Toshiba e-STUDIO 30P, e-STUDIO 40P SERVICE HANDBOOK

TOSHIBATOSHIBA

SERVICE MANUALSERVICE MANUAL

PAGE PRINTER

ee--STUDIO 30P/40PSTUDIO 30P/40P

Edition: May 2001
The following paragraph does not apply to any country where such provisions are

inconsistent with local law: Toshiba America Business Solutions, INC. PROVIDES THIS

PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not allow disclaimer of express or implied warranties in certain transactions; therefore, this
statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are
periodically made to the information herein; these changes will be incorporated in later
editions. Improvements or changes in the products or the programs described may be
made at any time.

Comments may be addressed to Toshiba America Business Solutions,

2 Musick, Irvine CA. 92618 Atten: National Service Training

Toshiba America Business Solutions may use or distribute any of the
information you supply in any way it believes appropriate without incurring any obligation
to you. You can download additional copies of publications related to this product by
visiting the Toshiba S.I.S. /Tech-To -Go Website.

PostScript is a registered trademark of Adobe Systems Incorporated.
PCL is a registered trademark of the Hewlett-Packard Company.
Other trademarks are the property of their respective owners.

© Copyright Toshiba America Business Solutions 2001.
All rights reserved.

UNITED STA TES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use,
duplication or disclosure by the Government is subject to restrictions as set forth in
subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at
DFARS 252.227-7013 and in applicable FAR provisions: Toshiba America Business Solutions
Irvine, CA. 92618

P/N: 12G3959

Table of Content

Laser Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Tools Required for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Service Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

User Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

User Attendance Messages. . . . . . . . . . . . . . . . . . . . . . . 2-29

Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . 2-41

Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Charge Roll Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-47

Cover Open Switch/Cab le Serv ic e Chec k . . . . . . . . . . . . 2-49

Dead Machine Service Check . . . . . . . . . . . . . . . . . . . . . 2-50

Duplex Option Service Check . . . . . . . . . . . . . . . . . . . . . 2-53

Envelope Feeder Option Servic e Check . . . . . . . . . . . . . 2-56

Fan Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Cold Fuser Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-65

Hot Fuser Service Check. . . . . . . . . . . . . . . . . . . . . . . . . 2-67

Fuser Solenoid Service Check. . . . . . . . . . . . . . . . . . . . . 2-68

Input Sensor Service Check . . . . . . . . . . . . . . . . . . . . . . 2-68

Input Tray(s) Option Service Check. . . . . . . . . . . . . . . . . 2-69

High-Capacity Feeder Input Tray Service Check. . . . . . . 2-72

Main Drive Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-85

Operator Panel Service Check . . . . . . . . . . . . . . . . . . . . 2-86

Options Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

Output Bin Sensor Standard Tray Service Check . . . . . . 2-90

Output Expander Service Check . . . . . . . . . . . . . . . . . . . 2-91

High-Capacity Output Stacker Service Check . . . . . . . . . 2-96

5-Bin Mailbox Service Check. . . . . . . . . . . . . . . . . . . . . . 2-99

Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . 2-105

Parallel Port Service Check. . . . . . . . . . . . . . . . . . . . . . 2-107

Printhead Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-108

iii

Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . .2-109

Smart Cartridge Contact Assembly Service Check. . . . .2-121

Serial Port Service Check. . . . . . . . . . . . . . . . . . . . . . . .2-122

Toner Sensor Service Check . . . . . . . . . . . . . . . . . . . . .2-122

Transfer Roll Service Check . . . . . . . . . . . . . . . . . . . . . .2-123

StapleSmart Finisher Service Check . . . . . . . . . . . . . . .2-125

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Diagnostic/Configurati on Men u . . . . . . . . . . . . . . . . . . . . . .3-1

Configuration Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Exiting the Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . .3-6

Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Quick Disk Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Disk Test/Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Flash Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Disabling Download Emulations . . . . . . . . . . . . . . . . . . . . .3-8

Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Duplex Quick Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Duplex Sensor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Duplex Motor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Duplex Feed 1 Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Duplex Feed 2 Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Viewing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Clearing the Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

LCD Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

SDRAM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

ROM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

Parallel Wrap Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Serial Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Input Tray Feed Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Input Tray Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Output Bin - Feed to all Bins Test . . . . . . . . . . . . . . . . . . . . . .3-20

Output Bin Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Output Bin Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Finisher Tests, StapleSmart Finisher Option . . . . . . . . . . . . . .3-24

Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

StapleSmart Finisher Tests. . . . . . . . . . . . . . . . . . . . . . . .3-26

StapleSmart Finisher Sensor Test . . . . . . . . . . . . . . . . . .3-27

iv Service Manual

5-Bin Mailbox Diverter Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Setting the Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Viewing the Permanent Page Count . . . . . . . . . . . . . . . . 3-30

Maintenance Page Count . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Setting Configuration ID. . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Restore EP Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Print Quality Test Pages . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Printing Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . 3-36

Auto Compensator Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Autoconnect System, Paper Tray Options, Envelope Feeder and

Output Expander Operations . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Fuser Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Hot Roll Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Paper Feed Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Paper Jams - Base Printer. . . . . . . . . . . . . . . . . . . . . . . . 3-40

Paper Jams - Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Duplex Motor Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fuser Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Printhead Assembly Adjustment . . . . . . . . . . . . . . . . . . . . 4-4

Paper Alignment Assembly Adjustment. . . . . . . . . . . . . . . 4-5

Screw Identification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Center Pan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Card Assembly (NAND Flash) . . . . . . . . . . . . . . . . . . . . . 4-18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Developer Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . 4-20

Duplex Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Duplex Front Cover Assembly. . . . . . . . . . . . . . . . . . . . . 4-21

Duplex Front Cover Door. . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Duplex Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

EMC Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

v

Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

Fuser Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Fuser Detack Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Fuser Detack Housing Assembly . . . . . . . . . . . . . . . . . . .4-32

Fuser Transfer Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33

Fuser Envelope Conditi one r Solen o id. . . . . . . . . . . . . . . .4-34

Fuser Narrow Media Sensor/Flag Assembly. . . . . . . . . . .4-35

Fuser Exit Sensor Flag Assembly. . . . . . . . . . . . . . . . . . .4-35

Fuser Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35

Fuser Lower Exit Guide Assembly . . . . . . . . . . . . . . . . . .4-36

High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . .4-37

Integrated Tray Compensator Assembly. . . . . . . . . . . . . .4-37

Integrated Tray Compensator Pick Roll Assembly . . . . . .4-38

Interconnect Board Assem bly . . . . . . . . . . . . . . . . . . . . . .4-40

Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . .4-42

Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43

Main Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45

Multipurpose Tray/Lower Deflector Assembly. . . . . . . . . .4-46

Operator Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . .4-48

Operator Panel Cable/Cover Open Switch Assembly. . . .4-49

Optional 250/500 Paper Tray Assembly . . . . . . . . . . . . . .4-50

Paper Alignment Assembly. . . . . . . . . . . . . . . . . . . . . . . .4-51

Paper Deflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-53

Paper Input Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54

Paper Size Sensing Board . . . . . . . . . . . . . . . . . . . . . . . .4-54

Pick Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54

Printhead (4069-520/52n). . . . . . . . . . . . . . . . . . . . . . . . .4-55

Printhead (4069-722/72n). . . . . . . . . . . . . . . . . . . . . . . . .4-56

Redrive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-57

Smart Cartridge Contact Assembly. . . . . . . . . . . . . . . . . .4-58

Toner Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59

Transfer Roll Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . .4-60

Upper Paper Deflector Assembly . . . . . . . . . . . . . . . . . . .4-60

Upper Front Cover Hinge Assembly . . . . . . . . . . . . . . . . .4-61

Upper Front Cover Interlock Switch Assembly . . . . . . . . .4-62

Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . .5-1

High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . .5-3

Interconnect Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Envelope Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Duplex Option Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

vi Service Manual

Autoconnect - Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Output Expander Control Board. . . . . . . . . . . . . . . . . . . . 5-12

High-Capacity Output Stacker Board. . . . . . . . . . . . . . . . 5-14

System Board Connector Locations . . . . . . . . . . . . . . . . 5-16

System Board Connector Locations . . . . . . . . . . . . . . . . 5-20

StapleSmart Finisher Option - Staple Card Assembly. . . 5-27

Cables - Base Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Fuser Cable, DC Internal . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Autoconnect Cable, (Fuser to LVPS). . . . . . . . . . . . . . . . 5-31

Deflector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Fuser Cable, AC EP Autoconnect to Fuser Top Cover . . 5-32

Integrated Tray Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

HSYNC Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

Mirror Motor Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Main Drive Motor Cable. . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Laser Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Front Harness Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Fuser Cable, DC EP Autoconnect to System Board . . . . 5-34

Autoconnect Cable - System Board to

Top/Interconnect Board . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Autoconnect Cable - System Board to

Front/Bottom/Interconnect Board. . . . . . . . . . . . . . . . . . . 5-35

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Lubrication Specifi cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to Use this Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Assembly 1: Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 3: Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 4: Paper Feed (Auto compensator). . . . . . . . . 7-12

Assembly 5: Paper Feed - Multipurpose Unit . . . . . . . . . 7-14

Assembly 6: Paper Feed - Alignment . . . . . . . . . . . . . . . 7-16

Assembly 7: Paper Feed - Output . . . . . . . . . . . . . . . . . . 7-18

Assembly 8: Integrated Paper Tray - 500 Sheet . . . . . . . 7-20

Assembly 9: Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Assembly 10: Developer Drive. . . . . . . . . . . . . . . . . . . . . 7-24

Assembly 11: Hot Roll Fuser . . . . . . . . . . . . . . . . . . . . . . 7-26

Assembly 12: Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Assembly 13: Charging . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Assembly 14: Electronics . . . . . . . . . . . . . . . . . . . . . . . . 7-34

vii

Assembly 14: Electronics (continued) . . . . . . . . . . . . . . . .7-36

Assembly 14: Electronics (continued) . . . . . . . . . . . . . . . .7-48

Assembly 15: 250-Sheet Tray. . . . . . . . . . . . . . . . . . . . . .7-50

Assembly 16: 500-Sheet Tray. . . . . . . . . . . . . . . . . . . . . .7-56

Assembly 17: Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-60

Assembly 18: Output Expander . . . . . . . . . . . . . . . . . . . .7-66

Assembly 19: Envelope Feeder . . . . . . . . . . . . . . . . . . . .7-70

Assembly 20: High-Capacity Feeder. . . . . . . . . . . . . . . . .7-74

Assembly 21: Kiosk - Vertical Paper Adapter . . . . . . . . . .7-88

Assembly 22: Kiosk - Horizontal Paper Adapter. . . . . . . .7-90

Assembly 23: High-Capacity Output Stacker . . . . . . . . . .7-92

Assembly 24: 5-Bin Mailbox . . . . . . . . . . . . . . . . . . . . . . .7-98

Assembly 25: StapleSmart Finisher . . . . . . . . . . . . . . . .7-102

Assembly 26: Options . . . . . . . . . . . . . . . . . . . . . . . . . .7-112

Assembly 27: Miscellaneous . . . . . . . . . . . . . . . . . . . . .7-114

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

viii Service Manual

Laser Notices

The following laser notice labels may be affixed to this printer as
shown:

Laser Advisory Label

Laser Notices ix

Class 1 Laser Statement Label

x Service Manual

Laser Notice

The printer is certified in the U.S. to conform to the requirements of
DHHS 21 CFR Subchapter J for Class I (1) laser products, and
elsewhere is certified as a Class I laser product conforming to the
requirements of IEC 60825.

Class I laser products are not considered to be hazardous. The
printer contains internally a Class IIIb (3b) laser that is nominally a 5
milliwatt gallium arsenide laser operating in the wavelength region of
770-795 nanometers. The laser system and printer are designed so
there is never any human access to laser radiation above a Class I
level during normal operation, user maintenance, or prescribed
service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die
Anforderungen der Bestimmung DHHS (Department of Health and
Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1).
In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I,
der die Anforderungen der IEC (International Electrotechnical
Commission) 60825 gemäß amtlicher Bestätigung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des
Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es
sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen
der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der
Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung
durch den Benutzer oder bei ordnungsgemäßer Wartung durch den
Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde,
Menschen keinesfalls erreicht.

Laser Notices xi

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux
provisions DHHS 21 CFR alinéa J concernant les produits laser de
Classe I (1). Pour les autres pays : cette imprimante répond aux
normes IEC 60825 relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comme des produits
non dangereux. Cette imprimante est équipée d’un laser de Classe
IIIb (3b) (arséniure de gallium d’une puissance nominale de 5
milliwatts) émettant sur des longueurs d’onde comprises entre 770
et 795 nanomètres. L’imprimante et son système laser sont conçus
pour impossible, dans des conditions normales d’utilisation,
d’entretien par l’utilisateur ou de révision, l’exposition à des
rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme
ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di
classe 1 ed è certificata negli altri Paesi come prodotto laser di
classe 1 conforme ai requisiti della norma CEI 60825.

I prodotti laser di classe non sono considerati pericolosi. La
stampante contiene al suo interno un laser di classe IIIb (3b)
all’arseniuro di gallio della potenza di 5mW che opera sulla
lunghezza d’onda compresa tra 770 e 795 nanometri. Il sistema
laser e la stampante sono stati progettati in modo tale che le
persone a contatto con la stampante, durante il normale
funzionamento, le operazioni di servizio o quelle di assistenza
tecnica, non ricevano radiazioni laser superiori al livello della classe

1.

Laser Notices xii

Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los
requisitos para los productos láser de Clase I (1) establecidos en el
subcapítulo J de la norma CFR 21 del DHHS (Departamento de
Sanidad y Servicios) y, en los demás países, reúne todas las
condiciones expuestas en la norma IEC 60825 para productos láser
de Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La
impresora contiene en su interior un lás er de Clase IIIb (3b) de
arseniuro de galio de funcionamiento nominal a 5 milivatios en una
longitud de onda de 770 a 795 nanómetros. El sistema láser y la
impresora están diseñados de forma que ninguna persona pueda
verse afectada por ningún tipo de radiac ión láser superior al nivel de
la Clase I durante su uso normal, el mantenimiento realizado por el
usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os
requisitos da regulamen t ação DHHS 21 CFR Subcapítulo J para a
Classe I (1) de produtos laser. Em outros locais, está certificada
como um produto laser da Classe I, em conformidade com os
requisitos da norma IEC 60825.

Os produtos laser da Classe I não são considerados perigosos.
Internamente, a impressora contém um produto laser da Classe IIIb
(3b), designado laser de arseneto de potássio, de 5 milli watts
,operando numa faixa de comprimento de onda entre 770 e 795
nanómetros. O sistema e a impressora laser foram concebidos de
forma a nunca existir qualquer possiblidade de acesso humano a
radiação laser superior a um nível de Classe I durante a operação
normal, a manutenção feita pelo utilizador ou condições de
assistência prescritas.

Laser Notices xiii

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een
laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen
vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in
IEC 60825.

Laserprodukten van klasse I worden niet als ongevaarlijk
aangemerkt. De printer is voorzien van een laser van klasse IIIb
(3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met
een golflengte van 770-795 nanometer. Het lasergedeelte en de
printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of
reparatie conform de voorschriften, nooit blootstelling mogelijk is
aan laserstraling boven een niveau zoals voorgeschreven is voor
klasse 1.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i
overenstemmelse med kravene i IEC 60825.

Klasse I-laserprodukter betragtes ikke som farlige. Printeren
indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5
milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet
770-795 nanometer. Lasersystemet og printeren er udformet
således, at mennesker aldrig udsættes for en laserstråling over
Klasse I-niveau ved normal drift, brugervedligeholdelse eller
obligatoriske servi c ebet ing el se r.

Laser Notices xiv

Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS
21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I
laserlaitteiden IEC 60825 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle.
Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin
galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei
altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen
normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden
huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina
näkymättömälle lasersäteilylle. Älä katso säteeseen.

VARNING! Osynlig laserstrålning när denna del är öppnad och
spärren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21
CFR, underparagraf J för laserprodukter av Klass I (1). I andra
länder uppfyller skr ivaren kraven för laserprodukter av Klass I enligt
kraven i IEC 60825.

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en
inbyggd laser av Klass IIIb (3b) som består av en laserenhet av
gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770­795 nanometer. Lasersystemet och skrivaren är utformade så att det
aldrig finns risk för att någon person utsätts för laserstrålning över
Klass I-nivå vid normal användning, underhåll som utförs av
användaren eller annan föreskriven serviceåtgärd.

Laser Notices xv

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR,
underkapittel J, for klasse I (1) laserprodukter, og er i andre land
godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC

60825.
Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren

inneholder internt en klasse IIIb (3b)-laser, som består av en
gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet
770-795 nanometer. Lasersystemet og skriveren er utformet slik at
personer aldri utsettes for laserstråling ut over klasse I-nivå under
vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne
serviceoperasjoner.

Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora
compleix els requisits de DHHS 21 CFR, apartat J, pels productes
làser de classe I (1), i segons ha estat certificat en altres llocs, és un
producte làser de classe I que compleix els requisits d’IEC 60825.

Els productes làser de classe I no es consideren perillosos. Aquesta
impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li,
nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona
de 770-795 nanòmet re s. El siste ma làser i la impressora han sigut
concebuts de manera que mai hi hagi exposició a la radiació làser
per sobre d’un nivell de classe I durant una operació normal, durant
les tasques de manteniment d’usuari ni durant els serveis que
satisfacin les condicions prescrites.

Laser Notices xvi

Japanese Laser Notice

Chinese Laser Notice

Laser Notices xvii

Korean Laser Notice

xviii Service Manual

Safety Information

• This product is designed, tested and approved to meet strict

global safety standards with the use of specific Toshiba
components. The safety features of some parts may not always
be obvious. Toshiba is not responsible for the use of other
replacement parts.

• The maintenance information for this product has been

prepared for use by a professional service person and is not
intended to be used by others.

• There may be an increased risk of electric shock and personal

injury during disassembly and servicing of this product.
Professional service personnel should understand this and take
necessar y pr ec autions.

Consignes de Sécurité

• Ce produit a été conçu, testé et approuvé pour respecter les

normes strictes de sécurité globale lors de l'utilisation de
composants Toshiba spécifiques. Les caractéristiques de
sécurité de certains éléments ne sont pas toujours évidentes.
Toshiba ne peut être tenu responsable de l'utilisation d'autres
pièces de rechange.

• Les consignes d'entretien et de réparation de ce produit

s'adressent uniquement à un personnel de maintenance
qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter

certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.

Safety Information xix

Norme di sicurezza

• Il prodotto è stato progettato, testato e approvato in conformità a

severi standard di sicurezza e per l’utilizzo con componenti
Toshiba specifici. Le caratteristiche di sicurezza di alcune parti
non sempre sono di immediata comprensione. Toshiba non è
responsabile per l’utilizzo di parti di ricambio di altri produttori.

• Le informazioni riguardanti la manutenzione di questo prodotto

sono indirizzate soltanto al personale di assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto, il

rischio di subire scosse elettriche e danni alla persona è più
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.

Sicherheitshinweise

• Dieses Produkt und die zugehörigen Komponenten wurden

entworfen und getestet, um beim Einsatz die weltweit gültigen
Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten
Funktionen der Bauteile und Optionen sind nicht immer
offensichtlich. Sofern Teile eingesetzt werden, die nicht von
Toshiba sind, wird von Toshiba keinerlei Verantwortung oder
Haftung für dieses Produkt übernommen.

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des

Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständige
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.

xx S ervice Manual

Pautas de Seguridad

• Este producto se ha diseñado, verificado y aprobado para

cumplir los más estrictos estándares de seguridad global
usando los componentes específicos de Toshiba. Puede que
las características de seguridad de algunas piezas no sean
siempre evidentes. Toshiba no se hace responsable del uso de
otras piezas de recambio.

• La información sobre el mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de
mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser consciente de este
peligro y tomar las precauciones necesarias.

Informações de Segurança

• Este produto foi concebido, testado e aprovado para satisfazer

os padrões globais de segurança na utilização de componentes
específicos da Toshiba. As funções de segurança de alguns
dos componentes podem não ser sempre óbvias. A Toshiba
não é responsável pela utiliza ção de outros componentes de
substituição.

• As informações de segurança relativas a este produto

destinam-se a profissio nai s destes serviços e não devem ser
utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

desmontagem e manutenção deste produto. Os profissionais
destes serviços devem estar avisados deste facto e tomar os
cuidados necessários.

Safety Information xxi

Informació de Seguretat

• Aquest producte està dissenyat, comprovat i aprovat per tal

d'acomplir les estrictes normes de seguretat globals amb la
utililització de components específics de Toshiba. Les
característiques de seguretat d'algunes peces pot ser que no
sempre siguin òbvies. Toshiba no es responsabilitza de l'us
d'altres peces de recanvi.

• La informació pel manteniment d’aquest producte està

orientada exclusivament a professionals i no està destinada a
ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar

durant el procés de desmuntatge i de serv e i d’aquest producte.
El personal professional ha d’estar-ne assabentat i prendre les
mesures convenients.

xxii Service Manual

Safety Information xxiii

Preface

This book is designed for service personnel. It is divided into the
following chapters:

1. General Information contains a general description of the
printer and the maintenance approach used to repair it. Special
tools and test equipment are listed in this chapter, as well as
general environmental and safety instructions.

2. Diagnostic Information contains an error indicator table,
symptom tables, and service checks used to isolate failing field
replaceable units (FRUs).

3. Diagnostic Aids contains tests and checks used to locate or
repeat symptoms of printer problems.

4. Repair Information provides instructions for making printer
adjustments and removing and installing FRUs.

5. Connector Locations uses illustrations to identify the
connector locations and test points on the printer.

6. Preventive Maintenance contains the lubrication specifications
and recommendations to prevent problems.

7. Parts Catalog contains illustrations and part numbers for
individual FRUs.

xxiv Service Manual

1- General Information

The following options are available. Some options may require a
special order. Contact your point of purchase for available
options.

Memory options of 32MB, 64MB and 128MB
SDRAM Card Assembly
Flash memory options of 2MB, 4MB, 8MB and 16MB
Card Assembly
Integrated network options
Token-Ring
Ethernet
Tri-Port Adapter
USB/Parallel Port
250 and 500-sheet paper trays
250 Sheet Special Media Tray Assembly
500 Sheet Special Media Tray
2000 Sheet High Capacity Feeder
Envelope Feeder
Duplex Option - 250 Sheet
Duplex Option - 500 Sheet
Output Expander
5-Bin Mailbox
High-Capacity Output Stacker
StapleSmart™ Finisher Option

1-1 Service Manual

Maintenance Approach

The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the service error codes,
user status messages, user error messages, service checks, and
diagnostic aids to determine the printer problem and repair the
failure. After you complete the repair, perform tests as needed to
verify the repair.

Tools Required for Service

Flat-blade screwdriver
#1 Phillips screwdriver
#2 Phillips screwdriver
T10 Torx screwdriver

7.0 mm nut driver

5.5 mm wrench
Needlenose pliers
Diagonal pliers
Spring hook
Feeler gauges
Analog or digital multimeter
Parallel wrap plug 1319128
Serial wrap plug 1329048
Twinax/serial debug cable 1381963
Coax/serial debug cable 1381964

General Information 1-2

Acronyms

CSU Customer Setup
DIMM Dual In-Line Memory Module
DRAM Dynamic Random Access Memory
EDO Enhanced Data Out
EP Electrophotographic Process
EPROM Erasable, Programmable Read-Only

Memory
ESD Electrostatic Discharge
FRU Field Replaceable Unit
GB Gigabyte
HVPS High Voltage Power Supply
LASER Light Amplification by Stimulated Emission

of Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
MROM Masked Read Only Memory
NAND
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
PC Photoconductor
POR Power-On Reset
POST Power-On Self Test
RIP Raster Imaging Processor
ROM Read Only Memory
SDRAM Sync hr on ous Dual Rand om Ac ce ss

Memory
SRAM Static Random Access Memory
UPR Used Parts Return
V ac Volts alternating current
V dc Volts direct current

1-3 Service Manual

2. Diagnostic Information

Start

CAUTION: Remove the power cord from the printer or wall outlet

before you connect or disconnect any cable or electronic board or
assembly for personal safety and to prevent damage to the printer.
Use the handholds on the side of the printer. Make sure your fingers
are not under the printer when you lift or set the printer down.

Use the service error code, user status message, user error
message, symptom table, service checks, and diagnostic aids in this
chapter to determine the corrective action necessary to repair a
malfunctioning printer.

Service error codes are indicated by a three-digit error code. If a
service error code is displayed, go to the “Service Error Codes” on

page 2-2.

User status messages provide the user with information on the
current status of the printer. Ready is displayed on the first line of the
display unless Power Saver is invoked, and then Power Saver is
displayed. If a user status message is displayed, go to the “User

Status Screens” on page 2-24.

User error messages are indicated by a two or three-digit error code
that provides the user with information that explains a problem with a
print cartridge, paper jam, option, port, and so on. If a user error
message is displayed, go to the “User Atte nda nce Mess ages” on

page 2-29.

If your machine completes the “Power-On Self Test (POST)” on

page 2-41 without an error, and you have a symptom, go to the
“Symptom Tables” on page 2-42. Locate your symptom and take

the appropriate action.
If a service error code appears while you are working on the

machine, go to the “Service Error Codes” on page 2-2 and take
the indicated action for that error.

Diagnostic Information 2-1

Service Error Codes

Service Error Codes are generally non-recoverable except in an
intermittent cond iti on when you can POR the prin ter to temporar i ly
recover from the error condition.

Error Code Action

900 RIP Software Contact the next support level or call Lexmark.
901 Engine Flash Indicates that the flash which the engine code is

programmed into is bad. Replace the system board.

902 General
Engine Software

903 Paperport
Link Driver Error

904 Interface
Violation by the
controller
software

905 Interface
Violation by
Paperport Device

906 Controller­Engine Link
Driver Error

910 DC Pick
Motor DC Pick
Motor Stall

911 DC Pick
Motor Excessive
PWM

912 DC Pick
Motor below
speed

These errors indicate an unrecoverable engine software
error. Replace the system board.

Check for correct location of the jumpers on the
interconnect board for the model/type printer you are
servicing. Incorrect jumper settings can cause a 902
service error. If jumpers are set correctly, replace the
system board.

Error Codes 910,911,912,913 and 914 are indications
that a Tray 1 paper feed pr oblem has been detected. Go
to the “Input Tray(s) Option Service Check” on

page 2-69.

913 DC Pick
Motor over speed

2-2 Service Manual

Error Code A ction

914 DC Pick
Motor: No
encoder feedback

917 Transfer Roll Indicates a problem in the transfer roll area. Go to the

920 Fuser Error Indicates that the fuser is below temperature when

921 Fuser Error Indicates that the fuser is below standby temperature

922 Fuser Error Fuser failed to reach standby temperature. Go to the

923 Fuser Error Fuser is too hot during printing or when printer is idle . Go

924 Fuser Error An open circuit has been detected in the Fuser

Check the integr ated pa per tray (tray 1) for correct pape r
loading. Reload the paper and POR the printer. If the
error continues , go to the “Input T ray(s) Option Service

Check” on page 2-69.

“Transfer Roll Service Check” on page 2-123.

printing. Go to the “Cold Fuser Service Check” on

page 2-65. Use of the “Base Printer (Fu ser) Sub Err or
Codes” on page 2-17 may help diagnose fuser failure.

when the printer is idle. Go to the “Cold Fuser Service

Check” on page 2-65. Use of the “Base Printer
(Fuser) Sub Error Codes” on page 2-17 may help

diagnose fuser failure.

“Cold Fuser Service Check” o n page 2-65. Use of the
“Base Printer (Fuser) Sub Error Codes” on page 2-17

may help diagnose fuser failure.

to the “Hot Fuser Service Check” on page 2-67. Use
of the “Base Printer (Fuser) Sub Error Codes” on

page 2-17 may help diagnose fuser failure.

Thermistor Circuit. Go to the “Hot Fuser Service

Check” on page 2-67. Use of the “Base Printer
(Fuser) Sub Error Codes” on page 2-17 may help

diagnose fuser failure.

925 Fuser Error 1. Indicates the wrong fuser lamp is installed. Check the

927 Fan Stalled Indicates a printer fan stalled. Go to the “Fan Service

fuser lamp for the correct type of lamp that should be
installed.

2. Check the line voltage to ensure it is not above the
maximum rating for the printer.

3. This error ma y also indic ate the fuser reached standb y
temperature too quickly.

4. The hot roll may not be correct for this fuser. Ensure
that the correct hot roll is installed.

Check” on page 2-63.

Diagnostic Information 2-3

Error Code Action

929 T one r Sensor The toner sensor is n ot operat ing properly, the dev eloper

930 Printhead
Error

932-935
Printhead Error

932 Printhead
Error

933 Printhead
Error

934 Printhead
Error

935 Printhead
Error

936-937
Transport Motor

936 - Main Drive
Motor initial lock
failure

drive assembly is not operating properly or the print
cartridge is defective . Go to the “Toner Sensor Service

Check” on page 2-122.

The wrong printhead is installed. Replace with the
correct printhead.

These errors represe nt a p rob lem with the p rinthead. G o
to the “Printhead Service Check” on page 2-108.

Indicates a problem with the mai n drive motor. Go to the

“Main Drive Service Check” on page 2-85.

937 - Main Drive
Motor lost lock

939 RIP-Engine
Communications
Lost

2-4 Service Manual

The RIP and engine cannot communicate with one
another. The system board or Interconnect board is
defective. Check for correct installation. If no problem is
found, replace the FRUs in the following order:

System Board
Interconnect Board
Note: If a problem still exists, the RIP software can

cause a 939 error code. Contact your next level for
software support.

Error Code A ction

940 Service LV
Power Supply

947 PQET Error Indicates that the PQET RAM test was incomplete or a

948 PEL Clock
Error

949 Delay Line
Calibration
Failure

953 - 954
NVRAM Failure

The low voltage power supply zero crossover test failed.

• Check the LVPS for correct installation. Ensure that
the connector on the LVPS assembly is firmly seated
with the connector on the int erconn ect card co nnecto r.

• This error can be caused by a noisy AC input power
source.

• Check to make sure the correct LVPS has been
installed.

• If all the above are correct, replace the LVPS
assembly.

PQET RAM test busy failure occurred. Replace the
system board.

Indicates the PEL clock check failed. Replace the
system board.

Indicates a delay line calibration failure. Replace the
system board.

System board failures.
953 NVRAM Chip Failure
954 NVRAM CRC Failure
Replace system board.

955 Code CRC
<loc>

956 - 959 System
Board

Code ROM and NAND failed CRC check
*<loc> = For a ROM CRC failure, the location (loc) will be

a failing block or (Bn).
*<loc> = For a NAND CRC failure, the location (loc) will

be a failing page or (Pn).
Replace System Board.
Error codes 956 thru 959 are system board failures.
*956 = Processor Failure

*957 = ASIC Failure
*958 = SRAM Failure

For any of these failures, replace the system board.

Diagnostic Information 2-5

Error Code Action

958 NAND
Failure

960 - 963 RAM
Memory Error

964 Emulation
Error

975 - 979
Network Card X

Before proceeding when a 958 NAND failure is
displayed, perform a Power On Reset (power the printer
Off then On) to see if the ECC (Error Correction Code)
can reflash NAND.

Error codes 960 thru 963 indicate the following specific
RAM error:

*960 - RAM soldered on the system board is failing.
Replace the system board.
*961 - RAM in slot 1 is failing.
*962 - RAM in slot 2 is failing
*963 - RAM in slot 3 is failing.

For errors 961 thru 963, if a vailable, switch me mory from
the failing slot with one from a non-failing slot to see if it
fixes the problem. If it does fix the problem, replace the
system board. If this fixes the problem, replace the
defective RAM.

Download Emulation CRC failure has occurred.

The following errors indicate a failure with the network
card in the specified slot. X=any card installed in slots
1,2 or 3. 975 - Unrecognizable Network Card x. Replace
Network Card x.
976 - Unrecoverable software error in Network Card x.
977 - Controller software detects that a Network Card is
installed in slot x but cannot establish communications
with it.
978 - Bad checksum while programming Network Card
x. Replace Network Card x.
979 - Flash parts failed while programming Network
Card x.
If the printer is a network model, replace the system
board.

2-6 Service Manual

Error Code A ction

980 - 984 Service
<device> Comm.

These error codes indicate the specified device
<device> has detected a paper port failure.

Specified device <device> can be one of the following:
*System Boar d

*Duplex
*Tray x (x = 1,2,3,4 or 5)
*Envelope Feeder
*Output Bin x (x = 1,2,3 to 6)
**Will be displayed for single bin output options.
*Output Bins x to y (x to y = 1 to 5, 2 to 6, 6 to 10)
**Will be displayed for multiple bin output options.

980 = The engine is experiencing unreliable

communications to the specified device.

981 = Engine protocol v iolation has bee n detected b y the

specified device.

982 = Communications error detected by the specified

device.
983 = Invalid command received by the specified device.
984 = Invalid comm and parameter received by the

specified device.

Diagnostic Information 2-7

Error Code Action

990 Service
<device>

991 Service
<device> Card

This error will be displayed when an equipment check
condition has occurred in the specified device
(<device>), but the device is unable to identify the exact
component failure.

Specified device <device> can be one of the following:
*System Board

* Duplex
*Tray x (x = 1,2,3,4 or 5)
*Envelope Feeder
*Output Bin x (x = 1,2,3 to 6)
**Will be displayed for single bin output options.
*Output Bins x to y (x to y = 1 to 5, 2 to 6, 6 to 10)
**Will be displayed for multiple bin output options.
*StapleSmart Finisher Option

This message will be displayed when the specified
device has detected an equipment check in its system
card.

Specified device <device> can be one of the following:
* Duplex

*Tray x (x = 1,2,3,4 or 5)
*Envelope Feeder
*Output Bin x (x = 1,2,3 to 6)
**Will be displayed for single bin output options.
*Output Bins x to y (x to y = 1 to 5, 2 to 6, 6 to 10)
**Will be displayed for multiple bin output options.
*StapleSmart Finisher Option

Sub Error Codes for 9XX and 2XX Error Codes

The sub error codes are helpful troubleshooting a paper path
problem, especially paper jams in the base printer, en velope feeder
and duplex unit.

When a 9XX or 2XX error displays:

1. Press and hold Return and press Select to enter for sub error
codes.

2. The first screen of information is displayed. Write down the
information.

2-8 Service Manual

3. Continue pressing Return and Select until each screen of
information is obtained .

4. When the last screen displays, the original message displays.

The following is an example of how the printer shows a duplex unit
sub error code.

DU
DU

Byte 1
XX
XX
Byte 5

Byte 2
XX
XX
Byte 6

Byte 3
XX
XX
Byte 7

Byte 4
XX
XX
Byte 8

Diagnostic Information 2-9

Base Printer Sub Error Codes

Each status byte has a different level of troubleshooting value for
each area of the printer. The following table displays up to 8 status
bytes of data. Some or all of these bytes may be used to help
diagnose a printer problem. These status bytes are designed to help
isolate paper jams and paper feed problems in the base printer

Legend for Tray Source: x=10 (MPT), x-11 (Tray 1), x=12, (Tray 2),
x=13 (Tray 3), x-14 (T r ay 4), x=15 (Tray 5), x=31 (Env Feeder), X=40
(Manual)

Legend for Stacker Destination: x=91 (Stacker 1), x=92 (Stacker 2),
x-93 (Stacker 3)

Legend for media size: x=1 (letter), x=2 (legal), x=3 (B5), x=4 (A4),
x=5 (Executive), x=6 (A5), x=7 (Custom), x=9 (73/4 Env), A-#9 Env,
B-#10 Env, C=8.661” Env, D=C5 Env, E=B5 Env, F=Legal Env.

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value.

Explanation

84 xx 00 x1 x2This code indicates that the input sensor in the printer is still

84 xx 01 x1 Video never started on the page.

actuated from the firs t sheet and th e second she et is ready t o
arrive at the sensor.
(x1=media size, x2=media source)
*Check the printer input se nsor and flag for co rrect operatio n.

The flag should operate freely.
*Check for any signs of debris in the area of the input sensor.
*Check the are a of t he tran sf er p late and in put to the fuser f or

anything that might cause the paper to remain over the
input senso r.

(x-1=media size)
*The video signal never started within 2 inches after

actuating the input sensor. Check input sensor and flag.

2-10 Service Manual

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value.

Explanation

84 xx 02 x1 This error is the most common type of paper jam. Possible

84 xx 04 The input sensor was covered during POST by a piece of

84 xx 05 There was a media at the input sensor too early. There was

84 00 06 A paper jam has been declar ed by a smart devi ce. Immed iate

84 00 07 A paper jam has been declared by a smart device. Homing

84 xx 0B x1
x2 x3

causes are (x1=media size):
*Multi sheet feeding.
*A tray size sensing problem.
*The media feeding from the paper source is slipping or

media is slipping in input to the printer.

media stil l in the machine when it was turned on.
*Clear the media from the printer.
*Run the base sensor test (input sensor) from the diagnostic

tests menu to test the input sensor and flag for correct
operation.

not enough time between printhead start and the printhead
mirror motor to lock. Possible causes for this error are:
*Paper might be pre-staged in the paper source tray.
*Paper is picking too fast.
*A defective input sensor.

stop homing not allowed.

was allowed before the stop.
The option tray pass thru sensor was never actuated by a

piece of media. (x-1=media size) (x-2=media source) (x­3=paper source where paper jam was detected)
*Run the sensor test for the option tray that is displaying the

error code and check the pass thru sensor for that tray for
correct operation.

*Check for paper picking from the selected paper input

source.

*If the error is being det ect ed from a lower paper source, see

if paper is feeding corre ct ly from a paper sour ce above the
detected source.

Diagnostic Information 2-11

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value.

Explanation

84 xx 0f x1
x2 x3

84 00 10 The main motor ID failed to identify either motor after two

84 xx 17 There is an envelope or envelopes in the envelope feeder

84 xx 18 There is media over the Tray 2 pass thru se nsor du ring w arm-

84 xx 19 There is media over the Tray 3 pass thru se nsor du ring w arm-

The option Tray pass thru sensor was never deactivated.
(x-1=media size) (x-2=media source) (x-3=media source
where paper jam was detect ed)
*Check the pass thru sensor and flag for correct operation.
*Check to see if paper has cleared the pass thru area of the

option where the paper jam occurred.

tries. Possible causes for this error are:
*The main drive motor has stalled.
*An incorrect main drive motor/gearbox assembly has been

installed.

during warm-up. An en v e lope may have partially fed from the
envelo pe feeder.
*Remove any envelopes from the feeder and check the

envelope feeder for correct operation.

up. Check for media over the sensor. If no media is present,
check the pass thru sensor, flag, and cables.
*Try running the Input Tray Tests for Tray 2 and see if Tray 2

is feeding paper correctly and all the sensors are working

correctly.
*Check to make sure the paper size setting is correct for the

size paper in the tray.

up. Check for media over the sensor. If no media is present,
check the pass thru sensor, flag, and cables.
*Try running the Input Tray Tests for Tray 3 and see if Tray 3

is feeding paper correctly and all the sensors are working

correctly.
*Check to make sure the paper size setting is correct for the

size paper in the tray.

2-12 Service Manual

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value.

Explanation

84 xx 1A There is media over the Tra y 4 pa ss thru sen sor during warm-

84 xx 1B There is media over the Tra y 5 pa ss thru sen sor during warm-

84 xx 1C There is media o v er t he Tray 6 pa ss thru sensor during w arm-

84 xx 1D The en ve lope f eeder pass thru se nsor ne ver dea ctiva ted. The

up. Check for media over the sensor. If no media is present,
check the pass thru sensor, flag, and cables.
*Try running the Input Tray Tests for Tray 4 and see if Tray 4

is feeding paper correctly and all the sensors are working
correctly.

*Check to make sure the paper size setting is correct for the

size paper in the tray.

up. Check for media over the sensor. If no media is present,
check the pass thru sensor, flag, and cables.
*Try running the Input Tray Tests for Tray 5 and see if Tray 5

is feeding paper correctly and all the sensors are working
correctly.

*Check to make sure the paper size setting is correct for the

size paper in the tray.

up. Check for media over the sensor. If no media is present,
check the pass thru sensor, flag, and cables.
*Try running the Input Tray Tests for Tray 6 and see if Tray 6

is feeding paper correctly and all the sensors are working
correctly.

*Check to make sure the paper size setting is correct for the

size paper in the tray.

display o f thi s cod e i ndi ca tes th at a n envelope never crossed
over the sensor flag and passed beyond the sensor, or the
flag and sensor are not operating properly. Go to the

“Envelope Feeder Option Service Check” on page 2-56.

84 xx 1E x1 x2The envelo pe feeder pass thru sensor was never activated.

(x1=Media Size, x2=Media Source)
Ensure that envelopes are feeding over the sensor. If an
envelope feeds over the sensor but the sensor does not
activate, check the sensor and flag for correct operation. If
the sensor and flag are operating correctly, go to the

“Envelope Feeder Option Service Check” on page 2-56.

Diagnostic Information 2-13

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value.

Explanation

84 xx 20 x1 x2The imaged page is not the expected page.

84 xx 21 x1 x2The smart tray x did not pick a sheet of paper.

84 xx 22 x1 x2This code indicates that the media activated the input sensor

84 xx 23 x1 x2The transfer servo never started.

84 xx 25 This code indicates that the media has activated the input

(x1=Media Size, x2=Media Source)
Check the pass thru sensor to make sure it is operating

properly. If no problem is found, it may be necessary to try a
new pass thru sensor.

(x1=Media Size, x2=Media Source)
Check tray x auto compensator and tray parts for correct

operation. If no problem is found, go to the “Input Tray (s)

Option Service Check” on page 2-69.

before the printer EP was ready.
(x1=Leading Edge of Media State , x2=Trailing Edge of Media
State)

(x1=Media Size, x2=Leading Edge of Media State)

sensor before the printhead has locked. Enough time has
elapsed since printhead start to expect a lock.
One of the following may be failing:
*Printhead Assembly
*System Board
*Printhead Cables

84 xx 26 This code indicates that media has activated the input

sensor; howev er, the printhead fell out of loc k con dition or no t
enough time elapsed since the printhead start to expect a
stable lock. The media may have also reached the input
sensor early.

2-14 Service Manual

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value.

Explanation

89 00 01 The exit sensor in the fuser is activated by a piece of media

89 xx 03 The fuser exit sensor did not detect the trailing edge of the

89 xx 04 x1 The fuser exit sensor never actuated from the sheet going

89 xx 07 The narrow med ia sensor in t he fuser wa s co ve red b y a she et

indicating there is a piece of media in the machine during
POST.
*Check for media in the exit of the fuser assembly or redrive

assembly. Feed a sheet of paper, and if the same error
occurs after clearing the fuser or the same error occurs
when no media is present, check the exit sensor assembly,
internal fuser assembly cabling, DC fuser cable to the
system board, and the cable connection to J14 on the
system board.

TIP: Turn the printer off, enter the diagnostic tests menu, and
select the base sensor test. Select output sensor and check
the sensor for correct operation.

media going through the fuser assembly.
*This failure can be caused by a broken fuser exit sensor

flag.

*This may also be caused by erratic operation of exit sensor

flag or exit sensor or a defective piece of media.

through the fuser before the next page begins feeding.
(x-1=Media Size)

of paper when not expected or a piece of media is in the
machine during POST.
*This error can occur when a 202 paper jam has occurred.
*Remove any piece of media that is over the narrow media

sensor.

*Try to feed a piece of paper through the printer (could run

the print test from the diagnostic test menu). If the media
stops over the narrow media sensor again, check the flag
and sensor for correct operation.

89 xx 0B x1 The fuser exit sensor may be bouncing.

*This error can be caused by a failing exit sensor or system

board.

Diagnostic Information 2-15

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value.

Explanation

89 xx 0D The fuser exit sensor bounced. Check the exit sensor for

8D 00 00 The fuser exit sensor was never activated by the leading

8E xx 02 x1 x2This error can be caused by the input sensor not being

8E xx 06 x1 The second pick failed from a paper source when paper was

8E xx 07 x1 The second pick failed from a paper source when paper was

correct operation. Check the fuser DC cable to J14 on the
system board. Also, the system board may be failing.

edge of the media fed through the printer.
*This error can be displayed after a 201 paper jam.
*This can be caused by a defective fuser exit sensor

assembly.
Enter the diagnostic tests menu, select base sensor tests,

select output sensor test and check the fuser exit sensor for
correct operation. If the test fails, check the internal fuser
cabling, DC autoconne ct on the fus er frame, fuser DC
autoconnect to the system board cable, and the cable
connection to J14 on the system board.

activated b y a page t hat was kno wn to ha v e been pic k ed by a
source other than the duplex option.
*Ensure the correct source has been sel ec ted and the media

is feeding from that source.

in the source and the only sheet in the paper path.

in the source. Other sheets may have started to feed, but
none were in the paper path.

8E xx 08 The paper in the output bin wa s flu sh ed. The pa per ahead of

it, in the paper path, never made it past the output bin sensor
or into the tray.

8E xx 09 x1 The second pick from the MPT, Tray 1 or feeder failed when

paper was in the source. Other sheets may be in the paper
path.
(x1=Media Source)

8E xx 0A x1 The second pick from the MPT, Tray 1 or feeder failed when

paper was in the source. Other sheets may have started to
pick, but none were in the paper path.
x1=Media Source)

2-16 Service Manual

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value.

Explanation

8E x1 0B The DC auto compensator failed or stalled when trying to

8E xx 11 It took too long for the DC auto compensator motor to come

8E xx 13 x1 x2Late feeding fro m a paper source interf ered with the ne xt pic k

feed a sheet of media.

up to speed.

retry. (x-1=Media Size)(x-2=Media Source)

Base Printer (Fuser) Sub Error Codes

The following Sub Error Codes could be a help in diagnosing
Fuser Assembly failures:

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value

920 Service - Fuser Error (Under temperature while printing)
EN 08 xx yy

- 1
EN- zz - - 2

Explanation

xx=Actual Fuser Temperature
yy=The temperature that the fuser wants to reach.
When zz=00 The Hot Roll took too long to heat up.

zz=01 The Hot Roll fell too far below the desired

temperature while printing.

zz=02 The Hot Roll was too cool while the system was

doing some checking.

zz=03 The Hot Roll was too cool when heating to the

desired temperature.

921 Service - Fuser Error (Fuser under temperature while at standby)

Diagnostic Information 2-17

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value

Explanation

EN 41 xx yy

-- 1
EN -- zz -- -­2

922 Service - Fuser Error (Fuser failed to reach standby temperature)
EN 42 xx yy

-- 1
EN z1 z2 -- -

- 2

923 Service - Fuser Error (Fuser over temperature)

xx=Actual Fuser Temperature
yy=The temperature that the fuser wants to reach.
zz=00 The fuser temper at ure did not ch ange e nou gh from the

fuser lamp temperature at turn on.

01 The fuser temperature ros e more than desire d from the

fuser temperature at turn on.

xx=Actual Fuser Temperature
yy=The temperature that the fuser wants to reach.
zz=00 The fuser temper at ure did not ch ange e nou gh from the

fuser lamp temperature at turn on.

01 The fuser temperature ros e more than desire d from the

fuser temperature at turn on.

z2=00 The Hot Roll did not reach standb y temp er ature i n time

during standby.

01 The Hot Roll took too long to reach the begin ning lamp

detection temperature.

02 The Hot Roll reached ‘final lamp detection

temperature’ but took longer than expected.

03 The Hot Roll timed out trying to reach the ‘final lamp

detection temperature.’

04 After Hot Roll lamp detection, did not reach steady

state control in time.

05 The Hot Roll did not reach operating temperature in

time.

EN 12 xx yy

-- 1
EN -- -- -- -­2

924 Service - Fuser Error (Open Thermistor Failure)
EN 18 xx -- -

- 1
EN -- 00 -- -­2

This sub error code is di sp layed anytime that the Hot Rol l h as
reached a higher than desired temperature.
xx=Actual Fuser Temperature
yy=The temperature that the fuser wants to reach.

This code is usually generated when an open circuit check is
made of the thermistor circuit in the fuser.
xx=Actual Fuser Temperature

2-18 Service Manual

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value

925 Service - Fuser Error (Wrong Fuser Lamp Installed)
Note: The Sub Error Codes below are only for an incorrect lamp being
installed.

Explanation

EN 07 xx yy
zz 1
EN -- -- -- 2

This error code is generated anytime an incorrect lamp is
detected.
xx=00 Lamp detection performed and found an error.

01 It took long to d o l am p dete cti on an d NV RAM detected
a previous wrong lamp detected.
yy=Actual Temperature
zz=The temperature that the fuser was trying to reach.

Envelope Feeder Sub Error Codes

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value

84 xx 17 There is an envelope in the feeder during POST.

Explanation

Diagnostic Information 2-19

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value

Explanation

84 xx 1D x1 x2The envelope feeder pass thru sensor activated but never

84 xx 1E x1 x2An envelope never activated the envelope feeder pass thru

deactivated. (x1=Media Size)(x2=Media Source)
This error can be caused by an envelope over the pass thru
sensor. Remove the envelope and try to feed an envelope. If
the envelope stops over the pass thru sensor, try the
following:
*Select the diagnostic test menu, select input tray sensor

tests, select envelope feeder sensor test.

*Check the envelope pass thru sensor to ensure it is

operating correctly. If the sensor test fails, go to the

“Envelope Feeder Option Service Check” on page 2-56.

If the test passes, look for anything that might cause the
envelope to stop over the sensor.

sensor or the sensor never sensed the presence of an
envelope. (x1=Media Size)(x2=Media Source)
*Check to make sure the envelope feeds to the pass thru

sensor.

*Check to see if the envelope actuates the pass thru sensor

flag.

2-20 Service Manual

Stacker Sub Error Codes

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value

84 xx 14 There is media in stacker 1 during POST. Usually associated

84 xx 15 There is media in stacker 2 during POST. If present, remove

Explanation

with a 271 P aper Jam Erro r message . Ma y be disp la yed whe n
a finisher option is in stalled in lo west or first po sition abo ve the
printer.

If present, remove the media from stacker 1. If the error
continues to be displayed or there is no media present in the
stacker, check the pass thru sensor and flag of stacker 1 or , if
installed, check the option below stacker 1.

the media from stacker 2. If the error continues to be
displayed, or there is no media pres ent in the stacker, check
the pass thru sensor and fl ag of sta c k er 2, or c hec k the option
below stacker 2.

84 xx 16 There is media in stacker 3 during POST. If present, remove

95 xx 00 x1 x2Stacker sensor x never became uncovered.

95 xx 01 x1 x2Stacker sensor x never was covered or actuated.

98 xx 02 x1
x2 x3

the media from stacker 3. If the error continues to be
displayed, or there is no media pres ent in the stacker, check
the pass thru sensor and fl ag of sta c k er 3, or c hec k the option
below stacker 3.

(x1=sensor’s stacker, x2=stacker destination)
Check stac k er x to see i f a piece of pa per i s o v er the s ensor. If
not, check to see if the sensor and flag are working correctly.

(x1=sensor’s stacker, x2=stacker destination)
Check stacker x to see if the sensor and flag are operating
correctly.

Stacker x did not indicate that a page had been received in
the output.
(x1=stacker destination)

Diagnostic Information 2-21

Duplex Unit Sub Error Codes

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value

89 xx 00 The duplex unit did not send back a device control.
89 xx 02 The duplex unit did not send an Option Ready response.

Explanation

89 xx 06 The duplex option did not send back a page in output

8E xx 00 x1 A sheet of paper bei ng f e d throu gh th e dupl e x e r n e v er made it

8E xx 03 The error code is displayed whenever the printer never sent a

8E xx 04 The printer n ever sa w a sig na l fro m t he dup lexer on a page to

response.

to the printer input sensor. The sheet was slow or delayed
being fed from the duplex option.
(x1=media source)

Select Output device control signal to the duplex option. This
can happen when a sheet of paper is leaving the duplex
option and the duplex option never sent a Select Input device
signal to the printer.

be picked from the duplex option when the duplex option was
waiting on a page to pass over the printer input sensor.

StapleSmart Finisher Option Sub Error Codes

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value

Explanation

84 xx 07 The Sub Error code indi cates that f inisher o ption has detected

a paper jam and hom in g was allowe d b efore the stop. Usually
associated with 281 Paper Jams in the finisher.

2-22 Service Manual

First 6
Bytes Sub
Error Code
Data - Note:
xx can be
any value

Explanation

8D xx 01 A timeout associated with the stapling operation timed out

98 xx 03 x1
x2 x3

while waiting f o r the last pa ge of a jo b to be saf e in the stapl er
accumulator.

Never saw operation complete on a staple job.
(x1=destination)

Diagnostic Information 2-23

User Status Screens

User Status Screens Status Action

Ready

Ready
<Fax Status>

Ready/Hex The printer is ready and

Power Saver

Power Saver
<Fax Status>

The printer is ready to
receive and process
data

or

The printer will display
the FAX status.

HEX Trace is active,
which is known as HEX
Trace Ready.

When in the po wer sav er
mode, the printer will
display this screen
instead of the Ready
screen. When a job is
received, the power
saver screen remains
displayed until the
printer exits the power
saver mode and warms
up the printer.

The printer has been
configured to receive or
send FAX. This screen
is displayed.

Press Menu> or
<Menu to take the
printer out of Ready
and enter all the
Menus except the
TESTS MENU (Busy
State).

Press Menu> or
Menu< to take the
printer out of Ready
and enter the TESTS
MENU (Busy State).
Press Select for the
value s. Press Menu>
until Reset Printer is
on the second line of
the display. Press
Select to Reset the
printer.

Press Menu > or
Menu< to take the
printer offline and
access the Ready
Menu Group.

or

Press GO to take the
printer out of power
saver and initiate a
printer warm up cycle.

or

Press Stop to take the
printer offline. The Not
Ready message is
displayed, no more
data is processed.
The Go button must
be pressed to return
the printer to the
previous state.

2-24 Service Manual

User Status Screens Status Action

Res Reduced

Res Reduced
<Fax Status>

Waiting <Interpreter> These screens will be

The printer is processing
data or printing pages
and the resolution of a
page belonging to the
current job has been
reduced from 600 to 300
DPI to prevent a
Memory Full Error.

Will be displayed
whenever the printer has
been configured to
receive or send FAX.

displayed until the
current job is terminated
or until additiona l data is
received on the active
link.
(PCL1, PS, PJL, PPDS,
SIC or HEX may be
displayed for interpreter
if the printer is not
configured for FAX).

Press Stop to take the
printer offline. Not
Ready is displayed,
no more data will be
processed and the
current job in the
paper path is
processed. Press Go
to return the printer to
the previous state.

or

Press Menu> or
Menu< to access the
Busy/Waiting Menu
group. The following
functions may be
available via the Busy/
Waiting Menu group:
*Cancel Job
*Reset Printer
*Reset Active Bin
*Cancel FAX

Press Go to print the
contents of the printer
buffer, staple the
accumulated sheets
or terminate the
collation set.
Note: Go does not
terminate the current
print job.

or

Press Menu> or
Menu< to access the
Busy/Waiting Menu
group. The following
functions may be
available via the Busy/
Waiting Manu group:
*Cancel Job
*Reset Printer
*Reset Active Bin
*Print Buffer

Diagnostic Information 2-25

User Status Screens Status Action

Busy The printer is busy

receiving or processing
data, or printing data.

Note: The printer
indicator light blinks
while the printer is
processing data.

Flushing Buffer The printer is flushing

corrupted print data and
the current print job is
being discarded.

Printing Menu Settings The printer is processing

or printing a list of
current settings menus
because Print Menu
Settings is selected fro m
the menu.

Press Stop to take the
printer out of Busy.
The Not Ready
message is displ ay ed.
No more data is
processed, but the
printer processes all
paper currently in the
printer paper path.
Press Go to return to
Ready.

No button actions are
possible while this
message is displayed.

Press Stop to take the
printer out of Ready.
The Not Ready
message is displ ay ed.
No more data is
processed, but the
printer processes all
paper currently in the
printer paper path.
Press Go to return to
Ready after the page
prints. Press Menu>
or <Menu to take the
printer out of Ready
and enter the TESTS
MENU (Busy State).
Press Select for the
value s. Press Menu>
until Reset Printer is
on the second line of
the display. Press
Select to reset the
printer.

2-26 Service Manual

User Status Screens Status Action

Printing Directory List A directory of the flash

Restoring Factory
Defaults

Performing Self Tests The printer is running

and disk contents is
processing or printing
because Print Directory
is selected from the
menu.

The printer is restoring
factory def aul ts.

the normal series of
start-up tests after it is
powered On. When the
tests are complete, the
printer returns to Ready.

Press Stop to take the
printer out of Ready.
The Not Ready
message is displa y ed.
No more data is
processed, but the
printer processes all
paper currently in the
paper path. Press Go
to return to Ready
after the page prints.
Press Menu> or
<Menu to take the
printer out of Ready
and enter the TESTS
MENU (Busy Stat).
Press Select for the
values. Press Menu>
until Reset Printer is
on the second line of
the display. Press
Select to reset the
printer.

No button actions are
possible while this
message is displayed.

No button actions are
possible while this
message is displayed.

Not Ready
(Press Go)

The printer is in the Not
Ready state, which
means it is not ready to
receive or process data.
This message displays
when Menu> or <Menu
is pressed during a print
job.

Diagnostic Information 2-27

Press Go to take the
printer out of the Not
Ready state. Press
Menu> or <Menu to
take the printer out of
Ready and enter the
TESTS MENU (Busy
state). Press Menu>
until Reset Printer is
on the second line of
the display. Press
Select to reset the
printer.

User Status Screens Status Action

Resetting Printer The printer is deleting

Formatting Flash
(Do Not Power Off)

Program Flash
(Do Not Power Off)

Formatting Disk The disk is being

Programming Disk
(Do Not Power Off)

any print jobs i n proc ess
and restoring all s ettings
to user defaults.

The flash memory is
being formatted.

The flash memory is
being programmed,
which means fonts or
macros are being w ritten
to flash memory.

formatted.

The disk is being
programmed, whic h
means fonts or macros
are being written to disk.

No button actions are
possible while this
message is displayed.

No button actions are
possible while this
message is displayed.

Do not perform any
button actions while
this message is
displayed.

No button actions are
possible while this
message is displayed.

No button actions are
possible while this
message is displ ay ed.

Note: If information is
written to flash
memory and to disk at
the same time, the
Program Flash
message is displayed.

Menus Disabled The printer menus have

Activating Men u
Changes

been disabled. This
occurs when Menu> or
<Menu is pressed while
the printer is Ready and
Menu Lockout is active.
The printer display
shows this message for
one second and then
returns to the Ready
message.

The printer is reset to
activate a printer setting
changed in the menus.

2-28 Service Manual

No button actions are
possible while this
message is displayed.

No button actions are
possible while this
message is displayed.

User Attendance Messages

User Message
Primary

200 Paper Jam
Remove Cartridge

201 Paper Jam
Remove Cartridge

User
Message
Secondary

Leave Job in
Finisher

Leave Job in
Finisher

Explanation

Primary: Paper is jammed at the printer
Input Sensor. Open the printer upper
front door and remo ve the print cartridge
to access the paper jam area.
Secondary: When this message is
displayed, do not remove accumulated
sheets during the jam clearance
procedure as the printer will not reprint
the removed sheets. Also, if the
accumulated sheets are rem o ved, the
portion of the job printed after the jam
will not be stapled.

Primary: Paper is jammed between the
printer input and exit sensors. Open the
printer upper front door and remove the
print cartridge to access the jam area.
Secondary: When this message is
displayed, do not remove accumulated
sheets during the jam clearance
procedure as the printer will not reprint
the removed sheets. Also, if the
accumulated sheets are rem o ved, the
portion of the job printed after the jam
will not be stapled.

202 Paper Jam
Open Rear Door

Leave Job in
Finisher

Primary: Paper is jammed at the printer
exit sensor . Open the print er rear door to
access the jam area.
Secondary: When this message is
displayed, do not remove accumulated
sheets during the jam clearance
procedure as the printer will not reprint
the removed sheets. Also, if the
accumulated sheets are rem o ved, the
portion of the job printed after the jam
will not be stapled.

Diagnostic Information 2-29

User Message
Primary

User
Message
Secondary

Explanation

230 Paper Jam
Check Duplex

24X Paper Jam
Check Tray X

Leave J ob in
Finisher

Leave J ob in
Finisher

Primary: The paper is most likely
jammed in the Duplex Unit. Remov e th e
duplex front cover to access the jam
area. If the paper is jammed in the rear
of the duplex, then repla ce the dup lex
front cover and open the duplex rear
door. If the paper is not jammed in the
duplex unit, then it may be jammed in
the rear of the printer. Open the printer
rear door to access the jam.
Secondary: When this message is
displayed, do not remove accu mulated
sheets during the jam clearance
procedure as the printer will not reprint
the removed sheets. Also, if the
accumulated sheets are removed, the
portion of the job printed after the jam
will not be stapled.

Primary: Paper is jammed around Tray
X (X=tray 1 thru 5). Try opening Tray X.
If the tray is difficult to remove, then you
may have to remove the tray above or
below tray X to remove the jammed
pages.
Secondary: When this message is
displayed, do not remove accu mulated
sheets during the jam clearance
procedure as the printer will not reprint
the removed sheets. Also, if the
accumulated sheets are removed, the
portion of the job printed after the jam
will not be stapled.

250 Paper Jam
Check MP Feeder

2-30 Service Manual

Leave J ob in
Finisher

Primary: Paper is jammed in the
multipurpose feeder.
Secondary: When this message is
displayed, do not remove accu mulated
sheets during the jam clearance
procedure as the printer will not reprint
the removed sheets. Also, if the
accumulated sheets are removed, the
portion of the job printed after the jam
will not be stapled.

User Message
Primary

User
Message
Secondary

Explanation

260 Paper Jam
Check Envelope
Feeder

27X Paper Jam
Check Output Bin
X

280 Paper Jam
Check Finish er

Leave Job in
Finisher

Leave Job in
Finisher

Leave Job in
Finisher

Primary: Paper is jammed in the
envelope feeder.
Secondary: When this message is
displayed, do not remove accumulated
sheets during the jam clearance
procedure as the printer will not reprint
the removed sheets. Also, if the
accumulated sheets are rem o ved, the
portion of the job printed after the jam
will not be stapled.

Primary: Paper is jammed in output bin
X (X=1 thru 3). Open the rear door of
Output Bin X to access the jammed
pages.
Secondary: When this message is
displayed, do not remove accumulated
sheets during the jam clearance
procedure as the printer will not reprint
the removed sheets. Also, if the
accumulated sheets are rem o ved, the
portion of the job printed after the jam
will not be stapled.

Primary: Paper is jammed in the
finisher option. Open the finisher option
side door or top cover to access the
jammed pages.
Secondary: When this message is
displayed,do not remove accumulated
sheets during the jam clearance
procedure as the printer will not reprint
the removed sheets. Also, if the
accumulated sheets are rem o ved, the
protion of the job printed after the jam
will not be stapled.

281 Paper Jam
Check Finish er

Remove Job
From
Finisher

Primary: Paper is jamm ed in the
finisher option. Open the finisher option
side door or top cover to access the
jammed pages.
Secondary: When this message is
displayed, remove the job from the
finisher . The printer wi ll not reprint the
removed sheets.

Diagnostic Information 2-31

User Message
Primary

User
Message
Secondary

Explanation

282 Staple Jam
Check Stapler

283 Staple Jam
Check Stapler

In s ert Cartridge or
Close Door

Remov e Job
from Finisher

Remov e Job
from Finisher

Primary: A staple jam has been
detected during normal stapler
operation.
Secondary: The printer flashes the
secondary message to indicate that all
accumulated sheets should be rem o ved
during the jam clearance.

Primary: A staple jam has been
detected during the priming operation.
Secondary: The printer flashes the
secondary message to indicate that all
accumulated sheets should be rem o ved
during the jam clearance.

Note: The follo wing action s can be taken
while either of the primary or seco nda ry
messages is displayed

1. Press GO to initiate priming and
resume printing.

This message displays when the printer
front door is open or the print cartridge
is missing.
If this message cannot be cleared go to
the “Cover Open Switch/Cable

Service Check” on page 2-49.

2-32 Service Manual

User Message
Primary

User
Message
Secondary

Explanation

31 Defective Pr int
Cartridge

32 Unsupported
Print Cartridge

Error code 31 is displayed when the top
front cover is closed and a defective
print cartridge is detected. It may take
the printer 10-20 seconds to determine
if the print cartridge is defective.
Depending on the setting o f the Mac hine
Class ID the printer may be allowed to
print pages during this 10-20 second
interval. If pages are allowed to print,
they are not reprinted once a good print
cartridge is inserted.

Note: This error indicates the printer
was able to re ad the cartridge ID , bu t the
ID did not pass the verification test. To
pass the verification test, the ID read
from the print cartridge must match the
ID from the last “good” print cartridge or
the same ID must be read from the print
cartridge twice. The last “good” print
cartridge ID is stored in NVRAM.

Error 32 is displa y ed whe n the t op co v er
is closed and an unsupported print
cartridge is detected. It may take the
printer 10-20 seconds to determine if
the print cartridge is supported.
Depending on the setting o f the Mac hine
Class ID the printer may be allowed to
print pages during this 10-20 second
interval. If pages are allowed to print,
then they are not reprinted once a good
print cartridge is inserted. If this does
not fix the problem, go to the “Smart

Cartr idge Contact Assembly Service
Check” on page 2-121.

34 Short Paper The printer determines the paper len gth

is too short to print the formatted data.
This occurs when the printer does not
know the actual paper size loaded in the
tray. For auto-size sensing trays, this
error occurs if the paper stop is in the
incorrect position. Make sure the Paper
Size setting i s correct for the size paper
that is being used.

Diagnostic Information 2-33

User Message
Primary

User
Message
Secondary

Explanation

36 Resolution
Reduced

37 Insufficient
Collation Memory

38 Memory Full This message is displayed when the

39 Complex Page This message is displayed when the

51 Defective Flash This message is displayed when the

The resolution of the page has been
reduced from 600 dpi to 300 dpi to
prevent a Memory Full error. This
message can only occur if the
Resolution Reduction setting is turned
on.

Note: 1200 dpi pages are n ot re so lution
reduced. If a 1200 dpi job runs out of
memory, a Memory Full error is
displayed.

This message is displayed when the
printer memory used to store pages is
too full to collate the print job.

printer memory used to store pages is
full.

page is too complex to print.

printer detects a defective flash. This
error may occur at power on, or during
flash format and write op er ations. Press
Go to clear the message. The flash is
marked as bad and normal operation
continues. Flash ope rations are not
allowed until the problem is resolved.

52 Flash Full This message is displ ay ed when t here is

53 Unformatted
Flash

not enough free space in the flash
memory to hold the resources tha t have
been requested to be written to flash.

This message is displayed when the
printer detects an unformatted flash at
power on. Press Go to clear the
message. The flash is mark ed as bad
and normal operation continues. Flash
operations are not all owed unti l the flash
is formatted.

2-34 Service Manual

User Message
Primary

User
Message
Secondary

Explanation

54 Standard Serial
Error

54 Serial Option X
Error

56 Standard Serial
Disabled

56 Parallel Port
Disabled

58 Too Many Trays
Attached

58 Too Many Bins
Attached

This error is displayed when a serial
error (framing or parity) is detected on
the standard serial port. This usually
indicates the serial port is not set up
correctly.

This error is displayed when a serial
error (framing or parity) is detected on
the optional serial port. This usually
indicates the optional serial port is not
set up correctly.

This error is display ed when data is sent
to the printer across the standard serial
port, but the port has been disabled.

This error is display ed when data is sent
to the printer across the parallel port, but
the parallel port has been disabled.
Once this message is displayed,
reporting of further errors is suppressed
until the menus are entered, or the
printer is reset.

This error code is displayed when t oo
many input trays are attached to the
printer.

This error code is displayed when t oo
many optional output bins are attached
to the printer.

58 T oo Many Disks
Installed

61 Defective Disk This error code is displayed when the

This error is displayed when too many
disks are attached to the printer.

printer detects a defective disk. This
error may occur at power on or during
disk format and write operations.While
this message is displa yed: press Go to
clear the message. The disk is marked
defective and normal printer operations
continue. Disk operations are not
allowed with a defective disk. The
Format Disk menu is not shown.

Diagnostic Information 2-35

User Message
Primary

User
Message
Secondary

Explanation

62 Disk Full This error code is displayed when there

63 Unformatted
Disk

80 Scheduled
Maintenance

81 Engine Code
CRC Failure

is not enough free space on the disk to
hold the resources that have been
requested to be written to the disk. This
message displa y s f or b oth reso urce an d
PostScript Disk operators whe n the disk
is full.

This error code displays when the
printer detects an unformatted disk at
power on. Press Go to clear the
message. The disk is marked as bad
and normal operation continues. Disk
operations are not allowed until the disk
is formatted.

The operator panel displays this
message at each 300K page count
interval. It is necessary to replace the
fuser assembly, transfer roller, and
charge roll at this interval to ma intain the
print quality and reliability of the printer.
The parts are available as a
maintenance kit. For more information,
go to the “Scheduled Maintenance”

on page 6-2.

This error displays when the micro co de
to be programmed in the engine flash
code module has f ai le d a CRC che ck.
Press Go to clear the message. The
microcode data is discarded and must
be re-transmitted from the host
computer.

88 Toner Low This message displays when toner low

occurs and the toner low alarm is
activated. Press Go to clear this
message.

2-36 Service Manual

User Line 2 Messages

If none of the conditions exist that are listed in the following table,
line 2 is blank. If any of the messages in the table are displayed the
following actions can be taken:

Press Menu> or <Menu to take the printer offline and access the
Ready Menu group.

Note: The Menu buttons are not active if Menu Lockout is turned
on.

Press Stop to take the printer offline. The Not Ready message is
displayed. No more data is processed from the host computer. Press
Go to return the printer to the Ready state.

User Message Explanation

Toner Low If the toner cartridge is low, then “Toner Low”

Tray X Missing If any of the input trays are missing, then “Tray X

displays. The Toner Low condition clears
whenever the upper front door is opened, and
Toner Low displays again if the condition exists
after the upper front door is closed.

Missing” displays (where X designat es which Tray
(1 through 5) is missing. If multiple trays are
missing, they are prioritized in this order: Tray 1,

2..., then Tray 5. Tray X Missing status clears
whenever Tray X is reinserted.

Diagnostic Information 2-37

User Message Explanation

Tray X Empty If any of the input trays are empty, then “Tray X

Tray X Low If any of the inp ut trays are low, t hen “Tray X Low”

Empty” displays where X designates which tray
(Tray 1 through 5) is empty. If multiple trays are
empty, then they are prioritized in this order: Tray
5, Tray 4,...Tray 1.

Note: Tray X Empty status clears whenever Tray
X is removed. When Tray X is reinserted, it is
examined and the appropriate status, if any,
displays. Also note that Empty status is not
displayed for the Envelope Feeder or
Multipurpose Feeder.

displays where X designates which tray (1
through 5) displays. If multiple trays are low, they
are prioritized in the following order: Tray
5,4,3,2,1.

Note: Tray X Low clears whenever Tray X goes
empty, or Tray X is removed. When Tray X is
reinserted, it is examined and the appropriate
status, if any, displays.

Note: The printer cannot detect when the
envelope feeder or multipurpose f ee der are lo w.

User Line 2 Link Messages

If the printer is locked on a particular link, the link indication displays.
If the printer is ready to process any link, no messages display. Link
messages are listed in the following table.

User Message Explanation

Parall el Standard Parallel Port, if available .
Serial Standard Serial Port, if available.
Serial X Serial Port, where X=1,2,3, is attached to PCI

Network X Network card X, X=1,2,3, is attached to PCI

connector X.

connector X.

2-38 Service Manual

User Message Explanation

LocalTalk X LocalTalk Card X,X=1,2,3, is attached to PCI

Infrared Standard Infrared port, if available.
Infrared X Infrared Port X, X=1,2,3, is attached to PCI

connector X.

connector X.

Check Device Connection Messages

The messages in the following table display when the printer looses
communications with one of the following devices.

User Status Mess age Explanation

Check Output B in X
Connection

Check Env Feeder
Connection

Check Tray X
Connection

Check Duplex
Connection

Check Output Bin X (X=1,2,or 3).

Check Envelope Feeder Option Connection.

Check Tray X (X=1,2,3,4 or 5).

Check Duplex Option Connection.

Diagnostic Information 2-39

The messages in the following table can occur in two ways. The
specified device could have been removed from the printer, for
instance to clear a paper jam. Otherwise, the device can still be
attached to the printer, but is experiencing a communications
problem, not fully connected, or having a hardware failure.

• If the device is temporarily removed or not connected properly,

then reattach it. When the option is recognized, the printer
automatically clears the error and continues.

• If the option is experiencing a hardware problem, turn the printer

off and back on. If the error occurs again, turn the printer off,
remove the option and call for service.

User Status Message Explanation

Turn Printer OFF to
Enable Option

Insert Duplex Front
Cover

Close Duplex Rear Door This message displays when the duplex rear door

This message displays when a printer option,
Input Tray, Output Bin or Envelope Feeder, has
been attached while th e printer is po wered On . To
use the option, the printer must first be powered
off and back on again. Data loss results if print
jobs are activ e when the printer is po wer c ycled. If
a print job is active, then remove the option and
finish the job. The printer automatically clears the
message once the option is removed. Once the
job is complete, turn off the printer and attach the
option again.

This message displays when the duplex front
access cover is not installed.

is open.

2-40 Service Manual

Power-On Self Test (POST)

When you turn the printer On, it performs a Power-On Self Test.
Check for correct POST functioning of the base printer by observing
the following:

1. The LED comes on.

2. The operator panel displays one and a half row of pels, and then
clears.

3. Diamonds scroll across the display, and then clear.

4. The operator panel displays one and a half row of pels, and then
clears.

5. The top line of the operator panel displays one square block of
pels that turn on one at a time until all sixteen blocks display and
then they all turn off.

6. Amount of memor y dis played.

7. “P erforming Self Test” appears on the displ ay.

– The 2000 sheet high capacity option elevator tray moves to

the uppermost position (if installed).

– The duplex option is checked (if installed).

8. The fuser lamp turns on. The fuser takes longer to warm up
from a cold start than a warm start.

9. The main fan turns on.

10. The main drive motor turns on.

11. The developer drive assembly drives the developer shaft in the
toner cartridge.

12. “Ready” appears on the display.

13. StapleSm art Finisher option homes (if installed).

14. The exit rollers turn.

15. The output expander option, 5-bin mailbox, or high capacity
output stacker exit rollers turn (if installed).

Diagnostic Information 2-41

Symptom Tables

Symptom Table - Base Printer

Symptom Action

Cartridge Fan (722/72n) f ail s to
run or is noisy

Printhead Fan fails to run or is
noisy (722/72n).

Dead Machine Go to the “Dead Machine Service

Operator Panel - One or more
buttons do not work.

Operator Panel - Display is blank.
Printer sounds 5 beeps.

Operator Panel - Display is blank.
Printer does not sound 5 beeps.

Operator Panel continuously
displays all diamonds, sounds 5
beeps and does not complete
POST.

Paper feed problems - Base
printer or Integrated 250 Paper
Tray

Paper jams at exit of Redrive
Assembly - No Duplex Option
installed.

Go to the “Cartridge Fan Service

Check” on page 2-64.

Go to “Printhead Fan Service

Check” on page 2-63. If the fan is

noisy, replace the fan assembly.

Check” on page 2-50.

Go to the “Operator Panel Buttons

Service Check” on page 2-86.

Go to the “Operator Panel Service

Check” on page 2-86.

Replace the operator panel
assembly.

Go to the “Operator Panel Service

Check” on page 2-86.

Go to the “Paper Feed Service

Check” on page 2-105.

Go to the “Paper Feed Service

Check” on page 2-105.

Paper jams at exit of Redrive
Assembly - Duplex Option
installed

Fuser Solenoid fails to operate. Go to the “Fuser Solenoid Service

Print quality - Black page Go to the “Print Quality - All Black

Print quality - Blank page Go to the “Print Quality - Blank

Go to the “Duplex Option Service

Check” on page 2-53.

Check” on page 2-68.

Page” on page 2-110.

Page” on page 2-110.

2-42 Service Manual

Symptom Action

Print quality - Light print Go to the “Print Quality - Toner on

Print quality - Background Go to the “Print Quality -

Print quality - Residual image Go to the “Print Quality - Residual

Print quality - Skew Go to the “Paper Feed Service

Print quality - Banding Go to the “Print Quality - Banding”

Print quality - Random marks Go to the “Print Quality - Random

Print quality - Toner on backside
of printed page.

Print quality - Vertical blac k ban ds
on edge of copy.

Unable to clear a
“32-Unsupported Print Cartridge”
User Error Message.

backside of printed page” on
page 2-120.

Background” on page 2-114.

Image” on page 2-119.

Check” on page 2-105.

on page 2-117.

Marks” on page 2-112.

Go to the “Print Quality - Toner on

backside of printed page” on
page 2-120.

Go to the “Print Qual ity - Black

bands on outer edges of the
page.” on page 2-117.

Go to the “Smart Cartridge

Contact Assembly Service C heck”
on page 2-121.

Symptom Table - High-Capacity Feeder Option (2000 Shee t)

Symptom Action

The printer does not recognize
the high-capacity feeder option
installed.

Paper feed problem with the high
capacity feeder option.

Go to the “High-Capacity Feeder

Input Tray Service Check” on
page 2-72.

Go to the“High-Capacity Feeder

Input Tray Service Check” on
page 2-72.

Diagnostic Information 2-43

Symptom Table: Paper Tray Options

Symptom Action

Paper feed problem with 250­Sheet Paper Tray Option.

Paper feed problem with 500­Sheet Paper Tray Option.

Media fails to pass thru from the
lower attached Paper Tray option
to the next higher mou nted opt ion.

Go to the “Input Tray(s) Option

Service Check” on page 2-69.

Go to the “Input Tray(s) Option

Service Check” on page 2-69.

Go to the “Input Tray(s) Option

Service Check” on page 2-69.

Symptom Table - Duplex Option

Symptom Action

Paper feed problem with Duplex
Option.

Paper jams at Paper Removal
Tray.

Paper skews in the Duplex
Option.

Paper fails to pass from lower
option thru the Duplex Option.

Go to the “Duplex Option Service

Check” on page 2-53.

Go to the “Duplex Option Service

Check” on page 2-53.

Go to the “Duplex Option Service

Check” on page 2-53.

Go to the “Duplex Option Service

Check” on page 2-53.

Symptom Table - Envelope Feeder Option

Symptom Action

Envelopes do not feed from the
envelope feeder.

Envelopes do not feed properly
into base printer.

Go to the “En velope Feeder Option

Service Check” on page 2-56.

Go to the “En velope Feeder Option

Service Check” on page 2-56.

2-44 Service Manual

Symptom Table - Output Expander

Symptom Action

Printer does not display Output
Bin Full.

Paper does not feed all the way
into the output tray.

Go to the “Output Bin Sensor

Standard Tray Service Check” on
page 2-90.

Go to the “Output Expander

Service Check” on page 2-91.

Symptom Table - StapleSmart Finisher

Symptom Action

Finisher does not staple. Go to the “StapleSmart Finisher

Printer does not recognize
StapleSmart Finisher Option as
being installed.

Close Top Cover displayed.
Unable to clear or reset message
(POST inc omplete).

Close Finisher Side Cover
display ed. Unab le to cl ear or reset
message (POST incomplete).

Paper feeds into finisher option
output tray. Paper is not stapled
and paper does not align with the
right side.

Service Check” on page 2-125.

Go to the “StapleSmart Finisher

Service Check” on page 2-125.

Go to the “StapleSmart Finisher

Service Check” on page 2-125.

Go to the “StapleSmart Finisher

Service Check” on page 2-125.

Go to the “StapleSmart Finisher

Service Check” on page 2-125.

Paper feeds into finisher option.
Paper aligns with the right side.
The stapler does not staple.

Paper is transported into the
output tray but is not stapled.

Stapled sheets are not
transported to the output tray.

Go to the “StapleSmart Finisher

Service Check” on page 2-125.

Go to the “StapleSmart Finisher

Service Check” on page 2-125.

Go to the “StapleSmart Finisher

Service Check” on page 2-125.

Diagnostic Information 2-45

Service Checks

Note: Anytime the system board is replaced, the Configuration ID
must be reset in NVRAM on the new system board. Go to “Setting

Configuration ID” on page 3-31.

Review the following information before performing any service
checks.

• Paper feed problems (especially paper jams): Go to “Viewing

the Error Log” on pa ge 3-13 and check the printer error log for

indications of repetitive entries that help to isolate a problem to
a particular area of the printer or option.

• Paper feed problems with error message: Use the “Sub Error

Codes for 9XX and 2XX Error Codes” on page 2-8 to help

diagnose the problem.

• Print quality problems: Go to “Print Quality Test Pages” on

page 3-34 and print a test page to help diagnose problems

before changing any settings or working on the printer.

• Use the resident diagnostics test provided to help isolate a

problem before taking the machine apart or removing any
options.

2-46 Service Manual

Charge Roll Service Check

Service Tip: Close and evenly spaced repetitive marks 47.19 mm
(1.86 inch) apart or spots on the page can be caused by a damaged
or contaminated charge roll.

Service Tip: Check to make sure the right charge roll arm bushing is
correctly installed and operates correctly.

To remove the charge roll:

1. Wrap a piece of plain white paper around the charge roll to
prevent contamination or damage.

2. Carefully remove the roll by pressing outward and to the right on
the charge roll link arm and remove the charge roll from the
right side charge roll bearing.

3. Remove the charge roll from the left side charge roll bearing
and remove the roll from the printer. Leave the paper wrapped
around the charge roll until it is reinstalled.

FRU Action

1 Charge Roll Assembly Check the charge roll for correct

installation, toner buildup, marks,
cuts or other signs of contamination
or damage. Replace as necessary.

2 Left Side Charge Roll Link Check the left side charge roll link

assembly for correct assembly
operation. Check for damage to the
arm or bearing assembly.

Diagnostic Information 2-47

FRU Action

3 Right Side Char ge R o ll L ink

Right Charge Roll Bushing

Check the right side charge roll link
assembly for correct assembly
operation. If incorrect, replace the
charge roll link assembly with the
charge roll link assembly kit. If
correct, check the right charge roll
link assembly bearing for signs of
wear or contamination. Excessive
contamination could cause
intermittent charging of the charge
roll. If incorrect, replace the link
assembly. Check f or c ontin uity of t he
right link assembly from the bearing
to the charge roll high voltage
contact on the right side frame. If
incorrect, replace the link assembly.

Make sure the char ge ro ll bushing is
installed and operating correctly.

Note: The screw that attaches the
charge roll lead to the contact must
be secure.

2-48 Service Manual

Cover Open Switch/Cable Service Check

FRU Action

1 Toner Cartridge Check the toner cartridge to make

2 Cover Open Switch/Cable

Assembly

sure it is correctly installed and that
the right and left ca rtridge tracks are
not loose or broken. Check to make
sure the cov er open s witch activ ation
tab on the toner cartridge is not
broken and that the tab correctly
activates the cover open switch
spring.

Check the cover open switch for
proper mechanical operation. If
incorrect, repair as necessary.
Disconnect the cover open switch
cable from J3 at the system board
and measure the voltage at J4-3. It
measures approximately +5 V dc. If
the voltage is incorrect, replace the
system board. If the voltage is
correct, check the voltage at J3-1. If
the voltage measures greater than
+1.0 V dc, replace the sy stem board.
If the voltage is correct, check the
continuity between J3-1 and J3-3 on
the cable. If no change in continuity
occurs as the switch is activated,
replace the cover open switch/cable
assembly. If the continuity changes
as the switch is activated, replace
the system board.

Diagnostic Information 2-49

Dead Machine Service Check

Note: If a high-capacity input tray is installed, remove the option and

check the base printer for correct operation. If the base printer
operates correctly, go to “High-Capacity Feeder Input Tray

Service Check” on page 2-72. If the base printer continues to not

operate correctly, remove any other attached paper handling
options. Observe all necessary ESD precautions when removing
and handling the system board or any of the installed option cards or
assemblies.

Service Tip: When removing the LVPS from the printer observe the
following:

1. The LVPS uses a self docking connector that mates with
another connector mounted on the left side frame assembly.
Some force may be required to pull the LVPS loose from the
connector.

2. Gently remove the LVPS supply using caution not to damage
the printed circuit board. Pull the LVPS out far enough to reach
the fuser lamp cable.

3. The fuser lamp cable uses a locking type of connector system.
Unlock the fuser lamp cable connector, disconnect the cable
and remove the LVPS from the printer.

Note: If the LVPS is blowing fuses, remove the LVPS from the
printer. Check the metal LVPS shield for signs of damage that
causes the shield to touch components on the LVPS board
assembly.

FRU Action

1 Line Voltage Check the AC l ine voltage. If the line

2 AC Line Cord Check the line cord for any signs of

voltage is incorrect, inform the
customer.

damage. If correct, check the
continuity of the line cord and
replace if necessary.

2-50 Service Manual

FRU Action

3 +5 V dc at the system

board test point

4 LVPS Fuse F1 Remove the LVPS from the printer

5 LVPS Fuse F1 - continues

to blow F1 after LVPS
reinstalled.

Check for +5 V dc at the +5V dc test
point on the system b oard. If corre ct,
replace the system board. If
incorrect, go to step 4.

and check fuse F1 . Replace the fuse
if the fuse is blown. If the fuse is not
blown go to step 6.

CAUTION: Before removing the
LVPS from the printer and checking
fuse F1, turn the LVPS off and
remove the AC line cord.

Replace fuse F1 if necessary. Turn
the LVPS off and pull the LVPS far
enough out of the printer to break
contact with the interconnect card
autoconnector. Connect the AC line
cord, turn the LVPS on. If fuse 1
blows again replace the LVPS
assembly. If the fuse does not blow,
turn the LVPS off, reinstall the LVPS
back into the printer and go to
step 7.

CAUTION: Before chec king fuse F1,
turn the L VPS off and rem ov e the AC
line cord.

Diagnostic Information 2-51

FRU Action

6 LVPS Remove the LVPS from the printer.

CAUTION: Before making any
measurements on the LVPS output
connector (CN3), observe all
necessary safety p r ecautions before
applying AC power. Measure the
voltage on CN3-1, 2, 10 or 11. The
voltage measures approximately
+5V dc. If incorrect replace the
LVPS.

7 System Board Turn the printer off and disconnect

all the cables f rom the system b oard.
Check for +5V dc at the system
board test point. If incorrect replace
the FRU in the order shown.

interconnect board
system bo ard

If correct, turn the printer off and
reconnect one cable at a time until
you find the defective assembly.

Service Tip: A short or low
resistance load that is attached to
the system board can pull the +5V
dc supply down to approximately
0Vdc.

2-52 Service Manual

Check for burn marks or other signs
of damage to the system board.

Duplex Option Service Check

The printer does not recognize the Duplex Option is attached. The
printer does not recognize tray options below the duplex option
are installed.

FRU Action

1 Fuse F1 on Duplex Option

System Board

2 Auto co nne ct Ca bles/

Connectors

If fuse F1 is blown, replace the fuse.
If fuse F1 continues to blow, check
the stepper motor for a short
between the motor case and pins
J3-1 through J3-4. If no problem is
found, check the D .C. servo motor
pins J1-1 and J1-2 to the motor
housing for a short. If a short is
found, replac e the motor assemb ly . If
no short is found, replace the system
board.

Check the autoconnect cables for
damage to the cables or the pins in
the connectors. If damaged, replace
the cable(s). If no damage is found,
check to make sure the cables are
connected to J9, J10, J11 and J12
on the duplex system board. If no
problem is found, replace the duplex
system board.

Diagnostic Information 2-53

POST fails, 230 Paper Jam, Check Duplex message displays.

FRU Action

1 Duplex D.C. Servo Drive

Motor

2 Input Sensor, Input Sensor

Flag

3 Paper Exit Sensor and Flag Check the duplex exit sensor for

Check the D.C. servo motor cables
for signs of cuts or other damage.
Check the D.C. servo motor sensor
cable connector for pin damage. If
no problem is found, replace the
FRUs in the following order:

D.C. motor assembly
duplex option system board

Run the Duple x Sensor Test from the
diagnostics menu. If the test fails,
check the input sensor cable at J5
on the system board for correct
installation. If no problem is found,
replace the FRUs in the following
order:

input sens or assembly
duplex option system board

correct installation and free
movement of the sensor flag. Check
to make sure the sensor cable is
connected to J8 on the system
board. If no problem is found,
replace the FRUs in the following
order:

2-54 Service Manual

exit sensor assembly
duplex option system board

230 Paper Jam - Check Duplex message displays. The page is not
duplexed and only exits half way out of the redrive.

FRU Action

1 Duplex Stepper Motor Check the stepper motor cable for

cuts or pinc hed wiring. Check the
routing of the motor leads along the
left side of the bottom tr a y. Check fo r
correct installati on of the motor cable
connector at J3 on the system
board. Check for a ny shorts betw een
each pin of the motor cable and the
motor housing. If shorts are found,
replace the motor. Check the
resistance of the stepper motor
between J3-1 (Stpmtr A-) to J3-2
(Stpmtr A+). The resistance
measures approximately 10 ohms.
The resistance between J3-3
(Stpmtr B-) to J3-4 (Stpmtr B+)
measures appro xim ately 1 0 ohms . If
the resistance is incorrect, replace
the stepper motor. Check for shorts
between windings on pins J3-1 to
J3-2 and pins J3-3 to J3-4. If a s ho rt
is found, replace the stepper motor
assembly. If no short is found,
replace the duplex system board.

Diagnostic Information 2-55

Envelope Feeder Option Service Check

Service Tip: Check the envelope feeder paper path for any debris,
pieces of envelope and so on. If any other options are installed make
sure they are operating normally. If only the envelope feeder is failing
to operate correctly, continue with this service check.

Service Tip: The envelope feeder option receives its +5 V dc
operating voltage from the +24 V dc bulk at J1-7. If +24 V dc is not
present at J1-7, tray 1 is the only tray option that is recognized.

Note: If a 260 Paper Jam Check Envelope message displays, check
the “Sub Error Codes for 9XX and 2XX Error Codes” on

page 2-8.

Printer does not recognize the envelope feeder as an attached
input option.

FRU Action

1 Envelope Feeder Check to make sure the envelope

2 Front Autoconnect on

Printer

feeder is correctly installed and
mated to the autoco nnect at t he front
of the printer.

Check the connector for signs of
damage to the connector or
contacts. If y ou find dam age, repla ce
the damaged cable/conn ec tor
assembly. Remove the envelope
feeder option a nd chec k the volta ges
at the autoconnect on the fro nt of the
printer. If incorrect, check the
interconnect board. If correct,
reinstall the envelope option and
continue with step 3.

2-56 Service Manual

FRU Action

3 Auto co nne ct on the

Envelope Option

Check for any signs of damage to
the connector o r c ont ac ts . If you find
damage, replace the damaged
cable/connector assembly.
Disconnect the a utocon nect cab le at
J1 on the envelope system board
and measure the fol lowing voltag es :

J1-3 measures +5 V dc
J1-5 measures +5 V dc
J1-7 measures +24 V dc

If any of the voltages are incorrect,
replace the autoconnect
cable/connector. If the voltages are
correct, replace th e envel ope system
board.

Diagnostic Information 2-57

Operator panel displays 260 Paper Jam immediately when
envelope feed is requested - POST incomplete.

FRU Action

1 Pass thru Sensor Check for any debris, pieces of

envelope and so on over the pass
thru sensor. Check for correct
installation of the pass thru sensor
flag. Make sure the sensor cable is
attached to the envelope system
board. Perform an envelope feeder
sensor test to check both the sensor
and sensor flag.

Note: It may be necessary to use a
small tool to actuate the sensor flag
because it is located under the front
cover. Be careful not to damage the
flag.

If the test fails , chec k the fla g f or an y
signs of damage or binds. If
incorrect, replace the flag. If the flag
is operating correctly, check the
voltage at J3-3. The voltage
measures approximately +5 V dc. If
incorrect, replace the envelope
system bo ard. If correct, check the
voltage at J3-2. The voltage c hanges
from 0 to +5 V dc when the flag is
moved in and out of the sensor. If
incorrect, replace the sensor
assembly. If this does not fix the
problem, replace the envelope
system bo ard.

2-58 Service Manual

Operator panel displays 260 Paper Jam after attempted feed but
before envelopes are put in the hopper OR the operator panel
continues to display "Load Envelopes" after envelopes are placed
in the hopper.

Service Tip: The kick rolls rotate during the attempted feed cycles.

FRU Action

1 Envelope Out Hopper

Sensor Flag

2 Env elo pe Out Ho pper In put

Sensor

Check the envelope out sensor flag
for damage, correct installation and
operation. If incorrect, repair or
replace the flag.

Check the sensor to make sure it is
installed correctly and the sensor
cable is properly connected to the
envelope system board. If correct,
perform the Envelo pe Feed Sensor
Test to check both the sensor and
flag. If the test fails, remove any
envelopes in the hopper, turn the
printer off and disconnect J3 from
the system bo ard. Turn the printer on
and check the voltage at J 3-3 on the
system board. The voltage
measures approximately +5 V dc. If
incorrect, replace the envelope
system board. If correct, replace the
input sensor assembly.

Diagnostic Information 2-59

990 Service Error, envelopes fail to feed from the hopper.

FRU Action

1 D .C. Feed Motor Assembly Check the motor an d motor c ab le f o r

2 Envelope Feeder System

Board

any signs of loose wires or poor
connections. Check to make sure
the motor cable is connected to the
envelope system board.

Check the voltage on J4-1. The
voltage measures approximately
+24 V dc. If incorrect, replace the
envelope system board, if correct,
measure the voltage at J4-6. The
voltage measures approximately
+5 V dc. If incorrect, disconnect J4
and measure the voltage again. If
incorrect, replace the envelope
feeder system board. If correc t,
replace the D.C. motor assembly.

260 Paper Jam displays, unable to clear and envelopes fail to feed
from the hopper. Kick rolls ARE NOT rotating.

FRU Action

1 Main Drive Belt Check the belt for correct installation

and for signs of damag e. Re place as
necessary.

2 Gears Check all the gears for correct

3 Clutch Latch Assembly Check the clutch latch assembly to

4 Master Cam Gear Master/

Kick Gear

installation and for signs of damage.
Repair or replace parts as
necessary.

make sure it moves f reely.
Check the master cam gear and

master/kick gea r to make sure they
rotate together. If not, then the
tenons on the master kick gear may
be sheared off. If incorrect, replace
the master kick gear.

2-60 Service Manual

260 Paper Jam displays, unable to clear and envelopes fail to feed
from the hopper. Kick rolls ARE rotating.

Check the deflector gap adjustment before continuing this service
check.

FRU Action

1 Deflector Gap Adju stm en t Check the deflec tor gap adju st ment.

The adjustment may be too narrow.

2 Weight Assembly Check the weight assembly to make

3 Envelope Edge Guide Check the envelope edge guide to

sure it moves up and down freely
without any binds. Also check to
make sure the weight assembly
rests on all the rear kic k rollers when
the hopper is empty. Replace the
weight assembly if it is damaged or
does not operate properly.

make sure it is n ot warped or set too
close to the en v elopes in the hop per .
Replace the edge guide if it is
damaged or does not operate
properly.

Diagnostic Information 2-61

260 Paper Jam displays, envelope stops in feeder paper path.

FRU Action

1 Kick Rolls/Feed Rolls/Drive

Rolls

2 Deflector Gap Adjustment Check the deflector gap adjustment.

Check all the ro lls fo r any signs of oil,
grease or other contam ination. If yo u
find a problem, clean the rolls. If this
does not correct the problem,
replace the envelope feeder option.

The adjustment may be too narrow.

Envelope Feeder multifeeds or may not display a 260 Paper Jam
message.

FRU Action

1 Envelopes Check the envelopes being used in

2 Deflector Check the deflector ga p adjustment.

3 Restraint Roll Bias Spring Check for a missing, broken or

the feeder. Check for signs of the
envelop es being stu ck together or
signs of glue. Check to make sure
the flaps are not interleav ed .

The adjustment may be too wide.

incorrectly installed restr aint roll bias
spring. If incorrect, reinstall or
replace the spring.

260 Paper Jam displays an envelope stopped in the paper path of
the feeder and an envelope also stopped in the base printer paper
path.

FRU Action

1 Latch Lever Check to make sure the tip of the

latch lev er is cent ered in the o pening
in the floor of the paper path. The
latch lever may not be detented on
the latch.

2-62 Service Manual

Fan Service Chec k

Printhead Fan Service Check

The printhead fan is in models 722/72n.
Note: If the printhead fan is inoperative and a lot of graphics are

printed, you may see darker than normal copies.

Fan does not run or is noisy.

FRU Action

1 Fan Assembly Check the fan for proper installation

2 System Board Check to make sure the printhead

and for ex cessive noise . If inco r rec t,
replace the fan and cable assembly.

fan cable is seated on connector J4
on the system board. If correct,
check for +24 V dc on J4-1 on the
system board. If incorrect, replace
the system board. If correct, replace
the fan assembly.

Note: When the printer is in warm­up the voltage at J4-1 measures
approximately +12 V dc. When the
printer is running, the voltage
measures approximately +24 V dc.

Main Fan Service Check

Check the cable connections at J5 on the

system board and at the

main fan assembly . The main fan runs continuously when the printer
is powered on unless the printer is in the Power Saver mode.

FRU Action

1 Main Fa n Manually spin the fan and check that

it rotates freely. Check the cable
connection to the system board, J5
for correct installation.

Diagnostic Information 2-63

FRU Action

2 Main Fan to System Board

Cable

3 Error Code 927 (Fan runs) Check the voltage at J5-1 on the

4 Error Code 927

(Fan not running)

Check the continuity of the cable. If
incorrect, replace the cable.

system board. The voltage
measures +5 V dc (static) 0 V dc (f an
running). If incorrect, replace the
main fan. If this does not fix the
problem, replace the system board.

Check the voltage at J5-3 on the
system board. The voltages are:

+22 V dc to +24 V dc
(printer and fan running)

+12 V dc to +15 V dc
(printer not running - fan running
about half speed).

If incorrect, replace the system
board. If this does not fix the
problem, replace the main fan.

Cartridge Fan Service Check

This cartridge fan is used in models 722 and 72n
Fan does not run or is noisy.

FRU Action

1 Fan Assembly

(noisy)

2-64 Service Manual

Check the fan for proper installation
and for excessive noise. If incorrect,
replace the fan and cable assembly.

FRU Action

2Fan Assembly

System Board

Check to make sure the auxiliary fan
cable is seated on connector J6 on
the system board. If correct, check
for +24 V dc on J6-1 on the system
board. If incorrect, replace the
system board. If correct, replace the
cartridge fan.

Note: When the printer is in warm­up the voltage at J6-1 measures
approximately +12 V dc. When the
printer is running, the voltage
measures approximately +24 V dc.

Cold Fuser Service Check

Error codes 920, 921, and 922 may display for a cold fuser failure. A
920 error caused by low line voltage can sometimes be cleared by
turning the machine off and then on again. A 925 service error
indicates the wrong fuser lamp is installed in the printer and does not
match the one stored in the printer code.

Note: If the correct lamp is installed and you still have 925 fuser
errors, try the following:

1. The fuser may have reached standby temperature too quickly.
Check the fuser assembly, system board or LVPS.

2. Ensure that the correct hot roll is installed.

3. Check the AC line voltage to ensure it is not above the
maximum rating for the printer.

Note: Make sure the fuser is correctly installed before proceeding
with this service check. The fuser must be firmly seated in the two
rear connectors. Both the right and left lock down screws must be
tight.

Service Tip: Set the Fuser Temperature to NORMAL before starting
this service check.

Diagnostic Information 2-65

FRU Action

1 Fuser Lamp (I ncorrect

Lamp/925 Service Error)

2 Fuser Lamp Note: If the correct lamp is installed

3 LVPS

LVPS to Fuser Auto
Docking Connector
Fuser AC Cable

Install the correct voltage and
wattage lamp or fuser assembly.

and you still have 925 fuser errors,
try the following:

1. The fuser may ha ve reached
standby temperature too quickly.
Check the fu ser ass embl y, system
board or LVPS.

2. Ensure that the correct hot roll is
installed.

3. Check the AC line voltage to
ensure it is not above the
maximum rating for the printer.

Unplug the printer and check the
continuity between the two pins on
the fuser lamp cable going to the
fuser assembly. If you do not
measure continuity, remove the fuser
assembly and c heck t he contin uity of
the lamp. If incorrect, replace the
lamp. If correct, replace the fuser
cover asse m bly.

Turn the printer off. Remove the
fuser assembly. Turn the printer
power on. Measure across the AC
fuser cable pins for line voltage with
the cable connected. If incorrect,
turn the printer off and disconnect
the power cord. Check the continuity
of the LVPS to fuser AC cable. If
incorrect, replace the cable. If
correct, replace the LVPS.

4 Fuser Top Cover Assembly

(Thermal Fuse/Thermistor
Assembly)

2-66 Service Manual

Disconnect the thermistor cable. Th e
resistance is:

HOT - J2-1 - J2-2 = 2.5K ohms
COLD = 150K ohms to 260K ohms

Hot Fuser Service Check

Error codes 923 and 924 may display for a hot fuser failure.
CAUTION: The fuser may be hot, use caution before removing or

servicing.

FRU Action

1 Fuser Cover Assembly

(Assembl y inc lu des
Thermistor and Thermal
Fuses.)

2 System Board Error code 924 indicates the system

3 Fuser Hot Roll

Backup Roll Bearings

Check for damage to the thermistor
assembly. Check the resistance of
the thermistor:

HOT - J2-1 to J2-2 = 2.5K ohms
COLD =150K ohms to 260K ohms
If the resistance is incorrect, replace

the fuser cover assembly.

board detects an open circuit in the
thermistor circuit for the fuser
assembly. The voltage on J14-6 on
the system board measures
approximately +5 V dc. If incorrect,
replace the system board. If correct,
check the continuity of the DC fuser
cable in the fuser assembly and the
DC fuser cable (system board to
auto docking connector) attached to
J14 on the system board. If there is
no continuity, replace the cable.

Examine the fuser assembly for
signs of overheating or damage.
Check the h ot roll and bac kup roll for
signs of excessive toner, label glue,
labels or other contaminants. If any
are found, repair as necessary or
replace the fuser assembly.

Diagnostic Information 2-67

Fuser Solenoid Service Check

Service Tip: Try changing the envelope enhance level setting. A
different setting may correct the problem.

Note: Check the fuser envelope conditioner solenoid adjustment as
described in the adjustment section “Fuser Solenoid Adjustment”

on page 4-3.

FRU Action

1 Fuser Envelope Conditioner

Solenoid
Fuser Solenoid Cable to DC

Cable inside Fuser Assembly

2 Fuser DC Cable (System

Board to Fuser)

The operation of the fuser solenoid
can be observed by removing the
redrive assembly. Check for proper
mechanical operation of the solenoid
and associated hardware, link and so
on. If correct, check the resistanc e of
the solenoid. The resistance
measures between 5 ohms and 10
ohms. If incorrect, replace the
solenoid assembly. Check continuity
of the fuser solenoid cable to DC
autoconnect connector. If incorrect,
replace the cable.

Check for continuity of the DC fuser
cable that is attached between J4 on
the system board and the DC
autocount on the fuse r assembly. If the
cable does not measure continuity,
replace the cable. If the cable
measures continuity, replace the
system board.

Input Sensor Service Check

Service Tip: Run the Base Sensor Test. Check the input sensor for
proper operation. The display changes from open to closed as the
sensor flag is manually moved in and out of the sensor.

2-68 Service Manual

FRU Action

1 Input Sensor Flag Check the input sensor flag for

2 System Board Check for approximately +5 V dc at

3 Input Sensor Cable Check the continuity of the input

damage and proper operation. If a
problem is found, repair as
necessary.

J25-10 on the system board. If
incorrect, replace the system board.

sensor cable section of the front
wiring harness. If incorrect, replace
the harness. If correct, replace the
input sensor assembly.

Input Tray(s) Option Service Check

250 Sheet and 500 Sheet Trays

Service Tip: Try all the other input paper sources to make sure they
are properly feeding paper.

For 990 Error Code- Service Tray X, X= displays the number of the
tray that has a problem or needs service.

FRU Action

1 Tray X option System Board

or Compensator Assembly
or Autoconnect Cable

Check the autoconect cables and
connectors f or any sig ns of damag e.
Replace if necessary. Check the
cables for co ntinuity. If incorrect,
replace the compensator assembly
cable. If the cables, connectors and
connections are good, replace the
FRUs in the following order:

auto compensator assembly option
system board

Diagnostic Information 2-69

24X Paper Jam message displays, paper jammed over the Pass
Thru Sensor . (The prin ter displa y s the value of X for the paper tr a y
where the error occurs. Example: 241 is a Paper Jam Tray 1)

FRU Action

1 Pass Thru Sensor and Flag

Assembly

2 Power Takeoff Shaft and

Spring, Bevel Gear,
Feedroll Gear, Drive Roll
Assembly, Wear Plate,
Drive Shaft Bearings and
Skewed Backup Roller

The tray x option system board did
not detect a piece o f pape r a ctuating
the pass thru sensor. Remove any
jammed sheets of paper from the
printer and check the pass thru
sensor and flag for proper operation
by running the appropriate Tray
Sensor Test from the diagnostics
menu. If the test fails, check the
sensor for co rrect installati on and the
flag for proper operation. Also check
the sensor cable to make sure it is
correctly connected to the option
system board. If incorr ect, replace
the tray x option pass thru sensor
assembly.

Check these parts for signs of
broken or damaged parts,
contamination on the drive rollers or
wear plate and wear or damage to
the drive shaft bearings. Check the
drive roll assembly and skewed
backup roller for signs of wear, slick
spots, material buildup, and oil or
grease on the rollers. Also check for
proper operation of the paper
aligning assembly. Repair or replace
parts as necessary.

2-70 Service Manual

Tray X Low message displays when Tray X is full or has adequate
paper in the tray.

FRU Action

1 Paper Low Sensor

Assembly
Paper Low Sensor Flag
Tray X Option System
Board

Run the Tray X Sensor Test and
check the sensor for proper
operation. If incorrect, check the
following:

Paper low sensor flag for smooth
and correct operation.

Paper low sensor for correct
installation on the au to compen sat or
housing.

Paper low sensor cable for signs of
cuts, pinched wiring or other
damage especially at connector J5
on the system board.

If no problem is found, replace the
paper low sensor assembly. If this
does not correct the problem,
replace the option system board.

Tray X Empty message displays when Tray X has paper in the tray.

FRU Action

1 Paper Out Sensor Flag Check the paper out sensor flag for
2 Paper Out Sensor (On

Option System Board)

correct operation and installation. If
correct, replace the option system
board. (The paper out sensor is
mounted on the system board).

Diagnostic Information 2-71

Printer does not recognize Tray X is installed.

FRU Action

1 Autoconect Cables

Tray X System Board

Check the autoconnect from the
printer or option above tray x. Check
for signs of cuts, pinch ed wiring or
damage to the contacts in the
connector. Check the autoconnect
cable(s) for correct installa tio n at the
tray x system boa rd. If correct, chec k
the continuity of the autoconnect
cable(s). If co rrect, r eplac e the t ray x
system board. If incorr ect, replace
the cable.

Paper from Tray X does not reach the Pass Thru Sensor.

Service Tip: Check the media in tray x to make sure it is within
specifications. Some types of labels, foil material and slick papers
can cause misfeeds and slippage of the rollers.

FRU Action

1 Auto compensator

Assembly

Check the auto compensator pick
arm rollers for any sign of glazing,
toner or other buildup. Clean or
replace as necessary.

High-Capacity Feeder Input Tray Service Check

Note: Voltage measurements in the high-capacity feeder input tray

service checks must be made with the high-capacity feeder attached
to the base printer to obtain accurate results.

Service Tip: Be sure the paper size switch is set to the correct paper
size setting and the rear paper guides are in the correct locations for
the size of paper installed in the high-capacity feeder tray.

Service Tip: Check the other paper sources to be sure they are
operating correctly.

2-72 Service Manual

The base printer indicates a dead machine condition when the
high capacity input tray is installed.

FRU Action

1 AC Line Cord

AC Jumper (HCIT to
Printer)
AC input and Output
Receptacles
AC Wiring Harness

If the base printer works normally
using the AC line cord from the AC
wall outlet and does not work when
using the AC jumper from the HCIT,
check the AC jumper cord. If
defective, replace the cord. If not
defective, check the AC input and
output receptacles and wiring
harness in the HCIT. Repair or
replace the recep tac le s o r AC wiring
harness as required.

NOTE: Mak e s ure the grou nd w ire is
installed correctly from the A C wiring
harness to the frame of the HCIT
and the nut and lock washer are
tightened.

Diagnostic Information 2-73