Lexmark C540 Service Manual

Page 1
Lexmark™ C540n, C543dn, C544n,
C544dn, C544dtn, and C544dw
5025-2xx, 4xx
• Table of contents
• Start diagnostics
• Safety and notices
• Index
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
Edition: October 14, 2008
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5025-2xx, 4xx
Edition: October 14, 2008
The following paragraph does not apply to any country where such provisions are inconsistent with local law:
LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time.
Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.
References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the user’s responsibility.
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
PCL® is a registered trademark of the Hewlett-Packard Company. PCL is Hewlett-Packard Company’s designation of a set of printer commands (language) and functions included in its printer products. This printer is intended to be compatible with the PCL language. This means the printer recognizes PCL commands used in various application programs, and that the printer emulates the functions corresponding to the commands.
All other trademarks are the property of their respective owners.
© 2008 Lexmark International, Inc.
All rights reserved.
UNITED STATES GOVERNMENT RIGHTS
This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense.
P/N 12G9819
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5025-2xx, 4xx
Table of contents
Table of contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii
Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Options and features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Print quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Connectivity (network support) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Data streams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Power and electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Environment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Media handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Input and output sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Duplex capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Media input size specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Media input type specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Media output size and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Media guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Paper characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Unacceptable paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Selecting paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Selecting preprinted forms and letterhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Storing paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Using recycled paper and other office papers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
POR (Power-On Reset) sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Print quality symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Error codes and messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
User status and customer attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Paper Jam messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Service error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
122.xx—Fuser temperature incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
90x.xx error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
925.01—Fan error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
930.xx–935.xx—Printhead errors service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Table of contents iii
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936.xx, 937.xx—Transport motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
950.xx NVRAM Failure service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Autocompensator mechanism service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
Bin full sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
Dead printer service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
Duplex/manual feed sensor (S1) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
Front door sensor or switches service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Fuser exit sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
Fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Input sensor (S2) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
Main drive gear assembly (EP drive) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35
Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36
One or more operator panel buttons fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36
Operator panel display blank, five beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37
Operator panel display blank, printer beeps five times and pauses . . . . . . . . . . . . . . . . . . . . . .2-38
Operator panel displays all diamonds, no beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Operator panel displays all diamonds, five beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Operator panel display is dim and unchanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41
Print quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
Print quality—background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43
Print quality—blank page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Print quality—blurred or fuzzy print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45
Print quality—half-color page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45
Print quality—horizontal banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46
Print quality—horizontal line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46
Print quality—insufficient fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47
Print quality—missing image at edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47
Print quality—mottle (2–5mm speckles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47
Print quality—narrow vertical line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Print quality—random marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Print quality—residual image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
Print quality—solid color page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
Print quality—vertical banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
Printhead service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51
Toner meter cycle (TMC) card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52
Toner meter sensors (Y, C, M, K) on TMC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53
Tray 1 sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53
User operator panel and Administration menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55
Printer operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55
Operator panel buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55
Menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56
Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Diagnostics Menu (Diag Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Diagnostics Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Input source tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Print quality test pages (Prt Quality Pgs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
iv Service Manual
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Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Quick Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Top Margin (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Left Margin (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Feed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Miscellaneous tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Motor Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Page counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Engine Setting 1 through 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
ITU Barcode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Reset Fuser Cnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
EP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
EP Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Fuser Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
DC Charge Adjust, Dev Bias Adj, Transfer Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
TPS Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Right or Left TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Cal Ref Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Reset Color Cal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Print Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Clear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
EXIT Diags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Configuration menu (Config Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Prt Quality Pgs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Color Trapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Auto Color Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Font Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E
xit Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Avoiding jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Understanding jam numbers and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
200 paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
201 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
202 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
230 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
235 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
. . . . . . . . 3-27
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24x paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
250 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Print engine theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
Electrophotographic process (EP process) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
Electrophotographic process basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
Step 1: Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
Step 2: Expose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
Step 3: Develop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
Step 4a: First transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Step 4b: Second transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
Step 5: Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
Step 6: Clean/erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
Paper path, transport components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
Paper path Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
Transport components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
Duplex process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
Color theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
What is RGB color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
What is CMYK color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
How is color specified in a document to be printed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
How does the printer know what color to print? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
Should I use PostScript or PCL emulation printer software? What settings should
I use for the best color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
Why doesn't the printed color match the color I see on the computer screen? . . . . . . . . . . . . .3-45
The printed page appears tinted. Can I adjust the color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
My color transparencies seem dark when they are projected. Is there anything I can
do to improve the color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
What is manual color correction? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
How can I match a particular color (such as a corporate logo)? . . . . . . . . . . . . . . . . . . . . . . . .3-47
What are detailed Color Samples, and how do I access them? . . . . . . . . . . . . . . . . . . . . . . . . .3-47
Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Front cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Left cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Operator panel bezel and name plate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Right cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Rear shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Autocompensator mechanism (ACM) removal—standard tray . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Bin full sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Bin full sensor flag and exit deflector removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Controller board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
Developer unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
Duplex sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
Exit deflector and bin full sensor flag removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
Fuser assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
Fuser drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
Fuser exit sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
High-voltage power supply (HVPS) assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
Image transfer unit (ITU) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33
Imaging unit (IU) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35
Low-voltage power supply (LVPS) assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37
Lower frame removal, right and left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39
Left lower frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Right lower frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
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Main drive gear assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Pick tires removal—standard media tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Toner cartridge contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Toner density sensor (TDS) removal—left or right sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Toner meter cycle (TMC) card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Tray present sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
USB port connector removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Waste toner bottle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Wireless network antenna removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
Wireless network card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
Connector locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Controller board diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
High-voltage power supply (HVPS) diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Low-voltage power supply (LVPS) diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Toner meter cycle (TMC) card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Wireless network card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Preventive maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Assembly 2: Frames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Assembly 3: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Assembly 4: Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Assembly 5: Options and miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-7
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Notices and safety information
CAUTION
This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery manufacturer’s instructions and local regulations.
The laser notice label may be affixed to this printer.
Laser notice
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 645-670 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 Commission) 60825-1 gemäß amtlicher Bestätigung 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 645-670 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 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 645 et 670 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 .
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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 lunghezza d’onda compresa tra 645 e 670 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 645 a 670 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 645 e 670 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.
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 645-670 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.
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Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 645-670 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.
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Laserilmoitus
Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) ­lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.
Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 5 mW:n galliumarsenidilaser ja toimii 645 - 670 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön, ylläpidon tai huollon aikana.
Huomautus laserlaitteesta
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 645 - 670 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.
VARO! Avattaessa 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-notis
Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1.
Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 645-670 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 645-670 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.
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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 perillosos. 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 645-670 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.
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Safety information
The safety of this product is based on testing and approvals of the original design and specific
components. The manufacturer is not responsible for safety in the event of use of unauthorized
replacement parts.
The maintenance information for this product has been prepared for use by a professional service person
and is not intended to be used by others.
There may be an increased risk of electric shock and personal injury during disassembly and servicing of
this product. Professional service personnel should understand this and take necessary 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 composants particuliers. Le fabricant n'assume
aucune responsabilité concernant la sécurité en cas d'utilisation de pièces 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
parti.
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 elevato. Il personale di assistenza
autorizzato deve, quindi, adottare le precauzioni necessarie.
ATTENZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del prodotto.
Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l'intervento.
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Sicherheitshinweise
Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und
bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen.
Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.
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 Seguridad
La seguridad de este producto se basa en pruebas y aprobaciones del diseño original 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 Segurança
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 serviços e não
devem ser utilizadas por outras pessoas.
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.
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Informació de Seguretat
La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components
específics.
El fabricant no es fa responsable de les qüestions de
seguretat si s'utilitzen peces de recanvi no autoritzades.
La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està
destinada
a ningú que no ho sigui.
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.
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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, as well as general environmental and safety instructions, are discussed.
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. Repair information provides instructions for making printer adjustments and removing and installing
FRUs.
5. Connector locations 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.
Conventions
Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software.
There are several types of caution statements:
CAUTION
A caution identifies something that might cause a servicer harm.
CAUTION
This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
CAUTION
This type of caution indicates a hot surface.
CAUTION
This type of caution indicates a tipping hazard.
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1. General information
The Lexmark™ C54x printer (5024-2xx, 4xx) is a color network printer in a compact size. Some models have internal duplexing, USB-A host ports for flash drives on the operator panel, and an optional 650-sheet Duo Drawer with 550 sheets in the input tray and 100-sheets for the multipurpose feeder. The Lexmark C544dw comes with wireless network and duplex printing.
Models
Model name
Lexmark C540n 5025-210 Ethernet network
Lexmark C543dn 5025-230 Ethernet network, duplex
Lexmark C544n 5025-410 Ethernet network, USB-A host ports for flash drives
Lexmark C544dn 5025-430 USB-A host ports for flash drives, duplex
Lexmark C544dw 5025-43W 802.11n network wireless network, duplex
Options and features
Machine type/ model
Description
Certain options are available on selected printer models only.
Available options include:
650-Sheet Duo Drawer—a 550-sheet drawer with a 100-sheet multipurpose feeder (MP Feeder).
Additional memory—One 128, 256, or 512MB memory card may be added.
Flash memory card—One 64MB card may be added.
Font cards—One
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Printer specifications
Memory
—Supported —Not supported
Memory
Optional slots One slot Standard DIMM sizes Optional (DDR2) 128MB, 256MB, and 512MB Maximum printer memory
Option Slots (single slot is available or either font or flash memory card)
Font card support N/A 1 font card Optional user flash memory card sizes N/A 64MB
Connections
USB 2.0 High Speed
Ethernet 10/100 BaseTx
USB-A (allows direct USB printing using approved USB flash memory device)
PictBridge (allows printing photos directly from a compatible camera)
Wireless standard 802.11 b/g/n
a
Dual Inline Memory Module. An optional memory card that can be plugged into an available memory slot.
b
The maximum usable DDRSDRAM is standard (soldered) plus 512MB.
a
128MB
b
640MB
Lexmark C540n, C543dn
✔✔
✔✔
✘✔
✘✔
Lexmark C544n,
C544dn, C544dw
(C544dw only)
Print quality
During the life of the printer, components are subject to wear based on usage. Printers continuously operating at or near the maximum duty cycle may require service for replacement of these components to ensure high­quality printing and good performance throughout the life of the printer. The fuser and ITU replacement should be determined by checking the last sheet of the Menu Settings Page. Either OK or Replace appears.
To print a Menu Settings page:
1. Press Menu ( ) on the operator panel.
2. Select Reports from the Admin Menu, and press Select ().
3. Select Menu Settings, and press Select ().
Replacement is recommended every 30,000 pages for the imaging unit.
4800C Q (default) full printer speed
1200 dpi (reduced printer speed) is supported in PS and PCL only
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Connectivity (network support)
—Supported —Not supported
Lexmark C540n, C543dn,
Network protocol
C544dn Lexmark C544dw
Standard Ethernet 10/100 Base T
Standard USB-B (Full speed) device port
USB-A host ports
(In front, low/full speed) This port only supports the following flash drives and file types:
Supported flash drives (512 MB/1GB size), SanDisk Cruzer Micro (512 MB/1 GB size), or Sony (512 MB/ 1GB).
Supported file types .bmp, .png, .tiff, .tif, .pcx, .dcx
802.11n Wireless Network card
Manufacturing installs the wireless card. A wireless card CANNOT be installed post­manufacturing.
a
While other USB flash drives have not been tested, and therefore cannot be approved by Lexmark, these
products may function if the storage device meets the following qualifications:
• Supports the USB 2.0 specification supporting the Full-Speed mode
• Uses the FAT file system
b
PDF files used with Direct USB printing must support PDF standard version 1.5 or earlier. PDF files with
restricted printing permissions or encryption are not supported.
Operating modes
a
: Lexar FireFly
b
:.pdf,.gif,.jpeg,.jpg,
✔✔
✔✔
✘✔
✘✔
Mode Description
Normal Factory default Quiet Designed for customers where noise levels are a very important
Eco-Mode (Energy and Energy + Paper)
factor.
• Print quality is maintained at factory default level.
• Speed is reduced.
Designed for customers where the environment is a key factor. There are three options; Energy, Paper, and Energy+ Paper.
• Print quality is maintained.
• Power Saver is set to one minute.
• Fuser standby is off.
• The operator panel back light is off.
• Power supply energy consumption is reduced.
• Duplex is on if Energy + Paper is selected (duplex models
only) (can be overwritten by the driver).
General information 1-3
Page 22
5025-2xx, 4xx
Data streams
—Supported —Not supported
Data streams
Lexmark C540n, C543dn
Lexmark C544n,
C544dn, C544dw
PCL 6 emulation
PostScript Level III emulation
Version 3011 of the Adobe definition of PostScript 3 is supported.
PDF
Supports version 1.6
PPDS
By default, the PPDS interpreter is inactive. A user can activate the data stream by PJL or by the PPDS Emulation setting in the Configuration Menu.
PictBridge
Directimage
Devices that support Directimage support all of the following graphics formats: TIFF, TIF, JPEG, JPG, GIF, PNG, BMP, PCX, and DCX.
Host-Based Printing (HBP)/Graphics Device Interface (GDI)
Version 3 (color) uses PCL XL.
Dimensions
✔✔
✔✔
✘✔
✘✔
✘✔
✘✔
✔✔
Models Height Width D epth Weight
Lexmark C540n, C543dn, C544n, C544dn, C544dw
Lexmark C544dtn The Lexmark C544dn printer
with optional 640-sheet duo drawer
650-sheet duo drawer 133 mm (5.2 in.) 424 mm (16.7 in.) 416 mm (16.4 in.) 4 kg (8.7 lb)
291 mm (11.5 in.) 424 mm (16.7 in.) 400 mm (15.7 in.) 21 kg (46.2 lbs)
422 mm (16.6 in.) 424 mm (16.7 in.) 416 mm (16.4 in.) 25 kg (54.9 lbs)
1-4 Service Manual
Page 23
5025-2xx, 4xx
Clearances
Description Dimensions
Lexmark C540n, C543dn,
C544n, C544dn, and C544dw
1 Rear 102 mm (4 in.) 102 mm (4 in.) 2 Front 508 mm (20 in.) 508 mm (20 in.) 3 Right side 152 mm (6 in.) 254 mm (10 in.) 4 Left side 76 mm (3 in.) 76 mm (3 in.) 5 Above 254 mm (10 in.)* 254 mm (10 in.)*
* Add 133 mm (5.2 in.) to the top if you want to add an optional 650-sheet Duo Drawer (Lexmark C54x
models only).
C544dtn
General information 1-5
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5025-2xx, 4xx
Power and electrical specifications
The following table specified nominal average power requirements for the base printer configurations. All power levels are shown in Watts (W). Maximum current is given in Amperes (A).
Printing states Lexmark C540n, C543dn
Average power while printing
Simplex 480 W 500 W Automatic duplex* 340 W 340 W
Average power while idle
Power Saver 18 W 18 W Ready 34 W 36 W Off 0 W 0 W
* Automatic duplex is not supported on the C540n and C544n.
Lexmark C544n, C544dn, C544dw, and C544dtn
Typical electricity consumption2
Model Mode
Lexmark C540n, C543dn
1
3.73 kwh 3.5 kwh 3.92 kwh
TEC
1
—Eco Mode 3.41 kwh 3.30 kwh 3.55 kwh
TEC
Lexmark C544n, C544dn, C544dw, C544dtn
1
TEC
1
—Eco Mode 3.57 kwh 3.42 kwh 3.57 kwh
TEC
1
TEC—Typical Electricity Consumption.
2
Energy measurements are made according to ENERGY STAR Qualified Imaging Equipment Typical Electricity Consumption Test Procedure, and are in units of kilowatts per week (kwh/week). Actual electricity consumption will vary by device usage.
100 V/50 Hz 115 V/60 Hz 230 V/50 Hz
3.97 kwh 4.06 kwh 4.20 kwh
Power supply voltage (kwh)
Low-voltage models
110 to 127 V ac at 47 to 63 hertz (Hz) nominal
99 to 137 V ac, extreme
100 voltage models
100 V ac at 47 to 63 hertz (Hz) nominal
90 to 110 V ac, extreme
High-voltage models
220 to 240 V ac at 47 to 63 hertz (Hz) nominal (not available in all countries)
198 to 259 V ac, extreme
Notes:
Using a 220 V ac to 110 V ac power converter with a low voltage printer is not recommended.
Using an inverter to change DC to AC voltage (12 V to 120 V for example) is not recommended.
All duplex models are ENERGY STAR compliant.
1-6 Service Manual
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5025-2xx, 4xx
Acoustics
All acoustic measurements are made in accordance with ISO 7779-1999 and reported in conformance with ISO9296:1988-04-15.
Operating mode 1-Meter average sound pressure at 4800 CQ
Lexmark
Lexmark C544dn, C544dw
Printing (simplex) 47 dBA 47 dBA 49 dBA 49 dBA 49 dBA Printing (automatic
duplex) Idle Inaudible Inaudible Inaudible Inaudible Inaudible Quiet Mode (simplex) 46 dBA 46 dBA 46 dBA 46 dBA 46 dBA
C540n
N/A 50 dBA N/A 51 dBA 51 dBA
Lexmark C543dn
Lexmark C544n
Lexmark C544dn, C544dw
Lexmark C544dtn
Environment specifications
Environment Specifications
Operating
Air temperature—operating 15.6 to 32.20° C (60 to 90.0° F) Air temperature—power off 10.0 to 43.30° C (50 to 110.0° F) Air relative humidity Relative Humidity 8 to 80% Wet bulb temperature—operating 22.80° C (73.0° F) maximum Wet bulb temperature—power off 26.70° C (80.10° F) maximum Altitude 0–3,048 meters (10,000 ft.) Atmospheric pressure 74.6 kPa Ambient operating environment* 15.6 to 32.2° C (60 to 90° F) and 8% to 80% RH
Ship / Storage
Cartridges -40 to 43.3° C (-40 to 110.0° F) Printer with cartridges -40 to 43.3° C (-40 to 110.0° F) Printer without cartridges -40 to 43.3° C (-40 to 110.0° F) Air relative humidity Relative Humidity 8 to 80% Altitude 10,300 meters (34,000 feet) Wet bulb temperature—power off 26.70° C (80.10° F) Maximum * In some cases, performance specifications (such as paper OCF, EP cartridge usage) are specified to be
measured at an ambient condition.
General information 1-7
Page 26
5025-2xx, 4xx
Media handling
Input and output sources
Sheet numbers are assuming 20 lb. xerographic paper
Standard input sources
Standard input tray (250-sheet tray) 250 sheets 250 sheets 250 sheets Manual feed slot (1-sheet) 1 sheet 1 sheet 1 sheet Second tray capacity (650-sheet Duo
Drawer) Multipurpose try capacity (650-sheet Duo
Drawer)
Optional input sources (maximum 1, total of all inputs is 4)
a
650-sheet duo drawer (includes 100-sheet MP feeder)
Maximum total input capacity 901 901 901
Duplex
Standard output sources (no optional output sources are available)
Standard 100-sheet bin 100 100 100
a In the 650-sheet duo drawer, the 550-sheet tray and the integrated MP feeder count as two independent
input sources. The MF feeder is configured as “cassette” does not show up as Configure MP in the Paper Menu.
Lexmark C540n, C544n
N/A N/A 550 sheets
N/A N/A 100 sheets
550 sheets
(or 100 sheets in
MP feeder)
N/A Duplex
Lexmark C543dn, C544dn, C544dw
550 sheets
(or 100 sheets in
MP feeder)
Lexmark C544dtn (C544dn with second tray)
0
Duplex capability
—Supported—Not supported
Models
Lexmark C540n Lexmark C543dn
Lexmark C544n
Lexmark C544dn
Lexmark C544dw
Duplex capability
1-8 Service Manual
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5025-2xx, 4xx
Media input size specifications
—Supported without size
sensing
—Not supported
(in the
a
Input source
A4 210 x 297mm
A5a 148 x 210mm
A6 ✘✘
JISb B5a 182 x 257mm
JISb B4 ✘✘✘✘✘
Letter 8.5 x 11 in.
Legal 8.5 x 14 in.
Executive 7.25 x 10.5 in.
Oficio (Mexico)
Foliod 8.5 x 13 in.
Statement 5.5 x 8.5 in. ✘✘
Universalc
148 x 210mm to
215.9 x 355.6mm (5.83 x 8.27 in. to
8.5 x 14 in.)
d
250-sheet tray
Optional 650-sheet
duo drawer
MP feeder
650-sheet duo drawer)
Manual slot
Duplex
✔✔✔✔✔
✔✔✔✔
✔✘
✔✔✔✔✔
✔✔✔✔✔
✔✔✔✔✔
✔✔✔✔
✔✔✔✔
✔✔✔✔
✔✔
✔✔✔✔
76.2.x 127mm to
215.9 x 355.6mm (3 x 5 in. to 8.5 x 14 in.)
210mm x 279.4mm to
215.9mm x 355.6mm (8.27 in. x 11 in. to
8.5 in. to 14 in.)
7¾ Envelopea 98.4 x 190.5mm ✘✘
9 Envelopea ✘✘
10 Envelopea 104.8 x 241.3mm
(4.12 x 9.5 in.)
DL Envelopea 110 x 220mm
(4.33 x 8.66 in.)
C5 Envelopea 162 x 229mm
(6.38 x 9.01 in.)
✔✔✔✔
✘✘
✘✘
✘✘✔✔
✔✔
✔✔
✔✔
✔✔
✔✔
General information 1-9
Page 28
5025-2xx, 4xx
—Supported without size
sensing
—Not supported
(in the
a
Input source
B5 Envelopea ✘✘✔✔
Other envelopea
Length: 98.4–431.8mm (3.8–17 in.) Width: 89–297mm (3.5–11.7 in.)
a
The MP feeder runs slower if A5, statement, B5, or envelopes are loaded.
b
Japanese Industry Standard.
c
Although the user may select Universal paper size for these sources, not all tray guides can be adjusted to all Universal media sizes.
d
If a source supports size sensing and this feature is activated, then neither Oficio or Folio appear in the list of supported media sizes. These values only appear in a list of supported media sizes when the source is non-size sensing or the size sensing is deactivated.
Media input type specifications
—Supported —Not supported
Input type
250-sheet tray
Optional 650-sheet
duo drawer
✘✘
250-sheet tray
Optional
650-sheet
Duo Drawer
MP feeder
650-sheet duo drawer)
Manual slot
✔✔
a
MP feeder
(in 650-sheet
Duo Drawer)
Manual feeder
Duplex
Duplex
Plain paper ✔✔✔✔✔
Card stock ✔✔✔✔
Transparency ✔✔✔✔
Recycled
Glossy ✔✔✔✔✔
Heavy glossy
Paper-backed labels ✔✔✔✔
Bond ✔✔✔✔✔
Envelopes
Rough envelopes ✘✘✔✔
Letterhead ✔✔✔✔✔
Preprinted ✔✔✔✔✔
1-10 Service Manual
b
✔✔✔✔✔
✘✘✘✘✘
✘✘✔✔
Page 29
5025-2xx, 4xx
—Supported —Not supported
Input type
Colored paper ✔✔✔✔✔
Light paper ✔✔✔✔✔
Heavy paper ✔✔✔✔✔
Rough or cotton ✔✔✔✔✔
Custom type <x>
a
For MP feeder and manual feeders, the Default Source Menu displays Manual Paper and Manual Env. Select Manual Env. for envelopes or when the type in Custom Type <x> is an envelope. For other types, use Manual Paper.
b
The duplex unit supports this media type as long as the customer has selected the custom type from those types the duplex unit supports.
b
Media output size and type
There is a single 100-sheet output bin available for this printer and no additional output options.
a
250-sheet tray
✔✔✔✔✔
Optional
650-sheet
Duo Drawer
MP feeder
(in 650-sheet
Duo Drawer)
Manual feeder
Duplex
Weight ranges for each media type
Material Type Weight Select
2, 5, 7, 8
Paper
Specialty papers Gloss Book 88 to 176 g/m
Card stock—upper limit (grain long)
Card Stock—upper limit (grain short)
Transparency Labels—upper limit Paper 131 g/m
Xerographic or
6
business paper
Gloss Cover 162 to 176 g/m Index Bristol 120 g/m2 (67 lb)
1
Tag 120 g/m Cover 135 g/m Index Bristol 163 g/m2 (90 lb)
1
Tag 163 g/m Cover 176 g/m
Laser printer 170 to 180 g/m2 (45 to 48 lb bond)
60 to 74. 9 g/m2 grain long (16 to 19.9 lb bond)
75 to 89.9 g/m (20 to 23.8 lb bond)
90. to 104.9 g/m (23.9 to 27.8 lb bond)
105 to 176 g/m (27.9 to 47 lb bond)
2
(74 lb)
2
(50 lb)
2
(100 lb)
2
(65 lb)
2
(35 lb bond)
2, 5
2
grain long
2
grain long
2
grain long
7
2
grain long (60 to 120 lb book)
2
grain long (60 to 65 lb cover)
Light Paper
Plain Paper
Heavy Paper
Card stock
General information 1-11
Page 30
5025-2xx, 4xx
Material Type Weight Select
Envelopes (Multipurpose
feeder or manual slot only)
1
For 60 to 176 g/m2 paper, grain long fibers are recommended.
2
Paper less than 75 g/m2 (20 lb) must be printed with Paper Type set to Light Paper.
3
100% cotton content maximum weight is 24 lb bond.
4
28 lb bond envelopes are limited to 25% cotton content.
5
The duplex unit supports paper weights between 60–105 g/m2 (16–28 pound) grain long bond. The duplex
unit does not support card stock, transparencies, envelopes, or labels.
6
Lexmark transparency part numbers 12A8240 and 12A8241 are supported from the standard tray, manual slot, and the multi-purpose feeder.
7
Paper 90 to 104.9 g/m2 (23.9 to 27.8 lb) must be printed with Paper Type set to Heavy Paper.
8
Paper 105 to 176 g/m2 (27.9 to 47 lb) must be printed with Paper Type set to Cardstock.
Sulfite, wood-free or up to 100% cotton bond
60 to 105 g/m
2
to 28 lb bond)
3, 4
Media guidelines
Paper characteristics
The following paper characteristics affect print quality and reliability. Consider these characteristics when evaluating new paper stock.
Weight—The printer can automatically feed paper weights from 60 to 176 g/m
long. Paper lighter than 75 g/m performance, use 80 g/m in.), we recommend 90 g/m
2
(20 lb) might not be stiff enough to feed properly, causing jams. For best
2
(21 lb bond) grain long paper. For paper smaller than 182 x 257 mm (7.2 x 10.1
2
or heavier paper.
Curl—Curl is the tendency for paper to curl at its edges. Excessive curl can cause paper feeding
problems. Curl can occur after the paper passes through the printer, where it is exposed to high temperatures. Storing paper unwrapped in hot, humid, cold, or dry conditions, even in the trays, can contribute to paper curling prior to printing and can cause feeding problems.
Smoothness—Paper smoothness directly affects print quality. If paper is too rough, toner cannot fuse to it
properly. If paper is too smooth, it can cause paper feeding or print quality issues. Always use paper between 100 and 300 Sheffield points; however, smoothness between 150 and 200 Sheffield points produces the best print quality.
Moisture content—The amount of moisture in paper affects both print quality and the ability of the printer
to feed the paper correctly. Leave paper in its original wrapper until it is time to use it. This limits the exposure of paper to moisture changes that can degrade its performance. Condition paper before printing by storing it in its original wrapper in the same environment as the printer for 24 to 48 hours before printing. Extend the time several days if the storage or transportation environment is very different from the printer environment. Thick paper may also require a longer conditioning period.
Grain direction—Grain refers to the alignment of the paper fibers in a sheet of paper. Grain is either grain
long, running the length of the paper, or grain short, running the width of the paper. For 60 to 176 g/m to 47 lb bond) paper, use grain long fibers.
Fiber content—Most high-quality xerographic paper is made from 100% chemically treated pulped wood.
This content provides the paper with a high degree of stability resulting in fewer paper feeding problems and better print quality. Paper containing fibers such as cotton possesses characteristics that can negatively affect paper handling.
2
(16 to 47 lb bond) grain
2
(16
Unacceptable paper
The following paper types are not recommended for use with the printer:
Preprinted papers with chemicals that may contaminate the printer
Preprinted papers that can be affected by the temperature in the printer fuser
Coated papers (erasable bond), synthetic papers, thermal papers
Rough-edged, rough or heavily textured surface papers, or curled papers
1-12 Service Manual
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5025-2xx, 4xx
Recycled papers containing more than 25% post-consumer waste that do not meet DIN 19 309, and
weighing more than 80 g/m
Paper weighing less than 80 g/m
2
2
(21 lb)
Multiple-part forms or documents
Selecting paper
Using appropriate paper prevents jams and helps ensure trouble-free printing. To help avoid jams and poor print quality:
Always use new, undamaged paper.
Before loading paper, know the recommended print side of the paper. This information is usually indicated
on the paper package.
Do not use paper that has been cut or trimmed by hand.
Do not mix paper sizes, types, or weights in the same source; mixing results in jams.
Do not use coated papers unless they are specifically designed for electrophotographic printing.
Selecting preprinted forms and letterhead
Use these guidelines when selecting preprinted forms and letterhead:
Use grain long for 60 to 176 g/m
2
weight paper.
Use only forms and letterhead printed using an offset lithographic or engraved printing process.
Avoid papers with rough or heavily textured surfaces.
Use papers printed with heat-resistant inks designed for use in xerographic copiers. The ink must be able to withstand temperatures up to 200° C (392° F) without melting or releasing hazardous emissions. Use inks that are not affected by the resin in toner. Inks that are oxidation-set or oil-based generally meet these requirements; latex inks might not. When in doubt, contact the paper supplier.
Preprinted papers such as letterhead must be able to withstand temperatures up to 200° C (392° F) without melting or releasing hazardous emissions.
Storing paper
Use these paper storage guidelines to help avoid jams and uneven print quality:
For best results, store paper where the temperature is 21°C (70°F) and the relative humidity is 40%. Most
label manufacturers recommend printing in a temperature range of 18 to 24°C (65 to 75°F) with relative
humidity between 40 and 60%.
Store paper in cartons when possible, on a pallet or shelf, rather than on the floor.
Store individual packages on a flat surface.
Do not store anything on top of individual paper packages.
Using recycled paper and other office papers
As an environmentally conscious company, Lexmark supports the use of recycled office paper produced specifically for use in laser (electrophotographic) printers. In 1998, Lexmark presented to the US government a study demonstrating that recycled paper produced by major mills in the US fed as well as non-recycled paper. However, no blanket statement can be made that all recycled paper will feed well. Lexmark consistently tests its printers with recycled paper (20–100% post-consumer waste) and a variety of test paper from around the world, using chamber tests for different temperature and humidity conditions. Lexmark has found no reason to discourage the use of today's recycled office papers, but generally the following property guidelines apply to recycled paper.
Low moisture content (4–5%)
Suitable smoothness (100–200 Sheffield units, or 140–350 Bendtsen units, European)
Note: Some much smoother papers (such as premium 24 lb laser papers, 50–90 Sheffield units) and
much rougher papers (such as premium cotton papers, 200–300 Sheffield units) have been engineered to
General information 1-13
Page 32
5025-2xx, 4xx
work very well in laser printers, despite surface texture. Before using these types of paper, consult your paper supplier.
Suitable sheet-to-sheet coefficient of friction (0.4–0.6)
Sufficient bending resistance in the direction of feed
Recycled paper, paper of lower weight (<60 g/m paper that is cut grain-short for portrait (or short-edge) fed printers may have lower bending resistance than is required for reliable paper feeding. Before using these types of paper for laser (electrophotographic) printing, consult your paper supplier. Remember that these are general guidelines only and that paper meeting these guidelines may still cause paper feeding problems in any laser printer (for example, if the paper curls excessively under normal printing conditions).
2
[16 lb bond]) and/or lower caliper (<3.8 mils [0.1 mm]), and
Tools required for service
Flat-blade screwdrivers, various sizes #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade Long-shank Phillips screwdriver at least 8 in. or 200 mm long, preferably magnetized 7/32 inch (5.5 mm) open-end wrench
7.0 mm nut driver Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax/serial debug cable 1381963 Coax/serial debug cable 1381964 Flashlight (optional)
1-14 Service Manual
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5025-2xx, 4xx
Acronyms
ACM Autocompensator Mechanism (paper pick mechanism) BLDC Brushless DC Motor BOR Black Only Retract CCyan DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory EEPROM Electrically Erasable Programmable Read-Only Memory EP ElectroPhotographic ESD Electrostatic Discharge FRU Field Replaceable Unit GB Gigabyte HVPS High-Voltage Power Supply ITU Image Transfer Unit IU Imaging Unit JIS Japanese Industry Standard KBlack LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light-Emitting Diode LVPS Low-Voltage Power Supply M Magenta MPF Multipurpose Feeder (also MP feeder) NVRAM Nonvolatile Random Access Memory PC Photoconductor pixel Picture elements (same as pel) POR Power-On Reset POST Power-On Self Test PWM Pulse Width Modulation RIP Raster Imaging Processor ROM Read Only Memory SDRAM Synchronous Dual Random Access Memory SIMM Single Inline Memory Module TDS Toner Density Sensor (see Toner Patch Sensor) TPS Toner Patch Sensor (also referred to as Toner Density Sensor) V ac Volts alternating current V dc Volts direct current YYellow
General information 1-15
Page 34
5025-2xx, 4xx
1-16 Service Manual
Page 35
5025-2xx, 4xx
2. Diagnostic information
Start
CAUTION
Unplug power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals.
Begin here to locate the service error code, user status message, user error message, symptom table, service checks, and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer. They will lead you to solutions or service checks, including use of various tests.
Does the POR stop? Check the “POR (Power-On Reset) sequence” on page 2-2.
Do you have a symptom, rather than an error message? Locate your symptom and take the appropriate
action:
“Printer symptom table” on page 2-3“Print quality symptom table” on page 2-4
Do you have an error message or persistent user message, check the following:“Service error messages” on page 2-12“User status and customer attendance messages” on page 2-5“Paper Jam messages” on page 2-11“Paper jams” on page 3-28“Service checks” on page 2-24 for individual error messages
Additional information can be found at the following locations:“User operator panel and Administration menus” on page 2-55“Theory of operation” on page 3-33
Diagnostic information 2-1
Page 36
5025-2xx, 4xx
POR (Power-On Reset) sequence
The following is an example of the events that occur during the POR sequence for the base machine with no paper handling options installed.
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 turns on.
2. The main fan turns on.
3. The operator panel turns on.
4. A partial row of pixels appears.
5. The operator panel display clears.
6. Another row of pixels appears.
7. The operator panel display clears again.
8. The operator panel displays system information. For example:
*128MB 500Mhz
9. The fuser turns on. The fuser takes longer to warm up from a cold start than a warm start.
10. The operator panel LED starts blinking.
11. The following errors or messages may appear:
Close Door or Insert Cartridge displays if the upper front cover is open or the print cartridge is
missing.
Any cartridge errors, such as Defective Cartridge or Missing Cartridge.
12. Ready appears on the display.
13. The main drive motor turns on.
14. The EP drive assembly drives the developer shaft located in the toner cartridge.
15. The printer calibrates.
2-2 Service Manual
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5025-2xx, 4xx
Symptom tables
Printer symptom table
Symptom Action
Dead printer Go to “Dead printer service check” on page 2-28. Operator panel—one or more buttons do
not work. Operator panel—display is blank. Printer
may sound five beeps. Operator panel continuously displays all
diamonds and does not complete POST. Operator panel display is dim and
unchanging. Pages print blank after replacing the
controller board.
Tray linking does not work. • Check that the same size and type of paper are in each tray.
Unexpected page breaks occur. • Increase the Print Timeout value on the operator panel
Multipurpose feeder has constant misfeeds or jams.
Page that jammed does not reprint after you clear the jam.
Go to “One or more operator panel buttons fail” on
page 2-36.
Go to “Operator panel display blank, five beeps” on
page 2-37.
Go to “Operator panel displays all diamonds, no beeps” on
page 2-39.
Go to “Operator panel display is dim and unchanging” on
page 2-41.
When replacing the controller board, verify the cable from the high-voltage power supply is seated properly. The cable may have come loose from the HVPS.
Warning: A blank page that should have toner on it could be an indication that toner is applied to the ITU belt but not transferred. Therefore the toner goes into the ITU cleaner which cannot process massive amounts of toner. It is important to prevent extensive blank pages from being processed if they should have toner on them.
• Check the location of the paper guides.
• The multipurpose feeder does not automatically sense the paper size. You must set the size from the Paper Size/Type menu.
• Print a menu settings page and compare the settings for each tray, and adjust on the operator panel, if necessary.
To print a menu settings page:
1. Press Menu ( ) on the operator panel.
2. Select Reports from the Admin Menu, and press Select
().
3. Select Menu Settings, and press Select ().
(Settings–>General Settings–>Timeouts–>Print Timeout.)
• Remove and flex the paper in the tray. Reload the paper, and try printing.
• Remove the paper, turn it over and place it back in the tray.
• Make sure the feeder is properly installed.
• Make sure the paper is loaded correctly in the tray.
• Make sure the paper is not damaged.
• Make sure the paper meets specifications. See “Media
handling” on page 1-8.
• Make sure the paper guides are positioned correctly for the paper size loaded in the tray.
Jam Recovery may be set to Off. Change the setting to Auto or On on the operator panel (Settings–>General settings–>Print Recovery–>Jam Recovery.)
Diagnostic information 2-3
Page 38
5025-2xx, 4xx
Print quality symptom table
Symptom Action
Background Go to “Print quality—background” on page 2-43. Blank page Go to “Print quality—blank page” on page 2-44. Blurred or fuzzy print Go to “Print quality—blurred or fuzzy print” on page 2-45. Half-color page Go to “Print quality—half-color page” on page 2-45. Horizontal banding Go to “Print quality—horizontal banding” on page 2-46. Horizontal line Go to “Print quality—horizontal line” on page 2-46. Insufficient fusing Go to “Print quality—insufficient fusing” on page 2-47. Missing image at edge Go to “Print quality—missing image at edge” on page 2-47. Mottle (2–5mm speckles) Go to “Print quality—mottle (2–5mm speckles)” on
Narrow vertical line Go to “Print quality—narrow vertical line” on page 2-48. Random marks Go to “Print quality—random marks” on page 2-48. Residual image Go to “Print quality—residual image” on page 2-49. Solid color page Go to “Print quality—solid color page” on page 2-50. Vertical banding Go to “Print quality—vertical banding” on page 2-50. Color matching problems See “Color theory” on page 3-45. Light print on solids See “Media guidelines” on page 1-12.
page 2-47.
2-4 Service Manual
Page 39
5025-2xx, 4xx
Error codes and messages
User status and customer attendance messages
User primary message
Calibrating The printer is performing a color adjustment. Close Door Message clears when front cover, right cover, and toner door are closed or securely
Check Config ID The printer configuration ID is invalid. Check Model Name Message clears when a valid model name is set. Check Serial Num Message clears when a valid serial number is set. Defragmenting Flash
DO NOT POWER OFF
Formatting Flash DO NOT POWER OFF
Insert Tray <x> This message is displayed when the printer requests the user to insert tray x before it
Install Tray <x> or Cancel job
Invalid Engine Code The engine code is invalid. Invalid Network Code The network code is invalid. Load <source>
<custom string>
Load <source> <custom type>
Load <source>
ze>
<si
Load <source> <type> <size>
Explanation
fastened.
The printer is performing the defragmentation operation of flash memory. Wait for the message to clear.
Warning: Do not turn the printer off while this message appears on the display. Wait for the message to appear. Warning: Do not turn the printer off while this message appears on the display.
can continue printing the job. The printer needs to pick media from the missing tray or the trays below it.
Tray x=Tray 1 or Tray 2 Note: This message displays when refilling the trays during a job. Before filling a tray,
take the printer offline by pressing Stop ( ), and wait for pages to stop feeding into the output bin.
The following actions can be taken:
• Insert the requested tray.
•Press Stop ( ), and then press Select ( ) to cancel printing.
Printer detects that tray <x> is missing, where x is 1 or 2. This message appears if the job was begun, but the paper has not yet been retrieved. The tray is no longer detected. Replace the indicated tray.
Printer does not detect media meeting the description <custom string> in <source>, where <source> is Tray 1, Tray 2, or multipurpose feeder.
• Load the input source with the correct type and size media.
•Press Stop ( ), and then press Select ( ) to cancel printing.
Printer does not detect media meeting the description <custom type> in <source>, where <source> is Tray 1, Tray 2, or multipurpose feeder.
• Load the input source with the correct type and size media.
•Press Stop ( ), and then press Select ( ) to cancel printing.
Printer does not detect media meeting the size requested in the source indicated.
• Load the input source with the correct type and size media.
•Press Stop ( ), and then press Select ( ) to cancel printing.
Printer does not detect media meeting the size or type requested in the source indicated.
• Load the input source with the correct type and size media.
•Press Stop ( ), and then press Select ( ) to cancel printing.
Diagnostic information 2-5
Page 40
5025-2xx, 4xx
User primary message
Load Manual <custom string>
Load Manual <custom type>
Load Manual <size>
Load Manual <type> <size>
PJL ST Message Try one or more of the following:
Programming Code The printer is receiving a file that is a code update. Do not power off. Wait for the
Programming Flash Fonts and macros are being written to flash. Do not power off. Wait for the message
Replace <color> Cartridge
Remote Management Active
Remove Paper Standard Bin
emove Packaging
R Material
Std Bin Full Empty the standard exit bin to clear the message and continue printing. Toner Low Try one or more of the following:
Tray <x> Empty Load the paper tray or other source with the correct paper type and size. Tray <x> Low Load the paper tray or other source with the correct paper type and size. Tray <x> Missing Insert the specified tray into the printer. Unplug and Change
Mode
Explanation
Printer does not detect media meeting the description <custom string> in the single sheet feeder (manual feeder).
The following actions can be taken:
• Load paper, press Select ( ), and the job continues.
•Press Select ( ) to override the source, and an alternate source for media is
selected.
•Press Stop ( ), and then press Select ( ) to cancel printing.
Printer does not detect media meeting the description <custom type> in the single sheet feeder (manual feeder).
The following actions can be taken:
• Load paper and the job continues.
•Press Select ( ), and choose an alternate source for media.
•Press Stop ( ), and then press Select ( ) to cancel printing.
Printer does not detect media meeting the description <size> in the single sheet feeder (manual feeder).
The following actions can be taken:
• Load paper and the job continues.
•Press Select ( ), and choose an alternate source for media.
•Press Stop ( ), and then press Select ( ) to cancel printing.
Printer does not detect media meeting the description <type> and <size> in the single sheet feeder (manual feeder).
The following actions can be taken:
• Load paper and the job continues.
•Press Select ( ), and choose an alternate source for media.
•Press Stop ( ), and then press Select ( ) to cancel printing.
•Press Select ( ) to clear the message, and continue printing.
• Wait for the message to clear.
message to clear to continue printing.
to clear to continue printing. Replace the toner cartridge of the indicated color. The printer continues after the
toner door is closed. The printer is offline while it configures settings. Do not power off. Wait for the
message to clear to continue printing. The standard output bin is full or nearly full. Remove the media from the bin.
Packaging material is detected by the printer. Remove the packaging material, and press Select ( ). If all the packaging material is removed, then the printer resumes.
•Press Select ( ) to clear the message, and continue printing.
• Replace the indicated toner cartridge, and then close the toner door.
Camera is not in a proper mode to use the PictBridge feature. Unplug the camera cable to the printer, and change the camera mode.
2-6 Service Manual
Page 41
5025-2xx, 4xx
User primary message
Unsupported USB Device, Please Remove
Unsupported USB HUB, Please Remove
30.xx <color> Cartridge Missing
31.xx Defective <color> Cartridge
31.xx Defective Imaging Kit
32.xx Unsupported <color> Cartridge
34 Short Paper • Make sure the print job is requesting the correct size of paper.
37 Insufficient Memory to Collate Job
37 Insufficient Memory for Flash Memory Defragment Operation
Explanation
Remove the unrecognized device from the USB port on the front of the printer.
Remove the unrecognized USB hub from the USB port on the front of the printer.
The specified toner cartridge is missing. Re-install the missing toner cartridge to clear the message, and then continue printing. If the message recurs remove and re-install the cartridge. Listen for the click to ensure the cartridge is installed properly. Close the front cover.
The specified cartridge is defective. Try one of the following:
• Open and close the top cover.
• Remove and re-install the cartridge(s). Listen for the click to ensure the cartridge is installed properly.
• Turn the printer power off and turn the printer power on.
If the message persists, replace the cartridge with a new one, and close the front cover.
Defective imaging kit. Try one or more of the following:
• Open and close the top cover.
• Remove and re-install the cartridge(s). Listen for the click to ensure the cartridge is installed properly.
• Turn the printer power off, and then turn the printer power on.
If the message persists, determine if the imaging kit counter indicates it is time for replacement. Print the Menu Setting page, and look on the last page. It will indicate OK, Replace Black, or Replace Black and Color. If the indicator says Replace Black or Replace Black and Color, then replace the appropriate kit. See “Imaging unit
(IU) removal” on page 4-35. If the indicator says OK, replace only the
photoconductor unit. Keep the developers from the original unit and reinstall them in the new photoconductor unit.
Remove the specified cartridge, replace with a supported cartridge, and close the front cover.
• Check tray length and width guides to ensure paper is properly fitted in the tray.
• Adjust the Paper Size setting for the size paper you are using. If MP Feeder Size is set to Universal, make sure the paper is large enough for the
formatted data.
•Press Select ( The printer does not automatically reprint the page that prompted the message.
•Press Stop ( ), and then press Select ( ) to cancel printing.
This message is displayed when the printer memory used to store pages is too full to collate the print job.
Try one of the following:
•Press Select ( ) to clear the message and continue printing.
•Press Stop ( ), and then press Select ( ) to cancel printing.
This message is displayed when insufficient printer memory is available to perform Flash Memory Defragment operation.
This message appears prior to the actual start of the defragment operation. Press Select ( ) to stop the defragment operation. To perform the defragment operation, you can:
• Delete fonts, macros, and other data in RAM.
• Install additional printer memory.
•Press Stop ( ), and then press Select ( ) to cancel printing.
) to clear the message and continue printing.
Diagnostic information 2-7
Page 42
5025-2xx, 4xx
User primary message
38 Memory Full This message is displayed when the printer is processing an incoming job and there
39 Complex Page This message is displayed when a page is too complex to print.
40 <color> Invalid Refill Change Cartridge
50 PPDS Font Error This error only occurs when a printer is formatting PPDS print data.
51 Defective Flash Detected
52 Flash Full Not enough free space in flash memory for resources.
53 Unformatted Flash Detected
Explanation
is not enough memory available to continue processing the job. The following actions can be taken:
• Determine how to make more memory available to your print job by:
- Deleting fonts and other data in RAM.
- Simplify your print job by reducing the amount of text or graphics on a page.
- Install additional memory
•Press Select ( ) to clear the message and continue printing.
The job may not print correctly.
•Press Stop ( ), and then press Select ( ) to cancel printing.
The following actions can be taken:
•Press Select ( ) to clear the message and continue printing.
The job may not print correctly.
• Simplify the print job by reducing the amount of text or graphics on a page.
•Press Stop ( ), and then press Select ( ) to cancel printing.
Replace the toner cartridge with a new one.
The PPDS interpreter has detected a font error. When a specific font, which is not installed, is requested based on a PPDS mode Set Font Global command, a Select Code Page command, or a Comprehensive Font Selection command, and the printer Best Fit setting is off. If Best Fit is on, the printer performs a best fit search to find a similar font, and this error does not occur.
This error also displays when the printer receives invalid PPDS download font data. Try one or more of the following:
•Press Select ( ) to clear the message and continue printing.
The job may not print correctly.
• The printer cannot find the requested font. From the PPDS menu, select Best Fit, and then select On. The printer will find a similar font and reformat the affected text.
•Press Stop ( ), and then press Select ( ) to cancel printing.
Press Select () You must install different flash memory before you can download any resources to
flash.
Try one or more of the following:
•Press Select ( ) to clear the message and continue printing.
• Delete fonts, macros, and other data stored on the flash memory.
• Install a larger capacity flash memory card.
Try one or more of the following:
•Press Select ( ) to clear the message and continue printing.
• Format the flash memory before you store any resources on it. If the error message remains, the flash memory may be defective and require
replacing.
to clear the message and continue printing.
2-8 Service Manual
Page 43
5025-2xx, 4xx
User primary message
54 Standard Network Software Error
54 Network <x> Software Error
56 Standard USB Port Disabled
58 Too many Flash Options Installed
58 Too Many Trays Installed
59 Incompatible Tray <x>
82 Replace Waste Toner
82 Waste Toner Nearly Full
82 Waste Toner Missing
Explanation
The printer detects a network port, but cannot communicate with it. The printer disables all communication to the associated network interface.
Try one or more of the following:
•Press Select ( ) to clear the message and continue printing.
The job may not print correctly.
• Upgrade the network firmware in the printer or the print server.
• Turn the printer power off and then back on to reset the printer.
The printer disables all communications to the associated network interface. No data may be received or sent from or to the associated interface.
•Press Select ( ) to clear the message and continue printing.
The job may not print correctly.
• Turn the printer power off and then back on to reset the printer.
• Upgrade the network firmware in the printer or the print server.
This message may appear when data is sent to the printer across a USB port, but the port is disabled.
Note: Once the error is displayed the first time, reporting of further errors is suppressed until the printer is reset or menus are entered.
The following actions can be taken:
•Press Select ( ) to clear the message.
Any data received on the USB port is discarded.
•Press Menus ( ) to access the Administrative Menus.
Make sure the USB Buffer menu item is not set to Disabled. (Press Menus () to access the Administrative Menus, select Network/Ports, USB Menu, and USB Buffer.)
Too many optional flash memory cards or optional firmware cards are installed on the printer.
1. Turn off and unplug the printer.
2. Remove the excess flash memory or optional firmware cards.
3. Plug in the printer, and turn it on.
Too many tray are installed.
1. Turn off and unplug the printer.
2. Remove the additional trays.
3. Plug in the printer, and turn it on.
1. Turn off and unplug the printer.
2. Remove the specified incompatible tray.
3. Plug in the printer, and turn it on.
Replace the waste toner bottle to clear the message and continue printing. See
“Waste toner bottle removal” on page 4-60.
Note: The printer will not continue until the waste toner bottle is replaced.
Try one or more of the following:
• Replace the waste toner bottle, and then press Select ( ) to clear the message and continue printing. See “Waste toner bottle removal” on page 4-60.
•Press Select ( ) to clear the message and continue printing.
• Order the waste toner bottle so it will be available when the replacement message is displayed. Once the replacement message is displayed, the printer will not continue until the waste toner is replaced.
Install a waste toner bottle, and then press Select ( ) to clear the message and continue printing. See “Waste toner bottle removal” on page 4-60.
Diagnostic information 2-9
Page 44
5025-2xx, 4xx
User primary message
88 <color> Cartridge Low
88 Replace <color> Cartridge
Explanation
The term <color> includes black, cyan, magenta, and yellow. The cartridge Try one or more of the following:
• Replace the toner cartridge, and then close the toner door to clear the message and continue printing.
•Press Select ( ) to clear the message and continue printing.
The term <color> includes black, cyan, magenta, and yellow. Replace the toner cartridge, and then close the toner door to continue printing.
2-10 Service Manual
Page 45
5025-2xx, 4xx
Paper Jam messages
Paper jam messages (2xx)
Error code Description Action
200.xx Paper Jam Check <area>
200.xx Paper Jam <x> Pages Jammed
201.xx Paper Jam Check <area>
201.xx Paper Jam <x> Pages Jammed
202.xx Paper Jam Check <area>
202.xx Paper Jam <x> Pages Jammed
230.xx Paper Jam Check <area>
230.xx Paper Jam <x> Pages Jammed
A single page of media jam at the input sensor.
Multiple pages of media are jammed at the input sensor.
A single page of media is jammed between the input and exit sensors.
Multiple pages of media are jammed between the input and exit sensors.
A single page of media is jammed at the exit sensors.
Multiple pages of media are jammed at the exit sensor.
A single page of media is jammed at the inner door.
Multiple pages of media are jammed at the inner door.
Pull out tray 1, and then remove the jammed page. See “200 paper jams” on
page 3-30.
Pull out tray 1 and open the front door to remove all the jammed pages. See “200
paper jams” on page 3-30.
Open the front door and then remove the jammed page. See “201 paper jam” on
page 3-30.
Open the front door, and then remove all the jammed pages. See “201 paper jam”
on page 3-30.
Open the front door to access the jam area. Remove the jammed page. See “202
paper jam” on page 3-31.
Open the front door to access the jam area. Remove all the jammed pages. See
“202 paper jam” on page 3-31.
Open the front door, and then remove the jammed page. See “230 paper jam” on
page 3-32.
Open the front door, and then remove all the jammed pages. See “230 paper
on page 3-32.
jam”
24x.xx Paper Jam Check <area>
24x.xx Paper Jam <x> Pages Jammed
250.xx Paper Jam Check Manual Feeder
250.xx Paper Jam <x> Pages Jammed
A single or multiple page media jam in the 650-sheet duo drawer (tray 2).
Multiple pages of media are jammed in the 650-sheet duo drawer (tray 2).
A single page of media is jammed in the multipurpose feeder.
Multiple pages of media are jammed in the multipurpose feeder.
See “24x paper jam” on page 3-32.
Pull the tray out and remove all the jams. See “24x paper jam” on page 3-32.
Open tray 2 to access the jam area. Remove the jammed page. See “250
paper jam” on page 3-32.
Open tray 2 to access the jam area. Remove all the jammed pages. See “250
paper jam” on page 3-32.
Diagnostic information 2-11
Page 46
5025-2xx, 4xx
Service error messages
Service error messages (1xx, 9xx)
Error code Description Action
106.xx Service Yellow Printhead
106.01 Service Yellow Printhead
106.02 Service Yellow Printhead
106.03 Service Yellow Printhead
106.04 Service Yellow Printhead
106.05 Service Yellow Printhead
106.06 Service Yellow Printhead
106.07 Service Yellow Printhead
Yellow printhead error. Perform a POR. If the problem persists, go
The yellow printhead lost HSYNC. Perform a POR. If the problem persists, go
The yellow printhead failed to complete servo.
The yellow printhead mirror motors failed to achieve lock.
The yellow printhead mirror motors lost motor lock.
Failure reading NVRAM from printhead.
The yellow printhead thermistor is open.
The yellow printhead thermistor is shorted to ground.
to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
106.08 Service Yellow Printhead
106.09 Service Yellow Printhead
106.10 Service Yellow Printhead
106.11 Service Yellow Printhead
10
6.12 Service
Yellow Printhead
106.13 Service Yellow Printhead
107.xx Cyan Printhead Error
107.01 Service Cyan Printhead
The yellow laser showed bad in testing. Perform a POR. If the problem persists, go
SOS/EOS measurement did not complete.
Bad SOS/EOS measurement. Perform a POR. If the problem persists, go
Failure writing data tot he printhead. Perform a POR. If the problem persists, go
Failure reading data from the printhead.
Printhead declared error. Perform a POR. If the problem persists, go
Cyan printhead error. Perform a POR. If the problem persists, go
The cyan printhead lost HSYNC. Perform a POR. If the problem persists, go
to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
.
2-12 Service Manual
Page 47
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code Description Action
107.02 Service Cyan Printhead
107.03 Service Cyan Printhead
107.04 Service Cyan Printhead
107.05 Service Cyan Printhead
107.06 Service Cyan Printhead
107.07 Service Cyan Printhead
107.08 Service Cyan Printhead
107.09 Service Cyan Printhead
The cyan printhead failed to complete servo.
The cyan printhead mirror motors failed to achieve lock.
The cyan printhead mirror motors lost motor lock.
Failure reading NVRAM from the cyan printhead.
The cyan printhead thermistor is open. Perform a POR. If the problem persists, go
The cyan printhead thermistor is shorted to ground.
The cyan laser showed bad in testing. Perform a POR. If the problem persists, go
SOS/EOS measurement did not complete.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
107.10 Service Cyan Printhead
107.11 Service Cyan Printhead
107.12 Service Cyan Printhead
107.13 Service Cyan Printhead
108.
xx Se
Magenta Printhead
108.01 Service Magenta Printhead
108.02 Service Magenta Printhead
108.03 Service Magenta Printhead
rvice
Bad SOS/EOS measurement. Perform a POR. If the problem persists, go
Failure writing data tot he printhead. Perform a POR. If the problem persists, go
Failure reading data from the printhead.
Printhead declared error. Perform a POR. If the problem persists, go
Magenta printhead error. Perform a POR. If the problem persists, go
The magenta printhead lost HSYNC. Perform a POR. If the problem persists, go
The magenta printhead failed to complete servo.
The magenta printhead mirror motors failed to achieve lock.
to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Diagnostic information 2-13
Page 48
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code Description Action
108.04 Service Magenta Printhead
108.05 Service Magenta Printhead
108.06 Service Magenta Printhead
108.07 Service Magenta Printhead
108.08 Service Magenta Printhead
108.09 Service Magenta Printhead
108.10 Service Magenta Printhead
108.11 Service Magenta Printhead
The magenta printhead mirror motors lost motor lock.
Failure reading NVRAM from the magenta printhead.
The magenta printhead thermistor is open.
The magenta printhead thermistor is shorted to ground.
The magenta laser showed bad in testing.
SOS/EOS measurement did not complete.
Bad SOS/EOS measurement. Perform a POR. If the problem persists, go
Failure writing data tot he printhead. Perform a POR. If the problem persists, go
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
108.12 Service Magenta Printhead
108.13 Service Magenta Printhead
109.xx Service Black Printhead
109.01 Service Black Printhead
10
9.02 Service
Black Printhead
109.03 Service Black Printhead
109.04 Service Black Printhead
109.05 Service Black Printhead
Failure reading data from the printhead.
Printhead declared error. Perform a POR. If the problem persists, go
Black printhead error. Perform a POR. If the problem persists, go
The black printhead lost HSYNC. Perform a POR. If the problem persists, go
The black printhead failed to complete servo.
The black printhead mirror motors failed to achieve lock.
The black printhead mirror motors lost motor lock.
Failure reading NVRAM from printhead.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
2-14 Service Manual
Page 49
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code Description Action
109.06 Service Black Printhead
109.07 Service Black Printhead
109.08 Service Black Printhead
109.09 Service Black Printhead
109.10 Service Black Printhead
109.11 Service Black Printhead
109.12 Service Black Printhead
109.13 Service Black Printhead
The black printhead thermistor is open. Perform a POR. If the problem persists, go
The black printhead thermistor is shorted to ground.
The black laser showed bad in testing. Perform a POR. If the problem persists, go
SOS/EOS measurement did not complete.
Bad SOS/EOS measurement. Perform a POR. If the problem persists, go
Failure writing data tot he printhead. Perform a POR. If the problem persists, go
Failure reading data from the printhead.
Printhead declared error. Perform a POR. If the problem persists, go
to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
Perform a POR. If the problem persists, go to “Printhead service check” on
page 2-51.
to “Printhead service check” on
page 2-51.
122.xx Service Fuser Error
122.01 Service Fuser Error
122.02 Service Fuser Error
122.03 Service Fuser Error
122.04 Service Fuser Error
122.05 Service Fuser Error
122.06 Service Fuser Error
122.11 Service Fuser Error
122.12 Service Fuser Error
122.13 Service Fuser Error
122.14 Service Fuser Error
Fuser error Go to “Fuser service check” on
Attempting to print with estimated power at or below minimum power.
Fuser over temperature. Go to “Fuser service check” on
Fuser open thermistor check failed. Go to “Fuser service check” on
Fuser reached start temperature too quickly.
Fu
ser failed to reach final temperature
in time.
Estimated power is at or below minimum power.
Fuser under temperature error while in standby.
Fuser under temperature error while printing.
Fuser open thermistor check failed for second thermistor.
Fuser shorted thermistor check failed for hot roll thermistor.
page 2-32.
Go to “Fuser service check” on
page 2-32.
page 2-32.
page 2-32.
Go to “122.xx—Fuser temperature
incorrect” on page 2-24.
Go to “122.xx—Fuser temperature
incorrect” on page 2-24.
Go to “122.xx—Fuser temperature
incorrect” on page 2-24.
Go to “Fuser service check” on
page 2-32.
Go to “Fuser service check” on
page 2-32.
Go to “Fuser service check” on
page 2-32.
Go to “Fuser service check” on
page 2-32.
Diagnostic information 2-15
Page 50
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code Description Action
122.15 Service Fuser Error
122.16 Service Fuser Error
141.xx Service Staging Motor
141.01 Service Staging Motor
141.02 Service Staging Motor
141.03 Service Staging Motor
141.04 Service Staging Motor
141.05 Service Staging Motor
150.xx Service Black/ITU cartridge Motor
150.01 Service Black/ITU cartridge Motor
Fuser storted thermistor check failed for second thermistor
Estimated power is at or above maximum power.
Staging motor error. Go to “Autocompensator mechanism
Staging motor has exceeded the ramp up table.
Staging motor has exceeded number of encoders at minimum PWM.
Staging motor has exceeded number of encoders at maximum PWM.
Motor encoder count did not change between interrupts.
Staging motor has encountered a stall timeout.
Black/ITU Cartridge Motor Go to “Main drive gear assembly (EP
Failed to achieve lock for motor within allotted time.
Go to “Fuser service check” on
page 2-32.
Go to “Fuser service check” on
page 2-32.
service check” on page 2-27.
Go to “Autocompensator mechanism
service check” on page 2-27.
Go to “Autocompensator mechanism
service check” on page 2-27.
Go to “Autocompensator mechanism
service check” on page 2-27.
Go to “Autocompensator mechanism
service check” on page 2-27.
Go to “Autocompensator mechanism
service check” on page 2-27.
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
150.02 Service Black/ITU cartridge Motor
150.03 Service Black/ITU cartridge Motor
15
0.04 Service Black/ITU cartridge Motor
150.05 Service Black/ITU cartridge Motor
150.06 Service Black/ITU cartridge Motor
150.07 Service Black/ITU cartridge Motor
152.xx Service Cyan Cartridge Motor
152.01 Service Cyan Cartridge Motor
152.02 Service Cyan Cartridge Motor
Timeout waiting for SAP BLDC motor to reach valid FG speed.
Timeout waiting for MP_NUM_INITIAL_SAP_HALLS.
Timeout waiting for SAP BLDC motor FG.
Lost lock for motor. Go to “Main drive gear assembly (EP
Excessive SAP BLDC PWM. Go to “Main drive gear assembly (EP
Motor stalled in time-based commutation.
Failed to achieve lock for motor within allotted time.
Timeout waiting for SAP BLDC motor to reach valid FG speed.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
drive) service check” on page 2-35.
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
2-16 Service Manual
Page 51
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code Description Action
152.03 Service Cyan Cartridge Motor
152.04 Service Cyan Cartridge Motor
152.05 Service Cyan Cartridge Motor
152.06 Service Cyan Cartridge Motor
152.07 Service Cyan Cartridge Motor
153.xx Service Magenta Cartridge Motor
153.01 Service Magenta Cartridge Motor
153.02 Service Magenta Cartridge Motor
153.03 Service Magenta Cartridge Motor
153.04 Service Magenta Cartridge Motor
Timeout waiting for MP_NUM_INITIAL_SAP_HALLS.
Timeout waiting for SAP BLDC motor FG.
Lost lock for motor. Go to “Main drive gear assembly (EP
Excessive SAP BLDC PWM. Go to “Main drive gear assembly (EP
Motor stalled in time-based commutation.
Failed to achieve lock for motor within allotted time.
Timeout waiting for SAP BLDC motor to reach valid FG speed.
Timeout waiting for MP_NUM_INITIAL_SAP_HALLS.
Timeout waiting for SAP BLDC motor FG.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
drive) service check” on page 2-35.
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
153.05 Service Magenta Cartridge Motor
153.06 Service Magenta Cartridge Motor
153.07 Service Magenta Cartridge Motor
154.xx Service Yellow Cartridge Motor
154.01 Service Yellow Cartridge Motor
154.02 Service Yellow Cartridge Motor
154.03 Service Yellow Cartridge Motor
Lost lock for motor. Go to “Main drive gear assembly (EP
Excessive SAP BLDC PWM. Go to “Main drive gear assembly (EP
Motor stalled in time-based commutation.
Failed to achieve lock for motor within allotted time.
Timeout waiting for SAP BLDC motor to reach valid FG speed.
Timeout waiting for MP_NUM_INITIAL_SAP_HALLS.
drive) service check” on page 2-35.
drive) service check” on page 2-35.
Go
to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Diagnostic information 2-17
Page 52
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code Description Action
154.04 Service Yellow Cartridge Motor
154.05 Service Yellow Cartridge Motor
154.06 Service Yellow Cartridge Motor
154.07 Service Yellow Cartridge Motor
900.xx Service RIP Software
902.xx Service Engine Software
903.xx Service Engine Software
904.xx Service Engine Software
905.xx Service Engine Software
906.xx Service Engine Software
Timeout waiting for SAP BLDC motor FG.
Lost lock for motor. Go to “Main drive gear assembly (EP
Excessive SAP BLDC PWM. Go to “Main drive gear assembly (EP
Motor stalled in time-based commutation.
Unrecoverable RIP software error/ illegal trap.
A general engine software error. Go to “90x.xx error” on page 2-24.
A paperport link driver error. Go to “90x.xx error” on page 2-24.
An interface violation by RIP. Go to “90x.xx error” on page 2-24.
An interface violation by paperport device.
A RIP interface driver error. Go to “90x.xx error” on page 2-24.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
drive) service check” on page 2-35.
drive) service check” on page 2-35.
Go to “Main drive gear assembly (EP
drive) service check” on page 2-35.
Go to “90x.xx error” on page 2-24.
Go to “90x.xx error” on page 2-24.
910.xx Service DC Pick Motor
911.xx Service DC Pick Motor
912.xx Service DC Pi
ck Motor
913.xx Service DC Pick Motor
914.xx Service PC Pick Motor
917.xx Service Transfer Roll
925.01 Service Fan Stalled
927.xx Service Fan Stalled
The DC pick motor stalled. Go to “Autocompensator mechanism
The DC pick motor has excessive PWM.
The DC pick motor is below speed. Go to “Autocompensator mechanism
The DC pick motor over speed. Go to “Autocompensator mechanism
The DC pick has no encoder feedback. Go to “Autocompensator mechanism
There is a problem with the transfer roll.
The printer fan has stalled. Go to “925.01—Fan error service check”
The printer fan has stalled.
service check” on page 2-27.
Go to “Autocompensator mechanism
service check” on page 2-27.
service check” on page 2-27.
service check” on page 2-27.
service check” on page 2-27.
Go to “Transfer roll service check” on
page 2-53.
on page 2-25.
2-18 Service Manual
Page 53
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code Description Action
929.xx Service Toner Sensor
930.xx Service LVPS Error
931.xx Service Printhead Error
932.xx Service Printhead Error
933.xx Service Printhead Error
935.xx Service Printhead Error
936.xx Service Transport Motor
937.xx Service Transport Motor
940.xx Service LV Power Supply
The printer doesn't register a transition on the toner sensor for a set period of time. Either the printer's toner sensor is faulty or its print cartridge is defective.
The LVPS did not detect zero crossing.
There is no first HSYNC. Go to “930.xx–935.xx—Printhead errors
The HSYNCs are lost. Go to “930.xx–935.xx—Printhead errors
Mirror motor is locked. No HSYNC received.
Mirror motor is unable to reach operating speed.
The transport motor had an initial lock failure.
The transport motor lost lock. Go to “936.xx, 937.xx—Transport motor
A RIP to engine communication failure. The zero crossing signal used for fuser control in the low-voltage (LV) power supply has failed, or the wrong low­voltage power supply has been installed.
The Servicer should follow these steps to resolve this problem:
• Use the base sensor test in Diagnostics Menu to inspect the toner sensor's operation.
• If the toner sensor is operating correctly, then the problem is the print cartridge.
service check” on page 2-25.
service check” on page 2-25.
Go to “930.xx–935.xx—Printhead errors
service check” on page 2-25.
Go to “930.xx–935.xx—Printhead errors
service check” on page 2-25.
Go to “936.xx, 937.xx—Transport motor
service check” on page 2-26.
service check” on page 2-26.
Replace the low-voltage power supply. See “Low-voltage power supply (LVPS)
assembly removal” on page 4-37.
940.0x Service Cyan TMC Sensor
94
1.0x Service Magenta TMC Sensor
942.0x Service Yellow TMC Sensor
943.0x Service Black TMC Sensor
948.xx Service Engine Card
949.xx Service Engine Card
The cyan cartridge toner meter cycle (TMC) switch error.
The magenta cartridge toner meter cycle (TMC) switch error.
The yellow cartridge toner meter cycle (TMC) switch error.
The black cartridge toner meter cycle (TMC) switch error.
The pel clock check failed. If this error message persists, replace the
Delay line calibration failure If this error message persists, replace the
Go to “Toner meter sensors (Y, C, M, K)
on TMC card” on page 2-52
Go to “Toner meter sensors (Y, C, M, K)
on TMC card” on page 2-52.
Go to “Toner meter sensors (Y, C, M, K)
on TMC card” on page 2-52.
Go “Toner meter sensors (Y, C, M, K) on
TMC card” on page 2-52.
controller board. See “Controller board
removal” on page 4-19.
controller board. See “Controller board
removal” on page 4-19.
Diagnostic information 2-19
.
Page 54
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code Description Action
950.xx Service NVRAM Failure
951.xx Service NVRAM Failure
952.xx Service NVRAM Failure:n
953.xx Service NVRAM Failure
954.xx Service NVRAM Failure
955.xx Service Code CRC <loc>
There is a mismatch between controller EEPROM and mirror.
• 950.00 through 950.29 codes: mismatch between controller and mirror
• 950.30 through 950.60 codes: mismatch between secure and controller
Mismatch between controller EEPROM and mirror.
• 951.00 through 951.29 codes: mismatch between controller and mirror
• 951.30 through 951.60: mismatch between secure and controller
A recoverable MVRAM Cyclic Redundancy Check (CRC) error occurred. n is the offset at which the error occurred.
NVRAM chip failure with mirror.
The NVRAM chip failure with controller part.
The Code ROM or NAND flash failed the Cyclic Redundancy Check (CRC) check or the NAND experienced an uncorrectable multi-bit failure. <loc> indicates the source of the failure and has one of the following values:
CRC Failure: The source is a failing package indicated by Pn where n is the package number. This error could occur on a controller with ROM or NAND flash and could occur as a result of the CRC check done when the machine is powered on. The range of package numbers is from 0 to
15.
Error Correction Code (ECC) Failure: The source is a failing page indicated by Bn where “n” is the page number. This error occurs only if a multi-bit failure is detected during the ECC execution. Single bit failures will be corrected automatically and will not result in a service error. The range of page numbers is from 0 to 1023.
Go to “950.xx NVRAM Failure service
check” on page 2-26.
Performing a POR will clear this error.
956.00 Service System Board
956.01 Service System Board
2-20 Service Manual
Controller board failure. Processor
ilure.
fa
Processor over temperature. Replace the controller board. See
Replace the controller board. See
“Controller board removal” on page 4-19.
“Controller board removal” on page 4-19.
Page 55
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code Description Action
957.xx Service System Board
958.xx Service NAND Failure
959.01 Service Invalid Firmware
959.02 Service Invalid Firmware
959.03 Service Invalid Firmware
959.04 Service Invalid Firmware
959.05 Service Invalid Firmware
959.20 Service System Board
959.21 Service System Board
Controller board failure. ASIC failure.
Printer has performed more than 100 “shift and reflash” operations as a result of ECC bit corrections.
Controller verification failure of system boot code
Failure to authenticate Signature Verification Code.
Signature verification Code failure to authenticate a code partition.
Jump to unverified address. Update firmware or replace the controller
Unknown Boot Failure. Update firmware or replace the controller
System hardware failure. Replace the controller board. See
System did not respond to command request.
Update firmware or replace the controller board. See “Controller board removal”
on page 4-19.
Update firmware or replace the controller board. See “Controller board removal”
on page 4-19.
Update firmware or replace the controller board. See “Controller board removal”
on page 4-19.
board. See “Controller board removal”
on page 4-19.
board. See “Controller board removal”
on page 4-19.
“Controller board removal” on page 4-19.
Replace the controller board. See
“Controller board removal” on page 4-19.
959.22 Service System Board
959.23 Service System Board
959.24 Service System Board
959.25 Service System Board
959.26 Service System Board
959.27 Service System Board
959.28 Service System Board
Challenge Secret Failure. ASIC/SP mismatch. Replace the controller
System self test failure during initialization.
EEPROM Retention Error (write failure)
Insufficient device space during hardware programming.
I
ncremental counter reset exceeds
maximum value.
Increment count failed due to maximum value limit.
Invalid SP memory configuration. Replace the controller board. See
board. See “Controller board removal”
on page 4-19.
Replace the controller board. See
“Controller board removal” on page 4-19.
Replace the controller board. See
“Controller board removal” on page 4-19.
Replace the controller board. See
“Controller board removal” on page 4-19.
Replace the controller board. See
“Controller board removal” on page 4-19.
Replace the controller board. See
“Controller board removal” on page 4-19.
“Controller board removal” on page 4-19.
Diagnostic information 2-21
Page 56
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code Description Action
960.xx Service Memory Error
961.xx Service Memory Failure
962.xx Service Memory Failure
964.xx Service Emulation Error
975.xx Service Standard Network
or
975.xx Service Network Card x
976.xx Service Standard Network
or
976.xx Service Network Card x
RAM memory error: RAM soldered on the board is bad.
RAM memory error: slot 1 RAM is bad. Replace the controller board. See
RAM memory error: slot 2 RAM is bad. Replace the controller board. See
Download emulation cyclic redundancy check (CRC) failure has occurred. A checksum failure detected in the emulation header or emulation file.
Network error: unrecognizable network port.
Unrecoverable software or error in network or network card x.
Replace the controller board. See
“Controller board removal” on page 4-19.
“Controller board removal” on page 4-19.
“Controller board removal” on page 4-19.
The following actions may be taken:
1. Disable the Download Emulation.
2. Program the download emulation into the code overlay SIMM again.
3. If the problem is not resolved replace the code overlay SIMM, and download emulation again.
Replace the standard network card or the card in the specified slot.
If unable to clear the error message, check the following:
• If installed, check network card for correct installation.
• If correctly installed, replace the network card.
• If a network card is not installed, replace the controller board.
978.xx Service Standard Network
or
978.xx Service Network Card x
979.xx Service Standard Network
or
979.xx Service Network Card x
2-22 Service Manual
Bad checksum while programming Standard Network or Network Card x port.
Flash parts failed while programming the Standard Network or Network Card x port.
Check the following:
• Make sure you have downloaded the code in binary mode, not ASCII.
• Reprogram the Network card.
• If the problem persists, and if installed, check the network card for correct installation.
• If correctly installed, replace the network card.
f a network card is not installed, replace
I the controller board.
Check the following:
• If installed, check the network card for correct installation.
• If correctly installed, replace the network card.
• If a network card is not installed, replace the controller board.
Page 57
5025-2xx, 4xx
Service error messages (1xx, 9xx) (continued)
Error code Description Action
980.xx Service <device> Comm.
981.xx Service <device> Comm.
982.xx Service <device> Comm.
983.xx Service <device> Comm.
Engine is experiencing unreliable communications with the specified device.
Note: <device> can be one of the following:
• Duplex unit.
•Tray 2.
Engine protocol violation detected by the specified device.
Note: <device> can be one of the following:
• Duplex unit.
•Tray 2.
Communications error detected by the specified device.
Note: <device> can be one of the following:
• Duplex unit.
•Tray 2.
Invalid command received by the specified device.
Note: <device> can be one of the following:
• Duplex unit.
•Tray 2.
984.xx Service <device> Comm.
990.xx Service <device>
991.xx Service evice> Card
<d
Invalid command parameter received by the specified device.
Note: <device> can be one of the following:
• Duplex unit.
•Tray 2.
This error message indicates that an equipment check condition has occurred in the specified device, but the device is unable to identify the exact component failure.
Note: <device> can be one of the following:
• Duplex unit.
•Tray 2.
The specified device has detected an equipment check in its controller board.
Go to the service check for the device indicated.
Diagnostic information 2-23
Page 58
5025-2xx, 4xx
Service checks
122.xx—Fuser temperature incorrect
This service check covers fuser temperature errors, including 122.xx.
Step Questions / actions Yes No
1 Check the clearance around the printer. See
“Clearances” on page 1-5 or check the chart
below:
Description Dimensions
Rear 102 mm (4 in.) Front 508 mm (20 in.) Right side 152 mm (6 in.) Left side 76 mm (3 in.) Above 254 mm (10 in.)
Does the error clear?
Check the fuser connections on the fuser, at
2
JFUSES1 on the controller board, and the AC connection at the LVPS.
Are the connections correct?
Turn the printer on, and then check the
3
following values at JFUSES1.
JFUSES1
Pin Value
5 Between +0.6 V dc and +3.28 V dc 6 Ground 8 Ground
9 +3.3 V dc 10 Between +0.6 V dc and +3.15 V dc 11 Ground
Problem resolved. Make sure the proper
Replace the fuser. See
“Fuser assembly removal” on page 4-26.
Replace the fuser assembly. See “Fuser assembly
removal” on page 4-26.
clearance is maintained.
Problem resolved.
Replace the controller board. See “Controller
board removal” on page 4-19.
Are these values approximately correct?
90x.xx error
Step Questions / actions Yes No
1 Turn the printer off, and remove the rear
shield. See “Rear shield removal” on
page 4-11. Check the cable connections.
Are all the cable connections secure?
Replace the controller board. See “Controller
board removal” on page 4-19.
Securely make all the connections. POR the printer.
2-24 Service Manual
Page 59
5025-2xx, 4xx
925.01—Fan error service check
Step Questions / actions Yes No
1 Turn the printer off, and remove the rear
shield. See “Rear shield removal” on
page 4-11. Check the fan cable at JFAN1 for
the following values:
JFAN1
Pin Value
1 +3.3 V dc 2 Ground 3 0 (fan off)
Are the measured values correct?
Replace the top cover (which includes the fan). See “Top cover assembly
removal” on page 4-12.
Replace the controller board. See “Controller
board removal” on page 4-19.
930.xx–935.xx—Printhead errors service check
Step Questions / actions Yes No
1 Turn the printer off, and remove the rear
shield. See “Rear shield removal” on
page 4-11. Check the cables connected at
JMIRR1 and JPH1 on the controller board. Check for damage.
Are the cables damaged?
Turn the printer on, and verify the following
2
values at JMIRR1:
JMIRR1
Pin Value
2 +3.3 V dc 4 Ground 5+24 V dc
Replace the printhead. See
“Printhead removal” on page 4-49.
Replace the printhead. See
“Printhead removal” on page 4-49.
Go to step 2.
Replace the controller board. See “Controller
board removal” on page 4-19.
Are the values approximately correct?
Diagnostic information 2-25
Page 60
5025-2xx, 4xx
936.xx, 937.xx—Transport motor service check
Step Questions / actions Yes No
1 Turn the printer off, and remove the rear
shield. See “Rear shield removal” on
page 4-11. Check the cable at JCARB1 for
proper connection to the controller board. Is the cable properly connected?
Turn the printer on, and ten measure the
2
values of the cable at JCARB1:
JCARB1
Pin Value
4 +24 V dc 6 +24 V dc 8 +24 V dc
9 Ground 12 Ground 13 +24 V dc 15 +24 V dc 17 +24 V dc
Are the values approximately correct?
950.xx NVRAM Failure service check
Reconnect the cable. Go to step 2.
Replace the main drive gear assembly. See “Main drive
gear assembly removal” on page 4-45.
Replace the controller board. See “Controller
board removal” on page 4-19.
Warning: Replace one of the following components, and perform a POR before replacing a second
component. Never replace both of the components without performing a POR after installing each one, or the printer will be rendered inoperable:
Operator panel assembly
Controller board
Warning: Never install and remove components listed above as a method of troubleshooting components.
Once a component has been installed in a printer, and the printer is powered on, it cannot be used in another printer. It must be returned to the manufacturer.
This error code indicates a mismatch between the memory on the operator panel assembly and the one on the controller board.
Step Questions / actions Yes No
1 Have any updates been made to the firmware? Reload the firmware and try
Did reloading the firmware correct the
2
problem?
again. Go to step 2.
Problem resolved. Replace the controller board
Replace the controller board with a new, and not previously installed controller board. See
“Controller board removal” on page 4-19.
with a new, and not previously installed controller board. See
“Controller board removal” on page 4-19.
2-26 Service Manual
Page 61
5025-2xx, 4xx
Autocompensator mechanism service check
Step Questions / actions Yes No
1 Turn the printer off, and then remove the rear
shield. See “Rear shield removal” on
page 4-11. Check the cable at JSP1 on the
controller board for proper connection. Is the cable properly connected?
Did the printer function correctly after
2
reconnecting the cables?
Turn the printer on, and then verify the
3
following approximate values at JSP1:
JSP1
Pin Value Pin Value
2 +24 V dc 10 +5 V dc 4 +24 V dc 13 Ground 6 Ground 15 +5 V dc 7 Ground 16 Ground 8 Ground
Are the values approximately correct?
Go to step 3. Properly connect the cables,
Problem resolved. Go to step 3.
Replace the autocompensator mechanism. See
“Autocompensator mechanism (ACM) removal—standard tray” on page 4-15.
and POR the printer. Go to step 2.
Replace the controller board. See “Controller
board removal” on page 4-19.
Bin full sensor service check
Step Questions / actions Yes No
1 Is the bin full sensor dislodged or damaged? Repair or replace the bin full
Does the flag rotate freely and interrupt the
2
sensor beam when in normal position?
Turn the printer off, and remove the rear
3
shield. See “Rear shield removal” on
page 4-11. Turn the printer on, and then check
the values below at JBIN1:
JBIN1
Pin Value
1 > 0 V dc 2 +3.3 V dc beam blocked
0 V dc unblocked
3 Ground
Are the values correct?
sensor. See “Bin full
sensor removal” on page 4-18.
Go to step 3. Reposition or replace the
Problem resolved. Replace the controller
Go to step 2.
flag.
board. See “Controller
board removal” on page 4-19.
Diagnostic information 2-27
Page 62
5025-2xx, 4xx
Dead printer service check
A dead printer is one which, when powered on from a known good electrical outlet, displays no indication of power to the printer by changes to the LCD, LED, or any movement of the fan or motors. If the printer appears dead but makes a beeping sound, check the operator panel. See “Operator panel display blank, five beeps”
on page 2-37.
If a 650-sheet duo drawer is installed, remove the option and check the base printer for correct operation. If the base printer operates correctly, replace the 650-sheet duo drawer.
Warning: Observe all necessary ESD precautions when removing and handling the controller 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 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.
Remove any input paper-handling options from the printer.
Step Questions / actions Yes No
1 Check the AC line voltage.
Is the line voltage correct?
Is the AC line cord damaged? Replace the line cord. Go to step 3.
2
Is the LVPS cable correctly connected at
3
JLVPS1 on the controller board?
Turn the printer off, and then on.
4
Does the problem persist?
Warning: Damage to the printer is possible.
5
Be careful to touch only one conductor at a time. Rest the probe against the connector to steady it.
With the printer on, verify the following values at JLVPS1:
JLVPS1 (exposed conductors)
Pin Value Pin Value
1 +5 V dc 7 +24 V dc 3 +5 V dc 9 +24 V dc 5 +5 V dc 11 +24 V dc
Are the values approximately correct?
Go to step 2. Inform the customer.
Go to step 5. Reconnect the cable at
Go to step 5. Problem resolved.
Replace the controller board. See “Controller
board removal” on page 4-19.
JLVPS1, and then go to step 4.
Replace the LVPS. See
“Low-voltage power supply (LVPS) assembly removal” on page 4-37.
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Duplex/manual feed sensor (S1) service check
Step Questions / actions Yes No
1 Is the printer setting on a hard, flat surface? Go to step 2. Make sure the printer is
Enter Diagnostics Menu (turn the printer off,
2
press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).
Perform the Base Sensor Test. See “Base
Sensor Test” on page 3-16.
1. Select Base Sensor Test, and press Select ().
2. Select S1, and press Select ().
3. Install tray 1.
Does the display indicate InputS1—Media Clear…?
Pull tray 1 out.
3
Does the display indicate InputS1Media Present…?
Remove the tray, and inspect the sensor.
4
Is there something obstructing the sensor?
Inspect the spring-loaded shaft/flag in the tray.
5
The flag portion of the shaft intercepts the sensor, except when a sheet is being staged for duplexing.
Does the shaft rotate freely and return to home position (flag at top of rotation)?
Go to step 3. Go to step 5.
The sensor is functioning correctly.
Remove the obstruction, and restart the test.
Go to step 6. Replace the tray with a new
setting on a level, flat surface.
Go to step 4.
Go to step 5.
one.
Is the flag on the shaft broken? Replace the tray. Go to step 7.
6
Verify the cable is correctly connected to
7
JFUSES1 on the controller board and to the sensor.
Is the sensor cable properly connected?
Turn the printer off, and remove the rear
8
shield. See “Rear shield removal” on
page 4-11. Turn the printer on, and check the
values at JFUSES1:
JFUSES1
Pin Value
8 Ground 9 +3.3 V dc
Are the values approximately correct?
Go to step 8. Reconnect the cable.
If the problem persists, go to step 8.
Replace the duplex sensor. See “Duplex sensor
removal” on page 4-21.
Replace the controller board. See “Controller
board removal” on page 4-19.
Diagnostic information 2-29
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Front door sensor or switches service check
Step Questions / actions Yes No
1 Enter Diagnostics Menu (turn the printer off,
press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).
Perform the Base Sensor Test. See “Base
Sensor Test” on page 3-16.
1. Select Base Sensor Test, and press Select ().
2. Select Front Door, and press Select ().
3. Open and close the front door, and observe the display.
Does the display indicate Value Closed with the door closed and Value Opened with the door opened?
Open the front door, and check the thin, tall,
2
plastic web (pivot plate) at the top right of the printer. With the other covers in place and closed, this web interacts with switches in the door.
Open the toner cover, and check the motion of the web. Is the web loose, damaged, or missing?
Open the toner door, and inspect the vertical
3
web that pushes and rotates the pivot plate. Is it damaged?
Sensor, toner door, and right doors are OK.
Replace the right cover assembly. See “Right
cover assembly removal” on page 4-10.
Replace the top cover assembly. See “Top cover
assembly removal” on page 4-12.
Go to step 2.
Go to step 3.
Go to step 4.
With the front cover open, inspect the two
4
switches. Using a tool, such as a spring hook, push the metal arms to check the movement.
Is there any damage to the switches or the surrounding area?
Turn the printer off, and remove the rear
5
shield. See “Rear shield removal” on
page 4-11. Turn the printer on, and verify the
following values at JINT1 and JCVR1:
JINT1 JCVR1
Pin Value Pin Value
1 +5 V dc 1 +24 V dc 2 Ground
Are the values approximately correct?
Replace the right cover assembly. See “Right
cover assembly removal” on page 4-10.
Go to step 6. Replace the controller
Go to step 5.
board. See “Controller
board removal” on page 4-19.
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Step Questions / actions Yes No
Close the front cover and the toner door. Be
6
sure the right cover is in place. Turn the printer off, and then disconnect the cables at JINT1 and JCVR1. Test continuity at the connector under the following conditions:
With front cover and toner door closed:
Test pin 1 and pin 3 at JINT1 cable end and pin 1 and pin 2 at JCVR1 cable end.
With one or both doors open:
Pin 2 and 3 at JINT1 cable end should indicate continuity, but pins 1 and 2 at JCVR1 should have no continuity.
Are the tests verified?
Contact your next level of support.
Replace the front cover assembly. See “Front
cover assembly removal” on page 4-2.
Fuser exit sensor service check
Step Questions / actions Yes No
1 Enter Diagnostics Menu (turn the printer off,
press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).
Perform the Base Sensor Test. See “Base
Sensor Test” on page 3-16.
1. Select Base Sensor Test, and press Select ().
2. Select Fuser Exit Sensor, and press Select ().
3. Open and close the front door, and inspect the fuser exit sensor located on the LVPS shield.
Is the sensor dislodged or damaged?
Correct the sensor, or replace it. See “Fuser exit
sensor removal” on page 4-30.
Go to step 2.
Rotate the flag (paper diverter) in and out of
2
the sensor. Does the display indicate Media Clear and
Media Present with the cycle?
Does the flag rotate freely, but return to block
3
the sensor?
Turn the printer off, and then remove the rear
4
shield. See “Rear shield removal” on
page 4-11.
Is the cable correctly connected to JBIN1 on the controller board and to the sensor?
Sensor is good. Go to step 3.
Go to step 4. Replace the fuser. See
“Fuser assembly removal” on page 4-26.
Go to step 5. Reconnect the cable.
Diagnostic information 2-31
Page 66
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Step Questions / actions Yes No
Turn the printer on, and check the values at
5
JBIN1:
JBIN1
Pin Value
4 +5 V dc 5 +0 V dc (no media), +3.3 V dc (media) 6 Ground
Are the values correct?
Replace the fuser exit sensor. See “Fuser exit
sensor removal” on page 4-30.
Replace the controller board. See “Controller
board removal” on page 4-19.
Fuser service check
Step Questions / actions Yes No
1 Some low-voltage power supply FRUs have a
voltage selector switch. If it does, the switch needs to be set to the correct voltage for your area.
Check the switch on the side of the LVPS to verify the correct voltage is set.
Go to step 2.
Has the LVPS been changed?
Turn the printer off, and remove the rear
2
shield. See “Rear shield removal” on
page 4-11. Check the cable at JFUSES1 for
proper connection to the controller board, the cable for pinch points, and the cable or connector for any other damage.
Is the cable damaged?
Check the connector JLVPS1 for proper
3
connection to the controller board, the cable for pinch points, and the cable or connector for any other damage.
Is the cable damaged?
Check the power cable on the left side of the
4
fuser and the thermistor cables and connections on the right side of the fuser.
Are the cables or connectors damaged?
Replace the fuser cable. Go to step 3.
Repair or replace the LVPS cable.
Repair the cables. If the cables cannot be repaired, replaced the fuser. See
“Fuser assembly removal” on page 4-26.
Go to step 4.
Go to step 5.
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Step Questions / actions Yes No
Check the following values at JFUSES1:
5
JFUSES1
Pin Value
5 +3.3 V dc 6 Ground
8 Ground 10 +2.7 V dc 11 Ground
Are the values approximately correct?
Replace the fuser. See “Fuser assembly
6
removal” on page 4-26.
Does the error clear?
Go to step 6. Replace the controller
board. See “Controller
board removal” on page 4-19.
Problem resolved. Replace the controller
board. See “Controller
board removal” on page 4-19.
Diagnostic information 2-33
Page 68
5025-2xx, 4xx
Input sensor (S2) service check
The Input sensor (S2) is part of the ACM FRU.
Step Questions / actions Yes No
1 Enter Diagnostics Menu (turn the printer off,
press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).
Perform the Base Sensor Test. See “Base
Sensor Test” on page 3-16.
1. Select Base Sensor Test, and press Select ().
2. Select S2, and press Select ().
3. Pull tray 1 out, and rotate the S2 sensor flag (S2 is located in front of the center autocompensator mechanism housing.) It should rotate freely and return to its original position.
Is the input (S2) sensor flag damaged?
Watch the display while rotating the flag.
2
Does the display indicate Media Clear and Media Present?
Turn the printer off, and remove the rear
3
shield. See “Rear shield removal” on
page 4-11.
Is the JSP1 cable connector properly connected to the controller board?
Turn the printer on, and check the voltage at
4
JSP1 pin 15. Is the voltage approximately +5 V dc?
Replace the autocompensator mechanism. See
“Autocompensator mechanism (ACM) removal—standard tray” on page 4-15.
Problem resolved. Go to step 3.
Go to step 4. Reseat the connector.
Replace the autocompensator mechanism. See
“Autocompensator mechanism (ACM) removal—standard tray” on page 4-15.
Go to step 2.
Replace the controller board. See “Controller
board removal” on page 4-19.
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Main drive gear assembly (EP drive) service check
Step Questions / actions Yes No
1 Turn the printer off, and remove the rear
shield. See “Rear shield removal” on
page 4-11. Check the cable at JCARTB1 for
proper connection to the controller board, the cable for pinch points, and the cable or connector for any other damage.
Is the cable damaged?
Verify the following values at JCARTB1 on the
2
controller board.
JCARTB1
Pin Value
4 +24 V dc 6 +24 V dc 8 +24 V dc
9 Ground 12 Ground 13 +24 V dc 15 +24 V dc 17 +24 V dc
Are the values approximately correct?
Replace the main drive assembly. See “Main
3
drive gear assembly removal” on page 4-45.
Does the error clear?
Replace the JCARTB1 cable.
Go to step 3. Replace the controller
Problem resolved. Replace the controller
Go to step 2.
board. See “Controller
board removal” on page 4-19.
board. See “Controller
board removal” on page 4-19.
Diagnostic information 2-35
Page 70
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Operator panel service check
Warning: Replace one of the following components, and perform a POR before replacing a second
component. Never replace both of the components without performing a POR after installing each one, or the printer will be rendered inoperable:
Operator panel assembly
Controller board
Warning: Never install and remove components listed above as a method of troubleshooting components.
Once a component has been installed in a printer, and the printer is powered on, it cannot be used in another printer. It must be returned to the manufacturer.
One or more operator panel buttons fail
Step Questions / actions Yes No
1 Enter Diagnostics Menu (turn the printer off,
press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).
Perform the Panel Test. See “Panel Test” on
page 3-11. The Panel Test should show
alternating display of all pixels on, and all pixels off. Press Stop to end the test.
Did the test show errors on the display?
Perform the Button Test. See “Button Test”
2
on page 3-12 in Diagnostics Menu.
Did any of the buttons fail the test?
Remove the rear shield. “Rear shield
3
removal” on page 4-11.
Turn the printer on, and verify the following values at JOPP1:
JOPP1
Pin Value
2 +5 V dc 4 Ground 5 +5 V dc 6 +3.3 V dc 7 Ground
Replace the operator panel assembly. See “Operator
panel removal” on page 4-9.
Replace the operator panel assembly. See “Operator
panel removal” on page 4-9.
Replace the operator panel. See “Operator panel
removal” on page 4-9.
If this does not fix the problem, replace the front cover assembly which contains the operator panel cables. See “Front cover
assembly removal” on page 4-2.
Go to step 2.
Go to step 3.
Replace the controller board. See “Controller
board removal” on page 4-19.
Are the values approximately correct?
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Operator panel display blank, five beeps
Service tip: The printer has detected a problem with the controller board, the operator panel assembly cable (part of the front cover assembly), or the operator panel assembly if POST does not complete. The printer emits five beeps, and sticks in a continuous pattern until the printer is turned off.
Step Questions / actions Yes No
1 Is the operator panel assembly cable properly
installed at controller board JOPP1 and at the operator panel assembly?
Turn the printer off, and remove the rear
2
shield. See “Rear shield removal” on
page 4-11.
Turn the printer on, and verify the following values at JOPP1:
JOPP1
Pin Value
2 +5 V dc 4 Ground 5 +5 V dc 6 +3.3 V dc 7 Ground
Are the values approximately correct?
Check continuity of the operator panel
3
assembly cable. Is there continuity?
Go to step 2. Reinstall the cable.
Go to step 3. Replace the controller
Replace the operator panel assembly. See “Operator
panel removal” on page 4-9.
board. See “Controller
board removal” on page 4-19.
Replace the front cover assembly. See “Front
cover assembly removal” on page 4-2.
Diagnostic information 2-37
Page 72
5025-2xx, 4xx
Operator panel display blank, printer beeps five times and pauses
Step Questions / actions Yes No
1 Turn the printer off, and remove the rear
shield. See “Rear shield removal” on
page 4-11.
Turn the printer on, and verify the following values at JOPP1 on the controller board:
JOPP1
Pin Value
10 V dc 2 +5 V dc 30 V dc 4 Ground 5 +5 V dc 6 +3.3 V dc 7 Ground
Are all these values approximately correct?
Turn the printer off, and check for continuity in
2
the operator panel cable. Note: Remove the three screws holding the
operator panel, and place it facedown on top of the printer. The cable connector pins will be exposed and easier to contact.
Do all the conductors indicate continuity?
Go to step 2. Replace the controller
Replace the operator panel. See “Operator panel
removal” on page 4-9.
board. See “Controller
board removal” on page 4-19.
Replace the front cover assembly. See “Front
cover assembly removal” on page 4-2.
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Operator panel displays all diamonds, no beeps
Step Questions / actions Yes No
1 Turn the printer off, and remove the rear
shield. See “Rear shield removal” on
page 4-11.
Disconnect the cable at JOPP1 on the controller board. Verify the following values:
JOPP1
Pin Value
10 V dc 2 +5 V dc 30 V dc 4 Ground 5 +5 V dc 6 +3.3 V dc 7 Ground
Are all these values approximately correct?
Check for continuity in the operator panel
2
cable connector. Note: Remove the three screws holding the
operator panel, and place it facedown on top of the printer. The cable connector pins will be exposed and easier to contact.
Do all the conductors indicate continuity?
Go to step 2. Replace the controller
Replace the operator panel. See “Operator panel
removal” on page 4-9.
board. See “Controller
board removal” on page 4-19.
Replace the front cover assembly. See “Front
cover assembly removal” on page 4-2.
Diagnostic information 2-39
Page 74
5025-2xx, 4xx
Operator panel displays all diamonds, five beeps
Step Questions / actions Yes No
1 Turn the printer off, and remove the rear
shield. See “Rear shield removal” on
page 4-11.
Turn the printer on, and verify the following values at JOPP1:
JOPP1
Pin Value
10 V dc 2 +5 V dc 30 V dc 4 Ground 5 +5 V dc 6 +3.3 V dc 7 Ground
Are all these values approximately correct?
Check for continuity in the operator panel
2
cable connector. Note: Remove the three screws holding the
operator panel, and place it facedown on top of the printer. The cable connector pins will be exposed and easier to contact.
Do all the conductors indicate continuity?
Go to step 2. Replace the controller
Replace the operator panel. See “Operator panel
removal” on page 4-9.
board. See “Controller
board removal” on page 4-19.
Replace the front cover assembly. See “Front
cover assembly removal” on page 4-2.
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Operator panel display is dim and unchanging
Step Questions / actions Yes No
1 Turn the printer off, and remove the rear
shield. See “Rear shield removal” on
page 4-11.
Turn the printer on, and verify the following values at JOPP1 on the controller board:
JOPP1
Pin Value
10 V dc 2 +5 V dc 30 V dc 4 Ground 5 +5 V dc 6 +3.3 V dc 7 Ground
Are all these values approximately correct?
Check for continuity in the operator panel
2
cable connector. Note: Remove the three screws holding the
operator panel, and place it facedown on top of the printer. The cable connector pins will be exposed and easier to contact.
Do all the conductors indicate continuity?
Go to step 2. Replace the controller
Replace the operator panel. See “Operator panel
removal” on page 4-9.
board. See “Controller
board removal” on page 4-19.
Replace the front cover assembly. See “Front
cover assembly removal” on page 4-2.
Diagnostic information 2-41
Page 76
5025-2xx, 4xx
Print quality service check
Note: This symptom may require replacement of one or more CRUs (Customer Replaceable Units) designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission, you may need to install a developer (toner) cartridge or photoconductor unit.
Service tip
Before troubleshooting any print quality problems, do the following:
1. Print a menu settings page, and check the life status of all supplies. Any supplies that are low should be
replaced. To print a menu settings page:
a. Press Menu ( ) on the operator panel. b. Select Reports from the Admin Menu, and press Select (). c. Select Menu Settings, and press Select ().
Note: Be sure and keep the original menu page to restore the customer's custom settings if needed.
2. On the menu page, make sure the following is set to the default level:Color Correction: Set to Auto.Print Resolution: Set to 600 dpi (print quality problems should be checked at different resolution
settings).
Toner Darkness: Set to 4 (default).Color Saver: Set to OFF.RGB Brightness, RGB Contrast, RGB Saturation: Set to 0.Color Balance: Select Reset Defaults to zero out all colors.Check the paper type, texture, and weight settings against what is loaded in the printer.
Once the printer has been restored to its default levels, do the following:
1. Inspect the imaging unit for damage, including the developers and toner cartridges. Replace if damaged.
2. If paper other than 20lb plain letter/A4 paper is being used, load 20lb plain letter/A4.
3. Print the Print Quality pages to see if the problem remains. Look for variations in the print from what is
expected. To print the print Quality pages:
a. Enter Diagnostics (turn the printer off, press and hold Left ( ) and Select ( ), turn the printer on,
and release when the installed memory and processor speed displays).
b. Select PRINT TESTS, and press Select ( ). c. Select Print Quality Pgs, and press Select ().
The message Printing Quality Test Pages is displayed.
An incorrect printer driver for the installed software can cause problems. Incorrect characters could print, and the copy may not fit the page correctly.
Measure all voltages from the connector to the printer ground.
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Print quality—background
Service tip: Some background problems can be caused by using rough paper or incorrectly setting the operator panel settings to rough texture when the texture is not rough. Using non-Lexmark toner cartridges may also cause the problem.
Some slick or coated papers may also cause background problems. Some problems occur by running a large amount of graphics in a humid environment.
Step Questions / actions Yes No
1 Read the current status of the imaging unit
from the customer menus. To view the status of the photoconductor units:
1. In Ready mode, press Menus ().
2. Select Reports, and press Select ( ).
3. Select Device Statistics, and press Select ().
It is possible a new imaging unit was installed, but the counter was not reset.
Has the imaging unit been recently replaced?
Is the background only one of the primary
2
colors; yellow, cyan, magenta, or black?
Did replacing the developer unit correct the
3
problem?
Replace the photoconductor unit.
4
Does this fix the problem?
Check the high-voltage contact from the HVPS
5
to the image transfer unit (ITU). Is a problem found?
Reset the value. To reset this value:
1. In Ready mode, press
Menus ().
2. Select Supplies Menu, and press Select ().
3. Select Replace Supply, and press Select ().
4. Select the imaging unit , and press Select ().
5. Select Yes, and press Select ().
If this does not fix the problem, go to step 2.
Replace the developer unit for the background color and retest. See “Developer
unit removal” on page 4-21.
Go to step 3.
Problem resolved. Go to step 4.
Problem resolved. Go to step 5.
Replace the failing part:
• Image transfer unit
(ITU). See “Image
transfer unit (ITU) removal” on page 4-33.
• High-voltage power supply (HVPS). See
“High-voltage power supply (HVPS) assembly removal” on page 4-31.
Go to step 2.
Go to step 4.
Go to step 6.
Reseat the cable in the JHVPS1 connector.
6
Does this fix the problem?
Replace the HVPS. See “High-voltage power
7
supply (HVPS) assembly removal” on page 4-31.
Does this fix the problem?
Clean the printhead.
8
Does this fix the problem?
Problem resolved. Go to step 7.
Problem resolved. Go to step 8.
Problem resolved. Replace the printhead. See
“Printhead removal” on page 4-49.
Diagnostic information 2-43
Page 78
5025-2xx, 4xx
Print quality—blank page
Step Questions / actions Yes No
1 Is all the packing material for the imaging unit
in question removed?
Print a document that requires all four colors
2
with just a few characters to verify if one specific color is a problem. For example, print the Print Quality Test Pages:
1. Enter Diagnostic mode. (Turn the printer
off, press and hold Left ( ) and Select ( ), turn the printer on, and then release the buttons when the installed memory and processor speed displays.)
2. Select PRINT TESTS, and press Select ().
3. Select Prt Qual Pgs, and press Select ().
Is only one color missing?
Replace the imaging unit. See “Imaging unit
3
(IU) removal” on page 4-35.
Does this fix the problem?
Enter the Diagnostics Menu (turn the printer
4
off, press and hold and , turn the printer on, and release the buttons when installed memory and processor speed displays), and run the appropriate cartridge drive motor test for the missing color:
1. Select MISC TESTS in the Diag Menu, and press Select ().
2. Select Motor Detect. Remove Cartridge. Press Select appears.
Note: Do not press Select yet.
3. Remove all toner cartridges and the imaging unit.
4. Close the front cover. If you press Select before closing the front
cover, a message appears: Close Cover. Press Select.
5. Press Select (). Motor Detection In Progress… appears.
The motor detection process takes about 10 seconds, and stops automatically.
Detect Complete. Rebooting… appears, and the printer performs a POR (Power On Reset).
Did the motor run?
Go to step 2. Remove the packing
Replace the developer unit for the missing color.
Problem resolved. Go to step 4.
Go to step 5. Replace the Main drive gear
material.
Go to step 3.
assembly. See “Main drive
gear assembly removal” on page 4-45.
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Step Questions / actions Yes No
Remove the developer unit. See “Developer
5
unit removal” on page 4-21. Check the
developer cartridge contacts from the HVPS to the IU.
Are all the toner cartridge contacts clean on both the pins and IU?
Are all the spring-loaded pins in the HVPS free
6
to move in and out with an equal amount of spring force?
Turn the printer off, and remove the rear
7
shield. See “Rear shield removal” on
page 4-11. Check the continuity between the
spring-loaded pins and the JSC1 connector on the controller board.
Are all conductors continuous?
Replace the printhead. See “Printhead
8
removal” on page 4-49.
Did this fix the problem?
Go to step 6. Clean the developer
Go to step 7. Replace the HVPS. See
Go to step 8. Replace the cable.
Problem resolved. Replace the controller
Print quality—blurred or fuzzy print
Run the automatic alignment. The TPS sensor may be damaged. To run Reset Color Cal:
cartridge contacts. See
“Developer unit removal” on page 4-21.
“High-voltage power supply (HVPS) assembly removal” on page 4-31.
board. See “Controller
board removal” on page 4-19.
1. Enter the Diagnostics Menu. (Turn the printer off, press and hold and , turn
the printer on, and release the buttons when installed memory and processor speed displays.
2. Select TPS Setup from Diag Menu, and press Select ().
3. Select Reset Color Cal, and press Select ().
Resetting appears. When the reset is complete, the screen is automatically returned to TPS Setup.
Blurred or fuzzy print is usually caused by a problem in the main drive gear assembly or in the image transfer unit (ITU). Check the main drive gear assembly and ITU for correct operation.
Blurred print can also be caused by incorrect feeding from one of the input paper sources, media trays, or duplex paper path.
Check the high-voltage spring contacts to ensure they are not bent, corroded, or damaged. Replace the high­voltage power supply as necessary. See “High-voltage power supply (HVPS) assembly removal” on
page 4-31.
Print quality—half-color page
The imaging unit and developer units may not properly seated. Reseat the imaging unit. If that does not work, remove the imaging unit and reseat each of the developer units.
Diagnostic information 2-45
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Print quality—horizontal banding
Print the Print Defect Page:
1. At the Ready prompt, press Menu ().
2. Select Reports, and press Select ().
3. Select Print Defects, and press Select ().
Step Questions / actions Yes No
1 Measure the distance between repeating
bands. Is the distance between bands either 34.6 or
94.2 mm?
Does the distance measure 95 mm or
2
108 mm?
Does the distance measure 37.7, 55, or
3
78.5 mm?
Does the distance measure 43.9 mm or 45.5? Replace the developers that
4
Replace the photoconductor unit. Remove the imaging unit and remove the original developer units, and then put them back into the new photoconductor unit, and reinstall the imaging unit. See “Imaging unit (IU)
removal” on page 4-35.
Replace the fuser. See
“Fuser assembly removal” on page 4-26.
Replace the ITU. See
“Image transfer unit (ITU) removal” on page 4-33.
match the missing color (black, cyan, magenta, or yellow). See “Developer
unit removal” on page 4-21.
Go to step 2.
Go to step 3.
Go to step 4.
Check the various rollers in the printer for debris.
Print quality—horizontal line
Either the photoconductor unit or one of the developer units that make up the imaging unit is defective. Remove and inspect the imaging unit. Replace the damaged part of the imaging unit. See “Imaging unit (IU) removal”
on page 4-35.
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Print quality—insufficient fusing
Step Questions / actions Yes No
1 Is the printer setup to use the correct media? Go to step 2. Change the settings to
Check the fuser connections on the left and
2
right side of the printer. Are the cables and connection correct?
Is the fuser properly installed? Go to step 4. Install the fuser properly.
3
Replace the fuser. See “Fuser assembly
4
removal” on page 4-26.
Does this fix the problem?
Go to step 3. Properly reconnect or
Problem resolved. Replace the LVPS. See
indicate the correct media.
replace the cables.
“Low-voltage power supply (LVPS) assembly removal” on page 4-37.
Print quality—missing image at edge
Remove and reseat the following:
Toner cartridge
Imaging unit
Developer units.
Print quality—mottle (2–5mm speckles)
Keep running prints through, and the problem normally clears up. If the problem persists, replace the developer.
Diagnostic information 2-47
Page 82
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Print quality—narrow vertical line
ABCDE ABCDE ABCDE
Step Questions / actions Yes No
1 Replace the photoconductor unit. See
“Imaging unit (IU) removal” on page 4-35.
Problem resolved. Replace the developer unit.
See “Developer unit
removal” on page 4-21.
Print quality—random marks
Service tip: The primary cause of random marks is loose material moving around inside the printer and attaching to the photoconductor unit, developer roll, or transfer belt.
Step Questions / actions Yes No
1 Is there any loose or foreign material on the
imaging unit?
Is there any loose or foreign material on the
2
developer roll?
Is there any loose or foreign material on the
3
transfer belt?
Inspect the imaging unit by looking at the individual developers and photo conductors. Clean or replace the faulty unit. See
“Imaging unit (IU) removal” on page 4-35.
Replace the developer unit. Go to step 3.
Replace the image transfer unit. See “Image transfer
unit (ITU) removal” on page 4-33.
Go to step 2.
Contact your next level of support.
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Print quality—residual image
ABCDE ABCDE ABCDE
Step Questions / actions Yes No
1 Check the condition of the imaging unit using
the customer menus (administrative menus):
1. At the Ready prompt, press Menu ().
2. Select Supplies Menu, and press Select
().
3. Select Imaging Kit, and press Select ().
Does the display indicate OK?
Measure the distance from the original image
2
to the same point on the residual image. Is the distance 43.9 mm?
Is the distance between the original image and
3
the residual image 94.2 mm?
Run the Menu Setting Page twice to clear any
4
debris. To print a menu settings page:
1. Press Menu ( ) on the operator panel.
2. Select Reports from the Admin Menu, and press Select ().
3. Select Menu Settings, and press Select ().
Is there still any toner contamination on the fuser assembly?
Go to step 2. Replace the imaging unit or
Replace the developer corresponding to the color of the image. See “Developer
unit removal” on page 4-21.
Replace the photoconductor. See
“Developer unit removal” on page 4-21.
Replace the fuser. See
“Fuser assembly removal” on page 4-26.
the photoconductor unit. See “Imaging unit (IU)
removal” on page 4-35.
Replace the imaging unit or the photoconductor unit. See “Imaging unit (IU)
removal” on page 4-35.
Contact your next level of support.
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Print quality—solid color page
Service tip: A solid color page is generally caused by a problem in the high-voltage controller or an incorrect high-voltage in the printing process resulting in toner development on the entire photoconductor drum.
Step Questions / actions Yes No
1 Replace the photoconductor unit (part of the
imaging unit). Remove the imaging unit and remove the developers. Place the original developers in the new photoconductor, and then replace the imaging unit. See “Imaging
unit (IU) removal”.
Does this fix the problem?
A faulty printhead can cause the problem. To
2
test the printhead for solid colors, place a narrow strip of paper over the gap between the developers. Make sure the paper stays in place when you replace the imaging unit. This will block the laser from discharging the photoconductors. Print a Quality Test Page.
Does the page have a white vertical band?
Check the high-voltage contact from the HVPS
3
to the photoconductor charge roll. Ensure the contact springs are properly mounted and that the charge roll contact spring is making good contact with the HPVS spring that runs through the left printer frame. See “Toner cartridge
contacts” on page 4-50 to view the proper
mounting and for removal procedures. Are the spring(s) defective?
Turn the printer off, and check the continuity of
4
the HVPS cable. Is there continuity?
Problem resolved. Go to step 2.
Replace the printhead. See
“Printhead removal” on page 4-49.
Replace the transfer contact assembly. See “Toner
cartridge contacts” on page 4-50.
Go to step 5. Replace the cable
Go to step 3.
Go to step 4.
assembly.
Replace the HVPS. See “High-voltage power
5
supply (HVPS) assembly removal” on page 4-31.
Did this solve the problem?
Print quality—vertical banding
Replace the developer unit.
2-50 Service Manual
Problem resolved. Replace the controller
board. See “Controller
board removal” on page 4-19.
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Printhead service check
This service check includes the following errors:
Error code Color
106.xx Yellow
107.xx Cyan
108.xx Magenta
109.xx Black
Step Questions / actions Yes No
1 Turn the printer off, and remove the rear
shield. See “Rear shield removal” on
page 4-11. Check the cable at JMIRR1 for
proper connection to the controller board, the printhead cable for pinch points, and the cable or connector for any other damage.
Is the cable damaged?
Turn the printer on, and then wait until the
2
printer posts an error. Using a voltmeter, check the following values at JMIRR1:
JMIRR1
Pin Volt.
(V dc)
15
23.3 35 4GND 524
Are the values approximately correct?
Replace the printhead. See
“Printhead removal” on page 4-49.
Replace the controller board See “Controller board
removal” on page 4-19.
Go to step 2.
Replace the printhead. See
“Printhead removal” on page 4-49.
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Toner meter cycle (TMC) card
Step Questions / actions Yes No
1 Perform the Base Sensor Test:
1. Enter Diagnostics menu (turn the printer
off, press and hold and Select (), turn the printer on, and release the buttons when the installed memory and processor speed displays).
2. Select Base Sensor Test, and press Select ().
3. Select the sensor you want to test, open the toner door, remove the corresponding toner cartridge, and press Select ().
4. Note whether the operator panel shows a change in state.
Note: If the reflective disk is not showing on the cartridge, rotate the gear clockwise to expose the reflective surface.
For additional information about the Base Sensor Test, see “Base Sensor Test” on
page 3-16.
Does the operator panel display a change of state?
Replace the toner cartridge. Replace the toner meter
cycle (TMC) card. See
“Toner meter cycle (TMC) card removal” on page 4-55.
Toner meter sensors (Y, C, M, K) on TMC card
Step Questions / actions Yes No
1 Remove the toner cartridge, and inspect the
lenses on the toner meter cycle (TMC) card. Are the lenses blocked, damaged, or dirty?
Repair or replace the TMC card. See “Toner meter
cycle (TMC) card removal” on page 4-55.
Go to step 2.
Turn the printer off, and remove the rear
2
shield. See “Rear shield removal” on
page 4-11. Turn the printer on, and measure
the values below at JCTM1 during POR:
JCTM1
Pin Value
1 +5 V dc 2 +3.3 V dc 3 +3.3 V dc 4 +3.3 V dc 5 +3.3 V dc 6 Ground
Are any of the values incorrect?
Replace the controller board. See “Controller
board removal” on page 4-19.
Replace the TMC card. See
“Toner meter cycle (TMC) card removal” on page 4-55.
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Transfer roll service check
Step Questions / actions Yes No
1 Turn the printer off, and remove the rear
shield. See “Rear shield removal” on
page 4-11. Turn the printer on, and check the
cable at JHVPS1 connector on the controller board without disconnecting it. Verify the following values:
JHVPS1
Pin Value
7 +3.3 V dc 11 +3.3 V dc 13 +24 V dc 14 Ground 16 Ground
Are the values approximately correct?
Turn the printer off, and remove the ITU. See
2
“Image transfer unit (ITU) removal” on page 4-33. Check the three spring-loaded
contacts between the HVPS and the ITU located at the left rear of the printer and above the HVPS.
Are the contact dirty?.
Tray 1 sensor service check
Replace the HVPS. See
“High-voltage power supply (HVPS) assembly removal” on page 4-31.
If the problem persists, go to step 2.
Clean the contacts, and reinstall the ITU.
Replace the controller board. See “Controller
board removal” on page 4-19.
Replace the ITU. See
“Image transfer unit (ITU) removal” on page 4-33.
Step Questions / actions Yes No
1 When the printer is in Ready state, pull the
standard tray out. The display should indicate Tray 1 Missing. Insert the tray.
Does the message remain on the display?
Check the vertical wall (or web) at the right
2
rear of the tray for damage. Is the tray damaged?
Check for a dislodged sensor.
3
Is the sensor dislodged?
Does the message Tray 1 Missing fail to
4
appear when the tray is pulled out?
Go to step 2. Go to step 4.
Replace the tray. Go to step 3.
Replace the tray 1 sensor. Go to step 6.
Go to step 5. Problem resolved.
Diagnostic information 2-53
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Step Questions / actions Yes No
Turn the printer off, and remove the rear
5
shield. See “Rear shield removal” on
page 4-11. Disconnect the cable at JTRAY1
connector on the controller board. Turn the printer on, and measure the values below:
JTRAY1
Pin Value
1 +5 V dc 2 +5 V dc 3 Ground
Are the values approximately correct?
Test the continuity in the cable. See “Tray
6
present sensor removal” on page 4-57 to
access both ends of the cable. Is the cable damaged?
Go to step 6. Replace the controller
Replace the cable (Miscellaneous cables FRU).
board. See “Controller
board removal” on page 4-19.
Contact the next level of support.
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User operator panel and Administration menus
Printer operator panel
The printer operator panel has a two-line, back lit, grayscale text display. The Back, Menu, and Stop buttons are located to the left of the display and the navigation buttons are located below the display.
Menu
Indicator light
USB Direct interface
Stop/Cancel
Back
Operator panel buttons
Button or indicator Function
Select Press Select ( ) to initiate action on a menu item.
Indicator light Indicates the printer status:
Stop/Cancel Stops all printer activity.
Navigation buttons Press or to scroll through menu lists. Use the Select button in the center to
Navigation button
Status Indicates
Off The power is off. Blinking green The printer is warming up, processing data, or printing a job. Solid green The printer is on, but idle. Blinking red Operator intervention is needed.
A list of options is offered once Stopped appears on the display.
initiate action on a menu item.
Select button
Navigation button
Back Returns the display to the previous screen.
Menu Opens the menu index.
USB Direct interface Note: The USB connector is available on some models.
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Menu map
This menu map identifies menus available to customers. The diagram shows the menus on the operator panel and items available under each menu.
Some menu items or values are displayed only if a specific option or feature is installed on your printer. Other menu items may only be effective for a particular printer language. You can select these values at any time, but they affect printer function only when you have the optional equipment, feature on your model, or the specified printer language.
Supplies Menu
Cyan Cartridge Magenta Cartridge Yellow Cartridge Black Cartridge Imaging Kit Waste Toner Bottle
Paper Menu
Default Source Size/Type Paper Texture Paper Weight Paper Loading Custom Types Universal Setup
Units of Measure Portrait Width Portrait Height Feed Direction
Reports
Menu Settings Page Device Statistics Network Setup Page Profiles List Print Fonts Print Directory Print Defects Print Demo
Demo Page PPDS Info
Asset Report
Network/Ports
Active NIC Network Menu
PCL Smartswitch PS Smartswitch NPA Mode Network Buffer Mac Binary PS Network Setup
Reports Network Card TCP/IP IPv6 Wireless AppleTalk SE Menu
USB Menu
PCL Smartswitch PS Smartswitch NPA Mode USB Buffer Mac Binary PS USB With ENA
ENA Address ENA Netmask ENA Gateway ENA Gateway
Settings
General Settings
Display Language Eco-Mode Quiet Mode Run Initial Setup Alarms Timeouts Print Recovery Factory Defaults
Setup Menu
Printer Language Print Area Download Target Resource Save
Finishing Menu
Sides (Duplex) Duplex Bind Copies Blank Pages Collate Separator Sheets Separator Source N-up (Pages/Side) N-up Ordering Orientation N-up Border
Quality Menu
Color Correction Print Resolution Toner Darkness Enhance Fine Lines Color Saver RGB Brightness RGB Contrast RGB Saturation Color Balance Color Samples Manual Color Color Adjust
Utilities Menu
Format Flash Defragment Flash Hex Trace Coverage Estimator
PDF Menu PostScript Menu PCL Emul Menu PPDS Menu Image Menu PictBridge Menu Flash Drive Menu
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3. Diagnostic aids
Accessing service menus
There are different test menus that can be accessed during POR to identify problems with the printer.
Diagnostics Menu 1. Turn the printer off.
2. Press and hold Left ( ) and Select ().
3. Turn the printer on.
4. Release the buttons when the installed memory and processor speed displays.
Configuration Menu 1. Turn the printer off.
2. Press and hold Select () and Right ().
3. Turn the printer on.
4. Release the buttons when the installed memory and processor speed displays.
The following menus do not require a POR:
Network SE Menu 1. From the Ready prompt, press
Menu ().
2. Select Customer Network/ Ports menu.
3. Press and hold Left ( ) and Right ().
The Diagnostics menu group contains the settings and operations used while manufacturing and servicing the printer.
See “Diagnostics Menu (Diag Menu)” on
page 3-2 for more information.
The Configuration menu group contains a set of menus, settings, and operations which are infrequently required by a user. Generally, the options made available in this menu group are used to configure a printer for operation.
See “Configuration menu (Config Menu)” on
page 3-24 for more information.
4. Release the buttons when the menu appears.
SE Menu In a browser, add /se to device’s
Additional error message information
Enter Invalid Engine Mode (POR Sequence)
To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostics Menu or in the Configuration Menu.
IP address. For example, http://
158.183.3.2/se. While the error displays on the
panel, press Back ( ) and Right ().
Press Back ( ) and Left ( ). Load updated engine code.
Enters the SE menus online.
Access secondary debug information.
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Diagnostics Menu (Diag Menu)
Note: Tray 2 refers to the 550-sheet tray located in the 650-sheet duo drawer.
Diagnostics Menu structure
When the Diagnostics menu is entered, each Diagnostics main menu item displays on the operator panel. When a diagnostic test is selected from the main menu, a sub menu displays and each individual test displays in the order shown. Any options that are referred to in the menus are displayed when the option is installed.
Available tests
The tests display on the operator panel in the order shown:
Diagnostics Menu
Registration (black registration)
Top Margin See “Registration” on page 3-4. Bottom Margin Left Margin Right Margin Skew See “Skew” on page 3-5. Quick Test See “Quick Test” on page 3-5.
Alignment Menu (color alignment)
Cyan See “Alignment” on page 3-7. Yellow Magenta Factory Scanner A summary page for all the color alignment settings: it can be used in Factory Manual
PRINT TESTS
Tray 1 See “Input source tests” on page 3-10. Tray 2 (if installed) Manual Feeder (if installed) MP Feeder (if installed) Prt Quality Pgs See “Print quality test pages (Prt Quality Pgs)” on page 3-11.
Hardware Test
Panel Test See “Panel Test” on page 3-11. Button Test See “Button Test” on page 3-12. DRAM Test See “DRAM Test” on page 3-12.
DUPLEX TESTS (if installed)
Quick Test See “Quick Test (duplex)” on page 3-13. Top Margin See “Top Margin (duplex)” on page 3-14. Left Margin See “Left Margin (duplex)” on page 3-14.
INPUT TRAY TESTS
Feed Tests See “Feed Tests” on page 3-15. Sensor Test See “Sensor Test” on page 3-15.
place of alignment pages for each individual color.
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Diagnostics Menu (continued)
Base Sensor Test
Input See “Base Sensor Test” on page 3-16. Standard Bin S1 S2 Fuser exit Sensr C-TMC Sensor M-TMC Sensor Y-TMC Sensor K-TMC Sensor
MISC TESTS
Motor Detect See “Motor Detect” on page 3-16.
DEVICE TESTS
Flash Test (if flash memory is installed)
Printer Setup
Defaults See “Defaults” on page 3-17. Prt Color Pg Count See “Page counts” on page 3-17. Prt Mono Pg Count Perm Page Count Serial Number See “Serial Number” on page 3-18. Engine Setting 1 See “Engine Setting 1 through 4” on page 3-18. Engine Setting 2 Engine Setting 3 Engine Setting 4 Model Name See “Model Name” on page 3-18. Config ID (Configuration ID) See “Configuration ID” on page 3-18. ITU Barcode See “ITU Barcode” on page 3-19. Reset Fuser Cnt See “Reset Fuser Cnt” on page 3-19.
EP Setup
EP Defaults See “EP Defaults” on page 3-19. Fuser Temp See “Fuser Temperature” on page 3-19. DC Charge Adjust See “DC Charge Adjust, Dev Bias Adj, Transfer Adjust” on page 3-20. Dev Bias Adjust Transfer Adjust
TPS Setup
Right See “Right or Left TPS” on page 3-20. Left Cal Ref Adjust See “Cal Ref Adj” on page 3-20. Reset Color Calibration See “Reset Color Cal” on page 3-21.
Reports
Menu Settings Page See “Menu Settings Page” on page 3-21.
See “Flash Test” on page 3-17.
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Diagnostics Menu (continued)
Event Log
Display Log See “Display Log” on page 3-21. Print Log See “Print Log” on page 3-22. Clear Log See “Clear Log” on page 3-22.
Exit Diags This selection exits the Diagnostics Menu. The printer performs a POR,
and returns to normal mode.
Registration
Print registration makes sure the black printing plane is properly aligned on the page. This is one of the steps in aligning a new printhead. See “Alignment” on page 3-7. It is also the first step in aligning the duplex registration. See “Quick Test (duplex)” on page 3-13.
To set print registration:
1. Select Registration from the Diag Menu, and press Select ().
2. Use or to select Print Quick Test, and press . See “Quick Test” on page 3-5 for additional
information. The message Printing…, appears on the display, and the page prints.
Retain this page to determine the changes you need to make to the margin settings.
3. Press Select ( ) to enter the Registration.
4. Use or to select the margin setting you need to change, and press Select ().
5. Use to decrease or to increase the offset values, and press Select ( ) to confirm the value.
The message Submitting changes displays, and the original margin setting screen appears. The print registration ranges are:
Description Value Direction of change
Top margin -50 to +50
Each increment corresponds to 8 scans at a 600 dpi scan rate (0.0133 inches or 0.339 mm)
The default is 0.
Bottom margin -25 to +25
Each increment causes approximately 0.55 mm shift in the bottom margin.
The default is 0.
Left margin -50 to +50
Each increment corresponds to 4 pixels at 600 dpi (0.00666 in. or
0.1693 mm). The default is 0.
Right margin -50 to +50
Each increment corresponds to an approximate shift of 4 pixels at 600 dpi.
The default is 0.
.
A positive change moves the image down the page and increases the top margin. A negative change moves the image up and decreases the top margin. No compression or expansion occurs.
A positive offset moves text down the page and narrows the bottom margin, while a negative offset moves text up the page and narrows the bottom margin. The image is compressed or expanded.
A positive change moves the image to the left, and a negative change moves the image to the right. No compression or expansion occurs.
A positive change moves the image to the left, and a negative change moves the image to the right.
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Description Value Direction of change
Skew -100 to +100
Each increment corresponds to 1/1200 of an inch.
The default is 0.
A positive value causes the left end of the scan line to move down the page. A negative value causes the left end of the scan line to move up the page. The right end stays fixed. There is no compression or expansion of the image.
6. Print another copy of the Quick Test to verify your changes.
7. Continue changing the settings by repeating steps 3 through 5.
To exit Registration, press Back (
) or Stop ( ).
Skew
One printhead houses the four color planes. The black plane is aligned to the printer, and the other color planes are internally aligned to black. Electronic alignment fine tunes the alignment of the color planes to the black plane once the printhead is installed. See “Alignment” on page 3-7 for instructions on setting printhead alignment. This must be performed before color skew adjustment is attempted. The following illustration shows proper alignment versus skewed alignment.
Straight Skewed
Quick Test
The Quick Test contains the following information:
Print registration settings
Alignment diamonds at the left, right, top, and bottom
Horizontal lines to check for skew
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General printer information, including current page count, installed memory, serial number, and code level.
To print the Quick Test page:
Note: Print the Quick Test Page on letter or A4 paper.
1. Select Registration from Diag Menu, and press Select ().
2. Select Quick Test Page, and press Select ( ).
The message Printing… appears on the display. Once the Quick Test Page completes printing, the Registration screen displays again.
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Alignment
Aligns each of the color planes to the black plane. Print the Quick Test under each color, Cyan, Yellow, and Magenta, and adjust the Top Margin, Left Margin, Right Margin, Skew, and Bow.
Prints the Print Alignment Pages and requires that the best line in each set of lines must be selected.
To get started:
1. Select Alignment Menu from the Diag Menu, and press Select ( ).
2. Select a color (Cyan, Yellow, or Magenta), and press Select ().
Note: The yellow alignment page markings are more difficult to see, so you might not want to pick it first.
3. Select the Quick Test, and press Select ( ) to begin printing.
The message Printing… appears on the display. A page similar to the following prints:
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4. Select Top Margin, and press Select ().
5. Select the best choice for fine or coarse adjustment in Step 1 (first page), and add it to the current value for
the Top Margin.
6. Use or to enter the sum of the numbers, and press Select ().
Submitting changes… appears. Print the Quick Test again to verify the observed value is the same as the current value (no change is
needed). If change is still needed, repeat steps 4–6. When the observed values and the current value are the same, continue to the next step.
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7. Select the Skew value in the same way, enter the value, press Select ( ), and print the Quick Test to see
if the observed values and the current values are the same.
8. On the second page of the latest Quick Test you printed, proceed to Step 2; adjust the left, right, and bow
settings. Continue printing the Quick Test after each adjustment to verify your settings.
9. Continue on the other two colors in the same manner.
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Print Tests
Input source tests
The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options. The contents of the Print Test Page vary depending on the media installed in the selected input source.
Check each Test Page from each source to assist in print quality and paper feed problems.
To run the Print Test Page:
1. Select PRINT TESTS from the Diag Menu, and press Select ().
2. Select the media source (Tray 1, Tray 2, Manual Feeder, or Multi-Purpose Feeder), and press
Select (),
3. Select Single or Continuous, and press Select ().
If Single is selected, a single page is printed.
If Continuous is selected, printing continues until Stop ( ) is pressed to cancel the test.
If a source is selected that contains envelopes, an envelope test pattern is printed. If Continuous is selected, the test pattern is printed only on the first envelope.
Note: The Print Test Page always prints on one side of the paper, regardless of the duplex setting.
4. Press Back ( ) to return to PRINT TESTS.
3-10 Service Manual
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