LEXMARK T52x Service Manual

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Lexmark™ T52x

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

4520-xxx

•Index

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

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Edition: July 2002

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

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

This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase.

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

ImageQuick and Optra Forms are trademarks of Lexmark International, Inc. Other trademarks are the property of their respective owners.

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 DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.

P/N: 12G3967

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Notices and Safety Information. . . . . . . . . . . . . . . . . . . . . . . ix

Laser Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiii

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Tools Required for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

Service Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

User Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

User Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . 2-35

Symptom Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Charge Roll Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-40

Cover Open Switch/Cable Service Check . . . . . . . . . . . . 2-42

Dead Machine Service Check . . . . . . . . . . . . . . . . . . . . . 2-43

Duplex Unit Service Check. . . . . . . . . . . . . . . . . . . . . . . . 2-45

Envelope Feeder Service Check . . . . . . . . . . . . . . . . . . . 2-48

Fuser Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Fuser Solenoid Service Check . . . . . . . . . . . . . . . . . . . . . 2-60

Input Sensor Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-61

Input Tray(s) Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-62

High-Capacity Feeder Input Tray Service Check . . . . . . . 2-66

Main Drive Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-77

Operator Panel Service Check. . . . . . . . . . . . . . . . . . . . . 2-79

Options Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81

Output Bin Sensor Standard Tray Service Check . . . . . . 2-83

Paper Feed Service Check. . . . . . . . . . . . . . . . . . . . . . . . 2-84

Parallel Port Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-86

Printhead Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-87

Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-88

Smart Contact Assembly Service Check . . . . . . . . . . . . 2-100

Serial Port Service Check. . . . . . . . . . . . . . . . . . . . . . . . 2-101

Toner Sensor Service Check . . . . . . . . . . . . . . . . . . . . . 2-102

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Transfer Roll Service Check . . . . . . . . . . . . . . . . . . . . . 2-103

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Disabling Download Emulations . . . . . . . . . . . . . . . . . . . . 3-5

Duplex Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Duplex Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Duplex Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Duplex Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Duplex Feed 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Duplex Feed 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Viewing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Hardware Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

SDRAM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

ROM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Parallel Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Serial Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Input Tray Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Input Tray Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Output Bin Test - Standard Bin . . . . . . . . . . . . . . . . . . . . 3-16

Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Print Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Printer Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Setting the Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Viewing the Permanent Page Count . . . . . . . . . . . . . . . . 3-18

Maintenance Page Count . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Setting Configuration ID. . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Restore EP Factory Defaults . . . . . . . . . . . . . . . . . . . . . . 3-21

Print Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Print Quality Test Pages . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Print Test with RIP (Controller Board) Removed . . . . . . . 3-24

Printing Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . 3-24

Autocompensator Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Autoconnect System, Paper Tray Options, Envelope Feeder 3-26

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Fuser Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Paper Feed Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-Sensitive Parts. . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Duplex Motor Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fuser Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Printhead Assembly Adjustment. . . . . . . . . . . . . . . . . . . . . 4-4

Paper Alignment Assembly Adjustment . . . . . . . . . . . . . . . 4-5

Screw Identification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Covers Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Center Pan Assembly Removal . . . . . . . . . . . . . . . . . . . . 4-16

Controller Board Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Developer Drive Assembly Removal . . . . . . . . . . . . . . . . 4-18

Duplex Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Duplex Front Cover Assembly Removal. . . . . . . . . . . . . . 4-19

Duplex Front Cover Door Removal . . . . . . . . . . . . . . . . . 4-19

Duplex Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

EMC Shields Removals . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Engine Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Main Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Frames Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Fuser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Fuser Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Fuser Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Fuser Detack Housing Assembly Removal . . . . . . . . . . . 4-32

Fuser Transfer Plate Removal . . . . . . . . . . . . . . . . . . . . . 4-32

Fuser Envelope Conditioner Solenoid Removal. . . . . . . . 4-33

Fuser Narrow Media Sensor/Flag Assembly Removal . . . 4-34

Fuser Exit Sensor Flag Assembly Removal . . . . . . . . . . . 4-34

Fuser Lamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Fuser Lower Exit Guide Assembly Removal . . . . . . . . . . 4-35

High Voltage Power Supply Removal. . . . . . . . . . . . . . . . 4-36

Integrated Tray Compensator Assembly Removal. . . . . . 4-37

Integrated Tray Compensator Pick Roll Assembly Removal . .

4-38

Interconnect Board Assembly Removal . . . . . . . . . . . . . . 4-39

Low Voltage Power Supply Removal . . . . . . . . . . . . . . . . 4-40

Main Drive Assembly Removal. . . . . . . . . . . . . . . . . . . . . 4-43

Main Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-44

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Multipurpose Tray/Lower Deflector Assembly Removal . 4-45

Operator Panel Assembly Removal. . . . . . . . . . . . . . . . . 4-47

Operator Panel Cable/Cover Switch Removal. . . . . . . . . 4-48

Optional 250/500 Paper Tray Assembly Removal. . . . . . 4-49

Paper Alignment Assembly Removal . . . . . . . . . . . . . . . 4-50

Paper Deflectors Removals . . . . . . . . . . . . . . . . . . . . . . . 4-52

Paper Input Sensor Removal. . . . . . . . . . . . . . . . . . . . . . 4-53

Paper Size Sensing Board Removal . . . . . . . . . . . . . . . . 4-53

Pick Roll Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Printhead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

Redrive Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . 4-55

Smart Contact Assembly Removal . . . . . . . . . . . . . . . . . 4-56

Toner Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

Transfer Roll Assembly Removal . . . . . . . . . . . . . . . . . . 4-58

Upper Paper Deflector Assembly Removal . . . . . . . . . . . 4-58

Upper Front Cover Hinge Assembly Removal. . . . . . . . . 4-59

Upper Front Cover Interlock Switch Assembly Removal. 4-60

Pick Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

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

Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 5-1

High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Engine Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Engine Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Controller Board - Non Network. . . . . . . . . . . . . . . . . . . . 5-10

Controller Board - Network . . . . . . . . . . . . . . . . . . . . . . . 5-11

Fuser Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Interconnect Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Envelope Feeder Board . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Duplex Unit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to Use This Parts Catalog. . . . . . . . . . . . . . . . . . . . . . . . 7-1

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

Assembly 2: Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 3: Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 4: Paper Feed (Autocompensator) . . . . . . . . . 7-10

Assembly 5: Paper Feed - Multipurpose Unit . . . . . . . . . 7-12

Assembly 6: Paper Feed - Alignment . . . . . . . . . . . . . . . 7-14

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Assembly 7: Paper Feed - Output . . . . . . . . . . . . . . . . . . 7-16

Assembly 8: Integrated Paper Tray - 500 Sheet . . . . . . . 7-18

Assembly 9: Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Assembly 10: Developer Drive . . . . . . . . . . . . . . . . . . . . . 7-22

Assembly 11: Hot Roll Fuser . . . . . . . . . . . . . . . . . . . . . . 7-24

Assembly 12: Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Assembly 13: Charging . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Assembly 14: Electronics 1 . . . . . . . . . . . . . . . . . . . . . . . 7-30

Assembly 15: Electronics II . . . . . . . . . . . . . . . . . . . . . . . 7-34

Assembly 16: Electronics III . . . . . . . . . . . . . . . . . . . . . . . 7-36

Assembly 17: Electronics IV . . . . . . . . . . . . . . . . . . . . . . . 7-38

Assembly 18: Electronics V . . . . . . . . . . . . . . . . . . . . . . . 7-40

Assembly 19: Electronics VI . . . . . . . . . . . . . . . . . . . . . . . 7-42

Assembly 20: 250-Sheet Tray . . . . . . . . . . . . . . . . . . . . . 7-44

Assembly 21: Integrated Paper Tray - 250 Sheet . . . . . . 7-48

Assembly 22: 500-Sheet Tray . . . . . . . . . . . . . . . . . . . . . 7-50

Assembly 23: Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . 7-54

Assembly 24: Envelope Feeder . . . . . . . . . . . . . . . . . . . . 7-60

Assembly 25: High-Capacity Feeder . . . . . . . . . . . . . . . . 7-62

Assembly 26: Kiosk - Vertical Paper Adapter. . . . . . . . . . 7-72

Assembly 27: Kiosk - Horizontal Paper Adapter. . . . . . . . 7-74

Assembly 28: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76

Assembly 29: Miscellaneous . . . . . . . . . . . . . . . . . . . . . . 7-78

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

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viii Service Manual

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Notices and Safety Information

Laser Notices

The following laser notice labels may be affixed to this printer as shown:

Laser Advisory Label

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Class 1 Laser Statement Label

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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 60825.

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 condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 60825 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 Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

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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 60825 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 norma CEI 60825.

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

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Avisos sobre el láser

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

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 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.

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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 60825.

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.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825.

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.

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Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825 -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.

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 60825.

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 skrivaren 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.

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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

60825.

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.

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 60825.

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.

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Japanese Laser Notice

Chinese Laser Notice

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Korean Laser Notice

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

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

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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.

• Le informazioni riguardanti la manutenzione di questo prodotto

sono indirizzate soltanto al personale di assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto, il

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

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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.

• 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.

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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 normes 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.

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Chinese Safety Information

Korean Safety Information

Ozone Information

This product does not produce measurable amounts of ozone gas.

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Preface

This manual is divided into the following chapters:

• “General Information” contains a general description of the

printer, options, and the maintenance approach used to repair it. General environmental and safety instructions as well as special tools and test equipment are listed in this chapter.

• “Diagnostic Information” contains a service error code table,

user status message table, user error message table, symptom table, and service checks used to isolate failing field replaceable units (FRUs).

• “Diagnostic Aids” contains tests and checks used to locate or

repeat symptoms of printer problems. Printer operation information is provided to enhance the tests and checks.

• “Repair Information” provides instructions for making printer

adjustments and removing and installing FRUs.

• “Connector Locations” uses illustrations to identify the major

components and test points on the printer.

• “Preventive Maintenance” contains safety inspection guidelines,

lubrication specifications, and maintenance information to prevent problems and maintain performance.

• “Parts Catalog” contains illustrations and part numbers for

individual FRUs.

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1. General Information

The Lexmark

T laser printers are letter quality page printers designed to attach to IBM-compatible personal computers and to most computer networks.

The Lexmark

Model Name Type

Lexmark T522 4520-210 Non network

Lexmark T522n 4520-220 Network

Lexmark T520 4520-001 Non network

Lexmark T520n 4520-002 Network

T laser printers are available in the following models:

General Information 1-1

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Options

The following options are available. Some options are not available in every country. Contact your point of purchase for options available in your country.

Memory options of 4MB, 8MB, 16MB, 32MB, 64MB and 128MB SDRAM

Flash memory options of 2MB, 4MB, 8MB and 16MB Integrated network options

Tok en -R in g Ethernet Tri-Port Adapter IR Adapter IPDS Card Assembly PRESCRIBE Card Assembly Image QuickCard Assembly Bar code Card Assembly Parallel Interface Card SES for SCS USB/Parallel Port

Marknet Print Servers 250 and 500-sheet paper trays of A5, letter, and legal size. 250 Sheet UAT (Universally Adjustable Tray) 400 Sheet UAT (Universally Adjustable Tray) 2000 Sheet High Capacity Feeder Envelope Feeder Duplex Unit - 250 Sheet (For T520 & T520n) Duplex Unit - 500 Sheet (For T522 & T522n) Hard Disk - 5.0 & GB Forms Hard Disk - 5.0 & GB or Larger Vertical Kiosk Presenter Horizontal Kiosk Presenter

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Maintenance Approach

The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the service error codes, user status messages, user error messages, service checks, and diagnostic aids to determine the printer problem and repair the failure. After you complete the repair, perform tests as needed to verify the repair.

Tools Required for Service

Flat-blade screwdriver #1 Phillips screwdriver #2 Phillips screwdriver T10 Torx screwdriver

7.0 mm nut driver

5.5 mm wrench Needlenose pliers Diagonal pliers Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Serial wrap plug 1329048 Twinax/serial debug cable 1381963 Coax/serial debug cable 1381964

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Acronyms

CSU Customer Setup DRAM Dynamic Random Access Memory EDO Enhanced Data Out EP Electrophotographic Process EPROM Erasable, Programmable Read-Only

Memory ESD Electrostatic Discharge FRU Field Replaceable Unit GB Gigabyte HVPS High Voltage Power Supply LASER Light Amplification by Stimulated Emission

of Radiation LCD Liquid Crystal Display LED Light-Emitting Diode LVPS Low Voltage Power Supply MROM Masked Read Only Memory NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer PC Photoconductor POR Power-On Reset POST Power-On Self Test RIP Raster Imaging Processor ROM Read Only Memory SDRAM Synchronous Dual Random Access

Memory SRAM Static Random Access Memory UPR Used Parts Return V ac Volts alternating current V dc Volts direct current

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2. Diagnostic Information

Start

CAUTION: Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Use the handholds on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down.

Use the service error code, user status message, user error message, symptom table, service checks, and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer.

Service error codes are indicated by a three-digit error code. If a service error code is displayed, go to the

page 2-2

User status messages provide the user with information on the current status of the printer. Ready is displayed on the first line of the display unless Power Saver is invoked, and then Power Saver is displayed. If a user status message is displayed, go to the

Status Messages” on page 2-22

“Service Error Codes” on

“User

User error messages are indicated by a two or three-digit error code that provides the user with information that explains a problem with a print cartridge, paper jam, option, port, and so on. If a user error message is displayed, go to the

If your machine completes the

page 2-35 “Symptom Tables” on page 2-36. Locate your symptom and take the

without an error, and you have a symptom, go to the

“User Error Messages” on page 2-25.

“Power-On Self Test (POST)” on

appropriate action.

If a service error code appears while you are working on the machine, go to the

“Service Error Codes” on page 2-2 and take the

indicated action for that error.

Diagnostic Information 2-1

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Service Error Codes

Service Error Codes are generally non-recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition.

Error Code Action

900 RIP Software Contact the next support level or call Lexmark.

901 Engine Flash Indicates that the flash which the engine board code is

programmed into is bad. Replace the engine board.

902 General Engine Software

903 Paperport Link Driver Error

904 Interface Violation by the controller software

905 Interface Violation by Paperport Device

906 ControllerEngine Link Driver Error

910 DC Pick Motor DC Pick Motor Stall

911 DC Pick Motor Excessive PWM

912 DC Pick Motor below speed

These errors indicate an unrecoverable engine software error. Replace the engine board.

Error Codes 910,911,912,913 and 914 are indications that a Tray 1 paper feed problem has been detected. Go to the “Input Tray(s) Service Check” on page 2-62.

913 DC Pick Motor over speed

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Error Code Action

914 DC Pick Motor: No encoder feedback

917 Transfer Roll Indicates a problem in the transfer roll area. Go to the

920 Fuser Error Indicates that the fuser is below temperature when

921 Fuser Error Indicates that the fuser is below standby temperature

922 Fuser Error Fuser failed to reach standby temperature. Go to the

923 Fuser Error Fuser is too hot during printing or when printer is idle. Go

924 Fuser Error An open circuit has been detected in the Fuser

925 Fuser Error Wrong fuser lamp installed. Check the fuser lamp for the

Check the integrated paper tray (tray 1) for correct paper loading. Reload the paper and POR the printer. If the error continues, go to the “Input Tray(s) Service Check”

on page 2-62.

“Transfer Roll Service Check” on page 2-103.

printing. Go to the “Fuser Service Check” on page 2-56.

when the printer is idle. Go to the “Fuser Service Check”

on page 2-56.

“Fuser Service Check” on page 2-56.

to the “Fuser Service Check” on page 2-56.

Thermistor Circuit. Go to the “Fuser Service Check” on

page 2-56.

correct type of lamp that should be installed.

If the correct fuser lamp is installed and the 925 error remains, the fuser may have reached standby temperature too quickly. Check the following:

• The correct hot roll has been installed.

• The line voltage is not exceeding the maximum rating for the printer.

929 Toner Sensor The toner sensor is not operating properly, the developer

930 Printhead Error

drive assembly is not operating properly or the print cartridge is defective. Go to the “Toner Sensor Service

Check” on page 2-102.

The wrong printhead is installed. Replace with the correct printhead.

Diagnostic Information 2-3

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Error Code Action

931-935 Printhead Error

932 - Printhead: Lost Hsync

933 - Mirror Motor Locks/Lost Hsync

934 - Mirror Motor Lost Lock

935 - Mirror Motor unable to reach operating speed.

936-937 Transport Motor

936 - Main Drive Motor initial lock failure

937 - Main Drive Motor lost lock

939 Controller Engine Communications Error

These errors represent a problem with the printhead. Go to the “Printhead Service Check” on page 2-87.

Indicates a problem with the main drive motor. Go to the

“Main Drive Service Check” on page 2-77.

The controller board and the engine board cannot communicate with one another. The controller board, engine board or interconnect board is defective. Check each board for correct installation and secure ground. If no problem is found, replace the FRUs in the following order:

1. Controller board

2. Engine board

3. Interconnect board Note: The controller software also can cause a 939 error

code. Contact your next level for software support.

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Error Code Action

940 Service LV Power Supply

941 Controller Code CRC

941 Controller Font CRC

943 Controller Font Version

944 Controller Board Failure

945 Controller Board Failure ASIC Failure

The low voltage power supply zero crossover test failed.

• Check the LVPS for correct installation. Ensure that the connector on the LVPS assembly is firmly seated with the connector on the interconnect card connector.

This error may also be caused by a noisy AC input power source.

• Be sure the correct LVPS has been installed.

• If all the above are correct, replace the LVPS assembly.

A 941 error can be created by a defective code overlay card, a code upgrade, a defective IPDS or a PRESCRIBE card. These should be checked before replacing the controller board.

Replace the controller board.

Indicates that the controller code and FONT ROM are incompatible.

Replace the controller board.

946 Controller Board Failure SRAM Failure

947 PQET Error Replace the engine board.

948 PEL Clock Error

949 Delay Line Calibration Failure

953 NVRAM Failure

954 NVRAM Failure

Replace the controller board.

Indicates the PEL clock check failed. Replace the engine board.

Indicates a delay line calibration failure. Replace the engine board.

Indicates the NVRAM chip on the engine board has failed. Replace the engine board.

Indicates the NVRAM experienced a CRC failure. Replace the engine board.

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Error Code Action

956, 957, 959 System Board

958 NAND Failure

960 RAM Memory Error

961 RAM in Slot 1 is Bad.

962 RAM in Slot 2 is Bad.

963 RAM in slot 3 is Bad.

964 Emulation Error

965 Emulation Error

Error codes 956 thru 959 are system board failures.

Perform a power on reset (POR). If this does not fix the problem, replace the system board.

*956 = Processor Failure *957 = ASIC Failure *959 = SRAM Failure

Before proceeding when a 958 NAND failure is displayed, perform a power on reset (POR) to see if the ECC error correction code can reflash NAND.

If this does not fix the problem, replace the system board.

Indicates a DRAM Memory Error on the controller board. Replace the controller board.

Replace the card in Slot 1. If this does not fix the problem, replace the controller board.

Replace the card in Slot 2. If this does not fix the problem, replace the controller board.

Replace the card in slot 3. If this does not fix the problem, replace the controller board.

Indicates a failure within the Download Emulation which is programmed into the code overlay card. The specific error is as follows: 964 - Download Emulation CRC Failure. Checksum Failure. 965 - Download Emulation Outdated, The Download Emulation and the controller code are incompatible. Go to the “Disabling Download Emulations” on page 3-5.

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Error Code Action

975 - 979 Network Card X

980 <device> Comm

981 <device> The engine protocol violation detected by the specified

982 <device> Comm

983 <device> Invalid command received by the specified device.

984 <device> Invalid command parameter received by the specified

The following errors indicate a failure with the network card in the specified slot. X=any card installed in slots 1,2 or 3. 975 - Unrecognizable Network Card x. Replace Network Card x. 976 - Unrecoverable software error in Network Card x. 977 - Controller software detects that a Network Card is installed in slot x but cannot establish communications with it. 978 - Bad checksum while programming Network Card x. Replace Network Card x. 979 - Flash parts failed while programming Network Card x. If the printer is a network model, replace the controller board.

The engine is experiencing unreliable communications to the specified device.

device.

Communications error detected by the specified device.

device.

Note: Service Errors 980 thru 984 <device> can be one of the following: engine board, duplex, tray x (1,2,3,4 or

5), envelope feeder or output bin.

990 <device> Indicates an equipment check condition has occurred in

991 <device> Card

the specified device, but the device is unable to identify the exact component failure.

Note: <device> can be one of the following: duplex, tray x (1,2,3,4 or 5), envelope feeder or output bin.

The specified device has detected an equipment check in its system card.

Note: <device> can be one of the following: duplex, tray x(1,2,3,4 or 5), envelope feeder or output bin.

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Sub Error Codes for 9XX and 2XX Error Codes

The sub error codes are helpful troubleshooting a paper path problem, especially paper jams in the base printer, envelope feeder and duplex unit.

When a 9XX or 2XX error displays, press and hold Return and press Select to enter for sub error codes. The following is an example of how the printer shows a duplex unit sub error code.

Byte 1

Byte 5

Byte 2

Byte 6

Byte 3

Byte 7

Byte 4

Byte 8

Sub Error Codes for 9XX and 2XX Error Codes

The sub error codes are helpful troubleshooting a paper path problem, especially paper jams in the base printer, envelope feeder and duplex unit.

When a 9XX or 2XX error displays:

1. Press and hold Return and press Select to enter for sub error codes.

2. The first screen of information is displayed. Write down the information.

3. Continue pressing Return and Select until each screen of information is obtained.

4. When the last screen displays, the original message displays.

The following is an example of how the printer shows a duplex unit sub error code.

2-8 Service Manual

Byte 1

Byte 5

Byte 2

Byte 6

Byte 3

Byte 7

Byte 4

Byte 8

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Base Printer Sub Error Codes

Each status byte has a different level of troubleshooting value for each area of the printer. The following table displays up to 8 status bytes of data. Some or all of these bytes may be used to help diagnose a printer problem. These status bytes are designed to help isolate paper jams and paper feed problems in the base printer

Legend for Tray Source: x=10 (MPT), x-11 (Tray 1), x=12, (Tray 2), x=13 (Tray 3), x-14 (Tray 4), x=15 (Tray 5), x=31 (Env Feeder), X=40 (Manual)

Legend for Stacker Destination: x=91 (Stacker 1), x=92 (Stacker 2), x-93 (Stacker 3)

Legend for media size: x=1 (letter), x=2 (legal), x=3 (B5), x=4 (A4), x=5 (Executive), x=6 (A5), x=7 (Custom), x=9 (73/4 Env), A-#9 Env, B-#10 Env, C=8.661” Env, D=C5 Env, E=B5 Env, F=Legal Env.

First 6 Bytes Sub Error Code Data - Note: xx can be any value.

Explanation

84 xx 00 x1 x2This code indicates that the input sensor in the printer is still

84 xx 01 x1 Video never started on the page.

actuated from the first sheet and the second sheet is ready to arrive at the sensor. (x1=media size, x2=media source) *Check the printer input sensor and flag for correct operation.

The flag should operate freely. *Check for any signs of debris in the area of the input sensor. *Check the area of the transfer plate and input to the fuser for

anything that might cause the paper to remain over the input sensor.

(x-1=media size) *The video signal never started within 2 inches after

actuating the input sensor. Check input sensor and flag.

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First 6 Bytes Sub Error Code Data - Note: xx can be any value.

Explanation

84 xx 02 x1 This error is the most common type of paper jam. Possible

84 xx 04 The input sensor was covered during POST by a piece of

84 xx 05 There was a media at the input sensor too early. There was

84 00 06 A paper jam has been declared by a smart device. Immediate

84 00 07 A paper jam has been declared by a smart device. Homing

84 xx 0B x1 x2 x3

causes are (x1=media size): *Multi sheet feeding. *A tray size sensing problem. *The media feeding from the paper source is slipping or

media is slipping in input to the printer.

media still in the machine when it was turned on. *Clear the media from the printer. *Run the base sensor test (input sensor) from the diagnostic

tests menu to test the input sensor and flag for correct operation.

not enough time between printhead start and the printhead mirror motor to lock. Possible causes for this error are: *Paper might be pre-staged in the paper source tray. *Paper is picking too fast. *A defective input sensor.

stop homing not allowed.

was allowed before the stop.

The option tray pass thru sensor was never actuated by a piece of media. (x-1=media size) (x-2=media source) (x3=paper source where paper jam was detected) *Run the sensor test for the option tray that is displaying the

error code and check the pass thru sensor for that tray for correct operation.

*Check for paper picking from the selected paper input

source.

*If the error is being detected from a lower paper source, see

if paper is feeding correctly from a paper source above the detected source.

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First 6 Bytes Sub Error Code Data - Note: xx can be any value.

Explanation

84 xx 0f x1 x2 x3

84 00 10 The main motor ID failed to identify either motor after two

84 xx 17 There is an envelope or envelopes in the envelope feeder

84 xx 18 There is media over the Tray 2 pass thru sensor during warm-

84 xx 19 There is media over the Tray 3 pass thru sensor during warm-

The option Tray pass thru sensor was never deactivated. (x-1=media size) (x-2=media source) (x-3=media source where paper jam was detected) *Check the pass thru sensor and flag for correct operation. *Check to see if paper has cleared the pass thru area of the

option where the paper jam occurred.

tries. Possible causes for this error are: *The main drive motor has stalled. *An incorrect main drive motor/gearbox assembly has been

installed.

during warm-up. An envelope may have partially fed from the envelope feeder. *Remove any envelopes from the feeder and check the

envelope feeder for correct operation.

up. Check for media over the sensor. If no media is present, check the pass thru sensor, flag, and cables. *Try running the Input Tray Tests for Tray 2 and see if Tray 2

is feeding paper correctly and all the sensors are working

correctly. *Check to make sure the paper size setting is correct for the

size paper in the tray.

up. Check for media over the sensor. If no media is present, check the pass thru sensor, flag, and cables. *Try running the Input Tray Tests for Tray 3 and see if Tray 3

is feeding paper correctly and all the sensors are working

correctly. *Check to make sure the paper size setting is correct for the

size paper in the tray.

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First 6 Bytes Sub Error Code Data - Note: xx can be any value.

Explanation

84 xx 1A There is media over the Tray 4 pass thru sensor during warm-

84 xx 1B There is media over the Tray 5 pass thru sensor during warm-

84 xx 1C There is media over the Tray 6 pass thru sensor during warm-

84 xx 1D The envelope feeder pass thru sensor never deactivated. The

up. Check for media over the sensor. If no media is present, check the pass thru sensor, flag, and cables. *Try running the Input Tray Tests for Tray 4 and see if Tray 4

is feeding paper correctly and all the sensors are working correctly.

*Check to make sure the paper size setting is correct for the

size paper in the tray.

up. Check for media over the sensor. If no media is present, check the pass thru sensor, flag, and cables. *Try running the Input Tray Tests for Tray 5 and see if Tray 5

is feeding paper correctly and all the sensors are working correctly.

*Check to make sure the paper size setting is correct for the

size paper in the tray.

up. Check for media over the sensor. If no media is present, check the pass thru sensor, flag, and cables. *Try running the Input Tray Tests for Tray 6 and see if Tray 6

is feeding paper correctly and all the sensors are working correctly.

*Check to make sure the paper size setting is correct for the

size paper in the tray.

display of this code indicates that an envelope never crossed over the sensor flag and passed beyond the sensor, or the flag and sensor are not operating properly. Go to the

“Envelope Feeder Service Check” on page 2-48.

84 xx 1E x1 x2The envelope feeder pass thru sensor was never activated.

(x1=Media Size, x2=Media Source) Ensure that envelopes are feeding over the sensor. If an envelope feeds over the sensor but the sensor does not activate, check the sensor and flag for correct operation. If the sensor and flag are operating correctly, go to the

“Envelope Feeder Service Check” on page 2-48.

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First 6 Bytes Sub Error Code Data - Note: xx can be any value.

Explanation

84 xx 20 x1 x2The imaged page is not the expected page.

84 xx 21 x1 x2The smart tray x did not pick a sheet of paper.

84 xx 22 x1 x2This code indicates that the media activated the input sensor

84 xx 23 x1 x2The transfer servo never started.

84 xx 25 This code indicates that the media has activated the input

(x1=Media Size, x2=Media Source)

Check the pass thru sensor to make sure it is operating properly. If no problem is found, it may be necessary to try a new pass thru sensor.

(x1=Media Size, x2=Media Source)

Check tray x auto compensator and tray parts for correct operation. If no problem is found, go to the “Input Tray(s)

Service Check” on page 2-62.

before the printer EP was ready. (x1=Leading Edge of Media State, x2=Trailing Edge of Media State)

(x1=Media Size, x2=Leading Edge of Media State)

sensor before the printhead has locked. Enough time has elapsed since printhead start to expect a lock. One of the following may be failing: *Printhead Assembly *System Board *Printhead Cables

84 xx 26 This code indicates that media has activated the input

sensor; however, the printhead fell out of lock condition or not enough time elapsed since the printhead start to expect a stable lock. The media may have also reached the input sensor early.

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First 6 Bytes Sub Error Code Data - Note: xx can be any value.

Explanation

89 00 01 The exit sensor in the fuser is activated by a piece of media

89 xx 03 The fuser exit sensor did not detect the trailing edge of the

89 xx 04 x1 The fuser exit sensor never actuated from the sheet going

89 xx 07 The narrow media sensor in the fuser was covered by a sheet

indicating there is a piece of media in the machine during POST. *Check for media in the exit of the fuser assembly or redrive

assembly. Feed a sheet of paper, and if the same error occurs after clearing the fuser or the same error occurs when no media is present, check the exit sensor assembly, internal fuser assembly cabling, DC fuser cable to the system board, and the cable connection to J14 on the system board.

TIP: Turn the printer off, enter the diagnostic tests menu, and select the base sensor test. Select output sensor and check the sensor for correct operation.

media going through the fuser assembly. *This failure can be caused by a broken fuser exit sensor

flag.

*This may also be caused by erratic operation of exit sensor

flag or exit sensor or a defective piece of media.

through the fuser before the next page begins feeding. (x-1=Media Size)

of paper when not expected or a piece of media is in the machine during POST. *This error can occur when a 202 paper jam has occurred. *Remove any piece of media that is over the narrow media

sensor.

*Try to feed a piece of paper through the printer (could run

the print test from the diagnostic test menu). If the media stops over the narrow media sensor again, check the flag and sensor for correct operation.

89 xx 0B x1 The fuser exit sensor may be bouncing.

*This error can be caused by a failing exit sensor or system

board.

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First 6 Bytes Sub Error Code Data - Note: xx can be any value.

Explanation

89 xx 0D The fuser exit sensor bounced. Check the exit sensor for

8D 00 00 The fuser exit sensor was never activated by the leading

8E xx 02 x1 x2This error can be caused by the input sensor not being

8E xx 06 x1 The second pick failed from a paper source when paper was

8E xx 07 x1 The second pick failed from a paper source when paper was

correct operation. Check the fuser DC cable to J14 on the system board. Also, the system board may be failing.

edge of the media fed through the printer. *This error can be displayed after a 201 paper jam. *This can be caused by a defective fuser exit sensor

assembly.

Enter the diagnostic tests menu, select base sensor tests, select output sensor test and check the fuser exit sensor for correct operation. If the test fails, check the internal fuser cabling, DC autoconnect on the fuser frame, fuser DC autoconnect to the system board cable, and the cable connection to J14 on the system board.

activated by a page that was known to have been picked by a source other than the duplex option. *Ensure the correct source has been selected and the media

is feeding from that source.

in the source and the only sheet in the paper path.

in the source. Other sheets may have started to feed, but none were in the paper path.

8E xx 08 The paper in the output bin was flushed. The paper ahead of

it, in the paper path, never made it past the output bin sensor or into the tray.

8E xx 09 x1 The second pick from the MPT, Tray 1 or feeder failed when

8E xx 0A x1 The second pick from the MPT, Tray 1 or feeder failed when

paper was in the source. Other sheets may be in the paper path. (x1=Media Source)

paper was in the source. Other sheets may have started to pick, but none were in the paper path. x1=Media Source)

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First 6 Bytes Sub Error Code Data - Note: xx can be any value.

Explanation

8E x1 0B The DC auto compensator failed or stalled when trying to

8E xx 11 It took too long for the DC auto compensator motor to come

8E xx 13 x1 x2Late feeding from a paper source interfered with the next pick

feed a sheet of media.

up to speed.

retry. (x-1=Media Size)(x-2=Media Source)

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Base Printer (Fuser) Sub Error Codes

The following Sub Error Codes could be a help in diagnosing Fuser Assembly failures:

First 6 Bytes Sub Error Code Data - Note: xx can be any value

920 Service - Fuser Error (Under temperature while printing)

Explanation

EN 08 xx yy

- 1 EN- zz - - 2

921 Service - Fuser Error (Fuser under temperature while at standby)

EN 41 xx yy

-- 1 EN -- zz -- -2

922 Service - Fuser Error (Fuser failed to reach standby temperature)

xx=Actual Fuser Temperature yy=The temperature that the fuser wants to reach. When zz=00 The Hot Roll took too long to heat up.

zz=01 The Hot Roll fell too far below the desired

temperature while printing.

zz=02 The Hot Roll was too cool while the system was

doing some checking.

zz=03 The Hot Roll was too cool when heating to the

desired temperature.

xx=Actual Fuser Temperature yy=The temperature that the fuser wants to reach. zz=00 The fuser temperature did not change enough from the

fuser lamp temperature at turn on.

01 The fuser temperature rose more than desired from the

fuser temperature at turn on.

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First 6 Bytes Sub Error Code Data - Note: xx can be any value

Explanation

EN 42 xx yy

-- 1 EN z1 z2 -- -

- 2

923 Service - Fuser Error (Fuser over temperature)

EN 12 xx yy

-- 1 EN -- -- -- -2

924 Service - Fuser Error (Open Thermistor Failure)

EN 18 xx -- -

- 1 EN -- 00 -- -2

xx=Actual Fuser Temperature yy=The temperature that the fuser wants to reach. zz=00 The fuser temperature did not change enough from the

fuser lamp temperature at turn on.

01 The fuser temperature rose more than desired from the

fuser temperature at turn on.

z2=00 The Hot Roll did not reach standby temperature in time

during standby.

01 The Hot Roll took too long to reach the beginning lamp

detection temperature.

02 The Hot Roll reached ‘final lamp detection

temperature’ but took longer than expected.

03 The Hot Roll timed out trying to reach the ‘final lamp

detection temperature.’

04 After Hot Roll lamp detection, did not reach steady

state control in time.

05 The Hot Roll did not reach operating temperature in

time.

This sub error code is displayed anytime that the Hot Roll has reached a higher than desired temperature. xx=Actual Fuser Temperature yy=The temperature that the fuser wants to reach.

This code is usually generated when an open circuit check is made of the thermistor circuit in the fuser. xx=Actual Fuser Temperature

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First 6 Bytes Sub Error Code Data - Note: xx can be any value

925 Service - Fuser Error (Wrong Fuser Lamp Installed) Note: The Sub Error Codes below are only for an incorrect lamp being installed.

Explanation

EN 07 xx yy zz 1 EN -- -- -- 2

This error code is generated anytime an incorrect lamp is detected. xx=00 Lamp detection performed and found an error.

01 It took long to do lamp detection and NVRAM detected a previous wrong lamp detected. yy=Actual Temperature zz=The temperature that the fuser was trying to reach.

Envelope Feeder Sub Error Codes

First 6 Bytes Sub Error Code Data - Note: xx can be any value

84 xx 17 There is an envelope in the feeder during POST.

Explanation

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First 6 Bytes Sub Error Code Data - Note: xx can be any value

Explanation

84 xx 1D x1 x2The envelope feeder pass thru sensor activated but never

84 xx 1E x1 x2An envelope never activated the envelope feeder pass thru

deactivated. (x1=Media Size)(x2=Media Source) This error can be caused by an envelope over the pass thru sensor. Remove the envelope and try to feed an envelope. If the envelope stops over the pass thru sensor, try the following: *Select the diagnostic test menu, select input tray sensor

tests, select envelope feeder sensor test.

*Check the envelope pass thru sensor to ensure it is

operating correctly. If the sensor test fails, go to the

“Envelope Feeder Service Check” on page 2-48.

If the test passes, look for anything that might cause the envelope to stop over the sensor.

sensor or the sensor never sensed the presence of an envelope. (x1=Media Size)(x2=Media Source) *Check to make sure the envelope feeds to the pass thru

sensor.

*Check to see if the envelope actuates the pass thru sensor

flag.

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Duplex Unit Sub Error Codes

Status byte 4 contains the most valuable information to help isolate a failing part or assembly in the duplex unit and is the only byte contained in the following table.

Status Byte 4

00 No duplex error. No problem was reported to the engine by the

01 The leading edge of the sheet of paper never arrived at the input

02 The duplex unit engine board never received media notification

03 The trailing edge of the sheet of paper never cleared the input

04 The leading edge of the sheet of paper never arrived at the exit

05 The duplex logic thinks a sheet of paper is feeding to the duplex

06 The exit sensor detected a sheet of paper too early.

07 The sheet of paper trailing edge did not clear the exit sensor in the

Explanation

duplex system card.

sensor.

from the printer.

sensor.

sensor. Note: This error is the most common due to the long length of the paper path between the input sensor and the exit sensor.

unit due to a sensor malfunction in the paper path when in fact the printer has not sent a command to send a sheet of paper to the duplex unit.

desired length of time.

08 The feed motor experienced a complete motor stall.

0E The D.C. motor is under speed. The motor never reached the

correct operating speed.

13 There is paper left in the duplex unit. Paper was sensed during

the homing operation during POST.

15 There is paper left in the duplex unit. Paper was sensed during

18 The D.C. motor experienced an acceleration error.

3D There is paper left in the duplex unit. Paper was sensed during IR

the D.C. motor diagnostic test during POST.

clear during POST.

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User Status Messages

User Status Message Status Action

Ready The printer is ready to

receive and process data.

Ready/Hex The printer is ready and

HEX Trace is active, which is known as HEX Trace Ready.

Busy The printer is busy

receiving or processing data, or printing data.

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

Press Menu to take the printer out of Ready and enter all the Menus except the TESTS MENU (Busy state).

Press Menu to take the printer out of Ready and enter the TESTS MENU (Busy state). Press Select for the values. Press Menu> until Reset Printer is on the second line of the display. Press Select to Reset the printer.

Press Stop to take the printer out of Busy. The Not Ready message is displayed. No more data is processed, but the printer processes all paper currently in the printer paper path. Press Go to return to Ready.

Flushing Buffer The printer is flushing

corrupted print data and the current print job is being discarded.

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No button actions are possible while this message is displayed.

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User Status Message Status Action

Printing Menu Settings The printer is processing

or printing a list of current settings menus because Print Menu Settings is selected from the menu.

Printing Directory List A directory of the flash

and disk contents is processing or printing because Print Directory is selected from the menu.

Press Stop to take the printer out of Ready. The Not Ready message is displayed. No more data is processed, but the printer processes all paper currently in the printer paper path. Press Go to return to Ready after the page prints. Press Menu to take the printer out of Ready and enter the TESTS MENU (Busy state). Press Select for the values. Press Menu until Reset Printer is on the second line of the display. Press Select to reset the printer.

Press Stop to take the printer out of Ready. The Not Ready message is displayed. No more data is processed, but the printer processes all paper currently in the paper path. Press Go to return to Ready after the page prints. Press Menu to take the printer out of Ready and enter the TESTS MENU (Busy state). Press Select for the values. Press Menu until Reset Printer is on the second line of the display. Press Select to reset the printer.

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User Status Message Status Action

Restoring Factory Defaults

Performing Self Tests The printer is running

Not Ready (Press Go)

Resetting Printer The printer is deleting

Formatting Flash (Do Not Power Off)

The printer is restoring factory defaults.

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

The printer is in the Not Ready state, which means it is not ready to receive or process data. This message displays when Menu is pressed during a print job.

any print jobs in process and restoring all settings to user defaults.

The flash memory is being formatted.

No button actions are possible while this message is displayed.

Press Go to take the printer out of the Not Ready state. Press Menu to take the printer out of Ready and enter the TESTS MENU (Busy state). Press Menu until Reset Printer is on the second line of the display. Press Select to reset the printer.

No button actions are possible while this message is displayed.

Program Flash (Do Not Power Off)

Formatting Disk The disk is being

The flash memory is being programmed, which means fonts or macros are being written to flash memory.

formatted.

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Do not perform any button actions while this message is displayed.

No button actions are possible while this message is displayed.

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User Status Message Status Action

Programming Disk (Do Not Power Off)

Menus Disabled The printer menus have

Activating Menu Changes

The disk is being programmed, which means fonts or macros are being written to disk.

been disabled. 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.

The printer is reset to activate a printer setting changed in the menus.

User Error Messages

No button actions are possible while this message is displayed.

Note: If information is written to flash memory and to disk at the same time, the Program Flash message is displayed.

No button actions are possible while this message is displayed.

User Error Message Explanation

200 Paper Jam Remove Cartridge

201 Paper Jam Remove Cartridge

202 Paper Jam Open Rear Door

Paper is jammed at the printer Input Sensor. Open the printer upper front door and remove the print cartridge to access the paper jam area.

Paper is jammed between the printer input and exit sensors. Open the printer upper front door and remove the print cartridge to access the jam area.

Paper is jammed at the printer exit sensor. Open the printer rear door to access the jam area.

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User Error Message Explanation

230 Paper Jam Check Duplex

24X Paper Jam Check Tray X

250 Paper Jam Check MP Feeder

260 Paper Jam Check Envelope Feeder

27X Paper Jam Check Output

Insert Cartridge or Close Door

31 Defective Print Cartridge

The paper is most likely jammed in the Duplex Unit. Remove the duplex front cover to access the jam area. If the paper is jammed in the rear of the duplex, then replace the duplex front cover and open the duplex rear door. If the paper is not jammed in the duplex unit, then it may be jammed in the rear of the printer. Open the printer rear door to access the jam.

Paper is jammed around Tray X (X=tray 1 thru 5). Try opening Tray X. If the tray is difficult to remove, then you may have to remove the tray above or below tray X to remove the jammed pages.

Paper is jammed in the multipurpose feeder.

Paper is jammed in the envelope feeder.

Paper is jammed in output bin. Open the rear door to access the jammed pages.

This message displays when the printer front door is open or the print cartridge is missing. If this message cannot be cleared go to “Cover

Open Switch/Cable Service Check” on page 2-42.

Error code 31 is displayed when the top front cover is closed and a defective print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is defective. Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10-20 second interval. If pages are allowed to print, they are not reprinted once a good print cartridge is inserted.

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Note: This error indicates the printer was able to

read the cartridge ID, but the ID did not pass the verification test. To pass the verification test, the ID read from the print cartridge must match the ID from the last “good” print cartridge or the same ID must be read from the print cartridge twice. The last “good” print cartridge ID is stored in NVRAM.

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User Error Message Explanation

32 Unsupported Print Cartridge

34 Short Paper The printer determines the paper length is too

36 Resolution Reduced The resolution of the page has been reduced

Error 32 is displayed when the top cover is closed and an unsupported print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is supported. Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10-20 second interval. If pages are allowed to print, then they are not reprinted once a good print cartridge is inserted. If this does not fix the problem, go to the “Smart Contact Assembly Service Check” on

page 2-100.

short to print the formatted data. This occurs when the printer does not know the actual paper size loaded in the tray. For auto-size sensing trays, this error occurs if the paper stop is in the incorrect position. Make sure the Paper Size setting is correct for the size paper that is being used.

from 600 dpi to 300 dpi to prevent a Memory Full error. This message can only occur if the Resolution Reduction setting is turned on.

Note: 1200 dpi pages are not resolution reduced. If a 1200 dpi job runs out of memory, a Memory Full error is displayed.

37 Insufficient Collation Memory

38 Memory Full This message is displayed when the printer

39 Complex Page This message is displayed when the page is too

51 Defective Flash This message is displayed when the printer

This message is displayed when the printer memory used to store pages is too full to collate the print job.

memory used to store pages is full.

complex to print.

detects a defective flash. This error may occur at power on, or during flash format and write operations. Press Go to clear the message. The flash is marked as bad and normal operation continues. Flash operations are not allowed until the problem is resolved.

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User Error Message Explanation

52 Flash Full This message is displayed when there is not

53 Unformatted Flash This message is displayed when the printer

54 Standard Serial Error This error is displayed when a serial error

54 Serial Option X Error This error is displayed when a serial error

56 Standard Serial Disabled

56 Parallel Port Disabled This error is displayed when data is sent to the

enough free space in the flash memory to hold the resources that have been requested to be written to flash.

detects an unformatted flash at power on. Press Go to clear the message. The flash is marked as bad and normal operation continues. Flash operations are not allowed until the flash is formatted.

(framing or parity) is detected on the standard serial port. This usually indicates the serial port is not set up correctly.

(framing or parity) is detected on the optional serial port. This usually indicates the optional serial port is not set up correctly.

This error is displayed when data is sent to the printer across the standard serial port, but the port has been disabled.

printer across the parallel port, but the parallel port has been disabled. Once this message is displayed, reporting of further errors is suppressed until the menus are entered, or the printer is reset.

58 Too Many Trays Attached

58 Too Many Disks Installed

61 Defective Disk This error code is displayed when the printer

This error code is displayed when too many input trays are attached to the printer.

This error is displayed when too many disks are attached to the printer.

detects a defective disk. This error may occur at power on or during disk format and write operations. While this message displays: Press Go to clear the message. The disk is marked defective and normal printer operations continue. Disk operations are not allowed with a defective disk. The Format Disk menu is not shown.

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User Error Message Explanation

62 Disk Full This error code is displayed when there is not

63 Unformatted Disk This error code displays when the printer detects

80 Scheduled Maintenance

81 Engine Code CRC Failure

88 Toner Low This message displays when toner low occurs

enough free space on the disk to hold the resources that have been requested to be written to the disk. This message displays for both resource and PostScript Disk operators when the disk is full.

an unformatted disk at power on. Press Go to clear the message. The disk is marked as bad and normal operation continues. Disk operations are not allowed until the disk is formatted.

The operator panel displays this message at each 250K page count interval. It is necessary to replace the fuser assembly, transfer roller, and charge roll at this interval to maintain the print quality and reliability of the printer. The parts are available as a maintenance kit. For more information, go to “Scheduled Maintenance” on

page 6-2.

This error displays when the microcode to be programmed in the engine flash code module has failed a CRC check. Press Go to clear the message. The microcode data is discarded and must be re-transmitted from the host computer.

and the toner low alarm is activated. Press Go to clear this message.

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User Line 2 Messages

If none of the conditions exist that are listed in the following table, line 2 is blank. If any of the messages in the table are displayed the following actions can be taken:

Press Menu to take the printer offline and access the Ready Menu group. The Menu buttons are not active if Menu Lockout is turned on.

Press Stop to take the printer offline. The Not Ready message is displayed. No more data is processed from the host computer. Press Go to return the printer to the Ready state.

User Message Explanation

Toner Low If the toner cartridge is low, then “Toner Low”

Tray X Missing If any of the input trays are missing, then “Tray X

displays. The Toner Low condition clears whenever the upper front door is opened, and Toner Low displays again if the condition exists after the upper front door is closed.

Missing” displays (where X designates which Tray (1 through 5) is missing. If multiple trays are missing, they are prioritized in this order: Tray 1,

2..., then Tray 5. Tray X Missing status clears whenever Tray X is reinserted.

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User Message Explanation

Tray X Empty If any of the input trays are empty, then “Tray X

Tray X Low If any of the input trays are low, then “Tray X Low”

Empty” displays where X designates which tray (Tray 1 through 5) is empty. If multiple trays are empty, then they are prioritized in this order: Tray 5, Tray 4,...Tray 1.

Note: Tray X Empty status clears whenever Tray X is removed. When Tray X is reinserted, it is examined and the appropriate status, if any, displays. Also note that Empty status is not displayed for the Envelope Feeder or Multipurpose Feeder.

displays where X designates which tray (1 through 5) displays. If multiple trays are low, they are prioritized in the following order: Tray 5,4,3,2,1.

Note: Tray X Low clears whenever Tray X goes empty, or Tray X is removed. When Tray X is reinserted, it is examined and the appropriate status, if any, displays.

Note: The printer cannot detect when the envelope feeder or multipurpose feeder are low.

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User Line 2 Link Messages

If the printer is locked on a particular link, the link indication displays. If the printer is ready to process any link, no messages display. Link messages are listed in the following table.

User Message Explanation

Parallel Standard Parallel Port, if available.

Serial Standard Serial Port, if available.

Serial X Serial Port, where X=1,2,3, is attached to PCI

Network X Network card X, X=1,2,3, is attached to PCI

LocalTalk X LocalTalk Card X,X=1,2,3, is attached to PCI

Infrared Standard Infrared port, if available.

Infrared X Infrared Port X, X=1,2,3, is attached to PCI

connector X.

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Check Device Connection Messages

The messages in the following table display when the printer looses communications with one of the following devices.

User Status Message Explanation

Check Env Feeder Connection

Check Tray X Connection

Check Duplex Connection

Check Envelope Feeder Connection.

Check Tray X (X=1,2,3,4 or 5).

Check Duplex Unit Connection.

The messages in the following table can occur in two ways. The specified device could have been removed from the printer, for instance to clear a paper jam. Otherwise, the device can still be attached to the printer, but is experiencing a communications problem, not fully connected, or having a hardware failure.

If the device is temporarily removed or not connected properly, then reattach it. When the option is recognized, the printer automatically clears the error and continues. If the option is experiencing a hardware problem, turn the printer off and back on. If the error occurs again, turn the printer off, remove the option and call for service.

Diagnostic Information 2-33

Page 62

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User Status Message Explanation

Turn Printer OFF to Enable Option

Insert Duplex Front Cover This message displays when the duplex front

Close Duplex Rear Door This message displays when the duplex rear

This message displays when a printer option, Input Tray, or Envelope Feeder, has been attached while the printer is powered on. To use the option, the printer must first be powered off and back on again. Data loss results if print jobs are active when the printer is power cycled. If a print job is active, then remove the option and finish the job. The printer automatically clears the message once the option is removed. Once the job is complete, turn off the printer and attach the option again.

access cover is not installed.

door is open.

2-34 Service Manual

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Power-On Self Test (POST)

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

1. The LED comes on.

2. The operator panel displays one and a half row of pels, and then clears.

3. Diamonds scroll across the display, and then clear.

4. The operator panel displays one and a half row of pels, and then clears.

5. The top line of the operator panel displays one square block of pels that turn on one at a time until all sixteen blocks display and then they all turn off.

6. “Performing Self Test” appears on the display.

— The high capacity option elevator tray moves to the

uppermost position if installed.

— The duplex unit is checked if installed.

7. “Busy” appears on the display.

8. The fuser lamp turns on. The fuser takes longer to warm up from a cold start than a warm start.

9. The main fan turns on.

10. The main drive motor turns on.

11. The developer drive assembly drives the developer shaft in the toner cartridge.

12. The exit rollers turn.

13. The operator panel LED starts blinking.

14. “Ready” appears on the display.

Diagnostic Information 2-35

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Symptom Tables

Symptom Table - Base Printer

Symptom Action

Dead Machine Go to the “Dead Machine Service

Operator Panel - One or more buttons do not work.

Operator Panel - Display is blank. Printer sounds 5 beeps.

Operator Panel - Display is blank. Printer does not sound 5 beeps.

Operator Panel continuously displays all diamonds, sounds 5 beeps and does not complete POST.

Paper feed problems - Base printer or Integrated 500 Paper Tray

Paper jams at exit of Redrive Assembly - No Duplex Unit installed.

Paper jams at exit of Redrive Assembly - Duplex Unit installed.

Fuser Solenoid fails to operate. Go to the “Fuser Solenoid Service

Check” on page 2-43.

Go to the “Operator Panel Buttons

Service Check” on page 2-79.

Go to the “Operator Panel Service

Check” on page 2-79.

Replace the operator panel assembly.

Go to the “Operator Panel Service

Check” on page 2-79.

Go to the “Paper Feed Service

Check” on page 2-84.

Go to the “Paper Feed Service

Check” on page 2-84.

Go to the “Duplex Unit Service

Check” on page 2-45.

Check” on page 2-60.

Print quality - Black page Go to the “Print Quality - All Black

Page” on page 2-89.

Print quality - Blank page Go to the “Print Quality - Blank

Print quality - Light print Go to the “Print Quality - Light Print”

Print quality - Background Go to the “Print Quality -

Print quality - Residual image Go to the “Print Quality - Residual

Page” on page 2-90.

on page 2-98.

Background” on page 2-94.

Image” on page 2-98.

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Symptom Action

Print quality - Skew Go to the “Paper Feed Service

Print quality - Banding Go to the “Print Quality - Banding”

Print quality - Random marks Go to the “Print Quality - Random

Print quality - Toner on backside of printed page.

Print quality - Vertical black bands on edge of copy.

Unable to clear a “32-Unsupported Print Cartridge” User Error Message.

Check” on page 2-84.

on page 2-96.

Marks” on page 2-91.

Go to the “Print Quality - Toner on

backside of printed page” on page 2-99.

Go to the “Print Quality - Black

bands on outer edges of the page.” on page 2-96.

Go to the “Smart Contact Assembly

Service Check” on page 2-100.

Symptom Table - High-Capacity Feeder (2000-Sheet)

Symptom Action

• The printer does not recognize the high capacity feeder installed.

• Paper feed problem with the high capacity feeder.

Go to the “High-Capacity Feeder

Input Tray Service Check” on page 2-66.

Diagnostic Information 2-37

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4520-xxx

Symptom Table: Paper Trays

Symptom Action

Paper feed problem with 250 Sheet Paper Tray.

Paper feed problem with 500 Sheet Paper Tray.

Media fails to pass thru from the lower attached Paper Tray option to the next higher mounted option.

Go to the “Input Tray(s) Service

Check” on page 2-62.

Symptom Table - Duplex Unit

Symptom Action

• Paper feed problem with Duplex.

• Paper jams at Paper Removal Tray.

• Paper skews in the Duplex Unit.

• Paper fails to pass from lower option thru the Duplex Unit.

Go to the “Duplex Unit Service

Check” on page 2-45.

Symptom Table - Envelope Feeder

Symptom Action

Envelopes do not feed from the envelope feeder.

Envelopes do not feed properly into base printer.

2-38 Service Manual

Go to the “Envelope Feeder Service

Check” on page 2-48.

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4520-xxx

Service Checks

Note: Anytime the engine board is replaced, the Configuration ID must be reset in NVRAM on the new engine board. Go to

Configuration ID” on page 3-20

Review the following information before performing any service checks.

“Setting

• Paper feed problems (especially paper jams): Go to “Viewing the

Error Log” on page 3-10

indications of repetitive entries that help to isolate a problem to a particular area of the printer or option.

and check the printer error log for

• Paper feed problems with error message: Use the “Sub Error

Codes for 9XX and 2XX Error Codes” on page 2-8

the problem.

to help diagnose

• Print quality problems: Go to “Print Quality Test Pages” on

page 3-23

before changing any settings or working on the printer.

and print a test page to help diagnose problems

• Use the resident diagnostics test provided to help isolate a

problem before taking the machine apart or removing any options.

Diagnostic Information 2-39

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4520-xxx

Charge Roll Service Check

Service Tip: Close and evenly spaced repetitive marks 47.19 mm (1.86 inch) apart or spots on the page can be caused by a damaged or contaminated charge roll.

Service Tip: Check to make sure the right charge roll arm bushing is correctly installed and operates correctly.

To remove the charge roll:

1. Wrap a piece of plain white paper around the charge roll to prevent contamination or damage.

2. Carefully remove the roll by pressing outward and to the right on the charge roll link arm and remove the charge roll from the right side charge roll bearing.

3. Remove the charge roll from the left side charge roll bearing and remove the roll from the printer. Leave the paper wrapped around the charge roll until it is reinstalled.

FRU Action

1 Charge Roll Assembly Check the charge roll for correct

installation, toner buildup, marks, cuts or other signs of contamination or damage. Replace as necessary.

2 Left Side Charge Roll Link Check the left side charge roll link

assembly for correct assembly operation. Check for damage to the arm or bearing assembly.

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FRU Action

3 Right Side Charge Roll Link

Right Charge Roll Bushing

Check the right side charge roll link assembly for correct assembly operation. If incorrect, replace the charge roll link assembly with the charge roll link assembly kit. If correct, check the right charge roll link assembly bearing for signs of wear or contamination. Excessive contamination could cause intermittent charging of the charge roll. If incorrect, replace the link assembly. Check for continuity of the right link assembly from the bearing to the charge roll high voltage contact on the right side frame. If incorrect, replace the link assembly.

Make sure the charge roll bushing is installed and operating correctly.

Note: The screw that attaches the charge roll lead to the contact must be secure.

Diagnostic Information 2-41

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Cover Open Switch/Cable Service Check

FRU Action

1 Toner Cartridge Check the toner cartridge to make

2 Cover Open Switch/Cable

Assembly

sure it is correctly installed and that the right and left cartridge tracks are not loose or broken. Check to make sure the cover open switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover open switch spring.

Check the cover open switch for proper mechanical operation. If incorrect, repair as necessary. Disconnect the cover open switch cable from J4 at the engine board and measure the voltage at J4-3. It measures approximately +5 V dc. If the voltage is incorrect, replace the engine board. If the voltage is correct, check the voltage at J4-1. If the voltage measures greater than +1.0 V dc, replace the engine board. If the voltage is correct, check the continuity between J4-1 and J4-3 on the cable. If no change in continuity occurs as the switch is activated, replace the cover open switch/cable assembly. If the continuity changes as the switch is activated, replace the engine board.

2-42 Service Manual

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Dead Machine Service Check

Note: If a high-capacity input tray is installed, remove the option and check the base printer for correct operation. If the base printer operates correctly, go to

Check” on page 2-66

correctly, remove any other attached paper handling options. Observe all necessary ESD precautions when removing and handling the controller board, engine board or any of the installed option cards or assemblies.

Note: If the LVPS is blowing fuses, remove the LVPS from the printer. Check the metal LVPS shield for signs of damage that causes the shield to touch components on the LVPS board assembly.

FRU Action

1 Line Voltage Check the AC line voltage. If the line

2 AC Line Cord Check the line cord for any signs of

“High-Capacity Feeder Input Tray Service

. If the base printer continues to not operate

voltage is incorrect, inform the customer.

damage. If correct, check the continuity of the line cord and replace if necessary.

3 +5 V dc at any Option

Connector

4 +5 V dc at the controller

board test point

5 +5 V dc at the engine board

Tes t Po int

6 LVPS Fuse F1 Remove the LVPS from the printer

Check for +5 V dc on any of the option connectors. The easiest to access is the envelope feeder connector located behind the lower front door. If +5 V dc is present at any of the connectors, go to step 9. If +5 V dc is not present, go to step 4.

Check for +5 V dc at the +5 V dc test pad located on the controller board. If correct, go to step 9.

Check for +5 V dc at the +5 V dc test point on the engine board. If correct, replace the engine board. If incorrect, go to step 6.

and check fuse F1. Replace the fuse, if blown.

Diagnostic Information 2-43

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FRU Action

7 LVPS Fuse F1 - Continues

to blow after LVPS installed in the printer.

8LVPS CAUTION: Before making any

9 Engine Board Turn the printer off and disconnect

Replace fuse F1 if necessary. Turn the LVPS on/off switch off and connect the AC line cord and turn the LVPS on.

CAUTION: Before checking fuse F1 turn the LVPS Off and disconnect the AC line cord. Check fuse F1. If the fuse is blown, replace the LVPS.

measurements on the LVPS output connector, observe all necessary safety precautions before applying AC power. Measure the voltage on LVPS output connector CN3 (Pin 1, 2, 10, or 11). The voltage measures +5 V dc. If incorrect, replace the LVPS.

all the cables from the engine board. Check for +5 V dc at the engine board test point. If incorrect, replace the FRUs in the following order:

1. Engine board

2. Interconnect board If correct, turn the printer off and

reconnect one cable at a time until you find the defective assembly.

2-44 Service Manual

Service Tip: A short or low resistance load that is attached to the engine board can cause the LVPS to over-current and shut the +5 V dc supply down to 0 V dc.

Page 73

4520-xxx

Duplex Unit Service Check

The printer does not recognize the Duplex Unit is attached. The

printer does not recognize tray options below the duplex unit are installed.

FRU Action

1 Fuse F1 on Duplex Unit

System Board

2 Autoconnect Cables/

Connectors

If fuse F1 is blown, replace the fuse. If fuse F1 continues to blow, check the stepper motor for a short between the motor case and pins J3-1 through J3-4. If no problem is found, check the D.C. servo motor pins J1-1 and J1-2 to the motor housing for a short. If a short is found, replace the motor assembly. If no short is found, replace the system board.

Check the autoconnect cables for damage to the cables or the pins in the connectors. If damaged, replace the cable(s). If no damage is found, check to make sure the cables are connected to J9, J10, J11 and J12 on the duplex system board. If no problem is found, replace the duplex system board.

Diagnostic Information 2-45

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POST fails, 230 Paper Jam, Check Duplex message displays.

FRU Action

1 Duplex D.C. Servo Drive

Motor

2 Input Sensor, Input Sensor

Flag

3 Paper Exit Sensor and Flag Check the duplex exit sensor for

Check the D.C. servo motor cables for signs of cuts or other damage. Check the D.C. servo motor sensor cable connector for pin damage. If no problem is found, replace the FRUs in the following order:

1. D.C. motor assembly

2. Duplex unit system board

Run the Duplex Sensor Test from the diagnostics menu. If the test fails, check the input sensor cable at J5 on the system board for correct installation. If no problem is found, replace the FRUs in the following order:

1. Input sensor assembly

2. Duplex unit system board

correct installation and free movement of the sensor flag. Check to make sure the sensor cable is connected to J8 on the system board. If no problem is found, replace the FRUs in the following order:

1. Exit sensor assembly

2. Duplex unit system board

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230 Paper Jam - Check Duplex message displays. The page is not duplexed and only exits half way out of the redrive.

FRU Action

1 Duplex Stepper Motor Check the stepper motor cable for

cuts or pinched wiring. Check the routing of the motor leads along the left side of the bottom tray. Check for correct installation of the motor cable connector at J3 on the system board. Check for any shorts between each pin of the motor cable and the motor housing. If shorts are found, replace the motor. Check the resistance of the stepper motor between J3-1 (Stpmtr A-) to J3-2 (Stpmtr A+). The resistance measures approximately 10 ohms. The resistance between J3-3 (Stpmtr B-) to J3-4 (Stpmtr B+) measures approximately 10 ohms. If the resistance is incorrect, replace the stepper motor. Check for shorts between windings on pins J3-1 to J3-2 and pins J3-3 to J3-4. If a short is found, replace the stepper motor assembly. If no short is found, replace the duplex system board.

Diagnostic Information 2-47

Page 76

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Envelope Feeder Service Check

Service Tip: Check the envelope feeder paper path for any debris, pieces of envelope and so on. If any other options are installed make sure they are operating normally. If only the envelope feeder is failing to operate correctly, continue with this service check, otherwise verify the interconnect card is functioning properly.

Service Tip: The envelope feeder receives its +5 V dc operating voltage from the +24 V dc bulk at J1-7. If +24 V dc is not present at J1-7, tray 1 is the only tray that is recognized.

Note: If a 260 Paper Jam Check Envelope message displays, check the

“Sub Error Codes for 9XX and 2XX Error Codes” on page 2-8.

Printer does not recognize the envelope feeder as an attached input option.

FRU Action

1 Envelope Feeder Check to make sure the envelope

2 Front Autoconnect on

Printer

feeder is correctly installed and mated to the autoconnect at the front of the printer.

Check the connector for signs of damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Remove the envelope feeder and check the voltages at the autoconnect on the front of the printer. If incorrect, check the interconnect board. If correct, reinstall the envelope feeder and continue with step 3.

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FRU Action

3 Autoconnect on the

Envelope Feeder.

Check for any signs of damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages:

J1-3 measures +5 V dc J1-5 measures +5 V dc J1-7 measures +24 V dc

If any of the voltages are incorrect, replace the autoconnect cable/connector. If the voltages are correct, replace the envelope system board.

Diagnostic Information 2-49

Page 78

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Operator panel displays 260 Paper Jam immediately when envelope feed is requested - POST incomplete.

FRU Action

1 Pass thru Sensor Check for any debris, pieces of

envelope and so on over the pass thru sensor. Check for correct installation of the pass thru sensor flag. Make sure the sensor cable is attached to the envelope system board. Perform an envelope feeder sensor test to check both the sensor and sensor flag.

Note: It may be necessary to use a small tool to actuate the sensor flag because it is located under the front cover. Be careful not to damage the flag.

If the test fails, check the flag for any signs of damage or binds. If incorrect, replace the flag. If the flag is operating correctly, check the voltage at J3-3. The voltage measures approximately +5 V dc. If incorrect, replace the envelope system board. If correct, check the voltage at J3-2. The voltage changes from 0 to +5 V dc when the flag is moved in and out of the sensor. If incorrect, replace the sensor assembly. If this does not fix the problem, replace the envelope system board.

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Operator panel displays 260 Paper Jam after attempted feed but before envelopes are put in the hopper OR the operator panel continues to display "Load Envelopes" after envelopes are placed in the hopper.

Service Tip: The kick rolls rotate during the attempted feed cycles.

FRU Action

1 Envelope Out Hopper

Sensor Flag

2 Envelope Out Hopper Input

Sensor

Check the envelope out sensor flag for damage, correct installation and operation. If incorrect, repair or replace the flag.

Check the sensor to make sure it is installed correctly and the sensor cable is properly connected to the envelope system board. If correct, perform the Envelope Feed Sensor Test to check both the sensor and flag. If the test fails, remove any envelopes in the hopper, turn the printer off and disconnect J3 from the system board. Turn the printer on and check the voltage at J3-3 on the system board. The voltage measures approximately +5 V dc. If incorrect, replace the envelope system board. If correct, replace the input sensor assembly.

Diagnostic Information 2-51

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990 Service Error, envelopes fail to feed from the hopper.

FRU Action

1 D.C. Feed Motor Assembly Check the motor and motor cable for

2 Envelope Feeder System

Board

any signs of loose wires or poor connections. Check to make sure the motor cable is connected to the envelope system board.

Check the voltage on J4-1. The voltage measures approximately +24 V dc. If incorrect, replace the envelope system board, if correct, measure the voltage at J4-6. The voltage measures approximately +5 V dc. If incorrect, disconnect J4 and measure the voltage again. If incorrect, replace the envelope feeder system board. If correct, replace the D.C. motor assembly.

260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper. Kick rolls are not rotating.

FRU Action

1 Main Drive Belt Check the belt for correct installation

and for signs of damage. Replace as necessary.

2 Gears Check all the gears for correct

3 Clutch Latch Assembly Check the clutch latch assembly to

4 Master Cam Gear Master/

Kick Gear

installation and for signs of damage. Repair or replace parts as necessary.

make sure it moves freely.

Check the master cam gear and master/kick gear to make sure they rotate together. If not, then the tenons on the master kick gear may be sheared off. If incorrect, replace the master kick gear.

2-52 Service Manual

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260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper. Kick rolls are rotating.

Check the deflector gap adjustment before continuing this service check.

FRU Action

1 Deflector Gap Adjustment Check the deflector gap adjustment.

The adjustment may be too narrow.

2 Weight Assembly Check the weight assembly to make

3 Envelope Edge Guide Check the envelope edge guide to

sure it moves up and down freely without any binds. Also check to make sure the weight assembly rests on all the rear kick rollers when the hopper is empty. Replace the weight assembly if it is damaged or does not operate properly.

make sure it is not warped or set too close to the envelopes in the hopper. Replace the edge guide if it is damaged or does not operate properly.

Diagnostic Information 2-53

Page 82

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260 Paper Jam displays, envelope stops in feeder paper path.

FRU Action

1 Kick Rolls/Feed Rolls/Drive

Rolls

2 Deflector Gap Adjustment Check the deflector gap adjustment.

Check all the rolls for any signs of oil, grease or other contamination. If you find a problem, clean the rolls. If this does not correct the problem, replace the envelope feeder.

The adjustment may be too narrow.

Envelope Feeder multifeeds or may not display a 260 Paper Jam message.

FRU Action

1 Envelopes Check the envelopes being used in

2 Deflector Check the deflector gap adjustment.

3 Restraint Roll Bias Spring Check for a missing, broken or

the feeder. Check for signs of the envelopes being stuck together or signs of glue. Check to make sure the flaps are not interleaved.

The adjustment may be too wide.

incorrectly installed restraint roll bias spring. If incorrect, reinstall or replace the spring.

260 Paper Jam displays, an envelope stopped in the paper path of the feeder and an envelope also stopped in the base printer paper path.

FRU Action

1 Latch Lever Check to make sure the tip of the

latch lever is centered in the opening in the floor of the paper path. The latch lever may not be detented on the latch.

2-54 Service Manual

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4520-xxx

Main Fan Service Check

Check the cable connections at J1 on the engine board and at the main fan assembly. The main fan runs continuously when the printer is powered on unless the printer is in the Power Saver mode.

FRU Action

1 Main Fan Manually spin the fan and check that

it rotates freely. Check the cable connection to the engine board, J1 for correct installation.

2 Main Fan to Engine Board

Cable

3 Error Code 927 (Fan runs) Check the voltage at J1-1 on the

4 Error Code 927

(Fan not running)

Check the continuity of the cable. If incorrect, replace the cable.

engine board. The voltage measures +5 V dc (static) 0 V dc (fan running). If incorrect, replace the main fan. If this does not fix the problem, replace the engine board.

Check the voltage at J1-3 on the engine board. The voltages are:

+22 V dc to +24 V dc (printer and fan running)

+12 V dc to +15 V dc (printer not running - fan running about half speed).

If incorrect, replace the engine board. If this does not fix the problem, replace the main fan.

Diagnostic Information 2-55

Page 84

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Fuser Service Check

Cold Fuser Service Check

Error codes 920, 921, and 922 may display for a cold fuser failure. A 920 error caused by low line voltage can sometimes be cleared by turning the machine off and then on again. A 925 service error indicates the wrong fuser lamp is installed. Be sure the correct type of fuser lamp is installed in the printer.

If the correct lamp is installed and a 925 error remains, the problem may be due to the following:

• The fuser may have reached standby temperature too quickly.

• The line voltage may be above the maximum rating for the

printer.

Note: A 920, 921 or 922 fuser error may be caused by an incorrectly mounted thermistor.

Service Tip: Set the Fuser Temperature to NORMAL before starting this service check.

FRU Action

1 Fuser Lamp (Incorrect

Lamp/925 Service Error)

2-56 Service Manual

Install the correct voltage and wattage lamp or fuser assembly.

If the correct fuser lamp is installed and the 925 error remains, the fuser may have reached standby temperature too quickly. Check that the line voltage is not exceeding the maximum rating for the printer.

Page 85

4520-xxx

FRU Action

2 Fuser Lamp

Fuser Top Cover Assembly

3 LVPS

LVPS to Fuser AC Cable

Remove the controller board. Run the Diagnostic Print Test and observe the lamp through the left side frame. If the lamp does not come on, do the following:

• Remove the redrive assembly.

• Remove the fuser assembly, disconnect the LVPS to fuser AC cable from the fuser assembly and remove the fuser.

• Verify that the lamp is installed correctly. If correct, check the continuity of the fuser top cover assembly by verifying the lamp contacts on the right contact assembly. If incorrect, check continuity of the fuser lamp. If incorrect replace the lamp. If correct replace the fuser top cover assembly.

Caution: When taking measurements for AC power, observe all safety precautions.

Measure the AC line voltage between the two connectors on the fuser end of the LVPS to fuser AC cable. If the voltage is incorrect, turn the power off, and remove the LVPS. Measure the AC line voltage between pins CN1-1 and CN1-3 on the board. If correct, check the continuity of the LVPS to fuser AC cable. If incorrect, replace the cable.

4 Fuser Top Cover Assembly

(Thermal Fuse/Thermistor Assembly)

If the AC line voltage at CN1 is incorrect, check fuse F2. If the fuse is blown, replace the fuse. If the fuse is not blown, replace the LVPS assembly.

Disconnect the thermistor cable from the fuser board at J2. Resistance:

• HOT J2-1 - J2-2 = 2.5K ohms

• COLD 150K ohms to 260K ohms

Diagnostic Information 2-57

Page 86

4520-xxx

Hot Fuser Service Check

Error Code 923: Indicates the fuser is too hot during printing or when the printer is idle.

Error code 924: Indicates an open circuit has been detected in the fuser thermistor circuit.

Note: Check the fuser sub error codes to help diagnose between a 923 and 924 error.

CAUTION: The fuser may be hot, use caution before removing or servicing.

FRU Action

1 Fuser Cover Assembly

(Assembly includes Thermistor and Thermal Fuses.)

2 Fuser Control Board Check for continuity between J6-1

3 Fuser to Engine Board DC

Cable

Check for damage to the thermistor assembly. If damage is found, replace the fuser top cover assembly. If no damage is found, check the resistance of the thermistor between pins J6-1 and J6-2 on the cable.

• HOT = 2.5K ohms

• COLD =150K ohms to 260K ohms

If the resistance is incorrect, replace the fuser top cover assembly. If the resistance is correct, check each pin of J6 to ground. If there is continuity, replace the fuser cover assembly

and J1-2 and between J6-2 and J1-3. If incorrect, replace the fuser control board. If correct, go to step 3.

Check the continuity of the cable. If incorrect, replace the cable. If correct, go to step 4.

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FRU Action

4 Engine Board Perform the print test with the RIP

5 Fuser Hot Roll

Fuser Hot Roll Bearings Fuser Backup Roll Bearings Fuser Backup Roll Fuser Mechanical Parts

controller board removed.

Check the voltage on J16-3 on the engine board. The voltage should measure approximately 1.6 V dc as the thermistor goes from cold to hot. If incorrect, replace the engine board. If correct, go to step 5.

Examine the fuser assembly for signs of overheating or damage. Check the hot roll and backup roll for signs of excessive toner, label glue, labels or other contaminants. If problems are found with the hot roll or backup roll, replace the failing roll. If other problems are found, replace the fuser assembly.

Diagnostic Information 2-59

Page 88

4520-xxx

Fuser Solenoid Service Check

Service Tip: Try changing the envelope enhance level setting. A different setting may correct the problem.

Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section

page 4-3

FRU Action

“Fuser Solenoid Adjustment” on

1 Fuser Envelope Conditioner

Solenoid

2 LVPS Check the voltage at CN3-18 on the

3 DC Fuser to Engine Board

Cable

4 Fuser Control Board Check for continuity between J4-2 and

5 Interconnect Board

Engine Board

The operation of the fuser solenoid can be observed by removing the redrive assembly. Check for proper mechanical operation of the solenoid and associated hardware, link and so on. If correct, check the resistance of the solenoid between J4-1 and J4-2 on the fuser control board. The resistance measures between 5 ohms and 10 ohms. If incorrect, replace the solenoid assembly.

LVPS. The voltage measures approximately +42 V dc. If incorrect, replace the LVPS.

Check the continuity of the DC fuser to engine board cable. If incorrect, replace the cable.

J1-5 and J4-1 and J1-7 on the fuser control board. If incorrect, replace the fuser control board.

If no problems are found with the fuser solenoid, LVPS, DC cable or fuser control board, replace the FRUs in the following order:

1. Engine board

2. Interconnect board

2-60 Service Manual

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Input Sensor Service Check

Service Tip: Run the Base Sensor Test. Check the input sensor for proper operation. The display changes from open to closed as the sensor flag is manually moved in and out of the sensor.

Service Tip: Run a Diagnostic Print Test in the continuous mode with the controller board removed. A defective input sensor or circuit causes the first copy to exit only partially through the fuser assembly.

FRU Action

1 Input Sensor Flag Check the input sensor flag for

damage and proper operation. If a problem is found, repair as necessary.

2 Engine Board Check for approximately +5 V dc at

3 Input Sensor Cable Check the continuity of the input

J10-10 on the engine board. If incorrect, replace the engine board.

sensor cable section of the front wiring harness. If incorrect, replace the harness. If correct, replace the input sensor assembly.

Diagnostic Information 2-61

Page 90

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Input Tray(s) Service Check

250-Sheet and 500-Sheet Trays

Service Tip: Try all the other input paper sources to make sure they are properly feeding paper.

For 990 Error Code- Service Tray X, X= displays the number of the tray that has a problem or needs service.

FRU Action

1 Tray X Option System

Board or Compensator Assembly or Autoconnect Cable

Check the autoconect cables and connectors for any signs of damage. Replace if necessary. Check the cables for continuity. If incorrect, replace the compensator assembly cable. If the cables, connectors and connections are good, replace the FRUs in the following order:

1. Autocompensator assembly option

2. Option System board

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24X Paper Jam message displays, Paper jammed over the Pass Thru Sensor. (The printer displays the value of X for the paper tray

where the error occurs. Example: 241 is a Paper Jam Tray 1)

FRU Action

1 Pass Thru Sensor and Flag

Assembly

2 Power Takeoff Shaft and

Spring, Bevel Gear, Feedroll Gear, Drive Roll Assembly, Wear Plate, Drive Shaft Bearings and Skewed Backup Roller

The tray x option system board did not detect a piece of paper actuating the pass thru sensor. Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu. If the test fails, check the sensor for correct installation and the flag for proper operation. Also check the sensor cable to make sure it is correctly connected to the option system board. If incorrect, replace the tray x option pass thru sensor assembly.

Check these parts for signs of broken or damaged parts, contamination on the drive rollers or wear plate and wear or damage to the drive shaft bearings. Check the drive roll assembly and skewed backup roller for signs of wear, slick spots, material buildup, and oil or grease on the rollers. Also check for proper operation of the paper aligning assembly. Repair or replace parts as necessary.

Diagnostic Information 2-63

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Tray X Low message displays when Tray X is full or has adequate paper in the tray.

FRU Action

1 Paper Low Sensor

Assembly Paper Low Sensor Flag Tray X Option System Board

Run the Tray X Sensor Test and check the sensor for proper operation. If incorrect, check the following:

Paper low sensor flag for smooth and correct operation.

Paper low sensor for correct installation on the autocompensator housing.

Paper low sensor cable for signs of cuts, pinched wiring or other damage especially at connector J5 on the system board.

If no problem is found, replace the paper low sensor assembly. If this does not correct the problem, replace the option system board.

Tray X Empty message displays when Tray X has paper in the tray.

FRU Action

1 Paper Out Sensor Flag Check the paper out sensor flag for

2 Paper Out Sensor (On

Option System Board)

correct operation and installation. If correct, replace the option system board. (The paper out sensor is mounted on the system board).

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Printer does not recognize Tray X is installed.

FRU Action

1 Autoconect Cables

Tray X System Board

Check the autoconnect from the printer or option above tray x. Check for signs of cuts, pinched wiring or damage to the contacts in the connector. Check the autoconnect cable(s) for correct installation at the tray x system board. If correct, check the continuity of the autoconnect cable(s). If correct, replace the tray x system board. If incorrect, replace the cable.

Paper from Tray X does not reach the Pass Thru Sensor.

Service Tip: Check the media in tray x to make sure it is within specifications. Some types of labels, foil material and slick papers can cause misfeeds and slippage of the rollers.

FRU Action

1 Autocompensator

Assembly

Check the autocompensator pick arm rollers for any sign of glazing, toner or other buildup. Clean or replace as necessary.

Diagnostic Information 2-65

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High-Capacity Feeder Input Tray Service Check

Note: Voltage measurements in the high capacity feeder input tray service checks must be made with the high-capacity feeder attached to the base printer to obtain accurate results.

Service Tip: Be sure the paper size switch is set to the correct paper size setting and the rear paper guides are in the correct locations for the size of paper installed in the high-capacity feeder tray.

Service Tip: Check the other paper sources to be sure they are operating correctly.

The base printer indicates a dead machine condition when the high capacity input tray is installed.

FRU Action

1 AC Line Cord

AC Jumper (HCIT to Printer) AC input and Output Receptacles AC Wiring Harness

If the base printer works normally using the AC line cord from the AC wall outlet and does not work when using the AC jumper from the HCIT, check the AC jumper cord. If defective, replace the cord. If not defective, check the AC input and output receptacles and wiring harness in the HCIT. Repair or replace the receptacles or AC wiring harness as required.

NOTE: Make sure the ground wire is installed correctly from the AC wiring harness to the frame of the HCIT and the nut and lock washer are tightened.

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The base printer does not recognize that the high-capacity input tray is installed.

FRU Action

1 High-Capacity Feeder

Autoconnect Mechanical Check

2 Base Printer or option

mounted above

3 LVPS

Option System Board

Check the high capacity feeder input tray to make sure it is mounted correctly and is not pushed down into the frame assembly or damaged. Be sure the high capacity feeder input tray autoconnect is properly connected to the high capacity feeder tray option board assembly.

Check the option or base printer autoconnect for signs of damage. Repair the high capacity option autoconnect as necessary.

Check the voltages at J11-2 and J11-4. The voltage measures +24 V dc, If the voltage is correct, replace the high capacity system board assembly. If the voltage is incorrect, check the continuity of the AC input cable to the LVPS. If correct, replace the LVPS assembly. If incorrect, replace the AC cable to the input of the LVPS.

Diagnostic Information 2-67

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FRU Action

4 High Capacity Feeder

Option Control Board

Check the voltage on J8-1 (green). The voltage measures +24 V dc. If incorrect, check the autoconnect system for any problems. +24 V dc must come from the base printer through the autoconnect system to the high capacity input for the high capacity feeder to be recognized. If the voltage is correct, check the voltages at J11-3(red) and J114(red). The voltages measure +24 V dc. If correct, replace the high capacity feeder option system board. If incorrect, disconnect J8 from the system board and measure the voltages again. If incorrect, check the LVPS cable and the A.C. internal wiring from the input appliance receptacle. If incorrect, replace as necessary. If correct, replace the LVPS. If the voltages are correct, check the stepper motor for shorts from the motor housing to each pin on the motor connector. If you find a short between any pin and the motor housing, replace the motor assembly. If no shorts are found, replace the high capacity feeder option control board.

2-68 Service Manual

Check the voltage at J9-1 (light blue). The voltage measures approximately +24 V dc. If incorrect, disconnect the cable at J9 and check the voltage again. If the voltage continues to be incorrect, replace the high capacity feeder option system board. If the voltage measures correctly, check the cable. If the cable is damaged, replace as necessary. If no problem is found with the cable, replace the high capacity feeder option control board.

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24X Paper Jam message displays, Paper jammed over the Pass Thru Sensor. (X=The printer displays the value of X for the paper tray

where the error occurs. Example: 242 is a Paper Jam Tray 2)

FRU Action

1 Pass Thru Sensor and Flag

Assembly

2 Power Takeoff Shaft and

Spring, Bevel Gear, Feedroll Gear, Drive Roll Assembly, Wear Plate, Drive Shaft Bearings and Skewed Backup Roller

Diagnostic Information 2-69

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Tray X Paper Low Message displays when Tray X is full or has adequate Paper in the tray.

FRU Action

1 Paper Low Switch

Paper Low Switch Cable High Capacity Feeder Input System Board

Run the sensor diagnostics for tray X (X=the number that represents the high capacity input tray). If the test fails, disconnect the paper low switch cable from J3 on the high capacity system board. Short pins 1 and 2 together while observing the sensor test on the display. If the display does not change, replace the high capacity feeder system board. If the display changes check the continuity of the switch. If incorrect, replace the switch. If correct, replace the switch cable.

Tray X empty message displays when there is paper in the high capacity feeder input tray.

FRU Action

1 Paper Out Sensor Flag Check the paper out sensor flag for

2 Paper Out Sensor

(On Option System Board)

correct operation and installation. If correct, replace the high capacity feeder system board. (The paper out sensor is mounted on the high capacity feeder system board).

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The elevator tray fails to stop at the correct position and continues to drive into the bottom frame.

FRU Action

1 Lower Limit Switch

Lower Limit Switch Cable

2 High-Capacity Feeder

Control Board

Check continuity of the lower limit switch. If incorrect, replace the switch. If correct, check the switch cable. If incorrect, replace the cable. If correct, replace the high capacity feeder option control board.

Disconnect the lower limit switch cable and check the voltage at J2-1 (orange). The voltage measures approximately +5 V dc. If incorrect, replace the high capacity feeder option control board.

The elevator tray down button does not operate. The tray moves to the upper position.

Service Tip: Open the high-capacity feeder front door and check the black rubber bumper attached to the door switch spring. Be sure the rubber button is centered and not touching the sides of the hole or the switch will not function properly.

FRU Action

1 Lower Limit Switch

Lower Limit Switch Cable High-Capacity Feeder Control Board

Check the lower limit switch to make sure it is not closed (normally open). If incorrect, replace the switch. Check the lower limit switch cable for a short between pins 1 and 2. If incorrect, replace the cable. If correct, replace the high capacity feeder control board.

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Paper from the high capacity feeder input tray does not reach the pass thru sensor.

Service Tip: Be sure the paper in tray is within specifications.

FRU Action

1 Autocompensator

Assembly

2 Wear Strips Check the wear strips for glazing or

Check the autocompensator pick arm rollers for sign of glazing, toner or other buildup. Replace as necessary.

contamination. Replace as required. It is advisable to replace all four wear strips at the same time.

The elevator tray does not move up or down. The printer recognizes that the option is installed.

FRU Action

1 DC Drive Motor High-

Capacity Feeder Option System Board

Be sure the motor cable is correctly installed at J1 on the board. Check the cables, damaged or loose wires. Disconnect the motor. Check for a short between each pin and the motor housing. If a problem is found, replace the motor assembly. If no problem is found, measure the resistance between the following pins on the motor cable connector:

Pins 1 (brown) and pin 2 (Yellow)

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The resistance measures between approximately 7.5 and 10.5 ohms. If incorrect, replace the motor assembly. If correct, replace the high capacity feeder option system board.