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5058-030 Step Check 7 Check the LED printhead assembly for proper installation. Install the LED printhead assembly properly, and perform a print test. Go to "PRINT TESTS" on page 3-22. Does the problem remain? 8 Check the LED printhead. Replace the LED printhead. Go to "LED printhead removal" on page 4-96. Does the problem remain? 9 Check the upper printer engine PCBA for proper connectivity. Disconnect and reconnect all appropriate cables. Replace the upper printer engine PCBA. Go to "Upper printer engine PCBA removal" on page 4-181. Perform a print test. Go to "PRINT TESTS" on page 3-22. Does the problem remain? Spots Leading edge Yes Go to step 8. No Problem resolved Go to step 9. Problem resolved Problem solved. Replace the RIP PCBA. Go to "RIP PCBA removal" on page 4-144. Previous Next Go Back Trailing edge Step Check 1 Check the media condition. Load new, dry, recommended media. Reprint the defective image. Does the problem remain? 2 Check the media transfer route. Is the media route free of contamination or debris? Yes Go to step 2. Go to step 3. No Problem resolved Remove debris or contamination. Diagnostic information 2-227

Section	Page
Table of contents	4
Notices and safety information	23
Printhead LED notice	23
printhead LED-Hinweis	23
Avis relatif à l’utilisation de printhead LED	23
Avvertenze sui prodotti printhead LED	23
Avisos sobre el láser	23
Aviso sobre o printhead LED	24
printhead LEDinformatie	24
printhead LEDmeddelelse	24
printhead LEDilmoitus	24
printhead LED-notis	24
printhead LED-melding	24
Aviso de láser	25
Consignes de sécurité	27
Norme di sicurezza	27
Sicherheitshinweise	28
Pautas de Seguridad	28
Informações de Segurança	28
Informació de Seguretat	29
Preface	30
Navigation buttons	30
1. General information	33
Model	33
Options and features	33
Printer specifications	34
Electronics	34
SFP	34
Connectivity (network support)	35
Operating modes	35
Data streams	36
Dimensions	36
Clearances	36
Environment specifications	37
Media handling	38
Input and output sources	38
Media input size specifications	38
Media input type specifications	39
Media guidelines	43
Tools required for service	46
Acronyms	47
2. Diagnostic information	49
Start	49
POR (Power-On Reset) sequence	50
Error codes and messages	51
User status and attendance messages	51
Paper jam error codes	59
1xx service error codes	60
2xx service error codes	68
3xx service errors	72
4xx service error codes	76
8xx service error codes	79
9xx service error codes	79
Service checks	82
900.xx System software error	82
111.01 LED printhead (K) failure	85
111.02-111.04 LED printhead (K) signal failure	85
112.01 LED printhead (C) failure	86
112.02-112.04 LED printhead (C) signal failure	86
113.01 LED printhead (M) failure	86
113.02-113.04 LED printhead signal failure (M)	87
114.01 LED printhead failure (Y)	87
114.02-114.04 LED printhead (Y) signal failure	88
115.01 Multiple LED printhead power supply failure	88
115.02 Single LED printhead power failure	89
115.03 Multiple LED printhead download failure	89
115.04 Single LED printhead download failure	90
115.05 Multiple LED printhead mismatch failure	90
115.06 Single LED printhead mismatch failure	91
115.07 Multiple LED printhead read failure	91
115.08 Single LED printhead read failure	91
115.09 Multiple LED printhead write failure	92
115.10 Single LED printhead write failure	92
115.11 Multiple LED printhead communication failure	93
115.12 Single LED printhead communication failure	94
115.13 Multiple LED printhead clock failure	94
115.14 Single LED printhead clock failure	95
115.15 Tray module logic failure	95
120.01 Fuser motor failure	96
120.02 Fuser pressure roll retract motor failure	97
121.01 Encoder pulse failure	97
121.02 Encoder pulse failure	98
121.03 Heat belt (center) disconnection error	98
121.04 Heat belt (center) overheat error	98
121.05 Heat belt (rear) disconnection error	99
121.06 Heat belt (rear) overheat error	99
121.07 Heat belt (center) temperature increase failure	100
121.08 Heat belt (rear) temperature increase failure	100
121.09 Fuser temperature lag error	100
121.10 Heat belt rotation failure	101
121.11 Fuser temperature recovery failure	101
121.12 Incorrect fuser	101
121.13 Fuser thermostat failure	102
126.01 Fuser driver interface failure	102
126.02 Fuser driver to upper engine PCBA interface failure	102
126.03 Fuser driver communication failure	103
126.04 Fuser driver freeze failure	103
126.05 Fuser driver high voltage error	104
126.06 Fuser driver low voltage error	104
126.07 Fuser driver surge failure	104
126.08 IGBT high temperature error	104
126.09 IGBT temperature sensor failure	105
126.12 Input low current error	105
132.01 ATC sensor (K) failure	106
132.02 ATC sensor (Y) failure	107
132.03 ATC sensor (M) failure	109
132.04 ATC sensor (C) failure	110
137.01 Upper printer engine PCBA communication error	111
140.01 Registration drive motor failure	112
141.01 Drum drive motor (K) failure	112
141.02 Drum drive motor (Y/M/C) failure	113
151.01 Transfer belt motor failure	114
151.02 First transfer contact/retract failure	114
151.03 Second transfer contact/retract failure	115
154.01 Developer (Y/M/C) motor failure	116
155.01 Toner dispense motor (K) failure	117
156.01 Toner dispense motor (C) failure	118
157.01 Toner dispense motor (M) failure	118
158.01 Toner dispense motor (Y) failure	119
171.02 Fuser cooling fan failure	120
172.01 Front upper cooling fan failure	121
173.01 LVPS sub cooling fan failure	121
174.01 Charge roll HVPS cooling fan failure	121
175.01 Front right cooling fan failure	122
175.03 PC/developer drive motor cooling fan failure	122
175.04 Front left cooling fan failure	122
175.05 Suction fan failure	123
175.06 Center exhaust fan failure	123
175.07 Fuser driver PCBA cooling fan failure	123
175.08 Upper exhaust cooling fan failure	124
191.01 Lower engine PCBA detect failure	124
191.02–191.05 Upper engine PCBA fuse blown	124
191.06 Lower engine PCBA fuse 2 blown	125
191.07 Lower engine PCBA fuse 3 blown	125
191.08 Lower engine PCBA fuse 4 blown	126
191.09 Upper engine PCBA fuse 5 blown	126
191.10 Lower engine PCBA fuse 6 blown	126
191.11 Lower engine PCBA fuse 7 blown	127
191.12 Lower engine PCBA fuse 8 blown	127
191.13 Lower engine PCBA fuse 9 blown	128
191.14 Lower engine PCBA fuse 10 blown	128
191.15 Lower engine PCBA fuse 11 blown	128
191.16 Lower engine PCBA fuse 12 blown	129
191.17 Lower engine PCBA fuse 13 blown	129
191.18 Upper engine PCBA data failure	129
191.19 Upper engine PCBA access failure	130
191.20 Upper engine PCBA buffer failure	130
191.23 Lower engine PCBA fuse 14 blown	130
191.24 Lower engine PCBA fuse 15 blown	131
191.25 Lower engine PCBA fuse 16 blown	131
200.01 Sensor (registration) static jam	131
200.03 Sensor (registration) late jam (feeding from the tray)	132
200.03 Sensor (registration) late jam (feeding from the MPF)	134
200.05/200.55 Sensor (registration) lag jam	135
200.53 Sensor (registration) late jam (80K interval exceeded for feed rollers)	137
200.55 Sensor (registration) lag jam	140
201.01 Sensor (media on belt) static jam	140
201.03 Sensor (media on belt) late jam	141
202.01 Sensor (fuser exit) static jam	143
202.03 Exit Sensor 1 Late Jam	144
202.04/202.05 Sensor (fuser exit) lag jam	147
202.05 Sensor (fuser exit) lag jam	148
203.01 Sensor (upper redrive) static jam	149
203.03 Sensor (upper redrive) late jam	149
203.05 Sensor (upper redrive) lag jam	151
230.01 Sensor (duplex wait) static jam	153
231.03 Sensor (duplex wait) late jam	153
242.01 Sensor (tray 2 feed out) static jam	157
242.03/242.06 Sensor (tray 2 feed out) late jam	158
242.06 Sensor (tray 2 feed out) late jam	159
242.56 Sensor (tray 2 feed out) late jam (80K interval exceeded for feed rolls)	159
243.01 Sensor (tray 3 feed out) static jam	160
243.03/243.06 Sensor (tray 3 feed out) late jam	161
243.06 Sensor (tray 3 feed out) late jam	163
243.56 Sensor (tray 3 feed out) late jam (80K interval exceeded for feed rolls)	163
244.01 Sensor (tray 4 feed out) static jam	164
244.06 Sensor (tray 4 feed out) late jam	165
244.56 Sensor (tray 4 feed out) late jam (80K interval exceeded for feed rolls)	167
245.01 Sensor (tray 5 feed out) static jam	169
245.03 Sensor (tray 5 feed out) late jam	170
245.06 Sensor (tray 5 feed out) lag jam	171
245.56 Sensor (tray 5 feed out) late jam (80K interval exceeded for feed rolls)	172
245.56 Sensor (HCF feed out) late jam	174
250.05 Sensor (MPF feed out) lag jam	175
250.06 Sensor (MPF feed out) late jam	179
250.56 Sensor (MPF feed out) late jam (80K interval exceeded for feed rolls)	180
381.01 Sensor (front tamper HP) late jam	181
381.02 Sensor (front tamper HP) lag jam	182
381.03 Sensor (rear tamper HP) late jam	184
381.04 Sensor (rear tamper HP) lag jam	185
381.05 Sensor (stapler carriage HP) late jam	186
381.07 Stapler unit failure	188
381.08 Sensor (media eject clamp HP late jam	188
381.09 Sensor (media eject clamp HP) lag jam	189
381.10 Sensor (media eject shaft HP) late jam	190
381.11 Sensor (media eject shaft HP) lag jam	192
381.12 Stacker bin failure	193
381.13 Sensor (stacker bin upper limit) error	195
381.14 Sensor (stacker bin no media) error	197
381.15 Sensor (punch side reg 1/2) lag jam	199
381.16 Sensor (punch cam HP) late jam	201
381.17 Sensor (punch cam HP) lag jam	202
381.18 Sensor (punch carriage shift HP) late jam	203
381.19 Sensor (punch carriage shift HP) lag jam	204
381.26 Sensor (decurler cam HP) late jam	205
381.27 Sensor (decurler cam HP) lag jam	206
381.30 Sensor (booklet front tamper HP) late jam	207
381.31 Sensor (booklet front tamper HP) lag jam	209
381.32 Sensor (booklet end guide HP) lag jam	210
381.33 Sensor (booklet rear tamper HP) late jam	212
381.34 Sensor (booklet rear tamper HP) lag jam	213
381.35 Sensor (booklet knife folding) failure	215
381.36 Booklet unit fail	216
381.37 Sensor (booklet knife HP) late jam	217
381.38 Sensor (booklet knife HP) lag jam	219
381.39 Booklet Staple Fail	221
381.40 Sensor (booklet compiler media present) error	222
381.41 Communication error with booklet controller card assembly	223
401.01 Sensor (finisher media entrance) static jam	223
401.03 Sensor (bridge media entrance) late jam	224
401.05 Sensor (bridge media entrance) lag jam	225
402.01 Sensor (bridge media exit) static jam	226
402.03 Sensor (bridge media exit) late jam	228
481.01 Sensor (finisher media entrance) static jam	229
481.03 Sensor (finisher media entrance) late jam	230
482.01 Sensor (diverter gate) static jam A (to stacker bin)	230
482.01 Sensor (diverter gate) static jam B (to top bin)	231
482.03 Sensor (diverter gate) late jam	232
483.01 Sensor (buffer path) static jam	233
483.03 Sensor (buffer path) late jam	234
484.01 Sensor (compiler media present) static jam	236
485.01 Sensor (upper media exit) static jam	237
485.03 Sensor (upper media exit) late jam	238
485.05 Sensor (upper media exit) lag jam	239
486.01 Sensor (lower media exit) static jam	240
486.03 Sensor (lower media exit) late jam	241
486.05 Sensor (lower media exit) lag jam	242
487.05 Sensor (compiler media present) late jam	244
491.01 Sensor (booklet media entrance) static jam	246
491.03 Sensor (booklet media entrance) late jam	246
491.05 Sensor (booklet media entrance) lag jam	248
492.01 Sensor (booklet compiler media present) static jam	249
493.01 Sensor (booklet media exit) static jam	250
493.03 Sensor (booklet media exit) static jam	251
493.05 Sensor (booklet media exit) lag jam	252
849.00 Hard drive failure	253
910.02–910.07 Data communication error	254
939.00 RIP card assembly communication failure	254
940.02 Clock signal communication error	255
940.03 Controller communication failure	255
940.04 IM logic failure	255
951.xx RIP card assembly NVRAM failure	256
953.xx Operator panel assembly NVRAM failure	256
955.xx RIP card assembly NAND CRC failure	256
956.00 RIP card assembly processor failure	257
956.01 RIP card assembly processor over temperature failure	257
956.02 RIP card assembly cooling fan failure	257
956.03 RIP card assembly FPGA failure	258
980.04 Duplex controller card assembly communication failure	258
980.05 Engine flicker communication failure	259
957.01 BITZ1 initialize failure	259
957.02 BITZ2 initialize failure	259
995.00 Finisher NVM R/W failure	260
996.00 Finisher type failure	260
997.00 Duplex controller card assembly type failure	260
999.00 Finisher engine/RIP functional failure	261
Image quality troubleshooting	262
Printer-related troubleshooting	262
Image Quality	263
3. Diagnostic aids	289
User operator panel, menus and messages	289
Understanding the operator panel	289
Understanding the home screen	290
Menu map	291
Accessing service menus	292
Configuration Menu	293
Entering Configuration Menu	293
Available settings	293
Action for prompts	294
Automatic Alignment Adjust Calibration	294
Automatically Display Error Screens	295
Black Only Mode	295
Booklet Adjustments	295
Clear Custom Status	295
Color Trapping	295
Disk Encryption	295
Energy Conserve	296
Envelope Prompts	296
Erase all Information on Disk	296
Exit Tray 2	296
Factory Defaults	296
Font Sharpening	297
Jobs on Disk	297
Key Repeat Initial Delay	297
Key Repeat Rate	297
Panel Menus	298
Paper Prompts	298
PPDS Emulation	298
Print Quality Pages	298
REGISTRATION	298
Reports	299
Require Standby	299
Reset Maintenance Counter Value	299
Short-edge Printing	299
Size Sensing	300
Tray Insert Message Delay	300
UI Automation	300
USB Speed	301
Wipe All Settings	301
Diagnostics Menu	302
Entering Diagnostics Menus	302
Available tests	302
DEVICE TESTS	304
DUPLEX TESTS	304
EVENT LOG (Diagnostics Menu)	305
FINISHER TESTS	306
HARDWARE TESTS	306
INPUT TRAY TESTS	307
MOTOR TESTS	308
OUTPUT BIN TESTS	309
PRINT TESTS	310
PRINTER SETUP	310
REPORTS	311
SENSOR TESTS	311
Service Engineer (SE) Menu	314
Print SE Menus	314
Paper jams	315
Avoiding jams	315
Understanding jam numbers and locations	316
Security Reset Jumper	339
Printer theory of operations	340
Print engine theory	340
Paper path theory	348
Color theory	355
Finisher theory of operations	359
Media transport	359
Functions of sensors along the media path	367
Punch unit	369
Compiler unit assembly	372
Stapler	377
Booklet Operation	381
Functions of booklet sensors and motors	382
Booklet media bin	384
Stacker media bin	384
Booklet tray	388
Power supply and interlock	389
TTM theory of operations	391
Media transport	392
Media tray assembly	392
TTM media feed units	394
Main components	395
3TM theory of operations	398
Media transport	399
Media tray assembly	399
3TM media feed units	400
Main components	401
1TM theory of operations	404
Media transport	405
Media tray assembly	405
1TM media feed units	406
Main components	407
High capacity feeder theory of operations	410
Media feeding	410
HCF media feed unit assembly operation	411
HCF media transport roll assembly operation	413
HCF media feed unit assembly sensor/motor functions	413
Status monitoring	414
4. Repair information	421
Handling ESD-sensitive parts	421
Turning the printer off	421
Removal procedures	422
Cover removal procedures	423
Inner cover removal	423
Internal rear cover removal	425
Left rear lower cover removal	426
Left upper cover removal	426
MPF top cover removal	427
Operator panel front cover (SFP)	428
Operator panel top cover (SFP) removal	428
Printer front door removal	430
Printer right cover removal	431
Printer top cover removal	432
Rear lower cover removal	434
Rear upper cover removal	436
Top rear cover (SFP) removal	437
Print engine removal procedures	440
1st transfer conductor housing removal	440
1st transfer retract clutch assembly removal	442
2nd transfer roller removal	444
ATC sensor PCB bracket removal	445
ATC sensor PCB removal	446
Bridge PCBA removal	448
C toner auger removal	451
Charge roll HVPS cooling fan removal	454
Charge roll HVPS PCBA removal	456
CMYK toner dispense auger assembly removal	457
Controller cooling fan removal	460
Developer carrier removal and replacement	462
Developer housing (C) removal	465
Developer housing (K) removal	471
Developer housing (M) removal	476
Developer housing (Y) removal	482
Developer housing rear plunger removal	487
Developer HVPS PCBA removal	489
Feeder slide guide removal	491
Front left cooling fan removal	492
Front right cooling fan removal	494
Front upper cooling fan removal	496
Fuser assembly removal	498
Fuser cooling fan removal	498
Fuser driver PCBA cooling fan removal	501
Fuser driver PCBA removal	504
Fuser pressure roll retract motor removal	508
Fuser/lower redrive/1st BTR retract motor removal	511
Inner plate removal	512
K toner auger removal	514
LED printhead removal	516
Lower engine PCBA removal	518
Lower redrive shift motor assembly removal	519
LVPS front fan guide removal	525
LVPS PCBA removal	526
LVPS sub cooling fan removal	529
M toner auger removal	530
Main power GFI interface removal	533
Main power switch removal	535
Media feed lift motor removal	535
Media out actuator removal	537
Media size switch PCB removal	537
Media transport/MPF drive motor removal	538
MPF roller removal	541
MPF tray feeder removal	542
Operator panel assembly (SFP) removal	543
Operator panel PCBA (SFP) removal	544
Operator panel speaker (SFP) removal	546
PC smart chip socket (C, M, Y, K) removal	548
PC/developer drive motor cooling fan removal	550
PC/developer drive motor removal	552
Pick roller removal	555
Printer left duplex door assembly removal	556
Printer media turn guide removal	557
Printer tray 1 feeder removal	558
Printhead retract door removal	559
Registration drive motor removal	561
Registration/transport roller assembly removal	563
RIP PCBA removal	564
Sensor (image calibration) removal	567
Sensor (media level) removal	568
Sensor (media on belt) removal	569
Sensor (media out) removal	570
Sensor (printer left duplex door interlock) removal	572
Sensor (printer left front door interlock) removal	574
Sensor (printer right front door interlock) removal	576
Sensor (tray 1 pre-feed) removal	577
Sub LVPS PCBA removal	578
Suction fan removal	581
Suction filter removal	583
Toner dispense motor removal	583
Toner smart chip PCB removal	586
Touch screen (SFP) removal	587
Transfer belt assembly removal	588
Transfer belt cleaner removal	592
Transfer belt lever removal	594
Transfer roll HVPS PCBA removal	595
Upper exhaust cooling fan removal	598
Upper printer engine PCBA removal	601
Upper redrive assembly removal	603
Waste toner agitator motor removal	605
Waste toner auger chute removal	608
Waste toner sensor guide removal	610
Waste toner shaft gate removal	611
Y toner auger removal	613
Tray module removal procedures	616
3TM left door removal	616
Sensor (media level) removal	617
Sensor (media out) removal	617
Sensor (media present) removal	618
Sensor (tray module feedout) removal	620
Sensor (tray module left door interlock) removal	621
Sensor (TTM media size) removal	623
Sensor (TTM tray 3 feedout) removal	623
Sensor (TTM tray 4 feedout) removal	624
Tray module bottom cover removal	625
Tray module controller PCBA removal	626
Tray module left cover removal	626
Tray module lower transport motor removal	627
Tray module media feeder removal	628
Tray module rear cover removal	631
Tray module right cover removal	631
Tray module top cover removal	632
Tray module transport rollers removal	633
Tray module tray 2 media turn guide removal	634
Tray module upper transport motor removal	634
TTM left door removal	635
TTM lower transport motor removal	636
TTM tray 3 feeder removal	637
TTM tray 3 media tray removal	640
TTM tray 3 media turn guide removal	641
TTM tray 4 media feeder removal	641
TTM tray 4 media transport removal	644
TTM tray 4 media tray removal	645