Lexmark SC 1275 Service Manual

Lexmark Optra™ SC 1275

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

5040-001

• Index

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

First Edition (January 1998)

©

The following paragraph does not apply to any country where such provisions are
inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS

PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED,INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not allow disclaimer of express or implied warrantiesin certain transactions, therefore, this
statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are
periodically made to the information herein; these changes will be incorporated in later
editions. Improvements or changes in the products or the programs described may be
made at any time. Publications are not stocked at the address given below; requests for
publications should be made to your point of purchase.

A form for reader’s comments is provided at the back of this publication. If the form has
been removed, comments may be addressed to Lexmark International, Inc., Department
D22A/035-3, 740 New Circle Road NW, Lexington, Kentucky 40550, U.S.A. Lexmark may
use or distribute any of the information you supply in any way it believes appropriate
without incurring any obligation to you.

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

Other trademarks are the property of their respective owners.

Copyright Lexmark International, Inc. 1997. All rights reserved.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use,
duplication or disclosure by the Government is subject to restrictions as set forth in
subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at
DFARS252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,
Lexington, KY 40550.

Contents

NoticesandSafetyInformation..........................viii

LaserNotice....................................... viii

LaserAdvisoryLabel..............................ix

Class 1 Laser Statement Label ......................ix

GeneralInformation ..................................1-1

Maintenance Approach ............................. 1-1

Tools........................................... 1-1

Abbreviations..................................... 1-2

Paper Feed Operation .............................. 1-2

Drum Cartridge Toner Full Detection. ............... 1-6

SynchronizingRollers........................... 1-7

Paper Type Detection . . . ........................ 1-8

Development.................................... 1-10

TonerEmpty/TonerCartridgeDetection........... 1-10

AIDCSensorandEraseLamp................... 1-11

DiagnosticInformation ................................2-1

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

InitialCheck................................... 2-1

OperatorErrorMessageTable.................... 2-2

StatusMessages............................... 2-2

Line1StatusMessages......................... 2-3

Line2Messages.............................. 2-10

Supplies Status Messages ...................... 2-11

Attendance Messages. . . ....................... 2-11

ServiceErrorMessageTable.................... 2-26

SymptomTable............................... 2-29

ServiceChecks.................................. 2-33

FuserServiceCheck........................... 2-33

DevelopingMotorServiceCheck................. 2-34

TransportMotorServiceCheck................... 2-34

ImageTransferBeltServiceCheck................ 2-35

Paper Jam Service Check....................... 2-35

TonerCartridgeRackServiceCheck.............. 2-38

Printhead Cooling Fan Service Check.............. 2-39

Power Supply Cooling Fan Motor Service Check ..... 2-39

SuctionFanMotorServiceCheck................. 2-39

ACPowerServiceCheck....................... 2-40

MarksonPaperServiceCheck................... 2-41

Image Quality Troubleshooting ................... 2-42

iii Service Manual

SensorServiceCheck.......................... 2-47

Diagnostic Aids. .................................. 2-48

BasicPrinterPaperPassageTest................. 2-48

OperatorMenuDisabled........................ 2-48

Diagnostic Mode............................... 2-48

Diagnostic Menu Group ......................... 2-48

SettingPrinterRegistration...................... 2-50

PrintTests................................... 2-50

Quality Pages................................. 2-51

CleanEngineTest............................. 2-51

LCDHardwareTest............................ 2-51

ButtonTest................................... 2-51

DRAMMemoryTest............................ 2-51

ROMMemoryTest............................. 2-52

ParallelWrapTest............................. 2-53

SerialWrapTests.............................. 2-54

Input Tray Sensor Test. ......................... 2-55

SizeSensingSensorTest....................... 2-55

BaseSensorTest.............................. 2-56

QuickDiskCheck.............................. 2-57

DISKTest/Clean............................... 2-57

FlashTest.................................... 2-58

Setting the Page Count ......................... 2-58

Viewing the Permanent Page Count ............... 2-58

ViewingtheErrorLog........................... 2-58

ClearingtheErrorLog.......................... 2-59

ExitingDiagnosticMode......................... 2-59

PrintQualityTestPage ......................... 2-60

PrintQualityTestPage ......................... 2-61

RepairInformation ....................................3-1

PrecautionsforDisassemblyandCleaning........... 3-1

Instructions for Handling the PWBs with MOS ICs...... 3-1

Precautions for Handling the Drum Cartridge . ........ 3-2

Partsnottobetouched.......................... 3-2

Precautions for Handling the Laser Equipment ........ 3-3

Adjustment Procedures . . . .......................... 3-3

RegistrationAdjustment.......................... 3-3

RackLeverSolenoidAdjustment................... 3-5

RemovalProcedures............................... 3-5

OuterCoverRemovals........................... 3-5

ImageTransferRollerRemoval.................... 3-6

DrumCartridgeRemoval......................... 3-6

iv

Waste Toner Bottle Removal...................... 3-7

ImageTransferBeltRemoval..................... 3-7

FuserRemoval................................ 3-8

OilCoatingRollerRemoval....................... 3-9

HeaterLampRemoval.......................... 3-10

Printhead Removal ............................ 3-11

Paper Exit Removal............................ 3-12

High Voltage (HV1) / Sub High Voltage Board (PWB-F)

Removal .................................... 3-12

ShieldPlateRemoval.......................... 3-13

Power Supply Removal. . ....................... 3-13

Mechanical Control Board Removal . .............. 3-14

Power Supply Frame Removal ................... 3-14

Printhead Frame Removal....................... 3-15

Toner Empty / Toner Cartridge Detecting Board (PWB-B)

Removal .................................... 3-16

TonerCartridgeRackRemoval................... 3-16

Mechanical Controller Board Frame Removal. . . ..... 3-19

Paper Size/Cassette Detecting Board (PWB-E) Removal 3-19

Paper Take-Up Removal. ....................... 3-19

SuctionAssemblyRemoval...................... 3-25

SuctionFanMotorRemoval..................... 3-27

Locations ...........................................4-1

PartsofthePrinter................................. 4-1

PartsofthePrinter.............................. 4-2

PrintingProcess ............................... 4-6

SwitchesandSensors........................... 4-7

GearsandRollers............................. 4-10

Electrical Components. . . ....................... 4-12

Connectors . . ................................ 4-18

PrintedCircuitBoards.......................... 4-19

PartsCatalog ........................................5-1

HowtoUseThisPartsCatalog....................... 5-1

Housing.......................................5-2

Frames1......................................5-6

Frames2.....................................5-10

Drive ........................................5-14

Paper Take-Up 1...............................5-18

Paper Take-Up 2...............................5-22

ImageTransferBelt.............................5-24

ImageTransferBelt.............................5-26

TransferRoller.................................5-28

v Service Manual

Paper Transport ................................5-32

Rack.........................................5-34

Fuser1.......................................5-38

Fuser2.......................................5-40

Fuser/Exit.....................................5-42

Exit..........................................5-44

ElectricalParts.................................5-46

SecondCassette(Tray1) ........................5-50

ThirdCassette(Tray2) ..........................5-54

Paper Tray . ...................................5-56

ControllerCard.................................5-58

Index................................................X1

vi

vii Service Manual

Notices and Safety Information

References in this publication to products, programs, or services do
not imply that the manufacturer intends to make these available in all
countries in which it operates. Any reference to a product, program,
or service is not intended to state or imply that only that product, pro­gram, or service may be used. Any functionally equivalent product,
program, or service that does not infringe any existing intellectual
property rights may be used instead. Evaluation and verification of
operation in conjunction with other products, programs, or services,
except those expressly designated by the manufacturer, are the
user’s responsibility.

Laser Notice

The printer is certified in the U.S. to conform to the requirements of
DHHS 21 CFR Subchapter J for Class I (1) laser products, and else­where is certified as a Class I laser product conforming to the
requirements of IEC 825.

Class I laser products are not considered to be hazardous. The
printer contains internally a Class IIIb (3b) laser that is nominally a 5
milliwatt gallium arsenide laser operating in the wavelength region of
770-795 nanometers. The laser system and printer are designed so
there is never any human access to laser radiation above a Class I
level during normal operation, user maintenance, or prescribed
service c ondition.

Notices and Safety Information viii

Laser Advisory Label

Label is inside printerl

Class 1 Laser Statement Label

Label is on back of printer.

ix Service Manual

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die
Anforderungen der Bestimmung DHHS (Department of Health and
Human Ser vices) 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) 825 gemäß amtlicher Bestätigung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des
Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es
sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen
der Länge 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
KundendienstLaserbestrahlung, die die Klasse I übersteigen würde,
Menschen keinesfalls erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux
provisions DHHS 21 CFR alinéa J concernant les produits laser de
Classe I (1). Pour les autres pays : cette imprimante répond aux
normes IEC 825 relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comme des produits
non dangereux. Cette imprimante est équipée d’un laser de Classe
IIIb (3b) (arséniure de gallium d’une puissance nominale de 5
milliwatts) émettant sur des longueurs d’onde comprises entre 770
et 795 nanomètres. L’imprimante et son système laser sont conçus
pour impossible, dans des conditions normales d’utilisation,
d’entretien par l’utilisateur ou de révision, l’exposition à des
rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme
ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di
classe 1 ed è certificata negli altri Paesi come prodotto laser di
classe 1 conforme ai requisiti della norm a CEI 825.

Notices and Safety Information x

I prodotti laser di classe non sono considerati pericolosi. La
stampante contiene al suo interno un laser di classe IIIb (3b)
all’arseniuro di gallio della potenza di 5mW che opera sulla
lunghezza d’onda compresa tra 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
funzionamento, le operazioni di servizio o quelle di assistenza
tecnica, non ricevano radiazioni laser superiori al livello della classe

1.

Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los
requisitos para los productos láser de Clase I (1) establecidos en el
subcapítulo J de la norma CFR 21 del DHHS (Departamento de
Sanidad y Servicios) y, en los demás países, reúne todas las
condiciones expuestas en la norma IEC 825 para productos láser de
Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La
impresora contiene en su interior un láser de Clase IIIb (3b) de
arseniuro de galio de funcionamiento nominal a 5 milivatios en una
longitud de onda de 770 a 795 nanómetros. El sistema láser y la
impresora están diseñados de forma que ninguna persona pueda
verse afectada por ningún tipo de radiación láser superior al nivel de
la Clase I durante su uso normal, el mantenimiento realizado por el
usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os
requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a
Classe I (1) de produtos laser. Em outros locais, está certificada
como um produto laser da Classe I, em conformidade com os
requisitos da norma IEC 825.

Os produtos laser da Classe I não são considerados perigosos.
Internamente, a impressora contém um produto laser da Classe IIIb
(3b), designado laser de arseneto de potássio, de 5 milliwatts
,operando numa faixa de comprimento de onda entre 770 e 795
nanómetros. O sistema e a impressora laser foram concebidos de

xi Service Manual

forma a nunca existir qualquer possiblidade de acesso humano a
radiação laser superior a um nível de Classe I durante a operação
normal, a manutenção feita pelo utilizador ou condições de
assistência prescritas.

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een
laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen
vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in
IEC 825.

Laserprodukten van klasse I worden niet als ongevaarlijk
aangemerkt. De printer is voorzien van een laser van klasse IIIb
(3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met
een golflengte van 770-795 nanometer. Het lasergedeelte en de
printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of
reparatie conform de voorschriften, nooit blootstelling mogelijk is
aan laserstraling boven een niveau zoals voorgeschreven is voor
klasse 1.

Notices and Safety Information xii

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i
overenstemmelse med kravene i IEC 825.

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. Lasersystemet og printeren er udformet
således, at mennesker aldrig udsættes for en laserstråling over
Klasse I-niveau ved normal drift, brugervedligeholdelse eller
obligatoriske servicebetingelser.

Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS
21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I
laserlaitteiden IEC 825 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle.
Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin
galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei
altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen
normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden
huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina
näkymättömälle lasersäteilylle. Älä katso säteeseen.

VARNING! Osynlig laserstrålning när denna del är öppnad och
spärren är urkopplad. Betrakta ej strålen.

xiii Service Manual

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21
CFR, underparagraf J för laserprodukter av Klass I (1). I andra
länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt
kraven i IEC 825.

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 770­795 nanometer. Lasersystemet och skr ivaren är utformade så att det
aldrig finns risk för att någon person utsätts för laserstrålning över
Klass I-nivå vid normal användning, underhåll som utförs av
användaren eller annan föreskriven serviceåtgärd.

Laser-melding

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

825.
Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren

inneholder internt en klasse IIIb (3b)-laser, som består av en
gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet
770-795 nanometer. Lasersystemet og skriveren er utformet slik at
personer aldri utsettes for laserstråling ut over klasse I-nivå under
vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne
serviceoperasjoner.

Notices and Safety Information xiv

Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora
compleix els requisits de DHHS 21 CFR, apartat J, pels productes
làser de classe I (1), i segons ha estat certificat en altres llocs, és un
producte làser de classe I que compleix els requisits d’IEC 825.

Els productes làser de classe I no es consideren perillosos. Aquesta
impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li,
nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona
de 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 nivell de classe I durant una operació normal, durant
les tasques de manteniment d’usuari ni durant els serveis que
satisfacin les condicions prescrites.

Japanese Laser Notice

xv Service Manual

Chinese Laser Notice

Korean Laser Notice

Notices and Safety Information xvi

Safety Information

This product is designed, tested and approved to meet strict

•

global safety standards with the use of specific Lexmark
components. The safety features of some parts may not
always be obvious. Lexmark is not responsible for the use of
other replacement parts.

• The maintenance information for this product has been

prepared for use by a professional service person and is not
intended to be used by others.

• There may be an increased risk of electric shock and

personal injur y during disassembly and servicing of this
product. Professional service personnel should understand
this and take necessary precautions.

Consignes de Sécurité

Ce produit a été conçu, testé et approuvé pour respecter les

•

normes strictes de sécurité globale lors de l'utilisation de
composants Lexmark spécifiques. Les caractéristiques de
sécurité de certains éléments ne sont pas toujours évidentes.
Lexmark ne peut être tenu responsable de l'utilisation
d'autres pièces de rechange.

• Les consignes d'entretien et de réparation de ce produit

s'adressent uniquement à un personnel de maintenance
qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter

certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.

Norme di sicurezza

Il prodotto è stato progettato, testato e approvato in

•

conformità a severi standard di sicurezza e per l’utilizzo con
componenti Lexmark specifici. Le caratteristiche di sicurezza
di alcune parti non sempre sono di immediata comprensione.
Lexmark non è responsabile per l’utilizzo di parti di ricambio
di altri produttori.

xvii Service Manual

• Le informazioni riguardanti la manutenzione di questo

prodotto sono indirizzate soltanto al personale di assistenza
autorizzato.

• Durante lo smontaggio e la m anutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni alla persona è più
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.

Sicherheitshinweise

Dieses Produkt und die zugehörigen Komponenten wurden

•

entworfen und getestet, um beim Einsatz die weltweit
gültigen Sicherheitsanforderungen zu erfüllen. Die
sicherheitsrelevanten Funktionen der Bauteile und Optionen
sind nicht immer offensichtlich. Sofern Teile eingesetzt
werden, die nicht von Lexmark sind, wird von Lexmark
keinerlei Verantwortung oder Haftung für dieses Produkt
übernommen.

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des

Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständige
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.

Pautas de Seguridad

Este producto se ha diseñado, verificado y aprobado para

•

cumplir los más estrictos estándares de seguridad global
usando los componentes específicos de Lexmark. Puede
que las características de seguridad de algunas piezas no
sean siempre evidentes. Lexmark no se hace responsable
del uso de otras piezas de recambio.

• La información sobre el mantenimiento de este producto

está dirigida exclusivamente al personal cualificado de
mantenimiento.

Notices and Safety Information xviii

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser consciente de este
peligro y tomar las precauciones necesarias.

Informações de Segurança

Este produto foi concebido, testado e aprovado para

•

satisfazer os padrões globais de segurança na utilização de
componentes específicos da Lexmark. As funções de
segurança de alguns dos componentes podem não ser
sempre óbvias. A Lexmark não é responsável pela utilização
de outros componentes de substituição.

• As informações de segurança relativas a este produto

destinam-se a profissionais destes serviços e não devem ser
utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

desmontagem e manutenção deste produto.Os profissionais
destes serviços devem estar avisados deste facto e tomar os
cuidados necessários.

Informació de Seguretat

Aquest producte està dissenyat, comprovat i aprovat per tal

•

d'acomplir les estrictes nor mes de seguretat globals amb la
utililització de components específics de Lexmark. Les
característiques de seguretat d'algunes peces pot ser que no
sempre siguin òbvies. Lexmark no es responsabilitza de l'us
d'altres peces de recanvi.

• La informació pel manteniment d’aquest producte està

orientada exclusivament a professionals i no està destinada
a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar

durant el procés de desmuntatge i de servei d’aquest
producte. El personal professional ha d’estar-ne assabentat i
prendre les mesures convenients.

xix Service Manual

Notices and Safety Information xx

xxi Service Manual

1. General Information

Maintenance Approach

The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the error code charts,
symptom index, and service checks to determine the symptom and
repair the failure.

After you complete the repair, perform tests as needed to verify the
repair.

Tools

The removal and adjustment procedures described in this manual
require the following tools and equipment:

• Magnetic tip Phillips screwdrivers, large and small

• Flat-blade screwdriver

• Analog volt ohmmeter (a digital volt ohmmeter may also be

used)

• Needle nose pliers

When you make voltage readings, always use frame ground unless
another ground is specified.

General Information 1-1

Abbreviations

ASIC Application-Specific Integrated Circuit
CSU Customer Setup
DRAM Dynamic Random Access Memory
EEPROM Electrically Erasable Programmable Read-

Only Memory
EP Electrophotographic Process
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LAN Local Area Network
LASER Light Amplification by Stimulated Emission

of Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
PICS Problem Isolation Charts
PIXEL Picture Element
POR Power-On Reset
POST Power-On Self Test
PQET Print Quality Enhancement Technology
RIP Raster Image Processor
ROS Read-Only Storage
SRAM Static Random Access Memory
UPR Used Parts Replacement
VAC Volts alternating current
VDC Volts direct current

Paper Feed Operation

•

Paper can be fed into the printer from the Multi-Purpose Tray
(150 sheets) or from the Second Cassette Tray (Tray 1, 250
sheets).

• The Optional Third Cassette Unit (Tray 2 option, 250 sheets)

adds another feeding method. Its str ucture is the same as that
of the Second Cassette Tray.)

1-2

Multi Purpose Tray

When the paper take-up solenoid 1 (SL3) energizes, the transport
motor (M2) drives the paper take-up roller via the paper take-up
clutch. The paper take-up roller rotates one revolution. At the same
time, the depressing cam rotates and releases the paper lift-up plate
to feed the top sheet of paper. The paper is transported to the syn­chronizing roller section by the transport rollers.

The transport rolls are mounted free on the shaft of the paper take­up roller and rotate independently of the paper take-up roller. The
transport rolls rotate as the transport roller rotates.

The fixed separating pad separates paper and prevents multiple
paper feeds.

The paper empty sensor 1 (PC5) detects paper in the multi-purpose
tray.

General Information 1-3

Second Cassette (Tray 1)

When paper take-up solenoid 2 (SL7) energizes it rotates the paper
take-up roller which feeds the top sheet of paper.

Paper empty sensor 2 (PC11) detects paper in the second cassette.
Paper near empty sensor 1 (PC10) detects when the number of
sheets of paper in the tray becomes less than 50.

The combination of switches S1 and S2 on the 2nd paper size/cas­sette detecting board (PWB-E) detect the presence of the cassette
and the size of paper in the cassette.

1-4

Third Cassette Unit (Tray 2 Option)

The third cassette is constructed in the same way as the second
cassette.

General Information 1-5

Drum Cartridge Toner Full Detection

The drum cartridge toner full board (PWB-D1), on top of the image
transfer belt assembly, determines when the PC drum waste toner
boxisfull.

Waste toner full is detected by an LED (LED1) and a photo-sensor
(PT1) on the PWB-D1. Light from the LED (LED1) passes through
the LED passing window, is reflected by a mirror in the drum car­tridge, and then received by the photo sensor (PT1). The amount of
this light determines whether the drum cartridge is nearly full or full.

1-6

Synchronizing Rollers

The synchronizing rollers adjust any skewed paper transported from
the paper take-up/feed section. The rollers match the leading edge
of the image on the image transfer belt with the leading edge of the
paper.

The paper synchronizing sensor (PC1) detects when the leading
edge of paper has reached the synchronizing rollers.

General Information 1-7

Paper Type Detection

The overhead projection (OHP) sheet detect board (PWB-D2), con­sisting of an LED (LED1) and a photo sensor (PT1), determines
whether transparencies or plain paper is being fed through the
machine.

When plain paper is feeding, the light from the LED reflects off the
surface of the paper, and strikes PT1.

1-8

When a sheet of OHP transparencies is feeding, the light from the
LED passes through and PT1 receives no light.

General Information 1-9

Development

Toner Empty / Toner Cartridge Detection

Toner Empty Detection

Light from the toner empty detection LED (LED1) on the toner
empty/toner cartridge detecting board (PWB-B) is reflected by a mir­ror in the toner cartridge and received by photo sensor (PT1).

The amount of light received by the photo sensor determines
whether the toner is empty or nearly empty.

1-10

Toner Cartridge Detection

Light from the toner cartridge detection LED (LED2) on t he toner
empty/toner cartridge detecting board (PWB-B) is reflected by the
toner cartridge surface to the photo sensor (PT1).

The toner cartridge is detected during warm up.

AIDC Sensor and Erase Lamp

Automatic Image Density Control (AIDC)

The AIDC sensor detects the image density of the AIDC mark
formed by toner on the PC Drum to deter mine proper charging bias
and developing bias. The sensor is located on the AIDC/erase lamp
board (PWB-C) on top of the image transfer belt. AIDC detection is
accomplished with one LED (LED1) and two photo sensors (PT1,
PT2).

General Information 1-11

AIDC detection is done for each Color Toner Cartridge after the
developing rack position initializes.

1-12

Erase Lamp

Nineteen LEDs are placed in a row on the AIDC/Erase Lamp Board
(PWB-C). Following developing, the surface of the PC Drum is
exposed to light from these LEDs to neutralize negative the charge
on the areas to which no toner has been attracted.

General Information 1-13

1-14

2. Diagnostic Information

The diagnostic information in this chapter leads you to the failing
part. Before you replace an entire assembly, determine if just the
defective part is available in the parts catalog. Some diagnostic pro­cedures indicate the parts catalog location of the part to be checked
by including the assembly number and reference number in paren­thesis. Some part numbers are also included. Use the error code
tables, symptom table, service checks and the diagnostic aids chap­ter to determine the symptom and repair the failure. After you com­plete the repair, perform the appropriate tests to verify the repair.

If an error is displayed, locate it in the following Operator Error Mes­sage Table, or the Service Error Message Table and take the appro­priate action.

If an error message appears while you are working on the machine,
go to the error message table and take the indicated action.

Use the Locations chapter to find connector, board, and pin informa­tion. The sequence given in the service check is connector, board,
and pin. The board uses only a letter for an identifier. For example,
connector

CN8A-3; CN8 = connector, A = board, -3 = the pin.

Start

Initial Check

Before you star t troubleshooting, check the following:

Installation Environment

• The power supply line voltage is plus or minus 10% of the rated

line voltage.

• The machine is securely installed on a level surface in a well-

ventilated place.

• The room temperature is between 10 and 32°C (50 and 90°F)

and the relative humidity between 20 and 80%.

• Avoid sites generating ammonia gas, high temperature or high

humidity (near water faucets, kettles, humidifiers), cold spaces,
near open flames, and dusty areas.

Diagnostic Information 2-1

• Avoid sites exposed to direct sunlight.

Print Paper Checks

• Be sure the recommended paper for this printer is being used.

• Check the paper for dampness. Make a trial print with paper

from a newly opened package, and check the result.

Operator Error Message Table

The operator panel messages are divided into three groups: Status,
Attendance, and Service. Status messages give information about
the current state of the printer. Attendance messages indicate
printer errors that the operator must resolve. Service messages indi­cate printer problems that require servicing.

Printer status is shown on the first line of the display. Additional infor­mation about printer status may be displayed on the second line of
the display.

Status Messages

Line 1 on the display provides information about the printer, as
shown in the following table. A long message requires line 2 to pro­vide additional information about pr inter status.

2-2

Line1StatusMessages

Status Message Action
Ready The printer is ready to receive and

Ready Hex The printer is ready and Hex Trace

Busy The printer is busy receiving or pro-

process data.

•Press<Menu> to take the printer
out of Ready and enter the pri­mary menu selections.

•PressStop to take the printer
offline. Not Ready is displayed
and no more data is processed
from the host computer.

•PressGo to return to Ready.

mode is active.

•Press<Menu> to take the printer
out of Ready and to enter the pri-
mary menu selections.

•PressStop to take the printer
offline. Not Ready is displayed
and no more data is processed
from the host computer.

•PressGo to return to Ready.

cessing data, or printing data. The
printer language is shown to the
right of Busy on the display.

The printer indicator light blinks
while the printer is processing data.

If line 2 indicates that operator inter­vention is required:

•PressStop to take the printer
offline. Not Ready is displayed
and no more data is processed
from the host computer.

•PressGo to return to Ready.

Or, to reset the printer:

•Press<Menu> to access the
Busy menu.

• Select Reset Printer.

Diagnostic Information 2-3

Status Message Action
Waiting The printer has received a page of

data to print, but is waiting until an
End of Job or Form Feed command
occurs or until additional data is
received.

The display shows the printer lan­guage on line 1 to the right of Wait-

ing.

•PressStop to take the printer
offline. Not Ready is displayed
and no more data is processed
from the host computer.

•PressGo to return to Ready.

Or, to reset the printer:

•Press<Menu>> to access the
Busy menu.

•SelectReset Printer.

Engine Warming The printer is performing the neces-

sary action to warm the fuser mech­anism. No button actions are
possible while this message is dis­played.

Density Check The printer is performing the Image

Density Calibration. No button
actions are possible while this mes­sage is displayed.

Cleaning Engine From the Tests Menu the selection

Clean Engine is available to clean

the secondary transfer assembly.
This message is displayed if you
select Yes and the cleaning process
is in progress. No button actions are
possible while this message is dis­played. When the cleaning is com­plete, TESTS MENU is displayed.

2-4

Status Message Action
Flushing Buffer The current print job is being dis-

carded.
This message is displayed when a

PostScript job has an invalid opera­tororifSmartSwitchisdisabled.No
buttonactions are possible while this
message is displayed.

Power Saver The printer is in Power Saver mode.
Printing Menu Settings The printer is processing or printing

a list of current menu settings
because Print Menu Setting was
selected from the Tests Menu.

•PressStop to take the printer off-
line. The Not Ready message is
displayed. No more data is pro­cessed, but the printer processes
all paper currently in the printer
paper path.

•PressGo to return to Ready after
thepageprints.

Or, to reset the printer:

•Press<Menu> to access the
Busy menu.

• Select Reset Printer.

Printing Directory List A directory of the flash and disk con-

tentsisprocessingorprinting
because Print Directory is selected
from the menu.

•PressStop to take the printer
offline. The Not Ready message
is displayed. No more data is pro­cessed, but the printer processes
all paper currently in the printer
paper path.

•PressGo to return to Ready after
thepageprints.

Or, to reset the printer:

•Press<Menu> to access the
Busy menu.

• Select Reset Printer.

Diagnostic Information 2-5

Status Message Action
Printing Font List The printer is processing a print font

listing because Print Fonts is
selected from the menu. When all
the pages for a font listing format,
the printer display changes to the
Busy message as the pages print.

•PressStop to take the printer
offline. The Not Ready message
is displayed. No more data is pro­cessed, but the printer processes
all paper currently in the printer
paper path.

•PressGo to return to Ready after
the page prints.

Or, to reset the printer:

•Press<Menu> to access the
Busy menu.

•SelectReset Printer.

Restoring Factory Defaults The printer is restoring factory

defaults.
No button actions are possible while

this message is displayed.

Performing Self Test The printer is running the normal

series of start-up tests after it is pow­ered on. When the tests are com­plete, the printer returns to Ready.

2-6

No button actions are possible while
this message is displayed.

Status Message Action
Not Ready
Press Go

Resetting the Printer The printer is deleting any print jobs

Formatting Flash
DO NOT POWER OFF

Programming Flash
DO NOT POWER OFF

The printer is in the Not Ready state,
which means it is not ready to
receive or process data.

This message displayswhen Stop is
pressed during a print job. Press Go
to take the printer out of the not
ready state.

Or, to reset the printer:

•Press<Menu>toaccess theBusy
menu.

• Select Reset Printer.

in process and restoring all settings
to user defaults.

No button actions are possible while
this message is displayed.

The flash memory is being format­ted.

No button actions are possible while
this message is displayed.

The flash memory is being pro­grammed. Fonts or macros are
being written to flash memory.

No button actions are possible while
this message is displayed.

Formatting Disk The disk is being formatted.

No button actions are possible while
this message is displayed.

Diagnostic Information 2-7

Status Message Action
Programming Disk
DO NOT POWER OFF

Menus Disabled The printer menus have been dis-

The disk is being programmed.
Fonts or macros are being written to
disk.

No button actions are possible while
this message is displayed.

If information is written both to flash
memory and to disk at the same
time, the Programming Flash mes­sage is displayed.

abled. This occurs when <Menu> is
pressed while the printer is Ready
and Menu Lockout is active.

The printer display shows this mes­sage for one second and then
returns to the Ready message.

No button actions are possible while
this message is displayed.

If the operator has disabled the
menu and you want to run print tests,
turn the machine off, then press Go
and Stop as you turn the machine
on.

Activating Menu Changes Theprinterisresettoactivatea

printer setting changed in the
menus.

No button actions are possible while
this message is displayed.

2-8

Status Message Action
Files Will Be Lost. Go or Stop? This message is displayed when the

Job Buffer Size is changed in the

Setup Menu. The message indicates
that the disk is about to be formatted
to create the new job buffer partition.
All disk files will be lost if this action
continues.

•PressGo to continue. The disk is
formatted and the job buffer parti­tion is created.

•PressStop to cancel the opera-
tion.

Diagnostic Information 2-9

Line 2 Messages

Status Message Action
Supplies Toner is low, or a tray is empty or

missing. This message remains on
the operator panel until the supply is
replaced, or the tray is installed.

If you are unable to clear the sup­plies message, see the “Supplies
Status Messages” on page 2-11.

Parallel The printer is locked to the printer

standard parallel port.

Serial x x is 1, 2, or 3 and represents the

serial port attached to option con­nector x. The printer is locked to this
link.

Network x x is 1, 2, or 3 and represents the net-

work card attached to option con­nector x. The printer is locked to this
link.

LocalTalk x x is 1, 2, or 3 and represents the

LocalTalk card attached to option
connector x. The printer is locked to
this link.

Infrared x x is 1, 2, or 3 and represents the

Maintenance Maintenance is required for the

infrared port attached to option con­nector x. The printer is locked to this
link.

assembly shown. This message
remains on the operator panel until
the maintenance is completed.

2-10

SuppliesStatusMessages

Status Message Action
Paper Tray Missing, Size • Check size paper indicator for

Paper Low/Empty Tray 1 and 2 Go to the “Sensor Service Check” on

Paper Empty Multipurpose Tray Go to the “Sensor Service Check” on

damage and be sure it is inserted
correctly.

• Goto the “Sensor Service Check”
on page 2-47, run the sensor size
test and replace parts as neces­sary.

• Replace the 2nd paper size/cas­sette detection board (Tray 1,
PWB-E1, or Tray 2 (PWB-E2).

page 2-47 and check the actuators
and sensors for tray 1 and tray 2.

page 2-47 and check the actuators
and sensors for the multipurpose
tray.

Attendance Messages

Attendance messages indicate printer errors the user must solve.

Attendance Message Action
20x Paper Jam

24x
250

The printer has detected a paper
jam. The second line shows where
the paper jam may be. The entire
paper path must be cleared of paper.

Press Go to return to printing. If you
still have the problem, clear the
entire paper path of paper and go to
the “Paper Jam Service Check” on
page 2-35.

Diagnostic Information 2-11

Attendance Message Action
Close Door Either the top door is open or the

back door (fuser area) is open.
Be sure the transfer belt assembly is

installed.
Check the actuators and do a conti-

nuitycheck of interlock switch 1 (S2),
interlock switch 2 (S3) and PH scat­ter switch (S5). Replace the switch
or actuator as necessary.

30 Yellow Toner Cart Missing
30 Magenta Toner Cart Missing
30 Cyan Toner Cart Missing
30 Black Toner Cart Missing

34 Incorrect Media Themediatypeorsizethatis

The toner cartridge indicated is not
installed. Install the toner cartridge.
The message clears from the display
when the top door is closed.

If you still have the error, check the
contacts on the toner cartridge and
the toner cartridge rack. Clean or
replace as necessary. If this does
not correct the problem, replace the
toner empty/toner cartridge detect­ing board (PWB-B) and the mechan­ical controller board if necessary.

installed in a tray is different from the
size you selected on the operator
panel.

• Be sure the paper cassette is
securely closed.

• Besure the paper size indicator is
not damaged and that it is in the
correct position.

• Replace the paper size/cassette
detection board (PWB-E).

2-12

Attendance Message Action
35ResSaveOffDeficientMem-

ory

38 Memory Full The printer is processing data, but

The printer lacks the memory
needed to enable Resource Save.
This message usually indicates that
too much memory is allocated for
one or more of the printer link buff­ers.

•ToenableResource Save after
this message is displayed, either
install additional memory or set
each link buffer to the Auto value.

• After you set all link buffers to
Auto, exit the printer menus to
activate link buffer changes.

•WhenReady is displayed, enable
Resource Save in the Setup
Menu and modify the link buffers
again.

•PressGo to clear the message.
The printer automatically disables
Resource Save and continues.

the memory used to store pages is
full.

Reduce the complexity of the page.

• Simplify the print job by reducing
the amount of text or graphics on
a page.

• Delete unnecessary downloaded
fonts or macros.

• Install additional memory.

• Reduce the print resolution.

Send the job to print again.
Press Go to clear the message. The

printer continues printing the job;
however, some data may not print or
may not print correctly.
Or, to reset the printer:

•Press<Menu> to access the
Busy menu.

• Select Reset Printer.

Diagnostic Information 2-13

Attendance Message Action
39 Complex Page The amount of text, graphics, and

print information on the page is very
complex; therefore, the page may
not print correctly.

•SetPage Protect in the Setup
Menu to On and send the print job
again.

•PressGo to clear the message.
The printer continues printing the
job; however, some data may not
print or may not print correctly.

• Try to simplify your print job.

Or, to reset the printer:

•Press<Menu> to access the
Busy menu.

•SelectReset Printer.

51 Defective Flash The printer detects a defective flash

during power on, or during format
and write to flash operations.

Press Go to clear the message.
Flash operations are not allowed
until the problem is resolved.

Remove the defective flash memory
card and try another.

52 Flash Full There is not enough free space in

the flash memory card to hold the
data that was sent.

Press Go to clear the message and
continue processing. All downloaded
fonts and macros not written to flash
are deleted.
Or, to reset the printer:

•Press<Menu> to access the
Busy menu.

•SelectReset Printer.

2-14

Attendance Message Action
53 Unformatted Flash The printer detected an unformatted

flash memory card during the power
on process. Flash operations are not
allowed until the flash is formatted.

Try the following:

• Format the flash memory card
using Format Flash in the Tests
Menu.

• Send the data again.

• If the error condition remains, the
flash memory card is defective
and must be replaced.

•PressGo to clear the message.
The flash memory is ignored and
normal operation continues.

Diagnostic Information 2-15

Attendance Message Action
54 Serial Option x Error A serial interface error has been

detected (framing or parity). This
error usually indicates the serial link
has not been set up correctly.

x represents optional serial port 1
through 3.

Press and hold Select and then
press Return to determine the
cause of the host interface error.

When the serial error is displayed,
the reporting of other serial errors is
suppressed until interface p arame­ters are changed or the printer is
turned off.

Check the interface:

• Verify that the correct cable is
used.

• Make sure the serial interface
parameters(protocol,baud,parity,
data bits) are correct.

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

• To reset the printer:

•Press<Menu> to access the
Busy menu.

•SelectReset Printer.

54 Parallel Error An IEEE 1284 protocol error has

been detected on the parallel host
interface. This error may be due to a
faulty cable.

2-16

Attendance Message Action
56 Serial x Port Disabled Data is sent to the printer across the

serial port, but the serial port is dis­abled. When the serial error is dis­played, the reporting of other serial
errors is suppressed until the menus
are entered or the printer is reset.

x is 1, 2, or 3 and represents the
serial option attached.

Press Go to clear the message. The
printer discards any data receivedon
the serial port.

Enable the serial port.
Or,

To reset the printer:

•Press<Menu> to access the
Busy menu.

• Select Reset Printer.

56 Parallel Port Disabled Data is sent to the printer across the

parallel port, but the parallel port is
disabled. When the error is dis­played, the reporting of other errors
is suppressed until the menus are
entered or the printer is reset.

Make sure Parallel Buffer is
to Disabled in the Parallel Menu.

•PressGo to clear the message.
The printer discards any data
received on the parallel port.

Or, to reset the printer:

•Press<Menu> to access the
Busy menu.

• Select Reset Printer.

not

Diagnostic Information 2-17

set

Attendance Message Action
58 Too Many Disks Installed You have installed more than one

Hard Disk Option. The Hard Disk
Option can be installed only in con­nector 3.

Turn off the printer and remove the
extra Hard Disk Option.

61 Defective Disk The printer detects a defective disk

during power on, or during disk for­mat and write operations.

Press Go to clear the message.
Hard disk operations are not allowed
with a defective hard disk.

Remove the defective hard disk and
replaceitwithanewharddisk.

62 Disk Full There is not enough free space in

63 Unformatted Disk The printer detected an unformatted

the disk to hold the data that was
sent.

Press Go to clear the message and
continue processing. Any data cur­rentlybeingwrittentothediskislost.
Or, to reset the printer:

•Press<Menu> to access the
Busy menu.

•SelectReset Printer.

hard disk when the printer was
turned on. Disk operations are not
allowed until the disk is formatted.

• Format the hard disk with the For-
mat Disk setting in the Tests
Menu.

• Send the data again.

If the error condition remains, the
disk is defective and must be
replaced.

Or, press Go to clear the message.
The disk is ignored and normal oper­ation continues.

2-18

Attendance Message Action
64 Disk In Wrong Slot The Hard Disk Option is installed in

the wrong connector. The Hard Disk
Option can be installed only in con­nector 3.

1. Power off the printer.

2. Remove the incorrectly installed
disk.

3. Turn on the printer.

Print Jobs on Disk? The printer asks for confirmation to

print the waiting jobs, which were
previously spooled to disk. This mes­sage gives you the chance to print
the jobs or to cancel all spooled jobs.

•PressGotocontinue and print the
jobs.

•PressReturnorStop to cancel all
spooled jobs.

70-79 These numbered messages are

reservedforinternal network adapter
messages.

Referto the CD-ROM online Help for
more information. Also, refer to the
documentation that is included with
the internal network adapter.

Diagnostic Information 2-19

Attendance Message Action
8X Scheduled Maintenance The following messages appear to

alert you that certain assemblies
need replacing:

80 - Fuser Assembly and Second
Transfer Roll Assembly

81 - Transfer Belt Assembly
Press Go to clear the message.
The status of the two maintenance

items listed above will be displayed
in the User Maint Menu. The User
Maint Menu will be active only if one
or both maintenance items have
expired. Once the items have
expired, they should be replaced as
soon as possible. After you have
replaced the expired items, you must
reset the appropriate maintenance
message.

82 Waste Toner Bottle Missing The waste toner bottle is not

installed or there is a problem with
the toner collecting box detection
switch (S6). Open the top door,
install the waste toner bottle, and
close the top door.

The message clears from the display
when the top door is closed. If it
does not, go to the “Sensor Service
Check” on page 2-47.

82 Waste Toner Bottle Full Open the top door, remove the full

waste toner bottle. Replace the
waste toner bottle and close the top
door. The customer replaces this
part at prescribed intervals.

The message clears from the display
when the top door is closed. If it
does not, the toner full sensor (PC6)
couldbefailing.Gotothe“Sensor
Service Check” on page 2-47.

2-20

Attendance Message Action
83 Fuser or Coating Roll Miss-

ing

84 PC Missing The photoconductor unit is not

84 PC Life Warning The photoconductor unit needs to be

Open the back door and install the
fuser assembly and the fuser coating
roll. Close the back door.

The message clears from the display
when the door is closed. If it does
not, the oil coating roller assembly
sensor (PC3) could be failing. Go to
the “Sensor Service Check” on
page 2-47.

installed. Open the top door, install
the photoconductor unit, and close
the top door.

The message clears from the display
when the top door is closed. If it
does not:

• Check the contacts on the PC
drum cartridge connector.

• Be sure connector CN6 on the
mechanical controller board is
plugged in correctly.

• If you still have the problem,
replace the mechanical controller
board.

replaced. Open the top door and
remove the photoconductor unit.
Install the new photoconductor unit
and close the top door. The cus­tomer replaces this part at pre­scribed intervals.

If you do not have a replacement
photoconductor unit available, press
Go to continue normal printer opera­tions until you can get a replacement
unit.

Diagnostic Information 2-21

Attendance Message Action
84 PC Exhausted The photoconductor unit must be

replaced to continue operating the
printer. Open the top door and
remove the photoconductor unit.
Install the new photoconductor unit
and close the top door. The cus­tomer replaces this part at pre­scribed intervals.

The message clears from the display
when a new unit is installed and the
top door is closed.

2-22

Attendance Message Action
Change <tray>

<Custom Type Name>
<size>
<type><size>

Themediainthetrayisadifferent
size from the media detected by the
paper size sensor, or it is different
from the size that was set in the
Paper Size or Paper Type menu
items. The display shows the follow­ing information:

On line 1, <tray> indicates where
the printer expects the printed mate­rial to be.

On line 2, one of the following items
is displayed:

<Custom Type Name>

Custom Type 1 through 3 is a user­defined name that was created with
the MarkVision utility. The name is
truncatedto16characters.

<size>

If the requested type matches the
type currently in the tray, the paper
size is displayed if you have not
defined a custom type name. The
name is truncated to 16 characters.

<type><size>

The requested <type> is other than
acustomtype.Thetypenameis
truncated to 9 characters.
The requested <size> of paper is
displayed. The size name is trun­cated to 6 characters.

• Load the requested size and type
in the source.

• If the source has auto-size sens­ing (tray 1 or tray 2), the printer
automatically clears the message
and continues processing the job.
If the source does not have auto­size sensing, press Go after load­ing the requested size.

Or, to reset the printer:

•Press<Menu> to access the
Busy menu.

• Select Reset Printer.

Diagnostic Information 2-23

Attendance Message Action
Load <tray>

<Custom Type Name>

<size>

<type> <size>

The printer is requesting paper or
other print material from a source it
detects is empty. The display shows
the following information:

On line 1, <tray> indicates where
the printer expects the printed mate­rial to be.

On line 2, one of the following items
is displayed:

<Custom Type Name>

Custom Type 1 through 3 is a user­defined name that was created with
the MarkVision utility.The name is
truncated to 16 characters.

<size>

If the requested type matches the
type currently in the tray, the paper
size is displayed if you have not
defined a custom type name. The
name is truncated to 16 characters.

<type><size>

The requested <type> is other than
acustomtype.Thetypenameis
truncated to 9 characters.
The requested <size> paper is dis­played. The size name is truncated
to 6 characters.

• Load the requested size and type
in the source.

• If the source has auto-size sens­ing, the printer automatically
clears the message and continues
processing the job.
If the source does not have auto­size sensing, press Go after load­ing the requested size.

Or, to reset the printer:

2-24

•Press<Menu> to access the
Busy menu.

•SelectReset Printer.

Attendance Message Action
Load Manual

<Custom Type Name>

<size>

<type> <size>

The printer is requesting paper or
other printer material to be fed man­ually from the Multipurpose Feeder.
The display shows the following
information:

On line 2:

<Custom Type Name>

Custom Type 1 through 3 is a user­defined name that was created with
the MarkVision utility. The name is
truncatedto16characters.

<size>

If the requested type matches the
type currently in the tray, the paper
size is displayed if you have not
defined a custom type name. The
name is truncated to 16 characters.

<type><size>

The requested <type> is other than
acustomtype.Thetypenameis
truncated to 9 characters.
The requested <size> paper is dis­played. The size name is truncated
to 6 characters.

• Load the requested size and type
in the source. The printer auto­matically clears the message and
continues p rocessing the job.

• To ignore the message and print
on the material installed in the
tray, press Select.

Or, to reset the printer:

•Press<Menu> to access the
Busy menu.

• Select Reset Printer.

Diagnostic Information 2-25

Attendance Message Action
Insert <tray> This message is displayed when the

printer needs to select print material
from a missing tray. Often the mes­sage is displayed when a user
removes a tray to refill it while a job
is printing.

<tray>is Tray 1 or Tray 2.

•PressStop and wait for all pages
inthebuffertoprint.

• Insert the tray indicated.
The printer clears the message
and resumes printing.

Or, to reset the printer:

•Press<Menu> to access the
Busy menu.

•SelectReset Printer.

ServiceErrorMessageTable

Error Symptom or Message Action

900 Software Error Unrecoverablesoftware error.

Refer to the operator manual.

910 Transport Motor (M2) Failure Go to the “Transport Motor Ser-

vice Check” on page 2-34.

911 Developing Motor (M1) Fail-

ure

912 Toner Cartridge Rack Motor

(M3) Failure

913 Transfer Roller Error Theprinter fails to completely

914 Intermediate Transfer Belt Go to the “Image Transfer Belt

Go to the “Developing Motor Ser­vice Check” on page 2-34.

Go to the “Toner Cartridge Rack
Service Check” on page 2-38.

transfer the image to the paper or
does not transfer it at all.

The image transfer roll does not
lift when paper is passing over it.

Service Check” on page 35.

2-26

Error Symptom or Message Action

915 Power Supply Fan (M6) Fail-

ure

916 Suction Supply Fan (M7)

Failure

917 Printhead Cooling Fan Fail-

ure

920 Fuser Error Go to the “Fuser Service Check”

930 Printhead Error Check the printhead connectors.

939 Mechanical Controller Board

COMM Error

941 Code ROM Error Replace the EPROM code con-

942 Font ROM Error Replace the EPROM code con-

943 Controller Card, Font Error The font and controller cards are

Go to the “Power Supply Cooling
FanMotorServiceCheck”on
page 2-39.

Go to the “Suction Fan Motor Ser­vice Check” on page 2-39.

Go to the “Printhead Cooling Fan
Service Check” on page 2-39.

on page 2-33.

Replace the printhead if neces­sary.If you still have a failure,
replace the mechanical controller
board (PWB-A).

Replace the mechanical control­ler board (PWB-A).

troller SIMM (J3).

troller SIMM (J3).

incompatible.

944
945
946
947
950
953
954

960 Memory Error DRAM (J9) Replace memory SIMM J9.
961 Memory Error Option DRAM

962 Memory Error Option DRAM

Controller Card Error Replace the controller card. Be

sure to move the EPROM control­ler SIMM, memory, and option
cards from the old card to the new
one.

Replace memory SIMM J10.

(J10)

Replace memory SIMM J12.

(J12)

Diagnostic Information 2-27

Error Symptom or Message Action

964 Emulation Error

Download emulation CRC
failure

965 Emulation Error

Download emulation out­dated. Time stamps indicate
the download emulation and
RIP code are incompatible.

97X INA Failure Be sure the controller riser card

977 Network Card Error The system processor has

Contact Technical Support for
assistance.

Contact Technical Support for
assistance.

and the INA are properly installed.
Replace the INA. If you still havea

problem, replace the system
board.

detected an INA is installed but
cannot communicate with it. The X
after the card indicates which one
has the problem. Network card 1
always refers to the INA in the bot­tom slot and Network card 2
always refers to the INA in the top
slot.

Be sure the controller card riser
card is properly installed.

2-28

Symptom Table

Symptom Action

Blank copies when foils are run.
Machine fails to detect overhead projec-

tion foils.

The printer fails to completely transfer
the image to the paper or does not trans­fer it at all.

The image transferroll does not lift when
paper is passing over it.

Be sure OHP/Transparencies is
selected in the operator menu.

Go to the “Sensor Service
Check” on page 2 -47.

Replace the OHP sheet detec­tion board (PWB-D2).

Go to the “Sensor Service
Check” on page 2-47 and check
the image transfer roller position
sensor (PC2). If it works prop­erly, return to this check.

Run a test print. After the paper
has been released, open the top
cover to stop the printing pro­cess.Theimagewillbeonthe
transferbelt unit, but the transfer
roller will not be lifted.

Check the transfer roller assem­bly solenoid (SL5). Do a continu­ity check of the connector (CN5).
Replace the solenoid if neces­sary.

If you still have the problem,
replace the mechanical control­ler board.

The toner rack does not go to home
position or lock the rack into colors. The
font print test does not print in black.

Toner cartridge rack does not rotate. Go to the “Toner Cartridge Rack

Go to the “Sensor Service
Check” on page 2-47 and check
the rack lever sensor (PC12)
and the rack home sensor
(PC4). If they are good, replace
the mechanical controller board.

Service Check” on page 2-38.

Diagnostic Information 2-29

Symptom Action

The toner cartridge rack does not detent
when replacing toner cartridges or it
makes an unusual noise.

Toner cartridge rack fails to stop rotating. Go to the “TonerCartridge Rack

Paper jam in pick-up assembly Go to the “Paper Jam Service

Paper jam in exit assembly. Go to the “Paper Jam Service

Paper jam in fuser. Go to the “Paper Jam Service

Faulty developing motor (M1). The
developing motor tries to turn when the
print cycle is initiated.

• Check the rack detent on the
left side of the rack. This
detent is released when the
top cover is open.

• Checkthe toner cartridge rack
back check gear for damage.

• Check the rack lever and
detent pins

• Checkthe toner cartridge rack
lever sensor (PC12) for cor­rect operation.

• Check the back check sensor
for correct operation and
replace any damaged parts.

Service Check” on page 2-38.

Check” on page 2-35.

Check” on page 2-35.

Check” on page 2-35.
Go to the “Developing Motor

Service Check” on page 2-34.

Fuser failure Go to the “Fuser Service Check”

on page 2-33.

Fuser belt suction failure (M7). Go to the “Suction Fan Motor

Service Check” on page 2-39.

Printhead cooling fan (M5) failure. Go to the “Printhead Cooling

Fan Service Check” on
page 2-39.

No paper pick-up from multipurpose tray Go the “Paper Jam Service

No paper pick-up from upper or lower
cassette.

Check” on page 2-35.
Go to the “Paper Jam Service

Check” on page 2-35.

2-30

Symptom Action

Power supply fan failure. Go to the “PowerSupplyCooling

FanMotorServiceCheck”on
page 2-39.

Synchronizing/timing roller does not
rotate.

Operator panel does not operate prop­erly

• Foggy print

• Black pages

• Blank print

• White spots

• Poor reproduction

• Incorrect color image registration

• Dirt on back of paper

• Low image density

• White and black lines and bands

Go to the “Paper Jam Service
Check” on page 2 -35.

Go to the Diagnostic Aids chap­ter and run the LCD and Button
tests. If the tests fail, replace the
operator panel. If the display has
diamonds on it or is blank, run
the “Basic Printer Paper Pas­sage Test” on page 2-48. If the
test completes and the panel
remains blank, replace the oper­ator panel. If diamonds remain,
check the SIMMs and riser card
for proper installation. If you still
have a problem, replace the
ROMSIMMasitisthemost
likely failure. If you still have a
problem, replace the controller
card.

If your machine beeps 5 times
and the screen is blank or all
diamonds, replace the operator
panel.

Go to the “Image Quality Trou­bleshooting” on page 2-42.

Evenly spaced marks on the paper, or a
single mark in the same place on every
page.

Paper feed problems in the image trans­fer roll area

Gotothe“MarksonPaperSer­vice Check” on page 41.

Go to the “Paper Jam Service
Check” on page 2 -35.

Diagnostic Information 2-31

Symptom Action

Paper feed problems in the fuser and
delivery area.

Paper jam message will not clear.
Poor fusing Go to the “Image Quality Trou-

Toner scatter on front or back of paper Check the following:

Go to the “Paper Jam Service
Check” on page 2-35.

bleshooting” on page 2-42.

• Excessive toner buildup.
Clean off the toner and run a
test print with a transparency
or paper.

• Image transfer belt assembly

• Transport belt toner shields

• Toner waste bottle

2-32

Service Checks

Fuser Service Check

FRU Action

1•Heater

Lamp (H1)

•Thermostat
(S4)

•PowerUnit
(PU1)

• Mechanical
Controller
Board
(PWB-A)

2•Fuser

• Mechanical
Controller
Board
(PWB-A)

3•Fuser

• Mechanical
Controller
Board
(PWB-A)

Be sure the heater lamp (H1) lights up when the
power is turned on. (Open the rear door and acti­vatethe rear door inter lock to see the fuser lamp.) If
the lamp does not light up, check for voltage
between CN2PU-1 and CN2PU-3 of the power unit
(PU1).

If there is voltage, replace the heater lamp (H1) or
the thermostat (S4).

If there is no voltage, replace the power unit (PU1)
or the mechanical controller board (PWB-A).

Check for voltage between CN9A-6 and CN9A-7 of
thermistor 1 (TH1). If there is no voltage, replace
the fuser.

If there is voltage, replace the mechanical controller
board (PWB-A).

Check for voltage between CN9A-8 and CN9A-9 of
thermistor 2 (TH2). If there is no voltage, replace
the fuser.

If there is voltage, replace the mechanical controller
board (PWB-A).

Diagnostic Information 2-33

Developing Motor Service Check

FRU Action

1 Rollers, Gears If the developingmotor (M1) starts turning when a

print cycle is initiated, check the rollers and gears
for overload.

2 Mechanical

Controller
Board (PWB­A)

3 • Developer

Motor (M1)

• Mechanical
Controller
Board
(PWB-A)

Check the voltage across CN15A-5 on the mechan­ical controller board and GND. It should change
from 5 V dc to 0 V dc during a print cycle. If it does
not, replace the mechanical controller board.

Check the voltage across CN15A-3 on the mechan­ical controller board and GND. If it remains 0 V dc
during a print cycle, replace the developer motor
(M1). If it does not, replace the mechanical control­ler board.

Transport Motor Service Check

FRU Action

1 Rollers, Gears If the transport motor (M2) starts turning when a

print cycle is initiated, check the rollers and gears
for overload.

2 Mechanical

Controller
Board (PWB­A)

3 • Transport

Motor (M2)

• Mechanical
Controller
Board
(PWB-A)

Check the voltage across CN15A-6 on the mechan­ical controller board and GND. It should change
from 5 V dc to 0 V dc during a print cycle. If it does
not, replace the mechanical controller board.

Check the voltage across CN15A-4 on the mechan­ical controller board and GND. If it remains 0 V dc
during a print cycle, replace the transport motor.If it
does not, replace the mechanical controller board.

2-34

Image Transfer Belt Service Check

FRU Action

1 Image Trans-

fer Belt
(replaced by
customer)

2 • Mechanical

Controller
Board

•Image
TransferBelt
Assembly

Be sure the image transfer belt turns during a print
cycle, (check with the front cover removed). If it
does not, be sure the image transfer belt assembly
is installed correctly.

Use the sensor check test to check the image
transfer belt position sensor (PC7). If it operates
correctly, replace the mechanical controller board.
If it does not, replace the transfer belt assembly.

Paper Jam Service Check

If the machine is turned on and error code 200, 201, or 202 is dis­played, do the following before going on to the FRU check:

Clear all paper from the machine and note where it is when you clear
it.

Be sure the customer is using the correct paper.
POR the machine and see if you still get the error code. If you do not

get an error code, run the print test menu from each paper source to
check the machine. If you still get an error, run a single sheet of
paper through the machine, note the error code and the position of
the paper in the machine. Locate the error code from the following
and check parts as indicated.

Diagnostic Information 2-35

Jam 200

The jam occurred at the paper pickup source before it reached the
timing/synchronizing roller.

FRU Action

1 • Actuator

• Synchroniz­ing Paper
Sensor
(PC1)

2 • Paper Take-

up Solenoid
(SL3)

• Paper Take­up Solenoid
(SL7,SL8)

• Transport
Solenoid
(SL4)

3•Take-up

Roller

• Transport
Roller

• Paper Take­up Clutch

• Transport
Take-up
Clutch

•Depressing
Cam

• Separating
Pad

Go to the “Sensor Service Check” on page 2-47
and check the synchronizing/timing roll paper sen­sor. If it is good, return to this check and continue.

Check the paper takeup solenoid and the transport
solenoid for correct operation. Replace as neces­sary.

Check these parts for dirt or wear. Clean or change
as necessary.

2-36

Jam 201

The paper has stopped at the synchronizing roller, or has not
reached the exit roller.

FRU Action

1 Fuser Sensor

(PC9)

2 Synchronizing

Roller

3 • Synchroniz-

ing Sole­noid (SL2)

• Mechanical
Controller
Board

4•Image

Transfer
Roller

•Image
Transfer
Solenoid

•Image
Transfer
Sensor
(PC2)

5 Transport Belts Checkthe transport belts for damage and replace if

6 Fuser Assem-

bly

Gotothe“SensorServiceCheck”onpage2-47
and check the fuser sensor (PC9) and actuator. If it
is working correctly, return to this check.

Check the synchronizing/timing roller for dirt or
wear. Clean or replace as necessary.

If the synchronizing/timing roller does not rotate,
replace the synchronizing solenoid or the mechani­cal controller board.

If paper is stopped at the image transfer roller,
check the roller for dirt or wear and clean or replace
as necessary.

Check the image transfer solenoid for correct oper­ation. The image transfer roll should be lifted when
paper is passing over it.

necessary.
Check the fuser belts and the fuser lower roller for

wear or damage. If it is not operating correctly,
replace the fuser assembly. This is a customer
replaceable part at prescribed intervals.

Diagnostic Information 2-37

Jam 202

The paper has exited the fuser but not the printer.

FRU Action

1 Fuser Sensor

(PC9)

2 Paper Exit

Sensor (PC8)

3 Fuser Assem-

bly

4 Paper Exit

Rollers

Go to the “Sensor Service Check” on page 2-47
and check the fuser sensor (PC9) and actuator.If it
is working correctly, return to this check.

Go to the “Sensor Service Check” on page 2-47
and check the paper exit sensor (PC8) and actua­tor. If it is working correctly, return to this check.

Check the fuser belts and the fuser lower roller for
wear or damage. If it is not operating correctly,
replace the fuser assembly. This is a customer
replaceable part at prescribed intervals.

Check the paper exit rollers for dirt or damage.
Replace as necessary.

Toner Cartridge Rack Service Check

FRU Action

1•RackMotor

(M3)

• Mechanical
Controller
Board
(PWB-A)

2 • Toner Car-

tridge Rack
Latch

Be sure the rack motor (M3) turns during a
print cycle. If it does not, replace the motor. If
you still have the problem, replace the
mechanical controller board.

Check the latch for wear or damage.

3 Gears If the toner cartridge rack does not turn during a

print cycle, check the gears for overload.

4 • Rack Home

Position
Sensor
(PC4)

• Mechanical
Controller
Board
(PWB-A)

Use the sensor check test to check the rack home
position sensor (PC4). If it does not operate cor­rectly, replace the sensor (PC4). If it operates cor­rectly, replace the mechanical controller board.

2-38

Printhead Cooling Fan Service Check

FRU Action

1•Printhead

Cooling Fan
Motor (M5)

• Mechanical
Controller
Board
(PWB-A)

See if the printhead cooling fan motor (M5) rotates
when the power is turned on. If it does, replace the
mechanical controller board. If it does not, replace
the fan motor. If you still have the problem, replace
the mechanical controller board.

Power Supply Cooling Fan Motor Service Check

FRU Action

1•PowerSup-

ply Cooling
Fan Motor
(M6)

• Mechanical
Controller
Board
(PWB-A)

See if the power supply cooling fan motor (M6)
rotates when the power is turned on. If it does,
replace the mechanical controller board. If it does
not, be sure the fan is plugged into the low voltage
power supply. If this does not correct the failure,
replace the fan motor. If you still have the problem,
replace the mechanical controller board.

Suction Fan Motor Service Check

FRU Action

1•SuctionFan

Motor (M7)

• Mechanical
Controller
Board
(PWB-A)

See if the suction fan motor (M7) rotates when the
power is turned on. If it does, replace the mechani­cal controller board. If it does not, replace the fan
motor. If you still have the problem, replace the
mechanical controller board.

Diagnostic Information 2-39

AC Power Service Check

FRU Action

1 Voltage Be sure the switch is on and the power cord is

firmly plugged into the printer. Be sure the correct

voltage is present at the outlet.
2 Power Cord Check the power cord for continuity.
3 • FuseF1, F2

•Switch(S1)

4 • Power Sup-

ply (PU1)

• Mechanical
Controller
Board
(PWB-A)

The power supply fuses may be blown. Unplug the
machine and check fuses F1 and F2 on the power
supply (PU1) for continuity. If the fuses are good,
check the power switch connector for continuity.

The power supply may be defective.
The mechanical controller board may be defective.

2-40

Marks on Paper Service Check

If you have evenly spaced marks on the paper, measure the dis­tance between the marks and locate the symptom below. Check the
assembly for dirt or damage and clean as necessary. Run a test
print to verify the problem has been corrected. The indicated assem­blies are replaced by the customer at prescribed intervals.

Distance between marks FRU

25mm, single color Tonercartridge scuff
50mm, single color Tonercartridge developer
51mm, all colors Second transfer roll

65.5mm Fuser lower roller
94mm, light horizontal streaks Photoconductor cartridge
95mm, light to dark discoloring Imagetransfer belt assembly, check

for debris on the roller under the belt

172mm Fuser belt, toner offset indicates a

new fuser coating roll is needed

No repeat marks. One mark
appears in the same position on
each page.

Image transfer belt

Diagnostic Information 2-41

Image Quality Troubleshooting

Locate your symptom below, note the possible causes, and take the
appropriate action. Be sure all associated connectors are plugged in
correctly.

Low Image Density

Possible Cause Action

Poor development Replace the high voltage assembly

(HV1).
Defective PC drum Replace the PC drum cartridge.
Poor intermediate image transfer
Poor paper image transfer

2-42

Replace the image transfer belt asm.

Replace the image transfer roller

asm. This is a customer replaceable

part at prescribed intervals.

Replace the high voltage assembly

(HV1).

Replace the mechanical controller

board (PWB-A).

Foggy Background

Possible Cause Action

Poor development Replace the high voltage assembly

(HV1).
Replace the mechanical controller
board (PWB-A).

The following are customer replace­able parts at prescribed intervals:
Replace the toner cartridge.
Replace the PC drum cartridge.

Blank Print

Possible Cause Action

Dirty or damaged PC drum con­tacts

Transfer Roll Be sure the transfer roll is installed

Incorrect laser exposure Replace the printhead.

Poor development Gently rock the toner cartridge to

Clean and reseat the PC drum con­tacts. Replace if necessary.

correctly.

Replace the mechanical controller
board (PWB-A).

distribute the toner evenly. If you still
have the problem, replace the toner
cartridge. This is a customer
replaceable part at prescribed inter­vals.

Diagnostic Information 2-43

Black Print

If the PC drum cartridge has been replaced recently, check the con­tacts on the PC drum cartridge connector and all ground pins on the
PC cartridge assembly.

Possible Cause Action

Incorrect laser exposure Replace the printhead.

Replace the mechanical controller

board (PWB-A).
Incorrect charging Replace the high voltage assembly

(HV1).

Replace the mechanical controller

board (PWB-A).

White Spots

Possible Cause Action

Poor intermediate image transfer
Poor paper image transfer

Replace the image transfer belt.

Replace the image transfer roller

assembly. These customer replace-

able parts at prescribed intervals.

Replace the high voltage assembly

(HV1).

2-44

White and/or Black Lines and Bands

Possible Cause Action

Poor development Replace the toner cartridge. This is a

customer replaceable part at pre­scribed intervals.

Defective PC drum Replace the PC drum cartridge.This

is a customer replaceable part at
prescribed intervals.

Incorrect charging Replace the PC drum cartridge.This

is a customer replaceable part at
prescribed intervals.

Incorrect fusing Replace the fuser.This is a cus-

tomer replaceable part at prescribed
intervals.

Poor intermediate image transfer
Poor paper image transfer

Incorrect laser exposer Replace the printhead.

Replace the image transferbelt. This
is a customer replaceable part at
prescribed intervals.
Replace the image transfer roller
assembly.Thisisacustomer
replaceable part at prescribed inter­vals.
Replace the high voltage assembly
(HV1).

Diagnostic Information 2-45

Toner Smudges on Back Side of Paper

Possible Cause Action

Incorrect charging Replace the high voltage assembly

(HV1).

Replace the mechanical controller

board (PWB-A).
Poor development Replace the high voltage assembly

(HV1).

Replace the mechanical controller

board (PWB-A).
Incorrect fusing Replace the fuser (customer

replaces this).

Offset print

Possible Cause Action

Incorrect fusing Replace the oil coating roller.

Replace the fuser.

(Customer replaces these parts.)

Incorrect Color Image Registration

Possible Cause Action

Incorrect toner cartridge setting Reset the toner cartridge securely.
Defective intermediate image

transfer

Replace the image transfer belt

assembly (customer replaces this).

2-46

Poor Color Reproduction

Possible Cause Action

Defective AIDC Replace the image transfer belt

assembly (customer replaces this).
Replace the mechanical controller
board (PWB-A).

Defective paper image transfer Replace the high voltage assembly

(HV1).
Replace the humidity sensor (HS1).
Replace the mechanical controller
board (PWB-A).

Sensor Service Check

1. When a paper jam or malfunction occurs, identify the sensor
that is probably responsible for the problem (see “Electrical
Components” on page 4-12).

2. Enter the sensor check mode in diagnostic mode.

3. Change the state of the selected sensor and see if the signal is
changed.

For example: When a paper jam occurs, and you think paper exit
sensor (PC8) is responsible. Check it as follows:

1. Remove the paper jam.

2. Enter the sensor check mode on the controller.

3. Use a sheet of paper to move the PC8 actuator so that PC8 is
blocked.

4. Check for changes on the operator panel display for the on/off
operation of the sensor.

5. If the sensor is not working correctly and the actuator is not
damaged, replace the failing sensor.

6. If this does not correct the problem, replace the mechanical
controller board.

Diagnostic Information 2-47

Diagnostic Aids

Basic Printer Paper Passage Test

This test determines whether the engine or controller card is failing.

1. Turn off the power switch and remove the controller card.

2. Load the multipurpose tray, 2nd cassette, or 3rd cassette with
paper and turn on the power switch.

• If the paper is properly fed out of the printer, the controller

card, or a component on the controller card such as the
memory SIMM, code SIMM, riser card, or other option is
responsible for the malfunction.

• If the paper is not properly fed out, the engine is responsible

for the malfunction.

Operator Menu Disabled

If the operator has disabled the menu and you want to run operator
print tests, turn the machine off, then press Go and Stop as you turn
the machine on.

Diagnostic Mode

To access the diagnostics printer settings and operations:

1. Turn off the printer.

2. Press and hold the Go and Return buttons.

3. Turn on the printer. Release the buttons after the Performing
Self Test message displays.

Diagnostic Menu Group

The Diagnostic Menu Group contains multiple menus. They are dis­played in the control panel in the order shown in the table. The
names of the top-level menus are capitalized.

Top-Level Menu

REGISTRATION Top Margin

2-48

Intermediate Menu, Printer Setting, or
Printer Operation

Left Margin

Top-Level Menu

Intermediate Menu, Printer Setting, or
Printer Operation

PRINT TESTS Tray 1

Tray 2 (if installed)
MP Tray

HARDWARE TESTS Clean Engine

Sensor Test
LCD Test
Button Test
DRAM Memory Test
ROM Memory Test
Parallel Wrap
Serial1Wrap(ifavailable)
Serial2Wrap(ifavailable)
Serial3Wrap(ifavailable)

INPUT TRAY TEST Tray Sensor Test:

•Tray1

•Tray2

• Multipurpose Feeder

Size Sensor Test:

•Tray1

•Tray2

BASE SENSOR TEST Timing Roll/Synchronizing Roll

Fuser Sensor
Exit Sensor
Transparency Detect Sensor
Fuser Detect Sensor
Waste TonerBottle Detect Sensor
T/C Rack Detect Sensor
Waste Bottle Full Sensor
Coating Roll Detect Sensor
Image Transfer Belt Sensor

DEVICETESTS (Only displayedif
a flash or disk option is installed.)

Test
Disk Test/Clean
Flash Test

PRINTER SETUP Defaults

Page Count
Perm Page Count

Diagnostic Information 2-49

Top-Level Menu

Maintenance Menu 80Maint Cnt

Error Log Display Log

EXIT DIAGNOSTICS

Intermediate Menu, Printer Setting, or
Printer Operation

81 Main Cnt
Reset 80 Maint
Reset 81 Maint

Clear Log

Setting Printer Registration

When you first enter the Registration menu, the Top margin sign/
value pair flashes. This indicates it is the margin value being
changed. To change the value, press either Menu> or Menu<.Once
the value you want displays, press Select to save the value and
move to the next margin value.

To verify the margin values are correct, you must print the Quick Test
page on Letter, Legal, or A4 paper. From the Registration screen
containing each of the margin values, press Go. This button serves
as a hot key to the quick test page. As the page prints Quick Test
Printing appears on the display.

To exit the Registration menu, press Return.

Print Tests

The diagnostic PRINT TESTS menu verifies that the printer can print
on media from each of the installed input sources. Each of the
installed sources is listed as an option within this menu. For each
source the user has two choices.

• Single (print a Print Test page once),

• Continuous (continue printing a Print Test page until Return or

Stop is pressed)

2-50

Quality Pages

This function causes the printer to print the Print Quality Test Pages.
Once started, this operation cannot be canceled. All key presses are
ignored while the Prt Quality Pgs Printing message is displayed.

Clean Engine Test

Use this test to perform a cleaning cycle on the engine specifically
on the second transfermechanism. The value list is YES and NO.To
cancel the test, press Return or Stop.

LCD Hardware Test

This test causes the printer to continually execute the LCD display
test. To cancel the test, press Return or Stop.

Button Test

This test verifies the operation of each button on the operator
panel. When you select this test the following appears on the
display:

OP OP OP OP
OP OP

When you press a button, CL (closed) appears on the display. When
the button is not pressed, OP (open) is displayed. If the wrong mes­sage displays, the button is malfunctioning.

To exit the button test, press Return or Stop. The previous menu
screen displays when the button is released.

DRAM Memory Test

This test checks the validity of DRAM (both standard and optional).
The test involves writing patterns of data to DRAM to verify that each
bit in memory can be set and read correctly. When this test is
selected, the following screen displays and the printer begins testing
DRAM memory for the first time:

DRAM Memor y Test
P:###### F:#####

Diagnostic Information 2-51

• P:###### represents the number of times the memory test has

passed (finished successfully). Initially 000000 displays for
######. The maximum pass count is 999,999.

• F:##### represents the number of times the memory test has

failed (finished with errors). Initially 00000 displays for #####.
The maximum fail count is 99,999.

The power indicator blinks indicating the memory test is in progress.
The printer continually runs the same test until canceled from the
control panel by pressing Return or Stop.

Each time the test finishes, the screen is updated with the result. If
the test passes, then the Pass Count increments by 1. However, if
the test fails, then a failure message displays for approximately 3
seconds and then the Fail Count increments by 1.

• DRAM Error

Once the maximum pass count or fail count is reached, the test
stops, the power indicator turns on solid and the final test results dis­play. Press Return or Stop to exit the test.

ROM Memory Test

This test checks the validity of the RIP code and fonts. When this
test is selected, the following screen displays and the printer begins
testing ROM memory for the first time:

ROM Memory Test
P:###### F:#####

• P:###### represents the number of times the memory test has

passed (finished successfully). Initially 000000 displays for
######. The maximum pass count is 999,999.

• F:##### represents the number of times the memory test has

failed (finished with errors). Initially 00000 displays for #####.
The maximum fail count is 99,999.

The power indicator blinks indicating the memory test is in progress.
The printer continually runs the same test until canceled from the
control panel by pressing Return or Stop.

2-52

Each time the test finishes, the screen is updated with the result. If
the test passes, then the Pass Count increments by 1. However, if
the test fails, then one of the following messages display for approxi­mately 3 seconds and then the Fail Count increments by 1.

• ROMChecksumError

• ROM Burst Read Error

Once the maximum pass count or fail count is reached, the test
stops, the power indicator turns on solid and the final test results dis­play. Press Return or Stop to exit the test.

Parallel Wrap Test

This test uses a wrap plug to check the operation of the parallel port
hardware. Each parallel signal is tested.

To run the wrap test:

1. Disconnect the parallel interface cable, and install the parallel
wrap plug.

2. Select HARDWARE TESTS from the Diagnostics Menu.

3. Select Parallel Wrap to initiate the Parallel Wrap Test.

The following screen displays and the printer begins testing the par­allel hardware for the first time:

Parallel Wrap
P:###### F:#####

• P:###### represents the number of times the memory test has

passed (finished successfully). Initially 000000 displays for
######. The maximum pass count is 999,999.

• F:##### represents the number of times the memory test has

failed (finished with errors). Initially 00000 displays for #####.
The maximum fail count is 99,999.

The power indicator blinks indicating the memory test is in progress.
The printer continually runs the same test until canceled from the
control panel by pressing Return or Stop.

Diagnostic Information 2-53

Once the maximum pass count or fail count is reached, the test
stops, the power indicator turns on solid, and the final test results
display. Press Return or Stop to exit the test.

Serial Wrap Tests

This test uses a wrap plug to check the operation of the serial port
hardware. Each serial signal is tested.

To run the serial wrap test:

1. Disconnect the parallel interface cable, and install the serial
wrap plug.

2. Select HARDWARE TESTS from the Diagnostics Menu.

3. Select the appropriate Serial Wrap Test (Serial Wrap, Serial 1,
Serial 2, or Serial 3 Wrap).

The following screen displays and the printer begins testing the
serial hardware for the first time:

Serial Wrap X
P:###### F:#####

• X indicates which serial port is being tested (1=optional serial

port #1, 2=optional serial port #2, 3=optional serial port #3).

• P:###### represents the number of times the memory test has

passed (finished successfully). Initially 000000 displays for
######. The maximum pass count is 999,999.

• F:##### represents the number of times the memory test has

failed (finished with errors). Initially 00000 displays for #####.
The maximum fail count is 99,999.

The power indicator blinks indicating the memory test is in progress.
The printer continually runs the same test until canceled from the
control panel by pressing Return or Stop.

Each time the test finishes, the screen is updated with the result. If
the test passes, then the Pass Count increments by 1. However, if
the test fails, then one of the following messages display for approxi­mately 3 seconds and then the Fail Count increments by 1.

2-54

Once the maximum pass count or fail count is reached, the test
stops, the power indicator turns on solid, and the final test results
display. Press Return or Stop to exit the test.

Input Tray Sensor Test

This test determines whether or not the input tray sensors are work­ing correctly. To run the test, select the Sensor TestMenu and press
MENU> until you find the TRAY1,TRAY2, or MP FEEDER selection.
The following screen displays: <input tray> EM=OP LO=OP

• The selected input tray displays on line 1. One of the following is

displayed for <input tray>: Tray 1, Tray 2, or MP Feeder.

• EM or Empty refers to the input tray’s empty sensor.

• LO or Low refers to the input tray’s paper low sensor.

Once this screen is displayed,you can manually actuate each of the
input tray sensors. When the sensor is closed, CL is displayed.
When the sensor is open, OP is displayed. If the wrong message is
displayed, then the sensor must be malfunctioning.

Each source does not necessarily support all the sensors. The fol­lowing table shows which sensors are supported by which sources.

Source Empty Sensor Low Sensor

Tray 1 Yes Yes
Tray 2 Yes Yes
Multipurpose Feeder Yes No

To exit the sensor test, press Return or Stop.

Size Sensing Sensor Test

This test checks the state of the sensors in the printer. When a sen­sor is active it displays the active status and when the sensor is inac­tive the appropriate inactive status displays.

To run the test, select the Sensor Test Menu and press MENU> until
you find the TRAY 1 or Tray 2 selection. The following screen dis­plays: <input tray> Size SEN1=OP SEN2=OP

Diagnostic Information 2-55

• SEN1 or SENSOR 1 refers to sensor 1 of the size sensing logic.

• SEN2 or SENSOR 2 refers to sensor 2 of the size sensing logic.

The MP FEEDER does not haveany Size Sensing sensors therefore
the test is only valid for Tray 1 or Tray 2.

To exit the sensor test, press Return or Stop.

Base Sensor Test

This test determines whether or not the sensors located inside the
printer are working correctly.

Once this screen is displayed, you can open the doors and manually
actuate each of the sensors. When the sensor is closed, CL is dis­played. When the sensor is open, OP is displayed. If the wrong mes­sage is displayed, then the sensor is malfunctioning. See “Switches
and Sensors” on page 4-7.

The following sensors can be checked:

Timing Roll sensor
Fuser sensor
Exit sensor
Transparency Detect sensor
Fuser Detect sensor
Waste Toner Bottle Detect sensor
T/C Rack Detect Sensor
Coating Roll Detect sensor
Intermediate Transfer Belt sensor.

As the sensor test runs, the panel displays whether the sensor is
open (OP) or closed (CL). You may toggle each sensor by hand to
determine that the sensor is reliably switching between open and
close.

To exit the sensor test, press Return or Stop.

2-56

Quick Disk Check

This check runs a disk test that performs a non-destructive read/
write on one block per track on the disk.

The power indicator blinks while the test runs and the following mes­sage appears on the display:

QuickDiskTest
Testing...

If the test passes, the power indicator turns on solid and the follow­ing message displays:

QuickDiskTest
Test Passed

If the test fails, the power indicator turns on solid and the following
message displays:

QuickDiskTest
Test Failed

Press Go, Return, or Stop to return to the DEVICE TESTS screen.

DISK Test/Clean

This test causes the file system to scan the disk for bad sectors and
remove these blocks from the addressed space. This test destroys
all data on the disk and should not be attempted on a good disk.
Normally you only use this test when the disk contains bad data and
is therefore unusable.

The test executes in two phases: a writing or cleaning phase and a
verifying or testing phase.

This can be an extremely lengthy test depending on the size of the
disk. Each phase of the test on a 540 MB hard disk takes approxi­mately 14 minutes to complete.

This test leaves the disk unformatted. The servicer or user must
reformat the disk using the Format Disk menu operation.

Diagnostic Information 2-57

Flash Test

This test causes the file system to write and read data on the flash to
test the flash device. The test destroys all data on the flash which is
reformatted at the end of the test.

Setting the Page Count

Use this menu to reset the page count whenever you replace the
engine card. The engine card contains the printer’s NVRAM mem­ory. When you select Page Count from the PRINTER SETUP menu,
the current page count displays as follows:

Page Count
=1234567*

The left-most digit (1 in this example) blinks, indicating it is the first
digit to be changed. To change the value press Menu> or Menu< to
get the value you want. Press Select to move to the next digit. To
skip a digit (keep its current value) press Select.

Press Select after the final digit to store the new page count in
NVRAM.

Viewing the Permanent Page Count

The permanent page count setting cannot be changed through the
control panel. It can only be viewed with the diagnostics menu.
When you select Permanent Page Count the following screen dis­plays:

Perm Page Count
=1234567*

Viewing the Error Log

The error log provides a history of printer errors. It contains the 12
most recent errors that haveoccurred in the printer. The most recent
error displays in position 1, and the oldest error displays in position
12 (assuming 12 or more errors have occurred). If fewer than 12
errors have occurred, the oldest error displays in the position before
the empty log entries begin. Empty log entr ies are identified with the

2-58

error number of 000. Occupied log entries contain the error number
of the message displayed on the control panel.

Clearing the Error Log

To clear the error log, select the Clear Log operation from the
ERROR LOG menu. The printer displays the following message:

Clear Log

=Yes
Select Yes to confirm that you really want to clear the log.
Select No to exit the Clear Log menu. You can also press Return or

Stop to exit the menu.

Exiting Diagnostic Mode

To exit diagnostic mode and POR the printer into normal user mode,
press EXIT DIAGNOSTICS.

Diagnostic Information 2-59

Print Quality Test Page

2-60 Service Manual

Print Quality Test Page

Diagnostic Info 2-61

3. Repair Information

Precautions for Disassembly and Cleaning

Observe the following precautions whenever you service the printer:

• Be sure to unplug the printer from the outlet before attempting

to service the printer.

• To reassemble the printer, reverse the order of disassembly

unless otherwise specified.

• The basic rule is not to operate the printer anytime during disas-

sembly. If it is absolutely necessary to run the printer with its

covers removed, use care not to allow your clothing to be

caught in revolving parts such as the gears, rollers and fan

motor.

• Never touch the terminals of electrical parts or high-voltage

parts such as the high voltage unit.

• Be sure to handle the fuser carefully as it remains hot for a while

after the printer stops running. Always unplug connectors by

holding the connector housing.

• Be sure to use the fuse of the specified rating.

• Do not forget to install the ground wire or ground plate to ensure

positive conduction. Install the screw with a toothed washer in

the right position at reassembly.

Instructions for Handling the PWBs with MOS ICs

The following precautions must be observed when handling circuit
boards with MOS (Metal Oxide Semiconductor) ICs.

During Transportation/Storage:

• During transportation or when in storage, new circuit boards

must not be indiscriminately removed from their protective con-

ductive bags.

• Do not store or place circuit boards in a location exposed to

direct sunlight.

• When it becomes absolutely necessary to remove a board from

its conductive bag or case, always place it on its conductive mat

in an area as free as possible from static electricity.

• Do not touch pins of the ICs with your bare hands.

Repair Information 3-1

During Replacement:

• Before you unplug connectors from the circuit boards, be sure

the power cord has been unplugged from the power outlet.

• When you remove a board from its conductive bag or case, do

not touch the pins of the ICs or the printed pattern. Place it in
position by holding only the edges of the board.

• Before you plug connectors into the board, be sure the power

cord has been unplugged from the power outlet.

During Inspection:

• Avoidchecking the IC directly with a multimeter; use connectors

on the board.

• Never create a closed circuit across IC pins with a metal tool.

• When it is absolutely necessary to touch the ICs and other elec-

trical components on the board, be sure to ground your body.

Precautions for Handling the Drum Cartridge

The following precautions must be observed when handling the
drum cartridge:

During Transportation/Storage:

• Use the specified carton whenever moving or storing the drum

cartridge.

• The storage temperature is in the range between -20°C and
°C.

+40

Handling:

• The PC drum in the drum cartridge exhibits greatest light fatigue

after being exposed to strong light over an extended period of
time. Never, therefore, expose it to direct sunlight.

• Use care not to contaminate the surface of the PC drum with oil-

base solvent, fingerprints, and other foreign matter.

• Do not scratch the surface of the PC drum.

Parts not to be touched

Any part where the mounting screws are painted red, such as the
printhead, must not be removed, disassembled or adjusted.

3-2

Precautions for Handling the Laser Equipment

• When a service job needs to be performed in the laser beam

path, such as when working around the printhead and the drum
cartridge, be sure to turn the printer off first.

• A highly reflective tool can be dangerous if it is brought into the

laser beam path. Use utmost care when handling tools around
the laser beam.

• If the job requires that the pr inter be left on, take off your watch

and ring, and wear laser protective goggles which must meet
the following laser specifications:

• Max. power: 5mW

• Output wavelength: 780 - 810nm

Adjustment Procedures

Registration Adjustment

If you replace the mechanical controller board (PWB-A), go to the
diagnostic menu and run the Quick Test in the Registration Menu. If
the registration gap is not 4 mm, adjust the gap as follow:

Repair Information 3-3

1. Remove the outer covers and shield plate.

2. Adjust VR1 so that the registration gap is 4 mm. Turn VR1 on

the mechanical controller board in the + direction to increase
the gap and turn it in the opposite direction to make the gap
smaller.

3-4