Lexmark 4060-000, 4060-010, 4060-200, 4060-210, 4060-400 Service Manual

(including Lexmark T630, Lexmark T632, Lexmark T634)

(including 4060-000, 4060-010, 4060-200,

• Table of Contents

Revised: July 27, 2005

Lexmark™ T63x

4060-xxx

4060-210, 4060-400, 4060-410)

• Start Diagnostics

• Safety and Notices

•Trademarks

• Index

Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/ or other countries.

©

4060-xxx

Edition: July 27, 2005

The following paragraph does not apply to any country where such provisions are inconsistent with local law:

LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,
EITHER EXPRESS OR IMPLIED, INCLUDI NG, 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 warr anties in certain transa ctions; 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 wi ll be incorporated in later editions. Improvem ents or changes in the products or the
programs described may be made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 W est New Circle Road,
Lexington, Kentucky 40550, U .S.A or e-mail at ServiceInfoAndTraining@Lexmark. com . Lexmark may use or distribute any
of the inf ormati on you supply in any way it belie ves appropriate without incurring any obl igation to you. You can purchase
additional copies of publications related to this pro duct by calling 1-800-553-9727. In other countri es, contact your point of
purchase.

Lexmark, Lexmark with diamond design, MarkNet, MarkVisi on, and Prebate are trademarks of Lexmark International, Inc. ,
registere d in th e Unit ed States and/or other countries.

ImageQuick, Optra Forms, PrintCryption, and StapleSmart are trademarks of Le xm ark International, Inc.
LEXFAX is a service mark of Lexmark International, Inc.
Other trademarks are the property of their respective owners.

2005 Lexmark International, Inc.

All rights reserved.

UNITED STATES GOVERNMENT RIGHTS

This softwar e and any accompanyin g docum entation provided under this agreement ar e com me rci al computer softwar e
and documentation developed exclusively at private expense.

P/N 12G9328

4060-xxx

Table of conte nts

Laser notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xviii

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xviii

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Print speed and performance print speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Time to first print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Memory configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Operating clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Power and electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Media specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Print area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Media guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Envelopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Transparencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Messages and error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Service error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Sub error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Sub error codes for 9xx and 2xx error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Base printer sub error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Base printer (fuser) sub error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Duplex option sub error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Envelope feeder sub error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

User status displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

User status messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

User attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

User line 2 link messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Check device connection messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Table of contents iii

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Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Base printer symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

High-capacity feeder (2000-sheet) symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Paper tray symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Duplex option symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Envelope feeder symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Output expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

StapleSmart finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

5-Bin mailbox service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

900 Error Code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

950 Error Code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

Charge roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

Cover closed switch/cable service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

Dead machine service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Duplex option service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Envelope feeder service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Fuser service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

Cold fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

Hot fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

Fuser solenoid service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

High-capacity feeder input tray service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

High- capa city ou tput stacker se rvic e check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 6 2

Input sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

Input tray(s) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

Internal tray card/paper siz e se n s i ng servi ce check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6 6

Main drive service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68

Main fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

Operator panel buttons service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70

Operator panel display service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

Options service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

Flash Memory Option(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

DRAM Memory Option(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

Hard Disk Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71

Output bin sensor standard tray service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72

Output expander service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

Paper feed service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

Parallel port service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77

Printhead service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

Print quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78

Smart contact assembly service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85

StapleSmart finisher service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-86

Toner sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93

Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-94

iv Service Manual

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Diagnostic aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Entering Diagnostic Mode: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Exiting Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Device tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Disabling Download Emulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Duplex tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Duplex Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Duplex Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Duplex Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Duplex Feed 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Duplex Feed 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Viewing the error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Printing the error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Clearing the error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Hardware tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

SDRAM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

ROM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Parallel Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Input tray tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Input Tray Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Input Tray Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Output Bin Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Output Bin Test—Standard Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Output Bin Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Feed to All Bins Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Output Bin Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Finisher Tests for StapleSmart Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Finisher Feed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Finisher Sensor Te sts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Staple Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Cover and Door Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Pass and Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Bin Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Print registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Printer setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Setting the page count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Viewing the permanent page count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

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Maintenance page count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Setting configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Restore EP Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Print tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Print quality test pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

Printing menu settings page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Autocompensator operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Autoconnect system, paper tray options, envelope feeder—electrical . . . . . . . . . . . . . . . . 3-21

Autoc o nnec t cabling and co nnec to rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2 1

Duplex Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Option microcode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Paper feed jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Paper jams—base printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Paper jams—options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Error Message 23x Paper Jam - Check Duplex Option . . . . . . . . . . . . . . . . . . . . . . .3-24

Error Message 24x (x=tray 1 through 5) Paper Jam Check Tray x . . . . . . . . . . . . . . 3-25

Error Message 250 Paper Jam - Check MP Feeder . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Error Message 260 Paper Jam - Check Envelope Feeder . . . . . . . . . . . . . . . . . . . .3-25

Error Message 27x Paper Jam - Check Bin x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Error Message 28x Paper Jam (x=StapleSmart finisher) . . . . . . . . . . . . . . . . . . . . . . 3-25

Error Message 282 - Check Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

Error Message 283 - Check Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

Repair information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Adjustment procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 2

Duplex motor drive belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fuser solenoid adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Gap adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3

Printhead assembly adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Paper alignment assembly adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Screw identification table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Covers removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Left door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Upper front cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Laser cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Bevel gear removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Communications board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Cover closed switch/cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Developer drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Frames removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

EP frame assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

Left side frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Right side frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Fuser assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

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Fuser cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Fuser exit sensor or fuser narrow media sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Fuser lamp removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Fuser transfer plate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

High voltage power supply removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Inne r p aper deflector as sembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Inner shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Input sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Integrated tray autocompensator assembly remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Integrated tray autocompensator pick roll assembly removal . . . . . . . . . . . . . . . . . . . . . . 4-38

Interconnect board assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Internal tray card (ITC)/Paper size sensing board removal . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Low voltage power supply removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Main drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Main fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Multipurpose tray/lower deflector assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

Operator panel assembly remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Operator panel bezel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

Operator panel cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

Optional 250 or 500-sheet paper tray assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Paper tray autocompensator assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Paper tray frame assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Paper tray board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Paper tray paper out sensor flag removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Paper size spring comb removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Outer shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52

Paper alignment assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52

Paper bin full sensor flag assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

Pick roll removal (MPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

Redrive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

Smart contact assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

System board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Toner sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

Transfer roll assembly remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

Upper front cover hinge assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62

Upper paper deflector assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

Connector locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Autoconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Envelope feeder board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Fuser Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

High-capacity output stacker board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

High voltage power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Interconnect board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Low voltage power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Output expander control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

StapleSmart finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

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System board—non-network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

System board—network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Preventive mainte nan ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1

Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Scheduled maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Assembly 1: Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 2

Assembly 2: Frame 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 3: Frame 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 4: Printhead 1 (000/010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 5: Printhead 2 (200/210) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Assembly 6: Printhead 3 (400/410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 7: Paper feed—autocompens ator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Assembly 8: Paper feed—multipurpose feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Assembly 9: Paper feed—alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Assembly 10: Integrated paper tray—250-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Assembly 11: Integrated paper tray—500-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Assembly 12: Drives—Main drive and develop er drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Assembly 13: Hot roll fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Assembly 14: Transfer/charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Assembly 15: Electronics—power supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Assembly 16: Electronics—card assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Assembly 17: Electronics—shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Assembly 18: Cabling diagrams 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Assembly 19: Cabling diagrams 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Assembly 20: Cabling diagrams 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Assembly 21: 250-sheet paper tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

Assembly 22: 500-sheet paper tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

Assembly 23: Duplex option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48

Assembly 24: Envelope feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50

Assembly 25: Output expand er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

Assembly 26: High-capacity output expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56

Assembly 27: 5-bin mailbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60

Assembly 28: High-capacity feeder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64

Assembly 29: High-capacity feeder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66

Assembly 30: High-capacity feeder 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68

Assembly 31: High-capacity feeder 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70

Assembly 32: High-capacity feeder 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72

Assembly 33: Kiosk—vertical paper adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74

Assembly 34: Kiosk—horizontal paper adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76

Assembly 35: StapleSmart finisher I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78

Assembly 36: StapleSmart finisher 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80

Assembly 37: StapleSmart finisher 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82

Assembly 38: StapleSmart finisher 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84

Assembly 39: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86

Assembly 40: Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1

Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-7

viii Service Manual

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Laser notices

Laser no tice

The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for
Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the
requirements of IEC 60825-1.

Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb
(3b) laser that is nominally a 5 milliwat t gall ium 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 I level during normal operation, user maintenance, or
prescribed service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS
(Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In
anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC
(International Electrotechnical Comm ission) 60825-1 gem äß amtlicher Bestät igung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser
der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen
der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß
im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch
den Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde, Menschen keinesfalls
erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J
concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux
normes IEC 60825-1 relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette
imprimante est équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance
nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795
nanomètres. L’imprimante et son système laser sont conçus pour impossible, dans des conditions
normales d’utilisation, d’entretien par l’utilisateur ou de révision, l’exposition à des rayonnements
laser supérieurs à des rayonnements de Classe I .

Laser notices ix

4060-xxx

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR
Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di
classe 1 conforme ai requisiti della norma CEI 60825-1.

I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un
laser di classe IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla l unghezza d’onda
compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale
che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di
servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.

Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de
Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de
Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma
IEC 60825-1 para productos láser de Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un
láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una
longitud de onda de 770 a 795 nanómetros. El sistema láser y la impresora están diseñados de
forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al nivel
de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra
situación de servicio técnico.

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação
DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada
como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 60825-1.

Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém
um produto laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts
,operando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a
impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso
humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção
feita pelo utilizador ou condições de assistência prescritas.

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Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de
Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in
IEC 60825-1.

Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een
laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een
golflengte van 770-795 nanometer. 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 I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-

laser, der nominelt er en 5 milliwatt gal lium ar senid las er, som arbejder på bølgelængdeområdet 770­795 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for
en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske
servicebetinge lser.

Huomautu s las er laittees ta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J ­määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb
(3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä
ja kirjoitin on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle
kirjoittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien
yhteydessä.

V ARO! A vattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso
säteeseen.

VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej
strålen.

Laser notices xi

4060-xxx

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för
laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I
enligt kraven i IEC 60825-1.

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som
består av en laserenhet av gallium-arsenid på 5 milliwatt som arbe tar i våglängd sområdet 770-795
nanometer. Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person
utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av
användaren eller annan föreskriven serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1)
laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC
60825-1.

Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb
(3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770­795 nanometer. Lasersyst emet og skriveren er utformet slik at personer aldri utsettes f or la serstråling
ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne
serviceoperasjoner.

Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21
CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un
producte làser de classe I que compleix els requisits d’IEC 60825-1.

Els productes làser de classe I no es consideren perilloso s. Aquesta impressora conté un làser de
classe IIIb (3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud
d’ona de 770-795 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que
mai hi hagi exposició a la radiació làser per sobre d’un nivell de classe I durant una operació normal,
durant les tasques de manteniment d’usuari ni durant els serveis que satisfacin les condicions
prescrites.

xii Service Manual

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Japanese Laser Notice

Laser notices xiii

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Korean Laser Notice

xiv Service Manual

4060-xxx

Safety information

• The safety of this product is based on testing and approvals of the original design and specific

components. The manufacturer is not responsible for safety in the ev ent 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 shou ld understand this and take
necessary precautions.

• CAUTION: When you see this symbol, there is a danger from hazardous voltage in the

area of the product where you are working. Unplug the product before you begin, or use
caution if the product must receive power in order to perform the task.

Consignes de sécurité

• La sécurité de ce produit repose sur des tests et des

agréations portant sur sa conception d'origine et sur des composant s particuliers. Le fabricant
n'assume aucune responsabilité concernant la sécurité en cas d'utilisat ion de piè ces de
rechange non agréées.

• Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel

de maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le

personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.

• ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie

du produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou
faites preuve de vigilance si l'exécution de la tâche exige que le produit reste sous
tension.

Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei

componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione
non autorizzata delle part i.

• Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al

personale di assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni alla persona è più el evato. Il personale di assistenza
autorizzato deve, quindi, adottare le precauzioni necessarie.

• ATTE NZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del

prodotto. Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve
essere alimentato per eseguire l'intervento.

Safe ty inform at ion xv

4060-xxx

Sicherheitshinweise

• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells

und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller
keine Ve rantwor t ung oder Haftun g für die Sicherheit über nom me n.

• Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch

einen Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches

Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal
sollte entsprechende Vorsichtsmaßnahmen treffen.

• ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in

diesem Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät
den Netzstecker des Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt
für die Ausführung der Arbeiten an den Strom angeschlossen sein muß.

Pautas de Segu ridad

• La seguridad de este producto se basa en pruebas y aproba ciones del diseño or iginal y

componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de
piezas de repuesto no autorizadas.

• La información sobre el mantenimiento de este producto está dirigida exclusivamente al

personal cualificado de mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la

reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar
las precauciones necesarias.

• PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que está

trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si,
para trabajar con él, debe conectarlo.

Informações de Seguranç a

• A segurança deste produto baseia-se em testes e aprovações do modelo original e de

componentes específicos. O fabricante não é responsável pela segunrança, no caso de uso de
peças de substituição não autorizadas.

• As informações de segurança relativas a este produto destinam-se a profissionais destes

serv iç os e não devem ser utilizad as por outras pe s s oa s.

• Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste

produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os
cuidados necessários.

• CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial

tensão perigosa na zona do produto em que está a trabalhar. Antes de começar,
desligue o produto da tomada eléctrica ou seja cuidadoso caso o produto tenha de
estar ligado à corrente eléctrica para realizar a tarefa necessária.

xvi Service Manual

4060-xxx

Inf ormació de Seguretat

• La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els

components específics.
El fabricant no es fa responsable de les qüestions de
seguretat si s'utilitzen peces de recanvi no autoritzades.

• La informació pel manteniment d’aquest producte està orientada exclusivament a professionals

i no està destinada
a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de

servei d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre
les mesures convenients.

• PRECAUCIÓ: aquest símbol indica que el voltatge de la part de l'equip amb la qual

esteu treballant és perillós. Abans de començar, desendolleu l'equip o extremeu les
precaucions si, per treballar amb l'equip, l'heu de connectar.

Safety information xvii

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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.

2. Diagnostic information contains an error indicator table, symptom tables, and service checks

used to isolate failing field replaceable units (FRUs).

3. Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer

problems.

4. Repa ir informatio n provides instructions for making printer adjustments and removing and

installing FRUs.

5. Conne ct or l oca ti on s uses illustrations to identify the connector locations and test points on the

printer.

6. Preventive maintenance contains the lubrication specifications and recommendations to

prevent problems.

7. Parts catalog contains illustrations and part numbers for individual FRUs.

Definitions

Note: A note provides additional information.
Warning: A warning identifies something that might damage the product hardware or software.

CAUTION: A caution identifies something that might cause a ser vice r harm .

CAUTION: When you see this symbol, there is a danger from hazardous voltage in the

area of the product where you are working. Unplug the product before you begin, or use
caution if the product must receive power in order to perform the task.

xviii Ser v ice M anual

4060-xxx

1. General information

The Lexmark™ T63x laser printers are letter quality page printers designed to attach to
IBM-compatible personal computers and to most computer networks.

The Lexmark T63x laser printers are available in the following models:

Model name Configuration Machine type

Lexmark T630 Non-network 4060-000
Lexmark T630n Network 4060-010
Lexmark T632 Non-network 4060-200
Lexmark T632n Network 4060-210
Lexmark T634 Non-network 4060-400
Lexmark T634n Network 4060-410

Maintenance ap proach

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.

General information 1-1

4060-xxx

Options

The following options are available. Some options are not available in every country. Contact your
point of purchase for options available in your country.

• Memor y options of 8MB, 16MB, 32MB, 64MB and 128MB SDRAM

• Flash memory options of 16MB and 32MB

• Hard disk—20GB+ with adapter

• Integrated network options
– Token-ring
– E thernet
– External serial adapter
– IR adap ter
– IPDS card assembly and SCS/TNe
– ImageQuick™ card assembly
– B ar code card assembly
– Parallel interface card
– MarkNet™ Print Servers
– Lexmark PrintCryption™ card

• Media handling operations
– 250- and 500-sheet paper trays of A4, letter, A5, B5, Executive, folio, statement, and legal

size

– 250-sheet universally adjustable tray
– 250- and 500-sheet paper drawers
– 400-sheet universally adjustable tray
– 2000-sheet high-capacity feeder
– Envelope f eeder
– Duplex option—250-sheet (For Lexmark T630 and Lexmark T630n)
– Duplex option—500-sheet (For Lexmark T63 2, Lexmark T632n, Lexmark T634, and

Lexmark T634n)

– Output expander
– High-capa city output stacker
– S tapleS mart™ Finisher
– 5-bin Mailbox
– Vertical Kiosk Presenter
– Hori zontal Kiosk Presenter

• Application solutions
– Lexmark Document Solutions
– Optra Forms™, including a Forms Hard Disk—20+GB with adapter

• DBCS font cards
– S implified Ch inese
– T raditional Chinese
– Japanese

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4060-xxx

Print speed and performance print speed

Performance

Perf ormance speed depends on:

• Interface to the host (USB, serial, parallel, network)

• Host system and application

• Page complexity and content

• Printer options installed or selected

• Available printer memor y

• Media size and type

• Resolution

The following table specifies throughput based on resolution and media size.

Lexmark T630,

Lexmark T630n

300, 600,
1200
image
quality

1200 dpi

Lexmark T632,

Lexmark T632n

300, 600,
1200
image
quality

Simplex printing on full-size media (pages per minute)

Letter

35.1 18.0 40.1 21.5 45

8.5 in. x 11 in.
A4

33.2 17.1 38.0 20.4 43

8.3 in. x 11.7 in.
Legal

28.4 14.6 32.8 17.4

8.5 in. x 14 in.

Duplex prin ting on letter-siz e m edi a (sides per minute )

Letter

30.6 16.9 33.2 19.2

8.5 in. x 11 in.
A4

29.2 16.1 31.6 18.3

3.4 in. x 11.7 in.
Legal

22.6 14.4 27.8 15.8

8.5 in. x 14 in.

1200 dpi

Lexmark T634,

Lexmark T634n

300, 600,
1200
image
quality

1200 dpi

General information 1-3

4060-xxx

Time to first print

Time from standby mode <8.5 sec. <10 sec.
Time from Power Save r mode 42 sec. 42 sec.
All first cop y times are measur ed f or 600 dp i simple x pri nting on lette r siz e paper. The test job consists of the

character “A” followed by a form-feed (single page job). The first copy time is defined as the el apsed time
from pressing Enter on the PC keyboard to the page e xiting to the output bin. Al l te sts pick paper from the
indicated tray and the page e xits into the primary output bin.

Memory co nfiguration

Memory

Standard DRAM 32/64MB 64/64MB 64/80MB
Maximum 288/320MB 320/320MB 320/336MB

Depending upon the options and features used, additional memory may be required to optimize
performance.

Available memory options

Lexmark T630,
Lexmark T630n

Lexmark T630,
Lexmark T630n

Lexmark T632,
Lexmark T632n

Lexmark T632,
Lexmark T632n

Lexmark T634,
Lexmark T634n

Lexmark T634,
Lexmark T634n

Optional 8MB, 16MB, 32MB, 64MB, and 128MB SDRAM DIMMs are available from Lexmark. The
memory options are 168-pin synchronous DRAM DIMMs.

Flash memory options include 16MB and 32MB.

1-4 Service Manual

4060-xxx

Printer specifications

Dimensions

Description Width Depth Height Weight

Printer

Lexmark T630 (base printer) 16.6 in.

(421 mm)

Lexmark T632 (base printer) 17.2 in.

(436 mm)

Lexmark T634 (base printer) 17.2 in.

(436 mm)

Options

2,000-Sheet drawer 15.6 in.

(398 mm)

Output Expander 15.6 in.

(398 mm)

500-Sheet drawer 15.6 in.

(398 mm)

250-Sheet drawer 15.6 in.

(398 mm)

5-Bin Mailbo x 15.7 in.

(399 mm)

High-capacity output stacker 15.7 in.

(399 mm)

StapleSmart finisher 17.6 in.

(447.7 mm)

19.6 in.
(498 mm)

20.2 in.
(513 mm)

20.2 in.
(513 mm)

19.5 in.
(495 mm)

14.9 in.
(374 mm)

20.5 in.
(520 mm)

19.5 in.
(495 mm)

12.2 in.
(310 mm)

18 in.
(457 mm)

19.5 in.
(495.3 mm)

13.6 in.
(345 mm)

16 in.
(406 mm)

16 in.
(406 mm)

11.8 in.
(300 mm)

6.8 in.
(173.2 mm)

5.3 in.
(134 mm)

3.5 in.
(90 mm)

13.1 in.
(332 mm)

11.4 in.
(290 mm)

9.0 in.
(228.6 mm)

38 lb
(17 kg)

41.5 lb
(19 kg)

41.5 lb
(19 kg)

28 lb
(12.7 kg)

7 lb
(3.2 kg)

7 lb
(3.2 kg)

6 lb
(2.7 kg)

8.2 lb
(3.7 kg)

10 lb
(4.5 kg)

13 lb
(5.9 kg)

Envelope option (closed position) * 7.72 in.

Envelope option (support fully
extended)

Printer cabinet 30.4 in.

Printer cabinet stand 34.8 in.

* Envelope option fits within heigh t and wi dth of printer.

* 12.28 in.

(772 mm)

(883 mm)

(196 mm)

(312 mm)

23.2 in.
(594 mm)

23.2 in.
(594 mm)

*4 lb

*4 lb

31.8 in.
(808 mm)

31.8 in.
(808 mm)

(1.8 kg)

(1.8 kg)
76 lb

(34.5 kg)
83 lb

(37.6 kg)

General information 1-5

4060-xxx

Operating clearances

Printer side Measurement

Left and right side 12 in. (304.8 mm)
Fron t 20 in. (508 mm)
Rear 12 in. (304.8 mm)
Top* 54 in. (1 ,3 71.6 mm)
* Allow clearance above the printer front door clearance and for adding

options, such as additional input drawers, output expander, high-capacity
output stacker, or StapleSmart finisher.

Power and electrical speci fications

Average nominal power requirements for the base printer configuration (110 volt). Power lev els are
shown in watts.

Printing states

Printing—average power

Base model 429 W 432 W 523 W 527 W 584 W 590 W

All options

Idle—avera ge pow er

Power Saver on 12 W 15 W 14 W 14 W 15 W 16 W
Power Saver off 81 W 84 W 81 W 84 W 86 W 87 W

Printing—maximum current

110V 8.8 A 8.8 A 9.8 A 9.8 A 10.2 A 10.2 A
230V 4 A 4 A 5 A 5 A 5 A 5 A

Lexmark
T630

457 W 460 W 540 W 544 W 608 W 614 W

Note: Using a 220 to 110 power converter with the 110 volt printer is not recommended.

Electrical specifi cations

Low voltage mod el

Lexmark
T630n

Lexmark
T632

Lexmark
T632n

Lexmark
T634

Lexmark
T634n

• 100 to 127 V ac at 50 to 60 Hz nominal

• 99 to 137 V ac, extreme

High voltage model

220 to 240 V ac at 50 to 60 Hz nominal (not available in all countries)

•

• 190 to 259 V ac, extreme

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4060-xxx

Acoustics

All measurements are made in accordance with ISO 7779 and conform with ISO 9296.

Model Status

Lexmark T630(n) Idle (standby mode)

Lexmark T632(n) Idle (standby mode)

Lexmark T634(n) Idle (standby mode)

Measurements apply to 300 dpi, 600 dpi, and 1200 dpi printing.

Environment

Printer temperature and humidity

Simplex printing
Duplex printing

Simplex printing
Duplex printing

Simplex printing
Duplex printing

1 Meter average
sound pressure

31 dBA 4.6 Bels
52 dBA 6.7 Bels
55 dBA N/M Bels
32 dBA 4.7 Bels
54 dBA 6.8 Bels
57 dBA N/M Bels

Declared sound
power

• Operating
– Temperature: 16 to 32° C (60° to 90° F)
– Relative humidity: 8 to 80%
– A ltitude: 10,000 ft. (0 to 3,048 meters)

• Storage and shipping environment (packaged)
– T emperature: -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%

General information 1-7

4060-xxx

Media specifications

Media type

Media type

500-Sheet input

Multipurpose tray

2,000-Sheet draw er

Duplex

Standard output

5-Bin Mailbox

Output Expander

Finisher to staple,

hole punch, offset stack

or with output bin

Paper xxxxxxxx
Card stock xx xx x
Transparencies x x x x
Envelopes x
Vinyl labels x x
Paper labels x x
Polyester labels x x
Dual web labels x x x
Integrated labels x x x

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4060-xxx

Media size

Media size supported

Integrated tr ay

250 Input tray

250 Universall y adjustable tray

500 Input tray

400 Universall y adjustable tray

Multipurpose tray

2000-sheet draw er

Envel op e feed e r

Duplex

Standard output bin

Output Expander

5-Bin Mailbox

High-capacity output st acker

StapleSmart output bin

StapleSmart—Staple/jogger

A4 8.27 in. x 11.7 in.
(210 mm x 297 mm)

A5 5.83 in. x 8.27 in.
(148 mm x 210 mm)

JIS-B5 7.17 in. x 10.23 in.
(182 mm x 257 mm)

Letter 8.5 in. x 11 in.
(216 mm x 279 mm)

Legal 8.5 in. x 14 in.
(216 mm x 355.6 mm)

Executive 7.25 in. x 10.5 in.
(184 mm x 267 mm)

Folio 8.5 in. x 13 in.
(216 mm x 330 mm)

Statement 5.5 in. x 8.5 in.
(140 mm x 216 mm)

2

Universal

1

1

5.5 x 8.27 in. to 8. 5 x 14 in. (1 39.7
x 210 mm to 215.9 x 355.6 mm)

2.75 x 5 in. to 8.5 x 14 in. (69.85 x
127 mm to 229 x 355.6 mm)

xx x xx xxxxxxx

xxxxxxxxx

xx x xx xxxxxx

xx x xx xxxxxxx

xx x xx xxxxxxx

xx x xx xxxxxx

xx x x xxxxxxx

xxxx xxx

xxxxxx xx x

x xx xx x

5.83 x 7.17 in. to 8. 5 x 14 in. (148
x 182 mm to 215.9 x 355.6 mm)

1

This size does not appear in the Paper Size menu until Tray Size Sensi ng i s tu rned off.

2

This size setting formats the page f or 215.9 x 355.6 mm (8.5 x 14 in.) unless the size is specifie d b y the software

program.

xxxxxx x xx x

General information 1-9

4060-xxx

Media size supported

Integrated tr ay

250 Input tray

250 Universally adjustable tray

500 Input tray

400 Universally adjustable tray

Multipurpose tray

2000-sheet drawer

Envelope feeder

Duplex

Standard output bin

Output Expander

5-Bin Mailbox

High-capacity output stacker

StapleSmart output bin

StapleSmart—Staple/jogger

Envelopes

7¾ Envelope 3.875 in. x 7.5 in.

x x xx x

(98 mm x 191 mm)
9 Envelope 3.875 in. x 8.9 in. (98

x x xx x

mm x 225.4 mm)
10 Envelope 4.125 in. x 9.5 in.

x x xx x

(105 mm x 241 mm)
DL Envelope 4.33 in. x 8.66 in.

x x xx x

(110 mm x 220 mm)
C5 Envelope 6.38 in. x 9.01 in.

x x xx x

(162 mm x 229 mm)
B5 Envelope 6.93 in. x 9.84 in.

x x xx x

(176 mm x 250 mm)

Other envelope

3.87 x 6.38 in. to 6.93 x 9.84 in.

x x xx x

(98.4 x 162 mm to 176 x 250 mm)

Media types

Paper xxxxxxx xxxxxxx
Card stock xxxxxx xxx xx
Transparencies xxxxxx xx xxx
Vinyl labels

3

xxxx x xx x

Paper labels 3 xxxxxx xx x

3

Pol yester labels
Dual web and integr ated labels

3

Printing label application on the printer requir es a special label fuser cleaner which prevents duplexi ng. The label

xxxxxx xx x

3

xxxxxx xx x

fuser cleaner is inc luded with a special label cartridge for label applications.

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Input media types and weights

Media weights—input

Media Type Weight

Integrated trays and optional 500-sheet drawers

Paper Xerographic or business paper 60 to 176 g/m

(16 to 47 lb bond)

2

grain long

Card stock— m a x i mum
(grain long)

Card stock— m a x i mum
(grain short)

1

1

Index Bristol 163 g/m2 (90 lb bond)
Tag 163 g/m
Cover 176 g/m

2

(100 lb bond)

2

(65 lb bond)

Index Bristol 199 g/m2 (110 lb bond)

2

Tag 203 g/m
Cover 216 g/m

(125 lb bond)

2

(80 lb bond)
Transparencies Laser printer 138 to 146 g/m
Labels—maximum

Integrat ed forms Pre ssure sensitiv e area

2

Paper 180 g/m2 (48 lb bond)
Dual-web paper 180 g/m
Polyester 220 g/m

3

300 g/m2 (92 lb liner)

Vinyl

2

140 to 175 g/m2

2

(48 lb bond)

2

(59 lb bond)

Paper bas e (grain long) 75 to 135 g/m

Multipurpose feeder and optional 250-shee t drawer

Paper Xerographic or business paper 60 to 135 g/m

(16 to 36 lb bond)

Card stock— m a x i mum
(grain long)

1

Index Bristol 120 g/m
Tag 135 g/m
Cover 135 g/m

2

(67 lb bond)

2

(50 lb bond)

2

(50 lb bond)

2

(37 to 39 lb bond)

2

(20 to 36 lb bond)

2

grain long

Card stock— m a x i mum
(grain short)

1

Transparencies Laser printer 138 to 146 g/m
Labels—maximum

2

Index Bristol 163 g/m2 (90 lb bond)
Tag 163 g/m
Cover 176 g/m

2

(100 lb bond)

2

(65 lb bond)

2

(37 to 39 lb bond)

Paper 163 g/m2 (43 lb bond)

2

Dual-web paper 163 g/m
Polyester 220 g/m

3

Vinyl

260 g/m2 (78 lb liner)

(43 lb bond)

2

(59 lb bond)

General information 1-11

4060-xxx

Media weights—input (continued)

Media Type Weight

Integrat ed forms Pre ssure sensitiv e area 2 140 to 175 g/m2

2

Paper bas e (grain long) 75 to 135 g/m

Envelope Sulfite, wood- free or up to 100%

Envelope feeder

Envelope Sulfite, wood- free or up to 100%

2000-sheet drawer

Paper Xerographic or business paper 60 to 135 g/m

1

Grain short is prefer red for paper ov er 135 g/m2.

2

Printing label applications on your printer requires a special label fuser cleaner which prevents duplexing.

3

28 lb bond envelopes are limited to 25% cott on content.

4

Includes envelopes fed from the multipurpose feeder only.

5

Informatio n on whether your vinyl label converter has passed Lexmark’ s criteria is available at Lexm ark’s
Web site (www.lexmark.com). Search for “converter list.” You can also check Lexmark’s Aut omated Fax
system (LEXFAX

SM

).

cotton bond

cotton bond

60 to 105 g/m
(16 to 28 lb bond)

60 to 105 g/m
(16 to 28 lb bond)

(16 to 36 lb bond)

(20 to 36 lb bond)

2

3, 4

2

3, 4

2

grain long

Print area

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.

Media guidelines

Paper designed for use with xerographic copies should provide satisfactory print quality and feed
reliability. Other types of supplies may be suitable. We recommend that users test any particular
brand for suitability to their applications. Refer to the printer’s user information for additional media
specifications.

Paper

Use the following media guidelines for successful printing:

• Rough, highly textured, limp, or pre-curled paper results in low er print quality and more frequent

paper feed failures.

• Colored paper must be able to withstand 227° C (440° F) fusing temperature.

• Preprinted forms and letterheads should be selected using guidelines found in the printer’s user

information. The chemical process used in preprinting may render some papers unsuitable for
use with this printer.

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• Unsuitable papers include:
– Mu lti-part forms and documents
– Chem ically treated papers
– Coated, synthetic, and thermal papers
– A5 paper less than 80 g/m
– Recy cled paper less than 75 g/m

2

(21 lb)

2

(20 lb)

– Preprinted paper requiring a high degree of registration

• Recycled paper less than 80 g/m

2

(21 lb) may cause unacceptable results.

Envelopes

• All envelopes should be new, unused, and without package damage.

• Envelopes with excessive curl or twist exceeding 6 mm, those stuck together, those with bent

corners or nicked edges, or those that interlock should not be used.

• Minimum weight should not be less than 75 g/m

2

(20 lb).

• The following envelopes should not be used:
– E nvelopes with windows, holes, perforations, cutouts, or deep embossing
– E nvelopes with metal clasps, string ties, or metal folding bars
– Envelopes with exposed flap adhesive when the flap is in the closed position.

• For best results, printing on new 90 g/m

recommended.

2

(24 lb) sulfite or 25% cotton bond envelopes is

• Under high humidity conditions (over 60%), envelopes may seal during printing.

Transparencies

• Use letter or A4-size transparencies only.

• Transparencie s specifically designe d for xerographic copy machines or laser printers may be

used with this printer.

Labels

Select labels using guidelines from in this printer’s user information, refer to the Card Stock and
Label Guide, or depend upon tested acceptability.

General information 1-13

4060-xxx

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)

1-14 Service Manual

4060-xxx

Acronyms

BLDC Brushless DC motor
CSU Customer setup
DIMM Dual Inline Memor y Module
DRAM Dynami c Random Access Memory
DVM Digita l mult imeter
EDO Enhanc ed Data Ou t
EEPROM Electrically Erasable Programable Read-Only Memory
EP Electrophotographic process
EPROM Erasable Programmable Read-Only Memory
ESD E lectrostatic Discharge
FRU Field Replaceable Unit
GB G igabyte
HCIT High-capacity Input Tr ay
HVPS High Voltage Power Supply
ITC Internal Tray Card
LASER Light Amplification by Stimulated Emission of Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
MPF Multipurpose feeder
MROM Masked Read Only Memory
MS Microswitch
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
OPT Optical Sensor
PC Photoconductor
pel Picture element
POR Power-On Reset
POST Power-On Self Test
PWM Pulse Width Modulation
RIP Raster Imaging Processor
ROM Read Only Memory
SDRAM Synchronous Dynamic Random Access Memory
SIMM Single Inline Memor y Module
SRAM Static Random Access Memory
UPR Used Parts Return
V ac Volts alternating current
V dc Volts direct current
VOM Vol t Ohmmeter

General information 1-15

4060-xxx

1-16 Service Manual

4060-xxx

2. Diagnostic information

Start

CAUTION: Remove the power cord from the printer or wall outlet before you connect or

disconnect any cable or electronic board or assembly for personal safety and to prevent
damage to the printer. Use the handholds on the side of the printer. Make sure your
fingers are not under the printer when you lift or set the printer down.

Use the service error code, user status message, user error message, symptom table, service
checks, and diagnostic aids in this chapter to determine the corrective action necessary to repair a
malfunctioning printer.

Service error codes are indicated by a three-digit error code. If a service error code displays, go to

“Service error codes” on page 2-2.

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 Power Sa ver is invok ed, and then P ower Sav er displa ys.
If a user status message is displayed, go to “User status displays” on page 2-14.

User error 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 “U ser attend ance messages ” on page 2-19.

If your machin e compl e te s the “Power-On Self Test (POST)” on page 2-34 without an error, and
you have a symptom, go to “Symptom table s” on page 2 -3 5. Locate your symptom and take the
appropriate action.

If a service error code appears while you are working on the machine, go to “Service error codes”

on page 2-2 and take the indicated action for that error.

Diagnostic information 2-1

4060-xxx

Messag es an d er ror code s

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 code

Error code Action

900 RIP Software Go to “900 Error Code service check” on page 2-41.
901 Engine Flash Indicates that the flash which the system board code is programmed into is bad.

902 General Engine
Software Error

903 Paperport Link
Driver Error

904 Interface Violation
by RIP

905 Interface Violation
by P aperport Devic e

906 RIP Interface Driver
Error

910 DC Pick Motor DC
Pick Motor Stall

911 DC Pick Motor
Excessive PWM

912 DC Pick Motor
below speed

913 DC Pick Motor over
speed

914 DC Pick Motor: No
encoder feedback

Replace the syste m board.
These errors ind icate an unrecover able system software error . Replace the

system board.

Error Codes 910, 911, 912, 913, and 914 are indications that a Tray 1 paper feed
problem has been detected. Go to “Input tray(s) service check” on page 2-64.

Check the inte grated paper tra y (Tray 1) for correct paper loading. Reload the
paper and POR the printer. If the error continues, go to “Input tray(s) service

check” on pa ge 2-64.

917 Transfer Roll Indicates a problem in the transfer roll area . Go to “Transfer roll service check”

920 Fuser Error Indicates that the fuser is below temperatur e when printing. G o to “Fuser service

921 Fuser Error Indi cates that the fuser is below standby temperature when the printer is idle. Go

922 Fuser Error Fuser failed to reach sta ndby temperature. Go to “Fuser service checks” on

923 Fuser Error Fuser is too hot during printing or when printer is idle. Go to “Fuser service

2-2 Service Manual

on page 2-94.

checks” on page 2-52.

to “Fuser service checks” on p age 2-52.

page 2-52.

checks” on page 2-52.

4060-xxx

Service error code (c on tinued)

Error code Action

924 Fuser Error An open circuit has been detected in the Fuser Thermistor Circuit. Go to “Fuser

925 Fuser Error Wrong fuser lamp installed. Go to “Cold fuser service check” on page 2-52.
927 Fan Stalled This is an indi cati on that a p rinter fan has stalled. Go to “Main fan servi ce c hec k”

929 Toner Sensor The toner sensor is not operating properly, the developer drive assembly is not

930 Printhead Error The wrong printhead may be installed. If you have not replaced the syst em board

931-935 Printhead Error These error s repr esent a problem with the printhead. Go to “Printhead service
932 - Printhead: Lost

Hsync
933 - Mirror Motor

Locks/Lost Hsync
934 - Mirror Motor Lost

Lock
935 - Mirror Motor

unable to reach
operating speed.

service checks” on page 2-52.

on page 2-69.

operating p roperly or the print cartridge is defective. Go to “T on er se nsor se rvice

check” on pa ge 2-93.

recently, replace the correct printhead. If the prob lem remains , replace the system
board. If yo u have recently replaced the system board and you still have a 930
error, the wrong system board may be installed. Replace the system board with
the correct sys tem board.

check” on pa ge 2-78.

936-937 Transport
Motor

936 - Main Drive Motor
initial lock failure

937 - Main Drive Motor
lost lock

940 Service LV Power
Supply

948 PEL Clock Error Indicates the pel clock check failed. Replace the system board.
949 Delay Line

Calibration Failure
950 NVRAM

Mismatch
951 NVRAM

Secure NVRAM Missing
953 NVRAM Chip

Failure

Indicates a problem with the main driv e motor . Go to “Main drive service check”

on page 2-68.

The low volt age power supply zero crossover t est failed.
Check the LVPS for correct installation. Make sure th e connector on the LVPS
assembl y is f irmly seated with the connector on the interconnect card connector.
This error may also be caused by a noisy A C input power source.

• Be sure th e corr ect LVPS has been installed.

• If all the above are correct, re place the LVPS assembly.

Indicates a delay line calibration failure. Replace the system board.

Go to “950 Error Code service check” on page 2-42.

Replace the syste m board.

Indicates the NVRAM chip on the interconnect board has failed. Replace th e
interconnec t board.

Diagnostic information 2-3

4060-xxx

Service error code (c on tinued)

Error code Action

954 NVRAM CRC
Failure

955 Code CRC
<loc>

956, 957, 959 System
Board

958 NAND Failure Before proceeding when a 958 NAND failure displa ys, perform a power on reset

960 RAM Memory Error Indicates a DRAM Memory Error on the system board. Repl ace the system boa rd.
961 RAM in Slot 2 is

Bad

962 RAM in Slot 1 is
Bad

964 Emulation Error Indicates a failure within the Do wnload Emulation which is programmed into the

Indicates the NVRAM experienced a CRC failure. Repl ace the interconnect board.

Replace the syste m board. Where <loc> = CRC Failure or ECC Fai lur e on the
system board.

Error codes 956 thru 959 are system board failures.
Per form a power on reset (POR). If this does not fix the problem, replace the

system board.

• 956 = Proces sor failure

• 957 = ASIC failure

• 959 = SRAM failure

(POR) to see if the ECC error correc tion code can reflash NAND.
If this does not fi x the problem, replace the system board.

If another SDRAM memory DIMM is installed in slot 1, tu rn the power off, switch
the DIMM in slot 1 to slot 2. If the memory in slot 2 now works correctly, replace
the failing DIMM that was in slot 2. If this does not fix the problem, repl ace the
system board. If another DIMM is not av ailable, repl ace the memory option. If this
does not fix the problem, replace the system board.

If another SDRAM memory DIMM is installed in slot 2, tu rn the power off, switch
the DIMM in slot 2 to slot 1. If the memory in slot 1 now works correctly, replace
the failing DIMM that was in slot 1. If this does not fix the problem, repl ace the
system board. If another DIMM is not av ailable, repl ace the memory option. If this
does not fix the problem, replace the system board.

code ov erlay card. The specific error is as foll ows:
964 - Download Emulation CRC Failure. Checksum Failure. Go to “Disabling

Download Emulations” on page 3-3.

975 - 979 Network
Card x

980 <device> Comm The engine is experiencing unreliable communications to the specified device.
981 <device> The engine protocol violation detected by the specified device.
982 <device> Comm Communications error detected by the specified device.
983 <device> Invalid command received by the specified device.
984 <device> Inv alid command paramete r rec e ived by the speci fied device.

The foll owing errors indicate a failure with the netw ork car d in th e specified slot.
(x=any card insta ll ed in slots 1 or 2.)

• 975 - Unrecognizable Network Card x. Replace network card x.

• 976 - Unrecoverable software error in network card x.

• 978 - Bad checksum while programming network card x. Replace network
card x.

• 979 - Flash parts failed while programming network card x.

If the printer is a network model , replace the system boar d.

Note: Service errors 980 thru 984 <device> can be one of the following: system
board, duplex, tray x (1, 2, 3, 4, or 5), envel ope feeder or output bin.

2-4 Service Manual

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Service error code (c on tinued)

Error code Action

990 <device> Indicates an equi pm ent check conditi on has occurred in the specified device, but

991 <device> Card The specified device has detected an equipment check in its system card.

Sub error codes

Sub error codes for 9xx and 2xx error codes

The sub error codes are helpful troubleshooting a paper path problem, especially paper jams in the
base printer, envelope feeder, and duplex option.

Displayed error codes

When a 9xx or 2xx error displays:

1. Press and hold Return and press Select to enter for sub error codes.

The first screen of information displays. Write down the information.

2. Continue pressing Return and Select until each screen of information is obtained.

3. When the last screen displays, the original message displays.

the device is unable to identi fy the exact component failure.
Note: <device> can be one of the following: duplex, tray x (1, 2, 3, 4, or 5),

env elope feeder or outpu t bi n.

Note: <device> can be one of the following: duplex, tray x (1, 2, 3, 4, or 5),
env elope feeder or outpu t bi n.

The following is an example of how the printer displays a duplex option sub error code.

Byte 4

xx
xx

Byte 8

DU
DU

Byte 1

xx
xx

Byte 5

Byte 2

xx
xx

Byte 6

Byte 3

xx
xx

Byte 7

Printed error codes

Additional information is available by printing the error log. See “Printing t he error log” on

page 3-7.

Diagnostic information 2-5

4060-xxx

Base printer sub error codes

Each status byte has a different level of troubleshooting value for each area of the printer. The
following table displays up to 8 status bytes of data. Some or all of these bytes may be used to help
diagnose a printer problem. These status bytes are designed to help isolate paper jams and paper
feed problems in the base printer.

Sub error code variable values

Displayed value of x Printer area
Values for tray sources

10 Multipurpose Tray (MPT)
11 Tray 1
12 Tray 2
13 Tray 3
14 Tray 4
15 Tray 5
31 Envelope feeder
40 Manual feeder

Val ues for stacker destinations

91 Stacker 1
92 Stacker 2
93 Stacker 3

Val ues for media size

1Letter
2 Legal
3B5
4A4
5 Executive
6A5
7Custom size
9 7¾ in. envelope
A #9 Envelope
B #10 E nvel ope
C 8.661 in. Envelope
D C5 Envelope
E B5 Env elope
F Legal envelope

2-6 Service Manual

4060-xxx

Base printer sub error codes

First 6 bytes sub error
code data (xx can be
any valu e)

Explanation

84 xx 00 x1 x2 This code indicat es that the inp ut sensor in the printer is sti ll ac tuated from the f irst

84 xx 01 x1 Video never st arted on the page.

84 xx 02 x1 This error is the most common type of paper jam. Poss ible causes are:

84 xx 04 The input sensor wa s covered during POST by a piece of media still in the

84 xx 05 There was media at the input sensor too early. There was not enough time

sheet and the second sheet is ready to arrive at the sensor.
(x1=media size, x2=media source)

• Check the printer input sensor and flag for correct operation. The flag should
operate freely.

• Check for debris in the area of the input sensor .

• Check the area of the tr ansfer plate and input to the f user for anything that might
cause the paper to remai n over the input sens or.

(x1=media size)
The video signal never started within 2 inches after actuating the input sensor.

Check input sensor and flag.

(x1=media size)

• Multi sheet feeding.

• A tray size sensing problem.

• The media feeding from the paper sou rce is s lippi ng o r media i s sli pping i n input
to the printer.

machine when it was turned on.

• Clear the media from the printer .

• Run the base sensor test (input sensor) fr om the di agnostic tests menu to test
the input sensor and flag for correct operation.

between printhead start and the printhead mirror motor to lock. Possible causes
for thi s err or are:

• Paper might be pre-staged in the paper source tray.

• Paper is picking too fast.

• A defective input sensor.

84 00 06 A paper jam has been declared by a smart device. Immediate stop homing not

84 00 07 A paper jam has been d ecl ared b y a smart dev ic e. Homi ng w as all ow ed bef or e the

84 xx 0B x1 x2 x3 The option tray pass t hru sensor was never actuated by a piece of media.

84 xx 0f x1 x2 x3 The option tray pass thru sensor was never deactivated.

84 00 10 The mai n moto r ID failed to identify either motor af te r two tries . P o ssib le causes for

allowed.

stop.

(x1=media size, x2=media source, and x3=paper source where paper jam was
detected)

• Run the sensor test for the option tray that is displaying the error code and
check the pass thru sensor for that tray for correct operation.

• Check for paper picki ng from the selected paper input source.

• If the error is being detected from a lower paper source, see if paper is f eeding
correctly from a paper source above the detected source.

(x1=media size, x2=media source, and x3=media source where paper jam was
detected)

• Check the pass thru sensor and flag for correct operation.

• Check to see if paper has cleared the pass thru area of the option where the
paper jam occurred.

this error are:

• The main drive motor has stalled.

• An incorrect main drive motor/gearbox assembl y has been installed.

Diagnostic information 2-7

4060-xxx

Base printer sub error codes (continued)

First 6 bytes sub error
code data (xx can be
any valu e)

Explanation

84 xx 17 There is an envelope or envelopes in the envelope feeder during w arm up. An

84 xx 18 There is media over the Tray 2 pass thru sensor duri ng warm up. Chec k for media

84 xx 19 There is media over the Tray 3 pass thru sensor duri ng warm up. Chec k for media

84 xx 1A There is media ov er the Tray 4 pass thru sensor during w arm up. Check for media

84 xx 1B There is media ov er the Tray 5 pass thru sensor during w arm up. Check for media

env elope may have partially fed from the envelope feeder.
Remove any envelopes from the feeder and check the envelope feeder for correct
operation.

over the sensor. If no med ia i s present, check the pas s thru sen sor, flag, and
cables.

• Try running the Inpu t Tray Tests for Tray 2 and see if Tray 2 is feeding paper
correctly and all the sensors are working correctly.

• Make sure the paper size setting is correct for the size paper in the tray.

over the sensor. If no med ia i s present, check the pas s thru sen sor, flag, and
cables.

• Try running the Inpu t Tray Tests fo r Tray 3 and see if Tray 3 is feeding paper
correctly and all the sensors are working correctly.

• Make sure the paper size setting is correct for the size paper in the tray.

over the sensor. If no med ia i s present, check the pas s thru sen sor, flag, and
cables.

• Try running the Inpu t Tray Tests for Tray 4 and see if Tray 4 is feeding paper
correctly and all the sensors are working correctly.

• Make sure the paper size setting is correct for the size paper in the tray.

over the sensor. If no med ia i s present, check the pas s thru sen sor, flag, and
cables.

• Try running the Inpu t Tray Tests for Tray 5 and see if Tray 5 is feeding paper
correctly and all the sensors are working correctly.

• Make sure the paper size setting is correct for the size paper in the tray.

84 xx 1C There is media over the Tray 6 pass thru sensor during warm up. Check for m edia

84 xx 1D The en velope feeder pass thru sensor ne ver deactivated. The display of this code

84 xx 1E x1 x2 The envel ope feeder pass thru sensor was never activated.

84 xx 20 x1 x2 The imaged page is not the ex pected page.

84 xx 21 x1 x2 The smart tray x did not pick a sheet of paper.

over the sensor. If no med ia i s present, check the pas s thru sen sor, flag, and
cables.

• Try running the Inpu t Tray Tests for Tray 6 and see if Tray 6 is feeding paper
correctly and all the sensors are working correctly.

• Make sure the paper size setting is correct for the size paper in the tray.

indicates that an env elope never crossed over the sensor flag and passed beyond
the sensor, or the flag and sensor are not operating properly. Go to “Envelope

feeder service check” on page 2-49.

(x1=media size, x2=media source)
Make sure en velopes are feeding over t he sensor. If an en velope feeds over the

sensor bu t the sensor does not activate, check the sensor and flag for correct
operation. If the sensor and flag are operating correctly, go to “Envelope feeder

service check” on page 2-49.

(x1=media size, x2=media source)
Check the pass thru sensor to make sure it is operating properly. If no problem is

found, it may be necessary to try a new pass thru sensor.

(x1=media size, x2=media source)
Check tray

is found, go to “Input tray(s) servi ce check” on page 2-64.

x auto compensator and tray parts for correct operation. If no problem

2-8 Service Manual

4060-xxx

Base printer sub error codes (continued)

First 6 bytes sub error
code data (xx can be
any valu e)

Explanation

84 xx 22 x1 x2 This code indicates th at the m edia act iv ated the inpu t sensor befo re the pri nter EP

84 xx 23 x1 x2 The transfer servo never started.

84 xx 25 This code indicates that the media has activated the input sensor before the

84 xx 26 This code indicates that media has activated the input sensor; however, the

89 00 01 The exit sensor in the fuser is activated by a piece of media indicating there is a

89 xx 03 The fuser exit sensor did not detect the trailing edge of the media goi ng through

was ready.
(x1=leading edge of media state, x2=tr ailing edge of media state)

(x1=media size, x2=leading edge of media state)

printhead has locked. Enough time has elapsed since printhead start to expect a
lock.
One of the following may be failing:

• Printhead assembly

• System board

• Printhead cables

printhead f ell out of lock condition or not enough ti m e elapsed since the printhead
start to expect a stable lock. The media may have also reached the input sensor
early.

piece of media in the machine during POST.
Check for media in the exit of the fuser assembly or redrive assembly. Feed a
sheet of paper, and if the same error occ urs after clearing the fuser or t he sam e
error occurs when no media is present, check the exit sensor assembly, internal
fuser assembly cabling, DC fuser cable to the system boar d, and the cable
connection to J14 on the system board.
Service tip: Turn the printer off, enter the dia gnostic tests menu, and select the
base sensor test . Select output sen sor an d check t he sens or f or corr ect oper at ion.

the fuser assembly.

• This failure can be caused by a broken fuser exit sensor flag.

• This may also be caused b y err atic operat io n of e xit se nsor flag or e xi t sens or or
a defective piece of media.

89 xx 04 x1 The fuser exi t sens or nev e r actua ted from t he sheet going t hr ough the fu ser before

89 xx 07 The narrow media sensor in the fuser was covered by a sheet of paper when not

89 xx 0B x1 The fuser exit sensor may be bouncing.

89 xx 0D The fuser exit sensor bounced. Check the exit sensor for correct operation. Check

the next page begins feeding .
(x1=media siz e)

expected or a piece of media is in the machine during POST.
This error can occur when a 202 paper jam has occurred.

1. Remove any piece of media that is over the narrow media sensor.

2. Try to feed a piece of paper thr ough the printer (could run the print t est from the
diagnostic test menu). If the media stops over the narrow medi a sensor again,
check the flag and sensor for correct operation.

This error can be caus ed by a failing e xit sensor or system boa rd.

the fuser DC cabl e to J14 on t he system board. Also, the system board may be
failing.

Diagnostic information 2-9

4060-xxx

Base printer sub error codes (continued)

First 6 bytes sub error
code data (xx can be
any valu e)

Explanation

8D 00 00 The fuser exit sensor was never activated by the leading edge of the medi a fed

8E xx 02 x1 x2 This error can be caused by the input sensor not bei ng activated by a page that

8E xx 06 x1 The second pick failed f rom a paper sour ce when paper was in the sou rce and the

8E xx 07 x1 The second pick failed from a paper source when paper was in the source. Other

8E xx 08 The paper in the output bin was flushed. The paper ahead of it, in t he paper path,

8E xx 09 x1 The second pick from the MPT, T ray 1, or feeder failed when paper was in the

8E xx 0A x1 The second pick from the MPT, Tray 1, or feeder failed when paper was in the

through the printer.

• This error can be displayed after a 201 paper jam.

• This can be caused by a defective fuser exi t sensor assembly.

Note: Enter the diagnostic tests menu, select Base Sensor Tests, select
Output Sensor Test and check the fu ser exit sensor for correct operation. If

the test f ails, check the int ernal fuser cabling, DC autoconnect on the fuser
frame, fuser DC autoconnect to the syste m board cable, and the cable
connection to J14 on the system board.

was known to ha ve been pick ed by a source other than the duplex option.
Ensure the correc t source has been selected and the med ia i s feeding from that

source.

only sheet in the paper path.

sheets may have started to feed, but none were in the paper path.

nev er made it past the output bin senso r or i nto the tray.

source. Other sheets may be in the paper path.
(x1=media source)

source. Other sheets may have started to pick, but none were in the paper path.

x1=media source)
8E x1 0B The DC autocompensat or failed or stalled when trying to feed a sheet of media.
8E xx 11 It took too long for the DC autocompensator motor to come up to speed.
8E xx 13 x1 x2 Late feeding from a paper source interfered with the next pick retry.

(x1=media size, x2=media source)

2-10 Service Manual

4060-xxx

Base printer (fuser) sub error codes

The following sub error codes could help in diagnosing fuser assembly failures:

Base printer (fuser) sub error codes

First 6 bytes sub error
code data (xx can be
any valu e)

920 Service - Fuser Error (under tempe rature while printing)

Explanation

EN 08 xx yy - 1
EN- zz - - 2

921 Service - Fuser Error (fuser under temperature while at standby)
EN 41 xx yy -- 1

EN -- zz -- -- 2

922 Service - Fuser Error (fuser failed to reach standby temperature)
EN 42 xx yy -- 1

EN z1 z2 -- -- 2

xx= Actual fuser temperature
yy= The temperature that the fuser wants to reach.
zz= 00 The hot roll took too l ong to heat up.
zz= 01 The hot roll fell too far below the desired temperature while printing.
zz= 02 The hot roll was t oo cool while the system was doing som e checking.
zz= 03 The hot roll was too cool when heating to the desired t emperature.

xx= Actual fuser temperature
yy= The temperature that the fuser wants to reach.
zz= 00 The fuser temperature did not change enough from the fuser lamp

temperature at turn on.

01 The fu ser te m p eratu re rose m o re than de sire d from th e fuser

temperature at turn on.

xx= Actual fuser temperature
yy= The temperature that the fuser wants to reach.

zz= 00 The fuser temperature did not change enough fro m the fuser lamp

temperature at turn on.

01 The fu ser te m p eratu re rose m o re than de sire d from th e fuser

temperature at turn on.

z2= 00 The hot roll did not reach standby temperature in time during standby.

01 Th e hot roll took too long to reach the begi nning lamp detection

temperature.

02 The hot roll reached ‘final lamp detection temperature’ but took longer

than expected.

03 The hot roll timed out trying to reach the ‘final lamp detection

temperature.’
04 After hot roll lamp detection, did not reach steady stat e control in time.
05 The hot roll did not reach operating temperature in time.

923 Service - Fuser Error (Fuser Cover Temperature)
EN 12 xx yy -- 1

EN -- -- -- -- 2

924 Service - Fuser Error (Open Thermistor Failure)
EN 18 xx -- -- 1

EN -- 00 -- -- 2

This sub error code displays anyti m e that the hot roll has reached a hi gher than
desired temperature.

xx= Actual fuser temperature
yy= The temperature that the fuser wants to reach.

This code is usual ly generated when an open circuit check is made of the
thermistor circuit in the fuser.
xx= Actual Fuser Temperature

Diagnostic information 2-11

4060-xxx

Base printer (fuser) sub error codes (continued)

First 6 bytes sub error
code data (xx can be
any valu e)

925 Service - Fuser Error (Wrong Fuser Lamp Installed)

Note: The follo w ing sub error codes are only for an incorrect lamp bei ng installed.

Explanation

EN 07 xx yy zz 1
EN -- -- -- 2

This error code is generated anytime an i ncorrect lamp is detected.
xx= 00 Lamp detection per formed and found an error.

01 It t ook long to do lamp det ection and NVRAM detected a pr evious wrong

lamp detected.

yy= Actual temperature
zz= The temperature that the fuser was trying to reach.

Duplex option sub error codes

Status byte 4 contains the most valuable information to help isolate a failing part or assembly in the
duplex option and is the only byte contained in the following table.

Status byt e 4 Ex plan ation

00 No duplex error. No problem was reported to the engine by the duplex system

01 The leading edge of the sheet of paper never arrived at the input sensor.
02 The duple x option system board never received media notif ication from the pri nter.
03 The trailing edge of the sheet of paper never cleared the input sensor.
04 The leading edge of the sheet of paper never arrived at the exit sensor.

05 The duple x logic thinks a sheet of paper is feeding to the duplex option due to a

card.

Note: This error is the most common due to the long length of the paper path
between the input sensor and the exit sens or.

sensor malfunction in the paper path when in fact the printer has not sent a

command to send a sheet of paper to the duplex option.
06 The exi t sensor detected a sheet of paper to o early.
07 The sheet of paper trailing edge did not clear the exit sensor in the desired length

08 The feed motor experienced a complete motor stall.

0E The DC motor is under speed. The motor never reached the correct operating

13 There is paper left i n the duplex option. Paper was sensed during the homing

15 There is paper left i n the duplex option. Paper was sensed during the DC motor

18 The DC motor experienced an acceleration er ror.

3D There is paper left in the duplex option. Paper was sensed during IR clear during

2-12 Service Manual

of time.

speed.

operation during POST.

diagnostic test during POST.

POST.

4060-xxx

Envelope feeder sub error codes

First 6 bytes sub error
code data (xx can be
any valu e)

84 xx 17 There is an envelope in the feeder during POST.

Explanation

84 xx 1D x1 x2 The envelope feeder pass thru sensor activated but never deactivated.

84 xx 1E x1 x2 An envel ope never acti vated the envelope feeder pass thru sensor or the sensor

(x1=media size, x2=media source)
This error can be caus ed by an envelope over the pass thru sensor. Remove the

env elope and try to feed an env elope. If the envelope stops over the pass thru
sensor, try the followi ng:

• Enter the diagnostic test menu, sel ect Input Tray Sensor Tests, select
Envelope Feeder Sensor Test.

• Check the envelope pas s thru sen sor to ensure it is operating correctly. If the
sensor test fails, go to “Envelope feeder service check” on page 2-49.

If the tes t passes, look for anything that might cause the en velope to stop over the
sensor.

nev er sensed the presence of an envelope.
(x1=media size, x2=media source)

• Make sure the envelope feeds to the pass thru sensor.

• Check to see if the envelop e actuates the pass thru sensor fla g.

Diagnostic information 2-13

4060-xxx

User status displays

Each user status screen may also display a warning message. See “Warning messag es (second

lines)” on pa ge 2-16 for additional information when they display.

User status displays Status Action

Ready
<warning>

Ready <fax status>
<warning>

Ready HEX
<warning>

Power Saver HEX
<warning>

Power Saver <fax status>
<warning>

The printer is ready to re ceive and
process data.

Press Menu to take the printer out of
Ready and enter all the menus except
the Tests Menu (Busy State).

The printer displays the fax status. Press Menu to take the printer out of

Ready and enter all the menus except
the Tests Menu (Busy State).

The printer is ready and HEX Trace is
active, which is known as HEX Trace
Ready.

Press Menu to take the printer out of
Ready and enter the Tests Menu (Busy
State). Press Select for the values.
Press Menu until Reset Printer
displays on the second line. Press
Select to reset the prin t e r.

When in the power saver mode the
printer displays this screen instead of

Press Menu to take the printer offline

and access the Ready Menu Group.
the ready screen. When a job is
received, the power saver screen
remains displ ayed until the printer exits
the power saver mode and the printer
warms up.

When the printer ha s been configu red to
receive or send faxes t he printer
displays this screen.

Press Go to take the printer out of

power saver and initiate a prin ter warm

up cycle.

or

or

Press Stop to take the printer offline.

Not Ready is displayed and no more

data is processed. Press Go to retur n

the printer to the previous state.

Res Reduced
<warning>

Res Reduced <fax status >
<warning>

2-14 Service Manual

The printer is processing data or
printing pages and the res olution of a
page belonging to the current job has
been reduced from 600 to 300 dpi to
prevent a Memory Full Error.

Displayed whenever the printer has
been configured to receive or send
faxes.

Press Stop to take the pri nter offline.

Not Ready is displayed, no more data

is processed, and the current job in the

paper path is proce ssed. Press Go to

return the printer to the previous state.

or

Press Menu to access the Busy/

Waiting Menu. The following functions

may be available:

•Cancel Job

• Reset Printe r

• Reset Active Bin

•Cancel FAX

4060-xxx

User status displays Status Action

Waiting <interpreter>
<warning>

Displayed until the current job is
terminated or until additional data is
received on the active link. (PCL, PS,
PJL, PPDS, SIC , or HEX) may be
displayed for the value for interpreter if
the printer is not configured for f ax.

Press Go to print the contents of the
printer buffer, staple the accumula ted
sheets, or te rminate the collation set.
Note: Go does not terminate the
current print job.

Press Menu to access the Busy/
Waiting Menu group . The following
functions may be available:

• Cancel Job

• Reset Printe r

• Reset Active Bin

• Print Buffer.

Diagnostic information 2-15

4060-xxx

Warning messages (second lines)

These second line warnings apply to the User status displays (see “User status displays” on

page 2-14). 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 Menu to take the printer offline and access the Ready Menu group. The Menu buttons are

not active if Menu Lockout is turned on.

• Press Stop to take the printer offline. The Not Ready message displays. No additional data is

processed from the host computer. Press Go to return the printer to the Ready state.

User message Explanation

Toner Low If the toner cartridge is low, then Toner Low displays. The Toner Low condition

Tray x Missing If any of the input trays equipped with tray present sensing are missing, then

Tray x Empty If any of the input trays are empty, then Tray x Empty displays, where x designat es

Tray x Low If any of the input trays are low, then “Tray x Low” displays, where x designates

clears whenever the upper front door is opened, and Toner Low displays aga in i f
the condition exists after the upper front door is closed.

Tray x Missing displays (where x designates whi ch tray (1 throu gh 5) is missing. If
multiple trays are missing, they ar e priorit ized in this o rder: 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

“Paral lel port service check” on page 2-77. If Tray 2 through 5 Missing

message does not clear b y inserting the tray, go to “Input tray(s) service check”

on page 2-64.

which tra y (Tray 1 through 5) is empty. If multiple tra ys are empty, then they are
prioritized in this order: Tray 5, Tray 4,...Tray 1.
Note: Tray x Empty status clears whenev er Tray x is removed. When Tray x is
reinserted, it is examined and the appropriate status, if any, displays.
Empty status is not displayed f or the Envelope Feeder or Multipurpose Feeder.

which tra y (1 through 5) is low. If multiple t rays are low, they are prioritized in the
follo w ing order: Tray5, 4, 3, 2, and 1.
Note: Tray x Low clears whenever tray x is empty, or tray x is removed. When
tray x is reinserted, it is examined and the appropriate status, if any, displays.
The printer cannot detect when the envel ope feeder or multipurpose feeder are
low.

2-16 Service Manual

4060-xxx

User status me ss ag es

User status messages Status Action

Busy

Flushing Buffer

Printing Menu Settings

Printing Directory List

The printer is busy receiving or
processing data, or printing data.
Note: The printer indicator light blinks
while the printer is processing data.

The printer is flushing corrupted print
data and the current print job is being
discarded.

The printer is processing or printing a
list of current settings menus becau se
Print Menu Sett ings is sel ect ed from t he
menu.

A directory of the flash and disk
contents is processing or printing
because Print Direct ory is select ed fr om
the menu.

Press Stop to take the printer out of
Busy status. Not Ready displays. No
additional data processes, but the
printer processes all paper currently in
the printer paper path . Press Go to
return to Ready.

No button actions are possible while
this message displ ays.

Press Stop to take the printer out of
Ready status . Not Ready displays. No
additional data is processed, but the
printer processes all paper currently in
the printer paper path . Press Go to
return to Ready status after the page
prints. Press Menu to take the printer
out of Ready and enter the Tests
Menu (Busy state). Press Select for
the values. Press Menu until Reset
Printer displa ys on the second line.
Press Select to reset the printer.

Press Stop to take the printer out of
Ready status . Not Ready displays. No
additional data is processed, but the
printer processes all paper currently in
the paper path. Press Go to return to
Ready after the page print s. Press
Menu to take the printer out of Ready
and enter the Tests Me nu (B usy
state). Press Select for the values.
Press Menu until Reset P r inter
displays on the second line. Press
Select to reset the prin t e r.

Restoring Factory Defaults

Performing Self Tests

Not Ready
(Press Go)

Resetting Printer

The printer is restoring factory defaults. No button actions are possible while

this message displ ays.

The printer is running the normal series
of start-up tests after i t is powered on.

No button actions are possible while

this message displ ays.
When the tests are complet e, the printer
retur n s to Ready.

The printer is in the Not Ready state,
which means it is not ready to receiv e or
process data. Thi s m essage displays
when Menu is pressed during a print
job.

Press Go to take the printer out of the

Not Ready state. Press Menu to take

the printer out of Ready and enter the

Tests Menu (Busy state). Press Menu

until Reset Printer displays on t he

second line. Press Select to reset the

printer.
The printer is deleting any print jobs in

process and restoring all settings to

No button actions are possible while

this message displ ays.
user defaul ts.

Diagnostic information 2-17

4060-xxx

User status messages Status Action

Formatting Flash
(Do Not Power Off)

Program Flash
(Do Not Power Off)

Formatting Disk

Programming Disk
(Do Not Power Off)

Menus Disabled

Activating Menu Changes

The flash memory is being formatted. No button actions are possibl e whil e

this message displ ays.

The flash memory is being
programme d, which means fonts or

Do not perfor m any button actions

while this mes s a ge di splays.
macros are being writ ten to flash
memory.

The disk is being formatted. No button actions are possi ble while

this message displ ays.

The disk is being programmed, which
means fon ts or macros are being wri tten
to disk.

No button actions are possible while

this message displ ays.

Note: If information is written to flash

memory and to disk at the same time,

the Program Flas h mes sage displays.
The printer menus have been disabled.

This occurs when Menu is pressed

No button actions are possible while

this message displ ays.
while the printer is Ready and Menu
Lockout i s active. The printer display
shows this message f or one second and
then returns to the Ready m essage.

The printer is reset to activate a printer
setting changed in the menus.

No button actions are possible while

this message displ ays.

2-18 Service Manual

4060-xxx

User atten da nce me ss ag es

User attendance messages

Primary message Secondary message Explanation

Change Cartridge
Invalid Refil l

Change <input source>
<Custom Type name>

Change <input source>
<custo m strin g>

Change <input source>
<size>

Select one of the following actions:

• Remove the toner cartridge and install a new
cartridge.

• Press an d hold Select and press Return to dis play
debug data for the engine and cartridge code.

Note: This message ma y help diagnose a po tenti al
printer problem.

This message displays when the user shoul d change
the media installed in one of the input options.

•<input source>=Tray 1, Tray 2, Tray 3, Tray 4, Tray
5, MPF Feeder, Env elope Feeder.

•<Custom Type name>=Custom 1 through
Custom 6 using the MarkVision™ utility. When the
printer is prompti ng for one of the custom ty pes
which has been named b y the user, then only the
custom type name is displ ayed on line 2. The name
may be truncated to fit the display.

This message displays when the user shoul d change
the media installed in one of the input options.

•<input source>=Tray 1, Tray 2, Tray 3, Tray 4, Tray
5, MPF Feeder, Env elope Feeder.

•<custom string>= a user definabl e nam e.

This message displays when the user shoul d change
the media installed in one of the input options:

•<input source>=Tray 1, Tray 2, Tray 3, Tray 4, Tray
5, MPF Feeder, Env elope Feeder.

•<size>=letter, legal, B5, A4, Executive, Universal,
A5, B4, A3, 11x17, Folio, or Statement. For
env elopes, <size>=7¾ Envelope, 9 Envelope,
10 Envelope, DL Envelope, C5 Envelope,
B5 Envelope, or other Envelope.

Change <input source>
<type><size>

This message displays when the user shoul d change
the media installed in one of the input options.

•<input source>=Tray 1, Tray 2, Tray 3, Tray 4, Tray
5, MPF Feeder, Env elope Feeder.

•<type>=Bond, Card stock, Colored, Envelope,
Labels, Ltr head, Plain, Preprint, or Transparency.

•<size>=letter, legal, B5, A4, Executive, Universal,
A5, B4, A3, 11x17, Folio, or Statement. For
env elopes, <size>=7¾ Envelope, 9 Envelope,
10 Envelope, DL Envelope, C5 Envelope,
B5 Envelope, or other Envelope.

Diagnostic information 2-19

4060-xxx

User attendance messages (continued)

Primary message Secondary message Explanation

Check Duplex
Connection

Check Tray x
Connection

This messages displays for the following conditions:

• The duplex option may have been removed from
the printer, possibly to clear a paper jam or to
remove the option.

• The duplex option may be attached to the printer
but a communi cations problem may prev ent the
printer from det ection . F or e xampl e, ther e ma y b e a
poor connection or a hardware failure.

The foll owing actions may be taken:

• If the opti on was temporarily removed or not
connected properl y, reattach or reconnec t it.

• Press Go to execute a configurati on change which
notifies the pri nter the option has been hot
unplugged (removed with the pow er on) .
Note: This action is not availab le i f the printer is in
Diagnostics Mode or running diagnostics.

• If the device is experiencing a hardware problem,
turn the printer off and on. If the message
continues to be display ed, go to “Duplex option

service check” on page 2-47.

Tray x=Tray 2, Tray 3 , Tray 4 , or Tray 5
This messages displays for the following conditions:

• The spec ifie d de vice ma y ha ve b een r emov ed fr om
the printer, possibly to clear a paper jam or to
uninstall the option.

• The option m ay be attached to the printer but a
communicat ions problem ma y prevent the printer
from detecti ng the opt ion. For example, there may
be a poor connection or a hardware failure.

The foll owing actions may be taken:

• If the opti on was temporarily removed or not
connected properl y, reattach or reconnec t it.

• Press Go to execute a configurati on change which
notifies the pri nter the option has been hot
unplugged (removed with the pow er on) .

Note: This action is not availab le i f the printer is in
Diagnostics Mode or running diagnostics.

• If the device is experiencing a hardware problem,
turn the printer off and on. If the message
continues to be display ed, go to “Input tra y (s )

service check” on page 2-64.

Close Finisher Side
Door

Close Finisher Top
Cover

Delete All Jobs
Go/Stop?

2-20 Service Manual

Close the finisher side door. If the message does not
clear automatically when the door is closed, go to

“StapleSmart finis her service che ck” on page 2-86.

Close the finisher top cover. If the message does not
clear automatically when the cov er is closed, go to

“StapleSmart finis her service che ck” on page 2-86.

When the user has selected the Print and Hold Delete
All Jobs selection, this message is displayed. The
following actions may be taken:

• Press Go to confi rm the selection. All jobs are
deleted.

• Press Return or Stop to cancel the delet e
operation.

4060-xxx

User attendance messages (continued)

Primary message Secondary message Explanation

Disk Corrupted
Reformat?

Empty Box M This messag e is display ed when the hole punch alarm

Insert Box M This messag e is displa yed when the hole punch bo x is

The printer has detected there are errors on the hard
disk that canno t be co rrect ed. The dis k cannot be used
until it is reformatted.
Warning: All data on the disk will be lost if y ou format
the disk.
The foll owing actions can be tak en:

• Power off and remov e the disk. The disk will not be
formatted.

• Press Go to format the disk. All data is l ost when
you format the dis k.

is on and the printer informed by the code the hole
punch box M is ful l. The following actions may be
taken:

• Empty the hole punch box.

• Press Go to ignore the message. The Box M Full
appears on line 2 of the display and the job is
printed without hol e punching. The message
remains until the box is emptied.

If this message con ti nues to be displayed when the
box has been empt ied, go to “StapleSmart finisher

service check” on page 2-86.

missing or inst alled incorrectly. The message is
displayed during any of the following times, regard less
of the hole punch alarm setting:

• At POST

• Afte r the finisher side door has been closed

• Before the first page of a job requesting hole
punch. The message displays once per job.

The foll owing actions can be tak en:

• Install the hole punch box.

• Press Go to ignore the message. The Box M
Missing mess age 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 can not be cleared after inserting the
box, go to “StapleSmart finisher service check” on

page 2-86.

Insert Cartridge or Close
Door

Insert Staple Cartridge This message displays when the staple cartridge is

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 2-44.

missing or installed incorrectly. The message appears,
regardless of the Staple Alarm setting, at the following
times:

•At POR

• Afte r the Stapl er Door has been closed.

The foll owing actions can be tak en:

• Install the stapler cartridge.

• Press Go to clear the message . The printer
handles stapl ed jobs as if the staple cartridge wer e
installed, but empty. The Staples Empty message
appears on the stat us li ne and the Load Staples
may display.

Diagnostic information 2-21

4060-xxx

User attendance messages (continued)

Primary message Secondary message Explanation

Insert <tray><tray>=Tray 1, Tra y 2, Tray 3, T ray 4, or Tray 5.

The printer detects a tray needs to be inserted. The
printe r d o es no t co ntin ue until it detect s 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 Stop and wait for pages to reach the
output bin bef ore refilling the tray.
The foll owing actions may be taken:

• Insert the requested tray.

• Press Menu until Busy/Waiting displays. The
following selections are available:

-Cancel Job

- Reset Printer

- Reset Active Bin

If the message cannot be cleared, go to “Internal tray

card/paper size sensing service check” on
page 2-66 or “Input tray(s) service check ” on
page 2-64.

Install Bin x
or Cancel Job

Install Duplex
or Cancel Job

Install Env Feed
or Cancel Job

Bin x=Bin 1, Bin 2, or Bin 3.
This message is disp layed when a paper handling

option has been hot unplugged. The printer requires
the reinstall ation of the option to print a page which
has been fo rmatte d by t he int erpreter bef ore the opt ion
was removed.
The foll owing actions may be taken:

• Install the option.

• Press Menu 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 tra y( s)

service check” on page 2-64.

This message is displayed when a duplex option has
been hot unplugged. The printer requires the
reinstallation of the option to print a page which has
been formatted by the interpreter before the option
was removed.
The foll owing actions may be taken:

• Install the duplex option.

• Press Menu 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 2-47.

This message is displayed when the envelope feeder
has been hot unplugged. The printer requires the
reinstallation of the feeder t o print a page which has
been formatted by the interpreter before the feeder
was removed.
The foll owing actions may be taken:

• Install the envel ope feeder.

• Press Menu 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 2-49.

2-22 Service Manual

4060-xxx

User attendance messages (continued)

Primary message Secondary message Explanation

Install Tray x
or Cancel Job

Load Staples This message displays when the Staples Empty Alarm

Tray x=Tray 2, Tra y 3, Tra y 4, Tra y 5.
This message is disp layed when a paper handling
option has been hot unplugged. The printer requires

the reinstall ation of the option to print a page which
has been fo rmatte d by t he int erpreter bef ore the opt ion
was removed.
The foll owing actions may be taken:

• Install the option.

• Press Menu 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 tra y( s)

service check” on page 2-64.

is activ ated 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 foll owing actions may be taken:

• Install a new staple cartridge to clear this message
and select Start or Continue to resume printi ng
the staple job.

• Choose to i gnore the Load Staples message for
this print job by pressing Go or Select. The printer
starts or resumes printing , but does not staple the
rest of the job.

• Press Menu until Busy/Waiting displays. The
following actions may be availa ble:

-Cancel Job

- Reset Printer

- Reset Active Bin

Priming Failed
Retry . Go/Stop?

This message displays when an error has occ urred
during the staple primi ng operation. This message not
only notifies the user that a specific error interfered
with the priming, b ut al lows the user to request the
process begin again.
The foll owing actions are av ailable:

• Press Go to restart the priming operation.

• Press Return or Stop to cancel the priming
operation.

Diagnostic information 2-23

4060-xxx

User attendance messages (continued)

Primary message Secondary message Explanation

Reattach
Bins x–y

Reattach
Envelope Feeder

Bins x–y=Bins 1 to 5, Bins 2 to 6, or Bins 6 to 10
This messages displays for the following conditions:

• The speci fied output bins ma y have been r em oved
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
communicat ions problem ma y prevent the printer
from detecti ng the opt ion. For example, there may
be a poor connection or a hardware failure.

The foll owing actions may be taken:

• If the opti on was temporarily removed or not
connected properl y, reattach or reconnec t it.

• Press Go to execute a configurati on change which
notifies the pri nter the option has been hot
unplugged (removed with the pow er on) .
Note: This action is not availab le i f the printer is in
Diagnostics Mode or running diagnostics.

• If the device is experiencing a hardware problem,
turn the printer off and on. If the message
continues to be display ed, go to “Input tra y (s )

service check” on page 2-64.

This messages displays for the following conditions:

• The feeder may have been removed from the
printer , possibly to cl ear a paper jam or to remove
the option.

• The feeder may be attac hed to the printer but a
communicat ions problem ma y prevent the printer
from detecti ng the opt ion. For example, there may
be a poor connection or a hardware failure.

The foll owing actions may be taken:

• If the opti on was temporarily removed or not
connected properl y, reattach or reconnec t it.

• Press Go to execute a configurati on change which
notifies the pri nter the option has been hot
unplugged (removed with the pow er on) .

Note: This action is not availab le i f the printer is in
Diagnostics Mode or running diagnostics.

• If the device is experiencing a hardware problem,
turn the printer off and on. If the message
continues to be displa y ed, go t o “Envelope feeder

service check” on page 2-49.

Reattach
Output Bin x

2-24 Service Manual

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 m ay be attached to the printer but a
communicat ions problem ma y prevent the printer
from detecti ng the opt ion. For example, there may
be a poor connection or a hardware failure.

The foll owing actions may be taken:

• If the opti on was temporarily removed or not
connected properl y, reattach or reconnec t it.

• Press Go to execute a configurati on change which
notifies the pri nter the option has been hot
unplugged (removed with the pow er on) .
Note: This action is not availab le i f the printer is in
Diagnostics Mode or running diagnostics.

• If the device is experiencing a hardware problem,
turn the printer off and on. If the message
continues t o be displ a ye d, g o to“Output e xpander

service check” on page 2-72.

4060-xxx

User attendance messages (continued)

Primary message Secondary message Explanation

31 Defective Print
Cartridge

32 Unsupported Print
Cartridge

34 Short Paper The printer determines the paper length is t oo short to

Error code 31 displays when the top front cover is
closed and a defective print cartridge is detected. It
may tak e the printer 10-20 seconds to determine if the
print cartridge is def ecti v e. Dep ending on the s etti ng of
the Machine Class ID the print er may be allowed to
print pages during this 10-20 second interval. If pag es
are allow ed to pri nt, t hey ar e no t reprint ed onc e 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 fro m the last “good”
print cartridge or the same ID must be read fr om the
print cartridge twice. The la st “ good” print cartridge ID
is stored in NVRAM.

Error 32 displays when the top cover is closed and an
unsupported print cartridge i s de tected . It ma y tak e the
printer 10-20 seconds to determine if the print
cartridge is supported. Depending on the set ting of the
Machine Class ID the print er may be allowed to print
pages during this 10-20 second interval. If page s 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 “Smart contact assembly service

check” on pa ge 2-85.

print the formatt ed 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 Resolution Reduced The resolution of the page has been redu ced from 600

37 Insufficient Collation
Area

dpi to 300 dpi to prevent a Memory Full error . This
message can only occ ur i f 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.

This message displays when the printer memo ry is
insufficient to perform the Flash Memory Defragm ent
operation.
Note: This message is posted prior to the actual start
of the defragment operation. The printer cod e
determines if enough print er mem ory is a vailable to
complete the defragment operation. The user should
not be concerned with losing resources stored in the
flash option.
The foll owing actions may be taken:

• Press Go to clear the message . To perform the
defragment operation:

- Delete fonts, macros, and other data in RAM.

- Install additional printer memory.

• Press Menu until Busy/Waiting appears. The
following actions are available:

-Cancel Job

- Reset Printer

- Reset Active Bin

Diagnostic information 2-25

4060-xxx

User attendance messages (continued)

Primary message Secondary message Explanation

37 Insufficient Memory Held Jobs may be lost This message displays when the printer memory used

38 Memory Full This message displays when the printer is processing

39 Complex Page This message displays when the page is too comp lex

to restore the Print and Hold j obs from the disk and
found t hat some or al l of the j obs could not b e r estore d.
The printer ran out of memory while attempting to
restore the jobs.

• Press Go to clear the message. Some of the Print
and Hold jobs on t he disk will not be r estore d. The y
remain on the disk, but cannot be accessed .

• Press Menu until Busy/Waiting appears. The
following functions may be avail able:

-Cancel Job

- Reset Printer

- Reset Active Bin

an incoming job and the re i s insufficient memory
ava il able to continue processing the job. The follo wing
actions may be taken:

• Press Go to clear the message . Perform the
defragment operation:

- Perform the defragment operation

- Delete fonts, macros, and other data in RAM

- Install addi tional memory

• Press Me n u to display Busy /Wai t ing. The fol lowi ng
functions may be available:

-Cancel Job

- Reset Printer

- Reset Active Bin

to print. The fol lowing actions ma y be taken:

• Press Go to clear the message and continue the
job. Some data loss may occur. Simplify the print
job and reprint, if necessary .

• Press Menu until Busy/Waiting appears. The
following selections are possible:

-Cancel Job

- Reset Printer

- Reset Active Bin

50 PPDS Font Error This message displ ays when t he PPDS in terpreter has

51 Defective Flash This message displays when the printer detect s a

52 Flash Full This message displays when there is not enough free

2-26 Service Manual

encountered a font error.
Note: This error may only occur when the printer is
formatting PPDS print data.
The foll owing actions may be taken:

• Press Go to clear the message and continue
processing the job.

• Press Menu until Busy/Waiting appears. The
following are available:

-Cancel Job

- Reset Printer

- Reset Active Bin

defecti ve flash. This error may occur at power on, or
during flash format and write operations. Press Go to
clear the message. The flash is marked as bad and
normal operation continues. Flash operations are not
allowed until the problem is resolved.

space in the flas h memory to hold th e resources that
hav e been requested to be written to flash.

4060-xxx

User attendance messages (continued)

Primary message Secondary message Explanation

53 Unformatted Fl ash This mess age displays when the printer detects an

54 Standard Network
Software Error

54 Network x
Software Error

55 Unsupported option
in Slot x

55 Unsupported Flash in
Slot x

56 Standard Serial
Disabled

56 Serial Port x Disabled This error displ ays when data is sent to the printer

56 Standard USB Port
Disabled

unformatted flash at power on. Press Go to clear the
message. The flash is marked as bad and normal
operation continues. Flash operations are not all owed
until the flash is formatted.

This error displ ays when a network port is detected,
but the printer canno t establ ish communicat ions with it.

This error displ ays when a network port is detected,
but the printer cannot establish communications wi th it.

An unsupported option is installed in the specified
solutions port. Power off the print er and remove the
unsupported option in the specified slot.

An unsupported flash option is installed in the
solutions port. Power off the print er and remove the
unsupported flash option in the specified slot.

This error displ ays when data is sent to the print er
across the standa rd seri al port, but the port has been
disabled.

across an optional parallel port, but the port has been
disabled. Once this message displ ays, reporting of
further errors is suppressed until the menus are
entered, or the printer is reset.

Display ed when stat us is r equested ov er t he USB port,
but the port has been disabled. Once the error has
been displayed for th e fi rst time, reporting of further
errors i s suppr essed unti l th e men us are ent ered o r t he
printe r is re set.
The foll owing actions may be taken:

• Press Go to clear the message . The printer
discards any data received on the USB port.

• Press Menu until Busy/Waiting appears. The
following are available:

- Reset Printer

- Reset Active Bin

56 Standard USB Port x
Disabled

Displayed when status is requested over the USB port
indicated, but the port has been disabled. Once the
error has been disp layed for the first time, reporting of
further errors is suppressed until the menus are
entered or the printer is r eset.
The foll owing actions may be taken:

• Press Go to clear the message . The printer
discards any data received on the USB port.

• Press Menu until Busy/Waiting appears. The
following are available:

- Reset Printer

- Reset Active Bin

Diagnostic information 2-27

4060-xxx

User attendance messages (continued)

Primary message Secondary message Explanation

56 Standard Parallel
Port Disabled

56 Par al lel Po rt x
Disabled

57 Configuration
Change

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 display ed, reporting of
further errors is suppressed until the menus are
entered, or the printer is reset. The following actions
may be taken:

• Press Go to clear the message . The printer
discards any data received on the parallel port.

• Press Menu until Busy/Waiting appears. The
following are available:

- Reset Printer

- Reset Active Bin

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
menus are entered, or the printer is reset. The
following actions may be taken:

• Press Go to clear the message . The printer
discards any data received on the parallel port.

• Press Menu until Busy/Waiting appears. The
following are available:

- Reset Printer

- Reset Active Bin

The printer ha s atte mpted to restor e the Pri nt 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 di sk beca use the confi gurat ion of
the printer has changed. This message al ternates wi th
the secondary message, “Held jobs may not be
restored.”
Some configuration changes that may cause this
condition ar e:

• Code version change

• Paper handling option is removed

• Disk has been mo ved to a different model printer.

Press Go to clear the m essage. 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 Too Many Trays
Attached

58 Too Many Disks
Installed

59 Incompatible Output
Bin x

59 Incompatible
Envelope Feeder

2-28 Service Manual

This error c ode displ ay s when t oo man y input tra ys ar e
attached to the printer.

This error displays when too many disks are attached
to the printer.

An incompatible output bin is installed. For Output Bin
x, x=1, 2, or 3.

Remove th e incompatible outp ut bi n and press Go to
clear the message.

Note: If the user instal led the incompatib le device to
satisfy a Chec k Device Connections/reattach
message, the user should reinstall an associated
compatible option or hot unplug the opt ion.

An incompatible envelop e feeder is install ed.
Remove t he inco mpatib l e f eeder and pres s Go to clear
the message.
Note: If the user instal led the incompatib le device to
satisfy a Chec k Device Connections/reattach
message, the user should reinstall an associated
compatible option or hot unplug the opt ion.

4060-xxx

User attendance messages (continued)

Primary message Secondary message Explanation

59 Inc ompatible Tray x An inco mp a tibl e tray is in s ta lled . For Tray x, x= 2, 3, 4,

59 Incompatible Duplex An incompatib le duplex option is installed.

61 Defecti ve Disk This error code displ ays when the printer detect s a

62 Disk Full This error code displays when there is not enough free

or 5.
Remove the incompatible tray and press Go to clea r

the message.
Note: If the user instal led the incompatib le device to

satisfy a Chec k Device Connections/reattach
message, the user should reinstall an associated
compatible option or hot unplug the opt ion.

Remove th e incompatible duplex option and press Go
to clear the message.
Note: If the user instal led the incompatib le device to
satisfy a Chec k Device Connections/reattach
message, the user should reinstall an associated
compatible option or hot unplug the opt ion.

defective disk. This error may occur at power on or
during disk format and write operations. While this
message displays, press Go to cle ar th e mes sage.
The disk is marked defective and norma l printer
operations continue. Disk operations are not allowed
with a defective disk. The Format Disk menu is not
shown.

space on the dis k to hol d th e resour ces that ha ve be en
requested to be writte n to the disk. This message
displays for both resource and PostScript Disk
operators when t he disk is full.

63 Unformatted Disk This error code displays when the print er detects an

64 Unsupported Disk
Format

80 Scheduled
Maintenance

81 Engine Code CRC
Failure

88 Toner Low This message displays when toner low occurs and the

unformatted disk at power on. Press Go to clear the
message. The disk is marked as bad and normal
operation continues. Disk oper ations are not allowed
until the disk is formatted.

The printer detects an unsupported disk format at
POR.
Press Go t o clear the message. The disk i s marked as
bad and normal operation continues. Further disk
operations are not allowed until the disk is formatted.

The operator panel displays thi s message at each
300K page count interv al. It is necessary to replace
the fuser assemb l y, transfer rol ler , ch arge roll, and pi c k
rolls at this interval to maintain the print qual ity and
reliability of the printer. The parts are available as a
maintenance kit . For more inf ormation, go to

“Scheduled maintenance” on page 6-1.

This error displays when the microcode to be
programmed in the engine flash code module has
failed a CRC check. Press Go to clear t he me ssage.
The microcode data is discarded and must be re­transmitt ed from the host computer.

toner low alarm is activated. Press Go to clear this
message.

Diagnostic information 2-29

4060-xxx

User attendance messages (continued)

Primary message Secondary message Explanation

200 Paper Jam
Remove Cartridge

201 Paper Jam
Remove Cartridge

202 Paper Jam
Open Rear Door

231 Duplex Paper J am ­Rear

Leave Job in Finisher Primary: Paper is jammed at the printer input sen sor.

Open the print er upper front door and remo ve the print
cartridge to access the paper jam area.

Secondary: When this message is display ed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Als o, if the accumulated sheets are remo ved,
the portion of the job printed after the jam wi ll not be
stapled.

Leave Job in Finisher Primary: Paper is jammed between the printer inp ut

and e xit sensors . Open t he printe r upper fr ont door and
remove the print cartridge to access the jam area.
Secondary: When this message is display ed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Als o, if the accumulated sheets are remo ved,
the portion of the job printed after the jam wi ll not be
stapled.

Leave Job in Finisher Primary: Paper is jammed at the printer exit sensor.

Open the printer rear door to access the jam area.
Secondary: When this message is display ed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Als o, if the accumulated sheets are remo ved,
the portion of the job printed after the jam wi ll not be
stapled.

Leave Job in Finisher Primary: A piece of media did not arri ve at the duplex

input sensor, but did leave the printer exit sensor.
Secondary: When this message is display ed, do not
remove accumulated sheets during the jam clearance

procedure as the printer will not reprint the removed
sheets. Als o, if the accumulated sheets are remo ved,
the portion of the job printed after the jam wi ll not be
stapled.

232 Duplex Paper J am ­Rear

233 Duplex Paper J am ­Rear

234 Duplex Paper J am ­Rear

2-30 Service Manual

Leave Job in Finisher Primary: A piece of media did not clear the duplex

input sensor b u t di d leave the printer exit sensor.
Secondary: When this message is display ed, do not
remove accumulated sheets during the jam clearance

procedure as the printer will not reprint the removed
sheets. Als o, if the accumulated sheets are remo ved,
the portion of the job printed after the jam wi ll not be
stapled.

Leave Job in Finisher Primary: A piece of media failed to make the duplex

double feed sensor during turnaround.
Secondary: When this message is display ed, do not

remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Als o, if the accumulated sheets are remo ved,
the portion of the job printed after the jam wi ll not be
stapled.

Leave Job in Finisher Primary: The media did not reac h the duplex exit

sensor.
Secondary: When this message is display ed, do not

remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Als o, if the accumulated sheets are remo ved,
the portion of the job printed after the jam wi ll not be
stapled.

4060-xxx

User attendance messages (continued)

Primary message Secondary message Explanation

235 Duplex Paper J am ­Front

236 Duplex Paper J am ­Front

237 Duplex Paper J am ­Front

238 Duplex Paper Jam Leave Job in Finisher Primary: A piece of media is over one of the duplex

Leave Job in Finisher Primary: A piece of media is over the duplex double

feed sensor.
Secondary: When this message is display ed, do not

remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Als o, if the accumulated sheets are remo ved,
the portion of the job printed after the jam wi ll not be
stapled.

Leave Job in Finisher Primary: A piece of medi a did no t lea v e th e duple x e xit

sensor.
Secondary: When this message is display ed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Als o, if the accumulated sheets are remo ved,
the portion of the job printed after the jam wi ll not be
stapled.

Leave Job in Finisher Primary: A piece of media did not reach the printer

input sensor.
Secondary: When this message is display ed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Als o, if the accumulated sheets are remo ved,
the portion of the job printed after the jam wi ll not be
stapled.

sensors during a reset.
Secondary: When this message is display ed, do not
remove accumulated sheets during the jam clearance

procedure as the printer will not reprint the removed
sheets. Als o, if the accumulated sheets are remo ved,
the portion of the job printed after the jam wi ll not be
stapled.

239 Duplex Paper Jam Leave Job in Finisher Primary: A paper jam has occurred in the duplex

24x Paper Jam
Check Tray x

250 Paper Jam
Check MP Feeder

260 Paper Jam
Check Envelope Feeder

27x Paper Jam
Check Output

option.
Secondary: When this message is display ed, do not
remove accumulated sheets during the jam clearance

procedure as the printer will not reprint the removed
sheets. Als o, if the accumulated sheets are remo ved,
the portion of the job printed after the jam wi ll not be
stapled.

Paper is jammed around Tray x.
(x=tray 1 thru 5)
T ry opening Tray x. If the t r a y i s di ff ic ult t o r e mo v e , t hen
you may have to remov e the tray above or below tray x
to remove the jammed pages.

Paper is jammed in the multipurpose feeder.

Paper is jammed in the envelope feeder.

Paper is jammed in output bin. Open the rear door to
access the jammed pages.

Diagnostic information 2-31

4060-xxx

User attendance messages (continued)

Primary message Secondary message Explanation

280 Paper Jam
Check Finisher

281 Paper Jam
Check Finisher

282 Staple Jam
Check Stapler

283 Staple Jam
Check Stapler

1565 Emul Error
Load Emul Option

Leave Job in Finisher Primary: Paper is jammed in the fi nisher option. O pen

Remove Job from
Finisher

Remove Job from
Finisher

the finisher option side door or top cov er to access the
jammed pages.

Secondary: When thi s me ssage is display ed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Als o, if the accumulated sheets are remo ved,
the portion of the job printed after the jam wi ll not be
stapled.

Primary: Paper is jammed in the f inisher option. Open
the finisher option side door or top cov er to access the
jammed pages.
Secondary: When thi s me ssage is display ed, remove
the job f rom the fini sher. The printed wi ll not reprint the
remov ed sheets.

Primary: A staple jam has been det ected during
normal stapler operation.

Secondary: The printer fl ashes the secondary
message to indicat e that all accumulated sheets
should be removed during the jam clearance.

A staple jam has been detected during the priming
operation.

Note: Press Go to initi ate p riming a nd resum e pri nting
while either of the primary or secondary messages
displays.

This message appears when t he IPDS em ulation
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 func ti ons are affected. The correct IPDS
emulation must be downloaded.

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 car d x is attached to PCI connector x, whe re x=1, 2, or 3.
LocalTalk x LocalTalk Card x is attached to PCI connector x, where x=1, 2, or 3.
Infrared Standard In frared port, if availa ble.
Infrared x Infrare d Por t x is attached to PCI connector x, x=1, 2, or 3.

2-32 Service Manual

4060-xxx

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 Tray x
Connection

Check Duplex
Connection

Check envelope feeder connection.

Check tray x, where x=1, 2, 3, 4, or 5.

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 cl ea r a pa pe r ja m. Otherwise, the d evice ca n still b e
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 reat tach 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 power ed off and
back on again. Dat a loss results if print jobs are acti ve when the printer is power
cycled. If a prin t job i s activ e, then rem ov e t he opti on and fin ish 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

Close Duplex Rear Door The duplex rear door is open.

The duplex front access cover is not installed.

Diagnostic information 2-33

4060-xxx

Po wer-On Self Test (POST)

When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning
of the base printer by observing the following:

1. The LED comes on.

2. The operator panel displays one and a half row of pels, and then clears.

3. Diamonds scroll across the display, and then clear.

4. The operator panel displays one and a half row of pels, and then clears.

5. The top line of the operator panel displays one square block of pels that turn on one at a time

until all sixteen blocks display and then they all turn off.
For example:

*
32MB 350 Mhz

6. Performing Self Test appears on the display .

• The high-capacity option elevator tray moves to the uppermost position if installed.

• The duplex option is checked if installed.

7. Busy appears on the display.

If present, the following errors or messages may display:

• Close Door or Insert Cartridge display if the upper front cover is open or the print cartridge

is missing.

• Any cartridge errors, such as Defective Cartridge, Prebate Violation, or Missing Cartridge.

8. The fuser lamp turns on. The fuser takes longer to warm up from a cold start than a warm start.

9. The main fan turns o n.

10. The main drive motor turns on.

11. The developer drive assembly drives the developer shaft in the toner cartridge.

12. The exit rollers turn.

13. The operator panel LED starts blinking.

14. Ready appears on the display.

2-34 Service Manual

4060-xxx

Sympto m tables

Base printer symptoms

Symptom Action

Dead machine Go to “Dead m achine service check” on page 2-45.
Operator panel—one or more buttons do

not work.
Operator panel—di splay is blank . Printer

sounds 5 beeps.
Operator panel—di splay is blank . Printer

does not sound 5 beeps.
Operator panel cont inuously displays all

diamonds, sounds 5 beeps, and does not
complete POST.

Paper feed problems—base printer or
integrated 500-sheet paper tray

Paper jams at exit of redrive ass em bly—
duplex opti on not installed.

Paper jams at exit of redrive ass em bly—
duplex opti on installed.

Fuser solenoid fails to operate. Go to “Fuser solenoid service chec k” on page2-55.
Print quality—black page Go to “Print quality—all black page” on page 2-79.
Print quality—blank page Go to “Print quali ty— blank page.” on page 2-79.
Print quality—light pri nt Go to “Print quality—light print” on page 2-84.
Print quality—background Go to “Print quality—background” on page 2-82.
Print quality—residual image Go to “Print quality—residual image” on page 2-83.
Print quality—skew Go to “Paper feed service check” on page 2-76.
Print quality—banding Go to “Print quality—banding” on page 2-83.
Print quality—random marks Go to “Print quality— random marks” on page 2-80.
Print quality—toner on backside of printed

page.
Print quality—vertical black bands on edge

of copy.
Unable to clear a 32-Unsupported Print

Cartridge user error message.

Go to “Operator panel buttons service check” on page 2-70.

Go to “Operator panel service chec k” on page 2-70.

Replace the operato r panel assembly.

Go to “Operator panel service chec k” on page 2-70.

Go to “Paper feed service check” on page 2-76.

Go to “Paper feed service check” on page 2-76.

Go to “Duplex option service check” on page 2-47.

Go to “Print quality—toner on backside of printed page” on

page 2- 84.

Go to “Print quality—black bands on outer edges of the

page” on page 2-83.

Go to “Sm art conta ct assembly service ch eck” on

page 2- 85.

High-capacity feeder (2000-sheet) symptoms

Symptom Action

The printer does not recognize the high­capacity feeder installed.

Paper feed problem with the high-capacity
feeder.

Go to “High-capacity feeder input tray service check” on

page 2- 56.

Go to “High-capacity feeder input tray service check” on

page 2- 56.

Diagnostic information 2-35

4060-xxx

Paper tray symptoms

Symptom Action

Paper feed problem with 250-Sheet Paper
Tray.

Paper feed problem with 500-Sheet Paper
Tray.

Media fails to pass through from the lower
attached Paper Tray option to the next
higher mounted option.

Duplex option symptoms

Symptom Action

Paper feed problem with Duplex. Go to “Duplex option service check” on page 2-47.
Paper jams at Paper Removal Tray. Go to “Duplex option service check” on page 2-47.
Paper sk ews in the Duplex Option. Go to “Duplex option service check” on page 2-47.
Paper fails to pass from lower option

through the Duplex O ption.

Envelope feeder symptoms

Symptom Action

Go to “Input tray(s) service check” on page 2-64.

Go to “Input tray(s) service check” on page 2-64.

Go to “Input tray(s) service check” on page 2-64.

Go to “Duplex option service check” on page 2-47.

Envelopes do not feed from the en velope
feeder.

Envelopes do not feed properly into base
printer.

Output expander

Symptom Action

Printer does not display Output Bin Full. G o to “Output bin sen sor standard tray service check” on

Paper does not f eed all the way into the
output tra y.

Go to “Envelope fee der service check” on page 2-49.

Go to “Envelope fee der service check” on page 2-49.

page 2- 72.

Go to “Output expander service check” on page 2-72.

2-36 Service Manual

4060-xxx

StapleSmart finisher

Symptom Action

Finisher does not staple. Go to “StapleSmart finisher service check” on page 2-86.
Printer does not recognize StapleSmart

Finisher Option as being installed.
Close Top Cover display ed. Unable t o clear

or reset message (POST incomplete).
Close Finisher Side Cover displa yed.

Unable to clear or reset message (POST
incomplete).

Paper feeds into finisher option output tray.
Paper is not st apled and paper does not
align with the right side .

Paper feeds into finisher option. Paper
aligns with the right side. The stapler does
not staple.

Paper is t ranspo rted into t he output tr a y but
is not stapled.

Stapled sheets are not transported to the
output tra y.

Go to “StapleSmart finisher service check” on page 2-86.

Go to “StapleSmart finisher service check” on page 2-86.

Go to “StapleSmart finisher service check” on page 2-86.

Go to “StapleSmart finisher service check” on page 2-86.

Go to “StapleSmart finisher service check” on page 2-86.

Go to “StapleSmart finisher service check” on page 2-86.

Go to “StapleSmart finisher service check” on page 2-86.

Diagnostic information 2-37

4060-xxx

Service Checks

Anytime the syst em board i s replaced, th e Configur ati on ID must be reset in NVRAM. Go to “Setting

configuration ID” on page 3-18 .

Review the following information before performing any service checks.

• Paper feed problems (especially paper jams): Go to “Viewi ng t he error l og” on page 3-6 and

check the printer error 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 2-5 to help diagnose the problem.

• Print quality problems: Go to “Print quality test pages” on page 3-20 and print a test page to

help diagnose problems before changing any settings or working on the printer.

• 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 comp onent s 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 Fron t cover assembly Check the front cover assembly to make sure th e ESD brush gro und

lead is firmly attached to the 5-Bin mailbox frame. Also check to
make sure the ESD brush is not loose or dam aged.

2-38 Service Manual

4060-xxx

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 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 a utoconne cts, cab les , and connect or s of th e optio n f or an y

Mechanical linkage

2

assembly

signs of loose or damaged parts.
Remove the left and right side covers and check the two

autoconnects for damage, especially the conn ect or pin s. Remo v e t he
output option and ch eck the voltages on the standard output bin
autoconnect located on the top left rear of the printer. Go to

“Autoconn ect” on page 5-1. If the voltages a re correct, reinstall the

output option noting the position of the toroi d on the autoconnect
cable of the lower autoconnect. Check the voltages on each of the
autoconnects. If the toroid was moved, make sur e to move it back to
its original posi ti on on the cable. If the voltages are correct, replace
the control board. If the voltages are incorrect, replace the failing
autoconnect assembly.

271 Paper Jam - Check Bin 1 displays

FRU Action

1 Bottom pass thru sensor

flag assembly
Control board

Check the flag for correct opera tion, binding, broken parts, or
interf erence from the s ensor cab le . I f inc orrect , repair a s nec essa ry. If
correct, make sure the bottom pass thru sensor i s correctly
connected to J5 on the cont rol board. Disconnect the pass thru
sensor cable and check the volt age at J5-3. The voltage measures
approximately +5 V dc. If incorrect, check the volt age at J5-2. The
voltage measures approximately 0 V dc. If incorrect, replace the
sensor assemb ly. If this does not fix the problem, replace th e control
board.

274 Paper Jam - Check Bin 4 displays

Service tip: When a 274 Paper Jam Check Bin 4 message displays, a problem exists with the top
pass thru sensor assembly or the control board.

FRU Action

1 Top pass thru sensor flag

assembly
Control board

Check the flag for correct opera tion, binding, broken parts or
interf erence from the s ensor cab le . I f inc orrect , repair a s nec essa ry. If
correct check to make sure the top pa ss thru sensor is correct ly
connected to J11 on the cont rol board. Disconnect the pass thru
sensor cable and check the volt age at J11-3 The voltage measures
approximately +5 V dc. If incorrect, check the volt age at J11-2. The
voltage measures approximately 0 V dc. If incorrect, replace the
sensor assemb ly. If this does not fix the problem, replace th e lower
control board.

Diagnostic information 2-39

4060-xxx

Ready Bin x Full displays—May be able to clear message and feed paper into
bin selected.

FRU Action

1 Bin x sensor

Bin x sensor cable
Bin x sensor flag
Control board

Check the sensor and sensor cable f or the bin that is displa ying 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 thi s 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

1 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 i nstal led c orrect ly, check the sens or cab le 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.

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 n ot i n
an up positio n. If the sen sor flag is oper atin g corre ctly, replace the bi n
x sensor. If this does not fix the problem, replace the control board.

271 Paper Jam - Check Bin 1 displays—paper does not feed into the bin
selected

FRU Action

1 Deflector

Deflector spring
Deflector cover
Deflecto r cover spring
Shaft assembli es

Bin x solenoid assembly

2

Control board

Mechanical linkage

3

Motor assemb ly

2-40 Service Manual

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 teet h. If incorrect, repair as necessary.

Check the solenoi d for any binds. Make sure the solenoid is
contacting th e lat ch correctly. If incorrect, repair as neces sary. If the
solenoid appears to be operating mechanically, check th e resi stance
of the solenoid. It meas ures between 30 and 50 ohms. If incorrect,
replace the f ailing solenoid assem bly. If correct, replace the contro l
board.

If the DC motor is functioning properly, check the gears, clutch, and
other linkage parts for cor rect ope ra tion and wea r , brok en gea r teeth,
or damaged parts. If incorrect, replace the mechanical linkage
assembly/DC motor assembly.

4060-xxx

990 Service Error displays

FRU Action

1 Mechanical linkage

DC motor assembly

Control board Disconnect the motor cable J2 from the control board and che ck the

2

900 Error Code service check

FRU Action

Check the DC motor cabl e connector to be sure it is correctly
installed at J2 on the control board. If correct, disconnect J2 from the
control board and che ck 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.
Note: If the DC motor is shorted, it may also be nece ssary to replace
the control board.

voltages at J2 on the board.
Warning: Use caution not to short adj acent pins on the connector as
damage to the board could re sult.

Pin Measu r ed (mo tor 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.

1 Printer POR Tu rn the printer off and o n several times. If Error Code 900 continues

System board Make sur e the system board is properly seated in connector J7 on

2

Factory defaults Restore factory defaults. See “Re stor e EP Factory Defaults” on

3

Sub error codes With Error Code 900 d is pla y ed, pr ess Select and Return. Record the

4

to display, go to step 2.

the interconnect board.
Turn the machine off and on several times, waiting a few minutes

between pow er on and power off.
If Error Code 900 continues to display, go to step 3.

page 3-18. This resets the non-critical areas of the user NVRAM. If

Error Code 900 continues to display, go to step 4.

complete list of Sub Error Codes on the display. Check the “Base

printer sub error codes” on page 2-6. If none of the Sub Error

Codes are listed, then call your ne xt l evel of support or call Lexmark.

Diagnostic information 2-41

4060-xxx

OPTION CARD

OPTION CARD

950 Error Code service check

Note: Before proceeding with this service check, make sure you have the correct system board
installed in the prin ter.

950 Error displayed on the printer and you are not sure if the printer had the
interconnect or system boards previously replaced.

FRU Action

1 Interconnect board Note: Before r eplacing the i nter connect board, make absolutely sure

you hav e the correct FRU number for the interconnect board that
should go into your printer.

Warning: Any time the interconnect board assembly i s replaced, the
Configuration ID must be reset in NVRAM on the interconnect board.
See “Setting configuration ID” on page 3-18.

Unplug the machine and replace the interconnect board assembly.
Turn the printer on. If a 950 err or still displays, replace the system
board assembly.

950 Error after replacing the system board

FRU Action

1 System board Note: Make sure you have the correct system board FRU number

before installing the board in the printer.

J13

FRU label

50

49

100

99

J8

J10

FRU No

1

J16

XXXXXX

J27

J2

1

J3

J4

1

OPTION CARD

OPTION CARD

J5

J7

J9

+24V
1+3 3V
GND

1

1

1

1

1

J11

1

J14

1

J15

1

J19

1

J22

1

J24

1

J29

J26

1

J32

1

J31

J34

1

1

+42V

+5V

HEAT

1

J28

950 Error after replacing interconnect board

FRU Action

1 Interconnect board Note: Before r eplacing the i nter connect board, make absolutely sure

2-42 Service Manual

Replace the system board.

you hav e the correct FRU number for the interconnect board that
should go into your printer.
Warning: Any time the interconnect board assembly i s replaced, the
Configuration ID must be reset in NVRAM on the interconnect board.
Go to

“Setting conf i guration ID ” on page 3-18.

Replace the interconnect board.
If this doe s not cl ear t he mes sage, cont act t he ne xt le v el of supp ort or
Lexmark.

4060-xxx

Charge roll service check

Service tip: Close and evenly spaced repetitive marks 47.19 mm (1.86 in.) apart, or spots on the
page can be caused by a damaged or contaminated 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 char ge rol l for correct installation, toner buildup, ma rks,

Left side charge roll link Check the left side charge roll link assembly for correct assembly

2

Right side charge roll li nk

3

Right charge roll bushing

cuts, or other signs of contamination or damage. Replace as
necessary.

operation. Check for damage to the arm or bearing assembly.
Check the right side charge roll link assembly for corr ect assembly

operation. If incorrect, replace the charge roll link assembly with the
charge roll link assemb l y kit. If correct, check the ri ght charge roll link
assembly bea ring for signs of wear or contamination. Excessi ve
contamination could cause intermittent charging of the charge roll. If
incorrect, repl ace the link assembly. Check for continuity of the right
link assembly from the bearing to the charge roll high voltage contact
on the right side frame. If incorrect, replace the link assemb ly.
Make sure the charge roll bushing is installed and operating correc tl y.

Note: The screw that attaches the charge roll lead to the contact
must be secure.

Diagnostic information 2-43

4060-xxx

Cover closed switch/cable service check

FRU Action

1 Toner cartridge Make sure the toner cartridge is correctly installed and that the right

Cover closed switch/cable

2

assembly

and left cartridge track s are not lo ose or brok en. Make sure the co ver
closed switch activation tab on the toner cartridge is not broken and
that the tab correctly activates the cover closed switch spring.

Check the cover closed switch for proper me chanical operation. If
incorrect, repair as necessary. Disconnect the cover closed switch
cable fro m J3 at the s ystem board a nd meas ure the v olta ge at J3-3. It
measures appro ximately +5 V dc. If the voltage is incorrect, replace
the system board. I f the voltage is correct, check the voltage at J3-1.
If the voltage measures greater than +1.0 V dc, replace the system
board. If the v oltag e i s corr ect, chec k the cont inu ity be tw een J3-1 and
J3-3 on the cable. If no change in continuity occurs as the switch is
activated, replace the cover open switch/cable assembly. If the
continuit y changes as the switch is activated , replace the system
board.

Cover closed switch table

J3 Switch status
Pin number Cover open Cover closed

Pin 1-3 Open Closed
Pin 1-2 Closed Open

2-44 Service Manual

4060-xxx

Dead machine se r vic e 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-c apacity feeder inpu t tray service

check” on page 2-56. 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.

CAUTION: When you see this symbol, 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.

Remove any input and output paper handling options from the printer.

FRU Action

1 Line volta ge Check the AC line v oltage. If the line voltage is incorrect , inform the

AC line cord Unplug the line cord from the wall outlet and chec k the line cord for

2

+5 V dc test point on the

3

system board

customer.

damage, such as , a damaged plug, or cut or damaged cord. If
incorrect, r eplace th e cord. I f inc orrect , che c k the cont inui ty of the l ine
cord and replace if necessary . If the cord is correct , go to step 3.

Check for appr o ximate ly +5 V dc at the +5 V test point on the system
board.

Note: Use care not to short adjacent voltage test points.

+42V

+5V

HEAT

+24V
+3.3V
GND

J24

1

If the voltage is correct, replace t he system board assembl y. If the
voltage is incorrect, go to step 4.

System board and

4

interconnect board

Check the system board is firmly seated in connect or J7 on t he
interconnect board. If it is not seated correc tly, reseat and recheck
the voltage at the +5V dc test point on the system boar d.

If test point does not meas ure +5 V dc, go to step 5.

Diagnostic information 2-45

4060-xxx

FRU Action

LVPS Unplug the AC line cord from the LVPS and disconnect the

5

interconnect c ard cab le o n the LVPS. Reconnect the AC line cor d and
measure the voltage on CN2-1 on the LVPS. The voltage should
measure appro ximately +5 V dc.

18

9

If the voltage is correct, go to step 6. If the voltage is incorr ect, go to
step 10.

Interconnect board Unplug the AC line cord from the LVPS and reconnect the

6

interconnect boar d cab le t o CN2 on the LVPS. Reconnect the A C l ine
cord, turn the machine on and measure the voltage at the +5 V test
point on the interconnect board. The voltage should read
approximately +5 V dc.

10

1

CN2

Test
Points

+24V

If correct, replace the follo w ing FRUs in the order sho wn:

• System board

• Interconnect board

If the voltage is incorrect, go to step 7.

Interconnect board Unplug the AC line cord from the LVPS, remove the inner shield and

7

system board assemb ly from the interconnect board.
Note: The inner shield with system b oard attached can be moved far
enough away from the printer to acce ss the interconnect board

voltage tes t poi nts.
Measure the voltage at the +5 V test point on the interconnect board.

The voltage should measure +5 V dc. If correct, go to step 11. If
incorrect, go to step 8.

J4

+5V

J5

F1

F2

Communications card Turn the printer off and remove th e com m unications card. Check the

8

Features or option in stalled

9

on the interconne ct board
assembly

LVPS fuse F1 (primary

10

power)

2-46 Service Manual

voltage at the 5 V test point on the interco nnect board.
If the vol tage is correct, replace the communication card assembly. If
the voltage is incorrect, go to step 9.

Warning: Observe all the ESD precautions and turn the printer off
before any feature or option cards are removed or replaced.

Remove one opt ion/feature at a tim e to hel p isolate the fail ing part.
Replace the fa ulty part.

Unplug the AC line cord , remo ve the LVPS from the printer, and
check the continuity of fuse F1. See “Low voltage power supply

removal” on page 4-42.

If continuit y is cor rect, replace the LVPS assembly.
If continuity is incorrect, replace fuse F1 and measure the voltage at
CN2-1. If the volt age is correct, reconnect the interconnect board

cable, reinstall the syste m board, and recheck the printer for a dead
machine conditi on. If the printer is still inoperative , go to step 11.
If the voltage i s incorrect, replace the LVPS assembly.

4060-xxx

FRU Action

Loads connected to the

11

system board

Duplex option service check

Messages displayed when a 23x Duplex Paper Jam displays.

23x Paper Jam
Check Duplex

Primary message Secondary message

If sheets have been accumulated to be stapled or offset when the jam is detected, the printer
alternately flashes the primar y and sec ondary 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 messag e is used.

When the secondary message is poste d, 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

Turn the printer off and disconnect each cable connected to the
system board and each opti on insta lled on th e system board until t he
problem is loc ated.
Warning: When removing any card installed on the system board
observe all ESD precauti ons when handling these options.

Leave Job
in Finisher

23x jam code Jam location

231 Rear Media did not arriv e at the duplex input sensor, but did lea ve the fuser exit

232 Rear Media did not clear the duplex input sensor, but did lea ve the printer fuser exit

233 Rear Media failed to make the duplex double feed sensor during turnaround.
234 Rear Media did not arriv e at the duplex exit sensor.
235 Front A piece of media is over the duplex double f eed sensor .
236 Front Media did not leave the duplex exit sensor.
237 Front A duplexed sheet did not reach the printer input sensor.
238 General Error A piece of media is ov er the duplex sensors during a reset.

sensor.

sensor.

Diagnostic information 2-47

4060-xxx

Duplex does not recognize that the option is installed, or other options below
the duplex are installed

FRU Action

1 Autoc onnect cabl es/

connections

Check the top and bottom autoconnect connectors for signs of
damage. If damaged, replace the duplex option. If not damaged,
check the cables are correctly connected to the duplex syst em 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 .

231 Jam displays on the operator panel

FRU Action

1 Fuser exit sensor Check the sheet of medi a is leaving the e xit sensor in the fuser and

Duplex input sensor If the paper does not re ach the duplex input sensor, make sure the

2

feeding properly into the duplex option. Check the duplex link for
correct opera tion and any signs of damage. If the problem is prior to
the duplex in put 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.

sensor is connected to the duplex sys tem 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 Jam displays on the operator panel

FRU Action

1 Duplex input sensor If the paper reache s the duplex input sens or, but does not clear the

sensor, make sure the sensor is connected to the duplex system
board. If connected correctly, check for corre ct operation of the
sensor. If a problem is found and cannot be correct ed, replace the
duplex opti on 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 f ound, replace the duplex
option assembly.

233 Jam displayed on operator panel

FRU Action

1 Duplex double feed sensor If a sheet of paper fai ls to reach the double feed sensor during

turnaround, chec k for any signs of pape r or ot her objects that might
cause the paper to jam. If no pr oblem is found, r eplace the duplex
option assembly.

2-48 Service Manual

4060-xxx

Envelope feeder service check

Service tip: Check the envelope feeder paper path for any debris, pieces of envelope and so on. If
any other options are installed make sure 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 d c 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 2-5.

Printer does not recognize the envelope feeder as an attached input option.

FRU Action

1 Envelope f eeder Make sure the envelope f eed er is correct ly ins tall ed and mated to t he

Fron t aut oconnect on

2

printer

Autoconnect on the

3

envelope feeder

autoconnect at the front of the printer.
Check the connector for signs of dama ge to the connector or

contacts. If you find damage, replace the damaged cable/connector
assembly. Remove the e n v elope f eed er and c heck t he vol tages a t t he
autoconnect on the f ront of the printer. If incorrect, check the
interconnect board. If correct, reinstall the envelope feeder and
cont i n ue with st ep 3.

Check for damage to the connector or contacts. If you find damage,
replace the damaged cable/connecto r assembly. Disconnect the
autoconnect cable at J1 on the envelope system board and m easure
the following voltages:

• J1-3 measur es +5V dc

• J1-5 measur es +5V dc

• J1-7 measur es +24V 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 Paper Jam immediately when envelope feed is
requested—POST incomplete.

FRU Action

1 Pass thru sensor Check for an y deb ris or piece s of env el ope ov er the pass thru senso r.

Check for correct install ation of the pass thru sensor flag. Make sure
the sensor cable is attached to the envelope system board. Perform
an envelope feeder sensor test to check both the sensor and sensor
flag.

Note: It may be necessary to use a small to ol t o actuate the sensor
flag because it is located under the front cover. Be careful not to
damage the flag.
If the test fai ls, check the flag for damage or binds. If incorrect,
replace the f lag. If the flag is operating correctly, check the voltage at
J3-3. The volt age m easures approximately +5 V dc. If incorrec t,
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.

Diagnostic information 2-49

4060-xxx

Operator panel displays 260 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

sens o r flag
Envelope out hopper input

2

sensor

Check the envelope out sensor flag for damage, correct installation
and operation. If incorrect, repair or replace the flag.

Make sure the sen sor is installed correctly and the sensor cabl e is
properly connec ted to the envelope system board. If cor rect, perform
the Envelope Feed Sensor Test to check both the sensor and flag. If
the test fails, remove any envelopes in the hopper, turn the printer off
and disconnect J3 fr om the system board. Turn the printer on and
check the voltage at J3-3 on the system board. The voltage
measures appro ximately +5 V dc. If incorrect, replace the envelope
system board. If co rrect, replace the input sensor assembly.

990 Service Error, envelopes fail to feed from the hopper.

FRU Action

1 DC feed motor assembly Check the motor and motor cable fo r loose wires or poor

Envelope feeder system

2

board

connections . Mak e sure t he mo tor ca ble is connect ed t o the en vel ope
system board.

Check the voltage on J4-1. The voltage measures approximately
+24 V dc. If incorrect, replace the envelope system board. If correct,
measure the voltage at J4-6. The voltage measures approximately
+5 V dc. If incorrect, disconnect J4 a nd m easure the voltage again. If
incorrect, repl ace the envelope feeder system board. If correct,
replace the DC motor assembly.

260 Paper Jam displays, unable to clear and envelopes fail to feed from the
hopper—Kick rolls are not rotating.

FRU Action

1 Main drive belt Check the belt for correct installati on and for signs of damage .

Gears Check all the gears for correct installati on and for signs of damage.

2

Clutch latch assem bly Check the clutch latch assemb ly t o mak e sure it moves fr eely.

3

Master cam gear maste r/

4

kick gear

2-50 Service Manual

Replace as necessary.

Repair or replace parts as necessary.

Check the master cam gear and master/kick gear to make sure the y
rotate together. If not, then the tenons on the master kick gear may
be sheared off. If incorrect, repl ace the master kick gear.

4060-xxx

260 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 adjustm ent may be too

Weight assem bly Check the weight assembly to make sure it moves up and down

2

Envelope edge guide Check the en velope edge guide to make sure it is not warped or set

3

narrow.

freely without any binds. Make sure the weight assembly rests on all
the rear kick rol lers when the hopper is empty. Replace the weight
assembly if i t is dam aged or does not operate properly.

too close to t he envelopes in the hopper. Replace the edge guide if it
is damaged or does not operate properly.

260 Paper Jam displays, envelope stops in feeder paper path.

FRU Action

1 Kick rolls/feed rolls/drive

rolls

Deflector gap adjustment Check the deflector gap adjustment. The adjustm ent may be too

2

Check all t he rolls f or oil, grease, or other cont am ination. If you find a
problem, clean the rolls. If this does not correct the problem, replace
the envelope feeder.

narrow.

Envelope feeder multifeeds or may not display a 260 Paper Jam message.

FRU Action

1 Envelopes Check the envelopes being used in the feeder. Check for signs of the

Deflector Check the deflector gap adjustment. The adjustm ent may be too

2

Restraint roll bias spring Check for a mis sing, broken or incorrectly install ed rest raint roll bias

3

envelopes being stuck together or signs of glue. Make sure the flaps
are not interleaved.

wide.

spring. If incorr ect, reinstall or rep lace the spring.

260 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.

Diagnostic information 2-51

4060-xxx

Fuser service checks

Cold fuser service check

Error codes 920, 921, and 922 may display for a cold fuser failure. A 920 error caused by low line
voltage can sometimes be cleared by turning the machine off and then on again. A 925 service error
indicates the wrong fuser lamp is installed. Be sure the correct type of fuser lamp is installed.

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.

If the correct lamp is installed and a 925 error remains, the problem may be due to the following:

• The fuser may have reached standby temperature too quickly .

• The line voltage may be above the maximum rating for the printer.

Note: A 920, 921 or 922 fuser error may be caused by an incorrectly mounted thermistor.

Service tip: Set the Fuser Temperature to NORMAL before starting this service check.

FRU Action

1 Fuser lamp (incor re ct lamp/

925 Service Error)

Fuser lamp

2

fuser top cover assembly

LVPS

3

LVPS to fuser AC cable

Install the correct vol tage and wattage lamp or fuser assembly. See

“Fuser assembly removal” on page 4-23.

If the correct fuser lamp is installed and the 925 error remains, th e
fuser may have reached standby t em perature too qui ckly. Check that
the line voltage is not exceedi ng the maximum rating for the printer.

Observe the lamp through the left side frame . If the lamp does not
come on, do the following:

• Remove the redrive assembly.

• Remove the fuser assembly, disconnect the LVPS to fuser AC
cable from t he fuser ass embly, and remov e the fus er . See “Fuser

assembly removal” on page 4-23.

• Verify that the lamp is installed correctly. If correct, check the
continuity of the fuser top cover assembly by v eri fying the lamp
contacts on the right cont act assembly. If incorrect, chec k
continuity of the fuser lamp. If incorrect, replace the lamp. If
correct, replace the fuser top cov er assembly.

CAUTION: When taking measurements for AC power, observe all
safety precautions.
Measure the AC line voltage betwe en the t wo connectors on the
fuser end of the LVPS to fuser AC cable. If the voltage is inco rrect,
turn the power off, and remove the LVPS. Measure the A C line
voltage bet ween pins CN1-1 and CN1-3 on the board. If correc t,
check the conti nuity of the LVPS to fuser AC cable. I f in correct,
replace the cable.
If the AC line voltage at CN1 is incor rect, check f use F2. If the f use is
blown, repl ace the fuse. If the fuse is not blown, replace the LVPS
assembly.

2-52 Service Manual

4060-xxx

FRU Action

Fuser to p co ver assembly

4

(assembly includes
thermistor and thermal
fuses)

Disconnect the th ermist or cable from the fuser control board at J6.

1

1

J2

J4

1

J1

1

J5

1

J6

Resistance:

• HOT J2-1–J2-2 <10K ohms

• COLD approximately 450K ohms
If the resistance is incorrect, repl ace the fuser top cover assembly. If
the resistanc e is cor rect, check each pin of J6 to gr ound. If there is
continuit y, replace the fuser cover assembly. See “Fuser cover

removal” on page 4-25.

Diagnostic information 2-53

4060-xxx

Hot fuser service check

Error Code 923: Indicates the fuser is too hot during printing or when the printer is idle.
Error code 924: Indicates an open circuit has been detected in the fuser thermistor circuit.

Note: Check the fuser sub error codes to help diagnose between a 923 and 924 error.
CAUTION: The fuser may be hot, use caution before removing or servicing.

CAUTION: There is a danger from hazardous voltage in the area of the printer where you

are working. Unplug the printer before you begin, or use caution if the printer must receive
power in order to perform the task.

FRU Action

1 Fuser cover assembly

(assembly includes
thermistor and thermal
fuses)

Fuser assembly Check for conti nuity between J6-1 and J1-2 and between J6-2 and

2

Fuser to system board DC

3

cable
System board Measure the voltage on J14-3 on the syst em board. The voltage

4

Fuser hot roll

5

Fuser hot roll bearing s
Fuser backup rol l bearings
Fuser backup roll
Fuser mechanical parts

Check for damage to the thermistor assembly. If damage is found,
replace the fuser top cover asse mb ly. If no damage is found, check
the resistance of the thermistor between pins J6-1 and J6-2 on the
cable.

• HOT < 10K ohm s

• COLD = approximately 450K ohms

If the resistance is incorrect, repl ace the fuser top cover assembly. If
the resistanc e is cor rect, check each pin of J6 to gr ound. If there is
continuit y, replace the fuser cover assembly. See “Fuser cover

removal” on page 4-25.

J1-3. If incorrect, replace the fuser assem bly. If correct, go to step 3.
Check the conti nuity of the cable. If incorrect, rep lace the cable. If

correct, go to step 4.

should change from approximately +2.5 V dc with the thermistor cold
to approximately +1.6 V dc when the thermistor is hot. If incorrect,
replace the system board. If correct, go to step 5.

Examine the fuser assembly for si gns of overheati ng or damage.
Check the hot rol l and backup roll for signs of excessive toner, label
glue, labels, or other contami nants. If prob lems are f ound, replace the
fuser assembly.

2-54 Service Manual

4060-xxx

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 descr ibed in the adjustment
section “Fuser solenoid adjustment” on page 4-2.

FRU Action

1 Fuser en velope condit ioner

solenoid

Observe the operation of the fuser solenoid by removing the redrive
assembly. Check fo r proper mech anical operat i on of t he solen oid and
associated hardware, link, and so on. If correct, che ck the resist ance
of the solenoid between J4-1 and J4-2 on the fuser control board.

1

1

J2

J4

1

J1

1

J5

1

J6

The resistance measur es between 5 ohms and 10 ohms . If incorre ct,
replace the fuser assem bly. If correct, go to step 2.

System board Measure the voltage at the +42 V dc test point on the system board.

2

LVPS Measure the volt age at CN2-18 on the LVPS. The voltage should

3

Fuser board to system

4

board cable

The voltage should measure approximately +42 V dc. If incorrect, go
to step 3. If incorr ect, go to step 4.

measure approximately +42 V dc. If incorrect, replace the LVPS
assembly. If correct, replace the sy stem board. If th is does not fix the
problem, replace the interconnect board assembly.

Make sure the cable is connected properly to the system board and
fuser control board. Reconnect the cable, if necessary. If the cabl e is
connected correctly, go to step 5.

Fuser assembly If no problems were f ound in steps 1 through 4, replace the fuser

5

assembly. See “Fuser assembly r emoval” on page 4-23.

Diagnostic information 2-55

4060-xxx

High-capacity feeder input tray service check

Note: Voltage measurements in the high-capacity feeder input tray service checks must be made
with the high-capacity feeder attached to the base printer to obtain accurate results.

Service tip: Be sure the paper size switch is set to the correct paper size setting and the rear paper
guides are in the correct locations for the size of paper installed in the high-capacity feeder tray.

Service tip: Check the other paper sources to be sure they are operating correctly.

The base printer indicates a dead machine condition when the high-capacity
input tray is installed.

FRU Action

1 AC line cord

AC jumper (HCIT to printer)
AC input and output
receptacles
AC wiring harness

If the base printer works normally using the AC line cord from the AC
wall outlet and does not work when usi ng 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 in stalled correctly f rom 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

Base printer or option

2

mounted abov e
LVPS

3

Option system board

Check the high-capacity feeder input tray to make sure it is mounted
correctly and is not pushed down into the frame assembly or
damaged. Be sure the high-capacity feeder input tray autoconnect is
properly connecte d to th e high-capacity feeder tray opti on board
assembly.

Check the option or base pri nter autoconnect f or signs of damage.
Repair the high-capacity option autoconnect as necessary.

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 assemb ly. If the voltage i s incorrect, check the continuity of the
AC input cable to the LVPS. If correct, replace the LVPS assembly. If
incorrect, replace the AC cable to the input of the LVPS.

2-56 Service Manual

4060-xxx

FRU Action

High-capacity f eeder opt ion

4

control board

Check the voltage on J8-1 (green). The voltage measures +24 V dc.
If incorrect, check the autoconnect system for an y 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 +24V dc. If correct, replace
the high-capac ity f eede r opt ion sy stem board. I f inc orrect , dis connect
J8 from the system board and measure the voltag es again. If
incorrect, check the LVPS cable and the A C internal wiring from the
input applian ce receptacle. If incorrect, replace as necessary. If
correct, replace the LVPS. If the v oltages are correct, check the
stepper motor for shorts from the motor housing to each pin on the
motor connector. If you fin d a short between a ny pin and the motor
housing, replace the motor assembly. If no shorts are found, replace
the high-capaci ty feeder option control board.
Check the voltage at J9-1 (light b lue). The voltage mea sures
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 correct ly, check the cab le. If the cab le is da maged, repl ace
as necessary. If no problem is found with the cab le, replace the high­capacity feeder option control board.

24x 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 is a Paper Jam Tray 2

FRU Action

1 Pass thru sensor and flag

assembly

Power takeoff shaft and

2

spring, bev el gear, feed roll
gear, dri ve roll assembly,
wear plate, driv e shaft
bearings, and skewed
backup roll er

The tray x option system board did not detect a piec e o f paper
actuating the pass thru senso r . Remov e any j ammed sheet s 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 men u. If the test fail s, 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.

Check these parts f or si gns of broken or damaged parts,
contaminatio n on the drive rollers or wear plate and wear or damag e
to the drive sh aft bearings . Chec k the driv e r oll as semb ly and s k ewed
backup roll er for wear, slick spot s, 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 P a per L o w d isplays when tray x is full or has adequate paper in the tray .

FRU Action

1 Paper low switch

Paper low switch cabl e
High-capacity feeder Input
system board

Run the sensor diagnost ics for tray x (x=the number th at re presents
the high-capacity input tray) . If the test f ails, di sconnect the paper low
switch cable from J3 on the high-capacity sy stem board. Sh ort pins 1
and 2 together while observing the sensor test on the display. If the
display does not change, repla ce the high-capacity feeder system
board. If the displ ay changes check the continuity of the switch. If
incorrect, repl ace the switch. I f correct, replace the s witch cable.

Diagnostic information 2-57

4060-xxx

Tray x empty displays when there is paper in the high-capacity feeder input
tray .

FRU Action

1 Paper out sensor flag Check the paper out sens or fl ag f or c orrect opera tion an d in stallat i on.

Paper out sensor

2

(on option syste m board)

If correct, replace the high-capaci ty 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 limi t switc h

Lower limi t switc h c able

High-capacity feeder

2

control board

Check continuity of the lower lim it 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.

Disconnect the lower limit switch cable and check the voltage at J2-1
(orange). The v oltage 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 limi t switc h

Lower limi t switc h c able
High-capacity feeder
control board

Check the lower limit switch to make sure it is not closed (normally
open). If incorrect, replace the swi tch. Check the lower limit swit ch
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
Wear strips Check the wear strips for glazing or conta mination. Replace as

2

Check the autocompe nsat or pic k arm rolle rs f or sign of glazi ng, toner
or other buildup. Replace as necessary.

required. It is advisable to replace all four wear strips at the same
time.

2-58 Service Manual

4060-xxx

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 cabl e is correctly instal led 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 th e m otor assemb ly. If no problem is found,
measure the resist ance between the following pins on the motor
cable connector:
Pins 1 (brown) and pin 2 (Yellow)
The resistan ce mea sures b etw een appr o ximate ly 7. 5 an d 10.5 ohms .
If incorrect, replace the motor assemb ly. If correct, repl ace the high­capacity feeder option system board.

The elevator moves in one direction only.

FRU Action

1 DC dr ive motor ass e m bly

high-capacity feeder
system board

Check the voltages at J1 on the high-capacit y system board. The
voltages measure approximately as follows:

Pin Color Voltage
Static (motor not running)

J1-1 Brown 0 V dc
J1-2 Yellow 0 V dc

Motor running forward

J1-1 Brown 0 V dc
J1-2 Yellow +24 V dc

Motor running in reverse

J1-1 Brown +24 V dc
J1-2 Yellow 0 V dc

If any of the v oltages are incorrect, disconnect the motor and
measure the resistance between J-1 and J-2. The resistance
measures between 7.5 and 10.5 ohms. If incorrect, replace the
motor . If correct, replace the system board.

Diagnostic information 2-59

4060-xxx

Paper size switch not selecting paper size that is selected.

FRU Action

1 Paper size switch

High-capacity f eeder opt ion
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 le ad
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 continui ty when selected, replace
the paper size switch assembly. If the switch assembly is operating
correctly, replace the high-capacity feeder option control board.

24x Paper Jam Check Tray x displays when tray x is empty. Tra y x does not
display.

FRU Action

1 High-capacity f eeder opt ion

control board

Elevator top optical sensor

2

cable
Elevator top optical sensor

Check the voltages on the board at J4-1(r ed) and J4-3 (blue). The
voltages measure approximately +5 V dc. If incorrect, disconnect J4
from the board and measure t he voltages again. If i ncorrect, replace
the high-capaci ty feeder option control board.

Check the continuity of the sensor cable. If incorrect, replace the
cable. If correct, replace the top optical sensor assem bly.

Tray x Empty displays. Tray does not respond to loading paper. No response
from the front door switch.

FRU Action

1 High-capacity f eeder opt ion

control board

Elevator top optical sensor

2

cable
Elevator top optical sensor

2-60 Service Manual

Check the voltage on the board at J4-2 (gre en). The voltage
measures appr oxi mat ely +5V dc. If incorr ect, dis connect the cab l e a t
J4 and chec k the v olta ge ag ain. If i ncorrec t, r eplace the high- capacit y
feeder option control board.

Check the continuity of the sensor cable. If incorrect, replace the
cable. If correct, replace the top optical sensor assem bly.

4060-xxx

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

Paper low switch cabl e
High-capacity f eeder opt ion
control board

Run the sensor diagnost ics for tray x (x=the number that represents
the high-capacity input tray).
If the test fails, check the voltage at J3-1 (gray). The vol tage
measures approximately +24 V dc. If incorrect, di sconnect 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, r eplace the cable. If correct, check the switch for a
bent or deformed act uator lever or defective switch. If inc orrect,
replace the switch.

Excessive noise or vibration

FRU Action

1 DC motor assembly Make sure all the motor plate mounting screws are tight.

Idler p u lley

2

DC motor assembly

Drive pulley Check the drive pulley for wear, binds or damage to the pul ley or

3

Motor drive belt

4

tray drive belt

Make sure the idler pulley is not binding on the pulley shaft. Check
the pulley for wear. Check the idler pull ey shaft on the motor
mounting plate for damage or contamination.

pulley shaft. Make sure the pulley turns freely on the pulley shaft.
Check the DC motor drive belt for damage. Make sure the belt is

tracking correctly on the drive pulley, idler pulley, and motor pulley.
Check the tray drive belt f or damage. Make sur e the belt is tracking
correctly on the lower section of the driv e pulley and lead scr ew
pulleys.

Diagnostic information 2-61

4060-xxx

High-capacity output stacker service check

Service tip: The majority of the mechanical comp onent s 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 5-3 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 t o mak e 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 dam aged.

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

feeder
High-capacity output

2

stacker/mechanical linkage
assembly

Check the auto conne cts, cab les , and connect ors of th e optio n f or an y
signs of loose or damaged parts.

Remove the left and right side covers and check all f our
autoconnects for damage, especially the conn ect or pin s. Remo v e t he
output option and ch eck the voltages on the standard output bin
autoconnect located on the top left rear of the printer. Go to

“Autoconn ect” on page 5-1. If the voltages a re correct, reinstall the

output opti on and not e the posi tio ns of t he tor oi ds on t he au toconnec t
cables on the upper and lo wer assembl ies, and chec k the volt ages on
the autoconnects. If all voltages are correct and the lower assembly
is failing, replace the lower control board. If the upper assembly is
failing, replace the upper control board. If the voltages are incorrect,
replace the upper or lower failing mechanical linkage assembly.

2-62 Service Manual

4060-xxx

202 Pap er J am O pen Rear D oor displays an d a s heet of pap er is jam me d prio r
to the pass thru sensor flag or 202 Paper Jam Open Rear Door displays, a
sheet of p ap e r f eed s o ut to t he sta ndard b in e ven th ou gh b in x is selecte d and
paper exits half way out of the redrive assembly.

Service tip: For this type of problem check the “ B as e print e r sub error codes” on page 2-6. 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/

Flag Assembly

High-capacity output

2

stacker drive belt(s)
Drive pull eys
Belt idlers
Belt tension springs

Mechanical linkage/motor

3

assembly (upper or lower)

Check the flag for correct opera tion, binding, broken parts, or
interf erence from the sensor cable. If incorrect, repair as necessary.
If correct, check to make sure the lower pass thru sensor is correctly
connected to J3 on the lower cont rol board. Dis connect the pass thru
sensor cable and check the volt age at J3-3. The voltage measures
approximately +5 V dc. If incorrect, check the volt age at J3-2. The
voltage measures approximately 0 V dc. If incorrect, replace the
sensor assemb ly. If this does not fix the problem, replace th e lower
control board.

Check to ensure the out put stacker drive belt or the f ail ing assembly
is correctly ins talled on the drive pull ey and belt idler pulle y. Check
the belt tension spring to make sure it is not loose or broken. Repair
as necessary.

If the DC motor is functioning properly check the gears, clutch and
other linkage parts for cor rect ope ra tion and wea r , brok en gea r teeth,
or damaged parts. If incorrect, replace the mechanical linkage
assembly/DC motor assembly.

Remove Paper - Output Bin x Full displays. You may not be able to clear the
message.

FRU Action

1 Dual output bin sensor flag

(upper assembly)

Check the flag for correct opera tion, binding, broken parts, or
interf erence from the sensor cable. If incorrect, repair as necessary.

271 Paper Jam - Check Bin x, POST incomplete.

FRU Action

1 Upper pass thru se nsor flag

assembly
Upper control board

Check the flag for correct opera tion, binding, broken parts, or
interf erence from the s ensor cab le . I f inc orrect , repair a s nec essa ry. If
correct, make sure the lower pass thru sensor is correctly connected
to J3 on the lower control board. Disconnect the pass thru sensor
cable and check the voltage at J3-3. The voltage measures
approximately +5 V dc. If incorrect, check the volt age at J3-2. The
voltage measures approximately 0 V dc. If incorrect, replace the
sensor assemb ly. If this does not fix the problem, replace th e lower
control board.

Diagnostic information 2-63

4060-xxx

Input sensor service check

Service tip: Run the Base Sensor Te st. 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

System board Check for approx imately +5 V dc at J22-10 on the system board. If

2

Input sensor cable Check the continuity of the input sensor cable section of the fr ont

3

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 sys tem bo ard

or compensator assembly
or autoconnect cable

problem is f o und, repair as necessa ry.

incorrect, replace the system board.

wiring harness. If incorr ect, replace the harness. I f cor rect, replace
the input sensor ass embly.

Check the autoconnect cables and connectors for damage. Replace
if necessary. Check the cables for continuity. If incorrect, replace the
compensator assembly cable. If the cables, connectors, and
connections are good, replace the FRUs in the follow ing order:

• Autocompensator assembly option

• Option system board.

24x Paper Jam displays, paper jammed over the pass thru sensor.

(The printer displays the value of x for the paper tray where the error occurs. Example: 241 is a Paper
Jam Tray 1)

FRU Action

1 Pass thru sensor and flag

assembly

2-64 Service Manual

The tray x option system board did not detect a piec e o f paper
actuating the pass thru senso r . Remov e any j ammed sheet s 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 men u. If the test fail s, check the sensor for correct
installation and the flag for prop er 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.

4060-xxx

FRU Action

Power takeoff shaft and

2

spring, bev el gear, feed roll
gear, dri ve roll assembly,
wear plate, driv e shaft
bearings, and skewed
backup roll er

Check these parts fo r br oken or damaged parts, contamin ation on
the drive roll ers or wear plate, and wear or damage to the drive shaft
bearings. Chec k the drive roll assembly and skewed backup roller f or
signs of wear, slick spots, material buil dup, and oil or grease on the
rollers. Also check for proper operation of the paper al igning
assembly. Repair or replace parts as necessary.

Tray x Low displays when tray x is full or has adequate paper in the tray.

FRU Action

1 Paper low sens or assembl y

Paper lo w sensor flag tra y x
option system board

Run the Tray x Sensor Test and check the sensor for proper
operation. If incorrect, check the followin g:

• Paper low sensor flag for smooth and correct operation.

• Paper low sensor for correct installati on on the autocompensator

housing.

• Paper low sensor cab le for signs of cuts, pinched wiring, or other

damage especially at connector J5 on the system board.
If no probl em is found, rep lace the paper low se nsor 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

1 Paper out sensor flag Check the paper out sens or fl ag f or c orrect opera tion an d in stallat i on.

Paper out sensor (on o ption

2

system board)

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

1 Autoc onnect cabl es

Tray x system board

Check the autoconnect from the print er or option above t ray x. Check
for cuts, pinched wiring, or damage to the cont acts in the connector.
Check the autoconnect cable(s) for correct instal lation at the tray x
system board. If correct, check the cont inuity of the autoconnect
cable(s). If correct, replace the tray x system board. If incorrect,
replace the cable.

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.

FRU Action

1 Autocompensator

assembly

Check the autocompensator pick arm roller s for any sign of glazing,
toner or other buildup. Clean or replace as necessary.

Diagnostic information 2-65

4060-xxx

Internal tr ay card/pa pe r siz e sen s ing se rvice 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.

SW2

CN1

SW1

1

SW0

Paper size sensing switch chart

ITC
CN1 pin

Signal

ITC
switch

1 PSIZE2 SW1 X X X 1
2 Ground Ground 2
3 PSIZE1 SW0 X X X 3
4 PSIZE3 SW2 X X X 4

Paper tray size selection (X is activa ted) System

board

Letter Legal A4 Exec B5 A5

J34 pi n

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 swit ches.

Integrat ed card/

2

autocompensator cable

System board Check t he continuity between J34-2 on the system board and

3

2-66 Service Manual

L

G

L

A4

LTR

EXEC

B5

A5

2

W

S

1

W

S

0

W

S

If a problem is found, repair as neces sary. If no problem is found, go
to step 2.

Check for cor rect inst al lation of the cab l e at J34 on the s ystem boar d.
If installed correctly, go to step 3. If incorrectly ins talled, install and
recheck the printer.

ground. It should m easure approximately 0 ohms.