 are connected properly.
No: A loose connector was at fault. Turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
2 Check the voltages, as described in Chapter 9, “General Printer Maintenance”.

Are the voltages correct?
No: Replace the high voltage power supply unit, then turn to TAG 002: Check & Problem
Resolution.
Yes: Continue.
3 Has the developer unit been replaced recently?

Yes: Continue.
4 Replace the cleaner unit.

No: The cleaner unit was defective; turn to TAG 002: Check & Problem Resolution.
Yes: Reinstall the original cleaner unit and go to #6 in this TAG.
5 Replace the developer unit.

• Install a new toner cartridge.
No: The developer unit was defective; turn to TAG 002: Check & Problem Resolution.
Yes: Reinstall the original developer unit and continue.

6 Open the back cover and install an interlock by-pass tool.

• Check TP4-35 for +24 Vdc.
Yes: Continue.

No: Repair or replace the connectors or wiring from P41-35 to P23-5, then turn to TAG 002:
Yes: Continue.

P41-31 to P24-1
P41-30 to P24-2
P41-40 to P24-3
P41-31 to P24-1
P41-30 to P24-2
P41-40 to P24-3
Yes: Continue.
9 Disconnect P85 from the high voltage unit.

• Check P85-3 to J25-7 for continuity.
No: Repair or replace the connectors or wiring from P85-3 to J25-7, then turn to TAG 002:
Yes: Continue.
10 Disconnect J/P96.
No: Repair or replace the developer power supply lead from J/P96-1 to P85-3, then turn to
TAG 002: Check & Problem Resolution.
Yes: Replace the high voltage unit, then turn to TAG 002: Check & Problem Resolution.


No: Continue.

No: Continue.

No: Continue.
Yes: Replace the power control #2 board, then turn to TAG 002: Check & Problem Resolu-
tion.


TAG 031: Toner Patch Reference Level Too Low

Error Code: 031
Possible Causes: Contamination of the toner patch sensor or printhead lens
Possible Defects: Photoconductor unit
PCL board
Developer unit

• Perform the every-call cleaning procedure, described in Chapter 9, “General Printer Mainte-
nance”.
• Clean the toner patch sensor on the developer unit.
• Clean the printhead lens.
• Run at least 200 test prints to detone the printer’s engine.
No: Contamination was at fault. Turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

Resolution.
Yes: Continue.
3 Have the photoconductor and developer units been replaced recently?

No: Continue.
4 Replace the photoconductor unit.

• Run 200+ test prints to reduce toner concentration in the developer unit.
No: Reinstall the original photoconductor unit and continue.
Yes: The photoconductor was at fault; turn to TAG 002: Check & Problem Resolution.
5 Replace the developer unit.

No: Reinstall the original developer unit and continue.
Yes: Turn to TAG 002: Check & Problem Resolution. If the problem reappears, the toner/car-
rier mix may be old or contaminated.


• Remove the developer unit.
No: Repair or replace the connectors or wiring from P41-47 to J25-3.

TAG 032: Toner Patch Too Light

Error Code: 032, 033
IGS board
PCL board

Resolution.
Yes: Continue.
2 Have the photoconductor unit been replaced recently?

No: Continue.

Yes: The photoconductor was at fault; turn to TAG 002: Check & Problem Resolution.

nance”.
• Clean the toner patch sensor on the developer unit.
• Run at least 55 test prints
Yes: Continue
5 Run test prints.

Do the test prints appear overtoned, dark, or have background?
No: Go to #8 in this TAG
Yes: Continue.
6 Develop a toner patch, as described in Chapter 1, “Printer and Troubleshooting Overview”.

Is the toner patch developed and properly positioned?
No: Replace the IGS board, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue

7 Check the toner patch sensor board in the developer unit for loose wiring connectors.
Are all connectors and wiring connected properly?
No: Reconnect the wiring and connectors or replace the developer unit, then turn to TAG 002:
Yes: Go to TAG 808: Prints Overtoned/Dark Vertical Streaks, TAG 811: Background/Resid-
ual Images/Dark Prints, or both, to identify the problem further.
8 Do the prints appear light or blank?

Yes: Replace the photoconductor unit, then turn to TAG 002: Check & Problem Resolution.

TAG 035: Out of Toner or ADD TONER Indicator On

Error Code: 035
Possible Causes: Photoconductor unit
Toner cartridge seal not removed
Toner cartridge empty
High print coverage
Possible Defects: PCL board

Developer unit connectors or wiring
An 035 error may occur if the print coverage exceeds 25%. Do not run high print coverage
jobs for extended periods of time.

No: Continue.
Yes: Perform the every-call cleaning procedure, described in Chapter 9, “General Printer
Maintenance”. Clean the toner patch sensor and the printhead lens, then continue.

Resolution.
Yes: Continue.
3 Has the photoconductor unit been replaced recently?

No: Continue.

Yes: The photoconductor unit was at fault. Turn to TAG 002: Check & Problem Resolution.
5 Has the seal has been removed from the toner cartridge?
No: Continue.

6 Remove the toner cartridge seal.

No: Continue.
Yes: The toner cartridge seal was at fault. Turn to TAG 002: Check & Problem Resolution.

Yes: Replace the PCL board. If this resolves the problem, then turn to TAG 002: Check &
Problem Resolution. If the problem is still not resolved, go to TAG 610: Operator Panel
Malfunction.

TAG 036: Developer Unit Not Installed
TAG 036: Developer Unit Not Installed

Error Code: 036
Possible Defects: Developer unit not installed properly
PCL board

• Make sure the developer unit is installed properly.
• Confirm that the proper developer unit is installed.
No: A loose connector or improper developer unit was at fault. Turn to TAG 002: Check &
Problem Resolution.
Yes: Continue.

Resolution.
Yes: Continue.

No: Continue.
4 Remove the developer unit.

No: Repair or replace the connectors or wiring from: P41-45 to J25-12 or P41-46 to J25-8,
then turn to TAG 002: Check & Problem Resolution.
Yes: Replace the developer unit, then turn to TAG 002: Check & Problem Resolution.

TAG 040: Photoconductor Seam Sensor Malfunction

Error Code: 040, 041, 042
Main motor gear
Main motor gear keys
Main drive motor assembly
PCL board
Software
Seam sensor
Transfer corona

• Verify that J/P4, J/P9, J/P12, J/P14, J/P20, J/P40, J/P41, J/P63 (photoconductor seam sensor),
J/P64, J/P251, and J/P252 are connected properly.
• Remove the photoconductor unit.
• Clean the photoconductor unit contacts, the guide rail contacts, and the photoconductor cavity.
• Clean the seam sensor lens and cavity, and remove any obstructions.
Is error code 040, 041, or 042 still displayed?
No: Loose connectors or dirty contacts were at fault. Turn to TAG 002: Check & Problem
Resolution.
Yes: Continue.
2 Has the photoconductor unit been replaced recently?

No: Continue.

Yes: The photoconductor was at fault. Turn to TAG 002: Check & Problem Resolution.
4 Open the top cover and insert an interlock by-pass tool.

• Run diagnostic test 009.
Does the photoconductor belt rotate?
No: Continue.
5 Is error code 041 or 042 displayed while running diagnostic test 009?
No: Continue.


• Inspect it for damaged drive mechanism or belt slippage.
No: Replace the photoconductor unit, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
7 Reinstall the photoconductor unit.

• Remove the interlock by-pass tool and close the top cover.
• Remove the main drive motor assembly cover.
• Turn the printer on.
• Watch the main motor.
Does the main motor gear turn while running diagnostic test 009?
No: Continue.
Yes: Replace the main motor gear, main motor gear key, or both, or replace the main drive
gear assembly, as needed. Then turn to TAG 002: Check & Problem Resolution.
8 Run diagnostic test 009. Use extreme caution:

• Check J/P20-2 to J/P20-3 for 100 Vac while the test is running.
Is the voltage 100 vac?
No: Continue.
Yes: Replace the main drive motor assembly, then turn to TAG 002: Check & Problem Reso-
lution.

No: Continue.
Yes: Repair or replace the connectors or wiring from P14-2 to P20-3 or P14-3 to P20-2; then

No: Repair or replace the connectors or wiring from P40-33 to P12-7.
Yes: Replace the power control board; if this does not correct the problem, replace the PCL


• Inspect the photoconductor belt for damage.
• Check the timing hole for contamination or blockage.
Are the photoconductor belt and the timing hole both in good working order?
Yes: Continue.

• Check TP3-20 for +12 Vdc.
Yes: Continue.
13 Check TP3-21 for between +2 to +6 Vdc.

Is the voltage between +2 to +6 Vdc?
Yes: Continue.

• Disconnect J/P63, observing carefully the plug’s orientation before you remove it.
• P40-19 to J/P64-1 to J/P252, which is the center connector contact on the photoconductor
guide rail;
• P40-21 to J/P64-2 to J/P251, which is the top connector contact on the photoconductor
guide rail;
• P40-18 to J/P 64-3 to P63-1;
• P40-20 to J/P64-4 to P63-2.
No: Repair or replace the connectors or wiring that did not have continuity, then turn to TAG
002: Check & Problem Resolution.
Yes: Continue.
15 Repair or replace the photoconductor seam sensor.

• Reconnect J/P40 and J/P63.
• Reinstall the photoconductor.
No: Continue.
Yes: Go to TAG 002: Check & Problem Resolution.

16 Clean both the photoconductor LED and seam sensor using a cotton swab or compressed air.
• Run diagnostic 009.
• Using an oscilloscope connected to TP3-20 on the PCL board, adjust the signal so that it
matches figure A by moving the sensor bracket closer or farther from the photoconductor unit.
Figure B illustrates a bad signal. Note that 7ms is the recommended minimum length of time the
waveform should maintain 0v; you may have to settle for less. The two small signals prior to the
12v signal are from the smaller holes in the photoconductor unit; the larger signal is from the
cutout for the PC sensor.
Figure A Figure B
12V 12V
0V 0V
7 ms
Is the signal adjusted to match that illustrated in Figure A?

No: Repeat this step until the signal has been adjusted properly.
Yes: Turn to TAG 002: Check & Problem Resolution.

TAG 044: Charge Corona/Transfer Corona Circuit Open

Error Code: 044
Possible Defects: Charge corona
Transfer corona
High voltage unit
Upper paper guide
Charge corona terminal assembly
PCL board

• Make sure the high voltage unit charge corona lead is connected properly.
• Make sure the transfer corona lead is connected properly.
• Verify that the charge corona and transfer corona ground circuits are connected properly.
• Remove the transfer corona from the upper paper guide.
• Clean the transfer corona housing and contacts.
• Clean the transfer corona wire.
• Inspect the transfer corona socket in the upper paper guide for contamination.
• Verify that the transfer corona static eliminator brush on the transfer corona housing is grounded
to the transfer corona metal housing.
• Clean the charge corona contacts.
No: Loose connectors or a dirty transfer corona were at fault. Turn to TAG 002: Check &
Problem Resolution.
Yes: Continue.
2 Has the charge corona been replaced recently?

No: Continue.
3 Replace the charge corona and photoconductor unit.

No: Reinstall the original charge corona and photoconductor unit, and continue.
Yes: The charge corona was at fault. Turn to TAG 002: Check & Problem Resolution.

4 Remove the transfer corona.

• Inspect the housing for jammed paper.
Is paper jammed inside the transfer corona housing?
No: Continue.
Yes: Remove the jammed paper and check the transfer corona for damage, then turn to TAG
022: Paper Jam in the Transfer or Fuser Area.

No: Continue.

No: Continue.

No: The problem appears to be intermittent. Go to TAG 050: Transfer Corona Circuit
Shorted.
Yes: Go to TAG 050: Transfer Corona Circuit Shorted.

• Inspect the transfer corona wire.
Is the transfer corona wire damaged?
No: Continue.
Yes: Replace the transfer corona, then turn to TAG 002: Check & Problem Resolution.
9 With the upper paper guide assembly in its fully upright position, check the transfer corona's lower
receptacle for continuity to ground.
No: Replace or repair the upper paper guide assembly, then turn to TAG 002: Check & Prob-
lem Resolution.
Yes: Continue.
10 Disconnect high voltage unit lead to the transfer corona.

• Check the transfer corona's upper receptacle to the lead removed from the high voltage unit for
continuity.

No: Replace the upper paper guide assembly, then turn to TAG 002: Check & Problem Reso-
lution.

• Disconnect the charge corona lead from the high voltage unit.
• Check for continuity the charge corona lead terminal assembly’s lower contact to the lead
removed from the high voltage unit.
No: Repair or replace the charge corona lead or the charge corona terminal assembly, then
Yes: Continue.
12 Remove the cleaner unit.

• Check for continuity between the connector for the charge corona terminal assembly’s upper
contact and J/P85-10 at the high voltage unit.
No: Repair or replace the connectors or wiring, then turn to TAG 002: Check & Problem Res-
olution.
Yes: Continue.
13 Disconnect J/P41 and J/P23.

Yes: Continue.

Yes: Continue.
15 Reconnect the power.

• Check J/P41-35 for +24 Vdc.
Yes: Determine whether the high voltage unit or the charge corona terminal assembly is at
fault, replace the faulty unit, then turn to TAG 002: Check & Problem Resolution.

TAG 045: Charge Corona Circuit Shorted

Error Code: 045
High voltage unit
PCL board

• Verify that J/P23, J/P41, J/P85, P124, P143, and the high voltage unit charge corona lead are
connected properly.
No: Loose connectors or dirty contacts were at fault. Turn to TAG 002: Check & Problem
Resolution.
Yes: Continue.

No: Continue.
3 Replace the charge corona and photoconductor unit.

No: The charge corona was at fault. Turn to TAG 002: Check & Problem Resolution.
Yes: Reinstall the original charge corona and photoconductor unit, then continue.

• Disconnect the charge corona lead from the high voltage unit.
• Check for continuity the charge corona terminal assembly’s lower contact to the lead removed
from the high voltage unit.
No: Repair or replace the high voltage lead or the charge corona terminal block, then turn to
Yes: Continue.

5 Reconnect the charge corona high voltage lead.

• Disconnect P23 and J/P41.
• Check J/P41-34 to P23-6 for continuity.
Yes: Continue.

Yes: Replace the high voltage unit. If this corrects the problem, turn to TAG 002: Check &
Problem Resolution. If this does not correct the problem, replace the PCL board, then

TAG 050: Transfer Corona Circuit Shorted

Error Code: 050
Possible Defects: Transfer corona
High voltage unit
PCL board

• Verify that J/P23, J/P41 and the transfer corona high voltage unit lead are connected properly.
Yes: Continue.

• Remove and clean the transfer corona housing and contacts.
• Check between the two terminals on the back of the transfer corona for continuity.
No: Continue.
Yes: Repair or replace the transfer corona, then turn to TAG 002: Check & Problem Resolu-
tion.
3 Reinstall the transfer corona.

No: A dirty transfer corona was at fault. Turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

• Disconnect the transfer corona lead from the high voltage unit.
• Check the transfer corona high voltage unit lead for continuity to ground.
Is there continuity to ground?
No: Continue.
Yes: Repair or replace the upper paper guide assembly or transfer corona, then turn to TAG

5 Reconnect the transfer corona high voltage unit lead.

Yes: Continue.
6 Replace the transfer corona.

No: Replace the high voltage unit. If this resolves the problem, turn to TAG 002: Check &
Problem Resolution. If the problem has not been resolved, replace the PCL board, then

TAG 055: Erase Lamp Malfunction

Error Code: 055
Possible Defects: Erase lamp assembly
PCL board

• Verify that J/P26, J/P40 are connected properly.
No: Continue.

Is the value displayed less than 220?
Yes: Continue.

• Watch all the LEDs on the erase lamp.
Do all the LEDs on the erase lamp come on, even momentarily?
No: Continue.

• Check J/P26-2 for +12 Vdc immediately. After the start of the test, the voltage may drop to 0
Vdc.
Did you measure +12 Vdc?
No: Continue.



• Disconnect P26 and P40.
Yes: Repair or replace the erase lamp assembly. If this resolves the problem, turn to TAG 002:
Check & Problem Resolution. If this does not resolve the problem, replace the PCL
board, turn to TAG 002: Check & Problem Resolution.

TAG 070: Fuser Unit Malfunction

Error Code: 070, 073
Symptoms: No AC power at the fuser
AC power supply unit
DC power supply unit
PCL board
Note
A lack of continuity can result in fuser unit damage. If there
is no continuity, replace the fuser unit when replacing the
connectors and/or wiring

• Verify that J/P44, J/P4, J/P10, J/P11, J/P12, J/P70, J/P40, J/P41, J/P8, and J/P5 (bottom of fuser
unit) are connected properly.
• Verify that the fuser unit is installed properly.
• Read the following steps before taking further action.
• Watch through the output tray opening to see if the fuser lamp comes on.
Note
If the fuser lamp comes on immediately after power on,
turn off the printer and replace the AC power supply.
Is error code 070 or 073 displayed?

No: A loose connector was at fault.Turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

No: Continue.

• If the fuser lamp comes on immediately after power on, turn off the printer and replace the AC
power supply.


• Watch through the output tray opening to see if the fuser lamp comes on during the 15 seconds
following the output tray jogging test.
• If the fuser lamp comes on immediately after power on, turn the printer off and replace the AC
power supply.
Does the fuser lamp light?
Yes: Continue.
5 Read this entire step before taking any action.

• Check the voltage between TP4-21 and ground on the PCL board for a voltage increase during
the 15 seconds following the output tray jogging test.
Caution
If the voltage does not increase within 15 seconds, turn the
printer off immediately or additional damage may occur.
Did the voltage remain constant for 15 seconds after the output tray jogging test?
Yes: Continue.
6 Check TP4-22 on the PCL board for +5 Vdc.
Caution
Do not allow the printer to remain on for more than five
seconds or additional damage may occur.
Is the voltage approximately +5 Vdc?

Yes: Continue.

• Remove the fuser unit.
No: Repair or replace the connectors or wiring from P41-22 to P83-1 or J83-1 to P5-6, then
Yes: Continue.


No: Repair or replace the connectors or wiring from P41- 21 to P83-2 or J83-2 to P5-7, then
Yes: Continue.
9 Reinstall the fuser unit.

• Check P41-21 to P41-22 for resistance.
Is the resistance between I KΩ and 400 KΩ?
No: The new fuser unit seems to be defective. Replace it with a new fuser unit, then turn to

• Check J/P10-2 for +24 Vdc during the 15 seconds following power-on-reset.
Yes: Continue.

• Continue to check J/P10-2 for +24 Vdc.
Does the voltage drop from +24 Vdc to 0 Vdc during the 15 seconds following the
output tray jogging test?
Yes: Continue.

• Check J/P44-1 to J/P44-2 for at least 100 Vac during the 15 seconds following the output tray
jogging test.
Is the voltage at least 100 Vac?
Yes: Continue.


• Clean the contacts of connector J/P5.
• Check J44-2 to J5-4 and J44-1 to J5-1 for continuity.
No: Repair or replace the connectors or wiring as needed, then turn to TAG 002: Check &
Problem Resolution.
Yes: Continue.

No: Replace the fuser unit, then turn to TAG 002: Check & Problem Resolution.
Yes: Cleaning the contacts resolved the problem. Turn to TAG 002: Check & Problem Resolu-
tion.

• Check J/P4-1 to J/P4-2 for at least 100 Vac during the 15 seconds following the output tray jog-
ging test.
Was the voltage at least 100 Vac?
No: Replace the AC power supply, then turn to TAG 002: Check & Problem Resolution.
Yes: Repair or replace the connectors or wiring from J/P4-1 to J/P44-1, or J/P4-2 to J/P44-2,

No: Continue.

No: Continue.
Yes: Replace power control #2 board, then turn to TAG 002: Check & Problem Resolution.



Yes: Continue.
20 Check P70-2 and P10-2 for continuity.

Yes: Continue.
21 Reconnect J/P70.
• Connect negative lead of meter to P10-2 and positive lead of meter to P10-1.
Is the resistance approximately 550KΩ?
Yes: Continue.
• Check J10-2 (power control #2 board) for continuity to ground.
No: Continue.
tion.

• Check P40-36 for continuity to ground.

• Check TP3-36 on the PCL board for a voltage change from +24 Vdc to 0 Vdc during the 15 sec-
onds after the output tray jogging test.

TAG 071: Open Fuser Thermistor
TAG 071: Open Fuser Thermistor

Error Code: 071
Possible Defects: Connectors or wiring
Fuser unit
PCL board

• Make sure the fuser unit is installed properly.
Has the fuser unit been replaced recently?
No: Continue.

Is error code 071 displayed during power-on-reset?
No: The fuser unit was at fault. Turn to TAG 002: Check & Problem Resolution.
Yes: Reinstall the original fuser unit and continue.

• Check P41-21 to P5-7 and P41-22 to P5-6 for continuity.
No: Repair or replace the connectors or wiring as necessary, then turn to TAG 002: Check &
Problem Resolution.
Yes: Continue.
4 Check P41-21 and P41-22 for continuity to ground.

Is there continuity to ground on either?
No: Replace the fuser unit. If this resolves the problem, then turn to TAG 002: Check & Prob-
lem Resolution. If this does not resolve the problem, replace the PCL board, then turn to
Yes: Repair or replace the connectors or wiring that have continuity to ground:
P41-21 to P44-2,
J44-2 to P5-7, or
P41-22 to P44-1, J44-1 to P5-6;

TAG 072: Fuser Unit Temperature Too High

Error Code: 072
Fuser unit
PCL board
The conditions that cause error code 072 often cause the fuser unit’s thermal fuse to open.
This usually necessitates replacement of the fuser unit.

• Verify that J/P44, J/P40, J/P10, J/P70, and J/P8 are connected properly.
• Make sure the fuser unit is properly installed.
• Read the following steps before taking further actions.
power supply.
No: Continue.
Yes: A loose connector was at fault. Turn to TAG 002: Check & Problem Resolution.

No: Continue.

• Watch through the output tray opening to see if the fuser lamp comes on during the 15 seconds
after the output tray jogging test.
power supply.
Yes: The fuser unit was at fault. Turn to TAG 002: Check & Problem Resolution.

• Watch the fuser unit’s lamp.
Does the lamp turn on before error code 072 is displayed?
Yes: Continue.


No: Continue.
P41-21 to P44-2, or J44-2 to P5-7; then turn to TAG 002: Check & Problem Resolution.
6 Check P41-21 to P41-22 for resistance.

Is the resistance at least 1K‡WW?
No: Continue.

Is there resistance?
No: Continue.
Yes: Repair or replace the connectors or wiring that have resistance:
P41-21 to P44-2, or J44-2 to P5-7; then turn to TAG 002: Check & Problem Resolution.

Yes: Repair or replace the connectors or wiring that have resistance: P41-22 to P44-1, or J44-1
to P5-6; then turn to TAG 002: Check & Problem Resolution.

TAG 083: Job Offset Mechanism Malfunction

Error Code: 081, 082, 083
Symptoms: Jobs not offsetting
Jobs offsetting improperly
Continuous jogging
Possible Defects: Job offset mechanism
Jogging motor
Tray front sensor
Tray rear sensor

• Verify that J/P100, J/P101, J/P102, J/P19, J/P40, J/P54, J/P53, and J/P55 are connected properly.
No: Continue.
Yes: Loose connectors were at fault. Turn to TAG 002: Check & Problem Resolution.
2 Does the output tray jog continuously?

Yes: Continue.

No: Replace the power control #3 board, then turn to TAG 002: Check & Problem Resolu-
tion.

Does the output tray move back and forth?
No: Continue.

No: Continue.
Yes: Replace the jogging motor, then turn to TAG 002: Check & Problem Resolution.

Caution
Check J/P101-2 to J/P101-1 for 100 Vac while the test is running

Yes: Continue.

Yes: Continue.

No: Repair or replace the connector or wiring from P101-1 to P19-3, then turn to TAG 002:
Yes: Repair or replace the job offset assembly, then turn to TAG 002: Check & Problem Reso-
lution.

• Check J/P102-2 for +12 Vdc while the test is running.
tion.

• Check TP3-32 on the PCL board for +12 Vdc while the test is running.


• Check J/P102-1 for +12 Vdc while the test is running.
No: Continue.
tion.

• Check TP3-35 on the PCL board for +12 Vdc while the test is running.

Does the tone sound steadily while the output tray moves back and forth?
No: Continue.
lution.

• Disconnect J/P53, J/P55, and J/P40.
No: Repair or replace the connectors or wiring from P40-26 to J/P54-1 to P53-1, then turn to
Yes: Continue.

Yes: Continue.

Yes: Continue.


Yes: Continue.

Yes: Continue.

Yes: Continue.
20 Reconnect J/P40, J/P53, and J/P55.

No: Continue.
Yes: Verify again that J/P40, J/P53, J/P55, and J/P54 are connected properly. If they’re not,
connect them properly, then turn to TAG 002: Check & Problem Resolution. If they are,
replace the PCL board, then turn to TAG 002: Check & Problem Resolution.
21 Interchange P53 and P55.

Does the error code change from 081 to 082?
No: Continue.
Yes: Adjust the tray front sensor position. If this resolves the problem, turn to TAG 002:
Check & Problem Resolution. If this does not resolve the problem, replace the tray front
sensor, then turn to TAG 002: Check & Problem Resolution.
22 Does the error code change from 082 to 081?

No: Replace the job offset assembly, then turn to TAG 002: Check & Problem Resolution.
Yes: Adjust the tray rear sensor position. If this resolves the problem, turn to TAG 002: Check
& Problem Resolution. If this does not resolve the problem, replace the tray rear sensor or
job offset sensor, then turn to TAG 002: Check & Problem Resolution.

TAG 097: +12 Vdc Power Shorted or Sensing Problem

Error Code: 097
Possible Defects: DC power supply unit
Signal interface board
IGS board
Optional external attachment
Developer unit
Paper timing sensor
Output tray full sensor
Paper exit sensor
Tray front sensor
Tray rear sensor
Erase lamp
PCL board
Possible Defects, Duplex Printers:

Duplex control board #1
Paper path sensor
Cover open sensor
Restart side sensor
Restart paper sensor

• Verify that J/P303, J/P331, J/P323, J/P305, J/P310, J/P306, J/P32, and J/P33 are connected
properly.
No: Continue.

No: Continue.


No: Is the voltage +12 Vdc?
No: Continue.

Yes: Continue.

• Reconnect J/P32.
Yes: Continue.
6 Does the printer have an attachment option?

No: Replace the signal interface board, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

• Disconnect the DC cable (J/P73) for the attachment option.
Yes: Replace the attachment option, then turn to TAG 002: Check & Problem Resolution.


Yes: Continue.

Yes: Continue.

Yes: Continue.

No: Continue.


• Check P41-49 to P25-4 and P41-50 to P25-1 for continuity to ground.
Yes: Repair or replace the appropriate connectors or wiring, then turn to TAG 002: Check &
Problem Resolution.

• Check J8-6 for continuity to ground.
No: Continue.
Yes: Repair or replace the connectors or wiring from P8-6 to P32-10 to P91-3, then turn to

• Turn on the printer.
• Check J/P8-3 for +12Vdc.
Yes: Replace the disk drive assembly, then turn to TAG 002: Check & Problem Resolution.

Yes: Continue.

Yes: Continue.


Yes: Continue.
• Check P62-1 to P61-1 for continuity to ground.
No: Replace the lower paper empty sensor, then turn to TAG 002: Check & Problem Resolu-
tion.

No: Replace the paper timing sensor.

No: Replace the upper paper empty sensor.

• Check for continuity to ground:
P40-25 to J58-1, P40-25 to J60-1, and P40-25 to J62-1.
No: Continue.
Yes: Repair or replace the connectors or wiring from P40-25 to J58-1, P40-25 to J60-1, or
P40-25 to J62-1, then turn to TAG 002: Check & Problem Resolution.


• Reconnect J/P40, J/P58, J/P60, and J/P62.
Yes: Continue.

Yes: Continue.

No: Continue.
Yes: Replace the front tray sensor, then turn to TAG 002: Check & Problem Resolution.

No: Continue.
Yes: Replace the rear tray sensor, then turn to TAG 002: Check & Problem Resolution.

• Check J54-1 and J54-4 for continuity to ground.
Is there continuity to ground at either?
No: You have failed to isolate the problem. Return to the beginning of this TAG.
Yes: Repair or replace the connectors or wiring from: J54-1 to P53-1 or J54-4 to P55-1, then


Yes: Continue.

No: Replace the paper exit sensor, then turn to TAG 002: Check & Problem Resolution.
Yes: Replace the output tray full sensor, then turn to TAG 002: Check & Problem Resolution.

Is there continuity at either?
Yes: Repair or replace the connectors or wiring from: J50-1 to P49-1 or J50-4 To P51-1, then

No: Continue.
Yes: Repair or replace the connectors or wiring from: P40-26 to P54-1, P40-26 to P54-4, P40-
26 to P50-1, or P40-26 to P50-4, then turn to TAG 002: Check & Problem Resolution

• Reconnect J/P40, J/P50, and J/P54.
No: Continue.
tion.


No: Continue.

No: Continue.
tion.


Yes: Continue.

Yes: Continue.


• Disconnect J/P310 (inside the duplex tray).
No: Continue.

• Check P305-2 and P310-2 for continuity to ground.
No: Return to the beginning of this TAG and start again.
Yes: Repair or replace connectors or wiring P305-2 to P310-2, then turn to TAG 002: Check &
Problem Resolution.

Yes: Repair or replace the connectors or wiring from J323-2 to J305-2, then turn to TAG 002:

No: Continue.

• Check J331-2 to P306-2 for continuity to ground.
No: Repair or replace the connectors or wiring from: P330-2 to P331-2, or P330-2 to P323-2.
Yes: Repair or replace the connectors or wiring from J331-2 to P306-2.


No: Continue.

• Check for continuity to ground: P312-1 to P320-1, and P312-4 to P322-1
No: Replace the duplex control board #2, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: Repair or replace the connectors or wiring from P312-1 to P320-1, or P312-4 to P322-1,

No: Replace the restart side sensor, then turn to TAG 002: Check & Problem Resolution.
Yes: Replace the restart paper sensor, then turn to TAG 002: Check & Problem Resolution.

Yes: Continue.

Is the voltage at +12 Vdc?
No: Replace the paper path sensor, then turn to TAG 002: Check & Problem Resolution.
Yes: Replace the cover open sensor, then turn to TAG 002: Check & Problem Resolution.


P309-4 to P319-1, and
P309-3 to P318-1
No: Replace duplex control board #1, then turn to TAG 002: Check & Problem Resolution.
P309-4 to P319-1, or
P309-3 to P318-1;

TAG 098: -12 Vdc Power Shorted

Error Code: 098
PCL board
IGS board
External attachment option

No: Continue.
2 Check J/P32-3 for -12 Vdc.

Is the voltage -12 Vdc?
No: Continue.
Yes: Replace PCL board, then turn to TAG 002: Check & Problem Resolution.

• Check J/P8-8 for -12 Vdc.
No: Continue.

Yes: Repair or replace the connectors or wiring from P8-8 to P32-3.


Yes: Continue.

Yes: Continue.

Is the voltage at J/P8-8 -12 Vdc?

TAG 099: +24 Vdc Power Shorted

Error Code: 099
Possible Defects: DC power supply unit
PCL board
IGS board
High voltage unit
Paper timing clutch
Upper feed roller clutch
Upper pick-up clutch
Lower pick-up clutch
Lower feed roller clutch
Counter assembly
Possible Defects, Duplex Printers:

Route motor
In solenoid
‘C’ roller solenoid
‘A’ roller clutch
Exit solenoid
Restart motor

• Verify that J/P11, J/P8, J/P32, J/P33, J/P91, J/P303, J/P305, J/P306, J/P310, J/P323, and J/P331
are connected properly.
No: Continue.

No: Continue.

No: Continue.


Yes: Continue.

Yes: Continue.

No: Repair or replace the connectors or wiring from P10 to P70, then turn to TAG 002: Check
Yes: Replace the AC power supply unit, then turn to TAG 002: Check & Problem Resolution.

No: Replace power control #2 board, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.


Yes: Continue.

No: Continue.


Yes: Continue.


Yes: Continue.

Yes: Continue.

Yes: Continue.

No: Repair or replace the connectors or wiring from J81-1 to P82-1, then turn to TAG 002:
Yes: Replace the counter assembly, then turn to TAG 002: Check & Problem Resolution.


No: Continue.
Yes: Replace the lower pick-up roller assembly, then turn to TAG 002: Check & Problem Res-
olution.

No: Continue.
Yes: Replace the paper timing roller assembly, then turn to TAG 002: Check & Problem Reso-
lution.

No: Continue.
Yes: Replace the upper feed roller assembly, then turn to TAG 002: Check & Problem Resolu-
tion.

No: Continue.
Yes: Replace the lower feed roller assembly, then turn to TAG 002: Check & Problem Resolu-
tion.


P40-10 to J69-1,
P40-11 to J65-1,
P40-11 to J66-1,
P40-11 to J67-1, or
P40-11 to J 68-1;
Yes: Replace the upper pick-up roller assembly, then turn to TAG 002: Check & Problem Res-
olution.

P8-13 to P91-1, or
P8-11 to P11-1;

Yes: Continue.

Yes: Continue.


• Disconnect J/P310 (inside duplex tray).
No: Continue.


Yes: Repair or replace the connectors or wiring from J323-1 to J305-1, then turn to TAG 002:

No: Continue.


• Check J331-1 and P306-1 for continuity to ground.
P330-1 to P331-1 or
P330-1 to P323-1;

No: Continue.
Yes: Replace the restart motor, then turn to TAG 002: Check & Problem Resolution.

No: Repair or replace the connectors or wiring from P312 to J321, then turn to TAG 002:
Yes: Replace the duplex control board #2, then turn to TAG 002: Check & Problem Resolu-
tion.

No: Continue.
Yes: Replace the route motor, then turn to TAG 002: Check & Problem Resolution.


No: Continue.
Yes: Replace the “in” solenoid, then turn to TAG 002: Check & Problem Resolution.

No: Continue.
Yes: Replace the “C” roller solenoid, then turn to TAG 002: Check & Problem Resolution.

No: Continue.
Yes: Replace the “A” roller clutch, then turn to TAG 002: Check & Problem Resolution.

No: Continue
Yes: Replace the exit solenoid, then turn to TAG 002: Check & Problem Resolution.


No: Repair the duplex control board #1, then turn to TAG 002: Check & Problem Resolution.
P309 pins 7 through 10 to J313 pins 1 through 4
P308-1 to J314-1
P308-2 to J315-1
P308-3 to J316-1, or
P308-4 to P317-1;

TAG 100: PCL Board Interface Malfunction
TAG 100: PCL Board Interface Malfunction

Error Code: 100, 132, 140, 145, 160-162, 170-172, 180-182
Symptoms: PCL board failure
PCL board

No: Continue.
2 Was an error code displayed during the power-on-reset?

No: Refer to the mechanical malfunctions cross-reference table in “Mechanical Malfunction/
TAG Cross-Reference” on page 2-12.
Yes: Continue.
3 Was the error code the same as the one used to enter this TAG?
No: Refer to the error code cross-reference table in “Error Code/TAG Cross-Reference” on
page 2-3.

TAG 101: IGS Controller Diagnostic Failure
TAG 101: IGS Controller Diagnostic Failure

Error Code: 101
Possible Defects: IGS board

Is error 101 displayed on the operator panel.
No: The problem may be caused by power fluctuation. Turn to TAG 002: Check & Problem
Resolution.
Yes: Replace the IGS controller, then turn to TAG 002: Check & Problem Resolution.

TAG 130: Diskette/Disk Drive Malfunction

Error Code: 130, 131, 133, 134, 450, 451, 572-576, 586
Symptoms: Test prints do not run
Possible Defects: Diskette
Disk drive assembly
PCL board
IGS board
DC power supply
Electrical problems on wires J/P31 to J/P79 and J/P31 to ground may cause diskette and
disk drive malfunctions. If this TAG does not correct the problem, suspect an intermittent
failure from the disk drive to the IGS board cable and replace the cable from J/P31 to J/
P79 to J/P30.
The causes of error code 574 or 576 may alter the information on the diskette. You may
have to replace the diskette with another known to be good.
1 Verify that a diskette has been inserted properly.

• Verify that the write/protect notch is closed.
• Turn off the printer.
No: Continue.
2 Is error code 451 displayed?

Yes: Continue.

Yes: Continue.
4 Replace the diskette with another diskette known to be correct for the customer's system configura-
tion.
No: The diskette was at fault. Turn to TAG 002: Check & Problem Resolution.


Yes: Continue.

No: Replace the disk drive assembly. If this resolves the problem, turn to TAG 002: Check &
Problem Resolution. If this does not resolve the problem, replace the IGS board, then turn
Yes: Replace wire harness W46, then turn to TAG 002: Check & Problem Resolution.

Yes: Continue.
8 Turn the printer on.

Yes: Continue.

Yes: Continue.

Yes: Continue.

Yes: Continue.

• Check for continuity to ground: P31-34 to P79-34, P31-32 to P79-32, P31-16 to P79-16, and

P31-10 to P79-10.
Is there continuity on any?
No: Replace the disk drive assembly. If this does not resolve the problem, replace the IGS
board, then turn to TAG 002: Check & Problem Resolution.

Yes: Continue.

No: Replace wire harness W46, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
15 Check for continuity to ground: P31-18 to P79-18, P31-24 to P79-24, and P31-26 to P79-26.

Yes: Continue.

Is there continuity on each?
Yes: Replace the disk drive assembly. If this resolves the problem, turn to TAG 002: Check &

Yes: Continue.

• Check for continuity:

P31-22 to P79-22,
P31-24 to P79-24,
P31-26 to P79-26,
P31-28 to P79-28, and
P31-32 to P79-32.
Yes: Continue.
20 Check for continuity to ground:

P31-20,
P31-22,
P31-26, and
P31-32.
Is there continuity to ground on any?
No: Replace the disk drive assembly, then turn to TAG 002: Check & Problem Resolution.
Yes: Replace wire harness W46.
21 Is error code 130, 131, 133, or 134 displayed?

No: Continue.
22 Can the printer run test prints?

No: Continue.
Yes: Replace the disk drive assembly. If this resolves the problem, turn to TAG 002: Check &


TAG 200: IGS Internal Communication Malfunction

Error Code: 401, 454, 455, 500-509, 520-530, 540-566, 570, 571, 577-585, 600-605
Symptoms: IGS board failure
Possible Causes: IGS program error
Possible Defects: Wiring or connectors
IGS board
Software
Signal interface

No: Continue.
2 Was an error code displayed?

No: Refer to the mechanical malfunctions cross-reference table in “Mechanical Malfunction/
TAG Cross-Reference” on page 2-12.
Yes: Continue.
3 If the operator panel displayed more than one error code, was it the first code that
displayed on the panel that led you to this TAG?
No: Look in “Error Code/TAG Cross-Reference” on page 2-3 for the first error code that dis-
played, then turn to the TAG referenced in the table.
Yes: Continue.

No: Continue.
5 Replace the IGS board, making sure that IGS EPROM version is correctly matched to the software
release installed on the printer.
No: Reinstall the original IGS board and continue.
6 Does this printer contain a hard drive?

No: Continue.

7 Replace the software diskettes in drives A and B.

Yes: Software diskettes were at fault. Turn to TAG 002: Check & Problem Resolution.
8 Disconnect J/P76 (hard drive cable).

• Insert the emulation diskette into drive A.
Yes: Reconnect J/P76 and reload the software onto the hard drive; instructions for loading
software onto the printer’s hard drive are outlined in the Guide to Operations. Then turn

TAG 201: IGS-PCL Interface Malfunction

Error Code: 121-127, 199-215, 380-387
Symptoms: Communication failure between the IGS board and the PCL board
Possible Causes: Insufficient delay period between power off and power on
Electrical spikes
Optional hard drive not spinning up
PCL board
IGS board
DC power supply
High voltage power supply
Optional hard drive

Yes: Continue.

• Verify that J/P33 is connected properly.
No: Confirm that the IGS firmware is correct for the version of software being used; then
replace the IGS board. Turn to TAG 002: Check & Problem Resolution.
3 Is error code 121 or 123 displayed?

Yes: Continue.

Are the connectors or wiring damaged?
No: Continue.
5 Replace the PCL board.

No: Continue.

6 Replace the IGS board.

No: If error code 121 or 123 brought you to this TAG, replace the DC or high voltage power
supply, then turn to TAG 002: Check & Problem Resolution. For all other error codes,
replace the IGS board, then turn to TAG 002: Check & Problem Resolution.

TAG 405: IGS Bit-Map RAM Malfunction
TAG 405: IGS Bit-Map RAM Malfunction

Error Code: 606, 600, 610
Possible Defects: IGS board
1 The IGS bit-map RAM has malfunctioned. Replace the IGS board, then turn to TAG 002: Check &
Problem Resolution.

TAG 500: +5 Vdc Power Malfunction

Error Code: 500
Symptoms: Operator panel blank with AC power supply cooling fan running
Possible Defects: DC fuse
Operator panel circuit board
PCL board
IGS board
Disk drive assembly
LED printhead assembly
Attachment option
AC power supply

• Confirm that J/P94, J/P4, J/P41, J/P91, J/P90, J/P6, and J/P8 are connected properly.
Is the operator panel still blank?
No: Loose connectors were at fault. Turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

Yes: Continue.

Yes: Continue.

Yes: Continue.


Yes: Continue.

No: Repair or replace the connectors or wiring from P42-20 to J/P90-20 to J/P94-2 to P8-15,
Yes: Replace the operator panel circuit board. If this resolves the problem, turn to TAG 002:
board, wire harness W72, or wire harness W63, then turn to TAG 002: Check & Problem
Resolution.

No: Continue.

Yes: Continue.

• Reconnect J/P8.
No: Continue.


No: Continue.
Yes: Replace the LED printhead assembly, then turn to TAG 002: Check & Problem Resolu-
tion.

No: Continue.

No: Continue.
Yes: Replace the IGS board, then turn to TAG 002: Check & Problem Resolution.

Yes: Continue.


No: Replace the operator panel circuit board, then turn to TAG 002: Check & Problem Reso-
lution.
Yes: Repair or replace the connectors or wiring from P94-1 to J/P90-1 to P42-1, then turn to

Yes: Continue.

No: Repair or replace the connectors or wiring from J331-3 to P306-3, then turn to TAG 002:
tion.

Yes: Continue.

Yes: Continue.


• Disconnect J/P73, the DC cable for the attachment option.

No: Replace wire harness W127 or W128, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: Continue.

• Disconnect J/P310, found inside the duplex tray.
tion.
Yes: Repair or replace the connectors or wiring from J323-3 to J/P305-3 to P310-3, then turn
22 Turn the printer on. Use extreme caution:

• Check from J/P6-1 to J/P6-2 (neutral) for 100 Vac or more.
No: Continue.
Yes: Replace the DC power supply unit, then turn to TAG 002: Check & Problem Resolution.
23 Use extreme caution: Check from J/P4-7 to J/P4-8 (neutral) for 100 Vac or more.
No: Replace the AC power supply unit.
P4-7 to P6-1 or
P4-8 to P6-2;

TAG 600: AC Power Malfunction

Error Code: 600
Symptoms: Operator panel blank with fans not running
Printer Open indicator on
Circuit breaker keeps tripping
Possible Defects: Upper fuse in the AC power supply
Fuser unit
Back cover interlock switch
Front cover interlock switch
Top cover interlock switch
Toner supply motor
Cooling fans
Jogging motor
Main drive motor
Operator panel assembly

• Verify that J/P44, J/P84, J/P4, J/P9, J/P12, J/P40, J/P6, and the AC power cord are connected
properly.
No: Continue.

• Turn the printer on. Use extreme caution:
• Check from J/P9-2 to J/P9-1 for +100 Vac.
Is the voltage +100 Vac?
Yes: Continue.

No: Repair or replace the connectors or wiring as needed.
Yes: Replace the power control #2 board. If this resolves the problem, turn to TAG 002: Check
& Problem Resolution. If this does not resolve the problem, replace the PCL board, then

4 Does the PRINTER OPEN light come on with all the covers closed?
Yes: Continue.
5 Operate the top and front cover interlock switch actuators.

Are the interlock switch actuators working properly?
No: Repair or replace any defective actuator, then turn to TAG 002: Check & Problem Reso-
lution.
Yes: Continue.
6 Use extreme caution: Check from J/P4-4 to J/P4-3 for +100 Vac.
No: Continue.
Yes: Repair or replace the connectors or wiring from: P9-2 to P4-4 or P9-1 to P4-3. If this is a
duplex printer and the problem remains, go to TAG 900: Top Cover Interlock Malfunc-
tion, Duplex. If this corrects the problem, turn to TAG 002: Check & Problem Resolu-
tion.

• Remove the upper fuse in the AC power supply unit.
• Check the fuse for continuity.
Does the fuse have continuity?
No: Continue.
8 Replace the upper fuse in the AC power supply unit.

• Reconnect the power.
Was the power-on-reset successful?
Yes: Continue.

• Run diagnostic test 010 for approximately 5 seconds, then stop.
• Turn the printer off and unplug the power cord.
• Remove the fuse.
Yes: A defective fuse was at fault. Turn to TAG 002: Check & Problem Resolution.

10 Reinstall the fuse.

• Close the top cover.
Yes: Continue.
11 Remove the AC power supply unit.

• Operate the front cover interlock switch.
• Check for continuity as you operate the front interlock switch.
Does the front cover interlock switch have continuity?
No: Repair or replace the front interlock switch, then turn to TAG 002: Check & Problem
Resolution.
Yes: Repair or replace the AC power supply unit, then turn to TAG 002: Check & Problem
Resolution.
• Install a new upper fuse in the AC power supply unit.
• Run diagnostic test 010 for approximately 5 seconds, then stop.
tion.
Yes: Continue.
No: Replace the toner supply motor, then turn to TAG 002: Check & Problem Resolution.

• Turn the printer on for 5 seconds, then off.
• Remove the upper fuse.
Yes: Continue.

15 Reconnect J/P9.
• Install a good upper fuse in the AC power supply unit.
tion.
Yes: Continue.

• Disconnect J/P20, J/P21, J/P22, and J/P326 (duplex printers).
• Wait 2-1/2 minutes, then turn the printer off.
No: Repair or replace connectors or wiring that have continuity to ground: P21-1 to P13-4,
P22-1 to P13-6, J326-1 to P13-4, or P20-2 to P14-6; then turn to TAG 002: Check &
Problem Resolution.
Yes: Continue.

No: Replace the large cooling fan assembly, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: Continue.

• Turn the printer on for 2-1/2 minutes, then off.
• Remove the upper fuse from the AC power supply unit.
No: Replace the main drive motor, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.


• Turn on the printer for 2-1/2 minutes, then off.
No: Replace the vacuum transport unit, then turn to TAG 002: Check & Problem Resolution.
Yes: Replace the small cooling fan assembly, then turn to TAG 002: Check & Problem Reso-
lution.
20 Reconnect J/P9.
• Run diagnostic test 008 for approximately five seconds, then turn off the printer.
Yes: Continue.

• Install a good upper fuse in the AC power supply unit.
• Run diagnostic test 008 for approximately five seconds, then stop.
tion.
Yes: Continue.
No: Replace the jogging motor, then turn to TAG 002: Check & Problem Resolution.

No: Continue.
Yes: Repair or replace the connectors or wiring from P4-4 to P9-2 or P4-4 to P100-1; then turn

24 Close the top cover.

Yes: Repair or replace the top cover interlock switch assembly. If this resolves the problem,
turn to TAG 002: Check & Problem Resolution. If this does not resolve the problem,
repair or replace the connectors or wiring from: P4-5 to J/P84-1 to P131, or P132 to J/
P84-2 to P4-6; then turn to TAG 002: Check & Problem Resolution.
25 Is the operator panel blank and are the cooling and AC power supply fans off?
No: You have chosen an incorrect TAG. Refer to the mechanical malfunctions cross-reference
table in “Mechanical Malfunction/TAG Cross-Reference” on page 2-12, to identify a
more appropriate TAG.
Yes: Continue.

• Check the wall power outlet for proper voltage.
Is the voltage correct? If the circuit breaker was reset after beginning this TAG,
answer no.
Yes: Continue.
27 Unplug power cord from the printer and the wall outlet.
• Check the power cord for continuity.
No: Replace the power cord, then turn to TAG 002: Check & Problem Resolution.
Yes: Replace the AC power supply, then turn to TAG 002: Check & Problem Resolution.
28 Disconnect J/P4.
Yes: Continue.

• Check P4-1 to J/P44-3 to J5-1 to the fuser unit for continuity to ground.
No: Replace the fuser unit, making sure the fuser has the proper voltage rating, then turn to
Yes: Repair or replace connectors or wiring that have continuity, then turn to TAG 002: Check

30 Check J4-1 at the AC power supply unit for continuity to ground.

No: Continue.
31 Check P4-7 for continuity to ground.

Yes: Continue.
32 Disconnect J/P6.
33 Check J4-7 at the AC power supply unit for continuity to ground.

No: The customer’s circuit breaker may be defective. Verify that the wall outlet has the proper
voltage. If it does, continue; otherwise, turn to TAG 002: Check & Problem Resolution.
No: Repair or replace the connectors or wiring that lack continuity, then turn to TAG 002:
Yes: Continue.
35 Check J84-1 to P131 and J84-2 to P132 for continuity.

No: Repair or replace the connectors or wiring that lack continuity, then turn to TAG 002:
Yes: Continue.
36 Check J131 to J132 (top interlock switch) for continuity while activating the top cover interlock
switch.
No: Repair or replace the top cover interlock switch, then turn to TAG 002: Check & Problem
Resolution.
Yes: You have failed to isolate the problem. Return to the beginning of this TAG.

TAG 610: Operator Panel Malfunction

Error Code: 610
Symptoms: One or more message indicators will not light
Incomplete numbers are displayed
Tone does not work properly
All status lights remain on
One or more function keys do not work
Possible Causes: Operator panel
PCL board

• Turn the volume control (on operator panel inside front cover) up fully.
No: Continue.
2 Do the status lights stay on continuously?

No: Continue.

• Disconnect J/P42, J/P91, J/P8, and J/P32.
No: Repair or replace the connectors or wiring from P8-15 to J/P94-2 to J/P90-20 to P42-20,
Yes: Continue.
4 Reconnect J/P42, J/P91, J/P8, and J/P32.

• Press each function key and listen for the tone.
• Test prints may be produced. Press the STOP key or turn the printer off to quit.
Did you hear the tone after pressing each function key?
Yes: Continue.
5 Is one of the function keys not working properly?

Yes: Continue.


Yes: Continue.
7 Check P41-3 to P42-18 for continuity to ground.

No: Continue.

Yes: Continue.

No: Continue.

Yes: Continue.

No: Continue.

Yes: Continue.


No: Replace the operator panel. If this resolves the problem, turn to TAG 002: Check & Prob-
Yes: Repair or replace the connectors or wiring from P42-15 to J/P90-15 toP41-6, then turn to

No: Continue.

Yes: Replace the operator panel. If this resolves the problem, turn to TAG 002: Check & Prob-

• Note which status lights come on and what is displayed each time the tone sounds. Some of the
status lights may be very dim.
• Refer to the table at the end of this TAG.
Is the combination of lights and display you noted identified in the table?
No: Replace the operator panel. If this resolves the problem, then turn to TAG 002: Check &
Problem Resolution. If this does not resolve the problem, replace the PCL board, then
Yes: Continue.

• Check the wiring indicated on the table below.
Is there an open or short to ground continuity?
No: Replace the operator panel. If this resolves the problem, then turn to TAG 002: Check &
Problem Resolution. If this does not resolve the problem, replace the PCL board, then
Yes: Repair or replace the defective connectors or wiring, then turn to TAG 002: Check &
Problem Resolution.

Wiring Table
Refer to the table below to check the wiring for an open or short to ground. In the display
panel illustrations, “on” status lights (which may be dimly lit) are black.
Wiring Failure Description Operator Panel

J/P42-7 to Open
J/P90-7 to
J/P41-14 No indications
J/P42-7 to Short to ground

J/P90-7 to
J/P41-14
J/P42-11 to Open
J/P90-11 to
J/P41-10
J/P42-12 to Open
J/P90-12 to
J/P41-9
J/P42-13 to Open
J/P90-13 to
J/P41-8
J/P42-14 to Open
J/P90-14 to All lights ON
J/P41-7 CLR PAPER JAM light may be very dim
J/P42-8 to Open
J/P90-8 to
J/P41-13

J/P90-8 to
J/P41-13
CLOSE COVER light may be very dim

J/P42-9 to Open
J/P90-9 to
J/P41-12

J/P90-9 to
J/P41-12
ADD PAPER light may be very dim

Wiring Failure Description Operator Panel

J/P42-10 to Open
J/P90-10 to
J/P41-11

J/P90-10 to
J/P41-11
CLR PAPER light may be very dim

J/P90-11 to
J/P41-10

J/P90-12 to
J/P41-9

J/P90-13 to
J/P41-8

J/P90-14 to
J/P41-7

TAG 700: Output Tray Circuit Malfunction

Error Code: 700
Symptoms: Output Tray Full light remains on, will not light, or lights prematurely
Possible Defects: Output tray full sensor
Job offset assembly
PCL board
High capacity output unit

No: Continue.
2 Is a high capacity output unit installed on the printer?

Yes: Continue.

• Remove the high capacity output unit.
No: Continue.
Yes: The high capacity output unit is malfunctioning. Refer to Chapter 8, “Options”, for
instructions on repairing the high capacity unit.
4 Inspect the output tray full sensor actuator for damage or binding.
Yes: Continue.
5 Does Output Tray Full come on too soon?

No: Continue.
lution.


Yes: Continue.

Yes: Continue.

Yes: Continue.
9 Verify that the output tray full sensor is mounted properly.

• Verify that it moves down fully.
Is the output tray full sensor in good working order?
No: Replace the sensor, then turn to TAG 002: Check & Problem Resolution.
Yes: Replace the PCL board. If this resolves the problem, then turn to TAG 002: Check &
Problem Resolution. If this does not resolve the problem, replace wire harness W71 or
W52, then turn to TAG 002: Check & Problem Resolution.

TAG 702: Paper Size Detection Malfunction

Error Code: 702
Symptoms: Incorrect paper size displayed
Possible Defects: Upper cassette
Lower cassette
PCL board

• Remove the upper and lower cassettes.
• Make sure that the rear and side paper guides are securely against the paper.
• Insert the cassette exhibiting the problem.
Does the display still indicate the incorrect paper size?
No: A loose connector or incorrectly positioned paper guides were at fault. Turn to TAG 002:
Yes: Continue.
2 Remove the cassette exhibiting the problem.

• Take out the paper.
• Inspect the two paper size sensing balls on the bottom of the cassette by changing positions of
the side and rear paper guides.
Is the paper size sensing mechanism in good working order?
No: Replace the defective cassette, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
3 Inspect the upper and lower paper size sensor assemblies.

Is either paper size sensor assembly damaged or improperly mounted?
No: Continue.
Yes: Remount, repair or replace the faulty paper size sensor assembly, then turn to TAG 002:
4 Remove the upper paper size sensor assembly.

• Disconnect the upper circuit board from its mounting.
• Inspect the paper size sensor circuit board and mounting for damage or contamination.
Is the circuit board or mounting damaged or contaminated?
No: Continue.
Yes: Repair or replace the upper paper size sensor assembly, then turn to TAG 002: Check &
Problem Resolution.

5 Remove the lower paper size sensor assembly.

• Disconnect the circuit board from its mounting.
• Inspect the paper size sensor circuit board and mounting for contamination or damage.
Is the circuit board or mounting contaminated or damaged?
No: Continue.
Yes: Repair or replace the lower paper size sensor assembly, then turn to TAG 002: Check &
Problem Resolution.
6 Is the paper size sensing problem occurring with the upper cassette?
Yes: Continue.

• Refer to the tables at the end of this TAG.
• Check the connectors or wiring for the upper paper size sensor.
Is there a wiring problem?
No: Replace the upper paper size sensor assembly. If this resolves the problem, turn to TAG
002: Check & Problem Resolution. If this does not resolve the problem, replace the PCL
Yes: Repair or replace the connectors or wiring that are defective, then turn to TAG 002:

• Refer to the table at the end of this TAG.
• Check the connectors or wiring for the lower paper size sensor.
No: Replace the lower paper sensor assembly. If this resolves the problem, turn to TAG 002:
Yes: Repair or replace the connectors or wiring that are defective, then turn to TAG 002:

Wiring for the Upper Paper Size Sensor

Refer to the following table when performing continuity checks for an open or short to
ground for the upper paper size sensor.
Table 3-2. Wiring for the Upper Paper Size Sensor
Wiring Upper Paper Size Sensor

P40-41 to J/P52-10 to J43-1 to J47-10 to J45-10
P40-42 to J/P52-9 to J43-2 to J47-9 to J45-9
P40-43 to J/P52-8 to J43-3 to J47-8 to J45-8
P40-44 to J/P52-7 to J43-4 to J47-7 to J45-7
P40-45 to J/P52-6 to J43-5 to J47-6 to J45-6
P40-46 to J/P52-5 to J43-6 to J47-5 to J45-5
P40-47 to J/P52-4 to J43-7 to J47-4 to J45-4
P40-48 to J/P52-3 to J43-8 to J47-3 to J45-3
P40-49 to J/P52-2 to J43-9 to J47-2 to J45-2
Wiring for the Lower Paper Size Sensor

Refer to the following table when performing continuity checks for an open or short to
ground for the lower paper size sensor.
Table 3-3. Wiring for the Lower Paper Size Sensor

P40-41 to J/P52-10 to J43-1
P40-42 to J/P52-9 to J43-2
P40-43 to J/P52-8 to J43-3
P40-44 to J/P52-7 to J43-4
P40-45 to J/P52-6 to J43-5
P40-46 to J/P52-5 to J43-6
P40-47 to J/P52-4 to J43-7
P40-49 to J/P52-2 to J43-9
P40-50 to J/P52-1 to J43-10


Error Code: 703
Symptoms: Upper cassette does not load or unload properly
Upper cassette does not latch properly
Upper cassette release
Damper assembly
Wire cable/roller/spring
1 Inspect the upper cassette for damage.

Is the upper cassette in good working order?
No: Replace the upper cassette, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

• Upper cassette release
• Damper assembly
• Wire cable/roller/spring
Are all parts in good working order?
No: Repair or replace the damaged part, then turn to TAG 002: Check & Problem Resolution.
Yes: Only mechanical defects and malfunctions can cause this type of problem. Carefully rein-
spect each part. Repair or replace and defective parts, then turn to TAG 002: Check &
Problem Resolution.


Error Code: 704
Symptoms: Lower cassette does not load or unload properly
Lower cassette does not latch properly
Possible Defects: Lower cassette
Lower cassette release
Spring
1 Inspect the lower cassette for damage.

Is the lower cassette in good working order?
No: Replace the lower cassette, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

• Lower cassette release
• Spring
No: Repair or replace the damaged part, then turn to TAG 002: Check & Problem Resolution.
Yes: Only mechanical defects and malfunctions can cause this type of problem. Carefully rein-
spect each part. Repair or replace the damaged part, then turn to TAG 002: Check &
Problem Resolution.

TAG 705: Multiple Paper Feeding

Error Code: 705
Possible Causes: Wrong weight or type of paper loaded
Paper improperly loaded
Possible Defects: Upper feed roller assembly
Paper cassette
1 Remove paper from the cassette.

• Fan the paper stack and place it in the cassette.
• Make sure the paper curl is turned up in the cassette.
• Confirm that the paper in the cassettes meets paper specifications, outlined in the Guide to
Operations at the back of this manual.
• Run at least 20 test prints.
No: Continue.
Yes: The paper being used was at fault. Turn to TAG 002: Check & Problem Resolution.
2 Adjust the paper tension lever or pick pressure as outlined in Chapter 9, “General Printer Mainte-
nance”.
No: Replace the pick-up roller assembly, then turn to TAG 002: Check & Problem Resolu-
tion.

TAG 706: Paper Damaged or Wrinkled

Error Code: 706
1 Make sure the paper being used is not damaged.

• Make sure the paper is loaded properly.
• Make sure the side and rear paper guides in the paper cassettes are positioned properly.
• Check both upper and lower paper paths for obstructions or roller contamination.
Are the prints wrinkled or damaged?
No: Continue.

No: The paper in use was at fault. Turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
3 Run a test print from the cassette exhibiting the problem.

Is the print on the paper skewed?
No: Continue.
Yes: Go to TAG 807: Misregistered/Skewed Prints (Simplex).
4 Remove the exit cover assembly.

• Inspect the exit roller assembly for damage, wear, or contamination.
• Inspect the exit pinch roller for damage, wear, or contamination.
Is either part damaged, worn, or contaminated?
Yes: Repair or replace the part as needed, then turn to TAG 002: Check & Problem Resolu-
tion.

TAG 707: Upper Paper Guide Assembly Not Closing

Error Code: 707
Possible Causes: Obstructions
Photoconductor unit front or rear latch arm springs
Photoconductor unit latch arms in incorrect position
Upper paper guide latching mechanism damaged or binding
Front or rear photoconductor unit guides damaged
Possible Defects: Photoconductor latch arms
Upper paper guide latch
Photoconductor guide rails
1 Check under the upper paper guide assembly for obstructions.

• Remove the photoconductor unit from the printer.
• Inspect the front and rear photoconductor unit latch arm springs for damage.
• Inspect the front and rear photoconductor unit guide rails for damage.
• Make sure there are no obstructions in the mounting area of the photoconductor unit.
• Make sure the upper paper guide latching mechanism is functioning properly.
• Make sure the photoconductor unit latch arms are in the upper position.
No: Repair or replace any malfunctioning parts, then turn to TAG 002: Check & Problem
Resolution.
Yes: Continue.

• Close and lock the upper paper guide.
Did the upper paper guide lock into place?
No: Replace the upper paper guide, then turn to TAG 002: Check & Problem Resolution.
Yes: Only mechanical defects and malfunctions can cause this type of problem. Go to #1 in
this TAG and carefully reinspect each part.

TAG 750: Counter Malfunction

Error Code: 750
Symptoms: Counter does not count
Counter counts too often
Consumable components require replacement too frequently
Possible Defects: Counter assembly
PCL board

Is the counter functioning properly?
No: Continue.
Yes: The counter is working correctly. Turn to TAG 002: Check & Problem Resolution.
2 Verify that J/P41, J/P81, and J/P82 are connected properly.

No: Continue.
3 Is the counter either counting when it shouldn’t or counting too many times?
Yes: Continue.
4 Replace the counter.

Yes: The counter was at fault. Turn to TAG 002: Check & Problem Resolution.

Yes: Continue.

Yes: Continue.

7 Run test prints.

• Check TP4-25 for a voltage change from +24 Vdc to 0 Vdc while running the prints.
Yes: Replace the counter, then turn to TAG 002: Check & Problem Resolution.

No: Repair or replace the connectors or wiring from P41-26 to J/P81-1 to J82-1, then turn to
Yes: Continue.
9 Check P41-25 to J82-2 for continuity.

No: Repair or replace the connectors or wiring from P41-25 to J/P81-2 to J82-2, then turn to
Yes: Replace the counter. If this resolves the problem, turn to TAG 002: Check & Problem
Resolution. If this does not resolve the problem, replace the PCL board, then turn to TAG

TAG 751: Main Drive Motor Runs Continuously

Error Code: 751
Possible Defects: Power control #2 board
PCL board

No: Replace the power control #2 board. If this resolves the problem, turn to TAG 002: Check
& Problem Resolution. If this does not resolve the problem, replace the PCL board, then

TAG 753: External Communications Malfunction

Error Code: 753
Symptoms: Test prints can be made but jobs do not run
Jobs do not print correctly
Possible Causes: Improper DIP switch settings
Host computer
Improper application
Possible Defects: IGS board communications cable
Cable connectors
Diskette
Wrap connector
Attachment options.
Note
Communication problems may require trial replacement of numerous
parts. After each trial replacement, run the job that exhibited the failure.

• Verify that all communication cables are attached properly.
• Verify that the correct diskette is installed in the printer.
• Confirm that the DIP switches on the signal interface board are set to their proper positions.
• Confirm that the printer’s soft configuration is set properly.
• Run the failing job.
No: Continue.
Yes: Loose connectors, software configuration, or DIP switches were at fault. Determine
which of these is at fault, correct the problem, then turn to TAG 002: Check & Problem
Resolution.

• Recheck the diskette for suitability.
• Verify that the DIP switch settings on signal interface boards are correct.
• Confirm that the printer’s software configuration is set correctly to the interface you are using.
No: Continue.
Yes: Software configuration or DIP switch settings were at fault. Determine which of these is
at fault, correct the problem, then turn to TAG 002: Check & Problem Resolution.


• Remove fuse FH2, which is mounted to the signal interface board, and check for continuity.
No: Install a new fuse and retest. If the fuse is okay, turn to TAG 002: Check & Problem Res-
olution. If the new fuse fails, replace the signal interface board or attachment option and
install a new fuse, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
4 Disconnect the interface cable from the printer.

• Disconnect any attachment option.
• Install the RS-232C and RS-422 wrap connectors.
Did the diagnostic test run properly?
No: Continue.

• Inspect J/P71 (RS-232C), J/P72 (RS-422), and J/P74 for connector body cracks or damaged
pins.
Is there a problem with the connectors or pins?
Yes: Continue.
6 Replace the signal interface board.

No: Continue.
Yes: The signal interface board was at fault. Turn to TAG 002: Check & Problem Resolution.

Yes: Continue.

No: Continue.
Yes: Replace the signal interface board, then turn to TAG 002: Check & Problem Resolution.
If this does not resolve the problem, replace the IGS board, then turn to TAG 002: Check


Yes: Repair or replace connectors or wiring from P8-8 to P32-3, then turn to TAG 002: Check
10 Does the problem appear while using RS-232C communications?

No: The problem may be caused by the IGS board, signal interface board, host computer, or
host interface cable. Determine which of these are at fault, correct the problem, then turn
Yes: Continue.

• Install a breakout box on the printer to confirm that the host interface cable works as outlined in
the table that follows.
• Reconnect all communication lines.
• Reconnect any external attachment option.
• Run the failing job again.
Table 3-4. RS-232 Cable Reference Table
Host Computer Printer

Description
Signal Pin # Directions Pin # Signal
FG 1 1 FG
SG 7 7 SG
TD 2 _ < 2 TD Data Out (status)
TD 2 < _ 3 RD Data In (CMD/Data)
RTS 4 _ < 4 RTS Optional; continuous positive volt-
age for host computers that require
a “printer present” indication.
CTS 5 < 5 CTS Must go to a positive voltage from
the host computer. It is only looked
at by the printer at power-on initial-
DSR 6 < _ ization.
DTR 20 _ 20 DTR Depends on printer soft configura-
tion option 15. DTR will always be a
positive voltage if set to “DTR High.”
DTR will change from a positive to a
negative voltage if set to “DTR Pac-
ing” and the buffer is full
Does your cable work as outlined in the Cable Reference Table above?
No: The problem appears to be related to the host computer or host interface cable. Correct
the problem, then turn to TAG 002: Check & Problem Resolution.
Yes: The problem may be caused by the IGS board, signal interface board, or outdated printer
software. Determine which of these is at fault, correct the problem, then turn to TAG 002:

TAG 754: Attachment Option Malfunction

Error Code: 754
Symptoms: Job fails only when an attachment option is used.
Possible Causes: Lack of voltage
Possible Defects: Attachment option
Communication cables
Cable connectors
Signal interface board fuse
IGS board
Host computer
Host interface cable
Communication problems may require trial replacement of numerous parts. After each
trial replacement, run the job that exhibited failure.

• Disconnect all attachment cables.
• Confirm that J/P8, J/P32, and J/P74 are connected properly.
• Confirm that the signal interface board DIP switches are set correctly.
• Confirm that the printer has been correctly configured using the printer’s soft configuration
mode.
No: Continue.
Yes: Loose or damaged connectors, software configuration, or DIP switches were at fault.
Turn to TAG 002: Check & Problem Resolution.

• Check the signal interface board fuse for continuity.
No: Continue.
3 Disconnect the cables from the attachment option to the printer.

• Replace the signal interface board fuse.
• Turn on the printer for five seconds, then turn it off.
Yes: Continue.

4 Reconnect the attachment cables.

• Turn on the printer for five seconds, then turn it off.
No: Replace the attachment option, then turn to TAG 002: Check & Problem Resolution.
Yes: The signal interface board fuse was at fault. Turn to TAG 002: Check & Problem Resolu-
tion.

• Check for the indicated voltages:
J73-1 should be +5 Vdc;
J73-4 should be -12 Vdc;
J73-6 should be +5 Vdc.
Are all voltages correct?
No: Replace the signal interface board. If this resolves the problem, turn to TAG 002: Check
& Problem Resolution. If this doesn’t resolve the problem, go to TAG 753: External
Communications Malfunction, step 4.
Yes: Continue.

• Replace the external attachment option.
• Reconnect all communication cables.
No: The problem appears to be related to the host computer or the host interface cable. Cor-
rect the problem, then turn to TAG 002: Check & Problem Resolution.
Yes: The external attachment option was at fault. Turn to TAG 002: Check & Problem Resolu-
tion.

TAG 800: Prints Blank or With Dark Horizontal Bands

Error Code: 800
Possible Defects: Photoconductor unit,
Printhead assembly
IGS board
Transfer corona
High voltage unit
Developer unit
If there is a developed image on the paper other than dark horizontal bands, follow TAG
804: Prints With Light Horizontal Bands.

• Verify that J/P7, J/P27, J/P41, J/P23, J/P30, J/P31, and transfer corona high voltage unit lead are
connected properly.
nance”.
No: Continue.
Yes: Loose connectors or contamination were at fault. Turn to TAG 002: Check & Problem
Resolution.
2 Check the voltages, as outlined in Chapter 9, “General Printer Maintenance”.

Resolution.
Yes: Continue.
3 Have the photoconductor unit, charge corona, developer unit, and toner cartridge
been replaced recently?
No: Continue.
4 Replace the photoconductor unit and charge corona.

No: Reinstall original photoconductor unit and charge corona and continue.
Yes: The photoconductor unit was at fault. Turn to TAG 002: Check & Problem Resolution.

5 Replace the developer unit and toner cartridge.

Yes: Turn to TAG 002: Check & Problem Resolution. If the problem recurs, the toner carrier
mix may be old or contaminated.
6 Produce a developed image on the photoconductor.

Is a developed image on the photoconductor?
Yes: Continue.
7 Remove and clean the transfer corona unit.

• Clean the transfer corona unit contacts in the upper paper guide.
• Inspect the transfer corona contacts for proper alignment.
• Reinstall the transfer corona unit.
No: Continue.

• Remove the transfer corona unit.
• Check the lower transfer corona unit contact, with the upper paper guide assembly in its fully
upright position, for continuity to ground.
No: Replace the upper paper guide assembly, then turn to TAG 002: Check & Problem Reso-
lution.
Yes: Continue.
9 Replace the transfer corona unit.

No: Replace the upper paper guide assembly. If this resolves the problem, turn to TAG 002:
Check & Problem Resolution. If this does not resolve the problem, replace the high volt-
age unit, then turn to TAG 002: Check & Problem Resolution.
Yes: The transfer corona unit was at fault. Turn to TAG 002: Check & Problem Resolution.


• Watch the printhead LEDs while the test is running.
Do the LEDs illuminate?
Yes: Continue.
11 Are the prints blank without dark bands?

Yes: Continue.
12 Remove the photoconductor unit and place it in its protective packaging.

• Inspect the drive coupling on the developer unit for damage.
Is the coupling damaged?
No: Continue.
13 Rotate the drive coupling on the developer unit clockwise.

• Watch the magnetic brush.
Does the magnetic brush turn?
No: Replace the developer unit, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

• Watch the developer drive coupling at the rear of the developer unit cavity.
Does the developer drive coupling turn?
No: Repair or replace the main drive gear assembly, then turn to TAG 002: Check & Problem
Resolution.
15 Do the prints have one or more horizontal dark bands?

No: The problem has not been identified. Go back to TAG 001: Troubleshooting a Problem
and begin again.
Yes: Continue.


• Remove the photoconductor.
• Clean the photoconductor unit contacts and guide rail contacts.
• Check the bottom connector contact on the photoconductor guide rail for continuity to ground.
No: Repair or replace the grounding circuit wiring, then turn to TAG 002: Check & Problem
Resolution.
Yes: Continue.

Yes: Contamination was at fault. Turn to TAG 002: Check & Problem Resolution.

TAG 801: Prints Light or Light With Carrier Particles

Error Code: 801
Transfer corona unit
Print-head assembly
High voltage unit
Toner supply motor
PCL board
Developer unit
If the problem still exists after completing this TAG, go to TAG 800: Prints Blank or With
Dark Horizontal Bands.
1 Run test prints.

• Examine the letters A, V, and W for jaggedness on the diagonal lines.
Are they jagged?
No: Continue.
Yes: Refer to Chapter 4, “Print Quality Samples”. Review the printhead problem print sam-
ples, identify one similar to the test prints, and turn to the associated TAG.

nance”.
• Clean the printhead lens and toner patch sensor located on the developer unit.
No: Continue.
Yes: Contamination or loose connectors were at fault. Turn to TAG 002: Check & Problem
Resolution.
3 Check the voltages, as outlined in Chapter 9, “General Printer Maintenance”.Are the voltages cor-
rect?
Resolution.
Yes: Continue.
4 Have the photoconductor unit, charge corona, developer unit, and toner cartridge
been replaced recently?
No: Continue.


No: Reinstall the original photoconductor unit and charge corona and continue.
Yes: Run at least 200 test prints to detone the engine, then turn to TAG 002: Check & Problem
Resolution.


Is the developed image on the photoconductor correct?
Yes: Continue.
8 Remove and clean the transfer corona unit.

• Clean the transfer corona unit contacts in the upper paper guide.
• Reinstall the transfer corona unit.
No: Continue.

• Remove the transfer corona unit.
• Check the lower transfer corona unit contact, with the upper paper guide assembly in its fully
No: Repair or replace the upper paper guide assembly, then turn to TAG 002: Check & Prob-
lem Resolution.
Yes: Continue.


• Replace the transfer corona unit.
No: Replace the upper paper guide assembly. If this resolves the problem, turn to TAG 002:
Check & Problem Resolution. If this does not resolve the problem, replace the high volt-
age unit, then turn to TAG 002: Check & Problem Resolution.
Yes: The transfer corona unit was at fault. Turn to TAG 002: Check & Problem Resolution.
11 Open the front cover and install an interlock by-pass tool.

• Watch the toner motor coupling in the developer unit cavity.
Does the coupling turn?
Yes: Continue.
12 Inspect the toner drive coupling on the developer unit for damage.
No: Continue.
13 Rotate both the drive couplings on the developer unit clockwise.

Do both drive couplings rotate freely?
No: Replace the developer unit, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

• Watch the developer drive coupling in the developer cavity.
No: Repair or replace the main drive gear assembly, then turn to TAG 002: Check & Problem
Resolution.
Yes: Continue.


P41-30 to J24-4,
P41-38 to J23-2,
P41-43 to J25-5,
P41-44 to J25-2,
P41-47 to J25-3,
P41-48 to J25-6,
P41-49 to J25-4, and
P41-50 to J25-1.
No: Repair or replace the connectors or wiring that do not have continuity, then turn to TAG
Yes: Continue.

• Check TP4-30 for +24 Vdc for one minute.
Is the voltage +24 Vdc for the first minute after power-on-reset?
No: Replace the high voltage unit, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
17 Run test prints.

• Check TP4-30 for 0 Vdc while running the prints.
Does the voltage change to 0 Vdc?
Yes: Continue.
18 Is a meter with a high voltage probe available?

Yes: Continue.

• Using a high voltage probe, check J/P25-7 for the proper voltage, as outlined in Chapter 9,
“General Printer Maintenance”.
Is the voltage correct?


Yes: Continue.

No: Repair or replace the connectors or wiring from P18-1 to P13-5, P18-2 to P13-2, or both.
Yes: Replace the toner supply motor, then turn to TAG 002: Check & Problem Resolution.

• Check TP3-31 for 0 Vdc while the test is running.
Is the voltage 0 Vdc?
Yes: Continue.

tion.

• Replace the high voltage unit.
No: Reinstall the original high voltage unit and continue.

• Replace the charge corona terminal assembly.
No: Reinstall the original charge corona terminal assembly and continue.
Yes: Turn to TAG 800: Prints Blank or With Dark Horizontal Bands.


• Replace the printhead assembly unit.
No: Reinstall the original printhead assembly unit and continue.

• Replace the IGS board.
No: Reinstall the original IGS board and go to TAG 800: Prints Blank or With Dark Horizon-
tal Bands.

TAG 802: Prints With Voids or White Spots

Error Code: 802
Developer unit
1 Perform the every-call cleaning procedure.

Operations manual.
No: Continue.

Resolution.
Yes: Continue.
3 Have the photoconductor unit, developer unit, and fuser unit been replaced
recently?
No: Continue.
Yes: Refer to the Chapter 4, “Print Quality Samples”. Compare the test prints with the print
samples and identify a sample having the same print flaw as the test prints; turn to the
TAG listed under the sample.

No: Reinstall the original photoconductor unit and charge corona, and continue.



No: Reinstall the original fuser unit. Refer to the Chapter 4, “Print Quality Samples”. Com-
pare the test prints with the print samples, and identify a sample having the same print
flaw as the test prints; turn to the TAG listed under the sample.

TAG 803: Prints With Light or White Vertical Streaks

Error Code: 803
Possible Defects: Transfer corona unit
Printhead assembly unit
Photoconductor unit
Developer unit

• Verify that J/P13, J/P30, and J/P31 are connected properly.
• Make sure the customer's paper supply is not at fault.
nance”.
No: Continue.
Yes: Loose connectors or contamination were at fault. Turn to TAG 002: Check & Problem
Resolution.

Resolution.
Yes: Continue.
3 Have the photoconductor unit, charge corona, and developer unit been replaced
recently?
No: Continue.

No: Reinstall the original photoconductor unit and charge corona, and continue.



• Produce a developed image on the photoconductor.
Are there vertical streaks on the photoconductor belt image?
No: Replace the transfer corona unit, then turn to TAG 002: Check & Problem Resolution.
Yes: Replace the printhead assembly unit, then turn to TAG 002: Check & Problem Resolu-
tion.

TAG 804: Prints With Light Horizontal Bands

Error Code: 804
Possible Causes: Loose printhead connectors
Possible Defects: Transfer corona unit
Photoconductor unit
Charge corona

nance”.
No: Continue.
Resolution.

Resolution.
Yes: Continue.
3 Have the photoconductor unit and charge corona have been replaced recently?
No: Continue.
No: Replace the photoconductor unit and charge corona.

Yes: Turn on the printer.
4 Run test prints.

No: Reinstall the original photoconductor unit and charge corona, then continue.
5 Replace the transfer corona unit.

No: Replace the photoconductor unit. If this resolves the problem, turn to TAG 002: Check &
Problem Resolution. If this does not resolve the problem, refer to the Chapter 4, “Print
Quality Samples”. Compare the test prints with the print samples, and identify a sample
having the same print flaw as the test prints; turn to the TAG listed under the sample.

TAG 805: Black Prints

Error Code: 805
Possible Causes: Contaminated toner/carrier mix
Printhead assembly
PCL board
IGS board
High voltage unit
Charge corona lead
Photoconductor unit
Developer unit

• Verify that J/P23, J/P24, J/P41, and the charge corona high voltage lead are connected properly.
nance”.
• Clean the contacts on the charge corona.
• Open the printer’s top cover and install an interlock by-pass tool.
Is the photoconductor belt covered with toner?
No: Loose connectors or contamination were at fault. Turn to TAG 002: Check & Problem
Resolution.
Yes: Continue.

Resolution.
Yes: Continue.
3 Has the photoconductor unit, charge corona, developer unit, and cleaner unit been
replaced recently?
No: Continue.


5 Replace the developer unit, toner cartridge, and cleaner unit.

No: Reinstall the original developer unit and cleaner unit, then continue.
Yes: Turn to TAG 002: Check & Problem Resolution. If the problem recurs, the toner/carrier

Yes: Continue.

Yes: Continue.
8 Replace the charge corona terminal assembly.

No: Continue.
9 Replace the high voltage unit.

10 Replace the printhead assembly.

No: Reinstall the original printhead assembly and continue.

11 Replace the IGS board.

No: Replace the charge corona lead wiring, then turn to TAG 002: Check & Problem Resolu-
tion.

TAG 806: Prints with Dark Spots or Scratches

Error Code: 806
Possible Causes: Paper path contamination
Paper supply defects
Toner
Charge corona
Fuser unit
Developer unit
Cleaner unit

nance”.
No: Continue.

Resolution.
Yes: Continue.
3 Have the photoconductor unit, charge corona, fuser unit, cleaner unit, and devel-
oper unit with new toner cartridge been replaced recently?
No: Continue.


No: Reinstall the original cleaner unit and continue.



Yes: Turn to TAG 002: Check & Problem Resolution. If this problem recurs, the toner/carrier
8 Inspect the paper being used for scratches or dark spots.

Does the paper have any problems?
No: Continue.
Yes: Replace the paper. Turn to TAG 002: Check & Problem Resolution.

• Main drive motor gear
• Developer coupling on the developer unit and the printer
Are these mechanisms in good working order?
Yes: Verify that the photoconductor, charge corona, developer, and fuser units are new. If these
items are new, defective or contaminated toner may be the cause of the problem. Replace
the developer and cleaner units with units from the printer’s manufacturer, then turn to

TAG 807: Misregistered/Skewed Prints (Simplex)

If this problem occurs in the duplex printing mode only, go to TAG 901: Misregistration/
Error Code: 807
Lower cassette
Upper pick-up roller assembly
Upper pinch rollers
Lower pick-up roller assembly
Lower pinch rollers
Paper feed idler assembly
PCL board
If the test pattern has a 20 line indicator at the top of the page, registration is correct when
the line of the indicator is at the leading edge of the print (+ or-2).
If the problem varies from print to print, a mechanical binding malfunction may be at
fault.
1 Inspect both paper cassettes for damage.

• Make sure the paper in the cassettes is loaded properly.
• Make sure the side and rear paper guides are positioned properly.
• Inspect both paper paths for contamination and remove any obstructions.
• Remove and insert the cassette causing the problem. Confirm that the code, which displays on
the operator’s panel, corresponds to the paper size in the cassette. (The codes and the paper sizes
to which they correspond are listed in the Guide to Operations. Refer to TAG 702: Paper Size
Detection Malfunction.
Is the problem with the upper cassette?
Yes: Continue.


Is the problem also with the lower cassette?
Yes: Continue.

• Inspect the following for damage or contamination:
• Paper feed idler assembly
Are these parts clean and in good working order?
No: Repair or replace the parts as needed, then turn to TAG 002: Check & Problem Resolu-
tion.
4 Inspect the following for damage and contamination:

• Upper pick-up roller assembly
• Upper feed roller assembly
• Upper pinch rollers
• Upper cassette
tion.
Yes: You have not isolated the problem. Return to the beginning of this TAG.

Is the problem with the lower cassette?
No: Incorrectly loaded paper was at fault. Turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

6 Inspect the following for damage or contamination:

• Lower pick-up roller assembly
• Lower feed roller assembly
• Lower pinch rollers
• Lower cassette.
tion.
7 Is misregistration the symptom of the problem?

No: Skew problems can only result from mechanical causes. Return to the beginning of this
TAG.
Yes: Continue.
8 Run test prints.

Is the amount of misregistration within + or - 2 lines of the 20-line indicator from the
leading edge of the test print?
No: Continue.
Yes: The registration is within specification. Turn to TAG 002: Check & Problem Resolution.
9 Open the printer’s rear cover and insert an interlock by-pass tool.
• Set the four registration switches on the PCL board to off.
• Based on the test prints, increase the registration by changing the switches. Refer to the follow-
ing chart.
Did resetting the switches resolve the problem?
No: Replace the paper timing roller assembly, then turn to TAG 002: Check & Problem Reso-
lution. If this does not resolve the problem, replace the upper paper guide assembly or the
paper timing guide, then turn to TAG 002: Check & Problem Resolution.
Table 3-5. PCL Board Switch Settings
Setting DIP Switches

Number 1 2 3 4
0 OFF OFF OFF OFF
1 OFF OFF OFF ON
2 OFF OFF ON OFF
3 OFF OFF ON ON
4 OFF ON OFF OFF
5 OFF ON OFF ON
6 OFF ON ON OFF

Table 3-5. PCL Board Switch Settings
Setting DIP Switches

Number 1 2 3 4
7 OFF ON ON ON
8 ON OFF OFF OFF
9 ON OFF OFF ON
10 ON OFF ON OFF
11 ON OFF ON ON
12 ON ON OFF OFF
13 ON ON OFF ON
14 ON ON ON OFF
15 ON ON ON ON

TAG 808: Prints Overtoned/Dark Vertical Streaks

Error Code: 808
Possible Causes: Clogged cleaner
Contaminated toner/carrier mix
Possible Defects: Cleaner unit
Photoconductor unit
Charge corona
High voltage unit
PCL board
Developer unit
Overtoned print and dark print problems are very similar. If this TAG does not resolve the
problem, go to TAG 811: Background/Residual Images/Dark Prints.

nance”.
No: Continue.
Resolution.
2 Check the voltages, as outlined in Chapter 9, “General Printer Maintenance”

Resolution.
Yes: Continue.
3 Have the photoconductor unit, charge corona, cleaner unit, and developer unit with
toner cartridge been replaced recently?
No: Continue.

Yes: Run at least 200 test prints to detone the printer’s engine, then turn to TAG 002: Check &
Problem Resolution.


6 Replace the developer unit with toner cartridge.


• Open the front cover and install an interlock by-pass tool.
• Watch the toner motor coupling at the rear of the developer cavity.
Does the coupling turn continuously?
Yes: Continue.
8 Check TP3-31 for 0 Vdc.

tion.
Yes: Continue.

Yes: Replace the power control #2 board. If this resolves the problem, turn to TAG 002: Check
& Problem Resolution. If this doesn’t resolve the problem, replace the PCL board, then

10 Reinstall the developer unit.

• Check TP3-31 for a voltage change from +12 Vdc to 0Vdc while running test prints.
Does the voltage change from +12 Vdc to 0Vdc every other print cycle?
Yes: Continue.

P4 P41-44 to P25-2,
P41-47 to P25-3, and
P41-50 to P25-1.
Is there continuity at each?
P41-44 to P25-2,
P41-47 to P25-3, or
P41-50 to P25-1;
Yes: Continue.
12 Verify that the connector is securely plugged into the toner patch sensor circuit board, which is
mounted on the developer unit.
Is it connected properly?
No: Reconnect the connector, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
13 Clean the printhead lens and toner patch sensor.

• Run test prints while checking TP3-31 for a voltage change.
Does the voltage still change from +12 Vdc to 0 Vdc every other print cycle?
Yes: Replace the developer unit and cleaner unit, then turn to TAG 002: Check & Problem
Resolution.

No: Continue.

15 Reconnect J/P24.
Yes: Continue.

Yes: Continue.

Yes: Continue.

• Using a high voltage probe, check J/P25-7 for the proper voltage, as outlined in Chapter 9,
“General Printer Maintenance”.
19 Reconnect J/P85.
• Replace the high voltage unit.

20 Repair or replace the PCL board.

No: Reinstall the original PCL board. Confirm that the photoconductor, charge corona, devel-
oper unit, and fuser units are new. If these items are new, the toner/carrier mix may be old
or contaminated. Replace the developer and cleaner units with units from the printer’s
manufacturer. If this resolves the problem, turn to TAG 002: Check & Problem Resolu-
tion. Otherwise, turn to TAG 811: Background/Residual Images/Dark Prints.

TAG 809: Blurred or Smeared Vertical Streaks on Prints

Error Code: 809
Charge corona
Cleaner unit
Fuser unit
Fuser unit drive gear
Fuser drive idler and spring
Fuser drive belt
Main drive assembly
Printhead assembly

nance”.
No: Continue.
Resolution.

Resolution.
Yes: Continue.
3 Have the photoconductor, charge corona, cleaner, or fuser units been replaced
recently?
No: Continue.

No: Reinstall the original photoconductor and charge corona and continue.




• Vacuum transport unit
• Vacuum transport assembly ozone filter
• Fuser unit drive gear on the fuser unit and fuser unit cavity
• Main drive assembly
• Cleaner unit drive belt
• Cleaner drive idler assembly
• Cleaner drive assembly
tion.
Yes: Continue.
8 Open the printer’s top cover and install an interlock by-pass tool.
• Wait until the motor turns on, then proceed.
• Verify the vacuum transport fan is running by placing a sheet of paper over the holes in the
transport unit.
Does the vacuum fan hold the paper?
Yes: Continue.
9 Inspect the vacuum transport belts and gear for damage or binding.
Is the vacuum transport unit in good working order?
No: Repair or replace the vacuum transport unit, then turn to TAG 002: Check & Problem
Resolution.

10 Run test prints. Use extreme caution:

• Check J/P22-1 to J/P22-2 for 100 Vac.
No: Continue.
Yes: Replace the vacuum transport unit, then turn to TAG 002: Check & Problem Resolution.
11 Run test prints. Use extreme caution:

tion.
Yes: Repair or replace the connectors or wiring from J22-1 to P13-6 or J22-2 to P13-3, then
12 Inspect the fuser drive assembly and the fuser drive belt for damage or a slipping belt.
No: Replace the parts that are defective, then turn to TAG 002: Check & Problem Resolution.
Yes: Replace the printhead assembly, then turn to TAG 002: Check & Problem Resolution.

TAG 810: Uneven Density or Dark Areas on Prints

Error Code: 810
Charge corona
Developer unit
Cleaner unit
1 Perform the every-call cleaning procedure, described in Chapter 9, “General Printer Maintenance”.
No: Continue.

Resolution.
Yes: Continue.
3 Have the photoconductor unit, charge corona, cleaner unit and developer unit with
new toner cartridge been replaced recently?
No: Continue.
Yes: Go to TAG 811: Background/Residual Images/Dark Prints.




No: Reinstall the original developer unit and toner cartridge, then turn to TAG 811: Back-
ground/Residual Images/Dark Prints.

TAG 811: Background/Residual Images/Dark Prints

Error Code: 811
Charge corona
Cleaner unit
Developer unit
Erase lamp assembly
High voltage unit
PCL board
Cleaner terminal assembly

• Verify J/P23, J/P24, J/P85, and the charge corona high voltage lead are connected properly.
nance”.
• Clean the printhead lens and toner patch sensor located on the developer unit.
No: Continue.
Yes: Contamination or a loose connector was at fault. Turn to TAG 002: Check & Problem
Resolution.

Resolution.
Yes: Continue.
3 Have the photoconductor unit, charge corona, cleaner unit and developer unit with
new toner cartridge been replaced recently?
No: Continue.

• Run 200+ test prints, then evaluate the test print background.

5 Replace the developer unit and cleaner unit.

No: Reinstall the original developer unit and cleaner unit and continue.
6 Remove the photoconductor unit from the printer.

• Watch the erase lamp while the test is running.
Are all the erase lamps on?
No: Replace the erase lamp assembly, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

• Watch the toner motor coupling in the developer cavity.
Does the coupling turn continuously before error code 036 is displayed?
No: Continue.

• Check TP3-31 for voltage change from +12 Vdc to 0 Vdc while running test prints.
Does the voltage change from +12 Vdc to 0 Vdc every other print cycle?
Yes: Continue.

• Check for continuity: P41-44 to J25-2, P41-47 to J25-3, and P41-50 to J25-1.
No: Repair or replace the connectors or wiring: P41-44 to J24-2, P41-47 to J25-3, or P41-50
to J25-1; then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

10 Verify that the toner patch sensor board connector, mounted on the developer unit, is connected
properly.
Is it connected properly?
No: A loose connection was at fault. Turn to TAG 002: Check & Problem Resolution.

Yes: Continue.
12 Reconnect J/P24.
No: Continue.
13 Reconnect J/P23.
• Disconnect J/P85 from the high voltage unit.
Yes: Continue.

Yes: Continue.


• Check TP4-40 for 0.5 Vdc while running the prints.
Is the voltage 0.5 Vdc?
Yes: Continue.

Yes: Continue.
17 Using a high voltage probe, check J/P25-7 for the proper voltage, as described in Chapter 9, “Gen-
eral Printer Maintenance”.
Yes: Continue.
18 Check the charge corona, transfer corona, grid, and cleaning bias described in Chapter 9, “General
Printer Maintenance”.
Are any of the values out of specification?

20 Replace the PCL board.

No: Reinstall original PCL board. Go back to #3 in this TAG. If this does not resolve the prob-
lem, the IGS board, cleaner terminal assembly, or charge corona terminal assembly may
be at fault. Determine which of these is at fault, correct the problem, then turn to TAG
21 Check J/P40-31 for 0 Vdc.

tion.
Yes: Continue.


Yes: Continue.
tion.

TAG 812: Uneven or No Fusing on Prints

Error Code: 812
PCL board

• Verify that J/P44, J/P4, J/P10, J/P11, J/P12, J/P40, J/P83, J/P91, and J/P8 are connected prop-
erly.
nance”.
No: Continue.
Resolution.
2 Check the voltages, as outlined in Chapter 9, “General Printer Maintenance”

Resolution.
Yes: Continue.
3 Have the fuser unit and developer unit with new toner cartridge been replaced
recently?
No: Continue.




Does the lamp light within 1.5 minutes?
No: Go to TAG 070: Fuser Unit Malfunction.
Yes: Continue.
7 Run test prints.

Does the print seem to be excessively dark or do the characters feel raised on the
paper?
No: Continue.
Yes: Go to TAG 808: Prints Overtoned/Dark Vertical Streaks.
8 Confirm that the paper in the cassettes meets paper specifications, outlined in the Guide to Opera-
tions manual.
Is the paper within specification?
No: Do not use this paper. Turn to TAG 002: Check & Problem Resolution.
Yes: Continue.

No: Repair or replace the connectors or wiring from P41-22 to P83-1, or J83-1 to P5-6, then
Yes: Continue.

No: Repair or replace the connectors or wiring from P41-21 to P83-2, or J83-2 to P5-7, then
Yes: Continue.

Is the resistance between I KΩ and 400 KΩ?
No: Replace the fuser unit. If this resolves the problem, turn to TAG 002: Check & Problem
Resolution. If this does not resolve the problem, replace the PCL board, then turn to TAG

TAG 813: Residual Images on Prints

Error Code: 813
Possible Defects: Cleaner unit drive belt
Cleaner unit
High voltage unit
Photoconductor unit
Erase lamp assembly
Developer unit

nance”.
No: Continue.
2 Open the printer’s back cover.

• Remove the paper feed drive cover.
• Check the cleaner unit drive belt.
Is the belt attached?
No: Repair or replace the cleaner unit drive belt, then turn to TAG 002: Check & Problem
Resolution.
Yes: Continue.

Resolution.
Yes: Continue.
4 Have the cleaner unit, developer unit with new toner cartridge, and photoconductor
unit been replaced recently?
No: Continue.




Yes: Turn to TAG 002: Check & Problem Resolution. If the problem recurs, the toner may be
old or contaminated.

Yes: Continue.

Yes: Continue.
10 Check the charge corona, transfer corona, grid, and cleaning bias described in Chapter 9, “General
Printer Maintenance”.
Are any of the values out of specification?

12 Repair or replace the cleaner terminal assembly.

No: Reinstall the original cleaner terminal assembly, then go back to #5 in this TAG.

TAG 815: Prints Resulting From Printhead Malfunctions

Error Code: 815
Possible Causes: Additional lines or missing lines on page.
Possible Defects: Printhead assembly
IGS board

• Replace wire harness 46.
No: Continue.

• Replace the printhead assembly.

TAG 900: Top Cover Interlock Malfunction, Duplex

Error Code: 900
Possible Defects: Cover open sensor
PCL board
Complete TAG 600: AC Power Malfunction before starting this TAG.

• Confirm that the top and front covers are closing completely.
No: Loose connectors or obstructions were at fault. Turn to TAG 002: Check & Problem Res-
olution.
Yes: Continue.
2 Open the printer’s top cover and insert the interlock by-pass tool.
• Check J/P309-3 on duplex control board #1 for +12 Vdc.
tion.
Yes: Continue.
3 Check J/P309-1 on duplex control board #1 for +12 Vdc.

No: Continue.

P309-1 to P318-2,
P309-3 to P318-1, and
P309-5 to P318-3.
No: Repair or replace the wiring or connectors from:
P309-1 to P318-2,
P309-3 to P318-1, or
P309-5 to P318-3;
Yes: Replace the cover open sensor, then turn to TAG 002: Check & Problem Resolution.


• Check J/P36-1 on the PCL board for +12 Vdc.
tion.

TAG 901: Misregistration/Skewed Prints (Duplex)

Error Code: 901
Possible Defects: Duplex holding tray sensors
Duplex holding tray motor
Duplex drive/clutch
Pinch rollers A and B
Route separator
PCL board
Registration is correct when the top (+ or -2) of the 20-line indicator, found on the top of a
test print, is at the leading edge of the print.
If the problem varies from print to print, suspect a mechanical binding problem. if prob-
lems exist in the simplex mode, go to TAG 807: Misregistered/Skewed Prints (Simplex).
1 Verify that the upper and lower paper cassettes are not damaged.
Operations manual.
• Make sure the paper in both paper cassettes is loaded properly.
• Check both paper paths for obstructions or contamination.
No: Continue.

• Duplex drive/clutch assembly
• Timing belts
• Pinch roller springs
• Route separator and springs
No: Repair or replace any damaged parts as needed, then turn to TAG 002: Check & Problem
Resolution.
Yes: Continue.

3 Verify that J/P305, J/P310, J/P311, J/P312, J/P320, J/P321, and J/P322 are connected properly to
duplex control board #2.
• Verify that J/P306, J/P307, J/P308, J/P309, and J/P324 are connected properly to duplex control
board #1.
• Verify that J/P315 and J/P316 are connected properly to the “A” and “C” roller clutches.
• Run test prints in duplex.
Did the test indicate an error code?
No: Registration or skew problems can only result from mechanical causes. Return to the
beginning of this TAG.
Yes: Continue.
4 Did the side guides in the duplex tray move in and out while the test was running?
Yes: Continue.

Yes: Continue.
6 Manually move the side guides in the duplex tray to the inside positions.
• Check J/P312-2 on duplex control board #2 for 0 Vdc.
No: Continue.
Yes: Replace duplex control board #2, then turn to TAG 002: Check & Problem Resolution.

P312-1 to P320-1,
P312-2 to P320-2, and
P312-3 to P320-3.
P312-1 to P320-1,
P312-2 to P320-2, or
P312-3 to P320-3;
Yes: Replace the side sensor. If this resolves the problem, turn to TAG 002: Check & Problem
Resolution. If this does not resolve the problem, replace duplex control board #2, then


Did diagnostic test 017 indicate a duplex tray paper sensor problem?
No: Continue.

No: Repair or replace the wiring or connectors from P312-7 to J321-1, then turn to TAG 002:
Yes: Continue.

Yes: Continue.

Yes: Continue.

No: Repair or replace the wiring or connectors from P312-10 to J321-4, then turn to TAG
Yes: Replace duplex control board #2. If this resolves the problem, turn to TAG 002: Check &
Problem Resolution. If this does not resolve the problem, replace the registration motor,

Yes: Continue.

14 Manually activate the duplex tray paper sensor.

• Check J/P312-5 for 0 Vdc.
No: Replace the duplex tray paper sensor. If this resolves the problem, turn to TAG 002:
Check & Problem Resolution. If this doesn’t resolve the problem, repair or replace the
wiring or connectors from:
P312-4 to J322-1,
P312-5 to J322-2, or
P312-6 to J322-3;
Yes: Continue.

• Check J/P36-6 on the PCL board for 0 Vdc.
No: Replace duplex control board #2. If this resolves the problem, turn to TAG 002: Check &
Problem Resolution. If this doesn’t resolve the problem, repair or replace the wiring or
connectors from P311-7 to J/P305-11 to P36-4, then turn to TAG 002: Check & Problem
Resolution.

TAG 902: Paper Jam in Duplex Area

Error Code: 027, 060, 061, 062
Paper path not clear
Possible Defects: Duplex drive/clutch
“A” roller clutch
Duplex input solenoid
“C” roller clutch
Duplex feed motor

• Verify that J/P306, J/P307, J/P308, J/P309, J/P313, J/P314, J/P315, J/P316, J/P317, and J/P319
• Check the following components for damage:
• Duplex drive/clutch
• Timing belts
• Route separator
No: Continue.

Is the duplex paper path sensor in good working order?
No: Continue.

• Check J309-4 on duplex control board #1 for +12 Vdc.
Yes: Continue.

Yes: Continue.


• Check J319-1 for +12 Vdc.
Yes: Continue.
6 Check J319-2 for +12 Vdc.

Yes: Replace the paper pass sensor, then turn to TAG 002: Check & Problem Resolution.

Is the “A” roller clutch in good working order?
No: Continue.

• Check J308-3 on the duplex control board #1 for +24 Vdc.
Yes: Continue.

• Check P316-1 for +24 Vdc.
Yes: Replace the “A” roller clutch, then turn to TAG 002: Check & Problem Resolution.


Is the input solenoid in good working order?
No: Continue.

• Check J308-1 and J308-5 for +24 Vdc.
Yes: Continue.
P308-1 to J314-1
P308-5 to J314-2
P308-1 to J314-1 or
P308-5 to J314-2;
Yes: Replace the input solenoid, then turn to TAG 002: Check & Problem Resolution.

Is the C roller solenoid in good working order?
No: Continue.

Yes: Continue.
P308-2 to P315-1, and

P308-6 to P315-2.
P308-2 to P315-1, or
P308-6 to P315-2,
Yes: Replace the “C” roller solenoid, then turn to TAG 002: Check & Problem Resolution.

Is the feed motor in good working order?
No: Continue.

Yes: Continue.

No: Continue.
Yes: Replace duplex control board #1, then turn to TAG 002: Check & Problem Resolution.
P309-7 to J313-1,
P309-8 to J313-2,
P309-9 to J313-3, and
P309-10 to J313-4.
No: Repair or replace the wiring or connectors from P309 to J313 that have no continuity,
Yes: Continue.
20 Check the following for continuity:

• P313-1 to P313-2
• P313-3 to P313-4
No: Replace the route motor, then turn to TAG 002: Check & Problem Resolution.
tion.


• Check J/P306-3 to J/P306-4 for +5 Vdc.
No: Repair or replace the wiring or connectors from P306-3 to J/P331-3 to P330-3, then turn
Yes: Continue.
22 Check J/P306-2 to J/P306-4 for +12 Vdc.

Yes: Continue.



Chapter 4
Print Quality
Samples
June 1999 Print Quality Samples 4-1

Chapter Contents

Sample 1: Good Quality Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Sample 2: Washout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Sample 3: Blank Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Sample 4: Light Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Sample 5: Light Print With Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Sample 6: Voids or White Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Sample 7: Light Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Sample 8: Blank Vertical Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Sample 9: Light Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Sample 10: Black or Dark Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Sample 11: Dark Specks, Lines, or Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Sample 12: Dark Vertical Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Sample 14: Misregistration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Sample 15: Overtoned Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Sample 16: Blurred Images or Characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
Sample 17: Varying Print Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
Sample 18: Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
Sample 19: Residual Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
Sample 20: Wrinkles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
Sample 21: Fusing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
4-2 Print Quality Samples June 1999


This section contains flawed test prints, along with a good test print for comparison. Com-
pare print samples from your customer’s print job or from test prints you’ve run with the
samples in this section. If you find a match, note the TAG (i.e., troubleshooting procedure)
listed under the sample. Turn to that TAG to begin troubleshooting. All of the TAGs are
outlined in Chapter 3, “Troubleshooting Analysis Guide (TAGs)”
If your customer’s prints show more than one problem, resolve them one at a time, in the
order in which they are listed in this section.

Sample 1: Good Quality Print
Figure 4-1. Good Quality Print

Description: Good, properly registered print.

Sample 2: Washout
Sample 2: Washout
Figure 4-2. Washout

Description: Void areas, light spots, or blurs. This is a composite of possible symptoms.
Go to TAG 801: Prints Light or Light With Carrier Particles, TAG 802: Prints With Voids
or White Spots, TAG 809: Blurred or Smeared Vertical Streaks on Prints, or TAG 810:
Uneven Density or Dark Areas on Prints.

Sample 3: Blank Print
Figure 4-3. Blank Print

Description: No images or characters. The paper is not discolored.
Go to TAG 800: Prints Blank or With Dark Horizontal Bands, TAG 815: Prints Resulting
From Printhead Malfunctions.

Sample 4: Light Print
Figure 4-4. Light Print

Description: Images or characters are lighter than normal. Examine the letters H, T, M,
and E; if the vertical strokes are dark enough but the diagonal strokes are stair-stepped, the
problem is related to the printhead. Carrier particles may make the print feel gritty.
Go to TAG 801: Prints Light or Light With Carrier Particles.

Sample 5: Light Print With Background
Figure 4-5. Light Print With Background

Description: Images or characters lighter than normal, ranging from a few dark specks to a
large speckled background.
Go to TAG 811: Background/Residual Images/Dark Prints.

Sample 6: Voids or White Spots
Figure 4-6. Voids of White Spots

Description: Voids or white spots in image areas.
Go to TAG 802: Prints With Voids or White Spots.

Sample 7: Light Vertical Streaks
Figure 4-7. Light Vertical Streaks

Description: One or more light vertical streaked areas of varying widths.
Go to TAG 803: Prints With Light or White Vertical Streaks.

Sample 8: Blank Vertical Bands
Figure 4-8. Blank Vertical Bands

Description: One or more vertical blank bands of varying widths extend over the entire
length.
Go to TAG 803: Prints With Light or White Vertical Streaks.

Sample 9: Light Horizontal Bands
Figure 4-9. Light Horizontal Bands

Description: One or more light horizontal bands of varying width.
Go to TAG 804: Prints With Light Horizontal Bands.

Sample 10: Black or Dark Print
Figure 4-10. Black or Dark Print

Description: Black or very dark with no visible images.
Go to TAG 805: Black Prints, TAG 811: Background/Residual Images/Dark Prints.

Sample 11: Dark Specks, Lines, or Areas
Figure 4-11. Dark Specks, Lines, or Areas

Description: Dark specks or lines (like scratches), some in the same place on each print.
Go to TAG 806: Prints with Dark Spots or Scratches, TAG 810: Uneven Density or Dark
Areas on Prints.

Sample 12: Dark Vertical Lines
Figure 4-12. Dark Vertical Lines

Description: One or more dark lines of varying density. If the image can be rubbed off, go
to TAG 812: Uneven or No Fusing on Prints. If the image cannot be rubbed off, go to
TAG 808: Prints Overtoned/Dark Vertical Streaks.
Go to TAG 812: Uneven or No Fusing on Prints, TAG 808: Prints Overtoned/Dark Verti-
cal Streaks.

Sample 13: Skewed Prints
Figure 4-13. Skewed prints

Description: The entire image is not located squarely on the paper.
Go to TAG 807: Misregistered/Skewed Prints (Simplex) or TAG 901: Misregistration/

Sample 14: Misregistration
Figure 4-14. Misregistration

Description: The entire image is not correctly located from the leading edge of the paper.
The top or bottom image area may be missing.
Go to TAG 807: Misregistered/Skewed Prints (Simplex) or TAG 901: Misregistration/

Sample 15: Overtoned Print
Figure 4-15. Overtoned Print

Description: Similar to dark print quality problems. Narrow gaps between letters and
images may be filled with toner. Excess toner may be present on the surface of the print.
Extra toner can also cause background in the white areas.
Go to TAG 809: Blurred or Smeared Vertical Streaks on Prints.

Sample 16: Blurred Images or Characters
Figure 4-16. Blurred Images or Characters

Description: The images or characters are not clear. The lower edges of images and/or
characters are extended and may appear smeared.
Go to TAG 809: Blurred or Smeared Vertical Streaks on Prints.

Sample 17: Varying Print Density
Figure 4-17. Varying Print Density

Description: Some areas of the print are lighter or darker than normal. Examine the letters
H, T, M, and E on your test print. If the vertical sections are sufficiently dark, but the diag-
onal sections appear stair-stepped, the problem may be is related to the printhead.
Go to TAG 810: Uneven Density or Dark Areas on Prints, TAG 815: Prints Resulting
From Printhead Malfunctions.

Sample 18: Background
Figure 4-18. Background

Description: White areas on the prints have varying degrees of specks appearing in a spe-
cific pattern.
Go to TAG 811: Background/Residual Images/Dark Prints.

Sample 19: Residual Images
Figure 4-19. Residual Images

Description: Images from a previous print are visible. White areas on the print may have
varying degrees of specks appearing in a specific pattern.
Go to TAG 811: Background/Residual Images/Dark Prints, TAG 813: Residual Images on
Prints.

Sample 20: Wrinkles
Sample 20: Wrinkles
Figure 4-20. Wrinkles

Description: Wrinkles or creases, often at the top or bottom.
Go to TAG 706: Paper Damaged or Wrinkled.

Sample 21: Fusing Problems
Figure 4-21. Fusing Problems

Description: Images or characters may rub off the surface.
Go to TAG 812: Uneven or No Fusing on Prints.

Chapter 5
Diagnostic
Tests
June 1999 Diagnostic Tests 5-1

Chapter Contents
Diagnostic Tests
How to Run Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
001 Operator Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
002 Upper Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
003 Lower Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
005 Sensor Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
006 Paper Transport Clutch Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
007 Counter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
008 Jogging Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
009 Photoconductor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
010 Toner Supply Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
011 Charge Corona Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
012 Transfer Corona Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
013 Erase Lamp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
015 Negative Developer Bias Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
016 Duplex Feed Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
017 Duplex Input Sensor Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
018 Duplex Clutch Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
019 Duplex Tray Paper-Guide Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
020 High-Capacity Output Unit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
021 High-Capacity Input Unit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
022 Envelope Fuser Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
101 EIGS/MIGS Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
102 EIGS/MIGS Board Test (Continuous Loop) . . . . . . . . . . . . . . . . . . . . . . . . .5-20
103 Communication Loop-back Test (Single Loop) . . . . . . . . . . . . . . . . . . . . . . . 5-21
104 Communication Loop-back Test (Continuous Loop) . . . . . . . . . . . . . . . . . . . 5-22
105 EIGS Program RAM Test (Continuous Loop) . . . . . . . . . . . . . . . . . . . . . . . .5-22
107 EIGS/MIGS Bit Map Test (Single Loop) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
108 EIGS/MIGS Bit Map Test (Continuous Loop) . . . . . . . . . . . . . . . . . . . . . . .5-23
110 Format Disk/Clear Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
111 LED Printhead Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
112 Disk Drive Test (Single Loop With Stop on Error) . . . . . . . . . . . . . . . . . . . . 5-25
113 Disk Drive Test (Continuous Loop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
5-2 Diagnostic Tests June 1999

Diagnostic Tests
Diagnostic Tests
This section provides step-by-step instructions for running each of the diagnostic tests
available through the self-diagnostic mode of the printer. Each test is referenced by num-
ber. Check the contents page to find the page on which a specific test is described.
How to Run Diagnostics

Follow these steps to access the self-diagnostic mode of the printer:
1 Turn off the printer and wait five seconds.
2 Hold down the STOP and TEST keys simultaneously as you turn the printer back on.
Continue to hold the keys down until O appears on the display. The STANDBY light
flashes as the printer accesses its soft diagnostic mode, which takes approximately 1
minute. The tone, followed by 001 on the display, indicates you can now run a test.
3 Change the counter to the number of the test you wish to run by pressing CANCEL to
increase the counter or # TEST to decrease the counter. If you press these keys before
a test is complete, a long tone sounds and the test continues without interruption.
4 Press READY to run the test.
5 Press STOP to end the test (in most cases; see specific diagnostic procedures for direc-
tions on exiting a test).
6 To exit diagnostic mode, cycle printer power.
Most errors or conditions reported are valid for about 90 seconds, which is the timeout
period set for most of the diagnostic tests described in this section.
Note
Only diagnostics useful for field maintenance are documented
in this manual.

001 Operator Panel Test
001 Operator Panel Test

1 Turn the volume control on the operator panel up fully.
2 Go to: 001
3 Press: READY to run the test.
4 Confirm that the tone sounds and all lights turn on and off continuously.
5 Press: STOP to exit.
002 Upper Cassette Test

1 Make sure the upper paper cassette is installed with paper, the side and rear guides
securely against the edges of the paper in the cassette.
2 Go to: 002
4 Refer to the chart below to confirm that the code that displays corresponds to the
paper size in the cassette. (For example, if the cassette holds letter size paper, “1-3”
should appear on the display.) This indicates the paper size sensor is working properly.
The following codes indicate paper sizes:
Table 5-1. Paper Size Codes
Display Indication
1-0 Cassette not installed
1-1 A4-size paper in use
1-2 B5-size paper in use
1-3 Letter-size paper in use
1-4 Legal-size paper in use
1-5 Executive 1 size paper in use
1-8 Envelopes in use
1-9 Undefined paper size

003 Lower Cassette Test
003 Lower Cassette Test

1 Make sure the lower paper cassette is installed with paper, the side and rear guides
2 Go to: 003
4 Refer to the chart below to confirm that the code that displays corresponds to the
paper size in the cassette. (For example, if the cassette holds letter size paper, “1-3”
should appear on the display.) This indicates the paper size sensor is working properly.
Table 5-1, “Paper Size Codes”, lists the paper size codes.
Note
A 1-9 is displayed when a high-capacity paper feed unit is
installed; refer to “021 - High Capacity Unit Input Test”
(004 intentionally excluded)

005 Sensor Test Sequence
005 Sensor Test Sequence

1 Go to: 005
2 Press: READY to run the test. The code for the first sensor (i.e., “0-0” or “0-1”)
appears on the display, confirming that the sensor is working properly.
Note
No paper moves through the machine, so indications of
“No paper at sensor location” are normal.
3 Press: READY to advance to the next sensor. The display changes, showing the code
for the next sensor as outlined in Table 5-2, “Sensor Test Displays”, below.
Table 5-2. Sensor Test Displays
Sensor Description Display

Upper paper cassette 0-0: Cassette full
0-1: Cassette empty
Lower paper cassette 1-0: Cassette full
1-1: Cassette empty
Paper timing sensor 2-0: No paper at sensor location
2-1: Paper at sensor
Paper exit sensor 3-0: No paper at sensor location
Paper full sensor 4-0: Tray empty
4-1: Tray full
Jogging sensor, front 5-0: Tray in front position
5-1: Error – tray in rear position
Jogging sensor, rear 6-0: Tray in rear position
6-1: Error – tray in front position
PC seam sensor 7-0: Active
7-1: Not active
Developer interlock 8-0: Developer unit in place
8-1: Developer unit not in place
4 To check a specific sensor, press READY repeatedly until the code on the display cor-
responds to the sensor you want to check. Manually activate the sensor. Confirm that
the display changes when you activate the sensor. Refer to “Sensor and Switch Loca-
tions” on page 1-11 for sensor locations.

006 Paper Transport Clutch Test Sequence
006 Paper Transport Clutch Test Sequence

1 Go to: 006
2 Press: READY to run the test. The first clutch engages, signaled by a continuous
clicking sound. “3-0” appears on the display, corresponding to the upper pick-up roller
clutch.
3 Press: READY to test the next clutch. Listen for the clicking sound as the next clutch
engages. The number on the display changes to indicate the next clutch. The display
codes and the clutch they represent are listed in Table 5-3, “Clutch Test Displays”.
Table 5-3. Clutch Test Displays
Display Indication
3-0 Upper pick-up roller clutch
3-1 Lower pick-up roller clutch
3-2 Upper feed roller clutch
3-3 Lower feed roller clutch
3-3 Paper timing roller clutch
4 Repeat Step 3 until you have tested all of the clutches.

007 Counter Test

1 Open the front cover.
2 Go to: 007
• Confirm that the page counter advances by 1.
• The test then exits automatically.

008 Jogging Motor Test
008 Jogging Motor Test

1 Go to: 008
2 Press: READY to run the test. The output tray jogs back and forth.
3 Confirm that a tone sounds each time the tray contacts the sensor at each side.
The codes in the following table indicate specific error conditions:
Table 5-4. Jogging Motor Test Error Displays
Display Indication
081 Front tray sensor signal not received
082 Rear tray sensor signal not received
083 No signal received from either sensor
090 Close covers
009 Photoconductor Test

1 Go to: 009
2 Press: READY to run the test. The main motor rotates the photoconductor belt.
3 Confirm that a tone sounds repeatedly, indicating that the photoconductor belt is rotating.
These codes may indicate specific error conditions:
Table 5-5. Photoconductor Error Test Displays
Display Indication
030 Developer bias short detected
040 Photoconductor seam sensor not
received or detected or the developer
unit is not installed
041 Seam sensor (sender) short
042 Seam sensor (sender) open or the
photoconductor is not installed
055 Erase lamp malfunction
4 Press: STOP to exit

010 Toner Supply Motor Test
010 Toner Supply Motor Test

1 Open the front and top covers.
2 Remove the photoconductor unit and the developer unit. Place the photoconductor
unit in its protective packaging.
3 Insert the interlock by-pass tool in the front cover. Close the top cover.
4 Go to: 010
5 Press: READY to run the test. The toner supply motor runs continuously.
6 Observe the toner supply motor through the open developer unit cavity. Confirm that
the motor is turning counterclockwise, accompanied by a “1” on the display.
7 Press STOP and READY alternately several times to verify the toner supply motor
starts and stops. (This stops and restarts the test.)
Table 5-6. Toner Supply Motor Test Error Displays
Display Indication
4-0 You forgot to remove the developer unit
090 You forgot to insert the interlock by-pass tool

9 Reinstall the developer unit and photoconductor unit.
10 Remove the interlock by-pass tool and close the front cover.

011 Charge Corona Test
011 Charge Corona Test

1 Remove the photoconductor unit and place it in its protective packaging. Close the top
cover.
2 Go to: 011
3 Press: READY to run the test. The charge corona turns on and off repeatedly.
4 Confirm that the display alternates between “0” and “1,” accompanied each time by a
brief tone. The display indicates the following:
Table 5-7. Charge Corona Test Displays
Display Indication
0 Charge corona off
1 Charge corona on
Table 5-8. Charge Corona Test Error Displays
Display Indication
041 Photoconductor seam sensor short
045 Charge corona short
046 Charge corona open
4-1 You forgot to remove the photoconductor


012 Transfer Corona Test
012 Transfer Corona Test

1 Remove the photoconductor unit and place it in its protective packaging. Close the top
cover.
2 Go to: 012
3 Press: READY to run the test. The transfer corona turns on and off repeatedly.
Table 5-9. Transfer Corona Test Displays
Display Indication
0 Transfer corona off
1 Transfer corona on
Table 5-10. Transfer Corona Test Error Displays
Display Indication
050 Transfer corona short
051 Transfer corona open or not installed
4-1 You forgot to remove the photoconductor


013 Erase Lamp Test
013 Erase Lamp Test

1 Open the top cover and insert the interlock by-pass tool.
2 Remove the photoconductor unit and place it in its protective cover.
3 Select: 013
4 READY to run the test. The erase lamp turns on with all LEDs lighted.
5 Verify that all LEDs are illuminated and a number(s) appears on the display. The num-
ber is a readout from the A/D converter and does not affect the erase lamp test.
Table 5-11. Erase Lamp Test Error Displays
Display Indication
055 Erase lamp malfunction
4-1 You forgot to remove the photoconductor unit

8 Remove the interlock by-pass tool and close the top cover.

015 Negative Developer Bias Test
015 Negative Developer Bias Test

3 Go to: 015
4 Press: READY to run the test. The negative developer bias turns on and off repeatedly.
Table 5-12. Negative Developer Bias Test Displays
Display Indication
0 Negative developer bias off
1 Negative developer bias on
Table 5-13. Negative Developer Bias Test Error Displays
Display Indication
030 Developer bias short
090 You forgot to insert the interlock by-pass tool


016 Duplex Feed Motor Test
016 Duplex Feed Motor Test

1 Go to: 016
2 Press: READY to run the test. The duplex feed motor operates at full forward speed
and “7-0” appears on the display.
3 Press: READY to advance to the next motor speed.
4 Listen for the following motor frequencies and check the code that displays as you
move through the test sequence. The codes and their meaning are outlined in the chart
below:
Table 5-14. Duplex Motor Feed Test Displays
Display Indication
7-0 Full forward speed (high frequency)
7-1 Low forward speed (low frequency)
7-2 Full reverse speed (high frequency)
7-3 Half reverse speed (low frequency)
Note: To view roller movement while running the duplex feed motor test, open the
duplex cover and bypass the cover interlock switch.
Table 5-15. Duplex Motor Feed Test Error Displays
Display Indication
069 Duplex is not installed.
090 Cover is open. Close cover

017 Duplex Input Sensor Test Sequence
017 Duplex Input Sensor Test Sequence

1 Go to: 017
Note
3 Press: READY to advance to the next sensor. The display changes, showing the code
for the next sensor as outlined in the chart below.
Table 5-16. Duplex Input Sensor Test Displays

Paper sensor 0-0: No paper
Cover sensor 1-0: Cover closed
1-1: Cover open
Duplex tray sensor 2-0: No paper
responds to the sensor you want to check, then manually activate the sensor. Confirm
that the display changes when you activate the sensor.
Table 5-17. Duplex Input Sensor Test Error Displays
Display Indication
069 Duplex tray not installed
090 Cover is open. Close cover

018 Duplex Clutch Test Sequence
018 Duplex Clutch Test Sequence

1 Go to: 018
2 Press: READY to run the test. The first flipper engages, accompanied by a continuous
clicking sound, and “7-0” appears on the display.
3 Press: READY to activate the next clutch or flipper. Listen for the clicking sound as it
engages. The number on the display changes to indicate the next clutch or flipper. The
display codes and the clutch or flipper they represent are listed in the following chart.
Table 5-18. Duplex Clutch Test Displays
Display Indication
7-0 Duplex exit flipper
7-1 Duplex roller clutch A
7-2 Duplex re-entry flipper
7-3 Duplex roller C solenoid
4 To check a specific clutch or flipper, press READY repeatedly until the code on the
display corresponds to the item you want to check. Manually activate the sensor. Con-
firm that the display changes when you activate the sensor. For the locations of the
sensors, see “Sensor and Switch Locations” on page 1-11.
Table 5-19. Duplex Clutch Test Error Displays
Display Indication
069 Duplex is not installed.
090 Cover is open. Close cover.

019 Duplex Tray Paper-Guide Motor Test
019 Duplex Tray Paper-Guide Motor Test

1 Go to: 019
3 Press: READY again. The paper guide in the duplex tray moves to and from its home
position.
4 Confirm that the paper guide in the duplex tray moves back and forth each time you
press READY.
Table 5-20. Duplex Tray Paper Guide Motor Test Displays
Display Indication
069 Duplex tray not installed
084 Duplex tray registration sensor not active
085 Duplex tray registration sensor active

020 High-Capacity Output Unit Test
020 High-Capacity Output Unit Test

1 Go to: 020
Note
3 Press: READY to advance to the next sensor. The sensor’s code appears on the dis-
play; codes and their meaning are outlined in Table 5-21, “High-Capacity Output Unit
Test Displays”, below.
Table 5-21. High-Capacity Output Unit Test Displays

Installation sensor 0-0: Unit not installed
0-1: Unit installed
Paper exit sensor 1-0: No paper at sensor location
Paper full sensor 2-0: Paper not full
2-1: Paper full
Lower limit sensor 3-0: Tray stationary or moving down
3-1: Tray moving up
responds to the sensor you want to check. Manually activate the sensor. Confirm that
the display changes when you activate the sensor.

021 High-Capacity Input Unit Test
021 High-Capacity Input Unit Test

1 Go to: 021
2 Press: READY to run the test. The display registers the paper size installed in the unit,
as outlined on the chart (“1-0” will appear on the display if a high-capacity input unit
is not installed.)
3 Verify the correct paper size, as follows:
Table 5-22. High-Capacity Input Unit Test Displays
Display Indication
1-1 A4-size paper in use
1-3 Letter-size paper in use
1-4 Legal-size paper in use
022 Envelope Fuser Solenoid Test

2 Go to: 022
3 Press: READY to run the test. The main motor turns on and “0” appears on the dis-
play.
4 Press: READY again to activate the envelope fuser solenoid.
5 Listen for a clicking sound and confirm that the display alternates between “0” and
when the solenoid is activated. If you hear no clicking, either the machine does not
have an envelope fuser installed or the solenoid is not working properly.
6 Check for the following conditions:
Table 5-23. Envelope Fuser Solenoid Test Displays
Display Indication
4-1 You forgot to remove the photoconductor unit.
(023-100 intentionally excluded)

101 EIGS/MIGS Board Test
101 EIGS/MIGS Board Test

1 Select: 101
3 If an error is found:
• The error code appears.
• Look up the code in “Error Code/TAG Cross-Reference” on page 2-3 to determine
which TAG to follow.
• Power-on-reset to exit.
4 If no errors are found:
• The test continues to run.
• After about five minutes, press STOP to exit.
102 EIGS/MIGS Board Test (Continuous Loop)

1 Go to: 102
• The error code is displayed for at least 1 second.
• Look up the code in “Error Code/TAG Cross-Reference” on page 2-3 to determine
which TAG to follow.
• If the test resumes, press STOP to exit; if the test does not resume, power-on-reset.
4 If no errors are found:
• The test continues to loop.
• Press STOP to exit.

103 Communication Loop-back Test (Single Loop)
103 Communication Loop-back Test (Single Loop)

1 Remove the interface cable from the printer.
2 Check to make sure the four DIP switches on the signal interface board have been
pulled toward the printer’s back cover. Close the back cover.
3 Install the RS-232C and RS-422 loop-back connectors, found in the tool kit mounted
inside the right printer cover.
If you do not have loop-back connectors, jumper the connections as outlined in Table
5-24, “RS-232 Loopback Connections” and Table 5-25, “RS-422 Loopback Connec-
tions”.
Table 5-24. RS-232 Loopback Connections
RS-232 Loopback Connection Reference

pin 2 pin 3
pin 4 pin 5
pin 8 pin 20
pin 17 pin 24
Table 5-25. RS-422 Loopback Connections

pin 2 pin 4
pin 9 pin 11
pin 7 pin 6
pin 14 pin 13
4 Go to: 103
6 If an error code appears, check the “Error Code/TAG Cross-Reference” on page 2-3
to determine which TAG to follow.
7 If no error is detected, the test exits automatically.
8 Press: STOP to exit, if an error is detected. (For some errors, you may have to power-
on-reset the printer.)
9 Remove the wrap connectors.
10 Reinstall the interface cable.

104 Communication Loop-back Test (Continuous Loop)
104 Communication Loop-back Test (Continuous Loop)

2 Make sure the DIP switches on the signal interface board have been pulled toward the
printer’s back cover. Close the back cover.
3 Install the RS-232C and RS-422 loop-back connectors, found in the tool kit mounted
inside the right printer cover. If you do not have loop-back connectors, jumper the
connections as outlined in Table 5-24, “RS-232 Loopback Connections,” on page 5-
21 and Table 5-25, “RS-422 Loopback Connections,” on page 5-21.
4 Go to: 104
6 If an error is detected, the error code is displayed briefly and the test continues. Note
the error code and check the “Error Code/TAG Cross-Reference” on page 2-3 to
determine which TAG to follow.
7 If no errors are found, the test continues to loop. Allow the test to continue for at least
one minute.
8 Press: STOP to exit. (For some errors, you may have to power-on-reset the printer.)
9 Remove the loop-back connectors.
105 EIGS Program RAM Test (Continuous Loop)

1 Go to: 105
3 If an error code appears before the test has run for five minutes, look up the code in
“Error Code/TAG Cross-Reference” on page 2-3 to determine which TAG to follow.
4 Otherwise, a “201” may display after about five minutes, indicating that the test has
run successfully.
5 Power-on-reset the printer to exit.
Note
This test does not run on printers with MIGS boards.

107 EIGS/MIGS Bit Map Test (Single Loop)
107 EIGS/MIGS Bit Map Test (Single Loop)

1 Go to: 107
4 If an error code appears, look it up in “Error Code/TAG Cross-Reference” on page 2-
3 to determine which TAG to follow.
5 Press: STOP to exit, if an error is reported.
108 EIGS/MIGS Bit Map Test (Continuous Loop)

1 Go to: 108
3 If no errors are detected:
• The test continues to loop.
• Press STOP to exit.
• The error code displays briefly. If more than one error is detected, the error codes
appear sequentially.
• Look up the codes in the “Error Code/TAG Cross-Reference” on page 2-3 to deter-
mine which TAG to follow.
• Power-on-reset to exit after codes display.

110 Format Disk/Clear Error Log
110 Format Disk/Clear Error Log
Caution
When using the 110 function of the self-diagnostic mode,
any existing data on the specified disk is at risk!
• To format a disk, refer to the Guide to Operations manual.

5 To clear the error log, follow the procedure on clearing the log found in “Clearing the
Error Log” on page 1-24.
Caution
If you access this function by mistake, do not proceed.
Press STOP immediately to exit the utility.
111 LED Printhead Test

1 Open the top cover.
3 Remove the developer station.
4 To help you identify the LEDs, place a white sheet of paper in the photoconductor
cavity over the printhead’s fiber optics.
5 Go to: 111
6 Press: READY to run the test. The LED printhead turns on.
7 Verify that the LEDs cycle on and off from front to back.
Table 5-26. LED Printhead Test Error Displays
Display Indication


112 Disk Drive Test (Single Loop With Stop on Error)
112 Disk Drive Test (Single Loop With Stop on Error)

This test reads data from the drive selected. It checks the seek function, cycle redundancy,
parity, checksum, directory and allocation table integrity, and disk format.
1 Go to: 112
2 Insert a diskette or diskettes in the diskette drive or drives you wish to test.
3 Press: READY to run the test. “0” appears on the display indicating the A: drive.
4 Press: CANCEL to advance to the drive you wish to test.
Table 5-27. Disk Drive Test Drive Indications
Display Indication
0 Floppy drive A:
1 Floppy drive B:
2 Hard drive C:
5 Press: READY to activate the drive.

6 If no errors are found, the test exits automatically.
7 If an error code appears, refer to the Table 2-8, “IGS/Disk Drive Error Codes,” on
page 2-7, to determine which TAG to follow.
8 Press: STOP to exit, if errors are found.
9 To test another drive, repeat this procedure starting with Step 2.

113 Disk Drive Test (Continuous Loop)

This test reads data directly from the drive selected. It checks the seek function, cycle
redundancy, parity, checksum, directory and allocation table integrity, and disk format.
1 Go to: 113
2 Insert a diskette or diskettes in the diskette drive or drives you wish to test.
3 Press: READY to run the test. “0” appears on the display indicating the A: drive.
4 Press: CANCEL to advance to the drive you wish to test. Table 5-27, “Disk Drive Test
Drive Indications,” on page 5-25 lists the drive indications.
5 Press: READY to activate the drive.
6 If an error code appears, look it up in Table 2-8, “IGS/Disk Drive Error Codes,” on
page 2-7, to determine which TAG to follow.
7 Power-on-reset to exit.



Chapter 6
Wiring Diagrams
and Electrical Data
Chapter Contents

Wiring Diagrams and Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Connector (J/P) Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Connectors Inside the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Connectors Inside the Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Connectors on the Duplex Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Connectors Inside the Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Connectors Inside the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
Connectors on the Back Coverr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Connectors Inside the Back Cover (J/P2-14) . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Connectors Inside the Back Cover (Continued) J/P18-6262 . . . . . . . . . . . . .6-13
Connectors Inside the Back Cover (Continued) J/P 64-85 . . . . . . . . . . . . . . .6-14
Connectors Inside the Back Cover (Continued) J/P 90-800 . . . . . . . . . . . . . .6-15
Ground System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
Host Interface Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
RS-232C Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Standard DCE to DTE RS-232C Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
Special Considerations for RS-232 Host Interface Users . . . . . . . . . . . . . . . . 6-23
DTE Host to Printer (Option 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
DTE Host to Printer (Option 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
IBM PC/XT to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25
IBM PC/AT to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25
Macintosh Communication Port to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
RS-422 Host interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Centronics Parallel Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
IBM Parallel to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
Special Considerations for Centronics Parallel Interface Users . . . . . . . . . . . 6-29
Circuit Board Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
Signal Interface Board Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
PCL Board Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31
Printhead Circuit Board Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31
6-2 Wiring Diagrams and Electrical Data June 1999


This section provides a reference guide for all information related to the electrical system
of the printer, including:
• An index, arranged by connector number, to the connector’s location in the printer and
on the simplex and duplex schematics, which are found in this chapter.
Note
Connectors are referred to by J/P (jack/plug) numbers throughout
this manual. Use the J/P number when looking up the connector
in the index, schematics, and illustration.
• Complete connection diagram showing plugs, connectors, and wiring.

• Connector locations and illustrations.
• Voltage isolation diagrams.
• Host interface signal definitions and DIP switch settings.
June 1999 Wiring Diagrams and Electrical Data 6-3

Connector (J/P) Index
Schematic
Connector (J/P) Index Connector Page
Location
J/P 43 6-7 simplex/duplex D10
Schematic
Connector Page J/P 44 6-13 simplex/duplex E5
Location
J/P 1 6-7 simplex/duplex F5 J/P 45 6-7 simplex/duplex C10
J/P 2 6-12 simplex/duplex F4 J/P 46 6-7 simplex/duplex C9
J/P 3 6-12 simplex/duplex F4 J/P 47 6-7 simplex/duplex D10

J/P 4 6-12 simplex/duplex E6 J/P 48 6-7 simplex/duplex C10
J/P 5 6-10 simplex/duplex E5 J/P 49 6-9 simplex/duplex E9
J/P 6 6-12 simplex/duplex E7 J/P 50 6-13 simplex/duplex E9
J/P 7 6-12 simplex/duplex D8 J/P 51 6-9 simplex/duplex E9
J/P 8 6-12 simplex/duplex D7 J/P 52 6-13 simplex/duplex D9

J/P 9 6-12 simplex/duplex C4 J/P 53 6-9 simplex/duplex D10
J/P 10 6-12 simplex/duplex C4 J/P 54 6-9, simplex/duplex E10

6-13
J/P 11 6-12 simplex/duplex B4
J/P 57 6-10 simplex/duplex E9
J/P 14 6-12 simplex/duplex C3
J/P 22 6-9, simplex/duplex C3
6-13 J/P 64 6-14 simplex/duplex C5
J/P 22-1 6-8 duplex C2 J/P 65 6-14 simplex/duplex F8

J/P 23 6-13 simplex/duplex A7 J/P 66 6-14 simplex/duplex F9
J/P 24 6-13 simplex/duplex B7 J/P 67 6-14 simplex/duplex F9
J/P 25 6-13 simplex/duplex C4 J/P 68 6-14 simplex/duplex F9

J/P 26 6-13 simplex/duplex B6 J/P 69 6-14 simplex/duplex F10
J/P 27 6-13 simplex/duplex C6 J/P 70 6-14 simplex/duplex E5
J/P 30 6-13 simplex/duplex B6 J/P 71 6-14 simplex/duplex A8

J/P 33 6-11 simplex/duplex B8 J/P 74 6-11 simplex/duplex B8

J/P 36 6-11 duplex C8 J/P 76 6-11 simplex/duplex B8
J/P 37 6-11 simplex/duplex C8 J/P 77 6-14 simplex/duplex C6
J/P 40 6-11 simplex/duplex C8 J/P 79 6-14 simplex/duplex C6

J/P 41 6-11 simplex/duplex C8 J/P 81 6-14 simplex/duplex A5

Schematic Schematic
Connector Page Connector Page
Location Location
J/P 83 6-14 simplex/duplex E5 J/P 316 6-8 duplex E2
J/P 84 6-14 simplex/duplex E6 J/P 317 6-9 duplex D2
J/P 85 6-14 simplex/duplex B6 J/P 318 6-6 duplex F1
J/P 87 6-11 simplex/duplex C8 J/P 319 6-8 duplex F2
J/P 90 6-15 simplex/duplex B9 J/P 320 6-10 duplex G2
J/P 91 6-11 simplex/duplex C8 J/P 321 6-10 duplex G2
J/P 94 6-15 simplex/duplex B8 J/P 322 6-10 duplex F2
J/P 95 6-6 simplex/duplex C3 J/P 323 6-15 duplex D3
J/P 96 6-15 simplex/duplex C5 J/P 324 6-15 duplex E3
J/P 100 6-15 simplex/duplex D4 J/P 330 6-15 simplex/duplex E8
J/P 101 6-15 simplex/duplex D3 J/P 331 6-15 duplex D3
J/P 102 6-15 simplex/duplex C4 J/P 333 6-15 simplex/duplex A8,
simplex/duplex D2
J/P 500 6-15 simplex/duplex A8
J/P 121 6-15 simplex/duplex B6 J/P 800 6-15 simplex/duplex E5

J/P 255 6-15 simplex/duplex A5
J/P 305 6-10 duplex E3
J/P 310 6-10 duplex F3
June 1999 Wiring Diagrams and Electrical Data

Connector Locations
Connector Locations
The illustrations that follow show the relative location of all accessible connectors in the
printer, and illustrate the connector (except for a few instances in which the connector is so
simple that an illustration is unnecessary). For the connector’s schematic location, refer to
the chart on the preceding pages.
Connectors Inside the Front Cover
95
19 17 15 13 7 5 3 1
J/P 95 4 3 2 1
J/P 42
20 18 16 14 12 10 8 6 4 2
J/P 82 1 2 J/P 318 1 2 3

Connector Locations
Connectors Inside the Left Cover
3 6 9
J/P 1 2 5 8
1 4 7
J/P 43, 45, 47 J/P 59, 61 1 2 3
10 9 8 7 6 5 4 3 2 1
2 1 J/P 119, 120, 127, 128 1

J/P 46, 48

Connector Locations
Connectors on the Duplex Cover
J/P 22-1 3 2 1 J/P 314 1 2
J/P 306 1 2 3 4
J/P 315 1 2
J/P 307 1 2 3 4 5 6 7 8 9 10 11 12 13 14
J/P 316 1 2
J/P 308 1 2 3 4 5 6 7 8
J/P 309 1 2 3 4 5 6 7 8 9 10
J/P 319 1 2 3
J/P 313 1 2 3 4

Connector Locations
Connectors Inside the Right Cover
54
53 55
8 7 6 5 4 3 2 1
J/P 15 J/P 54 1 2 3 4 5 6
15 14 13 12 11 10 9
J/P 22 3 2 1 J/P 55 1 2 3
1 2 3 1 2
J/P 49, 51, 53 J/P 317

Connector Locations
Connectors Inside the Top Cover
+
J/P 5
1 2 3 4 J/P 310 1 2 3 4
+ 5 6 7 8
J/P 311 1 2 3 4 5 6 7 8
J/P 57 1 2 3
J/P 312 1 2 3 4 5 6 7 8 9 10
J/P 63 1 2
J/P 320 1 2 3
J/P 131-132 1
J/P 321 1 2 3 4
3 6 9 12
J/P 305 2 5 8 11
J/P 322 1 2 3
1 4 7 10

Connector Locations
Connectors on the Back Cover
74 32
31 41 40
76
36
91
37
33 87
2 4 6 8 10 12 14 16 18 20 22 2426 28 30 3234 36 38 40 42 44 46 48 50 52 54 56 58 60
J/P 31
1 3 5 7 9 11 1315 17 19 2123 25 27 29 3133 35 37 39 41 43 45 47 49 51 53 55 57 59
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
11 10 9 8 7
J/P 32 J/P 74
6 5 4 3 2 1
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
15 13 11 9 7 5 3 1
2 4 6 8 10 12 14 16 18 20 22 2426 28 30 32 34 36 38 40 42 44 46 48 50
J/P 33 J/P 76
1 3 5 7 9 11 1315 17 19 21 23 25 27 29 3133 35 37 39 41 43 45 47 49
16 14 12 10 8 6 4 2
19 17 15 13 7 5 3 1 15 13 11 9 7 5 3 1
J/P 36 J/P 87
20 18 16 14 12 10 8 6 4 2 16 14 12 10 8 6 4 2
15 13 11 5 3 1
J/P 37 J/P 91 1 2 3 4 5 6
16 14 12 10 8 6 4 2
2 4 6 8 10 12 14 16 18 20 2224 26 28 30 32 34 36 38 40 42 44 46 48 50
J/P 40, 41
1 3 5 7 9 15 17 19 21 23 25 27 29 31 33 35 41 43 45 47 49

Connector Locations
Connectors Inside the Back Cover (J/P2-14)
56 24
19
Jogging Motor
Control Board
54
101
102 100
52
Signal Interface
Board
71 72 73 500
10 1
J/P 8
J/P 2, 3 11 2
12 3 J/P 11 2 1
13 4
5
3 6 9
14 6 1 2 3 4 5 6 7 8 9 10
J/P 4 2 8
5
15 7 J/P 12
1 4 16 8
7
17 9
6 5 4
J/P 6 3 2 1 J/P 13
3 2 1
J/P 9 2 1
3 6
J/P 7
J/P 14 3 2 1
J/P 10 2 1
2 5
1 4

Connector Locations
Connectors Inside the Back Cover (Continued) J/P18-62
J/P 18 3 2 1
J/P 26 1 2
J/P 19, 20 4 3 2 1
3 6
J/P 27
2 5
J/P 21, 22 3 2 1 1 4
26 25
24 23
J/P 23 22 21
20 19
8 7 6 5 4 3 2 1
18 17
16 15
J/P 30 14 13
J/P 24 1 2 3 4 12 11
10 9
8 7
6 5
4 3
2 1
+
J/P 44 1 2
6 12
5 11
J/P 25
4 10
J/P 50 1 2 3 4 5 6
3 9
2 8
J/P 52 1 2 3 4 5 6 7 8 9 10
1 7
+
J/P 54 1 2 3 4 5 6
J/P 44 1 2 J/P 56, 58, 60, 62 1 2 3

Connector Locations
Connectors Inside the Back Cover (Continued) J/P 64-85
56 24
19
Jogging Motor
Control Board
54
101
102 100
Signal Interface 52
Board
71 72 73 500
J/P 64 1 2 3 4
J/P 77 4 3 2 1 34 33
32 31
30 29
28 27
26 25
J/P 65, 66, 67, 68, 69, 70 1 2 24 23
22 21
J/P 79
20 19
18 17
13 12 11 10 9 8 7 6 5 4 3 2 1 16 15
J/P 71 14 13
(RS-232C) 12 11
J/P 81, 83 1 2
10 9
25 24 23 22 21 20 19 18 17 16 15 14 8 7
6 5
8 7 6 5 4 3 2 1 4 3
2 1
J/P 72
(RS-422)
J/P 84 2 1
15 14 13 12 11 10 9
5 4 3 2 1
J/P 73
(DC) J/P 85 10 9 8 7 6 5 4 3 2 1
9 8 7 6

Connector Locations
21 17 13 9 5 1 J/P 323 4 3 2 1
22 18 14 10 6 2
J/P 90
23 19 15 11 7 3
24 20 16 12 8 4
3 6 9 12
J/P 324 2 5 8 11
J/P 94
2 1
1 4 7 10
1
J/P 96
J/P 330, 331 4 3 2 1
J/P 100 1 2
J/P 333 2 1
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
J/P 101 1 2 3
J/P 500
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
J/P 102 2 1
J/P 800 1 2 3
J/P 121, 122, 124

1
139, 140, 143
J/P 251, 252, 255 not illustrated

Voltage Isolation Diagrams

Use the following voltage isolation diagrams to locate the presence or loss of proper DC
potentials within the printer. Simplex circuit are shown first, followed by duplex circuits.
J/P8-8 J/P74-32 J/P73-4

DC Power IGS Signal Interface
Supply J/P32-3 Board J/P88-32 Board
External
Attachment
Connector
Figure 6-1. (Simplex) -12 Vdc Circuits
J/P8-1 J/P77-4
Disk Drive
J/P8-10 J/P32-5
IGS Board
J/P32-6
J/P8-14
DC Power
Supply J/P91-5
PCL Board
J/P90-1 J/P42-1 Operator Panel
Board
J/P94-1
J/P7-1 J/P27-1
J/P7-2 J/P27-2 Printhead

Board
J/P7-3 J/P27-3
Figure 6-2. (Simplex) +5 Vdc Circuit

J/P8-3 J/P77-1
Disk drive
DC J/P32-10 J/P73-3
IGS J/P74-34 Signal interface
Power Board board
Supply External
J/P8-6 J/P57-1 attachment
J/P58-1
Paper timing connector
sensor
J/P91-3
J/P40-25 J/P60-1 J/P59-1
Upper paper
empty sensor
J/P62-1 J/P61-1
Lower paper
empty sensor
PCL
J/P50-1 J/P49-1
Board Paper exit
sensor
J/P40-26 J/P50-4 J/P51-1
Output tray
full sensor
J/P54-1 J/P53-1
Tray front
sensor
J/P54-4 J/P55-1
Tray rear
sensor
J/P40-34 J/P12-8
Power control
board #2
J/P40-35 J/P12-1
Power control
Board #3
J/P41-49 J/P25-4
J/P41-50 J/P25-1 Developer unit
J/P40-3 J/P26-1
Erase lamp
Figure 6-3. (Simplex) +12 Vdc Circuits

J/P8-11 J/P10-1
J/P11-1 Power J/P70-1

AC
J/P12-2
Control Power
Board #2 Supply
J/P12-1
DC
Power J/P40-27
Supply
J/P40-28
J/P41-35 J/P23-5
High Voltage
Unit
PCL
Board
J/P8-13 J/P41-26 J/P81-1 J/P82-1
Counter
J/P91-1
J/P40-10 J/P69-1
J/P40-11 J/P65-1
Paper timing clutch
J/P66-1
Upper paper feed clutch
J/P67-1
Lower paper feed clutch
J/P68-1
Figure 6-4. (Simplex) +24 Vdc Circuits

J/P331-3 J/P306-3 Duplex

Control
Board #1
DC J/P330-3 J/P323-3 J/P305-3 J/P310-3 Duplex

Power Control
Supply Board #2
J/P333-1
Fuse (FH2)
Signal J/P73-1 (
Interface ) External
Board J/P73-6
) Attachment
( Connector
Figure 6-5. (Duplex) +5 Vdc Circuit
Duplex
Control
Board #1
J/P306-1 J/P309-7~10 J/P313-1~4
Route motor
J/P308-1 J/P314-1
In solenoid
J/P331-1
J/P308-2 J/P315-1
“C” roller solenoid
DC J/P308-3 J/P316-1
J/P330-1
Power “A” roller clutch
Supply
J/P308-4 J/P317-1
Exit solenoid
J/P323-1
Duplex
Control
J/P310-1 Board #2 J/P312-7~10 J/P321-1~4
Restart motor
J/P305-1
Figure 6-6. (Duplex) +24 Vdc Circuits

Duplex
Control
Board #1 J/P309-4 J/P319-1
Paper pass
sensor
J/P306-2
J/P331-2 J/P309-3 J/P318-1

Cover open
DC sensor
J/P330-2
Power
Supply
Duplex
Control
J/P323-2
Board #2 J/P312-1 J/P320-1
Registration side
sensor
J/P310-2
J/P305-2
J/P312-4 J/P322-1
Registration paper
sensor
Figure 6-7. (Duplex) +12 Vdc Circuits

Ground System
Ground System
J/P4-9 – AC power supply
J/P5-8 – Fuser unit
J/P6-3 – DC power supply
J/P18-3 – Toner supply motor
J/P19-4 – Jogging motor
J/P21-3 – Large cooling fan
J/P326-3 – Small cooling fan
J/P22-3 – Vacuum transport unit
J/P23-8 – High voltage unit
J/P20-1 – Main motor
J/P 255 – Photoconductor unit
J/P305-12 – Duplex control board #2
Back cover to frame grounding strap
Charge corona
Transfer corona

Host Interface Reference

Standard printers support three host interfaces: RS-232C, RS-422, and Centronics Parallel.
User-level information about the installation, configuration, and use of these interfaces is
included in the printer’s Guide to Operations.
RS-232C Host Interface

A printer is standard data terminal equipment (DTE), designed specifically for a direct
connection to a standard data communication equipment (DCE) host. The standard signal
definitions for DTE to DCE equipment are outlined in the table that follows.
Table 6-1. RS-232C DCE to DTE Signal Definitions
Signal
Pin Function
Name
1 FG Frame or chassis ground
2 TD Transmitted data
3 RD Received data
4 RST Request to send
5 CTS Clear to send
6 DSR Data set ready
7 SG Signal ground
8 DCD Data carrier detect
9 Positive DC test voltage
10 Negative DC test voltage (unassigned)
11 (S)DCD Secondary data carrier detect
12 (S)CTS Secondary clear to send
13 (S)CTS Secondary clear to send
14 (S)TD Secondary transmitted data
15 TC Transmitter clock
16 (S)RD Secondary received data
17 RC Receiver clock
18 RDC Receiver debit clock
19 (S)RTS Secondary receive to send
20 DTR Data terminal ready
21 SQ Signal quality detect
22 RI Ring indicator
23 DRS Data rate select
24 (TC) External transmitter clock
25 BSY Busy

Standard DCE to DTE RS-232C Cable

The standard DCE host to the printer (DTE) pin configuration follows..
Table 6-2. Standard DCE to DTE Signal Definition
Host Printer
Signal DCE DTE Signal
GND 1 1 GND
GND 7 7 GND
RI 22 22 RI
DTR 20 20 DTR
DCD 8 8 DCD
DSR 6 6 DSR
RTS 4 4 RTS
CTS 5 5 CTS
TD 2 2 TD
RD 3 3 RD
Special Considerations for RS-232 Host Interface Users

If the READY light comes on and the ON-LINE light does not come on when you are
installing the printer, one or more of the pin signals on the RS-232 cable may be incorrect.
The host computer may be using a non-DCE RS-232C port. If so, you may have to modify
your cable or purchase a new cable with the proper pin assignments. Several possible
alternate RS-232C cable configurations follow.

DTE Host to Printer (Option 1)

Table 6-3. DTE Host to Printer Connector Wiring (Option 1)
Host Printer
GND 1 1 GND
GND 7 7 GND
DTR 20 20 DTR
DCD 8 8 DCD
DSR 6 6 DSR
RTS 4 4 RTS
CTS 5 5 CTS
TD 2 2 TD
RD 3 3 RD

Table 6-4. DTE Host to Printer Connector Wiring (Option 2)
Host Printer
GND 1 1 GND
GND 7 7 GND
DTR 20 20 DTR
DCD 8 8 DCD
DSR 6 6 DSR
RTS 4 4 RTS
CTS 5 5 CTS
TD 2 2 TD
RD 3 3 RD

IBM PC/XT to Printer

Normally, the IBM PC/XT comes with a parallel interface for the printer with a 25-pin
female connector. To run RS-232, you must install a serial board, which will have a male
connector.
Table 6-5. IBM PC/XT to Printer Connector Wiring
PC/XT Printer
Signal DTE DTE Signal
------- 1 1 FG
TD 2 2 TD
RD 3 3 RD
RTS 4 4 RTS
CTS 5 5 CTS
DSR 6 6 DSR
SG 7 7 SG
DCD 8 8 DCD
DTR 20 20 DTR
IBM PC/AT to Printer

Normally, the IBM AT comes with a 9-pin serial connector.
Table 6-6. IBM PC/AT to Printer Connector Wiring
PC/AT Printer
DCD 1 1 FG
RD 2 2 TD
TD 3 3 RD
DTR 4 4 RTS
SG 5 5 CTS
DSR 6 6 ------
RTS 7 7 SG
CTS 8 8 DCD
RI 9 20 DTR

Macintosh Communication Port to Printer

Normally, the Macintosh comes with a 9-pin male connector.
Table 6-7. Macintosh Communication Port to Printer Connector Wiring
Macintosh Printer
FG 1 1 FG
2 2 TD
SG 3 3 RD
4 4 RTS
TD 5 5 CTS
6 6 ------
DSR 7 7 SG
8 8 DCD
RD 9 20 DTR
RS-422 Host interface

The RS-422 host interface uses the signal definitions defined below. A shielded cable is
required with the shield connected on one end only, preferably at the printer end.
Table 6-8. RS-422 Host Interface Connector Wiring
Host Printer
Signal Signal
GND 1 1 FG
SG 8 8 SG
2 2
TD TD
9 9
4 4
RD RD
11 11
5 5
DCD DCD
12 12
6 6
ST2 ST2
13 13
7 7
ST1 ST1
14 14
3 3
DTR DTR
10 10

Centronics Parallel Host Interface

The Centronics Parallel host interface uses the signal definitions defined below.
Table 6-9. Centronics Parallel Signal Definitions
Signal
Pin Function
Name
1 DS Data strobe (active low)

2 DB0 Data bit 0
3 DB1 Data bit 1
4 DB2 Data bit 2
5 DB3 Data bit 3

6 DB4 Data bit 4
7 DB5 Data bit 5
8 DB6 Data bit 6
9 DB7 Data bit 7
10 ACK Acknowledge (active low)
11 BSY Busy (active high)
12 PE Paper empty (active high)
13 SEL Select (active high)
14 AF Auto feed
15 Not used
16 SG Signal ground

18 PLH Peripheral logic high
19 to 30 Signal ground
31 IP INIT
32 ERR Error (active low)
33 to 35 Not used
36 SI Select input

IBM Parallel to Printer
Table 6-10. IBM Parallel to Printer Connector Wiring
Host Printer
Signal Signal
DS 1 1 DS
DB0 2 2 DB0
DB1 3 3 DB1
DB2 4 4 DB2
DB3 5 5 DB3
DB4 6 6 DB4
DB5 7 7 DB5
DB6 8 8 DB6
DB7 9 9 DB7
ACK 10 10 ACK
BSY 11 11 BSY
PE 12 12 PE
SEL 13 13 SEL
AF 14 14 AF
ERR 15 32 ERR
IP 6 31 IP
SI 17 36 SI
GND 18 33 GND
GND 19 19 GND
GND 20 21 GND
GND 21 23 GND
GND 22 25 GND
GND 23 27 GND
GND 24 29 GND
GND 25 30 GND

Special Considerations for Centronics Parallel Interface Users

For DOS host computers, add the following line to the AUTOEXEC.BAT file:
MODE PRN,,P
To edit the AUTOEXEC.BAT file, use any text editor or the EDLIN facility of DOS. If
you do not know how to edit this file, refer to the reference manual that came with the
DOS software.

Circuit Board Settings

Several of the circuit boards in the printer have jumpers and/or DIP switches used to con-
trol the functionality of the board. These settings are described the following section.
Signal Interface Board Settings

The signal interface board has both jumpers and DIP switches used to control host inter-
face interactions.
JP4 JP3
I KH
JP2
D J G
E
F
C
SW B
1 2 3 4 A
JP1
Figure 6-8. Signal Interface Board Jumper/Switch Locations

In general, the four jumpers on the signal interface board should remain as set at the fac-
tory. The jumpers control the following:
Table 6-11. Signal Interface Board Jumper Settings
Jumper Direction Description
JP1 b-c Baud rate crystal oscillator on IGS board 3.6854 MHz
a-b Baud rate crystal oscillator on IGS board 7.3728 MHz
JP2 d-e Unsolicited status reports enabled after power-on-reset

e-f Unsolicited status reports disabled after power-on-reset
JP3 g-h ERR (pin 32) error line output enabled

No jumper ERR (pin 32) error line output disabled
JP4 i-j PE (pin 12) out of paper line enabled

j-k PE (pin 12) out of paper line disabled
The four DIP switches on the signal interface board should be changed based on the host
interface being used.
For an RS-232C host interface: the DIP switches may be set in either direction; they
have no effect on an RS-232C interface.

For an RS-422 host interface: set all four DIP swiches to ON by raising them up away
from the printed circuit board.
ON
1 2 3 4
Figure 6-9. RS-422 Host Interface DIP Settings

For a Centronics Parallel Host Interface: set all four DIP switches to OFF by pushing
them down toward the printed circuit board.
ON
1 2 3 4
Figure 6-10. Centronics Parallel Host Interface DIP Settings
PCL Board Settings

The PCL board uses DIP switches to control the registration of prints. Change these set-
tings only if directed to do so when following TAG #807.
Printhead Circuit Board Settings

The printhead circuit board uses jumpers to match printhead characteristics to controller
characteristics. Do not change these jumper settings; they should remain as set at the fac-
tory.
J29
J28
SW1
• J30
••
••
••
••
•
••
••
••
JP1 •
1 8 JP2
••
Figure 6-11. Printhead Circuit Board Jumper/Switch Locations

Power Supply Strapping
Power Supply Strapping

The input source voltage for the printer is set by a strapping plug located behind the left
cover near the AC power switch. The strapping options and corresponding voltages are
shown in the following table.
Table 6-12. AC Power Strapping
Jumper Pins AC Voltage
1 to 3 100
1 to 4 120 3 6 9
1 to 5 200 2 5 8
1 to 6 220 1 4 7
1 to 7 230 Strapping Plug

1 to 8 240

Chapter 7
Removal/Replacement
Procedures
June 1999 Removal/Replacement Procedures 7-1

Chapter Contents
Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Back Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Lower Back Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Left Side Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Right Side Cover Removal (Simplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
Right Side Cover Removal (Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
Vacuum Transport Unit Removal (Simplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11
Vacuum Transport Unit Removal (Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
Top Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
Top Cover Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Top Cover Hinge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Front Duplex Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Operator Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
Counter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20
IGS Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
PCL Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Printhead Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Disk Drive Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
Cooling Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Duplex Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
Toner Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
High Voltage Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Photoconductor Seam Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
Photoconductor Rear Guide Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35
Signal Interface Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37
Power Control Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38
Jogging Motor Control Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-39
Upper or Lower Paper Size Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Upper Cassette Mount Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41
Lower Cassette Mount Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45
Upper Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-49
Upper Paper Guide Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51
Lower Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Cleaner Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-55
Fuser Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-57
7-2 Removal/Replacement Procedures June 1999

Fuser Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Paper Feed Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
Paper Timing Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Upper Feed Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
Lower Feed Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
Upper Pick-Up Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Upper Pick-Up Roller Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
Lower Pick-Up Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Lower Pick-Up Roller Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Job Offset Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Exit Pinch Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
Upper Static Brush Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Lower Static Brush Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Exit Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Exit Cover Removal (Simplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Exit Cover Removal (Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Paper Exit Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Paper Full Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Front Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Top Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
Erase Lamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
EP Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
Main Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
Main Gear Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89
Duplex Control Board #1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90
Duplex Control Board #2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91
Duplex Tray Registration Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92
Duplex Skew Correction Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
Upper Duplex Drive/Clutch Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 7-95
Duplex Route Motor/Solenoid Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 7-96
“A” Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97
“B” Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98
“C” Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
“C” Roller Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
Duplex Route Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101
Duplex Paper Path Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-103

Removal
Removal
This section includes step-by-step instructions for removing all field service replaceable
parts in the printer. Each part is addressed under its own heading, as outlined on the pre-
ceding contents pages. Most of the procedures are applicable to both the simplex and
duplex printer models. When the procedures differ between the two printers, the word
simplex or duplex is included in parentheses.
Before You Begin

To remove a part, follow the instructions provided. To replace a part, follow the steps in
reverse order unless otherwise noted. During reassembly, make sure to reconnect all con-
nectors properly and seat gears and other moving parts properly.
Power Considerations
Before removing a part, make sure the printer is turned off and that the power cord is dis-
connected.
Photoconductor Removal
If it is necessary to remove the photoconductor unit as part of a removal procedure, make
sure to place it in its protective packaging.

Front Cover Removal
Front Cover Removal

To remove the front cover:
2 While holding the cover up halfway, unhook the strap from the right side.
3 Duplex only: Remove the strap from the left side.
4 Slide the front cover to the right off its hinges.
Right Strap
Left Strap

Back Cover Removal
Back Cover Removal

To remove the back cover:
1 Remove all external cables and attachments.
2 Open the top and back covers.
3 Disconnect CN31, CN32, CN37, CN40, CN41, CN74, and CN91.
4 Duplex only: Disconnect CN36.
5 For the hard drive option, disconnect the drive’s data cable.
6 Remove the ground screw from the back cover.
7 While supporting the back cover, remove the screw holding each strap.
Caution: hold the plastic strap to avoid throwing the screw as it comes loose.
8 Lift the back cover up and away from the printer.
CN36
(C30D only)
CN37
CN40
CN41
CN33
CN91
Ground
Screw Hard Disk Drive
CN74 Connector
CN32
CN31

Lower Back Cover Removal
Lower Back Cover Removal

To remove the lower back cover:
1 Disconnect all external cables and attachments.
2 Open the back cover.
3 Loosen the two screws holding the lower back cover in place.
4 Lift the back cover off its hinges.
5 While supporting the back cover, lift the lower back cover out and away from the
printer.
6 Return the back cover to its hinges.
Loosen Screws
Lower Back Cover

Left Side Cover Removal

To remove the left side cover:
1 Open the top, back, and front covers.
2 Duplex only: Remove the duplex tray by disconnecting P305 and loosening the two
thumb screws.
3 Remove the upper and lower paper cassettes.
4 Loosen the two screws for the left side cover.
5 Lift the cover up and away from the printer.
Replacement Note:
When reinstalling, make sure the inside mounting tabs are properly positioned.
Loosen Screws

Right Side Cover Removal (Simplex)
Right Side Cover Removal (Simplex)
Note
The service kit is attached inside the right side cover.
To remove the right side cover:

1 Remove the paper output tray.
2 Open the top and front covers.
3 Loosen the two screws holding the right side cover.
4 Pull the cover out and away from the printer.
Replacement Note:
Loosen Screws
Service Kit

Right Side Cover Removal (Duplex)
Right Side Cover Removal (Duplex)
Note
The service kit is attached inside the right side cover.
To remove the right side cover:

3 Remove the two screws holding the right side cover in place.
Replacement Note:
Tighten the screws first. Then, gently lift the bottom tabs into place. Hold the top of the
right side cover in place as you open the top cover. (This avoids the possibility of damag-
ing the top cover.)
Service Kit

Vacuum Transport Unit Removal (Simplex)

To remove the simplex vacuum transport unit:
1 Open the top and back cover.
2 Disconnect CN22A.
3 Remove the retaining clip holding the cable in place.
4 Remove the ground screw on the left side of the back cover.
5 Remove the harness stays holding the cable in place.
6 Remove the vacuum transport unit (four screws).
Ground Screw
Retaining Clip
CN22A
Back Detail

Mounting Screws
Vacuum Transport Detail

Vacuum Transport Unit Removal (Duplex)
Vacuum Transport Unit Removal (Duplex)

To remove the duplex vacuum transport unit:
2 Remove the upper duplex roller cover (four screws).
3 Remove the lower duplex roller cover (four screws).
4 Disconnect CN22.
5 Remove the C-clip from the gas spring on the side marked “up.” Gently move the gas
spring out of the way so it does not block the wire harness area.
6 Remove the four harnesses stays holding the cable in place.
7 Remove the three ground screws.
8 Remove the vacuum transport unit (four screws).
Upper Duplex
Harness Stays Roller Cover
Vacuum Transport
Ground Screws
CN22
Harness Stay
Spring Detail
Lower Duplex
Roller Cover

Top Cover Removal
Top Cover Removal

To remove the top cover:
2 Remove the vacuum transport unit from the top cover. It is not necessary to remove it
completely from the printer (see page 7-11).
3 Remove the four screws for each support assembly.
4 Lift the top cover up and away from the printer.
Vacuum Transport Unit
Support Assembly Detail

Top Cover Support Removal
Top Cover Support Removal

To remove the top cover support:
2 Remove the spring from the top cover support (single screw).
3 Remove the screws holding the support to the base of the printer.
Replacement Note:
Replace one support at a time so that the other remains in place to stabilize the top cover.
Spring Screw
Support Detail

Top Cover Hinge Removal
Top Cover Hinge Removal

To remove the top cover hinge:
2 Remove the two screws holding the hinge/support to the top cover.
3 Remove the two screws holding the hinge/support to the printer base.
4 While supporting the top cover, loosen the top two screws.
5 Remove the hinge.
Replacement Note:
Replace one hinge at a time so that one always remains in place to support the top cover.
Loosen Screws
Hinge Detail

Rear Duplex Cover Removal

To remove the rear duplex cover:
2 Remove the lower screw for the rear duplex cover.
3 While supporting the cover, remove the upper screw for the rear duplex cover.
Replacement Note:
Do not substitute longer screws to hold the rear duplex cover in place.
Upper
Screw
Lower
Screw
Mounting Screw Detail

Front Duplex Cover Removal

To remove the front duplex cover:
2 Remove the rear duplex cover (see page 7-17).
4 Open the front duplex cover.
5 Remove the C-clip from each gas spring.
6 While supporting the cover, remove each gas spring from its post and lower it.
7 Close the front duplex cover.
8 Remove the front hinges from the top cover (two screws each).
9 Remove the two screws from each front cover hinge.
Gas Spring
C-Clip
Inside Front
Duplex Cover
Gas Spring Detail

Operator Panel Removal

To remove the operator panel:
2 Remove the two screws holding the operator panel in place.
3 Disconnect connector CN42.
4 Remove the ground screw.
Ground Screw
CN42

Counter Removal
Counter Removal
To remove the counter:
2 Remove the screw holding the counter in place.
3 Pull out the counter.
4 Disconnect connector CN82.
CN82

IGS Board Removal
IGS Board Removal

To remove the IGS board:
2 Disconnect connectors CN31, CN32, CN33, and CN74.
4 Push the two retaining clips away from the board.
5 Remove the IGS board.
Retaining
Clips
CN33
Hard Disk Drive

CN74 CN32 Connector
CN31

PCL Board Removal
PCL Board Removal

To remove the PCL board:
2 Disconnect connectors CN33, CN37, CN40, CN41, and CN91.
3 Duplex only: also disconnect connector CN36.
5 Remove the PCL board.
6 Change the settings of the DIP switches on the replacement PCL to match the switch
settings on the original PCL.
CN91
CN36
(C30D only)
CN37
CN40
CN41
Retaining Clip
Retaining Clip
CN33

Printhead Assembly Removal

To remove the printhead assembly:
1 Open the front, top, and back covers.
2 Remove the photoconductor unit and place in its protective packaging.
4 Remove the fuser drive cover (three screws).
5 Remove the main drive cover (one screw).
6 Remove the gear stay cover (one screw).
7 Remove the gear stay (three screws).
8 Disconnect connectors CN27, CN30, and CN96 (see back detail).
9 Remove the two back screws holding the printhead assembly in place.
Fuser Drive
Cover
CN30
CN27
CN96
Gear Stay
Gear Stay Cover

Mounting Screws
Main Drive Cover
Back Detail

10 Remove the two front screws holding the printhead assembly in place.
11 Pull the printhead assembly from the front of the printer.
Replacement Note:
Do not change the DIP switch setting on the replacement printhead circuit board. These
are set at the factory.
Front Detail Mounting Screws

Disk Drive Housing Removal
Disk Drive Housing Removal

To remove the disk drive housing:
1 Open the front and back covers.
2 Remove the diskette(s).
3 Disconnect CN77 and CN79.
5 Loosen the thumbscrew on the back of the disk drive housing.
6 Remove the disk drive housing from the front of the printer. Be careful not to damage
the cables on the sharp edges of the chassis.
Replacement Note:
For A drives, set the jumper on the drive circuit board to 0; for B drives, set the jumper to
1.
CN79
Hard Disk Drive
Connector
CN77 Thumbscrew
Back Detail

Cooling Fan Removal
Cooling Fan Removal

To remove the cooling fan:
3 Disconnect CN21.
4 Remove the cooling fan (four screws).
CN21
Fuser Drive Cover
Cooling Fan Detail

Duplex Fan Removal
Duplex Fan Removal

To remove the duplex fan:
1 Open the back and top covers.
3 Remove the EMI grounding plate (if present) from the rear of the printer (four
screws).
4 Remove the four screws holding the duplex fan in place.
5 Disconnect CN326.
6 Lift the duplex fan from the printer.
CN326
Fuser Drive Cover

Toner Motor Removal
Toner Motor Removal

To remove the toner motor:
2 Disconnect CN18.
3 Remove the toner motor (three screws).
CN18
Toner Motor Detail

AC Power Supply Removal

To remove the AC power supply:
1 Open the front, back, and top covers.
2 Duplex only: Remove the duplex tray.
4 Remove the left side cover (see page 7-8).
5 Remove the paper feed drive cover (three screws).
6 Remove the power control board cover (one screw).
Paper Feed Drive Cover
Power Control
Board Cover
CN4
Power Control Board

CN70
Back Detail

8 From the side of the printer, remove the three screws holding the AC power supply in
place.
9 Slide the AC power supply out from the side of the printer.
Note: Make sure that strapping plug P1 is correctly configured and installed on connector
J1. For jumper settings, see “Power Supply Strapping” on page 6-32.
Strapping
Plug

DC Power Supply Removal

To remove the DC power supply:
2 Disconnect CN6, CN7, CN8, and CN330.
3 Remove the output tray.
4 Remove the right side cover (see page 7-9).
5 Remove the bracket for the output tray guide (two screws).
6 Remove the DC power supply (two screws).
Replacement Note:
When replacing the output tray bracket, make sure it is seated inside the DC power supply.
CN330
Bracket Screws
CN6
DC Power Supply Screws

CN7 CN8
Right Side Detail Back Detail

High Voltage Unit Removal

To remove the high voltage unit:
2 Remove the EMI grounding plate (if present) from the rear of the printer (four
screws).
3 From the top, loosen the screw holding the high voltage unit in place.
4 Pull the high voltage unit out from the back of the printer.
5 Disconnect connectors CN23, CN24, CN85, and the two high voltage leads.
6 Remove the high voltage unit.

Photoconductor Seam Sensor Removal

To remove the photoconductor seam sensor:
2 Remove the photoconductor and place in its protective packaging.
5 Remove the bracket holding CN64 in place (one screw).
6 Remove the screw holding the seam sensor bracket in place. It is situated under the
bracket for CN64.
CN64 Bracket
Mounting Screw
(under CN64 bracket)
Back Detail

7 From inside the empty photoconductor cavity, disconnect connector CN63.

8 Lift the photoconductor seam sensor and bracket up out of the printer.
Note: Use caution not to bend the bracket.
Seam Sensor
and Bracket
CN63
Front Detail

Photoconductor Rear Guide Rail Removal

To remove the photoconductor rear guide rail:
5 Remove the photoconductor seam sensor (see illustration on page 7-33).
6 Remove the spring at the base of the guide rail. To do this, gently pull the spring for-
ward off its post.
7 Disconnect CN64.
9 Remove CN64 from its bracket.

Ground Screw
CN64
Back Detail

10 From inside the photoconductor cavity, remove the two screws holding the guide rail
in place.
11 Push CN64 and the ground wire through the photoconductor cavity to the front of the
printer.
12 Lift the photoconductor guide rail from the printer.
Spring
Front Detail

Signal Interface Board Removal
Signal Interface Board Removal

To remove the signal interface board:
3 Remove the lower back cover (see page 7-7).
4 Disconnect CN74 and P333.
5 Remove the signal interface board (two screws).
Replacement Note:
Replicate the DIP switch settings and jumper locations on any new signal interface board.
Jumpers
DIP Switches
CN74

Power Control Board Removal

To remove the power control board:
4 Disconnect CN9, CN10, CN11, CN12, CN13, and CN14.
5 Remove power control board (two screws).
Replacement Note:
Be sure that the back of the board is mounted properly in the frame slots.
Power Control
Board Cover

Mounting Slots
CN14
CN13
CN9
CN11
CN12 CN10
Power Control Board Detail

Jogging Motor Control Board Removal
Jogging Motor Control Board Removal

To remove the jogging motor control board:
4 Disconnect CN100, CN101, and CN102.
5 Disengage the board. To do this, pinch the two standoffs on the board.
6 Lift the board from its mounting bracket.
Power Control
Board Cover
Standoffs
CN101
CN100
CN102 Mounting Bracket
Jogging Motor Power Control Board Detail

Upper or Lower Paper Size Sensor Removal

To remove the upper or lower paper size sensor:
3 Using a small screwdriver, pry up the paper size sensor. Turn the sensor counterclock-
wise and lift up.
4 For the upper paper size sensor, disconnect CN45 and CN46.
5 For the lower paper size sensor, disconnect CN43, CN47, and CN48.
Note
Be careful not to damage the cables when disconnecting
Upper Paper
Size Sensor
Lower Paper
Size Sensor
CN46 CN48
CN43
Pry Slot Pry Slot
CN45 CN47
Upper Paper Size Sensor Detail Lower Paper Size Sensor Detail

Upper Cassette Mount Removal

To remove the upper cassette mount:
7 From the back, remove the two screws holding the upper cassette mount in place.
8 Loosen the CN62 jack and pull it to the back of the printer.
9 Disconnect CN62.
Mounting Screws Power Control

Board Cover
CN62
Back Detail

10 Remove the upper paper size sensor (see page 7-40).

11 Remove the cassette release cover (two screws).
12 Remove the plastic guide on the vertical edge of the printer. Depress the tabs visible
through the cassette housing. Gently turn the guide and lift from the printer.
Upper Paper Size Sensor
Cassette Release Cover

13 For the tray release mechanisms:

• Remove the upper and lower cassette release levers (one spring and C-clip each).
• Set the paper tension levers to their minimum (–) position.
• Carefully release the cable tension springs from their cables (only included on
more recent versions of the printer); remove the springs and cables.
• Remove the upper and lower latches (one spring and C-clip each).
• Remove the upper and lower cams (one screw each).
Upper Cassette
Release Lever
Cable Tension Spring Upper Paper
Tension Lever
Upper Latch
Upper Cam
Cable
Lower Latch
Edge
Guide Lower Cam
Damper
Assembly
Lower Cassette
Release Lever
Lower Paper Cable Tension Spring

Tension Lever
14 Disengage the top of the damper assembly. Push it to the right out of the way.

15 Remove the lower bracket (four screws; two front and two back).
16 Remove the tray (four screws; two front and two back).
17 Remove the upper tray lift arm (two screws with two plastic retainers).
18 Remove the upper bracket (four screws; two front and two back).
19 Remove the screws holding the upper cassette mount in place (two front and two
side).
20 Pull the upper cassette mount from its front and back mounting pins.
21 Rotate the upper cassette mount upwards and out of the printer.
Mounting Screws
Upper Bracket
Upper Cassette
Paper Mount
Lift Arm Tray
Lower Bracket
Retainers
Cassette Mount Detail
Left Side Detail
Upper Bracket
Upper Cassette
Mount
Upper Bracket
Tray
Upper Cassette
Mount Lower Bracket
Tray
Lower Bracket
Front Mounting Screw Detail

Back Mounting Screw Detail

Lower Cassette Mount Removal

To remove the lower cassette mount:
7 Remove the power control board (see page 7-38).
8 From the back, remove the two screws holding the lower cassette mount in place.
Power Control
Board Cover
Mounting Screws Paper Feed Drive Cover
Power Control Board
Back Detail

9 Remove the lower paper size sensor (see page 7-40).

through the cassette housing. Gently turn the guide and lift it from the printer.
Lower Paper Size Sensor

12 For the lower tray release:

• Remove the lower cassette release lever (one spring and C-clip).
• Set the lower paper tension lever to its minimum (–) position.
• Carefully release the cable tension spring from its cable (only on the most recent
versions of the printer); remove the spring and cable.
• Remove the lower latch (one spring and C-clip).
• Remove the lower cam (one screw).
Upper Cassette
Release Lever
Cable Tension Spring Upper Paper
Tension Lever
Upper Latch
Upper Cam
Cable
Lower Latch
Edge
Guide Lower Cam
Damper
Assembly
Lower Cassette
Release Lever
Lower Paper Cable Tension Spring

Tension Lever

14 Remove the tray (four screws, two front and two back)
15 Remove the AC power supply (see page 7-29).
16 Remove the lower tray lift arm (two screws with two plastic retainers).
17 Remove the screws holding the lower cassette mount in place (two front and two
side).
18 Pull the lower cassette mount from its front and back mounting pins.
19 Rotate the lower cassette mount upwards and out of the printer.
Tray
Paper
Lift Arm Lower Bracket
Lower Cassette
Mount
Retainers
Mounting Screws
Cassette Mount Detail Left Side Detail
Tray Tray
Lower Bracket
Lower Bracket
Lower Cassette
Mount
Lower Cassette
Mount
Front Mounting Screw Detail Back Mounting Screw Detail

Upper Paper Guide Removal

To remove the upper paper guide:
3 Disconnect the transfer corona high voltage lead from the HVPS.
4 Disconnect the ground screw for the transfer corona.
High Voltage Lead

Ground Screw
Mounting Screw
Back Detail


6 Raise the upper paper guide.
7 Remove the back screw holding the upper paper guide in place.
8 Remove the front screw holding the upper paper guide in place.
9 Release the two springs at the base of the upper paper guide.
10 Lift the upper paper guide out of the printer.
Mounting
Screw
Front Detail
Springs

Upper Paper Guide Roller Removal

To remove the upper paper guide roller:
2 Remove the two springs at each end of the roller. To do this, press down gently on the
end of the spring and move it out from under the plastic.
4 Remove the roller and bearings from the underside of the upper paper guide.
Upper Paper Guide

Underside
Springs

Lower Paper Guide Removal

To remove the lower paper guide:
3 Raise the lower paper guide slightly.
4 Push the base of the lower paper guide toward the back of the printer until the front
mounting peg is free.
5 Lift the lower paper guide out of the printer.
Note: Use caution. This piece is made of plastic and can easily break if mishandled.
Mounting
Pegs

Paper Timing Guide Removal

To remove the paper timing guide:
3 Remove the lower paper guide (see page 7-52).
Lower Paper Guide
Paper Timing Guide
Mounting Screw
Front Detail


5 Remove the back screw holding the paper timing guide in place. Remove the paper
timing guide.
6 Disconnect CN58.
Mounting Screw
CN58
Back Detail

Cleaner Drive Belt Removal

To remove the cleaner drive belt:
4 Lift the idler arm and slide the cleaner drive belt off the gear.
Idler Arm
Main Drive
Cover
Fuser Drive
Cover
Cleaner Drive Belt Detail

Cleaner Drive Removal

To remove the cleaner drive:
4 Remove the cleaner drive belt (see page 7-55).
5 Remove the two high voltage leads.
6 Remove the cleaner drive (three screws).
High Voltage Leads
Main Drive
Cover
Fuser Drive
Cover
Drive Belt
Cleaner Drive Detail

Fuser Drive Belt Removal

To remove the fuser drive belt:
6 Remove the main drive gear and bearing (single C-clip).
7 Remove the single upper left screw and the two lower screws holding the fuser drive
in place.
8 Loosen the upper right screw for the fuser drive and pivot the drive down.
9 Slide the fuser drive belt off the gear.
Loosen
Screw
Main Drive
Cover
Gear Stay
Gear Stay Cover
Fuser Drive Cover

Main Motor
Gear

Fuser Drive Removal
Fuser Drive Removal

To remove the fuser drive:
6 Remove the fuser drive belt (see page 7-57).
7 Remove the fuser drive (four screws).
Gear Stay
Gear Stay
Cover
Main Drive
Cover
Fuser Drive
Cover
Fuser Drive Detail

Paper Feed Drive Belt Removal

To remove the paper feed drive belt:
6 Push down on the idler arm and slide the paper feed drive belt off the gear.
Paper Feed
Drive Cover
Main Drive Cover
Fuser Drive Cover

Idler Arm
Cleaner Drive Belt

Paper Feed Drive Belt Detail

Paper Timing Roller Removal

To remove the paper timing roller:
3 Remove the photoconductor and place it in its protective bag.
5 Remove the paper feed drive belt from the paper timing roller gear.
6 Disconnect CN65.
7 Unscrew the standoff post from the collar surrounding the end of the roller.
8 Remove the front C-clip and bearing.
9 Slide the paper timing roller out the back of the printer.
Replacement Notes:
• Reinstall the original collar and standoff post with any new paper timing roller.
• Be sure to align all of the guide pins or the C-clip will not fit correctly.
Paper Feed
Drive Cover
CN65
C-Clip
and Bearing
Collar
Standoff Post
Front Detail

Upper Feed Roller Removal

To remove the upper feed roller:
3 Disconnect CN66.
4 Remove the paper feed drive belt from the upper feed roller gear.
7 Slide the upper feed roller out the back of the printer.
Paper Feed
Drive Cover
CN66
C-Clip and Bearing
Front Detail Cassette Release Cover

Lower Feed Roller Removal

To remove the lower feed roller:
3 Disconnect CN67.
4 Remove the paper feed drive belt from the lower feed roller gear.
7 Slide the lower feed roller out the back of the printer.
Paper Feed
Drive Cover
CN67
C-Clip and Bearing

Upper Pick-Up Roller Removal

To remove the upper pick-up roller:
3 Disconnect CN68.
6 Slide the upper pick-up roller out the back of the printer.
Note: You may need to remove the EMI grounding plate.
Paper Feed
Drive Cover
CN68
C-Clip and Bearing

Upper Pick-Up Roller Drive Removal
Upper Pick-Up Roller Drive Removal

To remove the upper pick-up roller drive:
3 Remove the upper pick-up roller drive (three screws).
Paper Feed
Drive Cover
Upper Pick-up Roller Drive Detail

Lower Pick-Up Roller Removal

To remove the lower pick-up roller:
3 Disconnect CN69.
6 Slide the lower pick-up roller out the back of the printer.
Paper Feed
Drive Cover
CN69
C-Clip and Bearing

Front Detail

Lower Pick-Up Roller Drive Removal
Lower Pick-Up Roller Drive Removal

To remove the lower pick-up roller drive:
3 Remove the lower pick-up roller drive (three screws).
Paper Feed
Drive Cover
Lower Pick-up Roller Drive Detail

Job Offset Assembly Removal

To remove the job offset assembly:
4 Remove the operator panel (see page 7-19).
Output Option
Mounting Pin
Mounting Screws
Front Detail

5 Remove the DC power supply (see page 7-31).

6 Remove the mounting bracket for the DC power supply (two screws).
9 Remove the five screws holding the job offset assembly in place (three front and two
back).
10 Remove the fuser drive cover mounting post.
11 Remove the output option mounting pin (single screw, located on the front of the
printer).
12 Remove the job offset assembly.
Fuser Drive
Cover
Bracket
CN19
Mounting
Pin
CN54
Fuser Drive Cover

Mounting Post
Bracket Mounting Screws Mounting Screws
Right Side Detail Back Detail

Exit Pinch Roller Removal

To remove the exit pinch roller:
2 Remove the fuser.
4 Remove the front screw holding the exit pinch roller in place.
5 Remove the front screw holding the exit guide in place.
Exit Pinch Roller Screw

C-Clip and Bearing
Exit Guide Screw
Front Detail


7 Remove the back screw holding the exit pinch roller in place.
8 Lift the exit pinch roller from the printer.
Note: Use caution so as not to damage the paper full or exit sensors.
Mounting Screw
Fuser Drive Cover
Back Detail

Upper Static Brush Removal

To remove the upper static brush:
2 Remove the fuser.
3 Remove the upper static brush from the exit pinch roller assembly (two screws).
Upper Static Brush Detail

Lower Static Brush Removal

To remove the lower static brush:
1 Open the top, front and back covers.
2 Remove the fuser.
4 Remove the exit pinch roller assembly (see page 7-69).
5 Remove the lower static brush (two screws).
Mounting Screws
Lower Static Brush

Exit Roller Assembly Removal

To remove the exit roller assembly:
2 Remove the fuser.
3 Remove the operator panel (See page 7-19).
C-Clip and Bearing
Exit Guide Screw
Front Detail


6 Remove the exit pinch roller (see page 7-69).
7 Duplex only: Remove the lower duplex drive (three screws).
8 Remove the back screw holding the exit guide in place.
9 Tilt the exit guide toward the center of the printer.
11 Slide the exit roller out the back of the printer.
Exit Guide
Fuser
Drive
Cover
Exit Pinch Roller Screw
Exit Guide Screw
Lower Duplex Drive

(C30D only)
Back Detail

Exit Cover Removal (Simplex)

To remove the simplex exit cover:
2 Remove the fuser.
Mounting Screws
Front Detail


9 Remove the four screws holding the exit cover in place (two front and two back).
10 Remove the wiring harness for CN42, CN49, and CN51 from the exit cover.
11 Lift the exit cover from the printer.
Mounting Screws
Fuser Drive Cover
Back Detail

Exit Cover Removal (Duplex)

To remove the duplex exit cover:
2 Remove the fuser.
CN317
Solenoid Screws


10 Disconnect CN317.
13 Remove the solenoid from the exit cover (two screws).
Mounting Screws
Fuser Drive Cover
Back Detail

Paper Exit Sensor Removal

To remove the paper exit sensor:
2 Remove the fuser.
5 Disconnect CN49.
6 Remove the two screws holding the exit cover in place (one front and one back).
7 Tilt the exit cover assembly toward the center of the printer.
8 From the underside, remove the paper exit sensor (single screw).
CN49
Paper Exit Sensor Detail

Paper Full Sensor Removal

To remove the paper full sensor:
2 Remove the fuser.
5 Disconnect CN51.
7 Tilt the exit cover toward the center of the printer.
8 From the underside, remove the paper full sensor (single screw).
CN51
Paper Full Sensor Detail

Front Cover Interlock Switch Removal

To remove the front cover interlock switch:
6 Remove the AC power supply top cover (two screws).
7 Disconnect the two wires connected to the interlock switch.
8 Remove the front interlock switch (two screws).
Wires
Front Cover Interlock Switch Detail

Back Cover Interlock Switch Removal

To remove the back cover interlock switch:
6 Remove the AC power supply side cover (one screw).
7 Disconnect the four wires connected to the interlock switch.
8 Remove the back cover interlock switch (two screws).
Wires
Side Cover
Back Cover Interlock Switch Detail
AC Power Supply

Top Cover Interlock Switch Removal

To remove the top cover interlock switch:
1 Open the top, front, and back covers.
5 Duplex only: Remove the duplex tray mount (four screws).
6 Remove the paper feed drive cover (three screws; duplex two screws).
8 Remove the top cover interlock switch (two screws).
Duplex Tray
Mount
(C30D only)
Paper Feed
Drive Cover
Wires
Top Cover Interlock Switch Detail

Erase Lamp Removal
Erase Lamp Removal

To remove the erase lamp:
2 Remove the photoconductor and place it in its protective packaging.
4 Disconnect CN26.
5 Remove the screw holding the erase lamp in place.
6 Disengage the front of the erase lamp from its guide pin.
7 Slide the unit out from the back of the printer.
Mounting Screw
CN26 Fuser Drive Cover
Back Detail

EP Cover Removal
EP Cover Removal
To remove the EP cover:
2 Remove the fuser.
Vacuum Transport
Supports
Support Screw
EP Cover Screws
Front Detail

EP Cover Removal

7 Remove the two supports for the vacuum transport unit (one screw each).
8 Duplex only: Remove the duplex fan (see page 7-27).
9 Remove the four screws holding the EP cover in place (two front and two back).
10 Remove the upper right screw holding the fuser drive in place.
11 Lift the EP cover straight up and out of the printer.
Replacement Note:
The higher of the two drive shaft support arms should be facing the left side of the printer.
Support Screw
Fuser Drive Screw
Fuser Drive Cover
EP Cover Screws
Back Detail

Main Motor Removal
Main Motor Removal
Caution
Do not allow the capacitor contacts to short out against your
body or the printer frame.
To remove the main motor:

5 Remove the back cover (see page 7-6).
7 Remove the signal interface board (see page 7-37).
Drive Shaft Key
Main Motor Gear Main Drive Cover

Gear Stay Cover
Gear Stay
Fuser Drive Cover

Back Detail

Main Motor Removal

9 Remove the counter (see page 7-20).
12 Remove the gear stay cover.
14 Remove the disk drive housing (see page 7-25).
15 Remove the printhead (see page 7-23).
16 Remove the DC power supply (see page 7-31).
17 Remove the main motor gear and bearing (two C-clips).
18 Disconnect CN95.
19 From the right side, remove the two screws holding the main motor in place.
20 From the back, remove the three screws holding the main motor in place.
21 Remove the main motor through the side of the printer.
Replacement Notes:
• Remove the drive shaft key from the old motor. Replacement motors are not sup-
plied with a key.
• Be sure to tuck the CN95 connector under the motor after installation so that the
wires do not protrude into the disk drive assembly area.
Main Motor Detail
Capacitor
CN95
Capacitor Contacts

Main Gear Drive Removal

To remove the main gear drive:
9 Remove the paper feed drive belt (see page 7-59).
10 Remove the main gear drive (three screws).
Paper Feed
Drive Cover
Main Drive
Cover
Gear Stay Cover
Gear Stay
Main Gear Drive Detail Fuser Drive Cover

Duplex Control Board #1 Removal

To remove duplex control board #1:
2 Remove the duplex control board cover (two screws).
4 Disengage duplex control board #1. To do this, pinch the four standoffs on the board
one at a time.
5 Lift the board from the mounting bracket.
Duplex Control Board Cover
CN308
CN309 CN306
CN307
Standoffs
Duplex Control Board #1 Detail


To remove duplex control board #2:
2 Remove the duplex tray.
3 Remove the paper guide from the duplex tray (four screws).
5 Remove duplex control board #2 (two screws).
Paper Guide
CN311
CN310
CN312
Duplex Control Board #2

Duplex Tray Registration Motor Removal

To remove the duplex tray registration motor:
3 Remove the paper guide inside the duplex tray (four screws).
4 Disconnect CN321.
5 Remove the registration motor (two screws).
Paper Guide
CN321
Mounting Screws
Registration Motor Detail

Duplex Skew Correction Cable Removal

To remove the duplex skew correction cable:
3 Remove the paper guide from inside the duplex tray (four screws).
4 Slide the skew correction guides toward the center of the duplex tray.
5 Remove the bracket holding the shaft in place (two screws).
6 Remove the screw holding the cable mounting plate in place.
7 Lift the skew correction guides and shaft up out of the duplex tray.
8 Remove two screws holding each pulley assembly in place.
9 Remove the spring from the cable.
10 Lift the skew correction cable and pulley assemblies from the duplex tray.
Replacement Notes:
The placement of the mounting bead is critical. Set it on precisely. Replace parts in this
order:
• First reinstall the pulley assembly.
• Then, wrap the cable three times around the drive gear pulley.
• Finally, connect the spring.

Paper Guide Skew Correction Guides
Mounting Plate
Screw
Shaft Bracket
Shaft
Mounting Bead
Skew Correction Cable
Drive Gear Pulley
Cable Mounting Plate
Tension Spring Pulley Assembly
Skew Correction Cable Detail

Upper Duplex Drive/Clutch Assembly Removal

To remove the upper duplex drive/clutch assembly:
4 Disconnect CN316.
5 Remove the upper duplex drive/clutch assembly (three screws).
Mounting Screws
CN316
Side Detail
Lower Duplex
Roller Cover

Duplex Route Motor/Solenoid Assembly Removal

To remove the duplex route motor/solenoid assembly:
5 Remove the duplex route motor/solenoid assembly (three screws).
Mounting Screws
CN314
CN313
Duplex Route Motor/Solenoid Detail
Upper Duplex
Roller Cover

“A” Roller Removal

To remove the “A” roller:
4 Remove the front C-clip and bearing from the “A” roller.
5 Lower the top cover to a 45 degree angle.
6 Slide the “A” roller out the back of the printer.
A Roller
Side Detail
Lower Duplex
Roller Cover
C-Clip and
Bearing

“B” Roller Removal

To remove the “B” roller:
5 Remove the front C-clip and bearing from the “B” roller.
6 Remove two screws holding the duplex control board cover in place.
7 Move the cover to the left out of the way.
8 Loosen the screw holding the idler roller in place.
9 Remove the duplex drive belt.
10 Remove the drive gear (single C-clip).
11 Slide the “B” roller out from the back of the printer.
Duplex Control
B Roller Board Cover
Drive Gear
Loosen Screw
Duplex
Drive Belt
Side Detail
Upper Duplex
Roller Cover
C-Clip and
Bearing
Lower Duplex
Roller Cover

“C” Roller Removal

To remove the “C” roller:
4 Remove the front mechanism cover (two screws).
5 Remove the front C-clip and bearing from the “C” roller.
6 Slide the “C” roller out from the back of the printer.
Upper Duplex
Roller Cover
C-Clip and Bearing

“C” Roller Solenoid Removal

To remove the “C” roller solenoid:
3 Disconnect CN315 and cut the cable tie securing the wires to the mounting plate.
4 Remove the two screws holding the “C” roller solenoid in place.
5 Loosen the set screw securing the actuator arm to the “C” roller.
6 Disengage the solenoid from the actuator arm and remove it.
Replacement Note:
Install a new cable tie to secure the wires from CN315 to the mounting plate.
Actuator Arm
CN315
Mounting Screws
C Roller Solenoid Detail

Duplex Route Separator Removal

To remove the duplex route separator:
4 Remove the duplex route motor/solenoid assembly (see page 7-96).
6 Open the duplex cover.
7 Remove screw holding the return arm in place.
8 Disengage the return spring.
Duplex Route Motor/

Solenoid Assembly
Return Arm Screw
Return Arm
Return Spring Front

Mechanism
Side Detail Cover
Upper Duplex
Roller Cover

9 Remove the front C-clip from the route separator.

10 Disengage the route separator from its side supports.
11 Lift the route separator out from the duplex cover.
C-Clip Location

Duplex Paper Path Sensor Removal

To remove the duplex paper path sensor:
2 Remove the two screws holding the duplex control board cover in place.
4 Disconnect CN319.
5 Remove the duplex paper path sensor (single screw).
Paper Path Sensor
Duplex Control
Board Cover
CN319
Mounting Screw
Paper Path Sensor
Underside Detail


Chapter 8
Options
June 1999 Options 8-1

Chapter Contents
Options
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
1200-Sheet/2500-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
Bench Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Prefeed Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
Input Control Board Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
1400-Sheet Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Bench Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Output Control Board Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14
Hard Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16
Troubleshooting Hard Disk Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16
8-2 Options June 1999

Introduction
Introduction
This section provides information on testing and troubleshooting of specific printer
options not covered elsewhere in this manual. These options include the 1200-sheet and
2500-sheet feeders, the 1400-sheet stacker, and the hard disk.
Installation instuctions for the sheets feeders and for the sheet stacker are included in the
C30/C30D Guide to Operations manual. Installation instructions for the hard disk are
included with the packaged option.
For a complete list of the parts contained in the 1200-sheet feeder, the 2500-sheet feeder,
and the 1400-sheet stacker, please see the Illustrated Parts Catalog.

1200-Sheet/2500-Sheet Feeder
Table 8-1. 1200-Sheet/2500-Sheet Component Acronyms
Acronym Component
DSW Door Switch (magnetic door lock)

IEM Input Elevator Motor (M1 – elevator motor)
ILLS Input Lower Limit Sensor
IPES Input Paper Tray Sensor
IPM Input Pick-up Motor (M2 – paper pick-up motor)
IULS Input Upper Limit Sensor
NF AC Noise Filter
NPS No Paper Solenoid
PCSW Power Control Switch (slope tray interlock switch)
PES Paper End Sensor
PHS Paper Head Sensor
SOL Solenoid
ILLS Rear side M1 (IEM)
NF
Input SOL
IULS
control
board
PES
Door
Printer side
PHS
M2
(IPM)
IPES PCSW
Power supply
DSW Front side
Figure 8-1. 1200-Sheet/2500-Sheet Physical Locations

Bench Test Procedure

The bench test procedure references the component acronyms in Table 8-1 on page 8-4
and the component locations in Figure 8-1 on page 8-4. To bench test the printer:
1 Turn the printer’s main power switch off, then disconnect the unit’s power cord.
2 Press down the printer’s lower cassette release lever, then remove the unit from the
printer and place it on a work bench or other suitable surface.
3 Remove the paper size lever, then lift up the slope tray and place the lever between the
slope tray and the frame. This will bypass the interlock switch (PCSW) located under
the slope tray, allowing 12 Vdc to be applied to the input control board.
Note: The slope tray is normally lifted into operating position by the printer’s lower
paper lift arm.
Slope Tray
Paper Size Lever
Paper Supply Tray Paper Access Door
Figure 8-2. Bench Test Procedure

4 Restore AC power to the unit (either the unit’s power cord or the printer’s power cord
may be used).
5 Open the paper access door. The elevator motor (M1) should turn on, moving the
paper stock down. There is an actuator attached to the elevator’s chain drive that will
activate photosensor ILLS signalling the input control board that the paper supply tray
is completely down.
Note: Remove any paper that may be on the unit’s slope tray

6 Close the paper access door. The elevator motor (M1) should turn on, moving the
paper stack up. There are two actuators that must enable two photosensors. Photosen-
sor IPES signals the input control board that paper is present on the elevator. Photo-
sensor IULS signals the input control board that the upper limit for the paper supply
tray and paper stack has been reached.
7 With the paper supply tray all the way up and with no paper present on the slope tray
(indicated to the input control board by photosensor PES, located in the middle of the
paper path), the pick-up roller assembly motor (M2) will turn on and transport a piece
of paper to the slope tray.
8 When the paper in transported to the slope tray, note that the (SOL) solenoid (under
the slope tray) energizes.
Note: The solenoid causes contact with the printer’s paper present sensor.
9 By removing the piece of paper from the slope tray, photosensor PHS signals the input
control board to turn the pick-up motor (M2) on to replace the piece of paper that was
removed.
10 When the last sheet of paper has been fed from the paper supply tray to the slope tray,
the actuator arm of photosensor IPES falls through a hole in the paper supply tray.
This signals the input control board to turn the elevator motor (M1) on to move the
paper supply tray down. The paper supply tray will remain down until the paper
access door is reopened (more paper is loaded), then closed.
11 When the last sheet of paper has been removed from the slope tray, confirm that the
solenoid (SOL) de-energizes.
Prefeed Adjustment Procedure

Because of subsequent revision to the input controller PCA, prefeed adjustments are no
longer necessary nor possible.

Input Control Board Logic

The table below indicates switching logic for the unit’s various components. Except for
the power control switch (PCSW), each component can be monitored from the various
pins of CN508 (located on the input control board).
When performing these checks, use test point TP 1 (located below CN507 on the input
control board).
Table 8-2. Monitoring Input Control Board Logic at Connector CN508
Connector Component Monitored Condition
CN508-4 PHS High Paper present

Low No paper present
CN508-13 PES High Paper present

CN508-19 IPES High Paper present

CN508-16 IULS High Limit
Low No Limit
CN508-21 DSW High Door open

Low Door closed
CN508-10 ILLS High Limit
Low No Limit
CN508-2 NPS High ON

Low Off
CN508-25, 26 IPM (M2) +12 Vdc Feed
0 Vdc No feed
CN508-23 IEM (M1) +12 Vdc Up

0 Vdc Off
CN508-24 IEM (M1) +12 Vdc Down

0 Vdc Off
CN507-2 PCSW 0 Vdc Unit mounted
+12 Vdc Unit not mounted

8-8
Options
Figure 8-3. Connection Diagram for 1200-Sheet/2500-Sheet Feeder
NF
W520 J600 J400 W508 P507
Gnd
AC
PH-1 P522 + 12Vdc
Power
W505 Supply P506
P523
Input
W506 J506
Control
Board
P527 P528
SW2
PCSW
W510 P508
P509
J509 P518 P519
W507
P529 P500 J518 J519
J529 P512 P513 P514 P515 J500

W514
P530 M1 M2
SOL
NPS PHS ILLS PES IULS IPES DSW IEM IPM

June 1999
1400-Sheet Stacker
1400-Sheet Stacker
Table 8-3. 1400-Sheet Stacker Component Acronyms
Acronym Component
ERM Exit Roller Motor (M1)

EPS Exit Paper Sensor
ERS Exit Roller Sensor
OEM Out Elevator Motor (M2)
OELS Out Elevator Limit Sensor
OEPS Out Exit Paper Sensor
OJFM Out Jogging Front Motor (M4)
OJFS Out Jogging Front Sensor
OJRM Out Jogging Rear Motor (M3)
OJRS Out Jogging Rear Sensor
OLLS Out Lower Limit Sensor
OULS Out Upper Limit Sensor
OEM (M2)
Rear
ERM (M1)
Power
supply OEPS OLLS OULS
OJRS Output tray
OJFS
Paper tray
Output full actuator
control
board
OJFM (M4) OJRM (M3)
OELS Front side
Figure 8-4. 1400-Sheet Stacker Component Locations

1400-Sheet Stacker

The bench test procedure references the component acronyms in Table 8-3 on page 8-9
and the component locations in Figure 8-4 on page 8-9.
Adapter Plate
Output Tray Guide
Stacker Unit
Output Tray
Power Cord
Jack
Control Connector Cable
Figure 8-5. 1400-Sheet Stacker Bench Test Preparation

To bench test the 1400-sheet stacker:
1 Turn the printer’s main power switch off.
2 Remove the output tray from the stacker unit.
3 Disconnect the stacker unit’s power cord from the printer and from the stacker, then
disconnect the unit’s control connector cable from the printer’s jack.
4 Remove the stacker unit from the printer, then place it on a work bench or other suit-
able surface.
5 Remove the printer’s power cord from the wall outlet and the printer’s lower back
cover.
6 Observe the pin configuration of the stacker unit’s control connector cable plug .
1 2 3 4 5 6 7
Plug 9 10 X X X X X

1400-Sheet Stacker
7 Place a jumper from pin 9 to pin 10 (ground). Using the printer’s power cord in place
of the unit’s power cord, plug the printer’s power cord in the stacker unit, then into the
wall outlet.
8 With the power applied to the stacker unit, the exit roller motor (ERM-M1) will be off.
This will signal the output control board to turn the exit roller motor (ERM-M1) on.
9 Remove the jumper from pin 9 and pin 10.
10 Lift the paper tray full actuator to enable photosensor OLLS to signal the output con-
trol board to cause the elevator motor (OEM-M2) to turn on and lower the output tray
guide.
11 As the output tray guide reaches its lowest allowable position, photosensor OELS is
enabled and signals the output control board to turn the elevator motor (OEM-M2) off.
12 Releasing the paper tray full actuator then enables photosensor OULS to signal the
output control board to turn the elevator (OEM-M2) on and raise the output tray guide.
13 As the output tray guide reaches its highest allowable position, the paper tray full actu-
ator enables both photosensor OLLS and photosensor OULS, which in turn signal the
output control board to turn the elevator motor (OEM-M2) off.
14 Disconnect the power cord from the stacker, then place a jumper from pin 3 to pin 6
and a second jumper from pin 2 to pin 7.
15 Reconnect the power cord, then (from the printer side of the unit) insert a folded piece
of paper into the unit to trigger the actuator and enable photosensor OEPS. This will
signal the output control board to turn the jogging rear motor (OJRM-M3) on.
16 After jogging has occurred, remove the piece of paper then reinsert it. This will again
trigger the acturator and enable photosensor OEPS. This will signal the output control
board to turn the jogging front motor (OJFM-M4) on.
17 The procedure is completed. Disconnect the power cord, remove the jumpers, then
reinstall the unit into the printer.

1400-Sheet Stacker
Connector Locations
CN416
Printer side
Figure 8-6. Connector Locations (front view, cover removed)

Connectors/circuit boards shown with broken lines are concealed from view.
CN409 CN426 CN425

Rear side
CN405
CN406
Fuse 1
CN401
Fuse 2
Output control
board
Front side
Power supply CN404
CN402
CN417 CN403
Frame ground CN412
Figure 8-7. Connector Locations (left side view, left cover removed)

1400-Sheet Stacker
Printer side
Output side
CN415
CN424 (AC power)
CN420 (Control connector plug)
Figure 8-8. Rear Side View (cover removed)

CN413
CN419
Printer side Output side
CN414
CN407
CN408
Figure 8-9. Top View (top cover removed)

1400-Sheet Stacker
Output Control Board Logic

The table below details specific stacker actions and which sensors supply the signals
needed for each action. Signals from the printer are also included.
Table 8-4. Stacker Actions and Sensor Inputs
Action Sensor Input
Elevator up OULS
(Wait signal to printer) OLLS
OELS
Elevator stop OULS

OLLS
OELS
Remove prints OULS

(signal to printer) OLLS
OELS
Elevator down OULS

OLLS
OELS
Paper exit EPS
OEPS
Paper exit jam (023) OEPS
Jogging start From printer
Jogging ERS (from printer)

OJRS
OEPS
OJFS
Jogging stop From printer

June 1999
P401
Figure 8-10. Connection Diagram for the 1400-Sheet Stacker
P420
PCL board W2 Output W5 P419 J419

J401
interface Control
Board W-
P406 P407 P408 P409

W7
J406
S-1 S-2 S-3
OULS OLLS OEPS
J405
P425 P426
J404 J402 J403
S-5 S-6
OJFS OJRS P404 P402 P403
W4
P412
S-4
OELS
W6
P41 P41 P41 P41
1400-Sheet Stacker
P424 P417 + –
W1 L 12V
PH-1
AC Power
Options
N
Supply J41 J41 J41 J41
100 ~ 240V
P418
M1 M2 M3 M4
ERM OEM OJRM OJFM

8-15
Hard Disk
Hard Disk
Instructions for installing and updating a hard disk are included with the packaged option.
Please refer to the original documentation.
Troubleshooting Hard Disk Problems

If you have difficulty installing your hard disk:
• Service Error 573 is most often caused by a loose cable. Recheck all cable connections
and retry the load process. Note that it may be necessary to remove the disk drive
assembly to recheck the cable connections at the hard disk.
• Make sure that the data cable from the hard disk is connected securely to both the back
of the drive and to the controller board.
• Make sure that the printer’s floppy drive is configured as the A: drive (i.e., make sure
that the jumper on the back of the drive is on DS0).
If your hard disk still does not function correctly, note any error codes displayed and
report them to your service representative.

Chapter 9
General Printer
Maintenance
General Printer Maintenance 9-1

Chapter Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
Every-Call Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6
Adjusting Paper Feed Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Tune-Up Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16
9-2 General Printer Maintenance

Introduction
Introduction
This section describes the primary printer maintenance procedures to be completed during
service calls. In addition, this introduction reviews safety precautions, tool requirements,
and the printer maintenance record.
Every-Call Cleaning Procedure (page 9-6)

The every-call cleaning procedure, as the name implies, is performed every time the
printer is serviced. It includes a thorough cleaning of the printer, requiring the removal of
all major components and performance of specific cleaning tasks related to each one. It
also includes vacuuming all excess toner and other contamination from the interior of the
printer.
Paper Feed Tension Adjustment Procedure (page 9-8)

You may need to adjust the paper feed tension to correct jamming.
Lubrication Procedures (page 9-9)

Lubrication procedures are performed whenever needed, though lubrication should be
applied sparingly. The required lubricants, including oil, molycote and red grease, can be
purchased from the printer’s manufacturer.
Tune-Up Procedure (page 9-16)

The tune-up maintenance procedure is performed when the printer has yielded sub-stan-
dard prints after you’ve completed standard maintenance procedures, or has printed one-
to two-million images. A tune-up maintenance kit is required for this procedure.
Safety Precautions
Whenever servicing sophisticated electronic/electro-mechanical equipment, common
sense, training, caution and experience help in avoiding accidents and mishaps. Be aware
of the following safety precautions:
• Follow all instructions in this document.
• Follow all warnings and instructions marked on the printer.
• Unplug the printer when performing any removal, replacement or cleaning procedure.
• Ensure that the power source for the printer matches the power specification label
located above the power outlet on the back of the printer.
• Keep combustible materials away from the printer.
• Provide adequate ventilation for the printer so that slots and openings in the cabinet
sides are not blocked.
• Do not push objects of any kind through the cabinet slots. They may contact danger-
ous voltage points or other hazards.

Introduction
• Do not expose the printer to liquids of any kind.

• Protect the power cord. Do not place it in a traffic pattern or allow anything to rest on
it.
Tool Requirements: Service Kit

A service kit intended for use solely by the service technician is shipped inside the right
side cover of the printer. This kit includes:
• Interlock by-pass tools (2)
• RS-232C loop back assembly
• RS-422 loop back assembly
• Multimeter jumpers (2)
• Corona cleaner brush
Tools/Supplies
To service the printer properly, you will also need to carry the following:
• Soft cleaning cloth
• Cotton swabs
• Corona cleaner
• Basic set of hand tools suitable for office automation equipment repair
• Digital multimeter with test leads, alligator clips, and a high voltage probe
• Service vacuum cleaner, properly grounded and equipped with a 10 micron filter
End User Cleaning Kit

Printers are shipped with an end-user cleaning kit taped inside the front cover. The clean-
ing kit consists of:
• Cotton swabs
• Corona cleaner brush
This kit is intended for use by the end user.
Printer/Maintenance Record
A maintenance record must be kept for every printer. During the initial service call or at
the time of installation, set up a maintenance record for the customer. A copy of the form,
illustrated on the following page, should be kept in the Guide to Operations so that the
maintenance form is always easily accessible.

HISTORY LOG
To Be Completed By User To Be Completed By HP
HP Notified HP Customer
Page Counter Operator Down-Time Date Time
Date/Time Engineer On Site
Malfunction Description: Action Required and Comments:
Introduction
9-5
Every-Call Cleaning Procedure

Perform the every-call cleaning procedure every time the printer is serviced. When trou-
bleshooting a printer problem, you may be directed to complete this procedure as you iso-
late or correct the problem. If the procedure is not specifically called out, always complete
it before concluding the service call.
The every-call cleaning procedure begins by removing the major consumable supplies
from the printer. When the supplies are out, use a toner vacuum to vacuum the printer thor-
oughly. Clean each consumable supply, following the instructions listed in this section,
before returning it to the printer. Conclude the every-call procedure by running test prints
to confirm the print quality.
The location of all major printer supplies and instructions for their removal are outlined
later in this manual.
Remove Major Consumable Supplies

• Photoconductor unit; place it in its protective packaging.
• Cleaner unit
• Developer unit
• Fuser unit
Inspect and Vacuum

• Inspect the areas in the printer around the developer unit, cleaner unit, photoconducto
unit, and fuser unit for damage and wear.
Clean Internal Areas

Clean the Fuser Unit

• Inspect the unit for damage and contamination; repair or replace as necessary.
• Clean the fuser unit connector, both on the fuser unit and in the printer, with a cotton
swab.
• Vacuum in and around the rollers to remove excess toner, contamination, and any for-
eign objects.
• Reinstall the fuser unit.

Clean the Developer Unit

• Clean any excess toner from the developer unit with a soft cloth.
• Clean the toner patch sensor lens with a soft cloth, making sure no lint remains on the
lens.
• Vacuum the felt areas around the magnetic roller, being careful not to vacuum toner
from the magnetic roller.
Clean the Cleaner Unit/Main Charger

• Remove the charge corona from the cleaner unit.
• Remove the grid to expose the corona wire.
• Clean the corona wire with a cotton swab.
• Clean any excess toner from the cleaner unit with a soft cloth.
• Reinstall the charge corona in the cleaner unit.
• Reinstall the cleaner unit.
Clean the Photoconductor Unit Area

• Clean the photoconductor seam sensor inside the printer.
• Inspect the photoconductor for damage or contamination; repair or replace as neces-
sary.
Clean the Transfer Corona

Run Test Prints

• Run test prints to verify print quality.

Adjusting Paper Feed Tension
Printers With Paper Tension Levers

Recently released simplex and duplex printers have pressure tension levers inside the front
cover, as illustrated in Figure 9-1, Paper Feed Tension Levers, below:
Lower Paper Tension Lever Upper Paper Tension Lever
Figure 9-1. Paper Feed Tension Levers

To adjust the tension:
1 Open the printer’s front cover.
2 Identify the cassette whose tension is to be adjusted, and select the correct lever.
3 Adjust the tension:
• To correct multiple feeds: move the lever toward the minus sign, decreasing the
feed pressure.
• To ease paper feeds: move the lever toward the plus sign, increasing the feed pres-
sure.
4 Close the front cover, then print paper from the cassette you are adjusting.
5 If the paper is still not feeding properly, repeat Steps 3 through 5 until the feed is prop-
erly adjusted.

Lubrication Procedure
Complete the lubrication procedure as-needed. Apply lubrication sparingly. Insufficient
lubrication may result in unnecessary noise and premature wear of components; excessive
lubrication may contaminate printer supplies and make the printer difficult to keep clean.
The following printer illustrations indicate where lubrication may be required. Charts fol-
lowing the illustrations include symbols that indicate the type of lubricant to use on each
component:
H Oil
P Molycote
L Red grease

Figure 9-2. Front View Lubrication Points

Front View Lubrication Tables

Table 9-1. All Printers – Front View Lubrication
Symbol Part Lubricant
H1 Front roller bearings (paper feed, paper pickup, timing oil

and exit rollers)
H2 Vacuum transport drive shaft oil

H3 Fuser drive bearing oil
H4 Upper paper guide roller oil
L5 Fuser drive gear red grease
L6 Vacuum transport drive gear red grease

L7 Vacuum transport gear red grease
P8 Vacuum transport rollers Molycote
Duplex Only
Table 9-2. Duplex Front View Lubrication
H9 Duplex roller bearings oil

P 10 Lower duplex drive assembly Molycote

13
1 2
12 1
11
8
1
10
2
9
3
7 4
6
5
Figure 9-3. Rear View Lubrication

Rear View Lubrication Tables

Table 9-3. All Printers – Rear View Lubrication
H1 Clutch shafts: upper pick-up roller, lower pick-up roller, oil

upper feed roller, lower feed roller, paper timing roller
P2 Upper and lower pick-up roller drive assemblies Molycote

P3 Main drive gear assembly Molycote
P4 Main drive gear Molycote
P5 Main drive motor gear Molycote
P6 Fuser drive gear Molycote

P7 Fuser drive assembly Molycote
Duplex Only
Table 9-4. Duplex Only Rear Lubrication
H8 Clutch shaft bearing oil
P9 Lower duplex drive assembly Molycote

P 10 Upper duplex drive assembly Molycote
P 11 A roller drive gears Molycote
P 12 B roller drive gears Molycote

P 13 C roller drive gears Molycote

1
1
1
1
Figure 9-4. Duplex Only: Top View Lubrication
Table 9-5. Duplex Top View Lubrication
H1 Duplex pinch rollers oil

Figure 9-5. Duplex Only: Duplex Holding Tray Lubrication
Table 9-6. Duplex Holding Tray Lubrication
P1 Drive gears Molycote

L2 Tray shaft red grease

Tune-Up Maintenance Procedure

The tune-up maintenance procedure should be performed when the printer: jams fre-
quently; yields sub-standard print quality even after completing regular maintenance pro-
cedures; and has printed more than one- or two-million prints. At this point in the life of
the printer, the roller assemblies, transfer corona, and static brushes must be replaced. All
of the required components are packaged together in a Tune-Up Maintenance Kit.
1 For detailed instructions on how to replace each of these components, refer to Chapter
7, “Removal/Replacement Procedures”. General guidelines follow for unpacking the
component, along with an outline of the order in which the components should be
replaced.
2 Unpack the maintenance kit, which is shipped in a folded cardboard pack. Remove the
shipping carton and unfold the cardboard pack.
3 Make sure that you have received all of these replacement components, shown in Fig-
ure 9-6, “Tune-Up Kit Components,” on page 9-17:
• Roller assembly, lower feed
• Roller assembly, upper feed
• Roller assembly, paper timing
• Roller assembly, exit
• Roller assembly, upper paper guide
• Transfer corona
• Roller assembly, upper pick up
• Roller assembly, lower pick up
• Static brush, upper (in cardboard folder)
• Static brush, lower (in cardboard folder)
• Label (taped to the top of the package)
4 Unplug the printer.
6 Remove the photoconductor unit. Place the unit in its protective packaging in a safe
place away from the work area.

Figure 9-6. Tune-Up Kit Components

7 Replace the component assemblies in this order:
• Paper timing roller
• Exit roller
• Upper pick up roller
• Lower pick up roller
• Upper feed roller
• Lower feed roller
• Transfer corona
• Lower static brush
• Upper static brush
• Upper paper guide roller
8 Perform the every-call cleaning procedure on page 9-6.
9 Plug in the printer and turn it on.
10 Run test prints to ensure that the paper feeds correctly through the printer.
11 Fill in the label with the date and meter count. Affix it inside the front cover next to
the printer’s serial number.


Appendix A
ACIA . . . . . . . . . Asynchronous Communication EPROM. . . . . . . Erasable Programmable Read
Interface Adapter Only Memory
ALU . . . . . . . . . . Arithmetic Logic Unit EPP . . . . . . . . . . Electrophotographic Process
APA . . . . . . . . . . All Points Addressable EPS . . . . . . . . . . Exit Paper Sensor
ARC . . . . . . . . . . “A” Roller Clutch ERASER . . . . . . Erase Lamp
(Duplex only) EV30 . . . . . . . . . Enhanced Video K30 printer
ARIF. . . . . . . . . . Array Interface EXS . . . . . . . . . . Exit Solenoid (Duplex only)
ATC . . . . . . . . . . Auto Toner Control FA4 . . . . . . . . . . Cooling Fan (Duplex only)
CLEANER . . . . . Cleaner Unit FDC. . . . . . . . . . Floppy Disk Controller
CNT . . . . . . . . . . Counter FDD. . . . . . . . . . Floppy Disk Drive
COOLING FA2 . Cooling Fan FL . . . . . . . . . . . Fuser Halogen Lamp
COS . . . . . . . . . . Cover Open Sensor FRU. . . . . . . . . . Field-Replaceable Unit
(Duplex only)
FUSER . . . . . . . Fuser Unit
CRS . . . . . . . . . . “C” Roller Solenoid
HCI . . . . . . . . . . High Capacity Input
(Duplex only)
HCO . . . . . . . . . High Capacity Output
CRT . . . . . . . . . . Cathode Ray Tube
HEAD . . . . . . . . LED Array Print Head
CRTC . . . . . . . . . CRT Controller
HDD . . . . . . . . . Hard Disk Drive
CRU . . . . . . . . . . Customer-Replaceable Unit
HVU . . . . . . . . . High Voltage Unit
DB-. . . . . . . . . . . Developer Bias Negative
IGS . . . . . . . . . . Image Generation System
DB+ . . . . . . . . . . Developer Bias Positive
IGS CONT . . . . Image Control System
DC P.S.1 . . . . . . . DC Power Supply
I.L. SW Front . . Interlocking Switch (Front)
DEV . . . . . . . . . . Developer Unit
I.L. SW Top. . . . Interlocking Switch (Top)
DMAC . . . . . . . . Direct Memory Access
Controller INS . . . . . . . . . . In Solenoid (Duplex only)
DMC. . . . . . . . . . Dynamic Memory Controller IPL. . . . . . . . . . . Initial Program Load)
DRAM . . . . . . . . Dynamic Random Access Jogging . . . . . . . Jogging Motor
Memory L PAPS . . . . . . . Lower Paper Sensor
DUPLEX1 . . . . . Duplex Control #1 LN03 . . . . . . . . . DEC emulation language
(Duplex only) LPC . . . . . . . . . . Lower Paper Feed Clutch
DUPLEX2 . . . . . Duplex Control #2 LPE . . . . . . . . . . Lower Paper Empty Sensor
(Duplex only) LPP . . . . . . . . . . Lower Pick Up Clutch
EIGS. . . . . . . . . . Enhanced Image Generation LPSS . . . . . . . . . Lower Tray Interlock Switch
System
Main . . . . . . . . . Main Motor
EL. . . . . . . . . . . . Eraser LED
MAP . . . . . . . . . Maintenance Analysis
Procedures
June 1999 Abbreviations and Acronyms A-1

MCH . . . . . . . . . .Charge Corona Unit RPS . . . . . . . . . . Registration Paper Sensor

MCS . . . . . . . . . .Charge Corona Sensor (Duplex only)
MIGS . . . . . . . . .Minter Image Generation RSS . . . . . . . . . . Registration Side Sensor
System (Duplex only)
MPU . . . . . . . . . .Micro Processing Unit SCC . . . . . . . . . . Serial Communication
Controller
MUX . . . . . . . . . .Multiplexer
SIG IF or SIF . . . Signal Interface Board
OPC. . . . . . . . . . .Organic Photoconductor
SRAM . . . . . . . . Static Random Access
OPPNL . . . . . . . .Operator Panel
Memory
PC . . . . . . . . . . . .Photoconductor
SRC . . . . . . . . . . System Reference Code
PCL . . . . . . . . . . .Hewlett-Packard Printer Con-
SRMR2 . . . . . . . Side Registration Motor
trol Language (Software)
Control #2 (Duplex only)
PCL . . . . . . . . . . .Printer Control Logic Board
Suction FA3 . . . . Suction Fan
(Hardware)
SW5 . . . . . . . . . . Upper Cassette In Switch
PCL5 . . . . . . . . . .HP Printer Control Language
(Version 5) SW6 . . . . . . . . . . Lower Cassette In Switch
PCU. . . . . . . . . . .Photoconductor Unit TAG . . . . . . . . . . Troubleshooting Analysis
Guide
PFS . . . . . . . . . . .Paper Full Sensor
TC . . . . . . . . . . . Toner Concentration
PH 1 . . . . . . . . . .A.C. Power Cord
TCH . . . . . . . . . . Transfer Corona Unit
PIA . . . . . . . . . . .Peripheral Interface Adapter
TCS . . . . . . . . . . Transfer Corona Sensor
PIT . . . . . . . . . . .Parallel Interface/Timer
TDS . . . . . . . . . . Toner Density Sensor
PMP . . . . . . . . . .Page Map Primitives
TES . . . . . . . . . . Toner Empty Sensor
POR. . . . . . . . . . .Power On Reset
TFS . . . . . . . . . . Tray Front Sensor
PPS . . . . . . . . . . .Paper Path Sensor
(B-C Sensor) (Duplex only) TH . . . . . . . . . . . Thermistor
PROM . . . . . . . . .Programmable Read Only TO SIG IF . . . . . To Signal Interface
Memory TOSIGIF CENT To Signal Interface Centronics
PS . . . . . . . . . . . .PostScript TONER . . . . . . . Toner Motor
PSS . . . . . . . . . . .Photoconductor Seam Sensor TPS . . . . . . . . . . Timing Paper Sensor
PTM . . . . . . . . . .Programmable Timer Module (Schematics)
PTS . . . . . . . . . . .Paper Timing Sensor TPS . . . . . . . . . . Toner Patch Sensor (Printer)
PW CONT2 . . . .Power Control #2 TRC . . . . . . . . . . Timing Roller Clutch
PW CONT3 . . . .Power Control #3 TRS . . . . . . . . . . Tray Rear Sensor
PWBA. . . . . . . . .Printed Wire Board Assembly PAPS . . . . . . . . . Upper Paper Sensor
RAM . . . . . . . . . .Random Access Memory UMT 1-3 . . . . . . Usage Meter Drive Signal
Resist Motor . . . .Registration Motor UPC . . . . . . . . . . Upper Paper Feed Clutch
(Duplex only) UPE . . . . . . . . . . Upper Paper Empty Sensor
ROM . . . . . . . . . .Read Only Memory UPP . . . . . . . . . . Upper Pick Up Clutch
Root Motor . . . . .“C” Roller Motor UPSS . . . . . . . . . Upper Tray Interlock
(Duplex only) VPCL. . . . . . . . . Video Printer Control Logic
Board
A-2 Abbreviations and Acronyms June 1999

Index
A problems with upper 3-135

"A" roller testing lower 5-5
removal 7-97 testing upper 5-4
abbreviations A-1 charge corona
AC power circuit malfunctions 3-61
malfunctions 3-118 problems 3-58
AC power supply testing 5-10
removal 7-29 circuit boards
acronyms A-1 IGS 1-3
add toner indicator IGS bit-map RAM malfunction 3-112
problems 3-51 IGS communication malfunctions 3-108
IGS controller malfunctions 3-103
B IGS to PCL interface malfunctions 3-110
"B" roller PCL 1-3
removal 7-98 PCL interface problems 3-102
back cover removing duplex control #1 7-90
connectors 6-11 removing duplex control #2 7-91
removal 7-6 removing IGS 7-21
back cover interlock switch removing jogging motor 7-39
removal 7-82 removing PCL 7-22
basic troubleshooting 3-5 removing power control 7-38
belts removing signal interface 7-37
removing cleaner drive 7-55 settings 6-30
removing fuser drive 7-57 cleaner drive
removing paper feed drive 7-59 removal 7-56
board tests cleaner drive belt
EIGS/MIGS 5-20 removal 7-55
brushes cleaning kit 9-4
removing lower static 7-72 cleaning procedure 9-6
removing upper static 7-71 communications
external problems 3-143
C problems 2-13, 3-146
"C" roller testing 5-21, 5-22
removal 7-99 connector index 6-4
"C" roller solenoid connector locations 6-6
removal 7-100 connectors
cassette mounts back cover 6-11
removing lower 7-45 duplex cover 6-8
removing upper 7-41 front cover 6-6
cassettes left cover 6-7
problems 2-12 right cover 6-9
problems with lower 3-136
June 1999 Index-1

Index
sheet stacker 8-12 duplex tray paper guide motor 5-17

top cover 6-10 EIGS program RAM 5-22
continuity checks 1-21 EIGS/MIGS bit map 5-23
cooling fan EIGS/MIGS board 5-20
removal 7-26 envelope fuser solenoid 5-19
counter erase lamp 5-12
malfunctions 3-140 input feeder 5-19
problems 2-13 jogging motor 5-8
removal 7-20 lower cassette 5-5
testing 5-7 operator panel 5-4
covers output stacker 5-18
removing back 7-6 paper transport clutch 5-7
removing EP 7-85 photoconductor 5-8
removing exit 7-75, 7-77 printhead assembly 5-24
removing front 7-5 running 5-3
removing front duplex 7-18 sensor sequence 5-6
removing left side 7-8 toner supply motor 5-9
removing lower back 7-7 transfer charger 5-11
removing rear duplex 7-17 upper cassette 5-4
removing right side 7-9, 7-10 diagrams
removing top 7-14 voltage isolation 6-16–6-20
cross references disk drive
error code/TAG 2-3 formatting 5-24
mechanical malfunction/TAG 2-12 malfunctions 3-104
print quality/TAG 2-10 testing 5-25, 5-26
disk drive housing
D removal 7-25
damaged paper 3-138 diskette drive
DC power supply malfunctions 3-104
removal 7-31 duplex clutch
developed image test sequence 5-16
producing 1-22 duplex control board #1
developer bias removal 7-90
problems 3-44 duplex control board #2
testing 5-13 removal 7-91
developer unit duplex cover
problems 3-53 connectors 6-8
diagnostics duplex fan
charge corona 5-10 removal 7-27
communication loop-back 5-21, 5-22 duplex feed motor 5-14
counter 5-7 duplex input sensor
developer bias 5-13 test sequence 5-15
disk drive 5-25, 5-26 duplex paper path sensor
duplex clutch 5-16 removal 7-103
duplex feed motor 5-14 duplex print cycle 1-5
duplex input sensor 5-15 duplex route motor/solenoid assembly
Index-2 June 1999

Index
removal 7-96 F
duplex route separator fans
removal 7-101 removing cooling 7-26
duplex skew correction cable removing duplex 7-27
removal 7-93 front cover
duplex tray paper guide motor connectors 6-6
testing 5-17 removal 7-5
duplex tray registration motor front cover interlock switch
removal 7-92 removal 7-81
E front duplex cover
removal 7-18
EIGS program RAM
fuser drive
testing 5-22
removal 7-58
EIGS/MIGS bit map
fuser drive belt
testing 5-23
removal 7-57
envelope fuser solenoid
fuser unit
testing 5-19
high temperature problems 3-73
envelope tray
malfuctions 3-67
latch problems 3-21
thermistor malfunctions 3-72
problems 3-14
EP cover G
removal 7-85 ground system 6-21
erase lamp guides
malfunctions 3-65 problems with upper paper 3-139
removal 7-84 removing lower paper 7-52
testing 5-12 removing paper timing 7-53
error code/TAG cross reference 2-3 removing upper paper 7-49
error codes 1-7
bit-map RAM 2-8 H
host communication 2-9 high voltage unit
IGS firmware 2-6 removal 7-32
IGS software 2-6
IGS/disk drive 2-7
I
PCL 2-4 IGS board 1-3
PCL failure 2-6 bit-map RAM malfunction 3-112
PCL/IGS communication 2-4, 2-5 communication malfunctions 3-108
printer 2-3 malfunctions 3-103
error log 1-17 removal 7-21
clearing 1-24, 5-24 IGS to PCL interface
every-call cleaning procedure 9-6 malfunctions 3-110
exit cover input feeder
removal 7-75, 7-77 testing 5-19
exit pinch roller input sheet feeder 8-4
removal 7-69 input tray
exit roller assembly paper size detection malfunctions 3-132
removal 7-73 interfaces 6-22
Centronics parallel 6-27
June 1999 Index-3

Index
RS-232C 6-22 M
RS-422 6-26 main gear drive
interlock by-pass tool 1-22 removal 7-89
interlock switches main motor
overriding 1-22 problems 3-142
top cover 3-192 removal 7-87
J maintenance
cleaning 9-6
job offset assembly
lubricating 9-9
problems 3-75
tune-up procedure 9-16
removal 7-67
maintenance record 9-4
jogging motor
maintenance supplies 9-4
testing 5-8
mechanical malfunction/TAG cross
jogging motor control board
reference 2-12
removal 7-39
misfeeds
jumpers
lower cassette 3-30
signal interface board 6-30
upper cassette 3-26
L motors
left side cover problems with main 3-142
connectors 6-7 removing duplex tray registration 7-92
removal 7-8 removing main 7-87
locating connectors 6-6 removing toner 7-28
lower back cover testing duplex feed 5-14
removal 7-7 testing duplex tray paper guide 5-17
lower cassette testing jogging 5-8
latch problems 3-24 testing toner supply 5-9
paper jams/misfeeds 3-30 multiple feeds 3-137
problems 3-16, 3-136 O
testing 5-5
operator panel
lower cassette mount
malfunctions 3-125
removal 7-45
problems 2-12
lower feed roller
removal 7-19
removal 7-62
testing 5-4
lower paper guide
out of toner indicator
removal 7-52
problems 3-51
lower paper size sensor
output sheet stacker 8-9
removal 7-40
output stacker
lower pick-up roller
testing 5-18
removal 7-65
output tray
lower pick-up roller drive
malfunctions 3-130
removal 7-66
problems 2-12
lower static brush
removal 7-72 P
lubrication 9-9 paper
damaged 3-138
Index-4 June 1999

Index
multiple feeds 3-137 removal 7-38

wrinkled 3-138 power supplies
paper exit sensor +12 Vdc malfunctions 3-79
removal 7-79 +24 Vdc malfunctions 3-92
paper feed drive belt +5 Vdc malfunctions 3-113
removal 7-59 -12 Vdc malfunctions 3-90
paper feed tension removing AC 7-29
adjusting 9-8 removing DC 7-31
paper full sensor removing high voltage 7-32
removal 7-80 power-on-reset (POR) 1-21
paper handling print cycle 1-3
problems 2-13 print quality
paper input timing background print example 4-21
problems 3-41 black print 3-163
paper jams example 4-13
duplex area 3-198 blank print 2-10, 3-148
fuser area 3-34 example 4-6
lower cassette 3-30 blank vertical bands example 4-11
output area 3-39 blurred print 2-11
transfer area 3-34 example 4-19
upper cassette 3-26 blurred vertical streaks 3-177
paper output timing dark areas 3-180
problems 3-43 dark horizontal bands 3-148
paper path 1-6 dark print 2-10, 3-182
paper size example 4-13
codes 5-4 dark speck example 4-14
paper timing guide dark spots 3-166
removal 7-53 dark vertical band example 4-15
paper timing roller dark vertical streaks 3-172
removal 7-60 fusing problems 3-187
paper transport clutch example 4-24
test sequence 5-7 light horizontal bands 3-162
parallel interface 6-27 example 4-12
PCL board 1-3 light print 2-10, 3-152
malfunctions 3-102 example 4-7
removal 7-22 light print with background example 4-8
PCL to IGS interface light vertical streaks 3-160
malfunctions 3-110 example 4-10
photoconductor misregistration 2-11, 3-168, 3-194
testing 5-8 example 4-17
photoconductor rear guide rail overtoned print example 4-18
removal 7-35 residual images 3-182, 3-189
photoconductor seam sensor example 4-22
problems 3-54 samples 4-3
removal 7-33 scratches 3-166
power control board skewed print 2-10, 3-168, 3-194
June 1999 Index-5

Index
example 4-16 removing duplex paper path 7-103

smeared vertical streaks 3-177 removing lower paper size 7-40
smearing 2-11 removing paper exit 7-79
uneven print density 2-11, 3-180 removing paper full 7-80
varying print density removing photoconductor seam 7-33
example 4-20 removing upper paper size 7-40
voids test sequence 5-6
example 4-9 testing duplex input 5-15
voids or white spots 3-158 upper paper size wiring 3-134
washout example 4-5 serial interface 6-22
white spots service calls
example 4-9 completing 1-23
wrinkle example 4-23 service record 9-4
print quality/TAG cross reference 2-10 service tool kit 9-4
printer operation 1-3 sheet feeder 8-4
printhead assembly input control board interface 8-7
malfunctions 3-191 prefeed adjustment 8-6
removal 7-23 test procedure 8-5
testing 5-24 sheet stacker 8-9
problem resolution 3-8 connector locations 8-12
output control board interface 8-14
R test procedure 8-10
rear duplex cover signal interface board
right side cover settings 6-30
connectors 6-9 simplex print cycle 1-5
removal 7-9, 7-10 supplies 9-4
rollers switches
removing "A" 7-97 locations 1-11
removing "B" 7-98 overriding interlock 1-22
removing "C" 7-99 PCL board registration 3-170
removing exit pinch 7-69 removing back cover interlock 7-82
removing lower feed 7-62 removing front cover interlock 7-81
removing lower pick-up 7-65 removing top cover interlock 7-83
removing paper timing 7-60 signal interface board 6-30
removing upper feed 7-61 top cover interlock 3-192
removing upper paper guide 7-51
removing upper pick-up 7-63 T
test prints 1-16
S testing 5-14
safety precautions 9-3 timing
self-diagnostic mode 5-3 paper input 3-41
sensors paper output 3-43
locations 1-11 toner motor
lower paper size wiring 3-134 removal 7-28
malfunctioning photoconductor seam 3- toner patch
54
Index-6 June 1999

Index
low reference level 3-47 V

producing 1-22 vacuum transport unit
too light 3-49 removal 7-11, 7-13
toner supply motor voltage
testing 5-9 isolation diagrams 6-16–6-20
tool kit 9-4 voltage ranges
top cover operating 1-18
connectors 6-10
removal 7-14 W
top cover hinge wrinkled paper 3-138
removal 7-16
top cover interlock switch
removal 7-83
top cover support
removal 7-15
transfer charger
circuit problems 3-58, 3-63
testing 5-11
troubleshooting analysis guide (TAG) 1-19
tune-up maintenance procedure 9-16
U
upper cassette
latch problems 3-18
paper jams/misfeeds 3-26
problems 3-12, 3-135
testing 5-4
upper cassette mount
removal 7-41
upper duplex drive/clutch assembly
removal 7-95
upper feed roller
removal 7-61
upper paper guide
problems 3-139
removal 7-49
upper paper guide roller
removal 7-51
upper paper size sensor
removal 7-40
upper pick-up roller
removal 7-63
upper pick-up roller drive
removal 7-64
upper static brush
removal 7-71
June 1999 Index-7

Models C30/C30D and C40D
Illustrated Parts Catalog
Section 10 Illustrated Parts Catalog
Page 2
This section identifies and illustrates the parts for the printer that can be replaced by the customer and by a field service representative.
The catalog is organized according the general interior locations of the printer. Each location includes an illustration of the parts within it and a
chart listing the corresponding part numbers, names, and descriptions.
To locate a specific part, you have several alternatives:
• If you know the part number, turn to the part number locator beginning on page 63 of this section. Here you will find a cross-reference chart
that tells you the page on which the part is illustrated.
• If you know the general location of the part, turn to the contents listing on the next page. Scan the general locations until you find the appro-
priate one. Then, turn to the page listed to find the part illustration.
• If the part is more general in nature (for example, fuses, lubricants, manuals, or maintenance kits), turn to page 43 where you will find a list-
ing of unillustrated parts.
Contents
Printer Supplies Customer Can Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4

Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6
Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10
Cassette Release Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12
Cassette Mount Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 14
AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16
Duplex Mechanism, Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18
Duplex Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20
Paper Output Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22
Upper Paper Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24
Vacuum Transport Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 26
Job Exit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 28
Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 30
Paper Feed Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 32
Tune-Up Print Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 34
Main Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36
Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38
Duplex Holding Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 40
1200/2500 Sheet High Capacity Input Unit - Main Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 46
1200/2500 Sheet High Capacity Input Unit - Detailed Front View . . . . . . . . . . . . . . . . . . . . . . . . . . page 48
1200/2500 Sheet High Capacity Input Unit - Main Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 50
1200/2500 Sheet High Capacity Input Unit - Detailed Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . page 52
1400 Sheet High Capacity Output Unit - Main Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 54
1400 Sheet High Capacity Output Unit - Detailed Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 56
1400 Sheet High Capacity Output Unit - Main Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 58
1400 Sheet High Capacity Output Unit - Detailed Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 60
June 1999 Illustrated Parts Catalog Page 3

Page 4
Printer Supplies Customer Can Install
(6)
Fuser Unit
Ozone Filter (4,5)
Photoconductor
Unit
Developer
Main Charge
Unit (2,3)
Corona
(7)
Toner
Catridge (8,9) Cleaner Unit (1)
Table 1 Printer Supplies List
Product
Item Number Description C30 C30D C40D
1 C4011A Cleaner unit u u u
2 C4015A Developer unit (C30/C30D) u u
3 C4677A Developer unit with ozone filter (C40D) u
4 C4675A Fuser unit (100/127 VAC) u u u
6 C4682A C30/C30D Photoconductor unit (includes main charge corona and ozone filter) u u
6 C4683A C40D Photoconductor unit (includes main charge corona and ozone filter u
7 11000214KT C30/C30D Charge corona kit (contains 2 main charge coronas) u u
7 11000215KT C40D Charge corona kit (contains 2 main charge coronas u
8 C4006A Toner cartridge (2 per package) u u u

Page 6
Front View
18
13 15
1
14
20
9
8 19
11
12
10
2
17
4
5
7 6 3
16
22
1
24
25
23
13
14
19
16 21 17

Page 8
Table 2 Front View Parts List

Item Ref # Part # Description Qty C30 C30D C40D
1 73860006KT Tray, paper output 1 u u u
2 21421610KT Strap, front cover support, right 1 u u u
3 Drive assembly (two floppy drives) 1 u u
4 11000130KT Floppy drive (only) 1 u u u
5 11000253KT Hard drive (only) 1 u u
5 11000137KT C40D Pre-Loaded Disk (HP internal use only) 1 u
6 51020795KT Print head assembly (300 dpi) 1 u u
6 81020108KT Print head assembly (300 dpi) 1 u
7 51020058KT Counter 1 u u u
8 51020018KT Erase lamp assembly 1 u u
8 81020153KT Erase lamp assembly 1 u
9 55020331KT Cover, EP 1 u u u
10 51020106KT PC guide, front 1 u u u
11 51020107KT PC guide, rear 1 u u u
12 Case, maintenance kit 1 u u u
13 Paper cassette, upper 1 u u u
14 Paper cassette, lower 1 u u u
15 61020023KT Vacuum transport assembly 1 u u
15 81120025KT Vacuum transport assembly 1 u
16 73820006KT Cover, left 1 u u u
17 Cover assembly, front 1 u
17 73920009KT Cover assembly, front 1 u
18 Cover assembly, top 1 u
19 73920011KT Right cover 1 u u u
20 Cover, exit assembly 1 u
21 51220072KT Strap, front cover support, left 1 u u
22 Hinge, back cover 1 u u
23 55020350KT Fan, duplex 1 u
24 Frame, exit assembly 1 u u
25 81620012KT Duplex registration tray, complete 1 u u
This page left intentionally blank
Page 10
Operator Panel
Digital Display
Status Lights
Function Keys
2 2
Duplex only
(button not shown
C30/30D Control Panel on simplex model) C40 Control Panel
Table 3 Operator Panel Parts List
Item Part Number Description Qty C30 C30D C40D
0 73820020KT C30 Operator Panel Assembly, English (includes all parts shown) 1 u
0 73920014KT C30D Operator Panel Assembly, English (includes all parts shown) 1 u
0 81620008KT Universal LCD Operator Panel Assembly (includes all parts shown) 1 u
1 51020256KT Operator Panel PCA 1 u
2 C30 Operator Overlay 1 u
2 C30D Operator Overlay 1 u
2 81620021KT C40D Operator Overlay 1 u
3 73820010KT Bezel, Operator Panel 1 u u u

Page 12
Cassette Release Assembly
8 11
5
4 9
1
2
10
Table 4 Cassette Release Assembly Parts List
1 21422770KT Cam, cassette release 2 u u u
2 21420074KT Latch, cassette release 2 u u u
3 Damper assembly 1 u u u
4 51220123KT Lever, lower cassette release 1 u u u
5 21421570KT Lever, upper cassette release 1 u u u
6 NLA Wire cable, upper 1 u u u
7 51220127KT Wire cable, lower 1 u u u
8 Spring 1 u u u
9 51220128KT Lever, upper paper pick pressure 1 u u u
10 51220131KT Lever, lower paper pick pressure 1 u u u
11 21420683KT Catch, magnet 1 u u u

Page 14
Cassette Mount Assemblies
2 1
Table 5 Upper Cassette Mount Assemblies Parts List
1 Mount, upper cassette 1 u u u
2 21421209KT Sensor assembly, upper paper size 1 u u u
3 Mount, paper size sensor 1 u u u
4 21421937KT Switch, micro, cassette present 1 u u u
Table 6 Lower Cassette Mount Assemblies Parts List

1 Mount, lower cassette 1 u u u
2 21421333KT Sensor assembly, lower paper size 1 u u u

Page 16
AC Power Supply
2
4
6 7
Table 7 AC Power Supply Parts List
0 55030024KT AC power supply assembly (includes all parts shown) 1 u u u
1 Relay, AC power supply 1 u u u
2 Relay, fuser, solid state 1 u u u
3 21420515KT Switch, interlock, front 1 u u u
4 21421962KT Switch, interlock, rear 1 u u u
5 Fuse, upper (3.15A/250V) 1 u u u
6 Fuse, lower (2A/250V) 1 u u u
7 55020482KT Plug, input, voltage set, 120V 1 u u u
7 Plug, input, voltage set, 200V 1 u u u

Page 18
Duplex Mechanism, Top View
3 8
7
9 11
6
7 5
2
10
4
1
Table 8 Duplex Mechanism, Top View Parts List
1 55020261KT Duplex C roller pinch assembly 1 u u
2 55020251KT Duplex AB pinch roller assembly 2 u u
3 55020116KT Spring A and B roller 4 u u
4 55020255KT Sensor, paper path 1 u u
5 55020028KT Spring, route separator” 1 u u
6 55020244KT Upper turn around guide 1 u u
7 55020285KT Duplex Cover Gas Support 2 u u
8 Guide top 1 u u
9 55020263KT Entry route separator assembly 1 u u
10 Spring, C roller 2 u u
11 55020052KT Pinch roller only 9 u u

Page 20
Duplex Mechanism
9 22
14
2 17
16
10
15
3
13
11
4
6
12
20
5 18
8
1 21
19
23
Table 9 Duplex Mechanism Parts List
Item Part Number Description Qty C30D C40D
1 55020231KT Exit route separator assembly 1 u u
2 Cover mechanism, front 1 u u
3 55020020KT Duplex control board # 1 1 u
4 55020019KT Top Cover Support, Rear 1 u u
5 55020257KT Top Cover Support, Front 1 u u
6 55020260KT Roller assembly, A and B feed (with gears and clutches) 2 u u
7 55020022KT Roller C feed 1 u
8 55020248KT Solenoid, route separator, paper exit, #1 1 u u
9 Plate, discharge 1 u u
10 55020026KT Solenoid, C roller 1 u u
11 21420290KT Photocell interrupter 1 u u
12 55020113KT Gear assembly, duplex drive, lower 1 u
13 55020024KT Timing belt #1 1 u u
14 NLA Timing belt, #2 1 u u
15 NLA C Motor, stepper 1 u
16 NLA Route solenoid, #2 1 u u
17 55020214KT Duplex route motor assembly (includes 14, 15, and 16) 1 u
18 55020594KT Duplex drive gear assembly, upper 1 u u
19 Exit tray latch assembly 1 u u
20 55020350KT Cooling fan, C30D duplex 1 u
21 55020196KT Lower turn around guide 1 u u
22 Top cover, front 1 u u
23 Top cover, rear 1 u u

Page 22
Paper Output Area
2
Table 10 Paper Output Area Parts List
1 51020077KT Sensor assembly, paper full 1 u u u
2 51020372KT Sensor assembly, paper exit 1 u u u
3 51020062KT Roller assembly, exit pinch (includes upper static brush) 1 u u u

Page 24
Upper Paper Guide Assembly
7 5
2
3
Table 11 Upper Paper Guide Assembly Parts List
1 81120042KT Upper paper guide assembly (includes all parts shown except corona assembly) 1 u u u
2 61020150KT Corona assembly, transfer 1 u u u
3 51020629KT Roller, upper paper guide 1 u u
4 55020052KT Pinch roller 3 u u
5 81020159KT Upper Guide Spring, Rear 1 u u u
6 81020160KT Upper Guide Spring, Front 1 u u u
7 21423777KT Lower paper guide assembly 1 u u u
8 81020137KT Guide, paper timing (including timing sensor and wire harness W-54) 1 u u u
Table 12 Lower Paper Guide Assembly Parts List

Table 13 Paper Timing Guide Assembly Parts List


Page 26
2
Table 14 Vacuum Transport Unit Parts List
0 61020023KT Vacuum transport assembly (all parts shown) 1 u u
0 81120025KT Vacuum transport assembly (all parts shown) 1 u
1 Blower 1 u u
1 Blower 1 u
2 21420894KT Belt, vacuum transport 4 u u u
3 21420896KT Gear, drive, vacuum transport 1 u u u

Page 28
Job Exit Assembly
1
2
Table 15 Job Exit Assembly Parts List
0 73820027KT Job offset assembly 1 u u
0 Job exit assembly 1 u
1 Jogging motor 1 u u

Page 30
Back View
11
10
12
5
14
3 8
2 13
Table 16 Back View Parts List
1 61020281KT DC power supply, universal 1 u u u
2 Cover, lower back, 100-240 VAC 1 u u
3 61020072KT Signal interface board 1 u u
3 11000059KT Serial/Parallel I/O PCA 1 u
4 Gear stay 1 u u u
5 51020088KT Power control board 1 u u u
6 51020682KT Fan, main cooling assembly 1 u u u
7 Cover, power control board 1 u u u
8 21423825KT Motor assembly, toner supply 1 u u u
9 51020089KT Jogging motor power control board 1 u u
10 61020022KT High voltage unit 1 u u
10 81020112KT High voltage unit 1 u
11 Cover, paper feed drive 1 u u u
12 Cover, fuser drive assembly 1 u u u
13 Cover, main drive gear 1 u u u
14 61020317KT Interlock by pass tool 2 u u u

Page 32
Paper Feed Roller
3 10
6 12 1
3
1
6
13
13
2 9
13
2 8
8 7 4
5 13 4 7 5 11
C30/C30D Paper Feed Rollers C40D Paper Feed Rollers

Table 17 Paper Feed Roller Parts List
1 11000248KT Roller assembly, upper pick-up 1 u u u
2 21420401KT Drive assembly, pick-up roller 2 u u
3 11000246KT Roller assembly, upper feed 1 u u
3 11000252KT Roller assembly, upper feed 1 u
4 11000249KT Roller assembly, lower pick-up 1 u u u
5 11000245KT Roller assembly, lower feed 1 u u
5 11000251KT Roller assembly, lower feed 1 u
6 61020336KT Roller assembly, timing 1 u u
6 81020246KT Roller assembly, timing 1 u
7 21420406KT Idler assembly 1 u u u
8 21420413KT Belt, paper drive 1 u u u
9 81020034KT Idler Belt 1 u
10 Idler assembly 1 u
11 Gear drive assembly 1 u
12 *61020325KT C30 timing roller clutch 1 u u
13 *61020327KT Pick-up roller clutch 1 u u u
* NLA from OEM

Page 34
Tune-Up Print Maintenance Kit
Roller assembly, paper timing

Lower static brush
(in cardboard holder) Roller assembly, upper feed
Roller assembly, lower feed
Roller assembly, exit
Exit pinch roller
Roller assembly, upper paper guide
Transfer Charger
Roller assembly, lower pick
Roller assembly, upper pick
Label taped to inside top of package

Table 18 Tune-Up Print Maintenance Kit Parts List
1 61030058KT Tune-Up Kit – Includes all parts shown 1 u u
1 81230003KT C40D Refurbishing Kit – Includes all parts shown plus the following: 1 u
81120012KT (see item 12, Table 9 on page 21)
2 81020168KT Lower Static Brush 1 u

Page 36
Main Drive Assemblies

1 10
11
13
2
14
4 8
12
9
15 5
7
6
9
C40D 6 C30/C30D
7
Table 19 Main Drive Assemblies Parts List
1 51020056KT Drive assembly, fuser 1 u u
1 81020139KT Drive assembly, fuser 1 u
2 21420412KT Belt, fuser drive 1 u u u
3 11000247KT Roller assembly, exit 1 u u
3 11000250KT Roller assembly, exit 1 u
4 51020342KT Gear, eject 1 u u
4 81020023KT Gear, eject 1 u
5 Bearing, main motor 2 u u
6 Gear, main motor (50 Hz) 1 u u
6 N/A Gear, main motor 1 u
7 21420131KT Key, main motor 1 u u u
8 61020028KT Main drive assembly (50 Hz) 1 u u
8 81020138KT Main drive assembly 1 u
9 51020866KT Motor, main drive (does not include drive gear) 1 u u
9 81020040KT Motor, main drive (does not include drive gear) 1 u
10 51020057KT Drive assembly, cleaner unit 1 u u
10 81020141KT Drive assembly, cleaner unit 1 u
11 51020072KT Drive belt, cleaner unit 1 u u u
12 Gear, main drive assembly (50 Hz) 1 u u
13 Guide exit 1 u u
14 55020113KT Gear assembly, duplex drive, lower 1 u u
15 81020146KT Main Motor Control PCA 1 u

Page 38
Back Cover
4
2
6
5
2
3
3 1
Table 20 Back Cover Parts List
1 Clip, PCL, IGS, RIGS and VPCL boards 4 u u u
2 Strap, back cover support 2 u u
3 73820007KT Cover assembly, back 1 u u
4 55020014KT PCL board, 300 dpi 1 u u
4 14000701KT AVPCL PCA 1 u
5 56220006KT EIGS board, 300 dpi 1 u u
5 14004602KT RIGS2 Controller PCA 1 u
6 W65 wire harness 1 u

Page 40
Duplex Holding Tray
3
Table 21 C40D Duplex Holding Tray Parts List
1 81620012KT Duplex holding tray (includes all parts shown) 1 u u
2 55020253KT Stepping motor 1 u u
3 81120046KT Duplex control board #2 1 u u
4 55020256KT Paper sensor 1 u u

Page 42
Table 22 Wire Harnesses Parts List

Item Part Number Wire Harness C30 C30D C40D
1 21720177KT W-37 (Pwr printhead) u u u
2 51020148KT W-43 (Cable, Data FDD) u u u
3 51020149KT W-44 (Cable, power, FDD) u u u
4 61020139KT W-46 u u
5 51020780KT W-61 (WH to fuser) u u u
6 W-65 u
7 81020046KT W-71 u
8 61020098KT W-72 u u
9 81020047KT W-72 u
10 W-73 u
11 62020036KT W-73 u
12 81020009KT W-73 u
13 W-109 u
14 W-109 u
15 (Cable, data, HDD) u u u
16 (Cable, power, HDD) u u u
Table 23 Additional Parts List (Not Illustrated)
Item Part Number Description Location in Printer Qty C30 C30D C40D
1 51020685KT Sensor assembly, upper cassette empty Above upper cassette 1 u u u
2 Holder, cassette empty sensor Above upper or lower cassette 1 u u u
3 Lever, cassette empty sensor, lower Above lower cassette 1 u u u
4 51020668KT Lever, cassette empty sensor, upper Above upper cassette 1 u u u
5 21421349KT Sensor assembly, lower cassette empty Above lower cassette 1 u u u
6 51020092KT Guide, cleaner assembly Photoconductor cavity 1 u u u
7 51020110KT Cleaner/charger terminal assembly Behind cleaner 1 u u u
8 Corona cleaner brush Service kit 1 u u u
9 RS-232C loop back assembly Service kit 1 u u u
10 RS-422 loop back assembly Service kit 1 u u
11 Jumper wire Service kit 1 u u u
12 21420290KT Photocell interrupter Below upper paper guide 1 u u u
13 Lever, paper timing sensor Below upper paper guide 1 u u
14 21421569KT Photo seam sensor assembly Photoconductor cavity 1 u u u
15 Fuse, 7.0A, 250V” DC power supply 1 u u u
16 Fuse, signal interface board Used on P/N 61020072KT 1 u u
17 AC Power Cord, US market only Lower back cover area 1 u u u
18 *51020874KT Molycote grease n/a 1 u u u
19 *51020875KT Red grease n/a 1 u u u
20 51020876KT Gear oil n/a 1 u u u
21 55030016KT Parts packet (assortment of 14 springs for duplex) n/a 1 u u u
22 51030028KT Parts packet (assortment of 22 springs) n/a 1 u u u
23 51030029KT Parts packet (assortment of 10 spring leaves, n/a 1 u u u
torsion and plate)
24 51030031KT Parts packet (assortment of 22 washers, nuts and n/a 1 u u u
rivets)
25 Parts packet (assortment of 20 clips and E-rings n/a 1 u u u
26 51030027KT Parts packet (assortment of 14 bearings) n/a 1 u u u
27 51030030KT Parts packet (assortment of 52 screws) n/a 1 u u u
28 Ozone filter, vacuum transport (included in photo- Top cover 1
conductor or developer package)
29 Actuator, top cover interlock Top cover 1 u

Page 44
30 Shaft, latch, top cover Top cover 1 u
31 Lever, latch, top cover Top cover 1 u
32 Shield, top cover interlock Top cover 1 u
33 21420515KT Switch, top cover interlock Top cover 1 u
34 Cover, paper feed Top input area 1 u
35 51020147KT Actuator, top cover interlock Top cover 1 u u
36 Spring solenoid Duplex mechanism output area 1 u u
37 51020065KT Brush, discharge, lower Paper output area 1 u u
38 51020664KT Brush, discharge, upper Paper output area 1 u u
39 5961-0701 HP PCL5 Technical Reference Manual Set n/a 1 u u u
40 Coupler, cleaner Behind cleaner 1 u u u
41 Spring, solenoid Duplex mechanism output area 1 u u u
42 55030015KT Parts packet (assortment of 6 bearings for duplex) n/a 1 u u u
43 Solenoid Duplex unit 1 u u u
44 10000016KT Printer Stand n/a 1 u u u
45 9320-1915 Dusting fabric, toner n/a 1 u u u
46 C4000-60007 C30/C30D SWF/MNL Kit FC Rev. A.01.10 n/a 1 u u
47 23420012KT C30 LED Printhead PCA LED Printhead 1 u u
48 14002900KT C40 LED Printhead PCA LED Printhead 1 u
49 11000137KT C40 Pre-loaded disk (HP internal use only)
50 73820063KT Cleaning Pen n/a 1 u u u
51 610203317 Interlock bypass tool (10 pack) n/a 10 u u u
* Red grease (51020875KT) may be used in place of white grease; do not substitute Molycote grease (51020874) for white grease
Page 46
1200/2500 Sheet High Capacity Input Unit - Main Front View
1 2
3
8
13
4
7
12
6
11
10
5
Table 24 1200/2500 Sheet High Capacity Input Unit - Main Front View Parts List
Part Number
Item Description Qty
1200 HCI 2500 HCI
1 54624003KT Cover, RR 1
2 Cover, top 1
3 Roller assembly 1
4 54020140KT 54020140KT Lever 1
5 54624009KT Cover, FR 1
6 Base plate assembly 1
7 Wire Harness, W-510 1
8 Insert wire harness assembly 1
9 Jamplate assembly 1
10 Chain 2
11 54020023KT Mag door catch 1
12 53020124KT 54224043KT Power supply 1
13 Slope assembly (complete with roller assembly, sensor and actuator) 1

Page 48
1200/2500 Sheet High Capacity Input Unit - Detailed Front View

3 14 2
13 11
12 9
10 4
15, 16 6
Table 25 1200/2500 Sheet High Capacity Input Unit - Detailed Front View Parts List
Part Number
1200 HCI 2500 HCI
1 54220012KT 54224072KT Pick-up roller assembly (complete, includes pick-up rollers) 1
2 54020043KT 54020043KT Pick-up rollers only 1
3 54020061KT 54020061KT Sensor assembly B 1
4 54224034KT 54224034KT Lever 1
5 Chain 2
6 54020023KT 54020023KT Mag door catch 1
7 Paper guide FR assembly (concealed from view) 1
8 54020284KT 54020284KT Sensor assembly A 1
9 53020095KT 54224036KT “Motor, pick up” 1
10 Paper guide RR assembly 1
11 21420290KT 21420290KT Photocell interrupter 5
13 53020069KT 54224038KT “Timing belt, 50M x L x 4.8” 2
14 54020125KT 54020125KT “Timing belt, 71M x L x 6.4 (concealed from view)” 1
15 Fuse 1 1
16 Fuse 2 1

Page 50
1200/2500 Sheet High Capacity Input Unit - Main Rear View
1
9
7
2
10
11
3
5 4
Table 26 1200/2500 Sheet High Capacity Input Unit - Main Rear View Parts List
Part Number
1200 HCI 2500 HCI
1 54020207KT 54224061KT Guide frame assembly (complete with jamplate assembly #9 and slope assembly #10) 1
2 54020058KT 54224064KT Door Assembly 1
3 54020189KT 54224019KT Gear 65T (1200 HCI), Gear 72T (2500 HCI) 1
4 54020024KT AC noise filter assembly 1
5 53020095KT 54224050KT Tray lift motor 2
6 Cover, R 1
7 54020053KT *N/A Actuator C assembly (photo sensor and flag) 5
8 8120-6302 AC jumper cord 1
10 Slope assembly (complete with roller assembly sensor and actuator) 1
11 54020210KT 54020210KT HCI Solenoid Assy 1
* Actuator C assemebly not available for 2500 HCI; order complete guide frame assembly (54224061KT)

Page 52
1200/2500 Sheet High Capacity Input Unit - Detailed Rear View
3
2
1
6
17
18
9
5
8
4
16 10 12
11 see inset
15 11
13 19
14
Table 27 1200/2500 Sheet High Capacity Input Unit - Detailed Rear View Parts List
Part Number
1200 HCI 2500 HCI
1 Ballcase 1
2 SUS ball (concealed from view) 3
3 Spring, C (concealed from view) 3
4 54020207KT 54224061KT Guide frame assembly complete with jamplate assembly and slope assembly 1
5 54020234KT 54020234KT Microswitch 1
7 54020058KT 54224064KT Door assembly 1
8 Chain 2
10 54020189KT 54224019KT Gear 65T (1200 HCI) , Gear 72T (2500 HCI) 1
11 Drive bracket assembly 1
12 53020069KT 54224038KT Timing belt, 50M x L x 4.8 2
15 60020002KT 60020002KT Input control board 1
16 Wire harness, W-514 1
18 53020054KT 53020054KT HCI/HCO Sprocket Wheel 4
19 54020183KT 54224018KT HCI Helical Gear 1

Page 54
1400 Sheet High Capacity Output Unit - Main Front View
5
10
6
3
1 4
8
Table 28 1400 Sheet High Capacity Output Unit - Main Front View Parts List
Item Part Number Description Qty
0 High Capacity Stacker Unit (100-240V) - generic
1 Guide, upper 1
2 Guide, lower 1
3 Cover, rear 1
4 Cover, front 1
5 Cover, top 1
6 Roller chain 2
7 53020124KT Power supply 1
8 60020003KT Output control board 1
9 53020121KT Adapter HCO - Job Offset Assembly 1
10 53620011KT Exit Tray Paper Stop 1

Page 56
1400 Sheet High Capacity Output Unit - Detailed Front View
16
15
6
7
8
14
10
5
2
1
9
12
17
11 13
Table 29 1400 Sheet High Capacity Output Unit - Detailed Front View Parts List
1 Fuse 1 1
2 Fuse 2 1
3 53020032KT Actuator B 1
4 53020088KT Photosensor 6
5 53020091KT Jogging assembly, complete (including frames, photosensor, actuator, roller assemblies and wire harness W-12) 1
6 Wire harness W-12 1
7 53020184KT Exit roller motor (includes pulley) 1
8 53820006KT Jogging subassembly (includes 2 jogging motors and jogging block) 1
9 Roller chain 2
10 53020029KT Roller (2 front, 2 rear) 4
13 Wire Harness W-7 1
14 Exit roller assembly 1
17 53020054KT HCI/HCO Sprocket Wheel 4

Page 58
1400 Sheet High Capacity Output Unit - Main Rear View
5 7
9
12
1
11
10
8
6
Table 30 1400 Sheet High Capacity Output Unit - Main Rear View Parts List
1 Guide, upper 1
2 Guide, lower 1
3 Cover, rear 1
4 Cover, front 1
5 Cover, top 1
6 Roller chain 2
7 53020121KT Adapter plate guide assembly 1
8 53020031KT Actuator A 1
9 53020183KT Stacker arm assembly 1
10 Wheel arm assembly 1
11 53620011KT Paper stop, adjustable 1
12 53020194KT Static brush 1

Page 60
1400 Sheet High Capacity Output Unit - Detailed Rear View

15
1
17
10
8 3
9
2 6
16 4
11
12
13
10
See Inset
5
Table 31 1400 Sheet High Capacity Output Unit - Detailed Rear View Parts List
1 53020095KT Elevator motor assembly (includes pulley) 1
2 53020069KT Timing belt, 50M x L x 4.8 1
3 53020065KT Pulley (30T) 1
4 53020051KT Gear D 1
5 53020052KT Gear E 1
6 53020050KT Gear C 1
7 Roller chain 2
10 53020090KT Elevator gear assembly (includes motor, worm gear, belt, pulley and drive gear) 1
11 Timing belt, 80M x L x 4.8 1
12 53224001KT Gear, exit 1
13 53224003KT Gear A (Z90) 1
14 8120-6302 AC power cord (not shown) 1
16 53020230KT Arm holder bracket 1

Page 62
Table 32 Part Numbers Related to Service Notes

S.N. Part Number Description Qty C30 C30D C40D
1 C4000-13402 3-1/2” Fonts Floppy 1 u u
1 C4000-13403 3-1/2” Function Code Floppy (A.01.09.02) 1 u u
2 54620010KT Shelf Kit for 2500 HCI 1 u u
3 C4000-60007 Function Code and Fonts Floppies (A.01.10) 1 u u
4 73820056KT Lever-Stop Clip (required when HCI attached to printer) 1 u u u
Table 33 Part Number Page Part Number Page Part Number Page
Part Number Locator
21420290KT 21, 29, 41 43, 23420012KT 44 51020664KT 44
Part Number Page 49, 53
51020018KT 8 51020668KT 43
21420401KT 33
10000016KT 44 51020056KT 37 51020682KT 31
21420406KT 33
11000059KT 31 51020057KT 37 51020685KT 43
21420412KT 37
11000130KT 8 51020058KT 8 51020780KT 42
21420413KT 33
11000137KT 8, 44 51020062KT 23 51020795KT 8
21420515KT 17, 44
11000214KT 5 51020065KT 44 51020866KT 37
21420683KT 13
11000215KT 5 51020072KT 37 51020874KT 43
21420894KT 27
11000245KT 33 51020077KT 23 51020875KT 43
21420896KT 27
11000246KT 33 51020088KT 31 51020876KT 43
21421209KT 15
11000247KT 37 51020089KT 31 51030027KT 43
21421333KT 15
11000248KT 33 51020092KT 43 51030028KT 43
21421349KT 43
11000249KT 33 51020106KT 8 51030029KT 43
21421569KT 43
11000250KT 37 51020107KT 8 51030030KT 43
21421570KT 13
11000251KT 33 51020110KT 43 51030031KT 43
21421610KT 8
11000252KT 33 51020147KT 44 51220072KT 8
21421937KT 15
11000253KT 8 51020148KT 42 51220123KT 13
21421962KT 17
14000701KT 39 51020149KT 42 51220127KT 13
21422770KT 13
14002900KT 44 51020256KT 11 51220128KT 13
21423777KT 25
14004602KT 39 51020342KT 37 51220131KT 13
21423825KT 31
21420074KT 13 51020372KT 23 53020029KT 57, 61
21720177KT 42
21420131KT 37 51020629KT 25 53020031KT 59, 61

Page 64
Part Number Page Part Number Page Part Number Page Part Number Page
53020032KT 57 54020024KT 51, 53 54224064KT 51, 53 55020255KT 19
53020050KT 61 54020043KT 49 54224072KT 49 55020256KT 41
53020051KT 61 54020053KT 51 54620010KT 62 55020257KT 21
53020052KT 61 54020058KT 51, 53 54624003KT 47 55020260KT 21
53020054KT 53, 57 54020061KT 49 54624009KT 47 55020261KT 19
53020065KT 61 54020125KT 49 55020014KT 39 55020263KT 19
53020069KT 49, 53, 61 54020183KT 53 55020019KT 21 55020285KT 19
53020088KT 57 54020189KT 51, 53 55020020KT 21 55020331KT 8
53020090KT 61 54020207KT 51, 53 55020022KT 21 55020350KT 8, 21
53020091KT 57 54020210KT 51 55020024KT 21 55020482KT 17
53020095KT 49, 51, 53, 61 54020234KT 53 55020026KT 21 55020489KT 17
53020121KT 55, 59 54020284KT 49 55020028KT 19 55020490KT 17
53020124KT 47, 55, 57 54220012KT 49 55020052KT 19, 25 55020491KT 17
53020183KT 59 54224018KT 53 55020113KT 21, 37 55020594KT 21
53020184KT 57, 61 54224019KT 51, 53 55020116KT 19 55030015KT 44
53020194KT 59 54224034KT 49 55020196KT 21 55030016KT 43
53020230KT 61 54224036KT 49 55020214KT 21 55030024KT 17
53224001KT 61 54224038KT 49, 53 55020231KT 21 56220006KT 39
53224003KT 61 54224043KT 47 55020244KT 19 5961-0701 44
53620011KT 55, 59 54224048KT 53 55020248KT 21 60020002KT 53

53820006KT 57, 61 54224050KT 51, 53 55020251KT 19 60020003KT 55, 57
54020023KT 47, 49 54224061KT 51, 53 55020253KT 41 61020013KT 37

61020022KT 31 73820063KT 44 81120012KT 21, 37, C4682A 5
61020023KT 8, 27 73920009KT 8 81120021KT 21 C4683A 5
61020028KT 37 73920011KT 8 81120025KT 8, 27
61020072KT 31 73920014KT 11 81120042KT 25
61020098KT 42 81020009KT 42 81120046KT 41
61020139KT 42 81020023KT 37 81120051KT 21
61020150KT 25 81020034KT 33 8120-6302 51, 61
61020281KT 31 81020040KT 37 81230003KT 35
61020317KT 31 81020046KT 42 81620008KT 11
61020325KT 33 81020047KT 42 81620012KT 8, 41
61020327KT 33 81020108KT 8 81620021KT 11
610203317 44 81020112KT 31 9320-1915 44
61020336KT 33 81020137KT 25 C4000-13402 62
61030058KT 35 81020138KT 37 C4000-13403 62
62020036KT 42 81020139KT 37 C4000-60007 44, 62
62020046KT 11 81020141KT 37 C4006A 5
73820006KT 8 81020146KT 37 C4007A 5
73820007KT 39 81020153KT 8 C4011A 5
73820010KT 11 81020159KT 25 C4015A 5
73820020KT 11 81020160KT 25 C4675A 5

73820027KT 29 81020168KT 35 C4676A 5
73820056KT 62 81020246KT 33 C4677A 5

Page 66
Table 34 Part Number Table Item Qty Part Number Table Item Qty Part Number Table Item Qty
Part Number/Table Index
21420131KT 19 7 1 5 4 1 51020110KT 23 7 1
21421937KT
Part Number Table Item Qty 9 11 1 6 4 1 51020147KT 23 35 1
10000016KT 23 44 1 15 2 2 21421962KT 7 4 1 51020148KT 22 2 1
11000059KT 16 3 1 21 5 1 21422770KT 4 1 2 51020149KT 22 3 1
21420290KT
11000130KT 2 4 1 23 12 1 11 7 1 51020256KT 3 1 1
21423777KT
2 5 1 25 11 5 12 7 1 51020342KT 19 4 1
11000137KT
23 49 1 27 9 5 21423825KT 16 8 1 51020372KT 10 2 1
11000214KT 1 7 N.A. 21420401KT 17 2 2 21720177KT 22 1 1 51020629KT 11 3 1
11000215KT 1 7 N.A. 21420406KT 17 7 1 23420012KT 23 47 1 51020664KT 23 38 1
11000245KT 17 5 1 21420412KT 19 2 1 51020018KT 2 8 1 51020668KT 23 4 1
11000246KT 17 3 1 21420413KT 17 8 1 51020056KT 19 1 1 51020682KT 16 6 1
11000247KT 19 3 1 7 3 1 51020057KT 19 10 1 51020685KT 23 1 1
21420515KT
11000248KT 17 1 1 23 33 1 51020058KT 2 7 1 51020780KT 22 5 1
11000249KT 17 4 1 21420683KT 4 11 1 51020062KT 10 3 1 51020795KT 2 6 1
11000250KT 19 3 1 21420894KT 14 2 4 51020065KT 23 37 1 51020866KT 19 9 1
11000251KT 17 5 1 21420896KT 14 3 1 51020072KT 19 11 1 51020874KT 23 18 1
11000252KT 17 3 1 21421209KT 5 2 1 51020077KT 10 1 1 51020875KT 23 19 1
11000253KT 2 5 1 21421333KT 6 2 1 51020088KT 16 5 1 51020876KT 23 20 1
14000701KT 20 4 1 21421349KT 23 5 1 51020089KT 16 9 1 51030027KT 23 26 1
14002900KT 23 48 1 21421569KT 23 14 1 51020092KT 23 6 1 51030028KT 23 22 1
14004602KT 20 5 1 21421570KT 4 5 1 51020106KT 2 10 1 51030029KT 23 23 1
21420074KT 4 2 2 21421610KT 2 2 1 51020107KT 2 11 1 51030030KT 23 27 1
Part Number Table Item Qty Part Number Table Item Qty Part Number Table Item Qty Part Number Table Item Qty
51030031KT 23 24 1 53020091KT 29 5 1 24 11 1 26 3 1
54020023KT 54224019KT
51220072KT 2 21 1 25 9 2 25 6 1 27 10 1
51220123KT 4 4 1 53020095KT 26 5 2 26 4 1 54224034KT 25 4 1
54020024KT
51220127KT 4 7 1 27 14 2 27 13 1 54224036KT 25 9 1
51220128KT 4 9 1 31 1 1 54020043KT 25 2 1 25 13 2
54224038KT
51220131KT 4 10 1 28 9 1 54020053KT 26 7 5 27 12 2
53020121KT
29 10 4 30 7 1 26 2 1 54224043KT 24 12 1
53020029KT 54020058KT
31 9 4 24 12 1 27 7 1 54224048KT 27 9 5
30 8 1 53020124KT 28 7 1 54020061KT 25 3 1 26 5 2
53020031KT 54224050KT
31 8 1 29 12 1 54020125KT 25 14 1 27 14 2
53020032KT 29 3 1 53020183KT 30 9 1 54020140KT 24 4 1 26 1 1

54224061KT
53020050KT 31 6 1 29 7 1 54020183KT 27 19 1 27 4 1
53020184KT
53020051KT 31 4 1 31 17 1 26 3 1 26 2 1
54020189KT 54224064KT
53020052KT 31 5 1 53020194KT 30 12 1 27 10 1 27 7 1
27 18 4 53020230KT 31 16 1 26 1 1 54224072KT 25 1 1
53020054KT 54020207KT
29 17 4 53224001KT 31 12 1 27 4 1 54620010KT 32 2 1
53020065KT 31 3 1 53224003KT 31 13 1 54020210KT 26 11 1 54624003KT 24 1 1
25 13 2 28 10 1 54020234KT 27 5 1 54624009KT 24 5 1
53020069KT 53620011KT
27 12 2 30 11 1 54020284KT 25 8 1 55020014KT 20 4 1
31 2 1 29 8 1 54220012KT 25 1 1 55020019KT 9 4 1
53820006KT
53020088KT 29 4 6 31 15 1 54224018KT 27 19 1 55020020KT 9 3 1
53020090KT 31 10 1 55020022KT 9 7 1

Page 68
55020024KT 9 13 1 55020331KT 2 9 1 61020098KT 22 8 1 73920014KT 3 0 1
55020026KT 9 10 1 2 23 1 61020139KT 22 4 1 81020009KT 22 12 1

55020350KT
55020028KT 8 5 1 9 20 1 61020150KT 11 2 1 81020023KT 19 4 1
8 11 9 55020482KT 7 7 1 61020281KT 16 1 1 81020034KT 17 9 1

55020052KT
11 4 3 55020489KT 7 7 1 16 14 2 81020040KT 19 9 1
61020317KT
9 12 1 55020490KT 7 7 1 23 52 10 81020046KT 22 7 1
55020113KT
19 14 1 55020491KT 7 7 1 61020325KT 17 12 1 81020047KT 22 9 1
55020116KT 8 3 4 55020594KT 9 18 1 61020327KT 17 13 1 81020108KT 2 6 1
55020196KT 9 21 1 55030015KT 23 42 1 61020336KT 17 6 1 81020112KT 16 10 1
55020214KT 9 17 1 55030016KT 23 21 1 61030058KT 18 1 1 11 8 1

81020137KT
55020231KT 9 1 1 55030024KT 7 0 1 62020036KT 22 11 1 13 8 1
55020244KT 8 6 1 56220006KT 20 5 1 62020046KT 3 1 1 81020138KT 19 8 1
55020248KT 9 8 1 5961-0701 23 39 1 73820006KT 2 16 1 81020139KT 19 1 1
55020251KT 8 2 2 60020002KT 27 15 1 73820007KT 20 3 1 81020141KT 19 10 1
55020253KT 21 2 1 28 8 1 73820010KT 3 3 1 81020146KT 19 15 1

60020003KT
55020255KT 8 4 1 29 11 1 73820020KT 3 0 1 81020153KT 2 8 1
55020256KT 21 4 1 61020013KT 19 8 1 73820027KT 15 0 1 81020159KT 11 5 1
55020257KT 9 5 1 61020022KT 16 10 1 73820056KT 32 4 1 81020160KT 11 6 1
55020260KT 9 6 2 2 15 1 73820063KT 23 50 1 81020168KT 18 2 1

61020023KT
55020261KT 8 1 1 14 0 1 73860006KT 2 1 1 81020246KT 17 6 1
55020263KT 8 9 1 61020028KT 19 8 1 73920009KT 2 17 1 9 12 1

81120012KT
55020285KT 8 7 2 61020072KT 16 3 1 73920011KT 2 19 1 19 14 1
Part Number Table Item Qty Part Number Table Item Qty
81120021KT 9 17 1 C4675A 1 4 N.A.
2 15 1 C4676A 1 5 N.A.
81120025KT
14 0 1 C4677A 1 3 N.A.
81120042KT 11 1 1 C4682A 1 6 N.A.
81120046KT 21 3 1 C4683A 1 6 N.A.
81120051KT 9 3 1
26 8 1
8120-6302
31 14 1
81230003KT 18 1 1
81620008KT 3 0 1
2 25 1
81620012KT
21 1 1
81620021KT 3 2 1
9320-1915 23 45 1
C4000-13402 32 1 1
C4000-13403 32 1 1
23 46 1
C4000-60007
32 3 1
C4006A 1 8 N.A.
C4007A 1 9 N.A.
C4011A 1 1 N.A.
C4015A 1 2 N.A.

Page 70
Cut Sheet Printers
Maintenance Manual
Model C40D
E1195
HP Part No. C4672-90005
Notice
Hewlett-Packard makes no warranty of any kind with regard to this material, including,
but not limited to, the implied warranties of merchantability and fitness for a particular
purpose. Hewlett-Packard shall not be liable for errors contained herein or for incidental
or consequential damages in connection with the furnishing, performance, or use of this
material.
Hewlett-Packard assumes no responsibility for the use or reliability of its software on
equipment that is not furnished by Hewlett-Packard.
This document contains proprietary information which is protected by copyright. All
rights are reserved. No part of this document may be photocopied, reproduced, or trans-
lated to another language without the prior written consent of Hewlett-Packard Company.
The information contained in this document is subject to change without notice.
MS 44MC
Cupertino, CA 95014
Printing History
New editions are complete revisions of the manual. Update pages, which are issued
between editions, contain additional and replacement pages to be merged into the manual
by the customer. The date on the title page changes only when a new edition or a new
update is published. No information is incorporated into a reprinting unless it appears as a
prior update; the edition does not change when an update is incorporated.
The software code printed alongside the date indicates the version level of the software
product at the time the manual or update was issued. Many product updates and fixes do
not require manual changes and, conversely, manual corrections may be done without
accompanying product changes. Therefore, do not expect a one-to-one correspondence
between product updates and manual updates.
Edition 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .November 1995
Edition 2. . . . . . . . . . . . . . . . . . . . . . . . . . .June 1999
ii June 1999
Preface
The C40D Maintenance Manual contains all the information needed to maintain and ser-
vice Hewlett Packard C40D printers. The C40D printer series are high-speed, non-impact
printers utilizing electrophotographic imaging technology.
The information in this manual is for authorized field representatives who are familiar
with basic printer operations. It serves as a supplement to training classes and provides a
basis for discussion with regional field service engineers and customer support representa-
tives.
Using This Manual

This manual is organized into the following sections:
Section 1, Troubleshooting
Reviews the organization of the manual, the way the printer works, and how to trouble-
shoot the printer, including some standard procedures to follow when troubleshooting.
This chapter also includes a chart detailing exactly what each causes each error code, illus-
trations of all sensors in the printer, and a list of abbreviations used throughout the manual.
Section 2, TAG Cross- Reference Tables

Provides cross-reference tables; look up specific printer problem description (in either the
mechanical malfunction, error code, or print quality description tables), then turn to the
TAG indicated on the chart to troubleshoot the problem.
Section 3, Troubleshooting Analysis Guides

Detailed step-by-step procedures to help you isolate and resolve specific printer problems.
If you are not sure which TAG to start with, begin with the overview, TAG 001.
Section 4, Print Quality Samples

Shows print test patterns indicating specific problems, and referencing the TAG that treats
each problem.
Section 5, Diagnostic Tests

Reviews each printer software diagnostic.
Section 6, Wiring Diagrams and Electrical Data

Shows printer schematics and locations of individual components.
Section 7, Removal/Replacement Procedures

Outlines procedures to follow when removing and replacing printer parts, also called
FRUs (Field-Replaceable Units).
June 1999 iii

Section 8, Options
Provides information about the optional High Capacity Input and High Capacity Output
bins.
Section 9, General Printer Maintenance

Reviews printer maintenance procedures to complete during service calls.
Index
Provides a list of references to topics mentioned in this manual.
Other Manuals
The C-Series Illustrated Parts Catalog shows every FRU and CRU (customer-replaceable
unit) in the printer, including part number information. This information is frequently
updated.
The C40D Installation Manual, C4672-90007, guides you through unpacking, setup, test-
ing, and network configuration of your C40D printer.
The C40D Operator’s Manual, C4672-90006, contains all the information needed to oper-
ate Hewlett Packard C40D printers.
The C40D Technical Reference Manual, C4672-60012, is a complete guide to using fonts
and the PJL and PostScript emulations on the C40D. It also documents aspects of printer
usage in detail.
The Cut Sheet Printers Paper Specifications Guide, C4672-90002, explains the various
kinds of papers usable in the printer, how to care for them, and how to minimize paper-
related problems with the C40D.
Copyright ©1999 Hewlett Packard, Inc. All rights reserved.

November 1995
Please address any comments or questions with respect to this document to:
Publications Manager
MS 44MC
Cupertino, CA 95014
iv June 1999
Contents
Contents
Troubleshooting
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
The Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Paper Path and Cycle Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Simplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Sensors and Switches Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Sensor and Switch Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
General Troubleshooting Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
The Problem: Printer or Host?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Running Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Protocol Converters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Confirming Line Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Using the Troubleshooting Analysis Guide (TAG) . . . . . . . . . . . . . . . . . . . . 1-15
Sample TAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Standard Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Power-on-reset (POR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Checking Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Installing the Interlock By-pass Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Producing a Developed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Producing a Toner Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Completing a Service Call. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Error Message and Code Technical Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Error Code/TAG Cross-Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Print Quality/TAG Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Mechanical Malfunction/TAG Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Troubleshooting Analysis Guides

TAG 001: Troubleshooting a Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
TAG 002: Check Problem Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
TAG 010: Upper Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
June 1999 v
Contents
TAG 011: Lower Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

TAG 012: Upper Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
TAG 013: Lower Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
TAG 021: Paper Jam/Misfeed in Lower Cassette Area . . . . . . . . . . . . . . . . . . . . . 3-22
TAG 023: Paper Jam in the Output Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
TAG 025: Paper in Input Area Before Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
TAG 026: Paper in Output Area Before Printing. . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
TAG 030: Developer Bias Short/Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
TAG 031: Toner Patch Reference Level Incorrect. . . . . . . . . . . . . . . . . . . . . . . . . 3-39
TAG 035: Out of Toner or ADD TONER Indication . . . . . . . . . . . . . . . . . . . . . . 3-43
TAG 036: Developer Not Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
TAG 047: PC Life Data Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
TAG 048: Developer Life Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
TAG 050: Transfer Corona Circuit Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
TAG 055: Erase Lamp Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
TAG 070: Fuser Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
TAG 071: Open Fuser/Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
TAG 072: Fuser Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
TAG 098: -12 Vdc Power Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
TAG 100: VPCL Board Interface Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
TAG 130: Disk Drive Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
TAG 200: RIGS Internal Communication Malfunction. . . . . . . . . . . . . . . . . . . . . 3-95
TAG 201: RIGS-VPCL Interface Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97
TAG 405: RIGS Bit-Map RAM Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
TAG 500: +5 Vdc Power Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
vi June 1999
Contents

Wiring for the Upper Paper Size Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
Wiring for the Lower Paper Size Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
TAG 753: Async IO Communications Malfunction . . . . . . . . . . . . . . . . . . . . . . 3-128
TAG 754: Smart I/O Card Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
TAG 805: Black Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
TAG 807: Misregistered/Skewed Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-150

Sample 1: Good Quality Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Sample 2: Washout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Sample 3: Blank Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Sample 4: Light Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
June 1999 vii

Contents
Sample 5: Light Print With Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Sample 6: Voids or White Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Sample 7: Light Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Sample 8: Blank Vertical Bands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Sample 9: Light Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Sample 10: Black or Dark Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Sample 11: Dark Specks, Lines, or Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Sample 12: Dark Vertical Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Sample 14: Misregistration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Sample 16: Blurred Images or Characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Sample 17: Varying Print Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Sample 19: Residual Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Sample 20: Wrinkles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Sample 21: Fusing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Diagnostic Tests
How to Run Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Operator Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Upper Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Lower Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fuser Thermistor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Roller Clutch Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Counter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Jogging Motor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Photoconductor Seam Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Toner Supply Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Charge Corona Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Transfer Corona Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Erase Lamp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Toner Empty Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Negative Developer Bias Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Duplex Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Duplex Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Duplex Clutch Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Duplex Tray Paper-Guide Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
viii June 1999

Contents
High-Capacity Output (HCO) Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

High-Capacity Input (HCI) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
LED Printhead Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
RIGS Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Com. Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Display File Version Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Format Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Clear Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Disk Drive Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Printhead Circuit Board Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Connector (J/P) Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Connectors Inside the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Connectors Inside the Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Connectors on the Duplex Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Connectors Inside the Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Connectors Inside the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Connectors on the Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Connectors Inside the Back Cover (J/P2-14). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Connectors Inside the Back Cover (Continued) J/P 18-62 . . . . . . . . . . . . . . . . . . 6-19
Connectors Inside the Back Cover (Continued) J/P 64-85 . . . . . . . . . . . . . . . . . . 6-20
Connectors Inside the Back Cover (Continued) J/P 90-800 . . . . . . . . . . . . . . . . . 6-21
-12 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
+5 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
+12 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
+24 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Ground System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Host Interface Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
RS-232C Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Standard DCE to DTE RS-232C Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
DTE Host to Printer (Option 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
DTE Host to Printer (Option 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
IBM PC/XT to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
IBM PC/AT to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Macintosh Communication Port to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
June 1999 ix
Contents
Centronics Parallel Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

IBM Parallel to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Photoconductor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Back Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Right Side Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Vacuum Transport Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Operator Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Counter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
RIGS Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
VPCL Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Printhead Circuit Board (ARIF) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Hard Disk Drive Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Floppy and Hard Disk Drive Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Cooling Fan Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Toner Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
This space left blank intentionally. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
High Voltage Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Photoconductor Seam Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Photoconductor Rear Guide Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Power Control Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Upper Cassette Mount Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Lower Cassette Mount Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Upper Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Upper Paper Guide Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
x June 1999
Contents
ULower Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48

Cleaner Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
Upper Pick-Up Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
Pick-Up Roller Drive Idler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Pick-Up Roller Drive Gear Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
Exit Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Exit Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Erase Lamp Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78
EP Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Main Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
Main Gear Drive Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
“A” Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
June 1999 xi
Contents
“B” Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94

“C” Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-96
“C” Roller Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97
Duplex Route Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98
Duplex Paper Path Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
Options
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
1200-Sheet/2500-Sheet Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
Guide to Component Acronyms/Physical Locations. . . . . . . . . . . . . . . . . . . . . 8-4
Bench Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Prefeed Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
1200-Sheet Feeder Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Connection Diagram for 1200-Sheet/2500-Sheet Feeder. . . . . . . . . . . . . . . . . . . . . 8-8
Connection Diagram for 1200-Sheet /2500-Sheet Feeder . . . . . . . . . . . . . . . . . . . . 8-8
Input Control Board Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
1400-Sheet Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
Guide to Component Abbreviations/Physical Locations. . . . . . . . . . . . . . . . . 8-10
Bench Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Front View (cover removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Left Side View (left cover removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Rear Side View (cover removed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Top View (top cover removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Connection Diagram for the 1400-Sheet Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Output Control Board Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Tool Requirements: Service Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Tools/Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Printer/Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Printer Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Adjusting Paper Feed Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Adjusting Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
xii June 1999

Contents
Front View Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

Front View Lubrication Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Rear View Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Rear View Lubrication Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Top View Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Duplex Holding Tray Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Tune-Up Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
June 1999 xiii

Contents
xiv June 1999

Section 1
Troubleshooting
June 1999 Troubleshooting 1-1

Contents
Troubleshooting
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
The Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Paper Path and Cycle Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Simplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Sensors and Switches Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Sensor and Switch Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
General Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
The Problem: Printer or Host? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Running Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Protocol Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Confirming Line Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
Using the Troubleshooting Analysis Guide (TAG) . . . . . . . . . . . . . . . . . . . . . 1-15
Sample TAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
Power-on-reset (POR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
Checking Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
Installing the Interlock By-pass Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
Producing a Developed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18
Producing a Toner Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18
Completing a Service Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19
Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19
Error Message and Code Technical Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1-2 Troubleshooting June 1999

Theory of Operation
Section 1
Troubleshooting
The information in this Field Service Manual is directed toward authorized field represen-
tatives who are familiar with basic printer operations. It serves as a supplement to training
classes and provides a basis for discussion with regional field service engineers and cus-
tomer support representatives.
Theory of Operation
The printer uses an electrophotographic imaging system, which is based on LED array
technology. Two key components of the printer are the image generation system (RIGS)
controller and the printer control logic (AVPCL) board. A brief description of the function
of each of these components follows.
Risc Image Generation System (RIGS) controller: Each printer is equipped with an
RIGS controller, which provides the interface between the host computer, the AVPCL
board, the interface cards, and the disk drives.
Video Printer Control Logic (AVPCL) board: The AVPCL board directs the mechani-
cal functions of the printer and print cycle timing, and controls the LED printhead. The
AVPCL board also receives initial machine information, such as empty paper cassettes,
paper jams, and fuser problems.
The Printing Process

The illustration on the following page details the printing process. The numbers represent
the sequence of events from the time that the RIGS controller receives data, through the
production of a print image, to the preparation for another print.
1 Receiving data
Host data is received through the Signal Interface PCA and passed to the RISC Image
Generating System (RIGS) PCA, which temporarily stores the data in RAM. The data
may consist of information generated on the host computer and sent over the host
communication interface or it may consist of information generated by printer soft-
ware, such as a request for test prints or to print the directory of the hard disk.

Theory of Operation
2 Bit Image
The RIGS transforms the host file into a bit map image of 1s and 0s and stores them in
bitmap RAM.
3 Charging the photoconductor belt
When the IGS controller receives data, it causes the AVPCL board to turn on the main
motor, which rotates the photoconductor belt. As the photoconductor belt rotates, the
charge corona applies a high negative charge to it, which repels toner from the photo-
conductor belt.
4 Exposing the image
The negatively charged belt then passes the LED printhead, where the AVPCL drives
the LEDs on and off to discharge the areas of the belt at a density of 300 dots per inch.
The 1s in the memory turn the LEDs on; 0s turn the LEDs off. The discharged areas
create a latent mirror image of the print on the photoconductor belt.
5 Developing the image
As the photoconductor belt continues to rotate, it brings the latent image to the devel-
oper. A negative developer bias is applied to toner and the toner is transferred to the
surface of the photoconductor belt. The negatively charged toner (which clings to
small metal carrier beads) is attracted to the discharged areas of the belt; the carrier
beads do not transfer. The belt, with the developed image on its surface, then rotates
out of the developer. At this time you can remove the photoconductor belt and read
what is printed on it, which you may need to do when troubleshooting print problems.
6 Activating paper
As the image is being developed, a sheet of paper is transported to the photoconductor
belt. The AVPCL board controls this activity. A series of paper pick-up, feed, and tim-
ing rollers guide the paper so the developed image is properly registered with the lead-
ing edge of the sheet.
7 Transferring the image to the paper
Next, the paper contacts the surface of the photoconductor belt. Above the paper and
the belt is the transfer corona, which has a high positive charge, and attracts the devel-
oped image from the belt to the surface of the paper. At this point, you can remove the
printed image to verify print quality, but the toner is not yet fused.
8 Fusing the image to the paper
The vacuum transport advances the paper with the image to the fuser where heat and
pressure bond the toner to the paper. The print then arrives at the paper output tray.
9 Cleaning routine
After a print is made, the photoconductor belt must be cleaned for the next print. The
belt first passes the erase lamp where any remaining latent image is erased. The belt
continues to the cleaner where a charged brush rotates against the surface to remove
any residual toner. This toner is recycled to the developer for reuse.


Transfer Corona Vacuum Transport Fuser
6 7 8
Paper Input Paper
Output
Erase Lamp
9 Cleaner
Photoconductor
3
Charge Corona
Toner
4 LED Printhead
5
AVPCL RIGS Inter- HOST
face
Developer
2 1
The RIGS board signals the AVPCL board that a page of data is ready to be printed. When
this happens the following sequence takes place.
Simplex Printing
1 AVPCL software downloaded to the AVPCL board from the disk drive system turns
on the main motor.
2 The AVPCL board engages the paper pick clutch which causes the roller to feed a
sheet of paper.
3 The paper is passed to the feed roller where the AVPCL board has engaged the feed
roller clutch.
4 The feed roller passes the paper to the paper timing roller. Prior to reaching the paper
timing roller, the paper passes over the paper timing sensor. If the paper does not ener-
gize this sensor in a specified amount of time, a jam error (020/021) will occur. The
leading edge of the paper is registered against the paper timing roller. The paper tim-
ing clutch is engaged and the paper is passed over the photoconductor for transfer.
This registers the paper to the printer and the image to the paper. The paper timing
sensor also signals the AVCPL to begin sending data.
5 The AVPCL board engages the paper timing roller clutch and, at the same time, turns
on the transfer corona to provide a high positive voltage. The developed image on the
photoconductor comes in contact with the paper and the high positive voltage causes
the image to transfer to the paper.

6 Because the toner is not yet fixed to the paper, a vacuum transport assembly, gripping
the paper from the back side, moves the paper to the fuser, where heat and pressure
bond the toner to the paper.
7 Upon leaving the fuser, the paper comes in contact with the paper exit sensor. (If the
paper does not energize this sensor in a given amount of time after leaving the paper
timing sensor [step 4], a jam error (022) will occur.)
8 The exit roller moves the paper to the exit tray. (If the exit sensor is not cleared in a
specified amount of time, a jam error (023) will occur.)
Duplex Printing
When duplex is selected, the AVPCL board controls the paper motion with page schedul-
ing assistance from the RIGS board. The duplex page router is engaged. When in duplex
mode, it is important to note that the printer runs multiple pages through the paper path at
the same time to increase speed.
1 In a duplex job, the duplex router solenoid behind the fuser is engaged and mechanical
fingers route the paper to the duplex area. Also, the “A” roller clutch engages to turn
the “A” and “B” rollers (connected via a belt).
2 The paper upon passing through the “B” roller comes in contact with the duplex sen-
sor. (If the paper does not energize this sensor in a given amount of time, a jam error
(060) will occur.)
3 The “C” roller bidirectional motor turns on and passes the paper into the turnaround
tray. The paper sensor in the turnaround tray is activated and the paper is center regis-
tered. (If the paper does not energize this sensor in a given amount of time after leav-
ing the duplex sensor, a jam error (061) will occur.)

4 At this time the solenoid for the router at the turnaround tray engages so the paper can
be routed to be printed on the duplex side.
5 In a given amount of time after the paper energizes the paper sensor in the turnaround
tray, the bidirectional motor reverses and passes the paper to the paper timing roller.
(If the paper does not energize the paper timing sensor in a given amount of time after
leaving the turnaround sensor, a jam error (062) will occur.)
6 At this point, the same steps happen as during a simplex cycle.

Sensors and Switches Illustrations

The following pages illustrate the locations of the printer’s sensors and switches.
Sensor and Switch Listing
Sensor/Switch Name Page Sensor/Switch Name Page
Cassette paper present sensors, upper and 1-8 Paper exit sensor 1-10
lower
Cassette present micro switches, upper and 1-8 Paper full sensor 1-10
lower
Duplex registration sensor 1-8 Paper size sensors, upper and lower 1-9
Duplex paper path sensor 1-9 Paper timing sensor 1-9
Interlock switch, duplex cover 1-9 Photoconductor seam sensor 1-9
Interlock switch, front 1-11 Automatic toner control 1-10
Interlock switch, rear 1-9 Toner empty sensor 1-10
Interlock switch, top 1-10 Toner patch sensor 1-9
Front left view

Rear view
Left end view Top view
Developer right view

Front view

Top view
Developer left view

Right side view
Top left, duplex tray view

Troubleshooting
Front view
Troubleshooting
Throughout the printer’s life problems occur, such as when it produces poor quality prints
or malfunctions in another way. Use the tools provided in this manual to diagnose and
resolve printer problems. These tools include:
• The Troubleshooting Analysis Guide, which contains troubleshooting procedures
called TAGs. TAG 001: Troubleshooting a Problem explains how to use TAGs.
• Cross reference tables, which link error messages, print quality problems, and
mechanical malfunctions to specific TAGs.
• Print quality samples, which help identify a printing problem and its associated TAGs.
• Diagnostics, which can uncover a range of problems.
The next several pages review troubleshooting basics and standard procedures followed in
every troubleshooting session, including:
• Identifying whether a problem belongs to the printer or host
• Isolating protocol converter problems
• Running test prints
• Reading the error log
• Confirming line power
• Using TAGs
• Power-On Reset
• Installing the interlock by-pass tool
• Checking continuity
• Producing a developed image
• Producing a toner patch
• Completing a service call
• Clearing the error log

Troubleshooting
General Troubleshooting Tips

When a printer problem arises, swapping out all printer supplies may temporarily mask
the problem. This is an unsatisfactory, short-term, and expensive solution to correcting the
problem. Dust and other contamination, rather than printer supplies, are more often the
causes of problems. Clean consumable connectors, alignment guides, and areas before
changing consumables.
Many failures add excess toner to the printer’s engine. When you are advised to de-tone
the printer as part of a problem fix, run at least 200 test prints before deciding that the
problem is resolved.
When you replace the photoconductor, run at least 500 prints before checking print qual-
ity. This number of prints is required to “synch” the new PC belt to the developer.
The Problem: Printer or Host?

The printer is one component in a large host system. Before you start any troubleshooting,
make sure that the problem really belongs to the printer rather than to some other compo-
nent in the host system. Print quality problems and mechanical malfunctions are almost
always associated with the printer. However, host interface and software emulation prob-
lems can be caused by some other component of the host system even though, at first
glance, they appear to be printer problems. For instance, text printed in the wrong location
on a page, improper page breaks, and missing segments of data strongly indicate a host,
not a printer, problem.
The first step in troubleshooting any problem is to isolate the printer from the host system;
you can then run test prints. Producing test prints exercises the printer as a stand-alone
machine, ensuring that the basic printer software and all mechanical functions of the
printer are working.
Running Test Prints

2 Make sure “Ready” displays on the panel.
3 Press ONLINE.
4 Press MENU
5 Press h to highlight “Test Print”
6 Press e to select “Test Print”
7 Choose “Simplex” or “Duplex” (Duplex is the default. Press h to choose simplex.)
8 Press e to start. A directory of the boot device and multiple listings of fonts prints. A
continuous flow of the test pattern then prints.
9 To stop printing the test pattern, press f. The printer will print all test prints stored in
the printer’s buffer, then stop.
If the test pattern prints successfully, the problem probably originates with the host system
or a protocol converter connected to the host.

Troubleshooting
Protocol Converters
Many protocol converters have a self-test function or configuration mode that enables the
user to check the proper functioning of the control. You can reconnect the host interface
and ask the customer to exercise this function of the converter. If the printer receives data
and prints it (even if the output is garbled) the problem may belong to the host or the pro-
tocol converter.
Reading the Error Log

The formatted error log is maintained by the printer in a file named “Error.log.” You have
the option to print this log when you are at the same panel used to print test prints. See
“Running Test Prints” on page 1-12.
• The first section lists the numbers and text of the last 15 errors.
• The second section of the formatted log lists paper jams. A 3-digit error code (or
codes) is followed by the error text and a 4-digit number indicating how many times
the error has occurred since the error log was last cleared. (Clearing the error log is
described on page 1-19.)
• The third section provides a complete error history since the error log was last cleared.
Errors are listed in numeric order in the first column, with the number of times each
error occurred listed in the second column.
• The fourth section indicates the last error that required a power-on-reset (POR).
The error log is two pages long. This partial illustration shows the main components of the
log.

Troubleshooting
Confirming Line Power

Erratic printer problems can be caused by improper line power. As a rule, the voltage of
the outlet should be checked at installation. However, if you are unable to isolate an inter-
mittent problem, the power should be checked again. Consult your country’s national elec-
tric code for the proper procedures to check for acceptable voltages, as outlined on the
following chart.
Probe connections 120v printer 230v printer
red to AC hot 120v +/- 10% 230v +/- 10%

black to AC neutral
red to AC neutral 3 vac or less 3 vac or less

black to ground
red to AC hot 120v +/- 10% 230 +/- 10%

black to ground
Please see Section 5, Diagnostic Tests, for additional information about troubleshooting
specific printer problems.
Please see Section 6, Wiring Diagrams and Electrical Data, for additional information
about the printer’s electrical systems.

Troubleshooting

The Troubleshooting Analysis Guide provides problem-solving sequences to help you
identify and resolve printer problems. Each TAG addresses a particular symptom or error
message of the printer. The TAG number often matches an error message code displayed
on the printer’s operator panel.
TAG Number TAG Name Sample TAG

Error Message: All related error messages are listed here.
Possible Causes: All possible causes are listed here.
Possible Defects: All possible defective parts are listed here. (In no particular order.)
1 To start:
Starting • Disconnect all peripheral cables
actions
Yes/No
Question Is an error message displayed?
No: Run test prints, following the procedure outlined in Section 1, then repeat this step. If the
To Do answer is still no, refer to the mechanical malfunctions cross-reference chart in Section 2 to
determine which TAG to follow. Then turn to that TAG.

Did the power-on-reset end with an error message?
No: Continue.
Yes: Refer to the error message cross-reference table in Section 2, using either the code that dis-
played after steps 1 and 2, or if multiple error messages continue to appear, the first error mes-
sage that displays. Turn to the TAG associated with the message.
Each TAG walks through a comprehensive procedure specific to a single problem. As you
progress through a TAG and eliminate possible causes, you may be directed to another
step out of sequence in the same TAG or to another TAG altogether.
The TAG number and its title may be followed by a listing of possible error messages,
possible causes, or possible defective parts related to the TAG.
The TAG then directs you to perform certain tasks. Based on the results of these tasks, the
TAG poses questions that can be answered by either yes or no. For yes answers, you fol-
low one path; for no answers, follow another path. Some of the paths may lead you to
other TAGs, so that you can methodically diagnose and resolve problems. When you have
corrected a problem, you will be directed to TAG 002 to confirm that the problem has been
completely resolved and standard cleanup procedures observed.

Troubleshooting
If it’s not clear how to diagnose a problem you’re working on, follow the steps outlined in
TAG 001, which includes references to the cross reference tables contained in Section 2,
TAG Cross- Reference Tables. Or, you may turn directly to the tables to get started.
As you use TAGs, you will sometimes refer to other sections of this manual for additional
information:
• Section 4, Print Quality Samples, contains print quality samples you’ll use to compare
the customer’s test prints with flawed and good print samples.
• Section 5, Diagnostic Tests, outlines how to conduct printer diagnostic tests.
• Section 6, Wiring Diagrams and Electrical Data, provides all wiring and connector
diagrams.
• Section 7, Removal/Replacement Procedures, provides step-by-step procedures for
removing and replacing all field-replaceable parts on the printer.
• Section 8, Options, reviews printer options (HCI, HCO) information.
• Section 9, General Printer Maintenance, presents general printer maintenance proce-
dures.

Standard Procedures
Standard Procedures
While using the TAGs, you may be asked to perform some of the following procedures.
Specific instructions for completing these procedures are included here, rather than
repeated in the body of each TAG. Please read this information before following any TAG.
Power-on-reset (POR)
When directed to power-on-reset the printer:
2 Wait at least 5 seconds.
3 Turn the power back on.
Checking Continuity
Make sure the printer is turned off and the power disconnected. Failure to do so may
result in personal injury, equipment damage, or both.
To perform a continuity check:

1 Turn off the printer and disconnect the power cord.
2 Set your meter to the lowest ohm setting.
3 Interpret the results as follows:
• An infinite reading indicates an open circuit.
• A zero or specific reading indicates continuity.
4 To check an open or short circuit to ground:
• Turn off the printer and disconnect the power cord.
• Locate the circuit in question. (Refer to Section 6, Wiring Diagrams and Electrical
Data, for circuit locations.)
• Check all connectors and wiring on each side for corrosion, foreign objects, bent
pins, loose socket housings, and/or loose wires.
Installing the Interlock By-pass Tool

The interlock by-pass tool overrides the cover interlock switches, allowing you to operate
the printer with the covers open. The interlock by-pass tool is a white plastic, V-shaped
tool with two finger pads. To use the tool, open the cover and locate the interlock switch
(for locations, see illustrations in “Sensors and Switches Illustrations” on page 1-8).
Squeeze the tool between thumb and forefinger and insert it into the interlock switch.
The printer ships with two spare interlock by-pass tools concealed behind the right cover.
Replace them when you are finished using them.
Do not attempt to close the printer cover while the interlock by-pass tool is in place.

Standard Procedures
Producing a Developed Image

Producing a developed image helps determine where exactly in the print cycle a problem
may be occurring. To produce a developed image:
3 Run a series of test prints. See “Running Test Prints” on page 1-12.
4 As test patterns print, observe paper moving from the upper paper tray to the paper
timing roller where it pauses briefly.
5 As soon as a sheet of paper begins to move from the paper timing roller, remove the
interlock by-pass tool.
6 Remove the photoconductor.
7 Examine the photoconductor belt to verify that a developed image was produced.
Caution: Do not touch the surface of the photoconductor belt; this damages the belt
and results in poor print quality.
Producing a Toner Patch

To produce a toner patch:
4 Start running test prints. When the leading edge of the first print enters the fuser, wait
one second then remove the interlock by-pass tool.
Producing a toner patch on the photoconductor.

Standard Procedures
6 Examine the photoconductor to verify that a toner patch has been produced. You may
have to rotate the belt slightly to observe the patch.
Caution: Do not touch the surface of the photoconductor belt; this damages the belt
and results in poor print quality.
Completing a Service Call

After resolving any printer problem, complete the service call as follows:
1 Reassemble the printer.
2 Perform the every-call cleaning procedure, described in Section 9, General Printer
Maintenance.
4 Clear the error log. (See the procedure described next.)
5 Run test prints in both the simplex and duplex mode from both the upper and lower
paper cassettes.
6 Fill in the Repair/Maintenance record taped inside the front cover. Make sure the
problem description and steps taken to resolve the problem are clearly documented.
Clearing the Error Log

• Hold down the MENU and STATUS keys simultaneously as you turn the printer back
on. Wait for all three LEDs to come on. This takes approximately 30 seconds.
2 Press h to display the first available test.
3 Once a test name is displayed, use the h key to move through the available tests.
4 Press the h key until “Clear Error Log” shows on the display.
5 Press e to activate the procedure.
6 Press h to advance to the drive where the error log is maintained. This is usually the
boot drive.
7 Press h to clear the error log on the selected drive.
8 Press f to exit the procedure.
9 Confirm that the error log has been cleared.
10 Exit diagnostic mode (power-on reset)
11 Print the error log. All errors in all sections should be reset to zero.

Error Message and Code Technical Definitions

Error messages/codes are listed here alphanumerically. Sensor and switch locations
referred to throughout these descriptions are illustrated on page 1-8.
Type Message Description
MACHINE CHECK 1. There is no text associated with the error.

Unknown Error 2. The error is not included in the error look-up tables.
PAPER JAM AVPCL board detected that the paper being fed from the upper
020 Upper Cassette cassette did not reach the timing paper sensor within the allot-
ted time.
PAPER JAM AVPCL board detected that the paper being fed from the lower
021 Lower Cassette cassette did not reach the timing paper sensor within the allot-
ted time.
PAPER JAM AVPCL board detected that the timing paper sensor was acti-
022 Transfer/Fuser vated immediately after one of the covers were closed or the
leading edge of the paper did not activate the exit paper sen-
sor within the allotted time.
PAPER JAM AVPCL board detected that the exit paper sensor in the printer
023 At/Near Exit (or in the HCO if installed) did not deactivate within the allotted
time.
Paper Jams
PAPER JAM AVPCL board detected that the paper did not reach the HCO
024 At/Near HCO Exit exit paper sensor within the allotted time.
PAPER JAM AVPCL board detected that either the exit paper sensor (within
025 At/Near Input the printer) or the paper exit sensor (within the HCO) were acti-
vated immediately after one of the covers was closed.
PAPER JAM (HCO only). The paper exit sensor (within the HCO) did not
026 At/Near Output become activated or deactivated within the allotted time.
PAPER JAM The AVPCL board detected paper in the duplex area after
027 In Duplex Area clearing a jam.
PAPER JAM AVPCL board detected that the leading edge of the paper did
060 Duplex Roller not activate the BC sensor within the allotted time.
PAPER JAM AVPCL board detected that the trailing edge of the paper did
061 Duplex Path not deactivate the BC sensor within the allotted time.
PAPER JAM Paper picked from the registration tray did not reach the timing
062 Duplex Tray roller sensor within the allotted time.

MACHINE CHECK AVPCL board detected a signal from the toner patch sensor
TPS Too Low board indicating that the reference voltage level on the photo-
Error #031 conductor was too low.
TPS Too Light board indicating that the toner patch on the photoconductor
Toner Control Errors
Error #032 was too light.
MACHINE CHECK AVPCL board detected too many successive signals from the
TPS Signal Overload toner patch sensor board for a toner feed.
Error #033
MACHINE CHECK AVPCL board detected no developer electrical interlock signal

No Developer from the J25 connector.
Error #036
TPS Too High board indicating that the reference voltage level on the photo-
Error #037 conductor was too high.

MACHINE CHECK AVPCL board sensed that the signal from the photoconductor
No Signal from PSS seam sensor either was not of sufficient amplitude or did not
Error #040 show the proper timing.
MACHINE CHECK AVPCL board detected an abnormally high amount of current

PSS Sensor Shorted needed to drive the photoconductor seam sensor LED (within
Error #041 the photoconductor).
MACHINE CHECK AVPCL board detected an open connection to the photocon-

PSS Sensor Open ductor seam sensor LED (within the photoconductor).
Error #042
MACHINE CHECK AVPCL board non-volatile RAM error.

AVPCL NVRAM
OPC Rotation Errors
Error #043
MACHINE CHECK AVPCL board detected a signal from the high-voltage power
Charge Corona Open supply indicating that either the charge corona or transfer
Error #044 corona circuits have an open connection.
Charge Corona Short supply indicating an abnormally high load on the bias voltage
Error #045 to the charge corona.
MACHINE CHECK AVPCL board received invalid life data from the photoconduc-
PC Life Data Error tor serializer board.
Error #047
MACHINE CHECK AVPCL board received invalid life data received from the
Developer Life Error developer serializer board.
Error #048
MACHINE CHECK AVPCL board detected invalid data from either the photocon-
CRU Series Mismatch ductor or developer units. Verify that the CRUs are correct for
Error #049 this printer.
Transfer Corona Short supply indicating an abnormally high load on the bias voltage
Error #050 to the transfer corona.
HVPS Errors
Transfer Corona Open supply indicating an open connection in the transfer corona cir-
Error #051 cuit. (Diagnostic test only.)
MACHINE CHECK AVPCL board detected that the current needed to drive the
Eraser Lamp Error erase lamp assembly was either higher or lower than the spec-
Error #055 ified limits. (Diagnostic test only.)
MACHINE CHECK Duplex turnaround tray is not electrically connected to the

Duplex not installed printer. (Diagnostic test only.)
Error #069

MACHINE CHECK AVPCL board sensed, via the fuser thermistor, that the temper-
Fuser/Thermal Fuse ature of the fuser did not change within the allotted time.
Error #070
Fuser Control Errors
MACHINE CHECK AVPCL board sensed an open connection in the fuser ther-
No Fuser/Thermistor mistor circuit.
Error #071
MACHINE CHECK AVPCL board sensed that the resistance of the fuser ther-
Fuser Temp Too High mistor was too low indicating that the temperature of the fuser
Error #072 was higher than the specified limit.
MACHINE CHECK AVPCL board sensed that the resistance of the fuser ther-
Fuser Temp Too Low mistor was too high indicating that the temperature of the fuser
Error #073 was lower than the specified limit.
MACHINE CHECK AVPCL board detected a signal from the duplex control board
Jogger
#2 indicating that either the registration side sensor was acti-

Errors
Duplex Registration
Error #086 vated and would not deactivate or was deactivated and would
not activate after a command was sent to the duplex control
board #2 to turn on the resist motor.
MACHINE CHECK AVPCL board detected that the photoconductor is installed

Bad PC Type improperly, or is of the wrong type. Verify that the photocon-
Error #091 ductor is the correct type for the printer.
MACHINE CHECK AVPCL board detected that the developer is installed improp-
LVPS Errors
Bad Dev Type erly, or is of the wrong type. Verify that the developer is the cor-
Error #092 rect type for the printer.
MACHINE CHECK AVPCL board detected a signal from the RIGS board indicat-
+12 DC Power Failure ing the absence of +12 Vdc.
Error #097
MACHINE CHECK AVPCL board detected a signal from the RIGS board indicat-
+24 DC Power Failure ing the absence of +24 Vdc.
Error #099
MACHINE CHECK RIGS board detected an error when attempting to download

IML Error information to the AVPCL flash EPROM.
Error #130
MACHINE CHECK RIGS board detected an error from the AVPCL board during
AVPCL Error
Bad AVPCL ROM Checksum initial AVPCL diagnostic.

Error #140
AVPCL PIA1 Reset Fail initial AVPCL diagnostic.
Error #160
AVPCL PIA1 R/W at POR initial AVPCL diagnostic.
Error #161

AVPCL PIA1 Reset Fail initial AVPCL diagnostic.
Error #170
AVPCL PIA1 R/W at POR initial AVPCL diagnostic.
Error #171
AVPCL PTM Reset Fail initial AVPCL diagnostic.
Error #180
AVPCL PTM Read/Write initial AVPCL diagnostic.
Error #181
AVPCL PTM IRQ Failure initial AVPCL diagnostic.
Error #182
AVPCL Errors (cont.)
MACHINE CHECK RIGS board detected a fatal error from the AVPCL board dur-
I 2COppanel Fatal ing initial AVPCL diagnostic.
Error #260
2
I C Oppanel Warning initial AVPCL diagnostic.
Error #261
MACHINE CHECK RIGS board detected transmit failed, lost arbitration, with the
Transmit Failed control panel.
Error #270
MACHINE CHECK RIGS board detected transmit failed, no acknowledgment, with

Transmit Failed the control panel.
Error #271
MACHINE CHECK RIGS board detected transmit failed, bus always busy, with the
Transmit Failed control panel.
Error #272
MACHINE CHECK RIGS board detected a transmit error on the I2C bus, with the
Transmit Error control panel.
Error #273
MACHINE CHECK RIGS board detected I2C host not ready.
Error #274

MACHINE CHECK RIGS board detected receiver overruns.
Error #275
MACHINE CHECK RIGS board detected a framing error on receive.
Error #276
MACHINE CHECK RIGS board detected a receive overflow.
Error #277
MACHINE CHECK Control panel has failed to establish communication with the
RIGS board. Verify the cabling between the control panel, the
Error #278 RIGS board, and the AVCPL boards.
MACHINE CHECK Control panel has lost communication with the RIGS board.
Verify the cabling between the control panel, the RIGS board,
Error #280 and the AVCPL boards
MACHINE CHECK Invalid command sent to the operator panel.

AVPCL Errors (cont.)
Error #281
AVPCL No Data VSS High initial AVPCL diagnostic.
Error #301
AVPCL TS High VSS Low initial AVPCL diagnostic.
Error #302
TC High but not VSC initial AVPCL diagnostic.
Error #303
VSC high too long initial AVPCL diagnostic.
Error #304
AVPCL VSC Invalid initial AVPCL diagnostic.
Error #305
TS high and data xfr initial AVPCL diagnostic.
Error #306
AVPCL Parity Error initial AVPCL diagnostic.
Error #307

MACHINE CHECK RIGS board detected an error during the internal diagnostic
PCL Cmd Retry Error testing of the RIGS board.
Error #380
PCL Cmd Rejected testing of the RIGS board.
Error #381
PCL Sent Bad Cmd testing of the RIGS board.
Error #382
PCL Sent Bad Byte testing of the RIGS board.
Controller Errors
Error #383
PCL Got TS-No Status testing of the RIGS board.
Error #384
PCL SIB/Count Bad testing of the RIGS board.
Error #385
PCL Bad SIB Offset testing of the RIGS board.
Error #386
PCL Parity Error testing of the RIGS board.
Error #387
MACHINE CHECK RIGS board detected an internal software error.

Unknown Error
Error #397


Fatal Software Error
Error #398

Software Error
Error #399
Peripheral Bus Error testing of the peripheral bus.
Error #401
Controller Errors (cont.)
MACHINE CHECK RIGS board detected an error in the program RAM during the
RAM Bank Selection internal diagnostic testing of the RIGS board.
Error #405
RAM Bank 0 Address internal diagnostic testing of the RIGS board.
Error #406
RAM Bank 0 Refresh internal diagnostic testing of the RIGS board.
Error #407
RAM Bank 1 Address internal diagnostic testing of the RIGS board.
Error #408
RAM Bank 1 Refresh internal diagnostic testing of the RIGS board.
Error #409
Disk Drive Errors
Incorrect Diskette testing of the RIGS board and software.

Error #450
Floppy Format Error testing of the RIGS board and software.
Error #451
Fatal Software Trap testing of the RIGS board and software.
Controller Errors
Error #454
Software Trap testing of the RIGS board and software.
Error #455
PIT0 Invalid testing of the RIGS board and software.
Error #500

PIT0 Read/Write Error testing of the RIGS board and software.
Error #501
PIT0 No Countdown testing of the RIGS board and software.
Error #502
PIT0 No Timer Halt testing of the RIGS board and software.
Error #503
PIT0 No Timer Intr testing of the RIGS board and software.
Error #504
PIT2 Invalid testing of the RIGS board and software.
Error #505
PIT2 Read/Write Err. testing of the RIGS board and software.

Error #506
PIT2 No Countdown testing of the RIGS board and software.
Error #507
PIT2 No Timer Halt testing of the RIGS board and software.
Error #508
PIT2 No Timer Intr testing of the RIGS board and software.
Error #509
No DMAC Reset testing of the RIGS board and software.
Error #520
DMAC Read/Write testing of the RIGS board and software.
Error #521
No DMA Transfer testing of the RIGS board and software.
Error #522
No DMA Transfer End testing of the RIGS board and software.
Error #523

No End DMA Interrupt testing of the RIGS board and software.
Error #524
DMA Software Abort testing of the RIGS board and software.
Error #525
DMA Software Intr. testing of the RIGS board and software.
Error #526
DMA Operation Error testing of the RIGS board and software.
Error #527
DMA Transfer Error testing of the RIGS board and software.
Error #528
DMAC2 Transfer Error testing of the RIGS board and software.

Error #529
No DMAC2 Transfer testing of the RIGS board and software.
Error #530
AVPCL SCC register R/W testing of the RIGS SCC UART.
Error #540
AVPCL break detected testing of the RIGS SCC UART.
Error #541
AVPCL SCC xmit not testing of the RIGS SCC UART.
Error #542
No AVPCL SCC Transfer testing of the RIGS SCC UART.
Error #543
AVPCL SCC Transfer testing of the RIGS SCC UART.
Error #544
Host SCC R/W testing of the RIGS SCC UART.
Error #545

Host xmit not ready testing of the RIGS SCC UART.
Error #546
No TX/RX interrupt testing of the RIGS SCC UART.
Error #547
SCC HOST/AVPCL Parity testing of the RIGS SCC UART.
Error #548
SCC unexpected Intr. testing of the RIGS SCC UART.
Error #549
SCC Transmission testing of the RIGS board and software.
Error #550
No AVPCL SCC Interrupt testing of the RIGS board and software.

Error #551
SCC-DMAC Interaction testing of the RIGS board and software.
Error #552
SCC-DMAC Transfer # testing of the RIGS board and software.
Error #553
SCC-DMAC Transfer testing of the RIGS board and software.
Error #554
RS232 Send/Rcv testing of the RIGS board and software.
Error #555
RS232 DTR/DCD testing of the RIGS board and software.
Error #556
RS232 RTS/CTS testing of the RIGS board and software.
Error #557
RS422 Send/Rcv testing of the RIGS board and software.
Error #558

RS422 Send/Rcv Clock testing of the RIGS board and software.
Error #559
CRTC Read/Write testing of the RIGS board and software.
Error #560
No Page Begin Intr. testing of the RIGS board and software.
Error #561
CRTC Address testing of the RIGS board and software.
Error #562
No VSYNC Generation testing of the RIGS board and software.
Error #563
No End of Page Intr. testing of the RIGS board and software.
Error #564
No CRTC Termination testing of the RIGS board and software.
Error #565
VSYNC Timeout Error testing of the RIGS board and software.
Error #566
MACHINE CHECK RIGS board detected an error when communicating with the
FDC/SCSI Read/Write floppy disk drive.
Error #570
FDC Busy Timeout floppy disk drive.
Disk Drive Errors
Error #571
Write Protected floppy disk drive.
Error #572
Floppy Not Ready floppy disk drive.
Error #573
FDC Restore Error floppy disk drive.
Error #574

FDC Seek Error floppy disk drive.
Error #575
FDC Read Error floppy disk drive.
Error #576
FDC Checksum Error floppy disk drive.
Error #577
FDC Write Error floppy disk drive.
Error #578
FDC R-M-W-V Error floppy disk drive.
Error #579
Disk Drive Errors (cont.)
FDC/PIT0 Interrupt floppy disk drive.
Error #580
FDC/DMA Interaction floppy disk drive.
Error #581
FDC/DMAC Transfer floppy disk drive.
Error #582
FDC/DMAC Transfer # floppy disk drive.
Error #583
FDC/DMAC Read floppy disk drive.
Error #584
FDC/DMAC Write floppy disk drive.
Error #585
FDC/DMAC Operations floppy disk drive.
Error #586

MACHINE CHECK RIGS board detected an error during internal testing.

Bit Map RAM Data
Error #600

Bit Map RAM Bank
Error #601

Bit Map RAM Refresh
Controller Errors
Error #602

Bit Map RAM Address
Error #603

ALU Op in Bit RAM
Error #604

Width/Origin Fault
Error #605

BMRAM Bank Fault
Error #606
MACHINE CHECK RIGS board detected an error when communicating with a

Interface
Errors
Host SCC Error host using serial communications on the ASYNC flex IO card.
Error #701–#708
MACHINE CHECK RAM test failure during power-on diagnostics.

Controller
Error
Host SCC Error

Error #709

Host SCC Error host using serial communications on the ASYNC flex IO card.
Error #710–#722
Interface

Errors
Parallel Error host using parallel communications on the ASYNC flex IO

Error #725–#741 card.

Smart flex IO Card Error host using an intelligent flex IO card.
Error #745–#784


Section 2
TAG Cross-
Reference Tables
June 1999 2-1

2-2 June 1999
Section 2

This section contains the three cross reference charts for troubleshooting print problems:
• Error Code/TAG Cross-Reference
• Print Quality/TAG Cross-Reference
• Mechanical Malfunction/TAG Cross-Reference
June 1999 TAG Cross-Reference Tables 2-3


Error codes, which display on the operator’s panel, indicate a wide variety of printer prob-
lems related to the control boards, software, and/or host communication problems. On the
chart find the error code in question, then turn to TAG associated with the code.
010 Upper paper tray out of paper 010

011 Lower paper tray out of paper 011
012 Upper paper tray not plugged in 012
013 Lower paper tray not plugged in 013
020 Upper paper tray paper jam 020
021 Lower paper tray paper jam 021
022 Transfer or fuser area paper jam 022
023 Exit area paper jam 023
024 Paper jam at/near HCO exit 023
025 Transfer or fuser area paper jam not cleared 025
026 Exit area paper jam not cleared 026

027 Duplex area paper jam 902
030 Developer bias short 030
031 Toner patch sensor reference level too low 031
032 Toner patch sensor black patch too light 032
033 Toner patch sensor overload 032
035 Toner empty error 035
036 No developer 036
037 Toner patch sensor too high 031
040 Photoconductor seam sensor malfunction 040
041 Photoconductor seam sensor short 040
042 Photoconductor seam sensor open 040
044 Charge/transfer corona open 044

045 Charge corona short 045
047 PC life error. Bad PC CRU information 047
048 Developer life error. Bad developer CRU information 048

050 Transfer corona short 050
2-4 TAG Cross-Reference Tables June 1999

055 Eraser lamp malfunction 055
057 Fan stopped sensor 752

069 Duplex tray not plugged in 900

070 Fuser lamp or thermal fuse malfunction 070
071 Fuser thermistor open or no fuser 071
072 Fuser temperature too high 072
073 Fuser temperature too low 070

081 No front job offset sensor 083
082 No back job offset sensor 083
083 Job offset mechanism malfunction 083
084 Duplex tray registration sensor not activated 901
085 Duplex tray registration sensor not deactivated 901
086 Duplex registration tray malfunction 901

090 Cover open 900
098 DC -12v power failure 098
100 VPCL board command timeout 100
Code VPCL/RIGS Communication Error Codes Go to TAG
121 No controller command; VPCL board VSC command asserted 201
122 Command tag asserted; VSC command not asserted 201

123 VSS not asserted; VPCL board status tag asserted 201
124 VSS asserted after VPCL board sent status 201
125 VSS not asserted again though VPCL board expects it 201
126 Command tag asserted during data byte sequence 201
127 VPCL board detected parity/overrun on command line 201

Code VPCL Error Codes Go to TAG
130 Address or length error at initial microcode load 130

131 Checksum error at initial microcode load 130
132 RAM error at initial microcode load 100
133 No next block at initial microcode load 130

134 Incorrect format in initial microcode load file 130
140 VPCL board ROM checksum error at power on diagnostic 100
145 VPCL board RAM error at power on diagnostic 100
160 VPCL board PIA1 register error after reset 100
161 VPCL board PIA1 registers read/write error 100
162 VPCL board PIA1 PA or PB read/write error 100
170 VPCL board PIA2 register error after reset 100

171 VPCL board PIA2 register read/write error 100
172 VPCL board PIA2 PB read/write error 100
180 VPCL board PTM register error after reset 100
181 VPCL board PTM read/write error 100
182 No IRQ generation on PTM 100
199 VSS not asserted before communication test 201
200 Status tag not asserted 201
201 Timeout waiting for a failed RIGS controller 201
202 No data received after VSS line asserted 201
203 VSS asserted after VPCL board sent status 201

204 Status tag asserted after VSS not asserted 201
205 No command tag after status tag not asserted 201
206 VSC command not asserted after command tag asserted 201
207 No data received after VSC asserted 201
208 VSC command asserted after command line asserted 201
209 Command tag asserted after VSC not asserted 201

210 No RQI after “request RQI” command 201
211 Parity error on command line 201
212 Parity or overrun sensed by VPCL board 201
213 Incorrect command received from VPCL board 201
214 Incorrect command received from RIGS controller 201
215 No transfer buffer empty on asynchronous communications 201

interface adapter after VPCL board sent data
RIGS Firmware Error Codes

Code These error codes signal a problem with the RIGS controller firmware. Go to TAG
No TAGs address these problems; report to Hewlett-Packard.
301 Status received after VSS asserted No TAG
302 Status tag asserted after VSS not asserted No TAG

303 VSC command not asserted after command tag asserted No TAG
304 VSC command asserted after data was sent No TAG
305 VSC command not asserted for next data byte No TAG
306 Status tag asserted while data was being sent No TAG
307 Parity error on command line No TAG
Code VPCL Failure Error Codes Go to TAG
380 VPCL board failure – command retries 201
381 VPCL board failure – command rejected 201

382 VPCL board failure – bad command received 201
383 VPCL board failure – unexpected byte received 201
384 VPCL board failure – no status received 201
385 VPCL board failure – bad status information block count 201
386 VPCL board failure – bad status information block offset 201
387 VPCL board failure – parity error 201
389 Floppy disk retry 130

RIGS Software Code Meaning

These error codes indicate a problem with the RIGS controller
Codes software. No TAGs address these problems; to determine whether the Go to TAG
faulty software is the customer’s or the manufacturer’s, contact
Hewlett-Packard.
397 RIGS software trap No TAG
Codes RIGS/Disk Drive Error Codes Go to TAG
401 Fatal RIGS PB error No TAG
405 RIGS RAM error 201
450 Incorrect diskette 130
451 Diskette format error or incorrect disk 130
454 Fatal trap 200
455 Trap 200
504 No PIT0 timer interrupt 200
509 No PIT2/timer interrupt 200
520 No DMAC reset 200

521 DMAC registers read/write error 200

522 No DMA transfer 200
523 No DMA transfer termination 200
524 No DMAC termination interrupt 200

525 No software abort operation 200
526 No software abort interrupt 200
527 DMAC operation error 200

528 DMA transfer error 200
529 Two-channel DMA transfer error 200
530 No two-channel DMA transfer 200
540 VPCL board serial controller registers read/write error 200

541 VPCL board break condition detected 200
542 VPCL board serial controller transmitter not ready 200
543 No VPCL board serial controller transfer 200
544 VPCL board serial controller transfer error 200
545 Host serial controller registers read/write error 200
546 Host transmitter not ready 200

547 No serial controller interrupts 200
548 Host serial controller/VPCL board parity error 200
549 Serial controller unexpected interrupt 200
550 Two-channel transfer error 200
551 No VPCL board/serial controller interrupt on break 200
552 No serial controller/DMAC interaction 200
553 Serial controller/DMAC transfer count error 200
554 Serial controller/DMAC transfer error 200

556 RS232 DTR/DTC path error 200
557 RS232 RTS/CTS path error 200

559 RS422 send clock/receive clock path error 200
560 CRTC register read/write error 200
561 No page begin (PIT2) interrupt 200

562 No CRTC address generation 200
563 No VSYNC generation (end of page) 200
564 No end of page (PIT2) interrupt 200

565 No CRTC count termination 200
566 VSYNC timeout error 200
570 Drive controller/SCSI read/write error 200

571 Drive controller busy timeout 200
572 Diskette is write protected 130
573 Drive not ready 130
574 Drive controller restore error 130

575 Drive controller seek error 130
576 Drive controller read sector error 130
577 Drive controller read sector data/checksum error 200
578 Drive controller write sector error 200
579 Drive controller read/modify/write error 200
580 No drive controller/PIT0 interrupt 200

581 No drive controller-DMA interaction 200
582 Drive controller/DMAC transfer error 200
583 Drive controller/DMAC transfer count error 200
584 Drive controller/DMAC read sector error 200
585 Drive controller/DMAC write sector error 200
586 Drive hard error 130
Code Bit Map RAM Error Codes Go to TAG
600 Bit-map RAM data path error 200

601 Bit-map RAM bank selection error 200
602 Bit-map RAM refresh error 200
603 Bit-map RAM address path error 200
604 Incorrect ALU operation in bit-map RAM data path 200
605 Incorrect origin data modifications 200

Code Bit Map RAM Error Codes Go to TAG
606 Total bit-map RAM bank fault 405
610 Bit-map RAM chip error 405
Code Host Communication Error codes Go to TAG
701–741 Async flex IO error 753
745–755 Smart flex IO error 754


Poor quality prints are another indication of printer problems. Begin by running a set of
test prints. Then, compare the test prints to the samples located in Section 4, Print Quality
Samples. The chart below summarizes the possible print quality problems you may
encounter and recommends a TAG in Section 3 to follow to address the problem.
Blank Prints Go to TAG
Complete 800
Partial 800
With dark horizontal bands 800
Light Prints Go to TAG
With carrier particles 801
With background 811
With voids/white spots 802
With light vertical streaks 803
With blank or white vertical lines 803

With light horizontal bands 804
Dark Prints Go to TAG
Dark black prints 805
With dark spots or scratches 806
With dark blotches 810
With dark vertical streaks (without fusing) 812
With dark vertical streaks (with fusing) 808
Skewed Prints Go to TAG
Simplex 807
Duplex 901

Misregistration Go to TAG
Simplex 807
Duplex 901
Smeared, Blurred, Uneven Prints Go to TAG
Smeared vertical streaks 809
Blurred prints 809
Uneven density 810
Prints with background 811

Prints with background and residual 811
images
Prints with residual images 813
Prints with offset images 814
Additional Print Quality Problems Go to TAG
Wrinkled or torn prints 706
Prints improperly fused 812
Prints exhibiting printhead problems 815


The chart below outlines possible mechanical malfunctions and recommends an appropri-
ate TAG to follow to resolve the problem.
Operator Panel Problems Go to TAG
Blank with AC power fan and cooling fan on 500
Blank with AC power fan on 500

Blank with no fans on 600
All lights on 610
Incomplete display immediately after POR 610
“Close cover” displayed 600
Remove prints light remains on or lights 700
“Add toner” displayed 035
Machine check light is on with no numerical 201

Display
One or more lights are off at POR 610
Tone not working 610
Incorrect paper size 702

Other operator panel malfunctions 610
Output Tray Problems Go to TAG
Sensor not sensing condition 701
Jogging incorrectly 083
Will not stop jogging 083
Job offset incorrect 083
Cassette Problems Go to TAG
Upper cassette 703
Lower cassette 704

Paper Handling Problems Go to TAG
Multiple paper feed 705

Multiple sheet feeds and jams 705
Wrinkled or torn paper 706
Simplex: misregistration and paper skew 807

Duplex: misregistration and paper skew 901
Paper will not feed from upper cassette 012
Paper jam in duplex area 902
Upper paper guide not closing 707
Counter Problems Go to TAG
Supplies seem to have short life span 750

Incorrect counting 750
Communication Problems Go to TAG
Printer will produce test prints 753
Incorrect data being printed 753
Additional Mechanical Malfunctions Go to TAG
Test prints won’t run after POR 130
Cooling fan not running 752
Vacuum transport fan not running 752
Circuit breaker trip 600
Main drive motor not turning off 751


Section 3
Troubleshooting
Analysis Guides
(TAGs)
June 1999 Troubleshooting Analysis Guides (TAGs) 3-1

Contents
TAG 001: Troubleshooting a Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
TAG 002: Check Problem Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
TAG 010: Upper Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
TAG 011: Lower Cassette Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
TAG 012: Upper Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
TAG 013: Lower Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
TAG 021: Paper Jam/Misfeed in Lower Cassette Area . . . . . . . . . . . . . . . . . . . . .3-22
TAG 023: Paper Jam in the Output Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
TAG 025: Paper in Input Area Before Printing . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
TAG 026: Paper in Output Area Before Printing. . . . . . . . . . . . . . . . . . . . . . . . . .3-34
TAG 030: Developer Bias Short/Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
TAG 031: Toner Patch Reference Level Incorrect. . . . . . . . . . . . . . . . . . . . . . . . . 3-39
TAG 035: Out of Toner or ADD TONER Indication . . . . . . . . . . . . . . . . . . . . . .3-43
TAG 036: Developer Not Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
TAG 047: PC Life Data Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
TAG 048: Developer Life Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55
TAG 050: Transfer Corona Circuit Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
TAG 055: Erase Lamp Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-58
TAG 070: Fuser Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60
TAG 071: Open Fuser/Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
TAG 072: Fuser Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66
TAG 098: -12 Vdc Power Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-78
TAG 100: VPCL Board Interface Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . .3-89
3-2 Troubleshooting Analysis Guides (TAGs) June 1999

TAG 130: Disk Drive Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
TAG 200: RIGS Internal Communication Malfunction . . . . . . . . . . . . . . . . . . . . 3-95
TAG 201: RIGS-VPCL Interface Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97
TAG 405: RIGS Bit-Map RAM Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
TAG 500: +5 Vdc Power Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
TAG 753: Async I/O Communications Malfunction. . . . . . . . . . . . . . . . . . . . . . 3-128
TAG 754: Smart I/O Card Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
TAG 805: Black Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
TAG 807: Misregistered/Skewed Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-150
June 1999 Troubleshooting Analysis Guides (TAGs) 3-3

Section 3

The Troubleshooting Analysis Guides (TAGs) contained in this section outline each of the
TAGs used to diagnose and resolve specific printer problems related to error messages,
print quality, and mechanical malfunctions. An overview of how the TAGs are organized
and how to use them is included in “Print Quality/TAG Cross-Reference” on page 2-12. If
you are using a TAG for the first time, please refer to this section for more specific instruc-
tions. Also note that Section 2, TAG Cross- Reference Tables, provides comprehensive
charts which cross reference specific error messages, print quality problems, and mechan-
ical malfunctions to the TAGs contained in this section.
As you use these TAGs, you may need to refer to other sections of this manual for addi-
tional information. Please turn to these sections as required.
The shorthand convention “MC” is used in place of the words “Machine Check” when
error messages that include this text are shown.
3-4 Troubleshooting Analysis Guides June 1999


If you are not sure how to troubleshoot a printer problem, start with this TAG. This and all TAGs
assume you are familiar with standard procedures, such as power-on-reset, presented in Section 1,
Troubleshooting. In addition, TAGs may refer you to Section 2, TAG Cross- Reference Tables
which contains:
• Error message cross-reference table
Arranged by error message; refers you to the TAG associated with the message.
• Print quality cross-reference table
Arranged by description of print-quality problem; refers you to the TAG
associated with the problem.
• Mechanical malfunction cross-reference table
Arranged by description of the mechanical malfunction; refers you to the TAG associated with
the malfunction.
1 To start:
• Disconnect all peripheral cables.
Did the printer display an error message?
No: Run test prints, following the procedure outlined in Section 1, Troubleshooting then repeat
this step. If the answer is still no, refer to the mechanical malfunctions cross-reference chart in
Section 2, TAG Cross- Reference Tables to determine which TAG to follow. Then turn to that
TAG.

Did the power-on-reset end with an error message?
No: Continue.
Yes: Refer to the error message cross-reference table in Section 2, TAG Cross- Reference Tables
using either the message that displayed after steps 1 and 2, or if multiple error messages con-
tinue to appear, the first error message that displays. Turn to the TAG associated with the mes-
sage.
3 Did the printer READY light come on with no error message?

No: Continue.
Yes: Go to TAG 753.
4 Run test prints from the upper cassette by completing the following:
Did an error message appear while running the prints?
No: Continue.
Yes: Look up the message in the error message cross-reference chart to determine which TAG to
follow, then turn to that TAG.
June 1999 Troubleshooting Analysis Guides 3-5

5 Run test prints from the lower cassette by completing the following:
• Press STOP and allow the cycle to finish.
Did an error message appear while running test prints?
No: Continue.
Yes: Look up the message in the error message cross-reference chart to determine which TAG to
follow, then turn to that TAG.
6 Check communications by completing the following:

• Turn the printer off.
• Reinstall the upper cassette.
Does the job fail?
No: Continue.
Yes: Go to TAG 753.
7 Complete the following:

Does an error message appear?
No: Continue.
Yes: Look up the message in the error message cross-reference chart, then turn to TAG indicated in
the chart.
8 Run a job which is known to be good.

• Compare the output from the problem print job to the output from the good print job.
Can you identify the problem?
No: Return to the beginning of the TAG, following the procedures carefully to determine the kind
of problem your customer has.
Yes: Identify the problem as either a print quality problem or a mechanical malfunction, find the
problem in the appropriate cross-reference chart, identify a TAG addressing that problem,
then turn to that TAG.

TAG 002: Check Problem Resolution

Follow the procedure outlined in this TAG when you have completed an action to resolve a
problem, and are sent to this TAG from another TAG.
1 Complete any actions directing you to this TAG.

• Make sure all connectors, covers, parts, and hardware have been reinstalled.
In the course of resolving the printer problem, did you complete the every-call cleaning pro-
cedure?
No: Continue.
2 Clean the printer thoroughly, following the every-call cleaning procedure described below.
1 Remove these major printer supplies:
• Photoconductor; place it in its protective packaging
• Cleaner
• Developer
• Fuser
2 Inspect and vacuum the printer:
• Inspect the areas in the printer around the developer, cleaner, photoconductor, and fuser for
damage and wear.
3 Clean internal areas:
4 Inspect and clean the fuser:
Caution! The fuser may be hot.
• Inspect the fuser for damage and contamination; repair or replace as necessary.
• Clean the fuser connector, both on the fuser and in the printer, with a cotton swab.
• Vacuum in and around the rollers to remove excess toner, contamination, and any foreign
objects.
• Reinstall the fuser.
5 Inspect and clean the developer:
• Inspect the developer for damage or contamination; repair or replace as necessary.
• Clean any excess toner from the developer with a soft cloth.
• Clean the toner patch sensor lens with a cotton swab, making sure no lint remains on the
lens.
• Vacuum the felt areas around the magnetic roller, being careful not to vacuum toner from
the magnetic roller.
• Reinstall the developer.
Inspect and clean the cleaner/charge corona:
Caution! Handle gently to avoid breaking the charger wire.
• Inspect the charger wire for damage or contamination; repair or replace as necessary.
• Remove the charge corona from the cleaner.
• Remove the grid to expose the charger wire.
• Clean the charger wire with a cotton swab or charger cleaning tool.
• Clean any excess toner from the cleaner with a soft cloth.

• Reinstall the charge corona in the cleaner.

• Reinstall the cleaner.
6 Clean and inspect the photoconductor area:
Caution! Do not touch the photoconductor belt, as this permanently damages it.
• Clean the photoconductor seam sensor inside the printer with a cotton swab or compressed
air.
• Inspect the photoconductor for damage or contamination; repair or replace as necessary.
7 Clean the transfer corona:
Caution! Handle gently to avoid breaking the charger wire.
Have you completed the every-call cleaning procedure?
No: Complete the procedure, then continue.
Yes: Continue.
3 Run test prints to confirm print quality, in both simplex and duplex modes and from upper and
lower paper cassettes. When you enter test print mode by pressing the keys listed below, the follow-
ing items print: a directory of the boot device and multiple listings of fonts; a continuous flow of
test prints.
To run test prints:
2 Make sure “Ready” displays on the panel.
3 Press ONLINE.
4 Press MENU
5 Press h to highlight “Test Print”
6 Press e to select “Test Print”
7 Choose “Simplex” or “Duplex” (Duplex is the default. Press h to choose simplex.)
8 Press e to start. A directory of the boot device and multiple listings of fonts prints. A continu-
ous flow of the test pattern then prints.
9 To stop printing the test pattern, press f. The printer will print all test prints stored in the
printer’s buffer, then stop.
If the test pattern prints successfully, the problem probably originates with the host system or a pro-
tocol converter connected to the host.
Are the test prints clean and printing correctly?
No: Go to Section 4, Print Quality Samples to identify a sample with the problem you see in the
test print, then turn to the TAG indicated.
Yes: Continue.

4 Clear the error log:

a Turn off the printer and wait 5 seconds.
b Hold down the MENU and STATUS keys simultaneously as you turn the printer back on.
Wait for all three LEDs to come on. This takes approximately 30 seconds.
2 Press e to display the first available test. Once a test name is displayed, you use the h key to
move through the available tests.
a Press h until “Clear Error Log” shows on the display.
3 Press e to activate the procedure.
4 Press: e to advance to the drive where the error log is maintained. This is usually the boot
drive.
5 Press: e to clear the error log on the selected drive.
6 Press: f to exit the procedure.
7 Confirm that the error log has been cleared. Exit diagnostic mode (POR) and print the error
log. All errors in all sections should be reset to zero.
Do the error log entries appear as 0000?
No: Return to the beginning of this step.
Yes: Continue.
5 Fill in the Repair/Maintenance record taped inside the printer’s front cover.
• Make sure the problem description and steps taken to resolve the problem are clearly
documented.
• Reinstall all connectors, covers, parts, and hardware.
You have successfully resolved the printer’s problem. Congratulations!

ERROR MESSAGE:FALSE “UPPER CASSETTE EMPTY” MESSAGE

Possible Defects (not listed in any particular order):

Upper paper empty actuator
Upper cassette tray
Spring
Connectors/wiring
VPCL board
1 Make sure paper is in the upper cassette.

Is a false “UPPER CASSETTE EMPTY” message displayed?
No: The paper was loaded incorrectly. Turn to TAG 002.
Yes: Continue.
2 Check upper cassette:

• Inspect the upper paper empty sensor actuator for binding, or for a damaged or broken part.
No: Replace the actuator, then turn to TAG 002.
Yes: Continue.
3 Power-on-reset the printer

Is a false “UPPER CASSETTE EMPTY” message displayed?
No: The upper paper empty sensor was bad.
Yes: Reinstall the old upper paper empty sensor and continue.

4 Check pressure lever:

• Cassette tray
• Damper assembly
Replace the defective part, then turn to TAG 002.
Yes: Replace the VPCL board, then turn to TAG 002.

ERROR MESSAGE:FALSE “LOWER CASSETTE EMPTY” MESSAGE


Lower paper empty actuator
Lower cassette tray
Lower cassette release lever
Spring
Connectors/wiring
VPCL board
1 Make sure paper is in the lower cassette.

Is a false “LOWER CASSETTE EMPTY” message displayed?
No: The paper was loaded incorrectly. Turn to TAG 002
Yes: Continue.

• Inspect the lower paper empty sensor actuator for binding, or for a damaged or broken part.
Yes: Continue.
3 Power-on-reset the printer

Is a false “LOWER CASSETTE EMPTY” message displayed?
No: The lower paper empty sensor was bad.
Yes: Reinstall the old lower paper empty sensor and continue.

4 Reinsert the lower cassette.

• Cassette tray
• Lower cassette release lever
• Replace the defective part, then turn to TAG 002.

ERROR MESSAGE:FALSE “UPPER CASSETTE NOT LATCHED” MESSAGE

Spring
Upper cassette
VPCL board

No: Continue.
2 Check for damage:

• Spring
Yes: Replace the damaged parts, then turn to TAG 002.

• Make sure the upper cassette in switch actuator is functioning properly.
Yes: Continue.

4 Run diagnostic test “Upper Cassette Test” on page 5-4.

Is UPPER CASSETTE TEST “NO CASSETTE” displayed?
No: Replace the VPCL board, then turn to TAG 002.
Yes: Continue.
5 Install the upper cassette.

Is a message other than “NO CASSETTE” displayed?
No: Continue.

No: Replace the upper cassette in switch or wire hardness W58, then turn to TAG 002.
Yes: Continue.
7 Reconnect J/P46.
Yes: Continue.

No: Continue.
Yes: Replace the upper paper size sensor assembly. If this does not resolve the
problem, replace the VPCL board. Turn to TAG 002.


No: Replace lower paper size sensor assembly, then turn to TAG 002.
Yes: Repair or replace the connectors or wiring from
P45-3 to P47-3,
P43-8 to J52-3, or
P40-48 to P52-3.
If this does not resolve the problem, replace the upper
paper size sensor assembly. Then turn to TAG 002

P45-2 to P47-2,
P43-9 to J52-2 or
P40-49 to P52-2.
If this does not resolve the problem, replace the upper paper
size sensor assembly. Then turn to TAG 002

ERROR MESSAGE:FALSE “LOWER CASSETTE NOT LATCHED” MESSAGE

Lower cassette in latch
Spring
Lower cassette
Lower cassette in switch
VPCL board

Is the lower cassette properly latched?
No: Continue.

• Lower cassette in latch
• Spring

• Make sure the lower cassette in switch actuator is functioning properly.
Yes: Continue.
4 Run self diagnostic test “Lower Cassette Test” on page 5-5.

• Is LOWER CASSETTE TEST “NO CASSETTE” displayed?
Yes: Continue.

5 Install the lower cassette.

Is a message other than “NO CASSETTE” displayed?
No: Continue.

No: Replace the lower cassette in switch or wire harness W59, then turn to TAG 002.
Yes: Continue.
7 Reconnect J/P48.
No: Repair or replace the connectors or wiring from
P43-10 to J52-1 or
P40-50 to P52-1.
Then turn to TAG 002.
Yes: Continue.

P43-8 to J52-3 or
P40-48 to P52-3.
Yes: Replace the lower paper size sensor assembly. If this does not resolve
the problem, replace the VPCL board. Then turn to TAG 002.

ERROR MESSAGE:PAPER JAM 020 UPPER CASSETTE


Upper pick-up roller drive assembly
Upper paper cassette
Paper timing sensor
VPCL board
1 Check both paper paths and remove any paper jams.

• Make sure the upper pick-up roller, feed roller, and pinch roller assemblies are clean.
• Confirm that the paper in the cassettes meets paper specifications.
Is error message PAPER JAM 020 UPPER CASSETTE still displayed?
Yes: Continue.
• Upper pick-up roller drive assembly
No: Replace any damaged parts, then turn to TAG 002.
Yes: Continue.


Is error message PAPER JAM 021 LOWER CASSETTE displayed?
Yes: Continue.

No: Replace the paper timing guide assembly, then turn to TAG 002.
Yes: Continue.
5 Replace the paper timing guide assembly.

Is error message PAPER JAM 020 UPPER CASSETTE still displayed?
No: Turn to TAG 002.
Yes: Reinstall the old paper timing guide assembly and continue.

No: Continue.

No: Replace the DC power supply, then turn to TAG 002.
Yes: Repair or replace the connectors or wiring from P91-1 to P8-13, then turn to TAG 002.

P40-16 to P57-2,
P40-25 to P57-1, and
P40-12 to P57-3.
P40-25 to J/P58-1 to P57-1,
P40-16 to J/P58-2 to P57-2, or
P40-12 to J/P58-3 to P57-3.
Yes: Replace the paper timing guide. If this does not resolve the problem, replace the VPCL board.


• Remove the paper feed cover to expose the upper paper pick roller assembly.
Use extreme caution as gears and belts are exposed.
• Run diagnostic test “Roller Clutch Tests” on page 5-7 to test the upper pick-up roller clutch.
• Check P66 for a voltage change from +24 Vdc to 0 Vdc.
No: Continue.

P40-9 to J68-2 or
P40-11 to J68-1.
Yes: Replace the upper pick-up roller assembly, then turn to TAG 002.

No: Repair or replace connectors or wiring from
P40-6 to J66-2 or
P40-11 to J66-1.
Yes: Replace the upper feed roller assembly, then turn to TAG 002.
12 Inspect the upper pick-up roller assembly for damage or binding.

No: Replace the upper pick-up roller assembly, then turn to TAG 002.
Yes: Continue.
13 Inspect the upper feed roller assembly for damage or binding.

No: Replace the upper feed roller assembly, then turn to TAG 002.
Yes: The upper pick-up roller or the feed rollers may not be delivering paper to the paper timing
sensor at the correct time. Return to the beginning of this TAG.

TAG 021: Paper Jam/Misfeed in Lower Cassette Area
ERROR MESSAGE:PAPER JAM 021 LOWER CASSETTE


Lower pick-up roller drive assembly
Lower paper cassette
Idler assembly
Paper timing sensor
VPCL board
1 Check both paper paths and remove any jams.

• Check that the pick-up roller, feed roller, and backup roller assemblies are clean.
• Confirm that the paper in the cassettes meets paper specifications, outlined in the HP 5000 Cut
Sheet Printers Paper Specifications Guide, C4672-90002.
Is error message PAPER JAM 021 LOWER CASSETTE displayed?
Yes: Continue.

• Lower pick-up roller drive assembly
No: Replace the damaged parts, then turn to TAG 002.
Yes: Continue.

Is error message PAPER JAM 020 UPPER CASSETTE displayed?
Yes: Continue.

No: Replace the paper timing guide assembly, then turn to TAG 002.
Yes: Continue.
5 Replace the paper timing guide assembly.

Is error message PAPER JAM 021 LOWER CASSETTE still displayed?
Yes: Reinstall the old paper timing guide assembly and continue.

No: Continue.



P40-16 to P57-2,
P40-25 to P57-1, and
P40-12 to P57-3.
Is there ground?
P40-25 to J/P58-1 to P57-1,
P40-16 to J/P58-2 to P57-2, or
P40-12 to J/P58-3 to P57-3.
Yes: Replace the paper timing guide. If this does not correct the problem, replace the VPCL board.

• Remove the paper feed cover to expose the lower paper pick-up assembly.
Use extreme caution as gears and belts are exposed.
• Run diagnostic test “Roller Clutch Tests” on page 5-7 to test the lower pick-up roller clutch.
No: Continue.

P40-8 to J69-2 or
P40-10 to J69-1.
Yes: Replace the lower pick-up roller assembly, then turn to TAG 002.

P40-5 to J67-2 or
P40-11 to J67-1.
Yes: Replace the lower feed roller assembly, then turn to TAG 002.

12 Inspect the lower pick-up roller assembly for damage or binding.

No: Replace the lower pick-up roller assembly, then turn to TAG 002.
Yes: Continue.
13 Inspect the lower feed roller assembly for damage or binding.

No: Replace the lower feed roller assembly, then turn to TAG 002.
Yes: The lower pick-up roller or lower feed roller may not be delivering the paper to the paper tim-
ing sensor at the correct time. Return to the beginning of this TAG.

ERROR MESSAGE:PAPER JAM 022 TRANSFER/FUSER


Fuser
Paper supply
Fuser drive assembly
Fuser drive belt
Vacuum transport
VPCL board
When clearing this jam, be careful not to get toner on your clothing, as it may stain. If toner
gets on your clothes, rinse your clothes with cold water immediately to avoid stains.
1 Check the paper path and remove any jammed paper.

Caution! The fuser may be very hot. Use caution when you:
• Check the fuser for paper wrapped around the heat roller.
Is paper wrapped around the heat roller?
No: Continue.
Yes: If the paper is black or very dark with no printing, go to TAG 805. If the paper is very dark
and does have printing, go to TAG 811.
2 Check both paper paths for damage or obstructions.

• Confirm that J/P13, J/P22, J/P40, J/P58, and J/P65 are connected properly.
• Check that the paper is properly loaded.
• Check that the fuser is installed properly.
Is error message PAPER JAM 022 TRANSFER/FUSER still displayed?
No: Paper incorrectly loaded, incorrect paper type in use, or a loose connector was at fault. Turn to
TAG 002.
Yes: Continue.

3 Has the fuser been replaced recently?

No: Continue.
4 Replace the fuser.

No: Reinstall the original fuser and continue.
Yes: The fuser was at fault. Turn to TAG 002.

No: Continue.
Yes: Replace the damaged part, then turn to TAG 002.
6 Is more than one sheet of paper jamming?

Yes: Continue.
7 Make sure the natural curl of the paper is turned up in the cassettes.
Does the multiple feed problem still exist?
No: The paper appears to be at fault. Turn to TAG 002.
Yes: Adjust the paper tension lever or pick pressure, as outlined in Section 9, General Printer
Maintenance, then turn to TAG 002.
8 Check the paper path for jams.

• Open the printer’s front cover and insert the interlock bypass tool.
• Watch the end of the paper timing roller shaft.
Does the paper timing roller shaft turn?
No: Continue.


No: Continue.

Yes: Repair or replace the connectors or wiring from P91-1 to P8-13, then
turn to TAG 002.
11 Run diagnostic test “Roller Clutch Tests” on page 5-7 to test the paper timing roller clutch.
No: Continue.

No: Repair or replace the connectors and wiring from:
P40-7 to J65-2 or
P40-11 to J65-1.
Yes: Replace the paper timing roller assembly, then turn to TAG 002.
13 Does paper stop or jam either before or during entry into the fuser?
Yes: Continue.
14 Remove the fuser.

• Check the fuser rollers for damage or toner contamination.
Are they damaged or contaminated with toner?
No: Continue.
Yes: Replace the fuser, then turn to TAG 002.

• fuser


• Check for paper jams.
• Inspect the exit roller, and exit pinch roller assemblies for damage, binding and contamination.
Are these parts in good working order?
No: Repair or replace the defective parts, then turn to TAG 002.
Yes: Continue.
17 Run test prints.

• Check the leading edge of the prints for improper registration.
Is there improper registration?
No: Continue.
Yes: Go to TAG 807 or TAG 901.
18 Inspect the vacuum transport for damage or binding.

Are the parts in good working order?
No: Repair or replace the vacuum transport, then turn to TAG 002.
Yes: Continue.

• While the main motor is running, cover all of the holes in the vacuum transport with a piece of
paper.
Does the vacuum transport fan hold the paper in place?
No: Continue.
20 ! Use extreme caution: Check for 100 Vac from J/P22-1 to J/P22-2.
No: Continue.
Yes: Replace the vacuum transport assembly.

! Use extreme caution:
• While the main motor is running, monitor J/P13-6 and J/P13-3 for 100 Vac.
No: Replace the power control board, then turn to TAG 002.
Yes: Repair or replace the connectors or wiring from J22-1 to P13-6 or J22-2 to P13-3. Then turn to
TAG 002.

ERROR MESSAGE:PAPER JAM 023 AT/NEAR EXIT
Possible Causes: Paper path obstruction

Output tray obstruction

Exit paper sensor
Fuser drive
VPCL board
If the printer has a high capacity output unit (HCO), unplug and remove it before you begin.
Test the printer without the HCO; if the problem remains, proceed with this TAG. If the prob-
lem occurs only with the HCO, the HCO is causing the problem. Repair or replace the HCO.

• Check the output tray and remove any paper jams.
Is error message PAPER JAM 023 AT/NEAR EXIT displayed?
No: Loose connectors or obstructions were at fault. Turn to TAG 002.
Yes: Continue.
2 Is paper stopped or jammed at the output tray?

No: Continue.
3 Inspect the exit paper sensor actuator for damage or binding.

No: Repair or replace the exit paper sensor actuator, then turn to TAG 002.
Yes: Continue.


P40-24 to P49-2,
P40-26 to P49-1, and
P40-13 to P49-3.
P40-26 to J/P50-1 to P49-1,
P40-24 to J/P50-2 to P49-2, or
P40-13 to J/P50-3 to P49-3.
Yes: Replace the exit paper sensor.

• Open the back cover and install an interlock bypass tool.
• Remove the fuser drive cover.
• Inspect the following for damage, binding, or contamination:
• Exit roller assembly
• Exit roller drive gear
• Exit pinch roller assembly
No: Replace the defective parts, then turn to TAG 002.
Yes: Continue.
6 Remove the fuser.

• Inspect the following for damage or binding:
Yes: Reinstall the fuser and continue.
7 Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8.

• Watch the fuser drive and the exit roller assembly.
Yes: Replace the fuser, then turn to TAG 002.

ERROR MESSAGE:PAPER JAM 025 AT/NEAR INPUT

Paper timing sensor
VPCL board

No: Replace the paper timing guide assembly and continue.
Yes: Continue.

Is error message PAPER JAM 025 AT/NEAR INPUT displayed?
No: Jammed paper, loose connectors, or the sensor actuator were at fault. Turn to TAG 002.
Yes: Continue.
3 Replace the VPCL board.

Is error message PAPER JAM 025 AT/NEAR INPUT displayed?
Yes: Reinstall the old VPCL board and continue.
4 Loosen the paper timing guide.

Is J/P57 connected properly?
No: Continue.
5 Reconnect J/P57.
• Reinstall the paper timing guide.
Is error message PAPER JAM 025 AT/NEAR INPUT still displayed?
No: J/P57 was at fault. Turn to TAG 002.
Yes: Continue.


• Loosen the paper timing guide.
P40-16 to P57-2,
P40-25 to P57-1, and
P40-12 to P57-3.
P40-25 to J/P58-1 to P57-1,
P40-16 to J/P58-2 to P57-2, or
P40-12 to J/P58-3 to P57-3.
Yes: Replace the paper timing guide. If that doesn’t resolve the problem, replace the VPCL board.

ERROR MESSAGE:PAPER JAM 026 AT/NEAR OUTPUT

Exit paper sensor
VPCL board
If the printer has a high capacity output unit (HCO), unplug and remove it before beginning
this TAG. Test the printer without the HCO; if the problem remains, proceed with this TAG. If
the problem occurs only with the HCO, the HCO is causing the problem. Repair or replace the
HCO.

• Inspect the exit paper sensor actuator for damage or binding.
No: Replace the exit paper sensor actuator and continue.
Yes: Continue.

Is error message PAPER JAM 026 AT/NEAR OUTPUT displayed?
No: Jammed paper, loose connectors, or sensor actuator were at fault; go to TAG 002.
Yes: Continue.

Yes: Continue.


P40-26 to P49-1,
P40-24 to P49-2, and
P40-13 to P49-3
P40-26 to J/P50-1 to P49-1,
P40-24 to J/P50-2 to P49-2, or
P40-13 to J/P50-3 to P49-3.
Yes: Replace the exit paper sensor. If that doesn’t resolve the problem, replace the VPCL board.

ERROR MESSAGE:MC DEVELOPER BIAS SHORT #030

Cleaner
DC power supply
VPCL board
Printhead assembly
Developer

• Verify that J/P23, J/P24, J/P40, J/P41, J/P96, and J/P85 are connected properly.
Is error message MC DEVELOPER BIAS SHORT #030 still displayed?
No: A loose connector was at fault. Turn to TAG 002.
Yes: Continue.
2 Refer to Section 9, General Printer Maintenance and check the voltages.

No: Replace the high voltage power supply, then turn to TAG 002.
Yes: Continue.
3 Has the developer been replaced recently?

Yes: Continue.
4 Replace the cleaner.

No: The cleaner was defective; turn to TAG 002.
Yes: Reinstall the original cleaner and go to #6 in this TAG.
5 Replace the developer.

• Install a new toner cartridge.
No: The developer was defective; turn to TAG 002.
Yes: Reinstall the original developer and continue.


No: Repair or replace the connectors or wiring from P41-35 to P23-5, then turn to TAG 002.
Yes: Continue.

• Check the following for continuity
P41-31 to P24-1,
P41-30 to P24-2, and
P41-40 to P24-3.
P41-31 to P24-1,
P41-30 to P24-2, or
P41-40 to P24-3.
Yes: Continue.
8 Disconnect P85 from the high voltage power supply.

No: Repair or replace the connectors or wiring from P85-3 to J25-7, then turn to TAG 002.
Yes: Continue.
9 Disconnect J/P96.
No: Repair or replace the developer power supply lead from
J/P96-1 to P85-3, then turn to TAG 002.
Yes: Replace the high voltage power supply, then turn to TAG 002.

No: The VPCL board was defective. Go to TAG 002.
Yes: Replace the VPCL board and continue.

No: Continue.


No: Continue.
Yes: Replace the power control #2 board, then turn to TAG 002.

Yes: Repair or replace the connectors or wiring from P8-11 to P11-1, then turn to
TAG 002.

TAG 031: Toner Patch Reference Level Incorrect
ERROR MESSAGE:MC TPS TOO LOW #031

MC TPS TOO HIGH #037
Possible Causes: Contamination of the toner patch sensor or printhead lens

Photoconductor
VPCL board
Developer

• Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce-
dure.
• Clean the toner patch sensor on the developer.
• Run at least 200 test prints to detone the printer’s engine.
No: Contamination was at fault. Turn to TAG 002.
Yes: Continue.
2 Refer to Section 9, General Printer Maintenance, and check the voltages.

Yes: Continue.
3 Have the photoconductor and developers been replaced recently?

No: Continue.
4 Replace the photoconductor.

• Run 200+ test prints to reduce toner concentration in the developer.
No: Reinstall the original photoconductor and continue.
Yes: The photoconductor was at fault; turn to TAG 002.

No: Reinstall the original developer and continue.
Yes: Turn to TAG 002. If the problem reappears, the toner/carrier mix may be old or contaminated.


• Remove the developer.
No: Repair or replace the connectors or wiring from P41-47 to J25-3.

ERROR MESSAGE:MC TPS TOO LIGHT #032

MC TPS SIGNAL OVERLOAD #033

Photoconductor
RIGS board
VPCL board

Yes: Continue.
2 Has the photoconductor been replaced recently?

No: Continue.

Yes: The photoconductor was at fault. Turn to TAG 002.

dure.
• Clean the toner patch sensor on the developer.
No: Contamination was at fault. Turn to TAG 002.
Yes: Continue.
5 Run test prints.

Do the test prints appear overtoned, dark, or have background?
Yes: Continue.
6 Develop a toner patch, as described in Section 1, Troubleshooting.

Is the toner patch developed and properly positioned?
No: Replace the RIGS board, then turn to TAG 002.
Yes: Continue.

7 Check the toner patch sensor board in the developer for loose wiring connectors.
Are all connectors and wiring connected properly?
No: Reconnect the wiring and connectors or replace the developer, then turn to TAG 002.
Yes: Go to TAG 808, TAG 811, or both, to identify the problem further.
8 Do the prints appear light or blank?

Yes: Replace the photoconductor, then turn to TAG 002.

TAG 035: Out of Toner or ADD TONER Indication
ERROR MESSAGE:MC TONER EMPTY ERROR #035
Possible Causes: Photoconductor

Toner cartridge seal not removed
Toner cartridge empty
High print coverage

VPCL board
Developer connectors or wiring
An MC TPS SIGNAL OVERLOAD #035 error may occur if the print coverage exceeds 25%.
Do not run high print coverage jobs for extended periods of time.

Is error message MC TONER EMPTY ERROR #035 displayed?
No: Continue.
Yes: Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning proce-
dure. Clean the toner patch sensor and the printhead lens, then continue.

Yes: Continue.

No: Continue.

5 Has the seal has been removed from the toner cartridge?
No: Continue.

6 Remove the toner cartridge seal.

No: Continue.
Yes: The toner cartridge seal was at fault. Turn to TAG 002.

Yes: Replace the VPCL board. If this resolves the problem, then turn to TAG 002. If the problem is
still not resolved, go to TAG 610.

TAG 036: Developer Not Installed
TAG 036: Developer Not Installed
ERROR MESSAGE:MC NO DEVELOPER #036

MC DEVELOPER CONN. OPEN #037

Developer not installed properly
VPCL board

• Make sure the developer is installed properly.
• Confirm that the proper developer is installed.
Is error message MC NO DEVELOPER #036 displayed?
No: A loose connector or improper developer was at fault. Turn to TAG 002.
Yes: Continue.

Yes: Continue.

No: Continue.
4 Remove the developer.

P41-45 to J25-12 or
P41-46 to J25-8,
then turn to TAG 002.
Yes: Replace the developer, then turn to TAG 002.

ERROR MESSAGE:MC NO SIGNAL FROM PSS #040

MC PSS SENSOR SHORTED #041
MC PSS SENSOR OPEN #042

Photoconductor
Main motor gear
Main motor gear keys
Main drive motor assembly
VPCL board
Software
Seam sensor

• Verify that J/P4, J/P9, J/P12, J/P14, J/P20, J/P40, J/P41, J/P63 (photoconductor seam sensor), J/
P64, J/P251, and J/P252 are connected properly.
• Clean the photoconductor contacts, the guide rail contacts, and the photoconductor cavity.
• Clean the seam sensor lens and cavity, and remove any obstructions.
Is error message MC NO SIGNAL FROM PSS #040, MC PSS SENSOR SHORTED #041 or
MC PSS SENSOR OPEN #042 still displayed?
No: Loose connectors or dirty contacts were at fault. Turn to TAG 002.
Yes: Continue.

No: Continue.

4 Open the top cover and insert an interlock by-pass tool.

• Run the dignostic test “Photoconductor Seam Sensor Test” on page 5-8.
Does the photoconductor belt rotate?
No: Continue.

5 Is error message MC PSS Sensor Shorted #041 or MC PSS Sensor Open #042 displayed
while running “Photoconductor Seam Sensor Test” on page 5-8?
No: Continue.

• Inspect it for damaged drive mechanism or belt slippage.
No: Replace the photoconductor, then turn to TAG 002.
Yes: Continue.
7 Reinstall the photoconductor.

• Remove the interlock by-pass tool and close the top cover.
• Remove the main drive motor assembly cover.
• Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8.
• Watch the main motor.
Does the main motor gear turn while running the Photoconductor Seam Sensor Test?
No: Continue.
Yes: Replace the main motor gear, main motor gear key, or both, or replace the main drive gear
assembly, as needed. Then turn to TAG 002.

No: Continue.
Yes: Replace the main drive motor assembly, then turn to TAG 002.

No: Continue.
P14-2 to P20-3 or
P14-3 to P20-2;


Yes: Replace the power control board; if this does not correct the problem, replace the VPCL
board. Then turn to TAG 002.

• Inspect the photoconductor belt for damage.
• Check the timing hole for contamination or blockage.
Are the photoconductor belt and the timing hole both in good working order?
Yes: Continue.

Yes: Continue.
13 Check J/P64 pin 2 for between +2 to +6 Vdc.

On J/P64, pin 1 is the top pin.
Is the voltage between +2 to +6 Vdc?
Yes: Continue.

• Disconnect J/P63, observing carefully the plug’s orientation before you remove it.
• P40-19 to J/P64-1 to J/P252, which is the center connector contact on the photoconductor
guide rail;
• P40-21 to J/P64-2 to J/P251, which is the top connector contact on the photoconductor guide
rail;
• P40-18 to J/P 64-3 to P63-1;
• P40-20 to J/P64-4 to P63-2.
No: Repair or replace the connectors or wiring that did not have continuity, then turn to TAG 002.
Yes: Replace the photoconductor seam sensor, reconnect J/P40 and J/P63, then turn to TAG 002.

ERROR MESSAGE:MC MAIN/TRANSFER OPEN #044

Charge corona
Transfer corona
Upper paper guide
VPCL board

• Make sure the high voltage power supply charge corona lead is connected properly.
• Make sure the transfer corona lead is connected properly.
• Verify that the charge corona and transfer corona ground circuits are connected properly.
• Remove the transfer corona from the upper paper guide.
• Clean the transfer corona housing and contacts.
• Clean the transfer corona wire.
• Inspect the transfer corona socket in the upper paper guide for contamination.
• Verify that the transfer corona static eliminator brush on the transfer corona housing is grounded
to the transfer corona metal housing.
Is error message MC MAIN/TRANSFER OPEN #044 displayed?
No: Loose connectors or a dirty transfer corona were at fault. Turn to TAG 002.
Yes: Continue.

No: Continue.
3 Replace the charge corona and photoconductor.

No: Reinstall the original charge corona and photoconductor, and continue.
Yes: The charge corona was at fault. Turn to TAG 002.

4 Remove the transfer corona.

• Inspect the housing for jammed paper.
Is paper jammed inside the transfer corona housing?
No: Continue.
Yes: Remove the jammed paper and check the transfer corona for damage, then turn to TAG 022.
5 Run diagnostic test “Charge Corona Test” on page 5-9.

Is error message 046 displayed?
No: Continue.
6 Run diagnostic test “Transfer Corona Test” on page 5-9.

Is error message MC TRANSFER CHRGR OPEN #051 displayed?
No: Continue.
7 Run diagnostic test “Transfer Corona Test” on page 5-9.

Is error message MC TRANSFER CHRGR SHORT #050 displayed?
No: The problem appears to be intermittent. Go to TAG 050.
Yes: Go to TAG 050.

• Inspect the transfer corona wire.
Is the transfer corona wire damaged?
No: Continue.
Yes: Replace the transfer corona, then turn to TAG 002.
9 With the upper paper guide assembly in its fully upright position, check the transfer corona's lower
receptacle for continuity to ground.
No: Replace or repair the upper paper guide assembly, then turn to TAG 002.
Yes: Continue.
10 Disconnect high voltage power supply lead to the transfer corona.

• Check the transfer corona's upper receptacle to the lead removed from the high voltage power
supply for continuity.
No: Replace the upper paper guide assembly, then turn to TAG 002.


• Disconnect the charge corona lead from the high voltage power supply.
• Check for continuity the charge corona lead terminal assembly’s lower contact to the lead
removed from the high voltage power supply.
No: Repair or replace the charge corona lead or the charge corona terminal assembly, then turn to
TAG 002.
Yes: Continue.
12 Remove the cleaner.

• Check for continuity between the connector for the charge corona terminal assembly’s upper
contact and J/P85-10 at the high voltage power supply.
No: Repair or replace the connectors or wiring, then turn to TAG 002.
Yes: Continue.

Yes: Continue.

Yes: Continue.
15 Reconnect the power.

Yes: Determine whether the high voltage power supply or the charge corona terminal assembly is
at fault, replace the faulty unit, then turn to TAG 002.

ERROR MESSAGE:MC MAIN CHARGER SHORT #045

Charge corona
VPCL board

• Verify that J/P23, J/P41, J/P85, P124, P143, and the high voltage power supply charge corona
lead are connected properly.
Is error message MC MAIN CHARGER SHORT #045 displayed?
No: Loose connectors or dirty contacts were at fault. Turn to TAG 002.
Yes: Continue.

No: Continue.
3 Replace the charge corona and photoconductor.

Is error message MC MAIN CHARGER SHORT #045 still displayed?
No: The charge corona was at fault. Turn to TAG 002.
Yes: Reinstall the original charge corona and photoconductor, then continue.

• Disconnect the charge corona lead from the high voltage power supply.
• Check for continuity the charge corona terminal assembly’s lower contact to the lead removed
from the high voltage power supply.
No: Repair or replace the high voltage lead or the charge corona terminal block, then turn to TAG
002.
Yes: Continue.

5 Reconnect the charge corona high voltage lead.

• Disconnect P23 and J/P41.
• Check J/P41-34 to P23-6 for continuity.
Yes: Continue.

Yes: Replace the high voltage power supply. If this corrects the problem, turn to TAG 002. If this
does not correct the problem, replace the VPCL board, then turn to TAG 002.

TAG 047: PC Life Data Error
TAG 047: PC Life Data Error
ERROR MESSAGE:MC PC LIFE DATA ERROR #047

Photoconductor
Software
VPCL board

• Make sure the photoconductor is properly installed.
• Clean the photoconductor contacts, the guide rail contacts, and the photoconductor cavity
• Confirm that the proper photoconductor is installed.
Is error message MC PC LIFE DATA ERROR #047 displayed?
No: A loose connector or improper photoconductor were at fault. Turn to TAG 002.
Yes: Continue.

Is error message MC PC LIFE DATA ERROR #047 displayed?
No: The photoconductor was at fault. Turn to TAG 002.
Yes: Replace the VPCL board. If the error persists, repair or replace the wiring between J/P251
(photoconductor contacts) and J/P64 and P40 (VPCL board), then turn to TAG 002.

TAG 048: Developer Life Error
TAG 048: Developer Life Error
ERROR MESSAGE:MC DEVELOPER LIFE ERROR #048

Developer
Software
VPCL board

• Make sure the developer is properly installed.
• Confirm that the proper developer is installed.
Is error message MC DEVELOPER LIFE ERROR #048 displayed?
No: A loose connector or improper developer were at fault. Turn to TAG 002.
Yes: Continue.

Is error message MC DEVELOPER LIFE ERROR #048 displayed?
No: The developer was at fault. Turn to TAG 002.
Yes: Replace the VPCL board. If the error persists, repair or replace the wiring between P25
(developer) and P40 (VPCL board), then turn to TAG 002.

ERROR MESSAGE:MC TRANSFER CHRGR SHORT #050

Transfer corona
VPCL board

• Verify that J/P23, J/P41 and the transfer corona high voltage power supply lead are connected
properly.
Yes: Continue.

• Remove and clean the transfer corona housing and contacts.
• Check between the two terminals on the back of the transfer corona for continuity.
No: Continue.
Yes: Repair or replace the transfer corona, then turn to TAG 002.
3 Reinstall the transfer corona.

No: A dirty transfer corona was at fault. Turn to TAG 002.
Yes: Continue.

• Disconnect the transfer corona lead from the high voltage power supply.
• Check the transfer corona high voltage power supply lead for continuity to ground.
No: Continue.
Yes: Repair or replace the upper paper guide assembly or transfer corona, then turn to TAG 002.

5 Reconnect the transfer corona high voltage power supply lead.

Yes: Continue.

No: Replace the high voltage power supply. If this resolves the problem, turn to TAG 002. If the
problem has not been resolved, replace the VPCL board, then turn to TAG 002.
Yes: Turn to TAG 002.

ERROR MESSAGE:MC ERASER LAMP #055

Erase lamp assembly
VPCL board

• Verify that J/P26, J/P40 are connected properly.
Is error message MC ERASER LAMP #055 displayed?
No: Continue.
2 Run diagnostic test “Erase Lamp Test” on page 5-10.

Is the value displayed less than 220?
Yes: Continue.

• Watch all the LEDs on the erase lamp.
Do all the LEDs on the erase lamp come on, even momentarily?
No: Continue.

• Check J/P26-2 for +12 Vdc immediately. After the start of the test, the voltage may drop to 0
Vdc.
Did you measure +12 Vdc?
No: Continue.



• Disconnect P26 and P40.
Yes: Repair or replace the erase lamp assembly. If this resolves the problem, turn to TAG 002. If
this does not resolve the problem, replace the VPCL board, turn to TAG 002.

TAG 070: Fuser Malfunction
ERROR MESSAGE:MC FUSER/THERMAL FUSE #070

MC FUSER TEMP TOO LOW #073
Symptoms: No AC power at the fuser

Fuser
AC power supply
DC power supply
VPCL board
A lack of continuity may result in fuser damage. If this has occurred, replace the fuser when
replacing connectors and/or wiring.

• Verify that J/P44, J/P4, J/P10, J/P11, J/P12, J/P70, J/P40, J/P41, J/P8, and
J/P5 (bottom of fuser) are connected properly.
• Verify that the fuser is installed properly.
• Read the following steps before taking further action.
If the fuser lamp comes on immediately after power on, turn off the printer and replace the AC
power supply.
Is error message MC FUSER/THERMAL FUSE #070 or MC FUSER TEMP TOO LOW #073
displayed?
No: A loose connector was at fault.Turn to TAG 002.
Yes: Continue.

No: Continue.

power supply.


• Watch through the output tray opening to see if the fuser lamp comes on during the first few
minutes after power on.
If the fuser lamp comes on immediately after power on, turn the printer off and replace the AC
power supply.
Does the fuser lamp light?
Yes: Continue.

Is error message MC FUSER/THERMAL FUSE #070 or MC FUSER TEMP TOO LOW #073
displayed?
Yes: Replace the VPCL board and continue.

• Remove the fuser.
No: Repair or replace the connectors or wiring from P41-22 to P83-1 or J83-1 to P5-6, then turn to
TAG 002.
Yes: Continue.

No: Repair or replace the connectors or wiring from P41- 21 to P83-2 or J83-2 to P5-7, then turn
to TAG 002.
Yes: Continue.
8 Reinstall the fuser.

Is the resistance between IKΩ and 400 KΩ?
No: The new fuser seems to be defective. Replace it with a new fuser, then turn to TAG 002.

• Check J/P10-2 for +24 Vdc during the 15 seconds following power-on-reset.
Yes: Continue.


Does the voltage drop from +24 Vdc to 0 Vdc during the first few minutes after power on,
while the fuser lamp is on?
Yes: Continue.

• Check J/P44-1 to J/P44-2 for at least 100 Vac during the first few minutes after power on, while
the fuser lamp is on.
Yes: Continue.

• Clean the contacts of connector J/P5.
• Check J44-2 to J5-4 and J44-1 to J5-1 for continuity.
No: Repair or replace the connectors or wiring as needed, then turn to TAG 002.
Yes: Continue.

No: Replace the fuser, then turn to TAG 002.
Yes: Cleaning the contacts resolved the problem. Turn to TAG 002.

• Check J/P4-1 to J/P4-2 for at least 100 Vac during the first few minutes after power on, while
the fuser lamp is on.
Was the voltage at least 100 Vac?
No: Replace the AC power supply, then turn to TAG 002.
Yes: Repair or replace the connectors or wiring from J/P4-1 to J/P44-1, or J/P4-2 to
J/P44-2, then turn to TAG 002.

No: Continue.


No: Continue.
Yes: Replace power control #2 board, then turn to TAG 002.


Yes: Continue.
19 Check P70-2 and P10-2 for continuity.

Yes: Continue.
20 Reconnect J/P70.
• Connect negative lead of meter to P10-2 and positive lead of meter to P10-1.
Is the resistance approximately 550KΩ?
Yes: Continue.
• Check J10-2 (power control #2 board) for continuity to ground.
No: Continue.



Does the voltage drop from +24 Vdc to 0 Vdc during the first few minutes after power on,
while the fuser lamp is on?
No: Reinstall the old VPCL board. Repair or replace the wiring between the fuser and the VPCL
board, then turn to TAG 002.
Yes: The VPCL board was at fault, Turn to TAG 002.

TAG 071: Open Fuser/Thermistor
TAG 071: Open Fuser/Thermistor
ERROR MESSAGE:MC NO FUSER/THERMISTOR #071

Fuser
VPCL board

• Make sure the fuser is installed properly.
Has the fuser been replaced recently?
No: Continue.

Is error message MC NO FUSER/THERMISTOR #071 displayed during power-on-reset?
No: The fuser was at fault. Turn to TAG 002.
Yes: Reinstall the original fuser and continue.

No: Repair or replace the connectors or wiring as necessary, then turn to TAG 002.
Yes: Continue.
4 Check P41-21 and P41-22 for continuity to ground.

Is there continuity to ground on either?
No: Replace the fuser. If this resolves the problem, then turn to TAG 002. If this does not resolve
the problem, replace the VPCL board, then turn to TAG 002.
P41-21 to P44-2, J44-2 to P5-7, or
P41-22 to P44-1, J44-1 to P5-6;

TAG 072: Fuser Temperature Too High
ERROR MESSAGE:MC FUSER TEMP TOO HIGH #072

Fuser
AC power supply
VPCL board
The conditions that cause error message MC FUSER TEMP TOO HIGH #072 often cause the
fuser’s thermal fuse to open. This usually necessitates replacement of the fuser.

• Make sure the fuser is properly installed.
• Read the following steps before taking further actions.
power supply.
No: Continue.
Yes: A loose connector was at fault. Turn to TAG 002.

No: Continue.

• Watch through the output tray opening to see if the fuser lamp comes on during the first few
minutes after power on.
power supply.
Yes: The fuser was at fault. Turn to TAG 002.

• Watch the fuser's lamp.
Does the lamp turn on before error message MC FUSER TEMP TOO HIGH #072 is dis-
played?
Yes: Continue.


No: Continue.
P41-21 to P44-2, or J44-2 to P5-7; then turn to TAG 002.

Is the resistance at least 1KΩ?
No: Continue.
7 Remove the fuser.

No: Continue.


ERROR MESSAGE:MC +12 DC POWER FAILURE #097

DC power supply
IO card
RIGS board
Optional external attachment
Developer Duplex control board #1
Paper timing sensor Duplex control board #2
Upper paper empty sensor Paper path sensor
Lower paper empty sensor Cover open sensor
Output tray full sensor Restart side sensor
Paper exit sensor Restart paper sensor
Tray front sensor
Tray rear sensor
Erase lamp
VPCL board

• Verify that J/P303, J/P331, J/P323, J/P305, J/P310, J/P306, J/P32, and J/P33 are connected
properly.
No: Continue.
Yes: Loose connectors were at fault. Turn to TAG 002.

No: Continue.

No: Continue.


Yes: Continue.

Yes: Continue.

• Remove any IO cards.
No: Replace the IO card(s) and continue.
Yes: Replace the IO card(s), then turn to TAG 002.

No: Replace the signal interface board, then turn to TAG 002.
Yes: Replace the attachment option, then turn to TAG 002.

Yes: Continue.


Yes: Continue.

Yes: Continue.

No: Continue.

Yes: Repair or replace the appropriate connectors or wiring, then turn to TAG 002.

• Check J8-6 for continuity to ground.
No: Continue.
Yes: Repair or replace the connectors or wiring from P8-6 to P32-10 to P91-3, then turn to TAG
002.


Yes: Replace the disk drive assembly, then turn to TAG 002.

Yes: Continue.

Yes: Continue.

Yes: Continue.
No: Replace the lower paper empty sensor, then turn to TAG 002.


No: Replace the paper timing sensor.

No: Replace the upper paper empty sensor.

P40-25 to J58-1,
P40-25 to J60-1, and
P40-25 to J62-1.
No: Continue.
P40-25 to J58-1,
P40-25 to J60-1, or
P40-25 to J62-1,

• Reconnect J/P40, J/P58, J/P60, and J/P62.
Yes: Continue.

Yes: Continue.


No: Continue.
Yes: Replace the front tray sensor, then turn to TAG 002.

No: Continue.
Yes: Replace the rear tray sensor, then turn to TAG 002.

Is there continuity to ground at either?
J54-1 to P53-1 or
J54-4 to P55-1,

Yes: Continue.

No: Replace the paper exit sensor, then turn to TAG 002.
Yes: Replace the output tray full sensor, then turn to TAG 002.


J50-1 to P49-1 or
J50-4 To P51-1,

No: Continue.
P40-26 to P54-1,
P40-26 to P54-4,
P40-26 to P50-1, or
P40-26 to P50-4,
then turn to TAG 002

• Reconnect J/P40, J/P50, and J/P54.
No: Continue.

No: Continue.

No: Continue.



Yes: Continue.

Yes: Continue.

• Disconnect J/P310 (inside the duplex tray).
No: Continue.

Yes: Repair or replace connectors or wiring P305-2 to P310-2, then turn to TAG 002.


Yes: Repair or replace the connectors or wiring from J323-2 to J305-2, then turn to TAG 002.

No: Continue.

• Check J331-2 to P306-2 for continuity to ground.
P330-2 to P331-2, or
P330-2 to P323-2.
Yes: Repair or replace the connectors or wiring from J331-2 to P306-2.

No: Continue.

P312-1 to P320-1, and
P312-4 to P322-1
No: Replace the duplex control board #2, then turn to TAG 002.
Yes: Repair or replace the connectors or wiring from P312-1 to P320-1, or P312-4 to P322-1, then
turn to TAG 002.


No: Replace the restart side sensor, then turn to TAG 002.
Yes: Replace the restart paper sensor, then turn to TAG 002.

Yes: Continue.

Is the voltage at +12 Vdc?
No: Replace the paper path sensor, then turn to TAG 002.
Yes: Replace the cover open sensor, then turn to TAG 002.

P309-4 to P319-1, and
P309-3 to P318-1.
P309-4 to P319-1, or
P309-3 to P318-1;

ERROR MESSAGE:MC -12 DC POWER FAILURE #098

DC power supply
VPCL board
RIGS board
IO card
External attachment option

No: Continue.

No: Continue.
Yes: Replace VPCL board, then turn to TAG 002.

No: Continue.

Yes: Repair or replace the connectors or wiring from P8-8 to P32-3.


Yes: Continue.


Is the voltage at J/P8-8 -12 Vdc?
No: Replace the signal interface board, then turn to TAG 002.
Yes: Replace the attachment option, then turn to TAG 002.

ERROR MESSAGE:MC +24 DC POWER FAILURE #099

DC power supply IO card
AC power supply Duplex control board #1
Connectors or wiring Duplex control board #2
VPCL board Route motor
RIGS board In solenoid
Power control #2 board “C” roller solenoid
High voltage power supply “A” roller clutch
Paper timing clutch Exit solenoid
Upper feed roller clutch Restart motor
Lower feed roller clutch
Counter assembly

• Verify that J/P11, J/P8, J/P32, J/P33, J/P91, J/P303, J/P305, J/P306, J/P310,
J/P323, and J/P331 are connected properly.
No: Continue.

No: Continue.


No: Continue.


Yes: Continue.

Yes: Continue.

No: Repair or replace the connectors or wiring from P10 to P70, then turn to TAG 002.
Yes: Replace the AC power supply, then turn to TAG 002.

No: Replace the power control #2 board, then turn to TAG 002.
Yes: Continue.


Yes: Continue.

No: Continue.


Yes: Continue.

Yes: Continue.


Yes: Continue.

Yes: Continue.

No: Repair or replace the connectors or wiring from J81-1 to P82-1, then turn to TAG 002.
Yes: Replace the counter assembly, then turn to TAG 002.

No: Continue.
Yes: Replace the lower pick-up roller assembly, then turn to TAG 002.

No: Continue.
Yes: Replace the paper timing roller assembly, then turn to TAG 002.


No: Continue.
Yes: Replace the upper feed roller assembly, then turn to TAG 002.

No: Continue.
Yes: Replace the lower feed roller assembly, then turn to TAG 002.

P40-10 to J69-1,
P40-11 to J65-1,
P40-11 to J66-1,
P40-11 to J67-1, or
P40-11 to J 68-1;
Yes: Replace the upper pick-up roller assembly, then turn to TAG 002.

P8-13 to P91-1, or
P8-11 to P11-1;


Yes: Continue.

Yes: Continue.

• Disconnect J/P310 (inside duplex tray).
No: Continue.


Yes: Repair or replace the connectors or wiring from J323-1 to J305-1-1, then turn to TAG 002.


No: Continue.

• Check J331-1 and P306-1 for continuity to ground.
P330-1 to P331-1 or
P330-1 to P323-1;

No: Continue.
Yes: Replace the restart motor, then turn to TAG 002.

No: Repair or replace the connectors or wiring from P312 to J321, then turn to TAG 002.
Yes: Replace the duplex control board #2, then turn to TAG 002.


No: Continue.
Yes: Replace the route motor, then turn to TAG 002.

No: Continue.
Yes: Replace the “in” solenoid, then turn to TAG 002.

No: Continue.
Yes: Replace the “C” roller solenoid, then turn to TAG 002.

No: Continue.
Yes: Replace the “A” roller clutch, then turn to TAG 002.

No: Continue.
Yes: Replace the exit solenoid, then turn to TAG 002.


P309-7~10 to J313-1~4,
P308-1 to J314-1,
P308-2 to J315-1,
P308-3 to J316-1, or
P308-4 to P317-1;

TAG 100: VPCL Board Interface Malfunction
TAG 100: VPCL Board Interface Malfunction
ERROR MESSAGE:130, 132, 140, 145, 160-162, 170-172, 180-182
Symptoms: VPCL board failure

VPCL board

No: Continue.
2 Was an error message displayed during the power-on-reset?

No: Refer to the mechanical malfunctions cross-reference chart in Section 2, TAG Cross-Refer-
ence Tables.
Yes: Continue.
3 Was the error message the same as the one used to enter this TAG?
No: Refer to the error message cross-reference chart in Section 2, TAG Cross-Reference Tables.

TAG 130: Disk Drive Malfunction
ERROR MESSAGE:130, 131, 133, 134

MC INCORRECT DISKETTE #450
MC FLOPPY FORMAT #451
MC WRITE PROTECTED #572 TO MC FDC READ #576
MC FDC/DMAC OPERATIONS #586
Symptoms: Test prints do not run

Diskette
Disk drive assembly
VPCL board
RIGS board
DC power supply
Electrical problems on wires J/P31 to J/P79 and J/P31 to ground may cause diskette and disk
drive malfunctions. If this TAG does not correct the problem, suspect an intermittent failure
from the disk drive to the RIGS board cable and replace the cable from J/P31 to J/P79 to J/P30.
The causes of error message MC FDC RESTORE #574 or MC FDC READ #576 can alter
the information on a diskette. You may have to replace the diskette with another known to be
good.

No: Continue.
2 Is error message MC FLOPPY FORMAT #451 displayed?

Yes: Continue.

Is error message MC FLOPPY FORMAT #451 still displayed?
Yes: Continue.
4 Remove any diskette from the printer’s disk drive assembly.

Is error message MC FLOPPY FORMAT #451 still displayed?
No: The diskette was at fault. Turn to TAG 002.
Yes: Replace the disk drive assembly and reload the printer’s software onto the hard disk, then turn
to TAG 002.

5 Is error message MC WRITE PROTECTED #572 displayed?

Yes: Continue.

No: Replace the disk drive assembly and reload the printer’s software onto the hard disk. If this
resolves the problem, turn to TAG 002. If this does not resolve the problem, replace the RIGS
Yes: Replace the wire harness from the drive assembly to the RIGS board, W46, then turn to TAG
002.
7 Is error message MC FLOPPY NOT READY #573 displayed?

Yes: Continue.

Yes: Continue.

Yes: Continue.

Yes: Continue.

Yes: Continue.


P31-34 to P79-34,
P31-32 to P79-32,
P31-16 to P79-16, and
P31-10 to P79-10.
does not resolve the problem, replace the RIGS board, then turn to TAG 002.
002.
13 Is error message MC FDC RESTORE #574 displayed?

Yes: Continue.

No: Replace the wire harness from the drive assembly to the RIGS board, W46, then turn to TAG
002.
Yes: Continue.

P31-18 to P79-18,
P31-24 to P79-24, and
P31-26 to P79-26.
002.
16 Is error message MC FDC SEEK #575 displayed?

Yes: Continue.


002.
Yes: Replace the disk drive assembly and reload the printer’s software onto the hard disk. If this
18 Is error message MC FDC READ #576 displayed?

Yes: Continue.

P31-22 to P79-22,
P31-24 to P79-24,
P31-26 to P79-26,
P31-28 to P79-28, and
P31-32 to P79-32.
002.
Yes: Continue.

P31-20,
P31-22,
P31-26, and
P31-32.
Is there continuity to ground on any?
No: Replace the disk drive assembly, then turn to TAG 002.
Yes: Replace the wire harness from the drive assembly to the RIGS board, W46.
21 Is error message 130, 131, 133, or 134 displayed?

No: Continue.
22 Can the printer run test prints?

No: Continue.
Yes: Replace the disk drive assembly and reload the printer’s software onto the hard disk. If this


002.

TAG 200: RIGS Internal Communication Malfunction
ERROR MESSAGE:MC PERIPHERAL BUS #401

MC FATAL SOFTWARE TRAP #454
MC SOFTWARE TRAP #455
MC PIT0 INVALID #500 TO MC PIT2 NO TIMER INTR #509
MC NO DMAC RESET #520 TO MC NO DMAC2 TRANSFER #530 #540
TO MC VSYNC TIMEOUT #566
MC FDC/SCSI READ/WRITE #570
MC FDC BUSY TIMEOUT #571
MC FDC CHECKSUM #577 TO MC FDC/DMAC WRITE #585 #600-#610
Symptoms: RIGS board failure
Possible Causes: RIGS program error

RIGS board
Software
I/O card

No: Continue.
2 Was an error message displayed?

No: Refer to the mechanical malfunctions cross-reference chart in Section 2, TAG Cross-Refer-
ence Tables.
Yes: Continue.
3 If the operator panel displayed more than one error message, was it the first mes-
sage that displayed on the panel that led you to this TAG?
No: Look in Section 2, TAG Cross-Reference Tables’s error message cross-reference chart under
the first error message that displayed, then turn to the TAG referenced in the chart.
Yes: Continue.

No: Continue.
Yes: Replace wire harness W46, then turn to TAG 002.

5 Replace the RIGS board, making sure that RIGS EPROM version is correctly matched to the soft-
ware release installed on the printer.
No: Reinstall the original RIGS board and continue.
6 Reinstall the printer’s software. Follow the instructions for loading software in the C40D Installa-
tion Guide.
No: Replace the I/O card, then turn to TAG 002.
Yes: Software was at fault. Turn to TAG 002.

TAG 201: RIGS-VPCL Interface Malfunction
ERROR MESSAGE:121-127, 199-215

MC PCL CMD RETRY #380 TO MC PCL PARITY #387
Symptoms: Communication failure between the RIGS board and the VPCL board
Possible Causes: Insufficient delay period between power off and power on
Electrical spikes

VPCL board
RIGS board
DC power supply
1 Is error message 201 displayed?

Yes: Continue.

• Verify that J/P33 is connected properly.
No: Confirm that the RIGS firmware is correct for the version of software being used; then replace
the RIGS board. Turn to TAG 002.
3 Is error message 121 or 123 displayed?

Yes: Continue.

Are the connectors or wiring damaged?
No: Continue.

No: Continue.

6 Replace the RIGS board.

No: If error message 121 or 123 brought you to this TAG, replace the DC or high voltage power
supply, then turn to TAG 002. For all other error messages, replace the RIGS board, then turn
to TAG 002.

TAG 405: RIGS Bit-Map RAM Malfunction
TAG 405: RIGS Bit-Map RAM Malfunction
ERROR MESSAGE:600-610

RIGS board
1 The RIGS bit-map RAM has malfunctioned. Replace the RIGS board, then turn to TAG 002.

Symptoms: Operator panel blank with AC power supply cooling fan running

DC fuse
DC power supply
Operator panel circuit board
VPCL board
RIGS board
Disk drive assembly
LED printhead assembly
Attachment option
AC power supply

• Confirm that J/P94, J/P4, J/P41, J/P91, J/P90, J/P6, and J/P8 are connected properly.
Is the operator panel still blank?
No: Loose connectors were at fault. Turn to TAG 002.
Yes: Continue.

Yes: Continue.

Yes: Continue.

Yes: Continue.

No: Repair or replace the connectors or wiring from P94-1 to J/P90-1 to P42-1, then turn to TAG
002.
Yes: Continue.


No: Repair or replace the connectors or wiring from P42-20 to J/P90-20 to J/P94-2 to P8-15, then
turn to TAG 002.
Yes: Replace the operator panel circuit board. If this resolves the problem, turn to TAG 002. If this
does not resolve the problem, replace the VPCL board, wire harness W72, or wire harness
W63, then turn to TAG 002.

No: Continue.

Yes: Continue.

• Reconnect J/P8.
No: Continue.
Yes: Replace the disk drive assembly, then turn to TAG 002.

No: Continue.
Yes: Replace the LED printhead assembly, then turn to TAG 002.


No: Continue.

• Remove the IO card(s).
No: Continue.

• Reinstall the IO card(s).
No: Continue.
Yes: Replace the RIGS board, then turn to TAG 002.

No: Replace wire harness W36, then turn to TAG 002.
Yes: Continue.

No: Replace the operator panel circuit board, then turn to TAG 002.
Yes: Repair or replace the connectors or wiring from P94-1 to J/P90-1 to P42-1, then turn to TAG
002.


Yes: Continue.

No: Repair or replace the connectors or wiring from J331-3 to P306-3, then turn to TAG 002.

No: Replace wire harness W127 or W128, then turn to TAG 002.
Yes: Continue.

• Disconnect J/P310, found inside the duplex tray.
Yes: Repair or replace the connectors or wiring from J323-3 to J/P305-3 to P310-3, then turn to
TAG 002.

• Check from J/P6-1 to J/P6-2 (neutral) for 100 Vac or more.
No: Continue.
Yes: Replace the DC power supply, then turn to TAG 002.

21 ! Use extreme caution: Check from J/P4-7 to J/P4-8 (neutral) for 100 Vac or more.
No: Replace the AC power supply.
P4-7 to P6-1 or
P4-8 to P6-2;

TAG 600: Vac Power Malfunction
Symptoms: Operator panel blank with fans not running

“Close cover” displayed
Circuit breaker keeps tripping

Upper fuse in the AC power supply
AC power supply
DC power supply
Fuser
Back cover interlock switch
Front cover interlock switch
Top cover interlock switch
Toner supply motor
Cooling fans
Jogging motor
Main drive motor
Vacuum transport
Operator panel assembly

• Verify that J/P44, J/P84, J/P4, J/P9, J/P12, J/P40, J/P6, and the AC power cord are connected
properly.
No: Continue.

! Use extreme caution: Check from J/P9-2 to J/P9-1 for +100 Vac.
Yes: Continue.

No: Repair or replace the connectors or wiring as needed.
Yes: Replace the power control #2 board. If this resolves the problem, turn to TAG 002. If this does
not resolve the problem, replace the VPCL board, then turn to TAG 002.

4 Does the CLOSE COVER message display on with all the covers closed?
Yes: Continue.
5 Operate the top and front cover interlock switch actuators.

Are the interlock switch actuators working properly?
No: Repair or replace any defective actuator, then turn to TAG 002.
Yes: Continue.
6 ! Use extreme caution: Check from J/P4-4 to J/P4-3 for +100 Vac.
No: Continue.
P9-2 to P4-4 or
P9-1 to P4-3.
If this is a duplex printer and the problem remains, go to TAG 900. If this corrects the prob-
lem, turn to TAG 002.

• Remove the upper fuse in the AC power supply.
No: Continue.
8 Replace the upper fuse in the AC power supply.

• Reconnect the power.
Yes: Continue.

• Run diagnostic test “Transfer Corona Test” on page 5-9 for approximately 5 seconds, then stop.
• Turn the printer off and unplug the power cord.
Yes: A defective fuse was at fault. Turn to TAG 002.

10 Reinstall the fuse.

• Close the top cover.
Yes: Continue.
11 Remove the AC power supply.

• Operate the front cover interlock switch.
• Check for continuity as you operate the front interlock switch.
Does the front cover interlock switch have continuity?
No: Repair or replace the front interlock switch, then turn to TAG 002.
Yes: Repair or replace the AC power supply, then turn to TAG 002.
• Install a new upper fuse in the AC power supply.
• Run diagnostic test “Transfer Corona Test” on page 5-9 for approximately 5 seconds, then stop.
Yes: Continue.
No: Replace the toner supply motor, then turn to TAG 002.

• Remove the upper fuse.
Yes: Continue.

15 Reconnect J/P9.
• Install a good upper fuse in the AC power supply.
Yes: Continue.

• Disconnect J/P20, J/P21, J/P22, and J/P326 (duplex printers).
• Wait 21/2 minutes, then turn the printer off.
No: Repair or replace connectors or wiring that have continuity to ground:
P21-1 to P13-4,
P22-1 to P13-6,
J326-1 to P13-4, or
P20-2 to P14-6;
Yes: Continue.

No: Replace the large cooling fan assembly, then turn to TAG 002.
Yes: Continue.

• Turn the printer on for 2-1/2 minutes, then off.
• Remove the upper fuse from the AC power supply.
No: Replace the main drive motor and power supply, then turn to TAG 002.
Yes: Continue.


• Turn on the printer for 21/2 minutes, then off.
No: Replace the vacuum transport, then turn to TAG 002.
Yes: Replace the small cooling fan assembly, then turn to TAG 002.
20 Reconnect J/P9.
• Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8 for approximately five
seconds, then turn off the printer.
Yes: Continue.

• Install a good upper fuse in the AC power supply.
• Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8for approximately five sec-
onds, then stop.
Yes: Continue.

No: Continue.
P4-4 to P9-2 or P4-4 to P100-1; then turn to TAG 002.


Yes: Repair or replace the top cover interlock switch assembly. If this resolves the problem, turn to
TAG 002. If this does not resolve the problem, repair or replace the connectors or wiring
from:
P4-5 to J/P84-1 to P131, or
P132 to J/P84-2 to P4-6;
24 Is the operator panel blank and are the cooling and AC power supply fans off?
No: You have chosen an incorrect TAG. Refer to the mechanical malfunctions cross-reference
chart in Section 2, TAG Cross-Reference Tables to identify a more appropriate TAG.
Yes: Continue.

• Check the wall power outlet for proper voltage.
Is the voltage correct? If the circuit breaker was reset after beginning this TAG, answer no.
Yes: Continue.
26 Unplug power cord from the printer and the wall outlet.
• Check the power cord for continuity.
No: Replace the power cord, then turn to TAG 002.
27 Disconnect J/P4.
Yes: Continue.
28 Remove the fuser.

• Check P4-1 to J/P44-3 to J5-1 to the fuser for continuity to ground.
No: Replace the fuser, making sure the fuser has the proper voltage rating, then turn to TAG 002.
Yes: Repair or replace connectors or wiring that have continuity, then turn to TAG 002.
29 Check J4-1 at the AC power supply for continuity to ground.

No: Continue.

30 Check P4-7 for continuity to ground.

Yes: Continue.
31 Disconnect J/P6.
32 Check J4-7 at the AC power supply for continuity to ground.

No: The customer's circuit breaker may be defective. Verify that the wall outlet has the proper
voltage. If it does, continue; otherwise, turn to TAG 002.
No: Repair or replace the connectors or wiring that lack continuity, then turn to TAG 002.
Yes: Continue.
34 Check J84-1 to P131 and J84-2 to P132 for continuity.

No: Repair or replace the connectors or wiring that lack continuity, then turn to TAG 002.
Yes: Continue.
35 Check J131 to J132 (top interlock switch) for continuity while activating the top cover interlock
switch.
No: Repair or replace the top cover interlock switch, then turn to TAG 002.
Yes: You have failed to isolate the problem. Return to the beginning of this TAG.

Symptoms: One or more message indicators will not light

Incomplete numbers are displayed
Tone does not work properly
All status lights remain on
One or more function keys do not work
Possible Causes: Operator panel

VPCL board

• Turn the volume control (on operator panel inside front cover) up fully.
• Run diagnostic test “Operator Panel Test” on page 5-4.
No: Continue.
2 Do the status lights stay on continuously?

No: Continue.

• Disconnect J/P42, J/P91, J/P8, and J/P32.
No: Repair or replace the connectors or wiring from P8-15 to J/P94-2 to J/P90-20 to P42-20, then
turn to TAG 002.
Yes: Continue.
4 Reconnect J/P42, J/P91, J/P8, and J/P32.

• When the “ready” indicator lights, press each function key and listen for the tone.
Test prints may be produced. Press STOP or turn the printer OFF to quit.
Did you hear the tone after pressing each function key?
Yes: Continue.
5 Is one of the function keys not working properly?

Yes: Continue.


TAG 002.
Yes: Continue.

No: Continue.
TAG 002.

TAG 002.
Yes: Continue.

No: Continue.
TAG 002.

TAG 002.
Yes: Continue.

No: Continue.
TAG 002.

TAG 002.
Yes: Continue.


No: Replace the operator panel. If this resolves the problem, turn to TAG 002. If this does not
resolve the problem, replace the VPCL board, then turn to TAG 002.
Yes: Repair or replace the connectors or wiring from P42-15 to J/P90-15 toP41-6, then turn to TAG
002.

No: Continue.
Yes: Repair or replace the connectors or wiring from P41-18 to J/P90-3 to P42-3, then turn to TAG
002.

002.
Yes: Replace the operator panel. If this resolves the problem, turn to TAG 002. If this does not
resolve the problem, replace the VPCL board, then turn to TAG 002.
16 Run diagnostic test “Operator Panel Test” on page 5-4.

Does the combination of lights and display match the description in the diagnostic test?
No: Replace the operator panel.
Does this resolve the problem?
No: Replace the operator panel and continue.
17 The problem is the wiring between the VPCL and operator panel. Repair or replace W63 and/or
W72, then turn to TAG 002.

Symptoms: Invalid REMOVE PRINTS message on display

Output tray full sensor
Job offset assembly
VPCL board
High capacity output unit

No: Continue.
2 Is a high capacity output unit installed on the printer?

Yes: Continue.

• Remove the high capacity output unit.
No: Continue.
Yes: The high capacity output unit is malfunctioning. Refer to Section 8, Options, for instructions
on repairing the high capacity unit.
4 Inspect the output tray full sensor actuator for damage or binding.
Yes: Continue.

002.
Yes: Continue.


002.
Yes: Continue.

002.
Yes: Continue.
8 Verify that the output tray full sensor is mounted properly.

• Verify that it moves down fully.
Is the output tray full sensor in good working order?
No: Replace the sensor, then turn to TAG 002.
Yes: Replace the VPCL board. If this resolves the problem, then turn to TAG 002. If this does not
resolve the problem, replace wire harness W71 or W52, then turn to TAG 002.

Symptoms: Incorrect paper size displayed

Upper cassette
Lower cassette
VPCL board

• Remove the upper and lower cassettes.
• Make sure that the rear and side paper guides are securely against the paper.
• Insert the cassette exhibiting the problem.
Does the display still indicate the incorrect paper size?
No: A loose connector or incorrectly positioned paper guides were at fault. Turn to TAG 002.
Yes: Continue.
2 Remove the cassette exhibiting the problem.

• Take out the paper.
• Inspect the two paper size sensing balls on the bottom of the cassette by changing positions of
the side and rear paper guides.
Is the paper size sensing mechanism in good working order?
No: Replace the defective cassette, then turn to TAG 002.
Yes: Continue.
3 Inspect the upper and lower paper size sensor assemblies.

Is either paper size sensor assembly damaged or improperly mounted?
No: Continue.
Yes: Remount, repair or replace the faulty paper size sensor assembly, then turn to TAG 002.
4 Remove the upper paper size sensor assembly.

• Disconnect the upper circuit board from its mounting.
• Inspect the paper size sensor circuit board and mounting for damage or contamination.
Is the circuit board or mounting damaged or contaminated?
No: Continue.
Yes: Repair or replace the upper paper size sensor assembly, then turn to TAG 002.

5 Remove the lower paper size sensor assembly.

• Disconnect the circuit board from its mounting.
• Inspect the paper size sensor circuit board and mounting for contamination or damage.
Is the circuit board or mounting contaminated or damaged?
No: Continue.
Yes: Repair or replace the lower paper size sensor assembly, then turn to TAG 002.
6 Is the paper size sensing problem occurring with the upper cassette?
Yes: Continue.

• Refer to the charts at the end of this TAG.
• Check the connectors or wiring for the upper paper size sensor.
No: Replace the upper paper size sensor assembly. If this resolves the problem, turn to TAG 002.
If this does not resolve the problem, replace the VPCL board, then turn to TAG 002.
Yes: Repair or replace the connectors or wiring that are defective, then turn to TAG 002.

• Refer to the chart at the end of this TAG.
• Check the connectors or wiring for the lower paper size sensor.
No: Replace the lower paper sensor assembly. If this resolves the problem, turn to TAG 002. If this
does not resolve the problem, replace the VPCL board, then turn to TAG 002.
Yes: Repair or replace the connectors or wiring that are defective, then turn to TAG 002.

Wiring for the Upper Paper Size Sensor

Refer to the chart when performing continuity checks for an open or short to ground for the upper
paper size sensor.
Wiring Upper Paper Size Sensor
P40-41 to J/P52-10 to J43-1 to J47-10 to J45-10

P40-42 to J/P52-9 to J43-2 to J47-9 to J45-9
P40-43 to J/P52-8 to J43-3 to J47-8 to J45-8
P40-44 to J/P52-7 to J43-4 to J47-7 to J45-7
P40-45 to J/P52-6 to J43-5 to J47-6 to J45-6

P40-46 to J/P52-5 to J43-6 to J47-5 to J45-5
P40-47 to J/P52-4 to J43-7 to J47-4 to J45-4
P40-48 to J/P52-3 to J43-8 to J47-3 to J45-3
P40-49 to J/P52-2 to J43-9 to J47-2 to J45-2

Refer to the chart when performing continuity checks for an open or short to ground for the lower
paper size sensor.
Wiring Lower Paper Size Sensor
P40-41 to J/P52-10 to J43-1
P40-42 to J/P52-9 to J43-2
P40-43 to J/P52-8 to J43-3
P40-44 to J/P52-7 to J43-4
P40-45 to J/P52-6 to J43-5
P40-46 to J/P52-5 to J43-6
P40-47 to J/P52-4 to J43-7
P40-49 to J/P52-2 to J43-9
P40-50 to J/P52-1 to J43-10

Symptoms: Upper cassette does not load or unload properly

Upper cassette does not latch properly

Upper cassette
Upper cassette release
Damper assembly
Wire cable/roller/spring
1 Inspect the upper cassette for damage.

Is the upper cassette in good working order?
No: Replace the upper cassette, then turn to TAG 002.
Yes: Continue.

• Upper cassette release
• Damper assembly
• Wire cable/roller/spring
No: Repair or replace the damaged part, then turn to TAG 002.
Yes: Only mechanical defects and malfunctions can cause this type of problem. Carefully reinspect
each part. Repair or replace and defective parts, then turn to TAG 002.

Symptoms: Lower cassette does not load or unload properly

Lower cassette does not latch properly

Lower cassette
Lower cassette release
Spring
1 Inspect the lower cassette for damage.

Is the lower cassette in good working order?
No: Replace the lower cassette, then turn to TAG 002.
Yes: Continue.

• Lower cassette release
• Spring
No: Repair or replace the damaged part, then turn to TAG 002.
Yes: Only mechanical defects and malfunctions can cause this type of problem. Carefully reinspect
each part. Repair or replace the damaged part, then turn to TAG 002.


Paper improperly loaded

Paper cassette
1 Remove paper from the cassette.

• Fan the paper stack and place it in the cassette.
• Make sure the paper curl is turned up in the cassette.
No: Continue.
Yes: The paper being used was at fault. Turn to TAG 002.
2 Adjust the paper tension lever or pick pressure as outlined in Section 9, General Printer Mainte-
nance.
No: Replace the pick-up roller assembly, then turn to TAG 002.



Fuser
1 Make sure the paper being used is not damaged.

• Make sure the paper is loaded properly.
• Check both upper and lower paper paths for obstructions or roller contamination.
No: Continue.

No: The paper in use was at fault. Turn to TAG 002.
Yes: Continue.
3 Run a test print from the cassette exhibiting the problem.

Is the print on the paper skewed?
No: Continue.
Yes: Go to TAG 807.
4 Remove the exit cover assembly.

• Inspect the exit roller assembly for damage, wear, or contamination.
• Inspect the exit pinch roller for damage, wear, or contamination.
Is either part damaged, worn, or contaminated?
Yes: Repair or replace the part as needed, then turn to TAG 002.

Possible Causes: Obstructions

Photoconductor front or rear latch arm springs
Photoconductor latch arms in incorrect position
Upper paper guide latching mechanism damaged or binding
Front or rear photoconductor guides damaged

Photoconductor latch arms
Upper paper guide latch
Photoconductor guide rails
1 Check under the upper paper guide assembly for obstructions.

• Remove the photoconductor from the printer.
• Inspect the front and rear photoconductor latch arm springs for damage.
• Inspect the front and rear photoconductor guide rails for damage.
• Make sure there are no obstructions in the mounting area of the photoconductor.
• Make sure the upper paper guide latching mechanism is functioning properly.
• Make sure the photoconductor latch arms are in the upper position.
No: Repair or replace any malfunctioning parts, then turn to TAG 002.
Yes: Continue.
Yes: Remove the photoconductor.
• Close and lock the upper paper guide.

Did the upper paper guide lock into place?
No: Replace the upper paper guide, then turn to TAG 002.
Yes: Only mechanical defects and malfunctions can cause this type of problem. Go to #1 in this
TAG and carefully reinspect each part.

Symptoms: Counter does not count

Counter counts too often
Consumable components require replacement too frequently

Counter assembly
VPCL board
1 Run diagnostic test “Counter Test” on page 5-7.

No: Continue.
Yes: The counter is working correctly. Turn to TAG 002.
2 Verify that J/P41, J/P81, and J/P82 are connected properly.

• Run diagnostic test “Counter Test” on page 5-7.
No: Continue.
3 Replace the counter.

Yes: The counter was at fault. Turn to TAG 002.

No: Replace the VPCL board and continue.
Yes: The VPCL board was at fault. Turn to TAG 002.

No: Repair or replace the connectors or wiring from P41-26 to J/P81-1 to J82-1, then turn to TAG
002.
Yes: Continue.


No: Repair or replace the connectors or wiring from P41-25 to J/P81-2 to J82-2, then turn to TAG
002.
Yes: Replace the counter. If this resolves the problem, turn to TAG 002. If this does not resolve the
problem, replace the VPCL board, then turn to TAG 002.


VPCL board

No: Replace the power control #2 board. If this resolves the problem, turn to TAG 002. If this does
not resolve the problem, replace the VPCL board, then turn to TAG 002.

TAG 753: Async IO Communications Malfunction
ERROR MESSAGE:MC HOST SCC ERROR #701–#722
Symptoms: Test prints can be made but jobs do not run

Jobs do not print correctly
Possible Causes: Improper DIP switch settings

Host computer
Improper application

RIGS board communications cable
Cable connectors
I/O card
Diskette
Wrap connector
DC power supply
Communication problems may require trial replacement of numerous parts. After each trial
replacement, run the job that exhibited the failure.

• Verify that all communication cables are attached properly.
• Verify that the correct software is installed in the printer.
• Reseat the IO card(s).
• Confirm that the printer’s soft configuration is set properly.
No: Continue.
Yes: Loose connectors or software configuration were at fault. Determine which of these is at fault,
correct the problem, then turn to TAG 002.

• Reload the software on the hard disk.
• Confirm that the printer’s software configuration is set correctly to the interface you are using.
No: Continue.
Yes: Software or software configuration were at fault. Determine which of these is at fault, correct
the problem, then turn to TAG 002.

3 Disconnect the interface cable from the printer.

• Install the RS-232C and RS-422 wrap connectors.
• Run diagnostic test “LED Printhead Test” on page 5-15.
No: Continue.

• Inspect J/P71 (RS-232C), J/P72 (RS-422), and J/P74 for connector body cracks or damaged
pins.
Is there a problem with the connectors or pins?
Yes: Continue.
5 Replace the I/O card(s).

No: Continue.
Yes: The I/O card was at fault. Turn to TAG 002.

No: Continue.
Yes: The RIGS board was at fault. Turn to TAG 002.

Yes: Continue.

No: Continue.
Yes: Replace the signal interface board, then turn to TAG 002. If this does not resolve the problem,
replace the RIGS board, then turn to TAG 002.

Yes: Repair or replace connectors or wiring from P8-8 to P32-3, then turn to TAG 002.

10 Does the problem appear while using RS-232C communications?

No: The problem may be caused by the RIGS board, I/O card, host computer, or host interface
cable. Determine which of these are at fault, correct the problem, then turn to TAG 002.
Yes: Continue.

• Install a breakout box on the printer to confirm that the host interface cable works as outlined in
the chart that follows.
• Reconnect all communication lines.
• Reconnect any external attachment option.
• Run the failing job again.
Host Computer Printer Description
Signal Pin # Directions Pin # Signal
FG 1 1 FG
SG 7 7 SG
TD 2 –> <– 2 TD Data OUT (status)
TD 2 <– –> 3 RD Data in (CMD/Data)
RTS 4 –> <– 4 RTS Optional; continuous positive voltage

for host computers that require a
“printer present” indication.
CTS 5 <– 5 CTS Must go to a positive voltage from the
host computer. It is only looked at by
DSR 6 <– –> the printer at power-on initialization.
DCD 8 <–
DTR 20 –> 20 DTR Depends on printer soft configuration

option 15. DTR will always be a posi-
tive voltage if set to “DTR High”. DTR
will change from a positive to a nega-
tive voltage if set to “DTR Pacing”
and the buffer is full.
Does your cable work as outlined in the Cable Reference Chart above?
No: The problem appears to be related to the host computer or host interface cable. Correct the
problem, then turn to TAG 002.
Yes: The problem may be caused by the RIGS board, signal interface board, or outdated printer
software. Determine which of these is at fault, correct the problem, then turn to TAG 002.

TAG 754: Smart I/O Card Malfunction
Symptoms: Job fails only when a smart I/O card is used.
Possible Causes: Lack of voltage

Attachment option
Communication cables
Cable connectors
Signal interface board fuse
RIGS board
Host computer
Host interface cable
Communication problems may require trial replacement of numerous parts. After each trial
replacement, run the job that exhibited failure.

• Disconnect all attachment cables.
• Confirm that J/P8, J/P32, and J/P74 are connected properly.
• Reseat the IO card.
• Confirm that the printer has been correctly configured using the printer’s soft configuration
mode.
No: Continue.
Yes: Loose or damaged connectors or software configuration were at fault. Turn to TAG 002.

• Check for the indicated voltages:
J73-4 should be -12 Vdc;
J73-6 should be +5 Vdc.
Are all voltages correct?
No: Replace the optional IO card. If this resolves the problem, turn to TAG 002. If this doesn’t
resolve the problem, go to the appropriate TAG for the incorrect voltage and continue.
Yes: Continue.


• Replace the optional IO card.
• Reconnect all communication cables.
No: The problem appears to be related to the host computer or the host interface cable. Correct the
problem, then turn to TAG 002.
Yes: The external attachment option was at fault. Turn to TAG 002.


Photoconductor
Printhead assembly
RIGS board
Transfer corona
Developer
If there is a developed image on the paper other than dark horizontal bands, follow TAG 804.

• Verify that J/P7, J/P27, J/P41, J/P23, J/P30, J/P31, and transfer corona high voltage power sup-
ply lead are connected properly.
dure.
No: Continue.
Yes: Loose connectors or contamination were at fault. Turn to TAG 002.

Yes: Continue.
3 Have the photoconductor, charge corona, developer, and toner cartridge been
replaced recently?
No: Continue.
4 Replace the photoconductor and charge corona.

No: Reinstall original photoconductor and charge corona and continue.
5 Replace the developer and toner cartridge.

Yes: Turn to TAG 002. If the problem recurs, the toner carrier mix may be old or contaminated.


Yes: Continue.
7 Remove and clean the transfer corona.

• Clean the transfer corona contacts in the upper paper guide.
No: Continue.

• Check the lower transfer corona contact, with the upper paper guide assembly in its fully
No: Replace the upper paper guide assembly, then turn to TAG 002.
Yes: Continue.

No: Replace the upper paper guide assembly. If this resolves the problem, turn to TAG 002. If this
does not resolve the problem, replace the high voltage power supply, then turn to TAG 002.
Yes: The transfer corona was at fault. Turn to TAG 002.
10 Replace the printhead.

Yes: Continue.
11 Are the prints blank without dark bands?

Yes: Continue.


• Inspect the drive coupling on the developer for damage.
No: Continue.
13 Rotate the drive coupling on the developer clockwise.

• Watch the magnetic brush.
Does the magnetic brush turn?
No: Replace the developer, then turn to TAG 002.
Yes: Continue.

• Watch the developer drive coupling at the rear of the developer cavity.
Does the developer drive coupling turn?
No: Repair or replace the main drive gear assembly, then turn to TAG 002.
15 Do the prints have one or more horizontal dark bands?

No: The problem has not been identified. Go back to TAG 001 and begin again.
Yes: Continue.

• Clean the photoconductor contacts and guide rail contacts.
• Check the bottom connector contact on the photoconductor guide rail for continuity to ground.
No: Repair or replace the grounding circuit wiring, then turn to TAG 002.
Yes: Continue.

Yes: Contamination was at fault. Turn to TAG 002.

18 Check J/P27-1, J/P27-2, and J/P27-3 for +5 Vdc.

Is there +5 Vdc at each?
No: Continue.
Yes: Replace wire harness W46. If this resolves the problem, turn to TAG 002. If this doesn’t
resolve the problem, replace the RIGS board, then turn to TAG 002.

Yes: Replace wire harness W37, then turn to TAG 002.


Photoconductor
Transfer corona
Printhead assembly
Toner supply motor
VPCL board
Developer
If the problem still exists after completing this TAG, go to TAG 800.
1 Run test prints.

• Examine the letters A, V, and W for jaggedness on the diagonal lines.
Are they jagged?
No: Continue.
Yes: Refer to Section 4, Print Quality Samples. Review the printhead problem print samples, iden-
tify one similar to the test prints, and turn to the associated TAG.

dure.
• Clean the printhead lens and toner patch sensor located on the developer.
No: Continue.
Yes: Contamination or loose connectors were at fault. Turn to TAG 002.

Yes: Continue.
4 Have the photoconductor, charge corona, developer, and toner cartridge been
replaced recently?
No: Continue.


Yes: Run at least 200 test prints to detone the engine, then turn to TAG 002.


Is the developed image on the photoconductor correct?
Yes: Continue.
8 Remove and clean the transfer corona.

• Clean the transfer corona contacts in the upper paper guide.
No: Continue.

• Check the lower transfer corona contact, with the upper paper guide assembly in its fully
No: Repair or replace the upper paper guide assembly, then turn to TAG 002.
Yes: Continue.

• Replace the transfer corona.
No: Replace the upper paper guide assembly. If this resolves the problem, turn to TAG 002. If this
does not resolve the problem, replace the high voltage power supply, then turn to TAG 002.
Yes: The transfer corona was at fault. Turn to TAG 002.

11 Open the front cover and install an interlock by-pass tool.

• Run diagnostic test “Toner Supply Motor Test” on page 5-8.
Yes: Continue.
12 Inspect the toner drive coupling on the developer for damage.

No: Continue.
13 Rotate both the drive couplings on the developer clockwise.

Do both drive couplings rotate freely?
No: Replace the developer, then turn to TAG 002.
Yes: Continue.

• Watch the developer drive coupling in the developer cavity.
No: Repair or replace the main drive gear assembly, then turn to TAG 002.
Yes: Continue.

P41-30 to J24-4,
P41-38 to J23-2,
P41-43 to J25-5,
P41-44 to J25-2,
P41-47 to J25-3,
P41-48 to J25-6,
P41-49 to J25-4, and
P41-50 to J25-1.
No: Repair or replace the connectors or wiring that do not have continuity, then turn to TAG 002.
Yes: Continue.


• Refer to Section 9, General Printer Maintenance, and check the voltages.

• Replace the charge corona terminal assembly.
No: Reinstall the original charge corona terminal assembly and continue.


• Replace the RIGS board.
No: Reinstall the original RIGS board and go to TAG 800.
20 Turn to TAG 002.

• Run diagnostic test “Toner Supply Motor Test” on page 5-8.
No: Replace the VPCL board. If this does not resolve the problem, repair or replace the wiring
from J/P 13 to P40, then turn to TAG 002.
Yes: Continue.

21 Run diagnostic test “Toner Supply Motor Test” on page 5-8.

No: Repair or replace the connectors or wiring from P18-1 to P13-5, P18-2 to P13-2, or both.
Yes: Replace the toner supply motor, then turn to TAG 002.


Photoconductor
Developer
1 Perform the every-call cleaning procedure.

No: Continue.

Yes: Continue.
3 Have the photoconductor, developer, and fuser been replaced recently?

No: Continue.
Yes: Refer to Section 4, Print Quality Samples. Compare the test prints with the print samples, and
identify a sample having the same print flaw as the test prints; turn to the TAG listed under the
sample.

No: Reinstall the original photoconductor and charge corona, and continue.



No: Reinstall the original fuser. Refer to Section 4, Print Quality Samples. Compare the test prints
with the print samples, and identify a sample having the same print flaw as the test prints; turn
to the TAG listed under the sample.


Transfer corona
Printhead assembly
Photoconductor
Developer

• Make sure the customer's paper supply is not at fault.
• Refer to Section 9, General Printer Maintenance and perform the every-call cleaning procedure.
No: Continue.
Yes: Loose connectors or contamination were at fault. Turn to TAG 002.

Yes: Continue.
3 Have the photoconductor, charge corona, and developer been replaced recently?
No: Continue.

No: Reinstall the original photoconductor and charge corona, and continue.


Are there vertical streaks on the photoconductor belt image?
No: Replace the transfer corona, then turn to TAG 002.
Yes: Replace the printhead assembly, then turn to TAG 002.

Possible Causes: Loose printhead connectors

Transfer corona
Photoconductor
Charge corona

dure.
No: Continue.

Yes: Continue.
3 Have the photoconductor and charge corona have been replaced recently?
No: Continue.

No: Reinstall the original photoconductor and charge corona, then continue.

No: Replace the photoconductor. If this resolves the problem, turn to TAG 002. If this does not
resolve the problem, refer to Section 4, Print Quality Samples. Compare the test prints with
the print samples, and identify a sample having the same print flaw as the test prints; turn to
the TAG listed under the sample.


Charge corona
Printhead assembly
VPCL board
RIGS board
Charge corona lead
Photoconductor
Developer

• Verify that J/P23, J/P24, J/P41, and the charge corona high voltage lead are connected properly.
dure.
• Open the printer’s top cover and install an interlock by-pass tool.
Is the photoconductor belt covered with toner?
No: Loose connectors or contamination were at fault. Turn to TAG 002.
Yes: Continue.

Yes: Continue.
3 Has the photoconductor, charge corona, developer, and cleaner been replaced
recently?
No: Continue.


5 Replace the developer, toner cartridge, and cleaner.

No: Reinstall the original developer and cleaner, then continue.
Yes: Turn to TAG 002. If the problem recurs, the toner/carrier mix may be old or
contaminated.

Yes: Continue.

Yes: Continue.
8 Replace the charge corona terminal assembly.

No: Continue.
9 Replace the high voltage power supply.

No: Reinstall the original high voltage power supply and continue.
10 Replace the printhead assembly.


No: Replace the charge corona lead wiring, then turn to TAG 002.

Possible Causes: Paper path contamination

Paper supply defects
Toner

Photoconductor
Charge corona
Fuser
Developer
Cleaner

dure.
No: Continue.

Yes: Continue.
3 Have the photoconductor, charge corona, fuser, cleaner, and developer with new
toner cartridge been replaced recently?
No: Continue.


No: Reinstall the original cleaner and continue.



Yes: Turn to TAG 002. If this problem recurs, the toner/carrier mix may be old or contaminated.
8 Inspect the paper being used for scratches or dark spots.

Does the paper have any problems?
No: Continue.
Yes: Replace the paper. Turn to TAG 002.
9 Inspect for damage or binding:

• Main drive motor gear
• Developer coupling on the developer and the printer
Are these mechanisms in good working order?
Yes: Verify that the photoconductor, charge corona, developer, and fusers are new. If these items
are new, defective or contaminated toner may be the cause of the problem. Replace the devel-
oper and cleaners with units from the printer’s manufacturer, then turn to TAG 002.

TAG 807: Misregistered/Skewed Prints

If this problem occurs in the duplex printing mode only, go to TAG 901.


Upper cassette
Lower cassette
Upper pinch rollers
Lower pinch rollers
Paper feed idler assembly
VPCL board
If the test pattern has a 20 line indicator at the top of the page, registration is correct when the
twentieth line of the indicator is at the leading edge of the print (+ or - 2).
If the problem varies from print to print, a mechanical binding malfunction may be at fault.
1 Inspect both paper cassettes for damage.

• Make sure the paper in the cassettes is loaded properly.
• Make sure the side and rear paper guides are positioned properly.
• Inspect both paper paths for contamination and remove any obstructions.
• Remove and insert the cassette causing the problem. Confirm that the message, which displays
on the operator’s panel, corresponds to the paper size in the cassette. Refer to TAG 702.
Is the problem with the upper cassette.
Yes: Continue.

Is the problem also with the lower cassette?
Yes: Continue.


• Paper feed idler assembly
No: Repair or replace the parts as needed, then turn to TAG 002.
4 Inspect the following for damage and contamination:

• Upper pick-up roller assembly
• Upper feed roller assembly
• Upper pinch rollers
• Upper cassette

Is the problem with the lower cassette?
No: Incorrectly loaded paper was at fault. Turn to TAG 002.
Yes: Continue.
6 Inspect the following for damage or contamination:

• Lower pick-up roller assembly
• Lower feed roller assembly
• Lower pinch rollers
• Lower cassette.
7 Is misregistration the symptom of the problem?

No: Skew problems can only result from mechanical causes. Return to the beginning of this TAG.
Yes: Continue.

8 Run test prints.

Is the amount of misregistration within + or - 2 lines of the 20-line indicator from the leading
edge of the test print?
No: Continue.
Yes: The registration is within specification. Turn to TAG 002.
9 Adjust the registration as described in Section 9, General Printer Maintenance.

Did adjusting the registration resolve the problem?
No: Replace the paper timing roller assembly, then turn to TAG 002. If this does not resolve the
problem, replace the upper paper guide assembly or the paper timing guide, then turn to TAG
002.

Possible Causes: Clogged cleaner

Contaminated toner/carrier mix

Cleaner
Photoconductor
Charge corona
VPCL board
Developer
Overtoned print and dark print problems are very similar. If this TAG does not resolve the
problem, go to TAG 811.

dure.
No: Continue.

Yes: Continue.
3 Have the photoconductor, charge corona, cleaner, and developer with toner car-
tridge been replaced recently?
No: Continue.

Yes: Run at least 200 test prints to detone the printer’s engine, then turn to TAG 002.


6 Replace the developer with toner cartridge.

Yes: Turn to TAG 002. If the problem recurs, the toner/carrier mix may be old or contaminated.

• Watch the toner motor coupling at the rear of the developer cavity.
Does the coupling turn continuously?
Yes: Continue.

Yes: Replace the power control #2 board. If this resolves the problem, turn to TAG 002. If this
doesn’t resolve the problem, replace the VPCL board, then turn to TAG 002.
9 Reinstall the developer.

• Replace the VPCL board.
No: Reinstall the old VPCL board and continue.
Yes: VPCL board was the problem. Turn to TAG 002.


P41-44 to P25-2,
P41-47 to P25-3, and
P41-50 to P25-1.
Is there continuity at each?
P41-44 to P25-2,
P41-47 to P25-3, or
P41-50 to P25-1;
Yes: Continue.
11 Clean the printhead lens and toner patch sensor.

No: Continue.

No: Continue.
13 Reconnect J/P24.
Yes: Continue.
Yes: Continue.

15 Reconnect J/P85.
• Replace the high voltage power supply.
No: Reinstall the original high voltage power supply and continue.
16 Repair or replace the VPCL board.

No: Reinstall the original VPCL board. Confirm that the photoconductor, charge corona, devel-
oper, and fusers are new. If these items are new, the toner/carrier mix may be old or contami-
nated. Replace the developer and cleaners with units from the printer’s manufacturer. If this
resolves the problem, turn to TAG 002. Otherwise, turn to TAG 811.


Photoconductor
Charge corona
Cleaner
Fuser
Vacuum transport
Fuser drive gear
Fuser drive idler and spring
Fuser drive belt
Main drive assembly
Printhead assembly

• Refer to Section 9, General Printer Maintenance and perform the every-call cleaning procedure.
No: Continue.

Yes: Continue.
3 Have the photoconductor, charge corona, cleaner, or fusers been replaced

recently?
No: Continue.





• Vacuum transport
• Vacuum transport assembly ozone filter
• fuser drive gear on the fuser and fuser cavity
• Main drive assembly
• cleaner drive belt
• Cleaner drive idler assembly
• Cleaner drive assembly
Yes: Continue.
8 Open the printer’s top cover and install an interlock by-pass tool.
• Wait until the motor turns on, then proceed.
• Verify the vacuum transport fan is running by placing a sheet of paper over the holes in the vac-
uum transport.
Does the vacuum fan hold the paper?
Yes: Continue.
9 Inspect the vacuum transport belts and gear for damage or binding.
Is the vacuum transport in good working order?
No: Repair or replace the vacuum transport, then turn to TAG 002.
10 Run test prints.



No: Continue.
Yes: Replace the vacuum transport, then turn to TAG 002.

11 Run test prints.

Yes: Repair or replace the connectors or wiring from J22-1 to P13-6 or J22-2 to P13-3, then turn to
TAG 002.
12 Inspect the fuser drive assembly and the fuser drive belt for damage or a slipping belt.
No: Replace the parts that are defective, then turn to TAG 002.
Yes: Replace the printhead assembly, then turn to TAG 002.


Photoconductor
Charge corona
Developer
Cleaner
1 Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning procedure.
No: Continue.

Yes: Continue.
3 Have the photoconductor, charge corona, cleaner and developer with new toner
cartridge been replaced recently?
No: Continue.
Yes: Go to TAG 811.



No: Reinstall the original developer and toner cartridge, then turn to TAG 811.
Yes: Turn to TAG 002. If the problem recurs, the toner/carrier mix may be old or
contaminated.


Photoconductor
Charge corona
Cleaner
Developer
Erase lamp assembly
VPCL board
Cleaner terminal assembly

• Verify J/P23, J/P24, J/P85, and the charge corona high voltage lead are connected properly.
dure.
• Clean the printhead lens and toner patch sensor located on the developer.
No: Continue.
Yes: Contamination or a loose connector was at fault. Turn to TAG 002.

Yes: Continue.
3 Have the photoconductor, charge corona, cleaner and developer with new toner
cartridge been replaced recently?
No: Continue.

• Run 200+ test prints, then evaluate the test print background.

5 Replace the developer and cleaner.

No: Reinstall the original developer and cleaner and continue.
6 Remove the photoconductor from the printer.

• Run diagnostic test “Erase Lamp Test” on page 5-10.
• Watch the erase lamp while the test is running.
Are all the erase lamps on?
No: Continue
Yes: The VPCL was the problem, Turn to TAG 002.

Does the coupling turn continuously before error message MC NO DEVELOPER #036 is dis-
played?
No: Continue.

• Replace the VPCL
Yes: Continue.

P41-44 to J25-2,
P41-47 to J25-3, and
P41-50 to J25-1.
No: Repair or replace the connectors or wiring:
P41-44 to J24-2,
P41-47 to J25-3, or
P41-50 to J25-1;
Yes: Continue.


Yes: Continue.
11 Reconnect J/P24.
No: Continue.
12 Reconnect J/P23.
• Disconnect J/P85 from the high voltage power supply.
Yes: Continue.

No: Repair or replace the connector or wiring from P41-40 to P24-3, then turn to TAG 002.
Yes: Continue.

• Check TP4-40 for 0.5 Vdc while running the prints.
Is the voltage 0.5 Vdc?
Yes: Continue.

Yes: Continue.


No: Reinstall original VPCL board. Go back to #3 in this TAG. If this does not resolve the prob-
lem, the RIGS board, cleaner terminal assembly, or charge corona terminal assembly may be
at fault. Determine which of these is at fault, correct the problem, then turn to TAG 002.
17 Check J/P40-31 for 0 Vdc.

Yes: Continue.

Yes: Continue.


Fuser
AC power supply
VPCL board

• Verify that J/P44, J/P4, J/P10, J/P11, J/P12, J/P40, J/P83, J/P91, and J/P8 are connected prop-
erly.
dure.
No: Continue.

Yes: Continue.
3 Have the fuser and developer with new toner cartridge been replaced recently?
No: Continue.




Does the lamp light within 1.5 minutes?
No: Go to TAG 070.
Yes: Continue.
7 Run test prints.

Does the print seem to be excessively dark or do the characters feel raised on the paper?
No: Continue.
Yes: Go to TAG 808.
8 Confirm that the paper in the cassettes meets paper specifications.

Is the paper within specification?
No: Do not use this paper. Turn to TAG 002.
Yes: Continue.

No: Repair or replace the connectors or wiring from P41-22 to P83-1, or J83-1 to P5-6, then turn
to TAG 002.
Yes: Continue.

No: Repair or replace the connectors or wiring from P41-21 to P83-2, or J83-2 to P5-7, then turn
to TAG 002.
Yes: Continue.

Is the resistance between IKΩ and 400 KΩ?
No: Replace the fuser. If this resolves the problem, turn to TAG 002. If this does not resolve the
problem, replace the VPCL board, then turn to TAG 002.


Cleaner drive belt
Cleaner
Photoconductor
Erase lamp assembly
Developer

dure.
No: Continue.
2 Open the printer’s back cover.

• Remove the paper feed drive cover.
• Check the cleaner drive belt.
Is the belt attached?
No: Repair or replace the cleaner drive belt, then turn to TAG 002.
Yes: Continue.

Yes: Continue.
4 Have the cleaner, developer with new toner cartridge, and photoconductor been
replaced recently?
No: Continue.




Yes: Turn to TAG 002. If the problem recurs, the toner may be old or contaminated.

No: Repair or replace the connector or wiring from P40-40 to P24-3, then turn to TAG 002.
Yes: Continue.
9 Repair or replace the cleaner terminal assembly.

No: Reinstall the original cleaner terminal assembly, then go back to #5 in this TAG.

Symptoms: Additional lines or missing lines on page.

Printhead assembly
RIGS board

• Replace wire harness 200.
No: Continue.

No: Continue.

• Replace the RIGS board.
No: Replace the RIGS board and continue.
Yes: RIGS board was at fault. Turn to TAG 002.

• Replace the VPCL board.
No: This is not a printhead malfunction. Replace the VPCL board and turn to TAG 808.
Yes: VPCL board was at fault. Turn to TAG 002.

ERROR MESSAGE:090

Cover open sensor
VPCL board
Complete TAG 600 before starting this TAG.

• Confirm that the top and front covers are closing completely.
Is error message 090 displayed?
No: Loose connectors or obstructions were at fault. Turn to TAG 002.
Yes: Continue.
2 Open the printer’s top cover and insert the interlock by-pass tool.
• Check J/P309-3 on duplex control board #1 for +12 Vdc.
Yes: Continue.

No: Continue.

P309-1 to P318-2,
P309-3 to P318-1, and
P309-5 to P318-3.
P309-1 to P318-2,
P309-3 to P318-1, or
P309-5 to P318-3,
Yes: Replace the cover open sensor, then turn to TAG 002.


• Check J/P36-1 on the VPCL board for +12 Vdc.


Duplex holding tray sensors
Duplex holding tray motor
Duplex drive/clutch
Pinch rollers A and B
Route separator
VPCL board
Registration is correct when the top (+ or - 2) of the 20-line indicator, found on the top of a test
print, is at the leading edge of the print.
If the problem varies from print to print, suspect a mechanical binding problem. If problems
exist in the simplex mode, go to TAG 807.
1 Verify that the upper and lower paper cassettes are not damaged.
• Make sure the paper in both paper cassettes is loaded properly.
• Check both paper paths for obstructions or contamination.
No: Continue.

Duplex drive/clutch assembly
Timing belts
Pinch roller springs
Route separator and springs
No: Repair or replace any damaged parts as needed, then turn to TAG 002.
Yes: Continue.

3 Verify that J/P305, J/P310, J/P311, J/P312, J/P320, J/P321, and J/P322 are connected properly to
duplex control board #2.
• Verify that J/P306, J/P307, J/P308, J/P309, and J/P324 are connected properly to duplex control
board #1.
• Verify that J/P315 and J/P316 are connected properly to the “A” and “C” roller clutches.
• Run test prints in duplex.
Did the test indicate an error message?
No: Registration or skew problems can only result from mechanical causes. Return to the begin-
ning of this TAG.
Yes: Continue.
4 Did the side guides in the duplex tray move in and out while the test was running?
Yes: Continue.

No: Replace duplex control board #2, then turn to TAG 002.
Yes: Continue.
6 Manually move the side guides in the duplex tray to the inside positions.
• Check J/P312-2 on duplex control board #2 for 0 Vdc.
No: Continue.
Yes: Replace duplex control board #2, then turn to TAG 002.

P312-1 to P320-1,
P312-2 to P320-2, and
P312-3 to P320-3.
P312-1 to P320-1,
P312-2 to P320-2, or
P312-3 to P320-3,
Yes: Replace the side sensor. If this resolves the problem, turn to TAG 002. If this does not resolve
the problem, replace duplex control board #2, then turn to TAG 002.
8 Run diagnostic test “Duplex Sensor Tests” on page 5-12.

Did the Duplex Sensor Test indicate a duplex tray paper sensor problem?
No: Continue.


No: Repair or replace the wiring or connectors from P312-7 to J321-1, then turn to TAG 002.
Yes: Continue.

Yes: Continue.

Yes: Continue.

Yes: Replace duplex control board #2. If this resolves the problem, turn to TAG 002. If this does
not resolve the problem, replace the registration motor, then turn to TAG 002.

Yes: Continue.

• Check J/P312-5 for 0 Vdc.
No: Replace the duplex tray paper sensor. If this resolves the problem, turn to TAG 002. If this
doesn’t resolve the problem, repair or replace the wiring or connectors from:
P312-4 to J322-1,
P312-5 to J322-2, or
P312-6 to J322-3,
Yes: Continue.


• Check J/P36-6 on the VPCL board for 0 Vdc.
No: Replace duplex control board #2. If this resolves the problem, turn to TAG 002. If this doesn’t
resolve the problem, repair or replace the wiring or connectors from P311-7 to J/P305-11 to
P36-4, then turn to TAG 002.

ERROR MESSAGE:PAPER JAM 027 IN DUPLEX AREA

PAPER JAM 060 DUPLEX ROLLER
PAPER JAM 061 DUPLEX PATH
PAPER JAM 062 DUPLEX TRAY

Paper path not clear

Duplex drive/clutch
Duplex input solenoid
“C” roller clutch
Duplex feed motor

• Verify that J/P306, J/P307, J/P308, J/P309, J/P313, J/P314, J/P315, J/P316, J/P317, and J/P319
• Check the following components for damage:
Duplex drive/clutch
Timing belts
Route separator
No: Continue.

• Run diagnostic test “Duplex Sensor Tests” on page 5-12.
Is the duplex paper path sensor in good working order?
No: Continue.

• Check J309-4 on duplex control board #1 for +12 Vdc.
Yes: Continue.


Yes: Continue.

Yes: Continue.
6 Check J319-2 for +12 Vdc.

Yes: Replace the paper pass sensor, then turn to TAG 002.

• Run diagnostic test “Duplex Sensor Tests” on page 5-12.
Is the “A” roller clutch in good working order?
No: Continue.

• Check J308-3 on the duplex control board #1 for +24 Vdc.
Yes: Continue.

• Check P316-1 for +24 Vdc.
Yes: Replace the “A” roller clutch, then turn to TAG 002.


• Run diagnostic test “Duplex Clutch Tests” on page 5-13.
Is the input solenoid in good working order?
No: Continue.

Yes: Continue.
P308-1 to J314-1, and
P308-5 to J314-2.
P308-1 to J314-1, or
P308-5 to J314-2,
Yes: Replace the input solenoid, then turn to TAG 002.

• Run diagnostic test “Duplex Clutch Tests” on page 5-13.
Is the C roller solenoid in good working order?
No: Continue.

Yes: Continue.

P308-2 to P315-1, and
P308-6 to P315-2.
P308-2 to P315-1, or
P308-6 to P315-2,
Yes: Replace the “C” roller solenoid, then turn to TAG 002.

• Run diagnostic test “Duplex Motor Tests” on page 5-11.
Is the feed motor in good working order?
No: Continue.

Yes: Continue.

No: Continue.
Yes: Replace duplex control board #1, then turn to TAG 002.
P309-7 to J313-1,
P309-8 to J313-2,
P309-9 to J313-3, and
P309-10 to J313-4.
No: Repair or replace the wiring or connectors from P309 to J313 that have no continuity, then
turn to TAG 002.
Yes: Continue.

20 Check the following for continuity:

P313-1 to P313-2, and
P313-3 to P313-4.
No: Replace the route motor, then turn to TAG 002.

• Check J/P306-3 to J/P306-4 for +5 Vdc.
No: Repair or replace the wiring or connectors from P306-3 to J/P331-3 to P330-3, then turn to
TAG 002.
Yes: Continue.

TAG 002.
Yes: Continue.

TAG 002.
Section 2 Troubleshooting Analysis Guides (TAGs)


Section 4
Print Quality
Samples
Section 3 Print Quality Samples

Contents
Sample 1: Good Quality Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Sample 2: Washout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Sample 3: Blank Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Sample 4: Light Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Sample 5: Light Print With Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Sample 6: Voids or White Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Sample 7: Light Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Sample 8: Blank Vertical Bands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Sample 9: Light Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Sample 10: Black or Dark Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Sample 11: Dark Specks, Lines, or Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Sample 12: Dark Vertical Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Sample 14: Misregistration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Sample 16: Blurred Images or Characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
Sample 17: Varying Print Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
Sample 19: Residual Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
Sample 20: Wrinkles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
Sample 21: Fusing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Section 4

This section contains flawed test prints, along with a good test print for comparison. Com-
pare print samples from your customer’s print job or from test prints you’ve run with the
samples in this section. If you find a match, note the TAG (i.e., troubleshooting procedure)
listed under the sample. Turn to that TAG to begin troubleshooting. All of the TAGs are
contained in Section 3, Troubleshooting Analysis Guides.
If your customer’s prints show more than one problem, resolve them one at a time, in the
order in which they are listed in this section.

Description: Good, properly registered print.

Sample 2: Washout
Sample 2: Washout
Void Areas
Blurs
Description: Void areas, light spots, or blurs. This is a composite of the possible
symptoms.
Go to TAG 801, 802, 809, or 810.

Void of
Any Image
Description: No images or characters. The paper is not discolored.

Go to TAG 800, 815.

Light Areas
Light Areas
Description: Images or characters are lighter than normal. Examine the letters H, T, M, and E; if the
vertical strokes are dark enough but the diagonal strokes are stair-stepped, the problem
is related to the printhead. Carrier particles may make the print feel gritty.
Go to TAG 801.

Light Areas
Background
Description: Images or characters lighter than normal, ranging from a few dark specks to a large
speckled background.
Go to TAG 811.

White Areas
Description: Voids or white spots in image areas.

Go to TAG 802.

Light Vertical
Streaks
Description: One or more light vertical streaked areas of varying widths.

Go to TAG 803.

Blank
Vertical
Bands
Description: One or more vertical blank bands of varying widths extend over the entire length.
Go to TAG 803.

Light
Horizontal
Bands
Description: One or more light horizontal bands of varying width.

Go to TAG 804.

Excessively
Dark or Black
Print
Description: Black or very dark with no visible images.

Go to TAG 805, 811.

Dark Specs,
Lines, or
Areas
Description: Dark specks or lines (like scratches), some in the same place on each print.
Go to TAG 806, 810.

Dark
Vertical
Lines
Description: One or more dark lines of varying density. If the image can be rubbed off, go to TAG
812. If the image cannot be rubbed off, go to TAG 808.
Go to TAG 812, 808.

Image is
Crooked
on Page
Description: The entire image is not located squarely on the paper.

Go to TAG 807 for simplex.
Go to TAG 901 for duplex.

Image not
Located
Properly from
Leading Edge
of Paper
Description: The entire image is not correctly located from the leading edge of the paper. The top or
bottom image area may be missing.
Go to TAG 807 for simplex. Go to TAG 901 for duplex.

Gaps Between
Images or
Characters
Filled with
Toner
Background
Description: Similar to dark print quality problems. Narrow gaps between letters and images may be
filled with toner. Excess toner may be present on the surface of the print. Extra toner can
also cause background in the white areas.
Go to TAG 808.

Smeared
Images or
Characters
Description: The images or characters are not clear. The lower edges of images and/or characters are
extended and may appear smeared.
Go to TAG 809.

Dark Density
Normal Density
Light Density
Description: Some areas of the print are lighter or darker than normal. Examine the letters H, T, M,
and E on your test print. If the vertical sections are sufficiently dark, but the diagonal
sections appear stair-stepped, the problem may be is related to the printhead.
Go to TAG 810, 815.

Unprinted
Areas have
Gray
Background
Description: White areas on the prints have varying degrees of specks appearing in a
specific pattern.
Go to TAG 811.

Residual Images
from Previous
Print
Description: Images from a previous print are visible. White areas on the print may have varying
degrees of specks appearing in a specific pattern.
Go to TAG 811, 813.

Sample 20: Wrinkles
Sample 20: Wrinkles
Wrinkled
Paper
Description: Wrinkles or creases, often at the top or bottom.

Go to TAG 706.

Description: Images or characters may rub off the surface.

Go to TAG 812.

Section 5
Diagnostic
Tests
Section 4 Diagnostic Tests

Contents
Diagnostic Tests
How to Run Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Operator Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Upper Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Lower Cassette Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Fuser Thermistor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Roller Clutch Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Counter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Jogging Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Photoconductor Seam Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Toner Supply Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Charge Corona Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Transfer Corona Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Erase Lamp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Toner Empty Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Negative Developer Bias Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Duplex Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Duplex Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Duplex Clutch Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Duplex Tray Paper-Guide Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
High-Capacity Output (HCO) Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
High-Capacity Input (HCI) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
LED Printhead Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
RIGS Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Com. Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Display File Version Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
Format Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
Clear Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Disk Drive Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

Section 5
Diagnostic Tests
This section provides step-by-step instructions for running each of the diagnostic tests
available. Check the contents page to find the page on which a specific test is described.
Note that some tests assume the condition set up in a previous test – for example, the
“Toner Empty Test” assumes that the developer was removed in the previous “Erase
Lamp” test. For this reason, perform the necessary tests in the sequence indicated.

Follow these steps to access the self-diagnostic mode of the printer:
1 Turn off the printer and wait five seconds.
2 Hold down MENU and STATUS while turning the printer on until all three LEDs are lit.
The printer takes about 1 minute to enter diagnostic mode. When the display reads
“Diagnostic Tests” – this is called the base panel – you are ready to runs tests.
3 Press e to display the first test. Once a test name is displayed, use these keys:
h to move to the next test
g to go back to preceding test
to return to the base panel

If you press these keys before a test is complete, a long tone sounds and the test con-
tinues without interruption.
4 Press e to run the test.
5 Press f to end the test (in most cases; see specific diagnostic procedures for directions
on exiting a test).
6 To exit diagnostic mode, cycle printer power.
Most errors or conditions reported are valid until you press a key.
Note: Only diagnostics useful for field maintenance are documented in this manual.

Operator Panel Test
Operator Panel Test

1 Turn the volume control on the operator panel up fully.
2 At the base panel, press e to enter the “Operator Panel Test.”
3 Press h to run the test.
4 The panel displays alphanumeric characters. Press h to scroll the characters.
5 Press f to exit.
Upper Cassette Test

1 Make sure the upper paper cassette is installed with paper, the side and rear guides
2 At the base panel, press e to enter the tests.
3 Press h until “Upper Cassette Test” is displayed.
5 The chart below gives the displays that show the paper size in the cassette. This indi-
cates the paper size sensor is working properly.
The following displays indicate paper sizes:
Display
No Cassette
Size A4
Size B5
Letter Size
Legal Size
Executive
6 Press f to exit.

Lower Cassette Test
Lower Cassette Test

1 Make sure the lower paper cassette is installed with paper, the side and rear guides
3 Press h until “Lower Cassette Test” is displayed.
5 The chart below gives the displays that show the paper size in the cassette. This indi-
cates the paper size sensor is working properly.
The following displays indicate paper sizes:
Display
No Cassette
Size A4
Size B5
Letter Size
Legal Size
Executive
Note: If you have installed the HCI, it should also cause the C40D to display the correct
paper setting during testing.
6 Press f to exit.
Fuser Thermistor Test

2 Press h until “Fuser Thermistor Test” is displayed.
4 You will see a response listing the A/D value, such as “A/D Value is nn”
5 Press f to exit.

Sensor Tests
Sensor Tests
Note: Remove the HCO from the printer before running this test.

2 Press h until “Sensor Tests” is displayed.
3 Press e to run the test. The name of the first sensor appears on the display, confirming
that the sensor is working properly.
Note: No paper moves through the machine, so indications of “Paper Not Hitting” are
normal.
4 Press e to advance to the next sensor. The display changes, showing the next sensor
as outlined in the chart below.
1st Display Line 2nd Display Line
Upper Cassette Not Empty

Empty
Lower Cassette Not Empty

Empty
Paper Timing Paper Not Hitting

Paper Hitting
Paper Exit Paper Not Hitting

Paper Hitting
Output Tray Full Not Full

Full
PC Seam PSS is Not Active

PSS is Active
Developer Unit Developer Connected

No Developer
5 To check a specific sensor, press e repeatedly until the name of the sensor you want to
check is displayed. Manually activate the sensor. Confirm that the display changes
when you activate the sensor. See “Sensors and Switches Illustrations” on page 1-8 for
the locations of the sensors.
6 Press f to exit.

Roller Clutch Tests
Roller Clutch Tests

2 Press h until “Roller Clutch Tests” is displayed.
3 Press e to run the test. The first clutch engages and disengages, signaled by a contin-
uous clicking sound. “Upper Paper Pick-up” appears on the display, corresponding to
the upper pick-up roller clutch. The display also shows “On” and “Off” alternately as
the clutch operates.
4 Press h to test the next clutch. The display changes to indicate the next clutch. Listen
Output Tray Front
Output Tray Back
Output Tray Front
Output Tray Back
for the clicking sound as the next clutch engages. The displays for each of the clutches
are listed in the following chart.
Display
Upper Paper Pick-up

Lower Paper Pick-up
Upper Paper Feed
Lower Paper Feed
Paper Timing Roller
5 Repeat Step 4 until you have tested all of the clutches.

6 Press f to exit.
Counter Test
3 Press h until “Counter Test” is displayed.
5 Press g to increment the counter.
6 Confirm that the page counter advances by 1 each time you press g.
7 Press f to exit.

Jogging Motor Test
Jogging Motor Test

Note: This test exercises the HCO. If you have no HCO attached to the C40D, you will not
notice any test activity.
2 Press h until “Jogging Motor Test” is displayed.
4 The HCO exit rollers jog left and right.
5 Press f to exit.
Photoconductor Seam Sensor Test

2 Press h until “PC Seam Sensor Test” is displayed.
3 Press e to run the test. The main motor rotates the photoconductor belt.
Be aware that the following error conditions may occur:

• Developer bias short detected
• Photoconductor seam sensor not received or detected
• Seam sensor (sender) short
• Seam sensor (sender) open or the photoconductor is not installed
• Erase lamp malfunction
4 Press f to exit.
Toner Supply Motor Test

1 Open the front and top covers.
2 Remove the photoconductor and the developer. Place the photoconductor in its protec-
tive packaging.
3 Insert the interlock by-pass tool in the front cover. Close the top cover.
5 Press h until “Toner Motor Test” is displayed.
6 Press e to run the test. The toner supply motor runs continuously.
7 Observe the toner supply motor through the open developer cavity. Confirm that the
motor is turning counterclockwise, accompanied by “On” on the display.

Charge Corona Test
8 Press f and e alternately several times to verify the toner supply motor starts and
stops. (This stops and restarts the test.)

• You forgot to remove the developer
• You forgot to insert the interlock by-pass tool
9 Press f to exit.
10 Reinstall the developer and photoconductor.
11 Remove the interlock by-pass tool and close the front cover.
Charge Corona Test

1 Remove the photoconductor and place it in its protective packaging. Close the top
cover.
3 Press h until “Main Charger Test” is displayed.
4 Press e to run the test. The charge corona turns on and off repeatedly.
5 Confirm that the display alternates between “Off” and “On,” accompanied each time
by a brief tone.

• Photoconductor seam sensor short
• Charge corona short
• Charge corona open
• You forgot to remove the photoconductor
6 Press f to exit.
Transfer Corona Test

1 Remove the photoconductor and place it in its protective packaging. Close the top
cover.
3 Press h until “Transfer Corona Test” is displayed.
4 Press e to run the test. The transfer corona turns on and off repeatedly.
by a brief tone.

Erase Lamp Test

• Transfer corona short
• Transfer corona open or not installed
6 Press f to exit.
Erase Lamp Test

2 Remove the photoconductor and place it in its protective cover.
4 Press h until “Erase Lamp Test” is displayed.
5 Press e to run the test. The erase lamp turns on with all LEDs lighted.
6 Verify that all LEDs are illuminated.

• Erase lamp malfunction
7 Press f to exit.
Toner Empty Test

2 Press h until “Toner Empty Test” is displayed.
3 Press e to run the test. Verify that the Toner Empty message appears on the display.
4 If the developer is not in the C40D, you will get a “No Developer” message.
5 Press f to exit.

Negative Developer Bias Test
Negative Developer Bias Test

4 Press h until “Neg Devel Bias Test” is displayed.
5 Press e to run the test. The negative developer bias turns on and off
repeatedly.
by a brief tone.

• Developer bias short
• You forgot to insert the interlock by-pass tool
7 Press f to exit.
Duplex Motor Tests

2 Press h until “Duplex Motor Tests” is displayed.
3 Press e to run the test. The duplex feed motor operates at full forward speed as indi-
cated on the display.
4 Press h to advance to the next motor speed.
5 Listen for the following motor frequencies and check the display as you move through
the test sequence:
Display
Forward Full Speed
Forward Slow Speed
Reverse Full Speed
Reverse Slow Speed
Note: To view the timing roller while running the test, open the printer top cover and
bypass the cover interlock.

Duplex Sensor Tests

• Duplex is not installed
• Cover is open/Close cover
6 Press f to exit.
7 Remove the cover interlock bypass.
Duplex Sensor Tests

2 Press h until “Duplex Sensor Tests” is displayed.
3 Press e to run the test. The name of the first sensor appears on the display, confirming
that the sensor is working properly.
normal.
4 Press h to advance to the next sensor. The display changes, showing the name of the
next sensor as outlined in the chart below.
B-C Paper Sensor Paper Not Hitting

Paper Hitting
Duplexer Cover Cover is Closed

Cover is Open
Duplex Tray Sensor Paper Not Hitting

Paper Hitting
5 To check a specific sensor, press h repeatedly until the sensor you want to check is
displayed, then manually activate the sensor. Confirm that the display changes when
you activate the sensor. See “Sensors and Switches Illustrations” on page 1-8 for the
locations of the sensors.
• Duplex tray is not installed
6 Press f to exit.

Duplex Clutch Tests
Duplex Clutch Tests

2 Press h until “Duplex Clutch Tests” is displayed.
3 Press e to run the test. The first flipper engages, accompanied by a continuous click-
ing sound, “Exit Flipper” appears on the display, and the display shows “On” or “Off”,
according to the flipper’s state.
4 Press h to activate the next clutch or flipper. Listen for the clicking sound as it
engages. The display changes to indicate the next clutch or flipper.
Display
Exit Flipper
A-roller Clutch
Re-entry Flipper
C-roller
5 To check a specific clutch or flipper, press h repeatedly until the code on the display
corresponds to the item you want to check. Manually activate the sensor. Confirm that
the display changes when you activate the sensor. See “Sensors and Switches Illustra-
tions” on page 1-8 for the locations of the sensors.
• Duplex tray is not installed
6 Press f to exit.
Duplex Tray Paper-Guide Motor Test

2 Press h until “Duplex Paper Guide” is displayed.
3 Press e to run the test. The paper guide in the duplex tray moves to and from its home
position.
4 Confirm that the paper guide in the duplex tray moves back and forth constantly.
• Duplex tray not installed
• Duplex tray registration sensor not activated
• Duplex tray registration sensor activated
5 Press f to exit.

High-Capacity Output (HCO) Sensor Tests
High-Capacity Output (HCO) Sensor Tests

2 Press h until “Hi Cap Output Sensor” is displayed.
3 Press e to run the test. The code for the sensor appears on the display, confirming that
the sensor is working properly.
normal.
4 Press h to advance to the next sensor. The sensor appears on the display; codes and
their meaning are outlined in the chart below.
HCO Unit Sensor Not Installed

Output Installed
Paper Exit Sensor Paper Not Hitting

paper Hitting
Paper Full Sensor Output Tray Not Full

Output Tray Full
Tray Wait Sensor Tray Ready

Tray Rising
5 To check a specific sensor, press h repeatedly until the sensor you want to check is
displayed. Manually activate the sensor. Confirm that the display changes when you
activate the sensor. See “Sensors and Switches Illustrations” on page 1-8 for the loca-
tions of the sensors.
6 Press f to exit.
High-Capacity Input (HCI) Test

2 Press h until “Hi Cap Input Size” is displayed.
3 Press e to run the test. The display registers the paper size installed in the unit, as out-
lined on the chart (“No Cassette” will appear on the display if a high-capacity input is
not installed.)

LED Printhead Test
4 Verify the correct paper size, as displayed.
Display
No Cassette
Size A4
Letter Size
Legal Size
5 Press f to exit.
LED Printhead Test

4 To help identify the LEDs, place a white sheet of paper in the photoconductor cavity
over the printhead’s fiber optics.
6 Press h until “LED Printhead Test” is displayed.
8 The LED printhead turns on.
9 Verify that the LEDs cycle on and off.
These codes indicate specific error conditions:
Display Indication
4-1 You forgot to remove the photoconductor unit.
10 Press f to exit.

RIGS Board Test
RIGS Board Test

2 Press h until “RIGS Board Test” is displayed.
• The error message and code appear.
• Look up the code in the “Error Code/TAG Cross-Reference” on page 2-4 to deter-
mine which TAG to follow.
• Press f to exit.
5 If no errors are found, the message “Test Successful” is displayed.
6 Press f to exit.
Com. Wrap Test

Note: You can run this test successfully without the C40D being configured for RS-232
operation.

2 Install the RS-232C wrap connector, found in the tool kit mounted inside the right
printer cover.
If you do not have wrap connectors, jumper the connections as outlined in the follow-
ing charts:
pin 2 <------------> pin 3
pin 4 <------------> pin 5

pin 8 <------------> pin 20
pin 17 <------------> pin 24

4 Press h until “Com. Wrap Test” is displayed.
5 Press e to select the test.
7 If an error code appears, check the “Error Code/TAG Cross-Reference” on page 2-4 to
determine which TAG to follow.

Display File Version Test
9 Press f to exit, if an error is detected. (For some errors, you may have to power-on-
reset the printer.)
10 Remove the wrap connectors.
Display File Version Test

2 Press h or g until the desired drive shows on the display.
3 Press e to select the drive.
4 Press h or g to find the file to test.
5 Press e to run the test. You will see “Version Number = nnnn”, where nnnn is the
function code version number.
6 Press f to exit.
Format Disk
2 Press h until “Format Disk” shows on the display.
3 Press e to select this function.
4 Press h to “Format Hard Drive C” and press e to select this drive.
5 You will see “Status = Erase Disk”. Press the Status key to format drive C.
6 Press f to exit.
Note: When using the FORMAT DISK function of the self-diagnostic mode, any existing
data on the specified disk is at risk!
Note: If you access this function by mistake, do not proceed. Press f immediately to exit
the utility.

Clear Error Log
Clear Error Log

2 Press h until “Clear Error Log” shows on the display.
4 Press h to advance to the drive where the error log is maintained. This is usually the
boot drive.
5 Press e to clear the error log on the selected drive.
6 Press f to exit.
7 Confirm that the error log has been cleared.
8 Exit diagnostic mode (power-on reset)
9 Print the error log. All errors in all sections should be reset to zero.
Disk Drive Test

Note: This is a non-destructive test. You can use it to test drive A, the 3.25” floppy disk
drive (if you have inserted a C40D formatted diskette in it), or drive C, the hard
drive.

2 Press h until “Disk Drive Test” is displayed.
4 Press h to change the drive parameter.
5 Press e to test the selected drive.
6 Press f to exit.

Section 6
Wiring Diagrams
and Electrical Data
Section 5 Wiring Diagrams and Electrical Data

Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Printhead Circuit Board Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Connector (J/P) Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Connectors Inside the Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
Connectors Inside the Left Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
Connectors on the Duplex Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
Connectors Inside the Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Connectors Inside the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
Connectors on the Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
Connectors Inside the Back Cover (J/P2-14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
Connectors Inside the Back Cover (Continued) J/P 18-62. . . . . . . . . . . . . . . . . . . 6-19
Connectors Inside the Back Cover (Continued) J/P 64-85. . . . . . . . . . . . . . . . . . . 6-20
Connectors Inside the Back Cover (Continued) J/P 90-800. . . . . . . . . . . . . . . . . . 6-21
Voltage Isolation Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
-12 Vdc Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
+5 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
+12 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
+24 Vdc Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
Ground System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
Host Interface Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
RS-232C Host Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Standard DCE to DTE RS-232C Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29
DTE Host to Printer (Option 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29
DTE Host to Printer (Option 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
IBM PC/XT to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
IBM PC/AT to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31
Macintosh Communication Port to Printer . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31
Centronics Parallel Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
IBM Parallel to Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

Introduction
Section 6
Wiring Diagrams and

Electrical Data
Introduction
This section provides a reference guide for all information related to the electrical system
of the printer, including:
• An index, arranged by connector number, to the connector’s location in the printer and
on the schematics, which are found in this chapter.
Note: Connectors are referred to by J/P (jack/plug) numbers throughout this manual. Use
the J/P number when looking up the connector in the index, schematics, and illus-
trations.
• Complete connection diagram showing plugs, connectors, and wiring.

• Connector locations and illustrations.
• Voltage isolation diagrams.
• Host interface signal definitions.
For a complete list of the abbreviations used in this section, please see page 6-9.
Printhead Circuit Board Settings

Note: The printhead circuit board uses DIP switches to match printhead characteristics to
controller characteristics. Do not change these DIP switch settings; they should
remain as set at the factory.

Connector (J/P) Index Schematic

Connector Page
Location
Schematic
Connector Page J/P 37 6-16 C8
Location
J/P 40 6-16 C8
J/P 2 6-18 F4
J/P 41 6-16 C8
J/P 3 6-18 F4
J/P 42 6-12 B9
J/P 4 6-18 E6
J/P 43 6-13 D10
J/P 5 6-16 E5
J/P 44 6-19 E5
J/P 6 6-18 E7
J/P 45 6-13 C10
J/P 7 6-18 D8
J/P 46 6-13 D9
J/P 8 6-18 D7
J/P 47 6-13 D10
J/P 9 6-18 C4
J/P 48 6-13 D9
J/P 10 6-18 C4
J/P 49 6-15 E9
J/P 11 6-18 B4
J/P 50 6-19 E9
J/P 12 6-18 B4
J/P 51 6-15 E9
J/P 13 6-18 B3
J/P 57 6-16 E9
J/P 14 6-18 C3
J/P 58 6-19 E9
J/P 15 6-15 D11
J/P 59 6-13 E9
J/P 18 6-19 B3
J/P 60 6-19 E9
J/P 20 6-19 C3
J/P 61 6-13 E10
J/P 21 6-19 B3
J/P 62 6-19 E10
J/P 22 6-15, 6-19 C3
J/P 63 6-16 C5
J/P 22-1 6-14 C2
J/P 64 6-20 C5
J/P 23 6-19 B7
J/P 65 6-20 F8
J/P 25 6-19 C4
J/P 66 6-20 F9
J/P 26 6-19 B6
J/P 67 6-20 F9
J/P 27 6-19 C6
J/P 68 6-20 F9
J/P 30 6-19 C6
J/P 69 6-20 F10
J/P 31 6-16 B8
J/P 70 6-20 E4
J/P 32 6-16 B8
J/P 76 6-16 B8
J/P 33 6-16 B8
J/P 77 6-20 D6
J/P 34 6-16 B8
J/P 79 6-20 C6
J/P 36 6-16 C8
6-4 Section 1: Printer and Troubleshooting Overview

Schematic Schematic
Connector Page Connector Page
Location Location
J/P 81 6-20 A5 J/P 311 6-16 F3
J/P 82 6-12 A4 J/P 312 6-16 F3
J/P 83 6-20 E5 J/P 313 6-14 F2
J/P 84 6-20 E6 J/P 314 6-14 E2
J/P 85 6-20 B6 J/P 315 6-14 E2
J/P 90 6-21 C9 J/P 316 6-14 E2

J/P 91 6-16 C8 J/P 317 6-15 D2
J/P 94 6-21 C8 J/P 318 6-12 F1
J/P 96 6-21 C5 J/P 319 6-14 E2
J/P 119 6-13 C9 J/P 320 6-16 G2

J/P 120 6-13 C9 J/P 321 6-16 G2
J/P 121 6-21 B6 J/P 322 6-16 F2
J/P 122 6-21 B6 J/P 323 6-21 D3
J/P 124 6-21 B6 J/P 324 6-21 E3
J/P 127 6-13 C9 J/P 330 6-21 E8
J/P 128 6-13 C9 J/P 331 6-21 D3

J/P 131 6-16 E6 J/P 333 6-21 A8, D2
J/P 132 6-16 E6 J/P400 6-14 B9
J/P 139 6-21 B6 J/P 600 6-16 C8
J/P 140 6-21 B6 J/P 800 6-21 E5
J/P 143 6-21 B6
J/P 251 6-21 B5
J/P 252 6-21 B5
J/P 255 6-21 A5
J/P 305 6-16 E3

J/P 306 6-14 E2
J/P 307 6-14 E3
J/P 308 6-14 E2

J/P 309 6-14 E2
J/P 310 6-16 F3
6-5
This space left intentionally blank.

This page indexed as the C40D schematic on page

6-7. Page 6-8 will be blank and the next regular
page is 6-9.


Acronyms and Abbreviations
Acronyms and Abbreviations FUSER .....................Fuser Unit

HCI ...........................High Capacity Input
ACIA........................ Asynchronous Communication HCO .........................High Capacity Output
Interface Adapter
HEAD.......................LED Array Print Head
ALU ......................... Arithmetic Logic Unit
HDD .........................Hard Disk Drive
APA.......................... All Points Addressable
HVU .........................High Voltage Unit
ARC ......................... “A” Roller Clutch
IGS ...........................Image Generation System
ARIF ........................ Array Interface
I.L. SW Front ...........Interlocking Switch (Front)
ATC .......................... Auto Toner Control
I.L. SW Top ..............Interlocking Switch (Top)
CLEANER ............... Cleaner Unit
INS ...........................In Solenoid
CNT ......................... Counter
IPL............................Initial Program Load
COOLING FA2........ Cooling Fan (Bootstrap)
COS.......................... Cover Open Sensor L PAPS .....................Lower Paper Sensor
CRS .......................... “C” Roller Solenoid LN03 ........................DEC emulation language
CRT .......................... Cathode Ray Tube LPC ..........................Lower Paper Feed Clutch
CRTC ....................... CRT Controller LPE...........................Lower Paper Empty Sensor
CRU ......................... Customer-Replaceable Unit LPP ...........................Lower Pick Up Clutch
DB-........................... Developer Bias Negative LPSS.........................Lower Tray Interlock Switch
DB+.......................... Developer Bias Positive Main .........................Main Motor
DC P.S.1 ................... DC Power Supply MAP .........................Maintenance Analysis
DEV ......................... Developer Unit Procedures
DMAC ..................... Direct Memory Access MCH.........................Charge Corona Unit
Controller MCS .........................Charge Corona Sensor
DMC ........................ Dynamic Memory Controller MPU .........................Micro Processing Unit
DRAM ..................... Dynamic Random Access MUX ........................Multiplexer
Memory
OPC ..........................Organic Photoconductor
DUPLEX1................ Duplex Control #1
OPPNL .....................Operator Panel
DUPLEX2................ Duplex Control #2
PC .............................Photoconductor
EL............................. Eraser LED
PCL ..........................1. Hewlett-Packard Printer Con-
EPROM.................... Erasable Programmable Read trol Language (Software)
Only Memory 2. Printer Control Logic Board
EPP........................... Electrophotographic Process (Hardware)
EPS........................... Exit Paper Sensor PCL5 ........................HP Printer Control Language
ERASER .................. Erase Lamp (Version 5)
EXS .......................... Exit Solenoid PCU ..........................Photoconductor Unit
FA4........................... Cooling Fan PFS ...........................Paper Full Sensor
FDC.......................... Floppy Disk Controller PH 1..........................A.C. Power Cord
FDD ......................... Floppy Disk Drive PIA ...........................Peripheral Interface Adapter
FL............................. Fuser Halogen Lamp PIT............................Parallel Interface/Timer
Flex IO ..................... Flex Input/Output card
FRU.......................... Field-Replaceable Unit
6-9
Acronyms and Abbreviations TES ...........................Toner Empty Sensor
(continued) TFS ...........................Tray Front Sensor
TH.............................Thermistor
TONER.....................Toner Motor
PMP..........................Page Map Primitives
TPS ...........................1. Timing Paper Sensor
POR ..........................Power On Reset
(Schematics)
PPS ...........................Paper Path Sensor 2. Toner Patch Sensor (Printer)
(B-C Sensor)
TRC ..........................Timing Roller Clutch
PROM ......................Programmable Read Only
TRS...........................Tray Rear Sensor
Memory
U PAPS .....................Upper Paper Sensor
PS .............................PostScript
UMT 1–3 ..................Usage Meter Drive Signal
PSS ...........................Photoconductor Seam Sensor
UPC ..........................Upper Paper Feed Clutch
PTM..........................Programmable Timer Module
UPE ..........................Upper Paper Empty Sensor
PTS ...........................Paper Timing Sensor
UPP...........................Upper Pick Up Clutch
PW CONT2..............Power Control #2
UPSS ........................Upper Tray Interlock
PW CONT3..............Power Control #3
VPCL........................Video Printer Control Logic
PWBA ......................Printed Wire Board Assembly
Board
RAM.........................Random Access Memory
Resist Motor .............Registration Motor
RIGS.........................RISC Image Generation
System
ROM.........................Read Only Memory
Root Motor ...............“C” Roller Motor
RPS...........................Registration Paper Sensor
RSS...........................Registration Side Sensor
SCC ..........................Serial Communication
Controller
SIG IF or SIF ...........Signal Interface Board
SRAM ......................Static Random Access
Memory
SRC ..........................System Reference Code
SRMR2.....................Side Registration Motor
Control #2
Suction FA3..............Suction Fan
SW5..........................Upper Cassette In Switch
SW6..........................Lower Cassette In Switch
TAGs ........................Troubleshooting Analysis
Guides
TC.............................Toner Concentration
TCH..........................Transfer Corona Unit
TCS ..........................Transfer Corona Sensor
TDS ..........................Toner Density Sensor
6-10 Section 1: Printer and Troubleshooting Overview

Connector Locations
The illustrations that follow show the relative location of all accessible connectors in the
printer, and illustrate the connector (except for a few instances in which the connector is so
simple that an illustration is unnecessary). For the connector’s schematic location, refer to
the chart on the preceding pages.

J/P 42 J/P 318
J/P 82

J/P 43,45, 47 J/P 59, 61
J/P 46, 48 J/P 119, 120, 127, 128 1

J/P 314
J/P 22-1
J/P 306
J/P 315
J/P 307
J/P 316
J/P 308
J/P 309
J/P 319
J/P 313

J/P 15 J/P 49, 51
J/P 22 J/P 317

J/P 5
J/P 310
J/P 311
J/P 57
J/P 312
J/P 63 J/P 320
J/P 131-132 1
J/P 321
J/P 305
J/P 322

J/P 31, 33, 34
J/P 76
J/P 32
J/P 600
J/P 36
J/P 91
J/P 37
J/P 400
J/P 40, 41

J/P 2, 3 J/P 8
J/P 11
J/P 12
J/P 4
J/P 13
J/P 6 J/P 9
J/P 14
J/P 7 J/P 10

J/P 18 J/P 26
J/P 20 J/P 27
J/P 21
J/P 30
J/P 22
J/P 23
J/P 44
J/P 50
J/P 25
J/P 58, 60, 62

J/P 64
J/P 79
J/P 65, 66, 67, 68, 69, 70

J/P 81, 83
J/P 77 4 3 2 1
J/P 84
J/P 85

J/P 323 4 3 2 1
J/P 90
J/P 324
J/P 94
J/P 330, 331 4 3 2 1
J/P 96
J/P 333 2 1
J/P 121, 122, 124

1
139, 140, 143
J/P 800
J/P 251, 252, 255 not illustrated


Use the following voltage isolation diagrams to locate the presence or loss of proper DC
potentials within the printer.
-12 Vdc Circuits
J/P8-8
DC Power RIGS
Supply Board
J/P32-3
+5 Vdc Circuits
J/P331-3 J/P306-3
Duplex
Control
Board #1
DC J/P330-3
Power J/P323-3 J/P305-3
J/P310-3
Supply Duplex
Control
Board #2
(SRMR2)

J/P8-1 J/P77-4
Disk Drive
J/P8-10 J/P32-5 RIGS Board
DC Power J/P32-6
Supply
J/P8-14
J/P91-5 VPCL Board
J/P90-1 J/P42-1 Operator Panel

Board
J/P94-1
J/P7-1 J/P27-1
J/P7-2 J/P27-2 Printhead

J/P7-3 J/P27-3 Board

+12 Vdc Circuits

J/P8-3 J/P77-1
Disk Drive
DC J/P32-10
RIGS
Power Board
Supply J/P58-1 J/P57-1
J/P8-6
Paper timing sensor
J/P91-3 J/P40-25 J/P60-1 J/P59-1 Upper paper
empty sensor
J/P62-1 J/P61-1 Lower paper

empty sensor
VPCL J/P49-1
J/P50-1
Board Paper exit sensor
J/P40-26 J/P50-4 J/P51-1

Output tray
full sensor
J/P40-34 J/P12-8
Power control
board #2
J/P41-49 J/P25-4
Developer
J/P41-50 J/P25-1
J/P40-3 J/P26-1
Erase lamp

Duplex
Control
Board #1 J/P309-4 J/P319-1
Paper pass
J/P306-2
sensor
J/P331-2 J/P309-3 J/P318-1

Cover open
DC J/P330-2 sensor
Power
Supply
Duplex
Control
Board #2
J/P323-2 J/P312-1 J/P320-1
Registration side
sensor
J/P310-2
J/P305-2
J/P312-4 J/P322-1
Registration paper
sensor

+24 Vdc Circuits

Duplex
Control
Board #1 J/P309-7~10 J/P313-1~4
Route motor
J/P306-1
J/P308-1 J/P314-1
In solenoid
J/P331-1 J/P308-2 J/P315-1

DC “C” roller solenoid
J/P330-1
Power
Supply J/P308-3 J/P316-1
J/P308-4 J/P317-1
Exit solenoid
J/P323-1
Duplex
Control
J/P310-1 Board #2 J/P312-7~10 J/P321-1~4
Resist motor
J/P305-1
J/P8-11 J/P10-1
J/P11-1 J/P70-1
DC J/P12-2
Power AC
Power Power
Supply Control
Board #2 J/P12-1 Supply
J/P40-27
J/P40-28
J/P41-35 J/P23-13
High Voltage
Unit
J/P8-13 J/P41-26 J/P81-1 J/P82-1

Counter
J/P91-1
J/P40-10 J/P69-1
J/P65-1
Paper timing clutch
J/P40-11 J/P66-1
Upper paper feed clutch
VPCL J/P67-1
Board Lower paper feed clutch
J/P68-1

Ground System
Ground System
J/P4-9—AC power supply
J/P5-8 —Fuser
J/P6-3—DC power supply #1
J/P18-3—Toner supply motor
J/P21-3—Large cooling fan
J/P23-16—High voltage power supply
J/P20-1—DC power supply #2
J/P 255—Photoconductor
J/P 305-12—Duplex control board #2 (SRMR2)
Transfer corona


Standard printers support two host interfaces: RS-232C and Centronics Parallel. User-
level information about the installation, configuration, and use of these interfaces is
included in the The C40D Installation Manual, C4672-90004, guides you through unpack-
ing, setup, testing, and network configuration of your C40D printer.
RS-232C Host Interface

The default host interface for the printer is RS-232C. A printer is standard data terminal
equipment (DTE), designed specifically for a direct connection to a standard data commu-
nication equipment (DCE) host. The standard signal definitions for DTE to DCE equip-
ment are outlined on the chart that follows.
Pin Name Signal Function

2 TD Transmitted data
3 RD Received data
4 RST Request to send
5 CTS Clear to send
6 DSR Data set ready (not used)
7 SG Signal ground
8 DCD Data carrier detect
9
10
11 (S)DCD Secondary data carrier detect (not used)
12 (S)CTS Secondary clear to send (not used)
13 (S)CTS Secondary clear to send (not used)
14 (S)TD Secondary transmitted data (not used)
15 TC Transmitter clock
16 (S)RD Secondary received data (not used)
17 RC Receiver clock
18 RDC Receiver debit clock (not used)
19 (S)RTS Secondary receive to send (not used)
20 DTR Data terminal ready
21 SQ Signal quality detect (not used)
22 RI Ring indicator (not used)
23 DRS Data rate select (not used)
24 (TC) External transmitter clock
25 BSY Busy (not used)

Standard DCE to DTE RS-232C Cable

The standard DCE host to the printer (DTE) pin configuration follows.
Host Printer
FG 1 ---------- 1 FG
TD 2 ---------- 2 TD
RD 3 ---------- 3 RD
RTS 4 ---------- 4 RTS
CTS 5 ---------- 5 CTS
DSR 6 6 DSR
SG 7 ---------- 7 SG
DCD 8 8 DCD
DTR 20 ---------- 20 DTR
Special Considerations for RS-232 Host Interface Users

The host computer may be using a non-DCE RS-232C port. If so, you may have to modify
your cable or purchase a new cable with the proper pin assignments. Several possible
alternate RS-232C cable configurations follow.
Host Printer
GND 1 1 GND
TD 2 2 TD
RD 3 3 RD
RTS 4 4 RTS
CTS 5 5 CTS
DSR 6 6 DSR
GND 7 7 GND
DCD 8 8 DCD
DTR 20 20 DTR

Host Printer
GND 1 1 GND
TD 2 2 TD
RD 3 3 RD
RTS 4 4 RTS
CTS 5 5 CTS
DSR 6 6 DSR
GND 7 7 GND
DCD 8 8 DCD
DTR 20 20 DTR
IBM PC/XT to Printer

Normally, the IBM PC/XT comes with a parallel interface for the printer with a 25-pin
female connector. To run RS-232, you must install a serial board, which will have a male
connector.
PC/XT Printer
------- 1 1 FG
TD 2 2 TD
RD 3 3 RD
RTS 4 4 RTS
CTS 5 5 CTS
DSR 6 6 DSR
SG 7 7 SG
DCD 8 8 DCD
DTR 20 20 DTR

IBM PC/AT to Printer

Normally, the IBM AT comes with a 9-pin serial connector.
PC/AT Printer
DCD 1 1 FG
RD 2 2 TD
TD 3 3 RD
DTR 4 4 RTS
SG 5 5 CTS
DSR 6 6 ------
RTS 7 7 SG
CTS 8 8 DCD
RI 9 20 DTR
Macintosh Communication Port to Printer

Normally, the Macintosh comes with a 9-pin male connector.
Macintosh Printer
FG 1 1 FG
2 2 TD
SG 3 3 RD
4 4 RTS
TD 5 5 CTS
6 6 -----
DSR 7 7 SG
8 8 DCD
RD 9 20 DTR

Centronics Parallel Host Interface

The signal definitions defined below are for the 1284 compatible mode. This interface also
supports other 1284 compatible modes.
Signal
Pin Function
Name
1 DS Data strobe (active low)
2 DB0 Data bit 0
3 DB1 Data bit 1
4 DB2 Data bit 2
5 DB3 Data bit 3
6 DB4 Data bit 4
7 DB5 Data bit 5
8 DB6 Data bit 6
9 DB7 Data bit 7
10 ACK Acknowledge (active low)
11 BSY Busy (active high)
12 PE Paper empty (active high)
13 SEL Select (active high)
14 AF Auto feed
15 Not used
16 SG Signal ground
18 PLH Peripheral logic high
19 to 30 Signal ground
31 IP INIT
32 ERR Error (active low)
33 to 35 Not used
36 SI Select input
Special Considerations for Centronics Parallel Interface Users

For DOS host computers, add the following line to the AUTOEXEC.BAT file:
MODE PRN,,P
To edit the AUTOEXEC.BAT file, use any text editor or the EDLIN facility of DOS. If
you do not know how to edit this file, refer to the reference manual that came with the
DOS software.

IBM Parallel to Printer
Host Printer
Signal Signal
DS 1 ---------- 1 DS
DB0 2 ---------- 2 DB0
DB1 3 ---------- 3 DB1
DB2 4 ---------- 4 DB2
DB3 5 ---------- 5 DB3
DB4 6 ---------- 6 DB4
DB5 7 ---------- 7 DB5
DB6 8 ---------- 8 DB6
DB7 9 ---------- 9 DB7
ACK 10 ---------- 10 ACK
BSY 11 ---------- 11 BSY
PE 12 ---------- 12 PE
SEL 13 ---------- 13 SEL
AF 14 ---------- 14 AF
ERR 15 ---------- 32 ERR
IP 6 ---------- 31 IP
SI 17 ---------- 36 SI
GND 18 ---------- 33 GND
GND 19 ---------- 19 GND
GND 20 ---------- 21 GND
GND 21 ---------- 23 GND
GND 22 ---------- 25 GND
GND 23 ---------- 27 GND
GND 24 ---------- 29 GND
GND 25 ---------- 30 GND


Section 7
Removal/
Replacement
Procedures
Section 6 Removal/Replacement Procedures

Contents
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Photoconductor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Back Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Right Side Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Vacuum Transport Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Operator Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Counter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
RIGS Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
VPCL Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
Printhead Circuit Board (ARIF) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
Hard Disk Drive Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
Floppy and Hard Disk Drive Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20
Cooling Fan Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
Toner Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22
High Voltage Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Photoconductor Seam Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
Photoconductor Rear Guide Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30
Power Control Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Upper Cassette Mount Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35
Lower Cassette Mount Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40
Upper Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45
Upper Paper Guide Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-47
Lower Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Cleaner Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51

Upper Pick-Up Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
Pick-Up Roller Drive Idler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Pick-Up Roller Drive Gear Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
Exit Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Exit Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Erase Lamp Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78
EP Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Main Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
Main Gear Drive Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
“A” Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
“B” Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94
“C” Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-96
“C” Roller Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97
Duplex Route Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98
Duplex Paper Path Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99

Before You Begin
Section 7
This section includes step-by-step instructions for removing all field service replaceable
parts in the printer. Each part is addressed under its own heading, as outlined on the pre-
ceding contents pages.
Before You Begin

To remove a part, follow the instructions provided. To replace a part, follow the steps in
reverse order unless otherwise noted. During reassembly, make sure to reconnect all con-
nectors properly and seat gears and other moving parts properly.
Power Considerations
Before removing a part, make sure the printer is turned off and the power cord is
disconnected.
Photoconductor Removal
If it is necessary to remove the photoconductor as part of a removal procedure, make sure
to place it in its protective packaging.
When you replace the photoconductor, run at least 500 prints before checking print qual-
ity. This number of prints is required to “synch” the new PC belt to the developer.

Front Cover Removal
Front Cover Removal

2 While holding the cover up halfway, unhook the strap from the right side.
3 Remove the strap from the left side.
4 Slide the front cover to the right off its hinges.

Back Cover Removal
Back Cover Removal

1 Remove all external cables and attachments, including the printer’s power cord.
3 Loosen the two thumb screws on the drive side of the top chassis and pull the back
cover down.
4 Disconnect CN31, CN32, CN37, CN40, CN41, CN91, CN600, and CN36.
5 Disconnect the hard drive’s data cable.
6 Remove the mounting screws holding the back cover hinge to the printer.
7 While supporting the back cover, remove the screw holding each strap.
Caution: hold the cloth strap to avoid throwing the screw as it comes loose.
8 Lift the back cover up and away from the printer.


2 Remove the duplex tray by disconnecting P305 and loosening the two thumb screws.
4 Loosen the two screws for the left side cover.
5 Lift the cover up and away from the printer.
Replacement Note:

Right Side Cover Removal
Right Side Cover Removal

Note: The service kit is attached inside the right side cover.

3 Remove the two screws holding the right side cover in place.
Replacement Note:
Tighten the screws first. Then, gently lift the bottom tabs into place.
Note: Hold the top of the right side cover in place as you open the top cover. (This avoids
the possibility of damaging the top cover.)

Vacuum Transport Unit Removal
Vacuum Transport Unit Removal

4 Disconnect CN22.
5 Remove the C-clip from the gas spring on the side marked “up.” Gently move the gas
spring out of the way so it does not block the wire harness area.
6 Remove the four harnesses stays holding the cable in place.
7 Remove the three ground screws.
8 Remove the vacuum transport (four screws).


2 Remove the lower screw for the rear cover.
3 While supporting the cover, remove the upper screw for the rear cover.
Replacement Note:
Do not substitute longer screws to hold the rear cover in place.


2 Remove the rear cover. (Refer to page 7-10.)
5 Remove the C-clip on each gas spring.
6 While supporting the cover, remove each gas spring from its post and lower it.
7 Close the front cover.
8 Remove the front hinges from the top cover (two screws each).
9 Remove the two screws from each front cover hinge.


2 Remove the two screws holding the operator panel in place.
3 Disconnect CN42.

Counter Removal
Counter Removal
2 Remove the screw holding the counter in place.
3 Pull out the counter.
4 Disconnect CN82.

RIGS Board Removal
RIGS Board Removal

1 Remove any installed flex IO cards.
4 Disconnect the hard drive’s data cable.
5 Remove the eight screws holding the board in place.
6 Remove the RIGS board.

VPCL Board Removal
VPCL Board Removal

2 Disconnect CN34, CN36, CN37, CN40, CN41, CN400, and CN91.
4 Remove the VPCL board.


8 Disconnect CN27, CN30, and CN96 (see back detail).
9 Remove the two back screws holding the printhead assembly in place.
Continued

10 Remove the two front screws holding the printhead assembly in place.
11 Pull the printhead assembly from the front of the printer.

Printhead Circuit Board (ARIF) Removal
Printhead Circuit Board (ARIF) Removal

1 Remove ribbon connector J28 and plug P29 from the ARIF PCA.
2 Remove the screw securing the ARIF PCA to the printhead assembly.
3 Separate the ARIF PCA from the printhead assembly.
Note: If you are installing a new ARIF PCA, check the settings of DIP switch U1. The
switches should be set to: ON - 1,2,3,5; OFF -4:
ON
1 2 3 4 5
U1
J29
J28
R3
R7
R6
R5
R4
J30
U6
U3
U5
U2
U4
C2 C1

Hard Disk Drive Housing Removal
Hard Disk Drive Housing Removal

3 Disconnect the hard drive’s data cable at the RIGs board.
4 Loosen the thumbscrew on the back of the disk drive housing.
5 Remove the disk drive housing from the front of the printer.
Note: Use caution to avoid damaging the hard disk drive ribbon data cable.
Replacement Note:
For floppy drives, set the jumper on the drive circuit board to 0.

Floppy and Hard Disk Drive Removal
Floppy and Hard Disk Drive Removal

Note: The edges of the drive casing may be rough. Avoid contact with these surfaces.
Floppy drive
1 Remove the casing that surrounds the floppy disk and the hard disk drives.
• Loosen the screws located on the casing, one on each side.
• Remove the screw at the top rear of the casing.
• Lift the casing up and away from the drive. Set it aside in a safe place.
2 Disconnect the power cable from the drive.
3 Disconnect the data cable from the drive.
4 Remove the screws holding the drive in place. Each drive is secured to the frame by
one screw on the top and two screws on the bottom.
5 Pull the drive forward to free it from the drive frame.

Cooling Fan Removal
Cooling Fan Removal

3 Remove the cooling fan’s two cover screws. Remove cover.
4 Disconnect CN21.
5 Remove the cooling fan (two screws).

Toner Motor Removal
Toner Motor Removal

2 Disconnect CN18.
3 Remove the toner motor (three screws).

Toner Motor Removal
This space left blank intentionally.


4 Remove the left side cover. (See page 7-7.)
8 From the side of the printer, remove the three screws holding the AC power supply in
place.
9 Slide the AC power supply out the side of the printer.
10 Verify that the Voltage Strapping Plug P1 is configured correctly and inserted in the
power supply. (Refer to the illustration on page 7-25)

3 6 9
2 5 8
1 4 7
Voltage Jumper
100 V 1-3
120 V 1-4
200 V 1-5
220 V 1-6
230 V 1-7
240 V 1-8
Voltage Strapping Plug P1


1 Open the front, top and back covers.
2 Remove the cooling fan cover (two screws).
4 Remove the output tray.
5 Remove the right side cover. (See page 7-8.)
6 Remove the bracket for the output tray guide (two screws).
7 Remove the DC power supply (two screws).
Replacement Note:
When replacing the output tray bracket, make sure it is seated inside the DC power supply.


2 Remove the EMI grounding plate from the rear of the printer (four screws).
3 From the top, loosen the screw holding the high voltage power supply in place.
4 Pull the high voltage power supply out from the back of the printer.
5 Disconnect CN23, CN85, and the two high voltage leads.
6 Remove the high voltage power supply .


5 Remove the bracket holding CN64 in place (one screw).
6 Remove the screw holding the seam sensor bracket in place. It is situated under the
bracket for CN64.
Continued
7 From inside the empty photoconductor cavity, disconnect CN63.

8 Lift the photoconductor seam sensor and bracket up out of the printer, as shown in the
illustration on page 7-29.

Note: Use caution to avoid bending the bracket.
Seam Sensor and Bracket


5 Remove the photoconductor seam sensor. (See page 7-28.)
6 Remove the spring at the base of the guide rail. To do this, gently pull the spring for-
ward off its post.
7 Disconnect C64.

9 Remove CN64 from its bracket.
10 From inside the photoconductor cavity, remove the two screws holding the guide rail
in place.
11 Push CN64 and the ground wire through the photoconductor cavity to the front of the
printer.

12 Lift the photoconductor guide rail from the printer.


4 Disconnect CN9, CN10, CN11, CN12, CN13, and CN14.
5 Remove power control board (two screws).
Replacement Note:
Be sure that the back of the board is mounted properly in the frame slots.


3 Using a small screwdriver, pry up the paper size sensor. Turn the sensor counterclock-
wise and lift up.
4 For the upper paper size sensor, disconnect CN45 and CN46.
5 For the lower paper size sensor, disconnect CN43, CN47, and CN48.
Note: Use caution not to break the cables.


7 From the back, remove the two screws holding the upper cassette mount in place.
8 Loosen the CN62 jack and pull it to the back of the printer.

9 Disconnect CN62.
10 Remove the upper paper size sensor.

through the cassette housing. Gently turn it and lift from the printer.
13 For the tray releases:
•Carefully release the tension spring cable from the pick pressure adjustment lever.
•Remove the spring and cable.
•Remove the upper and lower levers (one spring and C-clip each).
•Remove the upper and lower cams (one screw each).

•Remove the upper and lower latches (one spring and C-clip each).
(Continued on next page).
Continued
14 Disengage the top of the damper assembly. Push it to the right out of the way
16 Remove the tray (four screws; two front and two back).
17 Remove the upper tray lift arm (two screws with two plastic retainers).
18 Remove the upper bracket (four screws; two front and two back).
19 Remove the screws holding the upper cassette mount in place (two front and 2 side).
20 Pull the upper cassette mount from its front and back mounting pins.

21 Rotate the upper cassette mount upwards and out of the printer.



7 Remove the power control board. (See page 7-33.)

8 From the back, remove the two screws holding the lower cassette mount in place.
Continued
9 Remove the lower paper size sensor.

through the cassette housing. Gently turn it and lift from the printer.
12 For the lower tray release:
•Carefully release the tension spring cable from the pick pressure adjustment lever.
•Remove the spring and cable.
•Remove the lever (one spring and C-clip).

•Remove the cam (one screw).

•Remove the latch (one spring and C-clip).
Continued
(Continued on next page)

14 Remove the tray (four screws; two front and two back)
15 Remove the AC power supply. (See page 7-23.)
16 Remove the lower tray lift arm (two screws with two plastic retainers).
17 Remove the screws holding the lower cassette mount in place (two front and 2 side).
18 Pull the lower cassette mount from its front and back mounting pins.

19 Rotate the lower cassette mount upwards and out of the printer



2 Remove the EMI grounding plate from the rear of the printer (four screws).
4 Disconnect the transfer corona high voltage lead from the HVPS.
5 Disconnect the ground screw for the transfer corona.

8 Remove the back screw holding the upper paper guide in place.
9 Remove the front screw holding the upper paper guide in place.
10 Release the two springs at the base of the upper paper guide.
11 Lift the upper paper guide out of the printer

Upper Paper Guide Removal.


2 Remove the two springs at the ends of the roller. To do this, press down gently on the
end of the spring and move it out from under the plastic.
4 Remove the roller and bearings from the underside of the upper paper guide.


3 Raise the lower paper guide slightly.
4 Push the base of the lower paper guide toward the back of the printer until the front
mounting peg is free.
5 Lift the lower paper guide out of the printer.
Note: Use caution. This piece is made of plastic and can easily break if mishandled.


3 Remove the lower paper guide. (See page 7-48.)
4 Remove the front screw holding the paper timing guide in place.


6 Remove the back screw holding the paper timing guide in place. Remove the paper
timing guide.
7 Disconnect CN58.
Note: When reinstalling the paper timing guide, be sure the guide is properly aligned on
the mounting pins.


4 Lift the idler arm and slide the cleaner drive belt off the gear.


4 Remove the cleaner drive belt. (See page 7-51.)
5 Remove the two high voltage leads.
6 Remove the cleaner drive (three screws).


6 Remove the main drive gear and bearing (two C-clips and a washer).
7 Remove the single upper left and the two lower screws holding the fuser drive in
place.
8 Loosen the upper right screw for the fuser drive and pivot the drive down.
9 Slide the fuser drive belt off the gear.

Fuser Drive Removal
Fuser Drive Removal

6 Remove the fuser drive belt. (See page 7-53.)
7 Remove the fuser drive (four screws).


6 Push down on the idler arm and slide the paper feed drive belt off the gear.


3 Remove the photoconductor and place it in its protective bag.
5 Remove the paper feed drive belt from the paper timing roller gear.
6 Disconnect CN65.
7 Unscrew the standoff post from the collar surrounding the end of the roller.
8 Remove the C-clip and bearing from the front of the printer.
9 Slide the paper timing roller out the back of the printer.
Replacement Notes:
Reinstall the original collar and standoff post with any new paper timing roller. The C-clip
should move freely if installed correctly. Be sure to align all of the guide pins or the C-clip
will not fit correctly. Be careful not to scratch the surface of the roller when inserting it
into the printer.


3 Disconnect CN66.
4 Remove the paper feed drive belt from the upper feed roller gear.
6 Remove the front C-clip and bearing from the front of the printer.
7 Slide the upper feed roller out the back of the printer.


3 Disconnect CN67.
4 Remove the paper feed drive belt from the lower feed roller gear.
7 Slide the lower feed roller out the back of the printer.


3 Disconnect CN68.
6 Remove the pick-up roller drive belt from the gears.
7 Slide the upper pick-up roller out the back of the printer.

Pick-Up Roller Drive Idler Removal
Pick-Up Roller Drive Idler Removal

3 Remove the pick-up roller drive belt from the pick and feed gears.
4 Remove the pick-up roller drive idler (three screws).

Pick-Up Roller Drive Gear Removal
Pick-Up Roller Drive Gear Removal

3 Remove the pick-up roller drive belt.
4 Remove the pick-up roller drive gear and housing (three screws).


3 Disconnect CN69.
6 Slide the lower pick-up roller out the back of the printer.

Exit Assembly Removal

4 Remove the operator panel. (See page 7-12.)
5 Remove the DC power supply. (See page 7-26.)

6 Remove the mounting bracket for the DC power supply by removing two screws and
prying out the bracket with a small screw driver.

8 Remove the five screws holding the job exit assembly in place (three screws in front;
two screws in back).
9 Remove the fuser drive cover mounting post.
10 Remove the mounting pin for the output option (one screw).
11 Remove the job exit assembly.


2 Remove the fuser.
4 Remove the front screw holding the exit pinch roller in place.

7 Remove the back screw holding the exit pinch roller in place.
8 Lift the exit pinch roller from the printer.



2 Remove the fuser.
3 Remove the upper static brush from the exit pinch roller assembly (two screws).


1 Open the top, front and back covers.
2 Remove the fuser.
4 Remove the exit pinch roller assembly. (See page 7-65.)
5 Remove the lower static brush (two screws).


2 Remove the fuser.

6 Remove the exit pinch roller. (See page 7-65.)
7 Remove the lower duplex drive (three screws).
8 Remove the back screw holding the exit guide in place.

9 Tilt the exit guide toward the center of the printer.

11 Slide the exit roller out the back of the printer.

Exit Cover Removal
Exit Cover Removal

2 Remove the fuser.


Exit Cover Removal
10 Disconnect CN317.
13 Remove the solenoid from the exit cover (two screws)


2 Remove the fuser.
5 Disconnect CN49.
7 Tilt the exit cover assembly toward the center of the printer.
8 From the underside, remove the paper exit sensor (one screw).


2 Remove the fuser.
5 Disconnect CN51.
7 Tilt the exit cover toward the center of the printer.
8 From the underside, remove the paper full sensor (one screw).


6 Remove the AC power supply top cover (two screws).
8 Remove the front interlock switch (two screws).


6 Remove the AC power supply side cover (one screw).
7 Disconnect the four wires connected to the interlock switch.
8 Remove the back cover interlock switch (two screws).


1 Open the top, front, and back covers.
5 Remove the duplex tray mount (four screws).
6 Remove the paper feed drive cover (two screws).
8 Remove the top cover interlock switch (two screws).

Erase Lamp Removal
Erase Lamp Removal

4 Disconnect CN26.
5 Remove the screw holding the erase lamp in place.
6 Disengage the front of the erase lamp from its guide pin.
7 Slide the unit out the back of the printer.

EP Cover Removal
EP Cover Removal
2 Remove the fuser.

EP Cover Removal

7 Remove the two supports for the vacuum transport (one screw each).
8 Remove the four screws holding the EP cover in place (two front and two back).
9 Remove the upper right screw holding the fuser drive in place.

EP Cover Removal
10 Lift the EP cover straight up out of the printer.
Replacement Note:
The higher of the two drive shaft support arms should be facing the left side of the printer.

Main Motor Removal
Main Motor Removal

5 Remove the back cover. (See page 7-6.)
7 Remove the counter. (See page 7-13.)

Main Motor Removal

10 Remove the gear stay cover.
12 Remove the hard disk drive housing. (See page 7-19.)
13 Remove the printhead. (See page 7-16.)
14 Remove the DC power supply. (See page 7-26.)
15 Remove the main motor gear and bearing (two C-clips and a washer).

Main Motor Removal
16 Remove key, C-clip, and washer.

17 Disconnect CN20 and remove the female end from the chassis.
18 From the right side, remove the screw holding the D.C. main motor power supply in
place.
19 Remove the multicolored cable (PN2) from the D.C. main motor power supply.
20 From the back, remove the three screws holding the main motor in place.
Note: Remove the lower screw first.
21 Remove the main motor through the side of the printer.
Replacement Notes:
Remove the drive shaft key from the old motor. Replacement motors are not supplied with
a key.
Be sure to reroute CN20 after installation so that the wires do not protrude into the disk
drive assembly area. Reroute the counter cable for the same reason.


2 Remove the lower back cover. (See page 7-6.)
9 Remove the paper feed drive belt. (See page 7-55.)
10 Remove the main gear drive (three screws).


2 Remove the duplex control board cover (two screws).
4 Disengage the duplex control board #1. To do this, pinch the four standoffs on the
board, one at a time.
5 Lift the board from the mounting bracket.
Note: When reinstalling, make sure the duplex control board is pushed down towards the
vacuum transport.


3 Remove the paper guide from the duplex tray (four screws).
5 Remove duplex control board #2 (two screws).


4 Disconnect CN321.
5 Remove the registration motor (two screws).


1 Open the top cover. (See next page for illustration.)
4 Slide the skew correction guides toward the center of the duplex tray.
5 Remove the bracket holding the shaft in place (two screws).
6 Remove the screw holding the cable mounting plate in place.
7 Lift the skew correction guides and shaft up out of the duplex tray.
8 Remove the two screws holding each pulley assembly in place.
9 Remove the spring from the cable.
10 Lift the skew correction cable and pulley assemblies from the duplex tray.
Replacement Notes:
The placement of the mounting bead is critical. Set it on precisely. Replace parts in this
order:
1 Reinstall the pulley assembly first.

2 Then, wrap the cable three times around the drive gear pulley.
3 Finally, connect the spring.



2 Remove the rear duplex cover. (See page 7-10.)
4 Disconnect CN316.
5 Remove the upper duplex drive/clutch assembly (three screws).


5 Remove the duplex route motor/solenoid assembly (three screws).


4 Remove the front C-clip and bearing from the “A” roller.
5 Lower the top cover to a 45-degree angle.
6 Slide the “A” roller out the back of the printer.


5 Remove the front C-clip and bearing from the “B” roller.
8 Loosen the screw holding the idler roller in place.
9 Remove the duplex drive belt.
10 Remove the drive gear (one C-clip).

11 Slide the “B” roller out the back of the printer.


5 Remove the front C-clip and bearing from the “C” roller.
6 Slide the “C” roller out the back of the printer.


3 Disconnect CN315 and cut the cable tie securing the wires to the mounting plate.
4 Remove the two screws holding the “C” roller solenoid in place.
5 Loosen the set screw securing the actuator arm to the “C” roller.
6 Disengage the solenoid from the actuator arm and remove it.
Replacement Note:
Install a new cable tie to secure the wires from CN315 to the mounting plate.


4 Remove the duplex route motor/solenoid assembly. (See page 7-92.)
6 Open the duplex cover.
7 Remove the screw holding the return arm in place.
8 Disengage the return spring.
9 Remove the front C-clip from the route separator.
10 Disengage the route separator from its side supports.
11 Lift the route separator out from the duplex cover.


4 Disconnect CN319.
5 Remove the duplex paper path sensor (one screw).


Section 8
Options
Section 7 Options

Contents
Options
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
1200-Sheet/2500-Sheet Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Guide to Component Acronyms/Physical Locations. . . . . . . . . . . . . . . . . . . . . 8-4
Bench Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Connection Diagram for 1200-Sheet /2500-Sheet Feeder . . . . . . . . . . . . . . . . . . . . 8-8
Prefeed Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
Input Control Board Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
1400-Sheet Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Guide to Component Abbreviations/Physical Locations. . . . . . . . . . . . . . . . .8-10
Bench Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Front View (cover removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13
Left Side View (left cover removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13
Rear Side View (cover removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14
Top View (top cover removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14
Connection Diagram for the 1400-Sheet Stacker . . . . . . . . . . . . . . . . . . . . . . . . .8-15
Output Control Board Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16

Introduction
Section 8
Options
Introduction
This section provides information about troubleshooting and testing specific printer
options not covered elsewhere in the manual. These options include the 1200- and 2500-
sheet High Capacity Input (HCI) units, and the 1400-sheet High Capacity Output (HCO)
unit.
Installation instructions for the sheet feeders and sheet stacker are in the C40D Installation
Manual, which is shipped with the C40D.
For a complete list of the parts contained in the 1200-sheet feeder, the 2500-sheet feeder,
and the 1400-sheet stacker, please see the Illustrated Parts Catalog.

Guide to Component Acronyms/Physical Locations
Acronym Component
DSW Door Switch (magnetic door lock)

IEM Input Elevator Motor (M1 - elevator motor)
ILLS Input Lower Limit Sensor
IPES Input Paper Tray Sensor
IPM Input Pick-up Motor (M2 - paper pick-up motor)
IULS Input Upper Limit Sensor
NF AC Noise Filter
NPS No Paper Solenoid
PCSW Power Control Switch (slope tray interlock switch)
PES Paper End Sensor
PHS Paper Head Sensor
SOL Solenoid
Rear side
ILLS M1
NF
Input SOL
IULS (1200 HCI)
control IULS (2500 HCI)
board
PES
Door
Printer side
PHS
M2
IPES PCSW
Power supply
DSW Front side


1 Turn the printer’s main power switch off, then disconnect the unit’s power cord.
2 Press down the printer’s lower cassette release lever, then remove the unit from the
printer and place it on a work bench or other suitable surface.
3 Remove the paper size lever, then lift up the slope tray and place the lever between the
slope tray and the frame. This will bypass the interlock switch (PCSW) located under
the slope tray, allowing 12Vdc to be applied to the input control board.
The slope tray is normally lifted into operating position by the printer’s lower paper
lift arm.
Slope Tray
Paper Size Lever
Paper Supply Tray Paper Access Door
4 Restore AC power to the unit (either the unit’s power cord or the printer’s power cord
may be used).
5 Open the paper access door. The elevator motor (M1) should turn on, moving the
paper stock down. There is an actuator attached to the elevator’s chain drive that will
activate photosensor ILLS signalling the input control board that the paper supply tray
is completely down.
Remove any paper that may be on the unit’s slope tray.

Rear side
ILLS M1
SOL
IULS (1200 HCI)
IULS (2500 HCI)
PES
Door
Printer side
PHS
M2
IPES PCSW
DSW Front side
6 Close the paper access door. The elevator motor (M1) should turn on, moving the
paper stack up. There are two actuators that must enable two photosensors. Photosen-
sor IPES signals the input control board that paper is present on the elevator. Photo-
sensor IULS signals the input control board that the upper limit for the paper supply
tray and paper stack has been reached.
7 With the paper supply tray all the way up and with no paper present on the slope tray
(indicated to the input control board by photosensor PES, located in the middle of the
paper path), the pick-up roller assembly motor (M2) will turn on and transport a piece
of paper to the slope tray.
8 When the paper in transported to the slope tray, note that the (SOL) solenoid (under
the slope tray) energizes.
The solenoid causes contact with the printer’s paper present sensor.
9 By removing the piece of paper from the slope tray, photosensor PHS signals the input
control board to turn the pick-up motor (M2) on to replace the piece of paper that was
removed.
10 When the last sheet of paper has been fed from the paper supply tray to the slope tray,
the actuator arm of photosensor IPES falls through a hole in the paper supply tray.
This signals the input control board to turn the elevator motor (M1) on to move the
paper supply tray down. The paper supply tray will remain down until the paper
access door is reopened (more paper is loaded), then closed.
11 When the last sheet of paper has been removed from the slope tray, confirm that the
solenoid (SOL) de-energizes.


This procedure should only be done if you are replacing the control board or experi-
encing excessive paper jams.
1 Remove the side, top, and throat covers from the unit.
2 Disconnect J509.
3 Using the bench test procedure, feed paper to the slope assembly.
4 Set VR2 fully counter clockwise.
1200-Sheet Feeder Only

• Adjust VR1 so that the paper feeds to 20 to 30 mm (approximately 1 inch) past the
bend of the slope assembly.
2500-Sheet Feeder Only

• Adjust VR1 so that the paper feeds to 10 mm (approximately 3/8-inch) before the
bend of the slope assembly.

8-8
Connection Diagram for 1200-Sheet/2500-Sheet Feeder
Connection Diagram for 1200-Sheet/2500-Sheet Feeder

Connection Diagram for 1200-Sheet /2500-Sheet Feeder
NF
W520 J600 J400 W508 P507
Gnd
AC
PH-1 P522 + 12Vdc
Power
W505 Input
Supply P506
Control
P523 Board
W506 J506
P527 P528
SW2
PCSW
W510 P508
P509
J509 P518 P519
W507
P529 P500 J518 J519
J529 P512 P513 P514 P515 J500

W514
P530 M1 M2
SOL
Options
NP PH ILL PE IUL IPES DSW IEM IPM

June 1999

The table below indicates switching logic for the unit’s various components. Except for
the power control switch (PCSW), each component can be monitored from the various
pins of CN508 (located on the input control board).
When performing these checks, use test point TP 1 (located below CN507 on the input
control board).
Connector Component Monitored Condition
CN508-4 PHS High Paper present

CN508-13 PES Low Paper present

High No paper present
CN508-19 IPES High Paper present

CN508-16 IULS Low Limit

High No Limit
CN508-21 DSW High Door open

Low Door closed
CN508-10 ILLS High Limit

Low No limit
CN508-2 NPS High On

Low Off
CN508-25, 26 IPM (M2) +12Vdc Feed

0Vdc No feed
CN508-23 IEM (M1) +12 Vdc Up
0Vdc Off
CN508-24 IEM (M1) +12 Vdc Down

0Vdc Off
CN507-2 PCSW 0Vdc Unit mounted

+12Vdc Unit not mounted

1400-Sheet Stacker
1400-Sheet Stacker
Guide to Component Abbreviations/Physical Locations
Abb Component
ERM Exit Roller Motor (M1)

EPS Exit Paper Sensor
ERS Exit Roller Sensor
OEM Out Elevator Motor (M2)
OELS Out Elevator Limit Sensor
OEPS Out Exit Paper Sensor
OJFM Out Jogging Front Motor (M4)
OJFS Out Jogging Front Sensor
OJRM Out Jogging Rear Motor (M3)
OJRS Out Jogging Rear Sensor
OLLS Out Lower Limit Sensor
OULS Out Upper Limit Sensor
OEM (M2)
ERM (M1) Top View
OEPS OLLS OULS
Power
supply
Printer side
Output tray
OJRS
OJFS
Paper tray full
Output actuator
control
board
OJFM (M4) OJRM (M3)
OELS


1 Turn the printer’s main power switch off.
Stacker Unit Adapter Plate
Output Tray
Power Cord
Output Tray Guide
Jack
Control Cable Connector
2 Remove the output tray from the stacker unit.

3 Disconnect the stacker unit’s power cord from the printer and from the stacker, then
disconnect the unit’s control connector cable from the printer’s jack.
4 Remove the stacker unit from the printer, then place it on a work bench or other suit-
able surface.
5 Remove the printer’s power cord from the wall outlet and the printer’s lower back
cover.
6 Observe the pin configuration of the stacker unit’s control connector cable plug
(shown opposite page).
7 Place a jumper from pin 9 to pin 10 (ground). Using the printer’s power cord in place
of the unit’s power cord, plug the printer’s power cord in the stacker unit, then into the
wall outlet.
8 With the power applied to the stacker unit, the exit roller motor (ERM-M1) will be off.
This will signal the output control board to turn the exit roller motor (ERM-M1) on.
9 Remove the jumper from pin 9 and pin 10.
10 Lift the paper tray full actuator to enable photosensor OLLS to signal the output con-
trol board to cause the elevator motor (OEM-M2) to turn on and lower the output tray
guide.

Rear side
OEM
(M2) ERM (M1)
OEPS OLLS OULS
Printer side
Output tray
OJRS
OJFS
Paper tray
full actuator
OJRM (M3)
OJFM 1 2 3 4 5 6 7
OELS
Front side Plug 9 10 X X X X X
11 As the output tray guide reaches its lowest allowable position, photosensor OELS is
enabled and signals the output control board to turn the elevator motor (OEM-M2) off.
12 Releasing the paper tray full actuator then enables photosensor OULS to signal the
output control board to turn the elevator (OEM-M2) on and raise the output tray guide.
13 As the output tray guide reaches its highest allowable position, the paper tray full actu-
ator enables both photosensor OLLS and photosensor OULS, which in turn signal the
output control board to turn the elevator motor (OEM-M2) off.
14 Disconnect the power cord from the stacker, then place a jumper from pin 3 to pin 6
and a second jumper from pin 2 to pin 7.
15 Reconnect the power cord, then (from the printer side of the unit) insert a folded piece
of paper into the unit to trigger the actuator and enable photosensor OEPS. This will
signal the output control board to turn the jogging rear motor (OJRM-M3) on.
16 After jogging has occurred, remove the piece of paper then reinsert it. This will again
trigger the acturator and enable photosensor OEPS. This will signal the output control
board to turn the jogging front motor (OJFM-M4) on.
17 The procedure is completed. Disconnect the power cord, remove the jumpers, then
reinstall the unit into the printer.

Connector Locations
Connector Locations
Front View (cover removed)
CN416
Printer side
Left Side View (left cover removed)

CN409 CN426 CN425

Rear side
CN405
CN406
Fuse 1
CN401
Fuse 2
Output control board
Power supply CN404
CN402
CN417 CN403
Frame ground CN412

Connector Locations
Rear Side View (cover removed)
Printer side
Output side
CN415
CN424 (AC power)
CN420 (Control connector plug)
Top View (top cover removed)

CN413
Front side
CN419
Printer side
CN414
CN407
CN408

June 1999
Connection Diagram for the 1400-Sheet Stacker

P401
Options
P420
PCL board W2 Output W5 P419 J419

J401
interface Control
Board W-12
P406 P407 P408 P409

W7
J406
S-1 S-2 S-3
OULS OLLS OEPS
J405
P425 P426
J404 J402 J403
S-5 S-6
OJFS OJRS P404 P402 P403
Connection Diagram for the 1400-Sheet Stacker

W4
P412
S-4
OELS
W6
P41 P41 P41 P41
P424 P417 + –
W1
L 12V
PH-1
AC Power
N
Supply J41 J41 J41 J41
100 ~ 240V
P418
M1 M2 M3 M4
ERM OEM OJRM OJFM

8-15

The table below details specific stacker actions and which sensors supply the signals
needed for each action. Signals from the printer are also included.
Action Sensor Input
Elevator up OULS
(Wait signal to printer) OLLS
OELS
Elevator stop OULS

OLLS
OELS
Remove prints OULS

(signal to printer) OLLS
OELS
Elevator down OULS

OLLS
OELS
paper exit EPS

OEPS
Paper exit jam (023) OEPS
Jogging start From printer
Jogging ERS (from printer)

OJRS
OEPS
OJFS
Jogging stop From printer

Section 9
General Printer
Maintenance
Section 8 General Printer Maintenance
June 1999 General Printer Maintenance 9-1

Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4
Tool Requirements: Service Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4
Tools/Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5
Printer/Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5
Printer Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6
Remove Major Consumable Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
Inspect and Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Clean Internal Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Clean the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
Clean the Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Clean the Cleaner/Charge Corona . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8
Clean the Photoconductor Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8
Clean the Transfer Corona . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8
Run Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Adjusting Paper Feed Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Adjusting Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11
Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Front View Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Front View Lubrication Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14
Rear View Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15
Rear View Lubrication Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Top View Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Duplex Holding Tray Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18
Tune-Up Maintenance Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-19
9-2 General Printer Maintenance June 1999

Introduction
Section 9
Introduction
This section describes the primary printer maintenance procedures to be completed during
service calls. In addition, this introduction reviews safety precautions, tool requirements,
and the printer maintenance record.
Electrical Checks
Step-by-step instructions for performing several of the checks needed to solve printer
problems.

The every-call cleaning procedure, as the name implies, is performed every time the
printer is serviced. It includes a thorough cleaning of the printer, requiring the removal of
all major components and performance of specific cleaning tasks related to each one. It
also includes vacuuming all excess toner and other contamination from the interior of the
printer.
Paper Feed Tension Adjustment Procedure

You may need to adjust the paper feed tension to correct jamming.
Lubrication Procedures
Lubrication procedures are performed whenever needed, though lubrication should be
applied sparingly. The required lubricants, including oil, molycote, red grease, and non-
silicon white grease can be purchased from the printer’s manufacturer.
Tune-Up Procedure
The tune-up maintenance procedure is performed when the printer has yielded sub-stan-
dard prints after you’ve completed standard maintenance procedures, or has printed one-
to two-million images. A tune-up maintenance kit is required for this procedure.

Introduction
Safety Precautions
Whenever servicing sophisticated electronic/electro-mechanical equipment, common
sense, training, caution and experience help in avoiding accidents and mishaps. Be aware
of the following safety precautions:
• Follow all instructions in this document.
• Follow all warnings and instructions marked on the printer.
• Unplug the printer when performing any removal, replacement or cleaning procedure.
• Ensure that the power source for the printer matches the power specification label
located above the power outlet on the back of the printer.
• Keep combustible materials away from the printer.
• Provide adequate ventilation for the printer so that slots and openings in the cabinet
sides are not blocked.
• Do not push objects of any kind through the cabinet slots. They may contact danger-
ous voltage points or other hazards.
• Do not expose the printer to liquids of any kind.
• Protect the power cord. Do not place it in a traffic pattern or allow anything to rest
on it.
Tool Requirements: Service Kit

A service kit intended for use solely by the service technician is shipped inside the right
side cover of the printer. This kit includes:
• Interlock by-pass tools (2)
• RS-232C loop back assembly
• RS-422 loop back assembly
• Multimeter jumpers (2)
• Charger cleaner brush

Introduction
Tools/Supplies
To service the printer properly, you will also need to carry the following:
• Soft cleaning cloth
• Cotton swabs
• Charger cleaner
• Basic set of hand tools suitable for office automation equipment repair
• Service vacuum cleaner, properly grounded and equipped with a 10 micron filter
End User Cleaning Kit

Printers are shipped with an end-user cleaning kit taped inside the front cover. The clean-
ing kit consists of:
• Cotton swabs
• Charger cleaner brush
This kit is intended for use by the end user.
Printer/Maintenance Record
A maintenance record must be kept for every printer. During the initial service call or at
the time of installation, set up a maintenance record for the customer. A copy of the form,
illustrated on the following page, should be in a plastic bag taped inside the front cover so
that the maintenance form is always easily accessible.

Printer Maintenance Record
Printer Maintenance Record

Completed by user Completed by HP:
Page HP notified Down

Operator HP CE on site Date Time
Counter Date/Time time
Malfunction Description Action Required and Comments


Perform the every-call cleaning procedure every time the printer is serviced. When trou-
bleshooting a printer problem, you may be directed to complete this procedure as you iso-
late or correct the problem. If the procedure is not specifically called out, always complete
it before concluding the service call.
The every-call cleaning procedure begins by removing the major consumable supplies
from the printer. When the supplies are out, use a toner vacuum to vacuum the printer thor-
oughly. Clean each consumable supply, following the instructions listed in this section,
before returning it to the printer. Conclude the every-call procedure by running test prints
to confirm the print quality.
The location of all major printer supplies and instructions for their removal are outlined
later in this manual.
Remove Major Consumable Supplies

• Photoconductor; place it in its protective packaging.
• Cleaner
• Developer
• Fuser
Inspect and Vacuum

• Inspect the areas in the printer around the developer, cleaner, photoconductor, and
fuser for damage and wear.
Clean Internal Areas

Clean the Fuser

Caution! The fuser may be hot.
• Inspect the fuser for damage and contamination; repair or replace as necessary.
• Clean the fuser connector, both on the fuser and in the printer, with a cotton swab.
• Vacuum in and around the rollers to remove excess toner, contamination, and any for-
eign objects.
• Reinstall the fuser.

Clean the Developer

• Inspect the developer for damage or contamination; repair or replace as necessary.
• Clean any excess toner from the developer with a soft cloth.
• Clean the toner patch sensor lens with a soft cloth, making sure no lint remains on the
lens.
• Vacuum the felt areas around the magnetic roller, being careful not to vacuum toner
from the magnetic roller.
Clean the Cleaner/Charge Corona

Caution! Handle gently, to avoid breaking the charger wire.
• Inspect the cleaner/charge corona for damage or contamination; repair or replace as

necessary.
• Remove the charge corona from the cleaner.
• Remove the grid to expose the charger wire.
• Clean the charger wire with a cotton swab.
• Clean any excess toner from the cleaner with a soft cloth.
• Reinstall the charge corona in the cleaner.
• Reinstall the cleaner.
Clean the Photoconductor Area

Caution! Do not touch the photoconductor belt, as this permanently damages the
photoconductor.
• Clean the photoconductor seam sensor inside the printer.

• Inspect the photoconductor for damage or contamination; repair or replace as
necessary.
Clean the Transfer Corona

Caution! Handle gently, to avoid breaking the charger wire.


Run Test Prints

• Run test prints to verify print quality.


Pressure tension levers can be found inside the front cover, as illustrated below:
Paper feed tension levers
To adjust the tension:

1 Open the printer’s front cover.
2 Identify the cassette whose tension is to be adjusted, and select the correct lever.
3 Adjust the tension:
• To correct multiple feeds: move the lever toward the minus sign, decreasing the
feed pressure.
• To ease paper feeds: move the lever toward the plus sign, increasing the feed
pressure.
4 Close the front cover, then print paper from the cassette you are adjusting.
5 If the paper is still not feeding properly, repeat Steps 3 and 4 until the feed is properly
adjusted.

Adjusting Registration
Adjusting Registration
Registration controls the vertical placement of the printed image on the physical page.
Obtain a test print produced by the C40D printer. Note the 20 line registration indicator at
the top of the page. Registration is correct when the twentieth line of the indicator is at the
leading edge of the print (plus or minus 2).
This procedure uses a large amount of paper.
To display the registration menu, select the registration option from the main menu
(labeled menu) by using the fand e keys to move the asterisk to it, then press the e key
to confirm it.
You will see the following menu:
REGISTRATION
* RELATIVE ALIGNMENT
ABSOLUTE ALIGNMENT
Relative alignment aligns duplex images with relationship to each other. So when you
change the alignment, one image will shift up on the page, while the other image shifts
down.
Absolute alignment moves both images in the same direction. In this case, when you
change the alignment, both images on the page shift either up or down together. They stay
the same with relationship to each other, but their position on the physical paper changes.
Use the following guidelines when you are checking or changing the registration, no mat-
ter which type of alignment you are using:
1 When you select either one of the options on the Registration menu, the printer will
immediately begin printing test pages. Wait for about 10-15 pages, then look at an
image.
2 To shift the image up, press the gkey. To shift the image down, press the hkey. Wait
for about 15 more pages, then review the image to see if it has shifted enough.
3 Continue this until you are satisfied with the result.
4 Press the e key. The printer will complete printing the pages left in the buffer.

Complete the lubrication procedure as-needed. Apply lubrication sparingly. Insufficient
lubrication may result in unnecessary noise and premature wear of components; excessive
lubrication may contaminate printer supplies and make the printer difficult to keep clean.
The following printer illustrations indicate where lubrication may be required. Charts fol-
lowing the illustrations include symbols that indicate the type of lubricant to use on each
component:
H Oil
P Molycote
L Red grease
R White grease
For part numbers, refer to the “Additional Parts List” in the Illustrated Parts Catalog.

Front View Lubrication

Front View Lubrication Table
H 1 Front roller bearings (paper feed, paper Oil

pickup, timing and exit rollers)
H 2 Vacuum transport drive shaft Oil
H 3 Fuser drive bearing Oil
H 4 Upper paper guide roller Oil
L 5 Fuser drive gear Red grease
L 6 Vacuum transport drive gear Red grease
L 7 Vacuum transport gear Red grease
P 8 Vacuum transport rollers Molycote
H 9 Duplex roller bearings Oil
P 10 Lower duplex drive assembly Molycote

Rear View Lubrication

Rear View Lubrication Table
H 1 Clutch shafts: upper pick-up roller, lower pick-up roller, Oil

upper feed roller, lower feed roller, paper timing roller
P 2 Upper and lower pick-up roller drive assemblies Molycote
P 3 Main drive gear assembly Molycote
P 4 Main drive gear Molycote
P 5 Main drive motor gear Molycote
R6 Fuser drive gear White Grease
P 7 Fuser drive assembly Molycote
H 8 Clutch shaft bearing Oil
R9 Lower duplex drive assembly White Grease
P 10 Upper duplex drive assembly Molycote
P 11 A roller drive gears Molycote
P 12 B roller drive gears Molycote
P 13 C roller drive gears Molycote
R 14 Main Drive Assembly White Grease
R 15 Idler White Grease

Top View Lubrication
H 1 Duplex pinch rollers Oil

Duplex Holding Tray Lubrication
P 1 Drive gears Molycote
L 2 Tray shaft Red grease


The tune-up maintenance procedure should be performed when the printer: jams fre-
quently; yields sub-standard print quality even after completing regular maintenance pro-
cedures; and has printed more than one- or two-million prints. At this point in the life of
the printer, the roller assemblies, transfer corona, and static brushes must be replaced. All
of the required components are packaged together in a Tune-Up Maintenance Kit.
1 For detailed instructions on how to replace each of these components, refer to Section
7, Removal/Replacement Procedures. General guidelines follow for unpacking the
component, along with an outline of the order in which the components should be
replaced.
2 Unpack the maintenance kit, which is shipped in a folded cardboard pack. Remove the
shipping carton and unfold the cardboard pack.
3 Make sure that you have received all of these replacement components, shown in the
following illustration:
• Roller assembly, lower feed
• Roller assembly, upper feed
• Roller assembly, paper timing
• Roller assembly, exit
• Roller assembly, upper paper guide
• Transfer corona
• Roller assembly, upper pick up
• Roller assembly, lower pick up
• Static brush, upper (in cardboard folder)
• Static brush, lower (in cardboard folder)
• Label (taped to the top of the package)
• Duplex Drive Assembly (Not shown)

Tune-Up Kit Components
4 Unplug the printer.

6 Remove the photoconductor and place it in its protective packaging in a safe place
away from the work area.
7 Replace the component assemblies in this order:
• Paper timing roller
• Exit roller
• Upper pick up roller
• Lower pick up roller
• Upper feed roller
• Lower feed roller
• Transfer corona
• Lower static brush
• Upper static brush
• Upper paper guide roller
• Duplex Drive Assembly

8 Perform the every-call cleaning procedure outlined on page 9-7.

9 Plug in the printer and turn it on.
10 Run test prints to ensure that the paper feeds correctly through the printer.
11 Fill in the label with the date and meter count. Affix it inside the front cover next to
the printer’s serial number.


Index
Symbols bit-map RAM

“A” roller error codes 2-10
removal 7-93
“B” roller C
removal 7-94 carrier beads 1-4
“C” roller cassette paper present sensor
removal 7-96 locations 1-8
“C” roller solenoid cassette present micro switch
removal 7-97 locations 1-8
Centronics parallel interface 6-32
Numerics special considerations 6-32
1200/2500-sheet feeder 8-4 charge corona
bench test 8-5 diagnostic test 5-9
component acronyms 8-4 TAG 3-49, 3-52
component locations 8-4 cleaner drive
connection diagram 8-8 removal 7-52
input control board logic 8-9 cleaner drive belt
prefeed adjustment 8-7 removal 7-51
1400-sheet stacker cleaning
bench test 8-11 every-call procedure 9-7
component abbreviations 8-10 communications malfunctions
component locations 8-10 TAG 3-128
connection diagram 8-15 connector index 6-4
connector locations 8-13 connector locations 6-11
output control board logic 8-15, 8-16 connectors
back cover 6-17
A duplex cover 6-14
AC power supply front cover 6-12
removal 7-24 left cover 6-13
acronyms and abbreviations 1-3, 6-9 right cover 6-15
automatic toner control 1-10 top cover 6-16
continuity checks 1-17
B controls
back cover automatic toner 1-10
removal 7-6 cooling fan
back cover interlock switch removal 7-21
removal 7-76 counter
Index-1
diagnostic test 5-7 removal 7-92
removal 7-13 duplex route separator
TAG 3-125 removal 7-98
cross references duplex sensors
error code to TAG 2-4 diagnostic tests 5-12
mechanical malfunction to TAG 2-14 duplex skew correction cable
print quality to TAG 2-12 removal 7-89
duplex tray paper-guide motor
D diagnostic test 5-13
DC power supply duplex tray registration motor
DCE host interface 6-29
de-toning 1-12 E
developed image, producing 1-18 electrophotography 1-3
developer end-user cleaning kit 9-5
TAG 3-55 EP cover
developer bias removal 7-79
TAG 3-36 erase lamp
developer unit diagnostic test 5-10
diagnostic tests TAG 3-58
see Section 5, Diagnostic Tests error code/TAG cross reference 2-4
disk drive error codes
diagnostic test 5-18 bit-map RAM 2-10
error codes 2-8 defined 1-20–1-33
TAG 3-90 disk drive 2-8
disk formatting 5-17 host communication 2-11
DTE host interface 6-29 printer 2-4
duplex clutch RIGS board 2-5
diagnostic tests 5-13 VPCL board 2-5, 2-6
duplex control board error log
removal 7-86, 7-87 clearing 1-19, 3-9, 5-18
duplex cover interlock switch reading 1-13
location 1-9 exit assembly
duplex motor removal 7-63
diagnostic tests 5-11 exit cover
duplex paper path sensor removal 7-71
location 1-9 exit pinch roller
duplex registration sensor exit roller assembly
location 1-8 removal 7-69
duplex route motor/solenoid assembly
Index-2
F host communication
fan error codes 2-11
see cooling fan host interface
Flex IO card reference 6-28
TAG 3-131 host system
format disk 5-17 troubleshooting 1-12
front cover
removal 7-5 I
front cover interlock switch image
removal 7-75 producing developed 1-18
front interlock switch imaging system 1-3
location 1-11 interfaces
function code Centronics parallel 6-32
version number 5-17 IBM parallel 6-33
fuser IBM PC/AT 6-31
TAG 3-26, 3-66 IBM PC/XT 6-30
fuser drive Macintosh 6-31
removal 7-54 RS-232C 6-28
fuser drive belt interlock
removal 7-53 by-pass tool 1-17
fuser thermistor TAG 3-171
TAG 3-65
fusing problems
L
TAG 3-166 LED array technology 1-3
LED printhead
G diagnostic test 5-15
ground system 6-27 left side cover
removal 7-7
H line power 1-14
hard disk drive housing loopback connector
removal 7-19 diagnostic test 5-16
HCI lower cassette
see 1200/2500-sheet feeder diagnostic test 5-5
HCO TAG 3-12, 3-17, 3-22, 3-121
see 1400-sheet stacker lower cassette mount
high voltage power supply removal 7-40
removal 7-27 lower feed roller
high-capacity input unit removal 7-58
diagnostic test 5-14 lower paper guide
high-capacity output unit removal 7-48
diagnostic test 5-14 lower pick-up roller
Index-3
lower static brush paper feed tension
removal 7-68 adjusting 9-10
lubrication paper full sensor
procedure 9-12 location 1-10
lubrication points removal 7-74
duplex holding tray 9-18 paper jams
front view 9-13 fuser area 3-26
rear view 9-15 lower cassette 3-22
top view 9-17 output area 3-30
transfer area 3-26
M upper cassette 3-19
main drive motor paper path 1-5
TAG 3-127 illustrated 1-6
main gear drive paper problems
removal 7-85 damaged 3-123
main motor input area 3-32
removal 7-82 multiple feeds 3-122
maintenance output area 3-34
every-call cleaning procedure 9-7 paper size
lubrication procedure 9-12 TAG 3-117
paper feed tension 9-10 paper size sensor
mechanical malfunction locations 1-9
TAG cross reference 2-14 removal 7-34
paper timing guide
N removal 7-49
negative developer bias paper timing roller
paper timing sensor
O location 1-9
operator panel PC life data
diagnostic test 5-4 TAG 3-54
removal 7-12 photoconductor
TAG 3-112 cautions 7-4
output tray removal 7-4
TAG 3-115 photoconductor rear guide rail
removal 7-30
P photoconductor seam sensor
paper exit sensor diagnostic test 5-8
location 1-10 location 1-10
paper feed drive belt
Index-4
TAG 3-46 TAG cross reference 2-12
pick-up roller drive gear printer
removal 7-61 error codes 2-4
pick-up roller drive idler printer maintenance
removal 7-60 logs 9-6
power control board safety precautions 9-4
removal 7-33 supplies 9-5
power problems tools 9-4
+12 Vdc 3-68 printhead
+24 Vdc 3-80 TAG 3-170
+5 Vdc 3-100 printhead assembly
-12 Vdc 3-78 removal 7-16
ac input 3-105 printhead circuit board
TAG 3-68, 3-78, 3-80, 3-100, 3-105 removal 7-18
power-on-reset 1-17 settings 6-3
print problems printing process 1-3
background 4-21 problem resolution
black print 4-13 TAG 3-7
blank print 4-6 protocol converters 1-13
blank vertical bands 4-11
blurring 4-19 R
dark areas 4-14 rear duplex cover
dark lines 4-14 removal 7-10
dark print 4-13 rear interlock switch
dark specks 4-14 location 1-9
dark vertical lines 4-15 right side cover
density variations 4-20 removal 7-8
light horizontal bands 4-12 RIGS board
light print 4-7, 4-8 diagnostic test 5-16
light vertical streaks 4-10 error codes 2-5
misregistration 4-17 removal 7-14
overtoned print 4-18 RIGS controller
residual images 4-22 overview 1-3
skewed prints 4-16 TAG 3-95, 3-97, 3-99
toner fusing 4-24 roller clutch
voids 4-9 diagnostic test 5-7
washout 4-5 RS-232C interface 6-28
white spots 4-9
wrinkled sheets 4-23 S
print quality safety precautions 9-4
samples, see Section 4 self-diagnostic mode 5-3
Index-5
sensors toner patch
diagnostic tests 5-6 producing 1-18
duplex paper path 1-9 TAG 3-39, 3-41
duplex registration 1-8 toner path sensor
locations 1-8 location 1-9
lower cassette paper present 1-8 top cover interlock switch
lower paper size 1-9 removal 7-77
paper exit 1-10 top interlock switch
paper full 1-10 location 1-10
paper timing 1-9 transfer area
photoconductor seam 1-10 TAG 3-26
toner empty 1-10 transfer corona
toner patch 1-9 diagnostic test 5-9
upper cassette paper present 1-8 TAG 3-49, 3-56
upper paper size 1-9 troubleshooting
service call, completing 1-19 general tips 1-12
service kit 9-4 overview 1-11
switches TAG 3-5
bypassing interlock 1-17 tune-up
duplex cover interlock 1-9 maintenance procedure 9-19
front interlock 1-11 tune-up kit
locations 1-8 components 9-20
lower cassette present 1-8
rear interlock 1-9 U
top interlock 1-10 upper cassette
upper cassette present 1-8 diagnostic test 5-4
TAG 3-10, 3-14, 3-19, 3-120
T upper cassette mount
TAGs removal 7-35
sample 1-15 upper duplex drive/clutch assembly
using 1-15 removal 7-91
test prints upper feed roller
running 1-12, 3-8 removal 7-57
toner upper paper guide
automatic control 1-10 assembly 3-124
toner empty sensor upper pick-up roller
location 1-10 removal 7-59
toner motor upper static brush
removal 7-22
Index-6
V
vacuum transport unit
removal 7-9
voltage isolation diagrams 6-22–6-26
VPCL board
error codes 2-5, 2-6
overview 1-3
removal 7-15
TAG 3-89, 3-97
Index-7
Models C30/C30D and C40D
Section 10 Illustrated Parts Catalog
Page 2
This section identifies and illustrates the parts for the printer that can be replaced by the customer and by a field service representative.
The catalog is organized according the general interior locations of the printer. Each location includes an illustration of the parts within it and a
chart listing the corresponding part numbers, names, and descriptions.
To locate a specific part, you have several alternatives:
• If you know the part number, turn to the part number locator beginning on page 63 of this section. Here you will find a cross-reference chart
that tells you the page on which the part is illustrated.
• If you know the general location of the part, turn to the contents listing on the next page. Scan the general locations until you find the appro-
priate one. Then, turn to the page listed to find the part illustration.
• If the part is more general in nature (for example, fuses, lubricants, manuals, or maintenance kits), turn to page 43 where you will find a list-
ing of unillustrated parts.
Contents
Printer Supplies Customer Can Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4

Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6
Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10
Cassette Release Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12
Cassette Mount Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 14
AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16
Duplex Mechanism, Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18
Duplex Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20
Paper Output Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22
Upper Paper Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24
Vacuum Transport Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 26
Job Exit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 28
Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 30
Paper Feed Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 32
Tune-Up Print Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 34
Main Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36
Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38
Duplex Holding Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 40
1200/2500 Sheet High Capacity Input Unit - Main Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 46
1200/2500 Sheet High Capacity Input Unit - Detailed Front View . . . . . . . . . . . . . . . . . . . . . . . . . . page 48
1200/2500 Sheet High Capacity Input Unit - Main Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 50
1200/2500 Sheet High Capacity Input Unit - Detailed Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . page 52
1400 Sheet High Capacity Output Unit - Main Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 54
1400 Sheet High Capacity Output Unit - Detailed Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 56
1400 Sheet High Capacity Output Unit - Main Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 58
1400 Sheet High Capacity Output Unit - Detailed Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 60

Page 4
Printer Supplies Customer Can Install
(6)
Fuser Unit
Ozone Filter (4,5)
Photoconductor
Unit
Developer
Main Charge
Unit (2,3)
Corona
(7)
Toner
Catridge (8,9) Cleaner Unit (1)
Table 1 Printer Supplies List
Product
Item Number Description C30 C30D C40D
1 C4011A Cleaner unit u u u
2 C4015A Developer unit (C30/C30D) u u
3 C4677A Developer unit with ozone filter (C40D) u
6 C4682A C30/C30D Photoconductor unit (includes main charge corona and ozone filter) u u
6 C4683A C40D Photoconductor unit (includes main charge corona and ozone filter u
7 11000214KT C30/C30D Charge corona kit (contains 2 main charge coronas) u u
7 11000215KT C40D Charge corona kit (contains 2 main charge coronas u

Page 6
Front View
18
13 15
1
14
20
9
8 19
11
12
10
2
17
4
5
7 6 3
16
22
1
24
25
23
13
14
19
16 21 17

Page 8
Table 2 Front View Parts List

Item Ref # Part # Description Qty C30 C30D C40D
1 73860006KT Tray, paper output 1 u u u
2 21421610KT Strap, front cover support, right 1 u u u
3 Drive assembly (two floppy drives) 1 u u
4 11000130KT Floppy drive (only) 1 u u u
5 11000253KT Hard drive (only) 1 u u
5 11000137KT C40D Pre-Loaded Disk (HP internal use only) 1 u
6 51020795KT Print head assembly (300 dpi) 1 u u
6 81020108KT Print head assembly (300 dpi) 1 u
7 51020058KT Counter 1 u u u
8 51020018KT Erase lamp assembly 1 u u
8 81020153KT Erase lamp assembly 1 u
9 55020331KT Cover, EP 1 u u u
10 51020106KT PC guide, front 1 u u u
11 51020107KT PC guide, rear 1 u u u
12 Case, maintenance kit 1 u u u
13 Paper cassette, upper 1 u u u
14 Paper cassette, lower 1 u u u
15 61020023KT Vacuum transport assembly 1 u u
15 81120025KT Vacuum transport assembly 1 u
16 73820006KT Cover, left 1 u u u
17 73920009KT Cover assembly, front 1 u
18 Cover assembly, top 1 u
19 73920011KT Right cover 1 u u u
20 Cover, exit assembly 1 u
21 51220072KT Strap, front cover support, left 1 u u
22 Hinge, back cover 1 u u
23 55020350KT Fan, duplex 1 u
24 Frame, exit assembly 1 u u
25 81620012KT Duplex registration tray, complete 1 u u
Page 10
Operator Panel
Digital Display
Status Lights
Function Keys
2 2
Duplex only
(button not shown
C30/30D Control Panel on simplex model) C40 Control Panel
Table 3 Operator Panel Parts List
0 73820020KT C30 Operator Panel Assembly, English (includes all parts shown) 1 u
0 73920014KT C30D Operator Panel Assembly, English (includes all parts shown) 1 u
0 81620008KT Universal LCD Operator Panel Assembly (includes all parts shown) 1 u
2 C30 Operator Overlay 1 u
2 C30D Operator Overlay 1 u
2 81620021KT C40D Operator Overlay 1 u
3 73820010KT Bezel, Operator Panel 1 u u u

Page 12
Cassette Release Assembly
8 11
5
4 9
1
2
10
Table 4 Cassette Release Assembly Parts List
1 21422770KT Cam, cassette release 2 u u u
2 21420074KT Latch, cassette release 2 u u u
3 Damper assembly 1 u u u
4 51220123KT Lever, lower cassette release 1 u u u
5 21421570KT Lever, upper cassette release 1 u u u
6 NLA Wire cable, upper 1 u u u
7 51220127KT Wire cable, lower 1 u u u
8 Spring 1 u u u
9 51220128KT Lever, upper paper pick pressure 1 u u u
10 51220131KT Lever, lower paper pick pressure 1 u u u
11 21420683KT Catch, magnet 1 u u u

Page 14
Cassette Mount Assemblies
2 1
Table 5 Upper Cassette Mount Assemblies Parts List
1 Mount, upper cassette 1 u u u
2 21421209KT Sensor assembly, upper paper size 1 u u u
Table 6 Lower Cassette Mount Assemblies Parts List

1 Mount, lower cassette 1 u u u
2 21421333KT Sensor assembly, lower paper size 1 u u u

Page 16
AC Power Supply
2
4
6 7
Table 7 AC Power Supply Parts List
0 55030024KT AC power supply assembly (includes all parts shown) 1 u u u
1 Relay, AC power supply 1 u u u
2 Relay, fuser, solid state 1 u u u
3 21420515KT Switch, interlock, front 1 u u u
4 21421962KT Switch, interlock, rear 1 u u u
5 Fuse, upper (3.15A/250V) 1 u u u
6 Fuse, lower (2A/250V) 1 u u u

Page 18
Duplex Mechanism, Top View
3 8
7
9 11
6
7 5
2
10
4
1
Table 8 Duplex Mechanism, Top View Parts List
1 55020261KT Duplex C roller pinch assembly 1 u u
2 55020251KT Duplex AB pinch roller assembly 2 u u
3 55020116KT Spring A and B roller 4 u u
4 55020255KT Sensor, paper path 1 u u
5 55020028KT Spring, route separator” 1 u u
6 55020244KT Upper turn around guide 1 u u
7 55020285KT Duplex Cover Gas Support 2 u u
8 Guide top 1 u u
9 55020263KT Entry route separator assembly 1 u u
10 Spring, C roller 2 u u
11 55020052KT Pinch roller only 9 u u

Page 20
Duplex Mechanism
9 22
14
2 17
16
10
15
3
13
11
4
6
12
20
5 18
8
1 21
19
23
Table 9 Duplex Mechanism Parts List
Item Part Number Description Qty C30D C40D
1 55020231KT Exit route separator assembly 1 u u
2 Cover mechanism, front 1 u u
4 55020019KT Top Cover Support, Rear 1 u u
5 55020257KT Top Cover Support, Front 1 u u
6 55020260KT Roller assembly, A and B feed (with gears and clutches) 2 u u
7 55020022KT Roller C feed 1 u
8 55020248KT Solenoid, route separator, paper exit, #1 1 u u
9 Plate, discharge 1 u u
10 55020026KT Solenoid, C roller 1 u u
13 55020024KT Timing belt #1 1 u u
14 NLA Timing belt, #2 1 u u
16 NLA Route solenoid, #2 1 u u
18 55020594KT Duplex drive gear assembly, upper 1 u u
19 Exit tray latch assembly 1 u u
20 55020350KT Cooling fan, C30D duplex 1 u
21 55020196KT Lower turn around guide 1 u u
22 Top cover, front 1 u u
23 Top cover, rear 1 u u

Page 22
Paper Output Area
2
Table 10 Paper Output Area Parts List
1 51020077KT Sensor assembly, paper full 1 u u u
2 51020372KT Sensor assembly, paper exit 1 u u u
3 51020062KT Roller assembly, exit pinch (includes upper static brush) 1 u u u

Page 24
Upper Paper Guide Assembly
7 5
2
3
Table 11 Upper Paper Guide Assembly Parts List
1 81120042KT Upper paper guide assembly (includes all parts shown except corona assembly) 1 u u u
2 61020150KT Corona assembly, transfer 1 u u u
3 51020629KT Roller, upper paper guide 1 u u
4 55020052KT Pinch roller 3 u u
5 81020159KT Upper Guide Spring, Rear 1 u u u
6 81020160KT Upper Guide Spring, Front 1 u u u
Table 12 Lower Paper Guide Assembly Parts List

Table 13 Paper Timing Guide Assembly Parts List


Page 26
2
Table 14 Vacuum Transport Unit Parts List
0 61020023KT Vacuum transport assembly (all parts shown) 1 u u
0 81120025KT Vacuum transport assembly (all parts shown) 1 u
1 Blower 1 u u
1 Blower 1 u
2 21420894KT Belt, vacuum transport 4 u u u
3 21420896KT Gear, drive, vacuum transport 1 u u u

Page 28
Job Exit Assembly
1
2
Table 15 Job Exit Assembly Parts List
0 73820027KT Job offset assembly 1 u u
0 Job exit assembly 1 u
1 Jogging motor 1 u u

Page 30
Back View
11
10
12
5
14
3 8
2 13
Table 16 Back View Parts List
1 61020281KT DC power supply, universal 1 u u u
2 Cover, lower back, 100-240 VAC 1 u u
3 61020072KT Signal interface board 1 u u
3 11000059KT Serial/Parallel I/O PCA 1 u
4 Gear stay 1 u u u
5 51020088KT Power control board 1 u u u
6 51020682KT Fan, main cooling assembly 1 u u u
7 Cover, power control board 1 u u u
8 21423825KT Motor assembly, toner supply 1 u u u
9 51020089KT Jogging motor power control board 1 u u
10 61020022KT High voltage unit 1 u u
10 81020112KT High voltage unit 1 u
11 Cover, paper feed drive 1 u u u
12 Cover, fuser drive assembly 1 u u u
13 Cover, main drive gear 1 u u u
14 61020317KT Interlock by pass tool 2 u u u

Page 32
Paper Feed Roller
3 10
6 12 1
3
1
6
13
13
2 9
13
2 8
8 7 4
5 13 4 7 5 11
C30/C30D Paper Feed Rollers C40D Paper Feed Rollers

Table 17 Paper Feed Roller Parts List
1 11000248KT Roller assembly, upper pick-up 1 u u u
2 21420401KT Drive assembly, pick-up roller 2 u u
3 11000246KT Roller assembly, upper feed 1 u u
3 11000252KT Roller assembly, upper feed 1 u
4 11000249KT Roller assembly, lower pick-up 1 u u u
5 11000245KT Roller assembly, lower feed 1 u u
5 11000251KT Roller assembly, lower feed 1 u
6 61020336KT Roller assembly, timing 1 u u
6 81020246KT Roller assembly, timing 1 u
7 21420406KT Idler assembly 1 u u u
8 21420413KT Belt, paper drive 1 u u u
9 81020034KT Idler Belt 1 u
10 Idler assembly 1 u
11 Gear drive assembly 1 u
12 *61020325KT C30 timing roller clutch 1 u u
13 *61020327KT Pick-up roller clutch 1 u u u
* NLA from OEM

Page 34
Tune-Up Print Maintenance Kit
Roller assembly, paper timing

Lower static brush
(in cardboard holder) Roller assembly, upper feed
Roller assembly, lower feed
Roller assembly, exit
Exit pinch roller
Roller assembly, upper paper guide
Transfer Charger
Roller assembly, lower pick
Roller assembly, upper pick
Label taped to inside top of package

Table 18 Tune-Up Print Maintenance Kit Parts List
1 61030058KT Tune-Up Kit – Includes all parts shown 1 u u
1 81230003KT C40D Refurbishing Kit – Includes all parts shown plus the following: 1 u
2 81020168KT Lower Static Brush 1 u

Page 36
Main Drive Assemblies

1 10
11
13
2
14
4 8
12
9
15 5
7
6
9
C40D 6 C30/C30D
7
Table 19 Main Drive Assemblies Parts List
1 51020056KT Drive assembly, fuser 1 u u
1 81020139KT Drive assembly, fuser 1 u
2 21420412KT Belt, fuser drive 1 u u u
3 11000247KT Roller assembly, exit 1 u u
3 11000250KT Roller assembly, exit 1 u
4 51020342KT Gear, eject 1 u u
4 81020023KT Gear, eject 1 u
5 Bearing, main motor 2 u u
6 N/A Gear, main motor 1 u
7 21420131KT Key, main motor 1 u u u
8 81020138KT Main drive assembly 1 u
9 51020866KT Motor, main drive (does not include drive gear) 1 u u
9 81020040KT Motor, main drive (does not include drive gear) 1 u
10 51020057KT Drive assembly, cleaner unit 1 u u
10 81020141KT Drive assembly, cleaner unit 1 u
11 51020072KT Drive belt, cleaner unit 1 u u u
13 Guide exit 1 u u
14 55020113KT Gear assembly, duplex drive, lower 1 u u
15 81020146KT Main Motor Control PCA 1 u

Page 38
Back Cover
4
2
6
5
2
3
3 1
Table 20 Back Cover Parts List
1 Clip, PCL, IGS, RIGS and VPCL boards 4 u u u
2 Strap, back cover support 2 u u
3 73820007KT Cover assembly, back 1 u u
4 55020014KT PCL board, 300 dpi 1 u u
4 14000701KT AVPCL PCA 1 u
5 56220006KT EIGS board, 300 dpi 1 u u
5 14004602KT RIGS2 Controller PCA 1 u
6 W65 wire harness 1 u

Page 40
Duplex Holding Tray
3
Table 21 C40D Duplex Holding Tray Parts List
1 81620012KT Duplex holding tray (includes all parts shown) 1 u u
2 55020253KT Stepping motor 1 u u
3 81120046KT Duplex control board #2 1 u u
4 55020256KT Paper sensor 1 u u

Page 42
Table 22 Wire Harnesses Parts List

Item Part Number Wire Harness C30 C30D C40D
1 21720177KT W-37 (Pwr printhead) u u u
2 51020148KT W-43 (Cable, Data FDD) u u u
3 51020149KT W-44 (Cable, power, FDD) u u u
4 61020139KT W-46 u u
5 51020780KT W-61 (WH to fuser) u u u
6 W-65 u
7 81020046KT W-71 u
8 61020098KT W-72 u u
9 81020047KT W-72 u
10 W-73 u
11 62020036KT W-73 u
12 81020009KT W-73 u
13 W-109 u
14 W-109 u
15 (Cable, data, HDD) u u u
16 (Cable, power, HDD) u u u
Table 23 Additional Parts List (Not Illustrated)
1 51020685KT Sensor assembly, upper cassette empty Above upper cassette 1 u u u
2 Holder, cassette empty sensor Above upper or lower cassette 1 u u u
3 Lever, cassette empty sensor, lower Above lower cassette 1 u u u
4 51020668KT Lever, cassette empty sensor, upper Above upper cassette 1 u u u
5 21421349KT Sensor assembly, lower cassette empty Above lower cassette 1 u u u
6 51020092KT Guide, cleaner assembly Photoconductor cavity 1 u u u
7 51020110KT Cleaner/charger terminal assembly Behind cleaner 1 u u u
8 Corona cleaner brush Service kit 1 u u u
9 RS-232C loop back assembly Service kit 1 u u u
10 RS-422 loop back assembly Service kit 1 u u
11 Jumper wire Service kit 1 u u u
12 21420290KT Photocell interrupter Below upper paper guide 1 u u u
13 Lever, paper timing sensor Below upper paper guide 1 u u
14 21421569KT Photo seam sensor assembly Photoconductor cavity 1 u u u
15 Fuse, 7.0A, 250V” DC power supply 1 u u u
16 Fuse, signal interface board Used on P/N 61020072KT 1 u u
17 AC Power Cord, US market only Lower back cover area 1 u u u
18 *51020874KT Molycote grease n/a 1 u u u
19 *51020875KT Red grease n/a 1 u u u
20 51020876KT Gear oil n/a 1 u u u
21 55030016KT Parts packet (assortment of 14 springs for duplex) n/a 1 u u u
22 51030028KT Parts packet (assortment of 22 springs) n/a 1 u u u
23 51030029KT Parts packet (assortment of 10 spring leaves, n/a 1 u u u
torsion and plate)
24 51030031KT Parts packet (assortment of 22 washers, nuts and n/a 1 u u u
rivets)
25 Parts packet (assortment of 20 clips and E-rings n/a 1 u u u
26 51030027KT Parts packet (assortment of 14 bearings) n/a 1 u u u
27 51030030KT Parts packet (assortment of 52 screws) n/a 1 u u u
28 Ozone filter, vacuum transport (included in photo- Top cover 1
conductor or developer package)
29 Actuator, top cover interlock Top cover 1 u

Page 44
30 Shaft, latch, top cover Top cover 1 u
31 Lever, latch, top cover Top cover 1 u
32 Shield, top cover interlock Top cover 1 u
33 21420515KT Switch, top cover interlock Top cover 1 u
34 Cover, paper feed Top input area 1 u
35 51020147KT Actuator, top cover interlock Top cover 1 u u
36 Spring solenoid Duplex mechanism output area 1 u u
37 51020065KT Brush, discharge, lower Paper output area 1 u u
38 51020664KT Brush, discharge, upper Paper output area 1 u u
39 5961-0701 HP PCL5 Technical Reference Manual Set n/a 1 u u u
40 Coupler, cleaner Behind cleaner 1 u u u
41 Spring, solenoid Duplex mechanism output area 1 u u u
42 55030015KT Parts packet (assortment of 6 bearings for duplex) n/a 1 u u u
43 Solenoid Duplex unit 1 u u u
44 10000016KT Printer Stand n/a 1 u u u
45 9320-1915 Dusting fabric, toner n/a 1 u u u
46 C4000-60007 C30/C30D SWF/MNL Kit FC Rev. A.01.10 n/a 1 u u
47 23420012KT C30 LED Printhead PCA LED Printhead 1 u u
48 14002900KT C40 LED Printhead PCA LED Printhead 1 u
49 11000137KT C40 Pre-loaded disk (HP internal use only)
50 73820063KT Cleaning Pen n/a 1 u u u
51 610203317 Interlock bypass tool (10 pack) n/a 10 u u u
* Red grease (51020875KT) may be used in place of white grease; do not substitute Molycote grease (51020874) for white grease
Page 46
1200/2500 Sheet High Capacity Input Unit - Main Front View
1 2
3
8
13
4
7
12
6
11
10
5
Table 24 1200/2500 Sheet High Capacity Input Unit - Main Front View Parts List
Part Number
1200 HCI 2500 HCI
1 54624003KT Cover, RR 1
2 Cover, top 1
3 Roller assembly 1
4 54020140KT 54020140KT Lever 1
5 54624009KT Cover, FR 1
6 Base plate assembly 1
7 Wire Harness, W-510 1
10 Chain 2
11 54020023KT Mag door catch 1
12 53020124KT 54224043KT Power supply 1
13 Slope assembly (complete with roller assembly, sensor and actuator) 1

Page 48
1200/2500 Sheet High Capacity Input Unit - Detailed Front View

3 14 2
13 11
12 9
10 4
15, 16 6
Table 25 1200/2500 Sheet High Capacity Input Unit - Detailed Front View Parts List
Part Number
1200 HCI 2500 HCI
1 54220012KT 54224072KT Pick-up roller assembly (complete, includes pick-up rollers) 1
2 54020043KT 54020043KT Pick-up rollers only 1
3 54020061KT 54020061KT Sensor assembly B 1
4 54224034KT 54224034KT Lever 1
5 Chain 2
6 54020023KT 54020023KT Mag door catch 1
7 Paper guide FR assembly (concealed from view) 1
8 54020284KT 54020284KT Sensor assembly A 1
9 53020095KT 54224036KT “Motor, pick up” 1
10 Paper guide RR assembly 1
13 53020069KT 54224038KT “Timing belt, 50M x L x 4.8” 2
14 54020125KT 54020125KT “Timing belt, 71M x L x 6.4 (concealed from view)” 1
15 Fuse 1 1
16 Fuse 2 1

Page 50
1200/2500 Sheet High Capacity Input Unit - Main Rear View
1
9
7
2
10
11
3
5 4
Table 26 1200/2500 Sheet High Capacity Input Unit - Main Rear View Parts List
Part Number
1200 HCI 2500 HCI
1 54020207KT 54224061KT Guide frame assembly (complete with jamplate assembly #9 and slope assembly #10) 1
2 54020058KT 54224064KT Door Assembly 1
3 54020189KT 54224019KT Gear 65T (1200 HCI), Gear 72T (2500 HCI) 1
6 Cover, R 1
7 54020053KT *N/A Actuator C assembly (photo sensor and flag) 5
8 8120-6302 AC jumper cord 1
10 Slope assembly (complete with roller assembly sensor and actuator) 1
11 54020210KT 54020210KT HCI Solenoid Assy 1
* Actuator C assemebly not available for 2500 HCI; order complete guide frame assembly (54224061KT)

Page 52
1200/2500 Sheet High Capacity Input Unit - Detailed Rear View
3
2
1
6
17
18
9
5
8
4
16 10 12
11 see inset
15 11
13 19
14
Table 27 1200/2500 Sheet High Capacity Input Unit - Detailed Rear View Parts List
Part Number
1200 HCI 2500 HCI
1 Ballcase 1
2 SUS ball (concealed from view) 3
3 Spring, C (concealed from view) 3
4 54020207KT 54224061KT Guide frame assembly complete with jamplate assembly and slope assembly 1
5 54020234KT 54020234KT Microswitch 1
7 54020058KT 54224064KT Door assembly 1
8 Chain 2
10 54020189KT 54224019KT Gear 65T (1200 HCI) , Gear 72T (2500 HCI) 1
11 Drive bracket assembly 1
12 53020069KT 54224038KT Timing belt, 50M x L x 4.8 2
15 60020002KT 60020002KT Input control board 1
18 53020054KT 53020054KT HCI/HCO Sprocket Wheel 4
19 54020183KT 54224018KT HCI Helical Gear 1

Page 54
1400 Sheet High Capacity Output Unit - Main Front View
5
10
6
3
1 4
8
Table 28 1400 Sheet High Capacity Output Unit - Main Front View Parts List
0 High Capacity Stacker Unit (100-240V) - generic
1 Guide, upper 1
2 Guide, lower 1
3 Cover, rear 1
4 Cover, front 1
5 Cover, top 1
6 Roller chain 2
9 53020121KT Adapter HCO - Job Offset Assembly 1
10 53620011KT Exit Tray Paper Stop 1

Page 56
1400 Sheet High Capacity Output Unit - Detailed Front View
16
15
6
7
8
14
10
5
2
1
9
12
17
11 13
Table 29 1400 Sheet High Capacity Output Unit - Detailed Front View Parts List
1 Fuse 1 1
2 Fuse 2 1
3 53020032KT Actuator B 1
4 53020088KT Photosensor 6
5 53020091KT Jogging assembly, complete (including frames, photosensor, actuator, roller assemblies and wire harness W-12) 1
6 Wire harness W-12 1
9 Roller chain 2
14 Exit roller assembly 1
17 53020054KT HCI/HCO Sprocket Wheel 4

Page 58
1400 Sheet High Capacity Output Unit - Main Rear View
5 7
9
12
1
11
10
8
6
Table 30 1400 Sheet High Capacity Output Unit - Main Rear View Parts List
1 Guide, upper 1
2 Guide, lower 1
3 Cover, rear 1
4 Cover, front 1
5 Cover, top 1
6 Roller chain 2
7 53020121KT Adapter plate guide assembly 1
9 53020183KT Stacker arm assembly 1
10 Wheel arm assembly 1
11 53620011KT Paper stop, adjustable 1
12 53020194KT Static brush 1

Page 60
1400 Sheet High Capacity Output Unit - Detailed Rear View

15
1
17
10
8 3
9
2 6
16 4
11
12
13
10
See Inset
5
Table 31 1400 Sheet High Capacity Output Unit - Detailed Rear View Parts List
1 53020095KT Elevator motor assembly (includes pulley) 1
2 53020069KT Timing belt, 50M x L x 4.8 1
3 53020065KT Pulley (30T) 1
4 53020051KT Gear D 1
5 53020052KT Gear E 1
6 53020050KT Gear C 1
7 Roller chain 2
10 53020090KT Elevator gear assembly (includes motor, worm gear, belt, pulley and drive gear) 1
11 Timing belt, 80M x L x 4.8 1
12 53224001KT Gear, exit 1
13 53224003KT Gear A (Z90) 1
14 8120-6302 AC power cord (not shown) 1
16 53020230KT Arm holder bracket 1

Page 62
Table 32 Part Numbers Related to Service Notes

S.N. Part Number Description Qty C30 C30D C40D
1 C4000-13402 3-1/2” Fonts Floppy 1 u u
1 C4000-13403 3-1/2” Function Code Floppy (A.01.09.02) 1 u u
2 54620010KT Shelf Kit for 2500 HCI 1 u u
3 C4000-60007 Function Code and Fonts Floppies (A.01.10) 1 u u
4 73820056KT Lever-Stop Clip (required when HCI attached to printer) 1 u u u
Table 33 Part Number Page Part Number Page Part Number Page
Part Number Locator
21420290KT 21, 29, 41 43, 23420012KT 44 51020664KT 44
Part Number Page 49, 53
51020018KT 8 51020668KT 43
21420401KT 33
10000016KT 44 51020056KT 37 51020682KT 31
21420406KT 33
11000059KT 31 51020057KT 37 51020685KT 43
21420412KT 37
11000130KT 8 51020058KT 8 51020780KT 42
21420413KT 33
11000137KT 8, 44 51020062KT 23 51020795KT 8
21420515KT 17, 44
11000214KT 5 51020065KT 44 51020866KT 37
21420683KT 13
11000215KT 5 51020072KT 37 51020874KT 43
21420894KT 27
11000245KT 33 51020077KT 23 51020875KT 43
21420896KT 27
11000246KT 33 51020088KT 31 51020876KT 43
21421209KT 15
11000247KT 37 51020089KT 31 51030027KT 43
21421333KT 15
11000248KT 33 51020092KT 43 51030028KT 43
21421349KT 43
11000249KT 33 51020106KT 8 51030029KT 43
21421569KT 43
11000250KT 37 51020107KT 8 51030030KT 43
21421570KT 13
11000251KT 33 51020110KT 43 51030031KT 43
21421610KT 8
11000252KT 33 51020147KT 44 51220072KT 8
21421937KT 15
11000253KT 8 51020148KT 42 51220123KT 13
21421962KT 17
14000701KT 39 51020149KT 42 51220127KT 13
21422770KT 13
14002900KT 44 51020256KT 11 51220128KT 13
21423777KT 25
14004602KT 39 51020342KT 37 51220131KT 13
21423825KT 31
21420074KT 13 51020372KT 23 53020029KT 57, 61
21720177KT 42
21420131KT 37 51020629KT 25 53020031KT 59, 61

Page 64
53020032KT 57 54020024KT 51, 53 54224064KT 51, 53 55020255KT 19
53020050KT 61 54020043KT 49 54224072KT 49 55020256KT 41
53020051KT 61 54020053KT 51 54620010KT 62 55020257KT 21
53020052KT 61 54020058KT 51, 53 54624003KT 47 55020260KT 21
53020054KT 53, 57 54020061KT 49 54624009KT 47 55020261KT 19
53020065KT 61 54020125KT 49 55020014KT 39 55020263KT 19
53020069KT 49, 53, 61 54020183KT 53 55020019KT 21 55020285KT 19
53020088KT 57 54020189KT 51, 53 55020020KT 21 55020331KT 8
53020090KT 61 54020207KT 51, 53 55020022KT 21 55020350KT 8, 21
53020091KT 57 54020210KT 51 55020024KT 21 55020482KT 17
53020095KT 49, 51, 53, 61 54020234KT 53 55020026KT 21 55020489KT 17
53020121KT 55, 59 54020284KT 49 55020028KT 19 55020490KT 17
53020124KT 47, 55, 57 54220012KT 49 55020052KT 19, 25 55020491KT 17
53020183KT 59 54224018KT 53 55020113KT 21, 37 55020594KT 21
53020184KT 57, 61 54224019KT 51, 53 55020116KT 19 55030015KT 44
53020194KT 59 54224034KT 49 55020196KT 21 55030016KT 43
53020230KT 61 54224036KT 49 55020214KT 21 55030024KT 17
53224001KT 61 54224038KT 49, 53 55020231KT 21 56220006KT 39
53224003KT 61 54224043KT 47 55020244KT 19 5961-0701 44
53620011KT 55, 59 54224048KT 53 55020248KT 21 60020002KT 53

53820006KT 57, 61 54224050KT 51, 53 55020251KT 19 60020003KT 55, 57
54020023KT 47, 49 54224061KT 51, 53 55020253KT 41 61020013KT 37

61020022KT 31 73820063KT 44 81120012KT 21, 37, C4682A 5
61020023KT 8, 27 73920009KT 8 81120021KT 21 C4683A 5
61020028KT 37 73920011KT 8 81120025KT 8, 27
61020072KT 31 73920014KT 11 81120042KT 25
61020098KT 42 81020009KT 42 81120046KT 41
61020139KT 42 81020023KT 37 81120051KT 21
61020150KT 25 81020034KT 33 8120-6302 51, 61
61020281KT 31 81020040KT 37 81230003KT 35
61020317KT 31 81020046KT 42 81620008KT 11
61020325KT 33 81020047KT 42 81620012KT 8, 41
61020327KT 33 81020108KT 8 81620021KT 11
610203317 44 81020112KT 31 9320-1915 44
61020336KT 33 81020137KT 25 C4000-13402 62
61030058KT 35 81020138KT 37 C4000-13403 62
62020036KT 42 81020139KT 37 C4000-60007 44, 62
62020046KT 11 81020141KT 37 C4006A 5
73820006KT 8 81020146KT 37 C4007A 5
73820007KT 39 81020153KT 8 C4011A 5
73820010KT 11 81020159KT 25 C4015A 5
73820020KT 11 81020160KT 25 C4675A 5

73820027KT 29 81020168KT 35 C4676A 5
73820056KT 62 81020246KT 33 C4677A 5

Page 66
Table 34 Part Number Table Item Qty Part Number Table Item Qty Part Number Table Item Qty
Part Number/Table Index
21420131KT 19 7 1 5 4 1 51020110KT 23 7 1
21421937KT
Part Number Table Item Qty 9 11 1 6 4 1 51020147KT 23 35 1
10000016KT 23 44 1 15 2 2 21421962KT 7 4 1 51020148KT 22 2 1
11000059KT 16 3 1 21 5 1 21422770KT 4 1 2 51020149KT 22 3 1
21420290KT
11000130KT 2 4 1 23 12 1 11 7 1 51020256KT 3 1 1
21423777KT
2 5 1 25 11 5 12 7 1 51020342KT 19 4 1
11000137KT
23 49 1 27 9 5 21423825KT 16 8 1 51020372KT 10 2 1
11000214KT 1 7 N.A. 21420401KT 17 2 2 21720177KT 22 1 1 51020629KT 11 3 1
11000215KT 1 7 N.A. 21420406KT 17 7 1 23420012KT 23 47 1 51020664KT 23 38 1
11000245KT 17 5 1 21420412KT 19 2 1 51020018KT 2 8 1 51020668KT 23 4 1
11000246KT 17 3 1 21420413KT 17 8 1 51020056KT 19 1 1 51020682KT 16 6 1
11000247KT 19 3 1 7 3 1 51020057KT 19 10 1 51020685KT 23 1 1
21420515KT
11000248KT 17 1 1 23 33 1 51020058KT 2 7 1 51020780KT 22 5 1
11000249KT 17 4 1 21420683KT 4 11 1 51020062KT 10 3 1 51020795KT 2 6 1
11000250KT 19 3 1 21420894KT 14 2 4 51020065KT 23 37 1 51020866KT 19 9 1
11000251KT 17 5 1 21420896KT 14 3 1 51020072KT 19 11 1 51020874KT 23 18 1
11000252KT 17 3 1 21421209KT 5 2 1 51020077KT 10 1 1 51020875KT 23 19 1
11000253KT 2 5 1 21421333KT 6 2 1 51020088KT 16 5 1 51020876KT 23 20 1
14000701KT 20 4 1 21421349KT 23 5 1 51020089KT 16 9 1 51030027KT 23 26 1
14002900KT 23 48 1 21421569KT 23 14 1 51020092KT 23 6 1 51030028KT 23 22 1
14004602KT 20 5 1 21421570KT 4 5 1 51020106KT 2 10 1 51030029KT 23 23 1
21420074KT 4 2 2 21421610KT 2 2 1 51020107KT 2 11 1 51030030KT 23 27 1
51030031KT 23 24 1 53020091KT 29 5 1 24 11 1 26 3 1
54020023KT 54224019KT
51220072KT 2 21 1 25 9 2 25 6 1 27 10 1
51220123KT 4 4 1 53020095KT 26 5 2 26 4 1 54224034KT 25 4 1
54020024KT
51220127KT 4 7 1 27 14 2 27 13 1 54224036KT 25 9 1
51220128KT 4 9 1 31 1 1 54020043KT 25 2 1 25 13 2
54224038KT
51220131KT 4 10 1 28 9 1 54020053KT 26 7 5 27 12 2
53020121KT
29 10 4 30 7 1 26 2 1 54224043KT 24 12 1
53020029KT 54020058KT
31 9 4 24 12 1 27 7 1 54224048KT 27 9 5
30 8 1 53020124KT 28 7 1 54020061KT 25 3 1 26 5 2
53020031KT 54224050KT
31 8 1 29 12 1 54020125KT 25 14 1 27 14 2
53020032KT 29 3 1 53020183KT 30 9 1 54020140KT 24 4 1 26 1 1

54224061KT
53020050KT 31 6 1 29 7 1 54020183KT 27 19 1 27 4 1
53020184KT
53020051KT 31 4 1 31 17 1 26 3 1 26 2 1
54020189KT 54224064KT
53020052KT 31 5 1 53020194KT 30 12 1 27 10 1 27 7 1
27 18 4 53020230KT 31 16 1 26 1 1 54224072KT 25 1 1
53020054KT 54020207KT
29 17 4 53224001KT 31 12 1 27 4 1 54620010KT 32 2 1
53020065KT 31 3 1 53224003KT 31 13 1 54020210KT 26 11 1 54624003KT 24 1 1
25 13 2 28 10 1 54020234KT 27 5 1 54624009KT 24 5 1
53020069KT 53620011KT
27 12 2 30 11 1 54020284KT 25 8 1 55020014KT 20 4 1
31 2 1 29 8 1 54220012KT 25 1 1 55020019KT 9 4 1
53820006KT
53020088KT 29 4 6 31 15 1 54224018KT 27 19 1 55020020KT 9 3 1
53020090KT 31 10 1 55020022KT 9 7 1

Page 68
55020024KT 9 13 1 55020331KT 2 9 1 61020098KT 22 8 1 73920014KT 3 0 1
55020026KT 9 10 1 2 23 1 61020139KT 22 4 1 81020009KT 22 12 1

55020350KT
55020028KT 8 5 1 9 20 1 61020150KT 11 2 1 81020023KT 19 4 1
8 11 9 55020482KT 7 7 1 61020281KT 16 1 1 81020034KT 17 9 1

55020052KT
11 4 3 55020489KT 7 7 1 16 14 2 81020040KT 19 9 1
61020317KT
9 12 1 55020490KT 7 7 1 23 52 10 81020046KT 22 7 1
55020113KT
19 14 1 55020491KT 7 7 1 61020325KT 17 12 1 81020047KT 22 9 1
55020116KT 8 3 4 55020594KT 9 18 1 61020327KT 17 13 1 81020108KT 2 6 1
55020196KT 9 21 1 55030015KT 23 42 1 61020336KT 17 6 1 81020112KT 16 10 1
55020214KT 9 17 1 55030016KT 23 21 1 61030058KT 18 1 1 11 8 1

81020137KT
55020231KT 9 1 1 55030024KT 7 0 1 62020036KT 22 11 1 13 8 1
55020244KT 8 6 1 56220006KT 20 5 1 62020046KT 3 1 1 81020138KT 19 8 1
55020248KT 9 8 1 5961-0701 23 39 1 73820006KT 2 16 1 81020139KT 19 1 1
55020251KT 8 2 2 60020002KT 27 15 1 73820007KT 20 3 1 81020141KT 19 10 1
55020253KT 21 2 1 28 8 1 73820010KT 3 3 1 81020146KT 19 15 1

60020003KT
55020255KT 8 4 1 29 11 1 73820020KT 3 0 1 81020153KT 2 8 1
55020256KT 21 4 1 61020013KT 19 8 1 73820027KT 15 0 1 81020159KT 11 5 1
55020257KT 9 5 1 61020022KT 16 10 1 73820056KT 32 4 1 81020160KT 11 6 1
55020260KT 9 6 2 2 15 1 73820063KT 23 50 1 81020168KT 18 2 1

61020023KT
55020261KT 8 1 1 14 0 1 73860006KT 2 1 1 81020246KT 17 6 1
55020263KT 8 9 1 61020028KT 19 8 1 73920009KT 2 17 1 9 12 1

81120012KT
55020285KT 8 7 2 61020072KT 16 3 1 73920011KT 2 19 1 19 14 1
Part Number Table Item Qty Part Number Table Item Qty
81120021KT 9 17 1 C4675A 1 4 N.A.
2 15 1 C4676A 1 5 N.A.
81120025KT
14 0 1 C4677A 1 3 N.A.
81120042KT 11 1 1 C4682A 1 6 N.A.
81120046KT 21 3 1 C4683A 1 6 N.A.
81120051KT 9 3 1
26 8 1
8120-6302
31 14 1
81230003KT 18 1 1
81620008KT 3 0 1
2 25 1
81620012KT
21 1 1
81620021KT 3 2 1
9320-1915 23 45 1
C4000-13402 32 1 1
C4000-13403 32 1 1
23 46 1
C4000-60007
32 3 1
C4006A 1 8 N.A.
C4007A 1 9 N.A.
C4011A 1 1 N.A.
C4015A 1 2 N.A.

Page 70

CUT SHEET C30, C30D Parts and Service Manual

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Manuals for other Computer and

Printer / Copier Manufacturers

HP Part No. C4000-90006

June 1999 iii

Using This Manual

Chapter 1, “Printer and Troubleshooting Overview”

Chapter 2, “TAG Cross- Reference Tables”

Chapter 3, “Troubleshooting Analysis Guide (TAGs)”

Chapter 4, “Print Quality Samples”

Chapter 5, “Diagnostic Tests”

Chapter 6, “Wiring Diagrams and Electrical Data”

Chapter 7, “Removal/Replacement Procedures”

Chapter 9, “General Printer Maintenance”

Copyright © 1999 Hewlett-Packard Company. All rights reserved. May 1999

Printer and Troubleshooting Overview

TAG Cross-Reference Tables

Troubleshooting Analysis Guide (TAGs)

June 1999 vii

TAG 012: Upper Cassette Not Latched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

viii June 1999

TAG 804: Prints With Light Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-162

Print Quality Samples

Wiring Diagrams and Electrical Data

Connectors on the Duplex Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Replacement Note: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

xii June 1999

Paper Timing Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60

June 1999 xiii

General Printer Maintenance

xiv June 1999

Duplex Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

Abbreviations and Acronyms

xvi June 1999

June 1999 Printer and Troubleshooting Overview 1-1

Printing and Troubleshooting Overview

1-2 Printer and Troubleshooting Overview June 1999

June 1999 Printer and Troubleshooting Overview 1-3

Transfer Corona Vacuum Transport Fuser Unit

Figure 1-1. Cycle of Operation

1-4 Printer and Troubleshooting Overview June 1999

Paper Path and Cycle Sequence

June 1999 Printer and Troubleshooting Overview 1-5

Figure 1-2. Paper Path

1-6 Printer and Troubleshooting Overview June 1999

Error Code Technical Definitions

Table 1-1. Error Code Technical Definitions

Type Error Description

sensor indicating no paper present

June 1999 Printer and Troubleshooting Overview 1-7

Table 1-1. Error Code Technical Definitions (Continued)

Type Error Description

1-8 Printer and Troubleshooting Overview June 1999

Table 1-1. Error Code Technical Definitions (Continued)

Type Error Description

of the PCL board.

June 1999 Printer and Troubleshooting Overview 1-9

Table 1-1. Error Code Technical Definitions (Continued)

Type Error Description

701-703 IGS board detected an error when communicating with a host

using RS232 communications.