02 Nov 2009
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Table of contents Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Lithium warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostics information ............................................................... 2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Service errors (8xx.xx / 9xx.xx’s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flatbed motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flatbed home position service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADF cover open service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADF streak service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print SE Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Code Revision Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UICC cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65 USB cable mount bracket removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66 Operator panel support removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-66 Display rotation support removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly 2: Assembly 3: Assembly 4: Assembly 5: Assembly 6: Assembly 7: Imaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Tray assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Frame . . . . . . . . . . .
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Notices and safety information The following laser notice labels may be affixed to this printer. Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1. Class I laser products are not considered to be hazardous.
Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1). Los productos láser de Clase I no se consideran peligrosos.
Laserilmoitus Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi. Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 7 mW:n galliumarsenidilaser ja toimii 655 - 675 nanometrin aallonpituuksilla.
Avís sobre el Làser Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1. Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li, nominalment de 7 mil.
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Lithium warning CAUTION This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery manufacturer’s instructions and local regulations. Safety information • The safety of this product is based on testing and approvals of the original design and specific • • • components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts.
Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und • • • bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components • • • específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui.
Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General information contains a general description of the printer and the maintenance approach used to 2. 3. 4. 5. 6. 7. repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed. Diagnostic information contains an error indicator table, symptom tables, and service checks used to isolate failing field replaceable units (FRUs).
1. General information The Dell 3333dn/3335dn MFPs are monochrome multifunction laser printers designed for single users or small workgroups. The 3333dn/3335dn MFPs allow users to print, copy, scan, and fax documents. n A4, 25ppmMFPs. on legal). This book contains information on the 3333dn/3335dn Maintenance approach The diagnostic information in this manual leads to the correct field replaceable unit (FRU) or part.
Print engine specifications Memory Item X463, X464 / 3333dn, 3335dn X466 Standard memory 128MB 128MB Maximum memory 640MB 640MB 128MB DDR SDRAM unbuffered DIMMS ✔ ✔ 256MB DDR SDRAM unbuffered DIMMS ✔ ✔ 512MB DDR SDRAM unbuffered DIMMS ✔ ✔ 256 MB via flash memory card ✔ ✔ Optional font cards (DBCS) ✔ ✔ ISP (INA) slot 1 1 Memory slots 1 1 Flash memory/option card 2¹ 2¹ Optional memory Optional flash memory Option slots ¹ Both slots are active for either a 256MB Flash memory
Environment Specified operating environment Operating temperature range - 16 to 32 degrees C (60 to 90 degrees F Humidity - 8 to 80% Relative humidity Altitude 0 to 3048 meters (10,000 ft) Dimensions Height - 23.3 in (297mm) Width - 20.87 in (530 mm) Depth - 15.5 in (394 mm) w/ input tray set to letter, 16.14 in (410 mm) w/ input tray set to legal.
Media trays and supply capacity Item X463, X464 / 3333dn, 3335dn X466 Available input trays Integrated 250-sheet tray ✔ ✔ 50-sheet MP feeder ✔ ✔ 1-sheet manual feed slot x x 250-sheet drawer ✔ ✔ 550-sheet drawer ✔ ✔ Optional input sources Maximum input sheet capacity 850 850 (excluding envelopes) (excluding envelopes) Integrated Integrated x x ✔ ✔ 7,000 standard pages SWE¹ 3,500 standard pages ¹ 7,000 standard pages SWE¹ High toner cartridge 9,000 standard pages¹ 9,000 stan
Types of print media Note: Ensure trays are properly loaded. Never mix media types within a tray.
Media guidelines Paper characteristics The following paper characteristics affect print quality and reliability. Consider these characteristics when evaluating new paper stock. • Weight—The printer can automatically feed paper weights from 60 to 176 g/m2 (16 to 47 lb bond) grain • • • • • long. Paper lighter than 75 g/m 2 (20 lb) might not be stiff enough to feed properly, causing jams. For best performance, use 80 g/m2 (21 lb bond) grain long paper. For paper smaller than 182 x 257 mm (7.2 x 10.1 in.
Selecting paper Using appropriate paper prevents jams and helps ensure trouble-free printing. To help avoid jams and poor print quality: • Always use new, undamaged paper. • Before loading paper, know the recommended print side of the paper. This information is usually indicated on the paper package. • Do not use paper that has been cut or trimmed by hand. • Do not mix paper sizes, types, or weights in the same source; mixing results in jams.
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Digital imaging specifications General specifications ADF Scan speed Simplex ADF - Up to 25 ppm Duplex ADF - Up to 35 ppm (page sides) ADF Document handling ADF input capacity - 50 sheets. ADF output capacity - 50 sheets. ADF document width - 4.9’’ (125mm) to 8.5’’ (216mm) ADF document length - 5’’ (127mm) to 14.0” (356mm) Resolution and color depth • Flatbed maximum optical resolution - 600 x 600 dpi (Mono), 600 x 300 dpi (Color), with final resolution of • • • • 300 x 300 dpi CDD 1200 dpi, and 600 dpi.
Storage environments (unpacked) • Temperature - 0° to 40°C • Humidity - 5 to 80% relative humidity Tilt This device should operate within the stated parameters when it is level within 10mm from front to back and 10mm side to side.
Reduce / Enlarge -25% to 400% (Copy only) General information 1-11
Fax specifications Phone network connectivity Phone networks types supported PSTN or analog PABX (RJ-11) ITU COMPATIBILITY Standard Resolution Fine Superfine Ultrafine Coding Group 3/ECM 8 x 3.85 pels/mm (200X100dpi) (204x98) 8 x 7.7 pels/mm (200X200dpi) (204x196) 11.8 x 11.8 pels/mm (300x300 dpi) (204x391) 15.7 x 15.7 pels/mm (600x600 dpi) (612x587) ITU T.4 and T.6 (MH, MR, MMR, JPEG) Modem speed V.34 2,400-33,600 BPS, V.17 7,200-14,400 BPS, V.27 2,400-4,800 BPS, V.
Tools The removal and adjustment procedures require the following tools and equipment: • • • • • Spring hook Needle nose pliers Volt-ohmmeter #1 and #2 Phillips screwdriver Slotted screwdriver General information 1-13
Acronyms ac ACM ADF AFE AIO APS ASIC BLDC BOR CCD CCFL CCW CDB CMYK CPU CRC CRU CSU CW DBCS dc DIMM DLE DRAM DVM ECC ECM EDO EEPROM ENA EOL EP EPROM ESD FB FD FRU FU GB GFI GHz HBP HCF HCIT HCOF HCPF HTML HV HVPS HVU Hz 1-14 Service Manual Alternating Current Autocompensator Mechanism (or paper feed) Automatic document feeder Analog front end All-In-One Automatic Paper Size Application Specific Integrated Circuit Brushless DC Motor Black Only Retract Charge-Couple Device Cold Cathode Fluorescent Lamp Coun
INTL ITC ITU K LAN LASER LCD LCM LD LED LEF LES LSU LV LVPS MB MDC MFD MFP MH MIF mm MMR MPF MR MROM MS NAND NVM NVRAM OCF OEM OHP OPC OPT PC PDF PICS PIN PIXEL PJL POR POST PPDS ppm PQET PRC PSC PSD PSO PWM RAM RFID RH International Internal Tray Card Image Transfer Unit Black (Key) Local area network Light amplification by stimulated emission of radiation Liquid crystal display Liquid Crystal Module Laser Diode Light emitting diode Long edge feed LXK Embedded Solution (applications) Laser Scanning Unit L
RIP ROM ROS RPM SCC SDRAM SEF SIMM SOL SOS SRAM TAR TPS TTM TVOC UAT UPR USB V V ac V dc VOIP VOM VTB XPS 1-16 Service Manual Raster image processor Read-only memory Read-only storage Revolutions Per Minute Scanner Control Card Synchronous Dynamic Random Access Memory Short edge feed Single Inline Memory Module Solenoid Start of scan Static random access memory Toner Add Roll Toner Patch Sensing Tandem Tray Module Total Volatile Organic Compound Universally Adjustable Tray Used Parts Return Universal Seri
2. Diagnostics information Start CAUTION: Unplug power from the printer before connecting or disconnecting any cable, assembly, or electronic card. This is a precaution for personal safety and to prevent damage to the printer. Use the service error code, user status message, user error message, symptom table, service checks, and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer.
Symptom tables POST symptom table Symptom Action The main motor, cooling fan, and fuser do not come on. See “Cover interlock switch service check” on page 2-37. POST completes, but the display does not come on. See “Operator panel service check” on page 2-43. Main motor does not come on. See “Main motor service check” on page 2-40. Fan does not come on. See “Cooling fan service check” on page 2-37. Fuser does not cycle. See “Fuser service check” on page 2-39. Fuser does not turn on and off.
Printer symptom table Symptom Action Touchscreen displays upside down Replace the display keypad. Fan noisy or fan not working. See “Cooling fan service check” on page 2-37. Fuser parts melted. See “LVPS/HVPS service check” on page 2-39. Toner not fused to the media. See“Fuser service check” on page 2-39 or “Solving print quality problems” on page 2-51. Paper jams. See “Paper feed service checks” on page 2-43. Main motor noisy or not moving. See “Main motor service check” on page 2-40.
Scan / fax / copy symptom table Symptom Action 840.xx scanner error Go to “840.xx service check” on page 2-55. ADF won’t duplex (Duplex ADF only) Go to “ADF Duplex service check” on page 2-62. ADF skew Go to “ADF feed errors service check” on page 2-61. Multiple pages feed into ADF Documents won’t feed into ADF Printer picks letter size paper on a legal size scan This is a symptom of a failed paper length sensor. Scanner makes buzzing noise on startup or during a scan.
Overview of the operator panel and menus 1 2 1 4 GHI 7 PQRS * 2 ABC 5 JKL 8 3 DEF 6 MNO 9 TUV WXYZ 0 # 3 4 5 8 7 6 The use of the buttons and the layout of the display panel are described in the following table. Item Description 1 Display 2 Keypad 1 4 GHI 7 PQRS * View scanning, copying, faxing, and printing options as well as status and error messages. Enter numbers or symbols on the display.
Item Description 5 Home 6 Start 7 Indicator light 8 Stop 2-6 Service Manual Press to return to the home screen. • Press to initiate the current job indicated on the display. • From the home screen, press to start a copy job with the default settings. • If pressed while a job is scanning, the button has no effect. Indicates the printer status: • Off—The power is off. • Blinking green—The printer is warming up, processing data, or printing. • Solid green—The printer is on, but idle.
Understanding the home screen After the printer is turned on and a short warm-up period occurs, the display shows the following basic screen which is referred to as the home screen. Use the home screen buttons to initiate an action such as copying, faxing, or scanning; to open the menu screen; or to respond to messages. 1 2 8 Ready Touch any button to begin.
Display item Description Held Jobs Lock Device Opens a screen containing all the held jobs This button appears on the screen when the printer is unlocked and Device Lockout Personal Identification Number (PIN) has been set. Touching this button opens a PIN entry screen. Entering the correct PIN locks the printer control panel (touch screen and hard buttons). This button appears on the screen when the printer is locked. The printer control panel buttons and shortcuts cannot be used while it appears.
Using the touch-screen buttons Note: Depending on your options and administrative setup, your screens and buttons may vary from those shown.
Button Function Right arrow Scrolls right Submit Saves a value as the new user default setting Submit Back Navigates back to the previous screen Other touch-screen buttons Button Function Down arrow Moves down to the next screen Up arrow Moves up to the next screen Unselected radio button This is an unselected radio button. The radio button is gray to show it is unselected. Selected radio button This is a selected radio button. The radio button is blue to show it is selected.
Button Function Cancel Jobs Opens the Cancel Jobs screen. The Cancel Jobs screen shows three headings: Print, Fax, and Network. The following items are available under the Print, Fax, and Network headings: Continue Cancel Select • Print job • Copy job • Fax profile • FTP • E-mail send Each heading has a list of jobs shown in a column under it which can show only three jobs per screen. Each job appears as a button which you can touch to access information about the job.
Diagram of the printer menus The diagram shows the menu index on the operator panel and the menus and items available under each menu. Not all menus or selections will be available in all situations. These are accessed through the driver.
Messages and error codes User attendance messages The printer control panel displays messages describing the current state of the printer and indicates possible printer problems that must be resolved. This topic provides a list of all printer messages, explains what they mean, and tells how to clear the messages. The following table lists the messages in alphanumerical order. A message can also be located using the index.
User status and attendance messages (Continued) User primary message Explanation Held jobs may not be restored (Insufficient Memory 37) This message is only posted once after the firmware has tried to restore all of the jobs on disk, regardless of the number of held jobs that were not restored. There are three versions of this IR, depending upon cause. IRHeldB occurs when the printer runs out of memory while attempting to restore jobs from disk.
User status and attendance messages (Continued) User primary message Load Manual Explanation Printer does not detect media meeting the description and in the single sheet feeder (manual feeder). The following actions can be taken: • Load paper and the job continues. • press Select ( ), and choose an alternate source for media. • Cancel the current job. Paper Changes Needed Change or load new media.
User status and attendance messages (Continued) User primary message 35 RES Save Off Deficient Memory Explanation This message displays when the printer lacks sufficient memory to enable Resource Save. This message usually indicates the user has allocated too much memory for one or more of the printer link buffers; however, modification of other printer settings which affect the amount of available memory may also create this condition.
User status and attendance messages (Continued) User primary message 39 Complex Page Explanation This message is displayed when a page is too complex to print. The following actions can be taken: • press Select ( ) to clear the message and continue printing. The job may not print correctly. • Simplify the print job. • press Menus ( ) to access the Busy/Waiting Menu. The following functions may be available: - Cancel Job - Reset Printer Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu.
User status and attendance messages (Continued) User primary message Explanation 56 Serial Port disabled This error displays when data is sent to the printer across an serial port, but the port has been disabled. Once this message displays, reporting of further errors is suppressed until the menus are entered, or the printer is reset. 56 Standard USB Port Disabled This message may appear when data is sent to the printer across a USB port, but the port is disabled.
User status and attendance messages (Continued) User primary message 1565 Emul Error Load Emul Option Explanation This message is displayed when the DLE's version contained in the firmware card will not function with the printer code. The message will automatically clear in 30 seconds, and the DLE will be disabled. Other printer functions are not affected. The correct version of the DLE must be downloaded. Contact the second level support for the correct DLE version.
Cartridge error messages Error Description 30 Invalid refill 31 Missing or defective cartridge 32 Unsupported print cartridge Action Replace the cartridge. Paper jam error codes (200-series) Note: The Event log (See “EVENT LOG” on page 3-32) will list any of these errors that have occurred. Repeating jams or jam messages can be caused by any of the following: • • • • Faulty/contaminated pick solenoids or worn cams of the solenoids. Faulty/contaminated flags or springs. Debris in the paper path.
Error Description Action 200.13 The input sensor is covered when the media is not expected (media in machine during warm-up) Remove the toner cartridge/PC kit and inspect the input sensor flag. Replace the flag if necessary. 200.14 Trailing edge cleared manual feed, but did not successfully debounce the sensor. Potential causes are a small gap or a bouncy manual feed sensor. Remove the toner cartridge/PC kit.
Error Description 200.28 First writing line of a page at the developer nip, but laser servo cleanup is not complete. Likely pre staged media or a fast paper feed. Verify that the media is approved. Inspect the wear strips in the tray, and replace if they are worn. 200.29 Printhead drive control out of range due to an external event beyond what the control is designed to handle. Probable causes: ESD or noise on hsync signal. Check the cable routing for the printhead.
Error Description 201.25 Exit sensor never made by leading edge of media when feeding out the media that was detected during warm-up. 201.26 Page at fuser nip before fuser started ramping toward desired temperature. Indicates code may be receiving more interrupts than intended 201.27 Page at fuser nip before fuser reached acceptable operating temperature. Page arrived at fuser earlier than expected, so it was probably staged prematurely. 202.00 Paper jam around exit sensor.
Error Description 231.00 Duplex jam while reversing into the device 231.01 Duplex sensor never made by leading edge reversing into the duplex. 231.02 Bouncy duplex sensor never made. 233.00 Duplex jam while picking from the device 233.01 Page in duplex never picked. 233.02 Feed error picking from the duplex. 233.03 Paper never reached the input sensor, but was detected at the manual feed sensor.
Error Description Action 251.00 Paper jam near the manual feeder. Inspect the pick roller on the MPF or the rollers on the manual feed. If the MPF pick roller is damaged or worn, then replace the MPF. For a printer with a manual feed only (no MPF), clean the roller. 251.10 Second pick attempt failed from manual feeder. 251.11 Failed to feed from manual feeder. Pages in the paper path have been flushed to the output bin. 251.
Service error codes Service error codes are generally non-recoverable except in an intermittent condition when the printer can be put into POR to temporarily recover from the error condition. Error Description Action 8XX Scanner service errors 840.01 Scanner disabled The scanner is disabled and can’t be used. Enter the configuration menu, and re-enable the scanner module. Go to “840.xx service check” on page 2-55 840.02 Scanner auto disabled The scanner is disabled and can’t be used.
Error Description Rear scan module cable failure or SCC card failure 845.01 Action CCD channel failure. Check each channel(mono, R, G, B) for identical values indicating bad cable and/or SCC card. Excessive noise test for the dark data indicating some sort of CCD or analog electronics issue on that channel or channels. Go to “CCD service check” on page 2-57 845.02 845.03 845.
Error Description HD/Config ID Mismatch 849.01 Action A device has a hard drive installed, but its Configuration ID indicates that a hard drive shouldn’t be present. Engine software service errors 900.xx RIP software error Turn off MFP for 10 seconds and restart. If error re-occurs, replace controller board. 902.xx Engine software error Replace the controller board. See “Controller board service check” on page 2-35 903.xx Paperport link driver error 904.xx Interface violation by RIP 905.
Error Description Action Toner service errors 929.00 Toner sensor error 929.01 No home window 929.02 No sensor transition (closed) 929.03 No sensor transition (open) Remove the toner cartridge, and shake it Try a different toner cartridge, if possible. If the error persists, then replace the toner level sensor. See “Toner level sensor removal” on page 4-79. Printhead service errors 930.xx Wrong printhead installed 931.xx No first hsync Replace the printhead.
Error Description 954.xx NVRAM chip failure with system part. 955.xx The code ROM or NAND flash failed the Cyclic Redundancy Check or the NAND experienced an uncorrectible multi-bit failure. 956.00 RIP card failure: processor failure 956.01 Processor overtemp 957.xx RIP card failure: ASIC failure 958.xx Printer has performed more than 100 “shift and reflash” operations as a result of ECC bit corrections Action Replace the controller board. See “Controller board service check” on page 2-35.
Error Description 975.xx Unrecognizable network 976.xx Unrecoverable software error in network port 978.xx Bad checksum while programming network port 979.xx Flash parts failed while programing network port Action Call the next level of support. Other errors 980.xx Engine experiencing unreliable communication with the specified device 981.xx Engine protocol violation detected by the specified device 982.xx Communications error detected by the specified device 983.
Fax error log codes (Continued) Error code Description 7XX Error occurred when sending a frame. • Check line quality. • Adjust ‘Transmit Level’. • Select a lower ‘Max Speed’ value under Fax Send settings. 800 Received EOT unexpectedly from • If error persists disable V34 modulation scheme. the modem in V34 mode. 802 Too many timeouts occurred Action • If error persists disable ECM mode. during ECM reception.
Fax error log codes (Continued) Error code Description Action 813 Timeout occurred after waiting too long to receive a good frame. • Adjust “Receive Threshold”. 814 Tried too many times at selected speed using V34 modulation scheme. • Adjust ‘Transmit Level’. • Adjust to a lower modulation scheme. 815 Fax transmission was interrupted due to power failure. • Troubleshoot MFP if error persists. See “Modem / fax card service check” on page 2-63.
Fax error log codes (Continued) Error code Description 888 Failure to transmit training successfully at 2400 bps in V27 terminal modulation scheme. • Adjust “Transmit Level”. • Check line quality. 889 Failed to connect at the minimum speed supported by the MFP. • Adjust “Transmit Level”. • Incompatible connection. 88A Failed to connect using V.34 modulation scheme. • Check line quality. • Adjust to a lower modulation scheme. • Adjust Transmit Level Receive Threshold values.
Service checks Service checks which involve measuring voltages on the LVPS/HVPS (low voltage power supply/ high voltage power supply board) should be performed with the printer positioned on its back side. Note: When making voltage readings, always use frame ground unless another ground is specified. See the wiring diagram in the back of the book for more information. Note: The controller board is located beneath the flatbed. To access the controller board, see “ADF unit removal” on page 4-85.
Engine board service check Engine board service check FRU Action Engine board assembly POST (Power-On Self Test) Note: The printer should complete POST in approximately 45 seconds. If the printer fails to display lights or activate the drive motor, fuser, or fan, then check the following order: 1. Power to the LVPS/HVPS 2. Power from the LVPS/HVPS to the engine board. 3. Cables are plugged in correctly, especially for the operator panel. The printer will not power-up without a functioning operator panel.
Card reader service check Note: The card reader cover will need to be removed, and the op panel keyboard assembly will need to be removed to verify the cable connections. See “Card reader cable removal” on page 4-7. FRU Action Card reader cable Verify that the card reader USB cable is properly connected to the card reader card. Make sure the card reader USB cable plug is properly seated at J2 (controller board).
Dead machine service check CAUTION: Check the AC line voltage. The voltage should be within the following limits: • 100 V ac (volts alternating current)-127 V ac for the 110 V printer • 200 V ac-240 V ac for the 220 V printer FRU Action Unplug the printer. Remove the LVPS/HVPS, and check the fuses for continuity. LVPS/HVPS • If open, then replace the LVPS/HVPS. • If not open, then check the switch continuity across its conductors with the switch on. Turn the switch off.
Fuser service check When toner is partially fused to the media, it is usually caused by low fuser temperature. The line voltage to the printer must be within the following limits: • 100 V ac-127 V ac for the 110 V model printer • 200 V ac-240 V ac for the 220 V model printer This printer uses a belt fuser and therefore does not have a lamp. Fuser service check FRU Action Unplug the printer, and disconnect the fuser cable plug from the LVPS/HVPS board connector at CN102.
Main motor service check FRU Action Turn off the printer, and unplug the main motor cable at J17 on the engine board. Turn on the printer, and check for the following voltages at J17: Main motor gear drive Main motor cable LVPS/HVPS Engine board Warning: Do not replace the engine board and controller board at the same time. Each board contains the printer settings. When either of these boards is new, it obtains the settings from the other board.
Networking service check Note: Before starting this service check, print out the network setup page. This page is found under Menu Reports - Network Setup Page. Consult the network administrator to verify that the physical and wireless network settings displayed on the network settings page for the device are properly configured. If a wireless network is used, verify that the printer is in range of the host computer or wireless access point, and there is no electronic interference.
Step 13 Questions / actions Try using a different ethernet cable. Yes No Problem resolved Go to step 14. Replace the controller board. Go to “Controller board removal” on page 4-16 Contact the network administrator. Did this remedy the situation? 14 Have the network administrator check the network drop for activity. Is the drop functioning properly? 15 Is the printer on the same wireless network as the other devices? Go to step 17. Go to step 16.
Operator panel service check Inspect the operator panel cable for damage. Make sure the cable is plugged in securely. Run POST, and check each light for proper operation. See “Power–On Self Test (POST) sequence” on page 2-1.
Media picks but stops halfway through the printer FRU Action Input/duplex sensors (under print cartridge assembly) Input sensor (manual) Check the stairway cables to verify they are properly connected to the engine board at connectors J500 and J501, and on the controller board at connectors J26 and J27. Stairway cables If they are properly connected verify continuity on both cables. If this fails replace the cables. Make sure the input sensors are working properly.
FRU Action Engine board P/U and manual feed solenoid ASM Check the stairway cables to verify they are properly connected to the engine board at connectors J500 and J501, and on the controller board at connectors J26 and J27. If they are properly connected verify continuity on both cables. If this fails replace the cables. Disconnect the solenoid cable at J25 on the engine board and measure the resistance across cable pins 1 and 2. • The resistance should be approximately 70 ohms.
Option card service check Option card service check FRU Action Option cards Card Controller board Remove all the option cards from the device. Option card connection cable Install each card individually. Restart the MFP after each card is installed. Warning: Do not replace the engine board and controller board at the same time. Each board contains the printer settings. When either of these boards is new, it obtains the settings from the other board.
Print quality service checks Note: Ensure the cover closes tightly. A gap in the opening may allow light to expose the photoconductor, resulting in a ‘dirty’ print. Extreme environmental conditions, temperatures, and humidity will affect the print quality. Using print quality test pages To help isolate print quality problems, like streaking, print test pages using the print quality test pages. To print the print quality test pages: 1. Enter Configuration Menu. a. Turn off the printer. b.
Black page Note: Incorrect laser exposure or incorrect charging of the photoconductor causes an all black page. Always verify the same results from a different print cartridge assembly and developer before proceeding. FRU Action Toner electrodes (not a FRU) Check the three rearward electrodes below the toner cartridge assembly for contamination, damage, or a short to ground. Correct as necessary.
Partial blank image/white spots (no repeating pattern) FRU Action Toner cartridge (not a FRU) Remove the toner cartridge assembly, and gently shake the assembly to evenly distribute the toner. Check to make sure that the laser light path is not blocked. If toner cartridge is low, then try a new one. Paper (not a FRU) Make sure recommended media is being used. Check the media settings in the printer driver. A heavier media may require higher heat to properly fuse.
Light print FRU Action Toner cartridge (not a FRU) Make sure the toner cartridge and PC Kit are installed correctly and that the toner cartridge is not low on toner. If the problem continues, then install a new toner cartridge. Recheck condition before replacing PC Kit, if necessary. Check the transfer roll for signs of toner buildup and contamination. Inspect the HVPS contact (transfer roll) for contamination. Verify the high voltage cable is plugged into the LVPS/HVPS.
Solving print quality problems Note: Refer to the print defects guide at the end of the manual for repeating defects. Print quality problems Problem Cause / action Light or blurred characters. Light print See “Light print” on page 2-50. The toner cartridge may be getting low on toner: • • • • Remove the toner cartridge and print cartridge assembly. Shake it from side to side to redistribute the toner. Reinstall it, and recheck for condition.
Print quality problems (Continued) Problem Cause / action Toner smears or rubs off the page. • Toner is not being fused to the paper. Replace the fuser. • Change the media texture setting in the driver. If special media is being used, such as card stock or labels, then be sure to select the correct media type. • Try a different kind of paper. Paper designed for copiers gives the best quality fusing. The print is getting light, but the printer has not indicated it is low on toner.
Print quality problems (Continued) Problem Cause / action The printer is on and indicates ready, but nothing prints. • Make sure the parallel or USB cable is not damaged and is firmly plugged into the connector on the back of the printer. • Make sure the toner cartridge assembly is installed properly. • Print the menu page using the Menu Settings Page in the Reports Menu. - If a menu settings page cannot be printed, then contact the next level of support.
Print quality problems (Continued) Problem Cause / action Unexpected characters print, or characters are missing. • • • • Ensure correct printer driver is being used. Select hex trace mode to determine what the problem is. Restore factory defaults. Make sure the parallel cable or USB cable is firmly plugged in at the back of the printer. Jobs are not printing, and an error message is displayed. • The printer is waiting for an appropriate command.
Tray 2 service check FRU Action Tray 2 Turn the printer off. Separate the printer from Tray 2. Turn the printer on and check the voltages on connector J28 on the engine board. Pins 1, 4: 3.3 V Pin 2: 24 V Pin 6: Ground If the voltages are incorrect, then replace the engine board. If the voltages are correct, then try using Tray 2 again. If the printer error persists, then replace Tray 2. 840.xx service check Step Questions / actions 1 POR the machine into configuration mode.
Step Questions / actions 6 Replace the ADF cable. POR the machine into configuration mode. Go to the disable scanner menu item. See “Disable Scanner” on page 3-36. Touch “Enable ADF/FB -Enabled and press Submit to save the change. POR the MFP to operating mode. Try running a copy from the ADF and flatbed. Yes No Go to step 7. Stop. Problem solved. Go to step 8. Stop. Problem solved. Go to step 10. Go to step 9. Go to step 10. Stop Problem solved. Go to step 11 Stop. Problem solved.
Black or blank page copy service check Step Questions / actions Yes No 1 Print a menu page, or a page from the host. Is the page black? See “Black page” on page 2-48 Go to step 2. 2 Is the copy an ADF scan? Go to step 4. Go to step 3. 3 Run a flatbed copy. Go to step 5 Go to step 4 Is it blank or black? 4 Did the sheet feed into the ADF? Go to step 6. Go to step 5. 5 Is the CCD ribbon cable properly connected to J30 on the controller board? Go to step 6.
Flatbed home position service check Step Questions / actions Yes No 1 POR the MFP. Does the CCD move and return to the home position? Problem solved. Go to step 2. 2 Perform the home position sensor test. Go to “Scanner Tests” on page 3-25. Go to step 3. Go to step 5. Go to step 4. Properly connect the cable. Is the sensor working properly? 3 Check J28 on the controller board for proper connection. Is it connected properly? 4 Check pin 1 in J28 for voltage.
ADF cover open service check Step Questions / actions Yes No 1 Is the ADF cover properly closed Go to step 3. Go to step 2. 2 Close the ADF cover. Issue resolved Go to step 3. Does the problem go away? 3 Perform the ADF cover open sensor test. Go to “Scanner Tests” on page 3-25. Does the sensor work properly. Go to step 4 Go to step 8. 4 On the bottom of the ADF cover, inspect the ADF cover closed sensor actuator. Does it move freely? Go to step 6. Go to step 5.
ADF paper jam service check Note: This service check should be used if the paper feeds and jams in the ADF. If the paper is not feeding into the ADF see “ADF feed errors service check” on page 2-61. Step Questions / actions Yes No 1 If the ADF is multi-feeding, check for dirt on the ADF separator pad and ADF separator rollers. Are they dirty? Clean them with a lint free cloth and isopropyl alcohol. Replace the separator pad and ADF pick roll.
ADF feed errors service check Step Questions / actions Yes No 1 If the ADF is multi-feeding, check for dirt on the ADF separator pad and ADF separator rollers. Are they dirty? Clean them with a lint free cloth and isopropyl alcohol. Replace the separator pad and ADF pick roll. 2 If the paper is skewing when it is fed into the ADF, check the paper guide width. Is it set correctly? Go to step 3. Set the paper guides so they contact the edges of the paper.
ADF Duplex service check Step Questions / actions 1 Perform sensor 1, and sensor 2 sensor tests. Go to “Scanner Tests” on page 3-25. Yes No Go to step 2. Go to step 3. Go to step 3. Clean the actuators. If any actuators on the ADF are broken, replace the ADF unit. Go to “Duplex ADF removal” on page 4-63 Are the sensors working properly? 2 Check the ADF sensor actuators to see if they are dirty or jamming. Are the actuators ok? 3 Check all the connections on the ADF relay card.
Modem / fax card service check Step Questions / actions Yes No 1 Is the phone line properly connected to the modem card and the wall jack? Go to step 3. Go to step 2. 2 Properly connect the phone line to the modem card and wall jack. Problem resolved. Go to step 3. Go to step 5. Go to step 4. Problem resolved. Go to step 5. Did this fix the problem? 3 Test the phone line’s ability to send and receive calls.
Fax transmission service check Note: Before performing this service check, verify that the correct country code for the MFP is selected. This setting must match the country in which the MFP is used to transmit and receive faxes. If the setting is wrong, the modem settings can be changed in the Fax/SE menu. See step 14. These settings should only be changed with guidance from your second-level support.
Step Questions / actions 15 Adjust the “Transmit Level” setting in the SE menu. Press **411 to enter the SE menu, enter Modem settings, and select “Transmit Level”. Yes Stop. Problem resolved. No Go to your second-level of support. See “Escalating a fax issue to second-level support” on page 2-68. Test by adjusting the transmitted signal strength by decreasing/increasing the ‘Transmit Level’ setting in steps of 1db.
Fax reception service check Step Questions / actions Yes No 1 Is the phone line properly connected to the modem card and the wall jack? Go to step 3. Go to step 2. 2 Properly connect the phone line to the modem card and wall jack. Problem resolved. Go to step 3. Go to step 4. Go to step 6. Go to 7. Go to step 5. Go to step 7. Go to step 6. Problem resolved. Go to step 7. Go to step 9. Go to step 8. Problem resolved. Go to step 9. Did this fix the problem? 3 Check for a dial tone.
Step Questions / actions 17 Go to the Administrator menu. Enter the Fax settings - Analog Fax Settings submenu. Yes No Go to step 18. Go to step 19. Problem resolved. Go to step 19. Problem resolved Go to step 20. Problem resolved. Contact your second-level of support. See “Escalating a fax issue to second-level support” on page 2-68. Verify the remote device number is not in the Banned Fax List user setting.
Escalating a fax issue to second-level support Before contacting the second-level support, go to the SE menu on the MFP.and generate a Fax error file. This file contains machine settings information and debug information that will help second-level support determine the cause of a failure. To generate the fax error file, perform the following steps: 1. In a Web browser, type http://MFP ip address/se. 2. The MFP’s SE menu page will display. Click the “Dump Job History” link. The following displays: 3. 4.
3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer. Configuration Menu Diagnostics Mode 1. Turn off the printer. 2. Press and hold 2 and 6. 3. Turn on the printer. 4. Release the buttons after 10 seconds.
Configuration menu (CONFIG MENU) Available menus Maintenance Count Value See “Maintenance Count Value (Maint Cnt Value)” on page 3-3. Reset Maintenance Count See “Reset Maintenance Counter” on page 3-3. Reset Photoconductor Maintenance Count See “Reset Photoconductor Maintenance Counter (Reset PC Cnt)” on page 3-4. USB Scan to Local See “USB Scan to Local” on page 3-4. Print Quality Pages See “Print Quality Pages” on page 3-4. Reports See “Reports” on page 3-32.
Maintenance Count Value (Maint Cnt Value) This setting enables you to view the current maintenance count value of each maintenance kit. After selecting this item, you can choose a specific kit in order to view its current maintenance count value. To return to the Configuration Menu, press Back. All other control panel keys are ignored.
Reset Photoconductor Maintenance Counter (Reset PC Cnt) This setting resets the photoconductor kit page counter and clears any warnings or photoconductor exhausted messages. This operation should be performed only after a new photoconductor unit has been installed. USB Scan to Local USB Scan to Local enumerates a USB simple device or USB composite device. In the off position the simple USB device is enumerated: in the on position, the composite USB device is enumerated. To change this setting: 1.
To change the value of this setting: 1. Touch Panel Menus from the Configuration Menu. [setting's current value] screen. 2. Touch or to scroll through the setting's other possible values. 3. Touch Back to cancel and return to the Configuration Menu. 4. Touch Submit to save the change. appears on the touch- PPDS Emulation The value of the PPDS Emulation menu item determines if a device can recognize and use the PPDS datastream.
Factory Defaults Warning: This operation cannot be undone. This setting enables you to restore all of the printer’s settings to the base printer settings, the network settings, or to remove all LXK Embedded Solutions (LES) applications. To restore the Factory Default settings: 1. 2. 3. 4. Touch Factory Defaults from the Configuration Menu. Touch Restore Base to restore all non-critical base printer NVRAM settings. Touch Restore Network to restore all network NVRAM settings.
Num Pad Job Assist This setting determines if a user can configure and initiate a job using the panels hard buttons. To change this setting: 1. Touch Num Pad Job Assist from the Configuration Menu. touch-screen. 2. Touch or . The settings are On or Off. 3. Touch Submit to save the change. [setting's current value] appears on the Format Fax Storage This setting enables you to format the non-volatile storage used for storing faxes. To change this setting: 1.
To adjust the flatbed edge erase setting, perform the following steps: 1. Touch FB Edge Erase from the Configuration Menu. [setting's current value] touch-screen. 2. Touch to increase the value or to decrease the value. 3. Touch Submit to save the change. 4. Touch Back to cancel and return to the Configuration Menu. appears on the Scanner Manual Registration This item is used to manually register the flatbed and ADF on the MFP’s scanner unit.
Disable Scanner This menu item is used to disable the MFP scanner if it is malfunctioning. The MFP must be powered off and on for the new settings to take effect. To change this setting: 1. Touch Disable Scanner from the Configuration Menu. 2. Touch or to scroll through the setting's other possible values. The settings are Enable, Disable, ADF disable. 3. To save the setting's new value, touch Submit.
Jobs on Disk Jobs On Disk allows you to delete buffered jobs saved on the disk. To delete jobs saved on the disk: 1. Touch Jobs On Disk from the Configuration Menu. 2. Touch to decrease the setting's value; touch to increase the setting's value. 3. Touch Back to cancel and return to the Configuration Menu. Disk Encryption This setting determines if the printer encrypts the information that it writes to the hard disk. The values are Disable and Enable.
The following graphic appears when the formatting process is selected: Formatting Disk 1/2 0% DO NOT POWER OFF The panel provides many progress indicators during the two-stage process. • 1/2 indicates that the process is currently in the first stage. • 0% indicates the progress of the current stage of the process. • The progress bar indicates the overall completion of the entire process by filling in throughout each separate stage.
When the first stage of either process completes, the printer displays either of the following graphics depending on the process selected and then begins the second stage of the process: Encrypting Disk 2/2 0% DO NOT POWER OFF Formatting Disk 2/2 0% DO NOT POWER OFF The entire process is complete when the progress bar appears completely shaded and the percentage indicator shows 100%. After completion, the panel returns to Disk Encryption.
Wipe Disk This setting provides you with a tool for erasing the contents of a disk. Warning: Wipe Disk removes a disk's data in such a way that it cannot be recovered. To change this setting: 1. Touch Wipe Disk from the Configuration Menu. Note: If an advanced password has been established, you must enter this password in order to change the setting. If no advanced password exists, you can establish one by using the keyboard that appears on the LCD. 2. Touch Wipe disk now. Contents will be lost.
When the first stage of the process completes, the printer displays the following graphic and then begins the second stage of the process: Wiping Disk 2/2 0% DO NOT POWER OFF The entire process is complete when the progress bar appears completely shaded and the percentage indicator shows 100%. The panel returns to the screen that shows the values for the Wipe Disk setting.
If Standby Mode is on, the printer begins functioning in Standby Mode when it remains idle for an amount of time. The Standby Mode enables the printer: • To consume less energy than when operating in normal mode but not as little as when operating in Power • Saver To return to the Ready state more quickly than when operating in Power Saver LES Applications This disables all installed LXK Embedded Solution applications. The default is Enabled. To change this setting: 1.
Clear Custom Status No values exist for this operation. Pressing Touch initiates this operation. to select Clear Custom Status from the Configuration Menu. Note: Executing this operation erases any strings that have been defined by the user for the default or alternate custom messages. USB Speed The USB Speed setting is used to set the throughput of the USB port on the MFP. The settings are Auto, which is the default, and Full. Full forces the USB port to tun at full speed.
Diagnostics menu Entering Diagnostics menu 1. Turn off the printer. 2. Press and hold 3 and 6. 3. Turn on the printer. 4. Release the buttons after ten seconds. Available tests The tests display on the operator panel in the order shown: Registration See “Registration (printer)” on page 3-18. Print tests See “Print Tests” on page 3-20. Hardware tests See “Hardware Tests” on page 3-21. Duplex tests See “Duplex Tests” on page 3-24. Input Tray Tests See “Input Tray Tests” on page 3-26.
Registration (printer) Print registration makes sure the printing is properly aligned on the page. REGISTRATION Top Margin 0 Bottom Margin 0 Left Margin 0 Right Margin 0 Quick Test Submit Back The settings available are: Description Value Direction of change Top Margin -25 to +25 A positive change moves the image down the page and increases the top margin. A negative change moves the image up and decreases the top margin. Each increment causes approximately 4 pels shift (at 600 dpi).
To set print registration: 1. Print the Quick Test page. a. Touch REGISTRATION from the Diagnostics Menu. b. Touch to select Quick Test. You may need to scroll to the next page. Retain this page to determine the changes you need to make to the margins settings. The diamonds in the margins should touch the margins of the page. 2. To change the value of any of the margin settings: • Touch to the right of the appropriate margin setting.
Print Tests This setting tests the printer’s ability to generate printed output from each of its installed input sources and to test the printer’s current print quality. Input sources The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options. The contents of the Print Test Page varies depending on the media installed in the selected input source.
Hardware Tests Select the following Hardware Tests from this menu: • • • • Panel Test Button Test DRAM Test USB HS Test Mode Panel Test This test automatically toggles each pixel of the touchscreen through every contrast level beginning with the darkest and on to the brightest. This test continues until you press Stop . Button Test The Button Test verifies the operation of the buttons on the operator panel. When you select Button Test, a diagram of the operator panel appears on the panel.
DRAM Test The purpose of this test is to check the validity of DRAM memory, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Test: 1. Touch to select DRAM Test from the menu. The message DRAM Test Testing… displays. Then the message Resetting Printer appears, and the power indicator light blinks red. 2. Turn the printer off and on. While the DRAM test executes, the power indicator blinks green.
USB HS Test Mode 1. Select USB HS Test Mode from HARDWARE TESTS. 2. Press until the appears next to the Port to be tested, and then press 3. Select the desired Test, and then press . Port Test Appears on the display Port 0 Test J Test K Test SEO NAK Test Packet Test Force Enabled USB High Speed Certification Testing... Port 1 Test J Test K Test SEO NAK Test Packet Test Force Enabled USB High Speed Certification Testing...
Duplex Tests Quick Test (duplex) This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the top margin on the back side of a duplex page. You can run one duplexed page (Single), or continue printing duplexed pages (Continuous) until Stop is pressed. For information about changing the margin, see “Top Margin (duplex)” on page 3-25. Note: Before you set the duplex top margin, be sure to set the registration. See “Registration (printer)” on page 3-18.
Top Margin (duplex) This setting controls the offset between the first scan line on the front of the duplex page and the first scan line on the back of the page. Therefore, be sure to set the top margin in REGISTRATION before setting the duplex top margin. See “Registration (printer)” on page 3-18. To set the Top Margin (duplex): 1. Print the Quick Test (duplex): a. Touch to select Quick Test from DUPLEX TESTS. b. Select Single. c.
3. Touch Back or press Stop to exit the test. Duplex Feed 1 This test feeds a blank sheet of paper to the duplex paper stop position 1. This test can be run using any of the supported paper sizes. To run the Duplex Feed 1 Test: 1. Touch to select Duplex Feed 1 from DUPLEX TESTS. The power indicator blinks while the paper is feeding, and the message Duplex Feed 1 Feeding… displays.
3. Select the sensor to test. Various sources have different combinations of sensors. See the table below: Tray sensor support by source Empty (Input tray empty sensor) Low (Input tray paper low sensor) Tray 1 X X Tray 2 X X Multipurpose tray X Envelope feeder X Source passThru (Input tray pass thru sensor) X [sensor selected]=Open displays. • Empty—Input tray empty sensor • Low—Input tray paper low sensor • passThru—Input tray pass thru sensor 4.
Base Sensor Test This test is used to determine if the sensors located inside the printer are working correctly. To run the Base Sensor Test: 1. Select BASE SENSOR TEST from the DIAGNOSTICS menu. The following sensors are listed: • • • • Input—Input sensor Exit—Output (exit) sensor NarrowMedia—Output (exit) sensor Front Door—Front door sensor 2. Manually actuate the sensors to verify that each sensor switches from Open to Closed. 3. Press Stop to exit the test.
3. Once the test is complete, the power indicator turns on solid, and either the message Disk Test/Clean Test Passed or Disk Test/Clean Failed appears. If the message indicates failure, the disk is unusable. PRINTER SETUP PRINTER SETUP Defaults US Printed Page Count 127 Permanent Page Count 127 Serial Number xxxxxxx Engine Setting 1 0 Engine Setting 2 0 Submit Back The triangles pointing up or down indicate whether there are additional menus.
The model name can only be viewed and cannot be changed. Configuration ID The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors. The configuration IDs are originally set at the factory when the printer is manufactured, however, the servicer may need to reset Configuration ID 1 or Configuration ID 2 whenever you replace the system board.
EP SETUP EP SETUP EP Defaults Fuser Temp Fuser Page Count Normal 127 Warm Up Time Transfer Medium Print Contrast Medium Submit Back The triangles pointing up or down indicate whether there are additional menus. Touch the up or down arrows to display these additional menus. Note: If you make changes, touch Submit to make the change effective. EP Defaults This setting is used to restore each printer setting listed in EP SETUP to its factory default value.
Touch Back to return to Diagnostics Menu. Transfer The transfer can be adjusted to Low, Medium, or High. The default setting is Medium. Touch Back to return to Diagnostics Menu. Print Contrast The print contrast setting controls the developer voltage offset. The print contrast can be adjusted to Low, Medium, or High. The default setting is Medium. Touch Back to return to Diagnostics Menu. Charge Roll The charge roll can be adjusted to Low, Medium, or High. The default setting is Medium.
Print Log Additional diagnostic information is available when you print the event log from Diagnostics Menu rather than Configuration Menu. The Event Log printed from Diagnostics Menu includes: • • • • Detailed printer information, including code versions Time and date stamps Page counts for most errors Additional debug information in some cases Dell 3333dn (s/n xxxxxxxxx) The printed event log can be faxed to Dell or your next level of support for verification or diagnosis.
Scanner Tests ASIC Test A pattern appears and ASIC Test Passed displays. If xxxxxx displays, the test was unsuccessful. Press Stop to return to the SCANNER TESTS menu. Feed Test To run the Scanner Feed test: 1. Touch to select Feed Test from the SCANNER TESTS menu. 2. The panel displays the setting's current value [setting's current value] Letter, Legal, or A4. 3. Touch START to begin. Running Flatbed… displays. Press 4 to exit the test. 4. Touch Back to return to the Diagnostics Menu. .
3. To test the paper present sensor, push back on the actuator (A). If the sensor is functioning, the 0 next to the P on the display will change to 1. A 4. To test the flatbed cover closed sensor, lift the flatbed cover. The 0 next to the F will change to 1. Also check the actuator (B) to ensure it is functiong properly.
5. To test scanner sensor 1 press on the tab (C). The 0 next to the 1 will change to 1 if the sensor is working properly. C B 6. To test scanner sensor 2 press on the tab (D). The 0 next to the 2 will change to 1 if the sensor is working properly. 7. To test the ADF cover open sensor, open the ADF top cover. Id the sensor is functioning properly the 0 next to the A will change to 1. B D 8. Press Stop 3-36 Service Manual to return to the SCANNER TESTS menu.
Exit Diagnostics Selecting EXIT DIAGNOSTICS exits the Diagnostics menu, and Resetting the Printer displays. The printer performs a POR, and the printer returns to normal mode.
Printhead assembly electronic adjustment Note: Before aligning the printhead electronically, first align the printhead mechanically, if needed. See “Printhead assembly mechanical adjustment” on page 3-39. 1. Enter the Diagnostics menu. See “Entering Diagnostics menu” on page 3-17. 2. Touch Registration to enter the Registration menu. 3. Touch Quick test to print the Quick test page. Quick Test page (sample only; use actual sheet) 4. In the Registration menu, select the right margin setting. 5.
7. Print the Quick Test page again and check that the darkest line in the center graph is equal to zero. If it is, then check to see if the left, top, and bottom margins are detected. If it is not, then repeat step 5. Note: The alignment of the left margin positions the black plane to the right or left. The alignment of the right margin does not alter the margins and should only be used to adjust the printhead.
7. If the grid lines of the right flap align below the corresponding lines on the left flap, then adjust the printhead clockwise relative to the printer, and recheck. (See the left side of the figure below.) If the grid lines of the left flap align below the corresponding lines of the right side, then adjust the printhead counterclockwise. (See the right side of the figure below.) 8. After obtaining a properly adjusted image on the paper, tighten all three screws.
SE Menu Note: This is not the Fax SE menu. To enter the Fax SE menu, press **411 from the Ready screen. Note: This menu should be used as directed by second-level support. Print SE Menus General Copyright - Displays copyright information.
Paper jams Avoiding jams Most paper jams can be avoided by correctly loading paper and specialty media in the printer. The following hints can help prevent paper jams: • Use only the recommended print media. • Do not overload the print media sources. Make sure the stack height does not exceed the maximum height indicated by the stack line on the labels in the sources. • Do not load wrinkled, creased, damp, or curled print media. • Flex, fan, and straighten print media before loading it.
Understanding jam numbers and locations The following illustration shows the areas of the MFP where jams occur. When paper jams occur, follow the instructions in this section.
Jam messages and their locations 200 and 201 paper jams CAUTION: Hot surface. The inside of the printer may be hot. To reduce the risk of injury from a hot component, allow the surface to cool before touching it. 1. Pull the tray completely out. 2. Remove the paper jam.
3. If the paper is not visible, open the front door and remove the photoconductor kit and toner cartridge. 4. Remove the jam. 5. If the paper is still not visible, open the rear door. 6. Remove the jam.
7. Close the rear door. 8. Reinsert the photoconductor kit and toner cartridge. 9. Close the front door. 10. Touch Continue. 202 paper jam Touch Status/Supplies to identify the location of the jam. If the paper is exiting the MFP into the exit bin, pull the paper out and touch Continue. If the paper is still in the paper path: 1. Open the rear door. 2. Remove the jammed paper. 3. Close the rear door. 4. Touch Continue. 231 paper jam CAUTION: Hot surface. The inside of the printer may be hot.
3. Remove the jam. 4. Close the rear door. 5. Close the front door. 6. Touch Continue.
233 paper jam 1. Remove the tray from the printer. 2. Locate the duplex release lever and pull it down to release the paper. 3. Insert the tray. 4. Touch Continue. If this does not clear the jam, perform the steps found in 231 paper jam. See “231 paper jam” on page 3-46. 234 paper jam This jam error indicates single or multiple jams in the duplex are of the MFP. Perform the steps in the following jam removal procedures: 231 paper jam. See “231 paper jam” on page 3-46. 233 paper jam.
235 paper jam 1. Gently pull the jammed media from the fuser. 2. Touch Continue. 240 - 249 paper jams 1. Touch Supply/Status to identify the jam location. 2. Remove the standard tray. 3. Remove any jammed paper. 4. Reinsert the tray, and touch Continue. 5. If the jam message remains, remove the optional tray.
6. Remove any jammed paper. 7. Reinsert the option tray, and touch Continue. 250 paper jam 1. Touch Supplies/Status to find the jam location. 2. Remove the media from the multipurpose feeder. 3. Remove the jammed media from the multipurpose feeder. 4. Flex and fan the media. 5. Reload the media into the multi purpose feeder. 6. Adjust the guides if needed. 7. Touch Continue.
251 paper jam If the media is visible from the front of the MFP, gently pull the media out of the multipurpose feeder. If the media is not visible, perform the following steps to clear the jam: 1. Open the front door, and remove the photoconductor kit and toner cartridge. 2. Lift the flap at the front of the MFP, and remove any jams. 3. Reinsert the photoconductor kit and toner cartridge.
4. Close the front door. 5. Touch Continue. 290-294 paper jams Clearing jams under the ADF cover 1. Remove all original documents from the ADF input tray. 2. Open the ADF cover. 3. Unlock the ADF separator roll.
4. Remove the ADF separator roll. 5. Remove the jammed media. 6. Reinstall the ADF separator roll.
7. Lock the ADF separator roll. 8. Close the ADF top cover. Clearing ADF jams under the flatbed cover. 1. Lift the flatbed cover, and remove the jammed media from the ADF. 2. Touch Continue.
Clearing jams in the duplex ADF 1. Remove the ADF input tray. 2. Pull out the jammed media by pulling on the bottom sheet. 3. Reinstall the ADF input tray. 4. Touch Continue.
3-56 Service Manual
4. Repair information Warning: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD).
Removal procedures • Remove the toner cartridge and media tray before removing other printer parts. The toner cartridge should • • • • 4-2 be protected from light while out of the printer. We recommend disconnecting all external cables from the printer to prevent damage during service. Unless otherwise stated, reinstall the parts in reverse order of removal. When reinstalling a part held with several screws, start all screws before final tightening.
ACM pick tire roller removal 1. Place the printer on its side. Note: Be careful to not mar the finish of the printer. 2. Open the duplex jam door just far enough to pull out the ACM pick tires. Warning: Open the duplex door only far enough to remove the ACM pick tires. If the door is opened too far, then it can become disengaged and interfere with the paper tray. The tray may go in but will not come out, and will render the printer non-serviceable. 3.
4. Remove the ACM pick tire roller (A). • If the left hub is gray, then disconnect the old right and left tire/hub assemblies from the ACM, and replace with the new right and left tire/hub assemblies. • If the left hub is black, then remove the old right and left tires from the ACM hubs, and replace with the new tires. Do not attempt to remove the hubs.
Card reader removal 1. 2. 3. 4. Remove the scanner front cover. See “Scanner front cover removal” on page 3-31. Remove the operator panel keypad assembly. See “Operator panel keypad removal” on page 4-62 Release the tabs on the rear of the operator panel display and tilt it upright. Remove the two screws (A) securing the card reader housing to the tub assembly. A 5. Disconnect the card reader cable from the card reader. 6. Remove the LED light tube (B) from the upper card reader cover. C B 7.
Upper and lower card reader cover removal 1. Remove the scanner front cover. See “Scanner front cover removal” on page 3-31. 2. Remove the card reader. See “Card reader removal” on page 4-5. 3. Remove the four screws (A) fastening the upper and lower card reader covers.
Card reader cable removal 1. 2. 3. 4. Remove the scanner front cover. See “Scanner front cover removal” on page 3-31. Remove the operator panel keypad assembly. See “Operator panel keypad removal” on page 4-62 Release the tabs on the rear of the operator panel display and tilt it upright. Disconnect the card reader cable (A) from the J2 USB port on the controller board. A 5. Remove the two screws (B) securing the card reader housing to the tub assembly. B 6.
Controller board removal CAUTION This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery manufacturer’s instructions and local regulations. Warning: • • • • 1. Always touch a ground before touching the board. Handle the board carefully by the edges. Never replace the operator panel and controller board without a successful POR in between.
4. Using a flatblade screwdriver, depress the kickstand release tab (B). B 5. While depressing the tab, lift the scanner assembly until it is fully vertical. Warning: To avoid damage to the rear frame assemblies, hold the ADF while raising the flatbed to the upright position, then lower the ADF, slowly a shown above. Note: A piece of tape, if available, can be used to hold the ADF in place. This is desired since less pressure is placed on the frame assemblies. 6. Carefully tilt the ADF down as shown.
11. Remove the seven screws (C) securing the controller board to the controller board cage. A C 12. Lift the controller board, and remove. Note: When installing the controller board, place the USB port screw first, and then place the controller board screws.
Controller board shield 1. Remove the two screws (A) securing the controller shield bracket to the controller board cage.
2. Remove the three screws (B) securing the top of the controller shield.
3. Loosen the three screws (C) on each side of the controller board cage. C C 4. Remove the controller board shield.
Controller board cage 1. Remove the controller board. See Go to “Controller board removal” on page 4-8. 2. Remove the five screws (A) which secure the controller board cage to the tub assembly. 3. Tilt the front of the cage up and remove it from the MFP. Controller board fan 1. Remove the operator panel display. See Go to “Operator panel display removal” on page 4-63. 2. Disconnect the controller board fan cable from J99 on the controller board. 3.
Engine board removal CAUTION This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery manufacturer’s instructions and local regulations. 1. Remove the right side cover. See Go to “Right side cover removal” on page 4-77. 2. Disconnect all the cables from the engine board. 3. Remove the three screws (A securing the engine board to the print engine frame. 4. Remove the engine board.
Cover open sensor 1. Remove the right side cover. Go to “Right side cover removal” on page 4-77. 2. Disconnect the cable from connector J11 on the controller board. 3. Use a #1 Phillips screwdriver to remove the screw (A) holding the sensor. A 4. Remove the cover open sensor.
Door mount removal 1. 2. 3. 4. 5. 6. Open the front cover. Remove the lower front cover. See “Lower front cover removal” on page 4-35. Remove the left side cover. See “Left side cover removal” on page 4-33. Remove the right side cover. See “Right side cover removal” on page 4-77. Remove the cable through the opening. Remove the three screws (A) from the right side of the printer.
7. Disconnect the fuser link (B). B C 8. Remove the three screws (C) from the left side of the printer. C 9. 4-18 Remove the door mounts.
Duplex removal 1. Remove the right side cover. See “Right side cover removal” on page 4-77. 2. Remove the LVPS/HVPS. See “LVPS/HVPS removal” on page 4-37. 3. Remove the three screws (A) from the shield. A 4. Remove the four screws (B) from the duplex.
5. Lift the duplex slightly, push to the left, and tilt to clear the right side of the printer. 6. Remove the duplex.
Duplex/main motor gear drive interface removal 1. 2. 3. 4. Remove the Remove the Remove the Remove the LVPS/HVPS. See “LVPS/HVPS removal” on page 4-37. duplex. See “Duplex removal” on page 4-19. main motor gear drive. See “Main motor gear drive removal” on page 4-40. e-clip (A) from the gear. 5. Remove the gear (B) and gear shaft (C).
6. Remove the screw (D) from the gear (E). 7. Remove the plastic bushing (F).
8. Use a screwdriver to pop the retainer clip (G) loose from the gear. 9. Remove the gear (H).
Fan removal 1. Remove the right side cover. See “Right side cover removal” on page 4-77. 2. Disconnect the cable (A) from the engine board, and remove the two screws (B) holding the fan to the right side frame. A 3. Remove the fan.
Front access door removal 1. Remove the front door access cover. See “Front door access cover removal” on page 4-34. 2. Remove the left side cover. See “Left side cover removal” on page 4-33. 3. Remove the upper front guide assembly. See “Upper front guide assembly removal” on page 4-82, steps 1-3. 4. Close the front access door. 5. While closing the MPF cover, pull up on the MPF by the steel shaft until the MPF lifts from its hinges.
6. Disconnect the MPF from the lower front cover. 7. Disconnect the fuser link (A) from the front access door.
8. Disconnect the front access door from its hinges, and remove. Installation note: a. b. c. d. e. Install a new front access door at its hinges. Connect the fuser link. Remove the two screws (D). Slide the latch to the left to free it, and then rest it on the door. Keep the spring in place. Finish tightening the screws (F), and reinstall the remaining parts.
Fuser removal 1. Remove the rear exit guide. See “Rear exit guide assembly with sensor and reversing solenoid removal” on page 4-75. 2. Remove the two screws (A). 3. Partially pull the fuser forward for better access.
4. Push in on the cable connector cover (B), and remove. C B 5. Disconnect the AC cable (C). 6. Disconnect the thermistor cable (D).
7. Disconnect the exit sensor cable (E) from the engine board. F 8. Remove the fuser. Note: • Be careful to not damage the gears during the fuser installation. • Be sure to reinstall the AC cable during the fuser installation.
Scanner front cover removal 1. Use a flatblade screwdriver to pry the scanner front cover away from the side cover. Be careful to avoid marring the finish.
2. Carefully pull the scanner front cover away from the tub assembly.
Left side cover removal Note: • • 1. 2. 3. Leave the front door closed when removing the left side cover. Make sure that the fuser cables are out of the way when removing the left side cover. Remove the scanner front cover. See “Scanner front cover removal” on page 4-31. Move the scanner assembly to the up position. See “Lifting the Scanner to the up position” on page 4-102. Remove the plastic screw (A) that secures the left cover to the tub assembly. A 4.
7. Depress the two tabs (C) on the underside of the MFP. C 8. Lift the left cover up and pull the bottom of the cover away from the MFP. Note: You will need to pry the MPF cover door forward slightly to provide clearance to the left cover when you pull the cover away from the machine. Front door access cover removal 1. Remove bumper. See “Nameplate cover removal” on page 4-61. 2. Remove the two screws (A) securing the front door access cover to the front door assembly.
Lower front cover removal 1. Open the lower front cover. 2. Disconnect the MPF pins (A) from the right and left sides of the lower front cover. A 3. Flex the lower front cover, and disconnect it first from its right hinge and then from its left hinge. Note: An alternative to step 3 is to remove the front access door, and remove the three screws from the right door mount. See “Front access door removal” on page 4-25 and “Door mount removal” on page 4-17.
Installation note: Use a flathead screw driver to press in on the door mount (B) while pulling on the front access door to connect the cover to the hinge (C).
LVPS/HVPS removal 1. Remove the rear cover. See “Rear door and lower rear cover removal” on page 4-74. 2. Remove the left side cover. See “Left side cover removal” on page 4-33. 3. Place the printer on its top with the rear facing you. Note: Be careful to not mar the finish of the printer. 4. Remove the two screws (A) from the right rear foot assembly. A 5. Disconnect the fuser power cable (B).
6. Remove the four screws (C) from the LVPS/HVPS shield. C A 7. Lift the LVPS/HVPS, and disconnect the three cables (D).
Note: Squeeze the clip to remove the cables from their connectors (E). E F 8. Disconnect the transfer roll cable (F). F G 9. Lift and remove the LVPS/HVPS.
Main motor gear drive removal 1. Remove the left side cover. See “Left side cover removal” on page 4-33. 2. Disconnect the fuser link (A) from the front access door. A 3. Place the printer on its right side. Note: Be careful to not mar the finish of the printer. 4. Remove the four screws (B) from the main motor gear drive.
5. Lift the gear drive, and disconnect the main motor gear drive cable (C). 6. Remove the main motor gear drive.
Manual feed clutch removal 1. Remove the left side cover. See “Left side cover removal” on page 4-33. 2. Open the front access door, and disconnect the fuser link (A). A 3. Place the printer on its right side. Note: Be careful to not mar the finish of the printer. 4. Remove the four screws (B) from the main motor gear drive. B 5. Rotate the main motor gear drive enough to access the manual feed solenoid.
6. Use a screwdriver to remove the e-clip (C) from the manual feed clutch. C 7. Remove the manual feed clutch (D).
Manual feed solenoid removal 1. Remove the left side cover. See “Left side cover removal” on page 4-33. 2. Remove the duplex. See “Duplex removal” on page 4-19. 3. Open the front access door, and place the printer on its right side. Note: Be careful to not mar the finish of the printer. 4. Remove the two screws (A).
5. Remove the three screws (B) from the left door mount.
6. Lift and remove the left door mount (C) away from the side frame, and un route the cable (D) with a spring hook. 7. Reinstall the left door mount, and place the printer on its top. Note: Be careful to not mar the finish of the printer. 8. Disconnect the cable (D) from J25 on the engine board. Installation note: • Install the two screws holding the new solenoid in place, and route the cable (D) behind the MPF clutch (E).
Media ACM ASM feeder removal 1. 2. 3. 4. 5. 6. Remove the left side cover. See “Left side cover removal” on page 4-33. Remove the LVPS/HVPS. See “LVPS/HVPS removal” on page 4-37. Remove the duplex. See “Duplex removal” on page 4-19. Remove the main motor gear drive. See “Main motor gear drive removal” on page 4-40. Remove the media feed clutch. See “Media feed clutch with cable removal” on page 4-50. Use a screwdriver to pop the shaft retainer tab (A) loose from the ACM feed shaft. 7.
8. Use a screwdriver to pop the inner shaft lock (B) loose. 9. Remove the inner shaft lock (C).
10. Pull out the auto compensator shaft, and remove the spring (D). 11. Remove the auto compensator shaft. 12. Disconnect the spring (E) from the cylinder. E 13. Remove the media ACM ASM feeder.
Media feed clutch with cable removal 1. Remove the main motor gear drive. See “Main motor gear drive removal” on page 4-40. 2. Remove the duplex. See “Duplex removal” on page 4-19. 3. Disconnect the media feed clutch cable (A) from J34 on the engine board. A 4. Un route the cable from the bottom of the printer.
5. Remove the e-clip (B). 6. Remove the media feed clutch with cable (C).
Media manual input sensor 1. Remove the right side cover. See “Right side cover removal” on page 4-77. 2. Remove scanner assembly. 3. Place the machine on its side. Note: Be careful to not mar the finish of the printer. 4. Disconnect the sensor cable (A) from J23 (MPFS) on the engine board. A 5. Remove the screw (B) holding the sensor. B 6. Free the cable from its retainers, and pull it through the opening toward the sensor mount.
Re-installation note: • Prop open the duplex door, and insert the hook end of the spring hook through the frame opening (C) from the controller board side. Extend the hook until the sensor connector can be hooked. • Hook the spring hook (D) to the connector (E), and pull it through the opening. C D E • Place the sensor into position, and reconnect the cable on the controller board. • Using the spring hook, be sure to reroute the cable through the three retainers (F) between the sensor and side frame.
Warning: Check to make sure the duplex paper jam door is in its proper position. If it is not, then the paper tray will become lodged and the printer will need to be replaced.
Multipurpose feeder removal 1. Open the front access door. 2. Remove the four screws (A) from the upper front guide. A 3. Remove the upper front guide. 4. Remove the two screws (B).
5. Close the front access door, and pull up on the MPF by the steel shaft until the MPF lifts from its hinges. 6. Disconnect the MPF from the lower front cover.
7. Open the front access door, and remove the lower paper guide.
Multipurpose feeder (MPF) feed clutch removal 1. Remove the left side cover. See “Left side cover removal” on page 4-33. 2. Remove the duplex. See “Duplex removal” on page 4-19. 3. Disconnect the cable (A) from J24 on the engine board. A 4. Place the printer on its right side. Note: Be careful to not damage any cables or mar the finish of the printer.
5. Remove the three screws (B) from the left side of the printer.
6. Disconnect the left hinge (C) from the feed clutch, and remove the e-clip (D). 7. Lift and remove the multipurpose feeder (MPF) feed clutch.
Nameplate cover removal 1. Open the front access door. 2. Remove the three screws (A). A 3. Remove the nameplate.
Operator panel keypad removal 1. Lift the scanner assembly to the up position. 2. Release the two tabs (A) securing the keypad to the keypad to the tub assembly. A 3. Disconnect the UICC cable (B) from the operator panel PCB assembly. 4. Disconnect the two ribbon cables (C) from the operator panel PCB assembly. 5. Disconnect the ground (D) on the operator panel PCB assembly. B C 6. Tilt the operator panel keypad up and remove it from the MFP.
Operator panel display removal 1. Remove the operator panel keypad. 2. Press the tab on the left side of the operator panel display and raise the operator panel display to the up position. 3. Press the tabs (A) which fasten the operator panel display to the display rotation supports to the left to release the operator panel display from the display rotation supports. A 4. Disengage the operator panel display from the right display support and remove it from the MFP.
Display bezel 1. Remove the operator panel display. See “Operator panel display removal” on page 4-63. 2. Depress the two tabs (A) securing the display bezel to the operator panel display. A 3. Pull the bezel away from the display.
UICC cable removal 1. 2. 3. 4. Lift the scanner assembly to the up position. Disconnect the UICC cable from the controller board. Feed the cable through the hole in the front of the controller card cage. Release the two tabs (A) securing the keypad to the keypad to the tub assembly. A 5. Disconnect the UICC cable B) from the operator panel PCB assembly.
USB cable mount bracket removal 1. Remove the operator panel keypad. 2. Open the USB cable clamp and remove the USB cable. 3. Remove the screw (A) securing the USB cable mount bracket to the tub assembly. A B Operator panel support removal 1. Remove the operator panel keypad. 2. Remove the three screws (A) securing the operator panel support to the tub assembly. A Note: The same steps are performed for both supports.
Display rotation support removal 1. Remove the operator panel display. See “Operator panel display removal” on page 4-63. 2. Remove the three screws (A) securing the display rotation support to the tub assembly. A Note: The same steps are performed for both supports.
Left rear frame assembly removal 1. Remove the flatbed assembly. See “Flatbed removal” on page 4-86. 2. Remove the three screws (A) from the left rear frame assembly. A A A A 3. Carefully lift the left rear frame assembly off of the print engine frame.
Right rear frame assembly removal 1. Remove the flatbed assembly. See “Flatbed removal” on page 4-86. 2. Remove the three screws (A) from the right rear frame assembly. B A A B 3. B A Carefully lift the right rear frame assembly off of the print engine frame.
Tub assembly removal 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Remove the flatbed assembly. See “Flatbed removal” on page 4-86. Disconnect the remaining cables from the controller board. Thread the cables through the tub assembly and top cover. Remove the controller board cage. See “Controller board cage” on page 4-14. Remove the operator panel keyboard. See “Operator panel keypad removal” on page 4-62. Remove the operator panel display. See “Operator panel display removal” on page 4-63.
Paper input and duplex sensor assembly removal 1. Remove the right side cover. See “Right side cover removal” on page 4-77. 2. Remove the duplex. See “Duplex removal” on page 4-19. 3. Remove the two screws (A) from the sensors. A 4. Disconnect the sensor cable (B) from the controller board. B 5. Remove the paper input and duplex sensor assembly.
Printhead removal 1. Remove the top cover. See “Top cover assembly removal” on page 4-80. 2. Remove the right side cover. See “Right side cover removal” on page 4-77. 3. Disconnect the two cables (A), and unroute them back through the frame toward the printhead. A 4. Remove the three screws (B). Note: Use a pencil to mark the screw locations of the printhead on the metal frame. Align the new printhead relative to the location of the old printhead.
Mid rear cover removal 1. Remove the two metal screws (A). A 2. Pull the upper rear cover back. 3. Carefully disengage that snaps and remove the cover.
Rear door and lower rear cover removal 1. Remove the mid rear cover. See “Mid rear cover removal” on page 4-73. 2. Open the rear door. 3. Pull the rear door up at an angle, disconnect the door from the notch (A), and remove. A 4. Remove the two screws (B) from the top of the rear cover. B 5. Tilt the lower rear cover, and remove.
Rear exit guide assembly with sensor and reversing solenoid removal 1. 2. 3. 4. Remove the top cover. See “Top cover assembly removal” on page 4-80. Disconnect the narrow media sensor cable from J35 on the engine board. Remove the reversing solenoid cable from J10 on the engine board. Remove the six screws (B) from the rear exit guide assembly. B B B 5. Remove the solenoid cable (C) through the opening.
6. Remove the narrow media sensor cable (D) through the opening. 7. Remove the rear exit guide assembly. Note: Be careful to not damage the gears during the rear exit guide assembly removal and reinstallation.
Right side cover removal Note: Leave the front cover closed when removing the right side cover assembly. 1. Remove the scanner front cover. See “Scanner front cover removal” on page 4-31. 2. Lift and lock the scanner assembly in the up position. See “Lifting the Scanner to the up position” on page 4-102. 3. Remove the plastic screw (A) securing the cover to the tub assembly. A 4. Remove the screw (B) from the bottom right side of the printer. C B 5. Open the MPF cover. 6.
7. Depress the tab (D) on the bottom of the printer. C D 8. Open the front door. 9. Rotate the right side cover assembly slightly to the left, and pull out. Note: You will need to pry the MPF cover forward slightly to pride clearance for the cover when you pull the front of the side cover cover away from the machine.
Toner level sensor removal 1. Open the front access door. 2. Remove the right side cover. See “Right side cover removal” on page 4-77. 3. Disconnect the toner level sensor cable (A) from the engine board. B A 4. Squeeze the lower tabs (B) of the toner level sensor, and push it from its holder. 5. Remove the toner level sensor through the inside of the printer. Note: The toner level sensor must be installed properly, or the printer will not function.
Top cover assembly removal 1. Remove the scanner assembly. See “Scanner assembly removal” on page 4-88. 2. Lift the top cover, and remove. Note: • Be sure to lift the top cover assembly from the front to remove. • During reinstallation, be sure the exit guide and the paper bin align correctly. A mismatch can cause paper jams.
Transfer roll removal Note: A flashlight may be required to remove the transfer roll. 1. Open the front access door. 2. At the right side of the transfer roll, squeeze the holder arms (A) with the left hand while lifting. Stop when the holder is unlatched. 3. At the left side of the transfer roll, squeeze the holder arms with the right hand while lifting with the left 4. hand. Stop when the left holder is unlatched. With a hand at each end, lift the transfer roll out.
Upper front guide assembly removal 1. Open the front access door. 2. Remove the four screws (A) from the upper front guide. A 3. Remove the upper front guide.
Wear strip (tray 1 and 250-sheet tray 2) removal 1. Hold the tray with the bottom up. 2. Use a spring hook to disconnect the strip from the top of the tray. 3. Remove the strip from inside the tray.
Wear strip (550-sheet tray 2) removal 1. Use a spring hook to disconnect the strip from the top of the tray. 2. Life the strip, and remove. Note: When replacing the strip (for all trays): • Carefully insert the strip from the top of the tray, and push it down through the opening until it snaps into place. • Turn the tray over to view the bottom of the strip. Using the spring hook, check to make sure that the end of the strip is fastened tightly.
Imaging component removals ADF unit removal 1. Remove the ADF rear cover by releasing the three tabs (A) which fasten the ADF rear cover to the ADF unit. A 2. Disconnect the ADF cable (B) and two sensor connections (C) on the relay card above the ADF relay cable. B CB 3. Lift the ADF unit up and depress the tabs located on the bottom of the ADF hinges to release the ADF from the flatbed.
Flatbed removal 1. 2. 3. 4. 5. 6. 7. 8. 9. 4-86 Remove the left side cover. See “Left side cover removal” on page 4-33. Remove the left scanner cover. See “Left scanner cover removal” on page 4-100. Remove the right scanner cover. See “Right scanner cover removal” on page 4-101. Remove the right side cover. See “Right side cover removal” on page 4-77. Remove the ADF unit. See “ADF unit removal” on page 4-85. Raise the flatbed unit to the up position. Remove the controller board shield.
10. Remove the e-clip (A) from the flatbed hinge rod. A B 11. While holding the front of the flatbed with one hand, pull the flatbed hinge rod out. 12. Lift and remove the flatbed unit from the MFP.
13. Remove the kickstand (B). B C D 14. Remove the two flatbed supports (C). These will be used on the new flatbed. 15. Remove the controller shield (D). This will be used on the new flatbed. Scanner assembly removal 1. 2. 3. 4. 5. 6. 7. 8. 9. 4-88 Remove the left scanner cover. See “Left scanner cover removal” on page 4-100. Remove the right scanner cover. See “Right scanner cover removal” on page 4-101. Remove the left side cover. See “Left side cover removal” on page 4-33.
10. Disconnect the LSU laser diode cable from the controller board. 11. Thread the LSU diode cable, the cover interlock cable, the stairway cables, and the controller board power supply cable through the side of the printer away from the scanner assembly.
12. Disconnect LSU HSYNC extension cable at the connector in the middle of the cable.
13. Remove the three screws (A) from the left rear frame assembly.
14. Remove the three screws (B) from the right rear frame assembly.
15. Remove the screw (C) securing the left flatbed stop to the top of the print engine frame. C B 16. Remove the screw (D) securing the right flatbed stop to the top of the print engine frame. D 17. Lower the flatbed and ADF to the down position.
18. Remove the side screw (E) securing the left flatbed stop to the print engine frame. E C 19. Remove the side screw (F) securing the right flatbed stop to the print engine frame. F 20. Lift and remove the scanner assembly from the MFP.
ADF separator pad 1. Remove the ADF separator roll. See “ADF separator roll assembly” on page 4-96. 2. Pinch the two tabs on each side of the pad inward. 3. Tilt the pad up, and lift it out of the ADF assembly.
ADF separator roll assembly 1. Lift the locking lever (A). A 2. Slightly lift the separator roll assembly, and pull it out of the mount (B) on the opposite side.
Kickstand removal 1. Lift the flatbed assembly to the up position. 2. Release the kickstand from the left rear frame assembly by depressing the tab holding the kickstand in place. 3. Remove the e-clip (A) securing the kickstand rod to the flatbed. A 4. Slide the rod out and remove the kickstand from the flatbed.
Output bin LED and lens removal 1. Disconnect the output LED cable from the controller board. 2. Remove the controller board cage. See “Controller board cage” on page 4-14. 3. Press the tab (A) securing the lens to the tub assembly. A 4. Pull down on the lens and LED and remove it from the tub.
ADF cable removal 1. 2. 3. 4. Remove the left scanner cover. See “Left scanner cover removal” on page 4-100. Remove the left cover. See “Left side cover removal” on page 4-33. Remove the controller board shield. See “Controller board shield” on page 4-11. Lift the flatbed cover and unsnap the three tabs (A) securing the ADF rear cover to the ADF. A 5. Remove the rear ADF cover. 6. Disconnect the ADF cable (B) and two sensor connections (C) on the relay card above the ADF relay cable. B C C B 7.
9. Remove the ADF cable from the MFP. Left scanner cover removal 1. Lift the ADF to the up position. 2. Remove the two screws (A) securing the left scanner cover to the flatbed unit. A 3. Lift and carefully pull the left scanner cover up and away from the rear of the flatbed.
Right scanner cover removal 1. Lift the ADF to the up position. 2. Remove the two screws (A) securing the right scanner cover to the flatbed unit. A X 3. Lift and carefully pull the right scanner cover up and away from the rear of the flatbed.
Option board installs and removals Note: This information is also available in the X 46x series user guide. Lifting the Scanner to the up position 1. Turn the two rear frame assembly locks counter-clockwise to the unlock position. 2. Lift the scanner assembly to the up position. The kickstand will lock into place.
Installing an Internal Solutions Port (ISP) 1. Access the controller board. See “Lifting the Scanner to the up position” on page 4-102. 2. Unpack the ISP and tee. Note: Avoid touching components on the card. 3. Locate the standoff location on the controller board. Note: If an optional printer hard disk is currently installed, then the printer hard disk must first be removed. See “Printer hard disk removal” on page 4-106. 4.
6. Install the ISP onto the plastic tee. Note: Make sure the ISP card is properly aligned with the rear of the controller board cage. 7. Press down on the ISP to seat it in the tee. 8. Insert the thumbscrew. Note: Do not tighten the thumbscrew at this time.
9. Attach the two screws that came with the ISP to secure the ISP to the controller board cage. 10. Tighten the thumbscrew from step 8. 11. Insert the cable’s ISP connector into the ISP connector on the controller board. Note: If a printer hard disk was previously attached, reinstall it at this time. 12. Lower the scanner assembly and lock it.
Printer hard disk removal 1. Unplug the printer hard disk interface cable from the system board. 2. Remove the screws holding the printer hard disk in place.
3. Remove the printer hard disk by pulling it upwards from the standoffs. 4. Remove the thumbscrews that attach the printer hard disk mounting bracket to the printer hard disk if the drive is going to be installed on top of an ISP. Printer hard disk installation on an ISP 1. Access the controller board. See “Lifting the Scanner to the up position” on page 4-102. 2. Unpack the printer hard disk. 3. Locate the standoff location on the controller board.
4. Use a flatblade screwdriver to remove the screws attaching the mounting bracket. 5. Place the hard disk on top of the ISP, making sure the standoff on the hard drive line up with the holes on the ISP. 6. Gently press down on the hard drive until it locks into place. 7. Fasten the hard dive connector into the connector on the ISP card.
Printer hard disk installation directly on the controller board Note: Perform steps 1, 2, and 3 from above. before doing the rest of the installation. 1. Align the printer hard disk standoffs with the holes on the system board. 2. Press the hard disk down until it locks into place. 3. Attach the hard disk to the controller board cage using the screws that came with the hard disk.
4. Connect the hard disk interface cable to the connector on the controller board. Fax card installation 1. Access the controller board. 2. Unpack the fax card, 3. Remove the fax card cover on the controller board cage.
4. Insert the fax card into the controller board cage. 5. Tighten the two screws to secure it to the controller board cage.
6. Insert the fax card interface cable into the system board connector. 7. Lower and lock the scanner assembly.
5.
Rear view 5-2 Callout number Item name 1 Scanner locks 2 Kensington lock 3 Ethernet port 4 Host USB port 5 Fax / 6 Fax / 7 Rear door 8 Power switch 9 Power 10 Rear USB 11 ISP / Options cover Service Manual
Print engine paperpath A B C D E F G H I J K L M Paper path Manual feed sensor Upper end feed rolls Input sensor Transfer roll Fuser Fuser exit rolls Fuser exit sensor Exit rolls Exit sensor/narrow media sensor Duplex unit Duplex sensor Auto compensator A–B B–C C–D D–E E–F F–G G–H H–I I–J I–K K–L L–M M–B 125.3 9.0 59.8 44.9 112.7 21.4 114.8 7.5 17.0 211.7 93.4 8.4 177.
Main boards Controller board 1 1 J6 J6 1 1 J26 J11 J37 1 J27 1 J16 1 1 J7 J2 1 1 J35 J25 1 1 J3 J34 J8 1 J33 J99 J30 J1 1 J10 J4 1 1 J5 J12 1 1 J13 J28 1 J17 1 J3 5-4 Service Manual
Engine board J502 1 J503 1 1 1 J23 1 J504 J17 1 1 1 J13 J50 J24 J25 1 1 J34 1 1 J500 J501 1 1 J4 J27 J28 1 J36 J10 J14 J35 1 J12 1 1 1 1 Locations and connections 5-5
Controller and engine board connector pin values Note: The connections listed below are located on the controller board or the engine board. The comments column lists which board the connection appears on. Note: See the wiring diagram at back of book. These values were measured with all connections made (plugged) or with only one connector at a time unplugged to expose the pins. Always disconnect and connect with the printer power off. Otherwise, the values below may not match.
Connector J35 J12 J13 J14 J17 Pin # Value cable plugged 1 Value cable unplugged (if different) 5 V dc 2 5 V dc 3 Ground 1 5 V dc 2 Ground 1 0.6 V dc 2 Ground 3 0 V dc 1 > 0 V dc 2 5 V dc 3 Ground 1, 4 0.
Connector J502 J503 J37 Pin # Value cable plugged 1, 3, 5, 7, 11, 13, 15 5V dc 4 5 V dc 6 24 V dc 17, 19 24 V dc Other 0 V dc 11, 13 15 5V dc 17, 19 24V dc 10,12,14,16,18 Ground 11, 13 15 5V dc 17, 19 24V dc 10,12,14,16,18 J30 Value cable unplugged (if different) Comments LVPS - Engine Board HVPS - Engine Board PS (LVPS/HVPS) - Controller Board Ground 3, 4 +14V 6, 7 +5V 1,5,13,15,18, GND AFE (CCD Ribbon) - Controller Board 21,24,27,30, 31-36 J28 J17 J13 J12 5-8 1
6. Preventive maintenance This chapter describes procedures for printer preventive maintenance. Follow these recommendations to help prevent problems and maintain optimum performance. Safety inspection guide The purpose of this inspection guide is to aid you in identifying unsafe conditions. If any unsafe conditions exist, then find out how serious the hazard could be and if you can continue before you correct the hazard.
6-2 Service Manual
7. Parts Catalog How to use this parts catalog The following legend is used in the parts catalog: AsmIndex Part number Units/ mach Units/ FRU Description • Asm-index: identifies the assembly and the item in the diagram. For example, 3-1 indicates • • • • • • assembly 3 and the item number 1. Part number: identifies the unique number that identifies this FRU. Units/mach: refers to the number of units actually used in the machine or product.
Assembly 1: Covers 17 16 18 17 15 14 1 13 3 2 12 4 5 6 11 10 9 8 7 7-2 Service Manual
Assembly 1: Covers AsmIndex Part number Units/ mach Units/ FRU Description 1-1 40X5827 1 1 Mid rear cover 2 40X5839 1 1 Rear door 3 40X5838 1 1 Rear cover 4 40X5820 1 1 Rear left frame assembly 5 40X5821 1 1 Rear right frame assembly 6 40X5822 1 1 Right side cover 7 40X5379 1 1 Front door cover 8 40X5448 1 1 Nameplate cover 9 40X5806 1 1 Lower AIO access assembly 10 40X5778 1 1 Front access door cover 11 40X5823 1 1 Left side cover 12 40X5614 1
Assembly 2: Imaging 1 2 3 4 5 16 6 7 15 8 14 9 10 11 13 12 7-4 Service Manual
Assembly 2: Imaging AsmIndex Part number Units/ mach Units/ FRU Description 1 40X5471 1 1 ADF Separator roll 2 40X5472 1 1 ADF Separator pad 3 40X5470 1 1 ADF input tray 4 40X5540 1 1 ADF cable 5 40X5824 1 1 Duplex ADF unit 6 40X5804 1 1 Flatbed cushion 7 40X5825 1 1 Flatbed module 8 40X5818 1 1 Right scanner cover 9 40X5743 1 1 Operator panel button assembly 10 40X5810 1 1 UICC Cable (Operator panel cable) 11 40X5831 1 1 Operator panel USB cable 1
Assembly 3: Tray assemblies 1 5 2 4 3 7-6 Service Manual
Assembly 3: Tray assemblies AsmIndex Part number Units/ mach Units/ FRU Description 3-1 40X5398 1 1 Optional 250-sheet tray (new asm) 1 40X5399 1 1 Optional 550-sheet tray (new asm) 2 40X5394 1 1 250-sheet (Tray 2) assembly (new asm) 2 40X5395 1 1 550-sheet (Tray 2) assembly (new asm) 3 40X2855 1 4 Tray 2 wear strips (550-sheet tray only) (new asm) 4 40X5381 1 1 Primary tray 5 40X5382 1 6 Wear strips (250-sheet trays, optional and primary) (new asm) Parts Catalog 7-7
Assembly 4: Electronics 1 2 3 4 22 21 5 20 19 18 8 6 16 17 7 15 14 13 9 12 10 11 7-8 Service Manual
Assembly 4: Electronics AsmIndex Part number Units/ mach Units/ FRU Description 4-1 40X5829 1 1 Controller board 2 40X5816 1 1 LSU hsync extension cable 3 40X5832 1 2 Stairway cable 4 40X5833 1 1 Controller board cable 5 40X5344 1 1 Fuser assembly, 115 V 5 40X5345 1 1 Fuser assembly, 230 V 5 40X5346 1 1 Fuser assembly, 100 V 6 40X5365 1 1 Duplex and media sensor assembly 7 40X5360 1 1 Access door open sensor assembly 8 40X5392 1 1 Cooling fan (screws inc
Assembly 5: Frame 1 12 2 11 3 10 3 8 9 4 5 7 See instruction sheet in the FRU.
Assembly 5: Frame AsmIndex Part number Units/ mach Units/ FRU Description 5–1 40X5364 1 Transfer roll, bearings, gear, spring (CBM) 2 40X5372 1 Media exit guide assembly (redrive) 3 40X5397 1 4 40X5396 N/A 1 Front mounts Screws, miscellaneous 4 TP2NCX3X6PF-Ni 4 TP2C-4.0+8PF-Ni 4 M3.0*0.5+6PF-Ni 2 M3.0*0.5+4PF-Ni 2 M3.5*0.
Assembly 6: Options AsmIndex Part number Units/ mach Units/ FRU Description NS 40X5972 1 1 Japanese font card assembly NS 40X5970 1 1 Simplified Chinese font card assembly NS 40X5971 1 1 Traditional Chinese font card assembly NS 40X5969 1 1 Korean font card assembly NS 40X5952 1 1 Print cryption card assembly NS 40X0055 1 1 Bar code and forms NS 40X5937 1 1 128MB DIMM NS 40X5938 1 1 256MB DIMM NS 40X5939 1 1 512MB DIMM NS 40X5704 1 1 256MB flash NS 40X
Assembly 7: Power cords AsmIndex Part number Units/ mach Units/ FRU Description NS 40X0297 1 1 Power cord, 1.
7-14 Service Manual
Index Numerics 840.
Configuration ID 3-30 Defaults 3-29 Edge to Edge 3-30 engine settings 3-29 Model Name 3-29 Page Count 3-29 Perm Page Count 3-29 Serial Number 3-29 SCANNER TESTS ASIC Test 3-34 Feed Test 3-34 Sensor Tests 3-34 diagnostics mode 3-17 accessing 3-1 available tests 3-17 diagnostics mode— Registration 3-18 didital imaging specifications 1-9 DRAM Test 3-22 duplex tests Duplex Feed 1 3-26 Duplex Feed 2 3-26 Motor Test 3-25 Quick Test 3-24 Sensor Test 3-25 Top Margin 3-25 E Edge to Edge 3-30 engine board service ch
Panel Test 3-21 paper guidelines 1-6 recycled 1-7 unacceptable paper 1-6 paper feed service check 2-43 parts catalog covers 7-2 electronics 7-8 frame 7-10 options 7-12 power-on self test (POST) 2-1 symptoms 2-2 print media trays by model 1-4 types and sizes 1-5 print quality pages using 2-47 print quality problems service check 2-47 solving 2-51 printer symptom table 2-3 printhead service check 2-54 Q Quick Disk Test 3-28 Quick Test 3-24 R registration 3-18 removals ADF separator pad 4-95 ADF separator ro
duplex 3-25 transfer roll parts catalog 7-11 service check 2-54 trsy 2 service check 2-55 U Understanding the home screen 2-7 USB port service check 2-46 user attendance messages 2-13 Using the touch screen buttons 2-9 W warm up time 3-31 I-4 Service Manual
Part number index P/N Description Page 40X0055 40X0108 40X0270 40X0274 40X0275 40X0276 40X0278 40X0279 40X0280 40X0281 40X0282 40X0286 40X0287 40X0288 40X0296 40X0297 40X0399 40X0400 40X0401 40X1367 40X1368 40X1556 40X2855 40X4596 40X4819 40X4821 40X4822 40X4823 40X4826 40X4827 40X5038 40X5039 40X5057 40X5316 40X5344 40X5345 40X5346 40X5358 40X5360 40X5363 40X5364 40X5365 40X5366 40X5367 40X5368 40X5369 40X5370 40X5371 40X5372 40X5379 40X5380 40X5381 40X5381 40X5382 Bar code and forms - - - - - - - - -
40X5383 40X5385 40X5387 40X5392 40X5394 40X5395 40X5396 40X5397 40X5398 40X5399 40X5400 40X5400 40X5401 40X5401 40X5402 40X5440 40X5448 40X5451 40X5453 40X5470 40X5471 40X5472 40X5540 40X5606 40X5614 40X5704 40X5743 40X5778 40X5804 40X5805 40X5806 40X5807 40X5809 40X5810 40X5811 40X5813 40X5814 40X5815 40X5816 40X5817 40X5818 40X5819 40X5820 40X5821 40X5822 40X5824 40X5825 40X5826 40X5827 40X5829 40X5830 40X5831 40X5832 40X5832 40X5833 40X5834 40X5835 40X5837 40X5838 Upper front frame assembly - - - - - -
40X5839 40X5841 40X5842 40X5937 40X5938 40X5939 40X5952 40X5969 40X5970 40X5971 40X5972 56P0558 7377732 7377732 Rear door - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 LVPS/HVPS card assembly 220V - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9 LVPS/HVPS card assembly 110V - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
I-8 Service Manual
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