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Service Manual (P/N 12G9633)

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3. To interconnect card ASM m Cover Closed M FP base pri nter To printer scanner control A Cartridge Switch card ASM mpm ISEISIEIBLL Toroid Fan I es STD Bin Sensor Interconnect card ASM pit Toroid m Z H 5 515 tiu ls em fam AO z z E Ale esi amp ez lololo i 6 28 gag oodd elo ae z mi S SIS SISIS 554523359225 S S EE HOP LED 1 Gnd HOP FULL CN 12C DAT LS 12C CLK LS USB Device Port USB Board ExitSens Thumpret 99 QQ 5VSW QQ QO Thump E i z o J7 QQ QQ Oo gt Therm CN 99 99 E GND o eS OR TARAR NarrowMedia 29 BB H2 3 4 5 Q O zi 4aa ola iiz z 1 o o 50V AC Inlet o DC1 o DC2 mio g R Ejay eo Power J12 demeduume mese me aati dE deuten 52 53 Elolsv T Switch 7 N gt 0 3 3v gt CN
4. Sa 7002 xxx 25V OQ 3 SPSS eee Se SSS eS SS Our B 2 an e j GLK OUT Na CN2 O alai A eer S ED TA i 25V f9 615 6le aN BACK STEAN ON k Wirin dia ram OUT AY 8 74 Sap 7 COVER CLOSED GND Ea N nRESET UO 109 lo gf s 36 18 nADF PRESEN GND 1 x5VINIL FAN_BACK uad 12h h2 11 3 ee CN1 fad iaioe mo noc po scanner FAN ON GND GO 141 14 GND 13 START LINE perc I nHOME a nFLAT LENGTH3 E a DE teles S LE TS o nFLAT_LENGTH2 5 nFLAT_LENGTH1 F3 O 1817 18 Oop Es egg 5 GND GND 201g bo ah peers a ba OUT nB OUT B O bolo 22 pps Home o 30 12 25V IN MDC_DET OUT nB OUT B 242 24 23 Sensor I I 29 11 7 OUT nAP OUT Aj D Fo OUT_nAl OUT A J1 1 ND 2 b O U e GND 7 nCOVER CLOSED 5 CN4 2 nHON 1L U og nADF PRESENT GND a 3 N 31 u J ly MDC_RXD MDC_TXD ej I a ey Se a E I eee a a SS 24 6 SCLK GND I nSTART_LINEF Soe g SDI 18 ND l Sis CN2 GND Fs nTOP ADF Q i91 NASEN pn PR AE MET RUM nTOP FB 425V void 20 16 L 1 l 21 m n DATAO DATA2 I l l l l 25V po 25V 21h 21ranp 158 END l l 5x I 425V MDC ON C boha 22 142 I 2 t l Sa I 19 1 m mmm DATA3 DATA5 ee e pum R63 VV s GND 231 23 13 j 7 I TN ga xli C1 DATA4 DATA6 z 55 o IVS IS I l R3 WV s SD O 2412 24 GND 12 GND IE 10 ala o o a a n l A 25h 25 11 zin uus uu ui DATA ELTM
5. 3s1 amp zz 2610 26 AE VIDEO re NE I A3 ajal ajal aji NM LL CN5 242 P sawete nEF TEND i TES P po isssss2soscssoszos Qo Q 288 8 rE CLK 8 END i As m i I 1 pe F GS GO G GS G S G Gf a x SO fa Gfx 1 PE T 297 P93 cco CLAMP 7 GND i PEHK alg HPEERRRESRELENECONR S C 806 S9 ccp RESET 6 GND p LOLE o c i E J2 3115 Bite 5 XIIe S S S S e epv e Lie T Te i e Li a24 a2 CCD PHASE 4 ONP Soa Noe NTP SINT eem mule I om 53 CCD TRANSFER 424V I I A 1 E MEE dT EL ELS ilg i O 33 3 Ey CCD_BW_SELECT HHpowen SAVER l W o 11 Osa Seclala J Ili 2 342 S 524vIN 2 CCD ON f Lu i iSzmxoxxzztulixge eia m NNNM as 1 395 1 I l z l l a zH F wl aas ala aGo o L GND GND OF a Iu i I quj amp A Oo OE uu uuu 3ec 36 CtGND l ly zur x Q tu l TEELEN wpe uu C2 I p O wi HI or z o O Sy 9 9 S S Q thy te t lt x LLS Os es es ee l idaoz sgeotsseasoi l HZ OA AOSS oele oc cc O raaaagqagadave I LIS PI E RE RE RO m EO mm I p p i MASE A SE o n o oo 7i lal sof of ISI SSN ASA SS A181 SIS i SS SR NISI SEL SS o N ole 71 V IN Sensor cover 1 5 7 ST eee ool S SN x i ay o COVER cLosep O BSSE E R LISSE NSSsuamsee ze Qj close lS 3 GND O vv e co e SSSA A a ed ed S181 81S 1 Lal Sl co A Al e ed lS SP Elo Nn wo 9 7 45V IN I Sensor cover 1 co N GND aq DASP 1 5 nCOVER CLOSING Sensor paper Isl N 5 4039 4
6. rrr re 7 59 Front door assembly rurrruerrrrerrrerrrIIrrIIIIe 7 59 Pick arm assembly 2000 sheet r rurrrurrrrIrrrIIIIre 7 63 Power supply board 2 22 e creer cer ee ee eee eee eee eee eee eens 7 61 AC external jumper cord 222 22 e sneer ne ree eee eee eee eeee 7 61 Bellcrank spring arm rrrr erre 7 54 Bellcrank 250 sheet paper tray 2 2 erect ree eee eee eee eee eee eeeeee 7 52 Wear strips 2 22 eee terre ee ee te ee en eee eee eee eee eeeee 7 53 Bellcrank spring 500 sheet option tray IIIIIIIIIIIIIIe 7 54 Duplex assembly 500 sheet rurrrrrrrrrrIIII e 7 56 Complete vertical kiosk option IIIIIIIIIee 7 64 Complete horizontal kiosk option IrIIIIIee 7 64 Universal adjustable tray assembly 400 sheet rIIIIIIIIIIe 7 65 Paper out arm 250 sheet 22 2 c erect rr eee eee eee eee eee ee eees 7 52 Side restraint 500 sheet tray 2 2 c ee eee er et ee ee eee eee eee eee eceees 7 55 Paper out arm 500 sheet drawer 2 2 2 c ccc e creer eter eee eee eee eees 7 54 Back restraint 500 sheet tray 222 esse cnet eens nee eee eeees 7 55 Complete tray assembly 500 sheet r rrrrrrIIIIee 7 55
7. 22 2 eee eee eee eee eee eee ee eee eee eeee 7 13 Pickup arm assembly solenoid 222 ssc ec eee eee tween eee een eee eee eees 7 50 Pickup arm solenoid 2222s teen r etree eee ener eeeee 7 17 Complete flatbed scanner assembly reece rrr eee eee eee 7 19 ADF CCD module assembly 2 22 teeter ee ener eeeeee 7 14 Part number index 1 11 7002 xxx 40X0459 40X0460 40X0461 40X0462 40X0463 40X0464 40X0465 40X0466 40X0467 40X0468 40X0469 40X0470 40X0471 40X0474 40X0475 40X0476 40X0478 40X0479 40X0480 40X0480 40X0480 40X0481 40X0481 40X0481 40X0482 40X0483 40X0484 40X0485 40X0486 40X0487 40X0487 40X0490 40X0491 40X0491 40X0493 40X0494 40X0495 40X0496 40X0497 40X0498 40X0502 40X0506 40X0507 40X0509 40X0510 40X0513 40X0514 40X0515 40X0517 40X0518 40X0520 40X1375 40X1376 40X1377 40X1378 40X1508 40X1509 40X1510 40X1512 Upper entrance guide assembly 222see sense eee e eee eee eee eee eee eens 7 13 Lower exit guide assembly 2 2 2 e ee nner erent eees 7 14 Feed motor ADF feed 2 222 n teeter err eee eee eees 7 15 ADF scan motor assembly 2 22 22 r errr renee eee eee ee eeee 7 15 ADF scan cover ree rere ee eee eens 7 5 ADF front cover 22 222 ee en en ee ee ee eee eee eee eee eeee 7 5 ADF rear cover 9 22 etn tenn re ee ee eee ee ee eens 7 5 Flat
8. Locations 6 17 7002 xxx Scan control card connector pins continued emer Bem Spa 8 Sana Sina 8 8m ooo 8 Sana 8 Smd Ww 5m 8 Smd a a powe m fow ooo 3 os m Gm ooo 3 WoRY vores oo 9 RSEN Da L3 J15 to operator panel card 6 18 Service Manual 7002 xxx Scan control card connector pins continued mem 000000 m Sh J15 to operator panel card continued 3 pe Ground J23 to CN5 on flatbed interface card m e Locations 6 19 7002 xxx Scan control card connector pins continued L NM NL NEN J23 to CN5 on flatbed interface card continued s sani 35 o Motor driver board EST BEN AUN Ns Set JD e er Motor drive board connector pins mem hanno s Na o3 w o4 8 8 We 6 20 Service Manual 7002 xxx Motor drive board connector pins continued femmes Om Soe CN3 to ADF scan motor OUT A CN5 to pick arm solenoid SOL ON CN6 to flatbed interface card C1 5 nSTART LINE msme 000 s Wem s mowRdoxD 3 9A Locations 6 21 7002 xxx Motor drive board connector pins continued LONE NL NN CN6 to flatbed interface card continued CN7 to cover closed and cover closing sensors CN8 to paper tray sensor CNO9 to ADF exit sensor ADF second scan sensor 6 22 Service Manual 8 8d C fom Ground i 86 even o 6 mano
9. 222 2 s etree ener rere eee eee eens 7 31 Fuser cover assembly kit 22 222 e neers e eee enes 7 31 Fuser lamp 115V errrrrrree eee eee eee ener 7 31 Fuser lamp 220V 2 22 errr eee eee eee eee eeee 7 31 Narrow media sensor 222s errr ttre eee eee eee eee 7 31 Exit sensor 22 2 ener en ee eee eens 7 31 Parts kit charge roll link asm left side IIIIe 7 33 Charge roll assembly rH RIrIIrrrRrrIIIIIIIe 7 33 Parts kit right side charge roll link assembly 7 33 Transfer roll assembly 222222 e cece cer eee eee eee eee eee eee eee eens 7 33 Transfer roll assembly right arm 2 2 2222 eee cere eee eee eee eee eee eee eens 7 33 Transfer roll right spring e etter eee eee eee eee eee eee 7 33 Transfer pivot shaft 2 2 2 2c nec crc ee eee er eee eee eee eee ee eeee 7 33 Transfer roll left spring eee rere nee eee eee ee ee eee eee eeee 7 33 Transfer roll left arm 2 22 2222 eee eee eee ee eeee 7 33 Inner shield assembly 2 2 2 c eee r eet ere reer eee eee eee ee eee eee eeeee 7 39 Outer shield 2 22 22 s ert ner eee eee eeeee 7 39 USB board assembly r urrr rrr ee eee ee eeee 7 3 Ethernet shield blank 22 22 e
10. r rurr rrr 7 19 Interface card assembly uurrrrerrArrrIrIIIII e 7 19 Motor driver card urrrre rrr eee eee eee eeeee 7 17 7 50 Flatbed CCD cable r rrrrrrrrrrIIIIIIIIIIIIe 7 49 Flatbed CCD ribbon cable IIIIIIIIIIIIIIIIIIee 7 19 Belt tension spring uu rrerrrrrrrrIrIIIII e 7 19 Flatbed paper size sensor assembly rrrrrrrIIr e 7 19 Flatbed paper size sensors 3 including cable 7 49 MPT assembly 2 22 e terre ere eee eee ee eee ee ee eee eee eens 7 3 LCD touchscreen display assembly 222 22 s secre eter ener eee 7 3 Operator panel left cover assembly 2 2 2 ence reenter eee eee ee eeee 7 3 Cover assembly operator right 2222s ene eee eee eee eee ee eeee 7 3 LCD touchscreen inverter card 2 222 neers rr eee eee eee 7 3 Scan control card 2 eee nee ee eee ere tee eee eee eee eee eee eee eens 7 37 ADF CCD to ICC 36 pin cable 2 22 e nee cere eee eee eee eeee 7 51 MDC to ICC 36 pin cable 2 2 2 2 eee een eee eee eee eens 7 51 Modem 30 pin cable 2 222 2 ee eee treet eee e eee eee eee eee eeeee 7 37 7 49 Hard drive IDE 50 pin cable rrrrrrrr e 7 37 7 49 Hard drive 4 pin po
11. Service error codes 9xx xx continued Sub codes Error coda Display text Description CRC failure or ECC code failure on the system board 955 Code CRC System board processor failure System board processor failure Nand failure Printer has performed more than 100 shift and replace operations as a result of EC bit corrections Unreliable communications to Paperport device The engine is experiencing unreliable communications to the specified device 981 Interface protocol The engine protocol violation violation by engine detected by the specified device 982 XX Paperport Communications error detected by communication error the specified device 983 Invalid command Invalid command received by the received by device specified device 984 Invalid command Invalid command parameter parameter received by received by the specified device device General device equipment check Indicates an equipment check condition has occurred in the specified device but the device is unable to identify the exact component failure Device system card The specified device has detected failed basic assurance an equipment check in its system test card User status displays User status displays This error indicates a system board This error indicates a system board 7002 xxx Replace the system board See System board and inner shield removal on page 4 125 Replace the system board See
12. Wo answer A fax number is dialed but no connection is made No dial tone The MFP does not have a dial tone Queued for sending The scanning process of a fax job completed but it is not sent yet because another fax job is being sent or received As this one job waits for its turn this Display text Description action message appears for three seconds o j Receive complete The MFP has received an entire fax job Receiving page n The MFP receives page n of the fax job where n is the number of the page received EE sending page n The MFP sends page n of the fax job where n is the number of the page sent Set clock The Real Time Clock is not set This message appears if no other fax status message appears It remains until the clock is set Set the clock Waiti Waiting for redial for Waiting for redial al The MFP is waiting to redial the fax number User attendance messages User attendance messages EO RuD Primary message Description action code code y g P Change Cartri dge Select one of the following actions Invalid Refill Remove the toner cartridge and install a new cartridge Touch Cancel job to cancel the current job if needed Change src to Lets the user override the current print media source for the remainder of the Custom String print job The formatted page prints as is on the print media installed in the tray This may cause clipping of text or images Touch Use current
13. Diagnostic information 2 103 7002 xxx 291 01 Error code service check First ADF scan sensor A jam Note Before starting this service check make sure the first scan sensor cable is correctly installed Action The leading edge of the media was detected by the first scan sensor but never detected by the trailing edge Clear any media that may be in the ADF Enter Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS load some sheets of paper in the ADF paper tray and select Feed Tests If the error continues at or near the same point go to step 2 Area around the first scan Check the area around the first scan sensor for anything that might cause the stop or jam prior to exiting the first scan sensor If the problem continues and you cannot find anything causing this jam replace the complete ADF assembly Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 2 104 Service Manual 7002 xxx 291 02 Error code service check Second ADF scan sensor A jam The first scan sensor has detected the leading edge of the sheet but the second scan sensor does not detect the leading edge Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Feed Tests Load several sheets through the ADF to check for any jams prior to the second scan sensor If the jam is pers
14. aneseeeeeed n npspeDOCE 99 98 08 00m 7A 379800800 8 2370 0000 0O E s7 790000080 _ Jonnr957 20000008 B or nt 7a r C0 CCEG08 J c 5o 7 00000089 eect 28000300008 ooe000900000099090 I yom to CULA 4 Loosen the screws for the printer outer shield and slide shield to the left to allow enough room to remove the scanner control card shield and the hard drive shield Em l t j C eem EN sctseee TALALT u s geeeeeenrere M TETEE Ei p _ T2 2S 2 3 A ee ee ee AA AAA are ee eS m L3 2 20 TN I I ae 02 0 RA 4 AAA d os d A ds mm Pe ee db mom mommmim ne A AD M BE BB BS OA A 8 OS OD wd ommmuN eSgaxwgx Wow wow ow wm eee Bois 4 38 Service Manual 7002 xxx 5 Disconnect the two cables B 6 Remove the two screws C from the left side T Remove the screw D that attaches the ground bracket to the SCC HDD shield Mr ant TTD p Mapc cta im WP usa Mr Repair information 4 39 7002 xxx 8 Remove the right side cover 9 Remove the two screws from the right side E M E 10 Pull the scan unit forward to unhook the unit from the base printer and lift the scan unit from the base printer 4 40 Service Manual 7002 xxx Flatbed scan motor assembly removal Remove the scan cover flatbed See Scan cover flatbed removal on page 4 11 Remove the scanner right side cover See
15. Fail to feed from tray 3 Failure to feed Possible causes include Clear media jams Edge locking Replace pick tires See E Integrated tray Worn or contaminated pick tires autocompensator pick roll Overfilling of tray past fill line assembly removal on Failed sensor page 4 101 Check replace input sensor NO gt CO i Paper over tray 3 pass Paper left in path e Clear media jams Failed pass thru sensor e Check replace pass thru thru sensor on warm up sensor Late feed from a tray interfered with the pick retry 243 Failed to feed from tray Failure to feed Possible causes include e Clear media jams 3 Pages in the paper Ed TP e ge locking e Replace pick tires See path have been flushed Integrated tray to the output bin e OTN contaminated pies tires autocompensator pick roll Overfilling of tray past fill line assembly removal on Failed pass thru sensor page 4 101 Check replace input sensor N 243 One or more trays Tray removed Reinstall tray located above the source tray have been Sensors faulty Check sensors removed Paper jam near tray 4 ray removed Clear media jams e Sensors faulty e Check sensor Jam declared by a smart Fault reported by options tray 4 Clear all media jams device Immediate Stop Paperjam Check motor cables Motor or motor cable failure Check replace tray motor e Sensor failure Check replace sensor s e Replace e
16. T rIIIII eme 7 52 Drive shaft 250 sheet r r rrrrrrrrr III 7 52 7 62 Power takeoff spring r r r e 7 52 7 54 7 62 Wear strips r urrrrrrerrrrrrIIrrrIIIIIIIe 7 55 Drive shaft 500 sheet r urrrrrrrrrrrr III eees 7 54 Paper low switch uurrrrrEErrrrrrrrrr e 7 61 Door magnet r ruurrrree erre rrrrIIIIrIIIII e 7 59 Parts packet card asm mounting screw r r rrrrrr e 7 59 Parts packet card asm mounting rr rrrrrrI e 7 59 Parts packet 6 32 hinge mounting nut rIIIII e e 7 59 Parts packet nuts rrrrrrrrrr rrr rIIIII e 7 61 Parts packet hinge mounting flat washer T e 7 59 Parts packet hinge mounting star washer 7 59 Wear strip uu rrrr rrr rrr 7 59 Wear dimple strip rrrrrrrrr rre 7 59 Bellcrank spring 250 sheet paper tray IT ee 7 52 I 14 Service Manual Lexmark X644e X646e 7002 xxx Printhead Scanner control card ASM Wiring diagram
17. rrIIIIIIme 7 31 EP DC fan assembly r rrrrrrr erre 7 11 EP fan with cable 500 sheet 200 210 400 410 IIIIIII I 7 47 9 pin to Twinax cable rurrrrrrrrrrrrIIIII e 7 65 9 pin to Coax BNC cable rHrrrRrrIrrIr III 7 65 9 pin to 9 pin cable assembly rr rrrrrrrIIIe 7 65 Parts packet redrive mounting screws uur rrrrrrlIIIre 7 9 Power cord set 8 ft right angle Argentina 7 35 Power cord set 8 ft right angle Bolivia and Peru 7 35 Power cord set 8 ft right angle Chile Uruguay TIIIIeeee 7 35 Power cord set 8 ft right angle T T IIIIIIl 7 35 Power cord set 6 ft right angle Brazil 7 35 Power cord set 8 ft right angle 13 amp United States 7 35 Output bin sensor cable r r urrrrrrrrIrrIII e 7 40 Standard bin level sensor cable IIrIIIII ee 7 9 Power cord set Hong Kong ur rrurrrrrrr III 7 35 Power cord set Taiwan 2 2 22 e sence ere eee eee eee eee eee e eee eens 7 35 Frame clip eee eer ee III 7 7 RS232C seri
18. Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Diagnostic information 2 21 7002 xxx Service error codes 9xx xx continued Error SUb Display text code codes play Description 920 51 Hot roll took too long to Bad thermistor circuit or Go to 920 xx Cold fuser service heat up after cabling check on page 2 130 transitioning to new x An seed mode EUSOF Fuser not receiving AC power page count more than Poor supply line voltage 900 000 Low voltage or incorrect lamp Incorrect hot roll 920 52 Hot roll fell too far below Bad thermistor circuit or Go to 920 xx Cold fuser service desired temperature cabling check on page 2 130 while printing Fuser page count more than Noisy inermistor signal 500 000 Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 53 Hot roll too cool while Bad thermistor circuit or Go to 920 xx Cold fuser service checking for slope cabling check on page 2 130 change Fuser page on oE AN Noisy hermistor signal 500 000 Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 54
19. Parts catalog 8 51 7002 xxx Assembly 31 Optional 250 sheet paper drawer Part Units Units kit a Description number option or pkg 40X3230 250 sheet paper drawer complete assembly Parts packet screw switch spring PP 99A0263 99A0063 Switch activate spring 56P4129 Paper out arm 250 sheet Parts packet screw auto comp mounting PP 99A0263 Parts packet PP 99A0263 40X3232 Pick arm assembly 56P 1228 Bellcrank 250 sheet paper tray 99A1929 Bellcrank spring 250 sheet paper tray 99A0070 Pick roll assembly 40X3234 Bin low sensor with cable 40X3233 Option pass thru sensor 99A0272 Drive shaft 250 sheet 99A0275 Power takeoff spring 40X3237 Base assembly 8 52 Service Manual 7002 xxx Assembly 32 Optional 250 sheet paper tray LI i ie ome number option or pkg 40X3231 40X3235 56P1279 56P4230 99A0121 99A0120 40X3236 Description Tray assembly option 250 sheet Side restraint 250 sheet tray Wear strips Plate 250 sheet pass thru Plate 250 sheet tray wear Restraint pad Back restraint 250 sheet tray Parts catalog 8 53 7002 xxx Assembly 33 Optional 500 sheet paper drawer 40X3243 40X3246 056P 1228 56P2540 99A0070 40X3244 99A0275 99A0447 40X3245 40X3247 56P4145 99A0063 8 54 Service Manual Drawer assembly complete 500 sheet Parts packet auto comp mounting screw PP 99A0263 Pick arm assembly 500 sheet Bellcrank spring arm
20. System board and inner shield removal on page 4 125 Replace the system board See System board and inner shield removal on page 4 125 Replace the system board See System board and inner shield removal on page 4 125 Service errors 980 thru 984 lt device gt can be one of the following system board duplex tray X 1 2 3 4 or 5 envelope feeder or output bin Service errors 980 thru 984 device can be one of the following system board duplex tray X 1 2 3 4 or 5 envelope feeder or output bin Sub code Error code Display text Description action Bin x Full X represents the number of the output bin that is full when the MFP bins are linked Remove print media from the bins The message clears once the output level of the linked bins is no longer full Busy The MFP is busy receiving processing or printing data Press Stop to access the job queue mE Deleting selected The Delete button is touched after jobs have been selected job s Diagnostic information 2 39 7002 xxx User status displays continued Error Sub an l Display text Description action lm Flushing Buffer The MFP flushes corrupted data and discards the current print job Hex Trace The MFP is in Hex Trace mode Hex Trace isolates the source of a print job problem When Hex Trace is active all data sent to the MFP prints in hexadecimal and character representation Exit Hex Trace to print j
21. 2 Touch EP to select Restore to reset the values to the factory settings and touch Ex to select Do Not Restore to exit without changing the settings Touch Back to exit without changing the settings Fuser Temperature Fuser Temp This adjustment can be used to help solve some customer problems with paper curl on low grade papers and problems with letterheads on some types of media The fuser temperature can be adjusted to Normal Lower Lowest The default is Normal Touch Back to return to Diagnostics Menu Fuser Page Count The fuser page count can only be viewed and cannot be changed Touch Back to return to Diagnostics Menu 3 20 Service Manual 7002 xxx Warm Up Time You can change the amount of time the printer warms up before allowing pages to print by changing this setting from 0 to 5 The factory sets the warm up at 0 or no warm up time This time period lets the backup roll heat up and helps reduce curl in some environments Touch Back to return to Diagnostics Menu Transfer The transfer can be adjusted to Low Medium or High The default setting is Medium Touch Back to return to Diagnostics Menu Print Contrast The print contrast setting controls the developer voltage offset The print contrast can be adjusted to Low Medium or High The default setting is Medium Touch Back to return to Diagnostics Menu Charge Roll The charge roll can be adjusted to Low Medium or High The default setting is Me
22. 202 202 202 202 202 202 202 Sub Description codes P Exit sensor may have bounced Fuser page count between 200 000 and 299 999 Never sent the divert command to the stacker Fuser page count between 200 000 and 299 999 Page is covering the exit sensor during warm up Fuser page count between 200 000 and 299 999 Timeout waiting for the page ahead Fuser page counter between 200 000 and 299 999 Divert media command issued too soon Fuser page count between 200 000 and 299 999 Virtual page timed out waiting for last page of job to be safe in the stapler accumulator Fuser page count between 200 000 and 299 999 Paper jam around the fuser exit or redrive area Fuser page count between 300 000 and 399 999 Possible causes Exit sensor assembly Something is keeping the exit sensor covered A page may not have been cleared from a prior jam Page may be jammed in fuser exit or redrive area Go to Fuser exit sensor service check on page 2 135 Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose s
23. 7002 xxx Assembly 25 Cabling diagram 3 Part Units Units kit eer Description number mach or pkg 40X0034 40X0156 40X0223 40X0157 40X0224 Signature button contact assembly with cable Bottom front autoconnect cable assembly HVPS input sensor toner sensor cable assembly Top autoconnect cable assembly LVPS to system board cable assembly Parts catalog 8 43 7002 xxx Assembly 26 Cabling diagram 4 8 44 Service Manual 7002 xxx Assembly 26 Cabling diagram 4 Part Units Units kit Description number mach or n 26 1 40X0515 Upper front cover hinge assembly includes e A USB cable 1 e B Operator panel cable 1 e C Cover open switch cable 1 40X0162 System board to fuser board cable assembly 40X0163 Fuser AC lamp to LVPS cable assembly 40X0226 Fuser connector fuser AC to fuser lamp Parts catalog 8 45 7002 xxx Assembly 27 Cabling diagram 5 8 46 Service Manual 7002 xxx Assembly 27 Cabling diagram 5 Part Units Units kit eer Description number mach or pkg 40X0083 40X0159 40X0249 40x0053 40X0054 40X0161 Frame assembly with solenoid and cable Main drive motor cable assembly EP fan with cable 500 sheet 200 210 400 410 Main fan 250 sheet Main fan 500 sheet Ground cable Parts catalog 8 47 7002 xxx Assembly 28 Cable diagram 6 Qe lh SD 8 48 Service Manual 7002 xxx A
24. Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage The control code has been lost 7002 xxx Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Diagnostic information 2 25 7002 xxx Service error codes 9xx xx continued Error code 922 922 922 922 922 922 922 922 2 26 Sub Display text Hot roll did not reach operating temperature in time new enhanced control Fuser page count between 200 000 and 299 999 Fuser has ta
25. Touch Cancel Job to clear the message and continue without using the optional envelope feeder Install the optional envelope feeder Bins x y Bins 1 to 5 Bins 2 to 6 or Bins 6 to 10 This messages displays for the following conditions The specified output bins may have been removed from the printer possibly to clear a paper jam or to remove the option e The option s may be attached to the printer but a communications problem may prevent the printer from detecting the option For example there may be a poor connection or a hardware failure The following actions may be taken e f the option was temporarily removed or not connected properly reattach or reconnect it Accept the configuration change which notifies the printer the option has been hot unplugged removed with the power on Note This action is not available if the printer is in Diagnostics Mode or running diagnostics If the device is experiencing a hardware problem turn the printer off and on If the message continues to be displayed go to Input tray s service check on page 2 144 This messages displays for the following conditions The feeder may have been removed from the printer possibly to clear a paper jam or to remove the option The feeder may be attached to the printer but a communications problem may prevent the printer from detecting the option For example there may be a poor connection or a hardware failure The following ac
26. 1 Move the narrow media flag out of the way to clip the sensor securely into the cover e 4 4 2 Connect the fuser narrow media cable 3 Snap the bottom fastener of the sensor cover into place in the lower exit guide and rock the cover up until the top fastener snaps securely 4 Replace the screw securing the sensor cover Repair information 4 85 7002 xxx Fuser narrow media flag and spring removal 1 Remove the fuser narrow media sensor See Fuser narrow media sensor removal on page 4 84 2 Note the position of the spring A in relation to the flag B 3 Carefully ease the right arm C of the sensor cover just far enough apart to release the flag and spring B A C Spring replacement 1 Place the spring on the left pin A 2 Setthe tang B on the flag 4 86 Service Manual 7002 xxx 3 Rotate the bent end C of the spring to add tension place the pins between the sensor cover arms and rest the bent end against the sensor cover frame A Note After replacing the sensor flag and spring make sure the flag moves properly Repair information 4 87 7002 xxx Fuser to LVPS AC cable removal CAUTION Unplug the printer before you begin Remove the fuser wick assembly cover See Fuser wiper cover assembly removal on page 4 54 Remove the redrive assembly See Redrive assembly removal on page 4 123 Remove the right side cover See Printer right cover removal o
27. 2 2 Service Manual 7002 xxx 0 9 Note Referred to as the numeric keypad Pound or number character Clear All Backspace Asterisk Press these buttons to enter numbers when the LCD screen has a field that accepts the entry of numbers Also use these buttons to dial phone numbers for faxes Note If a number is pressed while on the home screen without pressing the button first the Copy menu opens and changes the Copy Quantity Press this button For a shortcut identifier e Within phone numbers For a Fax number with a enter it twice From the home screen the Fax Destination List menu item E mail Destination List menu item or Profile List menu item to access shortcuts Press to cause a two or three second dial pause in a fax number The button only functions within the Fax menu or with fax functions Press from the home screen to redial a fax number When outside of the Fax menu fax function or home screen pressing Dial Pause causes an error beep When sending a fax in the Fax To field a Dial Pause press is represented by a comma When in the function menus such as Copy Fax E mail and FTP it returns all settings to their default values and then returns the MFP to the home screen When in any other menu while the MFP is Ready it cancels all changes that have not been submitted and returns the MFP to the home screen Press to initiate the current job
28. 202 Page is covering the exit Something is keeping the exit sensor ina Check the fuser and area sensor during warm up covered position A page may not have around the fuser assembly for Fuser page count is not been cleared from a prior jam any signs of debris or pieces of available paper or media 202 Timeout waiting for the page ahead Fuser page count is not available 202 Divert media command issued too soon Fuser page count is not available 202 Virtual page timed out waiting for last page of job to be safe in the stapler accumulator Fuser page count is not available 231 Paper did not arrive at Duplex rear door not fully latched e Make sure the duplex the duplex input sensor ni assembly rear door is but did leave the printer Ec UM Boro properly latched exit sensor l Duplex feed system not working vid as upper redrive correctly iverter and diverter spring for any signs of damage a Printer and duplex not aligned loose spring or binding parts Repair the redrive as necessary Check duplex unit for correct installation and alignment to the printer If available try another duplex unit If none is available go to 231 xx Jam displays on page 2 126 Diagnostic information 2 81 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes Paper did not clear the Duplex rear door not fully l
29. Error Sub Description Possible causes code codes 200 14 Gap too small e Paper pre staged in path Check MFP mechanism and Bouncy input sensor friction pad e Fan media and stack flat in tray or MPF Use different media Laser power did not settle Main drive motor error Main drive motor not working Make sure paper path is possibly due to Hi clear l gh mechanical load due to paper jam mechanical load or bind e Check motor to system card connections e Replace transport motor Go to Main drive service check on page 2 149 200 32 Detected cover switch Upper cover not fully closed Check cover switch for proper bounce Cover switch not functioning function correctly Go to Cover closed switch cable service check base printer on page 2 123 201 Page did not reach exit Page jammed on fuser input guide e Check fuser entry guide for sensor Fuser page Pa toner build up ge did not enter or exit fuser nip ee Pe 0 and cleanly Check fuser for wear or TENE contamination If problem is Exit sensor not functioning correctly found replace the fuser assembly See Fuser assembly removal on page 4 75 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 201 01 Main motor identification Main motor not working Check motor connections to failed motor and system board If no Main drive motor problem is found go to Main identi
30. For the duplex drive system to pass the test the following results must display e AA 00 e BB inthe range of 29 through SF inclusively hex e CC in the range of 3A through 5D inclusively hex e DD inthe range of 11 through 1F inclusively hex 3 Touch Back or press Stop Q9 to exit the test 3 12 Service Manual 7002 xxx Duplex Feed 1 This test feeds a blank sheet of paper to the duplex paper stop position 1 This test can be run using any of the supported paper sizes To run the Duplex Feed 1 Test 1 Touch E to select Duplex Feed 1 from DUPLEX TESTS The power indicator blinks while the paper is feeding and the message Duplex Feed 1 Feeding displays The message Duplex Feed 1 Clear Paper displays when the paper reaches paper stop position 1 and the power indicator turns on solid 2 Remove the media from the duplex unit and clear the message on the operator panel by touching Back or pressing Stop Duplex Feed 2 This test feeds a blank sheet of paper to the duplex paper stop position 2 This test can be run using any of the supported paper sizes To run the Duplex Feed 2 Test 1 Touch E to select Duplex Feed 2 from DUPLEX TESTS The power indicator blinks while the paper is feeding and the message Duplex Feed 2 Feeding displays The message Duplex Feed 2 Clear Paper displays when the paper reaches the duplex paper stop position 2 and the power indicator turns on solid 2 Remove t
31. Fuser exit sensor service check on page 2 135 Check the connections to the motor and system board If not problem is found go to Main drive service check on page 2 149 Check the fuser entry guide for toner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 75 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Diagnostic information 2 65 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes 201 53 Video never started two inches past the input sensor Fuser pager count more than 500 000 201 54 Expected wide page not Page did not enter or exit fuser nip Mis ues by narrow cleanly media sensor possible accordion jam Fuser ey media sensor not functioning page count stopped at y 500 000 to preserve Actual page is narrow when wide data page was expected 201 Page did not reach exit Page jammed on fuser input guide sensor Fuser page count is not available E not enter or exit fuser nip Exit sensor not functioning correctly If label media ensure front edge meets 1 8 inch requirement Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 75 If media is
32. Input tray empty Input tray paper low Input tray pass thru sensor sensor sensor sensor selected Open displays e Empty lInput tray empty sensor e Low Input tray paper low sensor e passThru Input tray pass thru sensor 4 Once this message displays the servicer can manually actuate each sensor The tray empty sensor can be actuated by hand however a sheet of paper can be used to cover the pass thru sensor When the sensor is closed Closed displays when the sensor is open Open displays 5 Press Stop Q8 to exit the test OUTPUT BIN TESTS Feed Tests output bins Use these tests to verify that media can be fed to a specific output bin Media is fed from the default input source to the selected output bin No information is printed on the media fed to the output bin because the printhead is not engaged during this test These tests can use any media size or envelope supported by the printer Note If the Configure Bins printer setting is Link rather than Mailbox the printer selects its own internal bin linking regardless of which output bin is selected for the feed test To run the Feed Tests for the output bins 1 Touch E to select Feed Tests from the OUTPUT BIN TESTS 2 Touch gt to select the output bin you want the paper to exit into The standard bin as well as any output option bin installed on the printer is shown on the menu The output bins are displayed in the order installed on the printer 3 14
33. Paper jam around autocompensator Faulty motor cable Faulty motor Autocompensator gear bind Failed controller card Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor Paper left in path Failed pass thru sensor Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Could also be a failed pass thru sensor Tray removed Sensors faulty 7002 xxx Clear media jams Replace pick tires See Integrated tray autocompensator pick roll assembly removal on page 4 101 Check replace input sensor Clear all jams Check replace pass thru sensor Check for jam in tray Check pick assembly and controller card Clear media jams Replace pick tires See Integrated tray autocompensator pick roll assembly removal on page 4 101 Check replace input sensor Clear media jams Check replace pass thru sensor Clear media jams Replace pick tires See Integrated tray autocompensator pick roll assembly removal on page 4 101 Check replace input sensor Reinstall the tray Check sensors Diagnostic information 2 91 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx ERO SUD Description Possible causes code codes 250 Page did not reach input Paper jam around the multipurpose tray Check for jam in tray PESO Check pick assembly and controller card 250 07 Page was not properl
34. Parts catalog contains illustrations and part numbers for individual FRUs Definitions XX Note A note provides additional information Warning A warning identifies something that might damage the product hardware or software CAUTION A caution identifies something that might cause a servicer harm 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 When you see this symbol there is a danger from hazardous voltage in the Service Manual 7002 xxx 1 General information The Lexmark X644e and X646e are all in one laser MFPs that provide print copy scan and fax functions designed to attach to IBM compatible personal computers and to most computer networks The Lexmark X64xe laser MFPs are available in the following models Configured models The following illustrations show a standard MFP and an MFP with a duplex unit and a 500 sheet drawer Other print media handling options are also available Standard With duplex and drawer Scanner Standard output bin Control panel Tray 1 integrated tra pU PUES y or standard tray Multipurpose E EN feeder Duplex unit Tray 2 Tray 1 integrated tray 500 sheets or standard tray CAUTION Floor mounted configurations require additional furniture for stability You must use either a printer stand or printer base if
35. flatbed 2 14 system board connectors 5 3 parts catalog 7 36 removal 4 125 service check 2 162 T theory of operation autocompensator 3 37 autoconnect cabling and connectors 3 38 duplex unit 3 38 option microcode 3 38 toner sensor removal 4 126 tools 1 16 Top Margin duplex 3 11 simplex front side 3 5 touchscreen 2 2 7002 xxx transfer roll assembly parts catalog 7 32 removal 4 126 service check 2 163 U unique tools 1 16 upper front cover hinge assembly removal 4 130 upper paper deflector 4 132 upper sub cover removal 4 55 upper tray cover removal 4 127 USB removal 4 133 USB card connectors 5 14 user attendance messages 2 43 user line 2 link messages 2 57 user status displays 2 39 W warm up time 3 21 Wipe Disk 3 34 wiper cover 4 54 Wiper Message 3 36 wrap tests 3 10 Index l 7 7002 xxx l 8 Service Manual 7002 xxx Part number index P N 1319128 40X0001 40X0009 40X0021 40X0024 40X0025 40X0026 40X0027 40X0028 40X0030 40X0032 40X0033 40X0034 40X0034 40X0036 40X0039 40X0040 40X0042 40X0043 40X0044 40X0045 40X0046 40X0046 40X0048 40X0049 40X0050 40X0051 40X0052 40x0053 40X0054 40X0054 40X0058 40X0059 40X0060 40X0061 40X0061 40X0062 40X0065 40X0066 40X0069 40X0070 40X0072 40X0073 40X0074 40X0074 40X0076 40X0077 40X0079 40X0083 40X0084 40X0085 Description Page Parallel wrap plug r rIIIIIIIIIIIIIIIIIIIl l 2 155 3 10 Fuser wiper
36. ho N C1 ho N O1 245 03 Jam declared by asmart Fault reported by options tray 5 Clear all media jams device Homing allowed to stop Paper jam Check motor cables Motor failure Check replace tray motor e Sensor failure Check replace sensor s e Replace entire option 2 90 Service Manual User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description code codes P Option tray pass thru sensor never became covered Option tray pass thru sensor never became uncovered 245 Failed to pick from tray 5 245 1 Failure to feed from tray 5 245 3 Paper over tray 5 pass thru sensor on warm up 245 Late feed from a tray interfered with the pick retry 245 Failed to feed from tray 5 Pages in the paper path have been flushed to the output bin O gt Oo o a Li N O1 NO gt O1 One or more trays location above the source tray have been removed n2 Ol Paper jam near the multipurpose feeder Option tray pass thru sensor never became covered N C1 n5 C1 NO Option tray pass thru sensor never became uncovered Possible causes Failure to feed Possible causes include Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor Paper jam Failed sensor Failure to feed Possible causes include Failure to feed Possible causes include
37. 2 97 290 02 Error code service check ouod aud xn RR ound EIER E Roy Ron 9 RR doom SCARE OR OSA cdabe nk 2 99 290 10 Error COGS service Check ouuceachspor 9 6 oic bbb 1 te dne 3E eed He kos OOS 2 101 291 00 Error eode Service Check vunuo sesenta 525595 o068 84 2A Pu EkiBiee dde 4es5e e488 6 Eu 2 102 291 01 Error code service CCC nc dca ooh eb ere 2E Set hb oe Gee 37992 So OO eo 4 23 9 5 5 97596 2 104 291 02 Error code service check 0 0c ss 2 105 292 00 Error code service check LloleecerRe RER RFERTEERARTU PRERT RRAZEYFG4AE XQ uu x xS 2 106 293 Error code service check lee rrr 2 107 294 00 Eror code Service check lt ciccevu does ite sRECQWPRAC ReRA 4 EPGXQEY u Re ex d 2 108 294 01 Error code service check llle rs 2 109 294 02 Error code service check gc o4n6 oes 6e55b655566 6455664956655 8664 bo60 5045 bes es 2 111 294 03 Error code service check 0 0 0 ce RR s 2 112 298 01 Enor code service CEC ccc oo ow ed oo 564 545 466 6466S 55 SE RSS lt HE sb 4 rend d 2 114 298 02 Error code service check duae eder 37b ache Ob 60 b 4 7 RA ER haa P3 RUE AY 624506 e4 eo 4s 2 114 842 xXx Error eode service Check nancies asi hic s En3a dirir imt iarr iiot Edd 3 Ed AS 2 114 843 00 Error code service check 4 66454 0 0 66 nrbe Pi eQq dS QePVYESede SEX uas xese9 2 115 845 00 Error code service CHECK euuseuanauaaxuibee x EE he eee cease dee beekSeen ceases 2 115 848 00 Error code service check duae 5 6550 2 bo 2
38. 291 292 and 294 scanner jams 3 50 2xx paper jam and paper handing errors 2 58 500 sheet paper drawer option 7 54 500 sheet paper tray option parts catalog 7 55 service check 2 144 80 scheduled maintenance 6 1 900 xx error code service check 2 116 950 00 through 950 29 EPROM mismatch failure 2 118 950 30 through 950 60 EPROM mismatch failure 2 119 9xx Service error codes 2 15 A acronyms 1 17 adjustments fuser solenoid 4 2 gap adjustment 4 2 paper alignment assembly 4 3 printhead assembly 4 2 scanner registration 4 4 alignment assembly adjustment 4 3 parts catalog 7 24 removal 4 117 ASIC Test 3 23 autocompensator integrated tray parts catalog 7 21 pick roll installation 4 102 removal 4 99 autoconnect connections top 5 8 B bevel gear installation 4 72 removal 4 71 blower duct 7 11 Button Test 3 8 buttons accessing service menus 3 1 Button Test 3 8 upper front cover including buttons 7 3 upper front panel button kit 7 3 7002 xxx C cable diagrams 7 40 7 41 7 42 7 44 7 46 cabling diagrams 7 48 7 50 7 51 CACHE Test 3 9 Card Stock amp Label Guide 1 8 Configuration ID 3 19 configuration menu accessing 3 1 3 25 ADF Edge Erase 3 30 Automatic Scanner Registration 3 31 available menus 3 25 Disk Encryption 3 33 Energy Conserve 3 29 Envelope Prompts 3 33 EVENT LOG print only 3 32 Factory Defaults 3 29 FB Edge Erase 3 31 Font Sharpening 3 35 Format Fax Storage 3 30 Jobs On Disk 3 33 Key Repeat Init
39. 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Diagnostic information 2 19 7002 xxx Service error codes 9xx xx continued Error SUb Display text code codes play Description 920 31 Under temperature Bad thermistor circuit or Go to 920 xx Cold fuser service during steady state cabling check on page 2 130 control Fuser page v count between 300 000 Fuser not receiving AC power and 399 999 Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 32 Hot roll fell too far below Bad thermistor circuit or Go to 920 xx Cold fuser service desired temperature cabling check on page 2 130 while printing Fuser page count between Noisy inermistor signal 300 000 and 399 999 Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 33 Hot roll too cool while Bad thermistor circuit or Go to 920 xx Cold fuser service checking for slope cabling check on page 2 130 change Fuser page count between 300 000 Noisy hermistor signal and 399 999 Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 34 Hot roll too cool when Bad thermistor circuit or Go to 920 xx Cold fuser service heating to desired cabling check on page 2 130 temperature after slope change Fuser page Noisy kermi
40. Bellcrank spring 500 sheet option tray Pick roll assembly Option pass thru sensor Power takeoff spring Drive shaft 500 sheet Bin low sensor with cable Base assembly 500 sheet Paper out arm 500 sheet drawer Switch activate spring Parts packet screw PP 99A0263 7002 xxx Assembly 34 Optional 500 sheet paper tray Se 5 Part Units Units kit Ne Description number option or pkg 34 1 Jo OO C 56P4150 56P4137 99A0292 56P4196 99A0120 56P4195 56P4147 Complete tray assembly 500 sheet Side restraint 500 sheet tray Wear strips Pass thru plate Restraint pad Wear plate 500 sheet Back restraint 500 sheet tray a i OIX Eo i LX lt a N A a Parts catalog 8 55 7002 xxx Assembly 35 Duplex option D ay Part Units Units kit ee Description number option or pkg 8 56 Service Manual 7002 xxx Assembly 36 Envelope feeder c o pu Q O o o a Complete envelope option Units Units kit option or pkg Part e Parts catalog 8 57 7002 xxx Assembly 37 High capacity feeder 1 8 58 Service Manual 7002 xxx Assembly 37 High capacity feeder 1 Part Units Units kit Description number option or pkg 40X3250 Complete option assembly letter 40X3249 99A1818 99A0681 40X3254 56P4157 Complete option assembly A4 Wear dimple strip Wear strip Front door assembly D
41. For more details about the types of paper and specialty media your printer supports refer to the Card Stock amp Label Guide available on our Lexmark Web site at www lexmark com We recommend that you try a limited sample of any paper or specialty media you are considering using with the printer before purchasing large quantities Supported print media The following tables provide information on standard and optional sources for both input and output trays and bins e Print media sizes e Print media weights e Media weights supported in optional output bins Note If you use a print media size not listed select the next larger size Print media sizes Legend indicates support Print media size E L a EZ ee Dep ww Ll Ire He eed MA S EMEND D This size does not appear in the Paper Size menu until Tray Size Sensing is turned off Refer to the User Guide for more information This size setting formats the page for 215 9 x 355 6 mm 8 5 x 14 in unless the size is specified by the software application Multipurpose feeder 2000 sheet drawer option Envelope feeder option Duplex unit option Standard output bin gt gt p p Lond Lond L rd L rd o o Q Q Ka Ka o g e e LO e N LO e LO N SIS mm SINN Sasss Bs Paes TS STS 1 8 Service Manual Legend indicates support Print media size 184 2 x 266 7 mm 7 25 x 105 in 216 x 330 mm 8 6 x 13 in State
42. Fuser page count between 100 000 and 199 999 920 Hot roll fell too far below the desired temperature while printing Fuser page count between 100 000 and 199 999 920 Hot roll too cool while checking for slope change Fuser page count between 100 000 and 199 999 temperature after slope change Fuser page count between 100 000 and 199 999 920 Fuser is not increasing in temperature even though the lamp has been on for an extended time Fuser page count between 100 000 and 199 999 920 Fuser has been below the desired temperature for too long while the media is in the nip Fuser page count between 100 000 and 199 999 920 Hot roll too cool when heating to desired 2 18 Service Manual Description Bad thermistor circuit or cabling Very noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect
43. Fuser page count not available Hot roll too cool when heating to desired temperature after slope change Fuser page count not available Fuser is not increasing in temperature even though the lamp has been on for an extended time Fuser page count not available Fuser has been below the desired temperature for too long while media is in the nip Fuser page count not available Description Bad thermistor circuit or cabling Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll Fuser is not receiving AC power Poor supply line voltage Bad thermistor circuit or cabling Very noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Abrupt change in temperatures
44. If correct go to step 5 Diagnostic information 2 101 7002 xxx First scan sensor electrical checks 291 00 Error code service check Static jam second scan sensor A Turn the power off and reconnect CN10 to the motor driver card Measure the voltages in the table below with the sensor in normal operation sensor closed and with the sensor open paper over the sensor Pin number Sensor closed uncovered Sensor open covered If the voltages are incorrect replace the first scan sensor If this does not fix the problem replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 Note Before starting this service check make sure the second scan sensor cable is correctly installed The media is jammed or stuck in the ADF at the second scan sensor Check for any signs of paper or other debris that might be present or 2 102 Service Manual jammed in the ADF assembly around the second scan sensor Second scan sensor Second scan sensor cable second scan sensor to CN9 on the MDC card Motor driver card Second scan sensor electrical checks 7002 xxx Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Sensor Tests Check the second scan sensor for correct operation Note To
45. Note There are two cables between the motor driver card and the paper length sensor Check to make sure both cables are installed correctly ADF paper length sensor in ADF paper tray ADF paper length sensor Motor control card ADF paper length sensor 2 120 Service Manual Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Sensor Tests Check the ADF paper length sensor for correct operation by putting a sheet of paper in the tray over the sensor If the sensor does not operate properly go to step 2 Turn the power off and disconnect the cable to CN8 and measure the voltages at CN8 on the card Measure the voltages shown in the table below normally closed Connector CN8 motor driver card If incorrect replace the motor driver card If correct go to step 3 Turn the power off and reconnect CN8 to the motor driver card Measure the voltages in the table below If the voltages are incorrect replace the paper length sensor If this does not fix the problem replace the ADF paper tray assembly If the problem persists replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 7002 xxx ADF paper width sensor service check Note There are two cables between the motor driver card and the paper widt
46. Remove the power takeoff shaft and spring A through the bottom of the printer Printer outer shield removal 1 Remove the printer left door See Printer left side cover removal on page 4 56 2 Loosen the outer shield mounting screws A and remove the shield by sliding up SSSR o mam 5 a 06 55 5 P5 5S SN SD DEN mo SEO m RB m F OR BoRPRBRRRBSa 4585 s5s5S4s45s85B BECSSsS emaccresnsscggqagm d 48 dqeesdRssSSPMsSSSSNFN j i i Repair information 4 121 7002 xxx Printhead removal CAUTION The laser scanning unit is not a serviceable FRU Replace the entire unit when service is required 1 2 3 4 5 Remove the ADF scanner See ADF complete assembly removal on page 4 15 Remove the flatbed scanner See Flatbed scan assembly removal on page 4 38 Remove the printer upper cover See Upper cover removal base printer on page 4 127 Disconnect the printhead cable A from the printhead assembly Remove the four printhead mounting screws B and remove the printhead Note Do the Printhead assembly adjustment base printer on page 4 2 whenever you remove or replace the printhead assembly or loosen the mounting screws 4 122 Service Manual 7002 xxx Redrive assembly removal Remove the redrive door assembly Remove the redrive exit cover Remove the redrive assembly mounting screws A mo a Release the redrive assembly mounting latches B and r
47. Second scan sensor cable Check to make sure the interval sensor cable is correctly installed at Second scan sensor to the sensor and atCN10 on the motor driver card If the cable is not CN9 on the MDC card installed correctly reinstall the cable If installed correctly go to step 4 Diagnostic information 2 95 7002 xxx Motor driver card Turn the power off and disconnect CN10 on the Motor driver card Measure the voltages Interval sensor reflective type normally closed Connector CN10 motor driver card If incorrect replace the motor driver card If correct go to step 5 Interval sensor electrical Turn the power off and reconnect CN10 to the motor driver card checks Measure the voltages in the table below with the sensor in normal operation sensor closed and with the sensor open paper over the sensor If the voltages are incorrect replace the interval sensor If this does not fix the problem replace the complete ADF assembly Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 2 96 Service Manual 7002 xxx 290 01 Error code service check ADF pickup jam Note Before starting this service check make sure the interval sensor A cable is correctly installed Check to make sure the pickup arm is correctly installed If not installed correctly reinstall properly If installed correctly check the pi
48. The first sensor has detected the leading edge of the page but never detected the trailing edge The first scan sensor has detected the trailing edge of the page but the second scan sensor did not detect the leading edge of the page The ADF cover was opened while the ADF was scanning Remove feeder and clear jam Replace feeder Remove feeder and clear jam Replace feeder Remove feeder and clear jam Replace feeder Go to 290 00 Error code service check on page 2 95 Go to 290 01 Error code service check on page 2 97 Check for proper operation of the first scan sensor If the sensor is opening properly and no other problem is found go to 290 02 Error code service check on page 2 99 Check for any media or obstruction over the first scan sensor If no problem is found go to 290 10 Error code service check on page 2 101 Check for any media or obstruction over the second scan sensor If no problem is found go to 291 00 Error code service check on page 2 102 Go to 291 01 Error code service check on page 2 104 Clear any media from the ADF and close the cover If this does not fix the problem then go to 291 02 Error code service check on page 2 105 Clear any paper from the ADF and close the cover If this does not fix the problem then go to 292 00 Error code service check on page 2 106 Diagnostic information 2 93 7002 xxx Us
49. ccc eee een es 3 50 CNOA FDP DANS oc a 5 6 detrit 65 9 8 055 8 S RR REGE SUR RA RE Oe SS OEE 3 50 290 291 292 and 294 Scanner Jams 0 eee eee 3 50 MEDAN INTOMMGUON soe a co hee ee ewe RON ACC CC Ree SEES ECR RC GN RR E eS 4 1 Handling ESD sensitive parts ion a werk cowed cones eea as eed eee ss C9 n MC RH Re SR CR ACRES 4 1 AdjusSimont DFOCODUEDS uuu Gree he oki hh ed ri ecce i Bn curie cite arci eee rigo 4 2 Pie Se SO SIGN a 1r 24 tan sq ESHEPE e ER Yay LS S esas seams Ta ES 4 TE 4 2 We OUO aue enda Ee E P es eir A RUP IUe ddp PERI AE EEA E RES 4 2 Printhead assembly adjustment base printer llle 4 2 Paper alignment assembly adjustment 0 0c eee e 4 3 Cee Oy s d4queedasrQze vri qaa E per PE MP ines bh 454 Pe eS equis 4 4 Scann t he s iuo iom Ew OC ERR CREDI RR ER ee RR Oday abe que oid Doe dir i n 4 4 ule cies eC BD a eu scs deeper ERROR a VOR Fo ERER GP ESIXA3 Rd 4 4 Diana BOBO e s amp 4 wan dark s d o2 Ob EACR S RO eS owes Roa Hr ACIER en oue 4 4 Removal procedur S 66556664 06 66562465 anran CE REC ERE EERE Ede keke AES 4 5 Scanner ADF and flatbed removals 000 c eee es 4 5 Pr WOME COVE SIV iweqeee 6 hoe eee oe ee ee 8 heehee ENESES eee bes 4 5 AUF DIOE S5SEmpIV TemoVEl 12 dh c ER hd ode dea Re ARE A RGA Dh ees OR RR edd 4 6 ADF Tear cover oM l cw eh gp T 346 Sh ba ees Sb 9505 505446 Eua SEERE XC 3 4 6 ADF TOO COVE PEON kn oa 0b hd oho CR CREER CRGO REP 40e IPDS E RI
50. continued Error Sub i m D ription action sode eee Primary message escription actio Check Tray x Tray x Tray 2 Tray 3 Tray 4 or Tray 5 Connection This messages displays for the following conditions The specified device may have been removed from the printer possibly to clear a paper jam or to uninstall the option The option may be attached to the printer but a communications problem may prevent the printer from detecting the option For example there may be a poor connection or a hardware failure The following actions may be taken e f the option was temporarily removed or not connected properly reattach or reconnect it Accept the configuration change which notifies the printer the option has been hot unplugged removed with the power on Note This action is not available if the printer is in Diagnostics Mode or running diagnostics If the device is experiencing a hardware problem turn the printer off and on If the message continues to be displayed go to Input tray s service check on page 2 144 Clean scanner During a scanner calibration the firmware detects that the scanner backing backing strip strip for the backside of scan jobs may be dirty Touch Cancel Job if a scan job is processing when the attendance message appears This cancels the job and clears the message Touch Scan from Automatic Document Feeder if the page jam recovery is active Scanning resumes from the ADF immediately after t
51. on page 4 125 With the redrive assembly removed from the printer enter the Diagnostics mode and run the print test from tray 1 for example select PRINT TESTS Tray 1 and Continuous and observe the media as it passes over the exit and narrow media sensors Check that the sensor flags are operating correctly If the sensor flags and hardware are operating incorrectly repair or replace the failing sensor assembly If no problem is found check the fuser for any signs of media in the fuser or any signs of toner or other contamination If a problem is found clean or remove the debris or contamination Diagnostic information 2 135 7002 xxx Fuser narrow media sensor service check If any of the following error codes are displayed a problem may exist in the area of the narrow media sensor assembly 201 04 201 14 201 24 201 34 201 44 201 54 and 201 94 Fuser exit and fuser narrow media sensor status check Printer printing media over sensor s non narrow media fed through the printer Exit Sensor open Exit sensor closed Exit sensor closed Narrow media sensor open Narrow media sensor closed Narrow media sensor open Printer printing narrow media fed through the printer Printer not printing no media over sensors Fuser narrow media sensor Enter the Diagnostics mode select BASE SENSOR TEST and sensor test select the NM Sensor to test it for proper operation If the narrow media sensor fails the test go to step
52. remove the blockage Main fan blades turn during Measure the voltage at J4 1 on the system board The voltage should POR then stop Fan will not measure approximately 42 5 V dc If incorrect replace the main fan run when trying to print See Main fan removal on page 4 107 Main fan If that does not fix the problem replace the system board See System board System board and inner shield removal on page 4 125 Main fan blades do not turn Measure the voltage at J4 3 The voltage should measure 14 4 V dc with the fan running full and approximately 7 0 V dc when running half speed If incorrect replace the main fan See Main fan removal on page 4 107 If this does not fix the problem replace the system board See System board and inner shield removal on page 4 125 Cartridge fan service check Error code 927 02 indicates a problem with the cartridge fan Cartridge fan Check to make sure the cartridge is plugged into J5 on the system board If properly plugged in go to step 2 Cartridge fan Check for any signs of blockage in the fan If any is found remove and retry the printer If no problem is found go to step 3 3 Cartridge fan Replace the following FRUs in the order shown System board Cartridge fan e System board See System board and inner shield removal on page 4 125 Diagnostic information 2 117 7002 xxx 950 00 through 950 29 EPROM mismatch failure Warning When replacing any one of the follow
53. that has disrupted control 7002 xxx Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Diagnostic information 2 23 7002 xxx Service error codes 9xx xx continued Sub Display text Hot roll took too long to reach the beginning lamp detection temperature Fuser page count between 0 and 99 999 Error code 922 922 Hot roll reached final lamp detection temperature but took longer than largest time in lookup table Fuser page count between 0 and 99 999 922 Hot roll timed out in trying to reach the final lamp detection temperature Fuser page count between 0 and 99 999 922 Hot roll did not reach operating temperature in time new enhanced control Fuser page count between 0 and 99 999 922 Fuser has taken too long to reach desired temperature after increasing interrupt gap Fuser page count between 0 and 99 999 922 Hot roll took too long to reach the beginning lamp detection temperature Fuser page count between 100 000 and 199 999 922 Hot roll reached final lamp detection temperature but took longer than largest time in lookup table Fuser page count between
54. 1 Pd NG t O GND 2 USB Fi F2 lt Signature 250V 250V Button GND a n ut JU TONER WHEEL CN Cartridge p 5 5VDC SW Sensor 5VDC SW Sensor EJ INSENSOR e EB GND E aL DEVB LVPS SE i es 4 4 Ge 24VDC SW NNNM ees TXD1BR LC XFR B e GND TX ENB B 73 RXDIR ATSERVO J19 rg BLDC WIND 2 st B VC2 1 N V C20 E 5 __ 5VDC FUSED GND BLDC FG BLDC HALL 2 BLDC HALL 1 BLDC HALL 0 l i GND To Transfer Roll 24yDO PTO OFT PEELS Ts OT ele Ethernet o M RS Main Drive l FA PST Motor 424VDC RAW i I 424VDC RAW 24VDC RAW J16 24VDC RAW ZEROXING R I a I HEAT HEAT i L FAN DRV GND I e To J25 4 H e l hs z To J25 3 Ht I sea 3 8 bg Autoconnect W a i Sapa E iil dod oL Front I z e 2 z 2 amp i z m e 8 I A lt 8 G 8 e e g E ca To J18 1 P HI Flin l S S o9 i 2E EE E 34 l l E mc E F e sw2 Paper PEBETIBLETS Fg Q i 3 l l g eJsw1 oe Z ies oe NM n 1 O jswo Switches Motor Encoder 1 Autoconnect i Bottom FB Scan zio SSI eZ ia ae i 5 3 Hs o 8 ADF CCD Module Lexmark X644e X646e nFLAT_LENGTH1 5V IN GND GND
55. 100 000 and 199 999 o 2 24 Service Manual Description Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on pa
56. 109 Alignment assembly Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight Check the alignment assembly for worn rollers contaminated rollers or binds Replace the alignment assembly if any problem is found Inner deflector Check the inner paper deflector for correct installation If the deflector is bowed or not fitting correctly replace the deflector Autocompensator fails to feed paper Failures occur randomly throughout the stack of paper 1 Pessthusenor Check the pass thru sensor for correct installation and operation Autocompensator The autocompensator pick roll shaft assembly is not providing assembly enough torque if the pick rollers are not picking the paper correctly Replace the autocompensator assembly 2 152 Service Manual 7002 xxx Wear strips in tray x Check the wear strips for excessive wear scratches or rough spots problem is found Replace the wear strips if a problem is found Paper feed failures occur only near the top of the stack of paper The most common cause of this problem is paper curl Remove the paper from tray x and check for the natural curvature in the paper Reinstall the paper in the correct manner If the problem persists it may be necessary to reduce the stack height Replace both pick rolls if the paper appears to be flat in the tray but there is still a problem Failures occur mainly near the bottom of th
57. 152 Go to Paper feed service check base printer on page 2 152 Go to Paper feed service check base printer on page 2 152 7002 xxx Service error codes 9xx xx continued Error Sub o code Display text Description Problem with transfer 920 Hot roll took too long to heat up after transitioning to new enhanced mode standby control only Fuser page count between 0 and 99 999 920 Hot roll fell too far below the desired temperature while in standby Fuser page between 0 and 99 999 920 Hot roll too cool when checking for slope change in standby Fuser page count between 0 and 99 999 920 Hot roll too cool when heating to desired temperature after slope change standby control only Fuser page count between 0 and 99 999 920 Fuser is not increasing in temperature even though the lamp has been on for an extended time Fuser page count between 0 and 99 999 920 Fuser has been below the desired temperature for too long while media is in the nip Fuser page count between 0 and 99 999 transfer servo start error DC pick motor no Check autocompensator assembly encoder feedback Check HVPS Check system board Check HVPS input sensor toner sensor cable Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Fuser not receiving s
58. 3 Remove the MPF lower deflector assembly See IMPF lower paper deflector on page 4 112 4 Place the printer on its side 5 Gently pry the inner paper deflector from the left and right mounting posts A located on the bottom of the printer and remove the deflector 6 Disengage the two latches B on the upper part of the deflector from the upper edge of the frame C and lift to remove Repair information 4 97 7002 xxx Input sensor removal 1 Remove the upper paper deflector Upper paper deflector assembly removal on page 4 132 2 Loosen the MPF lower front cover See Multipurpose feeder lower front cover assembly removal on page 4 67 3 Remove the inner paper deflector Inner paper deflector assembly removal on page 4 97 gt Disconnect the input sensor cable A from the input sensor B 5 Release the input sensor from its mounting and remove r i y t UTR T y us y J w E Y a i i aj P ume di bo E Lt F jd 2 ia J 3 El B 4 98 Service Manual 7002 xxx Integrated tray autocompensator assembly removal Remove the ADF scanner assembly See ADF complete assembly removal on page 4 15 Remove the flatbed scanner assembly See Flatbed scan assembly removal on page 4 38 Remove the paper tray Remove the left door See Printer left side cover removal on page 4 56 Remove the outer shield See Printer outer shield removal on page 4
59. 3 11 R redrive assembly parts catalog 7 8 removal 4 123 redrive door 4 58 REGISTRATION 3 5 registration 3 5 automatic scanner 3 31 scanner automatic 4 4 manual 4 4 relocation kit 7 65 removal procedures and cautions 4 5 7002 xxx removals base printer removals bevel gear 4 71 developer drive assembly 4 73 developer drive coupler kit 4 74 ESD cover 4 74 fuser assembly 4 75 fuser cover removal 4 91 fuser exit sensor 4 78 fuser exit sensor flag and spring 4 80 fuser lamp 4 82 fuser narrow media flag and spring 4 86 fuser narrow media sensor 4 84 fuser to LVPS AC cable 4 88 fuser transfer plate 4 93 fuser wiper cover assembly 4 54 gear release link 4 94 high voltage power supply 4 95 inner paper deflector assembly 4 97 inner shield 4 125 input sensor 4 98 integrated tray autocompensator assembly 4 99 integrated tray autocompensator pick roll assembly 4 101 interconnect card assembly 4 103 LCD inverter card assembly 4 104 LCD touchscreen 4 64 left and right frame extensions 4 69 left cover handle holder 4 68 low voltage power supply LVPS 4 105 lower front cover assembly 4 67 lower paper deflector 4 112 main drive assembly 4 109 main fan 4 107 MPF arm assembly 4 111 MPF pick tire removal 4 113 MPF solenoid assembly 4 114 MPF lower front cover assembly 4 67 operator panel left cover assembly 4 61 operator panel right cover assembly 4 62 paper alignment assembly 4 117 paper bin
60. 3 23 flag fuser exit sensor flag and spring 4 80 fuser narrow media flag and spring 4 86 paper bin full sensor 4 119 Flash Test 3 17 flatoed interface card connectors 5 24 flatoed white cushion removal 4 31 Font Sharpening 3 35 Format Fax Storage 3 30 frame extensions 4 69 frames parts catalog 7 6 7 8 7 10 fuser connectors 5 9 installation 4 76 parts catalog 7 30 removals 4 75 service check 2 130 fuser board 5 9 fuser cover 4 91 fuser exit sensor flag and spring removal 4 80 parts catalog 7 31 removal 4 78 service check 2 135 fuser lamp parts catalog 7 31 removal 4 82 fuser narrow media sensor flag and spring 4 86 flag and spring parts catalog 7 31 flag and spring removal 4 86 parts catalog 7 31 service check 2 136 fuser solenoid adjustment 4 2 service check 2 137 fuser to LVPS AC cable removal 4 88 fuser transfer plate removal 4 93 fuser wiper cover assembly parts catalog 7 3 removal 4 54 G gap adjustment 3 21 4 2 gear release link removal 4 94 H handle left cover 4 68 7 7 right cover 4 68 7 7 high voltage power supply HVPS connectors 5 9 parts catalog 7 34 removal 4 95 7002 xxx high capacity feeder parts catalog 7 58 7 60 7 62 7 63 service check 2 138 Home screen 2 4 buttons 2 4 I indicator light 2 2 inner paper deflector removal 4 97 inner shield parts catalog 7 38 removal 4 125 input sensor removal 4 98 input sensor tray tests 3 14 input source tests 3 7 input tray feed test 3 1
61. 4 62 If the error persists go to step 6 Interconnect card Replace the original interconnect card assembly with a new and not previously installed interconnect card assembly If the error remains contact your next level of support Operator panel Replace the original operator panel board with a new and not previously installed interconnect card assembly If the error remains contact your next level of support 2 118 Service Manual 7002 xxx 950 30 through 950 60 EPROM mismatch failure Warning When replacing any one of the following components Operator panel right cover assembly e System board assembly e Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more 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 Note Before proceeding with this service check make sure you have the correct system board installed in the printer The system board has a label with an board ID and barcode Use the first eight numbers to identify the
62. 41 Page did not cleanly exit Page may be jammed in fuser exit or Make sure the redrive door os or redrive area redrive area is complete closed user page count between 400 000 and win is TC prany 499 999 gns of wear or i contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 202 42 Exit sensor covered too Page may be jammed in fuser exit or Make sure the redrive door long Fuser page count redrive area is complete closed between 400 000 and 499 999 Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor serv
63. 5 V dc test point on the system board If test point does not measure 5 V dc go to step 5 Unplug the AC line cord from the LVPS and disconnect the LVPS cable to the system board Reconnect the AC line cord and measure the voltage on CN2 1 on the LVPS The voltage should measure approximately 5 V dc If the voltage is correct go to step 6 If the voltage is incorrect replace the LVPS assembly See Low voltage power supply removal on page 4 105 Warning Observe all the ESD precautions and turn the printer off before any feature or option cards are removed or replaced Remove one option feature at a time to help isolate the failing part Replace the faulty part Unplug the AC line cord remove the LVPS from the printer and check the continuity of fuse F1 See Low voltage power supply removal on page 4 105 If continuity is correct replace the LVPS assembly If the voltage is incorrect replace the LVPS assembly Turn the printer off and disconnect each cable connected to the system board and each option installed on the system board until the problem is located Warning When removing any card installed on the system board observe all ESD precautions when handling these options Check for the correct installation of the interconnect card to the printer system board and to the scanner control card If correct go to step 10 7002 xxx System board Replace the following FRUs i
64. 9650540405 2h 560 a Eneak PR 540 4905554050465 3 26 Reset Maintenance Counter 0 6 eee eee eee ees 3 26 Pal Sen 0S X ES chun ek Sees can ee DOO LT vr 3 27 SPa ado ek oe a 4 9575 999 41 en bens 23 E E E bee ee eee 3 27 ee le eT cae Whee Saas ow ce Sao SRS EER ONES ond Se eORe dees eEcoee esos tees 3 28 rt ee og oy oo 0 6 9029 94 oo E bo ed qubd de vsu ac eae a pq E d 3 28 Pe Met T TT Truro beans ones sae eeu 3 29 BN ee 2250 15 3 cee re eee wee he eee ard d papeequ on dq cd Faq dps dog Paci quie 3 29 ILLE DESDE ho ee 21032 EQUIS DOE bee P eR Fd Be ped ihe deis d perd ded cs 3 30 FOUDRE OBEN 1 394 P ERE d du RP E deal EU dd dud EU pq Nude dea uie dd 3 30 AUP EOC EIAS iq dad dod a nda baw ee EA CR DE od ee oaks ees 3 30 PESE MOSS ccssrasha4dastd Xen dxoRbAWERRAXZTAG RE OS 405564 wERXAXQELIEA I ARE X3 3 31 Automatic Scanner Registration 4 o3 399 95 39 PRIORE IG 045880566544 de uwd sca Paucis 3 31 ee oa ee ws pe ae oe ee ee ee eee ee ne eens 3 32 Pe te bhp hg aw lap 3 32 Sei A 1 2 EE ee E DA QU een er eee ORC JURY o rare ed d pus d re Ando 3 33 Tee ranae o gt aaah E gga o oo ee dee qs ii be ed ee Gh eee quede d duibd See Ud p d db 3 33 ee he be bh wan E es als ohh ole ee TIT ee P 3 33 Vi Service Manual 7002 xxx e E oe et eee Seen ee ee eA eee eke bee dew ed oe RON Lee e bone aes 3 34 PEPE RN aaiioeex soy we Sea ah ele ERE de Se ek tke ek Ga ee ee ea 3 35 Regule UO soos ada rrm 3 35 ire ne
65. CONFIG MENU however a cartridge must be installed with a machine class ID matching the machine class ID stored in NVRAM Additional diagnostic information may be printed on the pages when printing from DIAGNOSTICS Diagnostic aids 3 7 7002 xxx The following is included in the DIAGNOSTICS version of the print quality pages Values from EP SETUP in DIAGNOSTICS including Fuser temperature warm up time transfer print contrast and charge roll settings Contents of the EVENT LOG from DIAGNOSTICS Configuration information including printer serial number controller code level engine code level operator panel code level font versions and cartridge information Default values for the QUALITY MENU settings used to print the pages HARDWARE TESTS Select the following Hardware Tests from this menu Panel Test Button Test DRAM Test CACHE Test Parallel 1 Wrap if available Serial Wrap if available Panel Test This test automatically toggles each pixel of the touchscreen through every contrast level beginning with the darkest and on to the brightest This test continues until you press Stop e Button Test The Button Test verifies the operation of the buttons on the operator panel When you select Button Test a diagram of the operator panel appears on the panel When you press a button on the operator panel an X appears on the corresponding diagram When you release the button an X disappears Press Stop e t
66. CPP Edd EE Rd IE ES 1 5 Pr Retell La parue d cae do tdi E E tee Pe od 10654 ae we eae ede eee dx 1 6 eS eNO M TCR TP 1 6 SWE Lodi ch dar pda pd a ites be Bie a Ete Oe ERI Eee ead ees SS REI TE SEX TIE d 1 7 ricco a en ee a eee ee A ee ee ee en E ee eee eee eee Te 1 7 Medii SUCCIICAUONG ua 6 5 6 504 00060 60 5 2 AG R4 X RU RAELRAG AER RAGAG RAERER AVCRCREEAA AGRAR EET 1 8 Paper and specialty media guidelines nnana aana 1 8 BUDE EBORE eara pau a UPC ey REC RP REMIT LATE IE uS dde d qure dadieqiersq 1 8 POE SESS 205 ade ede qp oA cO RACE UR CE EEEE E Fo d o UR di UR idR n 1 8 FHREIe da TGS Loser RE 4 0S ob XERUC EERREEPRRATEREARRESACERANAIG4dUeLL VR EES 1 10 PHOEBE Wea esr 3E P IGUASCDENS Eon Red qug quxurdebexd per deecpuP PERRA 1 10 I ea cassa oa 5e5 es aes oo oo 5 5 86 6 a ee 6 oh oh eee eens eeeees 1 12 Pee bap aes d XXE a ode Ado p SCR d OR woe ed E E OR B dodi RUE dp e E OR 1 12 g e tas oe xe coded Bas 0990 2 8 A CHOR OP ORO OC Red OR e en RES 1 12 TIBERI cas 443996 421142 09 434194937 d E43 dui ped he de b d psy dis 1 13 GS La 1194 3728 02 OR DARAUS OR 64S She bee AC BORGO VEE EE eee Nd 1 13 Es nn T 1 14 DU IDE ec wg Ges Howey Bade E E TRESS A Sy Vd IPC Pese eens d RP SFSP 1 15 ha eee oe ITI TEILT TD S COL 1 5 125 0 12 har ee oh eee nes 1 15 PEDIDOS 6 655 he dick a qot RC ER deu E oe bab ie balle OR DP d oaa o bun apa o
67. Diagnostics Menu Entering Diagnostics Menu Turn off the printer Press and hold 3 and 6 buttons simultaneously Turn on the printer o n Helease the buttons after 10 seconds Available tests The tests display on the operator panel in the order shown Note Some menus are not available depending on the configuration of the printer Diagnostics Menu tests See Registration base printer on page 3 5 TeMagn OOO o O O e Cewa ECS Cammo OOOO S See Quick Test on page 3 6 Tray 1 See Input source tests on page 3 7 Tray 2 if installed a A xo Tray 3 if installed Tray 4 Tray 5 if installed MP Feeder Envelope Feeder if installed if installed NENNEN Printing Print Quality Test Pages See Printing Quality Pages on page 3 7 HARDWARE TESTS Panel Test See Panel Test on page 3 8 Button Test See Button Test on page 3 8 DRAM Test See DRAM Test on page 3 9 Parallel 1 Wrap if installed See Parallel Wrap test on page 3 10 Note This setting only appears if a parallel port is available through the PCI slot 1 Serial 1 Wrap if installed See Serial Wrap test on page 3 10 Note This setting only appears if a serial port is available through the PCI slot 1 3 2 Service Manual 7002 xxx Diagnostics Menu tests continued DUPLEX TESTS if installed Quick Test See Quick Test duplex on page 3 11 Top Margin See Top Margin duplex on page 3 11 S
68. ECF COL YAFhLEVT IV YJ BORE 2 FOA VFI VAL ER FES TABI BY TIA AA 2A10Vv MgMUbov v i AH EI S5IComuvxossiemnmcozd AX T EN ELSE Se ES DE amp r 3 DHHS 21 CFR Subchapter I X 2r 2 E 1 E26 7 d BJ vh ME Tp E A fe DC EA ub IEC 825 I tn HE DIRAL A RUAAR SER A fT ED AL A BB A Ar 8 Ib 3b WIE PVE TE RSP 5 SRAM tk EUG He Kw El E 770 795 nm ZH BMI ASMITEP WWI aR VE d FHGE SEP SE PS K E TE To AREA MB fh DP ET DA ESSERI SR BST 7002 xxx Laser notices XV 7002 xxx Korean Laser Notice aule 1e slo x ASSO CHSt DHHS 21 CFR Subchapter 39 PAS Eda 918g ETES US ReH 32 9 teto amp 828 TAS e 154 Aly See ISS SUS ect oe olx ASSES ae Aozs HFL TEASE 5 HAVE AS orLeAl Lro z MA 770 795 plc FcH Of Aq sole Class fll 3b ajo x amp HFA zt Bes gjo AAD zaye SA As Sol RFA HS S LE Wu MIA Eol At7 Class Azo HoA HEA AFO Ack Suet gitE YAHA YECH ah XVI Service Manual 7002 xxx Safety information e 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 e 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 e There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service pers
69. Fuser exit sensor service check on page 2 135 Main drive motor Main drive motor not working Check motor connections to identification failed motor and system board If no Fuser page count problem is found go to Main between 200 000 and drive service check on 299 999 page 2 149 Page did not reach exit e Page jammed on fuser input guide e Check fuser entry guide for sensor Fuser page count between 200 000 and 299 999 Page did not enter or exit fuser nip toner build up cleanly e Check fuser for wear or s Eyi Ani contamination If a problem Exit sensor not functioning correctly is found replace the fuser assembly See Fuser assembly removal on page 4 75 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 2 62 Service Manual Video never started with page two inches past the input sensor Fuser page count between 200 000 and 299 999 Expected wide page not detected by narrow media sensor possible accordion jam Fuser page count between 200 000 and 299 999 Page did not reach exit sensor Fuser page count between 300 000 and 399 999 Main drive motor identification failed Fuser page count between 300 000 and 399 999 Page did not reach exit sensor Fuser page count between 300 000 and 399 999 Possible causes Page did not enter or exit fuser nip cleanly e Narrow media sensor not functioning correctly Ac
70. Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more 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 Replace the interconnect card See Interconnect card assembly removal on page 4 103 Warning When replacing any one of the following components Operator panel right cover assembly e System board assembly e Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more 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
71. M Rei Touch Continue to clear the message and continue the print job Install flash memory with more storage capacity Download the data Touch Cancel Job to cancel the current job if needed Touch Reset Active Bin to change to another linked bin Diagnostic information 2 53 7002 xxx User attendance messages continued Sub code Error Primary message code y g C1 Co Unformatted flash detected x lt X C1 AR C1 AR Network x software error x lt X Serial option x error C1 AR Standard network software error X C1 O1 x Unsupported option Lay Slot X C1 Oo x lt X Parallel port x disabled C1 Oo X X Serial port x disabled 2 54 Service Manual Description action The MFP detects unformatted flash memory Touch Continue to clear the message and continue printing The MFP continues with normal operations except for flash operations Reformat the flash to allow flash operations If the error message reappears the flash memory may be defective and require replacing The MFP cannot establish communications with a specified installed network port x indicates the number of the specified port Touch Continue to clear the message and continue printing The job may not print correctly The MFP disables attempts to communicate through the network interface No data may be sent or received Reset the MFP Program new firmware for the network interface
72. O 2s 3 D D lt m c D Qo approximate depending on brightness If the voltages at CN1 1 and CN 2 are incorrect replace the LCD inverter card See LCD inverter card assembly removal on page 4 104 If this does not fix the problem replace the operator panel right side cover assembly See Operator panel right cover assembly removal on page 4 62 If the voltages at CN1 1 and CN1 2 are correct replace the inverter card If this does not fix the problem replace the touchscreen display See LCD touchscreen removal on page 4 64 2 146 Service Manual 7002 xxx LCD backlight Unable to change LCD touchscreen backlight Inverter card 8 pin cable Check to make sure the cable is installed correctly to the inverter card and to the operator panel card Inverter card 8 pin cable Check continuity of the 8 pin inverter card cable If correct go to step 3 If incorrect replace the cable Inverter card Check the voltages on CN1 1 and CN1 2 They should measure approximately 12 V dc CN1 Pin 5 0 V dc screen light Z 4 5 V dc screen dark If incorrect replace the operator panel card assembly If correct go to step 4 Inverter card assembly Enter the following Menus Settings General Settings and Screen Operator panel right cover Brightness on the touchscreen display assembly Enter 22 on the touchscreen display and Submit the new setting Measure the voltage at CN1 5 The voltage should measure app
73. Print media weight Print media Integrated tray and Multipurpose l Envelope optional feeder and optional feeder 500 sheet drawer 250 sheet drawer Paper Xerographic 60 to 176 g m 60 to 135 g m or business paper grain long grain long 16 to 47 Ib bond 16 to 36 Ib bond Card stock Index Bristol 163 g m 90 Ib 120 g m 67 Ib maximum grain long EN 163 g m 100 Ib 120 g m 74 Ib 176 g m 65 Ib 135 g m 50 Ib Card stock Index Bristol 199 g m 110 Ib 163 g m 90 Ib n a maximum grain short Ta 203 g m 125 Ib 163 g m 100 Ib 216 g m 80 Ib 176 176 glm 65 Ib 65 176 glm 65 Ib Transparencies Laser printer 138 to 146 g m 138 to 146 g m 37 to 39 Ib bond 37 to 39 Ib bond 1 10 Service Manual Print media Labels 1 maximum Integrated forms Envelopes 100 cotton content maximum weight 24 Ib Type Paper Dual web paper Polyester Pressure sensitive area must enter the MFP first Paper base grain long Sulfite wood free or up to 100 cotton bonds Integrated tray and optional 500 sheet drawer 180 g m 48 Ib bond 180 g m 48 Ib bond 220 g m 59 Ib bond 300 g m 92 Ib liner Not recommended Grain short is preferred for papers over 135 g m 2 Includes envelopes fed from the multipurpose feeder only 3 28 Ib bond envelopes are limited to 25 cotton content Multipurpose feeder and optional 250
74. Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser to LVPS AC lamp cable D Warning The LVPS assembly may be difficult to remove from the printer Do not use excessive force in the removal 7 Remove the low voltage power supply 4 106 Service Manual 7002 xxx Main fan removal Remove the ADF scanner assembly See ADF complete assembly removal on page 4 15 Remove the flatbed scanner assembly See Flatbed scan assembly removal on page 4 38 Remove the printer left side cover See Printer left side cover removal on page 4 56 Open the left side cover Remove the outer shield See Printer outer shield removal on page 4 121 eS c9 Iu es Remove the two screws A securing the upper plenum T Remove the upper plenum Repair information 4 107 7002 xxx 8 Clip the cable tie B Note Be careful not to damage any of the cables Note the location of the cable tie for later replacement 9 Disconnect the main fan to the system board C at J4 be ew At 10 Remove the main fan eeeeneeaenaeene o 22 eee w ww o l 4 108 Service Manual 7002 xxx Main drive assembly removal 1 Remove the system board and inner shield See System board and inner shield removal on page 4 125 2 Remove the screw securing the gear guard A 3 Remove the power take off shaft and spring Se
75. Reinstall the envelope feeder Make sure it snaps into place 3 Flex and stack the envelopes 3 42 Service Manual 7002 xxx 4 Load the envelope feeder 5 Adjust the guide 6 Lower the envelope weight T Touch Continue Diagnostic aids 3 43 7002 xxx 23x and 24x jams Paper jams in these areas can occur on the incline surface of a tray or across more than one tray To clear these areas 1 Open the MFP paper tray and remove any jammed media N Open the duplex tray To remove the media pull up 3 44 Service Manual 7002 xxx 3 Open any optional trays beginning at the top and remove any jammed media Pull the print media either up or down If it does not pull easily one way try the other way C of CAUTION Floor mounted configurations require additional furniture for stability You must use either a printer stand or printer base if you are using a 2000 sheet drawer Certain other configurations also must have a printer stand or printer base More information is available on our Lexmark Web site at www lexmark com multifunctionprinters Diagnostic aids 3 45 7002 xxx 4 If you have an optional 2000 sheet feeder open the front door press the elevator button to lower the tray remove the jam and make sure the stack of print media is neat and aligned 5 Touch Continue CAUTION Floor mounted configurations require addit
76. Service Manual 7002 xxx 3 Release the top hinge from the latch B B Repair information 4 57 7002 xxx Redrive door 1 With the redrive door partially open lift and free the left side 2 Remove the redrive door Printer right cover removal Remove the upper sub cover See Upper sub cover removal on page 4 55 Open the upper and lower front covers Remove the print cartridge UD I Remove the right front cover mounting screw A 4 58 Service Manual 7002 xxx 5 Remove the redrive door See Redrive door on page 4 58 6 Remove the right rear cover mounting screw C E C T Remove the two redrive screws D 8 Press the two latches to remove the redrive assembly Repair information 4 59 7002 xxx 9 Press the latch D firmly to release the front of the right cover ry Note When replacing the right side cover make sure the three cover retainers E are correctly located in the appropriate slots in the right side frame 4 60 Service Manual 7002 xxx Operator panel left cover assembly removal Remove the printer left side cover See Printer left side cover removal on page 4 56 Open the printer upper front cover Remove the two screws A Pe a Remove the screw B attaching the inner left cover B A 5 Remove the operator panel left cover assembly Installation note Be sure the latches C on the back of the operator panel left c
77. Service Manual 7002 xxx 3 Touch EP to select either Single or Continuous Single feeds one sheet of media from the selected source e Continuous media continues feeding from the selected source until Stop is pressed Touch Back to return to OUTPUT BIN TESTS Sensor Test standard output bin This test is used to verify if the standard bin sensor is working correctly To run the Sensor Test for the standard bin 1 Touch to select Sensor Test from OUTPUT BIN TESTS 2 Touch E to select Standard Bin from Sensor Tests 3 Touch E to select NearFull or Full sensor to test The following screen is displayed Bin Empty empty Manually actuate the bin sensor by moving the flag in and out of the sensor The display indicates Open when the flag is out of the sensor and Closed when the flag is in the sensor 4 Press Stop to exit the test BASE SENSOR TEST This test is used to determine if the sensors located inside the printer are working correctly To run the Base Sensor Test 1 Select BASE SENSOR TEST from the DIAGNOSTICS menu The following sensors are listed Exit Exit sensor Front Door Front door sensor Input Input sensor NarrowMedia Output exit sensor Toner Level Toner level sensor remove the cartridge and replace to actuate the sensor 2 Manually actuate the sensors to verify that each sensor switches from Open to Closed 3 Press Stop Q9 to exit the test
78. V printer Lamp has excessive wattage 7002 xxx Go to 925 xx Hot fuser service check on page 2 134 Go to 925 xx Hot fuser service check on page 2 134 Go to 925 xx Hot fuser service check on page 2 134 Go to 925 xx Hot fuser service check on page 2 134 Go to 925 xx Hot fuser service check on page 2 134 Go to 925 xx Hot fuser service check on page 2 134 Go to 925 xx Hot fuser service check on page 2 134 Go to 925 xx Hot fuser service check on page 2 134 Go to 925 xx Hot fuser service check on page 2 134 Diagnostic information 2 31 7002 xxx Service error codes 9xx xx continued Error SUb Display text code codes play 925 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Fuser page count stopped at 500 000 to preserve data 925 Lamp detection performed and found error Writes to the fuser information chip have been disabled due to a previous write failure 925 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Writes to the fuser information chip have been disabled due to a previous write failure 927 Service fan error 927 Main fan stalled 927 Cartridge fan stalled 927 Main fan took too long to ramp up 927 Main fan underspeed or stalled during speed adjustment state 927 Main fan overspeed during speed adjustment stat
79. and invoking the Parallel Diagnostic Test This test helps isolate the printer from the parallel cable and host The test provides failure information on the display for approximately three seconds If the test indicates that a problem is detected replace the controller board Diagnostic information 2 155 7002 xxx Print quality service check base printer Service tip Before troubleshooting any print quality problems do the following Install another print cartridge if available before proceeding with the service checks Use Tray 1 to test for print quality of the base printer Replace the charge roll if it is damaged or contaminated Replace the transfer roll if it is damaged or contaminated Make sure the fuser assembly is installed correctly Verify proper paper type texture and weight settings for the media being used Test the printer using plain paper 20 Ib Select the following menu settings as indicated Be sure and note the original settings so you can return the printer to the original customer printer setup Print Resolution Set to 300 dpi print quality problems should be checked at different resolution settings Print Darkness Set to NORMAL Toner Saver Set to OFF PQET Set to OFF Fuser Temperature Set to NORMAL Test the printer using plain paper 20 Ib An incorrect printer driver for the installed software can cause problems Incorrect characters could print and the copy may not fit the page correc
80. and on several times If Error Code 900 continues to display go to step 2 Turn the machine off and on several times waiting a few minutes between power on and power off If Error Code 900 continues to display go to step 3 Restore factory defaults See EP Defaults on page 3 20 This resets the non critical areas of the user NVRAM If Error Code 900 continues to display go to step 4 With Error Code 900 displayed press and 2 Record the complete list of Sub Error Codes on the display then call your next level of support or call Lexmark Service scanner This error indicates defective modem hardware 927 xx Fan service check 927 xx can be used for the main fan or the cartridge fan e Main fan 927 00 927 01 and 927 03 through 927 07 e Cartridge fan 927 02 2 116 Service Manual 7002 xxx Main fan service check Service tip The main fan runs at full soeed at the end of POR or when the printer is printing It will only run half speed when the printer is in the Ready state and not printing Check the main fan to make sure it is plugged into J4 on the system board If the fan cable id correctly connected to J4 check the cable and the cable connector for any signs of damage If damaged replace the main fan assembly See Main fan removal on page 4 107 If undamaged go to step 2 Turn the printer off and check the main fan for any signs of blockage of the fan blades If there is any sign of blockage
81. another disk Di sk Corrupted Reformat appears on the LCD You can format the newly installed disk or remove it from the device Diagnostic aids 3 33 7002 xxx 3 Contents will be lost Continue appears on the touchscreen Touch No to cancel or Yes to proceed If you select Yes the printer performs the selected action on the hard disk The following graphic appears when the encryption process is selected Formatting Disk 1 2 076 1 DO NOT POWER OFF The panel provides many progress indicators during the two stage process e 1 2 indicates that the process is currently in the first stage e 0 indicates the progress of the current stage of the process e The progress bar indicates the overall completion of the entire process by filling in throughout each separate stage When the first stage of either process completes the printer displays either of the following graphics depending on the process selected and then begins the second stage of the process Formatting Disk 2 2 076 O dl DO NOT POWER OFF The entire process is complete when the progress bar appears completely shaded and the percentage indicator shows 100 After completion the panel returns to Disk Encryption Wipe Disk This setting provides you with a tool for erasing the contents of a disk Warning Wipe Disk removes a disk s data in such a way that it cannot be recovered To change this setting 1 Touch gt to select Wipe Disk fro
82. assembly See LCD touchscreen removal on page 4 64 Check the voltages on CN1 1 and CN1 2 They should measure approximately 12 V dc CN1 Pin 1 CN1 Pin 2 CN1 Pin 3 CN1 Pin 4 CN1 Pin 5 CN1 Pin 6 CN1 Pin 7 CN1 Pin 8 If incorrect replace the operator panel card assembly If correct go to step 4 Enter the following Menus Settings General Settings and Screen Brightness on the touchscreen display Enter 22 on the touchscreen display and Submit the new setting Measure the voltage at CN1 5 The voltage should measure approximately O to 41 5 V dc Enter 50 on the touchscreen display and Submit Measure the voltage at CN1 5 The voltage should measure approximately 2 7 V dc Enter 100 on the touchscreen display and Submit Measure the voltage at CN1 5 The voltage should measure approximately 5 0 V dc If the voltages do not change when going from 22 to 100 on the display replace the operator panel right cover assembly See Operator panel right cover assembly removal on page 4 62 If this does not fix the problem replace the LCD inverter card assembly See LCD inverter card assembly removal on page 4 104 Main drive service check 7002 xxx Service tip Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or system board Warning Whenever the gearbox assembly is removed from the machine it must be handled very carefully Do not allow any of th
83. assembly adjustment Do the alignment assembly adjustment whenever you replace the alignment assembly Always print a copy of the Quick Test Page before making any adjustments to the alignment assembly reference adjustment screw When replacing the alignment assembly it is necessary to back the reference adjustment screw out far enough to remove the old assembly and install the new one e If you are replacing the alignment assembly go to step A e If you are only adjusting the reference adjustment screw go to step B Step A Print a copy of the Quick Test Page and check the margin adjustments printed on the test page These settings should be within the range specified in Registration base printer on page 3 5 Do the reference adjustment if you are sure the margins are set correctly 1 Loosen the locknut on the inside rear of the alignment assembly 2 Remove the two screws holding the alignment assembly to the left side frame 3 Back the reference adjustment screw out far enough to allow the alignment assembly to be removed from the MFP It is not necessary to completely remove the screw 4 Install the new alignment assembly Turn the reference screw clockwise with a 7 mm nut driver or M3 Allen wrench until it touches the back of the reference plate and tighten the nut with a 5 5 mm wrench The reference adjustment screw can be adjusted without loosening the nut Turn the screw clockwise a few turns and print a copy of the Qu
84. aum eo hs Reg eee ERIT PEE Rees PAIS ERAS EE aM Eqs bee E ewes 3 35 koy Ropeat NNa DORY A P PK c r 3 36 Key Repeat re i465 hones dicia m EROR Eod qa hanes eae os bee oon enee ene es eee 3 36 ee RI au ia 223 9 4 eg get dw Se Se E 2 eee eee een d 3 36 PONG WOO 23 coene Jae ere 3141 ddp Es Sod eee Redes AE AA AY da fs 3 36 iis Serve rere eee ee ee See ee eee ee ee eee eS RURSUM IX eee ee V9 d VR V4 3 37 A locompensalor ODST BOE s dca qoin 3739 CORR e a E RRA SAAS aUe eR aed d e Ue ERE ERE d 3 37 Autoconnect system paper tray options envelope feeder electrical nannan anaana 3 38 Autoconnect cabling and connectors sasaaa saasa aaaea 3 38 Bls CB ELEITA S E E E E EEEE E ee EE 3 38 aeae EE e PPE E wy E E E E T E E E 3 38 Poner POOLEY ases RARE REO EE Tad aera a aA dene E RA eee 3 39 SI MITIS das Ss ee trie hog rie eie a A ANE 3 39 Pee eS ORC eek oo eh oo et eee a E E EEE s 3 40 Understanding jam RGSS SSS ones ck oes 65 9655 6 i ob oS rr EE E ES Ob hoe SOR ee RR SERO 3 41 COEUR ce oe WES RAA4 URTCSATEROPRRREGRASRYTISC ERSPCIEZTSQPITCOPIR 4 3 41 250 Pape Jdam Check MP FSBOBL aaepe CR PPREA CP Bh 54s 3E qud xad 0d QE T ea 3 41 260 Paper Jam Check Env Feeder 2 cece eee eens 3 42 ee gn TT PPC TET 3 44 200 and 201 Paper Jam Remove Cartridge 0 0 cc eee 3 47 202 Paper dum Open Rear DBOL 4 sar Ea d pL RAT OP SSH 4S ROSSI OES Qd 3 48 23x Paper Jam Open Duplex Rear Door 0 0
85. available in all countries or regions e 190 to 259 V ac extreme Notes e Using a power converter or inverter is not recommended e All models are ENERGY STAR qualified e All models ship with Power Save Mode on e The default timeout to power saver is 30 minutes for all models 1 6 Service Manual 7002 xxx Environment Printer temperature and humidity e Operating Temperature 16 to 32 C 60 to 90 F Relative humidity 8 to 80 Altitude 10 000 ft 0 to 3 048 meters e Storage and shipping environment packaged Temperature 40 to 43 C 40 to 110 F Relative humidity 596 to 95 Altitude equivalent to 10 300 meters 0 to 34 000 feet e Storage environment unpacked Temperature 0 to 40 C 32 to 104 F Relative humidity 5 to 80 Acoustics All measurements are made in accordance with ISO 7779 and conform with ISO 9296 Emission sound pressure level dBA pec eo SOUNE power level Bels Bystander position Standing Operator average LpAm Position LpAm General information 1 7 7002 xxx Media specifications Paper and specialty media guidelines Print media is paper card stock transparencies labels and envelopes This printer provides high quality printing on a variety of print media You must consider a number of things concerning print media before you print including Supported print media Selecting print media Storing print media Avoiding jams
86. board with the part number in the table below TN QO106000 412000067 Omer 1 Model Board bar code Corresponds to P N 7002 xxx Q0016002 40X2722 This error code indicates a mismatch between the system board and the interconnect card If the interconnect card assembly has been recently replaced go to step 3 If the interconnect card assembly has not been recently replaced contact the next level of support System board If the system board has been recently replaced go to step 4 If the system board has not been replaced contact the next level of support Interconnect card assembly Replace the current interconnect card assembly with the original interconnect card assembly See Interconnect card assembly removal on page 4 103 If the error remains go to step 5 System board Replace the current system board with the original system board See System board and inner shield removal on page 4 125 If the error remains go to step 6 Interconnect card assembly Replace the original interconnect card assembly with a new and not previously installed interconnect card assembly If the problem remains contact the next level of support System board Replace the original system board with a new and not previously installed system board If the problem remains contact the next level of support Diagnostic information 2 119 7002 xxx ADF paper length sensor service check
87. cabling Fuser not receiving sufficient AC power Poor supply line voltage 7002 xxx Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Diagnostic information 2 27 7002 xxx Service error codes 9xx xx continued Error code 922 922 922 922 922 922 922 Sub codes Display text Hot roll reached final lamp detection temperature but took longer than largest time in lookup table Fuser page count stopped at 500 000 to preserve data Hot roll timed out in trying to reach the final lamp detection temperature Fuser page count stopped at 500 000 to preserve data After hot roll lamp detection did not roll over to steady state control in time Fuser page count stopped at 500 000 to preserve data Hot roll did not reach operating temperature in time new enhanced control Fuser page count stopped at 500 000 to preserve data Fuser has taken too long to reach desired temperature after increasing interpage gap Fuser page count stopped at 500 000 to preserve data Hot roll took too long to reach the beginning lamp detection temperature Fuser page c
88. dna geen ee qud 425919 45 3 20 EP EUER Geen wean eons mE RO Ead dedi A Ems Ri n bate Rene ence ee nana rae 3 20 Fuser Temperature Fuser Temp 0 00 cece eee nn 3 20 Fuser Foe a lt a vd whe wang 2 Paw d bene bau e Ded qnse bey dud pecdexd vc dv 3 20 PILLS TI a au ce oe bee ee ee Oe ee ew 9 Suy ee eo ee ee eS 3 21 luci exegesis we ee eS a a Oe a ee ees 3 21 ALAT AERP ea a ae en oe ba Oye EE RENERE EIEE Oe ER ee ere Ir erIRA d 3 21 DDR PER cae sss eg crs ee ee ee a ee ee 3 21 CCP o i PE 3 21 EVELLO audor decus qutucd x qub di qued d Dich oh PUE PRA Oe ee eee ees 3 21 Wi cV Eo e EEA Get eee ee ede Ee oe eee bas aed eee eee T 3 21 Ri gra gue hg odo based E E ke dy be deh oe ed Oe ek ee ee S E Edi 3 22 xf ca de hope kde ee ele eb eee Wea a Se pe ae P 3 22 BR i hk hee doh ce ie Card X a1 14914 239 959 9429 433 FOr eee E te RU 3 23 Ap c eee odes heres ewan nee 3 23 Rc Mee oo one ayy Bade eee ee as Be ee ee ee eee ee bo eee ee es 3 23 Scanner Manual Registration Lua uoce ene eeew Gi eeSeeeneebsnee daewoo dude RR CR ans 3 23 BELT Ss 6 ooh ey oy FAY 8 Se Eee RERO ee Be EEE a ee 3 24 Configuration menu CONFIG MENU 0 cece 3 25 ee erator MENU 44 45 ou ene ooh oe 5 6 es oe e ei bees 3 25 Po Te NS us ioi odors 8 oh RUE oo IO ea oo ee no ee ea d uad f ds 3 25 Maintenance Page COUNT 64264644046 400
89. dup d od 1 15 TOOIS TEQUE aoazckabEGQRSARERRRERRSARAERERERDESPAERLEERREPRRRES SUAFREARQGRARSRAIXIdGRAY4 RR ds 1 16 GPO arca dX cee ERDERUE EUR EDEN ENDE DR pA EM ER Mop USt ino ae VR LEER ERAI EN 1 17 Diagnose INTOrMAHON zri gode S CURE ACU ritini RR RC RR CICOCHCAP CACERES co 2 1 SUNT oodx ee ee eee Oe OEE eC MEE EOD ea Ee CUR ME NERO COE NER a CK A EUER C MC 2 1 PEDIS TEE auo pagans anda sone asaya neyes Ren es bee E ATE E E E 2 1 SeNi BITOIS OIX ODIO 200008 134 4 7 P4 e brekt bed h basse QYPE ERE de 463 Pd 2 1 User status and attendance messages 1 0 ce ee eee ees 2 1 POON To lc aca dri apie of cies ged odd os qoo Sa 0H 6 8 hare Heed boo ee 2 1 Understanding the MFP control panel 00 c cece eee 2 2 Home screen and Home screen DUNONS 4324 p ze ecd E 240004546 00S ede oe ses 2 4 Using the LCD touch screen buttons iiec kRR REX REGODRREY x E RERREU E REX ERE 2 7 schbrg i e Oe deed pera oS eee ie eee ee se ee ee ee eed 2 7 Intormalion on touch screen DUIlODS lt 454 4c440444 5064566064 664546005546054 30428505 2 7 Table of contents iii 7002 xxx Sample screen BUDE Lu or amp pare Hoan ean es eee hee REO e Rd Ei hea od iR RR Se ee e ewe 2 9 Itormation on touch screen DUHONS oua 464644656 Hie AO bdo anr Cee SSS oe re ee ober 2 9 Other touch screen buttons 0 ee ee eee eae 2 10 PEE pe cee scan racer usd eee eae bee sa ene ee ae Pee EE Pewee she eA eae ena eee 2 11 I eae EE T EE ee OE A PE EE P EE ed EE
90. e Rcge dn 4 8 Scanner left side cover removal LeaesopseshReRETRSERRRTERERRRATEESAG RIOXGg OGCe e ER EORR ea 4 9 Fron ee Cover ea 2 oie os io Erbe rtp dari a e UH dH XE dues Cowes d ped qux p qd 4 10 Scan cover flatbed removal 4 4 pa dur 3n re CERE eer ARE RR re Ch RR ad 4 11 Scanner ng SUP Cover removal 2 2479 do 4b 9 1 EY uhiki 159 9 4X3 ete EAE A d rn 4 12 ADF anach SO FOIT s ci qa hw 2 9 3 09 29 9E 90 Say OS Sa oS Meee idc C dr eh a 4 13 ADF CCD module assembly removal 22229 pber epieeQed te dki redria ex 9 e E VEU 4 14 ADF complete assembly removal ua dono qeaca Rok o OR RR RC RR e ER ES Ra a c ARR RO 4 15 ADF upper entrance guide assembly removal 0 0 cece eee ee eee 4 16 CCD Dektremoval usdsausd 12435 Paus 944 S Odd e Bb by be 849 DO is OS 0 4 Qa Shee a 4 17 etle ooro iG oc os caus phate eee eye Sere eee kee oe ee Oe T ees 4 19 Dover closing scilualor removal iu ses Lic ER PER RERIGOREPGERESET REERSEREeO tRYe ends 4 21 Cover closed actuator r moval lt 6seuvedetobdus obde Gada eee fu 6550 6450545 9076416455 4 21 Table of contents VII 7002 xxx Document tray assembly removal 0 cc eee ee hh 4 22 Flatbed GOD Nbbon cable removal oss obsee corde etre dew A E bed PY RT 60555645525 T 3S 4 23 Flatbed CCD module assembly removal 0 000 ccc eee eee eee eens 4 27 Flaibeg COMmaG glass TEmMOVAL u5440esseau d dca ee doe see hee Sede Pe depre o C4 doles Hes 4 30 Flatbed white BUSTO PSIIOVI uod
91. e e ee ee ee TT 7 1 How t use ihis paris catalog 2 dys asker rdg qoe CR eens 24s weeks wA CUR CAO O QROR OC RO0 wA ON Un 7 1 Assembly 1 Covers base printer 0 00 ccc eet eee eee 7 2 Assembly 2 Covers ADF scanner llle eee hrs 7 4 ASSsOmDIUVS FANG TGOLAS aS EE EAR RSARAT ETYSXAEAGAAERPAAGORG E AdbR a do X Ao c dace ud Ro d code Seo 7 6 ASSOmDIU AS FOMO E ou aria e bea FORCE A ORC ee ee eee ee ee ee es 7 8 AssomDIV b FoM Qo iekeaARERARETASATES3AZASCAA3ARASERAASETAAASEESAAXxGESARAGSXGAAXG Rdaddd d 7 10 Assembly 6 Scanner automatic document feeder ADF pickup 7 12 Assembly 7 Scanner ADF paper feed llle 7 13 Table of contents IX 7002 xxx Assembly 8 Scanner ADF lower exit guide assembly 0 000 eee ees 7 14 Assembly 9 Scanner ADF motors and belts 0 0 0 0 cc eee 7 15 Assembly 10 Scanner ADF sensors l l eens 7 16 Assembly 11 Scanner flatbed leel ellen 7 18 Ass mDIV 12 Printhead 6 oi 66686446 AA ORARRAETISRARERAG3R TEAEEGZRAMSETSSAAAqEe ERIASASRAAGARSGd 7 20 Assembly 13 Paper feed autocompensator ees 7 21 Assembly 14 Paper feed multipurpose feeder 0 0 0 cee 7 22 Assembly 15 Paper feed alignment 0 ccc ete eee 7 24 Assembly 16 Integrated 500 sheet paper tray 0 0 0 0c tenes 7 26 As
92. e fea a 3 5 DUM TEAM E RREFRSREEKRTEE EREREAERRSRCXTRSRRRARERESRERRCRATEGRGCRERRANEPISERRERGSA 3 6 xal WON e465 ice bea sh bee ee dns oe bare bare e caret dee Gare ge ee eee eae eee 3 7 ic casdacashdneehndewhenee Goeeeige oe baer E E sie e cones be 3 7 FERE D FP Lu drapeau ddp dore Qobxed e pour d qu 9 god UO E 99 1 9 PLC 4 EU 3 7 Pe ee TESI ot cae aces sere enedes Sees eure AS sey ese a Pew ee ioe adea ASQ E SS 3 8 aA E cpa d ge g a oat he ge ie oe A ee Oh a eae eo eee eae teens eae ee d 3 8 clu RE on wee oe ee ee Ee eae ee ieee ee Lane eee eee ba 3 8 EHE TER oou o er er ee eee PRI eee ee ee eee ee E ET 3 9 du icr P cM eon Res 3 9 FUISTIS IBS sas Pasa 4 eos E RA oe eo EFE CRPTSqEU ER P CEPEAERdGqee Pes qxpar3 2232 3 10 SUMI ISI ons ERPPPPFEREPASENSPEUG Raten oe deti La NR DIRE EU RA 3 10 DUPLEX TESTS 2644 42646430564 05564046 64045 6404 5 5045660 004604 65041000065 955484 3 11 Quick Test duplex ca ice t 3 9 rue dO RA Go sande hun died cians dodo deba 3 11 TODO TUE Lea toe eR PROCURA Laney hae ween we ieee ewe EE AER ING 3 11 wi 41 PPP 3 12 coepegWE b a CRT r 3 12 er eB aiiqua cere E PEST Ida bd heeded Vp E CPP QE dq bv 4 d 3 13 Eis da 2 ncaa Aenean een TOTIS TUTTI 3 13 liM Ed ID P TP T M 3 13 Feed Tes Ut T ON ioa deu o Re Red Rr aes d bac depend danse ieee dees de 3 13 BEDS ee beso necro es ve ac
93. ee eeees 7 7 Pick arm assembly 500 sheet 2 2 2 e cece teeter eee eee eee eee eens 7 21 Parts packet bellcrank assembly for 500 sheet tray e 7 21 Pick roll assembly 22 2 eee eee eee eee 7 21 Paper out flag 500 sheet tray 2 222 eee teen eee eee eee eee eee een eee ee eeees 7 21 Paper low out sensor card assembly r rurrrrrr re 7 21 Autocompensator motor cable lt s 222s see e ene e ee eee eee eee eee eee eee ewes 7 41 Paper size autocompensator cable 22222 erence reece eee eee erences 7 21 Pick roll assembly 22 22 e eer e eee eee rete eee eee eee eee eee ee eeeee 7 23 Multipurpose feeder paper out flag II IIIIIIIIIII 7 23 Multipurpose feeder lower deflector assembly IIIIIIIee 7 23 Frame assembly with solenoid and cable 7 47 Paper feed alignment assembly paper feed ee 7 25 Reference ground clip 2222s enn ee ere eee eee eeeee 7 25 Part number index 1 9 7002 xxx 40X0086 40X0098 40X0099 40X0100 40X0101 40X0102 40X0103 40X0105 40X0106 40X0107 40X0111 40X0112 40X0113 40X0114 40X0115 40X0120 40X0121 40X0122 40X0123 40X0124 40X0125 40X0126 40X0127 40X0129 40X0130 40X0131 40X0132 40X0133 40X0134 40X0135 40X0149 40X0150 40X0151 4
94. from the Diagnostics menu 2 Select the media source to test Tray 1 Tray 2 if installed Tray 3 if installed Tray 4 if installed Tray 5 if installed MP Feeder if installed Envelope Feeder if installed 3 Select Single or Continuous e f Single is selected a single page is printed e f Continuous is selected printing continues until Stop is pressed to cancel the test If a source is selected that contains envelopes an envelope test pattern is printed If Continuous is selected the test pattern is printed only on the first envelope Note The Print Test Page always prints on one side of the paper regardless of the duplex setting or the presence of a duplex option Touch Back to return to PRINT TESTS Printing Quality Pages The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartridge lockout function disabled The print quality pages consist of four pages Page one contains a mixture of graphics and text Pages two and three only contain graphics The last page is blank If duplex is turned on the pages are duplexed The Print Quality Test pages are printed in English and must always be printed on letter legal or A4 paper To run the Print Quality Test Pages touch gj beside Printing Quality Test Pages from PRINT TESTS The message Printing Quality Test Pages is displayed Note The print quality test pages can also be printed from the Configuration menu
95. has occurred This is Perform POR to clear the error recoverable 7002 xxx This error code indicates a mismatch between the System Board assembly and the interconnect card assembly Warning In the event of replacement of any one of the following components Operator panel right cover assembly e System board assembly e Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more 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 machine it cannot be used in another machine It must be returned to the manufacturer Go to 950 30 through 950 60 EPROM mismatch failure on page 2 119 Diagnostic information 2 37 7002 xxx Service error codes 9xx xx continued Error Sub i o code codes Display text Description 953 954 2 38 Service Manual Replace the operator panel right cover assembly See Operator panel right cover assembly removal on page 4 62 Warning When replacing any one of the following components Operator panel right cover assembly System board assembly e
96. holddown assembly Upper paper feed deflector Inner paper feed deflector Developer support roller Input sensor Gear 60 MPF shield ESD shield with label EP duct Parts catalog 8 11 7002 xxx Assembly 6 Scanner automatic document feeder ADF pickup Part Units Units kit see Description number mach _ or pkg 6 1 40X0458 1 Pickupassembly oo 8 12 Service Manual 7002 xxx Assembly 7 Scanner ADF paper feed Part Units Units kit Description number mach orpkg 40X0459 1 1 Upper entrance guide assembly 40X2799 1 1 Torque limiter 40X0454 1 1 Reverse roller with clip Parts catalog 8 13 7002 xxx Assembly 8 Scanner ADF lower exit guide assembly Part Units Units kit Description number mach orpkg 8 1 40X0460 1 1 Lower exit guide assembly 2 40X0458 1 1 ADF CCD module assembly 8 14 Service Manual 7002 xxx Assembly 9 Scanner ADF motors and belts Part Units Units kit Description number mach or 40X0482 Belts including A Timing belt 52M194 B Timing belt 52M172 C Timing belt motor 52M292 D Timing belt second transport 52M152 E Timing belt first transport 52M132 F Timing belt knob 52M172 40X0461 Feed motor ADF feed 40X0462 ADF scan motor assembly Parts catalog 8 15 7002 xxx Assembly 10 Scanner ADF sensors 8 16 Service Manual 7002 xxx Assembly 10 ADF sensors Part Units Units kit Descri
97. hot roll Fuser is not receiving AC power Poor supply line voltage Bad thermistor circuit or cabling Very noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll Abrupt change in temperature that has disrupted control Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Service error codes 9xx xx continued Error code 920 920 920 920 920 920 Sub Display text Hot roll took too long to heat up after transitioning to new enhanced mode Fuser page count between 200 000 and 299 999 Hot roll fell too far below the desired temperature while printing Fuser page count between 200 000 and 299 999 Hot roll too cool while checking for slope change Fuser page count between 200 000 and 299 999 count between 200 000 Fuser is not increasing in temperature even though the lamp has been on for an extended tim Fuser page count between 200 000 and 299 999 Fuser has been below the desired temperature for too long while media is in
98. in Legal 8 5 x 14 in Executive 7 25 x 10 5 in Ca Folio 8 5 x 13 in Statement 5 5 x 8 5 in Information on touch screen buttons Function or description Down arrow Touch the down arrow to move down to the next item in a list such as a list of menu items or values The down arrow does not appear on a screen with a short listing It only appears if the entire listing cannot be seen on one screen On the last screen of the listing the down arrow is gray to indicate that it is not active since the end of the list appears on this screen Up arrow Touch the up arrow to move up to the next item in a list such as a list of menu items or values When on the first screen presented with a long list the up arrow is gray to indicate that it is not active On the second screen needed to show the rest of the listed item the up arrow is blue to show that it is active Unselected radio This is an unselected radio button button Selected radio This is a selected radio button Touch a radio button to select button it The radio button changes color to show it is selected In Sample screen two the only paper size selected is Letter v L Diagnostic information 2 9 7002 xxx Function or description me Mm Job Other touch screen buttons See Cancel Jobs on page 2 6 Touch Continue after a menu item or value on a screen is selected and more changes need to be made for a job f
99. in English and must always be printed on letter legal or A4 paper SIZE SENSING This setting controls whether the printer automatically registers the size of paper installed in an input source with size sensing Paper source Size sensing Tray 1 integrated Multipurpose feeder 250 sheet drawer 2000 sheet drawer 250 sheet duplex 500 sheet duplex Envelope feeder 500 sheet drawer When the setting is Auto every input option equipped with size sensing hardware automatically registers what size media it contains When the setting is Off the media size detected by hardware is ignored The media size can be set by the operator panel or the data stream Diagnostic aids 3 27 7002 xxx To change the size sensing setting 1 Touch gt to select SIZE SENSING from the Configuration Menu 2 The panel displays the setting s name in the header and lt q setting s current value gt below the header row Touch lt or P to change the setting The selections are Auto and Off 3 Touch Submit to save your change Touch Back to exit without changing the value Panel Menus To change the Panel Menus setting 1 Touch gt to select Panel Menus from the Configuration Menu 2 The panel displays the setting s name in the header and setting s current value below the header row Touch lt or P gt to change the setting The selections are Disable and Enable The default is Enable 3 Touch Submit to save your chang
100. incorrect disconnect J4 from the board and measure the voltages again If incorrect replace the high capacity feeder option control board Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly Tray x Empty displays tray does not respond to loading paper no response from the front door switch High capacity feeder option control board Elevator top optical sensor cable Elevator top optical sensor 2 142 Service Manual Check the voltage on the board at J4 2 green The voltage measures approximately 5 V dc If incorrect disconnect the cable at J4 and check the voltage again If incorrect replace the high capacity feeder option control board Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly 7002 xxx Tray x Paper Low displays when the high capacity feeder input tray is full or has adequate paper in the tray Paper low switch Run the sensor diagnostics for tray x x the number that represents Paper low switch cable the high capacity input tray High capacity feeder option If the test fails check the voltage at J3 1 gray The voltage control board measures approximately 24 V dc If incorrect disconnect the paper low switch cable from J3 and measure the voltage again on J3 1 If incorrect replace the high capacity feeder option control board If correct check t
101. information 4 15 7002 xxx ADF upper entrance guide assembly removal 1 Remove the three screws A i A p r 2 Lift the cover Replacement note Be sure to align the tabs 4 16 Service Manual 7002 xxx CCD belt removal 1 Remove the scan cover flatbed See Scan cover flatbed removal on page 4 11 2 Remove the scanner right side cover See Scanner right side cover removal on page 4 12 3 Remove the scanner left side cover See Scanner left side cover removal on page 4 9 4 Push the CCD belt tension spring to take tension from the belt 5 Unhook the belt from the motor shaft Repair information 4 17 7002 xxx 6 Push the flatoed CCD all the way to the left 7 Unhook the main CCD guide shafts E from the holes in the right side This allows you to remove the flatbed CCD module from the shafts E 8 Carefully lay the flatoed CCD module on the scan frame being careful not to touch the card lamp or mirrors 9 Disconnect the CCD belt from the retainer F in the flatbed CCD module assembly 10 Remove the CCD belt 4 18 Service Manual 7002 xxx CCD belt tension spring ee SY e Remove the scan cover flatbed See Scan cover flatbed removal on page 4 11 Remove the scanner right side cover See Scanner right side cover removal on page 4 12 Remove the scanner left side cover See Scanner left side cover removal on page 4 9 Push the CCD
102. limiter rrrrrrree re 7 13 250 sheet paper drawer complete assembly 7 52 Tray assembly option 250 sheet uuc rrrrrrlIIre 7 53 Pick arm assembly u rrrrrrrrrrIIrrIIIIIe 7 52 Option pass thru sensor r r rrIrrIIrIIIIIIe 7 52 7 63 Bin low sensor with cable rrrrrrrrrIII e 7 52 Side restraint 250 sheet tray rurrrrrrrrrIIrIe 7 53 Back restraint 250 sheet tray 2 2 e ee ee ere eee eee eee e eee e eee 7 53 Base assembly 2 2 c ccc c rrr er ee ee ee eee ee eee e eee eeeee 7 52 Drawer assembly complete 500 sheet 2 222 cece cert e eee e eee eeeeee 7 54 Option pass thru sensor 2 222 2 e teeter ee eee eees 7 54 Bin low sensor with cable 222 22 eee eee ee eee eee eee eees 7 54 Pick arm assembly 500 sheet 2 2 e errr c etree ee eee eee eee eees 7 54 Base assembly 500 sheet ur rrurrrrrrrIIIIIIIre 7 54 Complete envelope option 2 2 settee tee ee eee eee eee eens 7 57 Complete option assembly A4 2 22 eee cern er eee ee eee eee eeeee 7 59 Complete option assembly letter TIIIIIIII 7 59 2000 sheet option control card assembly
103. lt q to change the value The values are Auto default MP Feeder and Manual Envelope 3 Touch Submit to save the change Jobs On Disk If the hard disk is installed Jobs On Disk allows the user to delete buffered jobs saved on the disk The values are Delete and Do Not Delete To delete jobs saved on the disk 1 Touch gt to select Jobs On Disk from the Configuration Menu 2 Touch E to select Delete to decrease the setting s value 3 Touch f or lt q to change the value Touch Back to cancel and return to the Configuration Menu Disk Encryption If a hard disk is installed Disk Encryption selects whether the data on the disk is encrypted or not The values are Disable and Enable This setting determines if the printer encrypts the information that it writes to the hard disk The values are Disable and Enable Warning If the value is changed from Enable to Disable or from Disable to Enable then the printer completely formats the hard disk All information on the disk will be unrecoverable To change this setting 1 Touch gt to select Disk Encryption from the Configuration Menu Note If an advanced password has been established you must enter this password in order to change the setting If no advanced password exists you can establish one by using the keyboard that appears on the LCD 2 Touch gt next to either Enable or Disable If you remove an encrypted disk from a device and then try to install
104. maintenance advised X Co X Engine Code CRC Failure Co 00 Toner is low X 2 56 Service Manual Description action An unsupported optional envelope feeder is attached to the MFP Remove the optional envelope feeder The MFP ceases normal functions until the optional envelope feeder is removed Touch Continue to clear the message once the optional envelope feeder is removed An unsupported optional drawer and its matching tray are attached to the MFP Remove the optional drawer The MFP ceases normal functions until the optional drawer is removed Touch Continue to clear the message once the optional drawer is removed The MFP detects a defective hard disk 1 Turn the MFP off 2 Unplug the power cord from the wall outlet 3 Remove the defective hard disk 4 Install a new hard disk 5 Connect the power cord to a properly grounded outlet 6 Turn the MFP on The MFP detects that there is not enough memory or space on the hard disk to store the data of the print job Touch Continue to clear the message and continue processing the current print job Any information not previously stored on the hard disk is deleted Delete fonts macros and other data stored on the hard disk Install a hard disk with a larger memory capacity The hard disk is not formatted Format the hard disk prior to performing operations that require the hard disk If the message remains the hard disk may be defecti
105. margin See Registration base printer on page 3 5 To set the Top Margin duplex 1 Print the Quick Test duplex a Touch amp gt to select Quick Test from DUPLEX TESTS b Select Single C Hold the page to the light to see the whether the top margin of the backside aligns with the top margin of the frontside 2 Select Top Margin from DUPLEX TESTS 3 Use the arrows to increase or decrease the current setting displayed on the touchscreen to select the margin setting lt q setting s current value gt e Each increment shifts the duplex top margin by 1 100 of an inch e The Top Margin duplex range is 20 to 20 and the default value is O e Anincrease moves the top margin down and widens the top margin A decrease moves the top margin upward and narrows the top margin 4 Touch Submit 5 Print the Quick Test duplex again to verify the adjustment Repeat if necessary Diagnostic aids 3 11 7002 xxx Sensor Test duplex This test is used to determine whether or not the duplex sensors and switches are working correctly The test allows you to actuate the duplex input sensor located in the back part of the duplex unit and the duplex exit sensor located in the return paper path 1 Select Sensor Test from DUPLEX TESTS The message Sensor Test Testing displays 2 Manually actuate each of the duplex sensors When the sensor switch is closed CL closed displays and when the sensor switch is open OP o
106. narrow then turn off first sheet detection In Diagnostics Menu PRINTER SETUP Engine Settings 3 Select 16 and touch Submit The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 136 Check the fuser entry guide for toner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 75 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 201 91 Main drive motor Main drive motor not working Check the connections to the identification failed motor and system board If not Fuser page count is not problem is found go to Main available drive service check on page 2 149 201 92 Page did not reach exit e Page jammed on fuser input guide sensor Fuser page count s bot available a not enter or exit fuser nip Exit sensor not functioning correctly 2 66 Service Manual Check the fuser entry guide for toner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 75 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 User attendance messages paper jams and paper handling errors 2xx xx Error code 201 201 20
107. not a 115 V model then go to step 2 If the printer is a 220 V model then check to make sure that the correct lamp is installed Note If the fuser lamp is replaced allow the fuser to cool or a 925 xx error could be displayed AC power source Check the AC power source to make sure it meets specifications If the AC power source does not meet specifications inform the customer If it meets specifications go to step 3 2 134 Service Manual 7002 xxx Fuser lamp Turn the printer off and allow the fuser assembly to cool After the fuser assembly cools down turn the printer on If you receive the same error code replace the fuser lamp See Fuser lamp removal on page 4 82 Note If the fuser lamp is replaced allow the fuser to cool or a 925 xx error could be displayed Fuser exit sensor service check If any of the following codes are displayed there is a potential problem in the area of the exit sensor 201 00 201 02 201 10 201 12 201 22 201 30 201 32 201 40 201 41 201 42 201 50 201 52 201 92 202 00 202 02 202 04 202 10 202 11 202 12 202 14 202 20 202 21 202 22 202 24 202 30 202 31 202 32 202 34 202 40 202 41 202 42 202 44 202 50 202 51 202 52 202 54 202 90 202 91 202 92 and 202 94 Fuser exit and fuser narrow media sensor status chart Printer printing media over sensor s non narrow media fed through the printer Exit sensor open Exit sensor closed Exit sensor closed Narro
108. occurs For example 242 xx is a Paper Jam Tray 2 Pass thru sensor and flag The tray x option system board did not detect a piece of paper assembly actuating the pass thru sensor Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu If the test fails check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the tray x option pass thru sensor assembly 2 Power takeoff shaft and Check these parts for signs of broken or damaged parts spring bevel gear feed roll contamination on the drive rollers or wear plate and wear or damage gear drive roll assembly to the drive shaft bearings Check the drive roll assembly and skewed wear plate drive shaft backup roller for wear slick spots material buildup and oil or grease bearings and skewed on the rollers Also check for proper operation of the paper aligning backup roller assembly Repair or replace parts as necessary Tray x Paper Low displays when tray x is full or has adequate paper in the tray Paper low switch Run the sensor diagnostics for tray x x the number that represents Paper low switch cable the high capacity input tray If the test fails disconnect the paper low High capacity feeder Input switch cable from J3 on
109. on the flatbed 2 Place a colored piece of paper in the ADF making sure the edge guides are properly adjusted Note Use a light blue sheet of paper for the ADF registration The best results were obtained using Cascade MP Colors Blue 20 Ib paper Boise Cascade part P1 MP 2201 BE A moderate density blue paper should work if this paper cannot be found 3 Select Registration from the scanner tests menu in the Diagnostics Menu Select Auto Detect 5 Specify the size of the colored paper in the ADF gt The machine performs a POR When the machine completes POR the test runs the touchscreen indicates the test is active After the registration test is complete success or failure is indicated on the touchscreen 6 Verify the results by running a copy of a quick test page created during MFP registration See Print tests on page 3 6 for more information Manual registration Note Manual registration should be performed only after automatic registration is performed The primary purpose of manual registration is to fine tune the automatic adjustments already made 1 Select Manual from the scanner registration menu 2 Scroll through the four margins and adjust the desired margin s Note Adjust the margin by pressing the left and right navigation buttons Press the Select button 4 Ascan copy of the last MFP registration must be run to verify the settings 4 4 Service Manual 7002 xxx Removal procedures CAUT
110. or Input tray s service check on page 2 144 Bin x Bin 1 Bin 2 or Bin 3 This message is displayed when a paper handling option has been hot unplugged The printer requires the reinstallation of the option to print a page which has been formatted by the interpreter before the option was removed The following actions may be taken e Install the option e Select one of the following Cancel Job Reset Printer Reset Active Bin If the message cannot be cleared go to Input tray s service check on page 2 144 This message is displayed when a duplex option has been hot unplugged The printer requires the reinstallation of the option to print a page which has been formatted by the interpreter before the option was removed The following actions may be taken e Install the duplex option e Select one of the following Cancel Job Reset Printer Reset Active Bin If the message cannot be cleared go to Duplex option service check on page 2 125 7002 xxx User attendance messages continued Error Sub Primary message code code y g Install envelope feeder Install tray x Load manual feeder with Custom Sring Load manual feeder with Custom Type Name Description action The MFP detects that the optional envelope feeder is missing between the time the job processes but before the job prints Sometime during processing the optional envelope feeder is removed Install the optional e
111. or debris If nothing is found go to step 2 Diagnostic information 2 109 7002 xxx ADF exit sensor Motor driver card 2 110 Service Manual Check the exit sensor flag to make sure it operates freely and does not hang or bind If the flag does not operate correctly and cannot be made to operate correctly replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 If the flag operates correctly go to step 3 Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Sensor Tests Check the ADF exit sensor for correct operation Note You can check the ADF exit sensor by moving the exit sensor flag or by manually feeding a sheet of paper through the ADF If the sensor fails the test go to step 4 Turn the power off and disconnect CN9 on the motor driver card Measure the voltages in the table below normally closed If incorrect replace the motor driver card If the error persists replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 7002 xxx 294 02 Error code service check ADF exit jam sensor A off Check for an
112. 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 e NA Not available in the parts description column indicates the part is shown for identification purposes only and is not available as a FRU Model information used in the parts catalog Parts catalog 8 1 7002 xxx Assembly 1 Covers base printer 8 2 Service Manual 7002 xxx Assembly 1 Covers base printer Part Units Units kit Description number mach _ or pkg Jo c 2 c PD 10 11 12 13 14 15 16 NS 40X0001 40X0469 40X0468 40X0467 40X0471 40X0050 40X0515 40X0496 40X0493 40X0494 40X0476 40X0495 40X0151 40X0497 40X0009 40X0470 O ee LM ll Fuser wiper cover assembly Upper sub cover assembly Upper tray cover paper support Upper cover assembly Right cover assembly Counterbalance spring Upper front cover hinge assembly includes e Cable VICC 18 pin e Hinge operator panel USB cable 1 Cover open switch and cable 1 Left cable retainer 1 Right cable retainer 1 Left hinge spring 1 Right hinge spring 1 Cover assembly operator right including e Stop button 1 e Go button 1 Clear button 1 LED cap 1 Dial number pad User interface control card assembly Compression spring Operator panel right cover Operato
113. page 6 3 connector pins Locations 6 3 7002 xxx System board see System board on page 6 3 connector pins mem 0000000 mo 9m J2 Printhead laser cable ee a 8 pew J3 Printhead HSYNC mirror motor E o8 ooo o m Lx LH S i aM Ld S m J6 Hopper full output bin sensor 6 4 Service Manual 7002 xxx System board see System board on page 6 3 connector pins J8 Cover closed switch J10 Fuser DC J14 Signature button J15 HVPS input sensor Cartridge toner wheel sensor 8 s e oas 9 feve L9 ee 3 SW 23 fom 3 NSmO 4 24 V dc switched avem 8 Sm 8 feom ooo 3 WW Locations 6 5 7002 xxx System board see System board on page 6 3 connector pins J16 Ethernet port J17 Parallel port EEE E 24 V dc OTC OPT J20 Transport motor ty BLDC_HALL 0 2 BLDC_HALL 1 8 8mm 8 vemia 7 stewing 8 BDOWNDi 3 ewm J21 Autoconnect front bottom s vemor J25 Autoconnect bottom front 6 6 Service Manual 7002 xxx System board see System board on page 6 3 connector pins mem 00 mm s 00000 J26 Paper size sensor autocomp motor pep trav pour ef saves o o psf eNcoeR 3 fom Co Ground 8 J28 MPF paper out Locations 6 7 7002 xxx System board see System board on page 6 3 connector pins eomer O e NN ee ee a ee 8 o ee Lo EE NE NNENMNMMMMMSSZSZZSJWN J30 USB host ba
114. pick rolls Repair information 4 101 7002 xxx Installation 1 Remove the new pick rolls from their packaging 2 Pull the autocompensator arm down Locate the recessed area on the pick roll and align it with the tab on the arm There are two arrows on each pick roll Make sure the bottom arrow faces you as you align the recessed area with the tab 3 Push the pick roll onto the arm with the tab aligned Repeat this step on the other side to install the other pick roll 4 Gently release the autocompensator arm Insert integrated tray 4 102 Service Manual 7002 xxx Interconnect card assembly removal CAUTION Unplug the printer before you begin Warning When replacing any one of the following components e Operator panel right cover assembly e System board assembly e Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more 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 Warning Observe all ESD precautions
115. print too complex To avoid this error in the future Reduce the complexity of the page by reducing the amount of text or graphics on the page and deleting unnecessary downloaded fonts or macros Set Page Protect to On in the Setup Menu in the Settings menu Install additional memory Touch Cancel Job to cancel the current job if needed Touch Reset Active Bin to change to another linked bin 42 XY PRINCO ACA TF tdge Cartridge region code does not match MFP region code mismatch x printer region and y cartridge region The following regions may be listed o foii p Undeinedregion 50 XX PPDS Tout error The MFP has received a request for a font that is not installed when formatting PPDS print data Touch Continue to clear the message and continue printing the current job Touch Cancel Job to cancel the current job if needed Touch Reset Active Bin to change to another linked bin 51 XX Derecti ve TLasn The MFP detects a defective flash memory during power on or during flash detected format and write operations Touch Continue to clear the message and continue printing the current job At power on reset touch Continue to clear the message and the MFP continues with normal operations except for flash operations Install different flash memory to be able to download any resources to flash 52 XX Not enough free There is not enough space in the flash memory to store the data currently space in flash being downloaded
116. printer is unplugged before making any checks on the transfer roll or AN associated parts for personal safety and to prevent damage to the printer Check the transfer roll for toner buildup surface damage to the roll oil or other contaminants on the surface of the roll Replace the transfer roll as necessary Left transfer arm assembly Check the left transfer roll arm assembly to make sure it is fastened and locked in the down position If the arm is not locked down make sure the arm is not broken and locks into the EP frame correctly Check the left transfer arm assembly spring for proper operation Right transfer arm Check the right transfer arm assembly to make sure it is fastened and assembly locked in the down position If the arm is not locked down make sure the arm is not broken and locks into the EP frame correctly Check the right transfer arm assembly spring for proper operation For any background problems ensure the contact to the HVPS board is correct and that there is approximately 0 ohms resistance between the transfer roll shaft and the HVPS contact If correct go to Print quality background on page 2 158 HVPS 917 Error code Check the voltage at J15 3 The voltage changes from 24 V dc with the printer idle to 0 V dc when the printer runs the print test If the voltage is incorrect check the continuity of line J15 3 in the front cable harness to the HVPS If there is no continuity replace the cable harness If
117. removal on page 4 48 If correct replace the operator panel right cover assembly See Operator panel right cover assembly removal on page 4 62 Options service check Service tip When you have a problem with any of the options installed in the options slots on the interconnect card switch the non operating option to one of the other option slots to isolate the failure Flash memory option s Run a copy of the test page and check to see if the option you are checking is listed The printer does not recognize the option being installed if the option is not listed Make sure the memory card is installed correctly and is not broken or damaged If the memory card is correctly installed and not broken or damaged then run the Flash Test on page 3 17 If the test fails replace the Flash card If the problem continues replace the controller board DRAM memory option s This service check is the same as the flash memory option service check with the following exception Run the DRAM Test on page 3 9 from the menu if the SDRAM Memory card is correctly installed and not broken or damaged If the test fails replace the SDRAM card If the problem continues replace the controller board 2 150 Service Manual 7002 xxx Hard disk option Service tip These printers support one hard disk option Make sure only one hard disk option is installed Make sure the fixed disk and the fixed disk board are correctly installed Run the Quick D
118. repair or replace the failing sensor assembly If no problem is found check the fuser for any signs of media in the fuser or any signs of toner or other contamination If a problem is found clean or remove the debris or contamination 2 136 Service Manual 7002 xxx Fuser solenoid service check working Unplug the printer before you begin or use caution if the printer must receive power in CAUTION There is a danger from hazardous voltage in the area of the printer where you are AN order to perform the task Service tip Try changing the envelope enhance level setting A different setting may correct the problem Note Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section Fuser solenoid adjustment on page 4 2 Fuser LM conditioner Observe the operation of the fuser solenoid by removing the redrive solenoid assembly Check for proper mechanical operation of the solenoid and associated hardware link and so on If correct check the resistance of the solenoid between J4 1 and J4 2 on the fuser control board 1 QUOOQUUOQGOo J1 J6 The resistance measures between 5 ohms and 10 ohms If incorrect replace the fuser assembly If correct go to step 2 System board Measure the voltage at the 50 V dc test point on the system board The voltage should measure approximately 50 V dc If incorrect go to step 3 If incorrect go to step 4 LVPS Measure the voltage at CN2 18 on the
119. right angle Arabic Austria Belgium Bluemark CIS Czechoslovakia Finland France Germany Greece Hungary Ireland Italy Medmark 1 and 2 Netherlands Poland Portugal Russia Slavic countries Spain Turkey and UK Power cord set 6 ft right angle Brazil Power cord set 8 ft straight AS NZS Power cord set 8 ft straight Hong Kong Power cord set 8 ft right angle Japan Power cord set 6 ft straight Korea Power cord set 8 ft straight PRC Power cord set 6 ft right angle Taiwan Power cord set 8 ft right angle Denmark Norway and Sweden Power cord set 8 ft right angle Israel js Power cord set 8 ft right angle Botswana Lesotho Namibia Pakistan and South Africa Power cord set 8 ft right angle Switzerland High voltage power supply Parts packet PP 40X0165 Front cable harness HVPS input sensor toner sensor Parts catalog 8 35 7002 xxx C2 AA A Q ESI e A A 8 ggege Assembly 21 Electronics card assemblies 8 36 Service Manual 7002 xxx Assembly 21 Electronics card assemblies Part Units Units kit Ae Description number mach or pkg 40X0498 Scan control card 40X0509 Hard drive IDE 50 pin cable 40X0489 Hard file drive assembly 40X0520 Interconnect card assembly NO 40X0510 Hard drive 4 pin power cable 40X2722 System board assembly network Board ID Q0016000 40X2792 Bar code card assembly 40X2529 IPDS and SC5 TNe car
120. sca 8 WoFQNER 3 SVeN Motor drive board connector pins continued 7002 xxx LN NL NN CN10 to jam remove sensor ADF paper present sensor interval sensor first scan sensor 8 YAN 3 mOFWIENA oe SY amp N Locations 6 23 7002 xxx Flatbed interface card Flatbed interface card connector pins mem 00000000 mme ret J1 to CN6 on ADF motor drive card 4 nTOP ADF 8 weno 7 Gem e ncoveR GLosED 8 QUA pue Ground MDC RXD m 3 m L wem 3 AAD PRESENT 8 Gm m fom 3 fom m 3 fore 8 Gm ooo 9 nFLAT LENGTH nHOME 6 24 Service Manual 7002 xxx Flatbed interface card connector pins continued Connector J1 to CN6 on ADF motor drive card continued J2 to CN2 on ADF CCD module CN1 to J1 on scan control card EVEN Caven Caven mow ooo Mm ro RIN Oo on lt lt lt alala Olo o z mI D 4 O TU I UO TI Locations 6 25 7002 xxx Flatbed interface card connector pins continued L NENNEN NL NN CN1 to J1 on scan control card continued CN2 Flatbed scan motor s ome CN3 Flatbed paper length sensor assembly nFLAT LENGTH3 Lx LION DL O pem ee NM ON CN4 home sensor CN5 3 Sw 6 26 Service Manual 7002 xxx Flatbed interface card connector pins continued LONE NE NN m Ga 00 30 CCD CLAMP 31
121. sensor flag activated If the voltages are incorrect replace the ADF exit sensor If this does not fix the problem replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 294 03 Error code service check ADF exit jam sensor on This error generally indicates that the ADF exit sensor A is defective exit sensor cable is open or the voltages on the motor driver card at pins 1 2 or 3 are incorrect EM Pl 4 A rf ADF jammed media Check for any signs of media or other debris that might be present in the ADF assembly around the exit sensor flag Remove any media or debris If nothing is found go to step 2 2 112 Service Manual ADF exit sensor Motor driver card ADF exit sensor electrical checks 7002 xxx Check the exit sensor flag to make sure it operates freely and does not hang or bind If the flag does not operate correctly and cannot be made to operate correctly replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 If the flag operates correctly go to step 3 Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANN
122. sensor standard tray service check Service tip If the output bin standard tray fills up and the bin full sensor fails to post the Remove Paper Standard Bin message 1 Enter the Diagnostics Mode 2 Select Output Bin Tests 3 Select Sensor Tests 4 Select Standard Bin 5 Check the sensor and flag for proper operation If you find no problem with the sensor and flag continue with the service check Service tip Be sure the flag is correctly installed The output bin sensor is a normally closed sensor with the sensor flag down Therefore unless the flag is in the up position or out of the sensor slot a Remove Paper Standard Bin message does not display System board Check the voltage at J6 1 It measures 5 V dc when the flag is in the sensor and 0 V dc when the flag is out of the sensor If the voltage does not change replace the sensor cable assembly If this does not fix the problem replace the system board Printer fails to display Remove Paper Standard Bin message Output Bin Sensor Test fails Output bin sensor flag Make sure the correct flag is installed Check the flag for damage or improper operation If incorrect replace the flag Note A broken or improper operating sensor flag causes a Remove Paper Standard Bin message to display before POST completes and cannot be cleared Paper feed service check base printer If you have a 936 Transport Motor Error go to Main drive assembly removal on page 4
123. src to ignore the message and print on the print media loaded in the tray Touch Continue e which continues the job if the correct size and type are loaded in the tray and this size and type are specified in the Paper Menu using the control panel e which is ignored if there is no print media in the tray Diagnostic information 2 43 7002 xxx User attendance messages continued Error Sub Primary message code code y g Change lt src gt to Custom Type Name Change src to size Change src to size type Check Duplex Connection 2 44 Service Manual Description action New print media is required to finish a print job Load the indicated source with the requested size and type of print media Touch Continue to print with print media currently in the tray Lets the user override the current print media source for the remainder of the print job The formatted page prints as is on the print media installed in the tray This may cause clipping of text or images Touch Use current src to ignore the message and print on the print media loaded in the tray Touch Continue e which continues the job if the correct size and type are loaded in the tray and this size and type are specified in the Paper Menu using the control panel e which is ignored if there is no print media in the tray Touch Cancel job to cancel the current job if needed Lets the user override the current print media source for
124. standard interface x indicates the active interface is connected to the MFP through PCI connector x x y indicates the active interface is connected to the MFP through channel y on PCI connector x or that x equals 0 on the standard network interface 2 40 Service Manual An incorrect password is entered Touch Continue to return to the screen to enter a correct password 7002 xxx User status displays continued Error Sub f m Display text Description action serial x A serial interface is the active communication link Notes The current interface appears on the Menu Settings Page Interfaces shown without an x or y means the active host interface is a standard interface x indicates the active interface is connected to the MFP through PCI connector x x y indicates the active interface is connected to the MFP through channel y on PCI connector x or that x equals 0 on the standard network interface USB The MFP is processing data through the specified USB port USB x EN PUL RDYMSG This is the Printer Job Language PJL Ready message Power Saver The MFP is ready to receive and process data It is reducing its electricity consumption while idle If the MFP remains inactive for the period of time specified in the Power Saver menu item 60 minutes is the factory default the Power Saver message replaces the Ready message Send a job to print Press any operator panel button Printing page x A s
125. str ling i belgelengdeomr det 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstraling ut over klasse I niva under vanlig bruk vedlikehold som utf res av brukeren eller foreskrevne serviceoperasjoner Av s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes l ser de classe 1 i segons ha estat certificat en altres llocs s un producte l ser de classe que compleix els requisits d IEC 60825 1 Els productes laser de classe no es consideren perillosos Aquesta impressora cont un l ser de classe IIIb 3b d arseni r de gal li nominalment de 5 mil liwats i funciona a la regi de longitud d ona de 770 795 nan metres El sistema l ser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiacio laser per sobre d un nivell de classe durant una operaci normal durant les tasques de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites XIV Service Manual Japanese Laser Notice L 3 ic Bid SpA ott COZU LZS5 iX oCKBICIADHHS 21 CERY7 f 7 J OZIAI 1 oS M Leb tiS MOWED FKLKHMDAGCHIIEC 82504H8 U XIILVUI27 AILOv HECHSCLEMPWANTTWET 72AX1I0v V 8 amp igiicifsltEiEA UL oncomYY CO Zy 7 i i72 xNnb 3b ov wv zpmGuvcozY co L 3 ii BEOT7TO T950T772 5 0883888 C BH SL UDybhOAUVDLAUEDMERATALY P
126. the USB board assembly 4 Remove the two screws B securing the USB board assembly TH UU P ETT WLU B A 5 Remove the USB card Repair information 4 133 7002 xxx 4 134 Service Manual 7002 xxx 5 Locations and connections 6 Locations Sensors Flatbed paper size sensors Home sensor Locations and connections 5 1 7002 xxx ADF paper length sensor and ADF paper width sensor Exit scan sensor Paper present sensor ADF jam removal sensor ADF cover closing sensor ADF cover closed sensor Second scan sensor First scan ADF top cover sensor open sensor Interval sensor 6 2 Service Manual 7002 xxx Connections System board Mm U7 4 USB 3 LLL Co ee od E A1 18 4 F L o o 9 3 J19 a J1 du UL o oe Q Jt c ooooo0oo0oo0oo000000 eee say m ia 926 i242 J25 J22 aln Q B J23 O Q o C no c ooon oN c c a ooo oh S amp o J120 J6 1 10909000000 1 ooo eo E J15 J14 1 J13 J10 J18 1 99599s99e95es509 4 eg o000000 1199999000000 System board see System board on
127. the remainder of the print job The formatted page prints as is on the print media installed in the tray This may cause clipping of text or images Touch Use current src to ignore the message and print on the print media loaded in the tray Touch Continue e which continues the job if the correct size and type are loaded in the tray and this size and type are specified in the Paper Menu using the control panel which is ignored if there is no print media in the tray Touch Cancel job to cancel the current job if needed This messages displays for the following conditions The duplex option may have been removed from the printer possibly to clear a paper jam or to remove the option The duplex option may be attached to the printer but a communications problem may prevent the printer from detection For example there may be a poor connection or a hardware failure The following actions may be taken e f the option was temporarily removed or not connected properly reattach or reconnect it Accept the configuration change which notifies the printer the option has been hot unplugged removed with the power on Note This action is not available if the printer is in Diagnostics Mode or running diagnostics If the device is experiencing a hardware problem turn the printer off and on If the message continues to be displayed go to Duplex option service check on page 2 125 7002 xxx User attendance messages
128. to both the home sensor and to CN4 on the flatbed interface card bows nome pene Check for correct operation of the home sensor If it does not operate Flatbed interface card correctly replace the FRUs in the following order e Flatbed interface card See Flatbed ICC interface card removal on page 4 32 e Flatbed home sensor See Home sensor removal on page 4 46 If the problem persists go to step 6 Flatbed scanner assembly If the 843 00 error code continues to be displayed replace the complete flatbed scanner assembly See Flatbed scan assembly removal on page 4 38 Note If the flatbed scanner assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 845 00 Error code service check Service Scanner this error indicates a failure of the image processing ASIC on the scan control card Scan control card Replace the scan control card See Scan control card removal on page 4 48 Diagnostic information 2 115 7002 xxx 848 00 Error code service check Service scanner Modem Config ID mismatch This error indicates that no modem is installed on a modem MFP 848 01 Error code service check Service scanner Modem Config ID mismatch This error indicates that a mode is present on an MFP not configured to support a modem Printer POR System board Factory defaults Sub error codes 900 90 Error code service check Turn the printer off
129. to move down the page and a negative Each increment causes change moves the image up approximately 0 55 mm shift in the bottom margin Top Margin 25 to 25 A positive change moves the image down the page and increases the top margin A negative change moves the image up and decreases the top margin Each increment causes approximately 4 pels shift at 600 dpi Left Margin 25 to 25 A positive change moves the image right and a negative change moves the image left No compression occurs Right Margin 10 to 10 A positive change moves the image right and a negative change moves the image left Diagnostic aids 3 5 7002 xxx To set print registration 1 Print the Quick Test page a Touch REGISTRATION from the Diagnostics Menu b Touch to select Quick Test Retain this page to determine the changes you need to make to the margins settings The diamonds in the margins should touch the margins of the page Registration Line LYK EVA 2 To change the value of any of the margin settings e Touch gt to the right of the appropriate margin setting The panel displays the setting s name in the header and setting s current value in a menu below the header row e Touch lt q to decrease the value or Jf to increase the value e Tou
130. um UG GA AS HAS m AD AD ae de de um e He Ge 9 AS UAE UM Um NL d ese Ree ee eee ee ee Wowoww mw O eee mi bi 5 Remove the four screws B 6 Tilt the card to remove the scan control card Repair information 4 49 7002 xxx Scanner flatbed glass holder assembly removal 1 Open the document cover 2 Remove the two screws A 3 Carefully pry up the inner edge Warning Be careful not to touch the underside of the scanner flatbed glass holder Warning Do not use tools that can scratch the glass 4 Liftto release the three tabs B Warning Place the scanner flatbed glass holder assembly on a clean dry cloth to protect the glass from scratches 4 50 Service Manual 7002 xxx Warning Do not touch the calibration strip Repair information 4 51 7002 xxx Separator assembly torque limiter removal 1 Open the ADF top cover 2 Remove the ADF pick arm assembly See Document tray assembly removal on page 4 22 3 Unsnap and remove the paper guide A 4 Remove the clip B 5 Remove the reverse roller C 6 Slide the separator assembly torque limiter D off the shaft 4 52 Service Manual 7002 xxx Upper glass holder removal 1 Open the document cover 2 Slide the upper glass holder to the left to unlatch 3 Lift the upper glass holder to remove Warning Do not touch the calibration strip Repair information 4 53 7002 xxx Base printer remo
131. while handling ESD sensitive parts See Handling ESD sensitive parts on page 4 1 Note Any time the interconnect card assembly is replaced the Configuration ID must be reset in NVRAM on the new interconnect card Go to Configuration ID on page 3 19 1 Remove any feature or option cards from the interconnect card 2 Remove modem card A if installed 3 Remove the two screws securing the interconnect card B 4 Remove the interconnect card assembly Repair information 4 103 7002 xxx LCD inverter card assembly removal 2 Remove the operator panel left side cover See Operator panel left cover assembly 1 Remove the printer left side cover See Printer left side cover removal on page 4 56 A N removal on page 4 61 3 Remove the two cables A 4 Remove the two screws B 4 104 Service Manual 7002 xxx Low voltage power supply removal CAUTION Unplug the printer before you begin Remove the redrive assembly See Redrive assembly removal on page 4 123 Remove the right side cover See Printer right cover removal on page 4 58 Remove the pass thru plate See Pass thru plate on page 4 70 Remove the LVPS mounting screws A from the rear of the center pan E ad SY Disconnect the LVPS to system board cable The cable is difficult to disconnect There are catches B that firmly hold latches on the LVPS card connector C Repair information 4 105 7002 xxx 6
132. xxx Service error codes 9xx xx continued Error Sub o code Display text Description Loss of lock detected by Defective motor cable Go to Main drive service check higher level code Motor Defective main drive motor on page 2 149 is type 1 Paper jams 937 Driver over temperature Excessive gear loading in Go to Main drive service check detection Motor is gearbox assembly on page 2 149 type O 939 RIP engine System board POR the printer several times if the communications lost error code continues to be displayed replace the system board See System board and inner shield removal on page 4 125 940 LVPS zero crossing test e Incorrect LVPS installed Check to make sure the correct failed LVPS assembly has been installed Noisy AG power source If the correct supply is installed LVPS to system board cable check to make sure the LVPS to loose system board cable is installed correctly If correct replace the LVPS assembly See Low voltage power supply removal on page 4 105 947 PQET RAM test PQET failed to pass RAM tests on Replace the system board See incomplete the system board System board and inner shield PQET RAM test did not nen SERM RUNE complete PQET RAM test failed MARCHO PQET RAM test failed MARCH 1 PQET RAM test busy failure Pel clock check failed System board Replace the system board See System board and inner shield removal on page 4 125 Delay line c
133. your hands below the bevel gear itself When the gear double snaps into place it may pinch your hand 5 Install the power takeoff shaft and spring 6 Install the gear guard T Install the inner shield 4 72 Service Manual 7002 xxx Developer drive assembly removal 1 Remove the system board and inner shield See System board and inner shield removal on page 4 125 2 Remove the two short screws A and the one long screw B securing the developer drive assembly 3 Remove the developer drive assembly 4 Remove the developer drive coupler kit See Developer drive coupler kit removal on page 4 74 Installation 1 Place the developer coupler into the main motor drive shaft 2 Place the developer drive shaft on the developer drive 3 Align the developer drive shaft with the coupler S gl 4 Be sure to replace the screws in the same positions Repair information 4 73 7002 xxx Developer drive coupler kit removal 1 Remove the developer drive See Developer drive assembly removal on page 4 73 2 Remove the shaft drive and coupler ESD cover removal 1 Open the multipurpose tray and remove the tray from the two mounting posts See Multipurpose feeder lower front cover assembly removal on page 4 67 2 Carefully lift the latch on the left A and remove the ESD cover Note Be careful not to stress the hinge on the right B 4 74 Service Manual 7002 xxx
134. 002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes Video never started with page two inches past the input sensor Fuser page count between 100 000 and 199 999 Expected wide page not e Page did not enter or exit fuser nip If label media ensure front detected by narrow cleanly edge meets 1 8 inch media sensor possible TON requirement accordion jam Fuser Narrow media sensor not functioning ZOOOUREDONNGOR correctly Check fuser for wear or on 000 contamination If a problem and 199 999 Actual page is narrow when wide is found replace the fuser page was expacies assembly See Fuser assembly removal on page 4 75 If media is narrow then turn off first sheet detection In Diagnostics Menu PRINTER SETUP Engine Settings 3 Select 16 and touch Submit The fuser narrow media sensor may not be operating properly Go to Fuser narrow media sensor service check on page 2 136 Page did not reach exit e Page jammed on fuser input guide Check fuser entry guide for sensor Fuser page Pa toner build up e Page did not enter or exit fuser nip Reo el ad 200 000 cleanly Check fuser for wear or ps Evi ni contamination If a problem Exit sensor not functioning correctly is found replace the fuser assembly See Fuser assembly removal on page 4 75 The fuser exit sensor may not be functioning properly Go to
135. 0030 40X0032 40X0044 40X0048 40X0046 40X0049 40X0054 40X0052 40X0051 40X0264 40X0058 40X0232 40X0059 N c LL NO La a a c c c c c D ln c c Upper redrive deflector Upper diverter spring Redrive assembly 500 sheet in 500 out Transfer deflector Gear guard Parts packet PP 40X0165 Paper switch activate spring Paper size sensing board assembly Gear release link Main fan with cable 500 sheet output Standard bin level sensor bracket Standard bin level sensor Standard bin level sensor cable Output paper level flag Redrive door assembly 500 sheet Extension guide Parts packet redrive mounting screws P N 40X0254 Parts catalog 8 9 7002 xxx Assembly 5 Frame 3 8 10 Service Manual Assembly 5 Frame 3 7002 xxx Part Units Units kit Description number mach _ or pkg CO NO Of Co CO PY 40X0249 40X0208 40X0034 40X0033 40X0223 40X0036 40X0306 40X0213 40X0021 40X0040 40X0042 40X0039 40X0043 40X0209 40X0045 40X0207 lt e a qd LL LL m U ee Ill EP DC fan assembly Blower duct Parts packet PP 40X0165 Parts packet PP 40X0165 Signature button sensor assembly Machine mounting pad HVPS input sensor toner sensor cable assembly Toner sensor assembly High voltage contact kit including Charge roll contact 1 Doc TAR Dev contact 3 Screw 5 Screw block 4 Tray bias assembly e PC drum contact 1 Cartridge
136. 08080006 ornr rap rv eeeeee ec7 779777909 00008 eec 2880000093880 eosee000088808996 3 Loosen the screws for the printer outer shield and slide the shield to the left to allow enough room to remove the scanner control card shield and the hard drive shield a v eeneeeceeee eenveerr ere ff 2S gg gg I T mod mm dh mom m aom PARAL AL ALCUN db mom momom m m o GA GA GAS G D GAL a d dm um M Go Gm 9 US AD UD EOD UND D w mmmg DSgxsxwg4 Sere wow ww mw ww D oww uw 4 44 Service Manual 7002 xxx 4 Disconnect the two cables B 5 Remove the four screws C 6 Remove the hard drive Repair information 4 45 7002 xxx Home sensor removal Remove the scan cover flatbed See Scan cover flatbed removal on page 4 11 Remove the scanner right side cover See Scanner right side cover removal on page 4 12 Remove the scanner left side cover See Scanner left side cover removal on page 4 9 mo T Remove the screw A 5 Remove the sensor and bracket B 6 Disconnect the cable C from the sensor 7 Unclip the home sensor D from the bracket 4 46 Service Manual 7002 xxx Lower exit guide 1 Remove the ADF front cover See ADF front cover removal on page 4 5 2 Remove the flatbed white cushion See Flatbed white cushion removal on page 4 31 3 Open the document cover 4 Press the latch A to open the lower exit guide 5 Remove the two screws B an
137. 0X0152 40X0153 40X0156 40X0157 40X0159 40X0160 40X0161 40X0162 40X0163 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0171 Parts packet reference adjust 2 2 2 s ects eee tenet eee eee teen eee eee eens 7 25 Tray assembly 500 sheet tray r rrrrrrrrrrrrme 7 27 Side restraint rururre erre rr rrr rrII e 7 27 115 V Maintenance kit 2 2 2 2 eee eee ee eee eee ee eee eee eee eee eeee 6 1 220 V Maintenance kit 2 2 2 een ee enn eee ee eee eee eee eee eee 6 1 100 V Maintenance kit 222 222 e eee ener ener eee eee eee eeeee 6 1 Pass thru plate 500 sheet tray 2 22 enn rete eee eee eee eees 7 27 Restraint pad 2 22 22 nner er eee eees 7 27 Back restraint 2 22 ene re ee eee eee eens 7 27 Gearbox with motor 2 2 n eter ee eee 7 29 Power takeoff shaft 500 sheet r rrrrrrrrrIII e 7 29 Power takeoff shaft spring eee etre rn eee eee eee eee eens 7 29 Bevel gear with grease packet and washer r 7 29 Developer drive assembly rrrrrrrrrrIII e 7 29 Parts packet developer drive 22 222 esse ener eee renee eee eee eee 7 29 Fuser wiper cavity cover
138. 10 to the motor driver card Measure the voltages in the table below with the sensor in normal operation sensor closed and with the sensor open paper over the sensor First scan sensor Connector CN10 motor driver card Sensor closed uncovered Pin 2 0 03 V dc Pin 3 5 0 V dc Note All voltages are approximate values If the voltages are incorrect replace the first scan sensor If the voltages are correct go to step 6 Check the ADF scan motor for proper operation Turn the power off disconnect CN3 on the motor driver card and measure the voltages on CN3 on the card Connector CN3 motor driver card Operating CN3 Pin 1 41 5 V dc 24 V dc CN3 Pin 2 41 5 V dc 24 V dc CN3 Pin 3 411 5 V dc 24 V dc CN3 Pin 4 1 5 Vdc 24 V dc CN3 Pin 5 411 5 V dc 24 V dc CN3 Pin 6 411 5 V dc 24 V dc Note All voltages are approximate values If the voltages are incorrect replace the motor driver card If correct turn the power off reconnect the motor cable to CN3 and measure the voltages on the scan motor connector see the table above If correct go to step 7 Check the scan motor drive belt for any signs of wear or damage or the belt is off the gear If the belt is off the gear reinstall If the belt is worn or damaged replace the belt If no problem is found Replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced is necessa
139. 121 Place the printer on its back eee SY Disconnect the cannot motor cable A from the system board J24 Gp H m ee m B ii T NN hie d Y e 141 SU S pe a ee ee EE Mes ust AE LES ME A E uad inito eee e TER am ma i i f a j i N I lexkpSRY WX or ees hg aa LT 3 zi Repair information 4 99 7002 xxx 8 Locate the integrated tray autocompensator assembly B on the bottom of the printer and disconnect the autocompensator arm bias spring C Note When you remove the spring note the larger loop attaches to the side frame 9 Remove the C clip D that rests against the right side frame from the autocompensator pivot shaft cM uL p TA GAMMA Vl M i F B D C 10 Disconnect the autocompensator sensor cable E from the assembly 11 Remove the autocompensator assembly mounting screw F y F 12 Slide the shaft to the right and push the shaft from the outside of the frame 13 Remove the integrated tray autocompensator assembly 4 100 Service Manual 7002 xxx Integrated tray autocompensator pick roll assembly removal 1 Remove the integrated tray and look underneath the printer for the autocompensator arm Pull the arm down 2 Press on the end of the tab A and pull the pick roll off the arm Repeat this step for the pick roll on the other side Next gently release the autocompensator arm Discard the used
140. 13 Loosen the screws for the printer outer shield and slide shield to the left to allow enough room to remove the scanner control card shield and the hard drive shields dm gm SRR 4S SS mom mm dh mmm mA AS EE d mommmmmm dm gm GA 8388 4 amp CoP eee eee eee ee is Seer ree eee eee 15 Remove the toroid from the cable and set aside for reinstallation 16 Remove the flatbed CCD ribbon cable from the IF interface card 4 26 Service Manual 7002 xxx Flatbed CCD module assembly removal Ce SY Remove the scan cover flatbed See Scan cover flatbed removal on page 4 11 Remove the scanner right side cover See Scanner right side cover removal on page 4 12 Remove the scanner left side cover See Scanner left side cover removal on page 4 9 Push the CCD belt tension spring to take tension from the belt Unhook the belt from the motor shaft Repair information 4 27 7002 xxx 6 Push the flatbed CCD all the way to the left There is a slot in the frame to allow the flatbed CCD module assembly to be lifted out 7 Unhook the main CCD guide shafts E from the holes in the right side This allows you to remove the flatbed CCD module assembly from the shafts 4 28 Service Manual 7002 xxx 8 Disconnect the flatbed CCD ribbon cable B from the flatbed CCD module 10 Remove the flatbed CCD module assembly Repair information 4 29 7002 xxx Flatbed contact glass removal 1 Open t
141. 2 Sub codes 93 94 Description Video never started two inches past the input sensor Fuser page count is not available Expected wide page not detected by narrow media sensor possible accordion jam Fuser page count is not available Paper jam at fuser exit or redrive area Fuser page count between 0 and 99 999 Possible causes e Page did not enter or exit fuser nip cleanly e Narrow media sensor not functioning correctly Actual page is narrow when wide page was expected Page may be jammed in fuser exit or redrive area 7002 xxx If label media ensure front edge meets 1 8 inch requirement Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 75 If media is narrow then turn off first sheet detection In Diagnostics Menu PRINTER SETUP Engine Settings 3 Select 16 and touch Submit The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 136 Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Ch
142. 2 if the narrow media sensor does not pass the test go to step 5 Fuser narrow media sensor Check the fuser narrow media sensor cable for correct installation or cable any signs of damage to the cable or to the connectors If no problem is found go to step 3 If a problem with the installation is found install the cable correctly If damage to the cable or the connectors is found replace the cable Fuser narrow media sensor Make sure the sensor flag is not binding and is operating properly If flag the sensor is operating properly go to step 4 If the sensor is not operation properly repair or replace the sensor assembly See Fuser narrow media sensor removal on page 4 84 Fuser assembly Check the continuity of the fuser narrow media sensor cable If incorrect replace the cable if correct check the continuity of the dnd narrow mela sensor fuser to system board cable If incorrect replace the cable if correct replace the following FRUs in the order shown Fuser board Fuser board ca le Fuser assembly See Fuser assembly removal on page 4 75 e System board See System board and inner shield removal System board on page 4 125 5 With the redrive assembly removed from the printer enter Diagnostics mode and run the printer test from tray 1 and observe the media as it passes over the exit sensor Check to see that the sensor flag is operating correctly If the sensor flag and hardware are operating incorrectly
143. 3 installation bevel gear 4 72 fuser assembly 4 76 fuser exit sensor 4 79 fuser exit sensor spring 4 80 fuser narrow media sensor 4 85 fuser narrow media spring replacement 4 86 pick roll assembly integrated tray autocompensator 4 102 integrated tray autocompensator assembly parts catalog 7 21 removal 4 99 interconnect card connectors 5 10 parts catalog 7 36 removal 4 103 service check 2 145 J jams access doors and trays 3 40 avoiding jams 1 15 clearing 3 41 paper path 3 40 Jobs On Disk 3 33 K Key Repeat Initial Delay 3 36 Key Repeat Rate 3 36 keypad 2 3 kiosks vertical and horizontal paper adapters 7 64 L lamp fuser 4 82 LCD inverter board connectors 5 14 left cover handle holder removal 4 68 LES Applications 3 35 Lexmark Embedded Solution 3 35 light indicator 2 2 locations sensors 5 1 Index l 3 7002 xxx low voltage power supply LVPS connectors 5 11 parts catalog 7 34 removal 4 105 lower front cover assembly removal 4 67 lower paper deflector MPF 4 112 lubrication specifications 6 1 M main drive assembly parts catalog 7 28 removal 4 109 service check 2 149 main fan removal 4 107 maintenance ESD sensitive parts 4 1 flatbed white cushion 6 2 lubrication 6 1 maintenance kit 6 1 preventive 6 1 safety inspection guide 6 1 scanner glass 6 2 maintenance approach 1 2 maintenance kits 6 1 media specifications 1 8 menus 2 12 accessing service menus 3 1 messages attendance Replace all orig
144. 40X3249 40X3250 40X3252 40X3254 40X3255 40X3260 40X3262 56P 1228 56P 1228 56P1279 56P2540 56P4102 56P4108 56P4109 56P4116 56P4129 56P4137 56P4145 56P4147 56P4150 56P4157 56P4195 56P4196 56P4230 56P4244 1375947 99A0063 99A0070 99A0120 99A0121 7002 xxx simplified Chinese font card rrrrrrrrrrIIIr e 7 65 Traditional Chinese font card rrrrrrIIIIIre 7 65 Korean font card rurre rere eee eee eee eee eens 7 65 MarkNet 8050 wireless non US rrIrr III rIIIIIIe 7 65 32MB Flash card rurrrrrrrrrrrrrIIIIIIIII e 7 65 64MB Flash card r rrrrrrr rrr 7 65 IPDS and SC5 TNe card assembly r rrrrrrrIIIIIIme 7 37 Fuser assembly w 220 V lamp 22 2 c errr ttre reer eee eee eee eee eee eens 7 31 Fuser assembly w 100 V lamp 2 22 c ener treet eee eee ee eee rece eeeeeee 7 31 Fuser assembly w 115 V lamp 22 22 eee c tee rece eee ee eee reece eens 7 31 System board assembly network Board ID Q0016034 7 37 Forms card assembly 2 222 ccc ccc ree eee ee eee eee eee eee eees 7 65 Bar code card assembly 2 22 e creer tree reer eee teen eee cece 7 37 7 65 PRESCRIBE card assembly 2 2 2 e sneer erent e eee eee eeeee 7 37 7 65 Torque
145. 446 ie Reed dhe ew Bede 4 56 xc 31st EEE PELE E E OQ OLI TO TTL 4 58 Paer nur COVE NICE oeupseawepdxws t etie RERHESFKERSYIERELEN Se ee kd doas d dn 4 58 Operator panel left cover assembly removal llle 4 61 Operator panel right cover assembly removal eee eee 4 62 Touchscreen bezel remoVal 423 2 reo EROR PERS RODA CER OM E Rd per bord dores edad 4 64 LOD SSE FED oa yo bs ee oe ee RERWCKS TER RUPES ee Ses 4 64 Multipurpose feeder lower front cover assembly removal 000 cee eee es 4 67 Ler cover handle holder removal eese so 24 64 8eh444 Rx P xaO dx EAS Shee ee eden eed 4 68 Right cover handle holder removal 244 4604 9 ch E dre d CERE E 440 eh Pic ap dard RR REC S 4 68 Left and right frame extensions ua uc dee aerae EROR RE CRUCE ORC e ee Kr ORC OR DIORCA MCA ede ecd 4 69 xt 10n 4 Ar rrr 4 70 ENSURE sap ocio 3 bee TC CREE OCCORRE B WR o REPE RE Ede LP dT ME dd d 4 71 Developer drive assembly removal 4 439 9 94 97979994 oo SS P9 EO RO EC es 4 73 Developer drive coupler kit removal uasuce sordo om o bw ee O RR c ER 4 74 ESGD ODUSI TERDUM 4 a oo 65 E CREE ERA UR OF eS oS OE EES OSES 8 ESN ee hae eb ee eee 4 74 FUSES ac omn TOMOVI uu doo wk uo 3 099 09 a Shard oS CULA eR dS d ee P rae d a 4 75 FHSEFENELSSDSDI er as dca ed dre 5 eek oe be eG he RUCERARNCERGR AES REESE qixRPAES 4 78 Fuser exit sensor flag and spring removal celleeeee hn 4 80 FUSSFIEHIDTERNIOUA 6 44546665650550 960556
146. 47 2502 5 3 492 dee ap d x d dd 2 150 ORANIE MOY DPI oca og deca Pob e dog doe oS ROS ee ei ER AR RACE S 2 150 eee DEUS 212 4 bee RE dE TS dad eae ed DC TOT ERE I EA S cate a 2 9 94 92694 3 2 151 Output bin sensor standard tray service check 0 cc ee ens 2 152 Paper feed service check base printer llli 2 152 Paper size sensing service check uus qoe dac XCA Kk dm aO cR Rack AUR CACR CRAT cwn 2 154 lare por SEIVIER CHECK i cic V pakP FERE VAY REFAWEP4 EERE RR Pa ER GP YSeEEE RESET 2 155 Print quality service check base printer nanana naana 2 156 Fnihead Senice ONGC occ oy o5 6345464556590 9 0040 REX GR RERO PERI A X ERA GGX Gd eR xS 2 161 Signature button assembly service check llle 2 161 System board service CHECK lt 4 264408664045 bRSR ES dee So Rey tr b opm RR b RACE RTROR cde ats 2 162 Toner sensor Se Ce CIO 2 q 4rd door QE Fr 1 pat Rd OOH 3 3 1900 a RoE Ql ee Cb Mer 2 162 Teale rol Ger oe OTIBBE LucskanwdesebedasAZesaaqs43 OS BaP adu S HE OS dx ee ONS 2 163 oO ROIS qe TEE 3 1 ACCESSING BOLVIOB MENUS lt 5 ia sha ee sh ci adr wee EE VE Vd ada xia Reeser RE RC 3 1 PION RIGS MOM PI eee eee 3 2 Entenng Diagnostics MONU uud dos doe e d ERER EATE beans QR epu Se Eee eu 3 2 Pee ound ooh oo bee Seo ee S56 os 6 oo 65 56 eS Cp Su EPA TEERPERXA RE PAM Rd FE A 3 2 Registration base printer aiio iuo sweet anaek 64546640008 00640 wi RUD RUE E SRE
147. 499 999 Page did not reach exit sensor Fuser page count more than 500 000 Main drive motor identification failed Fuser page count more than 500 000 Page did not reach exit sensor Fuser page count more than 500 000 Possible causes Page did not enter or exit fuser nip cleanly e Narrow media sensor not functioning correctly Actual page is narrow when wide page was expected Page jammed on fuser input guide e Page did not enter or exit fuser nip cleanly e Exit sensor not functioning correctly Main drive motor not working Page jammed on fuser input guide e Page did not enter or exit fuser nip cleanly e Exit sensor is not functioning correctly If label media ensure front edge meets 1 8 inch requirement Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 75 If media is narrow then turn off first sheet detection In Diagnostics Menu PRINTER SETUP Engine Settings 3 Select 16 and touch Submit The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 136 Check the fuser entry guide for toner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 75 The fuser exit sensor may not be functioning properly Go to
148. 65559405 oes hb ak es es RaoPSEE ES HER OE EOS 4 82 Fuser narrow media sensor removal cse hs 4 84 Fuser narrow media flag and spring removal 000 eect n 4 86 Fuser tO LVP AC Gale removal auus 2 594 9 obese qe A oie 6 eee 1 99 909v 3 dae tee 900 904 4 88 Peer ONSE TOMOVA ase qure Wha AUF SAS Rd RUE EV REIN AA WRAP 69 NAE bee eee ee eee dc 4 91 Posar ee ee FEO sesasi 9 oh 479 479 4971 9 93 ba 03 hee iy Edd 9 EUR EA PER ER rH 4 4 93 Gear release link removal 414 2dd eR 4th REG RR AD ERERUEOR EFE AREE EG UR ERE Soe ERO EY Oe ERS 4 94 High voltage power SUDOIVIENIOVE aru depu qo dE P7463 d rieri ree pE ri CHE ECCO 043a 4 95 Inner paper deflector assembly removal 0 000 ccc eee teens 4 97 Pe SO Pe nuce ote RR 0 5 E E 0S E ee ee eee 4 98 Integrated tray autocompensator assembly removal 2 000 eee eee ees 4 99 Integrated tray autocompensator pick roll assembly removal 00000 ee eee 4 101 Interconnect card assembly removal 000 ee eee eee tenes 4 103 LCD inverter card assembly removal 0 00 cece eee eee eee eee 4 104 Low voltage power supply EMV Ol 44 3 di den hens bee ead Ow eek eee Re 4 105 RNIN 14249 RS RE dre duke deri d aa sure E NV ReR es A gari x Jo 4 107 ESI ive assembIy removal 4 4 4 wed 6o eye Er herd rr PETAT PICO deed Geese ad 4 109 MPF arm assembly TOI ater dic e aede e eder dde e o Toe ideae d o Re RC ER ded 4 111 Vill Service Manual 7002 xxx MPF lower p
149. 9d Qd 9379 rid Hae be 0149099 3 909 99 bbs eos 2 116 845 01 Error code service check 66 4245 en ado eH CRETEOSAE RUE EURO RO o X49 CIE Se dd 2 116 BUD XX Error code senice GIBSON aadaaused eiua RO XGUCRA Ee OE X ENS ci d e d 2 116 900 90 Error code service check ee RR RR RR RR es 2 116 aero FAN SONICS CCC 4g cong e cane seers hoe 545 6006 b445454 054 562 2940254505 xeu de 2 116 Main fan service check 0 000 cc ee rs 2 117 A tan Service COs ieseciwezsacNRES oe ee Qi Kader eques ds 2 117 950 00 through 950 29 EPROM misimiatoh failure 445 ucc so ae mm cim s 2 118 950 30 through 950 50 EPROM mismatch failure isses org dewey eae dda koe RR RR Rom n OR 2 119 ADF paper length sensor service check 13 uw aque dei p bar dob p HEPE 3962 933 4 pa n 2 120 ADF paper width sensor service check 0 00 ccc eee nn 2 121 Chare Set ODER hare dh bi hd bre 80 94 99 Dc eed HR CIO d p V4 enw HE d on ded ec ded durs 2 121 Cover closed sensors service check flatbed eee RR RR 2 122 Cover closed switch cable service check base printer 0 0 00 cee ee ees 2 123 Dead machine service check ce RR s 2 123 Duplex DDHOR Service ChCK 564405045445 ent 5509 54 d eR ROG Vo Ro RC ORR ES OEE ER E US 2 125 Envelope feeder service check 0 0 00 ee eee eee eee eens 2 127 Flatbed size sensor service check necked oe bc nose bbws be Os RE RGRERSE 3E RE bes 2 129 IV Service Manual 7002 xxx Fuser service che
150. CCD RESET CCD PHASE CCD TRANSFER CCD BW SE LECT sw Locations 6 27 7002 xxx Fax card Fax card connector pins meme 000000 ome So Si Sit 8 Gm J69 on fax card 6 28 Service Manual 7002 xxx 7 Preventive maintenance This chapter describes procedures for printer preventive maintenance Following these recommendations can help prevent problems and maintain optimum performance Safety inspection guide The purpose of this inspection guide is to aid you in identifying unsafe conditions If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard 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 e Possible safety exposure from any non Lexmark attachments Lubrication specifications No requirements for this printer Scheduled maintenance Maintenance kit The operator panel displays the message 80 Scheduled Maintenance at each 300K page count interval It is necessary to replace the fuser assembly transfer roller charge roll and pick tires at this interval to maintain the print quality and reliability of the printer The parts are available as a maintenance kit with the following part numbers Maintenance kits 115 V Maintenance
151. DF unit as a customer would observe them no printing is involved scan data is being forwarded to some other section of the unit hard drive or network for example Resolution 1200 1200 dpi 2400 Image Quality 1200 Image Quality 600 x 600 dpi General information 1 3 7002 xxx Data streams PostScript 3 emulation PCL 6 emulation PPDS migration tool PDF v1 5 emulation Memory configuration mem o M PS Lexmark X64e Lexmark X646e Standard DRAM MB T Optional memory MB 128 256 and 512 available One slot 100 pin DDR SDRAM unbuffered DIMMs Optional flash memory MB 32 and 64 available N A Note One firmware card and one flash memory card are supported Either slot supports both card types 20GB Depending upon the options and features used additional memory may be required to optimize performance Recommended operating clearances LLL NN Allow clearance above the printer front door clearance and for adding options such as additional input drawers 1 4 Service Manual 7002 xxx Dimensions ome m mm mm umo Lexmark X644e 28 0 in 22 0 in 25 4 in 83 0 Ib 710 mm 560 mm 645 mm 37 7 kg Lexmark X646e 28 0 in 22 0 in 25 4 in 84 5 Ib 710 mm 560 mm 645 mm 46 7 kg Lexmark X646e with duplex and 35 0 in 22 0 in 26 0 in 103 Ib 500 sheet option 890 mm 560 mm 660 mm 46 7 kg Duplex 500 page option 0 in 15 7 in 24 1 in 11 3 Ib 51 mm 398 mm 595
152. Diagnostic aids 3 15 7002 xxx DEVICE 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 To run the Quick Disk Test 1 Touch gt to select Quick Disk Test from DEVICE TESTS The power indicator blinks while the test is in progress and quick Disk Test lesting displays e Quick Disk Test Test Passed message displays if the test passes and the power indicator turns on solid e Quick Disk Test Test Failed message displays if the test failed and the power indicator turns on solid 2 Press Stop e 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 Also note that this test may run approximately 112 hours depending on the disk size To run the Disk Test Clean Test 1 Touch E to select Disk Test Clean from the Device Tests menu Contents will be lost Continue message displays to warn the user that all contents on the disk will be lost 2 Touch Yes to continue and No to exit If Yes is selected the following screen displays and updates periodically indicating the percentage of test completed FOrmav Grid DTSK 1 1 0 DO NOT POWER OFF The power indicator blinks during t
153. Door hinge nt tt ee eee eee neeee 7 59 Wear plate 500 sheet 2 22 enc eee rer ee eee eee eee rrr 7 55 Pass thru plate 2 22 2 eee eee eee eee eee eee eee eee ee eee eee eee eens 7 55 Plate 250 sheet pass thru r rurrrrrrrrlIIIre 7 53 High voltage power supply O T IIIrIIIrrIIIIIIIIll 7 35 Relocation kit 22 222 ener eer eee ee eee eee ee eee eee eee eees 7 65 Switch activate spring 2 rete eee eees 7 52 7 54 Pick roll assembly 22 2222 e cere entree eee eee ee eee ener e eee 7 52 7 54 7 63 Restraint pad 2 2 n en cere rr eee ee ee eee eee eee eee eee eeeee 7 53 7 55 Plate 250 sheet tray wear 22 eee rere ee ee eee eee eee eee eeee 7 53 Part number index I 13 7002 xxx 99A0263 99A0263 99A0263 99A0263 99A0263 99A0263 99A0272 99A0275 99A0292 99A0447 99A0654 99A0658 99A0675 99A0675 99A0676 99A0676 99A0677 99A0677 99A0681 99A1818 99A1929 Parts packet cect eee e eee eee eet eee eee eee ee eee eens 7 52 Parts packet auto comp assembly mounting screw 55 2255555525555555 7 63 Parts packet auto comp mounting screw 222s e reer terre eee eee 7 54 Parts packet screw 2222s ttt rt eee III 7 54 Parts packet screw auto comp mounting IIII me 7 52 Parts packet screw switch spring
154. ER TESTS and select Sensor Tests Check the ADF exit sensor for correct operation Note You can check the ADF exit sensor by moving the exit sensor flag or by manually feeding a sheet of paper through the ADF If the sensor fails the test go to step 4 Turn the power off and disconnect CN9 on the motor driver card Measure the voltages in the table below Interval sensor interrupter type normally closed Connector CN9 motor driver card CN9 Pin 1 0 V dc CN9 Pin 2 5 V dc N9 Pi Note All voltages are approximate values If incorrect replace the motor driver card If the voltage is correct go to step 5 Turn the power off and reconnect CN9 to the motor driver card Measure the voltages in the table below with the sensor in normal operation sensor closed and with the sensor open sensor flag activated If the voltages are incorrect replace the ADF exit sensor If this does not fix the problem replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 Diagnostic information 2 113 7002 xxx 298 01 Error code service check Scanner missing front side cable unplugged This is the ADF CCD 36 pin ICC cable connected to the ADF CCD ADF CCD cable Check the cable for correct connections to the flatbed interface connector on the rea
155. Error Sub Display text Description Main fan capture data is Corrupted feedback signal Go to Main fan service check on invalid and speed page 2 117 control is at maximum in fan control adjustment Toner sensor error a e Check the toner sensor Go to Toner sensor service problem has been check on page 2 162 detected with the toner Check cable Sensor Check system board Go to Toner sensor service check on page 2 162 An error has been Check toner cartridge e Check toner sensor detected No home windows has been detected 929 67 No toner sensor Check toner sensor Go to Toner sensor service transition Check toner cartridge check on page 2 162 An incorrect printhead Check the printhead Go to Printhead service check has been detected on page 2 161 Printhead lost HSYNC Check printhead Go to Printhead service check Check cables and connections Check system board on page 2 161 933 Mirror motor locked no e Check printhead first HSYNC received Check cables and connectors Go to Printhead service check on page 2 161 e Check system board 934 Mirror motor lost lock Check printhead Check cables and connections Check system board Mirror moor not up to e Check printhead Go to Printhead service check speed Check system board on page 27101 No hall effect detected e Check cable connections Go to Main drive service check at motor start Moto
156. Error code service communications failure check on page 2 114 Service Scanner This error indicates that a problems Go to 843 00 Error code service has been detected with the flatbed check on page 2 115 carriage mechanical hardware Service Image This error code indicates a failure of Replace the scan control card Processing Unit the image processing ASIC SCC See Scan control card removal on page 4 48 Diagnostic information 2 15 7002 xxx Service error codes 8xx xx continued Error Sub code codes Display text Modem Config ID Mismatch Modem Config ID Mismatch Service error codes 9xx xx Error Sub Display text code codes play Feat flash error Engine software error Paperport link driver error Interface violation by RIP Interface violation by Paperport device RIP interface driver error DC pick motor acceleration stall autocompensator motor j 2 16 Service Manual Description There is no modem installed on a modem version of the MFP Modem is present on a no modem version of the MFP Description 947 947 Modem Init Failed Init Failed Defective modem hardware Replace the modem card Indicates that the flash which the system board code is programmed into is bad Replace the system board These errors indicate an unrecoverable system software error These errors indicate an unrecoverable system software error These errors indicate
157. Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Diagnostic information 2 79 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes 202 91 Page did not cleanly exit Page may be jammed in the fuser exit or Make sure the redrive door fuser or redrive area redrive area is complete closed Fuser page count is not Check the fuser for an available signs of wear or d contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 202 92 Exit sensor covered too Page may be jammed in the fuser exit or Make sure the redrive
158. Fuser assembly removal CAUTION Unplug the printer before you begin 1 Remove the fuser wick assembly cover See Fuser wiper cover assembly removal on page 4 54 2 Remove the redrive assembly See Redrive assembly removal on page 4 123 3 Remove the fuser mounting screws A Repair information 4 75 7002 xxx 5 Disconnect the fuser to system board DC cable D from the fuser board Note Be sure to observe the routing of the LVPS to fuser lamp AC and the DC cable 6 Pull the cables free and remove the fuser Installation notes 1 When you reinstall the fuser be sure to route the fuser to LVPS AC cable A through the channel B on the right side frame above the LVPS under the clip C over the LVPS and through the notch in the frame D A B C D 2 Route the fuser lamp cable through the opening in the fuser E 4 76 Service Manual 7002 xxx 3 Connect the fuser to LVPS AC cable to the fuser lamp connector F at the LVPS Note Be sure to connect the fuser to system board DC cable after replacing the LVPS Repair information 4 77 7002 xxx Fuser exit sensor removal Remove the fuser See Fuser assembly removal on page 4 75 Disconnect the fuser exit cable A from the fuser control board Remove the screw B securing the cover containing the fuser exit sensor flag and spring Release the two clips C holding the sensor in the bracket Do IT 5 Unplug the fus
159. Ground On MI CLKTX 5 V dc IN Ground Signal Ground nRES Ground P87 Ground Not used Ground P86 Ground uNMI CLKTX 5 V dc IN Ground J10 to J15 on scan control card BU Co C1 Ground J13 to CN1 on inverter card 8 www 8 se Locations 6 13 7002 xxx LCD inverter board operator panel left cover LN NL NN CN1 to J13 on operator panel card CN2 to touchscreen display USB card operator panel left cover 6 14 Service Manual BACKLITE CONTROL Lamp on off control 3 4 Pi Br acct 0 HV DONOTWEASURE reese 8 Nw 4 8 3 4 5 1 2 3 4 HV DO NOT MEASURE Scan control card O0Oooooooooooooooooooo O0Oooooooooooooooooooo J5 Le Ooooo O0Oooooooooooo OOooooooooooo fees 2 J4 C C2 Scan control card connector pins Connector J1 to CN1 on flatbed interface card 7002 xxx CN pin no MDC DET 25 V dc IN Daven L E EN NN Locations 6 15 7002 xxx Scan control card connector pins continued mem 000000 m Sh J1 to CN1 on flatbed interface card continued om 8 Senet LR Im o0 L3 waeme po J4 Not used Ground VXADF RXD1 a a J7 To hard drive assembly 8 foe Sia 8 5mi 6 16 Service Manual 7002 xxx Scan control card connector pins continued LINE NL NN J12 to hard drive continued a
160. Ha csi 30 TA CSU closing GND gt 3837 i38 37 3 dth ATA DA2 ATA DAD tray width 3039 36 GND 95 ATA DA1 O NI 9 9 Fi 5V a ATA_IRQ HB aged Bg 9No og ATA DMACK ADF WIDTH Sensor paper 2807 log CSEL MASTER 7 ATA_IORDY ADF WIDTH tray length ooa log GND 55 ATA DIOR GND y leng J3 s423 24 GND 33 ATA_DIOW 1 al co lelexl l4 EO C ET A ARQ I ESES Ne ADE LENGTH 1 J4 J12 222i baee 51 ATA_DMARQ 45V IN E 2019 o A D KEY ag GND 8p ATA DD 15 ATA DD 0 l GNE x els 5 ee ns ATA DD 14 i ATA DD 1 1 GND pj 15 Sensor ATA DD 13 ATA DD 2 2 TFT B nADF_EXIT 1413 14 13 45V IN 2L exit sensor ATA DD 12 ATA DD 3 3 LET HSYNC TET BT l END 3 io i ATA DD 11 5 ATA DD 4 4 IET VSYNC TFT B2 GND nRESET 5V IN UM Sensor aa g ATA_DD 10 7 ATA_DD 5 5 E E i 5V IN FAN BACK n2ND SCAN 2 2nd scan 65 GL ATA DDO g ATA_DD 6 6 ET TFT B5 I FAN ONG GND GND 25 atali 4 ATA DDU Ss ATA DDG 2 UE i nHOME nFLAT LENGTH3 5 nADF COVER 714 Sensor 2 1 RE p eee 8 TFT ENAB nELAT LENGTH2 nFLAT LENGTH1 45V IN an ADF cover 9 Tay sw ame ore SCC Scan contr r enn n xi i OUTE OUT B GND can control boa 3 2 1 GND TFT RL OUTnB5 OUT B nJAM REMOVE Sensor jam J 5 iF Go TELID OUTnA OUT A 5V IN AR removal 1 5V SND OUTnA OUT A GND GND anD ncOVER CLOSED nADF PRESENT Sensor Paper ene i 1 2r t 4 GND I LDADF PRESENT 1 GND 5V IN lt u Present 3 BXD45 D
161. Hot roll too cool when Bad thermistor circuit or Go to 920 xx Cold fuser service heating to desired cabling check on page 2 130 temperature after slope change Fuser page Noisy kermisipi signal count more than Fuser not receiving AC power 900 000 Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 56 Fuser is not increasing Fuser is not receiving AC power Go to 920 xx Cold fuser service in temperature even check on page 2 130 though the lamp has Poor supply line voltage been on for an extended time Fuser count more than 500 000 920 57 Fuser has been below Bad thermistor circuit or Go to 920 xx Cold fuser service the desired temperature cabling check on page 2 130 for too long while media is in the nip Fuser page Very noisy Mense signal count more than Fuser not receiving AC power 900 000 Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll Abrupt change in temperatures that has disrupted control 2 22 Service Manual Service error codes 9xx xx continued Error code 920 920 920 920 920 920 Sub codes Display text Hot roll took too long to heat up after transitioning to new enhanced mode Fuser page count not available Hot roll fell too far below desired temperature while printing Fuser page count not available Hot roll too cool while checking for slope change
162. ID The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors The configuration IDs are originally set at the factory when the printer is manufactured however the servicer may need to reset Configuration ID 1 or Configuration ID 2 whenever you replace the system board The IDs consist of eight hexadecimal characters including 0 through 9 andA through F Note When the printer detects a Configuration ID that is not defined or invalid the following occurs e The default standard model Configuration ID is used instead e Configuration ID is the only function available in DIAGNOSTICS e Unless the menu is in DIAGNOSTICS Check Config ID displays To set the configuration ID 1 Touch gt to select PRINTER SETUP from the Diagnostics Menu 2 Touch the keyboard icon to display a keyboard with 1 through 0 and a through f The current values for Configuration ID 1 and Configuration ID 2 are displayed e Use keys to type the numbers for the two configuration IDs e Use the left arrow to move over a digit from the right of the number toward the left e When the numbers are correct touch Submit e f you have a question touch the question mark icon e To exit without changing the numbers touch Back Note Be sure to touch Submit or the number will not be changed Submitting Selection displays followed by the value for Configuration ID 1 Note If Invali
163. ION Remove the power cord from the MFP or wall outlet before you connect or disconnect J any cable or electronic board or assembly for personal safety and to prevent damage to the MFP CAUTION Use the handholds on the side of the MFP Make sure your fingers are not under the MFP when you lift or set the MFP down Note Some removal procedures require removing cable ties You must replace cable ties during reassembly to avoid pinching wires obstructing the paper path or restricting mechanical movement Scanner ADF and flatbed removals ADF front cover removal 1 Open the ADF top cover 2 Remove the two screws A 3 Release the ADF front cover latch B on the right side under the scanner and then release the latch B on the left side Repair information 4 5 7002 xxx ADF pick assembly removal 1 Grasp the pick assembly and gently push the shaft to the right to free the left side ADF rear cover removal 1 Remove the two screws A 4 6 Service Manual 7002 xxx 2 Remove the screw B on the right side C D Replacement note When replacing the ADF rear cover be sure to align the cables C in the notches D and press the square portions of the cables into the holes Repair information 4 7 7002 xxx ADF top cover removal Remove the ADF front cover See ADF front cover removal on page 4 5 Remove the ADF rear cover See ADF rear cover removal on page 4 6 Open the ADF top cove
164. J UA BG AR A DE y die Rh JJ EASA VE AT EE X a NT PE TA vi e AST ti IED fi IRS RA A FRAN SE A FA ANP in FERN EEN BESS FB A SS 5 TN Se ESTE RT m TEM HR AS vos Ss UG Br T fe A BE REG E NE Wid SRA BITSY WHER CERI m DC Aie Br HLS FE CE WEF BRE BU AP im FY FLUR k BLE we USE GOR BUT ESI A rM PRECAUCI aquest s mbol indica que el voltatge de la part de l equip amb la qual esteu treballant s perill s Abans de comencar desendolleu l equip o extremeu les Safety information xix 7002 xxx Preface This manual contains maintenance procedures for service personnel It is divided into the following chapters 1 ee o e 9 General information contains a general description of the printer and the maintenance approach used to repair it Special tools and test equipment are listed in this chapter as well as general environmental and safety instructions 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 lubrication specifications and recommendations to prevent problems
165. LVPS The voltage should measure approximately 50 V dc If incorrect replace the LVPS assembly If correct replace the system board If this does not fix the problem replace the interconnect card assembly Fuser board to system Make sure the cable is connected properly to the system board and board cable fuser control board Reconnect the cable if necessary If the cable is connected correctly go to step 5 Fuser assembly If no problems were found in steps 1 through 4 replace the fuser assembly See Fuser assembly removal on page 4 75 Diagnostic information 2 137 7002 xxx High capacity feeder input tray service check Note Voltage measurements in the high capacity feeder input tray service checks must be made with the high capacity feeder attached to the base printer to obtain accurate results Service tip Be sure the paper size switch is set to the correct paper size setting and the rear paper guides are in the correct locations for the size of paper installed in the high capacity feeder tray Service tip Check the other paper sources to be sure they are operating correctly The base printer indicates a dead machine condition when the high capacity input tray is installed AC line cord If the base printer works normally using the AC line cord from the AC AC jumper HCIT to printer wall outlet and does not work when using the AC jumper from the AC input and output HCIT check the AC jumper cord If defective replac
166. Note This action is not available if the printer is in Diagnostics Mode or running diagnostics e f the device is experiencing a hardware problem turn the printer off and on The standard output bin is full of print media Remove the stack of print media from the bin to clear the message and resume printing Touch Continue to make the MFP recheck the output level in the standard output bin One or more messages which interrupted a scan job are now cleared Replace the original documents in the scanner to restart the scan job Touch Cancel Job if a scan job is processing when the attendance message appears This cancels the job and clears the message Touch Scan from Automatic Document Feeder if the page jam recovery is active Scanning resumes from the ADF immediately after the last successfully scanned page Touch Scan from flatbed if page jam recovery is active Scanning resumes from the flatbed immediately after the last successfully scanned page Touch Finish job without further scanning if page jam recovery is active The job ends at the last successfully scanned page but the job is not canceled Successfully scanned pages go to their destination copy fax e mail or FTP Touch Restart job if job recovery is active and the job can be restarted The message clears A new scan job containing the same parameters as the previous job starts The MFP detects that the fuser wiper needs replacing 1 Replace the fuser wi
167. Nyogel 744 grease packet rrrrrrrrrrrIII e 7 65 Wear strip r ruurrrrr rrr eee eee eeeee 7 27 Plate 500 sheet tray wear r rrrrrr rrr rrIII e 7 27 EP duct rurrrrrr ee eee eee 7 11 Blower duct 2 222 s sent eee eees 7 11 Gear 60 MPF shield 2 2 2 eee nen ee eee nee 7 11 Tray bias assembly 2 2 2222 seen rte eee eee III 7 11 HPVS input sensor toner sensor cable assembly 7 11 7 35 7 40 HVPS input sensor toner sensor cable assembly 7 43 LVPS to system board cable assembly rm ee 7 43 Right side hand holder 22 22 22 sneer eee eee eee eee eeeee 7 7 Fuser AC to fuser lamp cable 2 2 2 eee nee eee eee eee eeeeee 7 31 7 45 Parts packet fuser mounting screw rrrrIIIIIIme 7 31 Narrow media sensor cable 222 22 eee eee eee eee eens 7 31 Exit sensor cable 2 22 22 nr eee eee eee eeee 7 31 Redrive door assembly 500 sheet rrrrrrrIIree 7 9 Exit narrow media sensor cover ruurrrrrr rre 7 31 Narrow media flag spring kit T TTTIIIIIIIIIIee 7 31 Exit sensor flag spring kit
168. OD AURORA RR CORR A 5 1 BEDS aa ee ee FREE oe ek TE OE ea scs d T ET 5 1 I ING poc ek ae oe as a a ew es Ree ees 5 3 GO og cate one E E 4 Ed E E ee ee ee eb bss ees 5 3 les PTT gta aed es 5 8 PIENE iG oo oo a ed Oy di eprdcpRITEA ISTRCORCPRRQC PRIGeIEqQ ePSq 4 Rer bese 4 5 9 Migh voltage DOWET SUDO cei cs dd o 6b sb sdk e ER EO rh OS iE CRI ied do 5 9 DEINER OSA oy bh oo ie ey we eX PYWeRPIR Ok Re Oe yard eee meer vq dics 5 10 LOW VO PONOT SUDI Leg git hss ed be be Oe eee ee 5 11 Operator panel card part of operator panel right cover assembly 0 0 00 cee eee ee 5 12 LCD inverter board operator panel left cover 0 ccc eee eens 5 14 USB card operator panel left cover 0 0 ee eee eee nes 5 14 Ot er rm 5 15 Per ae e ceca dcke dese bees ness donne nae REIS ee bane reas E acne EARS TI 5 20 ee tS el 36 o oo bog oho 6 4 oboe ob oa ee eo ne 64 Ore be Se oe oe eee 5 24 POE DB eta oe dade d ap E ed dole eee RC UR CR a a Oe tea elena 5 28 Preventive maintenance 000 cee es 6 1 Safely INSUECIION GUNG cis doe cree ee eee ee Ree ee coe ee caw as 6 1 Lubricalion SpocificatiohS 26 64 5545 e exon eee RO sakes eee acc seen es Wieden oe See ee oes 6 1 Sseheduisd MAMNGNANCE uaa acd ded EO cand NER CAO ee D e X ERR HC CR dae OR COR RR 6 1 IPH LE Gl 4 ee oe EAEE ee eee eee ee re er ee ee eee ee ee 6 1 Cleaning the scanner glass and flatbed white cushion ees 6 2 gen
169. Re OO Oe eee aes 2 12 SUMDIOIEI IQS 6456064500450 Rab RC CRI RCR ER a e ee eee ee ews 2 13 EIS NICE SON au oorr ss oS SS SS E E RP ERPER ERE E AU ed 2 13 Scanner Talbegd SUmbpIONIS sq pe bss dar det eh o Ree CR ORE RUDOROR OR OR EWES 2 14 High capacity feeder 2000 sheet symptoms ee eee es 2 14 Peter ee lite Attori 2 14 DUPE ON OH SVC io bene pU haute dees bees eee s TUER PUES 0998 419 408 EORR RUP 2 14 SCanNEr ADr SWTDIDITIB 4 004 auqa sud GHG Nu OE SEEDS HSS GOSS REO KOSS Edere an d aum 2 14 EnVelbDE TORO SMO ON aauciqias aq dered des ah be A dae ep 0546 PPP 00556 candace ees 2 15 Messages and error COQS iscuequaneesexescamews Oe Xe tirria KA a E CIRCA OR 2 15 i gan go kV od p EA d IDEE dor dob ce Qs RT DUAE 064 2 15 Sub error codes for 8xx 9xx and 2xx errorcodes 2 eee 2 15 lg eh areq ed rVRTdUEEEUPERQUERERNUPCRVCREIMEUPS PURPURAE SN RSS S E 2 39 User attendance messages ee en ee eee eee ees 2 43 User ine 2 link message hecosum aer C sete seb EREG4dCPE GE ded heb Sr 05405 beds 2 57 Check device connection MESSAGES 2 ee ee eee ees 2 57 User attendance messages paper jams and paper handling errors 2xx xx ee 2 58 DEPVIEE CBE Look drag FCR ee ee ECCO CR ERR ee ea E E E E eee Wa Indc Rn OR 2 95 290 00 Error eode service CHECK LooosoesbrrRRERWEEYTRERRXe 9TLPRREERRAZTZemSEX uzx4uGu 4e4 2 95 290 01 Error code service check 42941 w27 owed HERE dw e oben ebb ied dasa dseestes
170. Reset Active Bin to change to another linked bin Occurs when the MFP receives a manual feed request that specific print media be loaded into the multipurpose feeder The print media is previously defined as a custom type from Custom 1 through Custom 6 The custom type name appears on the control panel Touch Continue e If print media is in the multipurpose feeder the job continues to print e f there is no print media in the multipurpose feeder all requests for additional pages are automatically overridden and print media is selected from an automatic source Touch Cancel Job to cancel the current job if needed Touch Reset Active Bin to change to another linked bin Diagnostic information 2 47 7002 xxx User attendance messages continued Sub code Error Primary message code y g Load manual feeder with size Load manual feeder with type size Load src with Custom String Load Srch WTN Custom Type Name Load src with size 2 48 Service Manual Description action Occurs when the MFP receives a manual feed request for a specific size of print media when none is loaded into the multipurpose feeder Feed a sheet of print media into the multipurpose feeder to clear the message and continue the job Touch Continue if print media is in the multipurpose feeder The job continues Touch Continue if there is no print media in the multipurpose feeder All requests for additional pages ar
171. Scanner right side cover removal on page 4 12 Remove the scanner left side cover See Scanner left side cover removal on page 4 9 Remove the three screws A that attach the hinge support bracket to the rear scan bracket mo a l 5 Remove the two screws B from the top 6 Remove the two screws C from the left side and right side T Remove the two screws D from the left bottom and right bottom Repair information 4 41 7002 xxx 8 Push the flatbed CCD toward the motor to take tension from the CCD belt 9 Unhook the CCD belt from the motor shaft hi j f LUE E i s dL UNE Ao V 10 Carefully lay the flatbed CCD module on the scan frame being careful not to touch the card lamp or mirrors 11 Remove the three screws E that attach the FB scan motor assembly to the frame 4 42 Service Manual 7002 xxx 12 Remove the flatbed scan motor assembly Repair information 4 43 7002 xxx Hard disk removal 1 Remove the printer left side cover See Printer left side cover removal on page 4 56 2 Remove the six screws A from the SCC and HDD shield 2 3 ia w 2 eoeereseercecope _ Pc eereeevreeee she Neetc5seeeeecocoscj sa l a on os LE ee oonpoOODE sc 700808 2 99 8088 7 7 70080QDE S29 2700000008 E Se 70080808 D alea rc 799
172. Se N N p Lexmark X644e X646e MFP Service Manual 002 xxx e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index LEXMARK 7002 xxx Edition January 16 2006 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 D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServicelnfoAndTraining o 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 You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of purchase Lexmark Lexm
173. The MFP detects a serial error such as framing parity or overrun on the specified optional serial port x is the number of the optional serial port 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 Touch Continue to clear the message and continue processing the print job however the print job may not print correctly Turn the MFP off and then on to reset it The MFP firmware detects an installed network port but cannot establish communication with it Touch Continue to clear the message and continue printing The job may not print correctly The MFP disables attempts to communicate through the network interface No data may be sent or received Reset the MFP Program new firmware for the network interface The MFP detects an unsupported option in the specified slot x indicates the number of the specified slot 1 Turn the MFP 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 MFP on A status request occurs over the parallel port but the parallel port is disabled Touch Continue The MFP discards any data received on the parallel port Touch Reset Active Bin to reset the active bin for a linked set of bins The MFP receives data across a seria
174. after loading them Make sure the guides in the trays are properly positioned for the size of print media you have loaded Make sure the guides are not placed too tightly against the stack of print media e lf ajam occurs clear the entire media path Tools required Flat blade screwdrivers various sizes Phillips screwdrivers various sizes 7 32 inch open end wrench 7 0 mm nut driver 5 5 mm wrench Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax serial debug cable 1381963 Flash light optional 1 16 Service Manual Acronyms ADF AlO CCD CRU DIMM DRAM DVM EDO EEPROM EP EPROM ESD FRU GB HCIT HVPS ITC LASER LCD LED LES LVPS MDC MFP MPF MROM NVRAM OPT PC PIN PJL POR POST PP PPM PWM RIP ROM SCC SDRAM SIMM SPM SRAM SSC Vac V dc VOM 7002 xxx Automatic Document Feeder All In One Charge Coupled Device CCD Customer Replaceable Unit Dual Inline Memory Module Dynamic Random Access Memory Digital multimeter Enhanced Data Out Electrically Erasable Programable Read Only Memory Electrophotographic process Erasable Programmable Read Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte High capacity Input Tray High Voltage Power Supply Internal Tray Card Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light Emitting Diode Lexmark Embedded Solut
175. ail Shortcuts Manage FTP Shortcuts Manage Profile Shortcuts 2 12 Service Manual Network Ports TCP IP IPv6 E mail Server Setup Address Book Setup Wireless Standard Network Network lt x gt Standard USB USB lt x gt Standard Parallel Parallel lt x gt Standard Serial Serial lt x gt NetWare AppleTalk LexLink 4 4 4 Back Settings General Settings Copy Settings Fax Settings E mail Settings FTP Settings Print Settings Security Set Date and Time Help Print all guides Copy guide E mail guide Fax guide FTP guide Information guide Print defects guide Supplies guide 7002 xxx Symptom tables Base printer symptoms Go to Dead machine service check on page 2 123 Touchscreen panel blank LED is on Go to LCD touchscreen display service check on page 2 146 Touchscreen all white Go to LCD touchscreen display service check on page 2 146 Touchscreen icon buttons do not work Go to LCD touchscreen display service check on page 2 146 LCD backlight unable to change LCD Go to LCD backlight on page 2 147 touchscreen backlight Operator panel none of the buttons work Replace the operator panel right cover assembly See Operator panel right cover assembly removal on page 4 62 Operator panel one button does not work Replace the operator panel right cover assembly See Operator panel right cover assembly removal on page 4 62 Op
176. al interface card r rrrrrrrIIIIIIre 7 65 Parallel 1284 B interface card urrrrIrrrlIIIe 7 65 Power cord set 8 ft right angle rrrrrIIIIIIIIIIIIIIIe 7 35 Power cord set Denmark Norway and Sweden e 7 35 Power cord set lsrael uurrurrrrerrrIIrrIIIe 7 35 Power cord set AS NZ r eurrerrerrrrrrIrIIIIIIIIIIIe 7 35 Power cord set Japan lt 22sec cence es eee eee eee ee eee eee eee eee een eee eeees 7 35 Power cord set PRO 22 2 e nnn rr eee eens 7 35 Power cord set Botswana Lesotho Namibia Pakistan and South Africa 7 35 Power cord set Switzerland 222 2 e scene etree eee eee eens 7 35 High voltage contact kit 22 22sec eee e een tee eee ee eee eee eee eens 7 11 Multipurpose feeder pick arm assembly with solenoid e 7 23 Left side hand holder 22222 cess cece eee ee eee eee nee eee nee eee eens 7 7 Complete ADF assembly 2 222 essere n eee eter eee eee eeeee 7 5 Document tray assembly 222 cess eee eee et eee eee ee tees eee eee een eee eeees 7 5 ADF top cover assembly 2 2 2222 cece cence ener eee eee eee eee eee eee eens 7 5 Pickup assembly 22222 e cece r ct ct reer ee nee eee eee eee eee eeeee 7 12 Reverse roller with clip
177. alibration System board Replace the system board See failure System board and inner shield removal on page 4 125 NVRAM mismatch Go to 950 00 through 950 29 EPROM mismatch failure on page 2 118 or go to 950 30 through 950 60 EPROM mismatch failure on page 2 119 Diagnostic information 2 35 7002 xxx Service error codes 9xx xx continued Error Sub E Display text Description 2 36 Service Manual Replace the system board See System board and inner shield removal on page 4 125 Warning When replacing any one of the following components Operator panel right cover assembly System board assembly e Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more 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 Service error codes 9xx xx continued Error Sub Il Display text Description 950 30 Service NVRAM EPROM mismatch failure 60 mismatch 952 NV failure n CRC error
178. an unrecoverable system software error These errors indicate an unrecoverable system software error These errors indicate an unrecoverable system software error e Check autocompensator cable connectors e E autocompensator for binds D es motor excessive Check system board Check autocompensator motor DC pick motor Check system board underspeed error Check autocompensator DC pick motor Check system board overspeed error Check autocompensator Check to see if a modem card is installed in the MFP If no modem is installed install a modem card If the modem is installed go to 848 00 Error code service check on page 2 116 Hemove the modem that has been installed as this MFP does not support a modem Go to 900 xx Error code service check on page 2 116 Replace the system board See System board and inner shield removal on page 4 125 Replace the system board See System board and inner shield removal on page 4 125 Replace the system board See System board and inner shield removal on page 4 125 Replace the system board See System board and inner shield removal on page 4 125 Replace the system board See System board and inner shield removal on page 4 125 Replace the system board See System board and inner shield removal on page 4 125 Go to Paper feed service check base printer on page 2 152 Go to Paper feed service check base printer on page 2
179. ap tests 3 10 part number index 2 9 parts catalog 250 sheet paper drawer option 7 52 250 sheet paper tray option 7 53 500 sheet paper drawer option 7 54 500 sheet paper tray option 7 55 cabling 7 40 7 41 7 42 7 44 7 46 7 48 7 50 7 51 covers ADF scanner 7 4 covers base printer 7 2 drives main drive and developer drive 7 28 duplex option 7 56 electronics card assemblies 7 36 power supplies 7 34 shields 7 38 envelope feeder 7 57 frame 1 7 6 frame 2 7 8 frame 3 7 10 high capacity feeder 7 58 7 60 7 62 7 63 hot roll fuser 7 30 integrated paper tray 500 sheet 7 26 kiosk vertical and horizontal paper adapters 7 64 optional 250 sheet paper drawer 7 52 optional 250 sheet paper tray 7 53 options 7 65 paper feed alignment 7 24 autocompensator 7 21 multipurpose feeder 7 22 printhead 7 20 scanner ADF lower exit guide assembly 7 14 scanner ADF motors and belts 7 15 scanner ADF paper feed 7 13 scanner ADF pickup 7 12 scanner ADF sensors 7 16 scanner flatbed 7 18 transfer charging 7 32 pass thru plate 4 70 pick rolls integrated tray autocompensator 4 101 pick tire integrated tray autocompensator pick roll 4 101 MPF 4 113 power takeoff shaft and spring 4 121 PPDS Emulation 3 28 preventive maintenance 6 1 print quality pages 3 7 3 27 print registration 3 5 printhead adjustment 4 2 parts catalog 7 20 removal 4 122 service check 2 161 Q quality pages 3 7 3 27 Quick Disk Test 3 16 Quick Test 3 6
180. aper deflector anaana rrr 4 112 Pete PAL ye ae heard eee de dua Be ad be ee ee eee ee a ee idu add 4 113 MPF solenoid assembly TEImoVal 5223 i450 6655 Ee Rao oS 55554934006 5R SSS es 4 114 Paper alignment assembly removal 6 06543 0600 Dean EROR RC SCARE P ORC C ORC e n 4 117 Paper bin full sensor flag removal 4 534 3 4 199339 199 EFC 409 he R9 HP AOV HECHO d 4 119 Paper size sensing board removal ouod dcc ORCI OE Bee Oe bdo 3 d d EROR EO o 9 4 120 Power takeoff shaft and spring removal celles 4 121 Pamer ourse TEITIOVAL ave doy eC REESE Were AeEsVAse esidescecseraisees 4 121 xisi obine Me ob DEEST 4 122 Redrive assembly removal 4 c lt a6 5 lt 056 666 66554 5565655 609 6 o9 3C o BAERS ERODE CAU SOR a 4 123 Signature button contact assembly removal 0 0 cc ee eee ee 4 124 System board and inner shield removal 0 00 cece eee eee ee eee eens 4 125 JOHNS SSRSBPTERIDVBN 46546454 46S end 64 oho oe oe ee ee ee ee UK es 4 126 Transiter TolPassembly removal 64 6 lt k 4 esis 50 0 inire 556 low Ss 645 ORC 5455945465 RRM 4 126 Upper cover removal base printer 0 0 0 cc ee I 4 127 Upper front cover hinge assembly removal 0 0 ccc eee eee eens 4 130 Upper paper deflector assembly removal 0 ce eee ees 4 132 Oe Sees doe E Ope 4 133 Locations and connections 00 cee es 5 1 LOCHIONS cse2e ee cee k beso seed OR ub Kore
181. ard If data is being written the voltage measures approximately O V dc If incorrect disconnect the cable from J19 on the system board and check the voltage on J19 1 The voltage measures approximately 5 V dc e If incorrect replace the system board If correct replace the signature button cartridge contact assembly Diagnostic information 2 161 7002 xxx System board service check Warning When replacing any one of the following components e Operator panel right cover assembly e System board assembly e Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more 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 Toner sensor service check Service tip Check the print darkness menu setting before checking the toner sensor This service check is intended to be used when a 929 xx Service Error displays Developer drive assembly Incorrect operation of the developer drive assembly can cause the printer to display a 929 xx er
182. ark with diamond design MarkNet and MarkVision are trademarks of Lexmark International Inc registered in the United States and or other countries PrintCryption is a trademark of Lexmark International Inc 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 12G9633 7002 xxx Table of contents BE r gpl p xi Ug ited Lie EET TITO TOi QI ee ee xvii Oe aa uw er RR E Few RUN bee wr eae ee UCRORT SUR eee eh eee ae UC ORC R ee ee XX Boar e hs ee ee ee ee oe oe he eee a V XX General information cure ewe Va M ol do EORR MCN OR Ge 96 Bi ERE Ee ee eee enone ss 1 1 Configured modelS susce qb eA d oa pa poh skate A CR eee been h be eee hes ee bena ee hae PR ure os 1 1 soi UT 1 2 Maintenance AHPAC uk doe Sob d WC EGRE RR dC PORC MO ORAE De HICR SCA AR OR CR CR C c S n a RU e io a 1 2 cisco lier Sle ht es wo a oA m PE 1 3 DUBBI uude due Some d qub the nee ese bbe barkee reo a ee ne aeteend hia Ebr aie i eis 1 3 Pee RTO MWST p E eee eae eee reed eee ee OE 1 3 BOCE 214 403 3 22 24 3006 0 4 4 X aan hE ae eae Hane do de ioi T 1 4 re rM 1 4 Recommended operating clearances cles 1 4 DUNS 2 atrcenea eee oe eee aces Ghee sete ERAS r
183. ary Left side charge roll link Check the left side charge roll link assembly for correct assembly operation Check for damage to the arm or bearing assembly Right side charge roll link Check the right side charge roll link assembly for correct assembly operation If incorrect replace the charge roll link assembly with the PONE goare TONDA ese charge roll link assembly kit If correct check the right charge roll link assembly bearing for signs of wear or contamination Excessive contamination could cause intermittent charging of the charge roll If incorrect replace the link assembly Check for continuity of the right link assembly from the bearing to the charge roll high voltage contact on the right side frame If incorrect replace the link assembly Make sure the charge roll bushing is installed and operating correctly Note The screw that attaches the charge roll lead to the contact must be secure Diagnostic information 2 121 7002 xxx Cover closed sensors service check flatbed Note Check for correct installation of the sensor cable before proceeding with this service check Note Both the cover closing sensor A and the cover closed B sensor are located in the ADF assembly A B Flatbed cover closing and Enter the Diagnostics Menu turn on MFP while holding 3 and 6 flatoed cover closed select SCANNER TESTS and select Sensor Tests Check for sensors correct operation of the senors by opening and closing th
184. atched Make sure the duplex duplex input sensor but ani assembly rear door is did leave the printer exit ae d Not iumenonng properly latched sensor Check upper redrive et a systelH HORMONE diverter and diverter spring for any signs of damage a Printer and duplex not aligned loose spring or binding parts Repair the redrive as necessary Check duplex unit for correct installation and alignment to the printer If available try another duplex option If none is available go to 232 xx Jam displays on page 2 126 233 Paper failed to make Duplex rear door not fully latched Make sure the duplex duplex doublefeed assembly rear door is sensor during suis i system not working properly latched turnaround If available try another duplex option If none is available go to 233 xx Jam displays on page 2 126 234 Paper did not arrive at Duplex rear door not fully latched Check the media coming from duplex exit sensor the printer to the duplex option a system not working is not damaged or skewed If l the media is not damaged or Severely skewed media coming from skewed try another duplex the printer option if available If not available replace the duplex option after several attempts replace the duplex option If the tests pass retry to feed from the printer through the duplex option If the problem is still present replace the 235 Paper reached the Double feed separated in duplex e Remove the two shee
185. ation on the Charge roll link arm outer edges that correspond to the bands on the page Check the charge links and arms for proper operation binds or incorrectly mounted counterbalance springs Repair or replace as necessary 3 HVPS Check the following voltages at J15 8 on the system board e Printer Idle J15 8 measures 0 V dc e Printer Printing Test Page J15 8 voltage changes from 0 V dc to 4 V dc If the voltage does not vary check the continuity of line J15 8 in the front cable harness If there is no continuity replace the cable harness If there is continuity replace the HVPS If this does not correct the problem replace the system board Turn the printer off and check the resistance between J15 7 and printer ground The resistance measures approximately 0 ohms If incorrect make sure the system board is mounted correctly and securely grounded If correct replace the system board Print quality residual image Service tip Install a new print cartridge if available before doing this service check Residual image can be caused by the photoconductor cleaning blade and other parts inside the print cartridge Hot roll fuser assembly Check the fuser assembly for toner contamination The hot roll especially might cause toner to be retained and deposited on the page Diagnostic information 2 159 7002 xxx Print quality light print Service tip Check the toner saver and print darkness settings first if the prin
186. ator panel right cover assembly Installation note Be sure the latches D on the top of the operator panel right cover are fastened into the upper front cover hinge slots Repair information 4 63 7002 xxx Touchscreen bezel removal 1 Open the printer upper front cover 2 Usea small screwdriver or other small tool to carefully release the two tabs under the touchscreen bezel Warning Be careful not to scratch or mar the touchscreen bezel Warning Be careful not to scratch or mar the surface of the bezel 3 Remove the touchscreen bezel LCD touchscreen removal 1 Remove the operator panel left front cover See Operator panel left cover assembly removal on page 4 61 2 Remove the two screws A on the operator panel right front cover 4 64 Service Manual 7002 xxx 3 Lift the operator panel right cover assembly carefully to access the cables Warning Be careful not to tear or break the small ribbon cable from its connector B 4 Disconnect the cables C from the UI control card 5 Disconnect the cable D from the LCD inverter card assembly t TE LL e P Poe Pes peo EA i Hn MEET 6 Remove the touchscreen bezel See Touchscreen bezel removal on page 4 64 Repair information 4 65 7002 xxx T Press the two tabs E that limit range of motion and rotate the LCD touchscreen up until it disconnects 8 Setthe LCD touchscreen aside Warning Avoi
187. ature even though the lamp has been on for an extended time Fuser page count between 400 000 and 499 999 Fuser has been below the desired temperature for too long while media is in the nip Fuser page count between 400 000 and 499 999 44 Hot roll too cool when heating to desired temperature after slop change Fuser page and 499 999 Description Bad thermistor circuit or cabling Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Fuser is not receiving AC power Poor supply line voltage Bad thermistor circuit or cabling Very noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll Abrupt change in temperatures that has disrupted control 7002 xxx Go to 920 xx Cold fuser service check on page 2 130
188. autocompensator gear bind or failed controller card Paper jam around autocompensator faulty motor cable faulty motor autocompensator gear bind or failed controller card Replace the duplex option Replace the duplex option Replace the duplex option Replace duplex option Replace the duplex option Replace the duplex option Check duplex sensor cables for correct installation If no problem is found with the cables replace the duplex option Check for jam in tray Check for overloaded tray Check pick assembly and controller card Check for jam in tray Check pick assembly and controller card Check for jam in tray Check pick assembly and controller card Diagnostic information 2 85 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes Page did not reach input If source is tray 1 possible causes sensor include e Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor Page was not properly picked from tray 1 Page was not properly picked from tray 1 Edge locking Worn or contaminated pick tires Overfilling of tray past the fill line Page was not properly picked from tray 1 Edge locking Worn or contaminated pick tires Overfilling of tray past the fill line Failure to feed possible causes include Edge locking Wor
189. ay be jammed in fuser exit or long Fuser page count redrive area between 100 000 and 199 999 202 13 Page is covering narrow f page is not visible from front or rear media sensor during warm up Fuser page count between 100 000 and 199 999 of the machine partial piece may be torn off in the fuser covering the narrow media sensor e The narrow media sensor or flag may be dislodged or damaged 2 70 Service Manual Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output o
190. bed white cushion 2 22 2 e terete ener eee eees 7 19 Upper cover assembly 2 2 2222 ee en eee eee eee 7 3 Upper tray cover paper support IIIIIIIIIIMMIIIIIIIII 7 3 Upper sub cover assembly rrrrrrrrrrrrrIIIIree 7 3 Left cover assembly ruruurrrree rrr eee eee eee eeeee 7 3 Right cover assembly r r reeurrr rere eee eee eee eee 7 3 Front Cover 2 2 22ers eee eee eens 7 19 Scan cover lt n nr ees 7 19 Cover bezel with Lexmark logo e 7 3 Flatbed CCD module assembly rrrrrIIIIee 7 19 Flatbed CCD drive belt rrRrrRIrrIIIII e 7 19 Flatbed scan motor r rrrrrrrrrr rrr rIIIre 7 49 Scan motor assembly including damper 7 19 Scan motor cable 22 een r rrr eee eens 7 51 Home Sensor 2 2 errr rrr rt rr ee ee en eee eee eee eee eeee 7 19 Parts packet sensors 2222s eet e eter eee e ee eee eee eeeee 7 17 7 50 7 51 Parts packet sensors home sensor 2222s errr teeter treet teers eeeee 7 49 Belts lt 9 22 en ee eee eee eee eeee 7 15 Flatbed contact glass rurrrrr rrr rrrrIIrlII e 7 19 Glass holder assembly
191. belt tension spring toward the motor to take tension from the belt Unhook the belt from the motor shaft Repair information 4 19 7002 xxx 6 Unhook the main CCD guide shaft A from the hole in the right side and slide it out of the way This allows you to access the spring A T Remove the CCD belt tension spring A 4 20 Service Manual 7002 xxx Cover closing actuator removal oe a Remove the scan cover flatbed See Scan cover flatbed removal on page 4 11 Remove the scanner right side cover See Scanner right side cover removal on page 4 12 Remove the scanner left side cover See Scanner left side cover removal on page 4 9 With pliers pull firmly to remove the actuator A Cover closed actuator removal 2 T a Remove the scan cover flatbed See Scan cover flatbed removal on page 4 11 Remove the scanner right side cover See Scanner right side cover removal on page 4 12 Remove the scanner left side cover See Scanner left side cover removal on page 4 9 With pliers pull firmly to remove the actuator A Repair information 4 21 7002 xxx Document tray assembly removal 1 Remove the ADF front cover See ADF front cover removal on page 4 5 2 Remove the ADF rear cover See ADF rear cover removal on page 4 6 3 Remove the two screws A Ww ia E ES 11 T E iL T 4 Disconnect the connector B 4 22 Service Man
192. bles on page 2 13 Locate your symptom and take the appropriate action The following tables are available Base printer symptoms on page 2 13 High capacity feeder 2000 sheet symptoms on page 2 14 Paper tray symptoms on page 2 14 Duplex option symptoms on page 2 14 Envelope feeder symptoms on page 2 15 Service errors 8xx xx and 9xx xx s If a service error code appears while you are working on the machine go to Service error codes on page 2 15 and take the indicated action for that error Service error codes are indicated by a three digit error code followed by a period and additional numbers in the format XXX Y Y In most cases five digits are shown User status and attendance messages e User status messages provide the user with information on the current status of the printer Ready displays on the first line of the display unless invoked and then Power Saver displays If a user status message is displayed go to User status displays on page 2 39 e User attendance messages are indicated by a two or three digit error code that provides the user with information that explains a problem with a print cartridge paper jam option port and so on If a user error message displays go to User attendance messages on page 2 43 and User attendance messages paper jams and paper handling errors 2xx xx on page 2 58 Additional information Understanding the MFP control panel on page 2 2 Menus o
193. but the ID did not pass the verification test To pass the verification test the ID read from the print cartridge must match the ID from the last good print cartridge or the same ID must be read from the print cartridge twice The last good print cartridge ID is stored in NVRAM Diagnostic information 2 51 7002 xxx User attendance messages continued Error Sub Primary message code code y g Description action Unsupported Unsupported cartridge installed Replace cartridge cartridge gt lt X Unsupported Print Cartridge CO D oo N x X Short paper CO C1 Insufficient memory to support Resource Save feature gt lt x Resolution Reduced CO O X Insufficient memory for Flash Memory Defragment operation Co N Insufficient memory to collate job X Co N Insufficient memory some held jobs were lost X Co N Insufficient memory some Held Jobs were lost x x 2 52 Service Manual Error 32 displays when the top cover is closed and an unsupported print cartridge is detected It may take the printer 10 20 seconds to determine if the print cartridge is supported Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10 20 second interval If pages are allowed to print then they are not reprinted once a good print cartridge is inserted If this does not fix the problem go to Signature button assembl
194. card assembly Flatbed interface card 2 114 Service Manual 7002 xxx 843 00 Error code service check Service Scanner flatbed mechanical failure Note Check for correct installation of the home sensor cable before proceeding with this service check Flatbed scanner CCD drive Check to make sure that both of the CCD drive shafts are correctly shafts installed If correct go to step 2 Flatbed CCD module Check to make sure that the flatoed CCD module assembly is assembly ribbon cable connected correctly to both the CCD module and J2 on the scan control card If correct go to step 3 Flatbed CCD module Check the flatbed CCD assembly for any signs of damage and for assembly proper mechanical operation If any problems are found replace the flatbed CCD assembly If the flatoed CCD assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 Flatbed CCD scan motor Check for correct installation of the CCD scan motor cable to both the cable motor and to the flatbed interface card at CN2 Flatbed interface card Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Feed Tests lf the motor does not turn during the scanner Feed Test check for any signs of binds or mechanical problems Repair as necessary If no problem is found go to step 5 Flatbed home sensor cable Check to make sure that the home sensor cable is correctly installed
195. ce messages paper jams and paper handling errors 2xx xx Error SUD Description Possible causes code codes 241 16 Failed to feed from e Paper jam tray 1 Pages in the paper path have been flushed to the output bin e Clear paper jam e Worn pick tires e Check sensor 242 Paper jam near tray 2 e Paper jam Failed pass thru sensor 242 02 Fault reported by options tray 2 Clear all jams Jam declared by a smart device Immediate stop l l l i l Jam declared by a smart device Homing allowed stop Option tray pass thru sensor never became covered Option tray pass thru sensor never became uncovered Failed to pick from tray 2 e Paper jam e Motor or motor cable failure e Sensor failure Fault reported by options tray 2 e Paper jam e Motor failure e Sensor failure Failure to feed Possible causes include e Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor If source is tray 3 possible cause include e Paper path bind when feeding from tray 2 though tray 1 e Damaged PTO shaft Paper jam or failed sensor Paper jam around autocompensator Faulty motor cable Faulty motor Autocompensator gear bind Failed controller card Failed to feed from tray 2 Failed to feed Possible causes include e Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor Check mo
196. ceeding check for the correct paper size loaded in the tray and that the tray has been set to accept the size paper loaded in the tray Paper size sensing switch chart ITC Paper tray size selection X is activated e re ime Jem em m os as Psze2 jsw x x j x gem 2 Ground Ground J 8 jrez sw x x x 83po s 4 jPszs jew x j xXx Jx 4 Tray 1 not recognized as being installed unable to clear Tray 1 Missing message Check Tray 1 for damaged or broken autosize fingers Check for anything that would prevent the autosize fingers from activating the paper activate springs and ITC switches If a problem is found repair or replace the tray assembly If no problem is found go to step 2 Integrated card Check for correct installation of the cable at J26 on the system board autocompensator cable If installed correctly go to step 3 If incorrectly installed install and recheck the printer 3 System board Check the continuity between J26 2 on the system board and ground It should measure approximately 0 ohms 2 154 Service Manual 7002 xxx The printer does not recognize the paper size selected Back restraint Check all the paper size parts for damage or broken parts make sure Side restraint the parts operate correctly If a problem is found repair as necessary Snap in plate If no problem is found go to step 2 A
197. ch Submit to save the change or Touch Back to cancel and return to the Diagnostics Menu The device prints a Quick Test page from the appropriate paper tray While the Quick Test page prints Printing Alignment Page appears on the LCD Quick Test The Quick Test contains the following information e Margin settings e Alignment diamonds at the top bottom and each side e Horizontal lines for skew adjustment e General printer information including current page count installed memory serial number and code level To print the Quick Test page Note Print the Quick Test Page on letter or A4 paper 1 Touch REGISTRATION from the Diagnostics Menu 2 Touch gt to select Quick Test The message Quick lest Printing appears on the display Once the Quick Test Page completes printing the Registration screen displays again 3 Touch Back to return to the Diagnostics Menu 3 6 Service Manual 7002 xxx PRINT TESTS Selections on the screen vary since only installed input sources are listed followed by Printing Quality Test Pages Input source tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options The contents of the Print Test Page varies depending on the media installed in the selected input source Check each Test Page from each source to assist in print quality and paper feed problems To run the Print Test Page 1 Select PRINT TESTS
198. ck on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Service error codes 9xx xx continued Error code 922 922 922 923 923 923 923 923 Sub codes Display text Hot roll timed out in trying to reach the final lamp detection temperature Fuser page count not available After hot roll lamp detection did not roll over to steady state control in time Fuser page count not available Hot roll did not reach operating temperature in time new enhanced control Fuser page count not available Fuser has taken too long to reach desired temperature after increasing interpage gap Fuser page count not available Fuser over temperature Fuser page count between 0 and 99 999 Fuser over temperature Fuser page count between 100 000 and 199 999 Fuser over temperature Fuser page count between 200 000 and 299 999 Fuser over temperature Fuser page count between 300 000 and 399 999 Fuser over temperature Fuser page count between 400 000 and 499 999 Description Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Control code has been lost Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Excessive load on the fuser Fuser no
199. ck USB host front connection Printhead fan Autoconnect Connector Bottom autoconnect 6 8 Service Manual o S Prono so 24 V dc Fuser Board Fuser Board not a FRU 1 OO OOO 06 1 J1 Connector CN1 System board f U O Ke u l O T302 O 7002 xxx J6 Thermistor me 9m Developer PWM 24 V dc Return 24 V dc IN TX Enable TX CUR PWM m B Locations 6 9 7002 xxx Interconnect card re Ce i l i 6 10 Service Manual 7002 xxx Low voltage power supply LINK IL SE NNNM CN1 Fuser lamp AC 1 AC fuser lamp sig gen r L3 z d pB OOOOOO O OOOOOOOOO OOOOOO OOOOOOOOO E OOOOOO OOOOOOOOO OOOOOO OOOOOOOOO Not used AC fuser lamp CN2 DC output Ground 7 24 V dc ZZZLILTTIWKW SS Sw ZZZLLTIIW SS Heat on 5 V dc o feve Locations 6 11 7002 xxx Operator panel card part of operator panel right cover assembly Operator panel card connector pins Connector J3 to touchscreen display 6 12 Service Manual CN pin no X DRIVE 5 V dc IN Y X DRIVE NE NEN Y X 5 V dc IN 3 Gd 7002 xxx Operator panel card connector pins continued J7 Signal Ground Not used Ground Signal
200. ckS 56 242 29 eine ek dob BR 0h o mob eo Rb Rol eee do Rd Rio Ow Row 2 130 920 xx Cold fuser service check a iuoudaec p au seated REDE UR EO ER RC RUE 3e grs 2 130 922 xx Cold fuser check acad oo aana RODA ARX ORES SORUCUC REA LU e B omiit SESE 2 132 Ico Do Hb TuSSr Servie CTIBOK ons eee We Ree SECEDE Ro ACRIOR E I ea e TCR RR IO 2 133 924 xx Hot fuser service check iuo raraid oct E 39 Re ben EHE ORO pad Vo OC n 2 134 925 xx Hot fuser service check iu ened och EGRE RR ICA RR CUR eR CR eee icd Ud 2 134 Fuser OUI sensor sermoe CRGO uda q eee 8490 4990092 974 RU eee ee oa aX ICE Ro CR 2 135 Fuser narrow media sensor service check llle eee 2 136 PUSS solenoid SOVICE CHECK dcus oie op pree oh eee E Eo dopo seh Cri 9 REPTAW SPEYSR PP 2 137 High capacity feeder input tray service check 0 00 ccc eee eee ees 2 138 input sensor service chek auexsce rete Red rd aara AIR Aene ERENER GE 4 Ex dex 2 143 Inipur fray Service OTIBOK iu saw yum t ens i en E ReREE Re EQ AR P SXetqed Puede dac 2 144 Interconmeet card service CHECK euasexa bes i bee bee oboe Oe Riese bbe ree bese ed sys 2 145 LCD touchscreen display service Check 2222s see sense ceased ees estes ER E RR RR 2 146 Mam drive service Chek a re 2 149 Operator panel right cover assembly service check 0 0 eee eee ees 2 150 Options SETWDE Check chose ee 9 de QR d oars ERR UR Me RO eG NIU ae eee eee eee es 2 150 Pre ap icd qoot d eee oh du THEE 3 4 14749
201. ckup arm assembly for any signs of damage or broken parts If a problem is found replace the pickup arm assembly See Document tray assembly removal on page 4 22 Pickup arm solenoid Check the pickup arm solenoid springs to make sure they are springs correctly attached to the jam removal knob pulley If not installed correctly reinstall If installed correctly go to step 3 Pickup arm solenoid Check for any signs of broken or damaged pickup arm solenoid springs assembly springs If either spring is broken or damaged replace the solenoid assembly which contains both springs See Pickup solenoid assembly removal on page 4 48 If no problem is found go to step 4 Pickup arm solenoid Turn the power off disconnect CN5 on the motor driver card Measure the resistance between C5 1 and CN5 2 The resistance should measure approximately 41 0 ohms If correct go to step 5 If incorrect disconnect the solenoid from the solenoid cable on the front side of the ADF near the solenoid and measure the resistance between pins 1 and 2 on the cable attached to the solenoid The resistance should measure approximately 41 0 ohms If incorrect replace the solenoid assembly If correct replace the ADF assembly Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration Motor driver card Reconnect CN5 to the motor driver card and measure the voltage at CN5 1 and CN5 2 The voltage should measure ap
202. cleanly e Exit sensor not functioning correctly Main drive motor not working Page jammed on fuser input guide e Page did not enter or exit fuser nip cleanly e Exit sensor not functioning correctly 7002 xxx If label media ensure front edge meets 1 16 inch requirement Check the fuser for wear or contamination If found replace the fuser assembly See Fuser assembly removal on page 4 75 If media is narrow then turn off first sheet detection In Diagnostics Menu PRINTER SETUP Engine Settings 3 Select 16 and touch Submit The fuser narrow media sensor may not be operating properly Go to Fuser narrow media sensor service check on page 2 136 Check fuser entry guide for toner build up Check fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 75 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Check motor to system board connections Replace the main drive motor Main drive assembly removal on page 4 109 Check fuser entry guide for toner build up Check fuser for wear or contamination if a problem is found replace the fuser assembly See Fuser assembly removal on page 4 75 The fuser exit sensor may not be functioning correctly Go to Fuser exit sensor service check on page 2 135 Diagnostic information 2 61 7
203. cover assembly uurrrrrrrrrrIIIIIe 7 3 TLI ID serial number label blank 7 3 Cartridge holddown spring errr tern eee nees 7 11 Right frame extension 2 2 settee ere eee eee eee eee eeee 7 7 Left frame extension 2 2 nner ee ee eee eees 7 7 Contact RSF ground r urr ee eee 7 7 Upper redrive deflector 2 2 2 een rrr eer eee eee eee eee eee 7 9 Upper diverter spring rrr erre 7 9 Redrive assembly 500 in 500 out 2 2 2 n eee eee ee eee eee eee eee eeeee 7 9 Transfer deflector 2 2 2222 s ence crt eee ee eee III 7 9 Machine mounting pad 2 2 2 nner eer ee eee eee eens 7 11 Signature button contact assembly with cable 7 43 Signature button sensor assembly 222 2 e errr eter eee eee eens 7 11 Toner sensor assembly 22 2 c cece tre rrr cee eee eee eee ee eeee 7 11 Developer support roller T IIIIII I I f1 1 1 1 1 7 11 Upper paper feed deflector T IIIIIII II I 1 7 11 Inner paper feed deflector urrrrIrrrlIIIe 7 11 Input sensor 2 2 een ee errr ee ee ee ee ee eee eee eee eens 7 11 Gear guard 2 2 nn nr eee ees 7 9 ESD shield with
204. ct PIN to lock the control panel which locks both the control panel buttons and the touch screen buttons Once the control panel is locked the PIN entry screen clears and the Lock Device button is replaced with the Unlock Device button Note If an invalid PIN is entered Invalid PIN appears A pop up screen appears with the Continue button Touch Continue The home screen returns with the Lock Device button Diagnostic information 2 5 7002 xxx ee ee Unlock Device 2 6 Service Manual This button appears on the screen when the MFP is locked The control panel buttons and shortcuts cannot be used while it appears and no default copy starts may occur To unlock the MFP 1 Touch Unlock Device to open a PIN entry screen 2 Enter the correct PIN to unlock the numeric keypad 0 9 and the Backspace button on the control panel Note If an invalid PIN is entered Invalid PIN appears A pop up screen appears with the Continue button Touch Continue The home screen returns with the Unlock Device button To open the Cancel Jobs screen The Cancel Jobs screen shows any of the following items under three headings on the screen which are Print Fax and Network print job copy job fax profile FTP e mail send Each heading has its own list of jobs shown in a column under the heading Each column can only show three jobs per screen The job appears as a button If more than three jobs exist in a column
205. d Diagnostic information 2 149 7002 xxx Operator panel right cover assembly service check Operator panel LED off Warning When replacing any one of the following components e Operator panel right cover assembly System board assembly e Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more 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 UICC 18 pin operator panel Check to make sure the cable is correctly connected to J10 on the to scan control card cable operator panel card and to J15 on the scan control card If the cable is correctly connected go to step 2 UICC 18 pin operator panel Check the cable for any signs of damaged or bent pins If incorrect to scan control card cable replace the cable If correct go to step 3 Scan control card 3 Scan control card Measure the voltage at J15 17 and J15 18 The voltage should measure approximately 24 V dc If incorrect replace the scan control card See Scan control card
206. d ID appears the entry is discarded and the previous Configuration ID 1 is displayed on the screen If the process is successful Submitting Selection appears on the display followed by the current value for Configuration ID 2 3 Restart the printer Edge to Edge When this setting is On the text and graphics are shifted to the physical edges of the paper for all margins When the setting is Off the normal margins are restored Parallel strobe adjustment Par x Strobe Adj This setting adjusts the amount of time the strobe is sampled in order to determine if the valid data is available on the parallel port The range of values are from 4 to 6 and the default is O for Par S Strobe Adj Par 1 Strobe Adj and Par 2 Strobe Adj After adjustment of 1 increment the strobe samples 50 ns longer Diagnostic aids 3 19 7002 xxx EP SETUP EP SETUP Fuser Temp d Normal Fuser Page Count 127 Warm Up Time d b Transfer Nd Medium b Print Contrast Medium b The triangles pointing up or down indicate whether there are additional menus Touch the up or down arrows to display these additional menus Note If you make changes touch Submit to make the change effective EP Defaults This setting is used to restore each printer setting listed in EP SETUP to its factory default value Sometimes this is used to help correct print quality problems To restore EP Defaults 1 Touch gt to select EP Defaults from EP SETUP
207. d assembly 40X2793 PRESCRIBE card assembly Modem 40X0507 Modem 30 pin cable O ON NN OD OFF LH CO Note The system board has a label with an board ID and barcode Use the first eight numbers to identify the board with the part number in the table above H QO106000 412000067 Parts catalog 8 37 7002 xxx shields Ics Electron Assembly 22 8 38 Service Manual 7002 xxx Assembly 22 Electronics shields Part Units Units kit eer Description number mach or pkg 40X0150 40X0149 40X0153 40X0152 Outer shield Parts packet INA cover mounting screw PP 40X0165 Parts packet outer shield mounting screw PP 40X0165 Parts packet inner shield mounting screw PP 40X0165 Inner shield assembly INA flat cover blank Ethernet shield blank Parts catalog 8 39 7002 xxx Assembly 23 Cabling diagram 1 HVPS input sensor toner sensor cable assembly 40X0160 MPF sensor cable 40X0264 Output bin sensor cable 8 40 Service Manual 7002 xxx Assembly 24 Cabling diagram 2 Part Units Units kit e Description number mach orpkg 25 1 40X0061 1 1 Laser printhead cable assembly 2 40X0074 1 1 Autocompensator motor cable 3 40X0046 1 1 Paper size sensing board Tray 1 autocompensator paper out low cable Parts catalog 8 41 7002 xxx Assembly 25 Cabling diagram 3 E 1 EC hi cK 8 42 Service Manual
208. d on solid and the final results display To stop the test before completion turn the MFP off CACHE Test This test is used to verify the printer processor cache To run the CACHE Test 1 2 Touch amp gt to select CACHE TEST from HARDWARE TESTS The message CACHE Test Testing displays Then the message Resetting Printer appears The printer automatically performs a Power On Reset POR While the CACHE test executes the power indicator blinks green The following type of message appears CACHE Test lt dHH P UHHHHHE F THEE e 6P represents the number of times the cache has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 e F represents the number of times the cache has failed and finished with errors Initially 0000 displays with the maximum fail count being 99 999 Initially only four digits appear but additional digits appear as needed Each time a test is completed the number of passes and failures increments If the test fails the message Failure displays for approximately three seconds and the failure count increases by one The test continues until all of the printer processor s cache has been tested Once the maximum pass count or fail count is reached the test is stopped the power indicator is turned on solid and the final results display To stop this test before completion turn the MFP off Diagnostic aids 3 9 7002 xxx Paral
209. d remove the metal plate C Set the plate aside A 7 Remove the lower exit guide Installation Be sure to route the cable through the hole E in the front ADF frame Repair information 4 47 7002 xxx Pickup solenoid assembly removal 1 Remove the two screws A 2 Unhook the spring B Note Two springs attach to the same post The other spring should be hooked on first and spring B should be attached on the outside or in front of the other spring 3 Remove the cable from the cable guide 4 Disconnect the connector C and remove the pickup solenoid assembly B C A Scan control card removal 1 Remove the printer left side cover See Printer left side cover removal on page 4 56 2 Remove the six screws A from the SCC and HDD shield 3 a UR v eeeeccorecccocoop e s t Dpcoeoeeceoec70292920 7 p S x HM X e eteceveeeeeeeecess i M 9 A aan eecrriay 79900008 BE 3 9 fe e 0888 ui 370080080 M s 77 600000 6 7 nobpDhOQOsB Prat Ss PPC ras e o 0000008 a 7 2 5 80222202202288 ssee a an a ai5 EB RE 4 48 Service Manual 7002 xxx 3 Loosen the screws for the printer outer shield and slide the shield to the left to allow enough room to remove the scanner control card shield and the hard drive shield LIESS MIL 2 2 gg I I LE som m dh mmm mms p db mom momom um
210. d the fuser assembly for any signs of debris or pieces of paper or media Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Diagnostic information 2 71 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes 202 21 Page did not cleanly exit Page may be jammed in fuser exit or fuser or redrive area redrive area Fuser page count between 200 000 and 299 999 202 22 Exit sensor covered too Page may be jammed in fuser exit or long Fuser page count redrive area between 200 000 and 299 999 202 23 Page is covering narrow f page is not visible from front or rear media sensor during warm up Fuser page count between 200 000 and 299 999 of the printer a partial piece of page may be torn off in the fuser covering the narrow media sensor e The narrow media sensor or flag may be dislodged
211. d touching or placing pressure on the touchscreen Do not handle roughly or drop 9 Disconnect the ground cable You might want to use a pair of pliers and a small flat blade screwdriver m 4 66 Service Manual 7002 xxx Multipurpose feeder lower front cover assembly removal 1 Open the multipurpose tray to a position that allows the left and right tray hinge slots A to align with the D shape mounting posts B Pull upward on each tray hinge to remove the tray from the two mounting posts Warning Be careful not to break or stress the hinges 2 Remove the multipurpose tray lower front cover assembly Repair information 4 67 7002 xxx Left cover handle holder removal Open the left side cover Remove the outer system board shield See Printer outer shield removal on page 4 121 Remove the two screws A holding the top of the left handle holder in place Use the tab B to lift out the left handle holder a odi E Right cover handle holder removal 1 Remove the right side cover See Printer right cover removal on page 4 58 2 Remove the two screws A holding the top of the right handle holder in place 3 Lift out the right handle holder 8858BO5 b Cte Te 258595 5 4 68 Service Manual 7002 xxx Left and right frame extensions Le SY Remove the ADF and flatbed scanner assemblies See Flatbed scan assembly removal on page 4 38 Remove the toner cartridge Turn the prin
212. date stamps e Page counts for most errors e Additional debug information in some cases Model and Event Log Serial number Lexmark X534 jiin x00000000 pr wu Printer information SERIA Panel display Event Lg information when error occurred _ Page count Aiii Petis fragi Bami Sma ip Giles Salt DyT4 1 Bum bep UB Wb TAST3 PEDE WIT E dawn FG ken H oaces M mesa Mh es LLLI mw gt a Sa ung jig A S TEL EAE Tt Peet a8 SCuWXEEN CEE EEEEECEEEPE EE EIE L RRARRERSERSEAERT RATER rere 515 Earliest error code EE TEE EEELEETHTEHHRIER HE E LR HIBHHHIIIHIIIIIEE Next error code E ee The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis To print the event log Touch gt to select Print Log from EVENT LOG Clear Log Use Clear Log to remove the current information in the Event Log This affects both the viewed log and the printed log information 1 Touch gt to select Clear Log from the Event Log menu 2 Touch E to select Yes to clear the Event Log or touch Ex to select NO to exit the Clear Log menu If YES is selected Deleting EVENT LOG displays on the screen 3 22 Service Manual 7002 xxx SCANNER TESTS ASIC Test A pattern appears and ASIC Test Passed displays If xxxxxx displays the test was unsuccessful Press Stop to return to the SCANNER TESTS menu Feed Test To run
213. dium Touch Back to return to Diagnostics Menu Gap Adjust The setting adjusts the minimum gap between sheets Increasing this value may reduce curl of some printed media and eliminate some output bin stacking problems However increasing this value also results in slower overall performance measured in pages per minute The range of values is 0 to 255 and the default value is O Touch Back to return to Diagnostics Menu EVENT LOG Display Log The event log provides a history of printer errors It contains the 12 most recent errors that have occurred on the printer The most recent error displays in position 1 and the oldest error displays in position 12 if 12 errors have occurred If an error occurs after the log is full the oldest error is discarded Identical errors in consecutive positions in the log are entered so there may be repetitions All 2xx and 9xx error messages are stored in the event log To view the event log 1 Touch gt to select Display Log from EVENT LOG Up to three error codes display at a time Touch gt to display additional information if available 2 Touch Back to return to the EVENT LOG menu Diagnostic aids 3 21 7002 xxx Print Log Additional diagnostic information is available when you print the event log from Diagnostics Menu rather than Configuration Menu The Event Log printed from Diagnostics Menu includes e Detailed printer information including code versions e Time and
214. dling ESD sensitive parts on page 4 1 printer where you are working Unplug the printer before you begin or use caution if the printer must CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the AN receive power in order to perform the task Remove any input and output paper handling options from the printer Line voltage Check the AC line voltage If the line voltage is incorrect inform the customer AC line cord Unplug the line cord from the wall outlet and check the line cord for damage such as a damaged plug or cut or damaged cord If incorrect replace the cord If incorrect check the continuity of the line cord and replace if necessary If the cord is correct go to step 3 Diagnostic information 2 123 7002 xxx 5 V dc test point on the system board System board l Features or option installed on the interconnect card assembly LVPS fuse F1 primary power Loads connected to the system board Interconnect card Scanner control card 2 124 Service Manual Check for approximately 5 V dc at the 5 V test point on the system board Note Use care not to short adjacent voltage test points aOOOOO If the voltage is correct Go to step 9 If the voltage is incorrect go to step 4 Check to make sure the LVPS cable is correctly installed at J27 on the system board If not reseat and recheck the voltage at the
215. door long Fuser page count redrive area is complete closed is not available Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 202 93 Page is covering narrow If page is not visible from front or rear Check the fuser and area media sensor during of the printer a partial piece of a around the fuser assembly for warm up Fuser count is page may be torn off in the fuser any signs of debris or pieces of not available covering the narrow media sensor paper or media e The narrow media sensor or flag may be dislodged or damaged 2 80 Service Manual 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes 202 Exit sensor may have Exit sensor assembly Go to Fuser exit sensor bounced Fuser page service check on count is not available page 2 135 202 Never sent the divert command to the stacker Fuser page count is not available
216. duplex option receives the 24 V dc from the base printer for the duplex motors and also converts the voltage to 5 V dc for duplex electronics Duplex chassis grounding is provided from the printer to the duplex option through a ground spring attached to the frame and base of the printer The ground connection is automatically made when the option is installed below the printer The paper input sensor is located in the rear of the duplex option under the input paper guide The paper exit sensor is located on the left frame assembly Option microcode The options are Smart Options or options that have a system board The option system board has a microprocessor that controls the option mechanism A software architecture is provided that controls the option and communicates information such as paper path status sensor status motor status and so on to the base printer 3 38 Service Manual 7002 xxx Paper feed jams By carefully selecting print media and loading it properly you should be able to avoid most paper jams For more information on avoiding paper jams see Avoiding jams on page 1 15 If jams do occur follow the steps outlined in this section To resolve the paper jam messages you must clear the entire paper path and then touch Continue to clear the message and resume printing The MFP prints a new copy of the page that jammed if Jam Recovery is set to On or Auto however the Auto setting does not guarantee the pa
217. e 927 Main fan capture data is invalid and speed control is at maximum in fan control idle state 2 32 Service Manual Description Attempting to POR machine after receiving a 925 01 e 115 V lamp in 220 V printer e Lamp has excessive wattage Attempting to POR machine after receiving a 925 01 Loose connector External blockage of the fan preventing it from turning Bad fan External blockage of fan Fan may not turn due to internal fan problem Loose connector External blockage of the fan preventing it from turning Bad fan Loose connector External blockage of the fan preventing it from turning Bad fan Corrupted feedback signal Fan input voltage may be too low Corrupted feedback signal Fan input voltage may be too low Corrupted or non existent feedback signal Go to 925 xx Hot fuser service check on page 2 134 Go to 925 xx Hot fuser service check on page 2 134 Go to 925 xx Hot fuser service check on page 2 134 Go to Main fan service check on page 2 117 Go to Main fan service check on page 2 117 Go to Cartridge fan service check on page 2 117 Go to Main fan service check on page 2 117 Go to Main fan service check on page 2 117 Go to Main fan service check on page 2 117 Go to Main fan service check on page 2 117 7002 xxx Service error codes 9xx xx continued
218. e Touch Back to exit without changing the value PPDS Emulation This menu item allows the user to enable or disable PPDS emulation data stream When this setting is enabled the following settings are also changed e SmartSwitch settings for each port are turned off e he printer language is changed to PPDS Emulation Users can still switch languages on the operator panel and through the PJL data stream To change the PPDS Emulation setting 1 Touch gt to select PPDS Emulation from the Configuration Menu 2 The panel displays the setting s name in the header and setting s current value gt below the header row Touch lt or P to change the setting The selections are Activate and Deactivate The default is Deactivate 3 Touch Submit to save your change Touch Back to exit without changing the value 3 28 Service Manual 7002 xxx Factory Defaults This setting enables a user to restore all the printer settings to the original factory settings Selections are Restore Base Restore Network or Restore LES Restore LES enables you to remove all Lexmark Embedded Solutions applications LES Network does not appear unless you have a network printer The following settings are not changed e Display language e Settings in the NETWORK PORTS MENU group To reset factory defaults 1 Touch gt to select Factory Defaults from the Configuration Menu 2 Touch E to select either Restore Base Restore Net
219. e Touch Cancel Job to cancel the current job if needed Touch Reset Active Bin to change to another linked bin Occurs when a source is loaded with an incorrect print media size as specified in the Paper Menu Touch Continue Load the specified source that is set for the requested size Touch Automatically select media to override manual requests for Manua Paper and Manual Env for the rest of the print job All requests for additional pages are automatically overridden and print media is selected from an automatic source Touch Cancel Job to cancel the current job if needed Touch Reset Active Bin to change to another linked bin 7002 xxx User attendance messages continued Error Sub Primary message code code y g Load src with type size Reattach envelope feeder Reattach bins XY Reattach Envelope Feeder Description action Occurs when the MFP requests that a specific media source be loaded with a specific type and size as specified in the Paper Menu but the current source contains an incorrect media size and type Touch Continue Load the specified source that is set for the requested size and type Touch Cancel Job to cancel the current job if needed Touch Reset Active Bin to change to another linked bin The MFP detects that the optional envelope feeder is missing between the time the job processes and when it prints Sometime during processing the optional envelope feeder is removed
220. e Power takeoff shaft and spring removal on page 4 121 4 Remove the developer drive assembly See Developer drive assembly removal on page 4 73 5 Lift and remove the cables from the cable hooks B 6 Remove the ground cable screw C Repair information 4 109 7002 xxx T Remove the main drive assembly mounting screws D 2 D C D 8 Disconnect the gear release link E from the hole in the charge roll link F Note Lift the upper front cover to make it easier to remove the link E F 9 Disconnect the main drive motor cable from the main drive assembly 10 Remove the main drive assembly Warning Whenever the main drive assembly is removed from the printer it must be handled very carefully Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage It is also very important not to let any dirt paper staples or other material come in contact with the grease in the gears Note Be sure the main drive assembly gear shaft aligns with the hub on the left side frame when reinstalling the main drive assembly 4 110 Service Manual 7002 xxx MPF arm assembly removal 1 Open the left door pe Remove the MPF lower front cover See Multipurpose feeder lower front cover assembly removal on page 4 67 Remove the MPF lower paper deflector See MPF lower paper deflector on page 4 112 Remove the upper paper deflecto
221. e 3 Disconnect the gear release link A from the hole in charge roll link B Note Lift the upper front cover to make it easier to remove the link A B 4 Rotate the link to disconnect the link from the main drive assembly 5 Remove the gear release link 4 94 Service Manual 7002 xxx High voltage power supply removal working Unplug the printer before you begin or use caution if the printer must receive power in CAUTION There is a danger from hazardous voltage in the area of the printer where you are J order to perform the task 1 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 97 2 Remove the right side cover See Printer right cover removal on page 4 58 3 Disconnect the HVPS cable from the HVPS at connector A 4 Disconnect the transfer roll cable B from the HVPS board Warning Use care when disconnecting the cable from the transformer on the HVPS The cable and connector can be easily damaged d TELLE 299522 2550922 093 ees i ji Repair information 4 95 7002 xxx 5 Remove the HVPS mounting screws C C 6 Slide the HVPS to the left to release the mounting tab from the center pan and remove the HVPS 4 96 Service Manual 7002 xxx Inner paper deflector assembly removal 1 Remove the paper tray 2 Remove the upper paper deflector assembly See Upper paper deflector assembly removal on page 4 132
222. e ADF Flatbed closed and flatbed Check the flatbed actuators for any signs of a broken damaged or closing actuators missing part Replace either actuator if damaged or missing Flatbed cover closed and Turn the power off disconnect the cable to CN7 and measure the closing sensors voltages at CN7 on the card The voltages should measure as shown in the table below Paper length sensor reflective type normally closed scanner assembly If incorrect go to step 2 Connector CN7 motor driver card CN7 Pin 3 CN7 Pin 6 Note All voltages are approximate values If any of the voltages are incorrect replace the motor driver card If the voltages are correct go to step 4 Flatbed cover closing Check continuity of the flatbed cover closing closed sensor cable If closed sensors cable incorrect replace the complete ADF assembly ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 If correct replace the failing sensor 2 122 Service Manual 7002 xxx Cover closed switch cable service check base printer Make sure the toner cartridge is correctly installed and that the right and left cartridge tracks are not loose or broken Make sure the cover closed switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover closed switch spring C
223. e ADF front cover See ADF front cover removal on page 4 5 Remove the flatbed white cushion See Flatbed white cushion removal on page 4 31 Turn the ADF assembly upside down carefully supporting the unit Open the lower exit guide dE a ey Remove the four screws A and the two small screws B securing the ADF CCD module assembly T Remove the ADF jam tray sensor C from the mounting bracket to protect it from being bumped or damaged during removal of the ADF CCD module assembly 8 Remove the ADF CCD module assembly and disconnect the ADF CCD to scan control cable D Reinstallation notes e Be sure to avoid touching the glass of the new FRU during installation e Be sure to reinstall the ADF jam tray sensor 4 14 Service Manual 7002 xxx ADF complete assembly removal 1 Twist the thumbscrews to disconnect the two cables A at the back of the ADF assembly D N we T am Los hend Led T ALL m S Ca E nn E A nui out A 2 Remove the ADF attach screws See ADF attach screws removal on page 4 13 Note Do not remove the two screws in the back 3 Lift the ADF up and make sure you clear the two rear screws The hinge is slotted to allow the ADF to come off and leave the screws in place Note Whenever the complete ADF assembly is replaced it is necessary to perform the scanner registration See Scanner registration on page 4 4 Repair
224. e C clip A on the left side E 00000 esocc ee202099 ee00272 oo Y ce A 6 Press the clips on the end of the shaft to remove the MPF tires B T Remove the C clip C on the shaft i 4 114 Service Manual 7002 xxx 8 Remove the bushing D Note The bushing fits into a detent E in the frame of the MPF arm assembly i 9 Loosen the paper alignment screws F F 10 Remove the C clip securing the MPF solenoid assembly on the shaft Note This C clip is very difficult to locate and remove Repair information 4 115 7002 xxx 11 Pull the shaft assembly G to the right until the left end of the shaft is clear of the frame and slide the MPF solenoid assembly from the shaft Installation note Be careful not to lose the washer H that is between the MPF solenoid assembly and the C clip It belongs to the MPF arm assembly I 4 116 Service Manual 7002 xxx Paper alignment assembly removal 1 P Remove the upper paper deflector assembly See Upper paper deflector assembly removal on page 4 132 Remove the inner paper deflector assembly See Inner paper deflector assembly removal on page 4 97 Release the input paper sensor from its mounting and remove Remove the left door Remove the paper alignment assembly mounting screws A ra a siden i af Ag itis ad wey Repair information 4 117 7002 xxx 6 L
225. e at the fuser control board 3 Disconnect the AC fuser lamp cable B from the top right side of the fuser cover EL Repair information 4 91 7002 xxx 4 Carefully remove the two screws C from the right side of the fuser lamp contact cover D 5 Release the latch E and remove the cover 6 Remove the screw F on the left side and the screw G on the right side that attach the fuser upper cover assembly to the fuser frame T Remove screw H that attaches the side fuser lamp contact to the fuser top cover 4 92 Service Manual 7002 xxx 8 Remove the fuser cover Lv Fuser transfer plate removal Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 132 Remove the transfer roll See Transfer roll assembly removal on page 4 126 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 97 Do MX Lift the left side of the fuser transfer plate A and move the plate to the left to clear the right side from its mounting A 5 Remove the screw that attaches the transfer plate ground wire to the center pan 6 Remove the fuser transfer plate T Remove the screw that attaches the deflector cable to the transfer plate Repair information 4 93 7002 xxx Gear release link removal 1 Remove the system board and inner shield See System board and inner shield removal on page 4 125 2 Remove the developer driv
226. e automatically overridden and print media is selected from an automatic source Touch Cancel Job to cancel the current job if needed Touch Reset Active Bin to change to another linked bin Occurs when the MFP receives a manual feed request for a specific size and type of print media when none is loaded into the multipurpose feeder Touch Continue if print media is in the multipurpose feeder The job continues Touch Continue if there is no print media in the multipurpose feeder All requests for additional pages are automatically overridden and print media is selected from an automatic source Touch Automatically select media to override manual requests for Manua Paper and Manual Env for the rest of the print job All requests for additional pages are automatically overridden and print media is selected from an automatic source Touch Cancel Job to cancel the current job if needed Touch Reset Active Bin to change to another linked bin Occurs when a source is loaded with an incorrect print media size and type as specified in the Paper Menu Touch Continue Load the specified source that is set for the requested size and type Touch Cancel Job to cancel the current job if needed Touch Reset Active Bin to change to another linked bin Occurs when a source is loaded with an incorrect print media size and type as specified in the Paper Menu Touch Continue Load the specified source that is set for the requested size and typ
227. e bar Status Supplies Shows the current MFP status such as Ready or BuSy Shows MFP conditions such as Toner Low Shows intervention messages to give instructions on what the user should do so the MFP can continue processing such as Close door or insert print cartridge Appears on the LCD whenever the MFP status includes a message requiring intervention Touch it to access the messages screen for more information on the message including how to clear it All menus have a Tips button Tips is a context sensitive Help feature within the LCD touch screens Touch to access the File Transfer Protocol FTP menus A document can be scanned directly to an FTP site Release Held Faxes There are held faxes with a scheduled hold time previously set or Held Faxes ifin To access the list of held faxes touch this button Manual Mode Search Held Jobs To search on any of the following items and return any Held Jobs Lock Device matches User names for held or confidential print jobs Job names for held jobs excluding confidential print jobs Profile names Bookmark container or job names USB container or job names for supported extensions only To open a screen containing all the held jobs containers This button appears on the screen when the MFP is unlocked and Device Lockout Personal Identification Number PIN is not null or empty To lock the MFP 1 Touch Lock Device to open a PIN entry screen 2 Enter the corre
228. e between the following pins on the motor cable connector Pins 1 brown and pin 2 Yellow The resistance measures between approximately 7 5 and 10 5 ohms If incorrect replace the motor assembly If correct replace the high capacity feeder option system board The elevator moves in one direction only DC drive motor assembly high capacity feeder system board Check the voltages at J1 on the high capacity system board The voltages measure approximately as follows Pin Color vonas If any of the voltages are incorrect disconnect the motor and measure the resistance between J 1 and J 2 The resistance measures between 7 5 and 10 5 ohms If incorrect replace the motor If correct replace the system board Diagnostic information 2 141 7002 xxx Paper size switch not selecting paper size that is selected Paper size switch High capacity feeder option control board High capacity feeder option control board Elevator top optical sensor cable Elevator top optical sensor Check for continuity between the common pin J5 1 and the pin of the paper size selected Pin Color Papersize Hs Red ms If any position does not measure continuity when selected replace the paper size switch assembly If the switch assembly is operating correctly replace the high capacity feeder option control board Check the voltages on the board at J4 1 red and J4 3 blue The voltages measure approximately 5 V dc If
229. e clears A new scan job containing the same parameters as the previous job starts Diagnostic information 2 45 7002 xxx User attendance messages continued Error Sub Primary message code code y g Disk corrupted Disk Full Scan Job Canceled Insert Cartridge or Close Door Insert tray x Install Bin x or Cancel Job Install Duplex or Cancel Job 2 46 Service Manual Description action Occurs when the MFP attempts a hard disk recovery on a corrupted hard disk and the hard disk cannot be repaired The hard disk must be reformatted Touch Reformat disk to reformat the hard disk and clear the message Warning All files stored on the hard disk are deleted The scan job cancels or stops due to insufficient hard disk space Note The scanner finishes scanning currently committed pages in the ADF but data is lost when the job cancels itself Touch Continue to clear the message This message displays when the printer front door is open or the print cartridge is missing If this message cannot be cleared go to Cover closed switch cable service check base printer on page 2 123 Occurs when the MFP detects a missing tray x can be 1 2 3 4 or 5 Insert the specified tray to clear the message Touch Cancel Job to cancel the current job if needed Touch Reset Active Bin to change to another linked bin If the message cannot be cleared go to Paper size sensing service check on page 2 154
230. e count between 100 000 and 199 999 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Fuser page count between 100 000 and 199 999 Lamp detection performed and found error Fuser page count between 200 000 and 299 999 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Fuser page count between 200 000 and 299 999 Lamp detection performed and found error Fuser page count between 300 000 and 399 999 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Fuser page count between 300 000 and 399 999 Lamp detection performed and found error Fuser page count between 400 000 and 499 999 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Fuser page count between 400 000 and 499 999 Lamp detection performed and found error Fuser page count stopped at 500 000 to preserve data Description e 115 V lamp in 220 V printer e Lamp has excessive wattage Attempting to POR machine after receiving a 925 01 e 115 V lamp in 220 V printer e Lamp has excessive wattage Attempting to POR machine after receiving a 925 01 e 115 V lamp in 220 V printer e Lamp has excessive wattage Attempting to POR machine after receiving a 925 01 e 115 V lamp in 220 V printer e Lamp has excessive wattage Attempting to POR machine after receiving a 925 01 e 115 V lamp in 220
231. e gears to come in contact with any metal or other hard surface to avoid gear damage It is also very important not to let any dirt paper staples or other material come intact with the grease in the gearbox assembly Main drive assembly excessive noise or vibration Main drive motor assembly excessive noise gears ratcheting and so on Remove the controller board and run a Diagnostic Print Test in the continuous mode Check the main drive assembly for any excessive noise or vibration Determine if the noise is in the main drive toner cartridge fuser or main drive gearbox Look for any loose or worn parts in the developer drive assembly main drive gearbox or fuser Repair as necessary A service error code 936 Transport Motor may be displayed Check the voltage at J20 6 on the system board It measures approximately 5 V dc when the motor is not running and goes to 0 V dc when the motor is running If incorrect replace the system board If this does not fix the problem replace the main drive motor Main drive motor cable Check the continuity of the main drive motor cable If incorrect replace the cable Motor gear does not turn no 936 error code or 201 xx Paper Jam user message displays the voltages at J20 on the system board Voltage When main drive motor is running J20 11 11 24 V dc If the voltage is incorrect replace the FRUs in the following order Main drive motor assembly System boar
232. e incorrect turn the power off disconnect the cable attached to CN10 on the motor driver card and measure the voltages in the table below Paper present sensor interrupter type normally closed If the voltages are incorrect replace the motor driver card If the voltages are correct replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 Diagnostic information 2 107 7002 xxx 294 00 Error code service check Static jam ADF exit sensor A ADF exit sensor Motor driver card 2 108 Service Manual Check for any signs of media or other debris that might be present in the ADF assembly around the exit sensor flag Remove any media or debris If nothing is found go to step 2 Check the exit sensor flag to make sure it operates freely and does not hang or bind If the flag does not operate correctly and cannot be made to operate correctly replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 If the flag operates correctly go to step 3 Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Sensor Tests Check the ADF exit s
233. e is on the Menu Settings Page also check on page 2 144 Waiting The MFP receives a page of data to print but waits for an End of Job command a Form Feed command or additional data Press Stop Touch Continue to print the contents of the buffer Cancel the current job Wait for the message to clear Insert the tray to clear the message Fax status displays Tray Lx Empty X represents the number of the tray The tray has no print media installed 1 Remove the tray The message clears 2 Install print media in the tray according to the User s Guide 3 Insert the tray If the Tray 1 Missing message does not clear when tray 1 is inserted go to Parallel port service check on page 2 155 If Tray 2 through 5 Missing EBEN Call complete A fax call is completed Tray Lx Low x specifies the number of the tray that is low Load print media into the specified tray to clear the message message does not clear by inserting the tray go to Input tray s service BEEN Connect lt x gt bps The fax is connected x is the baud rate per second 2 42 Service Manual 7002 xxx User status displays continued Error Sub code code Dialing A fax number is dialed If the number is too long to fit on the screen only the word Dialing appears Fax failed The fax failed to send Job stored for The scanning completes for a delayed send fax job delayed transmission f o qunebuy 0 A fax number is dialed but the fax line is busy
234. e recommended print side on the paper package and load paper accordingly Paper characteristics The following paper characteristics affect print quality and reliability We recommend that you follow these guidelines when evaluating new paper stock For detailed information see the Card Stock amp Label Guide located on the Lexmark Web site at www lexmark com The laser printing process heats paper to high temperatures of 230 C 446 F For Magnetic Ink Character Recognition MICR applications and 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 you have chosen is acceptable for laser printers Weight The MFP can automatically feed paper weights from 60 to 176 g m 16 to 47 Ib bond grain long in the integrated and optional 500 sheet trays and paper weights from 60 to 135 g m 16 to 36 Ib bond grain long in the multipurpose feeder and optional 250 sheet trays 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 20 lb bond grain long paper When using paper narrower than 182 x 257 mm 7 2 x 10 1 in make sure the weight is greater than or equal to 90 g m 24 Ib bond Unacceptable paper The following papers are not recommended for use with the MFP e Some chemically treated papers used to make c
235. e stack of paper The autocompensator pick arm may not be coming down far enough to allow the pick rolls to properly contact the paper Also the autocompensator motor may be failing If this problem continues replace the autocompensator assembly Double feeding paper Note If double feeding paper occurs mostly from the bottom of the stack check for missing or damaged restraint pads in the tray Paper is usually the primary cause of a double feeding paper problem Flex the paper before placing the paper in the tray Edge welded paper is the most common cause of double feeding Loading the paper in the tray in different locations and directions and using rough paper and short grain paper also causes double feeding Autocompensator Make sure the counterbalance spring is not missing loose or broken at the top of the autocompensator arm assembly If you find a problem replace the autocompensator assembly Paper fails to feed from the multipurpose tray The pick roll should make one complete revolution and stop with the flat side down If the pick roll turns but does not pick paper check the roll for signs of wear oil or grease on the surface of the pick roll or slick spots If you find a problem replace the pick roll assembly Check to ensure the media that is being fed through the multipurpose tray assembly meets recommended paper specifications Diagnostic information 2 153 7002 xxx Paper size sensing service check Before pro
236. e the cord If not receptacles defective check the AC input and output receptacles and wiring AC wiring harness harness in the HCIT Repair or replace the receptacles or AC wiring harness as required Note Make sure the ground wire is installed correctly from the AC wiring harness to the frame of the HCIT and the nut and lock washer are tightened The base printer does not recognize that the high capacity input tray is installed high capacity feeder Check the high capacity feeder input tray to make sure it is mounted autoconnect mechanical correctly and is not pushed down into the frame assembly or check damaged Be sure the high capacity feeder input tray autoconnect is properly connected to the high capacity feeder tray option board assembly Base printer or option Check the option or base printer autoconnect for signs of damage mounted above Repair the high capacity option autoconnect as necessary LVPS Check the voltages at J11 2 and J11 4 The voltage measures Option system board 24 V dc If the voltage is correct replace the high capacity system board assembly If the voltage is incorrect check the continuity of the AC input cable to the LVPS If correct replace the LVPS assembly If incorrect replace the AC cable to the input of the LVPS 2 138 Service Manual 7002 xxx High capacity feeder option Check the voltage on J8 1 green The voltage measures 24 V dc control board If incorrect check the autoconnect
237. ea of the transfer plate assembly Clean the area and run another copy If the problem continues replace the FRUs in the following order e HVPS System board 7002 xxx Printhead service check CAUTION The printhead is not a serviceable FRU Do not disassemble the printhead The printhead assembly does not contain any service replaceable parts or components If service error code 930 xx displays the wrong printhead is installed in the printer See Printhead on page 8 20 Note A 201 xx paper jam may also indicate a failing printhead The paper may have jammed prior to or at the input sensor Print the event log and see if 201 or 931 errors are logged a Service error code Explanation Error code 931 xx These errors usually indicate a failure in the HYSNC signal to the No first HYSNC Signal printhead Check the continuity of the cables connected to J2 and J4 Error Code 932 on the system board If incorrect replace the defective cable The Lost HYSNC voltage at J4 1 measures approximately 5 V dc If incorrect replace the system board The voltage at J2 7 measures approximately 24 V dc If incorrect replace the system board If correct replace the printhead assembly See Printhead removal on page 4 122 Error Code 934 xx These error codes indicate a problem with the mirror motor circuit in Mirror motor lost lock Error the printhead assembly or the mirror motor cable to the system board Code 935 cable or system board ass
238. eck any installed output option s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Diagnostic information 2 67 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes 202 01 Page did not cleanly exit Page may be jammed in fuser exit or Make sure the redrive door Lid or redrive area redrive area is complete closed user page count between 0 and 99 999 Us MAL lor any contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output option s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 202 02 Exit sensor covered too Page may be jammed in fuser exit or Make sure the redrive door long Fuser page count redrive area is complete closed between 0 and 99 999 Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn med
239. ed DRAM is required to display the 100 MB selection 3 Touch Submit to save your change Touch Back to exit without changing the value Format Fax Storage This setting enables you to format the non volatile storage used for storing faxes To change this setting touch gt to select Format Fax Storage from the Configuration Menu Formatting Fax Flash DO NOI POWER OFF appears on the LCD while the format operation is active Note If an advanced password has been established you must enter this password in order to change the setting ADF Edge Erase The ADF Edge Erase and FB Edge Erase settings specify in millimeters the size of a border around the scanned image that will be erased For copies the printed page will have 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 To change this setting 1 Touch gt to select ADF Edge Erase from the Configuration Menu The panel displays the setting s name in the header and setting s current value gt below the header row 2 Touch gt to increase the value or lt q to decrease the value The values are 0 through 6 The default is 3 3 Touch Submit to save the change Touch Back to cancel and return to the Configuration Menu 3 30 Service Manual 7002 xxx FB Edge Erase The ADF Edge Erase and FB Edge Erase settings specify in millimeters the size of a border around the scanned image that wil
240. ed interface card assembly correct operation of the sensors by placing a piece of paper on the contact glass over the sensor assembly If any sensor fails the sensor test replace the sensor assembly If this does not fix the problem replace the flatbed interface card See Flatbed ICC interface card removal on page 4 32 Diagnostic information 2 129 7002 xxx Fuser service checks 920 xx Cold fuser service check Error codes 920 x and 922 xx may display for a cold fuser failure Some 920 xx error codes may be cleared by turning the printer on and off and allowing it to complete POR CAUTION There is a danger from hazardous voltage in the area of the printer where you are working Unplug the printer before you begin or use caution if the printer must receive power in order to perform the task Service tip Some 920 xx errors can be caused by multiple sheets of paper being fed up to the fuser Service tip Set the Fuser Temperature to NORMAL before starting this service check In Diagnostics mode select EP SETUP and Fuser Temp Service tip It may take several minutes for the error codes 920 xx and 922 xx to be displayed after the printer is turned on Fuser lamp Observe the lamp through the left near side of the printer It may be necessary to remove the redrive assembly to observe the lamp PRUSEN rane cable turning on and off If the lamp does not come on do the following e If not previously removed remove the r
241. edrive assembly See Redrive assembly removal on page 4 123 e Remove the fuser assembly See Fuser assembly removal on page 4 75 Make sure the correct type of lamp is installed voltage and wattage Verify that the fuser to fuser lamp cable is installed correctly to the fuser top cover assembly If incorrect install correctly if correct go to step 2 AC line voltage CAUTION When taking measurements for AC power observe all safety precautions Check the AC line voltage to make sure it is within operating specification If incorrect inform the customer if correct go to step 3 CAUTION When taking measurements for AC power observe all safety precautions Unplug the AC line cord from the printer and pull the LVPS out far enough to access CN1 on the LVPS board see Low voltage power supply removal on page 4 105 Disconnect the LVPS to fuser AC cable plug in the line cord turn the printer on and measure the voltage between CN1 1 and CN1 3 on the connector see the connector locations at Low voltage power supply on page 6 11 If incorrect replace the LVPS assembly see Low voltage power supply removal on page 4 105 if correct go to step 4 Fuser lamp Check continuity of the fuser to fuser AC cable fuser top cover assembly and fuser lamp by checking the continuity between the two pins on the fuser lamp AC cable connector e f there is continuity go to step 5 e f there is no continuity c
242. eee e treet reer cere eee nee ee eee neces 7 39 INA flat cover blank 2 222 eee ee eee reer eee nee eee eee ee eee eee eens 7 39 Bottom front autoconnect cable assembly ur 7 43 Top autoconnect cable assembly 22 222 cece c eee eee eee ee eee ences e eens 7 43 Main drive motor cable assembly 2 222 e cee rere ee cere eee eee ee eees 7 47 MPF sensor cable 22 2222 cece e cet ee cee eee ee ee eee eee ee eees 7 40 Ground cable 2222s cece etree eee eee eee eee eee ee eee eee en eeee 7 47 System board to fuser board cable assembly 7 45 Fuser AC lamp to LVPS cable assembly TTIIIIIIIIee 7 45 Parts packet 2 2 cece crete cere eee eee ee eee eee eens 7 7 7 9 7 11 7 31 7 35 Parts packet alignment asm mounting screw rlrrr e 7 25 Parts packet C clip pivot shaft TIIIIIIIIII 7 33 Parts packet charge roll screw r rrrrIIIIIIIIIIIIIIIe 7 33 Parts packet clip ref ground mounting screw I 7 25 Parts packet developer drive ground screw IIIIIIIIIIIIIe 7 29 Parts packet frame mounting screw r r rIrIIII e 7 23 Parts packet gearbox mounting screw 22s sce e eee ee eee e et eee eee eee eee ee
243. eees 7 29 Parts packet hanger 222 e nee e rr ere eee ee eee renee ener e ee eeee 7 21 Parts packet INA cover mounting Screw 2222 etter terete rte eee eee eee eee eens 7 39 Parts packet inner shield mounting Screw I e 7 39 Parts packet lower deflector mounting screw 12 mm III ee 7 23 Parts packet lower deflector mounting screw 8 mm IIIe 7 23 Parts packet outer shield mounting screw IIIIIIIIIIII 7 39 Parts packet pick roll shaft clip IIII e e 7 23 Parts packet printhead mounting screw IIIII e 7 20 Cartridge shipping package empty rIIIIIIIIIIIIIe 7 65 l 10 Service Manual 40X01 74 40X0179 40X0182 40X0183 40X0207 40X0208 40X0209 40X0213 40X0223 40X0223 40X0224 40X0225 40X0226 40X0227 40X0229 40X0230 40X0232 40X0236 40X0238 40X0239 40X0249 40X0249 40X0250 40X0251 40X0252 40X0254 40X0255 40X0256 40X0257 40X0258 40X0259 40X0260 40X0264 40X0264 40X0271 40X0281 40X0285 40X0290 40X0291 40X0293 40X0294 40X0295 40X0301 40X0302 40X0303 40X0304 40X0305 40X0306 40X0310 40X0331 40X0450 40X0451 40X0452 40X0453 40X0454 40X0456 40X0456 40X0457 40X0458 7002 xxx Parts packet cable ties u rrrIIIIIIIIIIIIIIIII 7 3
244. eference adjust 1 e Washer paper reference adjust 1 e Nut paper reference adjust 1 Parts packet alignment asm mounting screw PP 40X0165 Parts catalog 8 25 7002 xxx Assembly 16 Integrated 500 sheet paper tray 8 26 Service Manual 7002 xxx Assembly 16 Integrated 500 sheet paper tray Part Units Units kit Description number mach or pkg 40X0098 40X0099 40X0182 40X0103 40X0183 40X0105 40X0106 Tray assembly 500 sheet tray Side restraint Wear strip Pass thru plate 500 sheet tray Wear plate 500 sheet tray Restraint pad Back restraint Parts catalog 8 27 7002 xxx Assembly 17 Drives Main drive and developer drive TON SY VSN 8 28 Service Manual 7002 xxx Assembly 17 Drives Main drive and developer drive Part Units Units kit eer Description number mach or pkg 40X0107 40X0111 40X01 12 40X0113 40X0114 40X0115 Gearbox with motor Power takeoff shaft 500 sheet Power takeoff shaft spring Bevel gear with grease packet and washer e Bevel gear 1 e Instruction sheet 1 e Grease packet 1 Developer drive assembly Parts packet developer drive e Developer drive shaft 1 e shaft coupler gear 55 1 Parts packet developer drive ground screw PP 40X0165 Parts packet gearbox mounting screw PP 40X0165 Parts catalog 8 29 7002 xxx Assembly 18 Hot roll fuser 8 30 Service Manual Assembly 18 Hot roll fuse
245. elope feeder 0 0 ccc eee ee eee eee 7 57 Assembly 37 High capacity feeder 1 0 0 eee 7 58 Assembly 38 High capacity feeder 2 0 0 0 eee 7 60 Assembly 39 High capacity feeder 4 0 0 0 ees 7 62 Assembly 40 High capacity feeder 5 0 0 0 eee 7 63 Assembly 41 Kiosk vertical and horizontal paper adapters 7 64 Assembly 42 ODNONS oii 2hee 06h 48d REX 3E onu Ye nob CR Sd SEER ORE Ode eS 7 65 Cee E ee ee ee A N ee ee es ee ee ee ee ee ee Oe ee eee E l 1 POP CMe INGE ETT l 9 X Service Manual 7002 xxx Laser notices A laser notice label may be affixed to this MFP Laser notice The printer is certified in the U S to conform to the requirements of DHHS 21 CFR Subchapter J for Class 1 laser products and elsewhere is certified as a Class laser product conforming to the requirements of IEC 60825 1 Class laser products are not considered to be hazardous The printer contains internally a Class IIIb 3b laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770 795 nanometers The laser system and printer are designed so there is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Hea
246. embly The voltage at J5 2 measures Mirror motor unable to approximately 24 V dc If incorrect replace the system board If reach operating speed correct replace the FRUs in the following order e System board See System board and inner shield removal on page 4 125 Printhead assembly See Printhead removal on page 4 122 Signature button assembly service check Note lf you are unable to clear a 32 xx Unsupported Cartridge User Error message be sure a Lexmark T64x print cartridge is correctly installed in the printer The cartridge is easily identified by the contact board on the right side rear of the cartridge Install another print cartridge before attempting to troubleshoot the printer Make sure the signature button cable is properly connected to J14 on the system board Check the print cartridge for damage or improper installation of the chip Also be sure there is proper contact between the chip on the cartridge and the signature button contact assembly Service tip An intermittent 32 xx Unsupported Cartridge User Error message can be caused by poor contact between the signature button cartridge contacts in the upper front cover and the chip Also check for proper seating of the signature button cartridge cable to the system board Signature button contact Check the voltage on the signature button cartridge contact The assembly voltage measures approximately 3 8 V dc when not writing data to System board the system bo
247. emove If the problem persists go to 294 00 Error code service check on page 2 108 Verify that the exit sensor is operating properly If the problem persists and the exit sensor seems to be operating properly go to 294 01 Error code service check on page 2 109 Verify the exit sensor is operating properly If the problem persists and the exit sensor seems to be operating properly go to 294 02 Error code service check on page 2 111 Verify that the exit sensor is operating properly If the problem persists and the exit sensor seems to be operating properly go to 294 03 Error code service check on page 2 112 Clean the flatbed white cushion See Cleaning the scanner glass and flatbed white cushion on page 7 2 Clean the scanner glass for both the flatbed and ADF See Cleaning the scanner glass and flatbed white cushion on page 7 2 Check the cables on the rear of the scanner to make sure they are plugged in and fastened securely If no problem is found with the cables go to 298 01 Error code service check on page 2 114 Check the cables on the rear of the scanner to make sure they are plugged in and fastened securely If no problem is found with the cables go to 298 02 Error code service check on page 2 114 7002 xxx Service checks Anytime the system board is replaced the Configuration ID must be reset in NVRAM Go to Configuration ID on page 3 19 Review the foll
248. emove the redrive assembly B A hm fm Repair information 4 123 7002 xxx Signature button contact assembly removal Remove the print cartridge Remove the left side door See Printer left side cover removal on page 4 56 Remove the right cover See Printer right cover removal on page 4 58 Remove outer system board shield See Printer outer shield removal on page 4 121 Disconnect signature button cable from connector J14 on the system board On models 200 210 400 410 remove the two screws A securing the blower duct oS uev ay n 5 dis t CT ME AG ise 7 Remove the signature button contact assembly mounting screw B 8 Remove the assembly signature button contact assembly Note Be sure to route the cable in the same location as shown C when replacing the assembly 4 124 Service Manual 7002 xxx System board and inner shield removal Warning When replacing any one of the following components Operator panel right cover assembly e System board assembly e Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove comp
249. ensor Test See Sensor Test duplex on page 3 12 Motor Test See Motor Test duplex on page 3 12 Duplex Feed 1 See Duplex Feed 1 on page 3 13 Duplex Feed 2 See Duplex Feed 2 on page 3 13 INPUT TRAY TESTS Feed Tests See Feed Tests input tray on page 3 13 Tray 1 AB Tray 2 if installed Tray 3 if installed Tray 4 if installed Tray 5 if installed Envelope Feeder MP Feeder Sensor Tests See Sensor Test input tray on page 3 14 Tray 1 0 md A xo x Tray 2 if installed Tray 3 if installed Tray 4 Tray 5 if installed if installed Ner Envelope Feeder MP Feeder OUTPUT BIN TESTS Feed Tests Standard Bin Sensor Tests Standard Bin BASE SENSOR TEST Toner Sensor See OUTPUT BIN TESTS on page 3 14 See BASE SENSOR TEST on page 3 15 Input Sensor Standard Bin Sensor Upper Front Cover Narrow Media DEVICE TESTS Quick Disk Test if hard disk is installed See Quick Disk Test on page 3 16 Disk Test Clean if installed See Disk Test Clean on page 3 16 Flash Test if flash is installed See Flash Test on page 3 17 Diagnostic aids 3 3 7002 xxx Diagnostics Menu tests continued See Defaults on page 3 17 See Printed Page Count on page 3 18 See Permanent Page Count on page 3 18 See Model Name on page 3 18 See Configuration ID on page 3 19 See Edge to Edge on page 3 19 See Pa
250. ensor for correct operation Note You can check the ADF exit sensor by moving the exit sensor flag or by manually feeding a sheet of paper through the ADF If the sensor fails the test go to step 4 Turn the power off and disconnect CN9 on the motor driver card Measure the voltages in the table below normally closed If incorrect replace the motor driver card If correct go to step 5 ADF exit sensor electrical checks 294 01 Error code service check ADF eject jam 7002 xxx Turn the power off and reconnect CNO9 to the motor driver card Measure the voltages in the table below with the sensor in normal operation sensor closed and the sensor open sensor flag activated CN9 Pin 2 1 16 V dc 1 16 V dc CN9 Pin 3 45 0 V dc 0 15 V dc Note All voltages are approximate values If the voltages are incorrect replace the ADF exit sensor If this does not fix the problem replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 Note Before starting this service check make sure the ADF exit sensor A cable is installed correctly ADF jammed media A y A gt Check for any signs of media or other debris that might be present in the ADF assembly around the exit sensor flag Remove any media
251. ent log can only be printed in CONFIG MENU Additional options are available in DIAGNOSTICS See EVENT LOG on page 3 21 To print the event log 1 Touch gt to select Event Log from Configuration Menu 2 Touch EP to print the log Printing Event Log displays on the touchscreen 3 Touch Back to return to EVENT LOG Note An event log printed from the CONFIG MENU will not contain debug information or secondary codes for 900 service errors However the event log printed from DIAGNOSTICS mode does include this information Paper Prompts When a tray is out of the indicated paper size a prompt is sent to the user to load paper in a tray This setting controls the tray the user is directed to fill 1 Touch gt to select Paper Prompts from the Configuration Menu The panel displays the setting s name in the header and setting s current value below the header row 2 Touch or lt q to change the value The values are Auto default MP Feeder and Manual Paper 3 Touch Submit to save the change 3 32 Service Manual 7002 xxx Envelope Prompts This setting controls the tray the user is directed to refill when a specific envelope size is out The selections are Auto default MP Feeder and Manual Env 1 Touch gt to select Envelope Prompts from the Configuration Menu The panel displays the setting s name in the header and setting s current value gt below the header row 2 Touch or
252. er attendance messages paper jams and paper handling errors 2xx xx 294 294 294 295 287 297 298 298 2 94 EITOK SUD Description code codes P Paper Missing Jam Static Jam ADF Exit Sensor ADF Eject Jam ADF Exit Jam Sensor Off ADF Exit Jam Sensor On Clean Scanner Backing Strip Clean Scanner Glass Scanner Missing Front Side Cable Unplugged Scanner Missing Rear Side Cable Unplugged Service Manual Possible causes An attempt was made to force an ADF scan by a custom job page level jam recovery or so on with no paper in the ADF input tray or the paper was removed from the ADF input tray just as it was being staged The paper present sensor may be malfunctioning The page is stuck in the ADF at the exit sensor or the exit sensor is malfunctioning The exit sensor may not be operating properly or malfunctioning The exit sensor may not be operating properly or malfunctioning The exit sensor may not be operating properly or malfunctioning The flatbed white cushion inside the ADF is dirty The scanner document glass is dirty One of the cables on the rear of the scanner is unplugged or loose One of the cables on the rear of the scanner is unplugged or loose Make sure the media is loaded in the ADF when starting an ADF scan If no problem is found go to 293 Error code service check on page 2 107 Check for any jammed pages in the ADF and r
253. er eee E uz ua Y dx RR uS quedes Ed 3 14 Table of contents V 7002 xxx OUTPUT BIN TESES ao aii ddd eh oes chewed e RR dda es oars eic Ed ir Dee bee Roda 3 14 Fead TOSS OUID a ssa PIDE REN 5 ok RET 0 or E ru Pudor e qid dE ES S 3 14 Sensor Test standard output DIN aco ona Ra Rx Y AURA ORC CR RUN RR eic cm dee 3 15 DOE e OR IRA ok thee eae d qt Eques Sex Aug TI dene me qear i rdesbe be SES 3 15 DENIS TIBERIM z2494532 06s Cv bem Tv Pas ee dard pe dv PPP epe dd eR ET EU Ad X puters dead qaa 3 16 LEES DISK PENES Lid qoi Poen a ha ob ed eae E oae dor idc d dE b dece E dl e ee UR 3 16 Bu Wr P 3 16 x ip qnem 3 17 PARTER SEIN ede cay dg ged dh 422i EV Ee PREXSULP I VT Ga bars Gp tae oo ears Sree a eee e 3 17 ae ete ook oda a oe ewe ea Raed eae Reese ee EEEE E E 3 17 Pe ON dont oy EREET TEE TETES EOS OEE eee 95x A 3 18 a og os ay wc de aa Rea ae od eee ban 2 oe 058 e Ze 3 18 re NR cs a5 ooo 5555 5e ue eee eee E eee oe Genwi ete ae 3 18 e e om Enn B oua duck ee ee eS ee EEE ee ee 3 18 Engine Selling 1 MOUN A uua one y oe kia E34 TE 40068 DO REOR Eo b EePERR IER E 3 18 vieil cir ARTT 4g pace Oh ore Sey 5 Bare ogee Gaon Dera geo b deere bares E 3 18 COMA acne dod ord cere RE EHIER aes E RR anes ease bbe dense CREREAESQ reeds eos 3 19 Soe d for WC 3 19 Parallel strobe adjustment Par x Strobe Adj 0 0 ee eee 3 19 EC SEIL E E ga oe han ee dquo eben QEO EP qERETPREE ES de aes
254. er exit sensor cable from the sensor 4 78 Service Manual 7002 xxx Installation 1 Move the fuser exit sensor flag out of the way to clip the sensor securely into the cover E r 2 Connect the fuser exit sensor cable 3 Snap the bottom fastener of the sensor cover into place in the lower exit guide and use a small flat bladed screwdriver to ease the sensor cover into the clips 4 Replace the screw securing the sensor cover Note Make sure the flag moves properly Repair information 4 79 7002 xxx Fuser exit sensor flag and spring removal 1 Remove the fuser exit sensor See Fuser exit sensor removal on page 4 78 2 Note the position of the spring A in relation to the flag B 3 Carefully ease the right arm C until the fuser exit sensor cover releases the flag and spring B A C Spring replacement 1 Place the spring on the left pin A 2 Setthe tang B on the flag 4 80 Service Manual 7002 xxx 3 Rotate the bent end C of the spring to add tension place the pins between the sensor cover arms and rest the bent end against the sensor cover frame Note After replacing the sensor flag and spring make sure the flag moves freely and returns Repair information 4 81 7002 xxx Fuser lamp removal CAUTION The fuser and the fuser lamp may be hot You may need to allow them to cool before handling them 1 Remove the fuser assembly See Fuser assembly removal on pa
255. erator panel LED does not come on Go to Operator panel right cover assembly service check while MFP operates normally on page 2 150 Touchscreen panel blank LED off operator Go to Operator panel right cover assembly service check panel buttons do not work on page 2 150 Paper feed problems base printer or Go to Paper feed service check base printer on integrated 500 sheet paper tray page 2 152 Paper jams at exit of redrive assembly Go to Paper feed service check base printer on duplex option not installed page 2 152 Paper jams at exit of redrive assembly Go to Duplex option service check on page 2 125 duplex option installed Print quality skew Go to Paper feed service check base printer on page 2 152 Print quality banding Go to Print quality banding on page 2 159 Print quality random marks Go to Print quality random marks on page 2 157 Print quality toner on backside of printed Go to Print quality toner on backside of printed page on page page 2 160 Print quality vertical black bands on edge Go to Print quality black bands on outer edges of the of copy page on page 2 159 Unable to clear a 32 Unsupported Print Go to Signature button assembly service check on Cartridge user error message page 2 161 Diagnostic information 2 13 7002 xxx Scanner ADF symptoms ADF does not recognize paper length in the Go to ADF paper length sensor se
256. es amp Pages pop up menu Use transparencies designed specifically for laser printers Check with the manufacturer or vendor to determine whether your transparencies are compatible with laser printers that heat transparencies to 230 C 446 F Use only transparencies that are able to withstand these temperatures without melting discoloring offsetting or releasing hazardous emissions For detailed information see the Card Stock amp Label Guide which is available on the Lexmark Web site at www lexmark com Transparencies can be fed automatically from the multipurpose feeder and all standard and optional trays except the 2000 sheet drawer Before loading transparencies fan the stack to prevent sheets from sticking together Be careful when you handle transparencies Fingerprints on the surface of the transparency cause poor print quality Envelopes You can load up to 10 envelopes in the multipurpose feeder and 85 envelopes in the envelope feeder Try a sample of any envelopes you are considering using with the MFP before buying large quantities When printing on envelopes e To achieve the best possible print quality use only high quality envelopes that are designed for use in laser printers e Set the Paper Size Type in the Paper menu to MP Feeder Manual Env or Env Feeder depending on the source you are using Set the paper type to Envelope and select the correct envelope size from the control panel the MFP driver or from Mar
257. f correct replace the option system board The paper out sensor is Paper out sensor on option mounted on the system board system board Printer does not recognize Tray x is installed Autoconnect cables Check the autoconnect from the printer or option above tray x Check Tray x system board for cuts pinched wiring or damage to the contacts in the connector Check the autoconnect cable s for correct installation at the tray x system board If correct replace the tray option Paper from Tray x does not reach the pass thru sensor Service tip Check the media in tray x to make sure it is within specifications Some types of labels foil material and slick papers can cause misfeeds and slippage of the rollers Action Autocompensator Check the autocompensator pick arm rollers for any sign of glazing assembly toner or other buildup Clean or replace as necessary Interconnect card service check Warning When replacing any one of the following components e Operator panel right cover assembly e System board assembly e Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install a
258. f one is not available replace the duplex option Remove any sheets from the duplex option Try the duplex option again If it fails try another duplex option if available If one is not available replace the duplex option Remove any sheets from the duplex option Try the duplex option again If it fails try another duplex option if available If one is not available replace the duplex option Remove any sheets from the duplex option Try the duplex option again If it fails try another duplex option if available If one is not available replace the duplex option Remove any sheets from the duplex option Try the duplex option again If it fails try another duplex option if available If one is not available replace the duplex option Remove any sheets from the duplex option Try the duplex option again If it fails try another duplex option if available If one is not available replace the duplex option Replace the duplex option Replace the duplex option Replace the duplex option 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error code n2 C2 239 239 239 239 239 239 241 241 241 241 NO N A NO N Sub codes O1 O N A Co N Description Duplex did not send Device Controls response Duplex did not send Input Device Ready response Duplex did not send Page In Ou
259. fer roll left arm Parts packet charge roll screw PP 40X0165 Parts packet C clip pivot shaft PP 40X0165 l i b A Parts catalog 8 33 7002 xxx Assembly 20 Electronics power supplies 8 34 Service Manual 7002 xxx Assembly 20 Electronics power supplies 20 1 1 n m NM rnm MPO DMPO m5 NYP NY MY NY YN Tin To oF W N 40X0517 40X0518 40X0260 40X0256 40X0255 40X0257 40X0258 40X0293 40X0259 40X0301 40X0271 40X0302 40X0280 40X0303 40X0281 40X0294 40X0295 40X0304 40X0305 56P4244 40X0223 o I IL Il Il Ill I IL Il Il Ill Part Units Units kit Description number mach or i LVPS AlO 115 V ac LVPS AlO 220 V ac Power cord set 8 ft right angle 13 amp United States Canada Caribbean countries Colombia Costa Rica Dominican Republic El Salvador Equator Guatemala Honduras Mexico Nicaragua Panama Puerto Rico Saudi Arabia Venezuela and Virgin Islands Power cord set 8 ft right angle Bolivia and Peru Power cord set 8 ft right angle Argentina Power cord set 8 ft right angle Chile Uruguay Power cord set 8 ft right angle Arabic Austria Belgium Bluemark CIS Czechoslovakia Denmark Finland France Germany Greece Hungary Ireland Italy Medmark 1 and 2 Netherlands Norway Paraguay Poland Portugal Russia Slavic countries Spain Sweden Turkey and UK Power cord set 8 ft
260. fication failed d nuces Fuser page count pauses between 0 and 99 999 assembly See Fuser assembly removal on page 4 75 If no problem with wear or contamination is found go to Fuser exit sensor service check on page 2 135 201 02 Page did not reach exit e Page jammed on fuser input guide Check fuser entry guide for sensor Fuser page Pa toner build up e Page did not enter or exit fuser nip sar Maud 0 and cleanly Check the fuser for wear or dh J Evi Ani contamination If a problem Exit sensor not functioning correctly is found replace the fuser 2 60 Service Manual Video never started with page two inches past the input sensor Fuser page count between 0 and 99 999 Expected wide page not detected by narrow media sensor possible accordion jam Fuser page count between 0 and 99 999 Page did not reach exit sensor Fuser page count between 100 000 and 199 999 Main drive motor identification failed Fuser page count between 100 000 and 199 999 Page did not reach exit sensor Fuser page count between 100 000 and 199 999 User attendance messages paper jams and paper handling errors 2xx xx Error HD Description code codes P Possible causes Page did not enter or exit fuser nip cleanly e Narrow media sensor not functioning correctly Actual page is narrow when wide page was expected Page jammed on fuser input guide e Page did not enter or exit fuser nip
261. full sensor flag 4 119 paper size sensing board 4 120 pass thru plate 4 70 power takeoff shaft and spring 4 121 printer left side cover 4 56 printer outer shield 4 121 printhead 4 122 redrive assembly 4 123 redrive door 4 58 right cover handle holder 4 68 right cover removal 4 58 signature button contact assembly 4 124 system board and inner shield 4 125 toner sensor 4 126 touchscreen bezel 4 64 transfer roll assembly 4 126 upper front cover hinge assembly 4 130 upper paper deflector assembly 4 132 Index 1 5 7002 xxx upper sub cover 4 55 upper tray cover 4 127 upper tray cover paper support 4 56 USB card 4 133 scanner ADF and flatbed ADF attach screws 4 13 ADF CCD module assembly 4 14 ADF complete assembly 4 15 ADF front cover 4 5 ADF pick assembly 4 6 ADF rear cover 4 6 ADF top cover 4 8 ADF upper entrance guide assembly 4 16 CCD belt tension spring 4 19 CCD beth removal 4 17 cover closed actuator 4 21 Cover closing actuator 4 21 document tray assembly 4 22 flatbed CCD module assembly 4 27 flatbed CCD ribbon cable 4 23 flatbed contact glass 4 30 flatbed ICC interface card removal 4 32 flatbed paper length sensor assembly 4 34 flatbed scan assembly 4 38 flatbed scan motor assembly 4 41 flatbed white cushion 4 31 front flatbed cover 4 10 hard disk 4 44 home sensor 4 46 lower exit guide 4 47 pickup solenoid assembly 4 48 scan control card 4 48 scan cover flatbed removal 4 11 scanner flatbed glass ho
262. fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 75 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Diagnostic information 2 63 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes Video never started with page two inches past the input sensor Fuser page count betwee 300 000 and 399 999 Expected wide page not e Page did not enter or exit fuser nip If label media ensure front detected by narrow cleanly edge meets 1 8 inch ate ipi Narrow media sensor not functioning requirement D e correctly Check the fuser for wear or E E A contamination If a problem 300 000 and 399 999 Actual page is narrow when wide is found replace the fuser page was expacies assembly See Fuser assembly removal on page 4 75 If media is narrow then turn off first sheet detection In Diagnostics Menu PRINTER SETUP Engine Settings 3 Select 16 and touch Submit The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 136 Page did not reach exit e Page jammed on fuser input guide Check fuser entry guide for sensor Fuser page Pa toner build up e Page did not enter or exit fuser nip e Dele d 400 000 cleanly Check the fu
263. g Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage The control code has been lost Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Service error codes 9xx xx continued Error code 922 922 922 922 922 922 922 Sub Display text Hot roll took too long to reach the beginning lamp detection temperature Fuser page count between 400 000 and 499 999 Hot roll reached final lamp detection temperature but took longer than largest time in lookup table Fuser page count between 400 000 and 499 999 Hot roll timed out in trying to reach the final lamp detection te
264. ge 2 132 Service error codes 9xx xx continued Error code 922 922 922 922 922 922 922 Sub Display text Hot roll timed out in trying to reach the final lamp detection temperature Fuser page count between 100 000 and 199 999 After hot roll lamp detection did not roll over to steady state control in time Fuser page count between 100 000 and 199 999 Hot roll did not reach operating temperature in time new enhanced control Fuser page count between 100 000 and 199 999 Fuser has taken too long to reach desired temperature after increasing interpage gap Fuser page count between 100 000 and 199 999 Hot roll took too long to reach the beginning lamp detection temperature Fuser page count between 200 000 and 299 999 Hot roll reached final lamp detection temperature but took longer than largest time in lookup table Fuser page count between 200 000 and 299 999 Hot roll timed out in trying to reach the final lamp detection temperature Fuser page count between 200 000 and 299 999 After hot roll lamp detection did not roll over to steady state control in time Fuser page count between 200 000 and 299 999 Description Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage The control code has been lost Low wattage or incorrect lamp Bad thermistor circuit or cabling
265. ge 4 75 2 Disconnect the fuser lamp AC cable from the right side of the top cover assembly 3 Remove the two screws A from the right side fuser lamp contact cover Warning Take care when removing the screw as the lamp is under spring tension When the contact is released damage to the lamp or contact may occur 4 Remove the left lamp contact assembly 4 82 Service Manual 7002 xxx 5 Remove the fuser lamp Warning The lamp is under spring tension and care must be used when removing the lamp from the fuser Grip the lamp by the ceramic end piece and remove it from the fuser assembly Be careful not to touch the glass as skin oils and acids can reduce the life of the lamp Use the following table to identify and install the correct lamp Repair information 4 83 7002 xxx Fuser narrow media sensor removal 1 Remove the redrive assembly See Redrive assembly removal on page 4 123 2 Remove the screw A securing the narrow media sensor cover to the fuser 3 With a thumbnail release the catches B holding the sensor cover to the lower exit guide C in place Note You may need to move the narrow media flag out of the way to remove the sensor 4 Disconnect the fuser narrow media cable at the sensor 5 Release the catches holding the sensor in the cover Note Hold the narrow media flag out of the way to remove the sensor from the cover IT Ww 4 84 Service Manual 7002 xxx Replacement
266. ge will print Identifying jams If the MFP jams the appropriate jam message will be displayed on the touch screen Print status message bar Copy FTP 200 01 Paper jam x pages jammed Leave paper in bin See the diagram on Access doors and trays on page 3 40 for an overview of the paper path and areas where jams may occur The path varies depending on the MFP paper sources Diagnostic aids 3 39 7002 xxx Access doors and trays The following illustration shows the path that print media travels through the MFP The path varies depending on the input source trays multipurpose feeder envelope feeder you are using The numbers in following the illustration indicate the numbers that can appear on the control panel and designate the general area of a paper jam 291 293 27 201 Paper 4 jam Paper LK jam ALZA 294 Paper jam 200 paper ZA em SS lt A P Paper jam 202 Paper pe jam X VUE A 201 Paper We x o jam E ID Pd At 23x Paper a y A am c o Fagor KS 260 Paper pats 4 250 Paper 23x Paper D z mm jam E jam SI ro m 250 Paper 23x Paper E jam Jam up 23x Paper 24x Paper jam jam f 24x Paper jam Doors and trays Path and locations CAUTION Floor mounted configurations require additional furniture for stability You must use either a printer stand or printer base if you are using a 2000 sheet drawer Certain other configurations also must ha
267. h GND 1 Sensor J9 3 l GND nSTART LINE nADF_INTERVAL S TO GND nTOP ADF 5V IN 3 SA linterna PGS ee nTOP FB 25V GND 1 sensor Apc cuui ce 25V 25V 5V IN 2 lex re 1788 l 17 24 18 24V n n1ST SCAN SZ GND GND 425V GND 1516 f ts Lp Sensor e a 13UL TXD E Ul AXD O 1st scan gt GND GND i qaaa R os J15 sto oro ic CLKTXS oO y Y 5 55E 48 e ro r 9 O9 TN aW 516 5 X2 e 1X2 O lo 8 Solenoid pickup SEECEEHEERBEEEEBE 3 4 e E 4 Xie MASTER_RESET_N GND X_ DRIVE 5V IN arm ASM eperTerz rerrera S 8r 12H 2 O i X Y DRIVE OUC Scr n 1 ul i CL in f J3 fg DRIvE olo o eo 2 i 4 A Y DRIVE svi d i Q splay O O gi tv I I 12V ADF Scan i l 7 GND tor 6 GND mo o O ERNER T d ASM i i J10 J13 3 BACKLIGHT_CTRLI To interconnect car J7 4 SW D I f m l 12 T 3 GND l i 3 4 haha 1 2 GND l l l 5 6 Whi o 1 I j I 7 8 109 ayn AnBES DU MERE a eas a eae ees es yea I GND EY P Interconnect card ASM 12 im Stan i Se i e GND P86 ADF Feed F AX DATA 3 DATA 2 E NAE GERD motor DATA 4 GND 7 Card ASM UE lime 000000000 eene IM a a GND DATA 7 2 r J59 MOD ADDR 1 MOD ADDR O 2 High Voltage GND MOD ADDR 2 7 MOD ADDR4 MOD ADDR 3 a O GND MOD ADDR 5 uC ware pose LCD Inverter Card Asm MOD_CS IO READ 4 nv r r r MOD_RDY GND ze RESET N MOD PRE 7 ESE 1i Bor NOP PRES Printer engine card ASM
268. h sensor Check to make sure both cables are installed correctly ADF paper tray Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS a select Sensor Tests Check the ADF paper width sensor for correct operation by moving the paper width guides on the paper tray in and out If only one or two of the sensor widths does not operate properly replace the ADF paper tray assembly If none of the sensors operate correctly replace the ADF paper tray If this does not fix the problem replace the motor driver card Charge roll service check Service tip Close and evenly spaced repetitive marks 47 19 mm 1 86 in apart or spots on the page can be caused by a damaged or contaminated dual charge roll Service tip Make sure the right charge roll arm bushing is correctly installed and operates correctly To remove the charge roll 1 Wrap a piece of plain white paper around the charge roll to prevent contamination or damage 2 Carefully remove the roll by pressing outward and to the right on the charge roll link arm and remove the charge roll from the right side charge roll bearing 3 Remove the charge roll from the left side charge roll bearing and remove the roll from the printer Leave the paper wrapped around the charge roll until it is reinstalled Charge roll assembly Check the charge roll for correct installation toner buildup marks cuts or other signs of contamination or damage Replace as necess
269. he cable for a short between pins 1 and 2 on the cable If incorrect replace the cable If correct check the switch for a bent or deformed actuator lever or defective switch If incorrect replace the switch Excessive noise or vibration EI DC motor assembly Make sure all the motor plate mounting screws are tight Idler pulley Make sure the idler pulley is not binding on the pulley shaft Check DC motor assembly the pulley for wear Check the idler pulley shaft on the motor mounting plate for damage or contamination Drive pulley Check the drive pulley for wear binds or damage to the pulley or pulley shaft Make sure the pulley turns freely on the pulley shaft Motor drive belt Check the DC motor drive belt for damage Make sure the belt is tray drive belt tracking correctly on the drive pulley idler pulley and motor pulley Check the tray drive belt for damage Make sure the belt is tracking correctly on the lower section of the drive pulley and lead screw pulleys Input sensor service check Service tip Run the Base Sensor Test Check the input sensor for proper operation The display changes from open to closed as the sensor flag is manually moved in and out of the sensor Input sensor flag Check the input sensor flag for damage and proper operation If a problem is found repair as necessary System board Check for approximately 5 V dc at J15 10 on the system board If incorrect replace the system board Input senso
270. he document cover 2 Remove the flatbed glass slit assembly See Scanner flatbed glass holder assembly removal on page 4 50 3 Remove the upper glass holder See Upper glass holder removal on page 4 53 4 Slide the glass to the left and lift it CAUTION While the glass edge is beveled handle it carefully to avoid cutting your hand 4 30 Service Manual 7002 xxx Flatbed white cushion removal 1 Open the document cover 2 Peel the Velcro attached pad from one corner Repair information 4 31 7002 xxx Flatbed ICC interface card removal Remove the scan cover flatbed See Scan cover flatbed removal on page 4 11 Remove the scanner right side cover See Scanner right side cover removal on page 4 12 Remove the scanner left side cover See Scanner left side cover removal on page 4 9 mo T Remove the three screws A that attach the hinge support bracket to the rear scan bracket 5 Remove the two screws B from the top 6 Remove the two screws C from the left side and right side T Remove the two screws D from the left bottom and right bottom aem 4 E 4 32 Service Manual 7002 xxx 8 Disconnect all connectors E 9 Remove the four screws F 10 Remove the card Repair information 4 33 7002 xxx Flatbed paper length sensor assembly removal Remove the scan cover flatbed See Scan cover flatbed removal on page 4 11 Remove the scanne
271. he last successfully scanned page Touch Scan from flatbed if page jam recovery is active Scanning resumes from the flatbed immediately after the last successfully scanned page Touch Finish job without further scanning if page jam recovery is active The job ends at the last successfully scanned page but the job is not canceled Successfully scanned pages go to their destination copy fax e mail or FTP Touch Restart job if job recovery is active and the job can be restarted The message clears A new scan job containing the same parameters as the previous job starts Clean scanner During a scanner calibration the firmware detects that the scanner ADF or glass flatbed glass may be dirty Touch Cancel Job if a scan job is processing when the attendance message appears This cancels the job and clears the message Touch Scan from Automatic Document Feeder if the page jam recovery is active Scanning resumes from the ADF immediately after the last successfully scanned page Touch Scan from flatbed if page jam recovery is active Scanning resumes from the flatbed immediately after the last successfully scanned page Touch Finish job without further scanning if page jam recovery is active The job ends at the last successfully scanned page but the job is not canceled Successfully scanned pages go to their destination copy fax e mail or FTP Touch Restart job if job recovery is active and the job can be restarted The messag
272. he media from the duplex unit and clear the message on the operator panel by touching Back or pressing Stop Q9 INPUT TRAY TESTS Feed Tests input tray This test lets the servicer observe the paper path as media is feeding through the printer A blank sheet of paper feeds through the printer as the laser turns off during this test The only way to observe the paper path is to open the lower front door that is used to access the envelope or multipurpose feeder The paper is placed in the output bin To run the Input Tray Feed Tests 1 Touch to select Feed Tests from INPUT TRAY TESTS 2 Touch E to select the input source from the sources displayed on the Feed Tests menu All installed sources are listed 3 Touch EP to select either Single or Continuous e Single feeds one sheet of media from the selected source e Continuous media continues feeding from the selected source until Stop is pressed Diagnostic aids 3 13 7002 xxx Sensor Test input tray This test is used to determine if the input tray sensors are working correctly To run the Input Tray Sensor Test 1 Touch gt to select the Sensor Test from INPUT TRAY TESTS 2 Touch E to select the input source from the sources displayed on the Sensor Test menu All installed sources are listed 3 Select the sensor to test Various sources have different combinations of sensors See the table below Tray sensor support by source Empty Low passThru
273. he test Note The test can NOT be canceled 3 Once the test is complete the power indicator turns on solid and either the message Disk Test Clean Test PassedorDisk Test Clean Failed appears If the message indicates failure the disk is unusable 3 16 Service Manual 7002 xxx Flash Test This test verifies the functioning of the flash device by writing and reading data on the flash to test the flash Warning This test destroys all data on the flash because the flash is unformatted at the end of the test To reformat the flash the servicer or the user must use FORMAT FLASH from the UTILITIES MENU To run the Flash Test 1 Touch E to select Flash Test from DEVICE TESTS The message Contents will be lost Continue displays to warn the user that all contents on the flash device will be lost 2 To exit the test immediately and return to the Device Tests menu touch No To continue touch Yes The power indicator blinks while the test is running and the message Flash lest lesting displays Once the test is complete the power indicator turns on solid and either the message Flash Test Test PassedorFlash Test Test Failed displays 3 Touch Back or press Stop Q9 to return to DEVICE TESTS PRINTER SETUP PRINTER SETUP Defaults US bp A Printed Page Count 127 Permanent Page Count 127 Serial Number be Envelope Enhance Engine Setting 1 The triangles pointing up or down indicate whether there are addit
274. heck the continuity of the fuser to fuser lamp AC cable If incorrect replace the lamp if incorrect replace the fuser top cover assembly Note If the fuser lamp is replaced allow the fuser assembly to cool or a 925 xx error may be displayed Fuser top cover assembly Fuser connect cable fuser to fuser lamp cable 2 130 Service Manual LVPS to fuser AC cable Fuser top cover assembly thermistor thermistor cable Fuser to system board DC cable Error code 920 06 displayed LVPS System board System board to LVPS cable Fuser assembly 7002 xxx CAUTION When taking measurements for AC power observe all safety precautions Check the AC line voltage between the pins on the fuser end of the LPVS to fuser AC cable If the voltage is correct unplug the AC power cord from the LVPS cable If the voltage is correct unplug the AC power cord from the LVPS pull the LVPS out far enough to be able to check the voltage between CN 1 and CN1 3 on the LVPS board Plug in the power cord turn the printer on and check the voltage If correct replace the LVPS to fuser AC cable if incorrect replace the LVPS assembly Note If the fuses in the LVPS are blown the LVPS assembly must be replaced Check to make sure that the thermistor is installed correctly to J5 on the fuser control card If installed correctly check the cable for any signs of damage If any problems are found replace the fuser top cover assembly If no p
275. heet of print media moves through the MFP to be printed x represents the number of the sheet being printed Even though a duplex two sided sheet has two sides called pages it only counts as one sheet Printing page x Asheet of print media moves through the MFP to be printed Fd copy La b x represents the number of the sheet being printed Even though a duplex sheet has two sides called pages it only counts as one sheet So pages are not counted only sheets passing through the MFP The total number of sheets in a setis not known but the number of sets is known For example a user may have requested that three copies print so there are three sets of sheets but the number of sheets is unknown Printing page x A sheet of print media moves through the MFP to be printed Ly copy Lal L5 x represents the number of the sheet being printed A sheet is considered a front and back page of one piece of print media A group of sheets is called a set y represents the total number of sheets in a set a is the number of the current set printing Dis the total number of sets to be printed For example a user may send a 6 page duplex print job and select three copies to print So there are three sheets to print for each job This makes one set Three sets must print before the user has the complete job The MFP is ready to receive and process jobs Print fax scan e mail copy or use FTP Scanner automatic The aut
276. hrung der Arbeiten an den Strom angeschlossen sein mu Pautas de Seguridad e a 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 e La informacion sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento e Existe mayor riesgo de descarga el ctrica y de danos 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 e PRECAUCI N este s mbolo indica que el voltaje de la parte del equipo con la que est AN trabajando es peligroso Antes de empezar desenchufe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informa es de Seguran a e 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 e 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 r
277. ia over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output option s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 202 03 Page is covering narrow If page is not visible from front or rear of Check the fuser for any signs of media sensor during machine partial piece of page may be a piece of media stuck in the warm up Fuser page torn off in fuser covering narrow media fuser count between 0 and sensor Narrow media sensor or flag may 99 999 be dislodged damaged 2 68 Service Manual 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Description Possible causes codes Error code 202 202 202 202 202 202 202 04 05 07 10 Exit sensor bounced Exit sensor assembly Fuser page count between 0 and 99 999 Never sent the divert command to the stacker Fuser page count between 0 and 99 999 Page is covering exit Something is keeping the exit sensor in a sensor during warm up covered position A page may not have Fuser page count been cleared from a prior jam between 0 and 99 999 Timeout waiting for the page ahead Fuser page count between 0 and 99 999 Divert media command i
278. ial Delay 3 36 Key Repeat Rate 3 36 LES Applications 3 35 Maintenance Page Count 3 26 Min Copy Memory 3 30 Panel Menus 3 28 Paper Prompts 3 32 PPDS Emulation 3 28 Print Quality Pages 3 27 Require Standby 3 35 Reset Maintenance Counter 3 26 SIZE SENSING 3 27 Wipe Disk 3 34 Wiper Message 3 36 configurations models 1 1 connector locations autoconnect top 5 8 fax card 5 28 flatbed interface card 5 24 high voltage power supply HVPS 5 9 interconnect card 5 10 LCD inverter board 5 14 low voltage power supply LVPS 5 11 motor driver board 5 20 operator panel card 5 12 scan control card 5 15 USB card 5 14 connectors system board 5 3 cover closed switch 2 123 Index l 1 7002 xxx D defaults EP defaults 3 20 factory defaults 3 29 US Non US defaults 3 17 deflector inner paper deflector assembly 4 97 MPF lower paper deflector 4 112 upper paper deflector assembly 4 132 developer drive assembly parts 7 28 removal 4 73 developer drive coupler kit 4 74 diagnostics menu accessing 3 1 available tests 3 2 BASE SENSOR TEST 3 15 DEVICE TESTS Disk Test Clean 3 16 Flash Test 3 17 Quick Disk Test 3 16 DUPLEX TESTS Duplex Feed 1 3 13 Duplex Feed 2 3 13 Motor Test 3 12 Quick Test 3 11 Sensor Test 3 12 Top Margin 3 11 EP SETUP Charge Roll 3 21 EP Defaults 3 20 Fuser Page Count 3 20 Fuser Temp 3 20 Gap Adjust 3 21 Print Contrast 3 21 Transfer 3 21 Warm Up Time 3 21 EVENT LOG Clear Log 3 22 Display Log 3 21 Print Log 3 22 e
279. ice check on page 2 135 202 43 Page is covering narrow If page is not visible from front or rear Check the fuser and area media sensor during of the printer a partial piece of a around the fuser assembly for warm up Fuser page page may be torn off in the fuser any signs of debris or pieces of count between 400 000 covering the narrow media sensor paper or media and 499 999 e he narrow media sensor or flag may be dislodged or damaged 2 76 Service Manual 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error code 202 202 202 202 202 202 202 Sub Description codes P Exit sensor may have bounced Fuser page count between 400 000 and 499 999 Never sent the divert command to the stacker Fuser page count between 400 000 and 499 999 Page is covering the exit sensor during warm up Fuser page count between 400 000 and 499 999 Timeout waiting for the page ahead Fuser page count between 400 000 and 499 999 Divert media command issued too soon Fuser page count between 400 000 and 499 999 Virtual page timed out waiting for last page of job to be safe in the stapler accumulator Fuser page count between 400 000 and 499 999 Paper jam around the fuser exit or redrive area Fuser page count stopped at 500 000 to preserve data Possible causes Exit sensor assembly Something is keeping the exit sensor in a covered position A page
280. ick Test Page as you check the diamonds on the left margin Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want Step B Print a copy of the Quick Test Page and check the margin adjustments printed on the test page These settings should be within the range specified in Registration base printer on page 3 5 The reference screw can be adjusted without loosening the locknut Turn the screw a few turns and print a copy of the Quick Test Page as you check the diamonds on the left margin Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want An Repair information 4 3 7002 xxx Scanner calibration Select Scanner Manual Registration on page 3 23 from the SCANNER TESTS in the Diagnostics Menu After Diagnostics Menu is exited the calibration test is performed automatically on the next MFP POR Perform the scanner calibration when e The ADF assembly CCD RIP card or SCU card is replaced e NVRAM is reset e The operator panel is replaced Scanner registration Automatic registration Note Before performing scanner registration ensure MFP registration and alignment is properly set See Registration base printer on page 3 5 and Printhead assembly adjustment base printer on page 4 2 for more information 1 Place a colored piece of paper A4 or letter
281. in three areas the front of the MFP inside the MFP and at the rear of the MFP Jams in the front of the MFP occur in the input options or the duplex tray Jams inside the MFP occur in two locations and require the removal of the print cartridge Jams can also occur at the rear of the MFP or duplex unit Note The following clearing jam instructions may seem out of numerical sequence However they have been grouped to help you quickly clear the print path To go to a specific jam see Understanding jam messages on page 3 41 250 Paper Jam Check MP Feeder Remove the paper from the multipurpose feeder Flex fan and restack the media and place it into the multipurpose feeder Load the print media mo IS Slide the side guide toward the inside of the tray until it lightly rests against the edge of the media Diagnostic aids 3 41 7002 xxx 5 Touch Continue 260 Paper Jam Check Env Feeder The envelope feeder feeds envelopes from the bottom of the stack the bottom envelope will be the one that is jammed 1 Lift the envelope weight 2 Remove all envelopes If the jammed envelope has entered the MFP and cannot be pulled out remove the envelope feeder d Lift the envelope feeder out of the MFP and then set it aside b Remove the envelope from the MFP Note If you cannot remove the envelope the print cartridge will have to be removed See 200 and 201 Paper Jam Remove Cartridge on page 3 47 for more information C
282. inals if restarting job 2 50 Replace wiper 2 50 check device connection messages 2 57 service error codes 2 15 user attendance messages 2 43 user line 2 link messages 2 57 user status displays 2 39 Min Copy Memory 3 30 Model Name 3 18 models 1 1 7 1 motor driver board connectors 5 20 MPF arm assembly 4 111 MPF lower paper deflector 4 112 MPF solenoid assembly 4 114 multipurpose feeder parts catalog 7 22 removal 4 67 narrow media sensor See fuser narrow media sensor numeric keypad 2 3 O operator panel Button Test 3 8 description 2 2 operator panel card connectors 5 12 l 4 Service Manual Panel Test 3 8 upper front cover 7 3 options descriptions 1 2 parts catalog 7 65 service checks 2 150 outer shield parts catalog 7 38 removal 4 121 output bin sensor tests standard bin 3 15 P packaging 7 65 page count Fuser Page Count 3 20 Page Count 3 18 permanent page count 3 18 Panel Menus 3 28 Panel Test 3 8 paper bin full sensor flag 4 119 paper deflector assembly inner 4 97 upper 4 132 paper feed jams 200 and 201 remove cartridge 3 47 202 open rear door 3 48 23x and 24x jams 3 44 23x duplex rear door 3 50 250 MPF 3 41 260 envelope feeder 3 42 290 291 292 and 294 scanner jams 3 50 access door and trays 3 40 clearing 3 41 identifying jams 3 39 paper path 3 40 paper jam error codes 2 58 paper path 3 40 Paper Prompts 3 32 paper size sensing board 2 154 4 120 paper specifications 1 8 parallel wr
283. indicated on the control panel From the home screen press it to start a copy job with the default settings If pressed while a job runs through the scanner the button has no effect Press to cause the printing or scanning to stop During a scan job the scanner finishes scanning the current page and then stops which means paper may remain in the automatic document feeder ADF During a print job the print media path is cleared before the printing stops Stopping appears on the control panel during this process Within the Copy menu which is accessed by touching the Copy button press Backspace to delete the right most digit of the value in the Copy Count The default value of 1 appears if the entire number is deleted by pressing Backspace numerous times Within the Fax Destination List press Backspace to delete the right most digit of a number entered manually It also deletes an entire shortcut entry Once an entire line is deleted another press of Backspace causes the cursor to move up one line Within the E mail Destination List press Backspace to delete the character to the left of the cursor If the entry is in a shortcut the entire entry is deleted is used as part of a fax number or as an alphanumeric character Diagnostic information 2 3 7002 xxx USB Direct interface The host Universal Serial Bus USB direct interface on the control panel is used to plug in a USB flash memory device and print a
284. ing components e Operator panel right cover assembly e System board assembly e Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more 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 This error code indicates a mismatch between the operator panel board and the interconnect card Interconnect card If the interconnect card been recently replaced go to step 3 If the card has not been replaced go to step 2 Operator panel board If the operator panel board has been recently replaced go to step 4 If the operator panel board has not been replaced contact your next level of support Interconnect card Replace the current interconnect card assembly with the original interconnect card assembly See Interconnect card assembly removal on page 4 103 If the error remains go to step 5 Operator panel board Replace the current operator panel board with the original operator panel board See Operator panel right cover assembly removal on page
285. int quality blurred or fuzzy print Blurred of fuzzy print is usually caused by a problem in the main drive gearbox assembly alignment assembly any feed roller or in the transfer roll bearings or transfer roll Check the gearbox assembly for correct operation Check the transfer roll for binds or a contaminated shaft or bearings Blurred print can also be caused by incorrect feeding from one of the input paper sources paper trays duplex option or envelope feeder Check the high voltage contacts to ensure they are not bent corroded or damaged Replace as necessary Diagnostic information 2 157 7002 xxx Print quality background Service tip Some background problems can be caused by rough papers non Lexmark toner cartridges or if the media texture is set to the rough setting Some slick or coated papers may also cause background problems Some problems occur with printers that run a large amount of graphics in a humid environment The customer may try to improve the print quality by increasing the transfer setting Check the charge roll to make sure it is not at the end of life Printhead The printhead on this printer cannot be cleaned Try another printhead if all other attempts fail to correct a background problem Transfer roll assembly Check the high voltage contact from the HVPS to the transfer roll Check the transfer arm assembly right side bearing for contamination pitting or a loose cable to the bearing If any pr
286. inue 202 Paper Jam Open Rear Door 1 If the paper is exiting the MFP pull the media straight out and then touch Continue Otherwise continue with step 2 2 Open the MFP rear door CAUTION The inside of the MFP may be hot Allow the MFP to cool before touching any internal components CAUTION Do not use any pointed objects to remove the paper This could cause personal injury or damage to the MFP 3 48 Service Manual 7002 xxx 3 Remove the jammed media Diagnostic aids 3 49 7002 xxx 23x Paper Jam Open Duplex Rear Door 1 Open the duplex rear door 2 Remove the jammed media Depending on the media location pull the media either up or down 3 Close the duplex rear door Make sure it snaps into place 4 Touch Continue Clearing ADF Jams 290 291 292 and 294 Scanner Jams 1 Remove all original documents from the ADF 2 Open the ADF top cover and remove any jammed pages 3 50 Service Manual 7002 xxx ny jammed pages MOVE a r andre 3 Open the ADF cove ny jammed pages guide and remove a 4 Open the lower entrance 6 Close the ADF cover Diagnostic aids 3 51 7002 xxx 3 52 Service Manual 7002 xxx 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
287. ion applications Low Voltage Power Supply Motor Driver Control Multifunction Printer Multipurpose Feeder Masked Read Only Memory Nonvolatile Random Access Memory Optical Sensor Photoconductor Personal Identification Number Printer Job Language Power On Reset Power On Self Test Parts Packet Pages Per Minute Pulse Width Modulation Raster Imaging Processor Read Only Memory Scanner System Control Synchronous Dynamic Random Access Memory Single Inline Memory Module Sheet Per Minute Static Random Access Memory Volts alternating current Volts direct current Volt Onmmeter General information 7002 xxx 1 18 Service Manual 7002 xxx 2 Diagnostic information Start CAUTION Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer Use the handholds on the side of the printer Make sure your fingers are not under the printer when you lift or set the printer down Use the service error code user status message user error message symptom table service checks and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer They will lead you to solutions or service checks including use of various tests Symptom tables If your machine completes the does not display an error message and you have a problem go to Symptom ta
288. ion e DBCS font cards Simplified Chinese Traditional Chinese Japanese Korean Maintenance approach The diagnostic information in this manual leads you to the correct field replaceable unit FRU or part Use the service error codes user status messages user error messages service checks and diagnostic aids to determine the MPF problem and repair the failure After you complete the repair perform tests as needed to verify the repair See Start on page 2 1 1 2 Service Manual 7002 xxx Specifications General MFP specifications Scanner Scan area flatbed 8 5 in x 14 in 216 mm x 355 6 mm maximum Scanner ADF ADF type Single pass simplex ADF with C path ADF optical resolution 600 x 600 dpi maximum Document capacity 50 sheets assuming 20 Ib 75 g m Media thickness 0 05 mm minimum to 0 15 mm maximum Media weight 15 Ib 56 g m to 32 Ib 120 g m Scan speed ADF Mono letter or A4 measured in sheets per minute Simplex 600 x 300 dpi up to 35 spm 600 x 600 dpi up to 17 spm 600 x 300 dpi Up to 35 som 600 x 600 dpi up to 17 spm ADF scan area 8 5 in x 14 0 in 216 mm x 355 mm Print technology Hot roll fuser Simplex 600 dpi Up to 50 ppm letter Up to 75 9 ppm A4 Duplex 600 dpi Up to 37 4 spm letter Up to 36 2 spm A4 Modem Built in Group 3 compatible full function fax 33 600 bps Max V 34 half duplex ADF scan speed is defined as sides going through the A
289. ional furniture for stability You must use either a printer stand or printer base if you are using a 2000 sheet drawer Certain other configurations also must have a printer stand or printer base More information is available on our Lexmark Web site at www lexmark com multifunctionprinters 3 46 Service Manual 7002 xxx 200 and 201 Paper Jam Remove Cartridge 1 2 Push the release latch and lower the multipurpose feeder Push the release latch and open the top front cover CAUTION The inside of the MFP may be hot Allow the MFP to cool before touching any internal components Lift and pull the print cartridge out of the MFP Warning Do not touch the photoconductor drum on the underside of the cartridge Use the cartridge handle whenever you are holding the cartridge Place the print cartridge aside Note Do not leave the cartridge exposed to light for extended periods Note The print media may be covered with unfused toner which can stain garments and skin Pull the print media up and toward you CAUTION Do not use any pointed objects to remove the paper This could cause personal injury or damage to the MFP Warning If the print media does not move immediately when you pull stop pulling You need to access the print media from the MFP rear door Diagnostic aids 3 47 7002 xxx 6 Align and reinstall the toner cartridge T Close the top front cover 8 Close the multipurpose feeder 9 Touch Cont
290. ional menus Touch the up or down arrows to display these additional menus Note If you make changes touch Submit to make the change effective Defaults US Non US defaults changes whether the printer uses the US factory defaults or the non US factory defaults The settings affected include paper size envelope size PCL symbol set code pages and units of measure Warning Changing this setting resets the printer to factory defaults and data may be lost It cannot be undone Diagnostic aids 3 17 7002 xxx Printed Page Count The page count can only be viewed and cannot be changed Touch Back to return to Diagnostics Menu Permanent Page Count The permanent page count can only be viewed and cannot be changed Touch Back to return to Diagnostics Menu Serial Number The serial number can only be viewed and cannot be changed Touch Back to return to Diagnostics Menu Envelope Enhance This setting affects the level of the fuser solenoid To set Envelope Enhance 1 The current value is displayed lt q setting s current value P The values are Low Medium and High The default is Medium 2 Touch lt or P to change the value Touch Back to return to Diagnostics Menu Engine Setting 1 through 4 Warning Do not change these settings unless requested to do so by your next level of support Model Name The model name can only be viewed and cannot be changed 3 18 Service Manual 7002 xxx Configuration
291. ios CUIDADO Quando vir este s mbolo existe a poss vel presenca de uma potencial J tens o perigosa na zona do produto em que est a trabalhar Antes de comecar 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 xviii Service Manual Informacio de Seguretat A r9 r2i x 7002 xxx 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 q estions de seguretat si s utilitzen peces de recanvi no autoritzades La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui 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 precaucions si per treballar amb l equip l heu de connectar p rd ma um ee ee tm e ee e A uie elo eee eee he alee A ee ae 2 eee Bus po a ee pes ess At Ai EI H o z H Moo AT 2 ot ALC 10L A L L L Og WH oo We Se eque AS e wu ee es Gee 56 WA OP ela eS amp spz u ee Oy 27 S sepe a ofA A pes 2 ea ae ay ee 9 61 HA Ol L Cf F A1 OF Zzecte H o Al THL Tl o H TL E oH Toe x9 Sm sr E A 7 its ASP di HI ZETE EA JOR CP AE AE P m E
292. is feature indicates an attendance message exists Diagnostic information 2 11 7002 xxx Menus A number of menus are available to make it easy for you to change MFP settings or print reports To access the menus and settings press the menu button in the lower right corner of the home screen When a value or setting is selected and saved it is stored in MFP memory Once stored these settings remain active until new ones are stored or the factory defaults are restored Note Settings chosen for faxing scanning e mailing copying and settings for printing from the application may override the settings selected from the control panel The following diagram shows the touch screen menu index and the menus and items available under each menu For more information about menus and menu items see the Menus and Messages Guide on the Software and Documentation CD Paper Menu Default Source Paper Size Type Configure MP Envelope Enhance Substitute Size Paper Texture Paper Weight Paper Loading Custom Types Custom Names Custom Bin Name Universal Setup Bin Setup Paper Menu Reports Network Ports Settings Manage Shortcuts Calibrate Touch Screen Reports Menu Settings Page Device Statistics Network Setup Page Shortcut List Fax Job Log Fax Call Log E mail Shortcuts Fax Shortcuts FTP Shortcuts Profiles List NetWare Setup Page Print Fonts Print Directory Manage Shortcuts Manage Fax Shortcuts Manage E m
293. isk Test on page 3 16 from the Device Test on the Diagnostics menu when a problem is suspected either with the hard disk system board or with the hard disk 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 hard disk board The Disk Test Clean on page 3 16 is used to help restore the disk if the disk 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 Format 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 Error Code 976 xx Network Card x x Network card 1 2 or 3 A 976 error code indicates an unrecoverable software error in network card x Verify that network card x is correctly installed in the socket on the interconnect card and is properly grounded If you find no problem contact your next level of support before replacing the network card Error Code 977 xx Network Card x A 977 error displays when the RIP software detects that a network card is installed in slot x on the interconnect card but cannot establish communications with the network card Diagnostic information 2 151 7002 xxx Output bin
294. istent go to Step 2 ADF feed gears and Check the ADF feed gears pulleys and hardware for any signs of hardware binding broken or damaged parts If any problems are found replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 Note To help isolate a problem with the ADF feed system you can run the Feed Test from the SCANNER TESTS in the Diagnostics Menu Put several sheets of media in the ADF tray and observe the gears motor belts and other hardware for any signs of a malfunction that might cause the media not to reach the second scan sensor 3 Second scan sensor cable Check to make sure the second scan sensor cable is correctly second scan sensor to installed at the sensor at CN9 on the MDC motor driver card in the CN9 on the MDC card ADF If the cable is not installed correctly reinstall the cable If installed correctly go to step 4 Diagnostic information 2 105 7002 xxx Turn the power off and disconnect CN9 on the motor driver card Measure the voltages in the table below normally closed Connector CN9 motor driver card If incorrect replace the motor driver card If correct go to step 5 Second scan sensor Turn the power off and reconnect CN9 to the motor driver card electrical checks Measure the voltages in the table below wi
295. ize A4 size and legal size sheets Label adhesives face sheet printable stock and topcoats must be able to withstand temperatures of 230 C 446 F and pressure of 25 pounds per square inch psi Try a sample of any labels you are considering using with the MFP before purchasing a large quantity For detailed information on label printing characteristics and design see the Card Stock amp Label Guide available on the Lexmark Web site at www lexmark com publications Note Labels are one of the most difficult print media for laser MFPs All MFP models require a special fuser cleaner for label applications to optimize feed reliability After printing approximately 10 000 pages of labels or each time you replace the print cartridge complete the following steps to maintain MFP feeding reliability 1 Print five sheets of paper 2 Wait approximately five seconds 3 Print five more sheets of paper When printing on labels Set the Paper Size Type menu item to Labels in the Paper menu You can set the Paper Size Type from the MFP control panel the MFP driver or from MarkVision Professional Feed vinyl labels from the standard 250 or 500 sheet trays or the optional 250 or 500 sheet drawers For vinyl labels set the Paper Type to Labels the Labels Texture to Smooth and the Label Weight to Heavy or set the Paper Type to vinyl labels and the texture and weight to normal Do not load labels with paper or transparencies i
296. kVision Professional e For best performance use envelopes made from 75 g m 20 Ib bond paper You can use up to 105 g m 28 Ib bond weight for the multipurpose feeder or 105 g m 28 Ib bond weight for the envelope feeder as long as the cotton content is 25 or less Envelopes with 100 cotton content must not exceed 90 g m 24 Ib bond weight Use only new undamaged envelopes e For best performance and to minimize jams do not use envelopes that Have excessive curl or twist Are stuck together or damaged in any way Contain windows holes perforations cutouts or embossing Use metal clasps string ties or metal folding bars Have an interlocking design Have postage stamps attached Have any exposed adhesive when the flap is in the sealed or closed position Have nicked edges or bent corners Have rough cockle or laid finishes e Use envelopes that can withstand temperatures of 230 C 446 F without sealing excessive curling wrinkling or releasing hazardous emissions If you have any doubts about the envelopes you are considering using check with the envelope supplier e Load only one size of envelope at a time in the envelope feeder A combination of high humidity over 6096 and the high printing temperatures may seal the envelopes General information 1 13 7002 xxx Labels The MFP can print on many labels designed for use with laser printers These labels are supplied in letter s
297. ken too long to reach desired temperature after increasing interpage gap Fuser page count between 200 000 and 299 999 Hot roll took too long to reach the beginning lamp detection temperature Fuser page count between 300 000 and 399 999 Hot roll reached final lamp detection temperature but took longer than largest time in lookup table Fuser page count between 300 000 and 399 999 Hot roll timed out in trying to reach the final lamp detection temperature Fuser page count between 300 000 and 399 999 After hot roll lamp detection did not roll over to steady state control in time Fuser page count between 300 000 and 399 999 Hot roll did not reach operating temperature in time new enhanced control Fuser page count between 300 000 and 399 999 Fuser has taken too long to reach desired temperature after increasing interpage gap Fuser page count between 300 000 and 399 999 Service Manual Description Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cablin
298. kit 40X0100 220 V Maintenance kit 40X0101 100 V Maintenance kit 40X0102 After replacing the kit the maintenance count must be reset to zero to clear the 80 Scheduled Maintenance message See Maintenance Page Count on page 3 26 Preventive maintenance 7 1 7002 xxx Cleaning the scanner glass and flatbed white cushion 1 Open the document cover 2 Dampen a clean lint free cloth or cotton swab with isopropyl alcohol 95 3 Wipe the scanner glass and flatbed white cushion by moving the cloth or swab from side to side Flatbed cushion 4 Open the scan unit access door 5 Wipe the scanner glass and flatbed white cushion by moving the cloth or swab from side to side Scanner glass Flatbed white cushion 6 Close the scan unit access door 7 Close the document cover 7 2 Service Manual 7002 xxx 8 Parts catalog How to use this parts catalog The following legend is used in the parts catalog Units mach Units OR kit or Description Units option pkg Part number e Asm index identifies the assembly and the item in the diagram For example 3 1 indicates Assembly 3 and the item number 1 Part number identifies the unique number that identifies this FRU Units mach refers to the number of units actually used in the base machine or product Units option refers to the number of units used in the option and does not include the base machine Units kit or pkg refers to the number of units
299. l a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema l ser y la impresora est n disenados de forma que ninguna persona pueda verse afectada por ning n tipo de radiaci n l ser superior al nivel de la Clase durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declara o sobre Laser A impressora est certificada nos E U A em conformidade com os requisitos da regulamentac o DHHS 21 CFR Subcap tulo J para a Classe 1 de produtos laser Em outros locais est certificada como um produto laser da Classe I em conformidade com os requisitos da norma IEC 60825 1 Os produtos laser da Classe nao sao considerados perigosos Internamente a impressora cont m um produto laser da Classe Illb 3b designado laser de arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiac o laser superior a um nivel de Classe durante a operac o normal a manutenc o feita pelo utilizador ou condic es de assist ncia prescritas XM Service Manual 7002 xxx Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 60825 1 Laserprodukten van kla
300. l be erased For copies the printed page will have 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 To change this setting 1 Touch gt to select FB Edge Erase from the Configuration Menu The panel displays the setting s name in the header and lt q setting s current value gt below the header row 2 Touch gt to increase the value or lt q to decrease the value The values are 0 through 6 The default is 3 3 Touch Submit to save the change Touch Back to cancel and return to the Configuration Menu Automatic Scanner Registration To perform the Automatic Scanner Registration 1 Obtain two pieces of colored paper A4 or letter for the automatic registration Use a light blue sheet or other solid color paper 2 Touch gt to select Automatic Scanner Registration from the Configuration Menu Please place a piece of dark colored paper on the Flatbed and in the ADF 3 Place a colored piece of paper in the ADF making sure the edge guides are properly adjusted Place another piece of paper A4 or letter on the flatbed Touch Start Diagnostic aids 3 31 7002 xxx 4 The touchscreen displays DO NOT POWER OFF Scanner Registration When complete a screen similar to the following should appear Scanner registration successfully completed 5 Touch Continue EVENT LOG The event log provides a history of printer errors The ev
301. l in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair information 4 1 7002 xxx Adjustment procedures Fuser solenoid adjustment Perform the fuser solenoid adjustment whenever you replace the fuser solenoid Adjust the fuser solenoid while installed in the MFP Adjust the screw on the eccentric mounted on the solenoid housing to provide an air gap between the rear of the solenoid stator and the solenoid armature The solenoid air gap for all models is 4 5 mm 0 1 mm Gap adjustment The gap adjustment allows you to increase the minimum gap between sheets of paper as they are fed through the MFP This adjustment reduces the MFP overall performance such as pages per minute but can help in reducing the amount of curl of some printed media thus improving media stacking in the output bin 1 Enter the Diagnostic Menu 2 Select EP SETUP from the Diagnostic Menu 3 4 The range of the GAP adjustment is 0 to 255 Adjust the gap setting by using arrows to select the value Select Gap Adjust and press Submit If GAP 0 displays it indicates a factory setting to minimum gap Select a value and run several copies of the media that displays a curl problem It may take several tries before improvement is noticed Note This setting has no effect when duplexing Printhead assembly adjustment base printer Do the printhead assembly adjustment whenever y
302. l port but the port is disabled Touch Continue The MFP discards any data received on the serial port Touch Reset Active Bin to change to another linked bin 7002 xxx User attendance messages continued Sub code Error code C1 O gt X X C1 C1 Ol O x lt O1 NJ X C1 Co C1 Co x lt X X Primary message standard USB port disabled USB port Lx disabled Gontigurgution change some held jobs were lost Too many disks installed Too many flash options installed Too many trays attached Incompatible duplex Description action The MFP receives data through a USB port but the USB port is disabled Touch Continue The printer discards any data received through the USB port Make sure the USB Buffer menu item is not set to Disabled Touch Reset Active Bin to change to another linked bin The MFP receives data through a specified USB port but this USB port is disabled x is the number of the USB port Touch Continue The MFP discards any data received through the specified USB port Make sure the USB Buffer menu item is not set to Disabled Touch Reset Active Bin to change to another linked bin The MFP fails to restore held jobs due to configuration changes The message appears once Some held jobs are not restored They stay on the hard disk and are inaccessible The MFP detects an excess of hard disks installed 1 Turn the MFP off 2 Unplug the power cord fr
303. label 2 22 22 e een n eee rene eee eee ee eeee 7 11 Paper size sensing board assembly 2 222 sec e crete etree eee eee eeeeee 7 9 Paper size sensing board Tray 1 autocompensator paper out low cable 7 41 Paper switch activate spring 2 2 ee rer ret rete eee ener eee eee eee erences 7 9 Gear release link 2 222 eee ee eee eee eees 7 9 Counterbalance spring 22s erent re rr eee eee eens 7 3 Standard bin level sensor 22 22 sete etree eee eee eee eeee 7 9 Standard bin level sensor bracket 2 2 2 e reer ee etree ee eeeee 7 9 Main fan 250 sheet 22 2 cere rer ee rere eter eee eee ee eees 7 47 Main fan with cable 500 sheet output 22 2c eee ee ee eee ee eee ee eee eeeeee 7 9 Main fan 500 sheet 2 22 e eee e er nr eer ee eee eee eee eee eee eeeeee 7 47 Output paper level flag TIIIIIIII I I 21 1 2 7 9 Extension guide 2 222 entre cre nr ne ee eee eee eee eee eee eees 7 9 External ground clip u rrrrrrrrIrrrIIIIe 7 7 Laser cable assembly u rurururrrr eee eee ee eee eee eee ees 7 20 Laser printhead cable assembly rurrrrrr rrr 7 41 Printhead assembly includes all cables 7 20 Frame extension nut plate 2 2222 ees eee e ene eee eee eee nee eee eee eee
304. lder assembly 4 50 scanner left side cover 4 9 scanner right side cover 4 12 separator assembly torque limiter 4 52 upper glass holder 4 53 Require Standby 3 35 right cover handle holder removal 4 68 right cover removal 4 58 S safety information xvii safety inspection guide 6 1 Scan control card connectors 5 15 Scanner Manual Registration 3 23 scheduled maintenance 6 1 sensors flatbed paper length sensor assembly 4 34 fuser exit sensor 4 78 fuser narrow media sensor 4 84 home sensor 4 46 input 4 98 locations 5 1 output bin sensor integrated paper tray 2 152 paper bin full 4 119 paper size sensing board 4 120 l 6 Service Manual toner 4 126 serial number 3 18 serial wrap tests 3 10 service checks 290 00 error code 2 95 290 01 error check 2 97 290 02 error code 2 99 290 10 error code 2 101 291 00 error code 2 102 291 01 error code 2 104 291 02 error code 2 105 292 00 error code 2 106 293 error code 2 107 294 00 error code 2 108 294 01 error code 2 109 294 02 error code 2 111 294 03 error code 2 112 298 01 error code 2 114 298 02 error code 2 114 842 xx error code 2 114 843 00 error code 2 115 845 00 error code 2 115 848 00 error code 2 116 848 01 error code 2 116 900 90 error code 2 116 900 xx error code 2 116 927 xx error code fan 2 116 950 00 through 950 29 EPROM mismatch failure 2 118 ADF paper length 2 120 cartridge fan 2 117 charge roll 2 121 cold fuser 2 132 cover closed senso
305. le from the fuser to fuser lamp cable Plug the AC line cord AN into the printer and check the AC line voltage between the pins on the fuser end of the LVPS to fuser AC cable If the voltage is correct unplug the AC power cord from the LVPS cable and pull the LVPS out far enough to be able to check the voltage between CN 1 and CN 3 on the LVPS board Plug in the power cord turn the printer on and check the voltage If correct replace the LVPS to fuser AC cable if incorrect replace the LVPS assembly See Low voltage power supply removal on page 4 105 Note If the fuses in the LVPS are blown the LVPS assembly must be replaced Fuser top cover assembly Check to make sure that the thermistor is installed correctly to J5 on thermistor thermistor the fuser control card If installed correctly check the cable for any cable signs of damage If any problems are found replace the fuser top cover assembly Fuser narrow media sensor removal on page 4 84 If no problem is found check the fuser to system board DC cable for correct installation at J1 on the fuser control card If no problem is found check the fuser to system board cable for correct installation at J10 on the system board If no problem is found go to step 6 Fuser to system board DC cable 2 132 Service Manual 7002 xxx If no problem is found up to this point then replace the following in the order shown Fuser assembly See Fuser assembly removal
306. le the fuser board Measure the resistance between the two pins on the assembly thermistor cable if the resistance measures infinity open circuit replace the fuser top cover assembly Fuser to system board Reconnect the thermistor cable to J5 on the fuser board Disconnect cable the fuser to system board cable from J10 on the system board and System board measure the resistance between J10 3 and J10 4 on the cable If the resistance measures infinity open circuit check the continuity of pins Fuser assembly 3 and 4 of the cable If correct replace the fuser assembly See Fuser assembly removal on page 4 75 If incorrect replace the fuser to system board cable Note If the error code still displays replace the system board See System board and inner shield removal on page 4 125 925 xx Hot fuser service check Error Code 923 xx 924 xx and 925 xx may display for a hot fuser failure CAUTION The fuser may be hot use caution before removing or servicing working Unplug the printer before you begin or use caution if the printer must receive power in CAUTION There is a danger from hazardous voltage in the area of the printer where you are A N order to perform the task Service tip Set the Fuser Temperature to NORMAL before starting this service check In Diagnostics mode In Diagnostics mode select EP SETUP and Fuser Temp If the fuser is 220 V machine a 115 V fuser may be installed If the printer is
307. lel Wrap test This test is used with a wrap plug to check operation of the parallel port hardware Each parallel signal is tested Use Parallel Wrap for the standard parallel port Parallel 1 Wrap if a parallel port is available by PCI slot 1 or Parallel 2 Wrap if a parallel port is available by PCI slot 2 To run the Parallel Wrap tests 1 Disconnect the parallel interface cable and install the wrap plug P N 1319128 2 Select Parallel Wrap Parallel 1 Wrap or Parallel 2 Wrap from the HARDWARE TESTS menu The power indicator blinks green indicating the test is in progress The test runs continuously until a maximum number of tests is reached P UHHHHHE FuHHHE o PY represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 e F represents the number of times the memory test has failed and finished with errors Initially 0000 displays with the maximum fail count being 999 999 Initially only four digits appear but additional digits appear as needed Each time the test finishes the screen updates If the test passes the pass counter increases by 1 however if the test fails a message displays for approximately three seconds Once the maximum count is reached the test stops The power indicator goes on solid and the final results display To stop the test before completion press Stop e Serial Wrap test The serial wrap test
308. lth and Human Services 21 CFR Teil J f r Laserprodukte der Klasse 1 In anderen L ndern gilt der Drucker als Laserprodukt der Klasse l der die Anforderungen der IEC International Electrotechnical Commission 60825 1 gem amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse IIlb 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der Lange 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert da im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgem Ber Wartung durch den Kundendienst Laserbestrahlung die die Klasse bersteigen w rde Menschen keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux provisions DHHS 21 CFR alin a J concernant les produits laser de Classe 1 Pour les autres pays cette imprimante r pond aux normes IEC 60825 1 relatives aux produits laser de Classe I Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe Illb 3b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanometres L imprimante et son syst me laser sont concus pour impossible dans des conditions normales d utilisation d entretien par l utilisa
309. m feeder Replace feeder 260 12 Page did not reach input Paper jam around envelope feeder Remove feeder and clear sensor from envelope jam feeder Replace feeder 2 02 Service Manual 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx aha Hb Description code codes P Page was not properly picked from envelope feeder 260 Page was not properly picked from envelope feeder 260 Failed to feed from envelope feeder Pages in the paper path have been flushed to the output bin 290 Static jam ADF Interval Sensor 290 i ADF Pickup Jam 290 i ADF Feed Jam 290 Static jam First Scan Sensor 291 Static Jam Second Scan Sensor 291 First ADF Scan Sensor Jam 291 Second ADF Scan Sensor 292 ADF Cover Open Jam Possible causes Paper in envelope feeder on warm up Paper jam around envelope feeder Paper jam around envelope feeder Paper jam around envelope feeder The paper may be stuck in the ADF at or over the interval sensor e Interval sensor may be malfunction The ADF attempted to stage a page but the leading edge of the page did not reach the interval sensor The leading edge of the page reached the interval sensor but did not reach Paper may be stuck in the ADF at the first scan sensor or the first scan sensor may be malfunctioning Paper may be stuck in the ADF at the second scan sensor or the second scan sensor is not operating properly
310. m Configuration Menu Note If an advanced password has been established you must enter this password in order to change the setting If no advanced password exists you can establish one by using the keyboard that appears on the LCD 2 Touch E to select Wipe disk now Contents will be lost Continue appears on the touchscreen 3 Touch Back to return to EVENT LOG 4 Touch Yes to continue or touch No to exit 3 34 Service Manual 7002 xxx Font Sharpening This setting allows a user to set a text point size below which the high frequency screens are used when printing font data For example at the default 24 all text in font sizes 24 and less will use the high frequency screens The values for this setting range from 0 to 150 and the default value is 24 This setting affects PostScript PCL and XL To change this setting oY 4 Touch gt to select Font Sharpening from the Configuration Menu Touch to increase the value or to decrease the value Touch Back to cancel and return to the Configuration Menu Touch Submit to save the change This function is not supported when the device generates output at 600 dpi resolution Require Standby This setting determines if the Standby Mode is On or Off The default is On If Standby Mode is on the printer begins functioning in Standby Mode when it remains idle for an amount of time The Standby Mode enables the printer To consume less energy than when ope
311. maged replace the contact Note Inspect the HVPS PC drum contact on the board for damage or contamination Check the fuse on the HVPS If open replace the HVPS Check the voltages at J22 on the system board Measure the following voltages from connector J22 to printer ground e Printer Idle J15 5 measures 24 Vdc Printer Printing J15 5 measures 24 V dc If the voltages at J10 5 are incorrect replace the system board Front cable harness HVPS Check the front cable harness at J15 on the system board and at section CN1 on the HVPS to make sure the harness is connected properly If connected properly check the continuity of the cable harness If there is no continuity replace the front cable harness Printhead assembly Generally a 93x service error is posted if the printhead assembly fails and the printer does not give a blank copy symptom The printhead used in the printer does not have a mechanical shutter as previous laser printers The printer is interlocked through the front top cover interlock switch Print quality random marks Service tip The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor charge roll or transfer roll powe m Random marks Check the print cartridge for loose or foreign material that might be on the photoconductor Check the transfer roll and charge roll for any pieces of material that are stuck to the rolls Pr
312. manually activate the sensor you can either open the jam removal tray it is necessary to defeat the jam tray sensor by placing a piece of paper in the sensor to turn off the jam tray message on the display or you can manually feed a piece of paper through the ADF If the sensor fails the test go to step 3 Check to make sure the first scan cable is correctly installed at the sensor CN9 on the SCC scan control card in the ADF If the cable is not installed correctly reinstall the cable If installed correctly go to step 4 Turn the power off and disconnect CN9 on the motor driver card Measure the voltages in the table below normally closed N9 Pi Note All voltages are approximate values If incorrect replace the motor driver card If correct go to step 5 Turn the power off and reconnect CNO9 to the motor driver card Measure the voltages in the table below with the sensor in normal operation sensor closed and with the sensor open sensor flag activated Second scan sensor Connector CN9 motor driver card Sensor closed CN9 Pin 6 45 0 V dc Note All voltages are approximate values If the voltages are incorrect replace the second scan sensor If this does not fix the problem replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4
313. may not have been cleared from a prior jam Page may be jammed in the fuser exit or redrive area Go to Fuser exit sensor service check on page 2 135 Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Diagnostic information 2 77 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes 202 51 Page did not cleanly exit Page may be jammed in fuser exit or fuser or redrive area redrive area Fuser page count stopped at 500 000 to preserve data 202 52 Exit sensor covered too Page may be jammed in fuser exit or long Fuser page count redrive area stopped at 500 000 to preserve data 202 03 Page is covering narrow e f page is not visible from front or rear media sensor during
314. mbly from the left pivot arm 3 Lift the transfer roll assembly toward the left and remove it from the printer 4 126 Service Manual 7002 xxx Upper cover removal base printer po WO THEN 09 T9 T Remove the ADF scan assembly See ADF complete assembly removal on page 4 15 Remove the flatbed scan assembly See Flatbed scan assembly removal on page 4 38 Remove the left door See Printer left side cover removal on page 4 56 Remove the right cover See Printer right cover removal on page 4 58 Remove the upper tray cover See Upper tray cover removal paper support on page 4 56 Remove the upper sub cover See Upper sub cover removal on page 4 55 Remove the fuser wiper cover See Fuser wiper cover assembly removal on page 4 54 Remove the two screws A attaching the upper plenum and remove the upper plenum A Repair information 4 127 7002 xxx 10 Remove the two screws D from the top of the right side eeeeneeeeneene 22 eee w w x 11 Remove the two screws E from the top of the left side m 12 For those models with a hard disk remove the hard disk See Hard disk removal on page 4 44 4 128 Service Manual 7002 xxx 13 Remove the screw F through the back of the shield or from the position shown A A UU seer Z eeeeveeeeeeeg steveeeeeee ETITITIITIIT peeseoeese OT 9522056 Re
315. ment 139 7 x 215 9 mm 5 5 x 8 5 in Universal 139 7 x 210 mm to 215 9 x 355 6 mm 5 5 x 8 27 in to 8 5 x 14 in 69 85 x 127 mm to 215 9 x 355 6 mm 2 75 x5 in to 8 5 x 14 in 148 x 182 mm to 215 9 x 355 6 mm 5 83 x 7 17 in to 8 5 x 14 in 76 2 x 127 mm to 215 9 x 355 6 mm 3x5in to 8 5 x 14 in D M E E 3x7 in to 9 01 x 14 in C5Envelope C5Envelope 162x220 mm 6 38 x 9 01 in x 229 162x220 mm 6 38 x 9 01 in 6 38 x 9 01 in Other Envelope 98 4 x 162 mm to 176 x 250 mm 3 87 x 6 38 in to 6 93 x 9 84 in 7002 xxx 2000 sheet drawer option Envelope feeder option pu ce Q em o O Q pe gt Q gt Duplex unit option Standard output bin 250 sheet tray 500 sheet tray BRE SIRS sou S S sas on a A LI te A NENNMUONUZNL BENIN p LI 1e jjss L 1 PX ses S S SISISIS 1 This size does not appear in the Paper Size menu until Tray Size Sensing is turned off Refer to the User Guide for more information This size setting formats the page for 215 9 x 355 6 mm 8 5 x 14 in unless the size is specified by the software application General information 1 9 7002 xxx Print media types Card stock Printing label applications on the MFP requires a special label fuser cleaner The label fuser cleaner is included with a special label cartridge for label applications Print media weights
316. mes per second that a repeating key will repeat The range is 1 100 with a default of 15 times per second To change this setting 1 Touch gt to select Key Repeat Initial Delay from the Configuration Menu 2 Touch gt to increase the value or lt q to decrease the value 3 Touch Submit to save the change Touch Back to cancel and return to the Configuration Menu Wiper Message To change this setting 1 Touch gt to select Wiper Message from the Configuration Menu 2 Touch or lt q to change the value The values are On default and Off 3 Touch Submit to save the change Touch Back to cancel and return to the Configuration Menu Exit Configuration Menu Touch Exit Config Menu to exit the Diagnostics Menu and Resetting the Printer displays The printer performs a POR and the printer returns to normal mode 3 36 Service Manual 7002 xxx Theory Autocompensator operation The autocompensator is a paper pick device that generates its own normal force This force generation is inherent in the fundamental design of the pick arm If light media is used it picks very gently If a heavy media is used it picks very aggressively No customer adjustments are necessary therefore no special trays are needed for card stock or labels The gearing in the arm is designed so the input torque from the motor produces a movement about the pivot of the arm This movement produces a downward force at the pick rolls The fricti
317. message Reset Maint Cnt Reset displays momentarily When the reset operation is complete the menu returns to the main Configuration Menu 3 26 Service Manual 7002 xxx Print Quality Pages The print quality test pages can be printed from either the Diagnostics Menu or Configuration Menu CONFIG MENU When printed from the Diagnostics Menu additional information is included and the print cartridge lockout is bypassed See Print Quality Pages on page 3 27 Additional configuration information may be included on the print quality pages which is not included on the print menu page To print the Print Quality Test Pages touch gt to select Prt Quality Pgs from Configuration Menu The message Printing Quality Test Pages is displayed The following is printed e Settings from EP SETUP from the Diagnostics Menu Fuser temperature warm up time transfer print contrast and charge roll settings e Contents of the EVENT LOG from the Diagnostics Menu e Printer configuration information Printer serial number controller code level engine code level operator panel code level smart option code levels font versions and so on Values for the QUALITY MENU settings used to print the pages The print quality test consists of four pages Page one contains a mixture of graphics and text Pages two and three only contain graphics Page four is blank If duplex is turned on the pages are duplexed The Print Quality Test pages are printed
318. mm 5 1 kg 250 Sheet drawer 5 in 15 7 in 18 0 in 6 90 mm 398 mm 457 mm 2 7 kg 500 Sheet drawer 5 2 in 15 7 in 19 0 in 7 134 mm 398 mm 520 mm 3 2 kg Ib 2 000 Sheet drawer 15 0 in 15 7 in 18 0 in 381 mm 398 mm 457 mm Envelope option closed position i 7 72 in 196 mm i Envelope option support fully 12 28 in 4 Ib extended 312 mm 1 8 kg MFP Stand with Cabinet 31 5 in 22 4 in 24 5 in 64 Ib 800 mm 569 mm 622 mm 29 0 kg Low Profile MFP Stand 22 8 in 22 4 in 24 5 in 45 Ib 579 mm 569 mm 594 mm 20 4 kg MFP Stand without Cabinet 31 5 in 22 4 in 24 5 in 64 Ib 800 mm 569 mm 622 mm 28 1 kg Caster base 6 0 in 27 in 27 0 in 25 Ib 152 mm 685 mm 686 mm 11 3 kg Envelope option fits within height and width of printer General information 1 5 7002 xxx Power requirements Average nominal power requirements for the base printer configuration 110 volt Power levels are shown in watts W Maximum current is given in Amperes A Printing states Lexmark X644e Lexmark X646e Idle average power Power Saver on 20 W 20 W Power Saver off 90 W 95 W Continuous copying 875 W 875 W Continuous printing 675 W 830 W Printing maximum current Electrical specifications Low voltage model e 100 to 127 V ac at 50 to 60 Hz nominal e 90 to 137 V ac extreme High voltage model e 220 to 240 V ac at 50 to 60 Hz nominal not
319. mmand issued too soon Fuser page count between 300 000 and 399 999 Virtual page timed out waiting for last page of job to be safe in the stapler accumulator Fuser page count between 300 000 and 399 999 Paper jam around the fuser exit or redrive area Fuser page count between 400 000 and 499 999 Possible causes Exit sensor assembly Something is keeping the exit sensor covered A page may not have been cleared from a prior jam Page may be jammed in fuser exit or redrive Go to Fuser exit sensor service check on page 2 135 Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Diagnostic information 2 75 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes 202
320. mmediately when envelope feed is requested POST incomplete Check for any debris or pieces of envelope over the pass thru sensor Check for correct installation of the pass thru sensor flag Make sure the sensor cable is attached to the envelope system board Perform an envelope feeder sensor test to check both the sensor and sensor flag Note It may be necessary to use a small tool to actuate the sensor flag because it is located under the front cover Be careful not to damage the flag If the test fails check the flag for damage or binds If incorrect replace the flag If the flag is operating correctly check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect replace the envelope system board If correct check the voltage at J3 2 The voltage changes from 0 to 5 V dc when the flag is moved in and out of the sensor If incorrect replace the sensor assembly If this does not fix the problem replace the envelope system board Touchscreen displays 260 xx Paper Jam after attempted feed but before envelopes are put in the hopper OR the touchscreen continues to display Load Envelopes after envelopes are placed in the hopper Diagnostic information 2 127 7002 xxx Service tip The kick rolls rotate during the attempted feed cycles Envelope out hopper Check the envelope out sensor flag for damage correct installation sensor flag and operation If incorrect repair or replace the envelope feeder opti
321. mperature Fuser page count between 400 000 and 499 999 45 After hot roll lamp detection did not roll over to steady state control in time Fuser page count between 400 000 and 499 999 Hot roll did not reach operating temperature in time new enhanced control Fuser page count between 400 000 and 499 999 Fuser has taken too long to reach desired temperature after increasing interpage gap Fuser page count between 400 000 and 499 999 Hot roll took too long to reach the beginning lamp detection temperature Fuser page count stopped at 500 000 to preserve data Description Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage The control code has been lost Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Excessive load on the fuser Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or
322. n page 2 135 Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes 202 04 Exit sensor may have Exit sensor assembly Go to Fuser exit sensor bounced Fuser page service check on count stopped at page 2 135 500 000 to preserve data 202 bos Never sent the divert command to the stacker Fuser page count more than 500 000 202 96 Page is covering the exit Something is keeping the exit sensor in a Check the fuser and area sensor during warm covered position A page may not have around the fuser assembly for up Fuser page count been cleared from a prior jam any signs of debris or pieces of stopped at 500 000 to paper or media preserve data 202 57 Timeout waiting for the page ahead Fuser page count more than 500 000 202 58 Divert media command issued too soon Fuser page count more than 500 000 202 99 Virtual page timed out waiting for last page of job to be safe in the stapler accumulator Fuser page count more than 500 000 202 Paper jam around the Page may be jammed in fuser exit or Make sure the redrive door za or redrive area redrive area is complete closed user page count is not Check the fuser for any available signs of wear or contamination If any are found replace the fuser assembly See
323. n or contaminated pick tires Overfilling of tray past the fill line Failure to feed possible causes include Failure to feed possible causes include Fan media Turn media over Heduce amount of media loaded in tray 1 Replace pick tires See Integrated tray autocompensator pick roll assembly removal on page A 101 Fan media Turn media over Heduce amount of media loaded in tray 1 Replace pick tires See Integrated tray autocompensator pick roll assembly removal on page 4 101 Fan media Turn media over Heduce amount of media loaded in tray 1 Replace pick tires See Integrated tray autocompensator pick roll assembly removal on page 4 101 Fan media Turn media over Heduce amount of media loaded in tray 1 Replace pick tires See Integrated tray autocompensator pick roll assembly removal on page 4 101 e Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor 241 14 Page was not properly picked from MPT tray 1 or feeder 241 15 Late feed from a tray interfered with the pick retry 2 86 Service Manual Staging of paper in tray 1 Failure to feed Possible causes include Fan media Turn media over Heduce amount of media loaded in tray 1 Replace the pick tires See Integrated tray autocompensator pick roll assembly removal on page 4 101 Clear any paper jams Fan media 7002 xxx User attendan
324. n page 2 12 Diagnostics Menu on page 3 2 Configuration menu CONFIG MENU on page 3 25 Theory on page 3 37 Paper feed jams on page 3 39 Parts catalog on page 8 1 Diagnostic information 2 1 7002 xxx Understanding the MFP control panel MFP and scanner settings can be changed several ways through the MFP control panel the software application in use the print driver MarkVision Professional or the Web pages Settings changed from the application or print driver apply only to the job being sent to the MFP Changes made to print fax copy and e mail settings from an application override changes made from the control panel If a setting cannot be changed from the application use the MFP control panel MarkVision Professional or the Web pages Changing a setting from the MFP control panel MarkVision Professional or the Web pages makes that setting the user default The MFP control panel consists of 1 2 Callout Control panelitem Control panelitem item mo Is liquid crystal display LCD which shows home screen buttons menus menu items and values Allows for making selections o Ime Copy Fax and so on Indicator light Gives information about the status of the MFP using the colors red and green Status Indicates Off MFP power is off Blinking green MFP is warming up processing data or printing a job Solid green MFP is on but idle Solid red Operator intervention is required
325. n page 4 58 E Ie Disconnect the fuser to LVPS AC cable A from the fuser lamp connector on the fuser and remove the cable through the cable retainer B and the lower rectangular opening C in the fuser frame 5 Remove the pass thru plate See Pass thru plate on page 4 70 6 Disconnect the LVPS to system board DC cable D from the LVPS n 4 88 Service Manual 7002 xxx T Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser to LVPS AC cable from the LVPS E Note The LVPS assembly may be difficult to remove from the printer Do not use excessive force in the removal E 8 Remove the fuser to LVPS AC cable Installation 1 Plug in the fuser to LVPS AC cable A into the LVPS 2 Route the cable through the channel B on the right side frame above the LVPS under the clip C over the LVPS and through the notch in the frame D Repair information 4 89 7002 xxx 3 Route the cable through the lower rectangular opening E 4 Connect the fuser to LVPS AC cable to the fuser lamp connector F Note Be sure to connect the fuser to system board DC cable after replacing the LVPS 4 90 Service Manual 7002 xxx Fuser top cover removal CAUTION Unplug the printer before you begin 1 Remove the fuser assembly See Fuser assembly removal on page 4 75 2 Note the thermistor cable routing A and disconnect the thermistor cabl
326. n the order shown one at a time in until Scanner control card Interconnect card the problem is fixed e Scanner control card See Scan control card removal on page 4 48 e System board See System board and inner shield removal on page 4 125 e Interconnect card See Interconnect card assembly removal on page 4 103 Duplex option service check Duplex paper jams 231 Xxx Media did not arrive at the duplex input sensor but did leave the fuser exit sensor Media did not clear the duplex input sensor but did leave the printer fuser exit sensor Duplex does not recognize that the option is installed or other options below the duplex are installed Autoconnect cables Check the top and bottom autoconnect connectors for signs of connections damage If damaged replace the duplex option If not damaged check the cables are correctly connected to the duplex system board at J9 J10 J11 and J12 If no problem is found replace the duplex option Note Before proceeding with the following service checks verify the media used in the duplex option meets specification and is not dog eared or damaged in any way See Media specifications on page 1 8 Diagnostic information 2 125 7002 xxx 231 xx Jam displays Duplex input sensor 232 xx Jam displays Duplex input sensor Check the sheet of media is leaving the exit sensor in the fuser and feeding properly into the duplex option Check the duplex link f
327. n the same source mixing print media can cause feeding problems and print quality problems Do not use label sheets with a slick backing material Use full label sheets Partial sheets may cause labels to peel off during printing resulting in a jam Partial sheets also contaminate the MFP and your cartridge with adhesive and could void the MFP and cartridge warranties Use labels that can withstand temperatures of 230 C 446 F without sealing excessive curling wrinkling or releasing hazardous emissions Do not print within 1 mm 0 04 in of the edge of the label of the perforations or between die cuts of the label Do not use label sheets that have adhesive to the edge of the sheet We recommend zone coating of the adhesive at least 1 mm 0 04 in away from edges Adhesive material contaminates the MFP and could void the warranty If zone coating of the adhesive is not possible a 1 6 mm 0 1 in strip should be removed on the leading and driver edge and a non oozing adhesive should be used Remove a 1 6 mm 0 1 in strip from the leading edge to prevent labels from peeling inside the MFP Portrait orientation is preferred especially when printing bar codes Do not use labels that have exposed adhesive 1 14 Service Manual 7002 xxx Card stock Card stock is single ply and has a large array of properties such as the moisture content thickness and texture that can significantly affect print quality See Supported pri
328. nd 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 Check the interconnect card for correct installation and for any signs of damage If the card is damaged replace the interconnect card See Interconnect card assembly removal on page 4 103 Diagnostic information 2 145 7002 xxx LCD touchscreen display service check LCD touchscreen display complete dark operator panel LED on Note The LCD touchscreen display can be checked by entering the Diagnostics Menu selecting HARDWARE TESTS and running the Panel Test LCD inverter 8 pin cable Check the inverter 8 pin cable for correct installation to the operator panel card J13 and to the LCD inverter card CN1 assemblies If no problem is found go to step 2 LCD inverter 8 pin cable Check continuity of the inverter 8 pin cable If incorrect replace the cable If correct go to step 3 LCD inverter card Check the voltages at CN1 1 and CN1 2 Operator panel right cover assembly LCD touchscreen display LCD Touchscreen display Connector CN1 LCD inverter card Display lit CN1 1 Power 12 V dc CN1 2 Power 412 V dc CN1 3 Ground 0 V dc CN1 4 Ground 0 V dc CN1 5 Lamp Off 4 V dc CN1 6 Vbright adj 44 V dc CN1 7 Ground 0 V dc 0 V dc 0 V dc CN1 8 Ground o D 2 lt 2 D D o D D D Ke O
329. nner ADF Cover The scanner automatic document feed cover is open Open The message clears when the cover is closed Scanner Jam Access The scanner jam access cover is open Cover Open Close the cover to clear the message scanner Scanner registration is successful Fegistrabron successfully Touch Continue to clear the message completed Some held jobs Occurs when the MFP tries to restore all jobs on a hard disk regardless of were lost the number of held jobs not restored The message appears once Touch Continue to clear the message Some held jobs are not restored They stay on the hard disk and are inaccessible 30 XX Inve lia Ceri ls The MFP detects a refilled Lexmark Cartridge Return Program print change cartridge cartridge Install a new print cartridge to clear the message 31 DEeTeCLive e Smart chip cabling loose on controller card Reseat smart chip cabling Cartridge inside printer e Replace cartridge 31 XX DErecrive Print Error code 31 displays when the top front cover is closed and a defective Cartridge print cartridge is detected It may take the printer 10 20 seconds to determine if the print cartridge is defective Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10 20 second interval If pages are allowed to print they are not reprinted once a good print cartridge is inserted Note This error indicates the printer was able to read the cartridge ID
330. nt media on page 1 8 for information on the preferred weight and for the grain direction of print media Try a sample of any card stock you are considering using with the MFP before purchasing a large quantity After printing approximately 10 000 pages of card stock or each time you replace the print cartridge complete the following steps to maintain MFP feeding reliability 1 Print five sheets of paper 2 Wait approximately five seconds 3 Print five more sheets of paper When printing on card stock e Set the Paper Type menu item in the Paper menu to Card Stock from the control panel from the MFP driver or from MarkVision Professional e Be aware that preprinting perforation and creasing can significantly affect the print quality and cause print media handling or jamming problems e Avoid using card stock that may release hazardous emissions when heated Do not use preprinted card stock manufactured with chemicals that may contaminate the MFP Preprinting introduces semi liquid and volatile components into the MFP e We recommend the use of grain short card stock Storing print media Use the following guidelines to avoid paper feeding problems and uneven print quality e Store paper in an environment where the temperature is approximately 21 C 70 F and the relative humidity is 4096 e Store cartons of paper on a pallet or shelf rather than directly on the floor If you store individual packages of paper out of the o
331. ntire option NO IN iN NO IN iN 244 Jam declared by asmart Fault reported by options tray 4 Clear all media jams oo allowed Paper jam Check motor cables Motor failure Check replace tray motor e Sensor failure Check replace sensor s e Replace entire option 244 Option tray pass thru Failure to feed Possible causes include Clear media jams sensor never became covered Edge locking Replace pick tires See i l T Integrated tray Worn or contaminated pick tires autocompensator pick roll Overfilling of tray past fill line assembly removal on Failed sensor page 4 101 If source is tray 5 possible causes Check replace input sensor include e Check PTO shaft e Paper path bind when feeding from tray 2 through tray 1 e Damaged PTO shaft D E Diagnostic information 2 89 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes Option tray pass thru Paper jam Clear all jams sensor never became Failed sensor Check replace pass thru uncovered sensor 244 Failed to pick from tray 4 Paper jam around autocompensator e Check for jam in tray Faulty motor cable Check pick assembly and Faulty motor controller card Autocompensator gear bind Failed controller card 244 O NO A BA Oo La La En NO N O C1 oo Failure to feed from Failure to feed Possible causes incl
332. nual 7002 xxx 14 Remove the screw D attaching the hinge right side cable retainer and removal the UICC 18 pin to scan control card cable from the hinge arm D 15 Raise the upper front cover hinge assembly to a position that lets you lift the left pivot arm from the mounting bracket 16 Lift the left pivot arm from the bracket and move the upper cover hinge assembly toward the left to clear the right upper cover pivot arm from the mounting bracket 17 Remove the upper front cover hinge assembly Repair information 4 131 7002 xxx Upper paper deflector assembly removal 1 Either lift the ESD cover out of the way or remove it See ESD cover removal on page 4 74 Note The tabs holding the ESD cover are easily stressed or broken 2 Lift the left side to release the small tab A on the left and the MPF flag B and slide the upper paper deflector assembly to the right to unlatch the hooks C on the right Note Be careful not to put too much stress on the small tab A on the right im Won ER j mi 3 Lift to remove the upper paper deflector assembly Installation note Make sure the MPF flag B is in place 4 132 Service Manual 7002 xxx USB card 1 Remove the printer left side cover See Printer left side cover removal on page 4 56 2 Remove the operator panel left cover See Operator panel left cover assembly removal on page 4 61 3 Remove the USB cable A from
333. nvelope feeder The message clears Touch Cancel Job if needed Touch Reset Active Bin to reset the active bin for a linked set of bins If the message cannot be cleared go to Envelope feeder service check on page 2 127 The MFP detects that optional Tray x where x is the number of the tray is missing while the job processes but before the job prints Sometime during processing the optional tray is removed Install the optional tray specified by x The message clears Touch Cancel Job if needed Touch Reset Active Bin to reset the active bin for a linked set of bins If the message cannot be cleared go to Input tray s service check on page 2 144 Occurs when the MFP receives a manual feed request that a specific print media be loaded into the multipurpose feeder The print media is previously defined as a custom string which appears on the control panel Touch Continue e If print media is in the multipurpose feeder the job continues to print e f there is no print media in the multipurpose feeder all requests for additional pages are automatically overridden and print media is selected from an automatic source Touch Automatically select media to override manual requests for Manua Paper and Manual Env for the rest of the print job All requests for additional pages are automatically overridden and print media is selected from an automatic source Touch Cancel Job to cancel the current job if needed Touch
334. ny Portable Document Format PDF pdf file Joint Photographic Experts Group JPEG jpeg or jpg file Tagged Image File Format TIFF tiff or tif file Graphics Interchange Format GIF gif file Basic Multilingual Plane BMP bmp file Portable Network Graphics PNG png file PiCture eXchange PCX pcx file and PC Paintbrush File Format dcx file files The USB direct interface can also be used to scan a document to a USB flash memory device using the PDF TIFF or JPEG formats Home screen and Home screen buttons After the MFP is turned on and a short warm up period occurs the LCD shows the following basic screen which is referred to as the Home screen Use the Home screen buttons to initiate an action such as copy fax or scan to open the menu screen or to respond to messages CMS Copy Ready Toner low Touch any button to begin Callout number Copy Touch to access the Copy menus If the home screen is shown press a number to access the Copy menus too E mail Touch to access the E mail menus It is possible to scan a document directly to an e mail address Menus A key is shown on the Touch to access the menus These menus are only available when button the MFP is in the Ready state The Menus button is on a gray bar called the navigation bar The bar contains other buttons described as follows 2 4 Service Manual 7002 xxx Callout number Status messag
335. o cancel the test e t 3 8 Service Manual 7002 xxx DRAM Test The purpose of this test is to check the validity of DRAM memory both standard and optional The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly To run the DRAM Test 1 Touch gj to select DRAM Test from the menu The message DRAM Test Testing displays Then the message Resetting Printer appears and the power indicator light blinks red Turn the printer off and on While the DRAM test executes the power indicator blinks green The following type of message appears DRAM Test lt HHE P UHHHHHE F THEE e xxx represents the installed DRAM size 6P represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 e F represents the number of times the memory test has failed and finished with errors Initially 0000 displays with the maximum fail count being 99 999 Initially only four digits appear but additional digits appear as needed Each time a test is completed the number of pass and failures increments If the test fails the message Failure displays for approximately three seconds and the failure count increases by one The test continues until all standard and optional DRAM is tested Once the maximum pass count or fail count is reached the test is stopped the power indicator is turne
336. oblems are found replace the defective part Check the transfer roll shaft for contamination wear or pitting on the ends of the shaft that go into the bearings If a problem is found clean the ends of the shaft or replace the transfer roll assembly High voltage contacts Check the high voltage contacts on the right side frame to ensure they are clean and not bent deformed or pitted If incorrect replace the contact System board HVPS Check the following voltages at J15 on the system board Measure connector the voltages from J15 to printer ground J15 1 0 V dc to 5 V dc If J15 1 voltage is incorrect check the continuity of the front harness cable J15 1 line If there is no continuity replace the harness cable If there is continuity replace the HVPS If this does not correct the problem replace the system board If J15 2 voltage is incorrect or if the voltage remains at 0 V dc check the continuity of the front harness cable J15 2 line If there is no continuity replace the harness cable If there is continuity replace the HVPS If this does not correct the problem replace the system board If J15 4 voltage is incorrect check the front harness cable J15 3 line If there is not continuity replace the harness cable If correct replace the system board If this does not correct the problem replace the HVPS 2 158 Service Manual 7002 xxx Print quality banding Service tip Banding is difficult to detect e
337. obs normally To exit Hex Trace unplug the MFP There are not enough system resources at this time Try again after the current job is complete Insufficient resources ry again when the System is idle Invalid or incorrect password Miyata PRIN An incorrect Personal Identification Number PIN is entered Touch Continue to return to the screen to enter a correct PIN Job cannot be A job in the job list is touched but it cannot be canceled deleted Maintenance The MFP maintenance counter has exceeded its limit so the MFP requires maintenance Replace the maintenance items If necessary reset the MFP maintenance counter Network A network interface is the active communication link Network x Network x y Wait for the message to clear Notes The current interface appears on the Menu Settings Page Interfaces shown without an x or y means the active host interface is a standard interface x indicates the active interface is connected to the MFP through PCI connector x x y indicates the active interface is connected to the MFP through channel y on PCI connector x or that x equals 0 on the standard network interface BEEN No jobs selected The Delete button is touched when no jobs are selected Parallel A parallel interface is the active communication link Parallel x Notes The current interface appears on the Menu Settings Page Interfaces shown without an x or y means the active host interface is a
338. ocate the paper alignment assembly reference adjustment screw B through the left frame and remove the screw F T Remove the paper alignment assembly Note Do the Paper alignment assembly adjustment on page 4 3 when you reinstall the assembly 4 118 Service Manual 7002 xxx Paper bin full sensor flag removal Bo I Remove the left door See Printer left side cover removal on page 4 56 Remove the upper sub cover See Upper sub cover removal on page 4 55 Remove the fuser wiper cover assembly See Fuser wiper cover assembly removal on page 4 54 Remove the two screws A attaching the upper plenum and remove the upper plenum A Remove the screws from the upper cover See Upper cover removal base printer on page 4 127 Note lt is not necessary to remove the cover from the printer Lift the left rear corner of the printer upper top cover to access the flag B and remove the flag from the mounting bracket Repair information 4 119 7002 xxx Paper size sensing board removal 1 Remove the system board and inner shield See System board and inner shield removal on page 4 125 2 Remove the paper size sensing board mounting screw A a Disconnect the paper size sensing board cable B from the board 4 Remove the paper size sensing board from the latch C C A B 5 Remove the paper size sensing board 4 120 Service Manual 7002 xxx Power takeoff shaft and spring removal
339. om the wall outlet 3 Remove the excess hard disks 4 Connect the power cord to a properly grounded outlet 5 Turn the MFP on The MFP detects an excess of optional flash memory cards installed Touch Continue to clear the message and ignore the extra optional flash memory cards The message occurs again unless the excess optional flash memory cards are removed 1 Turn the MFP off 2 Unplug the power cord from the wall outlet 3 Remove the excess flash memory 4 Connect the power cord to a properly grounded outlet 5 Turn the MFP on The MFP detects that too many optional drawers and their matching trays are installed 1 Turn the MFP off 2 Unplug the power cord from the wall outlet 3 Remove the additional drawers 4 Connect the power cord to a properly grounded outlet 5 Turn the MFP on An unsupported optional duplex unit is attached to the MFP Remove the optional duplex unit The MFP ceases normal functions until the optional duplex unit is removed Touch Continue to clear the message once the optional duplex unit is removed Diagnostic information 2 55 7002 xxx User attendance messages continued Sub code Error Primary message code y g C1 X X Incompatible envelope feeder C1 X Incompatible tray LX O Remove defective disk X Disk full Unformatted disk x lt ER o o o e NO x x x X Unsupported disk format Scheduled
340. omatic document feeder ADF cover is open document feeder l h ver cover open Close the cove Diagnostic information 2 41 7002 xxx User status displays continued Error Sub m l Display text Description action Standard Bin Ful The standard bin is full Bim LX Full x represents the number of the bin that is full Lbin name Full bin name specifies a previously defined name for the bin such as Mary s bin and it is full Remove the stack of print media from the standard output bin or from the specified bin to clear the message System busy Not all resources needed for the job are available preparing resources for job Wait for the message to clear System busy Not all resources needed for the job are available Some held jobs are preparing deleted to free system memory resources TOF JOD Deleting held Wait for the message to clear Toner Low The toner cartridge is low on toner The Menu Settings Page shows the level It takes an unspecified amount of time for the MFP to read the level of toner Until the level is read the MFP does not show the message e The message clears automatically when the cover or door over the toner cartridge is opened or if the MFP power is turned off and then on e Replace the toner cartridge If it is not replaced the MFP issues the message again when the door or cover is closed Tray x Missing X represents the number of the tray missing from the MFP The messag
341. on DC feed motor assembly Check the motor and motor cable for loose wires or poor connections Make sure the motor cable is connected to the envelope system board If correct replace the envelope feeder option 260 xx Paper Jam displays unable to clear and envelopes fail to feed from the hopper Kick rolls are not rotating 260 xx Paper Jam displays unable to clear and envelopes fail to feed from the hopper Kick rolls are rotating Check the deflector gap adjustment before continuing this service check Weight assembly Check the weight assembly to make sure it moves up and down freely without any binds Make sure the weight assembly rests on all the rear kick rollers when the hopper is empty If the weight assembly is damaged or does not operate properly replace the envelope feeder assembly Envelope edge guide Check the envelope edge guide to make sure it is not warped or set too close to the envelopes in the hopper If the edge guide is damaged or does not operate properly replace the envelope feeder option 260 xx Paper Jam displays envelope stops in feeder paper path Kick rolls feed rolls drive Check all the rolls for oil grease or other contamination If you find a problem clean the rolls If this does not correct the problem replace the envelope feeder 2 128 Service Manual 7002 xxx Deflector gap adjustment Check the deflector gap adjustment The adjustment may be too narrow If the adjustment is c
342. on between the pick roll and the paper produces a frictional locking condition If the paper is physically held and not allowed to feed then the motor stalls Slippage between the roll and the paper is theoretically impossible When the motor is energized the pick rolls are driven down into the stack increasing the normal force and drive force until the bending strength of the paper is overcome and the paper bends and moves up the dam Once this critical threshold is achieved the normal force remains at a level just high enough to reliably feed the paper Rather than having a fixed spring force for feeding all weights of paper like the D roll this device has its own mechanical logic for producing only enough pick energy to feed a single sheet of paper regardless of its stiffness High normal force is one of the most significant contributors to double feeding paper The pick arm is counterbalanced by an extension spring located on the pick arm to reduce weight in the rest state This spring is factory set to exert no more than ten to fifteen grams on the stack This is as light as can be realistically set and always guarantee there is some force to start the autocompensating phenomena This spring is not to be considered an adjustment for feeding problems unless it is obvious that the pick arm cannot fall all the way down to the bottom of the tray or has come loose Poor gear efficiency can cause the arm to generate higher than normal forces If the pick a
343. on page 4 75 e System board assembly See System board and inner shield removal on page 4 125 LVPS See Low voltage power supply removal on page 4 105 923 xx Hot fuser service check Error Code 923 xx 924 xx and 925 xx may display for a hot fuser failure CAUTION The fuser may be hot use caution before removing or servicing working Unplug the printer before you begin or use caution if the printer must receive power in CAUTION There is a danger from hazardous voltage in the area of the printer where you are A N order to perform the task Service tip Set the Fuser Temperature to NORMAL before starting this service check In Diagnostics mode In Diagnostics mode select EP SETUP and Fuser Temp Check for any signs of overheating in the fuser assembly Check the hot roll hot roll bearings and the area around the thermistor for any signs of excessive heat If a problem is found replace the thermistor If no problem is found go to step 2 Fuser top cover assembly Turn the printer off and disconnect the fuser to system board cable thermistor from J10 on the system board Check the resistance between pins J10 3 and J10 4 The resistance should be greater than 100K ohms If correct go to step 3 if incorrect disconnect the thermistor cable from J5 on the fuser board and measure the resistance between the two pins on the thermistor cable If incorrect replace the fuser top cover assembly see Fuser na
344. onents 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 Warning Observe all ESD precautions while handling ESD sensitive parts See Handling ESD sensitive parts on page 4 1 1 Remove the outer shield See Printer outer shield removal on page 4 121 2 Disconnect all cables from the system board Note Sometimes cables may be difficult to remove Be careful not to damage the connectors 3 Remove all features and options from the interconnect card 4 Depending on your printer model remove the small USB port mounting screw A Note You may have additional screws in various models 5 Remove the five system board mounting screws B a l A i DL D TU 5 m um Back view Side view 6 Remove the system board and inner shield Repair information 4 125 7002 xxx Toner sensor removal 1 Remove the right side cover See Printer right cover removal on page 4 58 2 Remove the toner sensor mounting screw A 3 Disconnect the toner sensor cable and remove the toner sensor Transfer roll assembly removal Warning Be careful when handling the transfer roll Wrap a piece of plain white paper around the charge roll to prevent contamination or damage 1 Open the upper front cover and remove the print cartridge 2 Unsnap the transfer roll asse
345. onnections Printhead lock signal not working Printhead control not working Paper pre staged in path Lock signal went away Check MPF and friction pad Fan media and stack flat in tray or MPF Use different media Check config ID Perform a sensor test to check the sensor for the tray See Sensor Test input tray on page 3 14 Fan media and stack flat in tray or MPF Turn media over Heduce amount of media loaded to fill line Replace pick tires Go to Input sensor service check on page 2 143 Check MPF and friction pad e Fan media and stack flat in tray or MPF Use different media Check the main drive motor cable connections If no problem is found with motor connections go to Main drive service check on page 2 149 Check printhead to system card connections Check printhead motor system Go to Printhead service check on page 2 161 Check printhead to system card connections Check printhead motor system Go to Printhead service check on page 2 161 Timeout while waiting for laser power adjustment Input sensor covered during warm up sequence Page still covering input sensor Remove cartridge and make sure input sensor is not covered and is in upright position Go to Input sensor service check on page 2 143 Diagnostic information 2 59 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx
346. onnel should understand this and take necessary precautions 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 a 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 e Les consignes 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 o ATTENTION Ce symbole indique la pr sence d une tension dangereuse dans la partie AN 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
347. ontrol Motor is type 1 Loss of lock detected by higher level code Motor is type O Service Manual Description Check for paper jams Gear binds Defective motor Check motor cable and connections Check for paper jams Gear binds Defective motor Check motor cable and connections Check for paper jams Gear binds Defective motor Check motor cable and connections Check for paper jams Gear binds Defective motor Defective motor cable Cable connections Defective cable Check cable connections Defective motor Paper jams Defective cable Check cable connections Defective motor Paper jams Faulty motor sensor Faulty system board Faulty motor sensor Faulty system board Faulty motor sensor Faulty system board Faulty motor sensor Faulty system board Defective motor cable Defective main drive motor Paper jams Go to Main drive service check on page 2 149 Go to Main drive service check on page 2 149 Go to Main drive service check on page 2 149 Go to Main drive service check on page 2 149 Go to Main drive service check on page 2 149 Go to Main drive service check on page 2 149 Go to Main drive service check on page 2 149 Go to Main drive service check on page 2 149 Go to Main drive service check on page 2 149 Go to Main drive service check on page 2 149 Go to Main drive service check on page 2 149 7002
348. oor hinge Parts packet 6 32 hinge mounting nut PP 99A0676 Parts packet hinge mounting flat washer PP 99A0677 Parts packet hinge mounting star washer PP 99A0677 1 2 3 4 5 6 4 8 40X3252 2000 sheet option control card assembly Parts packet card asm mounting PP 99A0675 Parts packet card asm mounting screw PP 99A0675 99A0658 Door magnet Parts catalog 8 59 7002 xxx Assembly 38 High capacity feeder 2 8 60 Service Manual 7002 xxx Assembly 38 High capacity feeder 2 Part Units Units kit er 1 Description number option or pkg 99A0654 1 1 Paper low switch Parts packet nuts PP 99A0676 40X3262 1 1 AC external jumper cord 40X3260 1 1 Power supply board Parts catalog 8 61 7002 xxx Assembly 39 High capacity feeder 4 WS Part Units Units kit ats Description number option or pkg 39 1 99A0275 1 1 Power takeoff spring 2 99A0272 1 1 Drive shaft 250 sheet 8 62 Service Manual 7002 xxx Assembly 40 High capacity feeder 5 Parts packet auto comp assembly mounting screw PP 99A0263 40X3255 Pick arm assembly 2000 sheet 99A0070 Pick roll assembly 40X3233 Option pass thru sensor Parts catalog 8 63 7002 xxx Assembly 41 Kiosk vertical and horizontal paper adapters Part Units Units kit A Description number option or pkg 41 1 56P4108 1 Complete vertical kiosk option 2 56P4109 1 Com
349. opies without carbon paper also known as carbonless papers carbonless copy paper CCP or no carbon required NCR paper see the Card Stock amp Label Guide located on the Lexmark Web site at www lexmark com for supported chemically treated papers e Preprinted papers with chemicals that may contaminate the MFP e Preprinted papers that can be affected by the temperature in the MFP fuser e 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 e n some cases you can adjust registration with your software application to successfully print on these forms Coated papers erasable bond synthetic papers thermal papers Rough edged rough or heavily textured surface papers or curled papers Recycled papers containing more than 25 post consumer waste that do not meet DIN 19 309 Recycled paper having a weight less than 60 g m 16 Ib Multiple part forms or documents 1 12 Service Manual 7002 xxx Transparencies The MFP can print directly on transparencies designed for use in laser printers Print quality and durability depend on the transparency used Always print samples on the transparencies you are considering before buying large quantities The Paper Type setting should be set to Transparency to help prevent jams In Macintosh be sure to set the Paper Type to Transparency in the Print dialog on the Imaging choice in the Copi
350. or correct operation and any signs of damage If the problem is prior to the duplex input sensor and in the base machine repair as necessary If the jam occurs in the duplex option prior to the duplex input sensor go to step 2 If the paper does not reach the duplex input sensor make sure the sensor is connected to the duplex system board If correct check for any paper or other objects that might cause a paper jam If none are found replace the duplex option assembly Action If the paper reaches the duplex input sensor but does not clear the sensor make sure the sensor is connected to the duplex system board If connected correctly check for correct operation of the sensor If a problem is found and cannot be corrected replace the duplex option assembly If no problem is found check for a piece of paper or other object in the paper path that might cause a paper jam over the input sensor If no problem is found replace the duplex 233 xx Jam displays Duplex double feed sensor option assembly If a sheet of paper fails to reach the double feed sensor during turnaround check for any signs of paper or other objects that might cause the paper to jam If no problem is found replace the duplex option assembly 2 126 Service Manual 7002 xxx Envelope feeder service check Service tip Check the envelope feeder paper path for any debris pieces of envelope and so on If any other options are installed make sure
351. or and check the black rubber bumper attached to the door switch spring Be sure the rubber button is centered and not touching the sides of the hole or the switch will not function properly Lower limit switch Check the lower limit switch to make sure it is not closed normally Lower limit switch cable open If incorrect replace the switch Check the lower limit switch High capacity feeder cable for a short between pins 1 and 2 If incorrect replace the cable control board If correct replace the high capacity feeder control board Paper from the high capacity feeder input tray does not reach the pass thru sensor Service tip Be sure the paper in tray is within specifications Autocompensator Check the autocompensator pick arm rollers for sign of glazing toner assembly or other buildup Replace as necessary Wear strips Check the wear strips for glazing or contamination Replace as required It is advisable to replace all four wear strips at the same time 2 140 Service Manual 7002 xxx The elevator tray does not move up or down the printer recognizes that the option is installed DC drive motor high capacity feeder option system board Be sure the motor cable is correctly installed at J1 on the board Check the cables damaged or loose wires Disconnect the motor Check for a short between each pin and the motor housing If a problem is found replace the motor assembly If no problem is found measure the resistanc
352. or damaged 2 2 Service Manual Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error code
353. or for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the tray x option pass thru sensor assembly Check these parts for broken or damaged parts contamination on the drive rollers or wear plate and wear or damage to the drive shaft bearings Check the drive roll assembly and skewed backup roller for signs of wear slick spots material buildup and oil or grease on the rollers Also check for proper operation of the paper aligning assembly Repair or replace parts as necessary Tray x Low displays when tray x is full or has adequate paper in the tray Paper low sensor assembly Paper low sensor flag tray x option system board 2 144 Service Manual Run the Tray x Sensor Test and check the sensor for proper operation If incorrect check the following Paper low sensor flag for smooth and correct operation Paper low sensor for correct installation on the autocompensator housing Paper low sensor cable for signs of cuts pinched wiring or other damage especially at connector J26 on the system board If no problem is found replace the paper low sensor assembly If this does not correct the problem replace the option system board 7002 xxx Tray x Empty displays when tray x has paper in the tray ES Paper out sensor flag Check the paper out sensor flag for correct operation and installation I
354. order to perform the task Service tip Set the Fuser Temperature to NORMAL before starting this service check In Diagnostics mode select EP SETUP and Fuser Temp Fuser lamp Remove the fuser assembly and check to make sure the correct fuser lamp has been installed If the correct lamp has been installed go to step 2 Note If the fuser lamp is replaced allow the fuser assembly to cool or a 925 xx error code could be displayed AC line voltage CAUTION When taking measurements for AC power observe all safety precautions Check the AC line voltage to make sure it is within operating specification If incorrect inform the customer if correct go to step 3 CAUTION When taking measurements for AC power observe all safety precautions Unplug the AC line cord from the printer and pull the LVPS out far enough to access CN1 on the LVPS board see Low voltage power supply removal on page 4 105 Disconnect the LVPS to fuser AC cable plug in the line cord turn the printer on and measure the voltage between CN1 1 and CN1 3 on the connector see the connector locations at Low voltage power supply on page 6 11 If incorrect replace the LVPS assembly see Low voltage power supply removal on page 4 105 if correct go to step 4 l LVPS CAUTION When taking measurements for AC power observe all LVPS fuser AC cable safety precautions Disconnect the AC line cord from the printer Disconnect the LVPS to fuser cab
355. orrect replace the envelope feeder option Envelope feeder multifeeds or may not display a 260 xx Paper Jam message Envelopes Check the envelopes being used in the feeder Check for signs of the envelopes being stuck together or signs of glue Make sure the flaps are not interleaved If the envelopes meet the guidelines and are properly loaded go to step 2 Deflector Check the deflector gap adjustment The adjustment may be too wide If the deflector gap adjustment is correct go to step 3 If not replace the envelope feeder option Restraint roll bias spring Check for a missing broken or incorrectly installed restraint roll bias spring If incorrect replace the envelope feeder option 260 xx Paper Jam displays an envelope stopped in the paper path of the feeder and an envelope also stopped in the base printer paper path Action Make sure the tip of the latch lever is centered in the opening in the floor of the paper path The latch lever may not be detented on the latch If no problem is found and the problem persists replace the envelope feeder option Flatbed size sensor service check Check for correct installation of the sensor cable before proceeding with this service check Note All three sensors and their cables come attached together as a unit Flatbed paper size sensor Enter the Diagnostics Menu turn on MFP while holding 3 and 6 assembly select SCANNER TESTS and select Sensor Tests Check for Flatb
356. ou remove or replace the printhead assembly or loosen the mounting screws Install the new printhead with the three mounting screws centered in the slots in the printhead frame assembly Leave the screws loose enough to allow the printhead assembly to move from side to side within the slots It is necessary to perform a registration adjustment before locking down the three printhead mounting screws To perform the registration adjustment 1 9I ee Turn off the MFP Press and hold the 3 and 6 buttons simultaneously and turn on the MFP Release the buttons after 10 seconds Select Registration from the menu Select Quick Test Page The test page should only be printed on letter or A4 paper from Tray 1 The Quick Test Page consists of alignment diamonds horizontal lines that can be used for skew adjustment page count setting MFP serial number code levels and print registration settings Check the Quick Test Page for any sign of skew by checking the diamonds at the top left and top right of the test page for equal distance from the top of the page If necessary adjust the left or right printhead mounting screws and check the skew again by running another Quick Test Page This procedure may take two or three attempts before you get satisfactory results When you have the correct adjustment gently tighten the printhead mounting screws being careful not to move the printhead assembly 4 2 Service Manual 7002 xxx Paper alignment
357. ount stopped at 500 000 to preserve data Fuser page count not available Open thermistor check failure Fuser page count between 0 and 99 999 Open thermistor check failure Fuser page count between 100 000 and 199 999 Open thermistor check failure Fuser page count between 200 000 and 299 999 Open thermistor check failure Fuser page count between 300 000 and 399 999 Open thermistor check failure Fuser page count between 400 000 and 499 999 Open thermistor check failure Fuser page count over 500 000 Open thermistor check failure Fuser page count not available Lamp detection performed and found error Fuser page count between 0 and 99 999 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Fuser page count between 0 and 99 999 Service Manual Fuser over temperature Fuser over temperature Description Short in the thermistor circuit Noisy thermistor signal Fuser is actually overheating due to hardware faults Short in the thermistor circuit Noisy thermistor signal Fuser is actually overheating due to hardware faults Noisy thermistor signal Intermittent connection Thermistor cable not connected or thermistor actually open Noisy thermistor signal Intermittent connection Thermistor cable not connected or thermistor actually open Noisy thermistor signal Intermittent connection Thermistor cable not connected or thermis
358. ount not available Hot roll reached final lamp detection temperature but took longer than largest time in lookup table Fuser page count not available 2 28 Service Manual Description Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage The control code has been lost Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Excessive load on the fuser Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 POR the MFP and retry If the error message remains go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser che
359. over are fastened into the upper front cover hinge slots C Repair information 4 61 7002 xxx Operator panel right cover assembly removal Warning When replacing any one of the following components e Operator panel right cover assembly e System board assembly e Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more 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 1 Open the printer upper front cover 2 Remove the two screws A ia bp LS I Gr TTE d A 3 Lift the operator panel right cover assembly carefully to access the cables Warning Be careful not to tear or break the small ribbon cable from its connector B 4 62 Service Manual 7002 xxx 4 Disconnect the four cables C from the UI control card 1 E L MU Ay a 2 s D E l ANSE B a L T L 4 i m i k ai l E 4 ez p s t F C B C 5 Remove the oper
360. over closed switch cable Check the cover closed switch for proper mechanical operation If assembly incorrect repair as necessary Disconnect the cover closed switch cable from J8 at the system board and measure the voltage at J8 3 It measures approximately 5 V dc If the voltage is incorrect replace the system board If the voltage is correct check the voltage at J8 1 If the voltage measures greater than 1 0 V dc replace the system board If the voltage is correct check the continuity between J8 1 and J8 3 on the cable If no change in continuity occurs as the switch is activated replace the hinge assembly If the continuity changes as the switch is activated replace the system board Cover closed switch table je Switen status warme Coveropn Covercossd Dead machine service check A dead machine is a condition where the LCD touchscreen is blank the LED on the operator panel right cover is off no fans turn no motors turn and the fuser lamp does not come on If a high capacity input tray is installed remove the option and check the base printer for correct operation If the base printer operates correctly go to High capacity feeder input tray service check on page 2 138 If the base printer continues to not operate correctly remove any other attached paper handling options Warning Observe all necessary ESD precautions when removing and handling the system board or any installed option cards or assemblies See Han
361. owing information before performing any service checks e Paper feed problems especially paper jams Go to Display Log on page 3 21 and check the printer event log for indications of repetitive entries that help to isolate a problem to a particular area of the printer or option e Paper feed problems with error message Use the Sub error codes for 8xx 9xx and 2xx error codes on page 2 15 to help diagnose the problem e Print quality problems Go to Printing Quality Pages on page 3 7 and print a test page to help diagnose problems before changing any settings or working on the printer e Use the resident diagnostics test provided to help isolate a problem before taking the machine apart or removing any options 290 00 Error code service check Static jam ADF interval sensor A 1 Ld Note Before starting this service check make sure the interval sensor cable is correctly installed Check for any signs of paper or other debris that might be present in the ADF assembly over the interval sensor If nothing found go to step 2 Second scan sensor Enter the Diagnostic Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and then select Sensor Tests Check the interval sensor for correct operation Note You can check the interval sensor by putting a sheet of paper over the sensor This is easier to perform by first removing the pick arm assembly If the sensor fails the test go to step 3
362. own by an illustration e See a full text field on the left Diagnostic information 2 7 7002 xxx 2 8 Service Manual Right arrow button Scan the ADF Scan the flatbed Function or description Touch the right arrow button to scroll right to e Reach an increased value shown by an illustration See a full text field on the right On the gray navigation bar these two choices indicate that two types of scanning are possible One may choose to scan from the ADF or the flatbed A green button indicates a choice If a different value within a menu item is touched it needs to be saved to become the current user default setting To save the value as the new user default setting touch Submit When the Back button is shaped like this no other navigation is possible from this screen except to go back If any other choice is made on the navigation bar the screen closes For example in Sample screen one all the selections for scanning have been made One of the preceding green buttons should be touched The only other button available is Back Touch Back to return to the previous screen and all the settings for the scan job made on Sample screen one are lost When the Back button is shaped like this both forward and backward navigation is possible from this screen so there are other options available on the screen besides selecting Back 7002 xxx Sample screen two Unknown paper size Copy from Letter 8 5 x 11
363. pair information 4 129 7002 xxx Upper front cover hinge assembly removal 1 Remove the ADF scan assembly See ADF complete assembly removal on page 4 15 2 Remove the flatbed scan assembly See Flatbed scan assembly removal on page 4 38 3 Remove the operator panel left cover assembly See Operator panel left cover assembly removal on page 4 61 4 Remove the operator panel right cover assembly See Operator panel right cover assembly removal on page 4 62 Remove the touchscreen bezel See Touchscreen bezel removal on page 4 64 Remove the LCD touchscreen See LCD touchscreen removal on page 4 64 Remove printer left side cover See Printer left side cover removal on page 4 56 Remove printer right side cover See Printer right cover removal on page 4 58 Remove the printer upper cover See Upper cover removal base printer on page 4 127 SOMNON Remove the C clips A from the upper front cover hinge assembly left and right hinge pins and remove the pins Note the pin orientation and the C clip location on the inside of each hinge 11 Detach the two springs B from the upper front cover hinges 12 Detach two springs C from the left and right side of the hinge assembly ha i C B A B C 13 Disconnect the USB cable and cover open switch cable from the system board and UICC 18 pin to scan control card cable from the scanner control card 4 130 Service Ma
364. pen displays e Duplex input sensor e Duplex exit sensor 3 Press Stop to exit the test Motor Test duplex This test lets you test the duplex option paper feed drive system and verify that the power and velocity values are acceptable The duplex runs the DC motor at high speed and low speed taking an average of the power PWM required for each speed and calculating the KE value To run the Motor Test duplex 1 Select Motor Test from DUPLEX TESTS The power indicator light blinks and the message Motor Test Testing displays 2 When the motor stops the results are displayed DUPLEX MOTOR AA BB CC DD EE FF e AA O0 indicates success and any other value indicates failure e BB average PWM for the high speed portion of the test The results should be in the range of 20 through SF inclusively hex e CC average PWM for the low speed portion of the test The results should be in the range of 3A through 5D inclusively hex e DD minimum PWM for the low speed portion of the test The results should be in the range of 11 through 1F inclusively hex e Ignore bytes EE and FF If the test fails remove the drive belt from the duplex DC motor and run the motor test again For the duplex DC motor to pass the test the following results must display e AA 00 e BB inthe range of 29 through SE inclusively hex e CC in the range of 35 through 51 inclusively hex e DD inthe range of OC through 13 inclusively hex
365. per 2 Touch Continue to clear the message Touch Ignore to clear the message but at the next power on the message appears again 7002 xxx User attendance messages continued Error Sub code code Primary message Description action Restore held jobs Held jobs are found on the hard disk after a power on reset of the MFP Touch Yes to restore the held jobs to the hard disk and make them available The jobs data remains on the hard disk however the job control information is stored in the MFP memory Touch Quit to stop restoring held jobs before all jobs are restored Unrestored jobs remain on the hard disk and are retrievable again only at the next power on reset Note A pop up screen appears to indicate Restoring held jobs s xxx yyy where xxx indicates the number of the current job being restored and yyy is the total number of jobs to be restored Touch Do not restore to have the held jobs remain on the hard disk until they are deleted Scan Document Too The scan job exceeds the maximum number of pages Long Note The scanner finishes scanning current pages in the ADF but data is lost when the job cancels itself after reaching the maximum number of pages Touch Continue to clear the message Touch Cancel Job to clear the message if the job can be restarted Touch Restart job if the job can be restarted The message clears and a new scan job containing the same parameters as the previous job starts Sca
366. plete horizontal kiosk option 8 64 Service Manual Assembly 42 Options 7002 xxx Part Units Units kit Description number option or pkg 40X1508 40X1509 40X1510 40X1564 40X1565 40X2792 40X0252 40X0250 40X0251 40X2793 40X1375 40X1376 40X1377 40X1378 40X1562 40X0291 40X0290 40X2539 56P4116 40X2791 40X1513 40X1514 40X1515 40X1512 40X0179 40X01 71 7375947 40X0499 128MB memory option 256MB memory option 512MB memory option 32MB Flash card 64MB Flash card Bar code card assembly 9 pin to 9 pin cable assembly 9 pin to Twinax cable 9 pin to Coax BNC cable PRESCRIBE card assembly MarkNet 8000 Fast Ethernet MarkNet 8020 Gigabit Ethernet MarkNet 8030 Fiber Ethernet MarkNet 8050 wireless US MarkNet 8050 wireless non US Parallel 1284 B interface card RS232C serial interface card IPDS SCS INe card assembly Universal adjustable tray assembly 400 sheet Forms card assembly Simplified Chinese font card Traditional Chinese font card Korean font card Japanese font card Nyogel 744 grease packet Cartridge shipping package empty Relocation kit Screws parts packet Parts catalog 8 65 7002 xxx 8 66 Service Manual Index Numerics 200 and 201 paper jams 3 47 202 paper jams 3 48 23x and 24x paper jams 3 44 23x paper jam duplex 3 50 240 paper jams 3 41 250 sheet paper drawer option 7 52 250 sheet paper tray option parts catalog 7 53 service check 2 144 260 paper jam 3 42 290
367. plex Option 2 14 Service Manual 7002 xxx Envelope feeder symptoms Envelopes do not feed from the envelope Go to Envelope feeder service check on page 2 127 feeder Envelopes do not feed properly into base Go to Envelope feeder service check on page 2 127 printer Messages and error codes Service error codes Service error codes are generally non recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition Service error codes are indicated by a three digit error code followed by a period and additional numbers in the format XXX YY In most cases five digits are shown Additional sub error codes display if you press and hold and 2 when an error message is displayed Not all error conditions have additional sub error information Sub error codes for 8xx 9xx and 2xx error codes The sub error codes are helpful troubleshooting a paper path problem especially paper jams in the base printer envelope feeder and duplex option To display sub error codes where available When a 9xx or 2xx error displays 2 3 When the last ihe displays the original message displays Printed error codes Additional information is available by printing the error log See Print Log on page 3 22 Service error codes 8xx xx Error Sub f Display text Description Service Scanner This error indicates that a scanner Go to 842 xx
368. prevent damage to ESD sensitive parts follow the instructions below in addition to all the usual 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 carefu
369. pring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Diagnostic information 2 73 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes Page did not cleanly exit Page may be jammed in fuser exit or Make sure the redrive door oe or redrive area redrive area is complete closed user page count between 300 000 and E tie La 399 999 SA dais i contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Exit sensor covered too Page may be jammed in fuser exit or Make sure the redrive door long Fuser page count redrive area is complete closed between 300 000 and 399 999 Check the fuser for any signs of wear or contamination If any are found replace the fuser a
370. print the pages processed before the memory became full Some memory frees up so collating begins for the remainder of the print job For example if a 50 page print job is sent and 10 copies are requested and the MFP runs out of memory at page 30 pages 1 30 would collate and print 10 copies The MFP would then print and collate pages 31 50 and print 10 copies of these pages The MFP depletes its memory while it attempts to restore held jobs The message appears once Some held jobs are not restored They stay on the hard disk and are inaccessible Held jobs are deleted in order to process the current job The message appears once per job Touch Continue to clear the message and continue printing To avoid this error in the future for other jobs install more memory Touch Cancel Job to cancel the current job if needed 7002 xxx User attendance messages continued Error Sub code code Primary message Description action 38 XX Memory full The MFP is processing data but the memory used to store pages is full To avoid this error in the future Simplify the print job by reducing the amount of text or graphics on a page and deleting unnecessary downloaded fonts or macros Install additional memory Touch Cancel Job to cancel the current job if needed Touch Reset Active Bin to change to another linked bin 39 XX Page 1S too The page may not print correctly because the print information on the page is complex to
371. proximately 25 0 V dc If incorrect replace the motor driver card If correct go to step 6 Diagnostic information 2 97 7002 xxx 7 ADF feed motor Scan motor belt 2 98 Service Manual Check the ADF feed motor for proper operation Turn the power off disconnect CN2 on the motor driver card and measure the voltages on CN2 ADF feed motor Connector CN2 motor driver card Operating CN2 Pin 2 1 5 V dc 24 V dc CN2 Pin 3 141 5 V dc 24 V dc CN2 Pin 4 1 5 Vdc 24 V dc CN2 Pin 5 11 5 V dc 24 V dc CN2 Pin 6 1 5 V dc 24 V dc Note All voltages are approximate values If the voltages are incorrect replace the motor driver card If incorrect turn the power off reconnect the motor cable to CN2 and measure the voltages on the scan motor connector If incorrect replace the scan motor If correct go to step 7 Check the scan motor drive belt for any signs of wear or damage or the belt off the gear If the belt is off the gear reinstall If the belt is worn or damaged replace the belt If no problem is found replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 7002 xxx 290 02 Error code service check ADF feed jam Note Before starting this service check make sure the first scan sensor A cable is correctly ins
372. ption number mach or n 10 1 40X0456 Pickup arm solenoid 40X0481 Parts packet sensors A Second scan sensor B Interval sensor C First scan sensor D ADF top cover open E Jam access door F Flatbed cover open G Paper present 40X0486 Motor driver card Parts catalog 8 17 7002 xxx Assembly 11 Scanner flatbed a 8 18 Service Manual 7002 xxx Assembly 11 Scanner flatbed Part Units Units kit Description number mach _ or pkg 11 1 40X0457 40X0483 40X0466 40X0475 40X0513 40X0514 40X0478 40X0485 40X0490 40X0479 40X0480 40X0491 40X0474 40X0481 40X0487 40X0484 Complete flatbed scanner assembly Flatbed contact glass Flatbed white cushion Scan cover Flatbed cover closed actuator Flatbed cover closing actuator Flatbed CCD module assembly Interface card assembly Belt tension spring Flatbed CCD drive belt Scan motor assembly including damper Flatbed paper size sensor assembly Front cover Home sensor Flatbed CCD ribbon cable Glass holder assembly Parts catalog 8 19 7002 xxx Assembly 12 Printhead Part Units Units kit EN Description number mach orpkg 40X0061 1 1 Laser cable assembly Parts packet printhead mounting screw PP 40X0165 40X0062 1 1 Printhead assembly includes all cables CAUTION The printhead is not a serviceable FRU Do not disassemble the printhead 8 20 Service Manual Assembly 13 Pape
373. ptions s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error code 202 202 202 202 202 202 Sub Description codes P Exit sensor bounced Fuser page count between 100 000 and 199 999 Never sent the divert command to the stacker Fuser page count between 100 000 and 199 999 Page is covering exit sensor during warm up Fuser page count between 100 000 and 199 999 Timeout waiting for the page ahead Fuser page count between 100 000 and 199 999 Divert media command issued too soon Fuser page count between 100 000 and 199 999 Virtual page timed out waiting for the last page of the job to be safe in the stapler accumulator Fuser page count between 100 000 and 199 999 Paper jam around fuser exit or redrive area Fuser page count between 200 000 and 299 999 Possible causes Exit sensor assembly Something is keeping the exit sensor in a covered position A page may not have been cleared from a prior jam Paper may be jammed in fuser exit or redrive area Go to Fuser exit sensor service check on page 2 135 Check the fuser and area aroun
374. questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato e Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona piu elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie e ATTENZIONE Questo simbolo indica la presenza di tensione pericolosa nell area del J prodotto Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l intervento Safety information xvii 7002 xxx Sicherheitshinweise e Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprunglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen e 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 zust ndige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen e ACHTUNG Dieses Symbol weist auf eine gef hrliche elektrische Spannung hin die in AN diesem Bereich des Produkts auftreten kann Ziehen Sie vor den Arbeiten am Ger t den Netzstecker des Ger ts bzw arbeiten Sie mit gro er Vorsicht wenn das Produkt f r die Ausf
375. r ey Ss Remove the shoulder screw A on the front A 5 Remove the shoulder screw B on the rear with a long shank screwdriver 6 Remove the ADF top cover 4 8 Service Manual 7002 xxx Scanner left side cover removal 1 Remove the two screws A A 2 Slide the cover toward the rear to unlatch the cover and remove Repair information 4 9 7002 xxx Front flatbed cover removal Pull the top of the cover out first and lift away to remove 4 10 Service Manual 7002 xxx Scan cover flatbed removal 1 Remove the glass holder assembly See Scanner flatbed glass holder assembly removal on page 4 50 2 Remove the flatbed contact glass See Flatbed contact glass removal on page 4 30 3 Remove the front flatbed cover See Front flatbed cover removal on page 4 10 4 Remove the three screws A Repair information 4 11 7002 xxx Scanner right side cover removal 1 Remove the screw A 4 12 Service Manual 7002 xxx ADF attach screws removal Nota FRU 1 Open the document cover 2 Remove the two ADF attach screws A by turning them by hand um v e ina mme 1 a a pa YN ry TE n T j a Mik re z l ae m Note Do not remove the screws toward the rear Repair information 4 13 7002 xxx ADF CCD module assembly removal Remove the ADF assembly See ADF complete assembly removal on page 4 15 Remove th
376. r Part Units Units kit Description number mach _ or pkg 18 1 AA Cc UNa 12 13 NS 40X2592 40X2591 40X2590 40X0120 40X0122 40X0123 40X0121 40X0239 40X0236 40X0125 40X0230 40X0238 40X0124 40X0229 40X0226 7002 xxx Fuser assembly w 115 V lamp Fuser assembly w 100 V lamp Fuser assembly w 220 V lamp Fuser wiper cavity cover Fuser lamp 115V Fuser lamp 220V Fuser cover assembly kit including e Thermistor 1 e Thermostat 1 e Left and right fuser lamp contact assemblies 1 Parts packet fuser mounting screw PP 40X0254 Exit sensor flag spring kit including e Spring 1 e Flag 1 Exit narrow media sensor cover Parts packet PP 40X0165 Exit sensor Exit sensor cable Narrow media flag spring kit including e Spring e Flag Narrow media sensor Narrow media sensor cable Fuser AC to fuser lamp cable Parts catalog 8 31 7002 xxx Assembly 19 Transfer charging 8 32 Service Manual 7002 xxx Assembly 19 Transfer charging Part Units Units kit Description number mach _ or pkg 40X0126 Parts kit charge roll link asm left side 40X0127 Charge roll assembly dual 40X0129 Parts kit right side charge roll link assembly 40X0130 40X0131 40X0132 40X0133 40X0134 40X0135 4 Transfer roll assembly Transfer roll assembly right arm Transfer roll right spring Transfer pivot shaft Transfer roll left spring 2 3 4 5 6 T 8 9 Trans
377. r See Upper paper deflector assembly removal on page 4 132 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 97 Remove the MPF solenoid assembly See MPF solenoid assembly removal on page 4 114 Remove the C clip A E d E eS o FTL s e geeceo0 9009 aeeo0e oo gem aeeoe 8 Remove the washer and set it aside 9 Remove the MPF arm assembly Repair information 4 111 7002 xxx Installation note Note the order of C clips bushing and washer when you reinstall C clip C clip C clip MPF left side of frame Washer Bushing pick tire MPF lower paper deflector 1 Remove the MPF lower cover 2 Remove the four screws securing the MPF lower paper deflector SS o gt 3 Remove the defector 4 112 Service Manual 7002 xxx MPF pick tire removal 1 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 132 2 Release the pick roll retaining tab A and slide the pick roll off the shaft Repair information 4 113 7002 xxx MPF solenoid assembly removal 1 Open the left door 2 Remove the MPF lower front cover See Multipurpose feeder lower front cover assembly removal on page 4 67 3 Remove the MPF lower paper deflector See MPF lower paper deflector on page 4 112 4 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 132 5 Remove th
378. r cable Check the continuity of the input sensor cable section of the front wiring harness If incorrect replace the harness If correct replace the input sensor assembly Diagnostic information 2 143 7002 xxx Input tray s service check Optional 250 sheet and 500 sheet trays Service tip Try all the other input paper sources to make sure they are properly feeding paper For 990 Error Code Service Tray x x displays the number of the tray that has a problem or needs service Tray x Option system board or compensator assembly or autoconnect cable Check the autoconnect cables and connectors for damage If the cables connectors and connections are good replace the FRUs in the following order e Autocompensator assembly option Replace the option 24x xx Paper Jam displays paper jammed over the pass thru sensor The printer displays the value of x for the paper tray where the error occurs Example 241 is a Paper Jam Tray 1 Pass thru sensor and flag assembly Power takeoff shaft and spring bevel gear feed roll gear drive roll assembly wear plate drive shaft bearings and skewed backup roller The tray x option system board did not detect a piece of paper actuating the pass thru sensor Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu If the test fails check the sens
379. r feed autocompensator 40X0066 40X0069 40X0070 40X0072 40X0073 40X0074 Pick arm assembly 500 sheet Parts packet bellcrank assembly for 500 sheet tray e Bellcrank 1 e Spring 1 Pick roll assembly Paper out flag 500 sheet tray Paper low out sensor card assembly Parts packet hanger PP 40X0165 Paper size autocompensator cable 7002 xxx Parts catalog 8 21 7002 xxx Assembly 14 Paper feed multipurpose feeder 8 22 Service Manual 7002 xxx Assembly 14 Paper feed multipurpose feeder Part Units Units kit err Description number mach or pkg 40X0079 40X0310 40X0076 40X0077 i i I I Multipurpose feeder lower deflector assembly Multipurpose feeder pick arm assembly with solenoid Pick roll assembly Multipurpose feeder paper out flag Parts packet lower deflector mounting screw 8 mm PP 40X0165 Parts packet lower deflector mounting screw 12 mm PP 40X0165 Parts packet frame mounting screw PP 40X0165 Parts packet pick roll shaft clip PP 40X0165 Parts catalog 8 23 7002 xxx Assembly 15 Paper feed alignment 8 24 Service Manual 7002 xxx Assembly 15 Paper feed alignment Part Units Units kit Description number mach or pkg 40X0084 Paper feed alignment assembly paper feed Parts packet clip ref ground mounting screw PP 40X0165 40X0085 Reference ground clip 40X0086 Parts packet reference adjust e Screw paper r
380. r is Defective motor on page 2 149 Severe gear blinds in gearbox assembly System board Go to Printhead service check on page 2 161 Go to Main drive service check on page 2 149 No hall effect detected e Check cable connections at motor start Motor is Defective motor e Severe gear binds in gearbox assembly e System board 936 20 Failed to stop within Defective motor Go to Main drive service check timeout motor is type O Defective system board on page 2 149 936 21 Failed to stop within Defective motor Go to Main drive service check timeout motor is type 1 Defective system board on page 2 149 Diagnostic information 2 33 7002 xxx Service error codes 9xx xx continued N Error code 936 936 936 936 936 937 937 937 937 937 34 Sub Display text No lock detected at motor start for motor ID Motor is type 0 No lock detected at motor start for motor ID Motor is type 1 No lock detected at normal motor start Motor is type 0 No lock detected at normal motor start Motor is type 1 Stall detected during speed control Motor is type 0 Stall detected during speed control Motor is type 1 Overspeed detected during speed control Motor is type 0 Overspeed detected during speed control Motor is type 1 Overspeed detected during position control Motor is type 0 Overspeed detected during position c
381. r of the flatoed scanner assembly and to the ADF CCD assembly If incorrect install the cable correctly If correct replace the following FRUs in the order shown ADF CCD cable Flatbed interface card See Flatbed ICC interface card removal on page 4 32 ADF CCD assembly If ADF CCD assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 298 02 Error code service check Scanner missing rear side cable unplugged This is the MDC 36 pin ICC cable connected to the motor driver card MDC cable Check the cable for correct connections to the flatbed interface connector on the rear of the flatbed scanner assembly and to the motor driver card If incorrect install the cable correctly If correct replace the following FRUs in the order shown e MDC cable Flatbed interface card See Flatbed ICC interface card removal on page 4 32 Motor driver card 842 xx Error code service check Service Scanner scanner communications failure Scan control card to flatbed Check for correct installation of the scan control to flatbed interface interface card cable card cable Motor drive card to flatbed Check for correct installation of the motor driver card to flatbed interface card cable interface card cable Motor driver card If the cables are good and are properly connected replace the following FRUs in the order shown Flatbed interface card assembly Motor driver
382. r panel right side hook MPT assembly LCD touchscreen display assembly Cover bezel with Lexmark logo Operator panel left cover assembly USB board assembly LCD touchscreen inverter card TLI ID serial number label blank Left cover assembly Parts packet cable ties PP 40X01 74 Parts catalog 8 3 7002 xxx Assembly 2 Covers ADF scanner 8 4 Service Manual 7002 xxx Assembly 2 Covers ADF scanner Part Units Units kit eer Description number mach or pkg 40X0451 Document tray assembly 40X0452 ADF top cover assembly 40X0463 ADF scan cover 40X0465 ADF rear cover 40X0450 Complete ADF assembly 40X0464 ADF front cover Parts catalog 8 5 7002 xxx Assembly 3 Frame 1 8 6 Service Manual 7002 xxx Assembly 3 Frame 1 Part Units Units kit Description number mach or pkg 40X0065 Frame extension nut plate 40X0225 Right side hand holder Parts packet PP 40X0165 CO A 40X0024 40X0026 40X0025 40X0060 40X0331 40X0285 Right side frame ground contact Left frame extension External ground clip Left side hand holder Frame clip 1 1 4 1 Right frame extension 1 1 1 1 1 O CON OD OF C nm A 0 d Parts catalog 8 7 7002 xxx Assembly 4 Frame 2 8 8 Service Manual 7002 xxx Assembly 4 Frame 2 Part Units Units kit Description number mach _ or pkg 40X0027 40X0028 40X
383. r right side cover See Scanner right side cover removal on page 4 12 Remove the scanner left side cover See Scanner left side cover removal on page 4 9 mo T Remove the three screws A that attach the hinge support bracket to the rear scan bracket 5 Remove the two screws B from the top 6 Remove the two screws C from the left side and right side T Remove the two screws D from the left bottom and right bottom aem 4 E 4 34 Service Manual Remove the two screws from the sensor assembly cover 7002 xxx urn over the sensor cover and remove the three screws F from the cover Remove the three sensors G Repair information 4 35 7002 xxx 11 Remove the screw to remove the flatbed sensor cable cover H H G F Note Be sure you make a note of the routing of the cable to the ICC interface card 4 36 Service Manual 7002 xxx 12 Disconnect the sensor cable J from CN4 on the ICC interface card Repair information 4 37 7002 xxx Flatbed scan assembly removal 1 Remove the ADF assembly See ADF complete assembly removal on page 4 15 2 Remove the printer left side cover See Printer left side cover removal on page 4 56 3 Remove the five screws A from the SCC and HDD shield o 7 Wn w 900060076066000 2 2 06706060607 7 fe iol e ar N96 69 T 6 e 6e e e 9 o amp le
384. rallel strobe adjustment Par x Strobe Adj on PAR 1 STROBE ADJ if additional parallel P29 9 19 options are installed EP SETUP EP Defaults See EP Defaults on page 3 20 Fuser Temp See Fuser Temperature Fuser Temp on page 3 20 Fuser Page Count See Fuser Page Count on page 3 20 Warm Up Time See Warm Up Time on page 3 21 Transfer See Transfer on page 3 21 Print Contrast See Print Contrast on page 3 21 Charge Roll See Charge Roll on page 3 21 Gap Adjust See Gap Adjust on page 3 21 EVENT LOG Display Log See Display Log on page 3 21 Print Log See Print Log on page 3 22 Clear Log See Clear Log on page 3 22 SCANNER TESTS ASIC Test See ASIC Test on page 3 23 Feed test See Feed Test on page 3 23 Manual Registration See Scanner Manual Registration on page 3 23 Sensor Tests See Sensor Tests on page 3 24 Touch Exit Diag Menu to exit the Diagnostics Menu and Resetting the Printer displays The printer performs a POR and the printer returns to normal mode 3 4 Service Manual 7002 xxx Registration base printer Print registration makes sure the printing is properly aligned on the page REGISTRATION Top Margin Bottom Margin Left Margin A A A A VVVV Right Margin Quick Test The settings available are Bottom Margin 20 to 20 A positive change compresses the image so it appears
385. rating in normal mode but not as little as when operating in Power Saver To return to the Ready state more quickly than when operating in Power Saver To change this setting a 2 3 Touch gt to select Require Standby from the Configuration Menu Touch Back to cancel and return to the Configuration Menu Touch Submit to save the change LES Applications This disables all installed Lexmark Embedded Solution applications The default is Enabled To change this setting 1 Touch gt to select LES Applications from the Configuration Menu Note If an advanced password has been established you must enter this password in order to change the setting If no advanced password exists you can establish one by using the keyboard that appears on the LCD Touch Back to cancel and return to the Configuration Menu Touch Submit to save the change Diagnostic aids 93 35 7002 xxx Key Repeat Initial Delay When a key is touched repeatedly this is the delay before the key begins repeating The delay ranges from 0 25 seconds to 5 seconds The default is 1 second Values are given in increments of 0 25 seconds To change this setting 1 Touch gt to select Key Repeat Initial Delay from the Configuration Menu 2 Touch gt to increase the value or lt q to decrease the value 3 Touch Submit to save the change Touch Back to cancel and return to the Configuration Menu Key Repeat Rate This is the number of ti
386. red off and back on again Data loss results if print jobs are active when the printer is power cycled Ifa print job is active then remove the option and finish the job The printer automatically clears the message once the option is removed Once the job is complete turn off the printer and attach the option again Insert Duplex Front The duplex front access cover is not installed Cover Close Duplex Rear Door The duplex rear door is open User attendance messages paper jams and paper handling errors 2xx xx When the printer jams the appropriate jam message will be displayed on the printer operator panel If you select Show Areas on the operator panel you can view one or more images to help you clear the jam User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes Paper jam around input Multi sheet feed that is shingled Fan media and stack flat in Sensor Tray size sensing wrong size tray or multipurpose feeder Check for anything in the Paper jam leaving page over sensor paper path that might cause the paper to jam If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 143 200 01 Input sensor covered too Multi sheet feed that is shingled Fan media and stack flat in long Tray size sensing wrong size tray or MPF Check for anything in the Paper jam leaving page over sensor paper path tha
387. riginal carton make sure they rest on a flat surface so the edges do not buckle or curl e Do not place anything on top of paper packages Store paper in its original wrapper until you load it into the MFP Avoiding jams Use appropriate print media paper transparencies labels and card stock to help ensure trouble free printing Note Iry a limited sample of any print media you are considering using with the MFP before purchasing large quantities By selecting the appropriate print media and loading it properly you can avoid most jams The following hints can help you avoid jams Use only recommended print media Do not overload the print media sources Make sure the stack height does not exceed the maximum height indicated by the stack line on the labels in the sources Do not load wrinkled creased damp or curled print media e Flex fan and straighten print media before you load it If jams do occur with print media try feeding one sheet at a time through the multipurpose feeder e Do not use print media that you have cut or trimmed yourself Do not mix print media sizes weights or types in the same print media source e Make sure the recommended print side is loaded in the source according to your simplex or duplex needs General information 1 15 7002 xxx Keep print media stored in an acceptable environment See Storing print media on page 1 15 Do not remove trays during a print job Push all trays in firmly
388. roblem is found check the fuser to system board DC cable for correct installation at J1 on the fuser control card If no problem is found check the fuser to system board cable for correct installation at J10 on the system board Carefully check the installation of the LVPS to system board cable to J27 on the system board and to CN2 on the LVPS If the cable is not seated or installed properly reseat the cable and retry the printer If the cable is installed correctly replace the following FRUs in the order shown e LVPS assembly See Low voltage power supply removal on page 4 105 e System board assembly See System board and inner shield removal on page 4 125 LVPS to system board cable If no problem is found up to this point then replace the following in the order shown Fuser assembly See Fuser assembly removal on page 4 75 e System board assembly See System board and inner shield removal on page 4 125 e VPS See Low voltage power supply removal on page 4 105 Diagnostic information 2 131 7002 xxx 922 xx Cold fuser check Error codes 920 xx and 922 xx may display for a cold fuser failure Some 920 xx error codes may be cleared by turning the printer on and off and allowing it to complete POR working Unplug the printer before you begin or use caution if the printer must receive power in CAUTION There is a danger from hazardous voltage in the area of the printer where you are A N
389. rom the original screen Once Continue is touched the original screen appears For example if one touched Copy on the home screen the Copy screen appears like Sample screen two on page 2 9 The following example shows how the Continue button reacts 1 Touch the select button by the Copy to box and a new screen appears 2 Touch MP Feeder and a new screen appears 3 Touch Legal and a new screen appears 4 Touch Next and a new screen appears 5 Touch Plain Paper for the type of print media needed 6 Touch Continue The Copy screen returns to allow other selections besides Copy to The other settings on the Copy screen available are Duplex Scale Darkness Collate and Copies Touch Continue to return to the original screen and make other setting changes for a copy job before the Copy it button is touched to start the job g Select 2 10 Service Manual Allows for creating a custom button based on the user s needs Touch Cancel to cancel an action or a selection Touch to cancel out of a screen and return to the previous screen Touch to select a menu The next screen appears showing menu items Touch to select a menu item The next screen appears showing values Allows specifying that a job is finished For example when scanning an original document one could indicate that the last page is scanned and then printing the job would begin 7002 xxx Touch the Back button to return to the previous
390. ror code Toner Sensor Check the developer drive assembly for correct installation or any sign of worn loose or broken parts Front harness cable Check the toner sensor portion of the front harness cable to make Sure it is properly seated into the toner sensor If correct at both the sensor and system board J15 check the continuity of the cable If incorrect replace the cable 3 Toner sensor The toner sensor cable is part of the front harness and part of connector J15 on the system board Check the voltage at J15 11 It reads approximately 5 V dc If incorrect replace the system board If correct check the voltage at J15 12 It reads approximately 5 V dc with the system board removed from the printer If incorrect replace the system board If correct replace the toner sensor assembly A bad ground connection between J15 13 on the system board and pin 3 on the toner sensor results in a 929 service error 2 162 Service Manual 7002 xxx Transfer roll service check Service tip The transfer roll is 51 02 mm 2 009 inch circumference Any print quality problems such as lines that are spaced 51 02 mm apart indicate you should check the transfer roll for damage and check for toner or foreign material buildup Service tip The transfer roll assembly is part of the maintenance kit and is replaced when an 80 Scheduled Maintenance displays Ask the customer if they have replaced the transfer roll recently CAUTION Make sure the
391. roximately O to 41 5 V dc Enter 50 on the touchscreen display and Submit Measure the voltage at CN1 5 The voltage should measure approximately 2 7 V dc Enter 100 on the touchscreen display and Submit Measure the voltage at CN1 5 The voltage should measure approximately 5 0 V dc If the voltages do not change when going from 22 to 100 on the display replace the operator panel right cover assembly See Operator panel right cover assembly removal on page 4 62 If this does not fix the problem replace the LCD inverter card assembly See LCD inverter card assembly removal on page 4 104 Diagnostic information 2 147 7002 xxx LCD touchscreen display lights up icons displayed but it does not work when touched LCD touchscreen display 4 pin cable LCD touchscreen display Operator panel right cover assembly Inverter card Inverter card assembly Operator panel right cover assembly 2 148 Service Manual Check the 4 pin display to operator panel card cable for correct installation to J3 on the operator panel card Note This cable is a short ribbon cable that can easily become disconnected from J3 on the operator panel card If the cable is properly installed go to step 2 If the cable is connected properly to J3 replace the operator panel right cover assembly See Operator panel right cover assembly removal on page 4 62 If this does not fix the problem replace the LCD touchscreen display
392. rrow media sensor removal on page 4 84 if correct replace the fuser to system board cable System board Check the voltage on J10 3 ground on the system board The voltage should measure approximately 3 3 V dc If the voltage is correct replace the fuser top cover assembly See Fuser narrow media sensor removal on page 4 84 If incorrect replace the system board See System board and inner shield removal on page 4 125 Fuser top cover assembly Diagnostic information 2 133 7002 xxx 924 xx Hot fuser service check Error Code 923 xx 924 xx and 925 xx may display for a hot fuser failure CAUTION The fuser may be hot use caution before removing or servicing working Unplug the printer before you begin or use caution if the printer must receive power in CAUTION There is a danger from hazardous voltage in the area of the printer where you are A N order to perform the task Service tip Set the Fuser Temperature to NORMAL before starting this service check In Diagnostics mode In Diagnostics mode select EP SETUP and Fuser Temp Fuser assembly Check the thermistor cable for correct installation to J5 on the fuser card If installed correctly check for correct installation of J10 on the system board If all cables are installed correctly go to step 2 Fuser to system board cable Fuser top cover assembly Turn the printer off and disconnect the thermistor cable from J5 on thermistor thermistor cab
393. rs flatbed 2 122 cover open switch cable base printer 2 123 dead machine 2 123 DRAM memory options 2 150 duplex option 2 125 envelope feeder 2 127 flash memory option 2 150 flatbed size sensor 2 129 fuser 2 130 fuser exit sensor 2 135 fuser narrow media sensor 2 136 fuser solenoid 2 137 hard disk option 2 151 high capacity feeder input tray 2 138 hot fuser 2 133 2 134 input sensor 2 143 input tray optional 2 144 interconnect card 2 145 LCD touchscreen display 2 146 main drive 2 149 main fan 2 117 network card 976 xx 2 151 network card 977 xx 2 151 operator panel right cover assembly 2 150 options 2 150 output bin sensor 2 152 paper feed 2 152 paper size sensing board 2 154 paper width sensor 2 121 parallel port 2 155 print quality 2 156 printhead 2 161 signature button assembly 2 161 system board 2 162 toner sensor 2 162 transfer roll 2 163 service error codes 2 15 shield inner shield 4 125 outer 4 121 signature button contact assembly removal 4 124 specifications acoustics 1 7 data streams 1 4 dimensions 1 5 electrical 1 6 environment 1 7 media guidelines 1 8 memory configuration 1 4 operating clearances 1 4 power requirements 1 6 resolution 1 3 scanner 1 3 start 2 1 strobe adjustment 3 19 sub error codes 2 15 switch cover closed 2 123 symptoms base printer MFP 2 13 duplex option 2 14 envelope feeder 2 15 high capacity feeder 2 14 paper trays 2 14 scanner ADF symptoms 2 14 scanner
394. rvice check on paper tray page 2 120 ADF does not recognize one or all paper Go to ADF paper width sensor service check on widths of paper in the paper tray page 2 121 Scanner flatbed symptoms Symptom Action Flatbed scanner does not recognize paper Go to Flatbed size sensor service check on page 2 129 size High capacity feeder 2000 sheet symptoms mmm Ro The printer does not recognize the high Go to High capacity feeder input tray service check on capacity feeder installed page 2 138 Paper feed problem with the high capacity Go to High capacity feeder input tray service check on feeder page 2 138 Paper tray symptoms mem mao Paper feed problem with 250 Sheet Paper Goto Input tray s service check on page 2 144 Tray Paper feed problem with 500 Sheet Paper Go to Input tray s service check on page 2 144 Tray Media fails to pass through from the lower Go to Input tray s service check on page 2 144 attached Paper Tray option to the next higher mounted option Duplex option symptoms mmm ooo p oooO Paper feed problem with Duplex Go to Duplex option service check on page 2 125 Paper jams at Paper Removal Tray Go to Duplex option service check on page 2 125 Paper skews in the Duplex Option Go to Duplex option service check on page 2 125 Paper fails to pass from lower option Go to Duplex option service check on page 2 125 through the Du
395. ry to perform the scanner registration See Scanner registration on page 4 4 7002 xxx 290 10 Error code service check Static jam first scan sensor A Note Before starting this service check make sure the first scan sensor cable is correctly installed Check for any signs of paper or other debris that might be present in the ADF assembly over the first scan sensor Remove any media found over the sensor and retry by running the scanner feed tests Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Feed Tests If the media jams over the first scan sensor go to step 2 First scan sensor Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Sensor Tests Check the first scan sensor for correct operation Note Check the first scan sensor by manually feeding a sheet of paper through the ADF and checking the sensor for correct operation If the sensor fails the test go to step 3 First scan sensor cable Check to make sure the first scan cable is correctly installed at the first scan sensor to CN10 sensor CN10 on the motor drive card If the cable is not installed on the MDC card correctly reinstall the cable If installed correctly go to step 4 Motor driver card Turn the power off and disconnect CN10 on the motor driver card Measure the voltages in the table below normally closed If incorrect replace the motor driver card
396. s are used to check the operation of the serial port hardware using a wrap plug Use Serial 1 Wrap if a serial port is available through PCI slot 1 and Serial 2 Wrap if the serial port is available through PCI slot 2 To perform the Serial Wrap tests 1 Disconnect the serial interface cable and install the serial wrap plug 2 Select Serial 1 Wrap or Serial 2 Wrap from HARDWARE TESTS The power indicator blinks green indicating the test is in progress The test runs continuously until a maximum number of tests is reached P UHHHHHE FuHHHE 6P represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 F represents the number of times the memory test has failed and finished with errors Initially 0000 displays with the maximum fail count being 999 999 Initially only four digits appear but additional digits appear as needed Each time the test finishes the screen updates If the test passes the pass counter increases by 1 however if the test fails a message displays for approximately three seconds Once the maximum count is reached the test stops The power indicator goes on solid and the final results display To stop the test before completion press Stop 4 The message Serial Wrap x lest Canceled displays and the printer returns to the HARDWARE TESTS menu 3 10 Service Manual 7002 xxx DUPLEX TESTS Quick Tes
397. s ready to process any link no messages display Link messages are listed in the following table User message Explanation Check device connection messages The messages in the following table display when the printer loses communications with one of the following devices User status message Explanation Check Env Feeder Check envelope feeder connection Connection Check Tray x Connection Check tray x where x 1 2 3 4 or 5 Check Duplex Check duplex option connection Connection The messages in the following table can occur in two ways The specified device could have been removed from the printer for instance to clear a paper jam Otherwise the device can still be attached to the printer but is experiencing a communications problem not fully connected or having a hardware failure If the device is temporarily removed or not connected properly then the user is advised to reattach it When the option is recognized the printer automatically clears the error and continues If the option is experiencing a Diagnostic information 2 57 7002 xxx hardware problem turn the printer off and back on If the error occurs again the user is advised to turn the printer off remove the option and call for service User status message Explanation Turn Printer OFF to A printer option Input Tray or Envelope Feeder has been attached while the printer Enable Option is powered on To use the option the printer must first be powe
398. sad ano 05 544 dvi pea d ESOS dae gee aoe ES P EXP eae 4 31 Flatbed ICC interface card removal eee eee eee eens 4 32 Flatbed paper length sensor assembly removal 0000 e eee eee eet eens 4 34 Flatbed scan assembly TERmIDVEl o44 a05 9245084644 HERRERA 6004005065666 40000e0 000404 4 38 Flatbed scan motor assembly removal 00 0c ee ee ee eee ene 4 41 Hard OS EDIDI ais ard dedo ERU ae Rae Rex abii SAG eX aber EGA eode 1 EOS BREE Dd bias 4 44 Home SSmsbsr TETTIDVBI 6 054 md ntr nnr TOn Fr SES OSSG SEES KEES A eR R d XIX Er4qd p RGen 4 46 eS oink Bc oa ee oe oe So ea os OS oe ee Bee oses 4 47 Pickup solenoid assembly removal xis gsx y RERRYREAURR atri Err ERES riai ooh secede 4 48 Scan Sono ORI removal uiia qeu Oa i KENS EREE EA bad Redd ee ew EDU o a 3d iR ooo 4 48 Scanner flatbed glass holder assembly removal llle eee 4 50 Separator assembly torque limiter removal leere 4 52 Upper glass holder removal 4ua acu REOR bn e oto gor Rha Ee ACRES RON ACRI HH e i 4 53 Base DING TOMOVANS iaa 40ERPARXRR AR REERR PRU RADXREWRRASEVRETYEEFREASRUARERIZRAZA RR EE LEA RE E 4 54 Fuser wiper cover assembly removal iaa soc oto So eee S45 408 om RC Re Ra 4 54 Opel SUD ODUSE PRITIOVU uie ai b 39 Rd d po P ERqag d br CY hedad RAE bees bI pA Es 4 55 Upper tray cover removal paper support ssa kot bo RORCROR RR ROR COR RR Ria 4 56 Pre len SIUS cover removal agacsea e Qaa y que 3 9 199934 13 4 34 54
399. screen and no settings are saved on the screen where it was touched The Back button appears on each menu screen except for the home screen Touch the Home button to return to the home screen The Home button appears on every screen except the home screen See the Home screen and Home screen buttons on page 2 4 for more information Grayed out button When this button appears it looks faded with a faded word on it It means the button is not active or unavailable on this screen It was probably active on the previous screen but the selections made on the previous screen caused it to be unavailable on the current screen Gray button Touch this button to select the action appearing on the button Features Menus gt Settings Menu trail line A line is located at the top of each menu screen This feature Copy gt Settings gt acts as a trail It gives the exact location within the menus Number of Copies Touch any of the underlined words to return to that menu or menu item The Number of Copies is not underlined since this is the current screen If this feature is used on the Number of Copies screen before the Number of Copies is set and saved then the selection is not saved and it does not become the user default setting Attendance If an attendance message occurs which closes a function message alert such as copy or fax then a blinking red exclamation point appears over the function button on the home screen Th
400. scription code codes P Duplex exit sensor covered Duplex input and exit sensors covered Duplex doublefeed sensor covered Duplex doublefeed sensor covered Duplex doublefeed and exit sensors covered Duplex doublefeed input and exit sensors are covered Feed error in duplex unit Jam declared by a smart device Immediate stop Jam declared by a smart device Homing allowed Stop 84 Service Manual Possible causes Media left in the duplex and Continue selected Sensor is having mechanical or electrical problems Media left in the duplex and Continue selected Sensor is having mechanical or electrical problems Media left in the duplex and Continue selected Sensor is having mechanical or electrical problems Media left in the duplex and Continue selected Sensor is having mechanical or electrical problems Media left in the duplex and Continue selected Sensor is having mechanical or electrical problems Media left in the duplex and Continue selected Sensor is having mechanical or electrical problems Mechanical feed error due to belt slipping Timing error due to feed system Mechanical feed error due to belt slipping Timing error due to feed system Mechanical feed error due to belt Slipping Timing error due to feed system Remove any sheets from the duplex option Try the duplex option again If it fails try another duplex option if available I
401. sembly 17 Drives Main drive and developer drive llusssn 7 28 Assembly 18 HOPED fuser auque ux OC NUES tiasar reida de y I e den dip de OR heed is 7 30 Assembly 19 Transfer charging lllllllllleel rn 7 32 Assembly 20 Electronics power supplies 0 0 0 ccc eee ene 7 34 Assembly 21 Electronics card assemblies 0000 es 7 36 Assembly 22 Electronics shields lees 7 38 Assembly 23 Cabling diagram 1 0 0 ccc eee eee nnn 7 40 Assembly 24 Cabling diagram 2 0 ce eee eens 7 41 Assembly 25 Cabling diagram3 0 0 ccc eee 7 42 Assembly 26 Cabling diagram 4 0 cc ele 7 44 Assembly 27 Cabling diagram 5 sc ccs 660044 50444505 054644450 46460 85 Kh Sob oe eK ORS dca 7 46 Assembly 28 Cable diagram 6 0 00 ccc ee ee eee nes 7 48 Assembly 29 Cabling diagrams 7 0 0 ccc eee 7 50 Assembly 30 Cabling diagrams 8 0 0 cc eee eee nes 7 51 Assembly 31 Optional 250 sheet paper drawer 0 0 0 0 eee 7 52 Assembly 32 Optional 250 sheet paper tray 0 0 0 cc eee 7 53 Assembly 33 Optional 500 sheet paper drawer 0 0 0 0 ccc eee 7 54 Assembly 34 Optional 500 sheet paper tray 0 0 0 0 cc ee 7 55 Assembly 35 Duplex option 2 4 66466566 44 66S ORO OER Eee ew OER ACRCRON ee eo 7 56 Assembly 36 Env
402. ser for ud or pa Evi T contamination If a problem Exit sensor not functioning correctly is found replace the fuser assembly See Fuser assembly removal on page 4 75 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Main drive motor Main drive motor not working Check the motor connections to identification failed motor and system board If no Fuser page count problem is found go to Main between 400 000 and drive service check on 499 999 page 2 149 Page did not reach exit e Page jammed on fuser input guide Check the fuser entry guide sensor Fuser page count between 400 000 and 499 999 Page did not enter or exit fuser nip for toner build up cleanly Check the fuser for wear or Evi Ani contamination If a problem Exit sensor not functioning correctly is found replace the fuser assembly See Fuser assembly removal on page 4 75 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 2 64 Service Manual 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error HD Description code codes P Video never started with page two inches past the input sensor Fuser page count between 400 000 and 499 999 Expected wide page not detected by narrow media sensor possible accordion jam Fuser page count between 400 000 and
403. sheet drawer 163 g m 43 Ib bond Note Not supported in the multipurpose feeder 163 g m 43 Ib bond Note Not supported in the multipurpose feeder 220 g m 59 Ib bond Note Not supported in the multipurpose feeder 260 g m 78 lb liner Note Not supported in the multipurpose feeder 140 to 175 g m 140 to 175 g m 75 to 135 g m 75 to 135 g m 20 to 36 Ib bond 20 to 36 Ib bond 60 to 105 g m 16 to 28 Ib bond 3 Note 28 lb envelopes are limited to 25 cotton content Printing label applications on the MFP requires a special label fuser cleaner Information on whether your vinyl label converter has passed Lexmark criteria is available at the Lexmark Web site www lexmark com search for converter list You can also check the Lexmark Automated Fax system LEXFAX M 7002 xxx Print media weight Envelope feeder 60 to 105 g m 16 to 28 Ib bond General information 1 11 7002 xxx Selecting print media Selecting the appropriate print media for the MFP helps you avoid printing problems The following sections contain guidelines for choosing the correct print media for the MFP Paper Transparencies Envelopes Labels Card stock Paper For the best print quality use 75 g m 20 Ib xerographic grain long paper Try a sample of any paper you are considering using with the MFP before buying large quantities When loading paper note th
404. simultaneously Turn on the printer re v9 NS Helease the buttons after 10 seconds Available menus Note Some menus are not available depending on the configuration of the printer Automatic Scanner Registration Touch Exit Diag Menu to exit the Diagnostics Menu and Resetting the Printer displays The printer performs a POR and the printer returns to normal mode Diagnostic aids 93 25 7002 xxx Maintenance Page Count The current value for the maintenance page counter is displayed This counter tracks printer usage A print job containing a single page increments the counter by one and a duplex page by two At 300 000 the customer is reminded that the printer requires scheduled maintenance This counter is reset by the servicer after a 80 Scheduled Maintenance message displays and a maintenance kit is installed See Maintenance kit on page 7 1 for the part number To view the maintenance page count touch gt to select Maint Cnt Value from the Configuration Menu The value is displayed and cannot be changed Touch Back to return to the main Configuration Menu Reset Maintenance Counter After scheduled maintenance the servicer needs to reset the page counter To reset the maintenance page count to zero 1 Touch gt to select Reset Maintenance Counter from the Configuration Menu 2 Touch Yes to reset the counter or touch No to exit without resetting the counter Reset Maintenance Counter The
405. sipi signal count between 300 000 Fuser not receiving AC power and 399 999 Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 36 Fuser is not increasing Fuser is not receiving AC power Go to 920 xx Cold fuser service in temperature even check on page 2 130 though the lamp has Poor supply line voltage been on for an extended time Fuser page count between 300 000 and 399 999 920 37 Fuser has been below Bad thermistor circuit or Go to 920 xx Cold fuser service the desired temperature cabling check on page 2 130 for too long while media is in the nip Fuser page Very noisy HIS HmISIOE signal count between 300 000 Fuser not receiving AC power and 399 999 Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll Abrupt change in temperatures that has disrupted control 2 20 Service Manual Service error codes 9xx xx continued Error code 920 920 920 920 920 920 Sub Display text Hot roll took too long to heat up after transitioning to new enhanced mode Fuser page count between 400 000 and 499 999 Hot roll fell too far below the desired temperature while printing Fuser page count between 400 000 and 499 999 Hot roll too cool while chickens for slope change Fuser page count between 400 000 and 499 999 count between 400 000 Fuser is not increasing in temper
406. sse worden niet als ongevaarlijk aangemerkt De printer is voorzien van een laser van klasse IIIb 3b dat wil zeggen een gallium arsenide laser van 5 milliwatt met een golflengte van 770 795 nanometer Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 Lasermeddelelse Printeren er godkendt som et Klasse l laserprodukt i overenstemmelse med kravene i IEC 60825 1 Klasse l laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder pa belgelaengdeomr det 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig uds ttes for en laserstr ling over Klasse l niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Huomautus laserlaitteesta Tama kirjoitin on Yhdysvalloissa luokan I 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan laserlaitteiden IEC 60825 1 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan Illb 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometria Laserjarjestelma ja kirjoitin on suunniteltu siten etta kayttaja ei altistu luokan maari
407. ssembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Page is covering the If page is not visible from front or rear Check the fuser and area narrow media sensor of the printer a partial piece of a around the fuser assembly for during warm up Fuser page may be torn off in the fuser any signs of debris or pieces of page count between covering the narrow media sensor paper or media 300 000 and 399 999 e he narrow media sensor or flag may be dislodged or damaged 2 74 Service Manual 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error code 202 202 202 202 202 202 202 Sub Description codes P Exit sensor may have bounced Fuser page count between 300 000 and 399 999 Never sent the divert command to the stacker Fuser page count between 300 000 and 399 999 Page is covering the exit sensor during warm up Fuser page count between 300 000 and 399 999 Timeout waiting for the page ahead Fuser page count between 300 000 and 399 999 Divert media co
408. ssembly 28 Cable diagrams 6 Part Units Units kit Description number mach _ or pkg 40X0491 Flatbed paper size sensors 3 including cable 40X0481 Parts packet sensors ri sensor 40X0487 Flatbed CCD cable 40X0509 Hard drive IDE 50 pin cable 40X0510 Hard drive 4 pin power cable 40X0507 Modem 30 pin cable NA Motor driver to SCC card cable NOT AVAILABLE AS A FRU NA Motor driver to SCC card cable NOT AVAILABLE AS A FRU NA Flatbed scan motor cable NOT AVAILABLE AS A FRU 40X0480 Flatbed scan motor Co i 2 3 4 5 6 4 8 9 O Parts catalog 8 49 7002 xxx Assembly 29 Cabling diagrams 7 Part Units Units kit Description number mach orpkg 40X0481 1 1 Parts packet sensors e A Second scan sensor e B Jam access door sensor e C First scan sensor e D Interval sensor 40X0456 1 1 Pickup arm assembly solenoid 40X0486 1 1 Motor driver card NA 1 1 Paper present sensor cable NOT AVAILABLE AS A FRU 8 50 Service Manual 7002 xxx Assembly 30 Cabling diagrams 8 Part Units Units kit Description number mach or 40X0481 Parts packet sensors e A ADF top cover open sensor e B First scan sensor e C Flatbed cover closed sensors cover closing cover closed Feed motor cable NOT AVAILABLE AS A FRU 40X0502 ADF CCD to ICC 36 pin cable 40X0506 MDC to ICC 36 pin cable NA Flatbed cover open sensor cable NOT AVAILABLE AS A FRU 40X0480 Transport motor cable
409. ssembly is noisy replacement may be required The arm must pivot freely through its full range of motion On 500 sheet trays there are wrap springs located on the pivot arbors of the arm These springs help prevent the arm from bouncing If the arm appears to be binding or sticky near the bottom of the tray these springs may be the problem Reducing the tension on the counterbalance spring may be used as a temporary fix to get additional weight at the bottom until the pick assembly can be replaced However the counterbalance spring is not to be considered an adjustment for feeding problems Diagnostic aids 3 37 7002 xxx Autoconnect system paper tray options envelope feeder electrical Autoconnect cabling and connectors The printer options make electrical connection automatically requiring no external cables when the option is mechanically installed under the printer Communication between the option and the base printer stops when you remove an option The printer no longer recognizes the option and deletes associated messages Each installed option below the base printer provides an electrical autoconnect to the option attached below it We do not recommend to attach or Hot Plug any options with the base printer power turned on Duplex Option The duplex option interface is a six pin autoconnector that provides a 24 V dc 24 V dc return serial interface transmit signal serial interface receive signal and two ground pins The
410. ssued too soon Fuser page count between 0 and 99 999 Virtual page timed out waiting for last page of job to be safe in the stapler accumulator Fuser page count between Paper jam around fuser Page may be jammed in fuser exit or or redrive area Fuser redrive area page count between 100 000 and 199 999 Go to Fuser exit sensor service check on page 2 135 Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Diagnostic information 2 69 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes 202 11 Page did not cleanly exit Page may be jammed in fuser exit or fuser or redrive area redrive area Fuser page count between 100 000 and 199 999 202 12 Exit sensor covered too Page m
411. system for any problems 24 V dc must come from the base printer through the autoconnect system to the high capacity input for the high capacity feeder to be recognized If the voltage is correct check the voltages at J11 3 red and J11 4 red The voltages measure 24 V dc If correct replace the high capacity feeder option system board If incorrect disconnect J8 from the system board and measure the voltages again If incorrect check the LVPS cable and the AC internal wiring from the input appliance receptacle If incorrect replace as necessary If correct replace the LVPS If the voltages are correct check the stepper motor for shorts from the motor housing to each pin on the motor connector If you find a short between any pin and the motor housing replace the motor assembly If no shorts are found replace the high capacity feeder option control board Check the voltage at J9 1 light blue The voltage measures approximately 24 V dc If incorrect disconnect the cable at J9 and check the voltage again If the voltage continues to be incorrect replace the high capacity feeder option system board If the voltage measures correctly check the cable If the cable is damaged replace as necessary If no problem is found with the cable replace the high capacity feeder option control board 24x xx Paper Jam displays paper jammed over the pass thru sensor Where x the printer displays the value of x for the paper tray where the error
412. t duplex This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the top margin on the back side of a duplex page You can run one duplexed page Single or continue printing duplexed pages Continuous until Stop e is pressed For information about changing the margin see Top Margin duplex on page 3 11 Note Before you set the duplex top margin be sure to set the registration See Registration base printer on page 3 5 The paper you choose to print the page on should be either Letter or A4 To run the Quick Test duplex 1 Touch gt to select Quick Test from DUPLEX TESTS 2 Touch gt to select Single or Continuous e The single Duplex Quick test cannot be canceled e The printer attempts to print the Quick Test Page from the default paper source If the default paper source only supports envelopes then the page is printed from Tray 1 e Check the Quick Test Page for the correct offset between the placement of the first scan line on the front and back side of a duplexed sheet The single test stops automatically when a single duplex sheet is printed and the continuous test continues until you press Stop Q9 Top Margin duplex This setting controls the offset between the first scan line on the front of the duplex page and the first scan line on the back of the page Therefore be sure to set the top margin in REGISTRATION before setting the duplex top
413. t is light Transfer roll Check the right end of the transfer roll shaft for signs of wear or contamination If incorrect replace the transfer roll Right side transfer roll arm assembly HVPS M Printhead Check the right side transfer roll arm assembly bearing for wear or contamination Also make sure the transfer cable is firmly attached to the bearing If incorrect replace the right side transfer arm assembly Check the connection of the transfer roll assembly cable to the transformer on the HVPS board Check the continuity of the cable from the bearing to the spade terminal on the cable If incorrect none the right side transfer arm assembly If correct replace the HVPS A contaminated printhead may be the cause of light print If no other cause is found install a new printhead See Printhead removal on page 4 122 Print quality toner on backside of printed page Service tip This is generally caused by loose toner in the machine in the paper path being carried through the printer on the backside of the paper Hot roll fuser assembly Transfer roll transfer plate assembly 2 160 Service Manual Toner is being carried out on the backside of the media This problem is generally caused by a toner buildup on the fuser hot roll or backup roll Check the fuser hot roll and backup roll for any noticeable buildup of toner Repair as necessary Check the transfer roll for toner buildup or loose toner around the ar
414. t might cause the paper to jam Check cartridge for obstructions If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 143 Input sensor covered too Multi sheet feed that is shingled Fan media and stack flat in tray or MPF Check for anything in the paper path that might cause the paper to jam Check cartridge for obstructions If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 143 long Tray size sensing wrong size Paper jam leaving page over sensor 2 58 Service Manual 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error HD Description code codes P Input sensor covered too quickly Imaged page not expected page Option tray never picked Input sensor covered too quickly Did not receive proper motor feedback to start laser servo Printhead motor not locked when page crosses input sensor Printhead motor fell out of lock after page arrives at input sensor Possible causes Paper pre staged in paper path e Wrong configuration ID causes engine to assume 500 sheet paper path on 250 sheet model e Bouncy input sensor Bouncy pass thru sensor Fail to feed from option Possible causes may include media edge locking worn or contaminated pick tires stacking tray beyond recommended fill line e Paper pre staged in path e Bouncy input sensor Motor c
415. t receiving sufficient AC power Poor supply line voltage Short in the thermistor circuit Noisy thermistor signal Fuser is actually overheating due to hardware faults Short in the thermistor circuit Noisy thermistor signal Fuser is actually overheating due to hardware faults Short in the thermistor circuit Noisy thermistor signal Fuser is actually overheating due to hardware faults Short in the thermistor circuit Noisy thermistor signal Fuser is actually overheating due to hardware faults Short in the thermistor circuit Noisy thermistor signal Fuser is actually overheating due to hardware faults 7002 xxx Go to 922 xx Cold fuser check on page 2 132 POR and retry If the error message remains go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 922 xx Cold fuser check on page 2 132 Go to 923 xx Hot fuser service check on page 2 133 Go to 923 xx Hot fuser service check on page 2 133 Go to 923 xx Hot fuser service check on page 2 133 Go to 923 xx Hot fuser service check on page 2 133 Go to 923 xx Hot fuser service check on page 2 133 Diagnostic information 2 29 7002 xxx Service error codes 9xx xx continued Error code 923 923 924 924 924 924 924 924 924 925 925 2 30 Sub Display text Fuser page c
416. talled Check for any signs of paper or other debris that might be present in the ADF assembly over the interval sensor but short of the first scan sensor Remove any media found in the ADF and retry by running the scanner feed tests Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Feed Tests If the paper fails to reach the first scan sensor go to step 2 First scan sensor Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Sensor Tests Check the first scan sensor for correct operation Note Check the first scan sensor by manually feeding a sheet of paper through the ADF and checking the sensor for correct operation If the sensor fails the test go to step 3 First scan sensor cable Check to make sure the interval sensor cable is correctly installed at first scan sensor to CN10 the sensor CN10 on the motor drive card If the cable is not installed on the MDC card correctly reinstall the cable If installed correctly go to step 4 Motor driver card Turn the power off and disconnect CN10 on the motor driver card Measure the voltages in the table below normally closed If incorrect replace the motor driver card If correct go to step 5 Diagnostic information 2 99 7002 xxx First scan sensor electrical checks ADF scan motor T Scan motor belt 2 100 Service Manual Turn the power off and reconnect CN
417. ter on its back Remove the two screws A holding the right frame extension Remove the two screws B securing the left frame extension Repair information 4 69 7002 xxx Pass thru plate 1 Remove the redrive assembly See Redrive assembly removal on page 4 123 2 Remove the screw A securing the pass thru plate 3 Carefully remove the plate until it is loose 4 Remove the fuser to system board DC cable B secured through the plate Note Note the routing of the fuser card to system board DC cable 4 70 Service Manual 7002 xxx Bevel gear removal Open the left door Remove the inner shield Remove the gear guard Poo D Remove the power takeoff shaft and spring A through the bottom of the printer A 5 Place your thumb on the top of the gear and press firmly down and away Note You need to exert firm pressure to snap the bevel gear out 1 ew Repair information 4 71 7002 xxx Installation 1 Remove any washer that may be present A and discard 2 Lubricate areas A that engage the journal B with grease from the provided packet 3 Place the new washer C on the bevel gear shaft A B 4 Insert the bottom portion and press or pull into position Note You should hear two distinct snaps If you only hear one the bevel gear is only partially engaged and you should continue to press until the second snap is heard Very firm pressure is required CAUTION Do not brace
418. teur ou de r vision l exposition a des rayonnements laser sup rieurs des rayonnements de Classe Laser notices XI 7002 xxx Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825 1 prodotti laser di classe non sono considerati pericolosi La stampante contiene al suo interno un laser di classe IIb 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assistenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 Avisos sobre el l ser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos l ser de Clase 1 establecidos en el subcap tulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los dem s pa ses re ne todas las condiciones expuestas en la norma IEC 60825 1 para productos l ser de Clase 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase Illb 3b de arseniuro de galio de funcionamiento nomina
419. th the sensor in normal operations sensor closed and with the sensor open sensor flag activated If the voltages are incorrect replace the second scan sensor If this does not fix the problem replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 292 00 Error code service check ADF cover open jam ADF upper top cover Check the ADF upper top cover to make sure it closes properly and does not come loose or pop up while the ADF is scanning 2 106 Service Manual 7002 xxx 293 Error code service check Paper missing jam Note Before starting this service check make sure the sensor cable is correctly installed Check the ADF for any media that might be jammed in the ADF Turn the MFP off and then back on Feed several sheets of media through the ADF If the error still occurs go to step 2 Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Sensor Tests Check the paper present sensor for correct operation by inserting a sheet of paper into the ADF paper tray to activate the paper present sensor If the sensor does not operate properly go to step 3 Paper present cable Measure the voltages shown in the table below Motor driver car Note All voltages are approximate values If the voltages ar
420. the Scanner Feed test 1 2 3 4 Touch EP to select Feed Test from the SCANNER TESTS menu The panel displays the setting s current value lt q setting s current value gt Use the arrows to select from Letter Legal or A4 Touch START to begin Feed Test Testing displays Touch Back to return to the Diagnostics Menu Scanner Manual Registration 1 2 Touch EP to select Scanner Manual Registration from SCANNER TESTS The panel displays the setting s current value lt q setting s current value gt Use the arrows to select the new value The following settings are listed Scanner Manual Registration FB Left Margin FB Top Margin ADF Front Left Margin ADF Front Top Margin ADF Rear Left Margin A 4 4 hy A A VVVVVV ADF Rear Top Margin 3 Touch Submit to make the changes Diagnostic aids 3 23 7002 xxx Sensor Tests The following tests are available ADF cover Open ADF Exit Sensor ADF Interval ADF Jam Removal ADF Paper Present FB Cover Open Home Sensor SCAN QRY PAPER SIZE ADF LONG SCAN QRY PAPER SIZE ADF WIDTH 1 SCAN QRY PAPER SIZE ADF WIDTH2 SCAN QRY PAPER SIZE ADF WIDTH3 SCAN QRY PAPER SIZE FB LONG SCAN QRY PAPER SIZE FB MEDIUM SCAN QRY PAPER SIZE FB SHORT SCAN SENSOR FIRST SCAN BIT SCAN SENSOR SECOND SCAN BIT 3 24 Service Manual 7002 xxx Configuration menu CONFIG MENU Entering Configuration Menu Turn off the printer Press and hold 2 and 6 buttons
421. the duplex jam access tray is installed correctly Make sure the power takeoff shaft and spring are correctly installed and operating properly Try the duplex option again If it fails try another duplex option if available If another one is not available replace the duplex option Make sure the duplex jam access tray is installed correctly Make sure the power takeoff shaft and spring are correctly installed and operating properly Try the duplex option again If it fails try another duplex option if available If another one is not available replace the duplex option Make sure the duplex jam access tray is installed correctly Make sure the power takeoff shaft and spring are correctly installed and operating properly Try the duplex option again If it fails try another duplex option if available If another one is not available replace the duplex option Remove any sheets from the duplex option Try the duplex option again If it fails try another duplex option if available If one is not available replace the duplex option Remove any sheets from the duplex option Try the duplex option again If it fails try another duplex option if available If one is not available replace the duplex option Diagnostic information 2 83 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx 238 238 238 238 238 g 238 iu 239 239 239 N Error SUD De
422. the high capacity system board Short pins 1 system board and 2 together while observing the sensor test on the display If the display does not change replace the high capacity feeder system board If the display changes check the continuity of the switch If incorrect replace the switch If correct replace the switch cable Diagnostic information 2 139 7002 xxx Tray x Empty displays when there is paper in the high capacity feeder input tray EJ Paper out sensor flag Check the paper out sensor flag for correct operation and installation If correct replace the high capacity feeder system board The paper Paper out sensor out sensor is mounted on the high capacity feeder system board on option system board The elevator tray fails to stop at the correct position and continues to drive into the bottom frame Lower limit switch Check continuity of the lower limit switch If incorrect replace the Lower limit switch cable switch If correct check the switch cable If incorrect replace the cable If correct replace the high capacity feeder option control board High capacity feeder Disconnect the lower limit switch cable and check the voltage at J2 1 control board orange The voltage measures approximately 5 V dc If incorrect replace the high capacity feeder option control board The elevator tray down button does not operate The tray moves to the upper position Service tip Open the high capacity feeder front do
423. the nip Fuser page count between 200 000 and 299 999 24 Hot roll too cool when heating to desired temperature after slope change Fuser page and 299 999 Description Bad thermistor circuit or cabling Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Fuser is not receiving AC power Poor supply line voltage Bad thermistor circuit or cabling Very noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll Abrupt change in temperature that has disrupted control 7002 xxx Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to
424. then the down arrow appears at the bottom of the column Each touch of the down arrow accesses one job in the list When more than three jobs exist once the fourth job in the list is reached then an up arrow appears at the top of the column For illustrations of the up and down arrow buttons see Information on touch screen buttons 7002 xxx Using the LCD touch screen buttons The following section provides information on navigating through several screens Only a few are chosen to demonstrate the use of the buttons Sample screen one Copy from Sides Duplex Letter 8 5 x 11 in l Portrait 1 sided to 1 sided v Copy to Letter 8 5 x 11 in Plain Paper Text Photo Scale a Auto Jin Photograph Printed Image Darkness QUE Information on touch screen buttons Select button Touch the select button to have another screen appear with additional items On the first screen the user default setting is shown Once the select button is touched and the next screen appears touching another item shown on the screen changes the user default setting Left scroll decrease Touch the left scroll decrease button to scroll to another button value in decreasing order Right scrollincrease Touch the right scroll increase button to scroll to another button value in increasing order Left arrow button Touch the left arrow button to scroll left to Reach a decreased value sh
425. there is continuity replace the HVPS If the problem continues replace the system board Diagnostic information 2 163 7002 xxx 2 164 Service Manual 3 Diagnostic aids 7002 xxx This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer Diagnostics Mode 0O O O 01010 9 5 9 QO O Configuration Menu O 0020 OO 1 Turn off the printer Press and hold 3 and 6 buttons simultaneously Turn on the printer Release the buttons after 10 seconds Turn off the printer 2 Press and hold 2 and 6 buttons simultaneously Turn on the printer Release the buttons after 10 seconds The Diagnostics Menu group consists of menus settings and operations that are used to diagnose various printer problems Note While the Diagnostics menu group is active all host interfaces are offline See Diagnostics Menu on page 3 2 for more information 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 CONFIG MENU on page 3 25 for more information Diagnostic aids 3 1 7002 xxx
426. they are operating normally If only the envelope feeder is failing to operate correctly continue with this service check otherwise verify the interconnect card is functioning properly Service tip The envelope feeder receives its 5 V dc operating voltage from the 24 V dc bulk at J1 7 If 24 V dc is not present at J1 7 tray 1 is the only tray that is recognized Printer does not recognize the envelope feeder as an attached input option Envelope feeder Make sure the envelope feeder is correctly installed and mated to the autoconnect at the front of the printer Front autoconnect on Check the connector for signs of damage to the connector or printer contacts If you find damage replace the damaged cable connector assembly Remove the envelope feeder and check the voltages at the autoconnect on the front of the printer If incorrect check the interconnect card If correct reinstall the envelope feeder and continue with step 3 Autoconnect on the Check for damage to the connector or contacts If you find damage envelope feeder replace the damaged cable connector assembly Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages e J1 3 measures 5 V dc e J1 5 measures 5 V dc e J1 7 measures 24 V dc If any of the voltages are incorrect replace the autoconnect cable connector If the voltages are correct replace the envelope system board Touchscreen displays 260 xx Paper Jam i
427. tions may be taken e f the option was temporarily removed or not connected properly reattach or reconnect it Accept the configuration change which notifies the printer the option has been hot unplugged removed with the power on Note This action is not available if the printer is in Diagnostics Mode or running diagnostics If the device is experiencing a hardware problem turn the printer off and on If the message continues to be displayed go to Envelope feeder service check on page 2 127 Diagnostic information 2 49 7002 xxx User attendance messages continued Error Sub Primary message code code y g Reattach Output Bin x Remove paper from Standard output bin Replace all originals if restarting JOD I o 2 50 Service Manual Description action Bin x Bin 1 Bin 2 or Bin 3 This messages displays for the following conditions e The specified output bin may have been removed from the printer possibly to clear a paper jam or to remove the option e The option may be attached to the printer but a communications problem may prevent the printer from detecting the option For example there may be a poor connection or a hardware failure The following actions may be taken e Ifthe option was temporarily removed or not connected properly reattach or reconnect it Accept the configuration change which notifies the printer the option has been hot unplugged removed with the power on
428. tly Measure all voltages from the connector to printer ground All voltages measured during the print cycle are measured with the controller board removed while running the print test Print quality all black page Service tip An all black page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum High voltage contacts Check the high voltage contacts on the right side frame to ensure they fit securely and are not pitted contaminated or damaged If incorrect replace the contact with one from the HV contact kit Screws and plastic blocks are included to attach the contacts to the right side frame in the HV contact kit Charge roll conductive Make sure the charge roll bushing is correctly installed in the right bushing charge roll arm HVPS Check the voltages on J15 1 thru J15 8 If incorrect replace the system board HVPS cable Check the continuity of the HVPS cable If incorrect replace the part of front cable assembly If correct replace the system board harness cable System board 2 156 Service Manual 7002 xxx Print quality blank page Print cartridge Check the print cartridge for damage especially the PC drum contact on the cartridge High voltage contact Check the PC drum contact on the right side frame for damage PC drum contact wear or contamination If the contact is bent or da
429. tor actually open Noisy thermistor signal Intermittent connection Thermistor cable not connected or thermistor actually open Noisy thermistor signal Intermittent connection Thermistor cable not connected or thermistor actually open Noisy thermistor signal Intermittent connection Thermistor cable not connected or thermistor actually open Noisy thermistor signal Intermittent connection Thermistor cable not connected or thermistor actually open 115 V lamp in 220 V printer Lamp has excessive wattage Attempting to POR machine after receiving a 925 01 Go to 923 xx Hot fuser service check on page 2 133 Go to 923 xx Hot fuser service check on page 2 133 Go to 924 xx Hot fuser service check on page 2 134 Go to 924 xx Hot fuser service check on page 2 134 Go to 924 xx Hot fuser service check on page 2 134 Go to 924 xx Hot fuser service check on page 2 134 Go to 924 xx Hot fuser service check on page 2 134 Go to 924 xx Hot fuser service check on page 2 134 Go to 924 xx Hot fuser service check on page 2 134 Go to 925 xx Hot fuser service check on page 2 134 Go to 925 xx Hot fuser service check on page 2 134 Service error codes 9xx xx continued Error code 925 925 925 925 925 925 925 925 Sub Display text Lamp detection performed and found error Fuser pag
430. tor cables Check and or replace tray motor Check and or replace sensor s Replace entire option Clear all jams Check motor cables Check replace tray motor Check and or replace sensor s Replace entire option Clear all jams Replace pick tires See Integrated tray autocompensator pick roll assembly removal on page 4 101 Check and or replace input sensor Clear all jams Check replace pass thru sensor Check for jam in tray Check pick assembly and controller card Clear media jams Replace pick tires See Integrated tray autocompensator pick roll assembly removal on page 4 101 Check replace input sensor Diagnostic information 2 87 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes code codes Paper over tray 2 pass e Paper left in path e Clear media jams thru sensor on warm up Failed pass thru sensor e Check replace pass thru sensor Failed to feed from Failure to feed Possible causes include e Clear media jams tray 2 Pages in the n paper path have been Edge locking mE Replace pick dass flushed to the output bin Worn or contaminated pick tires Check replace input sensor Overfilling of tray past the fill line Failed pass thru sensor One or more trays ray removed Reinstall tray located above the i source tray as been Sensors faulty Check sensors remo
431. tput Device response Failed the last page of a staple job Engine never sent Select OUtput Device to the duplex unit because the page leaving the duplex never sent Select Input Device Engine never saw Input Source Read on a page to be picked from the duplex unit that is waiting on a page to pass the input sensor Sheet picked from duplex never made it to the input sensor Slow or delayed feed from the duplex unit Paper jam near tray 1 Not applicable to tray 1 Not applicable to tray 1 Failed to pick from tray 1 DC feed autocompensator stalled on a pick Received lots of dc feed interrupts before losing them Possible causes Mechanical feed error due to belt slipping Timing error due to feed system Mechanical feed error due to belt slipping Timing error due to feed system Mechanical feed error due to belt slipping Timing error due to feed system Mechanical feed error due to belt slipping Timing error due to feed system Mechanical feed error due to belt slipping Timing error due to feed system Mechanical feed error due to belt slipping Timing error due to feed system Mechanical feed error due to belt slipping Timing error due to feed system e Input sensor not working correctly Paper jam around autocompensator faulty motor cable faulty motor autocompensator gear bind failed controller card Paper jam around autocompensator faulty motor cable faulty motor
432. ts duplex exit sensor but from the duplex option and another sheet is still see if the duplex fails again detected over the Remove the sheets if it fails doublefeed sensor again Run the duplex Feed 1 and Feed 2 Tests to see if they pass See Duplex Feed 1 and Duplex Feed 2 on page 3 13 If the tests fail duplex option 2 82 Service Manual User attendance messages paper jams and paper handling errors 2xx xx EITOF HD Description code codes P 237 23 238 238 07 01 Paper did not leave the duplex exit sensor Paper did not reach the printer input sensor from the duplex unit Duplex paper jam There may be other jams in the paper path Paper is covering one of the duplex sensors during a reset Duplex input sensor covered Possible causes Duplex jam access tray is not fully latched Printer PTO not driving duplex feed rolls Duplex feed system not working correctly Duplex jam access tray is not fully latched Printer PTO not driving the duplex feed folls Duplex feed system not working correctly Duplex jam access tray is not fully latched Printer PTO not driving duplex feed rolls Duplex feed system not working correctly Media left in the duplex and Continue selected Sensor is having mechanical or electrical problems Media left in the duplex and Continue selected Sensor is having mechanical or electrical problems 7002 xxx Make sure
433. tual page is narrow when wide page was expected Page jammed on fuser input guide e Page did not enter or exit fuser nip cleanly e Exit sensor not functioning correctly Main drive motor not working Page jammed on fuser input guide e Page did not enter or exit fuser nip cleanly e Exit sensor not functioning correctly 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Error HD Description code codes P If label media ensure front edge meets 1 8 inch requirement Check fuser for wear or contamination If problem is found replace the fuser assembly See Fuser assembly removal on page 4 75 If media is narrow then turn off first sheet detection In Diagnostics Menu PRINTER SETUP Engine Settings 3 Select 16 and touch Submit The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 136 Check the fuser entry guide for toner build up Check fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 75 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Check the motor connections to motor and system board If no problem is found go to Main drive service check on page 2 149 Check the fuser entry guide for toner build up Check the
434. tyksia voimakkaammalle sateilylle kirjoittimen normaalin toiminnan k ytt j n tekemien huoltotoimien tai muiden huoltotoimien yhteydessa VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina nakymatt malle lasers teilylle Ala katso s teeseen VARNING Osynlig laserstr lning nar denna del ar ppnad och sparren ar urkopplad Betrakta ej stralen Laser notices Xiii 7002 xxx Laser notis Denna skrivare ar i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass 1 andra lander uppfyller skrivaren kraven for laserprodukter av Klass enligt kraven i IEC 60825 1 Laserprodukter i Klass anses ej h lsov dliga Skrivaren har en inbyggd laser av Klass IIIb 3b som best r av en laserenhet av gallium arsenid pa 5 milliwatt som arbetar i vaglangdsomradet 770 795 nanometer Lasersystemet och skrivaren ar utformade sa att det aldrig finns risk f r att n gon person uts tts f r laserstr lning ver Klass I niva vid normal anv ndning underh ll som utf rs av anv ndaren eller annan foreskriven serviceatgard Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse 1 laserprodukter og er i andre land godkjent som et Klasse l laserprodukt i samsvar med kravene i IEC 60825 1 Klasse l laserprodukter er ikke betrakte som farlige Skriveren inneholder internt en klasse IIIb 3b laser som best r av en gallium arsenlaserenhet som avgir
435. ual 7002 xxx Flatbed CCD ribbon cable removal Remove the scan cover flatbed See Scan cover flatbed removal on page 4 11 Remove the scanner right side cover See Scanner right side cover removal on page 4 12 Remove the scanner left side cover See Scanner left side cover removal on page 4 9 Push the flatbed CCD toward the motor to take tension from the belt Unhook the belt from the motor shaft Ce SY 6 Push the flatoed CCD all the way to the left Repair information 4 23 7002 xxx 7 Unhook the main CCD guide shafts A from the holes in the right side This allows you to remove the flatbed CCD module from the shafts A 8 Carefully lay the flatbed CCD module on the scan frame being careful not to touch the card lamp or mirrors 9 Disconnect the flatbed CCD ribbon cable B from the flatbed CCD module 4 24 Service Manual 10 Remove the screw C from the flatbed CCD ribbon cable clamp 7002 xxx C 11 Remove the printer left side cover See Printer left side cover removal on page 4 56 12 Remove the five screws D from the SCC and HDD shield m a e etecoaveeeeee oes N 740559590008 ne mePSemtsnS 00005b EP 20 00090 e 2586022200 LEEREN E NLINLZLELJ eo MA a i eeeeceerececcccccpe m an na ma ereeeeve cee r eh 4 E 27 00 ce Cems I Repair information 4 25 7002 xxx
436. ude Clear media jams tray 4 Edge locking Replace pick tires See Integrated tray Worn or contaminated pick tires autocompensator pick roll Overfilling of tray past fill line assembly removal on Failed sensor page 4 101 Check replace input sensor NO gt gt i Paper over tray 4 pass Paper left in path e Clear media jams thru sensor on warm up Failed pass thru sensor Check replace pass thru sensor Late feed from a tray interfered with the pick retry NO A BA Failed to feed from Failure to feed Possible causes include Clear media jams tray 4 Pages in the Edge locking e Replace pick tires See paper path have been Me Integrated tray flushed to the output bin orn or contaminated pick tires autocompensator pick roll Overfilling of tray past fill line assembly removal on Could also be a failed pass thru page 4 101 Senor e Check replace input sensor NO A EN One or more trays Tray removed e Reinstall the tray location above the source tray have been removed Paper jam near tray 5 e Paper jam e Clear media jam e Failed pass thru sensor e Check sensor Jam declared by a smart Fault reported by options tray 5 e Clear all media jams device Immediate stop Paper jam Check motor cables e Motor or motor cable failure Check replace tray motor e Sensor failure e Check replace sensor s e Replace entire option Sensors faulty Check sensors
437. ufficient AC power Poor supply line voltage Low wattage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Incorrect hot roll Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Incorrect hot roll Fuser is not receiving AC power Poor supply line voltage Bad thermistor circuit or cabling Very noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Abrupt change in temperature that has disrupted control Incorrect hot roll Go to Paper feed service check base printer on page 2 152 Go to Transfer roll service check on page 2 163 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Go to 920 xx Cold fuser service check on page 2 130 Diagnostic information 2 17 7002 xxx Service error codes 9xx xx continued Error SUb Display text code codes play Hot roll took too long to heat up after transitioning to new enhanced mode
438. utosize slider Autosize finger Switch activate spring Make sure the switch activate spring is not bent or broken Replace Paper size sending board the spring if damaged If the spring is not damaged go to step 3 System board Set the tray for the paper size that is not recognized and install the ITC cable tray in the printer Select the paper size and corresponding paper switch from table below Pin Static Static with paper tray in and set to V dc J26 tray out L dul de Letter Legal A4 Exc Bo Uo eue s o o sss ass 0 ass e eee pow 9 peo 5 qo S pszer sas vss sas o o o 33 4 psz as o eses 0 33 o 6 N A 7 a o ooo UNA y 8 33 33 33 33 43 3 33 13 3 43 3 9 NA O N A If the voltage on J26 does not change go to step 4 If the voltage changes recheck the printer If Tray 1Missing is still displayed replace the system board assembly System board Ground the appropriate pin on connector J26 on the system board Tray 1 Missing should not be displayed If it is not displayed go to step 5 If it still displays replace the system board assembly cable Check continuity of the autocomp cable If correct replace the ITC assembly If incorrect replace the autocomp cable Parallel port service check Run the Parallel Wrap test on page 3 10 Note The Parallel Wrap Test is designed to check the parallel port hardware by using a wrap plug P N 1319128
439. vals disconnect any cable or electronic board or assembly for personal safety and to prevent damage CAUTION Remove the power cord from the printer or wall outlet before you connect or AN to the printer CAUTION Use the handholds on the side of the printer Make sure your fingers are not under the printer when you lift or set the printer down Note Some removal procedures require removing cable ties You must replace cable ties during reassembly to avoid pinching wires obstructing the paper path or restricting mechanical movement Fuser wiper cover assembly removal 1 Squeeze the two latches together and pull up 2 Remove the fuser wiper cover assembly 3 Remove the fuser wiper cover assembly 4 54 Service Manual 7002 xxx Upper sub cover removal 1 Remove flatbed scanner assembly See Flatbed scan assembly removal on page 4 38 2 Remove screw A from right side frame holding upper sub cover 3 Pull up on the right side of the upper sub cover 4 Remove the upper sub cover Repair information 4 55 7002 xxx Upper tray cover removal paper support 1 Remove the flatbed scan assembly See Flatbed scan assembly removal on page 4 38 2 Raise the upper tray cover and lift to release the latches 3 Remove the upper tray cover Printer left side cover removal 1 Open the upper and lower front covers 2 Press the two left door latch buttons A and open the left door 4 56
440. ve a printer stand or printer base 3 40 Service Manual 7002 xxx Understanding jam messages The following table lists the jam messages that can occur and the action necessary to clear the message The jam message indicates the area where the jam occurred However it is best to clear the entire paper path to ensure you have cleared all possible jams Message What to do 200 and 201 Paper Jam Remove Open the bottom then top front covers remove the print cartridge Cartridge and then remove the jam 202 Paper Jam Open Rear Door Open the rear door on the MFP and remove the jam 23x Paper Jam Open Duplex Rear Remove the duplex tray from the duplex unit raise the duplex Door deflector and remove the jam Open the rear duplex door and remove the jam 250 Paper Jam Check MP Feeder Remove all media from the multipurpose feeder flex and stack the media reload the multipurpose feeder and adjust the guide 260 Paper Jam Check Env Feeder Lift the envelope weight remove all envelopes flex and stack the envelopes reload the envelope feeder and adjust the guide 290 291 292 and 294 Scanner Remove all original documents from the ADF Open the ADF cover Jams and remove any jammed pages Open the document cover and remove any jammed pages Open the scan unit access door and remove any jammed pages Clearing jams Although there are several places a jam can occur clearing the paper path is fairly easy Paper jams can occur
441. ve and require replacing The hard disk format is not supported Format the hard disk prior to performing operations that require the hard disk If the message remains the hard disk may be defective and require replacing Service is required to maintain printer performance Replace the maintenance items and if necessary reset the printer maintenance counter For more information go to Scheduled maintenance on page 7 1 This error displays when the microcode to be programmed in the engine flash code module has failed a CRC check POR the MFP to clear the message The microcode data is discarded and must be re transmitted from the host computer The toner cartridge is running low on toner Replace the toner cartridge if the toner low alarm sounds Touch Continue to clear the message if the toner low alarm does not sound 7002 xxx User attendance messages continued Error Sub code code Primary message Description action 1565 1565 Emul error load The download emulator contained in the firmware card does not function emulation option with the MFP firmware Note The MFP automatically clears the message in 30 seconds and then disables the download emulator on the firmware card For help downloading the correct download emulator version contact the place where you bought your printer User line 2 link messages If the printer is locked on a particular link the link indication displays If the printer i
442. ved Jam declared by smart Fault reported by options tray 3 Clear all media jams device Immediate Stop paper jam Check motor cables e Motor or motor cable failure Check replace tray motor e Sensor failure Check replace sensor s e Replace entire option Jam declared by smart Fault reported by options tray 3 Clear all media jams device Homing allowed Paperjam Check replace tray motor Motor failure e Check replace sensor s e Sensor failure Replace entire option Option tray pass thru Failure to feed Possible causes include Clear media jams sensor never became covered Edge locking Replace pick tires See e Integrated tray Worn or contaminated pick tires autocompensator pick roll Overfilling of tray past fill line assembly removal on Failed sensor page 4 101 Check replace input sensor e Check PTO shaft Option tray pass thru Paper jam Check all media jams sensor never became Failed sensor Check replace pass thru uncovered sensor Failed to pick from tray 3 Paper jam around autocompensator Check for jam in tray Faulty motor cable Check pick assembly and Faulty motor controller card Autocompensator gear bind Failed controller card 2 88 Service Manual 7002 xxx User attendance messages paper jams and paper handling errors 2xx xx Sub codes Error Description Possible causes code NO gt CO e Li amr NO O O1 Co 243
443. w media sensor open Narrow media sensor closed Narrow media sensor open Printer printing narrow media fed through the printer Printer not printing no media over sensors Fuser exit sensor exit Enter the Diagnostic mode select BASE SENSOR TEST select the sensor test Exit Sensor to test for proper operation If the exit sensor fails the test go to step 2 If the exit sensor passes go to step 5 Fuser exit sensor cable Check the fuser exit sensor cable for correct installation or for any signs of damage to the cable or connectors If no problem is found go to step 3 If a problem with the installation is found install the ee io If damage to the cable or connectors is found replace the cable Fuser exit sensor flag Make sure the sensor flag is not binding and is operating properly If the sensor is operating properly go to step 4 If it is not operating properly repair or replace the sensor assembly See Fuser exit sensor removal on page 4 78 Fuser assembly Check the continuity of the fuser exit sensor cable If incorrect replace the cable if correct check the continuity of the fuser to FUser EXE SENEONGADIE system board cable If incorrect replace the cable in correct replace Fuser board the following FRUs in the order shown Fuser to system board e Fuser board cable System board e Fuser assembly See Fuser assembly removal on page 4 75 e System board See System board and inner shield removal
444. warm up Fuser page count stopped at 500 000 to preserve data of the printer a partial piece of a page may be torn off in the fuser covering the narrow media sensor e The narrow media sensor or flag may be dislodged or damaged 2 8 Service Manual Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 135 Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 75 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be installed for correct installation and alignment The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check o
445. wer cable urrrrrrr e 7 37 7 49 Flatbed cover closed actuator r urrrrrrrr rrr 7 19 Flatbed cover closing actuator r rrrrrrlIIr e 7 19 Upper front cover hinge assembly IIIIIIIIIIl 7 3 7 45 LVPS AIO 115 V ac r rrrurrrrrrrr ee eee ees 7 35 LVPS AIO 220 V aC rHrrrurrrrrrrAr eee ee ees 7 35 Interconnect card assembly 2 222 2c rece eee eee eee eee eee eee ee eees 7 37 MarkNet 8000 Fast Ethernet 22222 sees nee e ene eee ee eee eee eee eee eee eens 7 65 MarkNet 8020 Gigabit Ethernet 222 22 c eee etree eee e reese 7 65 MarkNet 8030 Fiber Ethernet T IIIIrIIrIIIIlIIll 7 65 MarkNet 8050 wireless US 22 222 n eee eee net eee eee ee eees 7 65 128MB memory option 22st terre ree eee eee ee eee 7 65 256MB memory option 22s eter rrr tee eee eee eee eee eee 7 65 512MB memory option 2 2 eter ttre ee eee eee eee eee eee 7 65 Japanese font card 2 2 2 tener re ee eee eee eee eeee 7 65 I 12 Service Manual 40X1513 40X1514 40X1515 40X1562 40X1564 40X1565 40X2529 40X2590 40X2591 40X2592 40X2722 40X2791 40X2792 40X2793 40X2799 40X3230 40X3231 40X3232 40X3233 40X3234 40X3235 40X3236 40X3237 40X3243 40X3244 40X3245 40X3246 40X3247 40X3248
446. work or Restore LES Note There is no confirmation and selecting one of these settings immediately takes effect The MFP restarts and returns to Ready state Restoring Factory Defaults and then Resetting the Device are displayed Factory Defaults Restore Base Restore Network Restore LES Energy Conserve This menu controls what values appear on the Power Saver menu If Off is selected in Energy Conserve menu then Disabled appears in the Power Saver menu and Power Saver can be turned off If On is set in Energy Conserve the Power Saver feature cannot be disabled 1 Touch gt to select Energy Conserve from the Configuration Menu 2 The panel displays the setting s name in the header and lt q setting s current value gt below the header row Touch lt or P to change the setting The selections are On and Off The default is On 3 Touch Submit to save your change Touch Back to exit without changing the value Diagnostic aids 3 29 7002 xxx Min Copy Memory 1 Touch gt to select Min Copy Memory from the Configuration Menu The panel displays the setting s name in the header and setting s current value below the header row 2 Touch lt or P to change the setting For example the values may be 25 MB 35 MB 50 MB and 100 MB The default is 25 MB Values will only be displayed if the amount of installed DRAM is at least twice the amount of the value that is at least 200 MB of install
447. xcept on a page with a uniform gray or a large amount of graphics printed on the page Banding is primarily due to a variation in the speed of the paper as it feeds through the printer especially in the development and transfer process Inspect the alignment assembly main drive assembly and all other paper feed components for signs of wear dirt binds or damage especially the drive gears Banding appears as light or dark horizontal lines on a uniformly gray page Banding can also be caused by a defective charge roll brush contact or HVPS Check the charge roll contact for damage and for proper connection to the HVPS and print cartridge Print quality black bands on outer edges of the page This print quality problem appears as vertical black bands on one or both sides of the copy and can be wide narrow light or dark Charge roll counterbalance If the problem is just on one side of the page check the charge roll springs counterbalance spring on that side You can check to see if enough force is being applied to the charge roll by applying slight downward pressure with your finger to the charge roll link arm that the spring is attached to while you run a print test sample See if the problem changes or goes away If this fixes or changes the problem then check the springs and charge roll link arm assemblies for binds or defective parts Replace as necessary Charge roll assembly Check the charge roll for toner buildup or other contamin
448. xiting 3 4 HARDWARE TESTS Button Test 3 8 CACHE Test 3 9 DRAM Test 3 9 Panel Test 3 8 parallel wrap tests 3 10 serial wrap tests 3 10 INPUT TRAY TESTS Feed Test 3 13 Sensor Test 3 14 OUTPUT BIN TESTS Feed Test 3 14 Sensor Tests 3 15 PRINT TESTS input source 3 7 Prt Quality Pgs 3 7 l 2 Service Manual PRINTER SETUP Configuration ID 3 19 Defaults 3 17 Edge to Edge 3 19 engine settings 3 18 Envelope Enhance 3 18 Model Name 3 18 Page Count 3 18 Par x Strobe Adj 3 19 Perm Page Count 3 18 Serial Number 3 18 REGISTRATION 3 5 Quick Test 3 6 SCANNER TESTS ASIC Test 3 23 Feed Test 3 23 Scanner Manual Registration 3 23 Sensor Tests 3 24 dimensions 1 5 Disk Encryption 3 33 DRAM Test 3 9 duplex option parts catalog 7 56 service check 2 125 duplex tests Duplex Feed 1 3 13 Duplex Feed 2 3 13 Motor Test 3 12 Quick Test 3 11 Sensor Test 3 12 Top Margin 3 11 E Edge to Edge 3 19 Energy Conserve 3 29 Engine Setting 3 18 Envelope Enhance 3 18 envelope feeder parts catalog 7 57 service check 2 127 Envelope Prompts 3 33 EP duct 7 11 EPROM mismatch failure 2 118 2 119 error codes service 2 15 ESD cover 4 74 ESD sensitive parts 4 1 event log clear log diagnostics menu 3 22 display log diagnostics mode 3 21 print log configuration menu 3 32 print log diagnostics menu 3 22 F fans cartridge fan 2 117 EP fan 7 11 main fan 2 117 4 107 7 47 fax card connectors 5 28 Feed Test scanner
449. y Paper jam around the multipurpose Check for jam in tray picked from feeder multipurpose feeder EE DM and 250 Page was not properly Paper jam around the multipurpose Check for jam in tray picked from feeder multipurpose feeder Sau ee and 250 Page was not properly Paper jam around the multipurpose Check for jam in tray picked from feeder Check the pick assembl multipurpose feeder and le ead y 250 10 Page was not properly Paper jam around the multipurpose Check for jam in tray picked from feeder multipurpose feeder E E HN and 250 11 Failed to feed from Paper jam around the multipurpose Check for jam in tray multipurpose feeder feeder Check the wick assembl Pages in the paper path and santicller card have been flushed to the l output bin 260 Paper jam near the envelope feeder 260 01 Jam declared by a smart device Immediate stop 0 02 26 Jam declared by a smart device Homing allowed stop 260 05 Envelope feeder pass thru sensor never became uncovered 260 Envelope feeder pass thru sensor never became covered 260 07 Failed to pick from the Paper jam around the envelope feeder Remove feeder and clear envelope feeder jam Replace feeder 260 10 Page did not reach input Paper jam around envelope feeder Remove feeder and clear sensor from envelope jam feeder Replace feeder 260 11 Page did not reach input Paper jam around envelope feeder Remove feeder and clear sensor from envelope ja
450. y service check on page 2 161 The length of the print media is too short to print the formatted data Touch Continue to clear the message and continue printing The MFP does not automatically reprint the page that prompted the message Make sure the Paper Size setting in the Paper Menu is correct for the size of print media used If MP Feeder Size is set to Universal make sure the print media is large enough for the formatted data Touch Cancel Job to cancel the current job if needed The MFP lacks the memory needed to enable Resource Save This message usually indicates too much memory is allocated for one or more of the MFP link buffers Touch Continue to disable Resource Save and continue printing Install additional memory The resolution of the page has been reduced from 600 dpi to 300 dpi to prevent a Memory Full error This message can only occur if the Resolution Reduction setting is turned on Note 1200 dpi pages are not resolution reduced If a 1200 dpi job runs out of memory a Memory Full error displays The MFP cannot defragment flash memory because the memory used to store undeleted flash resources is full Touch Continue to clear the message To perform the defragment operation install additional memory or delete fonts macros and other data to free some memory space Touch Reset Active Bin to change to another linked bin The MFP cannot collate the job because the memory is full Touch Continue to
451. y signs of media or other debris that might be present in the ADF assembly around the exit sensor flag Remove any media or debris If nothing is found go to step 2 Check the exit sensor flag to make sure it operates freely and does not hang or bind If the flag does not operate correctly and cannot be made to operate correctly replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 If the flag operates correctly go to step 3 ADF exit sensor Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Sensor Tests Check the ADF exit sensor for correct operation Note You can check the ADF exit sensor by moving the exit sensor flag or by manually feeding a sheet of paper through the ADF If the sensor fails the test go to step 4 Motor driver card Turn the power off and disconnect CN9 on the motor driver card Measure the voltages in the table below normally closed If incorrect replace the motor driver card If the voltage is correct go to step 5 Diagnostic information 2 111 7002 xxx ADF exit sensor electrical Turn the power off and reconnect CNO9 to the motor driver card checks Measure the voltages in the table below with the sensor in normal operation sensor closed and with the sensor open
452. you are using a 2000 sheet drawer Certain other configurations also must have a printer stand or printer base More information is available on our Lexmark Web site at www lexmark com multifunctionprinters General information 1 1 7002 xxx Options The following options are available Some options are not available in every country or region Contact your point of purchase for options available in your country or region Memory options of 128MB 256MB and 512 SDRAM Flash memory options of 32MB and 64MB Hard disk 20GB with adapter Integrated network options Token ring Ethernet External serial adapter IPDS card assembly and SCS TNe PRESCRIBE card assembly Barcode card assembly Parallel interface card MarkNet Professional Print Servers Lexmark PrintCryption card Forms card single byte and Simplified Chinese e Media handling operations 250 and 500 sheet paper trays of A4 letter A5 B5 Executive folio statement and legal size 250 and 400 sheet universally adjustable trays 250 and 500 sheet paper drawers 400 sheet universally adjustable tray 2000 sheet high capacity feeder always used below any other drawer Envelope feeder Duplex option 500 sheet For Lexmark X644e and Lexmark X646e with integrated 500 sheet output tray e Application solutions Barcode card Lexmark Forms Card Software IPDS PRESCRIBE emulation card PrintCrypt

Service Manual (P/N 12G9633)

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