PRINTER e-STUDIO 500P P/N 12G9609
Edition: June 2005 The following paragraph does not apply to any country where such provisions are inconsistent with local law: Toshiba America Business Solutions PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you.
Table of contents Laser notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Base printer symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 High-capacity feeder (2000-sheet) symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Paper tray symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature button assembly service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . StapleSmart finisher service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System board service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Toner sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Setting 1 through 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Edge to Edge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 Paper Jam Open Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23x Paper Jam Open Duplex Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 and 280 Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27x Paper Jam Check Bin x. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator panel board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66 Operator panel buttons removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67 Outer shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67 Paper alignment assembly removal . . . . . . . . . . . . . . . . . . . . . . . .
Assembly 17: Assembly 18: Assembly 19: Assembly 20: Assembly 21: Assembly 22: Assembly 23: Assembly 24: Assembly 25: Assembly 26: Assembly 27: Assembly 28: Assembly 29: Assembly 30: Assembly 31: Assembly 32: Assembly 33: Assembly 34: Assembly 35: Assembly 36: Assembly 37: Assembly 38: Assembly 39: Assembly 40: Assembly 41: Assembly 42: Assembly 43: Assembly 44: Cabling diagrams 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabling diagrams 2 . . .
x Service Manual
Laser notices 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. The printer contains internally a Class IIIb (3b) laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770-795 nanometers.
Avvertenze sui prodotti laser Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825-1. I prodotti laser di classe non sono considerati pericolosi.
Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1. Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795 nanometer.
Laser-notis Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1. Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer.
Japanese Laser Notice Laser notices xv
Korean Laser Notice xvi Service Manual
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. The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product.
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 2. 3. 4. 5. 6. 7. approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.
1. G eneral information T he e-S T UDIO 500P las er printers are letter quality page printers designed to attach to IB M-compatible pers onal computers and to most computer networks. T he e-S T UDIO 500lP is available is the following models : Model name e-S T UDIO 500P C onfiguration Network Maintenanc e approac h T he diagnos tic information in this manual leads you to the correct field replaceable unit (F R U) or part.
C onfigured model T he following illus tration s hows a s tandard network printer.
Specifications Resolution • • • • 1200 1200 dpi 2400 Image Quality 1200 Image Quality 600 x 600 dpi Data streams • PostScript 3 emulation • PCL 6 emulation • • Print speed and performance print speed Performance Performance speed depends on: • • • • • • • Interface to the host (USB, parallel, network) Host system and application Page complexity and content Printer options installed or selected Available printer memory Media size and type Resolution Time to first print NA 1200 dpi e-STUDIO 500P 600 d
Memory c onfiguration e-S T UDIO 500P Memory type 128 S tandard DR AM (MB ) Optional memory (MB ) 128 and 512MB available (100 pin DDR S DR AM unbuffered DIMMs ) 640 Maximum (MB ) Depending upon the options and features used, additional memory may be required to optimize performance. Available memory options Optional 128MB and 512MB S DR AM DIMMs are available from T os hiba.. Operating clearances P rinter s ide Meas urement Left and right side 12 in. (30.48 cm) Front 20 in. (50.
Dimensions Description Height Width Depth Weight Printer e-STUDIO 500P 16.0 i n (406 mm) 17.2 2 in. (436 mm) 20.2 in. (513 mm) 51.6 lb (23.1 kg) Options Duplex 500 page option 2.13 in 15.6 in 23.4 in 11 lb 500-Sheet drawer 5.3 in. (134 mm) 15.6 in. (398 mm) 20.5 in. (520 mm) 7 lb (3.2 kg) 2,000-Sheet 11.8 in. (300 mm) 15.6 in. (398 mm) 19.5 in. (495 mm) 31 lb (14.1 kg) Envelope option* (closed position) 7.72 in. (196 mm) 4 lb (1.
Power requirements Average nominal power requirements for the base printer configuration (110 volt). Power levels are shown in watts (W). Maximum current is given in Amperes (A). Printing states e-STUDIO 500P Off (all models) .05 W .05 W .05 W Power Saver on 20 W 20 W 20 W Power Saver off 90 W 95 W 95 W Continuous printing 675 W 830 W 830 W 100 V 7.8 A 8.9 A 8.9 A 120 V 7.2 A 8.0 A 8.0 A 230 V 3.4 A 4.3 A 4.
Environment Printer temperature and humidity • Operating – Temperature: 16 to 32° C (60° to 90° F) – Relative humidity: 8 to 80% – Altitude: 10,000 ft.
Media s pecifications P aper and s pec ialty media guidelines P rint media is paper, car d s tock, trans par enc ies , labels , and en velopes . T his pr inter pr ov ides hi gh quality pr inting on a variety of pr int media.
Universal2, 3 139.7 x 210 mm to 215.9 x 355.6 mm (5.5 x 8.27 in. to 8.5 x 14 in.) 69.85 x 127 mm to 215.9 x 355.6 mm (2.75 x 5 in. to 8.5 x 14 in.) S tapleS mart F inis her ] S tapleS mart output bin ] ] High-c apac ity output stacker (option) 139.7 x 215.9 mm (5.5 x 8.5 in.) ] 5-bin mailbox (option) S tatement1 ] Output expander (option) ] S tandard output bin ] ] Duplex unit (option) 216 x 330 mm (8.5 x 13 in.) ] E nvelope feeder (option) F olio1 ] 400 UAT (option) 184.2 x 266.
O ther E nvelope1 1 S tandard output bin Duplex unit (option) E nvelope feeder (option) 2000-s heet drawer (option) Dimens ions (UAT — univers ally adjus table tray) Multipurpos e feeder P rint media s ize ( X indicates s upport) 500-s heet drawer (option) P rint media s izes (c ontinued) 98.4 x 162 mm to 176 x 250 mm (3.87 x 6.38 in. to 6.93 x 9.84 in.) X X X 98.4 x 162 mm to 229 x 342 mm (3.87 x 6.38 in. to 9.01x 12.76 in.
Print media weights Print media weight Print media Type Integrated tray and optional 500-sheet drawer Multipurpose feeder ~ ~ Paper Xerographic or business paper 60 to 176 g/m2 grain long (16 to 47 lb bond) 60 to 135 g/m2 grain long (16 to 36 lb bond) Card stock— maximum (grain long)1 Index Bristol 163 g/m2 (90 lb) 120 g/m2 (67 lb) 2 Tag 163 g/m (100 lb) Cover 176 g/m2 (65 lb) 135 g/m (50 lb) Index Bristol 199 g/m2 (110 lb) 163 g/m2 (90 lb) Tag 203 g/m2 (125 lb) 163 g/m2 (100 lb) Cov
Selecting print media Selecting the appropriate print media for your printer helps you avoid printing problems. The following sections contain guidelines for choosing the correct print media for your printer. • • • • • Paper Transparencies Envelopes Labels Card stock Paper For the best print quality, use 75 g/m2 (20 lb) xerographic, grain long paper. Try a sample of any paper you are considering using with the printer before buying large quantities.
• For best performance and to minimize jams, do not use envelopes that: – Have excessive curl or twist. – Are stuck together or damaged in any way. – Contain windows, holes, perforations, cutouts or embossing. – Use metal clasps, string ties, or metal folding bars. – Have an interlocking design. – Have postage stamps attached. – Have any exposed adhesive when the flap is in the sealed or closed position. – Have nicked edges or bent corners. – Have rough, cockle, or laid finishes.
• Portrait orientation is preferred, especially when printing bar codes. • Do not use labels that have exposed adhesive. Card stock Card stock is single ply, and has a large array of properties, such as the moisture content, thickness, and texture, that can significantly affect print quality. See “Supported print media” on page 1-8 for information on the preferred weight and for the grain direction of print media.
Avoiding jams Use appropriate print media (paper, transparencies, labels, and card stock) to help ensure trouble-free printing. See “Supported print media” on page 1-8 for more information. Note: Try a limited sample of any print media you are considering using with the printer before purchasing large quantities. By selecting the appropriate print media and loading it properly, you can avoid most jams. The following hints can help you avoid jams: • Use only recommended print media.
Acronyms BLDC CRU CSU DIMM DRAM DVM EDO EEPROM EP EPROM ESD FRU GB HCIT HVPS ITC LASER LCD LED LVPS MPF MROM MS NVRAM OEM OPT PC pel POR POST PP PWM RIP ROM SDRAM SIMM SRAM UAT UPR V ac V dc VOM 1-20 Service Manual Brushless DC motor Customer Replaceable Unit Customer setup Dual Inline Memory Module Dynamic Random Access Memory Digital multimeter Enhanced Data Out Electrically Erasable Programable Read-Only Memory Electrophotographic process Erasable Programmable Read-Only Memory Electrostatic Discharge F
2. Diagnostic information Start CAUTION: Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Use the handholds on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down.
Understanding the printer operator panel The operator panel on your printer is a 4-line back-lit gray scale display that can show both graphics and text. The Back, Menu, and Stop buttons are located to the left of the display, the navigation buttons are located below the display, and the numeric pad is located to the right of the display.
Operator panel (continued) Button Function Numeric pad The numeric pad consists of numbers, a pound '#' sign, and a backspace button. The 5 button has a raised bump for non-visual orientation. The numbers are used to enter numeric values for items like quantities or PINs. The backspace is used to delete the number to the left of the cursor. Pressing the backspace multiple times will delete additional entries. The pound '#' sign is not used.
Power-On Self Test (POST) sequence When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning of the base printer by observing the following: 1. 2. 3. 4. 5. 6. 7. The LED turns comes on. The operator panel turns on. A partial row of pixels are displayed. The operator panel display clears. Another row of pixels appears. The operator panel display clears again. The operator panel displays system information. For example: *128MB 449MH 8. The fuser lamp turns on.
Symptom tables Base printer symptoms Symptom Action Dead machine Go to “Dead machine service check” on page 2-80. Operator panel—one or more buttons do not work. Go to “One or more operator panel buttons fail” on page 2-106. Operator panel—none of the buttons work. Go to “No buttons work” on page 2-106. Operator panel—display is blank. Printer sounds 5 beeps. Go to “Operator panel display” on page 2-107. Operator panel—display is blank.
Paper tray symptoms Symptom Action Paper feed problem with 250-Sheet Paper Tray. Go to “Input tray(s) service check” on page 2-102. Paper feed problem with 500-Sheet Paper Tray. Go to “Input tray(s) service check” on page 2-102. Media fails to pass through from the lower attached Paper Tray option to the next higher mounted option. Go to “Input tray(s) service check” on page 2-102. Duplex option symptoms Symptom Action Paper feed problem with Duplex.
Diagnostic information 2-7
Messages and error codes Service error codes Service error codes are generally non-recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition. Service error codes (9xx.xx) Error code Sub codes Display text 900 .xx RIP Software 901 .xx Engine flash error Indicates that the flash which the system board code is programmed into is bad. Replace the system board. Replace the system board.
Service error codes (9xx.xx) (continued) Error code Sub codes 920 .01 Hot roll took too long to heat up after transitioning to new enhanced mode (standby control only. Fuser page count between 0 and 99,999. • Bad thermistor, circuit or cabling. • Fuser not receiving sufficient AC power. • Poor supply line voltage. • Low wattage or incorrect lamp. • Incorrect hot roll. Go to “920.xx—Cold fuser service check” on page 2-87. 920 .02 Hot roll fell too far below the desired temperature while in standby.
Service error codes (9xx.xx) (continued) Error code Sub codes 920 .12 Hot roll fell too far below the desired temperature while printing. Fuser page count between 100,000 and 199,999. • • • • • • Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Go to “920.xx—Cold fuser service check” on page 2-87. 920 .13 Hot roll too cool while checking for slope change.
Service error codes (9xx.xx) (continued) Error code Sub codes 920 .22 Hot roll fell too far below the desired temperature while printing. Fuser page count between 200,000 and 299,999. • • • • • • Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Go to “920.xx—Cold fuser service check” on page 2-87. 920 .23 Hot roll too cool while checking for slope change.
Service error codes (9xx.xx) (continued) Error code Sub codes 920 .32 Hot roll fell too far below desired temperature while printing. Fuser page count between 300,000 and 399,999. • • • • • • Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Go to “920.xx—Cold fuser service check” on page 2-87. 920 .33 Hot roll too cool while checking for slope change.
Service error codes (9xx.xx) (continued) Error code Sub codes 920 .42 Hot roll fell too far below the desired temperature while printing. Fuser page count between 400,000 and 499,999. • • • • • • Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Go to “920.xx—Cold fuser service check” on page 2-87. 920 .43 Hot roll too cool while chickens for slope change.
Service error codes (9xx.xx) (continued) Error code Sub codes 92 .52 Hot roll fell too far below desired temperature while printing. Fuser page count more than 500,000. • • • • • • Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Go to “920.xx—Cold fuser service check” on page 2-87. 920 .53 Hot roll too cool while checking for slope change. Fuser page count more than 500,000.
Service error codes (9xx.xx) (continued) Error code Sub codes 920 .92 Hot roll fell too far below desired temperature while printing. Fuser page count not available. • • • • • • • Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Excessive load on the fuser. Low voltage or incorrect lamp. Incorrect hot roll. Go to “920.xx—Cold fuser service check” on page 2-87. 920 .93 Hot roll too cool while checking for slope change.
Service error codes (9xx.xx) (continued) Error code Sub codes 922 .03 Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count between 0 and 99,999. • Low wattage or incorrect lamp. • Bad thermistor, circuit, or cabling. • Fuser not receiving sufficient AC power. • Poor supply line voltage. Go to “922.xx—Cold fuser check” on page 2-89. 922 .04 Hot roll timed out in trying to reach the final lamp detection temperature.
Service error codes (9xx.xx) (continued) Error code Sub codes 922 .16 Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count between 100,000 and 199,999. • Low wattage or incorrect lamp. • Bad thermistor, circuit, or cabling. • Fuser not receiving sufficient AC power. • Poor supply line voltage. Go to “922.xx—Cold fuser check” on page 2-89. 922 .17 Fuser has taken too long to reach desired temperature after increasing interpage gap.
Service error codes (9xx.xx) (continued) Error code Sub codes 922 .32 Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count between 300,000 and 399,999. • Low wattage or incorrect lamp. • Bad thermistor, circuit, or cabling. • Fuser not receiving sufficient AC power. • Poor supply line voltage. Go to “922.xx—Cold fuser check” on page 2-89. 922 .33 Hot roll reached final lamp detection temperature but took longer than largest time in lookup table.
Service error codes (9xx.xx) (continued) Error code Sub codes 922 .44 Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count between 400,000 and 499,999. 922 .45 After hot roll lamp detection, did not roll over to steady state control in time. Fuser page count between 400,000 and 499,999. 922 .46 Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count between 400,000 and 499,999. • Low wattage or incorrect lamp.
Service error codes (9xx.xx) (continued) Error code Sub codes 922 .56 Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count stopped at 500,000 to preserve data. • Low wattage or incorrect lamp. • Bad thermistor, circuit, or cabling. • Fuser not receiving sufficient AC power. • Poor supply line voltage. Go to “922.xx—Cold fuser check” on page 2-89. 922 .57 Fuser has taken too long to reach desired temperature after increasing interpage gap.
Service error codes (9xx.xx) (continued) Error code Sub codes 923 .01 Fuser over temperature. Fuser page count between 0 and 99,999. • Short in the thermistor circuit. • Noisy thermistor signal • Fuser is actually overheating due to hardware faults. Go to “923.xx—Hot fuser service check” on page 2-90. 923 .11 Fuser over temperature. Fuser page count between 100,000 and 199,999. • Short in the thermistor circuit. • Noisy thermistor signal • Fuser is actually overheating due to hardware faults.
Service error codes (9xx.xx) (continued) Error code Sub codes 924 .41 Open thermistor check failure. Fuser page count between 400,000 and 499,999. • Noisy thermistor signal. • Intermittent connection. • Thermistor cable not connected or thermistor actually open. Go to “924.xx—Hot fuser service check” on page 2-91. 924 .51 Open thermistor check failure. Fuser page count over 500,000. • Noisy thermistor signal. • Intermittent connection. • Thermistor cable not connected or thermistor actually open.
Service error codes (9xx.xx) (continued) Error code Sub codes 925 Display text Description Action .32 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected. Fuser page count between 300,000 and 399,999. Attempting to POR machine after receiving a 925.01. Go to “925.xx—Hot fuser service check” on page 2-91. 925 .41 Lamp detection performed and found error. Fuser page count between 400,000 and 499,999. • 115 V lamp in 220 V printer. • Lamp has excessive wattage.
Service error codes (9xx.xx) (continued) Error code Sub codes Display text 927 .02 Cartridge fan stalled. • Loose connector. • External blockage of the fan, preventing it from turning. • Bad fan. Go to “Cartridge fan service check” on page 2-76. 927 .03 Main fan took too long to ramp up. • Loose connector. • External blockage of the fan, preventing it from turning. • Bad fan. Go to “Main fan” on page 2-76. 927 .04 Main fan underspeed or stalled during speed adjustment state.
Service error codes (9xx.xx) (continued) Error code Sub codes 936 .00 Mirror moor not up to speed • Check printhead • Check system board Go to “Printhead service check” on page 2-122. 936 .10 No hall effect detected at motor start. Motor is type 0. • Check cable connections • Defective motor • Severe gear blinds in gearbox assembly • System board Go to “Main drive service check” on page 2-105. 936 .11 No hall effect detected at motor start. Motor is type 1.
Service error codes (9xx.xx) (continued) Error code Sub codes 937 .4 Overspeed detected during speed control. Motor is type 0. • Faulty motor sensor • Faulty system board Go to “Main drive service check” on page 2-105. 937 .41 Overspeed detected during speed control. Motor is type 1. • Faulty motor sensor • Faulty system board Go to “Main drive service check” on page 2-105. 937 .5 Overspeed detected during position control. Motor is type 0.
Service error codes (9xx.xx) (continued) Error code Sub codes 949 Display text Description Action .00 Delay line calibration failure System board Replace the system board. See “System board and inner shield removal” on page 4-76. 950 .00 NVRAM mismatch 951 .00 Go to “950.00 through 950.29 EPROM mismatch failure” on page 2-77. or go to “950.30 through 950.60 EPROM mismatch failure” on page 2-78. Replace the system board. See “System board and inner shield removal” on page 4-76.
Service error codes (9xx.xx) (continued) Error code Sub codes 953 .00 Display text Description Action Replace the operator panel board or upper front cover. See “Upper front cover removal” on page 4-11 or “Upper front cover removal” on page 4-11. Warning: When replacing any one of the following components: • Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly Only replace one component at a time.
Service error codes (9xx.xx) (continued) Error code Sub codes 954 .00 Display text Description Action Replace the interconnect card. See “Interconnect card assembly removal” on page 4-53. Warning: When replacing any one of the following components: • Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.
Service error codes (9xx.xx) (continued) Error code Sub codes 980 Display text Description Action .00 Unreliable comma to Paperport device The engine is experiencing unreliable communications to the specified device. 981 .00 Interface protocol violation by engine The engine protocol violation detected by the specified device. Service errors 980 thru 984 can be one of the following: system board, duplex, tray x (1, 2, 3, 4, or 5), envelope feeder or output bin. 982 .
User status displays Warning messages (second lines) These second line warnings apply to the user status displays (see “User status displays” on page 2-31). For example, Ready If none of the conditions exist that are listed in the following table, line two is blank. If any of the messages in the table are displayed, the following actions can be taken: • Press • to take the printer offline and access the Ready Menu group. The buttons are not active if Menu Lockout is turned on.
User attendance messages User attendance messages Error code Sub code Primary message Description/action Change Cartridge Invalid Refill Select one of the following actions: • Remove the toner cartridge and install a new cartridge. • Press and hold and press to display debug data for the engine and cartridge code. Note: This message may help diagnose a potential printer problem.
User attendance messages (continued) Error code Sub code Primary message Description/action Check Duplex Connection This messages displays for the following conditions: • The duplex option may have been removed from the printer, possibly to clear a paper jam or to remove the option. • The duplex option may be attached to the printer but a communications problem may prevent the printer from detection. For example, there may be a poor connection or a hardware failure.
User attendance messages (continued) Error code Sub code Primary message Description/action Disk Corrupted Reformat? The printer has detected there are errors on the hard disk that cannot be corrected. The disk cannot be used until it is reformatted. Warning: All data on the disk will be lost if you format the disk. The following actions can be taken: • Power off and remove the disk. The disk will not be formatted. • Press Empty Box M to format the disk. All data is lost when you format the disk.
User attendance messages (continued) Error code Sub code Primary message Description/action Insert =Tray 1, Tray 2, Tray 3, Tray 4, or Tray 5. The printer detects a tray needs to be inserted. The printer does not continue until it detects the tray is inserted. Note: This situation usually occurs when the tray is refilled during a job. To refill a tray during a printing session, press and wait for pages to reach the output bin before refilling the tray.
User attendance messages (continued) Error code Sub code Primary message Description/action Install Env Feed or Cancel Job This message is displayed when the envelope feeder has been hot unplugged. The printer requires the reinstallation of the feeder to print a page which has been formatted by the interpreter before the feeder was removed. The following actions may be taken: • Install the envelope feeder. • Press until Busy/Waiting displays.
User attendance messages (continued) Error code Sub code Primary message Description/action Reattach Bins x–y Bins x–y=Bins 1 to 5, Bins 2 to 6, or Bins 6 to 10 This messages displays for the following conditions: • The specified output bins may have been removed from the printer, possibly to clear a paper jam or to remove the option. • The option(s) may be attached to the printer but a communications problem may prevent the printer from detecting the option.
User attendance messages (continued) Error code Sub code Primary message Description/action 31 .xx Defective Print Cartridge Error code 31 displays when the top front cover is closed and a defective print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is defective. Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10-20 second interval.
User attendance messages (continued) Error code Sub code Primary message Description/action 37 .xx Insufficient Memory This message displays when the printer memory used to restore the Print and Hold jobs from the disk and found that some or all of the jobs could not be restored. The printer ran out of memory while attempting to restore the jobs. • Press to clear the message. Some of the Print and Hold jobs on the disk will not be restored. They remain on the disk, but cannot be accessed.
User attendance messages (continued) Error code Sub code Primary message Description/action 52 .xx Flash Full This message displays when there is not enough free space in the flash memory to hold the resources that have been requested to be written to flash. 53 .xx Unformatted Flash This message displays when the printer detects an unformatted flash at power on. Press to clear the message. The flash is marked as bad and normal operation continues.
User attendance messages (continued) Error code Sub code 56 .xx Primary message Description/action Standard Parallel Port Disabled This error is displayed when data is sent to the printer across the parallel port, but the parallel port has been disabled. Once this message is displayed, reporting of further errors is suppressed until the menus are entered, or the printer is reset. The following actions may be taken: • Press to clear the message.
User attendance messages (continued) Error code Sub code Primary message Description/action 59 .xx Incompatible Tray x An incompatible tray is installed. For Tray x, x= 2, 3, 4, or 5. Remove the incompatible tray and press to clear the message. Note: If the user installed the incompatible device to satisfy a Check Device Connections/reattach message, the user should reinstall an associated compatible option or hot unplug the option. 59 .
User line 2 link messages If the printer is locked on a particular link, the link indication displays. If the printer is ready to process any link, no messages display. Link messages are listed in the following table. User message Explanation Parallel Standard Parallel Port, if available. Serial Standard Serial Port, if available. Serial x Serial Port is attached to PCI connector x, where x=1, 2, or 3. Network x Network card x is attached to PCI connector x, where x=1, 2, or 3.
User attendance messages—paper jams and paper handling errors (2xx.xx) When the printer jams, the appropriate jam message will be displayed on the printer operator panel. If you select Show Areas on the operator panel, you can view one or more images to help you clear the jam. 23 Paper Jam, 3 pages jammed Continue Show Areas Show Areas Show Duplex Show Rear Door Show Finisher 1. Open manual feed door. User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 200 .
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 200 .08 Input sensor covered too quickly 200 .09 Did not receive proper motor feedback to start laser servo. 200 .10 Printhead motor not locked when page crosses input sensor • Printhead lock signal not working. • Printhead control not working. Go to “Printhead service check” on page 2-122. 200 .11 Printhead motor fell out of lock after page arrives at input sensor • Paper pre-staged in path.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 201 .02 Page did not reach exit sensor. Fuser page count between 0 and 99,999. • Page jammed on fuser input guide. • Page did not enter or exit fuser nip cleanly. • Exit sensor not functioning correctly. • Check fuser entry guide for toner build up. • Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 201 .12 Page did not reach exit sensor. Fuser page count between 100,000 and 199,999. • Page jammed on fuser input guide. • Page did not enter or exit fuser nip cleanly. • Exit sensor not functioning correctly. • Check fuser entry guide for toner build up. • Check fuser for wear or contamination. if a problem is found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 201 .22 Page did not reach exit sensor. Fuser page count between 200,000 and 299,999. • Page jammed on fuser input guide. • Page did not enter or exit fuser nip cleanly. • Exit sensor not functioning correctly. • Check fuser entry guide for toner build up. • Check fuser for wear or contamination. If a problem is found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 201 .32 Page did not reach exit sensor. Fuser page count between 300,000 and 399,999. • Page jammed on fuser input guide. • Page did not enter or exit fuser nip cleanly. • Exit sensor not functioning correctly. • Check the fuser entry guide for toner build up. • Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 201 .42 Page did not reach exit sensor. Fuser page count between 400,000 and 499,999. • Page jammed on fuser input guide. • Page did not enter or exit fuser nip cleanly. • Exit sensor not functioning correctly. • Check the fuser entry guide for toner build up. • Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 201 .52 Page did not reach exit sensor. Fuser page count stopped at 500,000 to preserve data. • Page jammed on fuser input guide. • Page did not enter or exit fuser nip cleanly. • Exit sensor is not functioning correctly. • Check the fuser entry guide for toner build up. • Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 201 .92 Page did not reach exit sensor. Fuser page count is not available. • Page jammed on fuser input guide. • Page did not enter or exit fuser nip cleanly. • Exit sensor not functioning correctly. • Check the fuser entry guide for toner build up. • Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 202 Description Possible causes Action .00 Paper jam at fuser exit or redrive area. Fuser page count between 0 and 99,999. Page may be jammed in fuser exit or redrive area. • Make sure the redrive door is complete closed. • Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26. • Turn media over to reduce +W curl.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 Description Possible causes .02 Exit sensor covered too long. Fuser page count between 0 and 99,999. Page may be jammed in fuser exit or redrive area. 202 .03 Page is covering narrow media sensor during warm up. Fuser page count between 0 and 99,999. If page is not visible from front or rear of machine, partial piece of page may be torn off in fuser covering narrow media sensor.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 202 Description Possible causes Action .10 Paper jam around fuser or redrive area. Fuser page count between 100,000 and 199,999. Page may be jammed in fuser exit or redrive area. • Make sure the redrive door is complete closed. • Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 Description Possible causes .12 Exit sensor covered too long. Fuser page count between 100,000 and 199,999. Page may be jammed in fuser exit or redrive area. 202 .13 Page is covering narrow media sensor during warm up. Fuser page count between 100,000 and 199,999. 202 .14 Exit sensor bounced. Fuser page count between 100,000 and 199,999. Exit sensor assembly.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 202 Description Possible causes Action .20 Paper jam around fuser exit or redrive area. Fuser page count between 200,000 and 299,999. Paper may be jammed in fuser exit or redrive area. • Make sure the redrive door is complete closed. • Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 Description Possible causes .22 Exit sensor covered too long. Fuser page count between 200,000 and 299,999. Page may be jammed in fuser exit or redrive area. 202 .23 Page is covering narrow media sensor during warm up. Fuser page count between 200,000 and 299,999. 202 .24 Exit sensor may have bounced. Fuser page count between 200,000 and 299,999.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 202 Description Possible causes Action .30 Paper jam around the fuser exit or redrive area. Fuser page count between 300,000 and 399,999. Page may be jammed in fuser exit or redrive area. • Make sure the redrive door is complete closed. • Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 Description Possible causes .32 Exit sensor covered too long. Fuser page count between 300,000 and 399,999. Page may be jammed in fuser exit or redrive area. 202 .33 Page is covering the narrow media sensor during warm up. Fuser page count between 300,000 and 399,999. 202 .34 Exit sensor may have bounced. Fuser page count between 300,000 and 399,999. Exit sensor assembly.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 202 Description Possible causes Action .40 Paper jam around the fuser exit or redrive area. Fuser page count between 400,000 and 499,999. Page may be jammed in fuser exit or redrive. • Make sure the redrive door is complete closed. • Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 Description Possible causes .42 Exit sensor covered too long. Fuser page count between 400,000 and 499,999. Page may be jammed in fuser exit or redrive area. 202 .43 Page is covering narrow media sensor during warm up. Fuser page count between 400,000 and 499,999. 202 .44 Exit sensor may have bounced. Fuser page count between 400,000 and 499,999.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 202 Description Possible causes Action .50 Paper jam around the fuser exit or redrive area. Fuser page count stopped at 500,000 to preserve data Page may be jammed in the fuser exit or redrive area. • Make sure the redrive door is complete closed. • Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 Description Possible causes .52 Exit sensor covered too long. Fuser page count stopped at 500,000 to preserve data. Page may be jammed in fuser exit or redrive area. 202 .53 Page is covering narrow media sensor during warm up. Fuser page count stopped at 500,000 to preserve data. 202 .54 Exit sensor may have bounced. Fuser page count stopped at 500,000 to preserve data. Exit sensor assembly.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 202 Description Possible causes Action .90 Paper jam around the exit or redrive area. Fuser page count is not available. Page may be jammed in fuser exit or redrive area. • Make sure the redrive door is complete closed. • Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26. • Turn media over to reduce +W curl.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 202 Description Possible causes .92 Exit sensor covered too long. Fuser page count is not available. Page may be jammed in the fuser exit or redrive area. • Make sure the redrive door is complete closed. • Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See “Fuser assembly removal” on page 4-26. • Turn media over to reduce +W curl.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 231 .00 Paper did not arrive at the duplex input sensor but did leave the printer exit sensor. • Duplex rear door not fully latched. • Printer diverter not functioning correctly. • Duplex feed system not working correctly. • Printer and duplex not aligned. • Make sure the duplex assembly rear door is properly latched.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 235. Description Possible causes 00 Paper reached the duplex exit sensor but another sheet is still detected over the doublefeed sensor. Double feed separated in duplex. 236 00 Paper did not leave the duplex exit sensor. • Duplex jam access tray is not fully latched. • Printer PTO not driving duplex feed rolls. • Duplex feed system not working correctly.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 238 .00 Paper is covering one of the duplex sensors during a reset. • Media left in the duplex and Continue selected. • Sensor is having mechanical or electrical problems. • Remove any sheets from the duplex option. • Try the duplex option again. If it fails, try another duplex option, if available. If one is not available, replace the duplex option. 238 .01 Duplex input sensor covered.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 238 .07 Duplex doublefeed, input, and exit sensors are covered. • Media left in the duplex and Continue selected. • Sensor is having mechanical or electrical problems. 239 .00 Feed error in duplex unit. • Mechanical feed error due to belt slipping. • Timing error due to feed system. Replace the duplex option. 239 .01 Jam declared by a smart device. Immediate stop.
User attendance messages—paper jams and paper handling errors (2xx.xx) Error code Sub codes 241 Description Possible causes Action .10 Page was not properly picked from tray 1. Failure to feed possible causes include: • Edge locking • Worn or contaminated pick tires • Overfilling of tray past the fill line. Fan media. Turn media over. Reduce amount of media loaded in tray 1. Replace pick tires. “Integrated tray autocompensator pick roll assembly removal” on page 4-51. 241 .
Service checks Anytime the system board is replaced, the Configuration ID must be reset in NVRAM. Go to “Configuration ID” on page 3-21. Review the following information before performing any service checks. • Paper feed problems (especially paper jams): Go to “Display Log” on page 3-23 and check the printer event log for indications of repetitive entries that help to isolate a problem to a particular area of the printer or option.
271.xx Paper Jam—Check Bin 1 displays 1 FRU Action Bottom pass thru sensor flag assembly Control board Check the flag for correct operation, binding, broken parts, or interference from the sensor cable. If incorrect, repair as necessary. If correct, make sure the bottom pass thru sensor is correctly connected to J5 on the control board. Disconnect the pass thru sensor cable and check the voltage at J5-3. The voltage measures approximately +5 V dc. If incorrect, check the voltage at J5-2.
Ready—Bin x Full displays and paper feeds into bin x 1 FRU Action Bin x sensor Bin x sensor control board Check the sensor flag for binds. Make sure the sensor flag is not in an up position. If the sensor flag is operating correctly, replace the bin x sensor. If this does not fix the problem, replace the control board. 271.
900.xx Error code service check FRU Action 1 Printer POR Turn the printer off and on several times. If Error Code 900 continues to display, go to step 2. 2 System board Turn the machine off and on several times, waiting a few minutes between power on and power off. If Error Code 900 continues to display, go to step 3. 3 Factory defaults Restore factory defaults. See “Factory Defaults” on page 3-28. This resets the non-critical areas of the user NVRAM.
927.xx Fan service check 927.xx can be used for the main fan or the cartridge fan. • Main fan—927.00, 927.01, and 927.03 through 927.07. • Cartridge fan—927.02 Main fan Service tip: The main fan runs at full speed at the end of POR or when the printer is printing. It will only run half speed when the printer is in the Ready state and not printing. FRU Action 1 Main fan Check the main fan to make sure it is plugged into J4 on the system board.
950.00 through 950.29 EPROM mismatch failure Warning: When replacing any one of the following components: • Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
950.30 through 950.60 EPROM mismatch failure Warning: When replacing any one of the following components: • Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
FRU Action 4 System board Replace the current system board with the original system board. See “System board and inner shield removal” on page 4-76. If the error remains, go to step 6. 5 Interconnect card assembly Replace the original interconnect card assembly with a new and not previously installed interconnect card assembly. If the problem remains, contact the next level of support. 6 System board Replace the original system board with a new and not previously installed system board.
Cover closed switch/cable service check FRU Action 1 Toner cartridge Make sure the toner cartridge is correctly installed and that the right and left cartridge tracks are not loose or broken. Make sure the cover closed switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover closed switch spring. 2 Cover closed switch/cable assembly Check the cover closed switch for proper mechanical operation. If incorrect, repair as necessary.
3 FRU Action +5 V dc test point on the system board Check for approximately +5 V dc at the +5 V test point on the system board. Note: Use care not to short adjacent voltage test points. If the voltage is correct, replace the system board assembly. If the voltage is incorrect, go to step 4. 4 System board Check to make sure the LVPS cable is correctly installed at J27 on the system board. If not, reseat and recheck the voltage at the +5 V dc test point on the system board.
Duplex option service check Messages displayed when a 23x Duplex Paper Jam displays. 23x Paper Jam Leave Job Check Duplex in Finisher Primary message Secondary message If sheets have been accumulated to be stapled or offset when the jam is detected, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam clearance procedure.
231.xx Jam displays on the operator panel FRU Action 1 Fuser exit sensor Check the sheet of media is leaving the exit sensor in the fuser and feeding properly into the duplex option. Check the duplex link for correct operation and any signs of damage. If the problem is prior to the duplex input sensor and in the base machine, repair as necessary. If the jam occurs in the duplex option prior to the duplex input sensor, go to step 2.
Envelope feeder service check Service tip: Check the envelope feeder paper path for any debris, pieces of envelope and so on. If any other options are installed make sure they are operating normally. If only the envelope feeder is failing to operate correctly, continue with this service check, otherwise verify the interconnect card is functioning properly. Service tip: The envelope feeder receives its +5 V dc operating voltage from the +24 V dc bulk at J1-7.
Operator panel displays 260.xx Paper Jam after attempted feed but before envelopes are put in the hopper OR the operator panel continues to display Load Envelopes after envelopes are placed in the hopper Service tip: The kick rolls rotate during the attempted feed cycles. 1 FRU Action Envelope out hopper sensor flag Check the envelope out sensor flag for damage, correct installation and operation. If incorrect, repair or replace the envelope feeder option. 990.
260.xx Paper Jam displays, envelope stops in feeder paper path FRU Action 1 Kick rolls/feed rolls/drive rolls Check all the rolls for oil, grease, or other contamination. If you find a problem, clean the rolls. If this does not correct the problem, replace the envelope feeder. 2 Deflector gap adjustment Check the deflector gap adjustment. The adjustment may be too narrow. If the adjustment is correct, replace the envelope feeder option. Envelope feeder multifeeds or may not display a 260.
Fuser service checks 920.xx—Cold fuser service check Error codes 920.x and 922.xx may display for a cold fuser failure. Some 920.xx error codes may be cleared by turning the printer on and off and allowing it to complete POR. CAUTION: There is a danger from hazardous voltage in the area of the printer where you are working. Unplug the printer before you begin, or use caution if the printer must receive power in order to perform the task. Service tip: Some 920.
FRU Action 5 LVPS LVPS to fuser AC cable CAUTION: When taking measurements for AC power, observe all safety precautions. Check the AC line voltage between the pins on the fuser end of the LPVS to fuser AC cable. If the voltage is correct, unplug the AC power cord from the LVPS cable. If the voltage is correct, unplug the AC power cord from the LVPS, pull the LVPS out far enough to be able to check the voltage between CN-1 and CN1-3 on the LVPS board.
922.xx—Cold fuser check Error codes 920.xx and 922.xx may display for a cold fuser failure. Some 920.xx error codes may be cleared by turning the printer on and off and allowing it to complete POR. CAUTION: There is a danger from hazardous voltage in the area of the printer where you are working. Unplug the printer before you begin, or use caution if the printer must receive power in order to perform the task. Service tip: Set the Fuser Temperature to NORMAL before starting this service check.
6 FRU Action Fuser assembly If no problem is found up to this point, then replace the following in the order shown: • Fuser assembly. See “Fuser assembly removal” on page 4-26. • System board assembly. See “System board and inner shield removal” on page 4-76. • LVPS. See “Low voltage power supply removal” on page 4-54. 923.xx—Hot fuser service check Error Code 923.xx, 924.xx, and 925.xx may display for a hot fuser failure. CAUTION: .The fuser may be hot, use caution before removing or servicing.
924.xx—Hot fuser service check Error Code 923.xx, 924.xx, and 925.xx may display for a hot fuser failure. CAUTION: .The fuser may be hot, use caution before removing or servicing. CAUTION: There is a danger from hazardous voltage in the area of the printer where you are working. Unplug the printer before you begin, or use caution if the printer must receive power in order to perform the task. Service tip: Set the Fuser Temperature to NORMAL before starting this service check.
3 FRU Action Fuser lamp Turn the printer off and allow the fuser assembly to cool. After the fuser assembly cools down, turn the printer on. If you receive the same error code, replace the fuser lamp. See “Fuser lamp removal” on page 4-32. Note: If the fuser lamp is replaced, allow the fuser to cool or a 925.xx error could be displayed. Fuser exit sensor service check If any of the following codes are displayed, there is a potential problem in the area of the exit sensor: 201.00, 201.02, 201.10, 201.
Fuser narrow media sensor service check If any of the following error codes are displayed, a problem may exist in the area of the narrow media sensor assembly: 201.04, 201.14, 201.24, 201.34, 201.44, 201.54, and 201.94.
Fuser solenoid service check CAUTION: There is a danger from hazardous voltage in the area of the printer where you are working. Unplug the printer before you begin, or use caution if the printer must receive power in order to perform the task. Service tip: Try changing the envelope enhance level setting. A different setting may correct the problem. Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section “Fuser solenoid adjustment” on page 4-2.
High-capacity feeder input tray service check Note: Voltage measurements in the high-capacity feeder input tray service checks must be made with the highcapacity feeder attached to the base printer to obtain accurate results. Service tip: Be sure the paper size switch is set to the correct paper size setting and the rear paper guides are in the correct locations for the size of paper installed in the high-capacity feeder tray.
4 FRU Action High-capacity feeder option control board Check the voltage on J8-1 (green). The voltage measures +24 V dc. If incorrect, check the autoconnect system for any problems. +24 V dc must come from the base printer through the autoconnect system to the high-capacity input for the high-capacity feeder to be recognized. If the voltage is correct, check the voltages at J11-3(red) and J11-4(red). The voltages measure +24 V dc. If correct, replace the high-capacity feeder option system board.
Tray x Empty displays when there is paper in the high-capacity feeder input tray FRU Action 1 Paper out sensor flag 2 Paper out sensor (on option system board) Check the paper out sensor flag for correct operation and installation. If correct, replace the high-capacity feeder system board. (The paper out sensor is mounted on the high-capacity feeder system board.
The elevator tray does not move up or down; the printer recognizes that the option is installed 1 FRU Action DC drive motor highcapacity feeder option system board Be sure the motor cable is correctly installed at J1 on the board. Check the cables, damaged or loose wires. Disconnect the motor. Check for a short between each pin and the motor housing. If a problem is found, replace the motor assembly.
Paper size switch not selecting paper size that is selected 1 FRU Action Paper size switch High-capacity feeder option control board Check for continuity between the common pin (J5-1) and the pin of the paper size selected. Pin Color J5-1 Black Paper size Common lead J5-2 Blue B5 J5-3 Green Executive J5-4 Yellow A4 J5-5 Orange Letter J5-6 Red Legal J5-7 Brown A5 If any position does not measure continuity when selected, replace the paper size switch assembly.
Tray x Paper Low displays when the high-capacity feeder input tray is full or has adequate paper in the tray 1 FRU Action Paper low switch Paper low switch cable High-capacity feeder option control board Run the sensor diagnostics for tray x (x=the number that represents the high-capacity input tray). If the test fails, check the voltage at J3-1 (gray). The voltage measures approximately +24 V dc. If incorrect, disconnect the paper low switch cable from J3 and measure the voltage again on J3-1.
The printer does not recognize one or more output options as installed Service tip: If more than a single output option is installed, check each one to see if the printer recognizes any single option as installed. If the printer recognizes any of the output options, the base printer autoconnect system is operating correctly. The problem is in the unrecognized option. Continue with this service check or go to the service check for the failing output option.
271.xx Paper Jam - Check Bin x, POST incomplete 1 FRU Action Upper pass thru sensor flag assembly Upper control board Check the flag for correct operation, binding, broken parts, or interference from the sensor cable. If incorrect, repair as necessary. If correct, make sure the lower pass thru sensor is correctly connected to J3 on the lower control board. Disconnect the pass thru sensor cable and check the voltage at J3-3. The voltage measures approximately +5 V dc.
24x.xx Paper Jam displays, paper jammed over the pass thru sensor (The printer displays the value of x for the paper tray where the error occurs. Example: 241 is a Paper Jam Tray 1) FRU Action 1 Pass thru sensor and flag assembly The tray x option system board did not detect a piece of paper actuating the pass thru sensor. Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu.
Paper from Tray x does not reach the pass thru sensor Service tip: Check the media in tray x to make sure it is within specifications. Some types of labels, foil material, and slick papers can cause misfeeds and slippage of the rollers. 1 FRU Action Autocompensator assembly Check the autocompensator pick arm rollers for any sign of glazing, toner or other buildup. Clean or replace as necessary.
Main drive service check Service tip: Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or system board. Warning: Whenever the gearbox assembly is removed from the machine it must be handled very carefully. Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage. It is also very important not to let any dirt, paper, staples, or other material come intact with the grease in the gearbox assembly.
Operator panel service check Note: The operator panel board is a separate FRU and is also part of the upper front cover FRU Warning: When replacing any one of the following components: • Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
Operator panel display Service tip: The printer has detected a problem with the system board, the operator panel cable (part of the upper front cover hinge assembly), or the operator panel board if POST does not complete, the printer emits 5 beeps, and stops in a continuous pattern until the printer is turned off.
Options service check Service tip: When you have a problem with any of the options installed in the options slots on the interconnect card, switch the non operating option to one of the other option slots to isolate the failure. Flash Memory Option(s) Run a copy of the test page and check to see if the option you are checking is listed. The printer does not recognize the option being installed if the option is not listed. Make sure the memory card is installed correctly and is not broken or damaged.
Output bin sensor standard tray service check Service tip: If the output bin standard tray fills up and the bin full sensor fails to post the Remove Paper Standard Bin message: 1. 2. 3. 4. 5. Enter the Diagnostics Mode. Select Output Bin Tests. Select Sensor Tests. Select Standard Bin. Check the sensor and flag for proper operation. If you find no problem with the sensor and flag, continue with the service check. Service tip: Be sure the flag is correctly installed.
Output expander service check Service tip: The majority of the mechanical components can be observed during operation by removing the left, right, and system board covers. The output expander functions without the covers installed. Make sure the option is correctly installed before attempting to service the unit. No jumpers should be installed at connector J6 on the output expander board.
Remove Paper—Output Bin x displays, POST incomplete, unable to clear the message 1 FRU Action Dual output bin sensor flag Check the flag for correct operation, binding, broken parts, or interference from the sensor cable, If incorrect, repair as necessary. or replace the output expander option. 271.xx Paper Jam—Check Bin x, POST incomplete 1 FRU Action Pass thru sensor and flag assembly Control board Check the sensor flag for proper operation.
Paper feed service check If you have a 936 Transport Motor Error go to “Main drive service check” on page 2-105. FRU Action 1 Alignment assembly Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight. Check the alignment assembly for worn rollers, contaminated rollers, or binds. Replace the alignment assembly if any problem is found. 2 Inner deflector Check the inner paper deflector for correct installation.
Paper fails to feed from the multipurpose tray The pick roll should make one complete revolution and stop with the flat side down. If the pick roll turns but does not pick paper, check the roll for signs of wear, oil or grease on the surface of the pick roll or slick spots. If you find a problem, replace the pick roll assembly. Check to ensure the media that is being fed through the multipurpose tray assembly meets recommended paper specifications.
Tray 1 not recognized as being installed; unable to clear Tray 1 Missing message 1 FRU Action Tray 1 Check Tray 1 for damaged or broken autosize fingers. Check for anything that would prevent the autosize fingers from activating the paper activate springs and ITC switches. LGL A4 LTR EXEC B5 A5 S W S S 2 W W 1 0 If a problem is found, repair or replace the tray assembly. If no problem is found, go to step 2.
The printer does not recognize the paper size selected FRU Action 1 Back restraint Side restraint Snap-in plate Autosize slider Autosize finger Check all the paper size parts for damage or broken parts. make sure the parts operate correctly. If a problem is found, repair as necessary. If no problem is found, go to step 2. 2 Switch activate spring Paper size sending board Make sure the switch activate spring is not bent or broken. Replace the spring if damaged.
Parallel port service check Run the “Parallel Wrap tests” on page 3-8. Note: The Parallel Wrap Test is designed to check the parallel port hardware by using a wrap plug (P/N 1319128) and invoking the Parallel Diagnostic Test. This test helps isolate the printer from the parallel cable and host. The test provides failure information on the display for approximately three seconds. If the test indicates that a problem is detected, replace the controller board.
4 FRU Action HVPS cable (part of front harness cable) System board Check the continuity of the HVPS cable. If incorrect, replace the cable assembly. If correct, replace the system board. Print quality—blank page FRU Action 1 Print cartridge Check the print cartridge for damage, especially the PC drum contact on the cartridge. 2 High voltage contact Check the PC drum contact on the right side frame for damage, PC drum contact wear or contamination.
Print quality—blurred or fuzzy print Blurred of fuzzy print is usually caused by a problem in the main drive gearbox assembly, alignment assembly, any feed roller, or in the transfer roll bearings or transfer roll. Check the gearbox assembly for correct operation. Check the transfer roll for binds or a contaminated shaft or bearings. Blurred print can also be caused by incorrect feeding from one of the input paper sources, paper trays, duplex option, or envelope feeder.
4 FRU Action System board HVPS connector Check the following voltages at J15 on the system board. Measure the voltages from J15 to printer ground. Pin J15 Voltage (approximate) Printer idle J15-1 0 V dc J15-2 +4 V dc J15-4 0 V dc Printer printing J15-1 0 V dc to +5 V dc J15-2 0 V dc to +4 V dc J15-4 0 V dc to +1.9 V dc If J15-1 voltage is incorrect, check the continuity of the front harness cable (J15-1 line). If there is no continuity, replace the harness cable.
Print quality—black bands on outer edges of the page This print quality problem appears as vertical black bands on one or both sides of the copy and can be wide, narrow, light, or dark. FRU Action 1 Charge roll counterbalance springs If the problem is just on one side of the page, check the charge roll counterbalance spring on that side.
Print quality—light print Service tip: Check the toner saver and print darkness settings first if the print is light. FRU Action 1 Transfer roll Check the right end of the transfer roll shaft for signs of wear or contamination. If incorrect, replace the transfer roll. 2 Right side transfer roll arm assembly HVPS Check the right side transfer roll arm assembly bearing for wear or contamination. Also make sure the transfer cable is firmly attached to the bearing.
Printhead service check CAUTION: The printhead is not a serviceable FRU. Do not disassemble the printhead. The printhead assembly does not contain any service replaceable parts or components. If service error code 930.xx displays, the wrong printhead is installed in the printer. See “Printhead” on page 7-10. Note: A 201.xx paper jam may also indicate a failing printhead. The paper may have jammed prior to or at the input sensor. Print the event log and see if 201 or 931 errors are logged.
Diagnostic information 2-123
2-124 Service Manual
Diagnostic information 2-125
System board service check Warning: When replacing any one of the following components: • Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
Toner sensor service check Service tip: Check the print darkness menu setting before checking the toner sensor. This service check is intended to be used when a 929.xx Service Error displays. FRU Action 1 Developer drive assembly Incorrect operation of the developer drive assembly can cause the printer to display a 929.xx error code (Toner Sensor). Check the developer drive assembly for correct installation or, any sign of worn, loose, or broken parts.
Transfer roll service check Service tip: The transfer roll is 51.02 mm (2.009 inch) circumference. Any print quality problems such as lines that are spaced 51.02 mm apart indicate you should check the transfer roll for damage and check for toner or foreign material buildup. Service tip: The transfer roll assembly is part of the maintenance kit and is replaced when an 80 Scheduled Maintenance displays. Ask the customer if they have replaced the transfer roll recently.
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. Diagnostics Mode 1. Turn off the printer. 2. Press and hold and . The Diagnostics Mode group contains the settings and operations used while manufacturing and servicing the printer. See “Diagnostics mode” on page 3-2 for more information.
Diagnostics mode Entering Diagnostics mode 1. Press and hold and . 2. Turn on the printer. 3. Release the buttons when Performing Self Test displays.
Diagnostics mode tests (continued) DUPLEX TESTS (if installed) Quick Test See “Quick Test (duplex)” on page 3-9 Top Margin See “Top Margin (duplex)” on page 3-10 Sensor Test See “Sensor Test (duplex)” on page 3-10 Motor Test See “Motor Test (duplex)” on page 3-11 Duplex Feed 1 See “Duplex Feed 1” on page 3-12 Duplex Feed 2 See “Duplex Feed 2” on page 3-12 INPUT TRAY TESTS Feed Tests See “Feed Tests (input tray)” on page 3-13 Sensor Test See “Sensor Test (input tray)” on page 3-13 OUTPUT BIN
Diagnostics mode tests (continued) EP SETUP EP Defaults See “EP Defaults” on page 3-22 Fuser Temp See “Fuser Temperature (Fuser Temp)” on page 3-22 Fuser Page Count See “Fuser Page Count” on page 3-22 Warm Up Time See “Warm Up Time” on page 3-22 Transfer See “Transfer” on page 3-22 Print Contrast See “Print Contrast” on page 3-22 Charge Roll See “Charge Roll” on page 3-22 Gap Adjust See “Gap Adjust” on page 3-22 EVENT LOG Display Log See “Display Log” on page 3-23 Print Log See “Print Log
3. Use or to select the margin setting you need to change, and press . The Top margin sign/value pair blinks. This indicates it is the margin value being changed. T=xxx* L=xxx* 4. Use to decrease or B=xxx* R=xxx* to increase the offset values, and press to confirm the value. The message Submitting selection displays, and the original REGISTRATION screen appears with the beside the previously selected margin setting.
PRINT TESTS Input source tests 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. Check each Test Page from each source to assist in print quality and paper feed problems. To run the Print Test Page: 1. Select PRINT TESTS from the Diagnostics menu. 2. Select the media source.
HARDWARE TESTS Select the following Hardware Tests from this menu: • • • • • • Panel Test Button Test DRAM Test ROM Memory Test Parallel Wrap (if available) Serial Wrap (if available) Panel Test This test automatically toggles each pixel of the operator panel 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.
CACHE Test This test is used to verify the printer processor cache. To run the CACHE Test: 1. Select CACHE TEST from HARDWARE TESTS. The message CACHE Test Testing… displays. Then the message Resetting Printer appears. 2. The printer automatically performs a Power On Reset (POR). While the CACHE test executes, the power indicator blinks green. The following type of message appears: CACHE Test x100 P:###### F:#### • P:###### represents the number of times the cache has passed and finished successfully.
Serial Wrap tests The serial wrap tests are used to check the operation of the serial port hardware using a wrap plug. Use Serial 1 Wrap if a serial port is available through PCI slot 1 and Serial 2 Wrap if the serial port is available through PCI slot 2. To perform the Serial Wrap tests: 1. Disconnect the serial interface cable, and install the serial wrap plug. 2. Select Serial 1 Wrap or Serial 2 Wrap from HARDWARE TESTS. The power indicator blinks green indicating the test is in progress.
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” on page 3-4. To set the Top Margin (duplex): 1. Print the Quick Test (duplex): a. Select Quick Test from DUPLEX TESTS. b. Select Single. c.
Motor Test (duplex) This test lets you test the duplex option paper feed drive system, and verify that the power and velocity values are acceptable. The duplex runs the DC motor at high speed and low speed, taking an average of the power (PWM) required for each speed and calculating the KE value. To run the Motor Test (duplex): 1. Select Motor Test from DUPLEX TESTS. The power indicator light blinks, and the message Motor Test Testing displays. 2. When the motor stops, the results are displayed.
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. Select Duplex Feed 1 from DUPLEX TESTS. The power indicator blinks while the paper is feeding, and the message Duplex Feed 1 Feeding… displays. The message Duplex Feed 1 Clear Paper displays when the paper reaches paper stop position 1, and the power indicator turns on solid. 2.
INPUT TRAY TESTS Feed Tests (input tray) This test lets the servicer observe the paper path as media is feeding through the printer. A blank sheet of paper feeds through the printer as the laser turns off during this test. The only way to observe the paper path is to open the lower front door that is used to access the envelope or multipurpose feeder. The paper is placed in the output bin. To run the Input Tray Feed Tests: 1. Select Feed Tests from INPUT TRAY TESTS. 2.
OUTPUT BIN TESTS Feed Tests (output bins) Use these tests to verify that media can be fed to a specific output bin. Media is fed from the default input source to the selected output bin. No information is printed on the media fed to the output bin because the printhead is not engaged during this test. These tests can use any media size or envelope supported by the printer.
Sensor Test (standard output bin) This test is used to verify if the standard bin sensor is working correctly. To run the Sensor Test for the standard bin: 1. Select Sensor Test from OUTPUT BIN TESTS. 2. Select Standard Bin from Sensor Tests. 3. Select NearFull or Full sensor to test. The following screen is displayed: Standard Bin x Full=Open NearFull=Open • Full—Bin full sensor • NearFull—Bin near full sensor 4. Manually actuate the bin sensor by moving the flag in and out of the sensor.
Sensor Test (high capacity output stacker) 1. Select Sensor Test from OUTPUT BIN TESTS. 2. Select Output Bin x (x=number of the output option to be tested). The following screen is displayed: HC Bin x • • • • TP=OPpassThru=Open Full=Open NearFull=Open TP—High-capacity top position sensor passThru—High-capacity pass thru sensor Full—High-capacity bin full sensor (lower part of dual sensor) NearFull—High-capacity bin near full sensor (upper part of dual sensor) 3.
Diagnostic aids 3-17
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: • • • • • Exit—Exit sensor Front Door—Front door sensor Input—Input sensor NarrowMedia—Output (exit) sensor Toner Level—Toner level sensor (remove the cartridge and replace to actuate the sensor) 2.
Disk Test/Clean Warning: This test destroys all data on the disk and should not be attempted on a good disk. Also note that this test may run approximately 1½ hours depending on the disk size. To run the Disk Test/Clean Test: 1. Select Disk Test/Clean from the Device Tests menu. Files will be lost/Go or Stop? message displays to warn the user that all contents on the disk will be lost. 2.
PRINTER SETUP Defaults US/Non-US defaults changes whether the printer uses the US factory defaults or the non-US factory defaults. The settings affected include paper size, envelope size, PCL symbol set, code pages, and units of measure. Warning: Changing this setting resets the printer to factory defaults, and data may be lost. It cannot be undone. Page Count The page count can only be viewed and cannot be changed. To view the page count: 1. Select Page Count from PRINTER SETUP. 2.
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. The IDs consist of eight hexadecimal characters, including 0 through 9 and A through F.
EP SETUP EP Defaults This setting is used to restore each printer setting listed in EP SETUP to its factory default value. Sometimes this is used to help correct print quality problems. To restore EP Defaults: 1. Select EP Defaults from EP SETUP. 2. Select Restore to reset the values to the factory settings, and select Do Not Restore to exit without changing the settings.
EVENT LOG Display Log The event log provides a history of printer errors. It contains the 12 most recent errors that have occurred on the printer. The most recent error displays in position 1, and the oldest error displays in position 12 (if 12 errors have occurred). If an error occurs after the log is full, the oldest error is discarded. Identical errors in consecutive positions in the log are entered, so there may be repetitions. All 2xx and 9xx error messages are stored in the event log.
To print the event log: Select Print Log from EVENT LOG. Press Back ( ) to return to EVENT LOG. Clear Log Use Clear Log to remove the current information in the Event Log. This affects both the viewed log and the printed log information. 1. Select Clear Log from the Event Log menu. 2. Select YES to clear the Event Log or NO to exit the Clear Log menu. If YES is selected, Deleting EVENT LOG displays on the screen. Press Back ( ) to return to EVENT LOG.
Configuration menu (CONFIG MENU) Entering Configuration Menu 1. Turn off the printer. 2. Press and hold and . 3. Turn on the printer. 4. Release the buttons when Performing Self Test displays. The message CONFIG MENU displays on the top line of the operator panel.
To view the maintenance page count: 1. Select Maint Cnt Value from CONFIG MENU. 2. Press Press Back ( to view the value. ) to return to the main Configuration menu. Maintenance page counter reset (Reset Maint Cnt) After scheduled maintenance, the servicer needs to reset the page counter. To reset the maintenance page count to zero: Select Reset Maintenance Count from the Configuration menu. The message Reset Maint Cnt=Reset displays momentarily.
SIZE SENSING This setting controls whether the printer automatically registers the size of paper installed in an input source with size sensing. Paper source Size sensing ✓ Tray 1 (integrated) Multipurpose feeder 250-sheet drawer ✓ 500-sheet drawer ✓ 2000-sheet drawer ✓ 250-sheet duplex 500-sheet duplex Envelope feeder When the setting is Auto, every input option equipped with size sensing hardware automatically registers what size media it contains.
Factory Defaults This setting enables a user to restore all the printer settings to the original factory settings. Selections are Restore Base and Restore Network. Network does not appear unless you have a network printer. The following settings are not changed: • Display language • Settings in the NETWORK/PORTS MENU group. Energy Conserve This menu controls what values appear on the Power Saver menu.
Font Sharpening This setting allows a user to set a text point size below which the high frequency screens are used when printing font data. For example, at the default 24, all text in font sizes 24 and less will use the high frequency screens. The values for this setting range from 0 to 150, and the default value is 24. This setting affects PostScript, PCL, and XL. To change the value, select Font Sharpening from the CONFIG MENU, and use to increase the value.
Menu settings page You can print a menu settings page to review the default printer settings and to verify your printer options are installed correctly. 1. Press Menu ( ) to display Menus. 2. Press until the 3. Press . 4. Press until the 5. Press . appears next to Reports. appears next to Menu Settings Page. The message Printing Menus Settings appears on the display. The printer returns to the Ready state after the menu settings page prints.
Theory Autocompensator operation The autocompensator is a paper pick device that generates its own normal force. This force generation is inherent in the fundamental design of the pick arm. If light media is used, it picks very gently. If a heavy media is used, it picks very aggressively. No customer adjustments are necessary, therefore no special trays are needed for card stock or labels. The gearing in the arm is designed so the input torque from the motor produces a movement about the pivot of the arm.
Autoconnect system, paper tray options, envelope feeder—electrical Autoconnect cabling and connectors The printer options make electrical connection automatically, requiring no external cables when the option is mechanically installed under the printer. Communication between the option and the base printer stops when you remove an option. The printer no longer recognizes the option and deletes associated messages.
P aper F eed J ams A c c es s doors and trays T he following illus tration shows the path that print media travels through the printer. T he path varies depending on the input s ource (trays, multipurpose feeder, envelope feeder) and output bins (finis her, s tacker, expander, mailbox) you are us ing.
250 Paper Jam Check MP Feeder 1. Remove the paper from the multipurpose feeder. 2. Flex, fan, and restack the media, and place it into the multipurpose feeder. 3. Load the print media. 4. Slide the side guide toward the inside of the tray until it lightly rests against the edge of the media. 5. Press 3-34 Service Manual .
260 Paper Jam Check Env Feeder The envelope feeder feeds envelopes from the bottom of the stack; the bottom envelope will be the one that is jammed. 1. Lift the envelope weight. 2. Remove all envelopes. If the jammed envelope has entered the printer and cannot be pulled out, remove the envelope feeder. a. Lift the envelope feeder up out of the printer, and then set it aside. b. Remove the envelope from the printer. c. If you cannot remove the envelope, the print cartridge will have to be removed.
23x and 24x jams Paper jams in these areas can occur on the incline surface of a tray or across more than one tray. To clear these areas: 1. Open the printer paper tray, and remove any jammed media. 2. Open the duplex tray. To remove the media, pull up. 3. Open any optional trays beginning at the top, and remove any jammed media. Pull the print media either up or down. If it does not pull easily one way, try the other way.
4. If you have an optional 2000-sheet feeder, open the front door, press the elevator button (A) to lower the tray, remove the jam, and make sure the stack of print media is neat and aligned. 5. Press . 200 and 201 Paper Jam Remove Cartridge 1. Push the release latch, and lower the multipurpose feeder. 2. Push the release latch, and open the top front cover. CAUTION: The inside of the printer is hot.
3. Lift and pull the print cartridge out of the printer. Warning: Do not touch the photoconductor drum on the underside of the cartridge. Use the cartridge handle whenever you are holding the cartridge. 4. Place the print cartridge aside. Note: Do not leave the cartridge exposed to light for extended periods. Note: The print media may be covered with unfused toner, which can stain garments and skin. 5. Pull the print media up and toward you.
202 Paper Jam Open Rear Door 1. If the paper is exiting the printer, pull the media straight out, and press . Otherwise continue with step 2. 2. Open the printer rear door. 3. Remove the jammed media. 4. Close the rear door. 5. Press .
23x Paper Jam Open Duplex Rear Door 1. Open the duplex rear door. 2. Remove the jammed media. Depending on the media location, pull the media either up or down. 3. Close the duplex rear door. Make sure it snaps into place. 4. Press 3-40 Service Manual .
Pages 3-42 through 3-44 have been removed from this document intentionally.
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).
Adjustment procedures Fuser solenoid adjustment Perform the fuser solenoid adjustment whenever you replace the fuser solenoid. Adjust the fuser solenoid while installed in the printer. Adjust the screw on the eccentric mounted on the solenoid housing to provide an air gap between the rear of the solenoid stator and the solenoid armature. The solenoid air gap for all models is 4.5 mm ± 0.1 mm.
Paper alignment assembly adjustment Do the alignment assembly adjustment whenever you replace the alignment assembly. Always print a copy of the Quick Test Page before making any adjustments to the alignment assembly reference adjustment screw. When replacing the alignment assembly, it is necessary to back the reference adjustment screw out far enough to remove the old assembly and install the new one. • If you are replacing the alignment assembly, go to step A.
Removal procedures CAUTION: Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. CAUTION: Use the handholds on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down. Note: Some removal procedures require removing cable ties.
Redrive cap cover removal 1. Pull up on the right side of the redrive cap cover to remove. 2. Remove the redrive cap cover. Paper support removal 1. Raise the paper support, and lift to release the latches. 2. Remove the paper support.
Left door removal 1. Open the upper and lower front covers. 2. Press the two left door latch buttons (A), and open the left door. 3. Release the top hinge from the latch.
4. Lift the door to release the bottom from the pin (B), and remove the door. Redrive door 1. With the redrive door partially open, lift and free the left side. 2. Remove the redrive door.
Right cover removal 1. 2. 3. 4. Remove the redrive cap. See“Redrive cap cover removal” on page 4-5. Open the upper and lower front covers. Remove the print cartridge. Remove the right front cover mounting screw (A). 5. Remove the redrive door. See “Redrive door” on page 4-7. 6. Remove the two screws (B).
7. Remove the right rear cover mounting screw (C). 8. Press the two latches to remove the redrive assembly.
9. Press the latch (D) firmly to release the front of the right cover. 10. Pull up and out on the right cover to release the three cover retainers (E) at the bottom. Note: When replacing the right side cover, make sure the three cover retainers are correctly located in the appropriate slots in the right side frame.
Upper front cover removal Warning: When replacing any one of the following components: • Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
6. Disconnect the cables. Note: It may be necessary to remove the operator panel cable from the cable clip (C) to be able to disconnect the cable from the operator panel. 7. Remove the upper front cover. Note: If you are replacing the upper front cover, remove the upper front cover outer bezel and upper front cover latch. Otherwise, carefully set the upper front cover aside to avoid scratching the bezel or loosening the latch and spring.
Upper front cover latch removal 1. Remove the upper front cover. 2. Remove the screw (A) holding the latch and spring to the upper front cover. Installation note: The spring (B) is installed as shown.
Upper front cover outer bezel removal 1. Open the lower front cover. 2. Open the upper front cover. 3. Remove the two small upper front cover outer bezel mounting screws (A). 4. Pull up to remove the outer bezel. NOTE: If available, place a soft, clean cloth on the open lower front bezel. The clear inner bebel (B) is not connect and may fall. The cloth may prevent scratches on the bezel.
Multipurpose feeder/lower front cover assembly removal 1. Open the multipurpose tray to a position that allows the left and right tray hinge slots (A) to align with the D-shape mounting posts (B). Pull upward on each tray hinge to remove the tray from the two mounting posts. Warning: Be careful not to break or stress the hinges. 2. Remove the multipurpose tray/lower front cover assembly.
Left cover handle holder removal 1. 2. 3. 4. Open the left side cover. Remove the outer system board shield. See “Outer shield removal” on page 4-67. Remove the two screws (A) holding the top of the left handle holder in place. Use the tab (B) to lift out the left handle holder. Right cover handle holder removal 1. Remove the right side cover. See “Right cover removal” on page 4-8. 2. Remove the two screws (A) holding the top of the right handle holder in place. 3. Lift out the right handle holder.
Left and right frame extensions 1. 2. 3. 4. Remove the toner cartridge. Turn the printer on its back. Remove the two screws (A) holding the right frame extension. Remove the two screws (B) securing the left frame extension.
Pass thru plate 1. Remove the redrive assembly. See “Redrive assembly removal” on page 4-74. 2. Remove the screw (A) securing the pass thru plate. 3. Carefully remove the plate until it is loose. 4. Remove the fuser to system board DC cable (B) secured through the plate. Note: Note the routing of the fuser card to system board DC cable.
Laser cover removal 1. 2. 3. 4. 5. 6. Remove the left door. See “Left door removal” on page 4-6. Remove the right cover. See “Right cover removal” on page 4-8. Remove the paper support. See “Paper support removal” on page 4-5. Remove the redrive cap. See “Redrive cap cover removal” on page 4-5. Press the fuser wiper cover latch, and remove the cover. Remove the screw (A) at the rear of the printer and the larger screw (B) at the front on the right side. 7.
8. Remove the paper bin full sensor flag from the mounting bracket. See “Paper bin full sensor flag removal” on page 4-70. 9. Unlatch the front right and front left cover posts, and remove the cover.
Bevel gear removal 1. 2. 3. 4. Open the left door. Remove the inner shield. Remove the gear guard. Remove the power takeoff shaft and spring (A) through the bottom of the printer. 5. Place your thumb on the top of the gear, and press firmly down and away. Note: You need to exert firm pressure to snap the bevel gear out.
Installation 1. Remove any washer that may be present (A) and discard. 2. Lubricate areas (A) that engage the journal (B) with grease from the provided packet. 3. Place the new washer (C) on the bevel gear shaft. 4. Insert the bottom portion and press or pull into position. Note: You should hear two distinct snaps. If you only hear one, the bevel gear is only partially engaged and you should continue to press until the second snap is heard. Very firm pressure is required.
Cartridge duct removal 1. Open the left door. 2. Disconnect the printhead laser cable from J2 on the system board. 3. Remove the three screws securing the cartridge duct (A). Note: It may be necessary to pull the main fan cable (B) up and out of the way to remove the duct. 4. Reconnect the printhead laser cable. Note: Be sure to reposition the main fan cable if you moved it out of the way when removing the duct.
Developer drive assembly removal 1. Remove the system board and inner shield. See “System board and inner shield removal” on page 4-76. 2. Remove the two short screws (A) and the one long screw (B) securing the developer drive assembly. 3. Remove the developer drive assembly. 4. Remove the developer drive coupler kit. See “Developer drive coupler kit removal” on page 4-25. Installation 1. Place the developer coupler into the main motor drive shaft. 2.
Developer drive coupler kit removal 1. Remove the developer drive. See “Developer drive assembly removal” on page 4-24. 2. Remove the shaft drive and coupler. ESD cover removal 1. Open the multipurpose tray, and remove the tray from the two mounting posts. See “Multipurpose feeder/ lower front cover assembly removal” on page 4-15. 2. Carefully lift the latch on the left (A), and remove the ESD cover. Note: Be careful not to stress the hinge on the right (B).
Fuser assembly removal CAUTION: Unplug the printer before you begin. 1. Remove the fuser wick assembly cover. See “Fuser wiper cover assembly removal” on page 4-4. 2. Remove the redrive assembly. See “Redrive assembly removal” on page 4-74. 3. Remove the fuser mounting screws (A). 4. Disconnect the fuser to LVPS AC cable (B) from the fuser lamp connector (C).
5. Disconnect the fuser to system board DC cable (D) from the fuser board. Note: Be sure to observe the routing of the LVPS to fuser lamp AC and the DC cable. 6. Pull the cables free and remove the fuser. Installation notes 1. When you reinstall the fuser, be sure to route the fuser to LVPS AC cable (A) through the channel (B) on the right side frame above the LVPS, under the clip (C) over the LVPS, and through the notch in the frame (D). 2. Route the fuser lamp cable through the opening in the fuser (E).
3. Connect the fuser to LVPS AC cable to the fuser lamp connector (F) at the LVPS. Note: Be sure to connect the fuser to system board DC cable after replacing the LVPS. Fuser exit sensor removal 1. 2. 3. 4. Remove the fuser. See “Fuser assembly removal” on page 4-26. Disconnect the fuser exit cable (A) from the fuser control board. Remove the screw (B) securing the cover containing the fuser exit sensor, flag, and spring. Release the two clips (C) holding the sensor in the bracket. 5.
Installation 1. Move the fuser exit sensor flag out of the way to clip the sensor securely into the cover. 2. Connect the fuser exit sensor cable. 3. Snap the bottom fastener of the sensor cover into place in the lower exit guide, and use a small flat bladed screwdriver to ease the sensor cover into the clips. 4. Replace the screw securing the sensor cover. Note: Make sure the flag moves properly.
Fuser exit sensor flag and spring removal 1. Remove the fuser exit sensor. See “Fuser exit sensor removal” on page 4-28. 2. Note the position of the spring (A) in relation to the flag (B). 3. Carefully ease the right arm (C) until the fuser exit sensor cover releases the flag and spring. Spring replacement 1. Place the spring on the left pin (A). 2. Set the tang (B) on the flag.
3. Rotate the bent end (C) of the spring to add tension, place the pins between the sensor cover arms, and rest the bent end against the sensor cover frame. Note: After replacing the sensor, flag, and spring, make sure the flag moves freely and returns.
Fuser lamp removal CAUTION: The fuser and the fuser lamp may be hot. You may need to allow them to cool before handling them. 1. Remove the fuser assembly. See “Fuser assembly removal” on page 4-26. 2. Disconnect the fuser lamp AC cable from the right side of the top cover assembly. 3. Remove the two screws (A) from the right side fuser lamp contact cover. Warning: Take care when removing the screw, as the lamp is under spring tension. When the contact is released, damage to the lamp or contact may occur.
5. Remove the fuser lamp. Warning: The lamp is under spring tension, and care must be used when removing the lamp from the fuser. Grip the lamp by the ceramic end piece, and remove it from the fuser assembly. Be careful not to touch the glass, as skin oils and acids can reduce the life of the lamp. Use the following table to identify and install the correct lamp.
Fuser narrow media sensor removal 1. Remove the redrive assembly. See “Redrive assembly removal” on page 4-74. 2. Remove the screw (A) securing the narrow media sensor cover to the fuser. 3. With a thumbnail, release the catches (B) holding the sensor cover to the lower exit guide (C) in place. Note: You may need to move the narrow media flag out of the way to remove the sensor. 4. Disconnect the fuser narrow media cable at the sensor. 5. Release the catches holding the sensor in the cover.
Replacement 1. Move the narrow media flag out of the way to clip the sensor securely into the cover. 2. Connect the fuser narrow media cable. 3. Snap the bottom fastener of the sensor cover into place in the lower exit guide, and rock the cover up until the top fastener snaps securely. 4. Replace the screw securing the sensor cover.
Fuser narrow media flag and spring removal 1. Remove the fuser narrow media sensor. See “Fuser narrow media sensor removal” on page 4-34. 2. Note the position of the spring (A) in relation to the flag (B). 3. Carefully ease the right arm (C) of the sensor cover just far enough apart to release the flag and spring. Spring replacement 1. Place the spring on the left pin (A). 2. Set the tang (B) on the flag.
3. Rotate the bent end (C) of the spring to add tension, place the pins between the sensor cover arms, and rest the bent end against the sensor cover frame. Note: After replacing the sensor, flag, and spring, make sure the flag moves properly.
Fuser to LVPS AC cable removal CAUTION: Unplug the printer before you begin. 1. 2. 3. 4. Remove the fuser wick assembly cover. See “Fuser wiper cover assembly removal” on page 4-4. Remove the redrive assembly. See “Redrive assembly removal” on page 4-74. Remove the right side cover. See “Right cover removal” on page 4-8.
7. Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser to LVPS AC cable from the LVPS (E). Note: The LVPS assembly may be difficult to remove from the printer. Do not use excessive force in the removal. 8. Remove the fuser to LVPS AC cable. Installation 1. Plug in the fuser to LVPS AC cable (A) into the LVPS. 2.
3. Route the cable through the lower rectangular opening (E). 4. Connect the fuser to LVPS AC cable to the fuser lamp connector (F). Note: Be sure to connect the fuser to system board DC cable after replacing the LVPS.
Fuser top cover removal CAUTION: Unplug the printer before you begin. 1. Remove the fuser assembly. See “Fuser assembly removal” on page 4-26. 2. Note the thermistor cable routing (A) and disconnect the thermistor cable at the fuser control board. 3. Disconnect the AC fuser lamp cable (B) from the top right side of the fuser cover.
4. Carefully remove the two screws (C) from the right side of the fuser lamp contact cover (D). 5. Release the latch (E) and remove the cover. 6. Remove the screw (F) on the left side and the screw (G) on the right side that attach the fuser upper cover assembly to the fuser frame. 7. Remove screw (H) that attaches the side fuser lamp contact to the fuser top cover.
8. Remove the fuser cover. Fuser transfer plate removal 1. 2. 3. 4. Remove the upper paper deflector. See “Upper paper deflector assembly removal” on page 4-79. Remove the transfer roll. See “Transfer roll assembly removal” on page 4-77. Remove the inner paper deflector. See “Inner paper deflector assembly removal” on page 4-47. Lift the left side of the fuser transfer plate (A), and move the plate to the left to clear the right side from its mounting. 5.
Gear release link removal 1. Remove the system board and inner shield. See “System board and inner shield removal” on page 4-76. 2. Remove the developer drive. 3. Disconnect the gear release link (A) from the hole in charge roll link (B). Note: Lift the upper front cover to make it easier to remove the link. 4. Rotate the link to disconnect the link from the main drive assembly. 5. Remove the gear release link.
High voltage power supply removal CAUTION: There is a danger from hazardous voltage in the area of the printer where you are working. Unplug the printer before you begin, or use caution if the printer must receive power in order to perform the task. 1. Remove the inner paper deflector. See “Inner paper deflector assembly removal” on page 4-47. 2. Remove the right side cover. See “Right cover removal” on page 4-8. 3. Disconnect the HVPS cable from the HVPS at connector (A). A 4.
5. Remove the HVPS mounting screws (C). 6. Slide the HVPS to the left to release the mounting tab from the center pan, and remove the HVPS.
Inner paper deflector assembly removal 1. Remove the paper tray. 2. Remove the upper paper deflector assembly. See “Upper paper deflector assembly removal” on page 4-79. 3. Remove the MPF lower deflector assembly. See “MPF lower paper deflector” on page 4-61. 4. Place the printer on its side. 5. Gently pry the inner paper deflector from the left and right mounting posts (A) located on the bottom of the printer, and remove the deflector. A 6.
Input sensor removal 1. Remove the upper paper deflector. “Upper paper deflector assembly removal” on page 4-79. 2. Loosen the MPF lower front cover. See “Multipurpose feeder/lower front cover assembly removal” on page 4-15. 3. Remove the inner paper deflector.“Inner paper deflector assembly removal” on page 4-47. 4. Disconnect the input sensor cable (A) from the input sensor (B). 5. Release the input sensor from its mounting, and remove.
Integrated tray autocompensator assembly removal 1. 2. 3. 4. 5. Remove the paper tray. Remove the left door. See “Left door removal” on page 4-6. Remove the outer shield. See “Outer shield removal” on page 4-67. Place the printer on its back. Disconnect the autocompensator motor cable (A) from the system board (J24).
6. Locate the integrated tray autocompensator assembly (B) on the bottom of the printer, and disconnect the autocompensator arm bias spring (C). Note: When you remove the spring, note the larger loop attaches to the side frame. 7. Remove the C-clip (D) that rests against the right side frame from the autocompensator pivot shaft. 8. Disconnect the autocompensator sensor cable (E) from the assembly. 9. Remove the autocompensator assembly mounting screw (F). 10.
Integrated tray autocompensator pick roll assembly removal 1. Remove the integrated tray, and look underneath the printer for the autocompensator arm. Pull the arm down. 2. Press on the end of the tab (A) and pull the pick roll off the arm. Repeat this step for the pick roll on the other side. Next, gently release the autocompensator arm. Discard the used pick rolls.
Installation 1. Remove the new pick rolls from their packaging. 2. Pull the autocompensator arm down. Locate the recessed area on the pick roll, and align it with the tab on the arm. There are two arrows on each pick roll. Make sure the bottom arrow faces you as you align the recessed area with the tab. 3. Push the pick roll onto the arm with the tab aligned. Repeat this step on the other side to install the other pick roll. 4. Gently release the autocompensator arm. Insert, integrated tray.
Interconnect card assembly removal CAUTION: Unplug the printer before you begin. Warning: When replacing any one of the following components: • Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
Low voltage power supply removal CAUTION: Unplug the printer before you begin. 1. Remove the redrive assembly. See “Redrive assembly removal” on page 4-74. 2. Remove the right side cover. See “Right cover removal” on page 4-8. 3. Remove the pass thru plate. See “Pass thru plate” on page 4-18. 4. Remove the LVPS mounting screws (A) from the rear of the center pan. 5. Disconnect the LVPS to system board cable. The cable is difficult to disconnect.
6. Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser to LVPS AC lamp cable (D). Warning: The LVPS assembly may be difficult to remove from the printer. Do not use excessive force in the removal. 7. Remove the low voltage power supply.
Main fan removal 1. Open the left side cover. 2. Remove the outer shield. See “Outer shield removal” on page 4-67. 3. Remove the two screws (A) securing the main fan cap. 4. Remove the main fan cap. 5. Clip the cable tie (B). Note: Be careful not to damage any of the cables. Note the location of the cable tie for later replacement. 6. Disconnect the main fan to the system board (C) at J4. 7. Remove the main fan.
Installation note: The fan has an orientation marking (D). Be sure to install the fan with the arrow pointing up. Main drive assembly removal 1. Remove the system board and inner shield. See “System board and inner shield removal” on page 4-76. 2. Remove the screw securing the gear guard (A). 3. Remove the power take off shaft and spring. See “Power takeoff shaft and spring removal” on page 4-72. 4. Remove the developer drive assembly. See “Developer drive assembly removal” on page 4-24.
5. Lift and remove the cables from the cable hooks (B). 6. Remove the ground cable screw (C). 7. Remove the main drive assembly mounting screws (D).
8. Disconnect the gear release link (E) from the hole in the charge roll link (F). Note: Lift the upper front cover to make it easier to remove the link. 9. Disconnect the main drive motor cable from the main drive assembly. 10. Remove the main drive assembly. Warning: Whenever the main drive assembly is removed from the printer it must be handled very carefully. Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage.
MPF arm assembly removal 1. Open the left door. 2. Remove the MPF lower front cover. See “Multipurpose feeder/lower front cover assembly removal” on page 4-15. 3. 4. 5. 6. 7. Remove the MPF lower paper deflector. See “MPF lower paper deflector” on page 4-61. Remove the upper paper deflector. See “Upper paper deflector assembly removal” on page 4-79. Remove the inner paper deflector. See “Inner paper deflector assembly removal” on page 4-47. Remove the MPF solenoid assembly.
Installation note: Note the order of C-clips bushing, and washer when you reinstall. MPF lower paper deflector 1. Remove the MPF lower cover. 2. Remove the four screws securing the MPF lower paper deflector. 3. Remove the defector.
MPF pick tire removal 1. Remove the upper paper deflector. See “Upper paper deflector assembly removal” on page 4-79. 2. Release the pick roll retaining tab (A), and slide the pick roll off the shaft. A MPF solenoid assembly removal 1. Open the left door. 2. Remove the MPF lower front cover. See “Multipurpose feeder/lower front cover assembly removal” on page 4-15. 3. Remove the MPF lower paper deflector. See “MPF lower paper deflector” on page 4-61. 4. Remove the upper paper deflector.
6. Press the clips on the end of the shaft to remove the MPF tires (B). 7. Remove the C-clip (C) on the shaft. C B 8. Remove the bushing (D). Note: The bushing fits into a detent (E) in the frame of the MPF arm assembly.
9. Loosen the paper alignment screws (F). F 10. Remove the C-clip securing the MPF solenoid assembly on the shaft. Note: This C-clip is very difficult to locate and remove. 11. Pull the shaft assembly (G) to the right until the left end of the shaft is clear of the frame, and slide the MPF solenoid assembly from the shaft.
Installation note: Be careful not to lose the washer (H) that is between the MPF solenoid assembly and the C-clip. It belongs to the MPF arm assembly.
Operator panel board removal Warning: When replacing any one of the following components: • Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
Operator panel buttons removal The operator panel and navigation buttons are in a single kit. 1. Remove the operator panel board. See “Operator panel board removal” on page 4-66. 2. Remove the functional rubber sheet (A) and the rubber dome sheet (B). 3. The navigation buttons and the select button can be removed by releasing the clips (C) on the back of the upper front cover. Outer shield removal 1. Remove the left door. See “Left door removal” on page 4-6. 2.
Paper alignment assembly removal 1. Remove the upper paper deflector assembly. See “Upper paper deflector assembly removal” on page 4-79. 2. Remove the inner paper deflector assembly. See “Inner paper deflector assembly removal” on page 4-47. 3. Release the input paper sensor from its mounting, and remove. 4. Remove the left door. 5. Remove the paper alignment assembly mounting screws (A).
6. Locate the paper alignment assembly reference adjustment screw (B) through the left frame, and remove the screw. B 7. Remove the paper alignment assembly. Note: Do the “Paper alignment assembly adjustment” on page 4-3 when you reinstall the assembly.
Paper bin full sensor flag removal 1. 2. 3. 4. Remove the left door. See “Left door removal” on page 4-6. Remove the redrive cap. See “Redrive assembly removal” on page 4-74. Remove the fuser wiper cover assembly. See “Fuser wiper cover assembly removal” on page 4-4 Remove the mounting screws (A) from the left side. A 5. Lift the left corner of the laser cover assembly cover to access the flag. 6. Use your thumb to bend the paper full flag assembly slightly to unlatch it from the mounting bracket.
Paper size sensing board removal 1. Remove the system board and inner shield. See “System board and inner shield removal” on page 4-76. 2. Remove the paper size sensing board mounting screw (A). 3. Disconnect the paper size sensing board cable (B) from the board. 4. Remove the paper size sensing board from the latch (C). C A B 5. Remove the paper size sensing board.
Power takeoff shaft and spring removal Remove the power takeoff shaft and spring (A) through the bottom of the printer.
Printhead removal CAUTION: The printhead is not a serviceable FRU. Do not disassemble the printhead. 1. Remove the laser cover. See “Laser cover removal” on page 4-19. 2. Disconnect the printhead cable (A) from the printhead assembly. 3. Remove the three printhead mounting screws (B), and remove the printhead. Note: Do the “Printhead assembly adjustment” on page 4-2 whenever you remove or replace the printhead assembly or loosen the mounting screws.
Redrive assembly removal 1. 2. 3. 4. Remove the redrive door assembly. Remove the redrive exit cover. Remove the redrive assembly mounting screws (A). Release the redrive assembly mounting latches (B), and remove the redrive assembly.
Signature button contact assembly removal 1. 2. 3. 4. 5. 6. Remove the print cartridge. Remove the left side door. See “Left door removal” on page 4-6. Remove the right cover. See “Right cover removal” on page 4-8. Remove outer system board shield. See “Outer shield removal” on page 4-67. Disconnect signature button cable from connector J14 on the system board. On models 200/210/400/410, remove the two screws (A) securing the blower duct. 7. Remove the signature button contact assembly mounting screw (B).
System board and inner shield removal Warning: When replacing any one of the following components: • Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
Toner sensor removal 1. Remove the right side cover. See “Right cover removal” on page 4-8. 2. Remove the toner sensor mounting screw (A). 3. Disconnect the toner sensor cable, and remove the toner sensor. Transfer roll assembly removal Warning: Be careful when handling the transfer roll. Wrap a piece of plain white paper around the charge roll to prevent contamination or damage. 1. Open the upper front cover, and remove the print cartridge. 2. Unsnap the transfer roll assembly from the left pivot arm.
Upper front cover hinge assembly removal 1. Remove the upper front cover. See “Upper front cover removal” on page 4-11. 2. Remove the laser cover assembly. See “Laser cover removal” on page 4-19. 3. Remove the C-clips (A) from the upper front cover hinge assembly left and right hinge pins, and remove the pins. Note the pin orientation and the C-clip location on the inside of each hinge. 4. 5. 6. 7. 8. Detach the two springs (B) from the upper front cover hinges.
Upper paper deflector assembly removal 1. Either lift the ESD cover out of the way or remove it. See “ESD cover removal” on page 4-25. Note: The tabs holding the ESD cover are easily stressed or broken. 2. Lift the left side to release the small tab (A) on the left and the MPF flag (B) and slide the upper paper deflector assembly to the right to unlatch the hooks (C) on the right. Note: Be careful not to put too much stress on the small tab (A) on the right. 3.
4061-xx0 USB board assembly removal 1. Remove the upper front cover. 2. Disconnect the USB cable from the USB board assembly. 3. Remove the screw (A) securing the USB board assembly.
5.
System board (see “System board” on page 5-1) Connector Pin no.
System board (see “System board” on page 5-1) Connector Pin no. J8 Cover closed switch J10 Fuser DC J13 Operator panel J14 Signature button J15 HVPS input sensor Cartridge toner wheel sensor Signal 1 Cov Closed 2 Ground 3 +5V dc 1 NARMEDIA* 2 Ground 3 THERM 4 Ground 5 THUMP 6 +5V dc 7 THUMPRET 8 EXIT SNS* 9 +3.3 V dc 10 I2C CLK L5 11 I2C DAT L5 1 I2C DAT 2 +5 V dc 3 I2C CLK 4 Ground 5 PANEL INT 6 +3.
System board (see “System board” on page 5-1) Connector J16 Ethernet port Pin no.
System board (see “System board” on page 5-1) Connector J26 Paper size sensor/autocomp motor J27 LVPS J28 MPF paper out J29 Top options Pin no. Signal 1 PSIZE2 2 Ground 3 PSIZE1 4 PSIZE3 5 Ground 6 TRAY1 POUT 7 TRAY1 PLOW* 8 +3.
System board (see “System board” on page 5-1) Connector Pin no. J30 USB host–back Signal 1 2 3 4 5 6 7 USB host—front connection Printhead fan 1 +5 V USBICN 2 USB DI– 3 USB DI+ 4 Ground 5 Ground 1 +24V dc 2 PH FAN* Autoconnect Connector Pin no.
Connector Pin no.
High-capacity output stacker board Connector Pin no.
High voltage power supply Connector CN no. -& 'U % -& -& 'HY -& -& 7$5 -& -& 3&' -& 7 -& &KJ -& CN1 System board Signal 1 Developer PWM 2 +24 V dc Return 3 Charge PWM 4 +24 V dc IN 5 TX PWM 6 TX Enable 7 TX CUR PWM 8 SVRO OUT &1 Interconnect card Connector Pin no.
Low voltage power supply CN pin no.
Output expander control board * " Pin no.
5-12 Service Manual
Connector locations and connections 5-13
5-14 Service Manual
6. Preventive maintenance This chapter describes procedures for printer preventive maintenance. Following these recommendations can 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, 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 - OR Units/option Units/ kit or pkg 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 base machine or product.
Assembly 1: Covers 7-2 Service Manual
Assembly 1: Covers AsmIndex Part number Units/ mach Units/ kit or pkg Description 1—1 40X0001 1 1 Fuser wiper cover assembly 2 40X0002 1 1 Redrive cap cover assembly 3 40X0003 1 1 Laser cover assembly—250-sheet output, 000/010 3 40X0004 1 1 Laser cover assembly—500-sheet output, 200/210/400/410 4 40X0050 2 1 Counterbalance spring 5 40X0005 1 1 Paper support 6 40X0006 1 1 Upper front cover hinge assembly, includes: • • • • • • USB cable (1) Cover open switch and cable
Assembly 2: Frame 1 7-4 Service Manual
Assembly 2: Frame 1 AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X0065 4 1 Frame extension, nut plate, 200/210/400/410 2 40X0225 1 1 Right side hand holder 3 4 4 Parts packet (PP 40X0165) 4 40X0024 1 1 Right frame extension, 200/210/400/410 5 40X0026 1 1 Right side frame ground contact 6 40X0025 1 1 Left frame extension, 200/210/400/410 7 40X0060 1 1 External ground clip 8 40X0331 1 1 Left side hand holder 9 40X0285 1 1 Frame clip Parts
Assembly 3: Frame 2 7-6 Service Manual
Assembly 3: Frame 2 AsmIndex Part number Units/ mach Units/ kit or pkg Description 3—1 40X0027 1 1 Upper redrive deflector 2 40X0028 1 1 Upper diverter spring 3 40X0029 1 1 Redrive assembly—250-sheet in/250 out, 000/010 3 40X0030 1 1 Redrive assembly—500-sheet in/500 out, 200/210/400/410 4 40X0032 1 1 Transfer deflector 5 40X0055 1 1 Left side frame ground contact 6 40X0044 1 7 1 Gear guard 3 Parts packet (PP 40X0165) Paper switch activate spring 8 40X0048 1 1
Assembly 4: Frame 3 7-8 Service Manual
Assembly 4: Frame 3 AsmIndex Part number Units/ mach Units/ kit or pkg Description 4—1 40X0235 1 1 EP DC fan assembly, 200/210/400/410 2 40X0208 1 1 Blower duct, 200/210/400/410 3 1 1 Parts packet (PP 40X0165) 3 1 1 Parts packet (PP 40X0165) 4 40X0034 1 1 Signature button sensor assembly 5 40X0035 1 1 EP DC fan assembly, 000/010 6 40X0033 4 1 Machine mounting pad 7 40X0223 1 1 HVPS/input sensor/toner sensor cable assembly 8 40X0036 1 1 Toner sensor assembly 9
Assembly 5: Printhead 7-10 Service Manual
Assembly 5: Printhead AsmIndex 4—1 Part number 40X0061 Units/ mach Units/ kit or pkg 1 1 2 3 Description Laser cable assembly Parts packet (printhead mounting screw) (PP 40X0165) 40X0062 1 1 Printhead assembly (includes all cables) CAUTION:The printhead is not a serviceable FRU. Do not disassemble the printhead.
Assembly 6: Paper feed—autocompensator 7-12 Service Manual
Assembly 6: Paper feed—autocompensator AsmIndex Part number Units/ mach Units/ kit or pkg Description 6—1 40X0066 1 1 Pick arm assembly—500-sheet, 200/210/400/410 1 40X0067 1 1 Pick arm assembly—250-sheet, 000/010 2 40X0068 1 1 Parts packet, bellcrank assembly—250-sheet tray, 000/010 • Bellcrank (1) • Spring (1) 2 40X0069 1 1 Parts packet, bellcrank assembly for—500-sheet tray, 200/210/400/410 • Bellcrank (1) • Spring (1) 3 40X0070 2 2 Pick roll assembly 4 40X0071 1 1 Paper
4061-xx0 Assembly 7: Paper feed—multipurpose feeder 7-14 Service Manual
~ Assembly 7: Paper feed—multipurpose feeder AsmIndex Part number Units/ mach Units/ kit or pkg Description 7—1 40X0079 1 1 Multipurpose feeder lower deflector assembly 2 40X0075 1 1 Multipurpose feeder arm assembly 3 40X0076 1 1 Pick roll assembly 4 40X0077 1 1 Multipurpose feeder paper out flag 5 Parts packet (lower deflector mounting screw, 8 mm) (PP 40X0165) 5 Parts packet (lower deflector mounting screw, 12 mm) (PP 40X0165) 5 1 Parts packet (frame mounting screw) (PP 40X
Assembly 8: Paper feed—alignment 7-16 Service Manual
Assembly 8: Paper feed—alignment AsmIndex 8—1 Part number 40X0084 Units/ mach Units/ kit or pkg 1 1 2 Description Paper feed alignment assembly paper feed Parts packet (clip ref ground mounting screw) (PP 40X0165) 3 40X0085 4 40X0086 1 1 Reference ground clip Parts packet (reference adjust) • Screw, paper reference adjust (1) • Washer, paper reference adjust (1) • Nut, paper reference adjust (1) NS Parts packet (alignment asm mounting screw) (PP 40X0165) Parts catalog 7-17
Page 7-19 has been removed from this document intentionally.
Assembly 10: Integrated 500-sheet paper tray 7-20 Service Manual
Assembly 10: Integrated 500-sheet paper tray AsmIndex Part number Units/ mach Units/ kit or pkg Description 10—1 40X0098 1 1 Tray assembly—500-sheet tray 2 40X0099 1 1 Side restraint 3 40X0182 4 1 Wear strip 4 40X0103 1 1 Pass thru plate—500-sheet tray 5 40X0183 1 1 Wear plate—500-sheet tray 6 40X0105 2 1 Restraint pad 7 40X0106 1 1 Back restraint Parts catalog 7-21
Assembly 11: Drives—Main drive and developer drive 7-22 Service Manual
~ Assembly 11: Drives—Main drive and developer drive AsmIndex Part number Units/ mach Units/ kit or pkg Description 11—1 40X0107 1 1 Gearbox with motor 2 40X0110 1 1 Power takeoff shaft—250-sheet, 000/010 2 40X0111 1 1 Power takeoff shaft—500-sheet, 200/210/400/410 3 40X0112 1 1 Power takeoff shaft spring 4 40X0113 1 1 Bevel gear with grease packet and washer • Bevel gear (1) • Instruction sheet (1) • Grease packet (1) 5 40X0114 6 40X0115 1 1 Developer drive assembly Par
Assembly 12: Hot roll fuser 7-24 Service Manual
Assembly 12: Hot roll fuser AsmIndex Part number Units/ mach Units/ kit or pkg Description 12—1 40X0116 1 1 Fuser assembly w/115 V lamp 1 40X0241 1 1 Fuser assembly w/100 V lamp 1 40X0117 1 1 Fuser assembly w/220 V lamp 2 40X0120 1 1 Fuser wiper cavity cover 3 40X0122 1 1 Fuser lamp, 115V 3 40X0123 1 1 Fuser lamp, 220V 4 40X0121 1 Fuser cover assembly kit, including: • Thermistor (1) • Thermostat (1) • Left and right fuser lamp contact assemblies (1) 5 6 Parts packet
Assembly 13: Transfer/charging 7-26 Service Manual
Assembly 13: Transfer/charging AsmIndex Part number 13—1 40X0126 2 40X0127 Units/ mach Units/ kit or pkg Description 1 Parts kit, charge roll link asm, left side 1 2 Charge roll assembly, dual 3 40X0129 1 Parts kit, right side charge roll link assembly 4 40X0130 1 1 Transfer roll assembly 5 40X0131 1 1 Transfer roll assembly right arm 6 40X0132 1 1 Transfer roll right spring 7 40X0133 1 1 Transfer pivot shaft 8 40X0134 1 1 Transfer roll left spring 9 40X0135 1 1
Assembly 14: Electronics—power supplies 7-28 Service Manual
Assembly 14: Electronics—power supplies AsmIndex Part number Units/ mach Units/ kit or pkg Description 14—1 56P4232 1 1 LVPS—115 V ac, 000/010 1 56P4233 1 1 LVPS—115 V ac, 200/210/400/410 1 56P4234 1 1 LVPS—220 V ac, 000/010 1 40X0220 1 1 LVPS—220 V ac, 200/210/400/410 2 40X0260 1 1 Power cord set (8 ft right angle, 13 amp)—United States, Canada, Caribbean countries, Columbia, Costa Rica, Dominican Republic, El Salvador, Equator, Guatemala, Honduras, Mexico, Nicaragua, Panama, P
7-30 Service Manual Note:
Assembly 15: Electronics—card assemblies AsmIndex Part number Units/ mach Units/ kit or pkg Description 15—1 40X0146 1 1 Interconnect card assembly (2 slot), 200/210/400/410 2 40X0147 1 1 Interconnect card assembly (1 slot), 000/010 3 40X0140 1 1 System board assembly (non-network), 000 (Board ID Q0016021) 3 40X0141 1 1 System board assembly (non-network), 200 (Board ID Q0016022) 3 40X0142 1 1 System board assembly (non-network), 400 (Board ID Q0016023) 4 40X0143 1 1 System
Assembly 16: Electronics—shields 7-32 Service Manual
Assembly 16: Electronics—shields AsmIndex 16—1 Part number 40X0150 Units/ mach Units/ kit or pkg 1 1 Description Outer shield—2 slot, 200/210/400/410 2 Parts packet (INA cover mounting screw) (PP 40X0165) 2 Parts packet (outer shield mounting screw) (PP 40X0165) 2 Parts packet (inner shield mounting screw) (PP 40X0165) 3 40X0149 1 1 Inner shield assembly—2 slot, 200/210/400/410 4 40X0153 1 1 INA flat cover (blank) 5 40X0152 1 1 Ethernet shield (blank), 000/200/400 6 40X0154 1
Assembly 17: Cabling diagrams 1 AsmIndex Part number Units/ mach Units/ kit or pkg Description 17—1 40X0223 1 1 HVPS/input sensor/toner sensor cable assembly 2 40X0160 1 1 MPF sensor cable 3 40X0034 1 1 Signature button contact assembly with cable 7-34 Service Manual
Assembly 18: Cabling diagrams 2 AsmIndex Part number Units/ mach Units/ kit or pkg 1 1 Description 18—1 40X0061 Laser printhead cable assembly 2 40X0074 1 1 Autocompensator motor cable 3 40X0046 1 1 Paper size sensing board/Tray 1 autocompensator paper out/low cable Parts catalog 7-35
Assembly 19: Cabling diagrams 3 7-36 Service Manual
Assembly 19: Cabling diagrams 3 AsmIndex Part number Units/ mach Units/ kit or pkg Description 19—1 40X0034 1 1 Signature button contact assembly with cable 2 40X0156 1 1 Bottom/front autoconnect cable assembly 3 40X0223 1 1 HPVS/input sensor/toner sensor cable assembly 4 40X0157 1 1 Top autoconnect cable assembly 5 40X0224 1 1 LVPS to system board cable assembly Parts catalog 7-37
Assembly 20: Cabling diagrams 4 7-38 Service Manual
Assembly 20: Cabling diagrams 4 AsmIndex 20—1 Part number 40X0006 Units/ mach Units/ kit or pkg 1 1 Description Upper front cover hinge assembly, includes: • USB cable (A) (1) • Operator panel cable (B) (1) • Cover open switch/cable (C) (1) 2 40X0162 1 1 System board to fuser board cable assembly 3 40X0163 1 1 Fuser AC lamp to LVPS cable assembly 4 40X0226 1 1 Fuser connector (fuser AC to fuser lamp) Parts catalog 7-39
Assembly 21: Cabling diagrams 5 7-40 Service Manual
Assembly 21: Cabling diagrams 5 AsmIndex Part number Units/ mach Units/ kit or pkg Description 21—1 40X0083 1 1 Frame assembly with solenoid and cable 2 40X0159 1 1 Main drive motor cable assembly 3 40X0035 1 1 EP fan with cable—250 sheet, 000/010 3 40X0249 1 1 EP fan with cable—500 sheet, 200/210/400/410 4 40x0053 1 1 Main fan, 250 sheet 4 40X0054 1 1 Main fan, 500 sheet Parts catalog 7-41
THE FOLLOWING PAGE (7-43) HAS BEEN OMITTED FROM THIS MANUAL INTENTIONALLY.
Assembly 24: Optional 500-sheet paper drawer AsmIndex 24—1 Part number Units/ option 20G0890 2 Units/ kit or pkg Description 1 1 Drawer assembly, complete—500-sheet 3 3 Parts packet (auto comp mounting screw) (PP 99A0263) 3 56P4139 1 1 Pick arm assembly—500 sheet 4 56P1228 1 1 Bellcrank spring arm 5 56P2540 1 1 Bellcrank spring—500-sheet option tray 6 99A0070 1 2 Pick roll assembly 7 56P4127 1 1 Option pass thru sensor 8 99A0275 1 1 Power takeoff spring 9 99A0447
Assembly 25: Optional 500-sheet paper tray AsmIndex Part number Units/ option Units/ kit or pkg Description 25—1 20G0890 1 1 Complete tray assembly—500-sheet 2 56P4137 1 1 Side restraint—500-sheet tray 3 99A0292 1 4 Wear strips 4 56P4196 1 1 Pass thru plate 5 99A0120 1 2 Restraint pad 6 56P4195 1 1 Wear plate—500 sheet 7 56P4147 1 1 Back restraint—500-sheet tray Parts catalog 7-45
Assembly 26: Duplex option AsmIndex Part number Units/ option Units/ kit or pkg 1 1 Description 26—1 1 20G0888 7-46 Service Manual Duplex assembly—500-sheet
Assembly 27: Envelope feeder AsmIndex Part number Units/ option Units/ kit or pkg Description 27— 20G0891 1 1 Complete envelope option 2 56P4229 1 1 Slide out support Parts catalog 7-47
Pages 7-49 through 7-57 of this manual have been omitted intentionally.
Assembly 35: High-capacity feeder 1 7-58 Service Manual
Assembly 35: High capacity feeder 1 AsmIndex Part number Units/ option Units/ kit or pkg Description 35—1 20G0892 1 1 Complete option assembly (letter) 1 56P4106 1 1 Complete option assembly (A4) 2 99A1818 1 1 Wear dimple strip 3 99A0681 4 1 Wear strip 4 56P4155 1 1 Front door assembly 5 56P4157 1 2 Door hinge 6 4 1 Parts packet (6-32 hinge mounting nut) (PP 99A0676) 7 4 1 Parts packet (hinge mounting flat washer) (PP 99A0677) 4 1 Parts packet (hinge mounting sta
Assembly 36: High-capacity feeder 2 7-60 Service Manual
Assembly 36: High-capacity feeder 2 AsmIndex 36—1 Part number 99A0654 Units/ option Units/ kit or pkg 1 1 2 Description Paper low switch Parts packet (nuts) (PP 99A0676) 3 99A1808 1 1 AC external jumper cord 4 99A0667 1 1 Power supply board Parts catalog 7-61
Assembly 37: High-capacity feeder 4 AsmIndex Part number Units/ option Units/ kit or pkg Description 37—1 99A0275 1 1 Power takeoff spring 2 99A0272 1 1 Drive shaft—250-sheet 7-62 Service Manual
Assembly 38: High-capacity feeder 5 AsmIndex Part number 38—1 Units/ option Units/ kit or pkg 3 Description Parts packet (auto comp assembly mounting screw) (PP 99A0263) 2 56P4162 1 1 Pick arm assembly—2000-sheet 3 99A0070 2 2 Pick roll assembly 4 56P4127 1 1 Option pass thru sensor Parts catalog 7-63
Pages 7-65 thru 7-70 ofthis manual were omitted intentionally.
Index Numerics C 1565 Emul Error Load Emul Option 2-42 250-sheet paper drawer, option 7-42 250-sheet paper tray, integrated 7-18 250-sheet paper tray, option parts catalog 7-43 service check 2-102 2xx paper jam and paper handing errors 2-44 500-sheet paper drawer, option 7-44 500-sheet paper tray, option parts catalog 7-45 service check 2-102 5-bin mailbox output sensor test 3-16 parts catalog 7-54, 7-56 service check 2-72 80 scheduled maintenance 6-1 900.xx error code service check 2-75 927.
developer drive assembly parts 7-22 removal 4-24 developer drive coupler kit 4-25 diagnostics mode 3-2 accessing 3-1 available tests 3-2 BASE SENSOR TEST 3-18 DEVICE TESTS Disk Test/Clean 3-19 Flash Test 3-19 Quick Disk Test 3-18 DUPLEX TESTS Duplex Feed 1 3-12 Duplex Feed 2 3-12 Motor Test 3-11 Quick Test 3-9 Sensor Test 3-10 Top Margin 3-10 EP SETUP Charge Roll 3-22 EP Defaults 3-22 Fuser Page Count 3-22 Fuser Temp 3-22 Gap Adjust 3-22 Print Contrast 3-22 Transfer 3-22 Warm Up Time 3-22 EVENT LOG Clear Lo
fuser connectors 5-7 installation 4-27 parts catalog 7-24 removals 4-26 service check 2-87 fuser board 5-7 fuser cover 4-41 fuser exit sensor flag and spring removal 4-30 parts catalog 7-25 removal 4-28 service check 2-92 fuser lamp parts catalog 7-25 removal 4-32 fuser narrow media sensor flag and spring 4-36 flag and spring parts catalog 7-25 flag and spring removal 4-36 parts catalog 7-25 service check 2-93 fuser solenoid adjustment 4-2 service check 2-94 fuser to LVPS AC cable removal 4-38 fuser transfe
menus accessing service menus 3-1 description 2-3 printing menu page 3-30 messages check device connection messages 2-43 service error codes 2-8 user attendance messages 2-32 user line 2 link messages 2-43 user status displays 2-31 warning messages (user status displays) 2-31 Model Name 3-20 models 1-1, 1-2, 7-1 MPF arm assembly 4-60 MPF lower paper deflector 4-61 MPF solenoid assembly 4-62 multipurpose feeder parts catalog 7-14 removal 4-15 N narrow media sensor See fuser narrow media sensor navigation bu
paper feed alignment 7-16 autocompensator 7-12 multipurpose feeder 7-14 printhead 7-10 StapleSmart finisher 7-65, 7-66, 7-67, 7-68 transfer⁄ charging 7-26 pass thru plate 4-18 pick rolls, integrated tray autocompensator 4-51 pick tire integrated tray autocompensator pick roll 4-51 MPF 4-62 power takeoff shaft and spring 4-72 power-on self test (POST) 2-4 preventive maintenance 6-1 print media avoiding jams 1-19 card stock 1-18 characteristics 1-15 envelopes 1-16 guidelines 1-15 labels 1-17 sizes 1-8 storing
S safety information xvii safety inspection guide 6-1 scheduled maintenance 6-1 sensors fuser exit sensor 4-28 fuser narrow media sensor 4-34 input 4-48 output bin sensor, integrated paper tray 2-109 paper bin full 4-70 paper size sensing board 4-71 toner 4-77 serial number 3-20 serial wrap tests 3-9 service checks 5-bin mailbox 2-72 900.xx error code 2-75 927.xx fan 2-76 950.00 through 950.
upper paper deflector 4-79 user attendance messages 2-32 user line 2 link messages 2-43 user status displays 2-31 W warm up time 3-22 warning messages (user status displays) 2-31 wiper cover 4-4 wrap tests 3-8 Index I-7
I-8 Service Manual
Part number index P/N Description Page 1319128 1319128 40X0001 40X0002 40X0003 40X0004 40X0005 40X0006 40X0007 40X0008 40X0009 40X0010 40X0011 40X0013 40X0015 40X0017 40X0020 40X0021 40X0023 40X0024 40X0025 40X0026 40X0027 40X0028 40X0029 40X0030 40X0032 40X0033 40X0034 40X0034 40X0035 40X0035 40X0036 40X0039 40X0040 40X0041 40X0042 40X0043 40X0044 40X0045 40X0046 40X0046 40X0048 40X0049 40X0050 40X0051 40X0052 40X0053 40x0053 40X0054 40X0054 Parallel warp plug - - - - - - - - - - - - - - - - - - - - -
40X0055 40X0056 40X0057 40X0058 40X0059 40X0060 40X0061 40X0061 40X0062 40X0065 40X0066 40X0067 40X0068 40X0069 40X0070 40X0071 40X0072 40X0073 40X0074 40X0074 40X0075 40X0076 40X0077 40X0079 40X0082 40X0083 40X0083 40X0084 40X0085 40X0086 40X0087 40X0090 40X0091 40X0092 40X0093 40X0094 40X0098 40X0099 40X0103 40X0105 40X0106 40X0107 40X0110 40X0111 40X0112 40X0113 40X0114 40X0115 40X0116 40X0117 40X0120 40X0121 40X0122 40X0123 40X0124 40X0125 40X0126 40X0127 40X0129 Left side frame ground contact - - - -
40X0130 40X0131 40X0132 40X0133 40X0134 40X0135 40X0140 40X0141 40X0142 40X0143 40X0144 40X0145 40X0146 40X0147 40X0149 40X0150 40X0151 40X0152 40X0153 40X0154 40X0156 40X0157 40X0159 40X0160 40X0162 40X0163 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0171 40X0174 40X0179 40X0182 40X0183 40X0195 40X0198 40X0199 40X0200 40X0207 40X0208 40X0209 40X0210 40X0211 40X0212 40X0213 40X0220 Transfer roll assembly - - - - - - - -
40X0222 40X0223 40X0224 40X0225 40X0226 40X0227 40X0229 40X0232 40X0233 40X0234 40X0235 40X0235 40X0236 40X0238 40X0239 40X0241 40X0248 40X0248 40X0249 40X0250 40X0251 40X0252 40X0255 40X0256 40X0257 40X0258 40X0259 40X0260 40X0263 40X0264 40X0265 40X0266 40X0267 40X0271 40X0281 40X0285 40X0290 40X0291 40X0292 40X0293 40X0294 40X0295 40X0301 40X0302 40X0303 40X0304 40X0305 40X0306 40X0330 40X0331 40X1375 40X1376 40X1377 40X1378 40X1379 40X1508 40X1509 40X1510 40X1512 Outer shield—1 slot, 000/010 - - - - -
40X1513 40X1514 40X1515 40X1564 40X1565 56P1228 56P1228 56P1279 56P2114 56P2115 56P2116 56P2540 Simplified Chinese font card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Traditional Chinese font card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Korean font card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32MB Fl
56P4194 56P4195 56P4196 56P4197 56P4198 56P4203 56P4204 56P4205 56P4206 56P4207 56P4208 56P4210 56P4211 56P4212 56P4213 56P4218 56P4219 56P4221 56P4222 56P4223 56P4224 56P4225 56P4226 56P4228 56P4229 56P4230 56P4232 56P4233 56P4234 56P4235 56P4240 56P4241 56P4242 56P4243 7375084 7375085 99A0063 99A0070 99A0104 99A0104 99A0120 99A0121 99A0263 99A0263 99A0263 99A0263 99A0263 99A0263 99A0263 99A0263 99A0272 99A0275 99A0292 99A0415 99A0447 99A0654 99A0658 99A0667 99A0675 Stacker pass thru sensor - - - - - - -
99A0675 99A0676 99A0676 99A0677 99A0677 99A0681 99A1785 99A1808 99A1818 99A1929 99A2542 Parts packet (card asm.
I-16 Service Manual
500P (4061) Wiring diagram 5 4 3 2 1 Printhead 7 5 6 3 4 1 2 13 12 11 10 9 8 7 6 5 4 3 2 1 Cover Closed Switch Cartridge Fan Main Fan Toroid 1 2 3 Toroid 4 8 7 6 5 3 2 1 3 2 1 3 2 1 STD Bin Sensor Toroid 11 10 9 8 7 6 5 4 3 2 1 3 2 1 3 2 1 3 2 1 J2 J3 J4 J5 3 2 1 3 2 1 HOP LED Gnd HOP FULL* CN 11 10 9 8 7 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1 12C DAT LS 12C CLK LS 3.3VDC ExitSens* Thumpret +5VSW Thump GND Therm CN GND NarrowMedia* 7 6 5 4 3 2 1 7 6 5 4 3 2 1 GND +3.
