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Toshiba e-STUDIO500P Printer User Manual

1. Gnd Signature SM Cart Button GND E TONER WHEEL CN Cartridge 5 5VDC SW 5VDC SW Sensor INSENSOR J14 ER J17 5 GND TXD1BR GND RXDIR BEES J25 Liel Hielal J15 EBGEZECEEB CHARGE B 24VDC SW XFRB TX ENB B ATSERVO GND TXD1BR GND RXDIR pj 322 T J19 BLDC WIND 2 VC21 VC20 5VDC FUSED GND BLDC FG BLDC HALL 2 BLDC HALL 1 BLDC HALL 0 Ely ely J24 J20 5VDC FUSED GND 24VDC GND GND 24VDC PTC OPT To Transfer Roll 3 4 5 6 7 8 9 um cer Main Drive Motor i Ethernet GND l 24VDC RAW 424VDC RAW ZEROXNGR 24VDC RAW 24VDC RAW HEAT HEAT L FAN DRV GND l I BEIBEDBILIIT 8 9Ti6 Fr 7 CEEI i To J25 4 GC a M a EX RNC ACER a a To J25 3 J16 ToJ18 2 Autoconnect Front AUTOCOMP MPFPick Tonen To 325 2 ToJ25 1 ToJ18 1 AC ENCODE CN To J25 2 To J25 1 TRAY1 PLO CN TRAY1 POUT CN 5VCD SWITCHED x e g o z 2 13 4 5 6 7 8 Paper Low Out Sens
2. ee eee 7 27 Transfer roll right spring ee eee ee ee 7 27 Transfer pivot shaft eee ee eee eee ee 7 27 Transfer roll left spring eee eee eee ee 7 27 Transfer roll left arm c l l 7 27 System board assembly non network 000 Board ID Q0016021 7 31 System board assembly non network 200 Board ID Q0016022 7 31 System board assembly non network 400 Board ID Q0016023 7 31 System board assembly network 010 Board ID Q0016001 7 31 System board assembly network 210 Board ID Q0016002 7 31 System board assembly network 410 Board ID Q0016003 7 31 Interconnect card assembly 2 slot 200 210 400 410 7 31 Interconnect card assembly 1 slot 000 010 7 31 Inner shield assembly 2 slot 200 210 400 410 7 33 Outer shield 2 slot 200 210 400 410 2 2 eee eee 7 33 USB board assembly 222 esses e scene cence nee eee nee eee eens 7 3 Ethernet shield blank 000 200 400
3. llllllllllllllllllll2 7 29 High voltage contact kit 7 9 Exit sensor cable llllllllll2 c 2 2 2 7 25 Left side hand holder 7 5 MarkNet 8000 Fast Ethernet 2 22 0222 eee ene eee 7 69 MarkNet 8020 Gigabit Ethernet 7 69 MarkNet 8030 Fiber Ethernet 22 22 02 7 69 MarkNet 8050 wireless US 2 2 2 eee nee ene ene 7 69 MarkNet 8050 wireless non US ll llllll ll ll 7 69 128MB memory option 2 22 eee eee eee eee eee eee eee 7 69 256MB memory option lllllllllllll 7 69 512MB memory option 2 2 2 n nner ne nee eeeee 7 69 Japanese font card lc llc l llle lllll ll l ll 7 69 I 12 Service Manual 40X1513 40X1514 40X1515 40X1564 40X1565 56P1228 56P1228 56P1279 56P2114 56P2115 56P2116 56P2540 20G0888 56P4103 20G0890 20G0892 56P4106 20G0891 56P4108 56P4109 56P4110 56P4111 56P4112 56P4116 56P4117 56P4122 56P4126 56P4127 56P4128 56P4129 56P4130 56P4131 56P4132 56P4133 56P4137 56P4139 56P4142 56P4143 56P4145 56P4147 20G0890 56P4155 56P4157 56P4162 56P4163 56P4176 56P4178 56P4179 56P4180 56P4181 56P4182
4. Error Sub Description Possible causes Action code codes 200 08 Input sensor covered too Paper pre staged in path Check MPF and friction pad quickly Bouncy input sensor Fan media and stack flat in tray or MPF Use different media 200 09 Did not receive proper Motor connections Check the main drive motor motor feedback to start cable connections laser servo If no problem is found with motor connections go to Main drive service check on page 2 105 200 10 Printhead motor not Printhead lock signal not working Go to Printhead service locked when page e Pri check on page 2 122 crosses input sensor Printhead control not working 200 11 Printhead motor fell out Paper pre staged in path Go to Printhead service of lock after page arrives check on page 2 122 at input sensor Lock signal went away 200 13 Input sensor covered Page still covering input sensor Go to Input sensor service during warm up check on page 2 102 sequence 200 16 Main drive motor error Main drive motor not working Go to Main drive service possibly due to check on page 2 105 mechanical load 200 32 Detected cover switch Upper cover not fully closed Go to Cover closed switch bounce eni cable service check on Cover switch not functioning correctly page 2 80 201 00 Page did not reach exit Page jammed on fuser input guide Check fuser entry guide for sensor Fuser page Pa
5. llllllllll l 7 44 Back restraint 500 sheet tray 2 2 2 eee eee eee eee eee eens 7 45 Complete tray assembly 500 sheet l ll 7 45 Front door assembly 2 2 2 ene een enn ne ne ee eee eee eens 7 59 Door hinge 22 222 n nner ne en nn een nee eee eee ene 7 59 Pick arm assembly 2000 sheet eee eee eee 7 63 Left side cover 2 22 22 nnn eee ee nee 7 48 Redrive cap cover 2 22 2222 een een nee eee eee een ee eee eeee 7 55 Right side cover 2 22 5022 eee eee eee eee ee ee nee eee eee ee eeee 7 55 Left side cover 2 2 2222 2 22 e een n nee nen eee eee ee eee eneee 7 55 Wire cover 9 2 2222 22 een n nee nn eee ee en eee eee eee eee eeee 7 55 Top bin cover 0 2 2252 eee eee nn eee nee eee eee eee ee eee eneee 7 55 Paper cap tray 9 2 2 enn enn nn nn ne en ne eee ee eee 7 55 Rear access door 2 2 2 nnn en nn nnn ne nn eee eens 7 55 Diverter solenoid 2 2 2 n ene en nen e eens 7 57 Bin full flag llllllllllllll 2 7 55 Dual paper height sensor 22 52 25 eee en eee eee eee eee eee eeeneee 7 55 5 bin mailbox pass thru sensor ll c l l 7 55 5 bin mailbox assembly kit
6. 7 59 Bellcrank spring 250 sheet paper tray 7 42 Output tray lllllllllllllll 2 l2l2 2 7 65 Part number index l 15 l 16 Service Manual 500P 4061 Wiring diagram Printhead Cartridge ELO Fan STD Bin MEJL IBBEL Autoconnect Top Toroid Tort 2 a Fuser Lamp LPOW FB LADJ CN D VIDEO 0 CN VIDEO 0 CN LADJ2 CN D VIDEO 1 CN VIDEO 1 CN MM START CN MM LOCKR HSYNC ID CN HSYNC CN MAINFAN CARTFAN 5PHead ID s 8 ul amp GND GND IN IN pore 8 7 e 5 4 3 2 1 HOP LED Gnd HOP FULL CN 12C DATLS 12C CLK LS 3 3VDC USB Board ExitSens Thumpret 5VSW Thump GND Therm CN GND OP Panel NarrowMedia J1 i cM wr i USB Device Port COV CLOSE GND 5VDC J7 200000000000 00000000000 00000000000 o O 99000000000 O GND o OO 3 3VDC PANEL INT GND 12C CLK 5VDC 12C DAT 50V 25 sv aav anD a e o 5 JT2 900 go Switch CN 1
7. 7 33 INA flat cover blank eee e eee e eee 7 33 Inner shield assembly 1 slot 000 010 7 33 Bottom front autoconnect cable assembly 7 37 Top autoconnect cable assembly 0 2 2 eee reer eee ee eeee 7 37 Main drive motor cable assembly 0 2 2 eee eee ee eeee 7 41 MPF sensor cable 2 2 2 eee ee en een eee eee ee eee eee eee 7 34 System board to fuser board cable assembly 7 39 Fuser AC lamp to LVPS cable assembly 7 39 Parts packet 7 5 7 7 7 9 7 25 7 29 Parts packet alignment asm mounting screw 7 17 Parts packet C clip pivot shaft 7 27 Parts packet charge roll screw eee eee eee ee eee 7 27 Parts packet clip ref ground mounting screw 7 17 Parts packet developer drive ground screw nn 7 23 Parts packet frame mounting screw nn 7 15 Parts packet gearbox mounting screw eee eee eeee 7 23 Parts packet hanger 0 22 eee eer ene eee eee eee eee 7 13 Parts packe
8. 7 29 Power cord set 8 ft right angle 13 amp United States 7 29 Pass thru plate 250 sheet tray 7 19 Standard bin level sensor cable 2 222 ee eee eee eee eee eee lt lt 7 7 PRESCRIBE card assembly 2 2 2022 e cece eee eee eee eee e eee eee 7 31 7 69 Single byte forms card assembly 2 2 eee eee eee enn nn eee nn ee eee eens 7 69 Double byte forms card assembly 7 69 Power cord set Hong Kong 7 29 Power cord set Taiwan c llllllllll llllll ll 7 29 Frame clip ll ll llllllllllll2lllll 7 5 Parallel 1284 B interface card 7 69 RS232C serial interface card 7 69 Hard disk with adapter 20 GB 7 69 Power cord set 8 ft right angle 7 29 Power cord set Denmark Norway and Sweden 7 29 Power cord set lsrael n 7 29 Power cord set AS NZ gt nnn 7 29 Power cord set Japan 2 2 2222 eee een ene ee eee ee eee eee eee eee eee 7 29 Power cord set PRC llcl lllllclllllcllll eee eee 7 29 Power cord set Botswana Lesotho Namibia Pakistan and South Africa 7 29 Power cord set Switzerland
9. ee ee eee eens 6 1 220 V Maintenance kit lll eee nnn eens 6 1 100 V Maintenance kit llll l 6 1 High voltage power supply 2522 2 eee eee e renee eee eee een eeee 7 29 Relocation kit 250 250 sheet printer 7 69 Relocation kit 500 500 sheet printer 7 69 Switch activate spring eee eee eee eee ee eee renee 7 42 7 44 Pick roll assembly 2 2 2 ee ne ene enn nM 7 42 7 44 7 63 Spring upper diverter 2 22 22 eee eee eee eee eee eee eee 7 67 Upper diverter Spring e AAA ee AURORA UU mame se 7 48 7 51 7 55 Restraint pad A A om RU numo RU mtm m 7 43 7 45 Plate 250 sheet tray Wear 7 43 Parts packet eee eee eee eee 7 42 7 48 7 51 Parts packet auto comp assembly mounting screw 7 63 Parts packet auto comp mounting screw 7 44 Parts packet board mounting screw 002552525 e eee eee nee eeee 7 55 7 57 Parts packet screw ee eee eee 7 44 Parts packet screw auto comp mounting 7 42 Parts packet screw switch spring 2 22 2222 eee eee eee eee eee eee 7 42 Screw
10. High capacity output stacker service check Service tip The majority of the mechanical components can be observed during operation by removing the left right and front covers The high capacity output stacker option functions without the covers installed Determine which paper path stacker assembly is not functioning properly Make sure the option s are installed correctly and the machine is configured correctly before attempting to service the high capacity output stacker option See High capacity output stacker board on page 5 8 to identify the correct jumper locations at J6 for the upper and lower units Problems with excessive static electricity buildup FRU Action 1 Front Cover Assembly Check the front cover assembly to make sure the ESD brush ground lead is firmly attached to the high capacity option Also check to make sure the ESD brush is not loose or damaged 2 100 Service Manual The printer does not recognize one or more output options as installed Service tip If more than a single output option is installed check each one to see if the printer recognizes any single option as installed If the printer recognizes any of the output options the base printer autoconnect System is operating correctly The problem is in the unrecognized option Continue with this service check or go to the service check for the failing output option FRU Action 1 High capacity stacker Check the
11. A 24 V dc RAW E al ZEROXING R EDS o 24 V dc RAW A HEAT E HEAT E co Ground N eo L FAN DRV J28 MPF paper out MPF POUT Ground MPF LED J29 Top options RXD1R Ground TXD1BR BR wo N oj MY Ground Connector locations and connections 5 5 System board see System board on page 5 1 Connector Pin no Signal J30 USB host back USB host front connection NI OO oO BRB wo N 5 V USBICN USB DI USB DI Ground Ground Printhead fan 24V dc mo oy BR Ww Pf PH FAN Autoconnect Connector Pin no Signal static Bottom autoconnect 24 V dc 0 V dc 5 V de 0 V dc 0 V dc oc 2 OJN 0 V dc Front autoconnect 0 V dc 0 V dc OV dc 5 V dc OV dc oO Oo A Ww 24 V dc 5 6 Service Manual Connector Pin no Signal static Top autoconnect 1 0 V dc 2 5 V dc 3 0 V dc 4 0 V dc NS 5 0 V dc we oe 6 5 V de OR 9 7 0 V dc 8 17 8 24 V dc Fuser Board Fuser Board not a FRU Connectors O 00000000 J1 J1 System board J2 Narrow media sensor J3 N A J4 Solenoid J5
12. User attendance messages paper jams and paper handling errors 2xx xx Error Sub code codes Description Possible causes Action 202 92 Exit sensor covered too long Fuser page count is not available Page may be jammed in the fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce W curl 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 92 202 93 Page is covering narrow media sensor during warm up Fuser count is not available f page is not visible from front or rear of the printer a partial piece of a page may be torn off in the fuser covering the narrow media sensor The narrow media sensor or flag may be dislodged or damaged Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media 202 94 Exit sensor may have bounced Fuser page count is not available Exit sensor assembly Go to Fuser exit sen
13. ati check on page 2 89 lamp detection Bad thermistor circuit or cabling temperature Fuser Fuser not receiving sufficient AC page count between power 300 000 and 399 999 Poor supply line voltage 922 35 After hot roll lamp The control code has been lost Go to 922 xx Cold fuser detection did not roll check on page 2 89 over to steady state control in time Fuser page count between 300 000 and 399 999 922 36 Hot roll did not reach Low wattage or incorrect lamp Go to 922 xx Cold fuser operating temperature in TNT check on page 2 89 time new enhanced Bad thermistor circuit or cabling control Fuser page Fuser not receiving sufficient AC count between 300 000 power and 399 999 Poor supply line voltage 922 37 Fuser da red too long Low wattage or incorrect lamp Go to 922 xx Cold fuser to reach desire Tm check on page 2 89 temperature after Bad thermistor circuit or cabling increasing interpage Fuser not receiving sufficient AC gap Fuser page count power ed 300 000 and Poor supply line voltage 922 42 Hot ree too long to Low wattage or incorrect lamp Go to 922 xx Cold fuser reach the beginning check on page 2 89 lamp detection Bad thermistor circuit or cabling temperature Fuser e Fuser not receiving sufficient AC page count between power 400 000 and 499 999 e Poor supply line voltage 922 43 ur i reached final Low wattage or incorr
14. l 7 55 Output expander pass thru sensor lll l l 7 49 Part number index I 13 56P4194 56P4195 56P4196 56P4197 56P4198 56P4203 56P4204 56P4205 56P4206 56P4207 56P4208 56P4210 56P4211 56P4212 56P4213 56P4218 56P4219 56P4221 56P4222 56P4223 56P4224 56P4225 56P4226 56P4228 56P4229 56P4230 56P4232 56P4233 56P4234 56P4235 56P4240 56P4241 56P4242 56P4243 7375084 7375085 99A0063 99A0070 99A0104 99A0104 99A0120 99A0121 99A0263 99A0263 99A0263 99A0263 99A0263 99A0263 99A0263 99A0263 99A0272 99A0275 99A0292 99A0415 99A0447 99A0654 99A0658 99A0667 99A0675 Stacker pass thru sensor 2 50 2502 e eee ee ee eee eee eee eee eee eee eeee 7 53 Wear plate 500 sheet 7 45 Pass thru plate llllllll 2l 2 7 45 Bin full dual sensor upper stacker assembly 7 48 7 51 Output expander tray 2 22 22 lll eller eller 7 48 Left cover lllcllllllllll1l1ll 7 50 Right cover 2 2 2222 ee en ee ee ene nen eee eee eee eee 7 50 Front cover 22 22 2222 eee eee een nn en ne eee eee eee eee 7 50 Rear access door assembly se sss ss a tien edema aed me ION BN HOM A LA enc fecil T9 TON Output tray assembly 20 2 2 5 2222 eee eee eee ee
15. 3 System board Check the continuity between J26 2 on the system board and ground It should measure approximately O ohms 2 114 Service Manual The printer does not recognize the paper size selected FRU Action 1 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 Autosize slider Autosize finger 2 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 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 Signal Static Static with paper tray in and set to V dc d Vic Letter Legal A4 Exec B5 A5 1 PSIZE2 3 3 0 0 3 3 433 0 3 3 2 Ground 0 0 0 0 0 0 0 3 PSIZE1 3 3 3 3 3 3 0 0 0 3 3 4 PSIZE3 3 3 0 3 3 3 3 0 3 3 0 5 N A 6 N A 7 N A 8 3 3 3 3 3 3 33 33 33 33 3 3 9 N A 10 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 assemb
16. N N C J2A Autoconnect 24 V dc Ground 5 V dc J2B W N prtxdout Ground prtrxd AJOJN Ground J3 Pass thru sensor a Ground Paper Present RVsnsr J4 DC motor j N mtrout1 mtrout2 Ground Ground tach Oo oO A OJN 5 V dc J5 Bin full near full dual sensor Ground Ground binful binful oy A Oj N RVsnsr J6 Jumper connector Not used N Not used Not used Connector locations and connections 5 11 5 12 Service Manual Connector locations and connections 5 13 5 14 Service Manual 6 Preventive maintenance This chapter describes procedures for printer preventive maintenance Following these recommendations can help prevent problems and maintain optimum performance Safety inspection guide The purpose of this inspection guide is to aid you in identifying unsafe conditions If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items Damaged missing or altered parts especially in the area of the on off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover Possible safety exposure from any non Toshiba attachments Lubrication specifications
17. Print quality background Go to Print quality background on page 2 118 Print quality residual image Go to Print quality residual image on page 2 120 Print quality skew Go to Paper feed service check on page 2 112 Print quality banding Go to Print quality banding on page 2 119 Print quality random marks Go to Print quality random marks on page 2 117 Print quality toner on backside of printed page Go to Print quality toner on backside of printed page on page 2 121 Print quality vertical black bands on edge of copy Go to Print quality black bands on outer edges of the page on page 2 120 Unable to clear a 32 Unsupported Print Cartridge user error message Go to Signature button assembly service check on page 2 122 High capacity feeder 2000 sheet symptoms Symptom Action The printer does not recognize the high capacity feeder installed Go to High capacity feeder input tray service check on page 2 95 Paper feed problem with the high capacity feeder Go to High capacity feeder input tray service check on page 2 95 Diagnostic information 2 5 Paper tray symptoms Symptom Action Paper feed problem with 250 Sheet Paper Tray Go to Input tray s service check on page 2 102 Paper feed problem with 500 Sheet Paper Tray Go to Input tray s service check
18. toner build up Page did not enter or exit fuser nip aun eee 0 and cleanly Check fuser for wear or MT e Eyi ioni contamination If problem is Exit sensor not functioning correctly found replace the fuser assembly See Fuser assembly removal on page 4 26 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 92 201 01 Main drive motor Main drive motor not working Check motor connections to identification failed Fuser page count between 0 and 99 999 motor and system board If no problem is found go to Main drive service check on page 2 105 Diagnostic information 2 45 User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 201 02 Page did not reach exit sensor Fuser page count between 0 and 99 999 Page jammed on fuser input guide Page did not enter or exit fuser nip cleanly Exit sensor not functioning correctly Check fuser entry guide for toner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 f no problem with wear or contamination is found go to Fuser exit sensor service check on page 2 92 201 04 Expected wide page not detected by narrow media sensor possible accordion jam Fus
19. 8 Remove the washer and set it aside 9 Remove the MPF arm assembly 4 60 Service Manual 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 3 Remove the defector Repair information 4 61 MPF pick tire removal 1 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 79 2 Release the pick roll retaining tab A and slide the pick roll off the shaft MPF solenoid assembly removal 1 Open the left door 2 Remove the MPF lower front cover See Multipurpose feeder lower front cover assembly removal on page 4 15 3 Remove the MPF lower paper deflector See MPF lower paper deflector on page 4 61 4 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 79 5 Remove the C clip A on the left side r 4 62 Service Manual 6 Press the clips on the end of the shaft to remove the MPF tires B 7 Remove the C clip C on the shaft D 8 Remove the bushing D Note The bushing fits into a detent E in the frame of the MPF arm assembly 1 Repair information 4 63 9 Loosen the paper alignment screws F F 10 Remove the C clip securing the MPF solenoid assembly o
20. turned on FRU Action 1 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 turning on and off If the lamp does not come on do the following f not previously removed remove the redrive assembly See Redrive assembly removal on page 4 74 Remove the fuser assembly See Fuser assembly removal on page 4 26 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 Fuser lamp AC cable go to step 2 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 3 LVPS 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 54 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 5 10 If incorrect replace the LVPS assembly see Low voltage power supply rem
21. Cold fuser the desired temperature e Noisy thermistor signal service check on page 2 87 while printing Fuser MP i page count between e Fuser not receiving AC power 400 000 and 499 999 e Poor supply line voltage e Low voltage or incorrect lamp e Incorrect hot roll 920 43 Hot roll too cool while Bad thermistor circuit or cabling Go to 920 xx Cold fuser chickens for slope e Noisy thermistor signal service check on page 2 87 change Fuser page A count between 400 000 e Fuser not receiving AC power and 499 999 Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 44 Hot roll too cool when Bad thermistor circuit or cabling Go to 920 xx Cold fuser heating to desired e Noisy thermistor signal service check on page 2 87 temperature after slop oe i change Fuser page e Fuser not receiving AC power An 400 000 Poor supply line voltage f e Low voltage or incorrect lamp e Incorrect hot roll 920 46 Fuser is not increasing Fuser is not receiving AC power Go to 920 xx Cold fuser in temperature even s service check on page 2 87 though the lamp has Poor supply line voltage been on for an extended time Fuser page count between 400 000 and 499 999 920 47 Fuser has been below Bad thermistor circuit or cabling Go to 920 xx Cold fuser the desired temperature service check on page 2 87 for too long while media Very noisy thermistor signal is i
22. ESD cover removal on page 4 25 Note The tabs holding the ESD cover are easily stressed or broken 2 Lift the left side to release the small tab A on the left and the MPF flag B and slide the upper paper deflector assembly to the right to unlatch the hooks C on the right Note Be careful not to put too much stress on the small tab A on the right 3 Lift to remove the upper paper deflector assembly Installation note Make sure the MPF flag B is in place Repair information 4 79 4061 xx0 USB board assembly removal 1 Remove the upper front cover 2 Disconnect the USB cable from the USB board assembly 3 Remove the screw A securing the USB board assembly 4 80 Service Manual 5 Connector locations and connections Connections System board 6ijuoo JONN Bjuoo yIOMJOU UON OC 9000000000000 oo 0000 NJ J26 Jo4 Jos J22 ooo eo ecccce0000 900000000000 NC O ses oo oo 21 i J120 J6 1 c00000000 feos s s J15 J14 4 J13 J10 0000000000000 122 0000000 1ff0o0000000000 sss 9 Connector locations and connections 5 1 System board see System board on page 5 1 Connector Pin
23. Flash Test on page 3 19 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 7 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 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 2 108 Service Manual Output bin sensor standard tray service check Service tip If the output bin standard tray fills up and the bin full sensor fails to post the Remove Paper Standard Bin message 1 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 w
24. User attendance messages paper jams and paper handling errors 2xx xx Frror Sub Description Possible causes Action code codes 241 10 Page was not properly Failure to feed possible causes include Fan media picked from tray 1 Edge locking Turn media over Worn or contaminated pick tires Reduce amount of media e Overfilling of tray past the fill line loaded in tray 1 Replace pick tires Integrated tray autocompensator pick roll assembly removal on page 4 51 241 11 Page was not properly Failure to feed possible causes include Fan media picked from tray 1 Edge locking Turn media over Worn or contaminated pick tires Reduce amount of media e Overfilling of tray past the fill line loaded in tray 1 Replace pick tires Integrated tray autocompensator pick roll assembly removal on page 4 51 241 12 Page was not properly Failure to feed possible causes include Fan media picked from tray 1 Edge locking Worn or contaminated pick tires Overfilling of tray past the fill line Turn media over Reduce amount of media loaded in tray 1 Replace pick tires Integrated tray autocompensator pick roll assembly removal on page 4 51 Diagnostic information 2 71 Service checks Anytime the system board is replaced the Configuration ID must be reset in NVRAM Go to Configuration ID on page 3 21 Review the following information before performing any service checks
25. 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 To change the size sensing setting 1 Select SIZE SENSING from the Configuration menu 2 Select Auto or Off and press Y Press Back to exit Panel Menus Settings are Disable and Enable The default is Enable 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 The printer language is changed to PPDS Emulation Users can still switch languages on the operator panel and through the PJL data stream Download Emuls Demo Mode There is a built in demonstration mode The settings allow you to Deactivate to turn off the demo mode and Activate to turn it on While Demo Mode is set the printer will start in Demo Mode until you change the setting Warning While Demo Mode is set to Activate only demonstration files can print and files received across the network or from the host computer are ignored Diagnostic aids 3 27 Factory Defaults This setting enables a user to restore all the printer settings to the original factory settings Selections are Restore Base and Restore Network Netw
26. Ww warm up time 3 22 warning messages user status displays 2 31 wiper cover 4 4 wrap tests 3 8 Index 1 7 l 8 Service Manual Part number index P N 1319128 1319128 40X0001 40X0002 40X0003 40X0004 40X0005 40X0006 40X0007 40X0008 40X0009 40X0010 40X001 1 40X0013 40X0015 40X0017 40X0020 40X0021 40X0023 40X0024 40X0025 40X0026 40X0027 40X0028 40X0029 40X0030 40X0032 40X0033 40X0034 40X0034 40X0035 40X0035 40X0036 40X0039 40X0040 40X0041 40X0042 40X0043 40X0044 40X0045 40X0046 40X0046 40X0048 40X0049 40X0050 40X0051 40X0052 40X0053 40x0053 40X0054 40X0054 Description Page Parallel warp plug 2 2 2202 see ee nnn eee nee ee nnn 3 8 Parallel wrap plug 22 22 nnn nnn M 2 116 Fuser wiper cover assembly 7 3 Redrive cap cover assembly lll eee ee eee 7 3 Laser cover assembly 250 sheet output 000 010 7 3 Laser cover assembly 500 sheet output 200 210 400 410 7 3 Paper support 22 222 een ne ne ee ee eee eeee 7 3 Upper front cover hinge assembly eee eee 7 3 7 39 Right side cover 250 sheet output 000 01 7 3 Right side cover 500 sheet output 200 210 400 410 7 3 TLI ID serial number label blank
27. and 299 999 The narrow media sensor or flag may be dislodged or damaged 202 24 Exit sensor may have Exit sensor assembly Go to Fuser exit sensor bounced Fuser page service check on page 2 92 count between 200 000 and 299 999 202 26 Page is covering the exit Something is keeping the exit sensor Check the fuser and area sensor during warm up covered A page may not have been around the fuser assembly for Fuser page count cleared from a prior jam any signs of debris or pieces of between 200 000 and paper or media 299 999 2 58 Service Manual User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 202 30 Paper jam around the fuser exit or redrive area Fuser page count between 300 000 and 399 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 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 s
28. between 100 000 and 199 999 925 12 Too hot to do lamp Attempting to POR machine after Go to 925 xx Hot fuser detection and NVRAM receiving a 925 01 service check on page 2 91 bit indicates previous wrong lamp detected Fuser page count between 100 000 and 199 999 925 21 Lamp detection 115 V lamp in 220 V printer Go to 925 xx Hot fuser performed and found gt service check on page 2 91 error Fuser page count Lamp has excessive wattage between 200 000 and 299 999 925 22 Too hot to do lamp Attempting to POR machine after Go to 925 xx Hot fuser detection and NVRAM receiving a 925 01 service check on page 2 91 bit indicates previous wrong lamp detected Fuser page count between 200 000 and 299 999 925 31 Lamp detection 115 V lamp in 220 V printer Go to 925 xx Hot fuser performed and found service check on page 2 91 error Fuser page count Lamp has excessive wattage between 300 000 and 399 999 2 22 Service Manual Service error codes 9xx xx continued Error code Sub codes Display text Description Action 925 32 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Fuser page count between 300 000 and 399 999 Attempting to POR machine after receiving a 925 01 Go to 925 xx Hot fuser service check on page 2 91 925 41 Lamp detection performed and found error Fuser page count between 400 0
29. dirigida exclusivamente al personal cualificado de mantenimiento e Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCI N este s mbolo indica que el voltaje de la parte del equipo con la que est 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 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 rios CUIDADO Quando vir este s mbolo existe a poss vel presen a de uma potencial AN tens o perigosa na zona do produto em que est a trabalhar Antes de come ar desligue o produto da tomada el ctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente el ctrica para realizar a tarefa necess ria xviii Service Manual In
30. eee eee 7 3 Upper front cover assembly 1 7 3 Upper cover latch spring ene ee eee eee eee eee 7 3 Clear LCD bezel 2 222 222 2222 ee eee ee eee eee eee eee ee 7 3 Operator panel outer bezel 1 11 1 7 3 Lower front cover assembly llle eee ee eee 73 Cover left side door 250 1 slot 000 010 7 3 Cartridge holddown spring 7 9 Cover left side door 500 2 slot 200 210 400 410 3 Right frame extension 200 210 400 410 7 7 5 Left frame extension 200 210 400 410 7 5 Contact RSF ground lll lll lll lll lllll 7 5 Upper redrive deflector 7 7 Upper diverter spring nnn TZ Redrive assembly 250 in 250 out 000 010 7 7 Redrive assembly 500 in 500 out 200 210 400 410 JT Transfer deflector llllllllll 2 2 7 7 Machine mounting pad l l l lll ll llle lll lllll 7 9 Signature button contact assembly with cable 7 34 7 37 Signature button sensor a
31. 0412000067 5 a ha Parts catalog 7 31 Assembly 16 Electronics shields 7 32 Service Manual Assembly 16 Electronics shields Asm Part Units Units kit Description Index number mach or pkg 16 1 40X0150 1 1 Outer shield 2 slot 200 210 400 410 2 Parts packet INA cover mounting screw PP 40X0165 2 Parts packet outer shield mounting screw PP 40X0165 2 Parts packet inner shield mounting screw PP 40X0165 3 40X0149 1 1 Inner shield assembly 2 slot 200 210 400 410 4 40X0153 1 1 INA flat cover blank 5 40X0152 1 1 Ethernet shield blank 000 200 400 6 40X0154 1 1 Inner shield assembly 1 slot 000 010 7 40X0222 1 1 Outer shield 1 slot 000 010 Parts catalog 7 33 Assembly 17 Cabling diagrams 1 Asm Part Units Units kit Description Index number mach or pkg 17 1 40X0223 1 1 HVPS input sensor toner sensor cable assembly 2 40X0160 1 1 MPF sensor cable 3 40X0034 1 1 Signature button contact assembly with cable 7 34 Service Manual Assembly 18 Cabling diagrams 2 Asm Part Units Units kit Description Index number mach or pkg 18 1 40X0061 1 1 Laser printhead cable assembly 2 40X0074 1 1 Autocompensator motor cabl
32. 2 Turn on the printer 3 Release the buttons when Performing Self Test displays Available tests The tests display on the operator panel in the order shown Diagnostics mode tests REGISTRATION See REGISTRATION on page 3 4 Bottom Margin Top Margin Left Margin Right Margin Quick Test See Quick Test on page 3 5 PRINT TESTS Tray 1 See Input source tests on page 3 6 Tray 2 if installed Tray 4 if installed Tray 3 if installed Tray 5 if installed MP Feeder Env Feeder if installed Prt Quality Pgs See Print quality pages Prt Quality Pgs on page 3 6 HARDWARE TESTS Panel Test See Panel Test on page 3 7 Button Test See Button Test on page 3 7 DRAM Test See DRAM Test on page 3 7 CACHE Test Parallel Wrap See Parallel Wrap tests on page 3 8 Parallel 1 Wrap if installed Parallel 2 Wrap if installed Serial 1 Wrap if installed See Serial Wrap tests on page 3 9 Serial 2 Wrap if installed 3 2 Service Manual Diagnostics mode tests continued DUPLEX TESTS if installed Quick Test See Quick Test duplex on page 3 9 Top Margin See Top Margin duplex on page 3 10 Sensor Test See Sensor Test duplex on page 3 10 Motor Test See Motor Test duplex on page 3 11 Duplex Feed 1 See Duplex Feed 1 on page 3 12 Duple
33. 56P4183 56P4185 56P4186 56P4188 56P4190 56P4191 56P4194 Simplified Chinese font card 7 69 Traditional Chinese font card 7 69 Korean font card 2 2 2522 22 een nee enn eee eee eee ee eee nese 7 69 32MB Flash card 2 2 2222 2 2 eee eee eee ee eee eee ee eee 7 69 64MB Flash card 2 2 2 ee eee nen eee eee eee eee eens 7 69 Bellcrank spring arm nn 7 44 Bellcrank 250 sheet paper tray lll 7 42 Wear strips 9 2 ee ee nn nn nnn nn nee eee 7 43 Right base assembly cover 20 2502 e ee eee eee e eee ee eee eee eeee 7 65 Stapler access door switch assembly 7 65 Stapler access cover 22 22 52 2s ene eee ee nee ee ee eee eee eee eeeee 7 65 Bellcrank spring 500 sheet option tray l c lllll 7 44 Duplex assembly 500 sheet 7 46 250 sheet paper drawer complete assembly 7 42 Drawer assembly complete 500 sheet 7 44 Complete option assembly letter 7 59 Complete option assembly A4 7 59 Complete envelope option M 7 47 Complete vertical kiosk option lllc 2 llll ll 7 64 Complete horizontal kios
34. General information 1 1 Configured model The following illustration shows a standard network printer Multipurpose feeder integrated tray or standard tray 1 2 Service Manual Specifications Resolution 1200 1200 dpi 2400 Image Quality 1200 Image Quality 600 x 600 dpi Data streams PostScript 3 emulation PCL 6 emulation Print speed and performance print speed Performance Performance speed depends on Interface to the host USB parallel network Host system and application Page complexity and content Printer options installed or selected Available printer memory Media size and type Resolution Time to first print NA e STUDIO 500P NA 1200 dpi 600 dpi 1200 dpi 600 dpi 1200 600 dpi Simplex printing from Ready on full size media seconds Letter 11 7 6 0 12 1 8 5 12 1 8 5 8 5 in x 11 in A4 17 0 11 4 22 7 13 0 22 7 13 0 8 3 in x 11 7 in Legal 14 5 12 1 24 3 24 3 24 3 13 5 8 5 in x 14 in Simplex printing from Power Saver on full size media seconds Simplex Letter 25 3 28 2 28 2 The test job consists of the character A followed by a form feed single page job The first copy time is defined as the elapsed time from pressing Enter on the PC keyboard to the page exiting to the output bin All tests pick paper from the indicated tray and the page exits into the primary output bin General information 1 3 M
35. If correct replace the high capacity feeder option system board The elevator moves in one direction only FRU Action 1 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 Voltage Static motor not running J1 1 Brown 0V dc J1 2 Yellow O V de Motor running forward J1 1 Brown 0Vdc J1 2 Yellow 24 V dc Motor running in reverse J1 1 Brown 24 V dc J1 2 Yellow O V dc 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 2 98 Service Manual Paper size switch not selecting paper size that is selected FRU Action Paper size switch High capacity feeder option control board Check for continuity between the common pin J5 1 and the pin of the paper size selected Pin Color Paper size J5 1 Black Common lead J5 2 Blue B5 J5 3 Green Executive J5 4 Yellow A4 J5 5 Orange Letter J5 6 Red Legal J5 7 Brown A5 If any position does not measure continuity when selected replace the paper size switch assembly If the switch assembly is operating correctly replace the high capacity feed
36. 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 3 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 Diagnostic information 2 85 260 xx Paper Jam displays envelope stops in feeder paper path FRU Action 1 Kick rolls feed rolls drive rolls Check all the rolls for oil grease or other contamination If you find a problem clean the rolls If this does not correct the problem replace the envelope feeder 2 Deflector gap adjustment Check the deflector gap adjustment The adjustment may be too narrow If the adjustment is correct replace the envelope feeder option Envelope feeder multifeeds or may not display a 260 xx Paper Jam message FRU Action 1 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 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 e
37. 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 Description Part number 115 V Maintenance kit 56P4240 220 V Maintenance kit 56P4241 100 V Maintenance kit 56P4242 After replacing the kit the maintenance count must be reset to zero to clear the 80 Scheduled Maintenance message See Maintenance page count Maint Cnt Value on page 3 25 Preventive maintenance 6 1 6 2 Service Manual 7 Parts catalog How to use this parts catalog The following legend is used in the parts catalog Model information used in the parts catalog Asm Index Part number Units mach OR Units option Units kit or pkg Description Asm index identifies the assembly and the item in the diagram For example 3 1 indicates Assembly 3 and the item number 1 Part number identifies the unique number that identifies this FRU Units mach refers to the number of units actually used in the base machine or product Units option refers to the number of units used in the option and does not include the bas
38. Parts catalog 7 21 Assembly 11 Drives Main drive and developer drive 7 22 Service Manual Assembly 11 Drives Main drive and developer drive Asm Part Units Units kit Des ription Index number mach _ or pkg P 11 1 40X0107 1 1 Gearbox with motor 2 40X0110 1 1 Power takeoff shaft 250 sheet 000 010 2 40X01 11 1 1 Power takeoff shaft 500 sheet 200 210 400 410 3 40X0112 1 1 Power takeoff shaft spring 4 40X0113 1 1 Bevel gear with grease packet and washer Bevel gear 1 Instruction sheet 1 Grease packet 1 5 40X0114 1 1 Developer drive assembly 6 40X0115 Parts packet developer drive Developer drive shaft 1 shaft coupler gear 55 1 7 3 Parts packet developer drive ground screw PP 40X0165 NS 4 Parts packet gearbox mounting screw PP 40X0165 Parts catalog 7 23 Assembly 12 Hot roll fuser 7 24 Service Manual Assembly 12 Hot roll fuser Asm Part Units Units kit Description Index number mach _ or pkg 12 1 40X0116 1 1 Fuser assembly w 115 V lamp 1 40X0241 1 1 Fuser assembly w 100 V lamp 1 40X0117 1 1 Fuser assembly w 220 V lamp 2 40X0120 1 1 Fuser wiper cavity cover 3 40X0122 1 1 Fuser lamp 115V 3 40X0123 1 1 Fuser lamp 220V 4 40X0121 1 Fuser cover assembly kit including Thermistor 1 Thermostat 1 Left and right fuser lamp contact assemblies 1 5 Parts packet fuser mounting screw PP 40X0227 6 40X
39. Stop button 1 Menu button 1 Back button 1 LED cap 1 Navigation buttons 4 Number pad buttons 1 Navigation select button 1 Number pad rubber dome sheet 1 USB board 1 Functional rubber sheet 1 12 40X0014 1 1 Operator panel outer bezel with Lexmark logo T640 12 40X0233 1 1 Operator panel outer bezel with Lexmark logo T642 12 40X0234 1 1 Operator panel outer bezel with Lexmark logo T644 13 40X0013 1 1 Clear LCD bezel 14 40X0235 1 1 Kit upper front panel button including Stop button 1 Menu button 1 Back button 1 LED cap 1 Navigation buttons 4 Number pad buttons 1 Navigation select button 1 Number pad rubber dome sheet 1 Functional rubber sheet 1 15 40X0195 1 1 Operator panel board assembly 16 40X0009 1 1 TLI ID serial number label blank 17 40X0020 1 1 Left side door cover 250 sheet 1 slot 000 010 17 40X0023 1 1 Left side door cover 500 sheet 2 slot 200 210 400 410 NS 5 10 Parts packet cable ties PP 40X0174 Parts catalog 7 3 Assembly 2 Frame 1 7 4 Service Manual Assembly 2 Frame 1 Asm Part Units Units kit Description Index number mach_ or pkg 1 40X0065 4 1 Frame extension nut plate 200 210 400 410 2 40X0225 1 1 Right side hand holder 3 4 4 Parts packet PP 40X0165 4 40X0024 1 1 Right frame extension 200 210 400 410 5 40X0026 1 1 Right side frame ground contact 6 40X0025 1 1 Left frame ext
40. and units of measure Warning Changing this setting resets the printer to factory defaults and data may be lost It cannot be undone Page Count The page count can only be viewed and cannot be changed To view the page count 1 Select Page Count from PRINTER SETUP 2 Press Back amp to return to PRINTER SETUP Perm Page Count permanent page count The permanent page count can only be viewed and cannot be changed To view the permanent page count 1 Select Perm Page Count from PRINTER SETUP 2 Press Back amp to return to PRINTER SETUP Serial Number The serial number can only be viewed and cannot be changed To view the serial number 1 Select Serial number from PRINTER SETUP 2 Press Back Q to return to PRINTER SETUP Envelope Enhance This setting affects the level of the fuser solenoid To set Envelop Enhance 1 Select Envelope Enhance from PRINTER SETUP 2 Select Low Medium or High The default is Medium 3 Press Back O to return to PRINTER SETUP 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 20 Service Manual Configuration ID The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors The configuration IDs are originally set at the factory when the printer is manufacture
41. circuit or cabling Go to 920 xx Cold fuser during steady state control Fuser page count between 300 000 and 399 999 e Fuser not receiving AC power e Poor supply line voltage e Low voltage or incorrect lamp e Incorrect hot roll service check on page 2 87 Diagnostic information 2 11 Service error codes 9xx xx continued Error Sub a sone codes Display text Description Action 920 32 Hot roll fell too far below Bad thermistor circuit or cabling Go to 920 xx Cold fuser desired temperature e Noisy thermistor signal service check on page 2 87 while printing Fuser MEN i page count between Fuser not receiving AC power 300 000 and 399 999 Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 33 Hot roll too cool while Bad thermistor circuit or cabling Go to 920 xx Cold fuser checking for slope e Noisy thermistor signal service check on page 2 87 change Fuser page count between 300 000 e Fuser not receiving AC power and 399 999 Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 34 Hot roll too cool when Bad thermistor circuit or cabling Go to 920 xx Cold fuser heating to desired e Noisy thermistor signal service check on page 2 87 temperature after slope m j change Fuser page Fuser not receiving AC power count between 300 000 P lv li It and 39
42. 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 237 07 Duplex paper jam There may be other jams in the paper path Duplex jam access tray is not fully latched Printer PTO not driving duplex feed rolls Duplex feed system not working correctly 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 2 68 Service Manual User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes Action code codes 238 00 Paper is covering one of Media left in the duplex and e Remove any sheets from the duplex sensors Continue selected the duplex option during a reset e Sensor is having mechanical or Try the duplex option again electrical problems If it fails try another duplex option if available If one is not available replace the duplex option 238 01 Duplex input sensor Media left in the duplex and e Remove any sheets from covered Continue selected the duplex option e Sensor is having mechanical or Try the
43. maximum 2 2 grain long 1 Tag 163 g m 100 Ib 120 g m 74 Ib Cover 176 g m 65 Ib 135 g m 50 Ib Card stock Index Bristol 199 g m 110 Ib 163 g m 90 Ib maximum 2 2 grain short Tag 203 g m 125 Ib 163 g m 100 Ib Cover 216 g m 80 Ib 176 g m 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 Labels maximum Paper 180 g m 163 g m 48 Ib bond 43 Ib bond Dual web paper 180 g m 163 g m 48 Ib bond 43 Ib bond Polyester 220 g m 220 g m 59 Ib bond 59 Ib bond Vinyl 300 g m 260 g m 92 Ib liner 78 Ib liner Integrated forms Pressure 140 to 135 g m 140 to 135 g m sensitive area must enter the printer first Paper base 75 to 135 g m 75 to 135 g m2 grain long 20 to 36 lb bond 20 to 36 Ib bond Envelopes Sulfite wood Not recommended 60 to 105 g m 60 to 105 g m 100 cotton content maximum weight 24 Ib free or up to 100 cotton bonds 16 to 28 Ib bond 4 16 to 28 Ib bond Grain short is preferred for papers over 135 g m Printing label applications on your printer requires a special label fuser cleaner which prevents duplexing 3 28 Ib envelopes are limited to 2596 cotton content Includes envelopes fed from the multipurpose feeder only PAGES 1 12 THRU 1 14 HAVE BEEN REMOVED INTENTIONALLY FROM THIS DOCUMENT General information 1 11 Sel
44. on page 2 102 Media fails to pass through from the lower attached Paper Tray option to the next higher mounted option Go to Input tray s service check on page 2 102 Duplex option symptoms Symptom Action Paper feed problem with Duplex Go to Duplex option service check on page 2 82 Paper jams at Paper Removal Tray Go to Duplex option service check on page 2 82 Paper skews in the Duplex Option Go to Duplex option service check on page 2 82 Paper fails to pass from lower option through the Duplex Option Go to Duplex option service check on page 2 82 Envelope feeder symptoms Symptom Action Envelopes do not feed from the envelope feeder Go to Envelope feeder service check on page 2 84 Envelopes do not feed properly into base printer Go to Envelope feeder service check on page 2 84 2 6 Service Manual Diagnostic information 2 7 Messages and error codes gt Service error codes Service error codes are generally non recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition Service error codes 9xx xx transfer servo start error Check system board Check HVPS input sensor toner sensor cable Error Sub a n codel codes Display text Description Action 900 XX RIP Soft
45. replace the high capacity output stacker option 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 FRU Action 1 Input sensor flag Check the input sensor flag for damage and proper operation If a problem is found repair as necessary 2 System board Check for approximately 5 V dc at J15 10 on the system board If incorrect replace the system board 3 Input sensor 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 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 FRU Action 1 Tray x Option system board Check the autoconnect cables and connectors for damage If the or compensator assembly cables connectors and connections are good replace the FRUs in or autoconnect cable the following order Autocompensator assembly option Replace the option 2 102 Service Manual 24x xx Paper Jam displays paper jammed over the pass thru sensor The printer displays th
46. replace the main fan See Main fan removal on page 4 56 If this does not fix the problem replace the system board See System board and inner shield removal on page 4 76 Cartridge fan service check Error code 927 02 indicates a problem with the cartridge fan FRU Action 1 Cartridge fan Check to make sure the cartridge is plugged into J5 on the system board If properly plugged in go to step 2 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 System board Replace the following FRUs in the order shown Cartridge fan e System board See System board and inner shield removal on page 4 76 2 76 Service Manual 950 00 through 950 29 EPROM mismatch failure Warning When replacing any one of the following components Operator panel assembly or upper front cover 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 troubleshoo
47. rrruereeeeeecrerreereeAIIAIeeRIIIIIIIIIIIIIIIII 7 49 Drive shaft 250 sheet 7 42 7 62 Power takeoff spring 2 2 2 reece renee ee eee ee eee eee eens 7 42 7 44 7 62 Wear strips 2 ee en nnn nnn nnn nM 7 45 Swing arm spring lllll lll lll lll lll c 7 51 Drive shaft 500 sheet lllc llllll l llclll lll ll 7 44 Paper low switch l lllllrr ll eee eee eee eens 7 61 Door magnet 2 2 2222 22 eee ee nnn ene ee nee eee eee eee eee 7 59 Power supply board 2 22 2222 ene een ee ee eee eee 7 61 Parts packet card asm mounting screw 7 59 I 14 Service Manual 99A0675 99A0676 99A0676 99A0677 99A0677 99A0681 99A1785 99A1808 99A1818 99A1929 99A2542 Parts packet card asm mounting e aa 7 59 Parts packet 6 32 hinge mounting nut 7 59 Parts packet nuts nn 7 61 Parts packet hinge mounting flat washer 7 59 Parts packet hinge mounting star washer 7 59 Wear strip llll l llllllllllIl l 7 59 Rear access Coorlaich A on aN eniek ems HUM ACID A ELA A CNN 799 Te AC external jumper cord 2 2 2222 en ee eee ene eee eee eee eee 7 61 Wear dimple strip
48. single option as being installed If the printer recognizes any of the output options then the base printer autoconnect system is operating correctly and the problem is in the unrecognized option Continue with this service check or go to the service check for the failing output option FRU Action 1 5 Bin mailbox option Check the autoconnects cables and connectors of the option for any signs of loose or damaged parts 2 Mechanical linkage assembly Remove the left and right side covers and check the two autoconnects for damage especially the connector pins Remove the output option and check the voltages on the standard output bin autoconnect located on the top left rear of the printer Go to Autoconnect on page 5 6 If the voltages are correct reinstall the output option noting the position of the toroid on the autoconnect cable of the lower autoconnect Check the voltages on each of the autoconnects If the toroid was moved make sure to move it back to its original position on the cable If the voltages are correct replace the control board If the voltages are incorrect replace the failing autoconnect assembly 2 72 Service Manual 271 xx Paper Jam Check Bin 1 displays FRU Action Bottom pass thru sensor flag assembly Control board Check the flag for correct operation binding broken parts or interference from the sensor cable If incorrect repair as necessary
49. 102 Tray x Empty If any of the input trays are empty then Tray x Empty displays where x designates which tray Tray 1 through 5 is empty If multiple trays are empty then they are prioritized in this order Tray 5 Tray 4 Tray 1 Note Tray x Empty status clears whenever Tray x is removed When Tray xis reinserted it is examined and the appropriate status if any displays Empty status is not displayed for the Envelope Feeder or Multipurpose Feeder Tray x Low If any of the input trays are low then Tray x Low displays where x designates which tray 1 through 5 is low If multiple trays are low they are prioritized in the following order Tray 5 4 3 2 and 1 Note Tray xLow clears whenever tray xis empty or tray xis removed When tray xis reinserted it is examined and the appropriate status if any displays The printer cannot detect when the envelope feeder or multipurpose feeder are low Diagnostic information 2 31 User attendance messages User attendance messages Error code Sub code Primary message Description action Change Cartridge Invalid Refill Select one of the following actions Remove the toner cartridge and install a new cartridge Press and hold anad press e to display debug data for the engine and cartridge code Note This message may help diagnose a potential printer problem Change input source Custom Type name This mess
50. 122 StapleSmart finisher service Check srcriiicrsrirkidis rd aea anpe 2 123 System bosrd Semice CHECK docdonsseedrini dispo e adem ne MPO E Was cee a ete ede AE 2 126 Toner sensor SERVICE CROCK xiii s ide 2 127 Transfer roll Service Check ssec pera esee RE Maya hee Geen sabe XUI PPP PIE PE 2 128 Diagnose AICS soria enna RA AA RARI CROCI Kane RARA RA 3 1 Accessing service MENUS uasa xad 9ackord don deceased ERR ER RUE oe ele SCR NU Ron RR o 3 1 Diagnostics mode kaa isda aman ea mee dae eda OR RA eli RR NR ae BR RRA A RA 3 2 Empenho Diagnoses made iii sd sd ep canbe a hada Kem RAT RS E RR ERA EET AB PE 3 2 DW NC M EUER 3 2 Eating Diagnosis MOUS 12522 2034 practice 3 4 REGISTRATION gt si a tradite at Read eS qqe dde aqq eed ed medida 3 4 GUION Facts tac oda daa as dd c MED E LEGE SEE D 3 5 PRINT TESTS edd be ppESET hen BRE HESS REF PPS HRRERS EP HEPRHRETPGR P RECS 3 6 lgut soupe TESTS ods do dined d a ecient gets id 3 6 Print quality pages Prt Quality PAS i uebesiesd Rer y tereit sre aa e e 3 6 HARDWARE TESTS d idus duae d RUE DOSES ddp b Drs d Bhs MI db due bd Shae dota be 3 7 Panel T8SE sacooi enxbrene9e 9 eet nepUO T eR VCI qr ppm ete eK TIHP PETER T PP 3 7 Buton FOSSE ssp er in ardeo adiit addi ded ed Sanh desde dus 3 7 DRAM sch P TP 3 7 CACHE TBSE aun edora tiota remos ears Hem a HR AU nhe eres ee odisea AAA a dan ab us 3 8 Paralel Wrap I88i 5L zac ao S cen d pna II ped aid Guide ES Fas i 3 8 Sena Wap NOSIS s qose aque d eddwd
51. 2 display 2 107 LCD Brightness 3 29 LCD Contrast 3 29 Panel Test 3 7 parts catalog 7 2 service check 2 106 upper front cover 4 11 7 3 upper front cover bezel 4 14 options descriptions 1 1 parts catalog 7 69 service checks 2 108 outer shield parts catalog 7 32 removal 4 67 output bin sensor tests 5 bin mailbox 3 16 high capacity output stacker 3 16 output expander 3 15 standard bin 3 15 output expander output sensor test 3 15 parts catalog 7 48 7 49 service check 2 110 output expander control board 5 11 l A Service Manual P packaging 7 69 page count Fuser Page Count 3 22 Page Count 3 20 permanent page count 3 20 Panel Test 3 7 paper and media specifications 1 8 paper bin full sensor flag 4 70 paper deflector assembly inner 4 47 upper 4 79 paper feed jams 200 and 201 Paper Jam Remove Cartridge 3 37 202 Paper Jam Open Rear Door 3 39 23x and 24x jams 3 36 23x Paper Jam Open Duplex Rear Door 3 40 250 Paper Jam Check MP Feeder 3 34 260 Paper Jam Check Env Feeder 3 35 270 and 280 Paper Jams 3 41 27x Paper Jam Check Bin x 3 41 28x Paper Jam Check Finisher 3 42 access doors and trays 3 33 clearing 3 33 paper jam error codes 2 44 paper size sensing board 2 113 4 71 paper support removal 4 5 parallel wrap tests 3 8 part number index 2 9 parts catalog 250 sheet paper drawer option 7 42 250 sheet paper tray option 7 43 500 sheet paper drawer option 7 44 500 sheet paper tray option 7 45 5 bin mailbox 7 54 7 56 cabli
52. 3 8 DRAM Test 3 7 Panel Test 3 7 parallel wrap tests 3 8 serial wrap tests 3 9 INPUT TRAY TESTS Feed Test 3 13 Sensor Test 3 13 OUTPUT BIN TESTS Diverter Test 3 16 Feed Test 3 14 Feed to All Bins 3 14 Sensor Tests 3 15 PRINT TESTS input source 3 6 Prt Quality Pgs 3 6 PRINTER SETUP Configuration ID 3 21 Defaults 3 20 Edge to Edge 3 21 l 2 Service Manual engine settings 3 20 Envelope Enhance 3 20 Model Name 3 20 Page Count 3 20 Par x Strobe Adj 3 21 Perm Page Count 3 20 Serial Number 3 20 REGISTRATION 3 4 Diverter Test 3 16 DRAM Test 3 7 duplex option parts catalog 7 46 service check 2 82 duplex tests Duplex Feed 1 3 12 Duplex Feed 2 3 12 Motor Test 3 11 Quick Test 3 9 Sensor Test 3 10 Top Margin 3 10 E envelope feeder parts catalog 7 47 service check 2 84 envelopes guidelines 1 16 EP duct parts catalog 7 9 EPROM mismatch failure 2 77 2 78 error codes 2 8 ESD cover 4 25 ESD sensitive parts 4 1 event log clear log diagnostics mode 3 24 display log diagnostics mode 3 23 print log configuration menu 3 28 print log diagnostics mode 3 23 F fans EP fan 7 9 7 41 flag fuser exit sensor flag and spring 4 30 fuser narrow media flag and spring 4 36 paper bin full sensor 4 70 Flash Test 3 19 frame extensions 4 17 frames parts catalog 7 4 7 6 7 8 functional rubber sheet 7 3 fuser connectors 5 7 installation 4 27 parts catalog 7 24 removals 4 26 service check 2 87 fuser board 5 7 fu
53. 6 to 10 Bins x y This messages displays for the following conditions The specified output bins may have been removed from the printer possibly to clear a paper jam or to remove the option The option s may be attached to the printer but a communications problem may prevent the printer from detecting the option For example there may be a poor connection or a hardware failure The following actions may be taken f the option was temporarily removed or not connected properly reattach or reconnect it Press Y to execute a 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 f 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 2 102 Reattach This messages displays for the following conditions Envelope Feeder 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 actions may be taken e f the option was temporarily removed or not connected properly reattach or reconnect it Press Y to execute a config
54. 76 2 26 Service Manual Service error codes 9xx xx continued Error code Sub codes Display text Description Action 949 00 Delay line calibration failure System board Replace the system board See System board and inner shield removal on page 4 76 950 00 NVRAM mismatch Go to 950 00 through 950 29 EPROM mismatch failure on page 2 77 or go to 950 30 through 950 60 EPROM mismatch failure on page 2 78 951 00 Replace the system board See System board and inner shield removal on page 4 76 Warning When replacing any one of the following components Operator panel assembly or upper front cover e System board assembly Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable 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 can not be used in another printer It must be returned to the manufacturer 952 00 NV failure n CRC error has occurred This is recoverable Perform POR
55. 79 70 5 4 24 V dc IN F 5 TX PWM 6 TX Enable O 7 TX CUR PWM 8 SVRO OUT b e o qp CN1 O 1 mes n pv n Interconnect card Connector Pin no Signal J1 1 J2 1 Connector locations and connections 5 9 Low voltage power supply Connector T Signal CN1 Fuser lamp AC 1 AC fuser lamp e 3 le Y 2 Not used MN ES 3 AC fuser lamp 20 a CMD e AN 000000 000000000 ER E a RE OW e c o a CN2 DC output 1 5 V dc 2 5 V dc 3 Ground 4 Ground 5 Ground 6 Ground 7 24 V dc 8 24 V dc 9 Heat on 10 5 V dc 11 5 V dc 12 Ground 13 Ground 14 Ground 15 Ground 16 24 V dc 17 ZC Out 18 42 V dc 5 10 Service Manual Output expander control board Connector Pin no Signal a Too Ir al s al o m 3 J3 1 ul m Il U7 JIA Autoconnect 24 V dc Ground 5 V dc J1B 2 0 N Prtxdin Ground prtrxd Ground ory BY
56. BASE SENSOR TEST 200 9 boy hace ii rai ede dee ee mdr aed ird 3 18 PEVICE TESTS sarta cruise ceiba LP b gu o4 d 3 18 eu db d rcr EU 3 18 a o A bd DO daba CE Ede dac d dqopq itai dd ROH 3 19 Rash FGSU 1 osos Rb e prebere HP REPE FERTPRPRURRPERPIA P DERE 3 19 PRINTER SETUP caddis i uh tds Aden UP AIRE ia Bans a Dti id 3 20 Deaultscsiiee esses pr ERI A A dete qe Rise EE REGE 3 20 Paige Cotidie esq aid Vd UR dde OSG wake Heda dL 3 20 Perm Page Count permanent page count 0 0 c cece ee eee 3 20 Sanabria aaa ars dae quid de 3 20 Envelope ENHANCE sa c bd de Kipp Corer een Pd bete Su qud SE id eens dig dis 3 20 Table of contents V Engine Seting t Mugen aieo do pb dd DEOR PRI ROK ue due Roe de pip d ROI eds 3 20 Modal NANI irae ERE ERE IR RENDER PENNE ERR RRR ER ERE A ee gee 3 20 CONTIGUA NO sont ocace LEE 3 21 Edge IO EdOB o cir bes eee eee ee ed adeb dde E opi Rae due 3 21 Parallel strobe adjustment Par x Strobe Adj 0 cece eee eee 3 21 ESSE aaa bed bid dad dua dote e estos bos Hee a a eae 3 22 A iussi ns the ar heRERE ee gee ease qe rp sided dort aeree eed edt gees 3 22 Fuser Temperature Fuser Temp isses denm a ected le ae 3 22 Fuser Page Count s ssoep sb RUPSREREGUGGRHOR bliseoeien ede PEEEEUEE FG Ue th Ide ds 3 22 Vant Up DIME ndo EE mer 3 22 TAS pe AI A LORDS AN A AA nia eee 3 22 Pin Gonta SY rasos paar ado aa A iO 3 22 Pao css m 3 22 Gap AUIUBL cipe ad dedere dq iD quiu Me pop T dad ue Head
57. Corrupted feedback signal Go to Main fan on invalid and speed page 2 76 control is at maximum in fan control adjustment state 929 00 Toner sensor error a Check the toner sensor Go to Toner sensor service problem has been check on page 2 127 detected with the toner Check cable sensor e Check system board 929 66 An error has been Check toner cartridge Go to Toner sensor service detected No home a check on page 2 127 windows has hesh Check toner sensor detected 929 67 No toner sensor Check toner sensor Go to Toner sensor service transition e Check toner cartridge check on page 2 127 930 00 An incorrect printhead Check the printhead Go to Printhead service has been detected check on page 2 122 932 00 Printhead lost HSYNC Check printhead Go to Printhead service Check cables and connections check on page 2 122 Check system board 933 00 Mirror motor locked no Check printhead Go to Printhead service first HSYNC received e Check cables and connectors check on page 2 122 Check system board 934 00 Mirror motor lost lock Check printhead Go to Printhead service Check cables and connections check on page 2 122 Check system board 2 24 Service Manual Service error codes 9xx xx continued Error Sub code codes Display text Description Action 936 00 Mirror moor not up to e Check printhead Go to Printhead service spee
58. DIAGNOSTICS This selection exits Diagnostics mode and Resetting the Printer displays The printer performs a POR and the printer returns to normal mode 3 24 Service Manual Configuration menu CONFIG MENU Entering Configuration Menu Turn off the printer Turn on the printer Pom Press and hold Qand p gt Release the buttons when Performing Self Test displays The message CONFIG MENU displays on the top line of the operator panel Available menus Maint Cnt Value Reset Maint Cnt Prt Quality Pgs SIZE SENSING Panel Menus PPDS Emulation Download Emuls Demo Mode Factory Defaults Energy Conserve EVENT LOG print log only Paper Prompts Env Prompts Jobs On Disk Disk Encryption Font Sharpening LCD Brightness LCD Contrast Exit Config Menu See Maintenance page count Maint Cnt Value on page 3 25 See Maintenance page counter reset Reset Maint Cnt on page 3 26 See Print quality pages Prt Quality Pgs on page 3 26 See SIZE SENSING on page 3 27 See Panel Menus on page 3 27 See PPDS Emulation on page 3 27 See Download Emuls on page 3 27 See Demo Mode on page 3 27 See Factory Defaults on page 3 28 See Energy Conserve on page 3 28 See EVENT LOG on page 3 28 See Paper Prompts on page 3 28 See Env Prompts on page 3 28 See Jobs On Disk on page 3 28 See Disk Encryption on page 3 28 See Font Sharpening on page 3 29 See LCD Brightness on page 3 29 See LCD Contrast on pag
59. Error Sub ae pode codes Display text Description Action 924 41 Open thermistor check Noisy thermistor signal Go to 924 xx Hot fuser failure Fuser page service check on page 2 91 count between 400 000 Intermittent connection and 499 999 e Thermistor cable not connected or thermistor actually open 924 51 Open thermistor check e Noisy thermistor signal Go to 924 xx Hot fuser failure Fuser page service check on page 2 91 count over 500 000 mter mittent connection e Thermistor cable not connected or thermistor actually open 924 91 Open thermistor check e Noisy thermistor signal Go to 924 xx Hot fuser failure Fuser page service check on page 2 91 Count not available Intermittent connection e Thermistor cable not connected or thermistor actually open 925 01 Lamp detection 115 V lamp in 220 V printer Go to 925 xx Hot fuser performed and found a service check on page 2 91 error Fuser page count Lamp has excessive wattage between 0 and 99 999 925 02 Too hot to do lamp Attempting to POR machine after Go to 925 xx Hot fuser detection and NVRAM receiving a 925 01 service check on page 2 91 bit indicates previous wrong lamp detected Fuser page count between 0 and 99 999 925 11 Lamp detection 115 V lamp in 220 V printer Go to 925 xx Hot fuser performed and found service check on page 2 91 error Fuser page count Lamp has excessive wattage
60. 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 12G9609 Table of contents Laser NONCES ci6 eke usua id Ra RE ea doa ds xi Safety INOIDADOD ia sand xd ER dd AAA dd xvii Prola oe rr re ee ee ere er ere ree re XX Bie Seer cee eee eee eee eee Te eee ee eee SS dS eee eee ee ee Tee ere ee XX Generali IIO OHIO 6562660480 0d endeeednnn ane 405 04 dees AAA 1 1 Maintenance approach sx ci ii A RC ROO ACA ae aaa Mea a aed RB a ae P EUR wa a a 1 1 ODHIOHS Gase tie Seabee eeia ad E dX db dde dde tees AS Hee RP bd a qud Paid id 1 1 COMU MOS parres Eee eRe RAO RODE REG DERKARER adim om ded nia appare 1 2 Specifications Mee P n 1 3 RESOMION abarrotes d ard depdab e q Od p gia 1 3 pata Siraains ius ii a P UE 1 3 Print speed and performance print Speed uoeuodee uode arion hEn SK a er on 1 3 xw cet cT 1 3 Timeo stp ocak es ree RORE re A AR 1 3 Menor CONNGUIBNON dista risa rd dota Modes cada Poor brat bess 1 4 Operating Cl6aranCGS corroe eta 1 4 AMERSIONS sra dedica 1 5 POWENFSQUIFSMENTS 2 oi AA 1 6 Elecmea soc ecupj ec PP ad 1 6 uer e TT 1 7 POSUSICS pm EE 1 7 Media SDECIICANONS 34422300893 3 548 3 db AR oL RU 0 8D do 08D oC BR o 020 cC Rl d E Rode Ro d Cab 1 8 Paper and Specialty media SuideliiS corra ori bro dava i qb eri te eee Se 1 8 Supported PM MEG ss vi
61. If correct make sure the bottom pass thru sensor is correctly connected to J5 on the control board Disconnect the pass thru sensor cable and check the voltage at J5 3 The voltage measures approximately 5 V dc If incorrect check the voltage at J5 2 The voltage measures approximately O V dc If incorrect replace the sensor assembly If this does not fix the problem replace the control board 274 xx Paper Jam Check Bin 4 displays Service tip When a 274 xx Paper Jam Check Bin 4 message displays a problem exists with the top pass thru sensor assembly or the control board FRU Action Top pass thru sensor flag assembly Control board Check the flag for correct operation binding broken parts or interference from the sensor cable If incorrect repair as necessary If correct check to make sure the top pass thru sensor is correctly connected to J11 on the control board Disconnect the pass thru sensor cable and check the voltage at J11 3 The voltage measures approximately 5 V dc If incorrect check the voltage at J11 2 The voltage measures approximately O V dc If incorrect replace the sensor assembly If this does not fix the problem replace the lower control board Ready Bin x Full displays May be able to clear message and feed paper into bin selected FRU Action Bin x sensor Bin x sensor cable Bin x sensor flag Control board Check the sensor and sensor cable for the
62. LVPS 115 V ac 200 210 400 410 1 56P4234 1 1 LVPS 220 V ac 000 010 1 40X0220 1 1 LVPS 220 V ac 200 210 400 410 2 40X0260 1 1 Power cord set 8 ft right angle 13 amp United States Canada Caribbean countries Columbia Costa Rica Dominican Republic El Salvador Equator Guatemala Honduras Mexico Nicaragua Panama Puerto Rico Saudi Arabia Venezuela and Virgin Islands 2 40X0256 1 1 Power cord set 8 ft right angle Bolivia and Peru 2 40X0255 1 1 Power cord set 8 ft right angle Argentina 2 40X0257 1 1 Power cord set 8 ft right angle Chile Uruguay 2 40X0258 1 1 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 2 40X0293 1 1 Power cord set 8 ft 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 2 40X0259 1 1 Power cord set 6 ft right angle Brazil 2 40X0301 1 1 Power cord set AS NZS 2 40X0271 1 1 Power cord set Hong Kong 2 40X0302 1 1 Power cord set Japan 2 40X0280 1 1 Power cord set Korea 2 40X0303 1 1 Power cord set PRC 2 40X0281 1 1 Power cord set Taiwan 2 40X0294 1 1
63. Left door removal on page 4 6 Remove the redrive cap See Redrive assembly removal on page 4 74 Remove the fuser wiper cover assembly See Fuser wiper cover assembly removal on page 4 4 Remove the mounting screws A from the left side PR 6 Use your thumb to bend the paper full flag assembly slightly to unlatch it from the mounting bracket 4 70 Service Manual Paper size sensing board removal 1 Remove the system board and inner shield See System board and inner shield removal on page 4 76 2 Remove the paper size sensing board mounting screw A 3 Disconnect the paper size sensing board cable B from the board 4 Remove the paper size sensing board from the latch C C A B 5 Remove the paper size sensing board Repair information 4 71 Power takeoff shaft and spring removal Remove the power takeoff shaft and spring A through the bottom of the printer 4 72 Service Manual Printhead removal CAUTION The printhead is not a serviceable FRU Do not disassemble the printhead 1 Remove the laser cover See Laser cover removal on page 4 19 2 Disconnect the printhead cable A from the printhead assembly 3 Remove the three printhead mounting screws B and remove the printhead Note Do the Printhead assembly adjustment on page 4 2 whenever you remove or replace the printhead assembly or loosen the mounting screws Repair information 4 73 Redrive assembly removal
64. Paper feed problems especially paper jams Go to Display Log on page 3 23 and check the printer event log for indications of repetitive entries that help to isolate a problem to a particular area of the printer or option Paper feed problems with error message Use the Sub error codes for 9xx and 2xx error codes on page 2 8 to help diagnose the problem e Print quality problems Go to Print quality pages Prt Quality Pgs on page 3 6 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 5 Bin mailbox service check Service tip The majority of the mechanical components can be observed during operation by removing the left and right side covers Make sure the option s are correctly installed and the machine is configured correctly before attempting to service the unit Problems with excessive static electricity buildup FRU Action 1 Front cover assembly Check the front cover assembly to make sure the ESD brush ground lead is firmly attached to the 5 Bin mailbox frame Also check to make sure the ESD brush is not loose or damaged The printer does not recognize one or more output options as installed Service tip If more than a single output option is installed check each one to see if the printer recognizes any
65. Power cord set Denmark Norway and Sweden 2 40X0295 1 1 Power cord set lsrael 2 40X0304 1 1 Power cord set Botswana Lesotho Namibia Pakistan and South Africa 2 40X0305 1 1 Power cord set Switzerland 3 56P4243 1 1 High voltage power supply 4 1 Parts packet PP 40X0165 5 40X0223 1 1 Front cable harness HVPS input sensor toner sensor Parts catalog 7 29 a e e LAME 7 30 Service Manual Note Assembly 15 Electronics card assemblies Per member meh erpeg Description 15 1 40X0146 1 1 Interconnect card assembly 2 slot 200 210 400 410 2 40X0147 1 1 Interconnect card assembly 1 slot 000 010 3 40X0140 1 1 System board assembly non network 000 Board ID Q0016021 3 40X0141 1 1 System board assembly non network 200 Board ID Q0016022 3 40X0142 1 1 System board assembly non network 400 Board ID Q0016023 4 40X0143 1 1 System board assembly network 010 Board ID Q0016001 4 40X0144 1 1 System board assembly network 210 Board ID Q0016002 4 40X0145 1 1 System board assembly network 410 Board ID Q0016003 5 40X0198 1 1 Bar code card assembly 5 40X0248 1 1 IPDS and SC5 TNe card assembly 5 40X0199 1 1 PrintCryption card assembly 5 40X0265 1 1 PRESCRIBE card assembly 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 Q00160 03
66. Primary message Description action 31 XX Defective Print Cartridge Error code 31 displays when the top front cover is closed and a defective print cartridge is detected It may take the printer 10 20 seconds to determine if the print cartridge is defective Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10 20 second interval 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 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 32 XX Unsupported Print Cartridge 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 assembly service check on page 2 122 34 XX Short Paper The printer determines the
67. RA RR MEER dE RR Ee 5 6 Fuser BOBO piston rai A dede qued equ diede ds 5 7 Higliscapacity output Staecker DOS coros aA EE aa eu aa SA 5 8 Highi voltage power SUBplV iiesoosse e rp E e EE eR pa 5 9 Intetconnect CAI 6 02540 odia ad n e arar qid E Dea SAO id xd Ride 5 9 Low voltage power supply esasecg aec a aoe be Gee A PERRA TREE PORTER 5 10 Output expander control Board acia a Ew USC RGAE PUR NR done 5 11 StapleSmarttiniSheN izsr esso os bk RE ERG A REG CERERI Tir EEE E HERR Ae 5 12 Preventive maintenance ci icd es ide cies ee eee dees Geet ceded EE RE RR A E 6 1 Safety INSPECHON guide susie anew ir does aon d RR calender dele HEU dU 4 3 sonal P Da adie 6 1 Lubrication specifications ikaxsokuak ak RR a naa ee ea A a nee ROA CROCO CROCO d 6 1 Scheduled maintenance is tie Se ee Cele eae 1314 Pb REA Nub wind A A RR Sea RN FUR 6 1 Maintenance dsc caceres Clade aduss edad sasaeasone ROSE Ris 0I pd 6 1 Paris CAIDO oid am d CER EROR OR EORR UR ER CR a ol ORAE EE ECCE CR ORO AE 7 1 Howto use this parts catalog iain vex rea Ra Rd kam Deere RE Ve eae ee eee Re e eae 7 1 Assembly 1s COVERS ossi 4E Ene R03 25 deed hab dba edu bos d Dad OR RE de E Oe Pu 7 2 Assembly 2 Frame Toc dart er ted oros bowery qudd aute editis 7 4 Assembly 3 Frame 2 esposito rs 7 6 Assembly 4 EIOS S arcoiris Rus eR o ADA 7 8 Assembly 5 Printhead os s2004 roo soo oe ERR RARE RD IEEE ae 7 10 Assembly 6 Paper feed autocompensator 0000 esee 7 1
68. Remove the redrive door assembly Remove the redrive exit cover Remove the redrive assembly mounting screws A POM M c Release the redrive assembly mounting latches B and remove the redrive assembly 4 74 Service Manual Signature button contact assembly removal Remove the print cartridge Remove the left side door See Left door removal on page 4 6 Remove the right cover See Right cover removal on page 4 8 Remove outer system board shield See Outer shield removal on page 4 67 Disconnect signature button cable from connector J14 on the system board On models 200 210 400 410 remove the two screws A securing the blower duct pO e Ho M S 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 Repair information 4 75 System board and inner shield removal Warning When replacing any one of the following components e Operator panel assembly or upper front cover 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
69. See Fuser assembly removal on page 4 26 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 92 201 24 Expected wide page not detected by narrow media sensor possible accordion jam Fuser page count between 200 000 and 299 999 Page did not enter or exit fuser nip cleanly Narrow media sensor not functioning correctly Actual page is narrow when wide page was expected f 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 26 f media is narrow then turn off first sheet detection engine settings 3 16 In Diagnostics mode select PRINTER SETUP and Engine Setting 3 The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 93 201 30 Page did not reach exit sensor Fuser page count between 300 000 and 399 999 Page jammed on fuser input guide Page did not enter or exit fuser nip cleanly Exit sensor not functioning correctly Check the fuser entry guide for toner build up Check fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 The fuser exit sensor may not be functioning properly Go to Fuser exit
70. Select Print Menus from the TESTS MENU The page contains the following information Alistof all the printer settings contained in the operator panel menus and their values Alistof the installed options and features such as RAM memory cards optional input paper trays envelope feeder duplex option output bins flash or disk Printer information such as serial number page count installed RAM engine code level RIP code level envelope feeder code level tray 1 5 code levels output bin 1 3 code levels operator panel code levels font ROM version and SRAM availability 3 30 Service Manual 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 friction 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
71. Service Manual 6 Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser to LVPS AC lamp cable D Warning The LVPS assembly may be difficult to remove from the printer Do not use excessive force in the removal 7 Remove the low voltage power supply Repair information 4 55 Main fan removal 1 Open the left side cover 2 Remove the outer shield See Outer shield removal on page 4 67 3 Remove the two screws A securing the main fan cap 4 Remove the main fan cap 5 Clip the cable tie B Note Be careful not to damage any of the cables Note the location of the cable tie for later replacement 6 Disconnect the main fan to the system board C at J4 7 Remove the main fan 4 56 Service Manual Installation note The fan has an orientation marking D Be sure to install the fan with the arrow pointing up Main drive assembly removal 1 Remove the system board and inner shield See System board and inner shield removal on page 4 76 2 Remove the screw securing the gear guard A 3 Remove the power take off shaft and spring See Power takeoff shaft and spring removal on page 4 72 4 Remove the developer drive assembly See Developer drive assembly removal on page 4 24 Repair information 4 57 5 Lift and remove the cables from the cable hooks B 3 S amp m PP lt S AS 6 Remove the ground cable scre
72. 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 O 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 FRU Action 1 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 2 120 Service Manual Print quality light print Service tip Check the toner saver and print darkness settings first if the print is light FRU Action 1 Transfer roll Check the right end of the transfer roll shaft for signs of wear or contamination If incorrect replace the transfer roll 2 Right side transfer roll arm assembly HVPS Check the right side transfer roll arm assembly bearing for wear or contamination Also make sure the transfer cable is firmly attached
73. You can change the amount of time the printer warms up before allowing pages to print by changing this setting from O 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 Transfer The transfer can be adjusted to Low Medium or High The default setting is Medium 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 Charge Roll The charge roll can be adjusted to Low Medium or High The default setting is Medium 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 0 3 22 Service Manual 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 a
74. 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 Diagnostic information 2 119 Print quality black bands on outer edges of the page This print quality problem appears as vertical black bands on one or both sides of the copy and can be wide narrow light or dark FRU Action 1 Charge roll counterbalance springs If the problem is just on one side of the page check the charge roll counterbalance spring on that side 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 2 Charge roll assembly Charge roll link arm Check the charge roll for toner buildup or other contamination on the 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 Printer Idle 415 8 measures 0 V dc Printer Printing Test Page 415 8 voltage changes from 0
75. 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 correctly 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 FRU Action 1 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 2 Charge roll conductive Make sure the charge roll bushing is correctly installed in the right bushing charge roll arm 3 HVPS Check the
76. assembly removal on page 4 57 2 46 Service Manual User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 201 12 Page did not reach exit sensor Fuser page count between 100 000 and 199 999 Page jammed on fuser input guide Page did not enter or exit fuser nip cleanly Exit sensor not functioning correctly Check fuser entry guide for toner build up Check fuser for wear or contamination if a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 The fuser exit sensor may not be functioning correctly Go to Fuser exit sensor service check on page 2 92 201 14 Expected wide page not detected by narrow media sensor possible accordion jam Fuser page count between 100 000 and 199 999 Page did not enter or exit fuser nip cleanly Narrow media sensor not functioning correctly Actual page is narrow when wide page was expected f label media ensure front edge meets 1 8 inch requirement Check fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 f media is narrow then turn off first sheet detection engine settings 3 16 In Diagnostics mode select PRINTER SETUP and Engine Setting 3 The fuser narrow media sensor may not be
77. at 500 000 to preserve data check on page 2 89 Diagnostic information 2 19 Service error codes 9xx xx continued Error Sub ode codes Display text Description Action 922 56 Hot roll did not reach Low wattage or incorrect lamp Go to 922 xx Cold fuser operating temperature in T check on page 2 89 time new enhanced Bad thermistor circuit or cabling control Fuser page Fuser not receiving sufficient AC count stopped at power 500 000 to preserve Poor supply line voltage data 922 57 Fuser has taken too long Low wattage or incorrect lamp Go to 922 xx Cold fuser to reach desired check on page 2 89 temperature after Excessive load on the fuser increasing interpage Fuser not receiving sufficient AC gap Fuser page count power stopped at 500 000 to P i preserve data oor supply line voltage 922 92 Hot ra too long to Low wattage or incorrect lamp Go to 922 xx Cold fuser reach the beginning 7 check on page 2 89 lamp detection Bad thermistor circuit or cabling temperature Fuser Fuser not receiving sufficient AC page count not power available Poor supply line voltage 922 93 ps id reached final Low wattage or incorrect lamp Go to 922 xx Cold fuser amp detection s TIE check on page 2 89 temperature but took Bad thermistor circuit or cabling longer than largest time e Fuser not receiving suffi
78. attached to PCI connector x x21 2 or 3 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 Connection Check envelope feeder connection Check Tray x Connection Check tray x where x 1 2 3 4 or 5 Check Duplex Connection Check duplex option 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 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 Enable Option A printer option Input Tray or Envelope Feeder has been attached while the printer is powered on To use the option the printer must first be powered off and back on again Data loss results if print jobs are active when
79. cabling Go to 920 xx Cold fuser checking for slope e Fuser not receiving sufficient AC service check on page 2 87 change in standby power Fuser page count between 0 and 99 999 Poor supply line voltage Low wattage or incorrect lamp Incorrect hot roll 920 04 Hot roll too cool when Bad thermistor circuit or cabling Go to 920 xx Cold fuser heating to desired e Fuser not receiving sufficient AC service check on page 2 87 temperature after slope power change standby control only Fuser page count Poor supply line voltage between 0 and 99 999 Low wattage or incorrect lamp Incorrect hot roll 920 06 Fuser is not increasing Fuser is not receiving AC power Go to 920 xx Cold fuser in temperature even A service check on page 2 87 though the lamp has Poor supply line voltage been on for an extended time Fuser page count between 0 and 99 999 920 07 Fuser has been below Bad thermistor circuit or cabling Go to 920 xx Cold fuser the desired temperature e service check on page 2 87 for too long while media Very noisy thermistor signal is in the nip Fuser page Fuser not receiving AC power owe 0 and Poor supply line voltage lt Excessive load on the fuser Low voltage or incorrect lamp Abrupt change in temperature that has disrupted control Incorrect hot roll 920 11 Hot roll took too long to Bad thermistor circuit or cabling Go to 920 xx
80. changes 7 To exit REGISTRATION press Back amp Quick Test The Quick Test contains the following information Print registration settings Alignment diamonds at the top and bottom Horizontal lines to check for skew 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 Select REGISTRATION from DIAGNOSTICS 2 Press W until the Y appears next to Quick Test The message Quick Test Printing appears on the display Once the Quick Test Page completes printing the Registration screen displays again Diagnostic aids 3 5 PRINT TESTS Input source tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options The contents of the Print Test Page varies depending on the media installed in the selected input Source Check each Test Page from each source to assist in print quality and paper feed problems To run the Print Test Page 1 Select PRINT TESTS from the Diagnostics menu 2 Select the media source Tray 1 Tray 2 if installed Tray 3 if installed Tray 4 if installed Tray 5 if installed Multipurpose Feeder if installed Envelope Feeder if installed 3 Select Single or Continuous e f Single is selected a single page is printed f Continuous is selected printing
81. code Jam location 231 xx Media did not arrive at the duplex input sensor but did leave the fuser exit sensor 232 xx Media did not clear the duplex input sensor but did leave the printer fuser exit sensor 233 xx Media failed to make the duplex double feed sensor during turnaround 234 xx Media did not arrive at the duplex exit sensor 235 xx A piece of media is over the duplex double feed sensor 236 xx Media did not leave the duplex exit sensor 237 xx A duplexed sheet did not reach the printer input sensor 238 xx r A piece of media is over the duplex sensors during a reset Duplex does not recognize that the option is installed or other options below the duplex are installed FRU Action 1 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 2 82 Service Manual 231 xx Jam displays on the operator panel FRU Action 1 Fuser exit sensor Check the sheet of media is leaving the exit sensor in the fuser and feeding properly into the duplex
82. continues until Stop 0 jis 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 Press Back to return to PRINT TESTS Print quality pages Prt Quality Pgs 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 three pages Page one contains a mixture of graphics and text Pages two and three only contain graphics 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 select Prt Quality Pgs 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 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 The following is included in the DIAGNOSTICS version of the print quality pages Values from EP SETUP in DIAGNOSTICS including Fuser temperature
83. da Classe nao sao considerados perigosos Internamente a impressora cont m um produto laser da Classe lllb 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 opera o normal a manuten o feita pelo utilizador ou condi es de assist ncia prescritas Service Manual 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 klasse worden niet als ongevaarlijk aangemerkt De printer is voorzien van een laser van klasse lllb 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 I 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 ga
84. daras gc ids 2 76 950 00 through 950 29 EPROM mismatch failure enses er eme kb nem mn 2 77 950 30 through 950 60 EPROM mismatch failure eie e de Sume 2 78 Charge roll Service cheek arcaica REPE She dd ORE ER RET GE REP RE 2 79 Cover closed switch cable service check oooooooooooonor eee eee eee 2 80 Dead Machine servite CNECK 224 2e 24 bed asper reper de pee oe eb PANS doen ce geese eaadeess 2 80 Duplex Optloinsenvice Chek raspa a PIRE RE sa ed 2 82 Envelope feeder service Check i ssssaesos casas REG posa Raed beds AA 2 84 Fuser service CHECKS aos ede ba epe Shae Kee ee beni whe Ed dede did febri ene aim 2 87 92036c O690ld Tuser Service CHECK iua sd aep cria op RE dor eus JR Rob Eb de Bo 2 87 022 3X COBId Tusel CHECK ake 6a EUH oes atone n nee ade stades dedu Ede dede 2 89 023 3xx Hot luser service CHECK usa succo bord pera SoA adde A rp does dedit pais 2 90 994 3x Hot f ser service Check 022302060 er RR Ie 2 91 925 KX Hot Iuser Service CHECK s a ica dene da 2 91 Fuser exit sensor service Check iscesst eo E ped eq E EX REPE RE REY ORE d he X dE E RES 2 92 Fuser narrow media sensor service check 002 c ce eee eee 2 93 Fuser solenoid service Check s10ccc cc2as couse he RESET ane E a euros eed 2 94 High capacity feeder input tray service check 20 c eee eee ee eee 2 95 High capacity output stacker service check 0600 e cece e eee eens 2 100 Inputsensor SEIVICO CHECK uu od eude doo ero
85. deh acepto od Rue amu eugene and 4 7 Right cover removal vasos kx e vies grseeo stab AA A 4 8 Upper tont cover TMV i4 ntdapaccde ae edee ER Oe Peto Sesame eH Saat dad apps 4 11 Upper Tront cover latcnvemOvall 1 23 3 2 24 5 409 rra ee po ETE ebd 4 13 Upper front cover outer bezel FEMOVEl 0 ocio sos be dre heeled ee E P RI erg 4 14 Multipurpose feeder lower front cover assembly removal 0 00 e eee eee eee ee 4 15 Eet cover handle holder Falmboval su arde ucro boxes ase x dee hee eee 4 16 Right cover handle holder eroval 422122422 e prb Er ra rudes ER Ede EORR bd Rd 4 16 Left and right frame extensions iss sc srd es pERRRERRRERREER REC RRRPREEN E REX RESTER 4 17 Pass THEO DIIS coa assa aso qd RI Sd idc RS dd x ed ap d Re Josie eee Seeds Some RS 4 18 Laser cover removal socer eter ERREPDEPFREEL Men ERE Edo nEPEPUE needed 4 19 Bevel gear removal viciado ad dedo dnp de ata ies dy duh Ended 4 21 Cattridge ductremoval 2224592599 ey b64 0404006020420 SE eee eel FERE RE RES RES 4 23 Developer drive assembly removal 2 eee eee ee eee eee eee n 4 24 Developer drive coupler kit removal ses eh m rnm mm emm eR ERES 4 25 ESD GOVE TOI OVAI caecitas abc ouod a epica dte date a dedi d iste D aote dup ois ed 4 25 Fuser assembly removal i 4eese ee coros cn cierre 4 26 Fuser Skit Sensor ie MOYA M P AA AAA AAA AA 4 28 Fuser exit sensor flag and spring removal conomcocacia rr rr buc Read hei d 4 30 F ser ap TOO vu qupd diea q
86. 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 Safety information xvii Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen 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 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 hrung der Arbeiten an den Strom angeschlossen sein mu Pautas de Seguridad La seguridad de este producto se basa en pruebas y aprobaciones del dise o original y componentes espec ficos El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas e La informaci n sobre el mantenimiento de este producto est
87. error codes 9xx xx continued Error Sub code cod s Display text Description Action 920 92 Hot roll fell too far below Bad thermistor circuit or cabling Go to 920 xx Cold fuser desired temperature service check on page 2 87 while printing Fuser Noisy mermigtor signal page count not e Fuser not receiving AC power available Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll 920 93 Hot roll too cool while Bad thermistor circuit or cabling Go to 920 xx Cold fuser checking for slope service check on page 2 87 change Fuser page Noisy thermistor signal count not available e Fuser not receiving AC power Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll 920 94 Hot roll too cool when Bad thermistor circuit or cabling Go to 920 xx Cold fuser heating to desired service check on page 2 87 temperature after slope Noisy thermistor signal change Fuser page Fuser not receiving AC power count not available Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll 920 96 Fuser is not increasing Fuser is not receiving AC power Go to 920 xx Cold fuser in temperature even service check on page 2 87 though the lamp has Poor supply line voltage been on for
88. 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 can not 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 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 21 1 Remove any feature or option cards from the interconnect card 2 Remove the two screws securing the interconnect card 3 Remove the interconnect card assembly Repair information 4 53 Low voltage power supply removal CAUTION Unplug the printer before you begin 1 Remove the redrive assembly See Redrive assembly removal on page 4 74 2 Remove the right side cover See Right cover removal on page 4 8 3 Remove the pass thru plate See Pass thru plate on page 4 18 4 Remove the LVPS mounting screws A from the rear of the center pan 5 Disconnect the LVPS to system board cable The cable is difficult to disconnect There are catches B that firmly hold latches on the LVPS card connector C 4 54
89. from the upper front cover 4 66 Service Manual Operator panel buttons removal The operator panel and navigation buttons are in a single kit 1 Remove the operator panel board See Operator panel board removal on page 4 66 2 Remove the functional rubber sheet A and the rubber dome sheet B 3 The navigation buttons and the select button can be removed by releasing the clips C on the back of the upper front cover Outer shield removal 1 Remove the left door See Left door removal on page 4 6 2 Loosen the outer shield mounting screws A and remove the shield by sliding up A 202 A EAS A 202 Repair information 4 67 Paper alignment assembly removal 1 Remove the upper paper deflector assembly See Upper paper deflector assembly removal on page 4 79 2 Remove the inner paper deflector assembly See Inner paper deflector assembly removal on page 4 47 3 Release the input paper sensor from its mounting and remove A Remove the left door 5 Remove the paper alignment assembly mounting screws A 4 68 Service Manual 6 Locate the paper alignment assembly reference adjustment screw B through the left frame and remove the screw 5E 7 Remove the paper alignment assembly Note Do the Paper alignment assembly adjustment on page 4 3 when you reinstall the assembly Repair information 4 69 Paper bin full sensor flag removal Remove the left door See
90. from the outside of the frame 11 Remove the integrated tray autocompensator assembly 4 50 Service Manual 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 LE 2 Press on the end of the tab A and pull the pick roll off the arm Repeat this step for the pick roll on the other side Next gently release the autocompensator arm Discard the used pick rolls Repair information 4 51 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 52 Service Manual Interconnect card assembly removal CAUTION Unplug the printer before you begin Warning When replacing any one of the following components e Operator panel assembly or upper front cover e System board assembly Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not
91. 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 18 6 Disconnect the LVPS to system board DC cable D from the LVPS 4 38 Service Manual 7 Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser to LVPS AC cable from the LVPS E Note The LVPS assembly may be difficult to remove from the printer Do not use excessive force in the removal 8 Remove the fuser to LVPS AC cable Installation 1 Plug in the fuser to LVPS AC cable A into the LVPS 2 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 IN Repair information 4 39 3 Route the cable through the lower rectangular opening E 4 Connect the fuser to LVPS AC cable to the fuser lamp connector F E F Note Be sure to connect the fuser to system board DC cable after replacing the LVPS 4 40 Service Manual Fuser top cover removal CAUTION Unplug the printer before you begin 1 Remove the fuser assembly See Fuser assembly removal on page 4 26 2 Note the thermistor cable routing A and disconnect the thermistor cable at the fuser control board A Repair information 4 41 4 Carefully remove the two screws C from the right side of the fuser lamp co
92. lookup table Fuser power page count between P ly li itage 100 000 and 199 999 boc ia 922 14 Hot roll timed out in Low wattage or incorrect lamp Go to 922 xx Cold fuser trying to reach the final a enti check on page 2 89 lamp detection Bad thermistor circuit or cabling temperature Fuser e Fuser not receiving sufficient AC page count between power 100 000 and 199 999 e Poor supply line voltage 922 15 After hot roll lamp The control code has been lost Go to 922 xx Cold fuser detection did not roll over to steady state control in time Fuser page count between 100 000 and 199 999 check on page 2 89 2 16 Service Manual Service error codes 9xx xx continued Error Sub code cod s Display text Description Action 922 16 Hot roll did not reach Low wattage or incorrect lamp Go to 922 xx Cold fuser operating temperature in e Bad thermistor circuit or cabling check on page 2 89 time new enhanced D d control Fuser page Fuser not receiving sufficient AC count between 100 000 power and 199 999 Poor supply line voltage 922 17 Fuser has taken too long Low wattage or incorrect lamp Go to 922 xx Cold fuser to reach desired check on page 2 89 temperature after Bad thermistor circuit or cabling increasing interpage Fuser not receiving sufficient AC gap Fuser page count power between 100 000 and i 19
93. measurements are made in accordance with ISO 7779 and conform with ISO 9296 Model Status 1 Meter average sound pressure Declared sound power Note Measurements apply Simplex printing 53 dBA 6 7 Bels Duplex printing 55 dBA N M Bels e STUDIO 500P Idle standby mode 32 dBA 4 7 Bels Simplex printing 54 dBA 6 8 Bels Duplex printing 57 dBA N M Bels Simplex printing 55 7 0 Duplex printing 58 N M to 300 dpi 600 dpi and 1200 dpi printing General information 1 7 Media s pecifications 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 cons ider a number of things conce rning pr int media before you print including S uppor ted print media Selecting pr int media Storing pr int media Avoiding jams We recommend that you try a limited sam ple of any paper or specialty media you are consi dering 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 Print media sizes Print media weights Media weights supp orted in optional output bins Media sizes suppo rted in the finisher Media weights supp orted in the finisher Note If you use a print media size not listed select the next larger
94. media sensor possible accordion jam Fuser page count stopped at 500 000 to preserve data Page did not enter or exit fuser nip cleanly Narrow media sensor not functioning correctly Actual page is narrow when wide page was expected f 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 26 f media is narrow then turn off first sheet detection engine settings 3 16 In Diagnostics mode select PRINTER SETUP and Engine Setting 3 The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 93 201 90 Page did not reach exit sensor Fuser page count is not available Page jammed on fuser input guide Page did not enter or exit fuser nip cleanly Exit sensor not functioning correctly Check the fuser entry guide for toner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 92 201 91 Main drive motor identification failed Fuser page count is not available Main drive motor not working Check the connections to the motor a
95. mounting screw PP 99A0675 11 99A0658 2 2 Door magnet Parts catalog 7 59 Assembly 36 High capacity feeder 2 7 60 Service Manual Assembly 36 High capacity feeder 2 Asm Part Units Units kit ot h Description Index number option or pkg 36 1 99A0654 1 1 Paper low switch 2 Parts packet nuts PP 99A0676 3 99A1808 1 1 AC external jumper cord 4 99A0667 1 1 Power supply board Parts catalog 7 61 Assembly 37 High capacity feeder 4 3 ee Re x Asm Part Units Units kit E Description Index number option or pkg 37 1 99A0275 1 1 Power takeoff spring 2 99A0272 1 1 Drive shaft 250 sheet 7 62 Service Manual Assembly 38 High capacity feeder 5 Asm Part Units Units kit Index number option or pkg Desorption 38 1 3 Parts packet auto comp assembly mounting screw PP 99A0263 2 56P4162 1 1 Pick arm assembly 2000 sheet 3 99A0070 2 2 Pick roll assembly 4 56P4127 1 1 Option pass thru sensor Parts catalog 7 63 Pages 7 65 thru 7 70 ofthis manual were omitted intentionally 7 64 Service Manual Index Numerics 1565 Emul Error Load Emul Option 2 42 250 sheet paper drawer option 7 42 250 sheet paper tray integrated 7 18 250 sheet paper tray option parts catalog 7 43 service check 2 102 2xx paper
96. option Check the duplex link for correct operation and any signs of damage If the problem is prior to the duplex input sensor and in the base machine repair as necessary If the jam occurs in the duplex option prior to the duplex input sensor go to step 2 2 Duplex input sensor 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 232 xx Jam displays on the operator panel FRU Action 1 Duplex input sensor 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 option assembly 233 xx Jam displayed on operator panel FRU Action 1 Duplex double feed sensor 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 Diagnostic informa
97. paper length is too short to print the formatted data This occurs when the printer does not know the actual paper size loaded in the tray For auto size sensing trays this error occurs if the paper stop is in the incorrect position Make sure the Paper Size setting is correct for the size paper that is being used 36 XX Resolution Reduced 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 37 XX Insufficient Collation Area This message displays when the printer memory is insufficient to perform the Flash Memory Defragment operation Note This message is posted prior to the actual start of the defragment operation The printer code determines if enough printer memory is available to complete the defragment operation The user should not be concerned with losing resources stored in the flash option The following actions may be taken Press Y to clear the message To perform the defragment operation Delete fonts macros and other data in RAM Install additional printer memory Press en until Busy Waiting appears The following actions are available Cancel Job Reset Printer Reset Active Bin 2 38 Service Manual User attendance messa
98. paper support before installing the upper front cover Make sure the operator panel cable is in the cable clip C if removed 4 12 Service Manual Upper front cover latch removal 1 Remove the upper front cover 2 Remove the screw A holding the latch and spring to the upper front cover Repair information 4 13 Upper front cover outer bezel removal 1 Open the lower front cover 2 Open the upper front cover 3 Remove the two small upper front cover outer bezel mounting screws A 4 Pull up to remove the outer bezel NOTE If available place a soft clean cloth on the open lower front bezel The clear inner bebel B is not connect and may fall The cloth may prevent scratches on the bezel 4 14 Service Manual 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 15 Left cover handle holder removal Open the left side cover Remove the outer system board shield See Outer shield removal on page 4 67 Remove the two screws A holding the top of the left handle holder in place Use the tab B to lift out the left handle holder E d
99. personer aldri utsettes for laserstr ling ut over klasse I niva under vanlig bruk vedlikehold som utfores av brukeren eller foreskrevne serviceoperasjoner xiv Service Manual Japanese Laser Notice L 3 icBiy 54104 IZO7ZULZS i KECADHHS 21 CEFRYTF TS 07241 1 OH Edi ULIVv yv 8s casos TwcvoE KKABUATAIIEC 8250545121175 ALOV YV WMECHSCEMMMANTIET 29XI0v Vv Wpiifsl amp tEd7zvcxAxoncoxEwv co 7Zy yr sZ i72ZzHnb 3b OL P AARMELTTOIEF CO LEE HERRBTTO T95T 22 72 o0838 8HC BH 53 737 0700 MEU MES LLP CF COLA YAFALIVA Il DEDOS 2 FOAVFPYAL H ES NIE BW TI ARM IFALTOVANVELLOL P ik HIM NSZCLORMWEABHANTHET AC FT EN OL ae 36 EIU E A E DHHS 21 CFR Subchapter I Xj 47 2 I 1 RIT i B9 ER E mE Hd Hb X Nu SEGA ES TEC 825 ES pn TE DE THI dh RR VR ROG Ek A TIED OLA ah amp A oy 28 Hb 3b HIE EREHE TALES mE CUERO EG ARK WE 770 795 nm z BMI ARRITNMHKRIT E RiR VE fH HEIDE ERE BIETET AA EA KB fh 4 ET A E SE ST V Laser notices XV Korean Laser Notice xvi ext 152 alo Ass O CHEF DHHS 21 CFR Subchapter 39 FAS Bsa wes n atol 4 oe a 12 2 Lar E 1 EC 825 732 Eo 15g alo x BORA 2132 ded a alo A HZS YN AOS zur E jte 5 Yeltes 23 oreA Lro alo Xx eX 770 795 Lpenle e uE EH Ol 4 SHSStE Class ill 3b ajo 43 HoA Za UVEC alo x AAMT DRY AA as Sol RA HS 3 EE PAA MwA Epo 7 2 Class PE loH Hol AZo Ach 328 As MAO USO Service Manual Safety information The safety of
100. power on or during disk format and write operations While this message displays press Y to clear the message The disk is marked defective and normal printer operations continue Disk operations are not allowed with a defective disk The Format Disk menu is not shown 62 XXX Disk Full This error code displays when there is not enough free space on the disk to hold the resources that have been requested to be written to the disk This message displays for both resource and PostScript Disk operators when the disk is full 63 XX Unformatted Disk This error code displays when the printer detects an unformatted disk at power on Press Y to clear the message The disk is marked as bad and normal operation continues Disk operations are not allowed until the disk is formatted 64 XX Unsupported Disk Format The printer detects an unsupported disk format at POR Press Y to clear the message The disk is marked as bad and normal operation continues Further disk operations are not allowed until the disk is formatted 80 XX Scheduled Maintenance The operator panel displays this message at each 300K page count interval It is necessary to replace the fuser assembly transfer roller charge roll and pick rolls at this interval to maintain the print quality and reliability of the printer The parts are available as a maintenance kit For more information go to Scheduled maintenance on page 6 1
101. procedures to identify printer failures and verify repairs have corrected the problem Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer Diagnostics Mode 1 Turn off the printer 2 Press and hold W and gt 3 Turn on the printer 4 Release the buttons when Performing Self Test displays The Diagnostics Mode group contains the settings and operations used while manufacturing and servicing the printer See Diagnostics mode on page 3 2 for more information Configuration Menu Turn off the printer 2 Press and hold Gand p gt 3 Turn on the printer 4 Release the buttons when Performing Self Test displays 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 Flash system code mode 1 Turn off the printer 2 Press and hold lt q Y and gt 3 Turn on the printer 4 Release the buttons when Performing Self Test displays To run the printer diagnostic tests described in this chapter you must put the printer in Diagnostic Mode Diagnostic aids 3 1 Diagnostics mode Entering Diagnostics mode 1 Press and hold W and gt
102. quality pages Prt Quality Pgs on page 3 6 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 select Prt Quality Pgs from CONFIG MENU The message Printing Quality Test Pages is displayed The following is printed Settings from EP SETUP from DIAGNOSTICS Fuser temperature warm up time transfer print contrast and charge roll settings Contents of the EVENT LOG from DIAGNOSTICS 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 in English and must always be printed on letter legal or A4 paper 3 26 Service Manual 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 Y Multipurpose feeder 250 sheet drawer Y 500 sheet drawer Y 2000 sheet drawer Y 250 sheet duplex 500 sheet duplex Envelope feeder
103. roll too cool when Bad thermistor circuit or cabling Go to 920 xx Cold fuser heating to desired A service check on page 2 87 temperature after slope Noisy thermistor signal change Fuser page Fuser not receiving AC power Ed than Poor supply line voltage LL 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 in temperature even service check on page 2 87 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 cabling Go to 920 xx Cold fuser the desired temperature a service check on page 2 87 for too long while media Very noisy Hiermistor signal is in the nip Fuser page Fuser not receiving AC power count more than P Iv li It 500 000 oor supply ine voltage Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll Abrupt change in temperatures that has disrupted control 920 91 Hot roll took too long to Bad thermistor circuit or cabling Go to 920 xx Cold fuser heat up after transitioning to new enhanced mode Fuser page count not available Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll service check on page 2 87 2 14 Service Manual Service
104. run the Input Tray Feed Tests 1 2 3 Select Feed Tests from INPUT TRAY TESTS Select the input source from the sources displayed on the Feed Tests menu All installed sources are listed 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 0 is pressed 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 2 Select the Sensor Test from INPUT TRAY TESTS Select the input source from the sources displayed on the Sensor Test menu All installed sources are listed Select the sensor to test Various sources have different combinations of sensors See the table below Tray sensor support by source Empty Low passThru Source Input tray empty Input tray paper low Input tray pass thru sensor sensor sensor Tray 1 Y 4 Tray 2 Y Y 4 Tray 3 Y Y Y Tray 4 Y V Y Tray 5 Y Y 4 Multipurpose tray Y Envelope feeder Y Y sensor selected 0P displays e Empty Input tray empty sensor e Low Input tray paper low sensor e passThru Input tray pass thru sensor 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 Clo
105. sensor bounced Fuser page service check on page 2 92 count between 400 000 and 499 999 202 46 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 been cleared from a prior jam any signs of debris or pieces of between 400 000 and paper or media 499 999 2 62 Service Manual User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 202 50 Paper jam around the fuser exit or redrive area Fuser page count stopped at 500 000 to preserve data Page may be jammed in the fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 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 92 202 51 Page did not cleanly exit fuser or redrive ar
106. the range specified in REGISTRATION on page 3 4 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 Repair information 4 3 Removal procedures 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 A N 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 Covers removals Fuser wiper cover assembly removal 1 Squeeze the two latches together and pull up 2 Remove the fuser wiper cover assembly 4 4 Service Manual Redrive cap cover removal 1 Pull up on the right side of the redrive cap cover to remove pr gt 2 Remove the redrive cap cover Paper support removal 1 Raise the paper support and lift to release the latches 2 Remove the paper support Repair information 4 5 Left door removal 1 Open the upper and lo
107. the transfer roll Wrap a piece of plain white paper around the charge roll to prevent contamination or damage 1 Open the upper front cover and remove the print cartridge 2 Unsnap the transfer roll assembly from the left pivot arm 3 Lift the transfer roll assembly toward the left and remove it from the printer Repair information 4 77 Upper front cover hinge assembly removal 1 Remove the upper front cover See Upper front cover removal on page 4 11 2 Remove the laser cover assembly See Laser cover removal on page 4 19 3 Remove the C clips A from the upper front cover hinge assembly left and right hinge pins and remove the pins Note the pin orientation and the C clip location on the inside of each hinge Detach the two springs B from the upper front cover hinges Detach spring C from the left side of the hinge assembly Remove the cover closed switch assembly Disconnect the operator panel cable from the operator panel board E DC Im imo Raise the upper front cover hinge assembly to a position that lets you lift the left pivot arm from the mounting bracket D 9 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 10 Remove the upper front cover hinge assembly 4 78 Service Manual Upper paper deflector assembly removal 1 Either lift the ESD cover out of the way or remove it See
108. the way to clip the sensor securely into the cover 2 Connect the fuser narrow media cable 3 Snapthe 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 35 Fuser narrow media flag and spring removal 1 Remove the fuser narrow media sensor See Fuser narrow media sensor removal on page 4 34 2 Note the position of the spring A in relation to the flag B 3 Carefully ease the right arm C of the sensor cover just far enough apart to release the flag and spring disc B A Spring replacement 1 Place the spring on the left pin A 2 Setthe tang B on the flag 4 36 Service Manual 3 Rotate the bent end C of the spring to add tension place the pins between the sensor cover arms and rest the bent end against the sensor cover frame Note After replacing the sensor flag and spring make sure the flag moves properly Repair information 4 37 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 4 Remove the redrive assembly See Redrive assembly removal on page 4 74 Remove the right side cover See Right cover removal on page 4 8 B mm Disconnect the fuser to LVPS AC cable A from the fuser lamp connector on the
109. 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 yee the right side transfer arm assembly If correct replace the 3 Printhead A contaminated printhead may be the cause of light print If no other cause is found install a new printhead 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 FRU Action 1 Hot roll fuser assembly 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 2 Transfer roll transfer plate assembly Check the transfer roll for toner buildup or loose toner around the area of the transfer plate assembly Clean the area and run another copy If the problem continues replace the FRUs in the following order HVPS System board Diagnostic information 2 121 Printhead service check CAUTION The printhead is not a serviceable FRU Do not disassemble the printhead The printhead assembly does not contain any
110. 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 FRU Action 1 AC line cord AC jumper HCIT to printer AC input and output receptacles AC wiring harness A If the base printer works normally using the AC line cord from the AC wall outlet and does not work when using the AC jumper from the HCIT check the AC jumper cord If defective replace the cord If not defective check the AC input and output receptacles and wiring 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 FRU Action 1 high capacity feeder autoconnect mechanical check Check the high capacity feeder input tray to make sure it i
111. upper front cover e System board assembly Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable 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 can not be used in another printer It must be returned to the manufacturer 955 00 Code CRC CRC failure or ECC code failure on the System board Replace the system board See System board and inner shield removal on page 4 76 956 00 System board This error indicates a system board processor failure Replace the system board See System board and inner shield removal on page 4 76 957 00 System board This error indicates a system board processor failure Replace the system board See System board and inner shield removal on page 4 76 958 00 Nand failure Printer has performed more than 100 shift and replace operations as a result of EC bit corrections Replace the system board See System board and inner shield removal on page 4 76 Diagnostic information 2
112. warm up time transfer print contrast and charge roll settings Contents of the EVENT LOG from DIAGNOSTICS e 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 3 6 Service Manual HARDWARE TESTS Select the following Hardware Tests from this menu Panel Test Button Test e DRAM Test e ROM Memory Test Parallel Wrap if available Serial Wrap if available Panel Test This test automatically toggles each pixel of the operator panel through every contrast level beginning with the darkest and on to the brightest This test continues until you press Stop 9 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 Pressing Back or Stop cancels the test 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 Select DRAM Test from the menu The message DRAM Test Testing displays Then th
113. xx Error code Sub codes Description Possible causes Action 202 20 Paper jam around fuser exit or redrive area Fuser page count between 200 000 and 299 999 Paper may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 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 92 202 21 Page did not cleanly exit fuser or redrive area Fuser page count between 200 000 and 299 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce W curl 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 t
114. xx Fan service check 927 xx can be used for the main fan or the cartridge fan Main fan 927 00 927 01 and 927 03 through 927 07 Cartridge fan 927 02 Main fan Service tip The main fan runs at full speed at the end of POR or when the printer is printing It will only run half speed when the printer is in the Ready state and not printing FRU Action 1 Main fan Check the main fan to make sure it is plugged into J4 on the system board 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 56 If undamaged go to step 2 2 Main fan 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 remove the blockage 3 Main fan blades turn during POR then stop Fan will not run when trying to print Main fan System board Measure the voltage at J4 1 on the system board The voltage should measure approximately 42 5 V dc If incorrect replace the main fan See Main fan removal on page 4 56 If that does not fix the problem replace the system board See System board and inner shield removal on page 4 76 4 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
115. 00 210 7 25 Fuser assembly w 220 V lamp 000 010 200 210 7 25 Fuser wiper cavity cover 7 25 Fuser cover assembly kit 7 25 Fuser lamp 115V l l lllllll ll ll lll llll 7 25 Fuser lamp 220V l llllllll llle lll ll lll eeee 7 25 Narrow media sensor l ll lllllll ll lll nnn eee eens 7 25 Exit Sensor llllllrrllrrrLLLllll lll 7 25 Parts kit charge roll link asm left side 7 27 Charge roll assembly 7 27 Parts kit right side charge roll link assembly 7 27 I 10 Service Manual 40X0130 40X0131 40X0132 40X0133 40X0134 40X0135 40X0140 40X0141 40X0142 40X0143 40X0144 40X0145 40X0146 40X0147 40X0149 40X0150 40X0151 40X0152 40X0153 40X0154 40X0156 40X0157 40X0159 40X0160 40X0162 40X0163 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0165 40X0171 40X0174 40X0179 40X0182 40X0183 40X0195 40X0198 40X0199 40X0200 40X0207 40X0208 40X0209 40X0210 40X0211 40X0212 40X0213 40X0220 Transfer roll assembly 22 2 2s cence tee ee eee 7 27 Transfer roll assembly right arm
116. 00 210 400 410 ET Operator panel outer bezel 7 3 Operator panel outer bezel 1 1 1 3 5 EP DC fan assembly 200 210 400 410 7 9 Kit upper front panel button 7 3 Exit narrow media sensor cover llllllllllllllllll 7 25 Narrow media flag spring kit 2 22 2222 eee eee eee eee eee eee 7 25 Exit sensor flag spring kit 7 25 Fuser assembly w 100 V lamp 7 25 Cx Tx card assembly 7 69 IPDS and SC5 TNe card assembly 7 31 EP fan with cable 500 sheet 200 210 400 410 7 41 9 pin to Twinax cable 2 2 2 eee eee eee eee eee eee eee 7 69 9 pin to Coax BNC cable 2 22 22 2 2 eee een e ene e eee ee eeeeee 7 69 9 pin to 9 pin cable assembly 202 50 eee eee eee eee eee e ee eeee 7 69 Power cord set 8 ft right angle Argentina 7 29 Power cord set 8 ft right angle Bolivia and Peru 7 29 Power cord set 8 ft right angle Chile Uruguay 7 29 Power cord set 8 ft right angle eee eee eee 7 29 Power cord set 6 ft right angle Brazil
117. 00 and 499 999 115 V lamp in 220 V printer Lamp has excessive wattage Go to 925 xx Hot fuser service check on page 2 91 925 42 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Fuser page count between 400 000 and 499 999 Attempting to POR machine after receiving a 925 01 Go to 925 xx Hot fuser service check on page 2 91 925 51 Lamp detection performed and found error Fuser page count stopped at 500 000 to preserve data 115 V lamp in 220 V printer Lamp has excessive wattage Go to 925 xx Hot fuser service check on page 2 91 925 52 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Fuser page count stopped at 500 000 to preserve data Attempting to POR machine after receiving a 925 01 Go to 925 xx Hot fuser service check on page 2 91 925 91 Lamp detection performed and found error Writes to the fuser information chip have been disabled due to a previous write failure 115 V lamp in 220 V printer Lamp has excessive wattage Go to 925 xx Hot fuser service check on page 2 91 925 92 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 Attempting to POR machine after receiving a 925 01 Go to 925
118. 0239 1 Exit sensor flag spring kit including Spring 1 Flag 1 7 40X0236 1 1 Exit narrow media sensor cover 8 Parts packet PP 40X0165 9 40X0125 1 1 Exit sensor 10 40X0330 1 1 Exit sensor cable 11 40X0238 1 Narrow media flag spring kit including 1 Spring 1 Flag 12 40X0124 1 1 Narrow media sensor 13 40X0229 1 1 Narrow media sensor cable NS 40X0226 1 1 Fuser AC to fuser lamp cable Parts catalog 7 25 Assembly 13 Transfer charging 7 26 Service Manual Assembly 13 Transfer charging Asm Part Units Units kit Description Index number mach_ or pkg 13 1 40X0126 1 Parts kit charge roll link asm left side 2 40X0127 1 2 Charge roll assembly dual 3 40X0129 1 Parts kit right side charge roll link assembly 4 40X0130 1 1 Transfer roll assembly 5 40X0131 1 1 Transfer roll assembly right arm 6 40X0132 1 1 Transfer roll right spring 7 40X0133 1 1 Transfer pivot shaft 8 40X0134 1 1 Transfer roll left spring 9 40X0135 1 1 Transfer roll left arm NS 1 Parts packet charge roll screw PP 40X0165 NS 1 Parts packet C clip pivot shaft PP 40X0165 Parts catalog 7 27 Assembly 14 Electronics power supplies f DS N 3 i L g AS A VS NA y gt 7 28 Service Manual Assembly 14 Electronics power supplies Asm Part Units Units kit Description Index number mach or pkg P 14 1 56P4232 1 1 LVPS 115 V ac 000 010 1 56P4233 1 1
119. 2 Assembly 7 Paper feed multipurpose feeder 0 0 00 cece eee 7 14 Assembly 8 Paper feed alignment 0 0 0 c eee eh 7 16 Assembly 9 Integrated 250 sheet paper tray ooo ooccoocoocrr 7 18 Assembly 10 Integrated 500 sheet paper tray 0 cece tee 7 20 Assembly 11 Drives Main drive and developer drive 0 0 e eee eee 7 22 Assembly 12 HolrolM JUSEF iiis sese terea de ESS ER qe adu A3 Qe e TU e pP dioe p RES 7 24 Assembly 13 TransfeUcharging ces coseno is ep E debe yeas 7 26 Assembly 14 Electronics power supplies 0 0 cee eens 7 28 Assembly 15 Electronics card assemblies ooooocooccrco 7 30 Assembly 16 Electronics shields eseeleseeee eee 7 32 viii Service Manual Assembly 17 Cabling diagrams 1 ooocccccoc eh 7 34 Assembly 18 Cabling diagrams 2 0 0c ccc rh 7 35 Assembly 19 Cabling diagrams 3 0 tenes 7 36 Assembly 20 Cabling diagrams 4 0 ccc e rh 7 38 Assembly 21 Cabling diagrams 5 0 cece tenets 7 40 Assembly 22 Optional 250 sheet paper drawer 0 0 0 cee lee eee 7 42 Assembly 23 Optional 250 sheet paper tray 0 cece tees 7 43 Assembly 24 Optional 500 sheet paper drawer 0 cece eee 7 44 Assembly 25 Optional 500 sheet paper tray 0 cece eee 7 45 Assembly 26 Duplex option couc
120. 2552 153 3 28 Disk Enep PTT 3 28 Font SNaAPENING ss ro a a e bd ds ba d erbe deu 3 29 LUGD BHODUIBSS ci cacaseansedaecapmides a cadens Rowe gene d 53 i dd eR Sd 3 29 LGB CONTAS oodd oi IA tee qus oo dai edu er mau dud dans 3 29 EXT COMI MENU uad ects seceded DLS Ie b doi ESLER LOS t P R RRL CREASE eS 3 29 Additional useful menu locations uia weak baa vides tiara bobo nivel RE eka ERE RR eae RR ew 3 29 A a abad cae NO bad ps 3 29 MENU senings PIO eripe pp d e Petia d Rs Wake Si dtd a qua edid dde GES 3 30 Printing menu settings Date ui Reden beiren earne RI EP E ERE Ed qp E qud RR aa 3 30 TACO caia d xe PX ed Roe RO CP RODA be OE pda rb Dub ee ib bol mee but ob a od adas 3 31 Autocompensator Operation iua dee aiiidh SIC QIPIPIP REPiadROR EE da Pid 3 pe 3 31 Autoconnect system paper tray options envelope feeder electrical oo oo ooo o 3 32 Putoconnecbbeabhrng and CONNECIONS 1 aia age 2 Liceo deor oR eR dg Ebo Sh qos ade HSS 3 32 Duplex OptiONicn ds cngedig radar drid SV FER Oe EE REGED e 3 32 ODOM IBI CIOCOUS 2623455 sed3eDPEOQRIQOZ RU RE I E Sqa qa ddgPqgdg dbi adden digi d 3 32 Paper teed ONIS caes Paar aeg a nen duced duke MP Hee P qupd Apu qi pp P qe UR 3 33 ALESES dobrs and MAYS As 3 33 Clearing priBter Iiis cod spice aras Y EPIO RADO RIA RE REA E ERR RR ERAT AA IAN 3 33 250 Paper Jam Check MP FOOD ero cire IA AAA dee 3 34 260 Pappr Jam Check Env Fed ics 1n zasp sy Le dob dor Pate nedacea he PIG qd Rd dude 3 35 2X
121. 29 Service error codes 9xx xx continued Error Sub EN code codes Display text Description Action 980 00 Unreliable comma to The engine is experiencing unreliable Service errors 980 thru 984 Paperport device communications to the specified device lt device gt can be one of the following system board duplex 981 00 Interface protocol The engine protocol violation detected by tray x 1 2 3 4 or 5 envelope violation by engine the specified device feeder or output bin 982 XX Paperport Communications error detected by the communication error specified device 983 00 Invalid command Invalid command received by the received by device specified device 984 00 Invalid command Invalid command parameter received by parameter received by the specified device device 990 00 General device Indicates an equipment check condition Service errors 980 thru 984 equipment check has occurred in the specified device but device can be one of the the device is unable to identify the exact following system board duplex component failure tray x 1 2 8 4 or 5 envelope feeder or output bin 991 00 Device system card The specified device has detected an failed basic assurance equipment check in its system card test 2 30 Service Manual User status displays Warning messages second lines These second line warnings apply to the user status displays see User statu
122. 3 22 EVENT LOG son due once 4 dobotulu 0 58 4 8 85 Deui dee Pp Eo eae e PR pede SO dC reda d dade 3 23 Display LOG ios eios e G04 Feo btoe CAS EE e 3 23 PEBEDOS s 2255 26856 dq d eg PRO iia dosis doer as dude postie 3 23 Clear LOG se sscepP 4 RRODTRTE OP HRBPERG HOP ER REPE ORE SI RRESARTERPIE Tee PERIERE Se 3 24 EXM DIAGNOSTICS 43459393 Wed edP E Od pe Wend PER dpi trance ds epee Rue dep cbe 3 24 Configuration menu CONFIG MENU oococcccc RI hh hh hn 3 25 Entering Configuration Menu ra decus d tt dotta tr daca a RA SU S mss dA Edi dae 3 25 Available MENUS iius se lescereqeeheeY RESO HM HG EEEE A b wee ep red perde ped 3 25 Maintenance page count Maint Cnt Value 00 cee tees 3 25 Maintenance page counter reset Reset Maint Cnt 0 2 ce eee ee eee 3 26 Print quality pages Prt Quality PQS scc 252b 24004046004 deron doe dere were a a eene we 3 26 SIZE SENSING otros ria Aa 3 27 Panel d m 3 27 PPDS Emblilatiol 5 3 5 1 R0 ri es n Sindee setae tot ds beaded ERR b hus 3 27 Downoad cio E PR 3 27 Deme MOGE senos ade teinte dodi Op RO eue s Dd dads UE ii ai 3 27 Factory Defaulls isbsspesicrrpettbesex pP PP EDEN a AAA Qe ees 3 28 Enemy CONSEN a a5 334 Coda dig bic ape De EP d du e d Pid bd Qi cs 3 28 EVENT LOG so cnpLLeqpe9ue RE X EE rr OEA chee eke hod eens GO EE P WP RR e 3 28 Paper EOS uri dendo edd Sih va tah Rai edet amoeboid dba 3 28 Env PIOMpts soria HEPEX ER RENI E 3 28 JOBS OmbpISE dai aiii rs is ais
123. 3 28 EVENT LOG 3 28 Factory Defaults 3 28 Font Sharpening 3 29 Jobs On Disk 3 28 LCD Brightness 3 29 LCD Contrast 3 29 Maint Cnt Value 3 25 Panel Menus 3 27 Paper Prompts 3 28 PPDS Emulation 3 27 Prt Quality Pgs 3 26 Reset Maint Cnt 3 26 SIZE SENSING 3 27 configurations models 1 2 connector locations autoconnect top 5 6 high voltage power supply HVPS 5 9 high capacity output stacker board 5 8 interconnect card 5 9 low voltage power supply LVPS 5 10 output expander 5 11 StapleSmart finisher 5 12 system board 5 1 cover closed switch 2 80 covers parts catalog 7 2 removals 4 4 D defaults EP defaults 3 22 factory defaults 3 28 US Non US defaults 3 20 deflector inner paper deflector assembly 4 47 MPF lower paper deflector 4 61 upper paper deflector assembly 4 79 Index l 1 developer drive assembly parts 7 22 removal 4 24 developer drive coupler kit 4 25 diagnostics mode 3 2 accessing 3 1 available tests 3 2 BASE SENSOR TEST 3 18 DEVICE TESTS Disk Test Clean 3 19 Flash Test 3 19 Quick Disk Test 3 18 DUPLEX TESTS Duplex Feed 1 3 12 Duplex Feed 2 3 12 Motor Test 3 11 Quick Test 3 9 Sensor Test 3 10 Top Margin 3 10 EP SETUP Charge Roll 3 22 EP Defaults 3 22 Fuser Page Count 3 22 Fuser Temp 3 22 Gap Adjust 3 22 Print Contrast 3 22 Transfer 3 22 Warm Up Time 3 22 EVENT LOG Clear Log 3 24 Display Log 3 23 Print Log 3 23 exiting 3 4 HARDWARE TESTS Button Test 3 7 CACHE Test
124. 4 44 Service Manual High voltage power supply removal CAUTION There is a danger from hazardous voltage in the area of the printer where you are working Unplug the printer before you begin or use caution if the printer must receive power in order to perform the task 1 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 47 2 Remove the right side cover See Right cover removal on page 4 8 3 Disconnect the HVPS cable from the HVPS at connector A 4 Disconnect the transfer roll cable B from the HVPS board Use care when disconnecting the cable from the transformer on the HVPS The cable and Warning connector can be easily damaged sosooo iia 299200278 025 aaa Repair information 4 45 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 46 Service Manual Inner paper deflector assembly removal 1 Remove the paper tray 2 Remove the upper paper deflector assembly See Upper paper deflector assembly removal on page 4 79 3 Remove the MPF lower deflector assembly See MPF lower paper deflector on page 4 61 4 Place the printer on its side 5 Gently pry the inner paper deflector from the left and right mounting posts A located on the bottom of the printer and remove the deflector 6 Disengage the two latches B on the upper part of the
125. 40X0165 5 Parts packet lower deflector mounting screw 12 mm PP 40X0165 5 1 Parts packet frame mounting screw PP 40X0165 6 40X0082 2 1 Pick roll shaft bushing 7 40X0083 1 1 Multipurpose feeder frame assembly with solenoid NS Parts packet pick roll shaft clip PP 40X0165 Parts catalog 7 15 ignment Paper feed ali Assembly 8 7 16 Service Manual Assembly 8 Paper feed alignment Asm Part Units Units kit Description Index number mach or pkg P 8 1 40X0084 1 1 Paper feed alignment assembly paper feed 2 Parts packet clip ref ground mounting screw PP 40X0165 3 40X0085 1 1 Reference ground clip 4 40X0086 Parts packet reference adjust Screw paper reference adjust 1 Washer paper reference adjust 1 Nut paper reference adjust 1 NS Parts packet alignment asm mounting screw PP 40X0165 Parts catalog 7 17 Page 7 19 has been removed from this document intentionally 7 18 Service Manual Assembly 10 Integrated 500 sheet paper tray 7 20 Service Manual Assembly 10 Integrated 500 sheet paper tray Asm Part Units Units kit Description Index number mach or pkg 10 1 40X0098 1 1 Tray assembly 500 sheet tray 2 40X0099 1 1 Side restraint 3 40X0182 4 1 Wear strip 4 40X0103 1 1 Pass thru plate 500 sheet tray 5 40X0183 1 1 Wear plate 500 sheet tray 6 40X0105 2 1 Restraint pad 7 40X0106 1 1 Back restraint
126. 41 Main fan with cable 500 sheet output yii Main fan 500 sheet 7 41 Part number index l 9 40X0055 40X0056 40X0057 40X0058 40X0059 40X0060 40X0061 40X0061 40X0062 40X0065 40X0066 40X0067 40X0068 40X0069 40X0070 40X0071 40X0072 40X0073 40X0074 40X0074 40X0075 40X0076 40X0077 40X0079 40X0082 40X0083 40X0083 40X0084 40X0085 40X0086 40X0087 40X0090 40X0091 40X0092 40X0093 40X0094 40X0098 40X0099 40X0103 40X0105 40X0106 40X0107 40X0110 40X01 11 40X0112 40X0113 40X0114 40X0115 40X0116 40X0117 40X0120 40X0121 40X0122 40X0123 40X0124 40X0125 40X0126 40X0127 40X0129 Left side frame ground contact llllc llell 77 Redrive door assembly 250 sheet 000 010 7 7 Output paper level flag 000 010 lllll lll ll lllll 7 7 Output paper level flag 200 210 400 410 77 Extension guide 22 2 eee eee enn nn nn nnn eee eee 7 7 External ground clip 7 5 Laser cable assembly eee eee 7 11 Laser printhead cable assembly lll cl ll 7 35 Printhead assembly includes all cables 7 11 Frame extension nut plate 200 210 400 410 urc llllcllllll
127. 5 00 Paper reached the duplex exit sensor but another sheet is still detected over the doublefeed sensor Double feed separated in duplex e Remove the two sheets from the duplex option and see if the duplex fails again Remove the sheets if it fails again e 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 12 If the tests fail 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 duplex option 236 00 Paper did not leave the duplex exit sensor Duplex jam access tray is not fully latched Printer PTO not driving duplex feed rolls Duplex feed system not working correctly 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 237 00 Paper did not reach the printer input sensor from the duplex unit Duplex jam access tray is not fully latched Printer PTO not driving the duplex feed folls Duplex feed system not working correctly Make sure the duplex jam access tray is installed correctly Make sure the power takeoff shaft and spring are
128. 7 5 Pick arm assembly 500 sheet 200 210 400 410 7 13 Pick arm assembly 250 sheet 000 010 7 13 Parts packet bellcrank assembly 250 sheet tray 000 010 7 13 Parts packet bellcrank assembly for 500 sheet tray 200 210 400 410 7 13 Pick roll assembly lllllll lll lll llllc 7 18 Paper out flag 250 sheet tray 000 010 743 Paper out flag 500 sheet tray 200 210 400 410 7 13 Paper low out sensor card assembly 7 13 Autocompensator motor cable lt lt 7 35 Paper size autocompensator cable 743 Multipurpose feeder arm assembly 7 15 Pick roll assembly 2 2 e sees eee een een nn nn eee eee 7 15 Multipurpose feeder paper out flag 7 15 Multipurpose feeder lower deflector assembly 5 7 15 Pick roll shaft bushing 7 15 Frame assembly with solenoid and cable c llclll ll 7 41 Multipurpose feeder frame assembly with solenoid 7 15 Paper feed alignment assembly paper feed 7 17 Reference ground
129. 81 XX Engine Code CRC Failure This error displays when the microcode to be programmed in the engine flash code module has failed a CRC check Press Y to clear the message The microcode data is discarded and must be re transmitted from the host computer 88 XX Toner Low This message displays when toner low occurs and the toner low alarm is activated Press Y to clear this message 1565 XX Emul Error Load Emul Option This message appears when the IPDS emulation version contained in the SIMM does not function with the printer code This message automatically clears in 30 seconds and the IPDS emulation is disabled No other printer functions are affected The correct IPDS emulation must be downloaded 2 42 Service Manual User line 2 link messages If the printer is locked on a particular link the link indication displays If the printer is ready to process any link no messages display Link messages are listed in the following table User message Explanation Parallel Standard Parallel Port if available Serial Standard Serial Port if available Serial x Serial Port is attached to PCI connector x where x 1 2 or 3 Network x Network card x is attached to PCI connector x where x21 2 or 3 LocalTalk x LocalTalk Card x is attached to PCI connector x where x 1 2 or 3 Infrared Standard Infrared port if available Infrared x Infrared Port x is
130. 9 999 Poor supply line voltage 922 22 Hot roll took too long to e Low wattage or incorrect lamp Go to 922 xx Cold fuser reach the beginning Bad thermistor circuit or cabling check on page 2 89 lamp detection a ne temperature Fuser Fuser not receiving sufficient AC page count between power 200 000 and 299 999 Poor supply line voltage 922 23 Hot roll reached final Low wattage or incorrect lamp Go to 922 xx Cold fuser lamp detection Bad thermistor circuit or cabling check on page 2 89 temperature but took a n longer than largest time e Fuser not receiving sufficient AC in lookup table Fuser power page count between P ly li Itaae 200 000 and 299 999 sc ee 922 24 Hot roll timed out in Low wattage or incorrect lamp Go to 922 xx Cold fuser trying to reach the final e Bad thermistor circuit or cabling check on page 2 89 lamp detection a A temperature Fuser Fuser not receiving sufficient AC page count between power 200 000 and 299 999 Poor supply line voltage 922 25 After hot roll lamp The control code has been lost Go to 922 xx Cold fuser detection did nat roll check on page 2 89 over to steady state control in time Fuser page count between 200 000 and 299 999 922 26 Hat roll did not reach Low wattage or incorrect lamp Go to 922 xx Cold fuser operating temperature in Bad thermistor circuit or cabling check on page 2 89 time new enhanced a un i
131. 9 999 oor supply ine 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 in temperature even service check on page 2 87 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 cabling Go to 920 xx Cold fuser the desired temperature e Very noisy thermistor signal service check on page 2 87 for too long while media y y E is in the nip Fuser page Fuser not receiving AC power count between 300 000 Poor supply line voltage and 399 999 Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll Abrupt change in temperatures that has disrupted control 920 Al Hot roll took too long to Bad thermistor circuit or cabling Go to 920 xx Cold fuser heat up after 3 a service check on page 2 87 transitioning to new Fuser not receiving AC power enhanced mode Fuser e Poor supply line voltage page count between eL It i t lamp 400 000 and 499 999 ow voltage or incorrect lamp Incorrect hot roll 2 12 Service Manual Service error codes 9xx xx continued Error Sub code cod s Display text Description Action 920 42 Hot roll fell too far below Bad thermistor circuit or cabling Go to 920 xx
132. CL Menu Front USB Print Quality Paper Loading Print Fonts HTML Menu Parallel Printing Guide Custom Types Print Directory Image Menu Parallel lt x gt Supplies Guide Universal Setup Serial lt x gt Media Guide Bin Setup NetWare Menu Map AppleTalk Information Guide LexLink Connection Guide Moving Guide Diagnostic information 2 3 Power On Self Test POST sequence When you turn the printer on it performs a Power On Self Test Check for correct POST functioning of the base printer by observing the following DUO qr Nes 11 12 13 14 15 Som The LED turns comes on The operator panel turns on A partial row of pixels are displayed The operator panel display clears Another row of pixels appears The operator panel display clears again The operator panel displays system information For example 128MB 449MH The fuser lamp turns on The fuser takes longer to warm up from a cold start than a warm start The operator panel LED starts blinking A clock face appears on the display If present the following errors or messages may display e Close Door orInsert Cartridge display if the upper front cover is open or the print cartridge is missing e Any cartridge errors such as Defective Cartridge Prebate Violation orMissing Cartridge Ready appears on the display The main fan turns on The main drive motor turns on The developer drive assembly drives the developer shaft in the toner cart
133. Cold fuser heat up after transitioning to new enhanced mode Fuser page count between 100 000 and 199 999 Very noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll service check on page 2 87 Diagnostic information 2 9 Service error codes 9xx xx continued Error Sub pode codes Display text Description Action 920 12 Hot roll fell too far below Bad thermistor circuit or cabling Go to 920 xx Cold fuser the desired temperature a service check on page 2 87 while printing Fuser Noisy thermistor signal page count between Fuser not receiving AC power 100 000 and 199 999 Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 13 Hot roll too cool while Bad thermistor circuit or cabling Go to 920 xx Cold fuser ore e Noisy thermistor signal service check on page 2 87 count between 100 000 Fuser not receiving AC power and 199 999 Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 14 Hot roll too cool when Bad thermistor circuit or cabling Go to 920 xx Cold fuser heating to desired A service check on page 2 87 temperature after slope Noisy thermistor signal change Fuser page Fuser not receiving AC power Eres 100 000 Poor supply line voltage s Low voltage or in
134. DD ao AJOJN Ground INPUTSENSX 5 V dc switched 11 5 V dc 12 TONER WHEELX 13 Ground Connector locations and connections 5 3 System board see System board on page 5 1 Connector Pin no Signal J16 Ethernet port 1 2 3 4 5 6 7 8 9 10 11 12 13 J17 Parallel port J18 Front bottom options 1 Ground 2 24 V dc OTC OPT J20 Transport motor BLDC_HALL 0 2 BLDC_HALL 1 3 BLDC_HALL 2 4 BLDC FG 5 Ground 6 5 V dc switched 7 BLDC WIND 8 BLDC WIND 1 9 BLDC WIND 2 J21 Autoconnect top 1 Ground 2 5 V dc fused 3 Ground 4 24 V de PTC OPT J23 MPF pick solenoid 1 MPF Pick 2 24V dc J24 Autocomp motor 1 24 V dc 2 AUTOCOMP J25 Autoconnect bottom front 1 Ground 2 24VPTCOPT 5 4 Service Manual System board see System board on page 5 1 Connector Pin no Signal J26 Paper size sensor autocomp motor J27 LVPS PSIZE2 Ground PSIZE1 PSIZE3 Ground TRAY1 POUT TRAY1 PLOW 3 3V dc OO CO NI OD oa BR wo My gt ENCODER o 5V dc 5 V dc 5 V dc 5 V dc Ground Ground Ground Ground Ground O CO N OD oO AJ OJN Ground Ground i o 24 V dc RAW E N Ground E 69 24 V dc RAW
135. Deflector spring Deflector cover Deflector cover spring Shaft assemblies Check all the bin parts for missing or loose springs binds in the deflector or deflector cover broken or binding shaft assemblies or broken gear teeth If incorrect repair as necessary 2 Bin x solenoid assembly Control board Check the solenoid for any binds Make sure the solenoid is contacting the latch correctly If incorrect repair as necessary If the solenoid appears to be operating mechanically check the resistance of the solenoid It measures between 30 and 50 ohms If incorrect replace the failing solenoid assembly If correct replace the control board 3 Mechanical linkage Motor assembly If the DC motor is functioning properly check the gears clutch and other linkage parts for correct operation and wear broken gear teeth or damaged parts If incorrect replace the mechanical linkage assembly DC motor assembly 990 xx Service Error displays FRU Action 1 Mechanical linkage DC motor assembly Check the DC motor cable connector to be sure it is correctly installed at J2 on the control board If correct disconnect J2 from the control board and check the resistance of the motor on the cable connector J2 1 to J2 2 measures between 115 and 135 ohms Also check J2 1 and J2 4 to the motor case for shorts If either the resistance is incorrect or a short is found replace the mechanical linkage DC motor assembly
136. Device Connections reattach message the user should reinstall an associated compatible option or hot unplug the option 59 XX Incompatible Envelope Feeder An incompatible envelope feeder is installed Remove the incompatible feeder and press Y to clear the message Note If the user installed the incompatible device to satisfy a Check Device Connections reattach message the user should reinstall an associated compatible option or hot unplug the option Diagnostic information 2 41 User attendance messages continued Error code Sub code Primary message Description action 59 XX Incompatible Tray x An incompatible tray is installed For Tray x x 2 3 4 or 5 Remove the incompatible tray and press Y to clear the message Note If the user installed the incompatible device to satisfy a Check Device Connections reattach message the user should reinstall an associated compatible option or hot unplug the option 59 XX Incompatible Duplex An incompatible duplex option is installed Remove the incompatible duplex option and press Y to clear the message Note If the user installed the incompatible device to satisfy a Check Device Comnections reattach message the user should reinstall an associated compatible option or hot unplug the option 59 XX Defective Disk This error code displays when the printer detects a defective disk This error may occur at
137. Exit sensor J6 Thermistor Connector locations and connections 5 7 High capacity output stacker board Connector Pin no Signal J6 connector jumper locations J1A Autoconnect 24 V dc Ground 5 V dc J1B U N Prtxdin Ground prtrxd Ground oy A Of N N C J2A Autoconnect a 24 V dc Ground 5 V dc J2B wo N prtxdout Ground prtrxd AJOJN Ground J3 Pass thru sensor Ground Paper Present RVsnsr J4 DC motor j N mtrout1 mtrout2 Ground Ground tach Oo Oo A OJN 5 V dc High capacity stacker board Pin 1 Pin 2 Pin 3 J5 Bin full near full dual sensor Ground Ground binful binful oy A Oj N RVsnsr Upper unit board X Not used Lower unit board Not used X J6 Jumper connector Upper unit N Upper Lower Unit Lower Unit 5 8 Service Manual High voltage power supply Connector CN no Signal CN1 System board 1 Developer PWM r a e AA 2 24 V dc Return El el all ll gl t 3 Charge PWM o9 od GobO 0 T302 3 T3 oT 73
138. If you have any doubts about the envelopes you are considering using check with the envelope supplier Load only one size of envelope at a time in the envelope feeder Acombination of high humidity over 60 and the high printing temperatures may seal the envelopes Labels Your printer can print on many labels designed for use with laser printers These labels are supplied in letter size A4 size and legal size sheets Label adhesives face sheet printable stock and topcoats must be able to withstand temperatures of 225 C 437 F and pressure of 25 pounds per square inch psi Try asample of any labels you are considering using with the printer before purchasing a large quantity Note Labels are one of the most difficult print media for laser printers All printer 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 printer feeding reliability 1 Print five sheets of paper 2 Wait approximately five seconds 3 Print five more sheets of paper When printing on labels e Setthe Paper Size Type menu item to Labels in the Paper Menu You can set the Paper Size Type from the printer operator panel the printer driver the Local Printer Setup Utility or from MarkVision e Do not load labels with paper or transparencies in the same source mixing p
139. J15 4 0 V dc Printer printing J15 1 O V dc to 5 V dc J15 2 O V dc to 4 V dc J15 4 O V dc to 41 9 V dc If J15 1 voltage is incorrect check the continuity of the front harness cable J15 1 line If there is no continuity replace the harness cable 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 O 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 Print quality banding Service tip Banding is difficult to detect except 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
140. 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 Health and Human Services 21 CFR Teil J f r Laserprodukte der Klasse I 1 In anderen L ndern gilt der Drucker als Laserprodukt der Klasse lI 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 lllb 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 er Wartung durch den Kundendienst Laserbestrah
141. M mismatch failure Warning When replacing any one of the following components e Operator panel assembly or upper front cover 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 can not 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 board with the part number in the table below Q0016003 0412000067 Model Board bar code Corresponds to P N 4061 000 non network Q0016021 40X0140 4061 010 network Q0016001 40X0141 4061 200 non network Q0016022 40X0142 4061 210 network Q0016002 40X0143 4061 400 non network Q0016023 40X0144 4061 410 network Q0016003 40X0145
142. N 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 FRU Action 1 Fuser lamp If the fuser is 220 V machine a 115 V fuser may be installed If the printer is 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 2 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 Diagnostic information 2 91 FRU Action 3 Fuser lamp Turn the printer off and allow the fuser assembly to cool After the fuser assembly cools down turn the printer on If you receive the same error code replace the fuser lamp See Fuser lamp removal on page 4 32 Note If the fuser lamp is replaced allow the fuser to cool or a 925 xx error could be displayed Fuser exit sensor service check If any of the fol
143. Note If the DC motor is shorted it may also be necessary to replace the control board 2 Control board Disconnect the motor cable J2 from the control board and check the voltages at J2 on the board Warning Use caution not to short adjacent pins on the connector as damage to the board could result Pin Measured motor idle J2 1 24 V dc J2 2 24 V dc J2 5 5 V dc J2 6 5 V dc If any of the voltages are incorrect replace the control board If correct replace the mechanical linkage DC motor assembly 2 74 Service Manual 900 xx Error code service check FRU Action 1 Printer POR Turn the printer off and on several times If Error Code 900 continues to display go to step 2 2 System board Turn the machine off and on several times waiting a few minutes between power on and power off If Error Code 900 continues to display go to step 3 3 Factory defaults Restore factory defaults See Factory Defaults on page 3 28 This resets the non critical areas of the user NVRAM If Error Code 900 continues to display go to step 4 4 Sub error codes With Error Code 900 displayed press Y and Record the complete list of Sub Error Codes on the display Check the Base printer sub error codes on page 2 9 If none of the Sub Error Codes are listed then call your next level of support or call Lexmark Diagnostic information 2 75 927
144. Output Expander This test is used to determine whether or not the output bin sensor is working correctly for the output expander if installed 1 Select Sensor Test from OUTPUT BIN TESTS Select Output Bin x x number of the output option to be tested from Sensor Tests The following screen is displayed Output Bin x passThru Open Full 0pen NearFull 0pen e passThru Pass thru sensor e Full Bin full sensor e NearFull Bin near full sensor Manually actuate each of the output expander sensors and the display by each sensor toggles from Open to Closed Press Back or Stop to exit the test Diagnostic aids 3 15 Sensor Test high capacity output stacker 1 Select Sensor Test from OUTPUT BIN TESTS 2 Select Output Bin x x number of the output option to be tested The following screen is displayed HC Binx TPzOPpassThru Open Full Open NearFull Open e TP High capacity top position sensor e passThru High capacity pass thru sensor Full High capacity bin full sensor lower part of dual sensor e NearFull High capacity bin near full sensor upper part of dual sensor 3 Manually actuate each of the sensors of the high capacity stacker and the display by each sensor toggles from Open to Closed 4 Press Back or Stop to exit the test Sensor Tests 5 bin mailbox 1 Select Sensor Tests from OUTPUT BIN TESTS 2 Select Output Bin x x number of the output option to be tested The followin
145. P N 12G9609 TOSHIBA RVICE MANUAL PRINTER e STUDIO 500P Edition June 2005 The following paragraph does not apply to any country where such provisions are inconsistent with local law Toshiba America Business Solutions PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you 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 Toshiba America Business Solutions 2 Musick Irvine CA 92618 Attn Service Training Toshiba may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can download copies of this manual from the Toshiba FYI website under Tech To Go In other countries contact your point of purchase MarkNet and MarkVision are trademarks of Lexmark International Inc Other trademarks are the property of their respective owners 2005 Toshiba America Business Solutions All rights reserved UNITED STATES
146. PWM Check autocompensator motor check on page 2 112 912 00 DC pick motor Check system board Go to Paper feed service underspeed error Check autocompensator check on page 2 112 913 00 DC pick motor Check system board Go to Paper feed service overspeed error Check autocompensator check on page 2 112 914 00 DC pick motor no Check autocompensator assembly Go to Paper feed service encoder feedback check on page 2 112 917 00 Problem with transfer Check HVPS Go to Transfer roll service check on page 2 128 2 8 Service Manual Service error codes 9xx xx continued Error Sub code cod s Display text Description Action 920 01 Hot roll took too long to Bad thermistor circuit or cabling Go to 920 xx Cold fuser heat up after Fuser not receiving sufficient AC service check on page 2 87 transitioning to new power enhanced mode standby control only Poor supply line voltage Fuser page count z between 0 and 99 999 Low wattage or incorrect lamp Incorrect hot roll 920 02 Hot roll fell too far below Bad thermistor circuit or cabling Go to 920 xx Cold fuser the desired temperature Fuser not receiving sufficient AC service check on page 2 87 while in standby Fuser power page between 0 and 99 999 Poor supply line voltage Low wattage or incorrect lamp Incorrect hot roll 920 03 Hot roll too cool when Bad thermistor circuit or
147. R A dens PRECES ER FER 4 62 Table of contents Vii Operator panel board remioVal siasii amato mE Robe a eR Rx a woe Rea e 4 66 Operator panel buttons removal iris eR ae ARR RERERRRAERSPREEKRRESRRRAEERRARSUERES 4 67 Outer shield TOMO Ell antes cores penetrate ara cic Aa qup ir Adana qub 4 67 Paper alignment assembly removal i scs secre Seon cede RR S abes a id 4 68 Paper bin full Sensor flag removal 22292222 be pr REET E de ee 4 70 Paper size sensing board removal 135243 53er ac ds dadde addons FR oes 4 71 Power takeoff shaft and spring removal 2 sse serm e eR epe pee ho dens 4 72 Primhgad tomova ere I HT dai a aai 4 73 Redrive assembly removal sesion rincon RAE ERI A 4 74 Signature button Contact assembly TeIiOVA se raros domed dian Ie id 4 75 System board and innershield removal ccasiadedicde gece seeees ead beer dqpeaedPdemakpekt 4 76 Toner SENSO FOlfoVal 25255 bed d ena ee ede EI See RICE MOERS Ke E eRe E dan 4 77 ianster roll assembly removal o vudxacuidesssesemdekpbipenudeL 4 idola bier dre aes 4 77 Upper front cover hinge assembly removal 244 n tear rr 4 78 Upper paper deflector assembly removal 52s2s 0c0scee8s0n ences iiiad ises CE ken RR e uis 4 79 USB board assembly removal c cie s 9 RR RR EIE cu es 4 80 Connector locations and connections 00 cece eee eee eee 5 1 CONNCCHONG P a a end eee oad aa 5 1 o a2uspe cu ROOMS o 3b RES EE MU ee E R pP bred eite Gaye rique eg ded 5 1 DBUIODODMIBOE dues eene AAA AS A A
148. RU Action 1 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 assembly or upper front cover 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 can not be used in another printer It must be returned to the manufacturer 2 104 Service Manual Main drive service check Service tip Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or System board Warning Whenever the gearbox assembly is removed from the machine it must be handled very carefully Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage It is also very important not to let any dirt paper staples or other material come intact with the grease i
149. Restraint pad 6 56P4195 1 1 Wear plate 500 sheet 7 56P4147 1 1 Back restraint 500 sheet tray Parts catalog 7 45 Assembly 26 Duplex option Asm Part Units Units kit Description Index number option or pkg P 26 1 1 20G0888 1 1 Duplex assembly 500 sheet 7 46 Service Manual Assembly 27 Envelope feeder 9 2 o o 2 T eB c S 29 amp 93 5 Q 90 Eg o o 2 Qoo b x ae salo T e 50 a5 El r ca 26 5 2 Oc N 210 T TEJI Q aja 1 X EB la va t Parts catalog 7 47 Pages 7 49 through 7 57 of this manual have been omitted intentionally 7 48 Service Manual Assembly 35 High capacity feeder 1 7 58 Service Manual Assembly 35 High capacity feeder 1 Asm Part Units Units kit Description Index number option or pkg 35 1 20G0892 1 1 Complete option assembly letter 1 56P4106 1 1 Complete option assembly A4 2 99A1818 1 1 Wear dimple strip 3 99A0681 4 1 Wear strip 4 56P4155 1 1 Front door assembly 5 56P4157 1 2 Door hinge 6 4 1 Parts packet 6 32 hinge mounting nut PP 99A0676 7 4 1 Parts packet hinge mounting flat washer PP 99A0677 8 4 1 Parts packet hinge mounting star washer PP 99A0677 9 56P4142 1 1 2000 sheet option control card assembly 10 4 4 Parts packet card asm mounting PP 99A0675 11 4 4 Parts packet card asm
150. STRATION 3 4 registration 3 4 relocation kit 7 69 removals bevel gear 4 21 cartridge duct 4 23 covers 4 4 fuser wiper cover assembly 4 4 laser cover 4 19 left and right frame extensions 4 17 left cover handle holder 4 16 left door 4 6 paper support removal 4 5 pass thru plate 4 18 redrive cap cover 4 5 redrive door 4 7 right cover handle holder 4 16 right cover removal 4 8 upper front cover 4 11 upper front cover latch 4 13 upper front cover outer bezel 4 14 developer drive assembly 4 24 developer drive coupler kit 4 25 ESD cover 4 25 fuser 4 26 fuser cover removal 4 41 fuser exit sensor 4 28 fuser exit sensor flag and spring 4 30 fuser lamp 4 32 fuser narrow media flag and spring 4 36 fuser narrow media sensor 4 34 fuser to LVPS AC cable 4 38 fuser transfer plate 4 43 gear release link 4 44 high voltage power supply 4 45 inner paper deflector assembly 4 47 inner shield 4 76 input sensor 4 48 integrated tray autocompensator assembly 4 49 integrated tray autocompensator pick roll assembly 4 51 interconnect card assembly 4 53 low voltage power supply LVPS 4 54 lower front cover assembly 4 15 lower paper deflector 4 61 main drive assembly 4 57 main fan 4 56 MPF arm assembly 4 60 MPF pick tire removal 4 62 MPF solenoid assembly 4 62 MPF lower front cover assembly 4 15 operator panel board removal 4 66 operator panel buttons 4 67 outer shield 4 67 paper alignment assembly 4 68 paper bin full sensor flag 4 70 paper size se
151. 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 Serial Wrap P HBHHHHHE F HERE e P 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 6F 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 The message Serial Wrap x Test Canceled displays and the printer returns to the HARDWARE TESTS menu DUPLEX TESTS Quick Test duplex This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the top margin on the back side of a duplex page You can run one duplexed page Single or continue printing duplexed pages Continuous until Stop 0 is pressed For information about changing the margin see Top Margin duplex on p
152. Service Manual Diagnostic information 2 125 System board service check Warning When replacing any one of the following components Operator panel assembly or upper front cover e System board assembly Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable 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 can not be used in another printer It must be returned to the manufacturer 2 126 Service Manual Toner sensor service check Service tip Check the print darkness menu setting before checking the toner sensor This service check is intended to be used when a 929 xx Service Error displays FRU Action 1 Developer drive assembly Incorrect operation of the developer drive assembly can cause the printer to display a 929 xx error code Toner Sensor Check the developer drive assembly for correct installation or any sign of worn loose or broken parts 2 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 c
153. This error code indicates a mismatch between the system board and the interconnect card FRU Action 1 Interconnect card assembly 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 2 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 3 Interconnect card assembly Replace the current interconnect card assembly with the original interconnect card assembly Interconnect card assembly removal on page 4 53 If the error remains go to step 5 2 78 Service Manual FRU Action 4 System board Replace the current system board with the original system board See System board and inner shield removal on page 4 76 If the error remains go to step 6 5 Interconnect card assembly Replace the original interconnect card assembly with a new and not previously installed interconnect card assembly If the problem remains contact the next level of support 6 System board Replace the original system board with a new and not previously installed system board If the problem remains contact the next level of support Charge roll service check Service tip Close and evenly spaced repetitive marks 47 19 mm 1 86 in apart or spots on the page
154. UTION The printhead is not a serviceable FRU Do not disassemble the printhead Parts catalog 7 11 Assembly 6 Paper feed autocompensator LOCUM wi AON Ps EN gt Y 7 12 Service Manual Assembly 6 Paper feed autocompensator Asm Part Units Units kit Description Index number mach _ or pkg 6 1 40X0066 1 1 Pick arm assembly 500 sheet 200 210 400 410 40X0067 1 1 Pick arm assembly 250 sheet 000 010 2 40X0068 1 1 Parts packet bellcrank assembly 250 sheet tray 000 010 Bellcrank 1 Spring 1 2 40X0069 1 1 Parts packet bellcrank assembly for 500 sheet tray 200 210 400 410 Bellcrank 1 Spring 1 3 40X0070 2 2 Pick roll assembly 4 40X0071 1 1 Paper out flag 250 sheet tray 000 010 4 40X0072 1 1 Paper out flag 500 sheet tray 200 210 400 410 5 40X0073 1 1 Paper low out sensor card assembly 6 Parts packet hanger PP 40X0165 7 40X0074 1 1 Paper size autocompensator cable Parts catalog 7 13 4061 xx0 Assembly 7 Paper feed multipurpose feeder 7 14 Service Manual Assembly 7 Paper feed multipurpose feeder Asm Part Units Units kit Description Index number mach or pkg 7 1 40X0079 1 1 Multipurpose feeder lower deflector assembly 2 40X0075 1 1 Multipurpose feeder arm assembly 3 40X0076 1 1 Pick roll assembly 4 40X0077 1 1 Multipurpose feeder paper out flag 5 Parts packet lower deflector mounting screw 8 mm PP
155. 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 92 202 53 Page is covering narrow f 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 stopped at covering the narrow media sensor paper or media mm to preserve The narrow media sensor or flag may ata be dislodged or damaged 202 54 Exit sensor may have Exit sensor assembly Go to Fuser exit sensor bounced Fuser page service check on page 2 92 count stopped at 500 000 to preserve data 202 56 Page is covering the exit Something is keeping the exit sensor ina Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media 2 64 Service Manual User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 202 90 Paper jam around the exit or redrive area Fuser page count is not available Page may be jammed in fuser e
156. a e Fuser is actually overheating due to hardware faults 923 91 Fuser over temperature Short in the thermistor circuit Go to 923 xx Hot fuser Fuser page count not service check on page 2 90 available Noisy thermistor signal l e Fuser is actually overheating due to hardware faults 924 01 Open thermistor check e Noisy thermistor signal Go to 924 xx Hot fuser dde M e Intermittent connection service check on page 2 91 99 999 e Thermistor cable not connected or thermistor actually open 924 11 Open thermistor check e Noisy thermistor signal Go to 924 xx Hot fuser failure Fuser page service check on page 2 91 count between 100 000 intermit nt connection and 199 999 e Thermistor cable not connected or thermistor actually open 924 21 Open thermistor check e Noisy thermistor signal Go to 924 xx Hot fuser failure Fuser page service check on page 2 91 count between 200 000 rer minent connection and 299 999 e Thermistor cable not connected or thermistor actually open 924 31 Open thermistor check e Noisy thermistor signal Go to 924 xx Hot fuser failure Fuser page count between 300 000 and 399 999 Intermittent connection e Thermistor cable not connected or thermistor actually open service check on page 2 91 Diagnostic information 2 21 Service error codes 9xx xx continued
157. a on page 1 18 Do not remove trays during a print job Push all trays in firmly 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 The printable area is limited to within 4 2 mm 0 167 in of all edges of the media Any information placed outside this specified printable area does not print Tools required Flat blade screwdrivers various sizes Phillips screwdrivers various sizes 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 General information 1 19 Acronyms BLDC CRU CSU DIMM DRAM DVM EDO EEPROM EP EPROM ESD FRU GB HCIT HVPS ITC LASER LCD LED LVPS MPF MROM MS NVRAM OEM OPT PC pel POR POST PP PWM RIP ROM SDRAM SIMM SRAM UAT UPR V ac V dc VOM 1 20 Service Manual Brushless DC motor Customer Replaceable Unit Customer setup Dual Inline Memory Module Dynamic Random Access Memory Digital multimeter Enhanced Data Out Electrically Erasable Programable Read Only Memory Electrophotographic process Erasable Programmable Read Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte High capacity Input Tray High Voltage Power Supply Internal Tray C
158. a 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 Printer not printing no media over sensors Printer printing 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 FRU Action 1 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 2 if the narrow media sensor does not pass the test go to step 5 2 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 3 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 34 4 Fuser assembly Check the continuity
159. able If incorrect repair as necessary If correct check to make sure the lower pass thru sensor is correctly connected to J3 on the lower control board Disconnect the pass thru sensor cable and check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect check the voltage at J3 2 The voltage measures approximately O V dc If incorrect replace the sensor assembly If this does not fix the problem replace the high capacity output stacker option Remove Paper Output Bin x Full displays you may not be able to clear the message FRU Action 1 Dual output bin sensor flag Check the flag for correct operation binding broken parts or upper assembly interference from the sensor cable If incorrect repair as necessary Diagnostic information 2 101 271 xx Paper Jam Check Bin x POST incomplete FRU Action 1 Upper pass thru sensor flag Check the flag for correct operation binding broken parts or assembly interference from the sensor cable If incorrect repair as necessary If correct make sure the lower pass thru sensor is correctly connected Upper control board to J3 on the lower control board Disconnect the pass thru sensor cable and check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect check the voltage at J3 2 The voltage measures approximately O V dc If incorrect replace the sensor assembly If this does not fix the problem
160. ack the envelopes 4 Load the envelope feeder 5 Adjust the guide 6 Lower the envelope weight 7 Press Y Diagnostic aids 3 35 23x and 24x jams Paper jams in these areas can occur on the incline surface of a tray or across more than one tray To clear these areas 1 Open the printer paper tray and remove any jammed media 2 Open the duplex tray To remove the media pull up 3 Open any optional trays beginning at the top and remove any jammed media Pull the print media either up or down If it does not pull easily one way try the other way 3 36 Service Manual 4 If you have an optional 2000 sheet feeder open the front door press the elevator button A to lower the tray remove the jam and make sure the stack of print media is neat and aligned 5 Press Y 200 and 201 Paper Jam Remove Cartridge 1 Push the release latch and lower the multipurpose feeder 2 Push the release latch and open the top front cover CAUTION The inside of the printer is hot Diagnostic aids 3 37 3 Lift and pull the print cartridge out of the printer Warning Do not touch the photoconductor drum on the underside of the cartridge Use the cartridge handle whenever you are holding the cartridge 4 Place the print cartridge aside Note Do not leave the cartridge exposed to light for extended periods Note The print media may be covered with unfused toner which can stain garments and s
161. after replacing the operator panel go to 950 00 through 950 29 EPROM mismatch failure on page 2 77 2 System board Disconnect the operator panel cable from J13 on the system board and measure the voltage at J13 5 The voltage should measure Operator panel poard approximately 3 3 V dc If incorrect replace the system board See Upper front cover hinge System board and inner shield removal on page 4 76 If assembly correct replace the operator panel board See Operator panel board removal on page 4 66 If this does not fix the problem check the operator panel cable If a problem is found replace the upper front cover hinge assembly See Upper front cover hinge assembly removal on page 4 78 No buttons work FRU Action 1 Operator panel board If none of the buttons work replace the operator panel board see Operator panel board removal on page 4 66 If a 950 xx error code is displayed after replacing the operator panel go to 950 00 through 950 29 EPROM mismatch failure on page 2 77 2 106 Service Manual Operator panel display Service tip The printer has detected a problem with the system board the operator panel cable part of the upper front cover hinge assembly or the operator panel board if POST does not complete the printer emits 5 beeps and stops in a continuous pattern until the printer is turned off Note If the operator panel is operating properly e
162. ag until you are ready to install the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair information 4 1 Adjustment procedures Fuser solenoid adjustment Perform the fuser solenoid adjustment when
163. age 3 10 Note Before you set the duplex top margin be sure to set the registration See REGISTRATION on page 3 4 The paper you choose to print the page on should be either Letter or A4 To run the Quick Test duplex 1 Select Quick Test from DUPLEX TESTS 2 Select Single or Continuous The single Duplex Quick test cannot be canceled 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 Diagnostic aids 3 9 Top Margin duplex This setting controls the offset between the first scan line on the front of the duplex page and the first scan line on the back of the page Therefore be sure to set the top margin in REGISTRATION before setting the duplex top margin See REGISTRATION on page 3 4 To set the Top Margin duplex 1 Print the Quick Test duplex 8 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 W or A to select the margin setting
164. age displays when the user should change the media installed in one of the input options e input source Tray 1 Tray 2 Tray 3 Tray 4 Tray 5 MPF Feeder Envelope Feeder e Custom Type name gt Custom 1 through Custom 6 using the MarkVision utility When the printer is prompting for one of the custom types which has been named by the user then only the custom type name is displayed on line 2 The name may be truncated to fit the display Change input source custom string This message displays when the user should change the media installed in one of the input options e input source Tray 1 Tray 2 Tray 3 Tray 4 Tray 5 MPF Feeder Envelope Feeder custom string a user definable name Change input source size This message displays when the user should change the media installed in one of the input options e input source Tray 1 Tray 2 Tray 3 Tray 4 Tray 5 MPF Feeder Envelope Feeder lt size gt letter legal B5 A4 Executive Universal A5 B4 A3 11x17 Folio or Statement For envelopes lt size gt 7 Envelope 9 Envelope 10 Envelope DL Envelope C5 Envelope B5 Envelope or other Envelope Change input source lt type gt lt size gt This message displays when the user should change the media installed in one of the input options input source gt Tray 1 Tray 2 Tray 3 Tray 4 Tray 5 MPF Feeder Envelope Feeder lt t
165. aid 23 ame stad ne eagle Sid ebd da edd REESE OQ eS pd etn eee pepe 3 36 200 and 201 Paper Jam Remove Cartridge 0 cee et eee eee 3 37 Vi Service Manual 202 Paper Jam Open Bear DO used eb ecu a re duce Eden a REGE S 3 39 23x Paper Jam Open Duplex Rear DOOLz ii e dL RR EHE VERS EEESUREREA HERR EPIS 3 40 2 0 and 280 Paper dates acnded lt aindcane decie dane wR ae ds Seruius ana 3 41 27X Paper Jam Check Bit X usse aids a 3 41 28x Paper Jam Check Finisher ease serbe pd be I REESE eee 3 42 Repair Lit 1 read wa rra RII e eer ee re 4 1 Handling ESD sernsilive parts 4 225244 43 25h kr ka d Rab Rn dE RR a eels a 4 1 Adjustment procedures assa ok RR OR IR REOR RCACR ara ER eR CRGO ea ER A 4 2 Fusersolendid adjustment sesi n basis FEIRRIDEEPEA EE rre 4 2 Cp CONUS ou aaoo rer tun eda wench eade a Vd dard du diede ddp qnd RU beg 4 2 Punthead assembly ASTM x aues Pies For Joe beaded eee FORE EORR acie good bur d 4 2 Paper altgninenr assembly adjustment ox acp oper pr ea tr REDE Pra Sed Puer ITE E INC S 4 3 Removal procedures 269235245 xx349X3 LAS fo 0 Db A 4 4 Covers TOM NAIS doce dee dax Meas dE dd a sad Md 4 4 Fuser wiper cover assembly removal cisco danio tancep ade en adres a 4 4 Redrive cap cover TemoVval ss src ri E PRSE RA VET qr PES 4 5 Paper support removal idi quede ade DRE rs edd eddie Sagen A 4 5 Eett door removal cid e eh HIR REURGHEEAN T ERSETR ORES ERRARE e P OE SS 4 6 Fade HON a is ad Arp ndiegsc sete earn
166. an duct 000 010 lt lt ence nen newness 7 7 Main fan duct 200 210 400 410 7 7 Tray bias assembly 2 22 2222 eee eee ee eee eee eee ee eee 7 9 LVPS 220 V ac 200 210 400 410 2 2 ee nnn nn eee eee eee ene eeee 7 29 Part number index I 11 40X0222 40X0223 40X0224 40X0225 40X0226 40X0227 40X0229 40X0232 40X0233 40X0234 40X0235 40X0235 40X0236 40X0238 40X0239 40X0241 40X0248 40X0248 40X0249 40X0250 40X0251 40X0252 40X0255 40X0256 40X0257 40X0258 40X0259 40X0260 40X0263 40X0264 40X0265 40X0266 40X0267 40X0271 40X0281 40X0285 40X0290 40X0291 40X0292 40X0293 40X0294 40X0295 40X0301 40X0302 40X0303 40X0304 40X0305 40X0306 40X0330 40X0331 40X1375 40X1376 40X1377 40X1378 40X1379 40X1508 40X1509 40X1510 40X1512 Outer shield 1 slot 000 010 502 220 e ee eee ee eee 7 33 HPVS input sensor toner sensor cable assembly 7 9 7 29 7 34 7 37 LVPS to system board cable assembly l lll 7 37 Right side hand holder 2 2 2222 see ee ee een ee eee ee eee eee 7 5 Fuser AC to fuser lamp cable 2 2 222 c cece cree eee ence ene ce eeees 7 25 7 39 Parts packet fuser mounting screw 7 25 Narrow media sensor cable 2 22 2222 ee eee eee eee eee eee eee ee eens 7 25 Redrive door assembly 500 sheet 2
167. an extended time Fuser page count not available 920 97 Fuser has been below Bad thermistor circuit or cabling Go to 920 xx Cold fuser the desired temperature service check on page 2 87 for too long while media Very noisy termistor signal is in the nip Fuser page e Fuser not receiving AC power count not available Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Abrupt change in temperatures that has disrupted control 922 02 Hot roll took too long to Low wattage or incorrect lamp Go to 922 xx Cold fuser reach the beginning lamp detection temperature Fuser page count between 0 and 99 999 Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage check on page 2 89 Diagnostic information 2 15 Service error codes 9xx xx continued Error Sub code codes Display text Description Action 922 03 Hot roll reached final Low wattage or incorrect lamp Go to 922 xx Cold fuser lamp detection T check on page 2 89 temperature but took Bad thermistor circuit or cabling longer than largest time e Fuser not receiving sufficient AC in lookup table Fuser power page count between 0 and 99 999 Poor supply line voltage 922 04 Hot roll timed out in Low wattage or incorrect lamp Go to 922 xx Cold fuser trying to reach the f
168. 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 28 4 Fuser assembly Fuser exit sensor cable Fuser board Fuser to system board cable System board Check the continuity of the fuser exit sensor cable If incorrect replace the cable if correct check the continuity of the fuser to system board cable If incorrect replace the cable in correct replace the following FRUs in the order shown Fuser board Fuser assembly See Fuser assembly removal on page 4 26 e System board See System board and inner shield removal on page 4 76 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 2 92 Service Manual Fuser narrow media sensor service check If any of the following error codes are displayed a problem may exist in the are
169. annot be cleared go to Input tray s service check on page 2 102 Load Staples This message displays when the Staples Empty Alarm is activated and one of the following occurs There are no staples in the stapler The maximum number of staples have been fired after the engine has reported that the staple cartridge is low The printer does not detect the staple cartridge is present The following actions may be taken Install a new staple cartridge to clear this message and select Start or Continue to resume printing the staple job Choose to ignore the Load Staples message for this print job by pressing Y The printer starts or resumes printing but does not staple the rest of the job Press 2 until Busy Waiting displays The following actions may be available Cancel Job Reset Printer Reset Active Bin Priming Failed Retry Go Stop This message displays when an error has occurred during the staple priming operation This message not only notifies the user that a specific error interfered with the priming but allows the user to request the process begin again The following actions are available Press Y to restart the priming operation Press Y or to cancel the priming operation 2 36 Service Manual User attendance messages continued Error Sub A Par code Bode Primary message Description action Reattach Bins x y Bins 1 to 5 Bins 2 to 6 or Bins
170. aper in the high capacity feeder input tray FRU Action 1 Paper out sensor flag 2 Paper out sensor on option system board Check the paper out sensor flag for correct operation and installation If correct replace the high capacity feeder system board The paper out sensor is mounted on the high capacity feeder system board The elevator tray fails to stop at the correct position and continues to drive into the bottom frame FRU Action 1 Lower limit switch Lower limit switch cable Check continuity of the lower limit switch If incorrect replace the Switch If correct check the switch cable If incorrect replace the cable If correct replace the high capacity feeder option control board 2 High capacity feeder control board Disconnect the lower limit switch cable and check the voltage at J2 1 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 door 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 FRU Action 1 Lower limit switch Lower limit switch cable High capacity feeder control board Check the lower l
171. ard Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light Emitting Diode Low Voltage Power Supply Multipurpose feeder Masked Read Only Memory Microswitch Nonvolatile Random Access Memory Original Equipment Manufacturer Optical Sensor Photoconductor Picture element Power On Reset Power On Self Test Parts Packet Pulse Width Modulation Raster Imaging Processor Read Only Memory Synchronous Dynamic Random Access Memory Single Inline Memory Module Static Random Access Memory Universally Adjustable Tray Used Parts Return Volts alternating current Volts direct current Volt Ohmmeter 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 Power On Self Test POST sequence on page 2 4 without an error and you have a symptom go to Symptom tab
172. 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 assembly 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 o
173. as i kean IAEA REPRE A da ET UP DRE YS 1 8 Selacund DIT MSHA awd oe tiradas had hee Hee P dS Saab aar uw EA head Pee ers 1 15 ac gc C mrTT 1 15 Paper chace CS c udo verbe o Pore ee eee means eames 1 15 MBIDIIE rad dida 1 15 Unacceptable paper e seb EUR ria Ar 1 15 TWANSDAIRNCIES a 24 053 ai edat RAG KES RECALL RCE dq ede EP d RES 1 16 Selecting traBsparencleS ie detcd x rae Ix RR RE EUROPE fried it enr at heud orea S EN RS 1 16 ENVIOS ainia TTE 1 16 LS ic tri A AAA AA 1 17 Card SOCR ERST 1 18 Stoning piate dido P PET 1 18 AVOIMIA carece ed gm rd sqq dd 1 19 PUNA cec 1 19 TOGIS FBOUIFGU udaendordx i dace ado CR oo AAA Mak AAA 1 19 ACCION dais TR LI 1 215 5 115 21115 1 0 1101 ia diia daa 1 20 Diagnostic information au xx qe dei dca cO dC RR Road CR RCRCAC AA 2 1 ICA ER eee cree ILL V LS TCC III Te 125 5 eee 2275 desa ds 2 1 Symptom tabl S cide dee ree EIA AA 2 1 Service errors ORK MS i idu dequo be Shee ase dG eda wibpucb e eb deb dpud d a 2 1 User status and attendance Messages 2 4 0 60400 eo Re err a 2 1 Peste nredu u P PC PPP HEURE 2 1 Understanding the printer operator panel wo c2ccc aee hk kon RR eed XE RR 2 2 Understanding ements sobren PCE AEE EAMES HOSE ee Lake dede ad 2 3 Power On Self Test POST sequence 0 0 0 cece eet eee eee eee e nee e enone 2 4 Table of contents _ iii Symptom table amp eric aoo de ea a KE ORO o eR OR RR an RA KR D CER RE CN Rn 2 5 Base priter eo H
174. autoconnects cables and connectors of the option for any feeder signs of loose or damaged parts 2 High capacity output Remove the left and right side covers and check all four stacker mechanical linkage autoconnects for damage especially the connector pins Remove the assembly output option and check the voltages on the standard output bin autoconnect located on the top left rear of the printer Go to Autoconnect on page 5 6 If the voltages are correct reinstall the output option and note the positions of the toroids on the autoconnect cables on the upper and lower assemblies and check the voltages on the autoconnects If all voltages are correct and the lower assembly is failing replace the lower control board Otherwise replace the High capacity output stacker option 202 xx Paper Jam Open Rear Door displays and a sheet of paper is jammed prior to the pass thru sensor flag or 202 xx Paper Jam Open Rear Door displays a sheet of paper feeds out to the standard bin even though bin x is selected and paper exits half way out of the redrive assembly Service tip For this type of problem check the Base printer sub error codes on page 2 9 They can help isolate the problem A 202 paper jam message can also occur prior to the high capacity output stacker pass thru sensors FRU Action 1 Lower Pass Thru Sensor Check the flag for correct operation binding broken parts or Flag Assembly interference from the sensor c
175. 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 can not be used in another printer It must be returned to the manufacturer Open the lower front cover Open the upper front cover Remove the screw A holding the upper front cover outer bezel to the hinge Remove the two screws B that hold the upper front cover to the hinge assembly p o N B A B 5 Liftthe upper front cover and pull forward to release the four tabs holding the upper front cover Repair information 4 11 6 Disconnect the cables Note It may be necessary to remove the operator panel cable from the cable clip C to be able to disconnect the cable from the operator panel E 7 Remove the upper front cover Note If you are replacing the upper front cover remove the upper front cover outer bezel and upper front cover latch Otherwise carefully set the upper front cover aside to avoid scratching the bezel or loosening the latch and spring Note When removing the upper front cover outer bezel use care not to lose or drop the clear plastic inner bezel Installation notes Lift the
176. bin that is displaying the message to make sure the sensor is seated correctly in the side of the tray and the cable is connected to the sensor and the control board Check the flag for binding and proper operation If correct replace the bin x sensor If this does not fix the problem replace the control board Note This sensor is in a normally open position with the flag out of the sensor slot Bin x is Full message that bin x is full does not display FRU Action Bin x sensor Bin x sensor cable Bin x sensor flag Bin x sensor flag Control board Check the sensor flag for binds broken or missing parts If correct check the bin sensor for correct installation in the side of the tray If the bin sensor is installed correctly check the sensor cable for correct installation to the sensor and control board If correct replace the bin x sensor If this does not fix the problem replace the control board Diagnostic information 2 73 Ready Bin x Full displays and paper feeds into bin x FRU Action 1 Bin x sensor Bin x sensor control board Check the sensor flag for binds Make sure the sensor flag is not in an up position If the sensor flag is operating correctly replace the bin x sensor If this does not fix the problem replace the control board 271 xx Paper Jam Check Bin 1 displays paper does not feed into the bin selected FRU Action 1 Deflector
177. 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 FRU Action 1 Charge roll assembly Check the charge roll for correct installation toner buildup marks cuts or other signs of contamination or damage Replace as necessary 2 Leftside charge roll link Check the left side charge roll link assembly for correct assembly operation Check for damage to the arm or bearing assembly 3 Right side charge roll link Right charge roll bushing Check the right side charge roll link assembly for correct assembly operation If incorrect replace the charge roll link assembly with the 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 r
178. capacty StapleS martF inis her Executive 184 2 x 266 7 mm 7 25 x 10 5 in la Multipurpose feeder Folio 216 x 330 mm 8 5 x 13 in 59 9 a 9 a Statement 139 7 x 215 9 mm 5 5 x 8 5 in Ei Ei Ei Universal 3 139 7 x 210 mm to 215 9 x 355 6 mm 5 5 x 8 27 in to 8 5 x 14 in 69 85 x 127 mm to 215 9 x 355 6 mm 2 75 x 5 in to 8 5 x 14 in 148 x 182 mm to 215 9 x 355 6 mm 5 83 x 7 17 in to8 5 x 14 in 76 2x 127 mm to 215 9 x 355 6 mm 3x5 in to 8 5 x 14 in 76 2x 177 8 mm to 215 9 x 355 6 mm 3x7 in to 8 5 x 14 in 7 34 Envelope 98 4 x 190 5 mm 3 875 x 7 5 in 9 Envelope 98 4 x 225 4 mm 3 875 x 8 9 in 10 Envelope 104 8 x 241 3 mm 4 12 x 9 5 in DL Envelope C5 Envelope B5 Envelope General information 1 9 Print media sizes continued z 5 2 als o o Q c Print media i m 3 S 2 5 3 size Dimensions v z 5 B 5 UE UAT universally a e olola X indicates vVio v 5 adjustable tray Ks oler 2 zl 3 support alov c 3 E 2 amp 5 2 c alv 2 313 E 8225 5 B TA z S La a un Other 98 4 x 162 mm X X X Envelope1 to 176 x 250 mm 3 87 x 6 38 in to 6 93 x 9 84 in 98 4 x 162 mm X X X to 229 x 342 mm 3 87 x 6 38 in to 9 01x 12 76 in Thi
179. ce normal motor start check on page 2 105 Motor is type 1 Gear binds e Defective motor e Defective motor cable e Cable connections 936 9 Stall detected during Defective cable Go to Main drive service speed control Motor is e Check cable connections check on page 2 105 type 0 i Defective motor Paper jams 936 91 Stall detected during Defective cable Go to Main drive service speed control Motor is type 1 Check cable connections Defective motor Paper jams check on page 2 105 Diagnostic information 2 25 Service error codes 9xx xx continued Error Sub ae code codes Display text Description Action 937 4 Overspeed detected Faulty motor sensor Go to Main drive service during speed control check on page 2 105 Motor is type 0 Faulty system board 937 41 Overspeed detected Faulty motor sensor Go to Main drive service during speed control 2 check on page 2 105 Motor is type 1 Faulty system board 937 5 Overspeed detected Faulty motor sensor Go to Main drive service during position control E check on page 2 105 Motor is type 0 Faulty system board 937 51 Overspeed detected Faulty motor sensor Go to Main drive service during position control E check on page 2 105 Motor is type 1 Faulty system board 937 7 Loss of lock detected by Defective motor cable Go to Main drive service higher level c
180. cient AC in lookup table Fuser power page count not i Available Poor supply line voltage 922 94 Hot roll timed out in e Low wattage or incorrect lamp Go to 922 xx Cold fuser trying to reach the final re check on page 2 89 lamp detection Bad thermistor circuit or cabling temperature Fuser e Fuser not receiving sufficient AC page count not power available Poor supply line voltage 922 95 After hot roll lamp Control code has been lost Go to 922 xx Cold fuser detection did not roll check on page 2 89 over to steady state control in time Fuser page count not available 922 96 Hot roll did not reach Low wattage or incorrect lamp Go to 922 xx Cold fuser operating temperature in TENE check on page 2 89 time new enhanced Bad thermistor circuit oi cabling control Fuser page Fuser not receiving sufficient AC count not available power Poor supply line voltage 922 97 Fuser has taken too long Low wattage or incorrect lamp Go to 922 xx Cold fuser to reach desired temperature after increasing interpage gap Fuser page count not available Excessive load on the fuser Fuser not receiving sufficient AC power Poor supply line voltage check on page 2 89 2 20 Service Manual Service error codes 9xx xx continued Error Sub icr A Act code cod s Display text Description ction 923 01 F
181. ck on page 2 89 temperature after Bad thermistor circuit or cabling increasing interpage Excessive load on the fuser gap Fuser page count A ivi iei between 400 000 and ed not receiving sufficient AC 499 999 i Poor supply line voltage 922 52 Hot oe too long to Low wattage or incorrect lamp Go to 922 xx Cold fuser reach the beginning check on page 2 89 lamp detection Bad thermistor circuit or cabling temperature Fuser e Fuser not receiving sufficient AC page count stopped at power 500 000 to preserve Poor supply line voltage data 922 53 a de reached final Low wattage or incorrect lamp Go to 922 xx Cold fuser amp detection ati check on page 2 89 temperature but took Bad thermistor circuit or cabling longer than largest time e Fuser not receiving sufficient AC in lookup table Fuser power page count stopped at 500 000 to preserve Poor supply line voltage data 922 54 Hot roll OE n Low wattage or incorrect lamp Go to 922 xx Cold fuser trying to reach the fina e ati check on page 2 89 lamp detection Bad thermistor circuit or cabling temperature Fuser Fuser not receiving sufficient AC page count stopped at power 500 000 to preserve Poor supply line voltage data 922 55 After hot roll lamp The control code has been lost Go to 922 xx Cold fuser detection did not roll over to steady state control in time Fuser page count stopped
182. clip 9 2 2222 ene enn ne eee eee eee 7 17 Parts packet reference adjust 7 17 Integrated 250 sheet tray 7 19 Back restraint 250 sheet tray ll 7 19 Restraint pad 2 2 sence enn nn nnn nn nee ee ee 7 19 Side restraint 250 sheet tray 2 22 22 eee ee ee ene eee ee eee eee 7 19 Wear strips 22 ee enn nnn nn nn ee nM 7 19 Wear plate 250 sheet tray 2 2 2222 eee een ee ee eee eee eee 7 19 Tray assembly 500 sheet tray lllllllll 7 21 Side restraint lt lt ooo 7 21 Pass thru plate 500 sheet tray 7 21 Restraint pad rrlrlrllllllll 7 21 Back restraint 2 2 ee eee nn nnn nnn nn nnn ene 7 21 Gearbox with motor 0 2 2 2222 2 ee eee eee eee eee eee eee eeee 7 23 Power takeoff shaft 250 sheet 000 010 7 23 Power takeoff shaft 500 sheet 200 210 400 410 7 23 Power takeoff shaft spring llcl llllcl ll 7 23 Bevel gear with grease packet and washer 7 23 Developer drive assembly lll 7 38 Parts packet developer drive 7 23 Fuser assembly w 115 V lamp 000 010 2
183. control Fuser page e Fuser not receiving sufficient AC count between 200 000 power and 299 999 Poor supply line voltage 922 27 Fuser has taken too long Low wattage or incorrect lamp Go to 922 xx Cold fuser to reach desired temperature after increasing interpage gap Fuser page count between 200 000 and 299 999 Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage check on page 2 89 Diagnostic information 2 17 Service error codes 9xx xx continued Error Sub 2 z pode codes Display text Description Action 922 32 Hot aa too long to Low wattage or incorrect lamp Go to 922 xx Cold fuser reach the beginning T check on page 2 89 lamp detection Bad thermistor circuit or cabling temperature Fuser Fuser not receiving sufficient AC page count between power 300 000 and 399 999 Poor supply line voltage 922 33 ER de reached final Low wattage or incorrect lamp Go to 922 xx Cold fuser amp detection TT check on page 2 89 temperature but took Bad thermistor circuit or cabling longer than largest time Fuser not receiving sufficient AC in lookup table Fuser power page count between i 300 000 and 399 999 Poor supply line voltage 922 34 Hot roll ines oo n Low wattage or incorrect lamp Go to 922 xx Cold fuser trying to reach the fina
184. correct lamp Incorrect hot roll 920 16 Fuser is not increasing Fuser is not receiving AC power Go to 920 xx Cold fuser Noua cdam bas e Poor supply line voltage service check on page 2 87 been on for an extended time Fuser page count between 100 000 and 199 999 920 AZ Fuser has been below Bad thermistor circuit or cabling Go to 920 xx Cold fuser od ees e Very noisy thermistor signal service check on page 2 87 media is in the nip Fuser not receiving AC power Sera rar and Poor supply line voltage 199 999 Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll Abrupt change in temperature that has disrupted control 920 21 Hot roll took too long to Bad thermistor circuit or cabling Go to 920 xx Cold fuser heat up after transitioning to new enhanced mode Fuser page count between 200 000 and 299 999 Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll service check on page 2 87 2 10 Service Manual Service error codes 9xx xx continued Error Sub code cod s Display text Description Action 920 22 Hot roll fell too far below Bad thermistor circuit or cabling Go to 920 xx Cold fuser MEUM ET e Noisy thermistor signal service check on page 2 87 page count between Fuser not receiving AC power 200 000 and 299 999 Po
185. creased the bar appears lighter Changes to this setting immediately change the operator panel The range of values is between 1 and 10 and the default value is 5 Exit Config Menu Press Y to exit the CONFIG MENU The message Resetting the Printer displays and the printer performs a POR and restarts in normal mode Additional useful menu locations User menus are available from the Ready state by pressing Menu 6 Hex Trace To turn Hex Trace on Press Menu to display Menus Press W until the Y appears next to Settings Press O Press W until the Y appears next to Utilities Menu Press Y Press W until the appears next to Hex Trace Press e Press Y again to select Activate or press Back to return to Utilities Menu without activating Hex Trace p O N Sr Ge 0N A Diagnostic aids 3 29 Menu settings page You can print a menu settings page to review the default printer settings and to verify your printer options are installed correctly Press Menu amp to display Menus Press until the WY appears next to Reports Press e Press W until the y appears nextto Menu Settings Page Press e The message Printing Menus Settings appears on the display mo I xm The printer returns to the Ready state after the menu settings page prints Printing menu settings page Note This test page must be printed on letter legal or A4 paper To print the Menu Settings Page 1 Select the TESTS MENU 2
186. cs 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 the 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 FRU Action 1 DC motor assembly Make sure all the motor plate mounting screws are tight 2 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 3 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 4 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
187. d Engine Setting 3 The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 93 2 52 Service Manual User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 202 00 Paper jam at fuser exit or redrive area Fuser page count between 0 and 99 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce W curl 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 92 202 01 Page did not cleanly exit fuser or redrive area Fuser page count between 0 and 99 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly remo
188. d 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 O through 9 and A through F Note When the printer detects a Configuration ID that is not defined or invalid the following occurs The default standard model Configuration ID is used instead Configuration ID is the only function available in DIAGNOSTICS Unless the menu is in DIAGNOSTICS Check Config ID displays To set the configuration ID 1 Select Printer Setup from the Diagnostic mode 2 Select Configuration ID from the Printer Setup menu Submitting Selection displays followed by the value for Configuration ID 1 3 Enter the Configuration ID 1 e To select a digit or character to change press lt q or gt until the digit or character is underlined e To change a digit or character press A to increase or W to decrease the value e When the last digit is changed press to validate the Configuration ID 1 If Invalid 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 Confirguration ID 2 4 Repeat the steps for entering the Configuration ID and press Q If the Configuration ID 2 is validated Submitting Selection appears and a check y appears next to Printer Setup 5 Restart the pr
189. d 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 FRU Action Signature button contact assembly System board Check the voltage on the signature button cartridge contact The voltage measures approximately 3 8 V dc when not writing data to the system board 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 f incorrect replace the system board If correct replace the signature button cartridge contact assembly 2 122 Service Manual Diagnostic information 2 123 2 124
190. d e Check system board check on page 2 122 936 10 No hall effect detected Check cable connections Go to Main drive service at motor start Motor is e Defective motor check on page 2 105 type O e Severe gear blinds in gearbox assembly e System board 936 11 No hall effect detected Check cable connections Go to Main drive service at motor start Motor is e Defective motor check on page 2 105 type 1 e Severe gear binds in gearbox assembly e System board 936 20 Failed to stop within Defective motor Go to Main drive service timeout motor is type 0 Defective system board check on page 2 105 936 21 Failed to stop within Defective motor Go to Main drive service timeout motor is type 1 e Defective system board check on page 2 105 936 30 No lock detected at Check for paper jams Go to Main drive service motor start for motor ID A check on page 2 105 Motor is type O GLADNA Defective motor Check motor cable and connections 936 31 No lock detected at Check for paper jams Go to Main drive service motor start for motor ID check on page 2 105 Motor is type 1 Gear binds Defective motor Check motor cable and connections 936 60 No lock detected at Check for paper jams Go to Main drive service normal motor start A check on page 2 105 Motor is type O cear pinds Defective motor Check motor cable and connections 936 61 No lock detected at Check for paper jams Go to Main drive servi
191. dae a a Gee Geer Sate Ss 3 9 DUPLEX EST cist cad n ehe do qaae cx eee dla iba otbba bs dE TAEEPRR A ESTA abus 3 9 Quick a oos edo HR eons aoai aerer e ane A aE A P PERS Sepe 3 9 Top Margin Up ceder babe Ser Bp added id ai 3 10 Sensor Test duplex raros rro 3 10 Motor Test GUHO casino aiii oda ida diia a 3 11 Duplex Feed Tl caseo iere inerte rote 3 12 Duplex Feed 8 cca papse eR a A eu edd Rp dai dadas Gace wes pe Medes doiud dos 3 12 INPUT TRAY TESTS dest pP PS CIO Nawab Geer EM ERE PU PUES YER PR 3 13 Feed TES MDU EAV h P PM 3 13 Sensor TeSt UODUE TI aoi aot cepas cerrarse 3 13 OUTPUT BIN TESTS assem dri d SER DIN EET qe RS A ders 3 14 Feed Tesis OUTDUDDIIS siod 76324 ia ERE RC BE AREE RE ERA id b Ped 3 14 Feed bo AMBOS ccna doce cic qu pon RUP Gaeta di eds 3 14 The test is continuous until Stop is pressed 0 00 disit 3 14 Sensor Test standard output DIN ccce seen eR e RE RE PEREAT EEG YR E 3 15 Sensor Test cOulput EAN isa dao ERR GERUUERE RAN UNE BERS REGE ERE 3 15 Sensor Test high capacity output stacker 0 cece eee stresa 3 16 Sensor Tests B OUT Malba bd bcn diodes 3 16 Diverter Test cis cii ir ox eR ERES de epr tpe bis ep SHAG dS dee es eaeeee geen 3 16 FIMESHER TESTS 3545354 da sra VUE DT UU Frid ASA A eqq vga Sees seein s 3 17 Staple T8SU css pbE EDI E OS n DDR T See Reger Aenea ieee aan Eau Dan 3 17 Feed Testeniinishet oscense Baie d 3 17 mega i a TERI TEP C T 3 17
192. de 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 Paper size sensing service check Before proceeding 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 Paper tray size selection X is activated System ITC ITC CNA pin 9 4 Switch board p Letter Legal A4 Exec B5 A5 J34 pin 1 PSIZE2 SW1 X X X 1 2 Ground Ground 2 3 PSIZE1 SWO X X 3 4 PSIZE3 sw2 X X X 4 Diagnostic information 2 113 Tray 1 not recognized as being installed unable to clear Tray 1 Missing message FRU Action 1 Tray 1 Check Tray 1 for damaged or broken autosize fingers Check for anything that would prevent the autosize fingers from activating the paper activate springs and ITC switches If a problem is found repair or replace the tray assembly If no problem is found go to step 2 2 Integrated card autocompensator cable Check for correct installation of the cable at J26 on the system board If installed correctly go to step 3 If incorrectly installed install and recheck the printer
193. deflector from the upper edge of the frame C and lift to remove Repair information 4 47 Input sensor removal 1 Remove the upper paper deflector Upper paper deflector assembly removal on page 4 79 2 Loosen the MPF lower front cover See Multipurpose feeder lower front cover assembly removal on page 4 15 3 Remove the inner paper deflector Inner paper deflector assembly removal on page 4 47 4 Disconnect the input sensor cable A from the input sensor B 5 Release the input sensor from its mounting and remove 4 48 Service Manual Integrated tray autocompensator assembly removal S Ne m m cs Remove the paper tray Remove the left door See Left door removal on page 4 6 Remove the outer shield See Outer shield removal on page 4 67 Place the printer on its back Disconnect the autocompensator motor cable A from the system board J24 Repair information 4 49 6 Locate the integrated tray autocompensator assembly B on the bottom of the printer and disconnect the autocompensator arm bias spring C Note When you remove the spring note the larger loop attaches to the side frame 7 Remove the C clip D that rests against the right side frame from the autocompensator pivot shaft C 8 Disconnect the autocompensator sensor cable E from the assembly 9 Remove the autocompensator assembly mounting screw F E F 10 Slide the shaft to the right and push the shaft
194. 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 If the option was temporarily removed or not connected properly reattach or reconnect it Press Y to execute a 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 f 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 2 102 Close Finisher Side Door Close the finisher side door If the message does not clear automatically when the door is closed go to StapleSmart finisher service check on page 2 123 Close Finisher Top Cover Close the finisher top cover If the message does not clear automatically when the cover is closed go to StapleSmart finisher service check on page 2 123 Delete All Jobs Go Stop When the user has selected the Print and Hold Delete All Jobs selection this message is displayed The following actions may be taken Pre
195. duplex option again electrical problems If it fails try another duplex option if available If one is not available replace the duplex option 238 02 Duplex exit sensor Media left in the duplex and Remove any sheets from covered Continue selected the duplex option e Sensor is having mechanical or Try the duplex option again electrical problems If it fails try another duplex option if available If one is not available replace the duplex option 238 03 Duplex input and exit Media left in the duplex and e Remove any sheets from sensors covered Continue selected the duplex option e Sensor is having mechanical or Try the duplex option again electrical problems If it fails try another duplex option if available If one is not available replace the duplex option 238 04 Duplex doublefeed Media left in the duplex and e Remove any sheets from sensor covered Continue selected the duplex option e Sensor is having mechanical or Try the duplex option again electrical problems If it fails try another duplex option if available If one is not available replace the duplex option 238 05 Duplex doublefeed Media left in the duplex and e Remove any sheets from sensor covered Continue selected the duplex option e Sensor is having mechanical or Try the duplex option again electrical problems If it fails try another duplex option if available If one is not available replace the duplex option 238 06 Dupl
196. e 3 40X0046 1 1 Paper size sensing board Tray 1 autocompensator paper out low cable Parts catalog 7 35 Assembly 19 Cabling diagrams 3 7 36 Service Manual Assembly 19 Cabling diagrams 3 Asm Part Units Units kit Description Index number mach_ or pkg 19 1 40X0034 1 1 Signature button contact assembly with cable 2 40X0156 1 1 Bottom front autoconnect cable assembly 3 40X0223 1 1 HPVS input sensor toner sensor cable assembly 4 40X0157 1 1 Top autoconnect cable assembly 5 40X0224 1 1 LVPS to system board cable assembly Parts catalog 7 37 Assembly 20 Cabling diagrams 4 i LESS a ee a 7 38 Service Manual Assembly 20 Cabling diagrams 4 Asm Part Units Units kit Des ription Index number mach _ or pkg P 20 1 40X0006 1 1 Upper front cover hinge assembly includes USB cable A 1 Operator panel cable B 1 Cover open switch cable C 1 2 40X0162 1 1 System board to fuser board cable assembly 3 40X0163 1 1 Fuser AC lamp to LVPS cable assembly 4 40X0226 1 1 Fuser connector fuser AC to fuser lamp Parts catalog 7 39 Assembly 21 Cabling diagrams 5 7 40 Service Manual Assembly 21 Cabling diagrams 5 Asm Part Units Units kit Description Index number mach or pkg 21 1 40X0083 1 1 Frame ass
197. e board voltage measures approximately 5 V dc If the voltage is incorrect replace the output expander option If correct replace the sensor assembly Diagnostic information 2 111 Paper feed service check If you have a 936 Transport Motor Error go to Main drive service check on page 2 105 FRU Action 1 Alignment assembly Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight Check the alignment assembly for worn rollers contaminated rollers or binds Replace the alignment assembly if any problem is found 2 Inner deflector Check the inner paper deflector for correct installation 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 FRU Action 1 Pass thru sensor Check the pass thru sensor for correct installation and operation 2 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 3 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
198. e 3 29 Some menus are not available depending on the configuration of the printer Maintenance page count Maint Cnt Value 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 6 1 for the part number Diagnostic aids 3 25 To view the maintenance page count 1 Select Maint Cnt Value from CONFIG MENU 2 Press Y to view the value Press Back to return to the main Configuration menu Maintenance page counter reset Reset Maint Cnt After scheduled maintenance the servicer needs to reset the page counter To reset the maintenance page count to zero Select Reset Maintenance Count from the Configuration menu The message Reset Maint Cnt Reset displays momentarily When the reset operation is complete the menu returns to the Printer Setup Reset Maintenance Count screen Print quality pages Prt Quality Pgs The print quality test pages can be printed from either the Diagnostics mode or Configuration Menu CONFIG MENU When printed from the Diagnostic mode additional information is included and the print cartridge lockout is bypassed See Print
199. e AAA AAA 2 102 lhnputtray s Service CHECK ua sas s enacdeade bed de PRX SPEC OEE PRSE E EPRPOQERRPEII Ed 2 102 interconnect card Service check osetia odes Rari da E PESE a AR Ie 2 104 Maii dove serviee CHECK cuu aspeoss Pe RV ADR EE EE hed ee ERR ie 2 105 Operator panel Semice CHECK oii or oon hae Mee A i 2 106 One or more operator panel buttons fail llle 2 106 No D ltoHS WOK esse rb REESE rarere RIT REESE ER Ce EUCHRRN ewe CM pere dE 2 106 Operator panel display sud ae ped d RO EO QI qe dique NER nia sis Sig 2 107 Options Service CHECK aieo keeper Ee I RR reine er 2 108 Flash Memory ODIOS iia odo d a dis 2 108 DRAM Memory OptlOD S aces cater cieeeevise es CR ERG REY GERBER SERERRTRPPESN TE RE E 2 108 rard DIS ORION DH CK 2 108 Output bin sensor standard tray service check oooooooocoocoorrror eee eee 2 109 Output Expander service Cheek iu drespted ded C ekri ry que pac hd See d hae ohare em dra ded 2 110 Paper deed sovice ChGCK socorrer der IRE CIR ERR REESE REE OE EE RE E EE 2 112 Paper size Sensing SOIVIcG CHRON o ig nda ween ebd UP ERU BUR E SORA o aora ard 2 113 Parallel port SSIVICO GIIBEK 2a duos dec tb eure Fade o e RATE ERES ERN I COPS oTi eS Rb dr 2 116 Print quality sevice chek userscsi se petiec e e y Y EE Fee pU PED C PER REESE ER 2 116 Pripthaad service Ene E a said y ne doque ga Ia ES Gaal Ases 2 122 iV Service Manual Signature button assembly service check 0 00 cee eee eee eens 2
200. e Duplex Feed 1 Test 1 Select Duplex Feed 1 from DUPLEX TESTS The power indicator blinks while the paper is feeding and the message Duplex Feed 1 Feeding displays The message Duplex Feed 1 Clear Paper displays when the paper reaches paper stop position 1 and the power indicator turns on solid 2 Remove the media from the duplex unit and clear the message on the operator panel by pressing Back or Stop Q9 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 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 the media from the duplex unit and clear the message on the operator panel by pressing Back or Stop 69 3 12 Service Manual 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
201. e machine Units kit or pkg refers to the number of units packaged together and identified by the part number NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP Parts Packet in the parts description column indicates the part is contained in a parts packet Model name Configuration Machine type Parts catalog e STUDIO 500P Net 40 210 Parts catalog 7 1 Assembly 1 Covers 7 2 Service Manual Assembly 1 Covers Asm Part Units Units kit Description Index number mach _ or pkg P 1 1 40X0001 1 1 Fuser wiper cover assembly 2 40X0002 1 1 Redrive cap cover assembly 3 40X0003 1 1 Laser cover assembly 250 sheet output 000 010 3 40X0004 1 1 Laser cover assembly 500 sheet output 200 210 400 410 4 40X0050 2 1 Counterbalance spring 5 40X0005 1 1 Paper support 6 40X0006 1 1 Upper front cover hinge assembly includes USB cable 1 Cover open switch and cable 1 Left cable cover 1 Right cable cover 1 Left hinge spring 1 Right hinge spring 1 7 40X0007 1 1 Right side cover 250 sheet output 000 010 7 40X0008 1 1 Right side cover 500 sheet output 200 210 400 410 8 40X001 1 1 1 Upper cover latch spring 9 40X0017 1 1 Lower front cover assembly 10 40X0151 1 1 USB board assembly 11 40X0010 1 1 Upper front cover assembly with Lexmark logo including Operator panel board 1
202. e message Resetting Printer appears and the power indicator light blinks red 2 Turn the printer off and on While the DRAM test executes the power indicator blinks green The following type of message appears DRAM Test XXX MB P HBHHHHE F 7HHHF e xxx represents the installed DRAM size e P represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 6F 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 is incremented 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 turned on solid and the final results display To stop the test before completion press Diagnostic aids 3 7 CACHE Test This test is used to verify the printer processor cache To run the CACHE Test 1 Select CACHE TEST from HARDWARE TESTS The message CACHE Test Testing displays Then the message Resetting Printer appears 2 The printer automatically performs a Po
203. e printer detects a tray needs to be inserted The printer does not continue until it detects the tray is inserted Note This situation usually occurs when the tray is refilled during a job To refill a tray during a printing session press and wait for pages to reach the output bin before refilling the tray The following actions may be taken Insert the requested tray Press er until Busy Waiting displays The following selections are available Cancel Job Reset Printer Reset Active Bin If the message cannot be cleared go to Paper size sensing service check on page 2 113 or Input tray s service check on page 2 102 Install Bin x or Cancel Job 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 Install the option Press 2 until Busy Waiting displays 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 2 102 Install Duplex or Cancel Job 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 remov
204. e right B Repair information 4 25 Fuser assembly removal CAUTION Unplug the printer before you begin 1 Remove the fuser wick assembly cover See Fuser wiper cover assembly removal on page 4 4 2 Remove the redrive assembly See Redrive assembly removal on page 4 74 3 Remove the fuser mounting screws A A 4 26 Service Manual 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 Repair information 4 27 3 Connect the fuser to LVPS AC cable to the fuser lamp connector F at the LVPS Note Be sure to connect the fuser to system board DC cable after replacing the LVPS Fuser exit sensor removal Remove the fuser See Fuser assembly removal on page 4 26 Disconnect the fuser exit cable A from the fuser control board Remove the screw B securing the cover containing the fuser exit sensor flag and spring Release the two clips C holding the sensor in the bracket Pv 0 NoT 5 Unplug the fuser exit sensor cable from
205. e value of x for the paper tray where the error occurs Example 241 is a Paper Jam Tray 1 FRU Action Pass thru sensor and flag assembly The tray x option system board did not detect a piece of paper actuating the pass thru sensor Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu 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 Power takeoff shaft and spring bevel gear feed roll gear drive roll assembly wear plate drive shaft bearings and skewed backup roller 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 xis full or has adequate paper in the tray FRU Action Paper low sensor assembly Paper low sensor flag tray x option system board Run the Tray x Sensor Test and check the sensor fo
206. ea Fuser page count stopped at 500 000 to preserve data Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce W curl 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 92 Diagnostic information 2 63 User attendance messages paper jams and paper handling errors 2xx xx sensor during warm up Fuser page count stopped at 500 000 to preserve data covered position A page may not have been cleared from a prior jam Error j Sub Description Possible causes Action code codes 202 52 Exit sensor covered too Page may be jammed in fuser exit or e Make sure the redrive door long Fuser page count redrive area is complete closed stopped a ud to Check the fuser for any preserve gata signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce
207. ect lamp Go to 922 xx Cold fuser amp detection iret check on page 2 89 temperature but took Bad thermistor circuit or cabling longer than largest time Fuser not receiving sufficient AC in lookup table Fuser power page count between A i 400 000 and 499 999 Poor supply line voltage 2 18 Service Manual Service error codes 9xx xx continued Error Sub code cod s Display text Description Action 922 44 Hot roll iba y Low wattage or incorrect lamp Go to 922 xx Cold fuser trying to reach the final E irei check on page 2 89 lamp detection Bad thermistor circuit or cabling temperature Fuser Fuser not receiving sufficient AC page count between power 400 000 and 499 999 Poor supply line voltage 922 45 After hot roll lamp The control code has been lost Go to 922 xx Cold fuser detection did not roll check on page 2 89 over to steady state control in time Fuser page count between 400 000 and 499 999 922 46 Hot roll did not reach Low wattage or incorrect lamp Go to 922 xx Cold fuser operating temperature in A irai check on page 2 89 time new enhanced Bad thermistor circuit or cabling control Fuser page Fuser not receiving sufficient AC count between 400 000 power and 499 999 Poor supply line voltage 922 47 Fuser has taken too long Low wattage or incorrect lamp Go to 922 xx Cold fuser to reach desired TOME che
208. ecting print media Selecting the appropriate print media for your printer helps you avoid printing problems The following sections contain guidelines for choosing the correct print media for your printer Paper Transparencies Envelopes Labels Card stock Paper For the best print quality use 75 g m 20 Ib xerographic grain long paper Try a sample of any paper you are considering using with the printer before buying large quantities When loading paper note the recommended print side on the paper package and load paper accordingly Paper characteristics The following paper characteristics affect print quality and reliability We recommend that you follow these guidelines when evaluating new paper stock Weight The printer 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 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 Ib 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 printer e Chemically treated papers used to make copies without carbon paper also known as carbonless papers carb
209. ed The following actions may be taken Install the duplex option Press 2 until Busy Waiting displays 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 82 Diagnostic information 2 35 User attendance messages continued Error code Sub code Primary message Description action Install Env Feed or Cancel Job This message is displayed when the envelope feeder has been hot unplugged The printer requires the reinstallation of the feeder to print a page which has been formatted by the interpreter before the feeder was removed The following actions may be taken Install the envelope feeder Press 2 until Busy Waiting displays Select one of the following Cancel Job Reset Printer Reset Active Bin If the message cannot be cleared go to Envelope feeder service check on page 2 84 Install Tray x or Cancel Job Tray x Tray 2 Tray 3 Tray 4 Tray 5 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 Install the option Press en until Busy Waiting displays Select one of the following Cancel Job Reset Printer Reset Active Bin If the message c
210. ed during the feed test The media feeds from the default paper source To run the Feed To All Bins Test Select Feed To All Bins from OUTPUT BIN TESTS The printer feeds a separate piece of media to the standard bin first then it feeds a separate piece of media to each output bin installed in the following order oe Output bins pri Output bins oe Output bins 1 Standard bin 9 Bin 8 17 Bin 5 2 Bin 1 10 Bin 9 18 Bin 4 3 Bin 2 11 Bin 10 19 Bin 3 4 Bin 3 12 Bin 10 20 Bin 2 5 Bin 4 13 Bin 9 21 Bin 1 6 Bin 5 14 Bin 8 22 Standard bin 7 Bin 6 15 Bin 7 8 Bin 7 16 Bin 6 The test is continuous until Stop is pressed Press Back to return to OUTPUT BIN TESTS 3 14 Service Manual 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 2 3 5 Select Sensor Test from OUTPUT BIN TESTS Select Standard Bin from Sensor Tests Select NearFull or Full sensor to test The following screen is displayed Standard Bin x Full 0pen NearFull 0pen e Full Bin full sensor e NearFull Bin near full sensor 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 Press Back or Stop to exit the test Sensor Test
211. eee eee eee 7 50 Tray sensing switch assembly 7 50 Output spring llllll nee eens 7 51 Rear door latch ee eee 7 50 Bin full dual sensor upper stacker assembly flag 7 51 Left base assembly cover 2 2 2022 ene ee ence ene ee eee teense 7 65 Top assembly cover 2 2 2 en ne nn nnn nn nn nen eee 7 65 Stacking bail kit 0 202 022 2250 eee ee eee eee 7 65 Rear access door 2 2 2 sn enn nn nn nn enn nen eee neee 7 65 Output assembly tray 22 222 eee eee ene eee eee eee eee 7 65 Stapler bin empty sensor 2 2 2 222s eee eee ne eee eee eee eee eens 7 65 Stapler bin empty sensor cover seen eee eee nn ne ene en nn nee eee eee 7 65 Stapler assembly 22 202 eee eee eee ee ne eee eens 7 66 Switch assembly top cover open eee eee eens 7 67 StapleSmart wheels maintenance kit 7 68 Slide out support 2 22 2222 eee ee ee ee ee eee 7 47 Plate 250 sheet pass thru 7 43 LVPS 115 V ac 000 010 e eee eens 7 29 LVPS 115 V ac 200 210 400 410 ee eee eee ee eens 7 29 LVPS 220 V ac 000 010 2 2 2 erent ee ee eee eens 7 29 Right side cover lt ee eee eee 7 49 115 V Maintenance kit
212. embly with solenoid and cable 2 40X0159 1 1 Main drive motor cable assembly 3 40X0035 1 1 EP fan with cable 250 sheet 000 010 3 40X0249 1 1 EP fan with cable 500 sheet 200 210 400 410 4 40x0053 1 1 Main fan 250 sheet 4 40X0054 1 1 Main fan 500 sheet Parts catalog 7 41 THE FOLLOWING PAGE 7 43 HAS BEEN OMITTED FROM THIS MANUAL INTENTIONALLY 7 42 Service Manual Assembly 24 Optional 500 sheet paper drawer Asm Part Units Units kit m Index number option or pkg Description 24 1 20G0890 1 1 Drawer assembly complete 500 sheet 2 3 3 Parts packet auto comp mounting screw PP 99A0263 3 56P4139 1 1 Pick arm assembly 500 sheet 4 56P 1228 1 1 Bellcrank spring arm 5 56P2540 1 1 Bellcrank spring 500 sheet option tray 6 99A0070 1 2 Pick roll assembly 7 56P4127 1 1 Option pass thru sensor 8 99A0275 1 1 Power takeoff spring 9 99A0447 1 1 Drive shaft 500 sheet 10 56P4128 1 1 Bin low sensor with cable 11 56P4143 1 1 Base assembly 500 sheet 12 56P4145 1 1 Paper out arm 500 sheet drawer 13 99A0063 1 1 Switch activate spring 14 1 1 Parts packet screw PP 99A0263 7 44 Service Manual Assembly 25 Optional 500 sheet paper tray Asm Part Units Units kit Description Index number option or pkg 25 1 20G0890 1 1 Complete tray assembly 500 sheet 2 56P4137 1 1 Side restraint 500 sheet tray 3 99A0292 1 4 Wear strips 4 56P4196 1 1 Pass thru plate 5 99A0120 1 2
213. emory configuration Memory type e STUDIO 500P 128 Standard DRAM MB Optional memory MB 128 and 512MB available 100 pin DDR SDRAM unbuffered DIMMs Maximum MB 640 Depending upon the options and features used additional memory may be required to optimize performance Available memory options Optional 128MB and 512MB SDRAM DIMMs are available from Toshiba Operating clearances Printer side Measurement Left and right side 12 in 30 48 cm Front 20 in 50 8 cm Rear 12 in 30 48 cm Top 54 in 137 16 cm Allow clearance above the printer front door clearance and for adding options such as additional input drawers 1 4 Service Manual Dimensions Description Height Width Depth Weight Printer e STUDIO 500P 16 0 in 1722 in 20 2 in 51 6 Ib 406 mm 436 mm 513 mm 23 1 kg Options Duplex 500 page option 2 13 in 15 6 in 23 4 in 11 Ib 500 Sheet drawer 5 3 in 15 6 in 20 5 in 7 Ib 134 mm 398 mm 520 mm 3 2 kg 2 000 Sheet 11 8 in 15 6 in 19 5 in 31 Ib 300 mm 398 mm 495 mm 14 1 kg Envelope option closed position 7 72 in 4 Ib 196 mm 1 8 kg Envelope option support fully extended 12 28 in 4 lb 312 mm 1 8 kg Envelope option fits within height and width of printer General information 1 5 Power requirements Average nominal powe
214. emoval 4 49 interconnect card connectors 5 9 parts catalog 7 30 removal 4 53 service check 2 104 IPDS emulation user message 2 42 K kiosks vertical and horizontal paper adapters 7 64 L labels guidelines 1 17 lamp fuser 4 32 laser cover removal 4 19 left cover handle holder removal 4 16 left door removal 4 6 low voltage power supply LVPS connectors 5 10 parts catalog 7 28 removal 4 54 lower front cover assembly removal 4 15 lower paper deflector MPF 4 61 lubrication specifications 6 1 main drive assembly parts catalog 7 22 removal 4 57 service check 2 105 main fan removal 4 56 maintenance ESD sensitive parts 4 1 lubrication 6 1 maintenance kit 6 1 preventive 6 1 safety inspection guide 6 1 maintenance approach 1 1 maintenance kits 6 1 Index 1 3 menus accessing service menus 3 1 description 2 3 printing menu page 3 30 messages check device connection messages 2 43 service error codes 2 8 user attendance messages 2 32 user line 2 link messages 2 43 user status displays 2 31 warning messages user status displays 2 31 Model Name 3 20 models 1 1 1 2 7 1 MPF arm assembly 4 60 MPF lower paper deflector 4 61 MPF solenoid assembly 4 62 multipurpose feeder parts catalog 7 14 removal 4 15 N narrow media sensor See fuser narrow media sensor navigation buttons 2 2 number pad rubber dome sheet 7 3 numeric pad 2 3 O operator panel board 4 66 Button Test 3 7 buttons 2 106 4 67 7 3 description 2
215. ension 200 210 400 410 7 40X0060 1 1 External ground clip 8 40X0331 1 1 Left side hand holder 9 40X0285 1 1 Frame clip Parts catalog 7 5 Assembly 3 Frame 2 7 6 Service Manual Assembly 3 Frame 2 Asm Part Units Units kit Description Index number mach or pkg 3 1 40X0027 1 1 Upper redrive deflector 2 40X0028 1 1 Upper diverter spring 3 40X0029 1 1 Redrive assembly 250 sheet in 250 out 000 010 3 40X0030 1 1 Redrive assembly 500 sheet in 500 out 200 210 400 410 4 40X0032 1 1 Transfer deflector 5 40X0055 1 1 Left side frame ground contact 6 40X0044 1 1 Gear guard 7 3 Parts packet PP 40X0165 8 40X0048 1 1 Paper switch activate spring 9 40X0046 1 1 Paper size sensing board assembly 10 40X0049 1 1 Gear release link 11 40X0053 1 1 Main fan with cable 250 sheet output 11 40X0054 1 1 Main fan with cable 500 sheet output 12 40X0212 1 1 Main fan duct 200 210 400 410 13 40X0211 1 1 Main fan duct 000 010 14 40X0052 1 1 Standard bin level sensor bracket 15 40X0051 1 1 Standard bin level sensor 16 40X0264 1 1 Standard bin level sensor cable 17 40X0057 1 1 Output paper level flag 000 010 17 40X0058 1 1 Output paper level flag 200 210 400 410 18 40X0210 1 1 Main fan cap 19 40X0056 1 1 Redrive door assembly 250 sheet 000 010 19 40X0232 1 1 Redrive door assembly 500 sheet 200 210 400 410 20 40X0059 1 1 Extension guide Parts catalog 7 7 Assembly 4 Frame 3 7 8 Service Ma
216. ensor service check on page 2 92 202 31 Page did not cleanly exit fuser or redrive area Fuser page count between 300 000 and 399 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 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 92 Diagnostic information 2 59 User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes Action code codes 202 32 Exit sensor covered too Page may be jammed in fuser exit or e Make sure the redrive door long Fuser page count redrive area is complete closed teed 300 000 and Check the fuser for any 299 signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for an
217. equesting hole punch The message displays once per job The following actions can be taken Install the hole punch box Press YD to ignore the message The Box M Missing message appears on the status line A job that is set for hole punching will not be punched The message continues to display on all subsequent jobs that request hole punching If this message cannot be cleared after inserting the box go to StapleSmart finisher service check on page 2 123 Insert Cartridge or Close Door 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 on page 2 80 Insert Staple Cartridge This message displays when the staple cartridge is missing or installed incorrectly The message appears regardless of the Staple Alarm setting at the following times At POR After the Stapler Door has been closed The following actions can be taken Install the stapler cartridge Press Y to clear the message The printer handles stapled jobs as if the staple cartridge were installed but empty The Staples Empty message appears on the status line and the Load Staples may display 2 34 Service Manual User attendance messages continued Error code Sub code Primary message Description action Insert tray tray Tray 1 Tray 2 Tray 3 Tray 4 or Tray 5 Th
218. er and atthe rear of the printer Jams in the front of the printer occur in the input options or the duplex tray Jams inside the printer occur in two locations and require the removal of the print cartridge Jams can also occur at the rear of the printer or in one of the output options Note The following clearing jam instructions may seem out of sequence However they have been grouped to help you quickly clear the print path Diagnostic aids 3 33 250 Paper Jam Check MP Feeder 1 Remove the paper from the multipurpose feeder 2 Flex fan and restack the media and place it into the multipurpose feeder 3 Load the print media 4 Slide the side guide toward the inside of the tray until it lightly rests against the edge of the media 5 Press Y 3 34 Service Manual 260 Paper Jam Check Env Feeder The envelope feeder feeds envelopes from the bottom of the stack the bottom envelope will be the one that is jammed 1 Lift the envelope weight 2 Remove all envelopes If the jammed envelope has entered the printer and cannot be pulled out remove the envelope feeder a Lift the envelope feeder up out of the printer and then set it aside b Remove the envelope from the printer 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 37 for more information C Reinstall the envelope feeder Make sure it snaps into place 3 Flex and st
219. er page count between 0 and 99 999 Page did not enter or exit fuser nip cleanly Narrow media sensor not functioning correctly Actual page is narrow when wide page was expected f 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 26 f media is narrow then turn off first sheet detection engine settings 3 16 In Diagnostics mode select PRINTER SETUP and Engine Setting 3 The fuser narrow media sensor may not be operating properly Go to Fuser narrow media sensor service check on page 2 93 201 10 Page did not reach exit sensor Fuser page count between 100 000 and 199 999 Page jammed on fuser input guide Page did not enter or exit fuser nip cleanly Exit sensor not functioning correctly Check fuser entry guide for toner build up Check fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 92 201 11 Main drive motor identification failed Fuser page count between 100 000 and 199 999 Main drive motor not working Check motor to system board connections Replace the main drive motor Main drive
220. er nip cleanly Exit sensor not functioning correctly Check the fuser entry guide for toner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 92 201 51 Main drive motor identification failed Fuser page count stopped at 500 000 to preserve data Main drive motor not working Check the connections to the motor and system board If not problem is found go to Main drive service check on page 2 105 2 50 Service Manual User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 201 52 Page did not reach exit sensor Fuser page count stopped at 500 000 to preserve data Page jammed on fuser input guide Page did not enter or exit fuser nip cleanly Exit sensor is not functioning correctly Check the fuser entry guide for toner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 92 201 54 Expected wide page not detected by narrow
221. er option control board 24x xx Paper Jam Check Tray x displays when tray xis empty tray x does not display FRU Action 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 incorrect disconnect J4 from the board and measure the voltages again If incorrect replace the high capacity feeder option control board Elevator top optical sensor cable Elevator top optical sensor 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 FRU Action High capacity feeder option control board 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 Elevator top optical sensor cable Elevator top optical sensor Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly Diagnostic information 2 99 Tray x Paper Low displays when the high capacity feeder input tray is full or has adequate paper in the tray FRU Action 1 Paper low switch Run the sensor diagnosti
222. ered jobs saved on the disk The values are Delete and Do Not Delete 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 Warning Whenever this value is changed data on the hard disk is erased 3 28 Service Manual Font Sharpening This setting allows a user to set a text point size below which the high frequency screens are used when printing font data For example at the default 24 all text in font sizes 24 and less will use the high frequency screens The values for this setting range from 0 to 150 and the default value is 24 This setting affects PostScript PCL and XL To change the value select Font Sharpening from the CONFIG MENU and use lt q to decrease the value and gt to increase the value Select Y to accept the value LCD Brightness This setting allows the user to increase or decrease the brightness of the operator panel LCD When the value is increased the backlight shines brighter and when the value is decreased the backlight is dimmer The operator panel responds immediately to the changes Use 4 to decrease the value and to increase the value The values range from 1 to 10 and 5 is the default value LCD Contrast When this setting is selected the operator panel displays a gray bar with a slider representing the values As the values are decreased the bar appears darker and when the values are in
223. ever you replace the fuser solenoid Adjust the fuser solenoid while installed in the printer Adjust the screw on the eccentric mounted on the solenoid housing to provide an air gap between the rear of the solenoid stator and the solenoid armature The solenoid air gap for all models is 4 5 mm x 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 printer This adjustment reduces the printer 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 Mode 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 e to select the value If Select Gap Adjust 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 Do the printhead assembly adjustment whenever you 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 s
224. ex doublefeed and Media left in the duplex and Remove any sheets from exit sensors covered Continue selected e Sensor is having mechanical or electrical problems 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 69 User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes Action code codes 238 07 Duplex doublefeed Media left in the duplex and Remove any sheets from input and exit sensors Continue selected the duplex option are covered e Sensor is having mechanical or Try the duplex option again electrical problems If it fails try another duplex option if available If one is not available replace the duplex option 239 00 Feed error in duplex Mechanical feed error due to belt Replace the duplex option unit slipping Timing error due to feed system 239 01 Jam declared by a smart Mechanical feed error due to belt Replace the duplex option device Immediate stop slipping Timing error due to feed system 239 02 Jam declared by a smart Mechanical feed error due to belt Replace the duplex option device Homing allowed slipping stop Timing error due to feed system 239 03 Duplex did not send Mechanical feed error due to belt Replace the duplex opt
225. f paper out of the original 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 printer 1 18 Service Manual Avoiding jams Use appropriate print media paper transparencies labels and card stock to help ensure trouble free printing See Supported print media on page 1 8 for more information Note Try a limited sample of any print media you are considering using with the printer before purchasing large quantities By selecting the appropriate print media and loading it properly you can avoid most jams The following hints can help you avoid jams Print area 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 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 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 Make sure the recommended print side is loaded in the source according to your simplex or duplex needs Keep print media stored in an acceptable environment See Storing print medi
226. f the voltages are correct and the problem persists replace the output expander option 202 xx Paper Jam Open Rear Door message displays a sheet of paper is jammed prior to the pass thru sensor flag 202 xx Paper Jam Open Rear Door message displays a sheet of paper feeds out to the standard bin even though bin x is selected paper exits half way out of the redrive Service tip For this type of problem check the sub error codes They can help isolate the problem 202 Paper Jam messages can also occur prior to the output expander pass thru sensor FRU Action 1 Output expander drive belt Pulley drive belt Idler pulley belt tension spring Check to ensure the output expander drive belt is correctly installed on the drive pulley and belt idler pulley Check the belt tension spring to make sure it is not loose or broken Repair as necessary Mechanical linkage DC motor assembly If the DC motor is functioning properly check the gears clutch and other linkage parts for correct operation and wear broken gear teeth or damaged parts If incorrect replace the output expander option 2 110 Service Manual Remove Paper Output Bin x displays POST incomplete unable to clear the message FRU Action 1 Dual output bin sensor flag Check the flag for correct operation binding broken parts or interference from the sensor cable If incorrect repair as necessary or replace the
227. formaci de Seguretat components espec fics La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els El fabricant no es fa responsable de les questions de seguretat si s utilitzen peces de recanvi no autoritzades i no est destinada a ning que no ho sigui La informaci pel manteniment d aquest producte est orientada exclusivament a professionals 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 A re ral gt o o Tu o nih ol rlo rH rt x 9 o 2M 9 ML ron 2 u PI 2 long o jo reo OF 24 W o JJ o A gt r ri 0 ox Fit Hill gt o ge pg pin ni FTT g H nio nio gt pH e 9 _ ra o 9 4 o H of r o gt 4 3e A lo g lo nm m7 no T ZE fi Jy fu AS i FI AE ATAR AEB IN XE FAIRS A ART IR a D RUE HIT cu gt e T M ASF i BRI KE PE OR Beh AVE XE P d HARA REEVE AT EADIE BER APO AEE Hr Pi SERRA ATE HATE PRECAUCIO aquest simbol indica que el voltatge de la part de l equip amb la qual esteu treballant s perill s Abans de comen ar desendolleu l equip o extremeu les precaucion
228. formation 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 printer 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 printer 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 operator panel from the printer driver in the Local Printer Setup Utility or from MarkVision e Be aware that preprinting perforation and creasing can significantly affect the print quality and cause print media handling or jamming problems Avoid using card stock that may release hazardous emissions when heated e Do not use preprinted card stock manufactured with chemicals that may contaminate the printer Preprinting introduces semi liquid and volatile components into the printer 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 Store paper in an environment where the temperature is approximately 21 C 70 F and the relative humidity is 4096 Store cartons of paper on a pallet or shelf rather than directly on the floor e f you store individual packages o
229. g screen is displayed Output Bin x P1 OP P2 OP L NL e passThru 5 bin mailbox pass thru sensor shows Open or Closed e mailboxEmpty 5 bin mailbox empty sensor shows Norma 1 for a normal level NearFul 1 for nearly full and Ful for full 3 Manually actuate each of the sensors of the 5 bin mailbox The pass thru sensor will indicate Open or Closed and the empty sensor mailboxEmpty indicates Normal NearFull or Full 4 Press Back O or Stop to exit the test Diverter Test This test verifies the functioning of each of the 5 bin mailbox output media diverters If more than one 5 bin mailbox is installed all installed diverters or tested To run the Diverter Test select Diverter Test from the OUTPUT BIN TESTS The test runs once and stops 3 16 Service Manual Diagnostic aids 3 17 BASE SENSOR TEST This test is used to determine if the sensors located inside the printer are working correctly To run the Base Sensor Test 1 Select BASE SENSOR TEST from the DIAGNOSTICS menu The following sensors are listed e Exit Exit sensor Front Door Front door sensor e nput lInput sensor e 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 Back O or Stop to exit the test DEVICE TESTS Quick Disk Test This test performs a non destr
230. ge Motor Test Testing displays 2 When the motor stops the results are displayed DUPLEX MOTOR AA BB CC DD EE FF AA OO0 indicates success and any other value indicates failure BB average PWM for the high speed portion of the test The results should be in the range of 20 through SF inclusively hex CC average PWM for the low speed portion of the test The results should be in the range of 3A through 5D inclusively hex DD minimum PWM for the low speed portion of the test The results should be in the range of 11 through 1F inclusively hex 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 AA 00 e BB in the range of 29 through 3E inclusively hex e CC in the range of 35 through 51 inclusively hex e DD in the range of OC through 13 inclusively hex For the duplex drive system to pass the test the following results must display AA 00 BB in the range of 29 through 3F inclusively hex e CC in the range of 3A through 5D inclusively hex e DD in the range of 11 through 1F inclusively hex 3 Press Back or Stop to exit the test Diagnostic aids 3 11 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 th
231. ges continued Error Sub A Pare code cod Primary message Description action 37 XX Insufficient Memory This message displays when the printer memory used to restore the Print and Hold jobs from the disk and found that some or all of the jobs could not be restored The printer ran out of memory while attempting to restore the jobs Press V to clear the message Some of the Print and Hold jobs on the disk will not be restored They remain on the disk but cannot be accessed e Press 2 until Busy Waiting appears The following functions may be available Cancel Job Reset Printer Reset Active Bin 38 XX Memory Full This message displays when the printer is processing an incoming job and there is insufficient memory available to continue processing the job The following actions may be taken Press Y to clear the message Perform the defragment operation Perform the defragment operation Delete fonts macros and other data in RAM Install additional memory Press 2 to display Busy Waiting The following functions may be available Cancel Job Reset Printer Reset Active Bin 39 XX Complex Page This message displays when the page is too complex to print The following actions may be taken Press Y to clear the message and continue the job Some data loss may occur Simplify the print job and reprint if necessary Press 2 until Busy Waiting appears The following selections are pos
232. hat 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 92 Diagnostic information 2 57 User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes Action code codes 202 22 Exit sensor covered too Page may be jammed in fuser exit or e Make sure the redrive door long Fuser page count redrive area is complete closed De 200 000 and Check the fuser for any 299 signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce W curl 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 92 202 23 Page is covering narrow f page is not visible from front or rear Check the fuser and area media sensor during of the printer a partial piece of page around the fuser assembly for warm up Fuser page may be torn off in the fuser covering any signs of debris or pieces of count between 200 000 the narrow media sensor paper or media
233. he reference adjustment screw out far enough to remove the old assembly and install the new one If you are replacing the alignment assembly go to step A 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 on page 3 4 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 printer 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 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 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 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
234. i BIDITIS 65 as io sob OU Bc cie Shee Corea hae sina ues edes ue 2 5 High capacity feeder 2000 shiaet SYMPTOMS ona nme a decr x mem s tih x EE 2 5 Paper tay SVIN PIONS cio emacs oie 2 6 Duplex OploniSVIMPIOMS seca deeds cede espa Meee VENERE PR RE REREETPq EE FPES SES 2 6 Envelope feeder amp ymploms vus spe E bemqeberuee bees Siro eds 2 6 QUuIpuL exSalldel 2 00 eeeosecersaveneddoeeeenetedce te RR ERPee E PIT ERPM RP TRPE TE 2 6 masesmart MUNN RING dc 9 9 99 9 9 4 p dc Rs S dors ebat ELO ad e cb d c ira t iud qutd bui dabo a dius 2 7 Messages and error cod s ii Lam Er RUE ERG VUA Vui Qaid D od os MUR ed Ud RR 2 8 mere BN OF DOES 626 Le EERE eee dec eee aexe eso dx abel ate bid gees 2 8 User Status diSplayS 2ocieocsstbecie eras RP PETI E ENRURYEY AA 2 31 Usar attendance Messages a 62 estuo E EH ax dedi qe d dee E 2 32 User ling linke messages Lu ost s8 pda aped d ded qued is dede 2 43 Ghack device connection Message aaa acit seann CHOR Reto roc obla feb sc PR edt s 2 43 User attendance messages paper jams and paper handling errors 2xx xx ooooooooooo 2 44 Service CHECKS id oaa beu ea bea bre P a eee bad bbb AA Ed RO A ab lla 2 72 Sl Mailbox Savice Check 22 3 oloasedaeiode deat de ae 2 72 CUD Error code Sonics CIBO odo dit oae d Hit addon YHP rer Ud Ea rut opcm ned e is 2 75 JETA FAMS DOCK 252054665 62 0n06 Ras rateros oc Soe bobo poe Peri 2 76 Maii Tall s dert er ee peas pe PP AAA 2 76 Canndge fan service Check au s dup E
235. i e cm Right cover handle holder removal 1 Remove the right side cover See Right cover removal on page 4 8 2 Remove the two screws A holding the top of the right handle holder in place 3 Lift out the right handle holder 4 16 Service Manual Left and right frame extensions Remove the toner cartridge Turn the printer on its back Remove the two screws A holding the right frame extension Remove the two screws B securing the left frame extension ge dat aa Repair information 4 17 Pass thru plate 1 Remove the redrive assembly See Redrive assembly removal on page 4 74 2 Remove the screw A securing the pass thru plate 3 Carefully remove the plate until it is loose 4 Remove the fuser to system board DC cable B secured through the plate Note Note the routing of the fuser card to system board DC cable En n r 2 o LA ma 5 Mets ab 4 18 Service Manual Laser cover removal 1 2 3 4 5 6 Remove the left door See Left door removal on page 4 6 Remove the right cover See Right cover removal on page 4 8 Remove the paper support See Paper support removal on page 4 5 Remove the redrive cap See Redrive cap cover removal on page 4 5 Press the fuser wiper cover latch and remove the cover Remove the screw A at the rear of the printer and the larger screw B at the front on the right side Repair informa
236. ight 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 79 Cover closed switch cable service check FRU Action 1 Toner cartridge Make sure the toner cartridge is correctly installed and that the right and left cartridge tracks are not loose or broken Make sure the cover closed switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover closed switch spring 2 Cover closed switch cable 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 cover open switch cable assembly If the continuity changes as the switch is activated replace the system board Cover closed
237. imit switch to make sure it is not closed normally open If incorrect replace the switch Check the lower limit switch cable for a short between pins 1 and 2 If incorrect replace the cable 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 FRU Action 1 Autocompensator assembly Check the autocompensator pick arm rollers for sign of glazing toner or other buildup Replace as necessary 2 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 Diagnostic information 2 97 The elevator tray does not move up or down the printer recognizes that the option is installed FRU Action 1 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 resistance 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
238. inal check on page 2 89 lamp detection Bad thermistor circuit or cabling temperature Fuser Fuser not receiving sufficient AC page count between 0 power and 99 999 Poor supply line voltage 922 06 Hot roll did not reach Low wattage or incorrect lamp Go to 922 xx Cold fuser operating temperature in TENIS check on page 2 89 time new enhanced Bad thermistor circuit or cabling control Fuser page e Fuser not receiving sufficient AC count between 0 and power 99 999 e Poor supply line voltage 922 07 Fuser has taken too long e Low wattage or incorrect lamp Go to 922 xx Cold fuser to reach desired check on page 2 89 temperature after Bad thermistor circuit or cabling increasing interrupt gap e Fuser not receiving sufficient AC Fuser page count power between 0 and 99 999 Poor supply line voltage 922 12 Hot roll took too long to Low wattage or incorrect lamp Go to 922 xx Cold fuser reach the beginning ati check on page 2 89 lamp detection Bad thermistor circuit or cabling temperature Fuser e Fuser not receiving sufficient AC page count between power 100 000 and 199 999 e Poor supply line voltage 922 13 Hot roll reached final Low wattage or incorrect lamp Go to 922 xx Cold fuser lamp detection n mm check on page 2 89 temperature but took Bad thermistor circult BE capling longer than largest time Fuser not receiving sufficient AC in
239. installed See Parallel strobe adjustment Par x Strobe Adj on page 3 21 Diagnostic aids 3 3 Diagnostics mode tests continued EP SETUP EP Defaults See EP Defaults on page 3 22 Fuser Temp See Fuser Temperature Fuser Temp on page 3 22 Fuser Page Count See Fuser Page Count on page 3 22 Warm Up Time See Warm Up Time on page 3 22 Transfer See Transfer on page 3 22 Print Contrast See Print Contrast on page 3 22 Charge Roll See Charge Roll on page 3 22 Gap Adjust See Gap Adjust on page 3 22 EVENT LOG Display Log See Display Log on page 3 23 Print Log See Print Log on page 3 23 Clear Log See Clear Log on page 3 24 EXIT DIAGNOSTICS Exiting Diagnostics mode Select Exit Diagnostics to exit the Diagnostics mode Resetting the Printer displays the printer performs a POR and returns to normal mode REGISTRATION Print registration makes sure the printing is printed properly aligned on the page The settings available are Bottom Margin Top Margin Left Margin Right Margin Quick Test To set print registration 1 Select REGISTRATION from the DIAGNOSTICS menu 2 Select Quick Test and press Y To print the Quick Test page a Press until the y appears next to Quick Test b Press Y The message Quick Test Printing appears on the display Retain this page to determine the changes you need to make to the margins settings 3 4 Se
240. 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 92 202 11 Page did not cleanly exit fuser or redrive area Fuser page count between 100 000 and 199 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 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 92 Diagnostic information 2 55 User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes Action code codes 202 12 Exit sensor covered too Page may be jammed in fuser exit or e Make sure the redrive door long Fuser page count redrive area is complete closed oe 100 000 and Check the fuser for any aod signs of wear or contamination If any are fou
241. inter 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 21 EP SETUP EP Defaults This setting is used to restore each printer setting listed in EP SETUP to its factory default value Sometimes this is used to help correct print quality problems To restore EP Defaults 1 Select EP Defaults from EP SETUP 2 Select Restore to reset the values to the factory settings and select Do Not Restore to exit without changing the settings 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 Fuser Page Count The fuser page count can only be viewed and cannot be changed To view the Fuser Page Count 1 Select Fuser Page Count from EP SETUP 2 Press Back Q to return to PRINTER SETUP Warm Up Time
242. inuity of the line cord and replace if necessary If the cord is correct go to step 3 2 80 Service Manual FRU Action 5 V dc test point on the System board Check for approximately 5 V dc at the 5 V test point on the system board Note Use care not to short adjacent voltage test points If the voltage is correct replace the system board assembly If the voltage is incorrect go to step 4 System board Check to make sure the LVPS cable is correctly installed at J27 on the system board If not reseat and recheck the voltage at the 5 V dc test point on the system board If test point does not measure 5 V dc go to step 5 LVPS 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 54 Features or option installed on the interconnect card assembly 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 LVPS fuse F1 primary power Unplug the AC line cord remove the LVPS from the p
243. ion device Controls slipping response Timing error due to feed system 239 04 Duplex did not send Mechanical feed error due to belt Replace the duplex option Input Device Ready slipping response Timing error due to feed system 239 05 Duplex did not send Mechanical feed error due to belt Replace the duplex option Page In Output Device slipping response Timing error due to feed system 239 06 Failed the last page of a Mechanical feed error due to belt Replace the duplex option staple job slipping Timing error due to feed system 239 07 Engine never sent Mechanical feed error due to belt Replace the duplex option Select OUtput Device to slipping the duplex unit because e Timi the page leaving the Timing error due to feed system duplex never sent Select Input Device 239 08 Engine never saw Input e Mechanical feed error due to belt Replace the duplex option Source Read on a page slipping to be picked from the e Timi duplex unit that is Timing error due to feed system waiting on a page to pass the input sensor 239 11 Sheet picked from e Mechanical feed error due to belt Check duplex sensor cables for duplex never made it to the input sensor Slow or delayed feed from the duplex unit slipping Timing error due to feed system Input sensor not working correctly correct installation If no problem is found with the cables replace the duplex option 2 70 Service Manual
244. 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 the 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 FRU Action 1 Paper 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 2 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 2 112 Service Manual Paper fails to feed from the multipurpose tray The pick roll should make one complete revolution and stop with the flat si
245. ith 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 FRU Action 1 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 Aa EIN nr does not change replace the sensor cable assembly If this does not Standard Bin message fix the problem replace the system board Output Bin Sensor Test fails 2 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 Diagnostic information 2 109 Output expander service check Service tip The majority of the mechanical components can be observed during operation by removing the left right and system board covers The output expander functions without the covers installed Make sure the option is correctly installed before attempting to service the unit No jumpers should be installed at connector J6 on the output expander board Problems with excessive static electricity buildup FRU Action 1 Output e
246. ive Bin 56 XX Standard USB Port x Displayed when status is requested over the USB port indicated but the port Disabled has been disabled Once the error has been displayed for the first time reporting of further errors is suppressed until the menus are entered or the printer is reset The following actions may be taken Press YD to clear the message The printer discards any data received on the USB port Press 2 until Busy Waiting appears The following are available Reset Printer Reset Active Bin 2 40 Service Manual User attendance messages continued Error code Sub code Primary message Description action 56 XX Standard Parallel Port Disabled This error is displayed when data is sent to the printer across the parallel port but the parallel port has been disabled Once this message is displayed reporting of further errors is suppressed until the menus are entered or the printer is reset The following actions may be taken Press V to clear the message The printer discards any data received on the parallel port Press 2 until Busy Waiting appears The following are available Reset Printer Reset Active Bin 56 XX Parallel Port x Disabled This error is displayed when data is sent to the printer across the parallel port but the parallel port indicated has been disabled Once this message is displayed reporting of further errors is suppressed until the men
247. jam and paper handing errors 2 44 500 sheet paper drawer option 7 44 500 sheet paper tray option parts catalog 7 45 service check 2 102 5 bin mailbox output sensor test 3 16 parts catalog 7 54 7 56 service check 2 72 80 scheduled maintenance 6 1 900 xx error code service check 2 75 927 xx fan service check 2 76 950 00 through 950 29 EPROM mismatch failure 2 77 950 30 through 950 60 EPROM mismatch failure 2 78 9xx Service error codes 2 8 A acronyms 1 20 adjustments fuser solenoid 4 2 gap adjustment 4 2 paper alignment assembly 4 3 printhead assembly 4 2 alignment assembly adjustment 4 3 parts catalog 7 16 removal 4 68 autocompensator integrated tray parts catalog 7 12 pick roll installation 4 52 removal 4 49 autoconnect connections top 5 6 B bevel gear installation 4 22 removal 4 21 bezel operator panel 4 14 blower duct 7 9 Button Test 3 7 buttons accessing service menus 3 1 Button Test 3 7 description function 2 2 operator panel button removal 4 67 upper front cover including buttons 7 3 upper front panel button kit 7 3 C cable diagrams 7 34 7 35 7 36 7 38 7 40 CACHE Test 3 8 Card Stock amp Label Guide 1 8 card stock guidelines 1 18 cartridge duct removal 4 23 characteristics print media 1 15 code update 3 1 Configuration ID 3 21 configuration menu accessing 3 1 3 25 available menus 3 25 Demo Mode 3 27 Disk Encryption 3 28 Download Emuls 3 27 Energy Conserve 3 28 Env Prompts
248. justment section Fuser solenoid adjustment on page 4 2 FRU Action 1 Fuser envelope 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 a 00000000 J1 The resistance measures between 5 ohms and 10 ohms If incorrect replace the fuser assembly If correct go to step 2 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 3 LVPS Measure the voltage at CN2 18 on the 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 4 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 5 Fuser assembly If no problems were found in steps 1 through 4 replace the fuser assembly See Fuser assembly removal on page 4 26 2 94 Service Manual High capacity feeder input
249. k option ll 2 ll 7 64 Complete 5 bin mailbox option lt 7 55 Complete output expander assembly 2 l llll lll 7 48 Complete high capacity output expander 7 50 Universal adjustable tray assembly 400 sheet 7 69 Complete StapleSmart option 7 65 Tray assembly option 250 sheet 2 22 eee een e nee eee 7 43 Pick arm assembly lllllllllllllllllc 2 7 42 Option pass thru sensor 7 42 7 44 7 63 Bin low sensor with cable 7 42 7 44 Paper out arm 250 sheet 2 2 2222 eee eee eee eee eee 7 42 Side restraint 250 sheet tray 2 22 22 eee en ee ee eee ee eee 7 43 Back restraint 250 sheet tray nnn 7 43 Output paper level flag lt o 7 48 Stud assembly ellc l lel 7 42 Side restraint 500 sheet tray n 7 45 Pick arm assembly 500 sheet llle eee eens 7 44 2000 sheet option control card assembly 20 0200 22 2525s eee e ee neeees 7 59 Base assembly 500 sheet eee eee 7 44 Paper out arm 500 sheet drawer
250. kin 5 Pull the print media up and toward you Warning If the print media does not move immediately when you pull stop pulling You need to access the print media from the printer rear door Reinstall the toner cartridge Close the top front cover Close the multipurpose feeder Press Y o OND 3 38 Service Manual 202 Paper Jam Open Rear Door 1 If the paper is exiting the printer pull the media straight out and press Q Otherwise continue with step 2 2 Open the printer rear door 3 Remove the jammed media 4 Close the rear door 5 Press Y Diagnostic aids 3 39 23x Paper Jam Open Duplex Rear Door 1 Open the duplex rear door 2 Remove the jammed media Depending on the media location pull the media either up or down 3 Close the duplex rear door Make sure it snaps into place 4 Press QD 3 40 Service Manual Pages 3 42 through 3 44 have been removed from this document intentionally Diagnostic aids 3 41 4 Repair information Warning Read the following before handling electronic parts Handling ESD sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive parts 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 b
251. les on page 2 5 Locate your symptom and take the appropriate action The following tables are available Base printer symptoms on page 2 5 High capacity feeder 2000 sheet symptoms on page 2 5 Paper tray symptoms on page 2 6 Duplex option symptoms on page 2 6 Envelope feeder symptoms on page 2 6 Output expander on page 2 6 StapleSmart finisher on page 2 7 Service errors 9xx xx s If a service error code appears while you are working on the machine go to Service error codes on page 2 8 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 YY In most cases five digits are shown User status and attendance messages 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 31 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 32 and User attendance messages paper jams and paper handling errors 2xx xx on page 2 44 Additional information Power On Self Tes
252. links during the test Note The test can NOT be canceled 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 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 Select Flash Test from DEVICE TESTS The message Files will be lost Go or Stop displays to warn the user that all contents on the flash device will be lost To exit the test immediately and return to the Device Tests menu press Back or Stop Q9 To continue with the test press YD The power indicator blinks while the test is running and the message Flash Test Testing 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 Press Back Q or Stop to return to DEVICE TESTS Diagnostic aids 3 19 PRINTER SETUP Defaults US Non US defaults changes whether the printer uses the US factory defaults or the non US factory defaults The settings affected include paper size envelope size PCL symbol set code pages
253. lliumarsenid laser som arbejder pa belgeleengdeomradet 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig uds ttes for en laserstraling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Laser notices Xiii 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 f r 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 r utformade s att det aldrig finns risk f r att n gon person uts tts f r laserstralning ver Klass I niva vid normal anv ndning underh ll som utf rs av anv ndaren eller annan f reskriven service tg rd 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 str ling i belgelengdeomr det 770 795 nanometer Lasersystemet og skriveren er utformet slik at
254. lots It is necessary to perform a registration adjustment before locking down the three printhead mounting screws To perform the registration adjustment 1 moore a Turn the printer off Press and hold and W Turn the printer on and release the buttons when Performing Self Test displays 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 printer 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 Paper alignment assembly adjustment Do the alignment assembly adjustment whenever you replace the alignment assembly Always print a copy of the Quick Test Page before making any adjustments to the alignment assembly reference adjustment screw When replacing the alignment assembly it is necessary to back t
255. lowing 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 Printer not printing no media over sensors Printer printing 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 FRU Action 1 Fuser exit sensor exit sensor test Enter the Diagnostic mode select BASE SENSOR TEST select the 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 2 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 cable correctly If damage to the cable or connectors is found replace the cable 3 Fuser exit sensor flag Make sure the sensor flag is not binding
256. lung 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 l Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe lllb 3b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanom tres L imprimante et son syst me laser sont concus pour impossible dans des conditions normales d utilisation d entretien par l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs des rayonnements de Classe Laser notices Xi 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 IIIb 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
257. ly 4 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 5 Autocomp cable Check continuity of the autocomp cable If correct replace the ITC assembly If incorrect replace the autocomp cable Diagnostic information 2 115 Parallel port service check Run the Parallel Wrap tests on page 3 8 Note The Parallel Wrap Test is designed to check the parallel port hardware by using a wrap plug P N 1319128 and invoking the Parallel Diagnostic Test This test helps isolate the printer from the parallel cable and host The test provides failure information on the display for approximately three seconds If the test indicates that a problem is detected replace the controller board Print quality service check 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 itis 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
258. m board 3 Remove the three screws securing the cartridge duct A Note It may be necessary to pull the main fan cable B up and out of the way to remove the duct 4 Reconnect the printhead laser cable Note Be sure to reposition the main fan cable if you moved it out of the way when removing the duct Repair information 4 23 Developer drive assembly removal 1 Remove the system board and inner shield See System board and inner shield removal on page 4 76 2 Remove the two short screws A and the one long screw B securing the developer drive assembly 3 Remove the developer drive assembly 4 Remove the developer drive coupler kit See Developer drive coupler kit removal on page 4 25 Installation 1 Place the developer coupler into the main motor drive shaft 2 Place the developer drive shaft on the developer drive 3 Align the developer drive shaft with the coupler 4 Be sure to replace the screws in the same positions 4 24 Service Manual Developer drive coupler kit removal 1 Remove the developer drive See Developer drive assembly removal on page 4 24 2 Remove the shaft drive and coupler ESD cover removal 1 Open the multipurpose tray and remove the tray from the two mounting posts See Multipurpose feeder lower front cover assembly removal on page 4 15 2 Carefully lift the latch on the left A and remove the ESD cover Note Be careful not to stress the hinge on th
259. m board 2 126 toner sensor 2 127 transfer roll 2 128 service error codes 2 8 shield inner shield 4 76 outer 4 67 signature button contact assembly parts catalog 7 34 removal 4 75 l 6 Service Manual specifications acoustics 1 7 dimensions 1 5 electrical 1 6 environment 1 7 media 1 8 memory configuration 1 4 operating clearances 1 4 power requirements 1 6 print media 1 15 resolution 1 3 speed and performance 1 3 StapleSmart finisher locations 5 12 parts catalog 7 65 7 66 7 67 7 68 service check 2 123 start 2 1 strobe adjustment 3 21 switch cover closed 2 80 symptoms base printer 2 5 duplex option 2 6 envelope feeder 2 6 high capacity feeder 2 5 output expander option 2 6 paper trays 2 6 StapleSmart finisher 2 7 system board connectors 5 1 parts catalog 7 30 removal 4 76 service check 2 126 system code 3 1 T theory of operation autocompensator 3 31 autoconnect cabling and connectors 3 32 duplex unit 3 32 option microcode 3 32 toner sensor removal 4 77 tools 1 19 Top Margin duplex 3 10 simplex front side 3 4 transfer roll assembly parts catalog 7 26 removal 4 77 service check 2 128 transparencies 1 16 U unique tools 1 19 unsatisfactory papers 1 15 upper front cover parts catalog 7 2 removal 4 11 upper front cover hinge assembly removal 4 78 upper front cover latch removal 4 13 upper paper deflector 4 79 user attendance messages 2 32 user line 2 link messages 2 43 user status displays 2 31
260. n the gearbox assembly FRU Action 1 Main drive assembly excessive noise or vibration 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 2 Main drive motor assembly excessive noise gears ratcheting and so on 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 3 Main drive motor cable Check the continuity of the main drive motor cable If incorrect replace the cable 4 Motor gear does not turn no 936 error code or 201 xx Paper Jamuser message displays Check the voltages at J20 on the system board Pin Voltage Static When main drive motor is running J20 11 24 V dc J20 8 5 V de 0 V dc J20 7 5 V dc 0 V dc J20 6 5 V de 2 5 V dc J20 5 5 V de 0 V dc J20 4 5 V de 5 V de J20 1 5 V de 0 V dc If the voltage is incorrect replace the FRUs in the following order Main d
261. n the nip Fuser page e Fuser not receiving AC power o 400 000 Poor supply line voltage gt Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll Abrupt change in temperatures that has disrupted control 920 51 Hot roll took too long to Bad thermistor circuit or cabling Go to 920 xx Cold fuser heat up after transitioning to new enhanced mode Fuser page count more than 500 000 Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll service check on page 2 87 Diagnostic information 2 13 Service error codes 9xx xx continued Error Sub code codes Display text Description Action 92 52 Hot roll fell too far below Bad thermistor circuit or cabling Go to 920 xx Cold fuser desired temperature service check on page 2 87 while printing Fuser Noisy thermistor signal page count more than Fuser not receiving AC power 500 000 Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 53 Hot roll too cool while Bad thermistor circuit or cabling Go to 920 xx Cold fuser checking for slope s service check on page 2 87 change Fuser page Noisy torneo signal count more than Fuser not receiving AC power 500 000 Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 54 Hot
262. n the shaft Note This C clip is very difficult to locate and remove 11 Pull the shaft assembly G to the right until the left end of the shaft is clear of the frame and slide the MPF solenoid assembly from the shaft 4 64 Service Manual 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 Repair information 4 65 Operator panel board removal Warning When replacing any one of the following components Operator panel assembly or upper front cover 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 can not be used in another printer It must be returned to the manufacturer 1 Remove the upper front cover See Upper front cover removal on page 4 11 2 Remove the seven screws A and remove the operator panel board Warning When the operator panel is removed some of the parts underneath are free to fall away
263. nd replace the fuser assembly See Fuser assembly removal on page 4 26 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 92 202 13 Page is covering narrow f page is not visible from front or rear Check the fuser and area media sensor during of the machine partial piece may be around the fuser assembly for warm up Fuser page torn off in the fuser covering the any signs of debris or pieces of count between 100 000 narrow media sensor paper or media and 199 999 The narrow media sensor or flag may be dislodged or damaged 202 14 Exit sensor bounced Exit sensor assembly Go to Fuser exit sensor Fuser page count service check on page 2 92 between 100 000 and 199 999 202 16 Page is covering 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 been cleared from a prior jam any signs of debris or pieces of between 100 000 and paper or media 199 999 2 56 Service Manual User attendance messages paper jams and paper handling errors 2xx
264. nd system board If not problem is found go to Main drive service check on page 2 105 Diagnostic information 2 51 User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 201 92 Page did not reach exit sensor Fuser page count is not available Page jammed on fuser input guide Page did not enter or exit fuser nip cleanly Exit sensor not functioning correctly Check the fuser entry guide for toner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 92 201 94 Expected wide page not detected by narrow media sensor possible accordion jam Fuser page count is not available Page did not enter or exit fuser nip cleanly Narrow media sensor not functioning correctly Actual page is narrow when wide page was expected f 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 26 f media is narrow then turn off first sheet detection engine settings 3 16 In Diagnostics mode select PRINTER SETUP an
265. ng correctly Printer and duplex not aligned Make sure the duplex assembly rear door is properly latched Check upper redrive diverter and diverter spring for any signs of damage a 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 the operator panel on page 2 83 233 00 Paper failed to make duplex doublefeed sensor during turnaround Duplex rear door not fully latched Duplex feed system not working correctly Make sure the duplex assembly rear door is properly latched f available try another duplex option If none is available go to 233 xx Jam displayed on operator panel on page 2 83 234 00 Paper did not arrive at duplex exit sensor Duplex rear door not fully latched Duplex feed system not working correctly Severely skewed media coming from the printer Check the media coming from the printer to the duplex option is not damaged or skewed If the media is not damaged or skewed try another duplex option if available If not available replace the duplex option Diagnostic information 2 67 User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 23
266. ng 7 34 7 35 7 36 7 38 7 40 covers 7 2 drives main drive and developer drive 7 22 duplex option 7 46 electronics card assemblies 7 30 power supplies 7 28 shields 7 32 envelope feeder 7 47 frame 7 4 7 6 7 8 high capacity feeder 7 58 7 60 7 62 7 63 high capacity output expander 7 50 7 51 hot roll fuser 7 24 integrated paper tray 250 sheet 7 18 integrated paper tray 500 sheet 7 20 kiosk vertical and horizontal paper adapters 7 64 optional 250 sheet paper drawer 7 42 optional 250 sheet paper tray 7 43 options 7 69 output expander 7 48 7 49 paper feed alignment 7 16 autocompensator 7 12 multipurpose feeder 7 14 printhead 7 10 StapleSmart finisher 7 65 7 66 7 67 7 68 transfer charging 7 26 pass thru plate 4 18 pick rolls integrated tray autocompensator 4 51 pick tire integrated tray autocompensator pick roll 4 51 MPF 4 62 power takeoff shaft and spring 4 72 power on self test POST 2 4 preventive maintenance 6 1 print media avoiding jams 1 19 card stock 1 18 characteristics 1 15 envelopes 1 16 guidelines 1 15 labels 1 17 sizes 1 8 storing 1 18 types 1 10 unsatisfactory types 1 15 weight 1 11 print quality pages 3 6 3 26 print registration 3 4 printhead adjustment 4 2 parts catalog 7 10 removal 4 73 service check 2 122 Q quality pages 3 6 3 26 Quick Disk Test 3 18 Quick Test 3 5 3 9 R redrive assembly parts catalog 7 6 removal 4 74 redrive cap cover removal 4 5 redrive door 4 7 REGI
267. nnot Software Error establish communications with it 54 XX Network x This error displays when a network port is detected but the printer cannot Software Error establish communications with it 55 XX Unsupported option in An unsupported option is installed in the specified solutions port Power off Slot x the printer and remove the unsupported option in the specified slot 55 XX Unsupported Flash in An unsupported flash option is installed in the solutions port Power off the Slot x printer and remove the unsupported flash option in the specified slot 56 XX Standard Serial This error displays when data is sent to the printer across the standard serial Disabled port but the port has been disabled 56 XX Serial Port x Disabled This error displays when data is sent to the printer across an optional parallel port but the port has been disabled Once this message displays reporting of further errors is suppressed until the menus are entered or the printer is reset 56 XX Standard USB Port Displayed when status is requested over the USB port but the port has been Disabled disabled Once the error has been displayed for the first time reporting of further errors is suppressed until the menus are entered or the printer is reset The following actions may be taken Press Y to clear the message The printer discards any data received on the USB port Press en until Busy Waiting appears The following are available Reset Printer Reset Act
268. no Signal J1 Interconnect card J2 Printhead laser cable Video Level 2 Video3 Ground 5PHead LPOW LADJ LPOW FB LENA J3 Printhead HSYNC mirror motor Ground HSYNC CN HSYNC ID 5 V dc O O J O 0O A O N CO J O oO A OJN E o a N J4 Main fan a FANSTALL Ground MAINFAN J5 Cartridge fan j N CARTFANSTAIL Ground CARTFAN J6 Hopper full output bin sensor j N HOP FULL Ground w m HOP LED J7 USB port a NI O O17 A OJN 5 2 Service Manual System board see System board on page 5 1 Connector Pin no Signal J8 Cover closed switch Cov Closed Ground Wj N 5V dc J10 Fuser DC NARMEDIA Ground THERM Ground THUMP 5V dc THUMPRET EXIT SNS o o NIOJ Aa AJ OJN 3 3 V dc 12C CLK L5 i a4 o 12C DAT L5 J13 Operator panel 12C DAT 5 V dc 12C CLK Ground PANEL INT 3 3 V dc ojoc m c0 InN Ground J14 Signature button k SM Cart N Ground J15 HVPS input sensor Cartridge toner wheel sensor ATSERVO TXENABLE XFR 24 V dc switched CHARGE Ground DEV CO NI
269. nsing board 4 71 power takeoff shaft and spring 4 72 printhead 4 73 redrive assembly 4 74 signature button contact assembly 4 75 system board 4 76 toner sensor 4 77 transfer roll assembly 4 77 upper front cover hinge assembly 4 78 upper paper deflector assembly 4 79 USB board assembly 4 80 right cover handle holder removal 4 16 right cover removal 4 8 Index 1 5 S safety information xvii safety inspection guide 6 1 scheduled maintenance 6 1 sensors fuser exit sensor 4 28 fuser narrow media sensor 4 34 input 4 48 output bin sensor integrated paper tray 2 109 paper bin full 4 70 paper size sensing board 4 71 toner 4 77 serial number 3 20 serial wrap tests 3 9 service checks 5 bin mailbox 2 72 900 xx error code 2 75 927 xx fan 2 76 950 00 through 950 29 EPROM mismatch failure 2 77 charge roll 2 79 cover closed switch cable 2 80 cover open switch cable 2 80 dead machine 2 80 duplex option 2 82 envelope feeder 2 84 fuser 2 87 fuser exit sensor 2 92 fuser narrow media sensor 2 93 fuser solenoid 2 94 high capacity feeder input tray 2 95 high capacity output stacker 2 100 input sensor 2 102 input tray optional 2 102 interconnect card 2 104 main drive 2 105 main fan 2 76 operator panel 2 106 options 2 108 output bin sensor 2 109 output expander 2 110 paper feed 2 112 paper size sensing board 2 113 parallel port 2 116 print quality 2 116 printhead 2 122 signature button assembly 2 122 StapleSmart finisher 2 123 syste
270. nt between 400 000 and 499 999 Page may be jammed in fuser exit or redrive Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 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 92 202 41 Page did not cleanly exit fuser or redrive area Fuser page count between 400 000 and 499 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce W curl 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 sens
271. ntact cover D 5 Release the latch E and remove the cover 6 Remove the screw F on the left side and the screw G on the right side that attach the fuser upper cover assembly to the fuser frame 7 Remove screw H that attaches the side fuser lamp contact to the fuser top cover 4 42 Service Manual 8 Remove the fuser cover aco Fuser transfer plate removal Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 79 Remove the transfer roll See Transfer roll assembly removal on page 4 77 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 47 Lift the left side of the fuser transfer plate A and move the plate to the left to clear the right side from its mounting E i ud om A 5 Remove the screw that attaches the transfer plate ground wire to the center pan 6 Remove the fuser transfer plate 7 Remove the screw that attaches the deflector cable to the transfer plate Repair information 4 43 Gear release link removal 1 Remove the system board and inner shield See System board and inner shield removal on page 4 76 2 Remove the developer drive 3 Disconnect the gear release link A from the hole in charge roll link B Note Lift the upper front cover to make it easier to remove the link A B 4 Rotate the link to disconnect the link from the main drive assembly 5 Remove the gear release link
272. nual Assembly 4 Frame 3 Asm Part Units Units kit Description Index number mach or pkg 4 1 40X0235 1 1 EP DC fan assembly 200 210 400 410 2 40X0208 1 1 Blower duct 200 210 400 410 3 1 1 Parts packet PP 40X0165 3 1 1 Parts packet PP 40X0165 4 40X0034 1 1 Signature button sensor assembly 5 40X0035 1 1 EP DC fan assembly 000 010 6 40X0033 4 1 Machine mounting pad 7 40X0223 1 1 HVPS input sensor toner sensor cable assembly 8 40X0036 1 1 Toner sensor assembly 9 40X0306 1 1 High voltage contact kit including Charge roll contact 1 Doc TAR Dev contact 3 PC drum contact 1 Screw 5 Screw block 4 10 40X0213 1 1 Tray bias assembly 11 40X0021 2 1 Cartridge holddown assembly 12 40X0040 1 1 Upper paper feed deflector 13 40X0041 1 1 Inner paper feed deflector 000 010 13 40X0042 1 1 Inner paper feed deflector 200 210 400 410 14 40X0039 2 1 Developer support roller 15 40X0043 1 1 Input sensor 16 40X0209 1 1 Gear 60 MPF shield 17 40X0045 1 1 ESD shield with label 18 40X0207 1 1 EP duct Parts catalog 7 9 Assembly 5 Printhead Bottom View 7 10 Service Manual Assembly 5 Printhead Asm Part Units Units kit Description Index number mach or pkg 4 1 40X0061 1 1 Laser cable assembly 2 Parts packet printhead mounting screw PP 40X0165 3 40X0062 1 1 Printhead assembly includes all cables CA
273. nvelope feeder option 3 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 FRU Action 1 Latch lever 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 2 86 Service Manual 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
274. ode Motor Defective main drive motor check on page 2 105 is type O Paper jams 937 71 Loss of lock detected by Defective motor cable Go to Main drive service higher level code Motor e Defective main drive motor check on page 2 105 is type 1 e Paper jams 937 80 Driver over temperature Excessive gear loading in gearbox Go to Main drive service detection Motor is assembly check on page 2 105 type O 939 00 RIP engine System board POR the printer several times if communications lost the error code continues to be displayed replace the system board See System board and inner shield removal on page 4 76 940 00 LVPS zero crossing test Incorrect LVPS installed Check to make sure the correct failed e Noi LVPS assembly has been Noisy AC power source installed If the correct supply is LVPS to system board cable loose installed check to make sure the LVPS to system board cable is installed correctly If correct replace the LVPS assembly See Low voltage power supply removal on page 4 54 947 00 PQET RAM test PQET failed to pass RAM tests on the Replace the system board See incomplete system board System board and inner PQET RAM test did not shield removal on page 4 76 complete PQET RAM test failed MARCHO PQET RAM test failed MARCH1 PQET RAM test busy failure 948 00 Pel clock check failed System board Replace the system board See System board and inner shield removal on page 4
275. of the fuser narrow media sensor cable If incorrect replace the cable if correct check the continuity of the di fuser to system board cable If incorrect replace the cable if correct cable replace the following FRUs in the order shown Fuser board Fuser board ber 1o GysteniPOSrd Fuser assembly See Fuser assembly removal on page 4 26 e System board See System board and inner shield removal System board on page 4 76 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 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 93 Fuser solenoid service check CAUTION There is a danger from hazardous voltage in the area of the printer where you are working Unplug the printer before you begin or use caution if the printer must receive power in order to perform the task Service tip Try changing the envelope enhance level setting A different setting may correct the problem Note Check the fuser envelope conditioner solenoid adjustment as described in the ad
276. on If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 f media is narrow then turn off first sheet detection engine settings 3 16 In Diagnostics mode select PRINTER SETUP and Engine Setting 3 The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 93 201 40 Page did not reach exit sensor Fuser page count between 400 000 and 499 999 Page jammed on fuser input guide Page did not enter or exit fuser nip cleanly Exit sensor not functioning correctly Check fuser entry guide for toner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 92 201 41 Main drive motor identification failed Fuser page count between 400 000 and 499 999 Main drive motor not working Check the motor connections to motor and system board If no problem is found go to Main drive service check on page 2 105 Diagnostic information 2 49 User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 201 42 Page did not reach exit sensor Fuser page c
277. ong Multi sheet feed that is shingled Tray size sensing wrong size Paper jam leaving page over sensor Fan media and stack flat in tray or MPF Check for anything in the 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 2 102 200 02 Input sensor covered too long Multi sheet feed that is shingled Tray size sensing wrong size Paper jam leaving page over sensor Fan media and stack flat in tray or MPF Check for anything in the paper path that might cause the paper to jam e If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 102 200 04 Input sensor covered too quickly Paper pre staged in path Wrong configuration ID causes engine to assume 500 sheet paper path on 250 sheet model Bouncy input sensor Check MPF and friction pad Fan media and stack flat in tray or MPF Use different media Check config ID 200 06 Imaged page not expected page Bouncy pass thru sensor Perform a sensor test to check the sensor for the tray See Sensor Test input tray on page 3 13 200 07 Option tray never picked a page Go to Input sensor service check on page 2 102 2 44 Service Manual User attendance messages paper jams and paper handling errors 2xx xx
278. onless copy paper CCP or no carbon required NCR paper e Preprinted papers with chemicals that may contaminate the printer Preprinted papers that can be affected by the temperature in the printer fuser Preprinted papers that require a registration the precise print location on the page greater than 0 09 in Such as optical character recognition OCR forms e In 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 General information 1 15 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 Use envelopes that can withstand temperatures of 225 C 437 F without sealing excessive curling wrinkling or releasing hazardous emissions
279. operating properly Go to Fuser narrow media sensor service check on page 2 93 201 20 Page did not reach exit sensor Fuser page count between 200 000 and 299 999 Page jammed on fuser input guide Page did not enter or exit fuser nip cleanly Exit sensor not functioning correctly Check fuser entry guide for toner build up Check fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 92 201 21 Main drive motor identification failed Fuser page count between 200 000 and 299 999 Main drive motor not working Check motor connections to motor and system board If no problem is found go to Main drive service check on page 2 105 Diagnostic information 2 47 User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 201 22 Page did not reach exit sensor Fuser page count between 200 000 and 299 999 Page jammed on fuser input guide Page did not enter or exit fuser nip cleanly Exit sensor not functioning correctly Check fuser entry guide for toner build up Check fuser for wear or contamination If a problem is found replace the fuser assembly
280. 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 Power takeoff shaft and spring bevel gear feed roll gear drive roll assembly wear plate drive shaft bearings and skewed backup roller Check these parts for signs of 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 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 Paper Low displays when tray x is full or has adequate paper in the tray FRU Action Paper low switch Paper low switch cable High capacity feeder Input system board Run the sensor diagnostics for tray x x the number that represents the high capacity input tray If the test fails disconnect the paper low switch cable from J3 on the high capacity system board Short pins 1 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 2 96 Service Manual Tray x Empty displays when there is p
281. or ejSw2 Paper ejswi size ZH Auto Compensator Motor Encoder Il To J18 2 To 325 3 bg Autoconnect I Bottom ejswo Switches S 2 st LE o o E o o
282. or service check on page 2 92 Diagnostic information 2 61 User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes Action code codes 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 PED 400 000 and Check the fuser for any dod signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce W curl 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 92 202 43 Page is covering narrow f 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 The narrow media sensor or flag may be dislodged or damaged 202 44 Exit sensor may have Exit sensor assembly Go to Fuser exit
283. or supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 23 Hot roll too cool while Bad thermistor circuit or cabling Go to 920 xx Cold fuser eee ie ae e Noisy thermistor signal service check on page 2 87 Fu count between 200 000 Fuser not receiving AC power and 299 999 Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll 920 24 Hot roll too cool when Bad thermistor circuit or cabling Go to 920 xx Cold fuser acct n oes e Noisy thermistor signal service check on page 2 87 change Fuser page Fuser not receiving AC power count between 200 000 s and 299 999 Poor supply ling voltage e Low voltage or incorrect lamp e Incorrect hot roll 920 26 Fuser is not increasing e Fuser is not receiving AC power Go to 920 xx Cold fuser tee eae e Poor supply line voltage service check on page 2 87 been on for an extended tim Fuser page count between 200 000 and 299 999 920 27 Fuser has been below Bad thermistor circuit or cabling Go to 920 xx Cold fuser Mea e Wn api uie Very noisy thermistor signal service check on page 2 87 is in the nip Fuser page Fuser not receiving AC power count between 200 000 and 299 999 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 920 31 Under temperature Bad thermistor
284. ork does not appear unless you have a network printer The following settings are not changed Display language Settings in the NETWORK PORTS MENU group Energy Conserve This menu controls what values appear on the Power Saver menu 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 EVENT LOG The event log provides a history of printer errors The event log can only be printed in CONFIG MENU Additional options are available in DIAGNOSTICS See EVENT LOG on page 3 23 To print the event log 1 Select Print Log from EVENT LOG 2 Press Back or Stop 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 Selections are Auto default MP Feeder and Manual Paper Env Prompts This setting controls the tray the user is directed to refill when specific envelope size is out The selections are Auto default MP Feeder and Manual Env Jobs On Disk If the hard disk is installed Jobs On Disk allows the user to delete buff
285. orrect 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 Diagnostic information 2 127 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 associated parts for personal safety and to prevent damage to the printer CAUTION Make sure the printer is unplugged before making any checks on the transfer roll or FRU Action 1 Transfer roll assembly Check the transfer roll for toner buildup surface damage to
286. ou bod e POP teres e qud e xd e E 7 46 Assembly 27 Envelope feeder 0 0 cece eet re 7 47 Assembly 28 Outputexpander1 0 0 eee ete 7 48 Assembly 29 Outputexpander2 o ocooocoo rh 7 49 Assembly 30 High capacity output expander 0 eee 7 50 Assembly 31 High capacity output expander 2 0 cee ee 7 51 Assembly 32 High capacity output expander 3 0 0 cee 7 52 Assembly 393 bin mallBOXx T iius oot Hoe Hdd dee ee tke aeta bod cup ae ds 7 54 Assembly 34 5S binimallboxX 2 2266 ccccceckac error eed ee ec ado er PUR de desde AA 7 56 Assembly 35 High capacity feeder 1 0 cee eee ees 7 58 Assembly 36 High capacity feeder 2 auauua 7 60 Assembly 37 High capacity feeder 4 0 ee ete ees 7 62 Assembly 38 High capacity feeder 5 o ooocoocococorr teen enees 7 63 Assembly 39 Kiosk vertical and horizontal paper adapters 20 eee eaeee 7 64 Assembly 40 StapleSmart finisher 000 eect tte ee 7 65 Assembly 41 StapleSmart finisher 2 0 0 00 ccc tees 7 66 Assembly 42 StapleSmart finisher 3 oooocooccocoorr 7 67 Assembly 43 StapleSmartfinisher4 oooocccoccooor 7 68 Assembly44 Options 522 Re Uu soii ria que frais aqui ed 7 69 IDA AAA AAA AAA 1 1 Part humber INGEN iiu d dk x caia AAA 1 9 Table of contents ix X Service Manual Laser notices
287. ount between 400 000 and 499 999 Page jammed on fuser input guide Page did not enter or exit fuser nip cleanly Exit sensor not functioning correctly Check the fuser entry guide for toner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 92 201 44 Expected wide page not detected by narrow media sensor possible accordion jam Fuser page count between 400 000 and 499 999 Page did not enter or exit fuser nip cleanly Narrow media sensor not functioning correctly Actual page is narrow when wide page was expected f 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 26 f media is narrow then turn off first sheet detection engine settings 3 16 In Diagnostics mode select PRINTER SETUP and Engine Setting 3 The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 93 201 50 Page did not reach exit sensor Fuser page count stopped at 500 000 to preserve data Page jammed on fuser input guide Page did not enter or exit fus
288. output expander option 271 xx Paper Jam Check Bin x POST incomplete Control board FRU Action 1 Pass thru sensor and flag Check the sensor flag for proper operation If correct check to make assembly sure the pass thru sensor cable is correctly connected to J3 on the control board Disconnect the pass thru sensor cable from J3 on the control board and check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect replace the control board If correct check the voltage at J3 2 The voltage measures approximately O V dc If incorrect replace the sensor assembly If this does not fix the problem replace the output expander option 271 xx Paper jam Check Bin x POST complete first sheet of paper feeds into output bin x Note Before performing the following checks run the Output Bin X Sensor Test and check for the failing sensor Sensor Test NF Near Full Upper part of sensor assembly F Full Lower part of sensor assembly P Pass Thru Sensor 990 Service Bin x If displayed replace the output expander option No indication that bin x is full or no indication that bin x is near full FRU Action 1 Dual output bin x sensor Check for correct installation of the sensor cable at J5 on the output assembly expander control board If either the Bin Full F or Bin Near Full NF Output expander control fail the sensor test then check the voltage at J5 3 and J5 4 Th
289. oval on page 4 54 if correct go to step 4 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 Fuser top cover dese mpl pins on the fuser lamp AC cable connector Fuser connect cable fuser to fuser lamp cable e If there is continuity go to step 5 e If there is no continuity check 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 Diagnostic information 2 87 FRU Action LVPS LVPS to fuser AC cable A 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 Fuser top cover assembly thermistor thermistor cable Fuser to sys
290. p es qai pU dqueqadbeqedq i aiit e Ped Ib drdqa dns 4 32 Fusernarrow media Sensor tomova issus d cc ici ad XU Ree 4 34 Fuser narrow media flag and spring removal seseeee A 4 36 Fuser Tob VPS AC cable removal 2422 3 abe a OI HORORRCRUK UR EU A LR BAUR ag 4 38 Fusertop coverfemoVal ike por ERE RR rra CI PRI PPRERSQEPTES ELE SEE PE 4 41 Fuser transier plate removal sisecigan said de R3 ge dadddd da d 49d bids 4 43 Gear release link remoVal 2 semis rei pe rra rr RARA ARA 4 44 High voltage power supply removal eo mera aper tends Geese Rae is taba dir 4 45 Inner paper deflector assembly removal 202 cece ee eee eee eee eee 4 47 Input sensor removal e costo wie meom A hae qa argo Samah ay giana gece dique rd wali 4 48 Integrated tray autocompensator assembly removal 0 000 c eee eee eee eee 4 49 Integrated tray autocompensator pick roll assembly removal eese 4 51 Interconnect card assembly removal pics seda ose n ERPEREREPEREGREPRPRRREAERREPERE 4 53 Low voltage power supply TRIIBVAl aua decurio 9o dt niche RUPEE eade e e pas 4 54 Naim Tam CemOVBl asas qaasi sd due oi ii cafus iei 4 56 Main drive assembly removal 5i RR ERE ERI REPE ERA RV PEPERIT 4 57 MPP armiassembly removal scams iii tds is de iibi 4 60 MPF lower paper deflector uma seek s bp Reha Gere sete geese ead serene canoer s 4 61 MPF pick tire removal ss descr raed Guns oder PRU ea 4 62 MPF solenoid assemibly removal i e tre rR RR REPRET U
291. page 4 78 If the correct replace the system board See System board and inner shield removal on page 4 76 4 Operator panel all diamonds no beeps Make sure a card is not plugged in backward This condition causes the printer to fail POST displaying all diamonds on the operator panel with no beeps 5 Operator panel all diamonds 5 beeps Check the voltage at Pin J13 1 and J13 3 The voltage measures approximately 3 3 V dc If incorrect replace the FRUs in the following order Operator panel board see Operator panel board removal on page 4 66 or the Upper front cover see Upper front cover removal on page 4 11 e System board See System board and inner shield removal on page 4 76 Upper front cover hinge assembly See Upper front cover hinge assembly removal on page 4 78 Diagnostic information 2 107 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
292. 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 Symptom Action 1 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 Diagnostic information 2 117 Print quality blurred or fuzzy print Blurred of fuzzy print is usually caused by a problem in the main drive gearbox assembly alignment assembly any feed roller or in the transfer roll bearings or transfer roll Check the gearbox assembly for correct operation Check the transfer roll for binds or a contaminated shaft or bearings Blurred print can also be caused by incorrect feeding from one of the input paper sources paper trays duplex option or envelope feeder Check the high voltage contacts to ensure they are not bent corroded or damaged Replace as necessary Print quality background Service tip Some background problems can be caused by rough papers non Lexmark toner cartridges or if the media text
293. r 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 32 Service Manual Paper Feed Jams Access doors and trays The following illustration shows the path that print media travels through the printer The path varies depending on the input source trays multipurpose feeder envelope feeder and output bins finisher stacker expander mailbox you are using 200 201 F 202 Paper Jam Paper Jam 201 Paper Jam 200 Paper Jam 23X Paper Jam 202 Paper Jam Bi 260 Paper Jam 23X Paper Jam f 260 Paper Jam Y lt lt aer E ON m E 250 Paper Jam TS E 250 Paper Jam 24X Paper Jam ay N 24x Paper Jam lA Clearing printer jams Although there are several places a jam can occur clearing the paper path is fairly easy depending on the jam message or messages displayed on the operator panel Paper jams can occur in three areas the front of the printer inside the print
294. r locations at Low voltage power supply removal on page 4 54 If incorrect replace the LVPS assembly see Low voltage power supply removal on page 4 54 if correct go to step 4 4 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 i fuser cable from the fuser to fuser lamp cable Plug the AC line cord 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 54 Note If the fuses in the LVPS are blown the LVPS assembly must be replaced 5 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 Fuser to system board DC cover assembly Fuser narrow media sensor removal on cable page 4 34 If no problem is found check the fuser to system board DC cable for cor
295. r 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 Tray x Empty displays when tray x has paper in the tray FRU Action Paper out sensor flag Paper out sensor on option system board Check the paper out sensor flag for correct operation and installation If correct replace the option system board The paper out sensor is mounted on the system board Printer does not recognize Tray x is installed FRU Action Autoconnect cables Tray x system board Check the autoconnect from the printer or option above tray x Check 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 Diagnostic information 2 103 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 F
296. r requirements for the base printer configuration 110 volt Power levels are shown in watts W Maximum current is given in Amperes A Printing states e STUDIO 500P Off all models 05 W 05 W 05 W Idle average power Power Saver on 20W 20W 20W Power Saver off 90W 95W 95W Continuous printing 675 W 880 W 880 W Printing maximum current 100 V 7 8 A 8 9 A 8 9 A 120 V 7 2 A 8 0 A 8 0 A 230 V 3 4 A 4 3 A 4 3 A Electrical specifications Low voltage model 100 to 127 V ac at 50 to 60 Hz nominal e 90to 137 V ac extreme High voltage model 220 to 240 V ac at 50 to 60 Hz nominal not available in all countries e 190 to 259 V ac extreme Notes Using a 220 to 110 power converter with the 110 volt printer is not recommended e All models are ENERGY STAR qualified The default timeout to power saver is 30 minutes for all models 1 6 Service Manual Environment Printer temperature and humidity Operating Temperature 16 to 32 C 60 to 90 F Relative humidity 8 to 8096 Altitude 10 000 ft 0 to 3 048 meters Storage and shipping environment packaged Temperature 40 to 43 C 40 to 110 F Relative humidity 5 to 95 Altitude equivalent to 10 300 meters 0 to 34 000 feet Storage environment unpacked Temperature 0 to 40 C 32 to 104 F Relative humidity 5 to 80 Acoustics All
297. r sticky near the bottom of the tray these springs may be the problem Reducing the tension on the counterbalance spring may be used asa 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 31 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 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 printe
298. re stored in the event log To view the event log 1 Select Display Log from EVENT LOG Up to three error codes display at a time Press A or W to view additional error codes 2 Press Back to return to the EVENT LOG menu Print Log Additional diagnostic information is available when you print the event log from DIAGNOSTICS rather than CONFIG MENU The Event Log printed from DIAGNOSTICS includes Detailed printer information including code versions Time and date stamps Page counts for most errors Additional debug information in some cases Model and Event Log Serial number Lessmort T642 ate coenerrene Device lnformacion Printer information Panel display Event Log alormetion when error occurred _ A Page count Earliest error code MM ies BP iut Next error code The printed event log can be faxed to Toshiba or your next level of support for verification or diagnosis Diagnostic aids 3 23 To print the event log Select Print Log from EVENT LOG Press Back to return to EVENT LOG Clear Log Use Clear Log to remove the current information in the Event Log This affects both the viewed log and the printed log information 1 Select Clear Log from the Event Log menu 2 Select YES to clear the Event Log or NO to exit the Clear Log menu If YES is selected Deleting EVENT LOG displays on the screen Press Back to return to EVENT LOG EXIT
299. rect 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 Diagnostic information 2 89 FRU Action 6 Fuser assembly If no problem is found up to this point then replace the following in the order shown Fuser assembly See Fuser assembly removal on page 4 26 System board assembly See System board and inner shield removal on page 4 76 VPS See Low voltage power supply removal on page 4 54 923 xx Hot fuser service check Error Code 923 xx 924 xx and 925 xx may display for a hot fuser failure CAUTION The fuser may be hot use caution before removing or servicing 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 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 FRU Action 1 Fuser assembly 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 s
300. ridge The exit rollers turn 2 4 Service Manual Symptom tables Base printer symptoms Symptom Action Dead machine Go to Dead machine service check on page 2 80 Operator panel one or more buttons do not work Go to One or more operator panel buttons fail on page 2 106 Operator panel none of the buttons work Go to No buttons work on page 2 106 Operator panel display is blank Printer sounds 5 beeps Go to Operator panel display on page 2 107 Operator panel display is blank Go to Operator panel display on page 2 107 Operator panel continuously displays all diamonds and does not complete POST Go to Operator panel service check on page 2 106 Paper feed problems base printer or integrated 500 sheet paper tray Go to Paper feed service check on page 2 112 Paper jams at exit of redrive assembly duplex option not installed Go to Paper feed service check on page 2 112 Paper jams at exit of redrive assembly duplex option installed Go to Duplex option service check on page 2 82 Fuser solenoid fails to operate Go to Fuser solenoid service check on page 2 94 Print quality black page Go to Print quality all black page on page 2 116 Print quality blank page Go to Print quality blank page on page 2 117 Print quality light print Go to Print quality light print on page 2 121
301. rint media can cause feeding 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 your printer and your cartridge with adhesive and could void your printer and cartridge warranties Use labels that can withstand temperatures of 225 C 437 F without sealing excessive curling wrinkling or releasing hazardous emissions e 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 e 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 your printer and could void your warranty e f zone coating of the adhesive is not possible a 3 mm 0 125 in strip should be removed on the leading and driver edge and a non oozing adhesive should be used e Remove a 3 mm 0 125 in strip from the leading edge to prevent labels from peeling inside the printer General information 1 17 Portrait orientation is preferred especially when printing bar codes e Do not use labels that have exposed adhesive Card stock Card stock is single ply and has a large array of properties such as the moisture content thickness and texture that can significantly affect print quality See Supported print media on page 1 8 for in
302. rinter and check the continuity of fuse F1 See Low voltage power supply removal on page 4 54 If continuity is correct replace the LVPS assembly If the voltage is incorrect replace the LVPS assembly Loads connected to the system board 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 Diagnostic information 2 81 Duplex option service check Messages displayed when a 23x Duplex Paper Jam displays 23x Paper Jam Leave Job Check Duplex in Finisher Primary message Secondary message If sheets have been accumulated to be stapled or offset when the jam is detected the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam clearance procedure Obviously if no sheets have accumulated for stapling then no message flashing occurs and the primary message is used When the secondary message is posted if accumulated sheets are removed during jam clearance the printer does not reprint the removed sheets Furthermore after the printer resumes printing and the print job is completed the portion of the job printed after the jam is not stapled Duplex paper jams 23x xx jam
303. rive motor assembly System board Diagnostic information 2 105 Operator panel service check Note The operator panel board is a separate FRU and is also part of the upper front cover FRU Warning When replacing any one of the following components e Operator panel assembly or upper front cover 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 can not be used in another printer It must be returned to the manufacturer Before continuing with this service check perform the Button Test on page 3 7 One or more operator panel buttons fail FRU Action 1 Operator panel buttons kit If any button fails the Button Test check the failing button or buttons and associated parts Repair using the button kit See Operator Operator panel board panel buttons removal on page 4 67 If the problem remains replace the operator panel board see Operator panel board removal on page 4 66 If a 950 xx error code is displayed
304. rting this service check In Diagnostics mode In Diagnostics mode select EP SETUP and Fuser Temp FRU Action Fuser assembly Fuser to system board cable 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 top cover assembly thermistor thermistor cable assembly Turn the printer off and disconnect the thermistor cable from J5 on the fuser board Measure the resistance between the two pins on the 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 System board Fuser assembly the fuser to system board cable from J10 on the system board and measure the resistance between J10 3 and J10 4 on the cable If the resistance measures infinity open circuit check the continuity of pins 3 and 4 of the cable If correct replace the fuser assembly See Fuser assembly removal on page 4 26 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 76 925 xx Hot fuser service check Error Code 923 xx 924 xx and 925 xx may display for a hot fuser failure CAUTIO
305. rvice Manual 3 Use W or A to select the margin setting you need to change and press Y The Top margin sign value pair blinks This indicates it is the margin value being changed T xxx L xxx B XXX R XXX 4 Use lt q to decrease or gt to increase the offset values and press Y to confirm the value The message Submitting selection displays and the original REGISTRATION screen appears with the y beside the previously selected margin setting The print registration range is Variable Description Value Direction of change B Bottom margin 20 to 20 Each increment causes approximately 0 55 mm shift in the bottom margin A positive change compresses the image so it appears to move down the page and a negative change moves the image up T Top margin 25 to 25 Each increment causes A positive change moves the image approximately 4 pels shift at 600 down the page and increases the dpi top margin A negative change moves the image up and decreases the top margin L Left margin 25 to 25 A positive change moves the image to the right and a negative change moves the image to the left No compression occurs R Right margin 10 to 10 A positive change moves the image to the right and a negative change moves the image to the left 5 Continue changing the settings by repeating steps 2 through 4 6 Print another copy of the Quick Test to verify your
306. s displays on page 2 31 For example Ready warning If none of the conditions exist that are listed in the following table line two is blank If any of the messages in the table are displayed the following actions can be taken Press 2 to take the printer offline and access the Ready Menu group The gt buttons are not active if Menu Lockout is turned on Press to take the printer offline The Not Ready message displays No additional data is processed from the host computer Press to return the printer to the Ready state User status displays Error code Sub code Display text Description action Toner Low If the toner cartridge is low then Toner Low displays The Toner Low condition clears whenever the upper front door is opened and Toner Low displays again if the condition exists after the upper front door is closed Tray x Missing If any of the input trays equipped with tray present sensing are missing then Tray x Missing displays where x designates which tray 1 through 5 is missing If multiple trays are missing they are prioritized in this order Tray 1 2 then Tray 5 Tray x Missing status clears whenever Tray x is reinserted If the Tray 1 Missing message does not clear when tray 1 is inserted go to Parallel port service check on page 2 116 If Tray 2 through 5 Missing message does not clear by inserting the tray go to Input tray s service check on page 2
307. s mounted correctly and is not pushed down into the frame assembly or damaged Be sure the high capacity feeder input tray autoconnect is properly connected to the high capacity feeder tray option board assembly 2 Base printer or option mounted above Check the option or base printer autoconnect for signs of damage Repair the high capacity option autoconnect as necessary 3 LVPS Option system board A Check the voltages at J11 2 and J11 4 The voltage measures 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 Diagnostic information 2 95 FRU Action High capacity feeder option control board A Check the voltage on J8 1 green The voltage measures 24 V dc If incorrect check the autoconnect system for any problems 24 V dc must come from the base printer through the autoconnect system to the high capacity input for the high capacity feeder to be recognized If the voltage is correct check the voltages at J11 3 red and J11 4 red The voltages measure 24 V dc If correct replace the high capacity feeder option system board If incorrect disconnect J8 from the system board and measure the voltages again If incorrect check the LVPS cable and the AC internal
308. s or PINs 000 The backspace is used to delete the number to the left of the cursor Pressing the backspace multiple times will delete additional entries The pound sign is not used 000 Display panel The display panel shows messages and graphics describing the current state of p ay p the printer and indicating possible printer problems you must resolve S Status Supplies The top line of the display is the header line If applicable it will contain the Y Ready graphic indicating the Back button can be used It will also display the current Tray 1 low status and the Supplies Warnings status If multiple warnings are present Understanding the menus The diagram shows the menu index on the operator panel and the menus and items available under each menu For more information about menus and menu items refer to the Menus and Messages book on your Publications CD S Menu y Paper Menu Reports Settings Paper Menu Reports Settings Network Ports Security Default Source Menu Settings Page Setup Menu IPv6 Max Invalid PIN Paper Size Type Device Statistics Finishing Menu TCP IP Job Expiration Configure MP Network Setup Page Quality Menu Standard Network Encrypt Disk Envelope Enhance Network x Setup Page Utilities Menu Network x Substitute Size Profiles List PDF Menu Standard USB Help Paper Texture Print Quick Ref PostScript Menu USB x Print All Paper Weight NetWare Setup Page P
309. s si per treballar amb l equip l heu de connectar UNE ft A i FERA A SED IR fe E PERRA RR E FX BEY PR S FG SIN WHER TPE IP im K R Wie ER IAE rfl tut WE Hn EEP M pH zH Se Se ERU CPU SES Rs BUSCA TEASE NDA Safety information xix Preface This manual contains maintenance procedures for service personnel It is divided into the following chapters 1 General information contains a general description of the printer and the maintenance approach used to repair it Special tools and test equipment 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 7 Parts catalog contains illustrations and part numbers for individual FRUs a pb O N o Definitions Note A note provides additional informa
310. s size does not appear in the Paper Size menu until Tray Size Sensing is turned off 2 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 No universal support for the following options 2000 sheet drawer Envelope Feeder 5 bin mailbox 3 5 in setting not supported if other options are installed above the 250 universally adjustable tray Print media types T a S ET nd o Gg a 9 ss s Print media m mam M 2 un o B 5 5 olei so o I m c v I v 3 o s lt c po lt o n 2 a E Blo vis o Se eL o e A ziqiu no wu Paper X X X XX Card stock X X X X Transparencies X X X Paper labels X X 1 Printing label applications on the printer requires a special label fuser cleaner which prevents duplexing The label fuser cleaner is included with a special label cartridge for label applications 1 10 Service Manual Print media weights Print media weight Multipurpose Print media Type Mee ee d tray and feeder Envelope 2000 Sheet p feeder drawer 500 sheet drawer _ Paper Xerographic or 60 to 176 g m grain 60 to 135 g m grain n a 60 to 135 g m business paper long 16 to 47 Ib long 16 to 36 lb 16 to 36 Ib bond bond bond Card stock Index Bristol 163 g m 90 Ib 120 g m 67 Ib n a
311. sed displays when the sensor is open Open displays Press Back or Stop to exit the test Diagnostic aids 3 13 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 Select Feed Tests from the OUTPUT BIN TESTS 2 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 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 0 is pressed Press Back to return to OUTPUT BIN TESTS Feed To All Bins This test can be used to verify that the printer can feed media to the standard bin or any installed output options No information will be printed on the test pages as the printhead is not engag
312. sembly 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 32 Service Manual 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 X Use the following table to identify and install the correct lamp Description P N Fuser Lamp 115 V 40X0122 Fuser Lamp 220 V 40X0123 Repair information 4 33 Fuser narrow media sensor removal 1 Remove the redrive assembly See Redrive assembly removal on page 4 74 2 Remove the screw A securing the narrow media sensor cover to the fuser 3 With a thumbnail release the catches B holding the sensor cover to the lower exit guide C in place Note You may need to move the narrow media flag out of the way to remove the sensor 4 Disconnect the fuser narrow media cable at the sensor 5 Release the catches holding the sensor in the cover Note Hold the narrow media flag out of the way to remove the sensor from the cover 4 34 Service Manual Replacement 1 Move the narrow media flag out of
313. sensor service check on page 2 92 201 31 Main drive motor identification failed Fuser page count between 300 000 and 399 999 Main drive motor not working Check the motor connections to motor and system board If no problem is found go to Main drive service check on page 2 105 2 48 Service Manual User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 201 32 Page did not reach exit sensor Fuser page count between 300 000 and 399 999 Page jammed on fuser input guide Page did not enter or exit fuser nip cleanly Exit sensor not functioning correctly Check the fuser entry guide for toner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 92 201 34 Expected wide page not detected by narrow media sensor possible accordion jam Fuser page count between 300 000 and 399 999 Page did not enter or exit fuser nip cleanly Narrow media sensor not functioning correctly Actual page is narrow when wide page was expected f label media ensure front edge meets 1 8 inch requirement Check the fuser for wear or contaminati
314. ser cover 4 41 fuser exit sensor flag and spring removal 4 30 parts catalog 7 25 removal 4 28 service check 2 92 fuser lamp parts catalog 7 25 removal 4 32 fuser narrow media sensor flag and spring 4 36 flag and spring parts catalog 7 25 flag and spring removal 4 36 parts catalog 7 25 service check 2 93 fuser solenoid adjustment 4 2 service check 2 94 fuser to LVPS AC cable removal 4 38 fuser transfer plate removal 4 43 fuser wiper cover assembly parts catalog 7 3 removal 4 4 G gap adjustment 3 22 4 2 gear release link removal 4 44 guidelines for media 1 15 H handle left cover 4 16 7 5 right cover 4 16 7 5 high voltage power supply HVPS connectors 5 9 parts catalog 7 28 removal 4 45 high capacity feeder locations 5 8 parts catalog 7 58 7 60 7 62 7 63 service check 2 95 high capacity output expander parts catalog 7 50 7 51 high capacity output stacker output sensor tests 3 16 service check 2 100 inner paper deflector removal 4 47 inner shield parts catalog 7 32 removal 4 76 input sensor removal 4 48 input sensor tray tests 3 13 input source tests 3 6 input tray feed test 3 13 installation bevel gear 4 22 fuser assembly 4 27 fuser exit sensor 4 29 fuser exit sensor spring 4 30 fuser narrow media sensor 4 35 fuser narrow media spring replacement 4 36 pick roll assembly integrated tray autocompensator 4 52 integrated forms 1 11 1 14 integrated tray autocompensator assembly parts catalog 7 12 r
315. service replaceable parts or components If service error code 930 xx displays the wrong printhead is installed in the printer See Printhead on page 7 10 Note A 201 xx paper jam may also indicate a failing printhead The paper may have jammed prior to or at the input sensor Print the event log and see if 201 or 931 errors are logged Service error code Explanation Error code 931 xx No first HYSNC Signal Error Code 932 Lost HYSNC These errors usually indicate a failure in the HYSNC signal to the printhead Check the continuity of the cables connected to J2 and J4 on the system board If incorrect replace the defective cable The 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 Error Code 934 xx Mirror motor lost lock Error Code 935 These error codes indicate a problem with the mirror motor circuit in the printhead assembly or the mirror motor cable to the system board cable or system board assembly The voltage at J5 2 measures Mirror motor unable to reach operating speed approximately 24 V dc If incorrect replace the system board If correct replace the FRUs in the following order System board Printhead assembly Signature button assembly service check Note If you are unable to clear a 32 xx Unsupporte
316. sible Cancel Job Reset Printer Reset Active Bin 50 XX PPDS Font Error This message displays when the PPDS interpreter has encountered a font error Note This error may only occur when the printer is formatting PPDS print data The following actions may be taken Press Y to clear the message and continue processing the job Press 2 until Busy Waiting appears The following are available Cancel Job Reset Printer Reset Active Bin 51 XX Defective Flash This message displays when the printer detects a defective flash This error may occur at power on or during flash format and write operations Press Y to clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the problem is resolved Diagnostic information 2 39 User attendance messages continued ERE SUD Primary message Description action code code y 9 P 52 XX Flash Full This message displays when there is not enough free space in the flash memory to hold the resources that have been requested to be written to flash 53 XX Unformatted Flash This message displays when the printer detects an unformatted flash at power on Press Y to clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the flash is formatted 54 XX Standard Network This error displays when a network port is detected but the printer ca
317. 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 202 04 Exit sensor bounced Exit sensor assembly Go to Fuser exit sensor Fuser page count service check on page 2 92 between 0 and 99 999 202 06 Page is covering 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 been cleared from a prior jam any signs of debris or pieces of between 0 and 99 999 paper or media 2 54 Service Manual User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 202 10 Paper jam around fuser or redrive area Fuser page count between 100 000 and 199 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 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
318. size Print media sizes s la Sle E i amp 3E 2 els E ajl s o Print media i 2 2 o sle s o e2 52 A Dimensions n l lo9 v lo l2 r l t amp lg I UAT univers all Ss S S8 v 8 5 S3 9 25 s indicates djus table tray S lE 2 2 v oe 2 92 E 3 poe 2 S suppot M R EP E Ss S ss a w S eea 8 8 95 5 5 vo o o o na o Sio x le amp 8 ele vo of ol e ofe 2 c amp 5 8 o a 2 c cicixicix 3alevej jo xi is s5 E p Q 2 n n u D ulD Q 9 o v S v v dilalalolo olz s 2 a lt e lt Ssa aja nioln nloleol 2lo 23 2 353 2 25 2 8 AI IDBI INA A n 2 AJu JQ njO n To ni un A4 210 x 297 mm 8 27 x 11 7 in Li me Li LEE A5 148 x 210mm 5 83 x 8 27 in m Ss e B JISB5 182 x 257mm 7 17 x 10 1 in s Letter 215 9 x279 4 mm amp amp amp ele 8 5x 11 in Legal 215 9 x 355 6 mm S amp 8 5 x 14 in 1 8 Service Manual Printmedia sizes continued Print media size indicates suppot Dimensions UAT univers ally adjustable tray 250 sheet tray 500 sheet tray 250 sheet drawer option 250 UAT option 500 sheet drawer option 400 UAT option 2000 s heetdrawer option Envelope feeder option Dupkx unit option Standard outputbin Outputexpander option 5 bin mailbox option outputstacker option StapleS mart output bin High
319. sor service check on page 2 92 202 96 Page is covering the exit sensor during warm up Fuser page count is not available Something is keeping the exit sensor in a covered position A page may not have been cleared from a prior jam Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media 2 66 Service Manual User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 231 00 Paper did not arrive at the duplex input sensor but did leave the printer exit sensor Duplex rear door not fully latched Printer diverter not functioning correctly Duplex feed system not working correctly Printer and duplex not aligned Make sure the duplex assembly rear door is properly latched Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check duplex unit for correct installation and alignment to the printer e If available try another duplex unit If none is available go to 231 xx Jam displays on the operator panel on page 2 83 232 00 Paper did not clear the duplex input sensor but did leave the printer exit sensor Duplex rear door not fully latched Printer diverter not functioning correctly Duplex feed system not worki
320. ss Y to confirm the selection All jobs are deleted e Press Y or to cancel the delete operation Diagnostic information 2 33 User attendance messages continued Error Sub A ode oda Primary message Description action Disk Corrupted The printer has detected there are errors on the hard disk that cannot be Reformat corrected The disk cannot be used until it is reformatted Warning All data on the disk will be lost if you format the disk The following actions can be taken Power off and remove the disk The disk will not be formatted Press Y to format the disk All data is lost when you format the disk Empty Box M This message is displayed when the hole punch alarm is on and the printer informed by the code the hole punch box M is full The following actions may be taken Empty the hole punch box Press Y to ignore the message The Box M Full appears on line 2 of the display and the job is printed without hole punching The message remains until the box is emptied If this message continues to be displayed when the box has been emptied go to StapleSmart finisher service check on page 2 123 Insert Box M This message is displayed when the hole punch box is missing or installed incorrectly The message is displayed during any of the following times regardless of the hole punch alarm setting At POST After the finisher side door has been closed Before the first page of a job r
321. ssembly 7 9 EP DC fan assembly 000 010 22 ee een e nn nn ee ee nee eee 7 9 EP fan with cable 250 sheet 000 010 7 41 Toner sensor assembly 2 22 2222 eee eee eller eee eee 7 9 Developer support roller 2 2 5255 5 eee ee 7 9 Upper paper feed deflector 7 9 Inner paper feed deflector 000 010 7 9 Inner paper feed deflector 200 210 400 410 7 9 Input sensor 7 9 Gear guard lllclllllcllllllllllllcrll llle llc llll 77 ESD shield with label lt 44444 7 9 Paper size sensing board assembly 7 7 Paper size sensing board Tray 1 autocompensator paper out low cable 7 35 Paper switch activate spring llllllllll l T Gear release link 7 7 Counterbalance spring 7 3 Standard bin level sensor 2 22 22 eee eee nee eee eee 7 7 Standard bin level sensor bracket 2 22 2222 seen ee ee ee eee eee eee eee 7 7 Main fan with cable 250 sheet output 7 7 Main fan 250 sheet llll nnn nee nee 7
322. 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 I 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase IIIb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema l ser y la impresora est n dise ados 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 Declarac o sobre Laser xii 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 I 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
323. switch table J8 Switch status Pin number Cover open Cover closed Pin 1 3 Open Closed Pin 1 2 Closed Open Dead machine service check A dead machine is a condition where the display is blank the LED on the operator panel 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 95 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 Handling 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 A N receive power in order to perform the task Remove any input and output paper handling options from the printer FRU Action 1 Line voltage Check the AC line voltage If the line voltage is incorrect inform the customer 2 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 cont
324. t INA cover mounting screw 7 33 Parts packet inner shield mounting screw 7 33 Parts packet lower deflector mounting screw 12 mm 7 15 Parts packet lower deflector mounting screw 8 mm 7 15 Parts packet outer shield mounting screw 55 5222 555255 e ener ee eee ee enee 7 33 Parts packet pick roll shaft clip 7 15 Parts packet printhead mounting screw 2 52502522522 e eee eee e eee nees 7 11 Cartridge shipping package empty e ee eee 7 69 Parts packet cable ties snoot 7 3 Nyogel 744 grease packet 2 2 2 eee eee eee eee ee eee eee eeee 7 69 Wear strip 2 ene nn re eee eens 7 21 Plate 500 sheet tray wear 0 2 2 2 ee eee eee eee eee eee ee eeee 7 21 Operator panel board assembly 222 222 c erence cence eee een eee en eee enenes 7 3 Bar code card assembly 7 31 7 69 PrintCryption card assembly M 7 31 7 69 Thinprint card assembly eee eee eee eee ee 7 69 EP duct 22 2 tenn nr eee 7 9 Blower duct 200 210 400 410 7 9 Gear 60 MPF shield 7 9 Main fan cap 2 2 2 een en eee eee ee ee ee eee eee eee eeeee 7 7 Main f
325. t POST sequence on page 2 4 Understanding the printer operator panel on page 2 2 Understanding the menus on page 2 3 Diagnostics mode on page 3 2 Configuration menu CONFIG MENU on page 3 25 Theory on page 3 31 Paper feed jams on page 3 33 Parts catalog on page 7 1 Diagnostic information 2 1 Understanding the printer operator panel The operator panel on your printer is a 4 line back lit gray scale display that can show both graphics and text The Back Menu and Stop buttons are located to the left of the display the navigation buttons are located below the display and the numeric pad is located to the right of the display Display panel Indicator light Navigation buttons Numeric pad USB port Select button The use of the buttons and the layout of the display panel are described in the following table Operator panel Button Function Back Press the Back button to return to the last screen you viewed Note Changes made on the screen will not be applied if you press the Back button Menu gt Press the Menu button to open the menu index Note The printer must be in the Ready state to access the menu index A message indicating the menus are unavailable will appear if the printer is not ready Stop Press Stop to stop the mechanical operation of the printer After pressing Stop the message Stopping is displayed When the printer has stopped the sta
326. tem board DC cable 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 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 Error code 920 06 displayed LVPS System board System board to LVPS cable 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 VPS assembly See Low voltage power supply removal on page 4 54 System board assembly See System board and inner shield removal on page 4 76 e VPS to system board cable Fuser assembly If no problem is found up to this point then replace the following in the order shown Fuser assembly See Fuser assembly removal on page 4 26 System board assembly See System board and inner shield removal on page 4 76 VPS See Low voltage power supply removal on page 4 54 2 88 Service Manual 922 xx Cold fuser check Error codes 920
327. tep 2 2 Fuser top cover assembly thermistor Turn the printer off and disconnect the fuser to system board cable 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 narrow media sensor removal on page 4 34 if correct replace the fuser to system board cable 3 System board Fuser top cover assembly 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 34 If incorrect replace the system board See System board and inner shield removal on page 4 76 2 90 Service Manual 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 AN order to perform the task Service tip Set the Fuser Temperature to NORMAL before sta
328. the printer is power cycled If a 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 Cover The duplex front access cover is not installed Close Duplex Rear Door The duplex rear door is open Diagnostic information 2 43 User attendance messages paper jams and paper handling errors 2xx xx When the printer jams the appropriate jam message will be displayed on the printer operator panel If you select Show Areas on the operator panel you can view one or more images to help you clear the jam 23 x Paper Jam 3 pages jammed Continue Show Areas Show Areas Show Duplex Show Rear Door Show Finisher 1 Open manual feed door User attendance messages paper jams and paper handling errors 2xx xx Error code Sub D ription codes Seer pum Possible causes Action 200 00 Paper jam around input sensor Multi sheet feed that is shingled Tray size sensing wrong size Paper jam leaving page over sensor Fan media and stack flat in tray or multipurpose feeder Check for anything in the paper path that might cause the paper to jam e If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 102 200 01 Input sensor covered too l
329. the roll oil or other contaminants on the surface of the roll Replace the transfer roll as necessary 2 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 3 Right transfer arm assembly Check the right transfer 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 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 2 118 4 HVPS 917 Error code Check the voltage at J15 3 The voltage changes from 24 V dc with the printer idle to O 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 there is continuity replace the HVPS If the problem continues replace the system board 2 128 Service Manual 3 Diagnostic aids This chapter explains the tests and
330. the sensor 4 28 Service Manual Installation 1 Move the fuser exit sensor flag out of the way to clip the sensor securely into the cover 2 Connect the fuser exit sensor cable 3 Snapthe 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 29 Fuser exit sensor flag and spring removal 1 Remove the fuser exit sensor See Fuser exit sensor removal on page 4 28 2 Note the position of the spring A in relation to the flag B 3 Carefully ease the right arm C until the fuser exit sensor cover releases the flag and spring B A Spring replacement 1 Place the spring on the left pin A 2 Setthe tang B on the flag 4 30 Service Manual 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 31 Fuser lamp removal CAUTION The fuser and the fuser lamp may be hot You may need to allow them to cool before handling them 1 Remove the fuser assembly See Fuser assembly removal on page 4 26 2 Disconnect the fuser lamp AC cable from the right side of the top cover as
331. this product is based on testing and approvals of the original design and specific components The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions CAUTION When you see this symbol there is a danger from hazardous voltage in the AN area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task Consignes de s curit La s curit de ce produit repose sur des tests et des agr ations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pi ces de rechange non agr es Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires ATTENTION Ce symbole indique la pr sence d une tension dangereuse dans la partie AN
332. ting components Once a component has been installed in a printer it can not 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 FRU Action 1 Interconnect card If the interconnect card been recently replaced go to step 3 If the card has not been replaced go to step 2 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 3 Interconnect card Replace the current interconnect card assembly with the original interconnect card assembly See Interconnect card assembly removal on page 4 53 If the error remains go to step 5 4 operator panel board Replace the current operator panel board with the original operator panel board See Operator panel board removal on page 4 66 If the error persists go to step 6 5 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 6 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 Diagnostic information 2 77 950 30 through 950 60 EPRO
333. tion 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 When you see this symbol there is a danger from hazardous voltage in the A N caution if the product must receive power in order to perform the task XX Service Manual 1 General information The e STUDIO 500P laser printers are letter quality page printers designed to attach to IBM compatible personal computers and to most computer networks The e S TUDIO 500P is available is the following models Model name Configuration e STUDIO 500P Network 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 printer problem and repair the failure After you complete the repair perform tests as needed to verify the repair See Start on page 2 1 Options The following options are available S ome options are not available in every country Contact your point of purchase for options available in your country Memory options of 128MB and 512 SDRAM Media handling operations 2000 sheet high capacity feeder Envelope feeder Duplex Option
334. tion 2 83 Envelope feeder service check Service tip Check the envelope feeder paper path for any debris pieces of envelope and so on If any other options are installed make sure they are operating normally If only the envelope feeder is failing to operate correctly continue with this service check otherwise verify the interconnect card is functioning properly Service tip The envelope feeder receives its 5 V dc operating voltage from the 24 V dc bulk at J1 7 If 24 V dc is not present at J1 7 tray 1 is the only tray that is recognized Note If a 260 Paper Jam Check Envelope message displays check the Sub error codes for 9xx and 2xx error codes on page 2 8 Printer does not recognize the envelope feeder as an attached input option FRU Action 1 Envelope feeder Make sure the envelope feeder is correctly installed and mated to the autoconnect at the front of the printer 2 Front autoconnect on printer Check the connector for signs of damage to the connector or 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 3 Autoconnect on the envelope feeder Check for damage to the connector or contacts If you find damage replace the damaged cable connector assembl
335. tion 4 19 8 Remove the paper bin full sensor flag from the mounting bracket See Paper bin full sensor flag removal on page 4 70 9 Unlatch the front right and front left cover posts and remove the cover 4 20 Service Manual Bevel gear removal Open the left door Remove the inner shield Remove the gear guard Se 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 Repair information 4 21 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 Insertthe 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 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 7 Install the inner shield 4 22 Service Manual Cartridge duct removal 1 Open the left door 2 Disconnect the printhead laser cable from J2 on the syste
336. to clear the error Diagnostic information 2 27 Service error codes 9xx xx continued Error code Sub codes Display text Description Action 953 00 Replace the operator panel board or upper front cover See Upper front cover removal on page 4 11 or Upper front cover removal on page 4 11 Warning When replacing any one of the following components Operator panel assembly or upper front cover System board assembly Interconnect card assembly Only replace one component at a time 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 can not be used in another printer It must be returned to the manufacturer 2 28 Service Manual Service error codes 9xx xx continued Error code Sub codes Display text Description Action 954 00 Replace the interconnect card See Interconnect card assembly removal on page 4 53 Warning When replacing any one of the following components Operator panel assembly or
337. tus Navigation buttons SA AS line in the operator panel will show Stopped and a list of options will appear A The Up or Down buttons are used to move up and down lists When navigating through a list using the Up or Down button the cursor W moves one line at a time Pressing the Down button at the bottom of the screen changes the screen to the next whole page The Left or Right buttons are used to move within a screen such as lt q gt moving from one menu index item to another They are also used to scroll through text that will not fit on the screen The Select button is used to initiate action on a selection Press Select when the cursor appears next to the selection you want such as following a link submitting a configuration item or when you want to start or cancel a job 2 2 Service Manual Operator panel continued Button Function Numeric pad The numeric pad consists of numbers a pound sign and a backspace button The 5 button has a raised bump for non visual orientation View Supplies restored Some held jobs were not pe Remove tray M remove print media each warning will be separated by a comma The other three lines of the display are the body of the screen This is where you view printer status supplies messages show me screens and make selections 000 The numbers are used to enter numeric values for items like quantitie
338. uctive 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 Select Quick Disk Test from DEVICE TESTS The power indicator blinks while the test is in progress and quick Disk Test Testing displays Quick Disk Test Test Passed message displays if the test passes and the power indicator turns on solid Quick Disk Test Test Failed message displays if the test failed and the power indicator turns on solid 2 Press Back or Stop to return to the Device Tests menu 3 18 Service Manual 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 172 hours depending on the disk size To run the Disk Test Clean Test 1 Select Disk Test Clean from the Device Tests menu Files will be lost Go or Stop message displays to warn the user that all contents on the disk will be lost To exit the test immediately and return to the Device Tests menu press Back or Stop To continue with the test press YD If is selected the following screen displays and updates periodically indicating the percentage of test completed Formatting Disk 1 1 0 DO NOT POWER OFF The power indicator b
339. ug 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 Parallel Wrap P HBHHHHE F HHHE e 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 0 3 8 Service Manual Serial Wrap tests The serial wrap tests are used to check the operation of the serial port hardware using a wrap plug Use Serial 1 Wrap if a serial port is available through PCI slot 1 and Serial 2 Wrap if the serial port is available through PCI slot 2 To perform the Serial Wrap tests 1 Disconnect the serial interface cable and install the serial wrap plug 2 Select Serial 1 Wrap or
340. uration 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 f 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 84 Reattach Output Bin x Bin x Bin 1 Bin 2 or Bin 3 This messages displays for the following conditions The specified output bin may have been removed from the printer possibly to clear a paper jam or to remove 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 Press Y to execute a 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 f the device is experiencing a hardware problem turn the printer off and on If the message continues to be displayed go to Output expander service check on page 2 110 Diagnostic information 2 37 User attendance messages continued Error code Sub code
341. ure 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 FRU Action 1 Printhead The printhead on this printer cannot be cleaned Try another printhead if all other attempts fail to correct a background problem 2 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 problems 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 3 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 2 118 Service Manual FRU Action 4 System board HVPS connector Check the following voltages at J15 on the system board Measure the voltages from J15 to printer ground Pin J15 Voltage approximate Printer idle J15 1 0 V dc J15 2 4 V dc
342. us are entered or the printer is reset The following actions may be taken Press YD to clear the message The printer discards any data received on the parallel port Press 2 until Busy Waiting appears The following are available Reset Printer Reset Active Bin 57 XX Configuration Change The printer has attempted to restore the Print and Hold jobs from the disk and found that some or all of the jobs could not be restored The printer could not restore jobs from the disk because the configuration of the printer has changed This message alternates with the secondary message Held jobs may not be restored Some configuration changes that may cause this condition are Code version change Paper handling option is removed Disk has been moved to a different model printer Press Y to clear the message Some of the Print and Hold jobs stored on the disk will not be restored They remain on the disk but cannot be accessed 58 XX Too Many Trays Attached This error code displays when too many input trays are attached to the printer 58 XX Too Many Disks Installed This error displays when too many disks are attached to the printer 59 XXX Incompatible Output Bin x An incompatible output bin is installed For Output Bin x x 1 2 or 3 Remove the incompatible output bin and press Y to clear the message Note If the user installed the incompatible device to satisfy a Check
343. user over temperature Short in the thermistor circuit Go to 923 xx Hot fuser Fuser page count service check on page 2 90 between 0 and 99 999 Noisy thermistor signal l e Fuser is actually overheating due to hardware faults 923 11 Fuser over temperature Short in the thermistor circuit Go to 923 xx Hot fuser Fuser page count 7 service check on page 2 90 between 100 000 and Noisy thermistor signal l 199 999 e Fuser is actually overheating due to hardware faults 923 21 Fuser over temperature Short in the thermistor circuit Go to 923 xx Hot fuser Fuser page count service check on page 2 90 between 200 000 and Noisy thermistor signal l 299 999 e Fuser is actually overheating due to hardware faults 923 31 Fuser over temperature Short in the thermistor circuit Go to 923 xx Hot fuser Fuser page count service check on page 2 90 between 300 000 and Noisy thermistor signal l 399 999 e Fuser is actually overheating due to hardware faults 923 41 Fuser over temperature Short in the thermistor circuit Go to 923 xx Hot fuser Fuser page count 3 service check on page 2 90 between 400 000 and Noisy TISHmistor signal l 499 999 e Fuser is actually overheating due to hardware faults 923 51 Fuser over temperature Short in the thermistor circuit Go to 923 xx Hot fuser ope it EODD T e Noisy thermistor signal service check on page 2 90 preserve dat
344. val on page 4 26 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 92 Diagnostic information 2 53 User attendance messages paper jams and paper handling errors 2xx xx Error Sub Description Possible causes Action code codes 202 02 Exit sensor covered too Page may be jammed in fuser exit or e Make sure the redrive door long Fuser page count redrive area is complete closed between 0 and 99 999 e Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce W curl 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 92 202 03 Page is covering narrow If page is not visible from front or rear of Check the fuser for any
345. voltages on J15 1 thru J15 8 If incorrect replace the System board 2 116 Service Manual FRU Action HVPS cable part of front harness cable System board Check the continuity of the HVPS cable If incorrect replace the cable assembly If correct replace the system board Print quality blank page FRU Action 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 damaged replace the contact Note Inspect the HVPS PC drum contact on the board for damage or contamination HVPS 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 Printer Idle J15 5 measures 24 V dc Printer Printing J15 5 measures 24 V dc If the voltages at J10 5 are incorrect replace the system board Front cable harness HVPS section Check the front cable harness at J15 on the system board and at 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
346. w C 7 Remove the main drive assembly mounting screws D 4 58 Service Manual 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 Repair information 4 59 MPF arm assembly removal 1 Open the left door IM Remove the MPF lower front cover See Multipurpose feeder lower front cover assembly removal on page 4 15 Remove the MPF lower paper deflector See MPF lower paper deflector on page 4 61 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 79 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 47 Remove the MPF solenoid assembly See MPF solenoid assembly removal on page 4 62 Remove the C clip A DEO mos w f My mm ece022 secoo o gt
347. ware Go to 900 xx Error code service check on page 2 75 901 XX Engine flash error Indicates that the flash which the system Replace the system board board code is programmed into is bad See System board and inner Replace the system board shield removal on page 4 76 902 XX Engine software error These errors indicate an unrecoverable Replace the system board See system software error System board and inner shield removal on page 4 76 903 XX Paperport link driver These errors indicate an unrecoverable Replace the system board See error system software error System board and inner shield removal on page 4 76 904 XX Interface violation by These errors indicate an unrecoverable Replace the system board See RIP system software error System board and inner shield removal on page 4 76 905 XX Interface violation by These errors indicate an unrecoverable Replace the system board See Paperport device system software error System board and inner shield removal on page 4 76 906 XX RIP interface driver error These errors indicate an unrecoverable Replace the system board See system software error System board and inner shield removal on page 4 76 910 XX DC pick motor e Check autocompensator cable Go to Paper feed service acceleration stall connectors check on page 2 112 a NEP e Check autocompensator for binds 911 00 DC pick motor excessive e Check system board Go to Paper feed service
348. wer On Reset POR While the CACHE test executes the power indicator blinks green The following type of message appears CACHE Test x100 P UBHHHHHE F HHHE P represents the number of times the cache has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 6F 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 is incremented 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 printer off Parallel Wrap tests 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 pl
349. wer front covers 2 Press the two left door latch buttons A and open the left door A 3 Release the top hinge from the latch 4 6 Service Manual 4 Lift the door to release the bottom from the pin B and remove the door Redrive door 1 With the redrive door partially open lift and free the left side 2 Remove the redrive door Repair information 4 7 Right cover removal Remove the redrive cap See Redrive cap cover removal on page 4 5 Open the upper and lower front covers Remove the print cartridge mE ai cm Remove the right front cover mounting screw A 5 Remove the redrive door See Redrive door on page 4 7 6 Remove the two screws B 4 8 Service Manual 7 Remove the right rear cover mounting screw C C Repair information 4 9 9 Press the latch D firmly to release the front of the right cover D 10 Pull up and out on the right cover to release the three cover retainers E at the bottom Note When replacing the right side cover make sure the three cover retainers are correctly located in the appropriate slots in the right side frame 4 10 Service Manual Upper front cover removal Warning When replacing any one of the following components e Operator panel assembly or upper front cover e System board assembly Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR
350. 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 can not 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 Outer shield removal on page 4 67 2 Disconnect all cables from the system board Note Sometimes cables may be difficult to remove Be careful not to damage the connectors w Remove all features and options from the interconnect card 4 Depending on your printer model remove the two small USB port mounting screws A the two parallel port mounting screws B and the ethernet port mounting screw C Note You may not have all these screws in every model 5 Remove the system board mounting screws including the screw in the upper left corner C the two small screws in the center top and bottom D and the three screws E on the lower left and top and bottom right 6 Remove the system board and inner shield 4 76 Service Manual Toner sensor removal 1 Remove the right side cover See Right cover removal on page 4 8 2 Remove the toner sensor mounting screw A 3 Disconnect the toner sensor cable and remove the toner sensor Transfer roll assembly removal Warning Be careful when handling
351. 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 occurs For example 242 xx is a Paper Jam Tray 2 FRU Action Pass thru sensor and flag assembly The tray x option system board did not detect a piece of paper actuating the pass thru sensor Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu If the test fails check the sensor for correct installation and the flag for proper
352. x Feed 2 See Duplex Feed 2 on page 3 12 INPUT TRAY TESTS Feed Tests See Feed Tests input tray on page 3 13 Sensor Test See Sensor Test input tray on page 3 13 OUTPUT BIN TESTS Feed Tests See Feed Tests output bins on page 3 14 Feed To All Bins See Feed To AII Bins on page 3 14 Sensor Test See Sensor Test standard output bin on page 3 15 Diverter Test if 5 bin See Diverter Test on page 3 16 installed FINISHER TESTS if installed BASE SENSOR TEST See BASE SENSOR TEST on page 3 18 Toner Input Output DEVICE TESTS Quick Disk Test if installed See Quick Disk Test on page 3 18 Disk Test Clean if installed See Disk Test Clean on page 3 19 Flash Test if installed See Flash Test on page 3 19 PRINTER SETUP Defaults See Defaults on page 3 20 Page Count See Page Count on page 3 20 Perm Page Count See Perm Page Count permanent page count on page 3 20 Serial Number See Serial Number on page 3 20 Envelope Enhance See Envelope Enhance on page 3 20 Engine Setting 1 through 4 See Engine Setting 1 through 4 on page 3 20 Model Name See Model Name on page 3 20 Configuration ID See Configuration ID on page 3 21 Edge to Edge See Edge to Edge on page 3 21 Par S Strobe Adj Par x Strobe Adj if additional parallel options are
353. xcept for a pel or a few pels missing or broken run the Panel Test on page 3 7 from the hardware tests before continuing with this service check FRU Action 1 Operator panel cable Check for proper installation of the cable at the system board J13 and at the operator panel Check the continuity of the operator panel cable If incorrect replace the upper front cover hinge assembly See Upper front cover hinge assembly removal on page 4 78 2 Operator panel display blank 5 beeps LED off Check for correct installation of the operator panel cable at J13 on the system board If incorrect reinstall the cable properly If correct measure the voltage at J13 2 on the system board The voltage should measure approximately 5 V dc If incorrect replace the system board System board and inner shield removal on page 4 76 If correct check continuity of the operator panel cable If the continuity is incorrect replace the upper front hinge assembly If the continuity is correct replace the operator panel board See Operator panel board removal on page 4 66 3 Operator panel display blank 5 beeps LED on Check for ground between J13 4 and ground If correct replace the operator panel board See Operator panel board removal on page 4 66 If incorrect check the operator panel cable If the cable is incorrect replace the upper front cover hinge assembly See Upper front cover hinge assembly removal on
354. xit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce W curl 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 92 202 91 Page did not cleanly exit fuser or redrive area Fuser page count is not available Page may be jammed in the fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce W curl 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 92 Diagnostic information 2 65
355. xpander control board cover Check the output expander control board cover to make sure the ESD brush ground lead is firmly attached to the output expander frame Also make sure the ESD brush is not loose Printer does not recognize one or more output expander options as being installed Service tip If more than a single output expander option is installed check each one to see if the printer recognizes any single option as being installed If the printer recognizes any of the output expander options then the base printer autoconnect system is operating correctly and the problem is in the unrecognized expander option FRU Action 1 Output expander option Make sure the output expander option is the only option that is not recognized by the base printer If the output expander is the only option not recognized by the printer continue with step 2 If not check the autoconnects of the options not recognized and the interconnect card and cable connections 2 Output expander assembly mechanical linkage Check the autoconnects for damage especially the connector pins Remove the left and right side covers Remove the front control board cover Check the cables at J1A J1B J2A and J2B on the control board to make sure they are attached securely and correctly Remove the output expander and check the voltages on the output bin autoconnect located on the top left rear of the printer Go to Autoconnect on page 5 6 I
356. xx Hot fuser service check on page 2 91 927 00 Service fan error Loose connector External blockage of the fan preventing it from turning Bad fan Go to Main fan on page 2 76 927 01 Main fan stalled External blockage of fan e Fan may not turn due to internal fan problem Go to Main fan on page 2 76 Diagnostic information 2 23 Service error codes 9xx xx continued Error Sub code codes Display text Description Action 927 02 Cartridge fan stalled Loose connector Go to Cartridge fan service External blockage of the fan check on page 2 76 preventing it from turning e Bad fan 927 03 Main fan took too long to Loose connector Go to Main fan on ramp up External blockage of the fan page 2 76 preventing it from turning Bad fan 927 04 Main fan underspeed or Corrupted feedback signal Go to Main fan on stalled during speed page 2 76 adjustment state Fan input voltage may be too low 927 05 Main fan overspeed Corrupted feedback signal Go to Main fan on during speed E page 2 76 adjustment state Fan input voltage may be too low 927 06 Main fan capture data is Corrupted or non existent feedback Go to Main fan on invalid and speed signal page 2 76 control is at maximum in fan control idle state 927 07 Main fan capture data is
357. xx Paper Jam after attempted feed but before envelopes are put in the hopper OR the operator panel continues to display Load Envelopes after envelopes are placed in the hopper Service tip The kick rolls rotate during the attempted feed cycles FRU Action 1 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 option 990 xx Service Error envelopes fail to feed from the hopper FRU Action 1 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 FRU Action 1 Clutch latch assembly Check the clutch latch assembly to make sure it moves freely 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 rotating Check the deflector gap adjustment before continuing this service check FRU Action 1 Deflector gap adjustment Check the deflector gap adjustment The adjustment may be too narrow 2 Weight assembly Check the weight assembly to make sure it moves up and down freely without any binds
358. 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 AN 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 FRU Action 1 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 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 3 LVPS 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 54 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 connecto
359. y Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages J1 3 measures 5 V dc J1 5 measures 5 V dc 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 Operator panel displays 260 xx Paper Jamimmediately when envelope feed is requested POST incomplete FRU Action 1 Pass thru sensor 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 a envelope feeder sensor test to check both the sensor and sensor ag 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 2 84 Service Manual Operator panel displays 260
360. y 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 92 202 33 Page is covering the f 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 The narrow media sensor or flag may be dislodged or damaged 202 34 Exit sensor may have Exit sensor assembly Go to Fuser exit sensor bounced Fuser page service check on page 2 92 count between 300 000 and 399 999 202 36 Page is covering the exit Something is keeping the exit sensor Check the fuser and area sensor during warm up covered A page may not have been around the fuser assembly for Fuser page count cleared from a prior jam any signs of debris or pieces of between 300 000 and paper or media 399 999 2 60 Service Manual User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action 202 40 Paper jam around the fuser exit or redrive area Fuser page cou
361. you need to change Each increment shifts the duplex top margin by 1 100 of an inch The Top Margin duplex range is 20 to 20 and the default value is 0 Anincrease moves the top margin down and widens the top margin A decrease moves the top margin upward and narrows the top margin 4 Press QD 5 Print the Quick Test duplex again to verify the adjustment Repeat if necessary 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 open displays Duplex input sensor Duplex exit sensor 3 Press Back O or Stop to exit the test 3 10 Service Manual 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 messa
362. ype gt Bond Card stock Colored Envelope Labels Ltrhead Plain Preprint or Transparency lt size gt letter legal B5 A4 Executive Universal A5 B4 A3 11x17 Folio or Statement For envelopes lt size gt 7 Envelope 9 Envelope 10 Envelope DL Envelope C5 Envelope B5 Envelope or other Envelope 2 32 Service Manual User attendance messages continued Error code Sub code Primary message Description action Check Duplex This messages displays for the following conditions Connection 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 Press Y to execute a 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 f 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 82 Check Tray x Tray x Tray 2 Tray 3 Tray 4 or Tray 5 Connection This messages

Toshiba e-STUDIO500P Printer User Manual

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