Lexmark E450dn Service Manual

• Table of contents
• Start diagnostics
Edition: Ma y 15, 2007
Lexmark™ E450dn
4512-630
• Safety and notices
•Trademarks
• Index
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/ or other countries.
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4512-630
dition: May 15, 2007 he following paragraph does not apply to an y country where such provisions are inconsistent with local law:
EXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,
ITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
ERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or
mplied warranties in certain transacti ons; therefor e, this statement ma y not apply to you.
his publi cation could include technical inaccuracies or typographical errors. Chang es are peri odically made to the
nformation her ein; these changes will be inco rporat ed in later editions . Improvements or changes in the products or the
rograms descri bed m ay be made at any time.
omments may be addressed to Lexmark Int ernational, Inc., Department D22A/032-2, 740 West New Circle Road, exington, Kentucky 40550, U .S.A or e-mail at ServiceInfoAndTraining@Lexmark .com. Lexmark may use or distribute an f the inf ormati on you supply in any way it believes appropriate without incurring any obligation to you.
eferences in this pub lication to products, progr am s, or services do not imply that the manufacturer intends to mak e thes vailable in all countries in whic h it operates. Any reference to a product, program, or service is not intended to state or
mply that only that pr oduct, progr am, or service may be used. Any functi onall y equiv alent pro duct, progr a m, or service tha
oes not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in onjunction with other products, programs, or service s, except those expressly desi gnated by the manufacturer, are the ser’s responsibil ity.
exmark, Le x mark with diam ond desi gn, M arkNet a nd MarkVisi on are t rademarks of Lex mark I nternational , I nc. , regist er e
n the United States and/or other countries.
ictureGrade is a trademark of Lexmark Int ernational, Inc.
CL® is a registered trademark of the Hewlett-P ackard Company.
ll other trademarks are the property of their respective owners.
2006 Lexmark International, Inc.
All rights reserved.
NITED STATES GOVERNMENT RIGHTS
his softwar e and any accompanying documentation pro vided under this agreemen t are commercial computer sof tware nd documentation developed exclusively at private expense.
P/N 12G9709
4512-630

Table of contents

Table of contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Overview of the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Print quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Media trays and supply capaci ty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Connectivity and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Types of print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Tips on preventing jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Diagnostics information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Service errors (9xx.xx’s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
User status and attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Overview of the operator panel and menu s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Diagram of the printer menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Messages and error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
User attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cartridge error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Paper jam error codes (200-series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Service error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
POST symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Controller card service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Cooling fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Cover interlock switch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Dead machine service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
LVPS/HVPS service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Main motor servi ce check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Paper feed service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Paper jam error indication during POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Media picks duri ng POST and/or continuously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Media picks but st ops halfway through the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
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Media never picks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Media occasionally mispicks or picks multiple sheets at once . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Media skews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
Media “trees,” wrinkles, stacks poorly, or curls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
Parallel or USB port servi ce check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2 3
Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
Blank page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
Black page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Heavy background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 2 5
Partial blank image/white spots (no repeat ing pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Variation in image density horizontal ly across page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Poor fusing of image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Light print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
White or black lines or bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -27
Toner on back of page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 2 7
Solving print quality problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 2 8
Printhead servi ce check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
Diagnostic aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 2
Entering Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Exiting Diagnostic s mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Printhead assembly electronic adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Printhead assembly mechanical adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
PRINT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Input source te sts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Print quality pages (Prt Quality Pgs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
HARDWARE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Parallel Wrap tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
DUPLEX TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Quick Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Top/Left Margin (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1 6
Sensor Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Duplex Feed 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
INPUT TRAY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
Feed Tests (input tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
OUTPUT BIN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
Feed Tests (output bins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 1 9
Sensor Test (standard output bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
BASE SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
PRINTER SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Perm Page Count (permanent page count) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Engine Setting 1 through 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Edge to Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Parallel strobe adjustment (Par x Strobe Adj) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
iv S e rv ice Manual
4512-630
EP SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
EP Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Fuser Temperature (Fuser Temp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Print Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Charge Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Gap Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Print Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Clear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
EXIT DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Configuration menu (CONFIG MENU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Entering Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Available menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Maintenance page count (Maint Cnt Value) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Maintenance page counter reset (Reset Maint Cnt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Print quality pages (Prt Quality Pgs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Paper Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Env Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Change Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Reduced Curl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
USB Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Exit Config Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Repair information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Handling ESD-sensiti ve parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Front access cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Left side cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Right side cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Auto comp removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Auto comp clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Auto comp drive shaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Bezel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Controller card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Cover open sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Developer drive coupling assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Duplex removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Duplex gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Flag removal (top cover right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Fuser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Fuser power cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Link developer dri ve and access door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
LVPS/HVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Main motor drive removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Manual feed sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Manual paper feed clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Manual feed solenoi ds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Media level indicator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Table of contents v
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Narrow media sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 35
Operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3 6
Paper exit guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37
Paper feed rollers (autocompensator tires) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38
Paper input and dupl ex sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39
Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40
Reversing solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 4 1
Toner level sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 1
Transfer roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42
Tray 2 auto comp tire removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43
Upper front frame group removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44
Wear strip removal (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 4 6
Wear strip removal (tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 4 6
Locations and connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Controller card connector pin values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 2
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Preventive mainte nan ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Lubrication spec if ications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Maintenance kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Assembly 1: Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Assembly 2: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Assembly 3: Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Assembly 4: Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Assembly 5: Power cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1
Part number index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5
vi Se rvi c e M anua l

Notices and safety information

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

Laser no tice

The printer is certified in the U .S. to confo rm to the requir ements of DHHS 21 CFR Subchapter J for Class I (1) laser product s, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
Class I laser products are not consi dered to be hazardous. The pri nter contains internal ly a Class IIIb (3b) laser that is nominally a 5 milliwatt galli um arsenide laser operati ng in the wav elength region of 770-795 nanometers. The laser system and printer are designed so there is never an y hum an access to laser radiation ab ove a Class I level during normal operation, user maintenance, or pr escri bed service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigu ng der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 60825-1 gemäß amtlicher Bestäti gung erfüllt.
4512-630
Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die Klasse I überstei gen würde, Menschen k einesfall s err eicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifi ée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pa ys: cette imprimante répond aux normes IEC 60825-1 relatives aux produits laser de Classe I.
Les produits laser de Classe I sont considérés comm e des produits non dangereux. Cette imprimante est équipée d’un l aser de Classe IIIb (3b) (arséniure de gall ium d’une puissance nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son sys tème laser sont conçus pour impossible, dans des conditions normales d’uti lisation, d’entretien par l’utilisateur ou de révision, l’exposition à des rayonnements lase r supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampant e è certificata negli St ati Uniti per ess ere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti las er di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conf orme ai requisiti del la norma CEI 60825-1.
I prodotti laser di class e non sono con sider ati pericol osi. La stampan te contiene al suo interno un l aser di classe IIIb (3b) all’arseniuro di gallio dell a potenza di 5mW che opera sulla lunghezza d’onda compresa t ra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzio namento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.
Notices and saf ety information vii
4512-630

Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
Los productos láser de Clase I no se consideran pel igrosos. La impre sora contiene en su interior un láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nomin al a 5 miliv atios en una longi tud de onda de 770 a 795 nanómetros. El sistema láser y la impresora están diseñados de for ma que ninguna persona pueda verse afectada por ningún tipo de radiac ión láser superior al nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situaci ón de servic io técnico.

Declaração sobre Laser

A impressora está ce rtificada no s E. U .A. e m conf ormidade co m os r equi sito s da reg ulamenta ção DHHS 2 1 CFR Subcapítulo J para a Cla sse I (1) de produt os laser. Em outros locais, está certifi cada como um produto lase r da Classe I, em conf ormidade com os requisitos da norma IEC 60825-1.
Os produtos lase r da Classe I não sã o conside rados peri gos os. I nternamente , a impr esso ra cont ém um produ to laser da Classe IIIb (3b), designado laser de arseneto de potássio , de 5 milliwatts ,oper ando numa faixa d e comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca ex ist ir qualquer possiblidade de acesso humano a radi ação laser superior a um nív el de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assist ência prescritas.

Laserinformatie

De printer v oldoet aan de eis en die ges teld w orde n aan ee n laserprodukt v an klass e I. Voor de Ver enigde Stat en zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.
Laserprodukten van klasse I worden nie t al s ongevaarlij k aangemerkt. De printer is voor zien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met e en g olflengte van 770-795 nanometer . Het laser gedeelt e en de printer zij n zo ont worpen dat bij normaal gebru ik, bij onde rho ud of repar atie conform de voorschriften, nooit blootstelling mogelijk is aan laserst raling boven een niveau zoals voorgeschreven is voor klasse 1.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der
nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer. Lasersystem et og printeren er udformet således, at mennesk er aldrig udsættes for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.
viii Service Manual

Laserilmoitus

Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) ­lasertuotteeksi j a m uualla IEC 60825-1 -standardin mukaiseksi luo kan I l asertuot teeksi.
Luokan I lasertuottei ta ei pidet ä hai talli sina. Tulostimen sisäl lä on luo kan IIIb (3b) laser, joka on nimellisteholt aan 5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat rakenteeltaan sellaisi a , et tä käyttäjä ei joudu alt ti iksi luokkaa 1 suuremmalle säteilylle normaalin käytön, ylläpidon tai huollon aikana.

Huomautu s las er laittees ta

Tämä kirjoi tin on Yh dysv alloi ssa lu okan I ( 1) lase rlait teide n DHHS 21 CFR Subchapt er J -mää rityks en muk ainen ja muualla luo kan I l aserl aitteiden IEC 60825-1 -määri tyksen mukainen.
Luokan I las e r la itt e id e n e i ka ts o ta ol evan vaarallis ia käyttä jä lle . K irjoittim e s sa on si säinen luok a n IIIb (3 b ) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Lase rjärjestelmä ja kirjoitin on suunnitelt u siten, että käyttäj ä ei al tistu luokan I määrityksi ä voimakkaammalle säteilylle kirjoittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.
VARO! Av attaessa ja suojalukitus ohitettaessa olet alttiina näky mättömälle lasersäteilylle. Älä katso säteeseen.
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VARNING! Osynlig laserst rålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skriv aren kraven för laserprodukter av Kl ass I enligt kraven i IEC 60825-1.
Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer. Lasersystem et och skrivaren är utformade så att det aldrig finns ris k för att någon person utsätts f ör laserstrå lning över Klass I-ni vå vid normal användning, underhåll som utförs av användaren eller annan föreskriv en serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kra vene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter , og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.
Klasse I-la serprodukter er ikke å betrakte som f arlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer . Lasersystem et og skriveren er utformet slik at personer al dri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk , vedlikehol d som utf øres av brukeren, eller foreskrevne serviceoperasjoner.
Notices and safety information ix
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Avís sobre el Làser

Segons ha estat certificat al s Estats Units , aquesta impressor a complei x els req uisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1.
Els productes l àser de classe I no es consideren perillosos. Aquesta impressora conté un làse r de cl asse IIIb (3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 770-795 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d’un niv ell de classe I durant una oper ació normal, durant les tasques de manteniment d’usuari ni durant els serveis que satisfacin les condicions prescrites.
x Service Manual
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Notices and safety information xi
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xii Service Manual
Safety information
The safety of this product is based on testi ng and approvals of t he original design and specific
components . The manufacturer is not responsibl e for safety in the event of use of unauthorized replacement parts .
The maintenance information for this product has been prepared for use by a professional service person
and is not intended to be used by others.
There may be an increased risk of electric shoc k and personal injury during disassem bly and servicing of
this product . Pro fessional service personnel should understand this and take necessary precautions.
CAUTION: When you see th is symbol , ther e is a danger f rom hazard ous v olt age in the ar ea of the
product where y ou ar e working . Unplug the product bef ore you beg in, or use c autio n if t he produc t must receive power in order to perform the task.

Consignes de sécurité

La sécurité de ce produit repose sur des tests et des
agréations portant sur sa conception d'origine et sur des composants particulier s. Le fabricant n'ass ume aucune respon sabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.
Les consignes d'entretien et de répar ati on de ce produit s'adressent uniquement à un personnel de
maintenance qualifié.
Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel
d'entretien qualifié devra prendre toutes les précautions nécessai res.
ATTENTION : Ce symbole indique la présence d'unetension dangereuse dans la partie du
produit sur laquelle vous tra vaillez. Débranchez le produit a vant de commencer ou f aites preuve de vigilance si l' exécution de la t âche exige que le produit reste sous tension.
4512-630

Norme di sicurezza

La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti
specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzion e non autorizzata delle parti.
Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di
assistenza autorizzato .
Durante lo smontaggio e la manutenzione di questo prodotto,
il rischio di subire scosse elettriche e danni al la persona è più elev ato. Il per sonale di assistenza autorizzato deve, quindi, adottare le precauzioni necessarie.
ATTENZIONE: Questo simbolo indica la presenza ditensione pericolosa nell'area del prodotto.
Scollegare il pr odotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l'intervento.
Safety information -xiii
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Sicherheitshinweise

Die Sicherheit di eses Produkts basiert auf Tests und Zulassungen des ursprüngl ichen Modells und
bestimmter Baut eil e. Bei Verwendung nicht genehmigter Ersatztei le wi rd vom Hersteller kei ne Verantwortung oder Haft ung für die Sicherheit übernommen.
Die Wartungsinformationen für dies es Produkt sind ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.
Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusät zliches Risiko eines
elektrischen Schlags und körperlicher Verletzung. Das zus tändige Fachpersonal sollte entsprechende Vorsichtsmaßn ahm en treffen.
ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in diesem
Bereich des Produkts auftreten kann. Zie hen Sie vor den Arbeiten am Gerät den Netzstecker des Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten an den Strom angeschlossen sein muß.

Pautas de Segu ridad

La seguridad de este prod ucto se basa en pruebas y aprobaciones del diseño original y component es
específico s. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas.
La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal
cualificado de mantenimiento.
Existe may o r riesg o de de scarga el éctrica y de dañ os person al es duran te e l desmont aj e y la r eparac ión de
la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.
PRECAUCIÓN: este símbolo indica que el voltaje dela parte del equipo con la que está
trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para trabajar con él, debe conectarlo.

Informações de Segurança

A segurança deste produto baseia-se em testes e aprovações do mode lo original e de componentes
específico s. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição não autorizadas.
As informações de segurança relativas a este produto dest inam-se a profissionais destes serviços e não
dev em ser utilizadas por outr as pessoas.
Risco de choques eléct ricos e ferimentos graves durante a desmontagem e manutenção deste produto .
Os profissio nais destes serviços devem estar avis ados deste facto e tomar os cuidados necessários .
CUIDADO: Quando vir este sí m bolo, existe a possível presença de uma potencial tens ão
perigosa na zona do produto em que está a trabalhar. Antes de começar, desligu e o produto da tomada eléctrica ou s eja cui dado so caso o pro duto te nha d e estar liga do à corrent e eléc trica para realizar a tarefa necessária.
-xiv Service Manual

Inf ormació de Seguretat

La seguretat d'aquest producte es basa en l'avaluació i apr ovació del disseny original i els components
específics. El fabricant no es fa responsable de les qüestions de seguretat si s'u tilitzen peces de recanvi no autoritzades.
La informació pel manteniment d’aquest producte està orientada exclusiv ame nt a professional s i no està
destinada a ningú que no ho sigui.
El risc de xoc elèctric i de danys personals pot augment ar durant el procés de desmuntatge i de servei
d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre les mesures con venients.
PRECAUCIÓ: aquest símbol in dica que el voltatge de la part de l'equip am b la qual esteu
treballan t és perillós . Abans de començar, desendolleu l'equ ip o extremeu les precaucions si, per treballar amb l'equip, l'heu de connectar.
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Safety information -xv
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Preface

This manual contains maintenance procedures for service personnel. It is divided into t he following ch apters:
1. General in fo rma tion contains a general description of t he printer and the maintenance approach used to
2. Diagn o sti c information contains an error indicator table, symptom tables, and service checks used to
3. Diagn osti c aids contains tests and checks used to locate or repeat symptoms of printer problems.
4. Repair info rma tion provides instructions for making printer adjustments and removing and installing
5. Connecto r locations uses illustrations to identify the connector locations and test points on the printer.
6. Preventive maintenance contai ns the lubrication specifications and recommendations to prev ent
7. Parts catalog contains illustrations and part numbers for individual FRUs.
Definitions
repair it. Special tools and test equipment are, as well as general environmental and safety instructions.
isolate failing field replaceable units (FRUs).
FRUs.
problems.
Appendix A contains service tips and info rmati on. Appendix B contains representative print samples.
Note: A note provides addition al i nformation. Warning: A warning identifies something that might damage the product hardware or software.
CAUTION: A caution identifies something that might cause a servicer harm.
CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the
product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
-xvi Service Manual

1. General information

The Lexmark™ E450dn is a monochrome laser pr inter designed for single users or small workgroups.
This book contains information on E450dn. For more information on E250d and E250dn, see the 4512-220, -230 service manual. manual.
minute on letter-size media (29 ppm on A4, 25ppm on legal).
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For inf ormation on E350d and 352dn, see the 4512-420, 430 service

Maintenance ap proach

The diagnostic information in this manua l le ads to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom ind ex, and service checks to determine the symptom and repair the f ailure. See
“Diagnostics info rmation” on page 2-1 for more information. See “Repair information” on page 4-1 to help
identify parts. After completing the repair, perform tests as needed to verify the repair.
General inf ormation 1-1
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Overview of the operator panel

The control panel consists of these items:
A 4-line, liquid crystal display (LCD) that can show both gr aphics and text
Eight buttons: Back, Menu, Stop, Select ( ), , , , and
Indicator light
A label located on the inside front door shows the control panel butt ons in your language. An additional translat ed label is included in the print er box.
Back Menu Stop
Voltar Zp t
ě Tilbage Terug Takaisin Retour Zurück Vissza Indietro
Tilbake Wró
aa
Hзд
Atrás Bakåt
Geri
Menu Nabídka Menu
ć
Menu Valikko Menu Menü Menü Menu
Meny Menu
Меню
Menú Meny
Menü
Parar Stop Stop Stop Seis Stop Stopp Leállítás Stop
Stopp Stop Стоп
Parar Stopp
Durdur
1-2 Se rvice Ma nual

Specifications

Memory

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Item
Standard DRAM 64MB Optional SDRAM 32MB Optional SDRAM 64MB Optional SDRAM 128MB Optional SDRAM 256MB Maximum DRAM 320MB Optional flash memory 32MB 1 Optional f ont cards (DBCS) 1
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Lexmark E450dn

Print qua li ty

Resolution
1200 Image qualit y ¹ 2400 Image qualit y ²
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Lexmark E450dn
1200 x 1200 dpi ³ 600 x 600 dpi 300 x 300 dpi ¹ 1200 Image quality defined as 600 dpi with 2 bit IET (image enhancement technology) default mode for all models ² 2400 Image quality defined as 600 and 4 bit IET ³ True 1200 dpi at ½ rated speed.
4
Although the printer supports the 300 dpi resol ution, it doesn’t supp ort a 300 dpi driver.
4
General inf ormation 1-3
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Media trays and supply capac ity

Item
Available input trays
250-sheet tray 550-sheet option drawer 550-sheet tray optional Dust cover optional
T oner and photoconductor
Toner cartridge 3,000 standard pages ¹ High toner cartridge n/a Photoconductor kit Up to 30,000 ¹ Declared va lue in accordance with ISO/IEC 19752 ² Based on approximately 5% coverage; actual yield may vary
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Lexmark E450dn
²
1-4 Se rvice Ma nual

Connectivity and compatibility

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Item
Data stream emulations
PCL 6 PostScript Level III Host Based Printing (HBP)/GDI Version 1 n/a Host Based Printing (HBP)/GDI Version 2 PPDS HTML n/a PDF (versio n 1.5) Compatibility Windows/Macintosh/Linux ¹
Standard local connections
Par allel (IEE 1284 bidirectional) USB*
Standard network connections
Ethernet (10/100 Base TX)
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Lexmark E450dn
Optional local connections
External print server support
Option slots
Memory slots (100-pin DIMM) 1 Flas h m emory / op tion ca rd 2 ² * The E450n product is a USB 2.0 certified de vice supporting high-speed (4 80M B/sec.) data transf er.
¹ Linux support for E450dn model is utilizing the PCL data stream. ² Only one slot active for flash memory or font card
General inf ormation 1-5
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Types of print media

Ensure tra ys are properly loaded. Never mix media types within a tr ay.
Source Sizes Types Weight
Input tra y 1 (250-sheet tray)
A4, A5, A6³, JIS, B5, letter, legal, executive, folio,
Paper, labels¹, transparencies
60–90 g/m (16–24 lb)
6
2
Input capacity (sheets)²
250 paper 50 labe ls¹ 50 transparenci es
statement
2nd Drawer option (550-sheet onl y—
E352dn only) Manual feed input
A4, letter, legal, A5, JIS, B5, executiv e, folio, statement
7
A4, A5, A6³, JIS, B5, letter, legal, executive, folio,
Paper, labels¹, transparencies
Paper, labels¹, transparencies, card stock,
4
envelopes
5
60–90 g/m (16–24 lb)
60–163 g/m (16–43 lb)
2
2
550 paper (20 lb) 50 labe ls¹ 50 transparenci es
1 sheet (all medias)
statement
5
Envelopes
:
monarch (7 ¾), 9, Com-10’, C5, B5, DL
Minimum f eed size: 76 X 127mm
Universa l (m a x ) paper: 216 X 357mm
¹ Single sided paper labels are supported for the occasional use of less than 20 pages per month. Labels such as vin yl labels, pharmacy labels or dual-sided labels are not supported.
² For 20 lb print material, unless otherwise noted. ³ A6 long grain media support/short grain A6 not supported
4
Card stock up to 90# i ndex. Designed to exit rear door. Short grain is recommended.
5
20 lb envelopes are recommended Wrinkling may also occur on the front side, but away from address or return address areas. Slight wrinkling (nit in address areas) is permitted on 24# enve lopes. Use envelopes that lay flat when individually placed on a table fac edown. The distance of any edge or corner from the table sh ould be less than 3 mm.
6
This refers to paper only. Treeing may occur on 16# paper.
7
Input using manual feeder is reduced to 1/2 speed
1-6 Se rvice Ma nual

Tips on preventing jams

Paper path

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*Measurement s are approximate paper lengths (millimeters) **Sensors are measured at rotation/posi tion which they are tripped
A Paper path A-B 117.8 B Manual feed sensor B-C 9.6 C Upper end feed rolls C-D 60.5 D Input sensor D-E 49.0 E Transf er roll E-F 110.7 F Fuser F-G 26.9 G Fuser exit rolls G-H 6.2 H Fuser exit sensor H-I 127.2
I Exit rolls I-J 26.4
J Exit sensor I-K 217.4 K Duplex unit K-L 102.5 L Duplex sensor L-M 16.2
M Auto compensator M-B 178.9
General inf ormation 1-7
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Most paper jams can be avoided by correctly loading paper and specialty media in the printer. The following hints can help prevent paper jams:
Do not load wrinkled, cre ased, or damp media.
Nev er mix media types within a tray.
Flex, fan, and straight en the media stack before loading it.
Note: Make sure the media stack is below the maximum media fill indicators on the 250-sheet tray before
pushing the tr ay into the printer.
Push all trays snugly into the print er after loading them.
Make sure paper guides are positioned be fore loading the paper or specialty media.
Do not remov e tr ays while a job is printing. Wait for a Load Paper light sequence .
Before loading transparencies, fan the stack to prevent sheets from sticking together.
Do not use envelopes that: – Have exces si ve curl
Are stuck together – Are damaged in any way – Contain windows, holes, perforations, cutouts, or embossments – Have metal clasps , string ties, or metal folding bars – Have post a ge sta m p s attac hed – Have any exposed adhesive when the fl ap is i n the sealed position
Use only recommended media. Refer to the Card Stock & Label Guide available on the Lexmark Web site at www .l exmark.com for more information about whi ch m edia provides optimum results for the curr ent printing environment.

Tools

The remov al and adjustment procedur es require the foll owing tools and equipment:
Spring hook
Needle nose pliers
Volt-ohmmeter
#1 and #2 Phillips screwd r ive r
Slotted screwdriver
Flashlight
1-8 Se rvice Ma nual

Acronyms

ACM Autocompensator Mechanism (or paper feed) ASIC Application Speci fi c Integrated Circui t CBM Complete Bill Of Material CRC Cyclic Redundancy Check DIMM Dual In-Line Memory Module EEPROM Erasable El ectrically Programmab le Read-Only
ENA External Network Adapter FRU Field Repl ac ea ble Uni t HBP Host Based Printing HVPS High Voltage Power Supply LCD Liquid Crystal Diode LED Light Emitting Diode LSU Laser Scanning Unit LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory PC Photoconductor PCL Printer Control Language POR Power-On Reset POST Power-On Self Test PPDS Per sonal Prin ter Data St ream PRC People’s Republic of China PSO Participating Standards Organization RIP Raster Image Processor TAR Toner Add Roll SDR Synchronous Dyna mic RAM USB Universal Serial Bus V ac Volts alternating current V dc Volts direct current
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Memory
General inf ormation 1-9
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1-10 Service Manual

2. Diagnostics information

Start

CAUTION: Un plug power from the printer before connecting or disconnecting any cable,
assembly, or elect roni c card. This is a precaution fo r personal safety and to prev ent damage to the printer.
Use the service error code, user status message, user error message , symptom table, service checks, and diagnostic aids in this chapter to determine the cor rective action necessary to repair a malfuncti oning printer . They will lead you to solutions or service che cks, includi ng use of various tests.
Sympto m tables
If your machine compl etes the “Power–On Self Test (POST) sequence” on page 2-1 without an error and you have a symptom, go to “ M essages and error codes” on page 2-5. Locate your symptom, and take the appropriate action.
Servic e er rors (9xx.xx’s)
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If a service error code appears while you are working on the machine, go to “Messages and error codes” on
page 2-5, and take the indicated action for that error.
Service error codes are ind icated by a three-digi t er ror code follow ed by a period and additional numbers in the format XXX.YY. In most cases, five digits are shown.
User status and attendance messages
User status mes sages prov ide the user with information on the cur rent status of the printer. Ready displays on the first line of the dis pla y unless i nv ok ed, and then Power Saver displays. If a user status message is displayed, go to “Messages and error codes” on page 2-5.
User attendance messages are indicated b y a two- or three-digit error code that provides t he user with
information that explains a problem with a print cartridge, paper jam, option, port, and so on. If a user error message displays, go to “User attendance messages” on page 2-5 and “Paper jam error codes (200-
series)” on page 2-8.
Power–On Self Test (POST) sequence
The foll owing is an example of the events that occur during the POR sequence when the printer is turned on.
1. Diamonds are displayed on the operator panel.
2. While code is being loaded into DRAM, dots scroll across the operator panel.
3. A screen is displayed wi th the memory and processor speed. A typical example of this message is :
*64MB
4. Performing Self Tes t is dis p layed.
5. Busy is displayed.
6. Close Door will be displayed if the cover is open.
7. Any cartridge errors, such as Defective Cartridge, are displayed.
8. Applicable maintenance messages are displayed.
9. Applicable toner low mess ages are displayed.
10. The printer displays Ready.
Diagnostics information 2-1
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Overview of the operator panel and menus

The operator panel on your printer is a 4-line, back-lit, grayscale display that can show both graphics and text. The Back, Menu, and Stop b uttons are located to the le ft of the display, the navigation buttons are located below the display, and the numeric pad is located to the right of the display.
Back
Menu
Stop
Indicator light
LCD
Select
Navigation buttons
The use of the buttons and the layout of the display panel are described in the following table.
Operator panel
Button Function
Press the Back button t o return to the last screen you vi ewed.
Back
Menu
Stop
Note: Changes made on the screen will not be applied if y ou press the Back
button. Press the Menu button to open the menu index.
Note: The printer must be in the Ready state to access the menu i ndex. A message indicating the menus are unavailable will appear if the printer is not ready.
Press Stop to stop the mechani cal operation of the printer. After pressing Stop, the message Stopping is displayed. When the printer has stopped, the status line in the operator panel will show Stopped, and a li st of options will appear.
2-2 Se rvice Ma nual
Operator panel (Continued)
Button Function
Nav igati on butt ons
Display panel
The display panel shows messages and graphics describing the current state of the printer and indicating possible printer problems you must resolve.
The top line of the display is the header line. If applicable, it will contain the graphic indicating the Back but ton can be used. It will also displ ay the current status, and the Supp li es (Warnings) stat us. If multiple warnings are present, each warning will be separated by a comma.
The other three li nes of the displ ay are the body of the screen. This is where you view printer status, supplies messa ges, show-me scre ens, and make selections.
4512-630
The Up or Down buttons are used to move up and down li sts. When navigating through a list using t he Up or Down button, the cursor
moves one line at a time. Pressing t he Down button at the bottom of the screen changes the screen to the next whole page.
The Left or Right buttons ar e used to move within a screen such as moving from one men u index item to another. They are also used to scroll through text that will not fit on the screen.
The Select button is used to initiat e acti on on a selection. Press Select when the cursor appears next to the selection you want such as follo w ing a link, submittin g a confi guration item, or when you want to start or cancel a job.
Diagnostics information 2-3
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Diagram of the printer menus

The diagram sho ws the men u ind ex on the operat or pane l and the menus and items a v ailab le unde r each menu. Not all menus or selections will be available in all situations. These are accessed through the driver.
Paper Menu
Paper Source Paper Size Paper Type Custom Types Universal Setup Substitute Size Paper Texture Paper Weight Paper Loading
Post Scri pt Menu
Print PS Error Font Priority
Finishing Menu
Duplex Dupl ex B i n d Copies Blank Pages Collation Separator Sheets Separator Sour ce Multipage Print Multipage Order Multipage View Multipage Border
PCL Emul Menu
Font Source Font Name Point Size Pitch Symbol Set Orientation Lines per Page A4 Width Tray Renumber Auto CR after LF Auto LF afte r C R
Utilities Menu
Print Menus Print Stats Print Net Setup Print Fonts Print Directory Factory Defaults Format Flash Defragment Flash Hex Trace
Setup Menu
Eco-Mode Quiet Mode Printer Language Pow er Saver Resource Save Print Timeout Wait Timeout Auto Contin ue Jam Recovery Page Pro tect Display Language Toner Alarm
Job Menu
Reset P rinter
Quality Menu
Print Resolution Toner Darkness Small Font Enh.
PPDS Menu
Orientation Lines per Page Lines per Inch Page Format Character Set Best Fit Tray 1 Renumber Auto CR after LF Auto LF after CR
2-4 Se rvice Ma nual
Parallel Menu
Std Parallel
Network Menu
Standard Network
USB Menu
Standard USB

Messag es an d er ror code s

User attendance messages

The printer control panel displa ys m essages describing the current state of the printer and indicates possible printer problems that must be resolv ed. This topic provides a list of all printer messages, explains what they mean, and tells ho w to clear the messages.
The foll owing table lists the messages in alphanumerical order. A messa ge can also be located using the index.
User at tendance messages
Message Action
Activa ti ng De mo Mode Wait for the message to clear. Activa ti ng Me nu Changes Wait for the message to clear. Activating/Deactivating PPDS Wait for the message to clear. Busy Wait for the message to clear, or cancel the prin t j ob. Cancel li ng Jo b Wait for the message to clear.
4512-630
Change Cart ri dge Invalid Refill The printer has detected an unsupported refilled ca rtridge. Remove the
Close do or Close the specified door to clear the message . Deacti va tin g Demo Mode Wait for the message to clear. Defragmenting Flash DO NOT POWER
OFF
Disabling Menus Wait for the message to clear.
Enabling Menus Wait for the message to clear. Flushing Buffer Wait for the message to clear. Format ti ng Fl ash DO NOT POWER
OFF
Invali d Eng in e Code Download v alid engine code to the printer. Invali d Sta nd ard Network Code The code in an internal pri nt server is not valid. The printer cannot receive
indicated print cartridge, and install a new one.
Warning: Do not turn the printer off while this message is disp layed. Wait for the message to clear.
Note: The printer sett ings cannot be changed from the contr ol panel while the m e nus are disabl ed .
Warning: Do not turn the printer off while this message is disp layed. Wait for the message to clear.
and process jobs until valid code is programmed into the internal print server. Download valid code to the internal print server.
Note: The network code can be downloaded whi le this message is displayed.
Load manual feeder with <Custom Type>
Load manual feeder with <Custom String>
Load manual feeder with <size> Load manual feeder with <size>
<type>
• Load the specified med ia i n the manual feed tray or multipurpose feeder.
• To ignore the manual feed request and print on media already installed in one of t he input sources, pres s . If the printer fi nds a tray that has media wi th the correct media type and size, it feeds media from that t ray. If the printer cannot find a tray with the correct media type and size, it prints on whate ver medi a i s in s t a l led in the defa ult inpu t sour ce.
• Cancel the current job.
Diagnostics information 2-5
4512-630
User attendance messages (Continued)
Message Action
Load <src> with <Custom Type Name>
Load <src> with <Custom String> Load <src> <size> Load <src> <type> <size> Maintenance Replace the maintena nce items and, if necessary, reset the printer
Menus Di sab le d The printer menus are disabled. The printer settings cannot be changed
Network A network interface is the activ e com m unication link. Networ k Car d Bu sy An internal print server (also called an internal network adapter or INA) is
Not Read y The printer is not ready to receive or process data. Someone pressed
Parallel A parallel inter face is the activ e com m unication link. Perfor mi ng Se lf Test The printer is running the series of start-up tests it performs after it is
• Load the input source with the correct type and size media.
• Cancel the current job.
maintenance coun ter.
from the control panel. Note: A job can still be canceled. Contact a system support person.
being reset. Wait for the message to clear.
to take the printer offline. Press to make the printer ready to receive jobs.
turned on. Wait for the message to clear.
Power Sa ver • Send a job to print.
• Press to warm the printer t o normal oper at ing te mperatu re an d display the Ready message.
Printing Directory List The printer is p rocessing or printing a directory of all files stored in flash
Printing Font List The printer is processing or printing a list of all available fonts for the
Printing Menu Settings The printer is processing or printing the menu settings page. Wait for the
Printing Device Statistics The printer is printing statistical information about the printer. Wait for the
Printing Quality Test Pages The printer is formatting and pri nti ng the Print Quality Test, which consists
Prog Engine Code DO NOT POWER OFF
Progra m Fla sh DO NOT POWER OFF
memory. Wait for the message to clear.
specified printer language. Wait for the message to cl ear.
message to clear.
message to clear.
of 4 pages. Page 1 contains a mixtur e of graphics and text, pages 2 and 3 contain only gr aphics, and page 4 is a blank page. If Duplex is tu rned on, then the pages are duplexed; oth erwise they are simplexed. Wait for the message to clear.
The printer is progr am ming new engine code. Wait for the message to clear and the printer to reset.
Warning: Do not turn the printer off while this message is disp layed. The printer is storing resources, such as fonts or macros, in flash memory.
Wait for the message to clear.
Warning: Do not turn the printer off while this message is disp layed.
2-6 Se rvice Ma nual
User attendance messages (Continued)
Message Action
4512-630
Prog System Code DO NOT POWER OFF
Ready Send a job to print. Remove Paper Standard Bin The standard output bin is full. Resetting Maint Cnt Valu The printer is resetting the counter that trac ks wear on the fuser. Resett in g PC Cn t Value The printer is resetting the counter that tracks w ear on the photoconductor. Resetting the Printer Wait for the message to clear. Res Redu ced The printer is reducing the resolution of a page in the current job fr om 600
Restoring Factory Defaults Wait for the message to clear.
The printer is progr am ming new system code. W ait for the mess age to clear and the printer to reset.
Warning: Do not turn the printer off while this message is disp layed.
dots per inch) dpi) to 300 dpi to preve nt a 38 Memory Full error. Res Reduced remains on the display while the job prints.
Note: When factory default setting are restored:
• All downloaded resources (fonts, macros, symbol sets) in the printer memory are deleted.
• All menu settin gs return to the factory def ault except:
The Display Lang uage setting in the Setup MenuAll settings in the Parallel Menu , Network Menu, and
USB Menu
Std Bin Ful l The standard bin is full. Toner Lo w • Replace the toner cartridge .
• Press to clear the message and continue printing.
Tray <x> Missing Insert the tray into the printer. USM The printer is processi ng data through the specified USB port. Waiting The printer has received a page of dat a to print, b ut is wai ting f or an End of
Job command, a Form Feed command, or additional data.
• Press to print the contents of the buffer.
• Cancel the current job.
Diagnostics information 2-7
4512-630

Cartridge error messages

Error Description
31 Defec tiv e ca rtridge 32 Unsup por te d print cartridge 33 Inval id re fi ll

Paper jam error codes (200-series)

Note: The Event log (see “EVENT LOG” on page 3-28) will list any of these errors that have occurred. Repeating jams or jam messages can be caused by any of the following:
Fau lty/contaminated pick solenoids or worn cams of the solenoids.
Faulty/contaminated flags or springs.
Debris in the paper path.
Media not of the specifi ed length.
Paper jam error codes (200-series)
Error Description
200.00 Paper jam around input sensor.
200.01 Classic input jam. The media is too long over the input sensor . Possible causes include mul ti-sheet fe ed, tray
200.02 The main input sensor ne ver became uncovered from the sheet ahead.
200.03 The video never started on the page at the input sensor within two inches after hitting the input sensor
200.04 The media at the input sensor before int errupt occurred - not enough time elapsed since the pri nthead started
200.06 Imaged page not expected page (bouncy passthru sensor)
200.08 Media reached the input sensor before the EP was ready
200.09 Transfer servo never started
200.12 Media detected at manual feeder sensor when not expected. Possible causes include user insert of media
200.13 The input sensor is covered when the media is not e xpected (media in machin e during warm-up)
200.14 Trailing edge cleared manual feed, but did not successfull y debounce the sensor. Potential causes are a smal l
200.15 UNRECOVERABLE NO GAP JAM. Engine detected no gap at the manual f eeder sensor, attempted to open
size sensing problem, and media slippage.
to expect the printhead mirror motor lock. Possible causes include bouncy sensor or exceptionally fast pick ­perhaps due to media pre-s taged in the source tray.
when motor is running or pre-staged media in the tra y.
gap or a bouncy manual feed sensor.
the gap by stopping the feed rolls, but no trailing edge was ever seen at th e input sensor.
200.16 Transport motor error detected
200.17 Took too long to ramp up transport motor
200.18 Manual feeder sensor never became uncovered from the sheet ahead.
200.19 The media never reached the input sensor, but was detected at manual feeder sensor.
2-8 Se rvice Ma nual
Paper jam error codes (200-series) (Continued)
Error Description
4512-630
200.20 The media is too long ov er the manual feeder sensor. Possib le causes include mult i- sheet feed, media si ze
200.22 F AILED SMALL GAP OR NO GAP JAM RECOVERY. Engine detected small gap or no gap at the manual
200.23 Laser Servo never started due to potential confl ict with the transfer servo. Possible causes: slo w or missing
200.24 The measured gap at the input sensor is too small to meet the video delivery requirements. (There is not
200.26 The trailing edge never cleare d the input sensor when fe eding out the media that was detected during warm-
200.27 Printhead Driver: Mirror motor fell out of l ock condition after the media at the input sensor - more time elapsed
200.28 First writing line of a page at the developer ni p, but laser servo cleanup is not complete. Likely pre staged
200.29 Printhead drive control out of range due to an external event beyond what the control is designed to handle.
200.30 Narrow media sensor covered during warm-up.
200.32 Media more than 14 inches too l ong over the manua l feeder sensor. Possible causes in clude multi-sheet feed
(length) problem, pre-staged media in the t ray.
feeder senso r , opene d the gap b y s toppi ng the feed rolls, but ne ver sa w the l eading ed ge of the seco nd pag e at the input sensor.
transport motor positional feedback, or the media is transferred too quickly to the input sensor.
enough time since prior image finished to start new image)
up.
since the printhead than t he expected stable lock time, but less than the printhead jitter-stab le specification. Mirror motor fell out of lock condit ion after media at the input se nsor - more time elapsed since the printhead
than expected stable lock time, but less than the printhead jitter-stab le specification.
media or a fast paper feed.
Probable causes: ESD or noise on hsync signal.
or pre-staged media in the t ray.
200.33 Page from tray 1 did not reach the input sensor after m ultiple attempts. Page did make it out of the tray at least
200.34 Timed out waiting for page from tray 1 to reach the input sensor afte r multiple pick attem pts, but the page was
200.35 Failed to create hsync during auto alignment
200.36 Lost hsyncs during auto alignment
200.37 Timeout on data collecti on duri ng auto alignment
200.38 Interpage servo gap is smaller than expected for printhead offset target evaluat ion
201.00 Paper jam between input and exit sensor
201.01 Transport motor ident ification failed to identify either motor after two tries .
201.02 Exit sensor never made by leading edge of page. Also known as internal jam.
201.03 Video never started on the page at the input sensor within two inches after hitting the input sensor
201.05 Restart attempted after an internal jam without the cover open/close event. It is likely that the jam was never
201.25 Exit sensor ne ver made by leading edge of media when feedi ng out the media that was det ected during warm-
201.26 Page at fuser ni p before fuser started ramping toward desired temperature. Indicates code may be recei ving
as far as the manual feeder sensor. Possible cause i s that the page stalled at the align me nt gat e.
later detected at the input sen sor while w ait ing f or an y pa ge(s) ahe ad to cle ar the pap er pa th. Possible cause is that the page is delayed at the alignment gate.
cleared.
up.
more hall interrupts than intended
Diagnostics information 2-9
4512-630
Paper jam error codes (200-series) (Continued)
Error Description
201.27 Page at fuser ni p before fuser reached acceptable opera ting temperature . Page arrived at fus er earl ier than
202.00 Paper jam around exit sensor.
202.01 Exit sensor never broke on the trailing edge of the sheet at the exit sensor.
202.02 Exit sensor never broke from sheet ahead of page heading toward the exit sensor.
202.06 Exit sensor bounced
202.13 Exit sensor cov ered, media not expected (media not in machine during warm-up)
202.25 Exit sensor nev er bro k e from the sheet ahead of th e page heading to w ard the e xit sens or when f eeding out the
202.26 Trailing edge never cleared exit sens or when feeding out media that w as detected during warm-up .
202.32 Long media or shingled mul ti feed stopped before sending to dupl ex.
231.00 Duplex jam while reversing i nto the device
231.01 Duplex sensor never made by leading edge reversing into the duplex.
231.02 Bouncy duplex sensor never made.
232.00 Duplex jam while staging in the device
232.01 Duplex sensor never broke by the sheet ahead after reversi ng into the duplex.
232.02 Page in duplex ahead of current reversing page never staged.
expected, so it was probably staged
media detected during warm-up.
233.00 Duplex jam while picking from the de vice
233.01 Page in duplex nev er pi cked.
233.02 Feed error pic king from the duple x.
233.03 Paper ne ver reached the inp ut sensor, but was detected at the man ual feed sensor.
234.01 Duplex sensor covered during wa rm-up.
235.01 Invali d duplex media
241.00 Paper jam near tr ay 1.
241.10 Second pick attempt failed from Tray 1
241.12 Second pick from manual feeder, tray 1, or feeder failed when the media was in the source while other sheets
241.16 Failed t o feed from tray 1. Pages in the pape r path have been flus hed to t he output bin.
241.17 MISIDENTIFIED SMALL GAP JAM. Engine detected small gap at the manual feeder sensor, attempted to
241.18 MISIDENTIFIED NO GAP JAM. Engine detected no gap at the manual feeder sensor, attempted to open the
241.19 Second pick attempt ed failed from Tray 1, no pages print ed since calling a 241.10 or a prior 241.19.
were committed to the paper path.
open the gap by stopping the feed rolls, trailing edge was seen at the inp ut sensor, manual feeder sensor is no longer covered.
gap by stopping the feed rolls, t railing edge was seen at the input sensor, manual feeder sensor is no longer covered.
242.00 Paper jam near tr ay 2.
2-10 Service Manual
Paper jam error codes (200-series) (Continued)
Error Description
242.01 Took too long to ramp up dc feed motor
242.08 Received lots of dc feed interrupts before losing them
242.10 Second pick attempt failed from Tray 2
4512-630
242.12 Second pick from manual feeder, tray 1, or feeder fa il ed when m edia was in the source, other sheets were
242.16 Failed t o feed from tray 2. Pages in the pape r path have been flus hed to t he output bin.
251.00 Paper jam near the manual feeder.
251.10 Second pick attempt failed from manual feeder.
251.11 Failed t o feed from manual feeder. Pages in the paper pat h have been flushed to the output bin.
251.12 Second pick from manual feeder, tray 1, or feeder failed when m edia was in the source while the other sheets
251.19 Media never reached the input sensor from the manual feeder.
committed to the paper path.
were committed to the paper path.
Diagnostics information 2-11
4512-630

Service error codes

Service error codes are gener ally non-recoverable except in an intermittent condition when the printer can be put into POR to temporarily recover fro m the error condition.
Servic e er ror co d es (9xx)
Error Description
Engine software servi ce errors
902.xx Engine software error
Transfer service errors
917.00 Transfer service error
917.01 Transfer servo result too low.
Fuser service errors
920.00 Under temperature during steady state control.
920.01 Fuser took too long to heat up after transitioning to new enhanced mode.
920.02 Fuser fel l too far below desired temperature while print ing.
920.03 Fuser too cool whi le checking for slope change.
920.04 Fuser too cool when heat ing to desired temperatur e after slope change.
920.05 Fuser under temperature while printing
920.06 Fuser under temperature while printing
920.07 Fuser under temperature while printing
920.08 Fuser temperature did not increase after IR recovery.
920.20 Belt fuser unde r temperature during steady st ate control. This can occur in printing or standby mod es.
921.00 Under temperature during standby contr ol.
921.01 Fuser temperature did not reach standby temperature after two attempts
922.00 Fuser failed to ramp to target temperature
922.01 Fuser did not reac h standby temperature in time (standby control)
922.05 After fuser lamp detection, the fuser di d not roll over to steady state control in time.
922.07 Media reached fuser nip and fuser is under temperature
922.08 Fuser warm-up failure (motor start condition)
922.09 Fuser warm-up failure (compres sion set)
922.20 Belt fuser failed to reach the preheat temperature for the motor to start during warm-up.
922.21 Belt fuser was under temperature when the media reached the fuser nip.
923.00 Fuser is over temperature .
923.01 Fuser is over temperature. This applies to the fuser and belt fusers.
924.00 Open thermistor check.
2-12 Service Manual
Servic e er ror co d es (9xx) (Continued)
Error Description
924.01 Open thermistor chec k failure. This applies to the fuser and belt fusers.
4512-630
924.02 Open thermistor check failure. The ADC failed to converge. Possib le noisy thermistor signal. This applies to the
Fan service errors
927.00 Service fan error
927.03 Main fan took too long to ramp up
927.04 Main fan is under speed or stalled during sp eed adjustment state
927.05 Main fan overspeed during speed adjustment state .
927.06 Main fan capture data is invalid and speed control is at maximum in fan control idle state
927.07 Main fan capture data is invalid and speed control is at maximum in fan control adjustment state.
Printhead service errors
931.00 No first hsync
931.01 No first hsync
932.00 Lost hsyncs
932.01 Lost hsyncs
933.00 Printhead boost signal failure
935.10 Printhead s w eep error, s wept through Hz range wi thout finding the resonant frequency
fuser and belt fusers.
935.11 Printhead s weep error, aut osweep hw state
935.12 Printhead s w eep error, coarse sweep stat e
935.13 Printhead s w eep error, init fine sweep state
935.14 Printhead s w eep error, f ine sweep state
935.15 Printhead s w eep error, check prelim amp state
935.16 Printhead s weep error, enable amp Kp state
935.17 Printhead s w eep error, amp Kp f ailed to converge
935.18 Printhead s w eep error, ena ble amp Ki state
935.19 Printhead s weep error, amp Ki failed to converge
935.20 Printhead s w eep error, enable offset contr oller state
935.21 Printhead sweep error, load scan regs state
935.22 Printhead sweep error, fwd and rev capture times differ by too much
935.23 Printhead sweep error, check sweep accuracy state
935.24 Printhead s w eep error, reserved
935.25 Printhead sweep error, detected resonant fr equency out of expected range
935.26 Printhead s weep error, t imed out waiting for end of sweep
Diagnostics information 2-13
4512-630
Servic e er ror co d es (9xx) (Continued)
Error Description
Transport motor service errors
936.01 No lock detected at normal motor start
936.02 No lock detected at motor start for motor ID
936.03 No halls detected at motor start
936.04 Fa il ed to stop within timeout
936.05 Stall detected during speed control
937.00 Main transport motor lost lock
937.01 Main transport motor lost lock, detected by engine control
937.02 Oversp eed detected during position control
937.03 Oversp eed detected during speed control
Power supply service errors
940.00 LVPS service error
940.01 Line frequency outside allowed range of 45Hz-64Hz
940.02 Line frequency below 43Hz
940.03 No zero cross detected on belt fuser model
2-14 Service Manual

Sympto m tables

POST symptom table

Symptom Action
4512-630
The main motor, cooling fan, and fuser do no t com e on.
POST completes, but LCD does not appear to be working.
Main motor does not come on. See “Mai n mo tor servic e ch eck” on p ag e 2- 20. Fan does not come on. See “Cooling fan service check” on page 2-18. Fuser does not cycle. See “Fuser service check” on page 2-19. Fuser does not turn on and off. See “Fuser service check” on page 2-19. The paper feed picks and tries to feed media. See “Paper feed service checks” on page 2-21.
Note: Investigate any displayed codes before procee ding with these sym ptoms. For example, a m issing toner cartridge will prevent PO ST from com p leting.
See “Cover interlock switch service check” on page 2-18.
See “Operator panel servi ce check” on page 2-21.
Diagnostics information 2-15
4512-630

Printer symptom table

Symptom Action
Dead machine (no power). See “Dead machine service check” on page 2-19. Fan noisy or fan not working. See “Cooling fan service check” on page 2-18. Fuser parts melted. See “LVPS/HVPS service check” on page 2-20. Toner not fused to the media. See“Fuser service check” on page 2-19. Paper jams. See “Paper feed service checks” on page 2-21. Main motor noisy or not moving. See “Mai n mo tor servic e check” on page 2- 20. Media ske w. See “Paper feed service checks” on page 2-21. Printer not communicating with host. See “Parall el or USB port service check” on page 2-23. Fron t access cover will not close. See “Cover interlock switch service check” on page 2-18. Operator panel button not responding. See “Operator panel service c h eck” on page 2-21. Operator panel lights are off or very dim. See “Operator panel service check” on page 2-21. Blank page. See “Blank page ” on page2-24. Black page. See “Black page” on page 2- 25. Heavy background. See “Heavy bac kground” on page 2-25. Light print. See “Light print” on page 2-27. White or black lines or bands. See “White or black lines or bands” on page 2-27. Toner on back of page. See “Toner on back of page” on page2-27. Media never picks. See “M edia never picks” on page 2-22. Media feeds continuously. See “Media pic ks duri ng POST and/or continuously” on
Media wrinkled or bent. See “Media “trees,” wrinkles, stacks poorly, or curls” on
Print quality problems
• Light print
• Blurred characters
• Toner on both sides of media
• Toner not fused
• Streaks
• Blank pages
page 2-21.
page 2-23.
See “Solving print quality problems” on page 2-28.
2-16 Service Manual

Service checks

Service checks which involve measuring voltages on the LVPS/HVPS (low voltage power supply/ high voltage power supply board) should be performed with the printer positioned on its back side .
Note: When making voltage readings, always use frame ground unless another ground is specified. See the wiring diagram in the back of the book for more information.

Controller card service check

Controlle r card service check
FRU Action
4512-630
Controller card assembly
Warning: Do not replace the oper ator panel and control ler card at the same time. Each card contains t he printer settings . When either of these cards is new , it obtai ns som e of the settings from the other card. Settings are lost when both are new and replaced at the same time.
POST (Power-On Self Test) Note: The printer should complete PO ST in appr oximately 30 seconds.
If the printer f ails to display li ghts or activate the drive motor, fuser or fan, check the following order:
1.Power to the LVPS/HVPS
2.Power from the LVPS/HVPS to the controller card
3.Cables are plugged in correctly, especially for the operator panel. The printer will not power-up wit hout a functioning operat or panel.
4.The controller card assembly.
5.The operator panel. See “Operator panel service check” on page 2-21.
V eri fy +24 V dc input from the LVPS/HVPS.
1.Turn the printer off.
2.Disconnect the LVPS/HVPS cable from the controller card at J19.
3.Turn the printer on.
4.Verify +24 V dc on positions 8 and 9 of the cable co nnector.
5.If voltage is co rrect , chec k the co nti nui ty in t he other cond uctors of the c ab le. If t he cabl e is good, check the connectors to the controller board.
6.Verify that pins 7 and 12 on both the cable and the card connector are grounded.
7.If grounds are not correct on the cab le, but the cable posses c ontinuity otherwise, check the LVPS/HVPS.
8.If the grounds are not correct on t he controller card, replace the controller card. (Check with one probe on the connector pin and the other on the card’s ground plane f ound at each screw head.)
Controller card voltage outputs Turn the printer off, and plug the LVPS/HVPS cable into J19 of the controller card. See the
wiring diagram at the end of the book which identifies the voltages and grounds for a good controller card.
Turn the printer off before plugging or unplugging any connector s.
Diagnostics information 2-17
4512-630
Controlle r card service check (Continued)
FRU Action
LVPS/HVPS Verify m a in pow e r to co n tro ller card
With the printer off, unplug the LPS/HVPS cable at J19 on the cont roller card. Verify grounds on pins 7, 12, and 14 for both the cabl e and the controller card. If any of these grounds are incor rect, check the cab le for contin uity. Replace the cab le or the respective card as necessary.
Turn the printer on with the cable still unplugged, and verify the foll owing on the cable (controller card wil l not be powered):
Pins Voltage
J19-8 +24 V dc J19-9 +24 V dc J19-13 +5 V dc
If any of the voltages are incorrect, replace the LVPS/HVPS. See “Dead machine service
check” on page 2-19.

Cooling fan servi ce check

FRU Action
Cooling fan Make sure the fan cable plug is properly seat ed at J4 (controller card).
Turn the printer off , and disconnect the cooling fan cable from the controller card. Turn the printer on. Within a few seconds , the controller card asse mb ly should apply
+24 V dc to pin 2.
• If voltage is present and the fan is not turning, replace the cooling fan. If the fa n still doesn’t funct ion, replace the control ler card.
• If voltage is not present, check the controller card.

Cover interlock switch service check

Note: Make sure a print cartridge assembly is in stalled and the cov er closes all the wa y, engaging the cover open swi tch lever.
FRU Action
Cover interlock switch Disconnect the cover interlock cable from the controller card at J6.
With the printer turned off, verify continuity between cabl e pin 1 and pin 2 with the door closed and discontinuity with the door open.
V erify contin uity betw een cab le pi n 1 and pin 3 wit h the door open and disc ont inui ty with the door closed.
Verify discontinuity between cable pins 2 and 3 whether the door is open or closed.
• If either fails, replace the cover interlock switch.
• If both pass continuity, turn the printer on, and measure +5 V dc on pin 2 at J6 on the controller card.
• Verify pin 3 at J6 is ground.
• If vol tage or ground is not present, see “Cont roller card service check” on page 2-17 for mo re info rmation.
2-18 Service Manual

Dead machine service check

CAUTION: Check the AC line voltage. The voltage should be within the following limits:
100 V ac (volts alternating current) – 127 Vac for the 110 V printer
200 V ac – 240 V ac for the 220 V printer
FRU Action
Unplug the printer. Remove the LVPS/HVPS, and check the f uses for contin uit y.
• If open, replace the LVPS/HVPS.
• If not open, chec k the switch conti nuity across its conductors with the switch on. Turn the switch off. Plug the AC line into the LVPS/HVPS and switch unit on.
LVPS/HVPS
Note: Voltages may be exposed at several places on the board. Do these verifications , and then unplug the card:
4512-630
Verify 24 V dc on pins 8, 9, and 10 at PCN1.
Verify approxi mately 3V on pins 1–3.
Verify approximately 5V on pins 4 and 13.
If voltages are not correct, replace the LVPS/HVPS.
If voltag es are correct, chec k the controller card. See “Cont roller card
connector pin val ues” on page 5-2.

Fuser service check

When toner is partially fused to the media, it is usually cause d by low fuser temperature. The line voltage to the printer must be within the following limi ts:
100 V ac–127 V ac for the 110 V model printer
200 V ac–240 V ac for the 220 V model printer
This printer uses a belt fuser and therefor e does not have a lamp.
Fuser service check
FRU Action
Unplug the printer, and disconnect the fuser cable plug from the LVPS/HVPS board connector at PCN5.
Check for continuity across the fuser by checking across the connector pins.
Fuser power cable LVPS/HVPS Fuser
Make sure the fuser thermistor is correctly connected to the controller board at J13. If the problem persists, disconnect the thermistor cable and check for less than +5 V dc on pin 1. Pin 2 should be ground. If line voltage is incorrect on pin 1, see “Controlle r card service
check” on page 2-17 for more info r m a tion.
• If there is continui ty, check the LVPS/HVPS. See “LVPS/HVPS service check” on
page 2-20.
• If there is no contin uity, disconnect t he fuser power cabl e at both ends and check each conductor for continuity. Replace cable if necessary.
• If the cable tests good, replace the fuser.
Fuser
Disconnect the th ermist or cable from J13 on the controller card. Measure the resist ance across the ends of the thermistor cable. Replace the fuser assem bly if the resistanc e is lower than 1K ohm or shorted. Note: Resistance measures approximately 400K ohms when cool and 1K ohms hot.
Diagnostics information 2-19
4512-630

LVPS/HVPS service check

FRU Action
LVPS portion of board
Fuses that open typically indicate a faulty LVPS/HVPS. Disconnect the po wer cable, and open th e LVPS/HVPS enough to test the switch. The
switch will show continuity across the conductors wi th a meter when the switch is on. If th e
LVPS/HVPS
switch is good, see “Dead machine service check” on page 2-19 for more diagnostics.
HVPS portion of board
Problems with the HVPS are exhibited in the print quali ty. See “LVPS/HVPS service
check” on page 2-20 for more info r m a tion.

Main motor service check

FRU Action
Turn off the printer, and unplug the main motor cable at J17. Turn on the printer, and chec k for the following voltages at J17:
Main gear drive Main motor cable LVPS/HVPS Controller card
Warning: Do not replace the oper ator panel and control ler card at the same time. Each card contains t he printer settings . When either of these cards is new, it obtains the settings from the other card. Settings are lost when both are new and replaced at the same time.
Verify ground at pin 5 for both the card and cable.
• If these voltages are correct, check the main motor cable for continuity.
- Remove the lef t si de cover to acces s the connector on the motor.
- If continuity exists on each wire, replace the main gear drive which includes the
- If continuity does not exist on one or more of the wires, replace the motor cable.
• If these voltages are not correct, see “Contr oller card connector pin values” on
page 5-2, or replace the controller card. See “Controller ca rd removal” on page 4-13.
J17 pins Voltages
Pins 1–4 Approx. +3.3 V dc Pin 6 Approx . +5V dc Pins 7–9 10 V dc–24 V dc
motor.
2-20 Service Manual

Operator panel service check

Inspect the operator panel cable for damage. Mak e sure the cable is plugged in se curely. Run POST, and check each light for proper operation. See “Power–On Self Test (POST) sequence” on page 2-1.
LCD Ope ra to r p an el serv ic e ch eck
FRU Action
4512-630
Operator panel (LED) Controller card
Warning: Do not replace the oper ator panel and control ler card at the same time. Each card contains t he printer settings . When either of these cards is new, it obtains the settings from the other card. Settings are lost when both are new and replaced at the same time.
Lights
If the LCD does not come on, open the contr oller card cage and locate the operator panel connector at J3. Make sure the cable is properly connected to the contr oller card and the controller card has input voltage to it.
With the printer on, veri fy the following without disconnecting the cable:
• Pins 1, 3, 5, and 6—3.3 v
•Pin 2—5 v
• Pins 4 and 7—GND
If these are correct and the operator panel is not functioning, replace the operator panel. If any are incorrect, see “Controller card service check” on page 2-17.
Buttons
If the buttons do not respond, replace the operator panel. There is no tes t or repair for the faulty switches.

Paper feed service checks

Paper jam error indication during POST
FRU Action
Fuser (exit sensor) If the exit sensor flag, which is visible at the bac k of the fuser, is in any position other than
vertical, the printer will display a paper jam. Make sure the flag is oper ating freely. Replace the fuser if the sensor is damaged.
Input/dupl ex sensor Manual feed sensor
Make sure the input paper feed sensor s are working properly. A stuck or incorrectly ins talled sensor causes a paper jam indication.
Media picks during POST and/or continuously
FRU Action
ACM Manual feed clutch
Check the ACM clutch for wear. The solenoid interacts with the clutch to control the motion of the pick tires.
If the ratchet teeth of the ACM clutch assem bly are worn or broken, the sol enoid may not stop the ACM from rotating. Replace the ACM clutch assembly if necessary.
Check the manua l feed clutch for damage.
Diagnostics information 2-21
4512-630
Media picks but stops halfway through the printer
FRU Action
Input/Duplex sensors (under print cartridge assem bly) Input sensor (manual)
Make sure the input sensors are working properl y. Check for a broken or stuck flag on the input sensors . Make sure the cables are seated on the cont roller card at J23 (Tray 1 input) and
J20 (manual input). Check for about +5 V dc on pin 6 at J23 (Input/dupl ex sensors) and pin3 at J20
(Input sensor).
• If correct, replace the input paper feed sensor.
• If these voltages are not correct, replace the controller card.
Media never picks
FRU Action
Paper feed (pick tires) tray 1 Paper feed (pick tires) tray 2 Media drive ASM Media feed clutch ASM Manual feed clutch ASM P/U and manual feed solenoid ACM dr ive sha ft
Open the left cover, and verify that the solenoids and cl utches are functioning when an attempt is made to feed the media.
Make sure the rubber tires on the ACM are installed and clean. Replace the tires, ACM drive, clutch assemblies, solenoids, or drive shaft as
necessary.
Media oc casionally m is p i cks or picks multip le sh eets at once
FRU Action
Tray 1 Tray 2 (option)
Paper pick tires (Tray 1 or tray 2)
ACM clutch complete bil l of material (CBM) Manual feed clutch CBM Media feed clutch ASM (tray 1 only) Manual feed clutch ASM
Controller card P/U and manual feed solenoid ASM.
Check tray for media cat ch points. If the sheet being fed stops momentarily, the ACM applies addi tional vertical force,
causing additional sheets to feed. Do not mix media types in one tray.
Check the tires in the ACM assembly for signs of wear or damage . Replace the tires as necessary.
Open left co v er , and observ e t he solen oid and c lutch act ions at the A CM and man ual feed shafts as a print job is attempted.
Replace the faulty part.
Disconnect the solenoid cable at J21 on the controller card. Measure the resistance across cable pins 1 and 2 and then pins 3 and 4.
• The resistance should be 180–250 ohms.
• If it is not, replace the solenoid assembl y.
• If the resistance is 180–250 ohms, check the controller card. See “Controll er card
service check” on page2-17 for more inf ormation.
Replace controller card as necessary.
2-22 Service Manual
Media skews
FRU Action
4512-630
Paper feed (pick tires) tray 1 Paper feed (pick tires) tray 2 Tray 1 Tray 2 (option)
Check tires for debris. If tires are new, try reversing each on its hub. Check side g uid es on Tray 1 and Tray 2. Gui des set fo r a f ull stac k of m edia ma y be
too wide when the stack is short.
Media “trees, ” wrinkles, stacks poorly, or curls
FRU Action
Fuser This probl em is most likely due to a worn backup roll. It causes the printer to run hotter than
required for the media being printed. Excessive heat can cause media treeing problems, poor stacking, or curl.
Print the menu sheet (press and release with the printer in ready mode). Look at the medi a setti ng s. Some , s uch as car d s tock or roug h te xt ure , ma y r equir e a highe r
fuser temperature, which leads to more of these problems (except stacking) in plain paper.
• Change settings using the printer driver.
• Use the local printer setup ut il ity (included on the CD) to change the NVRAM settings.
Try a different ream of paper. Moist media has a higher tendency to crease (treeing) and curl.

Parallel or USB port service check

1. Perform a print test to mak e sure the printer prints correctly. V erify that the indicator light is on, then press
to print menu settings.
2. Be sure the printer parallel cable is designed for bidirectional printing.
3. Be sure th e user’s application is set up correctly.
4. If the internal print test page prints correctl y, the user’s applicati on/printer driver is set up correctly, and the
correct bidirectional parallel cable is installed, but the printer still fails to print on command from the host computer, replace the cont roller card.
5. Check the USB cable for continuity.
Diagnostics information 2-23
4512-630

Print quality servic e chec k s

Note: Ensure the cover closes tightly. A gap in the opening may allow light to ex pose the photoconductor resulting in a ‘dirty’ print. Extreme environmental conditions, temperatures, and humidity will affect the print quality.
Using print quality test pages To help isolate print quality prob lems, like streaking, print test pages using the print quality test pages. To print
the print quality test pages:
1. Enter Configuration Menu. a. Turn off the printer. b. Turn on the printer while pressing and holding and . c. Release the buttons when Performing Self Test displays. d. The message CONFIG MENU displays. e. Press to Prt Quality Pgs. f. Press to print the pages.
Four page s prin t to hel p evaluate pri nt quality. The first page has various fonts and a graphic, t he second page is gray with graphics, the third page is bla ck, and the last page is bl ank.
2. Use the test pages to isolate problems such as light or toner str eaks. See “POST symptom table” on
page 2-15 for solutions to these probl em s.
3. Press to Exit Config Men u and press .
To exit configurati on, turn the printer off.
Blank page
FRU Action
Toner cartridge (not a FRU)
Printhead LVPS/HVPS Controller card
Remove the toner cartridge, and gently shake it to evenly distribute the toner. Check for cartridge damage.
Blank pages can be caused by a defective printhead assembl y, LVPS/HVPS, or contr oller card.
• Printhead errors typi cally result in printer service errors unless there is blockage of the beam or dust on the lens.
• Blank pages typically are caused by the PC roll not being properly charged. Try a different PC kit.
Unplug the printer, and check the cable continuity between the LVPS/HVPS connector marked OPC (at PCN 2) and the correspondi ng wire form (spring) found about 14 mm above and to the ri ght of the transfer roll gear.
• If there is not continuity, call the next level of service.
Try a different toner cartridge and PC kit.
• If those fail , r eplace the LVPS/HVPS, controller card, or the printhead i n that order.
2-24 Service Manual
Black page
Note: Incorrect laser exposure or incorrect charging of the photoconduct or causes an all blac k page. Always
verify the sam e results from a differ ent print cartridge assembly and de veloper before proceeding.
FRU Action
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T oner electrode s (not a FRU)
LVPS/HVPS board Controller card Miscellaneous cables
Check the three rearward electrodes below the print cartridge assembly for contamination or damage. Correct as necessary.
Check contin uity be tween th e cable (DEV, TAR, and doctor blade) connection PCN3 and on the contact tips below the print cartridge assembly.
• If continuity fails, call the next level of service.
With the printer off, disconnect the LVPS/HVPS cable from J19 on the controller card. Turn the printer on, and verify +24 V dc on pins 8 and 9 of the cable. Verify ground on pins 7, 12, and 14.
• If the voltage is incorrect, replace LVPS/HVPS board.
• If grounds are incorrect, check ground paths.
• Check confinuity in the cable. Replace the cabl e if necessary .
• If voltag e is cor rect and the toner electrodes are good, replace the controller card.
• See the “LVPS/HVPS service check” on page 2-20 and the “Contr oller card servi ce
check” on page 2-17, if necessary.
Heavy background
Poor development or poorly charged toner particles c ause e xces siv e bac kg round. Thi s is more not iceab le as t he toner cartridge nears end-of-life.
FRU Action
Toner cartridge (not a FRU) PC Kit (not a FRU)
Check the toner darkn ess setting in the driver. Try a lower setting. Make sure the toner cartridge and PC Kit are correctly installed and the high voltage
contacts are clean. If the toner cartridge and PC Kit are i nstalled correctly, try a new PC Kit first and then toner
cartridge.
LVPS/HVPS Controller card
Check the contact s for correct installation and contamination where contact is made between the print cartridge assem bly and s pring con tacts which co nnect t o the LVPS/HVPS board at PCN3. Clean as necessary.
If this does not corre ct t he problem, replace the following FRUs one at a time in the order shown:
• LVPS/HVPS board (See “Blac k page” on page 2-25 for pin values.)
• Controller card
Diagnostics information 2-25
4512-630
Partial blank image/white spots (no repeating pattern)
FRU Action
Toner cartridge (not a FRU)
Paper (not a FRU) Make sure recommended media is being used.
Remove the toner cartridge assembly, and gently shake the assembly to evenly distribute the toner.
Check to make sure that the laser light path is not blocked. If toner cartridge is low, try a new one.
Check the media settings in the printer driver. A heavier media may require higher heat to properly fuse.
Variation in image d ensity ho r i zon tally across page
FRU Action
PC Kit (not a FRU) The charge roll may have an unbalanced force against t he PC (photoconductor) drum.
Try a new PC Kit.
Trans fer roll Note: Do not tou ch the trans f e r roll e xc ept at its end s. Place a she et of paper ov er t he roll to
prevent damage from finger oils or hand lotion. Check the springs in the left and right transfer roll bearings . The bearing assemblies should
support the transfer roll, applying evenly distributed forces to the PC drum. Replace the trans fer roll assemb ly if the springs or bearings show signs of damage or
fatigue. Inspect the transfer roll for signs of wear, damage or contamination. Replace as necessary.
Poor fusing of image
FRU Action
Fuser The fuser may not be operating at the proper temp erature to fuse the toner to the media.
Media (not a FRU) Make sure recommended media is being used.
See“LVPS/HVPS service check” on page 2-20 for more information. Try changing the setting to hea vier media or even card stock.
Check the media sett ings in the printer driver.
2-26 Service Manual
Light print
FRU Action
4512-630
Toner cartridge (not a FRU)
Trans fer roll LVPS/HVPS card
Make sure the toner cartridge and PC Kit are installed correctly and that the toner cartridge is not low on toner .
If the problem continues, install a new toner cartridge. Recheck condition before replacing PC Kit, if necessary.
Check the trans fer roll for signs of toner buil dup and contamination. Inspect the HVPS contact (transfer roll) for contamination. Verify the high voltag e cable is plugged into the LVPS/HVPS. If all compone nts appear free of co ntamination, replac e the follo w ing FRUs one at a time in
the order shown:
• Tra nsfer roll
• LVPS/HVPS card
White or black l ines or ban d s
FRU Action
Print cartridge assembly (not a FRU) Deve lop er drive coupling assembly Main gear drive
Banding appears as l ight o r dark horizon tal l ines on a uni f ormly g ra y pag e or on a page wi th a large area of g raphi cs. Ban ding is primarily due t o a v ariation in the spee d of the m edia as it feeds t hrough the printer, especially in th e d eveloper and transfer process. It ma y also be a result of overly dry or moist environments.
With the printer off, check to make sure that the laser beam is not blocked. Inspect the toner cartridge and paper feed components, especially the drive coupler and
drive gears f or debris, binds, or dam age.
Toner on b ack o f p ag e
FRU Action
PC Kit (not a FRU) Print a menu page found under Utilities, and check settings for media type.
Inspect the overall paper path for signs of spilled toner. Gently clean the contaminated areas with a soft cl oth.
Fuser Inspect the fuser fo r signs of contamination.
Replace the fuser as nec essary .
Transfer roll A transfer roll contaminated with t oner can cause toner to transfer to the back of pages .
Inspect the transfer roll for contamination, and replace as necessary.
Diagnostics information 2-27
4512-630
Solving print quality problems
Note: Refer to the print defects guide at the end of the manual for repeating defects.
Print quality pr oblems
Problem Cause / action
Light or blurred characters.
T oner smudges appear on the front or back of the page.
Light print
See “Light print” on page 2-27. The toner cartridge may be getting low on toner:
• Remove the toner cartridge and print cartridge assembly.
• Shake it from si de to si de to redistribute the toner.
• Reinstall it and re check for condition.
• Make sure to use the recommended print media (see media types and sizes in the User’s Reference).
• Use MarkVision media weight.
• The toner cartridge or PC Kit may be defective. Replace the PC Kit first and recheck.
Blurred characters Blurred images , including characters, are usually caused by a defecti ve printhead.
Vertical w h it e li n es
See “V ertical streaks below. Vertical white lines may be caused by the laser beam, which may be partially blocked. With
the printer off, clear the path or clean the lens. The toner cartridge or fuser may be defective. Try a different toner cartridge. Inspect the fuser at its entry f or debris.
• Make sure the media is straight and unwrinkled.
• Replace the PC Kit and recheck befor e replacing the toner cartridge. See “Toner on
back of page” on page 2-27 for more information.
TM
to define the custom type setting for media type, media text ure, or
Vertical or horizontal streaks appear on the page.
2-28 Service Manual
Vertical streaks
Something could be caught between the PC kit and the fuser. Check t he paper path around the fuser entry. Try a different toner cartridge.
Vertical white lines may be caused by the laser beam which may be partially blocked. With the printer off, clear the path or clean the lens. The toner cartridge or fuser may be defective. Try a different toner cartridge. Inspect the fuser at its entry f or debris.
Horizontal streaks
The toner cartridge or the fuser may be the cause due to excessive page count or defect. Replace as needed.
If the lines are parallel and match the two intended ghost images, the Form Type may be incorrectly set. Check those settings.
The PC cleaner sump may be full. Replace the PC kit.
Print quality pr oblems (Continued)
Problem Cause / action
4512-630
Toner smears or rubs off the page.
The print is getting light, but the printer has not indicated it is low on toner .
The Toner Low message displays.
Solid blac k areas on transparencies
• Toner is not being fused to the media. Replace the fuser.
• Change the media texture setting in the driver. If special media is being used, such as card stock or l abels, be sure to select the correct media type .
• Try a different kind of media. Media designed for copiers gives the best qualit y fusi ng.
• Toner is beco ming low in the cartridge.
• The Tone r Low m essage does not di spla y i f the 1,500 page toner cartridge is installed .
• Remove the toner cartridge, and gently shake it from side to side to redistribute the toner.
• Replace the toner cartridge .
• Remove the toner cartridge, and gently shake it from side to side to redistribute the toner.
• Replace the toner cartridge .
• There is a mismatch in the tr ansparency and what the soft w are is expecti ng.
• Choose a different fill pattern in the soft ware program.
• Remove the toner cartridge, and gently shake it from side to side to redistribute the toner.
• Try a different type of transparenc y.
• Replace the toner cartridge .
Faint images or repetitiv e sp ots appe ar on the page.
• Select a different media type or form type setting from the printer driver.
• Try a different type of media. Media design ed for copiers gives the best quality.
• Replace the toner cartridge .
Pages ar e blank. • The print cartridge may be out of toner or defe cti ve. Replace the cartridge.
• There may be a software error . Re- ini tialize the printer by turning it off and back on.
• With the printer off, check the printhead beam path. If clear, check for a printhead error on POR. See “Printhead service ch eck” on page 2-31.
Diagnostics information 2-29
4512-630
Print quality pr oblems (Continued)
Problem Cause / action
The printer is on and indicates ready, but nothing prints.
Toner Low light is on and printing stops.
The Error light alone is on.
The Toner Low light is blinking, and the Error light is on.
The media ske ws or buckles.
The media sticks together, resulting in the printer feeding multiple sheets.
• Make sure the parallel or USB cable is not damaged and is firmly plugged into the connector on the back of the printer.
• Make sure the toner cartridge assembly is install ed properly.
• Print the menu page found under Utilities.
- If a menu settings page cannot be printed, contact the next level of support.
- If a menu settings page can be printed, the problem is one of the following:
Computer
Software program
Cable
(USB only) A failed controller card. Replace card.
Note: Test by unplugging USB and plugging it with the printer on. If the computer indicates
“unknown de vice,” replace the controller car d. If a 3.5K or more page toner cartridge is being used and t he Toner Low alarm is set to on,
the printer stops printing until the toner cartridge is replaced. Make sure the print er fr ont cover is cl osed.
• Make sure the toner cartridge is installed correctl y.
• Install a new toner cartridge.
• Tray is overfilled or media is too loose.
• Don’t overfill Tray 1 or the optional Tray 2 (see media capacities in the media types and sizes table in the User’s Guide).
• Make sure the paper guides are flush against th e edges of the media.
• The friction between sheets is too high.
• Remove the medi a from Tray 1 or Tray 2, and f an it.
• Don’t overfill Tray 1 or the optional Tray 2 (see media capacities in the media types and sizes chart in the User’ s Reference).
The media fails to feed from Tray 1.
The media fails to feed from the optional Tray 2.
The Load Paper message displays even though there is media loaded in the optional Tray 2.
The printer does not print after a paper jam has been cleared.
• Fricti onal force between tires and media is less than resisting force.
• Remove the medi a from Tray 1, and fan it.
• Make sure Tray 1 is selected fr om the pri nter driver. Do not overfill the tray.
• Check the condit ion of the rubber on the paper fe ed rolls. Replace if worn or contaminated.
• Verify that the ACM clutch is functioning correctly.
• Incorrect tray selection or inadequate picking f orce by tires .
• Make sure the correct tray and medi a type are selected from the driv er.
• Make sure the tray is pushed all the way in.
• Remove the medi a from the optional Tray 2, fan it, and reload.
• Check the rubber on th e paper feed tires for dirt or any other debris. Repla ce as necessary.
• Check the paper path in the tray for burrs or debris that may hinder media movement.
• Make sure the media does not exceed the stack height indicator.
• The input sensor does not sense media after picking.
• Make sure the tray is pushed all the way in.
• Press .
• Check the feed tires. (See two preceding actions.)
• The printer is waiting on the next command.
• Clear all jams.
• Press and release , or open and close the printer cover to rest art the printer.
• Make sure the print cartridge assembly is installed properly.
2-30 Service Manual
Print quality pr oblems (Continued)
Problem Cause / action
4512-630
Unexpected ch aracters print or characters are missing.
Jobs are not printing, and the error lig ht is on solid.
While in PostScript 3 emulation, the printer is flushing data (Ready/Data and Err or lights are blinking).
• Ensure correct printer driver is being used .
• Select hex tr ace mode to determine what the problem is.
• Restore factory defaults.
• Make sure the paral lel cable or USB cable is firmly plugged in at the back of the printer.
• The printer is waiting for an appropriate command.
• Make sure the print cartridge assembly is installed properly.
• Make sure the print er fr ont cover is cl osed.
• Ensure the correct PostScript driver is being used.
• The printer doesn’t have enough memory to print the job . Install more memory.

Printhead service check

FRU Action
Turn the printer off. Disconnect the printhead cables from J8 and J15 on th e controller card. Turn the printer on with the front door closed. On the controlle r car d, verify +5 V dc on pin 10 at J8 and +5 V dc on pins 1 and 2 at J15.
Printhead Note: New printhead
must be aligned. See
“Printhead assembly electronic adjustment” on page 3-6.
Verify grounds on pins 2, 4, and 7 at J8 and on pi n 4 at J15.
• If voltag es or grounds are incorrect, check the controller card. See “Contro ller card
• If voltages are correct, replace the printhead (comes with cabl es).
service check” on page2-17 for more information.

Transfer roll service check

FRU Action
Note: Do not touch the tr ansf e r roll e xc ept at its end s. Place a she et of paper ov er t he roll to
prevent damage from finger oils or hand lotion. Check the springs in the left and right transfer roll bearings . The bearing assemblies should
support the transfer roll, applying evenly distributed forces to the PC drum.
Trans fer roll
Note: Do not try to move the left spring. Replace the trans fer roll assemb ly if the springs or bearings show signs of damage or
fatigue. Inspect the transfer roll f or si gns of wear, damage or contamination. Replace as necessary.
Diagnostics information 2-31
4512-630
2-32 Service Manual
4512-630

3. Diagnostic aids

This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem.

Accessing service menus

There are different test menus tha t can be accessed during POR to identify problems with the printer.
Diagnostics Mode 1.Turn off the printer.
2.Press and hold and .
3.Turn on the print er.
4.Release the buttons when Performing Self Test displays.
Configuration Menu 1. Turn off the printer.
2.Press and hold and .
3.Turn on the print er.
4.Release the buttons when Performing Self Test displays.
Flash system code mode
1.Turn off the printer.
2.Press and hold , , and .
The Diagnostics M ode group contains the settings and operations used while manufacturing and servicing the printer.
See “Diagnostics mode” on page 3-2 for more information.
The Configuration Menu group contains a set of menus, setti ngs, and operations which ar e infrequently required by a user. Generally, the options made available in this men u group are used to configure a printer for operatio n.
See “This selection exits Diagnostics mode,
and Resetting the Printer displays. The printer performs a POR, and the printer re turns to normal mode.” on page 3-25 for more
information.
3.Turn on the print er.
4.Release the buttons when Performing Self Test displays.
To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostic Mode.
Diagnostic aids 3-1
4512-630

Diagnostics mode

Entering Diagnostics mode

1. Press and hold and .
2. Turn on the printer.
3. Release the buttons when Performing Self Test displays.

Available tests

The tests display on the operator panel in the order shown:
Diagnostics mode tests
REGISTRATION See “REGISTRATION” on page 3-4
Bottom Margin Top Margin Left Margin Right Margin Printhead See “Printhead assembly electronic adjustment” on page 3-6 Qui ck Test See “Quick Test” on page 3-12
PRINT TESTS
Tray 1 See “Input source tests” on page 3-13 Prt Quality Pgs See “Print quality pages (Prt Quality Pgs)” on page 3-13
HARDWARE TESTS
Panel Test See “Panel Test” on page 3-14 Button Test See “Button Test” on page 3-14 DRAM Test See “DRAM T est” on page 3-14 CACHE Test Parallel Wrap See “Parallel Wrap tests” on page 3-15 Parallel 1 Wrap (if insta lled)
3-2 Se rvice Ma nual
4512-630
Diagnostics mode tests (continued)
DUPLEX TESTS (if installed)
Qui ck Test See “Quick Te st (duplex)” on page 3-16 Top Margin See “Top/Left Margin (duplex)” on page 3-16 Sensor Test See “Sensor Test (duplex)” on page 3-17 Duplex Feed 1 See “Duplex Feed 1” on page 3-17
INPUT TRAY TESTS
Feed Tests See “Feed Tests (input tray)” on page 3-18
OUTPUT BIN TESTS
Feed Tests See “Feed Tests (output bins)” on pa ge 3-19 Sensor Test See “Sensor Test (standard output bin)” on page 3-19
BASE SENSOR TEST See “BASE SENSOR TEST” on pa ge 3-20
Exit Front Door Input
PRINTER SETUP
Defaults See “Default s” on page3-21 Page Count See “P age Count” on page 3-21 Perm Page Count See “Per m P age Count (permanent page count)” on page 3-21 Serial Number See “Serial Number” on page 3-21 Engine Setting 1 through 4 See “Engine Setting 1 through 4” on page 3-21 Model Name See “Model Name” on page 3-21 Configuration ID See “Configuration ID” on page 3-22 Edge to Edge See “Edge to Edge” on page 3-22 Par S Strobe Adj See “Parallel strobe adjustment (Par x Strobe Adj)” on page 3-22 Par x Strobe Adj (if additional
parallel options are installed)
Diagnostic aids 3-3
4512-630
Diagnostics mode tests (continued)
EP SETUP
EP Defaults See “EP Defaults” on page 3-23 Fuser Temp See “Fuser Temperature (Fuser Temp)” on page 3-23 Transfer See “Transfer” on page 3-23 Print Contrast See “Print Contrast” on page 3-23 Charge Roll See “Char ge Roll ” on page3-23 Gap Adjust See “ G ap Adjust” on page 3-23
EVENT LOG
Display Log See “Display Log” on page 3-24 Print Log See “Print Log” on page 3-24 Clear Log See “Cle ar Log” on page 3-25
EXIT DIAGNOSTICS

Exiting Diagnostics mode

Select Exit Diagnostics to exit the Diagnostics mode. Resetting th e Printer displays, the printer performs a POR, and returns to normal mode.

REGISTRATION

Print registration makes sure the printing is printed properly aligned on the page. The settings a vailable ar e:
Bottom Margin Top Margin Left Margin Right Margin Quick Test
To se t p r in t re g is tra tion:
1. Select REGISTRATION from the DIAGNOSTICS menu.
2. Select Quick Test, and press .
To print the Quick Test page:
a. Press unt il the appears next to Quick Test. b. Press .
Retain this page to det ermine the changes you need to make to the ma rgin settings.
The message Quick Te st Printin g… appears on the display.
3-4 Se rvice Ma nual
4512-630
3. Use or to select the margin setting you need to change, and press .
The Top margin sign/value pair blinks. This indicates it is the margin value being changed.
T=xxx* B=xxx* L=xxx* R=xxx*
4. Use to decrease or to increase the off set values, and pr ess to confirm the val ue.
The message Su bm it ting se le ct io n displays, and the original REGISTRATION screen appears with the beside the previously selected margin setting. The print registration range is:
Vari able Description Value Direction of change
B= Bottom margin -20 to +20 Each increment causes
approximately 0.55 mm shift in the bottom margin.
T= Top mar g in -25 to +25 Each inc rement ca us es
approximately 4 pels shift (at 600 dpi).
L= Left margin -25 to +25 A positive change moves the image
R= Right margin -10 to +10 A positive change moves th e image
A positive change compresses the image so it appears to move down the page and a negative change moves the image up.
A positive change moves the image down the page and increases the top margin. A negative change moves t he image up and decreases the top margin.
to the right, and a negative change moves the image to the left. No compression occurs.
to the right, and a negative change moves the image to the left.
5. Continue changing the settings by repeating steps 2 through 4.
6. Print another copy of the Quic k Test to verify your changes.
7. T o exit REGISTRATION, press Back ( ).
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Printhea d assembly elec tron i c adjustment
A step-by-s tep process to align a new printh ead.
Note: Before aligning the printhead electronically, first align the printhead mecahnically, if needed. See
“Printhead assembly mechanical adjustment” on page 3-10
1. Press Go to print Step 1 test page.
Step 1 printout
(sample only; use actual sheet)
2. In column <BA> of Step 1 test page, look for the position where the vertical lines are the closes t t o each
other. Press to select the corresponding number (new setting).
3. Press and release to move to the <CA> pattern on the right side of Step 1 te st page.
4. Press to select the <CA> setting.
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5. Press Go to print Step 2 test page.
Step 2 printout
(sample only; use actual sheet)
6. Press to change the <BA> settings to the number besi de the darkest portion of the vertical bar.
7. Press and release to move to the <CA> settings on th e right side of Step 2 test page.
8. Press to change the <CA> settings to the number besi de the dark est portion of the vertical bar.
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9. Press Go to print Step 3 test page.
Step 3 printout
(sample only; use actual sheet)
10. Press to change the <BA> setting to the number bes ide the darkest portion of the vertical bar.
11. Press and release to move to the <CA> settings on the right side of Step 3 test page.
12. Press to change the <CA> settings to the number beside the darkest portion of the v ertical bar.
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13. Press Go to print Visual alignment page.
Visual alignment printout
(sample only; use actual sheet)
14. Verify that the overall darkest line acr oss the page is “0.” If not, then run the alignment again.
15. Turn the printer off to ex it the printer alignment menu.
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Printhea d assembly mech an i cal adju stment
A printhead needs to be correctly positioned after it has been removed. Ali gn it to the frame or use the same position as the removed printhead. An indicator is located at the front right-hand screw for reference.
Note: Skew is caused by a sheet being fed through the printer while misaligned. The entire image is rotated relative to the sheet edges. However, a mechanically misaligned printhead causes the horizontal lines to appear skew ed while the vertical lines remai n parallel to the vertical edges.
Paper feed
skew
There are no adjust men ts for skew. Check the pick roll (paper pick assembly) for wear, the paper path for obstruction s, the fuser for proper setting, and the tr ay paper guides for fit to the media.
T o adjust the printhead:
Printhead
misalignment
1. Enter the Diagnostics Menu. See “Entering Diagnostics mode” on page 3-2.
2. Select PRINT TESTS.
3. Select Tray 1.
4. Select Single.
5. Fold the printed test page on the lef t side so that a few mill imeters of grid lines wrap around the outside of
the fold . See photo below.
6. Fold a second vertical f old near the center so that the l eft side top edge aligns with the right si de top edge.
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7. If the grid lines of the right flap align below the corresponding l ines on the left flap , adjust the printhead
clockwise relative to the printer and recheck. (See the left side of the figure belo w.) If the grid lines of the left flap align below the correspondi ng li nes of the right side, adjust the printhead countercl ockwise. (See the right side of the figure below.)
8. After obtaining a properly adjusted image on the paper, tighten all three screws.
Note: The printhead must be aligned electroni cally. See “Printhead assembly electronic adjustment” on
page 3-6.
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Quick Test
The Quick Test contains the following information:
Print registration settings
Alignment diamonds at the top and bottom
Horizontal lines to check for skew
General print er i nformation, including current page count , in stalled memory, serial number, and code level.
To print the Quick Test page:
Note: Print the Quick Test Page on letter or A4 paper.
1. Select REGISTRATION from DIAGNOSTICS.
2. Press unt il the appears next to Quick Test.
The message Quick Te st Printing … appears on the display. Once the Quick Test Page completes printing, the Registration screen displays again.
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PRINT TESTS

Input source tests
The purpose of the diagnosti c Print Tests is to verify that the print er can print on media fr om each of the i nstall ed input options. The contents of the Print Test Page v ari es depending on the media installed in the selected input source.
Check each Test Page from each source to assist in print quality and paper feed pr oblems. To run the Print Test Page:
1. Select PRINT TESTS from the Diagnostics men u.
2. Select the media source.
Tray 1 Tray 2 (if installed) Multipurpose Feeder (if installed) Envelope Feeder (if installed)
3. Select Single or Continuous.
If Single is selected, a single page is printed.
If Continuous is selected, printing continues until Stop ( ) is pressed to cancel the test.
If a source is selected that contains envelopes, an envelope test pattern is printed. If Continuous is selected, t he test pattern is printed only on the first envelope .
Note: The Print Test Page always prints on one side of the paper, regar dless of the duplex sett ing or the presence of a duplex option.
Press Back ( ) to return to PRINT TESTS.
Print quality pages (Prt Quality Pgs)
The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartridge lockout function disabled. The print quality pages consist of three pages. Page one contains a mixture of graphics and text. Pages two and three only con tai n graphics. If duplex is turned on, the pages are duplexed. The Print Quality Test pages are printed in English and must always be printed on letter, legal, or A4 paper.
To run the Print Quality Test Pages, select Prt Quality Pgs from PRINT TESTS. The message Printing Qualit y Tes t Pa ges is displayed.
Note: The print quality test pag es can also be printed from the Configuration menu (CONFIG MENU), however a cartridge must be installed wit h a ma chine class ID matching the machine class ID stored in NVRAM. Additional diagnostic information m ay be printed on the pages when printing fr om DIAGNOSTICS.
The foll owing is included in the DIAGNO STICS version of the print quality pages:
V alues from EP SETUP in DIAGNOSTICS, includin g:
Fuser temperature, warm up time, t ransfer, print contrast, and charge roll sett ings.
Contents of the EVENT LOG from DIAGNOSTICS.
Configurat ion in format ion, incl uding pri nter s erial n umber , contr oller code level, engine code l ev el , oper ator
panel code level, font versions, and cartridge inform ation.
Default values for the QUALITY MENU settings used to print the pages.
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HARDWARE TESTS

Select the following Hardware Tests from this menu:
Panel Test
Button Test
DRAM Test
ROM Memory Te st
Parallel Wrap (if available)
Serial Wrap (if available)
Panel Test
This test automatically toggles each pixel of the operator panel through every contrast level beginning with t he darkest and on to the brightest. This test continues until you press Stop ()
Button Test
The Button Test verifies the operat ion of the buttons on the operator panel. When yo u select Button Test, a diagram of the operator panel appears on t he panel. When you press a button on the operator panel, an X
appears on the corr esponding diagram. When you release the button, an X disappears. Pressing Back () or Stop ( ) cancels the test.
.
DRAM Test
The purpose of this test is to check the validity of DRAM memory, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly.
To run the DRAM Test:
1. Select DRAM Test from the menu .
The message DRAM Test Testing… displays. Then t he mes sage Resett in g Pr int er appears. The foll owing type of message appears:
DRAM Test xxx MB P:###### F:####
xxx represents the i nstalled DRAM size.
P:###### represents the number of times the memory test has passed and finished successfully.
Initiall y, 000000 displa ys wit h the maximum pass count being 999,999.
F:##### represents the number of times the memory test has failed and finished with errors. Initially,
0000 displays with the maximum f ail count being 99,999. Initially, only four digits appear, but additional digits appear as needed.
Each time the printer finishes a test, it increments “P” or “F” by 1 according to the success or failure of the DRAM.
While the DRAM test e x ecut es, the pow er i ndica tor l ight b li nks g reen. To stop the test be for e co mpleti on, turn the printer off.
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Parallel Wrap tests
This test is used with a wr ap plug to check operation of the parallel port hardware. Each parall el signal is tested. Use Parallel Wrap for the standard parallel port, Parallel 1 Wrap if a par all el port is available by PCI slot 1, or Paral lel 2 Wrap if a parallel port is available by PCI slot 2.
To run the Parallel Wrap test s:
1. Disconnect the parallel interface cable, and install the wrap plug (P/N 1319128).
2. Select Parallel Wrap , Parallel 1 Wrap, or Parallel 2 Wrap from the HARDWARE TESTS menu.
The power indicator blinks green, indicating the test is in progress. The test runs continuously until a maximum numb er of tests is reached.
Parallel Wrap P:###### F:####
P:###### represents the number of times the memory test has passed and finished successfully.
Initiall y, 000000 displa ys wit h the maximum pass count being 999,999.
F:##### represents the number of times the memory test has failed and finished with errors. Initially,
0000 displays with the maximum f ail count being 999,999. In itially, only four digits appear, but additional digits appear as needed.
Each time the test finishes, the screen updates. If the test passes, the pass counter increases by 1, howe ver if the tes t fails, a m essage displays for approximately three seconds. Once the m aximum count is reached, the test stops. The power indicator goes on solid, and the final results display.
To stop the test before compl etion, press Stop ().
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DUPLEX TESTS

Quick Test (duplex)
This test prints a duple x ver sion of the Quic k Test that can be used to verify that the correct placement of the top margin on the back side of a duplex page. You can run one duplexed page (Single), or continue printing
duplexed pages (Continuous) until Stop ( ) is pressed. For information about changing the margin, see
“T op/Left Margin (duple x)” on page 3-16.
Note: Before you set the duplex top margin, be sure to set the registration. See “REGISTRATION” on
page 3-4.
The paper you choose to print the page on should be either Letter or A4. To run the Quick Test (duplex):
1. Select Quick Test from DUPLEX TESTS.
2. Select Single or Continuous.
The single Duplex Quick test cannot be canceled.
The printer attempts to print the Quick Test Page from the default paper source. If the default paper
source only supports envelopes, then the page is printed from Tray 1.
Check the Quick Test Page for the corr ect offset between the placement of the first scan line on the
front and back side of a duplexed sheet.
The single test stop s automaticall y when a si ngle duplex sheet is printed, and the continuous test cont inues until you press Stop (
).
Top/Left Margin (duplex)
This setting controls the offset betw een the first scan line on the front of the duplex page and the first scan line on the back of the page . Therefore, be sure to set the top margin in REGISTRATION before setting the duplex top margin. See “REGISTRATION” on page 3-4.
To set the Top/Left Margin (duplex):
1. Print the Quick Test (duplex): a. Select Quick Test from DUPLEX TESTS.
b. Select Single. c. Hold the page to the light to see t he whether the top mar gin of t he back si de alig ns with the t op margin
of the frontside.
2. Select Top Ma rgin from DUPLEX TESTS.
3. Use or to select the margin setting you need to change .
Each increment shifts the duplex top margin by 1/100 of an inch.
The Top Margin (duplex) range is -20 to +20, and the default value is 0.
An increase moves the top margin down and wi dens the top margin. A decrease moves the top
margin upward and nar rows the top margin.
4. Press .
5. Print the Quick Test (duplex) again to verify the adjustment. Repeat if necessary.
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Sensor Test (duplex)
This test is used to det ermine whether or not the duplex sensors and switch es are working correctly. The test allows you to actuate the duplex input sensor located in the back part of the duplex unit and the dupl ex exit sensor located in the return paper path.
1. Select Sensor Test from DUPLEX TESTS.
The message Sensor Test Testing displays .
2. Manually actuate each of the duplex sensors. When the sensor/switch is cl osed, CL (closed) displays, and
when the sensor/s witch is open, OP (open) displays.
Duplex input sensor
Duplex exit sensor
3. Press Back ( ) or Stop ( ) to exit the test.
Duplex Feed 1
This test feeds a blank sheet of paper to the duplex paper stop position 1. This test can be run using any of the supported paper size s.
To run the Duplex Feed 1 Test:
1. Select Duplex Feed 1 from DUPLEX TESTS.
The power indicator blinks whil e the paper is feeding, and the message Duplex Feed 1 Feeding… displays.
The message Duplex Fee d 1 Clear Pap er displays when the paper reaches paper stop position 1, and the power indi cator turns on solid.
2. Remove the media from the duplex unit, and clear t he message on the operator panel by pressing Stop
(
).
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INPUT TRAY TESTS

Feed Tests (input tray)
This test lets the servicer observe the paper path as media is feeding thro ugh the printer. A blank sheet of paper feeds through the printer as the laser turns off duri ng thi s test. The paper is placed in the output bin.
To run the Input Tray Feed Tests:
1. Select Feed Tests from INPUT TRAY TESTS.
2. Select the input source from the source s dis pla y ed on the Fe ed Tests menu. All inst alled so urces are l isted .
3. Select either Single or Continuous.
Single—feeds one sheet of media from the selected source.
Continuous—media continues feeding from the selected source until Stop ( ) is pressed.
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OUTPUT BIN TESTS

Feed Tes ts (output bins)
Use these tests to verify that media can be fed to a specifi c output bin. M edia is fed from the defa ult input source to the selected output bin. No information is printed on the media fed to the output bin because the printhead is not engaged during this test. These tests can use any m edia size or envelope supported by the printer.
To run the Feed Tests f or the output bins:
1. Select Feed Tests from the OUTPUT BIN TESTS.
2. Select the output bin you want the paper to exit into. The standard bin as wel l as any output option bin
installed on the pri nter is shown on the menu. (Th e output bins are displayed in the order installed on the printer.)
3. Select either Single or Continuous.
Single—feeds one sheet of media from the selected source.
Continuous—media continues feeding from the selected source until Stop ( ) is pressed.
Press Back ( ) to return to OUTPUT BIN TESTS.
Sensor Test (standard output bin)
This test is used to verify if the standard bin sensor is working correct ly. To run the Sensor Test for the standard bin:
1. Select Sensor Test from OUTPUT BIN TESTS.
2. Select Standard Bin from Sensor Tests.
3. Select NearFull or Full sensor to test.
The following screen is displayed:
Standard Bin x Full=Open NearFull=Open
Full—Bin full sensor
NearFull—Bin near full sensor
4. Manually actuate the bin sensor by moving the flag in and out of the sensor. The display indicates Open
when the flag is out of the sensor and Closed when the flag is in the sensor.
5. Press Back () or Stop ( ) to exit th e test.
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BASE SENSOR TEST

This test is used to determine if the sensors locat ed inside the printer are working correctly. To run the Base Sensor Test:
1. Select BASE SENSOR TEST from the DIAGNOSTICS menu.
The following sensors are listed:
Exit—Exit senso r
Front Door—Front door sensor
Input—Input sensor
2. Manually actuate the sensors to verify that each sensor switches from Open to Closed.
3. Press Back () or Stop ( ) to exit th e test.
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PRINTER SETUP

Defaults
US/Non-US defaults changes whether the printer uses the US factory defaults or the non-US fac tory defaults. The settings af fected include paper si ze, env elope size, PCL symbol set, code pages, and units of measure.
Warning: Changing this setting resets the print er to factory de faults, and data may be lost. It cannot be undone .
Page Count
The page count can only be viewed and cannot be changed. To view the page count:
1. Select Page Count from PRINTE R S E T U P.
2. Press Back ( ) to return to PRINTER SETUP.
Perm Page Count (permanent page count)
The permanent page count can only be viewed and cannot be changed. To view the permanent page count:
1. Select Perm Page Count from PRINTER SETUP.
2. Press Back ( ) to return to PRINTER SETUP.
Serial Number
The serial number can only be viewed and cannot be changed. To view the serial number:
1. Select Serial number from PRINTER SETUP.
2. Press Back ( ) to return to PRINTER SETUP.
Engine Setting 1 through 4
Warning: Do not change the se settings unless requested to do so by your next level of support.
Model Name
The model name can only be viewed and cannot be changed .
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Configuration ID
The two configuration IDs are us ed to communicate info rmatio n about certain are as of the print er that cannot be determined using har dware sensors. The conf iguration IDs are originally set at the facto ry when the printer is manuf actured, however the servicer may need to reset Configurat ion ID 1 or Configuration ID 2 whene ver you replace the syst em board. The IDs consist of eight hexadecimal characters, including 0 through 9 and A through F.
Note: When the printer detects a Configuration ID that is not defined or invalid, the following occurs:
The default standard model Configuration ID is used instead.
Configuration ID is the only function available in DIA G NO STICS.
Unless the menu is in DIAGNOSTICS, Check Config ID displays.
To set the configuration ID:
1. Select Printer Setup from the Diagnostic mode.
2. Select Configuration ID from the Printer Set up menu.
Submit ti ng Se lection displays, follow ed by the value for Configurati on ID 1.
3. Enter the Configuration ID 1.
To select a digit or character to change, press or until the digit or character is underlined.
To change a digit or character, press to increase or to decrease the value.
When the last digit is changed, press to validate the Configuration ID 1.
If Inva li d ID appears, the entry is discarded, and the pre vious Configuration ID 1 is displayed on the screen. If the process is successful, Submitting Selection appears on the display, followed by the current value for Confirguration ID 2.
4. Repeat the steps for entering the Configuration ID, and press .
If the Configuration ID 2 is validated, Submi tt in g Selection appears, and a check ( ) appears next to Printer Setup.
5. Restart the printer.
Edge to Ed ge
When this setting is On, the text and gr aphics are shifted to the ph ysical edges of the paper for all margins. When the setting is Off, the normal margins are restored.
Parallel strobe ad j u stment (Par x S trob e A d j )
This setting adjusts the amount of time the strobe is sampled in order to determine if the v alid data is av ailable on the parallel port. The range of values are from -4 to 6, and the default is 0 for Par S Strobe Adj,
Par 1 Strobe Adj, and Par 2 Strob e Adj. After adjustment of 1 in crement, the strobe sampl es 50 ns longer.
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EP SETUP

EP Defau lt s
This setting i s used to restore each print er sett ing l isted in EP SETUP to its f ac tory def aul t v alue. Somet imes this is used to help correct print quality prob lems.
To restore EP Defaults:
1. Select EP Defaults from EP SETUP.
2. Select Restore to reset the values to the factory settings, and select Do Not Restore to exit without
changing the settings.
Fuser Temperature (Fuser Temp)
This adjustment can be used to help solve some cust om er pr oblems with paper curl on low gr ade papers and problems wit h let terheads on some types of media.
The fuser temperature can be adjusted to: Normal, Lower, Lowest. The default is Normal.
Transfer
The transfer can be adjusted to Low, Medium, or High. The default sett ing is Medium.
Print Contrast
The print contrast setting controls the develope r voltage offset. The print contrast can be adjusted to Low, Medium, or High. The default setting is Medium.
Charge Roll
The charge roll can be adjusted to Low, Medium, or High. The default setting is Medium.
Gap Adjust
The setting adjusts the minimum gap between sheets. Increasing this value may reduce curl of some printed media and eliminat e som e output bin stacking problems. However, increasi ng this value also results in slower overall performance , measured in pages per minut e. The range of value s is 0 to 255 , and the default value is 0.
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EVENT LOG

Display Log
The event log provides a history of printer err ors. It cont ains the 12 most recent error s that have occurred on the printer . The most recent error displays in position 1, and the oldest error d isplays in position 12 (if 12 err ors hav e occurred). If an er ror occurs after the log is ful l, the oldest error is discar ded. Identical errors in consecutive positions in the log are entered, so there may be repetitions. All 2xx and 9xx error messages are stor ed in the event log.
To view the event log:
1. Select Display Log from EVENT LOG.
Up to three error codes display at a time . Pr ess or to view additional error codes.
2. Press Back ( ) to return to the EVENT LOG menu.
Print Log
Additional diagnostic information is availab le when you print the event log from DIAGNOSTIC S rather than CONFIG MENU.
The Event Log printed from DIAGNOSTICS includes:
Detailed printer information, including code versions
Time and date stamps
Page counts for most errors
Additional debug information in some cases
The printed event log can be fa xed to Lexmark or your next level of support for verification or diagnosis.
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To print the event log: Select Print Log from EVENT LOG.
Press Back (
Clear Log
Use Clear Log to remov e the current information in the Event Log. Thi s affects both the viewed log and the printed log information.
1. Select Clear Log from the Event Log menu.
2. Select YES to cl ear th e Ev ent L og or NO to exit the Clear Log menu. If YES is selected, Deleting EVENT
LOG displays on the screen.
Press Back (

EXIT DIAGNOSTICS

This selection exits Diagnost ics mode, and Resettin g th e Printer displays. The printer performs a POR, and the printer returns to normal mode.
) to return to EVENT LOG.
) to return to EVENT LOG.
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Configuration menu (CONFIG MENU)

Entering Configuration Menu

1. Turn off the printer.
2. Press and hold and .
3. Turn on the printer.
4. Release the buttons when Performing Self Test displays.
The message CONFIG MENU displays on the top line of the operator panel.

Available menus

Maint Cnt Value See “Maintenance page count (Maint Cnt Value)” on page 3-27 Reset M a in t C nt S e e “Maintenance page counter reset ( Reset Maint Cnt)” on
Reset PC Cnt Prt Quality Pgs See “Print quality pages (Prt Quality Pgs)” on page 3-27 Panel Menu s See “Panel Menus” on page 3-27 PPDS Emulation See “” on page 3-27 Demo Mode See “Demo Mode” on page 3-28 Factory Defaults See “Factory Defaults” on page 3-28 Energy Conserve See “Energy Conserve” on page 3-28 EVENT LOG (print log only) See “EVENT LOG” on page 3-28 Paper Prompts See “Paper Prom pts” on page 3-28 Env Prompts See “Env Prompts” on page 3-28 Change Prompts See “Change Prompts” on page 3-29 Reduce Curl See “Reduced Curl” on page 3-29 USB Speed See “USB Speed” on page 3-29 Exit Config Menu See “Exit Config Menu” on page 3-29
page 3-27
Some menus are not a vailable, depending on the configur ation of the printer.
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Maintenance page count (Maint Cnt Value)

The current value for the maintenance page counter is displayed. This counter tracks printer usage. A print job containing a singl e page increments the counter by one and a duplex page by two. At 300,000, the customer is reminded that th e print er requires schedul ed maintenance. This counter is reset by the servicer af ter a 80 Scheduled Maintenance message displays and a maintenance kit is i nstalled. See “Maintenance kits” on
page 6-1 for the part number.
To view the maintenance page count:
1. Select Maint Cnt Value from CONFIG MENU.
2. Press to view the value.
Press Back (
) to return to the main Configuration menu.

Maintenance page counter reset (Reset Maint Cnt)

After schedul ed ma int enance, the servicer needs to reset the page counter. To reset the maintenance page count to zero: Select Reset Maintenance Count from the Configuration menu. The message Reset Ma in t Cnt=Res et displays momentarily. When the reset operation is com plete, the
menu returns to the Printer Setup Reset Maintenance Count scr een.

Print quality pages (Prt Quality Pgs)

The print quality te st pages can be printed from either the Diagnostics mode or Configuration Menu (CONFIG MENU). When printed from the Diagnostic mode, additi onal information is included, and the print cartridge lockout is bypassed. See “Print quality pages (Prt Quality Pgs)” on page 3-13. Additional confi guration information m ay be included on the print quality pages which is not included on the print menu page.
To print the Print Quality Test Pages, select Prt Quality Pgs from CONFIG MENU. The message Printing Qualit y Tes t Pa ges is displayed.
The following is printed:
Settings from EP SETUP from DIAGNOSTICS:
Fuser temperature, warm up time, t ransfer, print contrast, and charge roll sett ings.
Contents of the EVENT LOG from DIAGNOSTICS.
Printer configur ation information:
Printer serial n umber, controller code lev el, engine c ode l ev el , oper ator panel cod e l ev el , smart option c ode levels, font versions, and so on.
Values for the QUALITY MENU settings used to print the pages.
The print quality test consists of four pages. Page one contains a mixture of graphics and text. Pages two and three only contain graphics. Pag e four is bl ank. If duplex is turned on, the pages are duplexed. The Print Qualit y Test pages are printed in English and must always be printed on letter, legal, or A4 paper.

Panel Menus

Settings are Disable and Enable. The default is Enable.
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PPDS Emulation

This menu item allows the use r t o enable or disable PPDS emulation data stream. When thi s setting is enabled, the following settings are also changed:
SmartSwitch settings f or each port are turned off.
The printer language is changed to PPDS Emulation.
Users can still switch languages on the operator panel and through the PJL data stream.

Demo Mode

There is a built- in demonstration mode. The settings allo w you to Deactivate to turn off the demo mode and Activate to turn it on. While Demo Mode is set, the printer will start in Demo Mode until you change the setting.
Note: While Demo Mode is set to Activate, only demonstration files can print, and files received across
the network or from the host com puter are ignored.

Factory Defaults

This settin g enables a user to restore all the printer settings to the original factory settings. Selection s are Restore Base and Restore Network. Network does not appear unless you have a network printer. The follo w ing settings are not changed:
Display language
Settings in the NETWORK/POR TS MENU group.

Energy Conserve

This menu controls what values appear on the Power Saver menu. If Off is selected in Energy Conserve menu, then Disabl ed appears in the Power Saver menu and Power Saver can be turned off . I f On is set in Energy Conserve, the Power Saver feature cannot be disabled.

EVENT LOG

The ev ent log provides a history of printer errors. The event log can only be printed in CONFIG MENU. Additional options are available in DIAGNOSTICS. See “EVENT LOG” on page 3-24.
To print the event log:
1. Select Print Log from EVENT LOG.
2. Press Back ( ) or Stop ( ) to return to EVENT LOG.
Note: An event log printed from the CONFIG MENU wil l not contain debug inf ormati on or secondary codes for
900 service errors. However, the event log printed from DIA G NOSTIC S mode does include this inf ormati on.

Paper Prompts

When a tra y is out of th e indi cated paper size, a prompt is sent to the user to load paper in a tray. This setting controls the tray the user is directed to fill. Selections are Auto (default), MP Feeder, and Manual Paper.

Env Prompts

This setting controls the tray the user is directed to refill when a speci fic envelope size is out. The selections ar e
Auto (default), MP Feeder, and Manual Env.
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Change Pr om pt s

The value of this setting determines if the device displays any of the Change prompts.

Reduced Curl

This setting will cause the engine throughput to be significantly reduced if it is enabled. This mode will only be used if the media being prin ted is “Paper.” This sett ing is available as a last resort to help improve paper curl problems.

USB Speed

A value of “Full” forces the USB port to run at full sped and also disables its high-speed capabilities.

Exit Config Menu

Press to exit the CONFIG MENU. The message Resettin g the Printer displays, and the printer performs a POR and restarts in normal mode.
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4. Repair information

Warning: Read the following before handling electronic parts.

Handling ESD-sensitive parts

Many electronic products use parts that are known to be sensitive to elec trostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic cards:
Keep the ESD-sensitive part in its original shipping container (a special “ESD bag”) until the
part is ready to be installed into the printer.
Make the least-possible body mo vements to prevent an increase of static electricit y fr om
clothing fibers, carpets, and furniture.
Put the ESD wrist strap on y our wrist. Connec t the wrist ban d to the sy ste m ground poi nt. Thi s
discharges any static electric ity in your body to the print er.
Hold the ESD-sensiti ve part by its edge connector shroud (cover) ; do not touch its pins. If a
pluggable module is being remov ed, use the correct tool.
Do not place the ESD-sensitive part on the MFP cover or on a metal table; if the ESD-
sensitiv e part needs to be put down for any reason, first put it into its special bag.
Machine covers and metal tables are electrical grounds. They increase the risk of damage
because they m ake a discharge path from y our body through the ESD-sensitive part. (Large metal objects can be discharge paths without being grounded.)
Prevent ESD-sensitive parts from being accidentally touched by other person nel. Install
machine covers when the machine is not being worked on, and do not put unprotect ed ESD­sensitiv e parts on a tab le.
If possib le, keep all ESD-sensitive parts in a grounded metal cabinet (case).
Be extra car eful in working with ESD-sensitive parts when cold-weather heati ng is used,
because low humidity increases static electricity.

Removal proced ur e s

Note:
1. Remove the toner cartridge and media tray before removing other pri nter parts. The toner cartridge should
be protected from light while out of the printer.
2. We recommend disconnect ing all external cabl es from the printer to prevent damage during service.
3. Unless otherwise stated, reins tal l the parts in reverse order of removal.
4. When reinstalling a part held with several screws, start all screws before final tightening.
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Front acces s cov er r emoval
Remove Tray 1.
1.
2. Open the front access cover.
3. Open the rear door and the right side cover.
4. Loosen the four screws, and remove the controller card cover.
5. Disconnect the operator panel cable (A) from J3 on the controller card.
6. Extract the cable, and unhook the access cover by pressing t he righ t hinge to the right until it can be lifted
up and away from its pivot. Relax the hinge above the pivot.
7. In the same manner, mo ve the left hinge from its pivot point.
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8. Tilt the front cover down, and disconnect it on the l eft side from the link.
Warning: Make sure that the link is not bent or pulled out farther than normal. Otherwise, the toner cartridge
coupler may become dislodged.
9. Remove the front access cover.
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Left side cover removal
Remove Tray 1.
1.
2. Open the front access cover.
3. Open the rear door.
4. Remove the screw (A).
5. Unlatch the cover from the lat ches (B).
6. Position the print er wi th t he left rear corner hanging ov er the edge of the table.
7. Swing the cover open.
8. Lift the top rear of the cover over the piv ot point, and drop the cover awa y from the printer.
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Right side cover removal
Remove Tray 1.
1.
2. Open the front access cover.
3. Open the rear door.
4. Release the latches (A), and swing the cover open.
5. Position the print er wi th t he right rear corner hanging over the edge of the table.
6. Lift the top rear of the cover over the piv ot point, and drop the cover awa y from the printer.
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Rear cover removal
Remove th e right side cover. See “Right side cover removal” on page 4-5.
1.
2. Remove the left side cover . See “Left side cover removal” on page 4-4.
3. Remove the two screws (A).
4. Open the rear cover.
5. Lift the rear cover, unhooking it from the frame at the bottom, and remove.
Note: In re-installation, check to make sure that the fus er ground cable is routed out of the way and is not
pinched or damaged.
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Top cover removal
Remove th e right side cover. See “Right side cover removal” on page 4-5.
1.
2. Remove the left side cover . See “Left side cover removal” on page 4-4.
3. Open the rear door.
4. Remove the two screws (A) from the two front corners on the top cover, the two screws ( B) fr om the two
rear corners on the top cover , and the screw (C) on the left si de.
5. Open the front cover.
6. Remove the two screws (D).
7. Remove the controller card cover.
AB BC
D
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8. Disconnect the cable (E) of the narrow media sensor from J10 on th e controller card.
9. Free the cable while noting which top frame openi ng it goes through.
10. Release the latches (F) on bot h sides to unhook the top cov er.
11. Lift and remove the top cover.
Installation note:
Be sure to re-route the cable back through the same hole.
Be sure that the ground strap aligns at screw (C).
Verify the proper ali gnm ent of the top co ver with the paper exit guide along the mating edges at t he rear of
the exit tray.
Verify that the rollers in the top cover con tact the exit guide rollers at the top rear . There are arrows under
the top cover to verify the loca ti on of the rollers.
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Auto comp removal
Remove the duplex. See “Duplex removal” on page 4-18.
1.
2. Remove the auto comp clutch. See“Auto comp clutch removal” on page 4-10.
3. Use a spring hook or a small screwdriv er to rotate the latch to ward the bottom of the printer until it is
pointing do wnward.
4. Lay the printer on its top . Be sure to protect it from marring.
5. Raise the auto comp, and unhook the counter balance spring (A).
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6. Rotate the arm, and pull to remove the auto comp.
Auto comp clutch removal
Remove th e lef t side cover. See “Left side cover removal” on page 4-4.
1.
2. Remove the main motor drive. See “Main motor drive remov al” on page 4-28.
3. Remove the screws (A ) .
Note: Resistance to loosening the screw may have t o be applied to the shaft. Us e a finger or small screwdriver
against the coupler behind the clutch.
4. Remove the auto comp clutch.
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Au to co mp drive shaft asse mbly removal
Remove the auto comp clutch. See “Auto comp clutch removal” on page 4-10.
1.
2. Use a spring hook or a small screwdriver to dislodge the arm of the shaft bushing, and rotate the arm
countercloc kwise as far as it wil l go.
3. With the bushing aligned with the frame opening fo r clearance, unsnap the shaft from the ACM.
4. Remove the auto comp drive shaft assembly.
5. Use a screwdriver to align the ACM with the shaft bearing to help in installation.
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Bezel removal
Open the front access cover.
1.
2. Remove the two screws (A).
A
3. Lift the lower edge of the shield, slide it to the right, and remove.
4. Release the four inner latches (B).
5. Remove the bezel and lens whil e the door remains open.
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