Beruflich Dokumente
Kultur Dokumente
from PCTECHINFO!
from PCTECHINFO!
Cut Sheet Printers
Maintenance Manual
Models C30 and C30D
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.
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.
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.
June 1999 v
vi June 1999
Contents
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
x June 1999
Contents
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
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
June 1999 xv
Contents
Printer and
Troubleshooting
Overview
Section 1 Troubleshooting
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.
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.
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
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.
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.
conductor unit).
042 PCL board detected an open connection to the photoconductor
seam sensor LED (within the photoconductor unit).
044 PCL board detected a signal from the high-voltage power supply
unit indicating that either the charge corona or transfer corona cir-
cuits have an open connection.
045 PCL board detected a signal from the high-voltage power supply
unit indicating an abnormally high load on the bias voltage to the
charge corona.
046 PCL board detected a signal from the high-voltage power supply
unit indicating an open connection in the charge corona circuit
(diagnostic test only).
050 PCL board detected a signal from the high-voltage power supply
unit indicating an abnormally high load on the bias voltage to the
HVPS Errors
transfer corona.
051 PCL board detected a signal from the high-voltage power supply
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.
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).
085 PCL board detected a signal from the duplex control board #2 indi-
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).
086 PCL board detected a signal from the duplex control board #2 indi-
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.
098 PCL board detected a signal from the IGS board indicating the
absence of ‚-12 Vdc.
099 PCL board detected a signal from the IGS board indicating the
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
570-586 IGS board detected an error when communicating with the floppy
Controller
disk drive.
Errors
600-610 IGS board detected an error during the internal diagnostic testing
of the IGS board.
Top view
Front view
Front view
Rear view
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
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.
Paper Jams
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.
Sample TAG
1 To start:
• Disconnect all peripheral cables
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
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.
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.
Caution
Do not attempt to close the printer cover while the interlock
bypass tool is in place.
Caution
Do not touch the surface of the photoconductor belt; this
damages the belt and results in poor print quality.
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.”
Troubleshooting
Analysis Guide
(TAGs)
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?
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.
4 Did only the READY and ON LINE lights come on with no numeric display?
No: Continue.
Yes: Go to TAG 753: External Communications Malfunction.
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:
• Power-on-reset the printer.
• 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.
• Power-on-reset the printer.
• 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.
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
Caution
Handle gently to avoid breaking the corona wire
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
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.
1 Power-on-reset the printer.
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.
Caution
With this procedure you can either clear the error log or
format a disk. Pay careful attention to the options you select.
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!
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.
7 Reconnect J/P46.
• Disconnect J/P40 and J/P45.
• Check P40-49 to P45-2 for continuity.
Is there continuity?
No: Go to #10 in this TAG.
Yes: Continue.
7 Reconnect J/P46.
• Disconnect J/P40 and J/P45.
• Check P40-49 to P45-2 for continuity.
Is there continuity?
No: Go to #10 in this TAG.
Yes: Continue.
7 Reconnect J/P48.
• Disconnect J/P43 and J/P40.
• Check P40-50 to P43-10 for continuity.
Is there continuity?
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.
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.
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?
No: Go to #9 in this TAG.
Yes: Continue.
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.
Yes: Go to #12 in this TAG.
12 Run diagnostic test 006, testing the upper feed roller clutch.
• Check TP3-6 for a voltage change from +24 Vdc to 0 Vdc.
Does the voltage change from +24 Vdc to 0 Vdc?
No: Continue.
Yes: Go to #14 in this TAG.
2 Turn the printer off and inspect the following for damage or binding:
• Lower paper guide assembly
• Upper paper guide assembly
• Paper feed drive belt
• Paper feed drive pulley
• Paper feed drive idler assembly
• Main drive gear assembly
• Lower pick-up roller drive assembly
Are all the parts in good working order?
No: Replace the damaged parts, then turn to TAG 002: Check & Problem Resolution.
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?
No: Go to #9 in this TAG.
Yes: Continue.
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.
Then turn to TAG 002: Check & Problem Resolution.
Yes: Replace the paper timing guide. If this does not correct the problem, replace the PCL
board. Then turn to TAG 002: Check & Problem Resolution.
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.
• Check TP3-8 for a voltage change from +24 Vdc to 0 Vdc.
Does the voltage change from +24 Vdc to 0 Vdc?
No: Continue.
Yes: Go to #12 in this TAG.
12 Run diagnostic test 006, testing the lower feed roller clutch.
• Check TP3-5 for a voltage change from +24 Vdc to 0 Vdc.
Does the voltage change from +24 Vdc to 0 Vdc?
No: Continue.
Yes: Go to #14 in this TAG.
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
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.
Operations manual.
• Check that the fuser unit is installed properly.
• Power-on-reset the printer.
• Run test prints.
Is error code 022 still displayed?
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.
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.
• Run test prints.
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.
12 Run diagnostic test 006, testing the paper timing roller clutch.
• Check TP3-7 for a voltage change from +24 Vdc to 0 Vdc.
Does the voltage change from +24 Vdc to 0 Vdc?
No: Continue.
Yes: Go to #14 in this TAG.
14 Does paper stop or jam either before or during entry into the fuser unit?
No: Go to #17 in this TAG.
Yes: Continue.
No: Continue.
Yes: Open the top cover and install an interlock by-pass tool.
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.
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.
P40-13 to P49-3.
Is there continuity?
No: Repair or replace the connectors or wiring from:
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.
5 Reconnect J/P57.
• Reinstall the paper timing guide.
• Power-on-reset the printer.
Is error code 025 still displayed?
No: J/P57 was at fault. Turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
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.
10 Disconnect J/P96.
• Check P96-1 to J25-7 for continuity.
Is there continuity?
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.
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:
Check & Problem Resolution.
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.
An 035 error may occur if the print coverage exceeds 25%. Do not run high print coverage
jobs for extended periods of time.
5 Has the seal has been removed from the toner cartridge?
No: Continue.
Yes: Go to #7 in this TAG.
5 Is error code 041 or 042 displayed while running diagnostic test 009?
No: Continue.
Yes: Go to #12 in this TAG.
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
9 With the upper paper guide assembly in its fully upright position, check the transfer corona's lower
receptacle for continuity to ground.
Is there continuity?
No: Replace or repair the upper paper guide assembly, then turn to TAG 002: Check & Prob-
lem Resolution.
Yes: Continue.
No: Replace the upper paper guide assembly, then turn to TAG 002: Check & Problem Reso-
lution.
Yes: Go to #13 in this TAG.
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
Note
If the fuser lamp comes on immediately after power on,
turn off the printer and replace the AC power supply.
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?
No: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
Caution
Do not allow the printer to remain on for more than five
seconds or additional damage may occur.
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?
No: Replace the AC power supply, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
22 Disconnect J/P12.
• Check J10-2 (power control #2 board) for continuity to ground.
Is there continuity?
No: Continue.
Yes: Replace the power control #2 board, then turn to TAG 002: Check & Problem Resolu-
tion.
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.
Caution
Check J/P101-2 to J/P101-1 for 100 Vac while the test is running
18 Disconnect J/P61.
• Check P62-1 to P61-1 for continuity to ground.
Is there continuity?
No: Replace the lower paper empty sensor, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: Repair or replace the connectors or wiring from P62-1 to P61-1, then turn to TAG 002:
Check & Problem Resolution.
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.
Yes: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.
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.
4 Replace the diskette with another diskette known to be correct for the customer's system configura-
tion.
• Power-on-reset the printer.
Is error code 451 still displayed?
No: The diskette was at fault. Turn to TAG 002: Check & Problem Resolution.
Yes: Replace the disk drive assembly, then turn to TAG 002: Check & Problem Resolution.
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: Replace wire harness W46, then turn to TAG 002: Check & Problem Resolution.
15 Check for continuity to ground: P31-18 to P79-18, P31-24 to P79-24, and P31-26 to P79-26.
Is there continuity on any?
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
to TAG 002: Check & Problem Resolution.
Yes: Replace wire harness W46, then turn to TAG 002: Check & Problem Resolution.
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.
Is there continuity on each?
No: Replace wire harness W46, then turn to TAG 002: Check & Problem Resolution.
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.
5 Replace the IGS board, making sure that IGS EPROM version is correctly matched to the software
release installed on the printer.
• Power-on-reset the printer.
Has the problem been resolved?
No: Reinstall the original IGS board and continue.
Yes: Turn to TAG 002: Check & Problem Resolution.
1 The IGS bit-map RAM has malfunctioned. Replace the IGS board, 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.
Is the voltage at least 100 Vac?
No: Replace the AC power supply unit.
Yes: Repair or replace the connectors or wiring from:
P4-7 to P6-1 or
P4-8 to P6-2;
then turn to TAG 002: Check & Problem Resolution.
4 Does the PRINTER OPEN light come on with all the covers closed?
No: Go to #25 in this TAG.
Yes: Continue.
6 Use extreme caution: Check from J/P4-4 to J/P4-3 for +100 Vac.
Is the voltage +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.
12 Disconnect J/P13.
• Install a new upper fuse in the AC power supply unit.
• Run diagnostic test 010 for approximately 5 seconds, then stop.
• Remove the fuse.
• Check the fuse for continuity.
Does the fuse have continuity?
No: Replace the power control #2 board, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: Continue.
13 Disconnect J/P18.
• Check P13-5 to P18-1 for continuity to ground.
Is there continuity to ground?
No: Replace the toner supply motor, then turn to TAG 002: Check & Problem Resolution.
Yes: Repair or replace the connectors or wiring from P18-1 to P13-5, then turn to TAG 002:
Check & Problem Resolution.
15 Reconnect J/P9.
• Install a good upper fuse in the AC power supply unit.
• Disconnect J/P13 and J/P14.
• Turn the printer on for 5 seconds, then off.
• Remove the fuse.
• Check the fuse for continuity.
Does the fuse have continuity?
No: Replace the power control #2 board, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: Continue.
20 Reconnect J/P9.
• Disconnect J/P100.
• Install a new upper fuse in the AC power supply unit.
• Run diagnostic test 008 for approximately five seconds, then turn off the printer.
• Remove the fuse.
• Check the fuse for continuity.
Does the fuse have continuity?
No: Go to #23 in this TAG.
Yes: Continue.
22 Disconnect J/P19.
• Check P101-2 to P19-2 for continuity to ground.
Is there continuity to ground?
No: Replace the jogging motor, then turn to TAG 002: Check & Problem Resolution.
Yes: Repair or replace the connectors or wiring from P101-2 to P19-2, 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.
27 Unplug power cord from the printer and the wall outlet.
• Check the power cord for continuity.
Is there 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.
• Check P4-1 for continuity to ground.
Is there continuity?
No: Go to #30 in this TAG.
Yes: Continue.
32 Disconnect J/P6.
• Check P4-7 to P6-1 for continuity to ground.
Is there continuity?
No: Replace the DC power supply unit, then turn to TAG 002: Check & Problem Resolution.
Yes: Repair or replace the connectors or wiring from P4-7 to P6-1, then turn to TAG 002:
Check & Problem Resolution.
34 Disconnect J/P84.
• Check P4-5 to P84-1 and P4-6 to P84-2 for continuity.
Is there continuity on both?
No: Repair or replace the connectors or wiring that lack continuity, then turn to TAG 002:
Check & Problem Resolution.
Yes: Continue.
36 Check J131 to J132 (top interlock switch) for continuity while activating the top cover interlock
switch.
Is there continuity?
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.
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.
J/P42-8 to Open
J/P90-8 to
J/P41-13
4 Inspect the output tray full sensor actuator for damage or binding.
Is it in good working order?
No: Replace the actuator, then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
6 Is the paper size sensing problem occurring with the upper cassette?
No: Go to #8 in this TAG.
Yes: Continue.
2 Adjust the paper tension lever or pick pressure as outlined in Chapter 9, “General Printer Mainte-
nance”.
Has the problem been resolved?
No: Replace the pick-up roller assembly, then turn to TAG 002: Check & Problem Resolu-
tion.
3 Is the counter either counting when it shouldn’t or counting too many times?
No: Go to #5 in this TAG.
Yes: Continue.
Note
Communication problems may require trial replacement of numerous
parts. After each trial replacement, run the job that exhibited the failure.
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:
Check & Problem Resolution.
Communication problems may require trial replacement of numerous parts. After each
trial replacement, run the job that exhibited failure.
If there is a developed image on the paper other than dark horizontal bands, follow TAG
804: Prints With Light Horizontal Bands.
3 Have the photoconductor unit, charge corona, developer unit, and toner cartridge
been replaced recently?
No: Continue.
Yes: Go to #6 in this TAG.
If the problem still exists after completing this TAG, go to TAG 800: Prints Blank or With
Dark Horizontal Bands.
3 Check the voltages, as outlined in Chapter 9, “General Printer Maintenance”.Are the voltages cor-
rect?
No: Replace the high voltage power supply unit, then turn to TAG 002: Check & Problem
Resolution.
Yes: Continue.
4 Have the photoconductor unit, charge corona, developer unit, and toner cartridge
been replaced recently?
No: Continue.
Yes: Go to #7 in this TAG.
12 Inspect the toner drive coupling on the developer unit for damage.
Is the coupling damaged?
No: Continue.
Yes: Replace the developer unit, then turn to TAG 002: Check & Problem Resolution.
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.
3 Have the photoconductor unit, charge corona, and developer unit been replaced
recently?
No: Continue.
Yes: Go to #6 in this TAG.
3 Have the photoconductor unit and charge corona have been replaced recently?
No: Continue.
Yes: Go to #5 in this TAG.
3 Has the photoconductor unit, charge corona, developer unit, and cleaner unit been
replaced recently?
No: Continue.
Yes: Go to #6 in this TAG.
3 Have the photoconductor unit, charge corona, fuser unit, cleaner unit, and devel-
oper unit with new toner cartridge been replaced recently?
No: Continue.
Yes: Go to #8 in this TAG.
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.
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.
• Run test prints.
• 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.
Yes: Turn to TAG 002: Check & Problem Resolution.
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.
3 Have the photoconductor unit, charge corona, cleaner unit, and developer unit with
toner cartridge been replaced recently?
No: Continue.
Yes: Go to #7 in this TAG.
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.
15 Reconnect J/P24.
• Disconnect J/P23.
• Check P41-38 to P23-2 for continuity.
Is there continuity?
No: Repair or replace the connectors or wiring from P41-38 to P23-2, then turn to TAG 002:
Check & Problem Resolution.
Yes: Continue.
19 Reconnect J/P85.
• Reinstall the developer unit.
• Replace the high voltage unit.
• Run test prints.
Has the problem been resolved?
No: Reinstall the original high voltage unit and continue.
Yes: Turn to TAG 002: Check & Problem Resolution.
3 Have the photoconductor, charge corona, cleaner, or fuser units been replaced
recently?
No: Continue.
Yes: Go to #7 in this TAG.
8 Open the printer’s top cover and install an interlock by-pass tool.
• Turn the printer on.
• 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?
No: Go to #10 in this TAG.
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.
Yes: Go to #12 in this TAG.
12 Inspect the fuser drive assembly and the fuser drive belt for damage or a slipping belt.
Are they in good working order?
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.
1 Perform the every-call cleaning procedure, described in Chapter 9, “General Printer Maintenance”.
• Turn the printer on.
• Run test prints.
Has the problem been resolved?
No: Continue.
Yes: Contamination was at fault. Turn to TAG 002: Check & Problem Resolution.
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.
3 Have the photoconductor unit, charge corona, cleaner unit and developer unit with
new toner cartridge been replaced recently?
No: Continue.
Yes: Go to #5 in this TAG.
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: Replace the PCL board, then turn to TAG 002: Check & Problem Resolution.
12 Reconnect J/P24.
• Disconnect J/P23.
• Check P41-33 to P23-7 for continuity.
Is there continuity?
No: Continue.
Yes: Repair or replace the connectors or wiring from P41-33 to P23-7, then turn to TAG 002:
Check & Problem Resolution.
13 Reconnect J/P23.
• Disconnect J/P85 from the high voltage unit.
• Check P85-8 to J25-7 for continuity.
Is there continuity?
No: Repair or replace the connectors or wiring from P85-8 to J25-7, then turn to TAG 002:
Check & Problem Resolution.
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”.
Is the voltage correct?
No: Replace the high voltage unit, then turn to TAG 002: Check & Problem Resolution.
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?
No: Go to #20 in this TAG.
Yes: Replace the high voltage unit, then turn to TAG 002: Check & Problem Resolution.
23 Disconnect J/P12.
• Check P40-31 and P12-5 for continuity to ground.
Is there continuity?
No: Replace the power control #2 board, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: Repair or replace the connectors or wiring from P40-31 to P12-5, then turn to TAG 002:
Check & Problem Resolution.
3 Have the fuser unit and developer unit with new toner cartridge been replaced
recently?
No: Continue.
Yes: Go to #6 in this TAG.
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.
4 Have the cleaner unit, developer unit with new toner cartridge, and photoconductor
unit been replaced recently?
No: Continue.
Yes: Go to #8 in this TAG.
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?
No: Go to #12 in this TAG.
Yes: Replace the high voltage unit, then turn to TAG 002: Check & Problem Resolution.
2 Open the printer’s top cover and insert the interlock by-pass tool.
• Turn on the printer.
• Check J/P309-3 on duplex control board #1 for +12 Vdc.
Is the voltage +12 Vdc?
No: Replace the duplex control board #1, then turn to TAG 002: Check & Problem Resolu-
tion.
Yes: Continue.
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.
• Confirm that the paper in the cassettes meets paper specifications, outlined in the Guide to
Operations manual.
• Make sure the paper in both paper cassettes is loaded properly.
• Make sure the side and rear paper guides in the paper cassettes are positioned properly.
• Check both paper paths for obstructions or contamination.
• Run test prints.
Has the problem been resolved?
No: Continue.
Yes: Turn to TAG 002: Check & Problem Resolution.
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?
No: Go to #8 in this TAG.
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.
Is the voltage 0 Vdc?
No: Continue.
Yes: Replace duplex control board #2, then turn to TAG 002: Check & Problem Resolution.
12 Disconnect J/P314.
• Check for continuity:
P308-1 to J314-1
P308-5 to J314-2
Is there continuity?
No: Repair or replace the wiring or connectors from:
P308-1 to J314-1 or
P308-5 to J314-2;
then turn to TAG 002: Check & Problem Resolution.
Yes: Replace the input solenoid, then turn to TAG 002: Check & Problem Resolution.
15 Disconnect J/P315.
• Check the following for continuity:
P308-2 to P315-1, and
P308-6 to P315-2.
Is there continuity?
No: Repair or replace the wiring or connectors from:
P308-2 to P315-1, or
P308-6 to P315-2,
then turn to TAG 002: Check & Problem Resolution.
Yes: Replace the “C” roller solenoid, then turn to TAG 002: Check & Problem Resolution.
19 Disconnect J/P313.
• Check the following for continuity:
P309-7 to J313-1,
P309-8 to J313-2,
P309-9 to J313-3, and
P309-10 to J313-4.
Is there continuity?
No: Repair or replace the wiring or connectors from P309 to J313 that have no continuity,
then turn to TAG 002: Check & Problem Resolution.
Yes: Continue.
Print Quality
Samples
Section 2 Troubleshooting
Sample 2: Washout
Diagnostic
Tests
Section 3 Troubleshooting
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
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.
Note
Only diagnostics useful for field maintenance are documented
in this manual.
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
1-6 Executive 2 size paper in use
1-7 Executive 3 size paper in use
1-8 Envelopes in use
1-9 Undefined paper size
Note
A 1-9 is displayed when a high-capacity paper feed unit is
installed; refer to “021 - High Capacity Unit Input Test”
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.
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.
5 Press: STOP to exit.
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
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
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
Display Indication
4-0 You forgot to remove the developer unit
090 You forgot to insert the interlock by-pass tool
Display Indication
0 Charge corona off
1 Charge corona on
Display Indication
041 Photoconductor seam sensor short
045 Charge corona short
046 Charge corona open
4-1 You forgot to remove the photoconductor
Display Indication
0 Transfer corona off
1 Transfer corona on
Display Indication
041 Seam sensor (sender) short
050 Transfer corona short
051 Transfer corona open or not installed
4-1 You forgot to remove the photoconductor
Display Indication
041 Seam sensor (sender) short
055 Erase lamp malfunction
4-1 You forgot to remove the photoconductor unit
Display Indication
0 Negative developer bias off
1 Negative developer bias on
Display Indication
030 Developer bias short
041 Seam sensor (sender) short
090 You forgot to insert the interlock by-pass tool
4-1 You forgot to remove the photoconductor unit
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.
Display Indication
069 Duplex is not installed.
090 Cover is open. Close cover
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 the chart below.
4 To check a specific sensor, press READY repeatedly until the code on the display cor-
responds to the sensor you want to check, then manually activate the sensor. Confirm
that the display changes when you activate the sensor.
These codes may indicate specific error conditions:
Display Indication
069 Duplex tray not installed
090 Cover is open. Close cover
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.
These codes may indicate specific error conditions:
Display Indication
069 Duplex is not installed.
090 Cover is open. Close cover.
Display Indication
069 Duplex tray not installed
084 Duplex tray registration sensor not active
085 Duplex tray registration sensor active
090 Cover is open. Close cover.
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 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.
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.
5 Press: STOP to exit.
Display Indication
1-1 A4-size paper in use
1-3 Letter-size paper in use
1-4 Legal-size paper in use
Display Indication
4-1 You forgot to remove the photoconductor unit.
090 Cover is open. Close cover.
4 Go to: 103
5 Press: READY to run the test.
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.
Note
This test does not run on printers with MIGS boards.
Caution
When using the 110 function of the self-diagnostic mode,
any existing data on the specified disk is at risk!
Caution
If you access this function by mistake, do not proceed.
Press STOP immediately to exit the utility.
Display Indication
4-1 You forgot to remove the photoconductor unit
040 Seam sensor (sender) short
Display Indication
0 Floppy drive A:
1 Floppy drive B:
2 Hard drive C:
Wiring Diagrams
and Electrical Data
Section 4 Troubleshooting
Chapter Contents
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.
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
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 119 6-7 simplex/duplex C9
J/P 500 6-15 simplex/duplex A8
J/P 120 6-7 simplex/duplex C9
J/P 121 6-15 simplex/duplex B6 J/P 800 6-15 simplex/duplex E5
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.
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
3 6 9
J/P 1 2 5 8
1 4 7
10 9 8 7 6 5 4 3 2 1
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
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
+
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
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
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
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
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
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/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/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/P40-3 J/P26-1
Erase lamp
J/P8-11 J/P10-1
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
Lower pick-up clutch
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
Upper pick-up clutch
J/P333-1
Fuse (FH2)
Signal J/P73-1 (
Interface ) External
Board J/P73-6
) Attachment
( Connector
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
Duplex
Control
Board #1 J/P309-4 J/P319-1
Paper pass
sensor
J/P306-2
J/P305-2
J/P312-4 J/P322-1
Registration paper
sensor
Ground System
Charge corona
Transfer corona
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
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
Host Printer
Signal DCE DTE Signal
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
Host Printer
Signal DCE DTE Signal
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
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
PC/AT Printer
Signal DCE DTE Signal
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 Printer
Signal DCE DTE Signal
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
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
Signal
Pin Function
Name
14 AF Auto feed
15 Not used
16 SG Signal ground
19 to 30 Signal ground
31 IP INIT
33 to 35 Not used
36 SI Select input
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
JP4 JP3
I KH
JP2
D J G
E
F
C
SW B
1 2 3 4 A
JP1
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
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
1 2 3 4
J29
J28
SW1
• J30
••
••
••
••
•
••
••
••
JP1 •
1 8 JP2
••
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
Removal/Replacement
Procedures
Section 5 Troubleshooting
Removal/Replacement Procedures
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
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
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.
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.
Right Strap
Left Strap
CN36
(C30D only)
CN37
CN40
CN41
CN33
CN91
Ground
Screw Hard Disk Drive
CN74 Connector
CN32
CN31
Loosen Screws
Replacement Note:
When reinstalling, make sure the inside mounting tabs are properly positioned.
Loosen Screws
Note
The service kit is attached inside the right side cover.
Replacement Note:
When reinstalling, make sure the inside mounting tabs are properly positioned.
Loosen Screws
Service Kit
Note
The service kit is attached inside the right side cover.
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
Ground Screw
Retaining Clip
CN22A
Back Detail
Mounting Screws
Upper Duplex
Harness Stays Roller Cover
Vacuum Transport
Ground Screws
CN22
Harness Stay
Spring Detail
Lower Duplex
Roller Cover
Replacement Note:
Replace one support at a time so that the other remains in place to stabilize the top cover.
Spring Screw
Support Detail
Replacement Note:
Replace one hinge at a time so that one always remains in place to support the top cover.
Loosen Screws
Hinge Detail
Replacement Note:
Do not substitute longer screws to hold the rear duplex cover in place.
Upper
Screw
Lower
Screw
Gas Spring
C-Clip
Inside Front
Duplex Cover
Ground Screw
CN42
Counter Removal
To remove the counter:
1 Open the front cover.
2 Remove the screw holding the counter in place.
3 Pull out the counter.
4 Disconnect connector CN82.
CN82
Retaining
Clips
CN33
CN31
CN91
CN36
(C30D only)
CN37
CN40
CN41
Retaining Clip
Retaining Clip
CN33
Fuser Drive
Cover
CN30
CN27
CN96
Gear Stay
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.
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
CN21
CN326
CN18
Power Control
Board Cover
CN4
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
Replacement Note:
When replacing the output tray bracket, make sure it is seated inside the DC power supply.
CN330
Bracket Screws
CN6
CN64 Bracket
Mounting Screw
(under CN64 bracket)
Back Detail
Seam Sensor
and Bracket
CN63
Front Detail
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
Replacement Note:
Replicate the DIP switch settings and jumper locations on any new signal interface board.
Jumpers
DIP Switches
CN74
Replacement Note:
Be sure that the back of the board is mounted properly in the frame slots.
Power Control
Board Cover
CN14
CN13
CN9
CN11
CN12 CN10
Power Control Board Detail
Power Control
Board Cover
Paper Feed Drive Cover
Standoffs
CN101
CN100
Note
Be careful not to damage the cables when disconnecting
Upper Paper
Size Sensor
Lower Paper
Size Sensor
CN46 CN48
CN43
CN45 CN47
Upper Paper Size Sensor Detail Lower Paper Size Sensor Detail
CN62
Back Detail
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
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
Power Control
Board Cover
Mounting Screws Paper Feed Drive Cover
Back Detail
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
13 Remove the lower bracket (four screws; two front and two back).
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
Mounting Screw
Back Detail
Mounting
Screw
Front Detail
Springs
Springs
Mounting
Pegs
Mounting Screw
Front Detail
Mounting Screw
CN58
Back Detail
Idler Arm
Main Drive
Cover
Fuser Drive
Cover
Main Drive
Cover
Fuser Drive
Cover
Drive Belt
Loosen
Screw
Main Drive
Cover
Gear Stay
Gear Stay Cover
Gear Stay
Gear Stay
Cover
Main Drive
Cover
Fuser Drive
Cover
Fuser Drive Detail
Paper Feed
Drive Cover
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
Cassette Release Cover
Front Detail
Paper Feed
Drive Cover
CN66
Paper Feed
Drive Cover
CN67
Paper Feed
Drive Cover
CN68
Paper Feed
Drive Cover
Paper Feed
Drive Cover
CN69
Paper Feed
Drive Cover
Output Option
Mounting Pin
Mounting Screws
Front Detail
Fuser Drive
Cover
Bracket
CN19
Mounting
Pin
CN54
Front Detail
Mounting Screw
Back Detail
Mounting Screws
Front Detail
Exit Guide
Fuser
Drive
Cover
Mounting Screws
Front Detail
Mounting Screws
Back Detail
CN317
Solenoid Screws
Mounting Screws
Back Detail
CN49
CN51
Wires
Wires
Side Cover
AC Power Supply
Duplex Tray
Mount
(C30D only)
Paper Feed
Drive Cover
Wires
Mounting Screw
Back Detail
EP Cover Removal
To remove the EP cover:
1 Open the front, back, and top covers.
2 Remove the fuser.
3 Remove the photoconductor and place it in its protective packaging.
4 Remove the cleaner unit.
5 Remove the operator panel (see page 7-19).
Vacuum Transport
Supports
Support Screw
EP Cover Screws
Front Detail
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
EP Cover Screws
Back Detail
Caution
Do not allow the capacitor contacts to short out against your
body or the printer frame.
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.
Capacitor
CN95
Capacitor Contacts
Paper Feed
Drive Cover
Main Drive
Cover
Gear Stay Cover
Gear Stay
Main Gear Drive Detail Fuser Drive Cover
CN308
CN309 CN306
CN307
Standoffs
Duplex Control Board #1 Detail
Paper Guide
CN311
CN310
CN312
Paper Guide
CN321
Mounting Screws
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.
Mounting Plate
Screw
Shaft Bracket
Shaft
Mounting Bead
Mounting Screws
CN316
Side Detail
Lower Duplex
Roller Cover
Mounting Screws
CN314
CN313
Upper Duplex
Roller Cover
A Roller
Side Detail
Lower Duplex
Roller Cover
C-Clip and
Bearing
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
Upper Duplex
Roller Cover
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
Return Arm
Upper Duplex
Roller Cover
C-Clip Location
Duplex Control
Board Cover
CN319
Mounting Screw
Paper Path Sensor
Underside Detail
Options
Section 6 Troubleshooting
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
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
Acronym Component
NF
Input SOL
IULS
control
board
PES
Door
Printer side
PHS
M2
(IPM)
IPES PCSW
Power supply
DSW Front side
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.
1200-Sheet/2500-Sheet Feeder
Options
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
W507
P529 P500 J518 J519
1400-Sheet Stacker
Table 8-3. 1400-Sheet Stacker Component Acronyms
Acronym Component
OEM (M2)
Rear
ERM (M1)
Power
supply OEPS OLLS OULS
OJFS
Paper tray
Output full actuator
control
board
OJFM (M4) OJRM (M3)
Adapter Plate
Stacker Unit
Output Tray
Power Cord
Jack
Control Connector Cable
1 2 3 4 5 6 7
Plug 9 10 X X X X X
Control Connector Cable
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.
Connector Locations
CN416
Printer side
CN406
Fuse 1
CN401
Fuse 2
Output control
board
Front side
Power supply CN404
CN402
CN417 CN403
Figure 8-7. Connector Locations (left side view, left cover removed)
Printer side
Output side
CN415
CN413
CN419
CN414
CN407
CN408
Elevator up OULS
(Wait signal to printer) OLLS
OELS
P401
Figure 8-10. Connection Diagram for the 1400-Sheet Stacker
P420
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
Hard Disk
Instructions for installing and updating a hard disk are included with the packaged option.
Please refer to the original documentation.
General Printer
Maintenance
Section 7 Troubleshooting
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.
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.
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
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
Introduction
9-5
Every-Call Cleaning Procedure
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
Duplex Only
Table 9-2. Duplex Front View Lubrication
13
1 2
12 1
11
8
1
10
2
9
3
7 4
6
5
Duplex Only
Table 9-4. Duplex Only Rear Lubrication
1
1
1
1
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
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
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
(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
5 C4676A Fuser unit (200/240 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
9 C4007A Toner cartridge (8 per package) u u u
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
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
1 62020046KT 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
8 11
5
4 9
1
2
10
Table 4 Cassette Release Assembly Parts List
Item Part Number Description Qty C30 C30D C40D
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
2 1
Table 5 Upper Cassette Mount Assemblies Parts List
Item Part Number Description Qty C30 C30D C40D
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
AC Power Supply
2
4
6 7
Table 7 AC Power Supply Parts List
Item Part Number Description Qty C30 C30D C40D
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
7 55020489KT Plug, input, voltage set, 220V 1 u u u
7 55020490KT Plug, input, voltage set, 230V 1 u u u
7 55020491KT Plug, input, voltage set, 240V 1 u u u
7 Plug, input, voltage set, 100V 1 u u u
3 8
7
9 11
6
7 5
2
10
4
1
Table 8 Duplex Mechanism, Top View Parts List
Item Part Number Description Qty C30 C30D C40D
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
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
3 81120051KT 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
12 81120012KT 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
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
17 81120021KT 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
2
Table 10 Paper Output Area Parts List
Item Part Number Description Qty C30 C30D C40D
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
7 5
2
3
Table 11 Upper Paper Guide Assembly Parts List
Item Part Number Description Qty C30 C30D C40D
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
8 81020137KT Guide, paper timing (including timing sensor and wire harness W-54) 1 u u u
2
Table 14 Vacuum Transport Unit Parts List
Item Part Number Description Qty C30 C30D C40D
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
1
2
Table 15 Job Exit Assembly Parts List
Item Part Number Description Qty C30 C30D C40D
0 73820027KT Job offset assembly 1 u u
0 Job exit assembly 1 u
1 Jogging motor 1 u u
2 21420290KT Photocell interrupter 2 u u
Back View
11
10
12
5
14
3 8
2 13
Table 16 Back View Parts List
Item Part Number Description Qty C30 C30D C40D
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
3 10
6 12 1
3
1
6
13
13
2 9
13
2 8
8 7 4
5 13 4 7 5 11
Transfer Charger
14
4 8
12
9
15 5
7
6
9
C40D 6 C30/C30D
7
Table 19 Main Drive Assemblies Parts List
Item Part Number Description Qty C30 C30D C40D
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 Gear, main motor (60 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 61020013KT Main drive assembly (60 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
12 Gear, main drive assembly (60 Hz) 1 u u
13 Guide exit 1 u u
14 55020113KT Gear assembly, duplex drive, lower 1 u u
14 81120012KT Gear assembly, duplex drive, lower 1 u
15 81020146KT Main Motor Control PCA 1 u
Back Cover
4
2
6
5
2
3
3 1
Table 20 Back Cover Parts List
Item Part Number Description Qty C30 C30D C40D
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
3
Table 21 C40D Duplex Holding Tray Parts List
Item Part Number Description Qty C30 C30D C40D
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
5 21420290KT Photocell interrupter 1 u u
Item Part Number Description Location in Printer Qty C30 C30D C40D
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
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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
12 9
10 4
15, 16 6
Table 25 1200/2500 Sheet High Capacity Input Unit - Detailed Front View Parts List
Part Number
Item Description Qty
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
12 Insert wire harness 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
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
Item Description Qty
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
9 Jamplate assembly 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)
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
Item Description Qty
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
6 Insert wire harness assembly 1
7 54020058KT 54224064KT Door assembly 1
8 Chain 2
9 21420290KT 54224048KT Photocell interrupter 5
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
13 54020024KT AC noise filter assembly 1
14 53020095KT 54224050KT Tray lift motor 2
15 60020002KT 60020002KT Input control board 1
16 Wire harness, W-514 1
17 Wire harness, W-510 1
18 53020054KT 53020054KT HCI/HCO Sprocket Wheel 4
19 54020183KT 54224018KT HCI Helical Gear 1
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
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
Item Part Number Description Qty
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
11 60020003KT Output control board 1
12 53020124KT Power supply 1
13 Wire Harness W-7 1
14 Exit roller assembly 1
15 Wire Harness W-5 1
16 Wire Harness W-6 1
17 53020054KT HCI/HCO Sprocket Wheel 4
5 7
9
12
1
11
10
8
6
Table 30 1400 Sheet High Capacity Output Unit - Main Rear View Parts List
Item Part Number Description Qty
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
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
Item Part Number Description Qty
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
8 53020031KT Actuator A 1
9 53020029KT Roller (2 front, 2 rear) 4
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
15 53820006KT Jogging subassembly (includes 2 jogging motors and jogging block) 1
16 53020230KT Arm holder bracket 1
17 53020184KT Exit roller motor (includes pulley) 1
Part Number Page Part Number Page Part Number Page Part Number Page
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
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
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
Part Number Table Item Qty Part Number Table Item Qty Part Number Table Item Qty Part Number Table Item Qty
2 15 1 C4676A 1 5 N.A.
81120025KT
14 0 1 C4677A 1 3 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.
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.
Hewlett-Packard Company
System Peripherals Operation
MS 44MC
19111 Pruneridge Avenue
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.
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.
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.
Hewlett-Packard Company
19111 Pruneridge Avenue
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
Reading the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
June 1999 v
Contents
vi June 1999
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
June 1999 ix
Contents
Removal/Replacement Procedures
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Photoconductor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Back Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Left Side Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Right Side Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Vacuum Transport Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Rear Duplex Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Front Duplex Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Operator Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Counter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
RIGS Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
VPCL Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Printhead Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
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
AC Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
DC Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
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 or Lower Paper Size Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Upper Cassette Mount Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
This space left blank intentionally. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Lower Cassette Mount Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
This space left blank intentionally. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Upper Paper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Upper Paper Guide Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
x June 1999
Contents
June 1999 xi
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
Prefeed Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
1200-Sheet Feeder Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
2500-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
Troubleshooting
Section 1 Troubleshooting
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.
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.
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.
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
Rear view
Top view
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
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.
The error log is two pages long. This partial illustration shows the main components of the
log.
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.
1 To start:
Starting • Disconnect all peripheral cables
actions
Yes/No
• Power-on-reset the printer.
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.
Yes: Note the error message and continue.
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 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
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
Make sure the printer is turned off and the power disconnected. Failure to do so may
result in personal injury, equipment damage, or both.
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.
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.
MACHINE CHECK AVPCL board detected a signal from the toner patch sensor
TPS Too Light board indicating that the toner patch on the photoconductor
Toner Control Errors
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 a signal from the toner patch sensor
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.
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.
MACHINE CHECK AVPCL board detected a signal from the high-voltage power
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.
MACHINE CHECK AVPCL board detected a signal from the high-voltage power
Transfer Corona Short supply indicating an abnormally high load on the bias voltage
Error #050 to the transfer corona.
HVPS Errors
MACHINE CHECK AVPCL board detected a signal from the high-voltage power
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 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
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 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 from the AVPCL board during
AVPCL Error
MACHINE CHECK RIGS board detected an error from the AVPCL board during
AVPCL PIA1 Reset Fail initial AVPCL diagnostic.
Error #160
MACHINE CHECK RIGS board detected an error from the AVPCL board during
AVPCL PIA1 R/W at POR initial AVPCL diagnostic.
Error #161
MACHINE CHECK RIGS board detected an error from the AVPCL board during
AVPCL PIA1 Reset Fail initial AVPCL diagnostic.
Error #170
MACHINE CHECK RIGS board detected an error from the AVPCL board during
AVPCL PIA1 R/W at POR initial AVPCL diagnostic.
Error #171
MACHINE CHECK RIGS board detected an error from the AVPCL board during
AVPCL PTM Reset Fail initial AVPCL diagnostic.
Error #180
MACHINE CHECK RIGS board detected an error from the AVPCL board during
AVPCL PTM Read/Write initial AVPCL diagnostic.
Error #181
MACHINE CHECK RIGS board detected an error from the AVPCL board during
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
MACHINE CHECK RIGS board detected an error from the AVPCL board during
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, 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
Error #274
Error #275
Error #276
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
Error #281
MACHINE CHECK RIGS board detected an error from the AVPCL board during
AVPCL No Data VSS High initial AVPCL diagnostic.
Error #301
MACHINE CHECK RIGS board detected an error from the AVPCL board during
AVPCL TS High VSS Low initial AVPCL diagnostic.
Error #302
MACHINE CHECK RIGS board detected an error from the AVPCL board during
TC High but not VSC initial AVPCL diagnostic.
Error #303
MACHINE CHECK RIGS board detected an error from the AVPCL board during
VSC high too long initial AVPCL diagnostic.
Error #304
MACHINE CHECK RIGS board detected an error from the AVPCL board during
AVPCL VSC Invalid initial AVPCL diagnostic.
Error #305
MACHINE CHECK RIGS board detected an error from the AVPCL board during
TS high and data xfr initial AVPCL diagnostic.
Error #306
MACHINE CHECK RIGS board detected an error from the AVPCL board during
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
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PCL Cmd Rejected testing of the RIGS board.
Error #381
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PCL Sent Bad Cmd testing of the RIGS board.
Error #382
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PCL Sent Bad Byte testing of the RIGS board.
Controller Errors
Error #383
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PCL Got TS-No Status testing of the RIGS board.
Error #384
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PCL SIB/Count Bad testing of the RIGS board.
Error #385
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PCL Bad SIB Offset testing of the RIGS board.
Error #386
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PCL Parity Error testing of the RIGS board.
Error #387
MACHINE CHECK RIGS board detected an error during the internal diagnostic
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
MACHINE CHECK RIGS board detected an error in the program RAM during the
RAM Bank 0 Address internal diagnostic testing of the RIGS board.
Error #406
MACHINE CHECK RIGS board detected an error in the program RAM during the
RAM Bank 0 Refresh internal diagnostic testing of the RIGS board.
Error #407
MACHINE CHECK RIGS board detected an error in the program RAM during the
RAM Bank 1 Address internal diagnostic testing of the RIGS board.
Error #408
MACHINE CHECK RIGS board detected an error in the program RAM during the
RAM Bank 1 Refresh internal diagnostic testing of the RIGS board.
Error #409
MACHINE CHECK RIGS board detected an error during the internal diagnostic
Disk Drive Errors
MACHINE CHECK RIGS board detected an error during the internal diagnostic
Floppy Format Error testing of the RIGS board and software.
Error #451
MACHINE CHECK RIGS board detected an error during the internal diagnostic
Fatal Software Trap testing of the RIGS board and software.
Controller Errors
Error #454
MACHINE CHECK RIGS board detected an error during the internal diagnostic
Software Trap testing of the RIGS board and software.
Error #455
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PIT0 Invalid testing of the RIGS board and software.
Error #500
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PIT0 Read/Write Error testing of the RIGS board and software.
Error #501
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PIT0 No Countdown testing of the RIGS board and software.
Error #502
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PIT0 No Timer Halt testing of the RIGS board and software.
Error #503
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PIT0 No Timer Intr testing of the RIGS board and software.
Error #504
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PIT2 Invalid testing of the RIGS board and software.
Error #505
MACHINE CHECK RIGS board detected an error during the internal diagnostic
Controller Errors (cont.)
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PIT2 No Countdown testing of the RIGS board and software.
Error #507
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PIT2 No Timer Halt testing of the RIGS board and software.
Error #508
MACHINE CHECK RIGS board detected an error during the internal diagnostic
PIT2 No Timer Intr testing of the RIGS board and software.
Error #509
MACHINE CHECK RIGS board detected an error during the internal diagnostic
No DMAC Reset testing of the RIGS board and software.
Error #520
MACHINE CHECK RIGS board detected an error during the internal diagnostic
DMAC Read/Write testing of the RIGS board and software.
Error #521
MACHINE CHECK RIGS board detected an error during the internal diagnostic
No DMA Transfer testing of the RIGS board and software.
Error #522
MACHINE CHECK RIGS board detected an error during the internal diagnostic
No DMA Transfer End testing of the RIGS board and software.
Error #523
MACHINE CHECK RIGS board detected an error during the internal diagnostic
No End DMA Interrupt testing of the RIGS board and software.
Error #524
MACHINE CHECK RIGS board detected an error during the internal diagnostic
DMA Software Abort testing of the RIGS board and software.
Error #525
MACHINE CHECK RIGS board detected an error during the internal diagnostic
DMA Software Intr. testing of the RIGS board and software.
Error #526
MACHINE CHECK RIGS board detected an error during the internal diagnostic
DMA Operation Error testing of the RIGS board and software.
Error #527
MACHINE CHECK RIGS board detected an error during the internal diagnostic
DMA Transfer Error testing of the RIGS board and software.
Error #528
MACHINE CHECK RIGS board detected an error during the internal diagnostic
Controller Errors (cont.)
MACHINE CHECK RIGS board detected an error during the internal diagnostic
No DMAC2 Transfer testing of the RIGS board and software.
Error #530
MACHINE CHECK RIGS board detected an error during the internal diagnostic
AVPCL SCC register R/W testing of the RIGS SCC UART.
Error #540
MACHINE CHECK RIGS board detected an error during the internal diagnostic
AVPCL break detected testing of the RIGS SCC UART.
Error #541
MACHINE CHECK RIGS board detected an error during the internal diagnostic
AVPCL SCC xmit not testing of the RIGS SCC UART.
Error #542
MACHINE CHECK RIGS board detected an error during the internal diagnostic
No AVPCL SCC Transfer testing of the RIGS SCC UART.
Error #543
MACHINE CHECK RIGS board detected an error during the internal diagnostic
AVPCL SCC Transfer testing of the RIGS SCC UART.
Error #544
MACHINE CHECK RIGS board detected an error during the internal diagnostic
Host SCC R/W testing of the RIGS SCC UART.
Error #545
MACHINE CHECK RIGS board detected an error during the internal diagnostic
Host xmit not ready testing of the RIGS SCC UART.
Error #546
MACHINE CHECK RIGS board detected an error during the internal diagnostic
No TX/RX interrupt testing of the RIGS SCC UART.
Error #547
MACHINE CHECK RIGS board detected an error during the internal diagnostic
SCC HOST/AVPCL Parity testing of the RIGS SCC UART.
Error #548
MACHINE CHECK RIGS board detected an error during the internal diagnostic
SCC unexpected Intr. testing of the RIGS SCC UART.
Error #549
MACHINE CHECK RIGS board detected an error during the internal diagnostic
SCC Transmission testing of the RIGS board and software.
Error #550
MACHINE CHECK RIGS board detected an error during the internal diagnostic
Controller Errors (cont.)
MACHINE CHECK RIGS board detected an error during the internal diagnostic
SCC-DMAC Interaction testing of the RIGS board and software.
Error #552
MACHINE CHECK RIGS board detected an error during the internal diagnostic
SCC-DMAC Transfer # testing of the RIGS board and software.
Error #553
MACHINE CHECK RIGS board detected an error during the internal diagnostic
SCC-DMAC Transfer testing of the RIGS board and software.
Error #554
MACHINE CHECK RIGS board detected an error during the internal diagnostic
RS232 Send/Rcv testing of the RIGS board and software.
Error #555
MACHINE CHECK RIGS board detected an error during the internal diagnostic
RS232 DTR/DCD testing of the RIGS board and software.
Error #556
MACHINE CHECK RIGS board detected an error during the internal diagnostic
RS232 RTS/CTS testing of the RIGS board and software.
Error #557
MACHINE CHECK RIGS board detected an error during the internal diagnostic
RS422 Send/Rcv testing of the RIGS board and software.
Error #558
MACHINE CHECK RIGS board detected an error during the internal diagnostic
RS422 Send/Rcv Clock testing of the RIGS board and software.
Error #559
MACHINE CHECK RIGS board detected an error during the internal diagnostic
CRTC Read/Write testing of the RIGS board and software.
Error #560
MACHINE CHECK RIGS board detected an error during the internal diagnostic
No Page Begin Intr. testing of the RIGS board and software.
Error #561
Controller Errors (cont.)
MACHINE CHECK RIGS board detected an error during the internal diagnostic
CRTC Address testing of the RIGS board and software.
Error #562
MACHINE CHECK RIGS board detected an error during the internal diagnostic
No VSYNC Generation testing of the RIGS board and software.
Error #563
MACHINE CHECK RIGS board detected an error during the internal diagnostic
No End of Page Intr. testing of the RIGS board and software.
Error #564
MACHINE CHECK RIGS board detected an error during the internal diagnostic
No CRTC Termination testing of the RIGS board and software.
Error #565
MACHINE CHECK RIGS board detected an error during the internal diagnostic
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
MACHINE CHECK RIGS board detected an error when communicating with the
FDC Busy Timeout floppy disk drive.
Disk Drive Errors
Error #571
MACHINE CHECK RIGS board detected an error when communicating with the
Write Protected floppy disk drive.
Error #572
MACHINE CHECK RIGS board detected an error when communicating with the
Floppy Not Ready floppy disk drive.
Error #573
MACHINE CHECK RIGS board detected an error when communicating with the
FDC Restore Error floppy disk drive.
Error #574
MACHINE CHECK RIGS board detected an error when communicating with the
FDC Seek Error floppy disk drive.
Error #575
MACHINE CHECK RIGS board detected an error when communicating with the
FDC Read Error floppy disk drive.
Error #576
MACHINE CHECK RIGS board detected an error when communicating with the
FDC Checksum Error floppy disk drive.
Error #577
MACHINE CHECK RIGS board detected an error when communicating with the
FDC Write Error floppy disk drive.
Error #578
MACHINE CHECK RIGS board detected an error when communicating with the
FDC R-M-W-V Error floppy disk drive.
Error #579
Disk Drive Errors (cont.)
MACHINE CHECK RIGS board detected an error when communicating with the
FDC/PIT0 Interrupt floppy disk drive.
Error #580
MACHINE CHECK RIGS board detected an error when communicating with the
FDC/DMA Interaction floppy disk drive.
Error #581
MACHINE CHECK RIGS board detected an error when communicating with the
FDC/DMAC Transfer floppy disk drive.
Error #582
MACHINE CHECK RIGS board detected an error when communicating with the
FDC/DMAC Transfer # floppy disk drive.
Error #583
MACHINE CHECK RIGS board detected an error when communicating with the
FDC/DMAC Read floppy disk drive.
Error #584
MACHINE CHECK RIGS board detected an error when communicating with the
FDC/DMAC Write floppy disk drive.
Error #585
MACHINE CHECK RIGS board detected an error when communicating with the
FDC/DMAC Operations floppy disk drive.
Error #586
Error #602
Host SCC Error host using serial communications on the ASYNC flex IO card.
Error #701–#708
TAG Cross-
Reference Tables
125 VSS not asserted again though VPCL board expects it 201
126 Command tag asserted during data byte sequence 201
206 VSC command not asserted after command tag asserted 201
207 No data received after VSC asserted 201
305 VSC command not asserted for next data byte No TAG
306 Status tag asserted while data was being sent No TAG
385 VPCL board failure – bad status information block count 201
386 VPCL board failure – bad status information block offset 201
Complete 800
Partial 800
Simplex 807
Duplex 901
Misregistration Go to TAG
Simplex 807
Duplex 901
Troubleshooting
Analysis Guides
(TAGs)
1 To start:
• Disconnect all peripheral cables.
• Power-on-reset the printer.
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.
Yes: Note the error message and continue.
4 Run test prints from the upper cassette by completing the following:
• Power-on-reset the printer.
• Run test prints from the upper cassette.
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.
5 Run test prints from the lower cassette by completing the following:
• Press STOP and allow the cycle to finish.
• Remove the upper cassette.
• Power-on-reset the printer.
• Run test prints from the lower cassette.
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.
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.
• 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:
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.
• Clean the grid with the cleaner brush.
• Remove the grid to expose the charger wire.
• Clean the charger wire with a cotton swab or charger cleaning tool.
• Reinstall the grid.
• Clean any excess toner from the cleaner with a soft cloth.
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:
1 Disconnect the host interface.
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.
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!
7 Reconnect J/P46.
• Disconnect J/P40 and J/P45.
• Check P40-49 to P45-2 for continuity.
Is there continuity?
No: Go to #10 in this TAG.
Yes: Continue.
7 Reconnect J/P48.
• Disconnect J/P43 and J/P40.
• Check P40-50 to P43-10 for continuity.
Is there continuity?
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.
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.
Yes: Continue.
2 Turn the printer off and inspect the following for damage or binding:
• Lower paper guide assembly
• Upper paper guide assembly
• Paper feed drive belt
• Paper feed drive pulley
• Paper feed drive idler assembly
• Main drive gear assembly
• Lower pick-up roller drive assembly
Are all the parts in good working order?
No: Replace the damaged parts, then turn to TAG 002.
Yes: Continue.
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.
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.
• Run test prints.
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.
11 Run diagnostic test “Roller Clutch Tests” on page 5-7 to test the paper timing roller clutch.
• Check P65 for a voltage change from +24 Vdc to 0 Vdc.
Does the voltage change from +24 Vdc to 0 Vdc?
No: Continue.
Yes: Go to #13 in this TAG.
13 Does paper stop or jam either before or during entry into the fuser?
No: Go to #16 in this TAG.
Yes: Continue.
20 ! 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.
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.
5 Reconnect J/P57.
• Reinstall the paper timing guide.
• Power-on-reset the printer.
Is error message PAPER JAM 025 AT/NEAR INPUT still displayed?
No: J/P57 was at fault. Turn to TAG 002.
Yes: Continue.
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.
9 Disconnect J/P96.
• Check P96-1 to J25-7 for continuity.
Is there continuity?
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.
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.
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.
5 Has the seal has been removed from the toner cartridge?
No: Continue.
Yes: Go to #7 in this TAG.
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.
Yes: Go to #12 in this TAG.
9 With the upper paper guide assembly in its fully upright position, check the transfer corona's lower
receptacle for continuity to ground.
Is there continuity?
No: Replace or repair the upper paper guide assembly, then turn to TAG 002.
Yes: Continue.
A lack of continuity may result in fuser damage. If this has occurred, replace the fuser when
replacing connectors and/or wiring.
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?
No: Replace the AC power supply, then turn to TAG 002.
Yes: Continue.
21 Disconnect J/P12.
• Check J10-2 (power control #2 board) for continuity to ground.
Is there continuity?
No: Continue.
Yes: Replace the power control #2 board, then turn to TAG 002.
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.
18 Disconnect J/P61.
• Check P62-1 to P61-1 for continuity to ground.
Is there continuity?
No: Replace the lower paper empty sensor, then turn to TAG 002.
Yes: Repair or replace the connectors or wiring from P62-1 to P61-1, then turn to TAG 002.
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.
Yes: Replace the VPCL board, then turn to TAG 002.
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.
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.
5 Replace the RIGS board, making sure that RIGS EPROM version is correctly matched to the soft-
ware release installed on the printer.
• Power-on-reset the printer.
Has the problem been resolved?
No: Reinstall the original RIGS board and continue.
Yes: Turn to TAG 002.
6 Reinstall the printer’s software. Follow the instructions for loading software in the C40D Installa-
tion Guide.
• Power-on-reset the printer.
Has the problem been resolved?
No: Replace the I/O card, then turn to TAG 002.
Yes: Software was at fault. Turn to TAG 002.
Symptoms: Communication failure between the RIGS board and the VPCL board
Possible Causes: Insufficient delay period between power off and power on
Electrical spikes
ERROR MESSAGE:600-610
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
21 ! Use extreme caution: Check from J/P4-7 to J/P4-8 (neutral) for 100 Vac or more.
Is the voltage at least 100 Vac?
No: Replace the AC power supply.
Yes: Repair or replace the connectors or wiring from:
P4-7 to P6-1 or
P4-8 to P6-2;
then turn to TAG 002.
4 Does the CLOSE COVER message display on with all the covers closed?
No: Go to #24 in this TAG.
Yes: Continue.
6 ! Use extreme caution: Check from J/P4-4 to J/P4-3 for +100 Vac.
Is the voltage +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. If this corrects the prob-
lem, turn to TAG 002.
12 Disconnect J/P13.
• 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.
• Remove the fuse.
• Check the fuse for continuity.
Does the fuse have continuity?
No: Replace the power control #2 board, then turn to TAG 002.
Yes: Continue.
13 Disconnect J/P18.
• Check P13-5 to P18-1 for continuity to ground.
Is there continuity to ground?
No: Replace the toner supply motor, then turn to TAG 002.
Yes: Repair or replace the connectors or wiring from P18-1 to P13-5, then turn to TAG 002.
15 Reconnect J/P9.
• Install a good upper fuse in the AC power supply.
• Disconnect J/P13 and J/P14.
• Turn the printer on for 5 seconds, then off.
• Remove the fuse.
• Check the fuse for continuity.
Does the fuse have continuity?
No: Replace the power control #2 board, then turn to TAG 002.
Yes: Continue.
20 Reconnect J/P9.
• Disconnect J/P100.
• Install a new upper fuse in the AC power supply.
• Run diagnostic test “Photoconductor Seam Sensor Test” on page 5-8 for approximately five
seconds, then turn off the printer.
• Remove the fuse.
• Check the fuse for continuity.
Does the fuse have continuity?
No: Go to #22 in this TAG.
Yes: Continue.
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.
26 Unplug power cord from the printer and the wall outlet.
• Check the power cord for continuity.
Is there continuity?
No: Replace the power cord, then turn to TAG 002.
Yes: Replace the AC power supply, then turn to TAG 002.
27 Disconnect J/P4.
• Check P4-1 for continuity to ground.
Is there continuity?
No: Go to #29 in this TAG.
Yes: Continue.
31 Disconnect J/P6.
• Check P4-7 to P6-1 for continuity to ground.
Is there continuity?
No: Replace the DC power supply, then turn to TAG 002.
Yes: Repair or replace the connectors or wiring from P4-7 to P6-1, then turn to TAG 002.
33 Disconnect J/P84.
• Check P4-5 to P84-1 and P4-6 to P84-2 for continuity.
Is there continuity on both?
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.
Is there continuity?
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.
17 The problem is the wiring between the VPCL and operator panel. Repair or replace W63 and/or
W72, then turn to TAG 002.
4 Inspect the output tray full sensor actuator for damage or binding.
Is it in good working order?
No: Replace the actuator, then turn to TAG 002.
Yes: Continue.
6 Is the paper size sensing problem occurring with the upper cassette?
No: Go to #8 in this TAG.
Yes: Continue.
2 Adjust the paper tension lever or pick pressure as outlined in Section 9, General Printer Mainte-
nance.
Has the problem been resolved?
No: Replace the pick-up roller assembly, then turn to TAG 002.
Yes: Turn to TAG 002.
Communication problems may require trial replacement of numerous parts. After each trial
replacement, run the job that exhibited the failure.
FG 1 1 FG
SG 7 7 SG
DCD 8 <–
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.
Communication problems may require trial replacement of numerous parts. After each trial
replacement, run the job that exhibited failure.
If there is a developed image on the paper other than dark horizontal bands, follow TAG 804.
3 Have the photoconductor, charge corona, developer, and toner cartridge been
replaced recently?
No: Continue.
Yes: Go to #6 in this TAG.
If the problem still exists after completing this TAG, go to TAG 800.
4 Have the photoconductor, charge corona, developer, and toner cartridge been
replaced recently?
No: Continue.
Yes: Go to #7 in this TAG.
3 Have the photoconductor, charge corona, and developer been replaced recently?
No: Continue.
Yes: Go to #6 in this TAG.
3 Have the photoconductor and charge corona have been replaced recently?
No: Continue.
Yes: Go to #5 in this TAG.
3 Has the photoconductor, charge corona, developer, and cleaner been replaced
recently?
No: Continue.
Yes: Go to #6 in this TAG.
3 Have the photoconductor, charge corona, fuser, cleaner, and developer with new
toner cartridge been replaced recently?
No: Continue.
Yes: Go to #8 in this TAG.
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.
Overtoned print and dark print problems are very similar. If this TAG does not resolve the
problem, go to TAG 811.
3 Have the photoconductor, charge corona, cleaner, and developer with toner car-
tridge been replaced recently?
No: Continue.
Yes: Go to #7 in this TAG.
13 Reconnect J/P24.
• Disconnect J/P23.
• Check P41-38 to P23-2 for continuity.
Is there continuity?
No: Repair or replace the connectors or wiring from P41-38 to P23-2, then turn to TAG 002.
Yes: Continue.
14 Disconnect J/P85.
• Remove the developer.
• Check P85-8 to J25-7 for continuity.
Is there continuity?
No: Repair or replace the connectors or wiring from P85-8 to J25-7, then turn to TAG 002.
Yes: Continue.
15 Reconnect J/P85.
• Reinstall the developer.
• Replace the high voltage power supply.
• Run test prints.
Has the problem been resolved?
No: Reinstall the original high voltage power supply and continue.
Yes: Turn to TAG 002.
8 Open the printer’s top cover and install an interlock by-pass tool.
• Turn the printer on.
• 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?
No: Go to #10 in this TAG.
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.
Yes: Go to #12 in this TAG.
12 Inspect the fuser drive assembly and the fuser drive belt for damage or a slipping belt.
Are they in good working order?
No: Replace the parts that are defective, then turn to TAG 002.
Yes: Replace the printhead assembly, then turn to TAG 002.
1 Refer to Section 9, General Printer Maintenance, and perform the every-call cleaning procedure.
• Turn the printer on.
• Run test prints.
Has the problem been resolved?
No: Continue.
Yes: Contamination was at fault. Turn to TAG 002.
3 Have the photoconductor, charge corona, cleaner and developer with new toner
cartridge been replaced recently?
No: Continue.
Yes: Go to TAG 811.
3 Have the photoconductor, charge corona, cleaner and developer with new toner
cartridge been replaced recently?
No: Continue.
Yes: Go to #5 in this TAG.
11 Reconnect J/P24.
• Disconnect J/P23.
• Check P41-33 to P23-7 for continuity.
Is there continuity?
No: Continue.
Yes: Repair or replace the connectors or wiring from P41-33 to P23-7, then turn to TAG 002.
12 Reconnect J/P23.
• Disconnect J/P85 from the high voltage power supply.
• Check P85-8 to J25-7 for continuity.
Is there continuity?
No: Repair or replace the connectors or wiring from P85-8 to J25-7, then turn to TAG 002.
Yes: Continue.
19 Disconnect J/P12.
• Check P40-31 and P12-5 for continuity to ground.
Is there continuity?
No: Replace the power control #2 board, then turn to TAG 002.
Yes: Repair or replace the connectors or wiring from P40-31 to P12-5, then turn to TAG 002.
3 Have the fuser and developer with new toner cartridge been replaced recently?
No: Continue.
Yes: Go to #6 in this TAG.
4 Have the cleaner, developer with new toner cartridge, and photoconductor been
replaced recently?
No: Continue.
Yes: Go to #8 in this TAG.
ERROR MESSAGE:090
2 Open the printer’s top cover and insert the interlock by-pass tool.
• Turn on the printer.
• Check J/P309-3 on duplex control board #1 for +12 Vdc.
Is the voltage +12 Vdc?
No: Replace the duplex control board #1, then turn to TAG 002.
Yes: Continue.
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.
• Confirm that the paper in the cassettes meets paper specifications.
• Make sure the paper in both paper cassettes is loaded properly.
• Make sure the side and rear paper guides in the paper cassettes are positioned properly.
• Check both paper paths for obstructions or contamination.
• Run test prints.
Has the problem been resolved?
No: Continue.
Yes: Turn to TAG 002.
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?
No: Go to #8 in this TAG.
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.
Is the voltage 0 Vdc?
No: Continue.
Yes: Replace duplex control board #2, then turn to TAG 002.
12 Disconnect J/P314.
• Check for continuity:
P308-1 to J314-1, and
P308-5 to J314-2.
Is there continuity?
No: Repair or replace the wiring or connectors from:
P308-1 to J314-1, or
P308-5 to J314-2,
then turn to TAG 002.
Yes: Replace the input solenoid, then turn to TAG 002.
15 Disconnect J/P315.
• Check the following for continuity:
P308-2 to P315-1, and
P308-6 to P315-2.
Is there continuity?
No: Repair or replace the wiring or connectors from:
P308-2 to P315-1, or
P308-6 to P315-2,
then turn to TAG 002.
Yes: Replace the “C” roller solenoid, then turn to TAG 002.
19 Disconnect J/P313.
• Check the following for continuity:
P309-7 to J313-1,
P309-8 to J313-2,
P309-9 to J313-3, and
P309-10 to J313-4.
Is there continuity?
No: Repair or replace the wiring or connectors from P309 to J313 that have no continuity, then
turn to TAG 002.
Yes: Continue.
Print Quality
Samples
Section 3 Print Quality Samples
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
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
Light Vertical
Streaks
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
Excessively
Dark or Black
Print
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
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.
Wrinkled
Paper
Diagnostic
Tests
Section 4 Diagnostic Tests
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.
Display
No Cassette
Size A4
Size B5
Letter Size
Legal Size
Executive
6 Press f to exit.
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.
Sensor Tests
Note: Remove the HCO from the printer before running this test.
4 Press e to advance to the next sensor. The display changes, showing the next sensor
as outlined in the chart below.
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.
for the clicking sound as the next clutch engages. The displays for each of the clutches
are listed in the following chart.
Display
Counter Test
1 Open the front cover.
2 At the base panel, press e to enter the tests.
3 Press h until “Counter Test” is displayed.
4 Press e to run the test.
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.
8 Press f and e alternately several times to verify the toner supply motor starts and
stops. (This stops and restarts the test.)
Display
Note: To view the timing roller while running the test, open the printer top cover and
bypass the cover interlock.
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.
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.
Be aware that the following error conditions may occur:
• Duplex tray is not installed
• Cover is open/Close cover
6 Press f to exit.
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.
Be aware that the following error conditions may occur:
• Duplex tray is not installed
• Cover is open/Close cover
6 Press f to exit.
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.
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.
Display
No Cassette
Size A4
Letter Size
Legal Size
5 Press f to exit.
Display Indication
10 Press f to exit.
If you do not have wrap connectors, jumper the connections as outlined in the follow-
ing charts:
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.
11 Reinstall the interface cable.
Format Disk
1 At the base panel, press e to enter the tests.
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.
Wiring Diagrams
and Electrical Data
Section 5 Wiring Diagrams and Electrical Data
Section 6
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.
Schematic Schematic
Connector Page Connector Page
Location Location
6-5
Connector (J/P) Index
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
J/P 82
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 5
J/P 310
J/P 311
J/P 57
J/P 312
J/P 131-132 1
J/P 321
J/P 305
J/P 322
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 64
J/P 79
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 96
J/P 333 2 1
J/P 800
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
DC Power J/P32-6
Supply
J/P8-14
J/P94-1
J/P7-1 J/P27-1
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/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/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/P40-10 J/P69-1
Lower pick-up clutch
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
Upper pick-up clutch
Ground System
J/P5-8 —Fuser
J/P 255—Photoconductor
Transfer corona
Host Printer
Signal DCE DTE Signal
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
Host Printer
Signal DTE DTE Signal
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
Signal DTE DTE Signal
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
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
PC/AT Printer
Signal DCE DTE Signal
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 Printer
Signal DCE DTE Signal
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
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
17 FG Frame or chassis 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
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
Removal/
Replacement
Procedures
Section 6 Removal/Replacement Procedures
Section 7
Removal/Replacement Procedures
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.
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.
Replacement Note:
When reinstalling, make sure the inside mounting tabs are properly positioned.
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.)
Replacement Note:
Do not substitute longer screws to hold the rear cover in place.
Counter Removal
1 Open the front cover.
2 Remove the screw holding the counter in place.
3 Pull out the counter.
4 Disconnect CN82.
Continued
10 Remove the two front screws holding the printhead assembly in place.
11 Pull the printhead assembly from the front of the printer.
ON
1 2 3 4 5
U1
J29
J28
R3
R7
R6
R5
R4
J30
U6
U3
U5
U2
U4
C2 C1
Replacement Note:
For floppy drives, set the jumper on the drive circuit board to 0.
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.
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
Replacement Note:
When replacing the output tray bracket, make sure it is seated inside the DC power supply.
Continued
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.
Replacement Note:
Be sure that the back of the board is mounted properly in the frame slots.
9 Disconnect CN62.
•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
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 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.
8 From the back, remove the two screws holding the lower cassette mount in place.
Continued
19 Rotate the lower cassette mount upwards and out 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.
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.
Note: Use caution so as not to damage the paper full or exit sensors.
9 Remove the wiring harness for CN42, CN49, and CN51 from the exit cover.
10 Disconnect CN317.
11 Remove the four screws holding the exit cover in place (two front and two back).
12 Lift the exit cover from the printer.
13 Remove the solenoid from the exit cover (two screws)
EP Cover Removal
1 Open the front, back, and top covers.
2 Remove the fuser.
3 Remove the photoconductor and place in its protective packaging.
4 Remove the cleaner.
Replacement Note:
The higher of the two drive shaft support arms should be facing the left 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.
Replacement Notes:
The placement of the mounting bead is critical. Set it on precisely. Replace parts in this
order:
Replacement Note:
Install a new cable tie to secure the wires from CN315 to the mounting plate.
Options
Section 7 Options
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.
1200-Sheet/2500-Sheet Feeder
Acronym Component
NF AC Noise Filter
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
Slope Tray
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
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.
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.
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
W507
P529 P500 J518 J519
1400-Sheet Stacker
Abb Component
OEM (M2)
ERM (M1) Top View
Power
supply
Printer side
Output tray
OJRS
OJFS
Paper tray full
Output actuator
control
board
OJFM (M4) OJRM (M3)
OELS
Output Tray
Power Cord
Output Tray Guide
Jack
Control Cable Connector
Rear side
OEM
(M2) ERM (M1)
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
Control Connector Cable
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
CN416
Printer side
CN406
Fuse 1
CN401
Fuse 2
Output control board
CN402
CN417 CN403
Printer side
Output side
CN415
CN413
Front side
CN419
Printer side
CN414
CN407
CN408
P401
Options
P420
S-5 S-6
OJFS OJRS P404 P402 P403
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
Elevator up OULS
(Wait signal to printer) OLLS
OELS
General Printer
Maintenance
Section 8 General Printer Maintenance
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.
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.
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.
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
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.
• 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.
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.
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
R White grease
For part numbers, refer to the “Additional Parts List” in the Illustrated Parts Catalog.
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
removal 7-26 removal 7-88
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
TAG 3-45 removal 7-78
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
removal 7-99 removal 7-65
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
removal 7-62 removal 7-55
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
diagnostic test 5-11 removal 7-56
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
removal 7-73 removal 7-28
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
TAG 3-43 removal 7-45
toner empty sensor upper pick-up roller
location 1-10 removal 7-59
toner motor upper static brush
diagnostic test 5-8 removal 7-67
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
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
(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
5 C4676A Fuser unit (200/240 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
9 C4007A Toner cartridge (8 per package) u u u
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
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
1 62020046KT 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
8 11
5
4 9
1
2
10
Table 4 Cassette Release Assembly Parts List
Item Part Number Description Qty C30 C30D C40D
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
2 1
Table 5 Upper Cassette Mount Assemblies Parts List
Item Part Number Description Qty C30 C30D C40D
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
AC Power Supply
2
4
6 7
Table 7 AC Power Supply Parts List
Item Part Number Description Qty C30 C30D C40D
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
7 55020489KT Plug, input, voltage set, 220V 1 u u u
7 55020490KT Plug, input, voltage set, 230V 1 u u u
7 55020491KT Plug, input, voltage set, 240V 1 u u u
7 Plug, input, voltage set, 100V 1 u u u
3 8
7
9 11
6
7 5
2
10
4
1
Table 8 Duplex Mechanism, Top View Parts List
Item Part Number Description Qty C30 C30D C40D
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
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
3 81120051KT 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
12 81120012KT 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
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
17 81120021KT 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
2
Table 10 Paper Output Area Parts List
Item Part Number Description Qty C30 C30D C40D
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
7 5
2
3
Table 11 Upper Paper Guide Assembly Parts List
Item Part Number Description Qty C30 C30D C40D
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
8 81020137KT Guide, paper timing (including timing sensor and wire harness W-54) 1 u u u
2
Table 14 Vacuum Transport Unit Parts List
Item Part Number Description Qty C30 C30D C40D
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
1
2
Table 15 Job Exit Assembly Parts List
Item Part Number Description Qty C30 C30D C40D
0 73820027KT Job offset assembly 1 u u
0 Job exit assembly 1 u
1 Jogging motor 1 u u
2 21420290KT Photocell interrupter 2 u u
Back View
11
10
12
5
14
3 8
2 13
Table 16 Back View Parts List
Item Part Number Description Qty C30 C30D C40D
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
3 10
6 12 1
3
1
6
13
13
2 9
13
2 8
8 7 4
5 13 4 7 5 11
Transfer Charger
14
4 8
12
9
15 5
7
6
9
C40D 6 C30/C30D
7
Table 19 Main Drive Assemblies Parts List
Item Part Number Description Qty C30 C30D C40D
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 Gear, main motor (60 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 61020013KT Main drive assembly (60 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
12 Gear, main drive assembly (60 Hz) 1 u u
13 Guide exit 1 u u
14 55020113KT Gear assembly, duplex drive, lower 1 u u
14 81120012KT Gear assembly, duplex drive, lower 1 u
15 81020146KT Main Motor Control PCA 1 u
Back Cover
4
2
6
5
2
3
3 1
Table 20 Back Cover Parts List
Item Part Number Description Qty C30 C30D C40D
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
3
Table 21 C40D Duplex Holding Tray Parts List
Item Part Number Description Qty C30 C30D C40D
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
5 21420290KT Photocell interrupter 1 u u
Item Part Number Description Location in Printer Qty C30 C30D C40D
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
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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
12 9
10 4
15, 16 6
Table 25 1200/2500 Sheet High Capacity Input Unit - Detailed Front View Parts List
Part Number
Item Description Qty
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
12 Insert wire harness 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
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
Item Description Qty
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
9 Jamplate assembly 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)
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
Item Description Qty
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
6 Insert wire harness assembly 1
7 54020058KT 54224064KT Door assembly 1
8 Chain 2
9 21420290KT 54224048KT Photocell interrupter 5
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
13 54020024KT AC noise filter assembly 1
14 53020095KT 54224050KT Tray lift motor 2
15 60020002KT 60020002KT Input control board 1
16 Wire harness, W-514 1
17 Wire harness, W-510 1
18 53020054KT 53020054KT HCI/HCO Sprocket Wheel 4
19 54020183KT 54224018KT HCI Helical Gear 1
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
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
Item Part Number Description Qty
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
11 60020003KT Output control board 1
12 53020124KT Power supply 1
13 Wire Harness W-7 1
14 Exit roller assembly 1
15 Wire Harness W-5 1
16 Wire Harness W-6 1
17 53020054KT HCI/HCO Sprocket Wheel 4
5 7
9
12
1
11
10
8
6
Table 30 1400 Sheet High Capacity Output Unit - Main Rear View Parts List
Item Part Number Description Qty
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
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
Item Part Number Description Qty
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
8 53020031KT Actuator A 1
9 53020029KT Roller (2 front, 2 rear) 4
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
15 53820006KT Jogging subassembly (includes 2 jogging motors and jogging block) 1
16 53020230KT Arm holder bracket 1
17 53020184KT Exit roller motor (includes pulley) 1
Part Number Page Part Number Page Part Number Page Part Number Page
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
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
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
Part Number Table Item Qty Part Number Table Item Qty Part Number Table Item Qty Part Number Table Item Qty
2 15 1 C4676A 1 5 N.A.
81120025KT
14 0 1 C4677A 1 3 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.