Home

X925

1. Connector Pin no Signal J9 ADF cable 1 3 3V Note This connection 2 3 3V cannot be probed to check signals 3 24VM MOTOR ON 4 24VM MOTOR ON 5 GND 6 24VM MOTOR ON 7 NC 8 GND 9 NC 10 GND 11 FB ADF STEP 12 NC 13 ADF PICKUP STEP 14 PAPER DET 15 FB IO BUS 3 16 NC 17 FB IO BUS 1 18 FB IO BUS 2 19 FB IO BUS 0 20 FB IO BUS 4 21 FB IO BUS 5 22 FB IO BUS 6 23 GND 24 PAPER GAP 25 5VD 26 GND J10 ADF clutch 1 24V 2 GND Locations 5 33 7541 03x UICC connectors J23 uo 1 J21 oo gt V 1 J5 4 19320 m oooo oooo oo E J E J1 E J10 2 R1 000000000000 O J12 ee Q 1 Q J3 12 4 oo oo J8 oo oo o o oo o o o J1 N C J3 Touchscreen display 4 pin ribbon cable J5 N C J8 N C J10 Pop panel connector to RIP J12 Touchscreen display J20 N C J21 Speaker J22 USB card reader J23 Haptics motor J24 USB connection to RIP board J25 USB thumbdrive connector 5 34 Service Manual 7541 03x Option feeder locations Option feeder layout Upper UL1 Interface Transport Motor po e Transport Clutch zjz H pje pi o I io CN120 CN121 E few Paper tray lift motor 3 9 1 3 Ej H 8
2. 7 28 Service Manual 7541 03x Assembly 14 Electrical 2 Asm Part Units Units index number mach FRU Description 1 40X6746 Engine board 2 40X6747 Engine power supply cable 3 40X6210 Power supply fan cable 4 40X6262 Belt motor cable 5 40X6206 Main fan cable fan included 6 40X6203 Humidity sensor cable 7 40X6120 Paper size sensor cable 8 40X6427 Engine board fan cable fan included 9 40X6419 MPF clutch 10 40X6416 11 40X6190 12 40X6748 13 40X6261 14 40X6194 15 40X6165 16 40X6209 17 40X6171 18 40X6367 19 40X6161 20 40X6158 21 40X6749 NS 40X7454 NS 40X7455 NS 40X7456 NS 40X7448 MPF Engine board cable Registration sensor cable RIP Harness cable Photo interrupter cable Belt up down Paperfeed clutch cable Exit solenoid cable w solenoid Tray lift motor cable Fuser fan cable fan included Engine paperfeed cable Drive unit motor w motor Duplex clutch harness Main power cable Remote off switch cable Cover closed actuator cable Paper tray size switch cable wk jk i k l aak a t i a a a a a it iak a jaya fafa ajo fa fo ak i a a i a a a a i oa a aa a ai ali l a e a a a f Electrical screw parts pack Parts catalog 7 29 7541 03x Assembly 15 Upper assembly 7 30 Service Manual 7541 03x Assembly 15 Upp
3. eee rere ee eee eee eee eee eee 7 11 40X6349 ADF media paper path guide ee eee 7 11 40X6357 Right option tray cover 2 eee eee eee eee eee eee 7 39 40X6367 Engine paper feed motor cable 7 21 40X6367 Engine paperfeed cable rrn 7 25 40X6368 Engine power supply cable 7 21 40X6369 Printhead controller option cable 7 33 40X6370 RIP print controller cable 7 33 40X6432 Flatbed cushion rer eee ee eee eee eee eee ee 7 9 40X6433 ADF cable 2 0 ree eer er reer ee eee eee eee eee eee 7 9 40X6434 ADF solenoid 2 2 r errr eee eee eee eee eee eee 7 11 40X6440 Fuser power cable 220V eee errr eee eee eee eee eee eee 7 33 40X6443 Model name cover rrr rr rrr reer err eee ee ee eee eee eee 7 7 40X6531 ADF paperpath sensors eer eer eee ee eee ee eee eee 7 11 40X6532 Gear w spring holder eer errr rere eer eee eee eee 7 11 40X6533
4. 7 9 7 11 40X6158 Duplex clutch harness eee 7 29 40X6168 Paper exit sensor cable rere ere eee ee eee ee ee ee eee 7 33 40X6193 Registration sensor cable 7 33 40X6198 Theta sensor cable eee 7 33 40X6201 Density sensor cable rrr reer ee rr eee eee eee ee 7 33 40X6209 Tray lift motor cable 7 21 40X6210 Power supply cable eee 7 33 40X6211 Fuser power cable 110V 2 2 eee eee 7 33 40X6224 Stand base foot eer eee eee eee r rrr 7 39 40X6227 Drive roller eee eee eee ee eee eee 7 39 40X6248 Rear option cover c cre reer ere eee ee eee eee eee eee 7 39 40X6249 Rear connector cover 0 rrr rrr errr eee eee eee eee ee 7 39 40X6250 Left option cover rere eee eee eee eee eee 7 39 40X6251 Right front option cover 22 eee 7 39 40X6252 Right rear option cover
5. i b e e S E E a a NS 40X7451 Cassette screw parts pack Parts catalog 7 35 7541 03x Assembly 18 Fuser Service Manual 7 36 Assembly 18 Fuser 7541 03x Asm Part Units Units D scriplion index number mach FRU P 1 40X6013 1 1 110V Fuser 1 40X6093 1 1 220V Fuser Parts catalog 7 37 7541 03x Assembly 19 550 sheet option feeder covers 7 38 Service Manual 7541 03x Assembly 19 550 sheet option feeder covers Asm Part Units Units Description index number mach FRU 1 40X6357 1 1 Right option tray cover 2 40X6227 1 1 Drive roller 3 40X6251 1 1 Right front option cover 4 40X6252 1 1 Right rear option cover 5 40X6254 1 1 Right switch cover 6 40X6224 1 1 Stand base foot 7 40X6250 1 1 Left option cover 8 40X6248 1 1 Rear option cover 9 40X6249 1 1 Rear connector cover 10 40X6255 1 1 Upper front option cover 11 40X6253 1 1 Right middle option cover NS 40X1173 1 1 Photo interrupter Horizontal sensor NS 40X7452 1 1 550 sheet paperfeed screw parts pack Parts catalog 7 39 7541 03x Assembly 20 550 sheet option feeder base o 7 40 Service Manual fF Y O d Ko e 2 7541 03x Assembly 20 550 sheet option feeder base Asm Part Units Units Description index number
6. 2 0 e eee eee eee eee eee eee 7 39 40X6253 Right middle option cover eer errr e eee eee 7 39 40X6254 Right switch cover rrr eee ere re eee ee eee ee ee ee eee 7 39 40X6255 Upper front option cover eee eee eee 7 39 40X6278 Fuser exit sensor cable e err reer ree ee ee eee ee ee ee eee 7 33 40X6289 Upper front logo cover eer e reer eee eee eee eee eee 7 3 40X6292 RIP cover or rrr re ne rr er re ee ee ee eee eee eee 7 3 40X6293 Upper panel exit cover eee r rrr rrr 7 3 40X6294 Back cave cover 22 r rrr eee reer ee eee eee eee eee 7 3 40X6295 Upper right cover eee r e eee 7 3 40X6296 Printer top cover 2 0 eee r rrr rrr 7 3 40X6297 Cord cover rrr creer errr eee eee ee ee eee eee eee eee 7 3 40X6298 Back cover 2 0 eee eee eee eee eee eee 7 3 40X6301 Inner right cover 7 3 40X6302 Op panel front cover w card reader eee 7 3 40X6303 Op panel front cover eee e
7. cccmcmmII III 7 46 Simplified Chinese font card 40X5970 cmccm III III 7 46 South Africa powercord 40X1773 rrr rrr rrr III III III 7 46 Spain 8ft straight powercord 40X3141 ccccrc II III 7 46 Standard registration roller 40X6581 cccrc III III 7 25 Static discharge brush 40X6195 ceccmcmII III III 7 25 Stepper motor cable 40X6233 ccccmcmIIII II III 7 41 Sub drive unit 40X6163 ccnnn mI III III III 7 21 Sub frame 40X6160 22 oe ee eee ee ee ee ee eee ee eee ee eee 7 19 Sub tray 40X6141 s etc sit oe cle eS cine Se eee eer ccce See tie Ee eS 7 15 Switzerland powercord 40X1772 scecem I II III III 7 46 T Taiwan powercord 40X1791 2 2 eee RRRRIIRmRRIIIIIIIIIIIIIIIIIIIIII 7 46 Timing belt 40X6235 eee ee ee ee er ee ee eee ee ee eee 7 43 Timing belt 40X6360 7 41 Timing belt L 40X6237 eee nee ee ee ee ee ee ee eee ee eee 7 43 Toner sensorl 40X6214 22 ee eee ee ee ee ee re re ee ee ee ee eee eee 7 31 Torque limiter 40X6187 eee ee ee eee ee ee ee ee eee eee eres 7 25 Torque limiter clutch 40X1080 I RII III 7 43 Traditional Chinese font card 40X5971
8. reer eee e eee eee eee 7 46 Transfer belt door DS lock 40X6169 rrr rrr rere reer e reer eee 7 3 Transfer contact plate 40X6149 2 2 eee ee ee eee eee eee eee 7 13 Transfer roll 40X6012 2 I eee ne ee ee ee eee ee ee eee 7 13 Transfer roll bushing 40X6143 2 22 eee eee ee eee eee eee 7 13 I 12 Service Manual 7541 03x tray lift motor cable 40X6209 eee ree ee eee ee eee eee eee 7 29 Tray pinion gear 40X6221 eee eee er ee ee ee ee ee eee ee 7 35 Tray rack gear 40X6220 e ener rr nee eee 7 35 Tray stop 40X6121 22 eee ee ee ee ee ee ee eee 7 3 Type 2 feed roll 40X1111 2 eee eee ee eee eee eee eee eee 7 43 U UK straight powercord 40X0271 ere rrr ee er ee eee eee eee eee 7 46 UL1 interface cable 40X6361 9 erent rr rr rn renee 7 41 UL2 inteface cable 40X6362 ener ee rn rn eens 7 41 Uper registration spring 40X6184 oe errr eee eee eee ee eee 7 25 Upper assembly screw parts pack 40X7449 errr rrr rrr rrr ree 7 31 Upper registration spring 40X6422 ee eee er eee eer eee eee 7 25 USA powercord 40X7104 2 2 2 ree ee ee en ne ee ee eee ee ee ee eee eee 7 46 V Vertical paperfeed sens
9. Step Action and questions Yes No 1 Is the fuser properly installed Make sure that it is Go to step 2 Reinstall the properly seated fuser 2 Is the fuser cable properly connected to CN19 on the Go to step 3 Properly connect printhead controller board the connector 3 Checkthe fuser cable for continuity Is there continuity Problem solved Replace the fuser cable 4 Replace the printhead controller board Does this fix Problem solved Go to step 5 the problem 5 Replace the fuser Does this fix the problem Problem solved Contact second level support 2 46 Service Manual 121 03 Thermistor 3 3 error Note If the error is 121 05 the fuser is at the end of life 7541 03x Step Action and questions Yes No 1 Is the fuser properly installed Make sure that it is Go to step 2 Reinstall the properly seated fuser 2 Is the fuser cable properly connected to CN19 on the Go to step 3 Properly connect printhead controller board the connector 3 Check the fuser cable for continuity Is there continuity Problem solved Replace the fuser cable 4 Replace the printhead controller board Does this fix Problem solved Go to step 5 the problem 5 Replace the fuser Does this fix the problem Problem solved Contact second level support 121 04 Belt thermistor error Step Action and questions Yes No 1 Is the fuser properly installed Make sure that it is Go
10. ccccccmIc III III III 7 13 E Electrical screw parts pack 40X7448 ccmccccIn I III 7 27 7 29 engine board 40X6746 2 rrr rrr rrr rr rr rene 7 29 engine board fan cable 40X6427 22 2 r rr rrr rrr rrr rrr ree 7 29 engine paperfeed cable 40X6367 22 2 rrr rrr rrr rrr II III 7 29 engine power supply cable 40X6747 200 r rrr rrr rrr III 7 29 Exit drive unit motor 40X6164 cccccmc c III III 7 21 Exit drive unit solenoid 40X6165 ccccccm III III 7 21 Exit sensor cable 40X6168 ccccmcmcI III I II 7 17 Exit solenoid bracket 40X6355 eccmm III III 7 21 exit solenoid cable 40X6165 cceccmm III II II III 7 29 F F2 S transfer spring 40X6159 ceccmc c III III 7 13 Feed roll 40X6179 222220 ee ene eerie See eee cee a Reece sees Soe reu 7 25 Feed roll gear 40X6177 2 2 r rrr rrr rr rrr rr ree 7 25 Forms and barcode card 40X6924 2 20 errr rrr rrr ne 7 46 Front cover 40X6280 rrr rr rrr rrr renee 7 3 Fuser duct 40X6170 e e III 7 21 Fuser exit sensor cable 40X6278 ccccucmI II III 7 21 fuser fan 40X6171 ceem I I II mI III 7 29 Fuser fan 40X6742 2 2 2 rr errr rrr ree 7 21 H Handle cover 40X6
11. Print Quality Pages See Print Quality Pages on page 3 20 3 18 Service Manual 7541 03x HARDWARE TESTS Panel Test See Panel Test on page 3 21 Button Test See Button Test on page 3 22 DRAM Test See DRAM Test on page 3 22 Serial 1 Wrap if installed See Serial Wrap Test on page 3 23 USB HS Test Mode See INPUT TRAY TESTS if installed Feed Test See DEVICE TESTS if installed Quick Disk Test See Quick Disk Test on page 3 24 Disk Test Clean See Disk Test Clean on page 3 24 Flash Test See Flash Test on page 3 25 PRINTER SETUP Defaults See Defaults on page 3 25 Prt Color Pg Count Prt Mono Pg Count Perm Page Count See PAGE COUNTS on page 3 26 Serial Number See Serial Number on page 3 26 Model Name See Model Name on page 3 26 Configuration ID See Configuration ID on page 3 26 Par 1 Strobe Adj if installed See REPORTS EVENT LOG Display Log See Display Log on page 3 28 Print Log See Print Log on page 3 28 Clear Log See Clear Log on page 3 29 SCANNER TESTS Scanner Calibration Reset See Scanner Calibration Reset on page 3 29 ASIC Test See ASIC Test on page 3 29 Feed Test See Feed Test on page 3 29 Sensor Test See Sensor Test on page 3 29 ADF Magnification See ADF Magnification on page 3 2
12. dust assembly 3 Check the white strip on the bottom of the large platen Clean the white Go to step 4 glass strip and POR Is the white strip contaminated the machine 4 Check the scanner lens Clean the Go to step 5 Is the scanner lens contaminated scanner lens 5 Perform a print test using the ADF amp scanner unit Replace the Problem solved assemblies CCD assembly Does the error continue 6 Perform a print test using the ADF amp scanner unit Replace the ICC Problem solved assemblies board Does the error continue Go to ICC board on page 4 123 Diagnostic information 2 11 7541 03x Vertical lines process direction using the ADF Step Check Yes No 1 Check the small platen glass on the scanner unit Clean or replace Go to step 2 assembly the scanner Is the large and small platen glass contaminated or n glass damaged i Go to Flatbed upper cover on page 4 161 2 Check the three mirrors in the scanner unit assembly Clean the three Go to step 3 et three mirrors contaminated or show signs of ae ut assembly 3 Check the white strip on the bottom of the large platen Clean the white Go to step 4 glass strip and POR Is the white strip contaminated ie acting 4 Perform a print test using the scanner unit assembly Replace the Problem solved Does the error continue peel Go to Flatbed assembly removal on page 4 116 5 Perform a print test us
13. oo NI OD oO AJ OIN MOTOR CLK3 a oa aj O MOTOR CLK2 MOTOR CLK1 BE N TXD A wo RXD AR MBUSY IN CN3 N C CN4 Temp humidity sensor Temp S GND Humid S AJ OJN 5V CN5 Paper size sensor Std Cassette CPSIZE2 PCZCNG C CPSIZE1 PCZCNG C CPSIZEO PCZCNG C CN6 Paper tray lift motor PN2 mM oO a BR Oj N PN1 CN7 Paper size sensor MPF Cassette MPSIZE2 MPSIZE1 PCZCNG M AJOJN MPSIZEO 5 20 Service Manual Engine board 7541 03x Connector Connects to Pin no Signal CN8 Paperfeed clutches Paperfeed clutches VCC24V PF1CL VCC24V TRCL VCC24V MLTCL CN9 Waste toner 0 oO AJ WwW GND HTONER LD Belt pos sensor GND BELT U D Oo Oo AJ OJN LD CN10 Duplex solenoid DUPSOL GND CN12 Full sensor GND PFLIFTSW LD PE Sensor STD tray GND PP EMP LD PE Sensor MPF tray GND MPF DET o o NI oO Aa AJ OJN LD Reg sensor A o GND PRGSW E N PRGSW5V CN13 Duplex clutch DUPOUTCL N w GND CN14 Exit sensor GND DUP INSW Co N 45V CN15 Belt moto
14. A N FB_MS1 A 69 GND ex r TQ2 Aa ol TQ1 A Oo 24VM CCD a4 N FB_ADF_STEP A oo 24VM CCD J7 JTD1 GND JTD 0 GND JTCK GND RTCK JTMS OO CO NI I oO BR OIN 3 3V A o JIRST N 3 3V E N GND 5 28 Service Manual 7541 03x ICC board Connector Pin no Signal J8 To RIP Ribbon cable 1 GND 2 IN CLK M 3 IN CLK P 4 GND 5 98714 CLK M 6 98714 CLK P 7 GND 8 98714 OUT2 M 9 98714 OUT2 P 10 GND 11 98714 OUT1 M 12 98714 OUT1 P 13 GND 14 98714 OUTO M 15 98714 OUTO P 16 GND 17 AFE RESET 18 GND 19 98714 SDATA 20 98714 SCLK 21 98714 SEN N 22 98714 SH R 23 PWR_SVR 24 5V_CCD_IN 25 5V_CCD_IN 26 GND 27 24V_IN 28 24V IN 29 LAMP ON 30 GND Locations 5 29 7541 03x ICC board Connector Pin no Signal J9 CCD 30 pin 1 GND 2 LAMP ON 3 24V IN 4 24V IN 5 GND 6 5V CCD IN 7 5V CCD IN 8 PWR SVR 9 98714 SH R 10 98714 SEN N 11 98714 SCLK 12 98714 SDATA 13 GND 14 AFE RESET 15 GND 16 98714 OUTO P 17 98714 OUTO M 18 GND 19 98714 OUT1 P 20 98714 OUT1 M 21 GND 22 98714 OUT2 P 23 98714 OUT2 M 24 GND 25 98714 CLK P 26 98714 CLK M 27
15. Use current supplies This is the default The message will not appear during the remainder of the job Cancel job Wait for supplies This occurs if the job is parked Remove All Color Supplies If Color Lockout mode is enabled this message appears unless the printer is in Diagnostics Menu or Configuration Menu Remove Paper Standard Bin The standard output bin is full Remove the media to continue Remove Paper lt All bins gt Remove the paper from all output bins Restore Held Jobs Go Stop If the printer detects Print and Hold or parked jobs stored on the hard disk during Power On Self Test POST Choices are Restore Print jobs are restored and Restoring Held Jobs x y where x is the number of the job restored and y is the total number of jobs to restore You can quit restoring and the remainder of the jobs will remain on the disk but cannot be accessed until they are restored at the next POR Do not restore Held jobs will remain on the disk but cannot be accessed until they are restored at the next POR Held jobs may not be restored appears Tell me more additional information is available Supply Needed A supply is needed to complete a job Additional messages may include Prompt for supplies Cancel Wait for supplies Unsupported USB device Please Remove Remove the unrecognized device to continue Unsupported Mode Unplug camera and change it t
16. to open the Admin menus Select Settings and press Select v Select Quality and press Select Select Color Samples and press Select v Select the Color Conversion table to print and press Select moe m By examining Color Samples sets a user can identify the box whose color is the closest to the desired color The color combination labelled on the box can then be used for modifying the color of the object in a software program For more information see the software program Help topics Manual color correction may be necessary to utilize the selected color conversion table for the particular object Selecting which Color Samples set to use for a particular color matching problem depends on the Color Correction setting being used Auto Off or Manual the type of object being printed text graphics or images and how the color of the object is specified in the software program RGB or CMYK combinations When the printer Color Correction setting is set to Off the color is based on the print job information and no color conversion is implemented Note The Color Samples pages are not useful if the software program does not specify colors with RGB or CMYK combinations Additionally certain situations exist in which the software program or the computer operating system adjusts the RGB or CMYK combinations specified in the program through color management The result
17. 3 9 x 8 9 in 10 105 x 241 mm V4 Envelope 4 1 x 9 5 in B5 176 x 250 mm S Envelope 6 9 x 9 8 in C5 162 x 229 mm V4 Envelope 6 4 x9 in DL 110 x 220 mm V Envelope 4 3 x 8 7 in Other 86 x 165 mm V4 Envelope 3 4 x 6 5 in to 216 x 356 mm 8 5 x 14 in Media types Tray1 plain paper card stock labels bond transparencies and envelopes Tray2 plain paper and light card stock up to 347 Manual Feed Slot plain paper card stock labels bond transparencies and envelopes Optional input tray plain paper labels and bond Multi Purpose Feeder plain paper card stock labels bond transparencies and envelopes Paper sizes by options source and output Media guidelines both from user manuals General information 1 7 Media weights Subsystem Size Type Weight Tray 1 All sizes supported Xerographic Long Grain 16lb to 34lb 60g m2 to 128g m2 i a Ex oco banier TERON Short Grain 16lb to 34lb 60g m2 to 128g m2 drawers Recycled Long Grain 20lb to 34lb 75g m2 to 128g m2 Short Grain 28lb to 34lb 105g m2 to 128g m2 Card Stock Cover 50Ib 65lb 135g m2 176g m2 max Index 671b 90lb 120g m2 163g m2 Tag 741b 100lb 120g m2 163g m2 Labels max Paper 35lb 131g m2 Vinyl Not Supported Transparency TBD TBD Envelope Xerographic 20lb to 34lb 75g m2 to 128g m2 Xerographic Long G
18. Diagnostic aids 3 31 7541 03x Step 1 Charge During the charge step voltage is sent from the high voltage power supply to the charge roller A beside each of the four photoconductors The charge roller is part of the photoconductor unit The charge roller A puts a uniform negative charge over the entire surface of the photoconductor to prepare it for the LED Service tips e fthe surface of the charge roller is damaged such as a nick or pit it will cause the charge to be uneven on the photoconductor This will cause a repeating mark on the printed page Check the service manual for the repeating marks table e If the charge roller is severely damaged the surface of the photoconductor will not be charged properly and heavy amounts of toner will be deposited on the photoconductor This will cause the printed page to be saturated with 10096 of each color The imaging basket will need to be replaced Sooner 3 32 Service Manual 7541 03x Step 2 Expose During the expose step the LED exposes the surface of each photoconductor B and writes an invisible image called a latent image or electrostatic image for each color The LED actually discharges the surface only where the beam hits the photoconductor This creates a difference in charge potential between the exposed area and the rest of the photoconductor surface Service tips Never touch the surface of the photoconductor with your bare hand The oil from your
19. 5 Remove the two screws C that fasten the rear cave cover to the inner right cover 4 20 Service Manual 7541 03x 6 Use a screw driver to release the four tabs D that secure the inner right cover to the back cave cover 7 Pull the inner right cover forward and out of the device Repair information 4 21 7541 03x Left cover removal 1 Remove the rear cover See Rear cover on page 4 7 2 Remove the top cover See Output bin print engine top cover on page 4 17 3 Remove the rear screw A securing the left cover to the printer frame A 4 Remove the screw B securing the left cover to the left EMI shield 4 22 Service Manual 7541 03x 5 Remove the two screws C securing the left cover to the frame C 6 Remove the screw D securing the left cover to the printer frame Repair information 4 23 7541 03x 7 Slide the left cover back to release the tabs from the printer frame 8 Pull the left cover away from the frame 4 24 Service Manual 7541 03x Speaker removal 1 Remove the front operator panel cover 2 Remove the top operator panel cover 3 Remove the four screws A that secure the speaker cover to the op panel bottom cover 4 Remove the speaker Repair information 4 25 7541 03x Top removals Output bin full sensor actuator removal 1 Remove the op panel paper exit guide See Op panel paper exit guide removal on page 4 32 2 Re
20. Clear Custom Status See Clear Custom Status on page 3 16 USB Speed See USB Speed on page 3 17 Exit Config Menu Reset Fuser Counter This menu item is used to reset the fuser counter for the print engine 1 Touch the menu item A Reset Fuser Counter button is displayed 2 Touch that button to reset the counter Reset Maintenance Counter This menu item is used to reset the maintenance counter for the print engine 1 Touch the menu item A Reset Maintenance Counter button is displayed 2 Touch that button to reset the counter Reset Transfer Belt Counter This menu item is used to reset the fuser counter for the print engine 1 Touch the menu item A Reset Fuser Counter button is displayed 2 Touch that button to reset the counter USB Scan to Local When set to Off this setting tells the USB device driver to enumerate as a USB Simple device When this is set to on USB device driver enumerates as a USB Composite device multiple interfaces 3 10 Service Manual 7541 03x Black Only Mode When this setting is set to On the printer prints only grayscale printing The default is Off The result is similar to setting Print Mode to Black Only Note This setting appears only when the PUL Password Environment variable is set to 0 Print Quality Pages The Print Quality Test consists of five pages Pages one and two contain a mixture of graphics and text The remainder of the pages onl
21. Close Door message fails to appear replace the door open interlock switch f the Close door message appears and the paper tray level motor fails to operate check CN6 on the engine board for proper connection If the cable is properly connected at both connections replace the paper tray level motor f the paper tray level motor fails to operate and the close Door message fails to appear check CN6 on the engine board for proper connection If it is properly connected replace the engine board 2 Paper out sensor Paper feed unit Paper level sensor Turn the printer on and open the right cover and duplex Bypass the right cover door open interlock switch With the paper tray empty and the paper out sensor blocked pull out and replace the cassette If the tray rises and stays in place check for a dirty paper out sensor and inspect the paper empty sensor actuator on the paper feed unit f the paper empty sensor actuator is stuck or broken replace the actuator If the actuator is good replace the paper out sensor If the tray x empty message is displayed check the paper out sensor to ensure it is in place Turn the printer on and open the turn guide door Bypass the turn guide door open sensor Block the paper out sensor With the tray empty pull out and insert the cassette Ifthe tray fails to rise check for a dirty paper level sensor or broken casette present a
22. Locations 5 37 7541 03x 5 38 Service Manual 7541 03x 6 Preventive maintenance This chapter describes procedures for printer preventive maintenance Follow these recommendations to help prevent problems and maintain optimum performance Safety inspection guide The purpose of this inspection guide is to aid you in identifying unsafe conditions If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items Damaged missing or altered parts especially in the area of the On Off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover Possible safety exposure from any non Lexmark attachments Lubrication specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can cause premature failure Some unauthorized lubricants may chemically attack polycarbonate parts Use IBM no 10 oil P N 1280443 Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 IBM no 23 grease Approved equivalent Shell Darina 1 and grease P N 99A0394 to lubricate appropriate areas Use Nyogel type 774 to lubricate the Fuser Drive Assembly and Nyogel 744 to lubricate the ITU and Cartridge Drive assemblies Scheduled maintenance The following parts are used for regular maintenance on
23. Replace the waste toner box using the instruction sheet that comes with the replacement waste toner box Ensure that there is no interference between the waste toner box and the printer f the problem persists replace the engine board See Engine board MDCONT on page 4 92 f the problem persists contact your next level of service 82 Waste Toner Missing See Waste toner bottle missing service check on page 2 94 83 xx ITU Life Warning Select Continue to clear the message and continue printing Order a replacement transfer module When print quality is reduced install the new transfer module using the instruction sheet that comes with the replacement transfer module f the problem persists replace the system board See Printhead controller board removal on page 4 37 83 xx Replace ITU Replace the transfer module using the instruction sheet that comes with the replacement transfer module See Transfer belt CRU on page 4 40 f the problem persists replace the system board See Printhead controller board removal on page 4 37 83 41 ITU Missing Check for damage or loose parts on the belt Replace as needed Clean any dirty connections Try a different belt 84 11 color PC Unit Select Ignore to clear the message and continue printing Life Warning Order the specified photoconductor unit When print quality is reduced install the new specified photoconductor unit u
24. TT F5 F3 PAA s JGND1 F6 E aa st2 JMODEM1 JDIMM1 o 4l o Ble ale Diu st fo fa 7 i a E o jo slz c W B o lor e E o m o jal E 3v mo gO x 3 O CE l B k SDSDC dues 5 4 Service Manual 00000000000 9 00000000000 O Io Ls 00000000000 00000000000 O zi JBOOT1 7541 03x RIP board Connector Pin no Signal J3 ICC board 1 GND 2 FB_LAMP_ON_R 3 24V 4 24V 5 GND 6 5V_FB_CDU 7 5V_SCANNER 8 FB_PWRSVR_R 9 FBR_AFE_SH_R 10 FBR_AFE_SEN_R 11 FBR_AFE_SCK_R 12 FBR_AFE_SDIO_R 13 GND 14 FBR_AFE_NRST_R 15 GND 16 FB_LVDS_RXINO 17 FB LVDS RXINO 18 GND 19 FB LVDS RXIN1 20 FB LVDS RXIN1 21 GND 22 FB LVDS RXIN2 23 FB_LVDS_RXIN2 24 GND 25 FB LVDS RXCLK 26 FB LVDS RXCLK 27 GND 28 FB LVDS MCLK 29 FB_LVDS_MCLK 30 GND Locations 5 5 7541 03x RIP board Connector Pin no Signal J4 1 GND
25. r rIrSrIIlle 7 11 40X6975 Duplex out sensor r rr rSlIIIlISlIllle 7 11 40X6976 Duplex timing sensor IIIIIrIIIlle 7 11 40X6977 Op panel light pipe m RIIIIIIII III 7 7 40X6978 Flatbed front cover 9 2 ee enn nr nr nn ee eee ee 7 7 40X6979 ADF tray bottom cover errr re errr ee ee eee eee eee eee 7 9 40X6980 Flatbed unit 2 2 eee enn nn ee en ne eee ee 7 5 40X6981 MPF tray support arm 22 errr ee eee 7 15 40X6982 MPF paper empty lever 22 eer eee eee 7 13 40X6983 Duplex cover pin rrI rSlIrSSlILIlle 7 15 40X7117 Speaker assembly 2 0 errr reer eee eee eee eee eee eee eee 7 7 512M DDR DRAM DIMM 40X5302 r lllllllllSllllSl lll llle 7 46 550 sheet paperfeed screw parts pack 40X7452 7 39 7 41 7 43 A A S carrying roller 40X6152 l r lllllllllllSlllllll llle 7 13 A S link arm 40X6286 2 2 ene nn rn ne ee eee 7 3 A S link arm spring 40X6272 e rllllllllllllelllSl llle llle 73 A S pushing spring 40X6136 7 7757171 rrtt rtnn 7 15 Access cover 40X6124 2 2 e ee errr eee ee ee eee ee ee eee eee eee ee 7 3 Arabic font c
26. 2 Select a tray Only those trays with size sensing appear Select Auto to turn size sensing on for that tray or select Off to disable size sensing 3 Touch Back to exit Diagnostic aids 3 11 7541 03x Panel Menus Disabling Panel Menus prohibits users from modifying any setting or executing any operation available in the Ready Menu group PPDS Emulation This appears only if the PPDS interpreter is available Download Emuls Warning This setting should not be changed without specific instructions from the next level of support This setting temporarily disables downloaded emulators for troubleshooting purposes All downloaded emulators are re enabled automatically after two PORs Demo Mode This printer supports a demo mode that is usually used in retail environments to illustrate the features of the printer The printer features are illustrated by demonstration files stored in the RIP firmware flash option or disk option This mode is deactivated by default Factory Defaults The customer can restore either the network settings or the base printer settings to their factory default values When Restore Base is selected non critical base printer NVRAM settings are restored When Restore STD Net is selected all network NVRAM settings are restored to their factory default settings This option is available only on models with an integrated network adapter When Restore LES is selected all non standard applications are remove
27. 7541 03x Step Action and questions Yes No 1 Are CN 17 18 19 and 29 on the engine controller Go to step 2 Connect the board properly connected cables to the board 2 Arethe cables properly connected to the drive motors Go to step 3 Connect the cables to the motors 3 Replace the engine controller board Did this fix the Problem solved Go to step 4 issue 4 Replace the defective supply item Did this fix the Problem solved Replace the drive problem motor for the affected color 149 01 Fuser paper exit motor error Step Action and questions Yes No 1 Is the fuser paper exit motor cable properly connected Go to step 2 Connect the to the motor and CN16 on the engine board cables at both ends 2 Checkthe cable for continuity Is there continuity Go to step 3 Replace the fuser paper exit motor cable 3 Replace the paper exit fuser motor Did this fix the Problem solved Go to step 4 problem 4 Replace the engine board Did this fix the problem Problem solved Go to step 5 5 Replace the printhead controller board Did this fix the Problem solved Contact your issue second level support Diagnostic information 2 51 7541 03x 146 01 Traylerror Note This is the service check for the standard paper tray Step Action and questions Yes No 1 Check the cable connecting t
28. NI oO AJ WwW N GND GND Locations 5 25 7541 03x Scanner ICC board connectors ICC board Connector Pin no Signal J1 FB Cover open 1 FB COVER OPEN 2 DGND 3 5V J2 FB paper size sensor 2 1 GND 2 5V 3 FBPS2 3 4 FBPS2 2 5 FBPS2 1 J3 1 GND 2 24V RIP 3 24V RIP 4 24V RIP 5 GND 6 TOP FB 7 BOOT SEL 8 5V 9 5V 10 GND 11 MDC RXD 12 13 GND 14 ADF_PAPER_INMDC_TXD 15 F_COVER_OPEN 16 GND 17 HMSEN 18 PAPER_GAP 19 GND 20 RESET_N 21 3 3V 22 GND 23 HW RESERVE 24 IC2_CLK 25 IC2 DATA 26 GND 5 26 Service Manual 7541 03x ICC board Connector Pin no Signal J4 FB paper size sensor 1 1 GND 2 5V 3 FBPS1 3 4 FBPS1 2 5 FBPS1 1 J5 1 5V 2 24VM_ADF 3 24VM_ADF 4 GND 5 GND 6 lO BUSO 7 lO BUS2 8 lO BUSA 9 lO BUS6 10 ADF PICKUP STEP 11 FB ADF STEP 12 DGND 13 ADF PLUG 14 DGND 15 24VM ADF 16 DGND 17 NC 18 lO BUS1 19 NC 20 lO BUSS 21 NC 22 lO BUS5 23 ADF PAPER IN 24 NC 25 PAPER GAP 26 3 3V Locations 5 27 7541 03x ICC board Connector Pin no Signal J6 CCD RIP 18 pin a 3 3VM 3 3VM GND GND FB_DIR HM SEN GND FBM EN ojo OojOoOc BY Ww FB_RS A o GND a FB MS2
29. Operating system Driver type File type PCL PostScript XPS etc Go to step 8 Go to step 10 Restart the printer to operating mode Send a different print job to the device Does the 900 xx error reoccur Go to step 9 Go to step 10 2 60 Service Manual 7541 03x Step Action and questions Yes No 9 Upgrade the firmware Contact your next level of Go to step 31 Go to step 10 support for the correct firmware level to use Restart the printer to operating mode Send the printer a print job Does the 900 xx error reoccur 10 Is the device a Multi Function Printer Go to step 11 Go to step 13 11 Run a copy job Go to step 31 Go to step 12 Does the 900 xx error reoccur 12 Runascan to PC job Go to step 31 Go to step 13 Does the 900 xx error reoccur 13 Is there optional memory installed Go to step 14 Go to step16 14 Reinstall the memory and send a print job to the Go to step 15 Go to step 16 device Does the 900 xx error reoccur 15 Install a Lexmark recommended memory option Send Go to step 31 Problem a print job to the device resolved Does the 900 xx error reoccur 16 Is there a modem installed on the device Go to step 17 Go to step 21 17 Reinstall the modem Restart the device Go to step 18 Go to step 20 Does the 900 xx error reoccur 18 Upgrade the firmware Contact your next level of Go to step 19
30. Optical photo conductor Optical Sensor Photoconductor Portable Document Format Problem isolation charts Personal identification number Picture element Printer Job Language Power on reset Power on self test Personal Printer Data Stream Pages per minute Print Quality Enhancement Technology Peoples Republic of China Parallel Synchronous Communications Position Sensing Device Participating Standards Organization Pulse Width Modulation Random access memory Radio frequency identification Relative humidity Raster image processor Read only memory Read only storage Revolutions Per Minute Synchronous Dynamic Random Access Memory 7541 03x General information 1 17 7541 03x SEF SOL SRAM TAR TPS TTM TVOC UAT UPR USB V ac V dc VOM VTB XPS 1 18 Service Manual Short edge feed Solenoid Static random access memory Toner Add Roll Toner Patch Sensing Tandem Tray Module Total Volatile Organic Compound Universally Adjustable Tray Used Parts Return Universal Serial Bus Volts Volts alternating current Volts direct current Volt Ohmmeter Vacuum Transport Belt XML Paper Specification Yellow 2 Diagnostic information Start 7541 03x CAUTION A Unplug power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer Disconnect any connections between the printer and PC
31. Rear paper guide Discharge brush Fuser Remove any buildup of toner Replace any damaged or worn parts Check the paper exit flag on the fuser for damage Replace the fuser if necessary 2 Fuser entry sensor Check the fuser entry sensor to ensure it is in it s position and not dislodged Check the cable to ensure it is properly connected to CN6 on the printhead controller board Replace the sensor if it is faulty If this doesn t fix the problem replace the printhead controller board 3 Fuser separation pawl Replace the fuser if paper jams cannot be removed Paper has entered the fuser and exited the printer Paper jam 203 FRU Action 1 Fuser Remove any toner buildup and replace any worn or damaged parts 2 Output bin full lever Check the output bin full lever for smooth operation Replace if Paper exit unit Exit unit sensor Bin full sensor needed Check the exit unit sensor actuator for smooth operation If the actuator is broken replace the paper exit unit Check the exit unit and bin fill sensors on the paper exit unit for dirt and debris Clean if needed Check the cable for proper connection to CN7 on the printhead controller board If the cable is properly connected replace the sensor faulty sensor If this doesn t fix the problem replace the printhead controller board Diagnostic information 2 25 7541 03x Paper has entered the duplex unit P
32. on page 4 73 283 05 Scan sensor jam Step Action and questions Yes No 1 Remove the paper from the ADF Did this resolve the Problem resolved Go to step 2 problem 2 Does the duplex paper pass sensor have dust on it or Go to step 3 Go to step 4 debris blocking the sensor 3 Clean the sensor Did this fix the issue Problem resolved Go to step 4 4 Checkthe sensor ADF skew sensor for proper Go to step 4 Go to step 3 operation 1 Enter the Diagnostics Menu 2 Touch SCANNER TESTS 3 Touch Sensor Tests 4 Observe the line sensor ADF skew sensor Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 5 Check J1 on the ADF relay card for proper connectivity Go to step 7 Go to step 6 Is the sensor cable properly connected to the ADF relay card 6 Reconnect the cable to the ADF relay card Did this fix Problem resolved Go to step 7 the issue 7 Check pin 1 4 7 10 for 5V and pin 3 6 9 12 for GND Go to step 8 Go to step 9 on connector J1 on the ADF relay card Are they present 8 Replace the inner cover sensor assembly Did this fix Problem resolved Go to step 9 the issue 9 Checkthe ADF motor assembly for proper connection Go to step 10 Go to step 11 to J2 and J6 on the ADF relay card Are the motors properly connected 10 Connect the cables Did this fix the issue Problem resolved Got to step 11 11 Replace the ADF motor assembly Did this fi
33. 3 Touch Sensor Tests 4 Observe the line sensor ADF exit sensor Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 9 Check J4 on the ADF relay card for proper connectivity Go to step11 Go to step 10 Is the sensor cable properly connected to the ADF relay card 10 Reconnect the cable to the ADF relay card Did this fix Problem resolved Go to step 11 the issue 11 Check pin 1 for 5V and pin 3 for GND on connector J4 Go to step 12 Go to step 13 on the ADF relay card Are they present 12 Replace the duplex out sensor Did this fix the issue Problem resolved Go to step 14 13 Checkthe ADF cable for continuity Is there continuity Go to step 14 Go to step 15 14 Replace the ADF cable did this resolve the issue Problem Go to step 15 resolved 15 Replace the ADF relay card Did this fix the issue Problem resolved Go to step 16 16 Replace the ICC board Did this fix the issue Problem resolved Replace the RIP board See RIP board removal on page 4 73 2 32 Service Manual 290 11 Scanner ADF cover open jam Note In addition to the steps below See ADF cover open service check on page 2 77 7541 03x Step Action and questions Yes No 1 Open the ADF top cover and check the cover Go to step 4 Go to step 2 open sensor actuator to see if it moves freely Does the sensor actuator move freely
34. 3 46 Service Manual 7541 03x The X925 duplex ADF enables the user to create duplex scans automatically eliminating the need to stop the scanning process to flip the media being duplicated over The ADF uses a step motor and a series of sensors to determine the media s position in the paper path during the scan process The following steps are performed in creating a duplex scan on the X925 duplex ADF 1 To transfer text or an image from physical media to another piece of physical media or a digital file the following steps occur The first step of the process is the placement of the paper on the scanner The paper is placed on the flatbed or the ADF paper tray Once the paper is placed in the device the scan or copy command is initiated by the user This command can be issued from a computer or on the scanner itself 2 When the scan command is initiated the ICC board on the scanner first polls the paper present sensor in the ADF to see if there is paper in the ADF unit If the paper present sensor indicates the presence of paper the size sensors are polled to determine the length and width of the paper There are two paper length sensors They are found on the ADF input tray These sensors detect A4 vs folio for non US users and letter vs legal for US users The ADF paper width sensor is composed of three photo interrupt sensors that are actuated by the paper guides on the ADF tray The position of the guides places the three actuators on
35. DRAM Test 3 22 Panel Test 3 21 Serial Wrap Test 3 23 USB HS Test Mode 3 24 PRINT TESTS Print Quality Pgs 3 20 Quick Test Pages by input source 3 20 PRINTER SETUP Cal Ref Adj 3 26 Configuration ID 3 26 Defaults 3 25 Engine Setting x 3 26 Model Name 3 26 PAGE COUNTS 3 26 Par 1 Strobe Adj 3 27 Reset Calibration 3 26 Serial Number 3 26 Reports 3 27 Scanner Tests 3 29 Disk Encryption 3 16 Door interlock switch removal 4 89 Download Emuls 3 12 DRAM options 2 90 DRAM Test 3 22 Drive unit removal 4 79 Duplex removal 4 63 Duplex solenoid removal 4 90 Duplex unit service check 2 24 E Electrical specifications 1 4 Energy Conserve 3 12 Engine board MDCONT removal 4 92 Engine Setting x 3 26 Envelope Prompts 3 15 environment 1 5 Error code 976 Network card x service check 2 91 error codes and messages 3x 8x attendance messages 2 69 2 74 Escalating a fax issue to second level support 2 82 ESD sensitive parts 4 1 eSF solutions backup 4 3 EVENT LOG Clear Log 3 29 Display Log 3 28 Print Log 3 28 Exit guide paper exit roll removal 4 190 exiting configuration menu 3 17 F Factory Defaults 3 12 l 2 Service Manual false door open service check 2 86 Fax dials a number but no connection is made 2 83 Fax reception fails 2 80 Fax Storage Location 3 13 Faxes fail to transmit 2 78 Feed Test SCANNER 3 29 flash options service check 2 90 Flash Test 3 25 flatbed lock 2 35 Font Sharpening 3 16 Format Fax Storage 3 13 Fuser ent
36. Delivery roll Lower duplex transport roll Timing belt i eS E Duplex MPF sensor actuator Note Once the media reaches the Duplex Exit MPF detection lever it shares the same paper path as the MPF 3 45 Diagnostic aids 7541 03x Scanner Duplex ADF The following illustration shows the paperpath rollers and sensors used in the X925 duplex ADF 8 bs 9 10 16 Tm log on Callout Partim Affected CRU FRU part catalog name 1 ADF paper length and width sensors photo reflect Tray paper size sensor multi point contact 2 Paper pass sensor photo reflect Duplex timing sensor 3 ADF paper present photo interrupt ADF paper path sensor 4 ADF cover open ADF paper path sensor 5 Pick roll ADF pick roll CRU 6 Pick roll position sensor Photo interrupt ADF paper path sensor 7 Feed roll ADF pick roll CRU 8 Separator roll ADF Separator roll CRU 9 Paper gap sensor photo interrupt ADF paper path sensor 10 Paper in sensor Photo reflect Scan sensor 11 Scan roller ADF main feed unit 12 Scan sensor Photo interrupt Scan sensor 13 Takeaway roll ADF main feed unit 14 ADF paper exit sensor Photo interrupt Duplex out sensor 15 Stack roller ADF main feed unit 16 Pass roller ADF main feed unit
37. Diagnostic information 2 71 7541 03x Error code Action 56 USB Port x Disabled Select Continue to clear the message The printer discards any data received through the USB port Make sure the USB Buffer menu item is not set to Disabled f this does not fix the problem replace the PCI card 56 Standard USB Port Disabled Select Continue to clear the message The printer discards any data received through the USB port Make sure the USB Buffer menu item is not set to Disabled f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 57 Configuration Change Held Jobs May Not Be Restored See Configuration Change above not in IR as 57 Configuration changes may be Code version changes Paper handling options removed The disk was installed from a different model or speed of printer 58 Too Many Flash Options Too many flash options are installed To continue 1 Turn off and unplug the printer 2 Remove the excess flash memory 3 Plug in the printer and turn it on If this does not fix the problem replace the If this does not fix the problem replace the RIP board See RIP board removal on page 4 73 58 Too Many Trays Attached a Turn off and unplug the printer 2 Remove options until the supported number of options for that model Models C925 supports three additional trays 3 Plug in the printer and tur
38. Dld this fix the Problem solved Go to step 4 problem 4 Replace the engine board Did this fix the problem Problem solved Contact your second level support Diagnostic information 2 93 7541 03x Unable to print from USB thumb drive service check Step Action and questions Yes No 1 Try a different thumb drive Does that drive work Problem solved Go to step 2 2 Verify that the USB cable is properly connected to the Go to step 4 Go to step 3 UICC card and RIP board Is it connected 3 Re connect the cable Did this fix the issue Problem solved Go to step 4 4 Check the USB connector for damage Is there Go to step 5 Go to step 6 damage 5 Replace the cable Did this fix the problem Problem solved Go to step 6 6 Replace the UICC Did this fix the issue Problem solved Contact you second level support Waste toner bottle missing service check Step Action and questions Yes No 1 Open the front door and lower the inner Problem solved Go to step 2 photoconductor locking door Tell the customer Pull the toner bottle out and push it back in to that this issue position can occur Close the photoconductor locking unit door Instruct them to arret 2 perform the Did this fix the problem procedure performed in step 1 2 Clean the waste toner bottle sensor of any debris or Problem solved Go to step 3 toner Did this fix the issue 3 C
39. Fax error log codes Continued 7541 03x Error code Description Action 882 Failure to transmit training successfully Select a lower Max Speed under Fax in V17 V29 terminal modulation Send settings schemes Adjust the Transmit Level Check line quality 883 Failure to transmit training successfully Select a lower Max Speed under Fax in V17 V27 terminal modulation Send settings schemes Adjust the Transmit Level Check line quality 884 Failure to transmit training successfully Select a lower Max Speed under Fax in V29 V27 terminal modulation Send settings schemes Adjust the Transmit Level Check line quality 885 Failure to transmit training successfully Select a lower Max Speed under Fax in V17terminal modulation scheme Send settings Adjust the Transmit Level Check line quality 886 Failure to transmit training successfully Select a lower Max Speed under Fax in V29 terminal modulation scheme Send settings Adjust the Transmit Level Check line quality 887 Failure to transmit training successfully Select a lower Max Speed under Fax in V27 terminal modulation scheme Send settings Adjust the Transmit Level Check line quality 888 Failure to transmit training successfully Adjust Transmit Level at 2400 bps in V27 terminal modulation Check line quality scheme 889 Failed to connect at the minimum Adjust Tran
40. Fuser entry sensor removal oii ee ec naa eras bans rda nada ser kae Para na ssa 4 91 Engine board MDCONT 53 35x noi ox mre RE Roe ers a CER RE RCEUN UE RE EUR RU RR PR dees RR UN 4 92 FUSER Fan ices rp TI 4 92 Fuser exit drive unit motor removal 00 0 c cece e eee eee eee nee nnn nnn nn 4 93 Modem removal 5 nas ete ene ie Od ORS E e Ee eRe ewe kale de a e WU baled bail ce 4 94 Papertray lift motor removal 45x ihn dee EAR de HS RRR RR RC AUR 4 94 MIP Gabe removal teiecietackedaneeltioetiunees hosen DOLI Asa bes i LPs n bd tec 4 95 Toner ensor TEMOVAl i ascendant rd hor ARRA A ERU ARR oae RR dA Pep RR RRS RMR 4 97 Tranet r belt motor FOITIQVAT aas ac eden cee ic de de dead iced Qo CR RR RCACRUR QUU RE 9 AL aja 4 100 Temperature and humidity sensor removal eeeeeeeee nnn 4 101 Ri E E AID OLI QD ILL IL TID LILETSAILCIOITL TV 4 102 Sub frame UA iiisnssesoxzertta e kRieRkRS PREGA ER RODEG RE eii RGOREGOREG Ud RP ERG oe REN de 4 104 Paper Size swilchiremoVal 133234 543a icd KE RIA ns 2 RR Rund oko d Er Qood Ru dd a oic 4 105 Rear EMI shield Nota FH ceulice Rr RR Rer Rr E a ES Reis 4 106 Paper feed motor removal avis scias sce a ness cee ER ACAD AC OC ADR ane eam ewes 4 110 HVPS removal ussesdasacFkprP ER Per eed LUSEdemEe Pe PAP PvP Sequi IS 4 111 7541 03x Waste toner sensor removal amp akkk a ERRA REX RARE RGOCEG ROY REO EGOR Re ROROCR RCROR OA RR RRO 4 112 S6aDer dred FEDIDUUIS 2515 d 3538 15e no b UB E
41. Problem support for the correct firmware level to use resolved Restart the printer to operating mode Send the printer a print job Does the 900 xx error reoccur 19 Replace the modem Restart the device Go to step 31 Problem Does the 900 xx error reoccur resolved 20 Run a fax job Go to step 31 Go to step 21 Does the 900 xx error reoccur 21 Are there any ISP internal solutions port options Go to step 22 Problem installed resolved 22 Reinstall the first ISP option Restart the device Go to step 24 Go to step 23 Does the 900 xx error reoccur 23 Run a job to test the option Go to step 24 Go to step 26 Does the 900 xx error reoccur 24 Upgrade the firmware Contact your next level of Go to step 25 Problem support for the correct firmware level to use resolved Restart the printer to operating mode Does the 900 xx error reoccur 25 Replace the faulty ISP option Restart the device Go to step 31 Go to step 26 Does the 900 xx error reoccur Diagnostic information 2 61 7541 03x Step Action and questions Yes No 26 Are there any more ISP options to install Go to step 27 Problem resolved 27 Install the next ISP option Restart the device Does the 900 xx error reoccur Go to step 29 Go to step 28 28 Run a job to test the option Does the 900 xx error reoccur Go to step 29 Go to step 26 29 Upgrade the firmware Contact your n
42. Properly connect the cable at both ends Did Problem resolved Go to step 15 this fix the issue 15 Checkthe ADF cable for continuity Is there Go to step 17 Go to step 16 continuity 16 Replace the ADF cable Did this fix the Problem resolved Go to step 17 problem 17 Replace the ADF relay board Did this fix the Problem resolved Goto step 18 issue Diagnostic information 2 33 7541 03x Step Action and questions Yes No 18 Replace the ICC board Did this fix the issue 2 34 Service Manual Problem resolved Replace the RIP board See RIP board removal on page 4 73 291 06 Flatbed cover open 7541 03x Step Action and questions Yes No 1 POR the MFP Does the error re occur Go to step 2 Problem solved 2 Checkthe sensor FB Cover open for proper Go to step 4 Go to step 3 operation 1 Enter the Diagnostics Menu 2 Touch SCANNER TESTS 3 Touch Sensor Tests 4 Observe the line sensor FB Cover open Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 3 Check all the connections from the FB cover open Go to step 5 Go to step 4 sensor to J1 on the ICC board Are they properly connected 4 Properly connect the connections Did this fix the Problem resolved Go to step 5 problem 5 Replace the sensor Did this fix the problem Probl
43. Remove the excess paper from the trays Did this fix Problem solved Go to step 6 the problem 5 Inspect the paper feed rolls registration rolls and Go to step 8 Go to step 7 registration roll springs Are the registration rolls clean and in the proper place 6 Install the paper feed maintenance kit Did this fix the Problem solved Contact your issue second level support Imaging unit photo developer missing service check Step Action and questions Yes No 1 Are the imaging units properly seated Go to step 3 Go to step 2 2 Reseatthe imaging units and properly close the Problem solved Go to step 3 photodeveloper lock Did this fix the issue 3 Check the contacts on the rear of the photodeveloper Go to step 5 Go to step 4 for dirt or toner Are the contacts clean 4 Clean the contacts on the photodeveloper Did this fix Problem solved Go to step 5 the issue 5 Inspect the sub unit contacts for damage and dirt Are Go to step 6 Go to step 7 they dirty or damaged 6 Replace the subunit Did this fix the issue Problem solved Go to step 7 7 Replace the HVPS Did this fix the problem Problem solved Go to step 8 8 Replace the printhead controller board Did this fix the Problem solved Contact your problem second level support Diagnostic information 2 89 7541 03x Option card service check Step Action and questions Yes No 1 Remove all the c
44. Repair information 4 165 7541 03x 6 Carefully feed the sensor assembly cable through the ADF main feeder 7 Carefully feed the sensor assembly cable through the ADF paper guide assembly 8 Remove sensors and hinges from the inner cover to place on the new cover 4 166 Service Manual 7541 03x ADF relay card cover 1 Remove the two screws A securing the relay cover to the ADF assembly Left ADF cover 1 Remove the two screws A on top of the left ADF cover Repair information 4 167 7541 03x 2 Remove the screw B in the rear of the left ADF cover r B 3 Liftthe ADF top cover and remove the screw C 4 168 Service Manual 7541 03x 4 Liftthe cover up and slide the tab on the cover out of the ADF assembly Repair information 4 169 7541 03x Right ADF cover 1 Remove the screw A securing the cover to the flatbed cover A 2 Liftthe ADF top cover and remove the screw B securing the cover to the flatbed cover 4 170 Service Manual 7541 03x 3 Liftthe rear of the right ADF cover up and pull the cover away from the flatbed cover Repair information 4 171 7541 03x Duplex unit component removals Duplex clutch removal 1 Remove the duplex unit See Duplex removal on page 4 63 2 Remove the two screws A securing the duplex cover to the duplex unit 3 Disconnect the duplex clutch harness from the duplex clutch 4 Remove the e
45. Repeating defects sci cet reese dhe hwd kadr kes iinan rnes RES ERR EE RR MR Ed 2 4 One color MISSING uuisdexsce xima RO RR ERU CR c RR cR UR UE amp GURUR Ren Ro RR nds 2 5 Contaminated background 25 62 c0ciseececce cance RR RR t enr r er EE LER E sees sien 2 5 Lowered print density xxx sce er m RR IRURE OCC eae ACE ORC ed Re RACER EE ORC RR CR 2 6 Wine Sipes PI Er ms 2 6 Uneven DHL aiias xa xD E CR QR COUR CR UU UORONL RR egeo E UAR US A CR RRS OR RRR RR RE 2 6 eli lier rere C p cs eer did RU dc bob d oboli oun dolos i do rere ere reer ere 2 7 HepeBHng Marks san iocd e d ERRORI RERO AU io ORARE RU eR eC eR ROO e b e 2 7 BISCIC SRI DOS bass bibis bis iai Abbild Eb FER PERSA ERA IMEDA BIRD DIRECTE ERR ERR 2 7 Unprinted SPOS oaaacdoe kd ebEd A bE eee ee ene A GROS Re eb Foo UR code EDO eR dodo d 2 8 Pattally dark or Hiht BIDE s4cnd ntictutama paced sitetiitadiacedeiaebagaed db aC Ba c 2 8 Black Page coxa eade d ace aia RR Ode Vd e OE X EGER E VER Re o e MR o a Ea 2 9 7541 03x NG DIE cama haa i RERO RR RC RC EH CREA QUADRA NR CROCO AC ROC CR CROP ee RA eRe ADR OR 2 9 Sdn on Dack Ot DEO Laci iae bh EXER DEDANS ESAE ASSERERE ERE LINE FANS 2 10 FANGS 10 MUSE DC 2 10 Sams on edge Of Page cai incest cceicdvaswtneseedaseeies dag sebaden nes REDE EE RUE 2 10 ADP amp scanner print Quality iussa Ede RERO ARRA Y AREA ERR RE REEL ERR P a QR EV enn 2 11 Image quality SUVITIDIGITIS 2 52 cckecececeaeaoceae Ene ER
46. Separating the MPF tray and main tray paperfeed units 1 Remove the paperfeed unit from the printer See Power supply fan removal on page 4 55 2 Remove the clutches on the paperfeed unit See Paperfeed unit clutch removal on page 4 179 3 Remove the two screws A securing the paperfeed motor to the paperfeed motor frame B 4 Remove the seven screws B securing the paperfeed motor frame to the paper feed unit 5 Remove the paper feed motor frame Repair information 4 177 7541 03x 6 Remove the twelve screws C securing the paperfeed connect frame to the paperfeed units 7 Remove the eight screws D securing the paperfeed connect frame to the paperfeed units 4 178 Service Manual 7541 03x Paperfeed unit clutch removal Note This procedure applies to all the clutches on the paperfeed unit 1 Remove the paperfeed unit See Power supply fan removal on page 4 55 2 Disconnect the wiring harness A from the clutch 3 Remove the e clip B securing the clutch to the shaft Note When reinstalling the clutch make sure the clutch stopper on the paperfeed unit is lined up with the stop on the clutch Registration sensor MPF tray removal 1 Open the right cover door 2 Pullthe cassette guide down 3 Pinch the tabs A that secure the sensor to the cassette guide releasing the sensor 4 Disconnect the sensor from the sensor wire harness B Repair information 4 179 7541 03x Regi
47. support Contaminated background Step Action and questions Yes No 1 Check the imaging units and toner supplies to see if Go to step 2 Clean the they are clean Are they clean supplies Replace if needed 2 Check the imaging units for proper connection Are Go to step 3 Reinstall the they installed properly imaging units 3 Replace the HVPS Dis this fix the problem Problem resolved Contact your second level support Diagnostic information 2 5 7541 03x Lowered print density Step Action and questions Yes No 1 Check the paper for moisture Is the paper moist Replace the Go to step 2 paper 2 Checkthe LED printhead for dirt Is the printhead Go to step 3 Go to step 4 dirty 3 Clean the print head with a lint free cloth Did this fix Problem resolved Go to step 4 the problem 4 Replace the LED printhead Dis this fix the problem Problem resolved Go to step 5 5 Replace the HVPS Did this fix the problem Problem resolved Contact your second level support White stripes Step Action and questions Yes No 1 Are there scratches or dirt on the photo sensitive drum Replace the Go to step 2 of the imaging unit imaging unit 2 Is there dirt on the exposing surface of the LED Go to step 3 Go to step 4 printhead 3 Clean the LED printhead Did this fix the issue Problem resolved Go to step 4 4 Replace the defective LED prin
48. 1 Enter the Diagnostics Menu 2 Touch SCANNER TESTS 3 Touch Sensor Tests 4 Observe the line sensor ADF Skew and Scan sensor Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 6 Checkthe connections along the cable from the sensor Go to step 8 Go to step 7 to J1 on the ADF relay card Are all the connections properly connected 7 Properly connect the connectors Did this fix the issue Problem resolved Go to step 7 8 Check pins 1 4 7 10 for 5V and pins 3 6 9 12 for Go to step 9 Go to step 10 GND on connector J1 on the ADF relay card Are they present 9 Replace the sensor assembly in the ADF inner cover Problem resolved Go to step 10 Did this fix the issue 10 Checkthe ADF motor assembly for proper connection Go to step 11 Go to step 12 to J2 and J6 on the ADF relay card Are the motors properly connected 11 Connect the cables Did this fix the issue Problem resolved Gotto step 12 12 Replace the ADF motor assembly Did this fix the Problem resolved Go to step 13 issue 13 Replace the ADF relay card Did this fix the issue Problem resolved Go to step 14 2 30 Service Manual 7541 03x Step Action and questions Yes No 14 Replace the ICC board Did this fix the issue Problem resolved Replace the RIP board See RIP board removal
49. 159 Flatbed Upper COVOE 1 124 nk E RCRUM ERROR EQ aAA Ra dog OR ERREUR E 4 161 Guia ADETOD COVED 0545 scene FORTE S aes Megane BR PRA dd dud v dS du dob dd ERU EA 4 163 Inner ADF TtOD COVOF ian eaae kordopREdORER ARCA RCRCOR dee eae Ad aw RAUS 4 164 ADE Telay COMI COVe iundsd dad asd Reda d QUE Ea qb Qd d d au DE Ac dauid coe 200 ena REUS 4 167 Lett ADF COVER Lose esxwtekasted aC dat ede Ke e dora ARR een eoa 4 167 High AUF COVEN costesir tni Sabinin tase ES RSEN PII KE RAE SSE ease 4 170 Duplex unit component removals seeeeeeeeee n n hh hh hh 4 172 Duplex clutch removal 442 2 eh bx ax RARO issant UD idee RR RDA Ree RRR ES 4 172 Duplex timing belt removal 000 000 ce eee eee eee eee ee eee hahaha span 4 173 Duplex exit MPF sensor removal seeeeseee n n n nn nnn 4 173 MPF CIUICHFEMOVAl i225 2uask uocat va vk ene aar ER bales Renee Caled Rss PPS ER 4 174 MPF tray assembly removal iu isnt RE RR RR RR EROR ACATRCA ECRIRE ROCA RON RR RC 4 175 Paperfeed unit component removals eseseee eene nnn nn 4 177 Separating the MPF tray and main tray paperfeed units llle eee eee 4 177 Papsrieod gir clutem removal s ud tated nob edt icio COR e TEA ob rand A eo Mrd d b dod 4 179 Registration sensor MPF tray removal eese RII 4 179 Registration sensor actuator removal eeeeeeeeeee n nnn nn 4 180 Static discharge brush removal eseeeeeeeee e n
50. 2 3 4 24V_FEED_FAN 5 GND 6 TOP_FB_CN 7 BOOT_SEL_CN 8 5V SCANNER 9 5V SCANNER 10 GND 11 MDC_TXD_CN 12 MDC_RXD_CN 13 GND 14 ADF_PAPER_PRES_R 15 FB_COVER_CLOSING_R 16 GND 17 FB_NHOME_R 18 ADF_INTERVAL_R 19 GND 20 MDC_RST_NR 21 3 3V 22 GND 23 NC_MDC_23 24 IC2 CLK 25 IC2 DATA 26 GND 5 6 Service Manual 7541 03x RIP board Connector Pin no Signal JMODEM1 1 MOD_CS_R 2 GND 3 MOD_DINR 4 GND 5 MOD_DOUT_R 6 GND 7 MOD_CLK_R 8 GND 9 MOD_IRQ_R 10 5V 11 POR_CUHD 12 3 3V 13 3 3V 14 NC_MOD_P6 J9 1 UI RESET NR 2 GND 3 TX1 4 TX1 5 TX2 6 TX2 7 CLXTX 8 CLXTX 9 GND 10 5V 11 UI_RXD 12 UI_RXD 13 TXO 14 TX0 15 GND 16 5V 17 5V 18 5V 19 WAKE 20 GND 21 GND 22 AMBER_LED 23 5V_CONT 24 PWR_BUTTON Locations 5 7 7541 03x RIP board Connector Pin no Signal J11 Printhead controller board GND VSYN Y VSYN M VSYN C VSYN K HSYN Y HSYN M HSYN C HSYN K O N oO BY Ww o GND LEVELY O0 N LEVELY O1 wo LEVELY EO A LEVELY E1 5 8 Service Manual 7541 03x RIP board Connector Pin no Signal 15
51. 40X6730 28 40X6317 29 40X6427 30 40X6208 31 40X6212 32 40X6305 33 40X6309 NS 40X6310 NS 40X6311 NS 40X6312 NS 40X7055 NS 40X7448 Sub main power cable MPSP cable scanner low volt power supply RIP power supply cable 110V Scanner power supply 220V Scanner power supply Main power cable Sensor A S cleaner Sensor cover Sensor cover spring Density sensor Density sensor cable Humidity sensor Humidity sensor cable Paper size sensors Main fan Power supply fan HVT cable RIP harness cable RIP print controller cable RIP board Engine board fan High volt power supply cable High volt power supply UICC RIP cable USB front reader cable USB card reader cable RIP scanner FFC cable ribbon cable RIP scanner cable Modem card w a l a a a a a a S a a a a p p a a a a a a S t a a a a e ia a l i l a uA M o o i MA Lo o L oo o Lo oe oo i aM o o o o ee ee ee e M A Electrical screw parts pack Parts catalog 7 27 7541 03x Assembly 14 Electrical 2
52. 6 Remove the four screws A fastening the paperfeed mount plate to the right scanner stay ta t1755 Repair information 4 69 7541 03x 7 Remove the two screws B securing the right side of the paper feed unit to the printer frame 4 70 Service Manual 7541 03x 8 Remove the two screws C securing the upper left side of the paper feed unit to the printer frame Y C 9 Remove the two screws D securing the lower left side of the paper feed unit to the printer frame md R Repair information 4 71 7541 03x 10 Carefully remove the paperfeed unit Feed the cables through the printer frame while removing the unit Note When routing the cables through the frame be sure to make a note of where they go through the frame Note See Paperfeed unit component removals on page 4 177 for instructions to remove the paperfeed unit sub components Transfer Roll CRU 1 Open the right side cover duplex unit 2 Turn the transfer roll fasteners to the unlocked position 4 72 Service Manual 7541 03x Rear removals RIP board removal Warning Observe all ESD precautions while handling electrostatic discharge sensitive parts See Handling ESD sensitive parts on page 4 1 Warning When replacing any one of the following components Operator panel UICC assembly Controller RIP board Replace only one component at a time Replace the required component and perform a POR before replacing
53. B C A 3 Pull back the tab on the pick roll B and remove the pick roll Paperfeed roll removal Remove the paperfeed unit See Power supply fan removal on page 4 55 Remove the pick roll See Pick roll removal on page 4 182 Remove the nylon retainer clip C Remove the feed roll Bom 4 182 Service Manual 7541 03x Separator roll removal 1 Lower the duplex unit to the down position 2 Remove the outer cassette guide A 3 Remove the inner cassette guide B 4 Remove the plastic e clip C that secures the separator roll to the shaft 5 Remove the separator roll Repair information 4 183 7541 03x Registration roll removal Note This removal applies to both sets of registration rolls To remove the lower roll you will need to separate the MFP feed unit from the main feed unit See Separating the MPF tray and main tray paperfeed units on page 4 177 for instructions 1 Remove the static discharge brush plate top feeder only 2 Remove the static discharge brush top feeder only 3 Remove the registration roll gears A A Remove the e clips B securing the registration rolls to the paperfeed unit Remove the bushings C holding the registration roll to the paperfeed unit Remove the registration springs D Slide the registration rolls out of the paperfeed unit NDA 4 184 Service Manual 7541 03x MPF roll removal 1 Remove the MPF arms A from the MPF tray
54. BR KS da RC XR ESI BEES DRM ES 4 113 ADF assembly remoVal 4222 ekara 462502000600 ERREUR EXE REA BERGE RG 4 113 ADF Pick FOI TOTROVED sodri dnd Raw ebd dace idea 9 ERA XR Rob ades bu A RA RU NR RN 4 114 ADF Separat r roll removal 22244 meh RR o a RR UE ER tw dexiween Or eee eee LE RR S da RR 4 115 Flatbed assembly removal 5352634 dicare dried qd RR do EA d UR bacc oA doc de Ud RANA 4 116 Flatbed front COVBE a oenacdoed ad e REC needs RANTES PAD AUR OR ADEE TRAD ROTA 4 117 UIGGC TO6moval Lens exa saca wx psus tae E EXE KG RE MC ERA eR towne DERE xp E NC EE 4 120 Touchscreen assembly removal 00sec seen eee ehh hn nnn 4 121 ADF relay BOB 4 on exce xo 9 de qo CR En NCC RR coa OR COGO Ro GC Ro cce KC RU RI 4 122 eeo i Dem 4 123 CGD Chassis sscnski Gants ces RERO ON ROREM E WR RR REGERE S Rd RE ER ERGO EE EG eRe 4 124 CCH Dell eto ctpehP I RP A E ERI A PANIS PEE sted EE M NS qM MR RE EE p ES NE 4 126 Optical paper size sensOF 2 euecozuesuRua REA A REGUODRRRASESAARERXR RS REG Pea REG 4 127 Dido ev Pr IDEE 4 128 ADF IDOFOF NAME oisi keaa Ck exi Vo hee Coke o ER E UR I CR i REN CEU RE EHE 4 129 ADDE SONI zi sia iod E ba EQ RC bd X CS S a4 ees E QR d E Ia UR RE Rc 4 132 ADF drive CIUICR auaseoocosuRIr Rr rmx RRERORRREGRORS Sete amine Re ERRIG QR RA qae e RE 4 132 ADE DD IER uc oed t2eus IRBGA TREES IEEE PRMEEADEECUE pede es hed ME ad EU das aid 4 133 ADF Mali feeder icici dh ee ae Re d EPA S
55. Configuration menu press and hold 2 and 6 turn on the printer and release the buttons when the splash screen appears Navigate to Scanner Manual Registration gt Print Quick Test Adjust the flatbed a Place the printed test page facedown on the flatbed scanner glass and select Copy Quick Test Compare the copy to the original test page Select Flatbed and adjust the left and top margins as needed Touch Submit to save your changes To check the changes reload the original test page and then repeat the Copy Quick Test Repeat the steps as needed Adjust the ADF Front a Place the latest test page face up in the ADF and select Copy Quick Test Compare the copy to the original test page Select ADF Front and adjust the horizontal adjust and top margins as needed Touch Submit to save your changes To check the changes reload the original test page and then repeat the Copy Quick Test Repeat the steps as needed Adjust the ADF Back a Place the latest test page facedown in the ADF and select Copy Quick Test Compare the copy to the original test page Select ADF Back and adjust the horizontal adjust and top margins as needed Touch Submit to save your changes To check the changes reload the original test page and then repeat the Copy Quick Test Repeat the steps as needed oooc oooc ooo0c Touch Back to return to the Configuration Menu 4 206 Service Manual 7541 03x 5 Locations Locations Print engine cross
56. Connection Type Description Channel Quality 9 Analog VolP FoIP Clear Digital PAB OK CISD Some Noise Very Noisy Note The fields requesting the code levels model number type of problem are auto filled If the information is not in the fields it can be retrieved from the SE menu The SE menu can be accessed by pressing 411 on the keypad or typing http MFP ipaddress se in a Web browser 7 After all the requested information is entered into the Fax Checklist Web page press the Submit button on the bottom of the page A dialogue asking you to save the file will appear Note The file generated by the MFP is not automatically transmitted to second level support It is placed on the computer desktop 8 Enter a name for the file and indicate where you want to save the file 9 press OK The file appears on the desktop 10 E mail the file to second level support 2 82 Service Manual Words on fax are stretched The sending machine had a temporary jam Incoming fax has blank spaces or poor quality mosso mes No dial tone The sending fax machine may be faulty The sending fax machine may have a dirty document glass A noisy phone line can cause errors Check the MFP print quality by making a copy The print cartridge may be empty Replace as necessary 7541 03x Step Questions actions Yes No 1 Is the phone line properly connected to Go to step 3 Go to step 2 the modem card
57. D 4 46 Service Manual 7541 03x 7 Remove the one screw E 8 Remove the four screws F on top Repair information 4 47 7541 03x 9 Remove the two screws G on top 2 0 A 10 Remove the two screws H 4 48 Service Manual 7541 03x 11 Remove one screw I 12 Remove the screw J Repair information 4 49 7541 03x 13 Carefully insert the screwdriver through the main fan and remove the one screw K 14 Remove the Left EMI shield 4 50 Service Manual 7541 03x Low volt power supply removal A CAUTION SHOCK HAZARD Remove power from the printer before continuing or use caution if the product must be energized during this procedure The heat sink transformer core presents risk of electric shock Test before touching 1 Remove the left side EMI shield 2 Disconnect all the cables connected to the power supply Repair information 4 51 7541 03x 4 Remove the three screws B securing the bottom of power supply to the power supply cage 4 52 Service Manual 7541 03x Main fan removal Remove the HVPS Remove the engine board fan Disconnect the main fan cable from CN22 on the engine board Remove the screw A fastening the main fan stay to the left EMI shield ROND Repair information 4 53 7541 03x 6 Thread the fan cable through the cable stay A 7 h Pami 7 Liftthe fan up and pull the main fan stay away fro
58. DUI tosses cesses ease E ed SOS 3 11 Print Quality Pages seiss iius xa nh EGa KORG CREATE ACE ROEORTRRRCE RARE ERA ERROR E A RR 3 11 Bit eer ere corre eee Tee Te eee ey eA Ld M EUN Rund Ac Rd Rd pond od d RS 3 11 Color Trapping euclrezeus uos xa peeka bees b RARE WAR bese ie ARE dA RETE ERE RE 3 11 Dray Insert Message 5aa CES ERE QUEE RA Edd S dU 8 0b do Scb Mu EGER ME dido c Ud MGR OE E AR 3 11 SIZE SENSING sess dre dcx ad Ru RUDI RES RENS TREES T IRIGCqdsreGraeqeemec dax 3 11 Panel Menus vixsexni HERR GREG EEG RN RENUE EEG E RIiGGEQ E RIEENEFMERA QE ERE AP USERS X 3 12 PPDS Em lalloli xczcscesexcatrewre rera eR ERG T RODS Gee ERARE RS ERES a MEE 3 12 Download EMUS 255mm x ERE ERREUR GU anaes beans UM BOE EE de Ro E EO UR RE 3 12 Demo Mode iccoe dana nagd toonis ERR Wed ed Ea ua Edad Ra cus REN rds emi M Ru m on 3 12 Factory Defaulte s cc cde ucc rnRrEUECTERAEREBSSRPA RATIS ERN EERE RO NON IHRE RUE RN swe rS 3 12 Energy Conserve ulcscescceeucene o epe domed PRI sehe neuen EN E N pA S E eee MR NM ER 3 12 Fax Low PowerS DDOtI cusacuuuacanaca rck RR Rak REPARARE RA ERG e EGG AG eg ded 3 12 Mim Copy MEMO esarri iedit ond pod requi iq qd quU IG BEE SERES RM et eaa nt ees 3 12 N mPad Job ASSIST cun iubek x kt Edd Ea dE Ea Rae au bo RR dE ba KR RR Ros do RR 3 13 FaUnat Fax Storage raids inita ks BERI OR SSI DES RAE S MONIS NIS drip NER 3 13 Fax Storage LOCANON 22sioesaeie ae cR ERR detai eitad aihe iieiea 3 13 Vi Service Manual 75
59. Ed e pear Ra Ew Road KR aS Ra S RR ds i eed 4 134 ADF OUl PEERS ul 01 ke ORS ARR RRS RRS RR eS Mae mE 4 137 DOP BUS sc sace E A E docs od EP de ox pong 1 Dativ ne Ub RE qe 4 137 FB hinges ican sedem ce iuwar EE RE RR E FaQARG Rohs ERR RAT Lew E ERROR EER Ea Reese M ERR 4 138 Tray paper size Sensors cius sae d air einnar Eru Eon ina Eo CERE RR RS m od med 4 138 ADF cover open ADF pick Sensor sss eased exes eee eR ee eRe ROR RS 4 142 ADE COVEF open sensor aClus iudaauadoch deba o cacedond x6 A dO nee ACE ORG CR Gs doe AU ob aln 4 143 Paper present paper in sensor 00 c cece cece eee eee n Rh n n nnn 4 144 Paper Present sensor actuator uus xa asd s disi EA TEDE I OENAR Ra dE RENS ERA 4 145 Paper in Sensor actuator uuseoacsezaesadado o bR E Rad ds EN RA REOR ORA dr RR Po E Rd 4 145 Papel Pal Gensel su 2x2 d dna eua RAE dax aud Ra ds A dd ed cR Ad ted aci dutubdos DRE QR a RR 4 146 Scan selhsOl ioni ro eV RERUARRARRRXAERLRLA4EE AR EN LPRENERARE FE meet DER E E RE 4 146 Scan sensor actuator xu sense pO IRR KEN KEES GIO ACA Cu eR UCR Rc RR 4 148 Scan sensor cover nota fru cosi arr o mre Re rr Rr RET RAT rude 4 149 Duplex timing Sensor iius iaa ek eX RC4RAD A RR RR ndr tekenan EEN ERE eRe CARD CR ACRI 4 152 Duplex out scan out sensor 2 ee n n n hh n nnn 4 157 Duplex out sensor actuator sss s sae RC wane ee eR Ee eared ale sl ORO AD 4 158 Flatbed cover closed sensor 2 4 00 cioe eee eee al nena ee ene ger RARRARARRRA REA RAE 4
60. General information 1 1 7541 03x Printer configurations CAUTION TIPPING HAZARD printer stand or printer base if you are using a high capacity input tray a duplex unit and an input option or more than one input option If you purchased a multifunction printer MFP that Scans copies and faxes you may need additional furniture For more information see www lexmark com multifunctionprinters A Floor mounted configurations require additional furniture for stability You must use either a ADF input ADF output bin MPF feeder 550 sheet option tray tray 3 4 5 Caster unit Storage cabinet Standard 250 sheet tray tray 1 MPF 250 sheet tray tray 2 Output bin 10 10 touchscreen display OoN o a A OJ N The printer supports up to three 550 sheet trays 1 2 Service Manual 7541 03x Options and features Lexmark X925 printers support only Lexmark X925 paper handling options These options are not compatible with any other Lexmark printer Some of the following options are not available in every country or region Available internal options e Memory cards Printer memory Flash memory Fonts Firmware cards Bar Code PrintCryption Printer hard disk Lexmark Internal Solutions Ports ISP RS 232 C Serial ISP Parallel 1284 B ISP MarkNet M N8250 802 11 b g n Wireless ISP MarkNet N8130 10 100 Fiber
61. HERE 89 7 Iv 58 8 IUE eus 9 5 te A late 4 ae ux qus s sus spp Soe Ce eee etie ee OT ALA ep Bele ea pp FSE ae eA el mo gt ze fe e APE E DA OR Wh UR E P n BS A E EAE SE fl Jg MEHIARESVERT RU ERE BETE fld NT REE HA e A mE DUDEN VOIR AS A RR SEAN ST TE AE H e AP an EDR E EARRA A SEDI f ES TE m WIRE A AEA DAA N T Una WEE SUE KW SPARE BE BRI YoU T D o I WER CHE ib KER fife or FL ELE T8 FE Oe BRM WE DP t d 4k SEPT ep UE o BUSCO IES IY za M Safety information xvii 7541 03x Preface This manual contains maintenance procedures for service personnel It is divided into the following chapters 1 General information contains a general description of the printer and the maintenance approach used to repair it Special tools and test equipment as well as general environmental and safety instructions are discussed Diagnostic information contains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUs Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems Repair information provides instructions for making printer adjustments and removing and installing FRUs Connector locations uses illustrations to identify the connector locations and test points on the printer Preventive maintenance contains the
62. ISP MarkNet N8120 10 100 1000 Ethernet ISP Media handling options e 550 sheet tray General information 1 3 7541 03x Print engine specifications Power specifications Average nominal power requirements for the base printer configuration Power levels are shown in watts Printing states Power Off OW Sleep Mode 11W Hibernate Mode 3W Ready Mode 105W Continuous printing 620W Electrical specifications Low voltage models 100 to 127 V ac at 50 to 60 hertz Hz nominal e 90 to 137 V ac extreme High voltage models e 220 to 240 V ac at 50 to 60 hertz Hz nominal not available in all countries and regions Clearances L 7 l l l I I l I I I I 1 Right 385 mm 15 16 in 2 Front 609 6 mm 24 in 3 Left 100 mm 3 94 in 4 Rear 100 mm 3 94 in 5 Top 285 mm 11 22 in Allow additional clearance around the printer for adding options 1 4 Service Manual 7541 03x Acoustics All measurements are made in accordance with ISO 7779 and conform with ISO 9296 Status 1 meter average sound pressure Declared sound power level dBA Bels Idle Standby 37 dBA 5 4 Simplex printing 53 dBA 6 8 Duplex printing 54 dBA 7 0 Quiet Mode printing Mono 54 dBA 6 9 Quiet Mode printing Color 54 dBA 6 9 Measurements apply to 300 dpi 600 dpi and 1800 IQ printing Environment Printer Temperature and
63. LED ribbon cables properly the ribbon cables installed 7 Checkthe LED ribbon cable connectors on the Go to step 8 Replace the printhead controller board for 5V DC Is the voltage printhead correct controller board 8 Check all the connectors on the printhead controller Go to step 9 Properly connect board Are they properly connected the connectors 9 Replace the printhead controller board Did this fix the Problem Contact second problem resolved level support Diagnostic information 2 9 7541 03x Stain on back of page Step Action and questions Yes 1 Check for dirt on the transfer belt Is there dirt on the transfer belt Clean the transfer belt with a lint free cloth 2 Check for dirt along the paper path Is there dirt on the paper path Clean any dirty paper path components with a lint free cloth 3 Check the registration rolls for dirt or debris Is there dirt on the registration rolls Clean the registration rolls with a lint free cloth Failure to fuse Step Action and questions Yes No 1 Check the fuser for proper installation Is the fuser Go to step 2 Reinstall the properly installed fuser 2 Check connection CN on the LVPS for proper Go to step Go to step connection Is the cable properly connected 3 Check CN for the correct voltage Is the voltage Replace the Replace the correct fuser LVPS See Low volt power
64. More information the printer will present instructions Cancel Job the printer job can be cancelled Load Manual custom string If paper loaded is in the manual feeder the job continues If paper is not in the feeder pressing Select indicates to the printer it should search for a source with the proper custom string Additional messages may include More information the printer will present instructions Cancel Job the printer job can be cancelled Diagnostic information 2 67 7541 03x Error code Action Load Manual size If paper loaded is in the manual feeder the job continues If paper is not in the feeder pressing Select indicates to the printer it should search for a source with the proper size Additional messages may include More information the printer will present instructions Cancel Job the printer job can be cancelled Load Manual type size If paper loaded is in the manual feeder the job continues If paper is not in the feeder pressing Select indicates to the printer it should search for a source with the proper type and size Additional messages may include More information the printer will present instructions Cancel Job the printer job can be cancelled Paper Changes Needed This message appears at the beginning of a parkable job A load paper prompt will appear Additional messages may include Prompt for each change
65. No Are the cables connecting CN24 on the engine board CN5 on the printhead controller and CNO3 in the LVPS properly connected 2 62 Service Manual Go to step 3 Go to step 2 7541 03x Step Action and questions Yes No 2 Reconnect the cables Did this fix the problem Problem resolved Go to step 3 3 Checkthe cables for continuity Is there continuity Go to step 5 Go to step 4 4 Replace the cables Did this fix the issue Problem resolved Go to step 5 5 Check pins 1 3 and 7 on CNO3 on the LVPS for 5V Go to step 7 Go to step 6 and pins 5 and 9 for 24V Are the voltages correct Replace the LVPS Did this fix the problem Problem resolved Go to step 7 7 Replace the engine board Does this fix the issue Problem resolved Go to step 8 8 Replace the printhead controller board Did this fix the Problem resolved Contact your issue second level of support 941 03 CPU error Step Action and questions Yes No 1 POR the printer Problem resolved Go to step 2 Does the problem go away 2 Replace the printhead controller Does this fix the Problem resolved Go to step 3 problem 3 Replace the RIP board Did this fix the issue Problem resolved Contact your second level support 941 04 MDC controller error See the 941 02 MDC error 941 05 EEPROM error Step Action and questions Yes No 1 POR the printer a few
66. Process sicer iiig giesa eee eee 3 31 MFP electrophotographie process basics uoces gchar dva Goa Fera Ert S ores Vp 3 31 cuu ID M 3 32 Siop 7 EXPOSE Sec 9r vp dH ee addpe Reb R X Rare quei diues Rut g deest dd M Pd ee quiae 3 33 Sieh DOUGIOD ceu caede dade aLaawde bend bee od Ge tases Muir 8 aes Bede ubi bae did 3 34 Stop das Fist TANSO uar epe rhe Re qHe Errare ene px Tee ee RRS QUT RE A CR Ur 3 35 SCP 4b SOCODO ANSI ouis dee Dab pe PPP Ede DET P Ede ERA Ke RARE E EE 3 36 Slap B FUSS 6 oseceadsee taeda coe ny SWEIRETRE SP PAARE P IESU ENS TOTIS TC E RYE 3 37 Sep GO CIBHIU EISE 21g dip baton baba bese RR Ee bee Headed retd dide 3 38 Paper Path components i ruaorlue ee daa n eaannsrdemRaqaaaadadqsdmsse ace Gem a RP RR md 3 40 acbILEil oM HT a a a a E EEA 3 40 Feeding paper froma Way 22641 pew si o RRA ARS RPES oe E riper POP 3 42 Feeding paper Form E MPF csads de eodd ches qr ex Sed d x aded eode deba e dida Erde 3 43 angu eR ep er DT TETTE 3 46 Biogr s pm 3 46 COSTCO Ll UE ERA RDELSo bad SRLSCDbrS BARS ION NSE NCD IDEE L GER ERU 3 49 What le RGE CODIE ctcdc ceca nr tether iir ae E ICHIREE pue add aera m dE Gers q ees ae 3 49 Fig 3954 5 Amm 3 49 How is color specified in a document to be printed 0 00 c eee eee 3 49 How does the printer know what color to print 0 0 ee ee 3 49 Should use PostScript or PCL emulation What settings produce the best color 3 49 Why doesn t the printed
67. RIP board Did this fix the issue Problem resolved Contact your second level support 844 00 Lamp failure Front side Step Questions actions Yes No 1 Check the FFC ribbon cable connecting the RIP board Go to step 3 Go to step 2 to the ICC board on the flatbed for proper connectivity Is it properly connected Re connect the cable Did this fix the problem Problem resolved Go to step 3 3 Checkthe 8 pin and 30 pin cables on the CCD for Go to step 5 Go to step 4 proper connectivity Are they properly connected 4 Connectthe cables properly Did this fix the issue Problem resolved Go to step 5 5 Replace the CCD Did this fix the problem Problem resolved Go to step 6 6 Replace the ICC board Did this fix the problem Problem resolved Go to step 7 7 Replace the RIP board Did this fix the problem Problem resolved Contact your second level support 849 01 Device had modem installed but config ID indicates it should not Uninstall the modem 849 10 Device had HD installed but config ID indicates it should not Uninstall the hard drive Diagnostic information 2 59 7541 03x 900 xx System software error Note Before troubleshooting determine the operating system used when the error occured If possible determine whether a PostScript or PCL file was sent to the device when the error occured Ask the customer which Lexmark Solutions applications are installed on the device Step Action and questio
68. See Adjustments on page 4 205 4 136 Service Manual 7541 03x ADF clutch 1 Remove the ADF main feed unit See ADF main feeder on page 4 134 2 Remove the clip A securing the ADF clutch to the transport roll shaft 3 Slide the clutch off the shaft ADF hinge 1 Remove the ADF unit from the scanner assembly 2 Place the ADF unit upside down on a non marring surface 3 Remove the four screws A the secure the hinge to bottom of the flatbed cover Repair information 4 137 7541 03x FB hinge 1 Remove the ADF unit from the scanner assembly 2 Place the ADF unit upside down on a non marring surface 3 Remove the four screws A the secure the hinge to bottom of the flatbed cover Tray paper size sensors 1 Remove the ADF input tray from the ADF unit 2 Remove the three screws A fastening the tray bottom to the ADF input tray top 4 138 Service Manual 7541 03x 3 Release the tab B securing the tray top to the tray bottom B 4 Release the tab C securing the tray top to the tray bottom Repair information 4 139 7541 03x 5 Release the tab D securing the tray top to the tray bottom D 6 Release the tab E securing the tray top to the tray bottom E 7 Pull the tabs F back to release the width sensor cable from the tray bottom 4 140 Service Manual 7541 03x 8 Remove the two screws G securing the paper width actuator to the rack gear Repair
69. a PC via USB appears 3 8 Service Manual 7541 03x Configuration Menu The Configuration menu contains a set of menus settings and operations which are infrequently used by a user Generally the options made available in this menu are used to configure a printer for operation An asterisk in the value list in the following menus indicates the default value Entering Config Menu To enter the Configuration Menu 1 Turn off the printer 2 Press and hold 2 and 6 3 Turn on the printer 4 Hold the buttons until the splash screen appears The following are available from the Configuration Menu Configuration Menu Reset Fuser Counter See Reset Fuser Counter on page 3 10 Reset Maintenance Counter See Reset Maintenance Counter on page 3 10 Reset Transfer Belt Counter See Reset Transfer Belt Counter on page 3 10 USB Scan To Local See USB Scan to Local on page 3 10 Black Only Mode See Reset Maintenance Counter on page 3 10 Print Quality Pages See Print Quality Pages on page 3 11 Reports See Reports on page 3 11 Color Trapping See Color Trapping on page 3 11 Tray Insert Message See Tray Insert Message on page 3 11 SIZE SENSING See SIZE SENSING on page 3 11 Panel Menus See Panel Menus on page 3 12 PPDS Emulation See PPDS Emulation on page 3 12 Download Emuls See Download Emuls on page 3
70. application to successfully print on these forms Coated papers erasable bond synthetic papers or thermal papers Rough edged rough or heavily textured surface papers or curled papers Recycled papers that fail EN12281 2002 European Paper having a weight less than 60 g m 16 Ib Multiple part forms or documents Selecting paper Proper paper loading helps prevent jams and ensures trouble free printing To help avoid jams or poor print quality Always use new undamaged paper Before loading paper know the recommended print side of the paper This information is usually indicated on the paper package Do not use paper that has been cut or trimmed by hand Do not mix media sizes weights or types in the same source mixing results in jams Do not use coated papers unless they are specifically designed for electrophotographic printing 1 10 Service Manual 7541 03x Scan fax and copy specifications General specifications Processor Speed and type 1GHZ IBM Memory Standard 512 MB Max 1 5 GB Optional memory 256 MB 512 MB and 1024 MB DDR SODIMM Optional flash memory 256 MB Hard drive 160 GB or higher Connections Standard Gigabit ethernet and USB Option slots DRAMM DIMM slots 1 Wireless option Yes ISP INA slots 1 DLE Firmware card font card and flash 2 memory card sits The following combinations are supported when you use more than one slot DLE and user
71. applications and their setting could not be saved Note There is a size limit on the export file 128kb Because of this it is recommended that you don t use the global backup found in Settings gt Import Export gt Export Shortcuts File Export Settings File Export Embedded Solutions Settings File and Export Security Setups File Customers with a large number of applications or settings may exceed the file size limit and have information truncated in the exported file Repair information 4 3 7541 03x Removal procedures CAUTION AN Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer Disconnect any connections between the printer and PCs peripherals Arrangement of removals in this chapter The removals in this chapter are arranged by area of printer The areas are as follows Cover Removals on page 4 5 Top removals on page 4 26 Front removals on page 4 40 Left side removals on page 4 45 Right side removals on page 4 61 Rear removals on page 4 73 Scanner area removals on page 4 113 In addition to the sections the duplex unit and paperfeed unit sub component removals have their own sections They are Duplex unit component removals on page 4 172 Paperfeed unit component removals on page 4 177 Note Some removal proced
72. belt Clean the roll if needed Note Be careful when cleaning the dirt of the transfer roll Be careful to not deform the roll Replace the transfer roll if it is scratched 3 Imaging unit Check for scratches of unevenness on the photoconductor drum Replace the imaging unit if the drum is damaged Look for dirt on the rolls Replace the imaging unit if the rolls are dirty Black stripes Step Action and questions Yes No 1 Is there dirt on the imaging units developer roll or Clean the dirt if Go to step 2 charge roll 2 Are there scratches on the photoconductor drum Replace the Go to step 3 imaging unit 3 Is there dirt in the fuser belt Clean the belt Go to step 4 4 Arethere scratches on the fuser belt Replace the Go to step 5 fuser 5 Arethere lumps of toner on the fuser belt Remove the lump Go to step 6 of toner 6 Printa blank white page Are there black stripes on the Replace the Contact your page black LED second level printhead support Diagnostic information 2 7 7541 03x Unprinted spots Step Action and questions Yes No 1 Check the paper in the tray for moisture Is the paper Replace the Go to step 2 moist paper in the tray 2 Checkthe LED print head for moisture on the imaging Wipe the LED Go to step 3 surface Is there any moisture on the LED surface imaging surface with a lint free cloth 3 Does the imaging unit s photodeve
73. cage back Repair information 4 81 7541 03x 10 Remove the screw F in the lower right corner F 11 Remove the two screws G in the center bottom of the drive unit 4 82 Service Manual 7541 03x 12 Remove the two screws H in the lower left corner Drive unit motor C M Y K Note All four motors use this procedure 1 Remove the drive unit 2 Place the drive unit with the motors down on a table 3 Remove the two screws A securing the motor to the drive unit A Note Note When replace the drive motor be careful to not damage the gears in the drive unit with the metal gear on the motor Repair information 4 83 7541 03x Sub drive unit removal 1 Open the right cover and remove the fuser 2 Remove the rear cover See Rear cover on page 4 7 3 Remove the top cover See Output bin print engine top cover on page 4 17 4 Remove the rear EMI shield See Rear EMI shield Not a FRU on page 4 106 5 Remove the HVPS 6 Remove the rear engine board fan 7 Remove the op panel paper exit guide See Op panel paper exit guide removal on page 4 32 8 Remove the paper exit guide See Paper exit guide removal on page 4 33 9 Remove the fuser fan from the fuser duct This part does not need to be removed from the machine 10 Remove the black fuser duct This is not a FRU Note You will need to route the bin full and exit sensor cables around the tab on top
74. color match the color see on the computer screen 3 49 The printed page appears tinted Can adjust the color 0 0 cece eee 3 49 My color transparencies seem dark when they are projected Is there anything can do to improve the COIGET Lou ele e der teare aar Rr eA Dr ERU EUREN UPS ares ee eds Or 3 50 What i5 manualelor CONGCIONY a ed dona qd dre por EE PRICE Y Web pa deed eere dd 3 50 How can match a particular color such as a corporate logo eee ee eee 3 50 What are detailed Color Samples and how dol access them lllllsseeusu 3 51 Repair information Lio i teh THERE ITE RES PER THRES ERR PUER ERE pre EAR eae 4 1 Handling ESD setnsilive paris 1 2222 zik RR Ronda done ER BARRE ACA ROR S EON SUAE CR RA OR 4 1 RIP board operator panel replacement 0 00 c eee eee nn nnn 4 2 Printhead controller board engine board replacement lesesesleeeeeess 4 2 SSF solutos DACKUP cece dedu vedere d pere dame Nue e eed e qud a e rad eee RU des 4 3 Removal BrOGBOUTSS 1o qid es Diu 9b x hes Sce iE EDD QUA EORUM QE ACUS UL Mab A de bd Ad E gd d 4 4 Arrangement of removals in this chapter 000 e eee eee eee eee eee nnn 4 4 CoverRemovalS iussskmaca Esc EE Ra X QUIE REQUE RA RR KUNA TK RE RN ERN NR RD EdU RU ee RHE RET 4 5 ue AP 4 5 Scanner power supply access COVer 0 0 eee cece eee eee n n n nn nnn 4 6 Sold COVER Bo Gace ici pouce PHEP DRE RISE PLINIO cudieqe sue qER
75. eee reer ee 7 15 MPF registration roller 40X6580 e ee ere eee ee eee eee eee 7 25 MPF roll 40X6578 eee senses neq oeser ee ecu ieee debe doner de deed eri eee cee 7 15 MPF roller bushing 40X6418 2 eee er ree ee eee eee eee ee 7 15 MPF separator spring 40X6412 7 erro eee eee eee eee eee eee ee 7 15 MPF Engine board cable 40X6416 2 er eee eee re ee ee nr ee eee eee ee eee eee 7 13 Multi purpose tray 40X6223 2 2 eee ee nn nr ee ee ee ee er eee eee 7 35 O Opt tray door closed sensor 40X6234 ere rrr neces 7 43 Opt tray lift motor 40X6229 eee errr ee eee eee eee ee 7 41 Option cable 40X6369 erent ee rr rr eens 7 3 Option cover 40X6125 22 eee eee ee rn en eee ee ee eee eee eee 7 3 Option interface board 40X6231 2 22 ee eee ee ee ee eee ee eee 7 41 Option paper tray 40X6246 eee ee ee ee re ee ee ee ee eee ee 7 45 Option paperfeed cable 40X6365 rr errr rrr err RII III 7 43 Option paperfeed clutch 40X6236 u e RrrrRRIIIRRIIIIIIIIIIII 7 43 Option stepper motor 40X6230 eee RRRRIRIIIIIRIIIIIIIIIIIIIIIIIIIIIII 7 41 Option switch sensor 40X6430 7 0 eee ee rrr eee reer eee eee ee 7 41 Option tray feed roll
76. flash DLE and font card Font and User flash Paper handling Paper input standard 250 and 150 sheet tray 50 MPF Optional paper handling Input 550 sheet tray up to 3 Optional paper handling Output None Duplex Yes Finishing None Hard drive Standard Service Warranty One year on site parts and labor Furniture Standard None Optional furniture Caster base General information 1 11 Fax features Feature Notes Fax preservation Faxes are preserved over power cycle Color fax Enable color scans Auto convert color to mono fax Enable color fax receive When on the sending device transmits in color and the receiving device prints in grayscale e When off the sending device converts and transmits the job as a mono job Fax content Type text graphics text photo photo Source color laser black white laser inkjet photo film magazine newspaper press other Original size All sizes supported by device including mixed letter legal Dial mode Touch tone Pulse Custom job scanning Only appears if installed on hard drive Scan preview Only appears if installed on hard drive Fax cover page Includes to from message footers logo and total pages Fax number masking Active masking Maximum speed Settings for both Send and Receive Delayed send Supported Block junk fax banned fax list Ba
77. gear 14 40X6537 Spur G63 27T gear 15 40X6536 Spur G36T gear 16 40X6974 17 40X6975 18 40X6534 19 40X6535 20 40X6348 21 40X6335 22 40X6434 23 40X6330 24 40X6541 25 40X6533 26 40X6547 27 40X6336 NS 40X6341 NS 40X5867 Duplex out sensor actuator Duplex out sensor Scan sensor w paper in sensor Scan sensor actuator ADF main feeder ADF drive clutch ADF solenoid ADF motor frame w motors Cover open sensor actuator Idle roller w shaft Separator roll lock Roller Bearing Top cover release hook Pe Oe SS e CC Ce eC Ce re Cree i re ee CO eC eC eC eC eC Ce Ce a 4a 42 42 42 4 42 4 4 4 4af af afauf afasyasjasjafasjasjasjasyasyasyasjajsjafu ADF screws and fasteners parts pack Parts catalog 7 11 7541 03x Assembly 6 Duplex components 1 7 12 Service Manual Assembly 6 Duplex components 1t 7541 03x Asm Part Units Units Description index number mach FRU 1 40X6419 1 1 MPF Clutch 2 40X6259 1 1 Duplex ground cable 3 40X1104 8 1 Photo sensor 4 40X6416 1 1 MPF Engine board cable 5 40X6982 1 1 MPF paper empty lever 6 40X6152 1 1 A S Carrying roller 7 40X6147 8 1 Duplex roller bushing 8 40X6153 1 1 B S Carrying roller 9 40X6154 2 1 C S Carrying roller 10 40X6277 1 1 Discharge brush plate 11 40X6148 1 1 Duplex ground plate 12 40X6260 1 1 Duplex static brus
78. information 4 141 7541 03x 10 Remove the screw H securing the width sensor to the ADF paper tray AAAAAAAAAAAAIT ADF cover open ADF pick sensor Note The ADF cover open and ADF pick sensor are one assembly 1 Remove the flatbed upper cover 2 Disconnect the sensor cable A from the connector on the sensor A 3 Remove the screw B securing the sensor cable to the ADF inner cover 4 142 Service Manual 7541 03x 4 Remove the screw C securing the sensor to the inner cover 5 Remove the screw D securing the ADF pick sensor to the inner cover ADF cover open sensor actuator 1 Remove the screw securing the cover open sensor to the ADF inner cover 2 Remove the ADF cover open sensor actuator Repair information 4 143 7541 03x Paper present paper in sensor Note The ADF paper in and ADF paper present sensors are one assembly 1 Remove the ADF outer cover 2 Disconnect the sensor assembly A cable from the main cover sensor cable 3 Remove the screw B holding the cable to the ADF inner cover 4 Remove the screw C securing the ADF paper in sensor to the ADF inner cover O D C 5 Remove the screw D securing the paper present sensor to the ADF inner cover 4 144 Service Manual 7541 03x Paper present sensor actuator 1 Remove the screw securing the ADF paper present sensor to the ADF inner cover 2 Turn the actuator up and carefully remove the actuator
79. line s ability to send and Go to step 5 Go to step 4 receive calls Did the phone line work properly 4 Use the MFP on a properly functioning Problem resolved Go to step 5 phone jack Did this fix the problem 5 Is the phone line being used by the MFP an Goto step 8 Go to step 6 analog line 6 Is the line being used a VOIP line Go to step 7 Go to step 8 7 Have the system administrator verify that Go to step 8 Stop here The issue is the VOIP server is configured to receive VOIP related The faxes VOIP provider needs to Is the server properly configured change the server configuration 8 Is the MFP on a PABX Go to step 9 Go to step 10 9 Enable Behind a PABX under fax settings Problem fixed Disable Behind a in the Administration menu PABX and go to Did this fix the issue step10 10 Is a dial prefix needed to get an outside Go to step 11 Go to step 12 line 11 Try sending a fax using a dial prefix Problem fixed Go to step 12 Did the fax transmit 12 Is the fax failing to send to one specific Go to step 13 Go to step 14 destination 13 Check the device that cannot receive a fax Go to step 14 Stop here The issue is Can it send a fax with the other device 2 78 Service Manual 7541 03x Step 14 Questions actions Press 411 to enter the Fax SE Menu Select Print Logs Print the T30 transmission log Check the error being reported
80. mach FRU 1 40X6361 1 1 UL1 Interface cable 2 40X6362 1 1 UL2 Interface cable 3 40X6430 3 1 Option switch sensor 4 40X6358 1 1 Rising unit hub 5 40X6359 1 1 Rising unit spring 6 40X6360 1 1 Timing belt 7 40X6231 1 1 Option interface board 8 40X6232 1 1 Main interface cable 9 40X6233 1 1 Stepper motor cable 10 40X6230 1 1 Option stepper motor 11 40X6229 1 1 Opt tray paper lift motor NS 40X7452 1 1 550 sheet paperfeed screw parts pack Parts catalog 7 41 7541 03x Assembly 21 550 sheet option feeder paper feed 7 42 Service Manual 7541 03x Assembly 21 550 sheet option feeder paper feed Asm Part Units Units Description index number mach FRU 1 40X6365 1 1 Option paperfeed cable 2 40X1107 1 1 Vertical paperfeed sensor 3 40X1111 1 1 Type2 feed roll 4 40X1173 1 1 Horizontal sensor paperfeed 5 40X1106 1 1 Retainer clip 6 40X1078 1 1 Option tray feed roll 7 40X1077 1 1 Option tray pick roll 8 40X1079 1 1 Option tray separator roll 9 40X1080 1 1 Torque limiter clutch 10 40X6235 1 1 Timing belt S 11 40X6237 1 1 Timing belt L 12 40X6234 1 1 Opt tray door closed sensor 13 40X6232 1 1 Main interface cable 14 40X6236 1 1 Option paperfeed clutch NS 40X7452 1 1 550 sheet paperfeed screw parts pack Parts catalog 7 43 7541 03x Assembly 22 550 sheet option feeder tray 7 44 Service Manual Assembly 22 550 sheet option feeder tray 7541 03x A
81. nnn 4 180 TOGU dinner re MOVA aurais did dioe QUE di d 8 0870 3 d MUR Rod d aee Ar ARD AUR ROA cR OC 4 181 Upper and lower registration springs removal eeeen n nnn 4 181 Paperfeed maintenance kit removals ccc cece eee eee eee eee eee eee hn 4 182 Pick roll removal 1 424223 4r on wx nw semen RE le ane wee ed Rc e aoe caw a Beale aed em Uu 4 182 X Service Manual 7541 03x Paperfeed roll removal a 4cx sud CER CEA ie eee Ree Oe De ORR eRe eS 4 182 Separator roll temoval asinis RESET Seas ent ieee dein DR Pad A 4 183 Registration rol FemoVAl 6440c00 e 200s cece cadet deed RE RR pA RC dE eain aia 4 184 MPF FOUVOIIOUII uae E wate qud do amp 6 d a Rc stake dd doi dd oou c db RO odas Rus bd ee ae 4 185 MPF Dad POrnDVAl ias veda ata xoa ea C eR taken ER Ro i RO ea CR ox og o RR VR Rb 4 187 Exit guide paper exit roll removal 0 00 c eee e eee ee eee RII 4 190 Option paper feed removals sciosaceo ues mua Rh RRR REG akiti BERGE REA ARE 4 196 Paper teed roll removal iussse ka apa EXXRRCKR EXE eke idee dees home Lies Oe eS 4 196 Pick roll removal 114 za cig exa enu A RR Rod ERU R ERE Gla ah A RUN do PURA S Ub BU las hi mn EU wl 4 196 Separator roll removal 45 2 haee iex RUN RAs eke ORE RR AUR RR RR x c ARR s 4 197 Paper size switches removal 00 c cece eee e eee e ehh hn nn 4 197 Paper level sensor removal uisaknkkk mE GEO ERU RORCKTROR OR MEK REOR HORREA CR QNT ACR RR ee a 4 198 Transport Sensor
82. on the HVPS for proper connectivity Are the the connections connection properly connected 2 Checkthe HVPS printhead controller cable for Go to step 4 Go to strep 3 continuity Is there continuity 3 Replace the HVPS printhead controller cable Does Problem solved Go to step 4 this resolve the problem 4 Replace the printhead controller board Does this Problem solved Go to step 5 resolve the issue 5 Replace the HVPS Does this resolve the issue Problem solved Contact your second level support 132 00 Density sensor error Step Action and questions Yes No 1 Is the density sensor cleaner stuck in place Go to step 2 Release the cleaner Replace if damaged 2 Is the cable connecting the density sensor to CN14 on Go to step 3 Securely connect the printhead controller board connected securely on the cable both ends 3 Check the density sensor cable for continuity Is there Go to step 4 Replace the continuity density sensor cable 4 Replace the density sensor Does this fix the problem Problem solved Replace the printhead controller board Diagnostic information 2 49 7541 03x 132 xx Abnormal theta sensor Step Action and questions Yes No 1 Is the reference pattern for the color plane alignment Go to step 4 Go to step 2 printing properly on the transfer belt 2 Did all the colors print on the test pattern Go to step 4 Go to step
83. out 3 Close Tray 1 4 Press Continue jam cleared Jam in the optional trays 1 Open the side affected tray s access door and remove the jammed pages Note Make sure all paper fragments are removed 2 22 Service Manual 7541 03x 2 Open the affected tray and remove the jammed pages 3 Close the tray 4 Press Continue jam cleared 250 paper jam 1 Remove the jammed pages from the multipurpose feeder 2 Load paper into the multipurpose feeder 3 Press Continue jam cleared Diagnostic information 2 23 7541 03x Duplex unit service check FRU Action 1 Feed roller belts 2 Duplex clutch Check for wear or damage to the feed roller belts Replace as necessary Check the clutch cable for proper connection to CN13 on the engine board If it is properly connected replace the clutch If this doesn t fix the problem replace the engine board 3 Duplex solenoid Check for proper operation of the solenoid and linkage Replace as necessary Check the solenoid cable for proper connection to CN10 on the engine board If it is properly connected replace the solenoid If this doesn t fix the problem replace the engine board 4 Photo interrupter assembly Ensure that the photo interrupter actuators are operating correctly and are in the proper position Paper path service checks Paper is being picked up and carried to the registration roller Paper jams 200
84. removal o osc cnet Rear eri ar bassi S ara RR ERRARE RE RR n 4 198 Paper mpty sensor remoVal aida acke ape aad EXC 9 XR Io ORI RC dA RAT ACER 4 199 Paper dull sensor FGITIBUBI aus soda dad ook qoa deae dud o decies s QA RR Oe RUR do CE tendon nae 4 199 Option controller board removal eseseeeeeeee nh nnn 4 200 Biepper motoi FOMOVEl u s acne s Sca bates Sees aces sued el oases Rea GEB Fdld dq Rd d 4 200 Tray HE motor removal 52242xadakaa co eepAdd dd RA arsenide REA donde Ra eR ae 4 201 Option door inter lock Switch removal 2usa mna hmacsck n Re ERA RR Rud E ia e A e E ded 4 202 Paper feed clutchremoval i cao seed bus tae sara tetani X RR EUR ons REOR UR wien ded 4 203 Adjustmoets 442 2a socie Rcg era UR ac RU EE CA CR CORR C AE UC CR RR RR D RU 4 205 Calibrating Ihe Scanner oss v paie bespre pU PIE EP SCR e PER SEE SS REF Sa ET 4 205 Calibrating thie scanner black Ievels 5 caccte on pd Gckd d onra Gade wala OR rc G8 en 4 205 Adjusting ADF magnification asi lin e kin rrr tmn hh ERE RR ORI ERR ER RUN S RR iR 4 206 Adjusting scanner registration esseseeeeeeee nmn 4 206 LEGENDE Loo er een eyo ee Pee ee eee Te rS E MEER UN he te Rat ee renee ers ee ee cci UL SE dE 5 1 LiGCAUGNS ini ches ater easter dab meted u qr site eka Ru Guess mat nein en kunwe Ghia m ud 5 1 Print engine Cross section sucesos R3 seeders GP Ko OC N C ROE eee OR Gee CR OR CC C a E 5 1 Flatbed ADF SOBSOIS S oasis cud asado ibd Gades
85. replaced e If the developer roller is damaged it will not contact the surface of the photoconductor properly The result could be repeating marks thin vertical voids or thin vertical lines of color on the printed page Check the surface of the developer for damage 3 34 Service Manual 7541 03x Step 4a First transfer When the latent images are developed on each Photoconductor the high voltage power supply sends voltage to the 1st Transfer Rollers inside the transfer belt unit The charge difference between the developed toner image on the Photoconductor surface and the 1st Transfer Roller causes the images to transfer to the surface of the transfer belt for each color This takes place by a direct surface to surface contact between the Photoconductors and the transfer belt About 900v Transfer belt Transfer roller Service tips e Never touch the surface of the transfer belt with your bare hand The oil from your skin will cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page Then the transfer belt will have to be replaced Don t use solvents or other cleaners to clean the transfer belt surface No matter how careful you are the surface will be compromised causing scratches or a charge differential that will produce a void or light blotch on the printed page Then the transfer belt will need to be replaced Diagnost
86. sensor mounting bracket to the flatbed chassis 3 Remove the sensor cable from the connector Repair information 4 159 7541 03x 4 Pull the two tabs B back to release the sensor from the mounting bracket 4 160 Service Manual 7541 03x Flatbed upper cover 1 Remove the flatbed assembly See Flatbed assembly removal on page 4 116 2 Remove the flatbed front cover See Flatbed front cover on page 4 117 3 Remove the two screws A on the front of the flatbed unit A 4 Remove the screw B on the front of the cover Repair information 4 161 7541 03x 5 Remove the two screws C on the top rear of the cover C 6 Remove the two screws D on the top rear of the cover 7 Lift the cover off of the flatbed chassis 4 162 Service Manual 7541 03x Outer ADF top cover 1 Open the ADF top cover 2 Remove the left cover screw A that secures the outer cover to the inner cover A 3 Remove the middle cover screw B that secures the outer cover to the inner cover Repair information 4 163 7541 03x 4 Remove the right cover screw C that secures the outer cover to the inner cover Inner ADF top cover 1 Remove ADF outer top cover 2 Remove the ADF main feeder 3 Remove the screw A securing the hinge to the main feeder 4 164 Service Manual 7541 03x 4 Remove the hinge 5 Pull the inner top cover away from the ADF main feeder
87. sensors for dirt or debris Are the sensors clear 3 Clear the sensors of dirt and debris Did this fix the Problem resolved Go to step 4 problem 4 Checkthe sensors for proper connection to J3 on the Go to step 6 Go to step 5 ADF relay card Are they properly connected 5 Reconnect the cables Did this fix the problem Problem resolved Go to step 6 6 Check pin 4 on J3 for 5V and pin 5 for ground Are Go to step 8 Go to step 7 they present 7 Replace the ADF relay card Did this fix the problem Problem resolved Go to step 8 8 Replace the ADF paper size sensors Did this fix the Problem resolved Consult your problem second level of support 2 96 Service Manual 7541 03x 3 Diagnostic aids This chapter provides basic information to help you navigate the printer menus and explains the tests and procedures used to identify printer failures and verify repairs have corrected the problem Understanding the operator panel and menus Operator panel need new art 1 2 3 4 1 2asc goer fou Soo Guno Troas Gruv Q waz 7 6 Item Description 1 Display Shows the status of the printer 2 Indicator light Off The printer is off Blinking green The printer is warming up processing data or printing Solid green The printer is on but idle Solid red Operator intervention is required 3 Sleep Enables Sleep Mode or Hibernate Mode The following actions wake the printer from Sleep Mode Touching t
88. skin may cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page Then the photoconductor will have to be replaced The surface of the photoconductor is coated with an organic substance that makes it sensitive to light Be sure and cover the photoconductor when you are working on the printer so you don t burn it If exposed to light for too long it will cause light dark print quality problems and have to be replaced Diagnostic aids 3 33 7541 03x Step 3 Develop Once the laser exposes the photoconductor the high voltage power supply sends charge to the developer roll C For each color the toner cartridge engages the photoconductor so it is in contact with the surface Because of the charge difference between the toner on the developer roller and the electrostatic image created by the laser the toner will attract to the photoconductor only where the laser exposed the surface This process would be similar to using glue to write on a can and then rolling it over glitter The glitter sticks to the glue but won t stick to the rest of the can Service tips e Never touch the surface of the developer roller with your bare hand The oil from your skin may cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page Then the affected cartridge will have to be
89. step 9 169 254 8 POR the printer Problem resolved Go to step 10 Is the problem resolved 9 Reset the address on the printer to match the Problem fixed Go to step 10 IP address on the driver Did this resolve the issue 10 Have the network admin verify that the printer Go to step 12 Go to step 11 and PC s IP address have identical subnet addresses Are the subnet addresses the same 11 Using the subnet address supplied by the Problem resolved Go to step 12 network admin assign a unique IP address to the printer Note The printer IP address should match the IP address on the printer driver Did this fix the problem 2 84 Service Manual 7541 03x Step Questions actions Yes No 12 Is the device physically connected ethernet Go to step 13 Go to step15 cable to the network 13 Try using a different ethernet cable Problem resolved Go to step 14 Did this remedy the situation 14 Have the network administrator check the Replace the controller Contact the network network drop for activity board See RIP board administrator Is the drop functioning properly removal on Gage due 15 Is the printer on the same wireless networkas Go to step 17 Go to step 16 the other devices 16 Assign the correct wireless network to the Problem resolved Go to step 17 printer Did this fix the problem 17 Arethe other devices on the wireless
90. supply removal on page 4 51 Stains on edge of page Action and questions Check for dirt on the paperpath Clean as needed 2 10 Service Manual ADF amp scanner print quality 7541 03x Note Get a printout as a base and then follow the symptom table to identify the possible failing FRU Image quality symptoms Dark print Dark image quality using ADF or Scanner on page 2 11 Vertical stripes Vertical lines process direction using the ADF on page 2 12 Spots Spots using flatbed scanner on page 2 12 Skew Skew using ADF on page 2 14 Media damage Media damage using ADF on page 2 15 Note When horizontal lines and or spots occur periodically it is possibly caused by a particular roll In this case measure the interval on the print test and check the relation to the roll in the printer The interval does not necessarily match circumference of the roll Dark image quality using ADF or Scanner Before starting check the media route for foreign objects such as staples clips and scraps in the media path Step Check Yes No 1 Check the large and small platen glass on the scanner Clean both sides Go to step 2 unit assembly of the large and Is the large and small platen glass contaminated vibe tee 2 Check the three mirrors in the scanner unit assembly Clean the three Go to step 3 Are the three mirrors contaminated or show signs of M
91. surface normal 2 Properly load document into the ADF unit assembly and Go to step 3 Problem solved ensure all guides are set correctly Re print the defective image Does the error continue 3 Check for obstructions in the area of the media feed Go to step 4 Remove path in the ADF obstructions Is the media feed path free from any obstructions 4 Is the ADF left cover assembly properly and evenly Go to step 5 Open then closed properly close the ADF left cover assembly 5 Check the ADF pick roll assembly for damage and wear Go to step 6 Replace un P ADF feed pick a aoa feed pick roll assembly free from damage roll Bosse Go to ADF pick roll removal on page 4 114 6 Check the ADF separator roll Go to step 7 Replace the Is the ADF separator roll free from damage and T separation wear roll Go to ADF separator roll removal on page 4 115 2 14 Service Manual Media damage using ADF 7541 03x Diagnostic information 2 15 Step Check Yes No 1 Properly load document into the ADF unit assembly and Go to step 2 Problem solved ensure all guides are set correctly Re print the defective image Does the error continue 2 Check for obstructions in the area of the media feed Go to step 3 Remove path in the ADF obstructions Is the media feed path free from any obstructions 3 Is the ADF left cover assembly properly and evenly Go to step 4 Open then closed properly close
92. the ADF left cover assembly 4 Check the ADF pick roll assembly for damage and wear Go to step 5 e the ADF i feed pick roll n m feed pick roll assembly free from damage assembly Go to ADF pick roll removal on page 4 114 5 Check the ADF separator roll Go to step 6 Replace the Is the separator roll free from damage and wear separator roll Go to ADF separator roll removal on page 4 115 6 Check the ADF controller card assembly Replace the RIP Problem solved Replace the ADF relay board assembly board Go to ADF relay board on page 4 122 Go to HIP y pag board removal Perform a print test using the ADF on page 4 73 Does the error continue 7541 03x Black page from scanner Step Questions actions Yes No 1 Print a menu page or a page from the host See Go to Black page Go to step 2 Is the page black on page 2 9 2 Are the CCD ribbon cables properly Go to step 4 Go to step 3 connected to the ICC board 3 Properly connect the ribbon cables to the Problem resolved Go to step 5 ICC board and CCD Did this fix the problem 4 Check the cables for continuity Is there Go to step 6 Go to step 5 continuity 5 Replace the ribbon cables from the ICC Problem resolved Go to step 6 board to the CCD Did this fix the problem 6 Replace the ICC Did this fix the problem Problem resolved Go to step 7 7 Replace the CCD Did this fix the problem Problem resolved Go to step 8 8 Re
93. the X925 40X6372 300 000 page paper feed maintenance kit 40X6457 100 000 page MPF maintenance kit 40X6328 ADF separator roll Every 100 000 pages 40X6327 ADF pick roll Every 200 000 pages 40X6011 Transfer belt kit w transfer roll Every 100 000 pages 40X6012 Transfer roll Every 100 000 pages 40X6013 110V 40X6093 220V Fuser Every 120 000 pages 40X6432 Flatbed cushion as needed Preventive maintenance 6 1 7541 03x 6 2 Service Manual 7 Parts catalog How to use this parts catalog The following legend is used in the parts catalog 7541 03x Asm Part index number Units mach OR Units option Units FRU Description e Asm index Identifies the assembly and the item in the diagram For example 3 1 indicates Assembly 3 and item number 1 Part number Identifies the unique number that identifies this FRU in the table Units mach Refers to the number of units actually used in the base machine or product Units option Refers to the number of units in a particular option It does not include the rest of the base machine Units FRU Refers to the number of units packaged together and identified by the part number NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP Parts Packet in the parts description column indicates the part is contained in a parts packet Model information
94. the results message from the screen Feed Test This test performs a continuous feed test of either the flatbed scanner or ADF without producing any printed output or incrementing any of the scanner related counters For an ADF test select a paper size The ADF then performs a duplex scan using the chosen paper size settings For a flatbed test the scanner traverses the entire length of the flatbed Press Stop X to end the test Sensor Test This test checks each scanner related sensor and returns Closed or Open for each Sensor ADF Paper Present 0 means paper is not present in the ADF Sensor FB Cover Open 0 means the flatbed cover is down Sensor Home Sensor 1 means the CCD is in the home position Sensor Skew Sensor 0 means the actuator is in the up position Sensor ADF Cover open 0 means the ADF cover is closed Sensor ADF Exit 0 means paper is not present in exit sensor Sensor ADF Scan Sensor 0 means paper is not present in the scan sensor Sensor ADF Jam Sensor 0 means paper is not present in the jam sensor Sensor FB short 0 means sensor open Sensor FB medium 0 means sensor open Sensor FB long 0 means sensor open Sensor ADF long 0 means sensor open Sensor ADF width 1 0 means sensor open Sensor ADF width 2 0 means sensor open ADF Magnification Use this menu to adjust the ADF magnification from 99 to 100 The default setting i
95. this fix the issue Problem resolved Go to step 7 7 Replace the ICC board in the flatbed Did this fix the Problem solved Replace the RIP issue board 2 56 Service Manual 841 02 Delayed interrupt detected 7541 03x Step Questions actions Yes No 1 POR the device a few times Did the error re occur Go to step 2 Problem resolved 2 Update the firmware Before doing so contact your Problem resolved Go to step 3 second level support for the correct level firmware to flash the device with Did this resolve the issue 3 Replace the RIP board Did this fix the issue Problem resolved Contact second level support 841 03 Failed indirect register test Step Questions actions Yes No 1 POR the device a few times Did the error re occur Go to step 2 Problem resolved 2 Replace the RIP Did this fix the issue Problem resolved Contact second level support 841 04 Failed external DRAM test Step Questions actions Yes No 1 POR the device a few times Did the error re occur Go to step 2 Problem resolved 2 Replace the RIP Did this fix the issue Problem resolved Contact second level support 841 05 Image pipe time out Step Questions actions Yes No 1 POR the device a few times Did the error re occur Go to step 2 Problem resolved 2 Replace the RIP Did this fix the issue Problem resolved Contact second
96. to step 2 Reinstall the properly seated fuser 2 Is the fuser cable properly connected to CN19 on the Go to step 3 Properly connect printhead controller board the connector 3 Checkthe fuser cable for continuity Is there continuity Problem solved Replace the fuser cable 4 Replace the printhead controller board Does this fix Problem solved Go to step 5 the problem 5 Replace the fuser Does this fix the problem Problem solved Contact second level support Diagnostic information 2 47 7541 03x 121 05 Fuser fuser heater error Step Action and questions Yes No 1 Is the fuser installed and seated properly Go to step 2 Properly install the fuser 2 Are CNO2 and CNO04 on the LVPS and CN16 on the Go to step 3 Properly connect printhead control board properly connected all the cables 3 Checkthe fuser connectors on the fuser power cable Replace the fuser Go to step 4 for damage Is there any damage power cable 4 Checkthe fuser power cable for continuity Is there Go to step 5 Replace the fuser continuity power cable 5 Replace the fuser Does this fix the problem Problem solved Go to step 6 6 Replace the printhead controller board Does this fix Problem solved Go to step 7 the problem 7 Replace the LVPS See Low volt power supply Problem solved Replace the fuser removal on page 4 51 Does this fix the problem power cable Abnormal fuser temperature error N
97. to when the envelopes are sensed to be the wrong size Action for Prompts This setting enables users to have the printer resolve media change prompt situations automatically Such prompts occur when the selected media for the job is not available when the job prints This setting applies only to jobs that cannot be parked e Prompt user default setting The user must respond to the prompt and choose one of the following options each time e Continue The job prints on the closest available media and the printer preserves the requested size and type specifications e g Bond or Transparency If the available media is smaller than the requested size the printer crops the print image as needed Use Current The job prints on the media currently available and uses the size and type specifications of the available media instead of the original job If the media is smaller than the requested size the printer crops the print image as needed Diagnostic aids 3 15 7541 03x Jobs On Disk This setting appears only if a hard disk is installed Jobs can be deleted from the hard disk Settings are Delete and Do Not Delete default The Delete setting does not affect Print and Hold or parked jobs Disk Encryption This setting appears only if a hard disk is installed the disk is not read only and Disk Encryption is enabled Warning When the settings are changed all data on the hard disk is deleted Wipe Disk This setting perfor
98. transport upper roller P uc Duplex clutch Timing un Paper feed roller MPF feed clutch Lower duplex transport roll Std registration roller E Delivery roller 7 MPF tray Duplex exit MPF sensor actuator Duplex exit roller Diagnostic aids 3 43 7541 03x Heated roller Thermistor 1 at the center S Thermistor 2 at non driving side X Paper registration As the media trips the Registration Sensor it briefly stops at the Registration Rollers Here the leading edge is adjusted so it is parallel with the image on the Transfer Belt and synchronized with the Belt s rotation Next the paper feed motor triggers the Registration Clutch to rotate the Registration Rollers to feed the paper toward the Transfer Belt and 2nd Transfer Roller MPF Registration roll IN _ Transfer belt Registration roll OUT Registration sensor actuator Transfer belt The media passes between the Transfer Belt surface and 2nd Transfer Roller Here the image transfers to the page and continues upward toward the Fuser Rollers Fuser The media passes the Fuser Entry Detection Sensor and enters the Fuser Here heat and pressure are applied to the page to bond the image permanently to the media The toner is impregnated with wax so it releases from the fuser rolls without the need of a wiper or oil coating roller The
99. used in the parts catalog o Description 7541 032 X925 w duplex 7541 036 X925 w duplex and fax 7541 096 Parts catalog 7 1 Assembly 1 Covers 7541 03x 7 y p 7 2 Service Manual Assembly 1 Covers 7541 03x Asm Part Units Units Description index number mach FRU 1 1 40X6126 1 1 Complete Duplex 2 40X6272 1 1 A S link arm spring 3 40X6268 1 1 A S link arm 4 40X6303 1 1 Op panel front cover 4 40X6302 1 1 Op panel front cover w card reader 5 40X6120 1 1 Paper size sensor cable 6 40X6114 1 1 Paper size sensor 7 40X6354 1 1 Sensor frame 8 40X6121 1 1 Tray stop 9 40X6169 1 1 Transfer belt door DS Lock 10 40X6289 1 1 Upper front logo cover 11 40X6282 1 1 Right hinge 12 40X6280 1 1 Front cover 13 40X6283 1 1 Left hinge 14 40X6122 1 1 Left cover 15 40X6124 1 1 Access cover 16 40X6369 1 1 Option cable 17 40X6125 1 1 Option cover 18 40X6298 1 1 Back cover 19 40X6297 1 1 Cable cover 20 40X6296 Printer top cover 21 40X6743 1 1 Op panel paper exit guide 22 40X6417 1 1 Output bin full lever 23 40X6273 1 1 B S link arm spring 24 40X6269 1 1 B S link arm 25 40X6270 1 1 Safety switch spring 26 40X6267 1 1 Release link 27 40X6271 1 1 Release spring 28 40X6294 1 1 Back cave cover 29 40X6301 1 1 Inner right cover 30 40X6295 1 1 Upper right cover NS 40X6011 1 1 Transfer belt NS 40X6292 1 1 RIP cover NS 40X6304 1 1 Cave LED cover NS 40X6755 1 1 MFP cave light assem
100. 1 1 Door open switch 8 40X1104 8 1 Photo sensor 9 40X6278 1 1 Fuser exit sensor cable 10 40X6367 1 1 Engine paperfeed cable Paper exit unit 11 40X6164 1 1 Exit drive unit motor 12 40X6209 1 1 Tray lift motor cable 13 40X6172 1 1 Paper tray lift motor NS 40X7442 1 1 Base 2 screw parts pack Parts catalog 7 21 7541 03x Assembly 11 Base 3 7 22 Service Manual Assembly 11 Base 3 7541 03x Asm Part Units Units Description index number mach FRU 1 40X6174 2 1 Handle cover 2 40X6175 4 1 Bottom foot NS 40X6421 2 1 Rubber grip pad Parts catalog 7 23 7541 03x Paper feed Assembly 12 Og amp ry SEQ Wy 7 AE A J g amp gt 7 24 Service Manual 7541 03x Assembly 12 Paper feed Asm Part Units Units index number mach FRU Description 1 40X6176 1 Paperfeed unit 2 40X6193 Registration sensor cable 3 40X1104 Photo sensor 4 40X6189 Registration sensor actuator spring 5 40X6188 Registration sensor actuator 6 40X6195 Static discharge brush 7 40X6581 Standard registration roller 8 40X6580 MPF registration roller 9 40X6185 Registration gear 10 40X6183 11 40X6184 12 40X6179 13 40X6177 14 40X6178 15 40X6180 16 40X6186 17 40X6187 18 40X6181 19 40X6190 20 40X6422 21 40X6423 22 40X6191 23 40X6194 24 40X6192 25 40X6367
101. 1 7 media weights 1 8 paper sizes supported 1 6 Paperfeed roll removal 4 182 Paperfeed unit clutch removal 4 179 Papertray lift motor removal 4 94 Par 1 Strobe Adj 3 27 parts catalog covers 7 2 performance 1 6 photoconductor lock removal 4 43 Pick roll removal 4 182 4 196 POR sequence 2 3 Power supply Dead machine service check 2 92 Power supply fan removal 4 55 power on sequence POR 2 3 PPDS Emulation 3 12 print quality print quality test pages 3 20 Print Quality Pages 3 11 PRINT TESTS Print Quality Pgs 3 20 Quick Test Page 3 20 Printhead controller board engine board replacement 4 2 printhead controller board removal 4 37 Printhead service check 2 93 processor 1 6 Q Quick Disk Test 3 24 Quick Test Page 3 20 R Rear EMI shield Not a FRU removal 4 106 Rear fan removal 4 102 Registration roll removal 4 184 Registration sensor MPF tray removal 4 179 Index l 3 7541 03x Registration sensor actuator removal 4 180 removal bin full sensor removal 4 36 cassette stopper removal 4 44 density sensor removal 4 57 Door interlock switch removal 4 89 Duplex removal 4 63 Duplex solenoid removal 4 90 Engine board MDCONT 4 92 Exit guide paper exit roll removal 4 190 Fuser entry sensor removal 4 91 Fuser exit drive unit motor 4 93 Fuser Fan 4 92 handle cover removal 4 62 HVPS removal 4 111 LED assembly removal 4 29 LED print head removal 4 31 left cover removal 4 22 main fan removal 4 53 Modem 4 94 MPF clutch
102. 104 Service Manual 7541 03x Paper size switch removal 1 Remove the HVPS See HVPS removal on page 4 111 2 Disconnect the three cables Repair information 4 105 7541 03x 4 Depress the tabs holding the sensor in place Rear EMI shield Not a FRU Remove the rear cover See Rear cover on page 4 7 Remove the RIP cage See RIP cage removal on page 4 95 Remove the cross bar See Crossbar removal not a FRU on page 4 74 Remove the two silver screws A securing the top rear of the EMI shield to the frame PON 4 106 Service Manual 7541 03x 5 Remove the four screws B on the upper right side of the shield B 6 Remove the two screws C on the lower right side of the shield Repair information 4 107 7541 03x 7 Remove the screw D in the lower left corner of the shield 8 Remove the two screws E in the upper left corner 4 108 Service Manual 7541 03x 9 Remove the upper screw F securing the emi shield to the cage F Repair information 4 109 7541 03x 11 Remove the three cables out of the guides Paper feed motor removal 1 Remove the paper feed unit See Power supply fan removal on page 4 55 2 Disconnect the cable A from the paper feed motor B A 3 Remove the two screws B securing the paper feed motor to the paper feed unit 4 110 Service Manual 7541 03x HVPS removal Remove the rear cover See Rear co
103. 12 Factory Defaults See Factory Defaults on page 3 12 Energy Conserve See Energy Conserve on page 3 12 Fax Low Power Support See Fax Low Power Support on page 3 12 Min Copy Memory See Min Copy Memory on page 3 12 Num Pad Job Assist See NumPad Job Assist on page 3 13 Format Fax Storage See Format Fax Storage on page 3 13 Fax Storage Location See Fax Storage Location on page 3 13 Diagnostic aids 3 9 7541 03x Configuration Menu Auto Align Adj See Auto Align Adj on page 3 13 Color Alignment See Color Alignment on page 3 14 ADF Edge Erase See ADF Edge Erase on page 3 14 FB Edge Erase See FB Edge Erase on page 3 15 Scanner Manual See Scanner Manual Registration on page 3 15 Registration Disable Scanner See Disable Scanner on page 3 15 Paper Prompts See Paper Prompts on page 3 15 Envelope Prompts See Envelope Prompts on page 3 15 Action for Prompts See Action for Prompts on page 3 15 Jobs On Disk See Jobs On Disk on page 3 16 Disk Encryption See Disk Encryption on page 3 16 Wipe Disk See Wipe Disk on page 3 16 Font Sharpening See Font Sharpening on page 3 16 Require Standby See Require Standby on page 3 16 UI Automation Key Repeat Initial See Key Repeat Initial Delay on page 3 16 Delay Key Repeat Rate See Key Repeat Rate on page 3 16
104. 174 2 22 rrr rrr rrr rrr rr ee 7 23 Horizontal paperfeed sensor 40X1173 2 rrr rr rrr rrr rrr ree 7 43 humidity sensor 40X6203 2 20 rrr rr rrr rrr ree 7 29 Inner duplex cover 40X6142 ccccmn mc I III 7 13 IPDS SCS card 40X6925 r I III ee eee eee 7 46 Israel powercord 40X0275 ceceeemmmm III III 7 46 J Japan powercord 40X3609 c eemmmI II II III I eel 7 46 Japanese font card 40X5972 sceeccmm mI III III 7 46 K Korea powercord 40X1792 eeecceemI I III II 7 46 Korean font card 40X5969 cecemcmeIm III I II 7 46 L LED FFC cable 40X6216 n m mI I eec l 7 31 LED printhead 40X6218 cccrcmnm cm III III 7 31 LED printhead assembly 40X6429 ccccmcl II III III 7 31 Left cover 40X6122 cease eere ree RE aT mee Heec eR pie Sie omen RS sertis 7 3 Left hinge 40X6283 cccmm II II III I III c III 7 3 Lever guide 40X6132 crcnnm III II II II 7 15 Lever open spring 40X6131 ccccccmcIc III III II 7 15 Lever shaft 40X6130 cccrc II I III II III c 7 15 Lower registration spring 40X6183 ccccccoccccccccccccccccccccc cc cHccHcHlll 7 25 Lower registration spring 40X6423 25 025 r rrr rrr rr rere terre r
105. 191 7541 03x 6 Remove the spring washer e clip and bushing E from the shaft E 7 Release the tabs F that secure the black guide to the exit unit 4 192 Service Manual 7541 03x 8 Open the paper exit unit exposing the rollers 9 Pull back the tab G to release the roller Repair information 4 193 7541 03x 10 Remove the screw H that fastens the roller holder to the paper exit unit frame H 11 Pull the roller holder back and away from the paper exit unit 12 Repeat steps 9 thru 11 for the remaining rollers 4 194 Service Manual 7541 03x 13 Move the paper exit guide roll to the left lift it out of the frame and pull it to the lift releasing it from the paper exit unit Repair information 4 195 7541 03x Option paper feed removals Paper feed roll removal 1 Remove the paper tray from the option paper feed unit 2 Remove the clip A securing the paper feed roll to the shaft a O Z A 3 Slide the paper feed roll B off the shaft to remove it Pick roll removal 1 Remove the paper tray from the option paper feed unit 2 Pull back the tab A on the pick roll MN M AL Ee 3 Slide the pick roll B off of the shaft to remove it 4 196 Service Manual Separator roll removal 1 Remove the paper tray from the option paper feed u
106. 2 Arethere any obstructions preventing the Go to step 3 Go to step 4 actuator from moving freely 3 Remove the obstruction from the actuator Did Problem resolved Go to step 4 this fix the problem 4 Checkthe cover open for dust or dirt Is the Go to step 5 Go to step 6 sensor dusty 5 Clean the sensor off Did this fix the problem Problem resolved Go to step 6 6 Isthe sensor dislodged Go to step 7 Go to step 8 7 Properly install the sensor Did this fix the Problem resolved Go to step 8 problem 8 Checkthe sensor Cover open for proper Go to step 10 Go to step 9 operation 1 Enter the Diagnostics Menu 2 Touch SCANNER TESTS 3 Touch Sensor Tests 4 Observe the line sensor Cover open Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 9 Checkthe sensor connection for proper Go to step 11 Go to step 10 connection to CN1 on the ADF relay and the paper present sensor Is the cable properly connected 10 Connect the cables Did this resolve the issue Problem resolved Goto step 11 11 Check J1 pin 3 for 5V and pin 2 for ground Go to step 12 Go to step 13 Are these present 12 Replace the paper present sensor Did this fix Problem resolved Go to step 13 the issue 13 Is the ADF cable properly connected to J9 on Go to step 15 Go to step14 the ADF relay card and the ICC board connector on the rear under side of the flatbed 14
107. 250 24x FRU Action 1 Paper feed cassette If there are misfeeds and jams in the paper feed unit check to see if the corners of the paper in the cassette are curled upward If the corners are curled turn the entire stack of paper over The curling could be due to humidity conditions 2 Paper feed unit rollers Roller clutch Are the rollers dirty or worn Replace as needed If there is a failure to pick and the feed rollers are clean check the roller clutch on the paperfeed unit This check can be performed by turning the paper feed roll in both directions If the shaft can be turned in both directions replace the roller clutch 3 Paper feed roller MPF Paper feed rolls MPF Be sure the paper feed rollers are free of dirt and not damaged Be sure the MPF pad is free of dirt and not damaged tray 1 2 3 4 5 MPF pad Replace parts as necessary 4 Gears Be sure the paper feed gears are not damaged 5 Paper feed clutch MPF clutch MPF frame assembly Ensure the clutches are engaging properly Check connector CN 8 Main tray CN 28 MPF on the engine controller board and CN18 on the expansion feeder controller card for proper connection Replace the non working clutch If this doesn t fix the problem replace the engine board 6 Registration sensor MPF sensor Engine controller board 2 24 Service Manual Check the following engine controller board co
108. 2a 95 Seton EORNM qd xS ad ebd qe qud daba d 3 16 UL AUIOmallot iueaasucrexacer RE eNO hE A UE X ERE EORR KER OS KO CR ODE RR doe RU 3 16 Once enabled this setting creates an ENABLE UI AUTOMATION file in the shared directory As long as this file exists the printer permits external developers to test the stability of their applications against the printer to ensure that their applications have an appropriate level of stability Disabling this setting deletes the file llle 3 16 Key Repeat Initial Delay iusso sasuke hk REOR ts shade aad eee CR UC AL OR EORR RR 3 16 Key Hepeat Rale 1L euosoenes rund amcadu wq er hdc aro RM bed RR NAE R RM RU E a 3 16 Glear Custom Status iius scents cen e ao gs POR cae eed Ree Rw cR RR eR e RR OR RUD ERT 3 16 USB SHEGI i cc ETUR 3 17 Exit Contig Men i222 cicesebea jeden Rec ieat RERO ERR RR steko KEEPER ARA FERE RA 3 17 Diagnos HES Mode auda dx AOociQ Fau RE du add a RGa E RU AR DEA ENS DE REd Pa US KNEE 3 18 Entering DIAGNOSTICS Mod osassaxads exacta RR AR RRGRHRHRREAARRAG ERR QR A FERA LA RR 3 18 Dhadgnastie MOJ MENUS sei cud 55 add 2d Rie Edd a d abd sides i6 did acd oaa o dE 3 18 SCANNER CALIBRATION 2 2 2222 RR E RERREEESREEE Gd RAEWEAT GU Rd REG bimini REX 3 20 Aust Calibration Valles 225290342 9s ud e Ug eO qeu eed wa deen gaia dasu Rides 3 20 Reset Calibration ValilBS c idreeohobee RE rr ER bese dora P Pe e Pa E qb PIE eq 3 20 PRINT TESTS zissessestem nani I E EGG ME EGRE E denen er
109. 3 3 Replace the LED head of the colors that failed to print Problem solved Go to step 4 Did this fix the problem 4 Check CNO1 on the HVPS CN11 on the printhead Go to step 5 Connect the controller and the CN1 4 for proper connections Are cables properly the connected properly 5 Is the Theta sensor cable connected properly Go to step 6 Properly connect connected to CN 8 on the printhead controller board the cable to CN8 and Theta sensor on the printhead controller board and Theta sensor 6 Is the sensor misaligned the sponge blocking the Properly align the Go to step 7 sensor and the cover opening and closing smoothly sensor and reposition the sponge on the theta sensor cover Make sure the cover opens and closes smoothly 7 Replace the theta sensor Problem solved Go to step 8 8 Replace the engine controller board Does this fix the Problem solved Go to step 9 problem 9 Replace the HVPS Does this fix the problem Problem solved Contact your second level support 136 xx Temperature humidity sensor error Step Action and questions Yes No 1 Is CN4 on the MDCONT board securely connected Go to step 2 Connect the cable securely 2 Replace the humidity sensor cable Does this fix the Problem solved Go to step 3 problem 3 Replace the temperature humidity sensor Does this fix Problem solved Replace the the problem printhead controller board 2 50 Service Manual 140 Drive motor error
110. 4 seconds Then turn the printer back on POR the printer Is the error gone and can the printer print 4 Clear the NVRAM of the printer Go to step 5 Problem solved 1 Turn the printer power off 2 With the printer off press and hold 6 7 and 8 on the keypad 3 Turn the printer on 4 When Restoring Factory Defaults appears release the buttons Note If the printer locks up on the Restoring Factory Defaults wait two minutes and then turn the printer power off After ten seconds or more turn the printer power back on without holding down any buttons Does the error message still appear 5 Replace the OP panel UICC card See UICC Replace the RIP board Problem solved 2 64 Service Manual 959 xx Service invalid firmware error 7541 03x Step Action and questions Yes No 1 POR the printer a few times Does the problem re Go to step 2 Problem occur resolved 2 Put the machine into recovery mode and update the Problem resolved Go to step 3 firmware You will need to contact your second level support for the correct firmware level to use Did updating the firmware fix the issue 3 Replace the RIP board Did this fix the problem Problem resolved Call your second level support Diagnostic information 2 65 7541 03x User attendance messages User prompts Error code Action Adjusting color Wait until the process is completed Change src custom type
111. 40X1078 eee e eer eee eee e e ee 7 43 Option tray pick roll 40X1077 7 2 eee re ee ee eee eee eee ee 7 43 Option tray separator roll 40X1079 RII 7 43 Output bin full lever 40X6417 oe eee ee eee eee eee eee ee 7 3 P Paper exit guide 40X6745 2 errr eee ee eee ee ee eee eee 7 17 Paper exit roller 40X6579 eee e err eee ree eee eee eee 7 17 Paper exit sensor lever 40X6145 2 rr eo eee ee eee eee eee eee eee 7 13 paper feed clutch cable 40X6194 7 29 Paper size sensor 40X6114 2 2 eee ee ee ee re ne ee eee ee ee ee eee ee 7 3 Paper size sensor cable 40X6120 2 ere ne rr rr ne eee nes 7 3 paper size switch cable 40X6120 2 err ener tr rene 7 29 Paper tray lift motor 40X6172 2 2 errr eee ee ee eee ee eee eee 7 21 Paper tray size switch cable 40X7456 ee neers 7 29 Paperfeed clutch 40X6191 e eee eee eee ee ee eee eee eee eee ee eee 7 25 Paperfeed clutch cable 40X6194 r err rr renee 7 25 Paperfeed maintenance kit 40X6372 eee rere eee er eee eee ee 7 25 Paperfeed screw parts pack 40X7447 rrr rrr rrr rr
112. 40X6743 Op panel paper exit guide eee reer ee ee ee ee eee 7 3 40X6744 Op panel under cover rrr rere rere ere eee eee eee eee eee 7 3 40X6748 RIP harness cable 22 0 e eee eee eee ee ee ee eee eee 7 33 40X6749 Main power cable 22 e errr rr rr ern en ere ee ee ee ee eee eee 7 29 40X6755 MFP cave light assembly rrr rrr errr reer reer eee rere ee 7 3 40X6757 Scanner rubber pad 2 0 0 eee e ee ere eee ee eee ee eee eee 7 7 40X6758 Scanner stopper screw 2 r errr ree errr eee eee eee eee ee 7 7 40X6759 Scanner sub rubber screw 2 0 rrr rere rr eee eee eee eee ee 7 7 l 8 Service Manual 7541 03x 40X6760 Dimention screw rrrSrIl eee ee 7 7 40X6953 Mylar ADF pad r r rlS rSSlIIlSlIlIr e 7 11 40X6957 Button assembly op panel top rrSlrl e e 7 7 40X6958 Op panel bottom 2 enn rn en en ee eee 77 40X6959 Op panel access cover 32 enn eee eee 7 7 40X6966 Tray paper size sensors u rlSlISrSSlrl e 7 9 40X6973 UICC card errr rr errr ee ee eee ee eee eee eee eee ee 7 7 40X6974 Duplex out sensor actuator
113. 41 03x Color Adjustment ss cx rk x NR EE RE GO KE GG ERR E EXPE EE RE ERE ER XGA EE RS ees 3 13 AUTIDOIGIU UO aiii n Eu ho RUE RUE GERD needs news eee 48 M x x a RR GL RUE RU S DL AE QOL ses 3 13 Color Adj Stale ici sse sanus nu caer Reed REG REG bREUDE A ERG RE EURE ER E PA ORG EUER 3 13 Color ANIDIBOBE ad xis d ERES R3 ed RE DARE SEE ERA BS ERE GREEN QE E E EE cen 3 14 ADFEddge Erase 6 ns RR RE uy REESE UE EE ER ERR RE ER RES a ERE dA RE 3 14 FR EJOS ESG inno Pid DER UR ObR Page d dk 24 0d tees Fed der End Nd E Bad X SE tee 3 15 Scanner Manual Registration 225 22e oue hr una eee RR 4EERERRAG REAPER RRRG DERE 3 15 Disable Scanner assssos km se EN KG Meese Rew RO E RR eRe ET eR PT EXPE M EE T EE 3 15 Motor Calibration cesser cone ees kee cee eee ERE NE RR RESP IT Agna UE Rude 3 15 Paper Prompts uias docs xe on ded RR RAD CR Ua OR EROGO RR C ee RD RRR 3 15 Envelope PrOmpl6 cenen dass dd xinqra doxip aora d dee a RA AUR EORR UR CR RR m RR ERU RUE alee wn 3 15 Action for Prompts ign esackaa dE KR RCRRORCR RACE ORAN CUORE SOR GR TORS RRS Ce RRO ee 3 15 Jobs On DISK 2 ibus nee be re uw pRE PER BEER EGRE RTT GERM RR ERG RONIE RENE 3 16 DISK EBCTUDUOR censa exedaced ERe be RS ee erase Re CE d bd RA OO ROS DORR CERE SA d raa 3 16 WIDE DISK a 06945259 R RA BOE d ipd lui bud do quu ad dera uud E REN AR RR ed Ese 3 16 Font Sharpening 2x522z a zxek eR deen dikes DEERGR AE ER 4a REPRE REA RN ERR RA EA EG 3 16 Heguire SIandBy 11555 ipe 2
114. 41 03x Optical paper size sensor Remove the flatbed unit from the printer Place the flatbed unit facedown on a non marring surface and remove the bottom shield Disconnect the affected sensor s cable from the ICC board Turn the flatbed rightside up Remove the flatbed upper cover Remove the screw A securing the affected sensor to the flatbed assembly meme A 7 Lift the sensor and thread the sensor cable through the bottom of the flatbed assembly Repair information 4 127 7541 03x ADF cable Remove the cord cover See Cord cover on page 4 6 Remove the left ADF cover Remove the ADF relay card cover Disconnect the ground cable from the ADF relay board A Pons O j A 5 Disconnect the ground cable from the ADF main feeder chassis B 4 128 Service Manual 7541 03x 6 Disconnect the ADF cable C from the ADF relay board ADF motor frame 1 Remove the left ADF cover 2 Disconnect the motor cables from the ADF relay card Repair information 4 129 7541 03x 3 Remove the two screws A securing the motor frame to the ADF main feeder unit 4 130 Service Manual 7541 03x 4 Remove the motor frame from the ADF unit Note When replacing the frame make sure the ADF drive clutch stop B is properly aligned with the clutch Repair information 4 131 7541 03x ADF solenoid 1 Remove the ADF main feeder 2 Remove the four screws A securing the solen
115. 42 01 HW protocol 842 02 Logical protocol 2 58 843 00 Carriage Home 2 59 844 00 Lamp failure Front side 2 59 849 01 Device had modem installed but config ID indicates it should not 2 59 849 10 Device had HD installed but config ID indicates it should not 2 59 service checks 2 45 111 01 Black printhead error 2 45 112 01 Cyan printhead error Error 2 45 113 01 Magenta printhead error 2 45 121 05 Fuser fuser heater error 2 48 126 xx Power switch error 2 48 130 xx High voltage power supply error 2 49 132 00 Density sensor error 2 49 132 xx Abnormal theta sensor 2 50 136 xx Temperature humidity sensor error 2 50 140 Drive motor Error 2 51 146 01 Traylerror 2 52 146 03 Tray3error 2 52 146 04 Tray4 error 2 53 146 05 Tray5 error 2 54 149 01 Fuser paper exit motor Error 2 51 171 01 Fuser fan error 2 54 172 01 Power supply unit fan error 2 55 173 01 Main unit fan error 2 55 174 01 Rear fan error 2 55 54 Network Software error 2 91 900 xx System software 2 60 941 01 SDRAM R W error 2 62 941 03 CPU error 2 63 941 04 MDC controller error 2 63 941 05 EEPROM error 2 63 950 00 950 29 EPROM mismatch 2 64 Abnormal fuser temperature error 2 48 ADF paperfeed 2 36 ADF streaks 2 76 DRAM options 2 90 duplex 2 24 Error code 976 Network card x 2 91 false door open 2 86 Fax dials a number but no connection is made 2 83 Fax reception fails 2 80 Faxes fail to transmit 2 78 flash options 2 90 hard d
116. 5 ability to send and receive calls Did the phone line work properly 5 Use a telephone handset to verify the phone Go to step 7 Go to step 6 line is free of static or external noise Is the phone line noise free 6 Use the MFP on a properly functioning Problem resolved Go to step 7 phone jack Did this fix the problem 7 In diags config menus verify that the Go to step 9 Go to step 8 Enable Fax Receive setting is on Is the setting set to on 8 Set Enable Fax Receive to On Problem resolved Go to step 9 Did this fix the problem 9 Is Distinctive Ring enabled Go to step 11 Go to step 10 10 Turn on Distinctive ring Problem resolved Go to step 11 Did this fix the problem 11 Is the phone line analog Go to step 13 Go to step 12 12 Is the VOIP server configured to support Go to step13 Stop here This is an fax issue with the VOIP provider 13 Does the MFP have reception issues with Go to step 14 Go to step 15 only a certain remote device 14 Verify communications with a different The issue is with the Go to step 15 remote device other device Can the other device receive faxes 15 Go to the Administrator menu Enter the Fax Go to step 16 Go to step 17 settings Analog Fax Settings submenu Verify the Block No Name Fax user setting Is it enabled 2 80 Service Manual 7541 03x Step 16 17 Questions actions Di
117. 50 Service Manual 7541 03x 6 Remove the screw C securing the scan sensor cover to the ADF main feed unit is Repair information 4 151 7541 03x 8 Remove the screw E securing the scan sensor cover to the ADF main feed unit 9 Remove the scan sensor cover Duplex timing sensor 1 Remove the ADF main feed unit 2 Remove the fastener A 3 Remove the gear B 4 152 Service Manual 7541 03x 4 Turn the bushing C to release it from the ADF main feed unit Repair information 4 153 7541 03x 6 Turn the bushing E to release it from the ADF main feed unit 4 154 Service Manual 7541 03x 8 Lift the paper guide up and feed the duplex pass timing sensor cable through the ADF main feeder frame Er Repair information 4 155 7541 03x 10 Carefully pull the sensor PCBA away from the retainer H on the paper guide 4 156 Service Manual 7541 03x Duplex out scan out sensor 1 Remove the ADF main feed unit 2 Remove the screw a securing the duplex out sensor to the ADF main feed unit Repair information 4 157 7541 03x Duplex out sensor actuator 1 Remove the duplex out sensor 2 Remove the two screws A that fasten the sensor mount to the ADF main feed unit A 4 158 Service Manual 7541 03x Flatbed cover closed sensor 1 Remove the flatbed upper cover See Flatbed upper cover on page 4 161 2 Remove the two screws a securing the
118. 7541 03x LED print head removal 1 Remove the LED assembly See LED assembly removal on page 4 29 2 Using a screw driver pull the plastic casing A on the rear of the holder away from the tab on the printhead releasing it from the printhead holder A 3 Repeat the previous step for the front of the printhead assembly 4 Remove the printhead from the LED assembly 5 Carefully remove the ribbon cable B from the printhead Repair information 4 31 7541 03x Op panel paper exit guide removal 1 Remove the paper output bin See Output bin print engine top cover on page 4 17 2 Remove the two screws A on the front 4 32 Service Manual 7541 03x 4 Remove the ground screw C Paper exit guide removal Remove the top cover Remove the op panel paper exit guide See Op panel paper exit guide removal on page 4 32 Disconnect the paper exit bin full sensor cable from CN7 on the printhead controller board Thread the cable A through the fuser fan duct AON B A 5 Remove the screw B securing the paper exit guide to the sub drive unit Repair information 4 33 7541 03x 6 Remove the screw C securing the paper exit guide to the rear of the printer frame 99 e SS 7 Pull the fuser duct back to provide some clearance for the paper exit unit 4 34 Service Manual 7541 03x 8 Lift the unit up and remove it from the printer _ Lo f d
119. 8 xx Service NAND Failure Replace the RIP board For the 958 error replace the UICC card if replacing the RIP board does not fix the problem 959 xx Service Invalid Firmware Call the second level support to get the correct level of firmware and update the firmware or replace the RIP board 960 xx Service Memory Error Replace the RIP board 961 xx Service Memory Error Replace the memory in the DIMM slot 964 xx Service Emulation Error Disable the Download Emulation Program the download emulation into the firmware card again If this does not resolve the problem then replace the firmware card and download the emulation again 975 xx Standard network or Network Card X 976 xx Standard network or Network Card X 982 xx Service device 990 xx Service device 991 xx Service device Card Call your second level support Diagnostic information 2 39 7541 03x 8xx scanner error z codes Description Action 840 01 The scanner has been Enter the configuration mode to re manually disabled enable the scanner 840 02 The scanner has Enter the configuration mode to re automatically been disabled enable the scanner by the controller 840 03 Scanner cable unplugged Check the scanner cables for proper connection to the scanner and RIP board 841 00 Invalid configuration or ASIC See 841 00 Invalid configuration or
120. 9 EXIT DIAGNOSTICS Diagnostic aids 3 19 7541 03x SCANNER CALIBRATION Adjust Calibration Values This menu is used to manually adjust the scanner black levels to optimize printed text and images from scanned or copied originals Use this menu to adjust the levels after you replace any of the following parts Flatbed scanner assembly ADF unit assembly Flatbed scanner CCD assembly For more information see Calibrating the scanner on page 4 205 Reset Calibration Values This resets the scanner black levels to factory default settings These values must be reset after you replace any of the following parts Flatbed scanner assembly ADF unit assembly Flatbed scanner CCD assembly PRINT TESTS Print Tests input sources This test determines if the printer can print on media from any of the paper input sources Each of the installed sources is available within the Print Tests menu The content of the test page varies depending on the media installed in the selected input source e If a source is selected that contains paper then a page similar to the Quick Test Page is printed and does not contain the Print Registration diamonds e If a source is selected which contains envelopes then an Envelope Print Test pattern is printed This pattern contains only text which consists of continuous prints of each character in the selected symbol set f Continuous is selected then the sam
121. C Display cable Parts catalog 7 7 7541 03x Assembly 4 ADF 1 Assembly 4 ADF 1 7541 03x Asm Part Units Units index number mach FRU Description 1 40X6338 1 1 ADF input tray 2 40X6966 1 1 Tray paper size sensors 3 40X6979 1 1 ADF tray bottom cover 4 40X6345 1 1 ADF paper stop 5 40X6346 1 1 Upper flatbed top cover 6 40X6344 1 1 Right ADF cover 7 40X6334 1 1 Flatbed hinge 8 40X6347 1 1 Lower flatbed top cover 9 40X6432 1 1 Flatbed cushion 10 40X6333 1 1 ADF hinge 11 40X6329 1 1 ADF relay card 12 40X6433 1 1 ADF cable 13 40X6342 1 1 ADF relay card cover 14 40X6343 1 1 Left ADF cover 15 40X6542 1 1 Release arm 16 40X6544 1 1 Idle clutch roller 17 40X6543 1 1 Idle pulley roller NS 40X5867 1 1 ADF screws and fasteners parts pack Parts catalog 7 9 7541 03x Assembly 5 ADF 2 7 10 Service Manual 7541 03x Assembly 5 ADF 2 Asm Part Units Units index number Mach FRU Description 1 40X6331 Outer ADF top cover 2 40X6531 ADF paperpath sensors 3 40X6540 Paper present sensor actuator 4 40X6539 Paper in sensor actuator 5 40X6340 Top cover release handle 6 40X6332 Inner ADF top cover 7 40X6327 ADF pick roll assembly 8 40X6328 ADF separator roll 9 40X6953 Mylar ADF pad 10 40X6349 11 40X6976 12 40X6532 ADF media paperpath guide Duplex timing sensor Gear w spring holder 13 40X6538 Spur G28T
122. CN1 Yellow printhead 1 HD5V 2 GND 3 HD5V 4 GND 5 HD5V 6 GND 7 HD5V 8 GND 9 HD5V 10 GND 11 HD3V 12 SO Y 13 SCK Y 14 STROBE Y 15 DATA YO 16 DATA Y1 171 DATA Y2 18 DATA Y3 19 HSYNC Y 20 LOAD Y 21 GND 22 CLOCK N Y 23 CLOCK P Y 24 GND Locations 5 11 7541 03x Printhead controller board Connector Connects to Pin no Signal CN2 Cyan printhead 1 USB 5 V dc 2 USB D 1 HD5V 2 GND 3 HD5V 4 GND 5 HD5V 6 GND 7 HD5V 8 GND 9 HD5V 10 GND 11 HD3V 12 SO C 13 SCK C 14 STROBE C 15 DATA_CO 16 DATA_C1 171 DATA_C2 18 DATA_C3 19 HSYNC C 20 LOAD_C 21 GND 22 CLOCK N C 23 CLOCK P C 24 GND 5 12 Service Manual Printhead controller board 7541 03x Connector Connects to Pin no Signal CN3 Magenta printhead 1 USB 5 V dc 2 USB D 1 HD5V 2 GND 3 HD5V 4 GND 5 HD5V 6 GND 7 HD5V 8 GND 9 HD5V 10 GND 11 HD3V 12 SO M 13 SCK M 14 STROBE M 15 DATA MO 16 DATA M1 171 DATA M2 18 DATA M3 19 HSYNC M 20 LOAD M 21 GND 22 CLOCK N M 23 CLOCK P M 24 GND Locations 5 13 7541 03x Printhead controller board Connector Connects to Pin no Signal CN4 Black printhead 1 HD5V 2 GND 3 HD5V 4 GND 5 HD5V 6
123. Contact spring 40X6215 2 enn re ene 7 31 Cover 1 screw parts pack 40X6499 7 3 7 13 7 15 Cover closed actuator cable 40X7455 eee eee eee eee eee 7 29 D Discharge brush plate 40X6277 2 2 rrr errr eee ee ere eee eee eee 7 13 Door lever 40X6129 22 een nn rn en nn en eee eee 7 15 Door lever lock 40X6128 2 2 ne ee nr rn ene eee ee eee 7 15 Door open switch 40X6166 7 0 eer eee eee eee eee ee eee eee eee eee eee eee 7 21 Drive gear 40X6146 eee eer eee eee eee eee eee eee eee eee eee ee eee 7 13 Drive unit motor 40X6161 n ne rn en ee eee eee 7 19 Part number index l 9 7541 03x drive unit motor 40X6161 cccccmc c III III I 7 29 Duplex carrying gear 40X6144 ccsccccmmc II III 7 13 Duplex clutch 40X6157 cccccmmc II II III I 7 13 Duplex clutch cable 40X6158 cceccmcmn I III III 7 13 Duplex cover roller 40X6137 ccrcncI III III 7 15 Duplex ground cable 40X6259 ccccmcmc III III 7 13 Duplex ground plate 40X6148 cecen III III 7 13 Duplex roler bushing 40X6147 cccccmmc III III I III 7 13 Duplex static brush 40X6260 ccccccmcmI I III 7 13 Duplex timing belt 40X6155
124. Device had HD installed but config ID indicates it should not 2 59 900 xx System software error 2 60 941 SDRAM R W error 2 62 941 03 CPU error 2 63 941 04 MCD controller error 2 63 941 05 EEPROM error 2 63 959 xx Service invalid firmware error 2 65 abnormal fuser temperature error 2 48 SIZE SENSING 3 11 Speaker removal 4 25 specifications 1 6 acoustics 1 5 clearances 1 4 dimensions 1 4 electrical 1 4 environment 1 5 memory 1 6 performance 1 6 Power specifications 1 4 processor 1 6 Static discharge brush removal 4 180 Stepper motor removal 4 200 Sub drive unit removal 4 84 Sub frame unit removal 4 104 T Temperature and humidity sensor removal 4 101 Theory of operation Color theory 3 49 Printer engine 3 31 Scanner 3 46 Theta sensor removal 4 56 Toner sensor removal 4 97 tools required 1 15 Torque limiter removal 4 181 Transfer belt CRU removal 4 40 Transfer belt motor removal 4 100 transfer belt position sensor removal 4 41 Transfer belt up down check 2 93 Transfer Roll CRU removal 4 72 Transport sensor removal 4 198 Tray lift motor removal 4 201 U Unable to print from USB thumb drive service check 2 94 Upper and lower registration springs removal 4 181 USB HS Test Mode 3 24 l 6 Service Manual USB port service check 2 86 USB Scan to Local 3 10 User attendance messages 0 99 2 69 W waste toner bottle missing service check 2 94 Words on fax are stretched 2 83 Wrong paper size service check tr
125. EARS CRUCE EROR 7 1 Assembly 15 COVES ncn Cale bx o EPerbee EE Rad ME RU Rad Puedes aped dade deqqRdaque a 7 2 Assembiy 2 FPlatbed and AGP 23 0 scaccmeus arena wy eod RUPEE UR o hanes acreanae eta hed 7 4 Assembly 3 FAME 22eradue ramas tra nets sighs teada khea ieee p ded decided 7 6 Assembiy4 ADP d cesses up sesh sess eee a Uae nad e E eed e rd p mudo x ue sees qp 7 8 Assembly 5 DES oou alaidedsie jek de RR GRA RARE choles M Rbeppd qub n da cebu 7 10 Assembly 6 Duplexcomponents T aussen om ym aee ret goat Rode eoe ned tob i 7 12 Assembly 7 Duplex components 2 0 00 e eee eee eee nes 7 14 Assembly 8 Paperexit 22 4222 vc R9 P HRRR Coe Yee REEL e E ATQ RUNE REY eee es 7 16 xi 7541 03x Assembly 9 B sbl il 293 bp RE cS Ei bte ea be Rage d Pone olipire heec are RR HIE elis 7 18 Assembly 10 Base 23 soo dd RES PEDA hr Ra RARARETEERARISRAREPaPO d sepe Nuda 7 20 Assembly TE Base 3 ecooss coo me har kacis ieee s eee be audet d iode doeet loce eee RD 7 22 Assembly 12 Paper Teell iuscsgma eR LEE ER sees GRR CERA e EA RR P Rh e obe dub do canes 7 24 Assembly 13 El ctcal 1 ooo edere d areia rees eae aee GRE Re gd ardeo diu qus 7 26 Assembly 14 Electrical 2 oi 2 cc ccsawrcsewbsiaeediechetes peace eek a RARE Rx da 7 28 Assembly 15 Upper assembly eoe kh Role qo book ue deno dra ekle o Pac Voce eric det we 7 30 Assembly 16 Printhead controller board cables 00 0c eee eee 7 32 Assembly 17
126. ES PEU IER pid pa reda d iE 2 11 Dark image quality using ADF or Scanner 0000 e eee eee eee nee 2 11 Vertical lines process direction using the ADF esee 2 12 Spots using flatbed scanner eseseeeeeeeeeeeeeee nn nn nnn 2 12 Skew using ADF 5s gases gno e RURRRCR EUR seas UR UO S EU RR OR CR CR SR 2 14 Media damage USING ADF eeluseuu ean three E RR rr Se eels be rrr rr Ere ER 2 15 Black page from scanher iis asamsexnxda hac ead ac oRU ERROR REOR RR RODA ARRA CER 2 16 Papel IGS coe ndo tated TOR R GE DRE S Ra eu Ra Seika ERU di Gale Bel wale ER NU RC M IRR amp 2 17 Clearing and troubleshooting paper jams eeeee IRI 2 18 2ZUDOSSr JAM iu iucedeeisenendecop benphibereibeeQ gd ese ybem xs et See sou 2 18 2UTIBSpSI ANT dues pated hero qune S Pa elttoeo wp Pat Ud ead E V dahile aqu piu pd 2 18 AUS PAS AM s2iiachbcressretek epe reemnr perpebbcepdcqu d 4 3 Pd d o sque pe nuda 2 19 LOO pP aM 30d quidutirs R98 oro eec Beanie n dea n ibo e ding E UFU bow sites ed oae 2 20 231329 DADO All c422400 235 0o Det RUE PELLE ELE Cassi qu pea bqe E sar gee 2 21 24x PAPE JAM cds vee respice 9 eR UASS P IER dois R3 p PRAE areas RITE S Eee as eee 2 22 2DUIDSDOI IAM 2 203 5d cpb oe EC Ero x aber OQ bp ed edu eC SURE S ORC RESpPN ERE Ades 2 23 Duplex unit service check 0 cece cece eee eee tree eee hh e mnn 2 24 Paper path service Checks assu xax ia RA RERO adds iipasi s PEONES Re eRe CR C R
127. Edition 1 31 10 e Service Manual Lexmark X925 7541 03x e Table of contents e Start diagnostics e Safety and notices e Trademarks e Index LEXMARK 7541 03x Edition February 10 2011 The following paragraph does not apply to any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22X 002 1 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServicelnfoAndTraining 9 Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operat
128. Fuser Rollers continue to feed the paper upward to the Fuser Exit Sensor and Fuser Exit Rolls Fuser belt Separator Halogen heater Halogen heater Press roller Thermistor 3 Thermostat Fuser entry gear Fuser entry detecting lever Thermostat EN Fuser roller Fuser motor Paper exit If the sheet is single sided the paper passes the fuser exit sensor and is fed into the standard bin by the exit rolls 3 44 Service Manual Duplexing 7541 03x If a page is two sided a signal is sent to the Printer Controller Board once the trailing edge of the paper passes the Fuser Exit Sensor The leading edge of the paper partially feeds from the Exit Rolls and then reverses direction and feeds into the Duplex Unit This method of re feed is called a Peek a boo The Duplex Entry Rollers pass the paper down to the Duplex Transport Rollers along the right side of the printer Once the paper reaches the bottom the Duplex Exit MPF detection lever senses the leading edge of the media at the Duplex Exit Roller and it engages the Duplex re feed clutch to transport the sheet of paper into the EP paper path Paper Q Paper HT OS Paper exit sensor v SU Fuser exit ius oY 3 Mm MPF R e Duplex entry roller Timing belt 1 T3 z O Timing belt ey Transfer roll Paper or td Registration roller
129. GND 28 INCLK P 29 INCLK M 30 GND J10 FB paper size sensor 3 1 GND 2 5V 3 FBPS3 3 4 FBPS3 2 5 FBPS3 1 5 30 Service Manual ADF relay card connectors ADF relay card 7541 03x 1 0000000000000 0000000000000 J9 Connector Pin no Signal J1 ADF cover sensors 5V COVER OPEN GND 5V PICKUP ROLLER GND 5V GAP GND 5V gt O CO NI OD oO AJ OJN O PAPER DET ine GND J2 ADF scan motor OUT2B 1 OUT1A 1 OUT2A 1 OUT1B 1 J6 ADF pick motor A O N gt OUT2B 2 OUT1A2 OUT2A 2 A Oj N OUT1B2 J3 ADF paper width and length sensors B5SEN A4SEN B4SEN 5V GND A3SEN NI OO a BY OJ N L1SEN Locations 5 31 7541 03x ADF relay card Connector Pin no Signal J4 ADF paper out sensor 5V Paper out GND J5 Duplex paper pass V N 5V 2 PASS SEN w m GND J7 Scan sensor paper in 5V PAPER SCAN GND 5VD PAPER IN GND J8 Solenoids 0 oO AJ OJ N 24V GND 24V AJOJN GND 5 32 Service Manual ADF relay card 7541 03x
130. GND 7 HD5V 8 GND 9 HD5V 10 GND 11 HD3V 12 SO K 13 SCK K 14 STROBE K 15 DATA_KO 16 DATA_K1 171 DATA_K2 18 DATA_K3 19 HSYNC K 20 LOAD_K 21 GND 22 CLOCK N K 23 CLOCK P K 24 GND CN5 Engine board 1 MBUSY IN 2 SUBRXD 3 SUBTXD 4 MOTOR CLK1 5 MOTOR CLK2 6 MOTOR CLKS 7 MOTOR CLK4 8 GND 9 HTNB1 10 PEPCNG 11 GND 12 THETALED 18 PRG SW 14 LDPRG 5 14 Service Manual Printhead controller board 7541 03x Connector Connects to Pin no Signal CN6 Fuser entry sensor oa GND FUIN_SW LDPRG CN7 Paper exit j N GND PEX_SW IDPRG Bin full sensors GND STACK_SW 5V CN8 Theta sensor 0909 oO A Ww N A THETA j m GND CN9 CN 10 N C CN11 HVPS VCC24VFAN GND HV24V 2 HINB DACLK DASO DARIN CO N OD oO AJ WwW DA_LAT CN12 N C CN13 OPTION ADRO ADR1 OPTION RST OPTION RXD OPTION TXD OPT 24V OPT 24V GND GND 0 CO N oO AJ WY N OPT_5V GND Locations 5 15 7541 03x Printhead controller board Connector Connects to Pin no Signal CN14 Density sensor GLED VMON GND 5V a A Oj N VOUT CN15 LVPS 5V IN 45V GND 24V_IN 24V_GND Engin
131. Humidity Operating Temperature 10 0 to 33 00 C 50 to 91 40 F Relative humidity 8 to 8096 Altitude 7546 ft 0 to 2300 meters Atmospheric pressure 767 kPa Power off Temperature 23 to 104 F 5 to 40 C Relative humidity 8 to 8096 Maximum wet bulb temperature 80 1 F 26 7 C Altitude 7546 ft 0 to 2300 meters Atmospheric pressure 74 6 kPa e Ambient operating environment Temperature 15 6 to 32 20 C 60 to 900 F Relative humidity 8 to 80 Storage and shipping packaged printer with or without print cartridge Temperature 40 to 110 F 40 to 43 3 C In some cases performance specifications such as paper OCF EP cartridge usage are measured at an ambient condition General information 1 5 7541 03x Performance The X925 printers support up to 30 ppm Letter and 30 ppm A4 maximum print speeds Actual performance depends on Interface to host parallel serial USB or network Host system and application Complexity and content of the page Certain options added to or selected with the MFP Available memory in the MFP Media size media type and tray source Print Resolution Note The following special cases that may impact print speeds Vinyl Label Vinyl Label is a customer selectable media type When Vinyl Label is selected print speed is 35ppm Note When using custom size media it is critical that the user define the actual width via the Pape
132. I VPQR FI EESTI ga 4 6 Real COVE cuius auis ioc aA dannes QUARE CAH ORT ERE RR OC RO odo o Ro A RR c RC C a CR RUN 4 7 Front op panel COVER ius dita sies eai ee Ege E ROGER Geeks elem ERE QA ANE ER Rin dE a NA AE 4 11 Op paneltoD COVE iinscesucieankkaewkka e RRS4RRURG teori AR OG RRIGGU REA Pe REA p ARES 4 13 Ob panel HONOM COVE ooi xod sd Rr Added iquEM MA A RR BENE BEC NUES NE Ed ERE RUE RE 4 15 Upper ndht COVE saves exta kae Rack Pa Qoa V A a EE ORE ENDE whe deo edo d 4 16 Output bin print engine top cover eseseseeeeeees pan RII III Ih 4 17 B ck CAVE CONG ossors x pack ER d d hA Rad RA ERU seta es Redes End AR or RO de do dr 4 18 viii Service Manual 7541 03x Inner right Cover iis ace xoxo ORO REOR E ICD Lee RC CC eRe eee eee es 4 19 Lett Covel removal na saa Ed a ERR teeta s Cone dene DC OD NE Ud RO E AL CR tee 4 22 Speaker removal iciioences x e xg REA REAGAN REA ideede REEGzARRQEPEGXGS PEGGE eae 4 25 TOBTOITOUMS ari Eu qa dau bd Qe didus dod adit dd rbd d Qerd id nes Rd NR BONN PRI EE NE ERE E AP ME Rd 4 26 Output bin full sensor actuator removal leeeeeeeeeeee nnn 4 26 LED assembly FO GVBl uud xiva iien cea EE ERE sre Red e iE Pd REN LEER ses 4 29 LED print head removal uses eas ka hA eR RRRERd OE RR RR ARD REG RES Rd eK 4 31 Op panel paper exit guide removal eeeeeeeeee RR I nh 4 32 Paper exit quide reimoval o 0 6c cies ae eters kayak wa Rok RUE s EAR wae EUR ORE wane eee 4 33 Bin Tul
133. Idle roller w shaft eee ee 7 11 40X6534 Scan sensor w paper in sensor r rrr errr rere eee eee eee ee 7 11 40X6535 Scan sensor actuator 2 0 0 eee eee ee eee eee eee 7 11 40X6536 Spur G36T gear rrr errr r er eee eee eee eee eee eee eee 7 11 40X6537 Spur G63 27T gear 0 eee errr eee ere eee eee eee eee eee 7 11 40X6538 Spur G28T gear rrr eee rere eee eee eee eee eee eee 7 11 40X6539 Paper in sensor actuator 7 11 40X6540 Paper present sensor actuator 7 11 40X6541 Cover open sensor actuator eee eee 7 11 40X6542 Release arm rrr rrr reer rr eee re eee eee eee eee ee ee 7 9 40X6543 Idle pulley roller 2 2 ee ee eee eee 7 9 40X6544 Idle clutch roller 2 eee eee eee ee eee eee 7 9 40X5545 ADF hil se enne ect dn sina an E i E E dais kee Gna Due mda Ud ee an 7 5 40X6547 Separator roll lock rrRRIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII0 7 11 40X6548 Optical paper size sensors eee rere eee eee eee eee eee 7 7
134. LEVELM OO 16 LEVELM O1 17 LEVELM EO 18 LEVELM E1 19 LEVELC OO 20 LEVELC O1 21 LEVELC EO 22 LEVELC E1 23 LEVELK OO 24 LEVELK O1 25 LEVELK EO 26 LEVELK E1 27 FEED2 28 SBSY 29 GND RESRT 30 STATUS 31 FDRDY 32 CPRDY 33 STCLK 34 START 35 CBSY 36 PPRDY 37 STCLK 38 READY 39 COMMAND 40 GND J12 Printhead controller board 1 VCLK M 2 GND 3 VCLK Y 4 GND 5 VCLK C 6 GND 7 VCLK L 8 GND Locations 5 9 7541 03x Printhead controller connectors CN21VCLK CN8THET 8 1 1 00000000 ooooo 3 ooo CN4 HDK CN14 COLR CN16 POWR2 o0000000 CN15 POWR1 CN22 RIP Q O o e e 9 o O 00000000 CN2 HDC CN17 TONRCK B30 CN10 FROM OOooooooooo O O o CN12 SFLASH oooo0oo0000 CN3 HDM CN13 OPTN oooo0oo0000000 CN18 TONRYM O ooooo0oo0oo0000 O CN5 MDC loooo 00000000000000 CN9 TERM CN1 HDY 23 244 1 1 CN20 PRGC coo 900000 0000000 7 CN6 FUIN CN7 PSW CN19 FUSR 1 5 10 Service Manual Printhead controller board 7541 03x Connector Connects to Pin no Signal
135. LK E1 27 GND 28 FEED2 29 SBSY 30 FPF 31 STATUS 32 FDRDY 33 CPRDY 34 START 35 CBSY 36 PPRDY 37 STCLK 38 READY 39 COMMAND 40 GND 5 18 Service Manual 7541 03x Engine board connectors Q CN18 CN19 CN20 DS M DS C DS K CN17 DS Y CO ooo0 o Oooo G Goo CN24 POWR CN25 PFAN gt a m O OO THU oooo ooo O CN15 BELT CN22 CFAN O O CN27 PWOFF oo T oooo CN4 TEMP oooo CN1 TERM O 0000 oo0oo000000 O FFAN LIFT pgs O ooo gt n oo CN23 DRSW CN16 FEED ooooooQ CN21 CN6 _CN10 CN8CLUT oo0o0000 000000000000 Co 20 CN5 1992000 SIZEC CN9BEUD cN12 PRGSNS CN2 MAIN e sil 2 Z IN O oO D s Sz iE zo o 6 e l T OT oO LL RE gt CN28 tfo o i S no 8 3 _ 3 2 DUPIN CN29 O Q T 5 19 Locations 7541 03x Engine board Connector Connects to Pin no Signal CN1 N C CN2 Printhead Controller LDPRG PRGSW5V THETA LED GND PCZCNG HTNB1 GND MOTOR CLK4
136. NS 40X6372 NS 40X7447 Lower registration spring Upper registration spring Feed roll Feed roll gear Pickup gear Pick roll Separator roll Torque limiter Pickup lever A Registration sensor cable Upper registration spring Lower registration spring Paperfeed clutch Paperfeed clutch cable Paperfeed unit motor Engine paperfeed cable Paperfeed maintenance kit J RH I INI IN NI INI IN I INI IN I N J N Poo fe e O S S e a e a E S e G r E E E e e a e a e e e a a e A E E S E T Paper feed screw parts pack Parts catalog 7 25 7541 03x ical 1 Electr Assembly 13 7 26 Service Manual 7541 03x Assembly 13 Electrical 1 Asm Part Units Units index number mach FRU Description 1 40X6211 1 LV fuser power cable 1 40X6440 HV fuser power cable 2 40X6197 Theta sensor 3 40X6198 Theta sensor cable 4 40X6264 Sensor B S cleaner 5 40X6371 Main power button 6 40X6213 Insulation seal 7 40X6204 110 V Low voltage power supply 7 40X6424 220 V Low voltage power supply 8 40X6747 Engine power supply cable 9 40X6210 Power supply fan cable 10 40X6926 11 40X6753 12 40X6752 13 40X6750 13 40X6751 14 40X6749 15 40X6263 16 40X6266 17 40X6265 18 40X6199 19 40X6201 20 40X6202 21 40X6203 22 40X6428 23 40X6206 24 40X6205 25 40X6425 26 40X6748 27
137. Paper Jams 34 Short paper messages or other paper feed problems occur check the paper size in the tray against the size the printer thinks is loaded You can view the paper size in the Paper Menu Multipurpose feeder The MFP holds about 50 sheets of 20lb paper and does not have automatic size sensing the size must be set within the Paper Menu Diagnostic aids 3 41 7541 03x Feeding paper from a tray The printer controller sends a signal to turn on the paper feed clutch the pick roll grabs the top sheet of paper while the separator roll rotates backwards to prevent multiple sheets of paper from feeding The paper moves to the feed roll and is fed into the paper path Regisration roll OUT Std Registration Transport Clutch raner IN Paper feed motor Paper feed clutch d Feed roll Pick roll Separator roll torque limiter Pick roll Feed roll Normal feed EA VA B Or Separator roll Torque limiter Friction A gt B Multi feed Friction a gt b gt c 3 42 Service Manual 7541 03x Feeding paper from the MPF To start the paper feed the printer controller sends a signal to turn on the MPF feed clutch the paper feed motor starts turning to feed the top sheet of paper in the MPF tray one by one Once the duplex exit MPF detection lever senses the leading edge of the media at the duplex exit roller it engages the duplex re feed clutch to transport the sheet of paper into the paper path Duplex
138. Paper at 1 3 1 3 1 5 Sb 202 4 o Li 3 6 DO 2 2 Fez Slo 4 314 3 9 pT 3 p Z Paper mo SQ bo cO 0 1 3 2 Paper volume Li e eo z o Door interlock Lower UL2 Interface Locations 5 35 7541 03x Option board layout IC100 IC Socket __ CN108 CN103 5 36 Service Manual ASSY NO CN105 CN106 O Option board connector values Conne ctor AY 5 Signal Signal Pin Connect or Parts Name CN101 IB VAA 24V B IA VAA 24V A Transport Motor CN102 VAAISW N C Cover Open VAA 24V CGND Cover Open sw CN103 CGND Paper Full Sensor VCC 5V CGND Transport Sensor VCC 5V CGND Paper Empty Sensor VCC 5V pikas Paper Overload Sensor Transport Sensor Out of Paper Sensor CN105 SIZE 3 SIZE 2 CGND SIZE 1 SIZE 0 mo alo o 5 ov Ni co co e AIo v 25 o w 5 e m 2 o v mo 0 no n gt py 09 CN105 SIZE 3 SIZE 3 SIZE 2 CGND Size detect SW CGND SIZE 2 SIZE 1 CGND Size detect SW ajsan lason gt 00 NO cn o PO OB 0 S o on i oo N C SIZE_4 CGND FDE INET nls S meo 8 os os 1 oo co B
139. Paper trays 32s ci c4 cede cde add eudd oad Boos GS eee Berto St eS Iu eeeawess 7 34 Assembly 18 Fuse iso iaie PRA Sidi dam ieee tos bos pte bd dead dedii 7 36 Assembly 19 550 sheet option feeder covers 00 0 cece tees 7 38 Assembly 20 550 sheet option feeder base 0 cece eese 7 40 Assembly 21 550 sheet option feeder paper feed iiliiliilellseel eee 7 42 Assembly 22 550 sheet option feeder tray 0 0 cee esee 7 44 Assembly 23 Maintenance kits power cords and options 0e esses 7 46 j MC AEDES wh O WEDS CERT E E DLE OETA EN ET l 1 Far mmber Be eaa dada d x40 940 d Avr do EAR ROCA 8 D 3 Ro CRACK WOO A Rd l 7 xii Service Manual 7541 03x Notices and safety information This device is an LED based printer Notices and safety information Xiii 7541 03x XiV Service Manual 7541 03x 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 Professional service personnel should understand this and take necessary precaut
140. See HVPS removal on page 4 111 2 Disconnect all the cables from the engine board 3 Remove the screw A from the upper right corner Repair information 4 75 7541 03x 5 Remove the screw C from the upper left corner J D 7 Pull the board and frame away from the printer frame 4 76 Service Manual 7541 03x Drive unit cover not a FRU 1 Remove the HVPS unit See HVPS removal on page 4 111 2 Disconnect the drive unit motor cables from CN 17 18 19 and 20 on the engine board 3 Remove the screw A from the upper right corner 4 Remove the screw B from the lower right corner Repair information 4 77 7541 03x 5 Remove the screw C from the upper left corner D 6 Remove the screw D from the lower left corner C 7 Slide the drive unit cover away from the drive unit being careful to avoid damaging the contact springs on the sub unit 4 78 Service Manual 7541 03x Drive unit 1 Remove the plastic drive unit cover See Drive unit cover not a FRU on page 4 77 2 Remove the engine board and engine board mounting bracket See Engine board and mount removal not a FRU on page 4 75 3 Disconnect the drive motor wiring harnesses from the engine board 4 Remove the three screws A in the upper left corner Repair information 4 79 7541 03x 6 Remove the screw C between the two rightward motors C 4 80 Service Manual 7541 03x 8 Push the fan
141. This is a reflective sensor that determines paper position in the paper path and activates the actual scan image process 7 When the ADF scan sensor is actuated the paper advances to the scan area While the paper is advancing to the scan area the ADF motor generates pulses which are stored in an on board counter These counts along with the ADF scan sensor ensure that the media is travelling at the correct speed through the scan area The speed the document travels through the ADF scan area is dependent on the image DPI specified by the user 8 After a predetermined number of counts the media reaches the scan area and the image acquisition process is initiated While the image acquisition process is executing the ADF scan sensor is being polled to determine if the trailing edge of the media has reached the sensor 9 Once the trailing edge of the scan media has reached the ADF scan sensor that sensor goes to the off position After the ADF scan sensor is switched off the image acquisition process continues for a predetermined length of time 10 When the image acquisition process is completed the trailing edge of the media continues to the reverse point The duplex gate will be position by the gate solenoid to direct the paper to the pass through sensor Diagnostic aids 3 47 7541 03x 11 The duplex gate is moved into position by a solenoid After passing through the gate the paper reaches the paper pass sensor The paper pass sensor pe
142. a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace both of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer it cannot be used in another printer It must be returned to the manufacturer CAUTION POTENTIAL INJURY There is danger of explosion if a lithium battery is incorrectly replaced Replace it only with the same or an equivalent type of lithium battery Do not recharge disassemble or incinerate a lithium battery Discard used batteries according to the manufacturer s instructions and local regulations Remove the RIP cover See RIP cover on page 4 5 Disconnect all the cables from the board Remove any ISP options that are installed Remove the modem See Modem removal on page 4 94 Remove the two screws A securing the USB ports to the RIP cage nodum Repair information 4 73 7541 03x 6 Remove the fourteen screws B securing the RIP board to the RIP cage Crossbar removal not a FRU 1 Remove the RIP cage 2 Remove the five screws A securing the cross bar to the rear EMI shield and the vertical scanner supports 4 74 Service Manual 7541 03x Engine board and mount removal not a FRU 1 Remove the HVPS unit
143. a 2 24 Paperfeed unit service check 0 cece cece eee ee eee eee eee eee eee enone 2 27 MPF service Check 15s mn GRE RERO RR Oe EE Re eR 2 28 Clearing and resolving scanner jams seseseeeeee eee n nnn nnn 2 29 20006 Paper missing cee otl etr on ded dad qd oe P Se E Pda gae quite qa idu 2 29 283 01 Scanner static jam Scar sensor jal lt cc csecccesedtareocsac Race 3d Rx AE dE 2 30 2B3 05 SCHITEORSOK ART 6 ucro tate leder tree e x ere hl senem doe Gere RP pande oe Rp pci ed 2 31 2B5 05 Scanner ADE elect ANY ord deae qt eo doe URS E Le urn se XE LR Ga 2 32 290 11 Scanner ADF cover operr dlfi 2 ccoceccean ttis eumd ied hex Gr ES aad dre awe 2 33 291 05 Flatbed COVSI ODBII ciii ERE padethseedeedeka A edad E Ra d bsedd abe 2 35 292 01 Scanner carriage locked L4 cover ORE RE Ren RREPEEPd n ep PUES EP HR be YE 2 35 ADF paper jam service Check amp i sasc nRk enkRSARRERECAKEEXAWRQ ed Dee eee RUND 2 36 EHOFOCOU S vast cee rns box aos dob EUR RSEI EUN BR RO RR RR BUR e ib bale di UG ERR OA woe eens 2 38 149 01 Abnormal exit motOE xh mmm Reeds ADR ROS ERA SRO ROUES EERE KREMER 2 38 941 05 Abnormal EEPROM ccccccece caren nar mra E RID EPI ERIS E apa 2 39 950 xx Service NCVRAM Mismatch 0 00 eee cee eee eee Rn n n nn nnn 2 39 952 xx GErvice NV Faure ic said daw Sdat adde RA PAPE CE QE MD AS SES RIdREDLTPNA NE 2 39 953 xx Service NVRAM Fail re ise enu Rr arr Rar BER ERR EZes4RRRER ERE AE 2 39 954 xx Service NVRAM Falie
144. ally executes 2 Press Stop X to cancel the test Diagnostic aids 3 21 7541 03x Button Test This test verifies the operator panel button function To run the Button Test 1 From the Diagnostics menu navigate to HARDWARE TESTS gt Button Test With no buttons pressed an image the operator panel buttons is displayed Press each operator panel button one at a time and the button in the illustration turns blue 2 Press Stop X or touch Back to exit the test DRAM Test This test checks the validity of DRAM both standard and optional The test repeatedly writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly To run the DRAM Test 1 From the Diagnostics menu navigate to HARDWARE TESTS gt DRAM Test DRAM Test Testing appears on the screen followed by Resetting the Printer After the printer resets the results of the test appear DRAM Test x MB P HHHHH FAHHHEHBE x represents the size of the installed DRAM P represents the number of times the memory test has passed and finished successfully with the maximum pass count being 999 999 F represents the number of times the memory test has failed and finished with errors with the maximum fail count being 999 999 Once the maximum pass count or fail count is reached or once all the DRAM has been tested the test stops and the final results appear 3 22 Service Manual 7541 03x Serial Wrap Test Use
145. am cleared 201 paper jam 1 Open the right side cover 2 Determine where the jam is located and remove it a lf the paper is visible under the fuser grasp it on each side and pull it out p b If the paper is not visible remove the fuser and remove the jam See fuser removal 2 18 Service Manual 7541 03x 3 Remove the jammed paper 4 4 Close the right cover 5 Press Continue jam cleared 203 paper jam 1 Grasp any jammed paper that is visible in the exit bin and gently pull it out Note Make sure all paper fragments are removed If the page is in the fuser the fuser nip release lever should be lowered After removing the jammed page return the lever to the proper position 2 Press Continue jam cleared Diagnostic information 2 19 7541 03x 230 paper jam 1 Open the right cover 2 Liftthe duplexing unit mechanism away from the cover 3 Remove any jammed paper 4 Lower the mechanism 5 Close the right cover 6 Press Continue jam cleared 2 20 Service Manual 7541 03x 231 39 paper jam 1 Open the right cover 2 Lift the duplexing unit mechanism away from the cover 3 Remove any jammed paper 4 Lower the mechanism 5 Close the right cover 6 Press Continue jam cleared Diagnostic information 2 21 7541 03x 24x paper jam Jam in tray 1 1 Open the right cover and pull any jammed pages out 2 Open Tray 1 ad pull the jammed pages up and
146. and right cover 2 Lower the MPF tray 3 Remove the MPF roller cover 4 Slide the MPF coupling to the left Repair information 4 185 7541 03x 5 Take the MPF shaft out 4 186 Service Manual 7541 03x MPF pad removal 1 Remove MPF tray See MPF tray assembly removal on page 4 175 2 Gently pull the right side of the pad holder cover and disconnect it from the mount A A 3 Gently pull the left side of the pad holder cover and disconnect it from the mount B Repair information 4 187 7541 03x 4 Remove the right screw C securing the outer pad holder to the MPF unit C 5 Remove the left screw D securing the outer pad holder to the MPF unit 4 188 Service Manual 7541 03x 6 Pull the outer pad holder away from the machine 7 Carefully lift and remove the pad from the pad holder Note Reuse the spring that was between the pad and pad holder Repair information 4 189 7541 03x Exit guide paper exit roll removal Note You will need to remove the drive gear spring and washer on the paper exit roll and place it on the new paper exit roll 1 Remove the paper exit unit See 2 Remove the e clip A that fastens the exit unit roll to the paper exit unit 3 Remove the bushing B 4 190 Service Manual 7541 03x 4 Remove the e clip C securing the drive gear to the shaft 5 Remove the drive gear D from the shaft Repair information 4
147. and the wall jack 2 Properly connect the phone line to the Problem resolved Go to step 3 modem card and wall jack Did this fix the problem 3 Test the phone line s ability to send and Go to step 5 Go to step 4 receive calls Did the phone line work properly 4 Use the MFP on a properly functioning Problem resolved Go to step 5 phone jack Did this fix the problem 5 Is the modem card cable properly Go to step 7 Go to step 6 connected to the system board at J8 and the modem card 6 Properly connect the modem card cable Problem resolved Go to step 7 to the modem card and system board Did this fix the problem 7 Check the modem card cable for Go to step 8 Replace the modem continuity Is there continuity card cable 8 Check the voltages from connector Replace the modem Replace the RIP board JMODEM1 on the RIP board Check Pin card See RIP board 10 3 3VDC Pin 10 for 5VDC 2 4 6 removal on and 8 are grounds Are the signals or page 4 73 voltages present Fax dials a number but no connection is made The other fax machine may be turned off Ask the fax recipient to check their machine Diagnostic information 2 83 7541 03x Other service checks Networking service check Note Before starting this service check print out the network setup page This page is found under Menu Reports Network Setup Page Consult the network administrator to verify that the physical and wireless network settings dis
148. aper jam 230 231 9 FRU Action 1 Feed rollers Belts Check for wear or damage to feed rollers and belts 2 Duplex unit Be sure the duplex unit is properly installed and that all connections on the engine board CN 28 29 13 14 are correct 3 Duplex clutch Be sure the clutch turns freely with no binding and it is properly installed Check for wear or damage to the associated gears Replace as necessary 4 Feed roller solenoid assembly Paper re feed solenoid assembly Check for proper operation of the solenoid and linkage Replace as necessary 5 Paper tray Check to see if the paper edge guides have shifted If so re time by removing the screw and gear from the bottom of the tray and pushing the paper edge guides up against the paper lift plate Reinstall the screw and gear 2 26 Service Manual Paperfeed unit service check 7541 03x Note These tests can also be performed on the expansion paper feed units FRU Action 1 Door open interlock switch Paper tray level motor Printer controller board Turn the printer on Open the door Check the operator panel for Close Door message Bypass the door open interlock switch Pull out and replace the cassette Listen for the paper tray level motor to activate The tray may or may not rise The motor makes a low pitched vibrating sound f the paper tray level motor operates and the
149. ard 40X6337 2 2 een ne ee eee 7 46 Argentina powercord 40X0288 errr reer ee eee eee eee ee eee 7 46 Austrailia 8ft straight powercord 40X0301 2 rrr eee ee eee eee eee eee 7 46 B B S carrying roller 40X6153 r rlllllllllleelllll lll llle 7 13 B S link arm 40X6269 22 een nn nn ne eee eee 7 3 B S link arm spring 40X6273 enn nn llle llle 7 3 B S pushing spring 40X6135 eee nn nn eee 7 15 Base 1 screw parts pack 40X7052 2 2 2 een nn en ee eee 7 19 Base 2 screw parts pack 40X7442 2 2 eee ee eee ee eee ee ee eee eee eee ee ee 7 21 Belt motor 40X6162 3 2 oe nnn ne re en en ne eee 7 19 Belt motor cable 40X6262 22 ee nn rn nn en nn eee 7 19 belt motor cable 40X6262 22 eee nn nn en en nn eee 7 29 Bottom foot 40X6175 9 2 ene nnn rn en en ne eee 7 23 Brazil powercord 40X4596 2 2 2 ee eee eee eee eee eee eee eee 7 46 C C S carrying roller 40X6154 r ll lllllllllllelll llle llle 7 13 Carry cover 40X6257 ne enn ene 7 13 Cassette screw parts pack 40X7451 2 22 eee ee eee eee ee eee eee eee eee 7 35 Chile Uraguay powercord 40X0273 een renner eens 7 46 Complete duplex 40X6126 2 ener nn ene 7 3
150. ards and POR the machine Does the Go to step 3 Go to step2 printer work normally 2 Replace the RIP Does the printer work normally Go to step 3 Contact your second level support 3 Replace the cards and POR the machine until the Go to step 4 Problem solved error is replicated Did the error replicate itself 4 Checkthe ISP connector cable connected to the failed Go to step 6 Go to step 5 card for continuity Is there continuity 5 Replace the connector cable Did this fix the problem Problem solved Go to step 6 6 Replace the ISP card that triggered the error when it Problem solved Go to step 7 was added Did this fix the issue 7 Replace the RIP Did this fix the issue Problem solved Contact your second level support Serial port Run the Serial Wrap Test on page 3 23 Note The Serial Wrap Test is designed to check the serial port hardware by using a wrap plug P N 1329048 and invoking the Serial Post Diagnostic Test The test helps isolate the printer from the serial cable and host computer The test provides failure information on the display for approximately three seconds If the test indicates a problem replace the option card If the problem continues replace the RIP board Flash options 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 Be sure the memory card assembly is
151. arm MPF roller bushing Cover 1 screw parts pack a o2 2 o2 42 42 2 42 42 42 42 2 42 42 2 42 42 42 4 4 p a NIN FS ms Ss PO Ss ss A es aes es ef et Parts catalog 7 15 7541 03x Assembly 8 Paper exit 7 16 Service Manual 7541 03x Assembly 8 Paper exit Asm Part Units Units Description index number mach FRU 1 40X6579 1 1 Paper exit roller 2 40X1104 8 1 Photo sensor exit sensor 3 40X6168 1 1 Exit sensor cable 4 40X6745 1 1 Paper exit guide Parts catalog 7 17 7541 03x Assembly 9 Base 1 7 18 Service Manual Assembly 9 Base 1 7541 03x Asm Part Units Units index number mach FRU Description 1 40X6173 1 1 Main unit drive 2 40X6261 1 1 Photo interrupter cable 3 40X1104 8 1 Photo sensor 4 40X6160 1 1 Sub frame 5 40X6162 1 1 Belt motor 6 40X6262 1 1 Belt motor cable 7 40X6161 4 1 Drive unit motor NS 40X7052 1 1 Base 1 screw parts pack Parts catalog 7 19 7541 03x Assembly 10 Base 2 7 20 Service Manual Assembly 10 Base 2 7541 03x Asm Part Units Units index number mach FRU Description 1 40X6163 1 1 Sub unit drive 2 40X6742 1 1 Fuser fan 3 40X6170 1 1 Fuser duct 4 40X6355 1 1 Exit solenoid bracket 5 40X6165 1 1 Exit drive unit solenoid 6 40X6368 Engine power supply Door interlock cable 7 40X6166
152. arts a progress bar appears The test cannot be stopped or canceled once it has begun 3 Once the test is complete the power indicator turns on solid and a message appears indicating whether the test passed or failed Press Stop X to return to DEVICE TESTS 3 24 Service Manual 7541 03x Flash Test This test causes the file system to write and read data on the flash to test the flash Warning This test destroys all data on the flash because the flash is reformatted at the end of the test 1 Select Flash Test from DEVICE TESTS From the Diagnostics menu navigate to DEVICE TESTS gt Flash Test A Contents will be lost warning appears 2 To exit the test immediately and return to DEVICE TESTS select No and touch Submit To continue with the test select Yes and touch Submit When the test starts a progress bar appears The test cannot be stopped or canceled once it has begun 3 Once the test is complete the power indicator turns on solid and a message appears indicating whether the test passed or failed Press Stop X to return to DEVICE TESTS Input Tray Tests This test determines if the printer can feed media from any of the paper input sources Each of the installed Sources is available within the Input Tray Tests menu To run the Input TrayTest 1 From the Diagnostics menu touch INPUT TRAY TESTS 2 Select the input source 3 Select either Single or Continuous Note If Single is selected no buttons are active whil
153. ash screen appears The Configuration menu group contains a set of menus settings and operations which are infrequently required by a user Generally the options made available in this menu group are used to configure a printer for operation See Configuration Menu on page 3 9 for more information Network SE menu While in Network Ports Menu press and hold 9 7 and 6 SE menu At the printer perform the following steps 1 In the Admin menu navigate to Network gt Ports gt Standard Network gt Std Network Setup menu 2 Press and hold 9 7 and 6 3 Release the buttons when the Network SE Menu appears From a browser add se to the device IP address for example http 158 183 3 2 se THe MFP does not need to be restarted to enter this menu Invalid engine code mode 1 Turn off the printer 2 Press and hold 3 4 and 6 E N G 3 Turn on the printer 4 Release the buttons when the splash screen appears This mode is used if the machine has invalid code and needs the correct code loaded After entering this mode the firmware code can be updated Diagnostic aids 3 7 7541 03x Recovery mode 1 Turn off the printer This mode will allow the printer to 2 Press and hold 2 7 and 8 boot from a secondary set of instructions to allow a code flash 3 Turn on the printer to the printer Code can be 4 Release the buttons when the splash screen flashed from
154. ay1 2 95 Wrong paper size service check tray2 2 95 7541 03x Part number index P N Description Page 1 GB DDR DRAM DIMM 40X5303 2 eee eee eee eee eee eee ee eee eee 7 46 110V Fuser 40X6013 cnm c III rr rrr ree 7 37 160 GB hard drive 40X7058 2 0 e eee e eee eee eee 7 46 2 s transfer spring 40X6150 22 eee eee ee eee eee 7 13 220V Fuser 40X6093 e rrr rrr rrr rrr rrr rrr rrr rrr ree 7 37 256 MB NAND flash card feature 40X5704 7 46 256M DDR DRAM DIMM 40X5301 0 02 crc eee eee ee eee eee eee ee 7 46 300k paperfeed maintenance kit 40X6372 7 46 40X1104 Photo sensorr 2 20 er ee eee eee eee ee eee eee eee eee 7 13 40X1173 Photo interrupter Horizontal sensor 7 39 40X1431 Card reader screw packet rrr r rrr 7 46 40X4602 3121 card reader 20 0 2 ee ee eee eee 7 46 40X4603 5121 card reader 22 eee rr rrr rrn 7 46 40X4604 5125 card reader 2 2 e eee eee eee eee 7 46 40X5867 ADF screws and fasteners parts pack
155. bly NS 40X6314 1 1 Cave light cable NS 40X6744 1 1 Op panel under cover used on 40X6743 NS 40X6293 1 1 Upper paper exit cover used on 40X6743 NS 40X6499 1 1 Cover 1 screw parts pack Parts catalog 7 3 7541 03x Assembly 2 Flatbed and ADF 7 4 Service Manual Assembly 2 Flatbed and ADF 7541 03x Asm Part Units Units Describtion index number mach FRU Pp 2 1 40X6545 1 1 ADF unit whole unit 2 40X6980 1 1 Flatbed whole unit Parts catalog 7 5 7541 03x Assembly 3 Flatbed 7 6 Service Manual Assembly 3 Flatbed 7541 03x Asm Part Units Units Description index number mach FRU 1 40X6320 1 1 Flatbed upper cover 2 40X6321 1 1 CCD chassis 3 40X6323 1 1 30 pin FFC ribbon cable 4 40X6324 1 1 18 pin FFC ribbon cable 5 40X6322 1 1 ICC PCBA 6 40X6973 1 1 UICC User interface controller card 7 40X6957 1 1 Button assembly op panel top 8 40X6959 1 1 Op panel access cover 9 40X6958 1 1 Op panel bottom 10 40X6307 1 1 10 2 inch touchscreen display w haptics 11 40X6978 1 1 Flatbed front cover 12 40X6443 1 1 Model name cover 13 40X6326 1 1 CCD belt 14 40X6548 3 1 Optical paper size sensors 15 40X6325 1 1 Flatbed cover open sensor NS 40X6977 1 1 Op panel light pipe NS 40X6757 4 1 Scanner rubber pad NS 40X6758 4 1 Scanner stopper screw NS 40X6759 4 1 Scanner sub rubber screw NS 40X6760 4 1 Dimension screw NS 40X7117 1 1 Speaker assembly NS 40X6306 1 1 UIC
156. board B 3 Pull the modem up and inward to remove it from the cage Papertray lift motor removal 1 Remove the HVU See HVPS removal on page 4 111 2 Remove the rear fan See Rear fan on page 4 102 4 94 Service Manual 7541 03x 3 Disconnect the cable A from the DC Geared motor 4 Remove the three screws B securing the paper tray lift motor to the frame RIP cage removal Note The RIP board does not need to be removed to perform this procedure 1 Remove the rear cover See Rear cover on page 4 7 2 Disconnect all the cables from the RIP board 3 Remove the screw A securing the bottom of the RIP cage to the rear EMI shield and crossbar Repair information 4 95 7541 03x 4 Remove the two screws B securing the upper left corner of the RIP cage to the EMI shield B 5 Remove the six screws C on the inside of the RIP cage 4 96 Service Manual 7541 03x Toner sensor removal 1 Remove the drive unit See Drive unit on page 4 79 2 Remove the printhead controller board Printhead controller board removal on page 4 37 3 Remove the three screws A securing the board stay to the printer frame 4 Remove the five screws B securing the head pin plate to the printer frame Repair information 4 97 7541 03x 5 Remove the ten screws C securing the top support rail not a FRU to the top frame 6 Remove the four printhead assemblies See LED assembl
157. bracket to the frame 4 Remove the one screw B securing the interlock switch to the bracket 4 202 Service Manual 7541 03x Paper feed clutch removal 1 Remove the screw A securing the right front cover Remove the screw B securing the right rear cover Remove the screw C securing the right rear switch cover Remove the two screws D securing the vertical transport guide rail Remove the vertical transport cover Remove the two screws E securing the right middle cover Remove the screw F securing the vertical transport guide plate Set SS Repair information 4 203 7541 03x 8 Remove the two screws G securing the rear cover to the option feeder 9 Remove the left and right drum stays H E T es OSL 10 Remove the clutch 4 204 Service Manual Adjustments 7541 03x Calibrating the scanner After replacing any of the following components you must reset the scanner calibration values and check the black levels of the scanner Flatbed scanner assembly ADF unit assembly Flatbed scanner CCD assembly Resetting the calibration values Note If the printer menus do not match the following instructions then contact your next level of support 1 Enter the Diagnostic mode press and hold 3 and 6 turn on the printer and release the buttons when the splash screen appears 2 From the Diagnostics menu navigate to SCANNER CALIBRATION gt sel
158. cels out of a screen and return the previous screen Return Navigates back to the previous screen Unselected radio button Indicates that an item is not selected 3 4 Service Manual 7541 03x Icon Selected radio button Indicates a selection Index Displays information about the key functions of the printer including instructions on how to operate it C C ET Search Lets you search for files and menus ge Warning A Indicates a warning or error condition Diagnostic aids 3 5 7541 03x Administrative menus See the menu map for a brief overview of the printer menus available from the operator panel Select a menu or menu item for more details Unit Unit Fuser Supplies Menu Replace Supply Cyan Cartridge Magenta Cartridge Yellow Cartridge Black Cartridge Cyan Imaging Unit Magenta Imaging Yellow Imaging Black Imaging Unit Paper Menu Default Source Paper Size Type Configure MP Substitute Size Paper Weight Paper Loading Custom Types Custom Names Universal Setup Waste Toner Bottle Transfer Module Maintenance Kit Security Miscellaneous Disk Wiping Security Settings Confidential Print Security Audit Log Set Date and Time 3 6 Service Manual Settings General Settings Copy Settings Fax Settings E Mail Settings Flash Drive Menu Print Settings Setup Menu Finishing Menu Qualit
159. clip B that fastens duplex clutch to the carrying shaft 4 172 Service Manual 7541 03x Duplex timing belt removal 1 Remove the duplex clutch See Duplex clutch removal on page 4 172 2 Remove the timing belts Duplex exit MPF sensor removal POND Remove the duplex unit See Duplex removal on page 4 63 Remove the duplex exit MPF sensor actuator Disconnect the sensor harness Pinch the tabs C that secure the sensor to the duplex unit Repair information 4 173 7541 03x MPF clutch removal 1 Remove the duplex unit See Duplex removal on page 4 63 2 Remove the two screws A securing the MPF clutch cover to the duplex unit B Remove the e clip B securing the clutch to the MPF shaft Remove the MPF shaft C Remove the MPF paper empty lever D Remove the MPF clutch MARW 4 174 Service Manual 7541 03x MPF tray assembly removal 1 Open the MPF tray 2 Slide the MPF arm up to the opening on the tray A 3 Pull the arm out of the tray 4 Repeat steps 1 and 2 for the other arm 5 Remove the MPF roller cover Repair information 4 175 7541 03x 6 Lift and pull the tray away from the printer 4 176 Service Manual 7541 03x Paperfeed unit component removals Note The paperfeed separator and pick rolls are part of the 300 000 page maintenance kit See the Paperfeed maintenance kit removals on page 4 182 for removal instructions
160. control customizable reports and access to the growing list of downloadable and customizable solutions A variety of connectivity options enable the printer to be used in all types of system environments You can attach one internal adapter to support network configurations requiring Ethernet Token Ring LocalTalk serial infrared or additional parallel ports The printer also has flexible paper handling It supports a wide variety of paper sizes and has a standard multipurpose feeder that makes it easy to print on envelopes transparencies labels card stock and non standard size paper You can add optional inputs to the base printer which can increase the printer paper capacity to 2100 sheets Maintenance approach The diagnostic information in chapter two leads you to the correct field replaceable unit FRU or part Use the information to troubleshoot print quality paper jams user status messages error codes or general symptoms and then follow the instructions to repair the printer After you complete the repair perform tests as needed to verify the repair To begin diagnosing a problem see Diagnostic information on page 2 1 Models The Lexmark X925 7541 030 laser printer is available in the following models Lexmark X925 7541 032 10 e Task touch screen duplex Lexmark X925 7541 036 10 e Task touch screen duplex fax modem Lexmark X925 7541 096 10 e Task touch screen duplex fax modem
161. ctuator With the turn guide door open remove and reinsert the paper tray Ifthe paper feed roll fails to go up when the paper tray is reinserted replace the paper feed unit Ifthe actuator is broken replace the broken actuator If the actuator is good and the sensor was clean replace the paper level sensor Ifthe tray too full message is displayed clean or replace the sensor Diagnostic information 2 27 7541 03x FRU Action Relay sensor Paper feed clutch Bypass the turn guide door open sensor Turn the printer on while holding down the paper relay sensor If the operator panel does not display Paper Jam check for a dirty paper relay sensor f the paper relay sensor is clean or the actuator for the paper relay sensor is broken replace the sensor If the sensors are replaced and problem remains replace the printer controller board Check the clutch cables for proper connection to CN8 on the engine board and CN20 on the printer controller board Check the resistance of the clutch using a multi meter The resistance should measure 192 ohms If the clutch shows a significantly higher reading replace the clutch f you replace the paperfeed or transport clutches and the problem remains replace the engine board If replacing the registration clutch and the problem remains replace the printer controller board MPF service check FRU Action MPF tray
162. d Did this fix the issue Problem resolved Contact your second level support Wrong paper size service check tray2 Step Action and questions Yes No 1 Remove the tray and move the paper size guides to Go to step 3 Go to step 2 different positions Are the size pins moving when the length guide is moved 2 Try a different paper standard tray Did this fix the Problem resolved Go to step 3 problem 3 Checkthe sensor cables for proper connection to the Go to step 5 Go to step 4 sensors and engine controller board Are they properly connected 4 Properly connect the cables Did this fix the problem Problem resolved Go to step 5 5 Replace the sensors Did this fix the problem Problem resolved Go to step 6 6 Replace the engine controller board Did this fix the Problem resolved Contact your problem second level support Diagnostic information 2 95 7541 03x Paper in ADF size service check Step Action and questions Yes No 1 Check the sensors ADF long width 1 and width 2 for Go to step 7 Go to step2 proper operation 1 Enter the Diagnostics Menu 2 Touch SCANNER TESTS 3 Touch Sensor Tests 4 Observe the line sensor ADF long width 1 and width 2 Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 2 Checkthe ADF paper width sensor and ADF paper Go to step 4 Go to step 3 length
163. d and all framework and standard application settings are reset to factory default settings Energy Conserve When Energy Conserve is on the customer does not have access to disable the Sleep Mode function When Energy Conserve is off Disable appears as an additional menu item in the Sleep Mode menu This setting only affects the values that are displayed in the Sleep Mode menu Fax Low Power Support This menu has the following settings Auto The printer checks the Caller ID Pattern setting to determine if the fax chip should enter low power mode Permit Sleep The fax chip enters low power mode when needed regardless of the Caller ID Patter setting Disable Sleep tThe fax chip never enters low power mode Min Copy Memory This menu lets you select the amount of memory dedicated to storing copy jobs The values may be 25 MB 35 MB 50 MB 80 MB and 100 MB The default is 80 MB Values will be displayed only if the amount of installed DRAM is at least twice the amount of the value For example at least 200 MB of installed DRAM is required to display the 100 MB selection 3 12 Service Manual 7541 03x NumPad Job Assist When this setting is set to On a user can initiate scanner related jobs and enter values for a limited number of settings related to those jobs using the keypad Touch Back to exit without changing the setting Format Fax Storage This setting enables you to format the non volatile storage used for stor
164. dNB chaps hi S28 oe 44 IQPOPI SCRI AIRS 2898S X EE qddqaebcedd sey 2 76 Clipped image when scanning to USB from the ADF 0 0 0 0 eee eee eee 2 76 ADF Cover Open Service CHECK cc is hk d o ddch s Ed aide EA 6 p RD UE AEQ amd emmaaanms 2 77 Fox Symptoms oo oua tires CER deal ka dd ROCA GUION D a UR ACA CU KR Row o Pel boe Kod 2 78 Faxos Tall otras 2 32 sadips idea i ado be hoe re Sam ec and popa a epiboba adidas 2 78 Eso receptor Tall as a qoe ona 3p eed t opa Ee EP oa jette are dente A e poing ke 2 80 Escalating a fax issue to second level support 0 0 cece eee eee 2 82 Words on fax are stretched 1 sia aso ha kenit knee seal keen tEn ronnen eee 2 83 Incoming fax has blank spaces or poor quality eeeeeeenn 2 83 No dial tole 1iusoei auae suadere sd kudd aede x d dui dcn d A ER Ea Kd Ka pu WE a Ed E eels 2 83 7541 03x Fax dials a number but no connection is made leleleeeeee eee 2 83 DIher serves Checks ouiidnsam ink dada Esaiae iR eon li RRLA RUBRA RUD RR SUDO ER EAM 2 84 Networking Service CHECK i oaacea ache E d RR RAURA E RA CR Heo dit ERR de dob dC ACA do 2 84 DOpliomcard Service CHECK basesdndaseccdssResipBeitidmd sedes se Dg cde RO qued e ERE 2 86 USB portservice ChecK ui veces saci ssee ba ExRIR RES ERWUGRAR RA ER ERG ace duid iiia 2 86 False close door Service CheGK adio oa dada v RR E BAR P RE dba e dU A UE Sd dean 2 86 Operator panel service check seeeees
165. de uma potencial tens o perigosa na zona do produto em que est a trabalhar Antes de come ar desligue o produto da tomada el ctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente el ctrica para realizar a tarefa necess ria XVi Service Manual Informaci de Seguretat 7541 03x La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components espec fics El fabricant no es fa responsable de les questions de seguretat si s utilitzen peces de recanvi no autoritzades Lainformaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui e El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCI aquest s mbol indica que el voltatge de la part de l equip amb la qual esteu treballant s perill s Abans de comen ar desendolleu l equip o extremeu les precaucions si per treballar amb l equip l heu de connectar QUE AH Pee PAAY 58 tea Ht ase AERTS O usas HEA Td Ae ee Se a FUE WAS 92 9 WE AGS ALA SSE ee Ae let wT lar eee te 14 lee ARAM El WO Se HM ATL A Qs A A ALC 10 L A NL LE IC og T HH e ENESA
166. diately for the Single Stop tests 3 Select the desired Test Ports Tests Port 0 Test J Port 1 Test K Port 2 Test SEO NAK Port 3 Test Packet Single Stop Get Device Description Test Force Enable Single Stop Set Feature 4 To cancel the test turn the printer off DEVICE TESTS Note Disks or flash devices must be installed in order to perform these tests Quick Disk Test This test performs a non destructive read write on one block per track on the disk The test reads one block on each track saves the data and proceeds to write and read four test patterns to the bytes in the block If the block is good the saved data is written back to the disk 1 From the Diagnostics menu navigate to DEVICE TESTS gt Quick Disk Test The power indicator blinks while the test is in progress Quick Disk Test Test Passed appears if the test passes Quick Disk Test Test Failed appears if the test fails 2 Press Stop X or touch Back to return to the Device Tests menu Disk Test Clean Warning This test destroys all data on the disk and should not be attempted on a good disk This test may run approximately 112 hours depending on the disk size 1 From the Diagnostics menu navigate to DEVICE TESTS gt Disk Test Clean A Contents will be lost warning appears 2 To exit the test immediately and return to DEVICE TESTS select No and touch Submit To continue with the test select Yes and touch Submit When the test st
167. e KR ERR AEAN EQ ME CE EE RS 3 20 Print Tesis inpUt SOIN GBS cuscspurEem E II ERR E REO TRP T UICE QUERSPTQEA SO TRA EE 3 20 Print Quality Pages 4a 22s Spe a3 Spb AGUA dE tone E ESUERN a Dd RR 3 20 HARDWARE TESTS osie uia eror EPI Re ICE IS e REX E prbIrercSedca5e esessi qe 3 21 Panel LES e 3 21 B lol Test itis conns A E S E E NENE ENE AEA A ead ieee aes 3 22 DRAM TEC ao dicssa rU nieke qiaca e cen Baad a E A UR R eO 3 22 SSA WIaB TOSE 216292568 QU trsa Stee ORE SRE LOSES PRATO ER A E dip nd 3 23 USE HS Tost MOUG osos pd hebea ermie bacon Gaede nies frate D EE da dp pe EN E Mud ee 3 24 DEVICE TESES siciuaucatatugws panes snes Mees taeessuedhor REESE EON S Ss 3 24 Culek Disk Test CERCLE 3 24 Disk Test Eaa Succus oie iced entra anto opinio eiui ane RI odi Raabe Lara TE dep d 3 24 Flash TeSt si perePER REPRE REOR RI RR ERES AU KE e d P seeds snaeds se eoeted aoe ME 3 25 Input Tray Tests iiim do 9 ok cae RR ICON aa Hae Ru EU CR CORR CR RR URN RR ee 3 25 PRINTER SETUP ccc ccidenewes cake r3 E cIEEITREFIqGG de qa aq kalo de bee Geese RERS 3 25 ERTBINIS esas Subs bct be Edu tula Abc oTi E a Sek co ape aac e dub Roa bp dE dd E n des 3 25 PAGE COUNTS 3 159 59 ober ERE TULPEEIPEREPULPRAC PA EOR d rela Exe dd lags 3 26 Serial NOMBO 225m rei dees ween era quens Vee OI dee Ro heehee Game Rete E ean Meats 3 26 Engine Setting d eID aaa the mea cibg arb dob a hao PR EDT dede dde deb a ba did 3 26 MOUSE NASIYIB sug daas eur A ERE BE P ete dee eer edwee qu
168. e UICC 4 14 Service Manual 7541 03x Op panel bottom cover 1 Remove the op panel top cover 2 Remove the three screws A that secure the op panel bottom cover to the flatbed assembly E A 3 Lift the cover up and away from the flatbed assembly Repair information 4 15 7541 03x Upper right cover 1 Remove the op panel bottom cover See Op panel bottom cover on page 4 15 2 Remove the screw A at the rear of the cover A 3 Remove the screw B at the front of the cover 4 16 Service Manual 7541 03x 4 Liftthe cover up so it clears the tabs C and pull it away from the printer Output bin print engine top cover 1 Openthe front cover 2 Remove the two screws A securing the top cover to the printer frame Repair information 4 17 7541 03x 3 Remove the one screw B on the left side above the scanner power supply door 5 Lift and remove the top cover Back cave cover 1 Remove the inner right cover 2 Remove the top cover 4 18 Service Manual 7541 03x 3 Remove the two screws A on the left side of the back cave cover 4 Remove the cover Inner right cover 1 Remove the upper right cover 2 Remove the lower op panel cover 3 Remove the front screw A that secures the inner right cover to the frame Repair information 4 19 7541 03x 4 Remove the screw B that secures the front of the inner right cover to the back cave cover B
169. e board 24VSW CN16 LVPS 24V_GND HV25V SLEEP1 SLEEP2 HT1 HT2 HTS ZEROCRS CN17 Toner sensor K NI oy A j N H GT HR WO DY TNSETK k k GND TSZANK 5V Toner sensor C TNSETC k k GND TSZANC 0 O N oO a AJ OJ N 5V CN18 Toner sensor Y TNSETY k k GND TSZANY 5V 5 16 Service Manual Toner sensor M TNSETM k k GND TSZANM gt O CO N a A WO N gt 5V Printhead controller board 7541 03x Connector Connects to Pin no Signal CN21 RIP board VCLK Y GND VCLK M GND VCLK C GND VCLK K GND CN22 RIP board olni om om A olv GND VSYN Y VSYN C VSYN M VSYN K HSYN Y HSYN C HSYN M HSYN K gt 0 CO N oO AJ WY N GND a LEVELY O0 Locations 5 17 7541 03x Printhead controller board Connector Connects to Pin no Signal CN22 continued RIP Board continued 12 LEVELY O1 18 LEVELY EO 14 LEVELY E1 15 LEVELM OO 16 LEVELM O1 17 LEVELM EO 18 LEVELM E1 19 LEVELC OO 20 LEVELC O1 21 LEVELC EO 22 LEVELC E1 23 LEVELK OO 24 LEVELK O1 25 LEVELK EO 26 LEVE
170. e board to the ADF assembly 4 122 Service Manual ICC board ONDARON 7541 03x Remove the ADF assembly from the flatbed See ADF assembly removal on page 4 113 Remove the flatbed assembly from the print engine Place the scanner glass side down on a non marring surface Remove the 5 screws securing the shield to the flatbed assembly Remove the shield from the flatbed assembly Remove the two screws that secure the ADF cable connector to the bottom shield Disconnect all the cables from the ICC board Remove the five screws A securing the board to the flatbed assembly Repair information 4 123 7541 03x CCD chassis 1 Remove the flatbed upper cover 2 Remove the screw A securing the CCD guide rod to the flatbed frame A 3 Remove the screw B securing the CCD guide rod to the flatbed frame 4 124 Service Manual 7541 03x 4 Slide the guide rod towards the CCD chassis and remove the chassis from the rod Repair information 4 125 7541 03x 6 Remove the belt from the gears on the bottom of the CCD chassis CCD belt i Note After installing the new CCD perform the scanner calibration procedures See Adjustments on page 4 205 1 Remove the flatbed upper cover 2 Disconnect the belt from the clip on the right side 3 4 Remove the belt from the CCD chassis Disconnect the belt from the spring on the left side of the flatbed 4 126 Service Manual 75
171. e following Installation environment The power supply line voltage is plus or minus 1096 of the rated line voltage The machine is securely installed on a level surface in a well ventilated place The room temperature is between 10 and 32 C 50 and 90 F and the relative humidity between 20 and 8076 Avoid sites generating ammonia gas high temperature high humidity near water faucets kettles humidifiers cold spaces near open flames and dusty areas Avoid sites exposed to direct sunlight Print paper checks Use the recommended paper for this printer e Paper dampness Make a trial print with paper from a newly opened package and check the result To determine the corrective action necessary to repair a printer look for the following information Does the POR stop Check the POR Power On Reset sequence Do you have a symptom rather than an error message add symptom tables list f you have an error message or user message check the following Error tables 2xx Paper Jams User attendance messages Service checks for individual error messages Additional information can be found at the following locations Sub error code table Understanding the printer operator panel Service checks Note There may be printer error messages that are not contained in this service manual Call your next level support for assistance 2 2 Service Manual 7541 03x POR Power On Rese
172. e page prints continuously from the selected source until you press Stop If Continuous is selected from a source which contains envelopes then the envelope print test pattern is printed on the first envelope and the rest are blank The Print Test page always prints single sided regardless of the Duplex setting or the presence of the Duplex option To run the Print Test 1 From the Diagnostics menu touch PRINT TESTS 2 Select the paper source 3 Select either Single or Continuous Note If Single is selected no buttons are active while the Print Test Page is printing If Continuous is selected Stop X can be pressed to cancel the test 4 Atthe end of the test the printer returns to the PRINT TESTS menu Print Quality Pages The print quality test consists of five pages Pages one and two contain a mixture of graphics and text The remainder of the pages only contain graphics 3 20 Service Manual 7541 03x This test may be printed from either Configuration menu or the Diagnostics menu To run the print quality pages from the Diagnostics menu select PRINT TESTS and Print Quality Pages from the menu Once the test is started it cannot be canceled After the test pages print the printer returns to the PRINT TESTS menu HARDWARE TESTS Panel Test This test verifies the operator panel display function To run the Panel Test 1 From the Diagnostics menu navigate to HARDWARE TESTS gt Panel Test The Panel test continu
173. e paper smaller than 182 x 257 mm 7 2 x 10 1 in we recommend 90 g m 24 Ib bond or heavier paper Curl Curl is the tendency of media to curve at its edges Excessive curl can cause paper feeding problems Curl can occur after the paper passes through the printer where it is exposed to high temperatures Storing paper unwrapped in hot humid cold and dry conditions even in the trays can contribute to paper curling prior to printing and can cause feeding problems Smoothness The degree of smoothness of paper directly affects print quality If the paper is too rough the toner does not fuse to the paper properly resulting in poor print quality If the paper is too smooth it can cause paper feeding or print quality issues Smoothness needs to be between 100 and 300 Sheffield points however smoothness between 150 and 250 Sheffield points produces the best print quality General information 1 9 7541 03x Moisture content The amount of moisture in the paper affects both print quality and the ability of the printer to feed the paper properly Leave the paper in its original wrapper until it is time to use it This limits the exposure of the paper to moisture changes that can degrade its performance Condition paper while it is still in the original wrapper To condition it store it in the same environment as the printer for 24 to 48 hours before printing to let the paper stabilize in the new conditions Extend the time several days
174. e the RIP board See RIP board removal on page 4 73 7541 03x Error code Action 51 Defective Flash Select Continue to clear the message and continue printing Install different flash memory before downloading any resources to flash f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 52 Flash Full Select Continue to clear the message and continue printing Note Downloaded fonts and macros not previously stored in flash memory are deleted Delete fonts macros and other data stored in flash memory Install a larger capacity flash memory card e f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 53 Unformatted Flash Select Continue to clear the message and continue printing Format the flash memory before storing any resources on it If the error message remains replace the flash memory f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 54 Serial option x error Make sure the serial link is set up correctly and the appropriate cable is in use Make sure the serial interface parameters protocol baud parity and data bits are set correctly on the printer and host computer Select Continue to clear the message and continue printing The job may not print correctly POR the printer If this does not fix the problem replace
175. e the input device is feeding If Continuous is selected Stop X can be pressed to cancel the test 4 Atthe end of the test the printer returns to the INPUT TRAY TESTS menu PRINTER SETUP Defaults This setting is used by the printer to determine whether US or non US factory defaults should be selected The following printer settings have different US and non US values Printer default values US value Non US value Paper Sizes setting in the General Settings menu U S Metric Default Paper Size paper feeding sources which do not have Letter A4 hardware size sensing capabilities Default Envelope Size 10 Envelope DL Envelope envelope feeding sources which do not have hardware size sensing capability Fax media size Letter A4 PCL Symbol Set PC 8 PC 850 PPDS Code Page 437 850 Universal Units of Measure Inches Millimeters Modification of the printer setting Defaults causes the NVRAM space to be restored to the printer s factory settings Diagnostic aids 3 25 7541 03x PAGE COUNTS This menu lets you view the total page counts of the printer or the page counts broken down into color and mono pages printed Unlike in previous printers none of these values can be changed Touch Back to return to the Diagnostics menu Serial Number You can view the serial number Engine Setting 1 16 Warning The engine setting should not be changed without specific instructions from the next lev
176. ect an assembly gt Reset Calibration Values Calibrating the scanner black levels Note If the printer menus do not match the following instructions then contact your next level of support 1 From the Diagnostic menu navigate to PRINT TESTS gt Print Quality Pages Multiple test pages print Use the first printed page to test the scanner black levels Adjust the ADF Front a b e Load the printed test page face up into the ADF From the Diagnostics menu navigate to SCANNER CALIBRATION gt Copy Quick Test Compare the copy to the original test page and then navigate to Adjust Calibration Values ADF Front Black Adjust the values and then touch Submit to save your changes Increasing the value makes the black level darker To check the changes reload the original test page and then repeat the Copy Quick Test Repeat the steps as needed until you are satisfied with the ADF Front settings e Adjust the ADF Back a b c d Place the original test page facedown into the ADF and select Copy Quick Test Compare the copy to the original test page and then navigate to Adjust Calibration Values ADF Back Black Adjust the values and then touch Submit to save your changes To check the changes reload the original test page and then repeat the Copy Quick Test Repeat the steps as needed Adjust the Flatbed a b c Remove all pages from the ADF and then load the original test page on
177. ee eee eee ee 7 3 40X6304 Cave LED cover 2 0 eee rere eee ee eee eee eee 7 3 40X6306 UICC Display cable eee 7 7 40X6307 10 2 inch touchscreen display rrr rrr rrr rrr rere rere eee eee 7 7 40X6314 Cave light cable 2 2 eee RII III 7 3 40X6320 Flatbed upper cover 2 0 rrr errr rrr eee ee ee eee eee eee 7 7 40X6321 CCD Chassis 2 errr rere errr eee eee eee eee eee ee 7 7 40X6322 ICC PCBA rrr rrr ere rr errr ree ee eee ee eee eee ee 7 7 40X6323 30 pin FFC ribbon cable 7 7 40X6324 18 pin FFC ribbon cable 00 ere eee eee 7 7 Part number index l 7 7541 03x 40X6325 Flatbed cover open sensor rrr err rer err er ee ee ee eee ee 7 7 40X6326 CCD belt 2 20 ere ee ee eee eee eee eee ee eee ee eee eee 7 7 40X6327 ADF pick roll assembly eee errr reer ee eee eee ee eee 7 11 40X6328 ADF separator roll 2 0 0 eee e eee eee rrr 7 11 40X6329 ADF relay card 00 eee eee ee eee eee eee eee eee eee 7 9 40X6330 ADF motor frame w motors rrr rrr reer rr eee eee eee ee 7 11 40X6331 Oute
178. eed from MPF Be sure you have paper in the MPF Check the paper size and type Does it match the paper setting on the printer Be sure the MPF paper present sensor connector CN16 is connected to the CK1 daughter board If the paper still does not feed go to Paper path service checks on page 2 24 Scan copy ADF streaks Step Questions actions Yes No 1 Do streaks appear on the middle Clean the ADF glass on the No issue to fix of scans when using the ADF flatbed using a lint free cloth Kit 40X0392 is available for cleaning the glass on the flatbed Also clean the separator roll and pad with a damp cloth Clipped image when scanning to USB from the ADF Feed the ADF from the short edge of the paper 2 76 Service Manual ADF cover open service check 7541 03x Step Questions actions Yes No 1 Is the ADF cover properly closed Go to step 3 Go to step 2 2 Close the ADF cover Issue resolved Go to step 3 Does the problem go away 3 Perform the ADF cover open sensor test Go to step 4 Go to step 8 See SCANNER TESTS on page 3 29 Does the sensor work properly 4 On the bottom of the ADF cover inspect the Go to step 6 Go to step 5 ADF cover closed sensor actuator Does it move freely 5 Fix the actuator so it moves freely Issue resolved Go to step 6 Does this fix the problem 6 Remove the ADF rear cover and inspect the Go to step 7 Go to s
179. eeeeeeeeee nnne 2 87 Display functions but the keyboard doesn t work properly sssllll eese 2 87 Display tails to Ml minate 2m epp Perse c eens oie PS xd rx ER Y REFERRE 2 87 Insert tray service CHECK ass cunts ceeds E ROCACR EXON kinak RRO EU ACCION Ro RN HR RU 2 88 Paper Skew service check 2 cisuuuesanakaturesreaa ka Rda RR RR RAS RR led RR dU bie ee 2 89 Imaging unit photo developer missing service check eeeeeseeeeee 2 89 Option card service CHECK i ecie cues es tRe err RE a news bkee bk cee et hoes teens rake Ei 2 90 Send PO Cnm 2 90 Fasti ODDS 2c cendeoeia oad ze eps eim 25 35 oR S44 ER SPEER dc CEST RES 2 90 DRAMIDDIOBS 43499 3 09 80 areca ib qo RUE QUPD Rd ardebat gd M eb dot dra 2 Irae o der 2 90 Hard disk COON 2s dab rbd rede S Eo I Re olde d bas ce d dq scu e rper 2 91 Nework card ODUM oasear edd ties boe e SOR EHI tpi E dra ueber dome Pee ue deb rte UR pde 2 91 Errot codo D70 s NoIWOIK Call X si c2 55028456560660 69060 45 RIP Een Pena d SEP dE 2 91 54 Network oc SotlWale BITOE 62222402 CC xpREXI RP E XX PX RES X TIX QUEM E QUA RAPPER Sees 2 91 Power supply Dead machine service check 2000 cece cence eee eee eee 2 92 Printhead service Cheek i i once arcs Ir REG RR REA ee Glens dese wing ee bene p REA dS 2 93 Transfer belt up down Check i4 sc komo i Ron ROO RR ROCK KORR eee ees eed RO 2 93 Unable to print from USB thumb drive service check 000 eee eee ee eee eens 2 94 Was
180. eguridad e La seguridad de este producto se basa en pruebas y aprobaciones del dise o original y componentes espec ficos El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas La informaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCI N este s mbolo indica que el voltaje de la parte del equipo con la que est trabajando es peligroso Antes de empezar desenchufe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informa es de Seguran a A seguran a deste produto baseia se em testes e aprova es do modelo original e de componentes espec ficos O fabricante n o respons vel pela segunran a no caso de uso de pe as de substitui o n o autorizadas e As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios CUIDADO Quando vir este s mbolo existe a poss vel presen a
181. el of support Model Name You can view the model name 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 you 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 Note When the printer detects a Configuration ID that is not defined or invalid the following occurs The default standard model Configuration ID is used instead Configuration ID is the only function available in DIAGNOSTICS Unless the menu is in DIAGNOSTICS Check Config ID appears To set the configuration ID 1 From the Diagnostics menu navigate to Printer Setup Configuration ID Enter the Configuration ID 1 Touch the Configuration ID 2 value to select it and then enter the new Configuration ID 2 Touch Submit to save and validate the new IDs If either ID is invalid then the printer discards the changes and returns to the original IDs If both IDs are valid then the printer returns to the Diagnostics menu PON Reset Color Calibration Reset Color Cal resets the alignment of the color planes to factory default settings No buttons can be pressed while the printer is resetting the color calibration The printer aut
182. em solved Go to step 6 6 Checkthe cable connections from the ICC board to the Go to step 8 Go to step 7 RIP Are the cables properly connected 7 Reconnect the cables from the ICC to the RIP Did this Problem resolved Go to step 8 fix the issue 8 Checkthe cables from the ICC to the RIP for continuity Go to step 10 Go to step 9 Is there continuity 9 Replace the faulty cable Did this fix the issue Problem resolved Go to step 10 10 Replace the ICC board Did this fix the issue Problem resolved Replace the RIP board See RIP board removal on page 4 73 292 01 Scanner carriage locked Unlock the scanner flatbed CCD carrier module lock scanner lock The lock is located on the left hand side of the flatbed unit Diagnostic information 2 35 7541 03x ADF paper jam service check Note This service check should be used if the paper feeds and jams in the ADF If the paper is not feeding into the ADF see 280 06 Paper missing on page 2 29 If the paper fails to eject from the ADF see Step Questions actions Yes No 1 If the ADF is multi feeding check for dirt on Clean them with a lint free Replace the separator pad the ADF separator pad and ADF separator cloth and isopropyl alcohol and ADF pick roll rollers Are they dirty 2 If the paper is skewing when it is fed into the Go to step 3 Set the paper guides so ADF check the paper guide width Is it set they co
183. emad dut qd dd ripe ae 3 26 Sis erc MMC mE 3 26 Reset Calor Calibration isccittnccieae care P Ecke REOS RE RR ARE RE act paru RR aep S we 3 26 al BEL AB 22162226 chs dott ede os edee deh I Seed Cae oS odit Qa edidmqd dd qe bd ebd 3 26 Par 1 SUWODBJA veessosica pPecRPFS CER REG ead ees PCSR qa 1 RESPSEREUE EU C E 3 27 REPORTS i205 3camx eR EG RC S Sci EA canes naGens RRE eee RSE RE 3 27 EVENT LOG zuscsetee rr hPLVSZGqG EP LEE ane oe DUPLI M renee e RPITaG REESE 3 28 vii 7541 03x ovde P C cT ret T E TE 3 28 PIBELOS LL ose TCpRESSQQeRIEPPED S EERPCLARPRPPSQLERdE dea 4qa E issu E Rte i dd i pddE 3 28 Clean Log sci tbe rase Sch ec obe rd Qc acti eO D aC teak swe es Eq Re pare RENE REOR UR MUR 3 29 SCANNER TESTIS coriis oshi t Edid aai ANDE RR ES c GERE Reel aew E Ea md NE 3 29 Scanner Calibration R8BOel uuo asese acu ob ES RE dA REGda vend eae d oder dd 3 29 AGI OS S eiue qs PES ERR EQ Edid dep au dadubdexeddqRe duet bd cam did 3 29 PEGG TES cic capt RR ep eee CHI ehe UP E EN E E n e Ranma amas e ad 3 29 SCIUNT SEETIS TITEL ae a aaoewetr as 3 29 ADF Magnilicdlion 322220946 px RR a Ue PETIERE Orr PO RENE Eq Gast xu e RE das 3 29 EXIT DIAGNOSTICS xem sem ERROR RES RE RUE RR S Ra CERTE RR DRE RE RG REN 3 30 Theory Of operation iouis eue pud R a ER Rx ERR Ra RE RE Re so n3 ER UCR RR RUE RR A NI ROB RU ae 3 31 Printer amp ngln iaa irae xo RR C o9 994 A OR Ro KER KORE RU RO OR ORE A ACORN Ro RD t ARCA S 3 31 Electrophotographic Process EP
184. emoval 4 112 removals Back cave cover 4 18 Cord cover 4 6 Crossbar removal not a FRU 4 74 Drive unit 4 79 Drive unit motor C M Y K 4 83 Front op panel cover 4 11 Fuser removal 4 61 Inner right cover 4 19 Left EMI shield removal not a FRU 4 45 Low volt power supply removal 4 51 Main switch 4 58 Op panel bottom cover 4 15 Op panel paper exit guide removal 4 32 Op panel top cover 4 13 Output bin print engine top cover 4 17 Output bin full sensor actuator removal 4 26 Rear cover 4 7 RIP board removal 4 73 RIP cover 4 5 Scanner power supply access cover 4 6 Scanner power supply removal 4 58 Speaker removal 4 25 Transfer belt CRU 4 40 Transfer Roll CRU 4 72 Upper right cover 4 16 Reports 3 11 Reset Calibration 3 26 Reset Calibration Values 3 20 RIP board removal 4 73 RIP board operator panel replacement 4 2 RIP cage removal 4 95 S safety information ii Xv safety inspection guide 6 1 scanner lock 2 35 Scanner Calibration Reset 3 29 Scanner power supply removal 4 58 Selecting paper 1 10 Sensor Test SCANNER 3 29 Separator roll removal 4 183 4 197 Serial Number 3 26 serial port service check 2 90 Serial Wrap Test 3 23 service check 840 03 service check 2 56 841 00 Invalid configuration or ASIC not found 2 56 841 01 Invalid AFE setting 2 56 841 02 Delayed interrupt detected 2 57 841 03 Failed indirect register test 2 57 841 05 Image pipe time out 2 57 841 06 Scanner did not initiate scan 2 58 842 00 No response 8
185. engage the media in the tray with the pickup roller Tray 2 uses a tray lift motor to lift the paper to the paper feed mechanism Tray 1 holds approximately 150 sheets of 20lb paper and Tray 2 holds about 250 sheets of 20lb paper Bigs up Pick roll fixture guide ush up mechanism Pick roll p P MPF Tray Bottom plate Push up spring Release bar Tray 1 does not have automatic size sensing therefore the correct paper size must be set on the paper size wheel located on the front right of the trays see pictures below 3 40 Service Manual 7541 03x Tray 2 and optional trays 3 5 Trays 2 through Tray 5 use a motorized lift mechanism to engage the media in the tray with the pickup roller Tray 1 holds up to150 sheets of 20 Ib paper and the optional Trays 3 5 can hold up to 500 sheets of 20lb paper Upper limit sensor Light shield plate Pick roll push up mechanism WU n Pick roll m gt Bottom plate Push up plate connected to Paper cassette installation the paper tray lift motor Trays 2 5 do have automatic size sensing and automatically tell the printer the paper size based on the position of the tray guides on the drawer The sensor that detects the paper size is sensitive so positioning the Tray Guides 1 or 2 notches out of position could result in an incorrect paper size reading If any
186. ensure the best print quality and feed reliability use 90 g m 24 Ib xerographic grain long paper Business papers designed for general business use may also provide acceptable print quality We recommend Lexmark part number 12A5950 letter size glossy paper and Lexmark part number 12A5951 A4 size glossy paper Always print several samples before buying large quantities of any type of media When choosing any media consider the weight fiber content and color The Laser printing process heats paper to high temperatures of 180 C 356 F for non MICR applications Use only paper able to withstand these temperatures without discoloring bleeding or releasing hazardous emissions Check with the manufacturer or vendor to determine whether the paper chosen is acceptable for laser printers When loading paper note the recommended print side on the paper package and load paper accordingly Paper characteristics The following paper characteristics affect print quality and reliability Consider these characteristics when evaluating new paper stock For detailed information see the Card Stock amp Label Guide available on the Lexmark Web site at http support lexmark com Weight The printer can automatically feed paper weights from 60 to 220 g m 16 to 58 Ib bond grain long Paper lighter than 60 g m 16 Ib might not be stiff enough to feed properly causing jams For best performance use 75 g m 24 Ib bond grain long paper To us
187. er assembly Asm Part Units Units Description index number mach FRU 1 40X6429 4 1 LED printhead assembly 2 40X6216 4 1 LED FFC ribbon cable 3 40X6218 4 1 LED printhead 4 40X6756 1 1 Printhead controller board 5 40X6215 8 1 Contact spring 6 40X6214 2 1 Toner sensor NS 40X6369 1 1 PRCONT option cable NS 40X7449 1 1 Upper assembly screw parts pack Parts catalog 7 31 7541 03x Assembly 16 Printhead controller board cables 7 32 Service Manual 7541 03x Assembly 16 Printhead controller board cables Asm Part Units Units Description index number mach FRU 1 40X6193 1 1 Registration sensor cable 2 40X6211 1 1 Fuser power cable 110V 2 40X6440 1 1 Fuser power cable 220V 3 40X6168 1 1 Paper exit sensor cable 4 40X6278 1 1 Fuser exit sensor cable 5 40X6756 1 1 Printhead controller board 6 40X6201 1 1 Density sensor cable 7 40X6198 1 1 Theta sensor cable 8 40X6210 1 1 Power supply fan cable 9 40X6370 1 1 RIP print controller cable 10 40X6369 1 1 Printhead controller option cable 11 40X6748 1 1 RIP harness cable Parts catalog 7 33 7541 03x Assembly 17 Paper trays 7 34 Service Manual Assembly 17 Paper trays 7541 03x Asm Part Units Units index number mach FRU Description 1 40X6223 Multipurpose tray 2 40X6219 Main paper tray NS 40X6220 Tray rack gear NS 40X6221 Tray pinion gear
188. er rrr errr rrr ree 7 25 Registration sensor cable 40X6190 0 err rr rrr rrr rrr III 7 25 registration sensor cable 40X6190 ccccmcm I II III 7 29 Registration sensor cable 40X6193 ccccrcm III III 7 25 Release link 40X6227 ccmm III I III III M 7 3 Release spring 40X6271 ccercmIII III III 7 3 Remote off switch cable 40X7454 22 20 r rrr rrr rrr III 7 29 Retainer clip 40X1106 ccccmc nmm II III ree 7 43 Right cover 40X6134 2 22 errr rr rrr rrr ree 7 15 Right hinge 40X6282 20 er rrr rrr rrr rrr eee 7 3 RIP harness cable 40X6748 200 r rrr rr rrr rrr rr ee 7 29 Rising unit hub 40X6358 5 2 rrr errr rrr rr ree 7 41 Rising unit spring 40X6359 c ccccm II III III 7 41 Roller guide 40X6258 nn III III III 7 13 Roller guide spring 40X6151 ccccmcmc II III 7 13 Rubber grip pad 40X6421 ecem III III 7 23 Safety rod switch 40X6127 ercnmmm I III III 7 15 Safety spring 40X6133 rr III 7 15 Safety switch spring 40X6270 cmcn c II III III 7 3 Sensor Frame 40X6354 ecrmn I III renee 7 3 Separator roll 40X6186 rcr III 7 25 Serial interface card adapter 40X4819
189. ere r errr err eeee 7 25 I 10 Service Manual 7541 03x M Main Standard paper tray 40X6219 cuRIRIIIIIIIIII 7 35 Main drive unit 40X6173 ee errr eee ee eee ee eee eee eee 7 19 main fan 40X6206 er rere en rr ee ee ee eee eee reer ee 7 29 Main interface cable 40X6232 errr ree ee eee eee eee ee 7 41 7 43 Marknet N8120 10 1000 PCBA 40X4826 acumen eene ee mese eee eee eee eee eee ee 7 46 Marknet N8130 10 100 adapter 40X4827 rrr rrr rr rrr rrr ree 7 46 Marknet N8250 802 119 server rest of world 40X7063 eee eee 7 46 Marknet N8250 802 11g server US 40X7062 5 rrr rere eee 7 46 MFP maintenance kit 40X6457 oe eee errr ee ee ee eee eee eee 7 46 MPF bottom cover 40X6415 2 2 errr re eee ere eee eee eee eee eee 7 15 MPF catch 40X6414 lt sere be ee cee ese eee ee ee ud Hid cri ira 7 15 MPF Clutch 40X6419 urrIIIIIIIIIIIIIIIIIIIIII IIIIIIIlIl 7 13 mpf clutch 40X6419 2 eee er eee eee ee ee eee eee ee 7 29 MPF engine board cable 40X6416 eeurr erm 7 29 MPF maintenance kit 40X6457 eee ere eee ee eee eee eee 7 15 MPF pad holder 40X6411 2 2 errr ree eee rr ee ee ee
190. ervice check 2 87 option card service check 2 86 2 90 Option controller board removal 4 200 Option door inter lock switch removal 4 202 options and features description 1 3 Output bin full sensor actuator removal 4 26 P Panel Menus 3 12 Panel Test 3 21 paper 1 6 recommended types 1 9 unacceptable 1 10 paper and media paper checks 2 2 Paper empty sensor removal 4 199 paper exit guide removal 4 33 paper exit sensor removal 4 37 Paper feed clutch removal 4 203 Paper feed motor removal 4 110 Paper feed roll removal 4 196 paper feed unit removal 4 68 Paper full sensor removal 4 199 Paper has entered the duplex unit Paper jam 230 231 9 2 26 Paper has entered the fuser and exited the printer Paper jam 203 2 25 Paper has exited the registration roller and entered the fuser Paper jam 201 2 25 1234xxx Paper has stopped at the registration roller or has not reached the fuser Paper jams 200 250 24x 2 25 Paper in ADF size service check 2 96 Paper is being picked up and carried to the registration roller Paper jams 200 250 24x 2 24 paper jam 200 2 18 201 2 18 203 2 19 230 2 20 231 39 2 21 24x 2 22 250 2 23 Clearing and troubleshooting paper jams 2 18 Paper level sensor removal 4 198 Paper path service checks 2 24 Paper Prompts 3 15 paper size sensor removal 4 42 Paper size switch removal 4 105 Paper size switches removal 4 197 paper skew service check 2 89 Paper specifications 1 6 paper specifications media types
191. es Fax error log codes 7541 03x Error code Description Action 000 No error occurred during fax No action needed transmission 200 Error occurred when transmitting Check line quality training Select a lower Max Speed value under Fax Send settings Adjust the transmit level 3XX Error occurred when receiving Check line quality image data Adjust Receive Threshold Select a lower Max Speed value under Fax Receive settings 4XX Error occurred when sending Check line quality image data Adjust Transmit Level Select a lower Max Speed value under Fax Receive settings 5XX Received unknown response from No action needed Issue is with the other remote fax device device 6XX Error occurred when receiving a frame Check line quality Adjust Receive Threshold 7XX Error occurred when sending a frame Check line quality Adjust Transmit Level Select a lower Max Speed value under Fax Send settings 800 Received EOT unexpectedly from e If error persists disable V34 modulation the modem in V34 mode scheme 802 Too many timeouts occurred f error persists disable ECM mode during ECM reception 803 Fax cancelled by user No action needed 804 Unexpectedly received a disconnect Check line quality command from the remote end Adjust Transmit Level Receive Threshold values Remote device could be requesting an
192. es Any reference to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property right may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by the manufacturer are the user s responsibility Lexmark Lexmark with diamond design and MarkNet are trademarks of Lexmark International Inc registered in the United States and or other countries Optra Forms is a trademark of Lexmark International Inc PostScript is a registered trademark of Adobe Systems Incorporated PCL is a registered trademark of the Hewlett Packard Company All other trademarks are the property of their respective owners 2006 Lexmark International Inc All rights reserved UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense P N 12G0474 7541 03x Table of contents Notices and safety information 5 24s oo ao oras tena en RA xiii Sale IMOMMANON ua us bas trceucaSdad EA Ree ee ears eee PEDI CP ERE GERNE E SR ME SE xv PIEIBEB Lia dS bh E AERE d d RAO AO EURO ER A CE AR A EO C xviii CONVENTIONS iiuuiuucu Resa k daEdba RA ERERLEEEREEEE Fat
193. es basdude RR DIT RENS RE NEG ES xviii General information sos ie dso nc rk hae EEQUEREERSACUH KE EX Xp Pod PEOR UE qu PE eens 1 1 Maintenance aBDIOBCI sgri copii aaen au bdo bd deas k dod odo alc ded UR dul Qi OE RUE d dai d 1 1 MOUGIS oss d akacedo da CR CE Gd od RD o eH whe CERE OR US IRR ox RT CN bol de o ol eee bod e Re 1 1 P nter COnuguranons doa io bab 10685605 4 ba ORE E o6 1 BA 3d id dedo tesa Geen tema 1 2 Options and features iisnocenaeclericeexa uad RXXG REG GRERG RESGRREGE RE ade adams PEN 1 3 Puit engine SsBecill cB HOS 24 9 446 dn 4 4 R0 tance beds Jet AC Ra QURE dou QUAE eR eub GU ca GR GG ed RU 1 4 Power SDOCITICallOnS icin cians edu bd x Ra bad id os du RR LAE QE AU VR RUE ded aro We RR 1 4 Electrical specifications 5a sacs kai ORARE R kwon ee A UC eR EU Ro ORE OR GR 1 4 CIGAIANGCES iocos dcusrr PES VISA GER I REESE GER IR BER aeUPEM A RE VER EP PEE 1 4 ACOUSTICS ix ix a Ex Eo PACA RUN UR KOK OUR RO ROK DERE RD ab CUR LER ERRORS 1 5 Environment os ire exerce eia E e Pd uaa kde uar ncaa d qp pr E bud d rk wale ee rm 1 5 Performante xia ance sack d ka E CR Roa CdKea EH ON RRR RRR R RCARA GR I RARUS RRS 1 6 dil 9m eren 1 6 MEMON ia boss iR UR a eee dee Eo db o a a c UC XU GU EO aedi e a Rd 1 6 Pagel SDECIDOCaUOlS ssa cians teak Coda ERG d d dp i d Addere d die ded RR 1 6 Paper sizes sHIppoHeg by The DUEB cccdaci iredrie me dre p IR ROS Rot Venere ar rap ras 1 6 MGQGIVRCS MCI 1 7 M dia WEIdlis s oque erreitik qaot oe qub t Y
194. esent sensor Did this fix the issue Problem resolved Go to step 12 13 14 Is the ADF cable properly connected to J9 on the ADF relay card and the ICC board connector on the rear under side of the flatbed Properly connect the cable at both ends Did this fix the issue Go to step 14 Problem resolved Go to step15 Go to step 15 Diagnostic information 2 29 7541 03x Step Action and questions Yes No 15 Checkthe ADF cable for continuity Is there continuity Go to step 16 Go to step 15 16 Replace the ADF cable Did this fix the problem Problem resolved Go to step 16 17 Replace the ADF relay board Did this fix the issue Problem resolved Go to step 17 18 Replace the ICC board Did this fix the issue Problem resolved Replace the RIP board See RIP board removal on page 4 73 283 01 Scanner static jam Scan sensor jam Step Action and questions Yes No 1 Did the paper pick Go to step 10 Go to step 2 2 Is the pick roll in the up position Go to step 3 Go to step 8 3 Remove the ADF outer cover and inspect the sensors Go to step 5 Go to step 4 for dirt and debris Are the sensors clean 4 Clean the sensor Did this fix the issue Problem resolved Go to step 5 5 Check the sensor ADF Skew and Scan sensor for Go to step 6 Go to step 9 proper operation
195. ext level of support for the correct firmware level to use Restart the printer to operating mode Does the 900 xx error reoccur Go to step 30 Go to step 26 30 Replace the faulty ISP option Restart the device Does the 900 xx error reoccur Go to step 31 Go to step 26 31 Contact your next level of support You will need the following information for them Exact 900 xx error digits and complete error message Printed menu settings page Printed network settings page Device error log e A sample print file if error appears to be isolated to a single file File Application used if error is related to specific print file Device Operating System Driver used PCL PS Frequency of the occurrence of the error 941 01 SDRAM R W error Step Action and questions Yes No 1 Check all the cables connected to the printhead Go to step 3 Go to step 2 controller board Are they properly connected 2 Connect the cables Did this fix the problem Problem resolved Go to step 3 3 Replace the printhead controller board Did this fix the Problem resolved Contact your issue second level support 941 02 MDC error A Remove power from the printer before continuing or use caution if the product must be energized during this procedure The heat sink transformer core presents risk of electric shock Test before touching Step Action and questions Yes
196. f the option paper feed unit 2 Remove the paper empty sensor from the frame by pressing the tabs A on the sensor together and pulling it away from the frame 3 Disconnect the sensor from the harness Paper full sensor removal 1 Take the main printer unit off of the option paper feed unit 2 Remove the paper empty sensor from the frame by pressing the tabs A on the sensor together and pulling it away from the frame 3 Disconnect the sensor from the harness Repair information 4 199 7541 03x Option controller board removal 1 Remove the rear cover 2 Disconnect all the cables from the option controller board 3 Remove the four screws A securing the controller board to the rear frame Stepper motor removal 1 Remove the rear cover 2 Remove the stepper motor cable from the controller board 3 Remove the three screws A securing the bracket to the rear frame 4 Remove the gear and belt 4 200 Service Manual 7541 03x 5 Remove the two screws B securing the stepper motor to the bracket Tray lift motor removal 1 Remove the rear cover 2 Disconnect the tray lift cable from the tray lift motor 3 Remove the three screws A securing the tray lift motor to the frame Repair information 4 201 7541 03x Option door inter lock switch removal 1 Remove the rear cover 2 Disconnect the interlock cable from the interlock switch 3 Remove the one screw A securing the
197. fax device at the Verify MFD is answering to fax call and remote end not a voice call Decrease value of Rings To Answer setting 812 No more data rates available in V34 Adjust to a lower modulation scheme modulation scheme 813 Timeout occurred after waiting too long Adjust Receive Threshold to receive a good frame 814 Tried too many times at selected speed Adjust Transmit Level using V34 modulation scheme Adjust to a lower modulation scheme 815 Fax transmission was interrupted due Troubleshoot MFP if error persists See to power failure No dial tone on page 2 83 818 Fax transmission failed due to Adjust Memory Use setting to allocate insufficient memory to store scanned more memory for send jobs image 819 Fax transmission failed due to Adjust Memory Use setting to allocate insufficient memory to store received more memory for receive jobs image 81A A timeout occurred during transmission Select a lower Max Speed value under of a page in ECM mode Fax Send settings 880 Failure to transmit training successfully Select a lower Max Speed under Fax in V17 V29 V27 terminal modulation Send settings schemes Adjust the Transmit Level Check line quality 881 Failure to transmit training successfully Select a lower Max Speed under Fax in V33 V29 V27 terminal modulation Send settings schemes Adjust the Transmit Level Check line quality 2 42 Service Manual
198. for each error in the log Page count when the error occurred except for 900 service RIP software errors Code versions of all packages when error occurred Panel message when error occurred except for 900 service RIP software errors Debug information and secondary error codes depending on the error Event Log Lexmark C925 s a C0000000 T rmation Event Log Information 148 0 Service Motor Errat The Clear Log operation clears out the errors that print in this report The errors listed in the Display Log operation do not necessarily match in number nor in order with the errors from the printer log Note This log can be printed from configuration menu but the debug and secondary error codes are not printed on this log 3 28 Service Manual 7541 03x Clear Log This menu item deletes the event log Once the event log is deleted the only item remaining on the log is the Clear Log event Touch Back to return to the EVENT LOG menu SCANNER TESTS Scanner Calibration Reset This option resets the scanner calibration values to factory default settings This should be done after you replace the flatbed scanner unit For more information see Calibrating the scanner on page 4 205 Note Be sure the scanner glass and backing material are clean before performing this test ASIC Test This test initiates a scan of the scanner ASIC memory This is a pass fail test Press Stop X to clear
199. from the inner ADF to cover Paper in sensor actuator 1 Remove the ADF paper in sensor 2 Carefully remove the actuator from the inner ADF to cover Repair information 4 145 7541 03x Paper path sensor See Scan sensor on page 4 146 Scan sensor Note The scan sensor FRU assembly is made of the scan sensor and an optical paper path jam sensor Remove the ADF main feed unit Remove the scan sensor cover Remove the screw A securing the scan sensor to the scan sensor cover qu A 4 Remove the two screws B securing the paperpath sensor to the ADF main feed unit 4 146 Service Manual 7541 03x 5 Pull the scan sensor cable through the clip on the ADF main feed unit 6 Pull the sensor cable through the side of the ADF main feed unit Repair information 4 147 7541 03x Scan sensor actuator 1 Remove the scan sensor 2 Use a flatbed screwdriver to free the actuator from the scan sensor cover 3 Remove the actuator 4 148 Service Manual 7541 03x Scan sensor cover not a fru 1 Remove the ADF main feed unit 2 Use a flatblade screwdriver to remove the guide on the bottom of the ADF main feed unit 3 Pull the guide out of the ADF main feed unit Repair information 4 149 7541 03x 4 Remove the screw A securing the scan sensor cover to the ADF main feed unit A 5 Remove the screw B securing the scan sensor cover to the ADF main feed unit 4 1
200. g the new ADF assembly perform the scanner calibration procedures See Adjustments on page 4 205 Repair information 4 113 7541 03x ADF pick roll removal 1 Open the ADF top cover 2 Pull the tab 1 down 2 3 Remove the ADF pick roll 4 114 Service Manual ADF separator roll removal Open the ADF top cover 2 Pull the separator roll lock 1 up 3 Pull the separator roll shaft holder 2 up 4 Pull the lock 3 off the shaft een ET ur M E x Tw RS Mee o 5 Take the separator roll 4 off the shaft LM wh 7541 03x Repair information 4 115 7541 03x Flatbed assembly removal 1 IRN OND Remove the op panel assembly See Op panel top cover on page 4 13 and Op panel bottom cover on page 4 15 Remove the ADF assembly See ADF assembly removal on page 4 113 Remove the RIP cover See RIP cover on page 4 5 Remove the rear cover See Rear cover on page 4 7 Disconnect the flatbed cables A from the RIP Using a short handle screw driver remove the two screws B on the left underside of the flatbed platform Using a short handle screw driver remove the two screws C on the right underside of the flatbed platform Remove the flatbed from the scanner platform Remove the flatbed front cover See Flatbed front cover on page 4 117 Note After installing the new flatbed perform the scanner calibration procedures See Ad
201. h 13 40X6159 1 1 F2 S Transfer spring 14 40X6143 1 Transfer roll bushing 15 40X6151 2 1 Roller guide spring 16 40X6258 1 1 Roller guide 17 40X6012 1 1 Transfer roll 18 40X1104 8 1 Photo sensor 19 40X6158 1 1 Duplex clutch cable 20 40X6150 1 1 2 S Transfer spring 21 40X6149 1 1 Transfer contact plate 22 40X6259 1 1 Duplex ground cable 23 40X6142 1 1 Inner duplex cover 24 40X6144 1 Duplex carrying gear 25 40X6145 1 1 Paper exit sensor lever 26 40X6155 3 1 Duplex timing belt 27 40X6157 1 1 Duplex clutch 28 40X6146 1 1 Drive gear 29 40X6257 1 1 Carry cover NS 40X6499 1 1 Cover 1 screw parts pack Parts catalog 7 13 7541 03x Assembly 7 Duplex components 2 7 14 Service Manual 7541 03x Assembly 7 Duplex components 2 Asm Part Units Units Description index number mach_ FRU 1 40X6578 1 1 MPF roll 2 40X6457 MPF Maintenance kit 3 40X6412 MPF separator spring 4 40X6411 MPF pad holder 5 40X6415 MPF bottom cover 6 40X6414 MPF catch 7 40X6141 Sub tray 8 40X6136 A S pushing spring 9 40X6137 Duplex cover roller 10 40X6135 B S pushing spring 11 40X6134 Right cover 12 40X6133 Safety spring 13 40X6127 14 40X6128 15 40X6131 16 40X6130 17 40X6129 18 40X6132 19 40X6983 20 40X6981 NS 40X6418 NS 40X6499 Safety switch rod Door lever lock Lever open spring Lever shaft Door lever Lever guide Duplex cover pin MPF tray support
202. he paper tray lift motor to Go to step 3 Go to step 2 CN 6 on the engine board Is the cable properly connected at both ends 2 Connectthe cable properly at both ends Does this fix Problem Go to step 3 the problem resolved 3 Check the paper tray lift motor for continuity Is there Go to step 5 Go to step 4 continuity 4 Replace the paper tray lift motor cable Does this fix the Problem Go to step 5 problem resolved 5 Replace the paper tray lift motor Does this fix the Problem Go to step 6 problem resolved 6 Replace the engine board Does this fix the problem Problem Contact your resolved second level support 146 03 Tray 3 error Note This is the first expansion tray Step Action and questions Yes No 1 Check the cable connecting the option paper tray to the Go to step 3 Go to step 2 option connector on the back of the printer Is the cable properly connected on both ends 2 Connectthe cable properly at both ends Does this fix Problem Go to step 3 the problem resolved 3 Checkthe option cable s connection to CN 13 on the Go to step 4 Go to step 5 printhead controller board Is it properly connected 4 Checkthe option cable in the printer for continuity Is Go to step 5 Go to step 6 there continuity 5 Replace the option cable Did this fix the problem Problem Go to step 6 resolved 6 Check CN120 on the expansion feeder controller for Go to step 8 Go to step 7 proper connectivity Is it properly con
203. he screen or any hard buttons Opening an input tray cover or door e Sending a print job from a computer Performing a Power on Reset POR 4 Keypad Lets you enter numbers letters or symbols Submit Saves settings changes 6 Stop Cancel Stops all printer activity Note A list of options appears once Stopped appears on the display 7 Home Returns to the home screen Diagnostic aids 3 1 7541 03x Understanding the home screen Buttons appearing on the home screen may vary depending on home screen customization settings Bookmarks 43 fi A H wg Change Copy Language Shortcuts Fax 3e Held Jobs FIP USB D a 2 Ready Possible buttons and icons on the home screen Item Description Copy Opens the Copy menu E mail Opens the E mail menu Scan Opens the Scan menu Fax Opens the Fax menu Menus Opens the administrative menus when Ready appears on the display FTP Opens the FTP menu Note This option must be set up by a system administrator before it appears on the display Status message bar Shows the current printer status such as Ready or Busy Note Make sure Ready appears before performing any printer task Shows printer conditions such as Toner Low or Cartridge Low e Shows intervention messages and gives instructions for the printer to continue processing Status Supplies Displays a warning or error message whenever the pri
204. heckthe cable connecting the waste toner sensor to Go to step 5 Go to step 4 CN9 on the engine board Is the cable properly connected at both ends 4 Reconnect the cable at both ends Did this fix the Problem solved Go to step 5 problem 5 Checkthe cable for continuity Is there continuity Go to step 7 Go to step 6 6 Replace the waste toner sensor cable Did this fix the Problem solved Go to step 7 problem 7 Replace the waste toner sensor Did this fix the Problem solved Go to step 8 problem 8 Replace the engine board Did this fix the problem Problem solved Contact your second level of support 2 94 Service Manual Wrong paper size service check tray1 7541 03x Step Action and questions Yes No 1 Check the size indicator on the front of the tray Is it set Go to step 3 Go to step 2 to the correct size 2 Setthe indicator to the correct size Did this fix the Problem solved Go to step 3 issue 3 Is the sensor cable properly connected to the sensor Go to step 5 Go to step 4 and engine board 4 Connect the cable Did this fix the problem Problem resolved Go to step 5 5 Checkthe cable for continuity Is there continuity Go to step 7 Go step 6 6 Replace the cable Did this fix the issue Problem resolved Go to step 7 7 Replace the sensor Did this fix the issue Problem resolved Go to step 8 8 Replace the engine boar
205. iade amas karige ripen kik a pad d DEA Rud qa es 2 39 955 00 Service Code CRC lOG 22saza4e Rau amu hssmata ks icrkisirkER 4 REG Pagus 2 39 Bsb3uc Service System BOSE SA x xod Sab cos qoe eq bind Ex QS ades S addo dc e E db NE 2 39 957 xx Service System Board cers cece ssa cg ble dase na Ux Far REX am EE 2 39 958 xx Service NAND FallUfe csse ERR dons Enn EGRE dee ie kee ERES EIER 2 39 959 xx Service Invalid Firmware 2sllros de hr Ebor abe ewe 3 RU S RR RU wee perenne 2 39 960 xx Service Memory EITOE inen es ormai cpm cos oC ER UC KO tee ewe em RES 2 39 961 xx Service Memory Emon ioc ec ccs ee rh error cg RR aea gaan wee XR E Rn m Ros 2 39 964 xx Service Emulation EITOF 0 25 ccccccceeie ecw te ete ieee ee KRsRRERsGu ERR RE ARES 2 39 975 xx Standard network or Network Card X 2 2 eee ete eee eee 2 39 976 xx Standard network or Network Card X 2 ccc eee eee 2 39 982 3 Service SOVICE asas i EE PRA CRPRDSE E edd adds dud aidedaatedaiteaes 2 39 990 xx Service lt dGVICG gt cas anioa ba ERE RARER AERE bee ideas beatae eee Ce REG RE ERE RE 2 39 901 xx Service lt Oevices Cane 26 0265 2259209 code cee 9 18d xS Dd X RUE bd d D d URN 2 39 Fax T30 log error COUOS a cessa raikaa cad IRURE ORA OR AUR or RO o ARCA eee wld eee 2 41 SENCO CHECKS obs eobes sd ead dE Lid EE Sd E conus OPI RE LERES LAE E NR EE EE Ru tease 2 45 111 01 Black printhead error 2uluieeralleva cane hae Rr GRAUE GR EA bp E gene eee RO RA 2 45 112 01 Cyan printhead err
206. iade dde eade Eqs d ugg aus Ed 5 3 ADP re 5 3 Pabed Sensors ict es ecw beca QE Ded Ecos reed sea edes bed ose ERE 5 3 Rip Board CODDOCEOES aee dd CREAR d RR Heda Rad dO eens aes ee aaa Rx od 5 4 Scanner secondary power supply elueeeeeeeeeeeeeee nne 5 25 Scanner ICC board connectors siiecuaiuu suia Rasa REA RRERRARNE ER RR E EERE RES LEER 5 26 ADF relay card connectors iesesdqax equas kd nu XOU GUAE R RC RUR Rr R CURL CR CUR RR AULA CRGA 5 31 UICC connectols Lc cisoceciec ee ur rre n RI Exe e RPEWrEQ GGEQQeENFPTUEP P ene Pap ga 5 34 Option feeder locations xusssesxice re qx Soh ae Sed RUN GORGE X GUCKEN Ra E KO eR Ree ees 5 35 Option feeder layout 225 065 2500 ckw e phe re Er Ea cr RE RR RR biv Pain q E mma RS abe 5 35 Option board layout isumxcssoe nu amr REG ntame E AES REA RARE AUR RA RS CRUS RODA RR RR 5 36 Option board connector values 00 cece eee E E EEn R r nh nnn 5 37 Li fetches prea kes ede eue E sedavecknydetaedeksitess EAE REEL a KE E KR RE EE ads 5 37 Preventive maintenance ssssssssssss sss 6 1 Safety inspection quide s orende risien ita Roa a han dd een cede es eee er eons TRAE TEES 6 1 L brication SDecITICalioHS a i iaa oak ackied o E ORACE ACERO CAO UR RE Urano ed aa ee RU 6 1 Scheduled main ona nLa3odk redd eoe dp KI SL eee xS GS MR S Gib ade me eas 6 1 Parts catalog esena a aa aho easa 7 1 Howto use this parts Catalog sisecka eekatuakavamRazeA Enait An Lineen RAE
207. ic aids 3 35 7541 03x Step 4b Second transfer Once the four planes of color are transferred to the transfer belt from the photoconductors the image is carried towards the transfer roll This transfer roll is mounted on the duplex unit The paper passes between the transfer belt and transfer roll when the image on the belt reaches the second transfer area The timing of the paper reaching the second transfer area is determined by the registration rolls located in the paperfeed unit The high voltage power supply sends voltage to the transfer roll to create a positive charge Once the image on the transfer belt reaches the transfer roll the negatively charged toner clings to the media and the entire image is transferred from the transfer belt to the media Sheet of paper a Second transfer roller Transferred on a sheet of paper Transfer belt Service tips If the transfer roller has nicks pits or flat spots on it the surface doesn t come into contact with the media and transfer unit properly This will cause voids or light spots on the page or repeating voids light areas because the toner can t be fully transferred due to the charge difference in the areas of damage e If the transfer roller does not engage the transfer unit or does not have voltage coming from the high voltage power supply the toner will not fully transfer from the transfer unit the entire page will be very light or blank Any toner that doe
208. icular color such as a corporate logo on page 3 50 The printed page appears tinted Can I adjust the color Sometimes a printed page may appear tinted for example everything printed seems to be too red This can be caused by environmental conditions paper type lighting conditions or user preference In these instances adjust the Color Balance setting to create a more preferable color Color Balance provides the user with the ability to make subtle adjustments to the amount of toner being used in each color plane Selecting positive or negative values for cyan magenta yellow and black from the Color Balance menu will slightly increase or decrease the amount of toner used for the chosen color For example if a printed page has a red tint then decreasing both magenta and yellow could potentially improve the color balance Diagnostic aids 3 49 7541 03x My color transparencies seem dark when they are projected Is there anything can do to improve the color This problem most commonly occurs when projecting transparencies with reflective overhead projectors To obtain the highest projected color quality transmissive overhead projectors are recommended If a reflective projector must be used then adjusting the Toner Darkness setting to 1 2 or 3 will lighten the transparency Make sure to print on the recommended type of color transparencies What is manual color correction When manual color correction is enabled the printe
209. ide 0 000 e cece eee ee IBI 2 59 849 01 Device had modem installed but config ID indicates it should not 2 59 849 10 Device had HD installed but config ID indicates it should not 2 59 900 xx System software error sss mh Rhenani Ra EUR t UR EEEO EEROR COL SUR RON 2 60 941 01 SDRAM R W GIF os cic ce ce nace pr ERR RSE Sees seem PurESeUERERPeqe EY a dE 2 62 941 02 MDC EMOT cc tues ku eteccedee detente ded Ra REOR REA NIE Ed OR EROR P RU OP RR 2 62 DIL 03 CPU GIO 25342322 x ER Seen E694 rS AGE DR E RUSO dd RAUS dub R E dd 2 63 941 04 MDC controller eFTOF iisecauuesckuaaesa RR ha REG REGRERARRERRGR REPEAT ERES A ARE 2 63 OU1 05 EEPHOM ONOR inde udar cede dea Ld eines ta hed as dada diu A Edid ed De dad deu 2 63 950 00 950 29 EPROM mismatch failure 000 c cece eee eee 2 64 959 xx Service invalid firmware error leseseeeeeeeee nne 2 65 User attendance messages i uu cen sensed soa RRRRRREARARRRNRARARRERRGA REA addas 2 66 User prompts sx asd easi a estrenan rannd nid ie CROCO ICRCNO OR E RR CA ene Ca RC RO ACD RR eee 2 66 User attendance messages 0 99 0 eee c eee eee reece eee rn nnn nnn 2 69 Other symplofTis uuu osx opu xoig cR RGEUQ CR eee R ee REN eS m SUR RR I BUS URL RR CS 2 75 Print ENGINE 22514 do dia sad Pd dox dobinipadus RR waa cda Re Said ae xw parie ETENEE ds 2 75 Scal CODY as ccm x GRAVE TREE PCS USER DEREK FE RERSRGERRGX ERE CN GR A CADRE CER 2 76 AE SUO
210. if the storage or transportation environment is very different from the printer environment Thick paper may also require a longer conditioning period because of the mass of material Grain direction Grain refers to the alignment of the paper fibers in a sheet of paper Grain is either grain long running the length of the paper or grain short running the width of the paper For 60 to 135 g m 16 to 36 Ib bond paper grain long fibers are recommended For heavier papers grain short is recommended Fiber content Most high quality xerographic paper is made from 100 chemically pulped wood This content provides the paper with a high degree of stability resulting in fewer paper feeding problems and better print quality Paper containing fibers such as cotton possesses characteristics that can result in degraded paper handling Unacceptable paper The following papers are not recommended for use with the printer e Chemically treated papers used to make copies without carbon paper also known as carbonless papers carbonless copy paper CCP or no carbon required NCR paper Preprinted papers with chemicals that may contaminate the printer Preprinted papers that can be affected by the temperature in the printer fuser Preprinted papers that require a registration the precise print location on the page greater than 0 09 in such as optical character recognition OCR forms In some cases registration can be adjusted with the software
211. ify that the voltage to the machine is within Go to step 5 Try a different spec 110v ac 10 220v ac 10 Is the voltage power outlet in within spec 5 Verify that the cables connecting the power inlet the Go to step 6 Properly connect switch and secondary power supply are properly the cables connected 6 Verify that the cables connecting CNO2 on the Go to step 7 Properly connect secondary power supply unit to CNO3 on the LVPS are the cables connected properly 7 Replace the switch Did this fix the problem Problem solved Go to step 8 8 Arethe fuses blown on either supply Go to step 9 Go to step 10 9 Replace the power supply with the blown fuse Did this Problem solved Go to step 10 fix the problem 10 Check CNO3 on the scanner power supply for the Go to step 11 Replace the following voltages and grounds oe supply See Pins 1 and 2 should be 5V dc Scanner power Pins 2 and 4 should be 24V dc supply iiid Pins 5 6 7 and 8 are GND ial a ci Are the voltages correct 11 Replace the RIP board See RIP board removal on Problem solved Go to step 12 page 4 73 Did this fix the problem 12 Check CNO3 on the low voltage power supply for the Go to step 13 Replace the following voltages and grounds LVPS See Low gt volt power Pins 4 and 8 should be 5V dc supply removal Pins 2 and 6 should be 24V dc on page 4 51 Pins 1 3 4 and 7 are GND Are the voltages correct 13 Replace the printhead control
212. ing faxes Note If an advanced password has been established you must enter this password in order to change the setting Fax Storage Location This menu allows you to select either NAND or the printer hard disk Disk as the fax storage location If the printer hard disk is removed then this menu no longer appears Color Adjustment Color Adjustment enables you to select the amount of color adjustments the printer makes during automatic color adjustment You can select from the following Disabled Fewest color adjustments Fewer color adjustments Normal default setting Better color accuracy Best color accuracy Auto Align Adj The printer automatically runs a Toner Patch Sensing TPS diagnostic after certain key events Depending on the type of event the results of the diagnostics can trigger either a color adjust calibration or an alignment calibration If necessary the printer will automatically adjust the alignment If Auto Align Adj is set to Off then the diagnostic still runs but the printer will not use the resulting data to automatically adjust alignment This could eventually lead to the user having to adjust alignment manually Therefore Auto Align Adj should not be set to Off during normal printer usage Color Adj State Use this menu to select when color calibrations occur Busy When a calibration is needed all queued jobs finish printing and then the emulators pause and refuse to add jobs to the queue un
213. ing printed color may not be an exact match of the Color Samples pages 3 50 Service Manual 7541 03x What are detailed Color Samples and how do access them Detailed Color Samples sets are available only through the Embedded Web Server of a network printer A detailed Color Samples set contains a range of shades displayed as colored boxes that are similar to a user defined RGB or CMYK value The likeness of the colors in the set are dependent on the value entered in the RGB or CMYK Increment box To access a detailed Color Samples set from the Embedded Web Server Open a Web browser In the address bar type the network printer IP address Click Configuration Click Color Samples Click Detailed Options to narrow the set to one color range When the Detailed Options page appears select a color conversion table Enter the RGB or CMYK color number Enter an Increment value from 1 255 Note The closer the value is to 1 the narrower the color sample range will appear Click Print to print the detailed Color Samples set O oq m oro Orr ee Diagnostic aids 3 51 7541 03x 3 52 Service Manual 7541 03x 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 To prevent damage to ESD sensitive parts use the following instructions in addition to all the usual
214. ing the ADF unit assembly Replace the ICC Problem solved Does the error continue board Go to ICC board on page 4 123 Spots using flatbed scanner Step Check Yes No 1 Check the large platen glass on the scanner unit Clean or replace Go to step 2 assembly the scanner Is the large platen glass contaminated or damaged pn glass Go to Flatbed upper cover on page 4 161 2 Check the three mirrors in the scanner unit assembly Clean the three Go to step 3 coe three mirrors contaminated or show signs of EE ust assembly 3 Check the white strip on the bottom of the large platen Clean the white Go to step 4 glass strip and POR Is the white strip contaminated the machine 2 12 Service Manual 7541 03x Step Check Yes No 4 Perform a print test using the scanner CCD assembly Replace the Problem solved Does the error continue see on Go to CCD chassis on page 4 124 5 Perform a print test using the flatbed scanner assembly Replace the ICC Problem solved Does the error continue board Go to ICC board on page 4 123 Diagnostic information 2 13 7541 03x Skew using ADF The printed image is not paralleled with both sides of the media Step Check Yes No 1 Check printer installation placement Go to step 2 Correct the Check the installation surface for irregularities FISCI Check for damaged printer caster Is the setup
215. installed correctly and is not broken or damaged If the Memory card assembly is correctly installed not broken or damaged then run the Flash Test on page 3 25 If the test fails replace the Flash card assembly If the problem continues replace the RIP board DRAM options This service check is the same as the flash memory option service check with the following exception Run the DRAM Test on page 3 22 from the menu if the DRAM Memory card assembly is correctly installed and not broken or damaged If the test fails replace the DRAM card assembly If the problem continues replace the RIP board 2 90 Service Manual 7541 03x Hard disk option Service Tip The 5041 030 printers support one hard disk option Be sure only one hard disk option is installed Be sure the hard disk and the hard disk board are correctly installed Run the Quick Disk Test on page 3 24 from the Device Test on the Diagnostic Menu Note The Quick Disk Test is a non destructive test and indicates Pass or Fail If the test fails replace the hard disk If a problem still exists replace the RIP board Use the Disk Test Clean on page 3 24 to help restore the disk if it contains bad data and is unusable This test is divided into a cleaning and a verifying or testing section Warning This can be a very lengthy test depending on the disk size This test leaves the hard disk unformatted The servicer or user must reformat the disk using the Forma
216. int cartridge contacts for damage contamination Replace the print cartridge if defective Inspect the ribbon cable connection on the printhead controller board Properly connect the cable if not connected properly Replace the cable if damaged Replace the indicated cartridge If the problem still exists replace the printhead controller board See Printhead controller board removal on page 4 37 32 Unsupported Cartridge Check to see if the toner cartridge is a supported cartridge Note Once the cartridge shipped with the printer is exhausted it must be replaced by a supply cartridge refer to the User s Guide for part numbers If the specified toner cartridge is a supported cartridge reseat the cartridge Inspect the toner cartridge contacts for damage or contamination Replace the toner cartridge if defective Inspect CN17 18 cable connections on the printhead controller Properly connect the cable if not connected properly Replace the toner sensors if damaged If the problem still exists replace the system board See RIP board removal on page 4 73 34 Short Paper Select Continue to clear the message and continue printing Note The printer does not automatically reprint the page that prompted the message Check the tray length and width guides to ensure the media is properly fitted Make sure the print job is requesting the correct size of media Adjust the Paper Size setting for the media size being
217. ions CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task Consignes de s curit La s curit de ce produit repose sur des tests et des agr ations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pi ces de rechange non agr es Lesconsignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi e Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires ATTENTION Ce symbole indique la pr sence d une tension dangereuse dans la partie du produit sur laquelle vous travaillez D branchez le produit avant de commencer ou faites preuve de vigilance si l ex cution de la t che exige que le produit reste sous tension Norme di sicurezza e La sicurezza del prodotto si basa sui test e sull approvazione del progetto originale e dei componenti specifici Il produttore non responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti e Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di ass
218. isk options 2 91 imaging unit missing 2 89 Incoming fax has blank spaces or poor quality 2 83 insert tray 2 88 Network card option 2 91 networking 2 84 No dial tone 2 83 operator panel 2 87 option card 2 86 2 90 Paper has entered the duplex unit Paper jam 230 231 9 2 26 Paper has entered the fuser and exited the printer 1234xxx Paper jam 203 2 25 Paper has exited the registration roller and entered the fuser Paper jam 201 2 25 Paper has stopped at the registration roller or has not reached the fuser Paper jams 200 250 24x 2 25 Paper in ADF size service check 2 96 Paper is being picked up and carried to the registration roller Paper jams 200 250 24x 2 24 paper path 2 24 Paper has entered the duplex unit Paper jam 230 231 9 2 26 Paper has entered the fuser and exited the printer Paper jam 203 2 25 Paper has exited the registration roller and entered the fuser Paper jam 201 2 25 Paper has stopped at the registration roller or has not reached the fuser Paper jams 200 250 24x 2 25 Paper is being picked up and carried to the registra tion roller Paper jams 200 250 24x 2 24 paper skew 2 89 Power supply Dead machine service check 2 92 printhead service check 2 93 scanner fax copy ADF cover open 2 77 ADF paper am 2 36 escalating a fax issue to second level support 2 82 serial port 2 90 transfer belt up down check 2 93 unable to print from USB thumb drive 2 94 USB port 2 86 waste toner bott
219. ist If the src is Envelope Feeder Envelope Feeder will be used Additional messages may include Paper changed Select Continue Ignored if no paper in tray For size and type loaded in Source but not changed on paper menu More information the printer will present instructions Ignore This will ignore request and print on paper in tray Cancel Job the printer job can be canceled Incorrect Orientation This error can occur when the printer does not know the actual paper size that is loaded in a tray due to an incorrect paper orientation setting or because tray guides are not in proper location This message is not valid for the manual feeder or tray 5 Additional messages may include More information the printer will present instructions 2 66 Service Manual 7541 03x Error code Action Close Tray Door Close Front Door Close the front door securely Disk Corrupted Reformat The printer has attempted a disk recovery and cannot repair the disk The disk must be formatted to use Warning All files stored on the disk will be lost Held Jobs May Not Be Restored The printer has attempted to restore Held jobs but not all were restored Insert Tray x Insert tray to clear the message Install Tray lt x gt or Cancel Job Install tray to clear the message Load lt source gt lt custom type name gt Load paper in the indicated source and
220. istenza autorizzato Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona pi elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie ATTENZIONE Questo simbolo indica la presenza di tensione pericolosa nell area del prodotto Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l intervento Safety information XV 7541 03x Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlie lich f r die Verwendung durch einen Wartungsfachmann bestimmt e W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zustandige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen e ACHTUNG Dieses Symbol weist auf eine gef hrliche elektrische Spannung hin die in diesem Bereich des Produkts auftreten kann Ziehen Sie vor den Arbeiten am Ger t den Netzstecker des Ger ts bzw arbeiten Sie mit groBer Vorsicht wenn das Produkt f r die Ausf hrung der Arbeiten an den Strom angeschlossen sein muB Pautas de S
221. ituation 3 14 Service Manual 7541 03x FB Edge Erase The FB Edge Erase setting specifies in millimeters the size of a border around the scanned image that will be erased For copies the printed page will always have a at least a 2 mm no print border The larger of the 2 mm no print border and the Edge Erase setting will be used in this situation Scanner Manual Registration Use this menu to adjust the scanner margins after you replace any of the following parts Flatbed scanner assembly ADF unit assembly Flatbed scanner CCD assembly For more information see Adjusting scanner registration on page 4 206 Note The Scanner Manual Registration menu does not appear if Disable Scanner is set to Auto Disabled Disable Scanner Use this setting to enable or disable the flatbed scanner and ADF Note Auto Disabled can only be saved by the printer in response to failed scanner operation Users cannot save this setting Motor Calibration This test synchronizes the aligner and fuser motor speeds with the transfer belt Eight blank pages feed during the test and all buttons are disabled until the test finishes Note Motor Calibration must be performed using 600dpi resolution and with duplex disabled Paper Prompts Setting Paper Prompts controls which tray a change prompt is directed to when paper is sensed to be the wrong size Envelope Prompts Env Prompts controls which tray a change prompt is directed
222. jobs in order to process current jobs Select Continue to clear the message e f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 37 Insufficient memory Some Held Jobs Will Not Be Restored The printer was unable to restore some or all of the confidential or held jobs on the hard disk Select Continue to clear the message f this message occurs again replace the hard drive e f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 37 Insufficient Defrag Memory There is insufficient memory to perform the Flash Memory Defragment operation The user can Delete font macros and other data in memory Install additional printer memory 38 Memory Full The following options are available Select Continue to clear the message and continue printing The job may not print correctly Cancel the current job Install additional printer memory e f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 39 Complex Page The page is too complex to print Options are Select Continue to continue The job may not print correctly Cancel the job 50 PPDS Font Error 2 70 Service Manual Select Continue to clear the message and continue printing The job may not print correctly Cancel the current job If this does not fix the problem replac
223. justments on page 4 205 4 116 Service Manual 7541 03x Flatbed front cover 1 Remove the flatbed assembly from the flatbed platform 2 Turn the flatbed over on a non marring surface 3 Remove the screw A 4 Remove the screw B Repair information 4 117 7541 03x 5 Remove the screw C 6 Remove the screw D 4 118 Service Manual 7541 03x 7 Remove the screw E Repair information 4 119 7541 03x UICC removal 1 Remove the upper operator panel top cover See Op panel top cover on page 4 13 2 Disconnect the haptics cable A from the UICC B C A 3 Remove the UICC cable B from the UICC 4 Disconnect the ribbon cable C from the UICC 5 Remove the four screws D securing the UICC to the upper operator panel assembly 4 120 Service Manual 7541 03x Touchscreen assembly removal 1 Remove the upper operator panel assembly 2 Remove the UICC See UICC removal on page 4 120 3 Disconnect the UICC cable A from the touchscreen from the touchscreen B A B 4 Remove the seven screws B securing the touchscreen to the upper operator panel assembly Repair information 4 121 7541 03x ADF relay board 1 Remove the ADF relay board cover See ADF relay card cover on page 4 167 2 Disconnect the ADF cable ground A from the relay board O A 3 Disconnect all the cables from the relay board 4 Remove the other screw securing th
224. l Sensor removal 1255523 oxi teneant sewr OR RCR OR CGU RC RN C CR OCC E ln 4 36 Paper exit sensor removal 5 5 2259 ah hens a ERR dele dence E Bale bn wee de Sa 4 37 Printhead controller board removal 0 0 cece eee eee e eee eee eee nena eeeee 4 37 Front removale osc cect cer erpRGEOeRER ERGO dA e dd Ea Rd Kem ed A D PAR NA ee On B d a dead dt 4 40 Transfer belt CRU iissesun heu hh RRRRRRRARRERGERERARRRRRERESRARESRREEXGA RA 4 40 Transfer belt position sensor removal 00 cece cece pniti niri AEn ER nn 4 41 Paper size sensor removal i ici iewdcsetdarekdsiceaes RARE RU RE A Opa wea d RR 4 42 Phiotoconductor IOCK TEMOVAl iscemascs d bos eee OR OAK SUA CRCR DR A RA AC ena ed ICA RUE Rd 4 43 Cassette stopper removal lsuecasuacuuzeckezu e una Rh RREACREEGRRRGGRRAREG CP REGE E EE 4 44 LG E SIdOe FRIOVOES podina d nit dr PRAG OE Qd 8 Vid n E ER A RUE UR DU RAE A cR BU VUA GU d a M RUE ama 4 45 Left EMI shield removal nota FRU lseeeeeeee RII III 4 45 Low volt power supply removal csi sxsxxk sick ko X see ewe RRR CR EOD RR RR Ra 4 51 BIBI TAN POMMOVAL NP TI EDO EE T a P c 4 53 Power supply fan remova al 1 use kan RR ERROR tee idan ia QCRCACARCRORLE eee eR ees 4 55 Theta sefisor TemoVal 0 ode ran emu OR EAR RR sae S ORRRIN RU ACE cele nb RUN REOR S edm 4 56 Density sensor removal 4 5 ace icem kick ko RR KORR QU CR GEAR RR KA CR IRR c UU CR em wa eee 4 57 MSIE SWIICI ados 04 305 52 Edu I Ka B RUE Sue Ud Sub od u
225. lacing the option card replace the RIP board See RIP board removal on page 4 73 If there are no errors found testing the cards individually install the cards on at a time Restart the MFP after each card is installed Cables If the cards do not trigger an error check the option card connection cables for continuity USB port service check 1 Perform a print test to make sure the printer prints correctly Verify that the indicator light is on then print the menu settings by Menu Settings Page from the Reports Menu in the menus AON Be sure the printer USB cable is designed for bidirectional printing Be sure the user s application is set up correctly If the internal print test page prints correctly the user s application printer driver is set up correctly and the USB cable is installed but the printer still fails to print on command from the host computer then replace the controller board 5 Check the USB cable for continuity False close door service check Step Action and questions Yes No 1 Open and close the right cover Does the message Problem solved Go to step 2 reset 2 Check the right door release lever Does it operate Go to step 3 Replace the smoothly and is the interlock actuator intact faulty part on the door 3 Is the interlock switch cable properly connected to the Go to step 4 Properly connect interlock switch and CN23 on the engine board the interlock swi
226. lain 32 32 13 13 A4 plain 33 33 14 14 Note Scan performance is measured as 150 dpi 1 bit for mono and 150 depi 24 bit for color 1 14 Service Manual 7541 03x Tools required for service Flat blade screwdrivers various sizes 1 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic short blade 7 32 inch 5 5 mm open end wrench 7 0 mm nut driver Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax serial debug cable 1381963 Coax serial debug cable 1381964 Flashlight optional General information 1 15 Acronyms ac ACM ADF AFE APS ASIC BLDC BOR BUD C CCW CDB CMYK CPU CRC CRU CSU CW DBCS dc DIMM DLE DRAM DVM ECC ECM EDO EEPROM ENA EOL EP EPROM ESD FD FRU FU GB GFI GHz HBP HTML HV HVPS HVU Hz INTL ITC ITU K 1 16 Service Manual Alternating Current Autocompensator Mechanism or paper feed Automatic document feeder Analog front end Automatic Paper Size Application Specific Integrated Circuit Brushless DC Motor Black Only Retract Belt up down Cyan Counter clockwise Command Descriptor Blocks Cyan yellow magenta black Central processing unit Cyclic redundancy check Customer Replaceable Unit Customer Setup Clockwise Double byte character set Direct Current Dual Inline Memory Module Downloadable emulator Dynamic
227. le missing 2 94 Words on fax are stretched 2 83 wrong paper size service check tray1 2 95 Wrong paper size service check tray2 2 95 service error 111 01 black printhead error 2 45 112 01 cyan printhead error 2 45 113 01 magenta printhead error 2 45 114 01 yellow printhead error 2 45 121 01 thermistor 1 error 2 46 121 02 thermistor 2 error 2 46 121 03 thermistor 3 error 2 47 121 04 Belt thermistor error 2 47 121 05 fuser fuser heater error 2 48 126 xx power switch error 2 48 130 xx high voltage power supply error 2 49 132 xx density sensor error 2 49 132 xx abnormal theta sensor 2 50 136 xx temperature humidity sensor error 2 50 140 01 main motor error 2 51 146 01 tray 1 error 2 52 149 01 exit motor error 2 51 171 01 fuser fan error 2 54 172 01 power supply unit fan error 2 55 173 01 main unit fan error 2 55 174 01 rear fan error 2 55 840 03 service check 2 56 841 00 Invalid configuration or ASIC not found 2 56 Index l 5 7541 03x 841 01 Invalid AFE setting 2 56 841 02 Delayed interrupt detected 2 57 841 03 Failed indirect register test 2 57 841 04 Failed external DRAM test 2 57 841 05 Image pipe time out 2 57 841 06 Scanner did not initiate scan 2 58 842 00 No response 842 01 HW protocol 842 02 Logical protocol 2 58 843 00 Carriage Home 2 59 844 00 Lamp failure Front side 2 59 849 01 Device had modem installed but config ID indicates it should not 2 59 849 10
228. ler board See Problem solved Contact you next Printhead controller board removal on page 4 37 level support Did this fix the problem 2 92 Service Manual Printhead service check 7541 03x Step Action and questions Yes No 1 Check the LED for any dirt or toner that may distort the Go to step 2 Go to step 3 image Is the LED dirty 2 Clean the LED Did this fix the problem Problem solved Go to step 3 3 Checkthe ribbon cable for proper connectivity to the Go to step 5 Go to step 4 defective printhead and the printhead controller board Is the cable properly connected 4 Properly connect the cable on both ends Did this fix Problem solved Go to step 5 the problem 5 Check the cable for continuity Is there continuity Go to step 6 Go to step 7 6 Replace the defective cable Did this fix the problem Problem solved Go to step 7 7 Replace the printhead Did this fix the problem Problem solved Go to step 8 8 Replace the printhead controller board Did this fix the Problem solved Contact you problem second level support Transfer belt up down check Step Action and questions Yes No 1 Is the transfer belt position sensor actuator jammed or Replace the Go to step 2 broken transfer belt 2 Is the belt position sensor cable connected to the Go to step 3 Properly connect sensor and CN9 on the engine board the cable at both ends 3 Replace the belt position sensor
229. level support Diagnostic information 2 57 7541 03x 841 06 Scanner did not initiate scan Step Questions actions Yes No 1 Check the cables connecting the RIP board to the Go to step 2 Go to step 3 scanner for damage Is there any visible damage 2 Replace the faulty cables Did this fix the problem Problem resolved Go to step 3 3 Check the cables for continuity Is there continuity Go to step 5 Go to step 4 4 Replace the faulty cable Did this fix the problem Problem resolved Go to step 5 5 Is the flatbed LED illuminating when the scan Go to step 6 Go to step 7 command is issued Replace the CCD Did this fix the problem Problem resolved Go to step 7 7 Replace the ICC card Did this fix the problem Problem resolved Go to step 8 8 Replace the RIP board Did this fix the issue Problem resolved Contact second level support 842 00 No response 842 01 HW protocol 842 02 Logical protocol Step Questions actions Yes No 1 POR the device Did the error re occur Go to step 2 Problem resolved 2 Checkall the connections from the ICC card to the Go to step 3 Go to step 4 ADF relay card and RIP board to ICC card Also check the CCD cables for proper connectivity Are the cables properly connected 3 Properly connect all the cables Did this fix the issue Problem resolved Go to step 4 4 Checkthe cables for continuity Is there contin
230. loper drum have any Let the drum dry Go to step 4 dew on it out Do not wipe the drum with a cloth 4 Remove and reinstall the imaging unit Does this fix the Problem resolved Go to step 5 problem 5 Replace the imaging unit Does this resolve the issue Problem resolved Go to step 6 6 Checkthe transfer roll for dents Are there any dents in Replace the Go to step 7 the transfer roll transfer roll 7 Remove the transfer belt and check the surface for Replace the Contact your waviness or other irregularities Are the surface transfer belt second level irregularities support Partially dark or light print Step Action and questions Yes No 1 Check the drum on the imaging unit for over exposure Go to step 2 Go to step 3 to light Has it been over exposed to light 2 Replace the affected imaging unit Did this fix the Problem Go to step 3 issue resolved 3 Check the imaging unit for proper installation Is it Go to step 5 Go to step 4 properly installed 4 Reinstall the imaging units Did this fix the issue Problem Go to step 5 resolved 5 Clean the contacts on the imaging unit and the printer Problem Contact your Did this resolve the issue resolved second level support 2 8 Service Manual 7541 03x Black page Step Action and questions Yes No 1 Inspect the contact points for the imaging unit and the Go to step 3 Go to step 2 p
231. lowing 1 2 NO Cn Print a menu settings page and then check the life status of all supplies Any supplies that are low should be replaced On the menu page make sure the following is set to the default level Color Correction Set to Auto Print Resolution Set to 1200 dpi print quality problems should be checked at different resolution settings Toner Darkness Set to 4 default Color Saver Set to OFF RGB Brightness RGB Contrast RGB Saturation Set to 0 Color Balance Touch Reset Defaults to zero out all colors Check the paper type texture and weight settings against what is loaded in the printer Inspect the transfer module transfer belt and transfer roll for damage Replace if damaged Inspect the imaging units and toner cartridges for damage Replace if damaged If paper other than 20lb plain letter A4 paper is being used load 20lb plain letter A4 and print the Print Quality pages to see if the problem remains Use Tray 1 to test print quality problems Print the Print Quality Pages and then look for variations in the print from what is expected An incorrect printer driver for the installed software can cause problems Incorrect characters could print and the copy may not fit the page correctly Repeating defects The following table contains the circumferences of the imaging and transport components Check the intervals of any marks or defects that appear on a printout if they ma
232. lubrication specifications and recommendations to prevent problems Parts catalog contains illustrations and part numbers for individual FRUs Appendix A contains service tips and information Appendix B contains representative print samples Au oo Bo m Conventions Note A note provides additional information Warning A warning identifies something that might damage the product hardware or software There are several types of caution statements CAUTION A caution identifies something that might cause a servicer harm CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task CAUTION This type of caution indicates a hot surface CAUTION This type of caution indicates a tipping hazard gt PEP e xviii Service Manual 7541 03x 1 General information The Lexmark X925 7544 xxx is a network capable color MFP that uses electrophotographic technology to deliver high quality images presentation graphics line art and text It prints both four color and monochrome print jobs The X925 represents the latest in Lexmark printer innovation including a full color eTask touch screen with improved messaging and animation enhanced security features remote operator panel access and
233. m the printer a 1 xa 4 54 Service Manual 7541 03x Power supply fan removal Note Fan needs to be mounted with label pointed outwards 1 Remove the left side EMI shield 2 Remove the fan s wiring harness from the connector A on the shield Note The harness must be routed in this matter when the fan is reinstalled 3 Turn the shield over and remove the four screws B securing the fan to the shield Repair information 4 55 7541 03x Theta sensor removal 1 Remove the LVPS See Low volt power supply removal on page 4 51 2 Remove the scanner power supply See Scanner power supply removal on page 4 58 3 Remove the 7 screws A securing the power box shield to the printer frame 4 Disconnect the theta sensor harness from the theta sensor 5 Remove the one screw B securing the theta sensor mounting plate to the printer frame 6 Remove the two screws C securing the theta sensor to the mounting plate 4 56 Service Manual 7541 03x Density sensor removal 1 Remove the LVPS See Low volt power supply removal on page 4 51 2 Remove the scanner power supply See Scanner power supply removal on page 4 58 3 Remove the 7 screws securing the power box shield to the printer frame Y 4 Disconnect the density sensor harness from the density sensor 5 Remove the two screws D fastening the density senso
234. motors properly connected 12 Connect the cables Did this fix the issue Problem resolved Got to step 13 13 Replace the ADF motor assembly Did this Problem resolved Go to step 14 fix the issue 14 Check the ADF cable for continuity Is there Go to step 15 Replace the ADF cable continuity 15 Replace the ADF relay card Did this solve Problem resolved Go to step 16 the problem 2 36 Service Manual 7541 03x Step 16 Replace the ICC board Did this fix the issue Questions actions Yes Problem resolved No Replace the RIP board See RIP board removal on page 4 73 Diagnostic information 2 37 7541 03x Error codes In addition to the 1xx and 9xx error codes this device has displays a symptom where the device shuts down repeatedly The main symptom of this error is the switch going to the off position automatically when the device PORs This is due to a fuser and printhead controller abnormality If this symptom is displayed see Abnormal fuser temperature error on page 2 48 1xx error codes Action 121 01 Abnormal thermistor 1 See 121 01 Thermistor 1 error on page 2 46 121 02 Abnormal thermistor 2 See 121 02 Thermistor 2 error on page 2 46 140 01 Abnormal main motor See 140 Drive motor error on page 2 51 149 01 Abnormal exit motor 172 01 Abnormal power supply fan See 149 01 Fuser paper exit motor e
235. move the screw A from the op panel paper exit guide A 3 Remove the screw B from the op panel paper exit guide 4 26 Service Manual 7541 03x 4 Remove the screw C from the op panel paper exit guide 5 Remove the top cover of the guide Repair information 4 27 7541 03x 6 Use a flatblade screwdriver to release the actuator from the exit guide 7 Remove the actuator 4 28 Service Manual 7541 03x LED assembly removal 1 Remove the transfer belt See Transfer belt CRU on page 4 40 2 Remove the top cover See Output bin print engine top cover on page 4 17 3 Remove the rear EMI shield See Rear EMI shield Not a FRU on page 4 106 4 Remove the toner cartridges and imaging units 5 Disconnect the affected LED s ribbon cable from the printhead controller board 6 Guide the printhead ribbon cable through the top of the print engine A Note You will need to remove the top EMI shield to access the screw if you are removing the magenta or yellow LED assembly Repair information 4 29 7541 03x 8 Press up on the green touchpoint 9 Pull the LED assembly towards the front of the print engine Note Use two hands when removing the unit This is to prevent the LED assembly from dropping down and damaging the LED unit in the assembly Note Perform a color alignment after installing the new printhead See Color Alignment on page 3 14 4 30 Service Manual
236. ms a wipe of the printer hard disk erasing all data Warning Wipe Disk deletes all data on the printer hard disk including downloaded fonts macros and held jobs Do not initiate a disk wipe if you have information on the printer that you want to save Wipe disk fast This is a single pass wipe that overwrites all data and the file system This wipe is faster but less secure since it is possible to retrieve the deleted data with forensic data retrieval techniques e Wipe disk secure This multiple pass wipe overwrites all data without rewriting the file system This wipe is DoD 5220 22 M compliant since the deleted data is irretrievable Font Sharpening Font Sharpening allows the user to adjust the value of the high frequency screens used for font data For example if the value is 24 all fonts 24 points and less use the high frequency screens The default value is 24 This feature works only in PostScript emulation Require Standby If set to Off this setting disables Standby Mode in the General Settings menu UI Automation Once enabled this setting creates an ENABLE UI AUTOMATION file in the shared directory As long as this file exists the printer permits external developers to test the stability of their applications against the printer to ensure that their applications have an appropriate level of stability Disabling this setting deletes the file Key Repeat Initial Delay This setting determines the length of delay bef
237. ms are available under the Print Fax and Network headings Print job Copy job Fax profile FTP E mail send Each heading shows up to three jobs per screen If more than three jobs exist in a column then an arrow appears enabling you to scroll through the jobs Select a job to cancel it Using the touch screen Sample touch screen Copy from i o Sides Duplex Collate Letter 8 5 x 11 in 2 E j 2 4 2 SSS 1 A Copy to d Letter 8 5 x 11 in Plain Paper ito 2iSideH On Staple Punch Content Scale p p Auto a 1 f 100 i M 3 Staples Left On Text Photo Save as Shortcut Other Feature Color Darkness Fund lil Setting 1 Log Out Copies 999 amp Options mS Button Function Submit Saves settings changes Sample copy Prints a sample of a document or image Right arrow Opens the menu or options list beside it Diagnostic aids 7541 03x 3 3 7541 03x Button Function Right scroll increase Increases a value Left scroll decrease Decreases a value Home Returns to the home screen Exit Exits from the current screen to the home screen Tips Opens context sensitive Help on the touch screen Other touch screen buttons Icon Function Accept v Confirms selections and moves to the next screen Stop Cancel 2 Cancels an action or selection Can
238. n it on 61 Defective Disk Select Continue to clear the message and continue printing Install a different hard disk before performing any operations that require a hard disk f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 62 Disk full Select Continue to clear the message and continue processing Any information not previously stored on the hard disk is deleted Delete fonts macros and other data stored on the hard disk Install a larger hard disk f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 63 Unformatted disk Select Continue to clear the message and continue printing Format the disk f the error message remains replace the hard disk f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 64 Unsupported disk format Select Continue to clear the message and continue printing Format the disk f the error message remains replace the hard disk f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 2 72 Service Manual 7541 03x Error code Action 80 Fuser Near Life Select Continue to clear the message and continue printing Warning Show Me View Supplies and Tell Me More displays additional information Order a replacement fuser When print quality is red
239. n the third expansion paper feeder s Go to step 7 Go to step 6 expansion feeder controller board for proper connectivity Is it properly connected 6 Reconnect the cable to CN 103 Did this fix the Problem Go to step 7 problem resolved 7 Replace the paper full sensor Does this fix the Problem Go to step 8 problem resolved 8 Replace the expansion paper feeder controller board Problem Contact you Does this fix the problem resolved second level support 171 01 Fuser fan error Step Questions actions Yes No 1 Is there anything obstructing the fan s movement Clear the Go to step 2 obstruction 2 Check connector CN21 on the MDCONT board Is it Go to step 3 Reconnect the properly connected connectors 3 Replace the fuser fan Does this remedy the situation Problem solved Go to step 4 4 Replace the engine controller board Does this remedy Problem solved Contact your the situation second level support 2 54 Service Manual 172 01 Power supply unit fan error 7541 03x Step Questions actions Yes No 1 Is there anything obstructing the fan s movement Clear the Go to step 2 obstruction 2 Check connector CN22 on the MDCONT board and Go to step 3 Reconnect the CNO04 and CNO5 on the LVPS Are they properly connectors connected 3 Replace the power supply fan Does this remedy the Problem solved Go to step 4 situation 4 Replace the LVPS See Low volt powe
240. name gt orientation Change lt src gt lt Custom string gt lt orientation gt This message allows the user to override the source for the remainder of a job The page will be printed as it is formatted on the paper installed in the tray This may cause clipping No further Change prompts will be posted for the remainder of the current job If the src is MP Feeder Manual Paper or Manual Envelope the string Manual Feeder will be used instead of the src string from the Default Source list If the src is Envelope Feeder Envelope Feeder will be used Additional messages may include Paper changed Select Continue More information the printer will present instructions gnore use current source Cancel Job the printer job can be canceled The Change Orientation message is only displayed for Letter and A4 paper sizes This IR allows a user to override the source for the remainder of a job The page will be printed as it is formatted on the paper installed in the tray This may cause clipping No further Change prompts will be posted for the remainder of the current job If the src is MP Feeder Manual Paper or Manual Envelope the string Manual Feeder will be used instead of the src string from the Default Source list If the src is Envelope Feeder Envelope Feeder will be used Additional messages may include Paper changed Select Continue More information the printer will present instructions gn
241. nate Step Action and questions Yes No 1 Check the cable connection between the RIP and the UICC and check the connection from the UICC to the display Are all the cables properly connected Go to step 3 Go to step 2 Reconnect the cables POR the machine Did this fix the problem Problem solved Go to step 3 Using a multimeter check the cable connecting the RIP board and UICC and the cable connecting the UICC to the display for continuity Is there continuity in the cables Go to step 5 Go to step 4 Replace the defective cable POR the machine Did this fix the problem Problem solved Go to step 5 Are the LEDs on the operator panel lit Go to step 6 Go to step 7 Replace the display Did this fix the problem Problem solved Diagnostic information 2 87 Go to step 7 7541 03x Step Action and questions Yes No 7 Check connector J9 on the RIP board for the following Go to step 9 Go to step 8 voltages and grounds Pins 2 9 15 20 21 GND Pins 10 16 17 18 23 5V Do the voltages and ground readings approximately match the table 8 Replace the RIP board POR the machine into Problem solved Go to step 7 Diagnostics mode Did this fix the problem 9 Replace the UICC POR the machine into Diagnostics Problem solved Contact your mode second level Did this fix the pr
242. nected 7 Reconnect the connection at CN120 Did this fix the Problem Go to step 8 problem resolved 8 Checkthe cable connecting CN103 and the paper full Go to step 10 Go to step 9 sensor for proper connectivity Is the cable properly connected on both ends 9 Re connect the cable at both ends Did this fix the Problem solved Go to step 10 problem 10 Checkthe paper full sensor cable for continuity Is there Go to step 12 Go to step 11 continuity 2 52 Service Manual 7541 03x Step Action and questions Yes No 11 Replace the paper full sensor cable Did this fix the Problem solved Go to step 12 problem 12 Replace the paper full sensor Did this fix the issue Problem solved Go to step 13 13 Replace the expansion paper feeder controller board Problem solved Go to step 14 Did this fix the issue 14 Check pins 6 and 7 on CN13 of the printer controller Contact your Replace the board for 24V Is the voltage correct second level printer controller support board 146 04 Tray 4 error Note This is the second expansion tray Step Action and questions Yes No 1 Check CN 121 on the first expansion paper feeder s Go to step 3 Go to step 2 expansion feeder controller board for proper connectivity Is it properly connected 2 Reconnect the cable to CN 121 Did this fix the Problem Go to step 3 problem resolved 3 Check CN 120 on the second expa
243. network Go to step 18 Contact the network communicating properly administrator 18 Verify that the ISP wireless card cable and any Go to step 20 Go to step 19 other ISP cables are properly seated in their connectors Are the cables connected correctly 19 Properly reseat the ISP cables Problem resolved Go to step 20 Did this fix the problem 20 Perform the option card service check See Replace the faulty ISP Go to step 21 Option card service check on page 2 86 option Was there another faulty ISP option 21 Replace the ISP wireless card Problem resolved Replace the RIP See RIP Did this fix the problem board removal on page 4 73 Diagnostic information 2 85 7541 03x Option card service check Option card service check FRU Action Option cards Controller board Option card connection cable Warning Do not replace the engine board and controller board at the same time Each board contains the printer settings When either of these boards is new it obtains the settings from the other board Settings are lost when both are new and replaced at the same time Card Remove all the option cards from the device Install each card individually Restart the MFP after each card is installed Remove the card and repeat the previous step with a different card till all cards are checked When a faulty card is found replace the card If the error persists after rep
244. nit 4 90 Service Manual 7541 03x Fuser entry sensor removal 1 Remove the sub drive unit See Sub drive unit removal on page 4 84 2 Depress the tabs A fastening the fuser entry sensor to the sub drive unit Repair information 4 91 7541 03x Engine board MDCONT 1 Remove HVPS See HVPS removal on page 4 111 2 Remove the rear fan 3 Disconnect the cables from the board A 4 Remove the four screws A securing the board to the bracket Fuser Fan 1 Remove the rear EMI shield See Rear EMI shield Not a FRU on page 4 106 2 Remove the fuser duct 3 Remove the HVPS See HVPS removal on page 4 111 4 Remove the rear fan See Rear fan on page 4 102 5 Disconnect the fuser fan cable from CN21 the engine controller board 6 Remove the fuser fan Note Make sure the rating label is facing outward when reinstalling the fan 4 92 Service Manual 7541 03x Fuser exit drive unit motor removal 1 Remove the rear EMI shield See Rear EMI shield Not a FRU on page 4 106 2 Disconnect the cable from the connector A exit drive unit motor C 3 Remove the two screws B that secure the exit drive unit motor to the fuser motor damper Note The ground wire C is connected with one of the screws Be sure to replace the ground wire when replacing the motor Repair information 4 93 7541 03x Modem removal 1 Disconnect the modem cable A from CN U14 on the RIP
245. nit 2 Remove the clip A securing the separator roll to the shaft iur Mee E oo M ann Rm t A lt 2 T HINT VOU JA eme e M zd Hall n 3 Slide the separator roll B off the shaft to remove it Paper size switches removal 1 Remove the paper tray from the option paper feed unit 2 Disconnect the cables A from the sensors 7541 03x 3 Remove the two screws B securing the sensor mounting bracket to the option tray rear frame 4 Remove the switches C from the bracket Repair information 4 197 7541 03x Paper level sensor removal Remove the tray from the option paperfeed unit Remove the rear cover Disconnect the paper level sensor cable Push the tabs securing the paper level sensor to the rear of the tray Remove the sensor from the option paperfeed drawer meo Transport sensor removal 1 Take the main printer unit off of the option paper feed unit 2 Remove the screw A securing the transport sensor bracket to the option feeder A 3 Disconnect the harness from the transport sensor 4 Remove the transport sensor from the mounting bracket by pressing the tabs B on the sensor together and pulling the sensor away from the bracket 4 198 Service Manual 7541 03x Paper empty sensor removal 1 Take the main printer unit off o
246. nnectors for proper connection Registration sensor CN12 MPF sensor CN14 f the connectors are properly connected replace the sensors f replacing the sensors does not fix the problem replace the engine control board 7541 03x Paper has stopped at the registration roller or has not reached the fuser Paper jams 200 250 24x FRU Action 1 Registration roller clutch Registration roller Transfer belt unit Rear paper feed guide Check these parts for wear or damage Replace as necessary Be sure all guide surfaces in the paper path are free of dirt Check the registration roller clutch for continuity Does the clutch engage when the printer is printing a job Be sure connector CN20 on the printhead controller board is connected properly If the connection is properly connected check pin 1 on CN20 for 24Vdc and pin 3 for GND If the voltage and ground are present replace the clutch If replacing the clutch doesn t fix the problem replace the printhead controller board Registration sensor Printer controller board Check the registration sensor connection on CN12 on the engine controller board for proper connection If it is properly connected replace the registration sensor If this doesn t fix the problem replace the engine board Paper has exited the registration roller and entered the fuser Paper jam 201 FRU Action 1 Transfer belt unit
247. not found ASIC not found on page 2 56 841 01 Invalid AFE setting See 841 01 Invalid AFE setting on page 2 56 841 02 Delayed interrupt detected See 841 02 Delayed interrupt detected on page 2 57 841 03 Failed indirect register test See 841 03 Failed indirect register test on page 2 57 841 04 Failed external DRAM test See 841 04 Failed external DRAM test on page 2 57 841 05 Image pipe timeout See 841 05 Image pipe time out on page 2 57 841 06 Scanner did not initiate scan See 841 06 Scanner did not initiate scan on page 2 58 842 00 No response See 842 00 No response 842 01 HW protocol 842 02 Logical protocol on page 2 58 842 01 HW Protocol See 842 00 No response 842 01 HW protocol 842 02 Logical protocol on page 2 58 842 02 Logical protocol See 842 00 No response 842 01 HW protocol 842 02 Logical protocol on page 2 58 843 00 Carriage home See 843 00 Carriage Home on page 2 59 844 00 Lamp failure 844 00 Lamp failure Front side on page 2 59 849 01 Machine has an installed Uninstall the modem See 849 01 modem that should not be Device had modem installed but present config ID indicates it should not on page 2 59 849 10 Machine has an installed Uninstall the hard drive See 849 10 hard drive that should notbe Device had HD installed but config ID present indicates it should not on page 2 59 2 40 Service Manual Fax T30 log error cod
248. ns Yes No 1 POR the device Does the error reoccur Go to step 2 Problem resolved Write down the exact 900 xx error code displayed on the device Turn the device off Clear the print queues Disconnect all communication cables and remove all memory options Remove all ISP and modem cards Restart the device into diagnostic mode Does the 900 xx error reoccur during startup Go to step 3 Go to step 6 Check all the cables connected to the RIP board for proper connectivity Are the cables properly connected Go to step 5 Go to step 4 Properly connect the cables to the RIP board Restart the device into diagnostic mode Does the 900 xx error reoccur during startup Go to step 5 Go to step 6 Replace the RIP board and restart the device Does this fix the problem Note If an error different from the original 900 xx is displayed consult the service check for that error Problem resolved Go to step 31 Print the following Error log Menu settings page Network settings page Does the 900 xx error reoccur while these pages were printing Go to step 31 Go to step 7 Re attach the communications cable Restart the printer to operating mode Send the printer a print job Does the 900 xx error reoccur Note Before performing this step write down this information about the file being sent to the printer Application used
249. nsion paper feeder s Go to step 5 Go to step 4 expansion feeder controller board for proper connectivity Is it properly connected 4 Reconnect the cable to CN 120 Did this fix the Problem Go to step 5 problem resolved 5 Check CN 103 on the second expansion paper feeder s Go to step 7 Go to step 6 expansion feeder controller board for proper connectivity Is it properly connected 6 Reconnect the cable to CN 103 Did this fix the Problem Go to step 7 problem resolved 7 Replace the paper full sensor Does this fix the Problem Go to step 8 problem resolved 8 Replace the expansion paper feeder controller board Problem Contact you Does this fix the problem resolved second level support Diagnostic information 2 53 7541 03x 146 05 Tray 5 error Note This is the third expansion tray Step Action and questions Yes No 1 Check CN 121 on the second expansion paper feeder s Go to step 3 Go to step 2 expansion feeder controller board for proper connectivity Is it properly connected 2 Reconnect the cable to CN 121 Did this fix the Problem Go to step 3 problem resolved 3 Check CN 120 on the third expansion paper feeder s Go to step 5 Go to step 4 expansion feeder controller board for proper connectivity Is it properly connected 4 Reconnect the cable to CN 120 Did this fix the Problem Go to step 5 problem resolved 5 Check CN 103 o
250. nsor actuator to see if it moves freely Does the sensor actuator move freely Go to step 4 Go to step 2 Is there any paper or obstruction preventing the actuator from moving freely Go to step 3 Go to step 4 Remove the obstruction from the actuator Did this fix the problem Problem resolved Go to step 4 Check the paper present sensor for dust or dirt Is the sensor dusty Go to step 5 Go to step 6 Clean the sensor off Did this fix the problem Problem resolved Go to step 6 Is the sensor dislodged Go to step 7 Go to step 8 Properly install the sensor Did this fix the problem Problem resolved Go to step 8 Check the sensor ADF paper present for proper operation 1 Enter the Diagnostics Menu 2 Touch SCANNER TESTS 3 Touch Sensor Tests 4 Observe the line sensor ADF paper present Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 4 Go to step 3 Check the sensor connection for proper connection to CN1 on the ADF relay and the paper present sensor Is the cable properly connected Go to step 10 Go to step 9 10 Connect the cables Did this resolve the issue Problem resolved Go to step 10 11 Check J1 pin 12 for 5V and pin 10 for ground Are these present Go to step 11 Go to step 12 12 Replace the paper pr
251. nt engine top cover on page 4 17 3 Remove rear EMI shield See Rear EMI shield Not a FRU on page 4 106 Repair information 4 37 7541 03x 4 Remove the screws A securing the cable box to the scanner support EN A 5 Remove the screw B securing the cable box to the top shield 6 Remove the screws securing the top shield 7 Disconnect all the cables from printhead controller board Warning Be careful to avoid damaging the ribbon cables when removing them from the printhead controller board 4 38 Service Manual 7541 03x 8 Remove the six screws C fastening the printhead controller board to the frame Repair information 4 39 7541 03x Front removals Transfer belt CRU 1 Open the front cover x o 2 fe o a x o c o Q O N 3 Lower the transfer belt door 4 40 Service Manual 7541 03x 4 Using the handle on the transfer belt pull the belt outward till the two green handles appear on the top of the unit 5 Use the two handles to pull the unit all the way out Transfer belt position sensor removal 1 Remove the transfer belt 2 Remove the sensor cable from the belt position sensor 3 Press the tabs the fasten the belt position sensor to the printer frame Repair information 4 41 7541 03x Paper size sensor removal This is the paper size sensor for the top MPF tray 1 Remove the standard paper tray 2 Remove the MPF paper t
252. ntact the edges of correctly the paper 3 If paper is skewing when fed or jamming Properly close the top If the paper is jamming in check to see if the top cover is open or ajar cover the ADF go to step 6 Is the ADF top cover open or ajar 4 Is paper failing to feed into the ADF Go to step 5 There is no issue 5 Check the sensor ADF paper present for Go to step 6 Go to step 9 proper operation 1 Enter the Diagnostics Menu 2 Touch SCANNER TESTS 3 Touch Sensor Tests 4 Observe the line sensor ADF paper present Are the sensors working properly 6 Check the leading edge of the paper to Bad media Replace the Go to step 7 ensure the paper is not curled or bent in a media way that would keep it from contacting the paper present sensor actuator Is the paper damaged 7 Check for dirt in the ADF scan sensor paper Clean the sensors or Go to step 8 in sensor and paper pass sensor See remove debris from the Flatbed ADF sensors on page 5 3 for scan sensor actuator their locations Are the sensors clean 8 Is the sensor actuator on the ADF scan Replace the scan sensor Go to step 9 sensor damaged actuator 9 Are the sensor cable connectors properly Go to step 10 Go to step 10 connected on the ADF relay card 10 Connect the cables Did this fix the issue Problem resolved Go to step 11 11 Check the ADF motor assembly for proper Go to step 12 Go to step 13 connection to J2 and J6 on the ADF relay card Are the
253. nter requires intervention to continue processing Touch this to access the messages screen for more information on the message and how to clear it Tips Opens context sensitive Help information on the touch screen Note All menus have a Tips button USB Displays files on a flash drive Bookmarks Allows you to create organize and save a set of bookmarks URLs into a tree view of folders and file links Held Jobs Displays all held jobs Change Language not pictured Allows you to change the primary language and reports on the display and will remain in effect until changed Release Held Fax not pictured If this button is shown then there are held faxes with a scheduled hold time previously set To access the list of held faxes touch this button Lock Device not pictured This button appears when the printer is unlocked and the Printer Lockout Personal Identification Number PIN has been set Touching this button opens a PIN entry screen Enter the correct PIN to lock the operator panel 3 2 Service Manual Item Description Unlock Device not pictured This button appears when the printer is locked The operator panel buttons and shortcuts cannot be used while this appears Touching this button opens a PIN entry screen Enter the correct PIN to unlock the printer control panel Cancel Jobs not pictured Opens the Cancel Jobs screen The following ite
254. nthead controller board See Printhead controller board removal on page 4 37 88 xx color Cartridge Nearly Low Show Me View Supplies and Tell Me More displays additional information Replace the specified toner cartridge Select Continue to clear the message and continue printing e f the problem persists replace the printhead controller board See Printhead controller board removal on page 4 37 88 xx Replace color Cartridge Show Me View Supplies and Tell Me More displays additional information Replace the specified toner cartridge Select Continue to clear the message and continue printing Ifthe problem persists replace the printhead controller board See Printhead controller board removal on page 4 37 2 74 Service Manual 7541 03x Other symptoms Print engine Symptom Action You cannot print color Make sure the Color Correction menu item is not set to Black amp White Make sure the color print units are completely installed in the printer Go to Transfer belt up down check on page 2 93 Transparencies curl excessively Make sure you re using the recommended Lexmark transparencies Also be sure the paper delivery is set to the rear exit The printer seems slow to print If you set the Paper Type to Transparency or Card Stock the printer increases the fuser temperature and slows printing to improve the print quality After printing
255. o the ICC card for proper connection at both ends Are the cables properly connected Reseat the cable Go to step 2 Are any of the cables damaged Replace the damaged cable Go to step 3 Replace the ICC Did this fix the problem Replace the ADF relay card Did this fix the problem Problem resolved Problem resolved Go to step 4 Replace the RIP board 841 00 Invalid configuration or ASIC not found Step Questions actions Yes No 1 POR the device a few times Did the error re occur Go to step 3 Go to step 2 2 PORinto the diagnostic menu Run the ASIC test in Problem resolved Goto step 3 the Scanner Test menu Did the ASIC pass 3 Replace the RIP Did this fix the issue Problem resolved Contact second level support 841 01 Invalid AFE setting Step Questions actions Yes No 1 POR the device a few times Did the error re occur Go to step 2 Problem resolved 2 Checkthe connections on the 8 and 30 pin cables Go to step 3 Go to step 4 connecting the CCD to the ICC card Are the cables properly connected 3 Properly connect the cables Did this fix the issue Problem resolved Go to step 4 4 Checkthe 8 and 30 pin CCD cables for continuity Is Go to step 6 Go to step 5 there continuity 5 Replace the cable that lacked continuity Did this fix the Problem resolved Go to step 6 problem 6 Replace the CCD Did
256. o a mode where the camera can access PictBridge Plug the camera back in to continue Unsupported Disk Remove the unsupported disk to continue Paper Size Unsupported Make sure the paper is the correct size Also check the tray guides to ensure they are in the correct position Check the paper size sensors to ensure they are in the correct position Securely Clearing Disk Space 2 68 Service Manual Disk wiping process is recovering disk space The message clears when all memory blocks are cleared 7541 03x Error code Action USB Drive Error This is displayed when an error on the USB drive occurs The user is instructed to remove and reinsert the drive Disk Problem Error reading a disk Disk is improperly formatted Additional messages include Continue Format the disk View More information is displayed User will be instructed to reformat the disk All data will be lost User attendance messages 0 99 Error code Action 30 Toner cartridge Reseat the specified print cartridge missing Use different cartridge Check contacts on the photodeveloper Check the ribbon cable connecting the printhead and printhead controller board If the problem still exists replace the printhead controller board See Printhead controller board removal on page 4 37 31 Defective or Missing color Cartridge Reseat the specified print cartridge Inspect the pr
257. o apa ass hea Reda Aci dod waar n UR rue 4 58 Scanner power supply removal 22 2266 c eee ce ee ee eee eee eee eee ee 4 58 Might side FOITOVAIS oia 524 539 52 Ed dcE tenet US Kc ee recGiamiwetusicasasenon cognates 4 61 didi Mmm 4 61 Handle cover TOIOVOE uso uad pdcadd dedimus 1e a c d QUIE Reale ie ooipa Mo dedu dus abo Rub M d d 4 62 Duplex TelloVal uoa obs ac dh RR Ed e EHE a a kent 4 ACT E RUE d dead ame 4 63 Paper feed unit removal 44 3 xxr x kx CR CICER AC RORCKCR CREE ROAD ED EAA T 4 68 Transter Holl CHU Lis eue secu eraann o rur R Rn eI bees Ga melee bers a Glee EE Ta 4 72 Rear remo valS s s sce gps o EE Rak UR te ees SHE CANA ORC RC RR ORC LRCRCRUR CET RR ERROR RR 4 73 RIP Doar removal 2a sua en rues Re RR ORE ERR RR RR RUF OC AREE acq a ON Rb RR Rd e we 4 73 Crossbar removal nota FRU i c mr nmn jm RR Rass CRE REO CR RI RR EN 4 74 Engine board and mount removal not a FRU sseseeeeeee nnn 4 75 Drive unit cover nota FRU oc cece ti eee cate tends dees ia REA ARE tina Niit RES REA RA 4 77 Dive OIG uus ica eau Se bau be Sq weed ese moar AE Sdn RD CK Oda RS equi eee 4 79 Drive unit motor C IM Y K si iusicsekockuReekuh rea Reo REX ORE D RUE E caw eases eee 4 83 aub drive unit Fempva 2uessumdekemauscus Ramdbddmd n dA RENE ae eK bp ME EG 4 84 Door nt rlock switchiremoVal 225525224 kkni s adn dokn Ra REE aa ER Rd RH HE done a REA ta 4 89 Duplex sblenoid removal 45543 ace RACE RA d AURA DE oho d cede Ad dua cA E ORAE d 4 90
258. oblem Problem fixed Go to step 3 3 Replace the magenta LED printhead Does this fix the Problem fixed Replace the problem printhead controller board 114 01 Yellow printhead error Step Action and questions Yes No 1 Is the ribbon cable connecting CN1 on the printhead Go to step 2 Properly connect controller board to the black LED head securely the ribbon cable connected 2 Replace the ribbon cable Does this fix the problem Problem fixed Go to step 3 3 Replace the yellow LED printhead Does this fix the Problem fixed Replace the problem printhead controller board Diagnostic information 2 45 7541 03x 121 01 Thermistor 1 error Note If the error is 121 05 the fuser is at the end of life Step Action and questions Yes No 1 Is the fuser properly installed Make sure that it is Go to step 2 Reinstall the properly seated fuser 2 Is the fuser cable properly connected to CN19 on the Go to step 3 Properly connect printhead controller board the connector 3 Checkthe fuser cable for continuity Is there continuity Problem solved Replace the fuser cable 4 Replace the printhead controller board Does this fix Problem solved Go to step 5 the problem 5 Replace the fuser Does this fix the problem Problem solved Contact second level support 121 02 Thermistor 2 error Note If the error is 121 05 the fuser is at the end of life
259. oblem support Insert tray service check Step Action and questions Yes No 1 Remove the tray and inspect the tray for any damaged Go to step 2 Go to step 3 or broken parts that would prevent it from being installed properly or move around in the printer Are there loose or damaged parts on the tray 2 Try a different tray Did this fix the issue Problem resolved Go to step 3 3 Checkthe sensor cables for proper connection to the Go to step 5 Go to step 4 sensors and engine controller board Are they properly connected 4 Connect the cables Did this fix the issue Problem resolved Goto step 5 5 Checkthe size sensors for proper operation Are they Go to step 7 Go to step 6 working properly 6 Replace the sensors Did this fix the issue Problem resolved Got to step 7 7 Replace the engine controller board Did this fix the Problem solved Contact your issue second level support 2 88 Service Manual Paper skew service check 7541 03x Step Action and questions Yes No 1 Are the paper guides in the paper trays and MPF tray in Go to step 4 Go to step 3 there proper position 2 Adjust all the paper guides Did this fix the problem Problem solved Go to step 4 3 Checkthe tray to see if the paper in the tray is above Go to step 5 Go to step 6 the full mark on the side guides in the tray Is there too much paper in the trays 4
260. of each object in a document For more information see the software program Help topics How does the printer know what color to print When a user prints a document information describing the type and color of each object is sent to the printer The color information is passed through color conversion tables that translate the color into the appropriate amounts of cyan magenta yellow and black toner needed to produce the desired color The object information determines the application of color conversion tables For example it is possible to apply one type of color conversion table to text while applying a different color conversion table to photographic images Should I use PostScript or PCL emulation What settings produce the best color The PostScript driver is strongly recommended for best color quality The default settings in the PostScript driver provide the preferred color quality for the majority of printouts Why doesn t the printed color match the color see on the computer screen The color conversion tables used in Auto Color Correction mode generally approximate the colors of a standard computer monitor However because of technology differences that exist between printers and monitors there are many colors that can also be affected by monitor variations and lighting conditions For recommendations on how the printer color sample pages may be useful in solving certain color matching problems see How can I match a part
261. of the duct when reinstalling 11 Disconnect the duplex solenoid cable from CN10 on the engine board 4 84 Service Manual 7541 03x 12 Disconnect the cables A from the blade connectors on the interlock switch mum A 13 Disconnect the fuser paper exit motor cable B Repair information 4 85 7541 03x 14 Using a long shaft screwdriver remove the two black plastite screws C securing the sub drive cover to the sub drive unit C 15 Remove the black plastic sub drive cover 4 86 Service Manual 7541 03x 16 Remove the screw D at the bottom of the sub drive unit Repair information 4 87 7541 03x 18 Remove the screw F at the top of the sub drive unit Note If you are replacing the unit place the ground wire on the new unit 20 Disconnect the fuser entry sensor cable 4 88 Service Manual 7541 03x 21 Lift and remove the gear train portion of the sub drive unit out of the printer Door interlock switch removal 1 Remove the sub drive unit See Sub drive unit removal on page 4 84 2 Remove the two screws A securing the door interlock switch to the sub drive unit s Repair information 4 89 7541 03x Duplex solenoid removal 1 Remove the sub drive unit See Sub drive unit removal on page 4 84 2 Remove the left screw A securing the solenoid to the sub drive unit A 3 Remove the right screw B securing the solenoid to the sub drive u
262. of the indicated type Additional messages may include Paper loaded Select Continue More information the printer will present instructions Cancel Job the printer job can be canceled e Wait for supplies lf job parking is enabled and the job meets all the requirements for allowing the job to be parted the printer adds this message Load source Custom String Load paper in the indicated source and select Continue Additional messages may include More information the printer will present instructions Cancel Job the printer job can be cancelled Wait for supplies lf job parking is enabled and the job meets all the requirements for allowing the job to be parted the printer adds this message Load source size Load paper in the indicated source and of the indicated size and select Continue Additional messages may include More information the printer will present instructions Cancel Job the printer job can be cancelled e Wait for supplies lf job parking is enabled and the job meets all the requirements for allowing the job to be parted the printer adds this message Load source type size Load Manual custom type name If paper loaded is in the manual feeder the job continues If paper is not in the feeder pressing Select indicates to the printer it should search for a source with the proper custom type Additional messages may include
263. oids to the ADF main feeder ADF drive clutch 1 Remove the ADF main feeder unit 2 Remove the clip A securing the ADF drive clutch to the shaft A 3 Slide the ADF drive clutch off the shaft 4 132 Service Manual 7541 03x ADF input tray 1 Remove the screw A under the front side of the ADF input tray A 2 Remove the screw B under the rear side of the ADF input tray 3 Open the ADF top cover Repair information 4 133 7541 03x 4 Liftthe ADF input tray and disconnect the tray paper present sensor cable ADF main feeder Remove the left ADF cover Remove the right ADF cover Disconnect the cables from the ADF relay card Disconnect the ground wire A from the ADF main feeder Bom 5 Remove the ADF motor frame assembly 4 134 Service Manual 7541 03x 6 Remove the three screws B securing the right side of the ADF main feeder to the top flatbed cover IX B 7 Remove the screw C securing the right side of the ADF main feeder to the top flatbed cover Repair information 4 135 7541 03x 8 Remove the screw D beneath the spur gear securing the right side of the ADF main feeder to the top flatbed cover D 9 Remove the main feeder from the flatbed cover 10 Remove the solenoids 11 Remove the ADF clutch 12 Remove the Inner ADF top cover 13 Remove the ADF paper guide Note After reinstalling the new component perform the scanner calibrations
264. omatically returns to the Diagnostics menu once the reset is complete Cal Ref Adj Warning This setting should not be changed without specific instructions from the next level of support 3 26 Service Manual 7541 03x Par 1 Strobe Adj Parallel Strobe Adjustment enables you to change the amount of time the strobe is sampled in order to determine if data is available on the parallel port Increasing the value increases the amount of time by 50 ns per increment Decreasing the value decreases the sample time by 50 ns per increment Touch Back to return to the Diagnostics menu REPORTS From this menu you can print the Menu Settings Page or the Event Log Diagnostic aids 3 27 7541 03x EVENT LOG Display Log Display Log shows the message that appeared on the operator panel for each event in the log starting with the most recent Use the touch screen arrows to scroll through the log entries To see more in depth information about each event print the event log using the Print Log menu item Touch Back to return to the EVENT LOG menu Print Log The Print Log menu item prints a detailed report of each event in the log The first page of the event log contains a Printer Information section similar to what is printed on a Menu Setting Page Printed at the top of each page is the model name and serial number to assist in tracking each page of a report to a specific printer The printout of the log contains the following information
265. on these media the printer requires additional time to cool the fuser after you select another Paper Type setting such as Plain Paper or Letterhead If Printer Usage is set to Maximum Yield the printer calibrates the print head timing The printer performs this same calibration each time you turn the printer on and each time you open and close the top cover Depending on the types of jobs you print these adjustments may significantly slow print time If the belt is in the up position for color printing the printer prints at 30 ppm only If the printer is in quick print mode the printer prints at 17ppm until the printer is fully warmed up You cannot remove paper jammed in the fuser Open the fuser rollers by operating the fuser pressure relief lever If you cannot remove the jam replace the fuser The jam access panel can also be opened After letting the fuser cool unscrew the two thumbscrew and open the access panel You cannot clear the paper jam message To clear the paper jam messages you must remove all paper from the printer paper path Check both inside the printer as well as the paper source you were using Open and close the front cover and press Go If the message does not clear go to Paper path service checks on page 2 24 Paper jam in pick up assembly Go to Paper path service checks on page 2 24 Fuser failure Go to 121 05 Fuser fuser heater error on page 2 48 No pape
266. ond transfer to the media Fuse the toner to the media Clean erase the photoconductor and the ITU OS Oh In summary the printer s controller board receives print data and the command to print The controller board then initiates the print process The controller board is the command center for the EP process and coordinates the various motors and signals The high voltage power supply sends charge to various components in the EP process The laser fires on the photoconductors and alters the surface charge relative to the planed image for each photoconductor Each photoconductor rotates past its respective developer roll and toner is developed on the surface of each photoconductor The four separate color images are then transferred to the transfer belt on the ITU as it passes under the photoconductors After the image is transferred to the transfer belt the photoconductors are cleaned and recharged The transfer belt carries the four colored image towards the transfer roll Media is picked up from the tray and carried to the transfer roll where the image is transferred from the transfer belt to the media The timing of the paper pick is determined by the speed of the transfer belt The media is carried to the fuser rollers where heat and pressure are applied to the page to permanently bond the toner to the page The fuser rollers push the media into the output bin The transfer unit is cleaned and the process begins again for the next page
267. or iu usam exi rh Rude E RECO ERA EROR eRe RR GR RA RE MeO 2 45 113 01 Magenta printhead Grrr iiiciue nsa dae rnalksa rb s weed be Ole ae RS s aaa Ein d 2 45 iV Service Manual 7541 03x 114 01 Yellow printhead error asm eek recedes cease eka nd See edaRe das ERROR RR 2 45 121 01 Thermistor Tenor ai x3 ERE dU IRURE DR anne seeersede sedans cede 2 46 121 02 Ther mistoE 2 OITO i i sanae aeiehitEbR XA CERA E ERR REIR RUE HERUA T AREE a 2 46 T2403 THEM Stor a3 SITO sido cdciacnieerniae daturi do dde odd cow Fade Ed dad Rd add 2 47 121 04 Belt thermistor error iaa xs addita istaria atindat ated ERR X EA RE wedded 2 47 121 05 F ser fuser heater eH OF 2issisdknasiRraaaR bi n PEDE Rr RdUEE RR URA RA EUR NA RUD REO sea 2 48 Abnormal fuser temperature error selseseeeeeeeeeeeeee eere nnn 2 48 126 xx Power Switch erro 3 csas ss cass ie ERG CREE RA eae AE AA Pee a RR ee ACA RS cR wa 2 48 130 xx High voltage power supply error 2 0 cee eee eee 2 49 132 00 Density Sensor error esiri eer dncew tea gwd Kee REO eRe ER GR ACRIOR CR eS 2 49 132 xx Abnormal theta sensOr 6 000 see ee eee eee bpas In Enkes rra ERAS 2 50 136 xx Temperature humidity sensor error 2 cee eee eee 2 50 140 Drive motof errot oes soak eux seek ERA A RORRE GRO bee SERE SERRA S ERE REB REA cee 2 51 149 01 Fuser paper exit motor error sseseeeeeeeee RR nnn 2 51 146 01 Tray Ieo uoa aee Ronda dba e Rud Bee heed waked dc eid mera dtd ere LA RR A
268. ore use current source Cancel Job the printer job can be canceled Change lt src gt lt size gt orientation The Change Orientation message is only displayed for Letter and A4 paper sizes This IR allows a user to override the source for the remainder of a job The page will be printed as it is formatted on the paper installed in the tray This may cause clipping No further Change prompts will be posted for the remainder of the current job If the src is MP Feeder Manual Paper or Manual Envelope the string Manual Feeder will be used instead of the src string from the Default Source list If the src is Envelope Feeder Envelope Feeder will be used Additional messages may include Paper changed Select Continue More information the printer will present instructions Ignore This will ignore request and print on paper in tray Cancel Job the printer job can be canceled Change lt src gt lt type gt size orientation The Change Orientation message is only displayed for Letter and A4 paper sizes This IR allows a user to override the source for the remainder of a job The page will be printed as it is formatted on the paper installed in the tray This may cause clipping No further Change prompts will be posted for the remainder of the current job If the src is MP Feeder Manual Paper or Manual Envelope the string Manual Feeder will be used instead of the src string from the Default Source l
269. ore a repeating key starts repeating The default setting is 1 second You can adjust the setting by 25 second increments Key Repeat Rate This setting indicates the number of presses per second for repeating keys The default setting is 15 presses per second Clear Custom Status This setting erases any custom messages the user has created for the Default or Alternate custom messages 3 16 Service Manual 7541 03x USB Speed This setting determines the speed at which the USB port reads and writes data from flash drives Auto is the default setting Setting the USB Speed to Full disables the hi speed capabilities of the port Exit Config Menu Press Select to exit the Configuration menu and reboot the printer Diagnostic aids 3 17 7541 03x Diagnostics mode To run the printer diagnostic tests described in this chapter put the printer in Diagnostics mode Entering Diagnostics mode To enter the Diagnostics Mode 1 Turn off the printer 2 Press and hold 3 and 6 3 Turn on the printer 4 Hold the buttons until the splash screen appears Diagnostic mode menus SCANNER CALIBRATION Copy Quick Test Adjust Calibration Values Reset Calibration Values See SCANNER CALIBRATION on page 3 20 PRINT TESTS Tray 1 Tray 2 if installed Tray 3 if installed Tray 4 if installed Tray 5 if installed Multi Purpose Feeder See PRINT TESTS on page 3 20
270. orl 40X1107 HRrrRIIIRRIIIIIIIIIIIIIe 7 43 X CI rA 7 11 Part number index I 13 7541 03x l 14 Service Manual
271. os io o 2 o o Size detect SW CN106 CGND Paper Volume Sensor VCC 5V Paper level CN107 VAA Paper Feed Clutch EN A Transport Clutch CN108 UD motor 4 UD motor UD motor CN120 ADRO ADR1 IRST TXD RXD VAA 24V VAA 24V AGND AGND VCC 5V ES CGND Harness to connector 13 on the Printhead Controller Board CN121 ADRO ADR1 IRST E TXD RXD VAA 24V VAA 24V AGND oj NI mcr A co No 3 O 00 cn B oo PO Po Po o gt AGND VCC 5V Join loela e lan oo Oo no CGND Harness to connector 120 on the next Expansion Feeder Board co gt jln l Oo no co 3 son ne N C Ne CN300 ADRO ADRO ADR1 ADR1 IRST IRST TXD TXD RXD RXD VAA ISW VAA 24V VAAISW VAA 24V AGND AGND CO oo N o c sonj n o AGND AGND o VCC 5V VCC 5V En CGND CGND af CN120 MPF Control Board N OPEN_DET_H VAA SW 13 CENTA_DET_L CGND 14 VAA ISW NCAP VBR N C A ofv 21 2 o cv or o o s ov CN102 MPF Control Board CN301 VAA PICK UP SOL z o 7541 03x
272. ote If the machine turns off a few seconds after a POR follow the procedure below Step Action and questions Yes No 1 POR the printer a couple times Does the printer turn Go to step 2 Problem resolved off a few seconds after the POR Note When restarting the machine you should see the power switch physically move to the off position when the machine turns off 2 Replace the printhead controller Does this fix the Problem Go to step 3 problem resolved 3 Replace the power supply Does this fix the problem Problem Go to step 4 resolved 4 Replace the fuser Does this fix the problem Problem Contact your resolved second level support 126 xx Power switch error Step Action and questions Yes No 1 Is the power switch cable properly connected to CN27 Properly connect Go to step 2 on the engine controller board the connector 2 Replace the power switch Does this fix the problem Problem resolved Go to step 3 3 Replace the engine controller board Does this fix the Problem resolved Go to step 4 problem 4 Replace the power switch cable harness Does this fix Problem resolved Contact your the problem second level support 2 48 Service Manual 130 xx High voltage power supply error 7541 03x Step Action and questions Yes No 1 Check CN11 on the printhead controller board and Go to step 2 Properly connect CNO1
273. paper guides Check the guides to ensure they are not binding Also check the guides to ensure they are correctly adjusted for the paper in the tray MPF roll cover Make sure the MPF roll cover is properly installed and not obstructing the paperpath Check for broken tabs and replace the cover if any tabs are missing MPF roll Check for wear or damage to feed rollers and pad MPF pad Check for dirt on the roll and pad Clean them with a lint free damp cloth MPF clutch Check the MPF clutch cable for proper connection to the clutch and CN 28 on the engine board MPF paper empty lever actuator MPF sensor Make sure the MPF paper empty lever moves smoothly and doesn t bind Replace the lever if it is broken Check the MPF sensor cable for proper connection to the sensor and CN14 on the engine board Also check the cable for continuity Engine board If replacing the MPF clutch and sensor don t resolve and MPF feed issues replace the engine board 2 28 Service Manual Clearing and resolving scanner jams Note Before performing the ADF jam service procedures perform the following steps 1 Remove all documents from the ADF input tray 2 Open the ADF cover 3 Gently remove the jammed paper from the ADF Note Make sure all paper fragments are removed 280 06 Paper missing Step Action and questions Yes No 1 Open the ADF top cover and check the paper in se
274. place the RIP Did this fix the problem Problem resolved Contact second level support 2 16 Service Manual 7541 03x Paper jams User primary Location message Explanation 1 283 05 Scan Sensor Jams To resolve scanner jam issues see Clearing and resolving scanner 290 11 Scanner ADF Cover Open Jam jams on page 2 29 283 01 Scanner Static Jam Scan Sensor Jams 280 06 Paper Missing 285 05 Scanner ADF Eject Jam 2 200 xx Paper jam in the transfer carry area 3 250 Paper jam in the MPF tray 4 201 xx Paper jam in the fuser entry area 230 Paper jam in the duplex 231 39 Paper jam in the duplex Check the duplex sensor area at the bottom of the duplex 5 24x Paper jam in the papertray lt x gt indicates which tray the jam is in 6 203 Paper jam at the paper exit area 7 292 01 Scanner Carriage Locked To resolve these issues see Clearing and resolving scanner 8 291 06 Flatbed Cover Open jams on page 2 29 Diagnostic information 2 17 7541 03x Clearing and troubleshooting paper jams 200 paper jam 1 Open the right side cover 2 Pull the paper up and out to remove it from the paper path Note Make sure all paper fragments are removed If the page is in the fuser the fuser nip release lever should be lowered After removing the jammed page return the lever to the proper position 3 Close the right side cover 4 Press Continue j
275. played on the network settings page for the device are properly configured If a wireless network is used verify that the printer is in range of the host computer or wireless access point and there is no electronic interference Have the network administrator verify that the device is using the correct SSID and wireless security protocols For more network troubleshooting information consult the Lexmark Network Setup Guide Step Questions actions Yes No 1 If the device is physically connected to the Go to step 3 Go to step 2 network verify that the ethernet cable is properly connected on both ends If the network is wireless got to step 3 Is the cable properly connected 2 Connect the ethernet cable Problem resolved Go to step 3 Did this fix the problem 3 Checkthe printer s online status under Printers Go to step 5 Go to step 4 and Faxes on the host computer Delete all print jobs in the print queue Is the printer online and in a Ready state 4 Change the printer status to online Problem resolved Go to step 5 Did this fix the issue 5 Does the IP address displayed on the network Go to step 10 Go to step 6 settings page match the IP address in the port of the drivers using the printer 6 Does the LAN use DHCP Go to step 7 Go to step 9 Note A printer should use a static IP address on a network 7 Are the first two segments if the IP address Go to step 8 Go to
276. precautions such as turning off power before removing logic boards Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity inc
277. r a 1A BELT 1B BELT 2A BELT AJ Oj N 2B BELT Locations 5 21 7541 03x Engine board Connector Connects to Pin no Signal CN16 Paperfeed motor Fuser motor Paperfeed motor 1A FEED 1B FEED 2A FEED 2B FEED Fuser paper exit motor 1A FUSER 1B FUSER 2A FUSER 2B FUSER CN17 Motor Y Motor a DSYMOY A DSYMOY B DSYMOY A Aio N DSYMOY B CN18 Motor M Motor DSMMOY A DSMMOY B DSMMOY A AJOJN DSMMOY B CN19 Motor C Motor DSCMOY A DSCMOY B DSCMOY A DSCMOY B CN20 Motor K Motor aA ol pm a DSKMOY A DSKMOY B DSKMOY A Aio N DSKMOY B CN21 Fuser fan a FFAN FFALM GND CN22 Main fan U N CFAN CFALM GND CN23 Main switch U N 24V PR 24V PR CN24 LVPS N 5V IN 5V GND 24V PR 24V GND oy 2 wy N 24 V 5 22 Service Manual Engine board 7541 03x Connector Connects to Pin no Signal CN25 Power supply fan a PSFAN PSFALM wj N GND CN26 Rear fan a REAFAN REAFALM GND CN27 Remote switch U N GND P OFF CN28 MPF clutch N TMPCL N GND CN29 t MPF paper o
278. r ADF top cover 2 2 e reer rrr rr rn rn ree nee eee ee eee eee 7 11 40X6332 Inner ADF top cover 2 0 ree eee eee eee eee eee eee eee 7 11 40X6333 ADF hinge rrr rrr rrr rrr reer eee eee eee eee 7 9 40X6334 Flatbed hinge errr reer eee eee ee ee eee eee eee eee 7 9 40X6335 ADF drive clutch 2 2 eee eee eee eee 7 11 40X6336 Roller bearing rrr errr eee ere eee eee ee eee eee 7 11 40X6338 ADF input tray eee reer eee eee eee eee eee eee eee 7 9 40X6340 Top cover release handle rrr ree er ee eee eee eee ee eee 7 11 40X6341 Top cover release hook rrr rrr ere ee ee ee ee eee eee 7 11 40X6342 ADF relay card cover rrr reer eee eee eee eee eee eee 7 9 40X6343 Left ADF cover 2 0 eee eee ee eee eee ee eee ee eee eee 7 9 40X6344 Right ADF cover e reer ee ree ee eee ee ee ee ee eee 7 9 40X6345 ADF paper stop eee r errr ee eee ee eee eee eee eee 7 9 40X6346 Upper flatbed top cover eee reer ee eee ee eee eee eee eee 7 9 40X6347 Lower flatbed top cover 00 eee e errr eee ee eee ee eee eee 7 9 40X6348 ADF main feeder
279. r Menu Universal Setup on the op panel for best reliability Processor 1 GHZ IBM Power PC processor Memory Standard memory 512 mb Optional memory 256 512 and 1024 MB 1 200 pin x 64 DDR 2 SO DIMMs 1 slot Optional flash 256 mb Paper specifications Paper sizes supported by the printer Optional wuttipurpo Paper size Dimensions Tray 1 Tray 2 550 sheet fa Pra pose Duplex unit tray A3 297 x 420 mm V4 V4 V4 v4 V4 11 7 in x 16 6in A4 210 x 297 mm 8 3 x 11 7 in d d d d Y A5 148 x 210 mm 5 8 x 8 3in di Y v d A6 105 x 148 mm 4 1 x 5 8 in Y B4 v v v v v B5 182 x 257 mm 7 2 x 10 1 in Y d 4 Letter 216 x 279 mm 8 5 x 11 in 5 Y d Y d Legal 216 x 356 mm 8 5 x14 in Y d Y v 1 6 Service Manual 7541 03x Optional Multipurpose Paper size Dimensions Tray 1 Tray 2 550 sheet RENE P Duplex unit tray Executive 184 x 267 mm 7 3 x 10 5 in Y d Y d Y Oficio 216 x340 mm 8 5 x 18 4 in gt d Y Folio 216 x 330 mm 8 5 x 13 in y di Statement 140 x 216 mm 5 5 x8 5 in n Tabloid V4 V4 J V4 V4 Universal 140 x 210 mm S V4 210 to 297mm Plain Paper m x 8 3 in up x aa 216x356 mm 148 t0432 mm 148 to 8 5 x 14 in 432mm Banner 210 to 297mm x 433 to 12129mm 7 3 4 98 x 191 mm V4 Envelopes 3 9 x 7 5 in Monarch 9 98 x 226 mm WA Envelope
280. r cord NS 40X0273 Chile Uruguay power cord NS 40X0275 Israel power cord NS 40X1773 South Africa power cord NS 40X1772 Switzerland power cord NS 40X1431 Card reader screw packet NS 40X4602 3121 card reader NS 40X4603 5121 card reader a afjasjasjasjasjasjasjafjasjasjanfasjasjnafasjajsjafjasjajsjasjasjasjafjasjasjafasjasjafjasjajsjajasjasjajJajajua NS 40X4604 5125 card reader 7 46 Service Manual Index Numerics 3x 8x attendance messages 2 69 2 74 200 paper jam 2 18 201 paper jam 2 18 203 paper jam 2 19 230 paper jam 2 20 231 39 paper jam 2 21 24x paper jam 2 22 250 paper jam 2 23 40X6011 Transfer belt 7 3 54 Network Software error service check 2 91 A Acoustics 1 5 acronyms 1 16 ADF amp scanner image quality dark image quality 2 11 ADF cover open service check 2 77 ADF Magnification 3 29 ADF paper jam service check 2 36 ADF streaks 2 76 Adjust Calibration Values 3 20 ASIC Test 3 29 attendance messages 2 66 0 99 2 69 user prompts 2 66 2 69 Auto Align Adj 3 13 B bin full sensor removal 4 36 Black Only Mode 3 11 Button Test 3 22 buttons Button Test 3 22 description 3 1 C Cal Ref Adj 3 26 cassette stopper removal 4 44 clearances 1 4 Clearing and troubleshooting paper jams 2 18 Clipped image when scanning to USB from the ADF 2 76 Color Adj State 3 13 Color Adjustment 3 13 Color Alignment 3 14 Color Trapping 3 1 1 Configuration ID 3 26 Config
281. r employs user selected color conversion tables to process objects However Color Correction must be set to Manual or no user defined color conversion will be implemented Manual color correction settings are specific to the type of object being printed text graphics or images and how the color of the object is specified in the software program RGB or CMYK combinations Notes Manual color correction is not useful if the software program does not specify colors with RGB or CMYK combinations It is also not effective in situations in which the software program or the computer operating system controls the adjustment of colors The color conversion tables applied to each object when Color Correction is set to Auto generate preferred colors for the majority of documents To manually apply a different color conversion table How can match a particular color such as a corporate logo From the printer Quality menu nine types of Color Samples sets are available These are also available from the Color Samples page of the Embedded Web Server Selecting any sample set generates a multiple page printout consisting of hundreds of colored boxes Either a CMYK or RGB combination is located on each box depending on the table selected The observed color of each box is obtained by passing the CMYK or RGB combination labelled on the box through the selected color conversion table To print Color samples from the printer press Menu
282. r pick up from multipurpose tray Go to Paper path service checks on page 2 24 No paper pick up from upper or lower cassettes Go to Paper path service checks on page 2 24 Registration roller does not rotate Go to Paper path service checks on page 2 24 Operator panel does not operate properly Go to the Diagnostic aids chapter and run the LCD and Button tests If the tests fail replace the operator panel If you still have a problem replace the RIP controller board If your machine beeps 5 times and the screen is blank or all diamonds replace the operator panel See Foggy print Black pages Blank print White spots Poor reproduction ncorrect color image registration Dirt on back of paper Low image density White and black lines and bands Go to Print quality issues on page 2 4 Diagnostic information 2 75 7541 03x Symptom Action Evenly spaced marks on the paper or a single mark in the same place on every page Go to Transfer belt up down check on page 2 93 Poor fusing Go to 121 05 Fuser fuser heater error on page 2 48 Toner scatter on front or back of paper Check the following Excessive toner buildup on the transfer belt Clean off the toner and run a test print Transfer belt assembly Transfer belt toner waste bottle Transfer belt separation fingers Fuser separation pawl Paper will not f
283. r rr ree 7 25 Paperfeed unit 40X6176 errr eee ne nee ee ee ee ee ee eee eee 7 25 Paperfeed unit motor 40X6192 e errr eee nee een ne ne eee ree eee 7 25 Parallel 1284 B serial adapter 40X4823 rrr rrr rrr rrr rrr ee 7 46 Photo interrupter cable 40X6261 3 rr rrr rr rrr rrr ee 7 19 photo interuptor cable 40X6261 RII 7 29 Photo sensor 40X1104 0 eee ee err eee eee ee eee eee eee 7 13 7 17 Part number index l 11 7541 03x Photo sensorr 40X1104 ee ree 7 19 7 21 7 25 Pick roll 40X6180 urcm I II II II I I c 7 25 Pickup gear 40X6178 ccmcn III II III III 7 25 Pickup lever A 40X6181 ccncr II III III I 7 25 Power supply fan cable 40X6210 cccucc c II III 7 29 PRC powercord 40X0303 cccecmmeII III II III 7 46 PRCONT print head controller option cable 40X6369 7 31 Prescribe card 40X6928 2 2 rrr rrr rr rrr III 7 46 Printhead controller board 40X6756 2 0 r rrr rr rrr II III 7 31 7 33 R Registration gear 40X6185 22 rrr errr rr ne 7 25 Registration sensor actuator 40X6188 2 5 5 rr rrr errr rrr ree 7 25 Registration sensor actuator spring 40X6189 22 2 r
284. r supply Problem solved Go to step 5 removal on page 4 51 Does this remedy the situation 5 Replace the engine power supply cable Does this Problem solved Replace the remedy the situation engine controller board 173 01 Main unit fan error Step Questions actions Yes No 1 Is there anything obstructing the fan s movement Clear the Go to step 2 obstruction 2 Check connector CN22 on the engine controller board Go to step 3 Reconnect the Is it properly connected connector 3 Replace the main fan Does this remedy the situation Problem solved Replace the engine controller board 174 01 Rear fan error Step Questions actions Yes No 1 Is there anything obstructing the fan s movement Clear the Go to step 2 obstruction 2 Check connector CN26 on the engine controller board Go to step 3 Reconnect the Is it properly connected connector 3 Replace the rear fan Does this remedy the situation Problem solved Replace the engine controller board Diagnostic information 2 55 7541 03x 840 03 service check Step Questions actions Yes No Check the 8 and 30 pin ribbon cables connecting the CCD to the ICC card for proper connection Checkthe ribbon cable connecting the RIP board to the ICC card for proper connection Check the ADF cable for proper connection at both ends Check the cable connecting J4 on the RIP board t
285. r to the frame Repair information 4 57 7541 03x Main switch 1 Remove the main power switch cable 2 Disconnect both harnesses A from the power switch emi Scanner power supply removal 1 Remove the left cover 2 Remove the left EMI shield 3 Disconnect the three cables from the scanner power supply 4 58 Service Manual 7541 03x 4 Remove the four screws A from the top of the scanner power supply Repair information 4 59 7541 03x 6 Remove the screw C from the lower left corner of the scanner power supply n wwe Ss 4 60 Service Manual 7541 03x Right side removals Fuser removal 1 Open the right side door 2 Grab the handles on the fuser and gently pull the fuser out of the print engine Repair information 4 61 7541 03x Handle cover removal 1 Remove the two screws A securing the handle covers to the printer frame 2 Remove the handle cover 4 62 Service Manual 7541 03x Duplex removal 1 Remove the high voltage power supply 2 Remove the handle covers See Handle cover removal on page 4 62 3 Open the right cover and remove the transfer roll Warning Avoid damaging the transfer roll A A 4 While holding the right cover lift the duplex unit Repair information 4 63 7541 03x 5 Disconnect the two springs from the right cover 6 Disconnect the left and right link arm
286. rain 16lb to 34lb 60g m2 to 128g m2 and Bond Short Grain 16lb to 34lb 60g m2 to 128g m2 Recycled Long Grain 20lb to 34Ib 75g m2 to 128g m2 Short Grain 28lb to 34lb 105g m2 to 128g m2 Card Stock Cover 50Ib A42lb 135g m2 157g m2 nad Index 671b 75lb 120g m2 157g m2 Tag 74Ib 85lb 120g m2 157g m2 MFS amp MPF All sizes supported Xerographic Long Grain 16lb to 34lb 60g m2 to 128g m2 Duplexer py engine andbend Short Grain 16lb to 34lb 60g m2 to 128g m2 Recycled Long Grain 20lb to 34Ib 75g m2 to 128g m2 Short Grain 28lb to 34lb 105g m2 to 128g m2 Card Stock Cover 50Ib 65lb 135g m2 176g m2 ney Index 671b 90lb 120g m2 163g m2 Tag 741b 100lb 120g m2 163g m2 Labels max Paper 35lb 131g m2 Vinyl Occasional use up to 256 gsm Transparency TBD TBD Envelope Xerographic 20lb to 34lb 75g m2 to 128g m2 A5 B5 JIS B5 Xerographic Long Grain 171b to 34lb 64g m2 to 128g m2 EC Staleman and RONG Short Grain 171b to 34lb 64g m2 to 128g m2 Folio Letter A4 and Card Stock Long Grain 171b to 34lb 64g m2 to 128g m2 Legal A3 Tabloid ax Short Grain 171b to 34lb 64g m2 to 128g m2 1 8 Service Manual 7541 03x Media guidelines Selecting the appropriate media for the printer helps avoid printing problems For detailed information about media characteristics see the Card Stock amp Label Guide available on the Lexmark Support Web site at http support lexmark com Paper To
287. random access memory Digital multimeter Error correcting code Error correction mode Enhanced Data Out Electrical Erasable Programmable Read Only Memory External Network Adapter End of life Electrophotographic process Erasable programmable read only memory Electrostatic Discharge Facedown Field replaceable unit Face up Gigabyte Ground Fault Interrupter Gigahertz Host Based Printing Hypertext markup language High Voltage High voltage power supply High voltage unit Hertz International Internal Tray Card Image Transfer Unit Black Key LAN LASER LCD LCM LD LED LEF LES LV LVPS MB MDC MH MIF mm MMR MPF MR MROM MS NAND NVM NVRAM OCF OCR OEM OHP OPC OPT PC PDF PICS PIN PIXEL PJL POR POST PPDS ppm PQET PRC PSC PSD PSO PWM RAM RFID RH RIP ROM ROS RPM SDRAM Local area network Light amplification by stimulated emission of radiation Liquid crystal display Liquid Crystal Module Laser Diode Light emitting diode Long edge feed Lexmark Embedded Solution applications Low Voltage Low voltage power supply Magenta Megabyte Motor Driver Control Message handling Motor interface Millimeter Modified modified read Multipurpose feeder Modem ready Masked Read Only Memory Microswitch NAND usage NAND gate Nonvolatile Memory Nonvolatile Random Access Memory Operator correctable failure Oil coating roll Original Equipment Manufacturer Overhead projector
288. ray 3 Remove the 15 screws A securing the sensor support frame to the print engine frame 4 Remove the paper size sensors 4 42 Service Manual 7541 03x Photoconductor lock removal 1 Remove the standard paper tray 2 Remove the two screws A that secure the front metal cover to the printer frame 3 Remove the photoconductor lock Repair information 4 43 7541 03x Cassette stopper removal 1 Remove the standard and MPF trays 2 Disengage the tabs A securing the cassette stopper to the left side of the printer frame D C B D cel gt oclo Clo So o o clo oo oo SSP STS OWS lt lt Lad V pu Twist the stopper downward to release the two pawls B Insert a flat blade screwdriver at point C Pull the stopper forward to disengage the stopper from the printer frame Disengage the pawls D by tuning them in the direction indicated by the arrow Push the stopper up at point C to disengage the stopper from the frame 3 4 5 6 T 4 44 Service Manual 7541 03x Left side removals Left EMI shield removal not a FRU 1 Remove the top cover See Output bin print engine top cover on page 4 17 2 Remove the left cover See Left cover removal on page 4 22 3 Remove the screw A 4 Remove the three screws B Repair information 4 45 7541 03x 5 Remove the two screws C 6 Remove the two screws
289. rbd 2 52 146 03 Tray 3 ON OE ouod das Eri EXER aie iG MER RC dox ded d RR ORE Gc EE Ub dod ug 2 52 pe le acs ls 23 613 105 ee re ee RUN CORO e ee Carre E Rd 2 53 146 05 Tray 5 OEVOE ocu cre cents cece dena ees ROCA Dae ee A ERU o ERR P UR RR due eae 2 54 ATI FUSE TID GIGS stasatiateatateigedtracedaaeedanmersadetiawinsnenan can da dE 2 54 172 01 Power supply unit fan error lesen n nnn 2 55 173 01 Main nit fan erFOE iie icio idea io cx n ees d cR Roo cd QA CR CR RUD ec RA CR GO DO RR 2 55 TAO HOST SEO sor i ebd dp pibe PERI a aic pda duda d dde Pme liec ees 2 55 840 03 Service Check i cese kuac e REG i Erari aA PER DEN ER FC EEXGVE RE A PEN VE EE TEE 2 56 841 00 Invalid configuration or ASIC not found eee eee 2 56 841 01 Invalid AFE selling iisuas eg hpr sms kaw d EO RRR amd Hees RO ER 2 56 841 02 Delayed interrupt detectetl i24 zen d dos chi RUE ane RUE OA KR QE Redon ees 2 57 841 03 Failed indirect register test 525 2 oossad ura ad aka aad EAa ERE REA ATEARSARd aa 2 57 841 04 Failed external DRAM test 20 ccc cece eee eee eect eee eee nea 2 57 841 05 Image pipe HMO cssc esent REA oH AURRR ERE ARRA Ro ate 2 57 841 06 Scariner did not initiate SCAN auucuexieRessemea ie deno sm REG Rue eR E Roa d aid dos 2 58 842 00 No response 842 01 HW protocol 842 02 Logical protocol 2 58 843 00 Carriage HOME ux cnin apod emer Riedie ROS RES ERROR UR Ka RN GER 2 59 844 00 Lamp failure Front s
290. reases static electricity Repair information 4 1 7541 03x RIP board operator panel replacement This procedure should only be followed if both the RIP board and operator panel fail If you only need to replace one of the FRUs follow the startup procedure described in the FRU s removal procedure CAUTION POTENTIAL INJURY There is danger of explosion if a lithium battery is incorrectly disassemble or incinerate a lithium battery Discard used batteries according to the manufacturer s replaced Replace it only with the same or an equivalent type of lithium battery Do not recharge instructions and local regulations Warning If the operator panel and the RIP board are being replaced at the same time replace the parts in this order to avoid damage to the machine Replace the RIP card first Note Do not replace the new operator panel and RIP card in the machine at the same time After installing the new RIP card and before installing the new operator panel start the printer into diagnostics mode After the printer has completed startup turn off the printer and replace the operator panel Note Note If the operator panel display has failed the printers startup cycle is complete when the driver motor and fans shut down and the machine is quiet After installing the new operator panel start the printer in to diagnostics mode and allow the printer to go through a complete startup cycle and the display to go to Read
291. removal 4 174 MPF pad removal 4 187 MPF tray assembly removal 4 175 Option controller board removal 4 200 Option door inter lock switch removal 4 202 Paper empty sensor removal 4 199 paper exit guide removal 4 33 paper exit sensor removal 4 37 Paper feed clutch removal 4 203 Paper feed motor removal 4 110 Paper feed roll removal 4 196 paper feed unit removal 4 68 Paper full sensor removal 4 199 Paper level sensor removal 4 198 paper size sensor removal 4 42 Paper size switch removal 4 105 Paper size switches removal 4 197 Paperfeed roll removal 4 182 Paperfeed unit clutch removal 4 179 Papertray lift motor removal 4 94 photoconductor lock removal 4 43 Pick roll removal 4 182 4 196 power supply fan removal 4 55 printhead controller board removal 4 37 Rear EMI shield Not a FRU 4 106 Rear fan 4 102 Registration roll removal 4 184 Registration sensor MPF tray removal 4 179 Registration sensor actuator removal 4 180 RIP cage 4 95 Separator roll removal 4 183 4 197 Static discharge brush removal 4 180 Stepper motor removal 4 200 Sub drive unit removal 4 84 Sub frame unit 4 104 Temperature and humidity sensor removal 4 101 theta sensor removal 4 56 Toner sensor removal 4 97 Torque limiter removal 4 181 l A Service Manual Transfer belt motor removal 4 100 transfer belt position sensor removal 4 41 Transport sensor removal 4 198 Tray lift motor removal 4 201 Upper and lower registration springs removal 4 181 Waste toner sensor r
292. res the cover to the side frame 9 Remove the option connector cover 10 Use the flatblade screwdriver to pry the rear cover away from the side cover at the main fan 11 Use a small flatblade screwdriver to release the tabs G that fasten the option connector cable to the rear cover 12 Pull the rear cover away from the device Note If there are ISP cards installed remove the thumbscrews from the RIP cage 4 10 Service Manual 7541 03x Front op panel cover 1 Remove the one screw A on the front right side A 2 Remove the two screws B on the on the inner left side of the cover Repair information 4 11 7541 03x 3 Remove the two screws C on the under side of the cover C 4 Pull the cover back 5 Disconnect the USB cable D from the cover 4 12 Service Manual 7541 03x Op panel top cover 1 Remove the card reader cover See Front op panel cover on page 4 11 2 Remove the two screws A on the front of the cover 3 Remove the screw B in the upper left corner of the panel assembly Repair information 4 13 7541 03x 4 Remove the screw C in the upper right corner of the panel assembly 5 Release the tabs on the inside of the cover and gently lift the top cover assembly away from the bottom cover 6 Disconnect the speaker cable D from the UICC D F E 7 Disconnect the grey and blue USB cables E from the UICC 8 Disconnect the RIP UICC cable F from th
293. rforms two tasks It can determine whether a jam has taken place The jam is triggered by the time it takes for the paper to pass through the sensor The sensor also determines the position of the paper in the ADF paper path Based on the size of the paper in the scan job the sensor determines that the paper has left the ADF paper path At this point a signal is generated to trip the duplex gate moving it to the position allowing the paper to enter the duplex paper path Also a signal is generated triggering the gear solenoid The gear solenoid moves the reversing gear assembly into place reversing the direction of the duplex paper rolls This creates the peek a boo effect pulling the paper into the duplex paper path If the scan job is simplex the duplex gate is positioned to direct the media to the exit roller and the media exits the ADF to the output bin 12 The reversed exit roll pulls the paper back into the ADF The transport roll then moves the media to the paper in sensor When the paper in sensor is actuated the exit roll stops Also the paper in sensor indicates that this is the second side of the media to be scanned 13 The imaging process is repeated for the other side of the sheet of paper After the image is created the paper again proceeds to the paper pass sensor a second time 14 When the trailing edge of the media reaches the reverse point the second time the solenoid again moves the diverter gate to the down position and re
294. rinter Are they clean and free of debris 2 Clean the contacts Did this fix the issue Problem resolved Go to step 3 3 Checkthe sub frame for bent springs or contacts Are Replace the sub Go to step 4 the contacts on the sub frame damaged frame 4 Checkthe HVPS for proper installation Are the screws Go to step 5 Tighten the securing the HVPS to the subframe secure Screws 5 Disconnect and reconnect the HVPS cable at the Problem resolved Go to step 6 bottom of the HVPS Did this fix the problem 6 Replace the HVPS Did this fix the problem Problem resolved Contact your second level support No print Step Action and questions Yes No 1 Check the paper in the printer for moisture Is the paper Replace the Go to step 2 damp paper with dry paper 2 Checkfor dewing or moisture on the LED printheads Is Let the Go to step 3 there moisture on the printheads printheads dry Move the printer to a less humid location if needed 3 Using the Administrative menu move the transfer belt Go to step 4 Replace the belt to the up and down position Does the belt move 4 Checkthe transfer roll for proper installation Is the Go to step 5 Reinstall the transfer roll installed correctly transfer roll 5 Checkthe transfer roll contacts for dirt or wear Are the Go to step 6 Clean the transfer roll contacts clean contacts 6 Checkthe LED ribbon cables for proper connection at Go to step 7 Properly install both ends Are the
295. ror on page 2 48 132 xx Abnormal theta sensor See 132 xx Abnormal theta sensor on page 2 50 132 00 Density sensor error See 132 00 Density sensor error on page 2 49 2 38 Service Manual 7541 03x 9xx error codes Action 941 01 SDRAM R W error See 941 01 SDRAM R W error on page 2 62 900 xx Unrecoverable RIP software error illegal trap See 900 xx System software error on page 2 60 910 xx Unrecoverable engine firmware error Turn off printer for 10 seconds and restart If error re occurs replace RIP board 941 02 MDC error See 941 02 MDC error on page 2 62 941 03 CPU error See 941 03 CPU error on page 2 63 941 04 Abnormal MDC controller See 941 04 MDC controller error on page 2 63 941 05 Abnormal EEPROM See 941 05 EEPROM error on page 2 63 950 xx Service NCVRAM Mismatch Note A new controller board or operator panel has been installed and has not been properly prepared for this use Install a new note Do not install both the controller board and the operator panel at the same time without a POR in between See 950 00 950 29 EPROM mismatch failure on page 2 64 952 xx Service NV Failure Perform a POR to clear the error 953 xx Service NVRAM Failure 954 xx Service NVRAM Failure 955 00 Service Code CRC loc 956 xx Service System Board 957 xx Service System Board 95
296. rror on page 2 51 See 172 01 Power supply unit fan error on page 2 55 173 01 Abnormal machine fan See 173 01 Main unit fan error on page 2 55 121 05 Abnormal heater See 121 05 Fuser fuser heater error on page 2 48 146 01 Tray 1 error See 146 01 Traylerror on page 2 52 146 03 Tray 3 error See 146 03 Tray 3 error on page 2 52 146 04 Tray 4 error See 146 04 Tray 4 error on page 2 53 146 05 Tray 5 error See 146 05 Tray 5 error on page 2 54 121 04 Abnormal belt thermistor See 121 04 Belt thermistor error on page 2 47 113 01 HDCONT M HEAD error See 113 01 Magenta printhead error on page 2 45 112 01 HDCONT C HEAD error See 112 01 Cyan printhead error on page 2 45 114 01 HDCONT Y HEAD error See 114 01 Yellow printhead error on page 2 45 111 01 HDCONT K HEAD error See 111 01 Black printhead error on page 2 45 121 03 Abnormal thermistor 3 See 121 03 Thermistor 3 3 error on page 2 47 171 01Abnormal fuser fan See 171 01 Fuser fan error on page 2 54 174 01 Abnormal rear fan See 174 01 Rear fan error on page 2 55 130 xx Abnormal High Voltage unit See 130 xx High voltage power supply error on page 2 49 136 xx Abnormal temperature and humidity sensor See 136 xx Temperature humidity sensor error on page 2 50 126 xx Abnormal power switch See 126 xx Power switch er
297. ry sensor removal 4 91 Fuser exit drive unit motor removal 4 93 Fuser Fan removal 4 92 Fuser removal 4 61 G guidelines media 1 9 H handle cover removal 4 62 hard disk Disk Encryption 3 16 Jobs On Disk 3 16 hard disk option service check 2 91 HVPS removal 4 111 l image quality trouble image quality 2 11 troubleshooting 2 11 image quality troubles media damage 2 15 skew 2 14 spots 2 12 vertical stripes 2 12 Incoming fax has blank spaces or poor quality 2 83 initial check 2 2 insert tray service check 2 88 installation environment 2 2 J Jobs On Disk 3 16 L LED assembly removal 4 29 LED print head removal 4 31 left cover removal 4 22 Left EMI shield removal not a FRU 4 45 lock flatbed lock 2 35 Low volt power supply removal 4 51 lubrication specifications 6 1 M main fan removal 4 53 Main switch removal 4 58 maintenance scheduled 6 1 Media guidelines 1 9 media specifications characteristics 1 9 curl 1 9 smoothness 1 9 weight 1 9 recommended types 1 9 unacceptable 1 10 memory 1 6 menus 3 6 messages attendance 2 66 Min Copy Memory 3 12 Model Name 3 26 models 1 1 Modem removal 4 94 Motor Calibration 3 15 MPF clutch removal 4 174 MPF pad removal 4 187 N network card option service check 2 91 networking service check 2 84 No dial tone 2 83 NumPad Job Assist 3 13 O Op panel paper exit guide removal 4 32 operator panel description 3 1 indicator light 3 1 3 2 3 3 3 4 operator panel s
298. s O Diagnostic aids 3 29 7541 03x EXIT DIAGNOSTICS Select EXIT DIAGNOSTICS to exit the Diagnostics menu and return to normal mode 3 30 Service Manual 7541 03x Theory of operation Printer engine Electrophotographic Process EP Process The method that all laser and LED printers use to print is called the electrophotographic process These machines use differences in charge to manipulate and move toner from the toner cartridge to the printed page Even though the basic EP process is the same for every laser and LED printer the specifics for each printer are different We will discuss the print engine s method of printing MFP electrophotographic process basics This printer is a four LED device that uses four toner cartridges cyan yellow magenta and black to create text and images on media The printer has four photoconductors called a photodeveloper cartridge or PC unit and an image transfer unit ITU Each color toner is painted to it s respective photoconductor at the same time The transfer belt passes under the four photoconductors and the four color image is produced and transferred to the media in one pass During the printing process the printer follows the six basic EP Process steps to create its output to the page These six steps are Charge the photoconductor PC unit Expose the photoconductor PC unit with the LED Develop toner on the photoconductor PC unit First transfer to the ITU and sec
299. s from the duplex pin covers on the right cover 4 64 Service Manual 7541 03x 7 Disconnect the duplex clutch and sensor cables from the connectors B on the engine controller board 8 Disconnect the duplex ground wire from the frame Repair information 4 65 7541 03x 9 Route the duplex cables through the frame 10 Slide the duplex to the right freeing it from the left hinge 4 66 Service Manual 7541 03x 11 Pull the duplex away from the printer while carefully routing the cables through the right hinge on the printer 12 Remove the screws securing the duplex unit to the right cover Note See Duplex unit component removals on page 4 172 for instructions to remove the duplex sub components Repair information 4 67 7541 03x Paper feed unit removal 1 Remove the complete duplex unit See Duplex removal on page 4 63 2 Using a flatblade screwdriver gently push the tab securing the link arm to the link arm stay back and remove the right link arm Note Use care when pushing the tab back It can easily break if pushed too far 3 Disconnect the registration clutch harness from connector CN20 on the printhead controller board 4 Disconnect the pick roll separator roll and feed roll clutch cables from connector CN6 on the MDCONT engine board 5 Disconnect the paper feed unit motor harness from connect or CN16 on the MDCONT Engine board 4 68 Service Manual 7541 03x
300. s peripherals CAUTION N If the printer is kept on never touch the conductive parts while it is not specifically required Do nottouch the LVPS cards and the engine board unless they are properly discharged Never touch the live parts The diagnostic information in this chapter leads you to the failing part Before you replace an entire assembly determine if just the defective part is available in the parts catalog Use the error code tables symptom table service checks and the diagnostic aids chapter to determine the symptom and repair the failure The removal procedures in the Repair information chapter may help you identify parts After you complete the repair perform the appropriate tests to verify the repair The table below lists the errors and symptoms you might encounter Use the links in the table to locate the error message or symptom and take the indicated action Error code or symptom Location Print quality issues Scanner image issues Go to Print quality issues on page 2 4 Go to ADF amp scanner print quality on page 2 11 Paper jams 200 xx Go to Paper jams on page 2 17 Error codes Attendance messages Go to Error codes on page 2 38 Go to User attendance messages on page 2 66 Other symptoms Go to Other symptoms on page 2 75 Diagnostic information 2 1 7541 03x Initial check Before you start troubleshooting check th
301. s transfer will be due to a contact transfer instead of a charge transfer Check the high voltage power supply contacts to the transfer roller 3 36 Service Manual 7541 03x Step 5 Fuse Once the image has been fully transferred to the media the transfer roll helps move the paper into the fuser area The fuser applies heat and pressure to the page to melt the tiny toner particles and bond them permanently to the media The fuser moves the paper to the redrive rolls which move the paper to the output bin Cleaning Transfer belt Fussi Second transfer roller Transferred on a sheet of paper Service tips If the fuser rollers are damaged they can cause toner to be pulled off the page or cause paper jams Toner that rubs off a printed page can be a sign of a malfunctioning fuser or an improper media setting Always check the paper type setting before replacing the fuser A common mistake is to print on heavier media such as cardstock with the paper type set to plain paper When removing paper jams from the fuser be sure to use the fuser release tabs to relieve the pressure on the page In addition never pull unfused toner through the fuser if you can help it try to back the jammed page out of the fuser in the opposite direction it was travelling Diagnostic aids 3 37 7541 03x Step 6 Clean Erase There are two main cleaning processes that take place during the EP Process One proce
302. sable Block No Name Fax user setting Did this fix the issue Go to the Administrator menu Enter the Fax settings Analog Fax Settings submenu Verify the remote device number is not in the Banned Fax List user setting Is the remote device number in the banned fax list Yes Problem resolved Go to step 18 No Go to step 17 Go to step 19 18 Remove the remote number from the banned fax list Did this fix the problem Problem resolved Go to step 19 19 Adjust the Receive Threshold setting in the SE menu press 411 to enter the SE menu enter Modem settings and select Receive Threshold Test by adjusting the received signal level by decreasing increasing the Receive Threshold setting in steps of 2db For example if default value is 43 db changing it to 45db will decrease the received signal level by 2db and changing it to 41db will increase the received signal level by 2db Recommended adjustment range is between 33db and 48db in 2db steps Did this fix the problem Problem resolved Go to step 20 20 Press 411 to enter the SE Menu Select Print Logs Print the T30 transmission job log Check the error code being reported See Fax T30 log error codes on page 2 41 Perform the suggested resolution for the error Did this fix the problem Problem resolved Contact your second level of support See Escalating a fax iss
303. section F E Hf L ee Callout no Part name Charge roll LED head Developer roll Primary transfer roll Drum cleaning blade Photoconductor Doctor blade CO NI oy BY wy N gt Supply roll Locations 5 1 7541 03x Callout no Part name 9 Toner cartridge 10 Secondary transfer roll 11 Transfer belt cleaning blade 12 Fuser heater 13 Hot roll 14 Fuser belt 15 Fuser roll 16 Press roll 17 Transfer belt 18 Transfer belt drive roll 19 Pickup roll MP feeder 20 Feed roll MP feeder 21 Separator roll MP feeder 22 Pickup roll Std tray 23 Feed roll Std tray 24 Separator roll Std tray 25 Registration roll IN MP feeder 26 Registration roll OUT MP feeder 27 Registration roll IN Std tray 28 Registration roll OUT Std tray 29 Duplex input roll 30 Duplex transport roll 31 Duplex bottom transport roll 32 Duplex exit roll 33 Paper exit roll 34 Registration sensor actuator 35 Fuser input sensor actuator 36 Duplex exit sensor actuator 37 Paper exit sensor actuator 38 Transport roll 39 MPF feed roll 40 Bin full detection lever 5 2 Service Manual Flatbed ADF sensors 10 ADF I 12 Callout Par
304. sed on Caller ID or Remote Station ID Fax shortcuts Average shortcut includes 25 characters for name 10 characters for number and four characters for shortcut ID Shortcuts can contain one phone number or multiple numbers Each number is a location see the Preferences area for the maximum number of locations xxx Broadcast fax Maximum number of locations is 400 Fax forwarding Incoming faxes may be forwarded to the following e Fax using one fax shortcut Email using one email shortcut FTP using one FTP shortcut LDSS eSF supported via custom application Any fax resolution that can be received can also be forwarded Caller ID Available if subscribed to caller ID from phone provider Manual fax Disabled by default Fax from PC Supported using PostScript driver Fax print holding Appears only if installed on hard drive Fax logs Transmission log Receive error log Fax call log Fax job log Distinctive ring selection Available if subscribed from configured through phone provider 1 12 Service Manual 7541 03x Feature Notes Sound control Ringer volume Speaker volume Speaker mode On On until connected Off Fax server Fax server mode will send the scanned fax job to the fax server as an email where it will then be sent to the receiver The device should be tested for configurability and compatibility with the deserved third fax server produc
305. sing the instruction sheet that comes with the replacement specified photoconductor unit f the problem persists replace the system board See Printhead controller board removal on page 4 37 Diagnostic information 2 73 7541 03x Error code Action 84 Replace color Photoconductor Replace the specified photoconductor unit using the instruction sheet that comes with the replacement specified photoconductor unit e f the problem persists reset the supplies in the supplies menu 84 color PC Unit Missing See Imaging unit photo developer missing service check on page 2 89 84 color PC Unit Nearly low Select Continue to clear the message and continue printing Select more information o get more solutions to the issue Order the specified photoconductor unit When print quality is reduced install the new specified photoconductor unit using the instruction sheet that comes with the replacement specified photoconductor unit Ifthe problem persists replace the printhead controller board See Printhead controller board removal on page 4 37 88 xx color Cartridge Low Show Me View Supplies and Tell Me More displays additional information Replace the specified toner cartridge Select Continue to clear the message and continue printing Check CN17 and 18 on the printhead controller board for proper connectivity Ifthe problem persists replace the pri
306. sm Part Units Units Description index number mach FRU pHo 1 40X6246 1 1 Option paper tray Parts catalog 7 45 7541 03x Assembly 23 Maintenance kits power cords and options Asm Part Units index number FRU NS 40X6372 Description 300K paperfeed maintenance kit NS 40X6457 MFP maintenance kit NS 40X5301 256 M DDR DRAM DIMM NS 40X5302 512 M DDR DRAM DIMM NS 40X5303 1 GB DDR DRAM DIMM NS 40X4823 Parallel 1284 B serial adapter NS 40X4826 Marknet N8120 10 1000 PCBA NS 40X4827 Marknet N8130 10 100 F adapter NS 40X4819 NS 40X5704 Serial interface card adapter 256 MB NAND flash card feature NS 40X7058 160GB hard drive NS 40X7062 NS 40X7063 Marknet N8250 802 11g server US Marknet N8250 802 119 server RW NS 40X6337 Arabic font card NS 40X5969 Korean font card NS 40X5970 Simplified Chinese font card NS 40X5971 Traditional Chinese font card NS 40X5972 Japanese font card NS 40X6924 Forms and barcode card NS 40X6925 IPDS SCS card NS 40X6928 Prescribe card NS 40X0271 UK straight power cord NS 40X0301 Australia 8ft straight power cord NS 40X3609 NS 40X1792 Japan power cord Korea power cord NS 40X0303 PRC power cord NS 40X1791 Taiwan power cord NS 40X7104 USA power cord NS 40X0288 Argentina power cord NS 40X3141 Spain 8ft straight power cord NS 40X4596 Brazil powe
307. smit Level speed supported by the MFP Incompatible connection 88A Failed to connect using V 34 Check line quality modulation scheme Adjust to a lower modulation scheme Adjust Transmit Level Receive Threshold values 901 No fax tones detected from remote Verify destination phone number end Verify that the remote fax is authorized to receive faxes 902 No dial tone detected e Check by enabling Behind a PABX setting Check phone line Check MFD modem hardware 903 Busy tone detected Check with remote end if successive attempts fail 904 Hardware error detected See No dial tone on page 2 83 905 A timeout occurred after dialing the Check with remote end if successive number and waiting for a response attempts fail 906 Fax cancelled by user No action needed Diagnostic information 2 43 7541 03x Fax error log codes Continued Error code Description Action 907 Modem detected a digital line Verify the MFP is connected to an analog connection line See Faxes fail to transmit on page 2 78 908 Phone line was disconnected Restore phone line connection A00 Received request for unsupported No action needed function from remote fax device A01 Received request for unsupported No action needed image width from remote fax device A02 Received request for unsupported No action needed image resolution from remote fax device A03 Received request for unsupported No ac
308. ss cleans the transfer belt and the other cleans the photoconductors Transfer Unit Clean Once the toner image on the transfer belt has been transferred to the page the transfer belt rotates around and is cleaned by the cleaning blade This occurs for every page that is printed After the toner is moved to the cleaning blade the toner is moved from the cleaning blade to the waste toner area using an auger system Second transfer roller Transfer belt Waste toner box Transferred on a sheet of paper 3 38 Service Manual 7541 03x Photoconductor Clean Erase After each plane of color has been transferred to the transfer belt from the photoconductors a cleaning blade scrapes the remaining toner from the surface of each photoconductor This is the clean erase process Cleaning blade Now the photoconductor surface is prepared to begin the EP cycle once again This cleaning erasing cycle happens after each plane of color is transferred to the transfer belt Diagnostic aids 3 39 7541 03x Paper path components Paper feed The standard paper feed sources consist of a multi paper cassette Tray 1 a standard paper cassette Tray 2 and an MPF Tray The paper feed system on the paper cassettes uses a separation roll torque limiter to prevent multiple feeds The MPF on the other hand uses a separation pad Tray 1 and Tray 2 Tray 1 uses a spring loaded plate to
309. stration sensor actuator removal Note The paperfeed unit does not need to be removed from the printer 1 Open the right cover door 2 Pull the cassette guide down 3 Place a flatbed screwdriver under the right side of the actuator using it as a lever to pull the actuator shaft out of the cassette guide Static discharge brush removal 1 Remove the paperfeed unit See Power supply fan removal on page 4 55 2 Remove the six screws A that secure the discharge brush plate to the paperfeed unit 4 180 Service Manual 7541 03x Torque limiter removal 1 Remove the separator roll See Separator roll removal on page 4 183 2 Remove the torque limiter Upper and lower registration springs removal Remove the paperfeed unit See Power supply fan removal on page 4 55 Remove the clutches on the paperfeed unit See Paperfeed unit clutch removal on page 4 179 Separate the two paperfeed units See Separating the MPF tray and main tray paperfeed units on page 4 177 Remove the registration gears A B No A 5 Remove the e clips B 6 Remove the registration bushings C 7 Remove the registration springs D Repair information 4 181 7541 03x Paperfeed maintenance kit removals Pick roll removal 1 Remove the paperfeed unit See Power supply fan removal on page 4 55 2 Depress the tab A and remove the PE sensor actuator cic Op
310. t for example Biscom Equisys ZetaFax OMTool Captaris RightFax or Tobit Faxware Scanner specifications Scanner type Color flatbed scanner with ADF Scan technology Charge Coupled Device CCD Light source White LED Instant On Number of light sources 1 LED array per CCD module ADF scanner ADF type Re circulating Dual Pass Automatic Document Feeder RADF Scanner ADF document input and output capacity 100 sheets 20 Ib 75 g m bond Scanner media depth thickness Maximum 0 11mm Minimum 0 08 mm Scanner media weight Maximum 32 Ib 120 g m Minimum 16 Ib 60 g m Document size Maximum 11 8 x 25 in 299 72 x 635 mm Short Edge Feed SEF Minimum 4 x 5 04 in 101 6 x 128 02 mm SEF Document size sensing Yes length and width in ADF Document Sensing Yes ADF paper present LED and on off settable beep Flatbed scanner Max document size 11 x 17 in 279 4 x 431 8 mm Document size sensing Yes paper length sensing only on flatbed Print engine Print technology Color LED Duplex output Standard Paper feed orientation Short Edge Fed and Long Edge Fed Fax Modem Built in Group 3 compatible full function fax 33 600 bps Max V 34 Half Duplex General information 1 13 7541 03x MFP scan speed Simplex Duplex Media size Mono Color Mono Color Letter p
311. t sequence The following is an example of the events that occur during the POR sequence for the base machine with no paper handling options installed Son 10 11 Power the machine on Power supply fan rotates Splash screen with progress bar displayed Printer controller initialized e ROM is checked if there is an error power on is halted EEPROM checked if there is an error power on is halted Fuserthermistor checked if there is an error power on is halted LED illuminates RIP initialized e ROM is checked if there is an error power on is halted e Memory checked if there is an error power on is halted Main tray lift motor moves paper up to position Printer condition checked Check for jams if there is an error power on is halted Query the toner cartridge and imaging kit if there is an error power on is halted Check toner load if there is an error power on is halted Check temperature if there is an error power on is halted LED flashes The default home screen is displayed Diagnostic information 2 3 7541 03x Print quality issues Note This symptom may require replacement of one or more CRUs Customer Replaceable Units designated as supplies or maintenance items which are the responsibility of the customer With the customer s permission you may need to install a developer toner cartridge or photoconductor unit Service tip Before troubleshooting any print quality problems do the fol
312. t Disk Menu operation This is a destructive type of test All the data on the disk is destroyed and should not be performed on a known good disk Network card option The network is installed on the system board on network model printers See Networking service check on page 2 84 Error code 976 Network card x A 976 error code indicates an unrecoverable software error in network card x Verify that network card x is correctly installed and all the IPSP cables are properly connected If you find no problem contact your next level of support before replacing the network card 54 Network x Software error This error displays when the RIP software detects that a network card is installed in slot x on the interconnect board but cannot establish communications with the network card Diagnostic information 2 91 7541 03x Power supply Dead machine service check Note Before proceeding make sure that this is not an issue with the display Turn the machine on If the machine s fans and motors start up it could be an issue with the display Step Action and questions Yes No 1 Is the power cord connected to the printer and the wall Go to step 3 Go to step 2 outlet 2 Connect the power cord to the printer and wall outlet Problem solved Go to step 3 POR the printer Did it start 3 Try a different power cord Did this fix the problem Problem solved Go to step 4 4 Ver
313. t name iN FRU part 1 ADF paper length and width sensors photo reflect Tray paper size sensor multi point contact 2 Paper pass sensor photo reflect Duplex timing sensor 3 ADF paper present photo interrupt ADF paper path sensor 4 ADF cover open ADF paper path sensor 5 Pick roll ADF pick roll CRU 6 Pick roll position sensor Photo interrupt ADF paper path sensor 7 Feed roll ADF pick roll CRU 8 Separator roll ADF Separator roll CRU 9 Paper gap sensor photo interrupt ADF paper path sensor 10 Paper in sensor Photo reflect Scan sensor 11 Scan roller ADF main feed unit 12 Scan sensor Photo interrupt Scan sensor 13 Takeaway roll ADF main feed unit 14 ADF paper exit sensor Photo interrupt Duplex out sensor 15 Stack roller ADF main feed unit 16 Pass roller ADF main feed unit Flatbed Sensors The flatbed cover open sensor is located on the upper flatbed cover There are three paper size sensor located in the flatbed The CCD home position sensor is located on the CCD carriage Locations 5 3 7541 03x Rip Board connectors F1 J8 oooo 6 48 J13 E LI LT JUSBD1 J15 0000 J22 J3 EE JUSBHF1 0000000 1 JNVM1 Fa F7 J21
314. talling the new operator panel start the printer and allow the printer to go through a complete startup cycle and the display to go to Ready If the problems persist leave the new operator panel in the machine place the old RIP card back in the machine and start it up After the machine startup shut down the machine and install the new RIP card After installing the new RIP card restart the machine and let it go through the startup cycle After this procedure is completed successfully there is no need to adjust any settings If the above procedure fails you must contact the technical support center for further instructions 4 2 Service Manual 7541 03x eSF solutions backup If a technician needs to replace the RIP board the steps below should be taken to backup the eSF solutions and settings DARON 7 POR the printer into invalid engine code mode See Accessing the service menus on page 3 7 Open a Web browser and navigate to the printer s Web page Navigate to Settings and click the link Navigate to Solutions and click the link Navigate to Embedded Solutions and click the link On the Embedded Solutions page select the apps to be exported by clicking the selection box next to the app Choose Export If the Web page cannot be accessed or an error persists despite trying to boot in Invalid Engine code mode then there is no way to backup the eSF apps The technician needs to make the customer aware that the
315. tch cable 4 Replace the interlock switch Did this fix the problem Problem solved Go to step 5 5 Replace the engine board Did this fix the problem Problem solved Contact your second level support 2 86 Service Manual Operator panel service check Display functions but the keyboard doesn t work properly 7541 03x Step Action and questions Yes No 1 Check the cable connection between the RIP and the UICC and check the connection from the UICC to the display Are all the cables properly connected Go to step 3 Go to step 2 Reconnect the cables POR the machine into diagnostics mode and perform the button test Do any of the buttons fail the test Go to step 3 Problem solved Using a multimeter check the cable connecting operator panel to the RIP board for continuity Is there continuity Replace the defective cable POR the machine into diagnostics mode and perform the button test Do any of the buttons fail the test Replace the UICC POR the machine into diagnostics mode and perform the button test Do any of the buttons fail the test Go to step 5 Go to step 5 Go to step 6 Go to step 4 Problem solved Problem solved Replace the RIP board POR the machine into diagnostics mode and perform the button test Do any of the buttons fail the test Contact your second level support Problem solved Display fails to illumi
316. tch the intervals on the table they are most likely caused by the component listed Imaging transport component Circumference Registration rolls 50 mm Pickup feed and separator rolls 63 mm dimensions are the same for the expansion trays MPF roller 75 mm Transfer roll located in transfer belt 38 mm Fuser Fuser belt 141 mm Imaging unit parts Photoconductor 75 mm Developer roll 41 mm Charge roll 31 mm Supply roll 28 mm Transfer roll 57 mm 2 4 Service Manual One color missing 7541 03x Step Action and questions Yes No 1 Are the imaging units photoconductors properly Go to step 2 Reinstall the installed imaging units 2 Is the photoconductor lock door properly closed on Go to step 3 Open and close both sides the photoconductor lock door ensuring that t is locked in place on both ends 3 Is the ribbon cable for the missing colors LED Go to step 4 Properly connect printhead properly connected to the printhead the ribbon cable controller board and LED printhead on both ends 4 Replace the LED printhead Did this fix the problem Problem resolved Go to step 5 5 Arethe contacts on the HVPS clean Go to step Clean the contacts on the HVPS 6 Arethe spring contacts on the sub frame damaged Replace the Go to step 7 subframe 7 Replace the HVPS Did this fix the problem Problem resolved Contact your second level
317. te toner bottle missing service check 00 cece eee eee eee eee eee eee 2 94 Wrong paper size service check tray iusliluunasa uasa ka a RRaARARA RE RAARRRA aes 2 95 Wrong paper size service check Ir yZ o ioesosauascakasexkhaeektdascka ra aka esibd sis 2 95 Paper in ADF size service Check i ssiskesaknassEEda Ran ERR AA ERR A RA RA R RAE 6 8 XR a 2 96 Diagnostic pP Rm 3 1 Understanding the operator panel and menus 2000 e eee enne 3 1 Operator panel need new art 00 cc cece eee 3 1 Understanding the home screen 00sec sere eee eee eee enr hh hh hn 3 2 USING INS TOUCH Serten duaasxaaasd p dob A d d dual heeds bal a deii id 3 3 Administralive meg 5 qu kd dk diene dex e b de RR CR ke hae OE Oe RED CRURA RH KR o ode 3 6 Accessing the service menus x sxu sss aco ce enews OCCUR dR COLO o RR RC UR A 3 7 Configuration Menu i e s uere RR RR E Yu er benc E Re PANER PIU E Fr E RE FEE REG HR Rd 3 9 Entering Config Men csicscadscevemennse cee MR CERRO Mew eRe skewed QURE oan PCR UNIS OR 3 9 Reset Fuser COUNGE ossec ker e eure ma RR UR RR RERO HEP RE EEG equ EE RENE ERE 3 10 Reset Maintenance Counler csc casic cents ac gx ce tia ORU teens EUR URS RR UR FR Gn RR OR IR 3 10 Reset Transfer Belt Counter c creeeue io rh rrr ph rana psa ede ea RU wien RR ERE E 3 10 USB Scan to Local ticcasicecec dss ee btw dua ER ARR Ea RE IARE EE REXCEKESIERATRPE RES 3 10 Black Only MOUE iu leet orones tei EDT PIE
318. tep 8 ADF cover closed sensor for dirt and debris Is there dirt and debris present 7 Remove the ADF rear cover and clean the Issue resolved Go to step 8 dirt and debris from the sensor Does this fix the issue 8 Inspect the connections on the ADF relay Go to step 9 Secure all the connections card in the ADF Are all the connections properly connected 9 Check the ADF cable for continuity Is there Go to step 10 Replace the ADF cable See continuity ADF cable on page 4 128 10 Check for signals or voltages from J17 on Replace the ADF Replace the ICC card the ICC card Pin 11 and 12 should measure 24VDC Pin 14 should measure 5VDC Are there signals or voltages present Diagnostic information 2 77 7541 03x Fax symptoms Faxes fail to transmit Note Before performing this service check verify that the correct country code for the MFP is selected This setting must match the country in which the MFP is used to transmit and receive faxes If the setting is wrong the modem settings can be changed in the Fax SE menu See step 14 These settings should only be changed with guidance from your second level support Step Questions actions Yes No 1 Is the phone line properly connected to the Go to step 3 Go to step 2 modem card and the wall jack 2 Properly connect the phone line to the Problem resolved Go to step 3 modem card and wall jack Did this fix the problem 3 Test the phone
319. the PCI card 54 Std Network Software Error Select Continue to clear the message and continue printing The job may not print correctly Program new firmware for the network interface e POR the printer If this does not fix the problem replace the PCI card 54 Network x Software Error 55 Unsupported Option in Slot lt x gt 1 Turn the printer off 2 Unplug the power cord from the wall outlet 3 Remove the unsupported option 4 Connect the power cord to a properly grounded outlet 5 Turn the printer on If this does not fix the problem replace the RIP board See RIP board removal on page 4 73 56 Standard Parallel Port Disabled Select Continue to clear the message The printer discards any data received through the parallel port Make sure the Parallel Buffer menu item is not set to Disabled e f this does not fix the problem replace the PCI card 56 Parallel Port x Disabled Select Continue to clear the message The printer discards any data received through the parallel port Make sure the Parallel Buffer menu item is not set to Disabled f this does not fix the problem replace the PCI card 56 Serial Port x Disabled Select Continue to clear the message The printer discards any data received through the serial port Make sure the Serial Buffer menu item is not set to Disabled e f this does not fix the problem replace the PCI card
320. the guides in position to leave the sensor open or closed The width sensors detect A4 B5 and A5 widths for non US users and statement executive and letter widths for US users 3 With the size of the paper determined by the width and length sensors the cover open sensor is polled to ensure the ADF top cover properly closed If the cover is not properly closed and error is generated If the cover is closed the pick up sensor is polled The pickup sensor determines if the pick roll is in the proper position Before executing the pick the pick roll is in the up position If the sensor determines that the roll is in the up position the pick roll is moved to the down position to initiate the pick 4 With the pick roll in the proper position the signal to pick is generated from the ADF relay card The top sheet in the paper is pulled in to the ADF towards the feed roll To prevent double feeds a separator roll is present to provide resistance holding the other sheets in the paper input tray 5 Once the top sheet passes the feed roll it moves into the ADF paper path and triggers the gap sensor When the gap sensor is triggered by a physical actuator it begins counting the time for the paper to pass over it Based on the paper length the gap sensor can determine if a jam is encountered Also the paper length and position in the paper path is determined by this sensor 6 After passing over the gap sensor the paper reaches the paper in sensor
321. thead Did this fix the Problem resolved Contact your issue second level support Uneven print Step Action and questions Yes No 1 Check the condition of the paper Is it curled or wavy Replace the Go to step 2 paper 2 Check for dew or moisture on the imaging unit s drum Let the imaging Go to step 3 Is there moisture on the drum units drums dry off 3 Is there any dirt or debris on the imaging unit Clean off the Go to step 4 imaging unit with a lint free cloth 4 Isthere dirt of debris on the exposing surface of the Clean the LED Contact your LED printhead printhead with a second level lint free cloth support 2 6 Service Manual 7541 03x Partial dirt Step Action and questions Yes No 1 Is there toner attached to the developer roll especially Replace the Go to step 2 the lower part of the roll imaging unit 2 Checkthe transfer belt for defects or foreign matter Remove the dirt Go to step3 such as dirt Are there defects on the transfer belt from the belt 3 Replace the transfer belt Did this fix the problem Problem Contact your resolved second level support Repeating marks For repeating defects see Repeating defects on page 2 4 FRU CRU Action 1 Fuser Check for dirt on the fuser belt Clean if needed Check for scratches on the belt Replace if needed 2 Transfer roll Check for dirt or scratches on the transfer
322. this test to check the operation of the Serial Port Hardware using a wrap plug Each signal is tested Note this test is listed only if the serial option ISP card is installed To run the Serial Wrap Test 1 Disconnect the serial interface cable and install the wrap plug 2 From the Diagnostics menu navigate to HARDWARE TESTS gt Serial Wrap Test 3 Select the appropriate Serial Wrap Test from the list Values may include Serial Wrap Serial 1 Wrap Serial 2 Wrap or Serial 3 Wrap Each time the test finishes the screen updates with the result P and F represent the same numbers for DRAM If the test passes the Pass Count increases by 1 However if the test fails one of the following failure messages appears for approximately three seconds and the Fail Count increases by 1 Receive Status Interrupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Error Break Interrupt Error Framing Error Parity Error Overrun Error Data Error Data 232 Error Data 422 Error FIFO Error DSR Error DSR PIO Error DSR Interrupt Error CTS Error CTS PIO Error CTS Interrupt Error Once the maximum count is reached or a failure occurs the test stops Press Stop X to cancel the test Diagnostic aids 3 23 7541 03x USB HS Test Mode 1 From the Diagnostics menu navigate to HARDWARE TESTS gt USB HS Test Mode 2 Select the desired Port The test begins imme
323. til the calibration is finished e dle The printer must be idle with no jobs pending in order for a calibration to occur Diagnostic aids 3 13 7541 03x Color Alignment When you enter Color Alignment the printer generates four alignment pages that are used to set the color alignment on the print engine This needs to be run whenever a toner cartridge or imaging unit is installed on the print engine To set the alignment perform the following steps 1 Select Color Alignment from the configuration menu 2 Select Print Alignment Pages The pages are printed The alignment pages that are printed out contain vertical and horizontal alignment settings labeled A through L Example A is shown here In the Color Alignment sub menu Select A Look at item A on the sheets Look for the numerical value where the color lie is aligned with the two black lines on each end Note In the example above 10 would be the value to enter a RO 6 Using the arrows on the touch screen scroll to the value that matches the correct value on the printout 7 Touch the check mark 8 Repeat steps 3 through 6 for each alpha value on the printout ADF Edge Erase The ADF Edge Erase setting specifies in millimeters the size of a border around the scanned image that will be erased For copies the printed page will always have a at least a 2 mm no print border The larger of the 2 mm no print border and the Edge Erase setting will be used in this s
324. times Did this fix the issue Problem Go to step 2 resolved 2 Replace the printhead controller Does this fix the Problem resolved Go to step 3 problem 3 Replace the RIP board Did this fix the issue Problem resolved Contact your second level support Diagnostic information 2 63 7541 03x 950 00 950 29 EPROM mismatch failure Warning System board Flatbed scanner assembly Scanner interface card When replacing any of the following components replace only one component at a time or the printer will be rendered inoperable Replace the required component bring the printer up in Diagnostics mode see Diagnostics mode on page 3 18 and verify that the problem is fixed before performing a POR This error code indicates a mismatch between the operator panel assembly and the system board removal on page 4 120 Does the error message still appear See RIP board removal on page 4 73 Step Questions actions Yes No 1 Has the OP panel UICC card been replaced Replace the operator panel Go to step 2 recently assembly with a new and not previously installed UICC card See UICC removal on page 4 120 2 Has the system board been replaced Replace the RIP board with Go to step 3 recently a new and not previously installed system board See RIP board removal on page 4 73 3 Turn the printer power off for ten or more Problem solved Go to step
325. tion needed compression type from remote fax device A04 Received request for unsupported No action needed image length from remote fax device FOO Unknown error occurred No action needed 2 44 Service Manual Service checks 111 01 Black printhead error 7541 03x 112 01 Cyan printhead error Step Action and questions Yes No 1 Is the ribbon cable connecting CN4 on the printhead Go to step 2 Properly connect controller board to the black LED head securely the ribbon cable connected 2 Replace the ribbon cable Does this fix the problem Problem fixed Go to step 3 3 Replace the black LED printhead Does this fix the Problem fixed Replace the problem printhead controller board Step Action and questions Yes No 1 Is the ribbon cable connecting CN2 on the printhead Go to step 2 Properly connect controller board to the black LED head securely the ribbon cable connected 2 Replace the ribbon cable Does this fix the problem Problem fixed Go to step 3 3 Replace the cyan LED printhead Does this fix the Problem fixed Replace the problem printhead controller board 113 01 Magenta printhead error Step Action and questions Yes No 1 Is the ribbon cable connecting CN3 on the printhead Go to step 2 Properly connect controller board to the black LED head securely the ribbon cable connected 2 Replace the ribbon cable Does this fix the pr
326. to the flatbed scanner Select Copy Quick Test Compare the copy to the original test page and then navigate to Adjust Calibration Values gt Flatbed Black Adjust the values and then touch Submit to save your changes To check the changes reload the original test page and then repeat the Copy Quick Test Repeat the steps as needed Repair information 4 205 7541 03x Adjusting ADF magnification 8 Enter the Diagnostic menu press and hold 3 and 6 turn on the printer and release the buttons when the splash screen appears To print a test page from the Diagnostic menu navigate to REGISTRATION gt Quick Test To copy the test page from the Diagnostic menu navigate to SCANNER CALIBRATION gt Copy Quick Test Navigate to SCANNER TESTS gt ADF Magnification Compare the copy to the original test page and then adjust the value of the ADF Magnification setting as needed If the bottom margin is too small decrease the value If the bottom margin is too large increase the value Touch Submit to save your changes To check the changes reload the original test page and then repeat the Copy Quick Test Repeat the steps as needed Once the margins look correct check the registration of the ADF Perform the Copy Quick Test and then repeat the process if needed Adjusting scanner registration Note If the printer menus do not match the following instructions then contact your next level of support 1 2 Enter the
327. uced install the new fuser using the instruction sheet that comes with the replacement fuser Note Be sure to reset the fuser count e f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 80 Fuser Life Warning Select Continue to clear the message and continue printing Show Me View Supplies and Tell Me More displays additional information Order a replacement fuser When print quality is reduced install the new fuser using the instruction sheet that comes with the replacement fuser Note Be sure to reset the fuser count f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 80 Replace Fuser Show Me View Supplies and Tell Me More displays additional information Replace the fuser See Fuser removal on page 4 61 Note Be sure to reset the fuser count f this does not fix the problem replace the system board See RIP board removal on page 4 73 80 Fuser Missing Remove power from the printer before continuing or use caution if the product must be energized during this procedure The heat sink transformer core presents risk of electric shock Test before touching Reinstall the fuser See Reseat connectors behind fuser They may get dislodged and not make good contact when the fuser is installed Check the cable connectors for damage at the system board and at the LVPS 82 Replace Waste Toner
328. ue to second level support on page 2 82 Diagnostic information 2 81 7541 03x Escalating a fax issue to second level support Before contacting the second level support go to the SE menu on the MFP and generate a Fax error file This file contains machine settings information and debug information that will help second level support determine the cause of a failure To generate the fax error file perform the following steps 1 In a Web browser type http MFP ip address se 2 The MFP s SE menu page will display Click the Dump Job History link The following displays Fax Job Log Wednesday 2006 02 08 11 25 Action Date Time Job Length Station Name Number Pages Status SCAN 1969 12 31 19 00 OK SEND 2006 02 01 13 55 73 17 53 40 9 CANCELED SEND 2006 02 01 13 56 74 17 53 4029 CANCELED On Write down the type of connection the type of error and the job in which the error occurred In the Web browser address bar type http MFP ipaddress se Click Report a Fax Problem A The fax check list displays Fill in the requested information This is where you will type in the information you retrieved in step 3 Second level support can assist you if you have questions about the information requested on the page OPO Title Name of Tester Your Name Date of Event Date of Event mm dd yyyy Customer Customer Name Time of Event Time of Event hh mm A P M Job ID Job ID SERES Describe the Physical
329. uity Go to Step 6 Go to step 5 5 Replace the faulty cable Did this fix the issue Problem resolved Go to step 6 6 Is the CCD LED illuminating and not moving when a Replace the Go to step 7 scan command is given CCD 7 Replace the ICC card Did this fix the issue Problem resolved Goto step 8 8 Replace the ADF relay card Did this fix the issue Problem resolved Go to step 9 9 Replace the RIP board Did this fix the issue Problem resolved Contact your second level support 2 58 Service Manual 7541 03x 843 00 Carriage Home Step Questions actions Yes No 1 POR the device Did the error re occur Go to step 2 Problem resolved 2 Checkall the connections from the ICC card to the Go to step 3 Go to step 4 CCD carriage and RIP board to ICC card Are the cables properly connected 3 Properly connect all the cables Did this fix the issue Problem resolved Go to step 4 4 POR the machine into diagnostics mode and perform Go to step Go to step 5 the scanner sensor test Is the home position sensor displaying a 1 5 Is there any damage to the flag that actuates the home Go to step 6 Go to step 7 sensor 6 Replace the flatbed unit Did this fix the issue Problem resolved Go to step 9 7 Replace the ICC card Did this fix the issue Problem resolved Goto step 8 8 Replace the CCD Did this fix the issue Problem resolved Go to step 9 9 Replace the
330. unsupported feature 805 Remote fax device failed to respond to Adjust Transmit Level Receive the DCS command Threshold values Remote device could be malfunctioning 808 T1 timeout occurred when trying to Adjust Transmit Level Receive establish a connection with a remote Threshold values fax device 809 T2 Timeout occurred due to loss of Adjust Transmit Level Receive command response synchronization Threshold values Diagnostic information 2 41 7541 03x Fax error log codes Continued Error code Description Action 80A T5 Timeout occurred when transmitting Check line quality image data to remote fax device Adjust Transmit Level Select a lower Max Speed value under Fax Send settings 80B Too many errors when transmitting in Check line quality ECM mode e Adjust Transmit Level Select a lower Max Speed value under Fax Send settings 80C Remote device failed to respond to the Select a lower Max Speed value CTC command under Fax Send settings Adjust Transmit Level 80D Received too many requests from Check line quality remote end to repeat the previous Adjust Transmit Level command sent Check if line conditions on remote end will facilitate a good connection 80E Functional limitation Remote fax No action needed Issue with the remote device does not support G3 receive device capability 811 Failed to detect a
331. uration Menu Fax Storage Location 3 13 Format Fax Storage 3 13 Min Copy Memory 3 12 NumPad Job Assist 3 13 Configuration menu USB Scan to Local 3 10 configuration menu 3 9 7541 03x accessing 3 7 Auto Align Adj 3 13 Black Only Mode 3 11 Color Adj State 3 13 Color Adjustment 3 13 Color Alignment 3 14 Color Trapping 3 1 1 Demo Mode 3 12 Disk Encryption 3 16 Download Emuls 3 12 Energy Conserve 3 12 entering 3 9 Envelope Prompts 3 15 Exit Config Menu 3 17 Factory Defaults 3 12 Font Sharpening 3 16 Jobs On Disk 3 16 Motor Calibration 3 15 Panel Menu 3 12 Paper Prompts 3 15 PPDS Emulation 3 12 Print Quality Pages 3 11 Reports 3 11 SIZE SENSING 3 11 Crossbar removal not a FRU 4 74 D Defaults 3 25 Demo Mode 3 12 Density sensor removal 4 57 diagnostics 2xx paper jam message table 2 66 user attendance message table 2 66 Diagnostics Menu DEVICE TESTS 3 24 EVENT LOG 3 28 EXIT DIAGNOSTICS 3 30 HARDWARE TESTS 3 21 Print tests 3 20 PRINTER SETUP 3 25 Diagnostics menu SCANNER CALIBRATION 3 20 Adjust Calibration Values 3 20 Reset Calibration Values 3 20 SCANNER TESTS ADF Magnification 3 29 ASIC Test 3 29 Feed Test 3 29 Scanner Callibration Reset 3 29 Sensor Test 3 29 diagnostics menu accessing 3 7 Diagnostics Mode 3 18 DEVICE TESTS Disk Test Clean 3 24 Index l 1 7541 03x Flash Test 3 25 Quick Disk Test 3 24 entering 3 18 EVENT LOG Clear Log 3 29 Display Log 3 28 Print Log 3 28 HARDWARE TESTS Button Test 3 22
332. ures require removing cable ties You must replace cable ties during reassembly to avoid pinching wires obstructing the paper path or restricting mechanical movement 4 4 Service Manual 7541 03x Cover Removals RIP cover 1 Remove the two screws securing the RIP cover to the RIP cage 2 Remove the RIP cover Repair information 4 5 7541 03x Scanner power supply access cover 1 Press the access cover inward at the arrow and pull back removing the cover Cord cover 1 Remove the screw A securing the right side of the cord cover to the rear cover and scanner frame 4 6 Service Manual 7541 03x 2 Remove the screw B securing the left side of the cord cover to the rear cover and scanner frame B 3 Tilt the cord cover back and lift it up and away from the rear of the scanner Rear cover 1 Remove the cord cover See Cord cover on page 4 6 2 Remove the screw A above the rear fan mpm p e pnr d Repair information 4 7 7541 03x 3 Remove the two screws B in the lower left corner n B 4 Remove the screw C in the lower left corner 4 8 Service Manual 7541 03x 5 Remove the screw D in the upper right corner D 6 Remove the screw E in the top middle of the cover Repair information 4 9 7541 03x 7 Remove the screw F in the upper left corner of the cover F 8 Open the duplex unit and remove the one plastite screw that secu
333. used If the MP Feeder Size is set to Universal make sure the media is large enough for the formatted data If the problem still exists replace the RIP board See RIP board removal on page 4 73 Diagnostic information 2 69 7541 03x Error code Action 35 Insufficient memory to support Resource Save feature Select Continue to disable Resource Save and continue printing To enable Resource Save after receiving this message Make sure the link buffers are set to Auto then exit the menus to activate the link buffer changes When Ready is displayed enable Resource Save Install additional memory e f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 37 Insufficient memory to collate job Select Continue to print the portion of the job already stored and begin collating the rest of the job Cancel the current job f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 37 Insufficient memory for Flash Memory Defragment operation Select Continue to stop the defragment operation and continue printing Delete fonts macros and other data in printer memory Install additional printer memory e f this does not fix the problem replace the RIP board See RIP board removal on page 4 73 37 Insufficient memory Some Held Jobs Were Not Restored The printer deleted some held
334. ut GND N TMFDET LD1 Locations 5 23 7541 03x LVPS Connectors ooooo00000 gt B LVPS board Connector Connects to Pin no Signal CNO1 Scanner power supply 1 AC L 2 3 AC N CNO2 Fuser sensor 1 COM 2 HT3 3 HT2 4 HT1 5 24 Service Manual LVPS board 7541 03x Connector Connects to Pin no Signal CNOS Engine board GND 24V GND 5V Printhead controller board GND 24V GND 5V CN04 Printhead controller board NI O oO AJ OJN ACXerox P Heater3N Heater2N Heater1N Sleep2 Sleep1 HT24 GND Engine board FAN GND 0 CO NI OD oy BY WT Io FAN ARM FAN CNO6 Power supply fan FAN FAN ARM FAN GND Scanner secondary power supply Connector Connects to Pin no Signal CNO1 Power switch 110V or 220V in w GND CN02 LVPS COM 110V or 220V out CNOS RIP board 5V 5V 24V 24V GND GND CO
335. ver on page 4 7 Remove the top cover See Output bin print engine top cover on page 4 17 Remove rear EMI shield See Rear EMI shield Not a FRU on page 4 106 Remove three screws A attaching the HVU to the frame Note The upper left screw is different than the other two poh Repair information 4 111 7541 03x 6 Disconnect the power cable C from the HVU Waste toner sensor removal 1 Remove the HVPS See HVPS removal on page 4 111 2 Remove the rear fan See Rear fan on page 4 102 3 Depress the tabs A securing the waste toner sensor to the frame and push the sensor in After the sensor is detached pull it out of the frame A B 4 Disconnect the waste toner sensor cable B from the sensor 4 112 Service Manual 7541 03x Scanner area removals Note After replacing the ADF assembly the flatbed unit or CCD you will need to run the scanner registration procedure and scanner calibration procedure These are located in the Diagnostics menu and Calibration menu For more information see Adjustments on page 4 205 ADF assembly removal 1 Remove the cord cover See Cord cover on page 4 6 2 Remove the rear cover 3 Remove the two thumbscrews A that secure the ADF cable to the flatbed assembly A 4 Remove the thumbscrews securing the ADF and flatbed hinges to the flatbed 5 Tilt the ADF assembly up and lift it away from the flatbed assembly Note After installin
336. verses the exit roll The paper goes back into the ADF unit for a third time The paper passes through the paper path but no imaging occurs This pass is to turn the paper over to the original side up On the third pass of the media trailing edge over the reverse point the solenoid is not actuated The paper proceeds to the exit rolls and passes out of the ADF to the exit bin 3 48 Service Manual 7541 03x Color theory What is RGB color Red green and blue light can be added together in various amounts to produce a large range of colors observed in nature For example red and green can be combined to create yellow Televisions and computer monitors create colors in this manner RGB color is a method of describing colors by indicating the amount of red green or blue needed to produce a certain color What is CMYK color Cyan magenta yellow and black inks or toners can be printed in various amounts to produce a large range of colors observed in nature For example cyan and yellow can be combined to create green Printing presses inkjet printers and color laser printers create colors in this manner CMYK color is a method of describing colors by indicating the amount of cyan magenta yellow and black needed to reproduce a particular color How is color specified in a document to be printed Software programs typically specify document color using RGB or CMYK color combinations Additionally they allow users to modify the color
337. ves Ewa RE oe ae qe qd Verde d edad qus 1 8 Media GUIGEINGS 54523105982 xb Xx 58 Da 59D 1209 528 S ORO tease d ESTA O NU Md d UA 1 9 coc 1 9 Paper characters iC S ss ass oes Cedar a oul edu Rep E pe ud Mq d de ias 1 9 Unacceptable paper 4 2 3 99433 UR ESROIASOCTARIX E RESTq Pa TYPI ITE 1 10 SBIBcUD DANE 15 ipse tade conse Fin RM Ue atqae FRgdqes dE dreqaddaudpet gu dd 1 10 Scan fax and copy specifications leeeeeeeeeeeeeeee iere n n nnn 1 11 General specifications usse cx sms p sacred deena CREER RR ER E CE E ROC EQ NRI RR ER 1 11 I X LL C CA ERAT LIEU INI Vl V 1 0 711 220 1 5 1 5552 5215 527551 1050 5 2551 1 12 Scanner specifications 2 cisnas asado sew esse Ra REA E ERRRRERAARG RA E PORE E RR REA RUE acu 1 13 MEP Scam Speed A palude Ru oq iL S diga f amd Ku add qp E med d d down MAR Md me 1 14 Tools reditired TON SOEVICO 4 5 aac datas dde Urt od e OC RR Ead acd a a a EROR i eoe n 1 15 Pio Mi Meee eee ree ee ree ee ee ee CTL eT Gud Tee URS eee Nd do Edad RR Em 1 16 Dilagbosuc INIGHMGNION 5 11a ioo per HIE EREEOOS IA ei dao EE Es RES KREISE hi 2 1 SUBIT i ccsstcdsm ceeds px Eee d E ex E a GRE Aqua d cee CEREREM MEX MEE Lede Ue aad d died 2 1 Millal CHEEK canes caeasatusat eh ate keane sees TII UICE 2 2 POR Power On Reset Sequence 2 250 2cccc see eee Rura eee ta eee eee eee eee eee ee AER 2 3 Print quality IS8UBS fie icikxsac kp RE RO EORR UR ROC RORON OR GATA CORD eR TRG EKO ER OR RE TARE 2 4
338. with the fax error code table See Fax T30 log error codes on page 2 41 Perform the suggested resolution for the error Did this fix the problem Yes Problem resolved No Go to step 15 15 Adjust the Transmit Level setting in the SE menu Press 411 to enter the SE menu enter Modem settings and select Transmit Level Test by adjusting the transmitted signal strength by decreasing increasing the Transmit Level setting in steps of 1db For example if default value is 11 db changing itto 12db will decrease the signal strength by 1db and changing it to 10db will increase the signal strength by 1db Recommended adjustment range is 5 db in 1db steps from the default value Did this fix the problem Stop Problem resolved Go to your second level of support See Escalating a fax issue to second level support on page 2 82 Diagnostic information 2 79 7541 03x Fax reception fails Step Questions actions Yes No n O NI a el 1 Is the phone line properly connected to the Go to step 3 Go to step 2 modem card and the wall jack 2 Properly connect the phone line to the Problem resolved Go to step 3 modem card and wall jack Did this fix the problem 3 Check for a dial tone Go to step 4 Go to step 6 Is there a dial tone 4 Use a telephone to test the phone line s Go to 7 Go to step
339. x L T T Note When reinstalling the unit line up the slots D on the paper exit unit with the tabs E on the sub drive unit before pushing the unit down in place Repair information 4 35 7541 03x Bin full sensor removal 1 Remove the paper exit guide See Paper exit guide removal on page 4 33 2 Release the tabs A securing the black exit guide A 3 Open the guide exposing the bin full sensor 4 Release the tabs B securing the bin full sensor to the paper exit guide AV 5 Disconnect the blue cable from the sensor 4 36 Service Manual 7541 03x Paper exit sensor removal 1 Remove the paper exit guide See Paper exit guide removal on page 4 33 2 Release the tabs A securing the paper exit sensor to the paper exit guide 3 Disconnect the purple cable from the sensor Printhead controller board removal Warning When replacing any one of the following components Printhead controller board Engine board Replace only 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 Never replace both of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning 1 Remove the rear cover See Rear cover on page 4 7 2 Remove the top cover See Output bin pri
340. x the Problem resolved Go to step 12 issue 12 Checkthe ADF cable for continuity Is there continuity Go to step14 Go to step 13 13 Replace the ADF cable did this resolve the issue Problem Go to step 14 resolved 14 Replace the ADF relay card Did this fix the issue Problem resolved Goto step 15 15 Replace the ICC board Did this fix the issue Problem resolved Replace the RIP board See RIP board removal on page 4 73 Diagnostic information 2 31 7541 03x 285 05 Scanner ADF eject jam Step Action and questions Yes No 1 Remove the paper from the ADF Did this resolve the Problem resolved Go to step 2 problem 2 Remove the ADF main feed unit and inspect the Go to step 6 Go to step 3 duplex out sensor actuator Does it move freely 3 Remove any debris obstructing the actuator Did this fix Problem resolved Go to step 4 the issue 4 Isthe actuator improperly attached to the main feeder Go to step 6 Go to step 5 or broken 5 Reattach or replace the actuator Did this fox the Problem resolved Go to step 6 issue 6 Does the duplex out sensor have dust on it or debris Go to step 7 Go to step 8 blocking the sensor 7 Clean the sensor Did this fix the issue Problem resolved Go to step 8 8 Checkthe sensor ADF exit sensor for proper Go to step 10 Go to step 9 operation 1 Enter the Diagnostics Menu 2 Touch SCANNER TESTS
341. y If the problems persist leave the new operator panel in the machine place the old RIP card back in the machine and start it up After the machine startup shut down the machine and install the new RIP card After installing the new RIP card restart the machine and let it go through the startup cycle After this procedure is completed successfully there is no need to adjust any settings If the above procedure fails you must contact the technical support center for further instructions Printhead controller board engine board replacement This procedure should only be followed if both the printhead controller board and engine board are being replaced If you only need to replace one of the FRUs follow the startup procedure described in the FRU s removal procedure Warning If the printhead controller board and the engine board are being replaced at the same time replace 1 2 the parts in this order to avoid damage to the machine Replace the printhead controller board first Do not replace the printhead controller board and engine board in the machine at the same time After installing the new RIP card and before installing the new operator panel start the printer After the printer has completed startup turn off the printer and replace the operator panel Note If the operator panel display has failed the printers startup cycle is complete when the driver motor and fans shut down and the machine is quiet After ins
342. y Menu Job Accounting Menu Utilities Menu XPS Menu PDF Menu Postscript Menu PCL Emul Menu HTML Menu Reports Menu Settings Page Device Statistics Network Setup Page Network x Setup Page Shortcut list Fax Job Log Fax Call Log Copy Shortcuts E Mail Shortcuts Fax Shortcuts FTP Shortcuts Profiles List Print Fonts Print Directory Print Demo Asset Report Network Ports Active NIC Standard Network Standard USB Parallel x Serial x SMTP Setup Manage Shortcuts Fax Shortcuts Security E mail Shortcuts FTP Shortcuts Copy Shortcuts Profile Shortcuts Help Print All Guides Copy Guide E mail Guide Fax Guide FTP Guide Print Defects Guide Information Guide Supplies Guide Option Card List of all DLEs Downloadable emulators Accessing the service menus 7541 03x There are different test menus that can be accessed during POR to identify problems with the printer Diagnostics menu 1 Turn off the printer 2 Press and hold 3 and 6 3 Turn on the printer 4 Release the buttons when the splash screen appears The Diagnostics menu group contains the settings and operations used while manufacturing and servicing the printer For more information see Diagnostics mode on page 3 18 Configuration menu 1 Turn off the printer 2 Press and hold 2 and 6 3 Turn on the printer 4 Release the buttons when the spl
343. y contain graphics Use this test to identify print quality problems The Test Pages must be printed on A4 Legal or Letter paper Reports From this menu you can print the Menu Settings Page or the Event Log Will event log be added Color Trapping Color trapping is an aid to graphics and text When text or graphics appear over other colors a misalignment may allow white paper to show through at the borders of the colors Color trapping increases the amount of color under the upper image so a slight misalignment does not show This affects PCL 5e PCL XL PDF and PostScript printing Increasing the value increases the amount of color remaining beneath the black content in increments of 1 600 of an inch 1 Select Color Trapping from the Configuration menu 2 Select the value or Off The range is 1 to 5 and the default value is 2 Press to increase the value 3 Press Check to accept Tray Insert Message This setting determines how many seconds the panel will display the Tray Insert message after a user has inserted a tray into the printer The values are 1 90 seconds 1 Select Tray Insert Message from the Configuration menu 2 Use the arrows to scroll to the desire value 3 Press Check to accept 4 Touch Back to exit SIZE SENSING Automatic size sensing can be disabled or enabled in this menu Only paper sources that support Auto Size Sensing are displayed 1 Select SIZE SENSING from the Configuration menu
344. y removal on page 4 29 4 98 Service Manual 7541 03x 7 Remove the twelve screws D securing the top frame to the printer 8 Remove the four screws E securing the plastic body back to the left and right printer frames Repair information 4 99 7541 03x 9 Remove the screws F securing the toner sensors to the top frame Transfer belt motor removal 1 Remove the HVPS 2 Disconnect the motor harness A from the transfer belt 3 Remove the two screws B securing the motor to the frame 4 100 Service Manual 7541 03x Temperature and humidity sensor removal 1 Remove the rear cover The sensor will be located to the right side of the right rear scanner support 2 Disconnect the sensor cable A from the sensor A B 3 Remove the screw B securing the sensor to the printer frame Repair information 4 101 7541 03x Rear fan 1 Remove the high volt power supply See HVPS removal on page 4 111 2 Remove the three screws A securing the fan mounting duct to the printer A 3 Route the high volt power supply cable the fan mounting duct 4 102 Service Manual 7541 03x 4 Disconnect the fan cable B from the MDCONT engine board Repair information 4 103 7541 03x Sub frame unit 1 Remove the drive unit 2 Disconnect the belt up down sensor harness A if it is connected A 3 Remove the four screws B securing the sub unit to the head in plate 4

X925

Contents

Download Pdf Manuals

Related Search

Related Contents