{Adjust/Replace}{Production}{KodakServiceSup ort}

Codonics Service Manual

for the NP/EP 1600 Series Imagers

Part Number 905-028-001.02

Important
Use qualified personnel to service this equipment.
This equipment includes parts and assemblies sensitive to damage from electrostatic
discharge. Use caution to prevent damage during all service procedures.

Table of Contents Section

Engine Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Adjustments & Replacements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Controller Board Prom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service Notes for the NP-1660 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electronic Tray Assembly Troubleshooting and Replacements . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hyperterminal Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Part Number 907-059-001.01

Service Manual Addendum History

Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rev
7/17/03. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01
1/21/04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02
 22{Diagnostics}{Production}{KodakServiceSup ort}

ENGINE DIAGNOSTICS
for the Codonics NP/EP Series Imagers

Important
Use qualified personnel to service this equipment.
 .This equipment includes parts and assemblies sensitive to damage from electrostatic
discharge. Use caution to prevent damage during all service procedures.

Table of Contents
Description Page

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Purpose and Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
EXTERNAL and ENGINE MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Preliminary Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
THERMAL HEAD - Temperature Regulation. . . . . . . . . . . . . . . . . . . . . . . . 1-6
NP1660,EP1660,NP1600, and EP1650 Engine Controller boards . . . . . . . . 1-7
CONTROLLER BOARD - Test points and potentionmeter placements . . . 1-8
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
PRINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
PICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Mechanical Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Rewind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Eject Timing - No Lamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Eject Timing - With Lamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
RECEIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Yellow Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Magenta Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Cyan Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Black Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Lamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Eject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
LCD DISPLAY - Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Preparing to Use the Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Entering the Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Diagnostic Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
[DIAG: PANEL TEST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
[DIAG: ENG VER #S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
[DIAG: PRN USAGE] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
[DIAG: FAIL HIST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
[DIAG: RECEIVER] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
[DIAG: HEAD TEMP] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
[DIAG: HEAD TEST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
[DIAG: DONOR TEST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
[DIAG: PINCH TEST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
[DIAG: MOTORS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
[DIAG: OPTIONS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
[DIAG: CTRLR TEST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52
Voltage Verification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53
Preliminary Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53
POWER INDICATOR LED Not Illuminated . . . . . . . . . . . . . . . . . . . . . . . . 1-54

1-2
 No Printed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56
DONOR TRANSPORT and SENSING SYSTEM . . . . . . . . . . . . . . . . . . . . . 1-57
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57
Installation: DONOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
Donor Sensing Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62
Voltage Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63
Donor Sensing Preliminary Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64
Donor Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-65
DONOR PATCH SENSING LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-66
DONOR PATCH SENSING DETECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 1-67
DONOR TYPE BAR CODE SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68
PICKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
Installation: RECEIVER - Paper, Transparency, and 8x10 Film . . . . . . . . . . . 1-73
Paper Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-74
Picking Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-76
RECEIVER SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77
Printable Area on Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78
Image Placement at Lead Edge Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-79
Image Placement Left Border Right Side of Printer . . . . . . . . . . . . . . . . . . . . . . 1-80
MEDIA TRAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-83
Preliminary Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87
TRAY: Malfunctions - Error Codes 502 and 503 . . . . . . . . . . . . . . . . . . . . . 1-88
Media Sensing Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90
PICKING: Malfunctions - Error Codes 501 and 502 . . . . . . . . . . . . . . . . . . . . . 1-91
CONTROLLER BOARD ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94
Preliminary Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94
Error Codes 600, 601, 602, and 603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-95
Error Codes 608, 609, 60A, 60C, and 719 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96
Error Code 610 - No Display Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-97
Error Code 618 and 60B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-98
Error Codes 718 and 719 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-99
Error Codes 720 and 721 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-100
Error Codes 738 and 739 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101
Error Code 740 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-102
Error Codes 741 and 742 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-103
Error Codes 748, 749, 74A, 74B, 74C, 74D . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104
Error Code 757 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
Error Codes 760-773, 76E, 76F, 76A, 76B, 76C, 76D . . . . . . . . . . . . . . . . . . . 1-106
Error Codes 800 - 857 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-107
Error Codes 900-930, 90B, 91B, 92B, 93B, 94B, 750-756 . . . . . . . . . . . . . . . . 1-108
Error Code 710, 711 and 712 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109
Error Code BAD MEM or NONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110
THERMAL HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-112
Preliminary Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-112
THERMAL HEAD LIFT MOTOR - Error Codes 700, 701, 702, and 703 . . . . 1-113
THERMAL HEAD LIFT SENSOR - Error Codes 700, 701, 702, and 703 . . . 1-114
Error Code 730 - Cooling Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115
Error Code 733 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-116
Error Code 719 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-117
1-3
 [INIT ERROR] - Error Code 722 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-118
WATCH CYCLE.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-119
Preliminary Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-120
LCD Messages Watch Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121
TEST PRINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-122
Image Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-123
Artifact Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-123
Lead Edge/Trail Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-123
Lead Edge Fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-123
Side Edge Fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-124
Stretch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-124
Smiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-125
Comb Lines, Wit Code= 1238 - DONOR . . . . . . . . . . . . . . . . . . . . . . . . . 1-126
Comb Lines on each PrintTHERMAL HEAD . . . . . . . . . . . . . . . . . . . . . . 1-126
Paper Fold at Trail Edge/Paper Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-127
Border Size Not Correct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-128
Lead Edge Fold, Side Edge Fold, Stretch - After Normal to High Usage . 1-129
Lead Edge Fold, Side Edge Fold, Stretch - New PRINTER . . . . . . . . . . . . . . . 1-130
Stretch, Lead Edge Fold, Side Edge Fold - New THERMAL HEAD . . . . . . . . 1-131
Image Quality Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-132
Image Quality Troubleshooting Chart - DONOR/RECEIVER . . . . . . . . . . . . . 1-134

Part Number 907-060-001.01

1-4
Section 1: General Information
Purpose and Overview
The service diagnostics are located on the CONTROLLER BOARD. External communication devices are not
necessary to use the diagnostics. The diagnostics allow the service technician to operate the PRINTER, retrieve
service information, and do tests to diagnose malfunctions in the PRINTER only.
Diagnostics can be accessed from the ENGINE/READY, ERROR and IDLE modes after the main power is “ON”,
the PRINTER is energized, and is not processing or printing any documents. The PRINTER cannot receive
documents in the diagnostic mode.

FRONT PANEL

Caution
Do not use a sharp object to press the BUTTONS on the DISPLAY PANEL. This could cause malfunctions.
Use the FRONT PANEL to access all diagnostic menus. The FRONT PANEL includes:
• POWER INDICATOR
• FAULT INDICATOR
• LCD (LIQUID CRYSTAL DISPLAY)
• STATUS BUTTON
• CANCEL BUTTON
• SET-UP/ONLINE BUTTONS

Test Prints
There are 2 types of test prints, user test print, and a diagnostic test print. Test prints can only be activated when the
LCD DISPLAY reads “READY”. The user test print can only be accessed when the PRINTER is in the EXTERNAL
MODE. The diagnostic test print can only be accessed in the ENGINE MODE.

EXTERNAL and ENGINE MODES

The EXTERNAL MODE is the normal user mode of the PRINTER. The EXTERNAL MODE is controlled by the
EXTERNAL/ENGINE MODE SWITCH located on the CONTROLLER BOARD.
The ENGINE MODE is used during ENGINE DIAGNOSITCS. The ENGINE MODE is controlled by the
EXTERNAL/ENGINE MODE SWITCH located on the CONTROLLER BOARD.
Note
By selecting only the ENGINE MODE, the ENGINE is isolated for troubleshooting malfunctions

Preliminary Setup
The table below lists the preliminary set-up conditions necessary to operate each diagnostic test. For example,
“TRAY INSTALLED = YES” indicates the TRAY must be installed.
TRAY INSTALLED YES/NO
DONOR INSTALLED YES/NO
RECEIVER INSTALLED YES/NO
RECEIVER TYPE REFLECTIVE/TRANSPARENCY
DOOR OPEN YES/NO
POWER ON YES
SPECIAL FUNCTIONS YES/NO
SPECIAL ACTIONS

1- 5
THERMAL HEAD - Temperature Regulation

NORMAL FIXED

HOT - 2 MIN TIMEOUT

OPERATION ENABLE WIDTH

DISABLE
PRINTING
55

54 110

~
~ ~
~
ENABLE
PRINTING ~
~
106

FANS ON
DISABLE

HOT - 3 MIN TIMEOUT

PRINTING ADC
47 OUTPUT

HEATER
OFF
46 76
TEMP

NORMAL
C
45 72

ENABLE FANS OFF

PRINTING ENABLE
WARM

COOL
44 PRINTING 69
HEATER ON

43 65
DISABLE
PRINTING

42
COLD - 7 MIN TIMEOUT

41

HEATER OFF
FANS ON
40 56

FANS ON COOLING - 5 MIN TIMEOUT

39 52

HEATER
38 OFF 49
FANS OFF
NORMAL

HEATING - 5 MIN TIMEOUT

37

ENABLE
PRINTING
COOL

36 43
HEATER ON
COLD - 5 MIN TIMEOUT

35 40
DISABLE
PRINTING HEATER ON
FANS OFF

TEMPERATURE REGULATION A087_9004EC

1- 6
Above NP1660 and EP1660 Engine Controller Board with the SAB Board installed.

Below NP1600, EP1650, and EP1660 Non-Elmer Style IOCB Engine Controller Board.

1- 7
 C ONTR OLLE R BOAR D
reference only for test points
and potentioneter placements
Headlift S ensor/
Motors Bar C ode
Fan
Head P3
P1 P2
1
34 P5 1

4
TP 1
1 6 1 10

P6
1

TP 2 TP 4

Door
1 1 1 6

1
P7
R 16
4

6
E VE N ODD
Head F an Drive

R 23 6 6 XU9 P HM3 P HM3

R 21 TP 5

P8
TP 3

P icker
TP 14 1

1
TP 7 TP 8

20
1 6

P 10
6 P16

R oller
TP 6
CONTROLLER BOARD - Components

T rip Urge

1 1
1
U19 U20 R 35

1
TP 9

6 6
1 U42

5
7 Htr/Fuse
E MMULATION
1

TP 10

P 15
C ONNE C TOR

P9
U46

Dis play

T ray C
6 U45
E DGE BLUE P4

1 8
GR N
TP 11
Heater/F us e

1
8

P 11
R 63 R 66 R 64 TP 12

T ray A/B
1

1
34 6 Parallel I/F 1 S1
8 Power 5
R 70 P12
THR E S H 4 1 P13 E XTE R NAL E NGINE
6
50
S 1 ALLOWS Y OU TO R UN
DIAG NOS TIC S IN E NG INE
MODE .

A087_2004E C

1- 8
Section 2: Sequence of Operation
Cycles
PRINT

P rint
load engage Line T otal T ime (s ec)
T hermal Head T ime P lane Lines per P lane
(ms )
1500 2680 2890 3000 3600
P inch C los ed 1s t 27.90 47.60 51.10 52.95 62.95
16.7 2nd, 3rd
28.75 48.45 51.95 53.80 63.80
1s t 13.75 23.20 24.85 25.75 30.55
8 2nd, 3rd
P icker R etracted 14.60 24.05 25.70 26.60 31.40
1s t 8.95 14.85 15.90 16.45 19.45
5 2nd, 3rd 9.80 15.70 16.75 17.30 20.30
Lam 9.30 15.20 16.25 16.80 19.80
forward
Donor T ake Up
rewind
Donor S upply

B rake Off modulation

completed
forward - print s peed
S tepper
s trip or s tep
backlas h removed,
margin completed
donor ironed

T otal T ime

T1 T2 T3 T4

T 1 (s ec) Line T 3 (s ec)

B efore firs t T ime (sTec)
2
Lines per P lane
T4
(s ec)
plane 0.70 (ms )
1500 2680 2890 3000 3600
B efore 2nd, 16.7 0.50 25.05 44.75 48.25 50.10 60.10 1.65
3rd, or Lamina- 1.55 8 0.25 12.00 21.45 23.10 24.00 28.80 0.80
tion planes
5 0.20 7.50 13.40 14.45 15.00 18.00 0.55
Lam 0.15 7.55 13.45 14.50 15.05 18.05 0.05
A087_9023DC

1- 9
PICK

Time (seconds)

0 1 2 3 4 5 6 7 8 9
retract load
Thermal Head
open closed
Pinch
rcvr at
retract lead edge
Picker pick retract

Urge Not Available donor edge

delay sensed
forward expired pulse rewind
Donor Take Up
delay When bars are
forward rewind split - Upper
Donor Supply (lower) bar =
delay
on lead edge timing when
Brake cleared donor protect
delay ramp
rewind,
down slow rewind, did (did not)
forward, pick speed speed max speed + ramps occur
Stepper
delay
rcvr ready
to print
5.00 0.75 0.65

0.70 4.10 3.45

8.25

0.70 2.00 1.65 3.30

7.65

A087_9019DC

1- 10
 Time (seconds)
PICK

0 1 2 3 4 5 6 7 8 9 10 11 12
retract load
Thermal Head
open closed
Pinch
rcvr at
forward urge retract
Picker
delay When bars are
Urge
split - Upper
delay forward pulse rewind (lower) bar =
onor Take Up timing when
donor edge donor protect
delay forward rewind sensed
Donor Supply did (did not)
take place
delay on rcvr ready
Brake to print
delay forward, pick speed
Stepper

rcvr at
lead edge

5.00

0.70 1.15 0.40 0.75

0.25 1.50 2.65 0.80 2.45 1.0

2.40 2.65 0.80 2.45 1.0

2.05

10.5

11.4

A087_9022EC

1- 11
Mechanical Initialization

Mechanical Initialization with a R eceiver At The Urge S ensor And Not At The Lead E dge S ensor
Time (seconds)
0 3 6 9 12 2 15 18 1 24

engaged at load retracted

T hermal Head

open
P inch

urge delay expired rcvr at lead edge

P icker The first 5 seconds
of the cycle are the
same as the previous
full mech init with-
Urge
out lamination in
progress. Add bar code read after power
forward up or advance to firs t color after
Donor T ake Up P icker retracted cancel during printing. S ee previous
P inch clos ed diagrams for definition
Donor s lack take rewind forward rewind
up completed
Donor S upply

B rake
forward- strip complete
strip speed (delay expired)
S tepper

forward- forward-
pick s peed max s peed

0.80
5.00 1.35 1.65 1.50 1.35 4.55

6.30 5.00

22.85

A087_9020DC

1- 12
Rewind

R ewind
engage load
T hermal Head

P inch C los ed

P icker R etracted
next color previous color
s ens ed s ens ed

forward
Donor T ake Up
puls ed rewind
rewind
Donor S upply
rewind
B rake Off
rcvr ready
forward - maximum s peed to print
S tepper

T otal T ime

1.60 T1

T2

T 1 (s ec) T otal T ime (s ec)

Lines Donor Length (inches ) T 2 (s ec) Donor Length (inches )
7 12 14 7 12 14
1500 1.05 3.80 5.00 1.60 1.05 5.40 6.60
2680 - 1.65 2.75 2.85 - 4.45 4.45
2890 - 1.25 2.35 3.05 - 4.65 4.65
3000 - 1.05 2.15 3.20 - 4.80 4.80
3600 - - 1.05 3.85 - - 5.45

DC

1- 13
 E ject - No Lamination
T ime (s econds )

0 1 2 3 4 5 6 7 8 9 17 18
engage load-2 retract
T hermal Head
clos ed
delay open
P inch
rcvr out
of chute
P icker R etracted
Eject Timing - No Lamination

firs t color
forward forward s ens ed puls ed rewind
Donor T ake Up
rewind forward rewind
Donor S upply

B rake Off addition for 1500

rcvr line print on 2680
forward ejected line paper
S tepper

1.70 2.55 T1

0.45 5.00

3.45 1.05

T otal

T 1 (s ec) T otal T ime (s ec)

Lines Donor Length (inches ) Donor Length (inches )
7-WO/Lam 12-WO/Lam 14-WO/Lam 12-W/Lam 14-W/Lam 7-WO/Lam 12-WO/Lam 14-WO/Lam 12-W/Lam 14-W/Lam
1500 1.65 4.40 5.50 11.00 13.20 7.15 8.65 9.75 15.25 17.45
2680 - 2.15 3.35 8.75 11.05 - 7.15 7.60 13.00 15.30
2890 - 1.75 2.85 8.35 10.55 - 7.15 7.15 12.60 14.80
3000 - 1.65 2.75 8.25 10.45 - 7.15 7.15 12.50 14.70
3600 - - 1.65 - 9.35 - - 7.15 - 13.60

A087_9024E C

1- 14
Eject Timing - With Lamination
E ject - With Lamination
T ime (s econds )
0 1 2 3 4 75 6 98

engage load-2 load-2 retract

T hermal Head

clos ed open
delay
P inch

P icker R etracted
delay delay
expired expired -
donor and
receiver s eparated firs t color
without flas h s ens ed
rewind forward forward puls ed rewind
Donor T ake Up

rewind forward rewind

Donor S upply

on
B rake
rcvr
rewind forward ejected
S tepper

0.30
1.70 0.75 0.85 5.00

2.55 T1

2.20

8.60

Lines Donor Length T 1 (s ec)

(inches )
3600 14 1.55
3000 12 1.55
2890 12 1.75
2680 12 2.15
A087_9021DC

Overview
[1] The DONOR BRACKET BARCODE ASSEMBLY reads the DONOR BAR CODE.
[2] The PRINTER:
• receives a print command
• senses and verifies the type of TRAY
[3] The RECEIVER is moved into the PRINTER.
[4] A 4 pass process is used to print the image in 4 passes, yellow, magenta, cyan, and a laminant.
[5] After the laminant is completed, the print is complete.
[6] The print is ejected from the PRINTER.

1- 15
RECEIVER
[1] The PRINTER receives a print command.
[2] The DONOR TAKE-UP and the SUPPLY MOTORS energize. This causes the DONOR to pass the depleted
cyan from the previous print and advance to yellow. The DONOR TAKE-UP and SUPPLY MOTORS de-
energize. The DONOR BRACKET BAR CODE ASSEMBLY reads the DONOR BAR CODE.
[3] The HEAD POSITION MOTOR energizes, moving the THERMAL HEAD in the LOAD POSITION to allow
the DONOR and the RECEIVER to help in the process of RECEIVER LOADING. The HEAD POSITION
MOTOR de-energizes.
[4] The PICK MOTOR energizes, causing the RECEIVER to be picked into the paper path, the CHUTE.
[5] As the RECEIVER is being picked, the CAPSTAN MOTOR, the PLATEN BRAKE, and the DONOR TAKE-
UP and SUPPLY MOTORS are energized. The DONOR advances, allowing the RECEIVER to enter the NIP
and reach the LEAD EDGE SENSOR.
[6] The PINCH MOTOR energizes, PINCHING the RECEIVER in between the PINCH ROLLER and the
CAPSTAN TRACTION ROLLER.
[7] At this point, the PICK MOTOR, the CAPSTAN MOTOR, the PLATEN BRAKE, and the DONOR TAKE-UP
and SUPPLY MOTORS de-energize. The PICK MOTOR reverses to return the PICKER to its original position.
[8] The CAPSTAN MOTOR energizes in reverse at ≈ 5 times the print speed to position the RECEIVER for the
yellow transfer. The THERMAL HEAD reaches the operating temperature and the image data is obtained.
[9] The DONOR TAKE-UP and SUPPLY MOTORS are sent pulses in reverse to move the DONOR to the start of
the yellow patch.
[10] The CAPSTAN MOTOR and the DONOR TAKE-UP and SUPPLY MOTORS de-energize.

Yellow Transfer
[1] The THERMAL HEAD POSITION MOTOR energizes, the THERMAL HEAD moves into the ENGAGE
POSITION and de-energizes.
[2] The CAPSTAN MOTOR and the DONOR TAKE-UP and SUPPLY MOTORS are energized simultaneously.
[3] The CAPSTAN MOTOR moves in the forward direction to prevent GEAR TRAIN backlash and for correct
registration.
[4] The TAKE-UP MOTOR adjusts the tension of the DONOR during the print cycle.
[5] The DONOR SUPPLY MOTOR operates in reverse to cause a reduction of variability in brake slip friction.
[6] The yellow section of the image is printed.
[7] Once the transfer of image data is complete and the DONOR and RECEIVER are separated, the CAPSTAN
and DONOR MOTORS de-energize.
[8] The HEAD POSITION MOTOR energizes and moves the THERMAL HEAD back into the LOAD POSITION
and de-energizes.
[9] The CAPSTAN MOTOR energizes in reverse at ≈ 5 times the print speed to rewind the RECEIVER to the
correct position.
[10] At the same time, the CAPSTAN and DONOR MOTORS are energized to advance the DONOR to the magenta
patch. The rewind of the RECEIVER is complete and the DONOR is at the magenta patch.
[11] The CAPSTAN and the DONOR MOTORS de-energize.

1- 16
Magenta Transfer
[1] The THERMAL HEAD POSITION MOTOR energizes and the THERMAL HEAD moves into the ENGAGE
POSITION and de-energizes.
[2] The CAPSTAN MOTOR and the DONOR MOTORS are energized at the same time.
[3] The CAPSTAN MOTOR moves in the forward direction to remove the backlash of the GEAR TRAIN.
[4] The TAKE-UP MOTOR adjusts the tension of the DONOR during the print cycle.
[5] The DONOR SUPPLY MOTOR operates in reverse to cause a reduction of variability in brake slip friction.
[6] The magenta section of the image is printed.
[7] Once the transfer of image data is complete and the DONOR and the RECEIVER are separated, the CAPSTAN
and the DONOR MOTORS de-energize.
[8] The HEAD POSITION MOTOR energizes and moves the THERMAL HEAD back into the LOAD POSITION
and de-energizes.
[9] The CAPSTAN MOTOR energizes in reverse at ≈ 5 times the print speed to rewind the RECEIVER to the
correct position.
[10] Simultaneously, the CAPSTAN and DONOR MOTORS are energized to advance the DONOR to the cyan
patch. The rewind for the RECEIVER is complete and the DONOR is at the cyan patch.
[11] The CAPSTAN and DONOR MOTORS de-energize.

Cyan Transfer
[1] The THERMAL HEAD POSITION MOTOR energizes and the THERMAL HEAD moves into the ENGAGE
POSITION and de-energizes.
[2] The CAPSTAN MOTOR and the DONOR MOTORS are energized at the same time.
[3] The CAPSTAN MOTOR moves in the forward direction to remove the backlash of the GEAR TRAIN.
[4] The TAKE-UP MOTOR adjusts tension during the print cycle.
[5] The DONOR SUPPLY MOTOR operates in reverse to cause a reduction of variability in brake slip friction.
[6] The cyan section of the image is printed.

Black Transfer
[1] The THERMAL HEAD POSITION MOTOR energizes and the THERMAL HEAD moves into the ENGAGE
POSITION and de-energizes.
[2] The CAPSTAN MOTOR and the DONOR MOTORS are energized at the same time.
[3] The CAPSTAN MOTOR moves in the forward direction to remove the backlash of the GEAR TRAIN.
[4] The TAKE-UP MOTOR adjusts the tension of the DONOR during the print cycle.
[5] The DONOR SUPPLY MOTOR operates in reverse to cause a reduction of variability in brake slip friction.
[6] The black section of the image is printed.
[7] Once the transfer of image data is complete and the DONOR and RECEIVER are separated, the CAPSTAN
and DONOR MOTORS de-energize.
[8] The HEAD POSITION MOTOR energizes and moves the THERMAL HEAD back into the LOAD POSITION
and de-energizes.
[9] The CAPSTAN MOTOR energizes in reverse at ≈ 5 times the print speed to rewind the RECEIVER to the
correct position.
[10] Simultaneously, the CAPSTAN and DONOR MOTORS are energized to advance the DONOR to the cyan
patch. The rewind of the RECEIVER is complete and the DONOR is at the cyan patch.
[11] The CAPSTAN and DONOR MOTORS de-energize.

1- 17
Lamination
[1] The THERMAL HEAD POSITION MOTOR de-energizes and the THERMAL HEAD moves into the
ENGAGE POSITION and de-energizes.
[2] The DONOR MOTOR operates in rewind to cause a variability reduction in brake slip friction.
[3] The TAKE-UP MOTOR adjusts the tension during the lamination cycle.
[4] The STEPPER rewinds for a minute, then moves forward.
[5] The DONOR is advanced to the yellow patch and the CAPSTAN and DONOR MOTORS de-energize.

Eject
[1] Once the transfer of image data is complete and the DONOR and the RECEIVER are disconnected, the edge of
the RECEIVER is advanced past the CHUTE. The CAPSTAN and the DONOR MOTORS de-energize.
[2] The HEAD POSITION MOTOR energizes and moves the THERMAL HEAD into the RETRACT POSITION.
[3] Simultaneously, the PINCH MOTOR opens the PINCH and the DONOR SUPPLY MOTOR energizes in
reverse to apply tension to the DONOR.
[4] With the PLATEN BRAKE energized, the CAPSTAN MOTOR energizes at 10 times the print speed to eject
the print.
[5] The PRINT CYCLE is complete when the print is ejected and the CAPSTAN DRIVE and the PLATEN
BRAKES are de-energized.

1- 18
Section 3: LCD DISPLAY - Diagnostics
ENGINE
LCD Messages

Important
All of the LCD Messages are in [BOXES]. The messages will be displayed on the LCD.
If the operation of the POWER SUPPLY or CONTROLLER BOARD is not correct, you will not be able to access
the diagnostics.

1- 19
Preparing to Use the Diagnostics
[1] Open the CONTROLLER ENCLOSURE and DRAWER ASSEMBLY.

Important
If the P13 CONNECTOR is not removed, the ENGINE might enter into the initialization state while using the
diagnostics for the ENGINE.
[2] Remove the P13 CONNECTOR from the CONTROLLER BOARD.
[3] Check that the DIAGNOSTIC SELECTION SWITCH is in the ENGINE MODE.
[4] The J1401 on the sparc (NP series) and/or P5 on the IOCB (EP series) must be
unplugged when in engine mode.
[5] On NP1660 and older EP1660 models the Engine Loop Back Cable must be installed at P4 on SAB board.
[6] On NP1660 and Older EP1660 Models only, Remove the the ribbon cable at the P4 and install the Engine Loop
Back Tool (part number 670-065-001)
[7] On Newer EP1660 printers skip steps 6 and 7 as these units do not have a SAB board installed.
[8] Energize the PRINTER.
[9] Check that the LCD reads [READY], [SERVICE REQ], [SERVICE REQ____] (4-digit error code) or any of
the user errors such as [CLOSE COVER], [CHANGE DONOR], [LOAD DONOR], [INSERT TRAY], or
[ENGINE READY].
[10] Open the DOOR.
[11] Install:
• DONOR, if necessary
• TRAY

1- 20
Entering the Diagnostics
[1] Press and hold the SETUP/ONLINE BUTTON down. Do not release the SETUP/ONLINE BUTTON at this
time.
[2] While pressing and holding the SETUP/ONLINE BUTTON down, press the STATUS BUTTON 2 times and
the CANCEL BUTTON 2 times.
[3] Release the SETUP/ONLINE BUTTON.
[4] The LCD will read [DIAG: EXIT]. You are now in the diagnostic Menu.
(a) Press the CANCEL or STATUS BUTTONS to scroll through the diagnostic menu levels.
(b) After you select the main or top diagnostic menu, press the SETUP/ONLINE BUTTON to select a SUB-
MENU.
(c) To exit the diagnostics, scroll through the top menus until you reach and select [DIAG: EXIT].
(d) Press the SETUP/ONLINE BUTTON to initialize the PRINTER again and return you to where you began
with [ENGINE READY], [READY], [SERVICE REQ____] (4-digit error code), [READY_CALL
SERVC], [LOAD DONOR], [INSERT TRAY], [CHANGE DONOR], or any of the user errors.
[5] If you have exited the diagnostics, do Steps 1, 2, 3, 4, and 4a to enter them again.

1- 21
Diagnostic Menu Tree

On Dis play P anel: P us h and Hold Online and pus h S T AT US twice,

then C ANC E L twice, and R E LE AS E Online.

DIAG : E XIT DIAG : F AIL HIS T

DIAG : P ANE L T E S T 01 E XXXX P XXXX
DIAG : E NG V E R . #S 02 E XXXX P XXXX
V :P G : P G K B XXXX
V :C S : C S K B XXXX
V :C E : E E K B XXXX 32 E XXXX P XXXX OP T : C Y C LE T Y P E
V :S E : S E K B XXXX HIS T :E XIT >C Y C LE : XLS 8600
V :DP DP K B XXXX C Y C LE : B UR N-IN
V :S C R N S C R N VE R 9 DIAG :R E C E IV E R C Y C LE : 1 P LANE
V :S C R L S C R L VE R 9 S IZE AND T Y P E C Y C LE : P IC K /E J E C T
V :S C T N S C TN VE R 9 C Y C LE : E XIT
V :S C T L S C TL VE R 9
V :S K R N S KR N VE R 9 OP T : LOOP E NAB LE
V :S K R L S KR L VE R 9 >LOOP OP T : OF F
V :S K T 1 S KT1 VE R 9 DIAG : HE AD T E MP LOOP OP T : ON
V :S K T 2 S KT2 VE R 9 T E MP :F AN LOOP OP T : E XIT
V :DC R DC R _V E R 9 T E MP :HE AT E R
V :DC T DC T _V E R 9 T E MP :E XIT OP T : LOOP C OUNT
V :DK R DK R _V E R 9 INC C OUNT ###
V :DK T 1 DK T 1V E R 9 DE C C OUNT ###
V :DK T 2 DK T 2V E R 9 C OUNT : E XIT
V :E C R N E C R NV E R 9 OP T : E XIT
V :E C R L E C R LV E R 9 DIAG : HE AD T E S T
V :E C T N E C T NV E R 9 HE AD:R E T R AC T
V :E C T L E C T LV E R 9 HE AD:LOAD DIAG : C T R LR T E S T
V :E K R N E K R NV E R 9 HE AD:E NG AG E C T R LR : T E S T ALL
V :E K R L E K R LV E R 9 HE AD:E XIT C T R LR : MAT C H V E R S
V :E K T 1 E K T 1V E R 9 C T R LR : P R OM 0
V :E K T 2 E K T 2V E R 9 DIAG : DONOR T E S T C T R LR : P R OM 1
V :T C R T C R _V E R 9 DNR : T AK E S LAC K C T R LR : DS P P R OM
V :T C T T C T _V E R 9 DHR : ADV ANC E C T R LR : R AM 0
V :T K R T K R _V E R 9 DNR : R E WIND C T R LR : C E E P R OM
V :T K T 1 T K T 1V E R 9 DNR : R E AD T Y P E C T R LR : H E E P R OM
V :T K T 2 T K T 2V E R 9 DNR : E XIT C T R LR : ADC
V :G C R G C R _V E R 9 C T R LR : P HM
V :G K R G K R _V E R 9 DIAG : P INC H T E S T C T R LR : DS P
V :G K T 1 G K T 1V E R 9 P INC H: OP E N C T R LR : E XIT
V :S F S F __V E R 9 P INC H: C LOS E
V :S M S M__V E R 9 P INC H: E XIT
V :S S S S __V E R 9
V :T F T F __V E R 9 DIAG : MOT OR S
V :T M T M__V E R 9 MT R S : S T E P F WD
V :T S T S __V E R 9 MT R S : S T E P R E V
V :P F P F __V E R 9 MT R S : P IC K F WD
V :P M P M__V E R 9 MT R S : P IC K R E V
V :P S P S __V E R 9 MT R S : P LT N B R AK E
V :P P R P P R _V E R 9 MT R S : UR G E
V :MT M MT M_V E R 9 MT R S : E XIT
V :C C L C C L_V E R 9
V :H H4D0XXXX DIAG : OP T IONS
V :E XIT OP T : R E C E IV E R
>R C V R OP T : P AP E R
DIAG : P R INT US AG E R C V R OP T : T R ANS
US E :P WR XXXX R C V R OP T : E XIT
US E :P -S XXXX
US E :P -C XXXX
US E :P LN XXXX
US E :R F L XXXX
US E :T R N XXXX
US E :B -I XXXX
US E :E XIT K E Y P AD F UNC T IONS
P R INT - S C R OLL B AC K
C ANC E L - S C R OLL F OR WAR D
S E T -UP /S E LE C T S E LE C T ION OR E NT E R

NOT E
R E S E T MODE T O "E XIT " AND P OWE R C Y C LE T HE P R INT E R A087_9026E

1- 22
[DIAG: PANEL TEST]
The preliminary conditions are listed below. An LCD or CONTROLLER BOARD malfunction will cause PANEL
TEST failures.

TRAY INSTALLED NO
DONOR INSTALLED NO
RECEIVER INSTALLED NO
RECEIVER TYPE REFLECTIVE/TRANSPARENCY
DOOR OPEN YES
POWER ON YES
SPECIAL FUNCTIONS NO
SPECIAL ACTIONS

[1] Enter the diagnostics.

[2] Press and release the CANCEL BUTTON. The LCD will read [DIAG: PANEL TEST].
[3] To operate the [DIAG: PANEL TEST] and begin a scrolling of characters across the LCD from right to left,
press and hold the SETUP/ONLINESETUP/ONLINE BUTTON. The error LED will also illuminate and flash.
The LCD will read [HI#HI#HI#]. You are now in the SUB-MENU test. The message indicates to the technician
that the LCD is operating correctly.
[4] Release the SETUP/ONLINE BUTTON and the LCD will return to [DIAG: PANEL TEST].
[5] Press the CANCEL or STATUS BUTTONS to scroll to the correct menu, exit the diagnostics, or continue.

1- 23
[DIAG: ENG VER #S]

Important
ENGINE VER#s (ENGINE versions) allows the technician to check which versions are installed in the
CONTROLLER BOARD.
The preliminary conditions are:

TRAY INSTALLED NO
DONOR INSTALLED NO
RECEIVER INSTALLED NO
RECEIVER TYPE REFLECTIVE/TRANSPARENCY
DOOR OPEN YES
POWER ON YES
SPECIAL FUNCTIONS NO
SPECIAL ACTIONS

[1] Enter the diagnostics.

[2] Press the CANCEL BUTTON or STATUS BUTTON to scroll to the version numbers for the ENGINE. The
LCD will read [ENG: VER #S].
[3] Press and release the SETUP/ONLINE BUTTON. The LCD will read [VER:PG XXXX].
[4] You are now in the SUB-MENUs.
[5] The messages in the SUB-MENUs indicate the software and/or firmware versions. This allows the technician
to know the software version installed in the ENGINE and to check that all of the data is in these versions.
[6] To exit the SUB-MENU [ENG VER #S], press the CANCEL BUTTON.
[7] After you select [V: EXIT], press the SETUP/ONLINE BUTTON. The LCD will read
[DIAG: ENG VER #S].
[8] Press the CANCEL or STATUS BUTTON to scroll to the correct menu, exit the diagnostics, or continue.

1- 24
[DIAG: PRN USAGE]
The preliminary conditions are:

TRAY INSTALLED NO
DONOR INSTALLED NO
RECEIVER INSTALLED NO
RECEIVER TYPE REFLECTIVE/TRANSPARENCY
DOOR OPEN YES
POWER ON YES
SPECIAL FUNCTIONS NO
SPECIAL ACTIONS

[1] Enter the diagnostics.

[2] Press and release the CANCEL or STATUS BUTTON to scroll to [DIAG: PRN USAGE]. The LCD will read
[DIAG: PRN USAGE].
[3] Press and release the SETUP/ONLINE BUTTON. The LCD will read [USE: PWR XXXX].
[4] Press the CANCEL or STATUS BUTTON to scroll through all the possible messages/descriptions. See the
table below.
Note
All information is stored on the EEPROM on the CONTROLLER BOARD except for the plane count, which is
stored in the THERMAL HEAD.

LCD Messages
LCD Message Description
[USE: PWR ____] Number of times the PRINTER has been
energized.
[USE: P-S ____] Number of prints the PRINTER has started.
[USE: P-C ____] Number of prints that have been completed.
[USE: PLN ____] Number of PLANES that have been completed
by the PRINTER.
[USE: RFL ____] Number of completed REFLECTIVE, paper,
prints made by the PRINTER.
[USE: TRN ____] Number of completed TRANSPARENCIES
made by the PRINTER.
[USE: B-I ____] Number of burn-in actuations completed using
the burn-in cycle.
[USE: EXIT] Exits the SUB-MENU to the top diagnostic
menu.
[5] The [DIAG: PRN USAGE] allows the technician to check the operation of the PRINTER for feedback and
possible malfunctions.
[6] To exit the [DIAG: PRN USAGE] versions, when the LCD reads [USE: EXIT], press the SETUP/ONLINE
BUTTON. The LCD will read [DIAG: PRN USAGE].
[7] Press the CANCEL or STATUS BUTTON to scroll to the correct menu, exit the diagnostics, or continue.
Note
The data should be used with the FAIL HIST (failure history). If the print count matches the print count next to the
error in FAIL HIST, the failure or error is the present failure and should be diagnosed. If the print counts do not
match, it might be caused by a previous error that was left in the history during the manufacturing process. This data
can also be used during feedback.

1- 25
[DIAG: FAIL HIST]

Important
The failure history [DIAG: FAIL HIST] indicates the latest failures. The last failure, error code, should match with
the print count as listed in print usage. The correct failure should always be fed back. Sometimes, the failure history
will read “BAD MEM” or “NONE”, indicating the loss of data in the E2 (U9).
The preliminary conditions are:
TRAY INSTALLED NO
DONOR INSTALLED NO
RECEIVER INSTALLED NO
RECEIVER TYPE REFLECTIVE/TRANSPARENCY
DOOR OPEN YES
POWER ON YES
SPECIAL FUNCTIONS NO
SPECIAL ACTIONS

[1] Enter the diagnostics.

[2] Press and release the CANCEL or STATUS BUTTON to scroll to [DIAG: FAIL HIST]. The LCD will read
[DIAG: FAIL HIST].
[3] Press and release the SETUP/ONLINE BUTTON. The LCD will read [01 E___ C______].
[4] Press and release the CANCEL BUTTON. The LCD will scroll through all possible 32 failure logs. The LCD
will read [01 E____ C____] through [32 E____ C____].
(a) 01 through 32 are the failure numbers, E is for error number, and C is for the print count at which the error
occurred.
(b) The lower the failure number is, this indicates the most recent error. This information can be used by the
technician to determine what the error is, the number of times it occurs, and the PRINTER failure history.
See the section on Error Codes for a description of the error codes.
[5] The last SUB-MENU will read [USE: EXIT].
[6] To exit [DIAG: FAIL HIST], when the LCD reads [USE: EXIT], press and release the SETUP/ONLINE
BUTTON. The LCD will return to [DIAG: FAIL HIST].
[7] Press the CANCEL or STATUS BUTTON to scroll to the correct menu, exit the diagnostics, or continue.

1- 26
[DIAG: RECEIVER]

Important
This test allows the technician to check the operation of the 3 TRAY SENSORS, RECEIVER TYPE SENSOR, and
the CONTROLLER BOARD.
The preliminary conditions are:
TRAY INSTALLED YES
DONOR INSTALLED NO
RECEIVER INSTALLED YES
RECEIVER TYPE REFLECTIVE/TRANSPARENCY
DOOR OPEN YES
POWER ON YES
SPECIAL FUNCTIONS YES
SPECIAL ACTIONS 1. To do the TRAY test, it is necessary to install
and remove the TRAY.
2. To do the RECEIVER TYPE test, it is necessary to
install paper or a TRANSPARENCY in the TRAY.

Enter the diagnostics.

[1] Press and hold the CANCEL or STATUS BUTTON to scroll to [DIAG: RECEIVER]. The LCD will indicate
the RECEIVER type and size.
[2] Press and release the SETUP/ONLINE BUTTON The LCD will read [RCVR:TRAY].
[3] Press the CANCEL BUTTON and scroll to [RCVR: TYPE].
[4] Depending on the RECEIVER installed and the size selected, the display reads one of the following:
• 8.5 x 11-in. paper or the type media installed
• No TRAY = [NO PAPER]
• Empty TRAY
[5] To exit press the CANCEL or STATUS BUTTON.

1- 27
[DIAG: HEAD TEMP]
The preliminary conditions are:

TRAY INSTALLED NO
DONOR INSTALLED NO
RECEIVER INSTALLED NO
RECEIVER TYPE REFLECTIVE/TRANSPARENCY
DOOR OPEN YES
POWER ON YES
SPECIAL FUNCTIONS YES
SPECIAL ACTIONS 1. The correct approximate range for the THERMAL
HEAD temperature is 20 - 55 degrees C.
2. CAUTION: Do not exceed a THERMAL HEAD
temperature of 55 degrees C.

[1] Enter the diagnostics.

[2] Press and release the CANCEL or STATUS BUTTON to scroll to [DIAG: HEAD TEMP].

Important
If the temperature does not decrease when [TEMP: FAN] is selected, the FANS might not be operating.
[3] Press and release the SETUP/ONLINE BUTTON. The LCD will read [TEMP: FAN].
[4] Press and hold the SETUP/ONLINE BUTTON. The LCD will read [TEMP:___°C]. This is the present
centigrade temperature of the THERMAL HEAD. This will energize the 4 FANS that regulate the temperature
of the THERMAL HEAD. The digits on the LCD should also decrease as the FANS continue to operate. This
is the temperature.
Note
This test allows the technician to check the operation of the FAN, ADC, SENSORS, and the CONTROLLER
BOARD for a change in cooling.
[5] Release the SETUP/ONLINE BUTTON.
[6] Press the CANCEL BUTTON to scroll to [TEMP: HEATER].

Important
If the temperature does not increase when the HEATER is energized, for Style 1 THERMAL HEADS, the
THERMAL HEAD FUSE might be open or the JUMPER on TP6 on the CONTROLLER BOARD might not be
installed. The HEATER LIGHT, on the lower right corner of the CONTROLLER BOARD, illuminates even if the
THERMAL HEAD FUSE is open or the JUMPER on TP6 is missing. If the HEATER LIGHT does not illuminate,
there is a malfunction on the CONTROLLER BOARD or 12 V DC is not present. The HEATER LIGHT is not used
for Style 2 THERMAL HEADS. For Style 2 THERMAL HEADS, the temperature is increased by pulsing the
THERMAL HEAD.
[7] Press and hold the SETUP/ONLINE BUTTON. The LCD will read [TEMP:____°C]. These numbers indicate
the temperature of the THERMAL HEAD. These numbers should increase as you continue to hold the SETUP/
ONLINE BUTTON because you are energizing the HEATER or pulsing the THERMAL HEAD.
Note
This test allows the service technician to check the operation of the THERMAL HEAD HEATER, ADC, SENSORS,
CONTROLLER BOARD, and CONTROLLER LED.
[8] Release the SETUP/ONLINE BUTTON.
[9] Press the CANCEL BUTTON and scroll to [TEMP: EXIT].
[10] To exit [DIAG: HEAD TEMP] versions, when the LCD reads [TEMP: EXIT], press the SETUP/ONLINE
BUTTON. The LCD will read [DIAG: HEAD TEMP].
[11] Press the CANCEL or STATUS BUTTON to scroll to the correct menu, exit the diagnostics, or continue.

1- 28
[DIAG: HEAD TEST]

RETRACT
LOAD
NGAGE

A087_0059CCB
A087_0059CC

Caution
Do not close the DOOR until the THERMAL HEAD is fully RETRACTED.
If the THERMAL HEAD moves into the RETRACT, LOAD, or ENGAGE POSITIONS, the THERMAL HEAD
LIFT MOTOR is operating correctly. When checking the positions, observe the THERMAL HEAD moving into the
correct position. This test is also used to check the THERMAL HEAD LIFT SENSORS for correct operation.
The preliminary conditions are:
TRAY INSTALLED NO
DONOR INSTALLED NO
RECEIVER INSTALLED NO
RECEIVER TYPE REFLECTIVE/TRANSPARENCY
DOOR OPEN YES
POWER ON YES
SPECIAL FUNCTIONS YES
SPECIAL ACTIONS 1. CAUTION: Before opening or closing the DOOR,
check that the THERMAL HEAD is in the RETRACT POSITION.
If not, this could cause damage to the THERMAL
HEAD or PRINTER.

1- 29
[1] Enter the diagnostics.
[2] Press and release the CANCEL or STATUS BUTTON to scroll to [DIAG: HEAD TEST]. The LCD will read
[DIAG: HEAD TEST].
[3] Press and release the SETUP/ONLINE BUTTON. The LCD will read [HEAD: RETRACT].
[4] Press the SETUP/ONLINE BUTTON and release. The LCD will read [HEAD: RETRACTING] until the
THERMAL HEAD has reached the RETRACT POSITION.
Note
This test allows the technician to test the THERMAL HEAD LIFT MOTOR, THERMAL HEAD LIFT
MECHANISM, THERMAL HEAD LIFT SENSORS, and CONTROLLER BOARD.
[5] When the LCD reads [HEAD: RETRACT], the test is complete.
[6] Press the CANCEL BUTTON and scroll to [HEAD: LOAD].
[7] Press and release the SETUP/ONLINE BUTTON. The LCD will read [HEAD: LOADING] and the
THERMAL HEAD will move into the LOAD POSITION.
Note
This test allows the technician to test the THERMAL HEAD LIFT MOTOR, THERMAL HEAD LIFT
MECHANISM, THERMAL HEAD LIFT SENSORS, and CONTROLLER BOARD.
[8] When the LCD reads [HEAD: LOAD], the test is complete.
[9] Press the CANCEL BUTTON and scroll to [HEAD: ENGAGE].

1- 30
 RETRACT
LOAD
NGAGE

A087_0059CCB
A087_0059CC

[10] Press and release the SETUP/ONLINE BUTTON. The LCD will read [HEAD: ENGAGING]. The THERMAL
HEAD will move into the ENGAGE POSITION.
Note
This test allows the technician to test the THERMAL HEAD LIFT MOTOR, THERMAL HEAD LIFT
MECHANISM, THERMAL HEAD LIFT SENSORS.
[11] When the LCD reads [HEAD: ENGAGE], the test is complete.
[12] Press the CANCEL BUTTON and scroll to [HEAD: RETRACT].
[13] Press and release the SETUP/ONLINE BUTTON. The LCD will read [HEAD: RETRACTING].
[14] When the LCD reads [HEAD: RETRACT], check that the THERMAL HEAD is in the RETRACT POSITION.
[15] Press the CANCEL BUTTON and scroll to exit. The LCD will read [HEAD: EXIT].
[16] To exit the [DIAG: HEAD TEST] when the LCD reads [HEAD: EXIT], press the SET-UP SELECT BUTTON.
The LCD will read [DIAG: HEAD TEST].
[17] Press the CANCEL or STATUS BUTTON to scroll to the correct menu, exit the diagnostics, or continue.

1- 31
[DIAG: DONOR TEST]
The preliminary conditions are:

TRAY INSTALLED NO
DONOR INSTALLED YES
RECEIVER INSTALLED NO
RECEIVER TYPE REFLECTIVE/TRANSPARENCY
DOOR OPEN YES at beginning of test, then NO
POWER ON YES
SPECIAL FUNCTIONS YES
SPECIAL ACTIONS 1. When the DONOR is first installed with the
DOOR open, or anytime the DOOR is open with
DONOR installed, the LCD will always read
DNR: COLOR = CYN because the DONOR is not
sensed.
2. Follow the procedure to check when the
DOOR should be open or closed.

[1] Open the DOOR. Enter the diagnostics.

[2] Press and release the CANCEL or STATUS BUTTON to scroll to [DIAG: DONOR TEST]. The LCD will read
[DIAG: DONOR TEST.]
[3] Press and release the SETUP/ONLINE BUTTON. The LCD will read [DNR: TAKE SLACK].
[4] Press and hold the SETUP SELECT BUTTON. The LCD will read [DNR: COLOR = CLR=MAG/BLK]. The
DONOR SUPPLY CLUTCH will turn clockwise adjusting the tension in the DONOR.
Note
This test allows the technician to check the operation of the SUPPLY MOTOR, SPINDLE, CLUTCH, SPOOL, and
CONTROLLER BOARD.
[5] Close the DOOR.
[6] Press and hold the SETUP/ONLINE BUTTON. The LCD will read [DNR: COLOR = YEL, MAG, CYN or
LAM], depending on the position of the DONOR PATCH in reference to the DONOR SENSORS and LED.
Note
This test allows the technician to check the operation of the DONOR SENSING SYSTEM and CONTROLLER
BOARD.
[7] Press the CANCEL BUTTON and scroll to [DNR: ADVANCE].
[8] Press and hold the SETUP/ONLINE BUTTON. The LCD will read [DNR: CLR = YEL, MAG/BLK, CYN, or
LAM]. The LCD will change between YEL, MAG, and CYN in that sequence. This operates the DONOR
TAKE-UP and SUPPLY MOTORS. The DONOR SENSING SYSTEM is also detecting the 3 patches of
DONOR.
Note
This test allows the technician to check the operation of the DONOR SENSING SYSTEM, CONTROLLER BOARD
and the advance function of the DONOR.
[9] Release the SETUP/ONLINE BUTTON.
[10] Open the DOOR.
[11] Press and hold the SETUP/ONLINE BUTTON. The LCD will read [CLR=MAG/BLK]. The DONOR SUPPLY
CLUTCH GEAR will turn counterclockwise and the DONOR TAKE-UP CLUTCH GEAR will turn clockwise.
Note
This test allows the technician to check the DONOR TAKE-UP and SUPPLY MOTORS, CLUTCHES, SPINDLES,
and the CONTROLLER BOARD.
[12] Release the SETUP/ONLINE BUTTON.
[13] Press the CANCEL BUTTON to scroll to rewind. The LCD will read [DNR: REWIND].

1- 32
[14] Press and hold the SETUP/ONLINE BUTTON. The LCD will read [CLR=MAG/BLK]. This operates the
TAKE-UP CLUTCH GEAR counterclockwise in a step function. The SUPPLY CLUTCH GEAR will turn in
a clockwise movement.
Note
This test allows the technician to check the DONOR TAKE-UP and SUPPLY MOTORS, CLUTCHES, SPINDLES,
and the CONTROLLER BOARD.
[15] Release the SETUP/ONLINE BUTTON.
[16] Close the DOOR.
[17] Press and hold the SETUP/ONLINE BUTTON. The LCD will read [DNR: CLR=CYN, MAG/BLK, YEL, or
LAM]. The LCD will change between CYN, MAG, and YEL in that sequence. This operates the DONOR
TAKE-UP and SUPPLY MOTORS. The DONOR SENSING SYSTEM is also detecting the 3 patches of
DONOR.
Note
This test allows the technician to check the operation of the DONOR SENSING SYSTEM, CONTROLLER
BOARD, and the advance function of the DONOR.
[18] Release the SETUP/ONLINE BUTTON. The LCD will read [DNR: REWIND].
[19] Open the DOOR. The DOOR can remain open.
[20] Press and release the CANCEL BUTTON. The LCD will read [DNR: READ TYPE].
[21] Press and release the SETUP/ONLINE BUTTON. The LCD will read [DNR: TIGHTENING, READING,
REWIDING and then TYPE OK - > ##]. This test checks the BAR CODE SENSOR and BAR CODE LABEL.
The number indicates the type of DONOR. See the procedure “DONOR TYPE BAR CODE SENSING” on
Page 55 for the list of DONOR TYPES.
[22] Press the CANCEL BUTTON and scroll to exit. The LCD will read [DNR: EXIT].
[23] To exit the [DIAG: DONOR TEST] when the LCD reads [DONOR EXIT], press the SET-UP BUTTON. The
LCD will read [DIAG: DONOR TEST].
[24] Press the CANCEL or STATUS BUTTON to scroll to the correct menu, exit the diagnostics, or continue.

1- 33
[DIAG: PINCH TEST]
The preliminary conditions are:

TRAY INSTALLED NO
DONOR INSTALLED NO
RECEIVER INSTALLED NO
RECEIVER TYPE REFLECTIVE/TRANSPARENCY
DOOR OPEN YES
POWER ON YES
SPECIAL FUNCTIONS YES
SPECIAL ACTIONS 1. It is necessary to install a RECEIVER
between the CAPSTAN TRACTION ROLLER and
the PINCH ROLLER; this is done to check
that the PINCH holds the RECEIVER when it
is closed and releases it when it is
open.

[1] Enter the diagnostics.

[2] Press and release the CANCEL or STATUS BUTTON to scroll to [DIAG: PINCH TEST]. The LCD will read
[DIAG: PINCH TEST].
[3] Press and release the SETUP/ONLINE BUTTON. The LCD will read [PINCH: OPEN]. The position of the
PINCH MECHANISM is open.
[4] Install a RECEIVER until it reaches the LEAD EDGE SENSOR.
[5] Press the CANCEL BUTTON and scroll to close. The LCD will read [PINCH: CLOSE].
[6] Press and release the SETUP/ONLINE BUTTON. The LCD will read [PINCH: CLOSE] when it is complete.
This operates the PINCH MOTOR, PINCH CAM/SHAFT, PINCH ARMS, SPRING, and PINCH ROLLER.
[7] Use your THUMB to rotate the PINCH ROLLER. If it does not move, the PINCH is closed.
Note
This test allows the technician to check the PINCH MECHANISM and CONTROLLER BOARD.
[8] Pull on the RECEIVER on both front corners. It should be pinched evenly. The RECEIVER should not move.
If the RECEIVER moves or can be pulled out from either corner, the PINCH is not operating correctly.
[9] Press the STATUS BUTTON and scroll to open. The LCD will read [PINCH: OPEN].
[10] Press and release the SETUP/ONLINE BUTTON. The LCD will read [PINCH: OPENING] until it is complete.
The LCD will read [PINCH: OPEN].
[11] This operates the PINCH MOTOR, PINCH CAM SHAFT, PINCH ARMS, and PINCH ROLLER.
Note
This test allows the technician to check the PINCH MOTOR MECHANISM and CONTROLLER BOARD.
[12] Remove the RECEIVER.
[13] Press the CANCEL BUTTON and scroll to exit. The LCD will read [PINCH: EXIT].
[14] To exit the [DIAG: PINCH TEST] versions when the LCD reads [PINCH: EXIT], press the SETUP/ONLINE
BUTTON. The LCD will read [DIAG: PINCH TEST].
[15] Press the CANCEL or STATUS BUTTON to scroll to the correct menu, exit the diagnostics, or continue.

1- 34
[DIAG: MOTORS]
The preliminary conditions are:

TRAY INSTALLED NO
DONOR INSTALLED NO
RECEIVER INSTALLED NO
RECEIVER TYPE REFLECTIVE/TRANSPARENCY
DOOR OPEN YES
POWER ON YES
SPECIAL FUNCTIONS NO
SPECIAL ACTIONS

[1] Enter the diagnostics.

[2] Press and release the CANCEL or STATUS BUTTON to scroll to [DIAG: MOTORS]. The LCD will read
[DIAG: MOTORS].
[3] Press and release the SETUP/ONLINE BUTTON. The LCD will read [STEP: FWD].
[4] Press and hold the SETUP/ONLINE BUTTON. The LCD will read [MOTORS: STEPPING]. This operates the
STEPPER MOTOR, INTERMEDIATE GEAR, and TRACTION ROLLER in the forward position.
Note
This test allows the technician to check the STEPPER MECHANISM and CONTROLLER BOARD.
[5] Release the SETUP/ONLINE BUTTON.
[6] Press the CANCEL BUTTON and scroll to reverse. The LCD will read [MTRS: STEP REV].
[7] Press and hold the SETUP/ONLINE BUTTON. The LCD will read [MTRS: STEPPING]. This operates the
STEPPER MOTOR, INTERMEDIATE GEAR, and TRACTION ROLLER in the REWIND POSITION.
[8] Press the CANCEL BUTTON and scroll to [MTRS: PICK FWD].
[9] Press and hold the SETUP/ONLINE BUTTON. The LCD will read [MTRS: PICKING]. This operates the
PICKER MECHANISM and picks either a sheet of paper or TRANSPARENCY.
[10] Press the CANCEL BUTTON and scroll to [PICK REV:]. The LCD will read [MTRS: PICK REV].
[11] Press and hold the SETUP/ONLINE BUTTON. The LCD will read [MTRS: RETRACTING]. This test
RETRACTS the PICKER MECHANISM.
[12] Press the CANCEL BUTTON and scroll to [PLTN BRAKE]. The LCD will read [MTRS: PLTN BRAKE].
[13] Press and hold the SET/UP SELECT BUTTON. The LCD will read [MTRS: BRAKE ON]. This test checks
the operation of the PLATEN BRAKE.
(a) If the PLATEN BRAKE is operating correctly, the PLATEN ROLLER will rotate forward with
resistance. The PLATEN ROLLER will rotate approximately 1/4 turn in reverse then stop.
(b) Scroll to EXIT to exit the diagnostics.

1- 35
[DIAG: OPTIONS]
The preliminary conditions are:

TRAY INSTALLED NO
DONOR INSTALLED NO
RECEIVER INSTALLED NO
RECEIVER TYPE REFLECTIVE/TRANSPARENCY
DOOR OPEN YES
POWER ON YES
SPECIAL FUNCTIONS YES
SPECIAL ACTIONS 1. These tests allow the technician to select
the necessary options: RECEIVER TYPE OPTION,
LOOP OPTION, and the BURN IN OPTION. The
RECEIVER TYPE OPTION allows you to select
paper or a TRANSPARENCY. The LOOP OPTION
allows the technician to make continual
test prints when selected. The BURN IN
OPTION is used by the manufacturer.

[1] Enter the diagnostics.

[2] Press and release the CANCEL or STATUS BUTTON to scroll to [DIAG: OPTIONS]. The LCD will read
[DIAG: OPTIONS].
[3] Press and release the SETUP/ONLINE BUTTON. The LCD will read [OPT: RECEIVER].
[4] Press the SETUP/ONLINE BUTTON. The LCD will read [RCVR OPT: PAPER]. Press and release the
CANCEL BUTTON, the LCD will read [RCVR OPT: TRANS]. The symbol > indicates which option was
selected. You can scroll between the options.
[5] After you select your option, press the SETUP/ONLINE BUTTON, the symbol > will be in front to check your
option selection.
Note
This option is used to select either paper or TRANSPARENCY during the print cycle in the STAND-ALONE
MODE.
[6] After you select paper or TRANSPARENCY, press the CANCEL BUTTON and scroll to exit. The LCD will
read [RCVR OPT: EXIT].
[7] Press and RELEASE the SETUP/ONLINE BUTTON. The LCD will read [OPT: RECEIVER].
[8] Press the CANCEL BUTTON and scroll. The LCD will read [OPT: CYCLE TYPE].
[9] Press and release the SETUP/ONLINE BUTTON. The LCD will read [CYCLE:] or the correct model.
[10] Press the CANCEL BUTTON.
[11] The LCD will read:
• [CYCLE: BURN-IN] - used during manufacturing
• [CYCLE: 1-PLANE] - prints the magenta pass and laminate
• [CYCLE: PCK/EJECT] - operates the PICKER, PINCH STEPPER with no actual printing, picks, and
ejects the RECEIVER
• [CYCLE: EXIT]
[12] This test allows the technician to operate a series of configurations and to test the operations of the PICK and
EJECT.
[13] Press the CANCEL BUTTON and scroll. The LCD will read [OPT: LOOP-ENABLE].
[14] Press and release the SETUP/ONLINE BUTTON. The LCD will read [LOOP OPT: OFF] or [LOOP OPT: ON].
The symbol > indicates which option was selected. You can scroll through the options.

1- 36
[15] After you determine the correct option, select the option by pressing the SETUP/ONLINE BUTTON. The
symbol > will be in front to check your option.
Note
This function allows the technician to make multiple test prints when [LOOP OPT: ON] is selected by pressing the
TEST STATUS BUTTON in the READY MODE.
[16] Press the CANCEL BUTTON and scroll to exit. The LCD will read [LOOP OPT: EXIT].
[17] Press and release the SETUP/ONLINE BUTTON. The LCD will read [OPT: LOOP-ENABLE].
[18] Press the CANCEL BUTTON and scroll to [LOOP COUNT]. The LCD will read [OPT: LOOP COUNT].
[19] Press and release the SETUP/ONLINE BUTTON. The LCD will read [OPT INC COUNT ###] or [OPT DEC
COUNT ###]. The symbol > indicates the option selected. This operation allows the technician to increment or
decrement the test counter during burn-in.
[20] Press and release the SETUP/ONLINE BUTTON. The LCD will read [COUNT: EXIT].
[21] Press the CANCEL BUTTON and scroll to the next option.

1- 37
[DIAG: CTRLR TEST]
The preliminary conditions are:

TRAY INSTALLED NO
DONOR INSTALLED NO
RECEIVER INSTALLED NO
RECEIVER TYPE REFLECTIVE/TRANSPARENCY
DOOR OPEN YES
POWER ON YES
SPECIAL FUNCTIONS YES
SPECIAL ACTIONS 1. These tests indicate error codes if there
is a malfunction. See the error code table.

[1] Enter the diagnostics.

[2] Press and release the CANCEL or STATUS BUTTON to scroll to [DIAG: CTRLR TEST]. The LCD will read
[DIAG: CTRLR TEST].
[3] Press and release the SETUP/ONLINE BUTTON. The LCD will read [CTRLR: TEST ALL].
[4] Press and release the SETUP/ONLINE BUTTON. The LCD will read [CTRLR: TESTING].
[5] When the test is completed, the LCD will read [CTRLR: TEST ALL].
[6] This test is used to check that the test for the CONTROLLER operate correctly, allowing the technician to
diagnose malfunctions in the area of the CONTROLLER. The versions are:
• [DIAG: CTRLR TEST]
– [CTRLR: TEST ALL]
– [CTRLR: MATCH VERS]
– [CTRLR: PROM 0]
– [CTRLR: PROM 1]
– [CTRLR: RAM 0]
– [CTRLR: RAM 1]
– [CTRLR: C EEPROM]
– [CTRLR: H EEPROM]
– [CTRLR: ADC]
– [CTRLR: PHM]
– [CTRLR: EXIT]

CONTROLLER Test Option Definitions

• TEST ALL
– Performs all the tests listed in the CONTROLLER test section.
• MATCH VERS
– Performs a code check for U19 and U20, the PROGRAM PROMS located on the CONTROLLER
BOARD.
• PROM 0 and PROM 1
– Performs a test on U19 and U20, the PROGRAM PROMS located on the CONTROLLER BOARD.
• DSP PROM
– Performs a test on the DSP PROM, U42.
• RAM 0 and RAM 1
– Performs a memory check on the RAM located in the CONTROLLER BOARD.

1- 38
 • C EEPROM
– Performs a contents check on the CONTROLLER EEPROM, U9.
• H EEPROM
– Performs a contents check on the EEPROMS located on the THERMAL HEAD.
• ADC (Analog-Digital Converter)
– Performs a check on the analog-digital converter located on the CONTROLLER BOARD.
• PHM (PULSE HEAD MODULATOR)
– Performs a check on the PULSE HEAD MODULATOR IC located in the CONTROLLER BOARD.
• DSP (Digital Signal Processor)
– Performs a check on the DSP on the CONTROLLER BOARD - does not check the checksum.
[7] Press the CANCEL BUTTON and scroll to the SUB-MENUs. See the list of SUB-MENUs above.
[8] After you select SUB-MENU, press and release the SETUP/ONLINE BUTTON to access a SUB-MENU test.
[9] During each SUB-MENU test, the LCD will read [CTRLR: TESTING].
Note
This allows the technician to check that the tests operate correctly.
[10] Press the CANCEL BUTTON and scroll to exit. The LCD will read [CTRLR: EXIT].
[11] Press and release the SETUP/ONLINE BUTTON. The LCD will read [DIAG: CTRLR: TEST].
[12] It is now possible to scroll through the “Diagnostic Main Menu” by using the PRINT or CANCEL BUTTONS.
[13] To exit the diagnostics, scroll to [DIAG: EXIT].
[14] Press the SETUP/ONLINE BUTTON, the LCD will read [INITIALIZING].
[15] After initialization is complete, the LCD will read [READY], [SERVICE REQ ____] (4-digit error code), or
any of the user error states such as [CLOSE COVER], [CHANGE RIBBON], or [INSERT TRAY] depending
on the condition of the PRINTER.

1- 39
Section 4: Error Codes
Descriptions

Status Codes - this allows the print engine to share unsolicited information with the platform. The print engine returns
a 1-word Status Codes in the following conditions:
-whenever the print engine completes a command
-whenever the print engine detects an event that should be reported to the host. This includes user events (such
as removal of the receiver tray or pressing a front panel control) or other engine events (such as time-out for receiver
picking or head over temperature.

Status codes can be solicited (that is, in response to commands) or unsolicited (to report asynchronous events). The
most significant bit (MSB) of the Status Code indicates whether the code is solicited or not, as follows:
-MSB= 0 - Solicited Status Code
-MSB= 1 - Unsolicited Status Code

In the Status Code definitions below, the Status Code values are presented in hexa-decimal.

State Codes
The following Status Codes indicate the current state of the print engine. A state Status Code will always be issued
by the print engine after the completion of command execution or after an event in the print engine occurs. (i.e. One
of the following Status Codes will always be the last Status code issued in response to a command or an engine event.)

Ready State Codes

The print engine issues a Ready state Status Code when the engine is ready to receive a print command.

Status Code Definition

0000 Ready to print state
0001 Ready with trouble state
0002 Ready, wait for stable
printhead temperature state
0003 Ready state with special
configuration

Wait State Codes

Wait state Status Codes are only issued when the panel control switch is in the “EXT.” position. These codes are
issued when the engine has identified a need to perform a time consuming mechanical process.
Upon issued a wait state code, the engine waits for command (a RESTORE command that requests a mechanism
initialization) from the platform giving the engine the OK to start the pending mechanical operation.
These wait conditions are intended to allow the platform to update the control panel display before beginning time-
consuming operations. This means that the printer front panel can display a meaningful message when the print
engine is executing an initialization function (during which time the display can’t be updated).
Wait state Status Codes also allow the host platform to initiate alternate processes that can be done while the engine
is performing its mechanical tasks.

1- 40
 The START RESTORE command is required in order for normal operation to continue.

Status Code Definition

0010 Wait for platform to boot state, mechanism initialization START
RESTORE command required
0011 Waiting to initialize full mechanism state, mechanism
initialization START RESTORE command required
0012 Waiting to initialize donor state, mechanism initialization START
RESTORE command required
0013 Waiting to perform mini mechanism initialization state,
mechanism initialization START RESTORE command required
0014 Waiting to initialize full mechanism with tray out state,
mechanism initialization START RESTORE command required

Operator Service State Codes

The print engine issues an operator service state Status Code when operator service is required at the engine. This
service (an operator action) is required in order to prepare the engine for printing.

Status Code Definition

0020 Door open state
0021 Tray out state
0022 Door open and tray out state
0023 Door error state
0024 Door open with door error state
0025 Tray out with door error state
0026 Door open and tray out with door error state
0027 Tray error state
0028 Door open with tray error state
0029 Tray out with tray error state
002A Door open and tray out with tray error state
002B Door open with mechanism initialization required state
002D Door open and tray out with mechanism initialization required state
002E Door and tray error state
002F Door open with door and tray error state
0030 Tray out with door and tray error state
0031 Door open and tray out with door and tray error state

1- 41
Field Service Required State Codes
The print engine issues a filed service required state Status code when an error condition is encountered that
requires field service. In these states the engine is waiting for a restore command that requests a mechanism
initialization in order to attempt to recover from the error.

Status Code Definition

0040 Error after cold start complete, wait for restore command state
0041 Error before cold start complete, wait for restore command state
0042 Service request is pending, wait for platform to boot state

Diagnostic State Codes

The print engine issues a diagnostic state Status Code when the engine is in a diagnostic mode.

Status Code Definition

0050 Diagnostic state

Response Codes
The print engine issues the following Status codes in response to print engine events that are expected during
normal operation. (These are also termed “event” codes.)

Human Input Status Codes

The print engine issues a human input Status codes when a print engine event occurs due to an operator action
(e.g. removing the receiver tray, pressing a button, etc.)

Status Code Definition

0101 Print button pressed, no response
0102 Print button pressed while control panel under external control
0103 Print button released
0104 Test print started
0105 Cancel button pressed, no response
0106 Cancel button pressed while control panel under external control
0107 Cancel button released
0108 Started mechanism initialization
0109 Cold start
010B Setup button pressed, no response
010C Setup button pressed while control panel under external control
010D Setup button released
010E Go to diagnostic operation
010F Go to normal operation
0120 Receiver type changed
0121 Receiver type changed, no response
0123 Receiver tray changed, no response
0124 Receiver tray removed
0125 Receiver tray replaced
1- 42
 Status Code Definition
0126 Receiver size changed
0127 Door opened
0128 Door closed
0129 Door opened or closed, no response
012A Door opened while engine busy
012B Go to engine controls control panel operation
012C Go to external device controls control panel operation
012D Donor type changed

Internal Input Status Codes

The print engine issues internal input Status codes when a print engine event occurs to automatically compensate
for a condition that has made the print engine not ready to print.

Status Code Definition

0200 Head too hot
0201 Head too cold
0202 Head temperature OK

Command Status Codes

The print engine issues command Status Codes when it detects an error condition in a command. These errors
range from transaction sequence errors to the reception of data elements that are not valid.

Status Code Definition

0301 READ when WRITE expected
0302 WRITE when READ expected
0303 Undefined command code
0304 Command code not supported
0305 Undefined Item Code
0306 Item code not supported
0307 Item code not valid now
0308 SET of item not allowed
0309 GET of item not allowed
030A START of item not allowed
030B Invalid data
030C Data value not supported
030D Wrong data length for item
030E Receiver size mismatch
030F Receiver type mismatch
0310 Must set interpolation points first
0311 Controller EEPROM is marked bad due to past failure
0312 Printhead EEPROM is marked bad due to past failure

1- 43
 Status Code Definition
0313-0318 (not used)
0319 Printhead correction data previously marked absent (EEPROM is
functional)
031A STATUS READ when WRITE expected
031B STATUS READ when READ expected
031C, D (not used)
031E Item code not valid for selected media combination
0320 Selected ray sensitometry table is missing (Sxxx)
0321 Missing raw sensitometry table for media installed (Sxxx)
0322 Selected Dmin and Dmax values are missing (Dxx)
0323 Dmin and Dmax values for media installed are missing (Dxx)
0324 Selected base enable width is missing (Exxx)
0325 Base enable width for media installed is missing (Exxx)
0326 Selected thermal scale factors are missing (Tx)
0327 Thermal scale factors for media installed are missing (Tx)
0328 Selected transient parasitic data is missing (Txx)
0329 Transient parasitic data for media installed is missing (Txx)
032A Selected thermal smear factors are missing (Sx)
032B Thermal smear factors for media installed are missing (Sx)
032C Selected pulse position scale factor is missing (Px)
032D Pulse position scale factor for media installed is missing (Px)
032E Missing raw pulse position table (PPR)
032F Selected sampled pulse effectiveness is missing (Gxx)
0330 Sampled pulse effectiveness for media installed is missing (Gxx)
0333 Item code is invalid with current toggle options setting
0334 Mismatch between calibration table selected and donor currently
installed
0335 Overriding selected lamination state
0336 Overriding selected pass count setting
0337 Data not passed to Digital Signal Processor (DSP), the CPU/DSP
interface may be down
033A Calibration clip level value is missing
033B Overriding entered Y skip value

Donor/Door Status Codes

The print engine issues donor/door Status Codes when a normal print engine event takes place that requires the
operator to manipulate the door or the donor system that is attached to the door.

Status Code Definition

0400 Donor advance failure
0401 Donor rewind failure

1- 44
 Status Code Definition
0402 Donor type barcode sensor did not detect any bars
0403 A valid 2-of-8 donor type barcode was read; however, the donor type
is not supported by this printer

Receiver/Tray Status Codes

The print engine issues receiver/tray Status codes when a normal print engine event requires the operator to
manipulate the tray or the receiver in the tray.

Status Code Definition

0408 Failure to picker receiver

Machine Generated
Condition/Error Code Description
500 No RECEIVER at LEAD EDGE SENSOR when
expected
501 RECEIVER stuck at LEAD EDGE SENSOR
502 RECEIVER size change without removing TRAY
503 Invalid TRAY size input
510 BAR CODE LABEL not correct/BAR CODE
SENSOR or FRU malfunction
511 BAR CODE LABEL not correct or has damage/
BAR CODE SENSOR or FRU malfunction
600, 601, 602 603 CONTROLLER PROM or BOARD failure
608, 609, 60A, 60C THERMAL HEAD/CABLE, CONTROLLER
BOARD
610 LCD or CONTROLLER BOARD
618, 60B EEPROM, THERMAL HEAD
700 Inboard THERMAL HEAD POSITION SENSOR
#2 open
701 Inboard THERMAL HEAD POSITION SENSOR
#2 blocked
702 Outboard THERMAL HEAD POSITION
SENSOR #1 open
703 Outboard THERMAL HEAD POSITION
SENSOR #1 blocked
708 DONOR PATCH SENSING LED not sensing
DONOR
709 DONOR SENSORS not stable
710, 711, 712 DSP Linetime response times out
718 CONTROLLER BOARD
719 THERMAL HEAD/CABLE, CONTROLLER
BOARD

1- 45
 Condition/Error Code Description
720, 721 CONTROLLER BOARD/CABLE
730 THERMAL HEAD Cooling malfunction
733 THERMAL HEAD Heating malfunction
738, 739 CONTROLLER, RAM
740 PROGRAM PROMS or CONTROLLER BOARD
741, 742 PROGRAM PROMS or CONTROLLER BOARD
748, 749, 74A, 74B, 74C, PHM Failure
74D
750-756 Unexpected write from DSP
757 DSP Set Verify Failure
760-773, 76E, 76F, 76A, CONTROLLER BOARD
76B, 76C, 76D
800-857 General CONTROLLER BOARD
900-930, 090B, 091B, DSP BLOCK, CHECKSUM
092B, 093B, 094B

1- 46
Section 5: Troubleshooting
Power Distribution
Safety

Warning
Dangerous Voltage

Functional Description
The power distribution for the PRINTER is distributed from a POWER SUPPLY. This supplies power to the
CONTROLLER BOARD and THERMAL HEAD.
The POWER SUPPLY automatically senses the AC input and SWITCHES to the correct input. There are 2 AC input
ranges, range 1 = 90-132 V AC, and range 2 = 175 - 264 V AC. The AC frequency input operational range is 47 - 63
Hz.
The DELTA POWER SUPPLY is an integrated POWER SUPPPLY that includes:
• 5 and 12 V DC POWER SUPPLY
This POWER SUPPLY provides power to the CONTROLLER and FEE BOARDS. There are 3 different
voltages, 5 V DC, 12 V DC, and -12 V DC. The CONTROLLER BD uses 5 V DC and 12 V DC.
• THERMAL HEAD POWER SUPPLY
This POWER SUPPLY provides power to the THERMAL HEAD only. The voltage output range for the
THERMAL HEAD is adjustable at R523 on the POWER SUPPLY.
The CONNECTORS for the CONTROLLER are directly connected into the POWER SUPPLY. V DC to the system
is supplied through the P12 and J14 CONNECTORS.
• 5 V DC 5.0 minimum to 5.2 maximum V DC peak output at 4.0 amps
• 12 V DC 11.8 minimum to 12.2 maximum V DC peak output at 1.0 amps
• -12 V DC -11.4 to -12.6 V DC peak output at 0.86 amps
• Operating amps: 2.5 amps, 0.5 amps, 0.5 amps

1- 47
Exploded view of 1600 Series Imager with the power supply removed.

1- 48
Above NP1660 and EP1660 Non-Elmer Style IOCB Engine Controller Board with
the SAB Board installed.

Below NP1600, EP1650, and EP1660 Elmer Style IOCB Engine Controller Board.

1- 49
CONTROLLER BOARD - Components

1- 50
POWER SWITCH

Installed view of the power switch and plug wiring.

1- 51
Specifications
• Voltage
– Range 1: 90 - 132 V AC, Range 2: 175 - 264 V AC
• Watts
– 180 W for printing
– 107 W during THERMAL HEAD pre-heat
– 67 W in the idle/ready modes
• Frequency
– 47 - 63 Hz
• Ambient Temperature
– 15 - 30°C (59 - 86°F)
• Ambient Humidity
– 20 - 76% (relative humidity)
• Standard Safety
– UL1950, CSA 1402C, TUV/VDE: IEC 950

1- 52
Voltage Verification Chart

BOARD CONNECTOR PIN + and - (GND) Voltages Wire Color

CONTROLLER P12 4, 8 (2,5) +12 V DC Orange
CONTROLLER P12 1, 5 (2,5) +5 V DC Red
CONTROLLER P12 7 (2,5) Power fail Violet
4.5 V DC
CONTROLLER P12 2, 3, 6 GND Black
POWER SUPPLY J1 1-7 HEAD V Red
12-16.5 V DC
POWER SUPPLY J1 7-14 HEAD V - GND Black
PLATFORM FAN J20 NA Red = -12 V DC
Black = GND
POWER SWITCH NA 2, HOT 120/240 V AC to Black
PLUG
POWER SWITCH NA 3, HOT 120/240 V AC to Brown
POWER SUPPLY
PLUG NA NA HOT and 120/240 V Black
AC to SWITCH PIN 2
PLUG NA NA blue wire is
NEUTRAL and 120/
240 V AC to POWER
SUPPLY
PLUG NA NA green wire is GND

Preliminary Check
[1] Check:
• POWER CORD is correctly plugged into the PRINTER and the POWER OUTLET
• POWER SWITCH is on (I = ON HIGH)
• POWER OUTLET does not have a malfunction
• POWER CORD does not have a malfunction

1- 53
POWER INDICATOR LED Not Illuminated
The PRINTER does not operate.
[1] Do Steps 12 - 22 to check for DC voltage.
[2] De-energize the PRINTER.
[3] Remove the POWER COVER for the POWER SWITCH. If necessary, see the removal procedure for the
“POWER SWITCH” in the ADJUSTMENTS AND REPLACEMENTS.
[4] Set the DIGITAL VOLT METER to AC voltage; the ranges are Range 1: ≈ 115 V AC, and Range 2: ≈ 250 V
AC. Use Range 1 for North America and Range 2 for areas where 220 V AC is used.
[5] Energize the PRINTER.
[6] Check:
• POWER SWITCH is in the I position
• AC voltage at the back of the PLUG
[7] Connect:
• red PROBE to the black wire CONNECTOR
• black PROBE to the blue wire CONNECTOR
[8] If AC voltage is present, advance to the next step. If not, install a new PLUG.
[9] Check that AC voltage is present on the POWER SWITCH CONNECTOR.
[10] Connect:
• red PROBE to PIN 2 of the POWER SWITCH
• black PROBE to the blue wire CONNECTOR on the back of the PLUG
[11] If voltage is present, advance to PIN 3 of the POWER SWITCH. If voltage is present on PIN 3, advance to the
next step. If voltage is not present on PIN 2, check the wire from the PLUG and/or install a new wire. If voltage
is present on PIN 2 but not on PIN 3 install a new POWER SWITCH.
[12] Set the DIGITAL VOLT METER to DC voltage.
[13] Check the output of the POWER SUPPLY. Seat P12 on the CONTROLLER BOARD.
[14] Place the PROBE in PINS 2, 3, or 6 (GND) on P12 on the CONTROLLER BOARD.
[15] Measure the outputs; the correct voltages are:
• P12: PINS 1 and 5 = 5 V DC
• P12: PINS 4 and 8 = 12 V DC
• P12: PIN 7 = ≈ 4.5 V DC

1- 54
 Warning
Dangerous Voltage
[16] Seat CONNECTOR P12 on the CONTROLLER BOARD.
[17] Connect:
• black PROBE to P12 on the CONTROLLER BOARD, PIN 2, 3, or 6
• red PROBE to P12, PIN 4; the DIGITAL VOLT METER should read ≈ 12 V DC
• red PROBE to P12, PIN 8; the DIGITAL VOLT METER should read ≈ 12 V DC
• red PROBE to P12, PIN 1 and then PIN 5; the DIGITAL VOLT METER should read ≈ 5 V DC on both
PINS
[18] If the voltages are present, advance to Step 20 of this procedure.
[19] If any of the voltages are not present, install a new 5/12 V DC POWER SUPPLY.
[20] If the LEDS on the CONTROLLER BOARD are illuminated, the voltages are present at P12, and the PRINTER
does not operate, install a new CONTROLLER BOARD.
[21] If the 5 and 12 V DC LEDS are not illuminated and the voltages are present, install a new CONTROLLER
BOARD.
[22] If the PRINTER operates correctly and the LED is illuminated, the procedure is complete.

1- 55
No Printed Image
The PRINTER completes the print cycle, but there is no image on the completed print.
[1] Do the Preliminary Check on page 47.
[2] De-energize the PRINTER.
[3] Seat:.
• CONNECTOR J1 on the POWER SUPPLY
• CONNECTORS on the THERMAL HEAD
[4] Remove the POWER COVER for the POWER SWITCH. If necessary, see the removal procedure for the
“POWER SWITCH” in the ADJUSTMENTS AND REPLACEMENTS.
[5] Set the DIGITAL VOLT METER to AC voltage; the correct range is Range 1: ≈ 115 V AC, and
Range 2: ≈ 250 V AC. Use Range 1 for North America and Range 2 for areas where 220 V AC is used.
[6] Energize the PRINTER.
[7] Check:
• POWER SWITCH is in the I position
• that there is AC voltage at the back of the PLUG
[8] Connect:
• red PROBE to the black wire CONNECTOR
• black PROBE to the blue wire CONNECTOR
[9] If there is AC voltage, advance to the next step. If not, install a new PLUG.
[10] Check that there is AC voltage present at the POWER SWITCH CONNECTORS.
[11] Connect:
• red PROBE to PIN 2 of the POWER SWITCH
• black PROBE to the blue wire CONNECTOR on the back of the PLUG
[12] If voltage is present, advance to PIN 3 of the POWER SWITCH. If voltage is present on PIN 3, advance to the
next step. If voltage is not present on PIN 2, check the wire from the PLUG and/or install a new PLUG. If
voltage is present on PIN 2 but not PIN 3, install a new POWER SWITCH.
[13] Check that there is DC output from the J1 CONNECTOR on the POWER SUPPLY.
[14] Set the DIGITAL VOLT METER to DC.
[15] Connect:
• red PROBE to J1, PINS 1 - 7
• black PROBE to J1, PINS 8 - 14; the DIGITAL VOLT METER should read 12 - 16.5 V DC
[16] If voltage is not present on PINS 1 - 7, install a new POWER SUPPLY.
[17] If voltage is present, advance to the next step.
[18] De-energize the PRINTER.
[19] Check the continuity from the HARNESS from J1 to the THERMAL HEAD.
[20] If continuity is present, install a new THERMAL HEAD HEAT SINK ASSEMBLY.
[21] If continuity is not present, install a new HARNESS.

1- 56
DONOR TRANSPORT and SENSING SYSTEM
Safety
The DONOR TRANSPORT and SENSING SYSTEM is a low voltage area.

Functional Description
The DONOR TRANSPORT and SENSING SYSTEM is divided into 2 systems that are interdependent on each
other. 1 part of the system mechanically advances and rewinds the DONOR and adjusts tension. The other part of the
system detects the DONOR PATCH. The second part of the system detects type of DONOR. This part of the system
is used to inform the CONTROLLER which patch, yellow, magenta, or cyan, is being sensed by the DONOR LED
or SENSORS. It also detects what type of DONOR is installed as sensed by the BAR CODE reader.
The DONOR TRANSORT SYSTEM includes the SUPPLY BRACKET, SUPPLY SPINDLES, CLUTCH, ONE-
WAY INSERTION BRACKET, and the TAKE-UP SYSTEM which is integrated into the DOOR ASSEMBLY,
TAKE-UP SPINDLES and CLUTCH. The TAKE-UP and SUPPLY MOTORS are unit-directional. The SUPPLY
MOTOR operates at ≈ - 10.54 V DC while advancing, ≈ 10.44 V DC during rewind, and ≈ 10.42 V DC during tension
adjustment.
The TAKE-UP MOTOR operates at ≈ - 10.3 V DC while advancing, ≈ 3.85 V DC during rewind, and at 0 V DC
while adjusting tension. The DONOR TRANSPORT SYSTEM not only advances, rewinds, and adjusts tension on
the DONOR patches; it also moves the RECEIVER into the correct position at the beginning of the print cycle.
The DONOR PATCH SENSING SYSTEM includes the DONOR LED, BLUE and GREEN LEDs, and the DONOR
SENSORS. The DONOR LED are mounted to the FAN BRACKET, the DONOR SENSORS are mounted to the
ROLLER ASSEMBLY. With DONOR installed and the DOOR closed, the DONOR SENSORS are correctly
aligned. The DONOR SENSORS are used to detect the correct patch/color, cyan, magenta, yellow, and laminate, and
metering the DONOR. The BLUE and GREEN SENSORS can be adjusted to the correct range. The DONOR
SENSORS sense DONOR movement during the print cycle and check that the correct color patch is printed at the
correct time.

The DONOR type BAR CODE SENSING SYSTEM is attached to the DONOR SUPPLY BRACKET and includes
a BAR CODE SENSOR. The DONOR type is determined by reading the BAR CODE LABEL on the DONOR
SUPPLY SPOOL. The software can read the LABEL in the rewind and advance modes. A 2-of-8 BAR CODE is
used.
The DONOR type BAR CODE will read when a new DONOR SUPPLY SPOOL is installed. Since the ENGINE
does not contain SENSORS that detect the DONOR SUPPLY SPOOL, the DONOR BAR CODE is read when the
PRINTER is energized and when the DOOR is closed. This checks that the DONOR type is known after the end-user
has installed a new DONOR SUPPLY SPOOL.

If a malfunction occurs during a read, a valid 2-of-8 code is not read or the DONOR type code read is invalid. The
LCD displays a message indicating to load the correct type of DONOR.

1- 57
Installation: DONOR
For more information on the DONOR and software versions, see the SITE SPECIFICATIONS.

Caution
Prevent damage. Do not touch the DONOR. Contamination will occur.
[1] Remove the DONOR from the package and place the DONOR on its end on a surface that is not contaminated.

DONOR TAKE-UP DONOR SUPPLY

SPINDLES SPINDLES notch

notch
DONOR TAKE-UP
SPOOL

notch

DONOR SUPPLY
SPOOL

BAR CODE
A087_4074BCA
A087_4074BC

[2] Open the DOOR to the DONOR.

[3] Locate the DONOR TAKE-UP SPINDLE.

Important
When you install the DONOR TAKE-UP SPOOL, the notches must be to the right of the PRINTER.
[4] Insert the DONOR TAKE-UP SPOOL on the left side of the DONOR TAKE-UP SPINDLE by moving the
SPOOL to the left and compressing the TAKE-UP SPINDLE SPRING.
[5] With the left TAKE-UP SPINDLE SPRING compressed by the TAKE-UP SPOOL, insert the right side of the
DONOR TAKE-UP SPOOL on the right TAKE-UP SPINDLE and release.

1- 58
 RIGHT DRIVE
SPINDLE

DONOR SUPPLY
SPOOL
LEFT SPINDLE

PLASTIC END

PLASTIC END
BAR CODE LABEL
A087_0157HCA
A087_0157HC

[6] Locate the area of the DONOR SUPPLY.

[7] Hold the DONOR SUPPLY SPOOL from the plastic ends with the BAR CODE LABEL to the left.
[8] Insert the right end of the DONOR SUPPLY SPOOL on the DRIVE SPINDLE while holding the DONOR
SUPPLY SPOOL from the left plastic end.
[9] Compress the LEFT SPINDLE with your left hand.
[10] Place the left end of the DONOR SUPPLY SPOOL on the LEFT SPINDLE and release the SPINDLE.
[11] Rotate the DONOR SUPPLY SPOOL by either plastic end in the direction of the DOOR until the SUPPLY
SPOOL seats onto the SPINDLE TABS.

1- 59
 ADHESIVE STRIP
DONOR

A087_0079BCA
A087_0079BC

Caution
Prevent damage. Do not touch the DONOR. Contamination will occur.
[12] Unwind the DONOR from the DONOR SUPPLY ROLL.
[13] Locate and remove the tape covering the ADHESIVE STRIP on the DONOR.
[14] Hold the DONOR up and place the ADHESIVE STRIP in the center of the DONOR TAKE-UP SPOOL.
[15] Check that the ADHESIVE STRIP is correctly adhered to the DONOR TAKE-UP SPOOL by moving your
finger across the DONOR TAKE-UP SPOOL over the ADHESIVE STRIP from left to right.

ADHESIVE STRIP

Place the DONOR in

the center of the TAKE-UP.

A087_0084BCA
A087_0084BC

[16] Place the DONOR in the center of the TAKE-UP.

1- 60
 DONOR
TAKE-UP
SPOOL
MAGENTA
PATCH

DONOR
SUPPLY
SPOOL

A087_4082BCA
A087_4082BC

[17] Rotate the DONOR TAKE-UP SPOOL 2 complete rotations to the magenta patch to correctly wrap the
DONOR on the DONOR TAKE-UP SPOOL. Check that the DONOR LED are behind the magenta patch.
[18] Close the DOOR.

Important
You must clean the THERMAL HEAD after removing or installing the DONOR.
[19] Do the cleaning procedure for the THERMAL HEAD. See the PERIODIC MAINTENANCE.
[20] Check for correct operation.

1- 61
Donor Sensing Specification
Voltages:
• TAKE-UP, SUPPLY, MOTOR: ≈ 3-12 V DC
• BLUE DONOR SENSOR: on yellow patch, 3.9± 0.05 V DC, on cyan patch < 0.5 V DC, on magenta patch > 3.5
V DC
• GREEN DONOR SENSOR: on cyan patch, 3.7 ± 0.05 V DC, on magenta patch > 3.5 V DC, on yellow patch <
0.5 V DC

1- 62
Voltage Specifications
CONTROLLER BOARD while in Diagnostic Donor Test
CONNECTOR PIN Voltage
SUPPLY MOTOR TP3 (-) 6 ≈ - 10.7 V DC advance, ≈ 10.6 V DC
REWIND, ≈ 10.6 V DC take slack
SUPPLY MOTOR TP3 (+) 5
TAKE-UP MOTOR TP3 (-) 3 ≈- 10.6 V DC advance, ≈ 4.5 V DC
REWIND, 0 V DC take slack
TAKE-UP MOTOR TP3 (+) 4
CONTROLLER BD - P2 9* ≈ 12 V DC
CONTROLLER BD - P2 10* ≈ 12 V DC
CONTROLLER BD - P2 3 GND
GREEN DONOR SENSOR, TP8 (-) 5* See Table
BLUE DONOR SENSOR, TP8 (+) 6* See Table

* Use TP4, PIN 6 for GND.

DONOR SENSING TRUTH

Color BLUE LED, TP8-6 GREEN LED, TP8-5
YEL H > 3.5 V DC L < 0.5 V DC
MAG/BLK H > 3.5 V DC H > 3.5 V DC
CYN L < 0.5 V DC H > 3.5 V DC
LAM L < 0.5 V DC L < 0.5 V DC

H = Logic high of 1
L = Logic low of 0

FAN BRACKET BOARD - 3-PIN CONNECTOR

Wire Voltage
black GND
yellow ≈ 12 V DC
red ≈ 12 V DC

1- 63
Donor Sensing Preliminary Check
[1] De-energize the PRINTER.
[2] Check:
• DONOR is installed correctly
• for damage on the BAR CODE LABEL located on the right side of the DONOR SUPPLY SPOOL
• DONOR SUPPLY SPOOL is not empty
• 5 and 12 V DC LED is illuminated on the CONTROLLER BOARD
• GREEN and BLUE DONOR LED are illuminated on the FAN BRACKET ASSEMBLY
[3] Close the DOOR.

1- 64
DONOR TRANSPORT

Important
Check the 12 V DC input on the CONNECTOR P12 first before doing this procedure.
[1] Enter the diagnostic [DIAG: DONOR TEST].
[2] Do the TAKE SLACK, ADVANCE, and REWIND TESTS.
[3] Check that the DONOR REWINDS, ADVANCES, and has the correct tension.
[4] Check the MOTOR voltages; set the DIGITAL VOLT METER to DC voltage.
[5] Connect the black PROBE to TP3, PIN 6 and the red PROBE to TP3 PIN 5, SUPPLY MOTOR. The DIGITAL
VOLT METER will read:
• ≈ - 10.7 V DC in ADVANCE
• ≈ 10.6 V DC in REWIND
• ≈ 10.6 V DC while in TAKE SLACK
[6] Connect the black PROBE to TP3, PIN 3. Connect the red PROBE to TP3, PIN 4, TAKE-UP MOTOR. The
DIGITAL VOLT METER should read as listed below. If the voltages are present, advance to the next step. If
all of the voltages are not present, install a new CONTROLLER BOARD.
• ≈ - 10.5 V DC in ADVANCE
• ≈ 4.3 to 4.6 V DC in REWIND
• ≈ 0 V DC while in TAKE SLACK
[7] Check for continuity. Disconnect:

CONNECTOR P1 PINS Resistance

TAKE-UP MOTOR 3, 4 ≈ 20 ± 5 ohms
SUPPLY MOTOR 5, 6 ≈ 20 ± 5 ohms
[8] If the resistances are not correct, install a new MOTOR BRACKET ASSEMBLY.
[9] If the resistances are correct, do the following:
(a) Connect P1 to the CONTROLLER BOARD.
(b) Measure the resistance at TP3, PINS 6 and 5, SUPPLY MOTOR. The resistance should be ≈ 20 ± 5 ohms.
If not, install a new CONTROLLER BOARD.

1- 65
DONOR PATCH SENSING LED
[1] Check if the BLUE and GREEN DONOR LED are illuminated.
[2] If the DONOR LED are not illuminated, check for the 12 V DC on the FAN BOARD ASSEMBLY,
CONNECTOR P2, red, yellow and black wires.
[3] Set the DIGITAL VOLT METER to + DC VOLTAGE.
[4] Connect the red (+) PROBE to the FAN BOARD CONNECTOR red wire, then the yellow wire.
[5] Connect the black (-) PROBE to the FAN BOARD CONNECTOR black wire.
(a) If the voltage + 12 V DC is present, install a new FAN BRACKET ASSEMBLY.
(b) If the voltage is not present, advance to the next step.Check the continuity of the EMITTER CABLE.
Disconnect CONNECTOR P7 on the CONTROLLER BOARD and the 3-PIN CONNECTOR on the
FAN BRACKET.

CONNECTOR PIN 3-PIN CONNECTOR Resistance

P7 3 black wire ≈ 0 ± 1 ohm
P7 1 red wire ≈ 0 ± 1 ohm
P7 2 yellow wire ≈ 0 ± 1 ohm
[6] If continuity is present, advance to the next step. If continuity is not present, install a new LED/FAN BRACKET
HARNESS.
[7] Connect CONNECTOR P7 and the 3-PIN CONNECTOR on the FAN BRACKET ASSEMBLY.
[8] Check the voltage at P7 on the CONTROLLER PRINTED CIRCUIT BOARD.
[9] Set the DIGITAL VOLT METER to DC voltage.
[10] Connect the red PROBE to P7 and PIN 1, then PIN 2 on the CONTROLLER BOARD.
[11] Connect the black PROBE to any GROUND. The DIGITAL VOLT METER should read 12 V DC,
TP10-PIN 6.
[12] If 12 V DC is not present at P7 PIN 1, install a new CONTROLLER BOARD.

1- 66
DONOR PATCH SENSING DETECTORS

Important
Do the adjustments for the DONOR before doing this test.
[1] Check that DONOR is installed and that the BARCODE LABEL is present and not damaged on the DONOR
SUPPLY BRACKET.

Important
The PRINTER uses 5 different DONORS.
[2] Check that the LED BOARD, FAN BRACKET BOARD, is installed correctly and that the BLUE/GREEN
LED are illuminated.
[3] Set the DIGITAL VOLT METER to DC voltage.
[4] Connect:
• red PROBE to TP8, PIN 5, GREEN LED, on the CONTROLLER BOARD
• black PROBE to TP4, PIN 6, GROUND
[5] Enter the diagnostic test [DIAG: DONOR TEST].
[6] Close the DOOR.
[7] Advance the DONOR. The LCD DISPLAY should read as follows as the DONOR advances:
• DNR: COLOR = YEL
• DNR: COLOR = MAG/BLK
• DNR: COLOR = CYN
• DNR: COLOR = LAM
[8] As the DONOR advances in the diagnostics, the DIGITAL VOLT METER should read as in the table below
for TP8, PIN 5.
[9] Connect the red (+) PROBE to TP8, PIN 6, BLUE LED.
[10] Advance the DONOR; the DVM should read as in the table below for TP8, PIN 6.

COLOR TP PIN Voltage

YEL 8 5 GREEN < 0.5
MAG/BLK 8 5 GREEN > 3.5
CYN 8 5 GREEN > 3.5
YEL 8 6 BLUE > 3.5
MAG/BLK 8 6 BLUE > 3.5
CYN 8 6 BLUE < 0.5
LAM - CLEAR 8 5 GREEN < 0.5
LAM - CLEAR 8 6 BLUE < 0.5
[11] If the voltages are close to the threshold, the alignment is most likely not correct. Install a new FAN BRACKET
ASSEMBLY. If the voltages do not change, the DONOR DETECTOR may have a malfunction. Install a new
ROLLER ASSEMBLY.
[12] If all the voltages are correct, the CONTROLLER BOARD could have a malfunction. Install a new
CONTROLLER BOARD.

1- 67
DONOR TYPE BAR CODE SENSING

Important
Do the adjustment for the BAR CODE SENSOR before doing these tests. See the ADJUSTMENTS AND
REPLACEMENTS.

Type Code Not Detected

Normal Mode - OCP Read Diagnostic Mode Read Description
LOAD RIBBON [DNR: TYPE>NONE] The type code is not detected.
The BAR CODE SENSOR did
not detect any BARS. This
could indicate the following
malfunctions:
• No DONOR installed
• BAR CODE SENSOR not
in correct alignment
• BAR CODE READ FRU
malfunction
• BAR CODE LABEL
missing
• BAR CODE LABEL not
aligned correctly
• BAR CODE FRU not
connected
• CONTROLLER BOARD
malfunction

Type Code Not Detected - Procedure

[1] Check that the correct DONOR is installed. If not, install the correct DONOR and test the PRINTER.
[2] Check that the BAR CODE LABEL is installed on the DONOR SUPPLY SPOOL. If the BAR CODE LABEL
is installed, advance to the next step. If the BAR CODE LABEL is not installed, install new DONOR.
[3] Check that the BAR CODE LABEL is parallel with the end of the DONOR SUPPLY SPOOL. If not, install
new DONOR. If the BAR CODE LABEL is in the correct location, advance to the next step.
[4] Check that the BAR CODE SENSOR is not loose and is correctly aligned with the BAR CODE LABEL on the
DONOR SUPPLY SPOOL. If the BAR CODE SENSOR is not correctly aligned, install a new DONOR
SUPPLY BRACKET and test again. If it is correct, advance to the next step.
[5] Check that the BAR CODE SENSOR CABLE is connected to the CONTROLLER BOARD. If it is not
connected, seat the CABLE CONNECTOR and test the PRINTER. If it is connected, advance to the next step.
[6] Set the DVM to DC voltage.
[7] Connect the red PROBE to TP4, PIN 4 and the black PROBE to TP4, PIN 6 on the CONTROLLER BOARD.

Important
Do the adjustment for the BAR CODE SENSOR before doing these tests. See the ADJUSTMENTS AND
REPLACEMENTS.
[8] With the DONOR installed, rotate the DONOR SUPPLY SPOOL.
[9] The voltage should read ≥ 4.7 V DC on the wide black patch and ≤ 0.25 V DC on the white patch. If the voltage
is within specification, install a new CONTROLLER BOARD. If the voltage is not within specification, install
a new DONOR SUPPLY BRACKET ASSEMBLY.
1- 68
Type Code Not Supported
Normal Mode - OCP Read Diagnostic Mode Read Description
LOAD RIBBON DONOR [DNR: TYPE_BAD>##] The type is not supported. A
valid 2-of-8 BAR CODE was
read but the type of DONOR is
not supported by the
PRINTER.
[10] Check in DNR: READ TYPE that a DNR: TYPE_OK->## is displayed. If a DNR: TYPE_BAD># is displayed,
it means that ## is not usable. The DONOR TYPE number is:
• YMC = 01
• YMCX = 02
• BX = 03
• YMC LONG = 04
• YMC-7 = 05
• YMCX LONG = 06
• YMCK = 07

1- 69
BAR CODE - Read Incomplete
Normal Mode - OCP Read Diagnostic Mode Read Description
SR#0510 [DNR: SR#0510] The BAR CODE read is
incomplete. The BAR CODE
SENSOR sensed at least 1 BAR
but not the number of BARS
necessary for a valid code. This
may indicate the following
malfunctions:
• DONOR SUPPLY SPOOL
moves too slow
• BAR CODE SENSOR not in
correct alignment
• BAR CODE LABEL not
correctly aligned
• BAR CODE READ FRU
malfunction
• BAR CODE SENSOR not
operating for TYPE:NONE
BAR CODE - Read Incomplete
1. Check that DONOR SUPPLY SPOOL rotates correctly and at normal speed in the [DNR: ADVANCE] and
[DNR: REWIND] modes.
2. Check that the BAR CODE SENSOR is not loose and is correctly aligned with the BAR CODE LABEL on the
DONOR SUPPLY SPOOL. If the BAR CODE SENSOR is not correctly aligned, install a new DONOR
SUPPLY BRACKET. If it is correct, advance to the next step.
3. Check that the BAR CODE SENSOR CABLE is connected to P2 on the CONTROLLER BOARD. If it is not
connected, seat the CABLE CONNECTOR and test the PRINTER. If it is connected, advance to the next step.
4. Do the adjustment for the BAR CODE SENSOR. See the ADJUSTMENTS AND REPLACEMENTS.
5. If the adjustments for the BAR CODE SENSOR cannot be set to specification, install a new DONOR SUPPLY
BRACKET.
6. If all of the adjustments for the BAR CODE SENSOR are to specification, and the PRINTER still does not
operate, install a new CONTROLLER BOARD.

1- 70
BAR CODE Not 2-of-8 Code
Normal Mode - OCP Read Diagnostic Mode Read Description
SR#0511 [DNR: SR# 0511] The number of BARS
necessary for a valid type
DONOR BAR CODE was
sensed. When the BARS were
decoded, the resulting code
was not a valid 2-of-8 code.
This may indicate the
following malfunctions:
• BAR CODE LABEL not
correct
• BAR CODE LABEL has
damage
• DONOR SUPPLY
SPOOL speed is erratic
• BAR CODE SENSOR not
in correct alignment
• BAR CODE LABEL not
aligned correctly
• BAR CODE READ FRU
malfunction
BAR CODE Not 2-of-8 Code
1. Check that the BAR CODE LABEL is installed on the DONOR SUPPLY SPOOL. If the BAR CODE LABEL
is installed, advance to the next step. If the BAR CODE LABEL is not installed, install new DONOR.
2. Check that the BAR CODE LABEL is parallel with the end of the DONOR SUPPLY SPOOL. If not, install new
DONOR. If the BAR CODE LABEL is in the correct location, advance to the next step.
3. Check the BAR CODE LABEL for damage. If the BAR CODE LABEL has damage, install a new DONOR
ROLL. If the BAR CODE LABEL has no damage, advance to the next step.
4. Check that the BAR CODE SENSOR is not loose and is correctly aligned with the BAR CODE LABEL on the
DONOR SUPPLY SPOOL. If the BAR CODE SENSOR is not correctly aligned, install a new DONOR
SUPPLY BRACKET. If it is correct, advance to the next step.
5. Check that the [DNR: ADVANCE] and [DNR: REWIND] modes operate correctly.
6. If an error occurs, such as SR 510, check that the DONOR does not cause a bind due to a malfunction of the
THERMAL HEAD GAP in the LOAD POSITION. Check for damage of the MOTOR BRACKET. If there is no
bind in the DONOR, advance to the next step.
7. Install the DONOR SUPPLY BRACKET ASSEMBLY and test the PRINTER.
8. If the PRINTER still does not operate correctly, install a new CONTROLLER BOARD and/or CABLE from the
DONOR SUPPLY BRACKET ASSEMBLY to the CONTROLLER BOARD.

1- 71
PICKING
Safety
This is a low voltage area.

Functional Description
Picking occurs when the RECEIVER, paper/REFLECTIVE or TRANSPARENCY, is moved into the ROLLER
MECHANISM. This procedure uses the PAPER TRAY, TRAY TYPE SENSORS, RECEIVER TYPE SENSORS,
paper/REFLECTIVE or TRANSPARENCY, and the PICKER MECHANISM. Some actions must be completed
before the PICKING CYCLE begins to start the PRINT CYCLE. A TRAY must be detected, A, A4 the media
selection must match the media installed, and the CONTROLLER BOARD must detect both states.
After the conditions above occur, the PRINTER begins the PRINT CYCLE. Then the PICKING MECHANISM will
energize and move the RECEIVER into the ROLLER MECHANISM. If the RECEIVER does not move to the
ROLLER MECHANISM in the correct time, the PRINTER will “time out”. This could be caused if a RECEIVER
is not installed, the TRAY or PICKER MECHANISM has a malfunction, the environmental condition is not within
specification, or there is a paper jam in the PAPER CHUTE or NIP area of the ROLLER MECHANISM.

ROLLER ASSEMBLY

PINCH ROLLER

LEAD EDGE SENSOR

PLATEN ROLLER
CAPSTAN TRACTION ROLLER

PINCH ARM (2) RECEIVER

A087_0065DCB
A087_0065DC

As the RECEIVER is being picked, the CAPSTAN MOTOR, PLATEN BRAKE, and the DONOR TAKE-UP and
SUPPLY MOTORS are energized. The DONOR advances allowing the RECEIVER to enter the NIP and reach the
LEAD EDGE SENSOR.
The PINCH MOTOR energizes, PINCHING the RECEIVER in between the PINCH ROLLER and CAPSTAN
TRACTION ROLLER. At this time, the PICK MOTOR, CAPSTAN MOTOR, PLATEN BRAKE, and the DONOR
TAKE-UP and SUPPLY MOTORS de-energize. The PICK MOTOR reverses to return the PICKER to its original
position.

1- 72
Installation: RECEIVER - Paper, Transparency, 8x10 Film
Installation of A or A4 CVP. (Note A size media is shown in the figure below.)

In stalla tion of 8x1 0 D V F B

Caution
• Do not place more than 100 sheets of RECEIVER in the TRAY.
• The RECEIVER installed must match the size of the TRAY selected.
[1] Remove the TRAY COVER.

Caution
Do not remove the WHITE BOARD.
[2] Pick the RECEIVER up by the ends with the WHITE BOARD on the RECEIVER.
[3] If you are installing paper, check that the manufacturing printing faces up.
[4] If you are installing TRANSPARENCIES, check that the notches are in the right end corner.
[5] Check that the WHITE BOARD is installed under the RECEIVER in the bottom of the TRAY. If the WHITE
BOARD is not installed, this might cause a malfunction.
[6] Place the RECEIVERS on top of the TRAY PLATEN.
[7] Check that the stack is under both CORNER NAILS.
[8] Install the TRAY COVER.

1- 73
Paper Jam
There are 2 types of paper jams, a PICKER or a PINCH.

RECEIVER jam
in PRINT CYCLE

A087_4011DCA
A087_4011DC

1- 74
 RECEIVER jam in PICK CYCLE

A087_4010BCA
A087_4010BC

[1] Open the DOOR.

[2] Check for paper in the ROLLER ASSEMBLY.

Caution
When removing a RECEIVER that has caused a jam in the ROLLER ASSEMBLY, prevent damage to the
KICKERS/RUBBER WHEELS.
[3] If the paper is in the PINCH ROLLER, remove the jam from the top of the ROLLER ASSEMBLY.
[4] If the paper is in the CHUTE or the TRAY, remove the TRAY and carefully place your hand inside the TRAY
SLOT. Remove the jam.

1- 75
Picking Specifications

CONNECTOR PIN Voltage - PICKER MOTOR

TP2 (+) 4 ≈ - 10.5 V DC Forward
≈ 10.5 V DC Reverse
Voltage - TRAY Measured in V DC
TP10 A A Long 8 1/2 x 14 in. 9 1/2 x 14 in. A4 A4 Long A4 x 14 in. No TRAY
2 > 3.0 < 0.5 > 3.0 > 3.0 > 3.0 < 0.5 < 0.5 > 3.0
3 > 3.0 > 3.0 < 0.5 > 3.0 < 0.5 < 0.5 > 3.0 > 3.0
4 < 0.5 < 0.5 < 0.5 > 3.0 > 3.0 > 3.0 > 3.0 > 3.0

STEPPER MOTOR
Phase Voltage
All 4 phases ≈ 10.8 1 V AC in diagnostics

Important
During the PICKING/EJECT TEST, the PLATEN BRAKE is on for 1-2 seconds.
Use TP9, PIN 6 for GROUND.

PLATEN BRAKE
CONN PIN Picking/Ejecting V Printing/Ready V
TP9 (+) 5 < - 10.9 V DC Approximately 1 11.0
V DC in diagnostics

Important
The voltages are read during operation of the MOTOR.

PINCH ROLLER - Use TP7, PIN 2 for GROUND/- PIN

CONN PIN PINCH Closing V PINCH Opening V
TP7 1 ≈ - 11.20 V DC in ≈ 11.1 V DC in
Diagnostics Diagnostics

LEAD EDGE SENSOR - Use TP4, PIN 6 for GROUND

CONN PIN RECEIVER in PINCH No RECEIVER
TP8 3 < 0.5 V DC > 2.5 V DC

Adjustment Voltage
RECEIVER THRESHOLD 1.0 ± 0.1 V DC, paper in TRAY
RECEIVER BIAS Paper in TRAY = > 2.5 V DC
TRANSPARENCY in TRAY = < 0.5 V DC
STEPPER MOTOR 0.54 ± 0.01 V DC
LEAD EDGE SENSOR - TRANSPARENCY 0.18 ± 0.01 V DC
installed in PINCH

1- 76
RECEIVER SPECIFICATIONS

Size Inches - W x L Cm - W x L
A 8.5 x 11 ± 0.040 21.7 x 28.1 ± 0.1
8.5 x 12 ± 0.040 21.7 x 30.7 ± 0.1
8.5 x 14 ± 0.040 21.7 x 35.8 ± 0.1
A4 8.27 x 11.69 ± 0.040 21.0 x 29.7 ± 0.1
8.27 x 12 ± 0.040 21.0 x 30.7 ± 0.1
8.27 x 14 ± 0.040 21.0 x 35.8 ± 0.1
8x10 7.94 x 9.94 ± 0.168 201.6 x 252.4 ± 0.426

1- 77
Printable Area

Size Specification
A 20.32 x 22.69 ± 0.064 cm)
(8.00 x 8.933 ± 0.025 in.)
2400 pixels x 2680 lines

A 20.4 x 25.6 cm
(8.00 x 10.00 in.)
2400 pixels x 3000 lines
A 20.4 x 30.7 cm
(8.00 x 12.00 in.)
2400 pixels x 3626 lines
A4 20.32 x 24.47 ± 0.064 cm
(8.00 x 9.633 ± 0.025 in.)
2400 pixels x 2890 lines
A4 20.4 x 24.6 cm
(8.00 x 9.6 in.)
2400 pixels x 2890 lines
A4 20.4 x 25.6 cm
(8.00 x 10.00 in.)
2400 pixels x 3000 lines
9.5 x 14 in. 21.7 x 30.7 cm
(8.5 x 12.00 in.)
2550 pixels x 3626 lines
9.5 x 14 in. 21.7 x 30.7 cm
(8.5 x 12.00 in.)
2528 pixels x 3626 lines
8 x 10 in. 2280 pixels x 2565 lines

1- 78
Image Placement at Lead Edge Sensor
Type Specification
Lead Edge 2.60 ± 0.064 cm (1.025 ± 0.025 in.)

1- 79
Image Placement - Left Border, Right Side of PRINTER
Size Type Specification
A REFLECTIVE 0.63 ± 0.238 cm
(0.252 ± 0.095 in.)
A TRANSPARENCY 0.63 ± 0.275 cm
(0.252 ± 0.110 in.)
A4 REFLECTIVE 0.335 ± 0.238 cm
(0.134 ± 0.095 in.)
A4 TRANSPARENCY 0.335 ± 0.275 cm
(0.134 ± 0.110 in.)

6.4 +
_ 2.4 mm + 2.4 mm
3.4 _ + 2.4 mm
12.54 _
+ .095 in.) Reflective
(.252 _ (.134 +
_ .095 in.) Reflective +
_
(.494 .095 in.) Reflective
+ 2.79 mm
6.4 _ + 2.79 mm
6.4 _ + 2.79 mm
6.4 _
(.252 +
_ .110 in.) Transparency (.252 +
_ .110 in.) Transparency (.494 +
_ .110 in.) Transparency

203.2 mm 203.2 mm 215.9 mm

(8.00 in.) (8.00 in.) (8.50 in.)

26 +
_ .63 mm
+ .025 in.)
(1.025 _
_ .040 in.)
+ 1 mm
(12.00 in. +

A A4 9.5 x 14 in.
304.8 _

21mm
(.983 in.)

215.9 x 355.5 mm 210 x 358 mm 241.3 x 355.6 mm

A087_4038HC (8.5 x 14 in.) (8.26 x 14 in.) (9.5 x 14 in.)

1- 80
 + 2.4 mm
6.4 _ 3.4 +
_ 2.4 mm
+ .095 in.) Reflective
(.252 _ + .095 in.) Reflective
(.134 _
+
_
6.4 7.9 mm +
_
6.4 7.9 mm
+ .110 in.) Transparency
(.252 _ + .110 in.) Transparency
(.252 _

203.2 mm 203.2 mm
(8.00 in.) (8.00 in.)

+ .63 mm
26 _

_ .040 in.)
1.025 +
_ .025 in.)

+ 1 mm
(10.00 in. +
A A4

254 _
21mm
(.983 in.)

215.9 x 304.6 mm 210 x 305 mm

(8.5 x 12 in.) (8.26 x 12 in.) A087_4039HC

+ 2.4 mm
6.4 _ 3.4 +
_ 2.4 mm
(.252 +
_ .095 in.) Reflective + .095 in.) Reflective
(.134 _
6.4 +
_ 2.79 mm 6.4 +
_ 2.79 mm
+ .110 in.) Transparency
(.252 _ + .110 in.) Transparency
(.252 _

203.2 mm 203.2 mm
(8.00 in.) (8.00 in.)
_ 1.016 mm
_ 1.016 mm

26 +
_ .63 mm
_ .040 in.)
_ .040 in.

1.025 +
_ .025 in.)

A A4
8.933 +

244.678 +
(9.633 +
226.89 +

21mm
(.983 in.)

Standard A size
(8.5 x 11 in.) Standard A4 size
26.29 mm
(8.5 x 11 in.)
(1.035 in.) A087_4040HC

1- 81
8x10 specification

Size Type Specification

8x10 Clear/blue film 0.426 +/- 0.238 cm
0.168 +/- 0.095 in

1- 82
MEDIA TRAYS

8x10 media tray - slide selector

1- 83
A SIZE ADJUSTABLE TRAY RECEIVER

1- 84
A4 SIZE ADJUSTABLE TRAY RECEIVER

1- 85
 R E C E IV E R T R AY LAB E L (ID)

(no LAB E L)

T R AY T Y P E
S E NS OR 1 A4

T R AY T Y P E
S E NS OR 2 A

12 inch
(307 mm) Used for 8.5 x 12 in.
A4 x 12 in.
T R AY T Y P E 9.5 x 14 in.
S E NS OR 3 A4 x 14 in.

R eflective s urface
Opaque s urface
T R AY T Y P E

T R AY T Y P E
T R AY T Y P E
S E NS OR 1

S E NS OR 3
S E NS OR 2

Image S ize R eceiver S ize

A 8.000 x 8.933 203 x 227 8.504 x 10.984 216 x 279

A4 8.000 x 9.633 203 x 245 8.268 x 11.693 210 x 297

(A x 12) inch 8.000 x 10.000 203 x 254 8.504 x 12.087 216 x 307

(A4 x 12) inch 8.000 x 10.000 203 x 254 8.268 x 12.087 210 x 307

(9.5 x 14) inch 8.500 x 12.000 216 x 305 9.488 x 14.094 241 x 358

(A x 14) inch 8.000 x 12.000 203 x 305 8.504 x 14.094 216 x 358

(A4 x 14) inch 8.000 x 12.000 203 x 305 8.268 x 14.094 210 x 358

Note 1: Refer to Section 4 for 8x10 tray sensor information.

Note 2: Refer to page 1-82 for 8x10 film media size specifications.

A087_9028E C

1- 86
MEDIA TRAYS Preliminary Check
[1] Check:
• TRAY is installed and seated correctly
• you have selected the correct size of TRAY, 8.5 x 11 in. or 8.5 x 12 in., and the size matches the RECEIVER
• RECEIVER is installed and it matches the type selected, PAPER/TRANSPARENCY
• media for damage that might cause a paper jam
• curl in the RECEIVER
Note
The curl should not be more than 0.500 in. If the curl is greater than 0.500 in., it might be necessary to recommend
that the customer install 50 or fewer sheets at a time.
[2] Check that the BASE ENCLOSURE WALLS are in the correct position. This might occur during transport or
if the PRINTER has been damaged. This can cause the following malfunctions:
• Media jams
• DONOR advance malfunctions
• DONOR unwinds into the EXIT TRAY
• Print artifacts
• PRINTER does not operate
[3] If the WALLS are not in the correct position, do the following adjustments. See the ADJUSTMENTS AND
REPLACEMENTS.
• BASE ENCLOSURE WALLS
• THERMAL HEAD LOAD GAP - do this adjustment only if the BASE ENCLOSURE WALLS are not
in the correct position.
[4] Do the adjustment for the PICKER PENETRATION. See the ADJUSTMENTS AND REPLACEMENTS.
[5] Check that the adjustment for the THERMAL HEAD LOAD GAP is correct. See the ADJUSTMENTS AND
REPLACEMENTS.

1- 87
MEDIA TRAY: Malfunctions - Error Codes 502 and 503
[1] Do the following removal procedures. See the ADJUSTMENTS AND REPLACEMENTS.
• DOOR COVER
• ENCASEMENT
• CONTROLLER ENCLOSURE AND DRAWER AY
[2] Check that the TRAY CODE LABEL is correctly installed and is not partially removed from the TRAY.

Important
With the TRAY, check that the selection of REFLECTIVE LABELS matches the size of the RECEIVER.
[3] Enter the diagnostics and advance to [DIAG: RECEIVER]. Using the diagnostics, check that the LCD
DISPLAY changes from [NO PAPER] to one of the sizes below when removing and inserting the TRAY.
• [8.5 x 11 in._____]
• [8.5 x 12 in._____]
• [8.5 x 14 in._____]
• [9.5 x 14 in._____]
• [A4_____]
• [210 x 307 mm______]
• [210 x 358 mm_____]
Note
The _____ after the size displays PAPER or TRANSPARENCY if a RECEIVER is installed. If no RECEIVER is
installed, PAPER will display.

[4] If the TRAY selection matches the TRAY, the system is operating correctly. If the TRAY selection does not
change or read the correct type, advance to the next step.
[5] Check that the TRAY CODE SENSOR is not loose or has damage.
[6] Insert the TRAY and check that the TRAY CODE SENSORS align with the TRAY LABELS.
[7] Check the voltages from the TRAY CODE SENSORS.
(a) Set the DIGITAL VOLT METER to DC voltage.
(b) Connect the black PROBE (-) to TP11, PIN 5 for GROUND.
(c) Use the following table to measure the voltages for the A TRAY, A4 TRAY and NO TRAY.

Voltage - TRAY Measured in V DC

TP10 A A Long 8 1/2 x 14 in. 9 1/2 x 14 in. A4 A4 Long A4 x 14 in. No TRAY
2 > 3.0 < 0.5 > 3.0 > 3.0 > 3.0 < 0.5 < 0.5 > 3.0
3 > 3.0 > 3.0 < 0.5 > 3.0 < 0.5 < 0.5 > 3.0 > 3.0
4 < 0.5 < 0.5 < 0.5 > 3.0 > 3.0 > 3.0 > 3.0 > 3.0

Note 1: Refer to Section 4 for 8x10 tray troubleshooting information.

1- 88
 TRAYCODE
SENSORS
1 and 2

1.27cm
(1/2 in.)

TRAY CODE A087_0096BCC

A087_0096BC
SENSOR 3

Important
Use TP11, PIN 5 for GND.
[8] Remove the TRAY CODE SENSORS and align them facing toward the ALUMINUM BASE. Both TEST
POINTS (TP) from the voltage chart above should be below 0.5 V DC.
(a) If the TRAY CODE SENSORS change state under the voltage specification, align the TRAY CODE
LABELS to the TRAY CODE SENSORS.
(b) If the voltages are not correct or do not change state, advance to the next step.
[9] Check the TRAY CODE CABLE from the TRAY CODE SENSORS to CONNECTOR P11 on the
CONTROLLER BOARD. Check that CONNECTOR P11 is correctly seated.
(a) If the TRAY CODE SENSORS still do not change at the TEST POINTS listed in the chart above, install
a new TRAY CODE SENSOR ASSEMBLY.
(b) If the TRAY CODE SENSORS change within the specifications, but the size of the TRAY or removal is
not indicated during the diagnostic test, install a new CONTROLLER BOARD.

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Media Sensing Malfunctions
[1] Do the following removal procedures. See the ADJUSTMENTS AND REPLACEMENTS.
• DOOR COVER
• ENCASEMENT
• CONTROLLER ENCLOSURE AND DRAWER AY
[2] Set the DIGITAL VOLT METER to DC voltage.
[3] Do the adjustment for the RECEIVER THRESHOLD. See the ADJUSTMENTS AND REPLACEMENTS.
[4] If the voltages are not within specification, check that the RECEIVER TYPE SENSOR is not loose on the
PICKER MECHANISM.
[5] Check that the RECEIVER TYPE SENSOR is correctly seated on the CONTROLLER BOARD,
CONNECTOR P8.
[6] If the RECEIVER TYPE SENSOR voltage is not within specification, install a new PICKER ASSEMBLY.
See the ADJUSTMENTS AND REPLACEMENTS.
[7] If the voltages at TP2, PIN 6 (+) and TP4, PIN 6 (-) from the adjustment of the RECEIVER THRESHOLD are
within specification but change is not sensed, advance to the next step.
[8] Enter the diagnostics. Advance to [DIAG: RECEIVER].
(a) Install paper or TRANSPARENCY. The LCD DISPLAY should read [8 1/2 x 11-in. paper]
or [8 1/2 x 11 in. TRANS] depending on the size of the TRAY and RECEIVER selected.
(b) If change does not occur on the LCD DISPLAY, and the voltages are changing at TP2, PIN 6 and TP4,
PIN 6, install a new CONTROLLER BOARD.

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PICKING: Malfunctions - Error Codes 501 and 502
[1] Do the following removal procedures. See the ADJUSTMENTS AND REPLACEMENTS.
• DOOR COVER
• ENCASEMENT
• CONTROLLER ENCLOSURE AND DRAWER AY
[2] Check that there is paper installed and it does not have curl or damage that could cause a paper jam in the
PAPER CHUTE.
[3] Install the RECEIVER and DONOR.
[4] Insert only 25 RECEIVERS into the TRAY.

Important
SR 408 can be a nonfatal error that occurs when there is a PICKING malfunction. This might be caused by not having
the RECEIVER or DONOR installed, paper curl, damage on the BASE ENCLOSURE WALLS, or the distance for
the THERMAL HEAD LOAD GAP is not correct. See the “Preliminary Check” on Page 71.
[5] Enter the diagnostics. Advance to [OPTIONS]. Select the “PICK and EJECT CYCLE” [<CYCLE: PCK/EJCT].
The < indicates that the option is on in the cycle type setup.
[6] Select “Loop Enable” and exit the diagnostics.
[7] Press the STATUS BUTTON in “ENGINE Ready” to start the “PICK and EJECT CYCLE”.
(a) If the PRINTER picks, the PICKING malfunction could be caused by low humidity (< 15% relative
humidity). If the PRINTER does not PICK, advance to the next step.
[8] If the PRINTER will not PICK, check that the TRAY PLATEN and SPRINGS operate correctly.
(a) Press your hand down on the TRAY PLATEN then release. The TRAY PLATEN should move back up
when you release your hand and all 3 PLATEN SPRINGS should be in place.
(b) If the TRAY PLATEN moves back up, it is operating correctly. Advance to the next step. If the TRAY
PLATEN does not move back up, install a new TRAY.
[9] Check:
• PICKER MOTOR operates correctly
• CONNECTOR P8 is correctly seated on the CONTROLLER BD
[10] Check the voltage on the PICKER MOTOR:
(a) Set the DIGITAL VOLT METER to DC voltage.
(b) Connect:
• red PROBE to TP2, PIN 4
• black PROBE to TP2, PIN 5
(c) Enter the diagnostics. Advance to OPTIONS, [OPT: CYCLE TYPE] and start the PICK CYCLE. The
DIGITAL VOLT METER should read ≈ - 10.5 V DC when the PICKER MOTOR is PICKING and ≈ 10.5
V DC when the MOTOR is returning to position.
[11] If the voltage is present and the PICKER MOTOR does not operate, install a new PICKER ASSEMBLY.
[12] If the voltage is not present, install a new CONTROLLER BD.
[13] If the voltages are present and the PICKER MOTOR operates, there might be a jam in the RECEIVER in the
ROLLER ASSEMBLY. Advance to the next step.
[14] Enter the diagnostics. Advance to [DIAG: MOTORS]. Select [MTRS: FWD].
[15] Do the adjustment for the STEPPER MOTOR. See the ADJUSTMENTS AND REPLACEMENTS.
[16] Check:
• CONNECTOR P10 is correctly seated on the CONTROLLER BOARD
• AC voltage on the STEPPER PHASES

1- 91
[17] Connect the DIGITAL VOLT METER PROBES to the STEPPER PHASES.
[18] Connect:
PROBE CONNECTOR PIN PHASE
Red TP7 4 A1
Red TP9 2 B1
Red TP7 6 C1
Red TP9 4 D1
Black TP7 3 A2
Black TP9 1 B2
Black TP7 5 C2
Black TP9 3 C2
[19] The DIGITAL VOLT METER should read ≈ 10.8 V AC across each phase in diagnostics.
(a) If the voltages are present and the STEPPER MOTOR does not operate, install a new ROLLER
ASSEMBLY.
(b) If the voltages are not present, install a new CONTROLLER BOARD.
(c) If the STEPPER MOTOR operates and all the voltages are present, advance to the next step.
[20] Check that the PLATEN ROLLER rotates.
[21] Check the DC voltage across the PLATEN BRAKE:
(a) Set the DIGITAL VOLT METER to DC voltage.
(b) Connect:
• black PROBE to TP9 PIN 6
• CONNECTOR P10 is inserted into PINS 1 and 3
(c) Make a test print.
[22] The DIGITAL VOLT METER should read ≈ 10.9 V DC.
(a) If the voltages do not change, install a new CONTROLLER BOARD.
(b) If the voltages are present and change, but the PLATEN ROLLER has a bind, install a new ROLLER
ASSEMBLY.
(c) If the voltages are present and change and there is no bind in the PLATEN ROLLER, advance to the next
step.
[23] Check that the PINCH ROLLER operates and that voltage is present:
(a) Check that CONNECTOR P10 is correctly seated.
(b) Enter the diagnostics. Advance to [DIAG: PINCH TEST].
(c) Install a sheet of paper between the PINCH ROLLER and the CAPSTAN TRACTION ROLLER.
(d) Select [PINCH: CLOSE] in the diagnostics.
(e) The paper should be held in place by the PINCH.

1- 92
[24] Check the voltage:
(a) Set the DIGITAL VOLT METER to DC voltage.
(b) Connect:
• red PROBE to TP7, PIN 1
• black PROBE to TP7, PIN 2
(c) The DIGITAL VOLT METER should read ≈ 11.0 V DC when closing. The DIGITAL VOLT METER
should read ≈ -11.0 V DC when opening.
(d) If the voltages are present and the PINCH does not open or close, check that the PINCH MOTOR is not
loose and install a new ROLLER ASSEMBLY if necessary.
(e) If the voltages are not present, check the PINCH MOTOR wires and install a new CONTROLLER BD if
necessary.
(f) If the voltages are present and the PINCH operates, advance to the next step.
[25] Check that the LEAD EDGE SENSOR operates:
(a) Do the adjustment for the LEAD EDGE SENSOR. See the ADJUSTMENTS AND REPLACEMENTS.
(b) Enter the diagnostics. Advance to [DIAG: PINCH TEST]. Advance to [PINCH: OPEN].
(c) Insert a sheet of paper under the LEAD EDGE SENSOR.
[26] Set the DIGITAL VOLT METER to DC voltage:
(a) Connect:
• red PROBE to TP8, PIN 3
• black PROBE to any GROUND
(b) The DIGITAL VOLT METER should read < 0.5 V DC with a RECEIVER in the PINCH.
(c) The DIGITAL VOLT METER should read > 2.5 V DC with no RECEIVER in the PINCH.
(d) If one of the voltages is present but does not change, install a new ROLLER ASSEMBLY.
(e) If the voltage is not present, install a new CONTROLLER BOARD.
(f) If the voltages are present and change with and without a RECEIVER, advance to the next step.
[27] If there is still a malfunction in PICKING, determine the position of the RECEIVER when the malfunction
occurs. Environmental conditions or the DONOR does not move can cause a jam or malfunction.
[28] Check that the adjustment for the THERMAL HEAD LOAD GAP is correct. See the ADJUSTMENTS AND
REPLACEMENTS.

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CONTROLLER BOARD ERRORS
Safety
The CONTROLLER BOARD operates on 5 and 12 V DC.

Functional Description
The CONTROLLER BOARD is the electronic BOARD that operates the print ENGINE. It also interfaces with the
PLATFORM through the PRINT ENGINE INTERFACE (PEI). The CONTROLLER BOARD controls all of the
necessary operations of the mechanical ENGINE necessary to convert the digital image data into a hard copy print.
The CONTROLLER BOARD includes:
• Firmware PROMS - 2 PROMS that control the complete electro-mechanical print process of the ENGINE
• EEPROMS - includes the ENGINE calibration, enable widths, parasetic compensation, counters, failure history,
initialization messages, matrix coefficients, and interpolation points
• INTERFACE CONTROL PAL - includes the programmable logic necessary to control the communication
interface to the KIM BOARD
• MEMORY CONTROL PAL - programmable logic necessary to allow the CPU to communicate with the
PROMS, STATIC RAM, and PULSE HEAD MODULATOR
• I/O CONTROL PAL - includes the programmable logic necessary to allow the CPU to communicate with the
DISPLAY, A/D CONVERTER, temperature of the THERMAL HEAD, EEPROM, and I/O CONTROLLER
• PHM (PULSE HEAD MODULATOR) - a component that controls the pulses to the THERMAL HEAD during
the print cycle
• CPU - CENTRAL PROCESSING UNIT for the ENGINE
• CONNECTOR for the DONOR BRACKET BARCODE AY - the BARCODE SENSOR detects the DONOR
type
• DSP PROM (DIGITAL SIGNAL PROCESSING) - processes the image data and lookup tables

Specifications
The supply voltage is 5 and 12 V DC.

Preliminary Check
[1] Check:
• all CONNECTORS are correctly seated
• POWER LEDs are illuminated
[2] Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY.

1- 94
Error Codes 600, 601, 602, and 603

Important
Most of the error codes occur when the PRINTER initializes.
[1] Enter the diagnostics and select [DIAG: ENG VER #s].
[2] Scroll through the versions and check that the ENGINE version information does not display [BAD MEM] or
[NONE] in the following versions:
• [VER: CR____]
• [VER: CT____]
• [VER: PR____]
• [VER: ER____]
• [VER: ET____]
[3] Enter the diagnostics and select [DIAG: PRN USAGE]. Scroll through the usage information and check that it
does not display [BAD MEM] or [NONE] in the messages.
• [USE: PWR_______]
• [USE: P-S_______]
• [USE: P-C_______]
• [USE: PLN_______]
• [USE: RFL_______]
• [USE: TRN_______]
• [USE: B-1_______]
[4] Enter the diagnostics and select [DIAG: CTRLR TEST]. Scroll through the tests and select
[CTRLR: C EEPROM] or [CTRLR: TEST ALL].
[5] Check that after selecting and doing these tests that [CTRLR: SR# 600], [CTRLR SR# 601] or [SR# 602] is not
displayed.
[6] If [BAD MEM], [NONE], or [SR# 600], [SR# 601], or [SR# 602] is displayed in any of the previous steps,
install a new PROM U43 and energize the PRINTER.
[7] If the error code is still present, install new PROMS U19 and U20 and energize the PRINTER.
[8] If the error codes are still present, install a new CONTROLLER BOARD.

1- 95
Error Codes 608, 609, 60A, 60C, and 719

Important
Most of these error codes occur when the PRINTER initializes or during the PRINT CYCLE.
[1] Enter the diagnostics and select [DIAG: ENG VER #s]. Scroll through the versions and check that the ENGINE
version information in the version [VER: H ____] does not display [BAD MEM] or [NONE].
[2] Enter the diagnostics and select [DIAG: PRN USAGE]. Scroll through and check that the usage information in
[USE: PLN] does not display [BAD MEM] or [NONE].
[3] Enter the diagnostics and select [DIAG: CTRLR TEST]. Scroll through the test and select
[CTRLR: TEST ALL] or [CTRLR: H EEPROM].
[4] Check that after selecting and doing these CONTROLLER tests that [CTRLR: SR# 608], [SR# 609], [SR# 60a],
[SER # 60b], or [SR# 719] are not displayed.
[5] If [BAD MEM], [NONE], [CTRLR: SR# 608], [SR# 609], [SR# 60a], [SER # 60b], or [SR# 719] are displayed
in any of the previous steps, check that the THERMAL HEAD DATA CABLE is correctly installed and seated,
then energize the PRINTER.
[6] If the error codes are still present, install a new THERMAL HEAD DATA CABLE or THERMAL HEAD
ASSEMBLY and energize the PRINTER.
[7] If the error codes are still present, install a new CONTROLLER BOARD.

1- 96
Error Code 610 - No Display Message
[1] Check that the DISPLAY CABLE is connected.
[2] Energize the PRINTER.
[3] If the 16-SEGMENT LCD does not illuminate, install a new DISPLAY PANEL and energize the PRINTER.
[4] If the 16-SEGMENT LCD still does not illuminate, install a new CONTROLLER BOARD.

1- 97
Error Code 618 and 60B

Important
This error occurs if the data is missing from the CONTROLLER EEPROM or the THERMAL HEAD EEPROM.
[1] Enter the diagnostics and select [DIAG: ENG VER #s]. Scroll through the versions and check that the ENGINE
version information in the following versions does not display [NONE].
• [VER: CR____]
• [VER: CT____]
• [VER: PR____]
• [VER: ER____]
• [VER: ET____]
• [VER: H____]
[2] Enter the diagnostics and select [DIAG: PRN USAGE]. Scroll through and check that the usage information in
the following versions does not display [NONE].
• [USE: PWR____]
• [USE: P-S____]
• [USE: P-C____]
• [USE: PLN____]
• [USE: RFL____]
• [USE: TRN____]
• [USE: B-1____]
[3] Enter the diagnostics and select [DIAG: CTRLR TEST]. Scroll through the test and select
[CTRLR: TEST ALL], [CTRLR: C EEPROM], and [CTRLR: H EEPROM].
[4] Check that after selecting and doing all of the tests that [CTRLR: SR# 618] is not displayed.If [NONE] is
displayed in any of the versions below in print usage and [SR# 618] is displayed in
[DIAG: CTRLR TEST] and [CTRLR: C EEPROM], install a new EEPROM U43.
• [VER: CR]
• [VER: CT]
• [VER: PR]
• [VER: PT]
• [VER: ER]
• [VER: ET]
• [USE: PWR]
• [USE: P-S]
• [USE: P-C]
• [USE: RFL]
• [USE: TRN]
• [USE: B-1]
[5] If [NONE] is displayed in version [VER: H NONE] and in print usage [USE: PLN NONE] and [SR# 618] is
displayed in [DIAG: CTRLR TEST] [CTRLR: H EEPROM], install a new THERMAL HEAD.

1- 98
Error Codes 718 and 719
[1] Enter the diagnostics and select [DIAG: CTRLR TEST]. Scroll through the tests and select
[CTRLR: ADC] or [CTRLR: TEST ALL].
[2] Check that after selecting and doing these tests that [CTRLR: SR# 718] is not displayed.
[3] If error code 718 is displayed, install a new CONTROLLER BOARD.

1- 99
Error Codes 720 and 721
[1] De-energize the PRINTER.
[2] De-energize the PRINTER.
[3] Install a new CONTROLLER BOARD.
[4] Energize the PRINTER.
[5] Make a test print.

1- 100
Error Codes 738 and 739
[1] Enter the diagnostics and select [DIAG: CTRLR TEST]. Scroll through and select [CTRLR: RAM 0], [CTRLR:
RAM 1] or [CTRLR: TEST ALL].
[2] Check that after selecting and doing these tests that [CTRLR: SR# 738] or [SR# 739] is not displayed.
[3] If error codes 738 or 739 are displayed, install a new CONTROLLER BOARD.

1- 101
Error Code 740
[1] Enter the diagnostics and select [DIAG: CTRLR TEST]. Scroll through the tests and select
[CTRLR: MATCH VERS] or [CTRLR: TEST ALL].
[2] Check that after selecting and doing these tests that [CTRLR: SR# 740] is not displayed.
[3] If error code 740 is displayed, install new PROMS U19 and U20.
[4] If error code 740 is still displayed, install a new CONTROLLER BOARD.

1- 102
Error Codes 741 and 742
[1] Enter the diagnostics and select [DIAG: CTRLR TEST]. Scroll through and select [CTRLR: PROM 0],
[PROM 1], or [CTRLR: TEST ALL].
[2] Check that after selecting and doing these tests that [CTRLR: SR# 741] or [SR# 742] is not displayed.
[3] If error code 741 or 742 is displayed, install new PROMS U19 and U20.
[4] If error code 741 or 742 is still displayed, install a new CONTROLLER BD.

1- 103
Error Codes 748, 749, 74A, 74B, 74C, 74D
[1] Enter the diagnostics and select [DIAG: CTRLR TEST]. Scroll through the tests and select
[CTRLR: PHM] or [CTRLR: TEST ALL].
[2] Check that after selecting and doing these tests that [CTRLR: SR# 748, 749, 74A, 74B, 74C, 74D]
is not displayed.
[3] If the error codes are displayed, install a new CONTROLLER BOARD.

1- 104
Error Code 757
[1] Enter the diagnostics and select [DIAG: CTRLR TEST]. Scroll through the tests and select
[CTRLR: DSP] or [CTRLR: DSP PROM].
[2] Check if [CTRLR: SR# 757] is displayed.
[3] If error code 757 is displayed, install a new DSP PROM.
[4] If error code 757 is still displayed, install a new CONTROLLER BOARD.

1- 105
Error Codes 760-773, 76E, 76F, 76A, 76B, 76C, 76D
[1] Enter the diagnostics and select [DIAG: CTRLR TEST]. Scroll through the tests and select
[CTRLR: PHM] or [CTRLR: TEST ALL].
[2] Check that after selecting and doing these tests that [CTRLR: SR# 760] or [SR# 773] is not displayed.
[3] If the error codes are displayed, install a new CONTROLLER BOARD.

1- 106
Error Codes 800 - 857
[1] Enter the diagnostics and select [DIAG: CTRLR TEST]. Scroll through and select [CTRLR: TEST ALL].
[2] Check that after selecting and doing [CTRLR: TEST ALL] that no errors [CTRLR: SR# 800 - 857] are
displayed.
[3] If the error codes are displayed, install a new CONTROLLER BOARD.

1- 107
Error Codes 900-930, 90B, 91B, 92B, 93B, 94B, 750-756
[1] Enter the diagnostics and select [DIAG: CTRLR TEST]. Scroll through and select [CTRLR: TEST ALL].
[2] Check that after selecting and doing [CTRLR: TEST ALL] that [NO ERRORS] are displayed.
[3] If the error codes are displayed, install a new CONTROLLER BOARD.

1- 108
Error Code 710, 711 and 712

Important
Error codes 710, 711 and 712 sometimes display when the PRINTER is in the EXTERNAL MODE and connected
to a computer. The error codes might not display through the diagnostics or when the PRINTER is not connected to
a computer.
[1] Enter the diagnostics and select [DIAG: CTRLR TEST]. Scroll through and select [CTRLR: TEST ALL].
[2] Check that after selecting and doing [CTRLR: TEST ALL] that no errors are displayed.
[3] If error codes 710, 711, and 712 are displayed, install a new CONTROLLER BOARD.

1- 109
Error Code BAD MEM or NONE
[1] If BAD MEM or NONE displays in the EXTERNAL MODE, there is a PROM or CONTROLLER BOARD
malfunction.
[2] Install the PROMS on the CONTROLLER BOARD, U42, U9, U19, and U20. If this does not remove the
malfunction, install a CONTROLLER BOARD.

1- 110
THERMAL HEAD
Safety
This is a low voltage area.

Functional Description
The THERMAL HEAD is the part of the PRINTER that prints the image. The THERMAL HEAD transfers heat in
the form of pulses into the DONOR material, which then transfers its dye into the material of the RECEIVER. This
process occurs 4 times for the 4 colors of the DONOR, yellow, magenta, cyan, and laminant, to make the complete
image.
The THERMAL HEAD is moved into the correct position by the THERMAL HEAD LIFT MOTOR and SHAFT/
CAM. The correct positions are detected through the use of 2 THERMAL HEAD LIFT SENSORS that monitor the
position of the THERMAL HEAD. There is a DUAL FLAG on the THERMAL HEAD LIFT CAM to detect the
position of the THERMAL HEAD. The THERMAL HEAD LIFT MOTOR is part of the MOTOR BRACKET AY.
The THERMAL HEAD LIFT SPRINGS are fastened to the DOOR AY and the HEAT SINK. The LIFT SPRINGS
apply pressure on the HEAT SINK aligning the THERMAL HEAD to the PLATEN ROLLER.
The THERMAL HEAD moves into 4 positions during the print and idle states:
• RETRACT
– This is the position of the THERMAL HEAD during the READY and any idle state.
• LOAD 1
– This is the position of the THERMAL HEAD when the RECEIVER is PICKED and REWOUND.
• LOAD 2
– This is the position to adjust the THERMAL HEAD LOAD GAP.
• ENGAGE
– This is the position of the THERMAL HEAD when it is in contact with the PLATEN ROLLER of the
ROLLER ASSEMBLY. The PRINT CYCLE occurs in the ENGAGE POSITION.
The THERMAL HEAD includes:
• THERMAL HEAD - Style 1 and 2
• THERMAL FUSE - Style 1
• HEATER - Style 1
• BOARD - 2 EEPROMS containing data - Style 1 and 2
• THERMISTOR - Style 1 and 2
There are 2 styles of THERMAL HEADS installed into the PRINTERS depending on the model and serial•number.
Both styles include the resistive elements, or pixels, that transfers heat to the RIBBON, the HEAT SINK to maintain
temperature, and a THERMISTOR to monitor the temperature of the THERMAL HEAD. There is a BOARD with
EEPROMS that stores Uniformity Correction Tables, Plane Count Data, and RAM to store 2 lines of data for printing.
The Style 1 THERMAL HEAD has a HEATER to heat the THERMAL HEAD to the correct operating temperature,
and a THERMAL FUSE to prevent overheating. The Style 2 THERMAL HEAD uses pulses from the
CONTROLLER BOARD to heat the THERMAL HEAD to operating temperature. The THERMAL FUSE is not
needed on the Style 2 THERMAL HEAD.
The THERMISTOR senses the change in temperature of the THERMAL HEAD and feeds back the change to the
ANALOG-TO-DIGITAL (A/D) CIRCUIT of the CONTROLLER BOARD. The A/D CIRCUIT energizes the
HEATER for the Style 1 THERMAL HEADS, or pulses the Style 2 THERMAL HEADS to heat the THERMAL
HEAD to the correct operating temperature. If the temperature of the THERMAL HEAD needs to decrease, the
A/D CIRCUIT energizes the 4 HEAD FANS to cool the THERMAL HEAD.

1- 111
Specifications

Description Voltage/Resistance
THERMAL HEAD 11.4 - 15.7 V DC
THERMAL HEAD HEATER ≈ 12 V DC
THERMAL HEAD LIFT MOTOR ≈ 10.5 V DC
THERMAL HEAD FUSE 1 ohm or less
THERMAL HEAD FAN ≈ 12 V DC
THERMISTOR 10 ± 0.5 K ohms

Preliminary Check
[1] De-energize the PRINTER.
[2] Check that the POWER LEDs are illuminated.
[3] Seat all CABLES on the CONTROLLER BOARD and THERMAL HEAD.
[4] Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY.

1- 112
THERMAL HEAD LIFT MOTOR - Error Codes 700, 701, 702, and 703
[1] Enter the diagnostics and select [DIAG: HEAD TEST].
[2] Scroll to [DIAG: RETRACT], [DIAG: LOAD] or [DIAG: ENGAGE].
[3] Select [DIAG: RETRACT], [DIAG: LOAD] or [DIAG: ENGAGE].
[4] Check that the THERMAL HEAD moves.
[5] If the THERMAL HEAD moves in all 3 positions, advance to the error code for the THERMAL HEAD LIFT
SENSOR on Page 1-111.
[6] If the THERMAL HEAD does not move, advance to the next step.
[7] Set the DIGITAL VOLT METER to DC voltage.
[8] Connect:
• red PROBE to TP3, PIN 2
• black PROBE to TP4, PIN 6 - GROUND
[9] Select [DIAG: LOAD], [DIAG: ENGAGE], or [DIAG: RETRACT].
[10] The DVM should read ≈ 10.5 V DC.
(a) If the DVM does not read ≈ 10.5 V DC, install a new CONTROLLER BOARD.
(b) If the DVM does read ≈ 10.5 V DC, advance to the next step.
[11] Connect the DVM to PINS 1 and 2 on CONNECTOR P1.
[12] The DVM should read ≈ 10.5 V DC.
(a) If the DVM does not read ≈ 10.5 V DC, install a new CONTROLLER BOARD.
(b) If the DVM does read ≈ 10.5 V DC, install a new MOTOR BRACKET ASSEMBLY.

1- 113
THERMAL HEAD LIFT SENSOR - Error Codes 700, 701, 702, and 703
[1] Set the DVM to DC voltage.
[2] Connect:
• red PROBE to TP4, PIN 2
• black PROBE to TP4, PIN 6 - GROUND
[3] Enter the diagnostics.
[4] Select [DIAG: RETRACT].
[5] The DVM should read as follows:
• RETRACT MODE: 0 V DC to 5 V DC to 0 V DC during RETRACT
• LOAD MODE: 0 V DC to 5 V DC from the RETRACTED POSITION to the LOAD POSITION
• ENGAGE MODE: 0 V DC to 5 V DC from the RETRACTED POSITION to the ENGAGE POSITION
[6] Do Steps 1 to 5 again using TP4, PIN 1.
[7] If the voltage changes from 5 V DC to 0 V DC, install a new CONTROLLER BOARD.
[8] If the voltage does not change, install a new THERMAL HEAD LIFT CABLE and/or THERMAL HEAD LIFT
SENSOR.

1- 114
Error Code 730 - Cooling Malfunction
[1] Enter the diagnostics and scroll to [DIAG: HEAD TEMP].
[2] Press and release the SET-UP/SELECT BUTTON. The LCD will read [TEMP: FAN].
[3] Press and hold the SET-UP/SELECT BUTTON. The LCD will read [TEMP: __._ °C]. This will energize the
4 THERMAL HEAD FANS. The TEMP output should decrease as the FANS continue to operate.
[4] If the FANS are operating, advance to Step 16.
[5] If the FANS are not operating, advance to the next step.
[6] Set the DVM to DC voltage.
[7] Connect:
• red PROBE to TP5, PIN 4
• black PROBE to TP4, PIN 6
[8] The DVM should read ≈ 12 V DC when the FANS are not operating and ≈ 0.9 V DC when the FANS are
operating.
[9] If the voltage is not present, install a new CONTROLLER BOARD.
[10] If the voltage is present and the FANS do not operate, advance to the next step.
[11] Connect the red PROBE to P7, PIN 2.
[12] Use the diagnostics to operate the FANS.
[13] The DVM should read ≈ 9 V DC.
[14] If the voltage is not present, install a new CONTROLLER BOARD.
[15] If the voltage is present and the FANS do not operate, install a new FAN BRACKET HARNESS ASSEMBLY
and/or FAN BRACKET ASSEMBLY.
[16] De-energize the PRINTER.
[17] Disconnect CONNECTOR P5, THERMAL HEAD DATA CABLE.
[18] Set the DVM to ohm.
[19] Measure the resistance across CONNECTOR P5, PINS 3 and 4.
[20] The DVM should read 10 ± 0.5 K ohms.
[21] If the resistance is not 10 ± 0.5 K ohms, it might be necessary to install a new THERMAL HEAD.

1- 115
Error Code 733
[1] Enter the diagnostics and scroll to [DIAG: HEAD TEMP].
[2] Press and release the SET-UP/SELECT BUTTON. The LCD will read [TEMP: FAN].
[3] Press the CANCEL BUTTON to scroll to [TEMP: HEATER].Press and hold the SET-UP/ONLINE BUTTON.
The LCD will read [TEMP:__._°C].
(a) If the HEATER LED is illuminated and the temperature output increases on the DISPLAY, the circuit is
operating.
(b) If the HEATER LED is not illuminated and the temperature output does not increase, advance to the next
step.
[4] De-energize the PRINTER.
[5] Set the DVM to ohm.
[6] Measure the resistance on TP6, PINS 3 and 4 to TP6, PIN 6 if the PRINTER has a FUSE. If the PRINTER does
not have a FUSE, check that the JUMPER is installed correctly. Measure the resistance across the PINS 1 to 4
and 3 to 6.
(a) If the resistance is open (> 2 ohms), install a new FUSE.
(b) If the resistance is 1 or less, advance to the next step.
[7] Energize the PRINTER.
[8] Set the DVM to DC voltage.
[9] Connect:
• red PROBE to TP6, PIN 6
• black PROBE to TP4, PIN 6
[10] The DVM should read ≈ 12 V DC when the diagnostics have energized the HEATER.
(a) If voltage is not present, install a new CONTROLLER BOARD.
(b) If voltage is present, install a new THERMAL HEAD.

1- 116
Error Code 719
[1] De-energize the PRINTER.
[2] Seat the THERMAL HEAD DATA CABLE at CONNECTOR P5 on the CONTROLLER BD and at the
THERMAL HEAD CONNECTOR.
[3] Energize the PRINTER.
[4] If error code 719 is not present, check the operation by making a test print.
[5] If error code 719 is present, advance to the next step.
[6] De-energize the PRINTER.
[7] Disconnect CONNECTOR P5.
[8] Install a new THERMAL HEAD DATA CABLE.
[9] Energize the PRINTER.
[10] If error code 719 is not present, check the operation by making a test print.
[11] If error code 719 is present, install a new THERMAL HEAD.

1- 117
[INIT ERROR] - Error Code 722
Preliminary Check
[1] Check and seat all HOST connections to the back of the PRINTER.
[2] Energize the PRINTER.
[3] If [INIT ERROR] occurs, advance to the later section Troubleshooting See Page 6-10

1- 118
WATCH CYCLE
Additional information for the initialization errors follows the Front End Initialization Cycle Chart.
Front End Initialization Cycle

F R ONT E ND INIT IALIZAT ION C Y C LE

S tart (P ower S witch ON)

F an On
Init (Dis play)/Diagnos tic LE D F las h (1X)
*
Init (Dis play)
**
Mech Init
Mech Init (S tart)
Diagnos tic LE D off
F las h s equence begins
Mech Init (E nd)/R eady

P ower S upply
On

Diagnos tic LE D F las h on off F las h

LC D Dis play
Init* Init**

P rint E ngine
Initialization
0:02.92
0:00.0

0:35.0

0:38.0

1:10.0
0:01.7

0:04.27
0:04.87

T ime
(Minutes :S econds )
**
*
obs erve

obs erve

A087_9029DC

1- 119
Front End Initialization Cycle

F R ONT E ND INIT IALIZAT ION C Y C LE

S tart (P ower S witch ON)

F an On
Init (Dis play)/Diagnos tic LE D F las h (1X)
*
Init (Dis play)
**
Mech Init
Mech Init (S tart)
Diagnos tic LE D off
F las h s equence begins
Mech Init (E nd)/R eady

P ower S upply
On

Diagnos tic LE D F las h on off F las h

LC D Dis play
Init* Init**

P rint E ngine
Initialization
0:02.71

1:35.51
0:05:09

49.65
0:00.0

49.80
0:01.7

05:23

T ime
(Minutes :S econds )
**
*
obs erve

obs erve

A087_9056DC

Preliminary Check

Important
At this point, you have determined that the failure is internal to the PRINTER. You will be using the Front End
Initialization Cycle time-line in many of the steps.
[1] Follow the sequence of the WATCH CYCLE.
[2] Energize the PRINTER.

1- 120
LCD Messages Watch Cycle
[1] Use the time-line to check for the correct LCD messages. Observe the LCD and compare to the time-line.
[2] If the correct LCD message is not displayed during the correct time, check the LCD.
[3] If the correct LCD messages are displayed, continue with the procedure for the “WATCH CYCLE”.

1- 121
TEST PRINTER

Important
To do this procedure, the [INIT ERROR] has been removed.
[1] Energize the PRINTER.
[2] Make a front end test print.
[3] Have the end user down-load and print an image from his HOST Computer.
[4] If the test print cannot be started or if the end user cannot down-load an image and print, it is necessary to
troubleshoot the malfunctions.
[5] If the test print and end user interaction is satisfactory, check that all HOST Connections are installed and the
PRINTER is fully assembled and clean.

1- 122
Section 6: Image Quality

Artifact Descriptions
Lead Edge/Trail Edge
Lead Edge/Trail Edge - Lead edge is the edge of the
LEAD EDGE
image that is printed first and exits the PRINTER first.
Trail edge is the end of the image that exits the
PRINTER last.

TRAIL EDGE A087_4085AC

Lead Edge Fold

Lead Edge Fold - Lead Edge Fold only occurs on
REFLECTIVE material. It is a colored streak or fold
starting at the lead edge of the print. The fold is caused
by the folding of the DONOR starting in the previous
patch and continues into the next patch. Normally, the
patch where the fold starts is of higher density. The fold
can be observed in the used DONOR.

A087_4070AC

1- 123
Side Edge Fold
Side Edge Fold - Side Edge Fold only occurs on
REFLECTIVE material. The folds start at the edge of
the image caused by excessive wrinkling between the
printed and unprinted borders of the DONOR.

A087_4071AC

Stretch
Stretch - Stretch only occurs on REFLECTIVE
material. Folds that look like lightning bolts. They start
within the image and normally exceeds to the bottom
and toward the corners of the image branching out. This
occurs when there is an excessive amount of small text
or lines on the image without much other density. The
text becomes different colors because of the folds. This
can be reduced by adding a little density to the image
background. In extreme cases, even flat field minimum
densities exhibit this problem.

A087_4072AC

1- 124
Smiles
Smiles - Smiles occur on TRANSPARENCY material
only. Smiles are one or more folds that occur within the
image. They always occur in high density areas and
extend across the page. There is not much difference
between one smile and many smiles.

A087_4067AC

1- 125
Comb Lines DONOR and THERMAL HEAD
DONOR Comb lines are several evenly spaced lines,
1 or 2 mm (1/64 to 1/8 inch) wide close together and
alternately positive and negative density, running in the
print direction. Comb lines occur in random patches
lengthwise in a print and/or print to print. They are
observed most often in mid-scale densities, especially
in magenta or cyan images unless they were calibrated
into the THERMAL HEAD.

Comb lines on the DONOR do not necessarily run the

complete length of the image. They are not of consistent
density and can fade away or start within an image.
They can be throughout the image. These lines are
often observed in one color more than another,
magenta, flesh tones, or light flat fields. The lines are
sometimes at a slight angle to the image. To remove the
A087_4068AC
lines, install a new DONOR ROLL.

THERMAL HEAD Comb lines are comb lines that have been compensated
into the THERMAL HEAD. The lines are a result of
compensating THERMAL HEADS with DONOR that
has comb lines. The lines run straight through the
complete image and do not vary in width or density
from top to bottom. They show up in every color
because the calibration of the pixels was effected by the
DONOR. To test for these lines, install new DONOR
and see if this removes the lines. If the lines still occur,
install a new THERMAL HEAD.
Note
The graphics are not intended to dictate a pattern or
frequency of the lines on the images. They are an
example of what the individual lines look like.

A087_4069AC

1- 126
Paper Fold at Trail Edge/Paper Jam

LEAD EDGE
Symptom: The RECEIVER is folded 2.54 cm (1 in.)
from the trail edge and/or only the yellow pass
completes.

Cause: With the new TRAY, the RECEIVER and

TRAY are not compatible; this might be caused if the
TRAY setting selected is not correct for the
RECEIVER in use.
PAPER Solution: Check that the TRAY CODE LABELS on the
FOLD side of the TRAY match the size of the RECEIVER in
use.
Cause: The RECEIVER might be adhering to the
ROLLER ASSEMBLY CHUTE during REWIND. The
A087_5008ACA DONOR might be stripped.
TRAIL EDGE A087_5008AC

Solution: The humidity might be above 60% RH, the

RH must be reduced.

1- 127
Border Size Not Correct

LEAD EDGE
Symptom: The border on the right side of the print as it
exits the PRINTER is too narrow compared to the left
side of the print; the sides should be approximately the
same.

Cause: The LEFT WALL on the TRAY is damaged.

Solution: Install a new TRAY.
Cause: The RECEIVER is damaged.
Solution: Install a new RECEIVER.
Cause: The THERMAL HEAD LIFT CAM or
BEARING is missing a WASHER.
Solution: Check that the WASHER is installed.

TRAIL EDGE A087_5009AC

1- 128
Lead Edge Fold, Side Edge Fold, Stretch - After Normal to High Usage
Parts Effected: THERMAL HEAD, ROLLER ASSEMBLY, DONOR SUPPLY BRACKET, DOOR ASSEMBLY,
BASE ENCLOSURE WALLS
Symptom:
Lead Edge Fold, Side Edge Fold, or Stretch on a PRINTER after normal to high usage.

Cause:
DONOR or RECEIVER, the system has been moved by the customer, or parts malfunctions.
Solution:
[1] Check for damage to the PRINTER.
[2] Install new DONOR and/or RECEIVER.
[3] Do the stretch adjustment for the ROLLER ASSEMBLY and DONOR SUPPLY BRACKET.
[4] Check the adjustment for the THERMAL HEAD LOAD GAP. See the ADJUSTMENTS AND
REPLACEMENTS.
[5] Do the maintenance procedure for the THERMAL HEAD. See the PERIODIC MAINTENANCE.

1- 129
Lead Edge Fold, Side Edge Fold, Stretch - New PRINTER

Symptom: Lead Edge Fold, Side Edge Fold, or Stretch on a new PRINTER removed from the box.

Cause: The PRINTER was damaged during shipment.

Conditions: The THERMAL HEAD has a tolerance of 0.0011 to 0.0022 in. over the complete usable area. If the
PRINTER experiences over 25 to 30 g of shock, the tolerance might change, which causes this artifact.

Solutions:
[1] Check the PRINTER for shipping damage to the following areas:
• THERMAL HEAD
• DONOR SUPPLY BRACKET ASSEMBLY
• BASE ENCLOSURE WALLS
• MOTOR BRACKET ASSEMBLY
– Do all the GEARS mesh and have the correct backlash?
• DOOR/DONOR TAKE-UP ASSEMBLY
• Check that no wires or other parts are causing an obstruction with the DONOR
[2] Install a new roll of DONOR and new RECEIVERS.
[3] Do the THERMAL HEAD LOAD Gap Adjustment See Page 2-45
[4] Do the Stretch adjustment for the ROLLER ASSEMBLY and DONOR SUPPLY BRACKET See Page 2-14
[5] Do the maintenance procedure for the THERMAL HEAD. See the PERIODIC MAINTENANCE.
[6] If the PRINTER has serious damage and this is a new PRINTER, it is recommended to exchange the PRINTER.

1- 130
Stretch, Lead Edge Fold, Side Edge Fold - New THERMAL HEAD

Symptom: Stretch, Lead Edge Fold, or Side Edge Fold after installing a new THERMAL HEAD.

Causes:
• DONOR or RECEIVER
• Obstructions in the path of the DONOR
• Adhesive from the DONOR is causing a localized stall on the THERMAL HEAD
• THERMAL HEAD not installed correctly
• The wrong THERMAL HEAD for this PRINTER was installed. Use the correct THERMAL HEAD for that
model.
• There is a THERMAL HEAD malfunction.

Solution:
[1] Install new DONOR and/or RECEIVER.
[2] Clean the THERMAL HEAD.
[3] Move any wires or HARNESSES in the correct position.
[4] Do the maintenance procedure for the THERMAL HEAD. See the PERIODIC MAINTENANCE.
[5] Do the Stretch Adjustment for the ROLLER ASSEMBLY and DONOR SUPPLY BRACKET.
[6] The new THERMAL HEAD might have a less than nominal profile. Use another THERMAL HEAD.
Note
The ROLLER ASSEMBLY, DONOR SUPPLY BRACKET, and DOOR ASSEMBLY can cause or increase the
Stretch artifact.

1- 131
Image Quality Troubleshooting Chart

Malfunction Possible Cause Procedure

Print very light Setup, THERMAL HEAD Check that the correct
THERMAL HEAD is installed
and that the voltage settings are
correct.
THERMAL HEAD POWER Troubleshoot THERMAL
SUPPLY HEAD POWER SUPPLY,
output voltage, and POWER
CABLE CONNECTION.
Scratches appear from image Dirt on PAPER CHUTE or Clean the CHUTE and
to image that run the full length ROLLER ASSEMBLY ROLLER ASSEMBLY.
of print, including border
Scratches appear from image Dirt on THERMAL HEAD Clean THERMAL HEAD,
to image that run the full length then make a test print.
of image only Install a new THERMAL
HEAD if necessary.
White line running full length Blown pixel Clean THERMAL HEAD,
of image(s) then make a test print.
Install a new THERMAL
HEAD if necessary.
Horizontal bands of color THERMAL HEAD POWER Install a new THERMAL
across complete print, a line SUPPLY - dropping out HEAD POWER SUPPLY.
from one color plane is missing
and might appear in different
spots on the print, in different
planes
Lead edge fold, REFLECTIVE DONOR SUPPLY BRACKET Install a DONOR SUPPLY
only, multi-color streak in lead BRACKET.
edge of print - can occur when
previous color patch had high
density at trailing edge
THERMAL HEAD LOAD GAP Adjust the THERMAL HEAD
LOAD GAP.
THERMAL HEAD Install a new THERMAL
HEAD.
DOOR ASSEMBLY Install a new DOOR
ASSEMBLY.
Side edge fold, REFLECTIVE DOOR ASSEMBLY Install a new DOOR
only, “finger” of color that ASSEMBLY.
moves inward from the edge of
the image, usually down
toward the bottom of the print
THERMAL HEAD out of Check, if necessary, install a
tolerance new THERMAL HEAD.

1- 132
 Malfunction Possible Cause Procedure
Side edge fold, REFLECTIVE DONOR SUPPLY BRACKET Install a new DONOR
only, “finger” of color that SUPPLY BRACKET.
moves inward from the edge of
the image, usually down
toward the bottom of the print
Stretch, REFLECTIVE only, THERMAL HEAD Install a new THERMAL
folds that look like lightning HEAD.
bolts or comet trails. These
start within the image and
branch out towards the corners.
Normally occurs with areas of
high density, such as text, with
no background
Smiles, TRANSPARENCY THERMAL HEAD needs voltage Check the voltage of the
only, 1 or more curving folds adjustment THERMAL HEAD and
across the image in high compare to the value written
density areas on the THERMAL HEAD. If
necessary, adjust the voltage
down in increments of 0.1 V
until the problem is removed.
Comb lines - evenly spaced DONOR or THERMAL HEAD Install a new DONOR ROLL
lines running down the print and make another print.
—through the full image If the pattern continues, install
—consistent width and density a new THERMAL HEAD.
—displays in every color

1- 133
Image Quality Troubleshooting Chart - DONOR/RECEIVER

Malfunction Possible Cause Procedure

Print very light RECEIVER condition - Test with new RECEIVER that
REFLECTIVE has been stored and handled
correctly.
Print very light RECEIVER upside down - Check for correct orientation
TRANSPARENCY of TRANSPARENCY
RECEIVER in the TRAY.
Lead edge fold, REFLECTIVE DONOR wrinkled on spool Inspect and correct DONOR
only, multi-color streak in lead winding or obvious obstruction
edge of print - can occur when in DONOR path.
previous color patch had high Install a new DONOR ROLL.
density at trailing edge
Side edge fold, REFLECTIVE DONOR wrinkled on spool Check and correct DONOR
only, “finger” of color that winding, alignment of the
moves inward from the edge of DONOR, or obvious
the image, usually down obstruction in path of
toward the bottom of the print DONOR.
Install a new DONOR ROLL.
Stretch, REFLECTIVE only, Alignment of the DONOR Correct the DONOR
folds that look like lightning SPOOL installation and make another
bolts or comet trails - these print.
start within the image and
branch out towards the corners
- Normally occurs with areas of
high density, such as text, with
no background
Comb lines - evenly spaced DONOR Install a new DONOR ROLL
lines running down the print and make another print.
—random patches, varying
width, density
—might be at a slant
—normally more in one color
than another
—might fade or start within
image
Comb lines - evenly spaced DONOR or THERMAL Install a new DONOR ROLL
lines running down the print HEAD and make another print.
—through the full image If the pattern continues, install
—consistent width and density a new THERMAL HEAD.
—displays in every color

1- 134
This page is intentionally blank.

1- 135
{Adjust/Replace}{Production}{KodakServiceSup ort}

ADJUSTMENTS AND REPLACEMENTS

for the Codonics NP/EP Series Imagers

Important
Use qualified personnel to service this equipment.
 This equipment includes parts and assemblies sensitive to damage from electrostatic
discharge. Use caution to prevent damage during all service procedures.

Table of Contents
Description Page

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
PICKER PENETRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Picker Penetration (Field Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
DONOR SUPPLY BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
ROLLER AY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
To Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
To Adjust: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
LEAD EDGE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
To Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
To Adjust: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
RECEIVER THRESHOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
To Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
To Adjust: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
RECEIVER TYPE SENSOR BRACKET ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 2-26
RECEIVER TYPE SENSOR CIRCUIT CALIBRATION. . . . . . . . . . . . . . . . . . . . . 2-30
Reciver Type Sensor Calibration (Field Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Voltage for the THERMAL HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
To Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
To Adjust: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
STEPPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
To Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
To Adjust: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
DONOR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
To Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
To Adjust: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
DOOR INTERLOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
To Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
To Adjust: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
BAR CODE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
To Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
To Adjust: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
THERMAL HEAD LOAD GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
To Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
To Adjust: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
BASE ENCLOSURE WALLS
To Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
To Adjust: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
4th. TRAY SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
CONTROLLER ENCLOSURE AND DRAWER AY. . . . . . . . . . . . . . . . . . . . . . . . 2-54
DOOR COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
ENCASEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
 To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
MULTIPLE CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
CONTROLLER BD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
SAB BOARD REMOVAL AND INSTALLATION (1660 Models Only) . . . . 2-60
TRAY TYPE SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
PICKER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
TRAY GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
LEAD EDGE SENSOR BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
DONOR SENSOR BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
PINCH MOTOR and GEARS for the ROLLER AY . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
LCD DISPLAY and BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
DONOR SUPPLY BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
MOTOR BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
FAN BRACKET ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
THERMAL HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
THERMAL HEAD LIFT CAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
THERMAL HEAD LIFT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
DOOR INTERLOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
POWER SUPPLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
DRAWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

2-4
PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
POWER SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
To Remove: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
To Install: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Postrequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103

Part Number 907-061-001.01

Section 1: Adjustments
PICKER PENETRATION

Purpose: To make the PICKER ASSEMBLY have correct and continual operation.
Specification: Determined with the correct specification after the adjustment.
Special Tools: Picker tire height set, screwdriver, straight blade, 6.5x100, adhesive threadlocker, low
strength, 222MS
Prerequisites: Remove:
• DOOR COVER, ENCASEMENT
• Carefully read each step before performing actions
Postrequisites: Make test prints to check for correct operation.

To Check:
[1] Open the DOOR.
[2] Remove: DONOR, RECEIVER. Caution: Do not touch the donor. Contamination will occur.
[3] Raise picker penetration screw (setscrew) in order to apply threadlocker. Note: Loctite 222MS will setup in 20
minutes. Loctite 222MS will fully cure in 24 hours.

[4] Apply a small amount of threadlocker to threads. Tighten screw until about 0.125” of thread is showing. NOTE:
this height is arbitrary. The picker penetration screw will be accurately adjusted in the following instruction:

2-6
[5] Slide fixture into tray entrance. Make certain fixture is properly oriented with respect to tray guide.

[6] Move “point of application” score lines of fixture past picker tires. The “point of application” score lines will
be the indicator to properly align the fixture to the picker carriage.

2-7
 Score lines
highlighted here

[7] Gently place picker tires in picking position by lifting on the picker carriage lever, as shown. Only a gently force
is required to lift lever if the fixture is, at the same time, pulled back. CAUTION: Do not apply enough force to
deflect picker carriage.

[8] Align “point of application” lines with center of picker tire hubs by carefully pulling on the fixture handle to
slide fixture back. Picker tires should “grab” fixture arms. Always maintain constant contact between picker
carriage lever and picker penetration screw (setscrew).

2-8
 Hub

Score line

[9] Gently lift fixture arms and place back into position to make certain picker tires are not deformed or binding.
Always maintain constant contact between picker carriage lever and picker penetration screw.

[10] Adjust picker penetration screw to move fixture arms. The gage surface is the TOP of the fixture arm. Align
both gage surfaces within fixture “windows”. check repeatedly that the “point of application” score lines are
aligned with the center of the picker tire hub. Check repeatedly that the fixture arms are not deforming or finding
on the picker tires by gently lifting the fixture arms and place back into position. Always maintain constant
contact between picker carriage lever and picker penetration screw. CAUTION: If the “point of
application” scores lines are not perfectly aligned with the center of the picker tire hub, the fixture will not
perform correctly and give an inaccurate reading.

2-9
 Picker penetration
screw Gage surface Window

[11] If arms will not align with fixture “window”, remove fixture and try again. Note: If failure to align fixture arms
to “window” persists, contact Codonics Technical Support.
[12] Make certain picker tires are clean.
[13] Install: ENCASEMENT, DOOR COVER.

2-10
Section 2: Adjustments
PICKER PENETRATION (Field Adjustment)
Adjustment Specification

Purpose: To make the PICKER AY have correct and continual operation.

Specification: Determined with the correct specification after the adjustment.
Special Tools: PICKER HEIGHT GAUGE
Prerequisites: Remove:
• DOOR COVER
• ENCASEMENT
Postrequisites: Make test prints to check for correct operation.

To Check:
[1] Check that the PICKER ASSEMBLY is the correct height.

2-11
To Adjust:
PICKER
BRACKET

PICKER
WHEEL
CORRECT

CORRECT A114_0004BCA
A114_0004BC

[1] Open the DOOR.

Caution
Prevent damage. Do not touch the DONOR. Contamination will occur.
[2] Remove:
• DONOR
• RECEIVER
[3] Pull the PICKER BRACKET up to allow the PICKER WHEELS to move down.
[4] Do the following to check the PICKER PENETRATION. Use the PICKER HEIGHT GAUGE.
(a) The PICKER WHEEL must be in the center over the GAUGE. See the graphic above.
(b) With the PICKER WHEELS down, move the GAUGE under each PICKER WHEEL.

PICKER
WHEEL
LOW STEP NOT CORRECT

HIGH STEP
PICKER
WHEEL NOT CORRECT A114_0005BCA
A114_0005BC

(c) If the PICKER PENETRATION is within specification, the PICKER WHEELS will not make contact
with the LOW STEP and will make contact with the HIGH STEP.
(d) If the PICKER PENETRATION is correct, advance to Step 6. If not, continue with Step 5.

2-12
 PICKER PENETRATION SCREW
A114_0007BCA
A114_0007BC

Important
The PICKER PENETRATION SCREW has a patch that holds the SCREW. The patch should not loosen with use or
vibration. Only rotate the SCREW in 1/2 increments to keep the patch tight.
[5] Adjust:

Height Penetration Procedure

Either PICKER WHEEL Too deep Rotate the PICKER
contacts the LOW STEP on PENETRATION SCREW
the PICKER HEIGHT clockwise 1/2 rotation to
GAUGE decrease penetration.
Either PICKER WHEEL Too high Rotate the PICKER
does not make contact with PENETRATION SCREW
the HIGH STEP on the counterclockwise 1/2
PICKER HEIGHT rotation to increase
GAUGE penetration.

[6] Clean the PICKER WHEELS after the you have checked the penetration or have made any adjustments. Use
the LINT-FREE WATER PAD.
[7] Install:
• ENCASEMENT
• DOOR COVER

2-13
DONOR SUPPLY BRACKET
Adjustment Specification

DONOR SUPPLY BRACKET

A114_0008BCA
A114_0008BC

Purpose: To decrease folds and STRETCH artifacts on the leading edge of the print.
Specification: The distance between the DONOR TAKE-UP SPINDLE and the DONOR SUPPLY
SPINDLE should be 162.8 mm (6.410 in.)
Special Tools: DONOR SUPPLY BRACKET ALIGNMENT TOOL (Part number 680-490-001)
Prerequisites: None
Postrequisites: • “DIAG: DONOR TEST”
• Make 5 test prints.

2-14
To Check:
small
CUTOUT

large
CUTOUT

DONOR SUPPLY BRACKET DONOR SUPPLY BRACKET

ALIGNMENT TOOL-left ALIGNMENT TOOL-right

DONOR SUPPLY
BRACKET

A114_0028HCA
A114_0028HC

Important
The DONOR SUPPLY BRACKET ALIGNMENT TOOL 680-490-001 is 2 parts. 1 part is a right tool and has a large
CUTOUT. The other is a left tool and has the small CUTOUT.

[1] Do the following procedure to check that the DONOR SUPPLY BRACKET is correctly aligned. Use the
DONOR SUPPLY BRACKET ALIGNMENT TOOL 680-490-001.

2-15
 DONOR
TAKE-UP
BUSHING

DONOR
SUPPLY
BUSHING

A114_0029DCA
A114_0029DC

[2] Place the right tool onto the DONOR TAKE-UP BUSHING and DONOR SUPPLY BUSHING.
[3] Check that the right tool seats correctly onto the 2 BUSHINGS.

2-16
 [4] Place the left tool between the 2 SPRINGS. The
SPRING CUTOUT on the tool should be against the
CUTOUT SHAFT.

SHAFT

SPRING

A114_0030GCA
A114_0030GC

To Adjust:

INSIDE
SCREWS
OUTSIDE
SCREWS

DONOR SUPPLY A114_0027BCA

BRACKET A114_0027BC

[1] Remove the RIBBON.

[2] Loosen the 2 INSIDE SCREWS and the 2 OUTSIDE SCREWS on the DONOR SUPPLY BRACKET.

2-17
 DONOR
TAKE-UP
BUSHING

DONOR
SUPPLY
BUSHING

right tool

SCREW

DONOR
SUPPLY
A114_0029DCB BRACKET
A114_0029DC

[3] Place the right tool in the correct position. Check that the right tool is flush against the DONOR TAKE-UP
BRACKET and the DONOR SUPPLY BRACKET.
[4] Tighten the 2 SCREWS on the right side of the DONOR SUPPLY BRACKET.
[5] If the right tool is not flush against the 2 BRACKETS, do Steps 2 - 4 again.

2-18
 CUTOUT

SPRING

SHAFT

SCREW
left tool DONOR SUPPLY
BRACKET A114_0031BCA
SPRING A114_0031BC

[6] Place the left tool in the correct position. Tighten the 2 SCREWS on the left side of the DONOR SUPPLY
BRACKET.

2-19
ROLLER ASSEMBLY
Adjustment Specification

Purpose: To decrease STRETCH artifacts on the trailing edge of the print.

Specification: None
Special Tools: • LONG MAGNETIC SCREWDRIVER
Prerequisites: Remove:
• DOOR COVER
• ENCASEMENT
Postrequisites: Make test prints to check for correct operation.

To Check:
[1] Check:
TRAIL EDGE
• that the ROLLER AY is aligned correctly
with the THERMAL HEAD AY.
• for STRETCH on the trailing edge of the
print.
STRETCH [2] Determine if the print has STRETCH in areas 1 or
2 1 2.

4 3

A114_0010ACA
LEAD EDGE A114_0010AC

2-20
To Adjust:

SCREW POSITIONS - TOP VIEW

5th
3rd
2nd

1st

ROLLER AY 4th
FRONT

ROTATION -COUNTERCLOCKWISE
QUADRANT 1

BASE ENCLOSURE FLOOR

A114_0011HCA
A114_0011HC

Warning
Dangerous Voltage
[1] De-energize the PRINTER.
[2] Loosen the 5 SCREWS holding the ROLLER AY to the BASE ENCLOSURE FLOOR and the right SIDE
WALL.
[3] If the STRETCH artifact is in area 1, continue with Steps 4 to 8. If the STRETCH artifact is in area 2, advance
to Step 9.

2-21
 SCREW POSITIONS - TOP VIEW
5th
3rd
2nd

1st

ROLLER AY 4th
FRONT

MECHANISM PLATE

BASE ENCLOSURE WALL

ROTATION -COUNTERCLOCKWISE
QUADRANT 1

A114_0011HCB
A114_0011HC

[4] Pull the left side of the ROLLER AY toward the front of the PRINTER.
[5] Tighten the front SCREW on the left side.
[6] Press the right side of the ROLLER AY toward the back of the PRINTER.
[7] With minimum pressure, press down on the right MECHANISM PLATE holding the ROLLER AY to the right
side of the BASE ENCLOSURE WALL.
[8] Tighten the following SCREWS in the sequence indicated in the graphic above:
• 2nd SCREW
• 3rd SCREW
• 4th SCREW
• 5th SCREW
Note
If this procedure does not correct the artifact, the malfunction might be caused by other conditions:
• DONOR SUPPLY BRACKET
• THERMAL HEAD
• DOOR ASSEMBLY
• BASE ENCLOSURE WALLS
[9] Pull the right side of the ROLLER AY forward toward the front of the PRINTER.
[10] Tighten the front SCREW on the left side.
[11] Press the left side of the ROLLER ASSEMBLY toward the back of the PRINTER.
[12] With minimum pressure, press down on the right MECHANISM PLATE holding the ROLLER ASSEMBLY
to the right side of the BASE ENCLOSURE WALL.
[13] Tighten the following SCREWS in the sequence indicated in the graphic above:
• 2nd SCREW
• 3rd SCREW
• 4th and 5th SCREW

2-22
LEAD EDGE SENSOR
Adjustment Specification

LEAD
EDGE
SENSOR

A114_0012GCA
A114_0012GC

Purpose: To adjust the SENSOR to detect the lead edge of the RECEIVER.
Specification: 0.18 ± 0.01 V DC
Special Tools: None
Prerequisites: None
Postrequisites: Make a test print for correct operation.

To Check:
[1] Check for correct operation.

To Adjust:

Important
Do this adjustment when you install a new ROLLER AY or CONTROLLER BD. If necessary, do this adjustment
during some of the diagnostic procedures.
[1] Set the DIGITAL VOLT METER (DVM) to DC voltage.
[2] Connect the following on the CONTROLLER BD.
• red PROBE of the DVM to TP8, PIN 3
• black PROBE to TP4, PIN 6
[3] Open the DOOR ASSEMBLY

2-23
 [4] Remove the PAPER TRAY.

PAPER
TRAY

A114_0003ACA
A114_0003AC

Important
If possible, use a TRANSPARENCY to do this
adjustment.
[5] Insert a new TRANSPARENCY or
REFLECTIVE RECEIVER into the CHUTE.
[6] Enter the diagnostics.
[7] Close the PINCH.
PINCH
[8] Place the edge of the TRANSPARENCY or
REFLECTIVE RECEIVER in the correct position
as shown in the diagram to the left.
[9] Move the TRANSPARENCY until it is aligned
with the EXIT STATIC BRUSH. Use the
procedure “DIAG: STEPPER MOTOR”, forward
CHUTE
or reverse.
[10] For a TRANSPARENCY, adjust R63 until the
voltage measures 0.18 ± 0.01 V DC.
Note
The correct voltage adjustment for a REFLECTIVE
A114_0012GCB
A114_0012GC RECEIVER is 0.24 ± 0.01 V DC.
Note
If this adjustment cannot be made, you must install a
new LEAD EDGE/STATIC BRUSH AY or
CONTROLLER BD.
[11] Open the PINCH again.
[12] Remove the TRANSPARENCY or
REFLECTIVE RECEIVER.

2-24
RECEIVER THRESHOLD
Adjustment Specification
Purpose: To set the reference voltage for the RECEIVER TYPE SENSOR.
Specification: 1.0 ± 0.1 V DC
Special Tools: None
Prerequisites: None
Postrequisites: Adjust the RECEIVER TYPE SENSOR. This adjustment is done in conjunction with P/N
920-053-061 and 920-053-801 which are in the supplemental work instruction section of
this manual.

To Check:
[1] Check the LCD for correct RECEIVER TYPE.

To Adjust:
[1] Set the DIGITAL VOLT METER (DVM) to DC voltage.
[2] Connect the following on the CONTROLLER BD. See Page 41.
• red PROBE of the DVM to TP10, PIN 5
• black PROBE to TP4, PIN 6
[3] Adjust R70 until the DVM measures 1.0 V DC ± 0.1 V DC.

2-25
1660 RECEIVER TYPE SENSOR BRACKET ADJUSTMENT
Adjustment Specification
Purpose: The receiver type sensor is sensitive to perpendicularity to the media. A more
perpendicular angle of reflection allows for better contrast between DircetVista paper and
film types. The media under the sensor sits at an angle of about -3 degrees to a horizontal
plane. Currently, the sensor is titled 4 degrees off perpendicular toward the front of the
printer. By bending the bracket to 3 degrees past vertical toward the back of the printer, the
sensor is better suited to make the determination of which type of media is loaded in the
media tray. This procedure will be in effect until it is determined that it is no longer
required.
Specification: Bend receiver type sensor 3 degrees past vertical towards back of printer
Special Tools: Channel lock pliers - max jaw opening 1.5”, Codonics angle measurement fixture, two
piece fixture with magnetic attachment, blackened correct angle areas is set for 2.5 degrees
to 4 degrees.
Prerequisites: None
Postrequisites: Make a test print for correct operation.

Procedures
[1] Preparation Work - before start of test session, check to make sure that the printer is turned off.
[2] Bending the sensor mounting bracket - open printer door. Slide the plate in the printer media tray slot (figure
1). Lower the pole through the hole in front of the sensor, and seat in on the mount plate (figure 2). Be sure it
seats flat, and does not site on the lip of the base magnet. Also, make sure it is aligned side-to-side with the
magnet. Plull plate toward you and rotary finger will match profile of sensor angle, and register angle on top of
pole. Open channel locks to maximum position. Using the channel locks as shown in Figure 3, incrementally
squeeze and check angle until the rotary finger registers in the black area at the top of the pole (figure 4). Be
careful to slowly and incrementally bend so as not to overbend the bracket. Bending it back isn’t as easy. When
checking the angle, be sure to look from the side of the printer to get the proper perspective on the reading. If
bracket gets bent too far, see “what to do if . . .” IMPORTANT! As this fixture does contain permanent magnets,
it is important to take appropriate precautions around digital media and drives i.e. floppy disks/drives, ZIP
disks/drives, other magnetically sensitive material.

What to do if . . .
[1] If the bracket gets overbent, CAREFULLY use channel locks (in minimum jaw position) and gently bend b
racket back to position. DO NOT pinch the sensor with the pliers. Use the screw head and back of the bracket
as gripping points.

2-26
Sample Completed . . .

Figure 1: Install Plate

Figure 2: Install Pole

2-27
 MOTOR

Picker
Assembly Sensor
Bracket

Printer tray floor

Figure 3: Channel Lock Placement

Figure 4: Reading Angle Fixture

2-28
Figure 5: Initial Incorrect Reading Figure 6: Correct Reading

2-29
1660 RECEIVER TYPE SENSOR CIRCUIT CALIBRATION
Adjustment Specification
Purpose: The receiver type sensor circuit is a reflective infrared sensor connected to a comparator
circuit set to 1.00 Vdc. The receiver type sensor must be set for an 8 x 10” tray voltage at
0.3 Vdc or less.
Specification: • Reflective: 3.50 ± 0.05 V DC
• TRANSPARENCY: < 0.5 V DC
Special Tools: • Receiver type sensor calibration tray - use serialized fixtures with shim modification
and marked height of approximately 2.10”
• DMM multimeter 3/16” hex head socket
• Rev D 8 x 10” tray containing 100 sheets of blue film media, use standard foiled backer
board - may use multiple standard Rev D 8 x 10” trays with 15, 50 & 100 sheets of blue
DV
• Locktight
Prerequisites: • Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY, remove
encasement and door cover
• Do the adjustment for the RECEIVER THRESHOLD
Postrequisites: Make a test print.

Procedures
[1] Preparation Work - before start of test session check the receiver type sensor calibration fixture for proper
placement and surface cleanliness of the CV paper sample patch on top of the block. Log which fixture was
used.
[2] Checking and Setting the Comparator Voltage - remove the printer encasement. Attach calibrated DMM
Multimeter leads to TP10-5 (red or positive) and TP4-6 (black or ground). Adjust R70 until voltmeter reads
between 0.99 Vdc and 1.05 Vdc (1.0 Vdc ideally). If not able to adjust to this range, see section “what to do if
. . “.
[3] Setting the Sensor Height - move voltmeter leads to TP2-6 (red or positive) and TP4-6 (black or ground). Insert
the receiver type sensor calibration fixture and measure the resulting voltage. This is the original voltage, log
this voltage. If necessary, adjust R23 until the voltameter reads a Testing Voltage between 3.10 to 3.9 Vdc.
[4] Holding the picker sheet metal assembly inward of the pick tires with both hands, GENTLY force it up and
down and observe the voltage change, looking for a minimum value. Log the minimum value obtained. If
pushing the assembly down minimizes the voltage, the sensor needs to be moved down. If pushing it up
minimizes the voltage, the sensor needs to be moved up. Adjust by loosening 3/16” hex head sensor retaining
screw. Apply locktight to the screw threads between the sensor and the picker assembly taking care to avoid the
liquid covering the sensor bottom OR THE CALIBRATION TRAY! Re-install the retaining screw but do not
tighten. Keeping the sensor vertical, move the sensor up and down until the minimum voltage (recorded above)
is obtained. IMPORTANT: While doing this, be careful not to press on the picker assembly sheet metal in any
way, since this will disturb the results. LIGHTLY tighten the retaining screw to hold the screw in place.
[5] Holding the picker sheet metal assembly inward of the pick tires with both hands, GENTLY force it up and
down and observe the voltage change. If the voltage climbs quickly with light force downward, but does not
rise quickly with light force upwards, and does not rise quickly with a light downward force, the sensor is in the
proper location. IMPORTANT: The sensor height must be set to read the minimum voltage!
[6] Tighten the retaining screw, being careful not to move or rotate the sensor or to damage it from over tightening.
If screw is not removed, only apply one drop of Loctite on screw on side closest to the picker motor.
[7] Setting the Sensor Voltage - Repeat step 5 until the measured voltage after tightening is close the minimum
observed during the picker pushing (+/- 0.2 Vdc). Adjust R23 until the voltmeter reads between 3.40 and 3.60
Vdc. Log this voltage. Remove the calibration fixture. IF SENSOR RE-POSITIONING WAS REQUIRED!
2-30
 [8] Validating the Calibration Procedure - insert an 8” by 10” size tray with 15 sheets of blue film media and a white
backer board with reflective patch. Voltage reading must be 0.30 Vdc or less. Log voltage.
[9] Holding the tray at the outermost corners, move the tray to the left, the right, fully up and fully down. During
all this motion, voltage reading must be 0.30 Vdc or less. If not, see section “what to do if . . “.
[10] Insert an 8” by 10” size tray with 50 sheets of blue film media with the white board with reflective patch. voltage
reading must be 0.3 Vdc or less. Log voltage.
[11] Holding the tray at the outermost corners, move the tray to the left, the right, fully up and fully down. During
all of this motion, voltage reading must be 0.30 Vdc or less. If not, see section “what to do if . . .”.
[12] Insert 8” by 10” size tray with 100 sheets of blue DV media with the white board with reflective patch. Voltage
reading must be 0.30 Vdc or less. Log voltage.
[13] Holding the tray at the outermost corners, move the tray to the left, the right, fully up and fully down. During
all this motion, voltage reading must be 0.30 Vdc or less. If not, see section “what to do if . . .”.

What to do if . . .
[1] If the voltage level in step 2 cannot be set, replace the main pc board assembly, if a replacement is available,
and set aside the removed pc board assembly for disposition by QA. Re-test the unit from step 2. If the unit
failed again, inform Codonics Technical Support.
[2] If the voltage level in step 4 cannot be set, replace the picker assembly and re-test from step 2. If the until fails
again replace the main pc board assembly, (f a replacement is available). Re-test from step 2. If the unit fails
again, inform Codonics Technical Support.
[3] If the voltage limit required in steps 8, 10, or 12 is exceeded, contact Codonics Technical Support.

2-31
RECEIVER TYPE SENSOR (Field Adjustment)
Adjustment Specification
Purpose: To identify the RECEIVER as a TRANSPARENCY or a reflective.
Specification: • Reflective: 3.50 ± 0.05 V DC
• TRANSPARENCY: < 0.5 V DC
Special Tools: None
Prerequisites: • Open the CONTROLLER ENCLOSURE AND DRAWER AY
• Do the adjustment for the RECEIVER THRESHOLD
Postrequisites: Make a test print.

To Check:
[1] Check the LCD for correct RECEIVER TYPE.

To Adjust:
[1] Set the DIGITAL VOLT METER (DVM) to DC voltage.
[2] Install the PAPER TRAY with 100 sheets of a reflective RECEIVER.
[3] Connect the following on the CONTROLLER BD. See
Page 2-58.
• red PROBE to TP2, PIN 6
• black (-) PROBE to TP4, PIN 6 (ground)
[4] Adjust R23 for 3.50 ± 0.05 V DC.
[5] Install a TRAY with 1 TRANSPARENCY.
[6] Check:
• that the voltage is < 0.5 V DC
• for correct operation

2-32
Voltage for the THERMAL HEAD
Adjustment Specification

THERMAL
HEAD

A114_0013GCA
A114_0013GC

Purpose: To set the voltage for the THERMAL HEAD.

Specification: See the voltage printed on the VOLTAGE SET•POINT LABEL
Special Tools: None
Prerequisites: None
Postrequisites: Make a test print to check for correct operation.

To Check:
[1] Check the VOLTAGAE SET•POINT LABEL to obtain the correct voltage.

2-33
To Adjust:

VOLTAGE
SETPOINT
LABEL

A087_0193BCB
A087_0193BC

[1] Do this adjustment when:

• a new THERMAL HEAD, CONTROLLER
BD, or POWER SUPPLY is installed.
• a density change is observed.
R523 [2] Set the DIGITAL VOLT METER (DVM) to DC
voltage.
[3] Connect:
POWER • red PROBE of the DVM to any red wire of the
SUPPLY 14-PIN CONNECTOR
• black PROBE to any black wire of the 14-PIN
14 PIN
CONNECTOR
CONNECTOR [4] Adjust R523 on the POWER SUPPLY to the
voltage on the VOLTAGE SET•POINT LABEL.

A087_0194CCA
A087_0194CC

2-34
STEPPER MOTOR
Adjustment Specification

STEPPER A087_0062BCA
A087_0062BC
MOTOR

Purpose: To set the reference voltage.

Specification: 0.54 ± 0.01 V DC
Special Tools: None
Prerequisites: Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY
Postrequisites: • Make a test print.
• Check for artifacts.

To Check:
[1] Check for correct specifications.

To Adjust:

Important
You must do this adjustment when you install a new:
• ROLLER AY
• CONTROLLER BD
[1] Set the DIGITAL VOLT METER (DVM) to the DC voltage, 1 V or less.
[2] Connect the following on the CONTROLLER BD.
• red PROBE of the DVM to TP10, PIN 1
• black PROBE to TP4, PIN 6
[3] Adjust R21 to 0.54 ± 0.01 V DC.

2-35
DONOR SENSOR
Adjustment Specification

Purpose: To set the correct specifications.

Specification: See the specifications for the BLUE and GREEN LEDs.
Special Tools: None
Prerequisites: The DONOR and the DOOR COVER must be installed.
Postrequisites: Make test prints to check for correct operation.

To Check:
[1] Check for the correct specifications.

Adjustment LED Voltage Color Patch

R64 BLUE 3.90 ± 0.05 V DC yellow
Red: TP8, PIN 6
Black: TP4, PIN 6
R66 GREEN 3.70 ± 0.05 V DC cyan
Red: TP8, PIN 5
Black: TP4, PIN 6

To Adjust:
[1] To do the adjustment, use only yellow, magenta, cyan (YMC) or yellow, magenta, cyan, laminate (YMCL).
Install a new ribbon as shown below, or a ribbon which is not completely printed. In any case, do not use the
portion of a ribbon that has been used for printing or has dirt or fingerprints on it.

BLUE LED
[2] Enter the diagnostics. Select the test for the DONOR.
[3] Advance the DONOR until a not used patch of yellow DONOR covers the BLUE and GREEN LEDs on the
FAN BRACKET.

2-36
 Important
Do not acknowledge the “COLOR INDICATOR” on the LCD.
[4] Close the DOOR.
[5] Set the DVM to DC voltage.
[6] Connect the following on the CONTROLLER BD.
• red PROBE of the DVM to TP8, PIN 6
• black PROBE of the DVM to TP4, PIN 6
[7] Adjust R64 to 3.90 ± 0.05 V DC.
[8] If you can adjust R64 to 3.90 ± 0.05 V DC, go to the adjustment for the GREEN LED
[9] If you cannot adjust R64 to 3.90 ± 0.05 V DC, do Steps 10 to 25.
[10] Open the DOOR.

Caution
Prevent damage. Do not touch the DONOR.
Contamination will occur.
[11] Remove the DONOR.
[12] Select “DIAG: HEAD TEST”.
[13] Place the THERMAL HEAD in the ENGAGE
THERMAL position.
HEAD [14] Observe the movement of the THERMAL HEAD.
The THERMAL HEAD should move from the
LOAD RETRACT position to the ENGAGE position.
[15] Do this procedure again to check that the
THERMAL HEAD is in the ENGAGE position.

Warning
ENGAGE Dangerous Voltage
RETRACT [16] De-energize the PRINTER when the THERMAL
HEAD is in the ENGAGE position.

A114_0013GCB
A114_0013GC

2-37
 POWER
CONNECTOR

FAN BRACKET

A087_4066BCC
A087_4066BC

[17] Remove the POWER CONNECTOR from the FAN BRACKET.

2 NUTS
DONOR BD AY LED EMITTER
2 SCREWS FAN BRACKET AY
A087_0198BCB
A087_0198BC

[18] Loosen the 2 NUTS on the left and right sides of the FAN BRACKET AY. Use the 5/16 in. NUT DRIVER.
[19] Remove:
• 2 5/16 in. NUTS in the center of the FAN BRACKET AY
• FAN BRACKET AY
[20] Loosen the 2 SCREWS holding the DONOR BD AY to the FAN BRACKET AY.
[21] Adjust the DONOR BD AY until the BLUE and GREEN LED EMITTERS are in the correct position on the
FAN BRACKET AY.
[22] Tighten the 2 SCREWS.
[23] Install:
• FAN BRACKET ASSEMBLY
• POWER CONNECTOR

2-38
 Warning
Dangerous Voltage
[24] Energize the PRINTER.
[25] Do the adjustment for the BLUE LED again.

GREEN LED
[26] Advance the DONOR until a not used patch of cyan DONOR covers the BLUE and GREEN LEDs on the FAN
BRACKET.
[27] Close the DOOR.
[28] Connect the red PROBE of the DVM to TP8, PIN 5.
[29] Adjust R66 to 3.70 ± 0.05 V DC.
[30] If you cannot do the adjustment for R66, do Steps 10 - 25.
Final Check
[31] Check the LEDs with all of the color patches for correct voltages:

Color Patch BLUE LED GREEN LED

yellow 3.90 ± 0.05 V DC < 0.5 V DC
magenta > 3.5 V DC > 3.5 V DC
cyan < 0.5 V DC 3.70 ± 0.05 V DC
laminate < 0.5 V DC < 0.5 V DC

2-39
DOOR INTERLOCK SWITCH
Adjustment Specification
DOOR INTERLOCK
SWITCH

A114_0014GCA
A114_0014GC

Purpose: To make the DOOR INTERLOCK SWITCH operate correctly.

Specification: The LCD will display “READY” or “CLOSE COVER”.
Special Tools: None
Prerequisites: None
Postrequisites: Check for correct operation.

To Check:
[1] Check the LCD for any error messages when the DOOR is closed.

2-40
To Adjust:
[1] Install the DOOR INTERLOCK SWITCH.
DOOR INTERLOCK
SWITCH [2] Close the DOOR.

Warning
Dangerous Voltage
[3] Energize the PRINTER.
[4] Check that the LCD displays either:
• “READY”
• “CLOSE COVER”
2 SCREWS [5] If the LCD displays “CLOSE COVER”:
(a) move the DOOR INTERLOCK SWITCH
up.
(b) tighten the 2 SCREWS.
LCD [6] Open and close the DOOR 3 times to check that
the LCD displays “READY”.

A114_0014GCB
A114_0014GC

2-41
BAR CODE SENSOR
Adjustment Specification

BAR CODE SENSOR

A087_4129BCB
A087_4129BC

Purpose: To allow the BAR CODE SENSOR to read the DONOR BAR CODE LABEL correctly.
Specification: Component R16, 2.50 ± 0.1 V DC
Special Tools: BAR CODE SENSING ADJUSTMENT TOOL KIT 680-489-011
Prerequisites: Do the removal procedure for the CONTROLLER ENCLOSURE AND DRAWER
ASSEMBLY
Postrequisites: Check the LCD DISPLAY for the correct type of RIBBON.

To Check:
[1] Check that the BAR CODE SENSOR is correct.

2-42
To Adjust:

50-50 DUTY
CYCLE BAR
CODE LABEL

DONOR SUPPLY
SPINDLE

DONOR SUPPLY
TEST SPOOL A087_4129BCC
A087_4129BC

Important
Do this adjustment when:
• a new CONTROLLER BD or DONOR SUPPLY BRACKET is installed.
• Error Codes 510 or 511 displays on the LCD.
• the message “Invalid RIBBON/DONOR” displays on the LCD.

Warning
Dangerous Voltage
[1] De-energize the PRINTER.

Caution
Prevent damage. Do not touch the DONOR. Contamination will occur.
[2] Remove the DONOR if installed.
[3] Install the DONOR SUPPLY TEST SPOOL.
[4] Check that the 50-50 DUTY CYCLE BAR CODE LABEL is installed.
[5] Rotate the DONOR SUPPLY TEST SPOOL until it is seated on the TABS of the DONOR SUPPLY SPINDLE.
[6] Do the removal procedure for the CONTROLLER ENCLOSURE AND DRAWER AY.
[7] Locate TP4 on the CONTROLLER BD.
[8] Connect the DIGITAL VOLT METER (DVM) to:
• TP4, PIN 4 (+)
• TP4, PIN 6 (-)
[9] Remove CONNECTOR P13 from the CONTROLLER BD.
[10] Access ENGINE MODE See Page 1-20

2-43
 Warning
Dangerous Voltage
[11] Energize the PRINTER.
[12] Close the DOOR.
[13] Enter the diagnostics. Scroll to “DIAG: DONOR TEST”.
[14] Press:
(a) SETUP/SELECT BUTTON
(b) CANCEL BUTTON to advance to “DNR: ADVANCE”
(c) hold the SETUP/SELECT BUTTON to rotate the SUPPLY SPOOL
[15] Adjust R16 to 2.50 ± 0.1 V DC at TP4, PIN 4.
[16] Exit the diagnostics.
[17] De-energize the PRINTER.
[18] Open the DOOR. Remove the DONOR SUPPLY TEST SPOOL.

Caution
Prevent damage. Do not touch the DONOR. Contamination will occur.
[19] Install the DONOR if removed.
[20] Connect the CONNECTOR P13 to the CONTROLLER BD.
[21] Return unit to EXTERNAL MODE. See Page 1-19.
[22] Energize the PRINTER.

2-44
THERMAL HEAD LOAD GAP
Adjustment Specification

Purpose: To decrease STRETCH and have correct transport for the RECEIVER and DONOR.
Specification: 0.080 ± 0.010 in.
Special Tools: HEAD LOAD GAP TOOL 680-488-001
Prerequisites: Remove:
• DOOR COVER
• CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY
Postrequisites: Make a test print for the correct operation.

To Check:
[1] Check that the alignment for the BASE ENCLOSURE is correct. See the adjustment for the BASE
ENCLOSURE WALLS

To Adjust:

Warning
Dangerous Voltage
[1] Energize the PRINTER.
[2] Enter the diagnostics for the ENGINE. See the “LCD - Diagnostics” Section in the DIAGNOSTICS. See page
number 1-19.
[3] Close the DOOR.

Important
The THERMAL HEAD must be in the LOAD 2 position to check or adjust.
[4] Advance to:
(a) “DIAG: HEAD TEST”
(b) “HEAD: LOAD”; press SETUP/ ONLINE BUTTON to move the THERMAL HEAD to the LOAD 1
position.
(c) Press the SETUP/ONLINE BUTTON again to move the THERMAL HEAD to the LOAD 2
position.

2-45
 LOAD POSITION
THERMAL RIGHT MEASUREMENT
THERMAL HEAD LIFT HOLE
DOOR PLATE
HEAD LIFT SHAFT
SHAFT
TAB
HEAD LOAD
DOOR PLATE GAP TOOL

LEFT
ADJUSTMENT
SCREW
load

LEFT MEASUREMENT HOLE

RIGHT ADJUSTMENT
HEAD LOAD SCREW
GAP
TOOL THERMAL HEAD LIFT
SHAFT

THERMAL
DOOR HEAD
PLATE LIFT SHAFT

LEFT
ADJUSTMENT TAB
SCREW
THERMAL
HEAD LIFT
SHAFT
A114_0045DCA
A114_0045DC

[5] Place the HEAD LOAD GAP TOOL TL-5258 in the LEFT MEASUREMENT HOLE on the DOOR PLATE.
[6] Check:
• that the TOOL is flat on the DOOR PLATE.
• that the TAB of the TOOL touches the top of the THERMAL HEAD LIFT SHAFT when the TOOL is
moved forward and backward.
[7] If the TOOL is flat on the DOOR PLATE, but the TAB of the TOOL does not touch the THERMAL HEAD
LIFT SHAFT, rotate the LEFT ADJUSTMENT SCREW counterclockwise.
[8] If the TAB touches the top of the THERMAL HEAD LIFT SHAFT, but the TOOL is not flat on the DOOR
PLATE, rotate the LEFT ADJUSTMENT SCREW clockwise.
[9] Do Steps 5 to 8 for the RIGHT MEASUREMENT HOLE.
[10] Go to:
(a) “HEAD: RETRACT”
(b) “HEAD: LOAD”
[11] Check the adjustment. If the adjustment is not correct, do Steps 5 to 9 again.

2-46
BASE ENCLOSURE WALLS
Adjustment Specification

Purpose: To make the PRINTER operate correctly.

Specification: The REAR WALL, SIDE WALL, and LOCKING TABS have no damage.
Special Tools: None
Prerequisites: Remove:
• DOOR COVER - see Page 2-55
• ENCASEMENT - see Page 2-56
Open the CONTROLLER ENCLOSURE AND DRAWER AY. See Page 2-54.
Postrequisites: Make a test print to check for correct operation.

To Check:
[1] Check for damage in the REAR WALL, SIDE WALL or LOCKING TABS.
Note
If the REAR WALL, SIDE WALL, or LOCKING TABS are bent, remove and install a new BASE ENCLOSURE.

To Adjust:
side view REAR WALL REAR WALL
SIDE WALL SIDE WALL

correct not correct

rear view
SIDE WALL SIDE WALL

LOCKING LOCKING
TAB TAB

REAR WALL REAR WALL

correct not correct A087_0186HCA

A087_0186HC

[1] Check that the LOCKING TABS are not bent up or to the left or right sides.

2-47
 SIDE WALL SIDE WALL

REAR WALL REAR WALL

SIDE WALL
correct LOCKING not correct
TABS REAR WALL A106_0018BCA
A106_0018BC

side view REAR WALL REAR WALL

SIDE WALL SIDE WALL

correct not correct

rear view
SIDE WALL SIDE WALL

LOCKING LOCKING
TAB TAB

REAR WALL REAR WALL

[2] Check the left SIDE WALL that connects with the REAR WALL is flat.

2-48
 REAR WALL REAR WALL
SIDE WALL SIDE WALL

correct LOCKING not correct

TABS
A106_0022BCA
A106_0022BC

[3] Check that the right SIDE WALL that connects with the REAR WALL is flat.

2-49
4th TRAY SENSOR ADJUSTMENT
Adjustment Specification

Purpose: Set sensor LED current to appropriate level.

Effectivity: Effective for both EP-1660 and NP-1660 printers. This procedure is necessary for
IOCB4SLICK and for IOCB4NS boards. These boards can be identified by a blue trimpot
being present on board (trimpot is located in upper right-hand corner of the board).

Note: IOCB4SLICK/IOCB4NS in this procedure indicates either the IOCB4SLICK (NP-

1660) or IOCB4NS (EP-1660). When installing an IOCB4SLICK/IOCB4NS, replacing an
IOCB4SLICK/IOCB4NS, or replacing a 4th tray sensor attached to the IOCB4LSICK/
IOCB4NS, this 4th tray sensor adjustment procedure must be performed.
Specification:
Special Tools: 8.5”x11” adjustable media tray, digital voltmeter (DVM) with clip lead and sharp probes,
small trimmer screwdriver
Prerequisites:
Postrequisites: Make a test print to check for correct operation.

Procedure
IMPORTANT NOTE: In all steps requiring media tray slider to be moved, wait until
front panel displays INSERT TRAY OR REPLACE TRAY before reinserting the tray.
[1] IOCB4SLICK/IOCB4NS must be installed in an operational 1660 printer which is powered ON and in the
READY state.
[2] Connect DVM red (+) problem clip to:
IOCB4SLICK: TP4 pin 2 (see figure 1)
IOCB4NS: J1 pin 39 (see figure 2). Note: if the board was manufactured without the pin header J1 in place
probe the pin 39 solder pad using a sharply pointed probe to prevent probe from slipping during the
measurement.
[3] Connect DVM black (-) probe clip to:
IOCB4SLICK: TP6 pin 6
IOCB4NS: J10 pin 1
[4] Set DVM to DC Volts setting.
[5] Move media tray slider to 8.5x14 position and insert tray into printer. A MEDIA MISMATCH message may
appear on the printer front panel. This is OK and should clear when tray is returned to 8.5x11.
[6] Turn trimpot until DVM reads 0.20V +-0.01V. If voltage cannot be increased to 0.20V, then trim to the
maximum voltage available. NOTE: the label for the trimpot is R70 on IOCB4NS Rev. B and newer, POT1 on
IOCB4SLICK, an R52 on IOCB4NS Rev. A.
[7] Remove media tray. Move slider to 8.5x11 position and reinsert.
[8] Connect DVM black (-) probe to:
IOCB4SLICK: TP4 pin 6
IOCB4NS: J10 pin 13
[9] Read DVM voltage. (will be negative volts.)
[10] Record voltage two times. Add the numbers and record the result. This is the new voltage setting.
[11] Turn trimpot until DVM reads the new voltage setting (two times the initial voltage). If this voltage cannot be
achieved, check IOCB4SLICK/IOCB4NS or sensor for defects.
[12] Connect DVM black (-) probe to:
IOCB4SLICK: TP6 pin 6
IOCB4NS: J10 pin 1

2-50
[13] Verify that DVM reads >4.20V. If not, check sensor position, tray slider, or IOCB4SLICK/IOCB4NS.
[14] Remove media tray. Move slider to 8.5x14 position and reinsert.
[15] Verify that DVM reads <0.20V. If not, verify that procedure was correctly performed. Then check
IOCB4SLICK/IOCB4NS for defects.
[16] On NP-1660 printers only, do normal power shutdown. On EP-1660 printers only, wait until printer returns to
READY state then, turn power off.
[17] Return tray slider to 8.5x11 and insert.
[18] Re-apply power to printer and ensure printer returns to READY state. Do normal power shutdown.

2-51
TP3 1 2 3 4 5 6 TP5 1 2 3 4 5 6

TP4 1 2 3 4 5 6 TP6 1 2 3 4 5 6

POT1

Figure 1. IOCB4SLICK Test Point Locations

2-52
 J1 J10

2 4 6 8 10 12 14
40 39
1 3 5 7 9 11 13
38 37

36 35

Figure 2. IOCB4NS Test Point Locations

2-53
CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY
Prerequisites:
None

To Open:
[1] Remove the 5 SCREWS.
[2] Open and extend the CONTROLLER
ENCLOSURE AND DRAWER ASSEMBLY to
the maximum.

To Close:
[1] Reverse the steps for the removal procedure.

Postrequisites:
None
Prerequisites:

Caution
Prevent damage. Do not touch the DONOR. Contamination will occur.
[1] Remove the DONOR.

To Remove:

Warning
DOOR Dangerous Voltage
[1] De-energize the PRINTER.
[2] Open the DOOR and lift it up.

A114_0003ACB
A114_0003AC

LATCH 2 SCREWS
DOOR COVER

A087_4088BCB
A087_4088BC

[3] Remove:
• 2 SCREWS
• DOOR COVER
• LATCH
Prerequisites:
[1] Remove:
• DOOR COVER
• PAPER TRAY

To Remove:
12 LOCKING TABS notches
2 SCREWS
ENCASEMENT

LEAD EDGE SENSOR

MAIN
DOOR
SHAFT

A114_0015HCA
A114_0015HC

[1] Remove the 2 SCREWS.

Caution
Observe the position of the LEAD EDGE SENSOR. Do not cause damage to the parts or wires on the right side of
the ENCASEMENT.
[2] Move the ENCASEMENT 1.25 cm (1/2 in.) forward.
[3] Pull the ENCASEMENT up.
[4] Align the notches in the left and right sides of the ENCASEMENT over the MAIN DOOR SHAFT.
[5] Remove the ENCASEMENT.
[6] Check the 12 LOCKING TABS for damage. If the LOCKING TABS have damage, install a new
ENCASEMENT.
Prerequisites:
None

To Remove:

Important
Some of the CONNECTORS on the CONTROLLER BD are MULTIPLE CONNECTORS. See the graphic for the
CONTROLLER BD on Page 2-58. MULTIPLE CONNECTORS are CONNECTORS of individual components that
are inserted into a larger CONNECTOR, then inserted into the another CONNECTOR on the CONTROLLER BD.
These CONNECTORS are:
• P1
• P2
• P4
• P6
• P9
• P10
• P11
[1] Do the following procedure to disconnect a
LOCKING TAB MULTIPLE CONNECTOR:
female
(a) Press the LOCKING TAB.
(b) Remove the MULTIPLE CONNECTOR
from the CONTROLLER BD
CONNNECTOR.
(c) With the LOCKING TAB in the up position,
MAIN CONNECTOR insert a small FLAT-BLADE
SCREWDRIVER between the top of the
MAIN CONNECTOR and the MINI
MINI CONNECTOR CONNECTOR.
(d) Remove the MINI CONNECTOR to allow
A087_0077ACA
A087_0077AC
access to its components.

To Install:
[1] Reverse the steps in the removal procedure.

Postrequisites:
None
Above NP1660 and EP1660 Engine Controller Board with the SAB Board installed.

Below NP1600, EP1650, and EP1660 Non-Elmer Style IOCB Engine Controller Board.
 Warning
Dangerous Voltage
[3] De-energize and disconnect the PRINTER.
[4] Open and extend the CONTROLLER ENCLOSURE AND DRAWER AY to the maximum.

To Remove:
[1] Disconnect all CONNECTORS on the CONTROLLER BD.
[2] Remove:
• all SCREWS on the CONTROLLER BD
• CONTROLLER BD

To Install:
[1] Reverse the steps for the removal procedure.

Postrequisites:
[1] Adjust:
• LEAD EDGE SENSOR
• DONOR SENSORS
• BAR CODE SENSOR
• RECEIVER THRESHOLD
• RECEIVER TYPE SENSOR
• STEPPER MOTOR

SAB Installation/Replacement

SAB Test
The SAB and associated sensors and wiring can be tested by making an engine test print with the Loopback
Connector attached as follows:
• Shutdown printer
• Put unit in engine mode.
• Disconnect both IOCB ribbon cables from the engine controller board/SAB.
• Install 34-pin loopback adapter into 34-pin ribbon cable connector on SAB.
• Install A-size color ribbon and A-size paper into printer.
 Causes: Incorrect wiring to SAB P6

Message: OPEN COVER/CLEAR RIBBON JAM

Causes: Incorrect wiring to SAB P7.E or P7.S

Message: OPEN COVER/CHANGE RIBBON (ribbon is unraveled inside printer)

Causes: Incorrect wiring to SAB P1 (motor controls)

Message: SERVICE REQUEST 0700

Causes: Incorrect wiring to SAB P2 (head position sensors)
Incorrect wiring to SAB P1 (motor controls)

Message: LOAD RIBBON (ribbon not unraveled inside printer)

Causes: Ribbon not installed
Incorrect wiring to SAB P2 (bar code sensor)

Message: LOAD RIBBON (ribbon is unraveled inside printer)

Causes: Incorrect wiring to SAB P1 (motor controls)

Message: ENGINE READY/YMC-12 RIBBON/8.5 x 11 in PHOTO

Causes: System is OK so far

• If system is OK so far, press STATUS button to initiate an engine test print

Message: LOAD PHOTO
Causes: Paper tray empty (add paper and try again)
Paper jam during pick cycle (clear jam and try again)
Incorrect wiring to SAB P8 (paper pick motor control)
• If test print is successful, then SAB connection is OK. Turn OFF power to the printer. Re-install the 34-pin and
50-pin ribbon cables from the IOCB to the SAB/Engine Controller Board. Return the engine to “external” mode
(take out of “engine mode”).
TRAY TYPE SENSORS (Not including the 1660 8x10 Tray Sensor)
Prerequisites:
[1] Remove:
• DOOR COVER
• ENCASEMENT
[2] Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY
*** This Section does not include the 1660 8x10 Tray Sensor. For the 8x10
Tray Sensor See Section 4 later in this manual.
To Remove:
2 SCREWS
Important
It might be necessary to remove both of the TRAY
2 TRAY TYPE TYPE SENSORS.
SENSOR AYs
[1] Remove:
• SCREW
• TRAY TYPE SENSOR that has the
malfunction
[2] Disconnect the following CONNECTORS from
the CONTROLLER BD. See Page 2-58.
• P11 - for TRAY A and B SENSOR
• P15 - for TRAY C SENSOR
[3] Remove the HARNESS from either P11 and P15.
A087_4005ACC
A087_4005AC

To Install:
[1] Reverse the steps in the removal procedure.

Postrequisites:
[1] Check that the TRAY TYPE SENSOR detects the correct size of the TRAY.

2- 62
PICKER ASSEMBLY
Prerequisites:
[1] Remove the PAPER TRAY.
[2] Open the CONTROLLER ENCLOSURE AND
DRAWER ASSEMBLY
[3] Remove:
• DOOR COVER
• ENCASEMENT

To Remove:

[1] Remove:
• CONNECTOR P8
• PICKER HARNESS
• GROMMET

2- 63
[2] Remove:
• 4 SCREWS
• PICKER AY

To Install:
[1] Reverse the steps for the removal procedure.

Postrequisites:

RECEIVER
TYPE SENSOR

A087_0042BCB
PICKER MOTOR A087_0042BC

[1] Adjust:
• PICKER PENETRATION - See Pages 2-6 through 2-10 or 2-11 through 2-13 Field Adjustment
• RECEIVER TYPE SENSOR - See Pages 2-26 through 2-31 (Field Adjustment page 2-32)
[2] Do these diagnostic tests:
• “DIAG: RECEIVER, SIZE and TYPE”
• “DIAG OPTIONS: PICK/EJECT”

2- 64
TRAY GUIDE
Prerequisites:
[1] Remove the DOOR COVER.

To Remove:
[1] Remove:
• 2 SCREWS
• TRAY GUIDE

SCREW (2)
A087_0072ACB
TRAY GUIDE A087_0072AC

To Install:
[1] Reverse the steps in the removal procedure.

Postrequisites:
[1] Do the following diagnostic tests.
• “DIAG: RECEIVER”
• “RCVR: TRAY”
[2] Check for correct operation.

Important
The S1 SWITCH on the CONTROLLER BD must be in the ENGINE MODE.
[3] Check that the S1 SWITCH is in the ENGINE MODE on the CONTROLLER BD. See Pages 1-19 through 1-21
[4] Make a test print of the ENGINE.

Warning
Dangerous Voltage
[5] De-energize the PRINTER.
[6] Set the S1 SWITCH on the CONTROLLER BD to the EXTERNAL MODE. See Pages 1-19 through 1-21

2- 65
ROLLER ASSEMBLY
Prerequisites:
Special Tools:
• T-15 TORX MAGNETIC SCREWDRIVER
[1] Remove:
• PAPER TRAY
• DOOR COVER
• ENCASEMENT
[2] Open the CONTROLLER ENCLOSURE AND
DRAWER ASSEMBLY

To Remove:

Important

[1] Remove the SCREW holding the ROLLER AY to the right side of the BASE ENCLOSURE WALL.
[2] Use the LONG MAGNETIC Torx T-15 SCREWDRIVER to remove:
• 2 SCREWS from the right side
• 2 SCREWS from the left side

2- 66
[3] Remove:
• GROMMET
• ROLLER ASSEMBLY HARNESS
• CONNECTOR P10

[4] Remove the ROLLER ASSEMBLY.

To Install:
[1] Reverse the steps in the removal procedure.

2- 67
Postrequisites:
[1] Adjust:
• DONOR SENSOR See Pages 2-36 through 2-39
• LEAD EDGE SENSOR See Pages 2-23 through 2-24
[2] Do the following diagnostic tests:
• “PINCH” See Page 1-34
• “STEP MOTOR” See Page 1-35
• “PICK/EJECT” See Pages 1-36 through 1-37
[3] Make a print to check for correct operation.
[4] If the print has the STRETCH artifact, do these adjustment procedures:
• ROLLER ASSEMBLY See Pages 2-20 through 2-22
• DONOR SUPPLY BRACKET See Pages 2-14 through 2-19
• THERMAL HEAD LOAD GAP See Pages 2-45 through 2-46

2- 68
LEAD EDGE SENSOR BRACKET
Prerequisites:
[1] Remove the ROLLER ASSEMBLY

To Remove:

DONOR SENSOR ROLLER

BRACKET ASSEMBLY

A087_5027HCA
A087_5027HC

[1] Remove and lift up the DONOR SENSOR BRACKET from the ROLLER AY. Place the BRACKET as
indicated in the graphic.

2 SCREWS

LEAD EDGE
2 STATIC
SENSOR BRACKET
BRUSHES
cut here
ROLLER
ASSEMBLY
WIRE TIE

WIRE
HARNESS
A087_0205BCC
A087_0205BC 2 WASHERS 2 SPACERS 2 SCREWS

[2] Remove:
• 2 SCREWS holding the LEAD EDGE SENSOR BRACKET
• 2 SCREWS from the 2 STATIC BRUSHES
2- 69
 • front STATIC BRUSH
• 2 SPACERS
• back STATIC BRUSH
• 2 WASHERS
[3] Cut the WIRE TIE holding the WIRE HARNESS to the side of the ROLLER AY.

HARNESS
(Includes LEAD EDGE
SENSOR HARNESS,
DONOR SENSOR
HARNESS, and PINCH [4] Remove:
MOTOR HARNESS) • WIRE CLIP SCREW holding the WIRE
CLIP
• LEAD EDGE SENSOR HARNESS from the
WIRE CLIP

WIRE
CLIP

A087_5025GCB
A087_5025GC WIRE CLIP SCREW

INTERMEDIATE CONNECTOR

LEAD EDGE SENSOR CONNECTOR

A087_0204BCC
A087_0204BC

[5] Remove the LEAD EDGE SENSOR CONNECTOR from the INTERMEDIATE CONNECTOR.

2- 70
To Install:
DONOR
SENSOR
BRACKET

SLOT

TAB

A087_5026BCB
A087_5026BC

Important
You must align the TAB into the SLOT of the DONOR SENSOR BRACKET.
[1] Reverse the steps in the removal procedure.

Postrequisites:
[1] Do the following adjustments:
• LEAD EDGE SENSOR See Pages 2-23 through 2-24
• DONOR SENSOR See Pages 2-36 through 2-39

2- 71
DONOR SENSOR BRACKET
Prerequisites:
[1] Remove the ROLLER ASSEMBLY

To Remove:

DONOR SENSOR ROLLER

BRACKET ASSEMBLY

A087_5027HCA
A087_5027HC

[1] Remove and lift up the DONOR SENSOR BRACKET from the ROLLER AY. Place the BRACKET as
indicated in the graphic.

2- 72
 [2] Remove the WIRE CLIP SCREW holding the
HARNESS WIRE CLIP.
(Includes LEAD EDGE WIRE TIE
SENSOR HARNESS, [3] Cut the WIRE TIE.
DONOR SENSOR [4] Remove the DONOR SENSOR HARNESS from
HARNESS, and PINCH
MOTOR HARNESS)
the WIRE CLIP.

WIRE
CLIP

A087_5025GCC
A087_5025GC WIRE CLIP SCREW

INTERMEDIATE CONNECTOR

DONOR SENSOR BRACKET CONNECTOR

A087_0204BCD
A087_0204BC

[5] Remove the DONOR SENSOR BRACKET CONNECTOR from the INTERMEDIATE CONNECTOR.

2- 73
To Install:

SLOT

TAB

SCREW
A087_5026BCA
A087_5026BC

Important
You must align the TAB into the SLOT of the DONOR SENSOR BRACKET.
[1] Reverse the steps in the removal procedure.

Postrequisites:
[1] Do the adjustment for the DONOR SENSOR. See Pages 2-36 through 2-39

2- 74
PINCH MOTOR and GEARS for the ROLLER AY
Prerequisites:
[1] Remove:
• PAPER TRAY
• DOOR COVER
• ENCASEMENT
• ROLLER ASSEMBLY

2- 75
To Remove:
E-RING
BUSHING

3 SCREWS

PINCH MOTOR

PINCH MOTOR GEAR

IDLER GEAR

CAM GEAR
CAM SHAFT AY

LOCATOR TAB ROLLER AY

LOCATOR SLOT
A114_0032HCA
A114_0032HC

[1] Remove from the CAM SHAFT AY:

• E-RING
• BUSHING
[2] Move the CAM SHAFT AY to the right.
[3] Remove:
• CAM GEAR by pulling the LOCATOR TAB from the LOCATOR SLOT and the CAM SHAFT AY
• IDLER GEAR
• PINCH MOTOR GEAR
• 3 SCREWS holding the PINCH MOTOR to the ROLLER ASSEMBLY

2- 76
 [4] Remove from the WIRE CLIP:
• WIRE CLIP SCREW
• WASHER
• WIRES from the PINCH MOTOR

WIRE
CLIP

WIRES PINCH
WASHER
MOTOR
WIRE CLIP SCREW A114_0037GCA
A114_0037GC

INTERMEDIATE CONNECTOR

A087_0204BCB
A087_0204BC
PINCH MOTOR CONNECTOR

[5] Remove the PINCH MOTOR CONNECTOR from the INTERMEDIATE CONNECTOR.

To Install:
[1] Reverse the steps for the removal procedure.

Postrequisites:
[1] Adjust:
• DONOR SENSOR See Page Number 2-36 through 2-39
• LEAD EDGE SENSOR - See Page Number 2-23 through 2-24

2- 77
[2] Do the following diagnostic tests:
• “PINCH” See page 1-34
• “STEP MOTOR” See Page 1-35
• “PICK/EJECT” See Pages 1-36 through 1-37
[3] Make a print to check for correct operation.
[4] If the print has the STRETCH artifact, do these adjustment procedures:
• ROLLER ASSEMBLY See Pages 2-20 through 2-22
• DONOR SUPPLY BRACKET See Pages 2-14 through 2-19
• THERMAL HEAD LOAD GAP See Pages 2-45 through 2-46

2- 78
LCD DISPLAY and BRACKET
Prerequisites:
[1] Open the CONTROLLER ENCLOSURE AND
DRAWER ASSEMBLY
[2] Remove:
• PAPER TRAY
• DOOR COVER
• ENCASEMENT

To Remove:

[1] Disconnect CONNECTOR P9 from the

CONTROLLER BD.
[2] Remove:
• SCREW
• LCD BRACKET
• 4 NUTS
• LCD

To Install:
[1] Reverse the steps for the removal procedure.

Postrequisites:
[1] See the diagnostic procedure for “DIAG: PANEL TEST”. See Page Number 1-23

2- 79
DONOR SUPPLY BRACKET
Prerequisites:
[1] Open:
• CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY
• DOOR

Caution
Prevent damage. Do not touch the DONOR. Contamination will occur.
[2] Remove the DONOR.

To Remove:
[1] Energize the PRINTER.
[2] Enter the diagnostics and select “DIAG: HEAD
TEST”. See the DIAGNOSTICS. See Pages 1-29
through 1-31
[3] Move the THERMAL HEAD to the ENGAGE
position.
[4] De-energize the PRINTER.
[5] Remove:
THERMAL
HEAD • THERMAL HEAD DATA CONNECTOR
• CONNECTOR P5 from the CONTROLLER
BD

Important
CONNECTOR P2 is a MULTIPLE CONNECTOR.
The BAR CODE CONNECTOR is on the right side of
NGAGE P2.
[6] Remove CONNECTOR P2 from the
CONTROLLER BD.
A114_0013GCC
A114_0013GC

THERMAL HEAD
DATA CONNECTOR
A087_0051BCC
A087_0051BC

2- 80
 INSIDE
SCREWS
OUTSIDE
SCREWS

DONOR SUPPLY A114_0027BCA

BRACKET A114_0027BC

[7] Remove:
• 2 INSIDE SCREWS
• 2 OUTSIDE SCREWS
[8] Observe the positions of the CABLE TIES. Cut the CABLE TIES.
[9] Route through the hole on the BASE
BAR CODE
ENCLOSURE BACK WALL:
HARNESS
BACK WALL • THERMAL HEAD DATA CABLE
HOLE • BAR CODE HARNESS
[10] Remove the DONOR SUPPLY BRACKET AY.

THERMAL
HEAD DATA
CABLE

A087_4062ACE
A087_4062AC

To Install:
[1] Reverse Steps 8 - 10.

Important
Do not tighten the 4 SCREWS at this time.
[2] Install:
• 2 INSIDE SCREWS
• 2 OUTSIDE SCREWS
[3] Do the adjustment for the DONOR SUPPLY BRACKET. See Pages 2-14 through 2-19

2- 81
[4] Install:
• CONNECTOR P2 on the CONTROLLER BD
• CONNECTOR P5 on the CONTROLLER BD
• THERMAL HEAD DATA CONNECTOR

Postrequisites:
[1] Adjust the BAR CODE SENSOR. See Pages 2-42 through 2-44
[2] Do the “DIAG: DONOR TEST”. See 2-36 through 2-39
[3] Make a print from the ENGINE. If there are STRETCH artifacts, do the adjustment for the DONOR SUPPLY
BRACKET. See 2-14 through 2-19

2- 82
MOTOR BRACKET ASSEMBLY
Prerequisites:
[1] Remove the DOOR COVER.
[2] Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY

To Remove:
[1] Enter the diagnostics.
[2] Move the THERMAL HEAD to the ENGAGE
position. See Pages 1-29 through 1-31
[3] Do the removal procedure for the DONOR
SUPPLY BRACKET. See Pages 2-14 through 2-
19

THERMAL
HEAD

NGAGE

A114_0013GCC
A114_0013GC

2- 83
 BUSHING

FERRITE BEAD

RETAINING
RING

A114_0025BCA
A114_0025BC

Warning
Dangerous Voltage
[4] De-energize the PRINTER.
[5] Remove:
• RETAINING RING
• BUSHING
• FERRITE BEAD
[6] Disconnect the CONNECTOR P1 from the CONTROLLER BD.

MOTOR BRACKET AY

3 SCREWS

A087_0014BCC
A087_0014BC

[7] Remove:
• 3 SCREWS
• MOTOR BRACKET ASSEMBLY

To Install:
[1] Reverse the steps for the removal procedure.
2- 84
Postrequisites:
[1] Do the following diagnostic tests.
• “HEAD TEST” Pages 1-29 through 1-31
• “DONOR TEST” Pages 1-32 through 1-33
• “PICK/EJECT” Pages 1-36 through 1-37
[2] Make a print to check for correct operation.

2- 85
FAN BRACKET ASSEMBLY
Prerequisites:
[1] Remove the DOOR COVER.
[2] Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY

To Remove:
CONNECTOR P1

FAN BRACKET AY

4 NUTS

A087_0016BCC
A087_0016BC

[1] Disconnect the CONNECTOR P1 from the FAN BRACKET AY.

[2] Access the Engine Diagnostics See Pages 1-19 through 1-21
[3] Select the HEAD TEST and move the printhead into the ENGAGE position See Pages 1-29 through 1-31
[4] Denergize the printer
[5] Remove:
• 4 NUTS
• FAN BRACKET AY

To Install:
[1] Reverse the steps for the removal procedure.

Postrequisites:
[1] Adjust the DONOR.
[2] Do the following diagnostic tests.
• “HEAD TEMP” See Page 1-28
• “DONOR TEST” See Page 1-32 through 1-33
[3] Make a print to check for correct operation.

2- 86
THERMAL HEAD
Prerequisites:

Caution
Prevent damage. Do not touch the DONOR.
Contamination will occur.
[1] Remove:
• DOOR COVER
• PAPER TRAY
• DONOR
[2] Open:
• DOOR
• Open the CONTROLLER ENCLOSURE
AND DRAWER ASSEMBLY

To Remove:

Warning
Dangerous Voltage
[1] Energize the PRINTER.
[2] Enter the diagnostics. See Pages 1-19 through 1-
21

Caution
THERMAL Prevent damage.
HEAD [3] Move the THERMAL HEAD to the ENGAGE
position. See Pages 1-28 through 1-30
[4] De-energize the PRINTER.

NGAGE

A114_0013GCC
A114_0013GC

2- 87
 [5] For Style 1 THERMAL HEAD only, remove:
• CONNECTOR P4 from the CONTROLLER
BD
• FERRITE BEAD using a small FLAT-
BLADE SCREWDRIVER

FERRITE
BEAD

A087_4062ACF
A087_4062AC

THERMAL
HEAD
DATA
CABLE

A087_0051BCB
A087_0051BC

[6] Remove the THERMAL HEAD DATA CABLE.

2- 88
 INSIDE
SCREWS
OUTSIDE
SCREWS

DONOR SUPPLY A114_0027BCA

BRACKET A114_0027BC

[7] Remove from the DONOR SUPPLY BRACKET:

• 2 INSIDE SCREWS
• 2 OUTSIDE SCREWS

THERMAL
HEAD

DONOR SUPPLY
BRACKET

A114_0024BCA
A114_0024BC

[8] Move the DONOR SUPPLY BRACKET down to allow access to the THERMAL HEAD.

2- 89
 THERMAL
HEAD
POWER
CABLE
A087_0047BCB
A087_0047BC

[9] Remove the THERMAL HEAD POWER CABLE.

ground
wire

SCREW

THERMAL
HEAD

A087_4065HCB
A087_4065HC

[10] Remove the SCREW that holds the ground wire to the left side of the THERMAL HEAD.

2- 90
 POWER CONNECTOR

FAN BRACKET AY

BASE
ENCLOSURE
WALL
CABLE
TIES
HARNESS

A114_0006HCA
A114_0006HC

[11] Remove the 2 CABLE TIES.

[12] Route the HARNESS through the hole in the back of the BASE ENCLOSURE WALL.
[13] Remove the POWER CONNECTOR from the FAN BRACKET ASSEMBLY
[14] Move the POWER CONNECTOR to the left.
[15] Do the removal procedure for the FAN BRACKET ASSEMBLY

2- 91
 THERMAL
HEAD

A087_4077BCB
A087_4077BC

Caution
Prevent damage.
[16] Remove:
• THERMAL HEAD
• any contamination next to the THERMAL HEAD and DOOR
[17] Return the THERMAL HEAD. See the instructions sent with the new THERMAL HEAD.

To Install:

Caution
Prevent damage when you install the THERMAL HEAD. It is highly sensitive to damage.
[1] Reverse the steps for the removal procedure.

Postrequisites:
[1] Clean the THERMAL HEAD.
[2] Do the following adjustments:
• THERMAL HEAD LOAD GAP See Pages 2-45 through 2-46
• Voltage for the THERMAL HEAD See Pages 2-33 through 2-34
• DONOR SUPPLY BRACKET See Pages 2-14 through 2-19
• DONOR SENSOR See Pages 2-36 through 2-39
[3] Do the following diagnostics.
• “HEAD TEMP” See Page 1-28
• “HEAD TEST” See Pages 1-29 through 1-31
• “DONOR TEST” See Pages 1-32 through 1-33
[4] Make a print to check for correct operation.

2- 92
THERMAL HEAD LIFT CAM
Prerequisites:
[1] Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY
[2] Remove:
• DONOR SUPPLY BRACKET ASSEMBLY
• MOTOR BRACKET ASSEMBLY

To Remove:

Warning
Dangerous Voltage
[1] Energize the PRINTER.
[2] Enter the diagnostics. See Pages 1-19 through 1-
21
[3] Move the THERMAL HEAD in the ENGAGE
position. See Page 1-29 through 1-31
THERMAL
HEAD [4] De-energize the PRINTER.

NGAGE

A114_0013GCC
A114_0013GC

CAM

BUSHING

RETAINING RING

A087_0017BCE
A087_0017BC

[5] Remove the RETAINING RING.

[6] Move the BUSHING to the right.
[7] Remove the CAM.

2- 93
To Install:
[1] Reverse the steps for the removal procedure.

Postrequisites:
[1] Do the diagnostics for the “HEAD TEST”. See Pages 1-29 through 1-31

2- 94
THERMAL HEAD LIFT SENSOR
Prerequisites:
[1] Remove:
• DONOR SUPPLY BRACKET ASSEMBLY See Pages 2-80 through 2-82
• MOTOR BRACKET ASSEMBLY See Pages 2-83 through 2-85
[2] Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY See Page 2-54

To Remove:

THERMAL
HEAD LIFT
SENSOR

SCREW

CONNECTOR
A087_0019BCC
A087_0019BC

[1] Remove:
• CONNECTOR
• SCREW
• THERMAL HEAD LIFT SENSOR

To Install:
[1] Reverse the steps for the removal procedure.

Postrequisites:
[1] Do the diagnostic test for the “HEAD TEST”. See Page 1-29 through 1-31
[2] Adjustment for the DONOR SUPPLY BRACKET. See Pages 2-14 through 2-19

2- 95
DOOR ASSEMBLY
Prerequisites:
[1] Remove:
• DOOR COVER See Page 2-55
• ENCASEMENT See Page 2-56
• CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY See Page 2-54
• DONOR SUPPLY BRACKET ASSEMBLY See Pages2-80 through 2-82
• MOTOR BRACKET ASSEMBLY See Pages 2-83 through 2-85
• FAN BRACKET ASSEMBLY See Page 2-86
• THERMAL HEAD See Pages 2-87 through 2-92
• THERMAL HEAD LIFT SENSOR See Page 2-95

To Remove:

DOOR AY

DOOR BRAKE

Top
of
SPRING
2 DOOR SPRINGS
Bottom of
SPRING

A087_0035BCA
A087_0035BC

[1] Remove:
• 2 DOOR SPRINGS
• DOOR BRAKE
• DOOR AY by moving the AY up

To Install:
[1] Reverse the steps for the removal procedure.

Postrequisites:
[1] Do the following diagnostic tests.
• “HEAD TEMP” See Page 1-28
• “HEAD TEST” See Pages 1-29 through 1-31
• “DONOR TEST” See Pages 1-32 through 1-33
• “PICK/EJECT” See Pages 1-36 through 1-37
[2] Adjust:
• THERMAL HEAD LOAD GAP See Pages 2-45 through 2-46
• DONOR SENSOR - See Pages 2-36 through 2-39
[3] Make a print to check for correct operation.
2- 96
DOOR INTERLOCK SWITCH
Prerequisites:
[1] Remove:
• DOOR COVER
• ENCASEMENT
[2] Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY

To Remove:
DOOR
INTERLOCK Caution
SWITCH Do not allow the DOOR INTERLOCK SWITCH
PLATE to fall into the PRINTER.
[1] Remove:
• 2 SCREWS
HARNESS • DOOR INTERLOCK SWITCH PLATE
DOOR
INTERLOCK
• DOOR INTERLOCK SWITCH and
SWITCH HARNESS
PLATE • CONNECTOR P6 from the CONTROLLER
BD
2 SCREWS

A114_0018GCA
A114_0018GC

To Install:
[1] Reverse the steps for the removal procedure.

Postrequisites:
[1] Adjust the DOOR INTERLOCK SWITCH. See Pages 2-40 through 2-41
[2] Make a print to check for correct operation.

2- 97
POWER SUPPLY
Prerequisites:
[1] Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY

To Remove:

[1] Pull the CONTROLLER ENCLOSURE AND DRAWER AY out.

[2] Remove:
• CONNECTOR J14 reference IOCB document See Page 5-22
• CONNECTOR J12 from the CONTROLLER BD
• STRAP from the POWER COVER
• CONNECTOR J2

2- 98
[3] Remove:
• AC CONNECTOR TB1
• POWER COVER
[4] Disconnect:
• brown wire from position 2 on the POWER SWITCH
• blue wire on the PLUG

2- 99
[5] Remove:
• 5 NUTS
• POWER SUPPLY

To Install:
[1] Reverse the steps for the removal procedure.

Postrequisites:
[1] Adjust the voltage for the THERMAL HEAD. See Pages 2-33 through 2-34
[2] Make a print to check for correct operation.

2- 100
DRAWER FAN
Prerequisites:
[1] Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY See Page 2-54

To Remove:
[1] Disconnect the DRAWER FAN CONNECTOR.
[2] Remove:
• DRAWER STRAP
• 2 NUTS
• DRAWER FAN
• ground wire

To Install:
[1] Reverse the steps for the removal procedure.

Postrequisites:

Warning
Dangerous Voltage
[1] Energize the PRINTER.
[2] Check for correct operation.

2- 101
PLUG
Prerequisites:
[1] Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY See Page 2-54

To Remove:

[1] Remove:
• 3 SCREWS from the POWER COVER
• POWER COVER
• 2 SCREWS from the PLUG
• PLUG
• ground wire
• black wire from position 3
• brown wire from position 2

To Install:
[1] Reverse the steps for the removal procedure.

Postrequisites:
None

2- 102
POWER SWITCH
Prerequisites:
[1] Open the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY See Page 2-54

To Remove:

[1] Remove:
• 3 SCREWS from the POWER COVER
• POWER COVER
• 2 SCREWS from the POWER SWITCH
• POWER SWITCH BEZEL
• POWER SWITCH

To Install:
[1] Reverse the steps for the removal procedure.

Postrequisites:
None

2- 103
 {Adjust/Replace}{Production}{KodakServiceSup ort}

Controller Board Prom Replacement

for the Codonics NP/EP 1600 Series Imagers

Important
Use qualified personnel to service this equipment.
 This equipment includes parts and assemblies sensitive to damage from electrostatic
discharge. Use caution to prevent damage during all service procedures.

Table of Contents
Description Page

Controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Part Number 907-062-001.01

Controller Board Prom Replacement

[1] This instruction sheet should serve as a guide for replacement of the engine controller firmware on all Codonics
EP and NP series printers.
[2] Always remember to observe common ESD safety with respect to Codonics Electronic Devices. The printer
should be powered off.
[3] This procedure will require the following tools for proper replacement of the Proms: Phillips head screwdriver,
prom remover. Please note that U19 & U20 may be removed with extreme caution using a small standard
jewelers screwdriver.
[4] De-energize the printer.
[5] Remove the 5 screws from the REAR ENCLOSURE ASSEMBLY.

[6] Slowly and carefully pull the electronics tray out by pulling on the 2 black knobs on the back of the printer a
total distance of no more than 8”.

[7] The proms we are discussing are shown on the controller board in the picture below:

3-3
 Above NP1660 and EP1660 Engine Controller Board with the SAB Board installed.

[8] With the electronics tray pulled away or disconnected from the printer engine, use the special prom tool to
remove the U19, U20, U9 and U42 proms. Use special care not to bend or damage the old proms as they may
be needed in the future. Be careful not to damage the housing, especially on U9 and U42 as this material may
crack with excessive force.
[9] Install the new proms paying close attention the polarity notches on each prom. Placing a prom inverted to the
correct polarity will cause severe damage to the printer. The new proms should slide into place without much
force. If you find it requires you to push with much force check the pins for alignment and the polarity on the
chip.
[10] The printer may now be closed, making sure that no wires are pinched and no foreign materials are left in the
printer, and reinstall the 5 Phillips head screws you removed in step 5.
[11] The printer may now be powered on using the power switch and the printer should be ready for use.

3-4
 {Diagnostics}{Production}{KodakServiceSup ort}

Service Notes
for the Codonics NP/EP-1660 Series Imagers

Important
Use qualified personnel to service this equipment.
 .This equipment includes parts and assemblies sensitive to damage from electrostatic
discharge. Use caution to prevent damage during all service procedures.

Table of Contents
Description Page

General Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Status Indicates 8.5x11 Media when 8x10 Film is Installed. . . . . . . . . . . . . . . . . . . . . . . . 4-5
Media Type Mismatch Message on Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Ribbon Errors (Load, Invalid Ribbon, 500-Series) on Front Panel . . . . . . . . . . . . . . . . 4-6
Front Panel Blank or Cannot Run Engine Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
SAB Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
SAB Installation/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
SAB Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Bar Code Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Bar Code Sensor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Donor Type LED Adjustment & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Tray Type Detector #4 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Tray Type Detector #4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Printhead Replacement & Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Part Number 907-063-001.01

Section 1: Overview

The Codonics NP-1660 and EP-1660 series printers are very similar to their NP-1600 and EP-1600 series
predecessors. The primary difference between the 1660 series and the 1600 series printers is the addition of direct
thermal printing support in the 1660’s. This support involves the introduction of a new 8x10 inch media tray, the
addition of a tray sensor for 8x10 support, some additional circuitry and software on the I/O controller board (IOCB)
to support printing without ribbon, and the addition of software on the built-in SPARC workstation to support the
new media sizes, color tables and improved printhead calibration.
From a service technician’s perspective, the 1660-series printers behave exactly like 1600-series units in some
situations and very much like them in other situations. This intent of this document is to supplement the service
information required for a 1600-series printer with those items that are unique to the 1660 or that require special
attention.
Section 2: Hardware Description
The new hardware includes the following components:

[1] Input/output controller board (IOCB)

[2] Slick Adapter Board (SAB) NP1660
[3] Pick motor cable assembly
[4] Door sensor cable assembly
[5] Donor and fan control cable assembly
[6] Spool motors cable assembly
[7] Bar code cable assembly
[8] 4-position tray sensor cable assembly
[9] Watermark sensor cable assembly
[10] 34-pin ribbon cable assembly

Additionally, debugging is aided using the following:

[1] SAB loopback connector.

4-4
Section 3: General Troubleshooting
The following are some common 1660 series printer failure modes, followed by common causes and corrective
actions.

Problem: Status Indicates 8.5x11 Media when 8x10 Film is Installed

Causes:
[1] Tray sliver in incorrect position.
[2] Tray type sensor, SAB or IOCB failure.

Action
[1] Check tray sliver.
[2] Remove and re-insert media.
[3] Reboot printer.
[4] See tray type detector #4 Adjustment and Troubleshooting sections.

Problem: Media Type Mismatch Message on Front Panel

Causes:
[1] Tray slider in incorrect position.
[2] Wrong size receiver for the donor ribbon that is installed.
[3] Ribbon not installed and non-8x10 or A-size tray installed.
[4] Ribbon installed in combination with 8x10 tray.
[5] Tray Type Sensor, Bar Code Sensor, SAB or IOCB failure.

Actions:
[1] Check tray slider.
[2] Check for valid paper and ribbon size/type combinations.
[3] Remove and re-insert media.
[4] Reboot printer.
[5] See Tray Type Detector #4 Adjustment and Troubleshooting sections.
[6] See Bar Code Sensor Adjustment and Troubleshooting sections.

Problem: Ribbon Errors (Load Ribbon, Invalid Ribbon, 500-series Errors) on Front
Panel

Causes:
[1] Likely cause is software problems.
[2] Could also be Bar Code Sensor, SAB, or IOCB failure.

Action:
[1] Reboot printer.

4-5
[2] If rebooting does not help, contact Codonics Technical Support department.
[3] See Bar Code Sensor Adjustment and Troubleshooting sections.

Problem: Front Panel Blank or Cannot Run Engine Print

Causes:
[1] Bad U19 or U20 chips on engine controller board.

Action:
[1] Contact Codonics Technical Support department.

4-6
Section 4: SAB Troubleshooting
This section covers installation and testing of the Slick Adapter Board (SAB) and its wiring. The SAB Test procedure
is valuable not only for this purpose, but also in helping diagnose problems on the IOCB. This is because, with the
SAB Loopback Adapter attached to a properly-wired SAB, the printer engine is electrically unmodified from its
original state. A function that works properly with the Loopback Adapter and not with the IOCB normally connected
usually indication IOCB hardware or software problems.

4.1 SAB Installation/Replacement

4.2 SAB Test

The SAB and associated sensors and wiring can be tested by making an engine test print with the Loopback
Connector attached as follows:
• Shutdown printer
• Put unit in engine mode.
• Disconnect both IOCB ribbon cables from the engine controller board/SAB.
• Install 34-pin loopback adapter into 34-pin ribbon cable connector on SAB.
• Install A-size color ribbon and A-size paper into printer.
• Turn on power. Look for the following errors:
Message: CLOSE COVER
Causes: Incorrect wiring to SAB P6

Message: OPEN COVER/CLEAR RIBBON JAM

Causes: Incorrect wiring to SAB P7.E or P7.S

Message: OPEN COVER/CHANGE RIBBON (ribbon is unraveled inside printer)

Causes: Incorrect wiring to SAB P1 (motor controls)

Message: SERVICE REQUEST 0700

Causes: Incorrect wiring to SAB P2 (head position sensors)
Incorrect wiring to SAB P1 (motor controls)

Message: LOAD RIBBON (ribbon not unraveled inside printer)

Causes: Ribbon not installed
Incorrect wiring to SAB P2 (bar code sensor)

Message: LOAD RIBBON (ribbon is unraveled inside printer)

Causes: Incorrect wiring to SAB P1 (motor controls)

Message: ENGINE READY/YMC-12 RIBBON/8.5 x 11 in PHOTO

Causes: System is OK so far

4-7
• If system is OK so far, press STATUS button to initiate an engine test print
Message: LOAD PHOTO
Causes: Paper tray empty (add paper and try again)
Paper jam during pick cycle (clear jam and try again)
Incorrect wiring to SAB P8 (paper pick motor control)
• If test print is successful, then SAB connection is OK. Turn OFF power to the printer. Re-install the 34-pin and
50-pin ribbon cables from the IOCB to the SAB/Engine Controller Board. Return the engine to “external” mode
(take out of “engine mode”).

4-8
Section 5: Bar Code Sensor Adjustment
The bar code signal is read by the IOCB and then passed on to the engine if required. The steps for trimming this
sensor are identical to those used for the 1600 series printers, except that, instead of connecting DVM probes to TP4.3
and TP4.6 on the engine controller board for the adjustment, they should be attached as follows:

• Connect the POSITIVE (+) red probe to TP3.3 on the IOCB

• Connect the NEGATIVE (-) black probe to TP6.6 on the IOCB

The rest of the adjustment proceeds unchanged.

If during the procedure, the voltage reading cannot be made to go below 0.22 Volts, then the circularity has a
problem. Refer to the “Bar Code Sensor Troubleshooting” section.

4-9
Section 6: Bar Code Sensor Troubleshooting
Bar cod sensor troubleshooting should begin with an attempt to adjust the sensor as previously described in the
section “Bar Code Sensor Adjustment Changes”. If this adjustment cannot be performed successfully, then the
following debugging steps should be performed.
• Connect the POSITIVE (+) red probe to TP3.3 on the IOCB.
• Connect the NEGATIVE (-) black probe to TP6.6 on the IOCB.
• Rotate donor spool until the bar code sensor points to the widest white patch of bar code.
• Adjust potentiometer R16 on the engine controller board fully to the left and then fully to the right while noting
the range of the voltage ready.
• If the voltage reading remains generally unchanged during trimming at around 4.5V to 5.5V, then there is likely
a problem with the SAB connections or the IOCB. Shutdown the unit and replace the 34-pin ribbon cable on the
SAB with e SAB Loopback Adapter. Return power to the unit and perform standard 1600 Bar Code Sensor
Trimming with the DVM attached to TP4.3 (+) and TP4.6 (-) on the engine controller board. If sensor can be
trimmed without problem, then the IOCB must be replaced. If sensor cannot be trimmed, replaced the sensor. If
it cannot be trimmed with a new sensor, replace the SAB. If still not, replace the engine controller board.
• If the voltage reading varies but cannot be made to go below 0.22 Volts, then replace the sensor.
• If the voltage reading can be trimmed just fine, then return the sensor to a proper trim point. Connect the DVM
to TP4.3 (+) and TP4.6 (-) on the engine controller board. Slowly rotate the donor spool, watching the DVM
reading. If the DVM goes below 0.22 Volts and above 3.5 Volts as the bar code is rotated, then the sensor and
circuitry is operating properly. If the DMV reading varies by more then 1 Volt, but does not pull to below 0.22
Volts, then replaced the IOCB. Otherwise, replace the SAB. If this does not solve the problem, replaced the
IOCB.
• If none of these actions solves the problem, return the unit for service.

4-10
Section 7: Donor Type LED Adjustment and Troubleshoot
When ribbon is installed in a 1660 series printer, the blue and yellow donor patch LEDs operate identically as they
would in a 1600 printer. In this situation, they are always on. When ribbon is removed from the 1660 printer, the LEds
are usually on, but will flash on and off every six to twelve seconds during periods when the engine is trying to
determine the media type. This occurs every time the lid of the printer closed, every time the printer is powered up,
and any time the engine is reset. Normally, however, when the lid of the printer is open, the LEDs should be turned
on, regardless of whether or not ribbon is installed.

If the blue and yellow LEDs are NOT ON when the printer lid is open, this indicates faulty wiring of the SAB at
connectors P7.E or P7.S, or else it indicates a faulty IOCB.
• With the printer lid open, connect DVM probes to TP2.1 (+) and TP2.4 (-) on the IOCB. If it does not ready
approximately 12 Volts, double-check wiring to SAB P7.E and P7.S. If 12 Volts is present, move the positive
probe (+) to TP2.3 on the IOCB. The DVM should read less than 0.2 Volts. If not, replace the IOCB. If it does,
check the wiring to SAB P7.E and P7.S.
If the blue and yellow LEDs ARE ON when the printer lid is open, then the SAB and IOCB are operating correctly.
Donor LED adjustment and debugging can then be performed in the same manner as is done for 1600 series printers.

4-11
Section 8: Tray Type Detector #4 Adjustment
The trim setting for the Tray Detector #4 is digitally controlled. Normally, it should not require adjustment. The
default setting for this sensor is 140 decimal. To test that the adjustment is correct on a given IOCB, perform the
following steps.
• Connect DVM lead to TP5.4 (+) and TP6.6 on the IOCB. The reading should be 1.60+-0.1 Volts. If the reading
is not within these limits, refer to the Tray Type Detector #4 Troubleshooting section.

**** Note : The procedure above is valid only for revisions of the IOCB in which the the DAC chip is present. Earlier
versions of the IOCB have a trim pot (POT1) in place of the DAC chip. This trim pot is located in the upper right
corner of the IOCB board. If the trimpot is present, then ignore the above procedure.

4-12
Section 9: Tray Type Detector #4 Troubleshooting
• Perform the Tray Type Detector #4 Adjustment procedure described in the previous section. If the voltage
reading is not within limits, then contact Codonics Technical Support department.
• Connect DVM leads to TP4.2 (+) and TP6.6 (-). Insert an 8x10 size media tray with the tray sliver in the 8x10
position. The DVM should read less than 0.25 Volts. Remove the tray and insert an 8.5 x 11inch tray with the
tray slider in the 8.5 x 11 position. The DVM should read greater than 3.5 Volts. If the voltage range is not within
spec, contact Codonics Technical Support department.

**** Note : If trimpot POT1 is present in the upper right hand corner of the IOCB, the sensor can be adjusted.
Perform the procedure detailed in Section 2 (4th. Tray Sensor Adjustment)of this manual. If the sensor cannot be
trimmed properly according to that procedure, please contact Codonics Technicial Support.

**** Note : If trimpot POT1 is not present on the IOCB then contact Codonics Technicial Support.

4-13
Section 10: Printhead Replacement and Calibration
Printhead replaced is performed in the 1660 series printers in exactly the same manner as in the 1600 series printers.
However, the 1660’s have the additional step of installing the printhead calibration data that is associated with the
new printhead.

If the printer in question is an EP-1660 printer, then installation of the printhead calibration data is system specific.
The OEM of the system in question or Codonics Technical Support personnel should be contacted for details.

If the printer in questions is an NP-1660, then the following steps should be performed after installation of the new
head:

• Power up the unit in its standard configuration (not in engine mode).

• Once the unit is fully booted (the READY message will be displayed on the front panel), select the KEYS option
from the front panel menu system.
• Enter a key that has the following format: 99SSSSSS00, in which SSSSSS is the 6-character printhead serial
number that is indicated on the bar code label on the new printhead. Normally, this stands for an alphabetic
character. An example is “996J601300”, in which 6J66013 is a typical printhead serial number.
• Once the key is entered, insert the printhead calibration update floppy diskette that came with the new printhead
into the printer. Then select the UPDATE option from the front-panel menu system.
• When the floppy update is complete and the READY message is displayed, reboot the printer and the message
“Warning, Calibration Failed” printed on the lower-left-hand corner of the image, then some part of the floppy
update procedure failed. Most likely, the key that was entered does not match the serial number of the printhead
shown on the floppy disk. The printhead serial number, the serial number printed on the floppy disk, and the serial
number encoded in the key must match in or for calibration to work.
• The serial number key that was entered can be verified using the “stat” command from an NP-1660 telnet session
or from the serial port monitor. It can also be verified by making a status print or checking status through the
printer’s built-in web interface.

4-14
 ELECTRONIC TRAY
TROUBLESHOOTING & REPLACEMENTS

Important
Use qualified personnel to service this equipment.
Table of Contents
Description Page

Sparc Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Replacing or Upgrading Sparc Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Sparc Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
IOCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Hard Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Floppy Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

Part Number 907-065-001.01

5-2
SPARCengine Classic-II Diagnostic
This section describes the different types of diagnostic firmware and software tools available to you and how they
are related. The main categories of diagnostics are:

• Boot PROM diagnostic

Power-On Self-Test (POST)
On-Board Diagnostics

The text in this section is written at the “system” level, because you need to have a serial terminal to view the results
of the tests. The specifics of the procedures that follow must be adjusted to your particular situation.

Normally, you will require a terminal connected to the SPARCengine Classic-II serial port. If you are using alternate
equipment, ready and understand the documentation that is provided with that equipment, and adjust the following
procedures accordingly.

5-3
Power-On Self Test (POST)
The Power-On Self-Test (POST) runs when you turn on the system power switch and one of the following conditions
apply:
• Press the (enter) key in the first 10 seconds

5-4
On-Board Diagnostics

You have access to a number to tests called On-board diagnostics. To invoke the test, you must enter the Forth
Toolkit.

Caution
In order to run On-board diagnostics, you must halt the system in an orderly manner. When the operating system or
any other stand-alone program has already booted, use the front panel soft shutdown menu to stop the printer.
Abruptly aborting program execution may cause damage to data files.

To run On-board diagnostics:

[1] Save all your work and quit all applications.
[2] As root, halt the system by entering /usr/sbin/halt. You are presented with the ok prompt. The ok prompt is the
default prompt.
[3] Enter help diag to get a listing of tests comprising on-board diagnostics.

Halting the System and Displaying On-Board Diagnostics

hostname# /usr/sbin/halt
ok help diag
Category: Diag (diagnostics routines)
test device-specifier ( -- ) run self test method for specified device
Examples:
test /iommu/sbus/ledma@F,400010/le - test net
test net -test net (device-specifier is an alias)
test scsi -test scsi (device-specifier is an alias)
test floppy -test floppy disk drive
watch-clock (--) -show ticks of real-time clock
watch-net (--) -monitor broadcast packets using auto-selected interface
watch-aui (--) -monitor broadcast packets using AUI interface
watch-tpe (--) -monitor broadcast packets using TPE inferface
watch-net-all (--) -monitor broadcast packets on all net interfaces
probe-scsi (--) -show attached SCSI devices
probe-scsi-all (--) -show attached SCSI devices for all host adapters
test-all (--) -execute test for all devices with selftest method
test-memory (--) -test all memory if diag-switch? is true, otherwise test
memory specified by selftest-#megs

These on-board tests allow you to test the network controller, the diskette drive system, memory, and the system
clock.

Test<alian name>,Test<device path>

The test command, combined with a device alias or device pathname, will execute the selftest program. If a device
has no selftest program, this message will be displayed: No selftest method for <device name>. To run the selftest
program for a device, type the test command followed by the device alias or device pathname. For example:

ok test floppy
Testing floppy disk system. A formatted disk should be in the drive
Test succeeded

5-5
The following tests are supported in the SPARcengine EC system.

Type of Tests Description

test screen Tests the system video graphics hardware and monitor. The diag-switch?
NVRAM parameter must be set true for the test to run.
test floppy Tests the floppy drive ability to respond to commands. Requires a
formatted diskette to be inserted into the drive.
test scsi Tests the SCSI interface logic on the SPARCclassic Engine. The diag-
switch? NVRAM parameter must be set true for the test to run
test net Performs an internal and external loopback test on the auto-selected
system Ethernet interface. A cable must be attached to the system and to
an Ethernet tap or hub or the external loopback test will fail
test disk Tests internal or external SCSI disks which have a self diagnostic program
test disk0 contained in the drive controller. The drive must be spinning before this
test disk1 test is executed or the test will fail. Enter a boot <disk alias> command to
test disk2 cause the drive to spin up (disk and disk0 = SCSI target 3, disk1 = SCSI
test disk3 target 1, disk3 = SCSI target3, disk3 = SCSI target0).
test cdrom Performs a selftest diagnostic on the CDROM drive. The CDROM must
be set to SCSI target 6 and have a CD inserted or the test will fail.
test tape Tests the SCSI tape drive by executing the drive selftest program (tape
test tape0 and tape0 = SCSI target4, tape 1 = SCSI target5).
test tape1
test ttya This test outputs an alphanumeric test pattern on the system serial port
(ttya = serial port). you must attach a terminal to the tested port to observe
the output.

Test-All
The test-all command tests all devices in the system which have a selftest program. Tests are executed in order using
the device tree (viewed with the show-devs command) as reference. Disks, tapes, and CDROMs are not tested by
test-all.

Watch-clock
This test reads a register in the NVRAM/TOD (Non-Volatile RAM/Time of Day) chip on the SPARCengine Classic
II and displays the result as a seconds counter. The counter should count from 0 to 59 repeatedly until you interrupt
it by pressing any key on the keyboard.

The following screen gives you an example of a watch-clock test.

ok watch-clock
Watching the ‘seconds’ register of the real time clock chip
It should be ‘ticking’ once a second
Type any key to stop
41

Watch-net, Watch-aui, Watch-tpe and Watch-net-all

These tests monitor broadcast Ethernet packets on the Ethernet cable(s) connected to the system. Good packets
received by the system are indicated by a period (.) displayed on the screen. Errors are indicated with an X and the
error description. See the following example:

5-6
 ok watch-net
Internal loopback test -- succeeded
External loopback test -- Auto-selecting Ethernet cable I/F
Trying AUI
Received packet on AUI
Select cable - AUI
succeeded
Looking for Ethernet packets
‘.’ is a good packet.”X” is a bad packet
Type any key to stop
..................................................................................
..................................................................................
............................Framing error CRC error X.............................

Probe-SCSI, Probe-scsi-all
The probe-scsi test sends an inquiry command to internal and external SCSI devices connected to the SPARCengine
Classic-II on-board SCSI interface. If a SCSI deice is connected and powered up, the target address, unit number,
device type, and manufacturers name should be displayed. For example:

ok probe-scsi
Target 3
Unit 0 Disk SEAGATE ST1480 SUN04245828 Copyright (c) 1991 Seagate All rights reserved

The probe-scsi-all test sends an inquiry command to all SCSI devices on all the SCSI host adapters installed in the
system. The first identifier listed in the display is the SCSI host adapter address in the system devices tree, followed
by the SCSI device identification data. For example:

ok probe-scsi-all
/iommu@f,e0000000/sbus@f,e0001000/dma@1,81000/esp@1,80000
Target 2
Unit 0 Disk SEAGATE ST41600N SUN1.3G00286965 Copyright (c)1991 Seagate all rights
reserved

/iommu@f,e0000000/sbus@f,e0001000/espdma@f,400000esp@f,800000
Target 3
Unit 0 Disk SEAGATE ST1480 SUN04245828 Copyright (c)1991 Seagate all rights
reserved

Test-memory
All of the system main memory will be tested if the system diag-switch? parameter is true. If the diag-switch?
parameter is false, this test uses the selftest-#megs parameter in NVRAM to determine how much memory to test.
The default for the selftest-#megs parameter is 1, so only 1MB of memory is tested.

To change the amount of memory tested using the selftest-#megs parameter, type this command:

ok setenv selftest-#megs 16

5-7
This sets the desired memory size to 16 MB. Any whole number may be used as long as it does not exceed the actual
size of memory (in MB) installed in the system. When the test-memory diagnostic is running, the number of MD
being tested is displayed and counted down to zero during the test.

5-8
{Adjust/Replace}{Production}{KodakServiceSup ort}Replacing or upgrading sparc memory
[1] The purpose of this document is to instruct field engineers the recommended method for replacing or upgrading
the RAM in Codonics printers. This should only be done after consulting Codonics Technical Support. The
following procedure should be done with respect to common ESD procedures. This document does not apply
to Codonics EP series printers.
[2] The following tools will be required: Phillips head screwdriver, requirements for sparc classic II memory: 72-
pin, parity (x33 orx36), 60ns FPM (fast-page mode), must be installed in parts. There are 3 banks of 2 SIMMs
each 4, 16 and 32 MB SIMMs acceptable.
[3] To access the sparc board the rear cover must be removed. Remove the top three black screws on the rear cover
panel and the 2 crews next to the black knows.

[4] Pull the rear panel open about 6-8 inches to access the sparc board.
[5] From the perspective behind the printer you should see the sparc memory configured as sown below.

5-9
 [6] Each SIMM slot will be numbered 1,2 or 3. Be sure that each pair of numbers has a SIMM installed starting
from slot #1 then 2 then 3. All 6 slots need not be filled however the number slots must match each other. The
picture above shows a sparc board with slots 1 and 2 filled in pairs correctly. This configuration shows a total
of 4 MB SIMMs for a total of 16 MB. Always use the same memory SIMM in the slots.
[7] The minimum memory necessary for proper operation is 16 MB (4*4 MB). The maximum configuration for
memory is 96 MB (6*16 MB).
[8] The SIMMs may be removed by gently pushing outwards on the metal tabs on each side of the SIMM holder
with fingers and gently pushing the SIMM away from you as you face the back of the printer. The SIMM will
go forward about 45 degrees and then pull out.
[9] To install a SIMM locate the notch on the memory SIMM. The notch can be seen on the image below:

[10] Align this notch with the right side of the memory slot and gently install at a 45 degree angle and pull slowly
towards you. The SIMM should make a click sound as it locks into place.
[11] Continue placing SIMMs to achieve the desired configuration, making sure the SIMMs are identical and
matched in pairs.
[12] Reattach any cabling you may have removed and make sure no foreign objects were introduced to the printer
before you close the back.

5-10
[13] Power on the printer. The printer should come to the ready state. Failure to do so most likely means the memory
is either defective or installed incorrectly. Contact Codonics Technical Support for further information.

5-11
Replacement of Sparc Board

Purpose: Replacement of sparc board

Special Tools: ESD groundstrap and a Phillips head screw driver
Postrequisites: Make test prints to check for correct operation.

Procedures

Removal of the Sparc Board

[1] Remove the 5 screws from the rear of the printer that hold the electronic tray assembly in place.

[2] Pull on the 2 black knobs to open the electronic tray assembly. CAUTION: do not open the electronic tray
assembly to quickly, as cables are attached. Only open the electronic tray assembly approximately 5 inches at
this time. (See figure above) be sure to observe ESD precautions before pulling out the electronic tray
assembly.
[3] On NP-1660 models disconnect the ribbon cable at the P4 connector on the SAB.

5-12
[4] On both the NP-1600 and NP-1660 models disconnect the ribbon cable at the P13 connector on the engine
controller board.
[5] Pull the electronic tray assembly out further to expose the entire sparc board.

[6] Disconnect the 12 pin power connector at J1401 on the sparc board.

5-13
[7] Disconnect the 2 ribbon cables from the floppy and hard drive at J1302 and J1402 on the sparc board.

[8] Using a Phillips head screwdriver remove the sparc board locking screw.

5-14
 [9] With some force push the sparc away from the rear of the unit until it is disconnected from the IOCB.

[10] Lift the sparc board out of the printer and place it on an anti-static surface.

Installation of the sparc board

[1] Place the sparc board into the printer so that it’s edges are in between the vertical bivars. (There are 4 sets of
bivars in each corner of the sparc board).

5-15
[2] Once proper sparc board and bivar orientation is complete, push the sparc board with some force into the brown
IOCB connectors P9 and P12. You will hear a click when the sparc is fully in the IOCB connectors.

[3] Using a Phillips head screw drive reinstall the sparc board locking screw.

5-16
 [4] Reconnect the 2 ribbon cables from the hard drive and the floppy drive at J1302 and J1402 on the sparc board.
Note: these ribbon cables are not interchangeable.

[5] Reconnect the 12 pin power connector at J1401 on the sparc board (see figure 4).
[6] Push the electronic tray assembly into the printer until you have an opening of approximately 5 inches.
[7] On the NP-1600 and NP-1660 models reconnect the ribbon cable from the IOCB to the engine controller board
at connector P13 on the engine controller board.

[8] On the NP-1660 models reconnect the ribbon cable from the IOCB to the SAB at connector P4 on the SAB.
(See figure above).
[9] Without pinching any wires push the electronics tray assembly into the printer. Reinstall the 5 6x32 pan head
Phillips screws into the mounting holes.
[10] Run several test images to verify the replacement sparc board is operational.

5-17
Replacement of IOCB Board

Purpose: Replacement of IOCB board

Special Tools: ESD groundstrap and a Phillips head screw driver
Postrequisites: Make test prints to check for correct operation.

Procedures

Removal of the IOCB Board

[1] Remove the 5 screws from the rear of the printer that hold the electronic tray assembly in place.

[2] Pull on the 2 black knobs to open the electronic tray assembly. CAUTION: do not open the electronic tray
assembly to quickly, as cables are attached. Only open the electronic tray assembly approximately 5 inches at
this time. (See figure above) be sure to observe ESD precautions before pulling out the electronic tray
assembly.
[3] On NP-1660 models remove the ribbon cable at P4 connector on the SAB and P15 on the IOCB.

5-18
[4] On both the NP-1600 and NP-1660 models remove the ribbon cable at the P13 connector on the engine
controller board and P3 on the IOCB. (See figure above).
[5] Pull the electronic tray assembly out further to expose the entire sparc board.

[6] Disconnect the 12 pin power connector at J1401 on the sparc board.

5-19
[7] Disconnect the 2 ribbon cables from the floppy and hard drive at J1302 and J1402 on the sparc board.

[8] Using a Phillips head screwdriver remove the sparc board locking screw.

[9] With some force push the sparc away from the rear of the unit until it is disconnected from the IOCB.

5-20
[10] Lift the sparc board out of the printer and place it on an anti-static surface.
[11] Remove the nine 6x32 pan head screws from the outside of the electronic tray assembly that holds the IOCB in
place.

[12] Lift the IOCB out of the printer.

5-21
Installation of the IOCB board
[1] Install the IOCB into the printer and reinstall the nine 6x32 screws into the mounting holes.

[2] Place the sparc board into the printer so that it’s edges are in between the vertical bivars. (There is a bivar in
each corner of the sparc board).

5-22
[3] Once proper sparc board and bivar orientation is complete, push the sparc board with some force into the brown
IOCB connectors P9 and P12. You will hear a click when the sparc is fully in the IOCB connectors.

[4] Using a Phillips head screw drive reinstall the sparc board locking screw.

[5] Reconnect the 2 ribbon cables from the hard drive and the floppy drive at J1302 and J1402 on the sparc board.
Note: these ribbon cables are not interchangeable.

5-23
[6] Reconnect the 12 pin power connector at J1401 on the sparc board.

[7] Push the electronic tray assembly into the printer until you have an opening of approximately 5 inches.
[8] On the NP-1600 and NP-1660 models reconnect the ribbon cable from the IOCB to the engine controller board
at connector P13 on the engine controller board and P3 on the IOCB.

5-24
 [9] On the NP-1660 models reconnect the ribbon cable from the IOCB to the SAB at connector P4 on the SAB and
P15 on the IOCB. (See figure above).
[10] Without pinching any wires push the electronics tray assembly into the printer. Reinstall the 5 6x32 pan head
Phillips screws into the mounting holes.

[11] Run several test images to verify the replacement IOCB board is operational.

5-25
Replacement of Hard Drive
Purpose: Replacement of hard drive
Special Tools: ESD groundstrap and a Phillips head screw driver
Postrequisites: Make test prints to check for correct operation.

Procedures

Removal of the Hard Drive

[1] Remove the 5 screws from the rear of the printer that hold the electronic tray assembly in place.

[2] Pull on the 2 black knobs to open the electronic tray assembly. CAUTION: do not open the electronic tray
assembly to quickly, as cables are attached. Only open the electronic tray assembly approximately 5 inches at
this time. (See figure above) be sure to observe ESD precautions before pulling out the electronic tray
assembly.
[3] On NP-1660 models remove the ribbon cable at P4 connector on the SAB and P15 on the IOCB.

5-26
[4] On both the NP-1600 and NP-1660 models remove the ribbon cable at the P13 connector on the engine
controller board and P3 on the IOCB. (See figure above).
[5] Pull the electronic tray assembly out further to expose the entire sparc board.

[6] Disconnect the 2 ribbon cables from the floppy and hard drive at J1302 and J1402 on the sparc board.

[7] Disconnect the power connectors and ribbon cables at the floppy drive and the hard drive.

5-27
5-28
[8] Using a Philips head screw driver remove the 3 Philips head screws that mount the hard drive floppy drive
assembly.

5-29
 [9] Lift the floppy drive and hard drive assembly out of the printer and place it on an anti-static surface.

[10] Remove the 4 Philips head screws that mount the hard drive onto the sheetmetal bracket.

[11] Remove the hard drive from the sheetmetal.

5-30
Installation of the Hard Drive
[1] Install the hard drive onto the sheetmetal and reinstall the 4 Philips mounting screws.

[2] Place the hard drive floppy drive assembly into the printer and reinstall the 3 Philips mounting screws.

5-31
[3] Reinstall the 2 ribbon cables from the sparc board to the hard drive and the floppy drive. Note: these ribbon
cables are not interchangeable.

5-32
5-33
[4] Push the electronic tray assembly into the printer until you have an opening of approximately 5 inches.
[5] On the NP-1600 and NP-1660 models reinstall the ribbon cable from the IOCB to the engine controller board
at connector P13 on the engine controller board and P3 on the IOCB.

[6] On the NP-1600 and NP-1660 models reconnect the ribbon cable from the IOCB to the engine controller board
at connector P13 on the engine controller board and P3 on the IOCB.

5-34
 [7] On the NP-1660 models reconnect the ribbon cable from the IOCB to the SAB at connector P4 on the SAB and
P15 on the IOCB. (See figure above).
[8] Load the correct operating software if needed.
[9] Without pinching any wires push the electronics tray assembly into the printer. Reinstall the 5 6x32 pan head
Phillips screws into the mounting holes.

[10] Run several test images to verify the replacement hard drive is operational.

5-35
Replacement of Floppy Drive

Purpose: Replacement of floppy drive

Special Tools: Philips screwdriver, T15 small screw, T15 screwdriver, ESD wrist strap
Postrequisites: Make test prints to check for correct operation.

Procedures

Removal of the Hard Drive

[1] Remove the 5 screws from the rear of the printer that hold the electronic tray assembly in place.

[2] Pull on the 2 black knobs to open the electronic tray assembly. CAUTION: do not open the electronic tray
assembly to quickly, as cables are attached. Only open the electronic tray assembly approximately 5 inches at
this time. (See figure above) be sure to observe ESD precautions before pulling out the electronic tray
assembly.
[3] Disconnect the ribbon cables (2 for 1660, 1 for 1600) which extend from the IOCB board mounted on the back
panel of the tray to the print engine circuit board. Disconnect the cables at the print engine, not the IOCB board.
The lower cable should be unplugged at P13 on the controller board. The top cable (1660 only) should be
unplugged at P4 on the SAB. The picture below shows the NP-1660 ribbon cables, the NP-1600 will only have
the bottom ribbon cable.

5-36
[4] Remove the floppy drive and hard drive assembly. Disconnect the ribbon and power cables from the floppy
drive and SCSI hard drive. Completely remove the floppy drive able from the floppy drive and J1302 on the
sparc board. (See figures below).

5-37
[5] Remove the following screws to remove the floppy and hard drive bracket from the printer.

[6] Locate the new style bracket as shown below. Notice the screw holes for the floppy are grooved completely out.
This is necessary to install the upgrade drive.

5-38
[7] Install the hard drive on the bottom side of this bracket as it was removed from the previous bracket. Install the
floppy drive screws onto the floppy and place into the bracket as shown below but do not tighten them.

[8] Install the assembly into the printer and tighten down the 3 screws as shown below. Use care not to pinch the
AC power cable going to the power supply and the AC power switch.

5-39
[9] While pushing on the floppy gently as shown, tighten the 3 screws that hold the floppy to the bracket.

5-40
[10] Locate the new style floppy drive cable as shown below.

[11] Connect the floppy cable to the sparc board J1302.

[12] Connect the floppy drive cable to the new floppy drive and connect the power cable to the floppy drive as shown
below.

[13] Attach the nylon clip to the cabling to avoid cabling interference with components.

5-41
[14] Locate the following screw to determine if it needs to be replaced. If the screw can be clearly seen from this
view, replace it. The correct screw will be only slightly visible from this angle (<2mm exposed).

[15] If the screw must be replaced it is accessible by using a long Torx (T-15) or Philips head screwdriver and
replacing this screw. It maybe necessary to remove the lid cover.

[16] To ensure there is sufficient clearance for the floppy drive, insert and remove a floppy diskette from the drive.
There should be no interference from the frame or any other component. If there is a problem with interference,
check the installation again.
[17] Close the printer electronics tray slowly and watch for any pinched wires or any difficulty in closing the
electronics tray. Do not force the tray closed. It may be necessary to en the top cover to ease in the closing of
the electronics tray.
[18] Reinstall the 5 screws holding the electronics tray to the printer.
[19] THe printer may now be returned to its normal operating condition.
[20] TEST THAT THE INSTALLATION HAS BEEN SUCCESSFUL:
Insert the test disk labeled Test Print Update into the floppy drive

5-42
 Verify that the front panel displays READY
Press the SETUP key until the display shows SETUP:ADMIN or SETUP:NETWORK (this is dependent on the
software revision installed in the printer)
Press the Up-arrow key until the display shows SETUP:UPDATE
Press the SETUP button until the display shows UPDATE:YES
Press the SETUP key to begin reading the disk
[21] The printer will then print the test print in about 2.5 minutes. In the event that there are difficulties in obtaining
the test print, verify that the installation was performed according to the procedure, that connections are
properly made and tight, and then re-boot the printer and try the test again. If difficulties still exist, contact
Codonics Technical Support.

5-43
 {Adjust/Replace}{Production}{KodakServiceSup ort}

Troubleshooting
for the Codonics NP/EP 1600 Series Imagers

Important
Use qualified personnel to service this equipment.
 This equipment includes parts and assemblies sensitive to damage from electrostatic
discharge. Use caution to prevent damage during all service procedures.

Table of Contents
Description Document Number
Page

Setting Up Serial Connection to The Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Front Panel of Printer Stuck in Wait . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Front Panel Goes to READY Only & Opening & Closing Lid . . . . . . . . . . . . . . . . . . 6-5
Accessing Front Panel Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Making An Engine Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Part Replaced/Sensor to Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Resetting Flash Chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Service Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Part Number 907-066-001.01

Problem: Setting up serial connection to the printer

Solution: You will need

Laptop or computer with laplink (null modem) cable and a terminal program
or
Dumb terminal and null modum serial cable

Microsoft Hyperterminal Setup

[1] Click Start --> Programs --> Accessories --> Hyperterminal.
[2] Choose a connection icon and name.
[3] In the Connect To dialog box, select COM1. The other boxes should be grayed out. Click OK.
[4] The following screen lists your connection options. The correct options are:
• bits per second: 9600
• data bits: 8
• parity: none
• stop bits: 1
• flow control: hardware
[5] Click ok.
[6] Press return until a login prompt appears, and log in as root.
[7] Save a transcript of the session to file by clicking Transfer --> Capture Text.

6-3
Problem: Front panel of printer stuck in wait.

Solution: There are several possible causes. If you can telnet into the printer or if you're
connected over a serial port please follow the instructions below to reset the Forth code.

From Telnet or Serial Session

[1] Log in as root.
[2] Type cd /usr/local/forth
[3] There is a file in this directory called .np1600. To be sure that you are in the correct directory, please type:
ls -Al and look for a file called .np1600.
[4] Then type
mv .np1600 np1600 (the dot is very important)
[5] Type
sync (enter)
sync (enter)
halt (enter
[6] Switch the power off. Wait 10 seconds and switch the power on. Watch the messages on the serial connection.
hme0 (SPARC II) or le0 (SPARC I) refer to the network board. fsck and block counts refer to the hard drive. If
the session shows many lines of fsck errors, reinstall software. If the errors recur, replace the hard drive.
References to "Loopback Test Failed" either external or internal may refer to the network card, the IOCB, or
the processor board. Note that the external loopback test will fail initially, but should pass at a later time during
bootup. "Cannot open device target 3" indicates a problem with the hard drive: check the ribbon cable first.
SCSI errors to target 5 can be either the IOCB or PECB. To determine which, try running an engine test print.

6-4
Problem: Front panel goes to READY only after opening and closing lid, or removing and
and reinserting paper tray. The front panel is nonresponsive and the printer does not
print.

Solution: The printer is not really READY. Follow the proceeding instruction for
troubleshooting printer stuck in WAIT.

6-5
Problem: Accessing front panel diagnostics.

Solution: First switch the printer into engine mode, then perform the proper key
sequence.

To enter engine mode:

[1] Shut the printer down. Use the soft shutdown feature if possible.
[2] Open the back of the printer. Unscrew the 3 screws across the top of the printer, and the 2 screws just to the
outside of the black thumb pulls. Grasp the thumb pulls, and slide the processor tray back gently 6 inches.
[3] Locate the toggle switch on the bottom right of the print engine controller board. If you have trouble finding it,
reinsert the processor tray and locate the switch through the hole in the sheetmetal on the right.
[4] Flip the toggle from Ext to Eng mode. Disconnect power to the sparc and/or IOCB.
[5] Repower the printer. The front panel should come up to Engine Ready.
[6] To access diagnostics, press and hold the Online key while pressing and releasing the Status key twice and the
Cancel key twice. If the front panel reads "Key Invalid Now", repeat the key sequence.
[7] If the printer still returns KEY INVALID NOW, open the lid and try the sequence a couple more times.

6-6
Problem: Making an engine test print.

Solution: Engine test prints are useful because they isolate the printing mechanism from
the hard drive, processor board and input/output (IOCB) board. To initiate an engine test
print, switch the printer into Engine mode but do not enter diagnostics. Press and release
the Status key once.

6-7
Part Replaced/Sensor to Adjust

Part Replaced Sensor to Adjust

Controller board All sensors except printhead voltage
Roller assembly lead edge, donor sensor, motor sensor
Printhead NP-1600 & EP-1650 series Printhead voltage
Printhead NP-1660 series Printhead voltage and calibration
Donor frame assembly Barcode and physical alignment
Fan bracket & Mod 29 Donor sensors
Power supply Printhead voltage
8x10 Tray Sensor (1660 Models only) 8x10 Tray Sensor
IOCB (NP1660 Models) 8x10 Tray Sensor

6-8
Resetting Flash Chip

Resetting flash chip after reload or IOCB replacement. When replacing an IOCB or reloading software on both the
NP-1600 and NP-1660, it is recommended that the flash chip on the IOCB be rest.

Follow this procedure to reset the flash chip.

[1] Connect an ASCII terminal to the sparc port on the rear of the printer (see
[2] Once the NP-1600 or NP-1660 console login appears on the screen type in root then press return.
[3] Once you see the pound sign (#), type in the following commands:
#cd usr/local/forth (enter)
#mv .np1600 np1600 (enter)
#halt (enter)
[4] Once the OK prompt appears on the screen, turn the power off, wait 10 seconds, then power the printer back
up. It will take about 3 or 4 minutes to boot up completely. This 3-4 minutes is on this power up only. Normally
it will take 2-3 minutes to boot up completely.
[5] Once the NP-1600 or NP-1660 console login appears on the screen and READY is on the front panel, the printer
is completely boot up and ready to receive print jobs.

6-9
Service Troubleshooting

Printer Type Process Problem Found Solution

NP1600-1660 Upon boot up START UP FAIL/CYCLE IOCB
POWER message
NP1600-1660 Upon boot up Dram failure IOCB memory, IOCB
NP1600-1660 Upon boot up Init error Flash & prom, IOCB
NP1600-1660 Upon boot up Stuck in: Wait/ Sparc memory
NP1600-1660 Upon boot up NFS mount failed IOCB
NP1600-1660 Upon boot up Failed boot cycle IOCB
NP1600-1660 Loading software Stuck in remove disk SEEQ, Sparc, hard drive
NP1600-1660 Loading software Can’t read disk label Floppy, hard drive
NP1600-1660 Loading software Disk failed Hard drive
NP1600-1660 Upon boot up Newfsing 6 Sparc board
NP1600-1660 Loading software Level 15 interrupt Sparc memory, sparc
NP1600-1660 Loading software LCD not unique IOCB
NP1600-1660 Upon boot up Please wait, initializing Flash & Prom, IOCB
NP1600-1660 Upon boot up Scsi not responding or present Sparc, IOCB, cables
NP1600-1660 Upon boot up Timeout waiting for ARP/RARP Reset NVRAM
packet
NP1600-1660 Loading software Stuck in loading: 0mb Sparc memory, hard drive
NP1600-1660 Loading software Target 3 lun 0 not present Jumpers on hard drive, hard drive
NP1600-1660 Loading software Hung in: V098743502 Sparc memory
NP1600-1660 Upon boot up Does not communicate IOCB, sparc
NP1600-1660 Upon boot up No ribbon Ribbon, sensors, head seating
NP1600-1660 Upon boot up No ribbon Sab, controller, IOCB, roller assembly
NP1600-1660 Loading software Stuck in downloading Flash, sparc memory
NP1600-1660 Upon boot up Scrolling: FFFF<FFFF 3.0 chip, sparc, SEEQ
NP1600-1660 Upon boot up Sync fault error 3.0 chip, sparc
NP1600-1660 Print quality Parastetic resistance Power supply, chip set
NP1600-1660 At ready state Mod 20 goes on & off Reseat printhead
NP1600-1660 At ready state Goes to processing back to ready Reload software
NP1600-1660 Upon boot up stuck in initializing Sparc memory, sparc, flash & prom
NP1600-1660 Print quality Corrupt images Sparc or IOCB memory, hard drive
NP1600-1660 Print quality Corrupt images Sparc, IOCB
NP1600-1660 At ready state Takes print to exit tray w/add paper Lead edge, roller assembly
error
NP1600-1660 At ready state Reads KL-14 ribbon w/normal Barcode
color installed
NP1600-1660 Upon boot up Watch dog reset after hard drive Hard drive, sparc
test
NP1600-1660 At ready state Can’t run parallel Check settings, IOCB
NP1600-1660 Upon boot up Failed UTMPX entry Reload software

6-10
Printer Type Process Problem Found Solution
NP1600-1660 At ready state Can’t FTP or telnet Reload software
NP1600-1660 Upon boot up Data access error Sparc memory, hard drive
NP1600-1660 At ready state Stuck in processing Sparc memory, sparc
NP1600-1660 Print quality Dark prints Receiver sensor
NP1600-1660 Upon boot up Media mismatch Sab board, IOCB
NP1600-1660 At ready state Next plane error while printing IOCB
NP1600-1660 Upon boot up Error: warning cannot merge IOCB
HWCONE DEV INFO
NP1600-1660 Upon boot up Hangs in rebooting Sparc memory, sparc, hard drive
NP1600-1660 Upon boot up Illegal instruction NVRAM, sparc, sparc memory
NP1600-1660 Upon boot up Error: RETRYING STATUS 2 Hard drive, hard drive cable
NP1600-1660 At ready state PHM STATE=0000, flashes in fail Controller board
history
NP1600-1660 Upon boot up Insert tray/replace tray Tray sensors
NP1600-1660 Print quality Red tint on prints Load gen 1.5
NP1600-1660 Print quality Green tint on prints Change ribbon
NP1600-1660 Upon boot up SCSI device 5.0 not responding Sparc, IOCB
NP1600-1660 Upon boot up Get mode failed Sparc
NP1600-1660 At ready state Not reading correct memory Sparc
NP1600-1660 Upon boot up Short read error Hard drive
NP1600-1660 Upon boot up SCSI transport error IOCB, sparc
EP-1650 At ready state Connects but does not receive Reset
NP1600-1660 Print quality Ribbon fusing to head Head seating, sensors, head lift gap
NP1600-1660 Print quality Ribbon fusing to head Head voltage
NP1600-1660 Upon boot up Ribbon spew U19-U20, head load gap, sensors, tray
slider
NP1600-1660 Upon boot up Ribbon spew Head shaft, motor bracket, controller
board, memory
NP1600-1660 Print quality Stretch Paper tray, ribbon, load gap, donor
adjust
NP1600-1660 Print quality Stretch Printhead
NP1600-1660 At ready state Paper jamming Tray, lead edge, picker, load gap
NP1600-1660 Print quality Prints to dark on DV paper Receiver sensor
NP1600-1660 Loading software NOTICE: realloccg//file system is Floppy drive, sparc
full
NP1600-1660 Loading software Recovery 4 (2.3.2-03) Hard drive
NP1600-1660 Loading software Illegal inst., DMA hang condition Hard drive
is sparc diag test
NP1600-1660 Loading software Bad check sum file Hard drive
NP1600-1660 Upon boot up Hung in rebooting, terminal reads, Sparc memory
can’t invoke/error 5
NP1600-1660 Upon boot up No keyboard detected NVRAM

6-11
 Hyperterminal Logs
for the Codonics NP/EP 1600
Series Imagers

7-1
Table of Contents
Description Page

Bad Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Known Bad Memory 2 (sparc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Floppy Data Removed (forth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Floppy Data Cable Removed (sparc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Hard Drive Data Cable Removed (sparc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Hard Drive Data Cable Removed (forth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Init Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
No IOCB Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Memory Module Removed (sparc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Normal Boot-Up Sequence (forth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Normal Boot-Up Sequence (sparc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
P13 Disconnected (sparc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
P13 Disconnected (forth). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
P5 Disconnected (sparc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
P5 Disconnected (forth). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
P9 Disconnected (forth). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
P9 Diconnected (sparc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Installing Software (2.2.0) on Known Bad Hard Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Stuck in Initializing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
Bad Sparc.. SCSI Test Fatal Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50

Part Number 907-067-001.01

7-2
Bad Memory

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
Disk - OK
Testing Memory -

Memory - OK
Hit any key to interrupt boot sequence
Checking for bootable floppy...
Can't read disk label.
Can't open Sun disk label package
Floppy not bootable.

Testing Memory -

Initializing Memory |/-\|/-\

Boot device: /iommu/sbus/SUNW,fas@2,8800000/sd@3,0 File and args:

|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\(Can't deduct msgbuf from physical memory list) Program terminated
Type help for more information
ok

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 808662ac

7-3
 PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
Disk - OK
Testing Memory -

Memory - OK
Hit any key to interrupt boot sequence
Checking for bootable floppy...
Can't read disk label.
Can't open Sun disk label package
Floppy not bootable.

Testing Memory -

Initializing Memory |/-\|/-\

Boot device: /iommu/sbus/SUNW,fas@2,8800000/sd@3,0 File and args:

|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\(Can't deduct msgbuf from physical memory list) Program terminated
Type help for more information
ok diag mem
diag ?
ok help diag
Category: Diag (diagnostic routines)
test device-specifier ( -- ) run selftest method for specified device
Examples:
test /memory - test memory
test /iommu/sbus/ledma@4,8400010/le - test net
test floppy - test floppy disk drive
test net - test net (device-specifier is an alias)
test scsi - test scsi (device-specifier is an alias)
watch-clock ( -- ) show ticks of real-time clock
watch-net ( -- ) monitor broadcast packets using auto-selected interface
watch-aui ( -- ) monitor broadcast packets using AUI interface
watch-tpe ( -- ) monitor broadcast packets using TPE interface
watch-net-all ( -- ) monitor broadcast packets on all net interfaces
probe-scsi ( -- ) show attached SCSI devices
7-4
probe-scsi-all ( -- ) show attached SCSI devices for all host adapters
test-all ( -- ) execute test for all devices with selftest method
test-memory ( -- ) test all memory if diag-switch? is true, otherwise test memory specified by selftest-#megs
ok test /memory
Testing Memory \

Testing Memory /-\|/-

ok test-memory
Testing Memory \

Testing Memory /-\|/-

ok test all
Device all not found.
ok test-all
Testing /memory@0,2000000
Testing Memory \

Testing Memory /-\|/-

Testing /obio/SUNW,fdtwo@0,400000
Testing floppy disk system. A formatted disk should be in the drive.
No diskette, or incorrect format.
Selftest failed. Return code = -1
Testing /obio/zs@0,0
No Keyboard
Selftest failed. Return code = -1
Testing /obio/zs@0,100000
!"#$%&'()*+,-./
0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmnopqrstuvwxyz{|}~Testing /
iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000
CE DMA fill from address ffebb000 for 80 bytes ERROR: DMA Hang condition detected
ERROR: DMA Hang condition detected
ERROR: DMA failed
Address ffeba001
Expected 1
Observed 0
Selftest failed. Return code = -1
Testing /iommu@0,10000000/sbus@0,10001000/SUNW,hme@2,8c00000
Internal loopback test -- succeeded.
Transceiver check -- passed
ok

7-5
 HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
Disk - OK
Testing Memory -

Memory - OK
Hit any key to interrupt boot sequence
Checking for bootable floppy...
Can't read disk label.
Can't open Sun disk label package
Floppy not bootable.

Testing Memory -

Initializing Memory |/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\

Boot device: /iommu/sbus/SUNW,fas@2,8800000/sd@3,0 File and args: |/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\

SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
Copyright (c) 1983-1996, Sun Microsystems, Inc.
|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\configuring network interfaces: hme0.
Hostname: np1660
The system is coming up. Please wait.
file system is clean - log replay is not required
Restore from /save/config
starting routing daemon.
lpd started
starting rpc services: rpcbind keyserv kerbd done.
Setting default interface for multicast: add net 224.0.0.0: gateway np1600 syslog service starting.
May 15 11:29:12 np1660 unix: SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
May 15 11:29:12 np1660 unix: Copyright (c) 1983-1996, Sun Microsystems, Inc.
May 15 11:29:12 np1660 unix: vac: enabled
May 15 11:29:12 np1660 unix: cpu0: FMI,MB86904 (mid 0 impl 0x0 ver 0x4 clock 110 MHz)
May 15 11:29:12 np1660 unix: mem = 32768K (0x2000000)
May 15 11:29:12 np1660 unix: avail mem = 28499968
7-6
May 15 11:29:12 np1660 unix: Ethernet address = 8:0:20:86:62:ac
May 15 11:29:12 np1660 unix: root nexus = SUNW,SPARCclassic-II
May 15 11:29:12 np1660 unix: iommu0 at root: obio 0x10000000
May 15 11:29:12 np1660 unix: sbus0 at iommu0: obio 0x10001000
May 15 11:29:12 np1660 unix: fas0: rev 2.2 FEPS chip
May 15 11:29:12 np1660 unix: SUNW,fas0 at sbus0: SBus slot 2 0x8800000 and SBus slot 2 0x8810000 sparc ipl 4
May 15 11:29:12 np1660 unix: sd3 at SUNW,fas0: target 3 lun 0
May 15 11:29:12 np1660 unix: sd3 is /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0
May 15 11:29:12 np1660 unix: <QUANTUM-FIREBALLST2.1S-0F0C cyl 7066 alt 2 hd 3 sec 199>
May 15 11:29:12 np1660 unix: root on /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0:a
fstype ufs
May 15 11:29:12 np1660 unix: obio0 at root
May 15 11:29:12 np1660 unix: zs0 at obio0: obio 0x100000 sparc ipl 12
May 15 11:29:12 np1660 unix: zs0 is /obio/zs@0,100000
May 15 11:29:12 np1660 unix: zs1 at obio0: obio 0x0 sparc ipl 12
May 15 11:29:12 np1660 unix: zs1 is /obio/zs@0,0
May 15 11:29:12 np1660 unix: cpu 0 initialization complete - online
May 15 11:29:12 np1660 unix: SUNW,hme0: FEPS (Rev Id = 22) Found
May 15 11:29:13 np1660 unix: SUNW,hme0 at sbus0: SBus slot 2 0x8c00000 and SBus slot 2 0x8c02000 and SBus
slot 2 0x8c04000 and SBus slot 2 0x8c06000 and SBus slot 2 0x8c07000 sparc ipl 6
May 15 11:29:13 np1660 unix: SUNW,hme0 is /iommu@0,10000000/sbus@0,10001000/SUNW,hme@2,8c00000
May 15 11:29:13 np1660 unix: dump on /dev/dsk/c0t3d0s1 size 98492K
May 15 11:29:13 np1660 unix: SUNW,hme0: Using External Transceiver
May 15 11:29:13 np1660 unix: SUNW,hme0: Link Up

ppid started
rm: /data/tmp/www/pages is a directory
httpd started
snmpd started
scsid started

Network page received

Flushing routing table:
Options page received
Parallel page received
Image page received
Loading DAP schema ...
Loading DAP data ...
bstn0: Found Optical device at tgt1, lun0

bstn0: Vendor/Product ID = FUJITSU M2513A

Loading Print-SCP schema ...

7-7
Loading Print-SCP data ...
Configuring the AE data ...
Examining current state and environment
Generating AE configuration script for np16601 on np1660, ref 1 ...
Filling in standard template ...
No local customizations.
AE configuration script prepared
AE configuration complete
The system is ready.

np1660 console login: aarpd (Ethertalk) started

bstn0: Found Optical device at tgt1, lun0

bstn0: Vendor/Product ID = FUJITSU M2513A

sockbuf::read: Interrupted system call

class sockbuf: sockbuf::read
class sockbuf: sockbuf::read
class sockbuf: sockbuf::read
atis (Ethertalk) started
lwsrv (Ethertalk) started

np1660 console login:

7-8
Known Bad Memory 2 (SPARC)

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************
HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
Disk - OK
Memory - OK
Hit any key to interrupt boot sequence
Checking for bootable floppy...
Can't read disk label.
Can't open Sun disk label package
Floppy not bootable.

Boot device: /iommu/sbus/SUNW,fas@2,8800000/sd@3,0 File and args:

(Can't deduct msgbuf from physical memory list) Program terminated
Type help for more information
ok

******Additional possible errors messages but will not appear in *****

******Hyperterminal without user intervention *****

Type help for more information

ok diag mem
diag ?
ok help diag
Category: Diag (diagnostic routines)
test device-specifier ( -- ) run selftest method for specified device
Examples:
test /memory - test memory
test /iommu/sbus/ledma@4,8400010/le - test net
test floppy - test floppy disk drive

7-9
 test net - test net (device-specifier is an alias)
test scsi - test scsi (device-specifier is an alias)
watch-clock ( -- ) show ticks of real-time clock
watch-net ( -- ) monitor broadcast packets using auto-selected interface
watch-aui ( -- ) monitor broadcast packets using AUI interface
watch-tpe ( -- ) monitor broadcast packets using TPE interface
watch-net-all ( -- ) monitor broadcast packets on all net interfaces
probe-scsi ( -- ) show attached SCSI devices
probe-scsi-all ( -- ) show attached SCSI devices for all host adapters
test-all ( -- ) execute test for all devices with selftest method
test-memory ( -- ) test all memory if diag-switch? is true, otherwise
test memory specified by selftest-#megs
ok test /memory

ok test-memory

ok test all
Device all not found.
ok test-all
Testing /memory@0,2000000

Testing /obio/SUNW,fdtwo@0,400000
Testing floppy disk system. A formatted disk should be in the drive.
No diskette, or incorrect format.
Selftest failed. Return code = -1
Testing /obio/zs@0,0
No Keyboard
Selftest failed. Return code = -1
Testing /obio/zs@0,100000
!"#$%&'()*+,-./
0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmnopqrstuvwxyz{|}~Testing /
iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000
CE DMA fill from address ffebb000 for 80 bytes ERROR: DMA Hang condition detected
ERROR: DMA Hang condition detected
ERROR: DMA failed
Address ffeba001
Expected 1
Observed 0
Selftest failed. Return code = -1
Testing /iommu@0,10000000/sbus@0,10001000/SUNW,hme@2,8c00000
Internal loopback test -- succeeded.
Transceiver check -- passed
ok

7-10
Floppy Data Removed (Forth)
NP1600 v3.1.0.0
PDK103 loaded‹÷
SK200 loaded
8109 8010 10 10 10 10 108 0 0 0 0 0# 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0#
Loading NP1600 vocabulary 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

7-11
Floppy Data Cable Removed (SPARC)

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
Disk - OK
Testing Memory -

Memory - OK
Hit any key to interrupt boot sequence
Checking for bootable floppy...
Recalibrate failed. The floppy drive is either missing,
improperly connected, or defective.
Floppy not bootable.

** Booting (from hard drive) will continue as normal from this point. Console login should appear as normal **

7-12
Hard Drive Data Cable Removed (SPARC)

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
SCSI target 3 lun 0 is not present or not respondingDisk failedExtra scsi data. Fatal error.

7-13
Hard Drive Data Cable Removed (Forth)

NP1600 v3.1.0.0
PDK103 loaded‹÷
SK200 loaded
8109 8010 10 10 10 10 108 0 0 0 0 0# 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0#
Loading NP1600 vocabulary 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

7-14
INIT Error

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.0 (Classic-2)

SCSI device not present or not responding

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

Release 2.15 Version 113 created 97/09/09 13:47:52

PROM nvramrc+ version 2.1 (Classic-2)

Checking for bootable floppy...

Can't read disk label.
Can't open Sun disk label package
Floppy not bootable.

Booting from hard drive...

Boot device: /iommu/sbus/SUNW,fas@2,8800000/sd@3,0 File and args:
SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
Copyright (c) 1983-1996, Sun Microsystems, Inc.
WARNING: Cannot merge hwconf devinfo node SUNW,fas@2,8800000
WARNING: Cannot merge hwconf devinfo node SUNW,fas@2,8800000
configuring network interfaces:WARNING: Cannot merge hwconf devinfo node SUNW,hme@2,8c00000 hme0.
Hostname: np1660
The system is coming up. Please wait.
file system is clean - log replay is not required

7-15
Restore from /save/config
starting routing daemon.
lpd started
starting rpc services: rpcbind keyserv kerbd done.
Setting default interface for multicast: add net 224.0.0.0: gateway np1600
syslog service starting.
May 18 11:49:46 np1660 unix: SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
May 18 11:49:46 np1660 unix: Copyright (c) 1983-1996, Sun Microsystems, Inc.
May 18 11:49:46 np1660 unix: vac: enabled
May 18 11:49:46 np1660 unix: cpu0: FMI,MB86904 (mid 0 impl 0x0 ver 0x4 clock 110 MHz)
May 18 11:49:46 np1660 unix: mem = 32768K (0x2000000)
May 18 11:49:46 np1660 unix: avail mem = 28471296
May 18 11:49:46 np1660 unix: Ethernet address = 8:0:20:86:62:ac
May 18 11:49:46 np1660 unix: root nexus = SUNW,SPARCclassic-II
May 18 11:49:46 np1660 unix: iommu0 at root: obio 0x10000000
May 18 11:49:46 np1660 unix: sbus0 at iommu0: obio 0x10001000 May 18 11:49:46 np1660 unix: fas0: rev 2.2
FEPS chip
May 18 11:49:46 np1660 unix: SUNW,fas0 at sbus0: SBus slot 2 0x8800000 and SBus
slot 2 0x8810000 sparc ipl 4
May 18 11:49:46 np1660 unix: WARNING: Cannot merge hwconf devinfo node SUNW,fas@ 2,8800000
May 18 11:49:46 np1660 unix: sd3 at SUNW,fas0: target 3 lun 0
May 18 11:49:46 np1660 unix: sd3 is /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0
May 18 11:49:46 np1660 unix: <QUANTUM-FIREBALLST2.1S-0F0C cyl 7066 alt 2 hd 3 sec 199>
May 18 11:49:46 np1660 unix: WARNING: Cannot merge hwconf devinfo node SUNW,fas@2,8800000
May 18 11:49:46 np1660 unix: root on /iommu@0,10000000/sbus@0,10001000/SUNW,fas@
2,8800000/sd@3,0:a fstype ufs
May 18 11:49:46 np1660 unix: obio0 at root
May 18 11:49:46 np1660 unix: zs0 at obio0: obio 0x100000 sparc ipl 12
May 18 11:49:46 np1660 unix: zs0 is /obio/zs@0,100000
May 18 11:49:46 np1660 unix: zs1 at obio0: obio 0x0 sparc ipl 12
May 18 11:49:46 np1660 unix: zs1 is /obio/zs@0,0
May 18 11:49:46 np1660 unix: cpu 0 initialization complete - online
May 18 11:49:47 np1660 unix: SUNW,hme0: FEPS (Rev Id = 22) Found
May 18 11:49:47 np1660 unix: SUNW,hme0 at sbus0: SBus slot 2 0x8c00000 and SBus slot 2 0x8c02000 and SBus
slot 2 0x8c04000 and SBus slot 2 0x8c06000 and SBus slot 2 0x8c07000 sparc ipl 6
May 18 11:49:47 np1660 unix: SUNW,hme0 is /iommu@0,10000000/sbus@0,10001000/SUNW, hme@2,8c00000
May 18 11:49:47 np1660 unix: WARNING: Cannot merge hwconf devinfo node SUNW,hme@2,8c00000
May 18 11:49:47 np1660 unix: dump on /dev/dsk/c0t3d0s1 size 98492K
May 18 11:49:47 np1660 unix: SUNW,hme0: Using External Transceiver
May 18 11:49:47 np1660 unix: SUNW,hme0: Link Up
ppid started
WARNING: Cannot merge hwconf devinfo node SUNW,bpp@2,c800000
rm: /data/tmp/www/pages is a directory

7-16
httpd started
snmpd started
scsid started

May 18 11:49:54 np1660 scsid[631]: sdp open failed: No such device or address
Child term status 100
Loading DAP schema ...
Loading DAP data ...
May 18 11:49:59 np1660 scsid[639]: sdp open failed: No such device or address
Child term status 100
Loading Print-SCP schema ...
May 18 11:50:04 np1660 scsid[643]: sdp open failed: No such device or address
Child term status 100
Loading Print-SCP data ...
Configuring the AE data ...
Examining current state and environment
Generating AE configuration script for np16601 on np1660, ref 1 ...
Filling in standard template ...
No local customizations.
AE configuration script prepared
AE configuration complete
May 18 11:50:09 np1660 scsid[660]: sdp open failed: No such device or address
Child term status 100
aarpd (Ethertalk) started
May 18 11:50:14 np1660 scsid[665]: sdp open failed: No such device or address
Child term status 100
atis (Ethertalk) started
lwsrv (Ethertalk) started

May 18 11:50:19 np1660 scsid[668]: sdp open failed: No such device or address
Child term status 100
May 18 11:50:24 np1660 scsid[669]: sdp open failed: No such device or address
Child term status 100
May 18 11:50:29 np1660 scsid[670]: sdp open failed: No such device or address
Child term status 100
May 18 11:50:34 np1660 scsid[671]: sdp open failed: No such device or address
Child term status 100
May 18 11:50:39 np1660 scsid[672]: sdp open failed: No such device or address
Child term status 100

*********** These 2 lines of error messages will continue indefinately. ******

********** INIT ERROR displayed on front panel with Fault light ********
7-17
No IOCB RAM

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************
HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.4 (Classic I/II)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
Disk - OK
Testing Memory -

Memory - OK
Hit any key to interrupt boot sequence
Checking for bootable floppy...
Can't read disk label.
Can't open Sun disk label package
Floppy not bootable.

Testing Memory -

Initializing Memory |/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\

Boot device: /iommu/sbus/SUNW,fas@2,8800000/sd@3,0:a File and args:

|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-
SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
Copyright (c) 1983-1996, Sun Microsystems, Inc.
\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\configuring
network interfaces: hme0.
Hostname: np1660
Configuring the /devices directory
/usr/kernel/drv/bst symbol bioerror multiply defined
bst0: No response from target 2, lun 0

7-18
bstn0: No response from target 1, lun 0

Configuring the /dev directory

The system is coming up. Please wait.
file system is clean - log replay is not required
Restore from /save/config
starting routing daemon.
lpd started
starting rpc services: rpcbind keyserv done.
Setting default interface for multicast: add net 224.0.0.0: gateway np1600
syslog service starting.
Oct 25 15:33:48 np1660 unix: SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
ppid started
Oct 25 15:33:48 np1660 unix: Copyright (c) 1983-1996, Sun Microsystems, Inc.
Oct 25 15:33:48 np1660 unix: vac: enabled
Oct 25 15:33:48 np1660 unix: cpu0: FMI,MB86904 (mid 0 impl 0x0 ver 0x4 clock 110 MHz)
Oct 25 15:33:48 np1660 unix: mem = 32768K (0x2000000)
Oct 25 15:33:48 np1660 unix: avail mem = 28499968
Oct 25 15:33:48 np1660 unix: Ethernet address = 8:0:20:86:62:ac
Oct 25 15:33:48 np1660 unix: root nexus = SUNW,SPARCclassic-II
Oct 25 15:33:48 np1660 unix: iommu0 at root: obio 0x10000000
Oct 25 15:33:48 np1660 unix: sbus0 at iommu0: obio 0x10001000
Oct 25 15:33:48 np1660 unix: fas0: rev 2.2 FEPS chip
Oct 25 15:33:48 np1660 unix: SUNW,fas0 at sbus0: SBus slot 2 0x8800000 and SBus slot 2 0x8810000 sparc ipl 4
Oct 25 15:33:48 np1660 unix: sd3 at SUNW,fas0: target 3 lun 0
Oct 25 15:33:48 np1660 unix: sd3 is /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0
Oct 25 15:33:48 np1660 unix: <HARDDISKLABEL VTOC 1 cyl xxxx alt x hd x sec xxx>
Oct 25 15:33:48 np1660 unix: root on/iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0:a
fstype ufs
Oct 25 15:33:48 np1660 unix: obio0 at root
Oct 25 15:33:48 np1660 unix: zs0 at obio0: obio 0x100000 sparc ipl 12
Oct 25 15:33:48 np1660 unix: zs0 is /obio/zs@0,100000
Oct 25 15:33:48 np1660 unix: zs1 at obio0: obio 0x0 sparc ipl 12
Oct 25 15:33:48 np1660 unix: zs1 is /obio/zs@0,0
Oct 25 15:33:48 np1660 unix: cpu 0 initialization complete - online
Oct 25 15:33:48 np1660 unix: SUNW,hme0: FEPS (Rev Id = 22) Found
Oct 25 15:33:48 np1660 unix: SUNW,hme0 at sbus0: SBus slot 2 0x8c00000 and SBus slot 2 0x8c02000 and SBus
slot 2 0x8c04000 and SBus slot 2 0x8c06000 and SBus slot 2 0x8c07000 sparc ipl 6
Oct 25 15:33:48 np1660 unix: SUNW,hme0 is /iommu@0,10000000/sbus@0,10001000/SUNW,hme@2,8c00000
Oct 25 15:33:48 np1660 unix: dump on /dev/dsk/c0t3d0s1 size 98436K
Oct 25 15:33:48 np1660 unix: sdp0 at SUNW,fas0: target 5 lun 0
Oct 25 15:33:48 np1660 unix: sdp0 is
/iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sdp@5,0

7-19
Oct 25 15:33:48 np1660 unix: /usr/kernel/drv/bst symbol bioerror multiply defined
Oct 25 15:33:48 np1660 unix: bst0: No response from target 2, lun 0
Oct 25 15:33:48 np1660 unix: audio0 at sbus0: SBus slot 4 0x1300000 SBus level 7 sparc ipl 13
Oct 25 15:33:48 np1660 unix: audio0 is /iommu@0,10000000/sbus@0,10001000/audio@4,1300000
Oct 25 15:33:48 np1660 unix: SUNW,hme0: Using External Transceiver
Oct 25 15:33:48 np1660 unix: SUNW,hme0: Link Up
Oct 25 15:33:48 np1660 unix: SUNW,fdtwo0 at obio0: obio 0x400000 sparc ipl 11
Oct 25 15:33:48 np1660 unix: SUNW,fdtwo0 is /obio/SUNW,fdtwo@0,400000
Oct 25 15:33:48 np1660 unix: sbusmem0 at sbus0: SBus slot 0 0x0
Oct 25 15:33:48 np1660 unix: sbusmem0 is /iommu@0,10000000/sbus@0,10001000/sbusmem@0,0
Oct 25 15:33:48 np1660 unix: sbusmem1 at sbus0: SBus slot 1 0x0
Oct 25 15:33:48 np1660 unix: sbusmem1 is /iommu@0,10000000/sbus@0,10001000/sbusmem@1,0
Oct 25 15:33:48 np1660 unix: sbusmem2 at sbus0: SBus slot 2 0x0
Oct 25 15:33:48 np1660 unix: sbusmem2 is /iommu@0,10000000/sbus@0,10001000/sbusmem@2,0
httpd started
Oct 25 15:33:51 np1660 unix: sbusmem3 at sbus0: SBus slot 3 0x0
Oct 25 15:33:51 np1660 unix: sbusmem3 is /iommu@0,10000000/sbus@0,10001000/sbusmem@3,0
Oct 25 15:33:51 np1660 unix: sbusmem4 at sbus0: SBus slot 4 0x0
Oct 25 15:33:51 np1660 unix: sbusmem4 is /iommu@0,10000000/sbus@0,10001000/sbusmem@4,0
Oct 25 15:33:51 np1660 unix: SUNW,bpp0 at sbus0: SBus slot 2 0xc800000 SBus level 2 sparc ipl 3
Oct 25 15:33:51 np1660 unix: SUNW,bpp0 is /iommu@0,10000000/sbus@0,10001000/SUNW,bpp@2,c800000
Oct 25 15:33:51 np1660 unix: pseudo-device: llc10
Oct 25 15:33:51 np166
NP1600 v3.1.0.0
PDK103 loaded
Buffer error
Sparc preseþ‹÷
SK200 loaded
8109 8010 10 10 10 10 108 401 23 23 23 23

7-20
Memory Module Removed (SPARC)
WARNING: No Memory Detected !!!

ERROR : Sync Trap, PSR= 04100fc7, PC= 0002bde4, TBR= 70000290

ERROR : Sync Fault Status Reg = 70004218
ERROR : Sync Fault Address Reg = 70001fbð
ERROR : Sync Trap, PSR= 04100fc7, PC= 0002bde4, TBR= 70000290
ERROR : Sync Fault Status Reg = 70004218
ERROR : Sync Fault Address Reg = 70001fbð
ERROR : Sync Trap, PSR= 04100fc7, PC= 0002bde4, TBR= 70000290

***** These messages will continue to scroll indefinitely. *****

7-21
Normal Boot-Up Sequence (Forth)

NP1600 v3.1.0.0
PDK103 loaded
2MB buffer
Sparc preseþ‹÷
SK200 loaded
8109 8010 10 10 10 10 108 0 0 0 0 0# 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0#
Loading NP1600 vocabulary 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

7-22
Normal Boot-Up Sequence (SPARC)

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
Disk - OK
Testing Memory -

Memory - OK
Hit any key to interrupt boot sequence
Checking for bootable floppy...
Can't read disk label.
Can't open Sun disk label package
Floppy not bootable.

Testing Memory -

Initializing Memory |/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\

Boot device: /iommu/sbus/SUNW,fas@2,8800000/sd@3,0 File and args:

|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\
SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
Copyright (c) 1983-1996, Sun Microsystems, Inc.
|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\configuring network interfaces: hme0.
Hostname: np1660
The system is coming up. Please wait.
file system is clean - log replay is not required
Restore from /save/config
starting routing daemon.
lpd started

7-23
starting rpc services: rpcbind keyserv kerbd done.
Setting default interface for multicast: add net 224.0.0.0: gateway np1600
syslog service starting.
May 15 08:32:58 np1660 unix: SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
May 15 08:32:58 np1660 unix: Copyright (c) 1983-1996, Sun Microsystems, Inc.
May 15 08:32:58 np1660 unix: vac: enabled
May 15 08:32:58 np1660 unix: cpu0: FMI,MB86904 (mid 0 impl 0x0 ver 0x4 clock 110 MHz)
May 15 08:32:58 np1660 unix: mem = 32768K (0x2000000)
May 15 08:32:58 np1660 unix: avail mem = 28499968
May 15 08:32:58 np1660 unix: Ethernet address = 8:0:20:86:62:ac
May 15 08:32:58 np1660 unix: root nexus = SUNW,SPARCclassic-II
May 15 08:32:58 np1660 unix: iommu0 at root: obio 0x10000000
May 15 08:32:58 np1660 unix: sbus0 at iommu0: obio 0x10001000
May 15 08:32:58 np1660 unix: fas0: rev 2.2 FEPS chip
May 15 08:32:58 np1660 unix: SUNW,fas0 at sbus0: SBus slot 2 0x8800000 and SBus slot 2 0x8810000 sparc ipl 4
May 15 08:32:58 np1660 unix: sd3 at SUNW,fas0: target 3 lun 0
May 15 08:32:58 np1660 unix: sd3 is /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0
May 15 08:32:58 np1660 unix: <QUANTUM-FIREBALLST2.1S-0F0C cyl 7066 alt 2 hd 3 sec 199>
May 15 08:32:58 np1660 unix: root on /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0:a
fstype ufs
May 15 08:32:58 np1660 unix: obio0 at root
May 15 08:32:58 np1660 unix: zs0 at obio0: obio 0x100000 sparc ipl 12
May 15 08:32:58 np1660 unix: zs0 is /obio/zs@0,100000
May 15 08:32:58 np1660 unix: zs1 at obio0: obio 0x0 sparc ipl 12
May 15 08:32:58 np1660 unix: zs1 is /obio/zs@0,0
May 15 08:32:58 np1660 unix: cpu 0 initialization complete - online
May 15 08:32:58 np1660 unix: SUNW,hme0: FEPS (Rev Id = 22) Found
May 15 08:32:59 np1660 unix: SUNW,hme0 at sbus0: SBus slot 2 0x8c00000 and SBus slot 2 0x8c02000 and SBus
slot 2 0x8c04000 and SBus slot 2 0x8c06000 and SBus slot 2 0x8c07000 sparc ipl 6
May 15 08:32:59 np1660 unix: SUNW,hme0 is /iommu@0,10000000/sbus@0,10001000/SUNW,hme@2,8c00000
May 15 08:32:59 np1660 unix: dump on /dev/dsk/c0t3d0s1 size 98492K
May 15 08:32:59 np1660 unix: SUNW,hme0: Using External Transceiver
May 15 08:32:59 np1660 unix: SUNW,hme0: Link Up

ppid started
rm: /data/tmp/www/pages is a directory
httpd started
snmpd started
scsid started

Network page received

Flushing routing table:
Options page received

7-24
Parallel page received
Image page received
Loading DAP schema ...
Loading DAP data ...
bstn0: Found Optical device at tgt1, lun0

bstn0: Vendor/Product ID = FUJITSU M2513A

Loading Print-SCP schema ...

Loading Print-SCP data ...
Configuring the AE data ...
Examining current state and environment
Generating AE configuration script for np16601 on np1660, ref 1 ...
Filling in standard template ...
No local customizations.
AE configuration script prepared
AE configuration complete
The system is ready.

np1660 console login: aarpd (Ethertalk) started

bstn0: Found Optical device at tgt1, lun0

bstn0: Vendor/Product ID = FUJITSU M2513A

sockbuf::read: Interrupted system call

class sockbuf: sockbuf::read
sockbuf::read: Interrupted system call
class sockbuf: sockbuf::read
class sockbuf: sockbuf::read
class sockbuf: sockbuf::read
atis (Ethertalk) started
lwsrv (Ethertalk) started

np1660 console login:

np1660 console login:

7-25
P13 Disconnected (SPARC)

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
Disk - OK
Testing Memory -

Memory - OK
Hit any key to interrupt boot sequence
Checking for bootable floppy...
Can't read disk label.
Can't open Sun disk label package
Floppy not bootable.

Testing Memory -

Initializing Memory |/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\

Boot device: /iommu/sbus/SUNW,fas@2,8800000/sd@3,0 File and args:

|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\
SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
Copyright (c) 1983-1996, Sun Microsystems, Inc.
|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\configuring network interfaces: hme0.
Hostname: np1660
The system is coming up. Please wait.
file system is clean - log replay is not required
Restore from /save/config
starting routing daemon.
lpd started

7-26
starting rpc services: rpcbind keyserv kerbd done.
Setting default interface for multicast: add net 224.0.0.0: gateway np1600 syslog service starting.
May 15 12:50:45 np1660 unix: SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
May 15 12:50:45 np1660 unix: Copyright (c) 1983-1996, Sun Microsystems, Inc.
May 15 12:50:45 np1660 unix: vac: enabled
May 15 12:50:45 np1660 unix: cpu0: FMI,MB86904 (mid 0 impl 0x0 ver 0x4 clock 110 MHz)
May 15 12:50:45 np1660 unix: mem = 32768K (0x2000000)
May 15 12:50:45 np1660 unix: avail mem = 28499968
May 15 12:50:45 np1660 unix: Ethernet address = 8:0:20:86:62:ac
May 15 12:50:45 np1660 unix: root nexus = SUNW,SPARCclassic-II
May 15 12:50:45 np1660 unix: iommu0 at root: obio 0x10000000
May 15 12:50:45 np1660 unix: sbus0 at iommu0: obio 0x10001000
May 15 12:50:45 np1660 unix: fas0: rev 2.2 FEPS chip
May 15 12:50:45 np1660 unix: SUNW,fas0 at sbus0: SBus slot 2 0x8800000 and SBus slot 2 0x8810000 sparc ipl 4
May 15 12:50:45 np1660 unix: sd3 at SUNW,fas0: target 3 lun 0
May 15 12:50:45 np1660 unix: sd3 is /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0
May 15 12:50:45 np1660 unix: <QUANTUM-FIREBALLST2.1S-0F0C cyl 7066 alt 2 hd 3 sec 199>
May 15 12:50:45 np1660 unix: root on /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0:a
fstype ufs
May 15 12:50:45 np1660 unix: obio0 at root
May 15 12:50:45 np1660 unix: zs0 at obio0: obio 0x100000 sparc ipl 12
May 15 12:50:45 np1660 unix: zs0 is /obio/zs@0,100000
May 15 12:50:45 np1660 unix: zs1 at obio0: obio 0x0 sparc ipl 12
May 15 12:50:45 np1660 unix: zs1 is /obio/zs@0,0
May 15 12:50:45 np1660 unix: cpu 0 initialization complete - online
May 15 12:50:45 np1660 unix: SUNW,hme0: FEPS (Rev Id = 22) Found
May 15 12:50:46 np1660 unix: SUNW,hme0 at sbus0: SBus slot 2 0x8c00000 and SBus slot 2 0x8c02000 and SBus
slot 2 0x8c04000 and SBus slot 2 0x8c06000 and SBus slot 2 0x8c07000 sparc ipl 6
May 15 12:50:46 np1660 unix: SUNW,hme0 is /iommu@0,10000000/sbus@0,10001000/SUNW,hme@2,8c00000
May 15 12:50:46 np1660 unix: dump on /dev/dsk/c0t3d0s1 size 98492K
May 15 12:50:46 np1660 unix: SUNW,hme0: Using External Transceiver
May 15 12:50:46 np1660 unix: SUNW,hme0: Link Up

ppid started
rm: /data/tmp/www/pages is a directory
httpd started
snmpd started
scsid started

sdp0: scb 2

sdp_handle_sense

7-27
asc:26 acq:0
Loading DAP schema ...
Loading DAP data ...
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
Loading Print-SCP schema ...
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
Loading Print-SCP data ...
Configuring the AE data ...
Examining current state and environment
Generating AE configuration script for np16601 on np1660, ref 1 ...
Filling in standard template ...
No local customizations.
AE configuration script prepared
AE configuration complete
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
aarpd (Ethertalk) started
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
atis (Ethertalk) started
lwsrv (Ethertalk) started
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
sdp0: scb 2

7-28
sdp_handle_sense
asc:26 acq:0
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0

*** Will continue to cycle these 2 lines indefinately ***

*** Will have an "INIT ERROR" on the front panel ***

7-29
P13 Disconnected (Forth)

NP1600 v3.1.0.0
PDK103 loaded‹÷
SK200 loaded

7-30
Disconnected P5 (SPARC)

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
Disk - OK
Testing Memory -

Memory - OK
Hit any key to interrupt boot sequence
Checking for bootable floppy...
Can't read disk label.
Can't open Sun disk label package
Floppy not bootable.

Testing Memory -

Initializing Memory |/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\

Boot device: /iommu/sbus/SUNW,fas@2,8800000/sd@3,0 File and args:

|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\
SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
Copyright (c) 1983-1996, Sun Microsystems, Inc.
|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\configuring network interfaces: hme0.
Hostname: np1660
The system is coming up. Please wait.
file system is clean - log replay is not required
Restore from /save/config
starting routing daemon.
lpd started
starting rpc services: rpcbind keyserv kerbd done.
7-31
Setting default interface for multicast: add net 224.0.0.0: gateway np1600
syslog service starting.
May 15 12:15:26 np1660 unix: SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
May 15 12:15:26 np1660 unix: Copyright (c) 1983-1996, Sun Microsystems, Inc.
May 15 12:15:26 np1660 unix: vac: enabled
May 15 12:15:26 np1660 unix: cpu0: FMI,MB86904 (mid 0 impl 0x0 ver 0x4 clock 110 MHz)
May 15 12:15:26 np1660 unix: mem = 32768K (0x2000000)
May 15 12:15:26 np1660 unix: avail mem = 28499968
May 15 12:15:26 np1660 unix: Ethernet address = 8:0:20:86:62:ac
May 15 12:15:26 np1660 unix: root nexus = SUNW,SPARCclassic-II
May 15 12:15:26 np1660 unix: iommu0 at root: obio 0x10000000
May 15 12:15:26 np1660 unix: sbus0 at iommu0: obio 0x10001000
May 15 12:15:26 np1660 unix: fas0: rev 2.2 FEPS chip
May 15 12:15:26 np1660 unix: SUNW,fas0 at sbus0: SBus slot 2 0x8800000 and SBus slot 2 0x8810000 sparc ipl 4
May 15 12:15:26 np1660 unix: sd3 at SUNW,fas0: target 3 lun 0
May 15 12:15:26 np1660 unix: sd3 is /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0
May 15 12:15:26 np1660 unix: <QUANTUM-FIREBALLST2.1S-0F0C cyl 7066 alt 2 hd 3 sec 199>
May 15 12:15:26 np1660 unix: root on /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0:a
fstype ufs
May 15 12:15:26 np1660 unix: obio0 at root
May 15 12:15:26 np1660 unix: zs0 at obio0: obio 0x100000 sparc ipl 12
May 15 12:15:26 np1660 unix: zs0 is /obio/zs@0,100000
May 15 12:15:26 np1660 unix: zs1 at obio0: obio 0x0 sparc ipl 12
May 15 12:15:26 np1660 unix: zs1 is /obio/zs@0,0
May 15 12:15:26 np1660 unix: cpu 0 initialization complete - online
May 15 12:15:26 np1660 unix: SUNW,hme0: FEPS (Rev Id = 22) Found
May 15 12:15:27 np1660 unix: SUNW,hme0 at sbus0: SBus slot 2 0x8c00000 and SBus slot 2 0x8c02000 and SBus
slot 2 0x8c04000 and SBus slot 2 0x8c06000 and SBus slot 2 0x8c07000 sparc ipl 6
May 15 12:15:27 np1660 unix: SUNW,hme0 is /iommu@0,10000000/sbus@0,10001000/SUNW,hme@2,8c00000
May 15 12:15:27 np1660 unix: dump on /dev/dsk/c0t3d0s1 size 98492K
May 15 12:15:27 np1660 unix: SUNW,hme0: Using External Transceiver
May 15 12:15:27 np1660 unix: SUNW,hme0: Link Up

ppid started
rm: /data/tmp/www/pages is a directory
httpd started
snmpd started
scsid started

sdp0: scb 2

sdp_handle_sense

7-32
asc:26 acq:0
Loading DAP schema ...
Loading DAP data ...
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
Loading Print-SCP schema ...
Loading Print-SCP data ...
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
Configuring the AE data ...
Examining current state and environment
Generating AE configuration script for np16601 on np1660, ref 1 ...
Filling in standard template ...
No local customizations.
AE configuration script prepared
AE configuration complete
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
aarpd (Ethertalk) started
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
atis (Ethertalk) started
lwsrv (Ethertalk) started
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
sdp0: scb 2

7-33
sdp_handle_sense
asc:26 acq:0
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0
sdp0: scb 2

sdp_handle_sense
asc:26 acq:0

** This will continue to scroll indefinately **

** Also fault light will be lit with "Close Door displayed on the front panel **

7-34
P5 Disconnected (Forth)

NP1600 v3.1.0.0
PDK103 loaded‹÷
SK200 loaded
8109 8010 10 10 10 10 108 2B 2B 2B 2B

*** Close Door Error message on Front Panel ***

7-35
P9 Disconnected (Forth)

NP1600 v3.1.0.0
PDK103 loaded‹÷
SK200 loaded
8109 8610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 6
10 610 610 610 610 610 610 610 610 610 610 610 610
NP1600 v3.1.0.0
PDK103 loaded‹÷
SK200 loaded
610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610
610 610 610 610 610 610 610 610 610 610 610
NP1600 v3.1.0.0
PDK103 loaded‹÷

*** Will continue indefinately ***

7-36
P9 Disconnected (SPARC)

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

Release 2.15 Version 113 created 97/09/09 13:47:52

PROM nvramrc+ version 2.1 (Classic-2)

Checking for bootable floppy...

Can't read disk label.
Can't open Sun disk label package
Floppy not bootable.

Booting from hard drive...

Boot device: /iommu/sbus/SUNW,fas@2,8800000/sd@3,0 File and args:
SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
Copyright (c) 1983-1996, Sun Microsystems, Inc.
WARNING: Cannot merge hwconf devinfo node SUNW,fas@2,8800000
WARNING: Cannot merge hwconf devinfo node SUNW,fas@2,8800000
configuring network interfaces:WARNING: Cannot merge hwconf devinfo node SUNW,hme@2,8c00000 hme0.
Hostname: np1660
The system is coming up. Please wait.
file system is clean - log replay is not required
Restore from /save/config
starting routing daemon.
lpd started
starting rpc services: rpcbind keyserv kerbd done.
Setting default interface for multicast: add net 224.0.0.0: gateway np1600 syslog service starting.
May 15 13:43:33 np1660 unix: SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
May 15 13:43:33 np1660 unix: Copyright (c) 1983-1996, Sun Microsystems, Inc.
May 15 13:43:33 np1660 unix: vac: enabled
May 15 13:43:33 np1660 unix: cpu0: FMI,MB86904 (mid 0 impl 0x0 ver 0x4 clock 110 MHz)
May 15 13:43:33 np1660 unix: mem = 32768K (0x2000000)
May 15 13:43:33 np1660 unix: avail mem = 28471296
May 15 13:43:33 np1660 unix: Ethernet address = 8:0:20:86:62:ac
May 15 13:43:33 np1660 unix: root nexus = SUNW,SPARCclassic-II
May 15 13:43:33 np1660 unix: iommu0 at root: obio 0x10000000
7-37
May 15 13:43:33 np1660 unix: sbus0 at iommu0: obio 0x10001000
May 15 13:43:33 np1660 unix: fas0: rev 2.2 FEPS chip
May 15 13:43:33 np1660 unix: SUNW,fas0 at sbus0: SBus slot 2 0x8800000 and SBus slot 2 0x8810000 sparc ipl 4
May 15 13:43:33 np1660 unix: WARNING: Cannot merge hwconf devinfo node SUNW,fas@2,8800000
May 15 13:43:33 np1660 unix: sd3 at SUNW,fas0: target 3 lun 0
May 15 13:43:33 np1660 unix: sd3 is /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0
May 15 13:43:33 np1660 unix: <QUANTUM-FIREBALLST2.1S-0F0C cyl 7066 alt 2 hd 3 sec 199>
May 15 13:43:33 np1660 unix: WARNING: Cannot merge hwconf devinfo node SUNW,fas@2,8800000
May 15 13:43:33 np1660 unix: root on /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0:a
fstype ufs
May 15 13:43:33 np1660 unix: obio0 at root
May 15 13:43:33 np1660 unix: zs0 at obio0: obio 0x100000 sparc ipl 12
May 15 13:43:33 np1660 unix: zs0 is /obio/zs@0,100000
May 15 13:43:33 np1660 unix: zs1 at obio0: obio 0x0 sparc ipl 12
May 15 13:43:33 np1660 unix: zs1 is /obio/zs@0,0
May 15 13:43:33 np1660 unix: cpu 0 initialization complete - online
May 15 13:43:34 np1660 unix: SUNW,hme0: FEPS (Rev Id = 22) Found
May 15 13:43:34 np1660 unix: SUNW,hme0 at sbus0: SBus slot 2 0x8c00000 and SBus slot 2 0x8c02000 and SBus
slot 2 0x8c04000 and SBus slot 2 0x8c06000 and SBus slot 2 0x8c07000 sparc ipl 6
May 15 13:43:34 np1660 unix: SUNW,hme0 is /iommu@0,10000000/sbus@0,10001000/SUNW, hme@2,8c00000
May 15 13:43:34 np1660 unix: WARNING: Cannot merge hwconf devinfo node SUNW,hme@2,8c00000
May 15 13:43:34 np1660 unix: dump on /dev/dsk/c0t3d0s1 size 98492K
May 15 13:43:34 np1660 unix: SUNW,hme0: Using External Transceiver
May 15 13:43:34 np1660 unix: SUNW,hme0: Link Up
ppid started
WARNING: Cannot merge hwconf devinfo node SUNW,bpp@2,c800000
rm: /data/tmp/www/pages is a directory
httpd started
snmpd started
scsid started

May 15 13:43:50 np1660 scsid[628]: sdp open failed: No such device or address
Child term status 100
Loading DAP schema ...
aarpd (Ethertalk) started
May 15 13:44:29 np1660 scsid[635]: sdp open failed: No such device or address
Child term status 100
Loading DAP data ...
atis (Ethertalk) started
May 15 13:45:08 np1660 scsid[643]: sdp open failed: No such device or address
Child term status 100
Loading Print-SCP schema ...
lwsrv (Ethertalk) started

7-38
Loading Print-SCP data ...
Configuring the AE data ...
Examining current state and environment
Generating AE configuration script for np16601 on np1660, ref 1 ...
Filling in standard template ...
No local customizations.
AE configuration script prepared
AE configuration complete
Child term status 100
May 15 13:45:47 np1660 scsid[665]: sdp open failed: No such device or address
May 15 13:46:26 np1660 scsid[666]: sdp open failed: No such device or address
Child term status 100
May 15 13:47:05 np1660 scsid[669]: sdp open failed: No such device or address
Child term status 100
Child term status 100
May 15 13:47:44 np1660 scsid[672]: sdp open failed: No such device or address

7-39
Installing Software (2.2.0) on Known Bad Hard Drive

################### HARD DRIVE 1 #######################

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
SCSI target 3 lun 0 is not present or not respondingDisk failedMemory error during DMA transfer.
DMA control register = b2930a03 , DMA address = ffed7000
Extra scsi data. Fatal error.

################### HARD DRIVE 2 #######################

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK

7-40
Disk - OK
Testing Memory -

Memory - OK
Hit any key to interrupt boot sequence
Checking for bootable floppy...
Booting from floppy...
Initializing Memory |/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\

Boot device: /obio/SUNW,fdtwo File and args:

ffffffff npboot: started
Setting NVRAM parameters to default values.
npboot: nvbuf
npboot: NVRAM script loaded
Target 1
Unit 0 Removable Device type 7 FUJITSU M2513A 17004ˆ
A3058
Target 3
Unit 0 Disk QUANTUM FIREBALL_TM1280S300X11/01/96692700133369
GENERIC

Target 5
Unit 0 Printer CODONICSNP1600 PRINTER 0200
BOOT

Unit 4 Printer CODONICSNP1600 PRINTER 0200

BOOT

iocb isn't unique

Loading system info . . . done!
loader is 1744 blocks (48 sectors)
Reading in loader
................................................
Initializing program
Enable cache
Virtual : 0000.6000
Context : @ 0.01ff.f000 001f.eec1 # 0
Region : @ 0.01fe.ec00 001f.ee71
Segment : @ 0.01fe.e700 001f.ee61
Page : @ 0.01fe.e618 0000.06fe Cached Modified Referenced Access : rwx---
Physical : 0.0000.6000
Virtual : 000e.0000
Context : @ 0.01ff.f000 001f.eec1 # 0
7-41
Region : @ 0.01fe.ec00 001f.ee71
Segment : @ 0.01fe.e70c 001f.bcb1
Page : @ 0.01fb.cb80 0000.e09e Cached Access : rwx---
Physical : 0.000e.0000
Executing loader
Magic: 10010407Romvec: 3Plugin: 2Monitor: 2000f
lcd isn't unique
1281 MB disk ( 2503872 blocks )
cylinders 7872 alt 1 head 2 sectors 159
Loader size: 1744 blocks partitions: 50 50 0 0 0 0 -1 0
floppy 2.2.0

System time = 904245704

1048576 @ ffdbe000
Virtual : ffdb.e000
Context : @ 0.01ff.f000 001f.eec1 # 0
Region : @ 0.01fe.effc 001f.eeb1
Segment : @ 0.01fe.ebd8 001f.a461
Page : @ 0.01fa.46f8 001e.879e Cached Access : rwx---
Physical : 0.01e8.7000
Virtual : ffeb.e000
Context : @ 0.01ff.f000 001f.eec1 # 0
Region : @ 0.01fe.effc 001f.eeb1
Segment : @ 0.01fe.ebe8 001f.bcd1
Page : @ 0.01fb.cdf8 001f.87fe Cached Modified Referenced Access : rwx---
Physical : 0.01f8.7000
Initializing UFS
nfs_init
mbinit
domain_init
ip_init
udp_init
rip_init
Previous filesystem detected
swap = 143
0: 0 102714
1: 323 102714
2: 0 263280
hog 6: 646 2297868
swap offset 143
Loading 15 disks
Reading disk 1
................................................................................Checksum = e08e
7-42
Reading disk 2
................................................................................Checksum = b12f
Reading disk 3
................................................................................Checksum = 2df9
Reading disk 4
................................................................................Checksum = faf4
Reading disk 5
................................................................................Checksum = abc9
Reading disk 6
................................................................................Checksum = 1e97
Reading disk 7
................................................................................Checksum = 2a51
Reading disk 8
................................................................................Checksum = 5e6
Reading disk 9
................................................................................Checksum = 557e
Reading disk 10
................................................................................Checksum = adef
Reading disk 11
................................................................................Checksum = c66b
Reading disk 12
................................................................................Checksum = 7b49
Reading disk 13
................................................................................Checksum = 4919
Reading disk 14
................................................................................Checksum = 11bd
Reading disk 15
................................................................................Checksum = b266
0: 0 102714
1: 323 102714
2: 0 263280
hog 6: 646 2297868
# /OpenFirmware/disk3:
bytes/sector: 512
sectors/track: 159
cylinders: 7872
rpm: 1
interleave: 1

8 partitions:
# size offset
a: 102714 0
7-43
 b: 102714 323
c: 2503296 0
g: 2297868 646
offset 0
/OpenFirmware/disk3:0:102714 sectors in 323 cylinders of 2 tracks, 159 sectors 50MB in 21 cyl groups (16 c/g,
2MB/g, 640 i/g)
super-block backups (for fsck -b #) at:
32, 5280, 10208, 15456, 20384, 25632, 30560, 35808,
40736, 45984, 50912, 56160, 61088, 66336, 71264, 76512,
81440, 86688, 91616, 96864, 101792,
offset 32274
/OpenFirmware/disk3:6:2297868 sectors in 7226 cylinders of 2 tracks, 159 sectors
1122MB in 452 cyl groups (16 c/g, 2MB/g, 640 i/g)
super-block backups (for fsck -b #) at:
32, 5280, 10208, 15456, 20384, 25632, 30560, 35808,
40736, 45984, 50912, 56160, 61088, 66336, 71264, 76512,
81440, 86688, 91616, 96864, 101792, 107040, 111968, 117216,
122144, 127392, 132320, 137568, 142496, 147744, 152672, 157920,
162848, 168096, 173024, 178272, 183200, 188448, 193376, 198624,
203552, 208800, 213728, 218976, 223904, 229152, 234080, 239328,
244256, 249504, 254432, 259680, 264608, 269856, 274784, 280032,
284960, 290208, 295136, 300384, 305312, 310560, 315488, 320736,
325664, 330912, 335840, 341088, 346016, 351264, 356192, 361440,
366368, 371616, 376544, 381792, 386720, 391968, 396896, 402144,
407072, 412320, 417248, 422496, 427424, 432672, 437600, 442848,
447776, 453024, 457952, 463200, 468128, 473376, 478304, 483552,
488480, 493728, 498656, 503904, 508832, 514080, 519008, 524256,
529184, 534432, 539360, 544608, 549536, 554784, 559712, 564960,
569888, 575136, 580064, 585312, 590240, 595488, 600416, 605664,
610592, 615840, 620768, 626016, 630944, 636192, 641120, 646368,
651296, 656544, 661472, 666720, 671648, 676896, 681824, 687072,
692000, 697248, 702176, 707424, 712352, 717600, 722528, 727776,
732704, 737952, 742880, 748128, 753056, 758304, 763232, 768480,
773408, 778656, 783584, 788832, 793760, 799008, 803936, 809184,
814112, 819360, 824288, 829536, 834464, 839712, 844640, 849888,
854816, 860064, 864992, 870240, 875168, 880416, 885344, 890592,
895520, 900768, 905696, 910944, 915872, 921120, 926048, 931296,
936224, 941472, 946400, 951648, 956576, 961824, 966752, 972000,
976928, 982176, 987104, 992352, 997280, 1002528, 1007456, 1012704,
1017632, 1022880, 1027808, 1033056, 1037984, 1043232, 1048160, 1053408,
1058336, 1063584, 1068512, 1073760, 1078688, 1083936, 1088864, 1094112,
1099040, 1104288, 1109216, 1114464, 1119392, 1124640, 1129568, 1134816,
1139744, 1144992, 1149920, 1155168, 1160096, 1165344, 1170272, 1175520,

7-44
1180448, 1185696, 1190624, 1195872, 1200800, 1206048, 1210976, 1216224,
1221152, 1226400, 1231328, 1236576, 1241504, 1246752, 1251680, 1256928,
1261856, 1267104, 1272032, 1277280, 1282208, 1287456, 1292384, 1297632,
1302560, 1307808, 1312736, 1317984, 1322912, 1328160, 1333088, 1338336,
1343264, 1348512, 1353440, 1358688, 1363616, 1368864, 1373792, 1379040,
1383968, 1389216, 1394144, 1399392, 1404320, 1409568, 1414496, 1419744,
1424672, 1429920, 1434848, 1440096, 1445024, 1450272, 1455200, 1460448,
1465376, 1470624, 1475552, 1480800, 1485728, 1490976, 1495904, 1501152,
1506080, 1511328, 1516256, 1521504, 1526432, 1531680, 1536608, 1541856,
1546784, 1552032, 1556960, 1562208, 1567136, 1572384, 1577312, 1582560,
1587488, 1592736, 1597664, 1602912, 1607840, 1613088, 1618016, 1623264,
1628192, 1633440, 1638368, 1643616, 1648544, 1653792, 1658720, 1663968,
1668896, 1674144, 1679072, 1684320, 1689248, 1694496, 1699424, 1704672,
1709600, 1714848, 1719776, 1725024, 1729952, 1735200, 1740128, 1745376,
1750304, 1755552, 1760480, 1765728, 1770656, 1775904, 1780832, 1786080,
1791008, 1796256, 1801184, 1806432, 1811360, 1816608, 1821536, 1826784,
1831712, 1836960, 1841888, 1847136, 1852064, 1857312, 1862240, 1867488,
1872416, 1877664, 1882592, 1887840, 1892768, 1898016, 1902944, 1908192,
1913120, 1918368, 1923296, 1928544, 1933472, 1938720, 1943648, 1948896,
1953824, 1959072, 1964000, 1969248, 1974176, 1979424, 1984352, 1989600,
1994528, 1999776, 2004704, 2009952, 2014880, 2020128, 2025056, 2030304,
2035232, 2040480, 2045408, 2050656, 2055584, 2060832, 2065760, 2071008,
2075936, 2081184, 2086112, 2091360, 2096288, 2101536, 2106464, 2111712,
2116640, 2121888, 2126816, 2132064, 2136992, 2142240, 2147168, 2152416,
2157344, 2162592, 2167520, 2172768, 2177696, 2182944, 2187872, 2193120,
2198048, 2203296, 2208224, 2213472, 2218400, 2223648, 2228576, 2233824,
2238752, 2244000, 2248928, 2254176, 2259104, 2264352, 2269280, 2274528,
2279456, 2284704, 2289632, 2294880,
Mount point: / File: part0
Partition: 0
unzipping /OpenFirmware/disk3:1
archive is 0
call get_method
inbuf and inptr equal 0x7f160 0
no match warning
flags=0
calling work
free inode //702 had -1951070991 blocks
mode = 0150055, inum = 703, fs = /
panic: ffs_valloc: dup allocProgram terminated
Type help for more information
ok

7-45
Mount point: / File: part0
Partition: 0
unzipping /OpenFirmware/disk3:1
archive is 0
call get_method
inbuf and inptr equal
0x7f160 0
no match warning
flags=0
calling work
free inode //702 had -1951070991 blo
cks
mode = 0150055, inum = 703, fs = /
panic: ffs_valloc: dup allocProgram termina
ted
Type help for more information
ok

********* ffs_valloc: dup appears on the front panel ***************

################ HARD DRIVE 3 #######################

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 808662ac
PrinterID: 62ac
Ethernet Addr: 8:0:20:86:62:ac

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
Disk failedData Access Exception
Type help for more information
ok

7-46
Stuck in Initializing....

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 80ed77e0
PrinterID: 77e0
Ethernet Addr: 8:0:20:ed:77:e0

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
Disk - OK
Memory - OK
Hit any key to interrupt boot sequence
Checking for bootable floppy...
Can't read disk label.
Can't open Sun disk label package
Floppy not bootable.

Boot device: /iommu/sbus/SUNW,fas@2,8800000/sd@3,0 File and args:

SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
Copyright (c) 1983-1996, Sun Microsystems, Inc.
WARNING: /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000 (fas0):
Connected command timeout for Target 3.0

WARNING: /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000 (fas0):

Target 3 reducing sync. transfer rate

fas: Cmd dump for Target 3 Lun 0:

fas: cdb=[ 0x12 0x0 0x0 0x0 0x30 0x0 ]
fas: State=DATA_DONE Last State=DATA
fas: pkt_state=0x7<CMD,SEL,ARB> pkt_flags=0x80a pkt_statistics=0x60
configuring network interfaces: hme0.
Hostname: np1660
The system is coming up. Please wait.

7-47
file system is clean - log replay is not required
Restore from /save/config
starting routing daemon.
lpd started
starting rpc services: rpcbind keyserv kerbd done.
Setting default interface for multicast: add net 224.0.0.0: gateway np1600 syslog service starting.
May 21 12:29:01 np1660 unix: SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
May 21 12:29:01 np1660 unix: Copyright (c) 1983-1996, Sun Microsystems, Inc.
May 21 12:29:01 np1660 unix: vac: enabled
May 21 12:29:01 np1660 unix: cpu0: FMI,MB86904 (mid 0 impl 0x0 ver 0x4 clock 110 MHz)
May 21 12:29:01 np1660 unix: mem = 32768K (0x2000000)
May 21 12:29:01 np1660 unix: avail mem = 28499968
May 21 12:29:01 np1660 unix: Ethernet address = 8:0:20:ed:77:e0
May 21 12:29:01 np1660 unix: root nexus = SUNW,SPARCclassic-II
May 21 12:29:01 np1660 unix: iommu0 at root: obio 0x10000000
May 21 12:29:01 np1660 unix: sbus0 at iommu0: obio 0x10001000
May 21 12:29:01 np1660 unix: fas0: rev 2.2 FEPS chip
May 21 12:29:01 np1660 unix: SUNW,fas0 at sbus0: SBus slot 2 0x8800000 and SBus slot 2 0x8810000 sparc ipl 4
May 21 12:29:01 np1660 unix: WARNING: /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000
(fas0):
May 21 12:29:01 np1660 unix: Connected command timeout for Target 3.0
May 21 12:29:01 np1660 unix: WARNING: /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000
(fas0):
May 21 12:29:01 np1660 unix: Target 3 reducing sync. transfer rate
May 21 12:29:01 np1660 unix: fas: Cmd dump for Target 3 Lun 0:
May 21 12:29:01 np1660 unix: fas: cdb=[ 0x12 0x0 0x0 0x0 0x30 0x0 ]
May 21 12:29:01 np1660 unix: fas: State=DATA_DONE Last State=DATA
May 21 12:29:01 np1660 unix: fas: pkt_state=0x7<CMD,SEL,ARB> pkt_flags=0x8
0a pkt_statistics=0x60
May 21 12:29:01 np1660 unix: sd3 at SUNW,fas0: target 3 lun 0
May 21 12:29:01 np1660 unix: sd3 is /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0
May 21 12:29:02 np1660 unix: <QUANTUM-FIREBALLST2.1S-0F0C cyl 7066 alt 2 hd 3 sec 199>
May 21 12:29:02 np1660 unix: root on /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0:a
fstype ufs
May 21 12:29:02 np1660 unix: obio0 at root
May 21 12:29:02 np1660 unix: zs0 at obio0: obio 0x100000 sparc ipl 12
May 21 12:29:02 np1660 unix: zs0 is /obio/zs@0,100000
May 21 12:29:02 np1660 unix: zs1 at obio0: obio 0x0 sparc ipl 12
May 21 12:29:02 np1660 unix: zs1 is /obio/zs@0,0
May 21 12:29:02 np1660 unix: cpu 0 initialization complete - online
May 21 12:29:02 np1660 unix: SUNW,hme0: FEPS (Rev Id = 22) Found
May 21 12:29:02 np1660 unix: SUNW,hme0 at sbus0: SBus slot 2 0x8c00000 and SBus
slot 2 0x8c02000 and SBus slot 2 0x8c04000 and SBus slot 2 0x8c06000 and SBus slot 2 0x8c07000 sparc ipl 6

7-48
May 21 12:29:02 np1660 unix: SUNW,hme0 is /iommu@0,10000000/sbus@0,10001000/SUNW,hme@2,8c00000
May 21 12:29:02 np1660 unix: dump on /dev/dsk/c0t3d0s1 size 98492K
May 21 12:29:02 np1660 unix: SUNW,hme0: Using External Transceiver
May 21 12:29:02 np1660 unix: SUNW,hme0: Link Up
ppid started
rm: /data/tmp/www/pages is a directory
httpd started
snmpd started
scsid started

halt

WARNING: /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000 (fas0):

Connected command timeout for Target 5.0

fas: Cmd dump for Target 5 Lun 0:

fas: cdb=[ 0x12 0x0 0x0 0x0 0x30 0x0 ]
fas: State=CLEARING Last State=CLEARING
fas: pkt_state=0x1f<STS,XFER,CMD,SEL,ARB> pkt_flags=0x80a pkt_statistics=0x60

fas: Status=0x0
WARNING: /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0 (sd3):
SCSI transport failed: reason 'reset': retrying command

****** Initializing is displayed on front panel *******

7-49
Bad SPARC.... SCSI Test Fatal Error.. Error While Trying to Load 2.2.0.. Printer Not
Responding to Selection..

**************************************
Codonics NP-1600/NP-1660
Series Network Printer
**************************************

HostID: 80ed77e0
PrinterID: 77e0
Ethernet Addr: 8:0:20:ed:77:e0

NVRAM version 2.0 (Classic-2)

Self Tests...
Internal loopback test -- succeeded.
Transceiver check -- passed
Ethernet - OK
Disk - OK
Memory - OK
Hit any key to interrupt boot sequence
Checking for bootable floppy...
Can't read disk label.
Can't open Sun disk label package
Floppy not bootable.

Boot device: /iommu/sbus/SUNW,fas@2,8800000/sd@3,0 File and args:

SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
Copyright (c) 1983-1996, Sun Microsystems, Inc.
configuring network interfaces: hme0.
Hostname: np1660
The system is coming up. Please wait.
file system is clean - log replay is not required
Restore from /save/config
starting routing daemon.
lpd started
starting rpc services: rpcbind keyserv kerbd done.
Setting default interface for multicast: add net 224.0.0.0: gateway np1600 syslog service starting.
May 21 11:04:51 np1660 unix: SunOS Release 5.5.1 Version Generic [UNIX(R) System V Release 4.0]
May 21 11:04:51 np1660 unix: Copyright (c) 1983-1996, Sun Microsystems, Inc.
May 21 11:04:51 np1660 unix: vac: enabled
May 21 11:04:51 np1660 unix: cpu0: FMI,MB86904 (mid 0 impl 0x0 ver 0x4 clock 110 MHz)

7-50
May 21 11:04:51 np1660 unix: mem = 32768K (0x2000000)
May 21 11:04:51 np1660 unix: avail mem = 28499968
May 21 11:04:51 np1660 unix: Ethernet address = 8:0:20:ed:77:e0
May 21 11:04:51 np1660 unix: root nexus = SUNW,SPARCclassic-II
May 21 11:04:51 np1660 unix: iommu0 at root: obio 0x10000000
May 21 11:04:51 np1660 unix: sbus0 at iommu0: obio 0x10001000
May 21 11:04:51 np1660 unix: fas0: rev 2.2 FEPS chip
May 21 11:04:51 np1660 unix: SUNW,fas0 at sbus0: SBus slot 2 0x8800000 and SBus slot 2 0x8810000 sparc ipl 4
May 21 11:04:51 np1660 unix: sd3 at SUNW,fas0: target 3 lun 0
May 21 11:04:51 np1660 unix: sd3 is /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0
May 21 11:04:51 np1660 unix: <QUANTUM-FIREBALLST2.1S-0F0C cyl 7066 alt 2 hd 3 sec 199>
May 21 11:04:51 np1660 unix: root on /iommu@0,10000000/sbus@0,10001000/SUNW,fas@2,8800000/sd@3,0:a
fstype ufs
May 21 11:04:51 np1660 unix: obio0 at root
May 21 11:04:51 np1660 unix: zs0 at obio0: obio 0x100000 sparc ipl 12
May 21 11:04:51 np1660 unix: zs0 is /obio/zs@0,100000
May 21 11:04:51 np1660 unix: zs1 at obio0: obio 0x0 sparc ipl 12
May 21 11:04:51 np1660 unix: zs1 is /obio/zs@0,0
May 21 11:04:51 np1660 unix: cpu 0 initialization complete - online
May 21 11:04:51 np1660 unix: SUNW,hme0: FEPS (Rev Id = 22) Found
May 21 11:04:52 np1660 unix: SUNW,hme0 at sbus0: SBus slot 2 0x8c00000 and SBus slot 2 0x8c02000 and SBus
slot 2 0x8c04000 and SBus slot 2 0x8c06000 and SBus slot 2 0x8c07000 sparc ipl 6
May 21 11:04:52 np1660 unix: SUNW,hme0 is /iommu@0,10000000/sbus@0,10001000/SUNW,hme@2,8c00000
May 21 11:04:52 np1660 unix: dump on /dev/dsk/c0t3d0s1 size 98492K
May 21 11:04:52 np1660 unix: SUNW,hme0: Using External Transceiver
May 21 11:04:52 np1660 unix: SUNW,hme0: Link Up
ppid started
rm: /data/tmp/www/pages is a directory
httpd started
snmpd started
scsid started

Network page received

Flushing routing table:
Options page received
Parallel page received
Image page received
Loading DAP schema ...
Loading DAP data ...
Loading Print-SCP schema ...
Loading Print-SCP data ...
Configuring the AE data ...
Examining current state and environment

7-51
Generating AE configuration script for np16601 on np1660, ref 1 ...
Filling in standard template ...
No local customizations.
AE configuration script prepared
AE configuration complete
The system is ready.

np1660 console login: aarpd (Ethertalk) started

atis (Ethertalk) started
lwsrv (Ethertalk) started

****** Somehow I was able to print without any error messages... However, the following error message was
displayed testing SCSI:

ok test scsi
CE DMA fill from address ffed0000 for 80 bytes ERROR: DMA Hang condition detected
ERROR: DMA Hang condition detected
ERROR: DMA failed
Address ffecf001
Expected 1
Observed 0

scsi selftest failed. Return code = -1

ok

7-52
 {Adjust/Replace}{Production}{KodakServiceSup ort}

PERIODIC MAINTENANCE
for the Codonics NP/EP1600 Series Imagers

Important
Use qualified personnel to service this equipment.
 This equipment includes parts and assemblies sensitive to damage from electrostatic
discharge. Use caution to prevent damage during all service procedures.

Table of Contents
Description Page

Introduction/Cleaning Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Cleaning the THERMAL HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Cleaning the CHUTE and ROLLER AY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Cleaning the PICKER AY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Cleaning the SIDE WALLS/RAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Cleaning the CONTROLLER ENCLOSURE AND DRAWER AY/CAVITY 8-11

Part Number 907-068-001.01

Section 1: Introduction/Cleaning Materials

Important
For the PRINTER to operate correctly, you must do the periodic maintenance procedure.
For references on image quality, see the procedure for Image Quality in the DIAGNOSTICS.

Do this procedure when the PRINTER has:

• continual contamination problems
• scratches or artifacts on the prints

The materials necessary to do the maintenance procedures include:

• 99% ALCOHOL PAD
• 70% ALCOHOL PAD
• ADJUSTMENTS AND REPLACEMENTS
• DIAGNOSTICS

8-3
Section 2: Maintenance Procedures

Cleaning the THERMAL HEAD

Warning
Dangerous Voltage
[1] De-energize and disconnect the PRINTER.

DOOR
THERMAL HEAD

A087_0154BCB
A087_0154BC

[2] Open and lift the DOOR.

[3] Locate the THERMAL HEAD.
[4] Clean the THERMAL HEAD. Use:
• DEIONIZED WATER PAD
• 99% ALCOHOL PAD

RIBBON TAKE-UP SPOOL

RIBBON

RIBBON SUPPLY SPOOL

A087_4082BCB
A087_4082BC

Caution
Prevent contamination. Do not touch the RIBBON.
[5] Remove the RIBBON.
[6] Place the DONOR TAKE-UP SPOOL and the DONOR SUPPLY SPOOL with the ends in the up position on
a surface that is not contaminated.

8-4
 THERMAL HEAD
SEALANT PROTECTING
NOSE PIECE HEATER LINE BEAD CIRCUIT ROW

ROD

HEATER LINE
BEAD

SEALANT PROTECTING
CIRCUIT ROW

THERMAL HEAD: right side

NOSE PIECE

HEATER LINE
BEAD

SEALANT PROTECTING
CIRCUIT ROW
CIRCUIT COVER

A087_0156EC
A087_0156ECB

8-5
 Caution
Prevent damage:
• do not touch the SEALANT PROTECTING CIRCUIT ROW below the HEATER LINE BEAD
• do not press on the CIRCUIT COVER
[7] Check for contamination on the HEATER LINE BEAD.
[8] To clean the HEATER LINE BEAD:
(a) Use the DEIONIZED WATER PAD a minimum of 4 times in 1 direction the length of the BEAD.
(b) Wait 2 minutes for the BEAD to dry.
(c) Use the 99% ALCOHOL PAD a minimum of 4 times in 1 direction the length of the BEAD.
(d) Wait 2 minutes for the BEAD to dry.
[9] Using the DEIONIZED WATER PAD and the 99% ALCOHOL PAD, clean:
• NOSE PIECE
• ROD
[10] Install the RIBBON.
[11] Close the DOOR.

Warning
Dangerous Voltage
[12] Connect and energize the PRINTER.
[13] Make a test print to check that the artifacts are removed.
[14] If the artifacts are not removed:
• check the HEATER LINE BEAD with light and magnification.
• do Step 8 again.

8-6
Cleaning the CHUTE and ROLLER AY

GUIDE BAR

CAM SHAFT COVER

PINCH ROLLER

CAPSTAN ROLLER

PLATEN ROLLER
A087_1501BCA
CHUTE A087_1501BC

Warning
Dangerous Voltage
[1] De-energize the PRINTER.
[2] Remove the ENCASEMENT. See the ADJUSTMENTS AND REPLACEMENTS.
[3] Using the DEIONIZED WATER PAD and the 70% ALCOHOL PAD, clean:
• GUIDE BAR
• CHUTE
• PINCH ROLLER
• CAPSTAN ROLLER
• PLATEN ROLLER
• CAM SHAFT COVER
[4] Install the ENCASEMENT. See the ADJUSTMENTS AND REPLACEMENTS.

8-7
Cleaning the PICKER AYSSEMBLY

PICKER WHEELS

PICKER AY A087_0173BCB
A087_0173BC

Warning
Dangerous Voltage
[1] De-energize the PRINTER.
[2] Clean:
• all metal parts of the PICKER AY - use the 70% ALCOHOL PAD
• PICKER WHEELS - use the DEIONIZED WATER PAD

8-8
Cleaning the SIDE WALLS/RAILS (only when needed)

Warning
Dangerous Voltage
[1] De-energize the PRINTER.
[2] Remove the ROLLER AY. See the ADJUSTMENTS AND REPLACEMENTS.
[3] Clean the following parts. Use the 70% ALCOHOL PAD.
• DOOR AY
• LEFT SIDE WALL
• LEFT RAIL

[4] Clean the following parts. Use the 70% ALCOHOL PAD.
• RIGHT SIDE WALL
• RIGHT RAIL

8-9
 BASE ENCLOSURE REAR WALL

BASE ENCLOSURE
A087_0166HCC
A087_0166HC

[5] Clean the following parts. Use the 70 % ALCOHOL PAD.

• BASE ENCLOSURE REAR WALL
• BASE ENCLOSURE
[6] Install the ROLLER AY. See the ADJUSTMENTS AND REPLACEMENTS.

8-10
Cleaning the CONTROLLER ENCLOSURE AND DRAWER ASSEMBLY/CAVITY

Warning
Dangerous Voltage

[1] De-energize and disconnect the PRINTER.

[2] Open the CONTROLLER ENCLOSURE AND DRAWER AY. See the ADJUSTMENTS AND
REPLACEMENTS.
[3] Remove the RIBBON CABLE from the CONTROLLER BD.
[4] Disconnect CONNECTOR J12 from the CONTROLLER BD.
[5] Remove:
• STRAP from the POWER COVER
• CONNECTOR J2 from the POWER SUPPLY
• CONTROLLER ENCLOSURE AND DRAWER AY
[6] Use the ALCOHOL PAD to clean:
• CAVITY
• CONTROLLER ENCLOSURE AND DRAWER AY
[7] Install:
• CONTROLLER ENCLOSURE AND DRAWER AY
• STRAP
[8] Connect:
• CONNECTOR J2
• CONNECTOR J12
[9] Install the RIBBON CABLE.
[10] Close the CONTROLLER ENCLOSURE AND DRAWER AY.

8-11