Page 1
CS310, CS410, CS510, and C21312
Machine Type 5027-2x0, -4x0, -6x0, -639
Service Manual
• Start diagnostics
• Maintenance
• Safety and notices
• Trademarks
• Index
June 10, 2014 www.lexmark.com
P/N 12G3220
Page 2
Product information
Product name:
Lexmark CSx10 Series
Machine type:
5027
Model(s):
210, 230, 410, 430, 610, 630
5027
Edition notice
June 10, 2014
The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL,
INC., PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED
TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of
express or implied warranties in certain transactions; therefore, this statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these
changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any
time.
References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all
countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product,
program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual
property right may be used instead. Evaluation and verification of operation in conjunction with other products, programs, or services,
except those expressly designated by the manufacturer, are the user’s responsibility.
Trademarks
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other
countries.
PrintCryption is a trademark of Lexmark International, Inc.
Mac and the Mac logo are trademarks of Apple Inc., registered in the U.S. and other countries.
PCL® is a registered trademark of the Hewlett-Packard Company. PCL is Hewlett-Packard Company’s designation of a set of printer commands
(language) and functions included in its printer products. This printer is intended to be compatible with the PCL language. This means the
printer recognizes PCL commands used in various application programs, and that the printer emulates the functions corresponding to the
commands.
All other trademarks are the property of their respective owners.
© 2012 Lexmark International, Inc.
All rights reserved.
P/N 12G3220
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Table of contents
Product information.....................................................................................2
Edition notice...............................................................................................2
Notices and safety information..................................................................11
Laser notices............................................................................................................................................11
Safety information...................................................................................................................................14
Preface.......................................................................................................19
Service manual conventions....................................................................................................................19
Change history.........................................................................................................................................19
General information...................................................................................23
Media guidelines.....................................................................................................................................23
Paper guidelines ...............................................................................................................................................24
Supported paper sizes, types, and weights.............................................................................................26
Supported paper sizes ...................................................................................................................................... 26
Supported paper types and weights ................................................................................................................. 28
Using recycled paper and other office papers........................................................................................29
Data security notice.................................................................................................................................30
Tools required for service........................................................................................................................30
Diagnostic information...............................................................................33
Troubleshooting overview.......................................................................................................................33
Performing the initial troubleshooting check ...................................................................................................33
Power‑on Reset (POR) sequence ...................................................................................................................... 34
Using Safe Mode ...............................................................................................................................................34
Fixing print quality issues........................................................................................................................35
Initial print quality check .................................................................................................................................. 36
Toner smear check............................................................................................................................................36
Background or toner fog check.........................................................................................................................37
Blank pages check ............................................................................................................................................. 39
Blurred or fuzzy print check .............................................................................................................................. 40
Half‑color page check .......................................................................................................................................40
Horizontal banding check .................................................................................................................................41
Horizontal line check ........................................................................................................................................ 41
Missing image at edge check ............................................................................................................................ 41
Toner specks check ...........................................................................................................................................42
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Narrow vertical line check ................................................................................................................................ 42
Random marks check ........................................................................................................................................ 42
Residual image check........................................................................................................................................43
Solid color pages check .....................................................................................................................................43
Vertical banding check ......................................................................................................................................44
Light print on solids check ................................................................................................................................ 44
Color problems check ....................................................................................................................................... 44
Paper jams...............................................................................................................................................45
Avoiding jams....................................................................................................................................................45
Understanding jam messages and locations.....................................................................................................47
200 paper jams .................................................................................................................................................48
202 paper jams .................................................................................................................................................52
23y paper jams ................................................................................................................................................. 57
24y paper jams ................................................................................................................................................. 64
25y paper jams ................................................................................................................................................. 68
Understanding printer messages............................................................................................................71
Understanding the printer messages ............................................................................................................... 72
Printer hardware errors..........................................................................................................................80
110 errors ......................................................................................................................................................... 82
121 errors ......................................................................................................................................................... 84
126 errors ......................................................................................................................................................... 90
133 errors ......................................................................................................................................................... 90
141 errors ......................................................................................................................................................... 93
147 errors ......................................................................................................................................................... 95
171 errors ......................................................................................................................................................... 97
Steps before starting the 9yy service checks ....................................................................................................98
900 errors ....................................................................................................................................................... 100
91y errors..................................................................................................................... ................................... 106
938 errors ....................................................................................................................................................... 106
95y errors..................................................................................................................... ................................... 107
96y errors..................................................................................................................... ................................... 110
97y errors..................................................................................................................... ................................... 111
982 errors ....................................................................................................................................................... 112
990 errors ....................................................................................................................................................... 112
Base printer symptoms ................................................................................................................................... 114
Bin‑full/narrow media sensor service check................................................................................................... 115
Toner meter cycle (TMC) card service check .................................................................................................. 117
Dead printer service check ............................................................................................................................. 117
Front door sensor or switches service check .................................................................................................. 119
Operator panel (display is dim and unchanging) service check ...................................................................... 123
Operator panel (displays all diamonds, no beeps, or five beeps) service check ............................................. 127
Operator panel (display blank) service check ................................................................................................. 131
Operator panel (one or more operator panel buttons fail) service check......................................................135
Operator panel USB cable service check ........................................................................................................136
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USB service check ........................................................................................................................................... 137
Network service check .................................................................................................................................... 137
Input option hardware errors...............................................................................................................139
550‑sheet and 650‑sheet trays input option symptoms ................................................................................ 140
Tray (x) sensor service check .......................................................................................................................... 140
Option and media size not recognized service check ..................................................................................... 142
Double feed and printout skewed service check ............................................................................................144
Failed to load/feed from multipurpose feeder service check.........................................................................147
Failed to feed from option tray and leading edge damaged service check .................................................... 149
Tray 2 or tray 3 not detected service check.................................................................................................... 152
Tray 2 or tray 3 missing service check ............................................................................................................ 154
Tray 2 or tray 3 empty service check .............................................................................................................. 157
Incompatible tray 3 service check .................................................................................................................. 159
Service menus..........................................................................................163
Understanding the printer control panel..............................................................................................163
Using the printer control panel.......................................................................................................................163
Understanding the colors of the indicator light and Sleep button lights........................................................ 165
Diagnostics menu..................................................................................................................................166
Entering diagnostics mode ............................................................................................................................. 166
REGISTRATION ................................................................................................................................................ 167
Skew................................................................................................................................................................ 168
Quick Test ....................................................................................................................................................... 168
Alignment Menu .............................................................................................................................................169
MISC TESTS ..................................................................................................................................................... 170
PRINT TESTS .................................................................................................................................................... 171
Feed Tests ....................................................................................................................................................... 171
Print quality test pages ................................................................................................................................... 172
HARDWARE TESTS .......................................................................................................................................... 172
DUPLEX TESTS ................................................................................................................................................. 173
INPUT TRAY TESTS .......................................................................................................................................... 176
BASE SENSOR TEST.......................................................................................................................................... 176
DEVICE TESTS .................................................................................................................................................. 177
PRINTER SETUP ...............................................................................................................................................178
EP SETUP ......................................................................................................................................................... 181
TPS Setup: Right or Left ..................................................................................................................................181
TPS Setup: Reset Color Cal .............................................................................................................................. 182
TPS Setup: Cal Ref Adj ..................................................................................................................................... 182
REPORTS ......................................................................................................................................................... 182
EVENT LOG...................................................................................................................................................... 183
Exit Diagnostics ............................................................................................................... ................................184
Configuration menu..............................................................................................................................184
Entering configuration mode.......................................................................................................................... 184
Print Quality Pages..........................................................................................................................................185
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Fuser Cleaning Process ................................................................................................................................... 185
Reports ........................................................................................................................ ................................... 185
Color Trapping ................................................................................................................................................ 186
Tray Insert Msg ............................................................................................................................................... 186
Panel Menus ................................................................................................................................................... 186
PPDS Emulation .............................................................................................................................................. 186
Download emuls .............................................................................................................................................186
Safe Mode....................................................................................................................................................... 186
Demo Mode .................................................................................................................................................... 187
Energy Conserve ............................................................................................................................................. 187
Auto Color Adjustment .......................................................................................................... .........................187
Auto Align Adj ................................................................................................................................................. 187
Color Alignment .............................................................................................................................................. 188
Paper Prompts ................................................................................................................................................ 188
Envelope Prompts........................................................................................................................................... 188
Action for prompts.......................................................................................................................................... 189
Jobs on Disk .................................................................................................................................................... 189
Disk Encryption ............................................................................................................................................... 189
Font Sharpening.............................................................................................................................................. 190
Require Standby.............................................................................................................................................. 190
UI Automation ................................................................................................................................................ 190
LES Applications .............................................................................................................................................. 190
Key Repeat Initial Delay .................................................................................................................................. 190
Key Repeat Rate.............................................................................................................................................. 191
Clear Supply Usage History .............................................................................................................................191
Clear Custom Status........................................................................................................................................191
USB Speed....................................................................................................................................................... 191
Automatically Display Error Screens ...............................................................................................................192
USB PnP .......................................................................................................................................................... 192
Restore Factory Defaults ................................................................................................................................ 192
ADF Edge Erase ............................................................................................................................................... 193
Size sensing ..................................................................................................................................................... 193
Factory Defaults .............................................................................................................................................. 194
Exit Config ....................................................................................................................................................... 194
Entering invalid engine mode................................................................................................................194
Entering recovery mode........................................................................................................................195
Accessing the Network SE menu...........................................................................................................195
Accessing the service engineer (SE) menu............................................................................................195
Repair information...................................................................................197
Removal precautions.............................................................................................................................197
Data security notice ........................................................................................................................................197
Handling ESD‑sensitive parts ..........................................................................................................................198
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Controller board/control panel replacement .................................................................................................198
Restoring the printer configuration after replacing the controller board ...................................................... 199
Restoring solutions, licenses, and configuration settings ...............................................................................202
Updating the printer firmware ......................................................................................................................203
Backing up eSF solutions and settings ............................................................................................................204
Ribbon cable connectors ................................................................................................................................205
Zero Insertion Force (ZIF) connectors ........................................................................................................ 205
Horizontal top contact connector .............................................................................................................. 206
Horizontal bottom contact connector........................................................................................................209
Vertical mount contact connector ............................................................................................................. 212
Horizontal sliding contact connector ......................................................................................................... 215
Low Insertion Force (LIF) connector ...........................................................................................................218
Removal procedures.............................................................................................................................219
Left side removals.................................................................................................................................219
Left cover assembly removal .......................................................................................................................... 219
Drive unit motor removal ............................................................................................................................... 220
EP drive assembly removal ............................................................................................................................. 221
Low‑voltage power supply (LVPS) assembly removal ..................................................................................... 226
Fuser exit sensor removal............................................................................................................................... 228
Bin‑full/narrow media sensor flag removal ....................................................................................................231
Speaker removal .............................................................................................................................................232
Right side removals...............................................................................................................................232
Right cover assembly removal ........................................................................................................................ 232
Toner supply door removal............................................................................................................................. 233
Fuser drive motor assembly removal ............................................................................................................. 234
Toner meter cycle (TMC) card removal .......................................................................................................... 234
Toner density sensor (TDS) (left or right sensor) removal..............................................................................236
Developer unit removal .................................................................................................................................. 238
High‑voltage power supply (HVPS) removal ...................................................................................................239
Image transfer unit (ITU) removal .................................................................................................................. 243
Imaging unit (IU) removal ............................................................................................................................... 246
Toner cartridge contacts removal...................................................................................................................248
Waste toner bottle removal ...........................................................................................................................250
Waste toner bottle contact block removal .....................................................................................................251
Front removals......................................................................................................................................252
Front cover assembly removal........................................................................................................................ 252
Operator panel bezel removal ........................................................................................................................ 254
Operator panel removal (for CS310 models only) .......................................................................................... 254
Operator panel removal (for CS410 models only) .......................................................................................... 256
Operator panel removal (for CS510 models only) .......................................................................................... 259
Operator panel logo plate removal ................................................................................................................ 262
USB port connector removal ..........................................................................................................................263
Duplex reference edge removal .....................................................................................................................265
Fuser assembly removal .................................................................................................................................267
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Exit deflector removal..................................................................................................................................... 269
Right output bin deflector removal ................................................................................................................271
Bottom removals...................................................................................................................................271
Pick tires removal ...........................................................................................................................................271
Lower left frame removal ............................................................................................................................... 273
Lower right frame removal ............................................................................................................................. 280
Duplex sensor removal ................................................................................................................................... 284
Tray present sensor removal .......................................................................................................................... 285
Paper pick motor drive assembly standard tray removal ...............................................................................287
Rear side removals................................................................................................................................290
Rear cover removal.........................................................................................................................................290
Controller board removal ............................................................................................................................... 291
Top side removals.................................................................................................................................294
Top cover assembly removal .......................................................................................................................... 294
Bin‑full/narrow media sensor removal........................................................................................................... 297
Printhead removal .......................................................................................................................................... 299
Options removals..................................................................................................................................300
650‑sheet duo drawer tray assembly removal ............................................................................................... 300
650‑sheet duo drawer assembly removal ...................................................................................................... 301
Dust cover removal......................................................................................................................................... 302
Pick tire removal .............................................................................................................................................303
Component locations...............................................................................305
Controller board connectors.................................................................................................................305
Maintenance............................................................................................313
Inspection guide....................................................................................................................................313
Scheduled maintenance........................................................................................................................314
Maintenance kits ............................................................................................................................................ 314
Preventive maintenance.......................................................................................................................314
Device‑specific preventive maintenance ........................................................................................................ 314
Lubrication specification.......................................................................................................................315
Cleaning the printer..............................................................................................................................315
Cleaning the exterior of the printer................................................................................................................ 315
Cleaning the printhead lenses ........................................................................................................................ 315
Parts catalog............................................................................................316
Legend...................................................................................................................................................316
Assembly 1: Covers................................................................................................................................317
Assembly 2: Frames...............................................................................................................................321
Assembly 3: Electronics.........................................................................................................................323
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Assembly 4: Cables and sensors............................................................................................................327
Assembly 5: Media drawers and trays..................................................................................................329
Assembly 6: Options and miscellaneous...............................................................................................331
Appendix A: Printer specifications............................................................333
Power specifications..............................................................................................................................333
Electrical specifications.........................................................................................................................333
Operating clearances.............................................................................................................................334
Acoustics...............................................................................................................................................336
Environment..........................................................................................................................................336
Processor...............................................................................................................................................337
Appendix B: Options and features............................................................339
Available internal options.....................................................................................................................339
Media handling options.........................................................................................................................339
Option configurations...........................................................................................................................340
Appendix C: Theory of operation..............................................................343
Paper path and transport components.................................................................................................343
Paper path information ..................................................................................................................................343
Transport components ...................................................................................................................................344
Bubble sensors................................................................................................................................................ 344
Duplexing ........................................................................................................................................................345
Print engine theory................................................................................................................................346
Electrophotographic process (EP process)...................................................................................................... 346
Electrophotographic process basics ............................................................................................. .................. 346
Color theory..........................................................................................................................................350
Color theory ................................................................................................................... ................................. 350
Appendix D: Acronyms.............................................................................355
Acronyms...............................................................................................................................................355
Appendix E: Screw and retainer identification table.................................357
Screw and retainer identification table.................................................................................................357
Index........................................................................................................360
Part number index...................................................................................367
Part name index.......................................................................................371
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Notices and safety information
Laser notices
Laser notice
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR, Chapter I, Subchapter J for Class I
(1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser that is
nominally a 7 milliwatt gallium arsenide laser operating in the wavelength of 655-675 nanometers. The laser system
and printer are designed so there is never any human access to laser radiation above a Class I level during normal
operation, user maintenance, or prescribed service condition.
Laser-Hinweis
Der Drucker wurde in den USA zertifiziert und entspricht den DHHS-Vorschriften 21 CFR, Kapitel I, Unterkapitel J für
Laserprodukte der Klasse I (1); andernorts ist er als Laserprodukt der Klasse I zertifiziert, das den IEC 60825-1Anforderungen entspricht.
Laserprodukte der Klasse I werden nicht als gefährlich eingestuft. Der Drucker enthält im Inneren einen Laser der
Klasse IIIb (3b), und zwar einen 7-Milliwatt-Gallium-Arsenid-Laser, der im Wellenlängenbereich von 655 bis 675
Nanometern arbeitet. Das Lasersystem und der Drucker sind so konstruiert, dass unter normalen Betriebsbedingungen,
bei der Wartung durch den Benutzer oder bei den vorgeschriebenen Wartungsbedingungen Menschen keiner
Laserstrahlung ausgesetzt sind, die die Werte für Klasse I überschreitet.
Avis relatif à l'utilisation du laser
L'imprimante est certifiée conforme aux exigences de la réglementation des Etats-Unis relative aux produits laser (DHHS
21 CFR, Chapter I, Subchapter J for Class I (1)). Pour les autres pays, elle est certifiée conforme aux exigences des normes
IEC 60825-1 relatives aux produits laser de classe I.
Les produits laser de Classe I ne sont pas considérés comme dangereux. L'imprimante contient un laser de classe IIIb
(3b), laser arséniure de gallium 7 milliwatts opérant sur une longueur d'onde de l'ordre de 655 à 675 nanomètres. Le
système laser ainsi que l'imprimante ont été conçus de manière à ce que personne ne soit exposé à des rayonnements
laser dépassant le niveau de classe I dans le cadre d'un fonctionnement normal, de l'entretien par l'utilisateur ou de la
maintenance.
Avvertenze sui prodotti laser
La stampante è certificata negli Stati Uniti come stampante conforme ai requisiti DHHS 21 CFR, Capitolo I, Sottocapitolo
J per i prodotti laser di Classe I (1), mentre in altri paesi è certificata come prodotto laser di Classe I conforme ai requisiti
IEC 60825-1.
I prodotti laser di Classe I non sono considerati pericolosi. La stampante contiene un laser di Classe IIIb (3b), che è
nominalmente un laser ad arseniuro di gallio a 7 milliwatt funzionante a una lunghezza d'onda di 655-675 nanometri.
Il sistema laser e la stampante sono stati progettati in modo da impedire l'esposizione a radiazioni laser superiori al
livello previsto dalla Classe I durante le normali operazioni di stampa, manutenzione o assistenza.
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Aviso de láser
Esta impresora se ha certificado en EE. UU. de conformidad con los requisitos de DHHS 21 CFR, capítulo I, subcapítulo
J, para los productos láser de Clase I (1), y en otros países está certificada como un producto láser de Clase I de acuerdo
con los requisitos de IEC 60825-1.
Los productos láser de Clase I no se consideran peligrosos. La impresora contiene un láser interno de Clase IIIb (3b) que
nominalmente es un láser de arseniuro de galio de 7 milivatios que funciona en una longitud de onda de 655-675
nanómetros. El sistema láser y la impresora se han diseñado para que ningún individuo acceda nunca a las radiaciones
láser por encima del nivel de Clase I durante su uso normal, ni en tareas de mantenimiento o intervenciones de servicio
técnico prescritas.
Aviso sobre laser
A impressora foi certificada nos EUA por estar em conformidade com os requisitos do DHHS 21 CFR, capítulo I,
subcapítulo J, para produtos a laser de Classe I (1) e, nos demais países, foi certificada como produto a laser de Classe
I em conformidade com os requisitos da IEC 60825-1.
Os produtos a laser de Classe I não são considerados perigosos. A impressora contém, internamente, um laser de Classe
IIIb (3b) que é um laser de arsenieto de gálio de 7 miliwatts operando no comprimento de onda de 655-675 nanômetros.
O sistema do laser e a impressora foram projetados para que jamais haja acesso humano à radiação do laser acima do
nível da Classe I durante a operação normal ou a manutenção pelo usuário ou sob as condições de manutenção
prescritas.
Laserinformatie
Deze printer is in de Verenigde Staten gecertificeerd als een product dat voldoet aan de vereisten van DHHS 21 CFR,
hoofdstuk 1, paragraaf J voor laserproducten van klasse I (1). Elders is de printer gecertificeerd als een laserproduct
van klasse I dat voldoet aan de vereisten van IEC 60825-1.
Laserproducten van klasse I worden geacht geen gevaar op te leveren. De printer bevat intern een laser van klasse IIIb
(3b), een galliumarsenide laser met een nominaal vermogen van 7 milliwatt en een golflengtebereik van 655-675
nanometer. Het lasersysteem en de printer zijn zodanig ontworpen dat gebruikers nooit blootstaan aan laserstraling
die hoger is dan het toegestane niveau voor klasse I-apparaten, tijdens normaal gebruik, onderhoudswerkzaamheden
door de gebruiker of voorgeschreven servicewerkzaamheden.
Lasererklæring
Denne printer er certificeret i USA i henhold til kravene i DHHS 21 CFR, afsnit I, underafsnit J, for Klasse I-laserprodukter
(1) og certificeret andetsteds som et Klasse I-laserprodukt i henhold til kravene i IEC 60825-1.
Klasse I-laserprodukter anses ikke for at være farlige. Printeren indeholder internt en klasse IIIb (3b)-laser, der nominelt
er en 7 milliwatt galliumarsenid-laser, som fungerer i bølgelængdeområdet 655-675 nanometer. Lasersystemet og
printeren er udviklet på en sådan måde, at der ikke er en direkte laserstråling, der overskrider Klasse I-niveauet under
normal brug, brugers vedligeholdelse eller de foreskrevne servicebetingelser.
Laserilmoitus
Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR, Chapter I, Subchapter J -standardin mukaiseksi luokan I (1) lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.
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Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 7
mW:n galliumarsenidilaser ja toimii 655–675 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat
rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön, ylläpidon tai
huollon aikana.
Lasermeddelande
Skrivaren är certifierad i USA enligt kraven i DHHS 21 CFR, avsnitt I, underavsnitt J för laserprodukter av klass I (1) och
i andra länder är den certifierad som en laserprodukt av klass I som uppfyller kraven i IEC 60825-1.
Laserprodukter av klass I anses inte vara skadliga. Skrivaren innehåller en klass IIIb (3b)-laser, vilket är en 7 mW
galliumarseniklaser som arbetar inom en våglängd på 655–675 nm. Lasersystemet och skrivaren är utformade så att
människor aldrig utsätts för laserstrålning över klass I-nivå under normala förhållanden vid användning, underhåll eller
service.
Lasermerknad
Skriveren er sertifisert i USA for samsvar med kravene i DHHS 21 CFR, kapittel I, underkapittel J for laserprodukter av
klasse I (1), og er andre steder sertifisert som et laserprodukt av klasse I som samsvarer med kravene i IEC 60825-1.
Laserprodukter av klasse I anses ikke som helseskadelige. Skriveren inneholder en intern laser av klasse IIIb (3b) som
nominelt er en 7 milliwatt galliumarsenid-laser, og som opererer i bølgelengder på 655-675 nanometer. Lasersystemet
og skriveren er utformet slik at mennesker ikke utsettes for laserstråling utover nivået i klasse I under normal drift,
vedlikehold eller foreskrevet service.
Avís sobre el làser
Als EUA, la impressora està certificada de conformitat amb els requisits del capítol I, apartat J del CFR 21 del Departament
de Salut i Serveis Humans per a productes làser de classe I (1) i a la resta de països està certificada com a producte làser
de classe I d'acord amb els requisits de la norma IEC 60825-1.
Els productes làser de classe I no es consideren perillosos. A l'interior de la impressora hi ha un làser de classe IIIb (3b)
que nominalment es un arsenur de galió de 7 mil·liwatts que funciona a una longitud d'ona de 655-675 nanòmetres.
El sistema làser y la impressora s'han dissenyat amb l'objectiu d'impedir l'accés humà de la radiació làser superior al
nivell de classe I durant un funcionament normal, el manteniment per part de l'usuari o les condicions de servei
prescrites.
レーザーに関する通知
本機は、米国においてクラス I（1）レーザー製品に対する DHHS 21 CFR、Chapter I、Subchapter J の要件に準
拠し、その他の国では IEC 60825-1 の要件に準拠するクラス I レーザー製品として認可されています。
クラス I レーザー製品は、危険性がないとみなされています。 本機には、クラス IIIb（3b）レーザーが内蔵
されています。これは、655 ～ 675 ナノメートルの波長で動作する定格 7 ミリワットのガリウムヒ素レーザ
ーです。 レーザーシステムとプリンタは、通常の操作、ユーザーによるメンテナンス、または所定のサー
ビス条件の下で、ユーザーがクラス I レベルを超えるレーザー放射に絶対にさらされないように設計されて
います。
레이저 관련 공지
이 프린터는 미국에서 DHHS 21 CFR, Chapter I, Subchapter J 의 요구 사항을 준수하는 클래스 I(1) 레이저 제품으
로 승인되었으며 이외 지역에서 IEC 60825-1 의 요구 사항을 준수하는 클래스 I 레이저 제품으로 승인되었습니다.
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Class I 레이저 제품은 위험한 제품으로 간주되지 않습니다. 프린터에는 655-675 나노미터의 파장 영역에서 작동
하는 공칭 7 밀리와트 갈륨 비소 레이저인 클래스 IIIb(3b) 레이저가 내부에 포함되어 있습니다. 레이저 시스템
과 프린터는 정상적인 작동, 사용자 유지 관리 또는 사전 설명된 서비스 조건에는 사람에게 클래스 I 수준 이상
의 레이저 방사가 노출되지 않도록 설계되었습니다.
激光注意事项
本打印机在美国认证合乎 DHHS 21 CFR Chapter I，Subchapter J 对分类 I（1）激光产品的标准，而在其他地区则
被认证是合乎 IEC 60825-1 的分类 I 激光产品。
一般认为分类 I 激光产品不具有危险性。本打印机内部含有分类 IIIb（3b）的激光，在操作过程中会产生额定
7 毫瓦的砷化镓激光，其波长范围在 655-675nm 之间。本激光系统及打印机的设计，在一般操作、使用者维护
或规定内的维修情况下，不会使人体接触分类 I 以上等级的辐射。
雷射聲明
本印表機係經過美國核可，符合 DHHS 21 CFR，Chapter I，Subchapter J 規定的 I (1) 級雷射產品激光注意事项；
在美國以外的地區，為符合 IEC 60825-1 規定的 I 級雷射產品。
根據 I 級雷射產品的規定，這類產品不會對人體造成傷害。本機所採用之 IIIb (3b) 級雷射只會產生 7 百萬分之
一瓦特 (milliwatt)、波長 655 至 675 億分之一米 (nanometer) 的鎵砷放射線 (gallium arsenide laser)。使用者只要
以正確的方法操作及維護保養，並依照先前所述之維修方式進行修護，此印表機與其雷射系統絕不會產生 I 級
以上的放射線，而對人體造成傷害。
Safety information
Safety information
• The safety of this product is based on testing and approvals of the original design and specific components. The
manufacturer is not responsible for safety in the event of use of unauthorized replacement parts.
• The maintenance information for this product has been prepared for use by a professional service person and is
not intended to be used by others.
• There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product.
Professional service personnel should understand this and take necessary precautions.
CAUTION—POTENTIAL INJURY
The lithium battery in this product is not intended to be replaced. There is a danger of explosion if a lithium
battery is incorrectly replaced. Do not recharge, disassemble, or incinerate a lithium battery. Discard used
lithium batteries according to the manufacturer's instructions and local regulations.
Consignes de sécurité
• La sécurité de ce produit repose sur des tests et des agréations portant sur sa conception d'origine et sur des
composants particuliers. Le fabricant n'assume aucune responsabilité concernant la sécurité en cas d'utilisation de
pièces de rechange non agréées.
• Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance
qualifié.
• Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel d'entretien
qualifié devra prendre toutes les précautions nécessaires.
Notices and safety information
14
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5027
AVERTISSEMENT—RISQUE DE BLESSURE
La batterie lithium de ce produit n'est pas destinée à être remplacée. Il existe un risque d'explosion si une
batterie lithium est placée de façon incorrecte. Ne rechargez pas, ne démontez pas et n’incinérez pas une
batterie lithium. Mettez les batteries lithium usagées au rebut selon les instructions du fabricant et les
réglementations locales.
Norme di sicurezza
• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il
produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti.
• Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza
autorizzato.
• Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla
persona è più elevato. Il personale di assistenza autorizzato deve, quindi, adottare le precauzioni necessarie.
ATTENZIONE — PERICOLO DI LESIONI
La batteria al litio presente del prodotto non deve essere sostituita. In caso di sostituzione errata della
batteria al litio, potrebbe verificarsi un'esplosione. Non ricaricare, smontare o bruciare batterie al litio.
Smaltire le batterie al litio usate seguendo le istruzioni del produttore e le norme locali.
Sicherheitshinweise
• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter
Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung
für die Sicherheit übernommen.
• Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.
• Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.
VORSICHT - VERLETZUNGSGEFAHR
Die Lithiumbatterie in diesem Produkt darf nicht ausgetauscht werden. Wird eine Lithiumbatterie nicht
ordnungsgemäß ausgetauscht, besteht Explosionsgefahr. Lithiumbatterien dürfen auf keinen Fall wieder
aufgeladen, auseinander genommen oder verbrannt werden. Befolgen Sie zum Entsorgen verbrauchter
Lithiumbatterien die Anweisungen des Herstellers und die örtlichen Bestimmungen.
Pautas de Seguridad
• La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes específicos.
El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas.
• La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de
mantenimiento.
• Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máqui na.
El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.
PRECAUCIÓN: POSIBLES DAÑOS PERSONALES
La batería de litio de este producto no debe reemplazarse. Existe riesgo de explosión si se sustituye
incorrectamente una batería de litio. No recargue, desmonte ni incinere una batería de litio. Deseche las
baterías de litio según las instrucciones del fabricante y las normativas locales.
Notices and safety information
15
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5027
Informações de Segurança
• A segurança deste produto baseia-se em testes e aprovações do modelo original e de componentes específicos. O
fabricante não é responsável pela segunrança, no caso de uso de peças de substituição não autorizadas.
• As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser
utilizadas por outras pessoas.
• Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto. Os
profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.
ATENÇÃO — RISCO DE FERIMENTO
A bateria de lítio neste produto não deve ser substituída. Existe o risco de explosão se uma bateria de lítio
for substituída incorretamente. Não recarregue, desmonte ou incinere uma bateria de lítio. Descarte as
baterias de lítio usadas de acordo com as instruções do fabricante e regulamentos locais.
Informació de Seguretat
• La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics.
El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades.
• La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està destinada
a ningú que no ho sigui.
• El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d’aquest
producte. El personal professional ha d’estar-ne assabentat i prendre les mesures convenients.
ATENCIÓ
La bateria de liti d'aquest producte no ha estat dissenyada perquè es substitueixi. Hi ha perill d’explosió si
no es substitueix correctament la bateria de liti. No recarregueu, desmunteu o incinereu una bateria de
liti. Desfeu-vos de les bateries de liti usades d’acord amb les instruccions del fabricant i les regulacions
locals.
안전 사항
• 본 제품은 원래 설계및특정 구성에 대한 테스트 결과로 안정 성이 입증된 것입니다. 따라서 무허가 교체부품
을 사용하는 경 우 에는 제조업체에서 안전에 대한 책임을 지지 않습니다.
• 본 제품에 관한 유지 보수 설명 서는 전문 서비스 기술자 용으로 작성된 것이므로, 비 전문가는 사용할 수 없
습니다.
• 본 제품을 해체하거나 정비할 경우, 전 기전 인 충 경 을 받거나 상 처를 입을 위험이 커집니다. 전문 서비스
기술자는 이 사실을 숙지하고, 필요한 예방조치를 취하도록 하십시오.
주의—부상 위험
이 제품에 들어 있는 리튬 배터리는 교체할 수 없습니다. 리튬 배터리를 잘못 교체하면 폭발할 위험
이 있습니다. 리튬 배터리를 재충전하거나, 분해하거나, 태우지 마십시오. 제조업체의 지침과 지역
규정에 따라 다 쓴 리튬 배터리를 폐기하십시오.
安全信息
• 本产品的安全性以原来设计和特定产品的测试结果和认证为基础。万一使用来经许可的替换部件，制造商
不对安全性负责。
• 本产品的维护信息仅供专业服务人员使用，并不打算证其他人使用。
• 本产品在拆卸、维修时，遭受电击或人员受伤的危险性会增高，专业服务人员对这点必须有所了触，并采
取必要的预防措施。
Notices and safety information
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当心一可能的伤害
本产品中的锂电池不可更换。如果不正确更换锂电池，可能会有爆炸危险。不要再 充电、拆解或
焚烧锂电池。丢弃旧的锂电池时应按照制造商的指导及当地法规进行处理
：
。
Notices and safety information
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Preface
This manual contains maintenance procedures for service personnel.
It is divided into the following chapters:
• General information contains a general description of the printer. Special tools and test equipment are discussed.
• Diagnostic information contains diagnostic aids you can use to isolate failing FRUs. These diagnostic aids include
error code tables, symptom tables, and service checks.
• Service menus contains descriptions of the printer interface, the user and service menus.
• Repair information provides instructions for making printer adjustments and removing and installing FRUs.
• Component locations uses illustrations to identify the basic printer parts.
• Maintenance contains the lubrication specifications and recommendations to prevent problems.
• Parts catalog contains illustrations and part numbers for individual FRUs.
• Appendix A: Printer specifications contains detailed specifications about the product.
• Appendix B: Options and features contains the available options and other features of the product.
• Appendix C: Theory of operation contains the theory of operation.
• Appendix D: Acronyms contains the list of acronyms in the manual and their meanings.
Service manual conventions
Note: A note provides additional information.
Warning—Potential Damage: A warning identifies something that might damage the product hardware or software.
This service manual uses several different types of caution statements:
CAUTION—POTENTIAL INJURY: A caution identifies something that might cause the service technician harm.
CAUTION—SHOCK HAZARD: This type of caution indicates a danger from hazardous voltage in the area of the
product where you are working. Unplug the product before you start working, or use caution if the product
must receive power to perform the task.
CAUTION—HOT SURFACE: This type of caution indicates a hot surface.
CAUTION—TIPPING HAZARD: This type of caution indicates a tipping hazard.
Change history
June 10, 2014
• Updated the Inspection guide topic in the Maintenance chapter.
May 28, 2014
• Updated the Input option hardware errors section in the Diagnostics chapter.
Preface
19
Page 20
May 5, 2014
• Updated the fuser assembly removal topic in the repair chapter.
April 1, 2014
• Added PN 41X0001 in the parts catalog.
• Updated the Frames section in the parts catalog chapter.
• Added the Drive unit motor removal in the repair chapter.
• Removed the Transfer module removal topic from the repair chapter.
February 28, 2014
• Added the Restoring solutions, licenses, and configuration settings topic under Removal precautions.
• Updated the Restoring the printer configuration after replacing the controller board topic.
• Changed the title from eSF backup to Backing up eSF solutions and settings, and updated the topic.
• Updated the Controller board removal topic.
• Updated the Image transfer unit (ITU) removal topic.
• Editorial changes
5027
February 13, 2014
• Editorial changes.
February 5, 2014
• Editorial changes.
January 16, 2014
• Updated the Diagnostics menu and Configurations menu sections.
• Revised the Updating the printer firmware topic.
• Added the Image transfer unit (ITU) removal topic in the Repair chapter.
December 16, 2013
• Updated the Dead printer service check topic in the Diagnostic information chapter.
November 27, 2013
• Updated the controller board removal topic in the Repair chapter.
October 17, 2013
• Replaced PN 40X7634 with PN 40X7579 in the parts catalog.
• Removed PN 40X0395 from the parts catalog.
September 16, 2013
• Updated the printer model names in the cover page.
Preface
20
Page 21
August 19, 2013
• Updated the paper jam topics in the Diagnostics information chapter.
• Updated the installation note in the controller board removal topic.
August 8, 2013
• Updated the “Tray (x) sensor service check” topic.
• Added the 550 and 650 input option service check group and topics.
• Added the “Steps before starting the 9yy service checks” topic in the Diagnostics information chapter.
• Added PN 40X9244 in assembly 1 of the parts catalog.
• Added the “Restoring the printer configuration after replacing the controller board” topic under the Removal
precautions.
July 12, 2013
• Added relocation kit (PN 40X8701) in the parts catalog.
June 5, 2013
• Added BSD model name (C2132) in the parts catalog.
5027
May 27, 2013
• Added C2132 in the title.
• Added 5027‑639 in the machine type model.
• Added description for C2132 in the General Information chapter.
April 1, 2013
• Updated the safety information topic.
• Updated the installation note in the Printhead removal topic.
February 4, 2013
• Added the model numbers in the General information chapter.
• Added the “Updating the printer firmware” topic in the Service menus chapter.
January 17, 2013
• Updated the description for PN 40X3141 in Assembly 3 of the parts catalog chapter.
• Removed “Printhead to controller board cable” in the item list under PN 40X7647 in Assembly 4 of the parts catalog
chapter.
• Added an installation note in the controller board removal procedure in the Repair information chapter.
January 10, 2013
• Replaced PN 40X0259 to PN 40X4596 for the Brazil power cord in Assembly 3 of the parts catalog chapter.
• Updated the description for PN 40X1766 to Bolivia and Peru only in Assembly 3 of the parts catalog chapter.
• Added PN 40X0269 for the power cord for USA, Canada, APG, and LAD in Assembly 3 of the parts catalog chapter.
• Deleted these PNs in Assembly 6 of the parts catalog chapter: 40X1455, 40X7857, 40X7445, and 40X7567.
Preface
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General information
The LexmarkTM CS310 , CS410 , and CS510 models are color network printers in compact sizes. Some models have
internal duplex printing, USBA host ports for flash drives on the operator panel, and an optional 650-sheet Duo Drawer
with 550 sheets in the input tray and 100 sheets for the multipurpose feeder. The Lexmark 5027‑630 has a standard
650-sheet Duo Drawer and the option to add a 550-sheet tray, which brings the input for that model up to 1,451 sheets.
The Lexmark 5027‑610 comes with wireless network and duplex printing. All information in this service manual pertains
to all models unless explicitly noted.
The printers are available in the following models:
Model Configurations Machine type / model
CS310n Ethernet network, DDR3 DIMM, Flash memory, optional
650‑sheet duo drawer with integrated multipurpose feeder
CS310dn Ethernet network, duplex, DDR3 DIMM, Flash memory,
optional 550‑sheet tray, optional 650‑sheet duo drawer
with integrated multipurpose feeder
CS410n Ethernet network, USBA host port for flash drives, 2.4”
display and UICC card, standard 650‑sheet duo drawer with
integrated multipurpose feeder
CS410dn USBA host port for flash drive, duplex, Ethernet network,
2.4” display and UICC card, standard 650‑sheet duo drawer
with integrated multipurpose feeder
CS510de USBA host port for flash drive, duplex, 802.11n wireless
network, Ethernet network, hard disk option, UICC card,
4.3” display, standard 250‑sheet tray
CS510dte USBA host port for flash drive, duplex, 802.11n wireless
network, Ethernet network, hard disk option, UICC card,
4.3” display, standard 650‑sheet duo drawer with
integrated multipurpose feeder
C2132 USBA host port for flash drive, duplex, 802.11n wireless
network, Ethernet network, hard disk option, UICC card,
4.3” display, standard 250‑sheet tray
5027‑210
5027‑230
5027‑410
5027‑430
5027‑630
5027‑630
5027‑639
The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error
code charts, symptom index, and service checks to determine the symptom and then repair the failure. After you
complete the repair, perform tests as needed to verify the repair.
To begin diagnosing a problem, go to
for information about removing and reinstalling parts. See
“Diagnostic information” on page 33. See “Repair information” on page 197
“Parts catalog” on page 316 to help identify parts.
Media guidelines
• “Paper guidelines” on page 24
General information
23
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Paper guidelines
Paper characteristics
Selecting the appropriate media for the printer can help avoid printing problems.
For detailed information about media characteristics, see the Card Stock & Label Guide available on the Lexmark Support
Web site at http://support.lexmark.com.
The following paper characteristics affect print quality and reliability. Consider these characteristics when evaluating
new paper stock.
Weight
The printer can automatically feed paper weights from 60 to 220 g/m2 (16 to 58 lb bond) grain long. Paper lighter than
60 g/m
long paper. For paper smaller than 182 x 257 mm (7.2 x 10.1 in.), we recommend 90 g/m
Note: Duplex is supported only for 63 g/m
Curl
2
might not be stiff enough to feed properly, causing jams. For best performance, use 75 g/m2 (20 lb bond) grain
2
(24 lb) or heavier paper
2
–170 g/m2 (17 lb–45 lb bond) paper.
Curl is the tendency for paper to curl at its edges. Excessive curl can cause paper feeding problems. Curl can occur after
the paper passes through the printer, where it was exposed to high temperatures. Storing paper unwrapped in hot,
humid, cold, or dry conditions, even in the trays, can contribute to paper curling prior to printing.
Smoothness
Paper smoothness directly affects print quality. If paper is too rough, toner cannot fuse to it properly. If paper is too
smooth, it can cause paper feeding or print quality issues. Always use paper between 100 and 300 Sheffield points;
smoothness between 150 and 200 Sheffield points produces the best print quality.
Moisture content
The amount of moisture in paper affects both print quality and the ability of the printer to feed the paper correctly.
Leave paper in its original wrapper until it is time to use it. This limits the exposure of paper to moisture changes that
can degrade its performance. To condition paper before printing, store it in its original wrapper in the same environment
as the printer for 24 to 48 hours before printing. Extend the time several days if the storage or transportation
environment is very different from the printer environment. Thick paper may also require a longer conditioning period.
Excessive moisture will result in curl after printing.
Grain direction
Grain refers to the alignment of the paper fibers in a sheet of paper. Grain is either grain long, running the length of
the paper, or grain short, running the width of the paper. For 60 to 135 g/m
paper. For papers heavier than 135 g/m
2
, use grain short.
2
(16 to 36 lb bond) paper, use grain long
Fiber content
Most high-quality xerographic paper is made from 100% chemically treated wood pulp. This content provides the paper
with a high degree of stability, resulting in fewer paper‑feeding problems and better print quality. Paper containing
fibers such as cotton can negatively affect paper handling.
General information
24
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Unacceptable paper
The following paper types are not recommended for use with the printer:
• Chemically‑treated papers used to make copies without carbon paper, also known as carbonless papers, carbonless
copy paper (CCP), or no carbon required (NCR) paper
• Preprinted papers with chemicals that may contaminate the printer
• Preprinted papers that can be affected by the temperature in the printer fuser
• Preprinted papers that require a registration (the precise print location on the page) greater than ±2.4 mm
(±0.9 inch), such as optical character recognition (OCR) forms
In some cases, registration can be adjusted with a software application to successfully print on these forms:
• Coated papers (erasable bond), synthetic papers, thermal papers
• Rough‑edged, rough or heavily textured surface papers, or curled papers
• Recycled papers that fail EN12281:2002 (European)
• Paper weighing less than 60 g/m
2
(16 lb)
• Multiple‑part forms or documents
Selecting paper
Using the appropriate paper prevents jams and helps ensure trouble‑free printing.
To help avoid paper jams and poor print quality:
• Always use new, undamaged paper.
• Before loading paper, know the recommended printable side of the paper. This information is usually indicated on
the paper package.
• Do not use paper that has been cut or trimmed by hand.
• Do not mix paper sizes, types, or weights in the same tray; mixing results in jams.
• Do not use coated papers unless they are specifically designed for electrophotographic printing.
Selecting preprinted forms and letterhead
Use these guidelines when selecting preprinted forms and letterhead:
• Use grain long for 60 to 176 g/m
• Use only forms and letterhead printed using an offset lithographic or engraved printing process.
• Avoid papers with rough or heavily textured surfaces.
Use papers printed with heat-resistant inks designed for use in xerographic copiers. The ink must be able to withstand
temperatures up to 200°C (392°F) without melting or releasing hazardous emissions. Use inks that are not affected by
the resin in toner. Inks that are oxidation-set or oil-based generally meet these requirements; latex inks might not.
When in doubt, contact the paper supplier.
2
weight paper.
Preprinted papers such as letterhead must be able to withstand temperatures up to 200°C (392°F) without melting or
releasing hazardous emissions.
General information
25
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Storing paper
Use these paper storage guidelines to help avoid jams and uneven print quality:
• For best results, store paper where the temperature is 21°C (70°F) and the relative humidity is 40 percent. Most
label manufacturers recommend printing in a temperature range of 18–24°C (65–75°F) with relative humidity
between 40 and 60 percent.
• Store paper in cartons, on a pallet or shelf, rather than on the floor.
• Store individual packages on a flat surface.
• Do not store anything on top of individual paper packages.
• Take paper out of the carton or wrapper only when you are ready to load it in the printer. The carton and wrapper
help keep the paper clean, dry, and flat.
Supported paper sizes, types, and weights
The following tables provide information on standard and optional paper sources and the sizes, types, and weights of
paper they support.
Note: For unlisted paper sizes, select the closest larger listed size.
Supported paper sizes
Note: Your printer model may have a 650‑sheet duo tray, which consists of a 550‑sheet tray and an integrated
100‑sheet multipurpose feeder. The 550‑sheet tray of the 650‑sheet duo tray supports the same paper sizes as the
optional 550‑sheet tray. The integrated multipurpose feeder supports different paper sizes, types, and weights.
Paper size and
dimension
A4
210 x 297 mm
(8.3 x 11.7 in.)
A5
148 x 210 mm
(5.83 x 8.3 in.)
A6
105 x 148 mm
(4.1 x 5.8 in.)
1
The paper source supports paper size without size sensing.
2
Universal is only supported in the standard 250and optional 550sheet tray if the paper size is from 148 x 215.9 mm (5.83
x 8.5 inches) to 215.9 x 355.6 mm (8.5 x 14 inches).
3
Universal is only supported in the multipurpose feeder and manual feeder if the paper size is from 76.2 x 127 mm (3 x 5
inches) to 215.9 x 359.9 mm (8.5 x 14.17 inches).
4
Universal is only supported in duplex mode if the width is between 210 mm (8.27 inches) and 215.9 mm (8.5 inches) and
length is between 279.4 mm (11 inches) and 355.6 mm (14 inches).
Standard
250‑sheet tray
1 1 1 1
1 2 1 2
X
Manual
feeder
650‑sheet duo tray 550‑sheet
550‑sheet tray Multipurpose
feeder
X
1
Duplex
tray
XX
mode
X
General information
26
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5027
Paper size and
dimension
JIS B5
182 x 257 mm
(7.2 x 10.1 in.)
Letter
216 x 279 mm
(8.5 x 11 in.)
Legal
216 x 356 mm
(8.5 x 14 in.)
Executive
184 x 267 mm
(7.3 x 10.5 in.)
Oficio (Mexico)
216 x 340 mm
(8.5 x 13.4 in.)
Folio
216 x 330 mm
(8.5 x 13 in.)
Standard
250‑sheet tray
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
Manual
feeder
650‑sheet duo tray 550‑sheet
550‑sheet tray Multipurpose
feeder
tray
Duplex
mode
X
X
Statement
X X
1
XX
140 x 216 mm
(5.5 x 8.5 in.)
Universal
X
1,3
X
1,3
XX
76 x 127 mm (3 x 5 in.) to
216 x 356 mm
(8.5 x 14 in.)
Universal
1,2 1,2 1,2 4
148 x 210 mm (5.8 x 8.3
in) to 216 x 356 mm
(8.5 x 14 in).
7 3/4 Envelope
X
X
1
XX
(Monarch)
98 x 191 mm
(3.9 x 7.5 in.)
1
The paper source supports paper size without size sensing.
2
Universal is only supported in the standard 250and optional 550sheet tray if the paper size is from 148 x 215.9 mm (5.83
x 8.5 inches) to 215.9 x 355.6 mm (8.5 x 14 inches).
3
Universal is only supported in the multipurpose feeder and manual feeder if the paper size is from 76.2 x 127 mm (3 x 5
inches) to 215.9 x 359.9 mm (8.5 x 14.17 inches).
4
Universal is only supported in duplex mode if the width is between 210 mm (8.27 inches) and 215.9 mm (8.5 inches) and
length is between 279.4 mm (11 inches) and 355.6 mm (14 inches).
General information
27
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Paper size and
dimension
Standard
250‑sheet tray
Manual
feeder
650‑sheet duo tray 550‑sheet
550‑sheet tray Multipurpose
tray
Duplex
mode
feeder
9 Envelope
X
X
1
XX
98 x 225 mm
(3.9 x 8.9 in.)
10 Envelope
X
X
1
XX
105 x 241 mm
(4.1 x 9.5 in.)
DL Envelope
X
X
1
XX
110 x 220 mm
(4.3 x 8.7 in.)
C5 Envelope
X
X
1
XX
162 x 229 mm (6.4 x 9 in.)
B5 Envelope
X
X
1
XX
176 x 250 mm
(6.9 x 9.8 in.)
Other Envelope
X
X
1
XX
98 x 162 mm
(3.9 x 6.3 in.) up to
176 x 250 mm
(6.9 x 9.8 in.)
1
The paper source supports paper size without size sensing.
2
Universal is only supported in the standard 250and optional 550sheet tray if the paper size is from 148 x 215.9 mm (5.83
x 8.5 inches) to 215.9 x 355.6 mm (8.5 x 14 inches).
3
Universal is only supported in the multipurpose feeder and manual feeder if the paper size is from 76.2 x 127 mm (3 x 5
inches) to 215.9 x 359.9 mm (8.5 x 14.17 inches).
4
Universal is only supported in duplex mode if the width is between 210 mm (8.27 inches) and 215.9 mm (8.5 inches) and
length is between 279.4 mm (11 inches) and 355.6 mm (14 inches).
Supported paper types and weights
Notes:
• Your printer model may have a 650‑sheet duo tray, which consists of a 550‑sheet tray and an integrated
100‑sheet multipurpose feeder. The 550‑sheet tray of the 650‑sheet duo tray supports the same paper as the
550‑sheet tray. The integrated multipurpose feeder supports different paper sizes, types, and weights.
• Labels, transparencies, envelopes, and card stock always print at reduced speed.
General information
28
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Paper type 250‑sheet tray Manual feeder 650‑sheet duo tray 550‑sheet tray Duplex mode
550‑sheet tray Multipurpose
feeder
Paper
• Plain
• Recycled
• Glossy
• Bond
• Letterhead
• Preprinted
• Colored
• Light
• Heavy
• Rough/Cotton
• Custom Type [x]
Card stock X
Transparencies
Labels
X XX
X
• Paper
Envelope X
X XX
Using recycled paper and other office papers
As an environmentally conscious company, Lexmark supports the use of recycled office paper produced specifically for
use in laser (electrophotographic) printers. In 1998, Lexmark presented to the US government a study demonstrating
that recycled paper produced by major mills in the US fed as well as non-recycled paper. However, no blanket statement
can be made that all recycled paper will feed well.
Lexmark consistently tests its printers with recycled paper (20–100% post-consumer waste) and a variety of test paper
from around the world, using chamber tests for different temperature and humidity conditions. Lexmark has found no
reason to discourage the use of today's recycled office papers, but generally the following property guidelines apply
to recycled paper.
• Low moisture content (4–5%)
• Suitable smoothness (100–200 Sheffield units, or 140–350 Bendtsen units, European)
Note: Some much smoother papers (such as premium 24 lb laser papers, 50–90 Sheffield units) and much
rougher papers (such as premium cotton papers, 200–300 Sheffield units) have been engineered to work very
well in laser printers, despite surface texture. Before using these types of paper, consult your paper supplier.
• Suitable sheet-to-sheet coefficient of friction (0.4–0.6)
• Sufficient bending resistance in the direction of feed
2
Recycled paper, paper of lower weight (<60 g/m
that is cut grain-short for portrait (or short-edge) fed printers may have lower bending resistance than is required for
reliable paper feeding. Before using these types of paper for laser (electrophotographic) printing, consult your paper
[16 lb bond]) and/or lower caliper (<3.8 mils [0.1 mm]), and paper
General information
29
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5027
supplier. Remember that these are general guidelines only and that paper meeting these guidelines may still cause
paper feeding problems in any laser printer (for example, if the paper curls excessively under normal printing
conditions).
Data security notice
1 The printer contains various types of memory that store device and network settings, information from embedded
solutions, and user data.
The following are the types of memory and the types of data that they store.
• Volatile memory—The printer uses standard Random Access Memory (RAM) to buffer user data temporarily
during simple print and copy jobs.
• Non-volatile memory—The printer may use two forms of non-volatile memory: EEPROM and NAND (flash
memory). Both types are used to store the operating system, device settings, network information, scanner and
bookmark settings, and embedded solutions.
• Hard disk memory—The printer hard disk is designed for device-specific functionality and cannot be used for
the long‑term storage of data that is not print-related. The hard disk can retain buffered user data from complex
print jobs, form data, and font data.
To erase volatile memory, turn off the printer.
To erase the non-volatile and printer hard disk memory, see the
“Configuration menu” on page 184.
The following parts are capable of storing memory:
• Printer control panel
• UICC (User Interface Controller Card)
• Controller board
• Optional hard disk
Note: The control panel and controller board contain NVRAM.
2 After removing the old part, return it to your next level of support.
Tools required for service
• Flat-blade screwdrivers, various sizes
• #1 Phillips screwdriver, magnetic
• #2 Phillips screwdriver, magnetic
• #2 Phillips screwdriver, magnetic short-blade
• 7/32 inch (5.5 mm) open-end wrench
• 7.0 mm nut driver
• Needle‑nose pliers
• Diagonal side cutters
• Spring hook
• Feeler gauges
• Analog or digital multimeter
General information
30
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• Parallel wrap plug 1319128
• Twinax/serial debug cable 1381963
• Coax/serial debug cable 1381964
• Flash light (optional)
• 3 mm hex wrench
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General information
31
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32
Page 33
Diagnostic information
• “Troubleshooting overview” on page 33
• “Fixing print quality issues” on page 35
• “Paper jams” on page 45
• “Understanding printer messages” on page 71
• “Printer hardware errors” on page 80
• “Input option hardware errors” on page 139
CAUTION—SHOCK HAZARD: Remove the power cord from the electrical outlet before you connect or
disconnect any cable or electronic card or assembly for personal safety and to prevent damage to the printer.
Disconnect any connections between the printer and PCs/peripherals.
CAUTION—POTENTIAL INJURY: The printer weight is greater than 18 kg (40 lb) and requires two or more
trained personnel to lift it safely.
CAUTION—HOT SURFACE: The inside of the printer might be hot. To reduce the risk of injury from a hot
component, allow the surface to cool before touching.
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Troubleshooting overview
• “Performing the initial troubleshooting check” on page 33
• “Power‑on Reset (POR) sequence” on page 34
• “Using Safe Mode” on page 34
Performing the initial troubleshooting check
Before you start the troubleshooting procedures, perform the following checks:
• With the power cord unplugged from the electrical outlet, check that the cord is free from the breakage, short
circuits, disconnected wires, or incorrect connections.
• Make sure the printer is properly grounded. Check the power cord ground terminal.
• Make sure the power supply line voltage is within 10% of the rated line voltage.
• Make sure the machine is securely installed on a level surface in a well‑ventilated area.
• Make sure the room temperature is between 16 and 32°C (60 and 90°F) and that the relative humidity is between
20 and 80%.
• Avoid sites generating ammonia gas, high temperature, high humidity (near water faucets, kettles, humidifiers),
cold spaces, near open flames, and dusty areas.
• Avoid sites exposed to direct sunlight.
• Make sure the paper is the recommended paper for this printer.
• Make a trial print with paper from a newly opened package, and check the result.
Diagnostic information
33
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Power‑on Reset (POR) sequence
When you turn on the printer, it performs a POR sequence.
Check for correct POR functioning of the base printer by observing the following:
1 The LED turns on.
2 The main fan turns on.
3 The control panel turns on.
4 The fuser heater turns on.
Note: The fuser takes longer to warm up from a cold start than a warm start.
5 The control panel LED starts blinking.
6 A splash screen appears on the display. The following errors or messages may appear:
• Close Door or Insert Cartridge appears if the front access door is open or the print cartridge is
missing
• Cartridge errors, such as Defective Cartridge or Missing Cartridge
7 Ready appears on the display.
5027
8 The main drive motor turns on.
9 The EP drive assembly drives the developer shaft located in the print cartridge.
10 The exit rollers turn.
11 The printer may begin calibration.
Using Safe Mode
Safe Mode lets the printer continue to operate in a special limited mode in which it attempts to continue offering as
much functionality as possible despite known issues.
Warning—Potential Damage: Safe Mode is intended as a short‑term workaround and should be used only in the
case of a non‑critical error when a print job must be completed before service can be arranged to repair the printer.
The printer must be returned to standard operating mode before diagnostics can be run or full‑function printing can
continue.
You can enter Safe Mode in one of the following ways:
• Enable Safe Mode from the Configuration menu, and then POR the printer.
• For 2.4” display models, press the Stop and Back keys, and then POR the printer.
• For 4.3” and 7” display touchscreen models, press the 6 and 7 keys, and then POR the printer.
Return the printer to standard operating mode to service the printer and return to full‑function printing.
Safe mode print behavior
The following table outlines the behavior for this printer model while in Safe Mode:
Diagnostic information
34
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Safe Mode engine features Engine behavior Control panel behavior
Simplex printing only Reports that duplex printing is disabled. Duplex print option is not selectable.
Ignore duplex sensor
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Ignore standard bin full sensor Standard bin full messages are not
reported.
Print at narrow media operating point Pages are printed slower. N/A
Ignore all input options Reports that only Tray 1 is installed. Only Tray 1 and the MPF are selectable.
Ignore all output options Does not any report installed finishing
options.
Ignore rear door sensor Rear door open messages are not
reported.
Reduce print speed Pages are printed slower. N/A
Reduce time to first print Slower time to first print. N/A
Standard bin full messages will not
occur.
No finishing options are selectable.
Rear door open messages do not occur.
Fixing print quality issues
• “Initial print quality check” on page 36
• “Toner smear check” on page 36
• “Background or toner fog check” on page 37
• “Blank pages check” on page 39
• “Blurred or fuzzy print check” on page 40
• “Half‑color page check” on page 40
• “Horizontal banding check” on page 41
• “Horizontal line check” on page 41
• “Missing image at edge check” on page 41
• “Toner specks check” on page 42
• “Narrow vertical line check” on page 42
• “Random marks check” on page 42
• “Residual image check” on page 43
• “Solid color pages check” on page 43
• “Vertical banding check” on page 44
• “Light print on solids check” on page 44
• “Color problems check” on page 44
Diagnostic information
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5027
The symptoms described in this chapter might require replacement of one or more CRUs (Customer Replaceable Units)
designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's
permission, you might need to install a developer (toner) cartridge.
Initial print quality check
Before troubleshooting specific print problems, complete the following initial print quality check:
1 Print a menu settings page, and then check the life status of all supplies. Any supplies that are low should be replaced.
Be sure to keep the original menu page to restore the customer's custom settings if needed.
2 On the menu page, make sure the following settings are at the default level:
• Color Correction: Set to Auto.
• Print Resolution: Set to 4800 dpi (print quality problems should be checked at different resolution settings).
• Toner Darkness: Set to 4 (default).
• Color Saver: Set to OFF.
• RGB Brightness, RGB Contrast, RGB Saturation: Set to 0.
• Color Balance: Select Reset Defaults to zero out all colors.
• Check the paper type, texture and weight settings against the paper that is loaded in the printer.
3 Inspect the image transfer unit for damage. Replace, if damaged.
4 Inspect the print cartridges for damage. Replace, if damaged.
5 If paper other than 20 lb plain letter/A4 paper is being used, load 20 lb plain letter/A4 and print the Print Quality
pages to see if the problem remains. Use Tray 1 to test print quality problems.
6 Print the Print Quality Pages (Settings>Help>Print Defects Guide/Color Quality), and then look for variations in the
print from what is expected.
7 Check to ensure the correct printer driver for the installed software is being used. An incorrect printer driver for
the installed software can cause problems. Incorrect characters could print, and the copy may not fit the page
correctly.
8 Measure all voltages from the connector to the printer ground.
Toner smear check
Leading edge
ABC
DEF
Trailing edge
Diagnostic information
36
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Actions Yes No
5027
Step 1
From the Paper Menu on the printer control panel, check the paper type
and paper weight settings.
Is the paper tray set to the type and weight of paper in the tray?
Step 2
Check for paper with texture or rough finishes.
Are you printing on textured or rough paper?
Step 3
Is the fuser properly installed?
Step 4
Replace the fuser. See
Does this solve the problem?
Step 5
Replace the LVPS. See
removal” on page 226.
Does this fix the problem?
“Fuser assembly removal” on page 267.
“Low‑voltage power supply (LVPS) assembly
Go to step 2. Change the paper type
and weight settings to
match the paper in the
tray.
Change the textured or
rough paper to plain
paper and print again.
Go to step 4. Install the fuser
The problem is solved. Go to step 5.
The problem is solved. Contact your next level
Go to step 3.
properly.
of support.
Background or toner fog check
Actions Yes No
Step 1
Read the current status of the imaging unit from the customer menus.
To view the status of the photoconductor units:
a In Ready mode, press Menus
b Select Reports, and press Select
c Select Device Statistics, and press Select
It is possible a new imaging unit was installed, but the counter was not
reset.
Has the imaging unit been recently replaced?
Reset the value. To
reset this value:
1 In Ready mode,
press Menus
2 Select Supplies
Menu, and press
Select
3 Select Replace
Supply, and press
Select
4 Select the imaging
unit you want to
change, and press
Select
5 Select Yes, and
press Select
If this does not fix the
problem, then go to
step 2.
Go to step 2.
Diagnostic information
37
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Actions Yes No
5027
Step 2
Is the background only one of the primary colors; yellow, cyan, magenta,
or black?
Step 3
Replace the developer unit.
Did replacing the developer unit correct the problem?
Step 4
Replace the photoconductor unit.
Did this fix the problem?
Step 5
Check the high‑voltage contact from the HVPS to the image transfer unit
(ITU).
Is a problem found?
Go to step 3. Go to step 4.
Problem is solved. Go to step 4.
Problem is solved. Go to step 5.
Replace the failing part:
Go to step 6.
• Image transfer unit.
See
“Image
transfer unit (ITU)
removal” on
page 243.
• High‑voltage
power supply
(HVPS). See
“High‑voltage
power supply
(HVPS) removal”
on page 239.
Step 6
With the printer off, reset the cable in the JHVPS1 connector.
Does this fix the problem?
Step 7
Replace the HVPS. See
page 239.
Does this fix the problem?
Step 8
Clean the printhead.
Does this fix the problem?
“High‑voltage power supply (HVPS) removal” on
Problem is solved. Go to step 7.
Problem is solved. Go to step 8.
Problem is solved. Replace the printhead.
See
“Printhead
removal” on page
299.
Diagnostic information
38
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Blank pages check
5027
Check Yes No
Step 1
Is all the packing material for the imaging unit in question removed?
Step 2
Print a document that requires all four colors with just a few characters
to verify if one specific color is a problem. For example, print the Print
Quality Test Pages:
a Enter Diagnostic mode.
For CS310 models, turn the printer off, press and hold Down and
Right, turn the printer on, and then release the buttons when the
installed memory and processor speed displays.
For CS410 and CS510 models, turn the printer off, press and hold 3
and 6, turn the printer on, and then release the buttons when the
installed memory and processor speed displays.
b Select PRINT TESTS, and press Select
c Select Prt Qual pgs, and press Select
Is only one color missing?
Step 3
Replace the imaging unit. See Imaging unit (IU) removal.
Does this fix the problem?
Go to step 2. Remove the packing
material.
Replace the developer
unit for the missing
color.
Problem resolved. Go to step 4.
Go to step 3.
Step 4
a Remove the image unit and waste toner bottle.
b Replace the right cover and close the front door.
c Enter the Diagnostics Menu, and run the appropriate cartridge drive
motor test for the missing color.
d Select MISC TESTS in the Diag menu, and press Select.
e Select Motor Detect. Remove Cartridge. Press Select
appears.
Note: Do not press Select yet.
f Remove all toner cartridges and the imaging unit.
g Close the front cover. If you press Select before closing the front cover,
then a message appears: Close cover. Press Select.
h Press Select. Motor Detection In Progress... appears.
The motor detection process takes about 10 seconds, and stops
automatically. Detect Complete. Rebooting... appears,
and the printer performs a POR (Power On Reset).
Did the motor run?
Go to step 5. Replace the main drive
gear assembly. See
Main drive gear
assembly with motor
removal.
Diagnostic information
39
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Check Yes No
5027
Step 5
Remove the developer unit. See Developer unit removal. Check the
developer cartridge contacts from the HVPS to the IU.
Are all the toner cartridge contacts clean on both the Pin and IU?
Step 6
Are all the spring‑loaded Pins in the HVPS free to move in and out with an
equal amount of spring force.
Step 7
Turn the printer off, and remove the rear cover. See
on page 290. Check the continuity between the spring‑loaded Pin and
the JSC1 connector on the controller board.
Are all conductors continuous?
Step 8
Replace the printhead. See Printhead removal.
Did this fix the problem?
“Rear cove r removal”
Go to step 6.. Clean the developer
cartridge contacts. See
Developer unit
removal.
Go to step 7. Replace the HVPS. See
High‑voltage power
supply (HVPS)
assembly removal.
Go to step 8. Replace the cable.
Problem resolved. Replace the controller
board. See Controller
board removal.
Blurred or fuzzy print check
Run the automatic alignment. The TPS sensor may be damaged. To run Reset Color Cal:
1 Enter the Diagnostics Menu.
For CS310 models, turn the printer off, and press and hold Down and Right.
For CS410 and CS510 models, turn the printer off, and press and hold 3 and 6.
2 Select Reset Color Cal, and press Select.
3 Select Reset Color Cal, and press Select. Resetting appears. When the reset is complete, the screen is
automatically returned to TPS Setup.
Blurred or fuzzy print is usually caused by a problem in the main gear drive assembly or in the image transfer unit (ITU).
Check the main drive gear assembly and ITU for correct operation.
Blurred print can also be caused by incorrect feeding from one of the input paper sources, media trays, or duplex paper
path.
Check the high‑voltage spring contacts to ensure they are not bent, corroded, or damaged. Replace the high‑voltage
power supply as necessary. See High voltage power supply (HVPS) assembly removal.
Half‑color page check
A photoconductor unit is not properly seated. Reset the specific photoconductor unit.
Diagnostic information
40
Page 41
Horizontal banding check
Actions Yes No
5027
Step 1
Measure the distance between repeating bands.
Is the distance between bands either 34.6 or 94.2 mm?
Step 2
Does the distance measure 95 mm or 108 mm?
Step 3
Does the distance measure 37.7, 55, or 78.5 mm?
Step 4
Does the distance measure 43.9 mm or 45.5?
Replace the
photoconductor unit.
Remove the imaging
unit and remove the
original developer
units, and then put
them back into the new
photoconductor unit,
and reinstall the
imaging unit. See
“Imaging unit (IU)
removal” on page
246.
Replace the fuser. See
“Fuser assembly
removal” on page
267.
Replace the ITU. See
“Image transfer unit
(ITU) removal” on
page 243..
Replace the developers
that match the missing
color (black, cyan,
magenta, or yellow.)
See Developer unit
removal.
Go to step 2.
Go to step 3.
Go to step 4.
Check the various
rollers in the printer for
debris.
Horizontal line check
Either the photoconductor unit or one of the developer units that make up the imaging unit is defective. Remove and
inspect the imaging unit. Replace the damaged part of the imaging unit. See Imaging unit (IU) removal.
Missing image at edge check
Remove and reset the following:
• Toner cartridge
• Imaging unit
• Developer units
Diagnostic information
41
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5027
Toner specks check
Keep running prints through, and the problem normally clears up. If the problem persists, then replace the developer
cartridge.
Narrow vertical line check
Actions Yes No
Replace the photoconductor unit.
Does this solve the problem?
The problem is solved. Replace the developer
unit.
Random marks check
Service tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching
to the photoconductor unit, developer roll, or transfer belt.
Actions Yes No
Step 1
Is there any loose or foreign material on the imaging unit?
Step 2
Is there any loose or foreign material on the developer roll?
Inspect the imaging
unit by looking at the
individual developers
and photoconductors.
Clean or replace the
faulty unit. See
“Imaging unit (IU)
removal” on page
246.
Replace the developer
unit.
Go to step 2.
Go to step 3.
Step 3
Is there any loose or foreign material on the transfer belt?
Diagnostic information
42
Replace the ITU. See
“Image transfer unit
(ITU) removal” on
page 243.
Contact your next level
of support.
Page 43
5027
Residual image check
Service tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching
to the photoconductor unit, developer roll, or transfer belt.
Actions Yes No
Step 1
Check the condition of the imaging unit using the customer menus
(administration menus):
a At the Ready prompt, press Menu.
b Select Supplies Menu, and press Select.
c Select Imaging Kit, and press Select.
Does the display indicate OK?
Step 2
Measure the distance from the original image to the same point on the
residual image.
Is the distance 43.9 mm?
Step 3
Is the distance between the original image and the residual image 94.2
mm?
Step 4
Run the Menu Setting Page twice to clear any debris.
a Press Menu on the control panel.
b Select Reports from the Admin Menu, and press Select.
c Select Imaging Kit, and press Select.
Go to step 2. Replace the imaging
unit or the
photoconductor unit.
“Imaging unit (IU)
See
removal” on page
246.
Replace the developer
corresponding to the
color of the image. See
“Developer unit
removal” on page
238.
Replace the
photoconductor.l.
Replace the fuser. See
“Fuser assembly
removal” on page
267.
Replace the imaging
unit or the
photoconductor unit.
“Imaging unit (IU)
See
removal” on page
246.
Go to step 4.
Contact your next level
of support.
Is there still any toner contamination on the fuser assembly?
Solid color pages check
Service tip: A solid color page is generally caused by a problem in the high‑voltage power supply or an incorrect high
voltage in the printing process resulting in toner development on the entire photoconductor.
Diagnostic information
43
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Actions Yes No
5027
Step 1
Replace the photoconductor unit (part of the imaging unit). Remove the
imaging unit and remove the developers. Place the original developers in
the new photoconductor, and then replace the imaging unit. See
unit (IU) removal” on page 246.
Does this solve the problem?
Step 2
A faulty printhead can cause the problem. To test the printhead for solid
colors, place a narrow strip of paper over the gap between the developers.
Make sure the paper stays in place when you replace the imaging unit.
This will block the laser from discharging the photoconductors. Select the
Print Quality Page.
Does the uniform color page have a white vertical band?
Step 3
Check the high-voltage contact from the HVPS to the photoconductor
charge roll. Ensure the contact springs are properly mounted and that the
charge roll contact spring is making good contact with the HVPS spring
that runs through the left printer frame. See
removal” on page 248 to view the proper mounting and for removal
procedures.
“Toner cartridge contacts
“Imaging
Problem is solved. Go to step 2.
Replace the printhead.
“Printhead
See
removal” on page
299.
Replace the transfer
contact assembly. See
“Toner cartridge
contacts removal” on
page 248.
Go to step 3.
Go to step 4.
Are the springs defective?
Step 4
Turn the printer off, and check the continuity of the HVPS cable.
Is there continuity?
Step 5
Replace the HVPS. See
page 239.
Does this solve the problem?
“High‑voltage power supply (HVPS) removal” on
Go to step 5. Replace the cable
assembly.
Problem is solved. Replace the controller
board. See
board removal” on
page 291.
Vertical banding check
Replace the developer cartridge.
Light print on solids check
Light print can be caused by incorrect media. For more information, see “Media guidelines” on page 23.
Color problems check
“Controller
For more information on non‑mechanical color issues, see “Color theory” on page 350.
Diagnostic information
44
Page 45
Paper jams
• “Avoiding jams” on page 45
• “Understanding jam messages and locations” on page 47
• “200 paper jams” on page 48
• “202 paper jams” on page 52
• “23y paper jams” on page 57
• “24y paper jams” on page 64
• “25y paper jams” on page 68
Avoiding jams
Load paper properly
•
Make sure paper lies flat in the tray.
Correct loading of paper Incorrect loading of paper
5027
• Do not remove a tray while the printer is printing.
• Do not load a tray while the printer is printing. Load it before printing, or wait for a prompt to load it.
• Do not load too much paper. Make sure the stack height is below the maximum paper fill indicator.
Diagnostic information
45
Page 46
• Do not slide the paper into the tray. Load paper as shown in the illustration.
5027
• Make sure the guides in the tray or the multipurpose feeder are properly positioned and are not pressing tightly
against the paper or envelopes.
• Push the tray firmly into the printer after loading paper.
Use recommended paper
•
Use only recommended paper or specialty media.
• Do not load wrinkled, creased, damp, bent, or curled paper.
• Flex, fan, and straighten paper before loading it.
• Do not use paper that has been cut or trimmed by hand.
• Do not mix paper sizes, weights, or types in the same tray.
• Make sure the paper size and type are set correctly on the computer or printer control panel.
• Store paper according to manufacturer recommendations.
Diagnostic information
46
Page 47
Understanding jam messages and locations
When a jam occurs, a message indicating the jam location and information to clear the jam appears on the printer
display. Open the doors, covers, and trays indicated on the display to remove the jam.
Note: When Jam Recovery is set to On or Auto, the printer reprints jammed pages. However, Auto does not
guarantee that the page will print.
# Jam location Message on the display What to do
5027
1 Standard bin [x]‑page jam, clear standard
bin. [203.xx]
2 Fuser [x]‑page jam, open front door to clear
fuser. [202.xx]
3 Front door [x]‑page jam, open front door. [20y.xx] Open the front door, and then remove the jammed
4 Duplex [x]‑page jam, open front door to clear
duplex. [23y.xx]
5 Tray [x] [x]‑page jam, open tray [x]. [24y.xx] Pull the indicated tray out, and then remove the
6 Manual feeder [x]‑page jam, clear manual
feeder. [251.xx]
7 Multipurpose feeder [x]‑page jam, clear multipurpose
feeder. [250.xx]
Remove the jammed paper.
Open the front door, pull the tab and hold the fuser
cover down, and then remove the jammed paper.
paper.
Open the front door, and then remove the jammed
paper.
jammed paper.
Remove the jammed paper.
Push the paper release lever to lift the paper rollers,
and then remove the jammed paper.
Diagnostic information
47
Page 48
200 paper jams
200 paper jams
1 Pull tray 1 out.
5027
2 Firmly grasp the jammed paper, and then gently pull it out.
Note: Make sure all paper fragments are removed.
3 Push tray 1 back in.
4 From the operator panel, touch Continue, jam cleared.
Diagnostic information
48
Page 49
200 paper jam messages
Error code Description Action
5027
200.xx A single page of media jam at the input (S2)
sensor.
Multiple pages of media are jammed at the
input sensor.
200.01 The input (S2) sensor is obstructed. Go to
200.02 The input (S2) sensor was made early. Go to
200.03 The input (S2) sensor did not make. Go to
200.05 The input (S2) sensor did not break. Go to
200.20 The staging motor has an error. Go to
200.21 The staging motor has an error. Go to
200.22 The staging motor has an error. Go to
201.xx A software induced stoppage has occurred.
This should not happen in the field.
Go to
page 96.
page 96.
page 96.
POR the printer.
Input sensor (S2) jam service check
“Input sensor (S2) jam service check” on page 49.
“Input sensor (S2) jam service check” on page 49.
“Input sensor (S2) jam service check” on page 49.
“Input sensor (S2) jam service check” on page 49.
“Input sensor (S2) jam service check” on page 49.
“Paper pick motor drive assembly service check” on
“Paper pick motor drive assembly service check” on
“Paper pick motor drive assembly service check” on
The input (S2) sensor is part of the paper pick motor drive assembly FRU, and is not available otherwise.
Actions Yes No
Step 1
Problem resolved. Go to step 2.
a Pull out tray 1.
b Remove the jammed page(s).
Does the error clear?
Diagnostic information
49
Page 50
Actions Yes No
5027
Step 2
Remove tray 1.
Is the input S2 sensor flag (A) damaged?
Replace the paper pick
motor drive assembly.
“Paper pick motor
See
drive assembly
standard tray
removal” on page
287.
Go to step 3.
Diagnostic information
50
Page 51
Actions Yes No
5027
Step 3
Enter Diagnostics Menu.
For CS310 models, turn the printer on, press and hold Down and Right,
and release the buttons with the installed memory and processor speed
displays.
For CS410 and CS510 models, turn the printer on, press and hold 3 and
6, and release the buttons with the installed memory and processor speed
displays.
Perform the Base Sensor Test. See
“BASE SENSOR TEST” on page 176.
a Select Base Sensor Test, and press Select.
b Select S2 Sensor, and press Select.
c Pull tray 1 out, and rotate the S2 sensor flag (A). (The S2 sensor is
located in the front of the center paper pick motor drive assembly
housing.) It should rotate freely and return to its original position.
Problem resolved. Go to step 4.
d Watch the display while pushing up on the flag.
Does the display indicate Media Clean and Media Present?
Diagnostic information
51
Page 52
Actions Yes No
5027
Step 4
Turn the printer off, and remove the rear cover. See
on page 290.
Is the JSP1 cable connector properly connected to the controller board?
“Rear cove r removal”
Go to step 5. Reseat the connector.
Step 5
Turn the printer on, and check the voltage at JSP1 pin 15.
Is the voltage approximately +5 V dc?
202 paper jams
202 paper jams
Paper jam in the standard exit bin
1 Firmly grasp the paper on each side, and then gently pull it out.
Note: Make sure all paper fragments are removed.
Diagnostic information
52
Replace the paper pick
motor drive assembly.
“Paper pick motor
See
drive assembly
standard tray
removal” on page
287.
Replace the controller
board. See
board removal” on
page 291.
“Controller
Page 53
2 From the operator panel, touch Continue, jam cleared.
Paper jam in the fuser
1 Open the front door.
2 Open the fuser cover.
5027
3 Firmly grasp the jammed paper on each side, and then gently pull it out.
Note: Make sure all paper fragments are removed.
4 Close the front door.
5 From the operator panel, touch Continue, jam cleared.
Diagnostic information
53
Page 54
202 paper jam messages
Error code Description Action
5027
202.xx A single page of media is jammed at the exit sensor.
Multiple pages of media are jammed at the exit sensor.
202.01 The exit sensor is obstructed. Go to
202.02 The exit sensor was made early. Go to
202.03 The exit sensor did not make. Go to
202.04 The exit sensor broke early. Go to
202.05 The exit sensor did not break. Go to
202.51 The exit sensor is obstructed.
The fuser is past end of life.
202.52 The exit sensor was made early.
The fuser is past end of life.
202.53 The exit sensor did not make.
The fuser is past end of life.
202.54 The exit sensor broke early.
The fuser is past end of life.
Go to
page 55.
page 55.
page 55.
page 55.
page 55.
page 55.
Go to
page 55.
Go to
page 55.
Go to
page 55.
Go to
page 55.
“Fuser exit sensor service check” on
“Fuser exit sensor service check” on
“Fuser exit sensor service check” on
“Fuser exit sensor service check” on
“Fuser exit sensor service check” on
“Fuser exit sensor service check” on
“Fuser exit sensor service check” on
“Fuser exit sensor service check” on
“Fuser exit sensor service check” on
“Fuser exit sensor service check” on
202.55 The exit sensor did not break.
The fuser is past end of life.
“Fuser exit sensor service check” on
Go to
page 55.
Diagnostic information
54
Page 55
Fuser exit sensor service check
Actions Yes No
5027
Step 1
Open the front cover.
Replace the fuser exit
sensor. See
sensor removal” on
page 228.
“Fuser exit
Go to step 2.
Is the sensor dislodged or damaged?
Step 2
Enter Diagnostics Menu.
For CS310 models, turn the printer off, press and hold Down and Right,
turn the printer on, and then release the buttons when the installed
memory and processor speed displays.
For CS410 and CS510 models, turn the printer off, press and hold 3 and
6, turn the printer on, and then release the buttons when the installed
memory and processor speed displays)
Perform the Base Sensor Test. See
“BASE SENSOR TEST” on page 176.
a Select Base Sensor Test, and press Select.
b Select Fuser Exit Sensor, and press Select.
c Watch the display while rotating the flag in and out of the sensor.
Did the sensor go from closed to open?
Diagnostic information
55
Problem solved. Go to step 4.
Page 56
Actions Yes No
5027
Step 3
Turn the printer off, and then remove the rear cover. See
removal” on page 290.
Is the cable correctly connected to JBIN1 on the controller board and to
the sensor?
“Rear cover
Go to step 5. Reconnect the cable.
Step 4
Turn the printer on, and check the values at JBIN1:
Pin 4: 0 V dc (+5 V dc during cycle)
Pin 5: +0 V dc (unblocked), +3.3 V dc (blocked)
Pin 6: Ground
Are the values correct?
Diagnostic information
56
Replace the fuser exit
sensor. See
sensor removal” on
page 228.
“Fuser exit
Replace the controller
board. See
board removal” on
page 291.
“Controller
Page 57
23y paper jams
23y paper jams
1 Pull tray 1 out.
5027
2 Firmly grasp the jammed paper, and then gently pull it out.
Note: Make sure all paper fragments are removed.
3 Push tray 1 back in.
4 From the operator panel, touch Continue, jam cleared.
Diagnostic information
57
Page 58
23y paper jam messages
Error code Description Action
5027
230.xx A single page of media is jammed at the inner
door.
Multiple pages of media are jammed at the
inner door.
230.01 The Duplex (S1) sensor is obstructed. Go to
230.02 The Duplex (S1) sensor was made early. Go to
230.03 The Duplex (S1) sensor did not make. Go to
230.06 No media in duplexer. Go to
232.xx Paper jam at input sensor. Go to
232.02 The input (S2) sensor was made early while
duplexing.
232.03 The input (S2) sensor did not make while
duplexing.
232.05 The input (S2) sensor did not break while
duplexing.
Go to
page 58.
page 58.
page 58.
page 58.
page 58.
page 60.
Go to
page 60.
Go to
page 60.
Go to
page 60.
“Duplex/manual feed sensor (S1) service check” on
“Duplex/manual feed sensor (S1) service check” on
“Duplex/manual feed sensor (S1) service check” on
“Duplex/manual feed sensor (S1) service check” on
“Duplex/manual feed sensor (S1) service check” on
“Duplex/manual feed sensor (S2) service check” on
“Duplex/manual feed sensor (S2) service check” on
“Duplex/manual feed sensor (S2) service check” on
“Duplex/manual feed sensor (S2) service check” on
Duplex/manual feed sensor (S1) service check
Actions Yes No
Step 1
Is the printer setting on a hard, flat surface?
Step 2
Enter Diagnostics Menu.
For CS310 models, turn the printer off, press and hold Down and Right,
turn the printer on, and then release the buttons when the installed
memory and processor speed displays.
For CS410 and CS510 models, turn the printer off, press and hold 3 and
6, turn the printer on, and then release the buttons when the installed
memory and processor speed displays).
Perform the Base Sensor Test. See
“BASE SENSOR TEST” on page 176.
a Select Base Sensor Test, and press Select.
b Select S1, and press Select.
c Install tray 1.
Does the display indicate InputS1‑Media Clear...?
Go to step 2. Make sure the printer is
Go to step 3. Go to step 5.
setting on a level, flat
surface
Diagnostic information
58
Page 59
Actions Yes No
5027
Step 3
Pull tray 1 out.
Does the display indicate InputS1‑Media Present...?
Step 4
Remove the tray, and inspect the sensor (A).
The sensor is
functioning correctly.
Remove the
obstruction, and
restart the test.
Go to step 4.
Go to step 5.
Is there something obstructing the sensor?
Step 5
Inspect the spring‑loaded shaft/flag (B) in the tray.
The flag portion of the shaft intercepts the sensor, except when a sheet
is being staged for duplexing.
Does the shaft rotate freely and return to home position (flag at top of
rotation?)
Go to step 6. Replace the tray with a
new one.
Step 6
is the flag on the shaft broken?
Replace the tray. Go to step 7.
Diagnostic information
59
Page 60
Actions Yes No
5027
Step 7
Turn the printer off, and remove the rear cover. See
on page 290.
Verify the cable is correctly connected to JFUSES1 on the controller board
and to the sensor.
“Rear cove r removal”
Go to step 8. Reconnect the cable. If
the problem persists,
then go to step 8.
Is the sensor cable properly connected?
Step 8
Turn the printer on, and check the values at JFUSES1:
Pin 8: Ground
Pin 9: +3.3 V dc
Are the values approximately correct?
Replace the duplex
sensor. See
sensor removal” on
page 284.
“Duplex
Replace the controller
board. See
board removal” on
page 291.
Duplex/manual feed sensor (S2) service check
The input (S2) sensor is part of the paper pick motor drive assembly FRU, and is not available otherwise.
Actions Yes No
Step 1
a Open the front door to access the jam area.
b Remove the jammed page(s).
Does the error clear?
Diagnostic information
Problem resolved. Go to step 2.
“Controller
60
Page 61
Actions Yes No
5027
Step 2
Remove tray 1.
Is the input S2 sensor flag (A) damaged?
Replace the paper pick
motor drive assembly.
“Paper pick motor
See
drive assembly
standard tray
removal” on page
287.
Go to step 3.
Diagnostic information
61
Page 62
Actions Yes No
5027
Step 3
Enter Diagnostics Menu.
For CS310 models, turn the printer on, press and hold Down and Right,
and release the buttons with the installed memory and processor speed
displays.
For CS410 and CS510 models, turn the printer on, press and hold 3 and
6, and release the buttons with the installed memory and processor speed
displays.
Perform the Base Sensor Test. See
“BASE SENSOR TEST” on page 176.
a Select Base Sensor Test, and press Select.
b Select S2 Sensor, and press Select.
c Pull tray 1 out, and rotate the S2 sensor flag (A). (The S2 sensor is
located in the front of the center paper pick motor drive assembly
housing.) It should rotate freely and return to its original position.
Problem resolved. Go to step 4.
d Watch the display while pushing up on the flag.
Does the display indicate Media Clean and Media Present?
Diagnostic information
62
Page 63
Actions Yes No
5027
Step 4
Turn the printer off, and remove the rear cover. See
on page 290.
Is the JSP1 cable connector properly connected to the controller board?
“Rear cove r removal”
Go to step 5. Reseat the connector.
Step 5
Turn the printer on, and check the voltage at JSP1 pin 15.
Is the voltage approximately +5 V dc?
Diagnostic information
63
Replace the paper pick
motor drive assembly.
“Paper pick motor
See
drive assembly
standard tray
removal” on page
287.
Replace the controller
board. See
board removal” on
page 291.
“Controller
Page 64
24y paper jams
24y paper jams
1 Pull tray 1 out.
2 Firmly grasp the jammed paper, and then gently pull it out.
5027
Note: Make sure all paper fragments are removed.
3 Push tray 1 back in.
4 From the operator panel, touch Continue, jam cleared.
24y paper jam messages
Error code Description Action
242.xx A single or multiple page media jam in the 650-sheet
Duo Drawer (tray 2). Multiple pages of media are
jammed in the 650-sheet Duo Drawer (tray 2).
243.xx A single or multiple page media jam in the 550-sheet
Duo Drawer (tray 3). Multiple pages of media are
jammed in the 550-sheet Duo Drawer (tray 3).
Go to
on page 65.
Go to
on page 65.
“Tray X input sensor (S2) jam service check”
“Tray X input sensor (S2) jam service check”
Diagnostic information
64
Page 65
Tray X input sensor (S2) jam service check
The input (S2) sensor is part of the paper pick motor drive assembly FRU, and is not available otherwise.
Actions Yes No
5027
Step 1
a Clear paper path.
b Fan the media.
c Verify the proper tray settings for the media.
d Check the condition of the pick tires.
e Make sure the tray is fully inserted
Does the error clear?
Step 2
Remove tray 1.
Is the input S2 sensor flag (A) damaged?
Problem resolved. Go to step 2.
Replace the paper pick
motor drive assembly.
“Paper pick motor
See
drive assembly
standard tray
removal” on page
287.
Go to step 3.
Diagnostic information
65
Page 66
Actions Yes No
5027
Step 3
Enter Diagnostics Menu.
For CS310 models, turn the printer on, press and hold Down and Right,
and release the buttons with the installed memory and processor speed
displays.
For CS410 and CS510 models, turn the printer on, press and hold 3 and
6, and release the buttons with the installed memory and processor speed
displays.
Perform the Base Sensor Test. See
“BASE SENSOR TEST” on page 176.
a Select Base Sensor Test, and press Select.
b Select S2 Sensor, and press Select.
c Pull tray 1 out, and rotate the S2 sensor flag (A). (The S2 sensor is
located in the front of the center paper pick motor drive assembly
housing.) It should rotate freely and return to its original position.
Problem resolved. Go to step 4.
d Watch the display while pushing up on the flag.
Does the display indicate Media Clean and Media Present?
Diagnostic information
66
Page 67
Actions Yes No
5027
Step 4
Turn the printer off, and remove the rear cover. See
on page 290.
Is the JSP1 cable connector properly connected to the controller board?
“Rear cove r removal”
Go to step 5. Reseat the connector.
Step 5
Turn the printer on, and check the voltage at JSP1 pin 15.
Is the voltage approximately +5 V dc?
Diagnostic information
67
Replace the paper pick
motor drive assembly.
“Paper pick motor
See
drive assembly
standard tray
removal” on page
287.
Replace the controller
board. See
board removal” on
page 291.
“Controller
Page 68
25y paper jams
25y paper jams
1 Pull tray 1 out.
2 Firmly grasp the jammed paper, and then gently pull it out.
Note: Make sure all paper fragments are removed.
5027
3 Push tray 1 back in.
4 From the operator panel, touch Continue, jam cleared.
25y paper jam messages
Error code Description Action
250.xx A single page of media is jammed in the
multipurpose feeder.
Go to
“Multipurpose feeder input sensor (S2) jam
service check” on page 68.
Multipurpose feeder input sensor (S2) jam service check
The input (S2) sensor is part of the paper pick motor drive assembly FRU, and is not available otherwise.
Actions Yes No
Step 1
a Open tray 2 to access the jam area, and remove the jammed page.
b Fan the media.
c Verify the proper tray settings for the media.
d Check the condition of the pick tires.
Problem resolved. Go to step 2.
Does the error clear?
Diagnostic information
68
Page 69
Actions Yes No
5027
Step 2
Remove tray 1.
Is the input S2 sensor flag (A) damaged?
Replace the paper pick
motor drive assembly.
“Paper pick motor
See
drive assembly
standard tray
removal” on page
287.
Go to step 3.
Diagnostic information
69
Page 70
Actions Yes No
5027
Step 3
Enter Diagnostics Menu.
For CS310 models, turn the printer on, press and hold Down and Right,
and release the buttons with the installed memory and processor speed
displays.
For CS410 and CS510 models, turn the printer on, press and hold 3 and
6, and release the buttons with the installed memory and processor speed
displays.
Perform the Base Sensor Test. See
“BASE SENSOR TEST” on page 176.
a Select Base Sensor Test, and press Select.
b Select S2 Sensor, and press Select.
c Pull tray 1 out, and rotate the S2 sensor flag (A). (The S2 sensor is
located in the front of the center paper pick motor drive assembly
housing.) It should rotate freely and return to its original position.
Problem resolved. Go to step 4.
d Watch the display while pushing up on the flag.
Does the display indicate Media Clean and Media Present?
Diagnostic information
70
Page 71
Actions Yes No
5027
Step 4
Turn the printer off, and remove the rear cover. See
on page 290.
Is the JSP1 cable connector properly connected to the controller board?
“Rear cove r removal”
Go to step 5. Reseat the connector.
Step 5
Turn the printer on, and check the voltage at JSP1 pin 15.
Is the voltage approximately +5 V dc?
Understanding printer messages
• “Understanding the printer messages” on page 72
Diagnostic information
71
Replace the paper pick
motor drive assembly.
“Paper pick motor
See
drive assembly
standard tray
removal” on page
287.
Replace the controller
board. See
board removal” on
page 291.
“Controller
Page 72
Understanding the printer messages
Message Action
5027
Adjusting color
Change [paper source] to [custom type
name]
Change [paper source] to [custom string]
Change [paper source] to [paper type]
[paper size]
Close door
[Color] cartridge low [88.xy]
[Color] cartridge nearly low [88.xy]
[Color] cartridge very low [88.xy]
Wait for the process to complete.
Try one or more of the following:
• Load the correct size and type of paper in the tray, and
then select Finished changing paper on the printer control
panel to clear the message and continue printing. For
non‑touch‑screen models, press OK to confirm.
Note: Make sure the paper size and type are specified in
the Paper menu on the printer control panel.
• Cancel the job.
Make sure the right side cover is installed, and then close the
front and top doors to clear the message.
You may need to order a toner cartridge. If necessary, select
Continue to clear the message and continue printing. For
non‑touch‑screen models, press OK to confirm.
If necessary, select Continue to clear the message and
continue printing. For non‑touch‑screen models, press OK to
confirm.
You may need to replace the toner cartridge very soon. If
necessary, select Continue to clear the message and continue
printing. For non‑touch‑screen models, press OK to confirm.
Black and color imaging kit low [84.xy]
Black and color imaging kit nearly low
[84.xy]
Black and color imaging kit very low
[84.xy]
Complex page, some data may not have
printed [39]
You may need to order an imaging kit. If necessary, select
Continue to clear the message and continue printing. For
non‑touch‑screen models, press OK to confirm.
If necessary, select Continue to clear the message and
continue printing. For non‑touch‑screen models, press OK to
confirm.
You may need to replace the imaging kit very soon. If
necessary, select Continue to clear the message and continue
printing. For non‑touch‑screen models, press OK to confirm.
Try one or more of the following:
• From the printer control panel, select Continue to ignore
the message and continue printing. For non‑touch‑screen
models, press OK to confirm.
• Cancel the current job. For non‑touch‑screen models,
press OK to confirm.
• Install additional printer memory.
Diagnostic information
72
Page 73
Message Action
5027
Configuration change, some held jobs were
not restored [57]
Defective flash detected [51]
Error reading USB drive. Remove USB.
Error reading USB hub. Remove hub.
Held jobs are invalidated because of any of the following
possible changes in the printer:
• The printer firmware has been updated.
• The tray for the print job is removed.
• The print job is sent from a flash drive that is no longer
attached to the USB port.
• The printer hard disk contains print jobs that were stored
when the hard disk was installed in a different printer
model.
From the printer control panel, select Continue to clear the
message. For non‑touch‑screen models, press OK to confirm.
Try one or more of the following:
• Replace the defective flash memory card.
• From the printer control panel, select Continue to ignore
the message and continue printing. For non‑touch‑screen
models, press OK to confirm.
• Cancel the current print job.
An unsupported USB device is inserted. Remove the USB
device, and then insert a supported one.
An unsupported USB hub has been inserted. Remove the USB
hub, and then install a supported one.
Incompatible tray [x] [59]
Incorrect paper size, open [paper source]
[34]
Insert Tray [x]
Insufficient memory for Flash Memory
Defragment operation [37]
Remove, and then reinstall the indicated tray to clear the
message.
Try one or more of the following:
• Load the correct size of paper in the tray.
• From the printer control panel, select Continue to clear
the message and print using a different tray. For
non‑touch‑screen models, press OK to confirm.
• Check the tray length and width guides and make sure the
paper is loaded properly in the tray.
• Make sure the correct paper size and type are specified in
the Printing Preferences or in the Print dialog.
• Make sure the paper size and type are specified in the
Paper menu on the printer control panel.
• Make sure that the paper size is correctly set. For example,
if MP Feeder Size is set to Universal, then make sure the
paper is large enough for the data being printed.
• Cancel the print job.
Insert the indicated tray into the printer.
Try one or more of the following:
• From the printer control panel, select Continue to stop the
defragmentation and continue printing. For
non‑touch‑screen models, press OK to confirm.
Diagnostic information
73
Page 74
Message Action
5027
Insufficient memory, some Held Jobs were
deleted [37]
Insufficient memory to collate job [37]
Insufficient memory to support Resource
Save feature [35]
Insufficient memory, some held jobs will
not be restored [37]
Load [paper source] with [custom type
name]
Load [paper source] with [custom string]
Load [paper source] with [paper size]
Load [paper source] with [paper type]
[paper size]
The printer deleted some held job to process current job.
Select Continue to clear the message. For non‑touch‑screen
models, press OK to confirm.
Try one or more of the following:
• From the printer control panel, select Continue to print
the part of the job already stored and begin collating the
rest of the print job. For non‑touch‑screen models, press
OK to confirm.
• Cancel the current print job.
Install additional printer memory or select Continue on the
printer control panel to disable Resource Save, clear the
message, and continue printing. For non‑touch‑screen printer
models, press OK to confirm.
Try one or more of the following:
• From the printer control panel, select Continue to clear
the message. For non‑touch‑screen printer models, press
OK to confirm.
• Delete other held jobs to free up additional printer
memory.
Try one or more of the following:
• Load the tray or feeder with the correct size and type of
paper.
• To use the tray with the correct paper size or type, select
Finished loading paper on the printer control panel. For
non‑touch‑screen printer models, press OK to confirm.
Note: If the printer detects a tray that has the correct
paper type and size, then it feeds from that tray. If the
printer cannot detect a tray that has the correct paper
type and size, then it prints from the default paper
source.
• Cancel the current job.
Load Manual Feeder with [custom string]
Load Manual Feeder with [custom type
name]
Load Manual Feeder with [paper size]
Load Manual Feeder with [paper type]
[paper size]
Maintenance kit low [80.xy]
Diagnostic information
Try one or more of the following:
• Load the feeder with the correct size and type of paper.
• Depending on your printer model, touch Prompt each
page, paper loaded or press OK on the printer control
panel to clear the message and continue printing.
• Cancel the current job.
You may need to order a maintenance kit. For more
information, contact customer support at
http://support.lexmark.com or your service representative.
If necessary, select Continue to clear the message and
continue printing. For non‑touch‑sc reen printer models, press
OK to confirm.
74
Page 75
Message Action
5027
Maintenance kit nearly low [80.xy]
Maintenance kit very low [80.xy]
Memory full [38]
Network [x] software error [54]
For more information, contact customer support at
http://support.lexmark.com or your service representative.
If necessary, select Continue to clear the message and
continue printing. For non‑touch‑sc reen printer models, press
OK to confirm.
You may need to replace the maintenance kit very soon. For
more information, contact customer support at
http://support.lexmark.com or your service representative.
If necessary, select Continue to clear the message and
continue printing. For non‑touch‑sc reen printer models, press
OK to confirm.
Try one or more of the following:
• From the printer control panel, select Cancel job to clear
the message. For non‑touch‑screen printer models, press
OK to confirm.
• Turn off the printer, wait for about 10 seconds, and then
turn the printer back on.
• Update the network firmware in the printer or print
server. For more information, contact customer support.
Try one or more of the following:
• From the printer control panel, select Continue to
continue printing. For non‑touch‑screen printer models,
Not enough free space in flash memory for
resources [52]
press
to confirm.
• Turn off the printer, wait for about 10 seconds, and then
turn the printer back on.
• Update the network firmware in the printer or print
server. For more information, visit the Lexmark support
Web site at
Try one or more of the following:
http://support.lexmark.com.
• From the printer control panel, select Cancel job to clear
the message. For non‑touch‑screen printer models, press
OK to confirm.
• Delete fonts, macros, and other data stored in the flash
memory.
• Upgrade to a larger capacity flash memory card.
Note: Downloaded fonts and macros that are not
previously stored in the flash memory are deleted.
Diagnostic information
75
Page 76
Message Action
5027
Non‑Lexmark [color] [supply type], see
User’s Guide [33.xy]
Note: The supply type can be toner cartridge or the imaging
kit.
The printer has detected a non‑Lexmark supply or part
installed in the printer.
Your Lexmark printer is designed to function best with genuine
Lexmark supplies and parts. Use of third-party supplies or
parts may affect the performance, reliability, or life of the
printer and its imaging components.
All life indicators are designed to function with Lexmark
supplies and parts, and may deliver unpredictable results if
third-party supplies or parts are used. Imaging component
usage beyond the intended life may damage your Lexmark
printer or its associated components.
Warning—Potential Damage: Potential Damage ‑ Use of
third-party supplies or parts can affect warranty coverage.
Damage caused by the use of third-party supplies or parts
may not be covered by warranty. To accept any and all of
these risks, and to proceed with the use of non-genuine
supplies or parts in your printer, press and hold Cancel and
# on the printer control panel simultaneously for 15
seconds. For non‑touch‑screen printer models, press OK and
Cancel simultaneously for 15 seconds to clear the message
and continue printing. If you do not wish to accept these
risks, then remove the third-party supply or part from your
printer, and then install a genuine Lexmark supply or part.
Note: For the list of supported supplies, see the “Ordering
supplies” section of the User's Guide or visit
http://support.lexmark.com.
PPDS font error [50]
Reinstall missing or unresponsive
[color] cartridge [31.xy]
Try one or more of the following:
• From the printer control panel, select Continue to clear
the message and continue printing. For non‑touch‑screen
printer models, press OK to confirm.
• If the printer cannot find the requested font, then from
the printer control panel, navigate to: PPDS menu > Best
Fit > On
The printer will find a similar font and reformat the
affected text.
• Cancel the job.
Try one or more of the following:
• Install the missing toner cartridge. For more information,
see the "Replacing supplies" section of the User’s Guide.
• Remove the unresponsive cartridge, and then reinstall it.
Note: If the message appears after reinstalling the supply,
then the cartridge may be defective. Replace the cartridge.
Diagnostic information
76
Page 77
Message Action
5027
Reinstall missing or unresponsive black
and color imaging kit [31.xy]
Reload printed pages in Tray [x]
Remove packaging material, [area name]
Remove paper from standard output bin
Replace [color] cartridge, 0 estimated
pages remain [88.xy]
Try one or more of the following:
• Install the missing imaging kit. For more information, see
the "Replacing supplies" section of the User’s Guide.
• Remove the unresponsive imaging kit, and then reinstall
it.
Note: If the message appears after reinstalling the supply,
then the imaging kit may be defective. Replace the imaging
kit.
Try one or more of the following:
• From the printer control panel, select Continue to clear
the message and continue printing the second side of the
sheet. For non‑touch‑screen printer models, press OK to
confirm.
1 Remove any remaining packing material from the
indicated location.
2 From the printer control panel, touch Continue to clear
the message. For non‑touch‑screen printer models, press
OK to confirm.
Remove the paper stack from the standard bin.
Replace the indicated toner cartridge to clear the message and
continue printing. For more information, see the instruction
sheet that came with the supply.
Note: If you do not have a replacement cartridge, then see
the “Ordering supplies” section of the User’s Guide or visit
http://support.lexmark.com.
Replace [color] cartridge, printer
region mismatch [42.xy]
Install a toner cartridge that matches the region number of
the printer. x indicates the value of the printer region. y
indicates the value of the cartridge region. x and y can have
the following values:
• 0: Global
• 1: United States, Canada
• 2: European Union (EU), European Economic Area (EEA),
Switzerland
• 8: Rest of the world
• 9: Invalid
Notes:
• The x and y values are the .xy of the error code shown
on the printer control panel.
• The x and y values must match for printing to continue.
Diagnostic information
77
Page 78
Message Action
5027
Replace [type] imaging kit, 0 estimated
pages remain [84.xy]
Replace defective [color] cartridge
[31.xy]
Replace defective black and color imaging
kit [31.xy]
Replace maintenance kit, 0 estimated
pages remain [80.xy]
Replace the indicated imaging kit to clear the message and
continue printing. For more information, see the instruction
sheet that came with the supply.
Note: If you do not have a replacement imaging kit, then
see the "Ordering supplies" section of the User’s Guide or
http://support.lexmark.com.
visit
Replace the defective toner cartridge to clear the message.
For more information, see the instruction sheet that came
with the supply.
Note: If you do not have a replacement toner cartridge,
then see the "Ordering supplies" section of the User’s Guide
http://support.lexmark.com.
or visit
Replace the defective imaging kit to clear the message and
continue printing. For more information, see the instruction
sheet that came with the supply.
Note: If you do not have a replacement imaging kit, then
see the "Ordering supplies" section of the User’s Guide or
http://support.lexmark.com.
visit
Contact customer support at
your service representative, and then report the message. The
printer is scheduled for maintenance.
http://support.lexmark.com or
Replace missing [color] cartridge
[31.xy]
Replace missing black and color imaging
kit [31.xy]
Replace waste toner bottle [82.xy]
Replace unsupported [color] cartridge
[32.xy]
Replace unsupported black and color
imaging kit [32.xy]
Replace missing waste toner bottle
[82.xy]
Install the indicated toner cartridge to clear the message. For
more information, see the “Replacing supplies” section of the
User’s Guide.
Install the indicated imag ing kit to clear the message. For more
information, see the “Replacing supplies” section of the User’s
Guide.
Replace the waste toner bottle to clear the message.
Remove the toner cartridge, and then install a supported one
to clear the message.
Note: If you do not have a replacement cartridge, then see
the "Ordering supplies" section of the User’s Guide or visit
http://support.lexmark.com.
Remove the indicated imaging kit, and then install a supported
one to clear the message.
Note: If you do not have a replacement imaging kit, then
see the "Ordering supplies" section of the User’s Guide or
http://support.lexmark.com.
visit
Install the missing waste toner bottle to clear the message.
For more information, see the instruction sheet that came
with the supply.
Diagnostic information
78
Page 79
Message Action
5027
Restore held jobs?
SMTP server not set up. Contact system
administrator.
Some held jobs were not restored
Standard network software error [54]
Try one or more of the following:
• Select Restore on the printer control panel to restore all
held jobs stored in the printer hard disk. For
non‑touch‑screen printer models, press OK to confirm.
• Select Do not restore if you do not want any print jobs to
be restored. For non‑touch‑screen printer models, press
OK to confirm.
From the printer control panel, touch Continue to clear the
message.
Note: If the message appears again, then contact your
system support person
From the printer control panel, select Continue to clear the
message. For non‑touch‑screen printer models, press OK to
confirm.
Note: Held jobs that are not restored remain in the printer
hard disk and are inaccessible.
Try one or more of the following:
• From the printer control panel, select Continue to
continue printing. For non‑touch‑screen printer models,
press OK to confirm.
• Turn off the printer and then turn it back on.
• Update the network firmware in the printer or print
server. For more information, contact customer support.
Standard USB port disabled [56]
Supply needed to complete job
From the printer control panel, select Continue to clear the
message. For non‑touch‑screen printer models, press OK to
confirm.
Notes:
• The printer discards any data received through the USB
port.
• Make sure the USB Buffer menu is not set to Disabled.
Try one or more of the following:
• From the printer control panel, touch Prompt for supplies
to view all error messages that indicate what supplies are
needed to continue processing the current job. For
non‑touch‑screen printer models, press OK to clear the
message and continue printing.
1 Order the missing supply immediately.
2 Install the supply. For more information, see the
instruction sheet that came with the supply.
• Cancel the print job, then install the missing supply, and
then resent the print job.
Diagnostic information
79
Page 80
Message Action
5027
Too many flash options installed [58]
Too many trays attached [58]
Unformatted flash detected [53]
Waste toner bottle nearly full [82.xy]
1 Turn off the printer.
2 Unplug the power cord from the electrical outlet.
3 Remove the extra trays.
4 Connect the power cord to properly grounded electrical
outlet.
5 Turn the printer back on.
1 Turn off the printer.
2 Unplug the power cord from the electrical outlet.
3 Remove the extra trays.
4 Connect the power cord to a properly grounded electrical
outlet.
5 Turn the printer back on.
Try one or more of the following:
• From the printer control panel, select Continue to
continue printing. For non‑touch‑screen printer models,
press OK to confirm.
• Format the flash memory.
Note: If the error message remains, then the flash memory
may be defective and need to be replaced.
You may need to order a waste toner bottle. If necessary,
select Continue on the printer control panel to clear the
message and continue printing. For non‑touch‑screen printer
models, press OK to confirm.
Weblink server not set up. Contact system
administrator.
Printer hardware errors
• “110 errors” on page 82
• “121 errors” on page 84
• “126 errors” on page 90
• “133 errors” on page 90
• “141 errors” on page 93
• “147 errors” on page 95
• “171 errors” on page 97
• “Steps before starting the 9yy service checks” on page 98
• “900 errors” on page 100
• “91y errors” on page 106
An error occurred on the SMTP server, or the SMTP server is
not configured properly.
From the printer control panel, touch Continue to clear the
message.
Note: If the message appears again, then contact your
system support person.
Diagnostic information
80
Page 81
• “938 errors” on page 106
• “95y errors” on page 107
• “96y errors” on page 110
• “97y errors” on page 111
• “982 errors” on page 112
• “990 errors” on page 112
• “Base printer symptoms” on page 114
• “Bin‑full/narrow media sensor service check” on page 115
• “Toner meter cycle (TMC) card service check” on page 117
• “Dead printer service check” on page 117
• “Front door sensor or switches service check” on page 119
• “Operator panel (display is dim and unchanging) service check” on page 123
• “Operator panel (displays all diamonds, no beeps, or five beeps) service check” on page 127
• “Operator panel (display blank) service check” on page 131
• “Operator panel (one or more operator panel buttons fail) service check” on page 135
• “Operator panel USB cable service check” on page 136
• “USB service check” on page 137
• “Network service check” on page 137
5027
Diagnostic information
81
Page 82
110 errors
110 error messages
Error code Description Action
5027
110.xx The printhead <color> error. Go to
110.01 The printhead <color> lost HSYNC
110.02 The printhead <color> failed to complete servo.
110.03 The printhead <color> mirror motors lost motor
lock.
110.04 The printhead <color> mirror motors lost motor
lock.
110.05 Failure reading NVRAM from printhead
110.06 The printhead <color> thermistor is open.
110.07 The printhead <color> thermistor is shorted.
110.08 The printhead <color> laser showed bad in
testing.
110.09 The printhead <color> SOS EOS measurement did
not complete.
110.10 The printhead <color> has bad SOS EOS
measurement.
110.11 Failure writing data to the printhead.
110.12 Failure reading data from the printhead.
page 83.
“Printhead service check” on
110.13 Printhead declared error.
Diagnostic information
82
Page 83
Printhead service check
Actions Yes No
5027
Step 1
POR the printer.
Does this solve the problem?
Step 2
Turn the printer off, and then remove the rear cover. See
removal” on page 290.
Check the cables at JMIRR1 and JPH1 on the controller board for proper
connection, the printhead cable for pinch points, and the cable or
connector for any other damage.
Is the cable damaged?
“Rear cover
The problem is solved. Go to step 2.
Replace the printhead.
“Printhead
See
removal” on page
299.
Go to step 3.
Step 3
Turn the printer on, and then wait until the printer posts an error. Using
a voltmeter, check the following values at JMIRR1:
Pin 1: +5 V dc
Pin 2: +3.3 V dc
Pin 3: +5 V dc
Pin 4: Ground
Pin 5: +24 V dc
Are the values approximately correct?
Diagnostic information
83
Replace the controller
board. See
board removal” on
page 291.
“Controller
Replace the printhead.
“Printhead
See
removal” on page
299.
Page 84
121 errors
121 error messages
Error code Description Action
5027
121.xx Fuser error Go to
121.01 Attempting to print with estimated power at or
below minimum power.
121.02 Fuser is over temperature.
121.03 Fuser open thermistor check failed.
121.04 Attempting to print with estimated power at or
above minimum power.
121.05 Fuser failed to reach final temperature in time.
121.06 Attempting to print when the estimated power is
too low.
121.07 Timed out waiting for home sensor event
121.08 Wrong lamp bit is set in NVRAM.
121.10 Fuser failed to warm up.
121.11 Fuser under temperature error while in standby. Go to
121.12 Fuser under temperature error while printing.
121.13 Fuser open thermistor check failed for second
thermistor.
121.14 Fuser shorted thermistor check failed for hot roll
thermistor.
“Fuser service check” on page 86.
“Fuser service check” on page 86.
121.15 Fuser shorted thermistor check failed for second
thermistor.
121.16 Estimated power is at or above the maximum
power.
121.17 Total failure to close fuser nip.
121.26 Attempting to print with estimated power at or
below minimum power.
121.27 Fuser over temperature.
121.28 Fuser open thermistor check failed.
Diagnostic information
84
Page 85
Error code Description Action
5027
121.29 Attempting to print with estimated power at or
above minimum power.
121.30 Fuser failed to reach final temperature in time.
121.31 Fuser power is below minimum.
121.36 Fuser under temperature in standby.
121.37 Fuser under temperature while printing.
121.38 Fuser open thermistor.
121.39 Fuser shorted thermistor.
121.40 Fuser shorted thermistor.
121.42 Fuser power above maximum.
121.5x Fuser is past life and has an error. Go to
121.6x Fuser is past life and has an error.
121.7x Fuser is past life and has an error.
121.8x Fuser is past life and has an error.
121.9x Fuser is past life and has an error.
Go to
page 267.
“Fuser service check” on page 86.
“Fuser assembly removal” on
Diagnostic information
85
Page 86
Fuser service check
Actions Yes No
5027
Step 1
Some of these errors are caused by a faulty component on the LVPS. Check
the history file in the printer to verify other occurrences. If there are
others, then replace the LVPS. See
assembly removal” on page 226.
Does this solve the problem?
Step 2
Turn the printer off, and remove the rear cover. See
on page 290.
Check the cable at JFUSES1 for proper connection to the controller board,
the cable for pinch points, and the cable or connector for any other
damage.
“Low‑voltage power supply (LVPS)
“Rear cove r removal”
The problem is solved. Go to step 2.
Replace the fuser
cable.
Go to step 3.
Is the cable damaged?
Diagnostic information
86
Page 87
Actions Yes No
5027
Step 3
Check the connector JLVPS1 for proper connection to the co ntroller board,
the cable for pinch points, and the cable or connector for any other
damage.
Repair or replace the
LVPS cable.
Go to step 4.
Is the cable damaged?
Diagnostic information
87
Page 88
Actions Yes No
5027
Step 4
Open the front cover, and check the power cable (A) on the left side of
the fuser.
Remove the right cover assembly. See
on page 232.
Check the thermistor cables and connections (B) on the right side of the
fuser.
“Right cover assembly removal”
Repair the cables. If the
cables cannot be
repaired, then replace
the fuser. See
assembly removal” on
page 267.
“Fuser
Go to step 5.
Are the cables or connectors damaged?
Diagnostic information
88
Page 89
Actions Yes No
5027
Step 5
Check the following values at JFUSES1:
Pin 1: +24 V dc (door closed)
Pin 2: +24 V dc (doors closed)
Pin 3: +24 V dc (doors closed)
Pin 4: +24 V dc (doors closed)
Pin 5: Between 0.6 and 3.28 V dc
Pin 6: Ground
Pin 8: Ground
Pin 10: Between ‑3 and +3.3 V dc
Pin 11: Ground (no wire)
Go to step 6. Replace the controller
board. See
board removal” on
page 291.
“Controller
Are the values correct?
Step 6
Replace the fuser. See
Does the error clear?
“Fuser assembly removal” on page 267.
Diagnostic information
89
The problem is solved. Replace the controller
board. See
board removal” on
page 291.
“Controller
Page 90
126 errors
126 error messages
Error code Description Action
5027
126.xx Low voltage power supply did not detect zero
crossing.
126.01 Low voltage power supply did not detect zero
crossing.
Go to
assembly removal” on page 226.
Go to
assembly removal” on page 226.
133 errors
133 error messages
Error code Description Action
133.1x The black cartridge toner meter cycle (TMC)
switch error:
• .11 recoverable
• .12 nonrecoverable
133.2x The cyan cartridge toner meter cycle (TMC) switch
error:
• .21 recoverable
• .22 nonrecoverable
133.3x The magenta cartridge toner meter cycle (TMC)
switch error:
• .31 recoverable
• .32 nonrecoverable
Go to
TMC card service check” on page 91.
“Low‑voltage power supply (LVPS)
“Low‑voltage power supply (LVPS)
“Toner meter sensors (Y, C, M, K) on
133.4x The yellow cartridge toner meter cycle (TMC)
switch error:
• .41 recoverable
• .52 nonrecoverable
Diagnostic information
90
Page 91
Toner meter sensors (Y, C, M, K) on TMC card service check
Actions Yes No
5027
Step 1
Remove the toner cartridge, and inspect the lenses on the toner meter
cycle (TMC) card.
Are the lenses blocked, damaged, or dirty?
Repair or replace the
TMC card. See
meter cycle (TMC) card
removal” on page
234.
“Toner
Go to step 2.
Diagnostic information
91
Page 92
Actions Yes No
5027
Step 2
Turn the printer off, and remove the rear cover. See
on page 290.
Turn the printer on, and measure the values below at JCTM1 during POR:
Pin 1: +5 V dc
Pin 2: +3.3 V dc
Pin 3: +3.3 V dc
Pin 4: +3.3 V dc
Pin 5: +3.3 V dc
Pin 6: Ground
“Rear cove r removal”
Replace the controller
“Controller
board.
board removal” on
page 291.
Replace the TMC card.
“Toner meter cycle
See
(TMC) card removal”
on page 234.
Are any of the values incorrect?
Diagnostic information
92
Page 93
141 errors
141 error messages
Error code Description Action
5027
141.0x Cartridge motor error Go to
141.01 Failed to achieve lock for motor
within allotted time.
141.02 Time out waiting for SAP BLDC
motor to reach valid FG speed.
141.03 Time out waiting for
MP_NUM_INITIAL_SAP_HALLS
.
141.05 Lost lock for motor.
141.06 Excessive SAP BLDC PWM.
141.07 Motor stalled in timebased
communication.
141.2x Cyan/magenta/yellow
cartridge motor error.
141.21 Failed to achieve lock for motor
within allotted time.
141.22 Time out waiting for SAP BLDC
motor to reach valid FG speed.
141.23 Time out waiting for
MP_NUM_INITIAL_SAP_HALLS
.
“Cartridge motor error service check” on page 94.
141.24 Time out waiting for SAP BLDC
motor.
141.25 Lost lock for motor.
141.26 Excessive SAP BLDC PWM.
141.27 Motor stalled in timebased
communication.
Diagnostic information
93
Page 94
Cartridge motor error service check
Action Yes No
5027
Step 1
Turn the printer off, and remove the rear cover. See
on page 290.
Check the cable JCARTB1 for proper connection to the system board.
“Rear cove r removal”
Go to step 2. Reseat the cable.
Is the cable properly connected?
Step 2
Check the cable for damage.
Is the cable damaged?
Diagnostic information
94
Replace the BLDC K
image transfer unit
cable. See
transfer unit (ITU)
removal” on page
243.
“Image
Go to step 3.
Page 95
Action Yes No
5027
Step 3
Remove the left cover assembly. See
page 219.
Check the cables connected to the cartridge motor assembly.
Is the cable connected properly?
“Left cover assembly removal” on
Go to step 4. Reseat the cable.
Step 4
Replace the EP drive assembly. See
page 221.
Does the problem remain?
“EP drive assembly removal” on
Replace the controller
board. See
board removal” on
page 291.
147 errors
147 error messages
Error code Description Action
147.xx Staging motor error Go to
147.01 Staging motor has exceeded the ramp up table.
147.02 Staging motor has exceeded number of encoders
at minimum PWM.
147.03 Staging motor has exceeded number of encoders
at maximum PWM.
147.04 Motor encoder count did not change between
interrupts.
check” on page 96.
The problem is solved.
“Controller
“Paper pick motor drive assembly service
147.05 Staging motor has encountered a stall time out.
Diagnostic information
95
Page 96
Paper pick motor drive assembly service check
The input (S2) sensor is part of the paper pick motor drive assembly, and is not available separately.
Actions Yes No
5027
Step 1
Check the condition of the pick tires, and replace if necessary. See
tire removal” on page 303.
Does this solve the problem?
Step 2
Turn the printer off, and then remove the rear cover. See
removal” on page 290. Check the table at JSP1 on the controller board
for proper connection.
“Rear cover
“Pick
The problem is solved. Go to step 2.
Go to step 4. Properly connect the
cables, and POR the
printer.
Go to step 3.
Is the cable properly connected?
Step 3
Did the printer function correctly after reconnecting the cables?
Diagnostic information
96
The problem is solved. Go to step 4.
Page 97
Actions Yes No
5027
Step 4
Turn the printer on, and then verify the following approximate values at
JSP1:
Pin 2: +24 V dc
Pin 4: +24 V dc
Pin 5: +5 V (when paper is picked)
Pin 7: Ground
Pin 8: Ground
Pin 10: +5 V dc
Pin 12: _5 V dc (when paper is picked)
Pin 15: +5 V dc
Pin 16: Ground
Are the values approximately correct?
Replace the paper pick
motor drive assembly.
See
drive assembly
standard tray
removal” on page
287.
171 errors
171 error messages
Error code Description Action
“Paper pick motor
Replace the controller
board. See
board removal” on
page 291.
“Controller
171.01 The printer fan has stalled. Go to
“Fan error service check” on page 98.
Diagnostic information
97
Page 98
Fan error service check
Actions Yes No
5027
Turn the printer off, and remove the rear cover. See
on page 290.
Turn the printer on, and check the fan cable at JFAN1 for the following
values:
Pin 1: +3.3 V dc
Pin 2: Ground
Pin 3 0 (fan off)
“Rear cove r removal”
Replace the fan. Replace the controller
board. See
board removal” on
page 291.
“Controller
Are the measured values correct?
Steps before starting the 9yy service checks
Before starting the service checks in this section, you will need to retrieve certain information. This will aid your next
level of support in diagnosing the problem before replacing the controller board.
Warning—Potential Damage: Do not replace the controller board unless directed by your next level of support.
1 Collect the history information and firmware logs (Fwdebug and logs.tar.gz) from the SE menu.
2 Collect the settings from the menu settings page.
3 Collect information from the user.
Note: Not all of the items can be retrieved from the printer you are working on.
Diagnostic information
98
Page 99
A. Collecting the history information from the SE menu
Note: Make sure your printer is connected to a network or to a print server.
1 From a Web browser, type http://printer_IP_address/se, and then press Enter.
Notes:
• printer_IP_address is the TCP/IP address of the printer
• se is required to access the printer diagnostic information
2 Click History Information, copy all information, and then save it as a text file.
3 E-mail the text file to your next level of support.
B. Collecting the firmware logs (Fwdebug and logs.tar.gz) from the SE menu
Notes:
• Make sure your printer is connected to a network or to a print server.
• Some printers are designed to restart automatically after a 9yy error. On these printers, you can retrieve the
secondary crash code information using the SE menu.
• Fwedebugs can also be referred to as LBtrace. If FWEdebugs does not appear in the list, then look for LBtrace.
Multiple LBtrace logs can appear in the list of links referred to in step 2.
5027
1 From a Web browser, type http://printer_IP_address/se, and then press Enter.
2 Click List Fwedebugs captured during reboots. This will provide you a list of the secondary crash codes retrieved
from prior reboots.
Note: If there are Fwedebugs listed, click Dump Fwedebug log0, Dump Fwedebug log1, and Dump Fwedebug
log2. Clicking these links will dump the debug logs to the computer. Take note of the destination folder where
the logs are saved.
3 E-mail the logs to your next level of support.
Note: Some machine SE menus give you the option of clicking Logs Gzip Compressed. If this option is shown in
the menu, then click it and retrieve the compressed log file. Take note of the destination folder where the log
file is saved.
C. Collecting the settings from the menu settings page
Note: The menu settings page is different for each printer. For more information see the User’s Guide. Your next
level of support will tell you which page they want to see.
Copying the menu settings page from the Embedded Web Server (EWS)
Note: Make sure your printer is connected to a network or to a print server.
1 From a Web browser, type http://printer_IP_address, and then press Enter.
2 Click Settings, and then select one of the settings page from the links shown on the page.
3 Copy all information, and then save it as a text file.
4 E-mail the text file to your next level of support.
Diagnostic information
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Page 100
Printing the menu settings page
1 From the home screen, navigate to Reports > Menu Settings Page.
2 Print the menu settings page, and then use Scan to E-mail to send it to your next level of support.
D. Collecting information from the user
Ask the user for information about the following:
• Print job being run
• Operating system used
• Print driver used
• Other information on what was happening when the 9yy error occurred.
900 errors
900 error messages
Error code Description Action
5027
900.xx Unrecoverable RIP software error/illegal trap. Go to
on page 101.
“System software error service check”
Diagnostic information
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