Lexmark C746n, C746dn, C746dtn, C748e, C748de Service Manual

...

Download

Page 1

Lexmark™ C746n, C746dn, C746dtn,

• Tabl e of conte n t s

• Start diagnostics

Revised: April 19, 2012

C748e, C748de, C748dte

5026-3xx, 5xx

• Safet y and notices

• Trademarks

• Index

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

Page 2

Edition: April 19, 2012 The following paragraph does not apply to any country where such provis ions are inconsistent wit h 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, Lexmark with diamond design, and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

PrintCryption is a trademark of Lexmark International, Inc.

PCL® is a registered trademark of the Hewlett-Packard Company.

All other trademarks are the property of their respective owners.

GOVERNMENT END USERS

The Software Program and any related documentation are "Commercial Items," as that term is defined in 48 C.F.R. 2.101, "Computer Software" and "Commercial Computer Software Documentation," as such terms are used in 48 C.F.R. 12.212 or 48 C.F.R. 227.7202, as applicable. Consistent with 48 C.F.R. 12.212 or 48 C.F.R. 227.7202-1 through 227.7207-4, as applicable, the Commercial Computer Software and Commercial Software Documentation are licensed to the U.S. Government end users (a) only as Commerical Items and (b) with only those rights as are granted to all other end users pursuant to the terms and conditions herein.

5026

P/N 12G2599

Page 3

5026

Go Back

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix

Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Aviso sobre o laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-x

Lithium warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

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

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

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii

Navigation buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii-xix

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

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

Media options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Memory options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

Expansion opportuni ti es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Data streams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Environment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Electrical and power specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Acoustic specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Media specificat ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Input and output capaciti es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Input and output sizes and types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Paper guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Tools required for servi ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

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

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

Operator panel and menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

C746x operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

C746x buttons and light descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

C748x operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

C748x buttons and light descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Administrative menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Power-on self test (POST) sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Print quality symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

User status and attendance me ssages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Error codes and messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

31.xx—Cartridge errors service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

110.xx—Mirr or mot or service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

111.xx, 112.xx, 113.xx, and 114.xx—Printhead error service check . . . . . . . . . . . . . . . . . . . . . . 2-46

120.xx—Fuser error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

140.xx, 920.02—Autocomp (tray 1) motor error service check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

142.xx, 906.01–906.04—Motor (fus er) error service chec k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

143.xx—Motor (EP dr ive assembly top cartri dge 1 moto r) error service check . . . . . . . . . . . . 2-51

144.xx—Motor (EP drive assembly middle cartridge) error service check . . . . . . . . . . . . . . . . 2-52

Table of contents iii

Page 4

Go Back

5026

145.xx—Motor (EP drive assembly bottom cartri dge) error service check . . . . . . . . . . . . . . . . .2-54

146.xx, 148.xx—Motor (MPF/duplex) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

147.xx, 920.01—PO ST (power-on self test) aligner error service check . . . . . . . . . . . . . . . . . . .2-57

155.xx—Cam motor error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

156.xx—COD (Color On Demand) motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60

160.xx, 161.xx—M otor Error (optio n tray 2) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60

162.xx, 163.xx—M otor Error (optio n tray 3) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

164.xx, 165.xx—M otor Error (optio n tray 4) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

166.xx, 167.xx—M otor Error (optio n tray 5) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63

168.xx—Motor (HCIT elevator) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

200.11, 250.03—Paper Jam error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

201.06, 201.08, 201.31—Paper Jam error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65

203.09—Paper Jam error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68

230.03, 230.05—Paper Jam error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70

242.02—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7 1

242.03, 242.11—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72

242.05—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7 3

242.10—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7 4

242.17—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7 5

242.21, 243.21, 244.21. 245.21, 242.30, 243.30, 244.30, 245.30—Paper Jam service check . . . .2-76

242.26—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7 6

242.27—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7 7

242.29—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7 7

242.32, 243.32, 244.32, 245.32—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78

243.02—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7 8

243.03, 243.11—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79

243.05—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 0

243.10—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 1

243.17—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 2

243.26—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 3

243.27—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 3

243.29—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 3

244.02—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 4

244.03, 244.11—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-85

244.05—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 5

244.10—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 6

244.17—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 6

244.26—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 7

244.27—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 8

244.29—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 8

245.02—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 9

245.03, 245.11—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-90

245.05—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9 0

245.10—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9 1

245.17—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9 2

245.29—Paper Jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9 3

900.00–900.99 (except 900.05)—Syst em software error servi ce check . . . . . . . . . . . . . . . . . . . .2-93

900.05—Transfer module error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-96

902.59—Engine software error, NVRAM MGR problem service check . . . . . . . . . . . . . . . . . . . .2-96

920.03, 920.25—Transfer Module Missing or not connected service check . . . . . . . . . . . . . . . .2-97

920.04—POST (power-on self test) fuser motor not connecte d error service check . . . . . . . . .2-97

920.05—POST (power-on self test) printhead motor not conne cted error service check . . . . .2-98

920.06—Input sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-99

920.07—POST (power-on self test)—Narrow med ia sensor error service check . . . . . . . . . . . .2-99

920.08—Exit sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-100

920.09—POST (power-on self test)—Four toner sensors not connected error service check 2-102

920.10—POST—Three toner sensors not connected error servi ce check . . . . . . . . . . . . . . . .2-103

920.11—POST (power-on self test)—Two toner sensors not connected error service check 2-104

920.12—POST (power-on self test)—One toner sensor not connected error service check .2-105

iv Service Manual

Page 5

5026

Go Back

920.13—POST (power-on self test) cartridge motor 1 not connected error service check . . 2-106

920.14—POST (power-on self test)—Cartridge motor 2 not connec ted error service check . 2-107

920.15, 920.20—POST (power-on self test)—Bad transfer module NVRAM data error servi ce check

2-108

920.16—POST (power-on self test)—Bad print head NVRAM data error service check . . . . . 2-108

920.17—POST (power-on self test)—Output bi n cable not connected error service check . . 2-109

920.18—POST (power-on self test)—Cartridge motor 3 not connec ted error service check . 2-110

920.19—POST (power-on self test)—Transfer module stepper motor not connected error service

check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110

920.21—POST (power- on self test)—24 V power supply failure er ror service check . . . . . . . 2-112

920.23—POST (power- on self test)—Duplex motor not connec ted er ror service check . . . . 2-113

920.27, 920.28, 920.29—POST (power on self test) option tray error service check . . . . . . . . 2-114

920.32—MPF paper presen t sensor not connected service check . . . . . . . . . . . . . . . . . . . . . . 2-114

925.01, 925.03, 925.05—Fan error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114

925.02, 925.04, 925.06—Cartridge cooling fan error service check . . . . . . . . . . . . . . . . . . . . . 2-115

945.xx, 947.xx—Transfer roll error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116

950.00–950.29— EPROM misma tch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118

956.xx—System board failure service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119

5 V interlock switch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120

24 V interlock switch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121

Bubble sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122

Dead printer service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-124

Networking service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-124

Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127

Print quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128

Tray 1 missing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-135

Tray linking service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136

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

Accessing test and diag nosti c procedure menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostics menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Diagnostics menu stru cture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Motor tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Printhead Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

EP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

EXIT DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Configuration menu (CONFIG MENU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Reset Fuser Cnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Color Lock Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Print Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Color Trapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Tray Insert Msg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Download Emuls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Table of contents v

Page 6

5026

Go Back

Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

Automatic Color Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Auto Align Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Color Adj State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Enforce Color Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Color Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Motor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Paper Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Envelope Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Action for Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Jobs on Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Disk Encryption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Wipe Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Wipe All Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Duplex Gloss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Font Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Require Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

UI Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Key Repeat Initial Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Key Repeat Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Clear Custom Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

USB Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Automatically Display Error Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 3 5

Exit Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

Front cover locked in place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

Printhead verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

Error jam locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

Clearing jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 1

Paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51

Electrophotogr aphic (EP) process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 3

Electrical interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-73

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

Safety in fo r ma tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Data Security Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Handling ESD-sensiti ve parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Handing the photoconduct or uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Transportation/storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Parts not to be touched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Screw and retainer identifi cation table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Printhead alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Printer removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

Precautions to take before maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

Cover removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29

Front access cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29

Left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Operator panel assem bly removal (C746) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

Operator panel assem bly removal (C748) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37

Operator panel bezel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41

Operator panel buttons removal (C746) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41

Operator panel buttons removal (C748) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43

Output bin extension cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4 5

Paper tray dust cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 6

Rear frame cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47

vi Service Manual

Page 7

Go Back

5026

Rear left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Rear right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

Rear upper cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

Right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Top access cover assembl y removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Printe r re movals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

5 V interlock switch cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

24 V interlock switch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

Bin full sensor flag removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

Bin full sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

Cartridge cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Cartridge motor 1/fuser cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

Cartridge motor 2/3 cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69

Color on demand assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

Contact springs kit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

Cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85

Cooling fan filter removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86

Duplex reference edge guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87

Electrophotogr aphic (EP) drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90

Front door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100

Front door assembly fron t cabl e (left) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103

Front door assembly fron t cabl e (right) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-107

Fuser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-110

Fuser AC cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112

Fuser DC cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-113

Hard drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-114

High-voltage power supply (HVPS) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-115

High-voltage power supply (HVPS) cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-117

Left bell crank assembl y rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-118

Low-voltage power supply (LVPS) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119

Motor driver card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-121

Motor driver cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-122

Multipurpose fee der (MPF)/duplex gear and housing removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-123

Multipurpose fee der (MPF)/duplex motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-125

Multipurpose fee der (MPF)/duplex motor cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-128

Multipurpose fee der (MPF) paper present sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-129

MPF pick removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-131

Operator panel cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-132

Operator panel ground cab le removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-133

Operator panel USB connector cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-134

Option cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-135

Paper pick mechanis m asse mbl y rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137

Photoconductor unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-142

Pick arm roll removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-143

Printer pad removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-144

Printhead removal, installation, and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-145

Right bell crank assembly rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-154

Speaker removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-155

System board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-155

System board support shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-160

Toner level sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-163

Top cover camshaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-165

Transfer module removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-171

Transport cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-173

Transport motor cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-175

Waste toner assembly rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-176

Waste toner HV contact assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-177

Wireless network antenna removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-190

Table of contents vii

Page 8

5026

Go Back

Wireless network card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-191

Option removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-193

HCIT media tray assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-193

HCIT front tray cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-194

HCIT rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-195

HCIT right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-196

HCIT left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-197

Feed with bushing roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-198

HCIT controller board assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-199

HCIT drawer slide assembly rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-200

HCIT elevator motor with sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-200

HCIT pick arm roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-202

HCIT slide assembly with spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-203

Photointerrupter sensor with cable assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-205

Top plate assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-206

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

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

System board diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

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

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

Lubrication spec if ications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Maintaining the print er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Cleaning the exterior of the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Cleaning the printhead l enses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Moving the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

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

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

Assembly 1: Covers (C746). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Covers (C748). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 3: Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 4: Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 5: Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 6: Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 7: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Assembly 8: Cable parts packet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Assembly 9: Optional 550-sheet media draw er and tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Assembly 10: Optional special media tray assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Assembly 11: Optional high-capacity input option (HCIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Assembly 12: Options and features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

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

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

viii Service Manual

Page 9

5026

Go Back

Notices and safety information

The following laser notice labels may be affixed to this printer.

Laser no tice

This product 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) AlGaAs laser producing visible radiation in the wavelength of 770-800 nanometers enclosed in a nonserviceable printhead assembly. The laser system and printer are designed so there is never any human access to laser radiation exceeding Class I levels during normal operation, user maintenance, or prescribed service condition.

Laser-Hinweis

Dieses Produkt ist in den USA zertifiziert und entspricht den Anforderungen der Vorschriften DHHS21CFR UnterkapitelJ für Laserprodukte der KlasseI(1), andernorts ist er als Laserprodukt der KlasseI zertifiziert, das den Anforderungen von IEC60825-1 entspricht.

Laserprodukte der KlasseI werden nicht als gefährlich betrachtet. Der Drucker enthält im Inneren einen Laser der KlasseIIIb (3b) AlGaAs, der sichtbare Strahlung im Wellenlängenbereich von 770bis 800Nanometern abgibt. Dieser befindet sich in einer Druckkopfeinheit, die nicht gewartet werden kann. Das Lasersystem und der Drucker sind so konstruiert, dass unter normalen Betriebsbedingungen bei der Wartung durch den Benutzer oder bei den vorgeschriebenen Wartungsbedingungen Menschen keiner Laserstrahlung ausgesetzt sind, die die Werte für KlasseI überschreitet.

Avis relatif à l’utilisation de laser

Ce produit est certifié conforme aux exigences de la réglementation des Etats-Unis relative aux produits laser (DHHS21 CFR Sous-chapitreJ pour ClasseI (1)). Pour les autres pays, il est certifié conforme aux exigences des normes CEI60825-1 relatives aux produits laser de classeI.

Les produits laser de ClasseI ne sont pas considérés comme dangereux. L'imprimante contient un laser de ClasseIIIb (3b) AlGaAs qui produit des radiations visibles opérant sur une longueur d'onde de l'ordre de 770 à 800nanomètres au sein d'un boîtier non démontable de la tête d'impression. Le système laser et l'imprimante ont été conçus de manière à ce que personne ne soit jamais exposé à des radiations laser dépassant le niveau de classeI dans le cadre d'un fonctionnement normal, de l'entretien par l'utilisateur ou de la maintenance.

Notices and safety information ix

Page 10

5026

Go Back

Avvertenze sui prodotti laser

Questo prodotto è certificato negli Stati Uniti come prodotto conforme ai requisiti DHHS 21 CFR Sottocapitolo J per i prodotti laser di Classe I (1), mentre in altri paesi è certificato come prodotto laser di Classe I conforme ai requisiti IEC 60825-1.

I prodotti laser di Classe I non sono considerati pericolosi. La stampante contiene un laser Classe IIIb (3b) AlGaInP che emette una radiazione visibile a una lunghezza d'onda di 770-800 nanometri all'interno dell'unità testina di stampa non sottoponibile a manutenzione. Il sistema laser e la stampante sono stati progettati in modo da impedire l'esposizione a radiazioni laser superiori al livello previsto dalla Classe I durante le normali operazioni di stampa, manutenzione o assistenza.

Avisos sobre el láser

Este producto se ha certificado en EE.UU. cumpliendo con los requisitos de DHHS 21 CFR subcapítulo J para los productos láser de ClaseI (1) y en otros países está certificada como un producto láser de ClaseI de acuerdo con los requisitos de IEC 60825-1.

Los productos láser de ClaseI no se consideran peligrosos. Este producto contiene un láser interno de Clase IIIb (3b) AlGaAs que produce una radiación visible en una longitud de onda de 770-800 nanómetros cerrado en un conjunto de cabezal de impresión que no se puede reparar. El sistema láser y la impresora se han diseñado para que el ser humano no acceda nunca a las radiaciones láser por encima del nivel de Clase I durante el funcionamiento normal, mantenimiento del usuario o condición de servicio prescrita.

Declaração sobre Laser

Este produto foi certificado nos EUA por estar em conformidade com os requisitos do DHHS 21 CFR, subcapítulo J, para produtos a laser de Classe I (1) e, nos demais países, foi certificado como um produto a laser de Classe I em conformidade com os requisitos da IEC 60825-1.

Os produtos a laser de Classe I não são considerados prejudiciais. A impressora contém, internamente, um laser de Classe IIIb (3b) AlGaAs que produz radiação visível no comprimento de onda de 770-800 nanômetros incluso em um conjunto do cabeçote de impressão cuja manutenção não é facilitada. O sistema do laser e a impressora foram projetados para que jamais haja acesso humano à radiação do laser acima dos níveis da Classe I durante a operação normal ou a manutenção pelo usuário ou sob as condições de manutenção prescritas.

Aviso sobr e o las er

Nos E.U.A., este produto está classificado como estando em conformidade com os requisitos DHHS 21 CFR, Subcapítulo J, para produtos laser de Classe I (1) e, nas restantes regiões, está classificado como um produto de Classe I, estando em conformidade com os requisitos IEC 60825-1.

Os produtos laser de Classe I não são considerados perigosos. A impressora possui, no seu interior, um laser de Classe IIIb (3b) AlGaAs que produz radiação num comprimento de onda de 770-800 nanómetros. Este encontra-se fechado no conjunto da cabeça de impressão, que não é passível de manutenção. O sistema de laser e a impressora estão concebidos de forma a que nunca haja acesso humano à radiação laser que excede os níveis correspondentes à Classe I durante o funcionamento normal, manutenção ou em condições de assistência recomendada.

x Service Manual

Page 11

5026

Go Back

Laserinformatie

Dit product is in de Verenigde Staten gecertificeerd als een product dat voldoet aan de vereisten van DHHS 21 CFR paragraaf J voor laserproducten van klasse I (1). Elders is het product gecertificeerd als een laserproduct van klasse I dat voldoet aan de vereisten van IEC 60825-1.

Laserproducten van klasse I worden geacht geen gevaar op te leveren. De printer bevat intern een laser van klasse IIIb (3b) AlGaAs die zichtbare straling produceert in een golflengtebereik van 770-800 nanometer in een niet-bruikbare printkopeenheid. Het lasersysteem en de printer zijn zodanig ontworpen dat gebruikers nooit blootstaan aan laserstraling die hoger is dan het toegestane niveau voor klasse I-apparaten, tijdens normaal gebruik, onderhoudswerkzaamheden door de gebruiker of voorgeschreven servicewerkzaamheden.

Lasermeddelelse

Dette produkt er certificeret i USA i henhold til kravene i DHHS 21 CFRi underafsnit J for klasse l (1)laserprodukter og er andre steder certificeret som et klasse I laserprodukt i henhold til kravene i IEC 60825-1.

Klasse I-laserprodukter er ikke anset som farlige. Printeren indeholder internt en klasse IIIb (3b) AlGaAs-laser, der producerer synlig stråling med en bølgelængde på 770-800 nanometer, indkapslet i en ikke-servicerbar printhovedsamling. Lasersystemet og printeren er udviklet på en sådan måde, at der ikke er en direkte laserstråling, der overskrider Klasse I-niveauet under normal brug, brugers vedligeholdelse eller de foreskrevne servicebetingelser.

Laserilmoitus

Tämä tuote 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. Laitteen tulostuspääkokoonpanossa (ei huollettavissa) on sisäänrakennettu luokan IIIb (3b) AlGaAs -laser, joka tuottaa silminnähtävää säteilyä 770-800 nanometrin aallonpituudella. Laserjärjestelmä ja tulostin ovat rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön, ylläpidon tai huollon aikana.

Huomautu s las er laitteesta

Tämä tuote on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.

Notices and safety information xi

Page 12

5026

Go Back

Laser-notis

Denna produkt är certifierad i USA i enlighet med kraven i DHHS 21 CFR underkapitel J för klass I (1)laserprodukter, och på andra platser certifierad som en klass I-laserprodukt i enlighet med kraven i IEC 60825-1.

Klass I-laserprodukter betraktas inte som skadliga. Skrivaren innehåller en klass IIIb (3b) AlGaAs-laser som producerar synlig strålning inom våglängden 770-800 nm, innesluten i en icke-servicebar skrivhuvudenhet. Lasersystemet och skrivaren är utformade så att människor aldrig utsätts för laserstrålning som överskrider klass I-nivåerna under normala förhållanden vid användning, underhåll eller service.

Laser-melding

Dette produktet er sertifisert i USA for samsvar med kravene i DHHS 21 CFR, underkapittel J for laserprodukter av klasse I (1) og er andre steder sertifisert som et laserprodukt av klasse I som samsvarer med kravene i IEC 60825-1.

Laserprodukter av klasse I anses ikke som helseskadelige. Skriveren inneholder en intern AlGaAs-laser av klasse IIIb (3b) som produserer synlig stråling i bølgelender på 770-800 nanometer i en ikke-reparerbar skrivehodeenhet. Lasersystemet og skriveren er utformet slik at mennesker ikke utsettes for laserstråling utover nivåene i klasse I under normal drift, vedlikehold eller foreskrevet service.

Avís sobre el Làser

Este producto está certificado en Estados Unidos para el cumplimiento de los requisitos estipulados en DHHS 21 CFR Subcapítulo J para productos láser de Clase I (1), y cuenta con certificación para otros países como producto láser de Clase I de conformidad con los requisitos de IEC 60825-1.

Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior radiación láser visible AlGaAs Clase IIIb (3b) en la longitud de onda de 770 - 800 nanómetros dentro de un mecanismo de cabezal de impresión que no requiere servicio técnico. La impresora y el sistema láser están diseñados de forma tal que no exista nunca acceso humano a radiación láser que supere los niveles de Clase I durante el funcionamiento normal, las tareas de mantenimiento por parte del usuario o las condiciones de servicio técnico estipuladas.

xii Service Manual

Page 13

5026

Go Back

Notices and safety information xiii

Page 14

5026

Go Back

xiv Service Manual

Page 15

5026

Go Back

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.

Lithium warn ing

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.

Lithium warning xv

Page 16

5026

Go Back

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.

Inform a çõ es 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.

xvi Service Manual

Page 17

5026

Go Back

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.

Safety information xvii

Page 18

5026

Go Back

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.

Preface

This manual contains maintenance procedures for service personnel. It is divided into the following chapters:

1. General infor m a ti o n 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 infor ma t io n 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.

Appendix A contains service tips and information.

Appendix B contains representative print samples.

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:

xviii Service Manual

Page 19

5026

Go Back

Navigation buttons

This manual contains navigation buttons in the right margin of each page, making it easier and quicker to navigate.

Button Description

Click to move the document view backward by one page.

Click to move the document view forward by one page.

Go Back

Click to return to the last page viewed.

Conventions xix

Page 20

5026

Go Back

xx Service Manual

Page 21

5026

Go Back

1. General in formation

The Lexmark™ C746x and C748x family of color laser printers.

Models

Options

Printer name

Lexmark C746n 5026-310 Network-ready

Lexmark C746dn 5026-330 Network-ready with duplex

Lexmark C746dtn 5026-330 Network-ready with duplex and 550 sheet tray

Lexmark C748e 5026-510 Network-ready with etask touch screen

Lexmark C748de 5026-530 Network-ready with etask touch screen and duplex

Lexmark C748dte 5026-530 Network-ready with etask touch screen, duplex, and

Machine typ e and model

Description

550 sheet tray

General information 1-1

Page 22

5026

Go Back

Number Description

1 Standard output bin

2 Paper support

3 Printer operator panel

4 Standard 550-sheet stray (Tray 1)

5 Multipurpose feeder

6 Optional 550-sheet specialty media drawer

7 Optional 550-sheet tray

8 Optional 2,000-sheet high.capacity feeder

Note: Some configurations may require a caster base for stability.

Media options

The C746x and C748x printers support the 550-sheet drawer, special media drawers, and 2000-sheet highcapacity input tray. The C746x and C748x printers support up to four input options. The options can include any combination of 550 sheet drawers and 550 sheet Specialty Media Drawers, with a maximum of one 2000 sheet drawer (always at the lowest position.) A caster base is required with some configurations. Including the base machine capacity of 650 sheets, the C746x and C748x supports up to 4300 sheets.

The Lexmark C74x options are compatible with the Lexmark C73x SFP, X73x MFP, and X74x MFP, but not with any other Lexmark printers. No other options are supported by the C74x.

The media options include:

• 550-Sheet Drawer—This optional input source installs beneath the printer, and it holds approximately 550

sheets of (20 lb.) paper.

• High Capacity Input Tray—This optional input source installs beneath the printer, and it holds

approximately 2000 sheets of (20 lb.) paper.

• Specialty Media Drawer—This optional input source installs beneath the printer, and it holds

approximately 550 sheets of (20 lb.) paper, or 85 standard envelopes.

Memory options

• Additional memory card—The memory options for the C746x and C748x printers are 200 pin DDR2,

SODIMM, and they are available at 256MB, 512MB, and 1GB sizes.

• Flash memory card—Flash Memory cards are available in 256MB.

• Hard disk—If larger storage is required, an optional hard disk is available.

1-2 Service Manual

Page 23

5026

Go Back

Dimensions

The following table contains the dimensions and weight for each of the respective printer models. This does not include packaging.

Height Width Depth Weight

Basic printer (C746n/dn) 454.7 mm

Basic printer (C748e/de) 454.7 mm

C746dtn printer, with 550-sheet optional drawer

C748dte printer, with 550-sheet optional drawer

550-sheet drawer 169.0 mm

550-sheet special media drawer 169.0 mm

2000-sheet high capacity feeder 387.0 mm

Spacer 169.0 mm

Caster Base 127.0 mm

(17.9 in)

581.7 mm (22.9 in)

581.7mm (22.9 in)

(6.6 in)

(15.2 in)

(6.6 in)

(5.0 in)

435.0 mm (17.1 in)

435 mm (17.1 in)

778 mm (30.6 in)

400.0 mm (15.7 in)

545.0 mm (21.5 in)

545 mm (21.5 in)

812.0 mm (32.0 in)

25.2 kg (55.6 lbs)

25.6 kg (56.4 lbs)

29.7 kg (65.5 lbs)

30.1kg (66.4 lbs)

4.5 kg (10.0 lbs)

26.1 kg (57.5 lbs)

3.2 kg (7.0 lbs)

43.1 kg (95.0 lbs)

General information 1-3

Page 24

5026

Go Back

Clearances

Memory

Number Description Clearance

1 Right side 101.6 mm (4 in.)

2 Front 609.6 mm (24 in.)

3 Left side 152.4 mm (6 in.)

4 Rear 152.4 mm (6 in.)

5 Top 304.8 mm (12 in.)

C746 C748

Standard memory—The standard RAM is soldered onto the system board.

Memory size

Optional memory—Optional DIMM (Dual Inline Memory Module) is a card that can be plugged into an available memory slot on the system board. Flash memory is a card that can also be plugged into an available slot.

Maximum number of memory (DIMM) slots

Maximum number of flash memory slots

DIMM memory sizes available

256MB, 512MB, 1024MB 256MB, 512MB, 1024MB

512MB 512MB

1-4 Service Manual

Flash (Nand Flash)

Maximum possible memory

256 256

1536MB 1536MB

Page 25

5026

Go Back

Expansion opportunities

Interface card expansion slots 1

Code Enhancement Socket (application solution firmware)

Hard disk Interface (for optional hard disk)

Resolution

The following resolutions are available:

• 4800CQ (default resolution)

• 1200 x 1200 dpi (at reduced printer speed)

Data streams

• XPS

• PCL 6 emulation (includes PCL 5e and PCL XL interpreters)

• PostScript 3 emulation

• PDF 1.6

• PPDS

• PictBridge

• HTML (including DBCS)

• Direct Image (TIFF, TIF, JPEG, JPG, GIF, PNG, BMP, PCX, and DCX)

Environment specifications

Environment Specifications

Operating

Air temperature—Operating 15.6° to 32.2° C (60° to 90° F)

Air temperature—Power off 10° to 40° C (50° to 104° F)

Air Relative Humidity Relative humidity 8% to 80%

Wet Bulb Temperature—Operating 22.8° C (73.0° F) Maximum

Web Bulb Temperature—Power off 26.7° C (80.1° F) Maximum

Altitude 0–3,048 meters (10,000 ft.)

Ambient Operating Environment* 15.6° to 32.2° C (60° to 90° F) and 8% to 80% RH

Shipping and storage

Cartridges (packaged) -40° C to 40° C (104° Fahrenheit)

Printer with Cartridges (packaged) -40° C to 40° C (104° Fahrenheit)

Printer without Cartridges -40° C to 40° C (104° Fahrenheit)

Air Relative Humidity Relative humidity 8% to 80%

Altitude 0–10,300 meters (34,000 feet)

General information 1-5

Page 26

5026

Go Back

Environment Specifications

Web Bulb Temperature—Power Off 26.7° C (80.1° F) Maximum

* In some cases performance specifications, such as paper OCF and EP cartridge usage, are specified to

be measured at an ambient condition.

Electrical and power specifications

The following table specifies nominal average power requirements for the basic printer configurations. All power levels are shown in Watts (W). Maximum current is given in Amperes (A).

Printing states C746n/dn/dtn Lexmark C748e/de/dte

Off 0W 0W

Sleep mode 6.8W 7.3W

Hibernate mode 0.55W 0.55W

Ready Mode 48W 48W

Simplex Printing 535W 535W

Duplex Printing 420W 420W

Typical Electricity Consumption Test

Typical Electricity Consumption Test (Eco-Mode)

Average current while printing (110 Volts)

Average current while printing (120 Volts)

Average current while printing (230 Volts)

Low-voltage models

3.561 kwh / wk 3.687 kwh / wk

2.375 kwh / wk 2.491 kwh / wk

8.3 A 8.3 A

7.5 A 7.5 A

3.8 A 3.8 A

• 110 to 127 V at 50 to 60 Hertz (Hz) nominal

• 99 to 139.7 V, extreme

• 100 V at 50 to 60 Hertz (Hz) nominal

• 90 to 121 V, extreme

High-voltage models

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

• 198 to 259 V, extreme

Notes:

• Using a power converter or inverter with the Lexmark C740 Series printers is not recommended.

• The C740 series duplex models (C746dn, C746dtn, C748de, C748dte) are Energy Star Qualified.

• All models ship with Sleep Mode = On.

• The default time out to Sleep mode is 30 minutes.

1-6 Service Manual

Page 27

5026

Go Back

Acoustic specifications

All acoustic measurements are made in accordance with ISO 7779:1999—Accoustics : Measure ment of air borne noise emitted by information technology and telecommunications and reported in conformance with ISO 9296:

1988-04-15—Accoustics Declared noise emission values of computer and business equipment.

Operating mode

1 meter average sound pressur e

(dBA)

Declared sound pow er l evel

C746

Idle 32 dB 4.8 Bels

Simplex printing (mono) 53 dB 6.8 Bels

Simplex printing (color) 54 dB 6.8 Bels

Duplex printing (mono) 54 dB 6.9 Bels

Duplex printing (color) 55 dB 6.9 Bels

Quiet mode printing (mono) 48 dB 6.3 Bels

Quiet mode printing (color) 48 dB 6.3 Bels

C748

Idle 32 dB 4.8 Bels

Simplex printing (mono) 54 dB 6.8 Bels

Simplex printing (color) 55 dB 6.9 Bels

Duplex printing (mono) 53 dB 6.9 Bels

Duplex printing (color) 55 dB 6.9 Bels

(Bels)

Quiet mode printing (mono) 47 dB 6.3 Bels

Quiet mode printing (color) 48 dB 6.3 Bels

General information 1-7

Page 28

5026

Go Back

Media specifications

Paper designed for use with xerographic copiers should provide satisfactory print quality and feed reliability. Other types of media may be suitable. It is recommended that users test any particular brand for suitability to their applications. Refer to the printer User's Guide for additional media specifications.

Paper

Follow the media guidelines below for successful printing:

• Rough, highly textured, limp, or pre-curled papers will result in lower print quality and more frequent paper

feed failures.

• Colored papers must be able to withstand 190° C (374° F) fusing temperature.

• Preprinted forms and letterheads must be able to withstand 190° C (374° F) fusing temperature and should

be selected using guidelines found in the printer User’s Guide. The chemical process used in preprinting

may render some papers unsuitable for use.

• Unsuitable papers include: – Multi-part forms and documents – Chemically treated papers; coated – Synthetic and thermal papers – A5 paper less than 80 g/m – Recycled paper less than 75 g/m – Preprinted papers requiring a high degree of registration. – Recycled paper less than 80 g/m

(21 lb)

(20 lb)

(21 lb) may cause unacceptable results.

Envelopes

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

•

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

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

• Minimum weight: 60 g/m2 (16 lb.)

• The following envelopes should not be used:

• Envelopes with windows, holes, perforations, cutouts, or deep embossing

• Envelopes with metal clasps, string ties, or metal folding bars

• Envelopes with exposed flap adhesive when the flap is in the closed position.

• For best results, printing on new 90 g/m2 (24 lb.) sulfite or 25% cotton bond envelopes is recommended.

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

Transparencies

•

Use letter or A4-size transparencies for color laser printers only.

• See Ordering Information for the recommended transparencies for the Lexmark C746x/C748x laser

printers.

• Do not use inkjet transparencies.

Labels

Labels should be selected using guidelines found in the User's Guide or the Card Stock and Label Guide, and

tested for acceptability.

1-8 Service Manual

Page 29

5026

Go Back

Using recycled paper and other office papers

Recycled office paper produced specifically for use in laser (electrophotographic) printers may be used in your printer. However, no blanket statement can be made that all recycled paper will feed well.

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 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).

[16 lb bond]) and/or lower caliper (<3.8 mils [0.1 mm]), and

General information 1-9

Page 30

5026

Go Back

Input and output capacities

The following table describes the media options that each model supports, and the estimated capacities in stand and maximum configurations. Capacity may vary and is subject to media specifications and printer operating environment. The capacities are based on plain paper at 75g/m

Standard input sources

Primary tray capacity (sheets) 550

Multipurpose feeder capacity (sheets) 100

Number of standard sources (primary tray

and multipurpose feeder)

Total standard capacity (sheets) 650

Optional input sources

550-Sheet Drawer (sheets) 550

High-capacity input tray (HCIT) (sheets) 2,000

Specialty Media Drawer

Maximum number of 550-sheet drawers

(sheets) 550 (or 85 envelopes)

(including Speciality Media Drawer)

Maximum number of high-capacity input

tray (must be installed on the bottom)

Maximum number of standard and

optional input sources

Maximum capacity for standard and

4,300

options input sources (sheets)

Standard output bin capacity (sheets)

300

Maximum output bin capacity (sheets) 300

Duplex capability Standard for

C746dn,C746dtn,C748de,and

C748dte models

Each 550-sheet Specialty Media Drawer replaces one 550-sheet option.

The output bin capacity may be reduced by 50 sheets when the duplex feature is in use.

1-10 Service Manual

Page 31

5026

Go Back

Input and output sizes and types

Media Sizes

Primary 550-sheet tray

Multipurpose feeder

Optional 550-sheet tray

Optional Speciality

Media

Optional 2000-sheet

feeder (HCIT)

Duplex

Paper sizes

A4 210 x 297 mm ✓✓✓✓✓✓ A5 148 x 210 mm ✓✓✓✓ ✓ A6 105 x 148 mm ✓✓ JIS B5 182 x 257 mm ✓✓✓✓ ✓ Officio (Mexico) 216 x 340 mm ✓✓✓✓ ✓ Letter 8.5 x 11 in. ✓✓✓✓✓✓ Legal 8.5 x 14 in. ✓✓✓✓✓✓ Statement 5.5 x 8.5 in. ✓✓✓ Executive 7.25 x 10.5 in. ✓✓✓✓ ✓ Folio 8.5 x 13 in. ✓✓✓✓ ✓ Universal ✓✓✓✓ ✓

General information 1-11

Page 32

5026

Go Back

Media Sizes (continued)

Primary 550-sheet tray

Multipurpose feeder

Optional 550-sheet tray

Optional Speciality

Media

Envelopes

C6 Envelope 114 x 162 mm B6 Envelope 125 x 176 mm C65 Envelope 114 x 229 mm

✓✓

C5 Envelope 162 x 229 mm ✓✓ B5 Envelope 176 x 250 mm ✓✓ DL Envelope 110 x 220 mm ✓✓ 6 3/4 Envelope 3.4 x 6.5 in 7 3/4

Envelope 3.4 x 7.5 9 Envelope 3.9 10 Envelope 4.13

x 8.9 in ✓✓

x 9.5 in ✓✓

11 Envelope 4.5 x 10.4 in 12 Envelope 4.8 x 11 in

These sizes are accessible using Other Envelope setting.

✓✓

in ✓✓

✓✓

Optional 2000-sheet

feeder (HCIT)

Duplex

Media weight, primary tray and opt ion tray Size Type Weight

Letter, Legal, A4 Xerographic and bond Long grain 60 g/m

Short grain 162.7 g/m

Recycled Long grain 75 g/m

Short grain 105 g/m

Cardstock (maximum) Index long/short 162.7 g/m

Cover long/short 162.7g/m

Tag long/short 162.7g/m

Transparencies 161 g/m

Thickness: 0.12–0.14mm (4.8–5.4 mil)

Labels Paper 180 g/m

Vinyl 180 g/m

1-12 Service Manual

–162.7 g/m2 (16 lb–43 lb)

–198.9 g/m2 (43 lb–53.2 lb)

–177 g/m2 (20 lb–47 lb)

–218 g/m2 (28 lb–58 lb)

–198.9 g/m2 (90 lb–110 lb)

–198.9 g/m2 (60.1 lb–73.6 lb)

–198.9 g/m2 (100 lb–122.2 lb)

– 179 g/m

–300 g/m2 (48 lb–80 lb)

Page 33

5026

Go Back

Media weight, primary tray and opt ion tray Size Type Weight

A5, JIS B5, Executive Xerographic and bond Long grain 75 g/m

Short grain 90 g/m

Universal Xerographic and bond Long grain 75 g/m

Short grain 90 g/m

–177 g/m2 (20 lb to 47 lb)

–218 g/m2 (24 lb–58 lb)

–177 g/m2 (20 lb–47 lb)

–218 g/m2 (24 lb–58 lb)

Paper 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 162l7 g/m Paper lighter than 60 g/m performance, use 75 g/m we recommend 90 g/m

Note: Duplex is supported only for 63 g/m

(16 lb) might not be stiff enough to feed properly, causing jams. For best

(20 lb bond) grain long paper. For paper smaller than 182 x 257 mm (7.2 x 10.1 in.),

(24 lb) or heavier paper.

–170 g/m2 (17 lb–45 lb bond) paper.

(16 to 43 lb bond) grain long.

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 135 g/m bond) paper, grain long paper is recommended. For papers heavier than 135 g/m

, grain short is recommended.

(16 to 36 lb

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 can negatively affect paper handling.

Unacce p tab l e p aper

The following paper types are not recommended for use with the printer:

• Chemically treated papers used to make copies without carbon paper, also known as carbonless papers,

carbonless copy paper (CCP), or no carbon required (NCR) paper

• Preprinted papers with chemicals that may contaminate the printer

• Preprinted papers that can be affected by the temperature in the printer fuser

General information 1-13

Page 34

5026

Go Back

• Preprinted papers that require a registration (the precise print location on the page) greater than ±2.3 mm

(±0.9 in.), such as optical character recognition (OCR) forms Note: In some cases, registration can be adjusted with a software application to successfully print on these forms.

• Coated papers (erasable bond), synthetic papers, thermal papers

• Rough-edged, rough or heavily textured surface papers, or curled papers

• Recycled papers that fail EN12281:2002 (European)

• Paper weighing less than 60 g/m

(16 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 90 g/m

(16 to 20 lb) 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 190°C (374°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 190°C (374°F) without melting or releasing hazardous emissions.

1-14 Service Manual

Page 35

5026

Go Back

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.

Tools required for service

Flat-blade screwdrivers, various sizes #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade 7/32 inch (5.5 mm) open-end wrench

4.0 mm Allen wrench (HCIT removal)

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 Flash light (optional)

General information 1-15

Page 36

5026

Go Back

Acronyms

BLDC Brushless DC Motor BUR Back Up Roll CCyan COD Color On Demand DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory EP Electrophotographic Process ESD Electrostatic Discharge FRU Field Replaceable Unit GB Gigabyte HCIT High-Capacity Input Tray HVPS High Voltage Power Supply 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 NVRAM Nonvolatile Random Access Memory PC Photoconductor pel Picture element (pixel) POR Power-On Reset POST Power-On Self Test RIP Raster Imaging Processor SDRAM Synchronous Dual Random Access Memory V ac Volts alternating current V dc Volts direct current YYellow

1-16 Service Manual

Page 37

5026

Go Back

CAUTION

Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic card or assembly for personal safety and to prevent damage to the printer.

CAUTION—POTENTIAL INJURY:

The printer weight is greater than 54 lbs (24.5kg), and requires two or more trained personnel to lift safety.

2. Diagnostic information

Start

Use the service error code, user status message, user error message, symptom table, service checks, and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer. They will lead you to solutions or service checks, including the use of various tests.

Sympto m tables

If your printer completes the “Power-on self test ( P OST ) sequence” on page 2-9 without an error, and you have a symptom, go to “Symptom tables” on page 2-9. Locate your symptom, and take the appropriate action.

Servi ce erro r s (1xx.x x/9xx.xx)

If a service error code appears while you are working on the printer, go to “1xx service error codes” on

page 2-21 or “9xx service error messages” on page2-38, and take the indicated action for that error.

Service error codes are indicated by a three-digit error code followed by a period and additional numbers in the format XXX.YY. In most cases, five digits are shown.

Paper j am message s (2xx.x x)

User attendance messages that indicate a paper jam have been included with the service error codes since repeated instances may indicate an underlying service issue. Go to “2xx paper jam messages” on page 2-23.

User status and attendance messages

User status messages provide the user with information on the current status of the printer.

•

• User attendance messages are indicated by a two-digit code that provides the user with information that

explains a problem with a print cartridge, option, port, and so on. If a user error message displays, see “3x

through 8x attendance messages” on page 2-13 or “2xx paper jam messages” on page2-23.

Additional information

•

“Operator panel and menus” on page 2-2

• “Power-on self test (POST) sequence” on page 2-9

Diagnostic information 2-1

Page 38

Go Back

910

ABC3DEF

GHI5JKL6MNO

PQR8STU9WXYZ

5026

Operator pan el an d me nu s

C746x operator panel

C746x buttons and light descriptions

Use the To

1 Display • View printer status.

• Allow printer setup and operation.

2 Select button Submit changes made in the printer settings.

3 Navigation buttons Scroll up and down or left and right.

4 Keypad Enter numbers and letters.

5 Sleep button Enable Sleep mode.

The following are the statuses based on the indicator light and the Sleep button:.

• Entering or waking from Sleep mode

- The indicator light is illuminated solid green.

- The Sleep button is un-illuminated.

• Operating in Sleep mode

- The indicator light is illuminated solid green.

- The Sleep button is illuminated solid amber.

• Entering or waking from Hibernate mode

- The indicator light is illuminated solid green.

- The Sleep button is illuminated blinking amber.

• Operating in Hibernate mode.

- The indicator light is un-illuminated.

- The Sleep button is blinking amber for 0.1 second, and then goes completely un-illuminated for 1.9 seconds in pulsing pattern.

The following actions wake the printer from Sleep mode:

• Pressing any button

• Opening Tray 1 or loading paper in the multipurpose feeder

• Opening a door or cover

• Sending a print job from the computer

• Performing a power.on reset with the

6 Stop/Cancel button Stops all printer activities.

Note: A list of options are displayed once Stopped appears on the display.

7 Back Return to the previous screen.

8 Home button Go to the home screen.

2-2 Service Manual

Page 39

5026

Go Back

Indicator light status

Indicates

Off Printer power is off.

Blinking green Printer is warming up, processing data, or

printing a job.

Solid green Printer is on, but idle.

Blinking red Operator intervention is required.

2 34

67 5

ABC3DEF

GHI5JKL6MNO

PQR8STU9WXYZ

Use the To

9 Indicator light Check the status of the printer.

10 USB port Connect a USB Bluetooth adapter or a flash drive to the printer.

Note: Only the front USB port supports flash drives.

C748x operator panel

C748x buttons and light descriptions

Use the To

1 Display • View printer status.

• Allow printer setup and operation.

2 Home button Go to the home screen.

3 Keypad Enter numbers and letters.

Diagnostic information 2-3

Page 40

5026

Go Back

Indicator light status

Indicates

Off Printer power is off.

Blinking green Printer is warming up, processing data, or

printing a job.

Solid green Printer is on, but idle.

Blinking red Operator intervention is required.

Use the To

4 Sleep button Enable Sleep mode.

The following are the statuses based on the indicator light and the Sleep button:.

• Entering or waking from Sleep mode

- The indicator light is illuminated solid green.

- The Sleep button is un-illuminated.

• Operating in Sleep mode

- The indicator light is illuminated solid green.

- The Sleep button is illuminated solid amber.

• Entering or waking from Hibernate mode

- The indicator light is illuminated solid green.

- The Sleep button is illuminated blinking amber.

• Operating in Hibernate mode.

- The indicator light is un-illuminated.

- The Sleep button is blinking amber for 0.1 second, and then goes completely un-illuminated for 1.9 seconds in pulsing pattern.

The following actions wake the printer from Sleep mode:

• Pressing any button

• Touching the screen

• Opening Tray 1 or loading paper in the multipurpose feeder

• Opening a door or cover

• Sending a print job from the computer

• Performing a Power On Reset (POR) with the main power switch.

• Loading paper into the scanner ADF.

• Raising the scanner flatbed cover.

5 Stop/Cancel button Stops all printer activities.

Note: A list of options are displayed once Stopped appears on the display.

6 Indicator light Check the status of the printer.

7 USB port Connect a USB Bluetooth adapter or a flash drive to the printer.

2-4 Service Manual

Note: Only the front USB port supports flash drives.

Page 41

5026

Go Back

Using the touch screen buttons

Note: Your home screen, icons, and buttons may vary depending on your home screen customization settings,

administrative setup, and active embedded solutions.

Touch To

1 Up arrow Scroll up.

2 Delete folder Delete the file you selected.

3 Left arrow Scroll to the left.

4 Right arrow Scroll to the right.

5 Right scroll increase Scroll to another value in increasing order.

6 Left scroll decrease Scroll to another value in decreasing

order.

7 Down arrow Scroll down.

Diagnostic information 2-5

Page 42

5026

Go Back

2 3

5678

123.123.123.123

Touch To

8 Accept Save a setting.

9 Cancel • Cancel an action or a selection.

• Cancel out a screen and return to the previous screen

10 Back Navigate back to the previous screen.

Understanding the home screen

When the printer is turned on, the display shows a basic screen, referred to as the home screen. Use the home screen buttons and icons to initiate an action.

Note: Your home screen, icons, and the buttons may vary depending on your home screen customization settings, administrative setup, and active embedded solutions.

Touch To

1 Change Language Change the primary language of the printer.

2 Bookmarks Create, organize, and save a set of bookmarks (URLs) into a tree view of

folders and file links. Note: The tree view does not include bookmarks created within Forms and

Favorites, and the ones in the tree are not usable in Forms and Favorites.

3 Held Jobs Display all current held jobs.

4 USB or USB

Thumbdrive

View, select, or print photos and documents from a flash drive. Note: This icon appears only when you return to the home screen while a

memory card or flash drive is connected to the printer.

5 Menus Access printer menus.

Note: These menus are available only when the printer is in the Ready state.

2-6 Service Manual

Page 43

5026

Go Back

Touch To

6 Status message bar • Show the current printer status such as Ready or Busy.

• Show printer conditions such as Fuser missing or Cartridge Low.

• Show intervention messages and the instructions on how to clear them.

7 Status/Supplies • Display a warning or error message whenever the printer requires

intervention to continue processing.

• Access the messages screen for more information on the message, and how to clear it.

8 Tips Open a context.sensitive Help information on the touch screen.

This may also appear on the home screen:

Touch To

Search Held Jobs Search current held jobs.

Features

Feature Description

Attendance message alert If an attendance message affects a function, then this icon appears an d the red indicator

light blink s.

Warning If an error condition occurs, then this icon appears.

Printe r IP ad dr e ss Sample:

123.123.123.123.123

The IP address of your network printer is located at the top left corner of the home screen and appears as four sets of numbers separated by periods. You can use the IP address when accessing the Embedded Web Server so you can view and remotely configure printer set tings even when you are not physically near the printer.

Diagnostic information 2-7

Page 44

5026

Go Back

Administrative menus

Note: Some menu items may not be available based on the printer model or the options installed.

Supplies Menu Paper Menu Reports Settings

Replace Supply Default Source Menu Settings Page General Settings

Cyan Cartridge Paper Size/Type Device Statistics Flash Drive Menu

Magenta Cartridge Configure MP Network Setup Page Print Settings1

Yellow Cartridge Substitute Size Network [x] Setup Page

Black Cartridge Paper Loading Profiles List

Cyan Photoconductor Custom Types Print Fonts

Magenta Photoconductor Custom Names

Yellow Photoconductor Universal Setup Asset Report

Black Photoconductor

Waste Toner Bottle

Fuser

Transfer Module

Print Directory

Security Network/Ports Help

Miscellaneous Security

Active NIC Print All Guides

Settings

Confidential Print Standard Network OR Network [x]

Color Quality

Disk Wiping Standard USB Print Quality

Security Audit Log Parallel [x] Printing Guide

Set Date and Time Serial [x] Media Guide

SMTP Setup Print Defects Guide

Menu Map

Information Guide

Connection Guide

Moving Guide

Supplies Guide

This menu appears only in touch.screen printer models

Spending on the printer setup, this menu appears as a Standard Network, Wireless Network, or Network [x]

2-8 Service Manual

Page 45

5026

Go Back

Power-on self test (POST) sequence

When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning of the base printer by observing the following:

1. The operator panel turns on and displays the Lexmark logo.

2. A progress bar displays.

3. The LED turns on.

4. The main fan turns on.

5. The machine performs the following tests: a. Sensor check b. Motor check—initializes the following motors:

i. Cam motor ii. EP drive motor iii.Fuser motor iv.Cartridge motor

c. Supplies check

Note: The LED blinks red and an error message displays on the operator panel screen if the machine

detects errors during these test phases.

6. The LED light indicator blinks.

7. The loading screen displays.

Sympto m tab l e s

Printer symptom table

Symptom Action

Dead printer Go to “Dead printer servic e check” on page2-124.

Operator panel—one or more buttons do not work.

Operator panel—display is blank. Printer sounds five beeps.

Operator panel—display is blank. Go to “Operator pan el displ ay blank, five bee ps, LED on ” on

Operator panel—stripes display, distorted display, and other display issues

Tray 1 missing Go to “Tray 1 missing service check” on page 2-135. Tray linking will not work. Go to “Tray linking service check” on page 2-136. Front cover locks, and will not open Go to “Front cover locked in place” on page 3-36.

Go to “One or more operator panel buttons fail” on

page 2-127.

Go to “Operator panel dis play blank, five beeps, and LED is

off” on page 2-127 .

page 2-127.

Go to “Str ipes display, distorted display, and other displ ay

issues” on page 2-128

Diagnostic information 2-9

Page 46

5026

Go Back

Print quality sympto m table

Symptom Action

Background Go to “Print quality—background” on page 2-129. Blank page Go to “Print qual ity—blank page” on page 2-130. Blurred or fuzzy print Go to “Print quality—blurred or fuzzy print” on page 2-132. Half-color page Go to “Print quality—half-color page” on page 2-132. Horizontal banding Go to “Print qual ity—horizontal bandi ng” on page2-132. Horizontal line Go to “Print quality—horizontal line” on page 2-132. Insufficient fusing Go to “Print quali ty—insufficient fus ing” on page 2-132. Missing image at edge Go to “Print quality—mi ssing image at edge” on page 2-132. 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 2-132. Random marks Go to “Print quality—random marks” on page 2-133. Residual image Go to “Print qual ity—residual image ” on page 2-133. Solid color page Go to “Print quality—solid color page” on page 2-133. Vertical banding Go to “Print quality—ver ti cal banding” on page 2-134.

page 2-132.

2-10 Service Manual

Page 47

5026

Go Back

User status and attendance messages

Error code Action

Close Front Door Close the front door securely. If you continuously get this error, then either the 24 V interlock

switch or the 5 V interlock switch is bad. See “24 V interlock switch service check” on

page 2-121 and “5 V interlock switch service check” on page 2-120.

Disk Corrupted, Reformat?

The printer has attempted a disk recovery and cannot repair the disk. The disk must be formatted to use.

Warning: All files stored on the disk will be lost.

Held Jobs May Not Be

The printer has attempted to restore Held jobs, but not all were restored.

Restored

Insert Tray <x> Insert tray to clear the message.

Load <source> <custom type name>

Load paper in the indicated source and of the indicated type. Additional messages may include:

• Paper loaded—Select Continue.

• Show Me—the printer will present instructions.

• Cancel Job—the printer job can be canceled.

• Wait for supplies—If job parking is enabled, and the job meets all the requirements for allowing the job to be parted, the printer adds this message.

Load <source> <Custom String>

Load paper in the indicated source, and select Continue.

Additional messages may include:

• Show Me—the printer will present instructions.

• Cancel Job—the printer job can be cancelled.

• Wait for supplies—If job parking is enabled, and the job meets all the requirements for allowing the job to be parted, the printer adds this message.

Load <source> <size> Load paper in the indicated source and of the indicated size, and select Continue.

Additional messages may include:

• Show Me—the printer will present instructions.

• Cancel Job—the printer job can be cancelled.

• Wait for supplies—If job parking is enabled, and the job meets all the requirements for allowing the job to be parted, the printer adds this message.

Load Manual <custom type name>

If paper loaded is in the manual feeder, the job continues. If paper is not in the feeder, pressing Select indicates to the printer it should search for a source with the proper custom type.

Additional messages may include:

• Show Me—the printer will present instructions.

• Cancel Job—the printer job can be cancelled.

Load Manual <custom string>

If paper loaded is in the manual feeder, the job continues. If paper is not in the feeder, pressing Select indicates to the printer it should search for a source with the proper custom string.

Additional messages may include:

• Show Me—the printer will present instructions.

• Cancel Job—the printer job can be cancelled.

Load Manual <size> If paper loaded is in the manual feeder, the job continues. If paper is not in the feeder,

pressing Select indicates to the printer it should search for a source with the proper size.

Additional messages may include:

• Show Me—the printer will present instructions.

• Cancel Job—the printer job can be cancelled.

Diagnostic information 2-11

Page 48

5026

Go Back

Error code Action

Load Manual <type> <size>

Paper Changes Needed

PC Unit Exposure Warning

Remove All Color Supplies

Remove Paper Standard Bin

Remove Packaging Material

Restore Held Jobs Go/Stop?

If paper loaded is in the manual feeder, the job continues. If paper is not in the feeder, pressing Select indicates to the printer it should search for a source with the proper type and size.

Additional messages may include:

• Show Me—the printer will present instructions.

• Cancel Job—the printer job can be cancelled.

This warning occurs when the front door is left open too long. Close the front door to prevent damage to the PC unit. Select Tell me more for further information.

If Color Lockout mode is enabled, this message appears (unless the printer is in Diagnostics Menu or Configuration Menu).

The standard output bin is full. Remove the media to continue.

If packaging material is detected by the printer, Check all areas, Check <area name>, or Check <number of> areas may appear. Press Select to continue.

If the printer detects Print and Hold (or parked) jobs stored on the hard disk during Power-On Self Test (POST). Choices are:

• Restore—Print jobs are restored, and Restoring Held Jobs x/y, where x is the number

of the job restored and y is the total number of jobs to restore. You can quit restoring, and the remainder of the jobs will remain on the disk, but cannot be accessed until they are restored at the next POR.

• Do not restore—Held jobs will remain on the disk, but cannot be accessed until they are

restored at the next POR. Held jobs may not be restored appears.

• Tell me more—additional information is available

Securely Clearing Disk Space

Tray Length Guide

Disk wiping process is recovering disk space. The message clears when all memory blocks are cleared.

Replace the tray length guide.

Missing

Unsupported USB

Remove the unrecognized device to continue.

device, Please Remove

Unsupported USB hub,

Remove the unrecognized device to continue.

Please Remove

Unsupported Mode Unplug camera and change it to a mode where the camera can access PictBridge. Plug the

camera back in to continue.

Unsupported Disk Remove the unsupported disk to continue.

2-12 Service Manual

Page 49

5026

Go Back

Error code Action

3x through 8x attendance messages

31 Defective or Missing

<color> Cartridge

32 Unsupported Cartridge

• Reseat the specified toner cartridge.

• Inspect the smart chip card contacts (A) for damage, contamination or positioning error. If damaged, contact your next level of service.

• Inspect the toner cartridge contacts for damage/contamination. Replace the toner cartridge if defective.

• Replace the indicated cartridge.

• If the problem still exists, see “31.xx—Cartridge errors service check” on page 2-45.

• Check to see if the toner cartridge is a supported cartridge. Note: Once the cartridge shipped with the printer is exhausted, it must be replaced by a

supply cartridge (refer to the User’s Guide for part numbers.)

If the specified toner cartridge is a supported cartridge, reseat the cartridge.

• Inspect the toner cartridge contacts for damage or contamination. Replace the toner cartridge if defective.

• Inspect JSBTN1 cable connection. Properly connect the cable if not connected properly. Replace the cable if damaged.

• If the problem still exists, replace the system board. See “System board rem oval” on

page 4-155.

34 Short Paper • Select Continue to clear the message and continue printing.

Note: The printer does not automatically reprint the page that prompted the message.

• Check the tray length and width guides to ensure the media is properly fitted.

• Make sure the print job is requesting the correct size of media.

• Adjust the Paper Size setting for the media size being used.

• If the MP Feeder Size is set to Universal, make sure the media is large enough for the formatted data.

• Cancel the current job. Replace the paper pick mechanism. See “Paper pick

mechanism assembly removal” on page 4-137.

• If the problem still exists, replace the system board. See “System board rem oval” on

page 4-155.

35 Insufficient memory to support Resource Save feature

• Select Continue to disable Resource Save and continue printing.

• To enable Resource Save after receiving this message:

- Make sure the link buffers are set to Auto, then exit the menus to activate the link buffer changes.

- When Ready is displayed, enable Resource Save.

• Install additional memory.

• If this does not fix the problem, replace the system board. See “System boar d removal ”

on page 4-155.

Diagnostic information 2-13

Page 50

5026

Go Back

Error code Action

37 Insufficient memory to collate job

37 Insufficient memory for Flash Memory Defragment operation

37 Insufficient memory, Some Held Jobs Were Not Restored

37 Insufficient memory, Some Held Jobs Will Not Be Restored

37 Insufficient Defrag Memory

• Select Continue to print the portion of the job already stored and begin collating the rest

of the job.

• Cancel the current job.

• If this does not fix the problem, replace the system board. See “System board rem oval”

on page 4-155.

• Select Continue to stop the defragment operation and continue printing.

• Delete fonts, macros, and other data in printer memory.

• Install additional printer memory.

• If this does not fix the problem, replace the system. See “System board removal” on

page 4-155.

• The printer deleted some held jobs in order to process current jobs.

• Select Continue to clear the message.

• If this does not fix the problem, replace the system board. See “System board rem oval”

on page 4-155.

• The printer was unable to restore some or all of the confidential or held jobs on the hard disk.

• Select Continue to clear the message.

• If this message occurs again, replace the hard drive.

• If this does not fix the problem, replace the system board. See “System board rem oval”

on page 4-155.

There is insufficient memory to perform the Flash Memory Defragment operation. The user can:

• Delete font, macros, and other data in memory.

• Install additional printer memory.

38 Memory Full The following options are available:

• Select Continue to clear the message and continue printing. The job may not print correctly.

• Cancel the current job.

• Install additional printer memory.

• If this does not fix the problem, replace the system board. See “System board rem oval”

on page 4-155.

39 Complex Page The page is too complex to print. Options are:

• Select Continue to continue. The job may not print correctly.

• Cancel the job.

• Additional memory may fix the problem.

50 PPDS Font Error • Select Continue to clear the message and continue printing. The job may not print

correctly.

• Cancel the current job.

• If this does not fix the problem, replace the system board. See “System board rem oval”

on page 4-155.

51 Defective Flash • Select Continue to clear the message and continue printing.

• Install different flash memory before downloading any resources to flash.

• If this does not fix the problem, replace the system board. See “System boar d removal ”

on page 4-155.

2-14 Service Manual

Page 51

5026

Go Back

Error code Action

52 Flash Full • Select Continue to clear the message and continue printing.

Note: Downloaded fonts and macros not previously stored in flash memory are deleted.

• Delete fonts, macros, and other data stored in flash memory.

• Install a larger capacity flash memory card.

• If this does not fix the problem, replace the system board. See “System board rem oval”

on page 4-155.

53 Unformatted Flash • Select Continue to clear the message and continue printing.

• Format the flash memory before storing any resources on it. If the error message remains, replace the flash memory.

• If this does not fix the problem, replace the system board. See “System board rem oval”

on page 4-155.

54 Serial option <x>

error

54 Std Network Software Error

55 Unsupported Option

in Slot <x>

56 Standard Parallel Port Disabled

56 Parallel Port <x>

Disabled

• Make sure the serial link is set up correctly and the appropriate cable is in use.

• Make sure the serial interface parameters (protocol, baud, parity, and data bits) are set correctly on the printer and host computer.

• Select Continue to clear the message and continue printing. The job may not print correctly.

• POR the printer. If this does not fix the problem, replace the PCI card.

• Select Continue to clear the message and continue printing. The job may not print correctly.

• Program new firmware for the network interface.

• POR the printer. If this does not fix the problem, replace the PCI card.

1. Turn the printer off.

2. Unplug the power cord from the wall outlet.

3. Remove the unsupported option.

4. Connect the power cord to a properly grounded outlet.

5. Turn the printer on.

If this does not fix the problem, replace the system board. See “System boa rd removal” on

page 4-155.

• Select Continue to clear the message. The printer discards any data received through the parallel port.

• Make sure the Parallel Buffer menu item is not set to Disabled.

• If this does not fix the problem, replace the PCI card.

• Select Continue to clear the message. The printer discards any data received through the parallel port.

• Make sure the Parallel Buffer menu item is not set to Disabled.

• If this does not fix the problem, replace the PCI card.

56 Serial Port <x>

Disabled

56 Standard USB Port Disabled

• Select Continue to clear the message. The printer discards any data received through the serial port.

• Make sure the Serial Buffer menu item is not set to Disabled.

• If this does not fix the problem, replace the PCI card.

• Select Continue to clear the message. The printer discards any data received through the USB port.

• Make sure the USB Buffer menu item is not set to Disabled.

• If this does not fix the problem, replace the system board. See “System board rem oval”

on page 4-155.

Diagnostic information 2-15

Page 52

5026

Go Back

Error code Action

57 Configuration Change Held Jobs May Not Be Restored

58 Too Many Flash Options

58 Too Many Trays Attached

59 Incompatible Tray <x>

Configuration changes may be:

• Code version changes

• Paper handling options removed

• The disk was installed from a different model or speed of printer.

Too many flash options are installed. To continue:

1. Turn off and unplug the printer.

2. Remove the excess flash memory.

3. Plug in the printer, and turn it on.

If this does not fix the problem, replace the system board. See “System boa rd removal” on

page 4-155.

1. Turn off and unplug the printer.

2. Remove options until the supported number of options for that model.

3. Plug in the printer, and turn it on.

If this does not fix the problem, replace the system board. See “System boa rd removal” on

page 4-155.

There is an incompatible tray. To remove the option:

1. Turn off and unplug the printer.

2. Remove all option trays.

3. Install one option, plug in the printer and turn it on.

4. Continue adding one option at a time and checking whether the error occurs.

5. Install all options except the one identified as a problem.

- If no problem occurs, replace the option.

- If the same error occurs, replace the system board.

6. Plug in and power on

61 Defective Disk • Select Continue to clear the message and continue printing.

• Install a different hard disk before performing any operations that require a hard disk.

• If this does not fix the problem, replace the system board. See “System boar d removal ”

on page 4-155.

62 Disk full • Select Continue to clear the message and continue processing.

• Any information not previously stored on the hard disk is deleted.

• Delete fonts, macros, and other data stored on the hard disk.

• Install a larger hard disk.

• If this does not fix the problem, replace the system board. See “System board rem oval”

on page 4-155.

63 Unformatted disk • Select Continue to clear the message and continue printing.

• Format the disk.

• If the error message remains, replace the hard disk.

• If this does not fix the problem, replace the system board. See “System board rem oval”

on page 4-155.

64 Unsupported disk format

• Select Continue to clear the message and continue printing.

• Format the disk.

• If the error message remains, replace the hard disk.

• If this does not fix the problem, replace the system board. See “System board rem oval”

on page 4-155.

80 Fuser Near Life Warning

• Select Continue to clear the message and continue printing.

• Show Me, View Supplies, and Tell Me More displays additional information.

• Order a replacement fuser. When print quality is reduced, install the new fuser using the instruction sheet that comes with the replacement fuser.

Note: Be sure to reset the fuser count. See “Reset Fuser Cnt” on page 3-28.

• If this does not fix the problem, replace the system board.See “System board rem oval”

on page 4-155.

2-16 Service Manual

Page 53

5026

Go Back

AC autoconnect

DC autoconnect

Pin 1 Pin 3

Pin 5 Pin 4

Pin 6

Pin 7

Pin 8

Pin 9

Pin 10

Error code Action

80 Fuser Life Warning • Select Continue to clear the message and continue printing.

• Show Me, View Supplies, and Tell Me More displays additional information.

• Order a replacement fuser. When print quality is reduced, install the new fuser using the instruction sheet that comes with the replacement fuser.

Note: Be sure to reset the fuser count. See “Reset Fuser Cnt” on page 3-28.

• If this does not fix the problem, replace the system board. See “System board rem oval”

on page 4-155.

80 Replace Fuser • Show Me, View Supplies, and Tell Me More displays additional information.

• Replace the fuser. See “Fuser removal” on page 4-110. Note: Be sure to reset the fuser count. See “Reset Fuser Cnt” on page 3-28.

• If this does not fix the problem, replace the system board. See “System board rem oval”

on page 4-155.

80 Fuser Missing • Reinstall the fuser. See “Fuser removal” on page 4-110.

• Reseat connectors behind fuser. They may get dislodged and not make good contact when the fuser is installed.

• Check the cable connectors for damage at the system board and at the LVPS.

80.41 Fuser missing • Install the fuser. Replace the fuser if the problem persists.

• If the problem continues, turn the printer off and remove the rear frame cover. See “Rear

frame cover remova l” on pag e 4-47. Check the cable in connector JFUSER1 for proper

connection to the system board, the cable for pinch points, and the cable or the connector for any other damage. If the connector is damaged on system board, replace the system board. See “System board remova l” on page 4-155. If the fuser cable is damaged, replace the cable.

• Check for the following continuity between the DC autoconnect and FUSER1.

82 Waste Toner Nearly Full

82 Replace Waste Toner

• If continuity is not present, replace the fuser cable. If the problem persists after replacing cable, replace the system board. See “System board removal” on page 4-155.

• Select Continue to clear the message and continue printing.

• If printing continues, order a replacement waste toner box immediately.

• If the problem persists, open the front access door and check the aligner shaft for binding. Clear the binding if possible. If not possible, contact your next level of service.

• Replace the waste toner box using the instruction sheet that comes with the replacement waste toner box.

• Ensure that there is no interference between the waste toner box and the printer.

• If the problem persists, open the front access door and check the aligner shaft for binding. Clear the binding if possible.

• If the problem persists, replace the system board. See “System board removal” on

page 4-155.

• If the problem persists, contact your next level of service.

Diagnostic information 2-17

Page 54

5026

Go Back

Error code Action

82 Waste Toner Missing • Insert the waste toner box.

• Inspect the top cover camshaft assembly for proper operation. When the top access cover is closed, the printer should mechanically interlock.

• Check the cable in connector JBUMP1on the system board for defects and proper connection. If the cable wiring or the cable connection is defective, replace the bump multipurpose feeder/duplex motor assembly. See “Multipurpose feeder (MPF)/duplex

motor assembly removal” on page 4-125. If the cable in JBUMP1 connector is

damaged on the system board, replace the system board. See “System board re moval”

on page 4-155.

• Check the aligner shaft and the mechanical system for binds.

• Replace the bump multipurpose feeder/duplex motor assembly. See “Multipurpose

feeder (MPF)/duplex motor assembly removal” on page 4-125.

• If the problem persists, replace the system board. See “System board removal” on

page 4-155.

82.41 If you continuously get this error, then the problem is the aligner motor error. Go to “147.xx,

920.01—POST (power-on self test) aligner error service check” on page 2-57.

83.xx Transfer Module

Life Warning

• Select Continue to clear the message and continue printing.

• Order a replacement transfer module. When print quality is reduced, install the new transfer module using the instruction sheet that comes with the replacement transfer module.

• If the problem persists, replace the system board. See “System board removal” on

page 4-155.

83.xx Replace Transfer

Module

• Replace the transfer module using the instruction sheet that comes with the replacement transfer module. See “Transfer module removal ” on page4-171.

• If the problem persists, replace the system board. See “System board removal” on

page 4-155.

83.41 Transfer Module Missing

84.11 <color> PC Unit

Life Warning

If the you continuously get this error, go to “920.03, 920.25—Transfer Module Missing or

not connected servic e check” on page2-97.

• Select Ignore to clear the message and continue printing.

• Order the specified photoconductor unit. When print quality is reduced, install the new specified photoconductor unit using the instruction sheet that comes with the replacement specified photoconductor unit.

• If the problem persists, replace the system board. See “System board removal” on

page 4-155.

84 Replace <color> PC

Unit

• Replace the specified photoconductor unit using the instruction sheet that comes with the replacement specified photoconductor unit. Navigate to Menu > Supplies menu > Replace supplies.

• If the problem persists, replace the system board. See “System board removal” on

page 4-155.

Note: Make sure to reset the photoconductor unit counter(s).

2-18 Service Manual

Page 55

5026

Go Back

High voltage

contact path

High voltage

power supply

Finger

Error code Action

84 <color> PC Unit

Missing

• Scroll down the operator panel to see if the printer is showing that all four of the PC units are missing. If so, check the HVPS cable between the system board and the HVPS. Ensure that the cable is not plugged in backwards on the HVPS. Disconnect and reconnect the cable to make sure there is good contact.

• Insert or reinstall the specified photoconductor unit and see if problem clears. See

“Photoconductor unit removal” on page 4-142.

• Swap the photoconductor unit between two locations and see if the problem moves with photoconductor unit. If problem follows the photoconductor unit, replace the photoconductor unit. See “Photoconductor unit removal” on page 4-142.

• Remove the top access cover assembly (see “Top access cover assem bly removal”

on page 4-54), and confirm that the camshaft follower (A) on the left side is not out of the

groove (B). If the camshaft follower is out of the groove, raise the arm, use a screwdriver

to ease the camshaft follower back into the groove. You need to press down to snap it

into position.

• Check the high voltage contacts path, especially the “finger” on the specified photoconductor unit (printer is shown with components removed for clarity).

• If the contacts are good, replace the HVPS. See “High-voltage power supply (HVPS)

removal” on page 4-115.

• If the problem persists, replace the system board. See “System board removal” on

page 4-155.

Note: Make sure to reset the photoconductor unit counter(s).

Diagnostic information 2-19

Page 56

5026

Go Back

Error code Action

84 <color> PC Unit Near Life Warning

88.xx <color> Cartridge

Low

88.xx <color> Cartridge Nearly Low

88.xx Replace <color>

Cartridge

• Select Ignore to clear the message and continue printing.

• If the problem persists, replace the system board. See “System board removal” on

page 4-155.

Note: Make sure to reset the photoconductor unit counter(s).

• Show Me, View Supplies, and Tell Me More displays additional information.

• Replace the specified toner cartridge.

• Select Continue to clear the message and continue printing.

• If the problem persists, replace the system board. See “System board removal” on

page 4-155.

• Show Me, View Supplies, and Tell Me More displays additional information.

• Replace the specified toner cartridge.

• Select Continue to clear the message and continue printing.

• If the problem persists, replace the system board. See “System board removal” on

page 4-155.

• Show Me, View Supplies, and Tell Me More displays additional information.

• Replace the specified toner cartridge.

• Select Continue to clear the message and continue printing.

• If the problem persists, replace the system board. See “System board removal” on

page 4-155.

2-20 Service Manual

Page 57

5026

Go Back

Error codes and messages

Error code Description Action

1xx service error codes

110.01–110.07Mirror Motor Error

111.01–111.02 Printhead Error

112.01–112.02 Printhead Error

113.01–113.02 Printhead Error

114.01–114.02 Printhead Error

120.00–120.21 Fuser Error

140.01–140.10 Autocomp Motor Error

A mirror motor error has occurred. • POR the printer.

• If the error message persists, go to “110.xx—

Mirror motor service check” on page 2-45.

An error has occurred in the cyan channel of the printhead.

• POR the printer.

• If the error message persists, go to “111.xx,

112.xx, 113.xx, and 114.xx—Printhead error service check” on page 2-46.

An error has occurred in the magenta channel of the printhead.

• POR the printer.

• If the error message persists, go to “111.xx,

112.xx, 113.xx, and 114.xx—Printhead error service check” on page 2-46.

An error has occurred in the yellow channel of the printhead.

• POR the printer.

• If the error message persists, go to “111.xx,

112.xx, 113.xx, and 114.xx—Printhead error service check” on page 2-46.

An error has occurred in the black channel of the printhead.

• POR the printer.

• If the error message persists, go to “111.xx,

112.xx, 113.xx, and 114.xx—Printhead error service check” on page 2-46.

An error has occurred in the fuser. • Remove and reseat the fuser. See “Fuser

removal” on page 4-110.

• POR the printer.

• If the error message persists, go to “120.xx—

Fuser error service check” on page 2-47.

Tray 1 motor has failed. • POR the printer.

• If the error message persists, go to “140.xx,

920.02—Autocomp (tray 1) motor error service check” on page 2-49.

142.09—142.27 Motor Error

143.09–143.27 Motor Error

144.09–144.27 Motor Error

145.09–145.27 Motor Error

Fuser motor has failed. • POR the printer.

• If the error message persists, go to “142.xx,

906.01–906.04— M otor (fuser) error service check” on page 2-49.

EP Drive assembly cartridge 1 (top) motor has failed.

• POR the printer.

• If the error message persists, go to “143.xx—

Motor (EP drive assembly top cartridge 1 motor) error service check” on page 2-51.

EP Drive assembly cartridge 2 (middle) motor has failed.

• POR the printer.

• If the error message persists, go to “144.xx—

Motor (EP drive assemb ly middl e cartridge) error service check” on page 2-52.

EP drive assembly cartridge 3 (bottom) motor has failed.

• POR the printer.

• If the error message persists, go to “145.xx—

Motor (EP drive assemb ly bottom cartridge) error service check” on page 2-54.

Diagnostic information 2-21

Page 58

5026

Go Back

Error code Description Action

146.01–146.08 Motor Error

147.09–147.25 Motor Error

148.01–148.08 Motor Error

155.01, 155.03 Motor Error

156.01, 156.03 Motor Error

160.01–160.06 Motor Error

161.01–161.06 Motor Error

Duplex motor has failed. • POR the printer.

• If the error message persists, go to “146.xx,

148.xx—Motor (MPF/duplex) error service check” on page 2-55.

Aligner motor has failed. • POR the printer.

• If the error message persists, go to “147.xx,

920.01—POST (power-on self test) aligner error service check” on page 2-57.

The multipurpose feeder motor has failed.

• POR the printer.

• If the error message persists, go to “146.xx,

148.xx—Motor (MPF/duplex) error service check” on page 2-55.

Cam motor failed. • POR the printer.

• If the error message persists, go to “155.xx—

Cam motor error service check” on page 2-58.

COD (Color On Demand) motor failed. • POR the printer.

• If the error message persists, go to “156.xx—

COD (Color On Demand) motor service check” on page 2-60.

Tray 2 pick motor failed. • POR the printer.

• If the error message persists, go to “160.xx,

161.xx—Motor Error (option tray 2) ser vice check” on page 2-60.

Tray 2 feed motor failed. • POR the printer.

• If the error message persists, go to “160.xx,

161.xx—Motor Error (option tray 2) ser vice check” on page 2-60.

162.01–162.06 Motor Error

163.01–163.06 Motor Error

164.01–164.06 Motor Error

165.01–165.06 Motor Error

166.01–166.06 Motor Error

167.01–167.06 Motor Error

Tray 3 pick motor failed. • POR the printer.

• If the error message persists, go to “162.xx,

163.xx—Motor Error (option tray 3) ser vice check” on page 2-61.

Tray 3 feed motor failed. • POR the printer.

• If the error message persists, go to “162.xx,

163.xx—Motor Error (option tray 3) ser vice check” on page 2-61.

Tray 4 pick motor failed. • POR the printer.

• If the error message persists, go to “164.xx,

165.xx—Motor Error (option tray 4) ser vice check” on page 2-62.

Tray 4 feed motor failed. • POR the printer.

• If the error message persists, go to “164.xx,

165.xx—Motor Error (option tray 4) ser vice check” on page 2-62.

Tray 5 pick motor failed. • POR the printer.

• If the error message persists, go to “166.xx,

167.xx—Motor Error (option tray 5) ser vice check” on page 2-63.

Tray 5 feed motor failed. • POR the printer.

• If the error message persists, go to “166.xx,

167.xx—Motor Error (option tray 5) ser vice check” on page 2-63

2-22 Service Manual

Page 59

5026

Go Back

Error code Description Action

168.xx

HCIT elevator motor error. • POR the printer.

Motor Error

199.xx

Unrecoverable RIP software error. • POR the printer.

Software Error

2xx paper jam messages

200.02 Input sensor is made when printer tries to print from an idle state.

Possible causes:

• Paper jam leaving page over sensor

• Defective input sensor

• Faulty system board

200.04 Input sensor made late in the input sensor.

Possible causes:

• Paper jam leaving page over sensor

• Defective input sensor

• Faulty system board

• If the error message persists, go to “168.xx—

Motor (HCIT elevator ) error service check ” on page 2-64.

• If the error message persists with new code,

replace the system board. See “System board

removal” on page 4-155.

• Clear away anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “920.06—Input sensor service check”

on page 2-99.

• Clear away anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “920.06—Input sensor service check”

on page 2-99.

200.11 Input sensor does not break.

Possible causes:

• Incorrect media setting

• Incorrect paper loading

• Incorrect media restraint setting

• Transport belt module failure

• Lower guide failure

• Paper pick mechanism failure

• Input sensor failure

200.17 Input sensor is made when printer powers up or covers are closed.

Possible causes:

• Paper jam leaving page over sensor

• Defective input sensor

• Faulty system board

200.21 Aligner motor stalled.

Possible causes:

• Waste toner not seated.

• Faulty cable/connector

• 24 V interlock switch not working correctly

• Faulty align motor

• Faulty system board

1. Clear away anything in the paper path that might cause the paper to jam.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack flat in the tray.

4. Properly set media restraints in the paper tray.

5. Check the pick arm rolls (tires) and replace if worn.

If the problem persists, go to “200.11, 250.03—

Paper Jam error service check” on page 2-64.

• Clear away anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “920.06—Input sensor service check”

on page 2-99.

• Check that the waste toner is latched correctly in the printer.

• Check for anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “147.xx, 920.01—POST (power-on self

test) aligner error service check” on page 2-57.

Diagnostic information 2-23

Page 60

5026

Go Back

Error code Description Action

200.22 Pick (tray 1) motor stalled.

Possible causes:

• Faulty cable/connector

• Faulty pick motor

• Faulty system board

200.25 Input sensor is made when tray 1 is installed.

Possible causes:

• Improper placement of paper in tray 1

• Damaged input sensor flag or input sensor

• Faulty system board

200.30 Paper hit input sensor too soon.

Possible causes:

• Incorrect paper loading

• Damaged input sensor flag or input sensor

• Faulty system board

201.02 Bubble sensor active when printing started.

Possible causes:

• Paper jam leaving page over sensor

• Damaged bubble sensor

• Damaged fuser autoconnect

• Faulty fuser DC cable connection

• Faulty fuser

• Faulty system board

• Check for anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “140.xx, 920.02—Autocomp (tray 1)

motor error ser vice check” on page 2-49.

• Fan media, and stack flat in the tray or multipurpose feeder.

• Properly set media restraints in the paper tray.

• If clearing a paper jam does not fix the problem, go to “920.06—Input sensor service check”

on page 2-99.

• Fan the media, and then stack flat in the tray.

• Check for anything in the paper path that might cause the paper to jam.

• The input sensor may not be functioning properly. Go to “920.06—Input senso r service

check” on page 2-99.

1. Clear away anything in the paper path that might cause the paper to jam.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack flat in the tray.

4. Properly set media restraints in the paper tray.

If the problem persists, go to ““Bubble sensor

service check” on page 2-122.

201.06 Paper is jammed between the input sensor and the exit sensor.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Transport belt module failure

• Aligner failure

• Damaged fuser autoconnect

• Faulty fuser DC cable connection

• Faulty fuser

• Faulty system board

201.07 Exit sensor is made early.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Damaged fuser autoconnect

• Faulty fuser DC cable connection

• Faulty fuser

• Faulty system board

• Faulty input sensor flag

2-24 Service Manual

• Check for anything in the paper path that might cause the paper to jam.

•Go to “201.06, 201.08, 201.31—Paper Jam

error service check” on page 2-65.

• Check for anything in the paper path that might cause the paper to jam.

• The fuser exit sensor may not be functioning properly. Go to “920.08—Exit sensor service

check” on page 2-100.

• Check the input sensor flag.

Page 61

5026

Go Back

Error code Description Action

201.08 Exit sensor is never made.

Possible causes:

• Improper loading

• Paper wrapped in fuser

• Damaged paper exit sensor or paper exit sensor flag

• Damaged fuser autoconnect

• Faulty fuser DC cable connection

• Faulty fuser

• Faulty system board

• Faulty transfer belt module

201.10 Input sensor flag broke early.

Possible causes:

• Incorrect media set

• Defective input sensor

• Faulty system board

201.17 Power up or cover closed with bubble sensor active.

Possible causes:

• Paper jam leaving page over sensor

• Damaged bubble sensor

• Damaged fuser autoconnect

• Faulty fuser DC cable connection

• Faulty fuser

• Faulty system board

• Check for anything in the paper path that might cause the paper to jam.

• The fuser exit sensor may not be functioning properly. Go to “920.08—Exit sensor service

check” on page 2-100.

• Check the transfer belt module.

• Check for anything in the paper path that might cause the paper to jam.

• Ensure the proper media is set for the type of paper used.

•Go to “920.06—Input sensor service check”

on page 2-99.

1. Ensure the proper media is set for the type of paper used.

2. Fan the media, and stack flat in the tray or multipurpose feeder.

3. Properly set media restraints in the paper tray.

4. Clear away anything in the paper path that might cause the paper to jam.

If the problem persists, go to “Bubble sensor

service check” on page 2-122.

201.21 Cartridge motor 1 (top) or cartridge motor 2 (middle) has stalled.

Possible causes:

• Faulty cable/connector

• Faulty cartridge motor

• Faulty system board

201.24 A 201.08 jam occurred and was not cleared.

Possible cause—Failure to open and close the top access door.

201.31 Paper is jammed between the input sensor and the exit sensor during warm-up.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Transport belt module failure

• Lower guide failure

• Damaged fuser autoconnect

• Faulty fuser DC cable connection

• Faulty fuser

• Faulty system board

• Check for anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “143.xx—Mo tor (EP drive assembly top

cartridge 1 moto r) error service chec k” on page 2-51, and then go to “144.xx—Motor (EP drive assembly middle cartridge) error service check” on page 2-52, if necessary.

This error is generated as a protection for possible paper wrap in the fuser.

• Open the top access door, and check for a paper jam. Close the top access door.

•Go to “920.08—Exit sensor service check”

on page 2-100.

• Check for anything in the paper path that might cause the paper to jam.

•Go to “201.06, 201.08, 201.31—Paper Jam

error service check” on page 2-65.

Diagnostic information 2-25

Page 62

5026

Go Back

Error code Description Action

201.32 Paper is jammed between the input sensor and the exit sensor during input options warm-up.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Transport belt module failure

• Lower guide failure

• Damaged fuser autoconnect

• Faulty fuser DC cable connection

• Faulty fuser

• Input option damage

• Faulty system board

202.02 Exit sensor is made when printer tries to print from an idle state.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Damaged fuser autoconnect

• Faulty fuser DC cable connection

• Faulty fuser

• Faulty system board

202.12 Exit sensor broke early.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Faulty fuser

• Faulty system board

• Check for anything in the paper path that might cause the paper to jam.

• Open input tray and clear paper jams.

• Check for anything in the paper path that might cause the paper to jam.

• The fuser exit sensor may not be functioning properly. Go to “920.08—Exit sensor service

check” on page 2-100.

The fuser exit sensor may not be functioning properly. Go to “920.08—Exit sensor service

check” on page 2-100.

202.13 Exit sensor never broke.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Faulty fuser

• Faulty system board

• Faulty output bin flag

202.17 Exit sensor is made when the printer powers up or covers are closed.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Damaged fuser autoconnect

• Faulty fuser DC cable connection

• Faulty fuser

• Faulty system board

202.21 Fuser motor stalled.

Possible causes:

• Faulty cable/connector

• Faulty fuser motor

• Faulty system board

• Check exit sensor flag on fuser for proper operation. Ensure that paper is not hanging on the flag.

• The fuser exit sensor may not be functioning properly. Go to “920.08—Exit sensor service

check” on page 2-100.

• Check the output bin flag.

• Check for anything in the paper path that might cause the paper to jam.

• The fuser exit sensor may not be functioning properly. Go to “920.08—Exit sensor service

check” on page 2-100.

• Check for anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “142.xx, 906.01–906.04—Motor (fuser)

error service check” on page 2-49.

2-26 Service Manual

Page 63

5026

Go Back

Error code Description Action

202.31 Paper jam at exit sensor during warmup.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Damaged fuser autoconnect

• Faulty fuser DC cable connection

• Faulty fuser

• Faulty system board

203.09 During duplex printing retract, the exit sensor is never made.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Transport belt module failure

• Damaged fuser autoconnect

• Faulty fuser DC cable connection

• Faulty fuser

• Faulty system board

203.14 During duplex printing retract, the exit sensor broke early.

Possible causes:

• Incorrect paper settings

• Damaged paper exit sensor or paper exit sensor flag

• Faulty fuser

• Faulty system board

• Check for anything in the paper path that might cause the paper to jam.

• The fuser exit sensor may not be functioning properly. Go to “920.08—Exit sensor service

check” on page 2-100.

• Check for anything in the paper path that might cause the paper to jam.

• The fuser exit sensor may not be functioning properly. Go to “2 03.09—Paper Jam error

service check” on page 2-68.

• Ensure proper media is set for the type of paper used.

• The fuser exit sensor may not be functioning properly. Go to “920.08—Exit sensor service

check” on page 2-100.

203.15 During duplex printing, the exit sensor never broke.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Obstructed duplex

• Faulty fuser

• Faulty system board

• Duplex motor failure

• Faulty bin full sensor

203.20 During duplex, the page entered the duplex path before the previous page cleared the path.

Possible causes:

• Defective input sensor

• Faulty system board

• Wrong media size selected

• Defective exit sensor

• Check the duplex paper path for damage that would obstruct the print. If damage is found, replace the front door assembly. See “Front

door assembly removal ” on page4-100.

• The fuser exit sensor may not be functioning properly. Go to “920.08—Exit sensor service

check” on page 2-100.

• The duplex motor may not be functioning properly. Go to “1 46.xx, 148.xx—Motor (MPF/

duplex) error service check” on page 2-55.

• Check the bin full sensor and bin full sensor flag.

• Check for anything in the duplex paper path that might cause the paper to jam. This includes the paper guides in tray 1.

• If clearing the paper jam does not fix the problem and the paper is fan-folded, replace the front access assembly. See “Front door

assembly removal” on page 4-100.

• If clearing a paper jam does not fix the problem, go to “920.06—Input sensor service check”

on page 2-99.

• Make sure the selected media and media definitions match.

• Check the exit sensor.

Diagnostic information 2-27

Page 64

5026

Go Back

Error code Description Action

230.03 During duplex printing, the input sensor never broke.

Possible causes:

• Obstructed duplex path

• Duplex drive failure

• Defective input sensor

• Faulty system board

230.05 During duplex printing, the input sensor is not made.

Possible causes:

• Obstructed duplex path

• Defective input sensor

• Faulty system board

• Faulty duplex drive

230.21 Duplex motor stalled.

Possible causes:

• Obstructed duplex path

• Defective duplex motor

• Faulty system board

241.03 While feeding from tray 1, the input sensor does not break.

Possible causes:

• Incorrect media setting

• Incorrect paper loading

• Incorrect media restraint setting

• Paper pick mechanism failure

• Transport belt motor failure

• Check for anything in the duplex paper path that might cause the paper to jam. This includes the paper guides in tray 1.

•Go to “230.03, 230.05—Paper Jam error

service check” on page 2-70.

• Check for anything in the duplex paper path that might cause the paper to jam. This includes the paper guides in tray 1.

•Go to “230.03, 230.05—Paper Jam error

service check” on page 2-70.

• Check for anything in the duplex paper path that might cause the paper to jam. This includes the paper guides in tray 1.

• If clearing a paper jam does not fix the problem, go to “146.xx, 148.xx—Motor (MPF/duplex)

error service check” on page 2-55.

1. Clear away anything in the paper path that might cause the paper to jam.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack it flat in the tray or multipurpose feeder.

4. Properly set media restraints in paper tray.

5. Check the pick arm rolls (tires) and replace if worn.

If the problem persists, go to “200.11, 250.03—

Paper Jam error service check” on page 2-64.

241.05 While feeding from tray 1, the input sensor is never made.

Possible causes:

• Incorrect paper loading

• Incorrect media restraint setting

• Pick art rolls (tires) failure

• Paper pick mechanism failure

• System board failure

241.21 Tray 1 motor stalled.

Possible causes:

• Incorrect paper loading

• Paper pick mechanism failure

• System board failure

242.02 Tray 2 pass thru sensor made at POR.

Possible causes:

• Paper jam leaving paper over sensor

• Defective pass thru sensor

2-28 Service Manual

1. Remove all media present in the paper path.

2. Fan media, and stack it flat in the tray or multipurpose feeder.

3. Properly set media restraints in paper tray.

4. Check the pick arm rolls (tires) and replace if worn.

If the problem persists, go to “140.xx, 920.02—

Autocomp (tray 1) motor error service check” on page 2-49.

1. Remove all media present in the paper path.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack it flat in the tray or multipurpose feeder.

If the previous actions do not fix the problem, go to

“140.xx, 920.02—Autocomp (tray 1) moto r error service check” on page 2-49.

• Check for anything in the paper path that might cause the paper to jam.

• If the error persists, go to “242.02—Paper Jam

service check” on page 2-71.

Page 65

5026

Go Back

Error code Description Action

242.03 Pick timeout from tray 2 exceeded without a tray 2 sensor break.

Possible causes:

• Incorrect media setting

• Incorrect paper loading

• Incorrect media restraint setting

• Tray 2 assembly failure

• Aligner failure

• Transport belt module failure

242.05 Tray 2 picked, but page failed to reach the option sensor in time.

Possible causes:

• Incorrect media setting

• Incorrect paper loading

• Incorrect media restraint setting

• Loading card stock from the special media tray above the fill line

242.10 Tray 2 page exits pass thru made early.

Possible causes:

• Defective pass thru sensor

• Faulty cable in the connector JOPT1 on system board

1. Remove all media present in the paper path.

2. Ensure proper media is set for the type of paper used in tray 2.

3. Fan media, and stack flat in tray 2.

4. Properly set media restraints in tray 2.

If the paper jam message persists, go to “242.03,

242.11—Paper Jam service check” on page 2-72.

1. Ensure proper media is set for the type of paper used in tray 2.

2. Fan media, and stack flat in tray 2.

3. Properly set the media restraints in tray 2.

4. Check the pick arm rolls (tires) in tray 2 and replace if worn.

If the previous actions do not fix the problem, go to

“242.05—Paper Jam service check” on page 2-73.

• Ensure the proper media is set for the type of paper used in tray 2.

• Check for anything in the paper path that might cause the paper to jam.

• The exits pass thru sensor may not be functioning properly. Go to “242.10—Paper

Jam service check” on page 2-74.

242.11 Tray 2 sensor never broke.

Possible causes:

• Incorrect tray 2 media setting

• Incorrect Tray 2 paper loading

• Incorrect media restraint setting

• Paper tray 2 failure

• Aligner failure

• Transport belt module failure

• Loading card stock from the special media tray above the fill line

• High humidity (replace paper)

242.17 Tray 2 detected a jam from idle.

Possible causes:

• Paper jam leaving page over sensor

• Defective input sensor

• Faulty system board

242.21 Tray 2 motor stalled.

Possible causes:

• Incorrect paper loading

• Paper pick mechanism failure

• Printer option cable connector damaged

• Input option damage.

• System board failure

1. Ensure the proper media is set for the type of paper used in tray 2.

2. Fan media, and then stack flat in tray 2.

3. Properly set the media restraints in tray 2.

Go to “242.03, 242.11—Paper Jam service

check” on page 2-72.

• Clear away anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem,

“242.17—Paper Jam service check” on page 2-75.

1. Remove all media present in the paper path.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack it flat in the tray or multipurpose feeder.

If the previous actions do not fix the problem, go to

“242.21, 243.21, 244.21. 245.21, 242.30, 243.30,

244.30, 245.30—Paper Jam service check” on page 2-76.

Diagnostic information 2-29

Page 66

5026

Go Back

Error code Description Action

242.26 While feeding from tray 2, the pass thru sensor is not made.

Possible causes:

• Incorrect paper loading for lower tray

• Incorrect media restraint setting for lower tray

• Paper tray 2 assembly failure

• Lower tray 3 assembly failure

242.27 While feeding from a lower tray, pass thru sensor did not break.

Possible causes:

• Paper tray 2 assembly failure (feed through roller)

• Aligner failure

• Transport belt motor failure

242.29 Tray 2 is not ready or missing while printing.

Possible cause is paper tray 2 assembly failure

242.30 Tray 2 page reached pass-through sensor early.

Possible cause:

• Incorrect paper loading

• Paper pick mechanism failure

• Pick arm roll damaged

• Defective pass-through sensor

• Input option damaged

1. Clear away anything in the paper path that might cause the paper to jam.

2. Ensure the proper media is set for the type of paper used in the lower tray.

3. Fan the media, and then stack flat in the lower tray.

4. Properly set the media restraints in the lower tray.

5. Check the pick arm rolls (tires) in the lower tray, and then replace if worn.

If the problem persists, go to “242.26—Paper Jam

service check” on page 2-76.

• Clear away anything in the paper path that might cause the paper to jam.

• Reseat option tray 2.

•Go to “242.27—Paper Jam service check” on

page 2-77.

• Make sure that tray 2 is correctly inserted.

•Go to “242.29—Paper Jam service check” on

page 2-77.

1. Remove all media present in the paper path.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack it flat in the tray or multipurpose feeder.

If the previous actions do not fix the problem, go to

“242.21, 243.21, 244.21. 245.21, 242.30, 243.30,

244.30, 245.30—Paper Jam service check” on page 2-76.

242.32 Paper is jammed on tray 2 pass-through sensor during input options warm-up.

Possible damage:

• Obstruction on the pass-through sensor

• Damage on the pass-through sensor and flag

• Input option damage

• Damaged option autoconnect cable

• Damaged system board

243.02 Tray 3 pass thru sensor made at POR.

Possible causes:

• Paper jam leaving page over the sensor

• Defective pass thru sensor

2-30 Service Manual

Go to “242.32, 243.32, 244.32, 245.32—Paper

Jam service check” on page 2-78.

• Check for anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, see “243.02—Paper Jam service check” on

page 2-78.

Page 67

5026

Go Back

Error code Description Action

243.03 Pick timeout from tray 3 exceeded without a tray 3 sensor break.

Possible causes:

• Tray 3 incorrect media setting

• Tray 3 incorrect paper loading

• Tray 3 incorrect media restraint setting

• Tray 3 assembly failure

243.05 Tray 3 picked, but page failed to reach the option sensor in time,

Possible causes:

• Tray 3 incorrect media setting

• Tray 3 incorrect paper loading

• Tray 3 incorrect media restraint setting

• Tray 3 paper pick mechanism failure

• Loading card stock from the special media tray above the fill line

243.10 Tray 3 page exit pass thru sensor broken early.

Possible causes:

• Defective pass thru sensor

• Faulty cable in connector OPT1.

1. Remove all media present in the paper path.

2. Ensure proper media is set for the type of paper used in tray 3.

3. Fan media, and stack flat in tray 3.

4. Properly set media restraints in tray 3.

If the previous actions do not fix the problem, go to

“243.03, 243.11—Paper Jam service check ” on page 2-79.

1. Ensure proper media is set for the type of paper used in tray 3.

2. Fan media, and stack flat in tray 3.

3. Properly set the media restraints in tray 3.

4. Check the pick arm rolls (tires) in tray 3 and replace if worn.

If the previous actions do not fix the problem, go to

“243.05—Paper Jam service check” on page 2-80.

• Make sure the proper media is set for the type of paper used in tray 3.

• Check for anything in the paper path that might cause the paper to jam.

• The exit pass thru sensor may not be functioning properly. Go to “243.10—Paper

Jam service check” on page 2-81.

243.11 Tray 3 sensor never broke.

Possible causes:

• Incorrect tray 3 media setting

• Incorrect tray 3 paper loading

• Incorrect media restraint setting

• Paper tray failure

• Aligner failure

• Transport belt module failure

• Loading card stock from the special media tray above the fill line

• High humidity (replace paper)

243.17 Tray 3 detected a jam from idle.

Possible causes:

• Paper jam leaving page over sensor

• Defective input sensor

• Faulty system card

243.21 Tray 3 motor stalled.

Possible causes:

• Incorrect paper loading

• Paper pick mechanism failure

• Printer option cable connector damaged

• Input option damage.

• System board failure

1. Ensure the proper media is set for the type of paper used in tray 3.

2. Fan media, and then stack flat in tray 3.

3. Properly set the media restraints in tray 3.

4. Check the pick arm rolls (tires) in tray 3 and replace if worn.

If the problem persists, Go to “243.0 3, 243. 11—

Paper Jam service check” on page 2-79.

• Clear away anything in the paper path that might cause the media to jam.

• If the problem persists, go to “243.17—Paper

Jam service check” on page 2-82.

1. Remove all media present in the paper path.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack it flat in the tray or multipurpose feeder.

If the previous actions do not fix the problem, go to

“242.21, 243.21, 244.21. 245.21, 242.30, 243.30,

244.30, 245.30—Paper Jam service check” on page 2-76.

Diagnostic information 2-31

Page 68

5026

Go Back

Error code Description Action

243.26 While feeding from a lower tray, tray 3 pass thru sensor is not made.

Possible causes:

• Incorrect paper loading for lower tray

• Incorrect media restraint setting for lower tray

• Paper tray 3 assembly failure

• Lower tray 4 assembly failure

243.27 While feeding from a lower tray, tray 3 pass thru sensor did not break.

Possible cause is a paper tray 3 assembly failure

243.29 Tray 3 is not ready while printing.

Possible cause is paper tray 3 assembly failure.

243.30 Tray 3 page reached pass-through sensor early.

Possible cause:

• Incorrect paper loading

• Paper pick mechanism failure

• Pick arm roll damaged

• Defective pass-through sensor

• Input option damaged

1. Clear away anything in the paper path that might cause the media to jam.

2. Make sure proper media is set for the type of paper used in lower feeding tray.

3. Fan media, and stack flat in the lower feeding tray.

4. Properly set media restraints in the lower feeding tray.

5. Check the pick arm rolls in lower tray and replace if worn.

If the problem persists, go to “243.26—Paper Jam

service check” on page 2-83.

• Clear away anything in the paper path that might cause the paper to jam.

• Reseat option tray 3

• If the problem persists, go to “243.27—Paper

Jam service check” on page 2-83.

• Make sure that tray 3 is correctly inserted.

• If the problem persists, go to “243.29—Paper

Jam service check” on page 2-83.

1. Remove all media present in the paper path.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack it flat in the tray or multipurpose feeder.

If the previous actions do not fix the problem, go to

“242.21, 243.21, 244.21. 245.21, 242.30, 243.30,

244.30, 245.30—Paper Jam service check” on page 2-76.

243.32 Paper is jammed on tray 3 pass-through sensor during input options warm-up.

Possible damage:

• Obstruction on the pass-through sensor

• Damage on the pass-through sensor and flag

• Input option damaged

• Damaged option autoconnect cable

• Damaged system board

244.02 Tray 4 pass thru sensor made at POR.

Possible causes:

• Paper jam leaving page over the sensor

• defective pass thru sensor

Go to “242.32, 243.32, 244.32, 245.32—Paper

Jam service check” on page 2-78.

• Check for anything in the paper path that might cause the paper to jam.

• If the problem persists, go to “244.02—Paper

Jam service check” on page 2-84.

2-32 Service Manual

Page 69

5026

Go Back

Error code Description Action

244.03 Pick timeout from tray 4 was exceeded without a tray 4 sensor break.

Possible causes:

• Tray 4 incorrect media setting

• Tray 4 incorrect paper loading

• Tray 4 incorrect media restraint setting

• Tray 4 assembly failure

• Aligner failure

• Transport belt module failure

244.05 Tray 4 picked, but page failed to reach the option sensor in time.

Possible causes:

• Tray 4 incorrect media setting

• Tray 4 incorrect paper loading

• Tray 4 incorrect media restraint setting

• Tray 4 paper pick mechanism assembly failure

• Loading card stock from the special media tray above the fill line

244.10 Tray 4 page exit pass thru made early.

Possible causes:

• Defective pass thru sensor

• Faulty cable in connector OPT1

1. Remove all media present in the paper path.

2. Maker sure proper media is set for the type of paper used in tray 4.

3. Fan the media, and stack flat in tray 4.

4. Properly set media restraints in tray 4.

If the problem persists, go to “244.03, 244.11—

Paper Jam service check” on page 2-85.

1. Ensure proper media is set for the type of paper used in tray 4.

2. Fan media, and stack flat in tray 4.

3. Properly set the media restraints in tray 4.

4. Check the pick arm rolls (tires) in tray 4 and replace if worn.

If the problem persists, go to “244.05—Paper Jam

service check” on page 2-85.

• Make sure proper media is set for the type of paper used in tray 4.

• Check for anything in the paper path that might cause the paper to jam.

• The exit pass thru sensor may not be functioning properly. Go to “244.10—Paper

Jam service check” on page 2-86.

244.11 Tray 4 sensor never broke.

Possible causes:

• Incorrect tray 4 media setting

• Incorrect tray 4 paper loading

• Incorrect media restraint setting

• Paper tray failure

• Aligner failure

• Transport belt module failure

• Loading card stock from the special media tray above the fill line

• High humidity (replace paper)

244.17 Tray 4 detected a jam from idle.

Possible causes:

• Paper jam leaving page over the sensor

• defective input sensor

• Faulty system board

1. Ensure the proper media is set for the type of paper used in tray 4.

• Fan media, and then stack flat in tray 4.

• Properly set the media restraints in tray 4.

If the problem persists, go to “244.03, 244.11—

Paper Jam service check” on page 2-85.

• Clear away anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “243.17—Paper Jam service check” on

page 2-82.

Diagnostic information 2-33

Page 70

5026

Go Back

Error code Description Action

244.21 Tray 4 motor stalled.

Possible causes:

• Incorrect paper loading

• Paper pick mechanism failure

• Printer option cable connector damaged

• Input option damaged

• System board failure

244.26 While feeding from a lower tray, tray 4 pass thru sensor is not made.

Possible causes:

• Incorrect paper loading for the lower tray

• Incorrect media restraint setting for the lower tray

• Paper tray 4 assembly failure

• Paper tray 5 assembly failure

244.27 While feeding from a lower tray, tray 4 pass thru sensor did not break.

Possible cause is paper tray 4 assembly failure.

244.29 Tray 4 is not ready, or missing while printing.

Possible cause is paper tray 4 assembly failure.

1. Remove all media present in the paper path.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack it flat in the tray or multipurpose feeder.

If the previous actions do not fix the problem, go to

“242.21, 243.21, 244.21. 245.21, 242.30, 243.30,

244.30, 245.30—Paper Jam service check” on page 2-76.

1. Clear away anything in the paper path that might cause the paper to jam.

2. Make sure the proper media is set for the type of paper used in the lower tray.

3. Fan the media, and stack flat in the lower tray.

4. Properly set the media restraints in the lower tray.

5. Check the pick arm rolls in the lower feeding tray and replace if worn.

If the problem persists, go to “244.26—Paper Jam

service check” on page 2-87.

• Clear away anything in the paper path that might cause the paper to jam.

• Reseat option tray 4.

• If the problem persists, go to “244.27—Paper

Jam service check” on page 2-88.

• Make sure that tray 4 is correctly inserted.

• If the problem persists, go to “244.29—Paper

Jam service check” on page 2-88.

244.30 Tray 4 page reached pass-through sensor early.

Possible cause:

• Incorrect paper loading

• Paper pick mechanism failure

• Pick arm roll damaged

• Defective pass-through sensor

• Input option damaged

244.32 Paper is jammed on tray 4 pass-through sensor during input options warm-up.

Possible damage:

• Obstruction on the pass-through sensor

• Damage on the pass-through sensor and flag

• Input option damaged

• Damaged option autoconnect cable

• Damaged system board

1. Remove all media present in the paper path.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack it flat in the tray or multipurpose feeder.

If the previous actions do not fix the problem, go to

“242.21, 243.21, 244.21. 245.21, 242.30, 243.30,

244.30, 245.30—Paper Jam service check” on page 2-76.

•Go to “242.32, 243.32, 244.32, 245.32—Paper

Jam service check” on page 2-78.

2-34 Service Manual

Page 71

5026

Go Back

Error code Description Action

245.02 Tray 5 pass thru sensor made at POR.

Possible causes:

• Paper jam leaving a page over the sensor

• Defective pass thru sensor

245.03 Pick timeout from tray 5 exceeded without a tray sensor break.

Possible causes:

• Tray 5 incorrect media setting

• Tray 5 incorrect paper loaded

• Tray 5 incorrect media restraint setting

• Tray 5 assembly failure

• Aligner failure

• Transport module failure

245.05 Possible causes:

• Incorrect media setting

• Incorrect paper loading

• Incorrect media restraint setting

• Tray 5 paper pick mechanism

• Loading card stock from the special media tray above the fill line

• Check for anything in the paper path that might cause the media to jam.

• If the problem persists, go to “245.17—Paper

Jam service check” on page 2-92.

1. Remove all media present in the paper path.

2. Make sure proper media is set for the type of paper used in tray 5.

3. Fan the media, and stack flat in tray 5.

4. Properly set the media restraints in tray 5.

If the problem persists, go to “245.03, 245.11—

Paper Jam service check” on page 2-90.

1. Ensure proper media is set for the type of paper used in tray 5.

2. Fan media, and stack flat in tray 5.

3. Properly set the media restraints in tray 5.

4. Check the pick arm rolls (tires) in tray 5 and replace if worn.

If the problem persists, go to “245.05—Paper Jam

service check” on page 2-90.

245.10 Tray 5 page exits pass thru sensor broken early.

Possible causes:

• Defective pass thru sensor

• Faulty cable in connector JOPT1 on the system board

245.11 Tray 5 sensor never broke.

Possible causes:

• Incorrect tray 5 media setting

• Incorrect tray 5 paper loading

• Incorrect media restraint setting

• Paper tray failure

• Aligner failure

• Transport belt module failure

• Loading card stock from the special media tray above the fill line

• High humidity (replace paper)

245.17 Tray 5 detected a jam from idle.

Possible causes:

• Paper jam leaves a page over the sensor

• Defective input sensor

• Faulty system board

• Make sure the proper media is set for the type of paper used in tray 5.

• Check for anything in the paper path that might cause the paper to Jam.

• The exits pass thru sensor may not be functioning properly. Go to “245.10—Paper

Jam service check.

1. Ensure the proper media is set for the type of paper used in tray 5.

2. Fan media, and then stack flat in tray 5.

3. Properly set the media restraints in tray 5.

4. Check the pick arm rolls (tires) in tray 5 and replace if worn.

If the problem persists, go to “245.03, 245.11—

Paper Jam service check” on page 2-90.

• Clear away anything in the paper path that might cause the paper to jam.

• If the problem persists, go to “245.17—Paper

Jam service check.

Diagnostic information 2-35

Page 72

5026

Go Back

Error code Description Action

245.21 Tray 5 motor stalled.

Possible causes:

• Incorrect paper loading

• Paper pick mechanism failure

• Printer option cable connector damaged

• Input option damaged

• System board failure

245.29 Tray 5 is not ready or missing while printing.

Possible cause paper tray 5 assembly failure.

245.30 Tray 5 page reached pass-through sensor early.

Possible cause:

• Incorrect paper loading

• Paper pick mechanism failure

• Pick arm roll damaged

• Defective pass-through sensor

• Input option damaged

245.32 Paper is jammed on tray 5 pass-through sensor during input options warm-up.

Possible damage:

• Obstruction on the pass-through sensor

• Damage on the pass-through sensor and flag

• Input option damaged

• Damaged option autoconnect cable

• Damaged system board

1. Remove all media present in the paper path.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack it flat in the tray or multipurpose feeder.

If the previous actions do not fix the problem, go to

“242.21, 243.21, 244.21. 245.21, 242.30, 243.30,

244.30, 245.30—Paper Jam service check” on page 2-76.

• Make sure that tray 5 is correctly inserted.

• If the problem persists, go to “245.29—Paper

Jam service check” on page 2-93.

1. Remove all media present in the paper path.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack it flat in the tray or multipurpose feeder.

If the previous actions do not fix the problem, go to

“242.21, 243.21, 244.21. 245.21, 242.30, 243.30,

244.30, 245.30—Paper Jam service check” on page 2-76.

•Go to “242.32, 243.32, 244.32, 245.32—Paper

Jam service check” on page 2-78.

250.03 While feeding from the multipurpose feeder, the input sensor did not break.

Possible causes:

• Incorrect media setting

• Incorrect paper loading

• Incorrect media restraint setting

• Transport belt failure

• Paper tray failure

250.05 While feeding from the multipurpose feeder, the input sensor is not made.

Possible causes:

• Incorrect media setting

• Incorrect paper loading

• Incorrect media restraint setting

• Multipurpose feeder pick mechanism failure

• System board failure

2-36 Service Manual

1. Remove all media present in the paper path.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack it flat in the tray or multipurpose feeder.

4. Properly set media restraints in the paper tray.

5. Replace the paper tray.

If the problem persists, to “200.11, 250.03—Paper

Jam error service check” on page 2-64.

1. Remove all the media present in the paper path.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack it flat in the tray or multipurpose feeder.

4. Properly set media restraints in the paper tray.

5. Check the MP feeder pick tires and clean if necessary.

6. Replace the paper tray.

If the previous actions do not fix the problem, go to

“146.xx, 148.xx—Motor (MPF/duplex) error service check” on page 2-55

Page 73

5026

Go Back

Error code Description Action

250.21 Multipurpose feeder motor stalled.

Possible causes:

• Multipurpose feeder motor failure

• Cabling failure

• Multipurpose feeder gear assembly failure

• System board failure

• Defective media present sensor

1. Remove all the media present in the paper path.

2. Ensure proper media is set for the type of paper used.

3. Fan media, and stack it flat in the tray or multipurpose feeder.

4. Properly set media restraints in the multipurpose feeder.

If the previous actions do not fix the problem, go to

“146.xx, 148.xx—Motor (MPF/duplex) error service check” on page 2-55.

Diagnostic information 2-37

Page 74

5026

Go Back

Error code Description Action

9xx service error messages

900.00–900.99 Software Error (except 900.05)

900.05 Software Error.

902.01–902.99 Engine Software Error (except 902.59 and

902.60)

902.59 Error

902.60 Error

903.01–903.15 Engine Software Error

904.01–904.04 Software Error

Unrecoverable RIP software error. Go to “900.00–900.99 (except 900.05)—System

software error service check” on page 2-93.

Transfer module has failed • POR the printer.

• If the error message persists, go to “900.05—

Transfer module erro r service check” on page 2-96.

Unrecoverable system software errors.

• POR the printer.

• If the error message persists, replace the

system board. See “System board removal”

on page 4-155.

RIP NVRAM MGR problem. POR the printer.

If the error message persists, go to “902.59—

Engine software error, NVRAM MGR problem service check” on page 2-96.

Error communicating with cartridge. 1. POR the printer.

2. If the error message persists, check for the correct cartridges.

3. Replace the cartridges.

Unrecoverable system software errors.

• POR the printer.

• If the error message persists, replace the

system board. See “System board removal”

on page 4-155.

Unrecoverable system software errors.

• POR the printer.

• If the error message persists, replace the

system board. See “System board removal”

on page 4-155.

905.00–905.99 Software Error

910.xx

Engine Software Error

920.01 POST Error

920.02 POST Error

920.03 POST Error

2-38 Service Manual

Unrecoverable system software errors.

• POR the printer.

• If the error message persists, replace the

system board. See “System board removal”

on page 4-155.

RIP software error interface violation • POR the printer.

• If the error persists, replace the system board.

See “System board removal” on page 4-155.

Multipurpose feeder/duplex motor assembly not connected.

• POR the printer.

• If the error message persists, go to “147.xx,

920.01—POST (power-on self test) aligner error service check” on page 2-57.

Tray 1 motor not connected. • POR the printer.

• If the error message persists, go to “140.xx,

920.02—Autocomp (tray 1) motor error service check” on page 2-49.

Transfer module not connected. • POR the printer.

• If the error message persists, go to “920.03,

920.25—Transfer Module Missing or not connected service check” on page 2-97.

Page 75

5026

Go Back

Error code Description Action

920.04 POST Error

920.05 POST Error

920.06 POST Error

920.07 POST Error

920.08 POST Error

920.09 POST Error

Fuser motor not connected. • POR the printer.

• If the error message persists, go to “920.04—

POST (power-on self test) f user m otor not connected error service check” on page 2-97.

Printhead motor not connected. • POR the printer.

• If the error message persists, go to “920.05—

POST (power-on self test) printhead motor not connected error service check” on page 2-98.

Input sensor not connected. • POR the printer.

• If the error message persists, go to “920.06—

Input sensor service check” on page 2-99.

Narrow media sensor not connected. • POR the printer.

• If the error message persists, go to “920.07—

POST (power-on self test)—Narrow media sensor error service check” on page 2-99.

Exit sensor not connected. • POR the printer.

• If the error message persists, go to “920.08—

Exit sensor servic e ch eck” on page 2-100.

Four toner sensors are not connected. • POR the printer.

• If the error message persists, go to “920.09—

POST (power-on self test)—Four toner sensors not connected error service check” on page 2-102.

920.10 POST Error

920.11 POST Error

920.12 POST Error

920.13 POST Error

920.14 POST Error

920.15 POST Error

Three toner sensors are not connected.

• POR the printer.

• If the error message persists, go to “920.10—

POST—Three toner sensors not connected error service check” on page 2-103.

Two toner sensors are not connected. • POR the printer.

• If the error message persists, go to “920.11—

POST (power-on self test)—Two toner sensors not connected error service check” on page 2-104.

One toner sensor is not connected. • POR the printer.

• If the error message persists, go to “920.12—

POST (power-on self test)—One toner sensor not connected error service check” on page 2-105.

Cartridge motor 1 (top) not connected. • POR the printer.

• If the error message persists, go to “920.13—

POST (power-on self test) cartridge motor 1 not connected error service check” on page 2-106.

Cartridge motor 2 (middle) is not connected.

• POR the printer.

• If the error message persists, go to “920.14—

POST (power-on self test)—Cartridge motor 2 not connected error service check” on page 2-107.

Bad transfer module NVRAM data. • POR the printer.

• If the error message persists, go to

920.20—POST (power-on self test)—Bad transfer module NVRAM data error ser vice check” on page 2-108.

“920.15,

Diagnostic information 2-39

Page 76

5026

Go Back

Error code Description Action

920.16 POST Error

920.17 POST Error

920.18 POST Error

920.19 POST Error

920.20 POST Error

920.21 POST Error

Bad printhead NVRAM data. • POR the printer.

• If the error message persists, go to “920.16—

POST (power-on self test)—Bad printhead NVRAM data error service check” on page 2-108.

Output bin cable not connected. • POR the printer.

• If the error message persists, go to “920.17—

POST (power-on self test)—Output bin cabl e not connected error service check” on page 2-109.

Cartridge motor 3 (bottom) is not connected.

• POR the printer.

• If the error message persists, go to “920.18—

POST (power-on self test)—Cartridge motor 3 not connected error service check” on page 2-110.

Stepper motor not connected. • POR the printer.

• If the error message persists, go to “920.19—

POST (power-on self test)—Tr ansfer module stepper motor not connected error servic e check” on page 2-110.

Incompatible transfer module. • POR the printer.

• If the error message persists, go to “920.15,

920.20—POST (power-on self test)—Bad transfer module NVRAM data error ser vice check” on page 2-108.

+24 V power supply failure. • POR the printer.

• If the error message persists, replace the low-

voltage power supply. See “Low-voltage

power supply (LVPS) removal” on page 4-119.

920.22 POST Error

920.23 POST Error

920.25 POST Error

920.27 POST Error

920.28 POST Error

920.29 POST Error

Fuser bubble sensor is not connected. If the error message persists, go to “Bubble

sensor service check” on page 2-122.

Duplex motor is not connected. • POR the printer.

• If the error message persists, go to “920.23—

POST (power-on self test)—Duplex motor not connected error service check” on page 2-113.

Bad temperature and humidity sensor. • POR the printer.

• If the problem persists, go to “920.03, 920.25—

Transfer Module Missi ng or not connected service check” on page 2-97.

Option board ID unknown. If the error message persists, go to “920.27,

920.28, 920.29—POST (power on self test) option tray error service check” on page 2-114.

Option type unknown. If the error message persists, go to “920.27,

920.28, 920.29—POST (power on self test) option tray error service check” on page 2-114.

Option product ID unknown. If the error message persists, go to “920.27,

920.28, 920.29—POST (power on self test) option tray error service check” on page 2-114.

2-40 Service Manual

Page 77

5026

Go Back

Error code Description Action

920.30

Option sensor disconnected. Use the following list to determine which service

POST Error

920.31

Option hardware error (generic) Contact your next level of support.

POST Error

920.32 MPF paper present sensor not connected

925.01

Fan has stalled. • POR the printer.

Fan Error

925.02

Blower has stalled. • POR the printer.

Blower Error

925.03

Fan has stalled. • POR the printer.

Fan Error

check to use:

•Tray 2—Go to “242.02—Paper Jam service

check” on page 2-71.

•Tray 3—Go to “243.02—Paper Jam service

check” on page 2-78.

•Tray 4—Go to “244.02—Paper Jam service

check” on page 2-84.

•Tray 5—Go to “245.02—Paper Jam service

check” on page 2-89.

• POR the printer.

• If the error message persists, go to “920.32—

MPF paper present sensor not connected service check” on page 2-114.

• If the error message persists, go to “925.01,

925.03, 925.05—Fan error service check” on page 2-114.

• If the error message persists, go to “925.02,

925.04, 925.06—Cartridge cooli ng fan error service check” on page 2-115.

• If the error message persists, go to “925.01,

925.03, 925.05—Fan error service check” on page 2-114.

925.04

Blower Error

925.05

Fan Error

925.06

Blower Error

945.01

Transfer Roll

945.02

Transfer Roll

945.03

Transfer Roll

Blower has stalled. • POR the printer.

• If the error message persists, go to “925.02,

925.04, 925.06—Cartridge cooli ng fan error service check” on page 2-115.

Fan has stalled. • POR the printer.

• If the error message persists, go to “925.01,

925.03, 925.05—Fan error service check” on page 2-114.

Blower has stalled. • POR the printer.

• If the error message persists, go to “925.02,

925.04, 925.06—Cartridge cooli ng fan error service check” on page 2-115.

Yellow transfer roll has failed. • POR the printer.

• If the error message persists, go to “945.xx,

947.xx—Transf er rol l er ror servi ce check” on page 2-116.

Cyan transfer roll has failed. • POR the printer.

• If the error message persists, go to “945.xx,

947.xx—Transf er rol l er ror servi ce check” on page 2-116.

Magenta transfer roll has failed. • POR the printer.

• If the error message persists, go to “945.xx,

947.xx—Transf er rol l er ror servi ce check” on page 2-116.

Diagnostic information 2-41

Page 78

5026

Go Back

Error code Description Action

945.04 Transfer Roll

947.01 Transfer Roll

947.02 Transfer Roll

947.03 Transfer Roll

947.04 Transfer Roll

950.00–950.29 NVRAM Failure

951.01–951.99 NVRAM Failure

Black transfer roll has failed. • POR the printer.

• If the error message persists, go to “945.xx,

947.xx—Transf er rol l er ror servi ce check” on page 2-116.

Yellow transfer roll has failed. • POR the printer.

• If the error message persists, go to “945.xx,

947.xx—Transf er rol l er ror servi ce check” on page 2-116.

Cyan transfer roll has failed. • POR the printer.

• If the error message persists, go to “945.xx,

947.xx—Transf er rol l er ror servi ce check” on page 2-116.

Magenta transfer roll has failed. • POR the printer.

• If the error message persists, go to “945.xx,

947.xx—Transf er rol l er ror servi ce check” on page 2-116.

Black transfer roll has failed. • POR the printer.

• If the error message persists, go to “945.xx,

947.xx—Transf er rol l er ror servi ce check” on page 2-116.

A mismatch between the operator panel assembly and the system board.

• POR the printer.

• If the error message persists, go to “950.00–

950.29—EPROM mismatch failure” on page 2-118

System board NVRAM failure. • POR the printer.

• If the error message persists, replace the

system board. See “System board removal”

on page 4-155.

952.01–952.99 NVRAM Error

953.01–953.99 NVRAM Failure

954.01–954.99 NVRAM Failure

955.01–955.99 Code Failure

956.01–956.99 System Card Failure

957.00–857.99 System Failure

CRC error has occurred. This is

Perform a POR to clear the error.

recoverable.

Operator panel assembly NVRAM failure.

• POR the printer.

• Replace the operator panel assembly if the error

message persists. See “Operator panel

assembly removal (C746)” on page 4-34.

System NVRAM failure. • POR the printer.

• If the error message persists, replace the

system board. See “System board removal”

on page 4-155.

System board memory failure. • POR the printer.

• If the error message persists, replace the

system board. See “System board removal”

on page 4-155.

Processor failure. • POR the printer.

• If the error message persists, go to “956.xx—

System board failure service check” on page 2-119.

ASIC failure. • POR the printer.

• If the error message persists, replace the

system board. See “System board removal”

on page 4-155.

2-42 Service Manual

Page 79

5026

Go Back

Error code Description Action

958.01–958.99

Memory Failure

959.00–959.05

Engine Code Error

959.20–959.28

System Failure

960.00—960.99

Memory Error

961.00–961.99

Memory Failure

962.00–962.99

Memory Failure

Processor failure. • POR the printer.

• If the error message persists, replace the

system board. See “System board removal”

on page 4-155.

Invalid engine code • POR the printer.

• If the error message persists, download the engine code again.

• POR the printer again.

• If the error message persists, replace the system board. See “System board removal”

on page 4-155.

System board failure. • POR the printer.

• If the error message persists, replace the system board. See “System board removal”

on page 4-155.

Memory failure. • POR the printer.

• If the error message persists, RAM soldered on board is bad. Replace the system board. See

“System board removal” on p age 4-155.

Memory failure. • POR the printer.

• If the error message persists, replace the system board. See “System board removal”

on page 4-155.

Memory failure. • POR the printer.

• If the error message persists, replace the system board. See “System board removal”

on page 4-155.

963.00–963.99 Memory Failure

964.00–964,88 Emulation Error

975.00–975.99 Network Error

976.00–976.99 Network Error

978.00–978.99 Network Error

979.00–979.99 Network Error

980.00–980.99

Communications Error

981.00–981.99

Communications Error

Memory failure. • POR the printer.

• If the error message persists, replace the system board. See “System board removal”

on page 4-155.

Download emulation CRC error. • POR the printer.

• If the error message persists, download code a second time.

Unrecognized network port. Contact your next level of support.

Unrecoverable software error in

Contact your next level of support.

network port.

Bad checksum while programming

Contact your next level of support.

network port

Flash parts failed while programming

Contact your next level of support.

network port.

Unreliable communications with specified device.

• POR the printer.

• If the error message persists, replace the system board. See “System board removal”

on page 4-155.

Protocol violation by specified device. • POR the printer.

• If the error persists, replace the system board. See

“System board removal” on p age 4-155.

Diagnostic information 2-43

Page 80

5026

Go Back

Error code Description Action

982.00–982.12

Communications Error

983.00–983.99

Communications Error

984.00–984.99

Communications Error

990.00—990.29 Option Error

991.00–991.29

<device> Error

1565 Emul Error Load Emul Option

In IRs

Communications error by specified device.

1. Turn the power off.

2. Remove, and reinstall the option.

3. Turn the main power back on.

4. Check all option interface connections if the problem remains.

Invalid command parameter by specified device.

• POR the printer.

• If the error message persists, replace the

system board. See “System board removal”

on page 4-155.

Invalid command parameter by specified device.

• POR the printer.

• If the error message persists, replace the

system board. See “System board removal”

on page 4-155.

Contact your next level of support.

Specified device has detected an error.

• POR the printer.

• If the error message persists, replace the

system board. See “System board removal”

on page 4-155.

The DLE version contained in the firmware card will not function with the printer code. The message automatically clears in 30 seconds and the DLE is disabled. Download the correct version of the DLE.

2-44 Service Manual

Page 81

5026

Go Back

31.xx—Cartridge errors service check

Step Questions / actions Yes No

1 POR the printer.

Did this fix the problem?

Replace the toner cartridge.

Did this fix the problem?

Reseat the toner cartridges and make sure

they are installed to their correct color slots.

Did this fix the problem?

1. Check the contacts on the toner cartridge

chip for damage and contamination.

2. Clean the contacts.

Are the chip contacts damaged?

1. Check the cartridge contact and bell crank on the printer.

2. Press each of the contacts to check the spring force.

3. Check the bell crank for any damage.

Are the bell crank and cartridge contacts damaged?

1. Check JSB1 on the system board for proper connection.

2. Check for damage and pinch points on the connector.

3. Reseat cable.

Is the cable connector free of damaged?

Problem resolved. Go to step 2.

Problem resolved. Go to step 3.

Problem resolved. Go to step 4.

Replace toner cartridge. Go to step 5.

Replace the cartridge contact with bell crank.

Note: Only replace the parts that are damaged.

Replace the cartridge contact with bell crank.

Note: Only replace the parts that are damaged.

Go to step 6.

Go to step 7.

Check the whole length of the cable going to

the cartridge contact. Check for any damage and pinch points.

Are the cables damaged? Replace the system board. See “System

board removal” on page 4-155.

Did this fix the problem?

Replace the cartridge contact with bell crank.

Note: Only replace the parts that are damaged.

Problem resolved. Replace the cartridge

Go to step 8.

contact with bell crank. Note: Only replace the

parts that are damaged.

110.xx—Mirror motor service check

Step Questions / actions Yes No

1 View the Event Log:

1. Turn off the printer, press and hold buttons 3 and 6, then turn on the printer.

2. Select EVENT LOG.

3. Select Display Log.

Has an 110.xx error occurred three times or more?

Replace the printhead. See

“Printhead remova l, installation, and adjustment” on page 4-145.

Go to step 2.

Diagnostic information 2-45

Page 82

5026

Go Back

Step Questions / actions Yes No

Turn the printer off, and then remove the rear

frame cover. See “Rear fr am e co ver

removal” on page 4-47. Check the cable in

connector JMIRR1 for proper connection to the system board, the printhead cable for pinch points, and the cable or connector for any other damage.

Is the cable damaged?

Measure the continuity across all of the fuses

on the system board.

Are any of the fuses blown?

Perform the printhead verification to check

whether the new printhead will solve the problem. See “Printhead verification” on

page 3-39.

Perform the Mirror Motor Test. See “Mirror

Motor Test” on page 3-20.

Did the Mirror Motor pass the test?

Replace the printhead. See

“Printhead remova l, installation, and adjustment” on page 4-145.

Replace the system board. See “System board

removal” on page 4-155.

Replace the printhead. See

“Printhead remova l, installation, and adjustment” on page 4-145.

Go to step 3.

Go to step 4.

Replace the system board. See “System board

removal” on page 4-155.

111.xx, 112.xx, 113.xx, and 114.xx—Printhead error service check

Step Questions / actions Yes No

1 View the Event Log:

1. Turn off the printer, press and hold

buttons 3 and 6, then turn on the printer.

2. Select EVENT LOG.

3. Select Display Log.

Has an 111.xx,112.xx, 113.xx, or 114.xx error occurred three times or more?

Replace the printhead. See

“Printhead remova l, installation, and adjustment” on page 4-145.

Go to step 2.

Turn the printer off, and then remove the rear

frame cover. See “Rear fr am e co ver

removal” on page 4-47. Check the cable in

connector JPH1 for proper connection to the system board, the cable for pinch points, and the cable or connector for any other damage.

Is the cable damaged?

Measure the continuity across all of the fuses

on the system board.

Are any of the fuses blown?

Perform the printhead verification to check

whether the new printhead solves the problem. See “Printhead verification” on

page 3-39.

Perform the Servo Laser Test. See “Servo

Laser Test” on page 3-20.

Did the printhead motor pass the test?

2-46 Service Manual

Replace the 5 V interlock switch. See “5 V interlock

switch cable removal” on page 4-61.

Replace the system board. See “System board

removal” on page 4-155.

Replace the printhead. See

“Printhead remova l, installation, and adjustment” on page 4-145.

Go to step 3.

Go to step 4.

Replace the system board. See “System board

removal” on page 4-155.

Page 83

5026

Go Back

230

Fuser autoconnects

DC autoconnect

AC autoconnect

On printer

120.xx—Fuser error service check

Step Questions / actions Yes No

1 Check the input voltage switch on the back of

the low-voltage power supply (LVPS). Note: Some LVPS FRU do not have switches

and switch automatically. If your does not have a switch, go to step 2.

Is the voltage level (115 V/230 V) properly set?

1. Remove the fuser. See “Fuser removal”

on page 4-110.

2. Check the fuser AC autoconnect cable for damage, check the other end of the cable for damaged pins.

Go to step 2. Set the switch for the

proper country voltage.

Replace the appropriate

Go to step 3.

cable. See “Fuser AC

cable removal” on page 4-112 or “Fuser DC cable removal” on page 4-113.

3. Check the fuser DC autoconnect cable for damaged pins.

Are the connections damaged? Replace the fuser. See “Fuser removal” on

page 4-110.

Does the error clear?

Problem resolved. Go to step 4.

Diagnostic information 2-47

Page 84

5026

Go Back

DC autoconnect

JFUSER1

Pin 9 Pin 9

Pin 10 Pin 10

LVPS connect

AC Autoconnect

Pin 1 Pin 5

Pin 3 Pin 1

Step Questions / actions Yes No

Remove the rear frame cover. See“Rear

frame cover removal” on page 4-47. Check

the cable in connector JFUSER1 (fuser DC cable) for proper connection to the system board, the cable for pinch points, and the cable or connector for any other damage.

Is the cable damaged?

Check the cable in connector JLVPS2 for

proper connection to the system board, the cable for pinch points, and the cable or connector for any other damage.

Is the cable damaged?

Measure the continuity across all of the fuses

on the system board.

Are any of the fuses blown?

Check for the following continuity between the

DC autoconnect JFUSER1 on the system board.

Replace the fuser DC

Go to step 5.

cable.See “Fuse r DC

cable removal” on page 4-113.

Replace the LVPS. See

Go to step 6.

“Low-voltage power supply (LVPS) removal” on page 4-119.

Replace the system board.

Go to step 7.

See “System board

removal” on page 4-155.

Go to step 8. Replace the fuser DC

cable. See “Fuser DC

cable removal” on page 4-113.

Is continuity present?

Check for continuity between the following

pins of the AC autoconnect and the pins of the connector that connects to the LVPS.

2-48 Service Manual

Is continuity present?

Replace the system board. See “System board

removal” on page 4-155.

Replace the fuser AC cable. See “Fuser AC

cable removal” on page 4-112.

Page 85

5026

Go Back

140.xx, 920.02—Autocomp (tray 1) motor error service check

Step Questions / actions Yes No

1 1. Turn the printer off.

2. Remove the rear frame cover. See “Rear

frame cover removal” on page 4-47.

3. Check the cable in connector JFDPCK1 for proper connection to the system board, the cable for pinch points, and the cable or connector for any other damage.

4. Reseat the cable.

5. POR the printer.

Did the error clear?

Measure the continuity across all of the fuses

on the system board.

Are any of the fuses blown?

1. Disconnect the cable in the connector

JFDPCK1.

2. Connect the cable for the new paper pick mechanism.

3. Bring the printer up in Diagnostics Menu (Turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Navigate to MOTOR TESTS > Tray 1.

Did the new pick motor turn before the feed error occur?

Problem resolved. Go to step 2.

Replace the system board. See “System board

removal” on page 4-155.

Replace the paper pick mechanism. See “Paper

pick mechanism assembly removal” on page 4-137.

142.xx, 906.01–906.04—Motor (fuser) error service check

Go to step 3.

Replace the system board. See “System board

removal” on page 4-155.

Step Questions / actions Yes No

1 1. Turn the printer off.

2. Remove the rear frame cover. See “Rear

frame cover removal” on page 4-47.

3. Check the cables in connectors JCARTP1 and JCARTS1 (cartridge motor 1/fuser motor cable) for proper connection to the system board, for cable pinch points, and for any other damage to the cable or connectors.

Is either cable damaged?

Go to step 3. Go to step 2.

Diagnostic information 2-49

Page 86

5026

Go Back

Step Questions / actions Yes No

1. Remove the right cover. See “Right

cover removal” on page 4-51.

2. Check the cartridge motor 1/fuser motor cable for proper connection to the EP drive assembly (A), for pinch points for the cable, and for cable or connector damage.

Is either cable damaged?

Replace the cartridge motor1/fuser motor cable. See “Cartridge motor 1/fuser cable

removal” on page 4-67.

Note: Make sure to check the replacement

cable first before installation, leaving the original cable in place. Make sure to verify if the new cable is working properly. If new cable does not correct problem, do not install it.

Did the error clear?

Go to step 3. Go to step 4.

Problem solved Go to step 4.

Measure the continuity across all of the fuses

on the system board.

Are any of the fuses blown?

1. Plug the cartridge motor1/fuser motor

cable to a new EP drive assembly.

2. Bring the printer up in Diagnostics Menu (Turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

3. Navigate to MOTOR TESTS > Tray 1.

Did the error clear?

2-50 Service Manual

Replace the system board. See “System board

removal” on page 4-155.

Replace EP drive assembly. See

“Electrophotographic (EP) drive assembly removal” on page 4-90.

Go to step 5.

replace the system board. See “System board

removal” on page 4-155.

Page 87

5026

Go Back

143.xx—Motor (EP drive assembly top cartridge 1 motor) error service check

Step Questions / actions Yes No

1 1. Turn the printer off.

2. Remove the rear frame cover. See “Rear

frame cover removal” on page 4-47.

3. Check the cable in connector JCARTP1 and JCARTS1 (cartridge motor 1/fuser motor cable) for proper connection to the system board, for the cable for pinch points, and for the cable or connector for any other damage.

Is the cable damaged? Remove the right cover. See “Right cover

removal” on page 4-51. Check the cartridge

motor 1/fuser motor cable (A) for proper connection to the EP drive assembly, for pinch points for the cable, or damage to the cable or connector.

Replace the cartridge motor 1/fuser cable. See

“Cartridge motor 1/fuser cable removal” on page 4-67.

Replace the cartridge motor 1/fuser motor cable. See “Cartridge motor 1/

fuser cable removal ” on page 4-67.

Go to step 2.

Go to step 3.

Is either cable damaged?

Measure the continuity across all of the fuses

on the system board.

Are any of the fuses blown?

1. Disconnect the cartridge motor 1/fuser

motor cable on the motor and on the system board.

2. Connect a new motor 1/fuser motor cable on the motor and on the system board.

3. Run diagnostics motor check. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Select MOTOR TESTS.

Did the motor run?

Replace the system board. See “System board

removal” on page 4-155.

Replace the cartridge motor 1/fuser motor cable. See “Cartridge motor 1/

fuser cable removal ” on page 4-67.

Go to step 4.

Go to step 5.

Diagnostic information 2-51

Page 88

5026

Go Back

Step Questions / actions Yes No

1. Return the old motor 1/fuser motor cable.

2. Disconnect the motor drive cable from the EP drive assembly and connect it to the motor on a new EP drive assembly.

Note: Do not install the new EP drive assembly yet.

3. Run diagnostic motor check. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Select MOTOR TESTS.

Did the motor run?

1. Connect the new EP drive assembly with

a new cable from outside the machine.

2. Run diagnostics motor check. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

3. Select MOTOR TESTS.

Did motor run?

Replace the EP drive assembly. See

“Electrophotographic (EP) drive assembly removal” on page 4-90.

Replace the cable. Replace the system board.

Go to step 6.

See “System board

removal” on page 4-155.

144.xx—Motor (EP drive assembly middle cartridge) error service check

Step Questions / actions Yes No

1 1. Turn the printer off.

2. Remove the rear frame cover. See “Rear

frame cover removal” on page 4-47.

3. Check the cables in connector JCARTP2 and JCARTS2 (cartridge motor 2/3 cable) for proper connection to the system board, for cable pinch points, and for any other damage to the cable or connector.

Is the cable damaged?

Replace cartridge motor 2/ 3 cable. See “Cartridge

motor 2/3 cable removal” on page 4-69.

Go to step 2.

2-52 Service Manual

Page 89

5026

Go Back

Step Questions / actions Yes No

Remove the right cover. See “Right cover

removal” on page 4-51. Check the cartridge

motor 2/3 cable for proper connection to the EP drive assembly, pinch points for the cable, or damage to the cable or connector (A).

Is either cable damaged?

Measure the continuity across all of the fuses

on the system board.

Are any of the fuses blown?

Replace the cartridge motor 2/3 cable. See

“Cartridge motor 2/3 cable removal” on page 4-69.

Replace the system board. See “System board

removal” on page 4-155.

Go to step 3.

Go to step 4.

1. Disconnect the cartridge motor 2/3 cable

on the motor and on the system board.

2. Connect a new motor 1/fuser motor cable on the motor and on the system board.

3. Run diagnostics motor check. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Select MOTOR TESTS.

Did the motor run?

1. Return the old cartridge motor 2/3 motor

cable.

2. Disconnect the motor drive cable from the EP drive assembly and connect it to the motor on a new EP drive assembly.

Note: Do not install the new EP drive assembly yet.

3. Run diagnostic motor check. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Select MOTOR TESTS.

Did the motor run?

Replace the cartridge motor 2/3 cable. See

“Cartridge motor 2/3 cable removal” on page 4-69.

Replace the EP drive assembly. See

“Electrophotographic (EP) drive assembly removal” on page 4-90.

Go to step 5.

Replace the system board. See “System board

removal” on page 4-155.

Diagnostic information 2-53

Page 90

5026

Go Back

145.xx—Motor (EP drive assembly bottom cartridge) error service check

Step Questions / actions Yes No

1 1. Turn the printer off.

2. Remove the rear frame cover. See “Rear

frame cover removal” on page 4-47.

3. Check the cables in connector JCARTP2 and JCARTS2 (cartridge motor 2/3 cable) for proper connection to the system board, for cable pinch points, and for any other damage to the cable or connector.

Is the cable damaged?

Remove the right cover. Check the cartridge

motor 2/3 cable for proper connection to the EP drive assembly, pinch points for the cable, and damage to the cable or connector (A).

Replace cartridge motor 2/ 3 cable. See “Cartridge

motor 2/3 cable removal” on page 4-69.

Replace the cartridge motor 2/3 cable. See

“Cartridge motor 2/3 cable removal” on page 4-69.

Go to step 2.

Go to step 3.

Is either cable damaged?

Measure the continuity across all of the fuses

on the system board.

Are any of the fuses blown?

1. Disconnect the motor drive cable from the

EP drive assembly and connect it to the motor on a new EP drive assembly.

Note: Do not install the new EP drive assembly yet.

2. Run diagnostic motor check. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

3. Select MOTOR TESTS.

Did the motor run?

2-54 Service Manual

Replace the system board. See “System board

removal” on page 4-155.

Replace the EP drive assembly. See

“Electrophotographic (EP) drive assembly removal” on page 4-90.

Go to step 4.

Replace the system board. See “System board

removal” on page 4-155.

Page 91

5026

Go Back

146.xx, 148.xx—Motor (MPF/duplex) error service check

Step Questions / actions Yes No

1 1. Open the rear frame cover.

2. Reseat JDX1 cable.

Does the problem persist?

1. Remove the tray.

2. Check the MPF/duplex gear for any damage.

3. Check if the MPF/duplex gear can engage the duplex drive gear.

4. Manually turn the gear and check for any damage.

Does the error still exist?

1. Open the front door cover.

2. Disengage the duplex belt connecting to duplex drive gear/duplex rollers. The duplex reference edge assembly should not turn for isolation.

3. Remove the input tray.

4. Bring the printer up in Diagnostics Menu (Turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

5. Navigate to MOTOR TESTS > Duplex > Forward or Reverse.

6. Navigate to MOTOR TESTS > MPF Test> Forward or Reverse.

Does the error still exist?

1. Connect a new MPF motor with cable to

the JDX1 connector on the system board from outside of the machine.

2. Bring the printer up in Diagnostics Menu (Turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

3. Navigate to MOTOR TESTS > Duplex >

Forward or Reverse. Note: Perform this test for 5 to 10

seconds only.

4. Navigate to MOTOR TESTS > MPF Test>

Forward or Reverse. Note: Perform this test for 5 to 10

seconds only.

5. Check if the motor would turn for each test.

Does this clear the problem?

Go to step 2. Problem resolved.

Replace the MPF/duplex gear. See “Multipurpose

feeder (MPF)/duplex gear and housing removal” on page 4-123.

Go to step 4. Go to step 7.

Go to step 5. Replace the system board.

Go to step 3.

See “System board

removal” on page 4-155.

Diagnostic information 2-55

Page 92

5026

Go Back

Step Questions / actions Yes No

1. Disconnect the MPF motor cable on the

motor side.

2. Connect a new motor from outside of the machine.

3. Bring the printer up in Diagnostics Menu (Turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Navigate to MOTOR TESTS > Duplex >

Forward or Reverse. Note: Perform this test for 5 to 10

seconds only.

5. Navigate to MOTOR TESTS > MPF Test>

Forward or Reverse. Note: Perform this test for 5 to 10

seconds only.

6. Check if the motor would turn for each test.

Does the error still exist?

Connect a new MPF motor cable to the old MPF motor and connect it to JDX1 connector on the system board.

Does the error still exist?

1. Open the front door cover.

2. Check the duplex reference edge guide assembly for any damage.

3. Check rollers and belts for damage and misalignment.

4. Bring the printer up in Diagnostics Menu (Turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

5. Remove the input tray.

6. Navigate to MOTOR TESTS > Duplex > Forward.

7. Check if the duplex assembly runs.

8. Check if the MPF/duplex gear turns.

Is the duplex reference edge guide assembly free of damage?

Go to step 6. Replace the MPF duplex

Go to step 7. Replace the MPF/duplex

Replace the duplex reference edge guide assembly. See “Duplex

reference edge guide assembly removal” on page 4-87.

motor assembly. See

“Multipurpose feeder (MPF )/ du p l ex mo to r assembly removal” on page 4-125.

motor cable. See

“Multipurpose feeder (MPF )/ du p l ex mo to r cable removal” on page 4-128.

Go to step 8.

1. Check the front door assembly gears that

engages to the MPF/duplex gear for any damage.

2. Close the front door assembly and open the front door cover.

3. Check if the front door cover assembly gears can engage the MPF/duplex gear.

4. Manually turn the gears.

5. Check the front door assembly for any damage.

Is the front door assembly gear or the front door assembly damaged?

2-56 Service Manual

Replace the front door assembly. See “Front

door assembly removal” on page 4-100.

Go to step 9.

Page 93

5026

Go Back

Step Questions / actions Yes No

1. Check the MPF tray for any damage.

2. Manually turn the MPF gear on the tray, and check if the MPF pick arm assembly would turn.

3. Bring the printer up in Diagnostics Menu (Turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Lift the MPF pick arm using the lever.

5. Select MOTOR TESTS > MPF > Forward.

6. Check if the pick arm would turn.

Is the MPF pick arm assembly free of damage?

Remove the input tray and insert a new one.

Does this fix the problem?

Go to step 10. Replace the input tray.

Problem resolved. Replace the system board.

See “System board

removal” on page 4-155.

147.xx, 920.01—POST (power-on self test) aligner error service check

Step Questions / actions Yes No

1 1. Turn the printer off.

2. Remove the rear frame cover. See “Rear

frame cover removal” on page 4-47.

3. Check JFDPCK1 connector for proper connection and damage.

4. Reseat the connector.

5. POR the printer.

6. Perform a print test.

Is the problem still present?

Go to step 2. Problem resolved.

Check the cable in the connector JFDPCK1

for pinch points and for any other damage to the cable or connector.

Is the cable damaged?

1. Disconnect the cable in connector

JFDPCK1 and connect the cable from the new paper pick mechanism to JFDPCK1. Let the paper pick assembly hang.

2. Close the front cover and install the waste box on the side of the printer.

3. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Navigate to MOTOR TESTS > Align Motor Test > Forward.

Does the aligner motor run?

Replace paper pick mechanism. See “Paper

pick mechanism assembly removal” on page 4-137.

Replace the paper pick mechanism. See “Paper

pick mechanism assembly removal” on page 4-137.

Go to step 3.

Replace the system board. See “System board

removal” on page 4-155.

Diagnostic information 2-57

Page 94

5026

Go Back

155.xx—Cam motor error service check

Step Questions / actions Yes No

1 1. Turn the printer off.

2. Remove the rear frame cover. See “Rear

frame cover removal” on page 4-47.

3. Check the motor driver cable in connector JDVR1 on the system board for proper connection, for cable pinch points, and for any other damage to the cable or connector.

Is the cable damaged? Remove the right cover. See “Right cover

removal” on page 4-51. Check the motor

driver cable (A) for proper connection to the EP drive assembly, pinch points for the cable, and damage for the cable or connector.

Is the cable damaged?

Check the CAM motor cable from the cam

motor to the motor driver card for poor connections or damage.

Replace the motor driver cable. See “Motor driver

cable removal” on page 4-122.

Replace the motor driver cable. See “Motor driver

cable removal” on page 4-122.

Replace the EP drive assembly. See

“Electrophotographic (EP) drive assembly removal” on page 4-90.

Go to step 2.

Go to step 3.

Go to step 4.

Is the cable damaged?

Measure the continuity across all of the fuses

on the system board.

Are any of the fuses blown?

2-58 Service Manual

Replace the system board. See “System board

removal” on page 4-155.

Go to step 5.

Page 95

5026

Go Back

Step Questions / actions Yes No

Visually inspect the motor driver card.

Is the motor driver card damaged?

1. Connect a new motor driver card without

mounting it to the printer.

2. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

3. Navigate to MOTOR TESTS > CAM.

Did the motor run?

1. Reinstall old motor driver card to the

printer.

2. Plug in the CAM motor of the EP drive assembly to the EP driver card electrically without installing it into printer.

3. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Navigate to MOTOR TESTS > CAM.

Did the motor run?

Replace the motor driver card. See “Motor driver

card removal” on page 4-121.

Install the new motor driver card.

Replace EP drive assembly. See

“Electrophotographic (EP) drive assembly removal” on page 4-90.

Go to step 6.

Go to step 7.

Replace system board. See “System board

removal” on page 4-155.

Diagnostic information 2-59

Page 96

5026

Go Back

156.xx—COD (Color On Demand) motor service check

Step Questions / actions Yes No

1 1. Turn the printer off.

2. Remove the rear frame cover. See “Rear

frame cover removal” on page 4-47.

3. Check the cable in connector JBOR1 on the system board for proper connection, for cable pinch points, and for any other damage to the cable or connector.

Is the cable damaged?

Measure the continuity across all of the fuses

on the system board.

Are any of the fuses blown?

1. Disconnect the cable in connector JBOR1

and then connect the cable from the new COD group assembly.

2. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

3. Navigate to MOTOR TESTS > COD >

Forward. If nothing happens, select Reverse.

Did the COD motor pass the test?

Replace the COD assembly. See “Color on

demand assembly removal” on page 4-70.

Replace the system board. See “System board

removal” on page 4-155.

Replace the COD assembly. See “Color on

demand assembly removal” on page 4-70.

Go to step 2.

Go to step 3.

Replace the system board. See “System board

removal” on page 4-155.

160.xx, 161.xx—Motor Error (option tray 2) service check

Step Questions / actions Yes No

1 1. Turn the printer off.

2. Reseat option tray 2.

3. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Navigate to PRINT TESTS > Tray 2 > Single.

Did the page print?

1. Turn the printer off.

2. Remove the rear frame cover. See “Rear

frame cover removal” on page 4-47.

3. Check the option cable in connector JOPT1 on the system board for proper connection, for cable pinch points, and for any other damage to the cable or connector

Is the cable damaged?

Problem resolved. Go to step 2.

Replace the option cable. See “Option cable

removal” on page 4-135.

Go to step 3.

2-60 Service Manual

Page 97

5026

Go Back

Step Questions / actions Yes No

Remove the right cover. See “Right cover

removal” on page 4-51.

Check the option cable for pinch points and any damage.

Is the cable damaged?

Is the option tray 2 the high-capacity input tray

(2,000-sheet feeder)?

Replace the option cable. See “Option cable

removal” on page 4-135.

Replace the HCIT top plate assembly. See “Top plate

assembly removal” on page 4-206.

162.xx, 163.xx—Motor Error (option tray 3) service check

Go to step 4.

Replace the option tray 2 assembly.

Step Questions / actions Yes No

1 1. Turn the printer off.

2. Reseat option tray 3.

3. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Navigate to PRINT TESTS > Tray 3 > Single.

Did the page print?

1. Remove all input options connected to the

machine.

2. Connect tray 3 directly on the printer making it tray 2.

3. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, and turn on the printer).

4. Navigate to PRINT TESTS > Tray 2 > Single.

Did the page print?

Check the top and bottom autoconnect connectors of tray 2 (input option above tray

3) for damages.

Are the autoconnect connectors damaged?

Check the top and bottom autoconnect connectors of tray 3 for damages.

Are the autoconnect connectors damaged?

Problem resolved. Go to step 2.

Go to step 3. Go to step 4

Replace tray 2 550 input option

• For 550 option, replace tray 3 550 input option.

• For HCIT, replace the HCIT top plate assembly.

Go to step 4.

Go to step 5.

Diagnostic information 2-61

Page 98

5026

Go Back

Step Questions / actions Yes No

1. Turn the printer off.

2. Remove the rear frame cover. See “Rear

frame cover removal” on page 4-47.

3. Check the option cable in connector JOPT1 on the system board for proper connection, for cable pinch points, and for any other damage to the cable or connector.

4. Remove the right cover. See “Right

cover removal” on page 4-51,

5. Check the option cable for pinch points and any damage.

6. Check the autoconnect connector for damage.

Is the cable damaged?

Replace the option cable. See “Option cable

removal” on page 4-135.

• For 550 option, replace tray 3 550 input option.

• For HCIT, replace the HCIT top plate assembly.

164.xx, 165.xx—Motor Error (option tray 4) service check

Step Questions / actions Yes No

1 1. Turn the printer off.

2. Reseat option tray 4.

3. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Navigate to PRINT TESTS > Tray 4 > Single.

Did the page print?

Problem resolved. Go to step 2.

Turn the printer off, and then remove the rear

frame cover. See “Rear fr am e co ver

removal” on page 4-47.

Check the option cable in connector JOPT1 on the system board for proper connection, for cable pinch points, and for any other damage to the cable or connector.

Is the cable damaged? Remove the right cover. See “Right cover

removal” on page 4-51.

Check the option cable for pinch points and any damage.

Is the cable damaged?

Replace the option cable. See “Option cable

removal” on page 4-135.

Replace the option cable. See “Option cable

removal” on page 4-135.

Go to step 3.

Go to step 4.

2-62 Service Manual

Page 99

5026

Go Back

Step Questions / actions Yes No

Is the option tray 4 the high-capacity input tray

(2,000-sheet feeder)?

Replace the HCIT top plate assembly. See “Top plate

assembly removal” on page 4-206.

Replace the option tray 4 assembly.

166.xx, 167.xx—Motor Error (option tray 5) service check

Step Questions / actions Yes No

1 1. Turn the printer off.

2. Reseat option tray 5.

3. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Navigate to PRINT TESTS > Tray 5 > Single.

Did the page print?

1. Turn the printer off.

2. Remove the rear frame cover. See “Rear

frame cover removal” on page 4-47.

3. Check the option cable in connector JOPT1) on the system board for proper connection, for cable pinch points, and for any other damage to the cable or connector.

Is the cable damaged?

Problem resolved. Go to step 2.

Replace the option cable. See “Option cable

removal” on page 4-135.

Go to step 3.

Remove the right cover. See “Right cover

removal” on page 4-51.

Check the option cable for pinch points and any damage.

Is the cable damaged?

Is the option tray 5 the high-capacity input tray

(2,000-sheet feeder)?

Replace the option cable. See “Option cable

removal” on page 4-135.

Replace the HCIT top plate assembly. See “Top plate

assembly removal” on page 4-206.

Go to step 4

Replace the option tray 5 assembly.

Diagnostic information 2-63

Page 100

5026

Go Back

168.xx—Motor (HCIT elevator) error service check

Step Questions / actions Yes No

1 Is the paper properly loaded in the high-

capacity input tray (HCIT)?

1. Turn the printer off.

2. Reseat option the HCIT option.

3. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold buttons 3 and 6, then turn on the printer).

4. Navigate to PRINT TESTS > HCIT > Single.

Did the error clear?

1. Turn the printer off.

2. Remove the rear frame cover. See “Rear

frame cover removal” on page 4-47.

3. Check the option cable in connector JOPT1 on the system board for proper connection, for cable pinch points, and for any other damage to the cable or connector.

Is the cable damaged?

1. Remove the HCIT right cover. See“HCIT

right cover removal” on page 4-196.

2. Check the cable in the HCIT.

Is the cable damaged?

Go to step 2. Fan the media, and then

Problem resolved. Go to step 3.

Replace the option cable. See “Option cable

removal” on page 4-135.

Replace the elevator-up cable.

stack flat in the HCIT drawer.

Go to step 4.

Replace the elevator motor with sensor. See “HCIT

elevator motor with sensor removal” on page 4-200.

200.11, 250.03—Paper Jam error service check

Step Questions / actions Yes No

1 Open the front access door. Turn the

transport belt gear clockwise.

Did the transport belt move?

Go to step 2. Replace the transport belt.

See “Transfer module

removal” on page 4-171.

2-64 Service Manual

Lexmark C746n, C746dn, C746dtn, C748e, C748de Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

Notices and safety information

Laser no tice

Laser-Hinweis

Avis relatif à l’utilisation de laser

Avvertenze sui prodotti laser

Avisos sobre el láser

Declaração sobre Laser

Aviso sobr e o las er

Laserinformatie

Lasermeddelelse

Laserilmoitus

Huomautu s las er laitteesta

Laser-notis

Laser-melding

Avís sobre el Làser

Lithium warn ing

Safety information

Consignes de sécurité

Norme di sicurezza

Sicherheitshinweise

Pautas de Seguridad

Inform a çõ es de Segurança

Informació de Seguretat

Preface

Conventions

Navigation buttons

1. General in formation

Models

Options

Media options

Memory options

Printer specifications

Dimensions

Clearances

Memory

Expansion opportunities

Resolution

Data streams

Environment specifications

Electrical and power specifications

Acoustic specifications

Media specifications

Input and output capacities

Input and output sizes and types

Paper guidelines

Tools required for service

Acronyms

2. Diagnostic information

Start

Operator pan el an d me nu s

C746x operator panel

C746x buttons and light descriptions

C748x operator panel

C748x buttons and light descriptions

Administrative menus

Power-on self test (POST) sequence

Sympto m tab l e s

Printer symptom table

Print quality sympto m table

User status and attendance messages

Error codes and messages

Service checks

31.xx—Cartridge errors service check

110.xx—Mirror motor service check

111.xx, 112.xx, 113.xx, and 114.xx—Printhead error service check

120.xx—Fuser error service check

140.xx, 920.02—Autocomp (tray 1) motor error service check

142.xx, 906.01–906.04—Motor (fuser) error service check

143.xx—Motor (EP drive assembly top cartridge 1 motor) error service check

144.xx—Motor (EP drive assembly middle cartridge) error service check

145.xx—Motor (EP drive assembly bottom cartridge) error service check

146.xx, 148.xx—Motor (MPF/duplex) error service check

147.xx, 920.01—POST (power-on self test) aligner error service check

155.xx—Cam motor error service check

156.xx—COD (Color On Demand) motor service check