Lexmark X295 Service Manual

Revised: December 17, 2013

• Table of contents

• Start diagnostics

Lexmark™ X925

7541-03x

• Safety and notices

• Trademarks

• Index

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

Edition: December 17, 2013

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 D22X/002-1, 740 West New Circle Road,
Lexington, Kentucky 40550, U.S.A or e-mail at [e-mail]. Lexmark may use or distribute any
of the information you supply in any way it believes appropriate without incurring any obligation to you.

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

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

Optra Forms is a trademark of Lexmark International, Inc.

PostScript® is a registered trademark of Adobe Systems Incorporated.

PCL® is a registered trademark of the Hewlett-Packard Company.

All other trademarks are the property of their respective owners.

© 2006 Lexmark International, Inc.
All rights reserved.

UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are commercial computer software
and documentation developed exclusively at private expense.

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P/N 12G0474

7541-03x

Table of contents

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xviii

Navigation buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-xviii

Change history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-xix

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

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

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

Printer configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Options and features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Print engine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Power specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Paper specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Paper sizes supported by the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Media types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Media weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Media guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Paper characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Unacceptable paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Selecting paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Scan fax and copy specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Fax features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Scanner specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

MFP scan speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

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

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

Safety feature notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Flatbed / ICC card NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Initial check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

POR (Power-On Reset) sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Print quality issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Repeating defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

One color missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Contaminated background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Lowered print density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

White stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Uneven print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Partial dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Repeating marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

iii

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Black stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Unprinted spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Partially dark or light print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Black page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

No print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Stain on back of page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Failure to fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Stains on edge of page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

ADF & scanner print quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Image quality symptoms: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Dark image quality (using ADF or Scanner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Vertical lines (process direction using the ADF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Spots (using flatbed scanner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Skew (using ADF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Media damage (using ADF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Black page from scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

Paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

Clearing and troubleshooting paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

200 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

201 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

203 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

230 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

231-39 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

24x paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

250 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Duplex unit service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Paper path service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

Paperfeed unit service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

MPF service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

Clearing and resolving scanner jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

280.06 Paper missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

283.01 Scanner static jam - Scan sensor jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

283.05 Scan sensor jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

285.05 Scanner ADF eject jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

290.11 Scanner ADF cover open jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

291.06 Flatbed cover open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

292.01 Scanner carriage locked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

ADF paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

149.01 Abnormal exit motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

941.05 Abnormal EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

950.xx Service NCVRAM Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

952.xx Service NV Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

953.xx Service NVRAM Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

954.xx Service NVRAM Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

955.00 Service Code CRC <loc> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

956.xx Service System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

957.xx Service System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

958.xx Service NAND Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

959,xx Service Invalid Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

960.xx Service Memory Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

961.xx Service Memory Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

964.xx Service Emulation Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

975.xx Standard network or Network Card X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

976.xx Standard network or Network Card X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

982.xx Service <device> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

990.xx Service <device> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

991.xx Service <device> Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

Fax T30 log error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

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Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

111.01 Black printhead error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

112.01 Cyan printhead error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

113.01 Magenta printhead error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

114.01 Yellow printhead error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

121.01 Thermistor 1 error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

121.02 Thermistor 2 error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

121.03 Thermistor 3 3 error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

121.04 Belt thermistor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

121.05 Fuser - fuser heater error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

ON / OFF switch automatically switching to the Off position service check . . . . . . . . . . . . . . . 2-48

126.xx Power switch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

130.xx High voltage power supply error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

132.00 Density sensor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

132.xx Abnormal theta sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

136.xx Temperature humidity sensor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

140 Drive motor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

149.01 Fuser / paper exit motor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

146.01 Tray1error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

146.03 Tray 3 error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

146.04 Tray 4 error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

146.05 Tray 5 error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

171.01 Fuser fan error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

172.01 - Power supply unit fan error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

173.01 - Main unit fan error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

174.01 Rear fan error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

840.03 service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

841.00 Invalid configuration or ASIC not found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

841.01 Invalid AFE setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

841.02 Delayed interrupt detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

841.03 Failed indirect register test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

841.04 Failed external DRAM test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

841.05 Image pipe time-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

841.06 Scanner did not initiate scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

842.00 No response / 842.01 HW protocol / 842.02 Logical protocol . . . . . . . . . . . . . . . . . . . . . 2-58

843.00 Carriage Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

844.00 Lamp failure (Front side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

849.01 Device had modem installed, but config ID indicates it should not . . . . . . . . . . . . . . . . 2-59

849.10 Device had HD installed, but config ID indicates it should not . . . . . . . . . . . . . . . . . . . . 2-59

Steps before starting the 9yy service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

A. Collecting the history information from the SE menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

B. Collecting the firmware logs (Fwdebug and logs.tar.gz) from the SE menu . . . . . . . . . . . . . 2-60

C. Collecting the settings from the menu settings page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

D. Collecting information from the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

900.xx System software error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

941.01 SDRAM R/W error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

941.02 MDC error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

941.03 CPU error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

941.04 MDC controller error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

941.05 EEPROM error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

950.00–950.29—EPROM mismatch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

959.xx Service invalid firmware error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

User attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

User prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

User attendance messages (0–99) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

Other symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

Print engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

Scan / copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79

ADF streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79

v

7541-03x

Clipped image when scanning to USB from the ADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79

ADF cover open service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

Fax symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-81

Faxes fail to transmit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81

Fax reception fails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-83

Escalating a fax issue to second-level support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-85

Words on fax are stretched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-86

Incoming fax has blank spaces or poor quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-86

No dial tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

Fax dials a number, but no connection is made . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

Other service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-87

Networking service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-87

Option card service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89

USB port service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-89

False close door service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-89

Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-90

Display functions but the keyboard doesn’t work properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

Display fails to illuminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

Insert tray service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-91

Paper skew service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

Imaging unit (photo developer) missing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

Option card service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-93

Serial port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93

Flash options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93

DRAM options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93

Hard disk option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-94

Network card option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94

Error code 976 - Network card x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-94

54 Network <x> Software error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-94

Power supply (Dead machine) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

Printhead service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-96

Transfer belt up down check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-96

Unable to print from USB thumb drive service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-97

Waste toner bottle missing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-97

Wrong paper size service check - tray1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98

Wrong paper size service check - tray2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98

Paper in ADF size service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-99

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

Understanding the operator panel and menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Operator panel (need new art) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Understanding the home screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Using the touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Administrative menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Accessing the service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Entering Config Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Reset Separator Roll and Pick Assembly Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Reset Fuser Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Reset Maintenance Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Reset Transfer Belt Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

USB Scan to Local . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Black Only Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Print Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Fuser Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Color Trapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Tray Insert Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

SIZE SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

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Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Download Emuls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Fax Low Power Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Min Copy Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

NumPad Job Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Format Fax Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Fax Storage Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Auto Align Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Color Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

ADF Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

FB Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Scanner Manual Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Disable Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Paper Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Envelope Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Action for Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Jobs On Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Disk Encryption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Erase all information on Disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Wipe All Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Font Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Require Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

UI Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Key Repeat Initial Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Key Repeat Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Clear Custom Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

USB Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

USB PnP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Automatically Display Error Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Exit Config Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Entering Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Diagnostic mode menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

SCANNER CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Adjust Calibration Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Reset Calibration Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

PRINT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Print Tests (input sources) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Print Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

HARDWARE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Serial Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

USB HS Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

DEVICE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

PRINTER SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

PAGE COUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Engine Setting (1-16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

vii

7541-03x

Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Cal Ref Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Par 1 Strobe Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

REPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Print Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Clear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

SCANNER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Scanner Calibration Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

ASIC Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

ADF Magnification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

EXIT DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Printer engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

Electrophotographic Process (EP Process) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

MFP electrophotographic process basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Step 1: Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

Step 2: Expose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Step 3: Develop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Step 4a: First transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Step 4b: Second transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Step 5: Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Step 6: Clean/Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

Paper path components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

Paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

Feeding paper from a tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Feeding paper from the MPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Duplex ADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44

Color theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

What is RGB color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

What is CMYK color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47

How is color specified in a document to be printed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

How does the printer know what color to print? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Should I use PostScript or PCL emulation? What settings produce the best color? . . . . . . . . . 3-47

Why doesn't the printed color match the color I see on the computer screen? . . . . . . . . . . . . .3-47

The printed page appears tinted. Can I adjust the color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

My color transparencies seem dark when they are projected. Is there anything I can do to improve the

color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

What is manual color correction? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48

How can I match a particular color (such as a corporate logo)? . . . . . . . . . . . . . . . . . . . . . . . . 3-48

What are detailed Color Samples and how do I access them? . . . . . . . . . . . . . . . . . . . . . . . . .3-49

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

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Flatbed / ICC card NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

RIP board/operator panel replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Printhead controller board / engine board replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

eSF solutions backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

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

Arrangement of removals in this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Cover Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

RIP cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Scanner power supply access cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Cord cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

viii Service Manual

7541-03x

Rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Front op panel cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Op panel top cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Op panel bottom cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Upper right cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Output bin (print engine top) cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Back cave cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Inner right cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Speaker removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Top removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Output bin full sensor actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

LED assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

LED print head removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Op panel paper exit guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Paper exit guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Bin full sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

Paper exit sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Printhead controller board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Top EMI sheild removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Front removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Transfer belt – CRU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Transfer belt position sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Paper size sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Photoconductor lock removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Cassette stopper removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Left side removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Left EMI shield removal (not a FRU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Low volt power supply removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Main fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Power supply fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Theta sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

Density sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Scanner power supply removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Right side removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

Fuser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

Handle cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62

Duplex removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

Paper feed unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

Transfer Roll - CRU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72

Rear removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

RIP board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Crossbar removal (not a FRU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74

Engine board and mount removal (not a FRU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

Drive unit cover (not a FRU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Drive unit motor C/M/Y/K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83

Sub drive unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

Door interlock switch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89

Duplex solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90

Fuser entry sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91

Engine board (MDCONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92

Fuser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92

Fuser exit drive unit motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93

Modem removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94

Papertray lift motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94

RIP cage removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95

Toner sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97

ix

7541-03x

Transfer belt motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-100

Temperature and humidity sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-101

Rear fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-102

Sub frame unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-104

Paper size switch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-105

Rear EMI shield – Not a FRU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106

Paper feed motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-110

HVPS removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-111

Waste toner sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-112

Scanner area removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-113

ADF assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-113

ADF pick roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-114

ADF separator roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-115

Flatbed assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-116

Flatbed front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-117

UICC removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-120

Touchscreen assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-121

ADF relay board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-122

ICC board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-123

CCD chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-124

CCD belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-126

Optical paper size sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-127

ADF cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-128

ADF motor frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-129

ADF solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-132

ADF drive clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-132

ADF input tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-133

ADF main feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-134

ADF clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-137

ADF hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-137

FB hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-138

Tray paper size sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-138

ADF cover open / ADF pick sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-142

ADF cover open sensor actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-143

Paper present / paper in sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-144

Paper present sensor actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-145

Paper in sensor actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-145

Paper path sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-146

Scan sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-146

Scan sensor actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-148

Scan sensor cover (not a fru) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-149

Duplex timing sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-152

Duplex out (scan out) sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-157

Duplex out sensor actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-158

Flatbed cover closed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-159

Flatbed upper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-161

Outer ADF top cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-163

Inner ADF top cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-164

ADF relay card cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-167

Left ADF cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-167

Right ADF cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-170

Duplex unit component removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-172

Duplex clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-172

Duplex timing belt removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-173

Duplex exit / MPF sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-173

MPF clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-174

MPF tray assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-175

Paperfeed unit component removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-177

Separating the MPF tray and main tray paperfeed units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-177

x Service Manual

7541-03x

Main tray paper guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-178

Multi-purpose feed tray paper guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-180

Paperfeed unit clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-183

Registration sensor (MPF tray) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-184

Registration sensor actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-184

Static discharge brush removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-185

Torque limiter removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-185

Upper and lower registration springs removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-185

Paperfeed maintenance kit removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-187

Pick roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-187

Paperfeed roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-187

Separator roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-188

Registration roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-189

MPF roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-190

MPF pad removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-192

Exit guide (paper exit) roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-195

Option paper feed removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-201

Paper feed roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-201

Pick roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-201

Separator roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-202

Paper size switches removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-202

Paper level sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-203

Transport sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-203

Paper empty sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-204

Paper full sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-204

Option controller board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-205

Stepper motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-205

Tray lift motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-206

Option door inter lock switch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-207

Paper feed clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-208

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-210

Calibrating the scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-210

Calibrating the scanner black levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-210

Adjusting ADF magnification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-211

Adjusting scanner registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-211

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

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

Print engine cross section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Flatbed / ADF sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

ADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Flatbed Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Rip Board connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Scanner (secondary) power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Scanner ICC board connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

ADF relay card connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

UICC connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Option feeder locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Option feeder layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Option board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

Option board connector values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Preventive maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

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

xi

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

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

Assembly 2: Flatbed and ADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 3: Flatbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 4: ADF 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 5: ADF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 6: Duplex components 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 7: Duplex components 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Assembly 8: Paper exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Assembly 9: Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Assembly 10: Base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Assembly 11: Base 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Assembly 12: Paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Assembly 13: Electrical 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Assembly 14: Electrical 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Assembly 15: Upper assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Assembly 16: Printhead controller board cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Assembly 17: Paper trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Assembly 18: Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Assembly 19: 550 sheet option feeder covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Assembly 20: 550 sheet option feeder base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

Assembly 21: 550 sheet option feeder paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

Assembly 22: 550 sheet option feeder tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

Assembly 23: Maintenance kits, power cords, and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

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

Part number index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-7

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Notices and safety information

This device is an LED based printer.

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xiv Service Manual

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Safety information

• The safety of this product is based on testing and approvals of the original design and specific

components. The manufacturer is not responsible for safety in the event of use of unauthorized

replacement parts.

• The maintenance information for this product has been prepared for use by a professional service person

and is not intended to be used by others.

• There may be an increased risk of electric shock and personal injury during disassembly and servicing of

this product. Professional service personnel should understand this and take necessary precautions.

• CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the

product where you are working. Unplug the product before you begin, or use caution if the product
must receive power in order to perform the task.

Consignes de sécurité

• La sécurité de ce produit repose sur des tests et des

agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume

aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.

• Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de

maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel

d'entretien qualifié devra prendre toutes les précautions nécessaires.

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

produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou faites preuve
de vigilance si l'exécution de la tâche exige que le produit reste sous tension.

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Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti

specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle

parti.

• Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di

assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza

autorizzato deve, quindi, adottare le precauzioni necessarie.

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

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

Safety information xv

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Sicherheitshinweise

• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und

bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine
Verantwortung oder Haftung für die Sicherheit übernommen.

• Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen

Wartungsfachmann bestimmt.

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

elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende
Vorsichtsmaßnahmen treffen.

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

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

Pautas de Seguridad

• La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes

específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no
autorizadas.

• La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal

cualificado de mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de

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

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

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

Informações de Segurança

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

específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição
não autorizadas.

• As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não

devem ser utilizadas por outras pessoas.

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

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

• CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial tensão

perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da
tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para
realizar a tarefa necessária.

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Informació de Seguretat

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

específics.

El fabricant no es fa responsable de les qüestions de

seguretat si s'utilitzen peces de recanvi no autoritzades.

• La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està

destinada

a ningú que no ho sigui.

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

d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre

les mesures convenients.

• PRECAUCIÓ: aquest símbol indica que el voltatge de la part de l'equip amb la qual esteu

treballant és perillós. Abans de començar, desendolleu l'equip o extremeu les precaucions si, per
treballar amb l'equip, l'heu de connectar.

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Preface

This manual contains maintenance procedures for service personnel. It is divided into the following chapters:

1. General information contains a general description of the printer and the maintenance approach used to

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

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

isolate failing field replaceable units (FRUs).

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

4. Repair information provides instructions for making printer adjustments and removing and installing

FRUs.

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

6. Preventive maintenance contains the lubrication specifications and recommendations to prevent

problems.

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

Appendix A contains service tips and information.
Appendix B contains representative print samples.

Navigation buttons

This manual contains navigation buttons in the right margin of each page, making it easier and quicker to
navigate.

Button Description

Previous

Click to move the document view backward by one page.

Next

Click to move the document view forward by one page.

Go Back

Click to return to the last page viewed.

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Change history

Revision date Updates

2013/12/16 Removed the Reset color calibration topic from the Diagnostic information chapter.

2013/08/30 • Added “30K ADF separator roll and ADF pick roll maintenance kit” part number

2013/07/01 Added Steps before starting the 9yy.xx service checks.
2012/01/07 Added connector information for CN19 and CN20 under “Printhead controller

2012/10/23 Updated Imaging unit (photo developer) missing service check:

2012/06/25 • Added “Safety feature notice” on page 2-1.

2011/12/14 Added an installation note in the “Waste toner sensor removal” on page 4-112.
2011/12/01 • Added a note in the “Paper feed unit removal” on page 4-68.

2011/11/22 Updated the “Printhead controller board / engine board replacement” on page 4-2.
2011/10/04 • Changed PN 40X6424 with PN 40X5984 for the “220 V Low voltage power supply”

2011/08/25 Changed PN 40X6730 to 40X6370 for the “RIP print controller cable” on page 7-27.
2011/08/09 • Added the following menu items under “Configuration Menu” on page 3-9

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(40X9227).

• Updated the following Configuration menu items:

- Reset Separator Roll and Pick Assembly Counter

- Reset Fuser Counter

- Reset Maintenance Counter

- Reset Transfer Belt Counter

connectors” on page 5-10.

Step 5 and 6: 'Changed sub unit' to 'subframe'.

• Updated and changed the Abnormal fuser temperature error service check to “ON /

OFF switch automatically switching to the Off position service check” on
page 2-48.

• Added the following removal procedures:

- “Main tray paper guide removal” on page 4-178.

- “Multi-purpose feed tray paper guide removal” on page 4-180.

• Updated the parts catalog art for “Paper feed” on page 7-24.

on page 7-27.

• Added Change history section

• Added the navigation buttons

- “Reset Separator Roll and Pick Assembly Counter” on page 3-10

- “Fuser Speed” on page 3-11

- “Wipe All Settings” on page 3-16

- “Wipe All Settings” on page 3-16

- “Automatically Display Error Screens” on page 3-17

• Changed all references to Wipe Disk to “Erase all information on Disks” on

page 3-16.

• Removed the following menu item definitions:

- * Color Adjustment

- * Color Adj State

- * Motor Calibration

Preface xix

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CAUTION

A caution identifies something that might cause a servicer harm.

CAUTION

This type of caution indicates there is a danger from hazardous voltage in the area of the
product where you are working. Unplug the product before you begin, or use caution if the
product must receive power in order to perform the task.

CAUTION

This type of caution indicates a hot surface.

CAUTION

This type of caution indicates a tipping hazard.

Conventions

Note: A note provides additional information.
Warning: A warning identifies something that might damage the product hardware or software.

There are several types of caution statements:

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1. General information

The Lexmark™ X925(7541-xxx) is a network-capable color MFP that uses electrophotographic technology to
deliver high-quality images, presentation graphics, line art, and text. It prints both four-color and monochrome
print jobs.

The X925 represents the latest in Lexmark printer innovation, including a full-color eTask touch screen with
improved messaging and animation, enhanced security features, remote operator panel access and control,
customizable reports, and access to the growing list of downloadable and customizable solutions.

A variety of connectivity options enable the printer to be used in all types of system environments. You can
attach one internal adapter to support network configurations requiring Ethernet, Token-Ring, LocalTalk, serial,
infrared, or additional parallel ports.

The printer also has flexible paper handling. It supports a wide variety of paper sizes, and has a standard
multipurpose feeder that makes it easy to print on envelopes, transparencies, labels, card stock, and non­standard size paper. You can add optional inputs to the base printer, which can increase the printer paper
capacity to 2100 sheets.

Maintenance approach

The diagnostic information in chapter two leads you to the correct field replaceable unit (FRU) or part. Use the
information to troubleshoot print quality, paper jams, user status messages, error codes, or general symptoms,
and then follow the instructions to repair the printer. After you complete the repair, perform tests as needed to
verify the repair.

7541-03x

Models

To begin diagnosing a problem, see “Diagnostic information” on page 2-1.

The Lexmark X925 (7541-030) laser printer is available in the following models:

Lexmark X925 7541-032 10” e-Task touch screen, duplex

Lexmark X925 7541-036 10” e-Task touch screen, duplex, fax

modem

Lexmark X925 7541-096 10” e-Task touch screen, duplex, fax

modem

General information 1-1

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CAUTION—TIPPING HAZARD

Floor-mounted configurations require additional furniture for stability. You must use either a
printer stand or printer base if you are using a high-capacity input tray, a duplex unit and an
input option, or more than one input option. If you purchased a multifunction printer (MFP) that
scans, copies, and faxes, you may need additional furniture. For more information, see

www.lexmark.com/multifunctionprinters.

Printer configurations

.

10

9

8

7

6

1 ADF input
2 ADF output bin
3 MPF feeder
4 550 sheet option tray (tray 3, 4, 5)
5 Caster unit
6 Storage cabinet
7 Standard 250-sheet tray (tray 1)
8 MPF 250-sheet tray (tray 2
9 Output bin

10 10” touchscreen display

The printer supports up to three 550-sheet trays.

*

5

1

2

3

4

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Options and features

Lexmark X925 printers support only Lexmark X925 paper-handling options. These options are not compatible
with any other Lexmark printer.

Some of the following options are not available in every country or region.

Available internal options

• Memory cards
– Printer memory
– Flash memory
– Fonts

• Firmware cards
– Bar Code
– PrintCryption

• Printer hard disk

• Lexmark

TM

Internal Solutions Ports (ISP)

– RS-232-C Serial ISP
– Parallel 1284-B ISP
– MarkNet

TM

N8250 802.11 b/g/n Wireless ISP

– MarkNet N8130 10/100 Fiber ISP
– MarkNet N8120 10/100/1000 Ethernet ISP

7541-03x

TM

Media handling options

• 550-sheet tray

General information 1-3

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1

2

3

5

4

Print engine specifications

Power specifications

Average nominal power requirements for the base printer configuration. (Power levels are shown in watts.)

Printing states Power

Off 0W

Sleep Mode 11W

Hibernate Mode 3W

Ready Mode 105W

Continuous printing 620W

Electrical specifications

Low-voltage models

• 100 to 127 V ac at 50 to 60 hertz (Hz) nominal

• 90 to 137 V ac, extreme

High-voltage models

• 220 to 240 V ac at 50 to 60 hertz (Hz) nominal (not available in all countries and regions)

Clearances

1 Right 385 mm (15.16 in.)
2 Front 609.6 mm (24 in.)
3 Left 100 mm (3.94 in.)
4 Rear 100 mm (3.94 in.)
5 Top 285 mm (11.22 in.)

Allow additional clearance around the printer for
adding options.

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Acoustics

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

7541-03x

Status

Idle (Standby) 37 dBA 5.4

Simplex printing 53 dBA 6.8

Duplex printing 54 dBA 7.0

Quiet Mode printing (Mono) 54 dBA 6.9

Quiet Mode printing (Color) 54 dBA 6.9

Measurements apply to 300 dpi, 600 dpi, and 1800 IQ printing.

Environment

Printer Temperature and Humidity

• Operating

• Power off

• Ambient operating environment*

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

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

1 meter average sound pressure

dBA

– Temperature: 10.0 to 33.00 C (50 to 91.40 F)
– Relative humidity: 8 to 80%
– Altitude: 7546 ft. (0 to 2300 meters)
– Atmospheric pressure: 767 kPa

– Temperature: 23 to 104° F (-5 to 40° C)
– Relative humidity: 8 to 80%
– Maximum wet bulb temperature: 80.1° F (26.7° C)
– Altitude: 7546 ft. (0 to 2300 meters)
– Atmospheric pressure: 74.6 kPa

– Temperature: 15.6 to 32.20 C (60 to 900 F)
– Relative humidity: 8 to 80%

Declared sound power level

Bels

*In some cases, performance specifications (such as paper OCF, EP cartridge usage) are measured at an
ambient condition.

General information 1-5

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Performance

The X925 printers support up to 30 ppm (Letter) and 30 ppm (A4) maximum print speeds.

Actual performance depends on:

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

• Host system and application

• Complexity and content of the page

• Certain options added to or selected with the MFP

• Available memory in the MFP

• Media size, media type and tray source

• Print Resolution

Note: The following special cases that may impact print speeds:

Vinyl Label – Vinyl Label is a customer selectable media type. When Vinyl Label is selected, print speed is
35ppm.

Note: When using custom size media, it is critical that the user define the actual width via the Paper Menu –
Universal Setup on the op panel for best reliability.

Processor

1 GHZ IBM Power PC processor

Memory

Standard memory - 512 mb

Optional memory - 256, 512, and 1024 MB. 1 200 pin x 64 DDR 2 SO-DIMMs. 1 slot.

Optional flash - 256 mb

Paper specifications

Paper sizes supported by the printer

Paper size Dimensions Tray 1 Tray 2

A3 297 x 420 mm

(11.7 in x 16.6in)

A4 210 x 297 mm

1

A5

2

A6

B4

1

B5

Letter 216 x 279 mm

Legal 216 x 356 mm

(8.3 x 11.7 in.)

148 x 210 mm
(5.8 x 8.3in.)

105 x 148 mm
(4.1 x 5.8 in.)

182 x 257 mm
(7.2 x 10.1 in.)

(8.5 x 11 in.)

(8.5 x14 in.)

Optional
550-sheet
tray

Multipurpose
feeder

Duplex unit

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Paper size Dimensions Tray 1 Tray 2

Executive1184 x 267 mm

(7.3 x 10.5 in.)

Oficio 216 x340 mm

(8.5 x 13.4 in>)

Folio 216 x 330 mm

(8.5 x 13 in.)

Statement1140 x 216 mm

(5.5 x8.5 in.)

Tabloid

Universal

Plain Paper

- 64 to
297mm x
148 to

140 x 210 mm
(5.5 x 8.3 in.) up
to
216 x 356 mm
(8.5 x 14 in.)

432mm

Banner ­210 to
297mm x
433 to
12129mm

7 3/4
Envelopes
(Monarch)

9
Envelope

10
Envelope

B5
Envelope

C5
Envelope

DL
Envelope3

Other
Envelope

98 x 191 mm
(3.9 x 7.5 in.)

3

98 x 226 mm

3

(3.9 x 8.9 in.)

105 x 241 mm

3

(4.1 x 9.5 in.)

176 x 250 mm

3

(6.9 x 9.8 in.)

162 x 229 mm

3

(6.4 x 9 in.)

110 x 220 mm
(4.3 x 8.7 in.)

86 x 165 mm

2,4

(3.4 x 6.5 in.) to
216 x 356 mm
(8.5 x 14 in.)

Optional
550-sheet
tray

Multipurpose
feeder

Duplex unit

210 to 297mm

x

148 to432 mm

Media types

Tray1: plain paper, card stock, labels, bond, transparencies, and envelopes

Tray2: plain paper, and light card stock (up to 34#).

Manual Feed Slot: plain paper, card stock, labels, bond, transparencies, and envelopes

Optional input tray: plain paper, labels, and bond.

Multi-Purpose Feeder: plain paper, card stock, labels, bond, transparencies, and envelopes

Paper sizes by options, source and output. Media guidelines (both from user manuals)

General information 1-7

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Media weights

Subsystem Size Type Weight

Tray 1
Tray2 and

optional
drawers

MFS & MPF
Duplexer

All sizes supported
by engine.
Excluding banner

All sizes supported
by engine.

Xerographic
and Bond

Long Grain 16lb to 34lb (60g/m2 to 128g/m2)

Short Grain 16lb to 34lb (60g/m2 to 128g/m2)

Recycled Long Grain 20lb to 34lb (75g/m2 to 128g/m2)

Short Grain 28lb to 34lb (105g/m2 to 128g/m2)

Card Stock
(max)

Cover 50lb/65lb (135g/m2 / 176g/m2)

Index 67lb/90lb (120g/m2 / 163g/m2)

Tag 74lb/100lb (120g/m2 / 163g/m2)

Labels (max) Paper 35lb (131g/m2)

Vinyl Not Supported

TransparencyTBD TBD

Envelope Xerographic 20lb to 34lb (75g/m2 to 128g/m2)

Xerographic
and Bond

Long Grain 16lb to 34lb (60g/m2 to 128g/m2)

Short Grain 16lb to 34lb (60g/m2 to 128g/m2)

Recycled Long Grain 20lb to 34lb (75g/m2 to 128g/m2)

Short Grain 28lb to 34lb (105g/m2 to 128g/m2)

Card Stock
(max)

Cover 50lb/42lb (135g/m2 / 157g/m2)

Index 67lb/75lb (120g/m2 / 157g/m2)

Tag 74lb/85lb (120g/m2 / 157g/m2)

Xerographic
and Bond

Long Grain 16lb to 34lb (60g/m2 to 128g/m2)

Short Grain 16lb to 34lb (60g/m2 to 128g/m2)

Recycled Long Grain 20lb to 34lb (75g/m2 to 128g/m2)

Short Grain 28lb to 34lb (105g/m2 to 128g/m2)

Card Stock
(max)

Cover 50lb/65lb (135g/m2 / 176g/m2)

Index 67lb/90lb (120g/m2 / 163g/m2)

Tag 74lb/100lb (120g/m2 / 163g/m2)

Labels (max) Paper 35lb (131g/m2)

Vinyl Occasional use up to 256 gsm

TransparencyTBD TBD

A5, B5, JIS-B5,
Exec., Statement,
Folio

Folio, Letter, A4
and Legal, A3,
Tabloid

1-8 Service Manual

Envelope Xerographic 20lb to 34lb (75g/m2 to 128g/m2)

Xerographic
and Bond

Card Stock
(max)

Long Grain 17lb to 34lb (64g/m2 to 128g/m2)

Short Grain 17lb to 34lb (64g/m2 to 128g/m2)

Long Grain 17lb to 34lb (64g/m2 to 128g/m2)

Short Grain 17lb to 34lb (64g/m2 to 128g/m2)

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Media guidelines

Selecting the appropriate media for the printer helps avoid printing problems.

For detailed information about media characteristics, see the Card Stock & Label Guide available on the
Lexmark Support Web site at http://support.lexmark.com.

Paper

To ensure the best print quality and feed reliability, use 90 g/m2 (24 lb) xerographic, grain long paper. Business
papers designed for general business use may also provide acceptable print quality.

We recommend Lexmark part number 12A5950 letter-size glossy paper and Lexmark part number 12A5951 A4­size glossy paper.

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

The Laser printing process heats paper to high temperatures of 180°C (356°F) for non-MICR applications. Use
only paper able to withstand these temperatures without discoloring, bleeding, or releasing hazardous
emissions. Check with the manufacturer or vendor to determine whether the paper chosen is acceptable for
laser printers.

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

7541-03x

Paper characteristics

The following paper characteristics affect print quality and reliability. Consider these characteristics when
evaluating new paper stock.

For detailed information, see the Card Stock & Label Guide available on the Lexmark Web site at http://
support.lexmark.com.

Weight

The printer can automatically feed paper weights from 60 to 220 g/m
than 60 g/m

2

(16 lb) might not be stiff enough to feed properly, causing jams. For best performance, use 75 g/m2
(24 lb bond) grain long paper. To use paper smaller than 182 x 257 mm (7.2 x 10.1 in.), we recommend 90 g/m
(24 lb bond) or heavier paper.

Curl

Curl is the tendency of media to curve at its edges. Excessive curl can cause paper feeding problems. Curl can
occur after the paper passes through the printer, where it is exposed to high temperatures. Storing paper
unwrapped in hot, humid, cold and dry conditions, even in the trays, can contribute to paper curling prior to
printing and can cause feeding problems.

Smoothness

The degree of smoothness of paper directly affects print quality. If the paper is too rough, the toner does not fuse
to the paper properly, resulting in poor print quality. If the paper is too smooth, it can cause paper feeding or print
quality issues. Smoothness needs to be between 100 and 300 Sheffield points; however, smoothness between
150 and 250 Sheffield points produces the best print quality.

2

(16 to 58 lb bond) grain long. Paper lighter

2

General information 1-9

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Moisture content

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

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

Grain direction

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

For 60 to 135 g/m
short is recommended.

Fiber content

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

2

(16- to 36-lb bond) paper, grain long fibers are recommended. For heavier papers, grain

Unacceptable paper

The following papers are not recommended for use with the printer:

• Chemically treated papers used to make copies without carbon paper, also known as carbonless papers,

carbonless copy paper (CCP), or no carbon required (NCR) paper

• Preprinted papers with chemicals that may contaminate the printer

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

• Preprinted papers that require a registration (the precise print location on the page) greater than ±0.09 in.,

such as optical character recognition (OCR) forms. In some cases, registration can be adjusted with the
software application to successfully print on these forms.

• Coated papers (erasable bond), synthetic papers, or thermal papers

• Rough-edged, rough or heavily textured surface papers or curled papers

• Recycled papers that fail EN12281:2002 (European)

• Paper having a weight less than 60 g/m

2

(16 lb)

• Multiple-part forms or documents

Selecting paper

Proper paper loading helps prevent jams and ensures trouble-free printing.

To help avoid jams or poor print quality:

• Always use new, undamaged paper.

• Before loading paper, know the recommended print side of the paper. This information is usually indicated

on the paper package.

• Do not use paper that has been cut or trimmed by hand.

• Do not mix media sizes, weights, or types in the same source; mixing results in jams.

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

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Scan fax and copy specifications

General specifications

Processor

Speed and type 1GHZ, IBM

Memory

Standard 512 MB (Max 1.5 GB)

Optional memory 256 MB, 512 MB and 1024 MB DDR SODIMM

Optional flash memory 256 MB

Hard drive 160 GB or higher

Connections

Standard Gigabit ethernet and USB

Option slots

DRAMM DIMM slots 1

Wireless option Yes

ISP (INA) slots 1

DLE Firmware card, font card, and flash
memory card slots

7541-03x

2

The following combinations are supported when you use more
than one slot:

• DLE and user flash

• DLE and font card

• Font and User flash

Paper handling

Paper input standard 250- and 150-sheet tray

50 MPF

Optional paper handling: Input 550-sheet tray (up to 3)

Optional paper handling: Output None

Duplex Yes

Finishing None

Hard drive Standard

Service

Warranty One year on-site parts and labor

Furniture

Standard None

Optional furniture Caster base

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7541-03x

Fax features

Feature Notes

Fax preservation Faxes are preserved over power cycle

Color fax Enable color scans

Fax content Type: text, graphics, text/photo, photo

Original size All sizes supported by device, including mixed letter/legal

Dial mode Touch tone

Custom job scanning Only appears if installed on hard drive

Scan preview Only appears if installed on hard drive

Fax cover page Includes: to, from, message, footers, logo, and total pages

Fax number masking Active masking

Maximum speed Settings for both Send and Receive

Delayed send Supported

Block junk fax banned
fax list

Fax shortcuts Average shortcut includes: 25 characters for name, 10 characters for number,

Broadcast fax Maximum number of locations is 400

Fax forwarding Incoming faxes may be forwarded to the following:

Caller ID Available if subscribed to caller ID from phone provider

Manual fax Disabled by default

Fax from PC Supported using PostScript driver

Fax print holding Appears only if installed on hard drive

Fax logs Transmission log

Distinctive ring
selection

Auto convert color to mono fax

Enable color fax receive:

• When on, the sending device transmits in color and the

receiving device prints in grayscale.

• When off, the sending device converts and transmits the job as

a mono job.

Source: color laser, black/white laser, inkjet, photo/film, magazine, newspaper,
press, other

Pulse

Based on Caller ID or Remote Station ID

and four characters for shortcut ID.

Shortcuts can contain one phone number or multiple numbers. Each number is
a location; see the Preferences area for the maximum number of locations. xxx

• Fax—using one fax shortcut

• Email—using one email shortcut

• FTP—using one FTP shortcut

• LDSS

• eSF—supported via custom application

Any fax resolution that can be received can also be forwarded.

Receive error log

Fax call log

Fax job log

Available if subscribed from/configured through phone provider

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Feature Notes

Sound control Ringer volume

Fax server Fax server mode will send the scanned fax job to the fax server as an email,

Scanner specifications

Scanner type Color flatbed scanner with ADF

Scan technology Charge Coupled Device (CCD)

Light source White LED “Instant On”

Number of light sources 1 LED array per CCD module

ADF scanner

ADF type Re-circulating (Dual Pass) Automatic Document Feeder (RADF)

Scanner ADF
document input and
output capacity

Scanner media depth
(thickness)

Scanner media weight Maximum: 32 lb (120 g/m2)

Document size Maximum: 11.8 x 25 in. (299.72 x 635 mm) Short Edge Feed (SEF)

Document size sensing Yes—length and width in ADF

Document Sensing Yes—ADF paper present LED and on/off settable beep

7541-03x

Speaker volume

Speaker mode—On, On until connected, Off

where it will then be sent to the receiver. The device should be tested for
configurability and compatibility with the deserved third fax server product (for
example, Biscom, Equisys-ZetaFax, OMTool, Captaris-RightFax, or Tobit­Faxware).

100 sheets, 20 lb. (75 g/m2) bond

Maximum: 0.11mm

Minimum: 0.08 mm

Minimum: 16 lb (60 g/m2)

Minimum: 4 x 5.04 in. (101.6 x 128.02 mm) SEF

Flatbed scanner

Max document size 11 x 17 in. (279.4 x 431.8 mm)

Document size sensing Yes—paper length sensing only on flatbed

Print engine

Print technology Color LED

Duplex output Standard

Paper feed orientation Short Edge Fed and Long Edge Fed

Fax

Modem Built-in Group 3-compatible, full function fax, 33,600 bps, Max V.34 Half Duplex

General information 1-13

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MFP scan speed

Media size

Simplex Duplex

Mono Color Mono Color

Letter (plain 32 32 13 13

A4 (plain) 33 33 14 14

Note: Scan performance is measured as 150 dpi 1-bit for mono and 150 depi 24-bit for color.

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Tools required for service

Flat-blade screwdrivers, various sizes
#1 Phillips screwdriver, magnetic
#2 Phillips screwdriver, magnetic
#2 Phillips screwdriver, magnetic short-blade
7/32 inch (5.5 mm) open-end wrench

7.0 mm nut driver
Needlenose pliers
Diagonal side cutters
Spring hook
Feeler gauges
Analog or digital multimeter
Parallel wrap plug 1319128
Twinax/serial debug cable 1381963
Coax/serial debug cable 1381964
Flashlight (optional)

7541-03x

General information 1-15

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7541-03x

Acronyms

ac Alternating Current
ACM Autocompensator Mechanism (or paper feed)
ADF Automatic document feeder
AFE Analog front end
APS Automatic Paper Size
ASIC Application Specific Integrated Circuit
BLDC Brushless DC Motor
BOR Black Only Retract
BUD Belt up down
CCyan
CCW Counter clockwise
CDB Command Descriptor Blocks
CMYK Cyan yellow magenta black
CPU Central processing unit
CRC Cyclic redundancy check
CRU Customer Replaceable Unit
CSU Customer Setup
CW Clockwise
DBCS Double byte character set
dc Direct Current
DIMM Dual Inline Memory Module
DLE Downloadable emulator
DRAM Dynamic random access memory
DVM Digital multimeter
ECC Error correcting code
ECM Error correction mode
EDO Enhanced Data Out
EEPROM Electrical Erasable Programmable Read-Only Memory
ENA External Network Adapter
EOL End of life
EP Electrophotographic process
EPROM Erasable programmable read-only memory
ESD Electrostatic Discharge
FD Facedown
FRU Field replaceable unit
FU Face up
GB Gigabyte
GFI Ground Fault Interrupter
GHz Gigahertz
HBP Host Based Printing
HTML Hypertext markup language
HV High Voltage
HVPS High voltage power supply
HVU High voltage unit
Hz Hertz
INTL International
ITC Internal Tray Card
ITU Image Transfer Unit
KBlack (Key)

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7541-03x

LAN Local area network
LASER Light amplification by stimulated emission of radiation
LCD Liquid crystal display
LCM Liquid Crystal Module
LD Laser Diode
LED Light emitting diode
LEF Long edge feed
LES Lexmark Embedded Solution (applications)
LV Low Voltage
LVPS Low voltage power supply
M Magenta
MB Megabyte
MDC Motor Driver Control
MH Message handling
MIF Motor interface
mm Millimeter
MMR Modified modified read
MPF Multipurpose feeder
MR Modem ready
MROM Masked Read Only Memory
MS Microswitch
NAND NAND (usage: NAND gate)
NVM Nonvolatile Memory
NVRAM Nonvolatile Random Access Memory
OCF Operator correctable failure
OCR Oil coating roll
OEM Original Equipment Manufacturer
OHP Overhead projector
OPC Optical photo conductor
OPT Optical Sensor
PC Photoconductor
PDF Portable Document Format
PICS Problem isolation charts
PIN Personal identification number
PIXEL Picture element
PJL Printer Job Language
POR Power-on reset
POST Power-on self test
PPDS Personal Printer Data Stream
ppm Pages per minute
PQET Print Quality Enhancement Technology
PRC Peoples' Republic of China
PSC Parallel Synchronous Communications
PSD Position Sensing Device
PSO Participating Standards Organization
PWM Pulse Width Modulation
RAM Random access memory
RFID Radio frequency identification
RH Relative humidity
RIP Raster image processor
ROM Read-only memory
ROS Read-only storage
RPM Revolutions Per Minute
SDRAM Synchronous Dynamic Random Access Memory

General information 1-17

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SEF Short edge feed
SOL Solenoid
SRAM Static random access memory
TAR Toner Add Roll
TPS Toner Patch Sensing
TTM Tandem Tray Module
TVOC Total Volatile Organic Compound
UAT Universally Adjustable Tray
UPR Used Parts Return
USB Universal Serial Bus
VVolts
V ac Volts alternating current
V dc Volts direct current
VOM Volt Ohmmeter
VTB Vacuum Transport Belt
XPS XML Paper Specification
YYellow

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2. Diagnostic information

CAUTION

Unplug power cord from the electrical outlet before you connect or disconnect any cable or
electronic board or assembly for personal safety and to prevent damage to the printer.
Disconnect any connections between the printer and PCs/peripherals.

CAUTION

If the printer is kept on, never touch the conductive parts while it is not specifically required.
Do not touch the LVPS cards and the engine board unless they are properly discharged. Never
touch the live parts.

Start

The diagnostic information in this chapter leads you to the failing part. Before you replace an entire assembly,
determine if just the defective part is available in the parts catalog. Use the error code tables, symptom table,
service checks, and the diagnostic aids chapter to determine the symptom and repair the failure. The removal
procedures in the Repair information chapter may help you identify parts. After you complete the repair, perform
the appropriate tests to verify the repair.

7541-03x

The table below lists the errors and symptoms you might encounter. Use the links in the table to locate the error
message or symptom, and take the indicated action

Error code or
symptom

Print quality issues Go to “Print quality issues” on page 2-4

Scanner image issues Go to “ADF & scanner print quality” on

Paper jams (200.xx) Go to “Paper jams” on page 2-17

Error codes Go to “Error codes” on page 2-38

Attendance messages Go to “User attendance messages” on

Other symptoms Go to “Other symptoms” on page 2-78

Safety feature notice

This device is designed with a safety feature to prevent fire or damage due to an overheating fuser. In the event
the fuser should overheat, the printer will automatically shutdown. When the printer shuts down, the on/off power
switch will physically move to the off position. For more information on how to diagnose and service this event,
see “ON / OFF switch automatically switching to the Off position service check” on page 2-48.

Location

page 2-11.

page 2-69

Diagnostic information 2-1

7541-03x

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Flatbed / ICC card NVRAM

The flatbed ICC card contains NVRAM. Do not use an ICC card from another X925 printer. Using an ICC card or
complete flatbed assembly from another machine will result in a 950.10 NVRAM mismatch error.

Initial check

Before you start troubleshooting, check the following:

Installation environment

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

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

• The room temperature is between 10 and 32°C (50 and 90°F) and the relative humidity between 20 and

80%.

• Avoid sites generating ammonia gas, high temperature, high humidity (near water faucets, kettles,

humidifiers), cold spaces, near open flames, and dusty areas.

• Avoid sites exposed to direct sunlight.

Print paper checks

• Use the recommended paper for this printer.

• Paper dampness. Make a trial print with paper from a newly opened package, and check the result.

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

• Does the POR stop? Check the [POR (Power On Reset) sequence]

• Do you have a symptom, rather than an error message?
– [add symptom tables list]

• If you have an error message or user message, check the following:
– [Error tables]
– [2xx Paper Jams]
– [User attendance messages]
– [Service checks] for individual error messages

• Additional information can be found at the following locations:
– [Sub error code table]
– [Understanding the printer operator panel]
– [Service checks]

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

support for assistance.

2-2 Service Manual

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POR (Power-On Reset) sequence

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

1. Power the machine on.

2. Power supply fan rotates.

3. Splash screen with progress bar displayed.

4. Printer controller initialized.

• ROM is checked - if there is an error, power on is halted

• EEPROM checked - if there is an error, power on is halted

• Fuser thermistor checked - if there is an error, power on is halted

5. LED illuminates

6. RIP initialized.

• ROM is checked - if there is an error, power on is halted

• Memory checked - if there is an error, power on is halted

7. Main tray lift motor moves paper up to position.

8. Printer condition checked.

• Check for jams - if there is an error, power on is halted

• Query the toner cartridge and imaging kit - if there is an error, power on is halted

• Check toner load. - if there is an error, power on is halted

9. Check temperature - if there is an error, power on is halted

10. LED flashes.

11. The default home screen is displayed.

7541-03x

Diagnostic information 2-3

7541-03x

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Print quality issues

Note: This symptom may require replacement of one or more CRUs (Customer Replaceable Units) designated

as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission,
you may need to install a developer (toner) cartridge or photoconductor unit.

Service tip: Before troubleshooting any print quality problems, do the following:

1. Print a menu settings page, and then check the life status of all supplies. Any supplies that are low should

be replaced.

2. On the menu page, make sure the following is set to the default level:

–Color Correction: Set to Auto
.–Print Resolution: Set to 1200 dpi (print quality problems should be checked at different resolution
settings).
–Toner Darkness: Set to 4 (default).
–Color Saver: Set to OFF.
–RGB Brightness, RGB Contrast, RGB Saturation: Set to 0.
–Color Balance: Touch Reset Defaults to zero out all colors.
–Check the paper type, texture and weight settings against what is loaded in the printer.

3. Inspect the transfer module (transfer belt, and transfer roll) for damage. Replace if damaged.

4. Inspect the imaging units and toner cartridges for damage. Replace if damaged.

5. If paper other than 20lb plain letter/A4 paper is being used, load 20lb plain letter/A4 and print the Print

Quality pages to see if the problem remains.

6. Use Tray 1 to test print quality problems.

7. Print the Print Quality Pages, and then look for variations in the print from what is expected.

An incorrect printer driver for the installed software can cause problems. Incorrect characters could print, and
the copy may not fit the page correctly.

Repeating defects

The following table contains the circumferences of the imaging and transport components. Check the intervals
of any marks or defects that appear on a printout. if they match the intervals on the table, they are most likely
caused by the component listed.

Imaging / transport component Circumference

Registration rolls 50 mm

Pickup, feed, and separator rolls

* dimensions are the same for the
expansion trays

MPF roller 75 mm

Transfer roll (located in transfer belt) 38 mm

Fuser (Fuser belt) 141 mm

Imaging unit parts

Photoconductor

Developer roll

Charge roll

Supply roll

63 mm

75 mm

41 mm

31 mm

28 mm

Transfer roll 57 mm

2-4 Service Manual

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One color missing

Step Action and questions Yes No

7541-03x

1 Are the imaging units (photoconductors) properly

installed?

Is the photoconductor lock door properly closed on

2

both sides?

Is the ribbon cable for the missing color’s LED

3

printhead properly connected to the printhead
controller board and LED printhead?

Replace the LED printhead. Did this fix the problem? Problem resolved Go to step 5.

4

Are the contacts on the HVPS clean? Go to step. Clean the

5

Are the spring contacts on the sub frame damaged? Replace the

6

Replace the HVPS. Did this fix the problem? Problem

7

Contaminated background

Go to step 2. Reinstall the

Go to step 3. Open and close

Go to step 4. Properly connect

subframe.

resolved.

imaging units.

the
photoconductor
lock door
ensuring that t is
locked in place
on both ends.

the ribbon cable
on both ends.

contacts on the
HVPS.

Go to step 7.

Contact your
second level
support.

Step Action and questions Yes No

1 Check the imaging units and toner supplies to see if

they are clean. Are they clean?

Check the imaging units for proper connection. Are

2

they installed properly?

Replace the HVPS. Dis this fix the problem? Problem resolved Contact your

3

Go to step 2 Clean the

supplies.
Replace if
needed.

Go to step 3. Reinstall the

imaging units.

second level
support.

Diagnostic information 2-5

7541-03x

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Lowered print density

Step Action and questions Yes No

1 Check the paper for moisture. Is the paper moist? Replace the

2

3

4

5

White stripes

Step Action and questions Yes No

1 Are there scratches or dirt on the photo sensitive drum

2

3

4

paper.

Check the LED printhead for dirt. Is the printhead dirty? Go to step 3. Go to step 4.

Clean the print head with a lint free cloth. Did this fix
the problem?

Replace the LED printhead. Dis this fix the problem? Problem resolved Go to step 5.

Replace the HVPS. Did this fix the problem? Problem resolved Contact your

of the imaging unit?

Is there dirt on the exposing surface of the LED
printhead?

Clean the LED printhead. Did this fix the issue? Problem resolved Go to step 4.

Replace the defective LED printhead. Did this fix the
issue?

Problem resolved Go to step 4.

Replace the
imaging unit.

Go to step 3. Go to step 4.

Problem resolved Contact your

Go to step 2.

second level
support.

Go to step 2.

second level
support.

Uneven print

Step Action and questions Yes No

1 Check the condition of the paper. Is it curled or wavy? Replace the

Check for dew, or moisture on the imaging unit’s drum.

2

Is there moisture on the drum?

Is there any dirt or debris on the imaging unit? Clean off the

3

Is there dirt of debris on the exposing surface of the

4

LED printhead?

paper.

Let the imaging
unit’s drums dry
off.

imaging unit with
a lint free cloth

Clean the LED
printhead with a
lint free cloth.

Go to step 2.

Go to step 3.

Go to step 4.

Contact your
second level
support.

2-6 Service Manual

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Partial dirt

Step Action and questions Yes No

7541-03x

1 Is there toner attached to the developer roll, especially

the lower part of the roll.

Check the transfer belt for defects or foreign matter

2

such as dirt. Are there defects on the transfer belt?

Replace the transfer belt. Did this fix the problem? Problem

3

Repeating marks

For repeating defects, see“Repeating defects” on page 2-4

FRU / CRU Action

1 Fuser • Check for dirt on the fuser belt. Clean if needed.

Transfer roll Check for dirt or scratches on the transfer belt. Clean the roll if

2

Imaging unit Check for scratches of unevenness on the photoconductor drum.

3

Replace the
imaging unit.

Remove the dirt
from the belt.

resolved.

• Check for scratches on the belt. Replace if needed.

needed

Note: Be careful when cleaning the dirt of the transfer roll. Be
careful to not deform the roll.

Replace the transfer roll if it is scratched.

Replace the imaging unit if the drum is damaged.

Look for dirt on the rolls. Replace the imaging unit if the rolls are
dirty.

Go to step 2.

Go to step3

Contact your
second level
support.

Black stripes

Step Action and questions Yes No

1 Is there dirt on the imaging units developer roll, or

2

3

4

5

6

charge roll?

Are there scratches on the photoconductor drum? Replace the

Is there dirt in the fuser belt? Clean the belt. Go to step 4

Are there scratches on the fuser belt? Replace the

Are there lumps of toner on the fuser belt? Remove the lump

Print a blank white page. Are there black stripes on the
page?

Clean the dirt if. Go to step 2.

imaging unit.

fuser.

of toner.

Replace the
black LED
printhead.

Diagnostic information 2-7

Go to step 3.

Go to step 5.

Go to step 6.

Contact your
second level
support.

7541-03x

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Unprinted spots

Step Action and questions Yes No

1 Check the paper in the tray for moisture. Is the paper

moist?

Check the LED print head for moisture on the imaging

2

surface. Is there any moisture on the LED surface?

Does the imaging unit’s photodeveloper drum have

3

any dew on it.

Remove and reinstall the imaging unit. Does this fix the

4

problem?

Replace the imaging unit. Does this resolve the issue. Problem resolved Go to step 6.

5

Check the transfer roll for dents. Are there any dents in

6

the transfer roll?

Remove the transfer belt and check the surface for

7

waviness or other irregularities. Are the surface
irregularities?

Partially dark or light print

Step Action and questions Yes No

Replace the
paper in the tray.

Wipe the LED
imaging surface
with a lint free
cloth.

Let the drum dry
out. Do not wipe
the drum with a
cloth.

Problem resolved Go to step 5.

Replace the
transfer roll.

Replace the
transfer belt.

Go to step 2.

Go to step 3.

Go to step 4.

Go to step 7.

Contact your
second level
support.

1 Check the drum on the imaging unit for over exposure

to light. Has it been over exposed to light?

Replace the affected imaging unit. Did this fix the

2

issue?

Check the imaging unit for proper installation. Is it

3

properly installed?

Reinstall the imaging units. Did this fix the issue? Problem

4

Clean the contacts on the imaging unit and the printer.

5

Did this resolve the issue?

Go to step 2 Go to step 3

Problem
resolved.

Go to step 5. Go to step 4

resolved.

Problem
resolved.

Go to step 3

Go to step 5

Contact your
second level
support.

2-8 Service Manual

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Black page

Step Action and questions Yes No

7541-03x

No print

1 Inspect the contact points for the imaging unit and the

printer. Are they clean and free of debris?

Clean the contacts. Did this fix the issue? Problem resolved Go to step 3.

2

Check the sub frame for bent springs, or contacts. Are

3

the contacts on the sub frame damaged?

Check the HVPS for proper installation. Are the screws

4

securing the HVPS to the subframe secure?

Disconnect and reconnect the HVPS cable at the

5

bottom of the HVPS. Did this fix the problem?

Replace the HVPS. Did this fix the problem? Problem resolved Contact your

6

Step Action and questions Yes No

1 Check the paper in the printer for moisture. Is the

paper damp?

Check for dewing or moisture on the LED printheads.

2

Is there moisture on the printheads?

Go to step 3 Go to step 2

Replace the sub
frame.

Go to step 5 Tighten the

Problem resolved Go to step 6.

Replace the
paper with dry
paper.

Let the
printheads dry.
Move the printer
to a less humid
location if
needed.

Go to step 4.

screws.

second level
support.

Go to step 2.

Go to step 3.

Using the Administrative menu, move the transfer belt

3

to the up and down position. Does the belt move?

Check the transfer roll for proper installation. Is the

4

transfer roll installed correctly?

Check the transfer roll contacts for dirt or wear. Are the

5

transfer roll contacts clean?

Check the LED ribbon cables for proper connection at

6

both ends. Are the LED ribbon cables properly
installed?

Check the LED ribbon cable connectors on the

7

printhead controller board for +5V DC. Is the voltage
correct?

Check all the connectors on the printhead controller

8

board. Are they properly connected

Replace the printhead controller board. Did this fix the

9

problem?

Go to step 4. Replace the belt

Go to step 5. Reinstall the

Go to step 6. Clean the

Go to step.7 Properly install

Go to step.8 Replace the

Go to step.9 Properly connect

Problem
resolved.

Diagnostic information 2-9

transfer roll.

contacts.

the ribbon
cables.

printhead
controller board.

the connectors.

Contact second
level support.

7541-03x

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Stain on back of page

Step Action and questions Yes

1 Check for dirt on the transfer belt. Is there dirt on the

2

3

Failure to fuse

Step Action and questions Yes No

1 Check the fuser for proper installation. Is the fuser

2

3

transfer belt?

Check for dirt along the paper path. Is there dirt on the
paper path?

Check the registration rolls for dirt or debris. Is there
dirt on the registration rolls?

properly installed?

Check connection CN on the LVPS for proper
connection. Is the cable properly connected.

Check CN for the correct voltage. Is the voltage
correct?

Clean the
transfer belt with
a lint free cloth.

Clean any dirty
paper path
components with
a lint free cloth.

Clean the
registration rolls
with a lint free
cloth.

Go to step 2. Reinstall the

Go to step Go to step

Replace the
fuser.

fuser.

Replace the
LVPS. See

volt power
supply removal”
on page 4-51.

“Low

Stains on edge of page

Action and questions

Check for dirt on the paperpath. Clean as needed.

2-10 Service Manual

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ADF & scanner print quality

Note: Get a printout as a base, and then follow the symptom table to identify the possible failing FRU.

Image quality symptoms:

• Dark print — “Dark image quality (using ADF or Scanner)” on page 2-11.

• Vertical stripes— “Vertical lines (process direction using the ADF)” on page 2-12.

• Spots— “Spots (using flatbed scanner)” on page 2-12.

• Skew—“Skew (using ADF)” on page 2-14.

• Media damage— “Media damage (using ADF)” on page 2-15.

Note: When horizontal lines and/or spots occur periodically, it is possibly caused by a particular roll. In this

case, measure the interval on the print test, and check the relation to the roll in the printer. The interval does not
necessarily match circumference of the roll.

Dark image quality (using ADF or Scanner)

Before starting, check the media route for foreign objects, such as staples, clips, and scraps, in the media path.

Step Check Yes No

7541-03x

1 Check the large and small platen glass on the scanner

unit assembly.

Is the large and small platen glass contaminated?

Check the three mirrors in the scanner unit assembly.

2

Are the three mirrors contaminated or show signs of
dust?

Check the white strip on the bottom of the large platen

3

glass.

Is the white strip contaminated?

Check the scanner lens.

4

Is the scanner lens contaminated?

Perform a print test using the ADF & scanner unit

5

assemblies.

Does the error continue?

Perform a print test using the ADF & scanner unit

6

assemblies.

Does the error continue?

Clean both sides
of the large and
small platen
glass.

Clean the three
mirrors in the
scanner unit
assembly.

Clean the white
strip and POR
the machine.

Clean the
scanner lens.

Replace the
CCD assembly.

Replace the ICC
board.

Go to “ICC

board” on
page 4-123.

Go to step 2.

Go to step 3.

Go to step 4.

Go to step 5.

Problem solved.

Problem solved.

Diagnostic information 2-11

7541-03x

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Vertical lines (process direction using the ADF)

Step Check Yes No

1 Check the small platen glass on the scanner unit

assembly.

Is the large and small platen glass contaminated or
damaged?

Check the three mirrors in the scanner unit assembly.

2

Are the three mirrors contaminated or show signs of
dust?

Check the white strip on the bottom of the large platen

3

glass.

Is the white strip contaminated?

Perform a print test using the scanner unit assembly.

4

Does the error continue?

Perform a print test using the ADF unit assembly.

5

Does the error continue?

Clean or replace
the scanner
platen glass
cover.

Go to “Flatbed

upper cover”
on page 4-161.

Clean the three
mirrors in the
scanner unit
assembly.

Clean the white
strip and POR
the machine.

Replace the
scanner unit
assembly.

Go to “Flatbed

assembly
removal” on
page 4-116.

Replace the ICC
board.

Go to “ICC

board” on
page 4-123.

Go to step 2.

Go to step 3.

Go to step 4.

Problem solved.

Problem solved.

Spots (using flatbed scanner)

Step Check Yes No

1 Check the large platen glass on the scanner unit

assembly.

Is the large platen glass contaminated or damaged?

Check the three mirrors in the scanner unit assembly.

2

Are the three mirrors contaminated or show signs of
dust?

Check the white strip on the bottom of the large platen

3

glass.

Is the white strip contaminated?

2-12 Service Manual

Clean or replace
the scanner
platen glass
cover.

Go to “Flatbed

upper cover”
on page 4-161.

Clean the three
mirrors in the
scanner unit
assembly.

Clean the white
strip and POR
the machine.

Go to step 2.

Go to step 3.

Go to step 4.

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Step Check Yes No

7541-03x

Perform a print test using the scanner CCD assembly.

4

Does the error continue?

Perform a print test using the flatbed scanner assembly.

5

Does the error continue?

Replace the
scanner CCD
assembly.

Go to “CCD

chassis” on
page 4-124.

Replace the ICC
board.

Go to “ICC

board” on
page 4-123.

Problem solved.

Problem solved.

Diagnostic information 2-13

7541-03x

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Skew (using ADF)

The printed image is not paralleled with both sides of the media.

Step Check Yes No

1 Check printer installation placement.

Check the installation surface for irregularities.

Check for damaged printer caster.

Is the setup surface normal?

Properly load document into the ADF unit assembly and

2

ensure all guides are set correctly.

Re-print the defective image.

Does the error continue?

Check for obstructions in the area of the media feed

3

path in the ADF.

Is the media feed path free from any obstructions?

Is the ADF left cover assembly properly and evenly

4

closed?

Check the ADF/pick roll assembly for damage and

5

wear.

Is the ADF feed/pick roll assembly free from
damage and wear?

Check the ADF separator roll.

6

Is the ADF separator roll free from damage and
wear?

Go to step 2. Correct the

installation
placement.

Go to step 3. Problem solved.

Go to step 4. Remove

obstructions.

Go to step 5. Open then

properly close
the ADF left
cover assembly.

Go to step 6. Replace the

ADF feed/pick
roll assembly.

Go to “ADF

pick roll
removal” on
page 4-114.

Go to step 7. Replace the

ADF separation
roll.

Go to “ADF

separator roll
removal” on
page 4-115.

2-14 Service Manual

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Media damage (using ADF)

Step Check Yes No

7541-03x

1 Properly load document into the ADF unit assembly and

ensure all guides are set correctly.

Re-print the defective image.

Does the error continue?

Check for obstructions in the area of the media feed

2

path in the ADF.

Is the media feed path free from any obstructions?

Is the ADF left cover assembly properly and evenly

3

closed?

Check the ADF/pick roll assembly for damage and

4

wear.

Is the ADF feed/pick roll assembly free from
damage and wear?

Check the ADF separator roll.

5

Is the separator roll free from damage and wear?

Check the ADF controller card assembly.

6

Replace the ADF relay board assembly.
Go to “ADF relay board” on page 4-122.

Perform a print test using the ADF.

Does the error continue?

Go to step 2. Problem solved.

Go to step 3. Remove

Go to step 4. Open then

Go to step 5. Replace the ADF

Go to step 6. Replace the

Replace the RIP
board.

Go to “RIP

board removal”
on page 4-73.

obstructions.

properly close
the ADF left
cover assembly.

feed/pick roll
assembly.

Go to “ADF pick

roll removal” on
page 4-114.

separator roll.
Go to “ADF

separator roll
removal” on
page 4-115.

Problem solved.

Diagnostic information 2-15

7541-03x

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Black page from scanner

Step Questions / actions Yes No

1 Print a menu page, or a page from the host.

Is the page black?

2 Are the CCD ribbon cables properly

See Go to “Black page”

Go to step 2.

on page 2-9.

Go to step 4 Go to step 3.

connected to the ICC board?

3 Properly connect the ribbon cables to the

Problem resolved. Go to step 5.
ICC board and CCD. Did this fix the
problem?

4 Check the cables for continuity. Is there

Go to step 6. Go to step 5.
continuity?

5 Replace the ribbon cables from the ICC

Problem resolved Go to step 6.
board to the CCD. Did this fix the problem?

6 Replace the ICC. Did this fix the problem? Problem resolved Go to step 7.

7 Replace the CCD. Did this fix the problem? Problem resolved Go to step 8.

8 Replace the RIP Did this fix the problem? Problem resolved Contact second level

support.

2-16 Service Manual

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Paper jams

4

5

1

2

3

6

8

7

7541-03x

Location

1 283.05 Scan Sensor Jams To resolve scanner jam issues, see

2 200.xx Paper jam in the transfer / carry area.

3 250 Paper jam in the MPF tray

4 201.xx Paper jam in the fuser entry area.

5 24x Paper jam in the papertray. <x> indicates which tray the jam is in.

6 203 Paper jam at the paper exit area.

User primary
message

290.11 Scanner ADF Cover Open Jam

283.01 Scanner Static Jam - Scan Sensor

280.06 Paper Missing

285.05 Scanner ADF Eject Jam

230 Paper jam in the duplex.

231-39 Paper jam in the duplex. Check the duplex sensor area at the bottom of the

Explanation

“Clearing and resolving scanner
jams” on page 2-29.

Jams

duplex.

7 292.01 Scanner Carriage Locked To resolve these issues, see

8 291.06 Flatbed Cover Open

“Clearing and resolving scanner
jams” on page 2-29.

Diagnostic information 2-17

7541-03x

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Clearing and troubleshooting paper jams

200 paper jam

1. Open the right side cover.

2. Pull the paper up and out to remove it from the paper path.

Note: Make sure all paper fragments are removed. If the page is in the fuser, the fuser nip release lever

should be lowered. After removing the jammed page, return the lever to the proper position.

3. Close the right side cover.

4. Press Continue, jam cleared.

201 paper jam

1. Open the right side cover.

2. Determine where the jam is located and remove it.
a. If the paper is visible under the fuser, grasp it on each side and pull it out.

b. If the paper is not visible, remove the fuser and remove the jam. See fuser removal.

2-18 Service Manual

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3. Remove the jammed paper.

4. Close the right cover.

5. Press Continue, jam cleared.

203 paper jam

1. Grasp any jammed paper that is visible in the exit bin and gently pull it out.

7541-03x

Note: Make sure all paper fragments are removed. If the page is in the fuser, the fuser nip release lever

should be lowered. After removing the jammed page, return the lever to the proper position.

2. Press Continue, jam cleared.

Diagnostic information 2-19

7541-03x

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1

2

230 paper jam

1. Open the right cover.

2. Lift the duplexing unit mechanism away from the cover.

3. Remove any jammed paper.

4. Lower the mechanism.

2-20 Service Manual

5. Close the right cover.

6. Press Continue, jam cleared.

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231-39 paper jam

1

2

1. Open the right cover.

2. Lift the duplexing unit mechanism away from the cover.

3. Remove any jammed paper.

4. Lower the mechanism.

7541-03x

5. Close the right cover.

6. Press Continue, jam cleared.

Diagnostic information 2-21

7541-03x

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1

2

24x paper jam

Jam in tray 1

1. Open the right cover and pull any jammed pages out.

2. Open Tray 1, ad pull the jammed pages up and out.

3. Close Tray 1.

4. Press Continue, jam cleared.

Jam in the optional trays

1. Open the side affected tray’s access door and remove the jammed pages.

Note: Make sure all paper fragments are removed.

2-22 Service Manual

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2. Open the affected tray and remove the jammed pages.

7541-03x

3. Close the tray.

4. Press Continue, jam cleared.

250 paper jam

1. Remove the jammed pages from the multipurpose feeder.

2. Load paper into the multipurpose feeder.

3. Press Continue, jam cleared.

Diagnostic information 2-23

7541-03x

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Duplex unit service check

FRU Action

1 Feed roller belts Check for wear or damage to the feed roller belts. Replace as

• Duplex clutch Check the clutch cable for proper connection to CN13 on the

2

• Duplex solenoid Check for proper operation of the solenoid and linkage. Replace as

3

Photo-interrupter assembly Ensure that the photo-interrupter actuators are operating correctly

4

Paper path service checks

Paper is being picked up and carried to the registration roller (Paper jams 200, 250,
24x).

FRU Action

1 Paper feed cassette If there are misfeeds and jams in the paper-feed unit, check to see

necessary.

engine board. If it is properly connected, replace the clutch. If this
doesn't fix the problem, replace the engine board.

necessary.

Check the solenoid cable for proper connection to CN10 on the
engine board. If it is properly connected, replace the solenoid. If
this doesn't fix the problem, replace the engine board.

and are in the proper position.

if the corners of the paper in the cassette are curled upward.
If the corners are curled, turn the entire stack of paper over. The
curling could be due to humidity conditions.

Paper feed unit rollers

2

Roller clutch

• Paper feed roller (MPF)

3

• Paper feed rolls MPF,
tray 1, 2, 3, 4, 5

•MPF pad

Gears Be sure the paper feed gears are not damaged.

4

• Paper feed clutch

5

•MPF clutch

• MPF frame assembly

• Registration sensor

6

• MPF sensor

• Engine controller board

Are the rollers dirty or worn? Replace as needed.

If there is a failure to pick, and the feed rollers are clean, check the
roller clutch on the paperfeed unit. This check can be performed by
turning the paper feed roll in both directions.
If the shaft can be turned in both directions, replace the roller
clutch.

Be sure the paper feed rollers are free of dirt and not damaged.

Be sure the MPF pad is free of dirt and not damaged.

Replace parts as necessary.

Ensure the clutches are engaging properly.

Check connector CN 8 (Main tray), CN 28 (MPF) on the engine
controller board, and CN18 on the expansion feeder controller card
for proper connection.

Replace the non working clutch. If this doesn't fix the problem,
replace the engine board.

Check the following engine controller board connectors for proper
connection:

• Registration sensor—CN12

• MPF sensor—(CN14)

• If the connectors are properly connected, replace the sensors.

• If replacing the sensors does not fix the problem, replace the
engine control board.

2-24 Service Manual

7541-03x

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Paper has stopped at the registration roller or has not reached the fuser (Paper jams
200, 250, 24x).

FRU Action

1 • Registration roller

2

clutch

• Registration roller

• Transfer belt unit

• Rear paper feed guide

• Registration sensor

• Printer controller board

Check these parts for wear or damage. Replace as necessary. Be
sure all guide surfaces in the paper path are free of dirt.

Check the registration roller clutch for continuity. Does the clutch
engage when the printer is printing a job?

Be sure connector CN20 on the printhead controller board is
connected properly. If the connection is properly connected, check
pin 1 on CN20 for +24Vdc and pin 3 for GND. If the voltage and
ground are present, replace the clutch. If replacing the clutch
doesn’t fix the problem, replace the printhead controller board.

Check the registration sensor connection on CN12 on the engine
controller board for proper connection. If it is properly connected,
replace the registration sensor. If this doesn’t fix the problem,
replace the engine board.

Paper has exited the registration roller and entered the fuser (Paper jam 201).

FRU Action

1 • Transfer belt unit

• Rear paper guide

• Discharge brush

•Fuser

• Fuser entry sensor Check the fuser entry sensor to ensure it is in it’s position and not

2

Remove any buildup of toner. Replace any damaged or worn parts.

Check the paper exit flag on the fuser for damage. Replace the
fuser if necessary.

dislodged.

Check the cable to ensure it is properly connected to CN6 on the
printhead controller board.

Replace the sensor if it is faulty. If this doesn’t fix the problem,
replace the printhead controller board.

Fuser separation pawl Replace the fuser if paper jams cannot be removed.

3

Paper has entered the fuser and exited the printer (Paper jam 203).

FRU Action

1 Fuser Remove any toner buildup, and replace any worn or damaged

• Output bin full lever

2

• Paper exit unit

• Exit unit sensor

• Bin full sensor

parts.

Check the output bin full lever for smooth operation. Replace if
needed.

Check the exit unit sensor actuator for smooth operation. If the
actuator is broken, replace the paper exit unit.

Check the exit unit, and bin fill sensors on the paper exit unit for dirt
and debris. Clean if needed. Check the cable for proper connection
to CN7 on the printhead controller board. If the cable is properly
connected, replace the sensor faulty sensor. If this doesn't fix the
problem, replace the printhead controller board.

Diagnostic information 2-25

7541-03x

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Paper has entered the duplex unit (Paper jam 230, 231-9).

FRU Action

1 Feed rollers

Belts

Duplex unit Be sure the duplex unit is properly installed and that all

2

• Duplex clutch Be sure the clutch turns freely with no binding, and it is properly

3

• Feed roller solenoid

4

5

assembly

• Paper re-feed solenoid
assembly

Paper tray Check to see if the paper edge guides have shifted. If so, re-time

Check for wear or damage to feed rollers and belts.

connections on the engine board (CN 28, 29, 13, 14) are correct.

installed.

Check for wear or damage to the associated gears. Replace as
necessary.

Check for proper operation of the solenoid and linkage. Replace as
necessary.

by removing the screw and gear from the bottom of the tray and
pushing the paper edge guides up against the paper lift plate.
Reinstall the screw and gear.

2-26 Service Manual

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Paperfeed unit service check

Note: These tests can also be performed on the expansion paper-feed units.

FRU Action

7541-03x

1 Door open interlock switch

Paper tray level motor

Printer controller board

Paper out sensor

2

Paper feed unit

• Turn the printer on.

• Open the door.

• Check the operator panel for “Close Door” message.

• Bypass the door open interlock switch*.

• Pull out and replace the cassette. Listen for the paper tray level
motor to activate. (The tray may or may not rise. The motor
makes a low pitched vibrating sound.)

- If the paper tray level motor operates and the “Close Door”
message fails to appear, replace the door open interlock
switch.

- If the “Close door” message appears and the paper tray
level motor fails to operate, check CN6 on the engine board
for proper connection. If the cable is properly connected at
both connections, replace the paper tray level motor.

- If the paper tray level motor fails to operate, and the “close
Door” message fails to appear, check CN6 on the engine
board for proper connection. If it is properly connected,
replace the engine board.

• Turn the printer on, and open the right cover and duplex.
Bypass the right cover door open interlock switch*.

• With the paper tray empty and the paper out sensor blocked,
pull out and replace the cassette.

- If the tray rises and stays in place, check for a dirty paper
out sensor, and inspect the paper empty sensor actuator on
the paper feed unit.

- If the paper empty sensor actuator is stuck or broken,
replace the actuator.

- If the actuator is good, replace the paper out sensor.

- If the tray (x) empty message is displayed, check the paper
out sensor to ensure it is in place.

Paper level sensor

• Turn the printer on, and open the turn guide door. Bypass the
turn guide door open sensor*.

• Block the paper out sensor.

• With the tray empty, pull out and insert the cassette.

- If the tray fails to rise, check for a dirty paper level sensor or
broken casette present actuator. With the turn guide door
open, remove and reinsert the paper tray.

- If the paper feed roll fails to go up when the paper tray is
reinserted, replace the paper feed unit.

- If the actuator is broken, replace the broken actuator.

- If the actuator is good and the sensor was clean, replace
the paper level sensor.

- If the tray too full message is displayed, clean or replace
the sensor.

Diagnostic information 2-27

7541-03x

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FRU Action

Relay sensor

3

Paper feed clutch

MPF service check

FRU Action

1 MPF tray paper guides Check the guides to ensure they are not binding. Also, check the

• Bypass the turn guide door open sensor*.

• Turn the printer on while holding down the paper relay sensor.

- If the operator panel does not display “Paper Jam”, check
for a dirty paper relay sensor.

- If the paper relay sensor is clean, or the actuator for the
paper relay sensor is broken, replace the sensor.

If the sensors are replaced and problem remains, replace the
printer controller board.

• Check the clutch cables for proper connection to CN8 on the
engine board, and CN20 on the printer controller board.

• Check the resistance of the clutch using a multi meter. The
resistance should measure 192 ohms.

If the clutch shows a significantly higher reading, replace the
clutch.

• If you replace the paperfeed, or transport clutches and the
problem remains, replace the engine board. If replacing the
registration clutch and the problem remains, replace the printer
controller board.

guides to ensure they are correctly adjusted for the paper in the
tray.

MPF roll cover Make sure the MPF roll cover is properly installed, and not

2

MPF roll

3

MPF pad

MPF clutch Check the MPF clutch cable for proper connection to the clutch

4

MPF paper empty lever

5

(actuator)

MPF sensor

Engine board If replacing the MPF clutch and sensor don’t resolve and MPF feed

6

obstructing the paperpath. Check for broken tabs, and replace the
cover if any tabs are missing.

Check for wear or damage to feed rollers and pad.

Check for dirt on the roll and pad. Clean them with a lint free damp
cloth.

and CN 28 on the engine board.

Make sure the MPF paper empty lever moves smoothly, and
doesn’t bind. Replace the lever if it is broken.

Check the MPF sensor cable for proper connection to the sensor
and CN14 on the engine board. Also check the cable for continuity.

issues, replace the engine board.

2-28 Service Manual

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Clearing and resolving scanner jams

Note: Before performing the ADF jam service procedures, perform the following steps:

1. Remove all documents from the ADF input tray.

2. Open the ADF cover.

3. Gently remove the jammed paper from the ADF.

Note: Make sure all paper fragments are removed.

280.06 Paper missing

Step Action and questions Yes No

7541-03x

1 Open the ADF top cover and check the paper

in sensor actuator to see if it moves freely.
Does the sensor actuator move freely?

Is there any paper or obstruction preventing

2

the actuator from moving freely.

Remove the obstruction from the actuator. Did

3

this fix the problem?

Check the paper present sensor for dust or dirt.

4

Is the sensor dusty?

Clean the sensor off. Did this fix the problem? Problem resolved Go to step 6.

5

Is the sensor dislodged? Go to step 7. Go to step 8.

6

Properly install the sensor. Did this fix the

7

problem?

Check the sensor (ADF paper present) for

8

proper operation.

1. Enter the Diagnostics Menu.

2. Touch SCANNER TESTS.

3. Touch Sensor Tests.

4. Observe the line “sensor (ADF paper
present)”

Does the display on the operator panel,
change every time the sensing area of the
above sensor is interrupted or blocked?

Go to step 4. Go to step 2.

Go to step 3 Go to step 4.

Problem resolved Go to step 4.

Go to step 5. Go to step 6.

Problem resolved Go to step 8.

Go to step 4. Go to step 3.

Check the sensor connection for proper

9

connection to CN1 on the ADF relay, and the
paper present sensor. Is the cable properly
connected?

Connect the cables. Did this resolve the issue? Problem resolved Go to step 10.

10

Check J1 pin 12 for +5V and pin 10 for ground.

11

Are these present?

Replace the paper present sensor. Did this fix

12

the issue?

Is the ADF cable properly connected to J9 on

13

the ADF relay card, and the ICC board
connector on the rear under side of the

flatbed?

Properly connect the cable at both ends. Did

14

this fix the issue?

Go to step 10. Go to step 9.

Go to step 11. Go to step 12.

Problem resolved Go to step 12.

Go to step 14 Go to step15.

Problem resolved Go to step 15.

Diagnostic information 2-29

7541-03x

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Step Action and questions Yes No

Check the ADF cable for continuity. Is there

15

continuity?

Replace the ADF cable. Did this fix the

16

problem?

Replace the ADF relay board. Did this fix the

17

issue?

Replace the ICC board. Did this fix the issue? Problem resolved Replace the RIP

18

Go to step 16. Go to step 15.

Problem resolved Go to step 16.

Problem resolved Go to step 17.‘

board. See “RIP

board removal”
on page 4-73.

283.01 Scanner static jam - Scan sensor jam

Step Action and questions Yes No

1 Did the paper pick? Go to step 10. Go to step 2.

Is the pick roll in the up position? Go to step 3. Go to step 8.

2

Remove the ADF outer cover and inspect the sensors

3

for dirt and debris. Are the sensors clean?

Clean the sensor. Did this fix the issue? Problem resolved Go to step 5.

4

Check the sensor (ADF Skew, and Scan sensor) for

5

proper operation.

1. Enter the Diagnostics Menu.

2. Touch SCANNER TESTS.

3. Touch Sensor Tests.

4. Observe the line “sensor (ADF Skew, and Scan
sensor)”

Does the display on the operator panel, change every
time the sensing area of the above sensor is
interrupted or blocked?

Go to step 5. Go to step 4.

Go to step 6. Go to step 9.

Check the connections along the cable from the sensor

6

to J1 on the ADF relay card. Are all the connections
properly connected?

Properly connect the connectors. Did this fix the issue? Problem resolved Go to step 7.

7

Check pins 1, 4, 7, 10 for 5V and pins 3, 6, 9, 12 for

8

GND on connector J1 on the ADF relay card. Are they
present.

Replace the sensor assembly in the ADF inner cover.

9

Did this fix the issue?

Check the ADF motor assembly for proper connection

10

to J2 and J6 on the ADF relay card. Are the motors
properly connected?

Connect the cables. Did this fix the issue? Problem resolved Got to step 12.

11

Replace the ADF motor assembly. Did this fix the

12

2-30 Service Manual

issue?

Replace the ADF relay card. Did this fix the issue? Problem resolved Go to step 14.

13

Go to step 8. Go to step 7.

Go to step 9. Go to step 10.

Problem resolved Go to step 10.

Go to step 11 Go to step 12.

Problem resolved Go to step 13.

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Step Action and questions Yes No

Replace the ICC board. Did this fix the issue? Problem resolved Replace the RIP

14

283.05 Scan sensor jam

Step Action and questions Yes No

7541-03x

board. See “RIP

board removal”
on page 4-73.

1 Remove the paper from the ADF. Did this resolve the

problem?

Does the duplex paper pass sensor have dust on it, or

2

debris blocking the sensor?

Clean the sensor. Did this fix the issue? Problem resolved Go to step 4.

3

Check the sensor (ADF skew sensor) for proper

4

operation.

1. Enter the Diagnostics Menu.

2. Touch SCANNER TESTS.

3. Touch Sensor Tests.

4. Observe the line “sensor (ADF skew sensor)”

Does the display on the operator panel, change every
time the sensing area of the above sensor is
interrupted or blocked?

Check J1 on the ADF relay card for proper

5

connectivity. Is the sensor cable properly connected to
the ADF relay card?

Reconnect the cable to the ADF relay card. Did this fix

6

the issue?

Check pin 1, 4, 7, 10 for 5V and pin 3, 6, 9, 12 for GND

7

on connector J1 on the ADF relay card. Are they
present.

Replace the inner cover sensor assembly. Did this fix

8

the issue?

Problem resolved Go to step 2.

Go to step 3. Go to step 4.

Go to step 4. Go to step 3.

Go to step 7. Go to step 6.

Problem resolved Go to step 7.

Go to step 8. Go to step 9.

Problem resolved Go to step 9.

Check the ADF motor assembly for proper connection

9

to J2 and J6 on the ADF relay card. Are the motors
properly connected?

Connect the cables. Did this fix the issue? Problem resolved Got to step 11.

10

Replace the ADF motor assembly. Did this fix the

11

issue?

Check the ADF cable for continuity. Is there continuity? Go to step14. Go to step 13.

12

Replace the ADF cable did this resolve the issue? Problem

13

Replace the ADF relay card. Did this fix the issue? Problem resolved Go to step 15.

14

Replace the ICC board. Did this fix the issue? Problem resolved Replace the RIP

15

Go to step 10 Go to step 11.

Problem resolved Go to step 12.

Go to step 14.

resolved.

board. See “RIP

board removal”
on page 4-73.

Diagnostic information 2-31

7541-03x

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285.05 Scanner ADF eject jam

Step Action and questions Yes No

1 Remove the paper from the ADF. Did this resolve the

problem?

Remove the ADF main feed unit, and inspect the

2

duplex out sensor actuator. Does it move freely?

Remove any debris obstructing the actuator, Did this

3

fix the issue?

Is the actuator improperly attached to the main feeder,

4

or broken?

Re attach or replace the actuator. Did this fox the

5

issue?

Does the duplex out sensor have dust on it, or debris

6

blocking the sensor?

Clean the sensor. Did this fix the issue? Problem resolved Go to step 8.

7

Check the sensor (ADF exit sensor) for proper

8

operation.

1. Enter the Diagnostics Menu.

2. Touch SCANNER TESTS.

3. Touch Sensor Tests.

4. Observe the line “sensor (ADF exit sensor)”

Does the display on the operator panel, change every
time the sensing area of the above sensor is
interrupted or blocked?

Problem resolved Go to step 2.

Go to step 6. Go to step 3.

Problem resolved Go to step 4.

Go to step 6. Go to step 5.

Problem resolved Go to step 6.

Go to step 7. Go to step 8.

Go to step 10. Go to step 9.

Check J4 on the ADF relay card for proper

9

connectivity. Is the sensor cable properly connected to
the ADF relay card?

Reconnect the cable to the ADF relay card. Did this fix

10

the issue?

Check pin 1 for 5V and pin 3 for GND on connector J4

11

on the ADF relay card. Are they present.

Replace the duplex out sensor. Did this fix the issue? Problem resolved Go to step 14.

12

Check the ADF cable for continuity. Is there continuity? Go to step 14. Go to step 15.

13

Replace the ADF cable did this resolve the issue? Problem

14

Replace the ADF relay card. Did this fix the issue? Problem resolved Go to step 16.

15

Replace the ICC board. Did this fix the issue? Problem resolved Replace the RIP

16

Go to step11. Go to step 10.

Problem resolved Go to step 11.

Go to step 12 Go to step 13.

Go to step 15.

resolved.

board. See

board removal”
on page 4-73.

“RIP

2-32 Service Manual

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290.11 Scanner ADF cover open jam

Note: In addition to the steps below, See “ADF cover open service check” on page 2-80.

Step Action and questions Yes No

7541-03x

1 Open the ADF top cover and check the cover

open sensor actuator to see if it moves freely.
Does the sensor actuator move freely?

Are there any obstructions preventing the

2

actuator from moving freely.

Remove the obstruction from the actuator. Did

3

this fix the problem?

Check the cover open for dust or dirt. Is the

4

sensor dusty?

Clean the sensor off. Did this fix the problem? Problem resolved Go to step 6.

5

Is the sensor dislodged? Go to step 7. Go to step 8.

6

Properly install the sensor. Did this fix the

7

problem?

Check the sensor (Cover open) for proper

8

operation.

1. Enter the Diagnostics Menu.

2. Touch SCANNER TESTS.

3. Touch Sensor Tests.

4. Observe the line “sensor (Cover open)

Does the display on the operator panel,
change every time the sensing area of the
above sensor is interrupted or blocked?

Go to step 4. Go to step 2.

Go to step 3 Go to step 4.

Problem resolved Go to step 4.

Go to step 5. Go to step 6.

Problem resolved Go to step 8.

Go to step 10. Go to step 9.

Check the sensor connection for proper

9

connection to CN1 on the ADF relay, and the
paper present sensor. Is the cable properly
connected?

Connect the cables. Did this resolve the issue? Problem resolved Go to step 11.

10

Check J1 pin 3 for +5V and pin 2 for ground.

11

Are these present?

Replace the paper present sensor. Did this fix

12

the issue?

Is the ADF cable properly connected to J9 on

13

the ADF relay card, and the ICC board
connector on the rear under side of the
flatbed?

Properly connect the cable at both ends. Did

14

this fix the issue?

Check the ADF cable for continuity. Is there

15

continuity?

Replace the ADF cable. Did this fix the

16

problem?

Replace the ADF relay board. Did this fix the

17

issue?

Go to step 11. Go to step 10.

Go to step 12. Go to step 13.

Problem resolved Go to step 13.

Go to step 15 Go to step14.

Problem resolved Go to step 15.

Go to step 17. Go to step 16.

Problem resolved Go to step 17.

Problem resolved Go to step 18.‘

Diagnostic information 2-33

7541-03x

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Step Action and questions Yes No

Replace the ICC board. Did this fix the issue? Problem resolved Replace the RIP

18

board. See “RIP

board removal”
on page 4-73.

2-34 Service Manual

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291.06 Flatbed cover open

Step Action and questions Yes No

1 POR the MFP. Does the error re-occur. Go to step 2. Problem solved

7541-03x

Check the sensor (FB Cover open) for proper

2

operation.

1. Enter the Diagnostics Menu.

2. Touch SCANNER TESTS.

3. Touch Sensor Tests.

4. Observe the line “sensor (FB Cover open)”

Does the display on the operator panel, change every
time the sensing area of the above sensor is
interrupted or blocked?

Check all the connections from the FB cover open

3

sensor to J1 on the ICC board. Are they properly
connected?

Properly connect the connections. Did this fix the

4

problem?

Replace the sensor. Did this fix the problem? Problem solved Go to step 6.

5

Check the cable connections from the ICC board to the

6

RIP. Are the cables properly connected?

Reconnect the cables from the ICC to the RIP. Did this

7

fix the issue?

Check the cables from the ICC to the RIP for

8

continuity. Is there continuity?

Replace the faulty cable. Did this fix the issue? Problem resolved Go to step 10.

9

Go to step 4. Go to step 3

Go to step 5. Go to step 4.

Problem resolved Go to step 5.

Go to step 8. Go to step 7.

Problem resolved Go to step 8.

Go to step 10. Go to step 9.

Replace the ICC board. Did this fix the issue? Problem resolved Replace the RIP

10

board. See

board removal”
on page 4-73.

“RIP

292.01 Scanner carriage locked

Unlock the scanner flatbed CCD carrier module lock (scanner lock). The lock is located on the left hand side of
the flatbed unit.

Diagnostic information 2-35

7541-03x

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ADF paper jam service check

Note: This service check should be used if the paper feeds and jams in the ADF. If the paper is not feeding into

the ADF see

Step Questions / actions Yes No

“280.06 Paper missing” on page 2-29. If the paper fails to eject from the ADF see

1 If the ADF is multi-feeding, check for dirt on

the ADF separator pad and ADF separator

Clean them with a lint free
cloth and isopropyl alcohol.

Replace the separator pad
and ADF pick roll.

rollers. Are they dirty?

2 If the paper is skewing when it is fed into the

ADF, check the paper guide width. Is it set
correctly?

3 If paper is skewing when fed or jamming

check to see if the top cover is open or ajar.

Go to step 3. Set the paper guides so

they contact the edges of
the paper.

Properly close the top
cover.

If the paper is jamming in
the ADF, go to step 6

Is the ADF top cover open or ajar?

4 Is paper failing to feed into the ADF? Go to step 5. There is no issue.

5 Check the sensor (ADF paper present) for

Go to step 6 Go to step 9.

proper operation.

1. Enter the Diagnostics Menu.

2. Touch SCANNER TESTS.

3. Touch Sensor Tests.

4. Observe the line “sensor (ADF paper
present)”

Are the sensors working properly?

6 Check the leading edge of the paper to

ensure the paper is not curled or bent in a

Bad media. Replace the
media

Go to step 7.

way that would keep it from contacting the
paper present sensor actuator. Is the paper
damaged?

7 Check for dirt in the ADF scan sensor, paper

in sensor and paper pass sensor. See

“Flatbed / ADF sensors” on page 5-3 for

Clean the sensors, or
remove debris from the
scan sensor actuator.

Go to step 8.

their locations. Are the sensors clean?

8 Is the sensor actuator on the ADF scan

sensor damaged?

9 Are the sensor cable connectors properly

Replace the scan sensor

Go to step 9.

actuator.

Go to step 10. Go to step 10.

connected on the ADF relay card?

10 Connect the cables. Did this fix the issue? Problem resolved. Go to step 11.

11 Check the ADF motor assembly for proper

Go to step 12 Go to step 13.
connection to J2 and J6 on the ADF relay
card. Are the motors properly connected?

12 Connect the cables. Did this fix the issue? Problem resolved Got to step 13.

13 Replace the ADF motor assembly. Did this

Problem resolved Go to step 14.
fix the issue?

14 Check the ADF cable for continuity. Is there

Go to step 15. Replace the ADF cable.
continuity?

15 Replace the ADF relay card. Did this solve

Problem resolved Go to step 16.
the problem?

2-36 Service Manual

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Step Questions / actions Yes No

7541-03x

16 Replace the ICC board. Did this fix the

issue?

Problem resolved Replace the RIP board. See

“RIP board removal” on
page 4-73.

Diagnostic information 2-37

7541-03x

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Error codes

Note: In addition to the 1xx and 9xx error codes, this device displays a symptom where the device shuts down

repeatedly. The main symptom of this error is the switch going to the off position automatically when the device
PORs. This is due to a fuser and printhead controller abnormality. If this symptom is displayed see

switch automatically switching to the Off position service check” on page 2-48.

1xx error codes Action

121.01 Abnormal thermistor 1 See “121.01 Thermistor 1 error” on page 2-46.

121.02 Abnormal thermistor 2 See “121.02 Thermistor 2 error” on page 2-46

140.01 Abnormal main motor See “140 Drive motor error” on page 2-51

149.01 Abnormal exit motor See “149.01 Fuser / paper exit motor error” on page 2-51

“ON / OFF

172.01 Abnormal power supply
fan

173.01 Abnormal machine fan See “173.01 - Main unit fan error” on page 2-55.

121.05 Abnormal heater See “121.05 Fuser - fuser heater error” on page 2-48.

146.01 Tray 1 error See “146.01 Tray1error” on page 2-52

146.03 Tray 3 error See “146.03 Tray 3 error” on page 2-52.

146.04 Tray 4 error See “146.04 Tray 4 error” on page 2-53.

146.05 Tray 5 error See “146.05 Tray 5 error” on page 2-54.

121.04 Abnormal belt thermistor See “121.04 Belt thermistor error” on page 2-47

113.01 HDCONT M-HEAD error See “113.01 Magenta printhead error” on page 2-45.

112.01 HDCONT C-HEAD error See “112.01 Cyan printhead error” on page 2-45.

114.01 HDCONT Y-HEAD error See “114.01 Yellow printhead error” on page 2-45.

111.01 HDCONT K-HEAD error See “111.01 Black printhead error” on page 2-45.

121.03 Abnormal thermistor 3 See “121.03 Thermistor 3 3 error” on page 2-47

171.01Abnormal fuser fan See “171.01 Fuser fan error” on page 2-54

174.01 Abnormal rear fan See “174.01 Rear fan error” on page 2-55

See “172.01 - Power supply unit fan error” on page 2-55.

130.xx Abnormal High Voltage
unit

136.xx Abnormal temperature
and humidity sensor

126.xx Abnormal power switch See “126.xx Power switch error” on page 2-48

132.xx Abnormal theta sensor See “132.xx Abnormal theta sensor” on page 2-50

132.00 Density sensor error See “132.00 Density sensor error” on page 2-49

2-38 Service Manual

See “130.xx High voltage power supply error” on page 2-49

See “136.xx Temperature humidity sensor error” on page 2-50.

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9xx error codes Action

7541-03x

900.xx Unrecoverable RIP
software error / illegal trap

910.xx Unrecoverable engine
firmware error

See “Steps before starting the 9yy service checks” on page 2-60.
See “900.xx System software error” on page 2-62.

Turn off printer for 10 seconds and restart. If error re-occurs, replace RIP
board.

941.01 SDRAM R/W error See “941.01 SDRAM R/W error” on page 2-65

941.02 MDC error See “941.02 MDC error” on page 2-65.

941.03 CPU error See “941.03 CPU error” on page 2-65

941.04 Abnormal MDC controller See “941.04 MDC controller error” on page 2-66

941.05 Abnormal EEPROM See “941.05 EEPROM error” on page 2-66

950.xx Service NCVRAM

See “950.00–950.29—EPROM mismatch failure” on page 2-67.

Mismatch
Note: A new controller board or

operator panel has been
installed, and has not been
properly prepared for this use.
Install a new note. Do not install
both the controller board and the
operator panel at the same time
without a POR in between.

952.xx Service NV Failure Perform a POR to clear the error.

953.xx Service NVRAM Failure Replace the RIP board. For the 958 error, replace the UICC card if
replacing the RIP board does not fix the problem.

954.xx Service NVRAM Failure

955.00 Service Code CRC <loc>

956.xx Service System Board

957.xx Service System Board

958.xx Service NAND Failure

959,xx Service Invalid Firmware Call the second level support to get the correct level of firmware and

update the firmware, or replace the RIP board.

960.xx Service Memory Error Replace the RIP board.

961.xx Service Memory Error Replace the memory in the DIMM slot.

964.xx Service Emulation Error Disable the Download Emulation. Program the download emulation into
the firmware card again. If this does not resolve the problem, then
replace the firmware card and download the emulation again.

975.xx Standard network or

Call your second level support.

Network Card X

976.xx Standard network or

Network Card X

982.xx Service <device>

990.xx Service <device>

991.xx Service <device> Card

Diagnostic information 2-39

7541-03x

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8xx scanner error
codes

840.01 The scanner has been

840.02 The scanner has

Description Action

Enter the configuration mode to re-

manually disabled

enable the scanner.

Enter the configuration mode to re-

automatically been disabled

enable the scanner.

by the controller

840.03 Scanner cable unplugged Check the scanner cables for proper
connection to the scanner and RIP
board.

841.00 Invalid configuration or ASIC

not found.

See “841.00 Invalid configuration or

ASIC not found” on page 2-56.

841.01 Invalid AFE setting. See “841.01 Invalid AFE setting” on

page 2-56.

841.02 Delayed interrupt detected. See “841.02 Delayed interrupt

detected” on page 2-57.

841.03 Failed indirect register test. See “841.03 Failed indirect register

test” on page 2-57.

841.04 Failed external DRAM test. See “841.04 Failed external DRAM

test” on page 2-57.

841.05 Image pipe timeout See “841.05 Image pipe time-out” on

page 2-57

841.06 Scanner did not initiate scan. See “841.06 Scanner did not initiate

scan” on page 2-58

842.00 No response See “842.00 No response / 842.01 HW

protocol / 842.02 Logical protocol” on
page 2-58.

842.01 HW Protocol See “842.00 No response / 842.01 HW

protocol / 842.02 Logical protocol” on
page 2-58.

842.02 Logical protocol See “842.00 No response / 842.01 HW

protocol / 842.02 Logical protocol” on
page 2-58.

843.00 Carriage home See “843.00 Carriage Home” on

page 2-59.

844.00 Lamp failure “844.00 Lamp failure (Front side)” on

page 2-59.

849.01 Machine has an installed

modem that should not be
present.

Uninstall the modem. See “849.01

Device had modem installed, but
config ID indicates it should not” on
page 2-59.

849.10 Machine has an installed

hard drive that should not be
present.

Uninstall the hard drive. See “849.10

Device had HD installed, but config ID
indicates it should not” on page 2-59.

2-40 Service Manual

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Fax T30 log error codes

Fax error log codes

Error code Description Action

7541-03x

000

No error occurred during fax

transmission

200 Error occurred when transmitting

training.

No action needed

• Check line quality.

• Select a lower ‘Max Speed’.

• value under Fax Send settings

• Adjust the transmit level.

3XX Error occurred when receiving

image data.

• Check line quality.

• Adjust ‘Receive Threshold’.

• Select a lower ‘Max Speed’ value
under Fax Receive settings.

4XX Error occurred when sending

image data.

• Check line quality.

• Adjust ‘Transmit Level’.

• Select a lower ‘Max Speed’ value
under Fax Receive settings.

5XX Received unknown response from

remote fax device.

No action needed. Issue is with the other
device.

6XX Error occurred when receiving a frame. • Check line quality.

• Adjust ‘Receive Threshold’.

7XX Error occurred when sending a frame. • Check line quality.

• Adjust ‘Transmit Level’.

• Select a lower ‘Max Speed’ value
under Fax Send settings.

800 Received EOT unexpectedly from

the modem in V34 mode.

802 Too many timeouts occurred

• If error persists disable V34 modulation
scheme.

• If error persists disable ECM mode.

during ECM reception.

803 Fax cancelled by user No action needed.

804 Unexpectedly received a disconnect

command from the remote end.

• Check line quality.

• Adjust Transmit Level/Receive
Threshold values.

• Remote device could be requesting an
unsupported feature.

805 Remote fax device failed to respond to

the DCS command.

• Adjust Transmit Level/Receive
Threshold values.

• Remote device could be
malfunctioning.

808 T1 timeout occurred when trying to

establish a connection with a remote

• Adjust Transmit Level/Receive
Threshold values.

fax device.

809 T2 Timeout occurred due to loss of

command/response synchronization.

• Adjust Transmit Level/Receive
Threshold values.

Diagnostic information 2-41

7541-03x

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Fax error log codes (Continued)

Error code Description Action

80A T5 Timeout occurred when transmitting

image data to remote fax device.

80B Too many errors when transmitting in

ECM mode.

80C Remote device failed to respond to the

CTC command.

80D Received too many requests from

remote end to repeat the previous
command sent.

80E Functional limitation- Remote fax

device does not support G3 receive
capability.

811 Failed to detect a fax device at the

remote end.

812 No more data rates available in V34

modulation scheme.

• Check line quality.

• Adjust ‘Transmit Level’.

• Select a lower ‘Max Speed’value under
Fax Send settings.

• Check line quality.

• Adjust ‘Transmit Level’.

• Select a lower ‘Max Speed’value under
Fax Send settings.

• Select a lower ‘Max Speed’ value
under Fax Send settings.

• Adjust ‘Transmit Level’.

• Check line quality.

• Adjust ‘Transmit Level’.

• Check if line conditions on remote end
will facilitate a good connection.

No action needed. Issue with the remote
device.

• Verify MFD is answering to fax call and
not a voice call.

• Decrease value of ‘Rings To Answer’
setting.

• Adjust to a lower modulation scheme.

813 Timeout occurred after waiting too long

to receive a good frame.

814 Tried too many times at selected speed

using V34 modulation scheme.

815 Fax transmission was interrupted due

to power failure.

818 Fax transmission failed due to

insufficient memory to store scanned
image.

819 Fax transmission failed due to

insufficient memory to store received
image.

81A A timeout occurred during transmission

of a page in ECM mode.

880 Failure to transmit training successfully

in V17, V29, V27 terminal modulation
schemes.

881 Failure to transmit training successfully

in V33, V29, V27 terminal modulation
schemes.

• Adjust “Receive Threshold”.

• Adjust ‘Transmit Level’.

• Adjust to a lower modulation scheme.

• Troubleshoot MFP if error persists. See

“No dial tone” on page 2-86.

Adjust ‘Memory Use’ setting to allocate
more memory for send jobs.

Adjust ‘Memory Use’ setting to allocate
more memory for receive jobs.

Select a lower ‘Max Speed’ value under
Fax Send settings.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

2-42 Service Manual

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Fax error log codes (Continued)

Error code Description Action

7541-03x

882 Failure to transmit training successfully

in V17, V29 terminal modulation
schemes.

883 Failure to transmit training successfully

in V17,V27 terminal modulation
schemes.

884 Failure to transmit training successfully

in V29, V27 terminal modulation
schemes.

885 Failure to transmit training successfully

in V17terminal modulation scheme.

886 Failure to transmit training successfully

in V29 terminal modulation scheme.

887 Failure to transmit training successfully

in V27 terminal modulation scheme.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax
Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

888 Failure to transmit training successfully

at 2400 bps in V27 terminal modulation
scheme.

889 Failed to connect at the minimum

speed supported by the MFP.

88A Failed to connect using V.34

modulation scheme.

• Adjust “Transmit Level”.

• Check line quality.

• Adjust “Transmit Level”.

• Incompatible connection.

• Check line quality.

• Adjust to a lower modulation scheme.

• Adjust Transmit Level Receive
Threshold values.

901 No fax tones detected from remote

end.

• Verify destination phone number.

• Verify that the remote fax is authorized
to receive faxes.

902 No dial tone detected. • Check by enabling ‘Behind a PABX’

setting.

• Check phone line.

• Check MFD modem hardware.

903 Busy tone detected. Check with remote end if successive

attempts fail.

904 Hardware error detected. See “No dial tone” on page 2-86.

905 A timeout occurred after dialing the

number and waiting for a response.

Check with remote end if successive
attempts fail.

906 Fax cancelled by user. No action needed.

Diagnostic information 2-43

7541-03x

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Fax error log codes (Continued)

Error code Description Action

907 Modem detected a digital line

connection.

Verify the MFP is connected to an analog
line. See

“Faxes fail to transmit” on

page 2-81.

908 Phone line was disconnected Restore phone line connection.

A00 Received request for unsupported

No action needed.

function from remote fax device.

A01 Received request for unsupported

No action needed.

image width from remote fax device.

A02 Received request for unsupported

No action needed.
image resolution from remote fax
device.

A03 Received request for unsupported

No action needed.
compression type from remote fax
device.

A04 Received request for unsupported

No action needed.
image length from remote fax device.

F00 Unknown error occurred. No action needed.

2-44 Service Manual

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Service checks

111.01 Black printhead error

Step Action and questions Yes No

7541-03x

1 Is the ribbon cable connecting CN4 on the printhead

controller board to the black LED head securely
connected?

Replace the ribbon cable. Does this fix the problem? Problem fixed Go to step 3.

2

Replace the black LED printhead. Does this fix the

3

problem?

112.01 Cyan printhead error

Step Action and questions Yes No

1 Is the ribbon cable connecting CN2 on the printhead

controller board to the black LED head securely
connected?

Replace the ribbon cable. Does this fix the problem? Problem fixed Go to step 3.

2

Replace the cyan LED printhead. Does this fix the

3

problem?

113.01 Magenta printhead error

Go to step 2 Properly connect

the ribbon cable

Problem fixed Replace the

printhead
controller board.

Go to step 2 Properly connect

the ribbon cable

Problem fixed Replace the

printhead
controller board.

Step Action and questions Yes No

1 Is the ribbon cable connecting CN3 on the printhead

controller board to the black LED head securely
connected?

Replace the ribbon cable. Does this fix the problem? Problem fixed Go to step 3.

2

Replace the magenta LED printhead. Does this fix the

3

problem?

114.01 Yellow printhead error

Step Action and questions Yes No

1 Is the ribbon cable connecting CN1 on the printhead

controller board to the black LED head securely
connected?

Replace the ribbon cable. Does this fix the problem? Problem fixed Go to step 3.

2

Replace the yellow LED printhead. Does this fix the

3

problem?

Go to step 2 Properly connect

the ribbon cable

Problem fixed Replace the

printhead
controller board.

Go to step 2 Properly connect

the ribbon cable

Problem fixed Replace the

printhead
controller board.

Diagnostic information 2-45

7541-03x

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121.01 Thermistor 1 error

Note: If the error is 121.05., the fuser is at the end of life.

Step Action and questions Yes No

1 Is the fuser properly installed? Make sure that it is

properly seated.

Is the fuser cable properly connected to CN19 on the

2

printhead controller board?

Check the fuser cable for continuity. Is there

3

continuity?

Replace the printhead controller board. Does this fix

4

the problem?

Replace the fuser. Does this fix the problem Problem solved Contact second

5

121.02 Thermistor 2 error

Note: If the error is 121.05., the fuser is at the end of life.

Step Action and questions Yes No

1 Is the fuser properly installed? Make sure that it is

properly seated.

Is the fuser cable properly connected to CN19 on the

2

printhead controller board?

Check the fuser cable for continuity. Is there

3

continuity?

Go to step 2. Reinstall the

fuser.

Go to step 3. Properly connect

the connector.

Problem solved Replace the fuser

cable.

Problem solved Go to step 5.

level support.

Go to step 2. Reinstall the

fuser.

Go to step 3. Properly connect

the connector.

Problem solved Replace the fuser

cable.

4

5

2-46 Service Manual

Replace the printhead controller board. Does this fix
the problem?

Replace the fuser. Does this fix the problem Problem solved Contact second

Problem solved Go to step 5.

level support.

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121.03 Thermistor 3 3 error

Note: If the error is 121.05., the fuser is at the end of life.

Step Action and questions Yes No

7541-03x

1 Is the fuser properly installed? Make sure that it is

properly seated.

Is the fuser cable properly connected to CN19 on the

2

printhead controller board?

Check the fuser cable for continuity. Is there

3

continuity?

Replace the printhead controller board. Does this fix

4

the problem?

Replace the fuser. Does this fix the problem Problem solved Contact second

5

121.04 Belt thermistor error

Step Action and questions Yes No

1 Is the fuser properly installed? Make sure that it is

properly seated.

Is the fuser cable properly connected to CN19 on the

2

printhead controller board?

Check the fuser cable for continuity. Is there

3

continuity?

Replace the printhead controller board. Does this fix

4

the problem?

Go to step 2. Reinstall the

fuser.

Go to step 3. Properly connect

the connector.

Problem solved Replace the fuser

cable.

Problem solved Go to step 5.

level support.

Go to step 2. Reinstall the

fuser.

Go to step 3. Properly connect

the connector.

Problem solved Replace the fuser

cable.

Problem solved Go to step 5.

Replace the fuser. Does this fix the problem Problem solved Contact second

5

Diagnostic information 2-47

level support.

7541-03x

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121.05 Fuser - fuser heater error

Step Action and questions Yes No

1 Is the fuser installed and seated properly? Go to step 2. Properly install

Are CN02 and CN04 on the LVPS, and CN16 on the

2

printhead control board properly connected?

Check the fuser connectors on the fuser power cable

3

for damage. Is there any damage?

Check the fuser power cable for continuity. Is there

4

continuity?

Replace the fuser. Does this fix the problem? Problem solved Go to step 6.

5

Replace the printhead controller board. Does this fix

6

the problem?

Replace the LVPS. See “Low volt power supply

7

removal” on page 4-51. Does this fix the problem?

Go to step 3. Properly connect

Replace the fuser
power cable.

Go to step 5 Replace the fuser

Problem solved Go to step 7.

Problem solved Replace the fuser

the fuser.

all the cables.

Go to step 4.

power cable

power cable.

ON / OFF switch automatically switching to the Off position service check

Note: If the machine turns off a few seconds after a POR, follow the procedure below. The automatic shut
down of the printer is a safety feature implemented to avoid fire, or damage to the printer. This is a feature
of the device.

Step Action and questions Yes No

1 POR the printer a couple times. Does the printer turn

off a few seconds after the POR?
Note: When restarting the machine, you should see

the power switch physically move to the off position
when the machine turns off.

Replace the fuser, power supply, and printhead

2

controller board. Does this fix the problem?

126.xx Power switch error

Step Action and questions Yes No

1 Is the power switch cable properly connected to CN27

on the engine controller board?

Replace the power switch. Does this fix the problem? Problem resolved Go to step 3.

2

Replace the engine controller board. Does this fix the

3

problem.

Replace the power switch cable harness. Does this fix

4

the problem?

Go to step 2. Problem resolved

Problem
resolved.

Properly connect
the connector.

Problem resolved Go to step 4.

Problem resolved Contact your

Contact your
second level
support

Go to step 2

second level
support.

2-48 Service Manual

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130.xx High voltage power supply error

Step Action and questions Yes No

7541-03x

1 Check CN11 on the printhead controller board, and

CN01 on the HVPS for proper connectivity. Are the
connection properly connected?

Check the HVPS - printhead controller cable for

2

continuity. Is there continuity?

Replace the HVPS-printhead controller cable. Does

3

this resolve the problem?

Replace the printhead controller board. Does this

4

resolve the issue?

Replace the HVPS. Does this resolve the issue? Problem solved Contact your

5

132.00 Density sensor error

Step Action and questions Yes No

1 Is the density sensor cleaner stuck in place Go to step 2 Release the

Is the cable connecting the density sensor to CN14 on

2

the printhead controller board connected securely on
both ends.

Go to step 2 Properly connect

the connections.

Go to step 4. Go to strep 3.

Problem solved Go to step 4.

Problem solved Go to step 5.

second level
support.

cleaner. Replace
if damaged.

Go to step 3. Securely connect

the cable.

Check the density sensor cable for continuity. Is there

3

continuity?

Replace the density sensor. Does this fix the problem? Problem solved. Replace the

4

Go to step 4. Replace the

density sensor
cable.

printhead
controller board.

Diagnostic information 2-49

7541-03x

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Next

132.xx Abnormal theta sensor

Step Action and questions Yes No

1 Is the reference pattern for the color plane alignment

printing properly on the transfer belt?

Did all the colors print on the test pattern? Go to step 4. Go to step 3.

2

Replace the LED head of the colors that failed to print.

3

Did this fix the problem?

Check CN01 on the HVPS, CN11 on the printhead

4

controller, and the CN1-4 for proper connections. Are
the connected properly?

Is the Theta sensor cable connected properly

5

connected to CN 8 on the printhead controller board
and Theta sensor?

Is the sensor misaligned, the sponge blocking the

6

sensor and the cover opening and closing smoothly?

Replace the theta sensor Problem solved Go to step 8.

7

Replace the engine controller board. Does this fix the

8

problem?

Go to step 4. Go to step 2.

Problem solved Go to step 4.

Go to step 5. Connect the

Go to step 6. Properly connect

Properly align the
sensor and
reposition the
sponge on the
theta sensor
cover. Make sure
the cover opens
and closes
smoothly.

Problem solved Go to step 9.

cables properly.

the cable to CN8
on the printhead
controller board
and Theta
sensor.

Go to step 7.

Replace the HVPS. Does this fix the problem? Problem solved. Contact your

9

136.xx Temperature humidity sensor error

Step Action and questions Yes No

1 Is CN4 on the MDCONT board securely connected Go to step 2 Connect the

Replace the humidity sensor cable. Does this fix the

2

problem?

Replace the temperature humidity sensor. Does this fix

3

the problem?

second level
support.

cable securely.

Problem solved. Go to step 3.

Problem solved. Replace the

printhead
controller board.

2-50 Service Manual

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Next

140 Drive motor error

Step Action and questions Yes No

7541-03x

1 Are CN 17, 18, 19, and 29 on the engine controller

board properly connected?

Are the cables properly connected to the drive motors? Go to step 3. Connect the

2

Replace the engine controller board. Did this fix the

3

issue?

Replace the defective supply item. Did this fix the

4

problem?

149.01 Fuser / paper exit motor error

Step Action and questions Yes No

1 Is the fuser / paper exit motor cable properly connected

to the motor and CN16 on the engine board?

Check the cable for continuity. Is there continuity? Go to step 3. Replace the

2

Replace the paper exit/fuser motor. Did this fix the

3

problem?

Go to step 2. Connect the

cables to the
board.

cables to the
motors.

Problem solved Go to step 4.

Problem solved Replace the drive

motor for the
affected color.

Go to step 2 Connect the

cables at both
ends.

fuser/paper exit
motor cable.

Problem solved. Go to step 4.

Replace the engine board. Did this fix the problem? Problem solved. Go to step 5.

4

Replace the printhead controller board. Did this fix the

5

issue?

Problem solved. Contact your

second level
support.

Diagnostic information 2-51

7541-03x

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146.01 Tray1error

Note: This is the service check for the standard paper tray.

Step Action and questions Yes No

1 Check the cable connecting the paper tray lift motor to

CN 6 on the engine board. Is the cable properly
connected at both ends?

Connect the cable properly at both ends. Does this fix

2

the problem?

Check the paper tray lift motor for continuity. Is there

3

continuity?

Replace the paper tray lift motor cable. Does this fix

4

the problem.

Replace the paper tray lift motor. Does this fix the

5

problem?

Replace the engine board. Does this fix the problem? Problem

6

146.03 Tray 3 error

Note: This is the first expansion tray.

Step Action and questions Yes No

1 Check the cable connecting the option paper tray to

the option connector on the back of the printer. Is the
cable properly connected on both ends.

Go to step 3 Go to step 2

Problem
resolved.

Go to step 5. Go to step 4.

Problem
resolved.

Problem
resolved.

resolved.

Go to step 3 Go to step 2

Go to step 3.

Go to step 5.

Go to step 6.

Contact your
second level
support.

2

3

4

5

6

7

8

9

10

2-52 Service Manual

Connect the cable properly at both ends. Does this fix
the problem?

Check the option cable’s connection to CN 13 on the
printhead controller board. Is it properly connected?

Check the option cable in the printer for continuity. Is
there continuity?

Replace the option cable. Did this fix the problem? Problem

Check CN120 on the expansion feeder controller for
proper connectivity. Is it properly connected?

Reconnect the connection at CN120. Did this fix the
problem?

Check the cable connecting CN103 and the paper full
sensor for proper connectivity. Is the cable properly
connected on both ends?

Re connect the cable at both ends. Did this fix the
problem?

Check the paper full sensor cable for continuity. Is
there continuity?

Problem
resolved.

Go to step 4. Go to step 5.

Go to step 5. Go to step 6.

resolved.

Go to step 8. Go to step 7.

Problem
resolved.

Go to step 10. Go to step 9.

Problem solved. Go to step 10.

Go to step 12. Go to step 11.

Go to step 3.

Go to step 6.

Go to step 8.

Go Back

Previous

Next

Step Action and questions Yes No

7541-03x

Replace the paper full sensor cable. Did this fix the

11

problem?

Replace the paper full sensor. Did this fix the issue? Problem solved. Go to step 13.

12

Replace the expansion paper feeder controller board.

13

Did this fix the issue?

Check pins 6 and 7 on CN13 of the printer controller

14

board for + 24V. Is the voltage correct?

146.04 Tray 4 error

Note: This is the second expansion tray.

Step Action and questions Yes No

1 Check CN 121 on the first expansion paper feeder’s

expansion feeder controller board for proper
connectivity. Is it properly connected?

Reconnect the cable to CN 121.Did this fix the

2

problem?

Check CN 120 on the second expansion paper

3

feeder’s expansion feeder controller board for proper
connectivity. Is it properly connected?

Problem solved. Go to step 12.

Problem solved. Go to step 14.

Contact your
second level
support.

Go to step 3. Go to step 2.

Problem
resolved.

Go to step 5. Go to step 4.

Replace the
printer controller
board

Go to step 3.

Reconnect the cable to CN 120.Did this fix the

4

problem?

Check CN 103 on the second expansion paper

5

feeder’s expansion feeder controller board for proper
connectivity. Is it properly connected?

Reconnect the cable to CN 103.Did this fix the

6

problem?

Replace the paper full sensor. Does this fix the

7

problem?

Replace the expansion paper feeder controller board.

8

Does this fix the problem?

Problem
resolved.

Go to step 7. Go to step 6.

Problem
resolved.

Problem
resolved.

Problem
resolved.

Go to step 5.

Go to step 7.

Go to step 8.

Contact you
second level
support.

Diagnostic information 2-53

7541-03x

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146.05 Tray 5 error

Note: This is the third expansion tray.

Step Action and questions Yes No

1 Check CN 121 on the second expansion paper

feeder’s expansion feeder controller board for proper
connectivity. Is it properly connected?

Reconnect the cable to CN 121.Did this fix the

2

problem?

Check CN 120 on the third expansion paper feeder’s

3

expansion feeder controller board for proper
connectivity. Is it properly connected?

Reconnect the cable to CN 120.Did this fix the

4

problem?

Check CN 103 on the third expansion paper feeder’s

5

expansion feeder controller board for proper
connectivity. Is it properly connected?

Reconnect the cable to CN 103.Did this fix the

6

problem?

Replace the paper full sensor. Does this fix the

7

problem?

Replace the expansion paper feeder controller board.

8

Does this fix the problem?

171.01 Fuser fan error

Go to step 3. Go to step 2.

Problem
resolved.

Go to step 5. Go to step 4.

Problem
resolved.

Go to step 7. Go to step 6.

Problem
resolved.

Problem
resolved.

Problem
resolved.

Go to step 3.

Go to step 5.

Go to step 7.

Go to step 8.

Contact you
second level
support.

Step Questions/actions Yes No

1 Is there anything obstructing the fan’s movement? Clear the

2

3

4

2-54 Service Manual

obstruction.

Check connector CN21 on the MDCONT board. Is it
properly connected?

Replace the fuser fan. Does this remedy the situation? Problem solved. Go to step 4.

Replace the engine controller board. Does this remedy
the situation

Go to step 3 Reconnect the

Problem solved. Contact your

Go to step 2.

connectors.

second level
support.

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Next

172.01 - Power supply unit fan error

Step Questions/actions Yes No

7541-03x

1 Is there anything obstructing the fan’s movement? Clear the

Check connector CN22 on the MDCONT board, and

2

CN04 and CN05 on the LVPS. Are they properly
connected?

Replace the power supply fan. Does this remedy the

3

situation?

Replace the LVPS. See “Low volt power supply

4

removal” on page 4-51. Does this remedy the

situation.

Replace the engine power supply cable. Does this

5

remedy the situation

173.01 - Main unit fan error

Step Questions/actions Yes No

1 Is there anything obstructing the fan’s movement? Clear the

Check connector CN22 on the engine controller board.

2

Is it properly connected?

obstruction.

Go to step 2.

Go to step 3 Reconnect the

connectors.

Problem solved. Go to step 4.

Problem solved. Go to step 5.

Problem solved Replace the

engine controller
board.

Go to step 2.

obstruction.

Go to step 3 Reconnect the

connector.

Replace the main fan. Does this remedy the situation? Problem solved. Replace the

3

174.01 Rear fan error

Step Questions/actions Yes No

1 Is there anything obstructing the fan’s movement? Clear the

Check connector CN26 on the engine controller board.

2

Is it properly connected?

Replace the rear fan. Does this remedy the situation? Problem solved. Replace the

3

engine controller
board.

Go to step 2.

obstruction.

Go to step 3 Reconnect the

connector.

engine controller
board.

Diagnostic information 2-55

7541-03x

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840.03 service check

Step Questions/actions Yes No

1 • Check the 8 and 30 pin ribbon cables connecting

2

3

4

the CCD to the ICC card for proper connection.

• Check the ribbon cable connecting the RIP board
to the ICC card for proper connection.

• Check the ADF cable for proper connection at both
ends.

• Check the cable connecting J4 on the RIP board to
the ICC card for proper connection at both ends.

Are the cables properly connected?

Are any of the cables damaged? Replace the

Replace the ICC. Did this fix the problem? Problem resolved Go to step 4.

Replace the ADF relay card. Did this fix the problem? Problem resolved Replace the RIP

841.00 Invalid configuration or ASIC not found

Step Questions/actions Yes No

1 POR the device a few times. Did the error re-occur? Go to step 3. Go to step 2.

POR into the diagnostic menu. Run the ASIC test in

2

the Scanner Test menu. Did the ASIC pass?

Reseat the cable Go to step 2.

Go to step 3.

damaged cable.

board.

Problem resolved Go to step 3.

Replace the RIP. Did this fix the issue? Problem resolved Contact second

3

841.01 Invalid AFE setting

Step Questions/actions Yes No

1 POR the device a few times. Did the error re-occur? Go to step 2. Problem resolved

Check the connections on the 8 and 30 pin cables

2

connecting the CCD to the ICC card. Are the cables
properly connected?

Properly connect the cables. Did this fix the issue? Problem resolved Go to step 4.

3

Check the 8 and 30 pin CCD cables for continuity. Is

4

there continuity?

Replace the cable that lacked continuity. Did this fix the

5

problem?

Replace the CCD. Did this fix the issue. Problem resolved Go to step 7.

6

Replace the ICC board in the flatbed. Did this fix the

7

issue.

level support.

Go to step 3. Go to step 4.

Go to step 6. Go to step 5.

Problem resolved Go to step 6.

Problem solved Replace the RIP

board.

2-56 Service Manual

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841.02 Delayed interrupt detected

Step Questions/actions Yes No

1 POR the device a few times. Did the error re-occur? Go to step 2. Problem resolved

7541-03x

Update the firmware. Before doing so, contact your

2

second level support for the correct level firmware to
flash the device with. Did this resolve the issue?

Replace the RIP board. Did this fix the issue? Problem resolved Contact second

3

841.03 Failed indirect register test

Step Questions/actions Yes No

1 POR the device a few times. Did the error re-occur? Go to step 2. Problem resolved

Replace the RIP. Did this fix the issue? Problem resolved Contact second

2

841.04 Failed external DRAM test

Step Questions/actions Yes No

1 POR the device a few times. Did the error re-occur? Go to step 2. Problem resolved

Replace the RIP. Did this fix the issue? Problem resolved Contact second

2

Problem resolved Go to step 3.

level support.

level support.

level support.

841.05 Image pipe time-out

Step Questions/actions Yes No

1 POR the device a few times. Did the error re-occur? Go to step 2. Problem resolved

Replace the RIP. Did this fix the issue? Problem resolved Contact second

2

level support.

Diagnostic information 2-57

7541-03x

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841.06 Scanner did not initiate scan

Step Questions/actions Yes No

1 Check the cables connecting the RIP board to the

scanner for damage. Is there any visible damage?

Replace the faulty cables. Did this fix the problem? Problem resolved Go to step 3.

2

Check the cables for continuity. Is there continuity? Go to step 5. Go to step 4.

3

Replace the faulty cable. Did this fix the problem? Problem resolved Go to step 5.

4

Is the flatbed LED illuminating when the scan

5

command is issued?

Replace the CCD. Did this fix the problem? Problem resolved Go to step 7.

6

Replace the ICC card. Did this fix the problem? Problem resolved Go to step 8.

7

Replace the RIP board. Did this fix the issue? Problem resolved Contact second

8

Go to step 2. Go to step 3.

Go to step 6. Go to step 7.

842.00 No response / 842.01 HW protocol / 842.02 Logical protocol

Step Questions/actions Yes No

1 POR the device. Did the error re-occur? Go to step 2. Problem resolved

Check all the connections from the ICC card to the

2

ADF relay card and RIP board to ICC card. Also check
the CCD cables for proper connectivity. Are the cables
properly connected?

Go to step 3 Go to step 4.

level support.

3

4

5

6

7

8

9

2-58 Service Manual

Properly connect all the cables. Did this fix the issue? Problem resolved Go to step 4.

Check the cables for continuity. Is there continuity? Go to Step 6. Go to step 5.

Replace the faulty cable. Did this fix the issue? Problem resolved Go to step 6.

Is the CCD LED illuminating and not moving when a
scan command is given?

Replace the ICC card. Did this fix the issue? Problem resolved Go to step 8.

Replace the ADF relay card. Did this fix the issue? Problem resolved Go to step 9.

Replace the RIP board. Did this fix the issue? Problem resolved Contact your

Replace the
CCD.

Go to step 7.

second level
support.

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843.00 Carriage Home

Step Questions/actions Yes No

1 POR the device.Did the error re-occur? Go to step 2. Problem resolved

7541-03x

Check all the connections from the ICC card to the

2

CCD carriage, and RIP board to ICC card. Are the
cables properly connected?

Properly connect all the cables. Did this fix the issue? Problem resolved Go to step 4.

3

POR the machine into diagnostics mode and perform

4

the scanner sensor test. Is the home position sensor
displaying a 1?

Is there any damage to the flag that actuates the home

5

sensor?

Replace the flatbed unit. Did this fix the issue? Problem resolved Go to step 9.

6

Replace the ICC card. Did this fix the issue? Problem resolved Go to step 8.

7

Replace the CCD. Did this fix the issue? Problem resolved Go to step 9.

8

Replace the RIP board. Did this fix the issue? Problem resolved Contact your

9

844.00 Lamp failure (Front side)

Step Questions/actions Yes No

Go to step 3 Go to step 4.

Go to step. Go to step 5.

Go to step 6. Go to step 7.

second level
support.

1 Check the FFC ribbon cable connecting the RIP board

to the ICC board on the flatbed for proper connectivity.
Is it properly connected?

Re-connect the cable. Did this fix the problem? Problem resolved Go to step 3.

2

Check the 8 pin and 30 pin cables on the CCD for

3

proper connectivity. Are they properly connected?

Connect the cables properly. Did this fix the issue? Problem resolved Go to step 5.

4

Replace the CCD. Did this fix the problem? Problem resolved Go to step 6

5

Replace the ICC board. Did this fix the problem? Problem resolved Go to step 7.

6

Replace the RIP board. Did this fix the problem? Problem resolved Contact your

7

Go to step 3. Go to step 2.

Go to step 5. Go to step 4.

849.01 Device had modem installed, but config ID indicates it should not

Uninstall the modem

849.10 Device had HD installed, but config ID indicates it should not

Uninstall the hard drive.

Diagnostic information 2-59

second level
support.

7541-03x

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Steps before starting the 9yy service checks

Before starting the service checks in this section, you will need to retrieve certain information. This will aid your
next level of support in diagnosing the problem before replacing the controller board.

Warning: Do not replace the controller board unless directed by your next level of support.

1. Collect the history information and firmware logs (Fwdebug and logs.tar.gz) from the SE menu.

2. Collect the settings from the menu settings page.

3. Collect information from the user.

Note: Not all of the items can be retrieved from the printer you are working on.

A. Collecting the history information from the SE menu

Note: Make sure your printer is connected to a network or to a print server.

1. From a Web browser, type http://printer_IP_address/se, and then press Enter.

Notes:

• printer_IP_address is the TCP/IP address of the printer

• se is required to access the printer diagnostic information

2. Click History Information, copy all information, and then save it as a text file.

3. E-mail the text file to your next level of support.

B. Collecting the firmware logs (Fwdebug and logs.tar.gz) from the SE menu

Notes:

• Make sure your printer is connected to a network or to a print server.

• Some printers are designed to restart automatically after a 9yy error. On these printers, you can retrieve

the secondary crash code information using the SE menu.

• Fwedebugs can also be referred to as LBtrace. If FWEdebugs does not appear in the list, then look for

LBtrace. Mulitple LBtrace logs can appear in the list of links referred to in step 2.

1. From a Web browser, type http://printer_IP_address/se, and then press Enter.

2. Click List Fwedebugs captured during reboots. This will provide you a list of the secondary crash codes

retrieved from prior reboots.

Note: If there are Fwedebugs listed, click Dump Fwedebug log0, Dump Fwedebug log1, and Dump
Fwedebug log2. Clicking these links will dump the debug logs to the computer. Take note of the

destination folder where the logs are saved.

3. E-mail the logs to your next level of support.

Note: Some machine SE menus give you the option of clicking Logs Gzip Compressed. If this option is

shown in the menu, then click it and retrieve the compressed log file. Take note of the destination folder
where the log file is saved.

2-60 Service Manual

7541-03x

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C. Collecting the settings from the menu settings page

Note: The menu settings page is different for each printer. For more information see the User’s Guide. Your

next level of support will tell you which page they want to see.

Copying the menu settings page from the Embedded Web Server (EWS)

Note: Make sure your printer is connected to a network or to a print server.

1. From a Web browser, type http://printer_IP_address, and then press Enter.

2. Click Settings, and then select one of the settings page from the links shown on the page.

3. Copy all information, and then save it as a text file.

4. E-mail the text file to your next level of support.

Printing the menu settings page

1. From the home screen, navigate to Reports > Menu Settings Page.

2. Print the menu settings page, and then use Scan to E-mail to send it to your next level of support.

D. Collecting information from the user

Ask the user for information about the following:

• Print job being run

• Operating system used

• Print driver used

• Other information on what was happening when the 9yy error occurred.

Diagnostic information 2-61

7541-03x

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900.xx System software error

Notes:

Before troubleshooting:

• Perform the “Steps before starting the 9yy service checks” on page 2-60.

• Determine the operating system used when the error occured. If possible determine whether a PostScript

or PCL file was sent to the device when the error occured. Ask the customer which Lexmark Solutions
applications are installed on the device.

Step Action and questions Yes No

1 POR the device.

Does the error reoccur?

• Write down the exact 900.xx error code displayed

2

3

4

5

6

on the device.

• Turn the device off.

• Clear the print queues.

• Disconnect all communication cables, and remove
all memory options.

• Remove all ISP and modem cards.

• Restart the device into diagnostic mode.

Does the 900.xx error reoccur during startup?

Check all the cables connected to the RIP board for
proper connectivity.

Are the cables properly connected?

Properly connect the cables to the RIP board. Restart
the device into diagnostic mode.

Does the 900.xx error reoccur during startup?

Replace the RIP board, and restart the device.

Does this fix the problem?
Note: If an error, different from the original 900.xx, is

displayed, consult the service check for that error.

Print the following:

•Error log

• Menu settings page

• Network settings page

Go to step 2. Problem

Go to step 3. Go to step 6.

Go to step 5. Go to step 4.

Go to step 5. Go to step 6.

Problem
resolved.

Go to step 31. Go to step 7.

resolved.

Go to step 31.

Does the 900.xx error reoccur while these pages
were printing?

Re-attach the communications cable. Restart the

7

printer to operating mode. Send the printer a print job.

Does the 900.xx error reoccur?
Note: Before performing this step, write down this

information about the file being sent to the printer:

• Application used

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• Operating system

• Driver type

• File type (PCL, PostScript, XPS, etc.)

Go to step 8. Go to step 10.