Lexmark C77x, C78x Service Manual

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Edition: March 26, 2007

Lexmark™ C77x, Lexmark C78x printer

• Table of Contents

• Start Diagnostics

5061

• Safety and Notices

•Trademarks

• Index

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

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Edition: Marc h 26, 2007 The following paragraph does not apply to any country where such provisions are inconsistent with local law:

LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warr anties in certain transactions; theref ore, this statement may not apply to you.

This public ati on could include technical inaccuracies or typographical errors. Changes a re 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 an of the info rmatio n you supply in any way it believes appropriate without incurring any obli gation to you.

References in this pub lication to products, programs, or services do not imply t hat the manufacturer inte nds to make the s available in all countries in which it operates. Any reference to a pro duct, program, or service is not in tended to state or imply that only t hat product , progr am, or s ervice ma y be use d. An y funct ional ly equi val ent pro duct , prog ram , or service th a does not infringe any existing intel lectual property right may be used instead. Evaluation and verificati on of operation in conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the user’s responsibil ity.

Lexmark, Lexmark with diamond design, and Ma rkNet are trademarks of Lexm ark Int ernational, Inc., reg ist ered in the United States and/or other countries.

PrintCryption is a trademark of Lexmark International, Inc. StapleSmart is a trademark of Lexmark International, Inc. LEXF AX is a service mark of Lexmark International , I nc. PCL® is a registered trademark of the Hewlett-Packard Company. Other trademarks ar e the property of their respective owners.

UNITED STA TES GOVERNMENT RIGHTS

This softwar e and any accompanying doc um entation provided under this agreement are commer cial computer software and documentation developed exclusively at private expense.

P/N 12G9688

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Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi

Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

Safety in fo r mation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx

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

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

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Options and features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Options for all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Options for C772 and C782 (310 and 410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Power and performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Media specificat ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Media guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Paper characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Unacceptable paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Selecting paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Web oiler upgrade kit and replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

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

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

POR (Power-On Reset) sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Symptom table—base printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Symptom table—500-sheet drawer option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Symptom table—HCIT 2000-s heet option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Symptom table—output expander option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5

Symptom table—5-bin mailbox option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Symptom table—StapleSmart finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Service error code and paper jam message table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

100.01 ITU error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

100.02 ITU error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

122.01 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

122.02 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

122.03 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

122.04 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

122.05 and 122.06 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

122.07, 122.14, and 122.15 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

122.08 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

122.10 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

122.11 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

122.12 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

122.13 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

148.xx error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

150.xx error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

151.xx error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Table of contents iii

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152.xx error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

153.xx error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

177.xx error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

200.03 paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

200.04 paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

200.05 paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

200.06 paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

200.07 paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

200.16 paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

200.21, 200.28, and 200.29 paper jam service chec k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

200.93 paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 1

200.96 paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

201.xx and 202.xx paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

230.xx paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3 5

241.xx paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

242.xx paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

243.xx paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

244.xx paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

250.xx paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4 7

271.xx paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4 9

272.xx paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

282.98 paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

900.xx RIP Software Error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

925.02 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

926.01 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

927.03 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

930.09 error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

940.xx error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

941.xx error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

942.xx error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60

943.xx error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

956.xx service error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

982.xx error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

990.01 error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65

5-bin mailbox option service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67

500-sheet drawer opti on service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7 1

AC and DC power service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 4

Autocompensator service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76

Black only retract (BOR) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -78

Close door/HVPS/printhead interlock switch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79

Duplex option service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-81

Envelope feeder option service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8 3

HCIT 2000-sheet opt ion service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -84

Fuser drive assembly noise check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-87

Operator panel LCD/status LED/buttons service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-88

Output expander option service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-90

Print quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-93

Blank page (no image) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9 3

Entire page is mostly one color—Full bleed planes in one color . . . . . . . . . . . . . . . . . . . . . . . .2-94

Missing colors—Complete or partially missing color planes . . . . . . . . . . . . . . . . . . . . . . . . . . .2-95

Black and whit e only—cyan, magenta, and yellow are missing . . . . . . . . . . . . . . . . . . . . . . . . .2-96

Light print over the entire page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 9 6

Vertical lines or streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-98

Horizontal lines or streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 8

Low image density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-99

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Poor color alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99

Transparency print quality is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

Negative ghosting or faded image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

Residual image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

Uneven printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

Toner smears or rubs off the page with no error code displayed . . . . . . . . . . . . . . . . . . . . . . 2-102

Smudged or distorted images on fused page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102

Toner is on the back of the printed page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103

Light lines or str eaks appear on the page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103

White streak in color plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104

Paper wrapped around the second transfer roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104

User troubleshooting for quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105

Second transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109

StapleSmart finisher service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111

Tray 1 service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115

Tray 1 media size sensing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116

User operator panel, menus, and messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117

Understandin g the printer operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117

Operator panel buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117

Menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119

Selected menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120

Quality Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120

Utilities Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122

User attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-124

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

Diagnostic procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Printhead dia gnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Print quality defect locator chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Partial Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

HCIT standalone test mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Entering Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Diagnostic mode menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Exiting the Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

ALIGNMENT MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Setting alignment for color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Drift Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

MISC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Toggle ITU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Belt Tracking (ITU 4th point adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Printhead Inst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

PRINT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Print Tests (input sources) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Print Quality Pgs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

HARDWARE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

CACHE Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Parallel Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Serial Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Table of contents v

Page 6

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DUPLEX TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Duplex Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Duplex Top Margin Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

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

INPUT TRAY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

OUTPUT BIN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Feed to All Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Diverter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

FINISHER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Staple Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Finisher Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Finisher Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

BASE SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

DEVICE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Quick Disk T est . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

PRINTER SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

PAGE COUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2 6

Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Engine Setting x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Reset Color Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 2 8

Edge to Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Cal Ref Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

EP SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

EP Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Fuser Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

DC Charge Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 8

Dev Bias Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Transfer Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

ERROR LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

Print Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 9

Clear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

EXIT DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -31

Entering Config Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Exiting the Config Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Reset Fuser Cnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Black Only Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Prt Quality Pgs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Color Trapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Tray Insert Msg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

SIZE SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

vi Se rvic e M anual

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Auto Color Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Paper Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Env Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

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

Jobs On Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Disk Encryption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

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

Paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Identifying jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Access doors and trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Understanding jam messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Paper jam me ssages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Clearing the enti re paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Area A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Area B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Area C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Area D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Area T1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Area E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Area T<x> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Area J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Area K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Area L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Clearing mailbox, finisher, or output e xpander jams (Area M) . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Clearing fuser jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Clearing image transfer unit jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

If you still need help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

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

Handling ESD-sensiti ve parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Screw identification table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Operator panel bezel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Lens removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Front cover rear pivot cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Front cover or front cover backplate assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Redrive cap removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Front lower left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Paper path access door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Front left handle cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Front lower right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Front right handle cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Lower right door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Left lower cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Lower jam access door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Redrive door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Autocompensator pick assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

BOR drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Cartridge contact assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Cartridge drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Developer HVPS board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Friction buckler and buckler housing removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Front right light shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Fuser assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Table of co ntents vii

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5061

Fuser bottom duct removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45

Fuser drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46

Fuser fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46

Fuser top duct removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47

Inner system board shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48

ITU assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49

ITU drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52

LVPS assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-53

Media size sensing assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55

Media size sensing board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5 8

Multipurpose feeder (MPF) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5 9

Multipurpos e feeder (MPF) autocompensator or side restraints removal . . . . . . . . . . . . . . . . . . . . . .4-62

Multipurpose feeder (MPF) motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64

Nip relief handle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-65

Operator panel assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 8

Outer system board shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-69

Pick rolls removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-70

Printhead remov al and adj ustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 -72

Mechanical alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7 2

Black printhead electronic alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 77

Color printhead electronic alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-78

Rear bellcrank removal (cyan, magenta, yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-79

Rear bellcrank (black) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-81

Redrive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-82

Registration motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-83

Rib housing removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-84

RIP fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-86

S2/narrow media/ tr ansparency/multi purpose feeder cable remov al . . . . . . . . . . . . . . . . . . . . . . . . . .4-87

S2/narrow media/ transparency/mul tipurpose feeder senso rs removal . . . . . . . . . . . . . . . . . . . . . . . .4-88

Second transfer roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-88

System board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-89

Transfer HVPS board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-91

Transfer plate assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-94

Vacuum transport belt (VTB) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 5

Vacuum transport belt (VTB) fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 9 7

Waste container door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-97

Waste container latch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-98

Web oiler fuser ass em bly and card removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-99

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

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

Printer boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Printer motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Printer sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Cartridge contact assembly pin locations (cyan, magenta and yellow) . . . . . . . . . . . . . . . . . . . . . . . .5-4

Cartridge contact assembly pin locat ions (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 5

System board cabli ng reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

System board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Autoconnect— top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

Autoconnect— bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

Transfer high volt age power supply (HVPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

Developer high voltage power supply (HVPS) board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

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Low voltage power supply (LVPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

LVPS cab le connectors to system board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

LVPS fuser connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Media size sensing board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

High-capaci ty i nput tray (HCIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

StapleSmart finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

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

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

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

Standard fuser s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

ITU Maintenance ki ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Lubrication spec if ications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Lubrication for replacement motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Fuser drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Cartridge drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

ITU drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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

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

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

Assembly 2: Cartridg e mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 3: Fuser assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Assembly 4: Fuser drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 10

Assembly 5: Vacuum transport belt (VTB) assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Assembly 6: Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 7: Printheads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Assembly 8: Paper feed output (redrive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Assembly 9: Paper feed input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Assembly 10: Media si ze sensing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Assembly 11: Paper fe ed transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Assembly 12: Multipurpose feeder (MPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Assembly 13: 500-Sh eet i ntegrated tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Assembly 14: Autocompensator assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Assembly 15: ITU assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Assembly 16: ITU drive assem bly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 23

Assembly 17: ITU lo a ding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Assembly 18: Waste tone r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 26

Assembly 19: BOR drive asse mbly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

Assembly 20: Cartridge contact assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Assembly 21: Cartridge drive assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

Assembly 22: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Assembly 23: Electronics—cabling interconnections 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Assembly 24: Electronics—cabling interconnections 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Assembly 25: Electronics—cabling interconnections 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

Assembly 26: Electronics—cabling interconnections 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

Assembly 27: Output expander. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

Assembly 28: 5-Bin mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 46

Assembly 29: 500-Sh eet drawer option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50

Assembly 30: Duplex option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

Assembly 31: High-capacity input tray (HCIT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58

Assembly 32: StapleSmart finisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62

Assembly 33: Env e lope option

Assembly 34: Outdoor media tr ay option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68

Assembly 35: Banner opt ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69

Assembly 36: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66

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Appendix A—Service tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Identifying the printheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Redrive belt routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Duplex option deflector button replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Appendix B—Print quality samples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Print tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Print Quality Pages—Title page (total of fiv e) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1

Print Quality Pages—Page 1 (total of five) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Print Quality Pages—Page 2 (total of five) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Print Quality Pages—Page 3 (total of five) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

Print Quality Pages—Page 4 (total of five) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Registration and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Quick Test Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Printhead mechani cal alignment test page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 7

Printhead electronic alignment test page—Magenta (one of two). . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

Printhead electronic alignment test page— Ma genta (two of two) . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

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

Part number index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-9

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Notices and safety information

The foll owing laser notice label s m ay be affixed t o this printer.

Laser no tice

The printer is certified in the U .S. to confo rm to the requir ements of DHHS 21 CFR Subchapter J for Class I (1) laser product s, 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 int ernally a Class IIIb (3b) laser that is nominally a 5 milliwatt galli um arsenide laser operati ng in the wavelength region of 770-795 nanometers. The laser system and printer are designed so there is never an y hum an access to laser radiation above a Class I level during normal operation, user maintenance, or pr escri bed service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigu ng der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 60825-1 gemäß amtlicher Bestäti gung erfüllt.

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

Avis relatif à l’utilisation de laser

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

Les produits laser de Classe I sont considérés comm e des produits non dangereux. Cette imprimante est équipée d’un l aser de Classe IIIb (3b) (arséniure de gall ium d’une puissance nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son sys tème laser sont conçus pour impossible, dans des conditions normales d’utilisation, d’entr etien par l’utilisateur ou de révision, l’exposition à des rayonnements lase r supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampant e è certificata negli St ati Uniti per ess ere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti las er di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conf orme ai requisiti del la norma CEI 60825-1.

I prodotti laser di class e non sono con sider ati pericol osi. La stampan te contiene al suo interno un l aser di classe IIIb (3b) all’arseniuro di gallio dell a potenza di 5mW che opera sulla lunghezza d’onda compresa t ra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionam ento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.

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Avisos sobre el láser

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

Los productos láser de Clase I no se consideran pel igrosos. La impre sora contiene en su interior un láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nomin al a 5 miliv atios en una longi tud de onda de 770 a 795 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiac ión láser superior al nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualqui er otra situación de servic io técnico.

Declaração sobre Laser

A impressora está ce rtificada no s E. U .A. e m conf ormidade co m os r equi sito s da reg ulamenta ção DHHS 2 1 CFR Subcapítulo J para a Cla sse I (1) de produt os laser. Em outros locais, está certifi cada como um produto lase r da Classe I, em conf ormidade com os requisitos da norma IEC 60825-1.

Os produtos lase r da Classe I não sã o conside rados peri gos os. I nternamente , a impr esso ra cont ém um produ to laser da Classe IIIb (3b), designado laser de arseneto de potássio , de 5 milliwatts ,oper ando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca ex ist ir qualquer possiblidade de acesso humano a radi ação laser superior a um nív el de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assist ência prescritas.

Laserinformatie

De printer v oldoet aan de eis en die ges teld w orde n aan ee n laserprodukt v an klass e I. Voor de Ver enigde Stat en zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.

Laserprodukten van klasse I worden nie t al s ongevaarlij k aangemerkt. De printer is voor zien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met e en g ol flengte van 770-795 nanometer . Het laser gedeelt e en de printer zij n zo ont worpen dat bij normaal gebru ik, bij onde rho ud of repar atie conform de voorschriften, nooit blootstelling mogelijk is aan laserst raling boven een niveau zoals voorgeschreven is voor klasse 1.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der

nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer. Lasersystem et og printeren er udformet således, at mennesk er al drig udsættes for en l aserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

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Laserilmoitus

Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) lasertuotteeksi j a m uualla IEC 60825-1 -standardin mukaiseksi luo kan I l asertuot teeksi.

Luokan I lasertuottei ta ei pidet ä hai talli sina. Tulostimen sisäl lä on luo kan IIIb (3b) laser, joka on nimellisteholt aan 5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat rakenteeltaan sellaisi a, että käyttäjä ei joudu alttiiksi luokkaa 1 suur em ma lle säteilylle normaalin käytön, ylläpidon tai huollon aikana.

Huomautu s las er laitteesta

Tämä kirjoi tin on Yh dysv alloi ssa lu okan I ( 1) lase rlait teide n DHHS 21 CFR Subchapt er J -mää rityks en muk ainen ja muualla luo kan I l aserl aitteiden IEC 60825-1 -määri tyksen mukainen.

Luokan I las e r la itt e id e n e i ka ts o ta ol evan vaarallis ia käyttäjä lle . K irjoittimessa on sisäi nen lu ok a n IIIb (3 b ) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Lase rjärjestelmä ja kirjoitin on suunnitelt u siten, että käyttäj ä ei al tistu luokan I määrityksi ä voimakkaammall e säteilylle kirj oittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

VARO! Av attaessa ja suojalukitus ohitettaessa olet alttiina näkymä ttömälle lasersäteilylle. Älä katso säteeseen.

VARNING! Osynlig laserst rålning när denna del är öppnad och spär ren är urkopplad. Betrakta ej strålen.

Laser-notis

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

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer. Lasersystem et och skrivaren är utformade så att det aldrig finns ris k för att någon person utsätts f ör laserstrå lning över Klass I-ni vå vid normal användning, underhåll som utförs av användaren eller annan föreskriv en serviceåtgärd.

Laser-melding

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

Klasse I-la serprodukter er ikke å betrakte som f arlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer . Lasersystem et og skriveren er utformet slik at personer al dri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk , vedlikehol d som utf øres av brukeren, eller foreskrevne serviceoperasjoner.

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Avís sobre el Làser

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

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

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Safety information

• The safety of this product is based on testi ng and approvals of t he original design and specific

components . The manufacturer is not responsibl e 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 shoc k and personal injury during disassem bly and servicing of

this product . Pro fessional service personnel should understand this and take necessary precautions.

• CAUTION: When you see th is symbol , ther e is a danger f rom hazard ous v olt age in the ar ea of the

product where y ou ar e working . Unplug the product bef ore you beg in, or use c autio n if t he produc t 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 particulier s. Le fabricant n'ass ume aucune respon sabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.

• Les consignes d'entretien et de répar ati on 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 nécessai res.

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

produit sur laquelle vous tra vaillez. Débranchez le produit a vant de commencer ou f aites preuve de vigilance si l' exécution de la t âche exige que le produi t 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 sostituzion e 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 al la persona è più elev ato. Il per sonale di assistenza autorizzato deve, quindi, adottare le precauzioni necessarie.

• ATTENZIONE: Questo simbolo indica la presenza ditensione pericolosa nell'area del prodotto.

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

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Sicherheitshinweise

• Die Sicherheit di eses Produkts basiert auf Tests und Zulassungen des ursprüngl ichen Modells und

bestimmter Baut eil e. Bei Verwendung nicht genehmigter Ersatztei le wi rd vom Hersteller kei ne Verantwortung oder Haft ung für die Sicherheit übernommen.

• Die Wartungsinformationen für dies es Produkt sind ausschließl ich für die Verwendung durch ein en

Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusät zliches Risiko eines

elektrischen Schlags und körperlicher Verletzung. Das zus tändige Fachpersonal sollte entsprechende Vorsichtsmaßn ahm en treffen.

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

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

Pautas de Segu ridad

• La seguridad de este prod ucto se basa en pruebas y aprobaciones del diseño original y component es

específico s. 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 may o r riesg o de de scarga el éctrica y de dañ os person al es duran te e l desmont aj e y la r eparac ión de

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

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

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

Informações de Segurança

• A segurança deste produto baseia-se em testes e aprovações do mode lo original e de componentes

específico s. 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 dest inam-se a profissionais destes serviços e não

dev em ser utilizadas por outr as pessoas.

• Risco de choques eléct ricos e ferimentos graves durante a desmontagem e manutenção deste produto .

Os profissio nais destes serviços devem estar avis ados deste facto e tomar os cuidados necessários .

• CUIDADO: Quando vir este sí m bolo, existe a possível presença de uma potencial tens ão

perigosa na zona do produto em que está a trabalhar. Antes de começar, desligu e o produto da tomada eléctrica ou s eja cui dado so caso o pro duto te nha d e estar liga do à corrent e eléc trica para realizar a tarefa necessária.

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Inf ormació de Seguretat

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

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

• La informació pel manteniment d’aquest producte està orientada exclusiv ame nt a professional s i no està

destinada a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augment ar durant el procés de desmuntatge i de servei

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

• PRECAUCIÓ: aquest símbol in dica que el voltatge de la part de l'equip am b la qual esteu

treballan t és perillós . Abans de començar, desendoll eu l'equ ip o extremeu les precaucions si, per treballar amb l'equip, l'heu de connectar.

Sa fety informat ion xix

Page 20

5061

Preface

This manual contains maintenance procedures for service personnel. It is divided into t he following ch apters:

1. General in form a tion contains a general description of the printer and the maintenance approach used to

repair it. Speci al tools and test equipment, as well as general environmental and safety instructions, are discussed.

2. Diagnostic informat ion contains an error indicator table, symptom tables, and service checks used to

isolate failing field replaceable units (FRUs).

3. Diagn ostic aids contains tests and checks used to locate or repeat symptoms of printer problems.

4. Repair info rma tion provides instructions for making printer adjustments and removing and installing

FRUs.

5. Connecto r locations uses illustrations to identify the connector locations and test points on the printer.

6. Preventive maintenance contai ns the lubrication specifications and recommendations to prev ent

problems.

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

Appendix A contains service tips and info rmati on. Appendix B contains representative print samples.

Conventions

Note: A note provides addition al i nformation. Warning: A warning identifies something that might damage the product hardware or software.

There are several types of cauti on statements:

CAUTION

A caution identifies something that might cause a servicer harm.

CAUTION

This type of caution i ndicates there is a danger fro m haz ardous voltage in the area of the product where you are working. Unplug the product befor e you begin, or use caution if the product must recei ve power in order to perform the task.

CAUTION

This type of caution indicates a hot surface.

xx Service Manual

CAUTION

This type of caution i ndicates a tipping hazard.

Page 21

5061

1. General information

The Lexmark™ C77x, C78x (5061-xxx) is a network-capable color printer that uses electrophotographic technology to deliver high-quality images, presentation graphics, line art, and text. It prints both four-color and monochrome print jobs.

The flexible design supports a variety of printing needs. For example, if you need the printer to match the color process used in a particular appli cati on, you can sel ect RGB or CMYK color cor rections . You can also adjust the printed colors to more closely represent the colors on your comput er di splay.

A variety of con nectivity options enable the printer to be used in all types of system enviro nm ents. You can attach one internal adapter to support network configurati ons requiring Ethernet, Token-Ring, LocalTalk, serial, infrared, or additional parallel ports.

The printer has flexible paper handling. It supports a wide variety of paper sizes, and has a standard multipurpose feeder that makes it easy to print on envelopes, transparencies, labels, card stock, and nonstandard siz e paper. You can add optional i nputs to the base printer, which can increase the printer paper capacity to 3100 sheets.

Models

The Lexmark C77x and C78x (5061-xxx) laser printers are a vailable in four models:

Lexmark C770n 5061-110 Network Lexmark C772n 5061-310 Network Lexmark C780n 5061-210 Network Lexmark C782n 5061-410 Network

Tools required for service

Flat-blade screwdriver #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade Needlenose pli ers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Par allel wrap plug 1319128 Twinax/serial debug cable 1381963 Coax/serial debug cable 1381964

General inf ormation 1-1

Page 22

5061

Options and features

Lexmark C77x and C78x printers support only Lexmark C77x and C78x paper-handling options. These options are not compatib le with any other Le xm ark printer.

Note: The Envelope Feeder for the C772 (mode l 310) works only on the C772 models. The C782 (model 410) Enve lope Feeder works on the C772 and th e C782 (models 310 and 410).

Options for all models

500-Sheet drawer—(includes 500-sheet tray and support unit) installs beneath the printer and holds

•

appro ximatel y 500 sheet s of 20 lb, 75 g/m option drawer and high-capacity input tray. All models.

• 500-Sheet tr ay—for environments with space or budget constraints t his can be ordered for special media.

This temporarily replaces the standard tr ay in a 500-shee t dr awer and holds approximately 500 sheets of 20 lb, 75 g/m

paper. All models.

• Duplex opti on—of f ers two- side pri nting. The f irst option und er a duple x option mus t be a 500-shee t dra wer.

All model s.

Options for C772 and C782 (310 and 410)

•

2,000-Sheet drawer (High-capacity Input Tray)—installs beneath the printer and below any other optional input sources and holds approximately 2,000 sheets of 20 lb, 75 g/m

• Output expander—installs above the printer primary output bin to offer an additional output destination.

This holds approximately 650 sheets of 20 lb, 75 g/m supported.

• 5-Bin mailbo x— installs above the printer primary output bin to offer five output destinations in one option.

Each of the five bins supports approximately 100 pages of 20 lb, 75 g/m abov e the printer is supported.

• StapleSmart™ Finisher—offers stapling, and an additional output bin. The finisher supports up to 500

sheets of non-st apled. For stapled m edia, the output bin supports up to 15 stapled sets or about 375 sheets. The stapler staples a maximum of 25 sheets per set. Each printer supp orts one finisher.

• Enve lope drawer—installs beneath the printer, and holds approximatel y 60 envelopes (20 l b, 75 g/m

to three envelope drawers are supported or one envelope drawer and a high-capacity input tray. The Enve lope Dr awer fo r t he C772 works only on the mode ls C772 ( 310) . Th e C782 Env e lope Dr a wer works on the models C772 and C782 (310 and 410).

• Outdoor media drawer—install s beneath the printer is speci ally designed fo r use i n p rinting on a polyester

media used for outdoor signs. This heavy duty outdoor medi a is availab le in Letter or A4 sizes. The Outdoor media drawer only work

• Banner tray—extension of the Multipurpose Feeder allows printing of up to 50 sheets of 24 lb (90 (g/m²)

banner paper (up to 8.27 in. wide x 48 in. long (210mm x 1,219mm). It also serves as an extension of the output tray, to hold the printed banner paper as it exit s from the printer. The banner media tray is easily installed and features a fold-down t ray for space savings when not in use. Al l media which can be f ed from the MPF can be used when the Banner Tray is attached.

paper. Up to three dr a wers are supported simul taneous ly, or an

paper.

paper. Only one output option above the printer is

paper. Only one output option

). Up

High performance

•

Up to 25 ppm black or col or

• 500 MHz RISC processor (non-network) or 600 MHz (network)

• 128MB RAM

• Time to first page – Black: less than 13 seconds – Color: less than 15 seconds

1-2 Se rvice Manu a l

Page 23

5061

Automatic ca l ibr ation

The printer performs an automatic calibration under the following conditions.

• At power-on

• After exit from power saver mode with a significant change of I TU temperature compared to the last

calibration.

• Approximately every 500 pages, at the end of a job

• After changing a print cartridge

• After changin g an image tr ansfer unit (ITU)

A manual calibr ation can be initiated b y selecting Color Adjust from the Color Menu.

Resolution

1200 x 1200 dpi (one half printer speed)

•

• 4800 CQ (default) (full printer speed)

Toner darkness

Toner darkness settings offer five user-selectable settings to balance print darkness and toner savings. The higher the setting, the darker the print. The toner darkness default setting is 4. Color level 4 and level 5 are the same.

The toner darkness set ti ng is availab le through the operator panel under the Print Quality menu or through the Lexmark PostScript driver.

Setting 12345

Delta toner from default (mono) -50% -30% -15% Default +10% Delta toner from default (color) -50% -30% -15% Default N/A

Color corr ection setti n g s

The following correction settin gs are available:

• Auto (default): Applies different color correction to each object on the printed page depending upon the

type of object and how the color for each object is specified.

• Off: No color correction is implemented.

• Manual: Allo ws users to customize col or correction output f rom the driver or operator panel.

General inf ormation 1-3

Page 24

5061

Printer specifications

Description Height Width Depth Weight Printer

Lexmark C77x(n)/C78x(n) 20.8 in.

Lexmark C77xdn/C78xdn (including duplex option)

Lexmark C77xdtn/C78xdtn (including duplex unit and optional 500-sheet drawer)

Lexmark C772, C782 maxim um input trays (including duplex unit, three optional 500-sheet drawers and printer stand)

Lexmark C772, C782 with maxim um input sheets (includ ing duplex unit, opti onal 500-sheet drawer, and 2000-sheet drawer)

Options

500-sheet drawer 5 in.

500-sheet tra y 3.8 in.

Duplex optio n 3.5 in.

2,000-sheet tray (including stabilizer bars) 15.4 in.

Outdoor media drawer 5 in.

Banner Tray (including output bail) 9 in.

Envelope drawer 5 in.

Output expander 7 in

5-bin mailbo x 11.5 in.

StapleSmart Finisher 9 in.

Printer stand (including stabilizer bars) 4 in.

(528.3 mm)

24.3 in (617.2 mm)

28.9 in. (734.1 mm)

41.4 in. (1051.6 mm)

43.5 in. (1104.9 mm)

(127 mm)

(96.5 mm)

(88.9 mm)

(391.2 mm)

(127 mm)

(228.6 mm)

(127 mm)

(177.8 mm)

(292.1 mm)

(228.6 mm)

(101.6 mm)

23.8 in. (604.5 mm)

15.6 in. (396.2 mm)

23.8 in. (604.5 mm)

26 in. (660.4 mm)

23.8 in. (604.5 mm)

12 in. (304.8 mm)

23.8 in. (604.5 mm)

14.5 in. (368.3 mm)

17.6 in. (447.7 mm)

26.5 in. (673.1 mm)

18.5 in. (469.9 mm)

23.8 in. (604.5 mm)

18.5 in. (469.9 mm)

15.5 in. (386.1 mm)

18.5 in. (469.9 mm)

23.8 in. (604.5 mm)

18.5 in. (469.9 mm)

30.5 in. (774.7 mm)

18.5 in

469.9 mm

18.5 in. (469.9 mm)

19.5 in. (495.3 MM)

24 in. (609.0 mm)

105 lb (47.7 kg)

118 lb (53.8 kg)

132 lb (60 kg)

179.0 lb (81.4 kg)

181 lb (82.3 kg)

13.5 lb (6.1 kg)

2.6 lb (1.2 kg)

13.5 lb (6.1 kg)

49 lb (22.3 kg)

13.5 lb (6.1 kg)

7.2 lb (3.3 kg)

13.5 lb (6.1 kg)

5.4 lb (2.5 kg)

8.7 lb (4.0 kg)

13 lb (5.6 kg)

20 lb (9.1 kg)

1-4 Se rvice Manu a l

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5061

P o wer and ele ctrica l sp ecific ations

Average nominal power requirements for the base printer configuration (110 volt). (Power levels are shown in watts.) Maximum current shown in amp ergs.

Printing states Lexmark C77x(n) Lexmark C77xdn Lexmark C78x(n) Lexmark C78xdn

Printing—av erage power (W) Base model 500 500 675 675 All options 540 540 675 675 Idle—average power Power Saver On 30 31 25 27 Power Saver Off 180 180 150 150 Printing—maximum

current (110 V)

Notes:

10.2 10.2 11.9 11.9

• Using a 220V ac to 110 V ac power converter with the 110 volt printer is not recommended.

• Using an inverter (12 V dc to 120 V ac, for example) to power the printer is not recommended.

• The C77xn, C77xdn, and C77xdt n and C78xn, C78xdn, and C78xdtn are Energy Star-compliant. T hese

models include:

Electrical specifications

110 Volt model

• 110 to 127 V ac at 47 to 63 hertz (hz) nominal

• 99 to 137 V ac, extreme

Operatin g clea r an ces

Printer Side Model Measurement

Left side Right side All 15 in. (381 mm) Front All 20 in. (508 mm) Rear All 12 in. (304.8 mm) Top

Allow 48 in. (1,219.2 m m) clearance to the left if you are adding a banner option to the C772 or C782.

Allow clearance above the printer f or front door c learance, and for adding options, such as additional i nput

drawers, output expander, StapleSmart finisher, or 5-bin mailbox.

All 24 in. (609.6 mm)

C77x(dn)/C78x(dn) 42 in. (1,066.8 mm)2

C77xdtn/C78xdtn 34 in. (863.6 mm)

General inf ormation 1-5

Page 26

5061

Acoustics

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

Status (at 1 Meter average sound pressure)

Printing at 4800 CQ 52 dBA 52 dBA 52 dBA 53 dBA Idle (standby) 34 dBA 34 dBA 30 dBA 30 DBA Duplex models—printing simplex 52 dBA 52 dBA 52 dBA 53 dBA Duplex models—printing duplex 52 dBA 52 dBA 60 dBA 60 dBA Duplex models—idle 34 dBA 34 dBA 30 dBA 30 DBA

Lexmark C770n

Lexmark C772n

Lexmark C780n

Lexmark C782n

Environment

Printer Temperature and Humidity

• Operating – Temperature: 60 to 90° F (15.6 to 32.3° C) – Rela tive hu m i di ty : 8 to 80% – Maximum wet bulb temperature: 73° F (22.8° C) – Altitude: 10,000 ft. (0 to 3,0 48 meters) – Atmospheric pressure: 74.6 kPa

• Pow er o ff – Temperatur e: 50 to 110° F (10 to 43.3° C) – Rela tive hu m i di ty : 8 to 80% – Maximum wet bulb temperature: 80.1° F (26.7° C) – Altitude: 10,000 ft. (0 to 3,0 48 meters) – Atmospheric pressure: 74.6 kPa

• Ambient operating environment* – Temperature: 60 to 90° F (15.6 to 32.2° C) – Rela tive hu m i di ty : 8 to 80%

• Storage and shipping (packaged printer) with or without print cartridge

Temperature: -40 to 110° F (-40 to 43.3° C)

• Print cartridge

Temperature: -40 to 110° F (-40 to 43.3° C)

*In some cases, performance specif ications (such as paper OCF, EP cartridge usage) are measured at an ambient condit ion.

1-6 Se rvice Manu a l

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5061

Power and performance

Performance

Per formance speed depends on:

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

• Host system and appli cation

• Page compl exity and content

• Printer options i nstalled or selected

• Av ailable printer memory

• Media size and type

• Resolution

• Printer usage setti ng

Processor

Lexmark C77x

Processor frequen cy (Mhz)

Bus frequency (Mhz) 100 100 133 133

500 600 800 800

Lexmark C77x(n ), Lexmark C77xdn

Lexmark C78x

Lexmark C78x(n) Lexmark C78xdn

Time to first print

All first copy times are measured for 600 image quality, simplex printing on letter-size paper. The test job consists of the character “A” followed by a form feed (single-page job). The first cop y ti m e is defined as the elapsed ti me from pressing Enter on the ke yboard to the page exiting to the output bin. All tests pi ck paper from the primary input tra y and the page exits into the primary output bin.

Standby times may be longer if the toner control senses that toner flow needs to be checked or adjusted. Time to first print from standby mode

• Black: <13 seconds

• Color: <15 seconds

Time to first print fro m p ow er saver mo de

• Black: <120 seconds

• Color: <120 seconds

Duty cycle

Up to 60,000 pages maximum one-time usage

•

• Up to 4,000 pages per month average usage

General inf ormation 1-7

Page 28

5061

Memory configuration

Optional memory is available in 128MB, 256MB, and 512MB DIMM. There is only one DIMM slot available for optional memory.

DRAM memory

Standard 256MB 256MB 256 256 Maximum 640MB 768MB 768 768

Lexmark C77xndnLexmark C77xdtn

Lexmark C77, fn

Lexmark C78n Lexmark C78xdn

Lexmark C78xdtn

Ava ilable memory options

Optional 128MB, 256M B and 512M B SDRAM DIMMs are available from Lexmark. The memory options are 168-pin synchronous DRAM DIMMs (dual in-line memory modules) mee ti ng or exceeding the f ollowing specifications:

• 100MHz or greater

• 4KB refresh rate

• Unbuffered, non ECC

• x32

• 3.3 V

Unpredictable results may occur if an attempt is made to operate the printer with memory other than SDRAM DIMM memory with the stated specifications.

Flash Memory Options available are 32MB and 64M B. Expansion

• Memory slot for extra flash or DRAM

• Expansion slot for optional inter face cards

• Code expansion slot (application solution firmware cards)

• On-board hard disk interface (for optional hard disk)

Additional memory may be required for printing complex pages or full-page, high -resolution images in 1200 image quality at rated speeds.

1-8 Se rvice Manu a l

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Media specifications

Media input and output capacities

The capacities listed below are based on plain paper at 75g/m2.

Capacity (sheets)

Media source or output description

Input

Standard input sources

Tray 1 Tray 2 Multipurpose tray

Maximum total standard capacity (sheet s)

Optional available input sources

500-Sheet drawer (maximum of 3 or only one with a 2000-sheet drawer)1

2000-Sheet drawer (maximum of one)

Envelope drawer (maximum of 3 or only one with a 2000-sheet drawer)

Outdoor media drawer

Banner tray Maximum additional drawers Maximum input capacity

With added drawers (no

high-capacit y input tray)

With added drawer and

high-capacit y input tray

A maximum of one High-capaci ty Input Drawer is supported on an y C772 or C782 model.

A maximum combination of three optional 500-sheet drawers or a maxim um com bination of one optional 500-sheet

drawer plus one 2000-sheet drawer is supported on any C772 or C782 model.

Lexmark C770n, C770dn,

500 N/A 100 600

500

N/A

N/A N/A

1100

N/A

Lexmark C770dtn

500 500 100

1100

N/A

N/A N/A

1100

N/A

Lexmark C772n, C772dn

500 N/A 100 600

500-

1500

2000

100

2100

3100

Lexmark C772dtn

500 500 100

1100

500-

1500

2000

100

2100

3100

Lexmark C780n, C780dn

500 N/A 100 600

500

N/A

N/A N/A

1100

N/A

Lexmark C780dtn

500 500 100

1100

N/A

N/A N/A

1100

N/A

Lexmark C782n, C782dn

500 N/A 100 600

5001500

2000

100

2100

3100

Lexmark C782dtn

500 500 100

1100

500-

1500

2000

100

2100

3100

General inf ormation 1-9

Page 30

5061

Capacity (sheets)

Media source or output description

Lexmark C770n, C770dn,

Lexmark C770dtn

Lexmark C772n, C772dn

Lexmark C772dtn

Lexmark C780n, C780dn

Lexmark C780dtn

Lexmark C782n, C782dn

Lexmark C782dtn

Output

Standard output bin capacity 250 250 250 250 250 250 250 250 Optional outputs

5-Bin mailbox (maximum of one)

Output Expander

StapleSmart Finisher

N/A

N/A N/A

N/A

N/A N/A

500

650 500

500

650 500

N/A

N/A N/A

N/A

N/A N/A

500

650 500

500

650 500

unstapled StapleSmart Finisher

stapled

N/A

15 sets

or 350

15 sets

or 350

N/A

15 sets

or 350

15 sets

or 350

Maximum output paper capacity

250

900

250

900

Other:

Duplex Unit

Optional/

Standard

A maximum combination of one 5- Bin Mailbox, Output Expander, or StapleSmart Finisher is supported on any model.

An optional 500-sheet drawer is required for a 2000-sheet High-capacity Drawer and a Duplex Unit. The first option

Standard Standard Standard Optional/

Standard

Standard Standard Standard

under a duplex uni t must be a 500-sheet drawer.

Media sizes

Media sizes and support

Legend ✓ — supported with size sensing † — supported without size sensing ✘— unsupported

Media size Dimensions

JIS B4

JIS B5

Supported as selected paper with tray size sensing turned off in the appropriate trays.

When selected, the page is formatted for 215.9 x 355.6 mm (8.5 x 14 in.) unless otherwise specified.

297 x 420 mm (11.7 x 16.5 in.)

210 x 297 mm (8.27 x 11.7 in.)

148 x 210 mm (5.83 x 8.27 in.)

257 x 364 mm (10.1 x 14.3 in.)

182 x 257 mm (7.17 x 10.1 in.)

500-sheet tra ys

Multi-purpose feeder

Optional high capacity feeder

Optional duplex unit

Optional envelope drawer

Optional banner tray

Optional finisher

Optional 5-bin mailbo x

Standard

✘ ✘✘✘✘✘✘✘✘✘

✓ † ✓✓✘✘✓✓✓✓

✘ ✘✘✘✘✘✘✘✘✘

✓ † ✓✓✘✘✓✓✓✓

Offset

900

Staple

1-10 Service Manual

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5061

Media sizes and support (c ontinu ed)

Legend ✓ — supported with size sensing † — supported without size sensing ✘— unsupported

Media size Dimensions

Optional finisher

Letter

Legal

Executive

Folio

Statement

Tabloid

Universal

500-sheet trays

215.9 x 279.4 mm

✓ † ✓✓✘✘✓✓✓✓

(8.5 x 11 in.)

215.9 x 355.6 mm

✓ † ✓✓✘✘✓✓✓✓

(8.5 x 14 in.)

184.2 x 266.7 mm

✓ † ✓✓✘✘✓✓✓✓

(7.25 x 10.5 in.) 216 x 330 mm

††✘✓✘✘✓✓✓✓

(8.5 x 13 in.)

139.7 x 215.9 mm

††✘✓✘✘✘✓✓✘

(5.5 x 8.5 in.) 279 x 432 mm

✘ ✘✘✘✘✘✘✘✘✘

(11 x 17 in.)

69.85 x 127 mm to

297 x 1219.2 mm

††✘ ††✘✘✓✓✓

(2.75 x 3.5 in. to

Multi- purpose feed e r

Optional high capaci ty feeder

Optional duplex unit

Optional envelope drawer

Optional banner tray

Optional 5-bin mailbox

11.69 x 48 in.) 210 to 215.9 mm

✘ † ✘✘✘✓✘✘✘✘

wide by up to 1219.2

Banner

mm long (8.27 to 8 .5 inches wide b y up to 48 inches long)

7 3/4 Envelope (Monarch)

9 Envelope

10 Envelope

DL Envelope

C5 Envelope

B5 Envelope

98.4 x 190.5 mm (3.875 x 7.5 in.)

98.4 x 225.4 mm (3.875 x 8.9 in.)

104.8 x 241.3 mm (4.12 x 9.5 in.)

110 x 220 mm (4.33 x 8.66 in.)

162 x 229 mm (6.38 x 9.01 in.)

176 x 250 mm (6.93 x 9.84 in.)

104.8 mm x 210 mm

✘ † ✘✘✓✘✘✘✘✘

✘ † ✘✘† ✘✘✘✘✘

to 215.9 mm x 3 55. 6

Other Envelope

4.125 in. x 8.27 in. to 8.5 in. x 14 in.)

Supported as selected paper with tray size sensing turned off in the appropriate trays.

When selected, the page is formatted for 215.9 x 355.6 mm (8.5 x 14 in.) unless otherwise specified.

Standard

Offset

Staple

General information 1-11

Page 32

5061

Media support by type for optional features

Legend

✓ — supported ✘— unsupported

Media

Paper Card stock Transparencies Paper and Vinyl

labels Envelopes Glossy paper

Optional

500-sheet trays

✓✓✓✓✘✘✓✓✓✓ ✓✓✘✓✘✘✘✓✘✘ ✓✓✘✘✘✘✘✓✓✘ ✓✓✘✓✘✘✘✘✘✘

✘✓✘✘✓✘✘✘✘✘ ✓✓✓✓✘✘✘✘✘✘

Multipurpose feeder

Optional high capacity feeder

Optional duplex

Optional envelope drawer

Optional banner tray

Optional 5-bin mailbox

Finisher

Standard

Offset

Staple

1-12 Service Manual

Page 33

5061

Media types and weights (input options)

Media weight

Type

Media

Paper

2, 6, 9

Xerographic or business paper

500-sheet trays

60 to 74.9 g/m2 grain lon g (16 to 19.9 lb

2, 6

bond) 75 to 119.9 g/m

grain lon g (20 to 31.9 lb bond)

Xerographic or business paper

120 to 176 g/m grain lon g (32 to 47 lb

bond)

Gloss Book 88 to 176 g/m

grain lon g (60 to 120 lb

Specialty papers

book)

Gloss Cover 162 to 176 g/m

grain lon g (60 to 65 lb cover)

Card stock— maximum (grain long)

Card stock— maximum (grain short)

Transparencies

Labels—maximum

Index Bristol 163 g/m2 (90 lb) 163 g/m2 (90 lb) Not recommended Not supported

Tag 163 g/m Cover 176 g/m

(100 lb) 163 g/m2 (100 lb) Not recommended Not supported

(65 lb) 176 g/m2 (65 lb) Not recommended Not supported Index Bristol 199 g/m2 (110 lb) 199 g/m2 (110 lb) Not recommended Not supported Tag 203 g/m Cover 216 g/m Laser printer 161 to 169 g/m

(125 lb) 203 g/m2 (125 lb) Not supported Not supported

(80 lb) 216 g/m2 (80 lb) Not supported Not supported

(43 to 45 lb bond)

Paper 180 g/m

(48 lb

bond)

Dual-web paper 180 g/m

(48 lb

bond)

Polyester 220 g/m

(59 lb

bond)

Vinyl

300 g/m2 (92 lb

liner)

For 60 to 176 g/m2 (16 to 47 lb bond) paper, grain lon g fi bers are recommended. For papers heavier th an 176 g/m

(47 lb bond), grain short is recommended.

Paper weighing less than 75 g/m2 (20 lb bond) is limited to simplex printing only at less than 60% relative humidity.

Pressure-sensitive area must enter the printer first.

100% cotton content maximum weight is 90.2g/m2 (24 lb) bond.

105 g/m2 (28 lb bond) envelopes are limited to 25% cotton content.

The duplex opti on supports the same weights and types as the printer, except for paper 16–19.9 lb (60–74.9 grain long

bond, A5 card stock, transparencies, envelopes, viny l l abels, and polyester labels.

Vinyl labels are supported only when the printing environment and the media are at 20–32.2° C (68–90° F).

Lexmark transparency P/N12A8240 and 12A8241 are supported from the standard tray, optional 500-sheet trays , and

the multipurpose feeder.

Paper 105 to 176 g/m2 (28 to 47 lb) must be printed with Paper Weight set to Heavy.

Multipurpose feeder

60 to 74.9 g/m2 grain lon g (16 to 19.9 lb bond)

75 to 119.9 g/m grain lon g (20 to 31.9 lb bond)

120 to 176 g/m grain lon g (32 to 47 lb bond)

88 to 176 g/m grain lon g (60 to 120 lb book)

162 to 176 g/m grain lon g (60 to 65 lb cover)

161 to 169 g/m (43 to 45 lb bond)

199 g/m2 (53 lb bond)

220 g/m2 (59 lb bond)

260 g/m2 (78 lb liner)

2, 6

2000-sheet drawer

60 to 74.9 g/m2 grain lon g (16 to 19.9 lb

2, 6

bond)

75 to 176 g/m

grain lon g (20 to 47 lb bond)

120 to 176 g/m

grain lon g (32 to 47 lb bond)

88 to 176 g/m

grain lon g (60 to 120 lb book)

162 to 176 g/m

grain lon g (60 to 65 lb cover)

Not supported Not supported

Envelope drawer

Not supported

General information 1-13

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5061

Media types and weights (input options) (continued)

Media weight

Type

Media

Integrated forms (labels)

Envelopes

Pressure sensitive area

Paper bas e (grain long)

Sulfite, wood-free or up to 100%

500-sheet trays

140 to 175 g/m

75 to 135 g/m (20 to 36 lb bond)

Not supported 60 to 105 g/m

cotton bonds

For 60 to 176 g/m2 (16 to 47 lb bond) paper, grain lon g fi bers are recommended. For papers heavier th an 176 g/m

(47 lb bond), grain short is recommended.

Paper weighing less than 75 g/m2 (20 lb bond) is limited to simplex printing only at less than 60% relative humidity.

Pressure-sensitive area must enter the printer first.

100% cotton content maximum weight is 90.2g/m2 (24 lb) bond.

105 g/m2 (28 lb bond) envelopes are limited to 25% cotton content.

The duplex opti on supports the same weights and types as the printer, except for paper 16–19.9 lb (60–74.9 grain long

bond, A5 card stock, transparencies, envelopes, viny l l abels, and polyester labels.

Vinyl labels are supported only when the printing environment and the media are at 20–32.2° C (68–90° F).

Lexmark transparency P/N12A8240 and 12A8241 are supported from the standard tray, optional 500-sheet trays , and

the multipurpose feeder.

Paper 105 to 176 g/m2 (28 to 47 lb) must be printed with Paper Weight set to Heavy.

Multipurpose feeder

140 to 175 g/m2 Not

2000-sheet drawer

Recommended

75 to 135 g/m2 (20 to 36 lb bond)

(16 to 28 lb

4, 5

bond)

Not Recommended

Not supported 60 to 105 g/m

Envelope drawer

Not supported

(16 to 28 lb

4, 5

bond)

1-14 Service Manual

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Media typ es and weights ( output optio ns)

Media weight

StapleSmart finisher

Media Type

Standard output bin and optional output

5-bin mailbox

Output bin Offset Staple

expander

(125

60 to

74.9 g/m2 grain long (16 to 19.9 lb

2, 6

bond)

75 to 90 g/m grain long (20 to 24 lb bond)

Not supported 88 to 176 g/m

60 to 74.9 g/m2 grain l o ng (16 to 19.9 lb bond)

75 to 90 g/m grain l o ng (20 to 24 lb bond)

grain l o ng (60 to 120 lb book)

Not supported 162 to 176 g/m

grain l o ng (60 to 65 lb cover)

Not supported 163 g/m2

(90 lb)

Not supported 163 g/m2

(100 lb)

Not supported 176 g/m2

(65 lb)

Not supported 199 g/m2

(110 lb)

Not supported 203 g/m

(125 lb)

Not supported 216 g/m

(80 lb)

Not supported 161 to 169 g/m

(43 to 45 lb bond)

2, 6

60 to 74.9 g/m2 grain l o ng (16 to 19.9 lb bond)

75 to 90 g/m grain l o ng (20 to 24 lb bond)

88 to 176 g/m

2, 6

60 to 74.9 g/m2 grain long (16 to 19.9 lb bond)

75 to 90 g/m grain long (20 to 24 lb bond)

Not supported

2, 6

grain l o ng (60 to 120 lb book)

162 to 176 g/m

Not supported grain l o ng (60 to 65 lb cover)

163 g/m2

Not supported (90 lb)

163 g/m2

Not supported (100 lb)

176 g/m2

Not supported (65 lb)

199 g/m2

Not supported (110 lb)

203 g/m2

Not supported (125 lb)

216 g/m

Not supported (80 lb)

161 to 169 g/m

Not supported (43 to 45 lb bond)

Xerographic or business paper

60 to 74.9 g/m grain long (16 to 19.9 lb

2, 6

bond)

Paper

Xerographic or business paper

75 to 176 g/m grain long (20 to 47 lb bond)

Gloss Book 88 to 176 g/m

grain long (60 to 120 lb

Specialty papers

Gloss Cover 162 to 176 g/m

book)

grain long (60 to 65 lb cover)

Index Bristol 163 g/m2

(90 lb)

Card stock— maximum (grain long)

Tag 163 g/m

(100 lb)

Cover 176 g/m

(65 lb)

Index Bristol 199 g/m

(110 lb)

Card stock— maximum (grain short)

Tag 203 g/m

lb)

Cover 216 g/m

(80 lb)

Transparencies

Laser printer

161 to 169 g/m (43 to 45 lb bond)

For 60 to 176 g/m2 (16 to 47 lb bond) pape r, grain long fibers are rec ommended. For papers heavier than 176 g/m2 (47

lb bond), grain short is recomm ended.

Paper weighing less than 75 g/m2 (20 lb bond) is limit ed to simplex pri nti ng only at less than 60% rel ative humidity. and

is not supported in duplex. Paper less than 76 g/m

Pressure-sensitive area must enter the printer first.

100% cotton content maximum weight is 90.2 g/m2 (24 lb) bond.

28 lb bond envelopes are limited to 25% cotto n content.

The duplex opt ion supports the s ame weight s and types as t he printer e x cept f or pape r 16– 19.9 lb ( 60–7 4.9 g/m2) bond,

must be printed with Paper Weight set to Lig ht.

transparenci es, envelopes, vinyl labels, and polyes ter labels.

Vinyl labels are supported only when the printing environment and the media are at 20–32.2° C (68–90° F).

Refer to the Con verter Listing on the Lex mark Home Page and Automate d FAX system (LEXFAX™ ) f or information on

whether your vinyl label converter has passed the Lexmark criteria . Refer, also, to the Car d Stock and Label Guide for more details.

Paper 105–1 76 g/m2 (28–47 lb bond) must be printed with Paper Weight set to Heavy.

General information 1-15

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5061

Media typ es and weights ( output options ) (continued)

Media weight

StapleSmart finisher

Media Type

Standard output bin and optional output

5-bin mailbox

Output bin Offset Staple

expander

Paper 180 g/m

Not supported Not supported Not supported Not supported

(48 lb bond)

Not supported Not supported Not supported Not supported

Labels— maximum

Dual-Web paper

180 g/m (48 lb bond)

Polyester 220 g/m

(59 lb bond)

Vinyl

7, 8

300 g/m

Not supported Not supported Not supported Not supported

(92 lb bond)

Not supported Not supported Not supported Not supported

Integrated forms

Pressure sensitive

area Paper base

(grain long)

140 to 175 g/m (up to 48 lb bond)

75 to 135 g/m (20 to 36 lb bond)

Sulfite, wood-free,

Envelopes

For 60 to 176 g/m2 (16 to 47 lb bond) pap er, grain long fibers are rec ommended. For papers heavier than 17 6 g/m2 (47

or up to 100% cotton

bond

60 to 105 g/m2 (16 to 28 lb

3, 4

bond)

Not supported Not supported Not supported Not supported

lb bond), grain short is recomm ended.

Paper weighing less than 75 g/m2 (20 lb bond) is limit ed to simplex pri nti ng only at less than 60% rel ative humidity. and

is not supported in duplex. Paper less than 76 g/m2 must be printed with Paper Weight set to Lig ht.

Pressure-sensitive area must enter the printer first.

100% cotton content maximum weight is 90.2 g/m2 (24 lb) bond.

28 lb bond envelopes are limited to 25% cotto n content.

The duplex opt ion supports the s ame weight s and types as t he printer e x cept f or pape r 16– 19.9 lb ( 60–7 4.9 g/m2) bond,

transparenci es, envelopes, vinyl labels, and polyes ter labels.

Vinyl labels are supported only when the printing environment and the media are at 20–32.2° C (68–90° F).

Refer to the Con verter Listing on the Lex mark Home Page and Automate d FAX system (LEXFAX™ ) f or information on

whether your vin yl label conv erter has passed the Lexmark criteria. Refer, also, to the Car d Stock and Label Guide for more details.

Paper 105–1 76 g/m2 (28–47 lb bond) must be printed with Paper Weight set to Heavy.

1-16 Service Manual

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Media typ es and weights ( output options ) (continued)

Media weight

StapleSmart finisher

Media Type

Standard output bin and optional output

5-bin mailbox

Output bin Offset Staple

expander

Labels— maximum

Envelopes

2,4

Paper 180 g/m

(48 lb bond)

Dual-web paper

180 g/m bond)

Polyester 220 g/m

bond)

Vinyl 300 g/m

liner)

Sulfite, wood-free or up to

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

(48 lb

(59 lb

(92 lb

Not supported 180 g/m

(48 lb bond)

Not supported 180 g/m2

(48 lb bond)

Not supported 220 g/m2

(59 lb bond)

Not supported 300 g/m2 (92 lb

liner)

Not supported Not supported Not supported Not supported

180 g/m2 (48 lb

Not supported bond)

180 g/m

Not supported (48 lb bond)

220 g/m2

Not supported (59 lb bond)

300 g/m2 (92 lb

Not supported liner)

100% cotton bonds

For 60 to 176 g/m2 (16 to 47 lb bond) pape r, grain long fibers are rec ommended. For papers heavier than 176 g/m2 (47

lb bond), grain short is recomm ended.

Paper weighing less than 75 g/m2 (20 lb bond) is limit ed to simplex pri nti ng only at less than 60% rel ative humidity. and

is not supported in duplex. Paper less than 76 g/m2 must be printed with Paper Weight set to Lig ht.

Pressure-sensitive area must enter the printer first.

100% cotton content maximum weight is 90.2 g/m2 (24 lb) bond.

28 lb bond envelopes are limited to 25% cotto n content.

The duplex opt ion supports the s ame weight s and types as t he printer e x cept f or pape r 16– 19.9 lb ( 60–7 4.9 g/m2) bond,

transparenci es, envelopes, vinyl labels, and polyes ter labels.

Vinyl labels are supported only when the printing environment and the media are at 20–32.2° C (68–90° F).

Refer to the Con verter Listing on the Lex mark Home Page and Automate d FAX system (LEXFAX™ ) f or information on

whether your vinyl label converter has passed the Lexmark criteria . Refer, also, to the Car d Stock and Label Guide for more details.

Paper 105–1 76 g/m2 (28–47 lb bond) must be printed with Paper Weight set to Heavy.

Media guidelines

Selecting the appropriate media for the printer helps avoi d pri nti ng problems. The foll owing sections conta in gui delines for cho osing the correct media for the printer. For detailed information about media characteristics, see the Card Stock & Label Guide available on the

Lexmark Web site at www.lexmark.com/publications.

Paper

To ensure the best print quality and feed reliability, use 90 g/m2 (24 lb) xerog raphic, gra in l ong paper. Business papers designed for general business use may also provide accept able print quality.

We recommend Lexmark part number 12A5950 letter siz e glossy paper and Lexmark part number 12A5951 A4 size glossy paper.

Always print several samples before buying large quantities of any type of media. When choosing any media, consider the weight, fiber content, and color.

General information 1-17

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5061

The Laser printing process heats paper to high temperatures of 180°C (356°F) for non-MICR applicat ions. Use only paper abl e to wi thstand these temperatures without discoloring, bleeding, or relea sing hazardous emissions. Check with the manufacturer or vendor to determine whether the paper chosen is acceptable for laser printers.

When loading paper, note the recommended print side on the paper package, and load paper acco rdingly.

Paper characteristics

The foll owing pape r charac te ristics af fe ct print qualit y and reli abilit y. It is recommended that these gui delin es are follo wed when evaluating new paper stock.

For detailed information, see the Card Stock & Label Gui de available on the Lexmark Web site at www.lexmark.com/publications.

Weight

The printer can automat icall y f eed pap er weigh ts fro m 60 to 176 g/m than 60 g/m (24 lb bond) grain l ong paper . To use paper narrower than 182 x 2 57 m m (7.2 x 10.1 in.), it i s recommended that the weight be gr eater than or equal to 90 g/m

(16 lb) might not be sti ff enoug h to f eed properl y, causing jams. F or best perf ormance , use 90g/m2

(24 lb bond).

Curl

Curl is the tendency of medi a to curv e at its edges. Excessive curl can cause paper f eeding problems. Curl can occur after the paper passes through the printer, where it is exposed to high temperatures. Storing paper unwrapped in hot, hum id, cold and dry conditions, even in the trays, can contribute to paper curling prior to printing and can cause feeding problems.

(16 to 47 lb bond) grai n long. Paper lighter

Smoothness

The degree of smoot hnes s of paper di rect ly aff ect s print qualit y. If the paper is too rough, the toner does not fuse to the paper properly, resulting in poor print qual ity. If the paper is too smooth, it can cau se paper f ee ding or print quality issues. Smoothness needs to be between 100 and 300 Sheffield point s; however, smoothness between 150 and 250 Sheffield points produces the best print quality.

Moisture content

The amount of moisture in the paper affects both print quality and the ability of the printer to feed the paper properly. Leave the paper in its original wrapper until it is time to use it. This limits the e xposure of the paper to moisture changes that can degrade its performance.

Condition paper whil e it is still in the original wrapper. To condition it, store i t i n the same environment as the printer for 24 to 48 hours before printing to let the paper stabilize in the new conditions. Extend the time several days if the storage or transportation e nvironment is very different from the printer environment . Thick paper may also require a longer conditioning period because of the mass of material.

Grain direction

Grain refers to the alignment of the paper fibers in a sheet of paper. Grain is either grain long, running the le ngth of the paper, or grain short, running the width of the paper.

For 60 to 90 g/m

(16 to 24 lb bond) paper, grain long fibers are recommended.

Fiber content

Most high-qual ity xerographic paper is made from 100% chemi cally pulped wood. This content provides the paper with a high degree of stability result ing in fewer paper feeding problems and better print quality. Paper containing fibers such as cotton posses ses characteristics that can result in degraded paper handling.

1-18 Service Manual

Page 39

5061

Unacce p tab l e p ap er

The following papers 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 req uir ed (NCR) paper

• Preprinted papers wit h chem icals that may cont am inate the printer

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

• Preprinted pape rs t hat require a registration (the precise print location on the page) greater than ±0.09 in.,

such as optical character recognition (OCR) forms

• In some cases, registration can be adjusted with the software application to successfully print on these

forms.

• Coated papers (er asable bond), synt heti c papers, or thermal papers

• Rough-edged, rough or heavily textured surf ace papers or curled papers

• Recycled papers containing more than 25% post -consumer waste that do not mee t

DIN 19 309

• Paper having a weight less than 60 g/m

(16 lb)

• Multiple -p a rt forms or do c um en t s

Selecting paper

Proper paper loading helps prevent jams and ensures trouble-free printing. To help avoid jams or poor print quality:

• Always use new, undam aged 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 media sizes, weights, or t ypes in the same source; mixing results in jams.

• Do not use coated papers unless they are specif ically designed for electrophotographic printing.

• Do not forget to change the Paper Size setting when using a source t hat does not support auto size

sensing.

• Do not remove trays while a job is printi ng or Busy appears on the operat or panel.

• Make sure the Paper Type and Paper Weight settings are correct. (See “Paper Menu” in the Menus and

Messages Guide on the publications CD for detailed information about these settings.)

• Make sure the paper is properly loaded in the source.

• Flex paper back and forth. Do not fold or crease the paper. Straighten the edges on a level surface.

General information 1-19

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5061

Web oiler upgrade kit and replacements

The web oiler removes fuser roll contami nation in machines which run a large num ber of vinyl or dual web labels. The web oiler w orks wi th all media types and enables the prolonged use of labels without sacrificing fuser life.

• Web oiler fuser life: 120,000 (C78x model s), 200,000 (C77x models),

• Web oiler life: 100,000 pages

• Availability: Order the web oiler upgrade kit.

Upgrade kit

This kit allows you to upgrade your current printer.

Description Part number

Web oiler upgrade kit 40X1856 The installation of the web oiler upgrade kit converts a standard

Lexmark C77x printer to an oil web-capable printer. The web oiler upgrade kit in cludes an oiler fuser and web oiler.

1-20 Service Manual

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5061

Acronyms

BLDC Brushless DC Motor BOR Black On ly Retra c t CCyan CSU Customer Setup DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory EDO Enhanced Data Out EP Electrophotogr aphic Process EPROM Erasable Programmable Read-Onl y Memo ry ESD Electrostatic Discharge FRU Field Replaceable Unit GB Gigabyte HCIT High-Capaci ty I nput Tray HCOF High-Capacity Output Finishe r HVPS High Voltage Power Supply ITU Image Transfer Unit KBlack LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light-Emitting Diode LVPS Low Voltage Pow er Supply M Magenta MROM Masked Read Only Memory MS Microswitch NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manuf acturer OPT Optical Sensor PC Photoconductor pel, pixel Picture element POR Power-On Reset POST Power-On Self Test PSD Position Sensing Dev ice PWM Pulse Width Modulation RIP Raster Imaging Processor ROM Read Only Memory SDRAM Synchronous Dual Random Access Memory SIMM Single Inline Memory Module SRAM Static Random Access Memory TPS Toner Patch Sensing UPR Used Parts Return V ac Volts alternating current V dc Volts direct current VTB Vacuum Transport Belt YYellow

General information 1-21

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5061

2. Diagnostic information

Start

CAUTION

Unplug the power cord from the el ectrical outlet bef ore you connect or disconnec t any cable or electronic board or assembly for persona l saf ety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals.

CAUTION

The printer weighs 48–82 kg (105–181 lb) and requires at least three people to lift it saf ely. Remove the options before lifting the printer. M ake sure yo ur fingers are not under the printer when you lift or set the printer down.

To determine the corrective action necessary to repair a printer, look for the following information:

• Does the POR stop? Check the “POR (P ower-On Reset) sequence” on page 2-2

• Do you hav e a sym ptom, rather than an error mes sage? – “Symptom table—base printer” on page 2-3 – “Symptom table—500-sheet drawer option” on page 2-4 – “Symptom table—HCIT 2000-sheet option” on page 2-4 – “Symptom table—output expander option” on page 2-5 – “Symptom table—5-bin mailbox option” on page 2-5 – “Symptom table—StapleSmart finisher” on page 2-5

• If you have an error message or user mess age, check the following: – “1xx service errors” on page 2-7 – “2xx paper jams” on page 2-9 – “9xx service errors” on page 2-11 – “User attendance messa ges” on page 2-124 – “Service checks” on page 2-14 for individual error messages

• Additional information can be found at the following locations: – “Understanding the printer operator panel” on page 2-117 – “Service checks” on page 2-14

Note: There may be printer error messages that are not contained in this service manual. Contact your next

level of support for assistance.

Diagnostic information 2-1

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5061

POR (Power-On Reset) sequence

The foll owing is an example of the events that occur during the POR sequence for the base machine with no paper handling options installed .

1. Power the machine on.

2. +5 V LED (Power ON) on the system board comes on.

3. Fans turn on.

4. The oper ator panel LED comes on solid.

5. While loading code, dots scroll across the display.

6. The f ollowing is an e xample of the screen that displays after the code is loaded.

256MB 800Mhz

Where xxxMB di splays the insta ll ed m em ory and xxxMhz indicates the processor speed.

7. The image of a clock face appears on the display.

8. The heartbeat LED on system boar ds turns on.

9. Color cali bration may be initiated. This is displayed if one of the following occurs:

• The printer detects at power on, or the front cover assembly is closed, that a new or different toner

cartridge has been installed.

• The printer detects at power on when the cover is closed that a new or different ITU has been

installed.

• The printer detects at power on that the fuser temperature is below 60° C .

• When coming out of power saver if po wer saver has been active for eight hours or longer.

• If the printer is turned on when a calibration cycle was in progress s ince the printer was last powered

off.

10. The redrive exit roller turns.

11. Ready is displayed.

Various messages may appear during this sequenc e or immediately after. For example:

• ITU Missing is posted if the ITU is missi ng.

• Fuser Missing is posted if the fuser is missing.

• Close Door is posted if the front cover assem bly is open.

• Any cartridge errors are posted such as a defective cartridge, Return Program information, or missing

cartridge.

• Any applicable maintenance messages display such as 80 Fuser Maintenance or 83 ITU Maintenance.

• One of the toner low messages appears when applicable: 88 Yellow Toner Low, 88 Magenta Toner Low,

88 Cyan Toner Low, or 88 Black Toner Low.

2-2 Se rvice Manu a l

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5061

Sympto m tables

Symptom table—base printer

Symptom Action

Fus e r fan fai ls to run or is noi sy Go to “925.02 error code service chec k” on

RIP fan fails to run or is noisy Go to “927.03 error code service chec k” on

VTB fan fails to run or is noisy Go to “926. 01 error code service check” on

Excessive fuser drive motor assemb ly noise Go to “Excessive fuser drive motor assembly

Machine inoperat ive: F ans don’t turn, engine not on, lights not on, and none of the printer functions work.

Close Door displays constantly, unable to clear the message, POR incomplete

Printer does not complete POST and sta pler cycles several times.

Operator panel: One or more buttons do not work Go to “ O perator panel LCD/status LED/butt ons

Operator panel: Display is blank, printer does not sound 5 beeps, but printer is not inoperative

Operator Panel: Operator pane l di splays dots continuousl y, sounds 3 beeps, and POST is 18incomplete.

Operator panel: One pixel or random pixels are missing

Paper feed problems, base printer Go to “2xx paper jams” on pa ge 2-9. Paper feed problems, integrated tray Go to “Tray 1 service check” on page 2-115. Printer prints black only, no colors Make sure that the printer is not set up to print blac k

Print quality: 100% single color printed

• All black print

• All cyan print

• All magenta print

• All y ellow p rin t Print quality: Blank page (no image) Go to “Blank page (no image)” on page 2-93. Print quality: Evenly spaced hori zontal marks or lines

on the printed page Print quality: Black line Black horizontal li nes are most likely caused by a

Print quality: Magenta, cyan, or yellow lines. “Vertical lines or streaks” on page 2-98 or

Print quality: Colored l ines, streaks , or sm udges Go to “Vertical lines or streaks” on page 2-98 or

page 2-54.

page 2-55.

page 2-54.

noise” on page 2-87.

Go to “AC and DC power service check” on

page 2-74.

Go to “C lose door/HVPS/pr inthead interl ock sw itch

service check” on page 2-79.

Go to “POST incomplete—stapler cycles several

times” on page 2-114

service check” on page 2-88.

Replace the operator panel ass em bly. See “Operator

panel assembly removal” on page 4-68.

Go to “Operator panel LCD/status LED/butt ons

service check” on page 2-88.

Replace the operator panel ass em bly. See “Operator

panel assembly removal” on page 4-68.

only. If the printer i s set up correctly, check the Black Retract (BOR) Motor and gears for correct operation. If the gear s are oper ati ng corr ectl y, replace the Retr a ct Motor Assembly. See “BOR drive assembly

removal” on page 4-34. If this does not correct the

problem, go to “Black only retract (BOR) service

check” on page 2-78.

Go to “Entire page is mostly one color —Full bleed

planes in one color” on pa ge 2-94.

Go to “Vertical lines or streaks” on page 2-98.

shorted charge roll in the print cartridge. Repl ace the black print cartridge.

“Horizontal lines or streaks” on page 2-98.

Diagnostic information 2-3

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5061

Symptom Action

Print quality: Light l ines or streaks appear on the printed page

Print quality: Light print Go to “Light print over the entire page” on

Print quality: Missing colors Go to “Missing colors— C omp let e or parti ally

Print quality: Uneven printing Go to “Uneven printi ng” on page 2-101. Print quality: P oor color alignment Go to “Poor color alignment” on page 2-99. Print quality: Toner on the back of the page Go to “T oner is on the bac k of the printe d page” on

Print quality: Toner smears or rubs off the page Go to “Toner smears or rubs off the page with no

Print quality: Multiple horizontal lines G o to “Vertical lines or streaks” on page 2-98

Symptom table—500-sheet drawer option

Symptom Action

Printer fails to recognize the option is installed Go to “The base printer does not recognize that

The tray x autocompensator fails to retract, stays in down position

Paper Low message appears when adequate paper is installed (tray x)

Paper Out mess age appears when adequat e paper is installed (tr ay x)

Tray x does not detect size media is installed Go to “T ra y x does not detect size media insta lled”

Paper jams in the option tray (242 .xx, 243.xx, 244.xx) Go to “241.xx paper jam service check” on

Go to “Light lines or streaks appear on the page”

on page 2-103.

page 2-96.

missing color planes ” on page2-95.

page 2-103.

error code displa yed” on page 2-102.

tray x is installed.” on page 2-71.

Go to “Tray x autocompensator fail s to retract,

stays in down position.” on page 2-72.

Go to “The printer d etects pa per lo w in tra y x when

adequate paper is installe d in the t ray .” on page 2-72.

Go to “The printer detects paper out in tra y x when

adequate paper is installe d in the t ray .” on page 2-73.

on page 2-73.

page 2-36, or “243.xx paper jam servi ce check” on page 2-41.

Symptom table—HCIT 2000-sheet option

Symptom Action

Printer fails to recognize the option is installed Go to “Pri nter does not recognize that the HCIT

HCIT does not function. Ther e is no r esponse. The HCIT is inoperativ e.

HCIT does not recogniz e the correct media size Go to “HCIT 2000-sheet option does not recognize

Paper j ams in th e H CIT Go to “2xx paper jams” on pa ge 2-9. Paper jams in the HCIT (242.xx, 243.xx, 244.xx) Go to “242.xx paper jam service check” on

2-4 Se rvice Manu a l

2000-sheet option is insta lled.” on page 2-85.

Go to “HCIT i noperative” on page 2-86.

the size paper selected.” on page 2-87.

page 2-37, “243.xx paper jam service check” on page 2-41, or “244.xx paper jam servi ce check” on page 2-46.

Page 46

5061

Sympto m table—output expander option

Symptom Action

Printer fails to recognize the option is installed. The paper feeds into the standard bin.

Remove Paper—Output Bin x is displayed and cannot be cleared

Printer does not display Output Bin Ful l Go to “No indication that bin x is full or no

Excessive static electricity buildup Go to “Problems with excessive static electricity

271.xx paper jams appears “271.xx paper jam service check” on page 2-49.

Symptom table—5- bin mailbox option

Symptom Action

Printer fails to recognize the option is installed. P aper feeds into th e standard bin.

Ready Bin x Full displays and won’t clear Go to “Read y bin x ful l message—may be able to

Bin x is full but no message displays that Bin x is full Go to “Bin x full—no message that bin x is full

Bin full message displays but paper feeds into bin. Go to “Ready—bin x full displays and paper feeds

272 Paper J am appe ars, paper does not fe ed in to the bin selected.

Go to “Output expander option service check” on

page 2-90.

Go to “Remove Paper—Output Bin x is displayed,

POST is incomplete unable to clear the message.” on page 2-91

indication that bin x is near full.” on page 2-92.

buildup.” on page 2-92.

Go to “The printer does not recognize one or more

output options as installed.” on page 2-68.

clear message and will f eed paper into bin selected.” on page 2-69

message” on page 2-69

into bin x” on page 2-70

Go to “Paper does not feed into the bin selected.

272.xx Paper Jam—check bin 1 message” on page 2-70

Symptom table—StapleSmart finisher

Symptom Action

Printer does not complete POST, and stapler cycle s several times.

Problems with static electricity buildup. Go to “Problems with static electricity buildup” on

Printer does not recognize StapleSmart Finisher Option as being install ed.

Close Top Cover displayed. Unable to clear or re set message (POST incomplete).

Close Finisher Side Co ver display ed. Unable to clear or reset message (POST incomplete).

Paper feeds into finisher option output tray. Paper is not stapled and paper does not align with the right side.

Paper feeds into finisher option. Paper aligns with the right side. The stapl er does not staple.

Paper is tr ansported into the output tray but is not stapled.

Go to “POST incomplete—stapler cycles several

times” on page 2-114

page 2-111

Go to “Printer does not recognize StapleSmart

finisher option as being installed” on page 2-111

Go to “Close Finisher Top Cover displayed—unable

to clear or reset m essage (POST incomplete) ” on page 2-111.

Go to “Close Finisher Side Door displayed—unable

to clear or reset m essage (POST incomplete) ” on page 2-112.

Go to “Paper feeds into finisher option output

tray—Pap er is not stapled—Paper does not align with the right side” on page 2-112.

Go to “StapleSmart finisher service check” on

page 2-111.

Go to “Sheets are transported into output tray but

not stapled” on page 2-112.

Diagnostic information 2-5

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5061

Symptom table—StapleSmart finisher (continued)

Symptom Action

Stapled sheets are not transported to the output tray. Go to “ Stapled sheets are not transported to the

Finisher does not staple. Go to “StapleSmart finisher service check” on

output tray ” on page 2-113.

page 2-111

2-6 Se rvice Manu a l

Page 48

5061

Service error code and paper jam message table

Error codes and paper jam messages

Error code Action

User attendance messages

1xx service errors

100.01 ITU Error ITU belt track direction problem—go to “100.01 ITU error service check” on

100.02 ITU Error ITU belt tracking problem—go to “100.02 ITU error service check” on page 2-17.

100.xx (.03 through.99)

106.xx Printhead Error

107.xx Printhead Error

108.xx Printhead Error

page 2-14.

Replace the ITU assembly. See “ITU assembly removal” on page 4-49.

Cyan printhead error. Check for the correct installation of all the cables to the system board asse mbly and

to the printhead assem bly: JCY1, and JMMC1 on the system board. Go to “System

board” on page 5-8. If the cables are connected correctly to the system board and

to the printhead assem bly, go to “Printhead diagnostics” on page 3-1.

Note: Do not adjust or replace any printhead before performing checks in

“Printhead diagnostics” on page 3-1.

Magenta printhead er ror Check for the correct installation of all the cables to the system board asse mbly and

to the printhead assembly: JMMM1 and JMK1 on the system board. Go to “System

board” on page 5-8. If the cables are connected correctly to the system board and

to the printhead assem bly, go to “Printhead diagnostics” on page 3-1.

Note: Do not adjust or replace any printhead before performing checks in

“Printhead diagnostics” on page 3-1.

Yellow printhead error Check for the correct installation of all the cables to the system board asse mbly and

to the printhead assem bly: JMMY1 and JMMC1 on the system board. Go to

“System board” on page 5-8. If the cables are connected correctly to the system

board and to the printhead assembly, go to “Printhead diagnostics” on page 3-1.

Note: Do not adjust or replace any printhead before performing checks in

“Printhead diagnostics” on page 3-1.

109.xx Printhead Error

122.01 Fuser Error Fuser error—go to “122.01 error code service check” on page 2-18.

122.02 Fuser Error Fuser over temperature—go to “122.02 err o r code service check” on page 2-19.

122.03 Fuser Error Fuser open thermistor—go to “122.03 error code service check” on page 2-19.

122.04 Fuser Error Fuser cold—go to “122.04 error code service check” on page 2-20.

122.05 Fuser Error Fuser does not r aise temperature quickly enough or raises temperatur e too quickly—

Black printhead error Check for the correct installation of all the cables to the system board asse mbly and

to the printhead assem bly: JMK1 and JMMK1 on the syste m board. Go to “System

board” on page 5-8. If the cables are connected correctly to the system board and

to the printhead assem bly, go to “Printhead diagnostics” on page 3-1.

Note: Do not adjust or replace any printhead before performing checks in

“Printhead diagnostics” on page 3-1.

go to “122.05 and 122.06 error code service check” on page 2-21.

Diagnostic information 2-7

Page 49

5061

Error codes and paper jam messages (continued)

Error code Action

122.06 Fuser Error Fuser failed to raise temperature quickly enough or raises temperature too quickly—

122.07 Fuser Error Fuser timeout waiting for home sensor—go to “122.07, 122.14, and 122.15 error

122.08 Fuser Error Go to “122.08 error code service check” on page2-23.

122.09 Fuser Error Replace LVPS assembly. See “LVPS assembly removal” on page 4-53.

122.10 Fuser Error Fuser failed to warm up—“122.10 error code service check” on page 2-23.

122.11 Fuser Error Fuser under temper ature while in standby—go to “122.11 error code service

122.12 Fuser Error Fuser under temperature while printing—go to “122.12 error code service check”

122.13 Fuser Error Fuser open second thermistor—go to “122.13 error code service check” on

122.14 Fuser Error Fuser timeout waiting for motor to stop—go to “122.07, 122.14, and 122.15 error

122.15 Fuser Error Fuser timeout waiting for motor to stop—go to “122.07, 122.14, and 122.15 error

140.xx Motor Autocompensator motor error— replace the autocompensator motor. See

go to “122.05 and 122.06 error code service check” on page 2-21.

code service check” on page 2-22.

check” on pa ge 2-24.

on page 2-24.

page 2-24.

code service check” on page 2-22.

“Autoc ompe nsator pick assembly removal” on page 4-27.

If this does not fi x the pr oblem, replace the sys tem board. See “System board

removal” on page 4-89.

144.xx Motor Registration (staging) motor error—replace the registration motors. See

148.xx Motor ITU belt motor error—go to “148.xx error code service chec k” on page 2-25.

149.xx Motor Fuser motor error—replace the fuser drive assembly. See“Fuser drive assembly

150.xx Motor Black cartridge motor error—go to “150.xx error code service check” on

151.xx Motor Magenta cartridge motor error—go to “151.xx error code service chec k” on

152.xx Motor Cyan cartridge motor error—go to “152.xx er ror code service check” on

153.xx Motor Yellow Cartridge motor error—go to “153.xx error code service check” on

177.xx MFP Motor Error

“Registration motor removal” on page 4-83.

If this does not fi x the pr oblem, replace the sys tem board. See “System board

removal” on page 4-89.

removal” on page 4-46.

If this does not fi x the pr oblem, replace the sys tem board. See “System board

removal” on page 4-89.

page 2-26.

page 2-27.

MPF motor error—go to “177. xx error code service check” on page 2-28.

2-8 Se rvice Manu a l

Page 50

5061

Error codes and paper jam messages (continued)

Error code Action

2xx paper jams

200.03 Paper Jam Clear Paper Path

200.04 Paper Jam Clear Paper Path

200.05 Paper Jam Clear Paper Path

200.06 Paper Jam Clear Paper Path

200.07 Paper Jam Clear Paper Path

S2 sensor was made at an unexpected time . This message indicates that a paper jam has occurred at or near the printer Input Sensor. Open the printers left door (Pap er Jam Removal Door ) to access the jammed media.

If removing the jammed media does not fix the problem, go to “200.03 paper jam

service check” on page 2-28.

S2 sensor wasn’t made within timeout period. This mess age indicates that a paper jam has occurred at or near the printer input sensor. Open the printers left door (Pap er Jam Removal Door ) to access the jammed media.

If removing the jammed media does not fix the problem, go to “200.04 paper jam

service check” on page 2-29.

S2 sensor did not break wit hin timeout period. This message indicates that a paper jam has occurred at or near the printer input sensor. Open the printers left door (Pap er Jam Removal Door ) to access the jammed media.

If removing the jammed media does not fix the problem, go to “200.05 paper jam

service check” on page 2-29.

Narrow med ia sensor was m ade at an une xpected time. This message indicates t hat a paper jam has occurred at or near the pri nter input sensor. Open the printers left door (Paper Jam Removal Do or) to access the jammed media.

If removing the jammed media does not fix the problem, go to “200.06 paper jam

service check” on page 2-30.

Narrow media sensor did not break within the timeout period. This message indicates that a paper jam has occurred at or near the printer input sensor. Open the printers left doo r (Paper Jam Removal Door) to access the jammed media.

If removing the jammed media does not fix the problem, go to “200.07 paper jam

service check” on page 2-30.

200.16 Paper Jam Clear Paper Path

200.21 Paper Jam Clear Paper Path

200.28 Paper Jam Clear Paper Path

200.29 Paper Jam Clear Paper Path

200.69 Paper Jam Clear Paper Path

S2 sensor was made e xces siv ely earl y. This message indicates that a paper jam has occurred at or near the pri nter input sensor. Open the printers left door (Paper Jam Removal Door) to access the jammed media.

If removing the jammed media does not fix the problem, go to “200.16 paper jam

service check” on page 2-30.

Laser paper path sensor obstructed. This message indicates that a paper jam has occurred at or near the pri nter input sensor. Open the printers left door (Paper Jam Removal Door) to access the jammed media.

If removing the jammed media does not fix the problem, go to “200.21, 200.28, and

200.29 paper jam serv ice check” on page 2-31.

S2 paper path sensor obst ructed. This message indicates that a paper jam has occurred at or near the pri nter input sensor. Open the printers left door (Paper Jam Removal Door) to access the jammed media.

If removing the jammed media does not fix the problem, go to “200.21, 200.28, and

200.29 paper jam serv ice check” on page 2-31.

Narrow media sensor obstructed. This message indicates that a paper jam has occurred at or near the pri nter input sensor. Open the printers left door (Paper Jam Removal Door) to access the jammed media.

If removing the jammed media does not fix the problem, go to “200.21, 200.28, and

200.29 paper jam serv ice check” on page 2-31.

Autocompensator motor error— replace the autocompensator motor. See

“Autoc ompe nsator pick assembly removal” on page 4-27.

If this does not fi x the pr oblem, replace the sys tem board. See “System board

removal” on page 4-89.

Diagnostic information 2-9

Page 51

5061

Error codes and paper jam messages (continued)

Error code Action

200.72 Paper Jam Clear Paper Path

200.75 Paper Jam Clear Paper Path

200.92 Paper Jam Clear Paper Path

200.93 Paper Jam Clear Paper Path

200.96 Paper Jam Clear Paper Path

201.xx Paper Jam Clear Paper Path

202.xx Paper Jam Clear Paper Path

Autocompensator motor error— replace the autocompensator motor. See

“Autoc ompe nsator pick assembly removal” on page 4-27.

If this does not fi x the pr oblem, replace the sys tem board. See “System board

removal” on page 4-89.

Autocompensator motor error— replace the autocompensator motor. See

“Autoc ompe nsator pick assembly removal” on page 4-27.

If this does not fi x the pr oblem, replace the sys tem board. See “System board

removal” on page 4-89.

Narrow media detected when banner length media is specified. Narrow banner media is not supported.

Media has jammed at or before the fuser sensor. Open the printer lower right or center door to access the jammed media.

If removing the jammed media does not fix the problem, go to “200.93 paper jam

service check” on page 2-31.

Neither S2 nor narrow media sensor broke within the timeout period. This message indicates that a paper jam has occurred at or near the printer input sensor. Open the printers left doo r (Paper Jam Removal Door) to access the jammed media.

If removing the jammed media does not fix the problem, go to “200.96 paper jam

service check” on page 2-33.

Media has jammed at the fuser. Open the pri nter right door to access the jam are a. If removing the jammed media does not fix the problem, go to “201.xx and 202.xx

paper jam service c heck” on page 2-33.

Media has jammed at the fuser. Open the pri nter right door to access the jam are a. If removing the jammed media does not fix the problem, go to “201.xx and 202.xx

paper jam service c heck” on page 2-33.

230.xx Paper Jam Clear Paper Path

241.xx Paper Jam Clear Paper Path

242.xx Paper Jam Clear Paper Path

243.xx Paper Jam Clear Paper Path

244.xx Paper Jam Clear Paper Path

Paper has m ost l ikel y jammed in the dupl e x opt ion. Remov e the dupl e x t ra y t o access the jam.

If removing the jammed media does not fix the problem, go to “230.xx paper jam

service check” on page 2-35.

Paper is jammed in the primary paper tra y (tray 1). Rem ove the paper tray to access the jam. If removing the jammed media does not fix the problem, go to “241.xx

paper jam service c heck” on page 2-36.

Tray 2—this paper jam message can apply to the 500-sheet Option Tray, envelo pe option, special media option, or HCIT option, depending on the configur ation of the printer.

If removing the jammed media does not fix the problem, go to “242.xx paper jam

service check” on page 2-37.

Tray 3—this paper jam message can apply to the 500-sheet Option Tray, envelo pe option, special media option, or HCIT option, depending on the configur ation of the printer.

If removing the jammed media does not fix the problem, go to “243.xx paper jam

service check” on page 2-41.

Tray 4—this paper jam message can apply to the 500-sheet Option Tray, envelo pe option, spe cial media option, and HCIT option, depending on the configuration of the printer.

If removing the jammed media does not fix the problem, go to “244.xx paper jam

service check” on page 2-46.

2-10 Service Manual

Page 52

5061

Error codes and paper jam messages (continued)

Error code Action

250.xx Paper Jam Clear Paper Path

271.xx Paper Jam Clear Paper Path

272.xx Paper Jam Clear Paper Path

280.xx Paper Jam Clear Paper Path

282.98 Staple Jam Check Stapler

Paper is jammed in the MPF. If removing the jammed media does not fix the problem, go to “250.xx paper jam

service check” on page 2-47.

Paper has jammed at the output bin . Open the door of the bin to access the jammed media.

If removing the jammed media does not fix the problem, go to “271.xx paper jam

service check” on page 2-49.

Media is jammed i n the 5- Bin Mailbo x O ption. O pen the r ear door of opt ion to acces s the jammed media.

If removing the jammed media does not fix the problem, go to “272.xx paper jam

service check” on page 2-50.

This includes 280.36-40 and 280.80. Media has jammed in the StapleSmart finisher option. Open the finisher option front door to access the jammed pages .

Note: If the accumulated sheets are removed, the printer will not reprint these sheets. Als o if the print job is completed, the portion of the job print ed after the jam will not be stapled.

If removing the ja mmed media does not fix the probl em, replace the StapleSmart finisher option.

The stapler device detects a paper jam during normal st apler operation such as when printing and stapling jobs.

Check stapler are for jam in accumulator or stapler. Remove stapler cartridge to check for staple jam.

Press If this does not fi x the problem, go to “282.98 paper jam service check” on

page 2-51.

to initiate priming and resum e prin ti ng.

9xx service errors

900.xx RIP Software Error

902.xx Engine Software

903.xx Engine Software

904.xx Engine Software

905.xx Engine Software

906.xx Engine Software

907.xx Engine Software

908.xx Engine Hardware Fa ilure

920.xx TPS Sensor Unrecoverable TPS Sensor Error—Replace the ITU ass em bly. See “ITU assembly

Go to “900.xx RIP Software Err or service check” on page 2-51.

General Engine Sof tware Errors 902 through 907 i ndicate an unrecov erable engine software er ror. The system board may cause this ty pe of error. Turn the printer off and on to try and clear the error code. If this does not fix the problem after several attempts, contact your ne xt level of support before replacing the system board.

General Engine Har dware Error 908 indicates an unrecovera ble engine electronic hardware error. The system board may cause this type of error. Turn the printer off and on to try and clear the error code. If this does not fix the problem after several attempts, contact your ne xt level of support before replacing the system board.

removal” on page 4-49.

Diagnostic information 2-11

Page 53

5061

Error codes and paper jam messages (continued)

Error code Action

921.xx Registration Unrecoverable Registration Sensor Error—Replace the ITU assembly. See “ITU

925.02 Fan Stalled Fuser fan—Go to “925.02 error code service check” on page 2-54.

926.01 Fan Stalled VTB fan—Go to “926.01 error code service check” on page 2-54.

927.03 Fan Stalled RIP Fan—Go to “927.03 erro r code service check ” on page2-55.

930.09 LV Power Supply

940.xx TMC Error— Cyan

941.xx TMC Error— Magenta

942.xx TMC Error— Yellow

943.xx TMC Error— Black

950.00 to 950.29 NVRAM Failure

950.30 to 950.60 NVRAM Failure

951.xx NVRAM Failure

assembly re moval” on page 4-49.

Unable to find zero crossover point—Replace the LVPS. See “LVPS assembly

removal” on page 4-53.

Cyan TMC switch failure—Go to “940.xx error code service check” on page 2-56.

Magenta TMC switch failure—Go to “941.xx error code service check” on

page 2-58.

Yel low T MC switch failur e—Go to “942.xx error code service check” on

page 2-60.

Black TMC switch failure—Go to “943.xx error code service check” on page 2-62.

Either the system board or the operator panel assembly you just replaced was not a blank FRU. Replace that part with a new FRU.

Either the system board or the media size sensing board you replaced was not a blank FRU. Replace that part with a new FRU.

NVRAM chip fail ure—replace the media siz e sensing board. See “Media size

sensing board removal” on page 4-58.

952.xx NVRAM Failure

953.xx NVRAM Failure

954.xx NVRAM Failure

955.xx Code CRC <loc>

956.xx Service <xxxx> System Board

957.xx System Boa rd ASIC Failure

958.xx NAND Failure Replace the system board. See “System boar d removal” on pa ge 4-89.

960.xx RAM Memory Error

961.xx RAM Memory Error

NVRAM chip failure—POR the printer.

NVRAM chip failure opera tor panel assembly—replace the operator panel assembly. See “Operator panel assembly removal” on page 4-68.

NVRAM chip failure—Replace the system board. See “System board removal” on

page 4-89.

System board—This error indicates that the Code ROM or NAND failed the CRC check. The location of the failure is indicated by <loc>. Replace the system board. See “System board removal” on page 4-89

Go to “956.xx service error service chec k” on page 2-64.

Replace the syste m board. See “System board remova l” on page 4-89.

RAM soldered on board is bad. Replace the system board. See “System board

removal” on page 4-89.

There is an error in the memory installed in the memory option slot 1 on the system board. If another mem ory option is available, switch the memory options to isolate the problem. If you do not have a spare memory option to switch, then replace the memory installed. If this does not fix the problem, replace the system board. See

“System board remo val” on page 4-89.

2-12 Service Manual

Page 54

5061

Error codes and paper jam messages (continued)

Error code Action

962.xx RAM Memory Error

963.xx RAM Memory Error

964.xx Emulation Error

975.xx Standard Network or Network Card x

976.xx Standard Network

978.xx Standard Network or Network Card x

There is an error in the memory installed in the memory option slot 2 on the system board. If another mem ory option is available, switch the memory options to isolate the problem. If you do not have a spare memory option to switch, then replace the memory installed. If this does not fix the problem, replace the system board. See

“System board remo val” on page 4-89.

There is an error in the memory installed in the memory option slot 3 on the system board. If another mem ory option is available, switch the memory options to isolate the problem. If you do not have a spare memory option to switch, then replace the memory installed. If this does not fix the problem, replace the system board. See

“System board remo val” on page 4-89.

Download emulat ion CRC failure has occurred. The following actions may be taken:

1.Disable the Download Em ulation.

2.Program the down load emulation into the code overlay SIMM again.

3.If the problem is not resolved, replace the code overla y SIMM and download emulation agai n.

Unrecognizable network Errors 975 through 979 indicate a failure with the standard network port located on the syst em b oard or a network card in the specif ied slot x, x=1, 2 or 3. Replace the card in the specified slot.

Unrecoverable software or error in network for network card x. If unable to clear the error message, check the following:

• If installed, check network car d for correct instal lation.

• If correct ly i nstalled, replace the network card.

• If a network card is not installed, replace the system board.

Bad chec ksum while progr am ming Standard Network or Network Card x port. Chec k the following:

• Make sure y ou have downloaded the code in binary mode, not ASCII.

• Reprogram the Network card.

• If the problem persists, and if installed, check the network card for correct installation.

• If correct ly i nstalled, replace the network card.

• If a network card is not installed, replace the system board. See “System board

removal” on page 4-89.

979.xx Standard Network or Network Card X

982.xx <device> comm

Flash parts faile d whil e programming the Standar d Network or Network Card x port. Check the following:

• If installed, check the network card for correct installation.

• If correct ly i nstalled, replace the network card.

• If a network card is not installed, replace the system board. See “System board

removal” on page 4-89.

Communications error detected by the specified dev ice. Note: <device> can be one of the following:

• Duplex option.

•Tray

x (where x=2, 3, or 4).

• Output Expander or StapleSmart finisher—Output bin x (where x=1).

• 5-Bin Mailbox—Output bin x (where x=1 through 5).

Go to “982.xx error service check” on page 2-64

Diagnostic information 2-13

Page 55

5061

Error codes and paper jam messages (continued)

Error code Action

990.01 <device> This error message indicates that an equipment check condition has occurred in the specified de vice , but the error is unable to id entify the e xac t component f a ilure. Go to

“990.01 error service check” on page 2-65.

Note: <device> can be one of the following:

• Duplex option. See “Duplex option service check” on page 2-81.

•Tray x (where x=2, 3, or 4). See “500-sheet drawer option service check” on

page 2-71.

• Output Expander or StapleSmart finisher—Output bin x (where x=1). See

“Output expander option service check” on page 2-90 or “StapleSmart finisher service check” on page 2-111.

• 5-Bin Mailbox—Output bin x (where x=1 through 5). See “5-bin mailbox option

service check” on page 2-67.

Go to the service check for the device indicated.

Service checks

100.01 ITU error service check

A 100.01 ITU error indi cates t hat the printe r did not detect the ITU bel t home sensor. Before proceeding with th is service check, make sure that the Second Transfer Roll is cor rectly installed. After you reinstall the Second Transfer Roll, check to see if a 100.01 ITU error is still displayed. If a 100.01 ITU error is still being displayed, continue with thi s check.

The ITU has an optical sensor that watches f or a piece of reflective tape on the inside of the image bel t. This tape is read every revolution of the belt. If a signal is not received from the belt sensor within a certain time period, the printer posts an error due to the loss of signal. There are several causes f or the loss of signal. First, the belt has t racked too far to the front or rear of the printer. In this case, the belt is still turning, but the r e fl ective tape is no longer passing within view of the bel t sensor. Thi s is considered a belt trac king error and is initially posted as a 100.02 ITU Error. The other causes of a signal loss could be a belt sta ll , meaning the belt is not turning, or a true signal loss, which would be due to a bad sensor, broken cable, loose connection, or bad system board. These other causes post as a 100.01 ITU Error.

To assist the printer in determining the cau se of a si gnal loss, there is a buf fer that records the belt position for the last 50 re volutions. If the printer loses the belt si gnal, it refers to the buffer. If the buffer shows significant mistracking before signal loss, it will post a 100.02 ITU Error. If the buffer shows that the belt has been tracking in the center before signal loss, it posts a 100.01 ITU Error. Due to memory restrictions , th e buffer is not saved during POR. This means if a printer posts a 100.02 ITU Error, so th e belt is tracked off, and the custom er or servicer turns off the printer t o clear t he error, when the printer starts up, it will stil l not see t he belt si gnal and will now post a 100.01 ITU Error because the buffer is empty. When servicing a printer for a 100.01 ITU Error, it is important to view the error log. See “Display Log” on page 3-29. The error log can only be displayed at this point. Do no t try to print the log. Look for past occurrences of 100.01 ITU Errors preceded by a 100.02 ITU Error.

Step Actions and questions Yes No

1 Make sure all packing material is removed from the

2-14 Service Manual

printer. The detensioner is located underneath the toner cartridges. Make sure the ITU detensioner is remove d. Remove t he detensioner by pulling up on the red handle on the right side of the ITU.

Note: All the print cartridges must be removed to gain access to the detensi oner packing materia l.

Has all packin g materi al been removed from the printer?

Go to step 2 Rem ove any

remaining packing material from the printer.

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Step Actions and questions Yes No

Check the ITU release lever for correct operation. The

ITU release lever is the blac k lever lo cated on the left upper side frame above the ITU opening and can be seen by opening and lowering the MPF assembly. When locked, the lever should be at the 6 o'clock position. When unlocked, it shoul d be in a 3 o'clock position. Undue pressure is not required to operate the lever.

Does the ITU release lever operate correctly? Check the second transfer roll installation.

Is it installed correctly?

Check the display error log in the Diagnostic Menu. Is

100.01 ITU preceded in the lo g by a 100.02 ITU Error?

Go to step 3 Repair as

Go to step 4 R einstall the

Go to “100.02

ITU erro r service chec k” on page 2-17.

necessary.

second transfer roll.

Go to step 5

Remove the ITU assem bly and check that the sensor

cable is seate d in th e handle of the ITU assembly correctly.

Note: The sensor connector is lo cated on the side of the ITU handle assembly.

Is the cable seat ed correctly?

The front contamin ati on shield is attached to the font

plate of the ITU frame and lies on the top of the ITU belt.

Is the front contamination shield lying on the bel t? Make sure the I TU cleaner gea r (A) i s turning. Obs erve

the gear by op ening t he f ront pap er jam door abo ve the integrat ed paper tra y 1. Observe the white cleaner gear during POR. The gear should turn slo wly and smoothly for approximately 8 seconds before the printer displays a 100.01 ITU error.

Is the ITU Cleaner Gear turning?

Go to step 6 R einstall the

cable correctly. Check again f or a

100.01 ITU Error. If 100.01 ITU Error is displayed, go to step 6.

Go to step 7 Position the

shield on top of the belt.

Go to step 11 Go to step 8

Diagnostic information 2-15

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Step Actions and questions Yes No

Check to see if the ITU drive roll gear (A) is turning

during POR. Observe the gear by openi ng the MFP door to its horizontal position. Observe the gear o n the left end of the ITU drive roll. The ITU drive roll gear should turn for a few seconds slowly and smoothly before the printer posts a 100.01 ITU error.

Does the Gear turn? Check to see if the ITU drive motor is turning during

POR. Observe the ITU mo tor duri ng POR by removing the rear cover.

Is the ITU drive motor turning?

Check to see if the printer is setting on a solid, flat

surface. Is the printer setting on a sol id, flat surface?

Go to step 10 Go to step 9

Replace the ITU drive assembly. see “ITU drive

assembly removal” on page 4-52.

Go to step 11 Place the printer

Go to step 10

on a solid, flat surface.

Make sure the ITU drive m otor assembly cable is

correctly insta lled to the ITU dr ive motor and a t connector locat ion J16 on the system board.

Is the cable cor rectly installed? Make sure the ITU autoc onnect cable is installed

correctly at connector location J7 on the syst em board. Is the cable cor rectly installed?

Make sure the ITU autoco nnect connecto r in the printer

is seated correctly in the connector plate . Is the connector sea ted correctly?

Go to step 12 Install the cable

Go to step 13 Install the

Replace the follo wing FRUs in the following order:

1.ITU assembly. See “ITU

assembly removal” on page 4-49.

2.System board. See

“System board removal” on page 4-89.

correctly.

connector/cable correctly.

Replace the ITU autoconnect cable.

2-16 Service Manual

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100.02 ITU error service check

The ITU has an optical sensor that watches f or a piece of reflective tape on the inside of the image bel t. This tape is read every revolution of the belt. If a signal is not received from the belt sensor within a certain time period, the printer posts an error due to the loss of signal. There are several causes f or the loss of signal. First, the belt has t racked too far to the front or rear of the printer. In this case, the belt is still turning, but the r e fl ective tape is no longe r passing within view of the belt senso r. This is considered a belt tr acking error an d is posted as a 100.02 ITU Error. The other causes of a signal loss could be a belt stall, meaning the belt is not turning, or a true signal loss, which would be due to a bad sensor , broken cable, loose connection, or bad system board. These other causes post as a 100.01 ITU Error.

To assist the printer in determining what is the cause of a signal loss, there is a buffer that records the belt position f or the last 50 revolutions. If t he printer loses the belt signal, it refers to the buffer. If the buf fer shows significant mistr ac king be fo re signa l loss , it will post a 100. 02 ITU Err or. If the buffer sho ws that the bel t has been tracki ng in the center before signal loss, it posts a 100.01 ITU Erro r. Due to memory restrictions, the buffer is not sav ed duri ng PO R. Thi s means if a printer posts a 100.02 ITU Error, so the belt is track ed off, and the customer or servicer turns off the printer to clear the error, when the printer starts up, it will st il l not see the belt signal and will now post a 100.01 I TU Error because the buffer is empty. When servicing a printer for a 100.01 ITU Error, it is important to view the error log. See “Display Log” on page 3-29. The error log can only be displayed at this point. Do no t try to print the log. Look for past occurrences of 100.01 ITU Errors preceded by a 100.02 ITU Error.

Step Actions and questions Yes No

1 Make sure all packing material is removed from the

printer. The Detensioner is located underneath the toner cartridges. Make sure the ITU Detensioner is remove d. Remov e the Det ensioner b y pull ing u p on the red handle on the right side of the ITU.

Note: All the print cartridges must be removed to gain access to the Detensi oner packing material.

Has all packin g materi al been removed from the printer?

Check the ITU release lever for correct operation. The

Go to step 2 Rem ove any

remaining packing material from the printer.

Go to step 3 Repair as

necessary.

Does the ITU release lever operate correctly? Check the second transfer roll installation.

Is it installed correctly?

Go to step 4 R einstall the

second transfer roll.

Diagnostic information 2-17

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Step Actions and questions Yes No

Check the printer is setting on a solid, flat sur face.

Is the printer setting on a sol id, flat surface?

The front contami nati on shield is attached to the front

plate of the ITU frame and lies on the top of the ITU belt.

Is the front contamination shield lying on the IT U belt . Remove the ITU and check the ITU belt posit ion. If the

belt has shifted to the front or to the rear it should be replaced. The bel t must not shift more than 4 mm in either direction. Check by making the measurements as shown. The lower limit is 3.1 mm, the high limi t i s

8.1 mm, and the optimum position is 5.6 mm.

Go to step 5 Inform the

Go to step 6 Position the

Replace the ITU assembly. See

“ITU assembly removal” on page 4-49 and

run the belt tracki ng. See

“Belt Tracking (ITU 4th point adjustment)” on page 3-13.

customer that th e printer must be setting on a soli d, flat surface.

shield on top of the belt.

Treat as a belt stall or signal communications problem. See

“100.01 ITU error service check” on page 2-14.

Has the ITU Belt shifted to the front or to the rear?

122.01 error code service check

Hot fuser

Error code 122.01 indicates that the fuser heat ed up too quickly or not quickly enough. Error code 122.01 may also indicate a problem in the fuser assem bly with the hot roll bearings , hot roll thermistor, LVPS, or the system board.

Step Actions and questions Yes No

1 Turn the printer on. Open the right side fuser access

door. Observe the hot rol l l am p to see if it turns on and off. You may have to observe the lamp for a few minutes to see if it turns on and off.

Does the lamp turn on and off?

Turn the printer on. Measure the voltage on connector

J17-11 on the system board. The voltage shou ld measure approximately +0.13 V dc and +0.64 V dc as the hot roll lamp turns on and off.

Is the voltage correct?

Go to step 2 Replace the

Replace the fuser assembly. See

“Fuser assembly removal” on page 4-44.

LVPS assembly. See “LVPS

assembly removal” on page 4-53.

Replace the system board. See “System

board re moval” on page 4-89.

2-18 Service Manual

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122.02 error code service check

Hot fuser

Error code 122.02 displays whenever the printer detects a problem with the fuser running over temperature or the fuser l amps ha ve b een on t oo long . A prob lem could e x ist in th e fu ser assemb l y with the h ot rol l beari ngs , hot roll thermistor, or other hot roll parts. The LVPS or system board assembly can also be fail ing.

Step Actions and questions Yes No

1 Open the right fuser access door. Observe the fuser ,

and see if the hot roll fuser lamp turns on and off. You may have to observe for a few minutes.

Do the lamps turn off and on?

Turn the printer on, and meas ure t he voltage on

connector J17-11 on the system board. The voltage should measure approximately +0.13 V dc to +0.64 V dc as the hot roll lamp turns on and off.

Is the voltage correct?

122.03 error code service check

Hot roll thermistor circuit is open

If error code 122.03 displays, the printer detects a proble m in the fuser hot roll, fuser hot roll thermistor, system board, or LVPS fuser control circuits .

Step Actions and questions Yes No

1 Turn the printer on, and allow it to reach the Ready

prompt. Note: The printer may not comple te POR and post a

122.03 Error message . Measure the voltag e on connector J17-6 on the system

board. The voltage should measure approximately +3.3 V dc.

Is the voltage correct?

Go to step 2 Replace the

Replace the fuser assembly. See

“Fuser assembly removal” on page 4-44.

Go to step 2 Replace the

LVPS assembly. See “LVPS

assembly removal” on page 4-53.

Replace the system board. See “System

board re moval” on page 4-89.

system board. See “System

board re moval” on page 4-89.

Measure the vol tage on th e fuser DC cont rol co nnector

on the LVPS. Measure the voltage on pin 6 of the connector.

Does the voltag e mea sure approximately +3.3 V dc?

Replace the fuser assembly. See

“Fuser assembly removal” on page 4-44.

Diagnostic information 2-19

Replace the LVPS assembly. See “LVPS

assembly removal” on page 4-53.

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122.04 error code service check

Cold hot roll

Step Actions and questions Yes No

1 Measure the voltage on connector J17-11 on the

system board. The voltage should measure approximately +0.13 V dc to +0.64 V dc as the hot roll lamp turns off and on.

Is the voltage correct? Remove the fuser from the printer. Check continuity of

the hot rol l l amp b y measuri ng bet ween pins 1 an d 2 on the AC fuser connector on the fuser assembly.

Is there continuity? Check to make sure the hot roll lamp is installed

correctly. Is the hot roll lamp ins tal led correctly?

Reinstall the fuser assemb ly. Watc h to see if the l am ps

turn on and off as the lamp heats up. Do the lam p s turn on?

Turn the printer on, and all ow it to reach a Ready

prompt. Note: The printer ma y not complete POR and may

continue to display the error code. Remove the f user fr om the printe r . Meas ure t he vol tage

on connector J17-6 on th e system board. The voltage should measure approximately 3.3 V dc.

Is the voltage correct?

Go to step 2 Replace the

system board. See “System

board re moval” on page 4-89.

Go to step 4 G o to step 3

Go to step 4 Install the lamp

correc t ly. If this does not fix the problem, replace the fuser assembly. See

“Fuser assembly removal” on page 4-44.

Go to step 5 R eplace the fuser

assembly. See

“Fuser assembly removal” on page 4-44.

Go to step 6 Replace the

system board. See “System

board re moval” on page 4-89.

2-20 Service Manual

Measure the vol tage on th e fuser DC cont rol co nnector on the LVPS. Measure the voltage on pin 6 of the connect.

Does the voltag e mea sure approximately +3.3 V dc?

Replace the fuser assembly. See

“Fuser assembly removal” on page 4-44.

Replace the LVPS assembly. See “LVPS

assembly removal” on page 4-53.

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122.05 and 122.06 error code service check

Error codes 122. 05 and 122.-6 indicate that t he fuser didn’t increase in temperature enough. Error code 122.05 may also indi cate a problem in the fuser assembly with the hot roll beari ngs, hot roll thermistor, LVPS, or the system board.

Step Actions and questions Yes No

1 Measure the voltage on connector J17-11 on the

system board. The voltage measures approximately 0.13 V dc to

0.64 V dc as the hot roll lamp turns off and on. Is the voltage correct?

Remove the fuser from the printer. Check continuity of

the hot rol l l amp b y measuri ng bet ween pins 1 an d 2 on the AC fuser connector on the fuser assembly.

Is there continuity? Check to make sure that the hot roll lamp is installed

correctly. Is the hot roll lamp ins tal led correctly?

Reinstall the fuser assemb ly. Watc h to see if the l am ps

turn on and off as they heat up. Do the lam p s turn on?

Turn the printer on, and all ow it to reach a Ready

prompt. Note: The printer may not comple te POR and

continues to di splay the error code. Remove the fuser assembly from the printer. Measure

the voltage on connector J17-6 on the system board. The voltage should measure approximately +3.3 V dc.

Is the voltage correct?

Replace the fuser assembly. See

“Fuser assembly removal” on page 4-44.

Go to step 4 G o to step 3

Go to step 4 Install the lamp

Go to step 5 Replace the

Go to step 6 Replace the

Go to step 2

correc t ly. If this does not fix the problem, replace the fuser assembly. See

“Fuser assembly removal” on page 4-44.

LVPS assembly. See “LVPS

assembly removal” on page 4-53.

system board. See “System

board re moval” on page 4-89.

Measure the vol tage on th e fuser DC cont rol co nnector

on the LVPS. Measure the voltage on pin 6 of the connector.

Does the voltag e mea sure approximately +3.3 V dc?

Replace the fuser assembly. See

“Fuser assembly removal” on page 4-44.

Diagnostic information 2-21

Replace the LVPS assembly. See “LVPS

assembly removal” on page 4-53.

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122.07, 122.14, and 122.15 error code service check

Fuser assembly cam position is not found.

Step Actions and questions Yes No

1 Observe the fuse r drive assembly gears rotate during

POR. Do the ge a rs rotate?

Do the gears stop and the fuser dri ve assembly gear s

make a loud buzzing sound?

Check for correct installation of the fuser control cable

to J17 on the system board. Make sure the cable is properly connect ed.

Is the cable in stalled correctly? Remove the f user fr om the printe r . Meas ure t he vol tage

at the DC fuser control conn ector on the LVPS on pin 2 and 9 on the connector. The volt age should measure approximately +5 V dc.

Is the voltage correct?

Go to step 2 G o to step 5

Replace the FRUs in t he order shown:

1.Fuser drive assembly. See “Fuser

drive assembly removal” on page 4-46.

2.“Fuser

assembly removal” on page 4-44.

Go to step 4 Install the cable

Replace the fuser assembly. See

“Fuser assembly removal” on page 4-44.

Go to step 3

correctly.

Replace the LVPS assembly. See “LVPS

assembly removal” on page 4-53.

Check for correct installation of the fuser drive motor

cable to connector J15 on the system board. Is the cable in stalled correctly?

Remove the fu s e r fan to ga in access to th e mo to r

cable. Check the correct installation of the fuse r dri ve motor cable to connector J1 on the fuser driv e m otor board.

Is the cable in stalled correctly?

Go to step 6 Install the cable

Replace the follo wing FRUs in the order shown:

1.Fuser drive assembly. See “Fuser

drive assembly removal” on page 4-46.

2.System board. See

“System board removal” on page 4-89.

correctly.

Install the cable correctly.

2-22 Service Manual

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122.08 error code service check

Step Actions and questions Yes No

1 Replace the fuser assembly. See “Fuser assembly

removal” on page 4-44.

Does the error remain?

122.10 error code service check

Cold hot roll

Step Actions and questions Yes No

1 Measure the voltage on connector J17-11 on the

system board. The voltage should measure approximately +0.13 V dc to +0.64 V dc as the hot roll lamp turns off and on.

Is the voltage correct? Remove the fuser from the printer. Check continuity of

the hot rol l l amp b y measuri ng bet ween pins 1 an d 2 on the AC fuser connector on the fuser assembly.

Is there continuity? Check to make sure the hot roll lamp is installed

correctly. Is the hot roll lamp ins tal led correctly?

Replace the system board. See “System

board re moval” on page 4-89.

Go to step 2 Replace the

Go to step 4 G o to step 3

Go to step 4 Install the lamp

Problem resolved

system board. See “System

board re moval” on page 4-89.

correc t ly. If this does not fix the problem, replace the fuser assembly. See

“Fuser assembly removal” on page 4-44.

Reinstall the fuser assemb ly. Watc h to see if the l am ps

turn on and off as the lamp heats up. Do the lam p s turn on?

Turn the printer on, and all ow it to reach a Ready

prompt. Note: The printer may not comple te POR and may

continue to display the error code. Remove the f user fr om the printe r . Meas ure t he vol tage

on connector J17-6 on th e system board. The voltage should measure approximately 3.3 V dc.

Is the voltage correct? Measure the vol tage on th e fuser DC cont rol co nnector

on the LVPS. Measure the voltage on pin 6 of the connect.

Does the voltag e mea sure approximately +3.3 V dc?

Go to step 5 R eplace the fuser

Go to step 6 Replace the

Replace the fuser assembly. See

“Fuser assembly removal” on page 4-44.

Diagnostic information 2-23

assembly. See

“Fuser assembly removal” on page 4-44.

system board. See “System

board re moval” on page 4-89.

Replace the LVPS assembly. See “LVPS

assembly removal” on page 4-53.

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122.11 error code service check

Fuser hot roll is under temperature during standby

Step Actions and questions Yes No

1 Turn the printer on, and allow it to reach a Ready

prompt. Note: The print er may not co mplete POR and con tinu e

to display the 122.11 Error message. Remove the fuser assembly from the printer. Measure

the voltage on connector J17-6 on the system board. The voltage should measure approximately 3.3 V dc.

Is the voltage correct? Measure the vol tage on th e fuser DC cont rol co nnector

on the LVPS. Measure the voltage on pin 6 of the connector.

Does the voltag e mea sure approximately +3.3 V dc.

122.12 error code service check

Cold fuser

If error code 122.08 displays, the printer has detected a problem in the fuser hot roll lamp ci rcuity, fuser hot roll thermistor, system board, or LVPS fuser control circui ts.

Replace the f ollowing FRUs i n the order shown:

1. Fuser assembly. See “Fuser assembly removal” on page 4-44.

2. LVPS assembly. See “LVPS assembly removal” on page 4-53.

3. Syste m board. See “System board remova l” on page 4-89.

Go to step 2 Replace the

Replace the fuser assembly. See

“Fuser assembly removal” on page 4-44.

system board. See “System

board re moval” on page 4-89.

Replace the LVPS assembly. See “LVPS

assembly removal” on page 4-53.

122.13 error code service check

Secondary hot roll thermistor circuit is open

If error code 122.13 displays the printer detects a problem in t he fuser secondary hot roll, fuser hot roll thermistor, system board, or LVPS fuser control circui ts.

Step Actions and questions Yes No

1 Turn the printer on, and allow it to reach Ready.

Note: The printer ma y not complete POR and post a

122.13 Error message . Measure the voltag e on connector J17-7 on the system

board. The voltage should measure approximately +3.3 V dc.

Is the voltage correct? Measure the vol tage on th e fuser DC cont rol co nnector

on the LVPS. Measure the voltage on pin 7 of the connector.

Is the voltage me asure approximate ly +3.3 V dc.

2-24 Service Manual

Go to step 2 Replace the

Replace the fuser assembly. See

“Fuser assembly removal” on page 4-44.

system board. See “System

board re moval” on page 4-89.

Replace the LVPS assembly. See “LVPS

assembly removal” on page 4-53.

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148.xx error code service check

Step Actions and questions Yes No

1 Connector J16 on th e s ystem b oard —Chec k f or corr ect

installati on of t he ITU drive motor cable from the ITU drive motor to the system board connector J16.

Is the cable connected correctly? ITU drive motor—Chec k f or conti nuit y betw een pin 4 of

CON1 on the motor drive card and the remaining pins in the connector.

Do you measure continuity? Note: The ITU drive motor can be remov ed from the

printer without removing the complete ITU drive motor assembly. If the ITU drive motor assemb ly is removed be careful not to spill toner th at may be containe d in the auger system.

ITU drive mo tor cable—Check the continuity of the ITU

drive motor cable. Do you measure continuity?

ITU drive motor voltage check—Meas ure the voltage

on connector J16 on the system board. The voltages are approximately values.

Voltages with motor not runnin g

Connector pin Voltages (motor not running) J16- 2 +4.2 V dc J16- 4 +5.0 V dc J16- 6 +3.3 V dc J16-8 +24 V dc J16-10 Ground J16-12 0 V dc J16- 14 +3.3 V dc

Go to step 2 Install the cable

Replace the drive motor.

Go to step 4 Replace the ITU

Replace the drive motor.

correctly.

Go to step 3

drive motor cable.

Go to step 5

Are the voltages correct? ITU motor drive assembly—Remove the ITU assembly .

Manually turn the motor. The gears in the ITU motor assembly, the second transfer roll gears, and the cleaner gear should turn freely.

Do the gears turn freely?

ITU motor drive assembl y— R em ove the ITU drive

motor assembly. Manually turn the motor. Do the gears on the ITU drive motor assem bly turn

freely?

Replace the system board. See “System

board re moval” on page 4-89. If

this does not fix the problem, replace the ITU drive motor.

Contact you r ne xt level of support.

Diagnostic information 2-25

Go to step 6

Replace the ITU motor drive assembly.

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150.xx error code service check

Black cartridge drive assembly

This error indicates the bl ack cartridge drive motor has faile d to lock, has lost lock, or signature button could not be read.

Step Actions and questions Yes No

1 Check the b lac k cartridge d rive motor ca ble c onnec tion

to J16 on the system board. Is the cable in stalled correctly?

Check the b la ck cartridge d rive motor ca ble c onnecti on

to the black cartridge drive motor card. Is the cable in stalled correctly?

Check continuity of the black cartridge drive motor

cable. Is there continuity?

Replace the black cartridge drive assembly.

Does this fix the problem? Replace the system board. See “System board

removal” on page 4-89.

Does this fix the problem?

151.xx error code service check

Magenta cartridge drive assembly

This error indicates that the magenta cartridge driv e mo tor has failed to lock, has lost lock, or the signature button coul d not be read.

Go to step 2 Install the cable

correctly.

Go to step 3 Install the cable

correctly.

Go to step 4 Replace the

black cartridge assembly cable.

Problem resol ved Go to step 5

Problem resol ved Contact your next

level of support.

Step Actions and questions Yes No

1 Check the magenta cartridge drive motor cable

2-26 Service Manual

connection to J19 on th e system board. Is the cable in stalled correctly?

Check the magenta cartridge drive motor cable connection to th e mage nta cartridge drive motor card.

Is the cable in stalled correctly? Check continuity of the magenta cartridge drive motor

cable. Is there continuity?

Replace the magenta cartridge drive assembly. Does this fix the problem?

Replace the system board. See “System board

removal” on page 4-89.

Does this fix the problem?

Go to step 2 Install the cable

correctly

Go to step 3 Install the cable

correctly

Go to step 4 Replace the

magenta cartridge assembly cable.

Problem resol ved Go to step 5

Problem resol ved Contact your next

level of support.

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152.xx error code service check

Cyan cartr idge drive a ssembly

This error indicates that the cyan cartridge driv e m otor has failed to lock, has lost lock, or the signature but ton could not be read.

Step Actions and questions Yes No

1 Check t he c yan ca rtridge driv e mot or cab l e connec tion

to J19 on the system board. Is the cable in stalled correctly?

Check the cyan cartridge drive motor cable connection

to the cyan cartridge drive mo tor card. Is the cable in stalled correctly?

Check continuity of the cyan cartridge drive mo tor

cable. Is there continuity?

Replace the cyan cartridge drive assembly.

Does this fix the problem? Replace the system board. See “System board

removal” on page 4-89

Does this fix the problem?

153.xx error code service check

Yellow cartridge drive assembly

This error indicates that the yell ow cartridge drive motor has fail ed to lock, has lost lock, or the signature b utton could not be read.

Go to step 2 Install the cable

correctly.

Go to step 3 Install the cable

correctly.

Go to step 4 Replace the cyan

cartridge assembly cable.

Problem resol ved Go to step 5

Problem resol ved Contact your next

level of support.

Step Actions and questions Yes No

1 Check the yellow cartridge drive motor cable

connection to J15 on th e system board. Is the cable in stalled correctly?

Check the yellow cartridge drive motor cable

connection to the yellow cartridge drive motor car d . Is the cable in stalled correctly?

Check continuity of the yellow cartridge drive motor

cable. Is there continuity?

Replace the yellow cartridge drive assembly.

Does this fix the problem? Replace the system board. See “System board

removal” on page 4-89.

Does this fix the problem?

Go to step 2 Install the cable

correctly.

Go to step 3 Install the cable

correctly.

Go to step 4 Replace the

yellow cartridge assembly cable.

Problem resol ved Go to step 5

Problem resol ved Contact your next

level of support.

Diagnostic information 2-27

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177.xx error code service check

This error indicates a MPF motor error.

Step Actions and questions Yes No

1 MFP motor/sensor cable—check th e MPF moto r/

sensor cable to JMPF1 on the system board to make sure it is seated corr ectly. See “System board” on

page 5-7 for connector information.

Is the cable seat ed correctly? Voltage checks —di sconnect JMPF1 from the system

board. See “System board” on page 5-7 for connector information.

Is the cable seat ed correctly?

200.03 paper jam service chec k

S2 sensor was made at an unexpected time. See “Printer sensors” on page 5-3.

Step Actions and questions Yes No

Go to step 2 Install the cable

Replace the FRU in the fol lowing order:

• MPF drive assembly. See “Multi-

purpose feeder (MPF) motor removal” on page 4-64.

•MPF motor/ sensor cable.

correctly.

Replace the system board. See “System

board re moval” on page 4-89.

1 Is sensor flag obst ructed by paper debris , out of

position, or broken?

Perform the “BASE SENSOR TEST” on page 3-24.

Do both sensor pass the tes t? Is the inner deflect or out of place, causing sensor flag

to bind?

Are the sensors connecto rs fully seated? Go to step 5 Reseat the

Are connectors at J21 fully seated on the system

board?

Check sensor cables.

Are the cables cut or bro ken? Replace the sensor th at di d not pass the test.

Is the proble m resolved?

Clear the obstruction and reinst all or replace flag.

Problem resol ved Go to step 3

Install inner deflector properly.

Go to step 6 R eseat the

Replace the cables.

Go to step 2

Go to step 4

sensor connector.

connector on the system board.

Go to step 7

Replace the system board. See “System

board re moval” on page 4-89.

2-28 Service Manual

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200.04 paper jam service chec k

S2 sensor late

Note: See “Printer sensors” on page 5-3.

Step Actions and questions Yes No

1 Check the tra y fo r proper edge guide se ttin g and med ia

loading. Edge guides should be adjusted against edge of media. Media should be fanned and lay flat in the tray.

Is the media properly loaded in the tray? Check the pick tires for contamination or wear.

Are pick tires worn or contaminated?

Check for obstructions in the paper path.

Is the paper path obstructed? Is the inner deflect or out of position? Correct the

Is the autocompensator damaged or defect ive? Go to

Perf orm t he “B ASE SENSOR TEST” on page 3-24 on

the S2 sensor. Does the S2 sensor pass the test?

200.05 paper jam service chec k

Go to step 2 Properly load

Replace the pick rolls. See “Pick

rolls re moval” on page 4-70.

Clear the obstruction.

deflector pos it ion.

“Autocompensa tor service check” on page 2-76

Contact you r ne xt level of support.

media.

Go to step 3

Go to step 4

Go to step 5

Go to step 6

See “200.21,

200.28, and

200.29 paper jam service check.

S2 or narrow media sens or did not break in time

Note: See “Printer sensors” on page 5-3.

Step Actions and questions Yes No

1 Make sure the media installed in the tray meets

specifications. Does the media meet specif ications?

Check tray for the edge guide setting and media

loading. Edge guides should be adjusted against edge of media. Media should be fanned and lay flat in the tray.

Is the media properly loaded in the tray? Remove the ITU, and check for the jam at the second

trans fer roll. Is paper jammed at the second transfer roll?

Go to step 2 Inform the

Go to step 3 Properly load

Clear the jam. Contact you r next

Diagnostic information 2-29

customer that media loaded in Tray x does not meet specification

media.

level of support.

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200.06 paper jam service chec k

The narrow media sensor made at an unexpected time.

Note: See “Printer sensors” on page 5-3.

Step Actions and questions Yes No

1 Check tr ay for the edge gui de setting and media

loading. Edge guides should be adjusted against edge of media. Media should be fanned and lay flat in the tray.

Is the media properly loaded in the tray? Media may not have been clea red f rom a previous jam.

Is media in paper path?

200.07 paper jam service chec k

S2 or narrow media sens or did not break in time.

Note: See “Printer sensors” on page 5-3.

Step Actions and questions Yes No

1 Make sure the media installed in the tray meets

specifications. Does the media meet specif ications?

Check tray for the edge guide setting and media

loading. Edge guides should be adjusted against edge of media. Media should be fanned and lay flat in the tray.

Is the media properly loaded in the tray?

Go to step 2 Properly load

Clear the paper path.

Go to step 2 Inform the

Go to step 3 Properly load

media.

Contact you r ne xt level of support.

customer that media loaded in Tray x does not meet specification.

media.

Remove the ITU and check for the jam at the second

trans fer roll. Is paper jammed at the second transfer roll?

200.16 paper jam service chec k

S2 or narrow media sens or made early.

Note: See “Printer sensors” on page 5-3.

Step Actions and questions Yes No

1 Check tr ay for the edge gui de setting and media

loading. Edge guides should be adjusted against edge of media. Media should be fanned and lay flat in the tray.

Is the media properly loaded in the tray? Media may not have been clea red f rom a previous jam.

Is media in paper path?

2-30 Service Manual

Clear the jam. Contact you r next

Go to step 2 Properly load

Clear the paper path.

level of support.

media.

Contact you r ne xt level of support.

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200.21, 200.28, and 200.29 paper jam service check

Either the laser paper path, S2,or narrow media sensor is obstructed.

Note: See “Printer sensors” on page 5-3.

Step Actions and questions Yes No

1 Is sensor flag obst ructed by paper debris , out of

position, or broken?

Perform the “BASE SENSOR TEST” on page 3-24.

Do both sensor pass the tes t? Is the inner deflect or out of place, causing sensor flag

to bind?

Are the sensors connect ors fully seated? Go to step 5 R eseat the

Are connectors at J21 fully seated on the system

board?

Check sensor cables.

Are the cables cut or bro ken? Replace the sensor th at di d not pass the test.

Is the proble m resolved?

200.93 paper jam service chec k

Clear the obstruction and reinst all or replace flag.

Problem resol ved Go to step 3

Install inner deflector properly.

Go to step 6 R eseat the

Replace the cables.

Go to step 2

Go to step 4

sensor connector.

connector on the system board.

Go to step 7

Replace the system board. See “System

board re moval” on page 4-89.

The laser was made unexpectedly.

Step Actions and questions Yes No

1 Remove fuser from printer, remove oiler housing from

fuser, and pivot the paper guide up. Is paper jammed inside the fuser?

Check fuser entry guide for toner buildup.

Is toner built up on the fuser entry guide?

Check fus e r exit se ns o r flag .

Does the flag rotate freel y and return to normal position when released?

Clear the jam. Go to step 2

Replace the fuser assembly. See

“Fuser assembly removal” on page A-44.

Go to step 4 R eplace the fuser

Diagnostic information 2-31

Go to step 3

assembly. See

“Fuser assembly removal” on page A-44.

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5061

Step Actions and questions Yes No

Reinstall fuser and perfor m the “BASE SENSOR

TEST” on page 3-24.

Note: Use a spring hook to actuate the flag.

Does fuser exit sensor pass test?

Check the vacuum transport belts (VTB) for motion.

Observe the belt through the front door. Are the belts on the VTB assembly turning?

Go to step 5 Perform the

following in order:

1.Reseat the connector J17 on the system board.

2.Replace the fuser assembly. See “Fuser

assembly removal” on page 4-44.

3.Replace the LVPS assembly. See “LVPS

assembly removal” on page 4-53.

4.Replace the System board. See

“System board removal” on page 4-89.

Go to step 6 G o to “Vacuum

transport belt (VTB) rem oval” on page 4-95 to

verify corre c t installation.

Check the VTBs for wear or damage.

Are the belts worn or damaged?

Check the VTB plate for a buildup of debris .

Is there a debris buildup? Does media move smoothly into the fuser from the

VTB?

Replace the vacuum trans port belt. See

“Vacuum transport belt (VTB) rem oval” on page 4-95.

Clean off the VTB plate.

Call the next level of support.

Go to step 7.

Go to step 8

Replace the vacuum trans port belt. See

“Vacuum transport belt (VTB) fan removal” on page 4-97.

2-32 Service Manual

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200.96 paper jam service chec k

Neither the S2 nor narrow media sensor broke in time.

Note: See “Printer sensors” on page 5-3.

Step Actions and questions Yes No

1 Make sure the media installed in the tray meets

specifications. Does the media meet specif ications?

Check tray for the edge guide setting and media

loading. Edge guides should be adjusted against edge of media. Media should be fanned and lay flat in the tray.

Is the media properly loaded in the tray? Remove the ITU and check for the jam at the second

trans fer roll. Is paper jammed at the second transfer roll?

201.xx and 202.xx paper jam service check

Step Actions and questions Yes No

1 Remove the fuser from the printer. Remove the oil er

housing from the fuser, and pivot the paper guide up. Is media jammed inside the fuser?

Check fus e r exit se ns o r flag .

Does flag rotate freely and return to normal position when released?

Go to step 2 Inform the

Go to step 3 Properly load

Clear the jam. Contact you r next

Clear the jam from the fuser.

Go to step 4 R eplace the fuser

customer that media loaded in Tray x does not meet specification.

media.

level of support.

Go to step 2

assembly. See

“Fuser assembly removal” on page 4-44.

Check that the diverter gates in the fuser rotate f reely.

Do the diverter gates rotate freely?

Go to step 4 R eplace the fuser

assembly. See

“Fuser assembly removal” on page 4-44.

Diagnostic information 2-33

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5061

Step Actions and questions Yes No

Reinstall the fuser and perform the “BASE SENSOR

TEST” on page 3-24 for the fuser exit sensor.

Note: Use a spring hook to actuate the flag.

Does the fuser exit sensor pass?

Check that the duplex diverter rotates freely with the

redrive door closed. Does the duplex di verter rotate freely?

Go to step 5 Perform the

following in order:

1.Reseat the connector J17 on the system board.

2.Replace the fuser assembly. See “Fuser

assembly removal” on page 4-44.

3.Replace the LVPS assembly. See “LVPS

assembly removal” on page 4-53.

4.Replace the system board. See

“System board removal” on page 4-89.

Go to step 6 Replace the

redrive doo r. See

“Redrive door removal” on page 4-26.

Check for the proper operation of the red riv e.

Are both belt s in good condition and properly install ed?

If the duple x optio n is in use , chec k the lo wer right door

paper path. Does media pass freely between the door and the

metal plate?

If the duplex option is in use, remov e the duplex R.H.

access panel to check if the jam occurred at duplex entry edge guide.

Did the jam occur at the duplex entry edge guide? If the duple x opt ion is in use, che ck th e act uator b utt on.

See “Duplex opti on defl ector button replaceme nt”

on page A-3.

Should the actuator button be replaced?

Go to step 7 Install or replace

Go to step 8 Replace the

Replace the duplex option.

Replace the button.

the redrive door. See “Redrive

assembly removal” on page 4-82.

lower right door assembly. See

“Lower right door assembly removal” on page 4-24.

Go to step 9

Go to step 10

2-34 Service Manual

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5061

Step Actions and questions Yes No

Is a 5-bin mailbox option, StapleSmart finisher, or an

output expander option in use?

230.xx paper jam service chec k

Step Actions and questions Yes No

1 Thoroughly examine the duplex paper path for torn

paper that may be blocking the sensors or paper path. Is the duplex paper path clear?

Check the lower right door paper path.

Does media pass freely between the door and the metal plate?

Check the following:

• Reseat the option on the printer.

• Verify the top cover is properly seated on developer HVPS.

Go to step 2 Clear the paper

Go to step 3 Replace the

Contact you r ne xt level of support.

path.

lower right door assembly. See

“Lower right door assembly removal” on page 4-24.

Are any of the following conditions true?

• Only the back o f the page of a duple x j ob prints and exits into the standard bin.

• Media exits the right side of the printer.

• Media jams in the duplex at the diverter.

Open the redrive door, and check that the diverter

operates freely.

Does the diverter operat e freely? Close the redrive door, and check that the diverter

operates freely. Does the diverter operat e freely?

Go to step 4 G o to step 8

Go to step 5 R eplace the fuser

assembly. See

“Fuser assembly removal” on page 4-44.

Go to step 6 Replace the

redrive doo r. See

“Redrive door removal” on page 4-26.

Diagnostic information 2-35

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5061

Step Actions and questions Yes No

Check that the diverter actuator link is not bi nding or

damaged. Examine the li nk for damage under the duplex option.

Is link binding or damaged? Check the du pl ex act uator b utton. See “Dup lex option

deflector button replacement” on page A-3.

Should the button be replaced? Check for the correct sensor operation by performing

the Duplex Sensor test. See “Duplex Sensor T est ” on

page 3-19.

Make sure the sen sors are correctly connected to the

duplex system board. Are the cables cor rectly connected?

241.xx paper jam service chec k

500-sheet drawer

Media does not reach the pass thru sensor.

Step Actions and questions Yes No

1 Make sure the media installed in the tray meets

specifications. Does the media meet specif ications?

Repair the actuator link.

Replace the actuator button.

Replace the duplex option.

Go to step 2 Inform the

Go to step 7

Go to step 8

Go to step 9

Correctly conn ect the ca bles.

customer that media loaded in Tray x does not meet media specifications.

Make sure the medi a is l oa ded corr ectl y. Make sure the

side and back rest raints are located and seated properly.

Is the media loaded correctly? See if the paper is trying to f eed from the tray.

Note: You can observe the autocompen sat or f eed roll s

and the paper through the tray access door. Run the Tray x feed test from the Diagno stics menu to

help diagnose a f eed problem. See “Feed Test” on

page 3-20.

Is the media leaving the tray? Are both of the autocompe nsator pick rolls in stalled

and turning? Check the autocompensator pick roll s for wear or

contamination. Are the autocompensator pick rolls worn or

contaminated?

Check the pass thru sens or for correct ope ration by

running the Tray x sensor test from the Diagnostics Menu. See “Sensor Test” on page 3-20.

Does the pass thru sensor operate correctly?

Go to step 3 Load the media

Go to step 7 G o to step 4

Go to step 5 G o to step 8

Replace the pic k arm rolls. Replace both rolls at the same time.

Check for any obstructions that might catch the media and create a paper jam.

correctly.

Go to step 6

Go to step 7

2-36 Service Manual

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5061

Step Actions and questions Yes No

Make sure the pass thru sensor is correctly connected

to the Tray x system board. Is the sensor cabl e connected correctl y?

Check the autocompensator cable f or correct

installation to Tray x system board. Is the cable connected correctly?

Replace the FRUs in the following order:

1.Pass thru sensor assembly.

2.Electronics/ size sensing assembly with system board.

Replace the option, or replac e the following parts in the order until the error is cleared:

• Autocompensator pick assembly. See “Auto-

compensator pic k assembly removal” on page 4-27.

•Tray x system board.

Install the cable correctly.

242.xx paper jam service chec k

For seco nd installed tray/option.

500-sheet drawer opti o n

Media does not reach the pass thru sensor.

Step Actions and questions Yes No

1 Is Tray 2 a HCIT 2000-sheet option? Go to “HCIT” on

Make sure the media installed in the tray meets

specifications. Does the media meet specif ications?

Make sure the medi a is l oa ded corr ectl y. Make sure the

side and back rest raints are located and seated properly.

Is the media loaded correctly?

page 2-39

Go to step 2

Go to step 3 Inform the

customer that media loaded in Tray x does not meet media specifications.

Go to step 4 Load the media

correctly.

Diagnostic information 2-37

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5061

Step Actions and questions Yes No

See if the paper is trying to f eed from the tray.

Note: You can observe the autocompen sat or f eed roll s

and the paper through the tray access door. Run the Tray x feed test from the Diagno stics menu to

help diagnose a f eed problem. See “Feed Test” on

page 3-20.

Is the media leaving the tray? Are both of the autocompe nsator pick rolls in stalled

and turning? Check the autocompensator pick roll s for wear or

contamination. Are the autocompensator pick rolls worn or

contaminated?

Check the pass thru sens or for correct ope ration by

running the Tray x sensor test from the Diagnostics Menu. See “Sensor Test” on page 3-20.

Does the pass thru sensor operate correctly?

Make sure the pass thru sensor is correctly connected

to the Tray x system board. Is the sensor cabl e connected correctl y?

Go to step 8 G o to step 5

Go to step 6 G o to step 9

Replace the pic k arm rolls. Replace both rolls at the same time.

Check for any obstructions that might catch the media and create a paper jam.

Replace the FRUs in the following order:

1.Pass thru sensor assembly.

2.Electronics/ size sensing assembly with system board.

Go to step 7

Go to step 8

Install the cable correctly.

Check the autocompensator cable f or correct

installation to Tray x system board. Is the cable connected correctly?

Replace the option or replace the following parts in the order until the error is cleared:

• Autocompensator pick assembly. See “Auto-

compensator pic k assembly removal” on page 4-27.

•Tray x system board.

Install the cable correctly.

2-38 Service Manual

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5061

HCIT

Use the “HCIT standalone test mode” on page 3-5 inside the HCIT to help isolate paper jams. Run the Standalone Feeding Operati on Test to observe paper feeding from the tray and through the feed assembly. Use the “HCIT syste m board LED error code table” on page 2-84 to further isolat e paper jam or sensor problems.

Before proceeding with this service chec k, make sure the HCIT is installed correctly.

Step Actions and questions Yes No

1 Check for pieces of paper or other obstructions in the

feed assembly. Are any pieces of paper or obst ructions in the feed

assembly? Make sure the media loaded in the paper tray meets

printer supplies specifications and t he med ia is loaded corr ec tly. Make sure the side and ba ck r e straints are located and seated pr operl y.

Does the media meet specif ications?

Use the Standal one F eed in g Operat ion Test to observe

paper feeding from the tray. Does the paper feed from the paper tray?

Using the Standalone Feedi ng Operatio n Test, observe

the registration motor (the registration motor is the motor at the top of the f eed assembly).

Does the motor turn? Does the pick motor, the lower motor in the feed unit

assembl y, turn? Check the registration motor cable to HCIT system

board cable connected to CN3 for correct installation. Is the cable connected correctly?

Remove any paper or obstructions.

Go to step 3 Inform the

Go to step 14 Go to step 4

Go to step 5 G o to step 6

Go to step 8 G o to step 7

Replace the follo wing FRUs in the order shown:

1.HCIT system board.

2.Feed unit assembly.

Go to step 2

customer that media in the paper tray does not meet specifications.

Install the cable correctly.

Check the pick motor cable to HCIT system board

cable connected to CN4 for correct in stallation. Is the cable connected correctly?

Use the “HCIT system board LED error code table”

on page 2-84.

Does the LED flash 7 times? Make sure the registration home sens or cable is

installed correctly to the sensor and to CN6 on the system board.

Is the cable connected correctly?

Replace the follo wing FRUs in the order shown:

1.HCIT system board.

2.Feed unit assembly.

Go to step 9 G o to step 11

Go to step 10 Install the cable

Diagnostic information 2-39

Install the cable correctly.

correctly.

Page 81

5061

Step Actions and questions Yes No

Is the registrat ion home sensor operati ng correctly? Repl ace the

Use the “HCIT system board LED error code table”

on page 2-84.

Does the LED flash 8 times? Make sure the pick home sensor cable is installed

correctly to the sensor and to CN6 on the system board.

Is the cable connected correctly? Is the registrat ion home sensor operati ng correctly? Repl ace the

Use the Standalone F eeding Operation Test to

determine where the paper jams. Use the “HCIT

system board LED error code table” on page 2-84

to help isolate problems in the feed unit assembly. Are you able to determine where the failure is

occurring?

Replace the follo wing FRUs in the order shown:

1.HCIT system board.

2.Feed unit assembly.

Go to step 12 Go to step 14

Go to step 13 Install the cable

follo wing FRUs in the order shown:

1.HCIT system board.

2.Feed unit assembly.

Repair or replace parts as necessary.

foll o wing FR U s i n the order shown:

1.Registration sensor.

2.HCIT system board.

correctly.

Replace the foll o wing FR U s i n the order shown:

1.Registration sensor

2.HCIT system board.

Replace the fee d unit assembly.

Envelope feeder

Before proceeding with this service check, make sure the envelope option is in stalled correctly.

Step Actions and questions Yes No

1 Make sure the envelopes installed in the tray meet

specifications. Some guidelines tha t can be used in selection of

envelopes that will minimize the jam rate are:

• Flat envelopes that are not warped or twisted.

• Flexible envelopes that can conf orm to the paper path.

• Smooth surface on the enve lop es. Rough or ridged surfaces ma y cause t he env el opes to st ick together in the tray.

• No cotton content, or as little as possible to meet the user’s needs.

• If the envelopes have a pressure-sensitive adhesive flap, performance might be improved by reversing the orientation of the envelope in the tray and reversing the image in the driv e or appl ication.

Are any problems found with the envelopes?

Inform the customer of the problems wi th the envelope s that do not meet specifications.

Go to step 2

2-40 Service Manual

Page 82

5061

Step Actions and questions Yes No

Make sure the en velopes are loaded correctly. Make

sure the side and back restraints are located and seated properly.

Are the envelopes loaded correctly? Observe if the env elopes feed from the tray.

Note: You can observe the autocompensat or pick rolls

and the envelopes through the tray access door. Are the envel opes leaving the tray?

Check the pick rolls to verify both pick rolls are

installed. Are any of the pic k rol ls missing?

Check to m ake s ure the au tocom pensator pic k rolls ar e

correctly in stalled. Are the autocompensator pick rolls cor rectly installed?

Observe the pick r o ll s as they try to pick and feed

envelopes from the tray. Do the pick roll s turn?

Check the autocompensator pick rol ls for signs of wear

or contamination. Are the pick rolls worn or contaminated?

Go to step 3 Load the

Go to step 8 G o to step 4

Go to step 5 Install a new pair

Go to step 6 Install the pic k

Go to step 7 Replace the

Replace the pick rolls. Both pick rolls should be replaced at the same time. See

“Pick rolls removal” on page 4-70.

envelopes correctly.

of pick ro l l s. Bo t h pick rolls should be installed at the same time. See

“Pick rolls removal” on page 4-70.

rolls correctly. See “Pick rol ls

removal” on page 4-70.

envelope option.

Go to step 8

If you continue to ha v e probl ems , repl ace the complet e

envelope option.

243.xx paper jam service chec k

For thir d installed tray/option.

500-sheet drawer opti o n

Media does not reach the pass thru sensor.

Step Actions and questions Yes No

1 Is Tray 3 a HCIT 2000-sheet option? Go to “HCIT” on

Make sure the media installed in the tray meets

specifications. Does the media meet specif ications?

page 2-43.

Go to step 2

Go to step 3 Inform the

customer that media loaded in Tray x does not meet specifications.

Diagnostic information 2-41

Page 83

5061

Step Actions and questions Yes No

Make sure the medi a is l oa ded corr ectl y. Make sure the

side and back rest raints are located and seated properly.

Is the media loaded correctly? See if the paper is trying to f eed from the tray.

Note: You can observe the autocompen sat or f eed roll s

and the paper through the tray access door. Run the Tray x feed test from the Diagno stics menu to

help diagnose a f eed problem. See “Feed Test” on

page 3-20.

Is the media leaving the tray? Are both of the autocompe nsator pick rolls in stalled

and turning? Check the autocompensator pick roll s for wear or

contamination. Are the autocompensator pick rolls worn or

contaminated?

Check the pass thru sens or for correct ope ration by

running the Tray x sensor test from the Diagnostics Menu. See “Sensor Test” on page 3-20.

Does the pass thru sensor operate correctly?

Make sure the pass thru sensor is correctly connected

to the Tray x system board. Is the sensor cabl e connected correctl y?

Go to step 4 Load the media

Go to step 8 G o to step 5

Go to step 6 G o to step 9

Replace the pic k arm rolls. Replace both rolls at the same time.

Check for any obstructions that might catch the media and create a paper jam.

Replace the FRUs in the following order:

1.Pass thru sensor assembly.

2.Electronics/ size sensing assembly with system board.

correctly.

Go to step 7

Go to step 8

Install the cable correctly

2-42 Service Manual

Check the autocompensator cable f or correct installation to Tray x system board.

Is the cable connected correctly?

Replace the option, or replac e the following parts in the order until the error is cleared:

• Autocompensator pick assembly. See “Auto-

compensator pic k assembly removal” on page 4-27.

•Tray x system board.

Install the cable correctly.

Page 84

5061

HCIT

Before proceeding with this service chec k, make sure the HCIT is installed correctly.

Step Actions and questions Yes No

1 Check for pieces of paper or other obstructions in the

feed assembly. Are any pieces of paper or obst ructions in the feed

assembly? Make sure the media loaded in the paper tray meets

printer supplies specifications and t he med ia is loaded corr ec tly. Make sure the side and ba ck r e straints are located and seated pr operl y.

Does the media meet specif ications?

Use the Standal one F eed in g Operat ion Test to observe

paper feeding from the tray. Does the paper feed from the paper tray?

Using the Standalone Feedi ng Operatio n Test, observe

the registration motor (the registration motor is the motor at the top of the f eed assembly).

Does the motor turn? Does the pick motor, the lower motor in the feed unit

assembl y, turn? Check the registration motor cable to HCIT system

board cable connected to CN3 for correct installation. Is the cable connected correctly?

Remove any paper or obstructions.

Go to step 3 Inform the

Go to step 14 Go to step 4

Go to step 5 G o to step 6

Go to step 8 G o to step 7

Replace the follo wing FRUs in the order shown:

1.HCIT system board

2.Feed unit assembly.

Go to step 2

customer that media in the paper tray does not meet specifications.

Install the cable correctly.

Check the pick motor cable to HCIT system board

cable connected to CN4 for correct in stallation. Is the cable connected correctly?

Use the “HCIT system board LED error code table”

on page 2-84.

Does the LED flash 7 times? Make sure the registration home sens or cable is

installed correctly to the sensor and to CN6 on the system board.

Is the cable connected correctly?

Replace the follo wing FRUs in the order shown:

1.HCIT system board.

2.Feed unit assembly.

Go to step 9 G o to step 11

Go to step 10 Install the cable

Diagnostic information 2-43

Install the cable correctly.

correctly.

Page 85

5061

Step Actions and questions Yes No

Is the registrat ion home sensor operati ng correctly? Repl ace the

Use the “HCIT system board LED error code table”

on page 2-84.

Does the LED flash 8 times? Make sure the pick home sensor cable is installed

correctly to the sensor and to CN6 on the system board.

Is the cable connected correctly? Is the registrat ion home sensor operati ng correctly? Repl ace the

Use the Standalone F eeding Operation Test to

determine where the paper jams. Use the “HCIT

system board LED error code table” on page 2-84

to help isolate problems in the feed unit assembly. Are you able to determine where the failure is

occurring?

Replace the follo wing FRUs in the order shown:

1.HCIT system board.

2.Feed unit assembly.

Go to step 12 Go to step 14

Go to step 13 Install the cable

follo wing FRUs in the order shown:

1.HCIT system board.

2.Feed unit assembly.

Repair or replace parts as necessary.

foll o wing FR U s i n the order shown:

1.Registration sensor.

2.HCIT system board.

correctly

Replace the foll o wing FR U s i n the order shown:

1.Registration sensor

2.HCIT system board.

Replace the fee d unit assembly.

2-44 Service Manual

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5061

Envelope feeder

Before proceeding with this service check, make sure the envelope option is in stalled correctly.

Step Actions and questions Yes No

1 Make sure the envelopes installed in the tray meet

specifications. Some guidelines tha t can be used in selection of

envelopes that will minimize the jam rate are:

• Flat envelopes that are not warped or twisted.

• Flexible envelopes that can conf orm to the paper path.

• Smooth surface on the enve lop es. Rough or ridged surfaces ma y cause t he env el opes to st ick together in the tray.

• No cotton content, or as little as possible to meet the user’s needs.

Are any problems found with the envelopes? Make sure the en velopes are loaded correctly. Make

sure the side and back restraints are located and seated properly.

Are the envelopes loaded correctly? Observe if the env elopes feed from the tray.

Note: You can observe the autocompensat or pick rolls

and the envelopes through the tray access door. Are the envel opes leaving the tray?

Inform the customer of the problems wi th the envelope s that do not meet specifications.

Go to step 3 Load the

Go to step 8 G o to step 4

Go to step 2

envelopes correctly.

Check the pick rolls to verify both pick rolls are

installed. Are any of the pic k rol ls missing?

Check to m ake s ure the au tocom pensator pic k rolls ar e

correctly in stalled. Are the autocompensator pick rolls cor rectly installed?

Observe the pick r o ll s as they try to pick and feed

envelopes from the tray. Do the pick roll s turn?

Check the autocompensator pick rol ls for signs of wear

or contamination. Are the pick rolls worn or contaminated?

If you continue to ha v e probl ems , repl ace the complet e

envelope option.

Go to step 5 Install a new pair

Go to step 6 Install the pic k

Go to step 7 Replace the

Replace the pick rolls. Both pick rolls should be replaced at the same time. See

“Pick rolls removal” on page 4-70.

of pick ro l l s. Bo t h pick rolls should be installed at the same time. See

“Pick rolls removal” on page 4-70.

rolls correctly. See “Pick rol ls

removal” on page 4-70.

envelope option.

Go to step 8

Diagnostic information 2-45

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244.xx paper jam service chec k

HCIT—For the fourth installed option. Use the “HCIT standalone test mode” on page 3-5 inside the HCIT to help isolate paper jams. Run the

Standalone Feeding Operati on Test to observe paper feeding from the tray and through the feed assembly. Use the “HCIT syste m board LED error code table” on page 2-84 to further isolat e paper jam or sensor problems.

Before proceeding with this service chec k, make sure the HCIT is installed correctly.

Step Actions and questions Yes No

1 Check for pieces of paper or other obstructions in the

feed assembly. Are any pieces of paper or obst ructions in the feed

assembly? Make sure the media loaded in the paper tray meets

printer supplies specifications and t he med ia is loaded corr ec tly. Make sure the side and ba ck r e straints are located and seated pr operl y.

Does the media meet specif ications?

Use the Standal one F eed in g Operat ion Test to observe

paper feeding from the tray. Does the paper feed from the paper tray?

Using the Standalone Feedi ng Operatio n Test, observe

the registration motor (the registration motor is the motor at the top of the f eed assembly).

Does the motor turn? Does the pick motor, the lower motor in the feed unit

assembl y, turn? Check the registration motor cable to HCIT system

board cable connected to CN3 for correct installation. Is the cable connected correctly?

Remove any paper or obstructions.

Go to step 3 Inform the

Go to step 14 Go to step 4

Go to step 5 G o to step 6

Go to step 8 G o to step 7

Replace the follo wing FRUs in the order shown:

1.HCIT system board

2.Feed unit assembly.

Go to step 2

customer that media in the paper tray does not meet specifications.

Install the cable correctly.

2-46 Service Manual

Check the pick motor cable to HCIT system board cable connected to CN4 for correct in stallation.

Is the cable connected correctly?

Use the “HCIT system board LED error code table”

on page 2-84.

Does the LED flash 7 times? Make sure the registration home sens or cable is

installed correctly to the sensor and to CN6 on the system board.

Is the cable connected correctly?

Replace the follo wing FRUs in the order shown:

1.HCIT system board

2.Feed unit assembly.

Go to step 9 G o to step 11

Go to step 10 Install the cable

Install the cable correctly.

correctly

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Step Actions and questions Yes No

Is the registrat ion home sensor operati ng correctly? Repl ace the

Use the “HCIT system board LED error code table”

on page 2-84.

Does the LED flash 8 times? Make sure the pick home sensor cable is installed

correctly to the sensor and to CN6 on the system board.

Is the cable connected correctly? Is the registrat ion home sensor operati ng correctly? Repl ace the

Use the Standalone F eeding Operation Test to

determine where the paper jams. Use the “HCIT

system board LED error code table” on page 2-84

to help isolate problems in the feed unit assembly. Are you able to determine where the failure is

occurring?

Replace the follo wing FRUs in the order shown:

1.HCIT system board

2.Feed unit assembly.

Go to step 12 Go to step 14

Go to step 13 Install the cable

follo wing FRUs in the order shown:

1.HCIT system board

2.Feed unit assembly.

Repair or replace parts as necessary.

foll o wing FR U s i n the order shown:

1.Registration sensor

2.HCIT system board.

correctly.

Replace the foll o wing FR U s i n the order shown:

1.Registration sensor

2.HCIT system board.

Replace the fee d unit assembly.

250.xx paper jam service chec k

Unable to clea r th e message—mu l ti p u r p o se feeder loaded

Note: A 250 Paper Jam displays when using a multipurpose feeder.

Step Actions and questions Yes No

1 Make sure the media in the MPF meets specificat ions.

Does media meet specifi cations?

Does the media feed correctly from tray 1? Go to step 3 G o to“Tray 1

Is the Paper Type setting correct for media in t he M P F? Go to step 4 Correct the Paper

Check the media is loaded properly. The side restraint

should not be too tight. The leading edge of the media should be sitting on the friction buckler.

Is the media correctly loaded?

Go to step 2 Inform user that

the media in the MPF does not meet specifications.

service chec k” on page 2-115.

Type setting.

Go to step 5 Properly load the

media.

Diagnostic information 2-47

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Step Actions and questions Yes No

Open the MPF to the h oriz ontal posit ion, and chec k t he

paper path for obstructions. Is the paper path obstructed?

Raise the pick tir e off the media, and test the MPF.

Does the pick tire t urn? Open the lower jam access door, move the MPF

bracket assembly gear to th e lowest position and test the MPF.

Does the MPF bracket assembly rise and engage the gear?

Does media jam on the friction buckler? Replace the

Enter the Diagnostics Menu. Select INPUT TRAY

TESTS, Sensor T est, and MP Feeder. Manually

actuate the MPF sensor by moving the paper flag in the MPF.

Does the test pass? Make sure that the MPF sensor cable from the sys tem

board is correctly installed at J10 on the system board. Is the cable cor rectly installed?

Clear the obstruction.

Go to step 8 G o to step 7

Go to step 8 Replace the MPF

friction buckler. See “Friction

buckler and buckler hou sing removal” on page 4-40.

Replace the MPF assembly.

Go to step 11 Install the cable

Go to step 6

bracket assembly.

Go to step 9

Go to step 2

correctly.

Check the cable connection between the MPF sensor

cable and the sensor. Check that the sensor is snapped into the br acket.

Is the connection good between the two cables? Disconnect the sens or cable from J10 on the syst em

board. Measure the following voltages on J10, being careful

not to short any adjacent pins in the connector. All voltages are approximate values.

Connector pin Voltage J10-11 0 V dc J10-12 +5 V dc J10-13 +5 V dc J10-14 +5 V dc

Are the voltages correct? Check continuity of the sensor cabl e that is between

the system board and MPF assembly. Is there continuity?

Go to step 12 Install the cable

Go to step 13 Replace the

Replace the sensor assemb ly.

correctly.

system board. See “System

board re moval” on page 4-89.

Replace the sensor cable assembly.

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271.xx paper jam service chec k

Output bin

Note: Before proceeding with this service check, run the Output Bin x Sensor Test and check for the failing

sensor.

Sensor Tests: XNF Near Full (Upper part of sensor assembly)

F Full (Lower part of sensor assembly) P Pass Thru Sensor

Step Actions and questions Yes No

1 DC motor cable connection—Make sure the DC motor

connector is cor rectly installed at J4 on the out put expander option board.

Is the cable in stalled correctly? DC motor mechanical linkage assembly—Check the

resistance of the motor on the cable connector. Check the resistanc e between J4-1 and J4-2. The resi stance measures between 115 ohm s and 135 ohm s.

Is the resistance correct? DC motor mechanical linkage assembly—Check for

continuity between J4-1 and J4-2 and the case of the motor. It measures infinity.

Is there continuity between J4-1 or J4-2 and the case of the motor?

Note: If the motor is shorted from either J4-1 or J4-2 and the case of the motor, it may be necessary to replace the output expander control board.

Output expander board—Disconnect th e motor cable

from J4, and check the voltages at J4 on the board. Note: All voltages are approximate values:

J4—Motor cable (motor idle) J4-1 +24 V dc J4-2 +24 V dc J4-5 +5 V dc J4-6 +5 V dc

Go to step 2 Install the cable

Go to step 3 Replace the DC

Replace the DC motor mechanical linkage assembly.

correctly.

motor mechanical linkage assembly.

Go to step 4

Replace the output expander control board.

Warning: Be careful not to short to adjacent pins on the connector.

Are the voltages correct?

Diagnostic information 2-49

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272.xx paper jam service chec k

5-bin mailbox

Step Actions and questions Yes No

1 Bottom pass thru sensor f lag—Make sure the flag is

operating cor rectly and is not binding, broken, and there is no interference from the sensor cable.

Is there any problem found with the sensor flag? Bottom pass thru sensor—Make sure the sensor is

correctly con nected to J5 on the control board. Is the sensor connect ed correctly?

Bottom pass thru sensor v oltage check 1—Disconnect

the pass thru sensor cable and check the voltage at J5-3 on the board. The v oltage measures approximately +5 V dc.

Is the voltage correct? Bottom pass thru sensor voltage check 2—Check the

voltage at J5-2 on the board; the voltage measures approximately 0 V dc.

Is the voltage correct?

Fix or repl ace the flag.

Go to step 3 R eseat the cable.

Go to step 4 Replace the

Replace the sensor assemb ly.

5-bin mailbox POST incomplete

Step Actions and questions Yes No

1 Pass thru sensor flag—Check th e sensor flag for

correct opera ti on. Is the flag operating correctly?

Go to step 2 Repair or replace

Go to step 2

control board.

Replace the control board.

as necessary.

2-50 Service Manual

Pass thru sensor cable—Make sure the pass thru sensor cab le i s corr ectly conne cted t o J3 o n the cont rol board.

Is the cable connected correctly? Voltage chec k—Disconnect the pass thru sensor cable

from the control board and check the voltage on J3-3. The voltage measures approximately +5 V dc.

Is the voltage correct? Voltage check—Measure the voltage at J3-2. The

voltage measures approximately 0 V dc. Is the voltage correct?

Go to step 3 R eseat the cable.

Go to step 4 Replace the

Replace the control board.

control board.

Replace the sensor assemb ly.

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282.98 paper jam service chec k

282.98 Staple Jam—Check Stapler displays

Step Actions and questions Yes No

1 Staple cartridge holder—Check for jammed staples in

the staple cartridge holder. Are there any jammed staples?

Staple cartridge holder—Check the staple cartridge

holder for any signs of damage. Did you find any damage to the staple cartridge

holder?

900.xx RIP Software Error service check

The 900 error may indicate a communication problem (bad cable, network connection, and so on), software issue, or a hardware problem with the cont roller board/INA. The communication and software aspects should be checked first. Determine if the prob lem is constant or intermittent .

Constant 900.xx errors

Step Actions and questions Yes No

Replace the old strip of staples with a new strip. Perform the Finisher Feed Test from the Diagnostics Menu. See

“Finisher Feed Tes t” on page 3-23.

Replace the staple cartridge holder.

Go to step 2

Replace the stapler option.

1 Reset the ITU el ectric al di sconnect . Turn the printer off.

Check the ITU release lever for correct operation. The ITU release lever is the blac k lever lo cated on the left upper side frame above the ITU opening and can be seen by opening and lowering the MPF assembly. When locked, the lever should be at the 6 o'clock position. When unlocked, it shoul d be in a 3 o'clock position. Undue pressure is not required to operate the lever.

Turn the prin ter off, insert the ITU, mov e the l e v er to the 6 o'clock position, and turn the printer back on.

Does the 900 error display?

Go to step 2 Problem resolved

Diagnostic information 2-51

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Step Actions and questions Yes No

Disconnect the printer from any external connections.

Turn the power off and remove any parallel, USB, or network connections. Turn the printer on.

Does the 900 error display? Run the internal test pages. Print one of the internal

test pages from the Utilities Menu. If the printer works correctly while disconnected, have the user or their network administrator verify that there are no jobs in the queue which may be causing the error.

Does the error remain? Turn the printer off. Remove any options from the

system board, such as additional memory, hard disk drives, or option cards.

Does the 900 error persist when the printer is turned on?

Restore factory defaults from the Configuration Menu.

Warning: When factory defaults or restored, all menu

items are returned to the f actory default values excep t:

• Display Language.

• All settings in the Parallel Menu, Serial Menu, Network Menu, and USB Menu.

All downloaded resources (fonts, macros, and symbol sets) in printer m emory (RAM) ar e delet ed. ( Reso urces residing in flash memory or on the hard disk are unaffected.)

Go to step 4 G o to step 3

Inform the user or network administrator of the issue.

Go to step 5 Determine which

Record the secondary error codes. With the 900 Service RIP Error displayed, press Menu ( ) and together Record the complete list by scrolling with the arrows ( or

). The code may be a very long string of characters and numbers, but is needed for analysis.

Contact you r ne xt level of support.

Go to step 4

option is causing the 900 error.

Problem resolved

2-52 Service Manual

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Intermittent 900.xx Service RIP Error codes

It is important to determine under what circumstances the error occurs. Capturing the fol lowing inf ormati on aids in categorizing the nature of the intermittent error.

1. Crash codes—With the 900 Service RIP Error displayed, press Menu ( ) and together. Record the

complete secondary codes by scrolling wit h the ar rows ( or ). The code ma y be a very long string of characters and numbers, but it is needed to analyze the problem.

2. Print hist ory—Print the printer history by entering Diagnostics Mode and selecting Pri nt History in the

Development menu.

3. Code le vel—Obtain the code level f or the RIP, network, and engine . All of these can be found on Print

Menus page from the Utilities menu.

4. Type of connection being use d to print— Record the type of connection. For example, direct USB or

parallel, or network peer to peer, Ethernet, Token-Ring, or so on.

5. Software application—Does one particular application or print job sent to the printer produce this error?

6. Driver—What driver or driver level.

With this information in hand, contact you next le vel of support.

900.xx Er ror Co d e displayed wh en th e machine is connected to a network while still in Setup Required mode

Step Actions and questions Yes No

1 Perform the foll owing steps:

1.Power the printer off.

2.Disconnect the printer from the network.

3.Power the printer on, and complete the setup process.

4.When setup is complete, power off the printer and reconnect to the network.

Is the same 900 Service Error displayed?

Contact you r ne xt level of support.

Problem resolved

Diagnostic information 2-53

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925.02 error code service check

Fuser fan (main fan)

Step Actions and questions Yes No

1 Turn the power off, manuall y spin the fan, and chec k

that it rotates freely. Does the fan rot ate freely?

Check the fuser fan cable connec ti on to the system

board JM1 for correct installat ion. Is the cable in stalled correctly?

Disconnect the fuser fan from JM1 on the system

board, and check the voltages on JM1.

Pin Fan on Fan off Fan disc onnected

JM1-1 +1.6 V dc +3.3 V dc +3.3 V dc +3.3 V dc JM1-20 V0 V0 V 0 V JM1-3 +1.9 V dc 0 V dc 0 V +2 V dc JM1-4 +24 V dc +24 V dc +24 V dc +24 V dc JM1-5 Ground

Are the voltages correct?

926.01 error code service check

VTB fan

Fan switch on

Fan disconnected Fan switch off

Go to step 2 R eplace the fuser

fan. See “Fuser

fan removal” on page 4-46.

Go to step 3 Install the cable

correctly.

Replace the fuser fan. See “Fuser

fan removal” on page 4-46.

Replace the system board. See “System

board re moval” on page 4-89.

Step Actions and questions Yes No

1 Turn the power off, manuall y spin the fan, and chec k

Pin Fan on Fan off Fan

JY1-1 +1.6V dc +3.3 V dc +3.3 V dc +3.3 V dc JY1-20 V0 V0 V 0 V JY1-3 +3.1 V dc 0 V dc 0 V +2 V dc JY1-4 +24 V dc +24 V dc +24 V dc +24 V dc

2-54 Service Manual

that it rotates freely. Does the fan rot ate freely?

Check the VTB fan cable connectio n to the system board JY1 for cor rect installation.

Is the cable in stalled correctly? Disconnect the VTB f an f rom JY1 on t he sy stem boar d,

and check the voltages on JY1.

disconnected fan switch on

Fan disconnected fan switch off

Are the voltages correct?

Go to step 2 Replace the VTB

fan. See

“Vacuum transport belt (VTB) fan removal” on page 4-97.

Go to step 3 Install the cable

correctly.

Replace the VTB fan. See

“Vacuum transport belt (VTB) fan

Replace the system board. See “System

board re moval” on page 4-89.

removal” on page 4-97.

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927.03 error code service check

RIP fan

Step Actions and questions Yes No

1 Turn the power off, manuall y spin the fan, and chec k

that it rotates freely. Does the fan rotate freely?

Check the RIP fan cable connection to the system

board JR1 for cor rect installation. Is the cable in stalled correctly?

Disconnect th e RIP fan from JR1 on the system board,

and check the voltages on JR1.

Pin Fan on Fan off Fan

JR1-1 +1.6 V dc +3.3 V dc +3.3 V dc +3.3 V dc JR1-20 V0 V0 V 0 V JR1-3 +1.9 V dc 0 V dc 0 V +2 V dc JR1-4 +24 V dc +24 V dc +24 V dc +24 V dc

Are the voltages correct?

930.09 error code service check

LVPS

This problem with the fuser circuits is usually the zero crossover signal from the LVPS not working correctly.

disconnected Fan switch on

Fan disconnected Fan switch off

Go to step 2 Replace the RIP

Go to step 3 Install the cable

Replace the RIP fan. See “RIP

fan removal” on page 4-86.

fan. See “RIP

fan removal” on page 4-86.

correctly.

Replace the system board. See “System

board re moval” on page 4-89.

Step Actions and questions Yes No

1 LVPS cable—check the LVPS cable to J17 on the

system board to make sure it is seated correctly. Go to

“System board” on page 5-8.

Is the cable seat ed correctly? Voltage checks —Di sconnect JCVR1 from the system

board assembly. Go to “System board” on page 5-8. Check the voltage at J17, on the cable. It measures approximately +3.7 V dc.

Is the voltage correct?

Go to step 2 Install the cable

correctly.

Go to step 3 Replace the

foll o wing FR U s i n order:

1.LVPS assembly. See “LVPS

assembly removal” on page 4-53.

2.System board. See

“System board removal” on page 4-89.

Diagnostic information 2-55

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5061

Step Actions and questions Yes No

Is 930 error still displayed? Replace t he

940.xx error code service check

• 940.02—cyan toner metering cycle (TMC) pr oblem

• 940.05—cy an toner metering timeout problem

The TMC is where the code and electronics in the printer sense an addition of toner in the cartridge developing area. If the printer is expecting a toner addition cycle but one is not detected, a 94x.xx TMC Error is displayed.

Replacement of the cartridge may fix the problem temporarily if the problem is with the printer. Only replace the cartridge if there are no problem s with the printer or if the cartridge is known to be defective.

Note: Before proceedin g wit h thi s servi ce check, observe the error log for repetit ive occurrences of a 94x.xx ser vice error.

Step Actions and questions Yes No

1 Check the ton er metering cam (A) on the rear of the

cyan cartridge.

Note: In some cartridges, the toner metering cam is black.

LVPS assembly.

Problem resolved

See “LVPS

assembly removal” on page 4-53.

Go to step 2 If the toner

metering cam is not present, check the printer to make s u re it is not inside.

Replace the damaged cartridge.

2-56 Service Manual

Is the cam present on the cartridge?

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5061

Step Actions and questions Yes No

Check the TMC pin (B) in the cyan cartridge contact

assembly to make sure it moves freely .

Does the pin move fr eely? Go to the Base Sensor Test. See “BASE SENSOR

TEST” on page 3-24, and check the cyan TMC

sensor. When you press the TMC pin in the cyan cartridge contact assembly, make sure it actuates the TMC switch on the developer HVPS . When the TMC pin is pressed in, you hear a click when the switch actuates. Check for mechanical interference between the contact block and the developer HVPS.

Note: You may need to turn the printer off to hear the click.

Does the cyan TMC swit ch on the developer HVPS board actuate properly when the TMC pin is pressed?

Go to step 3 Replace the

Replace the cartridge.

cartridge contact assembly. See

“Cartridge contact assembly removal” on page 4-35.

Go to step 4

Check the de v elop er HVPS board to mak e sur e it is n ot

cracked or broken. Is the developer HVPS cracked or broken?

Check the mount ing of the de v elo per HVPS . Mak e sur e

the screws that mount the power supply are properly tightened down and the board is positioned and mounted correctl y.

Is the developer HVPS mounted correctly?

Make sure the developer HVPS cable is correctly

installed on the developer board assembly. Is the cable cor rectly installed?

Make sure the developer HVPS cable is correctly

installed at J6 on the system board. Is the cable pro perl y installed?

Check the voltage at connector J6-11 on the system

board while pressing the cyan TMC pin in the cartridge contact assemb ly.

Does the voltage change when the pin is pressed?

Go to step 6 G o to step 5

Replace the dev elo per HVPS board. See

“Developer HVPS board removal” on page 4-39.

Go to step 7 Correctly connect

Go to step 8 Correctly connect

Replace the system board. See “System

board re moval” on page 4-89.

If the board is incorrectly installed, install it correctly. Make sure all the mounting screws are tightened down. Recheck the pri n te r to se e if a 940 Error is still displayed.

the ca ble.

Go to step 9

Diagnostic information 2-57

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5061

Step Actions and questions Yes No

Check the voltage at connector J6-11 when t he cyan

TMC switch is pres sed. Does the voltag e mea sure approximately +3.3 V dc?

Check the developer HVPS to system board cable for

damage, broken connections, or wire and shorts between adjacent pins.

Are there any signs of damage to the cable?

Disconnect the de veloper HVPS cable from connector

J6 on the system board. Measure the voltage on connector J6-11 on t he system board.

Does the voltag e mea sure approximatel y 0 V dc?

941.xx error code service check

• 941.03—magenta toner metering cycle (TMC) prob lem

• 941.05—magenta toner metering cycle timeou t problem

Go to step 10 Go to step 11

Replace the cable.

Replace the system board. See “System

board re moval” on page 4-89.

Replace the Develop er HVPS board. See

“Developer HVPS board removal” on page 4-39.

Replace the dev elo per HVPS and dev eloper HVPS to system board cable.

Note: Before proceedin g wit h thi s servi ce check, observe the error log for repetit ive occurrences of a 94x ser vice error.

Step Actions and questions Yes No

1 Check the ton er metering cam (A) on the rear of the

magenta cartridge.

Note: In some cartridges, the toner metering cam is black.

Go to step 2 If the toner

metering cam is not present, check the printer to make s u re it is not inside.

Replace the damaged cartridge.

Is the cam present on the cartridge?

2-58 Service Manual

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Step Actions and questions Yes No

Check the TMC pin (B) in the magenta cartridge

contact assemb ly to make sure i t moves freely.

Does the pin move fr eely? Go to the “BASE SENSOR TEST” on page 3-24, and

check the magenta TM C sensor. When you press the TMC pin in the magenta cartridge contact assembly, make sure it act uates t he TMC s witch on the de v eloper HVPS. When the TMC pin is pressed in, you hear a click when the switch actuates. Check for mech anical interf erence between the contact block and the developer HVPS.

Note: You may need to turn the printer off to hear the click.

Does the magenta TM C swi tch on t he de v elo per HVP S board actuate properly when the TMC pin is pressed?

Go to step 3 Replace the

Replace the cartridge.

cartridge contact assembly. See

“Cartridge contact assembly removal” on page 4-35.

Go to step 4

Check the de v elop er HVPS board to mak e sur e it is n ot

cracked or broken. Is the developer HVPS cracked or broken?

Check the mount ing of the de v elo per HVPS . Mak e sur e

the screws that mount the power supply are properly tightened down and the board is positioned and mounted correctl y.

Is the developer HVPS mounted correctly?

Make sure the developer HVPS cable is correctly

installed on the developer board assembly. Is the cable cor rectly installed?

Make sure the developer HVPS cable is correctly

installed at J6 on the system board. Is the cable pro perl y installed?

Check the voltage at connector J6-6 on the system

board while pressing the magenta TMC pin in the cartridge contact assembly.

Does the voltage change when the pin is pressed?

Go to step 6 G o to step 5

Replace the dev eloper HPVS . See “Developer

HVPS board removal” on page 4-39.

Go to step 7 Correctly connect

Go to step 8 Correctly connect

Replace the system board. See “System

board re moval” on page 4-89.

If the board is incorrectly installed, install it correctly. Make sure all the mounting screws are tightened down. Recheck the pri n te r to se e if a 941 Error is still displayed.

the ca ble.

Go to step 9

Diagnostic information 2-59